1991 GMC C3500 Service and Repair Manual
This factory service and repair manual for the 1991 GMC C3500 keeps three engines and three body configurations in one volume. The engines are the 5.7L and 7.4L gasoline V8s and the 6.2L diesel V8; the bodies are the standard cab pickup, the extended cab pickup and the two-door cab and chassis, offered as Sierra, Sierra SLE or Sierra SLX. A cab-and-chassis truck often carries equipment the factory never saw, which makes accurate wiring diagrams, procedures and torque values worth having when something has to come apart.
Engines covered
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
- 6.2L V8 (379 cu in) — OHV, naturally aspirated, diesel
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 2-door standard cab pickup
- 2-door extended cab pickup
- 2-door cab & chassis
Trims covered
- Sierra
- Sierra SLE
- Sierra SLX
Known issues on the 1991 C3500. Two recalls apply to this model year. The first covers replacement oil filters whose seal can fail, releasing engine oil where it can ignite; the second describes transmission fluid driven out of the vent tube by heat and catching fire against a hot component. NHTSA holds two owner complaints as well, one on the tires and one on the service brakes. Lubrication service, transmission repair and the brake system are all documented in detail here, with the specifications, torque values and diagnostic procedures each of them needs.
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 VEHICLES LIST ABOVE. TH
THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN A FIRE.
HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING NOVEMBER 20
UNANTICIPATED HEAT IN THE TRANSMISSION CAN FORCE THE TRANSMISSION FLUID OUT OF THE VENT TUBE.
THE VENTED TRANSMISSION FLUID CAN CATCH FIRE IF EXPOSEDTO A SOURCE OF IGNITION.
INSTALL A LONGER TRANSMISSION VENT HOSE ROUTED TO THE LEFT SIDE OF THE ENGINE COMPARTMENT OF THE VEH
UNKNOWN
PE00 048; CONSUMER WAS TRAVELING ABOUT 65MPH ON HIGHWAY AND HEARD A NOISE. HE WAS ABLE TO PULL OVER, AND SAW THAT LEFT REAR TIRE (GOODYEAR WRANGLER GSA LT245/75R-16LE) HAD EXPERIENCED TREAD SEPARAT
REAR BRAKES FAILED. *DSH
