The Chevrolet Express (1996-2002) is a full-size van popular for its durability and versatility, often used for cargo, passenger transport, and commercial purposes. The vehicle’s electrical system is critical for its functionality, with the fuse box and relays playing key roles in managing various circuits and protecting essential components.
The fuse box in the Chevrolet Express is typically located in the engine compartment on the driver’s side and inside the cabin, under the dashboard. The engine compartment fuse box safeguards high-power components like the engine control module, headlights, and cooling fans. The interior fuse box handles circuits for lower-power systems, including the radio, power windows, and interior lighting. Each fuse ensures protection by breaking the circuit if there’s an overload or short, preventing damage to the system.
Relays in the Express control high-current circuits such as the starter motor, fuel pump, and air conditioning system. These relays allow the low-current systems to operate high-power components efficiently. Routine checks and maintenance of both the fuses and relays are essential for preventing electrical issues and ensuring the van runs smoothly, whether for personal or commercial use.
MUST READ: DYI – How to Check Car Fuses?
(1996-2002) Chevrolet Express fuse box and relay with Diagram
WARNING
- Never replace a fuse with one that has a higher amperage rating.
- A fuse with a too-high amperage could damage the electrical part and cause a fire.
- On no account should fuses be repaired (e.g. patched up with tin foil or wire) as this may cause serious damage elsewhere in the electrical circuit or cause a fire.
- If a fuse blows repeatedly, do not keep replacing it. Instead, have the cause for the repeated short circuit or overload tracked and fixed.
- Terminal and harness assignments for individual connectors will vary depending on vehicle equipment level, model, and market.
Chevrolet Express (1996-2002) fuse assignment
- Cigar lighter / power outlet fuses in the Chevrolet Express are the fuses №7 “PWR AUX” (Auxiliary Power Outlet) and №13 “CIG LTR” (Cigarette Lighter) in the Instrument panel fuse box.
Year of production: from 1996, 1997, 1998, 1999, 2001, 2002
Instrument Panel Fuse Box
Fuse Box Location
The fuse block access door is on the driver’s side of the instrument panel above the hood release lever.
Fuse box diagram
Assignment of the fuses in the Instrument Panel
| № | Fuse name | Circuit protected |
|---|---|---|
| 1 | STOP | Center High Mounted Stop Lamp, Stoplamps |
| 2 | HTD MIR | Electric Heated Mirrors |
| 3 | CTSY | Courtesy Lamps, Dome/RDG Lamps, Vanity Mirrors, Power Mirrors |
| 4 | GAUGES | IP Cluster, DRL Relay, DRL Module, HDLP Switch, Keyless Entry Illumination, Low Coolant Module, CHIME Module, DRAB Module |
| 5 | Hazard | Hazard Lamps/CHIME Module |
| 6 | CRUISE | Cruise Control |
| 7 | PWR AUX | Auxiliary Power Outlet, DLC |
| 8 | Crank | — |
| 9 | PARK LPS | License Plate Lamp, Parking Lamps, Taillamps, Front Sidemarkers, Glove Box Ashtray |
| 10 | AIR BAGS | Air Bags |
| 11 | WIPER | Wiper Motor, Washer Pump |
| 12 | HTR-A/C | A/C, A/C Blower, High Blower Relay, HTD Mirror |
| 13 | CIG LTR | Cigarette Lighter |
| 14 | ILLUM | Instrument Panel Cluster, HVAC Controls, RR HVAC Controls, Instrument Panel Switches, Radio Illumination, Door Switch Illumination |
| 15 | DRL | Daytime Running Lamp Relay |
| 16 | TURN B/U | Front Turn, RR Turn, Back-up Lamps, BTSI Solenoid |
| 17 | RADIO- 1 | Radio (Ign, Accy), Upfitter Provision Relay |
| 18 | BRAKE | 4WAL PCM, ABS, Cruise Control |
| 19 | RADIO-B | Radio (Battery), Power Antenna |
| 20 | TRANS | PRNDL, Automatic Transmission |
| 21 | STRG/SECURITY / SECURITY | EVO Steering, Passlock |
| 22 | RR DEFOG | Rear Window Defog |
| 23 | Not Used | — |
| 24 | RR HVAC | RR HVAC Controls, HIGH, MED, LOW Relays |
| A | PWR ACCY | Power Door Lock, Six-Way Power Seat, Keyless Entry Illumination Module |
| B | PWR WDO | Power Windows |
Engine Compartment Fuse Box
It is located on the driver’s side of the engine compartment at the rear.
Fuse box diagram
Assignment of the fuses and relay in the Engine Compartment
| Name | Circuit protected |
|---|---|
| SPARE | Spare Fuse |
| A.I.R. | Air Pump |
| BLOWER | Front Blower Motor |
| ABS | Electronic Brake Control Module |
| IGN-B | Ignition Switch |
| IGN-A | Starter Relay, Ignition Switch |
| BATT | Instrument Panel Fuse Block |
| LIGHTING | Instrument Panel Fuse Block, Headlamp Switch |
| RH-HDLP | Right-hand Headlamp (Export Only) |
| LH-HDLP | Left-hand Headlamp (Export only) |
| RH-HIBM | Right-hand High-beam Headlamp (Export Only) |
| LH-HIBM | Left-hand High-beam Headlamp (Export only) |
| ETC | Electronic Throttle Control |
| RR BLOWER | Rear Auxiliary Blower |
| FUEL SOL | Fuel Solenoid |
| ENG-I | Heated O2 Sensors, Mass Air Flow Sensor, Evap Canister Purge Valve, Crankshaft Position Sensor, Secondary Air Injection Relay (Diesel), Water in Fuel Sensor (Diesel), Fuel Heater (Diesel), Glowplug Relay (Diesel), Wastegate Solenoid (Diesel) |
| ECM-I | Ignition Coil, Crankshaft Position Sensor, VCM, Fuel Injectors, Coil Driver |
| IGN-E | Air Conditioning Clutch Relay |
| SPARE | Spare Fuse |
| SPARE | Spare Fuse |
| SPARE | Spare Fuse |
| A/C | Air Conditioning Clutch Relay |
| HORN | Horn Relay, Underhood Lamp(s) |
| ECM-B | Fuel Pump Relay, VCM, PCM, Fuel Pump and Engine Oil Pressure Switch |
| SPARE | Spare Fuse |
| SPARE | Spare Fuse |
| AUX A | Upfitter Provisions |
| AUX B | Upfitter Provisions |
| A/C RELAY | Air Conditioning |
| HORN RELAY | Horn |
| A.I.R. RELAY | Air |
| FUEL PUMP RELAY | Fuel Pump |
| STARTER | Starter |
| RELAY | |
| ABS EXPORT | ABS Export |
| RELAY |
Conclusion
For owners and enthusiasts of classic Chevrolet Express (1996-2002), understanding the fuse box and relay systems is essential for vehicle maintenance. Regular inspection and maintenance of these components helped ensure the vehicle’s longevity and reliability, preserving its status as a symbol of Chevrolet’s craftsmanship and innovation in the automotive industry during that era.
