Repair manual
Chevrolet C3500 HD Repair Manual
Step-by-step repair and maintenance instructions for the Chevrolet C3500 HD (1991–2000): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
71sections
429articles
ENManual language
- IDENTIFICATION
- SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM
- DIAGNOSTIC ENERGY RESERVE MODULE (DERM)
- AIR BAG RESTRAINT WARNING LIGHT
- ARMING SENSOR/DUAL POLE ARMING SENSOR
- DISCRIMINATING SENSORS
- SIR COIL ASSEMBLY
- INFLATOR MODULE
- RESISTOR MODULE
- SYSTEM OPERATION CHECK
- POST-COLLISION INSPECTION
- INTERMITTENTS & POOR CONNECTIONS
- SERVICE PRECAUTIONS
- SYSTEM REPAIR
- SENSOR HANDLING
- LIVE INFLATOR MODULE HANDLING
- SPECIAL TOOLS
- DISABLING & ACTIVATING AIR BAG SYSTEM
- DISABLING SYSTEM
- ACTIVATING SYSTEM
- DISPOSAL PROCEDURES
- DEPLOYED AIR BAG
- UNDEPLOYED AIR BAG
- SCRAPPED VEHICLE
- REMOVAL & INSTALLATION
- Removal
- Installation
- Removal (Driver-Side) - Leaf Spring & Notched Pin-Type
- Installation (Driver-Side) - Leaf Spring & Notched Pin-Type
- Removal (Driver-Side) - Ball Lock Fastener-Type
- Installation (Driver-Side) - Ball Lock Fastener-Type
- DIAGNOSIS & TESTING
- Diagnostic Trouble Codes (DTCs)
- Scan Tester Diagnostics
- On-Board Diagnostics
- Diagnostic Procedure
- Description
- Diagnostic Aids
- Action Taken
- Failure Conditions
- Test Conditions
- WIRE REPAIR
- CONNECTOR IDENTIFICATION
- TORQUE SPECIFICATIONS
- APPLICATION
- DESCRIPTION
- OPERATION
- PCM/TCM
- SENSORS & SWITCHES
- Shift Solenoids 1-2 & 2-3
- Pressure Control Solenoid
- TCC PWM Solenoid
- SELF-DIAGNOSTICS
- CLUTCH AND BAND APPLICATION
- ELECTRONIC SELF-DIAGNOSTICS
- RETRIEVING CODES WITHOUT SCAN TOOL - GASOLINE ENGINES
- RETRIEVING CODES WITH SCAN TOOL - GASOLINE ENGINES
- Preliminary Inspection
- Diagnostic Procedure
- Entering Or Exiting Diagnostic Mode
- TROUBLE CODE DEFINITIONS
- HARD OR INTERMITTENT TROUBLE CODE DETERMINATION - GASOLINE
- CLEARING TROUBLE CODES
- Diesel
- Gasoline
- Diagnostic Charts
- Diagnostic Aids
- DTC 15, COOLANT TEMPERATURE SENSOR SIGNAL VOLTAGE HIGH
- DTC 22, TPS SIGNAL VOLTAGE LOW
- DTC 59, TRANS. FLUID TEMP. LOW
- DTC 68, TRANSMISSION COMPONENT SLIPPING
- DTC 79, TRANS. FLUID TEMP. HIGH
- DTC 86, LOW GEAR RATIO ERROR
- DTC 87, HIGH GEAR RATIO ERROR
- CHART A-1, NO MIL (SERVICE ENGINE SOON LIGHT) - MODELS W/PCM
- CHART A-1, NO MIL (SERVICE ENGINE SOON LIGHT) - "G" & "P" SERIES WITH TCM
- CHART A-2, NO SCAN DATA, MIL (SERVICE ENGINE SOON) ON AT ALL TIMES OR WILL NOT FLASH MIL - MODELS WITH PCM
