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2005 Chevrolet Express 3500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Brake Service
- Fuel Filter Replacement
- 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 2005 Chevrolet Express 3500 VAN 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 3500 VAN automobile. Try the Automotix DIY solution today!
BRAKE SERVICE PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
Hydraulic Brake Systems -> Brake System Bleed -> Hydraulic System Flush -> Manual Bleed -> Master Cylinder Bleed -> Parking Brake Bleed -> Pressure Bleed
Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS
Manual Bleed
- If vehicle is equipped with power brakes, remove vacuum reserve by applying brakes several times with engine off.
- Fill master cylinder reservoirs with suitable brake fluid. Ensure to always keep master cylinder reservoirs at least half full during entire bleeding procedure.
- If master cylinder is suspected to have air in bore, it must be bled first. To bleed master cylinder, proceed as follows:
- Disconnect forward brake pipe connection at master cylinder.
- Allow brake fluid to fill master cylinder bore until it begins to flow from forward pipe connector port.
- Connect and ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Gasoline Engines Except Equinox, Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Uplander & Vue (2004-06) & 2004-06 Envoy, Rainier & TrailBlazer -> Returnless Fuel System
Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS
Returnless Fuel System
On models equipped with fuel injected engines, relieve fuel system pressure as outlined under "Fuel System Pressure Relief."
On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect the connector. Pri...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
DRIVESHAFT, Replace -> Front -> One Piece Driveshaft -> Rear -> Two Piece Driveshaft
Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS
Front
- Raise and support vehicle.
- Mark the front U-joint to the pinion yoke on the front differential.
- Mark the relationship of the rear U-joint to the transfer case drive flange.
- Remove the retaining nuts and bolts from the drive flange.
- Remove the clamps and retaining bolts from the front drive axle pinion flange.
- Remove the front propeller shaft from the vehicle.
- Using tape and or a rubber band, wrap the front U-joint bearing caps to ensure the caps do not separate from the U-joint.
- Reverse procedure to install, noting the following:
- Torque front propeller shaft retainer bolts 18 f...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
Starter, Replace
Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS
- Raise and support vehicle.
- Remove starter to engine brace and heat shields.
- Disconnect wires from solenoids.
- Remove starter motor mounting bolts, washers and lower starter. Record position of shims, if required.
- Remove starter motor from vehicle.
- Reverse procedure to install, noting the fol...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Service Throttle Soon Indicator Lamp ->
Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS
A "Service Throttle Soon" indicator lamp is mounted in the lower righthand instrument cluster corner on these models. It lights when the ignition is turned On, but should go out approximately 1-5 seconds after the engine starts.
Traditional throttle cables are no longer used on these models. The PCM receives signals from an electron...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
Radiator, Replace
Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS
- Drain cooling system into a suitable container, then disconnect hose from coolant reservoir.
- Remove coolant recovery reservoir retaining screws, then coolant recovery reservoir.
- Remove air intake duct, then disconnect mass air flow sensor electrical connector.
- Remove MAF/IAT sensor, then pull up on ai...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2005 Chevrolet Express 3500 VAN 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 2005 Chevrolet Express 3500 VAN AUTOMOBILES
Component location diagrams for most 2005 Chevrolet Express 3500 VAN cars and light trucks sold in the U.S. from 1990+.
 Battery Diagram for 2005 Chevrolet Express 3500 VAN 4.8 V8 GASComponents on diagram: |
 Rear Of The Engine Compartment Diagram for 2005 Chevrolet Express 3500 VAN 4.8 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 2005 Chevrolet Express 3500 VAN cars and light trucks sold in the U.S.
 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS Wiring DiagramComponents on diagram: |
 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
OEM TSB listings for most 2005 Chevrolet Express 3500 VAN cars and light trucks sold in the U.S. from 1985+.
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Document: GM of Canada New Vehicle Limited Warranty Tire Program Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS Auto Systems: |
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2005 Chevrolet Express 3500 VAN 4.8 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2005 Chevrolet Express 3500 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2005 Chevrolet Express 3500 VAN 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 2005 Chevrolet Express 3500 VAN 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 2005 Chevrolet Express 3500 VAN 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 2005 Chevrolet Express 3500 VAN 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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