GMC G35/G3500 VAN REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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GMC G35/G3500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC 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 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!
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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 GMC mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your GMC G35/G3500 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 GMC G35/G3500 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 GMC G35/G3500 VAN cars and light trucks from 1990+

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> CONDENSER, REPLACE -> ASTRO & SAFARI -> BRAVADA & S/T-10/15 -> C & K SERIES -> G SERIES -> LUMINA APV, SILHOUETTE & TRANS SPORT
Vehicle: 1992 GMC G35/G3500 VAN 6.2 V8 DIESEL

ASTRO & SAFARI

  • Disconnect battery ground cable, then recover refrigerant from A/C system.
  • Remove grille and front end panel.
  • Disconnect radiator tie bar support at top.
  • Disconnect refrigerant lines from condenser, then cap lines and open fittings.
  • Remove condenser.
  • Reverse procedure to install.

C & K SERIES

  • Remove the battery ground cable, then recover refrigerant from A/C system.
  • Remove grille assembly.
  • Remove condenser inlet and discharge lines, then cap all connections.
  • Remove the condenser to radia...

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BRAKE SERVICE PROCEDURES FOR GMC G35/G3500 VAN AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported GMC G35/G3500 VAN cars and light trucks from 1990+.

Anti-lock Brakes -> Kelsey-Hayes -> Diagnosis & Testing -> 1997 Astro -> 1997 C & K Series -> 1997 G-Series -> 1997 P-Series -> 1997 S & T Series -> 1997-99 -> 1997-99 Except 1999 Sierra & Silverado -> 1997-99 G Van & P Series -> 1998 Astro -> 1998 C & K Series -> 1998 G-Series -> 1998 P-Series -> 1998 S & T Series -> 1999 Astro -> 1999 C & K Series Except Sierra & Silverado -> 1999 G-Series -> 1999 P-Series -> 1999 S & T Series -> 1999 Sierra & Silverado -> 2000 Astro -> 2000 C & K Series except Sierra, Silverado, Suburban, Tahoe & Yukon -> 2000 G-Series -> 2000 S & T Series -> 2000 Sierra -> 2000 Silverado -> 2000 Suburban -> 2000 Tahoe -> 2000 Yukon -> 2000-01 -> 2000-01 G Van -> 2001 Astro -> 2001 C & K Series -> 2001 G-Series -> 2001 S & T Series -> Accessing Diagnostic Trouble Codes -> Astro, Safari & S & T Series -> C & K Series -> Clearing Diagnostic Trouble Codes -> Connector Pin ID -> Diagnostic Process -> Diagnostic Tests -> Diagnostic Trouble Code Interpretation -> Enhanced Diagnostics -> G Van & P Series -> Intermittents & Poor Connections -> Temperature Vs. Resistance -> Wiring Diagrams
Vehicle: 1998 GMC G35/G3500 VAN 6.5 V8 DIESEL

Accessing Diagnostic Trouble Codes

Diagnostic trouble codes (DTCs) can only be read by connecting a suitably programmed scan tool to the Data Link Connector (DLC) and following the tool manufacturer instructions.

Diagnostic Trouble Code Interpretation

Refer to Figs. and , for Diagnostic Trouble Code (DTC) interpretation.

Wiring Diagrams

Refer "Wiring Diagrams" in "Vehicle Systems"

Connector Pin ID

On 2000 S & T Series only, ensure correct anti-lock brake system connector pin identifications are used.

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Diagnostic Process

  • Inspect master cylinder reservoir fluid level and for possible fluid...
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FUEL FILTER REPLACEMENT PROCEDURES FOR GMC G35/G3500 VAN AUTOMOBILES

Fuel filter replacement procedures with corresponding images for most domestic and imported GMC G35/G3500 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: 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 GMC G35/G3500 VAN AUTOMOBILES

Includes CV axle, universal joint, and driveline replacement, for domestic and imported GMC G35/G3500 VAN cars and light trucks from 1990+.

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1993 GMC G35/G3500 VAN Rally 6.2 V8 DIESEL

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 GMC G35/G3500 VAN AUTOMOBILES

Includes starter and alternator replacement procedures for domestic and imported GMC G35/G3500 VAN cars and light trucks from 1990+.

