Engine Mount Inspection Chevrolet Chevy Express G2500

Engine Mount Inspection

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g2500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Inspect for loose or missing bolts at the following locations: The engine mount bracket to the engine. The engine mount to the frame.
3. Replace loose or missing bolts. Refer to the following procedures: «Engine Mount Replacement - Left»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) «Engine Mount Replacement - Right»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l)
4. Remove the starter, when checking the right side only. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
5. Using a jack on the square tab at the rear of the engine block raise the engine in order to complete the following tasks: Remove weight from the engine mount. Place a slight tension on the rubber cushion. Observe the engine mount while raising the engine.
6. Replace the engine mount if the following conditions exist: Heat check cracks cover the hard rubber surface. The rubber cushion is separated from the metal plate of the engine mount. There is a split through the rubber cushion.
7. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g2500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the engine mount to frame mounting bolts.
3. Use a jack on the square tab at the rear of the engine block, and raise the engine, left side shown.
4. Remove the engine mount to engine mounting bolts.
5. Remove the engine mount.

1. Install the engine mount to the vehicle.
2. Install the engine mount to engine mounting bolts. Tighten: Tighten the engine mount to engine bolts to 50 N.m (37 lb ft).
3. Lower the engine.
4. Install the engine mount to frame mounting bolts. Tighten: Tighten the engine mount to frame bolts to 60 N.m (44 lb ft).
5. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g2500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove the engine mount to frame mounting bolts.
4. Use a jack on the square tab at the rear of the engine block, and raise the engine, left side shown.
5. Remove the engine mount to engine mounting bolts.
6. Remove the engine mount from the vehicle.

1. Install the engine mount to the vehicle.
2. Install the engine mount to engine mounting bolts. Tighten: Tighten the engine mount to engine mounting bolts to 50 N.m (37 lb ft).
3. Lower the engine.
4. Install the engine mount to the frame mounting bolts. Tighten: Tighten the engine mount to frame mounting bolts to 60 N.m (44 lb ft).
5. Install the starter. Refer to «Starter Motor Replacement (4.8L, 5.3L, and 6.0L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Starter Motor Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/chevy-express-g2500/1996-2012/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the engine mount. Refer to «Engine Mount Replacement - Left»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) or «Engine Mount Replacement - Right»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
3. Remove the engine mount adapter mounting bolts.
4. Remove the engine mount adapter.

1. Install the engine mount adapter.
2. Install the engine mount adapter mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the engine mount. Refer to «Engine Mount Replacement - Left»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) or «Engine Mount Replacement - Right»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
4. Lower the vehicle.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls - 4.3L.
2. Disconnect the PCV valve hose assembly from the intake manifold.
3. Disconnect the PCV valve hose assembly from the left valve rocker arm cover.
4. Inspect the tube and hose for cuts or cracking.
5. Inspect the grommets in the valve rocker arm covers for cuts or cracking.
6. Replace the PCV hose/tube as required.

1. Connect the PCV valve hose assembly to the intake manifold.
2. Connect the PCV valve hose assembly to the left valve rocker arm cover.
3. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls - 4.3L.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
2. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner duct.
3. Disconnect the PCV tube from the right valve rocker arm cover.
4. Disconnect the PCV valve hose assembly from the intake manifold.
5. Disconnect the PCV valve hose assembly from the left valve rocker arm cover.
6. Inspect the tube and hose for cuts or cracking.
7. Inspect the grommets in the valve rocker arm covers for cuts or cracking.
8. Replace the PCV hose/tube as required.

