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2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.

40 Page 1
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Vehicle: Application and ID
Labels

Gross Vehicle Weight Rating - Label

Label - Vehicle Certification

The vehicle certification label is permanently located on the edge of the driver's door. Refer to this label in order to obtain the following
information:
^ The Gross Vehicle Weight Rating (GVWR)
^ The Gross Axle Weight Rating (GAWR), front and rear

The Gross Vehicle Weight (GVW) must not exceed the Gross Vehicle Weight Rating (GVWR).

The GVW is the weight of the vehicle and everything the vehicle carries. Include the following items when figuring the GVW:
^ The base vehicle weight (factory weight)
^ The weight of any added vehicle accessories
^ The weight of the driver and the passenger
^ The weight of any cargo being carried

The front and rear Gross Axle Weights (GAW) must not exceed the Gross Axle Weight Ratings (GAWR), front and rear.

The GAW is the weight exerted on one of the axles (front or rear).
Label - Service Parts ID
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Label - Service Parts ID

The service parts identification label has been developed and placed on the vehicle to help service and parts personnel identity parts and options
that were originally installed on the vehicle.

The service parts identification label is located on the inside of the left quarter trim access panel (1). Refer to RPO Code List in General
Information for a definition of the codes that are printed on the service parts identification label or referred to in this service information.
Tire Placard
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The tire placard is located on the inside edge of the driver's door. Refer to the tire placard to obtain the following information:
^ Maximum vehicle capacity weight
^ Cold tire inflation pressures
^ Original equipment tire sizes
^ Original equipment tire speed ratings
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Vehicle: Application and ID
Vehicle Identification Number (VIN)

Engine ID and VIN Derivative Location

The eighth digit of the Vehicle Identification Number (VIN) identifies the engine. The adhesive-backed labels attached to the engine, laser etching
or stampings on the engine block indicate the engine unit number/date code. All engines are stamped with a VIN derivative

The primary location (1) of the VIN derivative and the secondary location (2) of the VIN derivative for the 3400 (LA1) engine is above the starter
motor on the engine block. For additional information, refer to VIN Derivative.
VIN Derivative

VIN Derivative Table

All engines and transmissions are stamped with a partial Vehicle Identification Number (VIN). A VIN derivative may be used in order to determine
it a vehicle contains the original engine or transmission by matching the VIN derivative positions to their accompanying positions in the complete
VIN. The following table identifies the different VIN derivative characters, the equivalent VIN positions, the character positions and their
respective definitions.

VIN Derivative

A VIN derivative can be used to determine if a vehicle contains the original engine or transmission by matching the VIN derivative positions to
their accompanying positions in the complete VIN:
Transmission ID and VIN Derivative Location
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Transmission ID Location

All automatic transmissions have a metal Identification (ID) nameplate (9) attached to the case exterior.
VIN Derivative
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VIN Derivative Table

All engines and transmissions are stamped with a partial Vehicle Identification Number (VIN). A VIN derivative may be used in order to determine
it a vehicle contains the original engine or transmission by matching the VIN derivative positions to their accompanying positions in the complete
VIN. The following table identifies the different VIN derivative characters, the equivalent VIN positions, the character positions and their
respective definitions.

VIN Derivative

A VIN derivative can be used to determine if a vehicle contains the original engine or transmission by matching the VIN derivative positions to
their accompanying positions in the complete VIN:
Vehicle Identification

Vehicle Identification

The Vehicle Identification Number (VIN) plate (1) is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the
instrument panel and can be seen through the windshield from the outside of the vehicle.

Vehicle Identification Number (VIN) System


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Vehicle: Application and ID
RPO Codes

RPO Code Label Information

Typical RPO Label

DESCRIPTION
The Regular Production Option (RPO) label is placed on the vehicle to aid service and parts personnel in identifying parts and options
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originally installed on the vehicle. A typical RPO label is shown in the accompanying image.

Knowledge of the RPO identification system can help identifying and ordering parts. Systems and assemblies may be uniquely identified by
refering to the label.

GM assigns a three digit/letter code to parts, assemblies, and systems. These RPO codes designate "options" and are assigned by General
Motors. Some system testing and part suppliers require RPO information to accurately match systems, parts and assemblies.

LOCATION OF RPO LABEL


Locations of RPO labels vary by carline.

REPLACEMENT LABELS
Replacement labels are available through GM Service Parts Operations (SPO) for the following:

^ Vehicle Emission Control Information (Exhaust Emission Tune-up)


^ Spare Wheel Caution
^ Jacking
^ Spare Tire Storage
^ Serpentine Belt Routing
^ Engine Fan Caution

These and other labels will be found in the Standard Parts Catalog.

The Vehicle Certification Label, Tire Pressure Placard, and Service Parts Identification Label are not available as service parts.

RPO Code List


RPO Code List

RPO................................................................................................................................................................................................................. Description

ABA................................................................................................................................................................ Seat Configuration #1 (Req. 7 Pass. ZP7);


.............................................................................................................................................................................................. Row 1: Front Buckets - 2;
......................................................................................................................................................................... Row 2: 40/60 Bench - 2 (RPO AT5);
......................................................................................................................................................................... Row 3: 50/50 Bench - 3 (RPO AM9)
ABB................................................................................................................................................................ Seat Configuration #2 (Req. 7 Pass. ZP7);
..................................................................................................................................................................... Row 1: Front Buckets - 2; Row 2/3: Rear
............................................................................................................................................................................................... Buckets - 3/2 (RPO AL4)
ABD................................................................................................................................................................. Seat Configuration #4 (Req. 7 Pass ZP7);
.............................................................................................................................................................................................. Row 1: Front Buckets - 2;
............................................................................................................................................................................ Row 2: Captain Seats - 2 (RPO A04);
............................................................................................................................................................................. Row 3: 50/50 Bench - 3 (RPO AM9)
ABH................................................................................................ Seat Configuration #8 (Req. 7 Pass ZP7); Row 1: Front Buckets - 2; (RPO: AV5);
.............................................................................................................................................................................. Row 2: Solid Bench -2 (RPO AQ3);
.............................................................................................................................................................................. Row 3: Solid Bench - 3 (RPO AN1)
AB3....................................................................................................................................................................................... Seating Arrangement 6 Pass
AB4............................................................................................................................................................. Seating Arrangement 5 Pass, w/Bucket Seats
AB7.................................................................................................................................................................................. Window Tinted, Deep, Liftgate
ACG..................................................................................................................................................................... Filler Opaque Glass, Side RR Window
AG1.................................................................................................................................................................. Adjuster Front Seat Power 6-Way Driver
AG2............................................................................................................................................................ Adjuster, Front Passenger Seat Power 6-Way
AG9.......................................................................................................................................................................... Adjuster Seat Power 6-Way Dr/Pass
AJ1.............................................................................................. Window Tinted Deep, All Except Windshield and Doors (FRT)(Solar Privacy Glass)
AJ7................................................................................................................................. Restraint System FRT Seat, Inflatable, Dr/Pass, Front and Side
AL4............................................................................................................................................... Seat RR Bucket w/Reclin, HDREST (2nd /3rd Rows)
AM7.............................................................................................................................................................. Seat RR Folding (3-Pass Bench) (3rd Row)
AM9.......................................................................................................................... Seat Rr Split Back, Folding (50/50 Split Bench 3-Pass) (3rd Row)
AN2..................................................................................................................................................................... Seat Child Integral Single RH 2nd Row
AN5.............................................................................................................................................................. Seat Child Integral - Dual LH/RH 2nd Row
AP9........................................................................................................................................................................................................... Restraint Cargo
AQ4....................................................................................................................................................................................................................... Seat RR
AR9.............................................................................................................................................................................................. Seat Frt Bucket, Deluxe
AT5........................................................................................................................................... Seat Rr Center, Folding 2-Pass 40/60 Bench, (2nd Row)
AU0.................................................................................................................................. Lock Control Remote Entry (RFA)(Int Lights - On/Fade Oft)
AV5..................................................................................................................................................................................... Seat, Front Bucket, Highback
AX4................................................................................................................................................................ Restraint Conversion Seat, Man, European
A20.......................................................................................................................................... Window, Rear Quarter Vent Swing-Out-Power-Operated
A26.................................................................................................................................................................................. Window European Glazing, All
A31................................................................................................................................................................................... Window Power-Operated Side;
....................................................................................................................................................................................... Domestic Inc.: Express Down;
...................................................................................................................................................................... GME Inc. Auto Down/Auto Up/Anti-jam
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BAD................................................................................................................................................................................... Equipment Modification Trim
BAG........................................................................................................................................................................................................ Part PKG Export
BA8..................................................................................................................................................................... Compartment Stowage, FRT Seat, Pass
BS1..................................................................................................................................................................................... Insulation Acoustical Package
BA8........................................................................................................................................................... Compartment Stowage, Front Seat, Passenger
BF1............................................................................................................................................................................................. Covering RR Floor Mats
BF9........................................................................................................................................................................................... Covering FRT Floor Mats
BG9............................................................................................................................................................................................... Covering Floor Rubber
B18................................................................................................................................................................................... Ornamentation Interior, Deluxe
B3V................................................................................................................................................................................................................... Test Water
B37....................................................................................................................................................................... Covering Floor Mat, FRT & RR, AUX
B4U........................................................................................................................................................................................ Performance Package Sport
B57.................................................................................................................................................................................. Ornamentation Exterior, Deluxe
C25..................................................................................................................................................................... Wiper System RR Window, Intermittent
C28............................................................................................................................................................................................. Pump Coolant, Auxiliary
C3L.............................................................................................................................................................................................. GVW Rating 5357 Lbs.
C34..................................................................................................... HVAC System Air Conditioner Heater Combination (FRT/RR w/Rear Controls)
C49................................................................................................................................................................................... Defogger RR Window, Electric
C60............................................................................................................................................. HVAC System Air Conditioner Front Manual Controls
C69...................................................................................................................................................................................................................... Rear A/C
C79......................................................................................... Lamp Interior, Roof Rail, Courtesy & Single Reading (Rows 2/3 - SSD - Row 3 - DDS)
DD9......................................................................................................................... Mirror O/S LH & RH, Remote Control, Electric, Breakaway Color
DH6............................................................................................................................................ Mirror, I/S Sunshade ILLUM and Map HLDR - LH/R)
DK6.................................................................................................................................................................... Console, Interior Roof (Ext. - Inc. DIC)
DK7......................................................................................................................................................................................... Consolette, Overhead Base
DL5................................................................................................................................................. Decal Roadside Service Information (N/A Can/Exp)
DR1............................................................................................................................................................ Mirror 0/S LH & RH, Manual Control, Color
DR5............................................................................................................... Mirror 0/S LH & RH, Remote Control, Electric, Heated Manual Folding,
D55......................................................................................................................................................................................... Console FRT Compt, Floor
D60......................................................................................................................................................................................... Console FRT Compt, Floor
D84............................................................................................................................................................................................ Paint, Custom Two-Tone
D89..................................................................................................................................................................................................... Paint Special Decor
EXP......................................................................................................................................................................................................................... Export
E28................................................................................................................................................................................... Assist Grips, B-Pillar-Mounted
E58.......................................................................................................................................................................................... Door, Electric Sliding Side
E59............................................................................................................................................................................................... LH Power Sliding Door

E88................................................................................................................................................... Pocket Stowage (Cargo Net Storage - RH Sidewall)


FE1...................................................................................................................................................................................... Suspension System Soft Ride
FE2............................................................................................................................................................................. Suspension System Ride, Handling
FE3............................................................................................................................................................................................. Suspension System Sport
FE9.................................................................................................................................................................................... Certification Emission Federal
FR9................................................................................................................................................................................ Ratio Transaxle Final Drive 3.29
GQ1........................................................................................................................................................................................... Axle Rear Standard Ratio
G50............................................................................................................................................................................... Spring, Rear Heavy Duty, VAR 1
G67.............................................................................................................................................................................................. Level Control Auto, Air
IHB.................................................................................................................................................................................................... Trim Interior Design
IHE.................................................................................................................................................................................................... Trim Interior Design
IHN................................................................................................................................................................................................... Trim Interior Design
IPB................................................................................................................................................................................................ Trim Interior Design
IPC.................................................................................................................................................................................................... Trim Interior Design
IPD.................................................................................................................................................................................................... Trim Interior Design
IP2..................................................................................................................................................................................................... Trim Interior Design
JL9.................................................................................................................... Brake System Power, FRT and RR Disc, Antilock, FRT and RR Wheel
JM4.................................................................................................... Brake System Power, FRT Disc, RR Drum, Cast Iron, Antilock, FRT/RR Wheel
KA1........................................................................................................................................................................................................ Heater Seat, FRT
KC4........................................................................................................................................................................................ Cooling System Engine Oil
KG7................................................................................................................................................................................................... Generator 125 AMP
kG9.................................................................................................................................................................................................... Generator 140 AMP
KNB........................................................................................................................................................................................................ Air Cleaner, Dry
K05................................................................................................................................................................................................... Engine Block Heater

K12.................................................................................................................................................................................................... Filter, Air, Pollutant


K29......................................................................................................................................................................................... Module Powertrain Control
K34.......................................................................................................................................................................... Cruise Control Automatic Electronic
K45............................................................................................................................................................................................. Air Cleaner, Heavy Duty
K68................................................................................................................................................................................................... Generator, 105 AMP
LA1........................................................................................................................................................................... Engine, Gas, 6 Cyl. 3.4L, MFI, HO
MXO....................................................................................................................................................... Merchandises TRANS AUTO Provisions, O/D
M15........................................................................................................................................ Trans, Auto 4-Spd, HMD, (4T65-E) Enhanced Electronic
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NB8........................................................................................................................................................................ Emission Override California System
NC1....................................................................................................................................................................................... Emission, System California
NC7......................................................................................................................................................................... Emission, Override - Federal System
NF2................................................................................................................................................................................. Emission System Federal, Tier 1
NG1................................................................................................................................ Certification Emission, Geographically Restricted Registration
NK4................................................................................................................................................................................... Steering Wheel, Sport Leather
NM8............................................................................................................................................................................... Leaded Fuel System Compatible
NP7................................................................................................................................................................................ Steering Column EEG Approved
NV6................................................................................................................................................................................. Steering Power, Reduced Effort
NW9....................................................................................................................................................................................... Traction Control Electronic
NY8............................................................................................................................................................................................................ Shield Exhaust
N05...................................................................................................................................................................................... Lock Control Fuel Filler Cap

N30............................................................................................................................................................................ Steering Wheel, Deluxe (Urethane)


PB4................................................................................................................................................................................................................ Lock, Wheel
PG1.................................................................................................................................................................................................... Wheels 15 x 6, Steel
PH3.................................................................................................................................................. Wheels 15 x 6, Aluminum Cast 115 mm Bolt Circle
P42......................................................................................................................................................................................................... Tires Self Sealing
TL4............................................................................................................................................................................................................... Grille Painted
TT5................................................................................................................................................................................................ Headlamps Halogen, 2
TU8................................................................................................................................................................................... Lamp INTR, Stop, High Level
T2H.................................................................................................................................................. Ornamentation EXTR, Export Unique Requirement
T2J.................................................................................................................................................... Ornamentation INTR, Export Unique Requirement
T62.................................................................................................................................................................... Lamps System Daytime Running, Export
T65.................................................................................................................................................................... Lamps System Daytime Running, Export
T84................................................................................................................................................................... Headlamps RH Rule of the Road, E Mark
T89....................................................................................................................................................................................... Lamps Tail and Stop. Export
T90.......................................................................................................................................................................... Lamps Signaling and Marker, Export
UA6............................................................................................................................................................................................... Theft Deterrent System
UD4.................................................................................................................................................................................. Alarm Vehicle Speed, 120 K/H
UD7........................................................................................................................................................................................................ Rear Parking Aid
UH8.................................................................................................................... Cluster Instrument, Coolant Temperature, Trip Odometer, Tachometer

UK3............................................................................................................................................. Electronic System Steering Wheel Accessory Controls


UK6............................................................................................................................................................ Radio Control, RR Seat, and Earphone Jacks
UL0.......................................................................... Radio AM/FM Stereo, Seek/Scan, Auto Reverse Music Search Cassette, Auto Tone, Clock, ETR
UM7......................................................................................................................................................... Radio AM/FM Stereo, Seek/Scan, Clock, ETR
UN0.............................................................................................................. Radio AM/FM Stereo, Seek/Scan, Compact Disc, Auto Tone, Clock, ETR
UP0................................................................................................................ Radio AM/FM Stereo, Seek/Scan, Compact Disc, Equalizer, Clock, ETR
UX6...................................................................................................................................................................................... Speaker System Front, Dual
UZ4............................................................................... Speaker System, Four Dual Front Door Extended Range, Dual Rear Liftgate Extended Range
UZ5........................................................................................................... Speaker System, Four Dual Front Door Coaxial, Dual Rear Liftgate Coaxial
U1N.................................................................................... Radio AM/FM Stereo, Seek/Scan, Auto Rev Music Search Cass, Clock, Eqlzr, RDS, ETR
U1P........................................................................................................................... Radio AM/FM Stereo, Seek/Scan, CD, Clock, EQLZR, RDS ETR
U1Q......................................................................... Radio AM/FM Stereo, Seek/Scan, Auto Rev Music Search Cass, CD, Clock, EQLZR, RDS, ETR
U18............................................................................................................................................................................ Speedometer-lnstrument Kilo/Miles
U19................................................................................................................................................. Speedometer-Instrument Kilo/Miles; Kilo Odometer

U2E......................................................................................................................................... Cluster Instrument, Coolant Temperature, Trip Odometer


U29........................................................................................................................................................................................... Lamp INTR, I/P Courtesy
U42................................................................................................................................................................................ Entertainment System, Rear Seat
U76........................................................................................................................................................................................ Antenna, Windshield Radio
VH7.......................................................................................................................................................................................................... Bumper Custom
VH9........................................................................................................................................................................ Envelope Owner Information Manual
VK3............................................................................................................................................................................. License Plate Front Mounting Pkg
VZ6......................................................................................................................................................................................... Calibration Speedometer A
V08....................................................................................................................................................................................... Cooling System Heavy Duty
V1B............................................................................................................................................................................................. Discount Value Package
V2G.................................................................................................................................................................................................... Credit Full Fuel Fill
V41.............................................................................................................................................................................................................. Kit Accessory
V54.................................................................................................................................................................................... Luggage Carrier Roof, Painted
V73.......................................................................................................................................................................................... Vehicle Statement US/Can
V92........................................................................................................................................................................................................ Trailer Provisions
XCK......................................................................................................................................................... Tire Frt 215/70R15 WOL PE ST TL AL2 97S
XPA....................................................................................................................................... Tire Frt P215/70R15 WOL PE ST TL AL2 97S (Inc. P42)
XPK...................................................................................................................................................... Tire Frt P215/70R15 BW R/PE ST TL ALS 97S
XPU........................................................................................................................... Tire Frt P215/70R15 BW R/PE ST TL AL2 97S (Olds Req. FE3)
X88.............................................................................................................................................................................. Conversion Name PLT Chevrolet
YCK................................................................................................................................ Tire Rear P215/70R15 WOL PE ST TL AL2 97S Self Sealing
YB6...................................................................................................................................................................................................... Axle (Base Equip)
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YD5................................................................................................................................................................................... Spring Front, Base Equipment
YD6..................................................................................................................................................................................... Spring Rear, Base Equipment
YF5................................................................................................................................................................................ Certification Emission California
YNA................................................................................................................................................ Tire Rear P205/65R15 BW R/PE ST TL HWY 94H
YPA..................................................................................................................................................... Tire Rear P215/70R15 WOL PE ST TL AL2 97S
YPK.................................................................................................................................................... Tire Rear P215/70R15 BW R/PE ST TL ALS 97S
YPU.................................................................................................................................................... Tire Rear P215/70R15 BW R/PE ST TL AL2 97S
Y1F................................................................................................................................................................................................ Primary Color Exterior
Y11......................................................................................................................................................................................... Gold Package - Oldsmobile
Y4T............................................................................................................................................................................................... Merchandised PKG LT
Y91............................................................................................................................................................................ Merchandised PKG Luxury Edition
Y92............................................................................................................................................................................ Merchandised PKG Special Edition
ZP7........................................................................................................................................................................................ Seating Arrangement 7 Pass
ZP8........................................................................................................................................................................................ Seating Arrangement 8 Pass
ZX2............................................................................................................................................... Seating Arrangement Driver and Passenger Highback
ZY7........................................................................................................................................................... Color Combination Two Tone, Lower Accent
Z10............................................................................................................................................................................. Merchandised Package Cargo Van
Z49..................................................................................................................................... Export Canadian Modifications Mandatory Base Equipment
Z5X........................................................................................................................................................................... Mirror Provisions Arabic Language
01U.......................................................................................................................................................................... Primary Color Exterior, Special, (96)
09U............................................................................................................................. Primary Color Exterior, Crimson king (Metallic (Pont Req. D89)
1CL........................................................................................................................................................................................ Bumper Height Adjustment
14B..................................................................................................................................................................... Trim Combination Cloth Light Gray (B)
14C..................................................................................................................................................................... Trim Combination Cloth Light Gray (C)
14D............................................................................................................................................................. Trim Combination Cloth Light Gray (E) (92)
14E.............................................................................................................................................. Trim Combination Vinyl Light Gray/Cloth Light Gray
141......................................................................................................................................................................................... Interior Trim Light Gray (I)
14N.................................................................................................................................................................... Trim Combination Vinyl Light Gray (N)
142.................................................................................................................................................................. Trim Combination Leather, Light Gray (2)
16U......................................................................................................................................................................... Primary Color Exterior, Bright White
17L........................................................................................................................................................... Secondary Color Exterior, Silvermist MT (97)
17U............................................................................................................................................................... Primary Color Exterior, Silvermist Metallic
28U....................................................................................................................................................... Primary Color Exterior, Black Sapphire Metallic
30U................................................................................................................................................... Primary Color Exterior, International Blue Metallic
31U....................................................................................................................................................... Primary Color Exterior, Fernmist Green Metallic
49L...................................................................................................................................................... Secondary Color Exterior, Light Sandrift Metallic
49U......................................................................................................................................................... Primary Color Exterior, Light Sandrift Metallic
52B................................................................................................................................................................. Trim Combination Cloth Light Neutral (B)
52C................................................................................................................................................................. Trim Combination Cloth Light Neutral (C)
521..................................................................................................................................................................................... Interior Trim Light Neutral (I)
522.......................................................................................................................................................... Trim Combination Leather, LT Neutral (2) (92)
561............................................................................................................................................................................. Trim Combination, Med. Neutral II
6F5............................................................................................................................................................................................... Wiring Provisions Roof
6Y2........................................................................................................................................................................................ Rear Seat - Delete (3rd Seat
64B................................................................................................................................................................. Trim Combination Cloth, MED DK Sable)
64C.................................................................................................................................................................. Trim Combination Cloth, MED DK Sable
641...................................................................................................................................................................................... Interior Trim MED DK Sable
642............................................................................................................................................................... Trim Combination Leather, MED DK Sable
65U...................................................................................................................................................... Primary Color Exterior, Smokey Carmel Metallic
72U.................................................................................................................................................................... Primary Color Exterior, Redfire Metallic
9C6......................................................................................................................................................................................... SEO Vehicle Taxi Cab Inc.
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Vehicle: Symptom Related Diagnostic Procedures

Air Pressure Test


Air Pressure Test

1. Cover the pressure relief valve.


2. Turn the vehicle ventilation fan to HIGH.
3. Close all of the windows and doors.
4. Use one of the following items in order to listen for escaping air along the door and window seals:

* A stethoscope
* A piece of heater hose

Air/Wind Noise
Air/Wind Noise

The following conditions cause most windnoise:

* Leaking seals
* Misaligned body surfaces

There are 3 basic types of windnoise:

* Whistle
* Roar
* Rush

When moving at highway speeds, the air pressure inside of the vehicle becomes significantly greater than the air pressure outside. If a leak exists,
the escaping air causes a hiss or a whistle.

Air passing over or through an opening between 2 body surfaces causes wind roar. Adjusting the alignment of body surfaces may correct wind roar.

Air passing over the vehicle body causes wind rush. Wind rush is related to the aerodynamics of the vehicle.

Determine whether the windnoise is wind whistle or wind roar before concluding that it is wind rush. Wind whistle and wind roar can be repaired,
but the intrinsic aerodynamics of the vehicle cannot be repaired.

Use the following procedure in order to diagnose wind whistle or wind roar:

1. Note the details about the windnoise.

* Determine the perceived location.


* Determine the location of greatest volume.
* Determine when the wind noise occurs.
* Note the vehicle speed.
* Note the interior fan speed.
* Note the position of the windows.
* Identify what it sounds like.

2. Inspect the vehicle for all possible causes of the windnoise.


3. Test drive the vehicle in order to determine whether the windnoise is internal or external.

Soap Suds or Bubble Test


Soap Suds or Bubble Test

1. Cover the pressure relief valve.


2. Turn the vehicle ventilation fan to HIGH.
3. Close all of the windows and doors.
4. Apply a soapy solution to all potential leak areas.
5. Look for bubbles that reveal escaping air.
6. Consider the following procedure as an alternative to pressurizing the vehicle interior:

1. Use an air compressor air hose.


2. Do not exceed 207 kPa (30 psi).
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Tracing Powder or Chalk Test


Tracing Powder or Chalk Test

1. Clean the weather-strips with solvent.


2. Clean the contact surfaces with solvent.
3. Apply powder or chalk in an unbroken line to the contact surface of the weather-strip around the perimeter of the following surfaces:

* The rear compartment lid


* The door
* The door window
* The hood

4. Ensure that the surrounding areas are free of chalk or powder.

Important: Do not slam the panel.

5. Close the panel completely.


6. Inspect the applied line on the weather-strip.
The weather-strip will be marred where contact is good. A corresponding imprint will be on the mating surfaces.
7. Gaps or irregularities in the powder or chalk line indicate a poor seal.

Exterior Windnoise
Exterior Windnoise

Exterior windnoise will be louder with 1 or more of the windows open. Windnoise is caused by air passing over the following items:

* The body panels


* The seams
* The openings

Notice: If masking the grille or headlamp bezel areas, care must be taken not to restrict airflow. Restricting airflow can cause vehicle
overheating.

1. Test drive the vehicle.


2. Lower each window in order to determine the location of the windnoise.
3. Stop the vehicle.
4. Use a screwdriver or masking tape in order to temporarily repair the following items:

* The body panels


* The seams
* The openings

5. Tape over the gaps and moldings separately.


6. Test drive the vehicle.
7. Continue to tape over the gaps and moldings.
8. The origin of the windnoise is located when the windnoise stops.

Interior Windnoise
Interior Windnoise

Interior windnoise will not be heard with a lowered window. Interior windnoise is caused by air leaving the inside of the vehicle through a seal or a
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seam.

1. Tape over the pressure relief valves in order to increase the air pressure within the vehicle.
2. Test drive the vehicle.
3. Listen for windnoise whistle.
4. Stop the vehicle.
5. Use masking tape in order to make temporary repairs.
6. If you are still unable to determine the source of the interior windnoise, perform 1 or more of the following tests:

* The Tracing Powder or Chalk Test


* The Air Pressure Test
* The Soap Suds or Bubble Test

Body Waterleak Repair


Body Waterleak Repair

Waterleak Diagnosis

Caution: When the vehicle interior has been exposed to extensive water intrusion, such as waterleaks, window left open, driving through high
water and so forth, the Sensing and Diagnostic Module (SDM) and the SDM connector may need to be replaced. With the ignition OFF, inspect the
area under the front seat and the area around the SDM, including the carpet. If any significant soaking or evidence of significant soaking is
detected, the water must be removed, water damage repaired and the SDM and the SDM connector MUST be replaced. Before attempting any of
these repairs, the SIR system must be disabled. Refer to the Supplemental Inflatable Restraint (SIR) System for instructions on how to disable the
SIR system. Failure to disable the SIR system may result in possible air bag deployment, personal injury or otherwise unneeded SIR system repairs.

GM vehicles are designed in order to operate in normal environmental conditions. The design criteria for sealing materials and components is
sufficient to withstand natural elements. The specifications do not take into consideration any of the artificial conditions that may be encountered in
high pressure car washes.

The watertest procedure correlates to natural elements. The watertest procedure will determine the ability of a vehicle to perform under normal
operating conditions.

Repairing waterleaks involves the following actions:

* Proper testing
* Proper diagnosis

The following steps are included in waterleak repairs:

* Adjusting misaligned components


* Application of approved repair materials

In order to diagnose waterleaks, find the condition in which the waterleaks occur. The following list indicates some examples of waterleak
conditions:

* The leak is noticed only when the vehicle is parked on an incline.


* Water is in the spare tire compartment.

If the general leak area is found, isolate the exact entry point by using one of the following tests:

* A water hose test


* An air hose test

If the leak source is not obvious, use watertest equipment in order to determine the leak source.
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Remove the inner trim panels or any components as needed in order to locate and confirm the repairs.

Localized Testing (Spot Testing)


Localized Testing (Spot Testing)

Important: Pinpoint the leak area before making any repair. Do not perform random repairs. Random repairs temporarily restrict water
entry and make future diagnosis and repair more difficult.

Perform the localized testing with either water or air. Begin testing at the base of the suspected area. Continue testing the suspected area until you
locate the leak.

Continue the localized testing in the same general area in order to locate all possible leaks.

Air Hose Test


Air Hose Test

1. Apply a liquid soap bubble solution to the suspected leak area.

2. Apply air pressure with an air hose from the inside of the vehicle. Do not exceed 207 kPa (30 psi).
3. Observe the outside of the suspected leak area for bubbles.

Water Hose Test


Water Hose Test

1. Have an assistant detect the actual leak point inside the vehicle.

2. Apply an unrestricted water flow. Use a hose without a nozzle.


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3. Begin at the base of the suspected leak area. Move the water flow slowly upward.

Repair Instructions
Stationary Window Waterleak Repair

Caution: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to
reduce the chance of personal injury.

Caution: When the vehicle interior has been exposed to extensive water intrusion, such as waterleaks, window left open, driving through high
water and so forth, the Sensing and Diagnostic Module (SDM) and the SDM connector may need to be replaced. With the ignition OFF, inspect the
area under the front seat and the area around the SDM, including the carpet. If any significant soaking or evidence of significant soaking is
detected, the water must be removed, water damage repaired and the SDM and the SDM connector MUST be replaced. Before attempting any of
these repairs, the SIR system must be disabled. Refer to the Supplemental Inflatable Restraint (SIR) System for instructions on how to disable the
SIR system. Failure to disable the SIR system may result in possible air bag deployment, personal injury or otherwise unneeded SIR system repairs.

Use the kit GM P/N 12346284 or the equivalent in order to repair waterleaks without removing and reinstalling the window. Use the following
method only when using the urethane adhesive furnished in the kit:

1. Remove the reveal moldings in the area of the leak.


Remove the garnish moldings or finishing lace as needed in order to locate the source of the leak.
2. Mark the location of the leak.
3. Apply water to the area of the leak while performing the following steps:

1. Push outward on the window in the area of the leak in order to determine the extent of the leak.
2. Mark the extent of the leak area.

4. From the outside of the body, use water in order to clean any dirt or foreign material from the leak area.
Use an air hose in order to dry the area.

5. Use a sharp knife in order to trim off the uneven edges of the urethane adhesive material (1) at the leak point.
Trim off the uneven edge of urethane adhesive material 75 to 100 mm (3 to 4 in) on both sides of the leak point or leak area.
6. Prime (2) the affected area using Pinch-Weld Primer, Black Number 3.
Allow the primer to dry for 10 minutes.
7. Apply the urethane adhesive material at the following locations:

* The leak point


* On both sides of the leak point or leak area

8. Apply the urethane adhesive material 75-100 mm (3-4 in) on both sides of the leak point or leak area.
9. Use a flat-bladed tool (3) in order to work the urethane into the leak point of the original material and body. This action ensures a watertight
seal.
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Important: Do not run a heavy stream of water onto freshly applied urethane adhesive.

10. Use warm or hot water in order to test the area.


Ensure that the leak is corrected.
11. Replace all of the previously removed components.
12. Clean the excess urethane adhesive from the surface of the repaired window.
Use a damp cloth in order to apply the GM Window Cleaner GM P/N 1050427 or isopropyl alcohol.
13. Allow the window to air dry.
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Vehicle: Programming and Relearning

Control Module References

Crankshaft Position (CKP) - Variation Learn Procedure


The crankshaft position system variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been
performed. If the actual crankshaft position system variation is not within the crankshaft position system variation compensating values stored in
the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300.

The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true:
^ DTC P1336 is set.
^ The PCM has been replaced.
^ The engine has been replaced.
^ The crankshaft has been replaced.
^ The crankshaft harmonic balancer has been replaced.
^ The crankshaft position sensor has been replaced.

IMPORTANT: The scan tool crankshaft position system variation learn function will be inhibited if engine coolant temperature is less than 70°C
(158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the crankshaft position system variation learn procedure.

The scan tool crankshaft position system variation learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or
during the crankshaft position system variation learn procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs.

The crankshaft position system variation learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal
circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnoses the system
or sensor.
^ DTC P0336 Crankshaft Position (CKP) Sensor Performance.
^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation.
^ DTC P0341 Camshaft Position (CMP) Sensor Performance.

The scan tool crankshaft position system variation learn function will not be enabled until engine coolant temperature reaches 70°C (158°F)

Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn
fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed
of 5150 RPM (CKP system variation learn fuel cutoff) during the crankshaft position system variation learn procedure to store the crankshaft
position system variation compensating values and complete the procedure.

IMPORTANT: Set the vehicle parking brake and block the drive wheels when performing the Crankshaft Position System Variation Learning
Procedure in order to prevent personal injury. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during
the fuel cut off will allow the engine to decel at an even rate. Once the learn procedure is completed, the PCM will return the engine control to the
operator and the engine will respond to the throttle position.

1. Set the parking brake.


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2. Block the drive wheels.
3. Ensure the hood is closed.
4. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F).
5. Turn off the ignition switch.
6. Select and enable the crankshaft position variation learn procedure with the scan tool.
7. Start the vehicle.
8. Apply and hold the service brake pedal firmly.
9. Ensure the transaxle is in park.
10. Increase accelerator pedal position until the fuel cutoff is reached at 5150 RPM. Release the accelerator pedal after the second fuel cutoff has
been reached.
11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates.
12. Observe DIG status for DIG P1336.
13. If the scan tool indicates that DIG P1336 ran and passed, the crankshaft position system variation learn procedure is complete. If the scan tool
indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the crankshaft position
system variation learn procedure as necessary.
Feature Customization - Changing Modes
1. Turn off the IP dimmer switch.
2. Turn the ignition switch to the LOCK position.
3. Remove the BCM PRGRM fuse.
4. Turn the ignition switch to the ACC position. The BCM flashes the fasten belts indicator and sounds the chime 4 times, which indicates that
BCM type 4 is installed on the vehicle. At this point, the BCM has entered the feature customization mode.
5. In order to change the theft deterrent/shock sensor mode, turn the headlamp switch from OFF to PARK and back to OFF.The BCM flashes
the fasten belts indicator and sounds the chime a number of times equivalent to the theft deterrent/shock sensor mode. A transition past mode
4 repeats the sequence starting with mode 1.
6. Complete the following steps in order to change the theft deterrent arm/disarm mode:
6.1. Insert the key in the left front, right front, or liftgate door lock cylinder.
6.2. Rotate the key from the center to the unlock position.
6.3. Press the horn button on the remote keyless entry transmitter.
6.4. Count the number of chimes that you hear. The number of chimes tells you which mode you have set.
6.5. Press the horn button again in order to change the mode. Continue to press the button until you hear the number of chimes that indicates
the mode that you want.
6.6. Turn the key back to the center position and remove the key from the door key cylinder.

In order to exit and save the current feature customization modes use the following procedure:
1. Turn the ignition switch to the LOCK position.
2. Reinstall the BCM PRGRM fuse.

If you are unable to change locking modes link

Feature Customization - Changing the Interior Lighting Mode


Perform the following procedure to change the interior lighting mode:
1. Turn OFF the I/P dimmer switch.
2. Turn the ignition switch to the LOCK position.
3. Remove the BCM PRGRM fuse.
4. Turn the ignition switch to the ACC position.
- The BCM sounds the chime a number of times equivalent to the BCM type installed on the vehicle (1, 2, 3 or 4 chimes).
- Now the BCM has entered the feature customization mode.
5. To advance the interior lighting mode, cycle the I/P dimmer switch from OFF to DOME and back to OFF.

The BCM sounds the chime a number of times equivalent to the lighting mode currently set. A transition past mode 4 repeats the sequence starting
with mode 1.

To exit and save the current customization mode:


1. Turn the ignition switch to the LOCK position.
2. Reinstall the BCM PRGRM fuse.

Feature Customization - Delayed Illumination


- Enabled (modes 2 and 4): The interior courtesy lights turn ON for 25 seconds, then fade to OFF after the last door is closed.
- Disabled (modes 1 and 3): The interior lights turn OFF after the last door is closed.

Feature Customization - Dome Lamp, IP Courtesy Lamps and Cargo Lamp


The operation of these lamps is described as part of the interior courtesy lights operation. The BCM provides power (CKT 1393) and ground (CKT
690) to these lamps controlling their operation.
Feature Customization - Door Key Unlock Illumination (BCM Type 4 Only)
The BCM grounds CKT 690 for 36-44 seconds activating the interior courtesy lights, when the following conditions are met:
- The ignition switch is in the LOCK or the OFF position.
- The interior lamps override switch is in the ON position (interior courtesy lights enabled).
- Unlock the left front, the right front or the liftgate door using a door key cylinder lock (grounding CKT 781).
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Feature Customization - Entering Programming Mode


The feature customization mode is used to configure the BCM to function in various applications. The BCM can be customized to change the
following vehicle functions:
- Interior Lighting Features
- Door Lock System
- Keyless Entry System
- Content Theft Deterrent System

In order to enter the feature customization mode perform the following steps:
1. Turn the ignition switch to the LOCK position.
2. Remove the BCM PRGRM fuse.
3. Turn the ignition switch to the ACC position. When entering the feature customization mode, the BCM first identifies what type of BCM is
installed on the vehicle by flashing the fasten seat belts indicator and sounds the chime 2, 3 or 4 times depending on the type of BCM used on
the vehicle. There are 3 different types of BCM that can be installed on the vehicle based on the vehicle option content that matches the BCM
capabilities. Ensure that the BCM installed on the vehicle is compatible with all of the features on the vehicle. Refer to Body Control System
circuit description for BCM identification. For more information on features that can be customized, refer to:
- Interior Lights Circuit Description
- Automatic Door Lock System Description
- Keyless Entry System Circuit Description
- Content Theft Deterrent (CTD) Circuit Description

Feature Customization - Exit Illumination


- Enabled (modes 3 and 4): The interior courtesy lights turn ON for 25 seconds upon removing the key from the ignition switch.
- Disabled (modes 1 and 2): The interior courtesy lights stay off upon removing the key from the ignition switch.
Feature Customization - Inadvertent Load (Battery Rundown) Protection
The BCM has a feature called inadvertent load (battery rundown) protection. The BCM de-energizes CKT 328 and CKT 1398 9-11 minutes after
the ignition switch has been turned from the ACC or the RUN position to the LOCK or the OFF position. The BCM restores power to CKT 328 and
CKT 1393 when the interior lamps override switch is activated (interior courtesy lights enabled) and under the following conditions:
- Turning the ignition switch from the LOCK or the OFF position, to the ACC or the RUN position.
- Removing the key from the ignition lock cylinder.
- Opening any vehicle door.
- Turning the IP dimmer switch to the DOME position.
- Activating any of the roof rail reading lights.
- The BCM receives a message from the Remote Control Door Lock Receiver (BCM type 3 or 4 only).
- Locking a door using the key (BCM type 4 only).

The inadvertent battery power rundown protection feature is mileage-sensitive. Vehicles with less than 15 (24 km) total accumulated miles (km)
have a 2 minute and 32 second - 3 minute and 18 second time-out instead of a 10 minute time-out.

Feature Customization - Interior Lamps Override Switch


The interior lamps override switch is located in the overhead console switchbank. Pressing the symbol on the bottom of the rocker switch overrides
the control of the interior lights. This action interrupts the voltage supply from CKT 1393 to CKT 328, deactivating all of the interior lights.

Interior Lights Circuit Description

Feature Customization - IP Compartment Lamp


The IP compartment lamp activates when the IP compartment is open. The IP compartment lamp has a switch that closes (providing ground to the
lamp) when the IP compartment is open. The IP compartment lamp switch opens when the IP compartment is closed. The IP compartment lamp
switch receives voltage through CKT 328 and ground through CKT 150. The IP compartment lamp is protected by the inadvertent load (battery
rundown) protection in case that the IP compartment is left open.

Feature Customization - IP Dimmer Switch


The IP dimmer switch allows the operator to activate the interior courtesy lights from inside the vehicle. When the IP dimmer switch is in the
DOME position, the switch sends a ground signal to the BCM through CKT 156. This action causes the BCM to activate the interior courtesy
lights. When the IP dimmer switch is in the OFF position, the BCM deactivates the interior courtesy lights. With the ignition switch in the LOCK or
OFF position, the IP dimmer switch is protected by the inadvertent load (battery rundown) protection in case the IP dimmer switch is left in the
DOME position.

The IP dimmer switch is also used to change the interior lighting modes during the feature customization. Refer to Feature Customization for more
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information. In addition, the IP dimmer switch is also utilized to enter the input/output test during BCM diagnostics.
Feature Customization - Keyless Entry Unlock Illumination (BCM Type 3 and 4 Only)
The BCM grounds CKT 690 for 36-44 seconds, activates the interior courtesy lights when the following conditions are met:
- The ignition switch is in the LOCK or the OFF position.
- All of the vehicle doors are closed.
- The IP dimmer switch is in the OFF position.
- The interior lamps override switch is in the ON position (interior courtesy lights enabled).
- The BCM receives a message from the Remote Control Door Lock Receiver (RCDLR) in order to unlock the doors.

Feature Customization - Remote Activation Verification (RAV) Customization

Perform the following steps in order to verify your remote activation customization:

IMPORTANT: If the ignition switch is turned OFF or the driver door is opened while the Body Control Module (BCM) is in the customization
process, the process will be terminated and the BCM will remain in the most recent mode.

1. Remove the BCM PRGRM fuse from the fuse panel. Refer to Fuse Block in Wiring Systems.
2. Close all of the doors.
3. Close the liftgate.
4. Turn the ignition to ACC.
The seat belt telltale will flash and the chime will sound 1-4 times in order to indicate that the body control module (BCM) is in the feature
customization mode.
5. Press the transmitter LOCK button.
The seat belt telltale will flash and the chime will sound 1-2 times in order to indicate which remote unlock control mode the BCM is in. Each
time the transmitter LOCK button is pressed, the mode number will advance. A transition past mode 4 will start over again at mode 1.
6. Turn the ignition OFF.
7. If you wish to customize other features, customize the features before reinstalling the BCM PRGRM fuse block.
8. Replace the BCM PRGRM fuse back into the fuse panel. Refer to Fuse Block in Electrical Diagnosis. Your current customization is now
saved.

Feature Customization - Remote Unlock Control Customization

Perform the following steps in order to customize the remote unlock control:

IMPORTANT: If the ignition switch is turned OFF or the driver door is opened while the Body Control Module (BCM) is in the customization
process, the process will be terminated and the BCM will remain in the most recent mode.

1. Remove the BCM PRGRM fuse from the fuse panel.


2. Close all of the doors.
3. Close the liftgate.
4. Turn the ignition to ACC.
The seat belt telltale will flash and the chime will sound 1-4 times in order to indicate that the body control module (BCM) is in the feature
customization mode.
5. Press the transmitter UNLOCK button.
The seat belt telltale will flash and the chime will sound 1-2 times in order to indicate which remote unlock control mode the BCM is in.Each
time the transmitter UNLOCK button is pressed, the mode number will advance. A transition past mode 2 will repeat and start again at
model.
6. Turn the ignition OFF.
7. If you wish to customize other features, customize the features before reinstalling the BCM PRGRM fuse into the fuse panel.
8. Replace the BCM PRGRM fuse back into the fuse panel.
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Feature Customization - Roof Rail Reading Lamps


These lamps have switches that allow the operator to activate them. The switches, upon activation, provide ground to these lamps turning them to
the ON position. The switches obtain ground through CKT 650. The BCM does not turn on these lamps with the rest of the interior courtesy lights.
Power to the roof rail reading lamps is provided by the BCM through CKT 328, so that they are protected by the inadvertent load (battery rundown)
protection in case they are left in the ON position.

Feature Customization - Sunshade Illuminated Vanity Mirrors


The sunshade illuminated vanity mirror lamps activate when the mirror cover is open. The sunshade illuminated vanity mirror has a switch that
closes (providing ground to the lamps) when the mirror cover is open, and the switch opens when the cover is closed. The switch receives ground
through CKT 650.

Power to the sunshade illuminated vanity mirror is provided by the BCM through CKT 328, so that they are protected by the inadvertent load
(battery rundown) protection in case that a mirror cover is left open.

Feature Customization - Theater Dimming


The BCM dims the interior courtesy lights slowly from a full brightness to the OFF position in 3 seconds. This feature starts anytime the BCM is
turning off the interior courtesy lights.

Theater dimming does not work when turning the IP dimmer switch from the DOME position to the OFF position or when the illumination feature
is cancelled by locking the doors with a power door lock switch. Also, theater dimming does not work when the exit illumination feature is
disabled.

Feature Customization - Vehicle Speed Input


The BCM monitors the vehicle speed input to determine the total distance traveled in order to change the inadvertent battery rundown protection
timer.

The BCM determines the distance traveled by interfacing with the vehicle speed CKT 389 which makes a ground transition 4000 times per 1.6 km
(1 mile) traveled. Once the vehicle has been driven past the 15 mile (24 km) mark, the BCM changes inadvertent battery power rundown protection
timer from 3 minutes to 10 minutes.

In addition, the BCM uses the vehicle speed CKT 389 for the operation of the turn signal reminder.

If the inadvertent battery power rundown protection stays at 3 minutes on vehicles with more than 15 miles (24 km), refer to Audible Warnings for
possible malfunction of the turn signal reminder.

Feature Customization - Windshield Header Courtesy/Reading Lamps


The operation of these lamps is described as part of the interior courtesy lights operation. The BCM provides power (CKT 328) and ground (CKT
690) to these lamps, controlling their operation.

In addition, these lamps have switches that allow the operator to turn them on when the interior courtesy lights are off. The switches, upon
activation, provide ground to these lamps turning them to the ON position. The switches obtain ground through CKT 650. Power to these lamps is
provided by the BCM through CKT 328, so that they are protected by the inadvertent load (battery rundown) protection in case they are left in the
ON position.

Instrument Panel Cluster (IPC) - Programming/Synchronization


TOOLS REQUIRED
Scan Tool
When installing a new IP cluster it must be synchronized to the Supplemental Inflatable Restraint (SIR) module in order to synchronize the new
cluster, perform the following steps:
1. Connect the to the Data Link Connector (DLC).
2. Proceed to the SPECIAL FUNCTIONS key under INSTRUMENT PANEL CLUSTER.
3. Select the SYNCHRONIZE IPC and SIR key.
4. The screen will display: IPC and SIR modules-Now synchronizing modules.
5. If the procedure is completed successfully the screen will display: Module Synchronization Complete.
6. If communication is lost with the SIR or IPC, the screen will display: Loss of Communications with Vehicle - Check Diagnostics Link
Connector - Check Ignition (On/Off).

Memory Seat Calibration Procedure


MEMORY SEAT CALIBRATION PROCEDURE

The memory seat module uses position sensor inputs to establish soft stop locations for the adjuster motors several millimeters ahead of the
physical limits of the adjuster assembly. After replacing a memory seat module or adjuster components, it may be necessary to reset the adjuster
motor soft stop locations. When the repair procedure has been completed, operate the seat adjuster switch in every direction until the seat adjuster
reaches its mechanical hard stop by repeatedly pressing and releasing the switch as necessary.
Power Sliding Door (PSD) - Re-Initialization
IMPORTANT: Before you perform the PSD re-initialization, check for Diagnostic Trouble Codes (DTCs) by performing Diagnostic Mode 1.
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Refer to Diagnostic Modes in Power Sliding Door Diagnostic Information.

Perform the following PSD re-initialization procedure when any of the following conditions occur:
^ The PSD is inoperative.
^ Reconnecting the vehicle battery.
^ After recharging the vehicle battery.
^ After reinstalling or replacing the radio fuse located in the underhood accessory wiring junction block.
^ Exiting any of the diagnostic modes.

Perform this procedure in order to re-initialize the PSD:


1. Set the PSD on/off switch in the overhead console to the off position.
2. Manually open the PSD completely.
3. Manually close and latch the PSD.
4. Remove the RADIO fuse for 30 seconds.
5. Reinstall the RADIO fuse.
6. Wait 10 seconds.
7. Set the PSD on/off switch in the overhead console to the on position.
8. Press, then release either PSD open/close switch in order to completely open the PSD.
9. Wait 5 seconds.
10 Press, then release either PSD open/close switch in order to allow the PSD to close completely.
11. Wait 5 seconds.
12. Repeat steps 7 through 10 and re-check for proper PSD operation.

Remote Keyless Entry (RKE) - Transmitter


If you lose a transmitter, program the old and new transmitter(s) into the remote control door lock receiver's memory. Up to 4 transmitters may be
programmed.

IMPORTANT: Once the remote control door lock receiver enters the programming/diagnostic mode, the programming of the first transmitter
erases all previous transmitter programming information, requiring the programming of all transmitters.

Program only 1 vehicle remote control door lock receiver at a time. If more than 1 receiver is being programmed at the same time, it is possible that
the same transmitter could be programmed to more than 1 remote control door lock receiver.

Perform the following steps in order to program the transmitter:


1. Remove the ignition key from the ignition lock cylinder.
2. Remove the BCM PRGRM fuse from the fuse panel.
3. Close all of the doors.
4. Close the liftgate.
5. Turn the ignition lock cylinder to ACC.
6. Turn the ignition lock cylinder to OFF, and then back to ACC within 1 second.
7. Open and close any vehicle door.
A chime will be heard when the system enters the BCM programming/diagnostic mode.

IMPORTANT: After 7 seconds, a chime may be heard confirming successful synchronization. It is necessary to wait approximately 14
secondsfor a second chime that will confirm successful programming.

8. Press and hold the transmitter LOCK and UNLOCK buttons simultaneously for 14 seconds.
9. Repeat the previous step on each additional transmitter to be programmed.
10. Remove the ignition key from the ignition lock cylinder.
11. Install the BCM PRGRM fuse back into the fuse panel.
Remote Keyless Entry (RKE) - Transmitter - Resynchronization
The Remote Function Actuation (RFA) system uses a continually changing code for increased security. Normally, the remote control door lock
receiver will keep track of this changing code. However, loss of synchronization will occur if the transmitter is activated more than 256 times while
out of range of the vehicle.

If the transmitter stops working, you may need to synchronize the transmitter to the vehicle remote control door lock receiver. In order to
synchronize the transmitter to the vehicle remote control door lock receiver, press and hold the LOCK and the UNLOCK buttons for at least 7
seconds. If your vehicle is equipped with content theft deterrent, the horn will sound once the synchronization is complete. Inspect the transmitter
operation when the process is complete.

Theft Deterrent - Quick Learn Procedure - Keys Only


IMPORTANT:
^ Additional Master Theft Deterrent Controller Keys (Black) or Valet Keys (Gray) may be added (up to 10 keys) using this procedure when
there is an available learned Master Theft Deterrent Controller Key (Black).
^ This procedure adds keys only, it does not erase previously learned keys.
^ The keys to be learned must duplicate the mechanical cut of the current key.
1. With a previously learned Master Theft Deterrent Controller Key (Black),turn ON the ignition, with the engine OFF.
2. Turn OFF the ignition and remove the key.
3. Within 10 seconds insert the key to be learned and turn ON the ignition, with the engine OFF. The vehicle has now learned the new key(s).
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Theft Deterrent - Replacement Keys - IGN CYL, or PCM


IMPORTANT:
^ If replacing a theft deterrent controller module with an GM Service Parts Operation (SPO) Replacement Part, the module will learn keys
immediately. The existing PCM however, must learn the new fuel continue password when the theft deterrent controller module is replaced.
^ If replacing a PCM with a GM Service Parts Operation (SPO) Replacement Part, after programming, these modules will learn the incoming
fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, a
learn procedure must be performed to change this password again. A PCM which has been previously installed in another vehicle will have
learned the other vehicles fuel continue password and will require a Learn procedure after programming to learn the current vehicle's
password.
^ When performing the 10 Minute or the 30 Minute Re-Learn Procedures, all previously learned keys will be erased from the VTD module's
memory.
^ Additional keys may be learned immediately after the 10 Minute or 30 Minute Re-Learn Procedure by inserting the additional key to be
learned and turning the ignition to RUN within 10 seconds of removing the previously learned key.
Theft Deterrent - 10 Minute Re-Learn Procedure
Use this procedure after replacing:
^ The keys/lock cylinders
^ The theft deterrent controller module
^ The PCM (if necessary, see Important above)

Tools Required
^ Tech 2
^ Techline Terminal with current Service Programing System (SPS) software
1. Connect the Tech 2 Diagnostic tool.
2. Select Request Information under Service Programing.
3. Disconnect the Tech 2 from the vehicle and connect it to a Techline Terminal.
4. On the Techline Terminal, select Theft Module Re-Learn under Service Programming.
5. Disconnect the Tech 2 from the Techline Terminal and re-connect it to the vehicle.
6. Turn ON the ignition, with the engine OFF, using a Master Pass Key III Key (Black).
7. Select VTD Re-Learn under Service Programming.
8. At this point the Tech 2 must remain connected for the duration of the 10 minute Re-Learn period.
9. Observe the Security telltale, after approximately 10 minutes the telltale will turn off. (The vehicle is now ready to re-learn the key
information and/or passwords on the next ignition switch transition from OFF to CRANK)
10. Turn OFF the ignition and wait 5 seconds.
11. Start the vehicle (the scan tool has now learned the key and password information).
12. With the scan tool, clear any DTCs

Theft Deterrent - 30 Minute Re-Learn Procedure


Use this procedure after replacing:
^ The keys/lock cylinders
^ The theft deterrent controller module
^ The PCM (if necessary, see important above)
1. Turn ON the ignition, with the engine OFF using a Master Pass Key III Key (Black).
2. Observe the Security telltale, after approximately 10 minutes the telltale will turn off.
3. Turn OFF the ignition, and wait 5 seconds.
4. Repeat steps 1 through 3 two more times for a total of 3 cycles or 30 minutes.

IMPORTANT: The vehicle learns the key information and/or passwords on the ignition switch transition from OFF to CRANK. You must turn
the ignition OFF before attempting to start the vehicle.

5. Start the vehicle (the vehicle has now learned the key and password information).
6. With a scan tool, clear any DTCs.
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Engine: Description and Operation

Drive Belt System Description


The drive belt system consists of the following components:
^ The drive belt
^ The drive belt tensioner
^ The drive belt idler pulley
^ The crankshaft balancer pulley
^ The accessory drive component mounting brackets
^ The accessory drive components
- The power steering pump, if belt driven
- The generator
- The A/C compressor, if equipped
- The engine cooling fan, if belt driven
- The water pump, if belt driven
- The vacuum pump, if equipped
- The air compressor, if equipped

The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in
the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of
rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a
pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner
keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.

The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an
accessory drive component when the vehicle is not equipped with the accessory.

Engine Component Description


The cylinder block is made of cast alloy iron. The cylinder block has 6 cylinders that are arranged in a V shape. There are 3 cylinders in each bank.
The cylinder banks are set at a 60 degree angle from each other.

Starting from the front of the engine, the right bank cylinders are 1, 3, 5. The left bank cylinders are 2, 4, 6.

Four main bearings support the crankshaft. The crankshaft is retained by the bearing caps. The bearing caps are machined with the block for proper
alignment and clearances. The main bearing caps are drilled and tapped for the structural oil pan side bolts.

The aluminum cylinder heads have individual intake and exhaust ports for each cylinder. The valve guides are pressed in. The roller rocker arms
are located on a pedestal in a slot in the cylinder head. The roller rocker arms are retained on individual threaded bolts.

The crankshaft is cast nodular iron with deep rolled fillets on all 6 crankpins and all 4 main journals. Four steel-backed aluminum bearings are
used. The #3 bearing is the end-thrust bearing.

The camshaft is made from a new metal composite design. The camshaft profile is a hydraulic roller design. The camshaft is supported by 4
journals. The camshaft includes an oil pump drive gear.

The pistons are cast aluminum using 2 compression rings and 1 oil control ring. The piston pin is offset 0.8 mm (0.031 inch) towards the major
thrust side. This placement allows for a gradual change in thrust pressure against the cylinder wall as the piston travels its path. The pins are
chromium steel. The pins have a floating fit in the pistons. The pins are retained in the connecting rods by a press fit.

The connecting rods are made of forged steel. Full pressure lubrication is directed to the connecting rods by drilled oil passages from the adjacent
main bearing journal.

A roller rocker type valve train is used. Motion is transmitted from the camshaft through the hydraulic roller lifter and from the pushrod to the roller
rocker arm. The rocker arm pivots on the needle roller bearings. The rocker arm transmits the camshaft motion to the valve. The rocker arm
pedestal is located in a slot in the cylinder head. The rocker arm is retained in the cylinder head by a bolt. The pushrod is located by the rocker arm.

The intake manifold is a 2-piece cast aluminum unit. The intake manifold centrally supports a fuel rail with 6 fuel injectors.

The exhaust manifolds are cast nodular iron.

Installation Precautions
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General Information on Engine Service

Caution: Before removing or installing any electrical unit, or when a tool or equipment could easily come in contact with "live" or "hot all
the times" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle
or components. Unless instructed otherwise, the ignition switch must be in the OFF or LOCK position.

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a five exposed electrical
terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the
vehicle or its components.

Notice: The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to
reliable engine performance.

Use a block of wood under the oil pan when raising or supporting the engine. Jacking against the oil pan may cause the oil pan to bend against
the pump screen and result in a damaged pickup unit.
Any time the throttle body or throttle body air inlet tube is removed, the intake opening should be covered. Covering the opening will protect
against the accidental entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the
engine is started.

Notice: Pull on the spark plug boot, the heat shield or use an approved spark plug boot removal tool, twisting a half-turn to release the seal while
removing. Do not pull on the spark plug wire or it may be damaged.

Notice: Clean the spark plug recess area before removing the spark plug. Failure to do so could result in engine damage because of dirt or
foreign material entering the cylinder head, or by the contamination of the cylinder head threads. The contaminated threads may prevent the
proper seating of the new plug. Use a thread chaser to clean the threads of any contamination.

Notice: Allow the engine to cool before removing the spark plugs. Attempting to remove the spark plugs from a hot engine may cause the plug
threads to seize, causing damage to cylinder head threads.

Lubrication Description

Front View
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Rear View
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Right View

Full pressure lubrication, through a full flow oil filter, is furnished by a gear type oil pump. The oil is drawn up through the pickup screen and the
tube. The oil passes through the pump to the oil filter.

The oil filter is a full flow paper element unit. An oil filter bypass is used in order to ensure oil supply during the following conditions:
^ On a cold start
^ If the filter is plugged
^ If the filter develops excessive pressure drop

The bypass is designed to open at 69 - 83 kPa (10 - 12 psi).

A new priority oil delivery system supplies oil first to the crankshaft journals. The oil from the crankshaft main bearings is supplied to the
connecting rod bearings by intersecting the passages drilled in the crankshaft. The passages supply the oil to the crankshaft main bearings and the
camshaft bearings through the intersecting vertical drilled holes. The oil passages from the camshaft journals supply oil to the hydraulic lifters.

The hydraulic lifters pump oil up through the pushrods to the rocker arms. The cast dams in the crankcase casting direct the oil that drains back
from the rocker arms in order to supply the camshaft lobes. The camshaft chain drive is lubricated by indirect oil splash.

Replacing Engine Gaskets


1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any
gasket or sealing surface unless called out in the service procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to loosen the components. Perform the bumping at the
bends or at the reinforced areas in order to prevent the distortion of components.

Important: Do not use any other method or technique in order to remove the gasket material from a components.

Do not use the following items in order to clean the gasket surfaces:
^ Abrasive pads
^ Sand paper
^ Power tools

These methods of cleaning may damage the component.


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Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing
surfaces.

Important: Do not allow the sealant to enter any blind threaded holes. The sealant may cause the following conditions:
^ Prevent you from properly seating the bolt
^ Cause damage when you tighten the bolt

4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of
debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.
Separating Parts
In addition to the RTV sealant's sealing capabilities, the RTV sealants may form an adhesive bond between the components. This may make the
components difficult to remove or to separate. The RTV sealant is weakest in shear strength and parts. If possible, bump the components
sideways rather than using prying tools in order to remove the components. This technique prevents damage when the bonding strength of the
RTV sealant is stronger than the component itself. Perform bumping at the bends or at the reinforced areas in order to prevent part distortion.

Service Precautions
Important: Follow the engine service information below. This information is important in order to prevent damage and in contributing to
reliable engine performance.

In order to avoid damage to the engine oil pan, use a block of wood between the jack and the oil pan. Ensure that the block of wood extends past
the complete width of the oil pan. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause
the oil pan to bend against the pump screen. This condition results in a damaged oil pick-up unit.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

When working on the engine, remember that the 12 volt electrical system is capable of causing short circuits. When performing any work where
electrical terminals may possibly be grounded, disconnect the ground cable of the battery at the battery.

Any time you remove the air cleaner, cover the intake opening. This procedure protects against the accidental entrance of foreign material.
Foreign material may follow the intake passage into the cylinder. This condition causes extensive damage when you start the engine.

In the mechanical procedures described, generally no references will be made to the removal of optional equipment such as the power steering
pump, the air conditioning compressor, etc.

If you need to remove any optional equipment in order to perform other service, refer to the appropriate section for the specific information.

Tools and Equipment


Work in a clean and well-lit area. Have the following components available before you begin to work:
^ A suitable parts cleaning tank
^ A compressed air supply
^ Trays, in order to keep the parts and the fasteners organized
^ An adequate set of hand tools

An approved engine repair stand will prevent personal injury or damage to the engine components. The special tools are designed in order to
quickly and safely accomplish the operations for which the tools are intended. Using the tools will minimize possible damage to the engine
components. Precision measuring tools are required for the inspection of certain critical components. Torque wrenches are needed for the correct
assembly of various parts.

Use of RTV and Anaerobic Sealer


The following 2 types of sealer are commonly used in engines:
^ The RTV sealer
^ The anaerobic gasket eliminator sealer
Follow the service procedure instructions. Use the correct sealer in the proper place in order to prevent oil leaks. Do not interchange the 2 types
of sealers. Use the sealer recommended in the service procedure.

