2002 Chevrolet Express 1500 Service and Repair Manual

This factory service and repair manual for the 2002 Chevrolet Express 1500 covers three gasoline V-engines of 262, 305 and 350 cubic inches, the 4.3L V6 and the 5.0L and 5.7L V8s, every one of them overhead-valve and naturally aspirated. The bodies are the three-door cargo and passenger vans, and equipment runs Base, LS and LT. Procedures are organized system by system, from engine mechanical through fuel and emissions, driveline, brakes, steering and heating to the body, each with its own specifications and torque values.

Engines covered

• 5.0L V8 (305 cu in) — OHV, naturally aspirated, gasoline
• 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline
• 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 3-door standard cargo van
• 3-door standard passenger van

Trims covered

• Base
• LS
• LT

Known issues on the 2002 Express 1500. Owners have logged 82 complaints against this model year, the heaviest concentrations landing on the service brakes with twelve, engine and engine cooling with eleven, and the electrical system with ten. Those three systems share symptoms more often than owners expect, since a hard pedal, a hot engine and a dead circuit can all trace back to one neglected component. The manual carries hydraulic brake overhaul and bleeding procedures, cooling system pressures and thermostat specifications, and wiring diagrams detailed enough to run an intermittent circuit down to its ground.