Manual Coverage
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Systems Covered
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Engine:
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Yes (Detailed diagnostics, repair, overhaul)
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Transmission:
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Yes (Automatic and Manual, including internal components and diagnostics)
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Drivetrain:
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Yes (Front axle, rear axle, driveshafts, differentials, 4WD systems)
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Suspension:
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Yes (Front and rear suspension, steering components, alignment)
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Brakes:
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Yes (Hydraulic system, ABS, parking brake, component replacement)
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Electrical:
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Yes (Wiring diagrams, component testing, module diagnostics, lighting, starting and charging)
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Heating Air Conditioning:
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Yes (HVAC system operation, diagnostics, refrigerant handling)
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Body And Frame:
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Yes (Body panel repair, door mechanisms, glass, frame inspection)
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Fuel System:
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Yes (Fuel pumps, injectors, lines, evaporative emissions control)
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Exhaust System:
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Yes (Catalytic converters, mufflers, pipes, hangers)
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Cooling System:
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Yes (Radiator, thermostat, water pump, fans, coolant specifications)
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Steering:
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Yes (Power steering system, steering gear, linkage)
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Procedures Included
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Maintenance:
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Yes (Oil changes, filter replacements, fluid checks, tune-ups)
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Troubleshooting:
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Yes (Diagnostic flowcharts, symptom-based repair guides)
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Repair:
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Yes (Step-by-step instructions for component replacement and repair)
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Overhaul:
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Yes (Detailed procedures for engine and transmission rebuilds)
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Diagnostics:
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Yes (OBD-II codes, sensor testing, actuator testing, module programming)
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Specifications:
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Yes (Torque values, clearances, pressures, electrical parameters)
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Technical Depth
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Depth:
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OE Level (Factory-derived, comprehensive)
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Engine Specifications
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Primary Engine
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Engine Options:
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Likely includes 6.0L V8 Vortec (LQ4/LQ9) and potentially 8.1L V8 Vortec (Vortec 496) based on the 3500 designation.
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Performance
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Torque Specs:
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Detailed torque specifications for all engine fasteners and components.
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Fuel System
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Fuel Delivery:
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Electronic Fuel Injection (EFI)
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Engine Mechanical
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Cylinder Heads:
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Detailed procedures for removal, inspection, and installation of cylinder heads.
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Pistons Rings:
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Piston and ring installation specifications and clearances.
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Crankshaft Bearings:
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Crankshaft and connecting rod bearing inspection and clearance procedures.
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Engine Management
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Ignition System:
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Ignition timing, coil pack testing, spark plug specifications.
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Dimensions
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Exterior
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Overall Length:
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Varies by cab and bed configuration (e.g., approximately 237-259 inches for standard cabs).
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Overall Width:
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Approximately 79.7 inches (excluding mirrors).
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Overall Height:
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Approximately 77.2-77.9 inches (depending on configuration).
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Weights
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Curb Weight:
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Ranges significantly based on configuration (e.g., ~5,500-6,500 lbs for standard cab 2WD).
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Gross Vehicle Weight Rating Gvwr:
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Typically 10,000 lbs to 12,000 lbs for 3500 models.
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Towing Capacity:
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Varies widely, but designed for substantial towing (e.g., up to 10,500 lbs conventional, higher with fifth-wheel/gooseneck).
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for exact specifications).
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Transmission Fluid Change:
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Recommended every 50,000-100,000 miles for automatic transmissions, depending on use (refer to manual).
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Fluid Specifications
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Engine Oil:
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Likely SAE 5W-30 synthetic blend or full synthetic (API certified) for most gasoline engines.
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Coolant:
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50/50 mix of distilled water and Dex-Cool (orange) extended life coolant.
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Brake Fluid:
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DOT 3.
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Known Issues
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Common Problems:
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Potential for worn ball joints and tie rod ends, exhaust manifold leaks (Vortec V8s), fuel injector issues, and transmission cooler line leaks.
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Filters
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Oil Filter Part Number:
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Examples: ACDelco PF1218, WIX 57712 (specific to engine application, consult manual for definitive part number).
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Air Filter Part Number:
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Examples: ACDelco A2032C, WIX 49532 (specific to engine application, consult manual for definitive part number).
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