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1991 GMC G35/G3500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
BRAKE SERVICE PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
ANTI-LOCK BRAKES, GENERAL MOTORS -> Four Wheel Anti-Lock Brake System -> DESCRIPTION
Vehicle: 1991 GMC G35/G3500 VAN 6.2 V8 DIESEL
This braking system Fig. is designed to reduce the occurrence of wheel lock-up during severe braking conditions. To accomplish this function, the system regulates hydraulic brake line pressure by using an Electronic Hydraulic Control Unit (EHCU) module. This control module has two types of valves. Isolation valves which maintain pressure to each front wheel separately and rear wheels combined. Dump valves which dump pressure to each front wheel separately and rear wheels combined. These valves are controlled by a microcomputer which is part of the EHCU module. During a severe brak...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Component Locations -> Late 1986-06 Chevrolet & GMC G Series w/Gasoline Engines
Vehicle: 1991 GMC G35/G3500 VAN 5.7 V8 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
DRIVESHAFT, Replace -> One Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 1991 GMC G35/G3500 VAN Vandura 6.2 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 1991 GMC G35/G3500 VAN AUTOMOBILES
Alternator, Replace
Vehicle: 1991 GMC G35/G3500 VAN Rally 5.7 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 1991 GMC G35/G3500 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Change Trans Fluid Indicator ->
Vehicle: 1991 GMC G35/G3500 VAN Vandura 6.2 V8 DIESEL
This message will appear on the DIC (Driver Information Center) when it is time to change the transmission fluid....
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1991 GMC G35/G3500 VAN Vandura 6.2 V8 DIESEL
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp at radiator outlet and remove hose.
- Reposition hose clamp at water pump inlet and remove hose.
- Remove hose from vehicle.
- Reverse procedure...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1991 GMC G35/G3500 VAN Rally 7.4 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 1991 GMC G35/G3500 VAN AUTOMOBILES
Component location diagrams for most 1991 GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1990+.
Steering Column Components Diagram for 1991 GMC G35/G3500 VAN Rally 5.7 V8 GAS Components on diagram: |
Auxiliary Heater System Components Diagram for 1991 GMC G35/G3500 VAN 5.7 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1991 GMC G35/G3500 VAN cars and light trucks sold in the U.S.
1991 GMC G35/G3500 VAN 6.2 V8 DIESEL Wiring Diagram Components on diagram: |
1991 GMC G35/G3500 VAN 7.4 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
OEM TSB listings for most 1991 GMC G35/G3500 VAN cars and light trucks sold in the U.S. from 1985+.
Document: Car and Truck Fix It Right the First Time Issues Vehicle: 1991 GMC G35/G3500 VAN Rally 6.2 V8 DIESEL Auto Systems: |
Document: GM TIRE WARRANTY PROGRAM CLAIMS GOODWILL GUIDELINES - REVISED Vehicle: 1991 GMC G35/G3500 VAN Rally 6.2 V8 DIESEL Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1991 GMC G35/G3500 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1991 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 1991 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 1991 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 1991 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
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