- CHART A-2, NO DATA LINK CONNECTOR (DLC) DATA, WILL NOT DISPLAY DTC 12 OR MIL ON STEADY - "G" & "P" SERIES WITH TCM
- DTC 15, ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH (LOW TEMPERATURE INDICATED)
- DTC 59, TRANS. FLUID TEMP. SENSOR CIRCUIT HIGH (LOW TEMPERATURE INDICATED)
- DTC 69, TORQUE CONVERTER CLUTCH STUCK ON
- DTC 72, VEHICLE SPEED SENSOR CIRCUIT LOSS (TRANSMISSION OUTPUT SIGNAL)
- COMPONENT & WIRING HARNESS RESISTANCE CHECK
- PRESSURE SWITCH ASSEMBLY
- TECHNICAL SERVICE BULLETINS (TSB)
- 1994-95 "C", "G" & "K" 4WD Vehicles (ATRA TSB No. 343)
- Early, Late Or Erratic Shifts (All Models)
- 4WD-Low Diagnostic Check ("K" Series With Manually Or Electronically Shifted Transfer Case In High Position)
- INTRODUCTION
- SELF-DIAGNOSTIC SYSTEM
- Preliminary Inspection
- Diagnostic Procedure
- ENTERING & EXITING DIAGNOSTIC MODE
- TROUBLE CODE IDENTIFICATION
- CLEARING TROUBLE CODES
- PCM/TCM LOCATION
- SPECIAL TOOLS (DIAGNOSTIC)
- SCAN TESTER USAGE
- TYPICAL TECH 1 DATA VALUES
- TEST EQUIPMENT
- DIAGNOSTIC TROUBLE CODE CHARTS
- ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK (MODELS WITH PCM)
- CHART A-1, NO MIL (SERVICE ENGINE SOON LIGHT) (MODELS W/ PCM)
- Diagnostic Aids
- CHART A-2, NO SCAN DATA, MIL (SERVICE ENGINE SOON) ON AT ALL TIMES OR WILL NOT FLASH MIL (MODELS WITH PCM)
- CHART A-3, ENGINE CRANKS BUT WILL NOT RUN
- EGR CONTROL PRESSURE/BARO SENSOR OUTPUT CHECK
- DTC 13, ENGINE SHUTOFF SOLENOID CIRCUIT FAULT
- DTC 14, ECT SENSOR CIRCUIT LOW (HIGH TEMPERATURE INDICATED)
- DTC 15, ECT SENSOR CIRCUIT HIGH (LOW TEMPERATURE INDICATED)
- DTC 16, VEHICLE SPEED SIGNAL BUFFER FAULT
- DTC 17, HIGH RESOLUTION CIRCUIT FAULT
- DTC 18, PUMP CAM REFERENCE PULSE ERROR
- DTC 19, CRANKSHAFT POSITION REFERENCE ERROR
- DTC 21, APP NO. 1 CIRCUIT HIGH (MODELS WITH PCM)
- DTC 22, APP NO. 1 CIRCUIT LOW (MODELS WITH PCM)
- DTC 23, APP NO. 1 CIRCUIT RANGE FAULT
- DTC 24, VSS CIRCUIT LOW (TRANSMISSION OUTPUT SPEED SIGNAL)
- DTC 25, ACCELERATOR PEDAL POSITION (APP) NO. 2 CIRCUIT HIGH
- DTC 26, ACCELERATOR PEDAL POSITION (APP) NO. 2 CIRCUIT LOW
- DTC 27, APP NO. 2 CIRCUIT RANGE FAULT
- DTC 28, TRANSMISSION RANGE PRESSURE SWITCH CIRCUIT FAULT
- TRANSMISSION RANGE PRESSURE SWITCH COMBINATIONS
- DTC 29, GLOW PLUG RELAY CIRCUIT FAULT
- DTC 31, EGR CONTROL PRESSURE/BARO SENSOR CKT LOW (HIGH VAC)
- DTC 32, EGR CIRCUIT ERROR
- DTC 33, EGR CONTROL PRESSURE/BARO SENSOR CKT HIGH (LOW VAC)
- DTC 34, INJECTION TIMING STEPPER (ITS) MOTOR CIRCUIT FAULT
- DTC 35, INJECTION PULSE WIDTH ERROR (RESPONSE TIME SHORT)
