Before You Begin:
* Safety First: Disconnect the negative battery terminal. This prevents accidental shorts and shocks.
* Consult your owner's manual: Your manual will have specific diagrams and instructions for your van's engine. This is crucial.
* Gather tools: You'll need a socket wrench with the correct size socket for your spark plugs (likely a 5/8" or 13/16" depending on the engine), a spark plug socket (deep well is recommended), a ratchet, extension(s), possibly a universal joint, and a new set of spark plugs appropriate for your engine. Gloves are also a good idea.
General Steps (Will Vary Depending on Engine):
1. Locate the Engine: Open the hood. The spark plugs are typically located on top of the engine, one per cylinder.
2. Remove Air Filter Housing and Other Obstructions: To get good access, you'll likely need to remove the air filter housing and possibly other components. Consult your manual for exact steps.
3. Access the Spark Plugs: This is the trickiest part. The arrangement of components varies based on the engine. You may need to maneuver around intake manifolds, fuel lines, and other parts. Use a flashlight to see clearly.
4. Remove the Spark Plug Wires (Ignition Coils): Carefully disconnect the ignition coil wires or boots from each spark plug. Pay close attention to which wire goes to which plug – use a marker or take a picture to help you remember. For coil-on-plug systems (COP), you may need to remove the coil itself before accessing the spark plug. Coil-on-plug is more likely on later model year engines.
5. Remove the Spark Plugs: Use your spark plug socket and ratchet to carefully remove each spark plug. Avoid cross-threading. Go slow and use even pressure.
6. Install New Spark Plugs: Install the new spark plugs, tightening them to the manufacturer's specified torque. Over-tightening can damage the spark plugs and engine threads. Torque specifications can be found in your owner's manual or online repair manuals.
7. Reconnect the Wires/Coils: Carefully reconnect the ignition coil wires or coils to the spark plugs, ensuring a secure connection.
8. Reassemble: Reassemble all components you removed (air filter housing, etc.)
Important Considerations:
* Engine Size: Knowing your specific engine size (4.8L, 5.3L, or 6.0L) will dramatically improve the accuracy of any online search for specific instructions.
* Online Resources: Search for "2002 Chevy Express [Engine Size] spark plug replacement" on YouTube. Many videos demonstrate the process visually.
* Repair Manuals: A Haynes or Chilton repair manual for your specific year and model van will be invaluable.
This is a general guide. Improperly performing this task can damage your engine. If you're not comfortable working on your vehicle, it's best to take it to a qualified mechanic.
