1991 Chevrolet G20 Service and Repair Manual

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Factory-Grade Data

1991 Chevrolet G20 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Sportvan Extended Passenger Van 3-Door
  • Beauville Extended Passenger Van 3-Door
  • Chevy Van Standard Cargo Van 3-Door
  • Chevy Van Extended Cargo Van 3-Door

Engines covered

  • 5.0L 305Cu. In. V8 GAS OHV Naturally Aspirated
  • 6.2L 379Cu. In. V8 DIESEL OHV Naturally Aspirated
  • 4.3L 262Cu. In. V6 GAS OHV Naturally Aspirated
  • 5.7L 350Cu. In. V8 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1991 Chevrolet G20 Recalls & Complaints

NHTSA #07E08800024/10/2007Component: EQUIPMENT

CERTAIN HONEYWELL FRAM RACING BRAND HP4 AND HP8 OIL FILTERS THAT WERE MANUFACTURED FROM MAY 25, 2006, THROUGH SEPTEMBER 14, 2007, AND SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR VEHI

Consequence

THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN

Remedy

HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING N

NHTSA #06E04300019/05/2006Component: FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FU

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGA

NHTSA #91V04000011/03/1991Component: SEATS

SEAT BACK OF THE REAR BENCH SEAT MAY BREAK AWAY FROM THE SEAT CUSHION IN AN ACCIDENT.

Consequence

SEAT OCCUPANT WOULD BE SUBJECT TO GREATER INJURY; VEHICLEWOULD NOT COMPLY WITH FMVSS 207.

Remedy

INSTALL REINFORCEMENT THAT RUNS FROM SIDE OF SEAT BACK FRAME ASSEMBLY TO SEAT CUSHION FRAM

NHTSA #92V04700002/04/1992Component: SEAT BELTS:FRONT:ANCHORAGE

INSTALLATION OF SAFETY BELT ANCHORAGE BOLTS FAILED TO COMPLY WITH FMVSS 210.

Consequence

INCORRECT INSTALLATION OF SAFETY BELT ANCHORAGES COULDRESULT IN FAILURE OF THE SAFETY BELT

Remedy

TIGHTEN THE D-RING ANCHORAGE BOLTS TO THE PILLAR POST TO THE CORRECT TORQUE.

No service bulletins No technical service bulletins on file with NHTSA for the 1991 Chevrolet G20.
20000901Component: ENGINE AND ENGINE COOLING:ENGINE:GASOLINEFire reported

WHILE DRIVING THE VEHICLE STARTED TO SMOKE, WHEN THE VEHICLE WAS STOPPED AT THE ROADSIDE THE CONSUMER NOTICED ANTIFREEZE LEAKING OUT FROM THE ENGINE, THEN THE ENGINE CAUGHT FIRE. (

19971010Component: STRUCTURE:BODY:DOOR

LEFT DOOR STRIKER FAILED, METAL CAVED IN.

19970303Component: STRUCTURE:BODY:DOOR:HINGE AND ATTACHMENTS

THE DOOR HINGES ARE BREAKING OFF THE DOOR AND THERE WILL BE NOTHING TO HOLD THE DOOR CLOSED. *AK

19950807Component: SUSPENSION:FRONT:CONTROL ARM

BALL JOINTS ARE WEARING OUT SO FAST THAT SEEMS AS THOUGH THERE'S A TIRE PROBLEM; CAUSES POOR HANDLING OF VEHICLE; PULLS TO LEFT/RIGHT. TT

Showing the 4 most serious of 5 complaints filed with NHTSA.

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