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

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Chevrolet G20 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 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 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 Chevrolet G20 VAN AUTOMOBILES

Air Conditioner and Heater Service Includes module configuration procedures, general service, maintenance, automatic temperature control, compressor services, electric cooling fans, vacuum diagrams, specifications, and manual air conditioning and heater diagnostics and replacement procedures for domestic and imported Chevrolet G20 VAN cars and light trucks from 1990+

A/C Data -> Domestic Light Trucks & Vans -> General Motors Corp./Saturn -> 1992-2002 -> 2003-04
Vehicle: 1994 Chevrolet G20 VAN 5.7 V8 GAS

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BRAKE SERVICE PROCEDURES FOR Chevrolet G20 VAN AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Chevrolet G20 VAN cars and light trucks from 1990+.

Hydraulic Brake Systems -> Brake System Bleed -> Hydraulic System Flush -> Manual Bleed -> Master Cylinder Bleed -> Parking Brake Bleed -> Pressure Bleed
Vehicle: 1992 Chevrolet G20 VAN 6.2 V8 DIESEL

Manual Bleed

  • If vehicle is equipped with power brakes, remove vacuum reserve by applying brakes several times with engine off.
  • Fill master cylinder reservoirs with suitable brake fluid. Be sure to always keep master cylinder reservoirs at least half full during entire bleeding procedure.
  • If master cylinder is suspected to have air in the bore, it must be bled first, as follows:
    • Disconnect forward brake pipe connection at master cylinder.
    • Allow brake fluid to fill master cylinder bore until it begins to flow from forward pipe connector port.
    • Connect and tighten forward brake pipe at...

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FUEL FILTER REPLACEMENT PROCEDURES FOR Chevrolet G20 VAN AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported Chevrolet G20 VAN cars and light trucks sold in the U.S. for 1980+.

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: 1994 Chevrolet G20 VAN Sportvan 5.0 V8 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 Chevrolet G20 VAN AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported Chevrolet G20 VAN cars and light trucks from 1990+.

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1992 Chevrolet G20 VAN Sportvan 5.0 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 Chevrolet G20 VAN AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported Chevrolet G20 VAN cars and light trucks from 1990+.

Alternator, Replace
Vehicle: 1991 Chevrolet G20 VAN Sportvan 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 Chevrolet G20 VAN AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1990+.

General Motors Corp./Saturn Trucks -> Service Four Wheel Drive (4WD) System Warning Lamp ->
Vehicle: 1995 Chevrolet G20 VAN Sportvan 5.0 V8 GAS

This lamp should light for approximately 6-8 seconds when the ignition is turned On as a bulb check. If the ...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Chevrolet G20 VAN AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported Chevrolet G20 VAN cars and light trucks from 1990+

Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1992 Chevrolet G20 VAN 4.3 V6 GAS

Inlet

  • Remove air cleaner.
  • Drain cooling system into a suitable container.
  • Remove heater hose support clamp bolt.
  • Reposition heater core inlet hose clamp at engine.
  • Remove hose from engine.
  • Reposition heater hose inlet clamp at heater core.
  • Remove heater inlet hose from heater core.
  • Remove hose from vehicle.
  • Reverse procedure to install.

Outlet

  • Remove air cleaner.
  • Drain cooling system into a suitable container.
  • Remove heater hose support clamp bolt.
  • Reposition heater hose...

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SERPENTINE BELT SERVICE PROCEDURES FOR Chevrolet G20 VAN AUTOMOBILES

Serpentine belt replacement procedures with corresponding images for most domestic and imported Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1990+.

Serpentine Drive Belt, Replace
Vehicle: 1996 Chevrolet G20 VAN Express 4.3 V6 GAS

These engines use a single serpentine drive belt to drive all engine-mount accessories. All belt drive accessories are rigidly mounted with belt tension maintained by a spring loaded automatic tensioner.

  • Rotate tensioner counterclockwise using suitable 1/2 inch break...

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COMPONENT LOCATION DIAGRAMS FOR Chevrolet G20 VAN AUTOMOBILES

Component location diagrams for most Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1990+.

