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1992 Chevrolet G20 VAN 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 1992 Chevrolet G20 VAN AUTOMOBILES
Compressor Service -> Harrison HR-6 Compressor -> COMPRESSOR CLUTCH SERVICE -> CLUTCH COIL, REPLACE -> CLUTCH PLATE & HUB, REPLACE -> CLUTCH PULLEY & BEARING, REPLACE -> Installation -> Removal
Vehicle: 1992 Chevrolet G20 VAN Sportvan 5.7 V8 GAS
CLUTCH PLATE & HUB, REPLACE
Removal
- Support compressor in holding fixture J-33026, or equivalent.
- Using clutch hub holding tool No. J-25030-A, or equivalent, prevent clutch hub and driveplate assembly from turning. Remove shaft nut using shaft nut socket J-33022, or equivalent.
- Thread clutch plate and hub assembly removing tool No. J-33013-B, or equivalent onto hub with center screw forcing tip located to thrust against end of shaft. Hold body of remover with wrench and turn center screw into remover body to remove clutch plate and h...
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BRAKE SERVICE PROCEDURES FOR 1992 Chevrolet G20 VAN AUTOMOBILES
Anti-lock Brakes -> Four Wheel Anti-Lock Brake System -> System Service -> 1992-95 -> 1996 -> Astro & Safari -> Brake Pressure Modulator Valve (BPMV) -> Brake System Bleed -> C & K Series -> Combination Valve -> Component Replacement -> Electro-Hydraulic Control Unit (EHCU)/Brake Pressure Modulator Valve (BPMV) Module -> Electro-Hydraulic Control Unit Brake Pressure Modulator Valve (EHCU/BPMV) Module -> Electronic Brake Control Module (EBCM) -> Except S & T Series w/VCM & VCM-A -> Front Wheel Speed Sensor -> Pressure Bleed -> Rear Wheel Speed Sensor -> S & T Series -> S & T Series w/VCM & VCM-A -> Two-Person (Manual) Bleed
Vehicle: 1992 Chevrolet G20 VAN Sportvan 5.7 V8 GAS
Brake System Bleed
1992-95
Electro-Hydraulic Control Unit Brake Pressure Modulator Valve (EHCU/BPMV) Module
The EHCU/BPMV Module should be bled after replacement or if air is trapped in the unit. If bleeding is required, the module must be bled thoroughly before the wheel cylinders and calipers.
There are two bleeders on top of the unit that appear to be normal bleeders, Fig. . These are modulator bleeders and must remain closed when the unit is not pressurized.
The internal bleeders are on either side of EHCU/BPMV module. The valves are used to open the internal passages within the E...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1992 Chevrolet G20 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> Gasoline Engines Except Equinox, Montana SV6, Relay, Rendezvous w/3.6L Engine, Terraza, Uplander & Vue (2004-06) & 2004-06 Envoy, Rainier & TrailBlazer -> Returnless Fuel System
Vehicle: 1992 Chevrolet G20 VAN 4.3 V6 GAS
Returnless Fuel System
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. Pri...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1992 Chevrolet G20 VAN AUTOMOBILES
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1992 Chevrolet G20 VAN Sportvan 4.3 V6 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 1992 Chevrolet G20 VAN AUTOMOBILES
Alternator, Replace
Vehicle: 1992 Chevrolet G20 VAN 5.0 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 1992 Chevrolet G20 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Check Fuel Cap Lamp ->
Vehicle: 1992 Chevrolet G20 VAN Sportvan 4.3 V6 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. I...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1992 Chevrolet G20 VAN AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1992 Chevrolet G20 VAN Sportvan 4.3 V6 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from coolant pump.
- Remove radiator outlet hose from coolant pump and from vehicle.
- Reverse procedure...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1992 Chevrolet G20 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1992 Chevrolet G20 VAN Sportvan 5.0 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 1992 Chevrolet G20 VAN AUTOMOBILES
Component location diagrams for most 1992 Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1990+.
Cruise Control System & Multi-Function Lever Diagram for 1992 Chevrolet G20 VAN 5.7 V8 GAS Components on diagram: |
Battery Junction Block Diagram for 1992 Chevrolet G20 VAN 6.2 V8 DIESEL Components on diagram: |
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WIRING DIAGRAMS FOR 1992 Chevrolet G20 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1992 Chevrolet G20 VAN cars and light trucks sold in the U.S.
1992 Chevrolet G20 VAN Sportvan 5.7 V8 GAS Wiring Diagram Components on diagram: |
1992 Chevrolet G20 VAN Sportvan 5.7 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1992 Chevrolet G20 VAN AUTOMOBILES
OEM TSB listings for most 1992 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: 1992 Chevrolet G20 VAN 4.3 V6 GAS Auto Systems: |
Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1992 Chevrolet G20 VAN 4.3 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1992 Chevrolet G20 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1992 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 1992 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 1992 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 1992 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
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