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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Complete Engine Overhaul, Diagnostics, Timing, Valves, Pistons, Crankshaft, etc.
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Engine Electrical:
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Ignition System, Starting System, Charging System, ECU Diagnosis, Sensors
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Fuel System:
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Fuel Injection (TBI/MPI), Fuel Pump, Fuel Filter, Injector Testing, Evaporative Emission Control (EVAP)
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Transmission:
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Automatic and Manual Transmission Repair, Overhaul, Fluid Service, Shift Linkage
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Drivetrain:
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Transfer Case (4WD models), Driveshafts, U-Joints, Axles, Differential Service
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Brakes:
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Hydraulic System, ABS Diagnosis, Rotor/Pad Replacement, Caliper Service, Drum Brakes (Rear)
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Suspension:
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Front and Rear Suspension Components, Springs, Shocks/Struts, Control Arms, Bushings, Ball Joints, Steering Knuckles
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Steering:
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Power Steering System, Steering Gearbox/Rack and Pinion, Tie Rods, Steering Column
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Electrical System:
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Wiring Diagrams, Fuses, Relays, Lighting, Power Windows, Power Locks, Horn, Wiper System
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HVAC:
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Air Conditioning System Service, Heater Core, Blower Motor, Climate Control Module
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Body:
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Body Panel Repair, Doors, Hood, Tailgate, Interior Trim, Glass Replacement
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Chassis:
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Frame Inspection and Repair, Body Mounts
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Procedures Included
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Maintenance Procedures:
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Oil Change, Filter Replacement, Fluid Level Checks, Lubrication, Tire Rotation
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Repair Procedures:
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Component Replacement (Alternator, Starter, Water Pump, Radiator), Brake Pad/Shoe Replacement, Clutch Service
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Diagnostic Procedures:
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Troubleshooting Charts, Symptom Analysis, On-Board Diagnostics (OBD-I), Scan Tool Usage
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Overhaul Procedures:
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Engine Rebuild, Transmission Rebuild, Differential Rebuild
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Installation Procedures:
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Accessory Installation, Component Upgrades
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Technical Depth
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Depth:
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Comprehensive (from basic maintenance to complete engine/transmission overhauls and advanced diagnostics)
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Engine Specifications
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Primary Engine
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Engine 1:
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5.7L V8 Vortec OHV (L31)
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Engine 2:
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7.4L V8 Vortec OHV (L29)
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Engine 3:
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6.5L V8 Turbo Diesel (LP2)
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Performance
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5.7L V8 Vortec Horsepower:
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255 hp @ 4600 rpm (approx.)
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5.7L V8 Vortec Torque:
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330 lb-ft @ 2800 rpm (approx.)
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7.4L V8 Vortec Horsepower:
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290 hp @ 4000 rpm (approx.)
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7.4L V8 Vortec Torque:
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410 lb-ft @ 3200 rpm (approx.)
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6.5L V8 Turbo Diesel Horsepower:
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190 hp @ 3400 rpm (approx.)
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6.5L V8 Turbo Diesel Torque:
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430 lb-ft @ 1800 rpm (approx.)
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Fuel System
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Fuel Delivery Gasoline:
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Multi-Point Fuel Injection (MPI) or Throttle Body Injection (TBI) depending on specific engine variant
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Fuel Delivery Diesel:
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Direct Injection with Electronic Control Unit (ECU)
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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 - 7,500 miles (5,000 - 12,000 km) or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendations)
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Transmission Fluid Change:
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Every 30,000 - 60,000 miles (48,000 - 96,000 km) for automatic transmissions, depending on driving conditions. Manual transmissions have less frequent recommendations.
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Engine Coolant Change:
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Initial 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) or 5 years (check manual for specific coolant type and capacity)
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Fluid Specifications
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Engine Oil Gasoline:
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API SG or SH, SAE 5W-30 or 10W-30 (refer to manual for temperature-dependent viscosity)
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Engine Oil Diesel:
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API CF-4, CG-4, or CH-4, SAE 15W-40 (refer to manual for specific viscosity and service classification)
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Transmission Fluid 4L80-E:
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Dexron-III ATF (or equivalent)
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Transmission Fluid Nv4500:
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Manual Transmission Fluid (MTF), SAE 75W-90 (API GL-4 or GL-5)
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Coolant:
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Ethylene Glycol based coolant, typically a 50/50 mix with distilled water
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Known Issues
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Common Issue Tdi Rotary Pump:
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Wear in the Stanadyne DB2 rotary injection pump on 6.5L Diesel engines can lead to starting issues and performance problems.
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Common Issue Injector Lines Diesel:
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Corrosion and leaks in the injector lines of the 6.5L Diesel can occur.
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Common Issue Intake Manifold Gaskets:
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Leaking intake manifold gaskets can be an issue on some Vortec V8 engines, particularly the 5.7L.
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Common Issue Oil Cooler Lines:
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Leaking oil cooler lines on automatic transmissions are a known concern.
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Common Issue Body Rust:
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Rust on fenders, rocker panels, and frame rails is a common issue for trucks of this era, especially in areas with salt usage.
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