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HOMESERVICE MANUALSCHEVROLET2002CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 8.1 GREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMREPAIR INSTRUCTIONSWATER PUMP REPLACEMENT (4.3L, 5.0L, AND 5.7L)INSTALLATION PROCEDURE
2002 Chevrolet Chevy Express G3500, Van Passenger Extended, 8.1 G

Installation Procedure

2002 Chevrolet Chevy Express G3500, Van Passenger Extended, 8.1 GSECTION Installation Procedure
  1. Install the gasket and the water coolant pump.
  2. Apply Teflon Pipe Sealant GM P/N 12346004 or equivalent thread sealant on the water pump mounting bolts.
    CAUTION: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  3. Install the water pump mounting bolts.

    Tighten 

    Tighten the bolts to 42 N.m (31 ft lbs).

    Fig 1: Installing Gasket & Water Coolant Pump
    G01699578Courtesy of GENERAL MOTORS CORP.
  4. Install the heater outlet hose to the water pump.
    Fig 2: Installing Heater Outlet Hose
    G01699579Courtesy of GENERAL MOTORS CORP.
  5. Install the by-pass hose to the water pump.
    Fig 3: Installing By-Pass Hose
    G01699580Courtesy of GENERAL MOTORS CORP.
  6. Connect the radiator outlet hose to the water pump.
    Fig 4: Connecting Radiator Outlet Hose
    G01699581Courtesy of GENERAL MOTORS CORP.
  7. Install the water pump pulley to the water pump.
  8. Install the water pump pulley mounting bolts.

    Tighten 

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

  9. Install the drive belt in the vehicle. Refer to one of the following procedures:
  10. Install the fan clutch in the vehicle. Refer to Fan Clutch Replacement .
  11. Install the upper fan shroud. Refer to Fan Shroud Replacement .
  12. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement .
    Fig 5: Installing Water Pump Pulley & Mounting Bolts
    G01699582Courtesy of GENERAL MOTORS CORP.
  13. Install the air intake duct to the throttle body.
  14. Install the air cleaner assembly in the vehicle.
  15. Connect the battery negative cable to the battery terminal.
    CAUTION: When adding coolant, use DEX-COOL coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.
  16. Refill the engine coolant system. Refer to Draining and Filling Cooling System .
  17. Bleed the air from the cooling system.
  18. Inspect the system for coolant leaks.
    Fig 6: Installing Air Intake Duct
    G01699583Courtesy 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.