ESC Knock Sensor   Diagram for 1989 Chevrolet G20 VAN  5.0 V8 GASESC Knock Sensor Diagram for 1989 Chevrolet G20 VAN 5.0 V8 GAS

Components on diagram:
  • ESC Knock Sensor
  • RH Side Of Engine   Diagram for 1990 Chevrolet G20 VAN Sportvan 6.2 V8 DIESELRH Side Of Engine Diagram for 1990 Chevrolet G20 VAN Sportvan 6.2 V8 DIESEL

    Components on diagram:
  • Glow Plug
  • Fuel Shutoff
  • Fast Idle Solenoid Connector
  • Cold Advance & Fast Idle
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet G20 VAN PARTS/COMPONENTS LOCATION DIAGRAMS!

    WIRING DIAGRAMS FOR Chevrolet G20 VAN AUTOMOBILES

    OEM drawn wiring diagrams for most Chevrolet G20 VAN cars and light trucks sold in the U.S.

    1995 Chevrolet G20 VAN Sportvan 4.3 V6 GAS Wiring Diagram1995 Chevrolet G20 VAN Sportvan 4.3 V6 GAS Wiring Diagram

    Components on diagram:
  • Turn Signal Flasher
  • Backup Light Switch
  • 1990 Chevrolet G20 VAN Sportvan 4.3 V6 GAS Wiring Diagram1990 Chevrolet G20 VAN Sportvan 4.3 V6 GAS Wiring Diagram

    Components on diagram:
  • LH Side Marker Lamp
  • RH Side Marker Lamp
  • LH Headlamp Connector
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet G20 VAN WIRING DIAGRAMS!

    TECHNICAL SERVICE BULLETINS FOR Chevrolet G20 VAN AUTOMOBILES

    OEM TSB listings for most Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1985+.

    Document: WARRANTY ADMIN - DEALER PROHIBITED USE
    Vehicle: 1990 Chevrolet G20 VAN 4.3 V6 GAS

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • Document: WARRANTY ADMIN - EXPEDITING PARTS - REV
    Vehicle: 1990 Chevrolet G20 VAN 6.2 V8 DIESEL

    Auto Systems:
  • Labor Times, Manuals, Warranty, Aids
  • CLICK HERE TO GET FULL ACCESS TO Chevrolet G20 VAN TECHNICAL SERVICE BULLETINS!

    COMPONENT/PARTS SPECIFICATIONS FOR Chevrolet G20 VAN AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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 Chevrolet G20 VAN SPECIFICATIONS DATA!

    Shop online for auto body parts, engines, wheels, lights...

    Click here to view more details1973 Chevrolet G20 Van Ignition Lock Cylinder, With keys; Without retaining bolt; For locking steering column; A high quality, direct fit OE replacement ignition lock cylinder; With 2 years limited Trustbuilt warranty..

    Source: Auto Body Parts Store

    $30.04

    Click here to view more details1974 Chevrolet G20 Van Headlight, Driver Or Passenger Side, Bulbs included; Sealed beam and halogen type; Round; DOT and SAE approved; A high quality, direct fit OE replacement headlight assembly; With 3 years limited CertifiedXL warranty..

    Source: Auto Body Parts Store

    $22.43

    Click here to view more details about 2005 Chevrolet S10 Blazer 15" x 7" Steel Wheel2005 Chevrolet S10 Blazer 15" x 7" Steel Wheel, Steel Wheel; 15 X 7; 8 Slots; 5 Lug; 4.75 Inch BP; Ident TCJ; Flat Black, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $69.50

    Click here to view more details1995 Toyota Pickup L4, 2.4 L, 2366 CC Rebuilt Engine, OHC, RWD, Fuel injected or Carb. Fits 8/84-10/95, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,469.00

    Click here to view more details1993 Chevrolet G20 VAN Used Radiator Support Assembly, 6DR, 5.7, AUTO, RWD exc. 30HD; dual hdlps, Very Good.

    Source: Used Auto Parts Store

    $131.00

    Click here to view more details1983 Chevrolet G20 VAN Used Fan Clutch, 6.2, AUTO, 4X2 UPDATE ID, Very Good.

    Source: Used Auto Parts Store

    $77.00
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