Chevrolet Express, GMC Savana Full-Size Van Repair Manual 1996-2019

The Haynes Chevy Express, GMC Savana Full-Size Van Repair Manual 1996-2019 covers models indicated. This manual provides detailed step-by-step service and repair instructions for the following specific makes and models:

• 1996-2019 Chevrolet Express 1500
• 1996-2019 Chevrolet Express 2500
• 1996-2019 Chevrolet Express 3500
• 1996-2019 GMC Savana 1500
• 1996-2019 GMC Savana 2500
• 1996-2019 GMC Savana 3500

NOTE: The manual DOES NOT include information specific to all-wheel drive, diesel or 8.1L engine models.
Book Excerpt: 1996-2019 Chevy Express, GMC Savana Full-Size Van Repair Manual COOLING, HEATING AND AIR CONDITIONING SYSTEMS

WATER PUMP | REPLACEMENT
(Refer to illustrations 7.10, 7.11 and 7.12)

1. Drain the coolant (see Chapter 1).
2. Remove the air cleaner assembly and intake duct (see Chpt. 4).
3. Remove the upper radiator shroud and fan/clutch assembly (see Section 4).
4. Remove the drive belt (see Chapter 1).
5. On 4.3L, 5.0L, 5.7L and 7.4L engines, remove the water pump pulley, detach the lower radiator hose, the heater hose and the coolant by-pass hose from the water pump (see illustration). To detach the pulley you will need to hold the pulley with a strap wrench or equivalent to remove the bolts.
6. On 4.8L, 5.3L and 6.0L engines, remove the lower radiator hose and the thermostat housing (see Section 3). Also remove the upper radiator hose and the heater hoses from the water pump housing (see illustration).
7. Unbolt the water pump (see illustration). It may be necessary to tap the pump with a soft-face hammer to break the gasket seal. Inspect the pump?s impeller blades on the backside for corrosion. If any fins are missing or badly corroded, replace the pump with a new one.
8. Clean the sealing surfaces of all gasket material on both the water pump and block.
9. Apply a thin layer of RTV sealant to both sides of the new gasket and install the gasket on the water pump.
10. Place the water pump in position and install the bolts finger tight. Use caution to ensure that the gasket doesn?t slip out of position. Tighten the bolts to the torque listed in this Chapter?s Specifications. Note: on 4.3L, 5.0L, 5.7L and 7.4L engines, use RTV sealant on the water pump bolt threads.
11. The remainder of the installation procedure is the reverse of removal.
12. Add coolant to the specified level (see Chapter 1), start the engine and check for the proper coolant level. Be sure to bleed the cooling system of air as described in Chapter 1. Also check for leaks around the water pump and hoses.

BRAKES

MASTER CYLINDER | INSTALLATION

7. Bench bleed the new master cylinder before installing it. Mount the master cylinder in a vise, with the jaws of the vise clamping on the mounting flange.
8. Attach a pair of master cylinder bleeder tubes to the outlet ports of the master cylinder.
9. Fill the reservoir with brake fluid of the recommended type (see Chapter 1).
10. Slowly push the pistons into the master cylinder (a large Phillips screwdriver can be used for this) ? air will be expelled from the pressure chambers and into the reservoir. Because the tubes are submerged in fluid, air can?t be drawn back into the master cylinder when you release the pistons.
11. Repeat the procedure until no more air bubbles are present.
12. Remove the bleed tubes, one at a time, and install plugs in the open ports to prevent fuel leakage and air from entering. Install the reservoir cap.
13. Install the master cylinder over the studs on the power brake booster and tighten the attaching nuts only finger tight at this time. Be sure to install a new O-ring into the sleeve of the master cylinder.
14. Thread the brake line fittings into the master cylinder. Since the master cylinder is still a bit loose, it can be moved slightly in order for the fittings to thread in easily. Do not strip the threads as the fittings are tightened.
15. Fully tighten the mounting nuts, then the brake line fittings. Tighten the nuts to the torque listed in this Chapter?s Specifications.

Subject: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018, 2019 Chevy Express, GMC Savana Full-Size Van service, maintenance, repair. ISBN-10: 1620923777 | ISBN-13: 9781620923771 | UPC: 038345240812 | Haynes 24081