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Chevrolet G3500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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1998

Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Chevrolet G3500 VAN car and truck repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Chevrolet G3500 VAN automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Chevrolet mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your Chevrolet G3500 VAN vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Chevrolet G3500 VAN cars and light trucks from 1990+

Manual Air Conditioning & Heater System Diagnosis & Testing -> Light Duty Trucks & Vans -> System Diagnosis & Testing -> 1998 Tracker -> 1999-2000 Sierra & Silverado -> 1999-2000 Tracker -> A/C System Performance Test -> Astro & Safari -> C & K Series Except 1999-2000 Sierra & Silverado -> Diagnostic Tests -> Functional Test -> G Series -> Montana, Silhouette & Venture -> P Series -> S & T Series
Vehicle: 1998 Chevrolet G3500 VAN 7.4 V8 GAS

On models equipped with a Powertrain Control Module (PCM) or Vehicle Control Module (VCM) controlled A/C system, connect a suitable Scan Tool to the Diagnostic Link Connector (DLC), normally located behind the lefthand side of the instrument panel, near the steering column.

Functional Test

Refer to Figs. through for A/C system functional test.

A/C System Performance Test

  • Test must be performed with vehicle in a shaded area.
  • Open windows to ventilate interior, then connect suitable A/C service gauge set.
  • Determine relative hu...

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CLICK HERE TO GET FULL ACCESS TO Chevrolet G3500 VAN A/C & HEATER SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Chevrolet G3500 VAN cars and light trucks from 1990+.

Disc Brakes -> Delco Single Piston Sliding Caliper -> Troubleshooting -> Brake Rattle -> Brake Roughness Or Chatter; Pedal Pumping -> Caliper Brake Fluid Leak -> Excessive Pedal Effort -> Excessive Pedal Travel -> Heavy Brake Drag -> No Braking Effect When Brake Pedal Is Depressed -> Pull, Uneven Or Grabbing Brakes -> Rear Brakes Locking On Application
Vehicle: 1998 Chevrolet G3500 VAN 6.5 V8 DIESEL

Excessive Pedal Travel

  • Worn brake linings.
  • Disc pads knock back after cornering or rough road travel.
  • Piston and linings not properly seated or positioned.
  • Insufficient fluid in system.
  • Loose wheel bearing adjustment.
  • Damaged or worn caliper piston seal.
  • Improper booster pushrod adjustment.
  • Pads out of flat more than .005 inch.
  • Rear brake automatic adjusters inoperative.
  • Improperly ground rear brake shoes.

Brake Roughness Or Chatter; Pedal Pumping

  • Excessive lateral runout of rotor.
  • Rotor excessively out of parallel.

Excessive Pedal Effort

  • Frozen or seized pistons.
  • Brake fluid, oil or grease on ...

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FUEL FILTER REPLACEMENT PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported Chevrolet G3500 VAN cars and light trucks sold in the U.S. for 1980+.

General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1988-06 C/K, G & R/V Series w/Diesel Engines -> Normal Service -> Severe Service
Vehicle: 1998 Chevrolet G3500 VAN 6.5 V8 DIESEL

Normal Service

Repl...

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported Chevrolet G3500 VAN cars and light trucks from 1990+.

DRIVESHAFT, Replace -> One Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 1998 Chevrolet G3500 VAN 6.5 V8 DIESEL

One Piece Driveshaft
  • Raise and support vehicle.
  • Mark rear universal joint to drive shaft flange.
  • Remove retaining bolts and clamps.
  • Remove propeller shaft from pinion drive flange.
  • Remove propeller shaft from transmission/transfer case.
  • Using tape or a rubber band, wrap the U-Joint bearing caps to ensure bearing caps do not separate from U-Joint.
  • Reverse procedure to install, noting the following:
    • Align reference marks made during removal.
    • Torque yoke retainer bolts to 18 ft. lbs.
Two Piece Driveshaft
  • Raise and support vehicle.
  • Suppor...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported Chevrolet G3500 VAN cars and light trucks from 1990+.

Alternator, Replace -> Auxiliary -> Single Alternator
Vehicle: 1998 Chevrolet G3500 VAN 5.7 V8 GAS

Single Alternator

  • Disconnect battery ground cable.
  • Remove coolant reservoir and air cleaner.
  • Remove upper fan shroud.
  • Remove drive belt, using suitable removal tool.
  • Remove heater hose pipe from alternator and oil fill tubes from support bracket.
  • Remove alternator mounting bolts, then alternator from vehicle.
  • Disconnect electrical connectors.
  • Reverse procedure to install, noting the following:
    • Torque front alternator mounting bolt to 37 f...

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MAINTENANCE LAMP RESET PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported Chevrolet G3500 VAN cars and light trucks sold in the U.S. from 1990+.

General Motors Corp./Saturn Trucks -> Air Cleaner Restriction Indicator ->
Vehicle: 1998 Chevrolet G3500 VAN 6.5 V8 DIESEL

An air cleaner restriction indicator, Fig. , is located in the intake duct between the MAF sensor and the air cleaner assembly.

If the window shows green, no service is required at this time. However, if...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported Chevrolet G3500 VAN cars and light trucks from 1990+

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1998 Chevrolet G3500 VAN 7.4 V8 GAS

Lower

  • Drain cooling system into a suitable container.
  • Reposition hose clamp from radiator.
  • Remove radiator outlet hose from radiator.
  • Reposition hose clamp from water pump.
  • Remove radiator outlet hose from water pump and from vehicle.
  • Reverse procedure to install.

Upper

  • Drain co...

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SERPENTINE BELT SERVICE PROCEDURES FOR Chevrolet G3500 VAN AUTOMOBILES

Serpentine belt replacement procedures with corresponding images for most domestic and imported Chevrolet G3500 VAN cars and light trucks sold in the U.S. from 1990+.

