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1991 Chevrolet V2500 Suburban CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Brake Service
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- 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 Chevrolet V2500 Suburban 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 V2500 Suburban automobile. Try the Automotix DIY solution today!
BRAKE SERVICE PROCEDURES FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
POWER BRAKE UNITS, GENERAL MOTORS -> Bendix Brake Boosters -> POWER BRAKE UNIT, Replace -> 1990-91 C & K SERIES -> ASTRO VAN & SAFARI VAN -> CABALLERO & EL CAMINO -> FULL SIZE EXCEPT 1990-91 C & K SERIES
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL
CABALLERO & EL CAMINO
Pump brake pedal several times with engine off to deplete accumulator of fluid.
- Remove two nuts attaching master cylinder to booster, then move master cylinder away from booster with brake lines attached.
- Remove three hydraulic lines from booster. Plug and cap all lines and outlets.
- Remove retainer and washer securing booster pushrod to brake pedal arm.
- Remove four nuts attaching booster unit to dash panel.
- From engine compartment, loosen booster from dash panel and move booster pushrod inboard until it disconnects from brake pedal arm. Remove spring wa...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> 6.2L Diesel Engine
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL
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. Prior to reconnecting the connector, apply a few drops of clean motor oil to the male pipe ends.
On models equipped with plastic collar quick disconnect connectors, squeeze the connector plastic retainer release tabs to release the connector. Prior to reconnecting the connector, apply a few drops of clean motor...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL
- Raise and support vehicle.
- Remove wheel and tire assembly.
- Remove drive axle center cap, if equipped.
- Insert a drift or large screwdriver through brake caliper into one of the brake rotor vanes in order to prevent drive axle wheel drive shaft from turning.
- Remove nut and washer from hub. Do not reuse nut. A new nut must be used when installing wheel drive shaft.
- Using axle remover tool No. J 45859 or equivalent, press wheel drive shaft from hub.
- Remove bolts securing wheel dr...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
Alternator, Replace
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL
- 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 1991 Chevrolet V2500 Suburban AUTOMOBILES
General Motors Corp./Saturn Trucks -> Check Engine Oil Level ->
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL
This system is used to indicate a low engine oil level condition. The lamp should light during engine starting. If oil level is sufficient, the lamp should go off when engine is operating. If oil level is low the...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL
Inlet
- Drain cooling system into a suitable container.
- Reposition hose clamp at heater core.
- Remove inlet heater hose from heater core.
- Reposition hose clamp at thermostat housing.
- Remove inlet heater hose from thermostat housing.
- Remove hose from vehicle.
- Reverse proc...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 Chevrolet V2500 Suburban 6.2 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 1991 Chevrolet V2500 Suburban AUTOMOBILES
Component location diagrams for most 1991 Chevrolet V2500 Suburban cars and light trucks sold in the U.S. from 1990+.
 Rear Defogger I/P Wiring Diagram for 1991 Chevrolet V2500 Suburban 5.7 V8 GASComponents on diagram: |
 Electronic Engine Controls Diagram for 1991 Chevrolet V2500 Suburban 5.7 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
OEM drawn wiring diagrams for most 1991 Chevrolet V2500 Suburban cars and light trucks sold in the U.S.
 1991 Chevrolet V2500 Suburban 5.7 V8 GAS Wiring DiagramComponents on diagram: |
 1991 Chevrolet V2500 Suburban 5.7 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
OEM TSB listings for most 1991 Chevrolet V2500 Suburban 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 Chevrolet V2500 Suburban 6.2 V8 DIESEL Auto Systems: |
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Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1991 Chevrolet V2500 Suburban 6.2 V8 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 Chevrolet V2500 Suburban AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 Chevrolet V2500 Suburban 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 Chevrolet V2500 Suburban 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 Chevrolet V2500 Suburban 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 Chevrolet V2500 Suburban 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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