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Chevrolet Chevy Avalanche 2002-2006 Service Repair Workshop Manual Download PDF

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🏷️ Basic Information Identification Make: Chevrolet Model: Avalanche Model Generation: First Generation Codes Platform Code: GMT825 👋 Introduction Market Position Segment: Full-size Sport Utility Truck (SUT) Competitive Analysis Competitors: Ford...
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Chevrolet Chevy Avalanche 2002-2006 Service Repair Workshop Manual Download PDF
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
Avalanche
Model Generation:
First Generation
Codes
Platform Code:
GMT825
👋 Introduction
Market Position
Segment:
Full-size Sport Utility Truck (SUT)
Competitive Analysis
Competitors:
Ford Explorer Sport Trac, Honda Ridgeline (though the Ridgeline is a unibody crossover, it competes in a similar utility space).
Key Features
Unique Selling Proposition:
The Avalanche's distinctive Midgate feature, allowing the truck bed to be extended into the cabin by lowering the rear seats and the midgate, offering unparalleled cargo versatility for its time.
Target Audience:
Buyers seeking the utility of a pickup truck combined with the passenger comfort and capability of an SUV, often for recreational activities, hauling, or diverse lifestyle needs.
📋 Manual Details
Coverage Areas
Years Covered:
2002, 2003, 2004, 2005, 2006
Page Count
Estimated Pages:
1500-2500 (typical for this era GM service manuals)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, cooling, fuel, exhaust, ignition, starting, charging, powertrain control module (PCM) diagnostics.
Drivetrain:
Front-wheel drive (FWD), rear-wheel drive (RWD), transfer case (4WD models), drive shafts, axles, differentials, wheels, tires.
Suspension Steering:
Front independent suspension (IFS), rear solid axle, steering system, power steering, suspension components, alignment specifications.
Brakes:
Front disc brakes, rear disc brakes (often with integrated parking brake), ABS (Anti-lock Braking System), hydraulic system, service and repair procedures.
Electrical:
12-volt electrical system, battery, charging system, starting system, lighting, instruments, gauges, power accessories, Body Control Module (BCM), Powertrain Control Module (PCM), diagnostics.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant handling, components, diagnostics, and repair.
Body Chassis:
Body construction, exterior trim, interior trim, doors, windows, seats, tailgate, Midgate system, frame and chassis components, corrosion protection.
Procedures Included
Maintenance:
Oil change, fluid checks and top-offs, filter replacement (oil, air, fuel), spark plug replacement, tire rotation, battery maintenance, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, electrical diagnostics using wiring diagrams, engine performance issues, transmission problems, HVAC system faults.
Repair:
Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, starter replacement, alternator replacement, fuel pump replacement, body panel repair, door lock actuator replacement.
Diagnostics:
OBD-II (On-Board Diagnostics II) system, diagnostic trouble codes (DTCs), wiring diagrams for pinpoint testing, component testing procedures.
Technical Depth
Depth:
Comprehensive, covering everything from routine maintenance and minor repairs to major overhauls and complex diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printability:
Printable, allowing users to print individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Operating Systems:
Compatible with Windows and macOS operating systems.
Access
License:
Lifetime access, no expiry dates or renewal fees.
⚙️ Engine Specifications
Primary Engine
Engine Code And Description 1:
L31 - 5.7L Vortec 350 Small Block V8 (Early production 2002 models)
Engine Displacement 1:
5.7 Liters (350 cubic inches)
Engine Horsepower 1:
Approx. 255 hp @ 4600 rpm
Engine Torque 1:
Approx. 330 lb-ft @ 2800 rpm
Engine Code And Description 2:
LM7 - 5.3L Vortec 5300 Small Block V8 (Standard on most models)
Engine Displacement 2:
5.3 Liters (327 cubic inches)
Engine Horsepower 2:
Approx. 285-295 hp @ 5200 rpm (depending on model year and specific tune)
Engine Torque 2:
Approx. 325-335 lb-ft @ 4000 rpm (depending on model year and specific tune)
Performance
Engine Configuration:
V8 (OHV)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (Regular 87 octane recommended)
Engine Management
Ignition System:
Distributorless Ignition System (DIS) with coil-on-plug (COP) or coil packs.
