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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+
Electric Cooling Fans -> Light Duty Trucks & Vans -> Precautions -> Air Bag System Disarming & Arming -> Battery Ground Cable
Vehicle: 1999 Chevrolet Express 3500 6.5 V8 DIESEL
Air Bag System Disarming & Arming
Refer to and for air bag system disarming and arming procedures.
Battery Ground Cable
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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+.
Disc Brakes -> Delco Dual Piston Sliding Caliper -> Precautions -> Brake Disc Service -> Brake Lines & Linings -> Brake Roughness -> General
Vehicle: 2007 Chevrolet Express 3500 LT 6.0 V8 GAS
Brake Lines & Linings
Remove one of the front wheels and inspect the brake disc, caliper and linings.
Do not allow any oil or grease on the linings. It is recommended that linings be replaced in sets when worn or damaged.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness v...
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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 -> Late 1986-06 Chevrolet & GMC G Series w/Gasoline Engines
Vehicle: 2002 Chevrolet Express 3500 5.7 V8 GAS
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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, Replace -> Front -> One Piece Driveshaft -> Rear -> Two Piece Driveshaft
Vehicle: 2009 Chevrolet Express 3500 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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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+.
Reset Procedures
Vehicle: 2009 Chevrolet Express 3500 LS 6.0 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 3500 AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Chevrolet Express 3500 cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2002 Chevrolet Express 3500 8.1 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 -> Check Fuel Cap Lamp ->
Vehicle: 2005 Chevrolet Express 3500 6.0 V8 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. I...
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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+
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2000 Chevrolet Express 3500 7.4 V8 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump.
- Remove radiator outlet hose from water pump and from vehicle.
- Reverse procedure to install.
Upper
- Drain co...
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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: 2010 Chevrolet Express 3500 LS 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 3500 AUTOMOBILES
Component location diagrams for most Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1990+.
 Fuel Tank Diagram for 2006 Chevrolet Express 3500 6.6 V8 DIESELComponents on diagram: |
 Inside Rearview Mirror Diagram for 2002 Chevrolet Express 3500 8.1 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 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: EXTERIOR LAMP CONDENSATION AND REPLACEMENT GUIDELINES Vehicle: 2004 Chevrolet Express 3500 6.0 V8 GAS Auto Systems: |
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Document: MANUAL TRANSMISSION OPERATING CHARACTERISTICS 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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