2002 CHEVROLET EXPRESS Owners Manual

6-70 Wheel Nut Torque
MODEL TORQUE
All
140 lb
-ft (190 N´m)
Cooling System Capacity
ENGINE VIN QTY Without Rear Heater QTY With Rear Heater
ªVORTECº 4300 V6 W 11.0 quarts (10.4 L) 14.0 quarts (13.2 L)
ªVORTECº 5000 V8 M 17.0 quarts (16.0 L) 20.0 quarts (18.9 L)
ªVORTECº 5700 V8 R 17.0 quarts (16.0 L) 20.0 quarts (18.9 L)
ªVORTECº 8100 V8 G 23.0 quarts (21.8 L) 26.0 quarts (24.6 L)
After refill, the level MUST be checked as outlined under ªEngine Cooling Systemº in Section 5.
Engine Oil Capacity
ENGINE VIN Quantity
ªVORTECº 4300 V6 W 4.5 quarts (4.3 L)
ªVORTECº 5000 V8 M 5.0 quarts (4.8 L)
ªVORTECº 5700 V8 R 5.0 quarts (4.8 L)
ªVORTECº 8100 V8 G 6.5 quarts (6.15 L)

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

6-72
Normal Maintenance Replacement Parts
Replacement Parts
Replacement part numbers listed in this section are based on the latest information available at the time of printing,
and are subject to change. If a part listed in this manual is not the same as the part used in your vehicle when it was
built, or if you have any questions, please contact your GM dealer.
These specifications are for information only. If you have any questions, see the service manual for the chassis or
refer to the body manufacturer's publications.
EngineªVORTECº 4300
V6ªVORTECº 5000
V8ªVORTECº 5700
V8ªVORTECº8100
V8
VIN W M R G
Oil Filter PF47 PF1218 PF1218 PF454
Engine Air Cleaner Filter * A917C A917C A917C A917C
PCV Valve CV769C CV769C CV769C **
Spark Plugs
41
-932 41-932 41-932 TJ14R-P15
Fuel Filter GF481 GF481 GF481 GF481
Radiator Cap RC36 RC36 RC36 RC36
* Replace with ACDelco

Air Filter, Part No. A917C and for severe dusty conditions, use ACDelco
Air Filter,
Part No. 1236C.
**8100 V8 has an internal PCV which does not require replacement.

7-
7-1
Section 7 Maintenance Schedule
This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety,
dependability and emission control performance.
7
-2 Introduction
7
-4 Part A: Scheduled Maintenance Services
7
-9 Short Trip/City Scheduled Maintenance
7
-33 Long Trip/Highway Scheduled Maintenance7
-48 Part B: Owner Checks and Services
7
-53 Part C: Periodic Maintenance Inspections
7
-55 Part D: Recommended Fluids and Lubricants
7
-58 Part E: Maintenance Record

7-2
Have you purchased the GM Protection Plan? The Plan
supplements your new vehicle warranties. See your
Warranty and Owner Assistance booklet or your dealer
for details.
Introduction
Your Vehicle and the Environment
Proper vehicle maintenance not only helps to keep your
vehicle in good working condition, but also helps the
environment. All recommended maintenance procedures
are important. Improper vehicle maintenance can even
affect the quality of the air we breathe. Improper fluid
levels or the wrong tire inflation can increase the level
of emissions from your vehicle. To help protect our
environment, and to keep your vehicle in good
condition, please maintain your vehicle properly.
Maintenance Requirements
Maintenance intervals, checks, inspections and
recommended fluids and lubricants as prescribed in
this manual are necessary to keep your vehicle in good
working condition. Any damage caused by failure to
follow recommended maintenance may not be covered
by warranty.

