Repair manual
Wiring diagrams
Chevrolet Chevy Express G2500 Repair Manual
Step-by-step repair and maintenance instructions for the Chevrolet Chevy Express G2500 (1996–2012): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
71sections
351articles
ENManual language
- Fastener Tightening Specifications
- Engine Mechanical Specifications
- Sealers, Adhesives, and Lubricants
- Diagnostic Starting Point - Engine Mechanical
- Strategy Based Diagnostics
- Visual/Physical Inspection
- Intermittent
- Symptom List
- Base Engine Misfire without Internal Engine Noises
- Base Engine Misfire with Abnormal Internal Lower Engine Noises
- Base Engine Misfire with Abnormal Valve Train Noise
- Base Engine Misfire with Coolant Consumption
- Base Engine Misfire with Excessive Oil Consumption
- Engine Noise on Start-Up, but Only Lasting a Few Seconds
- Upper Engine Noise, Regardless of Engine Speed
- Lower Engine Noise, Regardless of Engine Speed
- Engine Noise Under Load
- Engine Will Not Crank - Crankshaft Will Not Rotate
- Coolant in Combustion Chamber
- Coolant in Engine Oil
- Engine Compression Test
- Cylinder Leakage Test
- Oil Consumption Diagnosis
- Oil Pressure Diagnosis and Testing
- Oil Leak Diagnosis
- Results Of Incorrect Operation
- Functional Check
- Diagnostic Aids
- Test Description
- Inspection Procedure
- Removal Procedure
- Installation Procedure
- Engine Mount Inspection
- Valve Stem Oil Seal and Valve Spring Replacement
- Tools Required
- Timing Chain, Sprockets, and/or Tensioner Replacement
- Balance Shaft Replacement
- Balance Shaft Bearing and/or Bushing Replacement
- Draining Fluids and Oil Filter Removal
- Engine Flywheel Removal
- Exhaust Manifold Removal - Left
- Exhaust Manifold Removal - Right
- Oil Level Indicator and Tube Removal
- Water Pump Removal
- Crankshaft Balancer Removal
- Valve Rocker Arm Cover Removal - Left
- Valve Rocker Arm Cover Removal - Right
- Distributor Removal
- Valve Rocker Arm and Push Rod Removal
- Cylinder Head Removal - Left
- Cylinder Head Removal - Right
- Valve Lifter Removal
- Oil Filter Adapter Removal
- Oil Pan Removal
- Oil Pump Removal
- Engine Front Cover Removal
- Timing Chain and Sprockets Removal
- Balance Shaft Removal
- Camshaft Removal
- Piston, Connecting Rod, and Bearing Removal
- Crankshaft Rear Oil Seal and Housing Removal
- Crankshaft and Bearings Removal
- Engine Block Plug Removal
- Engine Block Cleaning and Inspection
- Honing Procedure
- Boring Procedure
- Piston and Connecting Rod Disassemble
- Crankshaft and Bearings Cleaning and Inspection
- Measuring Crankshaft Bearing Clearances
- Measuring Crankshaft Bearing Clearances - Micrometer Method
- Measuring Connecting Rod Bearing Clearances - J 43690 Method
- Measuring Crankshaft Bearing Clearances - Plastic Gage Method
- Measuring Connecting Rod Bearing Side Clearance
- Camshaft and Bearings Cleaning and Inspection
- Camshaft Bearing Removal
- Camshaft Bearing Installation
- Balance Shaft Bearing and/or Bushing Removal
- Balance Shaft Bearing and/or Bushing Installation
- Cylinder Head Disassemble
- Cylinder Head Cleaning and Inspection
- Cylinder Head Assemble
- Oil Pump Cleaning and Inspection
- Oil Pump Assemble
- Intake Manifold Disassemble (LU3)
- Thread Repair
- Service Prior to Assembly
- Engine Prelubing
- Engine Block Plug Installation
- Crankshaft and Bearings Installation
- Crankshaft Rear Oil Seal and Housing Installation
- Piston, Connecting Rod, and Bearing Installation
- Piston Selection
- Camshaft Installation
- Balance Shaft Installation
- Timing Chain and Sprockets Installation
- Engine Front Cover Installation
- Oil Pump Installation
- Oil Pan Installation
- Oil Filter Adapter Installation
- Crankshaft Balancer Installation
- Valve Lifter Installation
- Cylinder Head Installation - Left
- Cylinder Head Installation - Right
- Valve Rocker Arm and Push Rod Installation
- Intake Manifold Installation
- Distributor Installation
- Valve Rocker Arm Cover Installation - Left
- Valve Rocker Arm Cover Installation - Right
- Oil Level Indicator and Tube Installation
- Water Pump Installation
- Exhaust Manifold Installation - Left
- Exhaust Manifold Installation - Right
- Engine Flywheel Installation
- Crankcase Ventilation System Description
- Drive Belt System Description
- Balance Shaft
- Camshaft
- Crankshaft
- Cylinder Heads
- Engine Block
- Exhaust Manifolds
- Intake Manifold
- Piston and Connecting Rod Assemblies
- Valve Train
- New Product Information
- Component Comparison
- Torque Values and/or Fastener Tightening Strategies
- Changed Engine Specifications
- New Sealants and/or Adhesives
- Disassembly and Assembly Procedure Revisions
- Engine Mechanical Diagnostic Procedure Revisions
- New Special Tools Required
- Lubrication Description
- Cleanliness and Care
- Separating Parts
- Gasket Reuse and Applying Sealant
- Separating Components
- Cleaning Gasket Surfaces
- Assembling Components
- Sealant Types
- Anaerobic Type Room Temperature Vulcanizing (RTV) Sealant
- Anaerobic Type Gasket Eliminator Sealant
- Anaerobic Type Threadlock Sealant
- Anaerobic Type Pipe Sealant
- Tools and Equipment
- Special Tools
- Fastener Tightening Specifications
- Power Steering Pump Specifications
- Visual/Physical Inspection
- Test Description
- Power Steering Fluid Leaks
- Steering Effort Hard in One or Both Directions
- Steering Effort Too Easy in One or Both Directions
- Checking and Adding Power Steering Fluid
- Removal Procedure
- Installation Procedure
- Power Steering Pulley Replacement
- Assembly Procedure
- Pitman Shaft Seal Replacement (Non Rack and Pinion)
- Tools Required
- Power Steering Cooler Pipe/Hose Replacement (GT4)
- Power Steering Cooler Pipe/Hose Replacement (GT5)
- Power Steering Reservoir Outlet Pipe/Hose Replacement
- Power Steering Gear Replacement (Non-Rack and Pinion)
- Disassembly Procedure
- Worm Thrust Bearing Preload Adjustment - Off Vehicle (700 Gear)
- Rack Piston and Worm Shaft Replacement - Off Vehicle (700 Gear)
- Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)
- Steering Gear Thrust Support Replacement - Off Vehicle (700 Gear)
- Special Tools
- SPECIAL CARE DURING MECHANICAL REPAIRS
- SYSTEM OPERATION CHECK
- PICKUPS WITH PASSENGER AIR BAG
- ALL MODELS EXCEPT PICKUPS WITH PASSENGER AIR BAG
- VEHICLES WITH PASSENGER PRESENCE SYSTEM
- SERVICE PRECAUTIONS
- DISABLING & ACTIVATING AIR BAG SYSTEM
- SUPPLEMENTAL INFLATABLE RESTRAINT DISABLING & ENABLING ZONES
- ALERO, GRAND AM & MALIBU
- Disabling System
- Activating System
- AVALANCHE, ESCALADE, ESCALADE ESV, ESCALADE EXT, SIERRA, SILVERADO, SUBURBAN, TAHOE, YUKON & YUKON XL
- AVEO
- BLAZER, CANYON, COLORADO, JIMMY, S10 PICKUP & SONOMA
- BRAVADA, ENVOY, ENVOY XUV, TRAILBLAZER, & RAINIER
- CLASSIC
- GTO
- SRX
- XLR