Chevrolet Express Service Repair Manual. Wiring Diagrams

The 2003-2012 Chevrolet Express Service Manual contains step-by-step procedures, detailed illustrations, diagrams and explanations to help you maintain and repair your vehicle. Repair of the engine and controls, location of sensors/Gages and assistance in their replacement, diagnostics of malfunctions. Circuit diagrams, wiring diagram

Chevrolet Express Owner’s Manual Download
GMC Savana Owner’s Manual Download

Engine Mechanical – 4.3L Download
Engine Mechanical – 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L Download
Engine Mechanical – 6.6L Download
Engine Controls and Fuel – 4.8L, 5.3L, 6.0L, 6.2L, or 7.0L Download
Engine Controls and Fuel – 4.3L Download
Engine Controls and Fuel – 6.6L Download
Engine Cooling Download
Engine Electrical Download

Automatic Transmission – 4L60-E/4L65-E/4L70-E Download
Shift Lock Control Download
Transfer Case – BW 4473-NP3 Download

Antilock Brake System Download
Disc Brakes Download

Hydraulic Brakes Download
Park Brake Download

Front Drive Axle Download
Propeller Shaft Download
Rear Drive Axle Download
Wheel Drive Shafts Download

Front Suspension Download
Rear Suspension Download
Tire Pressure Monitoring Download

Power Steering Download
Steering Linkage Download
Steering Wheel and Column Download

Bolted Exterior Body Panels and Closures Download
Bumpers and Fascias Download
Collision Repair Download
Exterior Trim Download
Fixed and Moveable Windows Download
Floor Coverings and Headlinings Download

Horns Download
Instrument Panel and Console Trim Download
Instrument Panel, Gages, and Console 2003-07 Download
Interior Trim 2003-07 Download
Interior Trim and Paneling Download
Lighting Download
Mirrors Download
Power Outlets Download
Power Seats Download
Seat Hardware, Trim, and Upholstery Download
Vehicle Access Download
Wipers and Washers Download

Immobilizer Download
Remote Functions Download
Seat Belts Download

Supplemental Inflatable Restraints Download

Cellular, Entertainment, and Navigation Download
Displays and Gages Download
Secondary and Configurable Customer Controls Download

Heating, Ventilation, and Air Conditioning Download
HVAC – Manual Download

Wiring Systems and Power Management Download
Antilock Brake System Download
Cruise Control Download
Defogger Download
Door Lock Download
Engine Cooling Download
Exterior Lights Download
Headlights Daytime Running Lights Download
Horns Download

Hydraulic Brake Download
Immobilizer Download
Instrument Cluster Download
Interior Lights Dimming Download
Interior Lights Download
Mirrors Download
Moveable Window Download
Power Outlets Download
Power Seat Driver Download
Power Seat Passenger Download
Release Systems Download
Remote Functions Download
Seat Belt Download
SIR Download
Starting and Charging Download
Wiper and Washers Download

General Information Download
Body Systems Download
Driver Information and Entertainment Download
Engine/Propulsion Download
HVAC Download
Power and Signal Distribution Download
Safety and Security Download
Transmission Download

Chevrolet Express is a commercial vehicle produced by the General Motors Corporation since 1996. It is produced in cargo and passenger versions, and it is the comfortable Van that is in demand on the market. This is explained by a high level of reliability, a solid reserve of power, high controllability, as for a minibus, and good cross-country ability (in all-wheel drive versions). Although you still won’t be able to go off-road on the Chevrolet Express. Primarily due to the low ground clearance, the ground clearance at the lowest point is about 18.8 cm.

As for the rear-wheel drive version, it consumes less gasoline, and the chassis runs longer in it. All because the chassis does not experience the increased load provided by the front axle, transfer case, etc. The disadvantages include the high fuel consumption of the Chevrolet Express – from 14 to 20 liters of gasoline per 100 km of travel.

Chevrolet Express engine
L35
The Vortec 4300 gasoline engine was used for the first generation Express. The gasoline V-shaped six-cylinder engine develops 197 horsepower. The torque of the power unit is 353 N·m.
The reliability of the internal combustion engine with the L35 index has been proven in practice. In order to extend the life of the fuel system of this unit, you should fill in high-quality AI-92 gasoline. As a preventive measure, we recommend adding FuelEXx Gasoline additive to the fuel tank. It will increase the octane index by 3–5 units, ensure complete fuel combustion, which will protect the injectors, combustion chamber, catalyst from soot. In addition, the combustion catalyst will save up to 10–15% of fuel.

The resource of the engine with proper maintenance reaches 400–500 thousand. km To increase the ego, use the RVS Master Engine Ga6 additive. It is optimally suitable for this Chevrolet Express engine, since the cylinder block is made of cast iron. And additive particles are able to build up a metal-ceramic layer on cast iron surfaces, which eliminates wear and increases compression. Thanks to the restoration of the nominal dimensions of the parts, the consumption of gasoline and oil is reduced.
In addition, Chevrolet Express owners with a Vortec 4300 engine are advised to clean the injector and fuel system annually, inspect and, if necessary, wash the radiator. After all, ego pollution is fraught with engine overheating.

L30
The 5.0-liter gasoline engine produces 220 horsepower, and its torque reaches 393 N·m. The V-shaped eight is quite reliable and works smoothly in domestic conditions. The main thing is to observe the service regulations. If you purchase a used Chevrolet Express with a 5-liter gasoline engine, we recommend preventively flushing the oil system with RVS Master Motor Flush MF5. It will remove soot from the cylinder walls, de-coke the rings, and make the rubber seals elastic.

L31
One of the popular Chevrolet eight-cylinder engines is the eight-cylinder Vortec 5700. Its power is 255 horsepower, and the torque reaches 447 N·m. Chevrolet Express consumption with a 5.7-liter engine is 16 liters per 100 km in the combined cycle. Among the features of the L31 are a cast-iron cylinder head, a special injection system – mono injection, and a plastic intake manifold gasket. The main causes of engine breakdowns include overheating and oil starvation. Sometimes the owners themselves, who do not properly maintain the car, use low-grade oil, are to blame. Despite this, the resource of the Vortec 5700 is still amazing – from 300 to 500 thousand. km