🏷️ Basic Information

Make:

Chevrolet

Model:

K2500

Year:

1991

👋 Introduction

Market Position:

Targeted at DIY enthusiasts and independent repair shops seeking authoritative repair data for the 1991 Chevrolet K2500.

Target Audience:

DIY mechanics, truck owners, mechanics specializing in classic or older GM trucks.

Competitive Analysis:

Offers a modern, accessible alternative to older, out-of-print physical manuals, providing licensed OE information.

Key Features:

Licensed OE materials, instant online access, compatibility with multiple devices, detailed repair procedures, diagnostic information.

Accessibility And Convenience:

Instant download provides immediate access to repair information, eliminating the wait for physical delivery and the inconvenience of carrying bulky manuals.

📋 Manual Details

Coverage Areas:

Full Service and Repair for 1991 Chevrolet K2500

Repair Scope:

Covers everything from minor adjustments and fluid changes to complete drivetrain rebuilds and body panel repairs.

Page Count:

Comprehensive (exact page count not specified, but implied to be extensive)

Manual Type:

Service and Repair Manual Software

Manual Source Licensing:

Officially licensed, derived from OE (Original Equipment) materials by RepairSurge.

Language:

English

Format:

PDF Download (Software)

Device Compatibility:

Compatible with PC, laptop, smartphone, or tablet with an internet connection and web browser.

📖 Manual Coverage

Systems Covered:

Engine, Drivetrain, Transmission, Suspension, Steering, Brakes, Electrical System, HVAC (Heat, Air Conditioning), Bodywork, Wiring Diagrams, Diagnostic Procedures

Electrical System Coverage:

Detailed wiring diagrams for all circuits, fuse/relay locations, diagnostic procedures for lighting, charging system, starting system, accessories, and instrumentation.

HVAC System Coverage:

Component identification, operation, troubleshooting of heating and air conditioning systems, refrigerant handling (safely), blower motor, A/C compressor, heater core, and evaporator service.

Drivetrain Coverage:

Front and rear axle service, propeller shaft inspection/replacement, U-joint service, four-wheel-drive system operation and repair.

Procedures Included:

Routine Maintenance, Troubleshooting, Major Repairs, Component Replacement, Engine Rebuilding, Brake System Overhaul, Suspension and Steering Alignment, Electrical System Diagnostics and Repair, HVAC System Servicing

Engine Rebuilding Procedures:

Comprehensive steps for cylinder head removal/installation, piston and connecting rod service, crankshaft main bearing replacement, camshaft and lifter service, timing gear/chain replacement, and full engine assembly.

Brake System Repair Procedures:

Front disc brake pad replacement, caliper service, rotor replacement, rear drum brake shoe replacement, wheel cylinder service, brake line inspection and replacement, bleeding the brake system.

Technical Depth:

OE-level technical information, diagnostic procedures, repair steps, specifications, torque values, wiring diagrams, component locations

Diagnostic Trouble Codes Coverage:

Information on diagnostic trouble codes (if applicable to this era's OBDI system) and systematic troubleshooting trees for common drivability issues.

Engine Torque Specifications Coverage:

Detailed torque specifications for cylinder head bolts, main bearing caps, connecting rod bolts, intake and exhaust manifolds, and all other critical engine components.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Digital (High Resolution for onscreen viewing and printing)

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine Offered 1991 K2500:

454 cubic inch (7.4L) V8 OHV

Engine Options 1991 K2500:

Also available with 350 cubic inch (5.7L) V8 OHV and 4.3L V6 OHV engines depending on specific K2500 configuration.

454 Ci V8 Horsepower 1991 K2500:

Approx. 230 hp @ 4000 rpm

454 Ci V8 Torque 1991 K2500:

Approx. 380 lb-ft @ 2000 rpm

Fuel System Type 1991 K2500:

Electronic Fuel Injection (EFI)

Engine Code 454 Ci V8:

L19 (for 454 CID V8)

Engine Code 350 Ci V8:

L05 (for 350 CID V8)

Engine Code 4.3L V6:

LB4 (for 4.3L V6)

🔧 Transmission

Standard Transmission 1991 K2500:

4-speed manual transmission (New Process NP435 or similar) or 4-speed automatic transmission (4L80-E)

Optional Transmission 1991 K2500:

3-speed Turbo-Hydramatic TH400 automatic transmission (less common on K2500 models)

Transmission Features 1991 K2500:

Heavy-duty components suited for towing and hauling, manual includes detailed overhaul and diagnostic procedures for both manual and automatic transmissions.

