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1994-2002 Chevrolet C/K Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: C/K Years Covered: 1994-2002 Codes Product Identifier: CHEV-CK-9402-SRM Generation Platform Generation: GMT400 (Third Generation) 👋 Introduction Market Position Target User: Professional technicians, DIY enthusiasts Value Proposition: Authoritative, vehicle-specific repair guidance Competitive Analysis Differentiation: Authentic dealership-level information, not generic automotive advice Key Features Uniqueness: Covers all models and repairs comprehensively for the specified generation Content Quality: Authoritative, detailed, and accurate technical data 📋 Manual Details Coverage Areas All Models Included: True All Repairs Included: True (A-Z) Page Count Estimated Pages: 2000+ Manual Type Type: Service and Repair Manual Source: Dealership Technician Level Language Primary Language: English Format Digital Format: PDF (searchable, printable) 📖 Manual Coverage Systems Covered Engine Mechanical: All V6 and V8 gasoline and diesel engines Engine Electrical: Ignition, fuel injection, sensors, computer controls (ECM/PCM) Transmission Manual: Manual transmissions (e.g., NV3500, NV4500) Transmission Automatic: Automatic transmissions (e.g., 4L60E, 4L80E, 4L85E) Drivetrain: Front suspension, rear axle, 4WD systems (NVG transfer cases) Brakes: Front disc, rear drum/disc, ABS systems Steering: Power steering, steering column Suspension: Independent front suspension (IFS), leaf spring rear suspension Body And Frame: Body panels, chassis, frame, doors, windows, interior trim HVAC: Heating, Ventilation, Air Conditioning systems Electrical Systems: Lighting, power windows, power locks, wipers, horn, instrument cluster Comfort And Convenience: Seats, mirrors, interior electronics Safety Systems: Airbags (SRS), seat belts Procedures Included Routine Maintenance: Oil changes, fluid checks, filter replacements, tire rotations Troubleshooting: Diagnostic flowcharts, symptom analysis Component Repair: Engine, transmission, drivetrain, brake, suspension, steering repairs Diagnostics: OBD-I and OBD-II diagnostic trouble codes (DTCs), sensor testing Electrical Diagnostics: Wiring diagrams, circuit testing, component testing Rebuilding: Engine, transmission, axle component rebuild procedures Specifications: Torque values, clearances, fluid capacities, electrical data Bodywork: Panel removal/installation, glass replacement Technical Depth Depth: Comprehensive (from basic maintenance to full engine rebuilds) Detail Level: Step-by-step instructions, diagrams, exploded views 📊 Manual Specifications File Format Searchability: Full text searchable Printability: Printable page by page or section Print Quality Resolution: High resolution (clear text and diagrams) Binding Type Binding: Digital (PDF) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Options: 4.3L V6 (Vortec), 5.0L V8 (Vortec), 5.7L V8 (Vortec 350), 7.4L V8 (Vortec 454), 6.5L Turbo Diesel V8 Performance Typical Hp Range: 155-295 HP (Varies by engine and year) Typical Torque Range: 255-455 lb-ft (Varies by engine and year) Fuel System Fuel Delivery: Sequential Fuel Injection (SFI), Throttle Body Injection (TBI - early models), Direct Injection (DI - later diesel) Fuel Type: Unleaded gasoline, Diesel fuel 🔧 Transmission Standard Transmission Available Manual: NV3500 5-speed manual, NV4500 5-speed manual (heavy duty) Optional Transmission Available Automatic: 4L60E 4-speed automatic, 4L80E 4-speed automatic, 4L85E 4-speed automatic Features Transfer Case: 2WD, Autotrac (push-button 4WD), electric shift transfer cases Axle Ratios: Common ratios: 3.42, 3.73, 4.10 (Varies by model and application) 📐 Dimensions Exterior Body Styles: Regular Cab, Extended Cab, Crew Cab; Short Bed, Long Bed; 1500, 2500, 3500 series Wheelbase: Varies by configuration (e.g., 117.5" for short bed regular cab, 131.5" for long bed regular cab, 143.5" for extended cab) Weights Curb Weight: Varies significantly by configuration and engine (approx. 4,500 - 6,500+ lbs) Gvw: Varies by series (e.g., GVWR for 1500 series typically 6000-6200 lbs, 2500 series 6600-8600 lbs, 3500 series 8600+ lbs) 🛡️ Safety Features Ratings Crash Test Performance: Varies by year and specific testing agency (e.g., NHTSA, IIHS). Generally performed well for its era but lacks modern safety structures. Active Features ABS: Available Anti-lock Braking System (ABS) on front and rear wheels Passive Features Airbags: Driver and passenger airbags standard on most models from mid-generation onwards Seat Belts: Front and rear seat belts 💡 Technology Features Infotainment Audio Systems: Factory AM/FM/Cassette, optional CD players, upgraded speaker systems Navigation: Not available from factory during this period. Driver Assistance Cruise Control: Standard or optional cruise control systems Connectivity Onstar: OnStar services became available in later model years within this range. 