1991 GMC G3500 Service and Repair Manual
This factory service and repair manual for the 1991 GMC G3500 names six trims, Magnavan, Rally, Rally Camper Special, Rally STX, Vandura and Vandura Special, and puts them across five bodies that run from a 3-door standard cargo van through extended cargo and passenger versions to a 2-door cutaway. Four naturally aspirated overhead-valve engines are covered, the 7.4L V8 of 454 cubic inches, the 6.2L diesel V8 of 379, the 4.3L V6 of 262 and the 5.7L V8 of 350. Each system has its procedures, specifications, torque values, wiring diagrams and diagnostics.
Engines covered
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
- 6.2L V8 (379 cu in) — OHV, naturally aspirated, diesel
- 4.3L V6 (262 cu in) — OHV, naturally aspirated, gasoline
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 3-door standard cargo van
- 3-door extended passenger van
- 2-door cutaway van
- 3-door standard passenger van
- 3-door extended cargo van
Trims covered
- Magnavan
- Rally
- Rally Camper Special
- Rally STX
- Vandura
- Vandura Special
Known issues on the 1991 G3500. Nothing is recorded against the 1991 G3500 federally, with no recalls and no owner complaints logged at NHTSA. The manual's contribution is the service data itself, covering fuel and ignition specifications for the three gasoline engines, the separate procedures the 6.2L diesel requires, torque values for the one-ton axles, brakes and steering, and wiring diagrams for each body listed. Diagnostics follow the same system order, so a fault on an extended passenger van is traced with the same structure as one on a cutaway.
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
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
