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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 573 (ENGINE MECHANICAL (INTRODUCTION) - 3.6L (LY7))SPECIFICATIONSTHREAD REPAIR SPECIFICATIONS

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Thread Repair Specifications

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Thread Repair Specifications

WARNING: This page is about a different car, the 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Left Cylinder Head Camshaft Cover Face

GM915922

Courtesy of GENERAL MOTORS CORP.

Left Cylinder Head Camshaft Cover Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8858	18.0	0.7087
2	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU
3	M6 x 1.0	701	N/A	N/A	203	204	205	28.5	1.1220	24.0	0.9449
4	M20 x 1.5	715	716	N/A	717	718	719	25.0	0.9842	17.0	0.6693

Fig 2: Left Cylinder Head Front Face

GM915924

Courtesy of GENERAL MOTORS CORP.

Left Cylinder Head Front Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	THRU		THRU
2	M12 x 1.75	856	857	N/A	858	859	416	40.0	1.5748	32.5	1.2795
3	M8 x 1.25	206	207	N/A	208	209	210	18.0	0.7087	22.5	0.8858

Fig 3: Left Cylinder Head Intake Face

GM915927

Courtesy of GENERAL MOTORS CORP.

Left Cylinder Head Intake Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055

Fig 4: Left Cylinder Head Exhaust Face

GM915932

Courtesy of GENERAL MOTORS CORP.

Left Cylinder Head Exhaust Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3189	27.0	1.0630
2	M12 x 1.5	705	706	N/A	707	708	709	27.5	1.0827	13.0	0.5118
3	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8858	18.0	0.0000
4	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055

Fig 5: Left Cylinder Head Rear Face

GM915951

Courtesy of GENERAL MOTORS CORP.

Left Cylinder Head Rear Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3189	27.0	1.0630

Fig 6: Right Cylinder Head Camshaft Cover Face

GM915963

Courtesy of GENERAL MOTORS CORP.

Right Cylinder Head Camshaft Cover Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU
2	M6 x 1.0	701	N/A	N/A	203	204	205	28.5	1.1220	24.0	0.9449
3	M20 x 1.5	715	716	N/A	717	718	719	25.0	0.9842	17.0	0.6693
4	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8858	18.0	0.7087

Fig 7: Right Cylinder Head Front Face

GM915968

Courtesy of GENERAL MOTORS CORP.

Right Cylinder Head Front Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	THRU		THRU
2	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8880	18.0	0.7087
3	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU
4	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
5	M12 x 1.75	856	857	N/A	858	859	416	40.0	1.5748	32.5	1.2795

Fig 8: Right Cylinder Head Intake Face

GM915974

Courtesy of GENERAL MOTORS CORP.

Right Cylinder Head Intake Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055

Fig 9: Right Cylinder Head Exhaust Face

GM915998

Courtesy of GENERAL MOTORS CORP.

Right Cylinder Head Exhaust Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8858	18.0	0.0000
2	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3189	27.0	1.0630
3	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055

Fig 10: Right Cylinder Head Rear Face

GM916091

Courtesy of GENERAL MOTORS CORP.

Right Cylinder Head Rear Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3189	27.0	1.0630

Fig 11: Engine Block Front

GM916121

Courtesy of GENERAL MOTORS CORP.

Engine Block Front Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
2	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3189	27.0	1.0630
3	M8 x 1.25	206	207	N/A	208	209	210	THRU		23.0	0.9055
4	M8 x 1.25	206	207	N/A	208	209	210	THRU		THRU
5	M10 x 1.5	211	212	N/A	213	214	215	28.0	1.1024	28.0	1.1024
6	M10 x 1.5	211	212	N/A	213	214	215	THRU		20.0	0.7874
7	M10 x 1.5	211	212	N/A	213	214	215	THRU		28.0	1.1024

Fig 12: Engine Block Left Side

GM916127

Courtesy of GENERAL MOTORS CORP.

Engine Block Left Side Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
2	M20 x 1.5	715	716	N/A	717	718	719	30.0	1.1810	20.0	0.7874
3	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3190	27.0	1.0630
4	M14 x 1.5	409	410	N/A	411	412	735	THRU		15.0	0.5905
5	M8 x 1.25	206	207	N/A	208	209	415	16.5	0.6496	11.0	0.4331

Fig 13: Engine Block Right Side

GM916131

Courtesy of GENERAL MOTORS CORP.

Engine Block Right Side Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8858	18.0	0.7087
2	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
3	M14 x 1.5	409	410	N/A	411	412	735	THRU		15.0	0.5905
4	M10 x 1.5	211	212	N/A	213	214	215	33.5	1.3190	27.0	1.0630

Fig 14: Engine Block Rear

GM916134

Courtesy of GENERAL MOTORS CORP.

