1994 GMC C3500 Service and Repair Manual
This factory service and repair manual for the 1994 GMC C3500 lists three engines, one of them the turbocharged 6.5L diesel V8 and the others naturally aspirated gasoline V8s of 5.7L and 7.4L. Five body configurations use them: standard, extended and crew cab pickups, and cab-and-chassis trucks with two or four doors. Trim is Sierra SL, Sierra SLE or Sierra SLT. Because so many combinations share one frame, the system-by-system organization matters — engine, driveline, chassis, body and electrical sections each carry their own specifications, torque values, wiring diagrams and diagnostics.
Engines covered
- 6.5L V8 (395 cu in) — OHV, turbocharged, diesel
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 2-door standard cab pickup
- 2-door cab & chassis
- 4-door crew cab pickup
- 4-door cab & chassis
- 2-door extended cab pickup
Trims covered
- Sierra SL
- Sierra SLE
- Sierra SLT
Known issues on the 1994 C3500. Two recalls are on record for this model year. One describes brake-light switch wiring installed with its polarity reversed, which wears the switch contacts prematurely until the lamps stop warning drivers behind that the truck is slowing. The other covers replacement oil filters that may seal poorly and let engine oil escape into a fire risk. Of the nine owner complaints held by NHTSA, five concern the service brakes and three the structure. Brake hydraulics, the stop lamp circuit and the frame and body mountings are all covered here with procedures, torque values, wiring diagrams and diagnostics.
CERTAIN HONEYWELL FRAM RACING BRAND HP4 AND HP8 OIL FILTERS THAT WERE MANUFACTURED FROM MAY 25, 2006, THROUGH SEPTEMBER 14, 2007, AND SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR VEHICLES LIST ABOVE. TH
THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN A FIRE.
HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING NOVEMBER 20
VEHICLE DESCRIPTION: PICKUP TRUCKS, CREW CABS, UTILITY TRUCKS AND SPORT UTILITY VEHICLES. THESE VEHICLES WERE BUILT WITH THE POLARITY OF THE WIRING FOR THE ZERO ADJUST BRAKE SWITCH REVERSED FROM WHA
THIS WOULD FAIL TO WARN A FOLLOWING DRIVER THAT THE VEHICLE IS BRAKING AND COULD LEAD TO A CRASH.
DEALERS WILL REPLACE THE BRAKE SWITCH AND REVERSE THE WIRING.
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
UNKNOWN
ANTILOCK BRAKES FAIL ON WET PAVEMENT.
INTERMITTENTLY WHEN MOVING FROM COLD START AUTO-TRANSMISSION MAY NOT CAUSE IT TO MOVE. PLEASE DESCRIBE DETAILS. *AK
FRAME CRACKED IN HALF, VEHICLE INOPERATIVE. *AK
FRONT FRAME FAILED. TT
Showing the 4 most serious of 9 complaints filed with NHTSA.
