2002 Chevrolet C/K Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: C/K Series Year: 2002 Codes Chassis Code: GMT800 (for 1500, 2500, 3500 series) Vin Code Year: 2 Generation Generation Name: Third Generation C/K (GMT800) Generation Years: 1999-2006 (2007 for Classic models) 👋 Introduction Market Position Vehicle Segment: Full-size pickup truck and heavy-duty truck segment. Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance, and professional technicians. Competitive Analysis Key Competitors: Ford F-Series, Dodge Ram. Key Features Manual Advantage: Provides vehicle-specific information, unlike generic aftermarket guides, ensuring accuracy and completeness for genuine repairs and maintenance. Content Focus: Emphasizes dealer-level repair procedures and diagnostic strategies. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Specific Models Covered: Includes Silverado, Sierra (as GM counterpart), C1500, K1500, C2500, K2500, C3500, K3500, including various configurations like pickup trucks, chassis cabs, and potentially Suburban/Yukon for shared platform components. Page Count Estimated Page Count: ~2000+ pages (typical for comprehensive dealer-level manuals of this era) Manual Type Type: Service and Repair Manual Authenticity: Factory service manual (OEM equivalent) Language Language: English Format Format: Likely printed booklet or digital PDF (as specified by seller) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, emission controls, cooling system, lubrication system, exhaust system, engine management (ECM/PCM). Drivetrain: Manual transmission, automatic transmission (4L60E, 4L80E, etc.), transfer case (2WD/4WD), drive shafts, axles, differentials, CV joints. Suspension Steering: Front suspension (independent torsion bar or coil spring), rear suspension (leaf spring), steering gear, power steering system, wheel alignment specifications. Brakes: Front disc brakes, rear drum or disc brakes, ABS system, parking brake, hydraulic system, brake component specifications and service procedures. Electrical Electronic: Battery, charging system (alternator), starting system (starter), lighting systems (headlamps, taillamps, interior), instrument cluster, body control module (BCM), comfort/convenience systems, trailer wiring harness. HVAC: Heating, ventilation, and air conditioning system components, refrigerant handling, diagnostics, and repair. Body Chassis: Body panels, doors, windows, interior trim, chassis frame, bumpers, towing information. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), tire rotation, brake pad inspection. Diagnostics: System diagnostic procedures, trouble code (DTC) interpretation, circuit testing, component testing, troubleshooting flowcharts. Repair: Component removal, installation, overhaul, and replacement for all major systems. Adjustment: Parking brake adjustment, headlight aim, door alignment. Specifications: Torque specifications, fluid capacities, electrical schematics, diagnostic parameters. Technical Depth Depth Level: Comprehensive; covers basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and electrical troubleshooting. Diagnostic Tools: Information implicitly or explicitly references use of OBD-II scanners, multimeter, oscilloscope, specialized diagnostic tools for GM vehicles. 📊 Manual Specifications File Format Digital Format If Applicable: Likely PDF with searchable text and high-resolution diagrams. Print Quality Diagram Quality: High-quality, detailed line drawings and exploded views for component identification and reassembly. Text Clarity: Clear, concise technical language with step-by-step instructions. Binding Type Physical Binding If Printed: Likely spiral-bound or saddle-stitched for lay-flat use in a workshop environment. Paper Type Physical Paper Type If Printed: Durable, often glossy or semi-gloss paper to withstand workshop conditions. ⚙️ Engine Specifications Primary Engine Engine Options: 4.3L V6 (Vortec 4300 L35), 4.8L V8 (Vortec 4800 LR4), 5.3L V8 (Vortec 5300 LM7), 6.0L V8 (Vortec 6000 LQ4 - HD models), 8.1L V8 (Vortec 8100 L18 - HD models), 6.6L Duramax Turbo-Diesel V8 (LB7). Performance 4.3L V6 Horsepower: ~200 hp 4.3L V6 Torque: ~260 lb-ft 5.3L V8 Horsepower: ~285-295 hp 5.3L V8 Torque: ~325-335 lb-ft 6.0L V8 Horsepower: ~300-325 hp 6.0L V8 Torque: ~370-380 lb-ft 6.6L Duramax Horsepower: ~300 hp 6.6L Duramax Torque: ~520 lb-ft Fuel System Fuel Delivery: Multi-port fuel injection (MPFI) for gasoline engines, common rail direct injection (CRDI) for Duramax diesel. Fuel Type: Unleaded gasoline (87 octane recommended for most V8s, premium for optimal performance), Diesel fuel for Duramax. Engine Management ECU Type: Powertrain Control Module (PCM) for gasoline, Engine Control Module (ECM) for diesel, managing fuel, ignition, emissions, and diagnostics. 🔧 Transmission Standard Standard Transmission Offered: 4-speed automatic (4L60E, 4L80E) was standard on most models. Manual transmissions were phased out or very rare for this year. Optional Optional Transmission Offered: Heavy-duty models may have offered variations of automatic transmissions or specific manual options in earlier years, but 2002 heavily favored automatics. Features Transmission Features: Electronically controlled transmission with overdrive, Tow/Haul mode on some models. Fluid Specifications Automatic Transmission Fluid Type: Dexron-III (or Dexron-VI as a compatible replacement) Fluid Capacity 4L60E Capacity Quarts: ~9.5 quarts (dry fill) 4L80E Capacity Quarts: ~11.4 quarts (dry fill) 📐 Dimensions Exterior Wheelbase Options: 130.0 inches (standard cab), 143.5 inches (extended cab/long bed), 167.0 inches (dually/long bed). Overall Length Options: Varies by cab and bed configuration (approx. 220-260 inches). Width Without Mirrors: Approx. 78.7 inches. Height Unladen: Approx. 74-78 inches (depending on configuration). Cargo Bed Length Options: 6.5 ft (short bed), 8.0 ft (long bed). Weights Curb Weight Range: ~4,500 - 6,500 lbs (depending on configuration and engine). Gvwr Range: ~6,000...