Applying RTV Sealer


^ Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include the
following locations:
- The exhaust manifold
- The head gasket
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- The other surfaces where gasket eliminator is specified
^ Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the part sideways in order to shear the RTV sealer.
Perform the bumping at the bends or the reinforced areas in order to prevent distortion of the components. The RTV sealant is weaker in
shear (lateral) strength than in tensile (vertical) strength.

Important: Do not use any other method or technique in order to remove the gasket material from a component.

^ Do not use the following items in order to clean the gasket surfaces:
- Abrasive pads
- Sand Paper
- Power tools
These methods of cleaning may damage the part.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.
^ Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite (R) brand gasket remover P/N 4MA or
the equivalent. Follow all of the safety recommendations and the directions that are on the container.

Important: Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions:
- Prevent you from properly seating the bolt
- Cause damage when you tighten the bolt

^ Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure. Apply the bead to the inside of any bolt holes.
^ Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait for the RTV sealant to skin over.

Important: Do not overtighten the bolts.


^ Tighten the bolts to specifications.

Applying Anaerobic Sealer


The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts (such as castings) are assembled
together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket
eliminator.

Important: Do not use any other method or technique in order to remove the gasket material from a component.

Do not use the following items in order to clean the gasket surfaces:
^ Abrasive pads
^ Sand paper
^ Power tools
These methods of cleaning may damage the part.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.
^ Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite (R) brand gasket remover P/N 4MA or
the equivalent. Follow all of the safety recommendations and the directions that are on the container.
^ Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces that you will reseal.

Important: Anaerobic sealed joints that are partially torqued and allowed to cure more than 5 minutes may result in incorrect shimming and
sealing of the joint.

^ Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions:
- Prevent you from properly seating the bolt
- Cause damage when you tighten the bolt
^ Spread the sealer evenly in order to get a uniform coating on the sealing surface.
^ Tighten the bolts to the specifications.
^ Remove the excess sealer from the outside of the joint.
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Engine: Testing and Inspection
Base Engine Misfire Diagnosis
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Engine: Testing and Inspection
Engine Noise Diagnosis

Engine Noise Diagnosis (Symptom - Cause/Correction)

Exhaust
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Valve Train

Base Engine

Engine Noise Diagnosis (General Description)


Notice: Some engine noise is characteristic to the design. Compare the sounds in other engines in order to make sure that you are not trying to
correct a normal condition.
^ Use the following four elements when diagnosing engine noise:
- The type of noise
- Under which operating conditions the noise exists
- At what rate the noise exists in the engine
- At what location the noise exists in the engine
^ Compare the sounds in other engines in order to ensure that the noise is not a normal condition.
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^ Engine noise is generally synchronized to either engine speed (caused by the crankshaft, connecting rods or pistons) or one-half engine speed
(valve train noise). Try to determine the rate at which the noise is occurring.

Main Bearing Noise


^ Damaged or worn main bearing noise is revealed by dull thuds or knocks which happen on every engine revolution. This noise is loudest
when the engine is under heavy load.
^ An intermittent rap or knock sharper than a worn main bearing indicates excessive crankshaft end play.
^ The following conditions cause main bearing noise:
- Low oil pump pressure
- Thin, diluted, or dirty oil and/or filter
- Excessive main bearing clearance
- Excessive crankshaft end play
- Out-of-round crankshaft journals
- Excessive belt tension
- A loose crankshaft pulley
- A loose flywheel or torque converter
- A loose main bearing cap
- Belt pilling

Connecting Rod Bearing Noise


A damaged or worn connecting rod bearing will produce a knock under all speeds. During the early stages of wear, connecting rod noise may be
confused with piston slap or loose piston pins. Connecting rod knock noise increases in volume with engine speed. This noise is loudest on
deceleration.
The following conditions cause connecting rod bearing noise:
^ Excessive bearing clearance
^ A worn crankshaft connecting rod journal
^ Thin, diluted, or dirty oil and/or filter
^ Low oil pressure
^ Crankshaft connecting rod journals out-of-round
^ A misaligned connecting rod
^ Connecting rod nuts not properly torqued
^ The wrong bearing inserts or misaligned bearing half

Timing Chain and Sprocket Noise


Engines equipped with a timing chain and sprockets may produce noise. The most common noise is a high frequency, light-knocking sound. This
sound will generally be the same in intensity whether the engine is idling, operating at high speeds, or under load.
The following conditions may cause timing chain and sprocket noise:
^ A worn timing chain
^ A damaged sprocket
^ A loose sprocket on the camshaft or crankshaft
^ Too much end play in the camshaft or crankshaft

Piston Noise
Piston pin, piston, and connecting rod noise are hard to separate. A loose piston pin causes a sharp double knock usually heard when the engine
is idling, or during sudden acceleration then deceleration of the engine. A piston pin that has been improperly fitted will emit a light ticking noise
that is more noticeable with no load on the engine. Excessive piston-to-cylinder bore clearance will cause a piston slap noise. The noise is similar
to a metallic knock, as if the piston were slapping the cylinder wall during the stroke.
As with most engine noise, understanding the cause of the noise will help you imagine what the noise sounds like. An indication of piston slap is
a decrease in noise as the engine warms up. When the engine is cold, the piston-to-bore clearance is greater and piston slap will be louder. The
following conditions may cause piston noise:
^ A worn or loose piston pin
^ Improper pin fit
^ Excessive piston-to-cylinder bore clearance
^ Lack of lubrication
^ Carbon deposits on top of the piston striking the cylinder head
^ Worn or broken piston ring land
^ Broken or cracked piston
^ Misaligned connecting rods
^ Worn or damaged rings
^ Excessive ring land clearance
^ Insufficient ring-end gap clearance
^ Piston 180 degrees out of position
^ Incorrect skirt profiles

Flywheel Noise

Notice: Converter bolts that are too long may dimple the torque converter clutch apply surface and cause a shudder condition.

A loose or cracked flywheel will produce an irregular thud or click. Complete the following steps in order to test for a loose or cracked flywheel:
1. Operate the vehicle at approximately 32 km/h (20 mph).
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2. Shut off the engine.
If a thud is heard, the flywheel may be loose or damaged. This type of thud is loudest on deceleration.
Loose torque converter-to-flywheel or flywheel-to-crankshaft bolts will resemble a bearing knock. This condition produces several raps during
quick acceleration on a free-running engine. Depending on the idle smoothness, when the transaxle is in gear, the noise may or may not appear.
Inspect the torque converter-to-flywheel and the flywheel-to-crankshaft bolts before attempting to investigate any bearing-related knock.

Valve Train Noise


A light tapping at one-half engine speed, or any varying frequency, may indicate a valve train problem. These tapping noises increase with the
engine speed. Warm up the engine before attempting to judge the valve train noise. This will bring all of the engine components to a normal state
of expansion. Run the engine at various speeds and listen for engine noise with the hood closed.

Caution: The following procedure is not recommended on engines with stainless steel exhaust manifolds because manifold temperature
will exceed the flash point of the oil causing a fire with possible personal injury.

If the valve mechanism is abnormally noisy, remove the valve rocker arm covers. Use a stethoscope in order to determine which valve train
components are causing the noise. The causes of the valve noise include the following conditions:
^ Broken or weak valve springs
^ Sticking or warped valves
^ Bent push rods
^ Dirty, stuck, or worn valve lifters
^ Damaged or improperly machined camshaft lobes
^ Insufficient or poor oil supply to the valve train (low oil pressure)
^ Excessive valve stem-to-guide clearance
^ Worn valve guides
^ Worn push rods
^ Worn valve rocker arms
^ A broken valve rocker arm bolt
^ Loose or worn valve rocker arm attachments
^ Missing or improperly positioned lifter guides (roller lifter engines)
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Engine: Testing and Inspection
Oil Consumption Diagnosis
An engine that has excessive oil consumption uses 0.9L (1 qt.) of oil, or more, within 2,000 mi (3 200 km). The following list indicates the
conditions and corrections of excessive oil consumption:

^ An improperly rea oil level indicator (dipstick)


- Inspect the oil level while the vehicle is parked on a level surface.
- Allow adequate drain-down time.
^ Improper oil viscosity
- Use the recommended SAE viscosity for prevailing temperatures.
- Refer to the proper oil viscosity specifications.
^ Continuous high-speed driving
^ Severe hauling, such as a trailer. This causes decreased oil mileage.
^ A malfunctioning crankcase ventilation system
^ External oil leaks
- Tighten the bolts, as needed.
- Replace the gaskets and seals, as needed.
^ Worn or omitted valve guides and/or valve stem seals
- Ream the guides.
- Install oversized service valves and/or new valve stem seals.
^ Broken or worn piston rings
^ Improperly installed or unseated piston rings
^ Improperly installed or improperly fitted piston
^ Plugged cylinder head gasket oil drain holes
^ Damaged intake gaskets
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Engine: Testing and Inspection
Oil Leak Diagnosis
^ Tools Required
- J 28428-E High Intensity Black Light

You may repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by resealing the gasket surface. Once
the leak is identified, determine the cause of the leak. Repair the leak and the cause of leak.

Locating and Identifying the Leak


Use the visual inspection method in order to determine if the leaking fluid is one of the following items:
^ Engine oil
^ Transmission fluid
^ Power steering fluid
^ Brake fluid
^ Some other fluid

Visual Inspection Method


Complete the following steps in order to perform the visual inspection method:
1. Bring the vehicle to normal operating temperature.
2. Park the vehicle over a large sheet of paper, or other clean surface.
3. Wait several minutes, then inspect for dripping fluids.
4. Identify the type of fluid, and the approximate location of the leak.
5. Visually inspect the suspected area. Use a small mirror if necessary.
6. Inspect for leaks at sealing surfaces, fittings, or from cracked or damaged components.
7. If you cannot locate the leak, perform the following steps:
7.1. Completely clean the entire engine and surrounding components.
7.2. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
7.3. Park the vehicle over a large sheet of paper, or other clean surface.
7.4. Wait several minutes, then inspect for dripping fluids.
7.5. Identify the type of fluid, and the approximate location of the leak.
7.6. Visually inspect the suspected area. Use a small mirror if necessary.
7.7. Refer to Possible Causes for Leaks.
8. If you still cannot locate the leak, use the powder method or the black light and dye method.

Powder Method
1. Completely clean the entire engine and surrounding components.
2. Apply an aerosol-type powder (baby powder, foot powder, etc.) to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Refer to Possible Causes for Leaks if
necessary.

Black Light and Dye Method


A dye and light kit is available for finding leaks.
1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the tool.
2. Visually inspect the suspected area. Use a small mirror if necessary. Refer to Possible Causes for Leaks if necessary.

Possible Causes for Leaks


Inspect the vehicle for the following conditions:
^ Higher than recommended fluid levels
^ Higher than recommended fluid pressures
^ Plugged or malfunctioning fluid filters or pressure bypass valves
^ Plugged or malfunctioning engine ventilation system
^ Improperly tightened or damaged fasteners
^ Cracked or porous components
^ Improper sealants or gaskets where required
^ Improper sealant or gasket installation
^ Damaged or worn gaskets or seals
^ Damaged or worn sealing surfaces
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Engine: Removal and Replacement

Engine Replacement
Removal Procedure

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Remove the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
3. Remove the cruise control cable from the engine and reposition the cable away from the engine. Refer to Cruise Control Cable Replacement
in Cruise Control.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable
whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or
lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

4. Remove the accelerator control cable from the engine and reposition the cable away from the engine. Refer to Accelerator Controls Cable
Replacement in Computers and Controls.
5. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
6. Disconnect the radiator hoses from the engine. Refer to Radiator Hose Replacement - Inlet and Radiator Hose Replacement - Outlet in
Cooling System.
7. Disconnect the heater hoses from the engine. Refer to Heater Hose Replacement - Inlet and Heater Hose Replacement - Outlet in Heating and
Air Conditioning.
8. Remove the engine mount struts. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right).

Important: Relief the fuel pressure. Refer to Fuel Pressure Relief Procedure in Computers and Controls.

9. Disconnect the fuel lines from the fuel rail. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) (Engine pipes) in Computers and
Controls.
10. Remove the engine wiring harness connectors.
11. Remove the vacuum hoses from the engine.
12. Remove the vacuum brake booster hose. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.
13. Remove the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement in Transmission
and Drivetrain.
14. Raise and support the vehicle. Refer to Vehicle Lifting.
15. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Without Oil Cooler) or Engine Oil and Oil Filter Replacement (With
Oil Cooler).
16. Remove the wiring harness grounds.
17. Remove the three-way catalytic converter exhaust pipe from the engine right side exhaust manifold. Refer to Catalytic Converter
Replacement in Powertrain Management.
18. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation.
19. Remove the engine splash shields. Refer to Splash Shield Replacement - Engine in Body and Frame.
20. Remove the stabilizer shaft links from the lower control arms. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension.
21. Remove the tie rod ends from the steering knuckles. Refer to Steering Knuckle Replacement in Steering and Suspension.
22. Remove the lower ball joints from the knuckles. Refer to Lower Ball Joint Replacement in Steering and Suspension.
23. Remove the transaxle cooler lines and bracket from the transaxle. Refer to Automatic Transmission Oil Cooler Hose Replacement in
Transmission and Drivetrain.
24. Disconnect the drive axles from the transaxle. Refer to Wheel Drive Shafts Replacement in Transmission and Drivetrain.
25. Secure the drive axles to the steering knuckle/struts.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the
steering gear and/or intermediate shaft. This damage may cause loss of steering control which could result in an accident and
possible personal injury

26. Remove the intermediate shaft from the steering gear. Refer to Lower/Upper Intermediate Steering Shaft Replacement in Steering and
Suspension.
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27. Lower the vehicle until the frame contacts the transaxle table.
28. Remove the frame bolts. Refer to Frame Replacement in Body and Frame.
29. Raise the vehicle in order to separate the powertrain/frame from the vehicle.

30. Remove the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (1 and 2).
31. Remove the engine flywheel to torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.
32. Remove the engine from the transaxle/frame to the engine stand.

Installation Procedure

1. Install the engine to the transaxle/frame from the engine stand.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (1 and 2).
^ Tighten the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (11 and 2) to 75 Nm (55 ft. lbs.).
3. Install the engine flywheel to torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.
4. Position the transaxle table with the powertrain/frame under the vehicle.
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5. Lower the vehicle until the frame contacts the transaxle table.
6. Install the NEW frame bolts. Refer to Frame Replacement in Body and Frame.
7. Raise and support the vehicle. Refer to Vehicle Lifting.
8. Remove the transaxle table.

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is
inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will
cause loss of steering control which could result in personal injury.

9. Install the intermediate shaft to steering gear. Refer to Lower/Upper Intermediate Steering Shaft Replacement in Steering and Suspension.
10. Install the drive axles to the transaxle. Refer to Wheel Drive Shafts Replacement in Transmission and Drivetrain.
11. Install the transaxle cooler lines and bracket to the transaxle. Refer to Automatic Transmission Oil Cooler Hose Replacement in Transmission
and Drivetrain.
12. Install the lower ball joints to the knuckles. Refer to Lower Ball Joint Replacement in Steering and Suspension.
13. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Steering and Suspension.
14. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link Replacement in Steering and Suspension.
15. Install the inner fender splash shield. Refer to Splash Shield Replacement - Engine in Body and Frame.
16. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Steering and Suspension.
17. Install the three-way catalytic converter exhaust pipe to the engine right side exhaust manifold. Refer to Catalytic Converter Replacement in
Powertrain Management.
18. Install the wiring harness grounds.
19. Lower the vehicle
20. Install the automatic transaxle range selector cable. Refer to Automatic Transmission Range Selector Cable Replacement in Transmission and
Drivetrain.
21. Install the vacuum brake booster hose. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.
22. Install the vacuum hoses to the engine.
23. Install the engine wiring harness connectors.
24. Install the fuel lines to the fuel rail. Refer to Fuel Hose/Pipes Replacement (Engine Compartment) (Engine pipes) in Computers and Controls.
25. Install the throttle body bracket and cables. Refer to Accelerator Controls Cable Replacement in Computers and Controls.
26. Install the engine mount strut. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right).
27. Connect the heater hoses to the engine. Refer to Heater Hose Replacement - Inlet and Heater Hose Replacement - Outlet in Heating and Air
Conditioning.
28. Connect the radiator hoses to the engine. Refer to Radiator Hose Replacement - Inlet and Radiator Hose Replacement - Outlet in Cooling
System.
29. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
30. Adjust the transaxle fluid level. Refer to the following information:
^ Transmission Fluid Checking Procedure in Transmission and Drivetrain
^ Capacities - Approximate Fluid
^ Fluid and Lubricant Recommendations
31. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Without Oil Cooler) or Engine Oil and Oil Filter Replacement (With
Oil Cooler).

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable
whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or
lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

32. Install the accelerator control cable to the engine. Refer to Accelerator Controls Cable Replacement in Computers and Controls.
33. Install the cruise control cable to the engine. Refer to Cruise Control Cable Replacement in Cruise Control.
34. Install the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
35. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
36. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure in Computers and Controls.
37. Inspect for proper fluid levels and possible fluid leaks.
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Engine Support Fixture


Installation Procedure

^ Tools Required
- J 28467-B Universal Engine Support Fixture
- J 28467-500 Engine Support Fixture

1. Remove the right side engine mount strut. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right).
2. Install the J 28467-500.

3. Install the spreader bar to the engine mount strut bracket.

4. Install the spreader bar to the engine right side engine lift hook.
5. Install the J 28467-6A.
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6. Install the J 28467-7A to the engine left side engine lift hook.
7. Install the J 28467-34.
8. Install the J 28467-6A.

9. Install the J 28467-8A to the spreader bar.


10. Install the J 28467-34.

11. The engine support fixture upper portion installed.

Important: Perform the following steps only if you are disconnecting both of the powertrain mounts from the frame or the powertrain.

12. Raise and support the vehicle. Refer to Vehicle Lifting.

Caution: The utility straps MUST be installed in order to prevent forward movement of the powertrain. If the utility straps are not
installed, the powertrain will move which may cause personal injury and vehicle damage.
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13. Install the J 28467-500UPD to the engine.

14. Install the J 28467-500UPD opposite end to the underbody rail.

15. Install the OTHER J 28467-500UPD to the transaxle.


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16. Install the J 28467-500UPD opposite end to the underbody rail.


17. Tighten both of the J 28467-500UPD utility straps in order to prevent forward movement of the powertrain.

Removal Procedure

1. Remove both of the J 28467-500UPD.


2. Lower the vehicle.
3. Remove the J 28467-34.
4. Remove the J 28467-7A.
5. Remove the J 28467-6A.
6. Remove the J 28467-34.
7. Remove the J 28467-8A.
8. Remove the J 28467-6A.
9. Remove the J 28467-500.
10. Install the right side engine mount strut. Refer to Engine Mount Strut Replacement (Left) or Engine Mount Strut Replacement (Right).

Rotating the Engine For Service Access


ROTATING THE ENGINE FOR SERVICE ACCESS.

^ Tools Required
- J 41131 Engine Tilt Strap

1. Remove the throttle body air inlet duct. See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Filter Element/Service and
Repair
2. Set the park brake.
3. Shift the transaxle into Neutral.
4. Remove the engine mount strut bolts. Swing the engine mount struts aside. Refer to Engine Mount Strut Replacement (Left) or Engine Mount
Strut Replacement (Right).

5. Install the J 41131.


6. Pull on the engine in order to rotate the engine forward.
7. Tighten the J 41131.
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Engine: Tools and Equipment
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Engine: Overhaul

Overhaul Procedure Steps


ENGINE OVERHAUL
In order to overhaul, follow the sequence below.

1. Draining Fluids and Oil Filter Removal


2. Crankshaft Balancer Removal
3. Engine Flywheel Removal
4. Drive Belt Tensioner Removal
5. Generator and Engine Lift Front Bracket Removal
6. Engine Mount Strut and Engine Lift Bracket Removal
7. Engine Mount Strut and A/C Compressor Bracket Removal
8. Oil Level Indicator and Tube Removal
9. Oil Filter Adapter Removal
10. Valve Rocker Arm Cover Removal
11. Intake Manifold Removal
12. Water Outlet Removal
13. Exhaust Crossover Removal
14. Exhaust Manifold Removal
15. Valve Rocker Arm and Push Rod Removal
16. Valve Lifter Removal
17. Water Pump Removal
18. Oil Pan Removal
19. Oil Pump Removal
20. Oil Pump Drive Removal
21. Crankshaft Front Oil Seal Removal
22. Engine Front Cover Removal
23. Timing Chain and Sprockets Removal
24. Cylinder Head Removal
25. Camshaft Removal
26. Piston, Connecting Rod, and Bearing Removal
27. Crankshaft Rear Oil Seal Removal
28. Crankshaft and Bearing Removal
29. Engine Block Disassemble
30. Engine Block Clean and Inspect
31. Cylinder Boring and Honing
32. Engine Block Assemble
33. Crankshaft and Bearing Clean and Inspect
34. Crankshaft Balancer Clean and Inspect
35. Engine Flywheel Clean and Inspect
36. Piston and Connecting Rod Disassemble
37. Piston, Connecting Rod, and Bearing Clean and Inspect
38. Piston Selection
39. Piston and Connecting Rod Assemble
40. Camshaft Bearing Removal
41. Camshaft and Bearings Clean and Inspect
42. Camshaft Bearing Installation
43. Timing Chain and Sprocket Clean and Inspect
44. Valve Lifters Clean and Inspect
45. Valve Rocker Arm and Push Rod Clean and Inspect
46. Cylinder Head Disassemble
47. Cylinder Head Clean and Inspect
48. Valve Guide Reaming, and Valve and Seat Grinding
49. Cylinder Head Assemble
50. Oil Pump Disassemble
51. Oil Pump Clean and Inspect
52. Oil Pump Assemble
53. Engine Front Cover Clean and Inspect
54. Valve Rocker Arm Cover Clean and Inspect
55. Oil Pan Clean and Inspect
56. Intake Manifold Clean and Inspect
57. Exhaust Manifold Clean and Inspect
58. Water Pump Clean and Inspect
59. Thread Repair
60. Service Prior to Assembly
61. Crankshaft and Bearing Installation
62. Crankshaft Rear Oil Seal Installation
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63. Piston, Connecting Rod, and Bearing Installation
64. Camshaft Installation
65. Timing Chain and Sprockets Installation
66. Engine Front Cover Installation
67. Crankshaft Front Oil Seal Installation
68. Oil Pump Drive Installation
69. Oil Pump Installation
70. Oil Pan Installation
71. Cylinder Head Installation
72. Water Pump Installation
73. Valve Lifter Installation
74. Valve Rocker Arm and Push Rod Installation
75. Exhaust Manifold Installation
76. Exhaust Crossover Installation
77. Intake Manifold Installation
78. Valve Rocker Arm Cover Installation
79. Water Outlet Installation
80. Oil Filter Adapter Installation
81. Oil Level Indicator and Tube Installation
82. Generator and Engine Lift Front Bracket Installation
83. Engine Mount Strut and Engine Lift Bracket Installation
84. Engine Mount Strut and A/C Compressor Bracket Installation
85. Drive Belt Tensioner Installation
86. Engine Flywheel Installation
87. Crankshaft Balancer Installation
1. Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.


2. Drain the engine oil.

3. Remove the oil filter.


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4. Remove the coolant drain plug from the left side.

5. Remove the coolant drain plug from the right side.


6. Drain the coolant.

2. Crankshaft Balancer Removal


^ Tools Required
- J 24420-C Crankshaft Balancer Puller

1. Remove the crankshaft balancer retaining bolt and washer.


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2. Remove the crankshaft balancer using the J 24420-C.

3. Engine Flywheel Removal

1. Remove the flywheel bolts.


2. Remove the flywheel retainer.
3. Remove the flywheel.

4. Drive Belt Tensioner Removal

1. Remove the drive belt tensioner bolt.


2. Remove the drive belt tensioner.

5. Generator and Engine Lift Front Bracket Removal


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1. Remove the generator bracket bolts (1 - 3).


2. Remove the generator bracket.
3. Remove the front engine lift hook.

6. Engine Mount Strut and Engine Lift Bracket Removal

1. Remove the engine mount strut and A/C compressor bracket bolts.
2. Remove the engine mount strut and A/C compressor bracket.

7. Engine Mount Strut and A/C Compressor Bracket Removal

1. Remove the engine mount strut and lift bracket bolts.


2. Remove the engine mount strut and lift bracket.

8. Oil Level Indicator and Tube Removal


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1. Remove the thermostat bypass pipe to throttle body nut (2).


2. Remove the thermostat bypass pipe to throttle body hose clamps (1).
3. Remove the thermostat bypass pipe to engine front cover bolt (4).
4. Remove the thermostat bypass pipe to cylinder head nut (3).
5. Remove the thermostat bypass pipe hose clamps (5).

6. Remove the thermostat bypass pipe hose.


7. Remove the thermostat bypass pipe.

8. Remove the oil level indicator and oil level indicator tube.

9. Oil Filter Adapter Removal


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1. Remove the oil filter bypass hole plug.

Important: Do not remove the oil filter fitting unless replacement or repair is needed.

2. Remove the oil filter fitting, if necessary.


3. Remove the oil filter bypass valve, by prying out with a suitable tool.

Left Valve Rocker Arm Cover

1. Remove the spark plug wires.


2. Remove the electronic ignition control module nuts and bolts.
3. Remove the electronic ignition control module.

4. Disconnect the vacuum lines from the upper intake manifold.


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5. Remove the valve rocker arm cover bolts.


6. Remove the valve rocker arm cover and gasket.

Right Valve Rocker Arm Cover

1. Remove the valve rocker arm cover bolts.


2. Remove the valve rocker arm cover and gasket.

Upper Intake Manifold

1. Disconnect the MAP sensor electrical connector.


2. Remove the MAP sensor screws.
3. Remove the MAP sensor.
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4. Remove the EGR valve pipe from the exhaust manifold.


5. Remove the EGR valve bolts.
6. Remove the EGR valve and gasket.
7. Remove the EGR valve pipe and gasket.

8. Remove the upper intake manifold.


9. manifold studs and bolts.
10. Remove the upper intake manifold gaskets.

11. Remove the upper intake manifold gaskets.

Lower Intake Manifold


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1. Remove the fuel feed and return pipe retaining clip bolt.
2. Remove the fuel feed and return pipe retaining clip.

3. Remove the fuel injector rail bolts.


4. Remove the fuel injector rail assembly.

5. Remove the heater inlet pipe nut.


6. Remove the heater inlet pipe.
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7. Remove the lower intake manifold bolts.


8. Remove the lower intake manifold.

12. Water Outlet Removal

1. Remove the water outlet bolts.


2. Remove the water outlet.
3. Remove the water outlet gasket.

4. Remove the thermostat.

13. Exhaust Crossover Removal


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1. Remove the exhaust crossover pipe heat shield bolts.


2. Remove the exhaust crossover pipe heat shield.

3. Remove the exhaust crossover pipe nuts.


4. Remove the exhaust crossover pipe.

Left Exhaust Manifold

1. Remove the exhaust manifold heat shield bolts.


2. Remove the exhaust manifold heat shield.
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3. Remove the exhaust manifold nuts.


4. Remove the exhaust manifold.
5. Remove the exhaust manifold gasket.

Right Exhaust Manifold

1. Remove the heated oxygen sensor.

2. Remove the exhaust manifold heat shield bolts.


3. Remove the exhaust manifold heat shields.
4. Remove the right side spark plugs.
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5. Remove the exhaust manifold nuts.


6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.

15. Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arm bolts.

Important: Place the valve train components in a rack in order to ensure that the components are installed in the same location from which
they were removed.

2. Remove the valve rocker arms.

3. Remove the push rods.


^ The intake push rods measure 144.18 mm (5.68 inch).
^ The exhaust push rods measure 152.51 mm (6.0 inch).
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4. Remove the intake manifold gaskets.

16. Valve Lifter Removal

1. Remove the valve lifter guide bolts.


2. Remove the valve lifter guides.

Important: Once removed, place the valve lifters in an organized order so the valve lifters can be installed into the original locations.

3. Remove the valve lifters.

17. Water Pump Removal

1. Remove the water pump pulley bolts.


2. Remove the water pump pulley.
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3. Remove the water pump bolts.


4. Remove the water pump.
5. Remove the water pump gasket.

18. Oil Pan Removal

1. Remove the oil pan side bolts.


2. Remove the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil pan gasket.

19. Oil Pump Removal

1. Remove the oil pump bolt.


2. Remove the oil pump and oil pump drive shaft.
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3. Remove the crankshaft oil deflector nuts.


4. Remove the crankshaft oil deflector.

20. Oil Pump Drive Removal

1. Remove the oil pump drive clamp bolt.


2. Remove the oil pump drive clamp.
3. Remove the oil pump drive.

21. Crankshaft Front Oil Seal Removal

Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

22. Engine Front Cover Removal


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1. Remove the engine front cover bolts (1), (2), and (3).
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

23. Timing Chain and Sprockets Removal


^ Tools Required
- J 5825-A Crankshaft Sprocket Puller

1. Remove the camshaft sprocket bolt.


2. Remove the camshaft sprocket and timing chain.

3. Remove the crankshaft sprocket. Use the J 5825-A.


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4. Remove the timing chain dampener bolts.


5. Remove the timing chain dampener.

24. Cylinder Head Removal - Left and Right

1. Remove the cylinder head bolts.


2. Remove the cylinder head.

3. Remove the cylinder head gasket.


4. Remove the dowel pins (cylinder head locator) (if required).

25. Camshaft Removal


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1. Remove the camshaft thrust plate screws.


2. Remove the camshaft thrust plate.

Notice: All camshaft journals are the same diameter, so care must be used in removing or installing the camshaft to avoid damage to the
camshaft bearings.

3. Complete the following steps in order to remove the camshaft:


3.1. Install a large screwdriver in the camshaft bolt hole. Do not damage the threads.
3.2. Carefully rotate and pull the camshaft out of the camshaft bearings.

26. Piston, Connecting Rod, and Bearing Removal


^ Tools Required
- J 24270 Ridge Reamer

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.

Notice: If there is a pronounced ridge at the top of the piston travel, the ridge must be removed with a ridge reamer before the piston and
connecting rod assembly are removed. Applying force may break the piston rings or damage the piston.
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3. Use the J 24270 in order to remove the cylinder bore ring ridge. Complete the following steps:
3.1. Turn the crankshaft until the piston is at the bottom of the stroke.
3.2. Cover the piston with a cloth.
3.3. Remove the cylinder ring ridge.
3.4. Turn the crankshaft until the piston is at the top of the stroke.
3.5. Remove the cloth.
3.6. Remove the metal shavings from the cylinder and piston.

4. Remove the connecting rod nuts and cap.


5. Remove the connecting rod cap and bearing half.

Notice: Install thread protector in order to avoid damage to the crankshaft journal.

6. Remove the connecting rod and piston assembly. Push out the assembly using a suitable tool.

27. Crankshaft Rear Oil Seal Removal

1. Remove the crankshaft rear oil seal.

Important: Do not damage the crankshaft or seal bore.

2. Pry out the crankshaft rear oil seal out using a suitable tool.

28. Crankshaft and Bearings Removal


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1. Remove the crankshaft main bearing cap bolt and studs.


2. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
3. Remove the crankshaft.
4. Remove the upper crankshaft main bearing halves.

29. Engine Block Disassemble

1. Remove the camshaft rear bearing hole plug.

2. Remove the rear oil gallery plugs (1, 2, 3).


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3. Remove the front oil gallery plugs (1, 2).


4. Remove all of the remaining engine block plugs.

5. Remove the knock sensor.

6. Remove the crankshaft position sensor stud.


7. Remove the crankshaft position sensor from the side of the engine block.
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8. Remove the camshaft position sensor bolt.


9. Remove the camshaft position sensor.

10. Remove the engine oil pressure switch.

30. Engine Block Clean and Inspect


^ Tools Required
- J 8001 Dial Indicator Set
- J 8087 Cylinder Bore Gage

1. Clean the sealing material from the gasket mating surfaces.


2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes.
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8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.

9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Carefully machine minor irregularities. Replace the block
if more than 0.25 mm (0.010 inch) must be removed.
10. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file in order to remove any nicks.

11. Inspect the mating surfaces of the transmission case.

Notice: A broken flywheel may result if the transmission case mating surface is not flat.

12. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt hole bosses:
12.1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
12.2. Hold the J 8001 gauge plate flat against the crankshaft flange.
12.3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0.
12.4. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.25 mm (0.010 inch).
12.5. Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 inch). If the crankshaft flange runout is within the
specification, replace the engine block.

Important: Perform the following inspections, and reconditioning (if necessary), with the crankshaft main bearing caps installed and
tightened to specification.

13. Inspect the crankshaft main bearing bores. Use the J 8087 in order to measure the bearing bore concentricity and alignment at the following
locations:
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^ The camshaft
^ The crankshaft
14. Replace the engine block if the bores are out of specification.

15. Use the J 8087 in order to inspect the cylinder bores. Inspect the bores for the following conditions:
^ Wear
^ Taper
^ Runout
^ Ridging

Important: If the bore is worn beyond the limits, refit the bore with 0.5 mm oversized pistons.

16. Leave sufficient material in order to allow honing when fitting the piston.

31. Cylinder Boring and Honing


Boring Procedure

1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may
provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the
boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts
to protect these parts during the boring or honing operation.
5. Leave 0.03 mm (0.001 inch) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing
and boring operation to maintain the specified clearances between pistons, rings, and cylinder bores.

Honing Procedure
1. Follow the manufacturer's recommendations for use, cleaning, and lubrication when honing the cylinders. Use only clean, sharp stones of the
proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. When using coarse or
medium-grade stones, leave sufficient metal so all stone marks may be removed with the fine stones used for finishing to provide the proper
clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct piston fit.
3. Make full strokes in the cylinder to eliminate taper. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder
bore.
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Notice: Handle the pistons with care. Do not force the pistons through the cylinder until you hone the cylinder to the correct size. The piston
can be distorted through careless handling.

4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to obtain a fine and uniform surface
finish in a cross hatch pattern.
5. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles and torn or folded metal.
6. Determine the finish hone cylinder measurement by measuring the piston to be installed, and by adding the average of the clearance
specification. Measure the block and the piston at normal room temperature.
7. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or cutter marks.
8. After final honing and before the piston is checked for fit, clean the bores with hot water and detergent. Scrub the bores with a stiff bristle
brush and rinse the bores thoroughly with hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive
material will wear the new rings, the cylinder bores, and the bearings lubricated by the contaminated oil. After washing dry the bore.
9. Permanently mark the piston for the cylinder to which the piston has been fitted.
10. Apply clean engine oil to each bore to prevent rusting.

32. Engine Block Assemble

1. Apply sealer GM P/N 12346004 or the equivalent to the oil pressure switch threads.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the engine oil pressure switch.


^ Tighten the engine oil pressure switch to 13 Nm (115 inch lbs.).

3. Install the camshaft position sensor.


4. Install the camshaft position sensor bolt.
^ Tighten the camshaft position sensor bolt to 10 Nm (89 inch lbs.).
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5. Install the crankshaft position sensor into the side of the engine block.
6. Apply threadlock GM P/N 12345382 or the equivalent to the position sensor stud threads.
7. Install the crankshaft position sensor stud.
^ Tighten the crankshaft position sensor stud to 11 Nm (98 inch lbs.).

8. Apply sealer GM P/N 12346004 or the equivalent to the knock sensor threads.
9. Install the knock sensor.
^ Tighten the knock sensor to 19 Nm (14 ft. lbs.).

10. Apply sealer GM P/N 12346004 or the equivalent to the front oil gallery plug threads (1 and 2).
11. Install the front oil gallery plug (1).
^ Tighten the oil gallery plug (1) to 19 Nm (14 ft. lbs.).
12. Install the front oil gallery plug (2).
^ Tighten the oil gallery plug (2) to 33 Nm (24 ft. lbs.).
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13. Apply sealer GM P/N 12346004 or the equivalent to the rear oil gallery plug threads (1 and 4).
14. Install the rear oil gallery plugs (1 and 4).
^ Tighten the oil gallery plugs (1 and 4) to 19 Nm (14 ft. lbs.).
15. Install the rear oil gallery plugs (2 and 3).
^ Tighten the oil gallery plugs (2 and 3) to 33 Nm (24 ft. lbs.).
16. Apply sealer GM P/N 12346004 or the equivalent to the engine block plugs.
17. Install the remaining engine block plugs.

18. Apply sealant GM P/N 12346004 or the equivalent to the coolant drain plug threads.
19. Install the left coolant drain plug.
^ Tighten the coolant drain plug to 19 Nm (14 ft. lbs.).

20. Apply sealant GM P/N 12346004 or the equivalent to the coolant drain plug threads.
21. Install the right coolant drain plug.
^ Tighten the coolant drain plug to 19 Nm (14 ft. lbs.).

33. Crankshaft and Bearings Clean and Inspect


^ Tools Required
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- J 8087 Cylinder Bore Gage
- J 36660-A Torque Angle Meter

1. Clean the crankshaft of the following elements:


^ Oil
^ Sludge
^ Carbon
2. Inspect the crankshaft oil passages for obstructions.

3. Inspect the crankshaft keyway for the following conditions:


^ A worn crankshaft key (1)
^ A worn crankshaft keyway (2)
4. Inspect the crankshaft threads (3) for damage.

Important: If cracks, severe gouges or burned spots are found, replace the crankshaft. Remove slight roughness using a fine polishing cloth
soaked in clean engine oil. Remove any burrs using a fine oil stone.

5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions:
^ Wear without any grooves or scratches (1)
^ Grooves or scoring (2)
^ Scratches or excessive wear (3)
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^ Pitting or embedded bearing material (4)
Inspect the corresponding crankshaft bearing inserts for embedded material and determine the source of the material.
^ Overheating (discoloration)

Notice: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will
etch the bearing surface.

6. The crankshaft bearings are the precision insert type.


7. Inspect the outer surfaces of the crankshaft bearings for the following conditions:
^ Wear - surface wear indicates either movement of the insert, or high spots in the surrounding material (spot wear).
^ Overheating or discoloration
^ Looseness or rotation indicated by flattened tangs and wear grooves

Important: Note the location of the crankshaft main bearing high spots. If the spots are not in line, the crankshaft is bent. Replace the
crankshaft.

8. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.
9. Inspect the thrust surfaces of the main thrust bearing for the following conditions:
^ Wear
^ Grooving - Grooves are caused by irregularities of the crankshaft thrust surface.

10. Inspect the crankshaft bearings for excessive scoring or discoloration.


11. Inspect the crankshaft main bearings for dirt or imbedded debris.
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12. Inspect the crankshaft main bearings for improper seating indicated by bright, polished sections.
13. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.

Important: If crankshaft bearing failure is due to conditions other than normal wear, investigate the cause of the condition. Inspect the
crankshaft or connecting rod bearing bores.

14. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure:
14.1. Tighten the bearing cap to specification.
14.2. Use the J 8087 in order to measure the bearing bore for taper and out-of-round. Record the readings for bearing selection.
14.3. No taper or out-of-round should exist.

Bearing Selection

Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance.
Method A gives more reliable results and is preferred.
^ Method A yields measurement from which the bearing clearance can be computed.
^ Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.

Method A

Important: Do not mix inserts of different nominal size in the same bearing bore.

1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification.
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
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5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.

Method B

Important: Do not mix inserts of different nominal size in the same bearing bore.

1. Clean the used bearing inserts.


2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps.

Notice: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into
the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the
crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.

5. Install the bearing cap bolts to specification.

Important: Do not rotate the crankshaft.

6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the
bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

34. Crankshaft Balancer Clean and Inspect

^ Inspect the crankshaft balancer sealing area for grooves (1).


^ Inspect the crankshaft balancer belt ribs for dents or damage.
^ Replace the crankshaft balancer if necessary.

35. Engine Flywheel Clean and Inspect


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Important: Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate.

^ Inspect the engine flywheel for cracks.


^ Inspect the engine flywheel teeth for damage.
^ Replace the engine flywheel if necessary.

36. Piston and Connecting Rod Disassemble


^ Tools Required
- J 24086-C Piston Pin Remover/Installer

Caution: Handle the piston carefully. Worn piston rings are sharp and may cause bodily injury.

1. Remove the piston rings from the piston. Use a suitable tool in order to expand the piston rings. Do not reuse the piston rings.

Important: Do not put any load on the piston during disassembly.


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2. Select fork insert J 24086-310. Install the fork upside down into the press.
3. Place the piston and connecting rod assembly into the J 24086-C and press out the piston pin. Ensure that the connecting rod is above the
fork when installing the piston and connecting rod assembly into the press.
4. Mark the piston pin to the piston from which the pin was removed.

37. Piston, Connecting Rod, and Bearings Clean and Inspect


Caution: Bodily injury may occur if the carburetor cleaning fluid is exposed to the skin or if the fumes are inhaled.

Important: Clean the piston ring grooves of carbon to the bare metal. Do not scrape the piston skirt.

1. Clean the sludge and carbon from the following components:


^ The piston
^ The piston pin
Soak the pin in a carburetor cleaning solution in order to remove the varnish from the piston.
^ The connecting rod

2. Clean the piston ring grooves using a suitable ring groove cleaning tool.
3. Clean the oil lubrication holes and slots.
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4. Inspect the connecting rod for bending or twisting.


4.1. Install the connecting rod cap.
4.2. Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or twisting.
4.3. Do not attempt to straighten the connecting rod.
Ensure that the connecting rod meets the following conditions:
^ The connecting rods are not bent more than 0.18 mm (0.007 inch).
The connecting rods are not twisted more than 0.038 mm (0.0015 inch).
4.4. Replace any bent or twisted connecting rods.
4.5. Inspect the new connecting rods before using the new rods.

5. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod bearing halves may indicate fatigue.

6. Inspect the connecting rod bearings for excessive scoring or discoloration.


7. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
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8. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearings.
9. Inspect the inside of the connecting rod bearing and the outside diameter of the connecting rod bearing journal for wear. This indicates high
spots.

10. Inspect the connecting rod bearing bore for taper and out-of-round.
11. Inspect the connecting rod piston pin bore for taper and out-of-round.
12. Inspect the connecting rod bores for nicks or gouges.

13. Inspect the piston for the following conditions:


^ Damage to the top of the piston (1)
^ Scoring of the skirt (2)
^ Scoring of the piston pin bore (3)
^ Broken ring groove lands
14. Inspect the piston pin for scoring or galling caused by improper installation.

Important: Take the measurements of the components with the components at normal room temperature.
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15. Measure the piston diameter. When measuring the piston for size or taper, ensure that the measurement is made as shown when the piston pin
is removed. If the piston is worn or damaged, replace the piston using a standard or oversize piston.

16. Inspect the piston ring-to-piston ring groove side clearance. Complete the following steps:
16.1. Insert the edge of the piston ring into the piston ring groove.
16.2. Roll the piston ring completely around the piston.
16.3. If binding is caused by a distorted piston ring groove, you may remove minor ring groove imperfections using a fine file.
16.4. If binding is caused by a distorted piston ring, replace the piston ring.

17. Measure the piston ring side clearance using a feeler gauge.
18. If the side clearance is too small, try another piston ring set.
19. If a proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston.
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20. Measure the piston pin diameter using an outside micrometer.

21. Measure the piston pin bore using an inside micrometer.


22. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-piston pin bore clearance.
23. Replace the piston and the piston pin if the piston and the piston pin are not within specifications.

24. Place the piston into the cylinder at the bottom of the ring travel.

Important: Measure the piston ring in the cylinder in which the piston may be used.

25. Place a piston ring on top of the piston.


26. Back off the piston.
27. Measure the ring gap. If the gap is below specification, increase the gap by carefully filing off excess material.

38. Piston Selection


^ Tools Required
- J 8087 Cylinder Bore Gauge
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Important: When fitting pistons, consider both the piston and the cylinder bore conditions together. Production and service pistons have the
same nominal weight and may be intermixed without affecting engine balance. If necessary, used pistons may be fitted selectively to any
cylinder of the engine, providing the pistons are in good condition and the same weight. Do not cut oversize pistons down or the engine
balance may be affected. Finish hone when selecting the piston.

1. Measure the piston diameter and record the reading. When measuring the piston for size or taper, ensure that the measurement is made as
shown when the piston pin is removed. If the piston worn or damaged, replace the piston with a standard or oversize piston.

2. Measure the cylinder bore, using the J 8087 If the piston is worn beyond specifications, rebore and hone to size.
3. If the cylinder bore needs reconditioning, measure the new piston diameter and hone the cylinder bore to the correct clearance.

4. Measure the J 8087. Record the reading.


5. Subtract the piston diameter from the cylinder bore diameter in order to determine the piston-to-bore clearance.
6. Compare the piston-to-bore clearance using the specifications in order to determine if the clearance is in acceptable range.
7. If a used piston is not acceptable, inspect the service piston sizes and determine if a new piston may be selected. Service pistons are available
in standard, and 0.5 mm (0.012 inch) oversize.
8. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston was fitted.
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39. Piston and Connecting Rod Assemble


^ Tools Required
- J 24086-C Piston Pin Remover/installer

1. Select the fork insert J 24086-310. Install the fork upside down into the press.
2. Place the piston and connecting rod into the J 24086-C. Ensure that the connecting rod is above the fork when installing the piston and the
connecting rod into the press.
3. Select the pin guide J 24086-6A gold. Insert the pin guide in the piston and the connecting rod from the bottom.
4. Set the installer J 24086-9 to E-9.

Important: Ensure that the marks on the piston and connecting rod are aligned the same as when removed. If installing a new piston, ensure
that the arrow on top faces towards the front of the engine. If no identification marks were made during disassembly, ensure that the flat area
on the bottom of the piston pin skirt is aligned with the small dimple above the connecting rod crankshaft bearing bore.

5. Coat the piston pin using clean engine oil.


6. Press the piston pin into place.
7. Inspect the piston for freedom of movement.

Notice: Use a piston ring expander to install the piston rings. The rings may be damaged if expanded more than necessary.

8. Install the following components of the oil control ring assembly:


^ The expander
^ The lower oil control ring
^ The upper oil control ring
9. Install the upper and lower compression rings.
^ The chrome ring is the upper compression ring and is 1.2 mm (0.05 inch) thick.
^ The lower compression ring is chamferred and is 1.5 mm (0.06 inch) thick. The chamfer (the thickest side of the compression ring) faces
towards the bottom of the piston.

40. Camshaft Bearing Removal


^ Tools Required
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- J 33049 Camshaft Bearing Remover/Installer

1. Select the expander assembly and driving washer.


2. Assemble the J 33049.

3. Drive out the camshaft bearings. Use the J 33049.

41. Camshaft and Bearings Clean and Inspect


^ Tools Required
- J 7872 Magnetic Base Dial Indicator Set

1. Clean the camshaft with cleaning solvent.


2. Inspect the camshaft for the following conditions:
^ Scored camshaft bearing journals (1)
^ Damaged camshaft lobes (2)
^ Damaged camshaft sprocket locator pins (3)
^ Damaged threads (4)
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3. Measure the camshaft journals using a micrometer. If the camshaft journals are not within specifications, replace the camshaft.

4. Measure the camshaft runout using the J 7872.


4.1. Mount the camshaft in V-blocks between the centers.
4.2. Use the J 7872 in order to measure the intermediate camshaft journal.
5. Measure the camshaft lobe lift using the J 7872.
5.1. Lubricate the camshaft using GM P/N 1052365 or the equivalent.
5.2. Set the camshaft on V-blocks.
5.3. Use the J 7872 in order to measure the lobe lift.
6. If the runout or lobe lift is not within specifications, replace the camshaft.

42. Camshaft Bearing Installation


^ Tools Required
- J 33049 Camshaft Bearing Remover/installer

1. Assemble the J 33049 according to the manufacturer's instructions.

Notice: Severe engine damage may result if the oil holes are not correctly aligned.
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2. Install the camshaft bearings in the following order:


2.1. Index the camshaft bearing oil holes with the engine block oil passages.
2.2. Place the bearing on the J 33049.
2.3. Install the third camshaft bearing.
2.4. Install the second camshaft bearing.
2.5. Install the outer camshaft bearings.

3. Apply sealer GM P/N 12345493 or the equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.

43. Timing Chain and Sprockets Clean and Inspect

^ Inspect the timing chain sprockets for teeth that are worn (1), broken (2), or chipped (3).
^ Inspect the timing chain for binding or stretching.
^ Inspect the timing chain dampener for excessive wear or cracks.
^ Replace the timing chain and sprockets as needed.

44. Valve Lifters Clean and Inspect


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1. Clean the valve lifters in cleaning solvent.

Caution: Wear safety glasses in order to avoid eye damage.

2. Dry the valve lifters with compressed air.


3. Inspect the valve lifters for the following:
^ Bent or broken clip (1)
^ Worn push rod socket (2)
^ Scuffed or worn sides (3)
If the valve lifter shows wear, inspect the engine block lifter bores for wear or damage.
^ Flat spots on the roller (4)
^ Loose or damaged pin (5)
^ Plugged oil hole (6)
^ Worn or damaged roller bearing
The roller should rotate freely with no binding or roughness.

4. Inspect the valve lifter guides for the following:


^ For cracks or damage
^ Excessive wear in the lifter mounting bores

45. Valve Rocker Arm and Push Rods Clean and Inspect
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1. Clean the valve rocker arms and push rods in cleaning solvent.

Caution: Wear safety glasses in order to avoid eye damage.

2. Dry the valve rocker arms and push rods with compressed air.
3. Inspect the valve rocker arms for the following conditions:
^ Excessive wear at the valve contact or push rod socket area (1)
^ A loose or damaged pin (2)
^ A worn or damaged roller bearing (2)
The roller should rotate freely with no binding or roughness.
^ The bolt threads for damage

Important: Keep the push rods in order. The intake and exhaust are different lengths. Exhaust is green, intake is yellow.

4. Inspect the push rods for the following conditions:


^ Straightness using a straight edge (1)
^ Excessive wear on the push rod ends (3)
^ Clogging of the oil passage (2)

46. Cylinder Head Disassemble


^ Tools Required
- J 38606 Valve Spring Compressor

Important: Ensure that the valve train components are marked, organized or sorted when disassembling the cylinder head. Install the valve
train components in the original location from which the components were removed.
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1. Remove the spark plugs.


2. Remove the fuel line bracket bolt and stud.
3. Remove the fuel line bracket.

Notice: Do not damage the valve guide. Remove any burrs that have formed at the key groove by chamfering the valve stem with an oil
stone or a file.

4. Compress the valve springs using the J 38606.

5. Remove the valve spring cap keys.


6. Remove the valve spring caps.
7. Remove the valve springs.
8. Remove the valves.
9. Remove the valve stem oil seals and spring seats as an assembly.

47. Cylinder Head Clean and Inspect


^ Tools Required
- J 8089 Carbon Removing Brush
- J 9666 Valve Spring Tester
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1. Inspect the cylinder head gasket and the mating surfaces. Inspect for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure:
^ Improper installation
^ A loose or warped cylinder head
^ Missing, off location, or not fully seated dowel pins
^ Low torque on the cylinder head bolts
^ Cylinder head bolts with the incorrect length
^ A warped engine block surface
^ Scratched surfaces
^ Excessive intake manifold torque
^ Cracked engine block threaded holes

Caution: Wear safety glasses in order to avoid eye damage.

Important: Do not scuff the chamber.

3. Use the J 8089 in order to remove the carbon from the combustion chambers.
4. Clean the following components:
^ The gasket surfaces
Do not use a motorized brush on any gasket sealing surface.
^ Valve stems and heads on a buffing wheel
^ The bolt hole threads
Remove all dirt, debris, or threadlocking material from the bolt holes.
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5. Inspect the cylinder head mating surfaces for flatness. Recondition the cylinder head mating surface, if necessary, by milling. Replace the
cylinder head if you must remove more than 0.25 mm (0.010 inch).
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. Do not attempt to weld the cylinder head. If the cylinder head is damaged, replace the cylinder
head.

8. Inspect the valve springs for squareness.

9. Use the J 9666 in order to measure the valve spring tension.


Replace the spring if the spring tension is not within specification.

48. Valve Guide Rearming and Valve and Seat Grinding


^ Tools Required
- J 8520 Camshaft Lobe Lift Indicator Set
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1. Inspect the valves for the following conditions:


^ Burnt or eroded areas (1)
^ A worn margin (2)
^ A bent stem (3)
^ A worn or scored stem (4)
^ A worn key groove (5)
^ A worn stem tip (6)

2. Inspect the valve face for the following conditions:


^ Worn margin (4)
^ No margin (1)
^ Pitted surfaces (2)
^ Burnt or eroded areas (3)
3. Inspect the valve seats for a loose fit in the cylinder head.

Important: Excessive valve stem-to guide clearance may cause the following conditions:
^ A noisy valve train
^ Premature valve stem oil seal wear
^ Component damage
^ Excessive engine oil consumption

Insufficient valve stem-to-guide clearance may result in noisy or sticking valves. Valves that are too tight may disturb engine smoothness or
lead to component damage.
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4. Inspect for excessive valve stem (1) to guide (2) clearance.

5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the following steps:
5.1. Install the valve into the guide.
5.2. Install the J 8520 onto the cylinder head.
5.3. Locate the dial indicator so that the movement of the valve stem from side to side (crosswise to the cylinder head) will cause a direct
movement on the indicator stem.
5.4. Ensure that the indicator stem contacts the side of the valve stem just above the valve guide.
5.5. Drop the valve head about 2 mm (1/8 inch) off the valve seat.
5.6. Use light pressure and move the valve stem side to side in order to obtain a clearance reading.
5.7. If the valve stem to guide clearance is not within specification, replace the valve and/or repair the guide in order to obtain the proper
clearances.

Important: Replace a valve stem that has excessive scoring or wear. A valve guide that is worn and has excessive stem-to-guide clearance
may need to be sleeved.

6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
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Important: Follow the manufacturers instructions when using valve guide reamers, sleeves, and installers.

7. Ream the valve guide in order to obtain the proper specification.

Important: Valves that are pitted must be refaced to the proper angle. Replace valve stems that show excessive wear, or replace valves that
are warped. Several different types of equipment are available for refacing valves and valve seats. Follow the manufacturers
recommendations when performing these procedures.

8. Inspect the valves for excessive scoring.

9. Inspect the valve face.


Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the head and the stem.

Important: Reconditioning the valve seats is very important. Ensure perfect seating of the valves in the engine in order to deliver optimum
power and performance. Clean the valve guides of all debris and dirt before grinding the valve seat.

11. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
12. The valve seats should be concentric to within 0.05 mm (0.031 inch) total indicator reading.
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13. Measure valve stem installed height when the following conditions have occurred:
^ The valve stem oil seal and valve spring seat are removed.
^ All of the reconditioning has been completed.
14. If the valve stem height is not within specifications install 0.25 mm (0.010 inch), rocker arm shims as needed. If more than 2 shims are
needed replace the cylinder head or valve.

49. Cylinder Head Assemble


^ Tools Required
- J 38606 Valve Spring Compressor

Important: Use oversize valve stem seals if you install oversize valves.

1. Install the valves.


2. Lightly lap the reconditioned valves into the valve seat.
3. Install the valve stem oil seals.
4. Install the valve springs.
5. Install the valve spring caps.

6. Compress the valve springs using the J 38606.


7. Install the valve spring cap keys.
Hold the valves in place with grease, if necessary.
8. Release the valve springs.
9. Ensure that the valve locks are seated.

Notice: In order to avoid damage, install the spark plugs after the cylinder head has been installed on the engine.
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10. Install the fuel line bracket.

Notice: Refer to Fastener Notice in Service Precautions.

11. Install the fuel line bracket bolt and stud.


^ Tighten the fuel line bracket bolt and stud to 50 Nm (37 ft. lbs.).

50. Oil Pump Disassemble

1. Remove the oil pump driveshaft and oil pump driveshaft retainer.

Important: DO NOT remove the oil pump screen from the pipe. The pipe and oil pump screen are serviced as a complete assembly.

2. Remove the oil pump screen (if necessary).


The oil pump screen has a press fit into the oil pump cover.
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3. Remove the oil pump cover bolts.

4. Remove the oil pump cover.

5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.

Caution: Wear safety glasses in order to avoid eye damage.

Caution: In some models, the pressure regulator valve spring is under pressure. Remove the retaining pin carefully in order to avoid
bodily injury.
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7. Remove the following items:


7.1. The oil pump pressure relief valve spring straight pin.
7.2. The oil pump pressure relief spring.

Caution: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.

7.3. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in carburetor cleaning solvent.

51. Oil Pump Clean and Inspect


Caution: Bodily injury may occur if the carburetor cleaning fluid is exposed to the skin or if the fumes are inhaled.

1. Clean all parts of sludge, oil, and varnish by soaking in carburetor or cleaning solvent.
2. Inspect for foreign material and determine the source of the foreign material.
3. Inspect the pump housing and cover for the following conditions:
^ Cracks or casting imperfections
^ Scoring (3)
^ Damaged threads
4. Do not attempt to repair the pump housing. Replace the pump housing.
5. Inspect the oil pump gears for the following conditions:
^ Scoring (1)
^ Excessive wear (2)
6. Inspect the idler shaft for looseness or scoring (4). If loose or damaged, replace the oil pump.
7. Inspect the drive gear shaft for looseness or scoring (5).
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8. Inspect the pressure regulator valve for the following conditions:


^ Scoring
^ Sticking
Burrs may be removed using a fine oil stone.
9. Inspect the pressure regulator valve spring for the following conditions:
^ Loss of tension
^ Bending
10. Inspect the suction pipe and screen assembly for the following conditions:
^ Looseness.
If the suction pipe is loose, bent or has been removed, replace the pump body cover and suction pipe.
^ Broken wire mesh or screen

11. Measure the oil pump gear lash. Install the gears, and measure in several places.

12. Measure the oil pump housing gear pocket (1, 2).
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13. Measure the oil pump gears (1, 2).

Important: When deciding pump serviceability based on end clearance, consider depth of the wear pattern in the pump cover.

14. Measure the oil pump gear side clearance.

52. Oil Pump Assemble


^ Tools Required
- J 21882 Oil Suction Tube Installer

1. Lubricate all the internal oil pump parts using engine oil during assembly.
2. Install the oil pump gears.
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3. Install the oil pump cover.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the oil pump cover bolts.


^ Tighten the oil pump cover bolts to 10 Nm (89 inch lbs.).

5. Install the pressure regulator valve.


6. Install the pressure regulator spring.
7. Install the cotter pin.

Important: Make sure the cotter pin is properly secured.

8. Apply sealer GM P/N 1050026 or the equivalent to the new suction pipe.
9. Tap the new suction pipe into place using a plastic hammer. Use the J 21882.

53. Engine Front Cover Clean and Inspect

1. Remove the crankshaft position sensor bolts from the engine front cover.
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2. Remove the crankshaft position sensor.

3. Clean the engine front cover with cleaning solvent.


4. Inspect the engine front cover sealing surfaces for damage.
5. Inspect the engine front cover threaded holes.
6. Repair or replace the engine front cover as necessary.

7. Install the crankshaft position sensor to the engine front cover.

Notice: Refer to Fastener Notice in Service Precautions.

8. Install the crankshaft position sensor bolts. Apply threadlock GM P/N 12345382 or the equivalent to the threads.
^ Tighten the crankshaft position sensor bolts to 10 Nm (89 inch lbs.).
54. Valve Rocker Arm Cover Clean and Inspect

1. Remove the rubber grommets.


2. Clean the valve rocker arm cover.
3. Inspect the valve rocker arm cover for damage. Replace the valve rocker arm cover if necessary.
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55. Oil Pan Clean and Inspect

1. Remove the oil level sensor bolt.


2. Remove the oil level sensor.
3. Clean the oil pan in solvent. Remove all sludge and debris from the bottom of the oil pan.
4. Inspect the oil pan sealing surfaces for damage. Replace the oil pan if necessary.
5. Install the oil level sensor.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the oil level sensor bolt.


^ Tighten the oil level sensor bolt to 10 Nm (89 inch lbs.).

Upper Intake Manifold

1. Remove the accelerator control cable bracket bolts (1, 2) and the nut (3).
2. Remove the accelerator control cable bracket.
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3. Remove the throttle body bolt and stud.


4. Remove the throttle body.
5. Remove the throttle body gasket.

6. Clean the intake manifold gasket surfaces.


7. Clean the intake manifold bolts and studs.
8. Inspect the intake manifold mating surfaces for nicks or cracks. Replace the intake manifold if damaged.

9. Install the throttle body gasket.


10. Install the throttle body.

Notice: Refer to Fastener Notice in Service Precautions.

11. Install the throttle body bolt and stud.


^ Tighten the throttle body bolt and stud to 25 Nm (18 ft. lbs.).

12. Install the accelerator control cable bracket.


13. Install the accelerator control cable bracket bolts and nut.
^ Tighten the accelerator control cable bracket bolts in sequence (1, 2, 3) to 10 Nm (89 inch lbs.).
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Lower Intake Manifold


^ Tools Required
- J 21882 Oil Suction Pipe Installer

1. Remove the engine coolant temperature sensor.

2. Remove the intake manifold coolant pipe bolt.


3. Remove the intake manifold coolant pipe.

4. Clean the intake manifold gasket mating surfaces.


5. Clean the fuel injector bores.
6. Inspect the threaded holes for damage.
7. Inspect the intake manifold mating surfaces for damage. Repair or replace the intake manifold as necessary.
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8. Apply sealant GM P/N 12345493 to the end of a new intake manifold coolant pipe.
9. Install the intake manifold coolant pipe using the J 21882.

Notice: Refer to Fastener Notice in Service Precautions.

10. Install the intake manifold coolant pipe bolt.


^ Tighten the intake manifold coolant pipe bolt to 10 Nm (89 inch lbs.).

11. Apply sealant GM P/N 12346004 or equivalent to the threads of the engine coolant temperature sensor.
12. Install the engine coolant temperature sensor.
^ Tighten the engine coolant temperature sensor to 23 Nm (17 ft. lbs.).

57. Exhaust Manifold Clean and Inspect

1. Inspect the exhaust manifold mating surface for flatness.


2. Inspect the exhaust manifold for cracks or damage. Replace the exhaust manifold if necessary.

58. Water Pump Clean and Inspect


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1. Remove all gasket material from the sealing surface.


2. Inspect the water pump impeller for damage.
3. Inspect the water pump shaft for looseness.
4. Replace the water pump if necessary.

59. Thread Repair


General purpose thread repair kits are available commercially.

Caution: Refer to Safety Glasses Caution in Service Precautions.

Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and which tap to use. Always avoid any
buildup of chips. Back out the tap every few turns and remove the chips.

1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
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8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel.

Important: The thread insert should be flush to 1 turn below the surface.

9. Lubricate the thread insert with clean engine oil (except when installing in aluminum) and install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.

60. Service Prior to Assembly


Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when
inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are
reinstalled into an engine, return the components to their original location, position, and direction. During assembly, lubricate all of the moving
parts with clean engine oil or engine assembly lubricant (unless otherwise specified). This will provide initial lubrication when the engine is first
started.

