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2004 Chevrolet Express 2500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
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- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Chevrolet Express 2500 car and truck
repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Chevrolet Express 2500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
Air Bag System Precautions -> General Motors Corp. -> Arming -> Light Trucks & Vans -> Passenger Cars
Vehicle: 2004 Chevrolet Express 2500 5.3 V8 GAS
Passenger Cars
Reverse disarming procedures to arm the Supplemental Restraint System, noting the following:
- Ensure all disconnected SRS electrical connectors are securely connected and routed.
- Install all removed fuses in proper locations.
- From a safe position at sides of or below air bag module, Turn ignition switch to ON position and observe Air Bag or SRS warning lamp.
- On all models except Prizm and 1990 Corvette, warning lamp should flash seven to nine times, then go off.
- On Prizm models, warning lamp should light for six seconds,...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
Disc Brakes -> Delco Dual Piston Sliding Caliper -> Rotor, Replace
Vehicle: 2004 Chevrolet Express 2500 4.8 V8 GAS
- Raise and support vehicle, then remove wheel and tire assemblies.
- Compress caliper pistons until they bottom in bores using suitable clamp.
- Remove calip...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Component Locations -> Late 1986-06 Chevrolet & GMC G Series w/Gasoline Engines
Vehicle: 2004 Chevrolet Express 2500 6.0 V8 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2004 Chevrolet Express 2500 5.3 V8 GAS
Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.
Disassemble
- Support propeller shaft in a line horizontal with table of a press.
- Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
- On models equipped with external snap ring retainers, proceed as follows:
- Disassemble snap rings by ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Chevrolet Express 2500 5.3 V8 GAS
- Disconnect battery ground cable.
- Remove coolant reservoir and air cleaner.
- Remove upper fan shroud.
- Remove drive belt.
- Remove heater hose pipe from alternator and oil fill tubes from support bracket.
- Remove alternator ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> Air Cleaner Restriction Indicator ->
Vehicle: 2004 Chevrolet Express 2500 4.3 V6 GAS
An air cleaner restriction indicator, Fig. , is located in the intake duct between the MAF sensor and the air cleaner assembly.
If the window shows green, no service is required at this time. However, if...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 2004 Chevrolet Express 2500 4.3 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at bypass pipe.
- Remove hose from bypass pipe.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Drain cooling system into a suitable container.
- Reposition heater hose outlet clamp at heater core.
- Disconnect heater outlet hose from hea...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Express 2500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Express 2500 4.8 V8 GAS
- Rotate tensioner clockwise to release belt tension using suitable wrench, then remove belt.
- Route belt over pulleys excep...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Chevrolet Express 2500 AUTOMOBILES
Component location diagrams for most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1990+.
 HVAC Controls Harness Routing Diagram for 2004 Chevrolet Express 2500 6.0 V8 GASComponents on diagram: |
 Upper Steering Column Diagram for 2004 Chevrolet Express 2500 4.3 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2004 Chevrolet Express 2500 AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S.
 2004 Chevrolet Express 2500 4.3 V6 GAS Wiring DiagramComponents on diagram: |
 2004 Chevrolet Express 2500 5.3 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Chevrolet Express 2500 AUTOMOBILES
OEM TSB listings for most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2004 Chevrolet Express 2500 4.3 V6 GAS Auto Systems: |
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Document: Front or Rear Axle Vent Hose Fluid Leak Vehicle: 2004 Chevrolet Express 2500 4.3 V6 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Chevrolet Express 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Chevrolet Express 2500 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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