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Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

C/K Series

Year:

Codes

Chassis Code:

GMT800 (for 1500, 2500, 3500 series)

Vin Code Year:

Generation

Generation Name:

Third Generation C/K (GMT800)

Generation Years:

1999-2006 (2007 for Classic models)

👋 Introduction

Market Position

Vehicle Segment:

Full-size pickup truck and heavy-duty truck segment.

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance, and professional technicians.

Competitive Analysis

Key Competitors:

Ford F-Series, Dodge Ram.

Key Features

Manual Advantage:

Provides vehicle-specific information, unlike generic aftermarket guides, ensuring accuracy and completeness for genuine repairs and maintenance.

Content Focus:

Emphasizes dealer-level repair procedures and diagnostic strategies.

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z

Specific Models Covered:

Includes Silverado, Sierra (as GM counterpart), C1500, K1500, C2500, K2500, C3500, K3500, including various configurations like pickup trucks, chassis cabs, and potentially Suburban/Yukon for shared platform components.

Page Count

Estimated Page Count:

~2000+ pages (typical for comprehensive dealer-level manuals of this era)

Manual Type

Type:

Service and Repair Manual

Authenticity:

Factory service manual (OEM equivalent)

Language

Language:

English

Format

Format:

Likely printed booklet or digital PDF (as specified by seller)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, emission controls, cooling system, lubrication system, exhaust system, engine management (ECM/PCM).

Drivetrain:

Manual transmission, automatic transmission (4L60E, 4L80E, etc.), transfer case (2WD/4WD), drive shafts, axles, differentials, CV joints.

Suspension Steering:

Front suspension (independent torsion bar or coil spring), rear suspension (leaf spring), steering gear, power steering system, wheel alignment specifications.

Brakes:

Front disc brakes, rear drum or disc brakes, ABS system, parking brake, hydraulic system, brake component specifications and service procedures.

