1990 Chevrolet K3500 Service & Repair Manual Software

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Basic Information Identification Make: Chevrolet Model: K3500 Year: 1990 Codes Chassis Code: GMT400 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance personnel Competitive Analysis Advantage Over...

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Type: Truck

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Sku: 46997

Tags: 1990 C/K Cars Chevrolet K3500 Truck

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Description

Basic Information
Identification
Make:	Chevrolet
Model:	K3500
Year:	1990
Codes
Chassis Code:	GMT400

Introduction
Market Position
Target Audience:	DIY enthusiasts, independent repair shops, fleet maintenance personnel
Competitive Analysis
Advantage Over Print:	Instant access, searchability, compatibility across multiple devices, lower cost compared to older printed manuals, convenient online delivery.
Key Features
Licensing:	Officially licensed, derived from OE (Original Equipment) materials by RepairSurge.
Accessibility:	Accessible via internet connection on PC, laptop, smartphone, or tablet using a web browser.
Access Period:	1 year of access included, with discounts for extensions.

Manual Details
Coverage Areas
Manual Coverage Scope:	Comprehensive factory-derived service and repair information
Page Count
Estimated Page Count:	Thousands (typical for full service manuals, exact count not specified but implied by depth)
Manual Type
Manual Type:	Service and Repair Manual
Language
Language:	English
Format
Digital Format:	PDF Download (with 1 year access)

Manual Coverage
Systems Covered
Engine Systems:	Engine mechanical (block, heads, pistons, crankshaft), lubrication, cooling, fuel delivery, ignition, emissions control, engine performance diagnostics, troubleshooting
Drivetrain Systems:	Clutch, manual transmission, automatic transmission, transfer case (if applicable to K3500 variants), driveshafts, axles, differentials, wheel hubs, bearings
Suspension Steering:	Front suspension (independent or solid axle depending on configuration), rear suspension (leaf springs, U-bolts), shock absorbers, springs, steering linkage, power steering system, steering column, wheel alignment
Brake Systems:	Front disc brakes, rear drum brakes, parking brake system, hydraulic lines, master cylinder, power booster, ABS (if equipped), brake diagnostics and repair
Electrical Systems:	Battery, charging system (alternator), starting system (starter motor), lighting system, instrument cluster, gauges, body control modules, power accessories, fuse box diagrams, wiring schematics, diagnostic trouble codes (DTCs)
HVAC Systems:	Heating system, air conditioning system, blower motor, evaporator, condenser, refrigerant handling, controls, ducting
Body And Chassis:	Frame, body panels, doors, hood, tailgate, bumpers, interior trim, glass, sealants, chassis lubrication
Heating Ventilation Air Conditioning HVAC:	Comprehensive coverage of HVAC components, operation, diagnostics, and repair, including refrigerant handling and system recharge procedures.
Body And Trim:	Details on body panel removal and installation, door mechanisms, glass replacement, interior trim panel removal and installation, weatherstripping, and paint repair recommendations.
Procedures Included
Routine Maintenance:	Oil changes, filter replacements (oil, air, fuel), fluid checks and top-offs, tire rotations, spark plug replacement, belt inspection and replacement, battery maintenance
Repair Procedures:	Detailed step-by-step instructions for component removal, installation, and repair across all major vehicle systems
Troubleshooting:	Diagnostic charts and procedures for identifying and resolving common and complex problems based on symptoms
Component Overhaul:	Information on rebuilding engines, transmissions, and other major components
Alignment Specifications:	Wheel alignment angles, caster, camber, toe settings, and adjustment procedures.
Wiring Schematics:	Detailed color-coded wiring diagrams for all electrical systems, essential for diagnosing electrical faults.
Torque Specifications:	Precise torque values for critical fasteners across all vehicle systems, ensuring proper assembly and preventing damage.
Technical Depth
Diagnostic Capabilities:	Advanced diagnostic procedures, including interpretation of sensor data and OBD-I (On-Board Diagnostics) codes relevant to the era.
Specification Detail:	Precise torque specifications, clearances, fluid capacities, electrical resistance values, and other critical technical data
Component Rebuild Instructions:	Detailed guides for overhauling engines, transmissions, differentials, and other major mechanical components, including part clearances and assembly sequences.

Manual Specifications
File Format
File Type:	PDF
Print Quality
Digital Quality:	High-resolution, clear text and diagrams derived from OE materials
Binding Type
Digital Binding:	N/A (Digital download)
Paper Type
Digital Paper Type:	N/A (Digital download)

Engine Specifications
Primary Engine
Engine Options:	Various V8 gasoline engines were common for the K3500 in 1990, including 5.0L (305 ci), 5.7L (350 ci), and potentially a 7.4L (454 ci) depending on specific configurations. Diesel options may also exist.
Fuel System Type:	Electronic Fuel Injection (EFI)
Engine Codes Typical:	LB4 (4.3L V6 - unlikely for K3500 heavy duty), L05 (5.0L V8), L03 (5.7L V8), L19 (7.4L V8). Manual will specify for available engines.
Performance
Horsepower Torque Ranges:	Varies significantly by engine. For example, a 5.7L V8 typically produced around 190-210 hp and 300-330 lb-ft of torque.

