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1991 Chevrolet G20 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator 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 1991 Chevrolet G20 VAN car and truck
repair procedures including Chevrolet 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 Chevrolet G20 VAN automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
A/C & Cooling System Maintenance -> General Motors Corp. -> 1990-95 Chevrolet & GMC C & K, G, P & R & V Series
Vehicle: 1991 Chevrolet G20 VAN 6.2 V8 DIESEL
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BRAKE SERVICE PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
DISC BRAKES, GENERAL MOTORS -> Bendix Single Piston Sliding Caliper -> CALIPER SERVICE -> ASSEMBLE -> DISASSEMBLE -> INSTALLATION -> REMOVAL
Vehicle: 1991 Chevrolet G20 VAN 4.3 V6 GAS
REMOVAL
- Siphon two-thirds of brake fluid from master cylinder reservoir serving front disc brakes.
- Raise vehicle, support on jack stands and remove front wheels.
- Bottom the caliper piston in bore. Insert a screwdriver between inboard shoe and piston, then pry piston back into bore. The piston can also be bottomed in the bore with a large C-clamp, Fig. .
- Remove support key retaining screw.
- Drive caliper support key and spring from steering knuckle with a suitable drift and hammer, Fig. .
- Lift caliper from anchor plate and off rotor, Fig. . Hang caliper from coil spring with wire. Do n...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1988-95 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 1991 Chevrolet G20 VAN 5.0 V8 GAS
Light Duty Emissions
Normal Service
Replace every 60,000 miles
Severe Service
Rep...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1991 Chevrolet G20 VAN Sportvan 5.7 V8 GAS
Never clamp propeller shaft tubing in a vise. Clamping could dent or deform the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks may damage the bushing or cut the lip seal.
Disassemble
- Support propeller shaft in a line horizontal with table of a press.
- Mark propeller shaft in order to show which end connects to transmission and which end goes to rear axle.
- On models equipped with external snap ring retainers, proceed as follows:
- Disassemble snap rings by ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Chevrolet G20 VAN Sportvan 6.2 V8 DIESEL
- Disconnect battery ground cable.
- Disconnect terminal plug and battery lead from rear of alternator.
- Remove accessory drive belt.
- Remove alternator mounting bolts.
- Separate alternator from mounting bracket.
- Rem...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Service Throttle Soon Indicator Lamp ->
Vehicle: 1991 Chevrolet G20 VAN Sportvan 4.3 V6 GAS
A "Service Throttle Soon" indicator lamp is mounted in the lower righthand instrument cluster corner on these models. It lights when the ignition is turned On, but should go out approximately 1-5 seconds after the engine starts.
Traditional throttle cables are no longer used on these models. The PCM receives signals from an electron...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Chevrolet G20 VAN Sportvan 5.0 V8 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition hose clamp at heater core.
- Remove inlet heater hose from heater core.
- Reposition hose clamp at thermostat housing.
- Remove inlet heater hose from thermostat housing.
- Remove hose from vehicle.
- Reverse proc...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Chevrolet G20 VAN Sportvan 6.2 V8 DIESEL
- Rotate tensioner to release belt tension, using a 1/2 inch breaker bar with a 5/8 inch socket placed on tensioner pulley.
- Remove drive belt.
- Route b...
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COMPONENT LOCATION DIAGRAMS FOR 1991 Chevrolet G20 VAN AUTOMOBILES
Component location diagrams for most 1991 Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1990+.
 Engine Components Diagram for 1991 Chevrolet G20 VAN 6.2 V8 DIESELComponents on diagram: |
 Engine Wiring Harness At Transmission Diagram for 1991 Chevrolet G20 VAN Sportvan 4.3 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Chevrolet G20 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Chevrolet G20 VAN cars and light trucks sold in the U.S.
 1991 Chevrolet G20 VAN 5.0 V8 GAS Wiring DiagramComponents on diagram: |
 1991 Chevrolet G20 VAN Sportvan 4.3 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Chevrolet G20 VAN AUTOMOBILES
OEM TSB listings for most 1991 Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1985+.
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Document: Car and Truck Fix It Right the First Time Issues Vehicle: 1991 Chevrolet G20 VAN 4.3 V6 GAS Auto Systems: |
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Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1991 Chevrolet G20 VAN 4.3 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Chevrolet G20 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Chevrolet G20 VAN 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 1991 Chevrolet G20 VAN 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 1991 Chevrolet G20 VAN 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 1991 Chevrolet G20 VAN 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
CLICK HERE TO GET FULL ACCESS TO 1991 Chevrolet G20 VAN SPECIFICATIONS DATA!
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