Electrical Electronic:

Battery, charging system (alternator), starting system (starter), lighting systems (headlamps, taillamps, interior), instrument cluster, body control module (BCM), comfort/convenience systems, trailer wiring harness.

HVAC:

Heating, ventilation, and air conditioning system components, refrigerant handling, diagnostics, and repair.

Body Chassis:

Body panels, doors, windows, interior trim, chassis frame, bumpers, towing information.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), tire rotation, brake pad inspection.

Diagnostics:

System diagnostic procedures, trouble code (DTC) interpretation, circuit testing, component testing, troubleshooting flowcharts.

Repair:

Component removal, installation, overhaul, and replacement for all major systems.

Adjustment:

Parking brake adjustment, headlight aim, door alignment.

Specifications:

Torque specifications, fluid capacities, electrical schematics, diagnostic parameters.

Technical Depth

Depth Level:

Comprehensive; covers basic maintenance to complete engine and transmission overhauls, advanced diagnostics, and electrical troubleshooting.

Diagnostic Tools:

Information implicitly or explicitly references use of OBD-II scanners, multimeter, oscilloscope, specialized diagnostic tools for GM vehicles.

📊 Manual Specifications

File Format

Digital Format If Applicable:

Likely PDF with searchable text and high-resolution diagrams.

Print Quality

Diagram Quality:

High-quality, detailed line drawings and exploded views for component identification and reassembly.

Text Clarity:

Clear, concise technical language with step-by-step instructions.

Binding Type

Physical Binding If Printed:

Likely spiral-bound or saddle-stitched for lay-flat use in a workshop environment.

Paper Type

Physical Paper Type If Printed:

Durable, often glossy or semi-gloss paper to withstand workshop conditions.

⚙️ Engine Specifications

Primary Engine

Engine Options:

4.3L V6 (Vortec 4300 L35), 4.8L V8 (Vortec 4800 LR4), 5.3L V8 (Vortec 5300 LM7), 6.0L V8 (Vortec 6000 LQ4 - HD models), 8.1L V8 (Vortec 8100 L18 - HD models), 6.6L Duramax Turbo-Diesel V8 (LB7).

Performance

4.3L V6 Horsepower:

~200 hp

4.3L V6 Torque:

~260 lb-ft

5.3L V8 Horsepower:

~285-295 hp

5.3L V8 Torque:

~325-335 lb-ft

6.0L V8 Horsepower:

~300-325 hp

6.0L V8 Torque:

~370-380 lb-ft

6.6L Duramax Horsepower:

~300 hp

6.6L Duramax Torque:

~520 lb-ft

Fuel System

Fuel Delivery:

Multi-port fuel injection (MPFI) for gasoline engines, common rail direct injection (CRDI) for Duramax diesel.

Fuel Type:

Unleaded gasoline (87 octane recommended for most V8s, premium for optimal performance), Diesel fuel for Duramax.

Engine Management

ECU Type:

Powertrain Control Module (PCM) for gasoline, Engine Control Module (ECM) for diesel, managing fuel, ignition, emissions, and diagnostics.

🔧 Transmission

Standard

Standard Transmission Offered:

4-speed automatic (4L60E, 4L80E) was standard on most models. Manual transmissions were phased out or very rare for this year.

Optional

Optional Transmission Offered:

Heavy-duty models may have offered variations of automatic transmissions or specific manual options in earlier years, but 2002 heavily favored automatics.

Features

Transmission Features:

Electronically controlled transmission with overdrive, Tow/Haul mode on some models.

Fluid Specifications

Automatic Transmission Fluid Type:

Dexron-III (or Dexron-VI as a compatible replacement)

Fluid Capacity

4L60E Capacity Quarts:

~9.5 quarts (dry fill)

4L80E Capacity Quarts:

~11.4 quarts (dry fill)

📐 Dimensions

Exterior

Wheelbase Options:

130.0 inches (standard cab), 143.5 inches (extended cab/long bed), 167.0 inches (dually/long bed).