- DTC 36, INJECTION PULSE WIDTH ERROR (RESPONSE TIME LONG)
- DTCS 37/38, TCC BRAKE SWITCH STUCK ON/OFF
- DTC 39, TCC STUCK OFF (4L80-E)
- DTC 41, BRAKE SWITCH CIRCUIT FAULT
- DTC 42, FUEL TEMP CIRCUIT LOW (HIGH TEMP INDICATED)
- DTC 43, FUEL TEMP CIRCUIT HIGH (LOW TEMP INDICATED)
- DTC 44, EGR PULSE WIDTH ERROR
- DTC 45, EGR VENT ERROR
- DTC 46, MALFUNCTION INDICATOR LIGHT (MIL) CIRCUIT FAULT
- DTC 47, IAT SENSOR CIRCUIT LOW (HIGH TEMPERATURE INDICATED)
- DTC 48, IAT SENSOR CIRCUIT HIGH (LOW TEMPERATURE INDICATED)
- DTC 49, SERVICE THROTTLE SOON LIGHT CIRCUIT FAULT
- DTC 51, PROM PROBLEM (FAULTY OR INCORRECT PROM)
- DTCS 52/53, SYSTEM VOLTAGE HIGH LONG
- DTC 54, PCM FUEL CIRCUIT ERROR
- DTC 56, INJECTION PUMP CALIBRATION RESISTOR ERROR
- DTC 57, PCM 5-VOLT SHORTED
- DTC 58, TRANSMISSION FLUID TEMP SENSOR CIRCUIT LOW (HIGH TEMP INDICATED) - 4L60-E & 4L80-E
- DTC 59, TRANSMISSION FLUID TEMP SENSOR CIRCUIT HIGH (LOW TEMP INDICATED) - 4L60-E & 4L80-E
- DTC 61, TURBO BOOST SENSOR CIRCUIT HIGH
- DTC 62, TURBO BOOST SENSOR CIRCUIT LOW
- DTC 63, APP NO. 3 CIRCUIT HIGH (MODELS WITH PCM)
- DTC 64, APP NO. 3 CIRCUIT LOW (MODELS WITH PCM)
- DTC 65, APP NO. 3 CIRCUIT RANGE FAULT
- DTC 66, 3-2 CONTROL SOLENOID CIRCUIT FAULT (4L60-E)
- DTC 67, TCC SOLENOID CIRCUIT FAULT (4L60-E)
- DTC 68, TRANSMISSION COMPONENT SLIPPING (4L80-E)
- DTC 69, TCC STUCK ON (4L60-E)
- DTC 69, TCC STUCK ON (4L80-E)
- DTC 71, SET/COAST SWITCH FAULT (MODELS WITH PCM)
- DTC 72, SPEED SENSOR CIRCUIT LOSS (TRANS OUTPUT SPEED SIGNAL) - 4L60-E & 4L80-E
- DTC 73, PRESSURE CONTROL SOLENOID CIRCUIT (CURRENT ERROR)
- DTC 74, TRANSMISSION INPUT SPEED SENSOR CIRCUIT (4L80-E)
- DTC 75, SYSTEM VOLTAGE LOW
- DTC 76, RESUME/ACCEL SWITCH FAULT
- DTC 78, WASTEGATE SOLENOID FAULT
- DTC 79, TRANSMISSION FLUID OVERTEMP - 4L60-E & 4L80-E
- DTC 81, 2-3 SHIFT SOLENOID CIRCUIT FAULT - 4L60-E & 4L80-E
- DTC 82, 1-2 SHIFT SOLENOID CIRCUIT FAULT - 4L60-E & 4L80-E
- DTC 83, TCC PWM SOLENOID CIRCUIT FAULT - 4L60-E & 4L80-E
- DTC 84, ACCELERATOR PEDAL POSITION (APP) CIRCUIT FAULT
- DTC 85, UNDEFINED RATIO ERROR (4L80-E)
- DTC 86, LOW RATIO ERROR (4L80-E)
- DTC 87, HIGH RATIO ERROR (4L80-E)
- DTC 88, TDC OFFSET ERROR
- DTC'S 91-98, CYLINDER BALANCE FAULT
- DTC 99, APP NO. 2 (5-VOLT REFERENCE FAULT)
- MODEL IDENTIFICATION
- INTRODUCTION
- TERMINOLOGY
- SELF-DIAGNOSTIC SYSTEM
- HARD FAILURES
- INTERMITTENT FAILURES
- DIAGNOSTIC PROCEDURE
- RETRIEVING CODES (NON-SCAN)
- READING TROUBLE CODES
- CLEARING TROUBLE CODES
- ECM LOCATION
- Diagnostic Aids