Automatic Transmission Code 4L80E:

4L80-E

Manual Transmission Code Np435:

NP435 (New Process 435)

📐 Dimensions

Exterior Wheelbase 1991 K2500:

Varies by configuration, common options include 131.5 inches (standard) and 155.5 inches (long bed).

Exterior Length 1991 K2500:

Varies by configuration (standard cab, long/short bed).

Weights Gvwr 1991 K2500:

Typically ranges from 7,200 lbs to 8,600 lbs, depending on configuration and options.

Weights Curb 1991 K2500:

Varies significantly based on engine, cab style, and drivetrain, generally around 5,000-6,000 lbs.

Body Styles 1991 K2500:

Regular Cab, Extended Cab (less common)

Bed Lengths 1991 K2500:

Short Bed (approx. 6.5 ft), Long Bed (approx. 8 ft)

🛡️ Safety Features

Safety Ratings 1991 K2500:

NHTSA ratings from the era; detailed crash test data is typically found in specific automotive safety publications but covered in service manuals for component safety.

Active Safety Features 1991 K2500:

Anti-lock Braking System (ABS) - Rear wheels only, standard on most K2500 models.

ABS Type 1991 K2500:

Rear-wheel only ABS

Passive Safety Features 1991 K2500:

Seat belts, reinforced safety cage construction.

💡 Technology Features

Infotainment Features 1991 K2500:

Basic AM/FM radio, optional cassette player, manual climate controls.

Driver Assistance Features 1991 K2500:

Limited to ABS on rear wheels. No advanced electronic driver aids.

Connectivity Features 1991 K2500:

N/A (No factory integrated connectivity options)

🔧 Maintenance

Oil Change Interval 1991 K2500:

Recommended every 3,000 miles or 3 months, with synthetic oils potentially extending this interval (consult manual for specifics).

Engine Oil Specification 1991 K2500:

API SG/SH service category. Viscosity: 10W-30 for most conditions, 5W-30 for very cold climates, 15W-40 for heavy-duty use (refer to owner's manual or service manual for precise recommendation based on engine).

Coolant Specification 1991 K2500:

Ethylene Glycol based antifreeze. Typically a 50/50 mix with distilled water. Specific GM specifications may apply (e.g., Dex-Cool equivalent for later models, but likely traditional green coolant for '91).

Automatic Transmission Fluid 1991 K2500:

Dexron-III (or equivalent)

Rear Differential Fluid 1991 K2500:

API GL-5. Viscosity typically 80W-90 or 75W-90. Limited-slip differentials require GL-5 with appropriate additive.

Common Issues 1991 K2500:

Potential for worn intake manifold gaskets (coolant leaks), distributor pickup coil failure, aging fuel pumps, and rust on body panels and frame, especially in areas with road salt.

Oil Filter Part Number Examples 1991 K2500:

AC Delco PF2, Fram PH8A, Wix 51515 (Note: specific part numbers can vary by engine and filter manufacturer; manual provides definitive cross-references).

Tune Up Components 1991 K2500:

Spark plugs, spark plug wires, distributor cap, rotor, PCV valve, air filter, fuel filter.

Automatic Transmission Fluid Change Interval 1991 K2500:

Every 30,000-50,000 miles, or as per severe service schedule (consult manual for details).

Coolant Flush Interval 1991 K2500:

Typically every 2 years or 30,000 miles for conventional coolants.

Brake Fluid Specification 1991 K2500:

DOT 3

Front Suspension Type 1991 K2500:

Independent Front Suspension (IFS) with torsion bars and control arms.

Steering Type 1991 K2500:

Recirculating ball steering gear, power assisted.

📚 Vehicle History

Brand Heritage Chevrolet:

Chevrolet, a division of General Motors, has a long history of producing durable and capable trucks dating back to the early 20th century.

Model Evolution K2500 1991:

The 1991 K2500 is part of the GMT400 platform, a significant redesign for Chevrolet/GMC trucks introduced in late 1987. This generation offered improved aerodynamics, ride comfort, and mechanicals compared to previous models.

Gmt400 Platform Significance:

The GMT400 platform marked a significant shift towards more integrated chassis and body design, offering improved NVH (Noise, Vibration, Harshness) and a more car-like ride for a heavy-duty truck.

Production Plant 1991 K2500:

Produced at various General Motors assembly plants across North America.