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GMC Sonoma 1994-2004 Service & Repair Workshop Manual

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🏷️ Basic Information Identification Make: GMC Model: Sonoma Model Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Codes Platform: GMT355 👋 Introduction Market Position Positioning: A compact pickup truck known for its utility, versatility, and often affordable entry price. Competed with Ford Ranger, Toyota Tacoma, and Dodge Dakota. Competitive Analysis Comparable Models: Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody/Frontier, Mazda B-Series Key Features Vehicle Strengths: Rugged construction, available V6 engines, practical bed configurations, reliable platform shared with Chevrolet S-10. Manual Value Proposition Value: Provides professional-level repair and maintenance information, enabling significant cost savings on service and repairs, increasing vehicle longevity. Model Lineup Variations Cab Styles: Regular Cab, Extended Cab (with rear-opening doors). Trim Levels: Various trim levels existed, such as SL, SLE, Sportside (bed style), and later some special editions. 📋 Manual Details Coverage Areas General Coverage: All repairs, servicing, and troubleshooting procedures Page Count Estimated Pages: Hundreds (exact count not specified, but described as very detailed) Manual Type Type: Service & Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system Engine Performance: Fuel injection, ignition system, emission controls, diagnostics Transmission Manual: Clutch system, manual transmission overhaul, gears, bearings, synchronizers Transmission Automatic: Automatic transmission overhaul, torque converter, valve body, planetary gears, hydraulic controls Drivetrain: Driveshaft, universal joints, rear axle, front axle (4WD), CV joints, differential Suspension: Front suspension (independent), rear suspension (leaf springs), shocks, struts, ball joints, control arms, bushings Steering: Steering gear, power steering system, steering column, tie rods, linkages Brakes: Front disc brakes, rear drum brakes, ABS system, brake fluid, lines, calipers, wheel cylinders, master cylinder Electrical System: Battery, charging system (alternator), starting system (starter), ignition system, lighting, wiring diagrams, fuses, relays Body And Frame: Body panel repair, doors, hood, tailgate, interior trim, glass, chassis, frame straightening HVAC: Air conditioning system, heater core, blower motor, climate control Restraints: Seat belts, airbag system (SRS) diagnostics and replacement Emissions Control: Catalytic converter, EGR system, O2 sensors, EVAP system, and related diagnostics and repair procedures. Instrument Panel: Gauges, warning lights, interior lighting, climate controls, wiper system. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, injectors, pressure regulator. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, lubrication, spark plug replacement, belt inspection and replacement Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, electrical system diagnostics, engine performance issues Repair: Step-by-step instructions for component removal, overhaul, and installation Diagnostics: On-board diagnostics (OBD-I/OBD-II), sensor testing, actuator testing, diagnostic trouble codes (DTCs) Wiring Diagrams: Detailed electrical wiring schematics for all major systems Alignment: Wheel alignment specifications and procedures. Tire And Wheel: Tire pressure specifications, wheel torque, tire rotation. Technical Depth Depth: Complete factory level detail, suitable for professional mechanics and advanced DIY enthusiasts 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Licensing Usage Rights: Unlimited use on multiple devices, lifetime access, no expiry Compatibility Operating Systems: Windows and MAC compatible Searchability Text Searchability: Yes (typically PDF format allows for text searching of terms). Accuracy Information Source: Factory service manual data, mirroring what professional technicians use. ⚙️ Engine Specifications Primary Engine 2.2L I4: Engine Code: LN2 (VIN 4). Power: Approx. 112 hp @ 4800 rpm. Torque: Approx. 130 lb-ft @ 2800 rpm. Fuel System: TBI (Throttle Body Injection) early models, MPFI (Multi-Port Fuel Injection) later models. 2.5L I4: Engine Code: LP5 (VIN 1) - Introduced later. Power: Approx. 122 hp @ 4800 rpm. Torque: Approx. 142 lb-ft @ 2400 rpm. Fuel System: MPFI. 4.3L V6: Engine Code: L35 (VIN W), LV3 (VIN X). Power: Approx. 160-190 hp @ 4400-4800 rpm. Torque: Approx. 230-260 lb-ft @ 2400-2800 rpm. Fuel System: MPFI. Commonly referred to as the Vortec 4300. Performance Engine Options Summary: Inline 4-cylinder (2.2L, 2.5L) and V6 (4.3L) options, offering a balance of fuel economy and power. Fuel System Fuel Type: Unleaded Gasoline Lubrication Oil Capacity: Varies by engine, typically 4.5-5 quarts (e.g., 4.5 quarts for 4.3L V6 with filter). Cooling Coolant Capacity: Varies by engine and configuration, approximately 10-12 quarts. 🔧 Transmission Standard Manual Transmission: 5-speed manual (NV1500, NV3500) available on most models. Optional Automatic Transmission: 4-speed automatic (4L60-E) commonly paired with the 4.3L V6 and available on other engines. Features Drivetrain Options: Rear-Wheel Drive (RWD) standard, Four-Wheel Drive (4WD) optional. 📐 Dimensions Exterior Wheelbase: Varies by cab configuration (Regular Cab, Extended Cab) and bed length. Common wheelbases range from 111.5 inches to 133.5 inches. Overall Length: Varies significantly by cab and bed configuration. Cargo Bed Lengths: Commonly available in 6-foot and 7-foot bed lengths. Weights Curb Weight: Varies widely based on configuration, typically ranging from 3,000 to 4,000+ lbs. 🛡️ Safety Features Ratings...
