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1991 GMC G35/G3500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC REPAIR SHOPS DON'T WANT YOU TO KNOW
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- 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 GMC G35/G3500 VAN 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 G35/G3500 VAN automobile. Try the Automotix DIY solution today!
BRAKE SERVICE PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
DRUM BRAKES, GENERAL MOTORS -> General Information -> SERVICE PRECAUTIONS
Vehicle: 1991 GMC G35/G3500 VAN Vandura 6.2 V8 DIESEL
When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, the amount of asbestos dust from brake lining wear is at a low level due to a chemical breakdown during use, and a few precautions will minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent e...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 GMC G35/G3500 VAN 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: 1991 GMC G35/G3500 VAN Vandura 6.2 V8 DIESEL
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 1991 GMC G35/G3500 VAN AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1991 GMC G35/G3500 VAN Vandura 7.4 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 GMC G35/G3500 VAN AUTOMOBILES
Starter, Replace
Vehicle: 1991 GMC G35/G3500 VAN 7.4 V8 GAS
- 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 GMC G35/G3500 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Change Trans Fluid Indicator ->
Vehicle: 1991 GMC G35/G3500 VAN Rally 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 GMC G35/G3500 VAN AUTOMOBILES
Radiator, Replace
Vehicle: 1991 GMC G35/G3500 VAN Vandura 5.7 V8 GAS
- Drain cooling system into a suitable container.
- Remove upper fan shroud.
- Remove radiator hose inlet.
- Remove radiator hose outlet.
- Remove transmission oil cooler lines.
- Remove overflow hose.
- Remove ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 GMC G35/G3500 VAN Rally 7.4 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 GMC G35/G3500 VAN AUTOMOBILES
Component location diagrams for most 1991 GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1990+.
 Engine Components Diagram for 1991 GMC G35/G3500 VAN Vandura 4.3 V6 GASComponents on diagram: |
 Auxiliary Heater System Components Diagram for 1991 GMC G35/G3500 VAN 6.2 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1991 GMC G35/G3500 VAN cars and light trucks sold in the U.S.
 1991 GMC G35/G3500 VAN Rally 5.7 V8 GAS Wiring DiagramComponents on diagram: |
 1991 GMC G35/G3500 VAN Vandura 4.3 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
OEM TSB listings for most 1991 GMC G35/G3500 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 GMC G35/G3500 VAN Rally 6.2 V8 DIESEL Auto Systems: |
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Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1991 GMC G35/G3500 VAN Rally 6.2 V8 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 GMC G35/G3500 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 GMC G35/G3500 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 GMC G35/G3500 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 GMC G35/G3500 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
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