1999 Chevrolet Express 3500 Service and Repair Manual

This factory service and repair manual for the 1999 Chevrolet Express 3500 documents a full-size van in five shapes: three-door cargo and passenger versions in standard and extended lengths, and a two-door cutaway left bare for a box or a bus body. Three overhead-valve V8s power it, the turbocharged 6.5L diesel of 395 cubic inches, the 7.4L of 454 and the 5.7L of 350, and buyers chose between Base and LS. Engine, chassis and body work each get their own section rather than one combined chapter.

Engines covered

• 6.5L V8 (395 cu in) — OHV, turbocharged, diesel
• 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
• 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 3-door extended cargo van
• 3-door standard cargo van
• 3-door extended passenger van
• 3-door standard passenger van
• 2-door cutaway van

Trims covered

• Base
• LS

Known issues on the 1999 Express 3500. One recall reaches this year, and it concerns replacement oil filters sold for the engine that may not seal properly, letting oil escape and creating a fire risk. Four owner complaints are on record, spread singly across the wheels, the electrical system and the service brakes with no cluster to speak of. Lubrication procedures and oil pressure specifications, brake hydraulic overhaul and bleeding, wheel and hub torque values, and the charging and lighting diagrams all sit in the manual's respective sections.