Transmission
Standard
Transmission Availability:	Likely offered with both manual and automatic transmissions. Manual transmissions would typically be 4-speed or 5-speed.
Optional
Automatic Transmission Options:	Common automatic transmissions included the TH400 (3-speed heavy-duty) or the 4L80-E (4-speed overdrive automatic) for heavy-duty applications.
Features
Transfer Case Options:	Four-wheel drive (4WD) models would feature a transfer case, likely manual shift or electronic shift depending on trim. This manual covers both 2WD and 4WD configurations.
Axle Ratio Options:	Various rear axle ratios available to suit towing and payload requirements, typically ranging from 3.73 to 4.10 or higher for heavy-duty applications.

Dimensions
Exterior
Body Styles:	Regular Cab, Extended Cab; Fleetside (standard bed) and Wideside (flared fenders) bed options.
Weights
Gross Vehicle Weight Rating Gvwr:	GVWRs would vary by configuration, but K3500 models are heavy-duty, typically ranging from 8,500 lbs to over 10,000 lbs.
Curb Weight:	Varies significantly by configuration, but typically ranges from 4,500 lbs to over 5,500 lbs for 4WD models with crew cabs and heavier engines.

Safety Features
Ratings
Crash Test Data:	Specific crash test data for 1990 models may be limited compared to modern standards. This manual would cover safety systems like seatbelts, potentially airbags (though less common or standard on base models in 1990), and structural integrity.
Active Features
ABS Availability:	Anti-lock Braking System (ABS) was an optional feature on some 1990 Chevrolet trucks.
Passive Features
Seatbelt Type:	Standard lap and shoulder belts

Technology Features
Infotainment
Audio System:	Factory AM/FM radio, possibly with cassette player. Aftermarket upgrades are common.
Driver Assistance
ABS System:	Optional ABS system, covered in detail within the manual.
Connectivity
On Board Diagnostics:	OBD-I system, crucial for engine performance diagnostics. The manual provides codes and troubleshooting trees.

Maintenance
Service Intervals
Oil Change Interval:	Typically 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Refer to manual for specific recommendations.
Transmission Fluid Change:	Recommended every 30,000-50,000 miles for automatic transmissions, depending on towing or heavy-duty use. Manual transmission fluid changes are less frequent but covered.
Coolant Change:	Typically every 24,000-36,000 miles or 2-3 years, using the specified coolant type.
Fluid Specifications
Engine Oil Type:	Commonly specified as API SF or SG service category, viscosity grades like 10W-30 or 10W-40 depending on ambient temperature. Exact specification in manual.
Transmission Fluid Type:	Automatic transmissions typically use Dexron-II or equivalent. Manual transmissions require specific gear oils.
Coolant Type:	Ethylene glycol based coolant, typically green in color. Specific type and mixture ratio provided in manual.
Brake Fluid Type:	DOT 3 brake fluid
Power Steering Fluid Type:	Dexron-II or equivalent
Transfer Case Fluid Type:	Typically ATF Dexron-II or equivalent for automatic transfer cases, specific gear oil for manual transfer cases.
Differential Fluid Type:	API GL-5 gear oil, with specific viscosity grades (e.g., 75W-90, 80W-90) depending on application. Limited-slip differentials may require friction modifier.
Known Issues
Common Wear Items:	Ball joints, tie rod ends, U-joints, brake components (pads, rotors, drums), exhaust systems, and potential for intake manifold gasket leaks on some V8 engines.
Electrical Gremlins:	As with many vehicles of this era, intermittent electrical issues can arise due to aging wiring, grounds, and switches. The manual's wiring diagrams are invaluable for diagnosis.
Engine Mounts:	Engine mounts can degrade over time, leading to vibrations and harshness. Replacement is a common repair.

Vehicle History
Brand Heritage
Chevrolet Truck Legacy:	Chevrolet has a long history of producing robust and capable pickup trucks, with the 'K' designation historically representing 4WD models and '3500' indicating heavy-duty capacity.
Model Evolution
Gmt400 Platform:	The 1990 K3500 is part of the GMT400 platform, which introduced a more modern and aerodynamic design compared to its predecessors. This platform represented a significant update in comfort, safety, and engineering for Chevrolet trucks.
Gmt400 Design Changes:	The GMT400 platform introduced a significant redesign, moving from the boxier C/K series to a more rounded, aerodynamic body style, improving ride comfort and handling.
Production
Manufacturing Locations:	GMT400 trucks were produced at various General Motors assembly plants in North America.

Awards & Recognition
Recognitions
Platform Reputation:	The GMT400 platform is generally regarded as a durable and capable truck platform, known for its towing and hauling capabilities.