61. Crankshaft and Bearings Installation


^ Tools Required
- J 36660-A Torque Angle Meter

Notice: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare fingers, the skin oil and acids will
etch the bearing surface.

Important: Ensure that the crankshaft bearing cap bolt holes and the crankshaft bearing cap mating surfaces are clean and dry.

1. Dip the crankshaft bearing cap bolts in clean engine oil.

Notice: Upper and lower inserts may be different. Do not obstruct any oil passages.

2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.

Important: The crankshaft bearing inserts will project slightly when put into place. Ensure that the bearing inserts project an equal distance
on both sides. Ensure that the insert tangs are engaged.

3. Coat the crankshaft main thrust bearing surface with GM EOS P/N 1052368 or the equivalent.
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4. Lubricate the crankshaft main bearing surface with clean engine oil.
5. Install the crankshaft.

Notice: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into
the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the
crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.

6. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 to the rear of the #4 crankshaft main bearing cap
sealing surface.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the crankshaft main bearing cap bolts.


Use the J 36660-A in order to tighten the crankshaft main bearing cap bolts to 50 Nm (37 ft. lbs.) plus 77 degrees.
8. Measure the crankshaft end play.

62. Crankshaft Rear Oil Seal Installation


^ Tools Required
- J 34686 Crankshaft Rear Oil Seal Installer

1. Apply engine oil to the inside diameter and the outside diameter of the new crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel until the back of the crankshaft rear oil seal bottoms squarely against the collar of the tool.
3. Perform the following steps in order to install the crankshaft rear oil seal:
3.1. Align the dowel pin of the J 34686 with the dowel pin in the crankshaft.

Notice: Refer to Fastener Notice in Service Precautions.

3.2. Attach the J 34686 to the crankshaft by hand, or tighten attaching screws to 5 Nm (45 inch lbs.).
3.3. Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal into the bore.
Turn the handle until the collar is tight against the case. Ensure that the seal is seated properly.
3.4. Loosen the T-handle until the T-handle comes to a stop.
3.5. Remove the attaching screws.

63. Piston, Connecting Rod, and Bearing Installation


^ Tools Required
- J 5239 Connecting Rod Guide
- J 8037 Piston Ring Compressor
- J 36660-A Torque Angle Meter

Important: The piston and cylinder bore have been measured and the bore has been sized for the proper clearance. Install the piston and
connecting rod assembly into the proper cylinder bore. The piston alignment mark MUST face the front of the engine block.
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1. Lightly lubricate the following components with clean engine oil:


^ The piston
^ The piston rings
^ The cylinder bore
^ The bearing surfaces
2. Stagger the oil control ring end gaps a minimum of 90 degrees.
3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 inch).
4. Install the J 8037 onto the piston and compress the piston rings.

Important: The piston alignment mark MUST be facing the front of the engine block.

5. Install the J 5239 on the connecting rod bolts.

6. Install the piston and connecting rod assembly into the proper cylinder bore.
7. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of
the piston rings enter the cylinder bore.
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8. Guide the connecting rod end onto the crankshaft journal.

Notice: Refer to Fastener Notice in Service Precautions.

9. Install the bearing, cap, and nuts.


9.1. Tighten the connecting rod bearing cap nuts a first pass to 20 Nm (15 ft. lbs.).
9.2. Tighten the connecting rod bearing cap nuts a second pass to 75 degrees using the J 36660-A.

10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to
make sure that the rods have side clearance.
11. Measure the connecting rod side clearance using a feeler gauge or dial indicator. Connecting rod side clearance should be within 0.18 - 0.44
mm (0.007 - 0.017 inch).

64. Camshaft Installation

1. Coat the camshaft journals with clean engine oil.


2. Coat the camshaft lobes with prelube GM P/N 1052365 or the equivalent.
3. Install the camshaft using the following procedure:
3.1. Install a large screwdriver into the camshaft bolt hole for support. Do not damage the threads.
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3.2. Rotate the camshaft while installing the camshaft into the camshaft bearings.

4. Install the camshaft thrust plate.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the camshaft thrust plate screws.


^ Tighten the camshaft thrust plate screws to 10 Nm (89 inch lbs.).

65. Timing Chain and Sprockets Installation


^ Tools Required
- J 38612 Crankshaft Sprocket Installer

1. Install the crankshaft sprocket using the J 38612.


2. Apply prelube GM P/N 1052365 or the equivalent to the crankshaft sprocket thrust surface.

3. Install the timing chain dampener.


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Notice: Refer to Fastener Notice in Service Precautions.

4. Install the timing chain dampener bolts.


^ Tighten the timing chain dampener bolt to 21 Nm (15 ft. lbs.).

5. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
7. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain dampener (3).

8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
9. Draw the camshaft sprocket onto the camshaft using the mounting bolt.
10. Coat the crankshaft and camshaft sprocket with engine oil.
^ Tighten the bolt to 140 Nm (103 ft. lbs.).
66. Engine Front Cover Installation

1. Install the engine front cover gasket.


2. Apply sealer GM P/N 12346004 or the equivalent to both sides of the lower tabs of the engine front cover gasket.
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3. Install the engine front cover.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the engine front cover bolts (3).


^ Tighten the bolts (3) to 55 Nm (41 ft. lbs.).
5. Install the engine front cover bolt (1).
^ Tighten the bolt (1) to 47 Nm (35 ft. lbs.).
6. Install the engine front cover bolts (2).
^ Tighten the bolts (2) to 21 Nm (115 ft. lbs.).
67. Crankshaft Front Oil Seal Installation
^ Tools Required
- J 35468 Crankshaft Front Oil Seal Installer

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool.

68. Oil Pump Drive Installation


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1. Apply prelube GM P/N 1052365 or the equivalent to the oil pump drive gear.
2. Apply engine oil to the oil pump drive gear assembly for ease of assembly.
3. Install the oil pump drive gear assembly.
4. Install the oil pump drive gear clamp.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the oil pump drive gear clamp bolt.


^ Tighten the oil pump drive gear clamp bolt to 36 Nm (27 ft. lbs.).

69. Oil Pump Installation

1. Install the crankshaft oil deflector.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the crankshaft oil deflector nuts.


^ Tighten the crankshaft oil deflector nuts to 25 Nm (18 ft. lbs.).

Important: Do not reuse the oil pump driveshaft retainer. During assembly, install a NEW oil pump driveshaft retainer.
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3. Install the oil pump.


4. Position the oil pump onto the pins.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap.
^ Tighten the oil pump bolt to 41 Nm (30 ft. lbs.).

70. Oil Pan Installation

1. Apply sealer GM P/N 1234579 or the equivalent to both sides of the crankshaft rear main bearing cap (1). Press sealer into gap using a putty
knife.

2. Install the oil pan gasket.


3. Install the oil pan.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the oil pan bolts.


^ Tighten the oil pan bolts to 25 Nm (18 ft. lbs.).
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5. Install the oil pan side bolts.
^ Tighten the oil pan side bolts to 50 Nm (37 ft. lbs.).

71. Cylinder Head Installation - Left and Right


This article has been updated with TSB 02-06-01-003B, 4/15/08
This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT TO BE RE-USED. Please discard Corporate
Bulletin Number 02-06-01-003A.

^ Tools Required
- J 36660-A Torque Angle Meter

1. Install the dowel pins (cylinder head locator) (if necessary).


2. Inspect the dowel pins (cylinder head locator) for proper installation.
3. Install the cylinder head gasket.

4. Install the cylinder head.

Notice: Refer to Fastener Notice in Service Precautions.

Notice: This component uses torque-to-yield bolts. When servicing this component, do not re-use the bolts. New torque-to-yield bolts must
be installed. Re-using used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield
bolts may lead to engine damage.

5. Install the NEW cylinder head bolts.


- Tighten the NEW cylinder head bolts to 60 Nm (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotate the
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cylinder head bolts an additional 95 degrees.
72. Water Pump Installation

1. Install the water pump gasket.


2. Install the water pump.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the water pump bolts.


^ Tighten the water pump bolts to 10 Nm (89 inch lbs.).

4. Install the water pump pulley.


5. Install the water pump pulley bolts.
^ Tighten the water pump pulley bolts to 25 Nm (18 ft. lbs.).

73. Valve Lifter Installation

1. Coat the valve lifters using prelube GM P/N 1052365 or the equivalent.
2. Install the valve lifters in their original locations.
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3. Apply threadlock GM P/N 12345382 or the equivalent to the threads.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the valve lifter guides and guide bolts.


^ Tighten the valve lifter guide bolts to 10 Nm (89 inch lbs.).

74. Valve Rocker Arm and Push Rod Installation


^ Tools Required
- J 36660-A Torque Angle Meter

1. Install the lower intake manifold gaskets.

2. Coat the ends of the push rods using prelube GM P/N 1052365 or the equivalent.

Important: The intake valve push rods measure 144 mm (5.75 inch) in length, (yellow).

3. Install the push rods in their original location. The exhaust valve push rods measure 152.5 mm (6.0 inch) in length, (green).
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4. Coat the rocker arm friction surfaces using prelube GM P/N 1052365 or the equivalent.

Important: Shims may be required under the valve rocker arm pedestals if reconditioning has been performed on the cylinder head or its
components. Refer to Cylinder Head Clean and Inspect.

5. Install the valve rocker arms in their original positions.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the valve rocker arm bolts.


Use the J 36660-A to tighten the valve rocker arm bolts to 19 Nm (14 ft. lbs.) plus 30 degrees.

Left Exhaust Manifold

1. Install the exhaust manifold gasket.


2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust manifold nuts.


^ Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).
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4. Install the exhaust manifold heat shield.


5. Install the exhaust manifold heat shield bolts.
^ Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).

Right Exhaust Manifold

1. Install the exhaust manifold gasket.


2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust manifold nuts.


^ Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).
4. Install the right side spark plugs.
^ Tighten the spark plugs to 27 Nm (20 ft. lbs.).

5. Install the exhaust manifold lower heat shield.


6. Install the exhaust manifold upper heat shield.
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7. Install the exhaust manifold heat shield bolts.
^ Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).

8. Coat the threads of the heated oxygen sensor with anti-seize compound GM P/N 5613695, or the equivalent.
9. Install the heated oxygen sensor.
^ Tighten the heated oxygen sensor to 42 Nm (31 ft. lbs.).

76. Exhaust Crossover Installation

1. Install the exhaust crossover pipe.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the exhaust crossover pipe nuts.


^ Tighten the exhaust crossover pipe nuts to 25 Nm (18 ft. lbs.).

3. Install the exhaust crossover pipe heat shield.


4. Install the exhaust crossover pipe heat shield bolts.
^ Tighten the exhaust crossover pipe heat shield bolts to 10 Nm (89 inch lbs.).
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Lower Intake Manifold

1. Apply sealer GM P/N 12345739 or the equivalent at the engine block-to-lower intake manifold mating surface. Ensure that the bead meets
the following conditions:
^ 2.0-3.0 mm (0.08-0.12 inch) wide
^ 3.0-5.0 mm (0.12-0.20 inch) thick
2. Install the lower intake manifold.

Notice: Failure to tighten vertical bolts before the diagonal bolts may cause an oil leak.

3. Apply sealer GM P/N 12345382 or the equivalent to the lower intake manifold bolt threads.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the lower intake manifold bolts.


^ Tighten the lower intake manifold bolts in sequence to 13 Nm (115 inch lbs.).

5. Install the heater inlet pipe.


6. Install the heater inlet pipe nut.
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^ Tighten the heater inlet pipe nut to 25 Nm (18 ft. lbs.).

Important: Do not press on the fuel pressure regulator valve when installing the fuel injector rail assembly.

7. Install the fuel injector rail assembly.


7.1. Lubricate the fuel injector O-rings using GM P/N 1051885 or the equivalent.
7.2. Install the injector nozzles into the lower intake manifold injector bores.
7.3. Press on the injector rail using the palms of both hands until the injectors are fully seated.
8. Install the fuel injector rail bolts.
^ Tighten the fuel injector rail bolts to 10 Nm (89 inch lbs.).

9. Install the fuel feed and return pipe retaining clip.


10. Install the fuel feed and return pipe retaining clip bolt.
^ Tighten the fuel feed and return pipe retaining clip bolt to 8 Nm (71 inch lbs.).

Upper Intake Manifold


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1. Install the upper intake manifold gaskets.


2. Apply threadlock GM P/N 12345382 or equivalent to the threads of the intake manifold bolts.
3. Install the upper intake manifold.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the upper intake manifold bolts and studs.


^ Tighten the upper intake manifold bolts and studs to 25 Nm (118 ft. lbs.).

5. Install the spark plug wires.


6. Install the EGR valve pipe and gasket.
^ Tighten the EGR valve pipe to 25 Nm (18 ft. lbs.).
7. Install the EGR valve and gasket.
8. Install the EGR valve bolts.
^ Tighten the EGR valve bolts to 25 Nm (18 ft. lbs.).

9. Install the MAP sensor.


10. Install the MAP sensor bolts.
^ Tighten the MAP sensor bolts to 5 Nm (44 inch lbs.).
11. Connect the MAP sensor electrical connector.

Left Valve Rocker Arm Cover


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1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12345739 or the equivalent to the notches where the cylinder head and intake manifold meet.
3. Install the valve rocker arm cover.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the valve rocker arm cover bolts.


^ Tighten the valve rocker arm cover bolts to 10 Nm (89 inch lbs.).

5. Install the electronic ignition control module.


6. Install the electronic ignition control module nuts and bolts.
^ Tighten the electronic ignition control module nuts and bolts to 25 Nm (18 ft. lbs.).
7. Install the spark plug wires.

Right Valve Rocker Arm Cover

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12345739 or the equivalent to the notches where the cylinder head and intake manifold meet.
3. Install the valve rocker arm cover.

Notice: Refer to Fastener Notice in Service Precautions.


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4. Install the valve rocker arm cover bolts.


^ Tighten the valve rocker arm cover bolts to 10 Nm (89 inch lbs.).

5. Install the vacuum lines to the upper intake manifold.

79. Water Outlet Installation

1. Install the Thermostat.

2. Install the water outlet gasket.


3. Install the water outlet.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the water outlet bolts.


^ Tighten the water outlet bolts to 25 Nm (18 ft. lbs.).

80. Oil Filter Adapter Installation


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1. Install the oil filter bypass valve.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the oil filter fitting, if necessary.


^ Tighten the oil filter fitting to 39 Nm (29 ft. lbs.).
3. Install the oil filter bypass valve plug. Apply sealer GM P/N 12345739 or the equivalent to the threads.
^ Tighten the oil filter bypass valve plug to 19 Nm (14 ft. lbs.).

4. Install the oil filter.


^ Tighten the oil filter to 13 Nm (115 inch lbs.).
81. Oil Level Indicator and Tube Installation

1. Apply sealer GM P/N 12345739 or the equivalent to the area of the oil level indicator tube that goes into the engine block.
2. Install the oil level indicator and oil level indicator tube.
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3. Install the thermostat bypass pipe.


4. Install the thermostat bypass pipe hose.
5. Install the thermostat bypass pipe hose clamps.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the thermostat bypass pipe to engine front cover bolt (4).
^ Tighten the thermostat bypass pipe to engine front cover bolt to 11 Nm (98 inch lbs.).
7. Install the thermostat bypass pipe to cylinder head nut (3).
^ Tighten the thermostat bypass pipe to cylinder head nut to 25 Nm (18 ft. lbs.).

8. Install the thermostat bypass pipe to throttle body hose clamps.


9. Install the thermostat bypass pipe to throttle body nut.
^ Tighten the thermostat bypass pipe to throttle body nut to 25 Nm (18 ft. lbs.).
82. Generator and Engine Lift Front Bracket Installation
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1. Install the front engine lift hook.


2. Install the generator bracket.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the generator bracket bolts.


^ Tighten the generator bracket bolts in sequence (1, 2, 3) to 50 Nm (37 ft. lbs.).

83. Engine Mount Strut and Engine Lift Bracket Installation

1. Install the engine mount strut and lift bracket.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the engine mount strut and lift bracket bolts.


^ Tighten the engine mount strut and lift bracket bolts to 70 Nm (52 ft. lbs.).

84. Engine Mount Strut and A/C Compressor Bracket Installation


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1. Install the engine mount strut and A/C Compressor bracket.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the engine mount strut and A/C Compressor bracket bolts.
^ Tighten the engine mount strut and lift bracket bolts to 50 Nm (37 ft. lbs.).

85. Drive Belt Tensioner Installation

1. Install the drive belt tensioner.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the drive belt tensioner bolt.


^ Tighten the drive belt tensioner bolt to 50 Nm (37 ft. lbs.).

86. Engine Flywheel Installation


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1. Install the flywheel.


2. Install the flywheel retainer.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the flywheel bolts.


^ Tighten the flywheel bolts to 71 Nm (52 ft. lbs.).

87. Crankshaft Balancer Installation

^ Tools Required
- J 29113 Crankshaft Balancer Installer

1. Apply sealer GM P/N 12345739 or the equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft.
4. Pull the crankshaft balancer into position.
5. Remove the J 29113 from the crankshaft balancer.

Notice: Refer to Fastener Notice in Service Precautions.


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6. Install the crankshaft balancer washer and bolt.


^ Tighten the crankshaft balancer bolt to 103 Nm (76 ft. lbs.).
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Compression Check: Testing and Inspection
A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket.

Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block.

1. Disable the ignition.


2. Disable the fuel systems.
3. Remove the spark plugs from all the cylinders.
4. Remove the air duct from the throttle body.
5. Block the throttle plate in the open position.
6. Measure the engine compression, using the following procedure:
6.1. Firmly install the compression gauge to the spark plug hole.
6.2. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder.
6.3. Record the readings on the gauge at each stroke.
6.4. Disconnect the gauge.
6.5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
^ The lowest reading should not be less than 70 percent of the highest reading.
^ No cylinder reading should be less than 689 kPa (100 psi).
8. The following list is examples of the possible measurements:
^ When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each
cylinder.
^ When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal
compression, the piston rings may be the cause.
^ If the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause.
^ When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause.
^ The addition of oil does not affect the compression, the valves may be the cause.
^ When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body.
11. Install the spark plugs.
12. Install the Powertrain Control Module (PCM) fuse.
13. Install the ignition fuse to the I/P fuse block.
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Crankshaft Balancer: Description and Operation

The 24X crankshaft position (CKP) sensor (1), secured in a mounting bracket (3) and bolted to the front side of the engine timing chain cover (2),
is partially behind the crankshaft balancer.

The 7X CKP sensor uses a two wire connector at the sensor and a three-way connector at the ignition control module.

The 24X CKP sensor contains a Hall-effect switch. The magnet and Hall-effect switch are separated by an air gap. A Hall-effect switch reacts like a
solid stale switch, grounding a low current signal voltage when a magnetic field is present. When the magnetic field is shielded from the switch by
a piece of steel placed in the air gap between the magnet and the switch, the signal voltage is not grounded. If the piece of steel (called an
interrupter) is repeatedly moved in and out of the air gap, the signal voltage will appear to go on-off, on-off, on-off. Compared to a conventional
mechanical distributor, this on-off signal is similar to the signal that a set of breaker points in the distributor would generate as the distributor shaft
turned and the points opened and closed.

In the case of the electronic ignition system, the piece of steel is a concentric interrupter ring mounted to the rear of the crankshaft balancer. The
interrupter ring has blades and windows that, with crankshaft rotation, either block the magnetic field or allow the field to reach the Hall-effect
switch. The Hall-effect switch is called a 24X CKP sensor, because the interrupter ring has 24 evenly spaced blades and windows. The 24X CKP
sensor produces 24 on-off pulses per crankshaft revolution.

The interrupter ring is a special wheel cast on the crankshaft that has seven machined slots, six of which are equally spaced 60 degrees apart. The
seventh slot is spaced 10 degrees from one of the other slots. As the interrupter ring rotates with the crankshaft, the slots change the magnetic field.
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This will cause the 7X to ground the 3X signal voltage that is supplied by the ignition control module. The ignition control module interprets the
7X on-off signals as an indication of crankshaft position. The ignition control module must have the 7X signal to fire the correct ignition coil.

The 7X interrupter ring and Hall-effect switch react similarly. The 24X signal is used for better resolution at a calibrated RPM.
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Drive Belt: Testing and Inspection

- Symptoms - Drive Belt


Important: Review the system operation in order to familiarize yourself with the system functions. Refer to Drive Belt System Description.

Visual/Physical Inspection
^ Inspect for aftermarket devices which could affect the operation of the drive belts.
^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
^ Inspect the drive belt for excessive wear, shredding, or missing sections.
^ Inspect the drive belt for contamination of excessive dirt, oil, coolant or other substances that may affect the drive belt operation.

Intermittent
^ Drive belt symptoms may be from intermittent failure of an accessory drive component.
^ Drive belt symptoms may occur from changes in load of the accessory drive components.
^ Ambient temperatures, moisture, or engine operating temperature can affect the drive belt operation.

Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:

^ Drive Belt Chirping Diagnosis


See: Drive Belt Chirping

^ Drive Belt Squeal Diagnosis


See: Drive Belt Squeal

^ Drive Belt Whine Diagnosis


See: Drive Belt Whine

^ Drive Belt Rumbling Diagnosis


See: Drive Belt Rumbling

^ Drive Belt Vibration Diagnosis


See: Drive Belt Vibration

^ Drive Belt Falls Off Diagnosis


See: Drive Belt Falls Off

^ Drive Belt Excessive Wear Diagnosis


See: Drive Belt Excessive Wear

Drive Belt Chirping


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Diagnostic Aids
The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be necessary to spray a small amount of water on the
drive belt(s) in order to duplicate the customers concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys
may be the probable solution.
A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not
proceed further with this table.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related
to the drive belt. When removing the drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs may set
when the engine is operating with the drive belt removed.
4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the drive belt grooves from the accumulation
of rubber dust.
6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory
drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the
pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation
procedure for that pulley.
10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt
from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the
pulley.
14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.

Drive Belt Excessive Wear


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Diagnostic Aids
Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive belt for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt(s) to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt(s) fall off.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt pulleys. Wear on the drive belt(s) may be caused by
mis-positioning the drive belt(s) by one groove on a pulley.
3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the
grooves on all of the pulleys.
4. This inspection is to verify the drive belt(s) is not contacting any parts of the engine or body while the engine is operating. There should be
sufficient clearance when the drive belt accessory drive components load varies. The drive belt(s) should not come in contact with an engine
or a body component when snapping the throttle.

Drive Belt Falls Off


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Diagnostic Aids
If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on
released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate
properly.
If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive
belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt
plys.
4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory
drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the
pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation
procedure of that pulley.
5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt
from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the
pulley.
6. Accessory drive component brackets that are bent or cracked may will let the drive belt fall off.
7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing, loose, or the wrong
fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of
the accessory component bracket.

Drive Belt Rumbling


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Diagnostic Aids
Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise.
The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom.
If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when the drive belt(s) is installed, there might be an
accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component
is causing the rumbling noise.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
3. This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to
the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the
water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt
removed.
4. Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise.
Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt.
5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for
proper operation.

Drive Belt Squeal


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Diagnostic Aids
A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the
noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An
overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not
proceed further with this table
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is
the drive belt(s) or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may
overheat. Also DTCs may set when the engine is operating with the drive belt removed.
4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the
accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on
the components to verify that the components operate properly.
5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension
May not be achieved to keep the drive belt from slipping which could cause a squeal noise.
6. This test is to verify that the drive belt(s) is not too long, which would prevent the drive belt tensioner from working properly. Also if an
incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong
direction.
7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory
drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the
pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation
procedure for that pulley.
8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.

Drive Belt Vibration


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Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power
steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary
the loads on the accessory drive components.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the
exhaust system, or the drivetrain.
3. This test is to verify that the drive belt(s) or accessory drive components may be causing the vibration. When removing the drive belt the
water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt
removed.
4. The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best time to inspect the condition of the belt.
6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
8. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect
the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump.
9. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.

Drive Belt Whine


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Diagnostic Aids
The drive belt(s) will not cause the whine noise.
If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum
capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the
generator failing.

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
3. This test is to verify that the noise is being caused by the drive belt(s) or the accessory drive components. When removing the drive belt the
water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt
removed.
4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt(s) may have to be
installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component
for the proper inspection and replacement procedure.
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Drive Belt Tensioner: Testing and Inspection
1. Inspect the drive belt tensioner pulley. Ensure that the drive belt tensioner pulley is vertically aligned with the other accessory drive pulleys.
If the drive belt tensioner pulley is NOT vertically aligned with the other accessory drive pulleys, replace the drive belt tensioner. Refer to
Drive Belt Replacement.
2. Ensure that the drive belt tensioner moves freely. Insert a breaker bar or ratchet into the tensioner in order to rotate the tensioner
counterclockwise, then slowly lower the drive belt tensioner pulley to the drive belt. If the drive belt tensioner binds or does not move freely,
replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
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Engine Lubrication: Description and Operation

Front View
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Rear View
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Right View

Full pressure lubrication, through a full flow oil filter, is furnished by a gear type oil pump. The oil is drawn up through the pickup screen and the
tube. The oil passes through the pump to the oil filter.

The oil filter is a full flow paper element unit. An oil filter bypass is used in order to ensure oil supply during the following conditions:
^ On a cold start
^ If the filter is plugged
^ If the filter develops excessive pressure drop

The bypass is designed to open at 69 - 83 kPa (10 - 12 psi).

A new priority oil delivery system supplies oil first to the crankshaft journals. The oil from the crankshaft main bearings is supplied to the
connecting rod bearings by intersecting the passages drilled in the crankshaft. The passages supply the oil to the crankshaft main bearings and the
camshaft bearings through the intersecting vertical drilled holes. The oil passages from the camshaft journals supply oil to the hydraulic lifters.

The hydraulic lifters pump oil up through the pushrods to the rocker arms. The cast dams in the crankcase casting direct the oil that drains back
from the rocker arms in order to supply the camshaft lobes. The camshaft chain drive is lubricated by indirect oil splash.
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Engine Oil Pressure: Testing and Inspection
Low or No Oil Pressure
The following conditions may cause low or no oil pressure:
^ Low oil level
Fill to the full mark on the oil level indicator.
^ Incorrect or malfunctioning oil pressure switch
Replace the oil pressure switch.
^ Incorrect or malfunctioning oil pressure gauge
Replace the oil pressure gauge.
^ Improper oil viscosity or diluted oil
- Install oil of proper viscosity for expected temperature.
- Install new oil if the oil is diluted.
^ A worn or dirty oil pump
Clean or replace the oil pump.
^ A plugged oil filter
Replace the oil filter.
^ A loose or plugged oil pickup screen
Replace the oil pickup screen.
^ A hole in the oil pickup tube
Replace the oil pickup tube.
^ Excessive bearing clearance
Replace the bearings.
^ Cracked, porous, or plugged oil gallery
Repair or replace the engine block.
^ Missing or improperly installed gallery plugs
Install or repair the plugs as needed.
^ A stuck pressure regulator valve
- Inspect the pressure regulator valve for sticking in the bore.
- Inspect the bore for scoring and burrs.
^ A worn or poorly machined camshaft
Replace the camshaft.
^ Worn valve guides
Repair the valve guides as needed.

Oil Pressure Testing

^ Tools Required
- J 25087-C Oil Pressure Test Kit

If the vehicle has low oil pressure complete the following steps:
1. Inspect the oil level.
2. Raise and support the vehicle. Refer to Vehicle Lifting.
3. Remove the oil filter.
4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of the J 25087-C base. Connect the
gauge to the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve.
6. Install the J 25087-C on the filter mounting pad.
7. Start the engine.
8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before
inspecting the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil.
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating
system, An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading
while pressing the valve indicates a faulty pump.
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Oil Level Warning Indicator: Description and Operation

The PCM monitors the engine oil level switch signal at start-up to determine if the engine oil is OK. If the PCM determines that a low oil level
condition exists, the PCM will communicate the information over the Class II circuit to the IPC and it will illuminate the indicator lamp.
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Oil Pressure Sensor: Description and Operation

The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is Ok. If the PCM determines that a low oil
pressure condition exists, the PCM will communicate the information over the Class II circuit to the IPC and it will illuminate the indicator lamp.
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Crankshaft Main Bearing Seal: Service and Repair
Removal Procedure

1. Remove the transaxle. Refer to Transmission Replacement in Transmission and Drivetrain.


2. Remove the engine flywheel. Refer to Engine Flywheel Removal.
3. Remove the crankshaft rear oil seal.

Important: Do not damage the crankshaft or seal bore.

4. Pry out the crankshaft rear oil seal out using a suitable tool.

Installation Procedure

^ Tools Required
- J 34686 Crankshaft Rear Oil Seal Installer

1. Apply engine oil to the inside diameter and the outside diameter of the new crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel until the back of the crankshaft rear oil seal bottoms squarely against the collar of the tool.
3. Perform the following steps in order to install the crankshaft rear oil seal:
3.1. Align the dowel pin of the J 34686 with the dowel pin in the crankshaft.

Notice: Refer to Fastener Notice in Service Precautions.

3.2. Attach the J 34686 to the crankshaft by hand, or tighten attaching screws to 5 Nm (45 inch lbs.).
3.3. Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal into the bore.
Turn the handle until the collar is tight against the case. Ensure that the seal is seated properly.
3.4. Loosen the T-handle until the T-handle comes to a stop.
3.5. Remove the attaching screws.
4. Install the engine flywheel. Refer to Engine Flywheel Installation.
5. Install the transaxle. Refer to Transmission Replacement in Transmission and Drivetrain.
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Front Crankshaft Seal: Service and Repair
Removal Procedure

1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.


2. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.
3. Inspect the crankshaft, the crankshaft balancer and the engine front cover for wear and/or damage. Replace the components as necessary.
Refer to the following procedures:
^ Crankshaft Balancer Clean and Inspect
^ Engine Front Cover Clean and Inspect

Installation Procedure

^ Tools Required
- J 35468 Crankshaft Front Oil Seal Installer

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool.
3. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
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Cooling System: Description and Operation

Air Baffles and Seals Description


A deflector redirects air flow. Deflectors are installed under the vehicle and redirects the air flow beneath the vehicle to flow through the cooling
system and increase radiator cooling.

Air baffles are used to direct air into the radiator and A/C condenser. Air seals ensure that air passes through, and does not bypass, the radiator
and the A/C condenser. A missing, damaged, or incorrectly installed baffle or seal may cause the engine to overheat.
Coolant
Notice: Antifreeze can be added to raise the boiling point of the coolant, but too much will affect the freezing point. Do not use a solution
stronger than 70 percent antifreeze, as the freeze level rises rapidly after this point. Pure antifreeze will freeze at -22°C (-8°F).
This vehicle as a newly developed engine coolant. GM Goodwrench DEX-COOL (R) was developed in order to last for 240,000 km (150,00
miles) or 5 years, whichever occurs first. Follow the instructions in Draining and Filling Cooling System. Use only GM Goodwrench
DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) when adding or changing the coolant.
A 50/50 mixture of ethylene glycol DEX-COOL (R) and water will provide the following protection:
^ Give freezing protection down to -37°C (-34°F)
^ Give boiling protection up to 129°C (265°F)
^ Protect against rust and corrosion
^ Help keep the proper engine temperature
^ Let the warning lights and gauges work as they should.

Coolant Heater Description


The engine heater is used to preheat the engine coolant for cold weather starting. The engine coolant heater operates from a 110-volt AC power
source and uses a heating element installed in the engine blocks water jacket. The heating element warms the coolant when the heater cord is
plugged into an AC power source.
The unit has a detachable electrical cord. If the heater fails to operate, check the cord connections and power supply before replacing the heating
element.

Coolant Level Module Description


Low Coolant Module
The low coolant module activates a light in the instrument cluster when the coolant in the radiator goes below a certain level. The low coolant
module is located in the radiator's right side tank.

Coolant Recovery System Description


Recovery Reservoir
The recovery reservoir is see-through, and is similar to the familiar windshield washer reservoir. The recovery reservoir is connected to the
radiator by a hose. The recovery reservoir collects the coolant that expands with rising temperature and would otherwise overflow from the
system. The coolant level should be at or above the COLD mark on the recovery reservoir cap overflow hose (inside the reservoir).

Cooling System Description


Cooling System
The cooling system maintains engine temperature at an efficient level during all engine operating conditions. When the engine is cold the system
cools slowly, or not at all, to allow the engine to warm up quickly.
The cooling system includes a radiator and coolant recovery subsystem, cooling fans, thermostat and housing, water pump, and drive belt.
Operation of the cooling system requires proper functioning of all components. Coolant is drawn from the radiator by the water pump and
circulated through coolant jackets in the engine block, intake manifold, and cylinder heads, and then directed back to the radiator where it is
cooled.
This system directs some coolant through hoses to the heater core, to provide for heating and defrosting. A recovery reservoir is connected to the
radiator to recover coolant displaced by expansion from high temperatures and maintain correct coolant level. As the coolant cools and contracts
it is drawn back into the radiator by vacuum.

Cooling System Circulation


The water pump is belt-driven. Coolant from the radiator outlet (lower right side of radiator) flows to the water pump inlet and is pumped
through coolant passages in the cylinder block and into the cavities surrounding the cylinder liners. Coolant then flows through holes in the
cylinder head gaskets into the cylinder head coolant passages and into the thermostat bypass system. Passages in the intake manifold direct the
coolant to the thermostat at the rear of the manifold. When the thermostat is closed (cold engine), the coolant is prevented from returning to the
radiator and is recirculated for quick engine warm-up.
Once the engine has warmed sufficiently, the thermostat opens and coolant flows to the inlet tank on the top left side of the radiator. It is cooled
as it flows across the horizontal core tubes to the outlet tanks on the right side of the radiator, completing the cycle.

Cooling Fan Relay


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Temperature Gauge
The temperature gauge replaces the warning lamp. The temperature switch is replaced with a transducer.

Coolant Temperature Fan Switch


The switch regulates voltage to the coolant fan relay, which operates the fan whenever the engine coolant temperature exceeds 110°C (230°F).
General Description

The electric cooling fans are used to lower the temperature of the engine coolant flowing through the radiator. They are also used to cool the
refrigerant (R-134a) flowing through the A/C condenser.
Operation
The electric cooling fan operates when the engine cooling temperature exceeds a certain value. The cooling fan on this engine is controlled by the
Powertrain Control Module (PCM). The PCM turns the cooling fan ON by grounding the coil of the cooling fan relays when certain conditions are
met. When the A/C is requested, the cooling fan will also be turned ON.

Power for the cooling fan motors are supplied through Maxifuses(R). The cooling fan relays are energized when current flows from the fuses in the
Underhood Accessory Wiring Junction Block, and through the relay coils to ground through the PCM. The Coolant Fan 1 Relay Control Circuit is
grounded for low speed fans operation. During low speed fans operation, both fans run at a slow speed. The Coolant Fan 1 Relay Control Circuit is
grounded for high speed operation. During high speed fans operation, both fans run at high speed.

IMPORTANT: When certain Diagnostic Trouble Codes (DTCs) are present, the PCM may command the cooling fans to run all the time. Perform
the A Powertrain On Board Diagnostic (OBD) System Check prior to diagnosing the engine cooling fans.

For more information regarding the Charging System, refer to Charging System Description, and Charging System Circuit Description in
Starting and Charging.

If a problem that involves the low speed cooling fan relay control circuit exists, DTC P0480 Cooling Fan Relay 1 Control Circuit should set. If the
problem affects the high speed cooling fan relay control circuit, DTC P0481 Cooling Fan Relay 2 Control Circuit should set. A problem with the
ECT sensor should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, DTC P0118 Engine Coolant Temperature
(ECT) Sensor Circuit High Voltage, DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, DTC P1115 Engine
Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. Any of these DTCs will affect cooling fan operation and should be
diagnosed before using the Electric Cooling Fan Diagnosis.

For more information regarding the Cooling System refer to Engine Cooling Fan Description - Electric, and Cooling System Description in
Cooling System.
Hot Coolant Temperature Indicator
The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM)
monitors the ECT to determine the engine coolant temperature. As the coolant temperature rises, the resistance of the ECT varies. If the coolant
temperature exceeds an acceptable level, the PCM detects this change and sends a class 2 message to the instrument panel cluster (IPC). The IPC
then illuminates the HOT COOLANT TEMP message.

Hot Coolant Temperature Indicator Circuit


The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) monitors
the ECT to determine the engine coolant temperature. The ECT is grounded by the PCM through circuit 469. As the coolant temperature rises, the
resistance of the ECT varies. If the coolant temperature exceeds an acceptable level, the PCM detects this change at circuit 410 and sends a class 2
message through the serial data line to the instrument panel cluster (IPC). The IPC then illuminates the HOT COOLANT TEMP message.
Low Coolant Level Indicator
The engine coolant level module is located in the radiator's right side tank and monitors the engine coolant level. When the coolant level falls below
an acceptable level, the module acts like a switch and closes. The instrument panel cluster then illuminates the LOW COOLANT LEVEL message.
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Low Coolant Level Indicator Circuit


The engine coolant level module is located in the radiator's right side tank and monitors the engine coolant level. Ground is applied at all times from
G113 to the engine coolant level module through circuit 451. When the coolant level falls below an acceptable level, the module acts like a switch
and closes. Ground is then applied from the module through circuit 68 to the IPC. The instrument panel cluster illuminates the LOW COOLANT
LEVEL message.

Pressure Cap

Radiator Filler Cap

The crossflow radiator uses a pressure-vent filler cap to allow a buildup of 103 kPa (15 psi) in the cooling system. The cap allows the system to
operate at a higher than atmospheric pressure. This pressure raises the boiling point of the coolant to about 129°C (265°F) at sea level, which
increases the cooling efficiency of the radiator.
The pressure-type cap contains a blowoff (pressure) valve (2) and a vacuum (atmospheric) valve (1). A spring of pre-determined strength holds
the pressure valve against the valve's seat. This spring protects the radiator by relieving any pressure that exceeds design limits. A spring holds
the vacuum valve against the valve's seat which permits opening of the valve in order to relieve vacuum created in the system when the system
cools. This prevents radiator collapse.

Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will
release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

Caution: As long as there is pressure in the cooling system, the temperature can be considerably higher than the boiling temperature of
the solution in the radiator without causing the solution to boil. Removal of the pressure cap while the engine is hot and pressure is high
will cause the solution to boil instantaneously - possibly with explosive force - spewing the solution over the engine, fenders and the
person removing the cap.

The radiator cap is designed to discourage unintentional removal. Safely remove the cap in the following way:
1. Slowly rotate the cap counterclockwise, do not press down, to the detent.
2. Allow any residual pressure, indicated by a hissing sound, to be relieved.
3. After the hissing stops, continue to rotate the cap counterclockwise until the cap is removed.
The following is embossed on the cap:
^ A caution regarding opening of the cap
^ Arrows that indicate the proper closed position

Radiator Assembly Description


These engines use a cross-flow, lightweight aluminum and plastic radiator.
^ A brazed aluminum tube and center core.
^ Two plastic end tanks.
^ A transmission oil cooler.
^ An engine oil cooler.
^ A radiator drain plug.

Clinch tabs fasten the end tanks to the core. A high temperature rubber gasket seals each of the end tanks. The right side end tank houses the
transmission oil cooler. The left side end tank houses the engine oil cooler. Rubber gaskets and nuts seal the oil cooler fittings to the end tanks. The
drain cock is plastic and this is at the bottom of the left side end tank.
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Cross-Flow Radiator Core and Outlet and Inlet Tanks


These models have an aluminum, cross-flow design core (1). The core uses a stack of horizontal tubes (2) that resist plugging. The cooling fins
(3) surround these tubes. The top and bottom ribs strengthen the assembly. The saw-cut in each strengthening rib allows for expansion during
temperature changes.
The inlet and the outlet tanks are molded from high-temperature, nylon reinforced plastic. A high-temperature rubber gasket seals the tank flange
around the edge. The inlet and the outlet tanks are clamped to the right side and the left side of the core with clinch tabs. These tabs are part of
the aluminum header at each end of the core. Radiators used with automatic transmissions have transmission oil coolers with inlet and outlet
fittings for transmission fluid circulation.
You can identify an aluminum-plastic radiator by the black plastic side tanks and an aluminum radiator core.

Engine Oil Cooler


The 3100 (L82) engine comes with an optional engine oil cooler which uses engine coolant flowing through an oil cooler at the oil filter.

Radiator Drain Cock


The radiator drain cock is on the bottom, left side of the radiator end tank. The drain cock includes the drain cock and the drain cock seal. Use
the drain cock when you drain the coolant.

Thermostat Description
The thermostat is a coolant flow control component that utilizes a temperature sensitive wax-pellet element.

The lower end of the thermostat, containing the element, is installed in the engine water jacket.

The thermostat performs the following functions:


^ Controls the flow of coolant through the radiator
^ Enables controlled engine warm-up
^ Assists in coolant temperature control

The wax pellet element (4) in the thermostat expands when heated, and contracts when cooled.

The element connects through a piston (1) to a thermostat valve (2).

When the element is heated, pressure is exerted against a rubber diaphragm (3) which forces the thermostat valve to open. As the element is cooled,
the contraction allows a spring (5) to close the thermostat valve.

While the coolant is cold, the thermostat valve remains closed. This prevents circulation of coolant through the radiator. At this point, coolant is
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only allowed to circulate throughout the engine block and heater core in order to allow the engine to warm quickly.

As the engine warms, the element expands and the thermostat valve opens. This permits coolant to flow through the radiator, where the heat
dissipates to the atmosphere.

Throttle Body Coolant System Description


The throttle body cooling system assists in maintaining the proper temperature of the throttle body under various ambient conditions. Engine
coolant flows around the throttle body via passages in the casting. During initial start up, the throttle body cooling system assists in warming the
throttle body. During normal operating temperatures, the throttle body cooling system assists in keeping the throttle body cool.

Transmission Oil Cooler Description


Transaxle Oil Cooler
The transaxle oil cooler is in the right side end tank of the radiator. You can replace the oil cooler by removing the tank from the core. This cools
the transaxle oil that flows through the cooler.

Water Pump Description


The coolant pump is a centrifugal-type pump that consists of the following components:
^ An impeller
^ An impeller driveshaft
^ A pulley flange
^ A cast housing The back side of the drive belt drives the pulley. The pulley attaches to the pump.
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Cooling System: Initial Inspection and Diagnostic Overview

Diagnostic Starting Point


Begin the system diagnosis with the A Diagnostic System Check. The Diagnostic System Check will provide the following information:

^ The identification of the control module(s) which command the system.

^ The ability of the control module(s) to communicate through the serial data circuit.

^ The identification of any stored diagnostic trouble codes (DTCs) and their status. The use of the Diagnostic System Check will identify the
correct procedure for diagnosing the system and where the procedure is located.

Diagnostic System Check

Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial
data circuit. The specified procedure will determine the particular condition.
3. The symptom list in Symptoms will determine the correct diagnostic procedure to use.
4. The presence of DTCs which begin with "U" indicate that loss of Class 2 communications has occurred.
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Cooling System: Symptom Related Diagnostic Procedures

A Symptoms - Engine Cooling


Important: The following steps must be completed before using the symptom tables.

1. Perform the A Diagnostic System Check before using the Symptom Tables in order to verify that all of the following are true:
^ There are no DTCs set.
^ The control module(s) can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to:
^ Hot Coolant Temperature Indicator Operation
^ Hot Coolant Temperature Indicator Circuit Description
^ Low Coolant Level Indicator Operation
^ Low Coolant Level Indicator Circuit Description

Visual/Physical Inspection
^ Inspect for aftermarket devices which could affect the operation of the Cooling System System. Refer to Checking Aftermarket Accessories
in Diagrams/Diagnostic Aids.
^ Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
^ Inspect the cooling system for the proper coolant level.

Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent and Poor Connections in
Diagrams/Diagnostic Aids.

Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
^ HOT COOLANT TEMP Message Always On
See: Hot Coolant Temp Message Always On

^ HOT COOLANT TEMP Message Inoperative


See: Hot Coolant Temp Message Inoperative

^ LOW COOLANT LEVEL Message Always On


See: Low Coolant Level Message Always On

^ LOW COOLANT LEVEL Message Inoperative


See: Low Coolant Level Message Inoperative
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Engine Overheating
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Loss of Coolant
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Cooling System: Component Tests and General Diagnostics

Non-Trouble Code Procedures


Leak Testing
1. Add water to the radiator to detect core leaks. Clean the core in order to make it easier to find the damaged area.
2. Remove dirt and insects from the fins with a common water hose without a nozzle. Excessive water pressure could damage the fins.
3. Scrub the core with a soft-bristle brush. Use clean hot water or hot water with a mild detergent solution.

On-Vehicle Testing

^ Tools Required
- J 24460-01 Cooling System Tester

1. Pressure test the aluminum/plastic radiator using a common pump and gage.
2. Make sure the cooling system is at a cool temperature, then remove the radiator cap.

3. Connect the gage and apply normal system operating pressure. Do not exceed 138 kPa (20 psi).
4. Watch the gage needle for an indication of a leak.
5. Examine the radiator and other cooling system parts for signs of escaping coolant.
6. Repair all hose and hose connections as required.
7. Check the radiator cap to ensure that it will maintain the correct pressure.
8. If the radiator is leaking during the pressure test, mark the leak area in order to find the leak once the radiator is removed.

Off-Vehicle Testing

Notice: Never use compressed air to pressure test a radiator that is not regulated to 138 kPa (20 psi). Pressures over 138 kPa (20 psi.) will
damage the radiator.

Do not use the boil-out tanks or vats or other tanks that have been used for copper and brass radiators. The flux, acid and caustic cleaners
remaining in these tanks will attack the aluminum and cause radiator failure. A separate test tank containing clean water is strongly recommended
for servicing an aluminum/plastic radiator.

1. Install the test fittings or rubber test caps in the inlet and outlet necks and seal the oil cooler footings with metal plugs. This will protect the
cooler and keep the fluid from running out.
2. Attach the pressure tester and gradually apply air pressure.
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^ Do not exceed 138 kPa (20 psi).
^ Check pressure gage to see if there is a pressure loss.
^ To ensure that there are no small leaks, run water over the repair area and look for bubbles. (A mild detergent is very helpful.)
^ If a large water tank is available, submerge the radiator and check for bubbles at the following locations:
- Inlet tank (1)
- Core tubes (2)
- Outlet tank (3)
- Oil cooler connections (4)
- Drain plug (5)

Coolant Concentration Testing


^ Tools Required
- J 23688 Coolant Tester (Fahrenheit Scale)
- J 26568 Coolant Tester (Centigrade Scale)

Some coolant manufacturers mix other types of glycol into their coolant formulations. Propylene glycol is the most common new ingredient.

A hydrometer does not always provide a correct measurement of freeze protection when anything other than ethylene glycol and water is being
tested. The degree of inaccuracy varies depending on the proportion of other glycols present in the coolant.

All new GM vehicles are produced with coolant that can be accurately measured with a hydrometer; however, when the type and quality of coolant
being measured is unknown, such as a customer vehicle that has accumulated mileage, the use of a refractometer is recommended.

Coolant testers J 26568 (Centigrade Scale) or J 23688 (Fahrenheit Scale) can be used to check the antifreeze protection of the coolant. Make sure
the refractometer markings are correct. Unless J 26568 or J 23688 has a provision for temperature correction, test the temperature at which J 26568
or J 23688 is calibrated. If the coolant is warmer or cooler, the reading may be incorrect. Follow the manufacturers' directions on using J 26568 or J
23688.

Important:
^ Before each use, swing back the plastic cover at the slanted end of the coolant tester, exposing the measuring window and the bottom of
the plastic cover.
^ Wipe the measuring window dry with a tissue or a clean, soft cloth.
^ Close the plastic cover.
^ Do not remove the clear plastic pump from the J 23688 or the J 26568.

1. Release the tip of the pump from the housing of the J 23688 or the J 26568.
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2. Insert the tip of the pump into the radiator filler neck. The tip of the pump must be below the level of the coolant.
3. Press the bulb. Release the pump bulb in order to obtain a sample of the coolant.
4. Insert the tip of the pump into the cover plate opening.
5. Press the pump bulb. Allow a few drops to fall onto the measuring surface. Do not open the plastic cover when taking readings because any
water evaporation will change the reading.

6. Point the coolant concentration tester toward any light source. Look into the eyepiece.
^ The coolant protection reading is at the point where the dividing line between light and dark crosses the scale. Antifreeze protection is the
scale on the right.
^ The temperature scale is reversed from a standard thermometer scale. Below zero readings are on the upper half of the scale.

7. If the readings are not clear, properly clean and dry the measuring surface. Conduct a new test.
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Pressure Testing the Pressure Cap


^ Tools Required
- J 24460-01 Cooling System Tester

Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will
release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.

1. Remove the radiator cap.


2. Wet the radiator cap gasket with water. Wash off any sediment from the sealing surface.
3. Install the cap to J 24460-01
4. Pump up the pressure to the pressure stamped on the cap by operating the plunger handle of J 24460-01
5. Note the rate of decrease in pressure.
6. The pressure reading should remain within the corresponding pressure segment of the scale for about 10 seconds.
7. If the cap does not hold the corresponding pressure, replace the cap.

Thermostat Diagnosis
Thermostat Test
The coolant thermostat can be tested using a temperature (tempil) stick. The temperature stick is a pencil like device. It has a wax material
containing certain chemicals which melt at a given temperature. Temperature sticks can be used to determine a thermostat's operating range, by
rubbing 87°C (188°F) and 97°C (206°F) sticks on the thermostat housing.

^ Tools Required
- J 24731-188 188'F Tempilstick
- J 24731-206 206OF Tempilstick
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1. Use a tempilstick in order to find the opening and the closing temperatures of the coolant thermostat.
^ J 24731-188 tempilstick melts at 87°C (188°F). The thermostat should begin to open.
^ J 24731-206 tempilstick melts at 97°C (206°F). The thermostat should be fully open.
2. Replace the coolant thermostat if it does not operate properly between this temperature range.
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Cooling System: Service and Repair
Draining and Filling Cooling System
Important: Do NOT add any engine coolant supplement sealant pellets to the cooling system.

Drain and refill the engine cooling system every five years or 240,000 km, (150,000 miles), whichever occurs first.

Draining Procedure

1. Park the vehicle on a level surface.


2. Remove and clean the coolant recovery reservoir.

Caution: Do not remove the radiator cap while the cooling system is hot. Serious personal injury may result. Only remove the
radiator cap from a cool engine.

3. Remove the radiator cap when the engine is cool:


3.1. Slowly rotate the cap counterclockwise to the detention tab. Do not press down while rotating pressure cap.
3.2. Wait until any residual pressure (indicated by a hissing sound) is relieved.
3.3. After all hissing stops, press down on the radiator cap and rotate the cap counterclockwise in order to remove the cap.

Important: Recover and store used coolant in a used coolant holding tank and submit the used coolant for recycling on a regular basis. Do
NOT pour used coolant down the drain! Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol into the sewer system or
ground water is both illegal and ecologically unsound!

4. Place a drain pan under the radiator drain valve in order to collect all of the used coolant.

5. Open the radiator drain valve located at the bottom of the radiator tank. If only partial cooling system draining is required, drain enough
coolant to perform the procedure.
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6. Open the air bleed valve on the thermostat housing two full turns.

7. Open the air bleed valve above coolant pump two full turns.
8. Place a drain pan under the engine block drains in order to collect the used coolant.

Important: Allow the coolant to drain completely.

9. Remove both of the engine block drains.


^ The front (left) engine block drain is located between the starter motor and the engine oil filter.
^ The rear (right) engine block drain is located near the crankshaft position sensor.

Filling Procedure
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1. Reinstall the engine block drains.

2. Close the radiator drain valve.

3. Install the coolant recovery reservoir.

Notice: When adding coolant, it is important that you use GM Goodwrench DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) coolant.
If Coolant other than DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) is added to the system the engine coolant will require change
sooner-at 50 000 km (30,000 mi) or 24 months.

4. Slowly add a 50/50 mixture of GM Goodwrench DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) and clean, drinkable water to the
radiator until the coolant level is at the base of the radiator fill neck.
5. Wait for two minutes and recheck the level of the coolant in the radiator. If necessary, add coolant to radiator until the coolant level is at the
base of the radiator fill neck.
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6. Install the radiator cap.

7. Ensure that the radiator cap arrow points toward the radiator overflow tube.

Important: The air bleed valves are brass. Do NOT over-tighten the air bleed valves.

8. Close the air bleed valve above coolant pump.


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9. Close the air bleed valve on the thermostat housing.


10. Fill the coolant reservoir with a 50/50 mixture of GM Goodwrench DEX-COOL (R) or HALVOLINE (R) DEX-COOL (R) and clean,
drinkable water.

Caution: Do not remove the radiator cap while the cooling system is hot. Serious personal injury may result. Only remove the
radiator cap from a cool engine.

Important: If coolant temperature indicator comes on. Turn the engine OFF immediately and allow the engine to cool. Do NOT remove the
radiator cap.

11. Start the engine and allow the engine cooling fan to cycle on and off three times.
If the low coolant indicator does not turn off and the coolant level is above the Full Cold mark on the coolant recovery reservoir, refer to
LOW COOLANT LEVEL Message Always On in Instrument Panel, Gauges and Warning Indicators.
12. Turn the ignition off.
13. Allow the engine to cool.
14. Ensure that the engine coolant concentration (freeze point) is sufficient. Refer to Coolant Concentration Testing.
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Cooling System: Service and Repair
Flushing
Important: Do NOT add any engine coolant supplement sealant pellets to the cooling system.

1. Park the vehicle on a level surface.


2. Remove and clean (flush) the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
3. Flush the engine cooling system. Follow the flushing equipment manufacturer's instructions.
4. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement
5. Add the appropriate amount of GM Goodwrench DEX-COOL (R) or HAVOLINE (R) DEX-COOL (R) to the cooling system (50% of the
cooling system capacity). Refer to Cooling System System Specifications.
6. Fill the coolant recovery reservoir with a 1:1 DEX-COOL (R)/clean, drinkable water ratio.
7. Install the radiator cap (if removed). Ensure that the radiator cap arrow points toward the radiator overflow tube.

Caution: Do not remove the radiator cap while the cooling system is hot. Serious personal injury may result. Only remove the
radiator cap from a coot engine.

Important: If coolant temperature indicator comes on. Turn the engine OFF immediately and allow the engine to cool. Do NOT remove the
radiator cap.

8. Start the engine and allow the engine cooling fan to cycle on and off three times.
If the low coolant indicator does not turn off and the coolant level is above the Full Cold mark on the coolant recovery reservoir, refer to
LOW COOLANT LEVEL Message Inoperative in Instrument Panel, Gauges and Warning Indicators.
9. Turn the ignition off.
10. Allow the engine to cool.
11. Ensure that the engine coolant concentration (freeze point) is sufficient. Refer to Coolant Concentration Testing.
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Auxiliary Water Pump: Service and Repair
Auxiliary Coolant Pump Replacement
AUXILIARY COOLANT PUMP REPLACEMENT

REMOVAL PROCEDURE

1. Drain the Cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
2. Disconnect the electrical connector from the auxiliary coolant pump.
3. Remove the auxiliary coolant pump to heater core inlet hose from the auxiliary coolant pump.
4. Remove the inlet pipe to auxiliary coolant pump hose from the coolant pump.

5. Remove the auxiliary coolant pump retaining clips.


6. Remove the auxiliary coolant pump from the diagonal brace.

INSTALLATION PROCEDURE
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1. Install the auxiliary coolant pump to the diagonal brace.


2. Install the auxiliary coolant pump retaining clips.
3. Install the inlet pipe to auxiliary coolant pump hose to the coolant pump.
4. Install the auxiliary coolant pump to heater core inlet hose to the auxiliary coolant pump.

5. Connect the electrical connector to the auxiliary coolant pump.


6. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
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Auxiliary Water Pump: Service and Repair
Auxiliary Coolant Bypass Pump Switch Replacement

Removal

1. Turn the ignition OFF.


2. Open the hood.
3. Disconnect the electrical connector from the auxiliary coolant pump bypass switch.
4. Unclip the switch from the back side of the front bumper beam.
5. Remove the switch from the vehicle.

Installation

1. Install the auxiliary coolant pump bypass switch to the vehicle.


2. Clip the switch to the back side of the front bumper beam.
3. Connect the electrical connector to the switch.
4. Close the hood.
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Coolant Line/Hose: Service and Repair
Thermostat Bypass Pipes Replacement
Removal Procedure

1. Drain the cooling system. Refer to Draining and Filling Cooling System.
2. Remove the spark plug wire harness from the thermostat bypass pipe.
3. Remove the thermostat bypass pipe to throttle body nut.

4. Remove the thermostat bypass pipe to throttle body hose clamps (1).
5. Remove the thermostat bypass pipe to cylinder head nut (3).
6. Remove the thermostat bypass pipe bolt (4).
7. Remove the thermostat bypass pipe hose clamp (5).

8. Remove the thermostat bypass pipe hose.


9. Remove the thermostat bypass pipe.

Installation Procedure
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1. Apply engine coolant to the bypass pipe seal in order to ease installation.
2. Install the thermostat bypass pipe.
3. Install the thermostat bypass pipe hose.

4. Install the thermostat bypass pipe hose clamp (5).


5. Install the thermostat bypass pipe bolt (4).
^ Tighten the thermostat bypass pipe bolt to 11 Nm (98 inch lbs.).
6. Install the thermostat bypass pipe to cylinder head nut (3).
^ Tighten the thermostat bypass pipe nut to 25 Nm (118 ft. lbs.).
7. Install the thermostat bypass pipe to throttle body hose clamps (1).

8. Install the thermostat bypass pipe to throttle body nut.


^ Tighten the thermostat bypass pipe nut to 25 Nm (18 ft. lbs.).
9. Install the spark plug wire harness to the thermostat bypass pipe.
10. Fill the cooling system. Refer to Draining and Filling Cooling System.
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Chevrolet Venture V6-3.4L VIN E 189
Coolant Line/Hose: Service and Repair
Throttle Body Heater Hose Replacement - Inlet
Removal Procedure

^ Tools Required
- J 38185 Hose Clamp Pliers

1. Remove the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
2. Remove the throttle cable bracket in order to gain access to the throttle body heater hose clamp.
3. Drain the coolant until the coolant level is below the throttle body heater hoses. Refer to Draining and Filling Cooling System.
4. Use the J 38185 in order to remove the hose clamp.
5. Remove the throttle body heater inlet hose.

Installation Procedure

1. Install the throttle body heater inlet hose.


2. Use the J 38185 in order to install the hose clamps.
3. Install the throttle cable bracket.
4. Fill the cooling system. Refer to Draining and Filling Cooling System.
5. Install the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
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Coolant Line/Hose: Service and Repair
Throttle Body Heater Hose Replacement - Outlet
Removal Procedure

^ Tools Required
- J 38185 Hose Clamp Pliers

1. Remove the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
2. Drain the coolant until the coolant level is below the throttle body heater hoses. Refer to Draining and Filling Cooling System.
3. Use the J 38185 in order to remove the hose clamp.
4. Remove the throttle body heater outlet hose.

Installation Procedure

1. Install the throttle body heater outlet hose.


2. Use the J 38185 in order to install the hose clamps.
3. Fill the cooling system. Refer to Draining and Filling Cooling System.
4. Install the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
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Coolant Reservoir: Service and Repair
Removal Procedure

1. Remove the reservoir hose clamp and the hose at the radiator overflow fitting.
2. Remove the mounting clips to the reservoir.
3. Remove the coolant reservoir.
4. Clean the coolant reservoir with soap and water. Rinse with clean water.

Installation Procedure

1. Install the coolant reservoir.


2. Install the mounting clips to the reservoir.
3. Lubricate the reservoir hose with clean water. Route the hose up to the radiator overflow fitting.
4. Install the clamp to the reservoir hose.
5. Refill the coolant reservoir. Refer to Draining and Filling Cooling System.
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Radiator Cooling Fan Motor: Description and Operation
General Description

The electric cooling fans are used to lower the temperature of the engine coolant flowing through the radiator. They are also used to cool the
refrigerant (R-134a) flowing through the A/C condenser.
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Radiator Cooling Fan Motor: Description and Operation
Operation
The electric cooling fan operates when the engine cooling temperature exceeds a certain value. The cooling fan on this engine is controlled by the
Powertrain Control Module (PCM). The PCM turns the cooling fan ON by grounding the coil of the cooling fan relays when certain conditions are
met. When the A/C is requested, the cooling fan will also be turned ON.

Power for the cooling fan motors are supplied through Maxifuses(R). The cooling fan relays are energized when current flows from the fuses in the
Underhood Accessory Wiring Junction Block, and through the relay coils to ground through the PCM. The Coolant Fan 1 Relay Control Circuit is
grounded for low speed fans operation. During low speed fans operation, both fans run at a slow speed. The Coolant Fan 1 Relay Control Circuit is
grounded for high speed operation. During high speed fans operation, both fans run at high speed.

IMPORTANT: When certain Diagnostic Trouble Codes (DTCs) are present, the PCM may command the cooling fans to run all the time. Perform
the A Powertrain On Board Diagnostic (OBD) System Check prior to diagnosing the engine cooling fans.

For more information regarding the Charging System, refer to Charging System Description, and Charging System Circuit Description in
Starting and Charging.

If a problem that involves the low speed cooling fan relay control circuit exists, DTC P0480 Cooling Fan Relay 1 Control Circuit should set. If the
problem affects the high speed cooling fan relay control circuit, DTC P0481 Cooling Fan Relay 2 Control Circuit should set. A problem with the
ECT sensor should set DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage, DTC P0118 Engine Coolant Temperature
(ECT) Sensor Circuit High Voltage, DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage, DTC P1115 Engine
Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage. Any of these DTCs will affect cooling fan operation and should be
diagnosed before using the Electric Cooling Fan Diagnosis.

For more information regarding the Cooling System refer to Engine Cooling Fan Description - Electric, and Cooling System Description in
Cooling System.
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Radiator Cooling Fan Motor: Service and Repair
Removal Procedure

Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and
tools away from any underhood electric fan.

Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be
replaced.

Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan
blades.

1. Turn the ignition off.


2. Remove the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement -Electric.
3. Remove the cooling fan. Refer to Fan Replacement.
4. Remove the cooling fan motor electrical connector.
5. Remove the cooling fan motor screws.
6. Remove the cooling fan motor.

Installation Procedure

1. Install the cooling fan motor.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the cooling fan motor screws.


^ Tighten the screws to 6 Nm (53 inch lbs.).
3. Install the cooling fan motor electrical connector.
4. Install the cooling fan. Refer to Fan Replacement
5. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric.
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Fan Blade: Service and Repair
Fan Replacement
Removal Procedure

Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and
tools away from any underhood electric fan.

Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be
replaced.

Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan
blades.

1. Turn the ignition off.


2. Remove the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric.
3. Remove the cooling fan nut.
4. Remove the cooling fan.

Installation Procedure

1. Install the cooling fan.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the cooling fan nut.


^ Tighten the nut to 6 Nm (53 inch lbs.).
3. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric.
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Fan Blade: Service and Repair
Cooling Fan Replacement - Electric
Removal Procedure

Caution: An electric fan under the hood can start up even when the engine is not running and can Injure you. Keep hands, clothing and
tools away from any underhood electric fan.

Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be
replaced.

1. Turn the ignition off.


2. Remove the cooling fan harness electrical connector.
3. Loosen the engine mount strut bolts (engine side). Refer to Engine Mount Strut Bracket Replacement (Radiator Upper Support) or Engine
Mount Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement (Right Side).
4. Remove the engine mount strut bracket brace bolts from the upper radiator support and rotate the struts and brackets rearward. Refer to
Engine Mount Strut Bracket Replacement (Radiator Upper Support) or Engine Mount Strut Bracket Replacement (Left Side) or Engine
Mount Strut Bracket Replacement (Right Side).
5. Remove the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
6. Remove the cooling fan shroud bolts.
7. Remove the transmission oil cooler lines from the transmission oil cooler line retainers.
8. Reposition the wiring harness at the upper radiator support in order to gain access.

9. Reposition and remove the cooling fans with the cooling fan shroud.

Installation Procedure
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1. Reposition the wiring harness at the upper radiator support in order to gain access.
2. Install the cooling fans with the cooling fan shroud.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the cooling fan shroud bolts.


^ Tighten the bolts to 6 Nm (53 inch lbs.).
4. Install the transmission oil cooler lines to the transmission oil cooler line retainers.
5. Install the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
6. Install the engine mount strut bracket brace bolts from the upper radiator support and rotate the struts and brackets rearward. Refer to Engine
Mount Strut Bracket Replacement (Radiator Upper Support) or Engine Mount Strut Bracket Replacement (Left Side) or Engine Mount Strut
Bracket Replacement (Right Side).
7. Tighten the engine mount strut bolts (engine side). Refer to Engine Mount Strut Bracket Replacement (Radiator Upper Support) or Engine
Mount Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement (Right Side).

8. Install the cooling fan harness electrical connector.


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Chevrolet Venture V6-3.4L VIN E 198
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream.

Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130
°C/266°F).

The PCM supplies a 5 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage is
high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. The
engine coolant temperature affects most systems the PCM controls.

The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then
stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air
temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant
Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage. The DTC
Diagnostic Aids also contains a chart to check for sensor resistance values relative to temperature.
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The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel.
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair

REMOVAL PROCEDURE
1. Turn OFF the ignition.
2. Relieve the coolant pressure.
3. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
4. Use a deep well socket and an extension in order to remove the sensor.

INSTALLATION PROCEDURE
1. Coat the ECT sensor threads with sealer GM P/N 9985253 or equivalent.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the sensor in the engine.

Tighten
Tighten the sensor to 23 N.m (17 lb ft).

3. Connect the ECT sensor electrical connector.


4. Start the engine.
5. Inspect for leaks.
6. Inspect the coolant level.
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Chevrolet Venture V6-3.4L VIN E 201
Fan Shroud: Service and Repair
Removal Procedure

Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and
tools away from any underhood electric fan.

Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be
replaced.

Important: If abnormal noise or vibration is felt from the engine compartment, inspect and clean any foreign material from the cooling fan
blades.

1. Turn the ignition off.


2. Remove the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric.
3. Remove the cooling fans. Refer to Fan Replacement.
4. Remove the cooling fan motors from the cooling fan shroud. Refer to Cooling Fan Motor Replacement - Electric.
5. Remove the cooling fan motor heat shields from the cooling fan shroud.

Installation Procedure

1. Install the cooling fan motor heat shields to the cooling fan shroud.
2. Install the cooling fan motors to the cooling fan shroud. Refer to Cooling Fan Motor Replacement - Electric.
3. Install the cooling fans. Refer to Fan Replacement.
4. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement -Electric.
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Heater Core: Service and Repair
Auxiliary Coolant Pump to Heater Core Inlet Hose Replacement
REMOVAL PROCEDURE

1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling Systems. See: Service and Repair/Draining and Filling
Cooling System
2. Remove the wiper module cover.
3. Remove the air cleaner duct and cover.
4. Rotate the engine forward.

5. Disconnect the auxiliary coolant pump to heater core inlet hose (2) from the auxiliary coolant pump.
6. Disconnect the auxiliary coolant pump to heater core inlet hose (2) from the heater core inlet.

7. If equipped with RPO C34, Rear HVAC System, disconnect the auxiliary coolant pump to heater core inlet hose from the hose-T.
8. Remove the auxiliary coolant pump to heater core inlet hose (2).

INSTALLATION PROCEDURE
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1. Install the auxiliary coolant pump to heater core inlet hose (2).
2. Connect the auxiliary coolant pump to heater core inlet hose to the heater core inlet.

3. If equipped with RPO C34, Rear HVAC System, connect the auxiliary coolant pump to heater core inlet hose to the hose-T.
4. Connect the inlet pipe to auxiliary coolant pump hose to the auxiliary coolant pump.
5. Rotate the engine rearward to the proper position.
6. Install the air cleaner cover and duct.

7. Install the wiper module cover.


8. Refill the cooling system.

For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application
and ID/RPO Codes
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Heater Core: Service and Repair
Heater Case/Cover Replacement
REMOVAL PROCEDURE

1. Remove the right instrument panel insulator.


2. Remove the left instrument panel insulator.
3. Remove the lower center console.
4. Remove the console bracket.
5. Remove the floor duct brace
6. Remove the floor duct
7. Remove the screws retaining the heater core outlet cover.
8. Remove the heater core outlet cover.

9. Remove the screws retaining the heater core cover.


10. Remove the heater core cover.

INSTALLATION PROCEDURE

1. Install the heater core cover.

NOTE: Refer to Fastener Notice in Service Precautions.


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2. Install the heater core cover retaining screws.

Tighten
Tighten the screws to 1.6 N.m (14 lb in).

3. Install the heater core outlet cover.


4. Install the heater core outlet cover retaining screws.

Tighten
Tighten the screws to 1.6 N.m (14 lb in).

5. Install the floor duct.


6. Install the floor duct brace.
7. Install the floor duct brace retaining nuts.

Tighten
Tighten the nuts to 10 N.m (89 lb in).

8. Install the console bracket.


9. Install the lower center console.
10. Install the left instrument panel insulator.
11. Install the right instrument panel insulator.
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Heater Core: Service and Repair
Heater Core Replacement
REMOVAL PROCEDURE

TOOLS REQUIRED
J 38185 Hose Clamp Pliers

1. Remove the air cleaner cover and duct assembly.


2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
3. Disconnect the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer System. See: Wiper and Washer
Systems/Wiper Motor/Service and Repair/Wiper Motor Crank Arm Replacement
4. Disconnect both of the heater hoses from the heater core using the J 38185.
5. Remove the heater core outlet cover.

6. Remove the screws retaining the heater core cover.


7. Remove the heater core cover.
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8. Remove and discard the cavity (1), whistle (2), and permagum (3) seals from the heater core cover.

9. Remove and discard the heater core outer seal (5) from the heater core.

10. Remove the heater core retaining clamp screw (1).


11. Remove the heater core retaining clamp.
12. Remove the heater core pipe retainer clamp screw (2).

13. Remove the heater core from the HVAC module.


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14. Remove and discard the heater core lower seal (4) from the HVAC module case.

15. Remove and discard the heater core center seal (3) from the HVAC module case.

16. Remove and discard the heater core upper seal (2) from the HVAC module case.

17. Remove the heater core pipe retainer clamp from the heater core pipes.
Using a flat bladed tool, release the retaining tab and open the clamp.
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INSTALLATION PROCEDURE

1. Install the heater core pipe retainer clamp to the heater core pipes.
Align the depression in the clamp to the ridge on one of the heater core pipes, then close the clamp to secure.

2. Install new heater cores side seals (1) to the HVAC module case.

3. Install a new heater core upper seal (2) to the HVAC module case.

4. Install a new heater core center seal (3) to the HVAC module case.
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5. Install a new heater core lower seal (4) to the HVAC module case.

6. Install the heater core to the HVAC module case.

NOTE: Refer to Fastener Notice in Service Precautions.

7. Install the heater core pipe retaining clamp screw (2).

Tighten
Tighten the screw to 1.6 N.m (14 lb in).

8. Install the heater core retaining clamp.


9. Install the heater core retaining clamp screw (1).

Tighten
Tighten the screw to 1.6 N.m (14 lb in).
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10. Install a new heater core outer seal (5) to the heater core.

11. Install a new cavity (1), whistle (2), and permagum (3) seals to the heater core cover.

12. Install the heater core cover.


13. Install the heater core cover retaining the screws.

Tighten
Tighten the screws to 1.6 N.m (14 lb in).

14. Install the heater core outlet cover. Refer to Heater Core Cover Replacement. See: Heater Case/Cover Replacement
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15. Connect both of the heater hoses and the clamps to the heater core using the J 38185 positioning the clamps as indicated.
16. Install the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer System. See: Wiper and Washer Systems/Wiper
Motor/Service and Repair/Wiper Motor Crank Arm Replacement
17. Refill the coolant.
18. Install the air cleaner cover and duct assembly.
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Heater Core: Service and Repair
Heater Core Replacement - Auxiliary
REMOVAL PROCEDURE

1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
2. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
3. Disconnect the heater hose quick disconnects.
4. Lower the vehicle.
5. Remove the left side rear quarter lower trim panel.

6. Remove the heater pipe bracket retaining screw.


7. Remove the heater pipe bracket.
8. Remove the heater pipe block fitting bolt.
9. Carefully push the heater pipes downward to disconnect the heater pipe block fitting from the heater core.
10. Remove the heater core retaining screws.

IMPORTANT: Carefully pull the heater core straight out from the HVAC module so not to damage the cooling fins of the heater core.
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11. Remove the heater core from the rear HVAC module.

INSTALLATION PROCEDURE

IMPORTANT: Carefully insert the heater core straight into the HVAC module so not to damage the cooling fins of the heater core.

1. Install the heater core to the rear HVAC module.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the heater core retaining screws

Tighten
Tighten the heater core retaining screws to 1.6 N.m (14 lb in).

3. Carefully pull the heater pipes up and align the heater pipe block fitting to the heater core.

4. Install the heater pipe block fitting retaining bolt.


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Tighten
Tighten the heater pipe block fitting retaining bolt 16 N.m (12 lb ft).

5. Install the heater pipe bracket.


6. Install the heater pipe bracket retaining screw.

Tighten
Tighten the heater pipe bracket retaining screw 1.6 N.m (14 lb in).

7. Install the left side rear quarter lower trim panel.


8. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.

9. Connect the heater hose quick disconnects


10. Lower the vehicle
11. Refill the cooling system.
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Heater Hose: Service and Repair

Auxiliary Coolant Pump to Heater Core Inlet Hose Replacement


REMOVAL PROCEDURE

1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling Systems. See: Service and Repair/Draining and Filling
Cooling System
2. Remove the wiper module cover.
3. Remove the air cleaner duct and cover.
4. Rotate the engine forward. Refer to Rotating the Engine for Service Access in Engine. See: Engine/Service and Repair/Removal and
Replacement

5. Disconnect the auxiliary coolant pump to heater core inlet hose (2) from the auxiliary coolant pump.
6. Disconnect the auxiliary coolant pump to heater core inlet hose (2) from the heater core inlet.

7. If equipped with RPO C34, Rear HVAC System, disconnect the auxiliary coolant pump to heater core inlet hose from the hose-T.
8. Remove the auxiliary coolant pump to heater core inlet hose (2).

INSTALLATION PROCEDURE
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1. Install the auxiliary coolant pump to heater core inlet hose (2).
2. Connect the auxiliary coolant pump to heater core inlet hose to the heater core inlet.

3. If equipped with RPO C34, Rear HVAC System, connect the auxiliary coolant pump to heater core inlet hose to the hose-T.
4. Connect the inlet pipe to auxiliary coolant pump hose to the auxiliary coolant pump.
5. Rotate the engine rearward to the proper position. Refer to Rotating the Engine for Service Access in Engine. See: Engine/Service and
Repair/Removal and Replacement
6. Install the air cleaner cover and duct.

7. Install the wiper module cover.


8. Refill the cooling system.

For a description of the RPO Code(s) shown in this article/image, refer to the RPO Code List found at Vehicle/Application ID See: Application
and ID/RPO Codes
Heater and A/C Pipe Repair - Auxiliary
Do not service the rear heater lines as a complete unit. Service the rear heater lines as a sectional repair.

You can obtain the different sections of line through GMSPO.


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TOOLS REQUIRED
J 41425 A/C Line Repair Kit

Use the J 41425 when any of the following actions damage the A/C or heater lines:
^ Rub-through
^ Collision damage
^ Leakage in the system

Follow the Straight Line Repair procedure in order to repair the type of damage described above.

If the A/C or heater lines have visible damage or a leak in a bend area, replace the lines. Section the lines in order to obtain the original line
shapes. Maintaining the original line shape will prevent vibrations and rub-through.

Follow the A/C Line Sectioning Repair procedure in order to repair any damage in a bend area.

STRAIGHT LINE REPAIR


1. If you are repairing the A/C lines, evacuate, charge and leak test the system. Refer to Refrigerant Recovery and Recharging. See: Heating
and Air Conditioning/Refrigerant/Service and Repair
2. If you are repairing the heater lines, drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service
and Repair/Draining and Filling Cooling System
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
4. Locate the area that requires repair.
5. Use a tubing cutter in order to cut the damaged line for repair.
6. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (.75 in) from the A/C line.
7. Use the LOK prep sealant in order to prep the A/C line.
8. Apply one drop of the J 41425-3 sealing compound to the outside of each end of the line.
9. Install the correct LOK fitting into the jaws:
9.1. Insert the line ends into the LOK fitting.
9.2. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines.
10. Verify that the connector ends are positioned in the counter bores of the jaw.
11. Install the J 41425-1 tool over the connectors and the tubes.
12. Hold the tool body with a 1/8 breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the
LOK fitting.
13. Loosen the forcing screw. Remove the tool from the repaired line.
14. Verify that the LOK fitting is correctly installed.
15. Lower the vehicle.
16. If you drained the cooling system, refill the coolant.
17. If you are repairing the A/C lines, recharge and leak test the system. Refer to Refrigerant Recovery and Recharging. See: Heating and Air
Conditioning/Refrigerant/Service and Repair

A/C LINE SECTIONING REPAIR


1. If you are repairing the A/C lines, evacuate the system. Refer to Refrigerant Recovery and Recharging. See: Heating and Air
Conditioning/Refrigerant/Service and Repair
2. If you are repairing the heater lines, drain the cooling system.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in Vehicle Lifting.
4. Obtain a new A/C line for sectioning.
5. Scribe a mark on the damaged A/C line that will be cut.
6. Scribe a mark on the new line that will be sectioned.
7. Use a tubing cutter in order to cut both of the A/C lines.
8. Use the cleaning pad from the J 41425 in order to clean any burrs or grease. Be sure to clean at least 19 mm (.75 in) from the A/C line.
9. Use the LOK prep sealant in order to prep the A/C line.
10. Apply one drop of the J 41425-3 sealing compound to the outside of each line end.
11. Install the correct LOK fitting into the jaws:
11.1. Insert the line ends into the LOK fitting.
11.2. Rotate the LOK fitting one complete turn in order to evenly distribute the sealing compound around the lines.
12. Verify that the connector ends are positioned in the counter bores of the jaw.
13. Install the J 41425-1 tool over the connectors and the tubes.
14. Hold the tool body with a 3/8 breaker bar. Turn the forcing screw until both of the connector collars bottom on the center shoulder of the
LOK fitting.
15. Loosen the forcing screw. Remove the tool from the repaired line.
16. Verify that the LOK fitting is correctly installed.
17. Repeat Step 4 through Step 13 for the other end of the repair line.
18. Lower the vehicle.
19. If you drained the cooling system, refill the coolant.
20. If you are repairing the A/C lines, recharge and leak test the system. Refer to Refrigerant Recovery and Recharging. See: Heating and Air
Conditioning/Refrigerant/Service and Repair

MINIMUM TUBE LENGTH REQUIRED TABLE


When you section the A/C lines, ensure that the correct minimum length remains in the straight part of the line on both sides of the splice.
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Heater And A/C Pipe Repair - Auxiliary

HEATER AND A/C PIPE REPAIR - AUXILIARY


Heater Hose Replacement - Inlet
REMOVAL PROCEDURE

1. Remove the air cleaner cover and duct assembly.


2. Disconnect the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer Systems. See: Wiper and Washer
Systems/Wiper Motor/Service and Repair/Wiper Motor Crank Arm Replacement
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling. See: Service and Repair/Draining and Filling
Cooling System
4. Disconnect the inlet hose (1) from the inlet pipe (2).

5. Disconnect the inlet hose from the heater core.


6. Remove the inlet hose.

INSTALLATION PROCEDURE
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1. Install the inlet hose.


2. Connect the inlet hose to the heater core and position the hose clamp as indicated.

3. Connect the inlet (1) hose to the inlet pipe (2).


4. Refill the coolant.
5. Connect the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer Systems. See: Wiper and Washer
Systems/Wiper Motor/Service and Repair/Wiper Motor Crank Arm Replacement
6. Install the air cleaner cover and duct assembly.
Heater Hose Replacement - Outlet
REMOVAL PROCEDURE

1. Remove the air cleaner cover and duct assembly.


2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
3. Disconnect the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer Systems. See: Wiper and Washer
Systems/Wiper Motor/Service and Repair/Wiper Motor Crank Arm Replacement
4. Disconnect the outlet hose (3) from the outlet pipe (4).
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5. Disconnect the outlet hose from the heater core.


6. Remove the outlet hose.

INSTALLATION PROCEDURE

1. Install the outlet hose.


2. Connect the outlet hose to the heater core and position the hose clamp as indicated.

3. Connect the outlet hose (3) to the outlet pipe (4).


4. Refill the cooling system.
5. Connect the wiper linkage. Refer to Wiper Motor Crank Arm Replacement in Wiper Washer Systems. See: Wiper and Washer
Systems/Wiper Motor/Service and Repair/Wiper Motor Crank Arm Replacement
6. Install the air cleaner cover and dust assembly.
Heater Pipe Replacement - Inlet
REMOVAL PROCEDURE
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1. Remove the air cleaner cover and duct assembly.


2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
3. Disconnect the inlet hose (1) from the inlet pipe (2).

4. Disconnect the electrical harness retainer from the inlet pipe bracket.

5. Disconnect the inlet pipe mounting nut.


6. Remove the inlet pipe by pulling pipe rearward to remove from thermostat housing.
7. Remove and discard the O-ring seal from the inlet pipe.

INSTALLATION PROCEDURE
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1. Install a new O-ring seal on the inlet pipe.


2. Install the inlet pipe into the thermostat housing.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the inlet pipe mounting nut.

Tighten
Tighten the nut to 7 N.m (62 lb in).

4. Connect the electrical harness retainer to the inlet pipe bracket.

5. Connect the inlet hose (1) to the inlet pipe (2).


6. Refill the coolant.
7. Install the air cleaner cover and duct assembly.
Inlet Pipe to Auxiliary Coolant Pump Hose Replacement
REMOVAL PROCEDURE
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1. Drain Cooling system. Refer to Draining and Filling Cooling System in Cooling System. See: Service and Repair/Draining and Filling
Cooling System
2. Remove the wiper module cover.
3. Remove the air cleaner duct and cover.
4. Rotate the engine forward and secure. Refer to Rotating the Engine for Service Access in Engine. See: Engine/Service and Repair/Removal
and Replacement

5. Disconnect the inlet pipe to auxiliary coolant pump hose from the inlet pipe.
6. Disconnect the inlet pipe to auxiliary coolant pump hose from the auxiliary coolant pump (4).
7. Remove the inlet pipe to auxiliary coolant pump hose (3).

INSTALLATION PROCEDURE

1. Install the inlet pipe to auxiliary coolant pump hose (3).


2. Connect the inlet pipe to auxiliary coolant pump hose to the auxiliary coolant pump (4).
3. Connect the inlet pipe to auxiliary coolant pump hose to the inlet pipe.
4. Rotate the engine rearward to the proper position. Refer to Rotating the Engine for Service Access in Engine. See: Engine/Service and
Repair/Removal and Replacement
5. Install the air cleaner cover and duct.
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6. Install the wiper module cover.


7. Refill the cooling system.
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Radiator: Service and Repair
Radiator Air Baffle Assemblies and Deflectors
Removal Procedure

1. Raise and suitably support the vehicle. Refer to Vehicle Lifting.


2. Remove the radiator lower air deflector mounting bolts.
3. Remove the radiator lower air deflector.

Installation Procedure

1. Install the radiator lower air deflector.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the radiator lower air deflector mounting bolts.


^ Tighten the bolts to 20 Nm (15 ft. lbs.).
3. Lower the vehicle. Refer to Vehicle Lifting.
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Radiator: Service and Repair
Radiator Replacement
Removal Procedure

1. Remove air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
2. Drain the coolant. Refer to Draining and Filling Cooling System.
3. Loosen the engine mount strut-to-engine mount strut bracket bolts. Refer to Engine Mount Strut Bracket Replacement (Radiator Upper
Support) or Engine Mount Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement (Right Side).
4. Remove the engine mount strut bracket brace bolts from the upper radiator support and reposition the struts and brackets rearward. Refer to
Engine Mount Strut Bracket Replacement (Radiator Upper Support) or Engine Mount Strut Bracket Replacement (Left Side) or Engine
Mount Strut Bracket Replacement (Right Side).
5. Remove the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement -Electric.
6. Remove the radiator upper hose from the radiator. Refer to Radiator Hose Replacement - Inlet.
7. Remove the radiator lower hose from the radiator. Refer to Radiator Hose Replacement - Outlet.
8. Remove the low coolant module. Refer to Coolant Level Module Replacement.
9. Disconnect the transaxle oil cooler lines from the radiator. Refer to Automatic Transmission Oil Cooler Pipes Replacement in Transmission
and Drivetrain.
10. Remove the radiator brackets and bolts.
11. Remove the radiator.

Installation Procedure

1. Install the radiator.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the radiator brackets and bolts.


^ Tighten the bolts to 24 Nm (18 ft. lbs.).
3. Connect the transaxle oil cooler lines to the radiator. Refer to Automatic Transmission Oil Cooler Pipes Replacement in Transmission and
Drivetrain.
4. Install the low coolant module. Refer to Coolant Level Module Replacement.
5. Install the radiator upper hose to the radiator. Refer to Radiator Hose Replacement - Inlet.
6. Install the radiator lower hose to the radiator. Refer to Radiator Hose Replacement - Outlet
7. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric.
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8. Reposition and install the engine mount strut bracket brace bolts to the upper radiator support. Refer to Engine Mount Strut Bracket
Replacement (Radiator Upper Support) or Engine Mount Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement
(Right Side).
9. Tighten the engine mount strut-to-engine mount strut bracket bolts. Refer to Engine Mount Strut Bracket Replacement (Radiator Upper
Support) or Engine Mount Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement (Right Side).

Notice: When adding coolant, it is important that you use GM Goodwrench DEX-C001 (R) or HAVOLINE(R) DEX-COOL (R) coolant. If
Coolant other than DEX-COOL (R) or HAVOLINE (R) DEX-C00L (R) is added to the system the engine coolant will require change
sooner-at 50,000 km (30,000 mi) or 24 months.

10. Fill the cooling system. Refer to Draining and Filling Cooling System.
11. Install the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
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Radiator Drain Plug: Service and Repair
Removal Procedure

1. Raise the vehicle. Refer to Vehicle Lifting.


2. Drain the coolant. Refer to Draining and Filling Cooling System.
3. Pull the stem out of the radiator body.
4. Clean or replace the seal and the stem as necessary.

Installation Procedure

1. Install the stem to the radiator body.


2. Fill the cooling system. Refer to Draining and Filling Cooling System.
3. Lower the vehicle.
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Radiator Hose: Service and Repair
Radiator Hose Replacement - Inlet
Removal Procedure

^ Tools Required
- J 38185 Hose Clamp Pliers

1. Partially drain the coolant. Refer to Draining and Filling Cooling System.
2. Disconnect the inlet hose from the thermostat housing using the J 38185.
3. Disconnect the inlet hose from the radiator using the J 38185.
4. Remove the inlet hose.

Installation Procedure

1. Install the inlet hose in position and align the marks on the hose.
2. Connect the inlet hose to the radiator using the J 38185.
3. Connect the inlet hose to the thermostat housing using the J 38185.

Important: To properly fill the system you must use of the air bleed vents. Refer to Draining and Filling Cooling System.

4. Refill the coolant. Refer to Draining and Filling Cooling System.


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Radiator Hose: Service and Repair
Radiator Hose Replacement - Outlet
Removal Procedure

^ Tools Required
- J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to Draining and Filling Cooling System.


2. Disconnect the outlet hose from the water pump housing using the J 38185.
3. Disconnect the outlet hose from the radiator using the J 38185.
4. Remove the outlet hose.

Installation Procedure

1. Install the outlet hose in position and align the marks on the hose.
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2. Connect the outlet hose to the radiator using the J 38185.
3. Connect the outlet hose to the water pump housing using the J 38185.

Important: To properly fill the system you must use of the air bleed vents. Refer to Draining and Filling Cooling System.

4. Refill the coolant. Refer to Draining and Filling Cooling System.


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Coolant Level Indicator Module: Service and Repair
Removal Procedure

1. Drain the coolant until the coolant level is below the low coolant level module. Refer to Draining and Filling Cooling System.
2. Remove the low coolant module electrical connector.

3. Lift one leg of the retainer and pull outward with a twisting motion in order to remove the low coolant module.
4. Ensure that the coolant level module seal is not damaged.

Installation Procedure

1. Lubricate the coolant level module seal with coolant.

Important: Ensure that the retainer is installed correctly on the low coolant module.

2. Install the low coolant module.


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3. Install the low coolant module electrical connector.


4. Fill the cooling system. Refer to Draining and Filling Cooling System.
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Thermostat: Service and Repair
Removal Procedure

1. Remove the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
2. Drain the coolant until the coolant level is below the thermostat. Refer to Draining and Filling Cooling System.
3. Remove the radiator hose from the thermostat housing. Refer to Radiator Hose Replacement - Inlet.
4. Remove the thermostat housing bolts and clean any sealer from the bolt threads.
5. Remove the thermostat housing and gasket.

6. Remove the thermostat.


7. Clean the mating surfaces.

Installation Procedure

1. Install the thermostat.


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2. Install the thermostat housing and gasket.


3. Install RTV sealer (GM P/N 1052366 or the equivalent) to the thermostat housing bolt threads.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the thermostat housing bolts.


^ Tighten the bolts to 25 Nm (18 ft. lbs.).
5. Install the radiator hose to the thermostat housing. Refer to Radiator Hose Replacement - Inlet.
6. Install the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Computers and Controls.
7. Fill the cooling system. Refer to Draining and Filling Cooling System.
8. Inspect the cooling system for leaks. Repair as necessary.
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Exhaust System: Description and Operation
The exhaust system is used to carry the gases that are created by the engine. When the engine exhaust valve opens hot gases created by the engine
combustion cycle are allowed to travel out through the cylinder head into the exhaust manifold. In the exhaust manifold the exhaust gases combine
with exhaust gases from the other cylinders and pass the through a flanged port into the exhaust resonator pipe. The resonator and the muffler are
used to reduce the noise levels of the exhaust. The exhaust system exits at the rear of the vehicle to reduce exhaust noise and fumes from entry in to
the vehicle. Exhaust system hangers and insulators support the weight of the exhaust system, isolate engine noise, isolate engine vibration, space
the system away from the underbody of the vehicle and allow for exhaust system expansion that occurs as the exhaust system warms up.
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Catalytic Converter: Description and Operation
To control emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and Oxides Of Nitrogen (NOx), a 3-way catalytic converter is used. The
catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting the HG and GO
into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting the NOx to nitrogen. The PCM has the ability to monitor
this process using the HO2S 1 and the HO2S 2 heated oxygen sensors. The HO2S 1 sensor produces an output signal which indicates the amount of
oxygen present in the exhaust gas entering the 3-way catalytic converter. The HO2S 2 sensor produces an output signal which indicates the oxygen
storage capacity of the catalyst. This in turn indicates the catalyst's ability to convert exhaust gases efficiently. If the catalyst is operating efficiently,
the HO2S 1 signal is far more active than that produced by the HO2S 2 sensor.

The catalyst monitor sensors operate the same as the fuel control sensors. Although the HO2S 2 sensor's main function is catalyst monitoring, the
sensor also plays a limited role in fuel control. If the sensor output indicates a voltage either above or below the 450 millivolt bias voltage for an
extended period of time, the PCM makes a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring.

A problem with the HO2S 2 signal circuit should set DTC P0137 HO2S Circuit Low Voltage Sensor 2, DTC P0138 HO2S Circuit High Voltage
Sensor 2, or DTC P0140 HO2S Circuit Insufficient Activity Sensor 2, depending on the specific condition.

A fault in the heated oxygen sensor heater element or its ignition feed or ground results in slower oxygen sensor response. This may cause
erroneous catalyst monitor diagnostic results. A fault in the HO2S 2 heater circuit should cause DTC P0141 HO2S Heater Performance Sensor2 to
set.
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Catalytic Converter: Service and Repair
Catalytic Converter Replacement
Removal Procedure

Replace the entire converter assembly in order to properly service the three way catalytic converter.

1. Raise and suitably support the vehicle. Refer to Vehicle Lifting.


2. Remove the exhaust manifold pipe nuts from the exhaust manifold pipe studs.

3. Remove the catalytic converter nuts from the exhaust pipe.


4. Remove the three-way catalytic converter.

Installation Procedure

Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The
vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

1. Install a new catalytic converter gasket.


2. Install a new exhaust manifold pipe gasket.
3. Position and support the new three-way catalytic converter under the vehicle.
4. Install the exhaust pipe to the three-way catalytic converter with the catalytic converter nuts. Do no tighten the nuts.
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Notice: Refer to Fastener Notice in Service Precautions.

5. Install the exhaust manifold pipe nuts to the exhaust manifold pipe studs.
^ Tighten the exhaust manifold pipe nuts to the exhaust manifold pipe stud to 35 Nm (26 ft. lbs.).
^ Tighten the catalytic converter nuts to the 34 Nm (25 ft. lbs.).
6. Lower the vehicle.
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Catalytic Converter: Service and Repair
Converter Hanger Assembly Replacement
Removal Procedure

1. Raise and suitably support the vehicle. Refer to Vehicle Lifting.


2. Remove the catalytic converter hanger insulators from the catalytic converter.
3. Remove the catalytic converter hanger bolts.
4. Remove the catalytic converter hanger.

Installation Procedure

1. Install the catalytic converter hanger.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the catalytic converter hanger bolts.


^ Tighten the catalytic converter hanger bolts to 35 Nm (26 ft. lbs.).
3. Install the catalytic converter hanger insulators to the catalytic converter.
4. Lower the vehicle.
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Exhaust Crossover Pipe: Service and Repair
Exhaust Crossover Replacement
Removal Procedure

1. Remove the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
2. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the inlet radiator hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
4. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System.
5. Remove the exhaust crossover pipe heat shield bolts.
6. Remove the exhaust crossover pipe heat shield.

7. Remove the exhaust crossover pipe nuts.


8. Remove the exhaust crossover pipe.

Installation Procedure

1. Install the exhaust crossover pipe.

Notice: Refer to Fastener Notice in Service Precautions.


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2. Install the exhaust crossover pipe nuts.


^ Tighten the exhaust crossover pipe nuts to 25 Nm (18 ft. lbs.).

3. Install the exhaust crossover pipe heat shield.


4. Install the exhaust crossover pipe heat shield bolts.
^ Tighten the exhaust crossover pipe heat shield bolts to 10 Nm (89 inch lbs.).
5. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System.
6. Install the inlet radiator hose to the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
7. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
8. Install the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
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Exhaust Crossover Pipe: Service and Repair
Exhaust Crossover Pipe Replacement
Removal Procedure

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Remove the throttle body air inlet duct.
3. Drain the coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
4. Remove the inlet radiator hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
5. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System.
6. Remove the exhaust crossover heat shield bolts.
7. Remove the exhaust crossover heat shield.

8. Remove the exhaust crossover pipe studs/nuts.


9. Remove the exhaust crossover pipe.

Installation Procedure

1. Install the exhaust crossover pipe.


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Notice: Refer to Fastener Notice in Service Precautions.

2. Install the exhaust crossover pipe studs/nuts.


^ Tighten the exhaust crossover pipe studs/nuts to 25 Nm (18 ft. lbs.).

3. Install the exhaust crossover heat shield.


4. Install the exhaust crossover heat shield bolts.
^ Tighten the exhaust crossover heat shield bolts to 10 Nm (89 inch lbs.).
5. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System.
6. Install the inlet radiator hose to the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
7. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
8. Install the throttle body air inlet duct.
9. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
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Exhaust Manifold: Service and Repair
Exhaust Manifold Replacement (Engine Left Side)
Removal Procedure

1. Remove the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
2. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement (Radiator Upper Support) or Engine Mount
Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement (Right Side).
4. Disconnect the inlet radiator hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
5. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System.
6. Remove the exhaust crossover pipe bolts from the engine left side exhaust manifold. Refer to Exhaust Crossover Removal.
7. Remove the exhaust manifold heat shield bolts.
8. Remove the exhaust manifold heat shield.

9. Remove the exhaust manifold nuts.


10. Remove the exhaust manifold.
11. Remove the exhaust manifold gasket.
12. Clean the engine left side exhaust manifold to the engine left side cylinder head sealing surfaces. Refer to Exhaust Manifold Clean and
Inspect.

Installation Procedure
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1. Install the exhaust manifold gasket.


2. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the exhaust manifold nuts.


^ Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).

4. Install the exhaust manifold heat shield.


5. Install the exhaust manifold heat shield bolts.
^ Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).
6. Install the exhaust crossover pipe. Refer to Exhaust Crossover Installation.
7. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Cooling System.
8. Connect the inlet radiator hose to the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
9. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement (Radiator Upper Support) or Engine Mount
Strut Bracket Replacement (Left Side) or Engine Mount Strut Bracket Replacement (Right Side).
10. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
11. Install the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
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Exhaust Manifold: Service and Repair
Exhaust Manifold Replacement (Engine Right Side)
Removal Procedure

1. Remove the windshield wiper motor cover. Refer to Wiper Module Cover Replacement in Wiper and Washer Systems.
2. Remove the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
3. Remove the accelerator cable bracket from the throttle body. Refer to Accelerator Controls Cable Replacement in Computers and Controls.
4. Remove the manifold air pressure (MAP) sensor. Refer to MAP Sensor Replacement in Computers and Controls.
5. Remove the exhaust gas recirculation (EGR) valve. Refer to EGR Valve Replacement in Computers and Controls.
6. Rotate the engine for service access. Refer to Rotating the Engine for Service Access.
7. Remove the ignition module and the ignition coils with the bracket.
8. Remove the spark plug wires from the engine right bank spark plugs.
9. Disconnect the oxygen sensor electrical connector.
10. Remove the evaporative emissions (EVAP) solenoid bracket.
11. Remove the exhaust crossover pipe nuts/studs from the engine right bank exhaust manifold. Refer to Exhaust Crossover Removal.
12. Raise and support the vehicle. Refer to Vehicle Lifting.
13. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Powertrain Management.
14. Remove the exhaust manifold heat shield bolts.
15. Remove the exhaust manifold heat shields.

16. Remove the exhaust manifold nuts.


17. Remove the exhaust manifold.
18. Remove the exhaust manifold gasket.
19. Lower the vehicle.
20. Clean the engine right side exhaust manifold sealing surfaces and the cylinder head sealing surfaces. Refer to Exhaust Manifold Clean and
Inspect.
21. If you are REPLACING the engine right side exhaust manifold, remove the Exhaust Gas Recirculation (EGR) valve pipe.
22. If you are REPLACING the engine right side exhaust manifold, remove the Heated Oxygen Sensor (H02S). Refer to Heated Oxygen Sensor
(HO2S) Replacement (HO2S1) or Heated Oxygen Sensor (HO2S) Replacement (HO2S2) in Computers and Controls.

Installation Procedure
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1. If removed, install the Heated Oxygen Sensor (HO2S). Refer to Heated Oxygen Sensor (H02S) Replacement (HO2S1) or Heated Oxygen
Sensor (HO2S) Replacement (H02S2) in Computers and Controls.
2. If removed, install the exhaust gas recirculation (EGR) valve pipe.
3. Raise and support the vehicle. Refer to Vehicle Lifting.
4. Install the exhaust manifold gasket.
5. Install the exhaust manifold.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the exhaust manifold nuts.


^ Tighten the exhaust manifold nuts to 16 Nm (12 ft. lbs.).

7. Install the exhaust manifold lower heat shield.


8. Install the exhaust manifold upper heat shield.
9. Install the exhaust manifold heat shield bolts.
^ Tighten the exhaust manifold heat shield bolts to 10 Nm (89 inch lbs.).
10. Install the catalytic converter. Refer to Catalytic Converter Replacement in Powertrain Management.
11. Lower the vehicle.
12. Install the exhaust crossover pipe nuts/studs to the engine right side exhaust manifold. Refer to Exhaust Crossover Installation.
13. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Installation.
14. Lower the vehicle.
15. Connect the Heated Oxygen Sensor (H02S) electrical connector.
16. Install the EVAP solenoid bracket.
17. Install the spark plug wires to the engine right bank spark plugs.
18. Install the ignition module and the ignition coils with the bracket.
19. Rotate the engine back to the original position. Refer to Rotating the Engine for Service Access.
20. Install the EGR valve to the intake manifold. Refer to EGR Valve Replacement in Computers and Controls.
21. Install the MAP sensor. Refer to MAP Sensor Replacement in Computers and Controls.
22. Install the accelerator cable bracket to the throttle body. Refer to Accelerator Controls Cable Replacement in Computers and Controls.
23. Install the throttle body air inlet duct. Refer to Air Filter Element Replacement in Computers and Controls.
24. Install the windshield wiper motor cover. Refer to Wiper Module Cover Replacement in Wiper and Washer Systems.
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Exhaust Pipe/Muffler Hanger: Service and Repair
Removal Procedure

1. Raise and suitably support the vehicle. Refer to Vehicle Lifting.


2. Remove the muffler hanger insulators from the muffler.
3. Remove the muffler hanger bolts.
4. Remove the muffler hanger.

Installation Procedure

1. Install the muffler hanger.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the muffler hanger bolts.


^ Tighten the muffler hanger bolts to 35 Nm (26 ft. lbs.).
3. Install the muffler hanger insulators to the muffler.
4. Lower the vehicle.
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Heat Shield: Service and Repair
Converter Heat Shield Replacement
Removal Procedure

1. Raise and support the vehicle. Refer to Vehicle Lifting.


2. Remove the catalytic converter. Refer to Catalytic Converter Replacement.
3. Use a drill to remove the catalytic converter heat shield rivets.
4. Remove the catalytic converter heat shield.

Installation Procedure

1. Install the catalytic converter heat shield.


2. Install the catalytic converter heat shield to the vehicle with new rivets.
3. Install the catalytic converter. Refer to Catalytic Converter Replacement.
4. Lower the vehicle.
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Heat Shield: Service and Repair
Exhaust Heat Shield Replacement
Removal Procedure

1. Raise and support the vehicle. Refer to Vehicle Lifting.


2. Remove the exhaust system muffler. Refer to Muffler Replacement
3. Use a drill in order to remove the rivets at the exhaust muffler heat shield.
4. Remove the exhaust muffler heat shield from the vehicle.

Installation Procedure

1. Install the exhaust muffler heat shield to the vehicle with new rivets.
2. Install the exhaust system muffler. Refer to Muffler Replacement.
3. Lower the vehicle.
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Muffler: Service and Repair
Removal Procedure

The muffler is serviced as one piece from the catalytic converter to the tail pipe.

1. Raise and support the vehicle. Refer to Vehicle Lifting.

Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The
vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

2. Use a utility stand in order to support the catalytic converter.


3. Remove the rear axle tie rod. Refer to Tie Rod Replacement in Steering and Suspension.
4. Lower the support and the tie rod.
5. Remove the catalytic converter nuts.
6. Remove the catalytic converter gasket.

7. Remove the exhaust hanger insulators from the exhaust pipes.


8. Remove the muffler and exhaust pipes towards the front of the vehicle and over the rear axle.
9. Clean the catalytic converter flange and the muffler flange.

Installation Procedure
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1. Install the muffler and exhaust pipes over the rear axle and towards the rear of the vehicle.
2. Install the exhaust hanger insulators to the exhaust pipes.
3. Install the rear axle tie rod. Refer to Tie Rod Replacement in Steering and Suspension.

4. Install a new catalytic converter gasket.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the catalytic converter nuts.


^ Tighten the catalytic converter nuts to 34 Nm (25 ft. lbs.).
6. Lower the vehicle.
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Ignition System: Description and Operation

Camshaft Position (CMP) Sensor

The Camshaft Position (CMP) sensor is located on the timing cover behind the water pump near the camshaft sprocket. As the camshaft sprocket
turns, a magnet in the sprocket activates the Hall-effect switch in the CMP sensor. When the Hall-effect switch is activated, the signal line to the
PCM is grounded, pulling the CMP sensor signal circuits applied voltage low. This is interpreted as a CAM signal.

The CAM signal is created as piston #1 is on the intake stroke. If the correct CAM signal is not received by the PCM, DTC P0341 will be set.
Circuits Affecting Ignition Control
In order to properly control ignition timing, the PCM relies on the following information:
^ Engine load (manifold pressure or vacuum)
^ Atmospheric (barometric) pressure
^ Engine temperature
^ Intake air temperature
^ Crankshaft position
^ Engine speed (RPM)

The IC system consists of the following components:


^ Ignition coils
^ IC module
^ 7X CKP sensor
^ 24X CKP sensor
^ PCM
^ All connecting wires

The electronic IC module connector terminals are identified as shown in the Electronic Ignition System graphic. These circuits perform the
following functions:
^ 3X reference high-The 7X crankshaft position sensor sends a signal to the electronic ignition control module which generates a reference
pulse that is sent to the PCM. The PCM uses this signal to calculate crankshaft position and engine speed (also used to trigger the fuel
injectors).
^ 3X reference low-This wire is grounded through the ICM and assures the ground circuit has no voltage drop between the ICM and the PCM.
^ Ignition control bypass-During initial cranking, the PCM will look for synchronizing pulses from the camshaft position sensor and the 7X
crankshaft position sensor. The pulses indicate the position of the #1 piston and the #1 intake valve. Five volts is applied to the bypass circuit
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at precisely the same time these signals are received by the PCM. This generally occurs within one or two revolutions of the crankshaft. An
open or grounded bypass circuit will set a DTC P1351 and the engine will run at base ignition timing. A small amount of spark advance is
built into the ignition control module to enhance performance.
^ Ignition Control (IC)-The PCM uses this circuit to trigger the electronic ignition control module. The PCM uses the crankshaft reference
signal to calculate the amount of spark advance needed.
^ 24X reference signal-The 24X crankshaft position sensor increases idle quality and low speed driveability by providing better resolution at a
calibrated RPM.
Electronic Ignition (EI) System
The Electronic Ignition (EI) system on the 3400 LA1 (VIN E) engine uses a coil pack with one ignition coil for each two cylinders in the engine.
Mounted under the ignition coils on each system is an Ignition Control Module (ICM) that performs ignition coil switching functions and interacts
with the Powertrain Control Module (PCM) to optimize ignition system operation. On these engine systems, the spark timing is controlled
electronically.

The ICM controls the spark timing during engine start-up, and provides a back-up timing system that will allow the engine to run in the event of an
open or ground in the Ignition Control (IC) circuit. Once the engine starts and is running above an approximate engine speed of 400 RPM, the
PCM takes over the spark timing and sends signals to the ICM for ignition coil switching. The electronic ignition systems used on these engines use
a waste spark method of spark distribution.

Each cylinder is paired with its opposing cylinder in the firing order, so that one cylinder on compression fires simultaneously with the opposing
cylinder on exhaust. The spark that occurs in the cylinder that is on the exhaust stroke is referred to as the waste spark. The spark plugs in the two
opposing cylinders are connected to the two secondary terminals of the same ignition coil. The spark voltage appears at the center electrode of one
of the spark plugs and jumps to the side electrode, then passes through the engine to the other spark plug. At the second spark plug, the spark jumps
from the side electrode to the center electrode and completes the series circuit back to the ignition coil.

The high level of energy available from the ignition coil is more than sufficient to fire both plugs simultaneously. Since the waste spark requires
very little of the available voltage to fire, most of the coil output voltage is available to fire the cylinder that is on the compression stroke. Engine
speed (RPM) and cylinder position in the intake-compression-power-exhaust sequence are sensed electronically and are used by the ICM and PCM
to control timing. These parameters are provided by a magnetic Crankshaft Position (CKP) sensor mounted in the engine block. The magnetic CKP
sensor consists of a wire coil wound around a permanent magnet. The sensor is positioned near a reluctor ring on the crankshaft. The reluctor ring
has notches which trigger signals in the magnetic sensor to indicate Crankshaft Position (CKP) and crankshaft speed (RPM). These signals are used
by the ICM during start up, then passed on to the PCM to help determine optimum timing while the engine is running. The PCM also uses other
inputs separate from the ignition system itself, to determine optimum timing.

For a description of the RPO Code(s) shown in this article/images refer to the RPO Code List found at Vehicle/Application ID See: Application and
ID
General Description
The electronic ignition system controls fuel combustion by providing a spark to ignite the compressed air/fuel mixture at the correct time. To
provide optimum engine performance, fuel economy, and control of exhaust emissions, the PCM controls the spark advance of the ignition system.

Electronic ignition has the following advantages over a mechanical distributor system:
^ No moving parts
^ Less maintenance
^ Remote mounting capability
^ No mechanical load on the engine
^ More coil cool down time between firing events
^ Elimination of mechanical timing adjustments
^ Increased available ignition coil saturation time

The electronic ignition system does not use the conventional distributor and coil. The ignition system consists of three ignition coils, an ignition
control module, a Camshaft Position (CMP) sensor, 7X Crankshaft Position (CKP) sensor in the block, a 24X CKP sensor behind the crankshaft
balancer, related connecting wires, and the Ignition Control (IC) and fuel metering portion of the PCM.

Conventional ignition coils have one end of the secondary winding connected to the engine ground. In this ignition system, neither end of the
secondary winding is grounded. Instead, each end of a coil's secondary winding is attached to a spark plug. Each cylinder is paired with the cylinder
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that is on the opposite side (1 and 4, 2 and 5, 3 and 6). These two plugs are on companion cylinders, i.e., on top dead center at the same time.

When the coil discharges, both plugs fire at the same time to complete the series circuit. The cylinder on compression is said to be the event
cylinder and the one on exhaust is the waste cylinder. The cylinder on the exhaust stroke requires very little of the available energy to fire the spark
plug. The remaining energy will be used as required by the cylinder on the compression stroke. The same process is repeated when the cylinders
reverse roles. This method of ignition is called a waste spark ignition system.

Since the polarity of the ignition coil primary and secondary windings is fixed, one spark plug always fires with normal polarity and the companion
plug fires with reverse polarity. This differs from a conventional ignition system that fires all the plugs with the same polarity. Because the ignition
coil requires approximately 30 percent more voltage to fire a spark plug with reverse polarity, the ignition coil design is improved, with saturation
time and primary current flow increased. This redesign of the system allows higher secondary voltage to be available from the ignition coils-more
than 40 kilovolts (40,000 volts) at any engine RPM. The voltage required by each spark plug is determined by the polarity and the cylinder
pressure. The cylinder on compression requires more voltage to fire the spark plug than the one on exhaust.

One spark plug may fire even though a plug wire from the same coil may be disconnected from the companion plug. The disconnected plug wire
acts as one plate of a capacitor, with the engine being the other plate. These two capacitor plates are charged as a spark jumps across the gap of the
connected spark plug. The plates are then discharged as the secondary energy is dissipated in an oscillating current across the gap of the spark plug
that is still connected. Secondary voltage requirements are very high with an open spark plug or spark plug wire. The ignition coil has enough
reserve energy to fire the plug that is still connected at idle, but the coil may not fire the spark plug under high engine load. A more noticeable
misfire may be evident under load, both spark plugs may then be misfiring.
Ignition Coils
Three twin-tower ignition coils are individually mounted to the ignition control module. Each coil provides spark for two plugs simultaneously
(waste spark distribution). Each coil is serviced separately. Two terminals connect each coil pack to the module. Each coil is provided a fused
ignition feed. The other terminal at each coil is individually connected to the module, which will energize one coil at a time by completing and
interrupting the primary circuit ground path to each coil at the proper time.
Ignition Control (IC) Module

The Ignition Control (IC) module performs the following functions:


^ Determines the correct ignition coil firing sequence, based on 7X pulses-This coil sequencing occurs at start-up. After the engine is running,
the module determines the sequence, and continues triggering the ignition coils in proper sequence.
^ Sends the 3X crankshaft reference (fuel control) signal to the PCM-The PCM determines engine RPM from this signal. This signal is also
used by the PCM to determine crankshaft speed for Ignition Control (IC) spark advance calculations.

The 3X reference signal sent to the PCM by the IC module is an on, off pulse occurring 3 times per crankshaft revolution.
Ignition Switch
The mechanical key and lock cylinder switch is located in the steering column on the right-hand side, just below the steering wheel. The electrical
switching portion of the assembly is separate from the key and lock cylinder.
Ignition System
There are important considerations to point out when servicing the ignition system. The following Noteworthy Information will list some of these,
to help the technician in servicing the ignition system.
^ The ignition coils secondary voltage output capabilities are very high - more than 40,000 volts. Avoid body contact with ignition high
voltage secondary components when the engine is running, or personal injury may result.
^ The 7X crankshaft position sensor is the most critical part of the ignition system. If the sensor is damaged so that pulses are not generated, the
engine will not start.
^ Crankshaft position sensor clearance is very important! The sensor must not contact the rotating interrupter ring at any time, or sensor
damage will result. If the balancer interrupter ring is bent, the interrupter ring blades will destroy the sensor.
^ Ignition timing is not adjustable. There are no timing marks on the crankshaft balancer or timing chain cover.
^ If crankshaft position sensor replacement is necessary, the crankshaft balancer must be removed first. The balancer is a press fit onto the
crankshaft. Removing the serpentine accessory drive belt and balancer attaching bolt will allow removal with the special tool J 38197
Balancer Remover. When reinstalled, proper torquing of the balancer attachment bolt is critical to ensure the balancer stays attached to the
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crankshaft.
^ If a crankshaft position sensor assembly is replaced, inspect the crankshaft balancer interrupter ring for any blades being bent. If this is not
inspected closely and a bent blade exists, the new crankshaft position sensor can be destroyed by the bent blade with only one crankshaft
revolution.
^ Neither side of the ignition coil primary or secondary windings is connected to engine ground. Although the ignition coil packs are secured to
the IC module, there is not an electrical connection to ground.
^ Be careful not to damage the secondary ignition wires or boots when servicing the ignition system. Rotate each boot to dislodge the boot
from the plug or coil tower before pulling the boot from either a spark plug or the ignition coil. Never pierce a secondary ignition wire or
boot for any testing purposes! Future problems are guaranteed if pinpoints or test lights are pushed through the insulation for testing.
^ The IC module is grounded to the engine block through 3 mounting studs used to secure the module to the mounting bracket. If servicing is
required, ensure that good electrical contact is made between the module and the mounting bracket, including proper hardware and torque.
^ A conventional tachometer used to check RPM on a primary ignition tach lead will not work on this ignition system. In order to check RPM,
use a Scan Tool.
Modes of Operation
Ignition Control (IC) spark timing is the PCMs method of controlling spark advance and ignition dwell when the ignition system is operating in the
IC Mode. There are two modes of ignition system operation:
^ Bypass Mode
^ IC Mode

In Bypass Mode, the ignition system operates independently of the PCM, with Bypass Mode spark advance always at 10 (BTDC). The PCM has no
control of the ignition system when in this mode. In fact, the PCM could be disconnected from the vehicle and the ignition system would still fire
the spark plugs, as long as the other ignition system components were functioning. (This would provide spark but no fuel injector pulses. The
engine will not start in this situation.) The PCM switches to IC Mode (PCM controlled spark advance) as soon as the engine begins cranking. After
the switch is made to IC Mode, the IC Mode will stay in effect until one of the following conditions occur:
^ The engine is turned off.
^ The engine quits running.
^ A PCM/IC module fault (DTC P1351, P1352, P1361, or P1362) is detected.

If a PCM/IC module fault is detected while the engine is running, the ignition system will switch to Bypass Mode operation. The engine may quit
running, but will restart and stay in Bypass Mode with a noticeable loss of performance.

In the IC Mode, the ignition spark timing and ignition dwell time is fully controlled by the PCM. IC spark advance and ignition dwell is calculated
by the PCM using the following inputs:
^ Engine speed (24X reference or 3X reference)
^ Crankshaft position (24X reference or 3X reference and Camshaft position PCM input signal)
^ Engine Coolant Temperature (ECT) sensor
^ Throttle Position (TP) sensor
^ Knock Signal (Knock Sensor)
^ Park/Neutral Position (PRNDL input)
^ Vehicle Speed (Vehicle Speed Sensor)
^ PCM and ignition system supply voltage

The following describes the PCM to ignition control module circuits:


^ 3X reference PCM input-The Ignition Control Module Generates the 3X reference signal from the 7X CKP Sensor. The IC module sends the
3X reference signal to the PCM. The PCM uses this signal to calculate engine RPM and crankshaft position at speeds above 1600 RPM. If
the PCM receives no pulses on this circuit, the PCM will use the 24X reference pulses to calculate RPM and crankshaft position. The engine
will continue to run and start normally as long as 7X CKP Sensor pulses are being received, but DTC P1374 will be set.
^ 24X reference PCM input-The 24X CKP Sensor generates the 24X reference signal to calculate engine speed and crankshaft position at
engine speeds below 1600 RPM. The 24X reference signal provides better resolution within the calibrated RPM range. This increases idle
quality and low speed driveability. When engine speed exceeds 1600 RPM, the PCM begins using the, 3X reference signal to control spark
timing. If the 24X reference signal is not received by the PCM while the engine is running, a DTC P0336 will be set and 3X reference will be
used to control spark advance under 1600 RPM, and Bypass Mode will be in effect under 400 RPM. The engine will continue to run and
start normally.
^ Reference low PCM input-The reference low circuit establishes a common ground between the ignition control module and the PCM. The
wire is connected to engine ground only through the ignition control module. The circuit minimizes electrical ground differences between the
PCM and the IC module. The PCM uses the reference low circuit to clearly recognize the 3X reference signals. If the circuit is open, or
connected to ground at the PCM, the circuit may cause poor engine performance and possibly a MIL (Service Engine Soon) without a DTC.
^ Knock Sensor (KS) PCM input-The PCM contains integrated knock sensor diagnostic circuitry. The KS system is comprised of the knock
sensor, PCM, and related wiring. The PCM monitors the knock sensor signal to detect engine detonation. When spark knock occurs, the
PCM retards the spark timing (IC) to reduce detonation. Retarded spark timing may also be the result of excessive engine mechanical or
transaxle noise. If a KS signal is found varying within the average voltage a DTC P0327 may set.
^ Bypass signal PCM output-The IC module controls spark timing until the PCM detects a calibrated number of 3X reference pulses (Bypass
Mode). When the PCM receives these pulses, the PCM then provides 5.0 volts to the IC module on the Bypass Circuit. This signals the IC
module to transfer spark timing control the PCM (IC Mode). Proper sequencing of the 3 ignition coils, i.e. which coil to fire, is always the job
of the ignition control module. If the PCM detects a short to voltage on the Bypass circuit DTC P1362 will set. An open in the Bypass Circuit
will set DTC P1352.
^ Ignition Control (IC) PCM output-The PCM sends out timing pulses to the IC module on the IC Circuit. When the ignition system is in the
Bypass mode (the PCM has not sent the 5.0 volt bypass signal), the IC module grounds these pulses. When the IC Mode (the PCM has
supplied the bypass signal), these pulses are sent to the IC module to control ignition spark timing. If the IC circuit is grounded when the
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engine is started, DTC P1361 will set and the ignition system will stay in the Bypass Mode. If the IC circuit becomes open or grounded
during IC Mode operation, DTC P1351 or P1361 may set. When this happens, the engine will quit running but will restart. Upon restart
following an ignition cycle, DTC P1361 will be set, and the ignition system will operate in Bypass Mode.
Powertrain Control Module (PCM)

Powertrain Control Module (PCM)

The PCM is responsible for maintaining proper spark and fuel injection timing for all driving conditions. To provide optimum driveability and
emissions, the PCM monitors input signals from the following components in calculating Ignition Control (IC) spark timing:
^ IC module
^ Engine Coolant Temperature (ECT) sensor
^ Intake Air Temperature (IAT) sensor
^ Mass Air Flow (MAF) sensor
^ Trans Range inputs from Transaxle Range switch
^ Throttle Position (TP) sensor
^ Vehicle Speed Sensor (VSS)

Secondary Ignition Wiring


The spark plug wiring used with ignition systems is a carbon impregnated cord conductor, encased in a 7 mm (9/32 in) or 8 mm (5/16 in) diameter
silicone rubber jacket. The silicone jacket withstands very high temperatures. Silicone spark plug boots form a tight seal on the plug. The boot
should be twisted 1/2 turn before removing. Care should also be used when connecting a timing light or other pick-up equipment. Do not force
anything between the boot and wiring, or through the silicone jacket. Connections should be made in parallel using an adapter. Do not pull on the
wire to remove. Pull on the boot, or use a tool designed for this purpose.
Spark Plugs

Extended Life Spark Plug (Typical)

Resistor type, tapered seat spark plugs are used on all engines. No gasket is used on these tapered seat plugs. When replacing spark plugs, use only
the type specified. Normal service is assumed to be a mixture of idling, slow speed, and high-speed driving. Occasional intermittent high-speed
driving is needed for good spark plug performance. Intermittent high-speed driving gives increased combustion heat, burning away carbon or
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oxides that have built up from frequent idling, or continual stop-and-go driving.

Spark plugs are protected by insulating boots made of special heat-resistant materials, which cover the spark plug terminal and extend downward
over a portion of the plug insulator. These boots prevent flash-over, which causes engine misfiring. Do not mistake corona discharge for flash-over,
or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of a
high-tension field and has no effect on ignition performance. Usually it can be detected only in darkness. This discharge may repel dust particles,
leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown
out between the shell and the insulator.
24X & 7X Crankshaft Position Sensors Interrupter Ring

The 24X crankshaft position (CKP) sensor (1), secured in a mounting bracket (3) and bolted to the front side of the engine timing chain cover (2),
is partially behind the crankshaft balancer.

The 7X CKP sensor uses a two wire connector at the sensor and a three-way connector at the ignition control module.

The 24X CKP sensor contains a Hall-effect switch. The magnet and Hall-effect switch are separated by an air gap. A Hall-effect switch reacts like a
solid stale switch, grounding a low current signal voltage when a magnetic field is present. When the magnetic field is shielded from the switch by
a piece of steel placed in the air gap between the magnet and the switch, the signal voltage is not grounded. If the piece of steel (called an
interrupter) is repeatedly moved in and out of the air gap, the signal voltage will appear to go on-off, on-off, on-off. Compared to a conventional
mechanical distributor, this on-off signal is similar to the signal that a set of breaker points in the distributor would generate as the distributor shaft
turned and the points opened and closed.
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In the case of the electronic ignition system, the piece of steel is a concentric interrupter ring mounted to the rear of the crankshaft balancer. The
interrupter ring has blades and windows that, with crankshaft rotation, either block the magnetic field or allow the field to reach the Hall-effect
switch. The Hall-effect switch is called a 24X CKP sensor, because the interrupter ring has 24 evenly spaced blades and windows. The 24X CKP
sensor produces 24 on-off pulses per crankshaft revolution.

The interrupter ring is a special wheel cast on the crankshaft that has seven machined slots, six of which are equally spaced 60 degrees apart. The
seventh slot is spaced 10 degrees from one of the other slots. As the interrupter ring rotates with the crankshaft, the slots change the magnetic field.
This will cause the 7X to ground the 3X signal voltage that is supplied by the ignition control module. The ignition control module interprets the
7X on-off signals as an indication of crankshaft position. The ignition control module must have the 7X signal to fire the correct ignition coil.

The 7X interrupter ring and Hall-effect switch react similarly. The 24X signal is used for better resolution at a calibrated RPM.
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Ignition System: Initial Inspection and Diagnostic Overview

Checking the Basics


DIAGNOSTIC NOTES
Diagnosing problems in modern automobiles can sometimes be very frustrating and confusing, especially when it involves computer controlled
systems. The fact is, for the most part automotive electronics have been proven quite reliable, and the greatest number of problems with new cars
are the same kinds of problems that older cars without computer controls have.

Before suspecting a computer problem, perform a careful visual inspection. Check under the hood for the same kinds of problems you would
look for on a non-computer controlled engine. These include fluid leaks, vacuum leaks, dirty filters, overheating, oil burning, poor connections
or loose wires, bad spark plug wires and/or spark plugs, restricted mufflers and exhaust systems, worn mechanical parts, exhaust leaks, and other
familiar kinds of problems. Be thorough! You may save a lot of time.

Begin all troubleshooting by Checking the Basics. Certain basic faults may be undetectable by the Powertrain Control Module (PCM)
self-diagnostic system and can actually interfere with self-checking and fault memory operation. Low battery voltage, for example, can cause
erroneous faults to set in PCM memory or can cause a system to go "Fail Safe" without setting a fault in memory. Because system fault memory
is cleared whenever PCM or battery are disconnected, fault codes should be read prior to any vehicle power interruption or troubleshooting. Prior
to any teardown, repair or component replacement, consider the following steps:

COMPLAINT VERIFICATION
Whenever possible, the technicians should personally verify the complaint. Having experienced the malfunction, technicians are less likely to
attempt repairing non-existent faults.

MALFUNCTION VERIFICATION
Sophisticated automotive systems are easily misunderstood. This can lead to repairs that attempt to force a system to perform as it was never
intended. The troubleshooting technician should compare actual system operation to nominal system operation as described in Description and
Operation. The technician is also encouraged to compare problem vehicle system operation with a known good vehicle.

PREVIOUS REPAIRS
Vehicle repair history can provide explanations to unusual complaints which seem to elude normal troubleshooting attempts. Incorrect
components or unapproved repairs can have subtle influences on seemingly unrelated systems.

BATTERY STATE OF CHARGE


Batteries in a state of partial discharge can have a dramatic effect on the PCM and related electrical components.

POSITIVE BATTERY CABLE INTEGRITY


All B+ connections must be in perfect condition for trouble-free electronic system operation.

FUSIBLE LINK INTEGRITY


Fusible links prevent possible damage to electrical components and wiring harnesses. These links and their connections must be without dynamic
resistance. Dynamic resistance can only be checked using the voltage drop method of testing.

