Repair manual
Wiring diagrams
GMC Savana H2500 Repair Manual
Step-by-step repair and maintenance instructions for the GMC Savana H2500 (2003–2003): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- Automatic Transmission - 4L80-E - Overhaul & Testing
- Automatic Transmission Removal & Installation
- Automatic Transmission Servicing (4L60-E)
- Automatic Transmission - 4L60-E/4L65-E - Overhaul & Testing
- Automatic Transmission Servicing (4L80-E)
- Automatic Transmission - Hydraulic Diagrams - 4L60-E/4L65-E
- Automatic Transmission - Hydraulic Diagrams - 4L80-E
- Automatic Transmission - 4L60-E/4L65-E (Service & Replacement)
- Automatic Transmission - 4L80-E/4L85-E (Service & Replacement)
- Shift Interlock System
- Installation Procedure
- Window Regulator Handle Replacement - Door
- Trim Panel Replacement - Side Front Door
- Trim Panel Replacement - Side Rear Door - 60/40 Left (E26, 40 door)
- Trim Panel Replacement - Side Rear Door - 60/40 Left (E26, 60 door)
- Trim Panel Replacement - Side Rear Door - 60/40 Right (E24, 40 Door)
- Trim Panel Replacement - Side Rear Door - 60/40 Right (E24, 60 Door)
- Removal Procedure
- Door Replacement - Side Front
- Door Replacement - Side Rear
- Inside Handle Replacement - Sliding Door
- Removal (4.3L - Upper Intake Manifold)
- Removal (4.3L - Lower)
- Removal (4.8L, 5.3L & 6.0L)
- Removal & Installation (4.3L)
- Removal & Installation (4.8L, 5.3L & 6.0L)
- Removal (4.3L)
- Removal & Installation (Metal Collar)
- Removal & Installation (Plastic Collar)
- Removal & Installation (Passenger/Cargo Van)
- Removal & Installation (Cutaway Van Rear Tank)
- Removal & Installation (Cutaway Van Side Tank)
- Installation (Engine Has Been Rotated With Distributor Removed)
- Installation (Engine Has Not Been Rotated With Distributor Removed)
- Removal & Installation (Cutaway Van)
- ON-BOARD DIAGNOSTICS
- Scan Tool Snapshot
- DIAGNOSTIC STARTING POINT - ENGINE CONTROLS
- Diagnostic Procedure
- RETRIEVING DIAGNOSTIC TROUBLE CODES
- CLEARING DIAGNOSTIC TROUBLE CODES
- Scan Tool
- SCAN TOOL USAGE
- Scan Tool Display
- Diagnostic Aids
- Conditions for Running
- DIAGNOSTIC TROUBLE CODE DEFINITIONS
- DIAGNOSTIC TESTS
- Conditions For Running DTC
- Conditions For Setting DTC
- Action Taken When DTC Sets
- Conditions For Clearing MIL/DTC
- Conditions For Clearing MIL or DTC
- Conditions For Clearing the MIL/DTC
- Conditions For Running The DTC
- Conditions For Setting The DTC
- Action Taken When The DTC Sets
- Conditions For Clearing DTC
- ON-BOARD DIAGNOSTICS
- Scan Tool Snapshot
- DIAGNOSTIC STARTING POINT - ENGINE CONTROLS
- Diagnostic Procedure
- RETRIEVING DIAGNOSTIC TROUBLE CODES
- CLEARING DIAGNOSTIC TROUBLE CODES
- Scan Tool
- Diagnostic Aids
- Conditions for Running
- DIAGNOSTIC TROUBLE CODE DEFINITIONS
- DIAGNOSTIC TESTS
- Conditions For Running DTC
- Conditions For Setting DTC
- Action Taken When DTC Sets
- Conditions For Clearing MIL/DTC
- Conditions For Clearing MIL or DTC
- Conditions For Clearing DTC
- Action Take When DTC Sets
- Diagnostic Starting Point - Engine Mechanical
- Strategy Based Diagnostics
- Visual/Physical Inspection
- Symptom List
- Engine Compression Test
