1991 Chevrolet G20 VAN REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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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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Get Full Access 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!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Chevrolet mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 1991 Chevrolet G20 VAN vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

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 Sportvan 5.0 V8 GAS

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BRAKE SERVICE PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES

POWER BRAKE UNITS, GENERAL MOTORS -> Bendix Brake Boosters -> HYDRO-BOOST -> ACCUMULATOR SERVICE -> ASSEMBLE -> BLEEDING BOOSTER -> CLEANING & INSPECTION -> DESCRIPTION -> DISASSEMBLE
Vehicle: 1991 Chevrolet G20 VAN Sportvan 5.0 V8 GAS

DESCRIPTION

The Hydro-Boost system, Fig. , provides an additional cylinder in the brake system. This cylinder contains no brake fluid. The Hydro-Boost cylinder is hydraulically operated, by pressurized fluid from the power steering pump, providing power assist to operate a dual master cylinder brake system.

The booster is composed of two sections; the linkage section and the power section.

The booster is designed so that if a total absence of power assist occurs, the brakes can be applied manually, but somewhat greater pressure on the brake pedal is required.

DISASSEMBLE

  • Place accumulato...

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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 5.7 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, Replace -> One Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 1991 Chevrolet G20 VAN 5.7 V8 GAS

One Piece Driveshaft
  • Raise and support vehicle.
  • Mark rear universal joint to drive shaft flange.
  • Remove retaining bolts and clamps.
  • Remove propeller shaft from pinion drive flange.
  • Remove propeller shaft from transmission/transfer case.
  • Using tape or a rubber band, wrap the U-Joint bearing caps to ensure bearing caps do not separate from U-Joint.
  • Reverse procedure to install, noting the following:
    • Align reference marks made during removal.
    • Torque yoke retainer bolts to 18 ft. lbs.
Two Piece Driveshaft
  • Raise and support vehicle.
  • Suppor...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES

Starter, Replace
Vehicle: 1991 Chevrolet G20 VAN 6.2 V8 DIESEL

  • Disconnect battery ground cable.
  • Raise and support vehicle.
  • Remove starter to engine brace and heat shields, if equipped.
  • Remove starter motor mounting bolts and lower ...

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MAINTENANCE LAMP RESET PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES

General Motors Corp./Saturn Trucks -> Change Trans Fluid Indicator ->
Vehicle: 1991 Chevrolet G20 VAN 5.7 V8 GAS

This message will appear on the DIC (Driver Information Center) when it is time to change the transmission fluid....

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 Chevrolet G20 VAN Sportvan 6.2 V8 DIESEL

Lower

  • Drain cooling system into a suitable container.
  • Reposition hose clamp at radiator outlet and remove hose.
  • Reposition hose clamp at water pump inlet and remove hose.
  • Remove hose from vehicle.
  • Reverse procedure...

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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Chevrolet G20 VAN AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 1991 Chevrolet G20 VAN 5.7 V8 GAS

  • Rotate tensioner counterclockwise, using a 1/2 inch breaker bar with a socket placed on tensioner ...

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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 DIESELEngine Components Diagram for 1991 Chevrolet G20 VAN 6.2 V8 DIESEL

Components on diagram:
  • Throttle Position Sensor
  • MAP Sensor
  • Fast Idle Solenoid
  • Fuel Shut Off Valve
  • Low Coolant Probe
  • A/C Compressor Controls Diagram for 1991 Chevrolet G20 VAN  5.0 V8 GASA/C Compressor Controls Diagram for 1991 Chevrolet G20 VAN 5.0 V8 GAS

    Components on diagram:
  • Blower Motor
  • High Blower Relay
  • Blower Resistor
  • High Pressure Cutout Switch
  • Evaporator Pressure Control Switch
  • CLICK HERE TO GET FULL ACCESS TO 1991 Chevrolet G20 VAN PARTS/COMPONENTS LOCATION DIAGRAMS!

    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  5.7 V8 GAS Wiring Diagram1991 Chevrolet G20 VAN 5.7 V8 GAS Wiring Diagram

    Components on diagram:
  • Backup Lamp Switch
  • LH Backup Lamp
  • RH Backup Lamp
  • 1991 Chevrolet G20 VAN  5.7 V8 GAS Wiring Diagram1991 Chevrolet G20 VAN 5.7 V8 GAS Wiring Diagram

    Components on diagram:
  • Turn Signal Switch
  • Horn Relay
  • Horn
  • Cigarette Lighter
  • CLICK HERE TO GET FULL ACCESS TO 1991 Chevrolet G20 VAN WIRING DIAGRAMS!

    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+.

    Document: Car and Truck Fix It Right the First Time Issues
    Vehicle: 1991 Chevrolet G20 VAN 4.3 V6 GAS

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED
    Vehicle: 1991 Chevrolet G20 VAN 4.3 V6 GAS

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Wheels, Tires, Wheel Bearings, Seals, Hubs
  • CLICK HERE TO GET FULL ACCESS TO 1991 Chevrolet G20 VAN TECHNICAL SERVICE BULLETINS!

    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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