GMC Sierra 2000-2006 Factory Workshop Service Repair Manual

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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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Description

🏷️ Basic Information

Identification

Make:

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:

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.