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GMC Sierra 2000-2006 Factory Workshop Service Repair Manual

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$141.00
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🏷️ Basic Information Identification Make: GMC Model: Sierra Generation: Second Generation (GMT800) Codes Chassis Code: GMT800 OBD Ii Codes Covered: Generic Trouble Codes, GM Specific Trouble Codes 👋 Introduction Market Position Product Type: Essential DIY and Professional Automotive Repair Resource Target Audience: GMC Sierra owners, independent repair shops, automotive technicians Competitive Analysis Value Proposition: Provides factory-level diagnostic and repair information, saving costs compared to dealership service. Key Features Content Depth: Vast coverage of all major systems across multiple model years and engine configurations. Visual Aid: Extensive use of high-resolution illustrations, photos, and diagrams to clarify complex procedures. Diagnostic Support: Includes generic and manufacturer-specific trouble codes for effective diagnosis. 📋 Manual Details Coverage Areas Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Specific Models Covered: GMC Sierra 1500, 2500, 2500HD, 3500 Page Count Total Pages: 8000+ Manual Type Type: Factory Workshop Service Repair Manual Language Language: English Format Digital Format: PDF Digital Compatibility: Windows & Mac Computers (all versions), Tablets, Phones (32/64-bit) 📖 Manual Coverage Systems Covered Powertrain Engines: 4.3L V6, 4.8L V8, 5.3L V8, 6.0L V8, 6.6L Duramax Diesel V8 (LB7), 8.1L V8 Powertrain Transmissions: Allison 1000/2000 Series Automatic, NV3500 Manual, NV4500 Manual Chassis Suspension: Front Suspension (Independent), Rear Suspension (Solid Axle), Electronic Suspension, Selectable Ride Control Chassis Brakes: Antilock Brakes (ABS), Hydraulic Brakes, Disc Brakes, Drum Brakes, Parking Brake Chassis Steering: Power Steering, Electronic Steering, Steering Column, Steering Linkage Electrical Engine: Engine Electrical Systems, Alternator, Starter, Ignition System, Fuel Injection Electrical Body: Body Electrical Components, Lighting (Exterior, Fog), Airbags, HVAC, Instrument Panels, Entertainment Systems, Garage Door Opener, Horns, Wiper/Washer Systems, Cruise Control Body Exterior: Body Front End, Bumpers, Doors, Doors/Windows Body Interior: Cabin Air Filter, Defoggers, Heater, HVAC, Instrument Panels, Steering Column Drivetrain: Drive Axles (Front, Rear Full Floating), Dana Full Floating Axle, Eaton Locking Differential, Transfer Case, Driveshaft, Quadrasteer (4-Wheel Steering) Procedures Included Diagnostics: Troubleshooting, Diagnostic Trouble Codes (DTCs), Component Testing Maintenance: Scheduled Maintenance, Fluid Changes, Filter Replacements, Belt Routing, Lubrication Repair Rebuild: Engine Overhaul, Transmission Overhaul (Automatic & Manual), Differential Service, Brake System Repair, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair Installation Removal: Engine Removal/Installation, Transmission Removal/Installation, Axle Removal/Installation, Major Component Replacement Electrical Procedures: Wiring Diagrams, Component Location, Fuses, Computer Relearn Procedures, Programming Chassis Procedures: Wheel Alignment, Drive Belt Routing, Suspension Adjustments, Brake Bleeding Engine Performance Tuning: Engine performance diagnostics, fuel system testing, ignition timing adjustments (where applicable). HVAC Procedures: HVAC system diagnostics, repair, and recharging procedures, including manual and automatic HVAC controls. Wheel Drive Systems: Coverage for 2WD and 4WD systems, including transfer case operation and service. Specific mention of Eaton Locking Axle and Dana Full Floating Axle suggests detailed coverage for heavy-duty models. Tire Pressure Monitoring: TPMS system operation and diagnosis (for 2004-2006 models). Vacuum Diagrams: Detailed vacuum routing diagrams for proper system function and troubleshooting. Technical Depth Depth: Comprehensive Workshop Level - Covers everything from basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. Includes detailed schematics and torque specifications. 