2002 GMC Sierra 3500 Service and Repair Manual

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Factory-Grade Data

2002 GMC Sierra 3500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Standard Cab Pickup 2-Door
  • SLT Crew Cab Pickup 4-Door
  • Base Extended Cab Pickup 4-Door
  • Base Crew Cab Pickup 4-Door
  • Base Cab & Chassis 4-Door
  • Base Cab & Chassis 2-Door
  • SLE Extended Cab Pickup 4-Door
  • SL Crew Cab Pickup 4-Door
  • SL Extended Cab Pickup 4-Door
  • SLE Cab & Chassis 4-Door
  • SL Cab & Chassis 2-Door
  • SLE Cab & Chassis 2-Door
  • SLE Crew Cab Pickup 4-Door
  • SL Standard Cab Pickup 2-Door
  • SLT Extended Cab Pickup 4-Door
  • SL Cab & Chassis 4-Door
  • SLE Standard Cab Pickup 2-Door

Engines covered

  • 6.6L 6599CC 403Cu. In. V8 DIESEL OHV Turbocharged
  • 6.0L 5967CC 364Cu. In. V8 GAS OHV Naturally Aspirated
  • 8.1L 496Cu. In. V8 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 GMC Sierra 3500 Recalls & Complaints

NHTSA #04V56200026/11/2004Component: EQUIPMENT ADAPTIVE/MOBILITY

ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.

Consequence

IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN

Remedy

DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL H

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11012907

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11010544

This service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

TSB #11004761

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should

TSB #11004557

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

TSB #11002312

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.

Showing the 8 most recent of 103 technical service bulletins on file with NHTSA.

20040408Component: AIR BAGSCrash reported1 injured

AIRBAGS DID NOT DEPLOY WHEN VEHICLE WENT OFF ROAD AND RASHED; ON-STAR DID NOT FUNCTION EITHER MANUALLY OR UPON IMPACT.*AK

20071016Component: AIR BAGS:FRONTALCrash reported

TL*THE CONTACT OWNS A 2002 GMC 3500. WHILE DRIVING 35 MPH, THE CONTACT SWERVED TO AVOID A DEER AND STRUCK A CONCRETE WALL. NONE OF THE AIR BAGS IN THE VEHICLE DEPLOYED. THE VEHICLE WAS TOWED FROM T

20050323Component: PARKING BRAKE:DRIVELINE:HYDRAULIC:HOSES, LINES/PIPING, AND FITTINGSCrash reported

THE PARKING BRAKE WAS ON AND THE VEHICLE WAS PARKED ON A SLIGHT INCLINE AND WITHOUT WARNING THE VEHICLE ROLLED DOWN THE STREET AND CRASHED INTO A TREE. VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION,

20110119Component: FUEL SYSTEM, GASOLINEFire reported

TL* THE CONTACT OWNS A 2002 GMC SIERRA 3500. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE BEGAN TO SMOKE AND LOSE POWER ABNORMALLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE FUEL FILT

20160422Component: ENGINE

TL* THE CONTACT OWNS A 2002 GMC SIERRA 3500. WHILE OPERATING THE VEHICLE, THE ODOR OF FUEL WAS NOTICEABLE INSIDE THE CABIN. UPON INSPECTION, THE CONTACT DISCOVERED FUEL HAD LEAKED FROM THE VEHICLE ONT

Showing the 5 most serious of 29 complaints filed with NHTSA.

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