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2002 GMC Sierra 2500 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: GMC Model: Sierra 2500 Year: 2002 Generation Generation Code: GMT800 (Second Generation) Codes Platform: GMT800 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair...
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Type: Truck
Vendor:
Sku: 330921
2002 GMC Sierra 2500 Service & Repair Manual Software
🏷️ Basic Information
Identification
Make:
GMC
Model:
Sierra 2500
Year:
2002
Generation
Generation Code:
GMT800 (Second Generation)
Codes
Platform:
GMT800
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, fleet maintenance
Competitive Analysis
Advantage Over Print:
Instant access, searchability, portability, cost-effectiveness, updated information (if applicable)
Key Features
Licensing:
Officially licensed, derived from OE (Original Equipment) materials
Provider:
RepairSurge
Interface:
User-friendly, push-button access to information
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual Software
Language:
English
Format:
Online Software (Web Browser Accessible)
Access Period:
1 Year Subscription
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnostics, component replacement (e.g., pistons, rings, bearings, valves, camshafts, crankshafts, cylinder heads)
Engine Electrical:
Ignition system, starting and charging systems, fuel injection system, sensors and actuators, powertrain control module (PCM) diagnostics
Transmission Manual:
Service and repair procedures for manual transmissions (if applicable to specific models covered)
Transmission Automatic:
Service and repair procedures for automatic transmissions, including hydraulic control, torque converter, valve body, and electronic controls
Drivetrain:
Front and rear axles, driveshafts, universal joints, differential service, four-wheel-drive system (transfer case, front axle engagement)
Suspension:
Front and rear suspension components, ball joints, control arms, springs, shock absorbers, bushings, alignment specifications
Steering:
Power steering system, steering gear/rack and pinion, tie rods, steering column, alignment specifications
Brakes:
Front and rear brake systems (disc and drum), hydraulic system, ABS system diagnostics and repair, parking brake
Electrical System:
Wiring diagrams, lighting system, power windows, power door locks, mirrors, instrument cluster, interior and exterior lighting
HVAC:
Heating, ventilation, and air conditioning system diagnosis, refrigerant handling, component replacement (compressor, condenser, evaporator)
Body And Chassis:
Frame inspection and repair, body panel replacement, door and tailgate service, glass replacement, interior trim
Diagnostic Trouble Codes:
OBD-II code interpretation and troubleshooting procedures
Procedures Included
Preventive Maintenance:
Oil and filter changes, fluid level checks, spark plug replacement, belt inspection and replacement, tire rotation
Routine Repairs:
Brake pad and rotor replacement, exhaust system repairs, suspension component replacement, minor engine diagnostics
Major Repairs:
Engine rebuilds, transmission overhauls, differential repairs, complex electrical diagnostics
Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon vehicle issues
Component Replacement:
Detailed instructions for replacing virtually all major and minor vehicle components
Electrical Schematics:
Comprehensive wiring diagrams for all vehicle systems
Torque Specifications:
Exact torque values for all critical fasteners
Diagnostic Flowcharts:
Visual guides for diagnosing system failures
Technical Depth
Depth Level:
Factory-level (OE) information
Diagnostic Capability:
Advanced diagnostics including sensor data interpretation and PCM troubleshooting
Repair Complexity:
Covers everything from basic fluid changes to complete engine and transmission rebuilds
📊 Manual Specifications
File Format
Access Method:
Web browser via internet connection
Compatibility:
PC, Laptop, Smartphone, Tablet
Print Quality
Digital Resolution:
High-resolution, clear text and diagrams
Binding Type
Binding:
Not Applicable (Software)
Paper Type
Paper Quality:
Not Applicable (Software)
⚙️ Engine Specifications
Primary Engine
Engine Options:
5.3L V8 Vortec (L59/LM7), 6.0L V8 Vortec (LQ4/LQ9), 8.1L V8 Vortec (L18)
Performance
5.3L V8 (Lm7) Horsepower:
285 hp @ 5200 rpm
5.3L V8 (Lm7) Torque:
325 lb-ft @ 4000 rpm
6.0L V8 (Lq4) Horsepower:
300 hp @ 4400 rpm
6.0L V8 (Lq4) Torque:
360 lb-ft @ 3200 rpm
8.1L V8 (L18) Horsepower:
330 hp @ 4000 rpm
8.1L V8 (L18) Torque:
455 lb-ft @ 3200 rpm
Fuel System
Fuel Delivery:
Sequential Fuel Injection (SFI)
Fuel Type:
Unleaded gasoline
🔧 Transmission
Standard
Standard Transmission:
4-speed automatic (4L80-E, 4L60E - depending on configuration)
Optional
Optional Transmission:
5-speed manual (NV4500 - typically with 2500HD/3500 models, but may apply to some 2500)
Features
Automatic Transmission Features:
Electronic control, overdrive
Manual Transmission Features:
Heavy-duty design, robust construction
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Extended Cab, Crew Cab
Wheelbase Options:
130.0 in (Regular Cab), 143.5 in (Extended Cab), 153.0 in (Crew Cab)
Bed Length Options:
6.5 ft (Standard Bed), 8.0 ft (Long Bed)
Weights
Curb Weight Range:
Approx. 5,500 - 7,000 lbs (varies by configuration)
Gvwr Range:
Approx. 8,600 - 10,500 lbs
Towing Capacity:
Up to approx. 12,000+ lbs (depending on configuration and trailering package)
Payload Capacity:
Up to approx. 4,000+ lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test:
5-star (Driver and Passenger) - For similar models of this era, specific data for 2002 Sierra 2500 may vary.
Active Features
Anti Lock Brakes:
Standard (ABS)
Traction Control:
Available (StabiliTrak may be available on higher trims or later models)
Passive Features
Airbags:
Driver and passenger front airbags
Seatbelts:
3-point safety belts with pretensioners
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM stereo with CD player, optional cassette, available premium sound system
Driver Assistance
Driver Assistance Features:
Cruise control, optional parking assist sensors (rear)
Connectivity
Connectivity Options:
Limited by modern standards; typically includes power outlets
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-5,000 miles or 6 months, or based on Oil Life Monitoring System (OLMS)
Engine Oil Type:
SAE 5W-30 synthetic blend or full synthetic recommended (check owner's manual for specific viscosity and API service category)
Transmission Fluid Change Interval Auto:
Typically 50,000-100,000 miles, or as per OLMS, depending on usage
Transmission Fluid Type Auto:
Dexron III/VI (check specific application)
Fluid Specifications
Coolant Type:
Ethylene glycol based, conventional green color coolant (or equivalent)
Brake Fluid Type:
DOT 3
Known Issues
Common Issues Power Steering:
Leaks in power steering lines or pump, whining noises
Common Issues Transmission:
Torque converter shudder, solenoid issues (especially in 4L60E), transmission fluid leaks
Common Issues Engine:
Intake manifold gaskets (LS engines), oil pressure sender failures, exhaust manifold leaks
Common Issues Electrical:
Window regulator failures, HVAC blower motor resistor failures, dashboard indicator light issues
📚 Vehicle History
Brand Heritage
Gmc Truck Legacy:
GMC has a long history of producing robust and capable trucks, emphasizing professional-grade performance.
Model Evolution
Sierra 2500 Context:
Part of the second generation (GMT800) Sierra lineup, which brought significant updates in styling, comfort, and capability over its predecessors.
Production
Production Years Gmt800:
1999-2007
🏆 Awards & Recognition
Recognitions
Truck Of The Year Nominations:
GMT800 platform trucks often received accolades for capability and reliability in the heavy-duty truck segment.
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