🏷️ Basic Information Identification Make: Chevrolet Model: Silverado 3500 Year: 2002 Codes Platform Code: GMT800 (also known as Silverado/Sierra generation 1) 👋 Introduction Market Position Segment: Full-size heavy-duty pickup truck Competitive Analysis Competitors: Ford F-350 Super Duty, Dodge Ram 3500 Key Features Durability: Known for robust construction and towing/hauling capability Engine Options: Powerful V8 gasoline and Duramax diesel engines Utility: Configurable for various work and commercial applications 📋 Manual Details Coverage Areas All Systems: Yes Page Count Estimated Pages: 1500-2000 (typical for comprehensive OE service manuals) Manual Type Type: Service and Repair Manual Software Language Language: English Format Format: PDF Download (Licensed Software) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, repair, timing, cooling, lubrication, fuel delivery (mechanical aspects) Engine Electrical: Ignition system, starting system, charging system, fuel injection system (electrical controls), engine sensors, ECM/PCM diagnostics Transmission Drivetrain: Automatic transmission (e.g., 4L80-E, 4L60E), manual transmission (if applicable), transfer case, driveshafts, differentials, axle assemblies Brakes: Hydraulic system, ABS, disc brakes, drum brakes (rear), parking brake, brake fluid specifications Suspension Steering: Front suspension (independent), rear suspension (solid axle), steering gear, power steering system, wheel alignment specifications Electrical Chassis: Lighting system, power windows, power locks, wipers, horn, instrument cluster, body control modules (BCM) HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant, servicing procedures Body Exterior: Body panel removal/installation, doors, hoods, tailgates, bumpers, glass, trim Body Interior: Interior trim panels, seating, dashboard assembly, floor coverings Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and changes, tire rotations, spark plug replacement Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides Repair Rebuild: Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation Diagnostics: OBD-II (On-Board Diagnostics II) code interpretation, live data analysis, diagnostic tool usage Specifications Data: Torque specifications, clearances, tolerances, fluid capacities, diagnostic parameters Technical Depth Depth: Comprehensive OE-level repair and diagnostic information suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format Digital Format: Searchable PDF Print Quality Printable: Yes, printable pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Option 1: 6.0L Vortec V8 (LQ4) Displacement 1: 5967 cc (364 cu in) Horsepower 1: 300-325 hp (approximate, depending on application) Torque 1: 355-370 lb-ft (approximate, depending on application) Fuel System 1: Multi-point Fuel Injection (MPFI) Engine Option 2: 6.6L Duramax Diesel (LB7) Displacement 2: 6599 cc (403 cu in) Horsepower 2: 300 hp Torque 2: 520 lb-ft Fuel System 2: Common Rail Direct Injection (High Pressure) 🔧 Transmission Standard Automatic Transmission: 4L80-E (heavy-duty 4-speed automatic) Optional Manual Transmission: NV4500 (5-speed manual, less common on 3500) or Allison 1000 (for Duramax diesel in later years, but 4L80-E was common in 2002) Features Transfer Case: NP246 (2-speed, full-time 4WD with AutoTrac) or NP149 (full-time 4WD) 📐 Dimensions Exterior Wheelbase Regular Cab: 133.0 inches (3378 mm) Wheelbase Extended Cab: 143.5 inches (3645 mm) Wheelbase Crew Cab: 153.0 inches (3886 mm) Bed Length Options: 6.5 ft (short bed), 8.0 ft (long bed) Weights Gvwr Max: Up to 11,400 lbs (depending on configuration) Curb Weight: Approx. 5,500 - 6,500 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Frontal Driver: Likely 4 stars (based on typical ratings for this era and class) NHTSA Frontal Passenger: Likely 4 stars (based on typical ratings for this era and class) Active Features ABS: Standard Anti-lock Braking System (ABS) Passive Features Airbags: Driver and front passenger airbags 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with CD player and optional premium audio system. Navigation: No integrated factory navigation system in this model year. Driver Assistance Cruise Control: Standard or optional cruise control. Connectivity Onstar: Optional OnStar communication system available. 🔧 Maintenance Service Intervals Engine Oil Change: Every 5,000-7,500 miles or 6 months (severe service may require more frequent changes) Engine Coolant Change: Initial: 100,000 miles or 5 years. Subsequent: 50,000 miles or 2.5 years Transmission Fluid Change: Every 50,000-100,000 miles, depending on usage (severe duty warrants shorter intervals) Fluid Specifications Engine Oil Gasoline: SAE 5W-30 (API Certified) Engine Oil Diesel: SAE 15W-40 (API CI-4 or CH-4, e.g., Mobil Delvac 15W-40) Coolant Type: Dex-Cool (Orange Long-Life) or equivalent approved coolant Transmission Fluid Automatic: Dexron III or Dexron VI (for 4L80-E) Known Issues Duramax Injector Problems: LB7 Duramax injectors were prone to premature failure and requiring replacement. Rear Main Seal Leaks: Some gasoline engines experienced rear main seal leaks. Transmission Overheating: Heavy towing can sometimes lead to transmission overheating, especially if fluid is not properly maintained. 📚 Vehicle History Brand Heritage Heritage: Chevrolet has a long history of producing reliable and capable trucks, dating back to the 1910s. Model Evolution Generation Name: GMT800 (Second Generation Silverado/Sierra) Design Era: This generation introduced a more modern and aerodynamic design compared to its predecessor....