Serpentine Drive Belt, Replace
Vehicle: 1998 Chevrolet G3500 VAN 5.7 V8 GAS

These engines use a single serpentine drive belt to drive all engine-mount accessories. All belt drive accessories are rigidly mounted with belt tension maintained by a spring loaded automatic tensioner.

  • Rotate tensioner counterclockwise using suitable 1/2 inch break...

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COMPONENT LOCATION DIAGRAMS FOR Chevrolet G3500 VAN AUTOMOBILES

Component location diagrams for most Chevrolet G3500 VAN cars and light trucks sold in the U.S. from 1990+.

RH Side Of Engine Diagram for 1998 Chevrolet G3500 VAN  6.5 V8 DIESELRH Side Of Engine Diagram for 1998 Chevrolet G3500 VAN 6.5 V8 DIESEL

Components on diagram:
  • Starter Solenoid
  • Generator
  • Engine Coolant Temperature Sensor
  • Crankshaft Position Sensor
  • Intake Air Temperature Sensor
  • Top Of Brake Pedal Support Diagram for 1998 Chevrolet G3500 VAN  6.5 V8 DIESELTop Of Brake Pedal Support Diagram for 1998 Chevrolet G3500 VAN 6.5 V8 DIESEL

    Components on diagram:
  • Convenience Center
  • Connector C-210
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet G3500 VAN PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR Chevrolet G3500 VAN AUTOMOBILES

    OEM drawn wiring diagrams for most Chevrolet G3500 VAN cars and light trucks sold in the U.S.

    1998 Chevrolet G3500 VAN  5.7 V8 GAS Wiring Diagram1998 Chevrolet G3500 VAN 5.7 V8 GAS Wiring Diagram

    Components on diagram:
  • Radio
  • Radio Speaker, RF Door
  • Radio Speaker, Tweeter RF Door
  • Radio Speaker, Tweeter, LF Door
  • Radio Speaker, LF Door
  • 1998 Chevrolet G3500 VAN  5.7 V8 GAS Wiring Diagram1998 Chevrolet G3500 VAN 5.7 V8 GAS Wiring Diagram

    Components on diagram:
  • Door Jamb Switch RF
  • Door Jamb Switch LF
  • Power Door Lock Switch LF
  • Power Side Window Switch LF
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet G3500 VAN WIRING DIAGRAMS!

    TECHNICAL SERVICE BULLETINS FOR Chevrolet G3500 VAN AUTOMOBILES

    OEM TSB listings for most Chevrolet G3500 VAN cars and light trucks sold in the U.S. from 1985+.

    Document: KEYCODE SECURITY RULES AND INFORMATION ON GM KEYCODE LOOK-UP APPLICATION - REVISED
    Vehicle: 1998 Chevrolet G3500 VAN 7.4 V8 GAS

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Glass, Doors, Hood, Decklid, Tailgate, Liftgate, Locks
  • Document: INFORMATION ON TIRE RADIAL FORCE VARIATION (RFV) - REVISED
    Vehicle: 1998 Chevrolet G3500 VAN 5.7 V8 GAS

    Auto Systems:
  • Wheels, Tires, Wheel Bearings, Seals, Hubs
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet G3500 VAN TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR Chevrolet G3500 VAN AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Chevrolet G3500 VAN cars and light trucks sold in the U.S. and Canada from 1970+.

    • Brake caliper mounting bolt torque
    • Brake drum runout, machining, & discard specs
    • Minimum brake lining thickness.
    • Brake rotor runout, parallelism, machining, discard, & finish specs

    A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Chevrolet G3500 VAN cars and light trucks sold in the U.S. and Canada from 1980+.

    • Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap

    COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.

    PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules

    QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Chevrolet G3500 VAN cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.

    • Automatic transmission/transaxles capacities, lubricant recommendations
    • Differential/final drive capacities, lube recommendations, grades, & viscosities
    • Final drive fill & drain plug torques
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
    • Number of lubrication fittings & plugs
    • Power steering, brake, & clutch fluid recommendations
    • Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
    • Severe service maintenance & interval recommendations
    • Tire sizes, wheel nut/bolt torque, pressures & rim sizes
    • Transfer case capacities, lube recommendations, grades, & viscosities

    TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Chevrolet G3500 VAN cars and light trucks sold in the U.S. and Canada from 1980+

    • Airflow sensor electrical specifications
    • Tensioning specifications for systems with automatic tensioners
    • Barometric pressure sensor specs
    • Battery group number and cranking performance
    • Crankshaft & camshaft position sensor resistance
    • Engine compression pressures
    • Coolant temperature sensor specs
    • Computer advance.
    • Diesel fuel temperature sensor resistance.
    • Distributor advance specifications
    • Ignition pickup coil resistance
    • Exhaust gas recirculation temperature sensor resistance
    • Engine fastener torque values
    • Firing order diagrams
    • Fuel system pressures
    • Generator (alternator) specs
    • Intake air temperature sensor specs
    • Ignition coil specifications
    • Fuel injector resistance
    • Engine idle speeds
    • Knock sensor resistance
    • Manifold absolute pressure sensor specs
    • Mixture control solenoid resistance
    • Voltage regulator specs
    • Spark plug applications & gaps
    • Starter motor electrical specs.
    • Tensioning specifications for systems without automatic tensioners
    • Throttle body temperature sensor resistance
    • Ignition timing in degrees at rpm
    • Transmission oil temperature sensor resistance
    • Throttle position sensor specs
    • Vacuum sensor valve specs

    CLICK HERE TO GET FULL ACCESS TO Chevrolet G3500 VAN SPECIFICATIONS DATA!

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