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GMC Sonoma 1994-2004 Service & Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
GMC
Model:
Sonoma
Model Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Codes
Platform:
GMT355
👋 Introduction
Market Position
Positioning:
A compact pickup truck known for its utility, versatility, and often affordable entry price. Competed with Ford Ranger, Toyota Tacoma, and Dodge Dakota.
Competitive Analysis
Comparable Models:
Ford Ranger, Toyota Tacoma, Dodge Dakota, Nissan Hardbody/Frontier, Mazda B-Series
Key Features
Vehicle Strengths:
Rugged construction, available V6 engines, practical bed configurations, reliable platform shared with Chevrolet S-10.
Manual Value Proposition
Value:
Provides professional-level repair and maintenance information, enabling significant cost savings on service and repairs, increasing vehicle longevity.
Model Lineup Variations
Cab Styles:
Regular Cab, Extended Cab (with rear-opening doors).
Trim Levels:
Various trim levels existed, such as SL, SLE, Sportside (bed style), and later some special editions.
📋 Manual Details
Coverage Areas
General Coverage:
All repairs, servicing, and troubleshooting procedures
Page Count
Estimated Pages:
Hundreds (exact count not specified, but described as very detailed)
Manual Type
Type:
Service & Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, pistons, crankshaft, camshaft, valve train, lubrication system, cooling system
Engine Performance:
Fuel injection, ignition system, emission controls, diagnostics
Transmission Manual:
Clutch system, manual transmission overhaul, gears, bearings, synchronizers
Transmission Automatic:
Automatic transmission overhaul, torque converter, valve body, planetary gears, hydraulic controls
Drivetrain:
Driveshaft, universal joints, rear axle, front axle (4WD), CV joints, differential
Suspension:
Front suspension (independent), rear suspension (leaf springs), shocks, struts, ball joints, control arms, bushings
Steering:
Steering gear, power steering system, steering column, tie rods, linkages
Brakes:
Front disc brakes, rear drum brakes, ABS system, brake fluid, lines, calipers, wheel cylinders, master cylinder
Electrical System:
Battery, charging system (alternator), starting system (starter), ignition system, lighting, wiring diagrams, fuses, relays
Body And Frame:
Body panel repair, doors, hood, tailgate, interior trim, glass, chassis, frame straightening
HVAC:
Air conditioning system, heater core, blower motor, climate control
Restraints:
Seat belts, airbag system (SRS) diagnostics and replacement
Emissions Control:
Catalytic converter, EGR system, O2 sensors, EVAP system, and related diagnostics and repair procedures.
Instrument Panel:
Gauges, warning lights, interior lighting, climate controls, wiper system.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, injectors, pressure regulator.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, lubrication, spark plug replacement, belt inspection and replacement
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting, electrical system diagnostics, engine performance issues
Repair:
Step-by-step instructions for component removal, overhaul, and installation
Diagnostics:
On-board diagnostics (OBD-I/OBD-II), sensor testing, actuator testing, diagnostic trouble codes (DTCs)
Wiring Diagrams:
Detailed electrical wiring schematics for all major systems
Alignment:
Wheel alignment specifications and procedures.
Tire And Wheel:
Tire pressure specifications, wheel torque, tire rotation.
Technical Depth
Depth:
Complete factory level detail, suitable for professional mechanics and advanced DIY enthusiasts
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Printable (single pages or entire manual)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Licensing
Usage Rights:
Unlimited use on multiple devices, lifetime access, no expiry
Compatibility
Operating Systems:
Windows and MAC compatible
Searchability
Text Searchability:
Yes (typically PDF format allows for text searching of terms).
Accuracy
Information Source:
Factory service manual data, mirroring what professional technicians use.
⚙️ Engine Specifications
Primary Engine
2.2L I4:
Engine Code: LN2 (VIN 4). Power: Approx. 112 hp @ 4800 rpm. Torque: Approx. 130 lb-ft @ 2800 rpm. Fuel System: TBI (Throttle Body Injection) early models, MPFI (Multi-Port Fuel Injection) later models.
