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2012 GMC Sierra 2500 HD Service & Repair Manual

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🏷️ Basic Information Identification Make: GMC Model: Sierra 2500 HD Year: 2012 Generation Generation Code: GMT900 Generation Years: 2007-2013 👋 Introduction Market Position Positioning: Heavy-duty truck segment, designed for commercial and demanding towing/hauling applications. Competitive Analysis Competitors: Ford F-250 Super Duty, Ram 2500, Chevrolet Silverado 2500 HD (sister model). Key Features Manual Advantage: Officially licensed, OE-derived information from RepairSurge, providing accurate and up-to-date data for DIY and professional use. Vehicle Advantage: Robust construction, powerful engine options for heavy-duty tasks, towing and payload capacity. Manual Value Proposition Value: Cost-effective alternative to dealership service, empowering owners to maintain and repair their vehicle. 📋 Manual Details Coverage Areas Coverage Scope: Complete Service and Repair Page Count Estimated Page Count: Thousands (digital format, comprehensive) Manual Type Type: Online Service and Repair Manual Software Language Language: English Format Format: Web-based/Online Access (via browser) 📖 Manual Coverage Systems Covered Engine Mechanical: All engine assemblies, including internal components, lubrication, cooling, and exhaust systems. Engine Performance: Fuel delivery, ignition, emissions control, starting and charging systems. Transmission Drivetrain: Manual and automatic transmission systems, transfer case, drive axles, propeller shafts, and differentials. Suspension Steering: Front and rear suspension components, steering gear, power steering system, wheel alignment. Brakes: Hydraulic brake systems (front and rear discs/drums), ABS, parking brake, hydraulic control unit. Electrical System: Battery, starting, charging, lighting, instruments, warning indicators, body control module (BCM). HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system components and operation. Body Interior: Body panels, doors, windows, seats, interior trim, glass, and related components. Chassis: Frame construction, collision repair, underbody components. Diagnostic Information: Diagnostic Trouble Codes (DTCs), symptom-based diagnostics, troubleshooting flowcharts. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement. Repair Procedures: Component removal, disassembly, inspection, repair, reassembly, and installation for all covered systems. Troubleshooting Guides: Step-by-step diagnostic procedures for identifying and resolving common and uncommon vehicle faults. Wiring Diagrams: Detailed electrical wiring diagrams for all vehicle circuits. Specifications Data: Torque specifications, clearances, fluid capacities, pressure readings, and other critical data. Technical Depth Depth: Comprehensive, from routine maintenance to major component overhauls and diagnostics. Manual Depth Detail Diagnostic Procedures: Includes detailed symptom-based troubleshooting, diagnostic trouble code (DTC) explanations, and repair procedures for diagnosing electrical and mechanical faults. 📊 Manual Specifications File Format Digital Requirements: Requires an active internet connection and a compatible web browser on any PC, laptop, smartphone, or tablet. Print Quality Print Ability: While digital, sections can typically be printed for offline reference (quality dependent on user printer). Binding Type Binding: N/A (Digital Online Access) Paper Type Paper Type: N/A (Digital Online Access) Access Duration Subscription Period: 1 Year (with discounts available for renewal) ⚙️ Engine Specifications Primary Engine Gas Engine Code Gas: L96 (Vortec 6.0L V8 SFI FlexFuel) Displacement Gas: 5967 cc (364 cubic inches) Horsepower Gas: 360 hp @ 5400 rpm Torque Gas: 380 lb-ft @ 4200 rpm Fuel System Gas: Sequential Fuel Injection (SFI), FlexFuel capable. Block Material Gas: Cast Iron Cylinder Head Gas: Aluminum Primary Engine Diesel Engine Code Diesel: V8DOHC (Duramax 6.6L Turbo Diesel V8 - RPO LML) Displacement Diesel: 6599 cc (403 cubic inches) Horsepower Diesel: 397 hp @ 3000 rpm Torque Diesel: 765 lb-ft @ 1600 rpm Fuel System Diesel: High-pressure Common Rail Direct Injection with Turbocharger. Block Material Diesel: Cast Iron Cylinder Head Diesel: Aluminum Engine Technology Diesel: Variable Geometry Turbocharger (VGT), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR) system (for LML). 🔧 Transmission Standard Transmission Type Standard: Allison 1000 6-speed automatic (with Diesel engines) Optional Transmission Type Optional: ZF S6-650 6-speed manual (less common, typically with gas engine) Features Transmission Features: Heavy-duty construction, Tow/Haul mode, grade braking, electronic transmission range selection (ETRS). 