- Cylinder Leakage Test
- Oil Consumption Diagnosis
- Oil Pressure Diagnosis and Testing
- Diagnostic Aids
- Inspection Procedure
- Engine Mount Inspection
- Engine Block Cleaning and Inspection
- Piston, Connecting Rod, and Bearings Cleaning and Inspection
- Crankshaft and Bearings Cleaning and Inspection
- Crankshaft Balancer Cleaning and Inspection
- Engine Flywheel Cleaning and Inspection
- Camshaft and Bearings Cleaning and Inspection
- Balance Shaft Cleaning and Inspection
- Timing Chain and Sprockets Cleaning and Inspection
- Valve Rocker Arm and Push Rods Cleaning and Inspection
- Cylinder Head Cleaning and Inspection
- Oil Pump Cleaning and Inspection
- Valve Rocker Arm Cover Cleaning and Inspection
- Intake Manifold Cleaning and Inspection
- Exhaust Manifold Cleaning and Inspection
- Water Pump Cleaning and Inspection
- Engine Mechanical Diagnostic Procedure Revisions
- Installation Procedure
- Removal Procedure
- Valve Stem Oil Seal and Valve Spring Replacement
- Valve Lifter Replacement
- Cylinder Head Replacement - Left
- Cylinder Head Replacement - Right
- Crankshaft Balancer Replacement
- Crankshaft Front Oil Seal Replacement
- Crankshaft Position (CKP) Reluctor Ring Replacement
- Timing Chain and Sprockets Replacement
- Balance Shaft Replacement
- Balance Shaft Bearing and/or Bushing Replacement
- Engine Oil Pressure Sensor and/or Switch Replacement
- Crankshaft Rear Oil Seal Replacement
- Engine Replacement
- Exhaust Manifold Removal - Left
- Exhaust Manifold Removal - Right
- Water Pump Removal
- Crankshaft Balancer Removal
- Valve Rocker Arm and Push Rod Removal
- Valve Lifter Removal
- Timing Chain and Sprockets Removal
- Piston, Connecting Rod, and Bearing Removal
- Engine Block Plug Removal
- Camshaft Bearing Removal
- Camshaft Bearing Installation
- Balance Shaft Bearing and/or Bushing Removal
- Balance Shaft Bearing and/or Bushing Installation
- Engine Block Plug Installation
- Crankshaft and Bearings Installation
- Crankshaft Rear Oil Seal and Housing Installation
- Piston, Connecting Rod, and Bearing Installation
- Balance Shaft Installation
- Timing Chain and Sprockets Installation
- Engine Front Cover Installation
- Crankshaft Balancer 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
- Water Pump Installation
- Intermittent
- Boring Procedure
- Deglazing Procedure
- Cleaning Procedure
- Measuring Main Bearing Clearance - Gaging Plastic Method
- Measuring Connecting Rod Bearing Clearance - Gaging Plastic Method
- Measuring Connecting Rod Bearing Clearance - Using J 43690/J 43690-100
- Piston and Pin
- Connecting Rod and Bearings
- Measuring Piston Ring End Gap
- Measuring Camshaft Lobe Lift
- Valve Guide Reaming/Valve and Seat Grinding
- Valve Guide Reaming
- Valve and Seat Grinding
- Thread Repair
- General Thread Repair
- Engine Prelubing
- Piston Selection
- Camshaft and Drive System
- Crankshaft
- Cylinder Heads
- Engine Block
- Exhaust Manifolds
- Intake Manifold
- Oil Pan
- Valve Train
- New Product Information
- New Sealants and/or Adhesives
- A Component Comparison from the Previous Year
- Cleanliness and Care
- Separating Parts
- Replacing Engine Gaskets
- Gasket Use and Applying Sealants