NEGATIVE GROUND CONNECTIONS


All B- connections must be checked and verified to be in perfect condition. A poor "common" ground point will cause seemingly unrelated
systems to influence one another. High current systems which encounter a poor "common" ground can back feed through other electrical
systems, causing unusual operation and inexplicable component failure. Electrical system ground side should be checked dynamically using the
voltage drop technique.

POWERTRAIN CABLE ATTACHMENTS


Metal cables attached to engine or transmission which appear overheated and/or discolored indicate the need to thoroughly test all ground
connections.

POWER SUPPLY RELAYS


Fuel pump and main relays, as well as their plug connections, can be a source of intermittent operation which will not set a code in PCM fault
memory.

HIGH TENSION COIL AND SECONDARY COMPONENTS WIRING


Secondary ignition system should be checked visibly as well as with a suitable engine analyzer and scope. Check components for tight
connections and freedom from carbon tracking, moisture and corrosion.

FUEL DELIVERY AND FUEL RAIL PRESSURE


Fuel delivery must begin at once when cranking and pressure in the fuel rails must be within specifications. Fuel pressure must be maintained
between fuel pump outlet and pressure regulator after engine shutdown.

SPARK PLUG CLEARANCE


Spark plug gap, if out of specification, can significantly impair engine performance. Verify spark plug type, condition, and gap according to
specification.

VACUUM AND VAPOR HOSE INTEGRITY


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Vacuum and vapor hoses must be routed correctly and not leaking. Always use the underhood label for primary information.

AIR/FUEL RATIO
Adaptive engine management systems efficiently compensate for conditions which may affect the combustion process. However, when
troubleshooting idle quality or driveability complaints, it is still necessary to consider the following:
- Injector spray pattern quality
- Presence of unmetered air leaks
- Evaporative purge system
- Excessive engine oil dilution
- Substandard fuel or unapproved additives
- Carbon build-up

TESTING EQUIPMENT
High quality testing equipment is essential for accurate results. Faulty equipment results in erroneous test results. Use only suitable test leads,
terminals, and probe tips.

Diagnostic System Check

Diagnostic Chart
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Refer to Engine Controls Schematics. See: Diagrams/Electrical Diagrams

CIRCUIT DESCRIPTION
The Powertrain On Board Diagnostic (OBD) System Check must be the starting point for any driveability complaint diagnosis. Before using this
procedure, you should perform a careful visual/physical inspection of the PCM and engine grounds for being clean and tight. The Powertrain On
Board Diagnostic (OBD) System Check is an organized approach to identifying a problem created by an electronic engine control system
malfunction.

MIL OPERATION
The Malfunction Indicator Lamp (MIL) is located on the instrument panel and is displayed as CHECK ENGINE lamp.

MIL FUNCTION
^ The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service as soon as possible
^ The MIL illuminates during a bulb test and a system test
^ A DTC will be stored if a MIL is requested by the diagnostic

MIL ILLUMINATION
^ The MIL will illuminate with ignition switch ON and the engine not running
^ The MIL will turn OFF when the engine is started
^ The MIL will remain ON if the self-diagnostic system has detected a malfunction
^ The MIL may turn OFF if the malfunction is not present
^ If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the ignition switch is ON.
^ If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is cycled OFF, then ON.

POWERTRAIN ON BOARD DIAGNOSTIC (OBD) SYSTEM CHECK


Perform the Powertrain On Board Diagnostic (OBD) System Check, when the following conditions are present:
^ When the MIL does not turn ON when the ignition switch is turned to the RUN position. See above for MIL Operation
^ When the MIL remains ON while the engine is running
^ When the MIL is flashing while the engine is running
^ When a driveability symptom is determined

DIAGNOSTIC AIDS
An intermittent may be caused by a faulty connection, rubbed through wire insulation, or a wire broken inside the insulation. Inspect for faulty
connections or a damaged harness. Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged
terminals, faulty terminal to wire connection, and damaged harness. Refer to Intermittent Conditions. See: Computers and Control
Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies/Intermittent Conditions

TEST DESCRIPTION
The numbers below refer to the step numbers on the diagnostic table:
1. The MIL should be ON steady with the key ON/ engine OFF. If not, the No Malfunction Indicator Lamp table should be used to isolate the
malfunction.
2. This test ensures that the PCM is capable of transmitting Class II serial data to the DLC and that the Class II data circuit is not open or
shorted. If a problem is encountered and a malfunctioning scan tool is suspected, try the scan tool on another vehicle to verify operation. If a
DLC problem exists, the DLC Diagnosis table should be used to diagnose the condition.
4. If the engine will not start, the Engine Cranks But Will Not Run table should be used to diagnose the condition. See: Computers and Control
Systems/Testing and Inspection/Symptom Related Diagnostic Procedures
5. The scan tool may display DTCs which are diagnosed in Automatic Transaxle Diagnosis. Refer to DTC List for a complete list of DTCs
supported by this vehicle application. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Descriptions

If multiple DTCs are stored, diagnose each DTC according the following priority:
^ PCM Error DTCs
^ System Voltage DTCs
^ Component Level DTCs (switches, sensor range/performance, sensor high voltage, sensor low voltage, ODMs, etc.)
^ System level DTCs (Fuel trim, Misfire, EGR flow, TWC System, Idle Control System, HO2S Response or HO2S Transition Time Ratio)
^ System Reference DTCs
6. A scan tool parameter which is not within the typical range may help to isolate the area which is causing the problem.
Strategy Based Diagnostics
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Strategy Based Diagnosis

The goal of Strategy Based Diagnostics is to provide guidance when you create a plan of action for each specific diagnostic situation. Following a
similar plan for each diagnostic situation, you will achieve maximum efliciency when you diagnose and repair vehicles. Although each of the
Strategy Based Diagnostics boxes is numbered, you are not required to complete every box in order to successfully diagnose a customer concern.
The first step of your diagnostic process should always be, Verify the Customer Concern (box 1). The final step of your diagnostic process should
be, Repair and Verify the Fix (box 7). Refer to the chart for the correct strategy based diagnostics.

(1) Verify the Customer Concern: The first part of this step is to obtain as much information as possible from the customer such as: Are there
aftermarket accessories on the vehicle? When does the condition occur? Where does the condition occur? How long and how often does the
condition occur? In order to verify the concern the technician should know the normal operation of the system and refer to the owner or service
manual for any information needed.

(2) Preliminary Checks: Conduct a thorough visual inspection. Review the service history. Detect unusual sounds or odors. Gather diagnostic
trouble code information in order to achieve an effective repair.

(3) Perform Diagnostic System Checks: One or more DTCs may not support a system. System checks verify the proper operation of the system.
This will lead the technician in an organized approach to diagnostics.

(4) Check Bulletins and Other Service Information: Such as videos, newsletters, and the Pulsat programs.

(5.1) Stored DTCs: Follow the designated DTC table exactly in order to make an effective repair.

(5.2) Symptom No DTC: Select the symptom from the symptom tables. Follow the diagnostic steps or suggestions in order to complete the repair,
or refer to the applicable component system check.

(5.3) No Diagnostics: Analyze the concern. Develop a plan for the diagnostics. Schematics will help you to see system power, ground, input and
output circuits. You can also identify splices and other areas where multiple circuits are tied together. Look at component locations to see if
components, connectors or harnesses may be exposed to extreme temperature, moisture, road salt or other corrosives (battery acid, oil or other
fluids). Utilize the wiring diagrams, system description and operation, and system circuit description.

(5.4) Intermittents: An intermittent condition is one that does not occur continuously and will occur when certain conditions are met. Generally,
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intermittents are caused by: Faulty electrical connections and wiring, malfunctioning components, electromagnetic radio frequency interference,
and aftermarket equipment.. Combine the technician knowledge with efficient use of the available service information. Evaluate the symptoms and
conditions described by the customer. Use a check sheet or other method in order to identify the component. Follow the suggestions for intermittent
diagnosis. The Tech 1, Tech 2 scan tools, and the J39200 (Fluke 87) have data capturing capabilities that can assist in detection of intermittents.

(5.5) Vehicle Operates as Designed: This condition exists when the vehicle is found to operate normally. The condition described by the customer
may be normal. Verify against another like vehicle that is operating normally under the same conditions described by the customer. Explain your
findings and the operation of that system to the customer.

(6) Re-examine the Concern: If a technician cannot successfully find or isolate the concern, a reevaluation is necessary. Re-verify the concern.
The concern could be an intermittent or normal.

(7) Repair and Verify Fix: After isolating the cause, make the repairs and validate for proper operation. Verify that the symptom has been
corrected which may involve road testing the vehicle.
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Ignition System: Component Tests and General Diagnostics

Diagnostic Chart (Part 1 Of 2)


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Diagnostic Chart (Part 2 Of 2)

Refer to Engine Controls Schematics Ignition System, Knock Sensor. See: Diagrams/Electrical Diagrams

CIRCUIT DESCRIPTION
During cranking, the IC Module monitors the 7X CKP sensor input for recognition of the sync signal. The sync signal is used only by the IC
Module for synchronization at start-up to determine the correct cylinder pair to spark. Once the engine speed reaches approximately 600 RPM
the PCM sends 5.0 V to the bypass control circuit at the IC Control Module causing the IC control circuit to become ungrounded allowing the
24X signal to be used for better low engine speed performance. At higher engine speeds (1650+) the PCM uses the 3X reference pulses to
control ignition timing because a higher resolution signal is not needed.

Conventional ignition coils have one end of the secondary winding connected to the engine ground. In this ignition system, neither end of the
secondary winding is grounded. Instead, each end of a coil's secondary winding is attached to a spark plug. Each cylinder is paired with the
cylinder that is opposite it (1-4, 2-5, 3-6). These two plugs are on companion cylinders, i.e., on top dead center at the same time. When the coil
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discharges, both plugs fire at the same time to complete the series circuit. The cylinder on compression is said to be the event cylinder and the
one on exhaust is the waste cylinder. The cylinder on the exhaust stroke requires very little of the available energy to fire the spark plug. The
remaining energy will be used as required by the cylinder on the compression stroke. The same process is repeated when the cylinders reverse
roles. This method of ignition is called a waste spark ignition system.

This table assumes there are no Ignition System, Fuel Injector, Cam Sensor, or Crank Sensor DTC's present. The Electronic Ignition System
Check tests for faulty ignition coils, spark plugs, plug wires, the 7X Crank Sensor, and IC Module. This table requires the J 26792 Spark Tester.

DIAGNOSTIC AIDS
Inspect for the following conditions:

IMPORTANT: Remove any debris from the connector surfaces before servicing a component. Inspect the connector gaskets when diagnosing
or replacing a component. Ensure that the gaskets are installed correctly. The gaskets prevent contaminate intrusion.

- Poor terminal connection-Inspect the harness connectors for backed out terminals, improper mating, broken locks, improperly formed or
damaged terminals, and faulty terminal to wire connection. Use a corresponding mating terminal to test for proper tension. Refer to
Diagrams.
- Damaged harness-Inspect the wiring harness for damage. If the harness inspection does not reveal a problem, observe the display on the scan
tool while moving connectors and wiring harnesses related to the sensor. A change in the scan tool display may indicate the location of the
fault. Refer to Diagrams.
- PCM and engine grounds for clean and secure connections

If the DTC is determined to be intermittent, reviewing the Failure Records can be useful in determining when the DTC was last set.

TEST DESCRIPTION
Numbers below refer to the step numbers on the Diagnostic Table:
2. It is necessary to disconnect the 24X Crank Sensor to ensure that the 7X signal is being read in the 3X reference parameter on the scan tool.
3. The J 26792 spark tester presents a more difficult load on the secondary ignition than a normal spark plug. If a miss, stumble, or hesitation is
being caused by a spark plug not firing, the spark tester should also not fire.
4. Use a 5% saltwater solution in a spray bottle to induce voltage arching to ground through faulty insulation of spark plug wires.
6. If the no spark condition follows the suspected coil, that coil is faulty. Otherwise, the ignition module is the cause of no spark. This test could
also be performed by substituting a known good coil for the one causing the no spark condition.
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Number One Cylinder: Locations
NUMBER 1 CYLINDER

For ignition system firing order, See: Firing Order/Specifications

See: Ignition Cable


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Timing Marks and Indicators: Locations
Crankshaft Rotation

Crankshaft Rotation (Typical Crankshaft Pulley)

CRANKSHAFT ROTATION
Crankshaft rotation is clockwise when viewed from in front of the crankshaft pulley as shown in the "Typical Rotation" image.
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Camshaft Position Sensor: Service and Repair

REMOVAL PROCEDURE
1. Turn OFF the ignition.
2. Remove the serpentine drive belt.
3. Disconnect the sensor electrical connector.
4. Remove the attaching bolt.
5. Remove the sensor.
6. Inspect the sensor for wear, cracks or leakage if the sensor is not being replaced.

INSTALLATION PROCEDURE
1. Lubricate the O-ring with clean engine oil. Replace the O-ring if the O-ring is damaged.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the camshaft position sensor.

Tighten
Tighten the retaining bolt to 10 N.m (8 lb ft).

3. Connect the sensor electrical connector.


4. Reinstall the serpentine drive belt.
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Crankshaft Position Sensor: Service and Repair
CKP System Variation Learn Procedure
The crankshaft position system variation compensating values are stored in the PCM non-volatile memory after a learn procedure has been
performed. If the actual crankshaft position system variation is not within the crankshaft position system variation compensating values stored in
the PCM, DTC P0300 may set. Refer to Diagnostic Aids for DTC P0300.

The Crankshaft Position System Variation Learn Procedure should be performed if any of the following conditions are true:
^ DTC P1336 is set.
^ The PCM has been replaced.
^ The engine has been replaced.
^ The crankshaft has been replaced.
^ The crankshaft harmonic balancer has been replaced.
^ The crankshaft position sensor has been replaced.

IMPORTANT: The scan tool crankshaft position system variation learn function will be inhibited if engine coolant temperature is less than 70°C
(158°F). Allow the engine to warm to at least 70°C (158°F) before attempting the crankshaft position system variation learn procedure.

The scan tool crankshaft position system variation learn function will be inhibited if any Powertrain DTCs other than DTC P1336 are set before or
during the crankshaft position system variation learn procedure. Diagnose and repair any DTCs if set. Refer to applicable DTCs.

The crankshaft position system variation learn function will be inhibited if the PCM detects a malfunction involving the camshaft position signal
circuit, the 3X reference circuit, or the 24X reference circuit. If a malfunction has been indicated, refer to the following list to diagnoses the system
or sensor.
^ DTC P0336 Crankshaft Position (CKP) Sensor Performance.
^ DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation.
^ DTC P0341 Camshaft Position (CMP) Sensor Performance.

The scan tool crankshaft position system variation learn function will not be enabled until engine coolant temperature reaches 70°C (158°F)

Selecting the crankshaft position system variation learn procedure on the scan tool will command the PCM to enable CKP system variation learn
fuel cutoff and allow the crankshaft position system variation compensating values to be stored in the PCM. The PCM must detect an engine speed
of 5150 RPM (CKP system variation learn fuel cutoff) during the crankshaft position system variation learn procedure to store the crankshaft
position system variation compensating values and complete the procedure.

IMPORTANT: Set the vehicle parking brake and block the drive wheels when performing the Crankshaft Position System Variation Learning
Procedure in order to prevent personal injury. Release the throttle when the engine reaches the second fuel cut off. Leaving the throttle open during
the fuel cut off will allow the engine to decel at an even rate. Once the learn procedure is completed, the PCM will return the engine control to the
operator and the engine will respond to the throttle position.

1. Set the parking brake.


2. Block the drive wheels.
3. Ensure the hood is closed.
4. Start the engine and allow engine coolant temperature to reach at least 70°C (158°F).
5. Turn off the ignition switch.
6. Select and enable the crankshaft position variation learn procedure with the scan tool.
7. Start the vehicle.
8. Apply and hold the service brake pedal firmly.
9. Ensure the transaxle is in park.
10. Increase accelerator pedal position until the fuel cutoff is reached at 5150 RPM. Release the accelerator pedal after the second fuel cutoff has
been reached.
11. The crankshaft position system variation compensating values are learned when the RPM decreases back to idle. If the procedure terminates.
12. Observe DIG status for DIG P1336.
13. If the scan tool indicates that DIG P1336 ran and passed, the crankshaft position system variation learn procedure is complete. If the scan tool
indicates DTC P1336 failed or not run, determine if other DTCs have set. If DTCs other than P1336 are not set, repeat the crankshaft position
system variation learn procedure as necessary.
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Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor Replacement (7X)

REMOVAL PROCEDURE
1. Turn OFF the ignition switch.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Disconnect the sensor electrical connector.
4. Remove the attaching bolt/screw.
5. Remove the sensor from the engine.
6. Inspect for wear, cracks, or leakage if the sensor is not being replaced.

INSTALLATION PROCEDURE
1. Lubricate the O-ring with clean engine oil before installation. Replace the O-ring if the O-ring is damaged.
2. Install the sensor to the block.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Reinstall the sensor attaching Bolt.

Tighten
Tighten the bolt to 8 N.m (71 lb in).

4. Connect the sensor electrical connector.


5. Lower the vehicle.
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Crankshaft Position Sensor: Service and Repair
Crankshaft Position (CKP) Sensor Replacement (24X)

REMOVAL PROCEDURE
1. Turn OFF the ignition.
2. Remove the serpentine drive belt from the crankshaft pulley.
3. Raise the vehicle on hoist. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the right front Tire and Wheel assembly.
5. Remove the right front engine splash shield.
6. Remove the crankshaft harmonic balancer.
7. Note the routing of sensor harness before removal.
8. Remove the harness retaining clip with bolt (1).
9. Disconnect the sensor electrical connector.
10. Remove the sensor bolts (2).
11. Remove the sensor.

INSTALLATION PROCEDURE
1. Install the 24X crankshaft position sensor with the bolts (2) and route the harness as noted during removal.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the harness retaining clip with the bolt (1).

Tighten
Tighten the bolts to 10 N.m (8 lb ft).

3. Connect the sensor electrical connector.


4. Reinstall the balancer on the crankshaft. Refer to Harmonic BalancerInstallation in Engine.
5. Lower the vehicle.
6. Reinstall the serpentine drive belt.
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Ignition Cable: Service and Repair
REMOVAL PROCEDURE

1. Turn the ignition OFF.

NOTE: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug
wire or the wire could be damaged.

2. Remove the spark plug wire(s) (2, 4 and 6) from the engine left side spark plug(s).
3. Remove the spark plug wire(s) from the retaining clips.
4. Rotate the engine forward. Refer to Rotating the Engine for Service Access in Engine.

5. Remove the spark plug wire(s) (1, 3 and 5) from the engine right side spark plug(s).
6. Remove the spark plug wire(s) from the retaining clips.

7. Remove the spark plug wire(s) from the ignition coil(s).


8. Remove the spark plug wire(s) from the engine.
9. If you are replacing the spark plug wires, transfer any of the following components:
^ Boot heat shields
^ Spark plug wire conduit
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^ Spark plug wire retaining clips

INSTALLATION PROCEDURE

1. Install the spark plug wire(s) to the engine.


2. Install the spark plug wire(s) to the ignition coil(s).

3. Install the spark plug wire(s) (1, 3 and 5) to the engine right side spark plug(s).
4. Install the spark plug wire(s) to the retaining clips.
5. Return the engine to the proper position. Refer to Rotating the Engine for Service Access in Engine.

6. Install the spark plug wire(s) (2, 4 and 6) to the engine left side spark plug(s).
7. Install the spark plug wire(s) to the retaining clips.
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Ignition Coil: Service and Repair

REMOVAL PROCEDURE
1. Disconnect the spark plug wires. Note the position from which the wires are removed.
2. Remove the 2 screws securing the ignition coil to the ignition control module.
3. Remove the ignition coil.

INSTALLATION PROCEDURE
1. Install the ignition coil.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Reinstall the 2 attaching screws.

Tighten
Tighten the screws to 4-5 N.m (40 lb in).

3. Reconnect the spark plug wires.


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Ignition Control Module: Service and Repair

REMOVAL PROCEDURE
1. Disconnect all the electrical connectors at the ignition control module.
2. Note position of spark plug wires for installation and disconnect the spark plug wires from ignition coils.
3. Remove the screws securing coil assemblies to ignition control module.
4. Disconnect the coils from ignition control module.
5. Remove the fasteners securing ignition control module assembly to engine.
6. Remove the ignition control module from the bracket.

INSTALLATION PROCEDURE
1. Install the ignition control module on the bracket.
2. Install the coils to ignition control module.
3. Reinstall the fasteners securing ignition control module assembly to engine.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Reinstall the screws.

Tighten
Tighten the screws to 4-5 N.m (40 lb in).

5. Connect the spark plug wires as noted during removal.


6. Connect the electrical connectors to the ignition control module.
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Knock Sensor: Service and Repair
REMOVAL PROCEDURE

1. Turn OFF the ignition.


2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
3. Disconnect the wiring harness connector from the knock sensor.
4. Remove the knock sensor from the engine block.

INSTALLATION PROCEDURE

IMPORTANT: DO NOT apply thread sealant to the sensor threads. The sensor threads are coated at the factory and applying additional sealant
affects the sensor's ability to detect detonation.

1. Install the knock sensor into engine block.

Tighten
19 N.m (14 lb ft).

2. Connect the knock sensor wiring harness connector to the knock sensor.
3. Lower the vehicle.
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Steering Column: Service and Repair

Tilt Head Housing - Assemble


Assembly Procedure

- Tools Required
- J23653-SIR Lock Plate Compressor

1. Align the race and upper shaft assembly (1) to the 12 o'clock position.
2. Put the lock cylinder in the LOCK position and remove the key.

3. Install the inner race (5).


4. Install the upper bearing inner race seat (4).
5. Install the upper bearing spring (3).
6. Lubricate the turn signal cancel cam assembly (2) using grease kit 26001884.
7. Install the turn signal cancel cam assembly (2).
8. Install the shaft lock shield assembly (1).

9. Install the bearing retaining using J 23653-SIR.


10. Remove J23653-SIR from the steering column.
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11. Install the wave washer.


12. Install the SIR coil assembly. Refer to Inflatable Restraint
Steering Wheel Module Coil - Assemble - Off Vehicle.

Tilt Head Housing - Disassemble


Disassembly Procedure

- Tools Required
- J23653-SIR Lock Plate Compressor

1. Remove the SIR coil assembly. Refer to Inflatable Restraint Steering Wheel Module Coil -Disassemble - Off Vehicle.

2. Remove the wave washer.

3. Remove the bearing retainer using J 23653-SIR and dispose of it.


4. Remove J 23653-SIR from the steering column.
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5. Remove the shaft lock shield assembly (1).


6. Remove the turn signal cancel cam assembly (2).
7. Remove the upper bearing spring (3).
8. Remove the upper bearing inner race (4).
9. Remove the inner race (5).

Tilt Lever
Removal Procedure

Pull the tilt lever in order to remove the tilt lever from the steering column.

Installation Procedure

Push the tilt lever onto the tilt lever shaft in order to install the tilt lever.

Tilt Spring - Assemble


Assembly Procedure
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1. Install the spring guide (1) to the tilt spring (2). Lubricate the spring guide with lithium grease.

Caution: The tilt spring and the spring guide are under pressure and could become and projectile. During the disassembly and
assembly procedures, secure the tilt spring with locking pliers. Exercise caution when removing or installing the tilt spring and the
spring guide, as bodily injury may result.

2. Install the tilt spring (1).


2.1. Install the tilt spring (1) to the post on the steering column support assembly (2).
2.2. Secure the tilt spring (1) with locking pliers.
3. Install the upper and lower shrouds. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
Tilt Spring - Disassemble
Disassembly Procedure
1. Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble -
Off Vehicle.

2. Use the tilt lever to tilt the column in the "UP" position.

Caution: The spring and the spring guide are under pressure and could become a projectile. During the disassembly and assembly
procedures, secure the tilt spring with locking pliers. Exercise caution when removing or installing the tilt spring and the spring
guide, as bodily injury may result.
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3. Remove the tilt spring (1).


3.1. Pry the tilt spring up until a bulge occurs and most of the tilt spring tension is removed.
3.2. Secure the tilt spring with locking pliers and continue prying until the tilt spring disengages from the post of the steering column support
assembly (3).

4. Remove the spring guide (1) from the tilt spring (2).

A/T Shift Lock Control - Assemble


Assembly Procedure

1. Install the electrical BTSI actuator.


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2. Adjust the electrical BTSI actuator.


2.1. Pull the tab (1) out on the block side (2) of the electrical BTSI actuator.
2.2. Shift the column into the neutral position.
2.3. Press on the adjuster block (2) to compress the internal adjuster spring to disengage the adjuster teeth. Slide the adjuster block as far
away from the solenoid as possible.
2.4. Shift the column into the park position.
2.5. Lock in place by pushing the tab (1) back in.
3. Inspect the electrical BTSI actuator.
3.1. The electrical BTSI actuator must lock the gear shift lever when it is put into the park position.
3.2. When the column is installed in the vehicle you will not be able to shift the gear shift lever out of the park position without pressing on
the brake pedal. The solenoid will be energized.
3.3. Readjust if needed.
4. Install the upper and lower shrouds. Refer to Steering Column Trim Covers - Assemble -Off Vehicle.

A/T Shift Lock Control - Disassemble


Disassembly Procedure
1. Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble -Off Vehicle.

2. Use a screwdriver to pry the electrical BTSI actuator from the steering column jacket assembly.
3. Remove the electrical BTSI actuator from the steering column.

A/T Shift Lock Control Actuator


Removal Procedure
1. Turn the ignition OFF.
2. Remove the lower steering column shroud. Refer to Steering Column Trim Covers - Disassemble -Off Vehicle.
3. Remove the shift lock control from the steering column. Refer to Automatic Transmission Shift Lock Control - Disassemble - Off Vehicle.

Installation Procedure
1. Install the shift lock control to the steering column. Refer to Automatic Transmission Shift Lock Control - Assemble - Off Vehicle.
2. Remove the lower steering column shroud. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
Electronic Column Lock Module
Removal Procedure

Caution: Refer to SIR Handling Caution in Service Precautions.

1. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
2. Remove the tilt lever. Refer to Tilt Lever Replacement - On Vehicle.
3. Remove the steering wheel. Refer to Steering Wheel Replacement.
4. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement - On Vehicle (Unable to Rotate Cylinder).
5. Remove the steering column trim covers. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.
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6. Remove the lock module assembly. Refer to Electronic Column Lock Module - Disassemble - Off Vehicle.

Installation Procedure
1. Install the lock module assembly. Refer to Electronic Column Lock Module - Assemble - Off Vehicle.
2. Install the steering column trim covers. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
3. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement - On Vehicle (Unable to Rotate Cylinder).
4. Install the steering wheel. Refer to Steering Wheel Replacement.
5. Install the tilt lever. Refer to Tilt Lever Replacement - On Vehicle.
6. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.

Electronic Column Lock Module - Assemble


Assembly Procedure
1. Install the lock module assembly (1).

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the 3 pan head tapping screws (2) into the lock module assembly.
Tighten the screws to 1.5 Nm (13 inch lbs.).

3. Install the park lock cable assembly (1) into the lock module assembly.
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4. Install the ignition and key alarm switch assembly (3) onto the lock module assembly (2) and secure by using 2 tapping screws.
- Tighten the screws to 4.7 Nm (42 inch lbs.).

5. Slide the PASSKEY 111 (2) onto the lock module assembly (1).
6. Install the steering column tilt head assembly. Refer to Steering Column Tilt Head Housing - Assemble - Off Vehicle.

Electronic Column Lock Module - Disassemble


Disassembly Procedure
1. Remove the steering column tilt head assembly. Refer to Steering Column Tilt Head Housing -Disassemble - Off Vehicle.

2. Slide the PASSKEY 111 (2) off of the lock module assembly (1).
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3. Remove the key alarm connector (1) from the lock module assembly (2).
4. Remove the 2 tapping screws from the ignition key alarm switch assembly (3).
5. Let both parts hang freely.

6. Remove the park lock cable assembly (1) from the lock module assembly.

7. Remove 3 pan head tapping screws (2) from the lock module assembly (1).
8. Remove the lock module assembly (1).

Ignition & Key Alarm Switch - Assemble


Assembly Procedure

Notice: Refer to Fastener Notice in Service Precautions.


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1. Install the ignition and key alarm switch assembly (3) onto the lock module assembly (2) and secure by using 2 tapping screws.
- Tighten the screws to 4.7 Nm (42 inch lbs.).
2. Install the key alarm connector (1) into the lock module assembly (2).

3. Slide the PASS KEY III (2) onto the lock module assembly (1).

4. Slide the turn signal switch assembly connectors (2) to the bulkhead connector (1).
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5. Install the wire harness assembly (4) into the wire harness strap (5).
6. Install the wire harness strap (2) into the steering column tilt head assembly (1).
7. Install the wire harness straps (3) onto the wire harness assembly (4).
8. Install the upper and lower shrouds. Refer to Steering Column Trim Covers - Assemble -Off Vehicle.

Ignition & Key Alarm Switch - Disassemble


Disassembly Procedure
1. Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.

2. Remove the wire harness assembly (4) from the wire harness strap (5).
3. Remove the wire harness straps (3) from the wire harness assembly (4).
4. Remove 1 wire harness strap (2) from the upper tilt head assembly (1).

5. Slide the turn signal switch assembly connectors (2) out from the bulk head connector (1).
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6. Pull the PASS KEY III (2) off of the lock module assembly (1).

7. Remove the key alarm connector (1) from the lock module assembly (2).
8. Remove the 2 tapping screws from the ignition key alarm switch assembly (3).
Ignition Lock Cylinder - Rotates
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.

Caution: Refer to SIR Handling Caution in Service Precautions.

2. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
3. Remove the inflator module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts.
4. Remove the steering wheel. Refer to Steering Wheel Replacement.
5. Remove the tilt lever.
6. Remove ONLY the steering column LOWER shroud. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.
7. Remove the steering column upper shroud FASTENERS ONLY.

8. Lift the upper steering column shroud in order to gain access to the lock cylinder access hole (1).
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9. Insert the bent tip awl into the ignition lock cylinder access hole (1).

10. Turn the ignition lock cylinder to START.

11. Use the bent tip awl in order to push down on the ignition lock cylinder retainer.
12. Release the ignition lock cylinder to RUN.

13. Remove the ignition lock cylinder from the lock module.

Installation Procedure
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1. Insert the ignition lock cylinder through the upper shroud.


2. Align the lock cylinder retaining tab and the position tab with the slots in the lock housing.
3. Push the lock cylinder into the lock housing completely.
4. Install the steering column upper shroud. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
5. Install the lower shroud. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
6. Install the tilt wheel lever.
7. Install the steering wheel. Refer to Steering Wheel Replacement
8. Install the inflator module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts.
9. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.
10. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.

Ignition Lock Cylinder - Unable to Rotate Cylinder


Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.

Caution: Refer to SIR Handling Caution in Service Precautions.

2. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
3. Remove the inflator module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts.
4. Remove the steering wheel. Refer to Steering Wheel Replacement.
5. Remove the tilt lever.
6. Remove ONLY the steering column LOWER shroud. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.
7. Remove the SIR coil. Refer to Inflatable Restraint Steering Wheel Module Coil Replacement in Air Bags and Seat Belts.
8. Remove the shaft lock shield and the turn signal cancel cam. Refer to Steering Column Tilt Head Housing - Disassemble - Off Vehicle
Steering Column Tilt Head Disassemble.
9. Remove the steering column upper shroud FASTENERS ONLY.
10. Remove the park lock cable from the lock module.

Important: The lock bolt has spring tension from the lock bolt spring. Hold the lock bolt while you remove the lock module.

11. Remove the lock module with the ignition switch, the theft deterrent module and the steering column upper shroud. Refer to Electronic
Column Lock Module - Disassemble - Off Vehicle.
12. Remove the lock module rear cover in order to gain access to the lock module sector gears.

Important: Make a mark (1) on both of the lock module sector gears in order to ensure proper sector gear timing after the lock module is
assembled.

13. Remove the lock module sector gears.


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14. Use a small burring tool in order to carefully remove the lock cylinder position tab.
15. Use a small flat-bladed tool in order to press and hold the lock cylinder retainer (1).
16. Remove the lock cylinder from the lock module.
17. Remove all of the metal shavings from the lock module.

18. Record the lock cylinder four-character key code (1) on the lock cylinder.
19. Cut a new key according to the four-character lock cylinder key code. Refer to Key and Lock Cylinder Coding.
20. Ensure that the new ignition key operates in all of the vehicle lock cylinders.
21. Code the NEW ignition lock cylinder according to the four-character lock cylinder key code. Refer to Key and Lock Cylinder Coding.

Installation Procedure

1. Align the marks (1) on the lock module sector gears and install the sector gears.
2. Ensure that the lock module is in the OFF/LOCK position.
3. Insert the ignition key into the NEW ignition lock cylinder.
4. Align the lock cylinder retaining tab and the position tab with the slots in the lock housing.
5. Push the lock cylinder into the lock housing completely.
6. Rotate the lock cylinder to ACC.
7. Ensure that the sector gear arrows point toward each other. If the sector gear arrows do not point toward each other, remove the sector gears
and install the sector gears properly.
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8. Install lock module rear cover.
9. Push the lock bolt completely into the into the tilt head and hold the lock bolt.
10. Install the lock module with the ignition switch, the theft deterrent module and the steering column upper shroud. Refer to Electronic Column
Lock Module - Assemble - Off Vehicle.
11. Install the park lock cable to the lock module.
12. Adjust the park lock cable.
13. Install the steering column lower shroud. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
14. Install the turn signal cancel cam and the shaft lock shield. Refer to Steering Column Tilt Head Housing - Assemble - Off Vehicle.
15. Install the SIR coil. Refer to Inflatable Restraint Steering Wheel Module Coil Replacement in Air Bags and Seat Belts.
16. Install the steering wheel. Refer to Steering Wheel Replacement.
17. Install the inflator module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts.
18. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.
19. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
Ignition Switch
Removal Procedure

Caution: Refer to SIR Handling Caution in Service Precautions.

1. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
2. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and
Charging.
3. Remove the left side closeout insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Wiring
Indicators.
4. Disconnect the steering column electrical connector from the vehicle.
5. Remove the steering column shrouds. Refer to Steering Column Trim Covers - Disassemble -Off Vehicle.
6. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement - On Vehicle (Unable to Rotate Cylinder).
7. Remove the ignition switch. Refer to Ignition and Key Alarm Switch Assembly - Disassemble - Off Vehicle.

Installation Procedure

1. Install the ignition switch. Refer to Ignition and Key Alarm Switch Assembly - Assemble - Off Vehicle.
2. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement - On Vehicle (Unable to Rotate Cylinder).
3. Install the steering column shrouds. Refer to Steering Column Trim Covers - Assemble -Off Vehicle.
4. Connect the steering column electrical connector to the vehicle.
5. Install the left side closeout insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Wiring
Indicators.
6. Connect the battery negative cable to the battery. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
7. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.
Linear Shift
Removal Procedure

Caution: Refer to SIR Handling Caution in Service Precautions.

1. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
2. Remove the tilt lever. Refer to Tilt Lever Replacement - On Vehicle.
3. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement -On Vehicle (Unable to Rotate Cylinder).
4. Remove the steering column trim covers. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.
5. Remove the linear shift assembly. Refer to Linear Shift Assembly - Disassemble - Off Vehicle.

Installation Procedure
1. Install the linear shift assembly. Refer to Linear Shift Assembly - Assemble - Off Vehicle.
2. Install the steering column trim covers. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
3. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement - On Vehicle (Unable to Rotate Cylinder).
4. Install the tilt lever. Refer to Tilt Lever Replacement - On Vehicle.
5. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.

Linear Shift - Assemble


Assembly Procedure

Notice: Refer to Fastener Notice in Service Precautions.

Important: Lubricate all moving parts of the linear shift assembly with synthetic grease.
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1. Install the gearshift lever assembly support bracket and secure by using the 3 flat head 6-lobed socket tap screws.
- Tighten the screws to 10 Nm (89 inch lbs.).

2. Insert the cam bushing (2) into the cable shift cam assembly (1).
3. Install the cable shift cam assembly (1).
4. Install the hexagon flange head bolt.
- Tighten the screw to 18 Nm (14 ft. lbs.).

5. Install the park lock cable assembly and secure by using 2 oval head 6-lobed socket tap screws.
- Tighten the screws to 6.5 Nm (58 inch lbs.).
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6. Install the shift [ever clevis (1).


7. Install the ball actuator assembly (2).
8. Install the hexagon flanged head bolt.
- Tighten the bolt to 18 Nm (14 ft. lbs.).

9. Install the park lock cable assembly into the lock module assembly (1).
10. Place steering column lock cylinder set into the off position.
11. Place the shift lever clevis into the park position.
12. Press the locking tab on the end of the park lock cable assembly (1) into the slot in the lock module assembly.
13. Inspect the park lock cable assembly by performing the following steps.
13.1. Insert the key into the ignition switch.
13.2. Place the steering column lock cylinder set in the OFF or the LOCK position. The gear shift lever must remain locked in the park
position.
13.3. Place the steering column lock cylinder set in the RUN position.
13.4. Place the gear shift lever in the neutral position.
13.5. With the gear shift lever in the neutral position, the steering column lock cylinder set must remain out of the OFF or the LOCK
position.
13.6. Place the gear shift lever in the park position.
13.7. Put the steering column lock cylinder set in the OFF or the LOCK position.
13.8. Remove the key from the ignition switch.
14. Install the electrical BTSI actuator assembly. Refer to Automatic Transmission Shift Lock Control-Assemble - Off Vehicle.
Linear Shift - Disassemble
Disassembly Procedure
1. Remove the electrical BTSI actuator assembly. Refer to Automatic Transmission Shift Lock Control - Disassemble - Off Vehicle.
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2. Remove the park lock cable assembly (1) from the lock module assembly.

3. Remove the hexagon flanged head bolt.


4. Remove the ball and actuator assembly (2).
5. Remove the shift lever clevis (1).

6. Remove the 2 oval head 6-lobed socket tapping screws from the shift gate.

7. Remove the hexagon flange head bolt.


8. Remove the cable shift cam assembly (1).
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9. Remove the cam bushing (2) from the cable shift cam assembly (1).

10. Remove 3 flat head 6-lobed socket tapping screws.


11. Remove the gearshift lever assembly support bracket.

Lower/Upper Intermediate Steering Shaft


Removal Procedure
1. Remove the instrument panel left side insulator. Refer to Closeout/Insulator Panel Replacement -Left in Instrument Panel, Gauges and
Wiring Indicators.
2. Pull the intermediate steering shaft seal down off of the steering column in order to access the intermediate steering shaft upper bolt.
3. Remove the intermediate steering shaft upper bolt.
4. Push the intermediate steering shaft down in order to remove the intermediate steering shaft from the steering column. If you are unable to
remove the intermediate shaft, perform the following steps:
4.1. Insert the tip of a large flat-bladed tool into the intermediate steering shaft end slot.
4.2. Twist the large flat-bladed tool in order to loosen the intermediate steering shaft.
5. Raise and support the vehicle. Refer to Vehicle Lifting
6. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment.
7. Apply silicone (non petroleum based) lubricant to the intermediate shaft lower seal.
8. Push the intermediate shaft lower seal up into the intermediate shaft upper seal in order to access to the intermediate shaft lower bolt.
9. Remove the intermediate shaft lower bolt.

10. Push the intermediate steering shaft (1) up in order to remove the intermediate steering shaft from the steering gear (2). If you are unable to
remove the intermediate shaft, perform the following steps:
10.1. Insert the tip of a large flat-bladed tool into the intermediate steering shaft end slot.
10.2. Twist the large flat-bladed tool in order to loosen the intermediate steering shaft.
11. Remove the intermediate steering shaft.

Installation Procedure
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1. Install the intermediate steering shaft through the intermediate steering shaft seal.
2. Install the intermediate steering shaft to the steering gear.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the intermediate steering shaft lower bolt.


- Tighten the intermediate steering shaft lower bolt to 48 Nm (35 ft. lbs.).
4. Install the intermediate steering shaft seal to the steering gear.
5. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment.
6. Lower the vehicle.
7. Install the intermediate steering shaft to the steering column.
8. Install the intermediate steering shaft upper bolt.
- Tighten the intermediate steering shaft upper bolt to 48 Nm (35 ft. lbs.).
9. Install the intermediate steering shaft seal to the steering column.
10. Install the instrument panel left side insulator. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Wiring
Indicators.

Multifunction, Turn Signal & Hazard Switch


Removal Procedure
1. Remove the HEADLAMP circuit breaker.

Caution: Refer to SIR Handling Caution in Service Precautions.

2. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
3. Remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and
Seat Belts.
4. Remove the steering wheel. Refer to Steering Wheel Replacement.
5. Remove the steering column shrouds. Refer to Steering Column Trim Covers - Disassemble -Off Vehicle.
6. Disconnect the steering column electrical connectors.
7. Remove the turn signal multifunction switch connectors from the steering column electrical connector.
8. Remove the turn signal multifunction switch. Refer to Turn Signal and Multifunction Switch Assembly - Disassemble - Off Vehicle.

Installation Procedure
1. Install the turn signal multifunction switch. Refer to Turn Signal and Multifunction Switch Assembly - Assemble - Off Vehicle.
2. Install the turn signal multifunction switch connectors to the steering column electrical connector.
3. Connect the steering column electrical connectors.
4. Install the steering column shrouds. Refer to Steering Column Trim Covers - Assemble -Off Vehicle.
5. Install the steering wheel. Refer to Steering Wheel Replacement.
6. Install the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat
Belts.
7. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.
8. Install the HEADLAMP circuit breaker.
Shift Lever
Removal Procedure
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1. Roll back the automatic transmission range selector lever seal.


2. Remove the automatic transmission range selector lever screw.
3. Remove the automatic transmission range selector lever.

Installation Procedure
1. Install the automatic transmission range selector lever.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the automatic transmission range selector lever screw.


- Tighten the automatic transmission range selector lever screw to 20 Nm (14 ft. lbs.).
3. Install the automatic transmission range selector lever seal.
4. Verify that there is a positive shift gate feel in all positions.
Shift Lever - Assemble
Assembly Procedure

1. Install the shift lever seal (2) onto the shift lever assembly (4).

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the shift lever assembly (4) into the linear shift assembly and secure it with a shift lever screw (3).
- Tighten the screw to 20 Nm (27 ft. lbs.).
3. Install the upper and lower shrouds. Refer to Steering Column Trim Covers - Assemble -Off Vehicle.
Shift Lever - Disassemble
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Disassembly Procedure
1. Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble -Off Vehicle.

2. Remove the shift lever screw (3) from the shift lever assembly (4).
3. Remove the shift lever assembly (4).
4. Remove the shift lever seal (2).

SIR Steering Wheel Module Coil - Centering


Centering Procedure

Notice: Refer to New SIR Coil Is Centered in Service Precautions.

1. Verify the following before centering the SIR coil assembly:


- The wheels on the vehicle are straight ahead.
- The block tooth (1) of the steering shaft assembly is in the 12 o'clock position.
- The ignition switch is in the LOCK position.

2. If the front (5) of the SIR coil assembly has a centering window (4), and on the back side (2) a spring service lock (1), perform the following
steps:
2.1. Hold the coil assembly with the face up.
2.2. While depressing the spring service lock, rotate the coil hub clockwise until the coil ribbon stops.
2.3. Rotate the coil hub slowly, counter clockwise, until the centering window appears yellow and both arrows (3) line up.
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2.4. Release spring service lock between the locking tab. The SIR coil is now centered.
2.5. Align the centered SIR coil assembly with the horn tower and slide onto the steering shaft assembly.

3. If the front (4) of the SIR coil has a centering window (3) and no spring service lock on the back side (1), perform the following steps:
3.1. Hold the coil assembly with the face up.
3.2. Rotate the coil hub clockwise until the coil ribbon stops.
3.3. Rotate the coil hub slowly, counter clockwise until the centering window appears yellow and both arrows (2) line up. This is center
position.
3.4. While holding the coil hub in center position, align the SIR coil assembly with the horn tower and slide onto the steering shaft assembly.

4. If no centering window is present on the front side (3) of the SIR coil assembly, but a spring service lock (1) is on the back side (2), perform
the following steps:
4.1. Hold the SIR coil assembly with the back side up.
4.2. While depressing the spring service lock, rotate the coil hub counter clockwise until the coil ribbon stops.
4.3. Still pressing the spring service lock, rotate the coil hub in the opposite direction 2 1/2 revolutions.
4.4. Release the spring service lock between locking tabs. The SIR coil is now centered.
4.5. Align the centered SIR coil assembly with the horn tower and slide onto the steering shaft assembly.

5. For no centering window on the front side (2) of the SIR coil assembly and no spring service lock on the back side (1), perform the following
steps:
5.1. Hold the coil assembly with the face up.
5.2. Rotate the coil hub clockwise until the coil ribbon stops.
5.3. Rotate the coil hub, slowly, counter clockwise, for 2 1/2 revolutions. This is center position.
5.4. While maintaining the coil hub in center position, align the centered SIR coil assembly with the horn tower and slide onto the steering
shaft assembly.
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SIR Steering Wheel Module Coil - Disassemble
Disassembly Procedure
1. Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.

2. Remove the wire harness assembly (4) from the wire harness strap (5).
3. Remove the wire harness straps (3) from the wire harness assembly (4).
4. Remove 1 wire harness strap (2) from the upper tilt head assembly (1).

5. Remove the retaining ring (1).


6. Remove the SIR coil assembly (2).

Inflatable Restraint Steering Wheel Module Coil - Assemble - Off Vehicle


Assembly Procedure

1. Align the block tooth on the race and upper shaft assembly (1) to the 12 o' clock position.
2. Put the lock cylinder in the LOCK position and remove the key.
3. A new SIR coil assembly will be precentered.
4. If reusing the original SIR coil assembly refer to Inflatable Restraint Coil Centering - Off Vehicle (Column Shift And Floor Shift).
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5. Align the SIR coil assembly (2) with the horn tower sticking through the shaft lock shield assembly (1).

Important: The retaining ring (1) must seat securely on the groove of the race and upper shaft assembly (2).

6. Install the retaining ring (1).


7. If using a new SIR coil, remove and dispose of the orange tab.

8. Install the wire harness assembly (4) into the wire harness strap (5).
9. Install the wire harness straps (2) into the steering column tilt head assembly (1).
10. Install the wire harness straps (3) onto the wire harness assembly (4).
11. Install the upper and lower shrouds. Refer to
Steering Column Trim Covers - Assemble -Off Vehicle.
Steering Column
Removal Procedure

- Tools Required
- J 42640 Steering Column Anti-Rotation Pin

Important: If the inflatable restraint module is deployed, inspect the SIR coil. Replace the SIR coil if the SIR coil exhibits any signs of damage
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caused by excessive heat.

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.

Caution: Refer to SIR Handling Caution in Service Precautions.

2. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
3. Remove the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and
Seat Belts.
4. Remove the steering wheel. Refer to Steering Wheel Replacement
5. Remove the instrument panel left insulator. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gauges and Wiring
Indicators.
6. Push the top of the intermediate shaft seal down in order to access to the intermediate shaft coupling upper bolt.
7. Install the J 42640 to the steering column.

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering
column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may
cause damage to the coil assembly.

8. Remove the steering intermediate shaft from the steering column. Refer to Lower/Upper Intermediate Steering Shaft Replacement Steering
Column- Tilt.

9. Remove the transaxle shift cable from the steering column.


10. Disconnect the steering column electrical connectors.
11. Remove the steering column bolts.
12. Remove the steering column nuts.
13. Remove the steering column anchor cable from the bracket stud.
14. Remove the steering column from the vehicle.

Installation Procedure
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1. Install the steering column to the vehicle.


2. Install the steering column to the intermediate shaft. Refer to Lower/Upper Intermediate Steering Shaft Replacement
3. Remove the J 42640 from the steering column.
4. Install the steering column anchor cable to the bracket stud.

Caution: In order to ensure the intended function of the steering column in a vehicle during a crash and in order to avoid personal
injury to the driver, perform the following:
- Tighten the steering column lower fasteners before you tighten the steering column upper fasteners. Failure to do this can
damage the steering column.
- Tighten the steering column fasteners to the specified torque. Overtightening the upper steering column fasteners could affect the
steering column collapse.

5. LOOSELY install the steering column nuts.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the steering column bolts.


- Tighten the steering column fasteners in the proper order.
6.1. Tighten the steering column bolts to 24 Nm (18 ft. lbs.).
6.2. Tighten the steering column nuts to 24 Nm (18 ft. lbs.).
7. Install the intermediate shaft seal to the steering column.

8. Install the transaxle shift cable to the steering column.


9. Connect the steering column electrical connectors.
10. Install the instrument panel left side insulator. Refer to Closeout insulator Panel Replacement - Left in Instrument Panel, Gauges and Wiring
Indicators.
11. Install the steering wheel. Refer to Steering Wheel Replacement.
12. Install the inflatable restraint steering wheel module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat
Belts.
13. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.
14. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
Steering Column Anchor Cable
Removal Procedure
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1. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges and Wiring Indicators.
2. Remove the steering column upper nut.
3. Remove the center console. Refer to Console Replacement - Front Floor in Instrument Panel, Gauges and Wiring Indicators.

4. Remove the anchor cable nut from the center console bracket.
5. Remove the anchor cable.

Installation Procedure

1. Properly route the steering column anchor cable.


2. Install the anchor cable to the center console bracket stud.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the anchor cable nut to the center console bracket stud.
- Tighten the steering column anchor nut to 10 Nm (114 ft. lbs.).
4. Install the steering column anchor cable end to the steering column stud.
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5. Install the steering column nut. Refer to Steering Column Replacement


6. Install the center console. Refer to Console Replacement - Front Floor in Instrument Panel, Gauges and Wiring Indicators.
7. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges and Wiring Indicators.

Steering Column Trim Covers


Removal Procedure

Caution: Refer to SIR Handling Caution in Service Precautions.

1. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.
2. Remove the tilt lever. Refer to Tilt Lever Replacement - On Vehicle.
3. Remove the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement On Vehicle (Unable to Rotate Cylinder).
4. Remove the steering column trim covers. Refer to Steering Column Trim Covers - Disassemble - Off Vehicle.

Installation Procedure
1. Install the steering column trim covers. Refer to Steering Column Trim Covers - Assemble - Off Vehicle.
2. Install the ignition lock cylinder. Refer to Ignition Lock Cylinder Replacement - On Vehicle (Cylinder Rotates) or Ignition Lock Cylinder
Replacement - On Vehicle (Unable to Rotate Cylinder).
3. Install the tilt lever. Refer to Tilt Lever Replacement - On Vehicle.
4. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.

Steering Column Trim Covers - Assemble


Assembly Procedure

- Tools Required
- J 41352 Modular Column Holding Fixture

1. Install the shroud protector (1) to the lower shroud (2).


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2. Install the upper shroud (2) onto the column.


3. Slide the shift lever seal down the shift lever and install into the upper shrouds (2).

Notice: Refer to Fastener Notice in Service Precautions.

4. Secure the upper shroud (2) using 1 TORX (R) head screw (1).
- Tighten the screw to 1.5 Nm (13 inch lbs.).

5. Install the lower shroud (2) and secure by using 2 pan head tapping screws (1). Adjust the shift lever seal into the shroud.
- Tighten the screws to 3.5 Nm (31 inch lbs.).

6. Take the column out from the J 41352.


7. Remove the top piece of J 41352 from the steering column.
8. Remove J 41352 from the vise.

Steering Column Trim Covers - Disassemble


Disassembly Procedure

- Tools Required
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- J 41352 Modular Column Holding Fixture

1. Place the bottom of J 41352 into a vise.


2. Set the steering column in the J 41352.
3. Place the top piece of J 41352 onto the column.
4. Pull the tilt lever out from the lower shroud.

5. Remove 2 pan head tapping screws (2) from the lower shroud (1).
6. Remove the lower shroud (1).

7. Remove 1 TORX (R) head screw (1) from the upper shroud (2).
8. Slide the shift lever seal up the shift lever.
9. Remove the upper shroud (2).
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10. Remove the shroud protector (1) from the lower shroud (2).

Steering Shaft, Lower Bearing & Jacket - Assemble


Assembly Procedure

- Tools Required
- J 41688 Centering Sphere Installer Tool

Important: Replace the steering column support assembly (1) if the steering column support assembly (1) has been staked 3 times.

1. Install the steering column support assembly (1) to the jacket assembly.

Notice: Refer to Fastener Notice in Service Precautions.

2. Secure by using 4 TORX (R) screws (2).


- Tighten the screws to 17 Nm (13 ft. lbs.).

3. Lubricate the centering sphere (1) with lithium grease.


4. Install the centering sphere (1) and the joint preload spring (2) into J 41688.
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5. Compress the centering sphere and joint preload spring with J 41688.

6. Install the race and upper shaft assembly. Rotate the race and upper shaft assembly 90 degrees and remove with the centering sphere.

7. Remove the race and upper shaft assembly with J 41688.


8. Rotate the race and upper shaft assembly 90 degrees and remove.
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9. Apply lithium grease to the race and upper shaft assembly.


10. Install the lower shaft assembly onto the race and upper shaft assembly following the marks from the disassemble procedure.

11. Install the steering shaft assembly (2) into the steering column tilt head assembly (1).

12. Install the tilt head assembly (1) and the lower steering shaft (3) into the steering column jacket assembly (2).

Important: Replace the steering column support assembly if the steering column support assembly has been staked 3 times.
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13. Install the 2 pivot pins onto the steering column support assembly.

14. Install the adapter and bearing assembly (1).


15. Install the lower bearing seat (2).
16. Install the lower bearing spring (3).
17. Install the lower spring retainer (4).
18. Install the sensor retainer (5).
19. Install the steering shaft seal (6).
20. Install the linear shift assembly. Refer to Linear Shift Assembly - Assemble - Off Vehicle.
21. Install the turn signal and multifunction switch assembly. Refer to Turn Signal and Multifunction Switch Assembly - Assemble - Off Vehicle.
22. Install the tilt spring. Refer to Tilt Spring - Assemble - Off Vehicle.
Install the lock module assembly. Refer to Electronic Column Lock Module - Assemble - Off Vehicle.

Steering Shaft, Lower Bearing & Jacket - Disassemble


Disassembly Procedure

- Tools Required
- J 21854-1 Pivot Pin Remover
- J 41688 Centering Sphere Installer Tool

1. Remove the lock module assembly. Refer to Electronic Column Lock Module - Disassemble - Off Vehicle.
2. Remove the tilt spring. Refer to Tilt Spring - Disassemble - Off Vehicle.
3. Remove the turn signal and multifunction switch assembly. Refer to Turn Signal and Multifunction Switch Assembly - Disassemble - Off
Vehicle.
4. Remove the linear shift assembly. Refer to Linear Shift Assembly - Disassemble - Off Vehicle.
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5. Remove the steering shaft seal (6).


6. Remove the sensor retainer (5).
7. Remove the lower spring retainer (4).

8. Remove the lower bearing spring (3).


9. Remove the lower bearing seat (2).
10. Remove the adapter and bearing assembly (1).
11. Remove 2 pivot pins (3) from the steering column support assembly (1) using the tool J 21854-1.

12. Remove the tilt head assembly (1) from the steering column jacket (2) with the lower steering shaft (3) still attached.
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13. Remove the tilt head assembly (1) from the steering shaft assembly (2).

Important: Mark the upper shaft assembly and the lower steering shaft assembly to ensure proper assembly. Failure to assemble properly
will cause the steering wheel to be turned 180 degrees.

14. Tilt the upper shaft assembly (1) 90 degrees to the lower steering shaft assembly (2) and disengage.
Insert the race and upper shaft assembly (1) into J 41688.

16. Insert J 41688 into a vise.


17. Rotate the driver 90 degrees in the counterclockwise direction in order to disengage the centering sphere from the race and upper shaft
assembly.
18. Remove the race and upper shaft assembly (1) from J 41688.
19. Remove the shaft preload spring and the centering sphere from J 41688.
20. If necessary, discard the old centering sphere and the old shaft preload spring.
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21. Remove the 4 TORX (R) screws (2) from the steering column support assembly (1).

Steering Wheel
Removal Procedure

- Tools Required
- J 1859-A Steering Wheel Puller
- J 42578 Steering Wheel Puller Legs

1. Turn the ignition OFF.

Caution: Refer to SIR Handling Caution in Service Precautions.

2. Disable the SIR system. Refer to Disabling the SIR System in Air Bags and Seat Belts.

3. Remove the inflator module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts.
4. If there are no alignment mark on the steering wheel hub, scribe an alignment mark on the steering wheel hub in line with the mark on the
steering shaft.
5. Loosen the steering wheel nut.
6. Position the steering wheel nut flush with the end of the steering column shaft.
7. Loosen the steering wheel using the following tools.
- For Pontiac vehicles use the J 1859-A and the J 42578.
- For Chevrolet and Oldsmobile vehicles use the J 1859-A.
8. Disconnect the steering wheel controls electrical connector (if equipped).
9. Disconnect the horn switch lead from the steering hub.
10. Remove the steering wheel nut.
11. Remove the steering wheel from the steering shaft.
12. Remove the steering wheel controls and the steering wheel controls harness from the steering wheel (if equipped). Refer to Steering Wheel
Control Switches Replacement (Pontiac) or Steering Wheel Control Switches Replacement (Oldsmobile) in Accessories and Optional
Equipment.

Installation Procedure
1. Install the steering wheel controls and the steering wheel controls harness to the steering wheel (if equipped). Refer to Steering Wheel
Control Switches Replacement (Pontiac) or Steering Wheel Control Switches Replacement (Oldsmobile) in Accessories and Optional
Equipment.
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2. Route the SIR connector through the steering wheel.


3. Align the mark on the steering wheel with the mark on the steering shaft.
4. Install the steering wheel.

Notice: Refer to Fastener Notice in Service Precautions.

Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if:
- The fastener and its counterpart are clean and free from rust
- The fastener develops 3 Nm (27 inch lbs.) of torque (drag) against its counterpart prior to the fastener seating.

If the fastener does not meet these criteria, REPLACE the fastener.

5. Install the steering wheel nut.


- Tighten the steering wheel nut to 45 Nm (33 ft. lbs.).
6. Connect the horn switch lead to the steering hub.
7. Connect the steering wheel controls electrical connector (if equipped).
8. Install the inflator module. Refer to Inflatable Restraint Steering Wheel Module Replacement in Air Bags and Seat Belts.
9. Enable the SIR system. Refer to Enabling the SIR System in Air Bags and Seat Belts.
10. Verify that the steering wheel controls operate properly (if equipped).
11. Verify that the horn operates properly.

Turn Signal & Multifunction Switch - Assemble


Assembly Procedure

Important: The electrical contact on the turn signal and multifunction switch assembly must rest on the turn signal cancel cam assembly.

1. Install the turn signal and multifunction switch assembly.

Notice: Refer to Fastener Notice in Service Precautions.


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2. Install the 2 pan head tapping screws.


- Tighten the screws to 7 Nm (62 inch lbs.).

3. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly onto the bulk head connector (1).

4. Install the wire harness assembly (4) into the wire harness strap (5).
5. Install the wire harness strap (2) into the steering column tilt head assembly (1).
6. Install the wire harness straps (3) onto the wire harness assembly (4).
7. Install the upper and lower shrouds. Refer to
Steering Column Trim Covers - Assemble -Off Vehicle.

Turn Signal & Multifunction Switch - Disassemble


Disassembly Procedure
1. Remove the upper and lower shrouds. Refer to Steering Column Trim Covers - Disassemble -Off Vehicle.
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2. Remove the wire harness assembly (4) from the wire harness strap (5).
3. Remove the wire harness straps (3) from the wire harness assembly (4).
4. Remove 1 wire harness strap (2) from the upper tilt head assembly (1).

5. Slide the 2 connectors of the turn signal and multifunction switch assembly (2) off of the bulk head connector (1).

6. Remove the the 2 pan head tapping screws.


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7. Remove the turn signal and multifunction switch assembly.


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Spark Plug: Application and ID
Spark Plug ............................................................................................................................................................................................ AC Type 41-940
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Spark Plug: Description and Operation

Extended Life Spark Plug (Typical)

Resistor type, tapered seat spark plugs are used on all engines. No gasket is used on these tapered seat plugs. When replacing spark plugs, use only
the type specified. Normal service is assumed to be a mixture of idling, slow speed, and high-speed driving. Occasional intermittent high-speed
driving is needed for good spark plug performance. Intermittent high-speed driving gives increased combustion heat, burning away carbon or
oxides that have built up from frequent idling, or continual stop-and-go driving.

Spark plugs are protected by insulating boots made of special heat-resistant materials, which cover the spark plug terminal and extend downward
over a portion of the plug insulator. These boots prevent flash-over, which causes engine misfiring. Do not mistake corona discharge for flash-over,
or a shorted insulator. Corona is a steady blue light appearing around the insulator, just above the shell crimp. It is the visible evidence of a
high-tension field and has no effect on ignition performance. Usually it can be detected only in darkness. This discharge may repel dust particles,
leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly regarded as evidence that combustion gases have blown
out between the shell and the insulator.
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Spark Plug: Testing and Inspection
Follow the scheduled maintenance services recommendations to assure satisfactory spark plug performance. Refer to Maintenance Schedule in
Maintenance and Lubrication. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the portion of the spark plug
that projects into the combustion chamber. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator
tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear
will also occur.

Engines which are not running properly are often referred to as misfiring. Spark plug misfiring can be indicated in a number of ways:
^ Poor fuel economy
^ Power loss Loss of speed
^ Hard starting
^ Poor engine performance

For information on misfiring, refer to Symptoms in Computers and Control Systems.

Flashover occurs when a damaged spark plug boot, along with dirt and moisture, permits the high voltage charge to short over the insulator to the
spark plug shell or the engine. Should misfiring occur before the recommended replacement interval, locate and correct the cause.

Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling
or slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Rich fuel mixtures or
poor ignition system output may also be the cause; refer to Symptoms in Computers and Control Systems 3.4L.

Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This
may be caused by oil getting past worn piston rings or valve seals. This condition also may occur during break-in of new or newly overhauled
engines.
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Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by-products become sufficient to
cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found
in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if
the deposits are heavier on the side of the spark plug that was facing the intake valve.

Excessive gap means that the airspace between the center and side electrodes at the bottom of the spark plug is too wide for consistent spark plug
firing. This may be due to improper gap adjustment or to excessive wear of the electrodes. Check of the gap size and compare the gap measurement
to that specified for the vehicle. Refer to Spark Plug Usage. See: Starting and Charging/Testing and Inspection/Initial Inspection and Diagnostic
Overview/Usage Charts/Spark Plug Usage

Excessive gap wear can be an indication of continuous operation at high speeds or with high engine loads, causing the spark plug to run too hot.
Too small of a gap indicates the plug was damaged at the time of installation. Another possible cause is an excessively lean fuel mixture.

