SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 657 (ENGINE MECHANICAL - 3.8L)REPAIR INSTRUCTIONSON-VEHICLE REPAIR INSTRUCTIONSENGINE REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine from the engine stand.
  2. Install the flywheel. Refer to ENGINE FLYWHEEL INSTALLATION  .
  3. With the aid of an assistant, install the engine to the vehicle.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  4. Install the bolts (2,3,4,5) which secure the upper transaxle to the engine.

    Tighten 

    Tighten the bolts to 75 N.m (55 lb ft).

  5. Remove the engine lifting device.
    Fig 1: Installing Upper Transaxle To Engine
    G02083714Courtesy of GENERAL MOTORS CORP.
  6. Install the A/C compressor and the A/C compressor nuts to the A/C compressor bracket.

    Tighten 

    Tighten the nuts to 30 N.m (22 lb ft).

  7. Install the heater hoses to the drive belt tensioner. Refer to HEATER HOSE REPLACEMENT - INLET (3.8L) and HEATER HOSE REPLACEMENT - OUTLET (3.8L) in Heating, Ventilation and Air Conditioning.
  8. Install the radiator outlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - OUTLET (3.8L) in Engine Cooling.
  9. Install the radiator inlet hose to the engine. Refer to RADIATOR HOSE REPLACEMENT - INLET (3.8L) in Engine Cooling.
  10. Reposition the engine wiring to the engine.
  11. Connect the upper engine electrical connectors to the following components:
    • Manifold absolute pressure (MAP) sensor
    • Exhaust gas recirculation (EGR) valve
    • EVAP purge solenoid
    • Idle air control (IAC) valve
    • Throttle position (T/P) sensor
    • Fuel injectors
    Fig 2: Installing A/C Compressor
    G02083715Courtesy of GENERAL MOTORS CORP.
  12. Install the upper engine wiring harness to the retaining clips.
  13. Install the power steering pump to the engine.

    Tighten 

    Tighten the power steering bolts to 34 N.m (25 lb ft).

  14. Connect the A/C vacuum hose to the engine.
  15. Install the vacuum booster hose to the engine. Refer to POWER BRAKE BOOSTER CHECK VALVE /HOSE in Hydraulic Brakes.
  16. Install the engine cooling fans. Refer to COOLING FAN REPLACEMENT - ELECTRIC in Engine Cooling.
  17. Connect the positive battery cable.

    Tighten 

    Tighten the cable terminal bolt to 15 N.m (11 lb ft).

  18. Install the engine mount brackets to the upper radiator support. Refer to ENGINE MOUNT STRUT BRACKET REPLACEMENT - UPPER RADIATOR SUPPORT  .
  19. Install the engine mount struts to the engine mount strut brackets. Refer to ENGINE MOUNT STRUT REPLACEMENT - RIGHT  and to ENGINE MOUNT STRUT REPLACEMENT - LEFT  .
    Fig 3: Installing Power Steering Pump And Bolts
    G02083716Courtesy of GENERAL MOTORS CORP.
  20. Install the water pump pulley.
  21. Install the water pump pulley bolts.

    Tighten 

    Tighten the pulley bolts to 13 N.m (116 lb in).

  22. Install the drive belt. Refer to DRIVE BELT REPLACEMENT (L36)  or DRIVE BELT REPLACEMENT (L67)  .
  23. Install the accelerator cable, the cruise control cable, and the bracket to the throttle body. Refer to ACCELERATOR CONTROLS CABLE BRACKET REPLACEMENT in Engine Performance - Removal and Installation.
  24. Connect the fuel vapor line. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
  25. Connect the fuel lines to the fuel rail. Refer to ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 or ENGINE CONTROLS - REMOVAL & INSTALLATION - V6 & V8 in Engine Performance - Removal and Installation.
    Fig 4: Installing Water Pump Pulley
    G02083717Courtesy of GENERAL MOTORS CORP.
  26. Install the air cleaner assembly.
  27. Raise the vehicle and remove the transaxle support.
  28. Install the bolt (6) and the stud (1) which secure the lower transaxle to the engine.

    Tighten 

    Tighten the bolt and the stud to 75 N.m (55 lb ft).

  29. Install the engine ground to the transaxle stud.

    Tighten 

    Tighten the engine ground nut to 35 N.m (26 lb ft).

  30. Install the oil filter adapter housing. Refer to OIL FILTER ADAPTER AND BYPASS VALVE ASSEMBLY REPLACEMENT  .
  31. Reposition and connect the electrical connectors to the following components:
    • Heated oxygen sensor (H02S)
    • Knock sensors
    • Oil level sensor
    • Oil pressure sensor
    • Vehicle speed sensor (VSS)
  32. Install the oil level sensor harness retainer to the engine.
  33. Install the oil level sensor harness retainer bolt.

    Tighten 

    Tighten the bolt to 10 N.m (89 lb in).

  34. Install the three-way catalytic converter pipe to the right exhaust manifold. Refer to CATALYTIC CONVERTER REPLACEMENT (3.8L) in Engine Exhaust.
    Fig 5: Installing Lower Transaxle To Engine
    G02083718Courtesy of GENERAL MOTORS CORP.
  35. Install the engine mount lower nuts.

    Tighten 

    Tighten the nuts to 78 N.m (58 lb ft).

  36. Install the transaxle brace. Refer to AUTOMATIC TRANSMISSION BRACE REPLACEMENT in Automatic Transaxle - 4T65 - E.
  37. Install the engine flywheel-to-torque converter bolts. Refer to FLYWHEEL TO TORQUE CONVERTER BOLT REPLACEMENT in Automatic Transaxle - 4T65 - E.
  38. Install the starter motor. Refer to STARTING SYSTEM in Battery.
  39. Install the torque converter covers.
    Fig 6: Installing Engine Mount
    G02083719Courtesy of GENERAL MOTORS CORP.
  40. Lower the vehicle.
  41. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L36)  or FUEL INJECTOR SIGHT SHIELD REPLACEMENT (L67)  .
  42. Install the hood. Refer to HOOD REPLACEMENT in Body Front End.
  43. Connect the negative battery cable. Refer to BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE in Battery.
  44. Fill the crankcase with engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT  .
  45. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM in Engine Cooling.
  46. Inspect for leaks.
  47. Perform the CKP system variation learn procedure. Refer to CKP SYSTEM VARIATION LEARN PROCEDURE in Engine Performance.
RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.