1986 GM CK Service Manual

LIGHT DUTY TRUCKS
FOREWORD
This service manual contains diagnosis, On-Vehicle maintenance, and light re
pair for Light Duty Truck Models ( C-K, P-Truck, and G-Van ). Procedures involving
disassembly and assembly of major components for these vehicles are published in a
separate Truck Unit Repair Manual. Wiring diagrams for these models are also
published in a separate Truck Wiring Diagram booklet.
This manual should be kept in a handy place for ready reference. If properly used, it
will meet the needs of technicians and vehicle owners.
CAUTION:
These vehicles contain some parts dimensioned in the metric system as well as in
the customary system. Some fasteners are metric and are very close in dimension to
familiar customary fasteners in the inch system. It is important to note that, during any
vehicle maintenance procedures, replacement fasteners must have the same mea
surements and strength as those removed, whether metric or customary. (Numbers on
the heads of metric bolts and on surfaces of metric nuts indicate their strength. Cus
tomary bolts use radial lines for this purpose, while most customary nuts do not have
strength markings.) Mismatched or incorrect fasteners can result in vehicle damage or
malfunction, or possibly personal injury. Therefore, fasteners removed from the vehi
cle should be saved for re-use in the same location whenever possible. Where the
fasteners are not satisfactory for re-use, care should be taken to select a replacement
that matches the original. For information and assistance, see your authorized dealer.
GMC TRUCK & COACH OPERATION

TRUCK & BUS GROUP
General Motors Corporation
Pontiac, Michigan
CAUTION
To reduce the chance of personal injury and/or property damage, the follow
ing instructions must be carefully observed.
Proper service and repair are important to the safety of the service techni
cian and the safe, reliable operation of all motor vehicles. If part replacement
is necessary, the part must be replaced with one of the same part number or
with an equivalent part. Do not use a replacement part of lesser quality.
The service procedures recommended and described in this service

manual are effective methods of performing service and repair. Some of these
procedures require the use of tools specially designed for the purpose.
Accordingly, anyone who intends to use a replacement part, service proce

dure or tool, which is not recommended by the vehicle manufacturer, must
first determine that neither his safety nor the safe operation of the vehicle will
be jeopardized by the replacement part, service procedure or tool selected.
It is important to note that this manual contains various Cautions and No

tices that must be carefully observed in order to reduce the risk of personal
injury during service or repair, or the possibility that improper service or repair
may damage the vehicle or render it unsafe. It is also important to understand
that these Cautions and Notices are not exhaustive, because it is impossi
ble to warn of all the possible hazardous consequences that might result from
failure to follow these instructions.
SEC NAME
GENERAL INFORMATION
OA
OB
General Information
Maintenance and Lubrication I
1986 HEATING AND AIR CONDITIONING
1A
1B
Heating
Air Conditioning
FRAME AND CAB

I
I
2A Frame and Body Mounts
2B Bumpers
2C Sheet Metal and Fiberglass
LIGHT DUTY STEERING, SUSPENSION,

WHEELS AND TIRES
TRUCK
3A Front End Alignment
3B1 Steering Linkage
3B2 Manual Steering
3B3 Power Steering
SERVICE
3B4 Steering Column
3C Front Axle and Suspension
3D Rear Suspension
3E Wheels and Tires
MANUAL PROPELLER SHAFT AND AXLES
I
4A Propeller Shaft
4B Rear Axle
4C Front Axle
BRAKES
C-K, P-TRUCK ENGINE

6A Engine
6A3 4.3 Liter V6
AND G-VAN 6A4
6A5
4.8 Liter L6
Small Block
MODELS 6A6
6A7
6B
7.4 Liter V8
6.2 Liter Diesel
Engine Cooling
6C Fuel System
6C1 Carburetors
6C2 Diesel Fuel Injection
The Table of Contents on this page in 6D Engine Electrical
dicates the sections covered in this 6E Drivability And Emissions
manual. At the beginning of each individ 6E8 Drivability And Emissions Carburetor
6E9 Drivability And Emissions Diesel
ual section is a Table of Contents which
6F Exhaust
gives the page number on which each 6H Vacuum Pump
major subject begins.
TRANSMISSION AND CLUTCH
7A Automatic Transmission
When reference is made in this manual
7B Manual Transmission
to a brand name, number, or specific tool, 7B1 3 Speed 76mm Transmission
an equivalent product may be used in 7B2 4 Speed 89mm Transmission
place of the recommended item. 7B3 4 Speed 117mm Transmission
7C Clutch
7D1 205 Transfer Case
All information, illustrations, and speci
7D2 208 Transfer Case
fications contained in this Manual are
based on the latest product information ELECTRICAL
available at the time of publication ap 8A Cab Electrical
8B Chassis Electrical
proval. The right is reserved to make
8C Intrument Panel
changes at any time without notice.
RADIO AND CRUISE CONTROL
9A Radio
9B Cruise Control
Printed in Canada 10 BODY

