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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 378 (ENGINE COOLING SYSTEM)REPAIR INSTRUCTIONSWATER CROSSOVER REPLACEMENT (L47)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Installation Procedure
WARNING: This page is about a different car, the 2002 Oldsmobile Aurora and 2001 Oldsmobile Aurora. However, it is still accessible from the selected car via links, so may be relevant.
  1. With all 8 crossover retaining bolts inserted, slide the upper and lower water housing crossover gaskets onto the bolts.

    Important:  Care should be taken when installing the water housing bolts, so that the gaskets are in the correct position.

    2. Fig 1: Installing Water Housing Crossover Gaskets
    G01817554Courtesy of GENERAL MOTORS CORP.
  2. Place the water housing crossover in position and hand start the bolts to hold the crossover in place.
    CAUTION: Refer to FASTENER NOTICE .
  3. Tighten the water housing crossover bolts.

    Tighten 

    Tighten the water housing crossover bolts to 25 N.m (18 ft lbs).

  4. Connect the heater hose to the water housing crossover.
  5. Connect the cable harness clip to the water housing crossover.
    Fig 2: Installing Water Housing Crossover
    G01817555Courtesy of GENERAL MOTORS CORP.
  6. Install the 2 bolts (3) attaching the water pump belt tensioner (1) to the water crossover.

    Tighten 

    Tighten the water pump belt tensioner bolts (3) to 10 N.m (89 in lbs).

  7. Install the water pump. Refer to Water Pump Replacement (LX5)  or Water Pump Replacement (L47)  .
  8. Connect the outlet radiator hose to the thermostat housing.
    Fig 3: Installing Water Pump Belt Tensioner
    G01817556Courtesy of GENERAL MOTORS CORP.
  9. Position the J 38185 (2)  to the clamp in order to connect the inlet radiator hose (1) to the water housing crossover.
    Fig 4: Connecting Outlet Radiator Hose
    G01817557Courtesy of GENERAL MOTORS CORP.
  10. Install the MAP sensor.
  11. Connect the electrical connector to the MAP sensor.
  12. Install the EGR valve. Refer to EGR VALVE .
    Fig 5: Installing MAP Sensor
    G01817558Courtesy of GENERAL MOTORS CORP.

    Important:  The EGR valve inlet pipe incorporates a crush seal connection at the water crossover. The EGR valve inlet pipe must be replaced if disconnected from the water crossover.

  13. Hand start the NEW EGR inlet pipe nut (1) to the front exhaust manifold pipe to prevent crossthreading.

    Tighten 

    Tighten the EGR inlet pipe nut to 60 N.m (44 ft lbs).

  14. Connect the EGR inlet pipe flange (3) to the water crossover.
  15. Install the EGR inlet pipe-to-water crossover flange bolt (2).

    Tighten 

    Tighten the EGR inlet pipe bolt to 25 N.m (18 ft lbs).

    16. Fig 6: Installing EGR Inlet Pipe
    G01817559Courtesy of GENERAL MOTORS CORP.
  16. Install the EVAP emission canister purge valve. Refer to EVAP CANISTER PURGE SOLENOID .
  17. Position the rear lift bracket to the water crossover.
  18. Install the rear lift bracket bolt.

    Tighten 

    Tighten the rear lift bracket bolt to 24 N.m (18 ft lbs).

  19. Install the surge tank inlet fitting.

    Tighten 

    Tighten the surge tank inlet fitting to 47 N.m (35 ft lbs).

    Fig 7: Installing Rear Lift Bracket
    G01817560Courtesy of GENERAL MOTORS CORP.
  20. Connect the surge tank inlet hose to the fitting.
  21. Connect the fuel rail bracket retaining nut to the rear lift bracket.

    Tighten 

    Tighten the fuel rail bracket retaining nut to 4 N.m (35 in lbs).

    Fig 8: Connecting Surge Tank Inlet Hose
    G01817561Courtesy of GENERAL MOTORS CORP.
  22. Connect the secondary AIR solenoid vacuum tube (2) to the housing crossover.
  23. Connect the fuel regulator vacuum tube (1).
    24. Fig 9: Connecting Fuel Regulator Vacuum Tube
    G01817562Courtesy of GENERAL MOTORS CORP.
  24. Connect the brake booster vacuum tube.
  25. Install the throttle body. Refer to THROTTLE BODY .
  26. Install the fuel injector sight shield. Refer to FUEL INJECTOR SIGHT SHIELD REPLACEMENT .
  27. Install the air cleaner assembly. .
  28. Fill the cooling system. Refer to Draining and Filling Cooling System .
RENDER: 1.0x

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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.