Sign In
Upload
Manuals
Brands
Chevrolet Manuals
Trucks
1991 Light Duty Truck
Chevrolet 1991 Light Duty Truck Manuals
Manuals and User Guides for Chevrolet 1991 Light Duty Truck. We have
1
Chevrolet 1991 Light Duty Truck manual available for free PDF download: Repair Manual
Chevrolet 1991 Light Duty Truck Repair Manual (856 pages)
Chevrolet 1991 Light Duty Truck Unit repair manual
Brand:
Chevrolet
| Category:
Trucks
| Size: 44.36 MB
Table of Contents
Table of Contents
6
General Information
7
Service Parts
7
Identification Label
7
Vehicle Identification Number
7
Engine Identification Number
8
Certification Label
8
Engine I.D. Locations
8
Transmission Identification Number
9
Model Reference
9
Metric Fasteners
9
Engine I.D. Location
9
5.0L, 5.7L, 7.4L Engine I.D. Location
10
6.2L Diesel Engine I.D. Location
10
Prevailing Torque Fasteners
11
Hydra-Matic 4L60 Transmission I.D.location
11
Hydra-Matic HM-117 Transmission I.D.location
11
Hydra-Matic 5LM60 Transmission I.D.location
12
Hydra-Matic 4L80E Transmission I.D.location
12
R/V Models
13
G Models
14
P Models
15
C/K Models
15
ST Models
16
M Models
17
Bolt and Nut Identification
17
Thread Notation
17
Six Lobed Socket Head Fasteners
18
Torque Nuts and Bolt Chart
19
Conversion Table
20
Decimal and Metric Equivalents
21
Air Conditioning
23
A-6 Air Conditioning Compressor
23
General Description
23
Table of Contents
23
Minor Rerair to the Compressor
24
Clutch Plate and Hub Assembly Replacement
24
Clutch Rotor and Bearing Assembly Replacement
24
Compressor Component View
25
Removing the Shaft Nut
26
Removing the Clutch Plate and Hub Assembly
26
Installing the Drive Plate
26
Removing the Pulley Retainer Ring
27
Removing the Pulley and Bearing
27
Removing the Pulley and Bearing Retainer Ring
27
Removing the Bearing from the Pulley
27
Clutch Coil Assembly Replacement
28
Installing the Pulley Bearing
28
Adhesive Fill Guide
28
Remove of Disconnect
28
Major Repair to the Compressor
29
Shaft Seal Replacement
29
Removing/Installing the Shaft Seal Seat and O-Ring
29
A Ir Conditioning C Om Pressor
29
Removing/Installing Shaft Seal and O-Ring
30
Shaft and Seal Position and Correct Position Gaging Guide
30
Pressure Relief Valve Replacement
31
Leak Testing
31
V-5 Air Conditioning Compressor
35
General Description
35
Rear Head Details
36
Mounting View
36
Compressor Components
37
Minor Repair to the Com Pressor
38
Removing the Clutch Plate and Hub and Shaft Key
38
Clutch Plate and Hub Assembly Replacement
38
Clutch Rotor And/Or Bearing Assembly Replacement
39
Bearing Stake Locations
41
Installing the Pulley Bearing Assembly
41
Staking the Pulley Bearing in the Pulley Bore
41
Removing the Clutch Coil Assembly
42
Staking the Clutch Coil to the Front Head
42
Major Repair to the Com Pressor
43
Shaft Seal Replacement
43
Pressure Relief Valve Replacement
44
Leak Testing
45
Specifications
46
Special Tools
47
R-4 Air Conditioning Compressor
49
General Description
49
Minor Repair to the Compressor
51
Clutch Plate and Hub Assembly Replacement
56
Major Repair to the Compressor
57
Shaft Seal Replacement
57
Pressure Relief Valve Replacement
59
Leak Testing
60
Specifications
61
Special Tools
62
Hr-6 He Air Conditioning Compressor
63
General Description
63
Minor Repair to the Compressor
65
Clutch Plate and Hub Assembly
65
Rotor And/Or Bearing Assembly Replacement
67
Clutch Coil Replacement