Low or high spark plug installation torque or improper seating of the spark plug can result in the spark plug running too hot and cause excessive
gap wear. The spark plug and cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads
in the head or on the spark plug can keep the spark plug from seating even though the proper torque is applied. Once the spark plugs are properly
seated, tighten the spark plug to the proper torque. Refer to Spark Plug Usage. See: Starting and Charging/Testing and Inspection/Initial Inspection
and Diagnostic Overview/Usage Charts/Spark Plug Usage

Low torque may result in poor contact of seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and also
result in poor contact between seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur.
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Cracked or broken insulators may be the result of improper installation, damage during spark plug regapping, or heat shock to the insulator
material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, or when the spark plug is hit from the
outside. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture
penetrates the crack later.

A broken or cracked lower insulator tip (around the center electrode) can result from damage during regapping or from heat shock ( spark plug
suddenly operating too hot).

Damage during regapping can happen if the gapping tool is pushed against the center electrode or the insulator around it, causing the insulator to
crack. When regapping a spark plug, make the adjustment by only bending the side electrode. Do not contact the other parts of the spark plug.

Heat shock breakage in the lower insulator tip generally occurs during severe engine operating conditions (high-speeds or heavy-loading) and may
be caused by over advanced timing or low grade fuels. Heat shock refers to a rapid increase in the tip temperature that causes the insulator material
to crack.

Spark plugs with less than the recommended amount of service can sometimes be cleaned and regapped, then returned to service. However, if there
is any doubt about the serviceability of a spark plug, replace it. Replace spark plugs with cracked or broken insulators. In some cases, such as
flashover, the ignition wire may need to be replaced.
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Spark Plug: Service and Repair
SPARK PLUG REMOVAL PROCEDURE

NOTE: Observe the following Service Precautions:


^ Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to
seize. This can damage the cylinder head threads.
^ Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material
entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new
spark plug.
^ Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the
vehicle. Installing spark plugs of another type can severely damage the engine.

1. Turn the ignition OFF.


2. If you are replacing the engine right bank (rear) spark plugs, perform the following steps:
2.1. Remove the windshield wiper module cover.
2.2. Rotate the engine for service access.

ROTATING THE ENGINE FOR SERVICE ACCESS.

^ Tools Required
- J 41131 Engine Tilt Strap

1. Remove the throttle body air inlet duct. See: Fuel Delivery and Air Induction/Air Cleaner Housing/Air Filter Element/Service and Repair
2. Set the park brake.
3. Shift the transaxle into Neutral.
4. Remove the engine mount strut bolts. Swing the engine mount struts aside. Refer to Engine Mount Strut Replacement (Left) or Engine Mount
Strut Replacement (Right).

5. Install the J 41131.


6. Pull on the engine in order to rotate the engine forward.
7. Tighten the J 41131.

3. Remove the spark plug wire(s) from the spark plug(s).


4. Remove the spark plug(s) from the engine.
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SPARK PLUG INSTALLATION PROCEDURE

NOTE: It is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during
handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause
poor engine performance and may even damage the engine.

1. Gap the spark plug(s) to the specifications.

NOTE: Be sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder
head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the
recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug.

2. Install the spark plug(s) to the engine.

Tighten
Tighten the spark plug(s)
Initial Installation: 20 Nm (15 lb ft)
Reinstallation: 15 Nm (11 lb ft)

3. Install the spark plug wire(s) to the spark plug(s).


4. If you are replacing the engine right bank (rear) spark plugs, perform the following steps:
4.1. Return the engine to the proper position.
4.2. Install the windshield wiper module cover.
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Fuel Delivery and Air Induction: Description and Operation
Fuel System
SYSTEM DESCRIPTION
The fuel pump fuse provides system voltage to the fuel pump relay. The PCM grounds the Fuel Pump Relay control circuit to energize the fuel
pump relay. When the ignition is turned ON, the PCM commands the fuel pump relay ON for at least 2 seconds, voltage is applied to the electric
fuel pump and will continue to energizes the fuel pump after the PCM receives 3X reference pulses. The fuel pump is an electric pump and is
part of the Modular Fuel Sender Assembly. The fuel pump supplies fuel through an in-line fuel filter, fuel rail assembly to the fuel injectors. A
fuel pressure regulator, attached to the fuel rail assembly, maintains a regulated fuel pressure for correct operation of the fuel injectors. Any
unused fuel is then returned to the fuel tank by a separate fuel return pipe.
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Fuel Delivery and Air Induction: Description and Operation
Fuel Supply Components

System Overview
The fuel tank stores the fuel supply. An electric fuel pump, located in the fuel tank within the modular fuel sender assembly, pumps fuel through an
in-line fuel filter to the fuel rail assembly. The pump provides fuel pressure greater than is needed by the injectors. The fuel pressure regulator
keeps fuel available to the injectors at a regulated pressure. A separate fuel pipe is used to return fuel to the fuel tank.
Fuel Level Sensor

Fuel Level Sensor

The fuel sensor consists of the following components: float, the wire float arm, and the ceramic resistor card. The fuel level sensor is mounted on
the modular fuel sender Assembly and is used as an input to the PCM. The PCM uses this information as a fuel level input for various diagnosis. In
addition the PCM transmits the fuel level over the Class 2 communication circuit to the IP cluster. This information is used for the IP gauge, and
low fuel warning indicator if applicable.
Fuel Pressure Regulator Assembly
The fuel pressure regulator attaches to the fuel rail on the fuel return side. The fuel pressure is a diaphragm operated relief valve and is referenced
to manifold vacuum. If the fuel pressure is too low, poor performance could result. If the pressure is to high, excessive odor and a Diagnostic
Trouble Code (DTC) may result.

Fuel Pipe O-Rings


Fuel feed and return pipe threaded connections at the fuel rail and fuel filter are sealed with replaceable O-ring seals. These O-rings seals are made
of special material, and should only be serviced with the correct service part.

Fuel Pump Strainer

The fuel pump strainer attaches to the lower end of the modular fuel sender assembly. The fuel pump strainer is made of woven plastic. The
functions of the fuel pump strainer is to filter contaminants and to wick fuel. The life of the fuel pump strainer is generally considered to be that of
the fuel pump, is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal
amount of sediment or water, in which case the tank should be thoroughly cleaned and replace the plugged fuel pump strainer with a new one.
Fuel Tank Pressure Sensor
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Fuel Tank Pressure Sensor

The Fuel Tank Pressure (FTP) Sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure.
The sensor mounts at the top of the fuel tank sending unit. The PCM supplies a 5 volt reference voltage and ground to the sensor. The sensor
provides a signal voltage between 0.1-4.9 voltsto the PCM. When the air pressure in the fuel tank is equal to the outside air pressure, such as when
the fuel fill cap is removed, the output voltage of the sensor will measure 1.3-1.7 volts.

When the air pressure in the tank is 4.5 inches H2O (1.25 kpa), the sensor output voltage should measure 0.5 ± 0.2 volts (1.25 kPa).

The sensor voltage increases to approximately 4.5 volts at 14 inches of H2O (-3.75 kPa).

In-Pipe Fuel Filter

In-Pipe Fuel Filter

The fuel feed pipe has a steel fuel filter installed ahead of the fuel injection system. The paper filter element (2) traps particles in the fuel that may
damage the injection system. The filter housing (1) is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in
temperature. The fuel filter has a quick-connect inlet fitting and a threaded outlet fitting. The threaded fitting is sealed with an O-ring. There is no
service interval for fuel filter replacement. Replace a restricted fuel filter.
Fuel Tank

Fuel Tank

The fuel tank (1) is located midway on the left inside of the vehicle and is used to store the fuel supply. The fuel tank is molded from high density
polyethylene and is held in place by three metal straps that secure it to the vehicle. The fuel tank shape includes a reservoir in order to maintain a
constant supply of fuel around the fuel pump strainer during low fuel conditions and aggressive vehicle maneuvers. A fuel tank filler pipe
check-valve tube is attached to the fuel tank and extends from the fuel tank inlet to the reservoir. The fuel tank filler pipe check-valve is located
inside the fuel tank filler pipe check-valve tube and prevents fuel from splashing back out of the fuel tank filler pipe during refueling.
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The tank also contains a fuel vapor vent valve with roll-over protection. The vent valve also features a two phase vent calibration which increases
fuel vapor flow to the canister when operating temperatures increase the tank pressure beyond an established threshold.

The fuel tank contains several rollover valves that prevents fuel from entering the fuel pipes in the event of a vehicle rollover. The rollover valves
are not repairable.
Fuel Tank Filler Pipe

Fuel Tank Filler Pipe

In order to prevent refueling with leaded fuel, the fuel tank filler pipe (2) has a built-in restrictor and deflector. The fuel tank filler pipe is connected
to the fuel tank filler extension (1) by clamps.

Fuel Tank Filler Pipe Cap


NOTE: Use a fuel tank filler pipe cap with the same features when a replacement is necessary. Failure to use the correct fuel tank filler pipe cap
can result in a serious malfunction of the fuel system.

Fuel Tank Filler Pipe Cap

The fuel tank filler pipe is equipped with a screw type fuel tank filler pipe cap. A built-in torque-limiting device prevents over tightening of the fuel
tank filler pipe cap. In order to install the fuel tank filler pipe cap, turn the fuel tank filler pipe cap clockwise until a clicking noises is heard. The
clicking noises signal that the correct torque has been reached and that the fuel tank filler pipe cap is fully seated. A fuel filler cap that is not fully
seated, may cause a malfunction in the emission system.

The Enhanced EVAP fuel tank pipe cap has a tether connected to the fuel filler door.
Modular Fuel Sender Assembly
The modular fuel sender assembly is attached to the top of the fuel tank, and extends from the top of the fuel tank to the reservoir.
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Fuel Level Sensor

The modular fuel sender assembly consists of the following major components: fuel pump, a fuel sender strainer (3), a fuel pump strainer, a
roll-over valve (2), fuel level sensor (4), and a fuel tank pressure sensor.
Nylon Fuel Pipes
CAUTION: In order to Reduce the Risk of Fire and Personal Injury:
^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes.
Replace them.
^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in
a possible fuel leak.
^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures
higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.
^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and
may prevent proper reconnection if not lubricated.)

Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel lines they replace. Nylon pipes are constructed to withstand
maximum fuel system pressure, exposure to fuel additives and changes in temperature. There are two sizes used: 3/8" ID for the fuel feed, and
5/16" ID for the fuel return and are used on the modular sender. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns.
However, if forced into sharp bends, nylon pipes will kink and restrict fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and
are more likely to kink if bent too far. Special care should be taken when working on a vehicle with nylon pipes.
Quick Connect Fittings
Quick-connect type fittings provide a simplified means of installing and connecting fuel system components. Depending on the vehicle model, there
are two types of quick-connect fittings, each used at different locations in the fuel system. Each type of quick-connect fitting consists of a unique
female connector and a compatible male fuel pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs or
fingers hold the quick-connect fittings together.
Fuel Feed and Fuel Return Pipes
The fuel feed and fuel return pipes carry fuel from the modular fuel sender assembly to the fuel injection system and back to the modular fuel
sender assembly.
Fuel Pump

The fuel pump is mounted in the fuel reservoir within the modular fuel sender. The fuel pump is an electric high pressure pump. The fuel is pumped
to the fuel rail at a specified flow and pressure. Excess fuel returns to the fuel tank by a return pipe. The fuel pump delivers a constant flow of fuel
to the engine even during low fuel conditions and aggressive vehicle maneuvers. The electric fuel pump operation is controlled by the Powertrain
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Control Module (PCM) through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise generated by the fuel pump.
The fuel pump is serviced as part of the modular fuel sender.
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Fuel Delivery and Air Induction: Description and Operation
Fuel Metering

Purpose
The basic function of the air/fuel metering system is to control air/fuel delivery to the engine. The best air/fuel mixture to minimize exhaust
emissions is 14.7 to 1, which allows the catalytic converter to operate most efficiently. Fuel is delivered to the engine by individual fuel injectors
mounted in the intake manifold near each intake valve. The main control sensor is the Heated Oxygen Sensor (HO2S), located in the exhaust
manifold. The HO2S tells the Powertrain Control Module (PCM) how much oxygen is in the exhaust gas and the PCM changes the air/fuel ratio to
the engine by controlling the fuel injector on time. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is
called a Closed Loop system.
Modes of Operation
The PCM monitors voltages from several sensors to determine the engine's fuel needs. Fuel is delivered under one of several conditions called
modes. All modes are controlled by the PCM and are described below.
Battery Voltage Correction Mode
When battery voltage is low, the PCM will compensate for the weak spark by:
^ Increasing the amount of fuel delivered.
^ Increasing the idle RPM.
^ Increasing ignition dwell time.
Catalytic Converter Protection Mode
The PCM constantly monitors engine operation and estimates conditions that could result in high catalytic converter temperatures. If the PCM
determines the catalytic converter may overheat, it causes the system to return to Open Loop operation and enriches the fuel mixture.
Clear Flood Mode
If the engine floods, clear it by pushing the accelerator pedal down all the way and then crank the engine. The PCM then de-energizes the fuel
injectors. The PCM holds the fuel injectors de-energized as long as the throttle remains above 80 percent and the engine speed is below 600-800
RPM. If the throttle position becomes less than 80 percent, the PCM again begins to pulse the fuel injectors ON and OFF, allowing fuel into the
cylinders.
Deceleration Mode
The PCM reduces the amount of fuel injected when it detects a decrease in throttle position and air flow. When deceleration is very fast, the PCM
may cut off fuel completely for short periods.
Fuel Cut Off Mode
The PCM has the ability to shut OFF the fuel injectors completely or selectively when certain conditions are met. This fuel shut off mode allows the
powertrain to protect itself from damage and also improve its driveability.

The PCM Will Disable the Injectors Under the Following Conditions
^ Ignition OFF (prevents engine run-on).
^ Ignition ON but no ignition reference signal (prevents flooding or backfiring).
^ High engine speed (above red line).
^ High vehicle speed (above rated tire speed).
^ Extended high speed closed throttle coastdown (reduce emissions and increases engine braking).
Fuel RPM Cut Off Ranges
IMPORTANT: These RPM cut off ranges may vary according to PCM calibration, axle ratio, tire size, and tire rating.
^ Park and neutral 6000 RPM.
^ Reverse 4000 RPM.
^ Drive 6000 RPM.
Run Mode
The run mode has two conditions called Open Loop and Closed Loop.

When the engine is first started and engine speed is above 400 RPM, the system is in Open Loop operation. In Open Loop the PCM ignores the
signal from the Heated Oxygen Sensor (HO2S), and calculates the air/fuel ratio based on inputs from the TP, ECT, and MAF sensors.

The system remains in Open Loop until the following conditions are met:
1. The HO2S has a varying voltage output showing that it is hot enough to operate properly (this depends on temperature).
2. The ECT has reached a specified temperature.
3. A specific amount of time has elapsed since starting the engine.

The specific values for the above conditions vary with different engines. When these conditions are met, the system enters Closed Loop operation.
In Closed Loop the PCM changes fuel injector on-time based on the signal from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1
.
Starting Mode
When the ignition is first turned ON the PCM energizes the fuel pump relay for two seconds, allowing the fuel pump to build up pressure. The
PCM then checks the Engine Coolant Temperature (ECT sensor and the Throttle Position (TP) sensor. During cranking, the PCM checks the
crankshaft position signal in order to determine the proper air/fuel ratio for starting. The PCM controls the amount of fuel delivered in the starting
mode by changing how long the fuel injectors are energized. This is done by pulsing the fuel injectors for very short times.
Acceleration Mode
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The PCM provides extra fuel when it detects a rapid increase in throttle position and air flow.

Fuel Metering System Components


The fuel metering system is made up of the following parts:
^ The fuel injectors.
^ The throttle body.
^ The fuel rail.
^ The fuel pressure regulator.
^ The PCM.
^ The crankshaft position sensor.
^ The camshaft position sensor.
^ The fuel pump.
^ The fuel pump relay.
Basic System Operation
The fuel metering system starts with the fuel in the fuel tank. An electric fuel pump, located in the fuel tank with the gauge sending unit, pumps fuel
to the fuel rail through an in-pipe fuel filter. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors.
A fuel pressure regulator in the fuel rail keeps fuel available to the fuel injectors at a constant pressure. Unused fuel is returned to the fuel tank by a
separate pipe. For further information on the fuel tank, in-pipe filter, and fuel pipes, Refer to Fuel Supply Component Description.

Accelerator Controls
The accelerator control system is cable-type. There are no linkage adjustments. Therefore, the specific accelerator control cable must be used.
Fuel Injector

The MULTEC 2 MPFI fuel injector assembly is a solenoid operated device, Controlled by an on-board computer called the Powertrain Control
Module (PCM), that meters fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) solenoid (2) to open a normally
closed ball valve (3). This allows fuel to flow into the top of the injector (1), past the ball valve, and through a director plate at the injector outlet.
The director plate has precision holes that control fuel flow, generating a spray of finely atomized fuel at the injector tip.

Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion
chamber.

The eight digit part number (2) is identified on the fuel injector body (1). A four digit number build date code is located to the far left of the part
number.
Fuel Pressure Regulator
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Fuel Pressure Regulator

The fuel pressure regulator is a diaphragm-operated relief valve with fuel pump pressure on one side and manifold pressure on the other. The
function of the fuel pressure regulator is to maintain the fuel pressure available to the fuel injectors at 3 times barometric pressure, adjusted for
engine load.

The fuel pressure regulator is mounted on the fuel rail and may be serviced separately.

If the fuel pressure is too low, poor performance and DTC P0171 could result. If the pressure is too high, excessive odor and/or DTC P0172 may
result. Refer to Fuel System Pressure Test.

Fuel Pump Electrical Circuit


When the key is first turned ON, the PCM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly. If the engine is not
started within two seconds, the PCM shuts the fuel pump OFF and waits until the engine is cranked. When the engine is cranked and the RPM
signal has been detected by the PCM, the PCM supplies 12 volts to the fuel pump relay to energize the electric in-tank fuel pump. An inoperative
fuel pump relay can result in long cranking times, particularly if the engine is cold. An inoperative fuel pump would cause a no start condition. A
fuel pump which does not provide enough pressure can result in poor performance.

Fuel Rail
The fuel rail assembly is made up of the left hand rail (5), which delivers fuel to the even cylinders (2,4,6) the right hand rail (1), which delivers
fuel to the odd cylinders (1,3,5) the fuel injectors (4), and the fuel pressure regulator assembly (3) which are mounted to the lower section of the
intake manifold and distributes fuel to the cylinders through the individual injectors.

Fuel is delivered to the fuel inlet tube (2) of the fuel rail by the fuel pipes. The fuel then goes through the fuel rail to the fuel pressure regulator. The
fuel pressure regulator maintains a constant fuel pressure at the fuel injectors. Remaining fuel is then returned to the fuel tank.
Idle Air Control (IAC) Valve
The purpose of the Idle Air Control (IAC) valve is to control engine idle speed, while preventing stalls due to changes in engine load. The IAC
valve, mounted in the throttle body, controls bypass air around the throttle plate. By moving a conical valve, known as a pintle, in (to decrease air
flow) or out (to increase air flow), a controlled amount of air can move around the throttle plate. If RPM is too low, the PCM will retract the IAC
pintle, resulting in more air being bypassed around the throttle plate to increase RPM. If RPM is too high, the PCM will extend the IAC pintle,
allowing less air to be bypassed around the throttle plate, decreasing RPM.

The IAC pintle moves in small steps called counts.


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During idle, the proper position of the IAC pintle is calculated by the PCM based on battery voltage, coolant temperature, engine load, and engine
RPM. If the RPM drops below a specified value, and the throttle plate is closed (TP sensor voltage is between 0.20-0.74), the PCM senses a near
stall condition. The PCM will then calculate a new IAC pintle position to prevent stalls.

If the IAC valve is disconnected and reconnected with the engine running, the idle RPM will be wrong. In this case, the IAC has to be reset.

The IAC resets when the key is cycled ON then OFF.

When servicing the IAC, it should only be disconnected or connected with the ignition OFF in order to keep from having to reset the IAC.

The position of the IAC pintle affects engine start up and the idle characteristics of the vehicle. If the IAC pintle is open fully, too much air will be
allowed into the manifold. This results in high idle speed, along with possible hard starting and a lean air/fuel ratio. DTC P0507 may set. If the IAC
pintle is stuck closed, too little air will be allowed in the manifold. This results in a low idle speed, along with possible hard starting and a rich
air/fuel ratio. DTC P0506 may set. If the IAC pintle is stuck part way open, the idle may be high or low and will not respond to changes in engine
load.
Mass Air Flow (MAF) Sensor
The MAF sensor is attached to the front (air inlet side) of the throttle body and is used to measure the amount of air entering the engine. The PCM
uses this information to determine the operating condition of the engine and to control fuel delivery. For further information, refer to In formation
Sensors/Switches Description.
Throttle Body Unit

The throttle body has a throttle plate to control the amount of air delivered to the engine. The TP sensor (2), and IAC sensor (1) are also mounted
on the throttle body.

Vacuum ports located behind the throttle plate provide the vacuum signals needed by various components.
Throttle Position (TP) Sensor
The nonadjustable TP sensor is mounted on the side of the throttle body opposite the throttle lever. It senses the throttle valve angle and relays that
information to the PCM. Knowledge of the throttle angle is needed by the PCM to generate the required injector control signals (pulse). For further
information, Refer to Information Sensors/Switches Description.
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Fuel Delivery and Air Induction: Component Tests and General Diagnostics

Fuel Pump Electrical Circuit Diagnosis

Diagnostic Chart (Part 1 Of 3)


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Diagnostic Chart (Part 2 Of 3)


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Diagnostic Chart (Part 3 Of 3)

Schematic
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CIRCUIT DESCRIPTION
When the ignition switch is first turned on, the PCM energizes the fuel pump relay which applies power to the in-tank fuel pump. The fuel pump
relay will remain on as long as the engine is running or cranking and the PCM is receiving reference pulses. If no reference pulses are present,
the PCM de-energizes the fuel pump relay within 2 seconds after the ignition is turned on or the engine is stopped.

The fuel pump delivers fuel to the fuel rail and injectors, then to the fuel pressure regulator. The fuel pressure regulator controls fuel pressure by
allowing excess fuel to be returned to the fuel tank.

DIAGNOSTIC AIDS
Inspect for the following:

IMPORTANT: Remove any debris from the connector surfaces before servicing a component. Inspect the connector gaskets when diagnosing
or replacing a component. Ensure that the gaskets are installed correctly. The gaskets prevent contaminate intrusion.

- Poor terminal connection-Inspect the harness connectors for backed out terminals, improper mating, broken locks, improperly formed or
damaged terminals, and faulty terminal to wire connection. Use a corresponding mating terminal to test for proper tension. Refer to
Diagrams.
- Damaged harness-Inspect the wiring harness for damage. If the harness inspection does not reveal a problem, observe the display on the scan
tool while moving connectors and wiring harnesses related to the sensor. A change in the scan tool display may indicate the location of the
fault. Refer to Diagrams.
- PCM and engine grounds for clean and secure connections

If the DTC is determined to be intermittent, reviewing the Failure Records can be useful in determining when the DTC was last set.

TEST DESCRIPTION
The numbers below refer to the step numbers on the Diagnostic Table:
2. Command both the ON and OFF states. Repeat the commands as necessary.
3. This step determines if the condition is located on the coil side or the switch side of the circuit.
4. This step verifies that the PCM is providing voltage to the fuel pump relay.
5. This step tests for an open in the fuel pump relay ground circuit.
6. This step determines if a voltage is constantly being applied to the fuel pump relay.
12. This tests for a grounded circuit between the in-line connector and the fuel pump fuse.
15. This step jumps the fuel pump relay in order to activate the fuel pump.
16. This step tests for an open in the fuel pump feed circuit between the in-line connector and the fuel pump relay.
17. This step tests for an open or high resistance in the fuel pump ground circuit.
20. This step determines if the condition with the circuit is intermittent. If the fuse does not open, inspect the supply voltage circuit between the
fuse and the fuel pump for an intermittent condition.

Fuel System Diagnosis

Diagnostic Chart (Part 1 Of 3)


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Diagnostic Chart (Part 2 Of 3)


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Diagnostic Chart (Part 3 Of 3)

SYSTEM DESCRIPTION
Proper fuel pressure is necessary to maintain efficient engine operation and emission levels, if fuel pressure is not within specifications vehicle
drivability may be affected or emission levels elevated.

The fuel system contains the following components:


- Fuel strainer
- Modular fuel sender assembly
- Fuel filter
- Fuel feed pipes/hoses
- Fuel pressure regulator
- Fuel rail
- Fuel injectors
- Fuel return pipes/hoses

TEST DESCRIPTION
Numbers below refer to the step numbers on the Diagnostic Table.
2. Tests the fuel systems ability to achieve a specific fuel pressure range. It may be necessary to cycle the fuel pump several times to achieve the
pressure range.
6. A fuel system that drops more than 5 psi in 10 minutes has a leak in one or more areas.
8. Tests the fuel systems ability to maintain a specific fuel pressure. It may be necessary to cycle the fuel pump several times to achieve the
pressure range.
9. Fuel pressure that drops-off during acceleration, cruise, or hard cornering may cause a lean condition. A lean condition can cause a loss of
power, surging, or misfire and may be diagnosed using a scan tool. If an extremely lean condition occurs, the oxygen sensors may drop
below 500 mV and the fuel injector pulse width will increase.
13. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure
regulator diaphragm, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the pressure changes, but the fuel pressure
at idle should always be less than the fuel pressure noted in Step 2 with the engine OFF.
14. This test determines if the high fuel pressure is due to a restricted fuel return pipe or fuel pressure regulator. A rich condition may cause a
DTC P0132 or DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black
smoke) and a strong sulfur smell in the exhaust.
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Fuel Pressure Release: Service and Repair

RELIEF PROCEDURE

TOOLS REQUIRED
^ J34730-1A Fuel Pressure Gauge
^ J 34730-262 Fuel Pressure Gauge Fitting

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery terminal.

IMPORTANT: Mount the fuel pressure gauge fitting above the belt to avoid contact with the belt.

2. Install the J 34730-262 Fuel Pressure Gauge Fitting adaptor to the fuel pressure connection.
3. Connect Fuel Pressure Gauge J34730-1A to the fuel adaptor pressure fitting. Wrap a shop towel around the fuel pressure connection while
connecting the fuel pressure gauge in order to avoid spillage.
4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for
servicing.
5. Drain any fuel remaining in the fuel pressure gauge into an approved container.
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Accelerator Pedal: Service and Repair

REMOVAL PROCEDURE
1. Remove the left instrument panel sound insulator.
2. Disconnect the accelerator cable from accelerator pedal.
3. Remove the bolts and studs holding the accelerator pedal to the bulk head.
4. Remove the accelerator pedal.

INSTALLATION PROCEDURE
1. Position the accelerator pedal to the bulkhead.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the accelerator pedal bolt and stud.

Tighten
Tighten the bolts and studs to 3.0 N.m (27 lb in).

3. Connect the accelerator cable to accelerator pedal.


4. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect the carpet fit under the accelerator
pedal.
5. Install the left instrument panel sound insulator.
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Air Cleaner Housing: Service and Repair
REMOVAL PROCEDURE

1. Remove the bolt from the coolant tank.


2. Remove the coolant tank and set aside.
3. Remove the 3 bolts from the support brace and remove the brace.
4. Disconnect the MAF sensor electrical connector.
5. Loosen the 2 clamps on the duct/MAF sensor assembly.
6. Remove the air inlet duct/MAF sensor assembly (1).
7. Unsnap the 2 latches and remove the air cleaner housing cover (2).
8. Remove the air filter element (3).

9. Unsnap the latch on the upper cover and remove the cover.
10. Carefully remove the PCM leaving the 2 harnesses connected and set aside.

11. Remove the 2 bolts (2) from the air cleaner assembly and remove the housing.
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INSTALLATION PROCEDURE

1. Position the air cleaner housing on the stud (3).

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the 2 bolts (1) through the housing.

3. Carefully Install the PCM into the housing.


4. Install the upper cover and snap it in place.

5. Install the air cleaner element (3) and air cleaner cover (2) and snap them in place.
6. Install the air inlet duct/Map sensor assembly (1) and tighten the 2 clamps.
7. Connect the MAF sensor electrical connector.
8. Position the support brace and install the 3 bolts.
9. Install the coolant tank and Install the retaining bolt.
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Air Filter Element: Service and Repair

REMOVAL PROCEDURE
1. Disconnect the MAF sensor electrical connector.
2. Loosen the air intake duct/MAF sensor hose clamps.
3. Remove the air intake duct/MAF sensor assembly (1).
4. Unsnap the 2 housing cover retaining clamps.
5. Remove the air cleaner cover (2) and carefully remove the air filter element (3).
6. Inspect the housing cover, seal assembly, and air ducting for damage. If a problem is found, replace as necessary.

INSTALLATION PROCEDURE
1. Carefully install the air filter element (3) into the air cleaner assembly.
2. Install the housing cover (2)and snap the retaining clamps in place.
3. Install the air intake duct/MAF sensor assembly (1).
4. Tighten the air intake duct/MAF sensor hose clamps.
5. Connect the MAF sensor electrical connector.
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Mass Air Flow (MAF) Sensor: Service and Repair

REMOVAL PROCEDURE
1. Turn OFF the ignition.
2. Loosen both clamps on the MAF sensor (1).
3. Remove the air inlet duct from the MAF sensor.
4. Remove the MAF sensor from air filter housing.

INSTALLATION PROCEDURE
1. Carefully install MAP sensor (1) to air inlet grommet.
2. Attach the MAF sensor (1) to air inlet duct and install the air inlet duct.
3. Tighten the MAP sensor clamps.
4. Connect the MAP sensor electrical connector.
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Fillpipe Restrictor: Description and Operation
Fuel Tank Filler Pipe

Fuel Tank Filler Pipe

In order to prevent refueling with leaded fuel, the fuel tank filler pipe (2) has a built-in restrictor and deflector. The fuel tank filler pipe is connected
to the fuel tank filler extension (1) by clamps.
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Fillpipe Restrictor: Description and Operation
Fuel Tank Filler Pipe Cap
NOTE: Use a fuel tank filler pipe cap with the same features when a replacement is necessary. Failure to use the correct fuel tank filler pipe cap
can result in a serious malfunction of the fuel system.

Fuel Tank Filler Pipe Cap

The fuel tank filler pipe is equipped with a screw type fuel tank filler pipe cap. A built-in torque-limiting device prevents over tightening of the fuel
tank filler pipe cap. In order to install the fuel tank filler pipe cap, turn the fuel tank filler pipe cap clockwise until a clicking noises is heard. The
clicking noises signal that the correct torque has been reached and that the fuel tank filler pipe cap is fully seated. A fuel filler cap that is not fully
seated, may cause a malfunction in the emission system.

The Enhanced EVAP fuel tank pipe cap has a tether connected to the fuel filler door.
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Fuel Filter: Service and Repair

REMOVAL PROCEDURE

IMPORTANT: There is no service interval for in-pipe fuel filter replacement. Only replace the in-pipe fuel filter if it is restricted.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
3. Remove the quick-connect fitting at the inlet of the in-pipe fuel filter.
4. Remove the quick-connect fitting at the outlet of the in-pipe fuel filter.
5. Drain any remaining fuel into an approved gasoline container.
6. Remove the in-pipe fuel filter mounting bracket attaching nut.
7. Remove the in-pipe fuel filter and mounting bracket.
8. Remove the in-pipe fuel filter from the in-pipe fuel filter mounting bracket.

INSTALLATION PROCEDURE
1. Remove the protective caps from the new in-pipe fuel filter.
2. Install the in-pipe fuel filter into the in-pipe fuel filter mounting bracket.
3. Install the in-pipe fuel filter and mounting bracket.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Reinstall the in-pipe fuel filter mounting bracket attaching nut.

Tighten
Tighten the nut to 10 N.m (89 lb in).

5. Connect the quick-connect fitting at the inlet of the in-pipe fuel filter.
6. Connect the quick-connect fitting at the outlet of the in-pipe fuel filter.
7. Lower the vehicle.
8. Tighten the fuel fill cap.
9. Reconnect the negative battery cable.
10. Inspect for fuel leaks.
10.1. Turn the ignition switch ON for 2 seconds.
10.2. Turn the ignition switch OFF for 10 seconds.
10.3. Turn the ignition switch ON.
10.4. Check for fuel leaks.
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Fuel Filter: Description and Operation

In-Pipe Fuel Filter

The fuel feed pipe has a steel fuel filter installed ahead of the fuel injection system. The paper filter element (2) traps particles in the fuel that may
damage the injection system. The filter housing (1) is made to withstand maximum fuel system pressure, exposure to fuel additives, and changes in
temperature. The fuel filter has a quick-connect inlet fitting and a threaded outlet fitting. The threaded fitting is sealed with an O-ring. There is no
service interval for fuel filter replacement. Replace a restricted fuel filter.
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Fuel Injector: Description and Operation

The MULTEC 2 MPFI fuel injector assembly is a solenoid operated device, Controlled by an on-board computer called the Powertrain Control
Module (PCM), that meters fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) solenoid (2) to open a normally
closed ball valve (3). This allows fuel to flow into the top of the injector (1), past the ball valve, and through a director plate at the injector outlet.
The director plate has precision holes that control fuel flow, generating a spray of finely atomized fuel at the injector tip.

Fuel from the injector tip is directed at the intake valve, causing it to become further atomized and vaporized before entering the combustion
chamber.

The eight digit part number (2) is identified on the fuel injector body (1). A four digit number build date code is located to the far left of the part
number.
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Fuel Injector: Service and Repair

REMOVAL PROCEDURE

NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector
nozzles. Do not - immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this
cleaning method.

IMPORTANT: Important the fuel injector is serviced as a complete assembly only. If the fuel injectors are found to be leaking, the engine oil
may be contaminated with fuel.

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.


2. Remove the fuel rail.
3. Remove the fuel injector retaining clips (1).
4. Remove the fuel injectors (3) from the fuel rail.
5. Remove the fuel injector Upper O-ring (2).
6. Remove the fuel injector lower O-ring (4).

INSTALLATION PROCEDURE

IMPORTANT: Important each fuel injector is calibrated for a specific flow rate. Be sure to use the correct part number when ordering
replacement fuel injectors. When replacing the fuel injector O-rings, be sure to install the brown O-ring in the lower position. The fuel injector
lower O-ring uses a nylon collar, called the O-ring backup, to properly position the O-ring on the fuel injector. Be sure to Install the O-ring
backup, or the sealing O-ring may move on the fuel injector when installing the fuel rail. If the sealing O-ring is not seated properly, a vacuum
leak is possible and driveability complaints may occur.

1. Install the fuel injector upper O-ring (2).


2. Install the fuel injector lower O-ring (4).
3. Install the fuel injector (3) to the fuel rail.
4. Install the fuel injector retaining clips (1).
5. Install the fuel rail.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

6. Connect the negative battery cable.


7. Inspect for fuel leaks using the following procedure:
7.1. Turn ON the ignition, for 2 seconds.
7.2. Turn OFF the ignition, for 10 seconds.
7.3. Turn ON the ignition.
7.4. Inspect for fuel leaks.
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Fuel Line Coupler: Service and Repair
Metal Collar
REMOVAL PROCEDURE

TOOLS REQUIRED
J 37088-A Fuel Line Quick-Connect Separator

CAUTION:
^ Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
^ Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to
reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will
catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

NOTE:
^ Before attempting any On-Vehicle Service, place a dry chemical (Class B) fire extinguisher near work area.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open
pipes and passages.

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each direction to loosen any dirt within the fitting.

3. Used compressed air in order to blow any dirt out of the fining.

4. Choose the correct tool from J 37088-A Tool Set for the size of the fitting. Insert the tool into the female connector and push inward in order
to release the locking tabs.
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5. Pull the connection apart.

NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent
damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and
burrs. Clean or replace the components and assemblies as required.

6. Use a clean shop towel in order to wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.

INSTALLATION PROCEDURE

CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of
clean engine oil to the male pipe ends.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

1. Apply a few drops of clean engine oil to the male pipe end.

2. Push both sides of the fitting together in order to snap the retaining tabs into place.

3. Once installed, pull on both sides of the fitting in order to ensure the connection is secure.
4. Tighten the fuel filler cap.
5. Reconnect the negative battery cable.
6. Inspect for leaks.
6.1. Turn the ignition switch ON for 2 seconds.
6.2. Turn the ignition switch OFF for 10 seconds.
6.3. Turn the ignition switch ON.
6.4. Inspect for fuel leaks.
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Fuel Line Coupler: Service and Repair
Plastic Collar
REMOVAL PROCEDURE

CAUTION:
^ Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to
reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will
catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

^ Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.

NOTE:
^ Before attempting any On-Vehicle Service, place a dry chemical (Class B) fire extinguisher near work area.
^ Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open
pipes and passages.

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Grasp both sides of the quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction in order to loosen any dirt within the
fitting.
3. Repeat the procedure for the other fuel pipe fitting.

4. Use compressed air at both ends of the fitting in order to blow any dirt from the quick-connect fittings.

5. Squeeze the plastic tabs on the male end connector.

6. Pull the connection apart. Repeat the procedure for the other fitting.
7. Use a clean shop towel in order to wipe off the male pipe end.
8. Clean or replace the components/assemblies as required.
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INSTALLATION PROCEDURE

CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of
clean engine oil to the male pipe ends.

This will ensure proper reconnection and prevent a possible fuel leak.

During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

1. Apply a few drops of clean oil to the male pipe end.

2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to make sure snap into place.

3. Pull on both sides of the quick connect fitting in order to make sure the connection is secure.
4. Tighten the fuel filler cap.
5. Reconnect negative battery cable.
6. Inspect for fuel leaks.
6.1. Turn the ignition switch ON for 2 seconds.
6.2. Turn the ignition switch OFF for 10 seconds.
6.3. Turn the ignition switch ON.
6.4. Check for leaks.
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Fuel Pressure Regulator: Service and Repair

REMOVAL PROCEDURE
1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the fuel pressure regulator vacuum line.
3. Remove the fuel pressure regulator retaining screw.
4. Using a shop towel to catch any spilled fuel, lift and twist the fuel pressure regulator in order to remove the fuel pressure regulator from the
fuel rail.
5. Remove the retainer and spacer bracket from rail and discard.
6. Remove the fuel pressure regulator from the engine fuel return pipe.
7. Remove the fuel pressure regulator inlet O-ring and discard.

INSTALLATION PROCEDURE

CAUTION: Connect the fuel return line before tightening the regulator attaching screw in order to prevent the regulator from rotating.
Rotation of the regulator could damage the retainer and spacer bracket and lead to a fuel leak at the regulator inlet.

NOTE
^ Do not use compressed air in order to test or clean a fuel pressure regulator as damage to the fuel pressure regulator may result.
^ Clean the fuel pressure regulator filter screen with gasoline if necessary.
^ Do not immerse the fuel pressure regulator in a solvent bath in order to prevent damage to the fuel pressure regulator.

1. Check the filter screen for contamination. If contaminated, replace the fuel pressure regulator.
2. Lubricate new pressure regulator inlet O-ring with clean engine oil and install on regulator inlet.
3. Install the fuel return pipe to regulator.
4. Install the new retainer and spacer bracket into slot on fuel rail.
5. Install the pressure regulator to fuel rail.

Tighten
Tighten engine fuel return pipe nut to 17 N.m (13 lb ft).

6. Connect the fuel pressure regulator vacuum line.

NOTE: Refer to Fastener Notice in Service Precautions.

7. Install the pressure regulator attaching screw.

Tighten
Tighten pressure regulator attaching screw to 8.5 N.m (76 lb in).

8. Tighten the pressure regulator fuel return pipe nut.

Tighten
Tighten fuel return pipe nut to 17 N.m (13 lb ft).

9. Inspect and verity that retainer and spacer bracket is engaged in slots in fuel rail. Grasp and pull on regulator to ensure that it is properly
seated.
10. Install the fuel filler cap.
11. Inspect for fuel leaks using the following procedure:
11.1. Turn ON the ignition, for 2 seconds.
11.2. Turn OFF the ignition, for 10 seconds.
11.3. Turn ON the ignition.
11.4. Inspect for fuel leaks.
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Fuel Pump Pickup Filter: Service and Repair
REMOVAL PROCEDURE

IMPORTANT: Always maintain cleanliness when servicing fuel system components.

Fuel Sender Assembly

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.


2. Remove the fuel sender assembly.

3. Support the reservoir with one hand and grasp the strainer with the other hand.
4. Use a screwdriver to pry the strainer ferrule off the reservoir.
5. Discard the strainer.

INSTALLATION PROCEDURE

1. Install the new strainer (4) to the reservoir.


2. Support the reservoir with one hand and grasp the strainer with the other hand twisting the strainer into position.
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3. Install the fuel sender assembly.
4. Inspect for fuel leaks using the following procedure:
4.1. Turn ON the ignition, for 2 seconds.
4.2. Turn OFF the ignition, for 10 seconds.
4.3. Turn ON the ignition.
4.4. Inspect for fuel leaks.
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Fuel Rail: Service and Repair
REMOVAL PROCEDURE

An eight digit identification number is stamped on the left hand fuel rail (fueling even cylinders 2,4,6). Refer to this number it servicing or part
replacement is required.

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector
O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring
in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of
different materials.

IMPORTANT: Important when servicing the fuel rail assembly, precautions must be taken to prevent dirt and other contaminants from entering
the fuel passages. It is recommended that the fittings be capped, and the holes be plugged during servicing.

1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.


2. Remove the upper intake manifold.
3. Disconnect the engine fuel feed pipe at fuel rail.

4. Disconnect the engine fuel return pipe at the fuel pressure regulator.
5. Remove the fuel feed pipe and fuel return pipe O-rings and discard.
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6. Disconnect the main injector harness electrical connector.

7. Pull up the lock release of the fuel injector connector (1).

8. Depress the lock tab (1) and lift the connector from the injector.
9. Remove the injector electrical harness from the fuel rail.
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10. Disconnect the coolant temperature sensor electrical connector.

11. Remove the fuel rail retaining bolts.


12. Remove the fuel rail assembly.
13. Remove the injector O-ring seal from spray tip end of each injector.

INSTALLATION PROCEDURE

NOTE
^ Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, the injector
O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
^ Do not use the compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
^ Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

1. Install The fuel rail assembly into the intake manifold. Tilt rail assembly to install injectors.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the fuel rail attaching bolts.

Tighten
Tighten the fuel rail attaching bolt to 10 N.m (7 lb ft).
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3. Connect the coolant temperature sensor electrical connector.

4. Install the injector electrical harness to the fuel rail.


5. Connect the injector connectors (2).
6. Push the slide locks (1) into position.

7. Connect the main injector harness electrical connector.


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8. Install the new O-rings on fuel feed pipe and fuel return pipe.
9. Install the fuel feed pipe at the fuel rail.

Tighten
Tighten the fuel feed pipe nut to 17 N.m (13 lb ft).

10. Connect the fuel return pipe at the fuel pressure regulator.

Tighten
Tighten the fuel return pipe nut to 17 N.m (13 lb ft).

11. Install the upper intake manifold.

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

12. Connect the negative battery cable.


13. Inspect for fuel leaks using the following procedure:
13.1. Turn ON the ignition, for 2 seconds.
13.2. Turn OFF the ignition, for 10 seconds.
13.3. Turn ON the ignition.
13.4. Inspect for fuel leaks.
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Fuel Supply Line: Service and Repair
Filter to Tank
CAUTION: In order to Reduce the Risk of Fire and Personal injury:
^ if nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes.
Replace them.
^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in
a possible fuel leak.
^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures
higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.
^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and
may prevent proper reconnection if not lubricated.)

NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.

REMOVAL PROCEDURE

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in general information.
4. Remove the quick-connect fittings on the fuel feed and return pipes at the in-pipe fuel filter.
5. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
6. Remove the fuel tank.

7. Remove the fuel feed and fuel return pipe attaching hardware.
8. Remove the fuel feed and fuel return pipes from the fuel tank.
9. Note the position of the fuel feed and return pipes and attaching hardware for installation.

INSTALLATION PROCEDURE

CAUTION: In order to Reduce the Risk Of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during
installation, they must be replaced.
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1. Remove the caps from the fuel sender fuel pipes.


2. Install new plastic connector retainers on the in-pipe fuel filter pipes and on the fuel sender fuel pipes.
3. Install the new fuel feed, fuel return pipes to the fuel tank as noted during removal.
4. Connect the quick-connect fittings on the fuel feed, and return pipes at the fuel tank.
5. Install the fuel pipe attaching hardware as noted during removal.
6. Install the fuel tank.

7. Remove the caps from the in-pipe fuel filter pipes.


8. Connect the quick-connect fittings on the fuel feed and return pipes at the in-pipe fuel filter.
9. Add fuel, and tighten the fuel fill cap.
10. Connect the negative battery cable.
11. Inspect for fuel leaks using the following procedure:
11.1. Turn ON the ignition, for 2 seconds.
11.2. Turn OFF the ignition, for 10 seconds.
11.3. Turn ON the ignition.
11.4. Inspect for fuel leaks.
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Fuel Supply Line: Service and Repair
Chassis
REMOVAL PROCEDURE

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
3. Disconnect the fuel feed and return pipe quick-connect fittings at the front frame rail.

4. Disconnect the fuel feed and return pipe quick-connect fittings at the out let side of the fuel filter.
5. Cap the in-pipe fuel filter pipes, and the engine fuel feed pipe, and engine fuel return pipe as needed to stop any fuel leakage.
6. Remove the fuel feed and return pipes.
7. Note the position of the fuel pipes for installation.

INSTALLATION PROCEDURE

1. Install the fuel feed and return pipes as noted on removal.


2. Remove the caps from the in-pipe fuel filter pipes, the engine fuel feed pipe, and the engine fuel return pipe.
3. Install new plastic connector retainers on the in-pipe fuel filter, the fuel feed pipe, and the return pipe.
4. Connect the fuel feed and return pipe quick-connect fittings at the outlet side of the fuel filter.

5. Connect the fuel feed and return pipe quick-connect fittings at the front frame rail.
6. Lower the vehicle.
7. Tighten the fuel fill cap.
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8. Inspect for fuel leaks.
8.1. Turn the ignition switch ON for 2 seconds.
8.2. Turn the ignition switch OFF for 10 seconds.
8.3. Turn the ignition switch ON.
8.4. Check for fuel leaks.
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Fuel Supply Line: Service and Repair
Engine Compartment (Engine Pipes)
REMOVAL PROCEDURE

TOOLS REQUIRED
J 37088-A Fuel Pipe Quick-Connect Separator

NOTE: Do not attempt to repair the engine fuel feed pipe or the engine fuel return pipe. Replace a damaged engine fuel feed pipe or the engine
fuel return pipe.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine fuel pipe
connections to avoid possible contamination of the fuel system.
3. Disconnect the quick-connect fittings in the engine compartment.
4. Plug the chassis fuel feed pipe and the chassis fuel return pipe as required.
5. Remove the upper intake manifold assembly.

6. Disconnect the engine fuel return pipe from the fuel pressure regulator. Discard the O-ring.

7. Disconnect the engine fuel feed pipe from the fuel rail. Discard the O-ring.
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INSTALLATION PROCEDURE

1. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel return pipe to the fuel pressure regulator.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Lubricate the new O-ring with clean engine oil, then connect the O-ring and the engine fuel feed pipe to the fuel rail.

Tighten
Tighten the engine fuel pipe fittings to 17 N.m (13 lb ft).

3. Install the upper intake manifold assembly.


4. Connect the quick-connect fittings in the engine compartment.
5. Tighten the fuel fill cap.
6. Inspect for fuel leaks using the following procedure:
6.1. Turn ON the ignition, for 2 seconds.
6.2. Turn OFF the ignition, for 10 seconds.
6.3. Turn ON the ignition.
6.4. Inspect for fuel leaks.
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Fuel Supply Line: Service and Repair
Engine Compartment (Engine Compartment)
REMOVAL PROCEDURE

TOOLS REQUIRED
J 37088-A Fuel Pipe Quick-Connect Separator

CAUTION: In order to Reduce the Risk of Fire and Personal Injury:


^ If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes.
Replace them.
^ When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in
a possible fuel leak.
^ Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures
higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period.
^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and
may prevent proper reconnection if not lubricated.)

NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.

IMPORTANT: Clean all engine fuel pipe connections and areas surrounding the engine fuel pipe connections before disconnecting the engine
fuel pipe connections to avoid possible contamination of the fuel system.

2. Disconnect the quick-connect fittings in the engine compartment.


3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.

4. Disconnect the quick-connect fitting at the front frame rail.


5. Gap the fuel feed pipe and the fuel return pipe as needed to stop any fuel leakage.
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6. Remove the fuel feed and fuel return pipe attaching hardware and the fuel feed and fuel return pipes.
7. Note the position of the fuel feed and return pipes and the fuel feed and return pipe attaching hardware for installation.
8. Inspect the pipes for bends, kinks and cracks.
9. Replace the fuel pipes if necessary.

INSTALLATION PROCEDURE

CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during
installation, they must be replaced.

1. Install the new fuel feed and return pipes and the fuel pipe attaching hardware as noted during removal.
2. Remove the caps from the fuel feed pipe and the fuel return pipe.
3. Install new plastic connector retainers on the fuel pipes.

4. Connect the quick-connect fitting at the front frame rail. Quick Connect Fitting(s) Service (Metal Collar)
5. Lower the vehicle.
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6. Connect the quick-connect fittings in the engine compartment.


7. Add fuel and tighten the fuel fill cap.
8. Inspect for fuel leaks using the following procedure:
8.1. Turn ON the ignition, for 2 seconds.
8.2. Turn OFF the ignition for 10 seconds.
8.3. Turn ON the ignition.
8.4. Inspect for fuel leaks.
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Fuel Tank: Testing and Inspection
IMPORTANT: Before attempting the Fuel Tank Leak Check place a dry chemical (Class B) fire extinguisher near the work area.
1. Install the J 41415-40 Fill Tank Cap Adaptor.
2. Connect the J 41413 EVAP Pressure/Purge Diagnostic Station to the fill tank cap adaptor.
3. With a scan tool, seal the EVAP system.
4. Raise the vehicle on a hoist. Refer to Vehicle Lifting Caution in Service Precautions.
5. With the Evaporative Emission System (EVAP) diagnostic station, maintain 15 in. H2O (3.75 kPa) within the fuel tank.

IMPORTANT: It may be necessary to partially lower the fuel tank to inspect the top of the fuel tank and fuel sender assembly O-ring. Refer to
Fuel Tank Replacement.

6. With the J 41416 ultrasonic leak detector, test for leaks in the fuel tank and EVAP pipes.
7. Visually inspect for fuel leaking from the fuel tank.
8. If a leak is detected refer to the following component replacements:
^ Fuel tank leak, refer to Fuel Tank Replacement.
^ Fuel sender O-ring or fuel sender leak, refer to Fuel Sender Assembly Replacement.
^ Fuel or EVAP pipe leak, refer to Fuel Hose/Pipes Replacement (Filter to Tank) in Fuel Supply Line or Fuel Return Line.
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Fuel Tank: Removal and Replacement
REMOVAL PROCEDURE

NOTE: Do not attempt to straighten any kinked nylon fuel lines. Replace any kinked nylon fuel feed or return pipes in order to prevent damage
to the vehicle.

IMPORTANT: Do not attempt to repair sections of nylon fuel pipes. If the nylon fuel pipes are damaged, replace the pipes.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
4. Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter.
5. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.

6. Disconnect the fuel tank EVAP pipe quick-connect fitting at the EVAP pipe canister.
7. Remove the EVAP fuel filler pipe from the side of the fuel tank.

8. Loosen the fuel tank filler pipe hose clamp.


9. Remove the fuel tank filler pipe.
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10. Loosen the fuel tank filler vent hose clamp.


11. Remove the fuel tank filler vent hose at the filler neck.

12. With the aid of an assistant, support the fuel tank and remove the fuel tank strap attaching bolts.
13. Disconnect the fuel sender electrical connector.
14. Disconnect the fuel tank pressure sensor electrical connector.

15. Remove the fuel tank from the vehicle and place the fuel tank in a suitable work area.
16. If the fuel tank is not being replaced, go to the Installation Procedure.

17. Disconnect the fuel feed and return pipe quick-connect fittings.
18. Remove the fuel feed pipe.
19. Remove the fuel return pipe.
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20. Remove the EVAP pipe assembly.


21. Remove the fuel sender assembly.

INSTALLATION PROCEDURE

1. Install the fuel sender assembly.


2. Install the EVAP pipe assembly.

3. Install the fuel feed pipe.


4. Install the fuel return pipe.
5. Connect the quick-connect fittings at the fuel sender.

6. With the aid of an assistant, position and support the fuel tank.
7. Connect the fuel sender electrical connector and the fuel sender retaining clips.
8. Connect the fuel tank pressure sensor electrical connector.

NOTE: Refer to Fastener Notice in Service Precautions.


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9. Install the fuel tank retaining strap attaching bolts.

Tighten
Tighten the fuel tank retaining strap bolts to 47.5 N.m (35 lb ft).

10. Connect the fuel tank filler vent hose to the fuel tank.

Tighten
Tighten the fuel tank filler vent hose clamp to 2.5 N.m (22 lb in).

11. Connect the fuel tank filler pipe to the fuel tank.

Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in).

12. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
13. Connect the fuel return pipe quick-connect fitting near the fuel filter.
14. Connect the EVAP fuel filler pipe to the side of the fuel tank.
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15. Connect the fuel tank EVAP pipe quick-connect fitting at the EVAP canister.

16. Lower the vehicle.


17. Add fuel and Install the fuel tank filler pipe cap.
18. Reconnect the negative battery cable.
19. Inspect for fuel leaks using the following procedure:
19.1. Turn ON the ignition, for 2 seconds.
19.2. Turn OFF the ignition, for 10 seconds.
19.3. Turn ON the ignition.
19.4. Inspect for fuel leaks.
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Fuel Gauge Sender: Service and Repair

REMOVAL PROCEDURE
1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain fuel tank. Refer to Fuel Tank Draining Procedure.
3. Remove the fuel tank.
4. Remove the fuel sender assembly.
5. Remove the fuel level sensor (5) from the modular fuel sender.

INSTALLATION PROCEDURE
1. Install the fuel level sensor (5) to the modular fuel sender.
2. Install the fuel sender assembly.
3. Install the fuel tank.
4. Lower the vehicle.
5. Add fuel and Install the fuel fill cap.
6. Inspect for fuel leaks using the following procedure:
6.1. Turn ON the ignition, for 2 seconds.
6.2. Turn OFF the ignition, for 10 seconds.
6.3. Turn ON the ignition.
6.4. Inspect for fuel leaks.
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Fuel Tank Unit: Service and Repair

REMOVAL PROCEDURE

TOOL REQUIRED
J 39348 Fuel Sender Spanner Wrench

NOTE: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage
the joints.

IMPORTANT: Always replace the fuel sender gasket when Installing the fuel sender assembly.

1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in Service Precautions.
4. Remove the fuel tank.
5. Clean all of the fuel pipe connections, all of the hose connections, and all of the areas surrounding the connections before disconnecting the
connections in order to avoid possible contamination of the fuel system.
6. Disconnect the quick-connect fittings at the fuel sender assembly.
7. Use the J 39348 fuel sender spanner wrench in order to remove the fuel sender assembly locking nut, the fuel sender assembly and the O-ring
from the fuel tank.
8. Discard the fuel sender assembly O-ring.

INSTALLATION PROCEDURE
1. Clean the fuel sender assembly O-ring sealing surfaces.
2. Position the new fuel sender assembly O-ring on the fuel tank.

IMPORTANT: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will
restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

3. Use the J 39348 fuel sender wrench in order to install the fuel sender assembly and the fuel sender assembly locking nut.
4. Connect the quick-connect fittings at the fuel sender assembly.
5. Install the fuel tank.
6. Lower the vehicle.
7. Add fuel and Install the fuel fill cap.
8. Connect the negative battery cable.
9. Inspect for fuel leaks using the following procedure:
9.1. Turn ON the ignition, for 2 seconds.
9.2. Turn OFF the ignition, for 10 seconds.
9.3. Turn ON the ignition.
9.4. Inspect for fuel leaks.
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Idle Air Control Motor (IAC): Service and Repair
REMOVAL PROCEDURE

1. Turn OFF the ignition.


2. Disconnect the Idle Air Control (IAC) electrical connector.

3. Remove the IAC valve attaching screws.

4. Remove the idle air control valve.

5. Remove the idle air control valve O-ring.

INSTALLATION PROCEDURE

NOTE: The IAC valve may be damaged if installed with the cone (pintle) extended more than 28 mm (1-1/8 in). Measure the distance that the
valve is extended before installing a new valve. The distance from the idle air control valve motor housing to the end of the idle air control valve
pintle should be less than 28 mm (1-1/8 in). Manually compressing the pintle until the extension is less than 28 mm (1-1/8 in).

1. Install the new idle air control O-ring.


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2. Install the idle air control valve into the throttle body.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the idle air control valve attaching screws.

Tighten
The screws to 3.0 N.m (27 lb in).

4. Connect the Idle Air Control (IAC) electrical connector.


5. The PCM will reset the idle air control valve whenever the ignition switch is turned ON, then OFF. Turn the ignition switch ON, then OFF.
6. Start the engine and allow the engine to reach operating temperature.
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Throttle Position Sensor: Service and Repair
REMOVAL PROCEDURE

1. Disconnect the Intake Air Temperature (IAT) electrical connector and breather tube from the air intake tube.
2. Remove the air intake tube.

3. Disconnect the TP sensor electrical connector.

4. Remove the 2 TP sensor attaching screws.


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5. Remove the TP sensor.

6. Remove the TP sensor O-ring.

INSTALLATION PROCEDURE

1. Install the IP sensor O-ring.


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2. With the throttle valve in the normal closed idle position, install the TP sensor on the throttle body assembly.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the 2 TP sensor attaching screws, using a thread-locking compound on the screws. Loctite(R) 262, GM P/N #1052624, or equivalent
should be used.

Tighten
Tighten the TP sensor attaching screws to 2.0 N.m (18 lb in).

4. Connect the TP sensor electrical connector.


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5. Reinstall the air inlet tube.


6. Connect the IAT electrical connector and breather tube to the air inlet tube.
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Throttle Body: Service and Repair
REMOVAL PROCEDURE

1. Drain coolant. Refer to Draining and Filling Cooling System.


2. Disconnect the IAT sensor electrical connector.
3. Disconnect the breather tube from the air intake tube.
4. Lossen the air intake tube clamps and remove the air intake tube.

5. Disconnect the Idle Air Control (IAC) valve electrical connector.

6. Disconnect the Throttle Position (TP) sensor electrical connector.


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7. Disconnect the accelerator controls cable.

8. If applicable disconnect the cruse control cable from the throttle lever and cable bracket.

9. Remove the accelerator control cable bracket.


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10. Disconnect the throttle body coolant bypass hoses.


11. Disconnect the heater pipe nut at the throttle body.
12. Remove the nuts and bolts holding the throttle body to the intake manifold.
13. Remove the throttle body assembly.

INSTALLATION PROCEDURE

NOTE: Do Not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to
the gasket surfaces and throttle body assembly may result.

Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.

1. Clean the gasket surface on the intake manifold and the throttle body assembly.
2. Install a new gasket, if necessary.
3. Install the throttle body assembly.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the throttle body retaining nuts and bolts.

Tighten
Tighten the throttle body retaining nuts and bolts to 28 N.m (21 lb ft).

5. Connect the throttle body coolant bypass hoses.


6. Connect the heater pipe nut at the throttle body.

7. Connect the IAC valve electrical connector.


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8. Connect the TP sensor electrical connector.

9. Install the accelerator controls cable bracket.

10. Connect the accelerator controls cable.


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11. If applicable connect the cruse cable to the throttle lever and accelerator bracket.

12. Install the air intake tube and tighten the clamps.
13. Connect the IAT sensor electrical connector.
14. Connect the breather tube to the air intake tube.
15. Refill the coolant.

IMPORTANT: The throttle should operate freely without binding between full closed and wide open throttle.

16. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect for poor carpet fit under the
accelerator pedal.
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Throttle Cable/Linkage: Service and Repair
Accelerator Controls Cable Replacement
REMOVAL PROCEDURE

1. Remove the left instrument panel sound insulator.


2. Disconnect the accelerator cable from the accelerator pedal.
3. Squeeze the accelerator cable cover tangs and push the accelerator cable through the bulkhead.

4. Remove the accelerator cable shield, if equipped.


5. Disconnect the accelerator cable from the retaining clip.
6. Disconnect the accelerator cable from the throttle body lever.
7. Disconnect the accelerator cable from the accelerator cable bracket.

8. Remove the accelerator cable from the vehicle. Note the cable routing for aid in installation.

INSTALLATION PROCEDURE

NOTE: Do not route flexible components (hoses, wires, conduits, etc.) within 50 mm (2 in) of moving parts unless flexible components can be
securely fastened. This is necessary in order to prevent possible interference and damage to the component.
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1. Install accelerator cable into car using routing noted during removal.

2. Install the snap retainer through the bulkhead.


3. Connect the accelerator cable through the slot in the accelerator pedal lever.
4. Seat the snap retainer in the accelerator pedal lever.

5. Connect the accelerator cable to the throttle body lever.


6. Connect the accelerator cable to the accelerator cable bracket.
7. Connect the accelerator cable into the retaining clip.
5. Reinstall the accelerator cable shield, if equipped.
9. Inspect and check for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under
the accelerator pedal.
10. Reinstall the left instrument panel sound insulator.
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Throttle Cable/Linkage: Service and Repair
Accelerator Controls Cable Bracket Replacement
REMOVAL PROCEDURE

1. Disconnect the accelerator cable cross slug from throttle body slot.
2. Depress the tangs and remove the accelerator cable from accelerator cable bracket.

3. If applicable disconnect the cruse control cable from the throttle lever and accelerator bracket.

4. Remove the nut (3) and bolts (1,2) holding the accelerator cable bracket to the throttle body.
5. Remove the accelerator cable bracket.

INSTALLATION PROCEDURE
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1. Position the accelerator cable bracket on the throttle body.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the nut (3) and bolts (1,2).

Tighten
^ Tighten the bolts in sequence (2,1) to 13 N.m (115 lb in).
^ Tighten the nut in sequence (3) to 10 N.m (89 lb in).

3. Connect the cruise control cable into accelerator cable bracket.


4. Connect the accelerator cable cross slug to the throttle body slots.
5. If applicable connect the cruse control cable to the throttle lever and accelerator bracket.
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Computers and Control Systems: Description and Operation
Information Sensors/Switches

Camshaft Position (CMP) Sensor And Cam Signal


The camshaft position sensor sends a cam signal to the PCM which uses it as a sync pulse to trigger the injectors in proper sequence. The PCM uses
the CAM signal to indicate the position of the #1 piston during its intake stroke. This allows the PCM to calculate true Sequential Fuel Injection
(SFI) mode of operation. If the PCM detects an incorrect CAM signal while the engine is running, DTC P0341 Camshaft Position (CMP) Sensor
Performance will set.

