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2002 GMC Sierra 2500 CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 GMC Sierra 2500 car and truck
repair procedures including GMC engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your GMC Sierra 2500 automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Expansion Tube (Orifice), Replace -> Astro & Safari -> Bravada, C, K, S & T Series -> G Series
Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS
Astro & Safari
- Remove air cleaner.
- Recover refrigerant as outlined under .
- Remove evaporator tube from evaporator.
- Remove O-ring seal.
- Use orifice tube removal tool No. J 26549-E, or equivalent, to remove orifice tube.
- If you have difficulty removing a restricted or plugged expansion (orifice) tube, use following procedure:
- Remove as much of any impacted residue as possible.
- If system has a pressure switch near expansion (orifice) tube location, it should be removed prior to heating pipe to avoid damage t...
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BRAKE SERVICE PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
Disc Brakes -> Bendix Single Piston Sliding Caliper -> Precautions -> Brake Disc Service -> Brake Lines & Linings -> Brake Roughness -> General
Vehicle: 2002 GMC Sierra 2500 6.0 V8 CNG
Brake Lines & Linings
Remove one of the front wheels and inspect the brake disc, caliper and linings.
Do not allow any oil or grease on the linings. It is recommended that linings be replaced in sets when worn or damaged.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness v...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Except Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Tracker & Uplander -> Engine Fuel Pressure Service Port -> Engines Less Fuel Pressure Service Port
Vehicle: 2002 GMC Sierra 2500 6.0 V8 CNG
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven while the vehicle relearns its adaptive strategy.
Engines Less Fuel Pressure ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
DRIVESHAFT, Replace -> Front -> Rear
Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS
Front
Before disassembly, observe and accurately reference mark all driveline components relative to the propeller shaft and axles. These items include the propeller shafts, wheel drive shafts, pinion flanges and output shafts
Assemble all components in the exact relationship to each other as they were prior to removal. Observe all published specifications and torque values, and any measurements obtained prior to disassembly.
- Raise and support vehicle.
- Remove transfer case shield, if equipped.
- If equipped with double clamp style boot, remove clamp at transfer case by prying up ex...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
Starter, Replace
Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS
- Disconnect battery ground cable.
- Remove mounting bolts and engine shield, if required.
- Remove mounting bolts and oil pan skid plate, if required.
- Remove righthand transmission cover bolt.
- Remove front axle mounting bracket nut, then position front axle mounting bracket bolt until tip is flush with support bushing. Do not remove bolt.
- Remove mounting bolts and slide starter forward until it clears transmission.
- Disconnect oil level sensor electrical connector.
- Remove start...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
Cabin Air Filter Service -> General Motors Corp./Saturn -> 1999-2007 Silverado, Sierra, 2000-07 Denali, Suburban, Tahoe, Yukon, Yukon XL, 2001-07 Escalade & 2002-07 Avalanche
Vehicle: 2002 GMC Sierra 2500 6.0 V8 BI-FUEL
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- Remove the righthand instrument panel hush panel.
- Remove the A/C and heater modul...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
General Motors Corp./Saturn Trucks -> Anti-Lock Brake System Warning Lamp ->
Vehicle: 2002 GMC Sierra 2500 6.0 V8 BI-FUEL
This lamp should light for approximately 6-8 seconds when the ignition is turned On as a bulb check. If the warn...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS
Lower
- Drain cooling system into a suitable container.
- Separate mass airflow (MAF)/intake air temperature (IAT) sensor assembly and air inlet tube by loosening hose clamp.
- Disconnect radiator inlet hose clip from air cleaner outlet duct.
- Remove air cleaner outlet duct.
- Reposition radiator outlet hose clamp at radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump.
- Remove radiator outlet hose from water pump and from vehicle.
- Reverse procedure to install.
Upper
- D...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 GMC Sierra 2500 AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS
- Rotate tensioner clockwise to release belt tension using suitable wrench, then remove belt.
- Route belt over pulleys excep...
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COMPONENT LOCATION DIAGRAMS FOR 2002 GMC Sierra 2500 AUTOMOBILES
Component location diagrams for most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S. from 1990+.
 Front of Vehicle Diagram for 2002 GMC Sierra 2500 6.0 V8 GASComponents on diagram: |
 Lower Steering Column Components Diagram for 2002 GMC Sierra 2500 6.0 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 GMC Sierra 2500 AUTOMOBILES
OEM drawn wiring diagrams for most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S.
 2002 GMC Sierra 2500 6.0 V8 GAS Wiring DiagramComponents on diagram: |
 2002 GMC Sierra 2500 6.0 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 GMC Sierra 2500 AUTOMOBILES
OEM TSB listings for most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS Auto Systems: |
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Document: DTC P0446 (Restricted/Blocked EVAP Vent Path) Set, Check Engine Light On Vehicle: 2002 GMC Sierra 2500 6.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 GMC Sierra 2500 AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 GMC Sierra 2500 cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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