- Separating Components
- Cleaning Gasket Surfaces
- Pipe Joint Compound
- RTV Sealer
- Anaerobic Sealer
- Tools and Equipment
- Diagnostic Starting Point - Engine Mechanical
- Strategy Based Diagnostics
- Visual/Physical Inspection
- Symptom List
- Engine Compression Test
- Cylinder Leakage Test
- Oil Pressure Diagnosis and Testing
- Diagnostic Aids
- Inspection Procedure
- Engine Mount Inspection
- Engine Block Cleaning and Inspection
- Crankshaft and Bearings Cleaning and Inspection
- Camshaft and Bearings Cleaning and Inspection
- Valve Rocker Arm and Push Rods Cleaning and Inspection
- Valve Lifters and Guides Cleaning and Inspection
- Cylinder Head Cleaning and Inspection
- Oil Pump Cleaning and Inspection
- Engine Front Cover Cleaning and Inspection
- Engine Rear Cover Cleaning and Inspection
- Engine Valley Cover Cleaning and Inspection
- Valve Rocker Arm Cover Cleaning and Inspection
- Oil Pan Cleaning and Inspection
- Exhaust Manifold Cleaning and Inspection
- Coolant Air Bleed Pipe Cleaning and Inspection
- Engine Mechanical Diagnostic Procedure Revisions
- Removal Procedure
- Installation Procedure
- Valve Stem Oil Seal and Valve Spring Replacement
- Cylinder Head Replacement - Left
- Cylinder Head Replacement - Right
- Valve Lifter Replacement
- Crankshaft Balancer Replacement
- Crankshaft Front Oil Seal Replacement
- Engine Front Cover Replacement
- Crankshaft Rear Oil Seal Replacement
- Engine Rear Cover Replacement
- Engine Oil Pressure Sensor and/or Switch Replacement
- Timing Chain and Sprockets Replacement
- Engine Replacement
- Draining Fluids and Oil Filter Removal
- Crankshaft Balancer Removal
- Engine Flywheel Removal
- Exhaust Manifold Removal - Right
- Throttle Body Removal
- Fuel Rail and Injectors Removal
- Intake Manifold Removal
- Valve Rocker Arm Cover Removal - Left
- Valve Rocker Arm Cover Removal - Right
- Valve Rocker Arm and Push Rod Removal
- Valve Lifter Removal
- Oil Pan Removal
- Timing Chain and Sprockets Removal
- Piston, Connecting Rod, and Bearing Removal
- Crankshaft and Bearings Removal
- Engine Block Plug Removal
- Camshaft Bearing Removal
- Camshaft Bearing Installation
- Engine Block Plug Installation
- Crankshaft and Bearings Installation
- Piston, Connecting Rod, and Bearing Installation
- Camshaft Installation
- Timing Chain and Sprockets Installation
- Oil Pump, Pump Screen and Deflector Installation
- Engine Rear Cover Installation
- Crankshaft Rear Oil Seal Installation
- Engine Front Cover Installation
- Crankshaft Front Oil Seal Installation
- Oil Pan Installation
- Oil Filter, Adapter, Pan Cover Installation
- Valve Lifter Installation
- Cylinder Head Installation - Left
- Cylinder Head Installation - Right
- Valve Rocker Arm and Push Rod Installation
- Valve Rocker Arm Cover Installation - Left
- Valve Rocker Arm Cover Installation - Right
- Engine Valley Cover Installation
- Coolant Air Bleed Pipe Installation
- Intake Manifold Installation
- Fuel Rail and Injectors Installation
- Throttle Body Installation
- Water Pump Installation
- Exhaust Manifold Installation - Left
- Exhaust Manifold Installation - Right
- Engine Flywheel Installation
