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1991 GMC K3500 Service & Repair Manual

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$133.00
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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 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 ABS: 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...
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1991 GMC K3500 Service & Repair Manual
🏷️ 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 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
ABS:
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.
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