1. Connect the PCV valve hose assembly to the intake manifold.
2. Connect the PCV valve hose assembly to the left valve rocker arm cover.
3. Connect the positive crankcase PCV tube to the air cleaner duct.
4. Connect the PCV tube to the right valve rocker arm cover.
5. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
3. Remove the coolant reservoir bolt and set the reservoir aside.
4. Disconnect the positive crankcase ventilation (PCV) tube from the air cleaner outlet duct.
5. Remove the retaining nut (1) from the air cleaner outlet.
6. Remove the air cleaner outlet duct (2) from the throttle body assembly.
7. Disconnect the accelerator control cable from the throttle shaft and the accelerator control cable bracket. Refer to «Accelerator Controls Cable Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
8. Disconnect the cruise control cable, if equipped, from the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/cruise-control-systems/#cruise-control-system) in Cruise Control.
9. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover.
10. Disconnect the following electrical connectors: The fuel meter body assembly connector (1) The EVAP canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3)
11. Disconnect the following electrical connectors: The throttle position (TP) sensor (1) The idle air control (IAC) motor (2) The engine coolant temperature (ECT) gage sensor (3) The A/C high pressure switch (4), if equipped
12. Remove the engine wiring harness bracket from the intake manifold stud.
13. Move and secure the engine wiring harness out of the way.
14. Disconnect the A/C vacuum hose from the intake manifold.
15. Remove the power brake booster vacuum hose bracket and nut from the intake manifold stud.
16. Disconnect the power brake booster vacuum hose from the intake manifold.
17. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
18. Remove the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
19. Remove the fuel lines from the fuel meter body assembly. Refer to «Fuel Hose/Pipes Replacement - Engine Compartment»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
20. Remove the distributor cap. Refer to «Distributor Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Electrical.
21. Remove the ignition control module. Refer to «Ignition Control Module Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Electrical.
22. Remove the studs for the upper intake manifold.
23. Remove the upper intake manifold.
24. Remove the upper intake manifold gasket from the groove.
25. Discard the gasket.
26. Remove the seal from the fuel meter body assembly.
27. Discard the seal.
28. Clean all sealing surfaces and the inside of the upper intake manifold with a shop towel and cleaning solvent.
29. Inspect the upper intake manifold for the following: Cracks or other damage to the exterior Cracking or damage to the gasket grooves Loose or damaged bolt hole thread inserts
30. If replacing the upper intake manifold, turn and remove the power brake booster vacuum tube fitting from the upper intake manifold.
31. Remove and discard the seal.
32. If replacing the upper intake manifold, turn and remove the PCV valve cover from the upper intake manifold.
33. Remove and discard the seal.
34. Remove the throttle body if replacing the upper intake manifold. Refer to «Throttle Body Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) .
35. Remove the MAP sensor if replacing the upper intake manifold. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

1. Install the throttle body, if removed. Refer to «Throttle Body Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) .
2. Install the MAP sensor, if removed. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
3. Install the PCV valve cover, if removed, using the following procedure: Install a NEW seal (O-ring) on the PCV valve cover. Lubricate the seal with clean engine oil. Install the PCV valve cover in the upper intake manifold. Turn and lock the PCV valve cover in position.
4. Install the power brake booster vacuum tube fitting, if removed, using the following procedure: Install a NEW seal (O-ring) on the power brake booster vacuum tube fitting. Lubricate the seal with clean engine oil. Install the power brake booster vacuum tube fitting in the upper intake manifold. Turn and lock the power brake booster vacuum tube fitting in position.
5. Install a NEW seal on the fuel meter body assembly.
6. Lubricate the seal with clean engine oil.
7. Install a NEW upper intake manifold to lower intake manifold gasket in the groove of the upper intake manifold.
8. Install the upper intake manifold onto the lower intake manifold.
9. If reusing the fasteners, apply Threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the upper intake manifold attaching bolts.
10. Install the upper intake manifold attaching studs. Tighten: Tighten the upper intake manifold attaching studs on the first pass to 5 N.m (44 lb in). Tighten the upper intake manifold attaching studs on the final pass to 9 N.m (80 lb in).
11. Install the fuel lines to the fuel meter body assembly. Refer to «Fuel Hose/Pipes Replacement - Engine Compartment»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
12. Install the distributor cap. Refer to «Distributor Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Electrical.
13. Install the ignition control module. Refer to «Ignition Control Module Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Electrical.
14. Install the EVAP canister purge solenoid valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
15. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. Tighten: Tighten the accelerator control cable bracket nuts and studs to 12 N.m (106 lb in).
16. Connect the A/C vacuum hose to the intake manifold.
17. Install the power brake booster vacuum hose bracket and nut to the intake manifold stud. Tighten: Tighten the power brake booster vacuum hose bracket nut to 11 N.m (97 lb in).
18. Connect the power brake booster vacuum hose to the intake manifold.
19. Install the bracket for the engine wiring harness on the lower intake manifold stud.
20. Install the engine wiring harness bracket nut. Tighten: Tighten the engine wiring harness bracket nut to 12 N.m (106 lb in).
21. Connect the following electrical connectors: The fuel meter body assembly connector (1) The EVAP canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3)
22. Connect the following electrical connectors: The throttle position (TP) sensor (1) The idle air control (IAC) motor (2) The engine coolant temperature (ECT) gage sensor (3) The A/C high pressure switch (4), if equipped
23. Connect the PCV valve hose assembly to the intake manifold and the valve rocker arm cover.
24. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/cruise-control-systems/#cruise-control-system) in Cruise Control.
25. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to «Accelerator Controls Cable Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
26. Install the air cleaner outlet duct (2) on the throttle body assembly.
27. Tighten the retaining nut (1). Tighten: Tighten the nut to 2 N.m (18 lb in).
28. Connect the PCV tube to the air cleaner outlet duct.
29. Position the coolant reservoir. Install the bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).
30. Install the air cleaner. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
31. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.