1985 General Motors Corporation November, 1985
INDEX
He knows
quality parts
make a difference
even on
simplejobs.
Mr. Goodwrench wants you to have the right parts for So keep that great GM feeling with genuine GM parts
your truckwhether you see him for service or whether at participating independent Mr. Goodwrench dealers
you do the work yourself. selling Chevrolets, Pontiacs, Oldsmobiles, Buicks,
Cadillacs, GMC and Chevy Trucks.
Thats why Mr. Goodwrench wants to have a good
stock of genuine GM Parts available. Everything from
exclusive GM Goodwrench replacement engines and
transmissions to GM Goodwrench Motor Oil that meets
O CNERAL M O T O R S C O R PO R A T IO N
or exceeds all specifications for General Motors cars
or light trucks. And Mr. Goodwrench has a complete
line of GM chemicals for fine care of your GM vehicle.
Plus accessories to add convenience
or just a little extra style.
B-05884
O A -1
SECTION 0
GENERAL INFORMATION
CONTENTS
SUBJECT PAGE
General In fo rm a tio n ................................................................................................................................................... OA- 1
Maintenance and L u b ric a tio n ..................................................................................................................................OB- 1
SECTION OA
GENERAL INFORMATION
CONTENTS
SUBJECT PAGE
Service Parts Identification L ab e l....................................................................................................................... OA- 2

Vehicle Identification P la te ..................................................................................................................................OA- 2
C ertification L a b e l................................................................................................................................................. OA- 2
Model Reference..................................................................................................................................................... OA- 2
Engine Identification N u m b e r............................................................................................................................. OA- 2
Emergency Starting Due to a Discharged B a tte ry .........................................................................................OA- 2
Graphic S y m b o ls ................................................................................................................................................... OA- 6
Metric Fasteners..........................................................................................................................................................OA- 8
Fastener Strength Id e n tific a tio n ......................................................................................................................... OA- 8
Prevailing Torque F asteners..................................................................................................................................OA-9
Six Lobed Socket Head F a ste n e rs....................................................................................................................... OA-9
RPO Listing (Regular Production O p tio n )............................................................................................................ OA-14
OA-2 GENERAL INFORMATION
models, the plate is on the dash and toe panel. To find

SERVICE PARTS I D E N T I F I C A T IO N_________
out the manufacturer, model and chasis type, engine
V .I .N .M H H m A S E H H B H S E H H
________________ V I N VEHICLE ID EN TIFIC ATIO N NUMBER_____________________ type, GVW range, model year, plant code, and
NOTF THE OPTIONAL -EQUIPMENT LISTED BELOW HAS BEEN IN STALLED ON THIS
VEHICLE FOR PROPER IDENTIFICATIO N OF REPLACEMENT PARTS BE
________SURE TO SPECIFY THE APPLICABLE OPTION NUMBERS______________________
sequential number, refer to figure 3.
CERTIFICATION LABEL
The Certification Label shows the GVWR, and the
IM P O R TA N T: RETAIN THIS LABEL AS A P ERM ANE NT RECORD front and rear GAWRs, and the Payload Rating for your
vehicle (figure 4).
B-07003 Gross Vehicle Weight (GVW) is the weight of the
orginally equipped vehicle and all items added to it
after it has left the factory. This would include bodies,
Figure 1Service Parts Identification Label winches, booms, etc.; the driver and all occupants; and
the load the vehicle is carrying. The GVW must not
SERVICE PARTS exceed the GVWR. Also, the front and rear gross axle
weights must not exceed the front and rear GAWRs.
IDENTIFICATION LABEL The Payload Rating shown on the label is the
maximum allowable cargo load (including the weight of
The Truck Service Parts Identification Label is
the driver and all occupants) that the vehicle can carry
provided on all models (figure 1). It is located on the
based on all factory installed equipment on the vehicle.
inside of the glove box door (or on an inner body panel
The Payload Rating is reduced if any accessories or
for Forward Control models). The Label lists the VIN
other equipment is added to the vehicle after final date
(Vehicle Identification Number), wheelbase, paint
of manufacture. The weight of these items should be
information and all Production options or Special
determined and deducted from the Payload Rating.
Equipment on the vehicle when it was shipped from
The vehicle may also have a GCWR (Gross
the factory. ALWAYS REFER TO THIS INFORMATION
C om bination W eight Rating). The GCW (Gross
WHEN ORDERING PARTS.
Combination Weight) is the total weight of the loaded
tow vehicle (including passengers) and a loaded trailer.
The tires on the vehicle must be the proper size and
VEHICLE IDENTIFICATION properly inflated for the load which you are carrying.
NUMBER The vehicle Certification Label shows the originally
equipped tire size and recom m ended inflation
The VIN is the legal identifier of the vehicle. On all pressures. For more information on tires, refer to
models except Forward Control, it is located on a plate WHEELS AND TIRES (Sec.3E).
which is attached to the left top of the instrument panel
and can be seen through the windshield from the
outside of the vehicle (figure 2). On Forward Control MODEL REFERENCE
Refer to figures 5 and 6 to determine the vehicle
model. For C/K models, a C is a two-wheel drive
vehicle and a K is a four-wheel drive vehicle.
ENGINE IDENTIFICATION
NUMBER
Refer to figure 7 to determine the location of the
engine I.D. number.
EMERGENCY STARTING
YOUR VEHICLE DUE TO A
DISCHARGED BATTERY
F-00687
If your vehicle will not start due to a discharged
battery, it can often be started by using energy from
Figure 2VIN Location another battery - a procedure called jump starting.
GENERAL INFORMATION OA-3
VEHICLE IDENTIFICATION NUMBER