If the CAM signal is lost while the engine is running, the fuel injection system will shift to a calculated sequential fuel injection mode based on the
last fuel injection pulse, and the engine will continue to run.

The engine can be restarted and will run in the calculated sequential mode as long as the fault is present with a 1 in 6 chance of injector sequence
being correct.
EGR Pintle Position Sensor
The EGR pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve
assembly.

The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault
if the pintle position sensor and control circuits are open or shorted.
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Linear EGR Control

If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a
tolerance considered acceptable for proper EGR system operation, the PCM sets DTC P1404 EGR Valve Stuck Open.
Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream.

Low coolant temperature produces a high resistance (100,000 ohms at -40°C/-40°F) while high temperature causes low resistance (70 ohms at 130
°C/266°F).

The PCM supplies a 5 volt signal to the engine coolant temperature sensor through a resistor in the PCM and measures the voltage. The voltage is
high when the engine is cold, and low when the engine is hot. By measuring the voltage, the PCM calculates the engine coolant temperature. The
engine coolant temperature affects most systems the PCM controls.
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The scan tool displays engine coolant temperature in degrees. After engine startup, the temperature should rise steadily to about 90°C (194°F) then
stabilize when thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air
temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit should set DTC P0117 Engine Coolant
Temperature (ECT) Sensor Circuit Low Voltage, or DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage. The DTC
Diagnostic Aids also contains a chart to check for sensor resistance values relative to temperature.

The ECT sensor (3) also contains another circuit which is used to operate the engine coolant temperature gauge located in the instrument panel.

Engine Oil Level Switch

The PCM monitors the engine oil level switch signal at start-up to determine if the engine oil is OK. If the PCM determines that a low oil level
condition exists, the PCM will communicate the information over the Class II circuit to the IPC and it will illuminate the indicator lamp.
Engine Oil Pressure Switch
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The PCM monitors the engine oil pressure switch (1) signal to determine if the engine oil pressure is OK. If the PCM determines that a low oil
pressure condition exists, the PCM will communicate the information over the Class II circuit to the IPC and it will illuminate the indicator lamp.
Fuel Control Heated Oxygen Sensor (HO2S 1)

Fuel Control Heated Oxygen Sensor (HO2S 1)

The fuel control Heated Oxygen Sensor (HO2S 1) is mounted in the exhaust manifold where the sensor can monitor the oxygen content of the
exhaust gas stream. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output.

This voltage should constantly fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV (low oxygen content rich
mixture). The heated oxygen sensor voltage can be monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the PCM
calculates what fuel mixture command to give to the injectors (lean mixture/low HO2S voltage = rich command, rich mixture/high HO2S voltage =
lean command).
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The HO2S 1 circuit, if open, should set a DTC P0134 HO2S Circuit Insufficient Activity Sensor 1 and the scan tool should display a constant
voltage between 400 and 500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) should set DTC P0131 HO2S Circuit
Low Voltage Sensor 1, while a constant voltage above 800 mV in the circuit should set DTC P0132 HO2S Circuit High Voltage Sensor 1. A fault
in the HO2S 1 heater circuit should cause DTC P0135 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S
is determined to be too slow, the PCM stores a DTC that indicates degraded HO2S performance.
General Description
All of the sensors and input switches can be diagnosed using a scan tool. Following is a short description of how the sensors and switches can be
diagnosed by using a scan tool. The scan tool can also be used to compare the values for a normal running engine with the engine you are
diagnosing.
Intake Air Temperature (IAT) Sensor
The Intake Air Temperature (IAT) sensor is a thermistor which changes value based on the temperature of air entering the engine. Low temperature
produces a high resistance (100,000 ohms at -40°C/-40°F), while high temperature causes low resistance (70 ohms at 130°C/266°F).

The PCM supplies a 5 volt signal to the sensor through a resistor in the PCM and measures the voltage. The voltage is high when the incoming air
is cold, and low when the air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to
adjust the spark timing according to incoming air density.

The scan tool displays the temperature of the air entering the engine, which should read close to the ambient air temperature when the engine is
cold, and rise as the underhood temperature increases.
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If the engine has not been run for several hours (overnight) the IAT sensor temperature and the engine coolant temperature should read close to
each other. A failure in the IAT sensor circuit should set DTC P0112 Intake Air Temperature (IAT)Sensor Circuit Low Voltage or DTC P0113
Intake Air Temperature (IAT) Sensor Circuit High Voltage.
Knock Sensor (KS)

The knock sensor detects abnormal vibration (spark knocking) in the engine. The sensor is located on the engine block near the cylinders. The
sensor produces an AC output voltage which increases with the severity of the knock. This signal voltage is input to the PCM. The PCM then
adjusts the Ignition Control (IC) timing to reduce spark knock. DTC P0325 Knock Sensor (KS) Circuit DTC P0327 Knock Sensor (KS) Circuit are
designed to diagnose the PCM, the knock sensor, and related wiring, so problems encountered with the KS system should set a DTC.

Refer to Knock Sensor (KS) System Description.


Manifold Absolute Pressure (MAP) Sensor
The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the
PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the key ON and the engine not running or at wide open throttle (low
vacuum).

The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (Refer to DTC P0401
Exhaust Gas Recirculation (EGR) Flow Insufficient ),to determine engine vacuum level for other diagnostics, and to determine Barometric
Pressure (BARO).
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If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 Manifold Absolute Pressure (MAP) Sensor
Circuit Low Voltage is set. A signal voltage higher than the possible range of the sensor sets DTC P0108 Manifold Absolute Pressure (MAP)
Sensor Circuit High Voltage. An intermittent low or high voltage sets DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent
Low Voltage or DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage respectively. The PCM can also detect a
shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors

Mass Air Flow (MAF) Sensor


The Mass Air Flow (MAF) sensor measures the amount of air which passes through the sensor. The PCM uses this information to determine the
operating condition of the engine and to control fuel delivery.

A large quantity of air indicates acceleration, while a small quantity indicates deceleration or idle.

The scan tool reads the MAF value and displays it in grams per second (gm/s). The MAF value should read between 4 gm/s at idle to 6 gm/s on a
fully warmed up engine. The values should change rather quickly on acceleration, but the values should remain fairly stable at any given RPM. A
failure in the MAF sensor or circuit should set DTC P0101 Mass Air Flow (MAF) Sensor Performance, DTC P0102 Mass Air Flow (MAF) Sensor
Circuit Low Frequency, or DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency.
PCM Controlled A/C
This vehicle may be equipped with Front(C60) and Rear(C34) A/C system. This system is designed to provide a comfortable environment inside
the passenger compartment. The Rear(C34) A/C system is controlled by the Front(C60) HVAC Control Assembly. Both electronic and vacuum
circuits determine air intake and discharge locations. PCM Controlled A/C operation is the same for either Front(C60) or the Front and Rear(C34)
HVAC system. Refer to PCM Controlled Air Conditioning Description for more information regarding the PCM Controlled Air Conditioning
system.
Throttle Position (TP) Sensor
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The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal
line, the PCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a
closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT),
the output voltage should be above 4 volts.

The PCM calculates fuel delivery based on the throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of
fuel from an injector and an unstable idle because the PCM detects that the throttle is moving. A hard failure in the TP sensor 5 volt reference or
signal circuits should set either a DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage DTC P0123 Throttle Position (TP) Sensor Circuit
High Voltage. A hard failure with the TP sensor ground circuit may set DTCs DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low
Voltage, DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage, DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage,
or DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage. Once a DTC is set, the PCM uses an artificial default value based
on engine RPM, engine load and mass air flow for throttle position and some vehicle performance returns. A high idle may result when either DTC
P0122 Throttle Position (TP) Sensor Circuit Low Voltage, or DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage is set.

The PCM can detect intermittent TP sensor faults. DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage, or DTC P1122
Throttle Position (TP) Sensor Circuit Intermittent Low Voltage will set if an intermittent high or low circuit failure is being detected.
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The PCM can also detect a shifted TP sensor. The PCM monitors throttle position and compares the actual TP sensor reading to a predicted TP
value calculated from engine speed. If the PCM detects an out of range condition, DTC P0121 Throttle Position (TP) Sensor Performance will be
set.
Transaxle Controls
The electrical components of this unit are as follows:
^ Two shift solenoid valves: 1-2/3-4 and 2-3
^ A Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid valve
^ A Pressure Control (PC) solenoid valve
^ An automatic Transmission Fluid Temperature (TFT) sensor
^ Two speed sensors: input shaft and vehicle speed sensors
^ An automatic Transmission Fluid Pressure (TFP) manual valve position switch
^ Either an Internal Mode Switch or an exterior-mounted Transmission Range Switch. See the data referenced by the Scan Tool or refer to
Automatic Transmission Electronic Component Views (Internal) or Automatic Transmission Electronic Component Views (External).
^ An automatic transmission (A/T) wiring harness assembly

For more information, refer to Electronic Component Description.


3X Reference
The PCM uses this signal, from the ignition control module to calculate engine speed and crankshaft position over 1600 RPM.

The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P1374 Crankshaft
Position (CKP) High to Low Resolution Frequency Correlation will set and the PCM will use the 24X reference signal circuit for fuel and ignition
control.

This is a ground circuit for the digital RPM counter inside the PCM, but the wire is connected to engine ground only through the ignition control
module. Although this circuit is electrically connected to the PCM, it is not connected to ground at the PCM.
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The PCM compares voltage pulses on the reference input circuits to pulses on this circuit, ignoring pulses that appear on both.

7X Crankshaft Position (CKP) Sensor

The 7X crankshaft position sensor provides a signal used by the ignition control module.

The ignition control module also uses the 7X crankshaft position sensor to generate 3X reference pulses which the PCM uses to calculate RPM and
crankshaft position.
24X Crankshaft Position (CKP) Sensor
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The 24X Crankshaft Position (CKP) Sensor (1) is used to improve idle spark control at engine speeds up to approximately 1600 RPM.
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Computers and Control Systems: Tools and Equipment

Special Tools And Equipment (Part 1 Of 3)


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Special Tools And Equipment (Part 2 Of 3)


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Special Tools And Equipment (Part 3 Of 3)


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Body Control Module: Description and Operation
Body Control Module (BCM)
The Body Control Module (BCM) type 4 controls the content theft deterrent system.

The BCM monitors the status of the following components:


^ The vehicle doors
^ The lock cylinders
^ The shock sensor
^ The power door locks
^ The keyless entry system

The BCM operates the following components according to the chosen mode of operation:
^ The exterior lights
^ The horn
^ The status security indicator lamp
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Body Control Module: Description and Operation
Body Control System Circuit

Body Control System Circuit Description

This vehicle is equipped with a Body Control Module (BCM) that performs multiple body control functions. The following vehicle systems are
controlled by the BCM:
^ Audible warnings
- key in the ignition reminder
- Fasten seat belt reminder
- Driver information reminder
- Turn signal reminder
- Headlamps on reminder
- Feature customization and diagnostics mode indication
- Auxiliary chime functions (Instrument cluster)
- Last door closed locking reminder
^ Inadvertent load monitoring
^ Fasten seat belt indicator control
^ Interior light illumination
^ Power door locks functions
^ keyless entry system functions (with AUO)
^ Key cylinder lock
^ Retained Accessory Power (RAP)
^ Content theft deterrent system (with UA6)
^ Feature customization
^ Service Diagnostics

These systems are controlled by the BCM's outputs. The BCM controls its outputs based upon input information obtained from the sensors and
switches that are directly connected to the BCM. The BCM evaluates the input information and controls the body systems by commanding an
output on or off.

BCM Identification
This vehicle is equipped with 1 of 3 types of BCMs. The BCM type installed on this vehicle is based on the vehicle equipment, point of sale, and
option content. Refer to On-Board Diagnostic Features for more information on how to identify the BCM type installed by using the on-board
diagnostic feature. The following identifies the functions and basic option content of all 3 BCM types:

BCM TYPE 2
BCM type 2 is the base BCM that provides all standard BCM functions.

BCM TYPE 3
BCM type 3 provides all of the features of the BCM type 2 plus keyless entry. Vehicles with RPO AU0 are equipped with a BCM type 3.

BCM TYPE 4
BCM type 4 provides all of the features of the BCM type 2 and type 3 plus content theft deterrent. Vehicles with RPO AU0 and UA6 are
equipped with a BCM type 4.

Interior Lighting
The BCM provides the following interior light functions:
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^ Interior illumination
^ Delayed illumination
^ Exit illumination
^ Theatre dimming
^ Door key unlock illumination
^ keyless entry unlock illumination
^ Inadvertent load (battery rundown) protection
^ Interior light feature customization
- Delayed illumination (on/off)
- Exit lighting (on/off)

Refer to the Interior Lights Circuit Description in Lighting for customization features.

Automatic Door Locks


The BCM provides the following automatic door lock functions:
^ Door key all doors unlock
^ Door key all doors lock
^ Last door closed locking
^ Lockout prevention
^ Ignition off unlock
^ Shift into PARK unlock
^ Shift out of PARK lock
^ Sliding door delayed locking
^ Door lock feature customization
- Automatic door lock (on/off)
- Automatic door unlock (on/off)
- Last door closed lock (on/off)
- Lockout prevention (on/off)
Refer to the Automatic Door Lock System Description in Doors for customization features.

Keyless Entry (BCM TYPE 3, 4)


The BCM provides the following keyless entry functions:
^ Driver door unlock
^ All doors unlock
^ All doors lock
^ Activation verification (horn and lights)
^ Content theft alarm
^ Keyless entry feature customization
- Activation verification (lights/horn and lights/off)
- Driver door unlock only (on/off)
Refer to the Keyless Entry System Circuit Description in Keyless Entry for more information.

Content Theft Deterrent (BCM TYPE 4)


The BCM provides the following content theft deterrent functions:
^ Intrusion detection
- Doors
- Lock cylinders
- Liftgate
- Sliding doors
- Shock sensor
- Power door lock switches
^ Intrusion notification
- Flashes the exterior lights
- Sounds the horn
- Security LED
^ Content theft feature customization
- Content theft deterrent system (on/off)
- Power door lock switch arming (on/off)
- Door key cylinder arm/disarm (on/off)
- Shock sensor (on/off)
- Remote arm/disarm only (on/off)
Refer to Content Theft Deterrent (CTD) Circuit Description in Theft Deterrent for more information.

On-Board Diagnostic Mode


The Body Control Module (BCM) provides on-board diagnostics to assist in diagnosing BCM related malfunctions. The BCM has the following
diagnostic capabilities when entering the on-board diagnostic mode:
^ Feature Customization
^ Displaying DTCs
^ Clearing DTCs
^ Input/Output Diagnostics
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To access the on-board diagnostic mode, refer to On-Board Diagnostic Features.

For a description of the RPO Code(s) shown in this article, refer to the RPO Code List found at Vehicle/Application and ID. See: Application and
ID
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Body Control Module: Initial Inspection and Diagnostic Overview

A Diagnostic Starting Point - Body Control System


Begin the diagnosis of the body control system by performing the Diagnostic System Check for the system in which the customer concern is
apparent. The Diagnostic System Check will direct you to the correct procedure for diagnosing the system and where the procedure is located.

A Diagnostic System Check - Body Control System

A Diagnostic System Check - Body Control System

TEST DESCRIPTION
The number(s) below refer to the step number(s) on the diagnostic table.
1. Tests if the BCM can enter the On-Board Diagnostic Mode. Refer to On-Board Diagnostic Features. See: Reading and Clearing Diagnostic
Trouble Codes
2. The presence of DTCs stored in the BCM. The specified procedure will compile all the available information before tests are performed.
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Body Control Module: Reading and Clearing Diagnostic Trouble Codes

Diagnostic Trouble Code (DTC) Clearing


CLEARING DTCS
BCM DTCs can only be cleared by completing the following procedure:
1. Enter the BCM on-board diagnostic mode. Refer to On-Board Diagnostic Features.
2. Press and hold the UNLOCK button on either power door lock switch for 4 seconds.
3. All stored DTCs will clear from the BCM.

Diagnostic Trouble Code (DTC) Displaying


1. Ensure that the BCM is in the feature customization mode. Refer to On-Board Diagnostic Features.
2. Turn the ignition switch from the ACC position to the LOCK position then back to the ACC position within 1 second.

The BCM will enter the on-board diagnostic mode and flash the fasten seat belts indicator and sound the chime equal to the number of DTCs stored
in the BCM memory. If no DTCs are stored, the BCM will not flash the fasten seat belts indicator or activate the chime.

The BCM flashes and sounds the first DTC with the lowest number, pauses, then continues with the next DTC until all of the DTCs are read. With
a DTC 1, the BCM will only sound the chime once, and the fasten seat belts indicator will not flash. Once all of the DTCs are read, the BCM
repeats this sequence 3 times.

Entering Feature Customization Mode


The feature customization mode is used to configure the BCM to function in various applications. The BCM can be customized to change the
following vehicle functions:
^ Interior Lighting Features
^ Door Lock System
^ Keyless Entry System
^ Content Theft Deterrent System

In order to enter the feature customization mode perform the following steps:
1. Turn the ignition switch to the LOCK position.
2. Remove the BCM PRGRM fuse.
3. Turn the ignition switch to the ACC position. When entering the feature customization mode, the BCM first identifies what type of BCM is
installed on the vehicle by flashing the fasten seat belts indicator and sounds the chime 2, 3 or 4 times depending on the type of BCM used on
the vehicle. There are 3 different types of BCM that can be installed on the vehicle based on the vehicle option content that matches the BCM
capabilities. Ensure that the BCM installed on the vehicle is compatible with all of the features on the vehicle. Refer to Body Control System
circuit description for BCM identification. For more information on features that can be customized, refer to:
^ Interior Lights Circuit Description
^ Automatic Door Lock System Description
^ Keyless Entry System Circuit Description
^ Content Theft Deterrent (CTD) Circuit Description

Entering Input/Output Diagnostic Mode


After the BCM reads all of the DTCs in the memory, the BCM enters the Input/Output Diagnostic Mode. The BCM flashes the fasten seat belts
indicator and sounds the chime once when any of the following inputs are activated:
^ Courtesy lamp switches
^ Door lock cylinder switches
^ Driver door ajar switch
^ Driver fasten seat belt switch
^ Driver Information Display (DID)
^ Headlamp switch
^ IP compartment lamp switch
^ Keyless entry request for door lock/unlock
^ Keyless entry request for the alarm (RPO UA6)
^ Passenger door ajar switch
^ Power door lock switches
^ Liftgate ajar switch
^ Sliding door ajar switch(es)
^ Shock sensor
^ Sunshade illuminated mirrors
^ Hazard switch

Perform the following procedure in order to test the BCM outputs:


1. Ensure that the BCM is in the diagnostic mode. Refer to Entering On-Board Diagnostic Mode.
2. Cycle the interior light switch ON then OFF.
3. The BCM will enter the Output Diagnostic Test Mode 1.
4. Each cycle of the interior light switch (ON/OFF) will to select from following test modes depending on BCM type:
^ Test Mode 1- De-activates the courtesy lights output and removes power to all of the interior lamps.
^ Test Mode 2- Activates the courtesy lights output and provides power to all of the interior lamps (interior lamp override switch must be
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ON).
^ Test Mode 3- Activates the courtesy lights output and turns ON all of the courtesy lamps (interior lamp switch must be ON).
^ Test Mode 4- Activates the theft deterrent relay for 1 second and turns ON the headlamps (BCM type 4).
^ Test Mode 5- Energizes the horn relay for 25 ms (BCM type 4).
^ Test Mode 6- Turns on the security LED indicator (BCM type 4).
^ Test Mode 7- Turns off the security LED indicator (BCM type 4).

When the BCM completes all test modes, the BCM will repeat the test mode sequence.

Exiting Diagnostics
Perform the following procedure in order to exit the BCM diagnostics mode and return to normal BCM operation:
1. Turn the ignition switch to the LOCK position.
2. Reinstall the BCM PRGRM fuse.
3. Turn the ignition switch to the RUN position.

For a description of the RPO Code(s) shown in this article, refer to the RPO Code List found at Vehicle/Application and ID. See: Application and
ID
Entering On-Board Diagnostic Mode
Complete the following steps in order to enter the diagnostics mode:
1. Turn the ignition switch to the LOCK position.
2. Remove the BCM PRGRM fuse.
3. Turn the ignition switch to the ACC position.
4. Turn the ignition switch from the ACC position to the LOCK position then back to the ACC position within 1 second.

The BCM will enter the on-board diagnostic mode and flash the fasten seat belts indicator and sound the chime equal to the number of DTCs stored
in the BCM memory. If no DTCs are stored, the BCM will not flash the fasten seat belts indicator or activate the chime.

The BCM flashes and sounds the first DTC with the lowest number, pauses, then continues with the next DTC until all of the DTCs are read. With
a DTC 1, the BCM will only sound the chime once, and the fasten seat belts indicator will not flash. Once all of the DTCs are read, the BCM
repeats this sequence 3 times.

IMPORTANT: If the fasten seat belts indicator does not flash, and the chime does not sound, complete the following procedure in order to
confirm that the BCM has entered the diagnostics mode:

1. Ensure that all of the vehicle doors are closed.


2. Open and close any vehicle door.
3. Fasten and release the driver seat belt.

The BCM sounds the chime when receiving an input signal such as opening a door or fastening the driver seat belt when the BCM is in the
diagnostics mode.

If the BCM does not sound the chime upon opening a door or fastening the driver seat belt, repeat Step 1 of Entering the Feature Customization
Mode. If the BCM does not enter the diagnostics mode, then refer to Body Control Module Inoperative.

General Information
This vehicle is equipped with an on-board diagnostic feature capable of performing the following functions:
^ Feature Customization
^ Displaying DTCs
^ Clearing DTCs
^ Input/Output Diagnostics
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Body Control Module: Symptom Related Diagnostic Procedures

Diagnostic Chart

TEST DESCRIPTION
The numbers below refer to the step numbers on the diagnostic table.
2. Tests for an open in the BCM battery positive voltage circuit(s) and the ignition voltage circuit(s).
3. Tests for an open in the BCM ground circuit(s).
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Body Control Module: Service and Repair
REMOVAL PROCEDURE

1. Disconnect the battery negative cable.


2. Remove the left side instrument panel insulator.
3. Push the release tab on the bottom of the bracket to release the body control module.
4. Slide the body control module from the bracket.

5. Disconnect the electrical connector.

INSTALLATION PROCEDURE

1. Connect the electrical to the body control module.


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2. Align the tabs on the body control module with the slots in the mounting bracket. Push the body control module up until it clicks in place.
3. Install the left side instrument panel insulator.
4. Connect the battery negative cable.
5. Setup the BCMs customized options.
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Intake Air Temperature (IAT) Sensor: Service and Repair

REMOVAL PROCEDURE
1. Disconnect the Intake Air Temperature (IAT) sensor electrical connector (1).
2. Carefully remove the IAT sensor.

INSTALLATION PROCEDURE
1. Install the IAT Sensor (snap into place).
2. Connect the IAT sensor electrical connector (1).
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Data Link Connector: Service and Repair

REMOVAL PROCEDURE
1. Remove the bolts/screws from the data link connector.
2. Remove the lower data link connector.

INSTALLATION PROCEDURE
1. Place the data link connector into position.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the bolts/screws to the data link connector.

Tighten
Tighten the bolts/screws to 2 N.m (18 lb in).
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EGR Valve Position Sensor: Description and Operation
The EGR pintle position sensor is an integral part of the EGR valve assembly. This sensor can not be serviced separately from the EGR valve
assembly.

The PCM monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM and to detect a fault
if the pintle position sensor and control circuits are open or shorted.

Linear EGR Control

If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a
tolerance considered acceptable for proper EGR system operation, the PCM sets DTC P1404 EGR Valve Stuck Open.
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Powertrain Control Module: Description and Operation
General Description
The powertrain used in this vehicle consists of a 3.4L pushrod 60° V-6 engine mated to a 4T65-E electronically controlled transaxle. Refer to
Engine Component Description in Engine Mechanical for more information on the powertrain. The powertrain has electronic controls to reduce
exhaust emissions while maintaining excellent driveability and fuel economy. The Powertrain Control Module (PCM) is the essence of this control
system.

The PCM is designed to maintain exhaust emission levels to Federal/California/other standards while providing excellent driveability and fuel
efficiency. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The PCM monitors
numerous engine and vehicle functions. The following are some of the functions that the PCM controls:
^ The engine fueling
^ The Ignition Control (IC)
^ The Knock Sensor (KS) system
^ The Evaporative Emissions (EVAP) system
^ The secondary Air Injection (AIR) system (if equipped)
^ The Exhaust Gas Recirculation (EGR) system
^ The automatic transmission functions
^ The generator
^ The A/C clutch control
^ The cooling fan control
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Powertrain Control Module: Description and Operation
PCM Function
The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and
emissions. The PCM also performs diagnostic tests on various pants of the system. The PCM can recognize operational problems and alert the
driver via the Malfunction Indicator Lamp (MIL). When the PCM detects a malfunction, the PCM stores a Diagnostic Trouble Code (DTC). The
problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The
input and output devices in the control module include analog to digital converters, signal buffers, counters, and output drivers. The output drivers
are electronic switches which complete a ground circuit when turned on. Most PCM controlled components are operated via output drivers. The
PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is
detected.
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Powertrain Control Module: Service and Repair
Repair Instructions

EEPROM Programming
1. Set-up - Ensure that the following conditions have been met:
^ The battery is fully charged and battery charger is not connected.
^ The ignition is ON.
^ The Techline equipment cable connection at the DLC is secure.
2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment users instructions.
3. If the PCM fails to program, proceed as follows:
^ Ensure that all PCM connections are OK.
^ Check the Techline equipment for the latest software version.
^ Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. You must program the replacement
PCM.
Functional Check
1. Clear any DTCs.
2. Perform the A Powertrain On Board Diagnostic (OBD) System Check.
3. Start the engine and allow the engine run for one minute.
4. Use a scan tool in order to scan for the DTCs.
PCM Replacement/Programming

NOTE:
^ In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the
circuit board.

Service of the Powertrain Control Module (PCM) should normally consist of either replacement of the PCM or Electrically Erasable
Programmable Read Only Memory (EEPROM) programming. If the diagnostic procedures call for PCM replacement, test the PCM first to
see if the PCM is the correct part. If the PCM is faulty, remove the PCM and install a new service PCM. The new service PCM is not
programmed. You must program the new PCM. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned.
^ In order to prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the
circuit board.
^ Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery
cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage.

IMPORTANT: When replacing the production PCM with a service PCM (controller), you must transfer the broadcast code and production PCM
number to the service PCM label. Do not record the information on the PCM cover. This allows positive identification of PCM parts throughout the
service life of the vehicle.
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REMOVAL PROCEDURE

CAUTION: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the negative battery cable.


2. Remove the coolant reservoir retaining bolt.
3. Remove the coolant reservoir and set aside.
4. Remove the SMCC module from the SMCC module bracket.
5. Remove the SMCC module bracket.
6. Remove the 3 bolts from the strut brace.
7. Remove the left front strut brace.
8. Unsnap the PCM cover and remove the PCM cover from the air cleaner housing.
9. Remove the PCM from the air cleaner housing.
10. Disconnect the PCM electrical connectors.

INSTALLATION PROCEDURE
1. Connect the PCM electrical connectors to the PCM.
2. Install the PCM into the air cleaner housing.
3. Reinstall the PCM cover to the air cleaner housing and snap the retainer.
4. Reinstall the left front strut brace.

NOTE: Refer to Fastener Notice in Service Precautions.

5. Reinstall the 3 strut brace retaining bolts.


6. Reinstall the SMCC module bracket.
7. Reinstall the SMCC module to the SMCC module bracket.
8. Reinstall the coolant reservoir. Be sure to check coolant system for proper level.
9. Reconnect the negative battery cable.
10. If a new PCM is being installed, program the EEPROM.
11. The PCM will need to learn the crankshaft variation. See: Testing and Inspection/Programming and Relearning
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Manifold Absolute Pressure (MAP) Sensor: Service and Repair

REMOVAL PROCEDURE
1. Turn OFF the ignition.
2. Remove the attaching bolt/screws.
3. Disconnect the MAP sensor electrical connector.
4. Disconnect the MAP inlet vacuum hose.
5. Remove the MAP sensor from the bracket.

INSTALLATION PROCEDURE
1. Install the MAP sensor to the bracket.
2. Connect the MAP inlet vacuum hose.
3. Connect the MAP sensor electrical connector.

NOTE: Refer to Fastener Notice in Service Precautions.

4. Install the bolts/screws.

Tighten
Tighten the bolts arid screws to 3 N.m (27 lb in).
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Manifold Absolute Pressure (MAP) Sensor: Description and Operation
The Manifold Absolute Pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the
PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the key ON and the engine not running or at wide open throttle (low
vacuum).

The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (Refer to DTC P0401
Exhaust Gas Recirculation (EGR) Flow Insufficient ),to determine engine vacuum level for other diagnostics, and to determine Barometric
Pressure (BARO).

If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 Manifold Absolute Pressure (MAP) Sensor
Circuit Low Voltage is set. A signal voltage higher than the possible range of the sensor sets DTC P0108 Manifold Absolute Pressure (MAP)
Sensor Circuit High Voltage. An intermittent low or high voltage sets DTC P1107 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent
Low Voltage or DTC P1106 Manifold Absolute Pressure (MAP) Sensor Circuit Intermittent High Voltage respectively. The PCM can also detect a
shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors
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Oxygen Sensor: Service and Repair
Heated Oxygen Sensor (HO2S) Replacement (HO2S1)

NOTE: Do not remove this pigtail from either the Heated Oxygen Sensor (HO2S) or the Oxygen Sensor (O2S). Removing the pigtail or the
connector will affect sensor operation.

Handle the oxygen sensor carefully. Do not drop the HO2S. keep the in-line electrical connector and the louvered end tree of grease, dirt, or other
contaminants. Do not use cleaning solvents of any type.

Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged.

This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or
terminals could result in the obstruction of the air reference and degraded sensor performance.

The following guidelines should be used when servicing the heated oxygen sensor:
^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing
poor performance.
^ Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign
materials to enter the sensor and cause performance problems.
^ Ensure the sensor or vehicle lead wires should not be bent sharply or kinked. Sharp bends or kinks could block the reference air path through
the lead wire.
^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this
ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance.
^ Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine
harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.

REMOVAL PROCEDURE
The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in
exhaust manifold or exhaust pipe.

1. Turn OFF the ignition.


2. Disconnect the sensor electrical connector.

IMPORTANT: A special anti seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in
fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors
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will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads
must have anti seize compound applied before reinstallation.

3. Use the J 39194-B heated oxygen sensor wrench in order to carefully back out the heated oxygen sensor.

INSTALLATION PROCEDURE
1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound GM P/N 5613695, or equivalent if necessary.

NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the heated oxygen sensor.

Tighten
Tighten the HO2S 1 (pre-catalytic converter) to 42 ± 4 N.m (31 lb ft).

3. Connect the sensor electrical connector.


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Oxygen Sensor: Service and Repair
Heated Oxygen Sensor (HO2S) Replacement (HO2S2)

NOTE: Do not remove this pigtail from either the Heated Oxygen Sensor (HO2S) or the Oxygen Sensor (O2S). Removing the pigtail or the
connector will affect sensor operation.

Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other
contaminants. Do not use cleaning solvents of any type.

Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged.

This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or
terminals could result in the obstruction of the air reference and degraded sensor performance.

The following guidelines should be used when servicing the heated oxygen sensor:
^ Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing
poor performance.
^ Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign
materials to enter the sensor and cause performance problems.
^ Ensure the sensor or vehicle lead wires should not be bent sharply or kinked. Sharp bends or kinks could block the reference air path through
the lead wire.
^ Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wired sensor may rely on this
ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance.
^ Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine
harness may be repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered
since this could result in the air reference being obstructed.

REMOVAL PROCEDURE
The heated oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in
the exhaust pipe.

1. Turn OFF the ignition.


2. Raise the vehicle.
3. Disconnect the sensor electrical connector.

IMPORTANT: A special anti seize compound is used on the heated oxygen sensor threads. The compound consists of graphite suspended in
fluid and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors
will already have the compound applied to the threads. If a sensor is removed from an engine and if for any reason is to be reinstalled, the threads
must have anti seize compound applied before reinstallation.

4. Use the J 39194-B heated oxygen wrench in order to carefully back out the heated oxygen sensor.

INSTALLATION PROCEDURE
1. Coat the threads of heated oxygen sensor/catalyst monitor with anti seize compound GM P/N #5613695, or equivalent if necessary.
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NOTE: Refer to Fastener Notice in Service Precautions.

2. Install the HO2S2.

Tighten
Tighten the HO2S 2 (post-catalytic converter) to 42±14 N.m (31 lb ft).

3. Connect the sensor electrical connector.


4. Lower the vehicle.
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Transmission Position Switch/Sensor: Adjustments
^ Tools Required
- J 41545 Park/Neutral Switch Alignment Tool

If a new PNP switch has been rotated and the pin is broken or if you are installing an old PNP switch, adjust the PNP switch.
1. Place the shift selector shaft into Neutral.
2. Use the J 41545 in order to align the slots of the PNP switch to the Neutral position.
3. Align the flats of the shift shaft to the flats in the PNP switch.
4. Install the PNP switch to the transaxle.

Important: If the PNP switch bolt holes do not align with the threaded holes in the transaxle, verify that the shaft is in the Neutral position.

5. Assemble the PNP switch bolts loosely.

6. Use the J 41545 in order to align the PNP switch.

Notice: Refer to Fastener Notice in Service Precautions.

7. Install the PNP switch bolts/screws.


^ Tighten the PNP switch bolts/screws to 25 Nm (18 ft. lbs.).
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Transmission Position Switch/Sensor: Service and Repair
Removal Procedure

1. Apply the parking brake.


2. Block the wheels.
3. Shift the transmission into Neutral.
4. Remove the throttle body air inlet duct. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
5. Use a flat-bladed tool in order to remove the automatic transaxle range selector cable from the cable lever.

6. Disconnect the electrical connectors.


7. Remove the automatic transaxle range selector lever. Refer to Automatic Transmission Range Selector Cable Lever Replacement.

8. Remove the PNP switch bolts.


9. Remove the PNP switch.

Installation Procedure

Tool Required
- J 41545 Park/Neutral Switch Alignment Tool
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1. Verify that the shift shaft in the Neutral position.

Important: DO NOT ROTATE A NEW PNP SWITCH. A new PNP switch is produced in the Neutral position. If the bolt holes do not align
with the holes in the transaxle, verify that the transmission is in Neutral.

Adjust the PNP switch if the new switch has been rotated and the pin is broken or if using an old PNP switch. Refer to PNP Switch Adjustment.

2. Align the flats of the shift shaft to the flats in the PNP switch.
3. Install the PNP switch to the transaxle.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the PNP switch bolts.


^ Tighten the PNP switch bolts to 25 Nm (18 ft. lbs.).
5. Install the automatic transaxle range selector lever. Refer to Automatic Transmission Range Selector Cable Lever Replacement.

6. Connect the electrical connectors.

7. Install the automatic transaxle range selector cable.

Important: Verify that the engine starts ONLY with the transmission in Park or Neutral. Adjust as necessary. Refer to PNP Switch
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Adjustment.

8. Install the throttle body air inlet duct. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
9. Remove the blocks from the wheels.
10. Release the parking brake.
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Vehicle Speed Sensor: Service and Repair
Removal Procedure

1. Raise and support the vehicle. Refer to Vehicle Lifting.


2. Remove the right front tire and wheel.
3. Remove the right engine splash shield.
4. Disconnect the vehicle speed sensor wiring harness connector.

5. Remove the vehicle speed sensor bolt (9).


6. Remove the vehicle speed sensor (10) from the extension case.

7. Remove the O-ring seal (11) from the vehicle speed sensor (10).

Important: Handle the vehicle speed sensor (10) carefully.

8. Inspect the vehicle speed sensor and O-ring seal for the following:
^ Damaged connector
^ Cracked housing
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 2
Chevrolet Venture V6-3.4L VIN E 449
^ Signs of rotor damage
^ Cuts or nicks on the O-ring seal (11)

Installation Procedure

1. Install the O-ring seal (11) to the vehicle speed sensor (10).
2. Install the vehicle speed sensor to the extension case.

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the vehicle speed sensor bolt (9).


^ Tighten the vehicle speed sensor bolt to 12 Nm (106 inch lbs.).

4. Connect the vehicle speed sensor wiring harness connector.


5. Install the right engine splash shield.
6. Install the right front tire and wheel.
7. Lower the vehicle.
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Vehicle: Specifications
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Chevrolet Venture V6-3.4L VIN E 451

GM Part Number 19001810


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Test Load 300 A

Cold Cranking Amperes 600 A

Reserve Capacity Rating 115 Minutes

Replacement Battery Number 78-6YR

Divide the reserve capacity by 4. The current drain in milliamps should not be more than this number.

Current draw Less than 25 milliamps is acceptable

Generator Model BOSCH NCB1

Rated Output 125 A

Load Test Output 87.5 A

Generator Model BOSCH KCB2

Rated Output 105 A

Load Test Output 70 A

Voltage
Voltage

Charging Voltage 13-16 Volts

Generator Model BOSCH NCB1

Rated Output 125 A

Load Test Output 87.5 A

Generator Model BOSCH KCB2

Rated Output 105 A

Load Test Output 70 A

Voltage
Voltage

Charging Voltage 13-16 Volts


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 4
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Temperature vs Resistance

Voltage
Voltage
ECT between 50-95 degrees F (10-35 degrees C)

Injector Voltage Reading 5.7 - 6.6 Volts


Please refer to Fuel Injector Coil Test procedure.

Resistance Ohms
Resistance Ohms
ECT between 50 - 95 degrees F (10 - 35 degrees C)

Ohms 11.4-12.6

Ignition Coil
Coil Resistance across leads ...................................................................................................................................................................... 5k-8k Ohms.
Ignition Timing
Information not supplied by the manufacturer.

A/C Compressor Hose Block Fitting to Accumulator Bolt 16 Nm

Accumulator Strap Bolt 5.5 Nm

Inflatable Restraint IP Module Fasteners 10 Nm

Inflatable Restraint Side Impact Sensor (SIS) Fasteners 10 Nm

Inflatable Restraint Sensing And Diagnostic Module (SDM) Fasteners 10 Nm


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 5
Chevrolet Venture V6-3.4L VIN E 454

Air Inlet Valve Electric Actuator Screws 1.6 Nm

Temperature Valve Electric Actuator Screws 1.6 Nm

Center Air Distribution Duct Retaining Nuts 10 Nm

Trim Hieght Specifications Non-Cargo Van D 5.47-6.25 in

J 9.21-10.00 in
(1) J Measurement taken 604 mm (24 inch) from
the centerline of the FRONT wheel.

K 10.07-10.86 in
(2) K Measurement taken 560 mm (22 inch) from
the centerline of the REAR wheel.

Z 2.28-3.07 in

Cargo Van (Z10) WITH Automatic D 5.78-6.57 in


Level Control (G67)

J 9.29-10.07 in
(1) J Measurement taken 604 mm (24 inch) from
the centerline of the FRONT wheel.

K 10.35-11.14 in
(2) K Measurement taken 560 mm (22 inch) from
the centerline of the REAR wheel.

Z 2.28-3.07 in

Cargo Van (Z10) WITHOUT D 6.53-7.32 in


Automatic Level Control (G67)

J 9.44-10.23 in
(1) J Measurement taken 604 mm (24 inch) from
the centerline of the FRONT wheel.

K 10.98-11.77 in
(2) K Measurement taken 560 mm (22 inch) from
the centerline of the REAR wheel.

Z 2.28-3.07 in

Front Camber Service Allowed (Acceptable) -1.20 to -0.20 deg

Service Preferred (Target) -0.70 deg

Caster (Nominal - No Means of Service Allowed (Acceptable) 2.40 to 3.40 deg


Adjustment Provided)

Service Preferred (Target) 2.90 deg

Cross Camber Service Allowed (Acceptable) -0.75 to 0.75 deg

Service Preferred (Target) 0 deg

Cross Caster (Nominal - No Service Allowed (Acceptable) -0.75 to 0.75 deg


Means of Adjustment Provided)
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Chevrolet Venture V6-3.4L VIN E 455
Service Preferred (Target) 0 deg

Total Toe Service Allowed (Acceptable) -0.20 to 0.20 deg

Service Preferred (Target) 0 deg

Rear (Nominal - No Means of Camber Service Allowed (Acceptable) -0.75 to -1.25 deg
Adjustment Provided)

Service Preferred (Target) -1.0 deg

Cross Camber Service Allowed (Acceptable) -0.50 to 0.50 deg

Service Preferred (Target) 0 deg

Total Toe Service Allowed (Acceptable) -0.30 to 0.30 deg

Service Preferred (Target) 0 deg

Trim Height Specifications Vehicles with 205/70R15 Tires D 5.23-6.02 in

J 8.97-9.76 in
(1) J Measurement taken 604 mm (24 inch) from
the centerline of the FRONT wheel.

K 9.84-10.62 in
(2) K Measurement taken 560 mm (22 inch) from
the centerline of the REAR wheel.

Z 2.28-3.07 in

Vehicles with 215/70R15 Tires D 5.23-6.02 in

J 9.25-10.03 in
(1) J Measurement taken 604 mm (24 inch) from
the centerline of the FRONT wheel.

K 10.15-10.94 in
(2) K Measurement taken 560 mm (22 inch) from
the centerline of the REAR wheel.

Z 2.28-3.07 in

Front Camber Service Allowed (Acceptable) -1.20 to -0.20 deg

Service Preferred (Target) -0.70 deg

Caster (Nominal- No Means of Service Allowed (Acceptable) 2.40 to 3.40 deg


Adjustment Provided)

Service Preferred (Target) 2.90 deg

Cross Caster Service Allowed (Acceptable) -0.75 to 0.75 deg

Service Preferred (Target) 0 deg

Cross Caster (Nominal- No Means of Service Allowed (Acceptable) -0.75 to 0.75 deg
Adjustment Provided)

Service Preferred (Target) 0 deg

Total Toe Service Allowed (Acceptable) -0.20 to 0.20 deg

Service Preferred (Target) 0 deg

Rear (Nominal- No Means of Camber Service Allowed (Acceptable) -0.75 to -1.25 deg
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 7
Chevrolet Venture V6-3.4L VIN E 456
Adjustment Provided)

Cross Camber Service Preferred (Target) -1.0 deg

Total Toe Service Allowed (Acceptable) -0.50 to 0.50 deg

Service Preferred (Target) 0 deg

Service Allowed (Acceptable) -0.30 to 0.30 deg

Service Preferred (Target) 0 deg

Trim Height Specifications Non-Cargo Van D 5.47-6.25 in

J 9.21-10.00 in
(1) J Measurement taken 604 mm (24 inch) from the
centerline of the FRONT wheel.

K 10.07-10.86 in
(2) K Measurement taken 560 mm (22 inch) from the
centerline of the REAR wheel.

Z 2.28-3.07 in

Cargo Van (Z10) WITH Automatic Level Control D 5.78-6.57 in


(G67)

J 9.29-10.07 in
(1) J Measurement taken 604 mm (24 inch) from the
centerline of the FRONT wheel.

K 10.35-11.14 in
(2) K Measurement taken 560 mm (22 inch) from the
centerline of the REAR wheel.

Z 2.28-3.07 in

Cargo Van (Z10) WITHOUT Automatic Level D 6.53-7.32 in


Control (G67)

J 9.44-10.23 in
(1) J Measurement taken 604 mm (24 inch) from the
centerline of the FRONT wheel.

K 10.98-11.77 in
(2) K Measurement taken 560 mm (22 inch) from the
centerline of the REAR wheel.

Z 2.28-3.07 in

Trim Height Specifications Vehicles with 205/70R15 Tires D 5.23-6.02 in

J 8.97-9.76 in
(1) J Measurement taken 604 mm (24 inch) from the
centerline of the FRONT wheel.

K 9.84-10.62 in
(2) K Measurement taken 560 mm (22 inch) from the
centerline of the REAR wheel.

Z 2.28-3.07 in

Vehicles with 215/70R15 Tires D 5.23-6.02 in


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Chevrolet Venture V6-3.4L VIN E 457

J 9.25-10.03 in
(1) J Measurement taken 604 mm (24 inch) from the
centerline of the FRONT wheel.

K 10.15-10.94 in
(2) K Measurement taken 560 mm (22 inch) from the
centerline of the REAR wheel.

Z 2.28-3.07 in

Generator B+ Terminal Nut 13 Nm

Generator Bolt 50 Nm

Generator Bracket Bolt 50 Nm

Generator Rear Cover Nut 12 Nm

Generator Rear Cover Screw 4 Nm

Generator Voltage Regulator Retaining Screw 2 Nm

Generator Voltage Regulator Terminal Screw 1 Nm

Antenna Cable Extension to Roof Bolt/Screw 3.2 Nm

Oil Pan to Case 10 ft.lb

Flywheel Bolts 52 lb. ft.

Fastener Tightening Specifications


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 9
Chevrolet Venture V6-3.4L VIN E 458

Part 1 of 2

Part 2 of 2
Transmission General Specifications
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Chevrolet Venture V6-3.4L VIN E 459

Part 1 of 2

Part 2 of 2
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Chevrolet Venture V6-3.4L VIN E 460

General
Bolt/Screw, Automatic Transaxle Case Extension M10 x 1.5 x 35 (Qty 4) ...................................................................................... 36 Nm (26 ft. lbs.)
Stud/Screw, Vehicle Speed Sensor - M8 x 1.25 x 12 (Qty 1) ...................................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Forward Band Servo Cover - M6 x 1.0 x 20 (Qty 3) ............................................................................................... 12 Nm (106 inch lbs.)
Bolt, Oil Pan Nm 6 x 1.0 x 17 (Qty 20) ............................................................................................................................................. 14 Nm (10 ft. lbs.)
Fitting, Transaxle Oil Cooler Pipe - 1/4 - 18 NPSF (Qty 2) .............................................................................................................. 38 Nm (28 ft. lbs.)
Plug, Automatic Transaxle Oil Pressure Test Hole 1/8 - 27 NPTF (Qty 1) ................................................................................. 12 Nm (106 inch lbs.)
Bolt/Screw, Case Side Cover (Flange) - M8 x 1.25 x 25 (Qty 9) ...................................................................................................... 25 Nm (18 ft. lbs.)
Bolt/Screw, Case Side Cover (Torx(R) Special) - M8 x 1.25 x 21 (Qty 4) ...................................................................................... 25 Nm (18 ft. lbs.)
Bolt/Screw, Case Side Cover (stud) - M8 x 1.25 x 24 (Qty 4) .......................................................................................................... 25 Nm (18 ft. lbs.)
Bolt/Screw, Manual 2-1 Band Servo Cover - M8 x 1.25 x 25 (Qty 3) .............................................................................................. 25 Nm (18 ft. lbs.)
Bolt/Screw, Accumulator Cover - M6 x 1.0 x 28 (Qty 11) .......................................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Automatic Transaxle Oil Pump Cover M6 x 1.0 x 20 (Qty 1) ..................................................................................... 8 Nm (70 inch lbs.)
Bolt/Screw, Automatic Transaxle Oil Pump - M6 x 1.0 x 95 (Qty 2) ............................................................................................... 16 Nm (11 ft. lbs.)
Bolt/Screw, Automatic Transaxle Oil Pump - M6 x 1.0 x 85 (Qty 9) ......................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 65 (Qty 3) .......................................................................................................... 12 Nm 106 inch lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 60 (Qty 3) ........................................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 30 (Qty 1) ........................................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Control Valve Body (Torx(R)) - M6 x 1.0 x 45 (Qty 2) .......................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 55 (Qty 3) ........................................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 95 (Qty 1) ................................................................................................................ 16 Nm (11 ft. lbs.)
Bolt/Screw, Control Valve Body - M8 x 1.25 x 90 (Qty 1) .............................................................................................................. 25 Nm (18 ft. lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 20 (Qty 2) ............................................................................................................... 8 Nm (70 inch lbs.)
Bolt/Screw, Control Valve Body - M6 x 1.0 x 85 (Qty 1) ........................................................................................................... 12 Nm (106 inch lbs.)
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Bolt/Screw, Automatic Transaxle Case Cover (Torx(R) Special) M6 x 1.0 x 32 (Qty 1) ........................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Automatic Transaxle Case Cover - M6 x 1.0 x 40 (Qty 3) ...................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Automatic Transaxle Case Cover - M8 x 1.25 x 50 (Qty 3) .......................................................................................... 25 Nm (18 ft. lbs.)
Bolt/Screw, Automatic Transaxle Case Cover - M6 x 1.0 x 30 (Qty 3) ...................................................................................... 12 Nm (106 inch lbs.)
Bolt/Screw, Drive Sprocket Support - M8 x 1.25 x 24 (Qty 4) ......................................................................................................... 25 Nm (18 ft. lbs.)
Nut, Manual Shift Shaft Detent Lever - M 10 x 1.5 (Qty 1) ............................................................................................................. 32 Nm (23 ft. lbs.)
Bolt/Screw, Manual Shift Shaft Detent - M6 x 1.0 x 16 (Qty 1) ................................................................................................. 12 Nm (106 inch lbs.)

General
ID Number I Dimension (mm) Dimension (inch) Color
Differential Carrier/Case Thrust Washer (714) Selection Guide
1 ..................................................................................................................................................................... 1.40-1.50 mm (0.055-0.059 inch) Orange
2 ....................................................................................................................................................................... 1.50-1.60 mm (0.059-0.062 inch) White
3 ......................................................................................................................................................................... 1.60-1.70 mm (0.062-0.066 inch) Blue
4 ......................................................................................................................................................................... 1.70-1.80 mm (0.066-0.070 inch) Pink
5 ..................................................................................................................................................................... 1.80-1.90 mm (0.070-0.074 inch) Brown
6 ....................................................................................................................................................................... 1.90-2.00 mm (0.074-0.078 inch) Green
7 ....................................................................................................................................................................... 2.00-2.10 mm (0.078-0.082 inch) Black
8 ...................................................................................................................................................................... 2.10-2.20 mm (0.082-0.086 inch) Purple
9 ........................................................................................................................................................... 2.20-2.30 mm (0.086-0.091 inch) Purple/White
10 ........................................................................................................................................................... 2.30-2.40 mm (0.091-0.095 inch) Purple/Blue
Bearing/input Clutch Hub Selective Thrust Washer (630) Selection Guide
1 .......................................................................................................................................................... 2.90-3.00 mm (0.114-0.118 inch) Orange/Green
2 .......................................................................................................................................................... 3.05-3.15 mm (0.120-0.124 inch) Orange/Black
3 ................................................................................................................................................................. 3.20-3.30 mm (0.126-0.130 inch) No Color
4 ....................................................................................................................................................................... 3.35-3.45 mm (0.132-0.136 inch) White
5 ......................................................................................................................................................................... 3.50-3.60 mm (0.138-0.142 inch) Blue
6 ......................................................................................................................................................................... 3.65-3.75 mm (0.144-0.148 inch) Pink
7 ..................................................................................................................................................................... 3.80-3.90 mm (0.150-0.154 inch) Brown
8 ....................................................................................................................................................................... 3.95-4.05 mm (0.156-0.159 inch) Green
9 ....................................................................................................................................................................... 4.10-4.20 mm (0.161-0.165 inch) Black
10 .................................................................................................................................................................... 4.25-4.35 mm (0.167-0.171 inch) Purple
11 ......................................................................................................................................................... 4.40-4.50 mm (0.173-0.177 inch) Purple/White

General
Important:
^ Rotor, vanes and slide must be chosen from the same size classification as the oil pump body.
^ Allowable rotor, vane and slide to oil pump body end play is as follows:
^ Slide to Oil Pump Body End Play - 0.033-0.076 mm (0.0013-0.0030 inch)
^ Rotor and Vane to Oil Pump Body End Play 0.050-0.083 mm (0.0020-0.0033 inch)

The oil pump assembly has a selective rotor, vane and slide components. These components are chosen based on pump body dimensions. Oil pump b

Rotor Selection
1 ..................................................................................................................................................................... 17.953-17.963 mm (0.7068-0.7072 inch)
2 ..................................................................................................................................................................... 17.963-17.973 mm (0.7072-0.7076 inch)
3 ..................................................................................................................................................................... 17.973-17.983 mm (0.7076-0.7080 inch)
4 ..................................................................................................................................................................... 17.983-17.993 mm (0.7080-0.7084 inch)

Size
Classification Thickness (mm) Thickness (inch)
Vane Selection
1 ..................................................................................................................................................................... 17.943-17.961 mm (0.7064-0.7071 inch)
2 ..................................................................................................................................................................... 17.943-17.961 mm (0.7064-0.7071 inch)
3 ..................................................................................................................................................................... 17.961-17.979 mm (0.7071-0.7078 inch)
4 ..................................................................................................................................................................... 17.961-17.979 mm (0.7071-0.7078 inch)
Slide Selection
1 ..................................................................................................................................................................... 17.957-17.967 mm (0.7070-0.7074 inch)
2 ..................................................................................................................................................................... 17.967-17.977 mm (0.7074-0.7078 inch)
3 ..................................................................................................................................................................... 17.977-17.987 mm (0.7078-0.7081 inch)
4 ..................................................................................................................................................................... 17.987-17.997 mm (0.7081-0.7085 inch)
Oil Pump Body Depth
1 ..................................................................................................................................................................... 18.000-18.010 mm (0.7087-0.7091 inch)
2 ..................................................................................................................................................................... 18.010-18.020 mm (0.7091-0.7094 inch)
3 ..................................................................................................................................................................... 18.020-17.030 mm (0.7094-0.7098 inch)
4 ..................................................................................................................................................................... 18.030-18.040 mm (0.7098-0.7102 inch)
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General
RPO Codes ........................................................................................................................................................................................... M15/MN3/MN7
Production Location ..................................................................................................................................................................................... Warren, MI
Vehicle Platform (Engine/Transmission) Usage ...................................................................................................................................... C, H, W, G, U
Transaxle Drive ............................................................................................................................................... Transverse Mounted Front Wheel Drive
1st Gear Ratio ...................................................................................................................................................................................................... 2.921:1
2nd Gear Ratio .................................................................................................................................................................................................... 1.568:1
3rd Gear Ratio ..................................................................................................................................................................................................... 1.000:1
4th Gear Ratio ..................................................................................................................................................................................................... 0.705:1
Reverse ................................................................................................................................................................................................................ 2.385:1
Torque Converter Size (Diameter of Torque Converter Turbine) .................................................................... 245 mm (M 15) 258 mm (MN3/MN7)
Pressure Taps ............................................................................................................................................................................................. Line Pressure
Transaxle Fluid Type ............................................................................................................................................................................ Dexron(TM) III
Transaxle Fluid Capacity (Approximate) ................. Bottom Pan Removal: 7.0L (7.4 qts) Complete Overhaul: 9.5L (10.0 qts) Dry: 12.7L (13.4 qts)
Transaxle Type: 4 ........................................................................................................................................................................... Four Forward Gears
Transaxle Type: T .............................................................................................................................................................................. Transverse Mount
Transaxle Type: 65 ................................................................................................................................................................................... Product Series
Transaxle Type: E ............................................................................................................................................................................ Electronic Controls
Chain Ratios (Designates Number of Teeth on the Drive/Driven Sprockets) ............................................................................................. 35/35 37/33
Final Drive Ratios .................................................................................................................................................................................. 2.86, 3.05, 3.29
Overall Final Drive Ratios ............................................................................................................................................................ 2.86, 3.05, 2.93, 3.29
Position Quadrant .............................................................................................................................................. P, R, N, D, 3, 2, 1 or P, R, N, OD, 2, 1
Case Material ................................................................................................................................................................................... Die Cast Aluminum
Transaxle Weight Dry ..................................................................................................................................................................... 87.9 kg (194.2 lbs)
Transaxle Weight Wet .................................................................................................................................................................... 97.0 kg (214.4 lbs)
Maximum Trailer Towing Capacity .................................................................................................................................................. 907 kg (2000 lbs)
Maximum Gross Vehicle Weight (GVW) ..................................................................................................................................... 2903 kg (6,400 lbs)
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Accumulator, A/T
Accumulator Cover to Case ......................................................................................................................................................................... 106 inch lbs

Fluid Filler Tube Bolt 115 in.lb

Fluid Filler Tube Nut 115 in.lb

2-1 Servo to Case 18 ft.lb

Forward Band Servo Cover to Case 106 in.lb

Tightening Specifications
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Tightening Specifications

Case Cover to Case 106 in.lb

Case Cover to Driven Sprocket Support 18 ft.lb

Case Cover to Driven Sprocket Support (Torx) 106 in.lb

Case Side Cover to Case 18 ft.lb

Case Side Cover to Case (Stud) 18 ft.lb

Case Side Cover to Case (Torx Special) 18 ft.lb

Detent Spring to Case Cover 106 in.lb

Pump Cover to Case Cover 106 in.lb

TFP Switch to Case Cover 106 in.lb

Case Extension to Case 26 ft.lb

Oil Cooler Hose Clip Bolt 17 ft.lb

Oil Cooler Pipe Fitting at Radiator 33 ft.lb

Oil Pan to Case 10 ft.lb

Pump Cover to Pump Body 70 in.lb

Flywheel to Torque Converter Bolts 47 ft.lb

Torque Converter Cover Bolts 89 in.lb

Oil Cooler Quick Connector 28 ft.lb

Oil Cooler Quick Connector with Checkball 28 ft.lb

PNP Switch Bolts 18 ft.lb

Transmission Pressure Test Port, A/T


Oil Pressure Test Hole Plug ......................................................................................................................................................................... 106 inch lbs
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TFP Switch to Valve Body 70 in.lb

Valve Body to Case 106 in.lb

Valve Body to Case 106 in.lb

Valve Body to Case Cover 106 in.lb

Valve Body to Case Cover 106 in.lb

Valve Body to Case Cover (Torx) 106 in.lb

Valve Body to Driven Sprocket Support 18 ft.lb

Battery Hold-Down Retainer Bolt 25 Nm

Battery Terminal Bolt 16 Nm

Battery Tray Bolt 10 Nm

Battery Ground (Negative) Cable Nut to Transaxle Stud 25 Nm

Battery Ground (Negative) Cable to Inner Fender Bolt 5 Nm

Battery Positive Cable to Underhood Electrical Center Nut 10 Nm

Blower Motor Screws 20 Nm

Blower Motor Resistor/Relay Screws 1.9 Nm

Body Front End


Fastener Tightening Specifications
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Body Rear End


Fastener Tightening Specifications

Bumper
Fastener Tightening Specifications
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Doors
Fastener Tightening Specifications

Exterior Moulding / Trim


Fastener Tightening Specifications

Front Subframe
Fastener Tightening Specifications

Hood Release Handle Bolts/Screws 2 Nm

Instrument Panel, Gauges, and Console - Fastener Tightening Specifications


Fastener Tightening Specifications
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Chevrolet Venture V6-3.4L VIN E 469

Interior Trim - Fastener Tightening Specifications


Fastener Tightening Specifications

Luggage Rack
Fastener Tightening Specifications

Rear Mirror Support Screw 2 Nm

Front Seat Nuts 40 Nm

Front Seat Recliner Bolts 48 Nm


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 21
Chevrolet Venture V6-3.4L VIN E 470

Rear Seat Riser Bolts (Bucket) 45 Nm

Rear Seat Riser Bolts (Split Benches) 32 Nm

Seat Adjuster Bolts 32 Nm

Seats - Fastener Tightening Specifications


Fastener Tightening Specifications

Liftgate Lock Cylinder Retaining Nuts 10 Nm

Liftgate Strut Ball Stud 25 Nm

Liftgate Strut Bracket to Liftgate Retaining Bolts 10 Nm

Lower Liftgate Wedge Retaining Screws 10 Nm

Upper Liftgate Wedge Retaining Screws 10 Nm

Liftgate Handle Retaining Bolts 10 Nm

Liftgate Handle Retaining Nuts 10 Nm

Liftgate Hinge Stud Nuts 25 Nm

Liftgate Hinge to Liftgate Retaining Bolts 25 Nm

Liftgate Latch Retaining Bolts 10 Nm

Liftgate Latch Striker Retaining Bolts 25 Nm

System Specifications
Front Brakes

Caliper Bore Diameter ........................................................................................................................................................................ 63.5 mm 2.500 in


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Rotor Diameter ................................................................................................................................................................................ 278.0 mm 10.945 in
Rotor Discard Thickness* ..................................................................................................................................................................... 30.7 mm 1.21 in
Rotor Maximum Lateral Runout ......................................................................................................................................................... 0.06 mm 0.002 in
Rotor Maximum Scoring .................................................................................................................................................................... 1.50 mm 0.059 in
Rotor Maximum Thickness Variation ............................................................................................................................................... 0.025 mm 0.001 in
Rotor Minimum Thickness After Refinish .......................................................................................................................................... 31.08 mm 1.22 in
Rotor Minimum Wear Stock ............................................................................................................................................................... 0.38 mm 0.015 in
Rotor Thickness - New ......................................................................................................................................................................... 32.2 mm 1.27 in

Rear Brakes

Caliper Bore Diameter ........................................................................................................................................................................ 38.1 mm 1.500 in


Rotor Diameter ................................................................................................................................................................................ 278.0 mm 10.945 in
Rotor Discard Thickness* ....................................................................................................................................................................... 9.0 mm 0.35 in
Rotor Maximum Lateral Runout ....................................................................................................................................................... 0.080 mm 0.003 in
Rotor Maximum Scoring .................................................................................................................................................................... 1.50 mm 0.059 in
Rotor Maximum Thickness Variation ............................................................................................................................................... 0.025 mm 0.001 in
Rotor Minimum Thickness After Refinish ............................................................................................................................................ 10.6 mm 0.41 in
Rotor Minimum Wear Stock ................................................................................................................................................................... 1.6 mm 0.06 in
Rotor Thickness (new) .......................................................................................................................................................................... 11.0 mm 0.43 in

* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace

The content of this article has been updated by manual update # 04-05-23-002A dated August 4, 2005 for Rotor Minimum Allowable Thickness Afte

Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV). 44 in.lb

Hydraulic Control Assembly - Antilock Brakes


ABS Modulator Bleeder Valves ......................................................................................................................................................... 9 Nm (80 inch lbs.)
Brake Pressure Modulator Valve (BPMV) and Electronic Brake Control Module (EBCM) Assembly to mounting bracket. ..... 10 Nm (89 inch lbs.)

