1991 GMC K3500 Service & Repair Manual

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🏷️ Basic Information Identification Make: GMC Model: K3500 Year: 1991 Codes Chassis Code: GMT400 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, fleet maintenance. Competitive Analysis Comparison...

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类型: Truck

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标签: 1991 Cars GMC K Series K3500 Truck

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Description

🏷️ Basic Information

Identification

Make:

Model:

K3500

Year:

Codes

Chassis Code:

GMT400

👋 Introduction

Market Position

Target Audience:

DIY mechanics, independent repair shops, fleet maintenance.

Competitive Analysis

Comparison To Printed Manuals:

Offers superior convenience, searchability, and up-to-date information compared to older printed manuals.

Key Features

Licensing:

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

Convenience:

Instant online access, no shipping delays, usable on multiple devices.

Value Proposition

Cost Savings:

Enables significant savings by empowering users to perform their own repairs and maintenance.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Format:

Online Software/Digital Access

Language:

English

Access Duration:

1 Year

Platform Compatibility:

PC, Laptop, Smartphone, Tablet (Web Browser)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, diagnostics, fuel injection, cooling, lubrication, exhaust, emissions controls.

Transmission Systems:

Manual and automatic transmission repair, diagnostics, fluid specifications, and internal component service.

Drivetrain Systems:

Front axle, rear axle, driveshafts, universal joints, differentials, and four-wheel-drive system service.

Suspension Steering Systems:

Front and rear suspension components (leaf springs, shocks, control arms), steering gear, power steering system, alignment specifications.

Brake Systems:

Front and rear disc/drum brake service, hydraulic system diagnostics, parking brake adjustment, ABS (if equipped) troubleshooting.

Electrical Systems:

Wiring diagrams, component testing, charging system, starting system, lighting, instrument cluster, body electricals, fuses and relays.

HVAC Systems:

Air conditioning system diagnosis and repair, heating system service, climate control components.

Body And Chassis:

Body panel repair, door mechanisms, glass replacement, chassis lubrication, frame inspection.

Procedures Included

Maintenance Procedures:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections/replacements.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, fault code interpretation (where applicable), electrical system testing methodologies.

Repair Procedures:

Step-by-step instructions for component removal, replacement, and reassembly of all major vehicle systems.

Rebuild Procedures:

Detailed instructions for engine, transmission, and differential rebuilds, including torque specifications and clearances.

Installation Procedures:

Guidelines for installing aftermarket parts or replacing major components.

Technical Depth

Depth Of Coverage:

Comprehensive factory-derived information covering routine maintenance to complete engine and transmission overhauls.

Diagnostic Capabilities:

Includes detailed diagnostic charts, symptom analysis, and component testing procedures.

Technical Specifications Detail:

Extensive listing of torque specifications, clearances, fluid capacities, electrical resistance values, and more.

📊 Manual Specifications

File Format

File Format:

Proprietary Digital Format (Accessible via Web Browser)

Print Quality

Print Quality:

N/A (Digital Access)

Binding Type

Binding Type:

N/A (Digital Access)

Paper Type

Paper Type:

N/A (Digital Access)

⚙️ Engine Specifications

Primary Engine

Engine Options:

4.3L V6 (VIN Z), 5.7L V8 (VIN R), 7.4L V8 (VIN L).

Performance

Horsepower 4.3L V6:

Approx. 160 hp @ 4000 rpm (variation by specific model and year).

Torque 4.3L V6:

Approx. 230 lb-ft @ 2000 rpm (variation by specific model and year).

Horsepower 5.7L V8:

Approx. 210 hp @ 4000 rpm (variation by specific model and year).

Torque 5.7L V8:

Approx. 300 lb-ft @ 2400 rpm (variation by specific model and year).

Horsepower 7.4L V8:

Approx. 230 hp @ 3600 rpm (variation by specific model and year).

Torque 7.4L V8:

Approx. 380 lb-ft @ 2000 rpm (variation by specific model and year).

Fuel System

Fuel Injection Type:

Throttle Body Injection (TBI) for 4.3L and 5.7L; Sequential Fuel Injection (SFI) may be available on some later models or specific configurations.