Alternator, Replace -> Auxiliary -> Single Alternator
Vehicle: 1998 GMC G35/G3500 VAN 7.4 V8 GAS

Single Alternator

  • Disconnect battery ground cable.
  • Remove coolant reservoir and air cleaner.
  • Remove upper fan shroud.
  • Remove drive belt, using suitable removal tool.
  • Remove heater hose pipe from alternator and oil fill tubes from support bracket.
  • Remove alternator mounting bolts, then alternator from vehicle.
  • Disconnect electrical connectors.
  • Reverse procedure to install, noting the following:
    • Torque front alternator mounting bolt to 37 f...

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MAINTENANCE LAMP RESET PROCEDURES FOR GMC G35/G3500 VAN AUTOMOBILES

Maintenance lamp reset procedures with corresponding images for most domestic and imported GMC G35/G3500 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 GMC G35/G3500 VAN Rally 7.4 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 GMC G35/G3500 VAN AUTOMOBILES

Includes radiator, cooling and heater hose replacement procedures for domestic and imported GMC G35/G3500 VAN cars and light trucks from 1990+

Radiator, Replace
Vehicle: 1998 GMC G35/G3500 VAN 6.5 V8 DIESEL

  • Drain coolant into a suitable container.
  • Remove air cleaner, duct and coolant recovery reservoir.
  • Remove mounting bolts, upper to lower mounting bolts and upper fan shroud.
  • Remove mounting bolts and low...

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SERPENTINE BELT SERVICE PROCEDURES FOR GMC G35/G3500 VAN AUTOMOBILES

Serpentine belt replacement procedures with corresponding images for most domestic and imported GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1990+.

Serpentine Drive Belt, Replace
Vehicle: 1995 GMC G35/G3500 VAN Vandura 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 GMC G35/G3500 VAN AUTOMOBILES

Component location diagrams for most GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1990+.

Fuel Filter Diagram for 1996 GMC G35/G3500 VAN  7.4 V8 GASFuel Filter Diagram for 1996 GMC G35/G3500 VAN 7.4 V8 GAS

Components on diagram:
  • Fuel Filter
  • LH & RH Cowl Panels Diagram for 1998 GMC G35/G3500 VAN  7.4 V8 GASLH & RH Cowl Panels Diagram for 1998 GMC G35/G3500 VAN 7.4 V8 GAS

    Components on diagram:
  • Power Door Lock Relay
  • Power Door Lock Control Module
  • Connector C-210
  • Connector C-212
  • Connector C-300
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    WIRING DIAGRAMS FOR GMC G35/G3500 VAN AUTOMOBILES

    OEM drawn wiring diagrams for most GMC G35/G3500 VAN cars and light trucks sold in the U.S.

    1990 GMC G35/G3500 VAN Rally 7.4 V8 GAS Wiring Diagram1990 GMC G35/G3500 VAN Rally 7.4 V8 GAS Wiring Diagram

    Components on diagram:
  • Brake Switch
  • Clutch Start Switch
  • Cruise Control Module
  • Cruise Control Servo
  • Digital Ratio Adapter
  • 1996 GMC G35/G3500 VAN Savana 7.4 V8 GAS Wiring Diagram1996 GMC G35/G3500 VAN Savana 7.4 V8 GAS Wiring Diagram

    Components on diagram:
  • Side Door Actuator Motor
  • LH Front Door Lock Actuator Motor
  • Rear Door Actuator Motor
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    TECHNICAL SERVICE BULLETINS FOR GMC G35/G3500 VAN AUTOMOBILES

    OEM TSB listings for most GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1985+.

    Document: PROPSHAFT & TIRE - SPEED REFERENCE CHART
    Vehicle: 1985 GMC G35/G3500 VAN Vandura 4.3 V6 GAS

    Symptoms:
  • Vibration
  • Auto Systems:
  • Drive Axles, Shafts, U-Joints, CV-Joints
  • Document: RWAL/4WAL - USE CORRECT BRAKE CARTRIDGE TO DIAGNOSE
    Vehicle: 1988 GMC G35/G3500 VAN 5.7 V8 GAS

    Auto Systems:
  • Brakes, Power Brakes, Traction Control
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    COMPONENT/PARTS SPECIFICATIONS FOR GMC G35/G3500 VAN AUTOMOBILES

    BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 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 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 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 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

    CLICK HERE TO GET FULL ACCESS TO GMC G35/G3500 VAN SPECIFICATIONS DATA!

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