📊 Manual Specifications File Format Quality: Hi Resolution Illustrations, Photos, and Diagrams Usability: Printable pages directly from CD/download, entire manual can be copied to hard drive, searchable text (assumed for PDF format) Print Quality Print Readability: Designed for clarity of instructions and diagrams for workshop use. Binding Type Binding Type: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 2000 2003 Base: 4.3L Vortec 4300 (L35) V6 Engine 2000 2003 Optional Gas: 4.8L Vortec 4800 (LR4) V8, 5.3L Vortec 5300 (LM7) V8, 6.0L Vortec 6000 (LQ4) V8 Engine 2000 2003 Optional Diesel: 6.6L Duramax (LB7) V8 Turbo Diesel Engine 2000 2003 Large Displacement: 8.1L Vortec 8100 (L18) V8 Engine 2004 2006 Base: 4.3L Vortec 4300 (L35) V6 Engine 2004 2006 Optional: 4.8L Vortec 4800 (LR4) V8, 5.3L Vortec 5300 (LM7/LH6) V8, 6.0L Vortec 6000 (LQ4/LQ9) V8 Performance Horsepower Torque Typical: 4.3L V6: ~200 hp / 260 lb-ft; 5.3L V8: ~285-295 hp / 320-330 lb-ft; 6.6L Duramax: ~300 hp / 520 lb-ft (LB7) Fuel System Fuel Delivery: Multi-port Fuel Injection (MPI) for gasoline engines, Common Rail Direct Injection (CRDI) for Duramax diesel. Ignition System: Distributorless Ignition System (DIS) or Coil-Near-Plug (CNP) depending on engine and year. 🔧 Transmission Standard Transmission Standard Light Duty: NV3500 5-speed Manual Transmission (common on 1500 models) Transmission Standard Heavy Duty: NV4500 5-speed Manual Transmission (common on 2500HD/3500 models) Optional Transmission Optional Automatic: 4L60E 4-speed Automatic (1500/light 2500), 4L80E 4-speed Automatic (heavy-duty 2500/3500), Allison 1000 (2500HD/3500 with Duramax/8.1L) Features Transmission Features: Overdrive gears, Tow/Haul mode (on automatics), Electronic controls for shifting and diagnostics. Fluid Specifications Automatic Transmission Fluid: Dexron III/VI (for 4L60E/4L80E), TES 295 (for Allison 1000/2000) Manual Transmission Fluid: GL-4 or GL-5 Gear Oil (specific weight depends on transmission model, consult manual for precise spec) 📐 Dimensions Exterior Wheelbase Options: Short Bed,...
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GMC Sierra 2000-2006 Factory Workshop Service Repair ManualGMC Sierra 2000-2006 Factory Workshop Service Repair ManualGMC Sierra 2000-2006 Factory Workshop Service Repair ManualGMC Sierra 2000-2006 Factory Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
GMC
Model:
Sierra
Generation:
Second Generation (GMT800)
Codes
Chassis Code:
GMT800
OBD Ii Codes Covered:
Generic Trouble Codes, GM Specific Trouble Codes
👋 Introduction
Market Position
Product Type:
Essential DIY and Professional Automotive Repair Resource
Target Audience:
GMC Sierra owners, independent repair shops, automotive technicians
Competitive Analysis
Value Proposition:
Provides factory-level diagnostic and repair information, saving costs compared to dealership service.
Key Features
Content Depth:
Vast coverage of all major systems across multiple model years and engine configurations.
Visual Aid:
Extensive use of high-resolution illustrations, photos, and diagrams to clarify complex procedures.
Diagnostic Support:
Includes generic and manufacturer-specific trouble codes for effective diagnosis.
