Basic Information Identification Make: Chevrolet Model: C2500 Year: 1991 Generation Generation Name: Third Generation (GMT400) Codes Platform Code: GMT400 Introduction Market Position Target Audience: Owners of 1991 Chevrolet C2500 trucks, independent repair shops, DIY enthusiasts. Competitive Analysis Comparison To Print: Offers superior convenience, searchability, and accessibility compared to traditional printed manuals. Key Features Licensing: Officially licensed, derived from OE (Original Equipment) materials. Access: 1-year access with options for renewal discounts, instant online access. Platform Compatibility: Compatible with PC, laptop, smartphone, and tablet via web browser. Manual Details Coverage Areas Main Coverage: Full Service and Repair Specific Systems: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Chassis Page Count Estimated Page Count: Varies by specific module, but comprehensive Manual Type Type: Service and Repair Manual Software Language Language: English Format Format: Digital Download (PDF compatible) Manual Coverage Systems Covered Engine Mechanical: Detailed diagnostics, repair procedures, component removal/installation for all gasoline and diesel engines offered. Engine Performance: Fuel injection systems, ignition systems, emissions control, cooling system, lubrication system. Transmission Drivetrain: Manual and automatic transmission overhaul, clutch service, driveshaft and axle repair, differential service. Suspension Steering: Front and rear suspension component replacement, alignment procedures, power steering system repair. Brakes: Disc and drum brake service, ABS system diagnostics (if equipped), hydraulic system repair. Electrical System: Wiring diagrams, starter, alternator, battery, lighting systems, fuses, relays, power windows, locks. HVAC: Air conditioning system service, heater core replacement, blower motor and controls. Body Chassis: Body panel repair, door mechanisms, interior trim, chassis lubrication, frame inspection. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, tune-ups. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for common and uncommon issues. Repair: Step-by-step instructions for component removal, installation, and repair. Diagnostics: Detailed diagnostic procedures, including information on using scan tools (if applicable for the era). Technical Depth Depth: Comprehensive, covering from basic routine maintenance to complete engine and transmission overhauls. Level: Professional Technician and Advanced DIYer Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Print Quality Resolution: High resolution for clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Engine Specifications Primary Engine Engine Options: 4.3L (262 ci) V6, 5.0L (305 ci) V8, 5.7L (350 ci) V8, 7.4L (454 ci) V8, 6.2L (379 ci) Diesel V8 Performance Horsepower Torque 4 3L: Approx. 160 hp @ 4000 rpm / 230 lb-ft @ 2000 rpm (varies slightly) Horsepower Torque 5 7L: Approx. 210 hp @ 4000 rpm / 300 lb-ft @ 2400 rpm (varies slightly) Horsepower Torque 7 4L: Approx. 230 hp @ 3600 rpm / 385 lb-ft @ 2000 rpm (varies slightly) Fuel System Fuel Delivery: Throttle Body Injection (TBI) for most gasoline engines, Diesel Injection for 6.2L. Ignition System Type: Electronic Spark Control (ESC) with Distributor Transmission Standard Transmission Options: 4-speed manual, 4-speed automatic (TH400, 4L60/4L60E variations, 4L80E for heavy duty) Optional Heavy Duty Options: 4-speed heavy-duty automatic (4L80E) often found on 2500/3500 models. Features Torque Converter: Lock-up torque converter on automatic transmissions for improved highway efficiency. Dimensions Exterior Body Styles: Regular Cab, Extended Cab Bed Lengths: 6.5 ft, 8 ft Weights Gvwr: Gross Vehicle Weight Rating ranges from approx. 6,000 lbs to 8,600 lbs depending on configuration. Curb Weight: Varies significantly based on configuration, typically 4,000-5,000 lbs. Safety Features Ratings NHTSA Ratings: Not readily available for this specific year and model in digital archives; typically 4-star for frontal impact during its era. Active Features Braking System: Front disc brakes, rear drum brakes. Optional ABS on rear wheels for some models. Passive Features Airbags: Driver-side airbag not standard in 1991, optional on some models. Seatbelts: Front 3-point seatbelts, rear lap belts. Technology Features Infotainment Audio System: AM/FM radio, optional cassette player, optional CD player. Basic speaker configurations. Driver Assistance ABS: Anti-lock Braking System available, typically on rear wheels for 2WD models, sometimes all wheels for 4WD. Not as sophisticated as modern systems. Connectivity Connectivity Features: No modern connectivity features like Bluetooth or USB ports. Analog gauges and controls. Maintenance Service Intervals Oil Change: Every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used. Air Filter: Inspect every 15,000 miles, replace as needed. Spark Plugs: Replace every 30,000-60,000 miles, depending on plug type (conventional vs. platinum). Transmission Fluid: Change fluid and filter every 30,000-50,000 miles for automatic transmissions. Fluid Specifications Engine Oil: API SG or SH, SAE 10W-30 or 10W-40 recommended for most gasoline engines (consult manual for specific viscosity based on temperature). Coolant: Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Dex-Cool not applicable for this era. Automatic Transmission Fluid: Dexron-II or equivalent for TH400, 4L60, 4L60E. Dexron-III or equivalent for 4L80E. Manual Transmission Fluid: GL-4 gear oil, SAE 75W-90 or 80W-90 recommended (check specific transmission type). Known Issues Common Problems: Cracked exhaust manifolds, intake manifold gasket leaks, wear...