- Crankshaft Balancer Installation
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information
- Waveforms - Injector Pattern Tutorial - General Information
- Electrostatic Discharge Warning - General Information
- Emission Control Description & Operation - Diesel
- State Emission Standards - Diesel
- Installation Procedure
- Removal Procedure
- Steering Knuckle Replacement (RWD)
- Steering Knuckle Replacement (4WD)
- Upper Control Arm Replacement
- Lower Control Arm Replacement (RWD)
- Lower Control Arm Replacement (4WD)
- Wheel Stud Replacement
- Wheel Hub, Bearing, and Seal Replacement (4WD)
- Torsion Bar and Support Assembly Replacement
- Compressor Replacement (4.8L, 5.3L, 6.0L)
- Installation Procedure
- Compressor Replacement (4.3L)
- Compressor Sealing Washers Replacement
- Removal Procedure
- Discharge Hose Replacement
- Suction Hose Replacement
- Evaporator Tube Replacement - Front
- Evaporator Tube Replacement - Inlet
- Evaporator Tube Replacement - Outlet (C60)
- Evaporator Tube Replacement - Outlet (C69)
- Air Conditioning (A/C) Refrigerant Filter Installation
- Air Conditioning (A/C) Refrigerant Filter Replacement
- Expansion (Orifice) Tube Replacement
- Air Conditioning (A/C) High Pressure Switch Replacement (HU6 Only)
- Air Conditioning (A/C) Low Pressure Switch Replacement
- Condenser Replacement
- Accumulator Replacement
- Air Conditioning (A/C) Evaporator and Blower Module Assembly Replacement
- Evaporator Core Replacement
- Heater Hose Replacement - Inlet
- Heater Hose Replacement - Outlet
- Recirculation Door Replacement
- Coolant Bypass Valve Replacement
- Heater Core Replacement
- Evaporator Core Replacement - Auxiliary
- Intermittents
- PCM
- Intermittent
- HVAC Compressor Clutch Does Not Engage
- Blower Motor Always On
- Blower Motor Inoperative
- Blower Motor Always On - Auxiliary (Passenger Van w/Aux)
- Blower Motor Malfunction - Auxiliary
- Too Hot in Vehicle
- Too Cold in Vehicle
- Too Hot in Vehicle - Auxiliary (Passenger Van w/Aux)
- Too Hot in Vehicle - Auxiliary (Cargo Van w/Aux)
- Too Hot in Vehicle - Auxiliary (Cargo Van w/Aux Rear Heater)
- Too Cold in Vehicle - Auxiliary (Passenger Van w/Aux)
- Too Cold in Vehicle - Auxiliary (Cargo Van w/Aux)
- Too Cold in Vehicle - Auxiliary (Cargo Van w/Aux Rear Heater)
- Auxiliary HVAC Control Processor
- Auxiliary Mode Actuator
- Air Speed
- Auxiliary Air Speed
- Mode Switch
- MAX A/C-If Equipped
- A/C-If Equipped
- BI-Level Mode
- Vent Mode
- Floor Mode
- Mix-Blend Mode
- Defrost Mode
- Auxiliary Air Distribution
- Air Temperature Actuator
- A/C Pressure Switches
- Bypass Valves
- Heater Mode - Auxiliary Heater without A/C
- Engine Coolant
- A/C Cycle
- A/C Cycle with Auxiliary
- Power Steering Pulley Replacement
- Installation Procedure
- Pitman Shaft Seal Replacement - On Vehicle (Non Rack and Pinion)
- Tie Rod Replacement - Inner - On Vehicle
- Tie Rod End Replacement - Outer
- Rack and Pinion Boot Replacement - On Vehicle
- Removal Procedure
- Power Steering Cooler Pipe/Hose Replacement (GT5)
- Power Steering Reservoir Inlet Pipe/Hose Replacement
- Power Steering Reservoir Outlet Pipe/Hose Replacement