📋 Manual Details
Coverage Areas
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005, 2006
Specific Models Covered:
GMC Sierra 1500, 2500, 2500HD, 3500
Page Count
Total Pages:
8000+
Manual Type
Type:
Factory Workshop Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
Digital Compatibility:
Windows & Mac Computers (all versions), Tablets, Phones (32/64-bit)
📖 Manual Coverage
Systems Covered
Powertrain Engines:
4.3L V6, 4.8L V8, 5.3L V8, 6.0L V8, 6.6L Duramax Diesel V8 (LB7), 8.1L V8
Powertrain Transmissions:
Allison 1000/2000 Series Automatic, NV3500 Manual, NV4500 Manual
Chassis Suspension:
Front Suspension (Independent), Rear Suspension (Solid Axle), Electronic Suspension, Selectable Ride Control
Chassis Brakes:
Antilock Brakes (ABS), Hydraulic Brakes, Disc Brakes, Drum Brakes, Parking Brake
Chassis Steering:
Power Steering, Electronic Steering, Steering Column, Steering Linkage
Electrical Engine:
Engine Electrical Systems, Alternator, Starter, Ignition System, Fuel Injection
Electrical Body:
Body Electrical Components, Lighting (Exterior, Fog), Airbags, HVAC, Instrument Panels, Entertainment Systems, Garage Door Opener, Horns, Wiper/Washer Systems, Cruise Control
Body Exterior:
Body Front End, Bumpers, Doors, Doors/Windows
Body Interior:
Cabin Air Filter, Defoggers, Heater, HVAC, Instrument Panels, Steering Column
Drivetrain:
Drive Axles (Front, Rear Full Floating), Dana Full Floating Axle, Eaton Locking Differential, Transfer Case, Driveshaft, Quadrasteer (4-Wheel Steering)
Procedures Included
Diagnostics:
Troubleshooting, Diagnostic Trouble Codes (DTCs), Component Testing
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Belt Routing, Lubrication
Repair Rebuild:
Engine Overhaul, Transmission Overhaul (Automatic & Manual), Differential Service, Brake System Repair, Suspension Component Replacement, Electrical Component Repair, Body Panel Repair
Installation Removal:
Engine Removal/Installation, Transmission Removal/Installation, Axle Removal/Installation, Major Component Replacement
Electrical Procedures:
Wiring Diagrams, Component Location, Fuses, Computer Relearn Procedures, Programming
Chassis Procedures:
Wheel Alignment, Drive Belt Routing, Suspension Adjustments, Brake Bleeding
Engine Performance Tuning:
Engine performance diagnostics, fuel system testing, ignition timing adjustments (where applicable).
HVAC Procedures:
HVAC system diagnostics, repair, and recharging procedures, including manual and automatic HVAC controls.
Wheel Drive Systems:
Coverage for 2WD and 4WD systems, including transfer case operation and service. Specific mention of Eaton Locking Axle and Dana Full Floating Axle suggests detailed coverage for heavy-duty models.
Tire Pressure Monitoring:
TPMS system operation and diagnosis (for 2004-2006 models).
Vacuum Diagrams:
Detailed vacuum routing diagrams for proper system function and troubleshooting.
Technical Depth
Depth:
Comprehensive Workshop Level - Covers everything from basic maintenance to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. Includes detailed schematics and torque specifications.
📊 Manual Specifications
File Format
Quality:
Hi Resolution Illustrations, Photos, and Diagrams
Usability:
Printable pages directly from CD/download, entire manual can be copied to hard drive, searchable text (assumed for PDF format)
Print Quality
Print Readability:
Designed for clarity of instructions and diagrams for workshop use.
Binding Type
Binding Type:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 2000 2003 Base:
4.3L Vortec 4300 (L35) V6
Engine 2000 2003 Optional Gas:
4.8L Vortec 4800 (LR4) V8, 5.3L Vortec 5300 (LM7) V8, 6.0L Vortec 6000 (LQ4) V8
Engine 2000 2003 Optional Diesel:
6.6L Duramax (LB7) V8 Turbo Diesel
Engine 2000 2003 Large Displacement:
8.1L Vortec 8100 (L18) V8
Engine 2004 2006 Base:
4.3L Vortec 4300 (L35) V6
Engine 2004 2006 Optional:
4.8L Vortec 4800 (LR4) V8, 5.3L Vortec 5300 (LM7/LH6) V8, 6.0L Vortec 6000 (LQ4/LQ9) V8
Performance
Horsepower Torque Typical:
4.3L V6: ~200 hp / 260 lb-ft; 5.3L V8: ~285-295 hp / 320-330 lb-ft; 6.6L Duramax: ~300 hp / 520 lb-ft (LB7)
Fuel System
Fuel Delivery:
Multi-port Fuel Injection (MPI) for gasoline engines, Common Rail Direct Injection (CRDI) for Duramax diesel.