🔧 Maintenance Service Intervals Oil Change: Typically every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendations) Filter Replacement: Air filter: 15,000-30,000 miles; Fuel filter: 30,000-60,000 miles; Cabin air filter: varies by availability and model year Transmission Service: Automatic transmission fluid (ATF) change: 30,000-100,000 miles, depending on fluid type and service (e.g., Dexron III/VI) Fluid Specifications Engine Oil: API SN/SP, ILSAC GF-6A; Viscosity: 5W-30 common for most Vortec engines (refer to manual for exact specs) Coolant: Dex-Cool (orange) or Conventional Green coolant; 50/50 mix with distilled water Transmission Fluid Auto: Dexron III (or equivalent like Dexron VI) Transmission Fluid Manual: GL-4 or GL-5 gear oil (refer to specific transmission type) Brake Fluid: DOT 3 or DOT 4 Known Issues Vortec Intake Gaskets: Leaking intake manifold gaskets (especially on 5.0L/5.7L engines) leading to coolant or vacuum leaks. Diesel Thermo Methoxy Button: Issues with the 6.5L diesel turbocharger, injector pump, and potential for...
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1994-2002 Chevrolet C/K Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Chevrolet
Model:
C/K
Years Covered:
1994-2002
Codes
Product Identifier:
CHEV-CK-9402-SRM
Generation
Platform Generation:
GMT400 (Third Generation)
👋 Introduction
Market Position
Target User:
Professional technicians, DIY enthusiasts
Value Proposition:
Authoritative, vehicle-specific repair guidance
Competitive Analysis
Differentiation:
Authentic dealership-level information, not generic automotive advice
Key Features
Uniqueness:
Covers all models and repairs comprehensively for the specified generation
Content Quality:
Authoritative, detailed, and accurate technical data
📋 Manual Details
Coverage Areas
All Models Included:
True
All Repairs Included:
True (A-Z)
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Service and Repair Manual
Source:
Dealership Technician Level
Language
Primary Language:
English
Format
Digital Format:
PDF (searchable, printable)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
All V6 and V8 gasoline and diesel engines
Engine Electrical:
Ignition, fuel injection, sensors, computer controls (ECM/PCM)
Transmission Manual:
Manual transmissions (e.g., NV3500, NV4500)
Transmission Automatic:
Automatic transmissions (e.g., 4L60E, 4L80E, 4L85E)
Drivetrain:
Front suspension, rear axle, 4WD systems (NVG transfer cases)
Brakes:
Front disc, rear drum/disc, ABS systems
Steering:
Power steering, steering column
Suspension:
Independent front suspension (IFS), leaf spring rear suspension
Body And Frame:
Body panels, chassis, frame, doors, windows, interior trim
HVAC:
Heating, Ventilation, Air Conditioning systems
Electrical Systems:
Lighting, power windows, power locks, wipers, horn, instrument cluster
Comfort And Convenience:
Seats, mirrors, interior electronics
Safety Systems:
Airbags (SRS), seat belts
Procedures Included
Routine Maintenance:
Oil changes, fluid checks, filter replacements, tire rotations
Troubleshooting:
Diagnostic flowcharts, symptom analysis
Component Repair:
Engine, transmission, drivetrain, brake, suspension, steering repairs
Diagnostics:
OBD-I and OBD-II diagnostic trouble codes (DTCs), sensor testing
Electrical Diagnostics:
Wiring diagrams, circuit testing, component testing
Rebuilding:
Engine, transmission, axle component rebuild procedures
Specifications:
Torque values, clearances, fluid capacities, electrical data
Bodywork:
Panel removal/installation, glass replacement
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine rebuilds)
Detail Level:
Step-by-step instructions, diagrams, exploded views
📊 Manual Specifications
File Format
Searchability:
Full text searchable
Printability:
Printable page by page or section
Print Quality
Resolution:
High resolution (clear text and diagrams)
Binding Type
Binding:
Digital (PDF)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Options:
4.3L V6 (Vortec), 5.0L V8 (Vortec), 5.7L V8 (Vortec 350), 7.4L V8 (Vortec 454), 6.5L Turbo Diesel V8
Performance
Typical Hp Range:
155-295 HP (Varies by engine and year)
Typical Torque Range:
255-455 lb-ft (Varies by engine and year)
Fuel System
Fuel Delivery:
Sequential Fuel Injection (SFI), Throttle Body Injection (TBI - early models), Direct Injection (DI - later diesel)
Fuel Type:
Unleaded gasoline, Diesel fuel
🔧 Transmission
Standard Transmission
Available Manual:
NV3500 5-speed manual, NV4500 5-speed manual (heavy duty)
Optional Transmission
Available Automatic:
4L60E 4-speed automatic, 4L80E 4-speed automatic, 4L85E 4-speed automatic
Features
Transfer Case:
2WD, Autotrac (push-button 4WD), electric shift transfer cases
Axle Ratios:
Common ratios: 3.42, 3.73, 4.10 (Varies by model and application)
📐 Dimensions
Exterior
Body Styles:
Regular Cab, Extended Cab, Crew Cab; Short Bed, Long Bed; 1500, 2500, 3500 series
Wheelbase:
Varies by configuration (e.g., 117.5" for short bed regular cab, 131.5" for long bed regular cab, 143.5" for extended cab)
Weights
Curb Weight:
Varies significantly by configuration and engine (approx. 4,500 - 6,500+ lbs)
Gvw:
Varies by series (e.g., GVWR for 1500 series typically 6000-6200 lbs, 2500 series 6600-8600 lbs, 3500 series 8600+ lbs)
🛡️ Safety Features
Ratings
Crash Test Performance:
Varies by year and specific testing agency (e.g., NHTSA, IIHS). Generally performed well for its era but lacks modern safety structures.
Active Features
ABS:
Available Anti-lock Braking System (ABS) on front and rear wheels
Passive Features
Airbags:
Driver and passenger airbags standard on most models from mid-generation onwards
Seat Belts:
Front and rear seat belts
💡 Technology Features
Infotainment
Audio Systems:
Factory AM/FM/Cassette, optional CD players, upgraded speaker systems
Navigation:
Not available from factory during this period.
Driver Assistance
Cruise Control:
Standard or optional cruise control systems
Connectivity
Onstar:
OnStar services became available in later model years within this range.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for specific recommendations)
Filter Replacement:
Air filter: 15,000-30,000 miles; Fuel filter: 30,000-60,000 miles; Cabin air filter: varies by availability and model year
Transmission Service:
Automatic transmission fluid (ATF) change: 30,000-100,000 miles, depending on fluid type and service (e.g., Dexron III/VI)
Fluid Specifications
Engine Oil:
API SN/SP, ILSAC GF-6A; Viscosity: 5W-30 common for most Vortec engines (refer to manual for exact specs)
Coolant:
Dex-Cool (orange) or Conventional Green coolant; 50/50 mix with distilled water
Transmission Fluid Auto:
Dexron III (or equivalent like Dexron VI)
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (refer to specific transmission type)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Vortec Intake Gaskets:
Leaking intake manifold gaskets (especially on 5.0L/5.7L engines) leading to coolant or vacuum leaks.
Diesel Thermo Methoxy Button:
Issues with the 6.5L diesel turbocharger, injector pump, and potential for injector issues.
ABS Module:
ABS warning lights and system failures due to faulty ABS control modules or wheel speed sensors.
Temperature Control Blends Door:
HVAC blend door actuator failures, resulting in inability to control temperature or airflow direction.
4Wd Actuator:
Front axle actuator failures in 4WD systems, preventing engagement.
Rust:
Common rust areas, particularly around wheel wells, rocker panels, and frame components in rust-belt regions.
📚 Vehicle History
Brand Heritage
Chevrolet Trucks:
Chevrolet has a long-standing reputation for durable and capable pickup trucks dating back to the early 20th century.
Model Evolution
C K Legacy:
The C/K line evolved through many generations, with this specific generation (GMT400) representing a significant redesign with a more aerodynamic and modern appearance.
Gmt400 Launch:
The GMT400 platform was introduced in 1988 and saw continuous updates through 2002, including the introduction of the Vortec engine family and improved interiors.
Production
Manufacturing Locations:
Various GM assembly plants across North America
Key Milestones:
Introduction of Vortec engines (1996), advanced transmissions (4L60E/4L80E), improved interiors, and safety features.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
While specific model year awards may vary, the C/K platform consistently competed in the highly contested full-size pickup truck market.
Ratings
Consumer Reports:
Consumer Reports typically ranked these trucks as average to above average in reliability for their time, with specific ratings varying by year and powertrain.
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