68
Removing the Pulley Bearing
68
Installing the Pulley Rotor Bearing
68
Staking Locations
69
Major Repair to the Compressor
71
Shaft Seal Replacement
71
Leak Testing
73
Specifications
74
Special Tools
75
Sd-709 Air Conditioning Compressor
77
Disassembly of the Clutch and Shaft Seal
78
Removing the Nut
79
Removing the Internal Snap Ring
79
Removing the Clutch Plate
79
Assembly of the Clutch and Shaft Seal
80
Disassembly of the Cylinder Head and Valve Plate
82
Assembly of the Cylinder Head and Valve Plate
82
Specifications
83
Special Tools
84
Manual Steering Gear
85
Steering Gear Components—Model 535
86
Remove and Install Worm Shaft Seal Gear Assembled
87
Remove and Install Pitman Shaft and Side Cover
87
Remove and Install Wormshaft and Ball Nut
88
Disassemble and Assemble Worm Bearing Adjuster
88
Disassemble and Assemble Wormshaft and Ball Nut
88
Adjust Worm Bearing Preload
89
Adjust “Over Center” Preload
89
Saginaw Model 5 3 5
90
Specifications
90
Adjustment
90
Fastener Torque
90
Special Tools
90
Power Steering
91
Description
91
Saginaw Integral Power Steering Gear
93
Unseating the Retaining Ring
93
Removing the Retaining Ring
93
Removing the Plug and Piston Rack
93
Disassembly
93
Separating the Wormshaft from the Valve Assembly
95
Removing or Installing the Stub Shaft Assembly
95
Removing or Installing Valve Spool Assembly
95
Cleaning and Inspection
95
Installing the Balls into the Rack Piston
96
Retaining the Balls in the Ball Guide
96
Assembly
96
Bottoming the Adjuster Plug
97
Marking the Housing
97
Remarking the Housing
97
Aligning the Adjuster Hole with the Second Mark
97
Aligning the Over-Center Preload
98
Installing the Retaining Ring
98
Saginaw (1C Series) Power Steering Pump
99
Power Steering (TC SERIES) Pump Components
99
Removing the Reservoir Clips
100
Removing the Reservoir
100
Removing the Fitting, Control Valve, Spring and Seal
100
Removing and Installing Retaining Ring
100
Disassembly
100
Removing and Installing Driveshaft Seal
101
Removing the Thrust Plate
101
Removing the Retainer Ring
101
Pump Housing Components
101
Cleaning and Inspection
101
Removing and Installing Return Lube
102
Installing of the Pressure Plate
102
Installing the Rotor
102
Aligning and Installing the Pump Ring
102
SAGINAW (Model P and N) POWER STEERING PUMP
103
Assembly
103
Disassembly
103
Power Steering Pump—Model P
104
Cleaning and Inspection
104
Assembly
104
Specifications
107
Special Tools
107
Rear Axle
109
7 1/2 and 7 5/8-Inch Ring Gear Axles
109
Checking the Axle before Disassembly
110
Disassembly of the Rear Axle
110
Rear Axle Identification
110
Rear Axle Components
111
Pinion Shaft Lock Bolt
112
Removing/Installing the Pinion Nut
112
Removing Differential Side Bearings
112
Differential
113
Checking Pinion Preload
113
Pinion Collapsible Spacer
113
Removing the Pinion Rear Bearing
113
Cleaning
113
Inspection
113
Assembly of the Rear Axle
114
Differential Case Assembly
115
Checking Pinion Depth
115
Side Bearing Pre-Load Adjustment
116
Installing the Side Bearing
116
Pinion Installation
117
Shim Thickness Chart
117
Installing the Pinion Inner Bearing
117
Backlash Adjustment
118
Gear Tooth Pattern Check
119
Final Assembly
119
Installing the Axle Seal
119
"C" Lock and Axle Shaft Seated in the Side Gear
119
Adjustments Affecting Tooth Contact
120
Gear Tooth Pattern
120
7 1/2 and 7 5/8-Inch Ring Gear Axle
