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1997 Chevrolet G20 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- 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 1997 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!
A/C & HEATER SERVICE PROCEDURES FOR 1997 Chevrolet G20 VAN AUTOMOBILES
Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Adjustments -> A/C -> C & K Series -> Control Cables -> G Series -> Less A/C -> Mode/Temperature/Recirculation Actuators -> S/T Series
Vehicle: 1997 Chevrolet G20 VAN Express 6.5 V8 DIESEL
Control Cables
G Series
Less A/C
- Attach inner cable and sheath to dash panel control.
- Move temperature cable to Cold then attach loop on inner cable to temperature door on heater case.
- Attach cable sheath to heater case, then move temperature lever to full Heat. This will require force to slide inner cable clip to its proper position.
- Move temperature adjusting lever quickly from Cold to Hot. Door should be heard seating at stops.
A/C
The temperature door cable is self-adjusting. Quickly move temperature lever from...
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BRAKE SERVICE PROCEDURES FOR 1997 Chevrolet G20 VAN AUTOMOBILES
Power Brake Units -> Bendix Brake Booster -> Power Brake Unit Replacement -> Astro & Safari -> C & K Series -> G Series -> P Series
Vehicle: 1997 Chevrolet G20 VAN Express 5.0 V8 GAS
Astro & Safari
- Apply parking brake.
- Disconnect reservoir and power steering hoses from booster.
- Remove master cylinder to brake booster retaining nuts.
- Position and support master cylinder away from booster. Do not remove hydraulic lines from master cylinder.
- Remove booster rod from top of brake pedal.
- Remove booster mounting nuts from inside of vehicle.
- Remove booster assembly and gasket.
- Reverse procedure to install, noting the following:
- Torque booster mounting nuts to 27 ft. lbs.
- Torque master cylinder retaining nuts to 27 ft. lbs.
- Torque power steering hoses to booster n...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1997 Chevrolet G20 VAN AUTOMOBILES
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1996-03 C/K, G & R/V Series w/Gasoline Engine -> Heavy Duty Emissions -> Light Duty Emissions -> Normal Service -> Severe Service
Vehicle: 1997 Chevrolet G20 VAN Express 5.0 V8 GAS
Light Duty Emissions
Normal Service
Replace every 30,000 miles
Severe Service
Rep...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1997 Chevrolet G20 VAN AUTOMOBILES
DRIVESHAFT, Replace -> One Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 1997 Chevrolet G20 VAN Express 5.7 V8 GAS
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 1997 Chevrolet G20 VAN AUTOMOBILES
Alternator, Replace -> Auxiliary -> Single Alternator
Vehicle: 1997 Chevrolet G20 VAN Express 6.5 V8 DIESEL
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 1997 Chevrolet G20 VAN AUTOMOBILES
General Motors Corp./Saturn Trucks -> Check Fuel Cap Lamp ->
Vehicle: 1997 Chevrolet G20 VAN Express 6.5 V8 DIESEL
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. I...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1997 Chevrolet G20 VAN AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1997 Chevrolet G20 VAN Express 5.0 V8 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from radiator.
- Remove radiator outlet hose from radiator.
- Reposition hose clamp from water pump.
- Remove radiator outlet hose from water pump and from vehicle.
- Reverse procedure to in...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1997 Chevrolet G20 VAN AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1997 Chevrolet G20 VAN Express 6.5 V8 DIESEL
- Rotate tensioner arm counterclockwise using 3/8 inch breaker bar.
- Remove belt from pulleys.
- Route new belt over all pulleys except tensioner arm.
- Rotate tensioner arm co...
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COMPONENT LOCATION DIAGRAMS FOR 1997 Chevrolet G20 VAN AUTOMOBILES
Component location diagrams for most 1997 Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1990+.
 Below Driver's Seat Diagram for 1997 Chevrolet G20 VAN Express 5.0 V8 GASComponents on diagram: |
 Below LH Side Of I/P Diagram for 1997 Chevrolet G20 VAN Express 6.5 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR 1997 Chevrolet G20 VAN AUTOMOBILES
OEM drawn wiring diagrams for most 1997 Chevrolet G20 VAN cars and light trucks sold in the U.S.
 1997 Chevrolet G20 VAN Express 5.0 V8 GAS Wiring DiagramComponents on diagram: |
 1997 Chevrolet G20 VAN Express 5.7 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1997 Chevrolet G20 VAN AUTOMOBILES
OEM TSB listings for most 1997 Chevrolet G20 VAN cars and light trucks sold in the U.S. from 1985+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 1997 Chevrolet G20 VAN Express 5.7 V8 GAS Auto Systems: |
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Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 1997 Chevrolet G20 VAN Express 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1997 Chevrolet G20 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1997 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 1997 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 1997 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 1997 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
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