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GMC G25/G2500 VAN CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT GMC REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about GMC G25/G2500 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 G25/G2500 VAN automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR GMC G25/G2500 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 G25/G2500 VAN cars and light trucks from 1990+
Manual Air Conditioning & Heater System Diagnosis & Testing -> Light Duty Trucks & Vans -> A/C SYSTEM DIAGNOSIS & TESTING -> Astro, Safari, C, G, K, P Series & Tracker & S & T Series w/4.3L & Lumina APV, Silhouette & Trans Sport w/3800 Engine -> FRONT A/C -> Lumina APV, Silhouette & Trans Sport -> Lumina APV, Silhouette & Trans Sport w/3.1L & S Series w/2.2L Engine -> REAR A/C
Vehicle: 1994 GMC G25/G2500 VAN Vandura 6.5 V8 DIESEL
On models equipped with a Powertrain Control Module (PCM) or Vehicle Control Module (VCM) controlled A/C system, connect a suitable Scan Tool to the Diagnostic Link Connector (DLC), normally located behind the lefthand side of the instrument panel, near the steering column.
FRONT A/C
Lumina APV, Silhouette & Trans Sport w/3.1L & S Series w/2.2L Engine
Re...
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BRAKE SERVICE PROCEDURES FOR GMC G25/G2500 VAN AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported GMC G25/G2500 VAN cars and light trucks from 1990+.
POWER BRAKE UNITS, GENERAL MOTORS -> Delco-Moraine Brake Boosters -> POWER BRAKE UNIT, Replace -> 1990-91 C & K SERIES -> ASTRO & SAFARI VAN -> CABALLERO & EL CAMINO -> FULL SIZE EXCEPT 1990-91 C & K SERIES -> LUMINA APV, SILHOUTTE & TRANS SPORT -> S/T 10 & 15 & BRAVADA
Vehicle: 1990 GMC G25/G2500 VAN Rally 6.2 V8 DIESEL
CABALLERO & EL CAMINO
- Remove vacuum hose from check valve and master cylinder retaining nuts.
- Pull master cylinder forward so it clears mounting studs and move to one side. Support cylinder to avoid stress on hydraulic lines.
- Remove power unit to dash nuts.
- Remove brake pedal pushrod retainer and disconnect pushrod from pin.
- Remove power brake unit from vehicle.
- Reverse procedure to install.
ASTRO & SAFARI VAN
- Disconnect master cylinder from power brake unit.
- Disconnect power brake unit pushrod from brake pedal.
- Remove power brake unit retaining nuts and the power brake unit.
- Rev...
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FUEL FILTER REPLACEMENT PROCEDURES FOR GMC G25/G2500 VAN AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported GMC G25/G2500 VAN cars and light trucks sold in the U.S. for 1980+.
General Motors Corp./Saturn Light Trucks, SUVs & Vans -> Component Locations -> Late 1986-06 Chevrolet & GMC G Series w/Gasoline Engines
Vehicle: 1995 GMC G25/G2500 VAN Vandura 4.3 V6 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR GMC G25/G2500 VAN AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported GMC G25/G2500 VAN cars and light trucks from 1990+.
DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble
Vehicle: 1998 GMC G25/G2500 VAN 4.3 V6 GAS
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 G25/G2500 VAN AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported GMC G25/G2500 VAN cars and light trucks from 1990+.
Alternator, Replace
Vehicle: 1992 GMC G25/G2500 VAN Vandura 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 mount...
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MAINTENANCE LAMP RESET PROCEDURES FOR GMC G25/G2500 VAN AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported GMC G25/G2500 VAN cars and light trucks sold in the U.S. from 1990+.
General Motors Corp./Saturn Trucks -> Diesel Engine Water In Fuel Or Drain Fuel Filter Warning Lamp ->
Vehicle: 1990 GMC G25/G2500 VAN Rally 6.2 V8 DIESEL
The "Water in Fuel" indicator will light when excessive water has entered the fuel system. A low pressure sensor activates the lamp as the fuel filter becomes plugged. The lamp will light during engine starting as a bulb check.
Once engine has started, the lamp should go Off. If the lamp is lit intermittently or remains lit, drain fuel filter. If the lamp still remains On after fuel filter has been drained, replace fuel filter. If lamp is lit during high speed opera...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR GMC G25/G2500 VAN AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported GMC G25/G2500 VAN cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 1991 GMC G25/G2500 VAN Rally 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 GMC G25/G2500 VAN AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported GMC G25/G2500 VAN cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 1993 GMC G25/G2500 VAN Rally 5.7 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 GMC G25/G2500 VAN AUTOMOBILES
Component location diagrams for most GMC G25/G2500 VAN cars and light trucks sold in the U.S. from 1990+.
 PCM Wiring Diagram for 1994 GMC G25/G2500 VAN Vandura 5.7 V8 GASComponents on diagram: |
 Engine Wiring Harness At Transmission Diagram for 1992 GMC G25/G2500 VAN Rally 6.2 V8 DIESELComponents on diagram: |
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WIRING DIAGRAMS FOR GMC G25/G2500 VAN AUTOMOBILES
OEM drawn wiring diagrams for most GMC G25/G2500 VAN cars and light trucks sold in the U.S.
 1994 GMC G25/G2500 VAN Rally 6.5 V8 DIESEL Wiring DiagramComponents on diagram: |
 1995 GMC G25/G2500 VAN Vandura 5.7 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR GMC G25/G2500 VAN AUTOMOBILES
OEM TSB listings for most GMC G25/G2500 VAN cars and light trucks sold in the U.S. from 1985+.
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Document: PITTING AND BRAKE DUST ON CHROME WHEELS - REVISED Vehicle: 1991 GMC G25/G2500 VAN Rally 5.0 V8 GAS Auto Systems: |
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Document: INFORMATION FOR DEALERS ON HOW TO SUBMIT A FIELD PRODUCT REPORT Vehicle: 1995 GMC G25/G2500 VAN Rally 5.7 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR GMC G25/G2500 VAN AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most GMC G25/G2500 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 G25/G2500 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 G25/G2500 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 G25/G2500 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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