Ignition System:
Distributorless Ignition System (DIS) or Coil-Near-Plug (CNP) depending on engine and year.
🔧 Transmission
Standard
Transmission Standard Light Duty:
NV3500 5-speed Manual Transmission (common on 1500 models)
Transmission Standard Heavy Duty:
NV4500 5-speed Manual Transmission (common on 2500HD/3500 models)
Optional
Transmission Optional Automatic:
4L60E 4-speed Automatic (1500/light 2500), 4L80E 4-speed Automatic (heavy-duty 2500/3500), Allison 1000 (2500HD/3500 with Duramax/8.1L)
Features
Transmission Features:
Overdrive gears, Tow/Haul mode (on automatics), Electronic controls for shifting and diagnostics.
Fluid Specifications
Automatic Transmission Fluid:
Dexron III/VI (for 4L60E/4L80E), TES 295 (for Allison 1000/2000)
Manual Transmission Fluid:
GL-4 or GL-5 Gear Oil (specific weight depends on transmission model, consult manual for precise spec)
📐 Dimensions
Exterior
Wheelbase Options:
Short Bed, Long Bed (approx. 130-150 inches depending on configuration)
Weights
Gvwr Range:
Ranges from ~6000 lbs for 1500 models up to 12,000+ lbs for 3500HD models.
🛡️ Safety Features
Ratings
NHTSA Ratings General:
Varies by year and configuration, generally good frontal impact ratings for the era.
Active Features
Active Safety Features:
Antilock Braking System (ABS), available Traction Control System (TCS) on some models.
Passive Features
Passive Safety Features:
Driver and Passenger Frontal Airbags, available Side Curtain Airbags on later models, strong safety cage construction.
💡 Technology Features
Infotainment
Infotainment Options:
Factory AM/FM/CD players, optional Bose premium audio, available DVD navigation systems on higher trims.
Driver Assistance
Driver Assistance Features:
Cruise control, optional parking assist sensors on some models.
Connectivity
Connectivity Features:
OnStar system availability on equipped models, basic power outlets.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (consult manual for specific recommendation).
Transmission Fluid Change:
Recommended every 30,000-100,000 miles for automatics, and every 50,000-100,000 miles for manuals, depending on usage and fluid type.
Coolant Flush Interval:
Typically every 30,000-100,000 miles or 2-5 years, depending on coolant type.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 synthetic or synthetic blend for most gasoline engines, SAE 15W-40 diesel oil for Duramax (consult specific engine requirements).
Coolant Specification:
Dex-Cool (orange) for most gasoline engines, traditional green coolant may be used in some Duramax applications (confirm with manual).
Known Issues
Common Duramax Lb7 Issues:
Injection control module (ICM) failure, injector issues (especially early models), glow plug failures.
Common Gasoline Engine Issues:
Intake manifold gaskets (LS-based V8s), oil pressure sensor failures, exhaust manifold leaks.
Common Transmission Issues:
4L60E torque converter shudder or clutch pack failure, 4L80E planetary gear wear, Allison internal wear with high mileage/heavy use.
Common Chassis Issues:
Front hub bearing failure, ball joint wear, steering linkage wear, rust on frames and body panels (depending on climate).
📚 Vehicle History
Brand Heritage
Gmc Truck Legacy:
GMC has a long-standing reputation for building durable and capable trucks, continuing the 'Professional Grade' slogan.
Model Evolution
Gmt800 Introduction:
The GMT800 platform represented a significant redesign for the Silverado/Sierra lineup, introducing more aerodynamic styling, improved interiors, and the introduction of the Duramax diesel engine.
Mid Cycle Refresh:
A significant refresh occurred for the 2003 model year, with further updates and option package changes for 2004, including improved interior ergonomics and powertrain management.
Production
Manufacturing Locations:
Primary assembly plants included Fort Wayne, Indiana; Pontiac, Michigan; and Oshawa, Ontario.
🏆 Awards & Recognition
Recognitions
Popular Mechanics Editor Choice:
Often recognized for its towing capability and robust construction in period reviews.
Motor Trend Truck Of The Year:
The GMT800 platform trucks (Silverado/Sierra) were strong contenders and often won or were nominated for Truck of the Year awards during their production run.
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