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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN PASSENGER EXTENDED, 5.0 MREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 429 (ENGINE MECHANICAL)REPAIR INSTRUCTIONSOFF-VEHICLE REPAIR INSTRUCTIONSENGINE BLOCK CLEANING AND INSPECTIONTOOLS REQUIRED
2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 M

Tools Required

2001 Chevrolet Chevy Express G2500, Van Passenger Extended, 5.0 MSECTION Tools Required
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  • J8001  Dial Indicator Set
  • J 8087  Cylinder Bore Gage
  1. Clean the sealing material from the gasket mating surfaces.
  2. Boil the engine block in caustic solution.
  3. Flush the engine block with clean water or steam.
  4. Clean the oil passages.
  5. Clean the blind holes.
  6. Spray the cylinder bores and the machined surfaces with engine oil.
  7. Inspect the threaded holes.
  8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
    Fig 1: Identifying Engine Block For Cleaning
    G01500692Courtesy of GENERAL MOTORS CORP.
  9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.25 mm (0.010 in) must be removed.
  10. Inspect the oil pan rail for nicks.

    Inspect the front cover attaching area for nicks.

    Use a flat mill file in order to remove any nicks.

    Fig 2: Testing Deck Surface For Flatness Using Straight Edge
    G01500693Courtesy of GENERAL MOTORS CORP.
  11. Inspect the mating surfaces of the transmission case.
    NOTE: A broken flywheel may result if the transmission case mating surface is not flat.
  12. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt hole bosses:
    1. 12.1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
    2. 12.2. Hold the J 8001  gage plate flat against the crankshaft flange.
    3. 12.3. Place the dial indicator stem on the transmission mounting bolt hole boss.

      Set the indicator to 0

    4. 12.4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.25 mm (0.010 in).
    5. 12.5. Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the crankshaft flange runout is not within the specification, replace the engine block.
    Fig 3: Inspecting Mating Surfaces Of Transmission Case
    G01500694Courtesy of GENERAL MOTORS CORP.

    Important:  Perform the following inspections, and reconditioning if necessary, with the crankshaft main bearing caps installed and tightened to specification.

  13. Inspect the crankshaft main bearing bores.

    Use the J 8087  in order to measure the bearing bore concentricity and alignment at the following locations:

    • The camshaft
    • The crankshaft
  14. Replace the engine block if the bores are out of specification.
    Fig 4: Inspecting Crankshaft Main Bearing Bores
    G01500695Courtesy of GENERAL MOTORS CORP.
  15. Use the J 8087  in order to inspect the cylinder bores. Inspect the bores for the following conditions:
    • Wear
    • Taper
    • Runout
    • Ridging

    Important:  If the bore is worn beyond the limits, refit the bore with 0.5 mm (0.02 in) oversized pistons.

  16. Leave sufficient material in order to allow honing when fitting the piston.
    Fig 5: Inspecting Cylinder Bores
    G01500696Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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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.