121
Specifications
121
Special Tools
122
8 1/2-Inch Ring Gear
123
Disassembly of the Rear Axle
124
Cleaning
124
Inspection
124
Axle Housing
126
Pinion and Ring Gear
126
Prying the Differential Case
126
Removing the Pinion Flange
127
Pinion Depth Adjustment
127
Assembly of the Rear Axle
127
Installing the Front Pinion Bearing Cup
128
Gage Plate Tools
128
Installing the Rear Pinion Bearing Cup
128
Gear Tooth Pattern Check
133
Adjustments Affecting Tooth Contact
134
Specifications
135
9 1/2-Inch Ring Gear
137
Removing the Differential Case
139
Cleaning
140
Inspection
140
Assembly of the Rear Axle
141
Gear Tooth Pattern Check
147
Adjustments Affecting Tooth Contact
147
Specifications
148
Specia L Tools
149
Disassembly of the Rear Axle
152
Cleaning
152
Inspection
152
Assembly of the Rear Axle
155
Gear Tooth Pattern Check
159
Adjustments Affecting Tooth Contact
159
Specifications
161
Special Tools
161
Dana Rear Axles
163
9 3/4-Inch Ring Gear
163
Disassembly of the Rear Axle
164
Cleaning
167
Inspection
167
Assembly of the Rear Axle
169
10 1/2-Inch Ring G Ear
176
Description
176
Checking the Axle before Disassembly
176
Disassembly of the Rear Axle
176
Cleaning
180
Inspection
181
Assembly of the Rear Axle
181
Specifications
190
Special Tools
191
8 1/2-Inch Ring Gear Front Axle
217
Description
218
Disassembly of Axle
218
Inspection
218
Disassembly
218
Cleaning and Inspection
221
Cleaning
221
Inspection
221
Assembly of Axle
222
P Inion Bearing Cup Insta Lla Tio N
222
Pinion Depth Adjustment
222
Pinion Installation
224
Differential Case Assembly
224
Side Bearing Preload Adjustment
225
Backlash Adjustment
226
Gear Tooth Contact Pattern Check
227
Final Assembly
228
Ring Gear Bolts
229
Bearing Cap Bolts
229
Specifications
229
Disassembly of Axle
232
Inspection
232
Disassembly
232
Cleaning and Inspection
236
Cleaning
236
Inspection
236
Assembly of Axle
237
Determining Total Differential Shim Pack Size
238
Pinion Depth Adjustment
239
Pinion Installation
240
Checking Backlash
243
Axle Cover Bolts
244
Available Shim Sizes Size
244
Differential Bearing Adjusting Shim
244
Outer Pinion Bearing Shim
244
Inner Pinion Bearing Shim
244
Ring Gear Bolts
244
Bearing Cap Bolts
244
Final Assembly
244
Specifications
244
Special Tools
245
Disassembly of Axle
249
Inspection
249
Disassembly
249
Cleaning and Inspection
252
Cleaning
252
Inspection
252
Assembly of Axle
253
Differential Case Assembly
253
Pinion Bearing Cup Installation
254
Pinion Depth Adjustment
254
Pinion Installation
254
Differential Assembly Installation
256
Adjusting Backlash
257
Gear Tooth Contact Pattern Check
258
Final Assembly
259
Drive Axle Assembly
261
Outer Deflector Ring
261
Outer Joint Seal
261
Outer Jo Int Assembly
263
Specifications
268
Special Tools
269
Disassembly of Axle
272
Inspection
272
Disassembly
272
Cleaning and Inspection
273
Cleaning
273
Inspection
273
Assembly of Axle
279
Pinion Bearing Cup Installation
279
Pinion Depth Adjustment
280
Pinion Installation
280
Differential Case Assembly
280
Differential Assembly Installation
282
Adjusting Backlash
283
Gear Tooth Contact Pattern Check
284
Carrier Case Assembly
286
Axle Tube Assembly
286
Final Assembly
287
Drive Axle Assembly
290
Outer Deflector Ring Replacement
290
Outer Joint Seal Replacement
290
Outer Joint Assembly Replacement
290
Specifications
296
Special Tools
297
Disassembly of Axle
