Instruction/ maintenance manual of the product 2002 Chevrolet
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2002 Avalanche 3-1 1 Door Fr ame Sectioning IMPORTANT: Section in specified areas only. Sectioning outside of these areas may compromise the structural integrity of the vehicle. Do not section in laser weld (1) areas of door frame sections. The door frame opening is a unique laser-weld design incorporating multiple metal thicknesses to ensure the structural integrity of the cab.
3-2 2002 Avalanche Windshield Pillar Sectioning Removal Procedure 1. Remove all related panels and components. 2. Restore as much of the damage as possible to factory specifications. 3. Note the location and remove the following as necessary: • Sealers • Sound deadeners • Anti-corrosion materials IMPORTANT: Perform sectioning in the windshield area 30␣ mm (1-3/16␣ in.
2002 Avalanche 3-3 Windshield Pillar Sectioning Installation Procedure 1. Cut the replacement pillar in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one and one-half times the metal thickness at the sectioning joint.
3-4 2002 Avalanche GAP = ONE AND ONE-HALF TIMES MET AL THICKNESS STITCH WELD Windshield Pillar Sectioning Installation Procedure con’t 11. Make 25␣ mm (1␣ in.) stitch welds along the seam with 25␣ mm (1␣ in.) gaps between them, then go back and complete the stitch weld.
2002 Avalanche 3-5 Fr ont Lower Hinge Pillar Sectioning Removal Procedure 1. Visually inspect and restore as much of the damage as possible to factory specifications. 2. Remove all related panels and components. 3. Note the location and remove the following as necessary: • Sealers • Sound deadeners • Anti-corrosion materials 4.
3-6 2002 Avalanche Fr ont Lower Hinge Pillar Sectioning Installation Procedure 1. On the service part, measure 50␣ mm (2␣ in.) down from the large wiring harness hole in the hinge pillar and mark a horizontal line. Cut the hinge pillar along this line.
2002 Avalanche 3-7 Center Pillar Sectioning Removal Procedure 1. Remove all related panels and components. 2. Restore as much of the damage as possible to factory specifications. 3. Note the location and remove the following as necessary: • Sealers • Sound deadeners • Anti-corrosion materials IMPORTANT: Take care not to damage the inner panels or reinforcements.
3-8 2002 Avalanche Center Pillar Sectioning Installation Procedure 1. Cut the replacement Center Pillar in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half times the metal thickness at the sectioning joint.
2002 Avalanche 3-9 GAP = ONE AND ONE-HALF TIMES MET AL THICKNESS STITCH WELD Center Pillar Sectioning Installation Procedure con’t 9. Align the Center Pillar to adjacent panels using three-dimensional measuring equipment. 10. Plug weld accordingly. 11.
3-10 2002 Avalanche Rear Lock Pillar Sectioning Removal Procedure 1. Remove all related panels and components. 2. Restore as much of the damage as possible to factory specifications. 3. Note the location and remove the following as necessary: • Sealers • Sound deadeners • Anti-corrosion materials IMPORTANT: Take care not to damage the inner panels or reinforcements.
2002 Avalanche 3-11 Rear Lock Pillar Sectioning Installation Procedure 1. Cut the replacement Rear Lock Pillar in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half times the metal thickness at the sectioning joint.
3-12 2002 Avalanche GAP = ONE AND ONE-HALF TIMES THE MET AL THICKNESS STITCH WELD Rear Lock Pillar Sectioning Installation Procedure con’t 9. Align the Rear Lock Pillar to adjacent panels using three- dimensional measuring equipment. 10. Plug weld accordingly.
2002 Avalanche 3-13 Rocker P anel Sectioning Removal Procedure 1. Remove all related panels and components. 2. Restore as much of the damage as possible to factory specifications. 3. Note the location and remove the following as necessary: • Sealers • Sound deadeners • Anti-corrosion materials IMPORTANT: Take care not to damage the inner panels or reinforcements.
3-14 2002 Avalanche Rocker P anel Sectioning Installation Procedure 1. Cut the replacement Rocker Panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half times the metal thickness at the sectioning joint.
2002 Avalanche 3-15 HINGE PILLAR 13 MM (1/2 IN) RO T ABRO A CH BIT HINGE REINFORCEMENT TYPICAL MIG WELD DRILL THROUGH HINGE ONL Y Fr ont Body-Side Hinge Replacement Removal Procedure 1. Remove related panels and component. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar.
