2002 Chevrolet Express 3500 Service and Repair Manual

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Factory-Grade Data

2002 Chevrolet Express 3500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Extended Cargo Van 3-Door
  • Base Standard Cargo Van 3-Door
  • Base Extended Passenger Van 3-Door
  • LS Extended Passenger Van 3-Door
  • LS Standard Passenger Van 3-Door
  • Base Standard Passenger Van 3-Door
  • Base Cutaway Van 2-Door

Engines covered

  • 6.5L 395Cu. In. V8 DIESEL OHV Turbocharged
  • 8.1L 496Cu. In. V8 GAS OHV Naturally Aspirated
  • 5.7L 350Cu. In. V8 GAS OHV Naturally Aspirated
  • 5.7L 350Cu. In. V8 BI-FUEL OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Payment methods

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  • Bancontact
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  • Visa

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Vehicle Safety Data

2002 Chevrolet Express 3500 Recalls & Complaints

NHTSA #07E08800024/10/2007Component: EQUIPMENT

CERTAIN HONEYWELL FRAM RACING BRAND HP4 AND HP8 OIL FILTERS THAT WERE MANUFACTURED FROM MAY 25, 2006, THROUGH SEPTEMBER 14, 2007, AND SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR VEHI

Consequence

THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN

Remedy

HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING N

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11012907

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11010544

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

TSB #11004761

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should

TSB #11004557

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

TSB #11002312

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.

Showing the 8 most recent of 64 technical service bulletins on file with NHTSA.

20210211Component: SUSPENSION

2002 CHEVROLET EXPRESS 3500. CONSUMER WRITES IN REGARDS TO BROKEN DRIVERS SIDE SPRING LEAF. *LD THE CONSUMER STATED AFTER A POTHOLE BROKE THE SPRING LEAVE, IT WAS DISCOVERED THA

20120824Component: ENGINE

TL* THE CONTACT OWNS A 2002 CHEVROLET EXPRESS CUTAWAY G3500. THE CONTACT STATED THAT THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST ONTO THE SHOULDER AND RESTAR

20061106Component: ENGINE AND ENGINE COOLING:ENGINE:DIESEL

2002 EXPRESS 3500 6.5 DIESEL VAN HAS STARTED INTERMITTENT STALLING AT HIGHWAY SPEEDS 60 MPH MID 09/2006. NO TROUBLE CODES LOCKED IN MEMORY. TWO CHEVY DLRS AND GM CUSTOMER SERVICE

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