📐 Dimensions Exterior Wheelbase Standard: 143.5 inches (3645 mm) (Regular Cab, Long Bed) Wheelbase Extended: 153.7 inches (3904 mm) (Extended/Crew Cab, Standard Bed) Wheelbase Longest: 167.5 inches (4255 mm) (Crew Cab, Long Bed) Weights Curb Weight Approx: 6,300 - 7,500 lbs (2858 - 3402 kg) (Varies by configuration) Gvwr Gross Vehicle Weight Rating: Up to 9,200 lbs (4173 kg) or 10,000 lbs (4536 kg) depending on configuration. Gcwr Gross Combined Weight Rating: Up to 22,000 lbs (9979 kg) for diesel models. 🛡️ Safety Features Ratings NHTSA Rollover Rating: 4 out of 5 stars (typical for this generation, check specific test data). Active Features Active Safety: StabiliTrak (Traction Control and Electronic Stability Control), Trailer Sway Control, Anti-lock Braking System (ABS). Passive Features Passive Safety: Frontal airbags, Side-impact airbags (optional/standard on some trims), Seatbelt pretensioners. 💡 Technology Features Infotainment Infotainment System: Available touch-screen infotainment systems with navigation, Bluetooth connectivity, and SiriusXM Satellite Radio. Driver Assistance Driver Assist Features: Integrated trailer brake controller (optional), rearview camera (optional). Connectivity Connectivity Options: OnStar capabilities (subscription-based), USB/Auxiliary input jacks. 🔧 Maintenance Service Intervals Oil Change Interval: 5,000 miles (8,000 km) for gasoline, 7,500 miles (12,000 km) for diesel, or...
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2012 GMC Sierra 2500 HD Service & Repair Manual
🏷️ Basic Information
Identification
Make:
GMC
Model:
Sierra 2500 HD
Year:
2012
Generation
Generation Code:
GMT900
Generation Years:
2007-2013
👋 Introduction
Market Position
Positioning:
Heavy-duty truck segment, designed for commercial and demanding towing/hauling applications.
Competitive Analysis
Competitors:
Ford F-250 Super Duty, Ram 2500, Chevrolet Silverado 2500 HD (sister model).
Key Features
Manual Advantage:
Officially licensed, OE-derived information from RepairSurge, providing accurate and up-to-date data for DIY and professional use.
Vehicle Advantage:
Robust construction, powerful engine options for heavy-duty tasks, towing and payload capacity.
Manual Value Proposition
Value:
Cost-effective alternative to dealership service, empowering owners to maintain and repair their vehicle.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete Service and Repair
Page Count
Estimated Page Count:
Thousands (digital format, comprehensive)
Manual Type
Type:
Online Service and Repair Manual Software
Language
Language:
English
Format
Format:
Web-based/Online Access (via browser)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
All engine assemblies, including internal components, lubrication, cooling, and exhaust systems.
Engine Performance:
Fuel delivery, ignition, emissions control, starting and charging systems.
Transmission Drivetrain:
Manual and automatic transmission systems, transfer case, drive axles, propeller shafts, and differentials.
Suspension Steering:
Front and rear suspension components, steering gear, power steering system, wheel alignment.
Brakes:
Hydraulic brake systems (front and rear discs/drums), ABS, parking brake, hydraulic control unit.
Electrical System:
Battery, starting, charging, lighting, instruments, warning indicators, body control module (BCM).
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system components and operation.
Body Interior:
Body panels, doors, windows, seats, interior trim, glass, and related components.
Chassis:
Frame construction, collision repair, underbody components.
Diagnostic Information:
Diagnostic Trouble Codes (DTCs), symptom-based diagnostics, troubleshooting flowcharts.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspections and replacement.
Repair Procedures:
Component removal, disassembly, inspection, repair, reassembly, and installation for all covered systems.
Troubleshooting Guides:
Step-by-step diagnostic procedures for identifying and resolving common and uncommon vehicle faults.
Wiring Diagrams:
Detailed electrical wiring diagrams for all vehicle circuits.
Specifications Data:
Torque specifications, clearances, fluid capacities, pressure readings, and other critical data.
Technical Depth
Depth:
Comprehensive, from routine maintenance to major component overhauls and diagnostics.
Manual Depth Detail
Diagnostic Procedures:
Includes detailed symptom-based troubleshooting, diagnostic trouble code (DTC) explanations, and repair procedures for diagnosing electrical and mechanical faults.
📊 Manual Specifications
File Format
Digital Requirements:
Requires an active internet connection and a compatible web browser on any PC, laptop, smartphone, or tablet.
Print Quality
Print Ability:
While digital, sections can typically be printed for offline reference (quality dependent on user printer).
