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2002 Chevrolet Express 2500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake 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 Express 2500 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 Express 2500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 Chevrolet Express 2500 AUTOMOBILES
Electric Cooling Fans -> Light Duty Trucks & Vans -> Precautions -> Air Bag System Disarming & Arming -> Battery Ground Cable
Vehicle: 2002 Chevrolet Express 2500 5.7 V8 GAS
Air Bag System Disarming & Arming
Refer to and for air bag system disarming and arming proced...
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BRAKE SERVICE PROCEDURES FOR 2002 Chevrolet Express 2500 AUTOMOBILES
Drum Brakes -> Inspection -> Adjuster Mechanism -> Backing Plate -> Brake Drums -> Brake Linings & Springs -> General System -> Parking Brake Cable
Vehicle: 2002 Chevrolet Express 2500 6.5 V8 DIESEL
General System
- Inspect components for damage or unusual wear. Replace as required.
- Inspect backing plate mounting bolts and ensure they are tight.
- Inspect wheel cylinders. Excessive fluid indicates cup leakage and need for wheel cylinder replacement. Slight amount of fluid is always present and is considered normal, acting as lubricant for cylinder pistons.
- Inspect adjuster screw operation. If satisfactory, lightly lubricate adjusting screw and washer with suitable brake lube. If operation is unsatisfactory, replace.
- Clean rust and dirt from shoe contact surfaces on backing plate using fi...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 2500 AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1996-03 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 2002 Chevrolet Express 2500 5.0 V8 GAS
Light Duty Emissions
Normal Service
Replace every 30,000 miles
Severe Service
Rep...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 2500 AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 2002 Chevrolet Express 2500 5.7 V8 GAS
Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.
Disassemble
- Support propeller shaft in a line horizontal with table of a press.
- Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
- On models equipped with external snap ring retainers, proceed as follows:
- Disassemble snap rings by ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 2500 AUTOMOBILES
Starter, Replace
Vehicle: 2002 Chevrolet Express 2500 4.3 V6 GAS
- 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 Express 2500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> Reduce Engine Power Indicator Lamp ->
Vehicle: 2002 Chevrolet Express 2500 5.7 V8 GAS
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 Express 2500 AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 2002 Chevrolet Express 2500 5.0 V8 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at bypass pipe.
- Remove hose from bypass pipe.
- 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.
- Disconnect heater outlet hose from hea...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Chevrolet Express 2500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Chevrolet Express 2500 4.3 V6 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 2002 Chevrolet Express 2500 AUTOMOBILES
Component location diagrams for most 2002 Chevrolet Express 2500 cars and light trucks sold in the U.S. from 1990+.
 Bulkhead Connector Components Diagram for 2002 Chevrolet Express 2500 6.5 V8 DIESELComponents on diagram: |
 Defroster Actuator Diagram for 2002 Chevrolet Express 2500 5.0 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Chevrolet Express 2500 AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Chevrolet Express 2500 cars and light trucks sold in the U.S.
 2002 Chevrolet Express 2500 5.0 V8 GAS Wiring DiagramComponents on diagram: |
 2002 Chevrolet Express 2500 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Chevrolet Express 2500 AUTOMOBILES
OEM TSB listings for most 2002 Chevrolet Express 2500 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 Express 2500 5.7 V8 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2002 Chevrolet Express 2500 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Chevrolet Express 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Chevrolet Express 2500 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 Express 2500 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 Express 2500 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 Express 2500 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
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