- Power Steering Gear Outlet Hose Replacement
- Power Brake Booster Inlet Hose Replacement
- Power Brake Booster Outlet Hose Replacement
- Power Steering Gear Replacement (Non-Rack and Pinion)
- Power Steering Gear Replacement (Rack and Pinion)
- Rack and Pinion Boot and Breather Tube Replacement - Off Vehicle
- Tie Rod Replacement - Inner (Quiet Valve)
- Steering Gear Stub Shaft Seals and Bearing Replacement - Off Vehicle
- Rack Piston and Worm Shaft Replacement - Off Vehicle (700 Gear)
- Pitman Shaft Seals and Bearing Replacement - Off Vehicle (700 Gear)
- Steering Gear Check Valve Replacement - Off Vehicle
- Steering Gear Thrust Support Replacement - Off Vehicle (700 Gear)
- Locking Differential Disassemble (8.6 Inch, 9.75 Inch Axles)
- Locking Differential Cam Unit Disassemble (9.75 Inch Axle)
- Locking Differential Cam Unit Disassemble (10.5 Inch Axle)
- Locking Differential Cam Unit Assemble (9.75 Inch Axle)
- Locking Differential Cam Unit Assemble (10.5 Inch Axle)
- Locking Differential Assemble (8.6 Inch, 9.75 Inch Axles)
- Locking Differential Assemble (10.5 Inch Axle)
- Removal Procedure
- Installation Procedure
- Rear Axle Shaft Seal and/or Bearing Replacement
- Rear Axle Hub, Bearing, Cup, and/or Seal Replacement
- Drive Pinion Flange/Yoke and/or Oil Seal Replacement (8.6 Inch Axle)
- Drive Pinion Flange/Yoke and/or Oil Seal Replacement (9.75 Inch, 10.5 Inch Axles)
- Drive Pinion and Ring Gear Replacement (8.6 Inch Axle)
- Drive Pinion and Ring Gear Replacement (9.75 Inch, 10.5 Inch Axles)
- Drive Pinion Bearings Replacement (8.6 inch Axle)
- Drive Pinion Bearings Replacement (9.75 Inch, 10.5 Inch Axles)
- Differential Replacement (9.75 Inch, 10.5 Inch Axles)
- Differential Side Bearings Replacement
- Rpo Code Definitions (Rpo 001-19F)
- Rpo Code Definitions (Rpo 19H-2EL).
- Rpo Code Definitions (Rpo 2F1-44I).
- Rpo Code Definitions (Rpo 44L-5J9).
- Rpo Code Definitions (Rpo 5K0-6FF).
- Rpo Code Definitions (Rpo 6FG-76A).
- Rpo Code Definitions (Rpo 76D-7XD).
- Rpo Code Definitions (Rpo 7XF-8M0).
- Rpo Code Definitions (Rpo 8M1-9C0).
- Rpo Code Definitions (Rpo 9C1-A0F).
- Rpo Code Definitions (Rpo A0G-AR4).
- Rpo Code Definitions (Rpo AR5-BCP).
- Rpo Code Definitions (Rpo BCQ-C12).
- Rpo Code Definitions (Rpo C13-CUR).
- Rpo Code Definitions (Rpo Cut-Dir).
- Rpo Code Definitions (Rpo DR7-EHE).
- Rpo Code Definitions (Rpo EHF-F5P).
- Rpo Code Definitions (Rpo F5Q-G1V).
- Rpo Code Definitions (Rpo G1W-HFN).
- Rpo Code Definitions (Rpo Hfo-Jrg).
- Rpo Code Definitions (Rpo Jrh-Kly).
- Rpo Code Definitions (Rpo Klz-Lqx).
- Rpo Code Definitions (Rpo LQY-MW9).
- Rpo Code Definitions (Rpo Mwe-Odk).
- Rpo Code Definitions (Rpo Odl-Ora).
- Rpo Code Definitions (Rpo Orb-Pde).
- Rpo Code Definitions (Rpo PDF-QH6).
- Rpo Code Definitions (Rpo QH7-R8D).
- Rpo Code Definitions (Rpo R8E-T07).
- Rpo Code Definitions (Rpo T08-TJ0).
- Rpo Code Definitions (Rpo TJ1-U10).
- Rpo Code Definitions (Rpo U11-US9).
- Rpo Code Definitions (Rpo USB-VG9).
- Rpo Code Definitions (Rpo VGA-W5Y).
- Rpo Code Definitions (Rpo W5Z-XE3).
- Rpo Code Definitions (Rpo XE4-Y9Z).
- Rpo Code Definitions (Rpo YA2-ZD9).
- Rpo Code Definitions (Rpo Zde-Zzz).