1 D C 1 4 N 4 G 1 0 0 0 0 1
JX. ^ [Productionêquence Number^"
Nation of Origin
1 - U.S. Built Assem bly Plant
2 = Canadian Built Baltimore, MD
3 = Mexican Built Flint, Ml
Code Series
Janesville, Wl
Manufacturers 1 1/2 Ton
St. Louis. MO
G = General Motors 2 ^4 Ton Pontiac, Ml
3 1 Ton Oshawa, ON
Code Make
Moraine, OH
A Chevrolet Bus' Code Body Type
D e tro it, M l
B Chevrolet Incomplete 0 Pickup/Panel Delivery
Scarborough, ON
C Chevrolet Truck 1 Hi-Cube/Cutaway Van
Lordstown, OH
D GMC Incomplete 2 Forward C ontrol
Shreveport, LA
E Cadillac Incomplete 3 Four-Door Cab
H GM ot Canada Bus 4 Two-Door C ab
Engine Type and Make
T GMC Truck 5 Van
Code Producer Type RPO
O GMC Bus 6 Suburban
B Chevrolet 2.8L V6 2BBL LR2
5 GMC MPV 7 M otor Home Chassis
C DDAD 6.2L V8 Diesel LH6
8 Chevrolet MPV 8 U tility (Jimmy/Blazer)
E Pontiac 2 .5 L L4 TBI LN8
'Van with 4th Seal 9 Stake
F Chevrolet 5.0L V8 4BBL LF3
GVW R/BRAKE S YS TE M Line and C h a ssis Type H Chevrolet 5.0L V8 4BBL LE9
Code GVW R Range Brake System Chassis J DDAD 6.2L V8 Diesel LL4
B 3001-4000 Hydraulic Code Line Type K Chevrolet 5.7L V8 LPG LT9 & KL7
C 4001-5000 H ydraulic C C onventional Cab 4x2 L Chevrolet 5.7L V8 4BBL LS9
D 5001-6000 H ydraulic D M ilitary Truck 4x4 M Chevrolet 5.7L V8 4BBL LT9
E 6001-7000 Hydraulic K C onventional Cab 4x4 N Chevrolet 4.3L V6 4BBL LB1
F 7001-8000 Hydraulic G Van 4x2 R Chevrolet 2 .8L V 6 T B I LL2
G- 8001-9000 Hydraulic P Forward C ontrol 4x2 T GM de M exico 4.8L L6 1BBL L25
H 9,001-10,000 Hydraulic S S m all C on ve n tion a l W Chevrolet 7.4L V8 4BBL LE8
J 10,001 14.000 Hydraulic Cab 4x2 z Chevrolet 4 .3 L V 6 T B I LB4
K 14,001-16,000 Hydraulic T Sm all C on ve n tion a l
'In c lu d e s G - Van Bus Cab 4x4
M Small Van .4x2 . F-00502
Figure 3Vehicle Identification Number (VIN)
Should your vehicle have an optional diesel engine NOTICE: Do not push or tow this vehicle to
with two batteries: start it. Under some conditions this may
damage the catalytic converter or other parts
P models and G Van models use only the of the vehicle. Also, since this vehicle has a 12
battery on the drivers side when jump starting. volt battery, be sure the vehicle or equipment
used to jump start your engine is also 12 volt.
C/K models use only the battery on the Use of any other type system may damage the
passengers side when jump starting. vehicles electrical components.
These battery locations are closer to the starter, thus

At low temperatures, it may not be possible to start
reducing electrical resistance. Ignore the second
your diesel engine from a single battery in another
battery.
vehicle. However, you can use your vehicle to jump
start another vehicle.
M FD. BY G E N E R A L M O TO R S CO R PO R ATIO N
I A L L A PP LIC AB LE FEDE
' S AFE TY S TA N D A R D S IN EFFECT
'M A N U F A C T U R E SHOWN ABO VE.
BOC100001 MPV
THU VENICLf EOUmO FOR 1000/453 L IS PAYLOAD
SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION
F-00597
Figure 4Certification Label

Pickup, Regular Cab C-K MODELS Chassis - Cab, Regular Cab
Chassis - Cab, Bonus/Crew Cab
Pickup, Bonus/Crew Cab Suburban
U tility Vehicle
Jimm y (Blazer)
B-09177
Figure 5 C-K Models
JUMP STARTING INSTRUCTIONS 1. Position the vehicle with the good (charged)
battery so that the booster (jumper) cables will
CAUTIO N: B a tte rie s p ro d u c e e x p lo s iv e reach, but never let the vehicles touch. Also, be
gases, contain corrosive acid, and supply sure booster cables do not have loose or missing
levels of electrical current high enough to insulation.
cause burns. Therefore, to reduce the risk of
2. In both vehicles:
personal injury when working near a battery:
A lw ays sh ie ld yo u r eyes and avoid Turn off the ignition and all lights and
le a n in g o v e r th e b a tte ry w h e n e v e r accessories except the hazard flasher or
possible. any lights needed for the work area.
Do n ot expose the b atte ry to open
Apply the parking brake firmly, and shift the
flames or sparks.
automatic transmission to Park (or manual
Be sure any batteries that have fille r
transmission to Neutral).
caps are properly filled with fluid.
Do not allow battery acid to contact 3. Making sure the cable clamps do not touch any
eyes of skin. Flush any contacted area other metal parts, clamp one end of the first
with water im m ediately and throughly, booster cable to the positive ( + ) terminal on one
and get medical help. battery, and the other end to the positive terminal
Follow each step in the jum p starting on the other battery (figure 8). Never connect ( + )
instructions. to (-).
G VAN MODELS
RALLY (SPORTVAN) VANDURA (CHEVY VAN)
CUTAWAY VAN MAGNAVAN (HI-CUBE VAN)
P MODELS
VALUE VAN (STEP VAN) MOTOR HOME CHASSIS
(ALUMINUM)
VALUE VAN (STEP VAN) FORWARD CONTROL CHASSIS