Scheme 12

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/chevy-express-g2500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
3. Remove the upper intake. Refer to «Intake Manifold Replacement - Upper»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
4. Disconnect the A/C compressor (1) and the exhaust gas recirculation (EGR) connector (2).
5. Remove the ground wire (4) from the stud at the water outlet.
6. Remove the radiator inlet hose at the water outlet. Refer to «Radiator Hose Replacement - Inlet»(/chevrolet/chevy-express-g2500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
7. Remove the heater hose from the intake manifold. Refer to «Heater Hose Replacement - Inlet»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and «Heater Hose Replacement - Outlet»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
8. Remove the water pump inlet hose from the intake manifold.
9. Remove the accelerator control cable bracket from the throttle body and the intake manifold.
10. Remove the distributor. Refer to «Distributor Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
11. Remove the spark plug wire harness retainer from the EGR valve inlet pipe.
12. In order to remove the front intake manifold bolt, perform the following: Remove the A/C compressor discharge hose from the vehicle. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Discharge Hose Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning. Remove the A/C compressor suction hose from the vehicle. Refer to «Suction Hose Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) . Loosen the nut for the power steering pump rear bracket. Remove the bolts and the nut for the power steering pump mounting bracket. Leave the A/C compressor, if equipped, and the power steering pump on the bracket. Slide the power steering pump bracket forward to access the bolt at the front of the intake manifold.
13. Remove the engine coolant temperature (ECT) sensor wire connector, if equipped, from the engine wiring harness bracket.
14. Remove the lower intake manifold bolts.
15. Remove the intake manifold assembly.
16. Remove and discard the lower intake manifold gaskets.
17. Clean all sealing surfaces and the intake manifold. Refer to «Intake Manifold Cleaning and Inspection»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
18. If the intake manifold requires replacement refer to «Intake Manifold Disassemble (LU3)»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l__intake-manifold-disassemble-lu3) and «Intake Manifold Assemble (LU3)»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .

Scheme 13

1. Apply a 4.0 mm (0.157 in) patch of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the cylinder head side of the lower intake manifold gasket at each end.
2. Install the lower intake manifold gasket onto the cylinder head. Use the gasket locator pins in order to properly seat the lower intake manifold gasket on the cylinder head.
3. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the front top of the engine block.
4. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
5. Apply a 5 mm (0.197 in) bead of adhesive GM P/N 12346141 (Canadian P/N 10953433) or equivalent to the rear top of the engine block.
6. Extend the adhesive bead 13 mm (0.50 in) onto each lower intake manifold gasket.
7. Install the lower intake manifold onto the engine block.
8. If reusing the fasteners, apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the threads of the lower intake manifold bolts.
9. Install the lower intake manifold bolts.
10. Tighten the lower intake manifold bolts. Tighten: Tighten the bolts on the first pass in sequence (1-8) to 3 N.m (27 lb in). Tighten the bolts on the second pass in sequence (1-8) to 12 N.m (106 lb in). Tighten the bolts on the final pass in sequence (1-8) to 15 N.m (11 lb ft).
11. Position the power steering pump mounting bracket.
12. Install the power steering pump mounting bracket, 3 bolts and the nut. Tighten: Tighten the power steering pump mounting bracket bolts and the nut to 41 N.m (30 lb ft). Tighten the power steering pump rear bracket nut to 41 N.m (30 lb ft). Tighten the power steering pump mounting bracket bolts and the nut and the power steering pump rear bracket nut to 41 N.m (30 lb ft).
13. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
14. Install the A/C compressor discharge hose from the vehicle. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Discharge Hose Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning.
15. Install the A/C compressor suction hose from the vehicle. Refer to «Suction Hose Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning.
16. Remove the spark plug for number one cylinder.
17. Rotate the crankshaft until number one cylinder is in the compression stroke.
18. Align the 2 reference marks on the crankshaft balancer (1) and (4) with the 2 alignment marks (2) and (3) on the front cover.
19. Install the spark plug. Refer to «Spark Plug Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
20. Install the distributor. Refer to «Distributor Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
21. Install the upper intake. Refer to «Intake Manifold Replacement - Upper»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
22. Install the accelerator control cable bracket, studs, and nuts to the intake manifold and the throttle body. Tighten: Tighten the accelerator control cable bracket nuts and studs to 12 N.m (106 lb in).
23. Install the water pump inlet hose to the intake manifold.
24. Install the heater hoses. Refer to «Heater Hose Replacement - Inlet»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and «Heater Hose Replacement - Outlet»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
25. Install the radiator inlet hose to the water outlet. Refer to «Radiator Hose Replacement - Inlet»(/chevrolet/chevy-express-g2500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
26. Connect the following electrical connectors: The fuel meter body assembly connector (1) The evaporative emission (EVAP) canister purge solenoid valve (2) The manifold absolute pressure (MAP) sensor (3) The A/C high pressure switch (4), if equipped
27. Connect the following electrical connectors: The A/C compressor clutch (1), if equipped The EGR valve (2) The ECT sensor (3)
28. Install the ground wire (4) and the nut to the water outlet stud. Tighten: Tighten the ground wire nut to 10 N.m (88 lb in).
29. Install the cruise control cable, if equipped to the throttle shaft and the accelerator control cable bracket. Refer to «Cruise Control Cable Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/cruise-control-systems/#cruise-control-system) in Cruise Control.
30. Install the accelerator control cable to the throttle shaft and the accelerator control cable bracket. Refer to «Accelerator Controls Cable Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
31. Refill the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/chevy-express-g2500/1996-2012/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
32. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls-4.3L.
33. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/chevy-express-g2500/1996-2012/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
34. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls - 4.3L.
3. Remove the positive crankcase ventilation hose from the valve rocker arm cover.
4. Disconnect the engine coolant temperature (ECT) gage sensor electrical connector.
5. Remove the ECT gage sensor connector from the bracket.
6. Remove the spark plug wires for the left side of the engine from the distributor cap.
7. Remove the air conditioning compressor discharge hose, if equipped. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Discharge Hose Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
8. Remove the air conditioning compressor suction hose, if equipped. Refer to «Suction Hose Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.

