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 MANUALSCHEVROLET2002EXPRESS 1/2 TON VAN V8-5.7L VIN RREPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTRELAYS AND MODULES - POWERTRAIN MANAGEMENTRELAYS AND MODULES - COMPUTERS AND CONTROL SYSTEMSENGINE CONTROL MODULESERVICE AND REPAIRPOWERTRAIN CONTROL MODULE (PCM) REPLACEMENT
2002 Chevrolet Express 1/2 Ton Van V8-5.7L VIN R
Powertrain Control Module (PCM) Replacement
2002 Chevrolet Express 1/2 Ton Van V8-5.7L VIN RSECTION Powertrain Control Module (PCM) Replacement
Powertrain control module (PCM) service should normally consist of either PCM replacement or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures require PCM replacement, check the PCM first to see if the correct part is being used.
IMPORTANT:
^ In order to prevent internal PCM damage, the ignition must be OFF when you disconnect or reconnect the power to the PCM. For example, disconnect the power when you work with the following components:
^ A battery cable
^ The PCM pigtail
^ The PCM fuse
^ Jumper cables
^ When you diagnose or replace the PCM, remove any debris from the PCM connector surfaces before servicing the PCM module connector gaskets. Ensure that the gaskets are installed correctly. The gaskets prevent contamination intrusion into the PCM.
^ The replacement PCM MUST be programmed.
Removal Procedure

1. Remove the air cleaner assembly.
NOTE:
^ Refer to PCM and ESD Notice in Service Precautions.
^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector.
2. Disconnect the PCM harness connectors (4).
3. Release the spring latch (3) from the PCM (1).

4. Lift the PCM from the PCM mounting tray (2).
5. Remove the PCM (1) from the engine compartment.
Installation Procedure

1. Install the PCM (1) to the PCM mounting tray (2).
2. Secure the spring latch (3) to the PCM (1).
NOTE: Refer to Fastener Notice in Service Precautions.

3. Connect the PCM connectors (4) to the PCM (1).
Tighten
Tighten the PCM connector end fasteners to 8 N.m (71 lb in).
4. Install the air cleaner assembly.
5. If a new PCM is being installed, program the PCM. Programming and Relearning
IMPORTANT:
^ In order to prevent internal PCM damage, the ignition must be OFF when you disconnect or reconnect the power to the PCM. For example, disconnect the power when you work with the following components:
^ A battery cable
^ The PCM pigtail
^ The PCM fuse
^ Jumper cables
^ When you diagnose or replace the PCM, remove any debris from the PCM connector surfaces before servicing the PCM module connector gaskets. Ensure that the gaskets are installed correctly. The gaskets prevent contamination intrusion into the PCM.
^ The replacement PCM MUST be programmed.
Removal Procedure
1. Remove the air cleaner assembly.
NOTE:
^ Refer to PCM and ESD Notice in Service Precautions.
^ In order to prevent internal damage to the PCM, the ignition must be OFF when disconnecting or reconnecting the PCM connector.
2. Disconnect the PCM harness connectors (4).
3. Release the spring latch (3) from the PCM (1).
4. Lift the PCM from the PCM mounting tray (2).
5. Remove the PCM (1) from the engine compartment.
Installation Procedure
1. Install the PCM (1) to the PCM mounting tray (2).
2. Secure the spring latch (3) to the PCM (1).
NOTE: Refer to Fastener Notice in Service Precautions.
3. Connect the PCM connectors (4) to the PCM (1).
Tighten
Tighten the PCM connector end fasteners to 8 N.m (71 lb in).
4. Install the air cleaner assembly.
5. If a new PCM is being installed, program the PCM. Programming and Relearning
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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.