(STEEL)
B-09178
Figure 6G Van and P Models

1 2 L6 ENGINE 4. Engine I.D. {0[Dtional Location)

5. Engine Case F
6. Engine I.D.
l3d
Jgj
1. Engine I.D.
2. D istributor Pad
3. Engine I.D. (Optional Location)
V8 E N G I N E ^ A ^ ^ ^ ^
7. Engine I.D. V 4 ^ /
8. Engine Case Pad
V6 ENGINE V8 ENGINES-DIESEL F-00527
Figure 7Engine I.D. Number Location
4. Clamp one end of the second cable to the or other parts that will move when the engine is
negative (-) terminal of the good (charged) battery started.
and make the final connection to a heavy metal 5. Start the engine of the vehicle with the good
bracket (such as the mounting bracket for the (charged) battery and run the engine at a
generator or air conditioner compressor if so moderate speed for several minutes. Then, start
equipped) on the engine about 450 millimeters the engine of the vehicle that has the discharged
(18 inches) from the discharged battery. Make battery.
sure the cables are not on or near pulleys, fans, 6. Remove the booster cables by reversing the
above installation sequence exactly. While
removing each clamp, take care it does not touch
Make Connections in Numerical Order any other metal while the other end remains
attached.
First Jum per Cable
Do N O T Allow
Vehicles to Touchl
Discharged GRAPHIC SYMBOLS
Battery
Second Jum per Cable Graphic symbols are used on some controls and
Make Last displays on the vehicle (figure 9). Many of these
Connection on symbols are used internationally.
Engine or Frame,
Away from Battery
Battery in Vehicle
w ith Charged Battery I
A-9816
TD
Figure 8Jump Starting Connections

(O)
1 t I 1
BRAKE
$
POWER TRAIN
OIL TEMPERATURE
WINDSHIELD
WASHER
WINDSHIELD
WIPER & WASHER
E3VENTILATING FAN
WINDSHIELD
DEFROSTER
M
REAR WINDOW
-
A B FASTEN
FUEL
t& r>
ENGINE OIL REAR WINDOW
V
DEFOGGER SEAT BELTS PRESSURE WIPER & WASHER
ID
A
mu
o
LPS
IDENTIFICATION LIGHTS OR HAZARD WARNING WINDSHIELD
TURN SIGNALS
LAMPS HIGH BEAM FLASHER WIPER
cao
CAUSTIC
FOG LAMP SPEAKER BRAKE BATTERY ACID
COULD CAUSE BURNS
h rr
HORN
A CAUTION
POSSIBLE INJURY
n
LIGHTER
i
DOOR
LOCK/UNLOCK
IIIUII
RADIO
SELECTOR
RADIO VOLUME
\\|//
SPARK OR FLAME
COULD
EXPLODE BATTERY
N D
\\\W
PARKING LIGHTS CHOKE

> r
HEATER

ENGINE COOLANT
TEMPERATURE
a
BATTERY
CHARGING
SYSTEM
& SEATBACK
WINGS IN/OUT
HEADLIGHT
LOWER BEAM
kPa
A
e
ENGINE OIL MANIFOLD TRANSMISSION HOOD
TEMPERATURE VACUUM OIL TEMPERATURE RELEASE
F-00702
Figure 9Graphic Symbols

METRIC FASTENERS
1. Grade 2 (GM 200-M)

2. Grade 5 (GM 280-M)
3. Grade 7 (GM 290-M)
4. Grade 8 (GM 300-M)
5. Manufacturers Identification
6. Nut Strength Identification
7. Identification Marks (Posidriv Screw Head)
1. Customary B olt 1/4-20

2. Metric B olt M6.0x1
A. 1/4-inch
B. 6 mm
C. 20 Threads Per Inch
D. 1 Thread Per M illim eter
F-00695 (25.4 Threads Per Inch) F-00705
Figure 10Bolt and Nut Identification Figure 11Thread Notation
Models are primarily dimensioned in the metric sys ISO (International Standards Organization). This was
tem. Many fasteners are metric and are very close in done to reduce the number of fastener sizes used and
dimension to well-known customary fasteners in the yet retain the best strength qualities in each thread
inch system. It is most important that replacement fas size. For example, the customary 1/4-20 and 1/4-28
teners be of the correct nominal diameter, thread pitch screws are replaced by the metric M6.0X1 screw which
and strength. has nearly the same diameter and has 25.4 threads per
O rig in a l equ ip m e nt m etric fasteners (except inch. The thread pitch is in between the customary
beauty bolts, such as exposed bumper bolts, and coarse and fine thread pitches.
cross recess head screws) are identified by a number
marking indicating the strength of the material in the Metric and customary thread notation differ slightly.
fastener as outlined later. Metric cross recess screws The difference is shown in figure 11.
are identified by a Posidriv or Type 1A shown in figure
10. Either a Phillips head or Type 1A cross recess
screwdriver can be used in Posidriv recess screw
heads, but Type 1A cross recess screwdrivers will per FASTENER STRENGTH
form better. IDENTIFICATION
NOTICE: Most metric fasteners have a blue Most commonly used metric fastener strength
color coating. However, this should not be property classes are 9.8 and 10.9 with the class
used as positive identification as some fasten identification embossed on the head of each bolt.
ers are not color coated. Customary (inch) strength classes range from grade 2
to 8 with radial line identification embossed on each
General Motors Engineering Standards, along with bolt head. Markings correspond to two lines less than
other North American Industries, have adopted a por the actual grade (i.e. grade 7 bolt will exhibit 5
tion of the standard metric fastener sizes defined by embossed radial lines on the bolt head). Some metric
nuts w ill be marked with single d ig it strength SIX LOBED SOCKET

