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2002 Chevrolet C3500 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 Chevrolet C3500 Pickup 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 C3500 Pickup automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
Electrical Symbol & Wire Color Code Identification -> Electrical Symbol Identification -> Domestic Vehicles
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 8.1 V8 GAS
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Except Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Tracker & Uplander -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
Engines Less Fuel Pressure ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
DRIVESHAFT, Replace -> Three Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL
Two Piece Driveshaft
- Raise vehicle on a hoist.
- Reference mark propeller shaft to pinion flange connection.
- Reference mark slip yoke to transmission for proper reassembly.
- When servicing propeller shafts with pop on seal, do not remove seal from sleeve. Removal of seal causes damage to seal lip where it contacts sleeve yoke. If removal of seal is necessary, replace seal with a new part.
- Remove retainer bolts.
- Remove retainers.
- Remove yoke and cross assembly, wrapping bearing cups with tape in order to prevent loss of bearing rollers. When removing propeller shaft, do not attempt to ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
Starter, Replace
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL
- Raise and support vehicle.
- Remove starter to engine brace and heat shields.
- Disconnect wires from solenoids.
- Remove starter motor mounting bolts, washers and lower starter. Record position of shims, if required.
- Remove starter motor from vehicle.
- Reverse procedure to install, noting the fol...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
General Motors Corp./Saturn Trucks -> Reduce Engine Power Indicator Lamp ->
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL
The Reduce Engine Power indicator lamp should light for a approximately 3 seconds when the ignition is turned On as a bulb check. If the warning lamp turns On during vehicle operation, a vehicl...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 8.1 V8 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at engine block.
- Remove bolts and from inlet pipe brackets.
- Remove nut from inlet pipe bracket.
- Remove pipe from engine block.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Drain cooling system into a suitable container.
- Reposition heater hose outlet clamp at heater core.
- Discon...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL
- Rotate tensioner to release belt tension, using a 1/2 inch breaker bar with a 5/8 inch socket placed on tensioner pulley.
- Remove drive belt.
- Route b...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
Component location diagrams for most 2002 Chevrolet C3500 Pickup cars and light trucks sold in the U.S. from 1990+.
 Transfer Case Controls Diagram for 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESELComponents on diagram: |
 Clutch Pedal Position Switch Diagram for 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Chevrolet C3500 Pickup cars and light trucks sold in the U.S.
 2002 Chevrolet C3500 Pickup HD Chassis CAB 8.1 V8 GAS Wiring DiagramComponents on diagram: |
 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
OEM TSB listings for most 2002 Chevrolet C3500 Pickup cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2002 Chevrolet C3500 Pickup HD Chassis CAB 6.5 V8 DIESEL Auto Systems: |
CLICK HERE TO GET FULL ACCESS TO 2002 Chevrolet C3500 Pickup TECHNICAL SERVICE BULLETINS!
COMPONENT/PARTS SPECIFICATIONS FOR 2002 Chevrolet C3500 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Chevrolet C3500 Pickup 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 2002 Chevrolet C3500 Pickup 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 2002 Chevrolet C3500 Pickup 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 2002 Chevrolet C3500 Pickup 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 2002 Chevrolet C3500 Pickup SPECIFICATIONS DATA!
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