300
Inspection
300
Disassembly
300
Cleaning and Inspection
300
Cleaning
300
Inspection
301
Assembly of Axle
301
Differential Case Assembly
301
Pinion Bearing Cup Installation
305
Pinion Depth Adjustment
305
Pinion Installation
306
Differential Assembly Installation
306
Adjusting Backlash
308
Gear Tooth Contact Pattern Check
308
Final Assembly
311
Drive Axle Assembly
311
Outer Deflector Ring
311
Outer Joint Seal
313
Outer Joint Assembly
314
Inner Tri-Pot Seal
315
Specifications
318
Special Tools
335
General Engine Mechanical
337
Subject Page
338
Statement on Cleanliness and Care
338
Use of Rtv Sealer and Anaerobic Gasket Eliminator
338
Replacing Engine Gaskets
339
Cylinder Bores, Pistons, Rings, and Connecting Rods
339
Measuring Cylinder Bore Taper and Out-Of-Round (All M Odels)
339
Cylinder Bore Reconditioning (2.5L Engines)
339
Cylinder Bore Reconditioning (2.8L E Ngines)
340
Cylinder Bore Reconditioning (All Except 2.5L and 2.8L Engines)
340
Boring
341
Honing
341
Piston and Connecting Rod Assemblies
341
Piston Selection (2.5L and 2.8L Engines)
343
Piston Selection (All Except 2.5L and 2.8L Engines)
344
Camshaft Bearing
347
Camshaft Bearing Replacement (2.5L and 6.2L Engines)
347
Camshaft Bearing Replacement (All Except 2.5L and 6.2L Engines)
347
Hydraulic Lifters
348
Hydraulic Lifter Overhaul
349
Valve Lifter Leak-Down Rate Test (Flat Type Lifters Only)
351
Cylinder Head
351
Disassembly
351
Cleaning and Inspection
351
Repair
353
Subject Page
360
Description
360
Engine Lubrication
360
Disassembly of the Engine
360
Tools and Shop Equipment
360
Accessory Removal
360
Cleaning
363
Parts Identification
363
Draining the Engine
363
Intake Manifold Removal
363
Exhaust Manifold Removal
363
Thermostat Housing Removal
365
Coolant Pump Removal
365
Valve Train Component Removal
366
Cylinder Head Removal
367
Crankshaft Pulley Hub Removal
368
Oil Pan Removal
368
Oil Pump Driveshaft Removal
368
Oil Pump Removal
368
Front Cover Removal
368
Piston and Connecting Rod Removal
369
Flywheel Removal
369
Crankshaft Removal
369
Crankshaft Rear Oil Seal Removal (W Ithout Removing Crankshaft)
370
Main Bearing Removal (W Ithout Removing the Crankshaft)
370
Camshaft Removal
370
Cleaning, Inspection, and Repair
371
Block
371
Cylinder Bores
371
Piston and Connecting Rod Assemblies
371
Piston Selection
371
Intake and Exhaust M Anifold
372
Camshaft
372
Camshaft Bearings
373
Front Cover
374
Coolant Pump
374
Oil Pump
375
Cylinder Head
376
Thermostat and Housing
377
Crankshaft and Bearings
377
Assembly of Engine
378
Prior to Assembly
378
Crankshaft and Main Bearing Insta Lla Tio N
409
Oil Pump Installation
413
Cylinder Head Installation
414
Valve Train Component Installation
414
Intake Manifold Installation
415
Exhaust Manifold Installation
416
Flywheel Installation
416
Engine Accessory Installation
416
Engine Set-Up and Testing
417
Specifications
417
Description
422
Engine Lubrication
422
Disassembly
422
Tools and Shop Equipment
422
Accessory Removal
423
Cleaning
423
Draining the Engine
425
Egr Valve Removal
425
Rocker Arm Cover Removal
425
Intake Manifold Removal
425
Cylinder Head Removal
425
Torsional Damper Removal
425
Rocker Arm Cover Bolts
425
Intake Manifold Bolts
425
Exhaust Manifold Bolts
425
Cylinder Head Bolts
425
Oil Pan Removal
426
Oil Pump Removal
426
Camshaft Removal
426
Torsional Damper Bolt
426
Front Cover Bolts
