John Loper II
0a2d660494
- README.md: Marked Fuel Pressure Issue as RESOLVED (battery replacement needed) - FuelPressureIssue/README.md: Updated to reflect battery as sole root cause - FuelPressureIssue/progress.md: Added battery replacement steps, updated history The van wouldn't start when battery was weak due to voltage sag preventing fuel pump from building proper pressure. When battery is charged, fuel pump builds full pressure immediately. No fuel pump or filter replacement needed.
2002 Chevrolet Express 3500 - Vehicle Maintenance Tracker
🚗 Vehicle Information
| Field | Value |
|---|---|
| Year/Make/Model | 2002 Chevrolet Express 3500 |
| VIN | 1GAHG39R821226228 |
| Engine | 5.7L V8 (L31 Vortec) |
| Horsepower | 258 HP @ 4,600 rpm |
| Torque | 330 lb-ft @ 2,800 rpm |
| Transmission | 4-speed Automatic (4L80-E heavy-duty) |
| Drivetrain | RWD |
| Fuel Capacity | 31 gallons |
| Curb Weight | 4,849 lbs |
| Max Towing Capacity | 8,000 lbs |
| Wheelbase | 135.0 inches (standard) / 155 inches (extended) |
| Overall Length | 218.8 inches (standard) / 238.8 inches (extended) |
| Overall Width | 79.2-79.4 inches |
| Overall Height | 82.5-82.8 inches |
| Tire Size | P245/75R16 |
| Rim Size | 16" steel |
| Valve Configuration | OHV (16-valve) |
| Compression Ratio | 9.4:1 |
| Engine Oil Capacity | 5.1 quarts (5W-30) |
| Brakes (Front) | Dual Hydraulic Disc |
| Brakes (Rear) | Dual Drum Brakes |
| Front Suspension | MacPherson Strut with Double Tube dampers |
| Rear Suspension | Multi-Link Coil Springs with Double Tube dampers |
| Headlight Bulb | 9007 Halogen |
| Mileage | 303,770 miles (as of 2026-03-23) |
| Date Started | 2026-03-20 |
🔍 VIN Decoder Reference
VIN Format: 1GAHG39R821226228
Decoder URL Pattern: https://www.decodethis.com/vin/[VIN]
VIN Breakdown:
- 1 = United States (Manufacturer)
- G = General Motors
- A = Chevy
- H = GVWR Range 9001-10000 lbs
- G3 = Express 3500 (1-ton)
- 9 = Brake System - Hydraulic
- R = 5.7L V8 Gasoline Engine (8th digit = engine code)
- 8 = Check Digit
- 2 = Model Year 2002
- 1 = Assembly Plant
- 226228 = Production Sequence Number
📋 Project Overview
This repository tracks all maintenance, repairs, and issues for the 2002 Chevy Express 3500. Each subfolder represents a specific issue or maintenance task with its own progress tracking.
Current Issues/Projects:
- Crank No Start - ✅ RESOLVED (distributor cap/rotor replacement)
- Power Steering Leak - 🔄 ACTIVE (fluid leak requiring periodic top-offs)
- Fuel Pressure Issue - ✅ RESOLVED (weak/failing battery identified and replaced)
Vehicle Specifications:
- Engine Oil: 5W-30, ~6 quarts with filter
- Transmission Fluid: DEXRON-III ATF
- Power Steering Fluid: DEXRON-III ATF
- Spark Plugs: 8x (exact type TBD - need VIN lookup)
- Fuel System: Electronic Fuel Injection (EFI), 55-62 PSI operating pressure
Maintenance History:
- 2026-03-21: Distributor cap and rotor replaced - Crank no-start resolved
- 2026-03-21: Power steering leak project initiated
- 2026-03-21: Fuel pressure issue diagnosed - weak fuel pump identified, replacement needed
Notes:
- Fuel pump confirmed weak - 37 PSI residual, requires 2 primes to reach 50 PSI
- Check valve is working fine (good pressure retention)
- Crankshaft position sensor (CKP) had history of issues on this vehicle
- Distributor corrosion is a recurring issue (~1x/year) on this van
- P0300 code - Random misfire code from crank no-start diagnosis (2026-03-20), should clear after fuel system repair
- Spark plugs - All 8 need replacement (matching set), low priority, pending fuel system repair first
Documentation:
- Each subfolder contains: README.md (issue description) + progress.md (current status)
- All changes committed to Gitea: https://gitea.loperfamily.com/Sage_Software/2002-Chevy-Express-3500