Overall Length Options:

Varies by cab and bed configuration (approx. 220-260 inches).

Width Without Mirrors:

Approx. 78.7 inches.

Height Unladen:

Approx. 74-78 inches (depending on configuration).

Cargo

Bed Length Options:

6.5 ft (short bed), 8.0 ft (long bed).

Weights

Curb Weight Range:

~4,500 - 6,500 lbs (depending on configuration and engine).

Gvwr Range:

~6,000 - 12,000+ lbs (depending on model 1500, 2500, 3500 and options).

Towing Capacity Max:

Up to 12,000+ lbs for properly equipped heavy-duty models.

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4/5 stars (typical for this generation of trucks).

Active Features

Standard Anti-lock Braking System (ABS) on all wheels for most models.

Traction Control:

Optional or standard on higher trims; often referred to as 'Active Handling' or 'Traction Control'.

Passive Features

Airbags:

Driver and front passenger airbags. Side airbags were less common or optional in this era.

Seatbelts:

Three-point seatbelts for all seating positions, with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio System Options:

AM/FM stereo with CD player, optional premium audio systems, cassette player may be present on base models.

Navigation:

Very limited or non-existent for factory options in 2002; aftermarket solutions would be common.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Assist:

Generally not available from the factory in 2002.

Connectivity

Onstar:

Available as an optional feature on many models, providing telematics and emergency services.

Diagnostic Ports

OBD Ii Port Location:

Located under the dashboard on the driver's side.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 3,000-7,500 miles depending on driving conditions and oil type used. The manual will specify based on oil quality and usage.

Transmission Fluid Interval:

Every 30,000-100,000 miles, with a recommendation for more frequent changes for heavy towing or severe service.

Coolant Change Interval:

Typically 30,000-100,000 miles depending on coolant type (e.g., traditional green or extended-life orange/pink).

Fluid Specifications

Engine Oil Type Viscosity:

5W-30 is common for most gasoline engines, with 15W-40 or 5W-40 for the Duramax diesel. Manual will confirm specific API classifications.

Coolant Type:

GM specified engine coolant (GMC 6043-M), typically a green ethylene glycol based coolant, or equivalent.

Brake Fluid Type:

DOT 3 brake fluid.

Known Issues

Common Problems Duramax:

Injectors (LB7 specific), glow plugs, fuel filter housing leaks, intake manifold gaskets.

Common Problems Gasoline V8:

Intake manifold gaskets (especially 5.3L), fuel pump failures, catalytic converter issues, oil pressure sensor failures.

Common Problems Drivetrain:

Transfer case actuator failures (4WD models), differential leaks, U-joint wear.

Common Problems Suspension Brakes:

Ball joint wear, tie rod end wear, brake rotor warping, ABS sensor failures.

Common Problems Electrical:

HVAC blower motor resistor failure, instrument cluster failures (pixelation), door lock actuator failures.

📚 Vehicle History

Brand Heritage

Chevrolet Truck Legacy:

Chevrolet has a long and storied history in the truck market, with the C/K line representing a significant portion of its commercial and personal vehicle sales for decades.

Model Evolution

Gmt800 Introduction:

The GMT800 platform, introduced for the 1999 model year, marked a significant redesign from the previous GMT400 platform, featuring improved aerodynamics, a stiffer frame, and updated interiors.

Mid-Cycle Updates:

While the 2002 model year was not a full redesign, subtle updates to engines, interior features, and technology were common across the GMT800 lifecycle.

Production

Production Locations:

North American assembly plants, including Fort Wayne, Indiana; Oshawa, Ontario; and Janesville, Wisconsin.

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While specific awards for the 2002 model might vary, the GMT800 platform was widely praised and contributed to Chevrolet's consistent presence and success in truck segment awards during this era.