2002 GMC Sierra 2500 HD Service and Repair Manual

This factory service and repair manual for the 2002 GMC Sierra 2500 HD covers a 2-door standard cab pickup, a 4-door crew cab pickup and a 4-door extended cab pickup sold as Base, SL, SLE or SLT. The engine bay could hold the 6.6L turbocharged diesel V8 of 403 cubic inches, the 8.1L naturally aspirated gasoline V8 of 496 cubic inches, or the 6.0L V8 of 364 cubic inches, which was itself offered on gasoline or as a bi-fuel gasoline and LPG or CNG unit. Every one of them has its own procedures, specifications, torque values, wiring diagrams and diagnostics.

Engines covered

• 6.6L V8 (403 cu in) — OHV, turbocharged, diesel
• 6.0L V8 (364 cu in) — OHV, naturally aspirated, gasoline or bi-fuel gasoline/LPG or CNG
• 8.1L V8 (496 cu in) — OHV, naturally aspirated, gasoline

Body styles covered

• 2-door standard cab pickup
• 4-door crew cab pickup
• 4-door extended cab pickup

Trims covered

• Base
• SL
• SLE
• SLT

Known issues on the 2002 Sierra 2500 HD. Seven recalls appear on the federal record for this year. On natural gas trucks, a throttle cable could contact and wear through a pressurized fuel line, opening a pinhole leak of gas. Separately, the tailgate support cables can corrode and fracture, letting the tailgate drop, and parking brake linings can wear past the point where the brake will hold. Owner complaints total 595, of which 325 concern the service brakes, with engine and cooling and steering some way behind. Fuel line routing, parking brake service and brake hydraulic diagnostics are the parts of this manual those point toward.