TCS Modulator Bleeder Valves 80 in.lb

Brake System Pressure Bleed Initial Pressure Adjustment Setting (Leak Testing the Hydraulic Brake System) 10 psi

Pressure Bleed Procedure Setting 35 psi

Brake Pedal Brace Bolt 89 in.lb

Brake Pedal Brace Nut 89 in.lb

Brake Pedal Bracket Nut 44 in.lb

Brake Pedal Maximum Travel* 2.91 in


*Specification with 450 N (100 lbs.) of force applied to
the brake pedal, the ignition OFF and the brake booster
vacuum depleted.
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 23
Chevrolet Venture V6-3.4L VIN E 472

Disc Brake Component Specifications


Front Brakes

Caliper Bore Diameter ........................................................................................................................................................................ 63.5 mm 2.500 in


Rotor Diameter ................................................................................................................................................................................ 278.0 mm 10.945 in
Rotor Discard Thickness* ..................................................................................................................................................................... 30.7 mm 1.21 in
Rotor Maximum Lateral Runout ......................................................................................................................................................... 0.06 mm 0.002 in
Rotor Maximum Scoring .................................................................................................................................................................... 1.50 mm 0.059 in
Rotor Maximum Thickness Variation ............................................................................................................................................... 0.025 mm 0.001 in
Rotor Minimum Thickness After Refinish .......................................................................................................................................... 31.08 mm 1.22 in
Rotor Minimum Wear Stock ............................................................................................................................................................... 0.38 mm 0.015 in
Rotor Thickness - New ......................................................................................................................................................................... 32.2 mm 1.27 in

Rear Brakes

Caliper Bore Diameter ........................................................................................................................................................................ 38.1 mm 1.500 in


Rotor Diameter ................................................................................................................................................................................ 278.0 mm 10.945 in
Rotor Discard Thickness* ....................................................................................................................................................................... 9.0 mm 0.35 in
Rotor Maximum Lateral Runout ....................................................................................................................................................... 0.080 mm 0.003 in
Rotor Maximum Scoring .................................................................................................................................................................... 1.50 mm 0.059 in
Rotor Maximum Thickness Variation ............................................................................................................................................... 0.025 mm 0.001 in
Rotor Minimum Thickness After Refinish ............................................................................................................................................ 10.6 mm 0.41 in
Rotor Minimum Wear Stock ................................................................................................................................................................... 1.6 mm 0.06 in
Rotor Thickness (new) .......................................................................................................................................................................... 11.0 mm 0.43 in

* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace

The content of this article has been updated by manual update # 04-05-23-002A dated August 4, 2005 for Rotor Minimum Allowable Thickness Afte

Front Brakes Brake Caliper Bleeder Valve 115 in.lb

Brake Caliper Bolt 63 ft.lb

Brake Caliper Bracket Bolt 137 ft.lb

Caliper Bore Diameter 2.500 in

Rear Brakes (Export) Brake Caliper Bleeder Valve 62 in.lb

Brake Caliper Bolt 33 ft.lb

Brake Caliper Bracket Bolt 92 ft.lb

Caliper Bore Diameter 1.500 in

Brake Pad
Replace the pads when the thickness is worn to within 0.76 mm (0.030 inch) of the shoe. Replace all pads in axle sets.

Measure the flatness of the inner and outer pads. Place the pad surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0

Brake Rotor/Disc
Front Brakes
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 24
Chevrolet Venture V6-3.4L VIN E 473
Caliper Bore Diameter ........................................................................................................................................................................ 63.5 mm 2.500 in
Rotor Diameter ................................................................................................................................................................................ 278.0 mm 10.945 in
Rotor Discard Thickness* ..................................................................................................................................................................... 30.7 mm 1.21 in
Rotor Maximum Lateral Runout ......................................................................................................................................................... 0.06 mm 0.002 in
Rotor Maximum Scoring .................................................................................................................................................................... 1.50 mm 0.059 in
Rotor Maximum Thickness Variation ............................................................................................................................................... 0.025 mm 0.001 in
Rotor Minimum Thickness After Refinish .......................................................................................................................................... 31.08 mm 1.22 in
Rotor Minimum Wear Stock ............................................................................................................................................................... 0.38 mm 0.015 in
Rotor Thickness - New ......................................................................................................................................................................... 32.2 mm 1.27 in

Rear Brakes

Caliper Bore Diameter ........................................................................................................................................................................ 38.1 mm 1.500 in


Rotor Diameter ................................................................................................................................................................................ 278.0 mm 10.945 in
Rotor Discard Thickness* ....................................................................................................................................................................... 9.0 mm 0.35 in
Rotor Maximum Lateral Runout ....................................................................................................................................................... 0.080 mm 0.003 in
Rotor Maximum Scoring .................................................................................................................................................................... 1.50 mm 0.059 in
Rotor Maximum Thickness Variation ............................................................................................................................................... 0.025 mm 0.001 in
Rotor Minimum Thickness After Refinish ............................................................................................................................................ 10.6 mm 0.41 in
Rotor Minimum Wear Stock ................................................................................................................................................................... 1.6 mm 0.06 in
Rotor Thickness (new) .......................................................................................................................................................................... 11.0 mm 0.43 in

* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace

The content of this article has been updated by manual update # 04-05-23-002A dated August 4, 2005 for Rotor Minimum Allowable Thickness Afte

Brake Shoe
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 25
Chevrolet Venture V6-3.4L VIN E 474
Minimum Linning Thickness ............................................................................................................................................................................ 0.030 in.
(Above Rivet Head or Backing Plate)

Brake Rear Wheel Cylinder Bleeder Valve 62 in.lb

Wheel Cylinder Bolts 110 in.lb

Brake Hose Bolt at Front Brake Caliper 40 ft.lb

Brake Hose Bolt at Rear Brake Caliper (Export Only) 32 ft.lb

Brake Pipe Fitting 15 ft.lb

Brake Pipe Fittings at Brake Pressure Modulator Valve (BPMV) and Master Cylinder. 18 ft.lb

Proportioning Valve Cap 20 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 26
Chevrolet Venture V6-3.4L VIN E 475

Parking Brake Cable


Park Brake Cable Clip Nut .............................................................................................................................................................. 3 Nm (27 inch lbs.)
Park Brake Cable Front Guide Bolt ............................................................................................................................................ 13 Nm (115 inch lbs.)
Park Brake Cable Rear Guide Nut .............................................................................................................................................. 14 Nm (124 inch lbs.)

gc00ubody_5-132a
gc00ubody_5-132a

Park Brake Lever Nuts 89 in.lb

Parking Brake Warning Switch


Park Brake Indicator Switch Screw ................................................................................................................................................. 3 Nm (27 inch lbs.)

Brake Booster Nut 18 ft.lb

Child Seat Tether Strap Anchor Bracket Bolt 43 Nm

Child Seat Tether Strap Anchor Plate Bolt And Nut 10 Nm

System Specifications
Compressor Mounting Bolts..........50 Nm 37 ft lb

Compressor Shaft Nut...............18 Nm 13 ft lb

Compressor Clutch
Compressor Clutch Gap
V5 Conventional Mount ..................................................................................................................................................................... 0.40 - 0.50 mm
V5 Direct Mount ........................................................................................................................................................................................... 0.40 mm

Heater A/C Controls Bolts/Screws 2.5 Nm


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 27
Chevrolet Venture V6-3.4L VIN E 476

Antifreeze GM Goodwrench DEX-CO0L (R) or HAVOLINE (R) DEX-COOL


(R)

Antifreeze to Water Ratio 56 %

Front HVAC System Only (C60) without Heavy Duty Cooling (V08 9.5 qt (US)

Front and Rear HVAC System (C34) without Heavy Duty Cooling 12.1 qt (US)
(V08)

Front HVAC System Only (C60) with Heavy Duty Cooling (VO8) 10.5 qt (US)

Front and Rear HVAC System (C34) with Heavy Duty Cooling (V08) 13.2 qt (US)

Coolant Recovery Reservoir 1 qt (US)

Thermostat Bypass Pipe to Cylinder Head Nut 18 ft.lb

Thermostat Bypass Pipe to Engine Front Cover Bolt 106 in.lb

Thermostat Bypass Pipe to Throttle Body Nut 18 ft.lb

Thermostat Bypass Pipe Bolt 98 in.lb

Thermostat Bypass Pipe Nut 18 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 28
Chevrolet Venture V6-3.4L VIN E 477

Cooling Fan Shroud Bolts 53 in.lb

Radiator Bracket Bolts 18 ft.lb

Radiator Lower Air Deflector Bolts 15 ft.lb

Cooling Fan Nut 53 in.lb

Cooling Fan Motor Screws 53 in.lb

Blade Diameter 14.1 in

Motor Type Generation II Low Profile Permanent Magnet

Water Outlet Bolt 18 ft.lb

Thermostat Housing Bolts 18 ft.lb

Water Pump Bolt 89 in.lb

Cruise Control Module Mounting Bracket to Inner Fender Bolts 6 Nm

Cruise Control Module to Mounting Bracket Bolt 6 Nm

Camshaft Sprocket Bolt 103 lb. ft.

Connecting Rod Bearing Cap Nut 15 ft.lb


+ 75 degrees

Water Pump Bolt 89 in.lb

Crankshaft Balancer Bolt 76 ft.lb

Cylinder Head Torque & Sequence


This article has been updated with TSB 02-06-01-003B, 4/15/08
This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT TO BE RE-USED. Please discard Corporate Bull

Notice: This component uses torque-to-yield bolts. When servicing this component, do not re-use the bolts. New torque-to-yield bolts must be ins
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 29
Chevrolet Venture V6-3.4L VIN E 478

Tighten the NEW cylinder head bolts to 60 Nm (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotate the cylinder

Exhaust Manifold Nut 12 ft.lb

Exhaust Manifold Stud 13 ft.lb

Exhaust Manifold Pipe Nut 26 ft.lb

Fastener Tightening Specifications


Fastener Tightening Specifications
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 30
Chevrolet Venture V6-3.4L VIN E 479

Part 1 of 2
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 31
Chevrolet Venture V6-3.4L VIN E 480

Part 2 of 2

Flywheel Bolts 52 lb. ft.

General Engine Data/Specifications


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 32
Chevrolet Venture V6-3.4L VIN E 481
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 33
Chevrolet Venture V6-3.4L VIN E 482

Main Bearing Cap Bolts First Pass 37 lb. ft.

Final Pass +77 Degrees

Metric-English Conversion Factors


CONVERSION FACTORS
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 34
Chevrolet Venture V6-3.4L VIN E 483

Oil Pump Oil Pump Drive Clamp Bolt 27 ft.lb

Oil Pump Mounting Bolt 30 ft.lb

Gear Length 1.199-1.200 inch


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 35
Chevrolet Venture V6-3.4L VIN E 484
Diameter 1.498-1.500 inch

Side Clearance 0.001-0.003 in

End Clearance 0.002-0.005 in

Valve to Bore Clearance 0.0015-0.0035 in

Gear Lash 0.0037-0.0077 inch

Gear Pocket Depth 1.202-1.204 in

Gear Pocket Diameter 1.503-1.505 in

Camshaft Sprocket Bolt 103 lb. ft.

Camshaft Thrust Plate Screw 89 in.lb

Lobe Lift (intake and Exhaust) 0.2727 in

Journal Diameter 1.868-1.869 in

Journal Clearance 0.001-0.0039 in

Journal Runout - Max 0.001 in

Rod Bearing Journal Clearance 0.0007-0.0024 in

Rod Side Clearance 0.007-0.017 in

Rod Bearing Bore Diameter 2.124-2.125 in

Connecting Rod Bearing Cap Nut 15 ft.lb


+ 75 degrees

Connecting Rod Bearing Cap Nut 15 ft.lb


+ 75 degrees

Rod Bearing Journal Clearance 0.0007-0.0024 in

Rod Side Clearance 0.007-0.017 in

Rod Bearing Bore Diameter 2.124-2.125 in

Camshaft Sprocket Bolt 103 lb. ft.


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 36
Chevrolet Venture V6-3.4L VIN E 485

Crankshaft-Main Bearing Cap Bolt/Stud 37 ft.lb


+ 77 degrees

Crankshaft Oil Deflector Nut 18 ft.lb

Main Journal Diameter 2.6473-2.6483 in

Main Journal Taper 0.0002 in

Out Of Round - Max 0.0002 in

Flange Runout - Max 0.0016 in

Cylinder Block Main Bearing Bore Diameter 2.8407-2.8412 in

Crankshaft Main Bearing Inside Diameter 2.6492-2.6502 in

Main Bearing Clearance 0.0008-0.0025 in

Main Thrust Bearing Clearance 0.0012-0.0030 in

Crankshaft End Play 0.0024-0.0083 in

Crankshaft Flange Runout - Max 0.0016 in

Rod Bearing Journal Diameter 1.9987-1.9994 in

Rod Bearing Journal Taper - Max 0.0002 in

Rod Bearing Journal Out Of Round - Max 0.0002 in

Rod Inside Bearing Diameter 2.000-2.002 in

Diameter 3.6228-3.6235 in

Out Of Round Maximum 0.0003 in

Taper - Thrust Side Maximum 0.0004 in

General Engine Specifications


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 37
Chevrolet Venture V6-3.4L VIN E 486
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 38
Chevrolet Venture V6-3.4L VIN E 487

Main Bearing Cap Bolts First Pass 37 lb. ft.

Final Pass +77 Degrees

Cylinder Block Main Bearing Bore Diameter 2.8407-2.8412 in

Crankshaft Main Bearing Inside Diameter 2.6492-2.6502 in

Main Bearing Clearance 0.0008-0.0025 in

Main Thrust Bearing Clearance 0.0012-0.0030 in

Crankshaft End Play 0.0024-0.0083 in

Diameter 3.6209-3.6216 in
Gaged on the skirt 13 mm (0.51 inch) below the centerline
of the piston pin bore
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 39
Chevrolet Venture V6-3.4L VIN E 488

Clearance 0.0013-0.0027 in

Pin Bore 0.9057-0.9060 in

Top Groove Side Clearance 0.002-0.0033 in

Second Groove Side Clearance 0.002-0.0035 in

Top Ring Gap 0.006-0.014 in

Second Ring Gap 0.0197-0.0280 in

Oil Ring Groove Clearance 0.008 in

Gap with segment at 92.0 mm (3.62 inch) 0.0098-0.05 in

Rod Bearing Journal Clearance 0.0007-0.0024 in

Rod Side Clearance 0.007-0.017 in

Rod Bearing Bore Diameter 2.124-2.125 in

Connecting Rod Bearing Cap Nut 15 ft.lb


+ 75 degrees

Rod Bearing Journal Clearance 0.0007-0.0024 in

Rod Side Clearance 0.007-0.017 in

Rod Bearing Bore Diameter 2.124-2.125 in

Coolant Drain Plug 14 ft.lb

Crankshaft Balancer Bolt 76 ft.lb

Main Bearing Cap Bolts First Pass 37 lb. ft.

Final Pass +77 Degrees

Cylinder Block Main Bearing Bore Diameter 2.8407-2.8412 in

Crankshaft Main Bearing Inside Diameter 2.6492-2.6502 in

Main Bearing Clearance 0.0008-0.0025 in

Main Thrust Bearing Clearance 0.0012-0.0030 in


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 40
Chevrolet Venture V6-3.4L VIN E 489
Crankshaft End Play 0.0024-0.0083 in

Crankshaft-Main Bearing Cap Bolt/Stud 37 ft.lb


+ 77 degrees

Crankshaft Oil Deflector Nut 18 ft.lb

Main Journal Diameter 2.6473-2.6483 in

Main Journal Taper 0.0002 in

Out Of Round - Max 0.0002 in

Flange Runout - Max 0.0016 in

Cylinder Block Main Bearing Bore Diameter 2.8407-2.8412 in

Crankshaft Main Bearing Inside Diameter 2.6492-2.6502 in

Main Bearing Clearance 0.0008-0.0025 in

Main Thrust Bearing Clearance 0.0012-0.0030 in

Crankshaft End Play 0.0024-0.0083 in

Crankshaft Flange Runout - Max 0.0016 in

Rod Bearing Journal Diameter 1.9987-1.9994 in

Rod Bearing Journal Taper - Max 0.0002 in

Rod Bearing Journal Out Of Round - Max 0.0002 in

Rod Inside Bearing Diameter 2.000-2.002 in

Coolant Heater Bolt/Screw 18 in.lb

Crankshaft Balancer Bolt 76 ft.lb

Diameter 0.9052-0.9054 in

Clearance In Piston 0.0004-0.0008 in

Fit In Rod 0.0006-0.0018 in

Top Groove Side Clearance 0.002-0.0033 in

Second Groove Side Clearance 0.002-0.0035 in

Top Ring Gap 0.006-0.014 in

Second Ring Gap 0.0197-0.0280 in

Oil Ring Groove Clearance 0.008 in


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 41
Chevrolet Venture V6-3.4L VIN E 490

Gap with segment at 92.0 mm (3.62 inch) 0.0098-0.05 in

Diameter 3.6209-3.6216 in
Gaged on the skirt 13 mm (0.51 inch) below the centerline
of the piston pin bore

Clearance 0.0013-0.0027 in

Pin Bore 0.9057-0.9060 in

Camshaft Sprocket Bolt 103 lb. ft.

Cylinder Head Torque & Sequence


This article has been updated with TSB 02-06-01-003B, 4/15/08
This bulletin is being revised to include a Notice advising that the cylinder head bolts are NOT TO BE RE-USED. Please discard Corporate Bull

Notice: This component uses torque-to-yield bolts. When servicing this component, do not re-use the bolts. New torque-to-yield bolts must be ins

Tighten the NEW cylinder head bolts to 60 Nm (44 lb ft) in the order shown. Use the J 36660-A torque angle meter in order to rotate the cylinder

Exhaust Manifold Nut 12 ft.lb

Exhaust Manifold Stud 13 ft.lb

Exhaust Manifold Pipe Nut 26 ft.lb

Intake Manifold Coolant Pipe Bolt 89 in.lb

Lower Intake Manifold Bolt 115 in.lb

Upper Intake Manifold Bolt/Stud 18 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 42
Chevrolet Venture V6-3.4L VIN E 491

Rocker Arm Assembly


VALVE ROCKER ARM BOLT:
First Pass ........................................................................................................................................................................................ 19 Nm (14 ft. lbs.)
Final Pass ................................................................................................................................................................................................. (30 degrees)

Valve Clearance
The manufacturer indicates that this vehicle has hydraulic lifters or adjusters and therefore does not require adjustment.

Valve Rocker Arm Cover Bolt 89 in.lb

Seat Angle 45 deg

Valve Seat Runout 0.002 in

Seat Width-intake 0.061-0.071 in

Seat Width-Exhaust 0.067-0.079 in

Valve Springs Free Length 1.89 in

Valve Springs Load (Closed) 75 lbf at 1.701 in

Valve Springs Load (Open) 230 lbf at 1.260 in

Installed Height Intake-Exhaust 1.701 in

Approx. # or coils 6.55

Valve Margin - Minimum Intake 0.083 in

Valve Margin - Minimum Exhaust 0.106 in

Valve Stem Clearance 0.0010-0.0027 in

Valve Face Angle 45 deg

Drive Belt Shield Bolt 89 in.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 43
Chevrolet Venture V6-3.4L VIN E 492

Drive Belt Tensioner Bolt 37 ft.lb

Generator Bracket and Front Engine Lift Hook Bolt 37 ft.lb

Engine Mount Bracket Bolt 43 ft.lb

Engine Mount Lower Nut 32 ft.lb

Engine Mount Strut and Lift Bracket Bolt - Engine Left Rear 52 ft.lb

Engine Mount Strut Bolt/Nut 35 ft.lb

Engine Mount Strut Bracket Bolt - Upper Radiator Support 21 ft.lb

Engine Mount Strut Bracket Bolt - Vehicle Right Side 37 ft.lb

Engine Mount Upper Nut 35 ft.lb

Oil Level Indicator Tube Stud 18 ft.lb

Oil Pan Drain Plug 18 ft.lb

Intake Manifold Torque & Sequence

Lower Intake Manifold

Install NEW lower intake manifold bolts.

The torque specification is a 2-step process; tighten the vertical lower intake manifold bolts (the four middle ones) to 7 Nm (62 lb in). Tighten the di

UPPER INTAKE MANIFOLD BOLT/STUD ................................................................................................................................... 25 Nm (18 lb. ft.)

Throttle Body Bolt/Stud 18 lb. ft.


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 44
Chevrolet Venture V6-3.4L VIN E 493

Valve Lifter Guide Bolt 89 in.lb

Roller Lifter Hydraulic

Oil Cooler Connector 37 ft.lb

Oil Filter Bypass Hole Plug 14 ft.lb

Oil Filter Fitting 29 ft.lb

Oil Filter 115 in.lb

Oil Level Sensor Bolt 89 in.lb

Engine Oil Level Switch 22 Nm

Oil Cooler Hose Fitting 14 ft.lb

Oil Cooler Pipe Bracket Bolt 89 in.lb

Oil Pan Bolt 18 ft.lb

Oil Pan Side Bolt 37 ft.lb

Engine Oil Pressure Indicator Switch 115 in.lb

Engine Oil Pressure Indicator 16 Nm

Oil Pump Cover Bolt 89 in.lb

Oil Pump Oil Pump Drive Clamp Bolt 27 ft.lb

Oil Pump Mounting Bolt 30 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 46
45
Chevrolet Venture V6-3.4L VIN E 494
Instrument Panel Cluster Screws 2.5 Nm
Gear
Flywheel Length
Bolts 52 lb. ft. 1.199-1.200 inch
Instrument Panel Compartment Latch Screws 1 Nm
Diameter 1.498-1.500 inch
Instrument Panel Compartment Screws 2.5 Nm
Side Clearance 0.001-0.003 in
Instrument
Battery PanelCable
Positive LowertoBrace Bolts/Screws
Underhood 2 Nm Nut 10 Nm
Electrical Center
End Clearance 0.002-0.005 in

Valve to Bore Clearance 0.0015-0.0035 in

Knee Bolster
Heater Bolts/Screws
Core Line
Gear LashScrew2.5 Nm1.6 Nm0.0037-0.0077 inch
Clip

Heater Core Mounting Clip


Gear Pocket Screw 1.6 Nm1.202-1.204 in
Depth

Gear Pocket Diameter 1.503-1.505 in


Forward Indicator Lamp Screws 1.9 Nm

Side Marker
Heater Lamp
Inlet Pipe Screws Nut 71.5
Mounting NmNm

Camshaft Sprocket Bolt 103 lb. ft.

Fog Lamps Screws


Compressor Pressure 9.5 NmValve 9 Nm
Relief

Crankshaft Balancer Bolt 76 ft.lb

Headlamp
A/C Capsule
Compressor Screws
Hose 7 Nm
Block Fitting to Compressor Nut 22 Nm

Sealed
A/C Beams Headlamp
Compressor
Timing Screws
Hose Block
Chain Dampener 157ft.lb
BoltFitting Nm
to Accumulator Bolt 16 Nm

Liquid Line at Block Fitting Bolt 16 Nm

Liquid Line at Condensor Fitting 27 Nm


Front Parking
Engine Lamp Bolt
Front Cover Lens- Screws
Large 941Nmft.lb
Liquid Line at Orifice Fitting 27 Nm
Engine Front Cover Bolt - Medium 35 ft.lb
Liquid Line at Rear Fitting (C34 only) 27 Nm
HVAC
EngineSystem
FrontAir Conditioner
Cover Bolt -Heater
SmallCombination (FRT/RR w/Rear
15 ft.lb
Controls)
Data Link Connector Bolts/Screws 2 Nm

Suction Line at Accumulator Fitting 47 Nm

Suction Line at Block Fitting Bolt 16 Nm


Catalytic Converter Nut 25 ft.lb
A/C Compressor Hose Block Fitting to Rear Suction Line Bolt 16 Nm

Housing Assembly HVAC


Data
Heater Link
Exhaust
A/C Connector
Crossover
Module Bolts/Screws
Pipe
Bolts Nut/Stud
to 182 ft.lb
Nm Compartment.....20
Inside Passenger Nm 15 ft lb

Heater A/C Module Nuts to Engine Compartment................10 Nm 89 in lb

Heater A/C Module Upper Mounting Screws.....................1.6 Nm 14 in lb


CamshaftManifold
Exhaust Position Nut
Sensor Bolt1289 in.lb
ft.lb
Rear Heater A/C Module Mounting Bolts and Nuts..............10 Nm 89 in lb
Exhaust Manifold Stud 13 ft.lb

Exhaust
InflatableManifold
RestraintPipe
SideNut 26Sensor
Impact ft.lb (SIS) Fasteners 10 Nm
Coolant Temperature Sensor 17 ft.lb

Exhaust Manifold
Instrument Heat Shield
Panel Accessory BoltPlate Screws
Trim 89 in.lb
2 Nm
Crankshaft Position Sensor Bolt - Front Cover 89 in.lb
Exhaust Crossover
Instrument Pipe Heat Shield Bolt 89 in.lb
Panel Bolts/Screws 10 Nm
Crankshaft Position Sensor Stud - Side of Engine Block 98 in.lb
Chevrolet Venture V6-3.4L VIN E 495
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 47
Chevrolet Venture V6-3.4L VIN E 496
Crankshaft Position Sensor Wiring Bracket Bolt 37 ft.lb

Idle Air Control Valve Attaching Screws 3 Nm

Knock Sensor 19 Nm

Manifold Absolute Pressure (MAP) Sensor Retaining Bolt 3 Nm

Heated Oxygen Sensor 41 Nm

Throttle Position Sensor Screws 2 Nm

EVAP Purge Valve Bracket 10 Nm

Exhaust Gas Recirculation Valve to Throttle Body Adapter Bolts 30 Nm

Fuel Tank Filler Pipe Hose Clamp 2.5 Nm

Firing Order
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 48
Chevrolet Venture V6-3.4L VIN E 497

Firing Order 1-2-3-4-5-6

For number 1 cylinder location, See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Ignition Timing/Number One C

See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Ignition Cable

In-Pipe Fuel Filter Outlet Nut 30 Nm

Fuel Rail Attaching Nuts or Bolts 10 Nm

Fuel Tank Retaining Strap Bolts 48 Nm

Idle Speed
Information not supplied by the manufacturer.
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 49
Chevrolet Venture V6-3.4L VIN E 498

Spark Plug Wires 1,968 Ohms/Meter

Ignition Coil to Ignition Control Module Screws 4.5 Nm

Ignition Coil to Ignition Control Module Screws 4.5 Nm

Ignition Control Module Bracket to Engine Studs and Nuts 25 Nm

Upper Intake Manifold Studs or Bolts 25 Nm

Spark Plug Gap


Spark Plug Gap .............................................................................................................................................................................. 1.524mm (0.060 in)
Spark Plug Torque
Initital Installation ................................................................................................................................................................................. 20 Nm (15 lb ft)
Reinstallation ........................................................................................................................................................................................ 15 Nm (11 lb ft)

Exhaust Gas Recirculation Valve to Throttle Body Adapter Bolts 30 Nm

Throttle Body Retaining Nuts or Bolts 28 Nm

Throttle Cable/Linkage
Accelerator Cable Bracket Retaining Nuts and Bolts 10 N.m

A/C Refrigerant Pressure Sensor 5 Nm

Front Seat/Retractor Side Seat Belt Lower Anchor Nuts 40 Nm

Front Shoulder Belt Guide Adjuster Bracket Bolts 50 Nm

Front Seat Belt Upper Guide Loop Anchor Nut 29 Nm

Lower Seat Belt Anchor Bolt (C-Pillar) 43 Nm

Lower Seat Belt Anchor Bolt (D-Pillar) 43 Nm

Upper Seat Belt Anchor Bolt (C-Pillar) 43 Nm

Upper Seat Belt Anchor Bolt (D-Pillar) 43 Nm

Rear Seat Center Belt Bolts 53 Nm

Front Seat Buckle Side Belt Nut 53 Nm

Rear Seat Buckle Belt Bolts (All) 53 Nm


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 50
Chevrolet Venture V6-3.4L VIN E 499
Rear Seat Buckle Belt Nut (All) 53 Nm

Mini-Buckle Bolt 53 Nm

Front Seat Belt Retractor Bolt 43 Nm

Seat Belt Retractor Bolt (C-Pillar) 43 Nm

Seat Belt Retractor Bolt (D-Pillar) 43 Nm

Driver Seat Belt Pretensioner Fastener 35 Nm

Passenger Seat Belt Pretensioner Fastener 35 Nm

Service Port HVAC


A/C Refrigerant Service Valve ............................................................................................................................................................................. 11 N.m

Starter Motor Bolt 47 Nm

Starter Motor BAT Terminal Nut 10 Nm

Starter Motor S Terminal Nut 3 Nm

Model PG260 F1

Cooler Pipe Retainer Bolt/Screw 89 in.lb

Power Steering Cooler Hose/Pipe Fittings 20 ft.lb

Power Steering Pump Bolts 25 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 51
Chevrolet Venture V6-3.4L VIN E 500

Steering Column Cover Bolts 38 in.lb

Steering Column Bolts 18 ft.lb

Steering Column Nuts 18 ft.lb

Power Steering Gear Nuts (at Frame) 59 ft.lb

Steering Intermediate Shaft Lower (Pinch) Bolt 33 ft.lb

Steering Wheel Nut 33 ft.lb


Steering Wheel Nut

Tie Rod Ball Stud Nut 22 ft.lb


+ 120 degrees (2 flats)

Wheel Bearing/Hub Bolts (NEW ONLY) 96 ft.lb

Wheel Bearing/Hub Bolts (NEW ONLY) 63 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 52
Chevrolet Venture V6-3.4L VIN E 501

Air Dryer, Suspension Control


Air Dryer Bracket Bolts/Screws ....................................................................................................................................................... 7 Nm (62 inch lbs.)
Air Line, Suspension Control
Air Line Tube Repair Nut ................................................................................................................................................................. 8 Nm (70 inch lbs.)

Front Wheel Drive Axle Nut 118 ft.lb

Rear Axle Tie Rod Bolt 92 ft.lb

Ball Stud Nuts (Replacement Ball Joint) 50 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 53
Chevrolet Venture V6-3.4L VIN E 502

Wear Limit
Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if:
- The fastener and its counterpart are clean and free from rust
- The fastener develops 2 Nm (18 inch lbs.) of torque (drag) against its counterpart prior to the fastener seating. If the fastener does not mee

Compressor/Pump Relay, Suspension Control


Air Compressor Relay Bolt/Screw ................................................................................................................................................... 3 Nm (27 inch lbs.)

Air Compressor Bolts/Screws 35 in.lb

Air Compressor Bracket Bolt/Screw 37 ft.lb

Air Compressor Bracket Nuts 89 in.lb

Air Compressor Head Bolts 53 in.lb

Air Compressor Shield Bolt/Screw 27 in.lb

Ball Stud Castle Nut (Lower Control Arm) 40 ft.lb

Lower Control Arm Nuts (at Frame) 83 ft.lb

Control Arm Nut 162 ft.lb

Inflator Relay Bolts/Screws 18 in.lb

Inflator Solenoid Fill Valve Nut 27 in.lb

Inflator Solenoid Nut 27 in.lb

Height Sensor Adjuster Bolt/Screw 44 in.lb

Height Sensor Ball Stud 35 in.lb

Height Sensor Bolts/Screws 35 in.lb

Height Sensor Bracket Bolts/Screws 89 in.lb

Shock Absorber Nut 63 ft.lb

Stabilizer Shaft Insulator Bracket Bolts 35 in.lb

Stabilizer Shaft Link Nut 17 ft.lb


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 54
Chevrolet Venture V6-3.4L VIN E 503

Strut Lower Nuts (at Knuckle) 90 ft.lb

Strut Shaft Nut 63 ft.lb

Strut Upper Nuts 30 ft.lb

Vacuum Tank Mounting Nuts 10 Nm

Wheel Nuts 100 ft.lb

Wheel Nut Caps (Pontiac and Export Vehicles with Aluminum Wheels) 27 in.lb

Lug Nut Torque Patterns

Windows
Fastener Tightening Specifications

Solvent Container Assembly Mounting Screws 6 Nm

Wiper Arm Assembly to Shaft Nut 48 Nm

Wiper Module Assembly to Vehicle Screws 10 Nm


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 55
Chevrolet Venture V6-3.4L VIN E 504

Wiper Motor Assembly Mounting Screws 7 Nm

Wiper Motor Crank Arm Assembly Screw 14-17 Nm

Wiper Linkage Assembly to Wiper Motor Crank Arm Assembly Screws 5 Nm

Wiper Motorover Assembly Screws 2 Nm

Wiper Linkage Assembly to Wiper Motor Crank Arm Assembly Screws 5 Nm

Compression Check
The lowest reading should not be less than 70 percent of the highest reading.

No cylinder reading should be less than 689 kPa (100 psi).

Engine Oil
For information regarding oil pressure specifications, refer to Lubrication System specifications. See: Engine, Cooling and Exhaust/Engine/Engine L

Oil Pressure - Warm 15 psi at 1100 rpm

Fuel Injector Pressure Drop


Fuel Injector Pressure Drop
If the pressure drop value for each injector is within 1.5 psi of the average drop value the fuel injectors are flowing properly.

Pressure Drop 1.5 psi

Fuel Injector Balance Test Example (Typical)

Fuel System Pressure


Fuel System Pressure
2000 Chevy Truck Venture
Chevrolet Venture
V6-3.4L VIN E V6-3.4L VIN E 505
Copyright © 2011,
ALLDATA 10.40
Page 56

Key On Engine Off 52-59 psi

Fuel System Pressure


Fuel System Pressure

Key On Engine Off 52-59 psi

Oil Pump, Engine


For information regarding oil pressure specifications, refer to Lubrication System specifications. See: Engine, Cooling and Exhaust/Engine/Engine L

Thermostat Temperature Range Starts To Open 87 Degrees C


188 Degrees F

Fully Open 97 Degrees C


206 Degrees F

System Specifications
Bottom Pan Removal ................................................................................................................................................................................ 7.0L (7.4 qts.)
Complete Overhaul .................................................................................................................................................................................. 9.5L (10.0 qts)
Dry ........................................................................................................................................................................................................ 12.7L (13.4 qts.)
Fluid - A/T
Transmission Fluid
Pan Removal .............................................................................................................................................................................................. 7.0L (7.4 Qt)
Overhaul ................................................................................................................................................................................................... 9.5L (10.0 Qt)
Dry ......................................................................................................................................................................................................... 12.7L (13.4 Qt)

With Rear Climate Control 11.9 qt (US)


Note: Recheck fluid level after filling system.

W/O Rear Climate Control 9.6 qt (US)


Note: Recheck fluid level after filling system.

Engine Oil
Engine Oil

With Filter Change ..................................................................................................................................................................................... 4.2L (4.5 Qt)

NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level.

Standard/Regular 19.8 gal (US)

Optional/Extended 25 gal (US)

System Specifications
Front A/C ................................................................................................................................................................................................ 0.90 kg / 2.0 lb

Front and Rear A/C................................................................................................................................................................................. 1.31 kg / 2.9 lb


Refrigerant
Refrigerant Capacity
C34 .................................................................................................................................................................................................................. 1.31 kg
C60 .................................................................................................................................................................................................................. 1.08 kg
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 57
Chevrolet Venture V6-3.4L VIN E 506
Refrigerant Oil
The manufacture does not provide refrigerant oil capacities for this vehicle.
Maintenance
FLUID CAPACITY/LEVELS
Note that ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level.

Type Dexron(R)-III Automatic Transmission Fluid or Equivalent

Fluid - A/T
Transmission Fluid Type

Type .................................................................................................................................................................................... DEXRON III or Equivalent

Brake Fluid Type Delco Supreme II (R) Fluid, GM P/N 12377967 Or DOT-3 Equivalent

Type Goodwrench(R) or Havoline(R) Silicate-Free DEX-COOL(R)

Coolant/Water Mixture 50/50 %

Engine Oil
Engine Oil

API Classification .................................................................................................................................................................. Look for Starburst Symbol


Grade ............................................................................................................................................................. 5W-30 (preferred), 10W-30 if above 0° F
A Recommended Fluids and Lubricants
Look for and use ONLY the oils, fluids and fuel that meet GM Specification. Oil or fluid that does not have the correct specification designation can
Automatic/Manual Transmission/Transaxle Shift Linkage
Lubricate shift linkage with engine oil.
C/V, Universal Joints, Yoke Splines and Clutch Fork
Chassis lubricant, GM P/N 12377985 or lubricant meeting the requirements of NLGI grade 2, category LB or GC-LB.
Chassis Lubrication
Chassis lubricant, GM P/N 12377985 or lubricant meeting the requirements of NLGI # 2, category LB or GC-LB.
Hinges and Locks
Multi-Purpose lubricant Superlube(R), GM P/N 12346241 or equivalent.
Key Lock Cylinders
Multi-Purpose lubricant Superlube(R), GM P/N 12346241 or equivalent.
Misc.. Linkage, Latches, Pivots and Spring Anchors
Lubriplate lubricant aerosol, GM P/N 12346293 or lubricant meeting the requirements of NLGI # 2, category LB or GC-LB.
Parking Brake Cable Guides
Chassis lubricant, GM P/N 12377985 or lubricant meeting the requirements of NLGI # 2, category LB or GC-LB.
Weatherstrip Conditioning
Dielectric Silicone Grease, GM P/N 12345579 or equivalent.
Wheel Bearings
Wheel bearing lubricant, GM P/N 1051344 or lubricant meeting requirements of NLGI grade 2, category GC or GC-LB.
Windshield Washer Solvent
GM Optikeen(R) washer solvent, GM P/N 1051515 or equivalent.
x
x
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 58
Chevrolet Venture V6-3.4L VIN E 507
Power Steering Fluid GM Power Steering Fluid (GM P/N 1050017 - 1 quart or Equivalent)

Cold Climate Power Steering Fluid 12345866 or Equivalent

Refrigerant
Refrigerant Type ................................................................................................................................................................................................ R-134a
Refrigerant Oil
A/C System O-ring and
Fitting Lubricant .................................................................................................................................................................. 525 Viscosity Mineral Oil

Internal Lubricant
(Including Compressor) ............................................................................................................ Poly-Alkaline Glycol (PAG) Synthetic Refrigerant Oil

Wheel Bearing
On models with serviceable wheel bearings, use GC Wheel Bearing Grease.

GC ............................................................................................................................................................. Wheel Bearing Grease, NLGI Classification


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 1
Chevrolet Venture V6-3.4L VIN E 508
Vehicle: Locations

Ashtray Illumination Lamp

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 2
Chevrolet Venture V6-3.4L VIN E 509

Locations View

Center of IP, mounted to the back of the ashtray


Cargo Lamp
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 3
Chevrolet Venture V6-3.4L VIN E 510

Locations View

Above the liftgate, on the roof headliner


Center High Mounted Stop Lamp (CHMSL)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 4
Chevrolet Venture V6-3.4L VIN E 511

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 5
Chevrolet Venture V6-3.4L VIN E 512

Locations View

Center, top of liftgate


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 6
Chevrolet Venture V6-3.4L VIN E 513

Locations View

Dome Lamp
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 7
Chevrolet Venture V6-3.4L VIN E 514

Locations View

Center of the roof headliner


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 8
Chevrolet Venture V6-3.4L VIN E 515

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 9
Chevrolet Venture V6-3.4L VIN E 516

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 10
Chevrolet Venture V6-3.4L VIN E 517

Locations View

Forward Lamp Harness


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 11
Chevrolet Venture V6-3.4L VIN E 518

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 12
Chevrolet Venture V6-3.4L VIN E 519

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 13
Chevrolet Venture V6-3.4L VIN E 520

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 14
Chevrolet Venture V6-3.4L VIN E 521

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 15
Chevrolet Venture V6-3.4L VIN E 522

Locations View

Front Roof Rail Reading Lamps


On both sides of the headliner between the B and C-pillars
Hazard Lamp Flasher (Export)
Below the IP, above the base of the steering column, left side of the steering column
Hazard Lamp/Turn Signal Flasher
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 16
Chevrolet Venture V6-3.4L VIN E 523

Locations View

Below the IP, above the base of the steering column, left side of the steering column
Headlamp Position Lamp (Export)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 17
Chevrolet Venture V6-3.4L VIN E 524

Locations View

Front of the vehicle


Instrument Panel (IP) Courtesy Lamp, Left
Below left side of the IP, near the park brake
IP Courtesy Lamp, Right
Below the right side of the IP
License Lamps
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 18
Chevrolet Venture V6-3.4L VIN E 525

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 19
Chevrolet Venture V6-3.4L VIN E 526

Locations View

Rear of the vehicle, above the license plate


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 20
Chevrolet Venture V6-3.4L VIN E 527

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 21
Chevrolet Venture V6-3.4L VIN E 528

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 22
Chevrolet Venture V6-3.4L VIN E 529

Locations View

Rear Roof Rail Reading Lamps


On both sides of the roof headliner, behind the left C-pillar and the left D-pillars
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 23
Chevrolet Venture V6-3.4L VIN E 530

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 24
Chevrolet Venture V6-3.4L VIN E 531

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 25
Chevrolet Venture V6-3.4L VIN E 532

Locations View

Security Indicator Lamp


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 26
Chevrolet Venture V6-3.4L VIN E 533

Locations View

Center of the IP, mounted to the trim plate, near the windshield defrost vent
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 27
Chevrolet Venture V6-3.4L VIN E 534

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 28
Chevrolet Venture V6-3.4L VIN E 535

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 29
Chevrolet Venture V6-3.4L VIN E 536

Locations View

Windshield Header Courtesy/Reading Lamps


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 30
Chevrolet Venture V6-3.4L VIN E 537

Locations View

Part of the roof console


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 31
Chevrolet Venture V6-3.4L VIN E 538

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 32
Chevrolet Venture V6-3.4L VIN E 539

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 33
Chevrolet Venture V6-3.4L VIN E 540

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 34
Chevrolet Venture V6-3.4L VIN E 541

Locations View

Air Injection Bleed Valve


Left rear of engine, above valve cover
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 35
Chevrolet Venture V6-3.4L VIN E 542

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 36
Chevrolet Venture V6-3.4L VIN E 543

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 37
Chevrolet Venture V6-3.4L VIN E 544

Locations View

Locations View

Auto Level Control (ALC) Air Compressor


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 38
Chevrolet Venture V6-3.4L VIN E 545

Locations View

Under the vehicle, behind the left rear wheelhouse


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 39
Chevrolet Venture V6-3.4L VIN E 546

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 40
Chevrolet Venture V6-3.4L VIN E 547

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 41
Chevrolet Venture V6-3.4L VIN E 548

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 42
Chevrolet Venture V6-3.4L VIN E 549

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 43
Chevrolet Venture V6-3.4L VIN E 550

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 44
Chevrolet Venture V6-3.4L VIN E 551
Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 45
Chevrolet Venture V6-3.4L VIN E 552

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 46
Chevrolet Venture V6-3.4L VIN E 553

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 47
Chevrolet Venture V6-3.4L VIN E 554

Locations View

Battery
Engine compartment, behind the right headlamp
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 48
Chevrolet Venture V6-3.4L VIN E 555

Locations View

Body Harness
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 49
Chevrolet Venture V6-3.4L VIN E 556

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 50
Chevrolet Venture V6-3.4L VIN E 557

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 51
Chevrolet Venture V6-3.4L VIN E 558

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 52
Chevrolet Venture V6-3.4L VIN E 559

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 53
Chevrolet Venture V6-3.4L VIN E 560

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 54
Chevrolet Venture V6-3.4L VIN E 561

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 55
Chevrolet Venture V6-3.4L VIN E 562

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 56
Chevrolet Venture V6-3.4L VIN E 563

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 57
Chevrolet Venture V6-3.4L VIN E 564

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 58
Chevrolet Venture V6-3.4L VIN E 565

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 59
Chevrolet Venture V6-3.4L VIN E 566

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 60
Chevrolet Venture V6-3.4L VIN E 567

Locations View

Brake Modulator
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 61
Chevrolet Venture V6-3.4L VIN E 568

Locations View

Left side of the engine compartment, mounted to the brake master cylinder
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 62
Chevrolet Venture V6-3.4L VIN E 569

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 63
Chevrolet Venture V6-3.4L VIN E 570

Locations View

Cigar Lighter
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 64
Chevrolet Venture V6-3.4L VIN E 571

Locations View

Center IP, right side of the ashtray

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 65
Chevrolet Venture V6-3.4L VIN E 572

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 66
Chevrolet Venture V6-3.4L VIN E 573

Locations View

Cruise Control Release Switch


Mounted to the brake pedal support
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 67
Chevrolet Venture V6-3.4L VIN E 574

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 68
Chevrolet Venture V6-3.4L VIN E 575

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 69
Chevrolet Venture V6-3.4L VIN E 576

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 70
Chevrolet Venture V6-3.4L VIN E 577

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 71
Chevrolet Venture V6-3.4L VIN E 578

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 72
Chevrolet Venture V6-3.4L VIN E 579

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 73
Chevrolet Venture V6-3.4L VIN E 580

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 74
Chevrolet Venture V6-3.4L VIN E 581

Locations View

Driver Information Display


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 75
Chevrolet Venture V6-3.4L VIN E 582

Locations View

In the roof console


Driver Seat Belt Pretensioner
---
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 76
Chevrolet Venture V6-3.4L VIN E 583

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 77
Chevrolet Venture V6-3.4L VIN E 584

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 78
Chevrolet Venture V6-3.4L VIN E 585

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 79
Chevrolet Venture V6-3.4L VIN E 586

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 80
Chevrolet Venture V6-3.4L VIN E 587

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 81
Chevrolet Venture V6-3.4L VIN E 588

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 82
Chevrolet Venture V6-3.4L VIN E 589

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 83
Chevrolet Venture V6-3.4L VIN E 590

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 84
Chevrolet Venture V6-3.4L VIN E 591

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 85
Chevrolet Venture V6-3.4L VIN E 592

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 86
Chevrolet Venture V6-3.4L VIN E 593

Locations View

Engine Harness
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 87
Chevrolet Venture V6-3.4L VIN E 594

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 88
Chevrolet Venture V6-3.4L VIN E 595

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 89
Chevrolet Venture V6-3.4L VIN E 596

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 90
Chevrolet Venture V6-3.4L VIN E 597

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 91
Chevrolet Venture V6-3.4L VIN E 598

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 92
Chevrolet Venture V6-3.4L VIN E 599

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 93
Chevrolet Venture V6-3.4L VIN E 600

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 94
Chevrolet Venture V6-3.4L VIN E 601

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 95
Chevrolet Venture V6-3.4L VIN E 602

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 96
Chevrolet Venture V6-3.4L VIN E 603

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 97
Chevrolet Venture V6-3.4L VIN E 604

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 98
Chevrolet Venture V6-3.4L VIN E 605

Locations View

Exhaust Gas Recirculation (EGR) VaIve


Upper left side of the engine

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 99
Chevrolet Venture V6-3.4L VIN E 606

Locations View

Front Door Lock


Inside, rear end of the front door
Front Door Lock (Actuator)
Part of the front door lock
Front Door Speakers
Inside the front door
Front Electric Accessory Plug Housing
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 100
Chevrolet Venture V6-3.4L VIN E 607

Locations View

Center of the IP, left of the ashtray


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 101
Chevrolet Venture V6-3.4L VIN E 608

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 102
Chevrolet Venture V6-3.4L VIN E 609

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 103
Chevrolet Venture V6-3.4L VIN E 610

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 104
Chevrolet Venture V6-3.4L VIN E 611

Locations View

Fuel Injectors
Top of the engine at each cylinder intake port
Fuel Level Sender
Mounted inside the fuel tank
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 105
Chevrolet Venture V6-3.4L VIN E 612

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 106
Chevrolet Venture V6-3.4L VIN E 613

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 107
Chevrolet Venture V6-3.4L VIN E 614

Locations View

Fuel Tank
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 108
Chevrolet Venture V6-3.4L VIN E 615

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 109
Chevrolet Venture V6-3.4L VIN E 616

Locations View

Below the left side, middle of the vehicle


Fuse Block
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 110
Chevrolet Venture V6-3.4L VIN E 617

Locations View

Right side of the IP, in the right front door opening


Fusible Link A
Bolted to the starter solenoid
Fusible Link C
Bolted to the starter solenoid
Fusible Link Z
Bolted to the starter solenoid
Fusible Links
Bolted to the starter solenoid
Generator
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 111
Chevrolet Venture V6-3.4L VIN E 618

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 112
Chevrolet Venture V6-3.4L VIN E 619

Locations View

Top rear right side of the engine


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 113
Chevrolet Venture V6-3.4L VIN E 620

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 114
Chevrolet Venture V6-3.4L VIN E 621

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 115
Chevrolet Venture V6-3.4L VIN E 622

Locations View

Headlamps
Front side of the vehicle
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 116
Chevrolet Venture V6-3.4L VIN E 623

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 117
Chevrolet Venture V6-3.4L VIN E 624

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 118
Chevrolet Venture V6-3.4L VIN E 625

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 119
Chevrolet Venture V6-3.4L VIN E 626

Locations View

Horn, Left
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 120
Chevrolet Venture V6-3.4L VIN E 627

Locations View

Front left side of the vehicle, mounted to the left side of the front lower crossmember
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 121
Chevrolet Venture V6-3.4L VIN E 628

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 122
Chevrolet Venture V6-3.4L VIN E 629

Locations View

Horn, Right
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 123
Chevrolet Venture V6-3.4L VIN E 630

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 124
Chevrolet Venture V6-3.4L VIN E 631

Locations View

Front right side of the vehicle, mounted to the right side of the front lower crossmember

Locations View

I/P Harness
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 125
Chevrolet Venture V6-3.4L VIN E 632

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 126
Chevrolet Venture V6-3.4L VIN E 633

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 127
Chevrolet Venture V6-3.4L VIN E 634

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 128
Chevrolet Venture V6-3.4L VIN E 635

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 129
Chevrolet Venture V6-3.4L VIN E 636

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 130
Chevrolet Venture V6-3.4L VIN E 637

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 131
Chevrolet Venture V6-3.4L VIN E 638

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 132
Chevrolet Venture V6-3.4L VIN E 639

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 133
Chevrolet Venture V6-3.4L VIN E 640

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 134
Chevrolet Venture V6-3.4L VIN E 641

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 135
Chevrolet Venture V6-3.4L VIN E 642

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 136
Chevrolet Venture V6-3.4L VIN E 643

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 137
Chevrolet Venture V6-3.4L VIN E 644

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 138
Chevrolet Venture V6-3.4L VIN E 645

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 139
Chevrolet Venture V6-3.4L VIN E 646

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 140
Chevrolet Venture V6-3.4L VIN E 647

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 141
Chevrolet Venture V6-3.4L VIN E 648

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 142
Chevrolet Venture V6-3.4L VIN E 649

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 143
Chevrolet Venture V6-3.4L VIN E 650

Locations View

Idle Air Control (IAC) Valve


Top of the engine, front of the throttle assembly
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 144
Chevrolet Venture V6-3.4L VIN E 651

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 145
Chevrolet Venture V6-3.4L VIN E 652

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 146
Chevrolet Venture V6-3.4L VIN E 653

Locations View

Instrument Cluster
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 147
Chevrolet Venture V6-3.4L VIN E 654

Locations View

Left side of the IP


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 148
Chevrolet Venture V6-3.4L VIN E 655

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 149
Chevrolet Venture V6-3.4L VIN E 656

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 150
Chevrolet Venture V6-3.4L VIN E 657

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 151
Chevrolet Venture V6-3.4L VIN E 658

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 152
Chevrolet Venture V6-3.4L VIN E 659

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 153
Chevrolet Venture V6-3.4L VIN E 660

Locations View

Liftgate Door Lock


Inside the liftgate, below the license plate
Liftgate Door Lock (Actuator)
Part of the liftgate door lock
Liftgate Harness
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 154
Chevrolet Venture V6-3.4L VIN E 661

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 155
Chevrolet Venture V6-3.4L VIN E 662

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 156
Chevrolet Venture V6-3.4L VIN E 663

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 157
Chevrolet Venture V6-3.4L VIN E 664

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 158
Chevrolet Venture V6-3.4L VIN E 665

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 159
Chevrolet Venture V6-3.4L VIN E 666

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 160
Chevrolet Venture V6-3.4L VIN E 667

Locations View

Mass Air Flow (MAF) Sensor


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 161
Chevrolet Venture V6-3.4L VIN E 668

Locations View

Left front of the engine compartment, in the air cleaner duct


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 162
Chevrolet Venture V6-3.4L VIN E 669

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 163
Chevrolet Venture V6-3.4L VIN E 670

Locations View

Outside Rearview Mirror


On the outside of the front door
Outside Rearview Mirror (Heated Defogger)
In the outside rearview mirror
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 164
Chevrolet Venture V6-3.4L VIN E 671

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 165
Chevrolet Venture V6-3.4L VIN E 672

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 166
Chevrolet Venture V6-3.4L VIN E 673

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 167
Chevrolet Venture V6-3.4L VIN E 674

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 168
Chevrolet Venture V6-3.4L VIN E 675

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 169
Chevrolet Venture V6-3.4L VIN E 676

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 170
Chevrolet Venture V6-3.4L VIN E 677

Locations View

Passenger Seat Belt Pretensioner


--

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 171
Chevrolet Venture V6-3.4L VIN E 678

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 172
Chevrolet Venture V6-3.4L VIN E 679

Locations View

Power Sliding Door Unlatch Actuator


In the right power sliding door at the front of of the door
Power Sliding Door Unlatch Actuator (+E58) RH
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 173
Chevrolet Venture V6-3.4L VIN E 680

Locations View

For a Description of RPO Code(s) shown in this image refer to the RPO Code List found at Vehicle/Application and ID See: Application and
ID/RPO Codes
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 174
Chevrolet Venture V6-3.4L VIN E 681

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 175
Chevrolet Venture V6-3.4L VIN E 682

Locations View

Radio
Center of the IP console
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 176
Chevrolet Venture V6-3.4L VIN E 683

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 177
Chevrolet Venture V6-3.4L VIN E 684

Locations View

Radio Liftgate Speakers


On both sides of the liftgate
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 178
Chevrolet Venture V6-3.4L VIN E 685

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 179
Chevrolet Venture V6-3.4L VIN E 686

Locations View

Radio Rear Seat Audio Control (WU3)


Part of the rear roof console, above the right passenger seat
Radio Rear Seat Audio Control (4 Door)
Part of the left rear armrest
Radio Rear Seat Audio Control (5 Door)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 180
Chevrolet Venture V6-3.4L VIN E 687

Locations View

Part of the rear roof console, above the driver seat


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 181
Chevrolet Venture V6-3.4L VIN E 688

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 182
Chevrolet Venture V6-3.4L VIN E 689

Locations View

Rear Door Lock (Actuator)


In the rear side door
Rear Electric Accessory Plug Housing
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 183
Chevrolet Venture V6-3.4L VIN E 690

Locations View

Inside the vehicle, behind the left rear wheelhouse


Rear Quarter Window Actuator
Rear part of the rear quarter window, on the D-pillar
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 184
Chevrolet Venture V6-3.4L VIN E 691

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 185
Chevrolet Venture V6-3.4L VIN E 692

Locations View

Rear Sliding Door Alarm


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 186
Chevrolet Venture V6-3.4L VIN E 693

Locations View

Attached to the rear side door actuator motor


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 187
Chevrolet Venture V6-3.4L VIN E 694

Locations View

Rear Window Defogger Grid


Rear liftgate window
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 188
Chevrolet Venture V6-3.4L VIN E 695

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 189
Chevrolet Venture V6-3.4L VIN E 696

Locations View

Remote Battery Stud


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 190
Chevrolet Venture V6-3.4L VIN E 697

Locations View

Engine compartment, connected to the underhood accessory wiring junction block, above the battery
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 191
Chevrolet Venture V6-3.4L VIN E 698

Locations View

Remote Control Door Lock Receiver (RCDLR)


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 192
Chevrolet Venture V6-3.4L VIN E 699

Locations View

Behind the center of the IP, underside of the IP trim, near the windshield defrost vent
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 193
Chevrolet Venture V6-3.4L VIN E 700

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 194
Chevrolet Venture V6-3.4L VIN E 701

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 195
Chevrolet Venture V6-3.4L VIN E 702

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 196
Chevrolet Venture V6-3.4L VIN E 703

Second Seat Audio (SSA) Control


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 197
Chevrolet Venture V6-3.4L VIN E 704

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 198
Chevrolet Venture V6-3.4L VIN E 705

Locations View

Overhead console, right side of video screen


Secondary Air Injection Pump
Mounted in lower portion of the drivers front fender
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 199
Chevrolet Venture V6-3.4L VIN E 706

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 200
Chevrolet Venture V6-3.4L VIN E 707

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 201
Chevrolet Venture V6-3.4L VIN E 708

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 202
Chevrolet Venture V6-3.4L VIN E 709

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 203
Chevrolet Venture V6-3.4L VIN E 710

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 204
Chevrolet Venture V6-3.4L VIN E 711

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 205
Chevrolet Venture V6-3.4L VIN E 712

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 206
Chevrolet Venture V6-3.4L VIN E 713

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 207
Chevrolet Venture V6-3.4L VIN E 714

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 208
Chevrolet Venture V6-3.4L VIN E 715

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 209
Chevrolet Venture V6-3.4L VIN E 716

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 210
Chevrolet Venture V6-3.4L VIN E 717

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 211
Chevrolet Venture V6-3.4L VIN E 718

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 212
Chevrolet Venture V6-3.4L VIN E 719

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 213
Chevrolet Venture V6-3.4L VIN E 720

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 214
Chevrolet Venture V6-3.4L VIN E 721

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 215
Chevrolet Venture V6-3.4L VIN E 722

Locations View

Sunshade Lighted Vanity Mirror, Right


Part of the right sunshade
Sunshade Lighted Vanity Mirrors
Part of both sunshades
Taillamp
Rear of the vehicle, on both sides
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 216
Chevrolet Venture V6-3.4L VIN E 723

Locations View

Taillamp, Right
Rear of the vehicle, right side
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 217
Chevrolet Venture V6-3.4L VIN E 724

Locations View

Third Seat Audio (TSA) Control


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 218
Chevrolet Venture V6-3.4L VIN E 725

Locations View

Right quarter trim panel, next to the [third row right seat]
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 219
Chevrolet Venture V6-3.4L VIN E 726

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 220
Chevrolet Venture V6-3.4L VIN E 727

Locations View

Trailer Wiring Harness


Under the left right side of the vehicle, near the left rear wheelhouse
Underhood Accessory Wiring Junction Block
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 221
Chevrolet Venture V6-3.4L VIN E 728

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 222
Chevrolet Venture V6-3.4L VIN E 729

Locations View

Engine compartment, front of the right wheelhouse, above the battery


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 223
Chevrolet Venture V6-3.4L VIN E 730

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 224
Chevrolet Venture V6-3.4L VIN E 731

Locations View

Video Cassette Player (VCP)


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 225
Chevrolet Venture V6-3.4L VIN E 732

Locations View

Front floor console


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 226
Chevrolet Venture V6-3.4L VIN E 733

Locations View

Video Screen
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 227
Chevrolet Venture V6-3.4L VIN E 734

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 228
Chevrolet Venture V6-3.4L VIN E 735

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 229
Chevrolet Venture V6-3.4L VIN E 736

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 230
Chevrolet Venture V6-3.4L VIN E 737

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 231
Chevrolet Venture V6-3.4L VIN E 738

Locations View

Window Washer Pump, Rear


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 232
Chevrolet Venture V6-3.4L VIN E 739

Locations View

Engine compartment, mounted to the rear washer solvent container


Windshield Antenna
Within the windshield
Windshield Washer Pump
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 233
Chevrolet Venture V6-3.4L VIN E 740

Locations View

Engine compartment, mounted to the front washer solvent container


Auxiliary Video Module (AVM)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 234
Chevrolet Venture V6-3.4L VIN E 741

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 235
Chevrolet Venture V6-3.4L VIN E 742

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 236
Chevrolet Venture V6-3.4L VIN E 743

Locations View

Overhead console, left side of video screen


Body Control Module (BCM)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 237
Chevrolet Venture V6-3.4L VIN E 744

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 238
Chevrolet Venture V6-3.4L VIN E 745

Locations View

Below the right side of the IP, right of the IP compartment


Cruise Control Module (CCM)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 239
Chevrolet Venture V6-3.4L VIN E 746

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 240
Chevrolet Venture V6-3.4L VIN E 747

Locations View

Locations View

Engine compartment, near the left strut tower


Daytime Running Lamps (DRL) Control Module
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 241
Chevrolet Venture V6-3.4L VIN E 748

Locations View

Right of the steering column, behind the IP


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 242
Chevrolet Venture V6-3.4L VIN E 749

Locations View

Electronic Brake Control Module (EBCM), without (NW9)


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 243
Chevrolet Venture V6-3.4L VIN E 750

Locations View

For a Description of RPO Code(s) shown in this image refer to the RPO Code List found at Vehicle/Application and ID See: Application and
ID/RPO Codes
Electronic Brake Traction Control Module (EBCM), with (NW9)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 244
Chevrolet Venture V6-3.4L VIN E 751

Locations View

For a Description of RPO Code(s) shown in this image refer to the RPO Code List found at Vehicle/Application and ID See: Application and
ID/RPO Codes
Engine Coolant Level Indicator Module
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 245
Chevrolet Venture V6-3.4L VIN E 752

Locations View

Mounted to the rear right side of the radiator, below the radiator cap
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 246
Chevrolet Venture V6-3.4L VIN E 753

Locations View

Fog Lamp Module (Export), Rear


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 247
Chevrolet Venture V6-3.4L VIN E 754

Locations View

Below IP left side of steering column


Ignition Control Module (ICM)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 248
Chevrolet Venture V6-3.4L VIN E 755

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 249
Chevrolet Venture V6-3.4L VIN E 756

Locations View

Top center rear of the engine


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 250
Chevrolet Venture V6-3.4L VIN E 757

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 251
Chevrolet Venture V6-3.4L VIN E 758

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 252
Chevrolet Venture V6-3.4L VIN E 759

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 253
Chevrolet Venture V6-3.4L VIN E 760

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 254
Chevrolet Venture V6-3.4L VIN E 761

Locations View

Inflatable Restraint Steering Wheel Module


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 255
Chevrolet Venture V6-3.4L VIN E 762

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 256
Chevrolet Venture V6-3.4L VIN E 763

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 257
Chevrolet Venture V6-3.4L VIN E 764

Locations View

Interface Module (IM)


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 258
Chevrolet Venture V6-3.4L VIN E 765

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 259
Chevrolet Venture V6-3.4L VIN E 766

Locations View

Inside overhead console, left corner


2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 260
Chevrolet Venture V6-3.4L VIN E 767

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 261
Chevrolet Venture V6-3.4L VIN E 768

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 262
Chevrolet Venture V6-3.4L VIN E 769

Locations View

Pass Key III Module


In the steering column, at the ignition switch
Powertrain Control Module (PCM)
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 263
Chevrolet Venture V6-3.4L VIN E 770

Locations View

Locations View
2000 Chevy Truck Venture V6-3.4L VIN E Copyright © 2011, ALLDATA 10.40 Page 264
Chevrolet Venture V6-3.4L VIN E 771

Engine compartment, secured in the air cleaner assembly


Rear Side Door Actuator Control Module

Locations View

Part of the rear side door actuator motor, right quarter panel, above the wheelhouse
Tape Retract Module (TRM)
2000 Chevy Truck Venture V6-3.4L VIN