identification numbers on the nut face. Figure 10
shows the different strength markings. HEAD FASTENERS
When replacing metric fasteners, be careful to use
bolts and nuts of the same strength or greater than the Six lobed socket head (Torx) fasteners are used in
original fasteners (the same number marking or some applications on vehicles covered in this manual
higher). It is likewise important to select replacement (figure 13). The door striker bolt is of this design.
fasteners of the correct size. Correct replacement bolts Tools designed for these fasteners are available
metric fasteners available in the aftermarket parts commercially. However, in some cases, if the correct
channels were designed to m etric standards of tool is not available, a hex socket head wrench may be
countries other than the United States, and may be of used.
a lower strength, may not have the numbered head
marking system, and may be of a different thread
pitch. The metric fasteners used on GM products are
designed to new, international standards that may not
yet be manufactured by some non-domestic bolt and
nut s u p p lie rs . In g e n e ra l, e xce p t for sp e c ia l
applicaitons, the common sizes and pitches are:
M6.0 x 1 M 10x1.5
M 8 x 1 .2 5 M 12x1.75
PREVAILING TORQUE FASTENERS

A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
most often accomplished by distortion of the top of an
all-metal nut by using a nylon patch on the threads in
the middle of the hex flat. A nylon insert may also be
used as a method of interference between nut and bolt
threads (figure 12).
A prevailing torque bolt is designed to develop an
interference between bolt and nut threads, or the
threads of a tapped hole. This is accomplished by
distorting some of the threads or by using a nylon
patch or adhesive (figure 12).
RECOMMENDATIONS FOR REUSE:

1. Clean, unrusted prevailing torque nuts and bolis
may be reused as follows:
a. Clean dirt and other foreign material off the
nut or bolt.
b. Inspect the nut or bolt to insure there are no
cracks, elongation, or other signs of abuse
or overtightening. (If there is any doubt,
replace w ith a new p revailing torque
fastener or equal or greater strength).
c. Assemble the parts and hand start the nut
or bolt.
d. Observe that, before fastener seats, it
develops torque per the chart in figure 10 (if
there is any doubt, replace with a new
prevailing torque fastener of equal or
greater strength).
e. Tighten the fastener to the torque specified
in the appropriate section of this manual.
2. Bolts and nuts which are rusty or damaged
should be replaced with new parts or equal or
greater strength.
0A-10 GENERAL INFORMATION
A
6 & 6.3 8 10 12 14 16 20
4 ,5 Nm 0.4 0.8 1.4 2.2 3.0 4.2 7.0
In. Lbs. 4.0 7.0 12 18 25 35 57
1,2, 3, 6, Nm 0.4 0.6 1.2 1.6 2.4 3.4 5.6
7, 8, 9 In. Lbs. 4.0 5.0 10 14 20 28 46
B
.250 .312 .375 .437 .500 .562 .625 .750
4 ,5 Nm 0.4 0.6 1.4 1.8 2.4 3.2 4.2 6.2
In. Lbs. 4.0 5.0 12 15 20 27 35 51
1,2, 3, 6, Nm 0.4 0.6 1.0 1.4 1.8 2.6 3.4 5.2
8, 9 In. Lbs. 4.0 5.0 9.0 12 15 22 28 43
A. Metric Sizes 1. Top Lock Type 6. Nylon Strip Or Patch
B. Inch Sizes 2. Center Lock 7. Nylon Washer Insert
3. Dry Adhesive Coating 8. Nylon Patch
4. Out Of Round Thread 9. Nylon Insert
5. Deformed Thread Profile
B-02406
Figure 12Torque Nuts and Bolts Chart

T - Internal Drive
E - External Drive
B-02221
Figure 13Six Lobed Socket Head (Torx)

Fasteners
OA-12
CONVERSION TABLE
GENERAL INFORMATION
to get equivalent to get equivalent
Multiply by number of: Multiply by number of:
LENGTH ACCELERATION
Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2(m/s2)
Foot 0.304 8 meters (m) Inch/sec2 0.025 4 meter/sec2
Yard 0.9144 meters TORQUE
Mile 1.609 kilometers (km)
Pound-inch 0.112 98 newton-meters (N m)
AREA Pound-foot 1.355 8 newton-meters
Inch2 645.2 millimeters2(mm2) POWER
6.45 centimeters2(cm2)
Horsepower 0.746 kilowatts (kW)
Foot 0.092 9 meters2(m2)
Yard2 0.836 1 PRESSURE OR STRESS
meters2
Conversion Table
VOLUME Inches of water 0.249 1 kilopascals (kPa)

Pounds/sq. in. 6.895 kilopascals
Inch3 16.387 mm1
16.387 cm3 ENERGY OR WORK
0.0164 liters (1) BTU 1 055 joules (J)
Quart 0.946 4 liters Foot-pound 1.355 8 joules
Gallon 3.785 4 liters Kilowatt-hour 3 600 000 joules (J * one W)
Yard3 0.764 6 meters3(m3) or 3.6 x 106
MASS LIGHT
Pound 0.453 6 kilograms (kg) Foot candle 1.076 4 lumens/meter2(lm/m2)
Ton 907.18 kilograms (kg) FUEL PERFORMANCE
Ton 0.907 tonne (t) Miles/gal 0.425 1 kilometers/liter (km/l)
FORCE Gal/mile 2.352 7 liter/kilometer (l/km)
Kilogram 9.807 newtons (N) VELOCITY
Ounce 0.278 0 newtons Miles/hour 1.609 3 kilometers/hr. (km/h)
Pound 4.448 newtons
TEMPERATURE
Degree
Fahrenheit (tF-32) 1.8 degree Celsius (C)
00
o
cn
co
-si
DECIMAL AND METRIC EQUIVALENTS

Fractions Decimal Metric Fractions Decimal Metric
In. MM. In. MM.
1/64 .015625 .39688 33/64 .515625 13.09687

1/32 .03125 .79375 17/32 .53125 13.49375
3/64 .046875 1.19062 35/64 .546875 13.89062
1/16 .0625 1.58750 9/16 .5625 14.28750
5/64 .078125 1.98437 37/64 .578125 14.68437
3/32 .09375 2.38125 19/32 .59375 15.08125
7/64 .109375 2.77812 39/64 .609375 15.47812
1/8 .125 3.1750 5/8 .625 15.87500
9/64 .140625 3.57187 41/64 .640625 16.27187
5/32 .15625 3.96875 21/32 .65625 16.66875
11/64 .171875 4.36562 43/64 .671875 17.06562
3/16 .1875 4.76250 11/16 .6875 17.46250
13/64 .203125 5.15937 45/64 .703125 17.85937
7/32 .21875 5.55625 23/32 .71875 18.25625
15/64 .234375 5.95312 47/64 .734375 18.65312
1/4 .250 6.3500 3/4 .750 19.05000
17/64 .265625 6.74687 49/64 .765625 19.44687
9/32 .28125 7.14375 25/32 .78125 19.84375
19/64 .296875 7.54062 51/64 .796875 20.24062
5/16 .3125 7.93750 13/16 .8125 20.63750
21/64 .328125 8.33437 53/64 .828125 21.03437
11/32 .34375 8.73125 27/32 .84375 21.43125
23/64 .359375 9.12812 55/64 .859375 21.82812
3/8 .375 9.52500 7/8 .875 22.22500
25/64 .390625 9.92187 57/64 .890625 22.62187
13/32 .40625 10.31875 29/32 .90625 23.01875
27/64 .421875 10.71562 59/64 .921875 23.41562
7/16 .4375 11.11250 15/16 .9375 23.81250
29/64 .453125 11.50937 61/64 .953125 24.20937
15/32 .46875 11.90625 31.32 .96875 24.60625
31/64 .484375 12.30312 63/64 .984375 25.00312
1/2 .500 12.70000 1 1.00 25.40000
B-05496
Decimal and Metric Equivalents

