2004 Chevrolet Express 2500

[dave945]

Okay, so you may recall this van just surpassed 500,000 miles. We’ve been looking for a replacement for it for a while, but the selection is slim and what is out there is way overpriced as far as I’m concerned. Which got me to thinking, “what if I just took some time/money and got the engine cleaned up and rebuilt, along with any other things wrong with the van. I could get the seats reupholstered, carpeting or flooring put in, go through the suspension/steering components and redo the sound system and probably come out ahead of the game and have a van that should be solid for the next couple hundred thousand miles.”

What do you think?  I’m not sure what the rebuild/cleanup would entail at this point, just throwing some thoughts around.


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[stlaser]

$10-$20k depending on what exactly you redo unless you’re doing it yourself then obviously just parts.

[rpar86]

Don may have a 6.0 for it soon… ;)

[TexasRedNeck]

$3k. Get a motor from a wrecking yard


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[Bob Smith]

I would think it would mostly depend on “ if you need something on the road or if it could be down while refreshing”. If looking at replacing with used then most likely better to rebuild what you have.

[dave945]

Don may have a 6.0 for it soon… ;)

I did think of that. But I’ll wait until he finishes shaking it down. That would make for a sweet riding people mover. :)


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[KensAuto]

Does everything have 500k? Transmission, diff, front end, sensors, HVAC system, etc. ?

If it has to be reliable, those are things that can potentially, scratch that, Will cause you to chase your tail unless done at the same time.

[dave945]

Does everything have 500k? Transmission, diff, front end, sensors, HVAC system, etc. ?

If it has to be reliable, those are things that can potentially, scratch that, Will cause you to chase your tail unless done at the same time.

Pretty much everything is original. Haven’t had to do too much with it. I see what you’re getting at, either do a full refresh or suffer the consequences of having 17 year 500k Mike’s old parts that will continue to age further.

So pick up a 6.0 w/4l80e from the junk yard, refresh/rebuild both.  Then pull old engine, refresh everything still on the chassis (brakes, suspension, differentials, steering, interior). Then drop in new engine/transmission, get it all buttons up and then drive it like I stole it.


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[TexasRedNeck]

Sounds like a plan


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[KensAuto]

Absolutely.
Or play the lottery.

[stlaser]

$10-$20k depending on what exactly you redo unless you’re doing it yourself then obviously just parts.

So we’re back to what I said eh? 

[Flyin6]

Don may have a 6.0 for it soon… ;)

I just may!

Dave, rebuilding yourself makes total sense. What do you really get buying new? Nothing really.

I'd consider buying one of Chevy's plug and play 6.2 liter setups with a 6-speed. Remove and reinstall, and with a warranty from Chevrolet. A lot more power, way better fuel economy, proven GM setup, and your van will feel much stronger with that low 1st and 2nd gears.

[dave945]

So the engine has been having a major miss, check engine light and hesitation for a while now. I finally got the time to take the engine cover off and swap plugs and wires for an initial attempt to clean up how it was running. As soon as I took the engine cover off, I found this.


After reconnecting the plug wire to the coil it ran a little better. Still swapping all the plugs and wires. I’ll let your know how it is after.


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[TexasRedNeck]

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[Bigdave_185]

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[Flyin6]

Dave...Local Dave, that is...You're gonna take some hits!

If you need another 6.0, I have a contact that has two of them on hand

[dave945]

I know I will, if I didn’t think I could handle it I wouldn’t have said anything. Plus, that’s part of what I like about this community. No pulling of punches.


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[EL TATE]

don't feel bad, paid $170 in diagnostics and $200 in flat bed towing to find out I had left the fuel rail harness unplugged in my 1991 Beretta pace car. (bitchin ride btw) and this is 1999 money we're talking about. at least you solved your own mystery.

[dave945]

Swapped out all the plugs and plug wires. All the old wires were breaking and coming apart when I was removing them. I’ll post a pic of the plugs for everyone’s enjoyment. Also found two  broken exhaust manifold bolts on the rear passenger side, and one broken on driver side rear.  I’m going to try the Dorman clamps for the exhaust manifold and see how they work out.


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[KensAuto]

When you installed the wires did you make sure to connect both ends?

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[Sammconn]

When you installed the wires did you make sure to connect both ends?

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[dave945]

I only connected four of the plug wires directly, i spliced the others into a switch panel so I can have a  Variable Cylinder Management system to save gas. Plus that will make the engine last longer since I’m only use a portion of it.

[wilsonphil]

don't feel bad, paid $170 in diagnostics and $200 in flat bed towing to find out I had left the fuel rail harness unplugged in my 1991 Beretta pace car. (bitchin ride btw) and this is 1999 money we're talking about. at least you solved your own mystery.

Dont know which part of this post is the worst part, spending the money on a screwup OR admitting to owning a Beretta Pace Car?  it hurts just thinks about it

[stlaser]

Hard to believe they allowed there to be a beretta pace car in the first place…… but yes Tate admitting he owned one too! Lol

[dave945]

Would you prefer he admit to owning a ford Probe?


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[stlaser]

Would you prefer he admit to owning a ford Probe?


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Honestly, they’re in the same category however I think the probes were actually somewhat fast if I recall…..

[EL TATE]

don't feel bad, paid $170 in diagnostics and $200 in flat bed towing to find out I had left the fuel rail harness unplugged in my 1991 Beretta pace car. (bitchin ride btw) and this is 1999 money we're talking about. at least you solved your own mystery.

Dont know which part of this post is the worst part, spending the money on a screwup OR admitting to owning a Beretta Pace Car?  it hurts just thinks about it

um, excuse me, who WOULDN'T want to own this magnificent beast in a 3.1L monster powerplant and automatic trans combo?

[dave945]

Them’s purty colors. 


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[wilsonphil]

AHHHHHHHHHH now my eyes hurt!

[Sammconn]

AHHHHHHHHHH now my eyes hurt!

X2

 

[stlaser]

Well, if that doesn’t take you back to the 90’s I’m not sure what does…..

I believe the 90’s was the last time I owned a running gm vehicle too!

[Bigdave_185]

I had a auto shop teacher that collected the geo metros.  Had a whole shop full of them!!
We did tons of learning on them.  At one point we stuffed a gas powered leaf blower into the engine compartment attached to the air intake hose. String for throttle on and off. Did pretty well for what it was for a power increase. Terribly noisy going down the street lol


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[KensAuto]

Them’s purty colors. 


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Looks like something someone from Washington would own...
.. at least it's not a Yugo, Renault Alliance, or an any car from the 80s.

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[dave945]

It’s all buttoned back up for now. All plugs and wires replaced and connected. I received the exhaust manifold brackets from Amazon and installed them. They were well packaged and quite stout.   Seemed to be about 5/16 thick brackets(I didn’t measure” and cam with the necessary bolts for install. Installation was easy and straightforward except that I couldn’t fit my torque wrench into the spot it needed to be so I free handed it.   Took it for a test drive and it definitely drives/accelerates better and there is quite a bit less noise, and no noticeable exhaust leaks from the manifold.

Still has a check engine light, but need to get to the auto Parts store to use their scanner and see what’s complaining now.

[Bob Smith]

Those existing codes might need to be cleared with the scanner and all might be well

[Flyin6]

Those existing codes might need to be cleared with the scanner and all might be well

X2. Clear the codes and I bet you're going to be "ops normal"