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Manual Coverage
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Systems Covered
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Engine:
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5.0L V8 (305ci), 5.7L V8 (350ci), 7.4L V8 (454ci) Gasoline; 6.5L V8 Turbo Diesel (L65)
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Transmission:
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4-speed Automatic (4L60, 4L80-E); 4-speed Manual (NV4500)
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Drivetrain:
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Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD) Systems
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Suspension:
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Front Independent (IFS), Rear Solid Axle, Shocks, Springs, Bushings
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Steering:
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Power Steering System, Steering Column, Tie Rods, Ball Joints
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Brakes:
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Front Disc, Rear Drum; ABS System (if equipped), Brake Lines, Master Cylinder, Calipers
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Electrical:
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Wiring Diagrams, Fuses, Relays, Lighting, Ignition System, Starting System, Charging System, ECUs
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HVAC:
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Heating, Ventilation, and Air Conditioning (HVAC) System Components and Service
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Body:
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Body Panels, Doors, Glass, Bumpers, Trim, Interior Components
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Fuel System:
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Fuel tank, fuel pump, fuel lines, injectors, fuel filters.
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Cooling System:
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Radiator, water pump, thermostat, heater core, hoses, fan.
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Exhaust System:
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Exhaust manifolds, pipes, catalytic converter, muffler.
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Instrumentation:
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Gauges, warning lights, instrument cluster.
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Procedures Included
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Maintenance:
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Scheduled Maintenance, Oil Changes, Fluid Flushes, Filter Replacements, Tune-ups
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Repair:
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Component Removal and Installation, Rebuild Procedures, Troubleshooting and Diagnosis
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Diagnostics:
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Step-by-step diagnostic procedures for common and complex issues
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Engine Repair:
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Engine teardown, rebuild, internal component replacement (pistons, rings, bearings, valves), timing chain/belt replacement (if applicable).
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Transmission Repair:
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Transmission removal/installation, internal diagnostics, seal and gasket replacement, fluid service.
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Electrical Diagnostics:
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Use of multimeters, oscilloscopes, scan tools (OBD-I), troubleshooting wiring faults, diagnosing sensor issues.
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HVAC Repair:
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Refrigerant handling (with appropriate certifications), component replacement (compressor, condenser, evaporator), leak detection.
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Body Repair:
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Panel alignment, rust repair techniques, door mechanism adjustment, glass replacement.
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Technical Depth
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Depth:
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Comprehensive: Covers routine maintenance to major component overhaul and advanced electrical diagnostics.
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Engine Specifications
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Primary Engine
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Engine Options:
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5.0L (305 cu in) V8; 5.7L (350 cu in) V8; 7.4L (454 cu in) V8; 6.5L (395 cu in) V8 Turbo Diesel
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Performance
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Horsepower Torque 5 0L:
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Approx. 175 hp @ 4000 rpm, 270 lb-ft @ 2400 rpm
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Horsepower Torque 5 7L:
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Approx. 200 hp @ 4000 rpm, 315 lb-ft @ 2400 rpm
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Horsepower Torque 7 4L:
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Approx. 230 hp @ 3600 rpm, 385 lb-ft @ 2000 rpm
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Horsepower Torque 6 5L Td:
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Approx. 190 hp @ 3400 rpm, 385 lb-ft @ 1800 rpm (Turbocharged)
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Fuel System
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Fuel Delivery Gasoline:
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Electronic Fuel Injection (EFI)
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Fuel Delivery Diesel:
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Direct Injection with Turbocharger
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Engine Codes
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Engine Code 5 0L:
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L03
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Engine Code 5 7L:
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L05 (early), LT1 (later, less common for C2500)
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Engine Code 7 4L:
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L19
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Engine Code 6 5L Td:
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L46 (NA), L65 (Turbo)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 3,000-5,000 miles or 3-6 months, depending on 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 for automatic transmissions, depending on load and use.
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Coolant Change:
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Every 30,000-50,000 miles or 2-3 years.
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Fluid Specifications
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Engine Oil Spec:
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API SG/SH, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature).
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Transmission Fluid Auto:
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Dexron-III Automatic Transmission Fluid (ATF)
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Coolant Type:
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Ethylene Glycol based, typically a green coolant (GM specification or equivalent)
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Known Issues
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Common Wear Items:
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Ball joints, tie rod ends, brake pads/rotors, exhaust systems, radiator, water pump, intake manifold gaskets (especially on 5.7L Gen VI).
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Diesel Specific Issues:
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Glow plug system issues, injector pump reliability on early 6.5L TD models, potential for head gasket failure under extreme load.
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