SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 9 (ENGINE MECHANICAL - 4.3L UNIT REPAIR)REPAIR INSTRUCTIONSPISTON, CONNECTING ROD & BEARING INSTALLATIONINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
  1. Apply clean engine oil to the following components:
    • The piston
    • The piston rings
    • The cylinder bore
    • The bearing surfaces
  2. Install the J 5239  onto the connecting rod bolts.
    Fig 1: Connecting Rod Bolt Guide Set
    G02503048Courtesy of GENERAL MOTORS CORP.
  3. Install the J 8037  onto the piston and compress the piston rings.
    Fig 2: Compressing Piston Rings
    G02503049Courtesy of GENERAL MOTORS CORP.

    Important:  The mark on the top of the piston must face the front of the engine block.

    When assembled, the flanges on the connecting rod and connecting rod cap should face to the front of the engine block on the left bank, and to the rear of the engine block on the right bank.

  4. Install the piston and connecting rod assembly, and the J 8037 into the proper cylinder bore.
    Fig 3: Installing Piston & Connecting Rod Assembly
    G02503050Courtesy of GENERAL MOTORS CORP.
  5. Use the J 8037 and the J 5239 and lightly tap the top of the piston with a wooden hammer handle.
    1. 5.1. Hold the J 8037 firmly against the engine block until all of the piston rings have entered the cylinder bore.
    2. 5.2. Use the J 5239 in order to guide the connecting rod onto the crankshaft journal.
      Fig 4: Installing Piston Into Engine Block
      G02503051Courtesy of GENERAL MOTORS CORP.
  6. Remove the J 5239  .
  7. Install the connecting rod caps, bearings, and nuts.
    1. 7.1. Tighten the nuts evenly on the first pass to 27 N.m (20 Lb ft).
    2. 7.2. Use the J 36660-A  in order to tighten the nuts on the final pass an additional 70 degrees.
      Fig 5: Installing Connecting Rod Caps, Bearings & Nuts
      G02503053Courtesy of GENERAL MOTORS CORP.
  8. After the piston and connecting rod assemblies have been installed, lightly tap each connecting rod assembly, parallel to the crankpin, in order to ensure that the connecting rods have side clearance.
  9. Use a feeler gage or a dial indicator to measure the connecting rod side clearance between the connecting rod caps. The connecting rod side clearance should be 0.15-0.44 mm (0.006-0.017 in).
    Fig 6: Measuring Connecting Rod Side Clearance
    G02503054Courtesy of GENERAL MOTORS CORP.
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.