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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
General Service Domestic Vehicles -> 2001-02 -> Precautions -> A/C Refrigerant Oil -> Battery Ground Cable -> Cleanliness -> Engine Coolant -> Exercise System -> General Service -> Product Compatibility -> R-134a -> Safety
Vehicle: 2002 Chevrolet Express 3500 5.7 V8 BI-FUEL
Battery Ground Cable
Prior to service disconnect battery ground cable and isolate as required.
Product Compatibility
A/C Refrigerant Oil
Before replenishing refrigerant oil, ensure product compatibility with the system being serviced. Refer to "A/C Data" for specifications.
Engine Coolant
Before adding or replacing engine coolant, ensure product compatibility with the system being serviced. If using orange silicate-free coolant, do not mix with green silicated coolant. If mixed, premature engine, heater core or radiator corrosion may result.
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BRAKE SERVICE PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Power Brake Units -> Delco Brake Booster -> Power Brake Unit Replacement -> Aztek & Rendezvous -> C & K Series -> Express & Savana -> Montana, Silhouette, Trans Sport & Venture -> S & T Series -> Vue
Vehicle: 2002 Chevrolet Express 3500 5.7 V8 BI-FUEL
Aztek & Rendezvous
- Remove coolant reservoir, then relieve fuel system pressure as outlined under. "Precautions."
- Remove cruise control cable from module, then disconnect electrical connector from cruise control module.
- Remove cruise control module from bracket, then the front end sheet metal diagonal brace.
- Remove PCM cover from air cleaner housing, then the PCM and set aside.
- Remove air cleaner intake duct, then bolts from air cleaner assembly and housing.
- Remove fuel lines from pipes and vapor line, then disconnect fluid level sensor switch from brake master cylinder.
- Disc...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Chevrolet Express 3500 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 3500 8.1 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 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
Vehicle: 2002 Chevrolet Express 3500 8.1 V8 GAS
- Disconnect battery ground cable.
- Remove coolant reservoir and air cleaner.
- Remove upper fan shroud.
- Remove drive belt.
- Remove heater hose pipe from alternator and oil fill tubes from support bracket.
- Remove alternator ...
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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 6.5 V8 DIESEL
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
Radiator, Replace
Vehicle: 2002 Chevrolet Express 3500 8.1 V8 GAS
- Drain coolant into a suitable container.
- Remove air cleaner, duct and coolant recovery reservoir.
- Remove mounting bolts, upper to lower mounting bolts and upper fan shroud.
- Remove ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Chevrolet Express 3500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Chevrolet Express 3500 8.1 V8 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.
- Ro...
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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+.
 Underhood Fuse-Relay Center Diagram for 2002 Chevrolet Express 3500 6.5 V8 DIESELComponents on diagram: |
 Trailer Wiring Provisions - Park, Turn, Stop Backup Diagram for 2002 Chevrolet Express 3500 5.7 V8 GASComponents 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 8.1 V8 GAS Wiring DiagramComponents on diagram: |
 2002 Chevrolet Express 3500 5.7 V8 GAS 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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