Related Manuals for Chevrolet CHEVY VAN G20 SERIES
Summarization of Contents
General Information and Lubrication
General Information
Covers model lineup, series identification, VIN, engine numbers, and unit locations.
Lubrication
Details lubrication points, periods, types, and specific component lubrication schedules.
Heater and Air Conditioning
Standard Heater
Explains the standard heater system, controls, component replacement, and airflow.
Air Conditioning
Details the C-62 and C-63 air conditioning systems, components, and theory.
Frame
General Description
Describes frame construction, underbody assembly, and alignment influence on door opening.
Underbody Alignment
Details methods for determining underbody alignment using a tram gauge and measuring points.
Front Suspension
Maintenance and Adjustments
Covers wheel bearing adjustment, front alignment procedures, caster, camber, and toe-in.
Component Parts Replacement
Details removal and installation for hubs, bearings, shocks, springs, and control arms.
Rear Suspension and Driveline
Rear Suspension
Covers shock absorber and leaf spring service, including removal and installation.
Rear Axle
Details axle lubrication, noise diagnosis, and component replacement procedures.
Brakes
Hydraulic Brakes
Explains the split brake system, master cylinder, combination valve, and brake components.
Maintenance and Adjustments
Covers brake inspection, fluid service, bleeding procedures, and parking brake adjustment.
Engine
Engine Tune-Up
Covers general tune-up procedures, mechanical checks, spark plugs, and ignition system.
Engine Mechanical (In Line)
Details removal and installation of engine components for the L6 engine.
Engine Mechanical (V8)
Details removal and installation of engine components for V8 engines.
Engine Cooling
Maintenance and Adjustments
Covers coolant level checks, system checks, periodic maintenance, and cleaning procedures.
Thermostatic Fan Clutch
Details the replacement procedure for the thermostatic fan clutch, including run-out checks.
Water Pump
Covers water pump removal and installation procedures.
Engine Fuel
CARBURETORS
Covers carburetor removal, installation, adjustments, and maintenance procedures.
FUEL PUMP
Details fuel pump service procedures, inspection, testing, removal, and installation.
AIR CLEANERS
Covers air cleaner maintenance, element replacement, and inspection procedures.
Emission Control Systems
POSITIVE CRANKCASE VENTILATION
Describes the PCV system for removing engine crankcase vapors.
TRANSMISSION CONTROLLED SPARK SYSTEM
Explains the TCS system for controlling ignition vacuum advance based on transmission gear.
AIR INJECTION REACTOR SYSTEM
Details the AIR system, pump, diverter valve, and injection tubes.
Engine Electrical
BATTERY
Covers battery general description, servicing, testing, and charging procedures.
CHARGING SYSTEMS
Explains the Delcotron AC generator and voltage regulator operation.
IGNITION SYSTEMS
Details distributor, contact points, spark plugs, and coil service.
STARTING SYSTEM
Covers starting motor, solenoid checks, and component replacement.
Clutches & Transmissions
CLUTCH CONTROLS
Explains clutch pedal travel adjustment, linkage, and cross-shaft service.
CLUTCHES
Covers diaphragm spring clutch maintenance, adjustments, and assembly replacement.
MANUAL TRANSMISSIONS
Details linkage adjustment and transmission removal and installation procedures.
TURBO HYDRA-MATIC 350
Provides diagnosis procedures, oil checks, linkage adjustments, and leaks for THM 350.
Fuel Tank and Exhaust
FUEL TANKS AND ATTACHMENTS
Covers fuel tank inspection, removal, installation, and filler neck identification.
FUEL LINES
Details fuel line service, inspection, and cleaning procedures.
EVAPORATION CONTROL SYSTEM (ECS) COMPONENTS
Describes canister, filter, hoses, and purge valve service.
EXHAUST SYSTEM
Covers exhaust pipe, muffler, and tailpipe replacement and installation.
Steering
STEERING GEAR
Covers lubrication, adjustments, and removal/installation of the steering gear.
STEERING LINKAGE
Details tie rod, relay rod, idler arm, and pitman arm removal and installation.
POWER STEERING
Covers power steering gear, pump, hoses maintenance, adjustments, and fluid level.
Wheels and Tires
TIRE TREAD WEAR INDICATOR
Explains how to identify tire wear using built-in tread indicators.
TIRE INFLATION
Details standard and optional tire inflation pressures and related notes.
SERVICE OPERATIONS
Covers wheel nut torques, tire wear correction, balancing, and jacking instructions.
Demounting and Mounting
Provides step-by-step instructions for removing and installing tubeless tires.
Front End Sheet Metal
HOOD ASSEMBLY AND ADJUSTMENT
Covers hood hinge alignment, bumper adjustment, and lock assembly procedures.
SHEET METAL CHECKING
Details proper gaps and hood adjustments for sheet metal alignment.
Electrical - Body and Chassis
LIGHTING SYSTEM
Covers headlamp, marker lamp, rear lighting, and switch service procedures.
INSTRUMENTS AND GAUGES
Details instrument cluster removal, indicators, gauges, and cable service.
WIPER MOTOR REPLACEMENT
Provides procedures for wiper motor removal, disassembly, and reassembly.
Radiator and Grille
RADIATOR SERVICE PROCEDURES
Covers radiator removal, installation, and cooling system checks.
GRILLE SERVICE PROCEDURES
Details grille removal and installation procedures.
BUMPER
FRONT BUMPER
Covers front bumper removal and installation procedures.
REAR BUMPER
Covers rear bumper removal and installation procedures.
ACCESSORIES
RADIO REPLACEMENT
Provides steps for radio removal and installation.
SPEAKER REPLACEMENT
Details speaker removal and replacement procedures.
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