426
Camshaft Sprocket Bolts
426
Piston and Connecting Rod Removal
427
Flywheel Removal
428
Connecting Rod Cap Nuts
428
Crankshaft Removal
429
Main Bearing Cap Bolts
429
Cleaning, Inspection and Repair
430
Block
430
Camshaft Bearings
431
Coolant Pump
432
Oil Pump
433
Hydraulic Lifters
434
Cylinder Head
434
Rocker Arm Studs
435
Crankshaft and Bearings
436
Prior to Assembly
437
Crankshaft and Main Bearing Installation
437
Rear Crankshaft Oil Seal Installation
438
Camshaft, Timing Chain and Sprocket Installation
439
Torsional Damper Installation
440
Piston and Connecting Rod Installation
440
Oil Pump Installation
441
Oil Pan Installation
442
Cylinder Head Installation
442
Valve Train Component Installation
442
Valve Adjustment
442
Intake Manifold Installation
444
Rocker Arm Cover Installation
445
Exhaust Manifold Installation
445
EGR Valve Installation
446
Flywheel Installation
446
Engine Accessory Installation
446
Engine Set-Up and Testing
447
Specifications
448
Special Tools
451
Disassembly
457
Accessory Removal
457
Cleaning
457
Draining the Engine
457
Tools and Shop Equipm Ent
457
Exhaust Manifold Removal
458
Intake Manifold Removal
459
Coolant Pump Removal
459
Valve Train Component Removal
460
Rocker Arm Cover Removal
460
Cylinder Head Removal
461
Torsional Damper Removal
462
Oil Pan Removal
462
Oil Pump Removal
462
Front Cover Removal
462
Camshaft Removal
463
Piston and Connecting Rod Removal
463
Timing Chain and Camshaft Sprocket Removal
463
Flywheel Removal
465
Rear Crankshaft Oil Seal Retainer Removal
465
REAR CRANKSHAFT OIL SEAL RETAINER REMOVAL (5.0L and 5.7L ENGINES)
465
Crankshaft Removal
466
Cleaning, Inspection and Repair
466
Cleaning, Inspection, and R E P Air
466
Block
466
Piston and Connecting Rod Assemblies
467
Camshaft
468
Camshaft Bearings
468
Timing Chain and Sprockets
468
Intake and Exhaust Manifold
468
Front Cover
469
Coolant Pump
470
Oil Pan and Rocker Arm Covers
470
Oil Pump
470
Valve Train Components
471
Cylinder Head
472
Thermostat and Water Outlet
475
Crankshaft and Bearings
476
Torsional Damper
481
Piston and Connecting Rod Installation
482
Oil Pump Installation
483
Cylinder Head Installation
484
Valve Adjustment
487
Rocker Arm Cover Installation
490
Exhaust Manifold Installation
490
Coolant Pump Installation
490
Engine Accessory Installation
490
Engine Setup and Testing
490
Specifications
491
Special Tools
496
Subject Page
498
Engine Lubrication
499
Disassembly
500
Accessory Removal
500
Draining the Engine
500
Vacuum Pump/Oil Pump Drive Removal
501
Intake Manifold Removal
501
Injection Line Removal
501
Injection Nozzle Removal
502
Glow Plug Removal
502
Exhaust Manifold Removal
503
Dipstick Tube Removal
503
Coolant Crossover Removal
503
Rocker Arm Cover Removal
503
Rocker Arm and Pushrod Removal
503
Cylinder Head Removal
504
Hydraulic Lifter Removal
504
Coolant Pump Removal
504
Torsional Damper Removal
504
Injection Pump Removal
504
Advertisement
Advertisement
Related Products
Chevrolet 1981 Light Duty Truck
Chevrolet 1969 CE10904
Chevrolet 1969 CE10905
Chevrolet 1969 KS10734
Chevrolet 1961 C30
Chevrolet 1961 P30
Chevrolet 1961 Tandem
Chevrolet 1980 K25 Pickup
Chevrolet 1980 P30042
Chevrolet 1980 Suburban
Chevrolet Categories
Automobile
Trucks
Car Navigation system
Car Video System
Automobile Accessories
More Chevrolet Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL