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Introduction
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Market Position
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Target Audience:
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DIY enthusiasts, independent repair shops, owners seeking detailed service information.
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Competitive Analysis
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Comparison To Print:
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More convenient, searchable, and often more affordable than older printed manuals.
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Key Features
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Accessibility:
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Accessible on any PC, laptop, smartphone, or tablet with an internet connection and web browser.
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Content Source:
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Licensed OE (Original Equipment) materials from RepairSurge.
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Value Proposition
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Cost Saving:
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Enables users to perform repairs themselves, saving significant money on labor costs compared to professional repair shops.
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Manual Coverage
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Systems Covered
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Engine:
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Complete engine service, diagnostics, overhaul, cooling system, lubrication system, fuel system, ignition system, emissions control.
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Drivetrain:
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Transmission (automatic and manual), transfer case, driveshafts, axles, differentials.
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Suspension:
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Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.
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Steering:
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Power steering system, steering wheel, steering column, tie rods, steering gear/rack.
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Brakes:
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Front and rear brakes (disc/drum), hydraulic system, ABS (if equipped), parking brake, bleeding procedures.
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Electrical:
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Wiring diagrams, battery, charging system (alternator), starting system, lighting, instruments, switches, fuses, relays, comfort controls, trailer wiring.
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HVAC:
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Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair, refrigerant handling, blower motor, A/C compressor, heater core.
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Body:
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Body panels, doors, windows, locks, interior trim, bumpers, glass replacement, corrosion protection.
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Chassis:
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Frame, body mountings, underbody components.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication, tune-ups.
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Troubleshooting:
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Diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation (where applicable).
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Repair:
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Detailed step-by-step repair instructions for all major systems, component removal and installation, torque specifications.
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Diagnostics:
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Engine diagnostics, electrical system diagnostics, ABS diagnostics, HVAC system diagnostics.
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Specifications:
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All necessary technical specifications, clearances, tolerances, fluid capacities, and tightening torques.
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Technical Depth
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Depth:
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Comprehensive from routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics.
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Engine Specifications
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Primary Engine
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Engine Code:
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L31 (5.7L V8 Vortec EFI)
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Engine Type:
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5.7L V8 OHV 16-valve Fuel Injected (Vortec)
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Displacement:
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5.7 Liters (350 cubic inches)
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Bore X Stroke:
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4.00 in x 3.48 in (101.6 mm x 88.4 mm)
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Compression Ratio:
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9.1:1
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Horsepower Gross:
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Approx. 205-215 hp @ 4000 rpm (specific rating may vary slightly)
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Torque Gross:
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Approx. 305-315 lb-ft @ 2400 rpm (specific rating may vary slightly)
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Fuel System
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Fuel Delivery:
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Central Sequential Fuel Injection (CSFI) or Multi-Port Fuel Injection (MPFI) later in the model year for Vortec
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Fuel Type:
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Unleaded Gasoline, 87 Octane Recommended
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Engine Oil
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Oil Capacity:
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5.0 Quarts (4.7 Liters) with filter
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Recommended Oil Viscosity:
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API Service SG or SH, SAE 5W-30 or 10W-30 (depending on climate)
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Cooling System
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Coolant Capacity:
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Approx. 16.0 Quarts (15.1 Liters)
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Coolant Type:
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GM Gen II OAT (Orange) or DEX-COOL (50/50 mix of antifreeze and distilled water)
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Transmission
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Standard
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Transmission Type:
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4L60-E 4-Speed Automatic Overdrive
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Optional
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Transmission Type:
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NV4500 5-Speed Manual Transmission (Less Common)
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Transmission Fluid
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Fluid Type Automatic:
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Dexron-III (or equivalent)
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Fluid Capacity Automatic:
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Approx. 11.5 Quarts (10.9 Liters) dry fill; 5.5 Quarts (5.2 Liters) for fluid change
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Fluid Type Manual:
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API GL-4 or GL-5, SAE 75W-90 Synthetic Gear Oil
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Fluid Capacity Manual:
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Approx. 2.6 Quarts (2.5 Liters)
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Transfer Case
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Transfer Case Type:
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NP241C (2 Speed, Electronic Shift Command - BW)
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Transfer Case Fluid:
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Dexron-III (or equivalent)
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Transfer Case Fluid Capacity:
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Approx. 2.0 Quarts (1.9 Liters)
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Dimensions
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Exterior
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Wheelbase:
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130.0 inches (3302 mm)
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Overall Length:
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219.1 inches (5565 mm)
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Overall Width:
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79.9 inches (2030 mm)
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Overall Height:
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75.0 inches (1905 mm)
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Front Track:
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66.5 inches (1689 mm)
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Rear Track:
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66.0 inches (1676 mm)
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Weights
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Curb Weight:
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Approx. 5,300 - 5,600 lbs (2404 - 2540 kg) depending on configuration
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Gross Vehicle Weight Rating Gvw:
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Approx. 7,200 lbs (3266 kg) - 7,500 lbs (3402 kg)
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Max Payload:
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Approx. 1,700 - 2,200 lbs (771 - 998 kg)
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Towing Capacity:
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Up to 7,600 lbs (3447 kg) with proper trailering package
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Cargo
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Cargo Volume Behind First Row:
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Approx. 127.3 cu ft (3605 Liters)
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Cargo Volume Behind Second Row:
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Approx. 40.0 cu ft (1133 Liters)
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Wheels Tires
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Wheel Size:
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16 x 7.0 inches
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Bolt Pattern:
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8 x 6.5 inches (8 x 165.1 mm)
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Tire Size Standard:
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P245/75R16
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000 to 5,000 miles (4,800 to 8,000 km) or 3 to 6 months, or as per onboard oil life monitor if equipped.
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Tire Rotation:
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Every 5,000 to 7,500 miles (8,000 to 12,000 km)
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Air Filter Replacement:
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Every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on inspection.
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Spark Plug Replacement:
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Approx. 60,000 to 100,000 miles (96,500 to 160,000 km) depending on spark plug type (e.g., platinum).
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Fluid Specifications
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Brake Fluid:
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DOT 3
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Power Steering Fluid:
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Dexron-III (or equivalent)
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Windshield Washer Fluid:
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Standard washer fluid (or mixture of washer fluid and distilled water).
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Known Issues
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Common Issues:
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Intake manifold gasket leaks, exhaust manifold leaks, radiator leaks, fuel pump failure, transmission issues (especially 4L60-E), ABS sensor failures, transfer case actuator problems (if electronically controlled).
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Common Issues Detailed:
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The 5.7L Vortec L31 engine is generally robust, but intake manifold gaskets are a known weak point for coolant leaks. Exhaust manifold cracks can lead to ticking noises. The 4L60-E transmission can develop torque converter shudder or shifting issues if not properly maintained.
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