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Chevrolet Express 2500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 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 Chevrolet Express 2500 AUTOMOBILES
Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Chevrolet Express 2500 cars and light trucks from 1990+
Manual Air Conditioning & Heater System Diagnosis & Testing -> Express & Savana -> Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Tests -> Intermittents -> System Performance Test
Vehicle: 2003 Chevrolet Express 2500 4.3 V6 GAS
Accessing Diagnostic Trouble Codes
Connect a suitably programmed scan tool to Data Link Connector (DLC) and follow manufacturer's instructions.
Intermittents
Because many intermittent faults are caused at electrical connections, diagnosis of such problems should begin with a visual and physical inspection of connectors involved with the code. App...
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BRAKE SERVICE PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Chevrolet Express 2500 cars and light trucks from 1990+.
Power Brake Units -> Bendix Brake Booster -> Precautions -> Battery Ground Cable
Vehicle: 2001 Chevrolet Express 2500 6.5 V8 DIESEL
Battery Ground Cable
Prior to service, dis...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Chevrolet Express 2500 cars and light trucks sold in the U.S. for 1980+.
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 2004-06 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 2005 Chevrolet Express 2500 6.0 V8 GAS
Light Duty Emissions
Normal Service
Service as required
Severe Ser...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Chevrolet Express 2500 cars and light trucks from 1990+.
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2008 Chevrolet Express 2500 6.6 V8 DIESEL
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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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Chevrolet Express 2500 cars and light trucks sold in the U.S. from mid 1990's+.
Reset Procedures
Vehicle: 2009 Chevrolet Express 2500 4.8 V8 GAS
The Low Tire Pressure warning lamp and/or the DIC (Driver Information Center) Low Tire Pressure message can be cl...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Chevrolet Express 2500 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2008 Chevrolet Express 2500 4.8 V8 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove right transmission cover bolt, if required.
- Disconnect engine wiring harness electrical connector from oil level sensor.
- Remove starter motor mounting bolts.
- Slide starter forward until it clears transmission.
- Remove attaching nut and starter solenoid S-terminal lead from soleno...
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MAINTENANCE LAMP RESET PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1990+.
General Motors Corp./Saturn Trucks -> Air Cleaner Restriction Indicator ->
Vehicle: 1999 Chevrolet Express 2500 5.0 V8 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 Chevrolet Express 2500 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Chevrolet Express 2500 cars and light trucks from 1990+
Radiator, Replace
Vehicle: 2007 Chevrolet Express 2500 4.8 V8 GAS
- Disconnect Mass Air Flow (MAF) harness connector and remove air cleaner hold down screw.
- Loosen outlet duct hose clamp and remove air cleaner.
- Partially drain coolant into suitable container.
- Disconnect coolant recovery reservoir hose.
- Remove mounting screws and coolant recovery r...
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SERPENTINE BELT SERVICE PROCEDURES FOR Chevrolet Express 2500 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2010 Chevrolet Express 2500 6.0 V8 FLEX
- 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 Chevrolet Express 2500 AUTOMOBILES
Component location diagrams for most Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1990+.
 Rear Body Components Diagram for 2007 Chevrolet Express 2500 6.6 V8 DIESELComponents on diagram: |
 Passenger Compartment Diagram for 1999 Chevrolet Express 2500 6.5 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR Chevrolet Express 2500 AUTOMOBILES
OEM drawn wiring diagrams for most Chevrolet Express 2500 cars and light trucks sold in the U.S.
 2004 Chevrolet Express 2500 5.3 V8 GAS Wiring DiagramComponents on diagram: |
 2001 Chevrolet Express 2500 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Chevrolet Express 2500 AUTOMOBILES
OEM TSB listings for most Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1985+.
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Document: VIBRATION ANALYSIS WORKSHEET - REVISED Vehicle: 2000 Chevrolet Express 2500 5.0 V8 GAS Symptoms: |
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Document: VEHICLES ORDERED WITHOUT ASHTRAY/SMOKERS PACKAGE Vehicle: 2004 Chevrolet Express 2500 4.8 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Chevrolet Express 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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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