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2002 Chevrolet Express 3500 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 3500 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 3500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Thermostat, Replace -> 1.6L Engine -> 2.0L Engine -> 2.2L Engine -> 2.5L Engine -> 3.0L Engine -> 4.8L, 5.3L & 6.0L Engines -> 8.1L Engine -> Astro & Safari -> Aztek -> Bravada, S & T Series -> C & K Series -> G Series -> Montana, Silhouette & Venture -> Rendezvous -> Tracker -> Vue
Vehicle: 2002 Chevrolet Express 3500 8.1 V8 GAS
Astro & Safari
- Drain coolant into suitable container, to a level below thermostat.
- Remove air cleaner assembly.
- Disconnect ground lead from coolant outlet.
- Remove bolt/stud and bolt on coolant outlet.
- Remove coolant outlet.
- Remove thermostat.
- Reverse procedure to install.
Aztek
- Remove air cleaner and duct assembly.
- Drain cooling system into suitable container until level is below thermostat.
- Remove crossover exhaust pipe.
- Remove radiator hose from thermostat housing.
- Remove thermostat housing an...
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BRAKE SERVICE PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Power Brake Units -> Bendix Brake Booster -> Description
Vehicle: 2002 Chevrolet Express 3500 6.5 V8 DIESEL
In order to properly service power brake systems, a thorough understanding of the power assist system is required. These systems provide a mechanical assist, acting to increase the force applied to the master cylinder piston by the driver while decreasing the effort required to obtain acceptable stopping performance.
Hydraulic assist units incorporate a basic open center spool valve, hydraulic cylinder and an accumulator assembly in a common housing. When the brake pedal is depressed, the hydraulic piston moves forward closing off fluid relief passages, the spool valve applies fluid ...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 3500 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 Express 3500 5.7 V8 BI-FUEL
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 Express 3500 AUTOMOBILES
DRIVESHAFT, Replace -> Front -> One Piece Driveshaft -> Rear -> Two Piece Driveshaft
Vehicle: 2002 Chevrolet Express 3500 5.7 V8 GAS
Front
- Raise and support vehicle.
- Mark the front U-joint to the pinion yoke on the front differential.
- Mark the relationship of the rear U-joint to the transfer case drive flange.
- Remove the retaining nuts and bolts from the drive flange.
- Remove the clamps and retaining bolts from the front drive axle pinion flange.
- Remove the front propeller shaft from the vehicle.
- Using tape and or a rubber band, wrap the front U-joint bearing caps to ensure the caps do not separate from the U-joint.
- Reverse procedure to install, noting the following:
- Torque front propeller shaft retainer bolts 18 f...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Alternator, Replace -> Auxiliary -> Primary
Vehicle: 2002 Chevrolet Express 3500 6.5 V8 DIESEL
Primary
- Disconnect battery ground cable.
- Remove surge tank and air cleaner.
- Remove upper fan shroud and accessory drive belt.
- Remove alternator mounting bolts, then alternator from vehicle.
- Disconnect electrical connectors.
- Reverse procedure to install, noting the following:
- Torque front alternator mounting bolt to 37 ft. lbs.
- Torque rear alternator mounting bolt to 18 ft. ...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> All Wheel Drive (AWD) System Warning Lamp ->
Vehicle: 2002 Chevrolet Express 3500 5.7 V8 BI-FUEL
This lamp should light for a approximately 6-8 seconds when the ignition is turned On as a bulb check. If the war...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 2002 Chevrolet Express 3500 8.1 V8 GAS
Inlet
- Drain cooling system into a suitable container.
- Remove upper fan shroud.
- Remove accumulator.
- Reposition heater core inlet hose clamp at coolant bypass valve.
- Remove hose from coolant bypass valve.
- 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.
- Remove upper fan shroud.
- Remove accumulator.
- Reposition heater hose ou...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Chevrolet Express 3500 6.5 V8 DIESEL
- Rotate tensioner arm counterclockwise using 3/8 inch breaker bar.
- Remove belt from pulleys.
- Route new belt over all pulleys except tensioner arm.
- Rotate tensioner arm co...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Component location diagrams for most 2002 Chevrolet Express 3500 cars and light trucks sold in the U.S. from 1990+.
 In-Line Fuse, LH Body Harness, Trailer Wiring Diagram for 2002 Chevrolet Express 3500 8.1 V8 GASComponents on diagram: |
 Rear Door Jamb Switch Diagram for 2002 Chevrolet Express 3500 6.5 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Chevrolet Express 3500 AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Chevrolet Express 3500 cars and light trucks sold in the U.S.
 2002 Chevrolet Express 3500 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
 2002 Chevrolet Express 3500 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Chevrolet Express 3500 AUTOMOBILES
OEM TSB listings for most 2002 Chevrolet Express 3500 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 3500 5.7 V8 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2002 Chevrolet Express 3500 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Chevrolet Express 3500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Chevrolet Express 3500 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 3500 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 3500 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 3500 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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