Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2002CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 8.1 GREPAIR AND DIAGNOSIS (SINGLE PAGE)QUICK LOOKUPSCOMMON SPECS & PROCEDURESSPECIFICATIONS INDEX
2002 Chevrolet Chevy Express G3500, Van Passenger Extended, 8.1 G
Specifications Index
2002 Chevrolet Chevy Express G3500, Van Passenger Extended, 8.1 GSECTION Specifications Index
EXPRESS & SAVANA SPECIFICATIONS INDEX
| System | Specification/Procedure | ||
|---|---|---|---|
| Air Conditioning | |||
| Service | SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Battery | BATTERY SPECIFICATIONS | ||
| Brakes | |||
| Bleeding Sequence | RR, LF, LR, RF | ||
| Disc Brakes | DISC BRAKE SPECIFICATIONS | ||
| Drum Brakes | DRUM BRAKE SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Charging | |||
| Generator | GENERATOR SPECIFICATIONS | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Drive Belts | |||
| Adjustment | BELT ADJUSTMENT | ||
| Belt Routing | |||
| 4.3L, 5.0L & 5.7L | BELT ROUTING | ||
| 6.5L | BELT ROUTING | ||
| 8.1L | BELT ROUTING | ||
| Engine Cooling | |||
| General Service Specifications | COOLING SYSTEM SPECIFICATIONS | ||
| Radiator Cap Pressure | 15 psi | ||
| Thermostat R & I | N/A | ||
| Water Pump R & I | 4.3L WATER PUMP REMOVAL 5.0L & 5.7L WATER PUMP REMOVAL 6.5 L WATER PUMP REMOVAL 8.1L WATER PUMP REMOVAL |
||
| Engine Mechanical | |||
| 4.3L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil Pressure Minimum at normal operating temperature |
6 psi (42 kPa) at 1000 RPM 18 psi (125 kPa) at 2000 RPM 24 psi (166 kPa) at 4000 RPM |
||
| Overhaul | ENGINE MECHANICAL SPECIFICATIONS | ||
| Torque | FASTENER TIGHTENING SPECIFICATIONS | ||
| 5.0L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil Pressure Minimum at normal operating temperature |
6 psi (42 kPa) at 1000 RPM 18 psi (125 kPa) at 2000 RPM 24 psi (166 kPa) at 4000 RPM |
||
| Overhaul | ENGINE MECHANICAL SPECIFICATIONS (5.0 L) | ||
| Torque | FASTENER TIGHTENING SPECIFICATIONS | ||
| 5.7L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil Pressure Minimum at normal operating temperature |
6 psi (42 kPa) at 1000 RPM 18 psi (125 kPa) at 2000 RPM 24 psi (166 kPa) at 4000 RPM |
||
| Overhaul | ENGINE MECHANICAL SPECIFICATIONS (5.7 L) | ||
| Torque | FASTENER TIGHTENING SPECIFICATIONS | ||
| 6.5L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil Pressure Mechanical Gage (Hot) |
6 psi (41 kPa) minimum at idle 30-43 psi (207-296 kPa) minimum at 2000 RPM |
||
| Overhaul | ENGINE MECHANICAL SPECIFICATIONS | ||
| Torque | FASTENER TIGHTENING SPECIFICATIONS | ||
| 8.1L | |||
| Compression | ENGINE COMPRESSION | ||
| Oil Pressure (Minimum) | 5 psi (34 kPa) at 1000 RPM 10 psi (69 kPa) at 2000 RPM |
||
| Overhaul | ENGINE MECHANICAL SPECIFICATIONS | ||
| Torque | FASTENER TIGHTENING SPECIFICATIONS | ||
| Fluid Specifications | See FLUIDS under MAINTENANCE tab. From within Manager or Service Writer, click the "30/60/90 Interval" or "Maint." button. | ||
| Flywheel/Flex Plate Torque | 4.3L 74 Ft. Lbs. (100 N.m) 5.0L & 5.7L 74 Ft. Lbs. (100 N.m) 6.5L 65 Ft. Lbs. (90 N.m) 8.1 L First Pass 30 Ft. Lbs. (40 N.m) Second Pass 59 Ft. Lbs. (80 N.m) Final Pass 74 Ft. Lbs. (100 N.m) |
||
| Fuel System | |||
| Pressure Specification | FUEL PUMP | ||
| Fuel Pressure Test Procedure | FUEL SYSTEM PRESSURE TEST (4.3L) FUEL SYSTEM PRESSURE TEST (4.8L, 5.3L, 6.0L & 8.1L) FUEL SYSTEM PRESSURE TEST (5.0L & 5.7L) BASIC FUEL SYSTEM CHECKS (DIESEL) |
||
| Ignition | |||
| Firing Order & Cylinder Identification | See FIRING ORDER & CYLINDER IDENTIFICATION | ||
| Ignition Wires (Resistance) | HIGH TENSION WIRE RESISTANCE | ||
| Ignition Wires (Routing) | 4.3L, 5.0L & 5.7L see appropriate illustration under FIRING ORDER 6.5L & 8.1 L N/A |
||
| Spark Plug | |||
| 4.3L | |||
| Type | AC R41-932 | ||
| Gap | .060 In. (1.52 mm) | ||
| Torque | .060 In. (1.52 mm) | ||
| 5.0L | |||
| Type | AC 41-952 | ||
| Gap | .060 In. (1.52 mm) | ||
| Torque | .060 In. (1.52 mm) | ||
| 5.7 | |||
| Type | 41-952 | ||
| Gap | .060 In. (1.52 mm) | ||
| Torque | .060 In. (1.52 mm) | ||
| 8.1 | |||
| Type | Denso TJ14R-P15 | ||
| Gap | .060 In. (1.52 mm) | ||
| Torque | 15 Ft. Lbs. (20 N.m) | ||
| Starting | |||
| Starter | STARTER APPLICATION | ||
| Torque | TORQUE SPECIFICATIONS | ||
| Wheel Alignment | |||
| Adjustment Specifications | WHEEL ALIGNMENT SPECIFICATIONS | ||
| Torque | FASTENER TIGHTENING SPECIFICATIONS | ||
| Wheel & Tire | |||
| Wheel Lug Nut Torque | Single Wheel 140 Ft. Lbs. (190 N.m) Dual Wheel 175 Ft. Lbs. (240 N.m) |
||
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.