- Removal Procedure
- Installation Procedure
- Windshield Reveal Molding Replacement
- Rearview Mirror Support Installation
- Windshield Replacement
- Body Side Stationary Window Replacement
- Hinged Rear Window Replacement
- Rear Window Replacement
- Urethane Adhesive Installation of Stationary Windows
- Urethane Adhesive Installation of Body Side Stationary Windows
- Minor Scratch and Abrasion Removal
- SEAL REPLACEMENT - INTERMEDIATE STEERING SHAFT
- INTERMEDIATE STEERING SHAFT REPLACEMENT - UPPER
- INTERMEDIATE STEERING SHAFT REPLACEMENT - LOWER
- INTERMEDIATE STEERING SHAFT BEARING REPLACEMENT
- Removal Procedure
- STEERING COLUMN TRIM COVERS REPLACEMENT
- Installation Procedure
- IGNITION SWITCH REPLACEMENT
- IGNITION LOCK CYLINDER REPLACEMENT
- IGNITION LOCK CYLINDER CASE REPLACEMENT (FLOOR SHIFT)
- IGNITION LOCK CYLINDER CASE REPLACEMENT (COLUMN SHIFT)
- SHIFT LEVER REPLACEMENT
- LINEAR SHIFT ASSEMBLY REPLACEMENT
- HORN SWITCH REPLACEMENT
- STEERING WHEEL CONTROL SWITCH ASSEMBLY REPLACEMENT
- STEERING WHEEL REPLACEMENT
- TILT SPRING REPLACEMENT
- STEERING COLUMN TILT HEAD HOUSING REPLACEMENT (TILT)
- STEERING COLUMN REPLACEMENT
- LOWER BEARING AND STEERING COLUMN JACKET REPLACEMENT (COLUMN SHIFT TILT)
- LOWER BEARING AND STEERING COLUMN JACKET REPLACEMENT (COLUMN SHIFT STANDARD)
- STEERING COLUMN WIRE HARNESS ASSEMBLY REPLACEMENT
- Engine Controls - Basic Diagnostic Procedures
- Engine Controls - Basic Diagnostic Procedures - 4.8L, 5.3L & 6.0L - Flex Fuel & Gasoline Engines
- Engine Controls - Basic Diagnostic Procedures - 6.0L W/bifuel & Cng Engines
- Engine Controls - Trouble Shooting - No Codes - 4.3L
- Engine Controls - Trouble Shooting - No Codes - 4.8L, 5.3L & 6.0L
- Engine Controls - Trouble Shooting - No Codes - 6.0L W/bifuel & Cng
- Engine Control System & Component Tests - 4.3L
- Engine Controls - System & Component Testing - 4.8L, 5.3L & 6.0L - Flex Fuel & Gasoline
- Engine Controls - System & Component Testing - 6.0L W/bifuel & Cng
- Engine Controls Self-Diagnostics - 4.3L
- Engine Controls Self Diagnostics - 4.8L, 5.3L & 6.0L Gasoline
- Engine Controls Self-Diagnostics - 6.0L Bi-Fuel & Cng
- Engine Controls - Strategy Based Engine Diagnosis
- Utility/Van Zoning
- Basic Knowledge Required
- Checking Aftermarket Accessories
- Probing Electrical Connectors
- Frontprobe
- Backprobe
- Using Fused Jumper Wires
- Measuring Voltage
- Measuring Voltage Drop
- Measuring Frequency
- With a DMM
- Fuse Powering Several Loads
- Round Wire Connectors
- Flat Wire (Dock and Lock) Connectors
- Inducing Intermittent Fault Conditions
- Salt Water Spray
- High Temperature Conditions
- Low Temperature Conditions
- Fuse Types
- Circuit Protection - Circuit Breakers
- Circuit Protection - Fusible Links
- Repairing a Fusible Link
- Repairing Damaged Wire Insulation
- Splicing Twisted or Shielded Cable
- SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair
- SIR/SRS Wire Pigtail Repair
- SIR/SRS Wire Repair
- Connector Position Assurance (CPA)
- Terminal Position Assurance (TPA)
- Flat Wire Repairs
- Connector Repairs
- Connector Position Assurance Locks
- Terminal Position Assurance Locks
- Terminal Repair
- Reinstalling Terminal
- Weather Pack Connectors
- Repairing Connector Terminals
- Master Electrical Component List — Part 1
- Master Electrical Component List — Part 2