7-3 How This Section is Organized
This maintenance schedule is divided into five parts:
ªPart A: Scheduled Maintenance Servicesº explains
what to have done and how often. Some of these
services can be complex, so unless you are technically
qualified and have the necessary equipment, you should
let your dealer's service department or another qualified
service center do these jobs.
CAUTION:
Performing maintenance work on a vehicle can
be dangerous. In trying to do some jobs, you can
be seriously injured. Do your own maintenance
work only if you have the required know
-how
and the proper tools and equipment for the job.
If you have any doubt, have a qualified
technician do the work.
If you want to get the service information, see ªService
and Owner Publicationsº in the Index.ªPart B: Owner Checks and Servicesº tells you
what should be checked and when. It also explains
what you can easily do to help keep your vehicle in
good condition.
ªPart C: Periodic Maintenance Inspectionsº
explains important inspections that your dealer's
service department or another qualified service center
should perform.
ªPart D: Recommended Fluids and Lubricantsº
lists some recommended products necessary to help
keep your vehicle properly maintained. These products,
or their equivalents, should be used whether you do the
work yourself or have it done.
ªPart E: Maintenance Recordº is a place for
you to record and keep track of the maintenance
performed on your vehicle. Keep your maintenance
receipts. They may be needed to qualify your vehicle
for warranty repairs.

7-4
Part A: Scheduled
Maintenance Services
Using Your Maintenance Schedule
We at General Motors want to help you keep your
vehicle in good working condition. But we don't know
exactly how you'll drive it. You may drive very short
distances only a few times a week. Or you may drive
long distances all the time in very hot, dusty weather.
You may use your vehicle in making deliveries.
Or you may drive it to work, to do errands or in
many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need
more frequent checks and replacements. So please
read the following and note how you drive. If you
have any questions on how to keep your vehicle in
good condition, see your dealer.
This part tells you the maintenance services you should
have done and when you should schedule them. If you
go to your dealer for your service needs, you'll know
that GM
-trained and supported service people will
perform the work using genuine GM parts.The proper fluids and lubricants to use are listed in
Part D. Make sure whoever services your vehicle
uses these. All parts should be replaced and all
necessary repairs done before you or anyone else
drives the vehicle.
These schedules are for vehicles that:

carry passengers and cargo within recommended
limits. You will find these limits on your vehicle's
Certification/Tire label. See ªLoading Your Vehicleº
in the Index.

are driven on reasonable road surfaces within legal
driving limits.

use the recommended fuel. See ªFuelº in the Index.
Selecting the Right Schedule
First you'll need to decide which of the two schedules
is right for your vehicle. Here's how to decide which
schedule to follow:

Scheduled Maintenance
7-5
Short Trip/City Definition
Follow the Short Trip/City Scheduled Maintenance if
any one of these conditions is true for your vehicle:

Most trips are less than 5 miles (8 km). This is
particularly important when outside temperatures
are below freezing.

Most trips include extensive idling (such as frequent
driving in stop
-and-go traffic).

You frequently tow a trailer or use a carrier on top
of your vehicle.

If the vehicle is used for delivery service, police,
taxi or other commercial application.
One of the reasons you should follow this schedule
if you operate your vehicle under any of these
conditions is that these conditions cause engine oil
to break down sooner.
Short Trip/City Intervals
At 3,000 Miles (5 000 km): Drive Axle Service
(2500 and 3500 Series with locking differential only).
Every 3,000 Miles (5 000 km): Engine Oil and Filter
Change (or 3 months, whichever occurs first). Chassis
Lubrication (or 3 months, whichever occurs first).
Drive Axle Fluid Check.
Every 6,000 Miles (10 000 km): Tire Rotation.
Every 15,000 Miles (25 000 km): Diesel Engine Only:
Engine Air Cleaner Filter Inspection, if driving in
dusty conditions. Drive Axle Service When Towing
(2500 and 3500 Series only). Gasoline Engine Only:
Noise Shields Inspection (GVWR above 10,000 lbs.
only). Diesel Engine Only: Shields and Underhood
Insulation Inspection. Diesel Engine Only:
Thermostatically Controlled Engine Cooling Fan
Check (or every 12 months, whichever occurs first).
Diesel Engine Only: Air Intake System Inspection.
Front Wheel Bearing Repack (or at each brake
relining, whichever occurs first).