2003-2010 Chevrolet Express 4.3L, 4.8L, 5.3L, 6.0L, 6.6L duratec engine repair manual

Table of Contents

1. General Information

• 1.1 Introduction
• 1.2 Vehicle Identification
• 1.3 Safety Precautions
• 1.4 Maintenance Schedule
• 1.5 Specifications

2. Engine Mechanical

• 2.1 Engine Description
• 2.2 Engine Identification
• 2.3 Fastener Tightening Specifications
• 2.4 Special Tools

3. Engine Disassembly and Assembly

• 3.1 Disassembly Procedures
• 3.2 Cleaning and Inspection
• 3.3 Assembly Procedures

4. Cylinder Head and Valves

• 4.1 Cylinder Head Removal and Installation
• 4.2 Valve Removal and Installation
• 4.3 Valve Adjustment
• 4.4 Cylinder Head Gasket Replacement

5. Pistons, Connecting Rods, and Crankshaft

• 5.1 Piston Removal and Installation
• 5.2 Connecting Rod Removal and Installation
• 5.3 Crankshaft Removal and Installation
• 5.4 Inspection and Repair

6. Timing System

• 6.1 Timing Gear Removal and Installation
• 6.2 Timing Chain/Belt Inspection and Replacement
• 6.3 Timing Adjustment

7. Lubrication System

• 7.1 Oil Pump Removal and Installation
• 7.2 Oil Filter Replacement
• 7.3 Oil Cooler
• 7.4 Lubrication Circuit Diagram

8. Cooling System

• 8.1 Radiator Removal and Installation
• 8.2 Water Pump Removal and Installation
• 8.3 Thermostat Replacement
• 8.4 Cooling Fan Inspection
• 8.5 Coolant Replacement

9. Fuel System

• 9.1 Fuel Injection Pump Removal and Installation
• 9.2 Fuel Injector Removal and Installation
• 9.3 Fuel Filter Replacement
• 9.4 Fuel Tank and Lines

10. Air Intake and Exhaust System

• 10.1 Air Filter Replacement
• 10.2 Turbocharger Removal and Installation (if applicable)
• 10.3 Exhaust Manifold Removal and Installation
• 10.4 Muffler and Pipes

11. Electrical System

• 11.1 Battery Maintenance
• 11.2 Alternator Removal and Installation
• 11.3 Starter Motor Removal and Installation
• 11.4 Wiring Diagram
• 11.5 Sensors and Actuators

12. Emissions Control

• 12.1 EGR System
• 12.2 PCV System
• 12.3 Catalytic Converter
• 12.4 Emission Control Testing

13. Troubleshooting

• 13.1 Engine Performance Issues
• 13.2 Overheating Problems
• 13.3 Lubrication Problems
• 13.4 Fuel System Issues
• 13.5 Electrical System Issues

14. Maintenance and Service

• 14.1 Periodic Maintenance Tasks
• 14.2 Lubrication Points
• 14.3 Service Intervals

15. Technical Specifications

• 15.1 General Specifications
• 15.2 Torque Specifications
• 15.3 Fluid Capacities

16. Appendices

• 16.1 Maintenance Records
• 16.2 Parts List
• 16.3 Index

Contact Information

• Manufacturer Contact Information
• Service Centers

The price of this manual, handbooks and repair guides are not set by the [RL] marketplace, but by the seller of the manuals himself, so it is possible that the same manual is offered at a different price on another page here. Please compare prices before deciding to purchase.

• For many of our manuals, there are comments and ratings from other users at the end of the detail page to make your purchase decision easier. Please leave a review after your purchase to help other users make their purchasing decision.
• Don't hesitate and download the repair manual you need now. You get a lifetime guarantee for the download, as described in our FAQs here.
• To contact the seller of the manual, please use our contact form here and we will forward your request or take care of it directly.