RPO LISTING
(REGULAR PRODUCTION OPTION)
The RPO list contains RPOs used on C-K Models, G B32 Floor Mats - Front
Vans, and Forward Control Chassis Models. Refer to B33 Floor Mats - Rear
the Service Parts Identification Label for a list of the B84 Extra Molding - Body Side
RPOs used on each specific vehicle. B85 Extra Molding - Belt Reveal
AA3 Windows - Deep Tint, Side Windows Only B93 Extra Molding - Door Edge Guard
AC2 Window - Sliding, Right Front Door B96 Extra Molding - Wheel Opening
AD5 Window - Right Rear, Side, Sliding CD4 Wiper System - Pulse
AD8 Door Check C36 Heater - Auxiliary
AJ1 Window - Deep Tint, Except Windshield and C42 Heater - Deluxe Outside Air
Doors C49 Defogger - Rear Window, Electric
AM7 Seat - Right Rear Folding C55 Vent - Roof
AP7 Partition - Sliding Plywood C56 Vent - Forced Air, Right Side
AQ3 Seat - Rear Center C60 Air Conditioning - Front Manual Controls
AQ4 Seat - Rear C69 Air Conditioner - Roof Mounted
AS1 Seat - Front Bucket, High Back, Driver C91 Lamp - Interior Courtesy
AS2 Seat - Front Bucket, High Back, Passenger DF1 Mirror - Camper Type, Painted
AS3 Seat - Right Rear, Suburban DF2 Mirror - Camper Type, SST
AT5 Seat - Center Folding, Suburban DG5 Mirror - West Coast Type
AU2 Lock - Cargo Door D20 Sunshade - Windshield, Passenger Side
AU3 Power Lock - Side Door D31 Mirror - Tilt
AU6 Power Lock - Tailgate Remote Control D34 Mirror - Visor Vanity
AV5 Seat - High Back, Bucket D44 Mirror - Outside, Painted
AW4 Door - Sliding Side Extension D45 Mirror - Outside, SST
AX5 Partition - Expanded Metal, Left Side D46 Mirror - West Coast Type with Clearance Lights
AX6 Partition - Expanded Metal w/Sliding Door D49 Mirror - Chrome
AX7 Partition - Expanded Metal w/Center Sliding Door D73 Pickup Box Hand Rail
AX8 Seat - Front Bucket, Pedestal, Driver D77 Mirror - Dual, Wide Angle, SST
AX9 Latch - Rear Cargo Door D92 Stripe - Lower Decor
A01 Window - Tinted, All Shaded Windshield E24 Door - Cargo Side, Hinged
A02 Windshield - Tinted, Shaded Upper E31 Body - Steel ,10 ft.
A07 Window - Body E32 Body - Forward Control, Var. 3
A08 Window - Body, Right Side E33 Body - Forward Control, Var. 4
A12 Window - Stationary, Back Door E34 Body - Steel, 10 ft. Standard Width
A13 Window - Stationary, Side Rear Door E36 Body - Aluminum, 10 ft.
A17 Window - Left Side Swing-Out E38 Body - Steel, 12 ft. x 8 ft.
A18 Window - Rear Door, Swing-Out E39 Body - Aluminum, 12 ft. x 8 ft.
A19 Glass - Side Rear Door, Swing-Out E46 Door - 66 in., Overhead Sliding w/Window
A28 Window - Right Rear, Full Width, Sliding E52 Door - 83 in., Wrap-Around
A31 Window - Side, Power E53 Door - 87 in., Wrap-Around
A33 Window - Tailgate, Power E71 Cargo Floor - Steel
A51 Seat - Front Bucket E76 Door - 60 in., Rear
A52 Seat - Front Bench E79 Door - 74 in., Rear, Strap Hinges
A57 Seat - Auxiliary, One Passenger, Folding E62 Pickup Box - Stepside (Fenderside)
A82 Head Restraints E94 Rally (Beauville) Equipment
A95 Seat - Front Bucket, High Back, Reclining E63 Pickup Box - Fleetside (Wideside)
BA8 Compartment - Front Seat Storage E89 Panel - Driver Door w/Window
BB5 Ornamentation FS3 Axle - Front I-Beam
BF3 Floor Covering - Step Well Mat F51 Shock Absorbers - Front and Rear, Heavy Duty
BW2 Ornamentation - Deluxe Body Side Molding F58 Stabilizer Shaft - Front, Heavy Duty
B3D School Bus Equipment F59 Stabilizer Shaft - Front
B3J Diesel Equipment F60 Spring - Front, Heavy Duty
B3M School Bus Equipment - Deluxe F66 Suspension System - Front
B30 Floor Carpet G50 Spring - Rear, Heavy Duty
G51 Spring - Rear, Special Heavy UA1 Battery - High Capacity

