2002 CHEVROLET EXPRESS Fuel system

6-71 Fuel Tank Capacity
TYPE QUANTITY MODEL TYPE
Standard Tank 31.0 U.S. gallons (117.3 L) Passenger and Cargo
Standard Tank 35.0 U.S. gallons (132.5 L) Cab and Chassis
Optional Tank* 55.0 U.S. gallons (208.1 L) Cab and Chassis
*159 inch wheelbase or 177 inch wheelbase only
Air Conditioning Refrigerant Capacity
If you do your own service work, you'll need the proper service manual. See ªDoing Your Own Service Workº in the
Index for additional information. It is recommended that service work on your air conditioning system be performed
by a qualified technician.
REFRIGERANT TYPE CAPACITY
R±134a 2.0 lbs. (0.91 kg)
Front
R±134a 3.5 lbs. (1.6 kg)
Front and Rear

Scheduled Maintenance
7-6
Short Trip/City Intervals
Every 24,000 Miles (40 000 km): Diesel Engine Only:
Fuel Cap Replacement, if driving in dusty conditions.
Every 30,000 Miles (50 000 km): Diesel Engine
Only: Engine Air Cleaner Filter Replacement.
Fuel Filter Replacement.
Every 50,000 Miles (83 000 km): Automatic
Transmission Service (vehicles over 8600 GVWR
or driven under severe conditions or equipped with
diesel engine).
Every 60,000 Miles (100 000 km): Engine Accessory
Drive Belt Inspection. If Equipped: Exhaust Gas
Recirculation System Inspection. Gasoline Engine
Only: Evaporative Control System Inspection. Diesel
Engine Only: Crankcase Depression Regulator Valve
(CDRV) System Check.
Short Trip/City Intervals
Every 100,000 Miles (166 000 km): Gasoline Engine
Only: Spark Plug Wire Inspection. Gasoline Engine
Only: Spark Plug Replacement. Gasoline Engine
Only: Automatic Transmission Service (normal
conditions). Gasoline Engine Only (Except 8.1L V8):
Positive Crankcase Ventilation (PCV)
Valve Inspection.
Every 150,000 Miles (240 000 km): Cooling System
Service (or every 60 months, whichever occurs first).
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.

Scheduled Maintenance
7-8
Long Trip/Highway Intervals
Every 30,000 Miles (50 000 km): Fuel Filter
Replacement. Diesel Engine Only: Engine Air
Cleaner Filter Replacement. Front Wheel Bearing
Repack (or at each brake relining, whichever
occurs first).
Every 50,000 Miles (83 000 km): Automatic
Transmission Service (vehicles over 8600 GVWR
or driven under severe conditions or equipped with
diesel engine).
Every 60,000 Miles (100 000 km): Engine Accessory
Drive Belt Inspection. If Equipped: Exhaust Gas
Recirculation System Inspection. Gasoline Engine
Only: Evaporative Control System Inspection. Diesel
Engine Only: Crankcase Depression Regulator Valve
(CDRV) System Check.
Long Trip/Highway Intervals
Every 100,000 Miles (166 000 km): Gasoline Engine
Only: Spark Plug Wire Inspection. Gasoline Engine
Only: Spark Plug Replacement. Gasoline Engine
Only: Automatic Transmission Service (normal
conditions). Gasoline Engine Only (Except 8.1L V8):
Positive Crankcase Ventilation (PCV)
Valve Inspection.
Every 150,000 Miles (240 000 km): Cooling System
Service (or every 60 months, whichever occurs first).
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.

Short Trip/City Scheduled Maintenance
7-23

Gasoline Engine Only: Conduct evaporative control system inspection. Check
all fuel and vapor lines and hoses for proper hook
-up, routing and condition.
Check that the purge valve works properly (if equipped). Replace as needed.
An Emission Control Service. (See footnote
.)
Diesel Engine Only: Replace engine air cleaner filter.
An Emission Control Service.
Gasoline Engine Only: See ªEngine Air Cleaner Filter Restriction Indicator
Checkº in the Index.
Rotate tires. See ªTire Inspection and Rotationº in the Index for proper
rotation pattern and additional information. (See footnote +.)
Diesel Engine Only: Check the air intake system installation to assure that
gaskets are properly sealed and that all hose connections, fasteners and other
components are tight. Also check to be sure that the air cleaner housing is
properly seated and the cover fits tightly. Tighten connections and fasteners or
replace damaged parts as necessary. This is a Noise Emission Control Service.
Applicable only to vehicles sold in the United States.
Diesel Engine Only: If your engine has a thermostatically controlled cooling fan,
inspect all hoses and ducts for proper hook
-up (or every 12 months, whichever
occurs first). Be sure the valve works properly. This is a Noise Emission Control
Service. Applicable only to vehicles sold in the United States.
Diesel Engine Only: Check the crankcase depression regulator valve
system for any worn, plugged or collapsed hoses. See service manual.
An Emission Control Service.