3-16 2002 Avalanche Fr ont Body-Side Hinge Replacement Installation Procedure 1. Repair any damage done to the pillar during the drilling or the removal. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge.
2002 Avalanche 3-17 Hinge Nuts Pillar Hinge Reinfor cement Studs Front Body-Side Hinge Replacement Installation Procedure con’t 15. Install the hinge to the pillar. Use the supplied nuts. 16. Torque the hinge to the pillar nuts to 25␣ ␣ N·m (18 ft lb.
3-18 2002 Avalanche Fr ont Door-Side Hinge Replacement Removal Procedure 1. Remove related panels and components. 2. Remove any excess sealer surrounding the hinge and scribe the location of the hinge on the door. 3. Lightly hand-sand the existing body hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the door.
2002 Avalanche 3-19 Fr ont Door-Side Hinge Replacement Installation Procedure 1. Repair any damage done to door during the drilling or the removal. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate.
3-20 2002 Avalanche Rear Body-Side Hinge Replacement Removal Procedure 1. Remove related panels and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the hinge pillar. 3. Lightly hand-sand the existing hinge with 100 grit or finer sandpaper in order to locate the 4 welds that attach the hinge to the pillar.
2002 Avalanche 3-21 Rear Body-Side Hinge Replacement Installation Procedure 1. Repair any damage done to the pillar during the drilling or the removal. 2. Position the service hinge within the scribe marks on the pillar. 3. Center punch each stud location on the hinge pillar according to the service hinge.
3-22 2002 Avalanche Hinge Nuts Pillar Hinge Reinfor cement Studs Rear Body-Side Hinge Replacement Installation Procedure cont’d 11. Draw the stud tight through the pillar. Use the nuts GM P/N 11516746, supplied. 12. Repeat steps 7 through 10 on the remaining stud locations.
2002 Avalanche 3-23 Rear Door-Side Hinge Replacement Removal Procedure 1. Remove related panel and components. 2. Remove any excess sealer surrounding the existing hinge and scribe the location of the hinge on the door. 3. Lightly hand-sand the existing door hinge with 100 grit or finer sandpaper in order to locate the four welds that attach the hinge to the door.
3-24 2002 Avalanche Rear Door-Side Hinge Replacement Installation Procedure 1. Repair any damage done to the door during the drilling or the removal. 2. Clean and prepare the backing plate mounting surfaces in order to ensure a flush fit of the backing plate.
2002 Avalanche 3-25 Quarter P anel Removal Procedure 1. Remove all related panels and components. 2. Restore as much of the damage as possible to factory specifications. 3. Note the location and remove the following as necessary: • Sealers • Sound deadeners • Anti-corrosion materials 4.
3-26 2002 Avalanche Quarter Panel Removal Procedure cont’d 6. Locate and drill out all factory welds. Note the number and location of welds for installation of the service part. 7. Remove the damaged Quarter Panel, leaving a 25 mm (1 in.) flange attached to the roof.
2002 Avalanche 3-27 Quarter P anel Installation Procedure 1. Trim and discard the upper mounting flange on the service Quarter Panel so that it will fit over the 25 mm (1 in.) flange left from the original panel. 2. Drill 8 mm (5/16 in.) plug weld holes along the sectioning cut on the service part.
3-28 2002 Avalanche Quarter Panel Installation Procedure cont’d 9. Position the Quarter Panel to the vehicle. 10. Plug weld accordingly. 11. To create a solid weld with minimum heat distortion, make 25 mm (1 in.) stitch welds along the seam with 25 mm (1␣ in.
2002 Avalanche 3-29 Fr ont Bumper Br acket Replacement— 1500 Series 1. Remove related panels and components. 2. Remove damaged bumper bracket. IMPORTANT: Do not remove any material from end of frame rail. 3. Position the service template on the end of the frame rail; use 3M’s Repositionable Adhesive or equivalent.
3-30 2002 Avalanche Fr ont Bumper Br acket Replacement— 2500 Series 1. Remove related panels and components. 2. Remove damaged bumper bracket. 3. Visually inspect frame and restore all damage to factory specifications using three-dimensional measuring.
2002 Avalanche 3-31 Rail End Fr ont Crush Cap Replacement Removal Procedure 1. Remove all of the related panels and the components. IMPORTANT: If the crush cap is bent or damaged in any way you must replace the crush cap. 2. Visually inspect the damage.