Engine Block Rear Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	420	33.5	1.3190	27.0	1.0630
2	M6 x 1.0	201	202	N/A	203	204	205	22.5	0.8858	18.0	0.7087
3	M14 x 1.5	409	410	N/A	411	412	735	THRU		15.0	0.5905
4	M10 x 1.5	211	212	N/A	213	214	216	39.5	1.5551	33.0	1.2992
5	M10 x 1.5	211	212	N/A	213	214	420	THRU		THRU

Fig 15: Engine Block Bottom

GM916146

Courtesy of GENERAL MOTORS CORP.

Engine Block Bottom Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 2.0	720	N/A	N/A	721	722	104	56.0	2.2047	49.0	1.9291
2	M8 x 1.25	702	N/A	N/A	703	704	620	46.0	1.8110	40.5	1.5945
3	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
4	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU

Fig 16: Engine Block Left Deck Face

GM916175

Courtesy of GENERAL MOTORS CORP.

Engine Block Left Deck Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
2	M11 x 2.0	723	N/A	N/A	724	725	108	102.5	4.0354	94.0	3.7008

Fig 17: Engine Block Right Deck Face

GM916197

Courtesy of GENERAL MOTORS CORP.

Engine Block Right Deck Face Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M11 x 2.0	723	N/A	N/A	724	725	108	102.5	4.0354	94.0	3.7008

Fig 18: Engine Front Cover

GM916649

Courtesy of GENERAL MOTORS CORP.

Engine Front Cover Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU
2	M6 x 1.0	201	202	N/A	203	204	205	21.5	0.8465	18.0	0.7087
3	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
4	M10 x 1.5	211	212	N/A	213	214	420	THRU		THRU
5	M10 x 1.5	211	212	N/A	213	214	420	33.5	1.3189	27.0	1.0630
6	M8 x 1.25	206	207	N/A	208	209	210	27.5	1.0827	23.0	0.9055

Fig 19: Upper Intake Manifold - Top

GM916833

Courtesy of GENERAL MOTORS CORP.

Upper Intake Manifold - Top Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU

Fig 20: Upper Intake Manifold - Front

GM916859

Courtesy of GENERAL MOTORS CORP.

Upper Intake Manifold - Front Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU

Fig 21: Upper Intake Manifold - Rear

GM916863

Courtesy of GENERAL MOTORS CORP.

Upper Intake Manifold - Rear Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU

Fig 22: Lower Intake Manifold - Top

GM916915

Courtesy of GENERAL MOTORS CORP.

Lower Intake Manifold - Top Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	201	202	N/A	203	204	205	THRU		THRU
2	M8 x 1.25	206	207	N/A	208	209	210	THRU		THRU

Fig 23: Oil Pan Front

GM916664

Courtesy of GENERAL MOTORS CORP.

Oil Pan Front Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	420	33.5	1.3189	27.0	1.0630
2	M8 x 1.25	206	207	N/A	208	209	210	28.5	1.1220	23.0	0.9055
3	M8 x 1.25	610	N/A	N/A	208	209	620	37.5	1.4764	32.0	1.2598

Fig 24: Oil Pan Left Side

GM916712

Courtesy of GENERAL MOTORS CORP.

Oil Pan Left Side Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M12 x 1.75	856	857	N/A	858	859	416	THRU		THRU
2	M10 x 1.5	211	212	N/A	213	214	420	33.5	1.3189	27.0	1.0630

Fig 25: Oil Pan Right Side

GM916776

Courtesy of GENERAL MOTORS CORP.

Oil Pan Right Side Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M20 x 1.5	715	716	N/A	717	718	719	THRU		THRU

Fig 26: Oil Pan Rear

GM916815

Courtesy of GENERAL MOTORS CORP.

Oil Pan Rear Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	420	33.5	1.3189	27.0	1.0630

Fig 27: Oil Pan Bottom

GM916820

Courtesy of GENERAL MOTORS CORP.

Oil Pan Bottom Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M10 x 1.5	211	212	N/A	213	214	420	33.5	1.3189	27.0	1.0630

Fig 28: Oil Pan Top

GM916826

Courtesy of GENERAL MOTORS CORP.

Oil Pan Top Repair Specifications

Hole Location	Thread Size	Drill	Counter Bore Tool	Stop Collar	Tap	Driver	Insert	Drill Depth (Maximum)		Tap Depth (Minimum)
		J 42385-						MM	(IN)	MM	(IN)
1	M6 x 1.0	701	N/A	N/A	203	204	205	28.0	1.1024	23.5	0.9252

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.