Long Trip/Highway Scheduled Maintenance
7-41

Gasoline Engine Only: Inspect Evaporative Control System. Check all fuel
and vapor lines and hoses for proper hook
-up, routing and condition.
Check that the purge valve works properly, if equipped. Replace as needed.
An Emission Control Service. (See footnote
.)
Diesel Engine Only: Check the air intake system installation to assure that
gaskets are properly sealed and that all hose connections, fasteners and other
components are tight. Also check to be sure that the air cleaner housing is
properly seated and the cover fits tightly. Tighten connections and fasteners or
replace damaged parts as necessary. This is a Noise Emission Control Service.
Applicable only to vehicles sold in the United States.
Diesel Engine Only: If your engine has a thermostatically controlled cooling
fan, inspect hoses and ducts for proper hook
-up (or every 12 months,
whichever occurs first). Be sure the valve works properly. This is a Noise
Emission Control Service. Applicable only to vehicles sold in the
United States.
Diesel Engine Only: Check the crankcase depression regulator valve
system for any worn, plugged or collapsed hoses. See service manual.
An Emission Control Service.

7-48
Part B: Owner Checks and Services
Listed in this part are owner checks and services which
should be performed at the intervals specified to help
ensure the safety, dependability and emission control
performance of your vehicle.
Be sure any necessary repairs are completed at once.
Whenever any fluids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
in Part D.
At the First 100, 1,000 and 6,000 Miles
(160, 1 600 and 10 000 km)
For vehicles with dual wheels, check dual wheel nut
torque. For proper torque, see ªWheel Nut Torqueº in
the Index.
At Each Fuel Fill
It is important for you or a service station attendant
to perform these underhood checks at each fuel fill.
Engine Oil Level Check
Check the engine oil level and add the proper oil
if necessary. See ªEngine Oilº in the Index for
further details.Engine Coolant Level Check
Check the engine coolant level and add DEX
-COOL

coolant mixture if necessary. See ªEngine Coolantº in
the Index for further details.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the
windshield washer tank and add the proper fluid if
necessary. See ªWindshield Washer Fluidº in the
Index for further details.
At Least Once a Month
Tire Inflation Check
Make sure tires are inflated to the correct pressures.
Don't forget to check your spare tire. See ªTiresº in
the Index for further details.
Cassette Deck Service
Clean cassette deck. Cleaning should be done every
50 hours of tape play. See ªAudio Systemsº in the
Index for further details.

7-50
Weatherstrip Lubrication
Silicone grease on weatherstrips will make them last
longer, seal better, and not stick or squeak. Apply
silicone grease with a clean cloth. During very cold,
damp weather more frequent application may be
required. See ªRecommended Fluids and Lubricantsº
in the Index.
Automatic Transmission Check
Check the transmission fluid level; add if needed. See
ªAutomatic Transmission Fluidº in the Index. A fluid
loss may indicate a problem. Check the system and
repair if needed.At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part D.
Body Lubrication Service
Lubricate all hood hinges, hood prop rod pivot, fuel
filler door, rear compartment hinges, latches, locks,
hood latch assembly, secondary latch, pivots, spring
anchor, release pawl and any moving seat hardware.
Part D tells you what to use. More frequent
lubrication may be required when exposed to a
corrosive environment.

7-54 Fuel System Inspection
Inspect the complete fuel system for damage or leaks.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they are
cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed. Clean the outside
of the radiator and air conditioning condenser. To help
ensure proper operation, a pressure test of the cooling
system and pressure cap is recommended at least once
a year.
Throttle System Inspection
(Gasoline Engine)
Inspect the throttle system for interference or binding,
and for damaged or missing parts. Replace parts as
needed. Replace any components that have high effort
or excessive wear. Do not lubricate accelerator and
cruise control cables.
Rear Axle Service
Check the gear lubricant level in the rear axle and add
if needed. See ªRear Axleº in the Index. A fluid loss
may indicate a problem. Check the axle and repair it
if needed.
Brake System Inspection
Inspect the complete system. Inspect brake lines and
hoses for proper hook
-up, binding, leaks, cracks,
chafing, etc. Inspect disc brake pads for wear and rotors
for surface condition. Also inspect drum brake linings
for wear and cracks. Inspect other brake parts, including
drums, wheel cylinders, calipers, parking brake, etc.
Check parking brake adjustment. You may need to have
your brakes inspected more often if your driving habits
or conditions result in frequent braking.