2.5L I4:
Engine Code: LP5 (VIN 1) - Introduced later. Power: Approx. 122 hp @ 4800 rpm. Torque: Approx. 142 lb-ft @ 2400 rpm. Fuel System: MPFI.
4.3L V6:
Engine Code: L35 (VIN W), LV3 (VIN X). Power: Approx. 160-190 hp @ 4400-4800 rpm. Torque: Approx. 230-260 lb-ft @ 2400-2800 rpm. Fuel System: MPFI. Commonly referred to as the Vortec 4300.
Performance
Engine Options Summary:
Inline 4-cylinder (2.2L, 2.5L) and V6 (4.3L) options, offering a balance of fuel economy and power.
Fuel System
Fuel Type:
Unleaded Gasoline
Lubrication
Oil Capacity:
Varies by engine, typically 4.5-5 quarts (e.g., 4.5 quarts for 4.3L V6 with filter).
Cooling
Coolant Capacity:
Varies by engine and configuration, approximately 10-12 quarts.
🔧 Transmission
Standard
Manual Transmission:
5-speed manual (NV1500, NV3500) available on most models.
Optional
Automatic Transmission:
4-speed automatic (4L60-E) commonly paired with the 4.3L V6 and available on other engines.
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) standard, Four-Wheel Drive (4WD) optional.
📐 Dimensions
Exterior
Wheelbase:
Varies by cab configuration (Regular Cab, Extended Cab) and bed length. Common wheelbases range from 111.5 inches to 133.5 inches.
Overall Length:
Varies significantly by cab and bed configuration.
Cargo
Bed Lengths:
Commonly available in 6-foot and 7-foot bed lengths.
Weights
Curb Weight:
Varies widely based on configuration, typically ranging from 3,000 to 4,000+ lbs.
🛡️ Safety Features
Ratings
Crash Test Data:
Specific ratings for this generation can vary by year and specific test. Consult NHTSA and IIHS for detailed reports from the period.
Active Features
Braking System:
Front disc brakes, rear drum brakes. Anti-lock Braking System (ABS) was optional or standard on higher trims/later years.
Passive Features
Airbags:
Driver-side airbag standard from 1994. Passenger airbag became available or standard on some models in later years.
Seat Belts:
Three-point seat belts for front occupants, lap belts for rear (if equipped).
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio, cassette player, CD player (optional). Standard speaker configurations.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) available as an option on rear-wheel anti-lock or four-wheel anti-lock systems.
Connectivity
Onboard Diagnostics:
OBD-I in earlier years, transitioning to OBD-II standard during this generation, supporting emission and engine diagnostics.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type. Consult manual for specific recommendations.
Transmission Fluid:
Automatic transmission fluid (ATF) typically recommended for change every 30,000-60,000 miles. Manual transmission fluid inspection at similar intervals.
Coolant Flush:
Recommended every 30,000-60,000 miles or 2-4 years.
Spark Plugs:
Varies by plug type. Platinum or iridium plugs can last 60,000-100,000 miles; standard plugs often 30,000 miles.
Fluid Specifications
Engine Oil:
Typically SAE 5W-30 or 5W-40 for V6 and 10W-30 for I4, API certified. Consult manual for precise grade and API rating.
Transmission Fluid Auto:
Dexron III or equivalent (e.g., Dexron VI) for 4L60-E transmissions.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, viscosity depends on temperature (e.g., 75W-90).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Coolant:
Ethylene glycol based, 50/50 mix with distilled water. Specific color/type may vary by year.
Known Issues
Common Problems:
Transmission issues (especially 4L60-E solenoids, torque converter clutch), intake manifold gaskets (V6), rear main seal leaks, fuel pump failures, ABS sensor failures, ball joint wear, rust on body panels and frame.
Suspension Wear:
Ball joints, tie rod ends, and sway bar links are common wear items due to the truck's utility use.
📚 Vehicle History
Brand Heritage
Gmc Legacy:
GMC has a long history of producing trucks and commercial vehicles, emphasizing 'Professional Grade' build quality.
Model Evolution
Generation Details:
The 1994-2004 Sonoma is the second generation of the GMC Sonoma, which replaced the GMC S-15. It shares its platform and many components with the Chevrolet S-10.
Production
Manufacturing Location:
Primarily manufactured in the United States (e.g., Shreveport, Louisiana).
Production Years
Model Run:
1994-2004 (This generation).
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the Sonoma are less publicized than some competitors, it consistently received positive remarks for its practicality and value in consumer and automotive reviews of the compact truck segment.
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