1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
5. Install the air conditioning compressor discharge hose, if equipped. Refer to «Discharge Hose Replacement (4.8L, 5.3L, 6.0L )»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Discharge Hose Replacement (4.3L)»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
6. Install the air conditioning compressor suction hose, if equipped. Refer to «Suction Hose Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
7. Connect the spark plug wires to the distributor cap.
8. Install the ECT gage sensor electrical connector to the bracket.
9. Connect the ECT gage sensor electrical connector.
10. Install the PCV hose to the valve rocker arm cover.
11. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
12. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls - 4.3L.

1. Remove the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls - 4.3L.
3. Remove the coolant reservoir bolt and set the reservoir aside.
4. Remove the spark plug wires for the right side of the engine from the distributor cap.
5. Remove the positive crankcase ventilation (PCV) tube from the valve rocker arm cover and the air inlet duct.
6. Move the engine wiring harness aside.
7. Remove the screw holding the oil fill tube to the oil fill tube lower support.
8. Remove the oil fill tube from the right valve rocker arm cover and move aside.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.

1. Install the NEW valve rocker arm cover gasket into the groove of the valve rocker arm cover.
2. Install the NEW valve rocker arm cover bolt grommets into the valve rocker arm cover.
3. Install the valve rocker arm cover onto the cylinder head.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the valve rocker arm cover bolts to 12 N.m (106 lb in).
5. Install the oil fill tube in the right valve rocker arm cover.
6. Install the oil fill tube and bolt to the oil fill tube lower support. Tighten: Tighten the oil fill tube to lower support bolt to 5 N.m (44 lb in).
7. Install the PCV hose in the valve rocker arm cover and to the air inlet duct.
8. Connect the spark plug wires to the distributor cap.
9. Position the engine wiring harness.
10. Install the engine cover. Refer to «Engine Cover Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
11. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/chevy-express-g2500/1996-2012/remont/testing-diagnostics/#engine-control-system-43l-introduction) in Engine Controls - 4.3L.
12. Reposition the coolant reservoir and install the bolt. Tighten: Tighten the bolt to 11 N.m (97 lb in).

1. Remove the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .
2. Remove the valve rocker arms.
3. Remove the valve rocker arm supports.
4. Remove the valve pushrods.
5. Clean and inspect the valve rocker arm and the valve pushrod. Refer to «Valve Rocker Arm and Push Rods Cleaning and Inspection»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .

Scheme 14

Scheme 15

1. Install the valve pushrods.
2. Install the valve rocker arm supports.
3. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent to the following valve rocker arm contact surfaces: Valve pushrod socket (1) Roller pivot (2) Valve stem tip (3)
4. Install the valve rocker arm assemblies as follows: Finger start the bolt at location (1) Finger start the bolt at location (2) Finger start the bolt at location (3) Finger start the remaining valve rocker arm bolts
5. Rotate the crankshaft balancer to position the crankshaft balancer alignment mark (1) 57-63 degrees clockwise or counterclockwise from the engine front cover alignment tab (2).
6. Tighten the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 30 N.m (22 lb ft).
7. Install the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/chevy-express-g2500/1996-2012/remont/mechanical/#engine-mechanical-43l) .