- Field Service Mode Check
- SPECIAL TOOLS (DIAGNOSTIC)
- SCAN TESTER USAGE
- SCAN TESTER DATA
- TROUBLE CODE CHARTS
- CODE 13, OPEN OXYGEN SENSOR CIRCUIT
- CODE 14, COOLANT SENSOR SIGNAL VOLTAGE LOW
- CODE 15, COOLANT SENSOR SIGNAL VOLTAGE HIGH
- CODE 16, VSS BUFFER FAULT
- CODE 21, TPS SIGNAL VOLTAGE HIGH
- CODE 22, TPS SIGNAL VOLTAGE LOW
- CODE 24, VEHICLE SPEED SENSOR - "C" & "K" SERIES
- CODE 24, VSS TRANSMISSION OUTPUT SIGNAL - A/T
- CODE 28, TRANSMISSION RANGE PRESSURE SWITCH
- CODE 32, EGR CIRCUIT ERROR BACKPRESSURE EGR WITH SOL
- CODE 32, EGR CIRCUIT ERROR WITH EVRV SOLENOID
- CODE 32, EGR CIRCUIT ERROR - "P" SERIES WITH LINEAR EGR
- CODE 32, EGR CIRCUIT ERROR - SERIES W/ LINEAR EGR
- CODE 33, MAP SENSOR SIGNAL VOLTAGE HIGH
- CODE 34, MAP SENSOR SIGNAL VOLTAGE LOW
- CODE 35, IDLE SPEED ERROR
- IAC Valve Reset Procedure
- System Too Lean
- System Too Rich
- Throttle Body
- IAC Valve Connections
- PCV Valve
- CODE 36, IDLE SPEED ACTUATOR FAULT - A/T
- CODES 37/38, TCC BRAKE SWITCH ON/OFF
- CODE 39, TCC STUCK OFF - 4L80-E TRANSMISSION
- CODE 42, IGNITION CONTROL
- CODE 43, KNOCK SENSOR WITHOUT SPARK MODULE (DUAL SENSORS)
- CODE 43, KNOCK SENSOR WITHOUT SPARK MODULE (SINGLE SENSOR)
- CODE 43, KNOCK SENSOR WITH SPARK CONTROL MODULE
- CODE 44, LEAN EXHAUST INDICATION
- O2 Sensor Wire
- Fuel Contamination
- Fuel Pressure
- Exhaust Leaks
- CODE 45, RICH EXHAUST INDICATION
- Fuel Pressure High
- Ignition Ground
- Fuel Canister
- MAP Sensor
- TPS
- O2 Sensor Contamination
- EGR Problem
- CODE 51, PROM ERROR (FAULTY OR INCORRECT PROM)
- CODE 52, FAULTY CALPAK
- CODE 52/53, SYSTEM VOLTAGE HIGH
- CODE 55, ECM/PCM ERROR
- CODE 54, FUEL PUMP CIRCUIT
- CODE 58, TRANSMISSION FLUID TEMPERATURE HIGH
- CODE 59, TRANSMISSION FLUID TEMPERATURE LOW
- CODE 66, 3-2 CONTROL SOLENOID CKT FAULT 4L60-E TRANSMISSION
- CODE 67, TCC SOLENOID CIRCUIT CHECK - 4L60-E TRANSMISSION
- CODE 68, OVERDRIVE RATIO ERROR - 4L80-E TRANSMISSION
- CODE 69, TORQUE CONVERTER CLUTCH STUCK ON 4L60-E TRANSMISSION
- CODE 69, TORQUE CONVERTER CLUTCH STUCK ON 4L80-E TRANSMISSION
- CODE 72, VSS CIRCUIT LOSS TRANSMISSION OUTPUT SIGNAL
- CODE 73, PRESSURE CONTROL SOLENOID (CURRENT ERROR)
- CODE 74, TRANSMISSION INPUT SPEED ERROR 4L80-E TRANSMISSION
- CODE 75, SYSTEM VOLTAGE LOW
- CODE 79, TRANSMISSION FLUID TEMPERATURE HIGH
- CODE 81, TRANSMISSION 2-3 ERROR
- CODE 82, TRANSMISSION 1-2 ERROR
- CODE 83, TCC SOLENOID CIRCUIT FAULT
- CODE 85, UNDEFINED GEAR RATIO
- CODE 86, LOW GEAR RATIO ERROR
- CODE 87, HIGH GEAR RATIO ERROR
- SUMMARY