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Chevrolet Express 3500 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 3500 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 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR Chevrolet Express 3500 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 3500 cars and light trucks from 1990+
Compressor Service -> Harrison HD6/HT6 Compressor -> Compressor Clutch Service -> Clutch Coil, Replace -> Clutch Plate & Hub, Replace -> Clutch Pulley & Bearing, Replace -> Installation -> Removal
Vehicle: 2000 Chevrolet Express 3500 6.5 V8 DIESEL
Clutch Plate & Hub, Replace
Service procedures given are for compressor removed and mounted in suitable holding fixture. However, on most applications, compressor clutch components can be serviced without removing compressor or recovering refrigerant from system. If refrigerant recovery becomes necessary, refer to "General Service" for procedure.
To prevent serious internal compressor damage, when removing or installing clutch components, never apply pressure directly to the compressor shaft. Always use a suitable shaft protector.
Removal
Refer to Fig. when performing compr...
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BRAKE SERVICE PROCEDURES FOR Chevrolet Express 3500 AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Chevrolet Express 3500 cars and light trucks from 1990+.
Hydraulic Brake Systems -> Adjustments -> Height Sensing Proportioning Valve
Vehicle: 2001 Chevrolet Express 3500 6.5 V8 DIESEL
Height Sensing Proportioning Valve
The height sensing proportioning valve must be adjusted whenever the valve and/or linkage is disassembled or removed for service. In addition, adjustment should be checked if excessive front wheel lock-up is experienced with a lower than desired brake application rate when vehicle is at or near maximum GVWR.
- Raise and support vehicle, leave wheels on and allow axle to hang freely.
- Remove lever retaining nut and disconnect lever from valve shaft, Fig. .
- Rotate valve shaft to permit installation of correct adjustment gauge, Fig. , ensure D shaped ho...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Chevrolet Express 3500 AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Chevrolet Express 3500 cars and light trucks sold in the U.S. for 1980+.
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Component Locations -> C/K, G & R/V Series w/6.2L, 6.5L & 6.6L Diesel Engines
Vehicle: 2008 Chevrolet Express 3500 6.6 V8 DIESEL
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Chevrolet Express 3500 AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Chevrolet Express 3500 cars and light trucks from 1990+.
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2000 Chevrolet Express 3500 7.4 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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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Chevrolet Express 3500 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 3500 cars and light trucks sold in the U.S. from mid 1990's+.
Component Replacement -> Installation -> Removal -> Tire Pressure Indicator Sensor
Vehicle: 2008 Chevrolet Express 3500 6.0 V8 GAS
Tire Pressure Indicator Sensor
Each tire pressure sensor has an internal power supply which has a service life of 10 years.
Removal
- Loosen the lug nuts.
- Raise and support vehicle with jack stands, then remove the wheel and tire assembly.
- Prior to dismounting the tire from the wheel, note the following precautions:
- Position the bead breaking fixture 90° from the valve stem when separating the tire bead from the wheel.
- Place the mounting and dismounting head so that the tire iron or pry bar can be inserted slightly clockwise of the sensor body when prying the tire bead up and over ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Chevrolet Express 3500 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Chevrolet Express 3500 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2006 Chevrolet Express 3500 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 Chevrolet Express 3500 AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1990+.
General Motors Corp./Saturn Trucks -> Reduce Engine Power Indicator Lamp ->
Vehicle: 2006 Chevrolet Express 3500 6.6 V8 DIESEL
The Reduce Engine Power indicator lamp should light for a approximately 3 seconds when the ignition is turned On as a bulb check. If the warning lamp turns On during vehicle operation, a vehicl...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Chevrolet Express 3500 AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Chevrolet Express 3500 cars and light trucks from 1990+
Radiator, Replace
Vehicle: 2007 Chevrolet Express 3500 LT 6.0 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 3500 AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 1999 Chevrolet Express 3500 6.5 V8 DIESEL
- Rotate tensioner arm counterclockwise using 3/8 inch breaker bar.
- Remove belt from pulleys.
- Route new belt over all pulleys except tensioner arm.
- Rotate tensioner arm co...
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COMPONENT LOCATION DIAGRAMS FOR Chevrolet Express 3500 AUTOMOBILES
Component location diagrams for most Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1990+.
 Door Diagram for 2006 Chevrolet Express 3500 6.6 V8 DIESELComponents on diagram: |
 Instrument Panel Diagram for 2007 Chevrolet Express 3500 LT 6.0 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Chevrolet Express 3500 AUTOMOBILES
OEM drawn wiring diagrams for most Chevrolet Express 3500 cars and light trucks sold in the U.S.
 1999 Chevrolet Express 3500 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
 2007 Chevrolet Express 3500 LS 6.0 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Chevrolet Express 3500 AUTOMOBILES
OEM TSB listings for most Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1985+.
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Document: MANUAL TRANSMISSION OPERATING CHARACTERISTICS Vehicle: 2005 Chevrolet Express 3500 6.0 V8 GAS Auto Systems: |
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Document: WARRANTY - CUSTOMER CONCERN NOT DUPLICATED / VERIFIED LABOR OPERATIONS - REVISED Vehicle: 2005 Chevrolet Express 3500 6.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR Chevrolet Express 3500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Chevrolet Express 3500 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 3500 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 3500 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 3500 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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