1994 Chevrolet G20 Service and Repair Manual

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Factory-Grade Data

1994 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
  • 4.3L 262Cu. In. V6 GAS OHV Naturally Aspirated
  • 5.7L 350Cu. In. V8 GAS OHV Naturally Aspirated
  • 6.5L 395Cu. In. V8 DIESEL 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

1994 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 #99I00600019/07/1999Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED

THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: CERTAIN LIGHT DUTY PICK

Consequence

THESE VEHICLES CAN EXPERIENCE EXTENDED STOPPING DISTANCES DURING ABS STOPS ON CERTAIN MULT

Remedy

DEALERS WILL MODIFY THE COMPUTER PROGRAM WHICH OPERATES THE ABS UNIT ON SOME VEHICLES, OR

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 #94V17700014/09/1994Component: SEATS:FRONT ASSEMBLY:HEAD RESTRAINT

THE FRONT DRIVER AND PASSENGER SEAT BACK HEIGHT DOES NOT CONFORM TO THE REQUIREMENTS OF FMVSS NO. 202, "HEAD RESTRAINTS."

Consequence

CONSEQUENCE OF NON-COMPLIANCE: SEAT OCCUPANTS ARE SUBJECT TO INCREASED RISK OF INJURY IN

Remedy

SHERRY DESIGNS WILL PROVIDE AN ATTACHABLE HEADREST FOR THE DEALER OR CUSTOMER TO ADD TO TH

NHTSA #95I00500013/12/1994Component: ENGINE AND ENGINE COOLING:ENGINE:DIESEL

VEHICLE DESCRIPTION: LIGHT DUTY PICKUP TRUCKS, VANS AND MOTORHOMES EQUIPPED WITH ELECTRONICALLY FUEL INJECTED 6.5L DIESEL ENGINE. THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH

Consequence

CERTAIN VEHICLES CAN EXHIBIT SOME DRIVEABILITY CONCERNS SUCH AS POOR THROTTLE RESPONSE, ST

Remedy

DEALERS WILL INSTALL SOME RECENTLY DEVELOPED ENHANCEMENTS WHICH WILL IMPROVE THE OVERALL D

NHTSA #94V12800011/07/1994Component: INTERIOR LIGHTING

THE TRANSFORMER USED TO POWER THE NEON CENTER LIGHTBEAM CAN OVERHEAT AND CATCH ON FIRE.

Consequence

THE OVERHEATING AND FIRES CAUSED BY THE NEON TRANSFORMER CAN RESULT IN DAMAGE TO THE LIGHT

Remedy

MARK III DEALERS WILL MODIFY THE ASSEMBLIES TO ELIMINATE THE NEON LIGHTING FIXTURE IN THE

NHTSA #94V08700009/05/1994Component: EQUIPMENT:OTHER:LABELS

THE MANUFACTURER'S CERTIFICATION LABEL AND/OR THE DRIVER AIR BAG ADVISORY LABEL MAY BE MISSING FROM THE VEHICLES, WHICH DOES NOT CONFORM TO THE REQUIREMENTS OF 49 CFR 567.

Consequence

CONSEQUENCE OF NON-COMPLIANCE: OWNERS OF VEHICLE WOULD BE UNAWARE OF THE LOAD CAPACITY OF

Remedy

THE LABELS WILL BE FURNISHED TO OWNER'S FOR INSTALLATION ON THE VEHICLES.

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

19980721Component: AIR BAGSCrash reported5 injured

NO DEPLOYMENT OF AIR BAG DURING COLLISION, SEAT BELTS DID NOT RESTRAIN, THESE FAILURES RESULTED IN SEVERAL INJURIES TO HEAD,NECK AND CHEST.

19980721Component: SEAT BELTS:FRONT:ANCHORAGECrash reported5 injured

NO DEPLOYMENT OF AIR BAG DURING COLLISION, SEAT BELTS DID NOT RESTRAIN, THESE FAILURES RESULTED IN SEVERAL INJURIES TO HEAD,NECK AND CHEST.

19980922Component: AIR BAGS:FRONTALCrash reported1 injured

CONSUMER WAS DRIVING AT 35 MPH, WHEN SHE HIT ANOTHER VEHICLE BROADSIDE, THE AIR BAG ON THE DRIVER'S SIDE DID NOT DEPLOY. CONSUMER KEPT BRAKING TO BRING VEHICHLE TO A COMPLETE STOP.

19980921Component: AIR BAGS:FRONTALCrash reported1 injured

THERE WAS NO DEPLOYMENT OF THE DRIVER'S SIDE AIR BAG DURING A COLLISION. ALSO, THE SEAT BELT DID RESTRAIN DRIVER. THESE FAILURES RESULTED IN SEVERAL INJURIES TO HEAD/ NECK AND CHE

Showing the 4 most serious of 53 complaints filed with NHTSA.

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