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1991 Chevrolet K2500 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- 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
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
A/C & Cooling System Maintenance -> General Motors Corp. -> 1990-95 Chevrolet & GMC C & K, G, P & R & V Series
Vehicle: 1991 Chevrolet K2500 Pickup 6.2 V8 DIESEL
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BRAKE SERVICE PROCEDURES FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
POWER BRAKE UNITS, GENERAL MOTORS -> Bendix Brake Boosters -> HYDRO-BOOST -> ACCUMULATOR SERVICE -> ASSEMBLE -> BLEEDING BOOSTER -> CLEANING & INSPECTION -> DESCRIPTION -> DISASSEMBLE
Vehicle: 1991 Chevrolet K2500 Pickup 7.4 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 K2500 Pickup AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> 6.2L Diesel Engine
Vehicle: 1991 Chevrolet K2500 Pickup 6.2 V8 DIESEL
On models equipped with fuel injected engines, relieve fuel system pressure as outlined under "Fuel System Pressure Relief."
On models equipped with metal collar quick disconnect connectors, GM tool No. J37088-A, or equivalent, will be required to disconnect the connector. Prior to reconnecting the connector, apply a few drops of clean motor oil to the male pipe ends.
On models equipped with plastic collar quick disconnect connectors, squeeze the connector plastic retainer release tabs to release the connector. Prior to reconnecting the connector, apply a few drops of clean motor...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Chevrolet K2500 Pickup 5.0 V8 GAS
- Raise and support vehicle.
- Remove wheel and tire assembly.
- Remove drive axle center cap, if equipped.
- Insert a drift or large screwdriver through brake caliper into one of the brake rotor vanes in order to prevent drive axle wheel drive shaft from turning.
- Remove nut and washer from hub. Do not reuse nut. A new nut must be used when installing wheel drive shaft.
- Using axle remover tool No. J 45859 or equivalent, press wheel drive shaft from hub.
- Remove bolts securing wheel dr...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Chevrolet K2500 Pickup 5.7 V8 GAS
- 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 K2500 Pickup AUTOMOBILES
General Motors Corp./Saturn Trucks -> Reduce Engine Power Indicator Lamp ->
Vehicle: 1991 Chevrolet K2500 Pickup 6.2 V8 DIESEL
The Reduce Engine Power indicator lamp should light for a approximately 3 seconds when the ignition is turned On as a bulb check. If the warning lamp turns On during vehicle operation, a vehicl...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Chevrolet K2500 Pickup 5.7 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 K2500 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Chevrolet K2500 Pickup 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 K2500 Pickup AUTOMOBILES
Component location diagrams for most 1991 Chevrolet K2500 Pickup cars and light trucks sold in the U.S. from 1990+.
Transmission Components Diagram for 1991 Chevrolet K2500 Pickup 7.4 V8 GAS Components on diagram: |
Transmission Components Diagram for 1991 Chevrolet K2500 Pickup 6.2 V8 DIESEL Components on diagram: |
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WIRING DIAGRAMS FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Chevrolet K2500 Pickup cars and light trucks sold in the U.S.
1991 Chevrolet K2500 Pickup 4.3 V6 GAS Wiring Diagram Components on diagram: |
1991 Chevrolet K2500 Pickup 7.4 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
OEM TSB listings for most 1991 Chevrolet K2500 Pickup 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 K2500 Pickup 4.3 V6 GAS Auto Systems: |
Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1991 Chevrolet K2500 Pickup 4.3 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Chevrolet K2500 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Chevrolet K2500 Pickup 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 K2500 Pickup 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 K2500 Pickup 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 K2500 Pickup 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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