Binding Type
Binding:
N/A (Digital Online Access)
Paper Type
Paper Type:
N/A (Digital Online Access)
Access Duration
Subscription Period:
1 Year (with discounts available for renewal)
⚙️ Engine Specifications
Primary Engine Gas
Engine Code Gas:
L96 (Vortec 6.0L V8 SFI FlexFuel)
Displacement Gas:
5967 cc (364 cubic inches)
Horsepower Gas:
360 hp @ 5400 rpm
Torque Gas:
380 lb-ft @ 4200 rpm
Fuel System Gas:
Sequential Fuel Injection (SFI), FlexFuel capable.
Block Material Gas:
Cast Iron
Cylinder Head Gas:
Aluminum
Primary Engine Diesel
Engine Code Diesel:
V8DOHC (Duramax 6.6L Turbo Diesel V8 - RPO LML)
Displacement Diesel:
6599 cc (403 cubic inches)
Horsepower Diesel:
397 hp @ 3000 rpm
Torque Diesel:
765 lb-ft @ 1600 rpm
Fuel System Diesel:
High-pressure Common Rail Direct Injection with Turbocharger.
Block Material Diesel:
Cast Iron
Cylinder Head Diesel:
Aluminum
Engine Technology Diesel:
Variable Geometry Turbocharger (VGT), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR) system (for LML).
🔧 Transmission
Standard
Transmission Type Standard:
Allison 1000 6-speed automatic (with Diesel engines)
Optional
Transmission Type Optional:
ZF S6-650 6-speed manual (less common, typically with gas engine)
Features
Transmission Features:
Heavy-duty construction, Tow/Haul mode, grade braking, electronic transmission range selection (ETRS).
📐 Dimensions
Exterior
Wheelbase Standard:
143.5 inches (3645 mm) (Regular Cab, Long Bed)
Wheelbase Extended:
153.7 inches (3904 mm) (Extended/Crew Cab, Standard Bed)
Wheelbase Longest:
167.5 inches (4255 mm) (Crew Cab, Long Bed)
Weights
Curb Weight Approx:
6,300 - 7,500 lbs (2858 - 3402 kg) (Varies by configuration)
Gvwr Gross Vehicle Weight Rating:
Up to 9,200 lbs (4173 kg) or 10,000 lbs (4536 kg) depending on configuration.
Gcwr Gross Combined Weight Rating:
Up to 22,000 lbs (9979 kg) for diesel models.
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
4 out of 5 stars (typical for this generation, check specific test data).
Active Features
Active Safety:
StabiliTrak (Traction Control and Electronic Stability Control), Trailer Sway Control, Anti-lock Braking System (ABS).
Passive Features
Passive Safety:
Frontal airbags, Side-impact airbags (optional/standard on some trims), Seatbelt pretensioners.
💡 Technology Features
Infotainment
Infotainment System:
Available touch-screen infotainment systems with navigation, Bluetooth connectivity, and SiriusXM Satellite Radio.
Driver Assistance
Driver Assist Features:
Integrated trailer brake controller (optional), rearview camera (optional).
Connectivity
Connectivity Options:
OnStar capabilities (subscription-based), USB/Auxiliary input jacks.
🔧 Maintenance
Service Intervals
Oil Change Interval:
5,000 miles (8,000 km) for gasoline, 7,500 miles (12,000 km) for diesel, or as indicated by oil life monitor.
Air Filter Replacement:
Every 30,000-50,000 miles (48,000-80,000 km) or as needed based on driving conditions.
Coolant Flush:
Every 50,000 miles (80,000 km) or 5 years for Dex-Cool coolant.
Fluid Specifications
Engine Oil Gas:
SAE 5W-30 (API SN, Dexos1 approved)
Engine Oil Diesel:
SAE 15W-40 (API CJ-4 or CK-4)
Transmission Fluid Auto:
Dexron VI (for Allison 1000)
Coolant Type:
GM P/N 12378515 (Orange Extended Life Coolant / Dex-Cool)
Known Issues
Common Complaints:
Potential for fuel injector issues or EGR problems on older diesel models, some electrical gremlins, and common wear items like ball joints and control arms due to heavy use.
📚 Vehicle History
Brand Heritage
Brand Identity:
GMC (General Motors Company) has a long history of producing trucks and commercial vehicles, emphasizing professional-grade capability.
Model Evolution
Sierra Heritage:
The Sierra nameplate has been used by GMC since 1998, with the 2500 HD representing the heavy-duty iteration of their full-size pickup.
Gmt900 Updates:
The 2012 model year falls within the second generation (GMT900) which received significant updates, including the introduction of the highly capable 6.6L Duramax LML diesel engine and improved styling.
Production
Manufacturing Location:
Fort Wayne, Indiana, USA (Primary Facility)
🏆 Awards & Recognition
Recognitions
Industry Awards:
Consistently ranked highly for towing capacity, durability, and diesel engine performance by automotive publications.
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