Engine Control Unit:
Powertrain Control Module (PCM)
🔧 Transmission
Standard
Transmission Type Std:
4-speed automatic (4L60-E)
Optional
Transmission Type Opt:
N/A (4-speed automatic was standard for all model years and configurations)
Features
Transmission Features:
Electronic overdrive, torque converter clutch (TCC) for improved highway fuel economy.
Drivetrain Options
Drivetrain:
Available in Rear-Wheel Drive (RWD) and All-Wheel Drive (AWD) or 4-Wheel Drive (4WD) depending on trim and year.
📐 Dimensions
Exterior
Wheelbase:
130.0 inches (3302 mm)
Overall Length:
221.4 inches (5624 mm)
Overall Width:
79.7 inches (2024 mm)
Overall Height:
75.5 inches (1918 mm)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 46.0 cubic feet (with Midgate closed)
Cargo Volume Max With Midgate Open:
Approx. 138.7 cubic feet (with rear seats folded and Midgate lowered)
Weights
Curb Weight Rwd:
Approx. 5,500 - 5,800 lbs (2495 - 2630 kg)
Curb Weight AWD:
Approx. 5,700 - 6,000 lbs (2585 - 2722 kg)
Max Towing Capacity:
Up to 8,500 lbs (3856 kg) with proper equipment and configuration
Payload Capacity:
Approx. 1,300 - 1,700 lbs (590 - 771 kg)
🛡️ Safety Features
Ratings
NHTSA Rollover Rating Rwd:
4 out of 5 stars (for 2WD models)
NHTSA Rollover Rating AWD:
4 out of 5 stars (for 4WD models)
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Available Traction Control System (TCS).
Passive Features
Airbags:
Standard front airbags for driver and passenger. Optional side-impact airbags were available on some trims.
Seatbelts:
Three-point seatbelts for all seating positions, with pretensioners and load limiters for front occupants.
💡 Technology Features
Infotainment
Audio System:
Various factory-installed audio systems, including AM/FM stereo with CD player, cassette player, and available premium sound systems with rear audio controls.
Navigation:
Optional factory navigation system was available on higher trim levels during this period.
Driver Assistance
Cruise Control:
Standard cruise control.
Parking Assist:
Rear parking assist sensors were an available option.
Connectivity
Onstar:
OnStar in-vehicle safety and communication system was an available option.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-7,500 miles (5,000-12,000 km) or 6 months, depending on driving conditions and oil type (refer to specific model year manual for exact recommendation).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Typically 60,000-100,000 miles (96,000-160,000 km) for platinum or iridium plugs, depending on the specific plug type installed.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 synthetic blend or synthetic oil meeting GM specification GM6094M.
Engine Oil Capacity:
Approx. 5.5 - 6.0 quarts (5.2 - 5.7 liters) with filter, depending on engine.
Transmission Fluid Type:
Dexron III/VI Automatic Transmission Fluid (ATF).
Coolant Type:
GM P/N 1052826 or equivalent (blue colored, 50/50 mix of antifreeze and deionized water).
Brake Fluid Type:
DOT 3 or DOT 4 automotive brake fluid.
Known Issues
Common Problem 1:
Intermediate Steering Shaft (ISS) lubrication issues leading to clunking or looseness.
Common Problem 2:
Active Fuel Management (AFM) related issues, such as oil consumption or lifter noise (primarily on later models or 5.3L engines with AFM, though less common in the 2002-2006 range for early 5.3Ls).
Common Problem 3:
Cooling system leaks, particularly radiator and heater core issues.
Common Problem 4:
Body module (BCM) or electrical gremlins, often intermittent.
📚 Vehicle History
Brand Heritage
Brand Strengths:
Chevrolet, a division of General Motors, has a long-standing reputation for building durable and capable trucks and SUVs.
Model Evolution
Generation Start Year:
2002
Generation End Year:
2006
Platform Basis:
Based on GM's GMT800 platform, shared with Chevrolet Silverado, Tahoe, Suburban, and GMC Sierra, Yukon, Yukon XL.
Major Updates Within Generation:
Minor styling updates and feature additions occurred throughout the generation, including potential engine power increases and revised option packages.
Production
Manufacturing Location:
Janesville, Wisconsin, USA.
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