3-32 2002 Avalanche 13mm 50mm GAP = ONE AND ONE-HALF TIMES THE THICKNESS OF THE MET AL Rail End Fr ont Crush Cap Replacement Installation Procedure 1. Drill 4 plug weld holes (2 at the top and 2 at the bottom), 13 mm (1/2␣ in.) from the cut line and 50 mm (2␣ in.
2002 Avalanche 3-33 PRELIMINAR Y Rear Module Replacement Removal Procedure 1. Remove all related panels and components. 2. Restore as much of the damage as possible to factory specifications. 3. Support the rear of the body at the outer edges of the rear cross sill to keep the vehicle stable while performing rear module replacement.
3-34 2002 Avalanche PRELIMINAR Y Rear Module Replacement Removal Procedure con’t 7. Grind remaining portion of rear rails back to middle section. 8. Remove the remaining section of the rear rails from the inside of middle section. 9. Remove the wax coating from inside and outside surfaces of the middle rails.
2002 Avalanche 3-35 PRELIMINAR Y Rear Module Replacement Installation Procedure 1. Prepare all bare metal surfaces as necessary. 2. Install and position the replacement module using three-dimensional measuring. Refer to frame dimensions. 3. Tack weld the rear module into position.
3-36 2002 Avalanche SRIM Composite Repair The Avalanche midgate and tailgate, as well as the Chevrolet Pro-tec ® composite pickup box, can be repaired using SRIM composite repair procedures. Repair Procedure 1. Remove all related panels and components.
2002 Avalanche 3-37 SRIM Composite Repair Repair Procedure con’t 6. Create a multi-layered reinforcement patch, as shown, using the procedure outlined in steps 7–27. 7. Cut one piece of glass cloth mat to form a patch large enough to extend 38 to 50 mm (1-1/2 to 2␣ in.
3-38 2002 Avalanche SRIM Composite Repair Repair Procedure con’t 10. Apply an 8 mm (1/4␣ in.) layer of repair material over the glass cloth mat. 12. Place a second sheet of release paper over the repair patch. 12. Roll patch with saturation roller until the mat is completely saturated with repair material.
2002 Avalanche 3-39 SRIM Composite Repair Repair Procedure con’t 17. Cut two pieces of glass cloth mat large enough to cover the beveled area on the front side of repair. 18. Mix and apply a layer of repair material to the front of the repair, repair material should be at a level slightly above the surrounding area.
3-40 2002 Avalanche SRIM Composite Repair Repair Procedure cont’d 21. Place the second layer of pre-cut mat over the repair material, smooth out and remove all trapped air. 22. Apply a third coat of repair material to the front of the repair, and place a sheet of release paper over it.
2002 Avalanche 3-41 Composite Box Repair Procedure cont’d 26. Finish contour sanding with a 220 grit abrasive or finer. 27. Refinish as necessary. Follow paint manufacturer’s recommendations for application instructions.
3-42 2002 Avalanche 1 1 1 1 1 1 3 2 2 A valanche P anel Identification (Metal) 1. Two-Sided Glavanized Steel 2. Ultra High-Strength Steel 3. Mild Steel.
2002 Avalanche 3-43 1 1 1 1 1 1 1 4 1 1 1 3 2 3 A valanche P anel Identification (Plastic) 1. Thermoplastic Olefin (TPO) 2. Fiberglass Reinforced Polyester 3.
3-44 2002 Avalanche 2000 and Newer Chevr olet Suburban/GMC Y ukon XL 2002 Chevr olet Avalanche Fr ame Dimensions C L C L Ø C Ø Ø Ø A 388 411 522 601 500 562 1441 1327 1827 3732 552 382 351 574 B D E 1921 1829 2212 2145 1343 1714 1459 1632 Description Location Length Width Height 13 mm hole A 1441 388 562 32 mm hole B 1327 411 552 22 x 19 mm slot zero line C 0 522 382 33 x 17 mm hole D 1827 601 351 19 mm hole E 3732 500 574 All dimensions are measured in millimeters, from a zero line, center line, and a common datum.
An important point after buying a device Chevrolet 2002 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Chevrolet 2002 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Chevrolet 2002 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Chevrolet 2002 you will learn all the available features of the product, as well as information on its operation. The information that you get Chevrolet 2002 will certainly help you make a decision on the purchase.
If you already are a holder of Chevrolet 2002, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Chevrolet 2002.
However, one of the most important roles played by the user manual is to help in solving problems with Chevrolet 2002. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Chevrolet 2002 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
