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+

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> THERMOSTAT, REPLACE -> ASTRO, BRAVADA, SAFARI & S/T 10-15 -> C, G, K & P SERIES -> Diesel Engine -> Except Diesel Engine -> LUMINA APV, SILHOUETTE & TRANS SPORT -> TRACKER
Vehicle: 1992 Chevrolet G20 VAN 5.7 V8 GAS

C, G, K & P SERIES

Except Diesel Engine
  • Disconnect battery ground cable, then remove engine cover, air cleaner and air inlet duct, as necessary.
  • Drain cooling system until radiator coolant level is below thermostat level.
  • Remove radiator hose at coolant outlet.
  • Remove thermostat housing retaining bolts and ground wire, if applicable.
  • Remove thermostat housing, thermostat and gasket.
  • Reverse procedure to install.
Diesel Engine
  • Disconnect battery ground cable.
  • Remove upper fan shroud, then drain e...

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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+.

Drum Brakes -> Brake Service -> C & K Series w/Non-Servo Brakes -> Duo-Servo Brakes -> Installation -> Lumina APV, Silhouette & Trans Sport -> Removal -> Tracker
Vehicle: 1994 Chevrolet G20 VAN 5.7 V8 GAS

Duo-Servo Brakes

Removal
  • Raise and support vehicle, then remove tire and wheel assembly.
  • Remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. Refer to individual truck chapter for procedure. If brake drum is rusted or corroded to axle flange and cannot be removed, lightly tap flange to drum mounting surface with a suitable hammer.
  • Using brake spring pliers or equivalent, unhook primary and secondary return springs, Fig. . Observe location of brake parts being removed to aid during installation.
  • Remove brake hold-down spri...

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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 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: 1997 Chevrolet G20 VAN Express 4.3 V6 GAS

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 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, Replace -> One Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 1997 Chevrolet G20 VAN Express 6.5 V8 DIESEL

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 Chevrolet G20 VAN AUTOMOBILES

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

Starter, Replace
Vehicle: 1993 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 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 -> Check Engine/Service Engine Soon Indicator Lamp -> Diesel Electronic Control System
Vehicle: 1995 Chevrolet G20 VAN 6.5 V8 DIESEL

The Check Engine/Service Engine Soon Lamp should light when the ignition is turned On. When the engine is started, the lamp should go off. If the lamp remains on after the engine is started, the self diagnosis system has detected a problem and has stored a code in the system Electronic Control Module (...

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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: 1994 Chevrolet G20 VAN Sportvan 6.5 V8 DIESEL

  • Rotate tensioner to release belt tension, using a 1/2 inch breaker bar with a 5/8 inch socket placed on tensioner pulley.
  • Remove drive belt.
  • Route b...

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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+.

I/P Components Diagram for 1992 Chevrolet G20 VAN Sportvan 5.0 V8 GASI/P Components Diagram for 1992 Chevrolet G20 VAN Sportvan 5.0 V8 GAS

Components on diagram:
  • DRL Module
  • DRL Relay
  • Assembly Line Diagnostic Link Connector
  • Diode Array
  • Fuel Filter   Diagram for 1989 Chevrolet G20 VAN Sportvan 5.0 V8 GASFuel Filter Diagram for 1989 Chevrolet G20 VAN Sportvan 5.0 V8 GAS

    Components on diagram:
  • Fuel Filter
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    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.

    1993 Chevrolet G20 VAN Sportvan 6.2 V8 DIESEL Wiring Diagram1993 Chevrolet G20 VAN Sportvan 6.2 V8 DIESEL Wiring Diagram

    Components on diagram:
  • Park Brake Warning Switch
  • Flow Switch
  • Hydro-Boost Pressure Warning Switch
  • Electronic Delay Module Assembly
  • Brake Warning Alarm Buzzer
  • 1994 Chevrolet G20 VAN  5.0 V8 GAS Wiring Diagram1994 Chevrolet G20 VAN 5.0 V8 GAS Wiring Diagram

    Components on diagram:
  • Battery
  • Starter Motor
  • Generator
  • Light Switch
  • 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: SERVICE INFORMATION UPDATE ON CONSOLIDATING THE USE OF GM LIQUID GASKET / ENGINE SEALANTS AND THE NEW SEALANT DISPENSER GE-48326 ESSENTIAL TOOL - REVISED
    Vehicle: 1987 Chevrolet G20 VAN 4.3 V6 GAS

    Auto Systems:
  • Tools, Equipment
  • Diesel Engines
  • Gasoline Engines
  • Seals, Gaskets, Sealants
  • Document: DEXRON-IIE ATX FLUID - CHARACTERISTICS
    Vehicle: 1985 Chevrolet G20 VAN Sportvan 4.3 V6 GAS

    Auto Systems:
  • Chemicals, Antifreeze, Additives
  • 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 Turn Signal Switch, Also controls hazard warning; A high quality, OE replacement turn signal switch; With 2 years limited TrustBuilt warranty..

    Source: Auto Body Parts Store

    $34.99

    Click here to view more details2011 Chevrolet Impala CCI Grille Overlay, CCI Grille Overlay; 3 Piece; Chrome Finish; ABS, , .

    Source: Wheels / Rims, Mirrors & Lights Store

    $111.50

    Click here to view more details1993 Jeep Cherokee L4, 2.5 L, 150 CID Rebuilt Engine, Block #532, 403, Head #403, 117 Crank #904, Crank snout 2.125", Oil bypass in filter, not in block, FI only, Warranty: 3-Year/100,000 Mile, .

    Source: Rebuilt Engines Store

    $1,297.00

    Click here to view more details1992 Chevrolet G20 VAN Used Parking Lamp, Driver Side, FADED, Good.

    Source: Used Auto Parts Store

    $51.00

    Click here to view more details1994 Chevrolet G20 VAN Used Grille, 6DR dual hdlps, Good.

    Source: Used Auto Parts Store

    $136.00
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