Basic Information Identification Make: Chevrolet Model: K3500 Year: 1991 Codes Chassis Code: GMT400 Introduction Market Position Vehicle Segment: Heavy-Duty Pickup Truck Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance Competitive Analysis Competitors 1991: Ford F-350, Dodge Ram 350 Key Features Manual Advantage: Officially licensed, OE material derived, convenient digital access, comprehensive coverage. Vehicle Purpose: Designed for heavy-duty work, towing, and hauling. Manual Details Coverage Areas Coverage Type: Service and Repair Specific Coverage Regions: North America Page Count Estimated Page Count: Extensive (Specific count not provided, but typical for OE service manuals) Manual Type Type: Digital Service Manual / Repair Manual Software Language Language: English Format Format: PDF Download (Web-based access with year subscription) Manual Coverage Systems Covered Powertrain: Engine (454, 366, 350 V8, 6.2L Diesel), Transmission (4L80-E Automatic, SM465 Manual), Drivetrain (4WD Systems, Differentials, Axles) Chassis: Suspension (Front Independent, Rear Leaf Spring), Steering (Power Steering System), Brakes (Front Disc, Rear Drum, ABS for some models) Electrical: Wiring Diagrams, Lighting, Ignition System, Starting System, Charging System, Instrumentation, Power Accessories HVAC: Heating, Ventilation, Air Conditioning (System components, Refrigerant, Operation) Body And Interior: Body Panels, Doors, Seats, Trim, Glass, Bumpers Procedures Included Maintenance: Fluid changes (Oil, Coolant, Transmission Fluid, Brake Fluid, Power Steering Fluid), Filter replacements (Oil, Air, Fuel), Lubrication, Spark Plug replacement, Belts and Hoses inspection/replacement, Battery maintenance Diagnostics: Troubleshooting guides for common drivability and electrical issues, Diagnostic trouble codes (if applicable for the era), Component testing procedures Repair: Engine component removal and installation (e.g., alternator, starter, water pump), Brake system repair (e.g., caliper replacement, brake line bleeding), Suspension component replacement (e.g., ball joints, tie rod ends), Drivetrain component repair (e.g., U-joints, CV axles), HVAC system component replacement Overhaul: Engine overhaul procedures (e.g., head gasket replacement, piston ring installation), Transmission overhaul (for applicable transmissions) Special Tools: Identification and usage of specialized tools required for specific repair procedures Technical Depth Depth: Comprehensive. Covers basic maintenance to complete engine and transmission rebuilds. Includes detailed diagnostics and repair procedures. Manual Specifications File Format Digital Format Details: Web-based access, requires internet connection and browser. Likely searchable text content. Print Quality Quality: High-resolution, factory-derived OE material. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) Engine Specifications Primary Engine Engine Options: 454 cu in (7.4L) V8, 366 cu in (6.0L) V8, 350 cu in (5.7L) V8, 379 cu in (6.2L) Diesel IDI V8 Performance Horsepower Range: Approx. 160-230 hp (depending on engine) Torque Range: Approx. 270-380 lb-ft (depending on engine) Fuel System Fuel Delivery: Throttle Body Injection (TBI) for gasoline V8s; Direct injection for 6.2L Diesel Recommended Fuel: Unleaded gasoline (Octane 87 minimum for V8s), Diesel fuel for 6.2L Diesel Cooling System Coolant Capacity: Approx. 22-24 quarts (depending on engine and radiator) Coolant Type: GM P/N 1052645 or equivalent (Green Ethylene Glycol based) Transmission Standard Standard Transmission: SM465 4-speed Manual (with Granny Gear) Optional Optional Transmission: 4L80-E 4-speed Automatic Features 4Wd Transfer Case: NP208 or NP241 Manual Transfer Case Fluid Specifications Automatic Transmission Fluid: Dexron-III (GM P/N 12377204 or equivalent) Manual Transmission Fluid: GL-4 Gear Oil (e.g., SAE 80W-90) Dimensions Exterior Wheelbase Options: 131.5 inches (standard cab), 154.5 inches (long bed) Overall Length: Varies by configuration (e.g., approx. 225 inches for standard cab long bed) Weights Curb Weight Range: Approx. 5,500 - 6,500 lbs (depending on configuration and engine) Gross Vehicle Weight Rating Gvwr: Up to 9,200 lbs (for K3500) Cargo Bed Length Options: 8 ft (Fleetside) Safety Features Ratings NHTSA Crash Test Data: Limited data available for this specific year and model; generally robust for its class but without modern safety feature integration. Active Features ABS: Available on rear wheels (RABS) for some configurations. Passive Features Seat Belts: Standard 3-point shoulder belts for front occupants. Crumple Zones: Designed with basic front and rear crumple zones. Technology Features Infotainment Audio System: AM/FM Radio, Cassette Player, optional CD player (rare). Instrument Cluster: Analog gauges for speedometer, tachometer (optional), fuel, temperature, oil pressure, voltage. Warning lights for critical systems. Driver Assistance Cruise Control: Optional feature on most models. Connectivity Connectivity Features: None (pre-digital era) Maintenance Service Intervals Oil Change Interval: Every 3,000 miles or 3 months (typical for this era, or refer to manual for specific synthetic recommendations if available). Transmission Fluid Change Interval: Every 30,000 - 60,000 miles for automatic transmissions, consult manual for manual transmissions. Coolant Flush Interval: Every 30,000 - 50,000 miles or 2-4 years. Fluid Specifications Engine Oil Spec: API Service SG or SH, SAE 10W-30 (or 5W-30 in colder climates) for gasoline V8s. Diesel oil for 6.2L Diesel. Brake Fluid Spec: DOT 3 Hydraulic Brake Fluid Power Steering Fluid Spec: GM P/N 1050017 or equivalent (likely Dexron-II/III compatible) Known Issues Common Wear Items: Ball joints, tie rod ends, sway bar links, brake pads/rotors, exhaust system components, fuel pumps (TBI systems), power steering pumps. Diesel Specific Issues: Glow plug system,...