2002 GMC Sierra 3500 Service & Repair Manual Software

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🏷️ Basic Information Identification Make: GMC Model: Sierra 3500 Year: 2002 Codes Platform: GMT800 👋 Introduction Market Position Positioning: Essential diagnostic and repair tool for 2002 GMC Sierra 3500 owners...

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Type: Truck

Vendor:

Sku: 330925

Tags: 2002 Cars GMC Sierra Sierra 3500 Truck

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Sierra 3500

Year:

Codes

Platform:

GMT800

👋 Introduction

Market Position

Positioning:

Essential diagnostic and repair tool for 2002 GMC Sierra 3500 owners and independent repair shops

Competitive Analysis

Advantage:

Licensed OE information, convenience of online access, affordability compared to printed manuals or dealership service

Key Features

Licensing:

Officially licensed, derived from OE (Original Equipment) materials

Access:

Year-long access, compatible with PC, laptop, smartphone, tablet with internet connection

User Interface:

Intuitive, push-button access to information

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance, Diagnostics, Troubleshooting, Overhauling

Page Count

Estimated Pages:

Extensive (Software format, equivalent to thousands of printed pages)

Manual Type

Type:

Software-based Service and Repair Manual

Language

Language:

English

Format

Format:

Online Digital Access (Web Browser Based)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshaft, timing, lubrication, cooling system, exhaust system

Engine Performance:

Fuel system, ignition system, emissions control, engine diagnostics, power control module (PCM) operation

Transmission Manual:

Manual transmission repair, clutch system, driveline components (driveshafts, U-joints)

Transmission Automatic:

Automatic transmission repair, torque converter, valve body, gear sets, hydraulic controls, electronic controls

Suspension:

Front suspension (independent), rear suspension (solid axle), springs, shock absorbers, control arms, ball joints, bushings

Steering:

Power steering system, steering gear, steering column, tie rods, linkage, alignment specifications

Brakes:

Front disc brakes, rear drum or disc brakes, hydraulic system, ABS (Anti-lock Braking System), parking brake, brake fluid specifications

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), ignition system, lighting, instrument cluster, power distribution

Body And Frame:

Body panels, doors, windows, locks, latches, interior trim, exterior trim, underbody, chassis components

HVAC:

Heating, ventilation, air conditioning (HVAC) system operation, refrigerant, compressor, condenser, evaporator, climate control

Wiring Diagrams:

Complete electrical wiring diagrams for all vehicle systems

Procedures Included

Routine Maintenance:

Oil change, fluid checks and top-offs, filter replacements, tire rotation, spark plug replacement

Engine Repair:

Engine tune-up, component replacement (alternator, starter, water pump), head gasket replacement, full engine overhaul

Transmission Service:

Transmission fluid and filter change, torque converter replacement, clutch replacement, internal transmission repair

Brake Repair:

Brake pad and rotor replacement, caliper overhaul, brake line repair, ABS module diagnosis and replacement

Suspension And Steering Repair:

Component replacement (shocks, struts, ball joints, tie rods), power steering pump replacement, steering gear repair

Electrical Diagnostics:

Troubleshooting electrical faults, component testing, wiring harness repair

HVAC Service:

Refrigerant recharge, component replacement (compressor, condenser), leak detection, climate control system diagnostics

Body And Trim:

Panel replacement, door and window regulator repair, interior trim installation and removal

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults

Technical Depth

Depth:

Comprehensive factory-level repair and diagnostic information

Diagnostics:

Detailed diagnostic trouble codes (DTCs), testing procedures, and symptom-based troubleshooting

Specifications:

Torque specifications, clearances, fluid capacities, electrical values, pressure readings

Rebuilds:

Complete overhaul procedures for major components like engines and transmissions

📊 Manual Specifications

File Format

File Format:

Web-based application, accessible via browser

Print Quality

Print Quality:

N/A (Digital format - printable pages are clear and legible)