Fuel Type:

Unleaded Gasoline

Engine Construction

Block Material:

Cast Iron

Cylinder Head Material:

Cast Iron

🔧 Transmission

Standard

Standard Transmission Options:

5-speed manual transmission (NV4500 or earlier Muncie/New Process variants).

Optional

Optional Transmission Options:

4-speed automatic transmission (TH400 or 4L80-E, depending on configuration and engine).

Features

Four Wheel Drive System:

Part-time 4WD system with manual or electronic transfer case engagement.

📐 Dimensions

Exterior

Body Styles:

Regular Cab, Extended Cab.

Wheelbase Options:

131.5 inches (Regular Cab), 153.1 inches (Extended Cab).

Weights

Gross Vehicle Weight Rating Gvwr:

Ranges from 8,600 lbs to 10,500 lbs depending on configuration and axle ratios.

Curb Weight:

Varies significantly based on configuration (engine, cab, drivetrain) but typically ranges from 4,500 lbs to 5,500 lbs.

🛡️ Safety Features

Ratings

Crash Test Information:

Information regarding crashworthiness may be limited for this era of vehicle, focus is on repair and maintenance.

Active Features

Braking System:

Power-assisted front disc brakes, rear drum brakes. Anti-lock Braking System (ABS) available on rear wheels only on some models.

Passive Features

Seat Belts:

Lap and shoulder belts for front occupants, lap belts for rear occupants.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM radio, optional cassette player, or CD player. Basic speaker system.

Driver Assistance

Rear-wheel ABS was optional on some models, providing enhanced braking stability.

Connectivity

Connectivity Features:

No integrated Bluetooth or modern connectivity features. Relies on aftermarket solutions.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 to 5,000 miles or 6 months, depending on driving conditions and oil type used. Refer to manual for precise recommendations.

Transmission Fluid Change Interval:

Automatic transmissions: typically every 30,000 to 50,000 miles. Manual transmissions: typically every 50,000 to 75,000 miles. Consult manual for exact fluid type and interval.

Coolant Flush Interval:

Every 24,000 miles or 24 months, or as specified by coolant type. Use of long-life coolants may extend this interval.

Fluid Specifications

Engine Oil Specification:

API SG or SH rated, SAE 10W-30 or 10W-40 recommended for most conditions. Consult manual for climate-specific recommendations.

Automatic Transmission Fluid Atf:

Dexron-III (or equivalent) for TH400 and 4L80-E transmissions.

Manual Transmission Fluid:

GL-4 rated gear oil, SAE 75W-90 or 80W-90 depending on temperature. Consult manual for specific transmission fill.

Coolant Type:

Conventional green ethylene glycol based antifreeze (50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 brake fluid.

Known Issues

Common Wear Items:

Leaf springs (sagging), U-joints, ball joints, tie rod ends, exhaust components, and brake wear are common on heavy-duty trucks of this era.

Electrical Gremlins:

As with many vehicles of this age, electrical system issues (corroded grounds, failing switches, wiring harness degradation) can occur.

Engine Specific Notes:

TBI systems can be sensitive to fuel pressure issues and sensor failures. The 4.3L V6 is generally reliable but can experience intake manifold gasket leaks.

Filter Part Numbers

Oil Filter Example:

AC-Delco PF2 or equivalent (e.g., Fram PH8A, Wix 51515). Confirm specific fitment.

Air Filter Example:

AC-Delco A3072C or equivalent. Confirm specific fitment.

📚 Vehicle History

Brand Heritage

Gmc Legacy:

GMC has a long history of producing robust trucks and commercial vehicles known for their durability and work capabilities.

Model Evolution

K Series Trucks:

The K-series represents GMC's line of four-wheel-drive trucks. The 1991 model falls within the GMT400 platform, which was a significant redesign for GM trucks introduced in 1988.

Production

Gmt400 Platform:

The GMT400 platform was produced from 1988 to 2002, with substantial updates and facelifts throughout its lifecycle.

🏆 Awards & Recognition

Recognitions

Truck Of The Year:

While specific 'Truck of the Year' awards for the 1991 K3500 might not be highlighted, the GMT400 platform as a whole was well-received for its modernization and capability.