Binding Type

Binding Type:

N/A (Digital format)

Paper Type

Paper Type:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Options:

4.3L V6 (Vortec 4300), 5.3L V8 (Vortec 5300), 6.0L V8 (Vortec 6000)

Engine 4.3L V6:

4.3L (262 cu in) OHV V6, ~200 hp @ 4600 rpm, ~255 lb-ft @ 2800 rpm

Engine 5.3L V8:

5.3L (327 cu in) OHV V8 with Active Fuel Management (AFM) potentially later models, ~285 hp @ 5200 rpm, ~325 lb-ft @ 4000 rpm

Engine 6.0L V8:

6.0L (364 cu in) OHV V8, ~300 hp @ 4400 rpm, ~370 lb-ft @ 3200 rpm

Performance

Aspirated:

Naturally Aspirated

Fuel System

Fuel Delivery:

Multi-Port Fuel Injection (MPFI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Standard Transmission:

4-Speed Automatic (4L60E for V8, 4L80E for heavy duty/specific V8 applications)

Optional

Optional Transmission:

5-Speed Manual (NV3500 for V6, NV4500 for V8 applications)

Features

Transmission Features:

Electronic controls, overdrive, tow/haul mode (automatic transmissions)

📐 Dimensions

Exterior

Wheelbase:

Varies by configuration (e.g., 130.0 inches for standard cab, 153.0 inches for extended/crew cab)

Length:

Varies by configuration (e.g., 229.6 inches for standard cab long bed)

Width:

Approx. 79.5 inches (excluding mirrors)

Height:

Approx. 73.8 inches (depending on configuration)

Weights

Curb Weight:

Varies significantly by configuration (approx. 5,000 - 6,500+ lbs)

Gvw Rating:

Up to 10,500 lbs (GVWR)

Payload Capacity:

Varies by configuration (significant payload capacity for a 3500 series)

Towing Capacity:

Up to 10,000+ lbs (with appropriate trailering package)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Not directly applicable to modern NHTSA rating system for this year, but general structural integrity for a heavy-duty truck

IIHS Frontal Offset:

Good (for models tested in this category)

Active Features

Standard Anti-lock Braking System (ABS) on all wheels

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

Three-point front seatbelts, available seatbelt pretensioners

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player, optional premium audio systems

Driver Assistance

Cruise Control:

Standard cruise control

Trailer Brake Controller:

Provision for or integrated trailer brake controller on some models

Connectivity

Onstar:

Optional OnStar system available

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-7,500 miles depending on oil type and driving conditions (refer to manual for specific recommendations)

Transmission Fluid Change:

Typically every 30,000-60,000 miles, or as indicated by severe service conditions.

Coolant Flush:

Every 30,000-100,000 miles depending on coolant type and manufacturer recommendations.

Spark Plug Replacement:

Varies by plug type, e.g., platinum plugs often 100,000 miles.

Fluid Specifications

Engine Oil:

API Certified SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature)

Transmission Fluid Automatic:

Dexron III/VI (check manual for precise specification)

Coolant:

GM specified silicate-free, extended-life coolant (Orange)

Brake Fluid:

DOT 3

Known Issues

Common Wear Items:

Ball joints, tie rod ends, wheel bearings, exhaust components, brake wear

Electrical Gremlins:

Occasional issues with body control modules, power windows, and instrument clusters

Transmission Hard Shifts:

Potential for rough shifting in automatic transmissions, often related to valve body or electronic controls

📚 Vehicle History

Brand Heritage

Heritage:

GMC has a long history of producing trucks and commercial vehicles, known for durability and capability.

Model Evolution

Generation:

2002 Sierra 3500 is part of the second generation GMT800 platform (1999-2007), which saw significant updates in styling, chassis, and powertrains.

Production

Manufacturing Location:

Various GM assembly plants in North America

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While specific awards for the 2002 model year might vary, the Sierra line consistently received recognition for its capability and durability in this era.