G52 Spring - Rear 15000 lbs. UB4 Lamps - Rear Side Marker
G60 Spring - Rear Auxiliary UD4 Alarm - Vehicle Speed
G80 Axle - Rear, Limited Slip UF2 Lamp - Cargo
KC4 Engine Oil Cooler System UJ1 Indicator System, Brake Warning
KL7 Gas Conversion - LP UM6 Radio - AM/FM Stereo, Seek/Scan, Cassette,
K05 Engine Block Heater Clock
K09 Generator - 120 Amp UN3 Radio - AM/FM Stereo, Cassette
K22 Generator - 94 Amp UY7 Wiring Harness - Truck Trailer, Heavy Duty
K34 Cruise Control U01 Lamp - Roof Marker
K46 Air Cleaner - Heavy Duty, Pre-Cleaner U18 Speedometer - Kilometer
K81 Generator - 66 Amp U35 Electric Clock
LB1 Engine - 4.3L V6 4BBL U37 Cigarette Lighter
LE8 Engine -4.7L V8 4BBL U58 Radio - AM/FM Stereo
LE9 Engine - 5.0L V8 4BBL, Hi Compression U63 Radio - AM
LF3 Engine - 5.0 V8 4BBL, Regular Compression U66 Speaker System - Dual Front, Dual Rear
LH6 Engine - 6.2L V8, Diesel U69 Radio - AM/FM
LL4 Engine - 6.2L V8, Heavy Duty Diesel U76 Antenna - Windshield
LS9 Engine - 5.7L V8 4BBL VE5 Bumper - Front and Rear Impact Strip
LT9 Engine - 5.7L V8 4BBL, Heavy Duty VF1 Bumper - Rear Chrome
L25 Engine - 4.8L V6 1BBL VR2 Trailer Hitch
MV4 Transmission - Auto. 3-Speed Clutch Converter VR4 Trailer Hitch - Weight Distributing
MY6 Transmission - Manual 4-Speed w/Overdrive V01 Radiator - Heavy Duty
NAS Emission System - Federal Requirements V02 Radiator - Heavy Duty w/Trans. Oil Cooler
NA6 Emission System - High Altitude Requirements V05 Increased Cooling
NE2 Fuel Tank - 40 gal. V22 Radiator Grille - Chrome
NK7 Fuel Tank - 31 gal. V31 Bumper Guards - Front, Chrome
NL2 Fuel Tank - Auxiliary V35 Bumper, Rear w/Recessed Lighting
NL7 Fuel Tank - 33 gal. V37 Bumper - Front and Rear Chrome
NM5 Emission system - Canadian Requirement V42 Bumper - Rear Step, Chrome
NN4 Fuel Tank - 60 gal. V43 Bumper - Rear Step, Painted
NY1 Fuei Tank Shield V46 Bumper - Front, Chrome
N05 Fuel Filler Cap Lock V76 Front Hook Towing Device
N31 Steering Wheel - Custom X6W Hub - Locking
N33 Steering Column - Tilt YE9 Equipment Package, Level 3
N40 Steering - Non-Variable YG1 Molding, Body Side and Wheel Opening
N41 Steering - Power YJ6 Decor Package - Econo
N51 Steering - Manual ZM2 Trim Package, Bonaventure
N67 Wheel - Rally Type ZW9 Base Body or Chassis
N90 Wheel - Aluminum Cast ZY1 Color Combination - Solid
PA1 Wheel - Trim Discs, Var. 5 ZY2 Color Combination - Two Tone
PA6 Wheel - Styled, Painted ZY4 Color Combination - Deluxe Two Tone
P01 Wheel - Trim Discs, Var. 1 Z53 Guage Package - Voltmeter, Oil Press, and Temp.
P10 Carrier - Spare Tire Z62 Equipment Package - Level 1
P11 Carrier - Spare Tire, Glide Out Z72 Trailering Package - L.D. Ball-Type Hitch
P13 Carrier - Spare Tire, Side-Mounted Z73 Trim - Special Interior
P14 Carrier - Inside Mounted Spare Tire, Left Side Z75 Shock Absorbers - Four Front
P15 Carrier - Inside Mounted Spare Tire, Right Side Z76 Special Chassis - Camper Package
P17 Cover - Spare Wheel/Tire Z80 Trim - Special Exterior
R05 Wheel Conversion - Dual Rear Z81 Camper - Special
TP2 Battery - Auxiliary Camper Z82 Trailer Hitch - Special Reese Type
TR9 Lamp Group 12A Stripe Accent - White
TT4 Headlamps - Halogen, Pencil Beam 12K Color Combination - White (Auxiliary Top)
TT5 Headlamps - Halogen 12L Secondary Color - White
TVR Lamp - Rear Dome and Reading 12U Primary Color - White
T63 Headlamps - Warning System 18C Trim Combination - Charcoal, Stnd. Cloth
T84 Headlamps - Right Rule 18D Trim Combination - Charcoal, Velour Cloth
T85 Headlamps - Left Rule 181 Interior Trim - Charcoal
18V Trim Combination - Charcoal, Vinyl Striped 90K Color Combination - Med. Grey (Auxiliary Top)
18W Trim Combination - Charcoal, Dual Grain Vinyl 90L Secondary Color - Grey Metallic
19A Stripe Accent - Black and Grey Two Tone 90U Primary Color - Grey Metallic
191 Interior Trim - Black 93U Primary Color - Lt. Driftwood Pearlmist
19K Color Combination - Black (Auxiliary Top) 9V8 Color Combination - Cardinal Red
19L Secondary Color - Black
19U Primary Color - Black
19W Trim Combination - Black, Dual Grain Vinyl
21L Secondary Color - Lt. Blue Metallic
21U Primary Color - Lt. Blue Metallic
23D Trim Combination - Blue, Velour Cloth
23G Trim Combination - Blue Cloth
23I Interior Trim - Blue Vinyl
23V Trim Combination - Blue Vinyl, Striped
23W Trim Combination - Blue Dual Grain Vinyl
28L Secondary Color - Dk. Blue Metallic
28U Primary Color - Dk. Blue Metallic
29A Stripe Accent - Dk. and Lt. Blue
29K Color Combination - Dk. Blue (Auxiliary Top)
29L Secondary Color - Dk. Blue
29U Primary Color - Dk. Blue
55L Second Color - Russet Metallic
55U Primary Color - Russet Metallic
61K Color Combination - Tan (Auxiliary Top)
61L Secondary Color - Tan
61U Primary Color - Tan
62C Trim Combination - Lt. Saddle, Stnd. Cloth
62D Trim Combination - Lt. Saddle, Velour Cloth
62G Trim Combination - Saddle Cloth
62I Interior Trim - Lt. Saddle
62V Trim Combination - Lt. Saddle Vinyl, Striped
62W Trim Combination - Lt. Saddle, Dual Grain Vinyl
66K Color Combination - Dk. Brown
66L Secondary Color - Dk. Brown Metallic
66U Primary Color - Dk. Brown Metallic
67L Secondary Color - Lt. Saddle Metallic
67U Primary Color - Lt. Saddle Metallic
72A Stripe Accent - Bright Red
72L Secondary Color - Bright Red
72U Primary Color - Bright Red
76C Trim Combination - Bronze, Stnd. Cloth
76D Trim Combination - Bronze, Velour Cloth
76G Trim Combination - Dk. Claret and Gold, Garnet
Red
76I Interior Trim - Bronze
76V Trim Combination - Bronze, Striped Vinyl
76W Trim Combination - Bronze, Dual Grain Vinyl
77C Trim Combination - Dk. Maple, Stnd. Cloth
77D Trim Combination - Dk. Maple, Velour Cloth
77G Trim Combination - Dk. Maple Cloth
77I Interior Trim - Dk. Maple
77V Trim Combination - Dk. Maple, Striped Vinyl
77W Trim Combination - Dk. Maple, Dual Grain Vinyl
78U Primary Color - Med. Rosewood Metallic
82D Trim Combination - Med. Dk. Grey Velour Cloth
82G Trim Combination - Med. Dk. Grey Cloth
82I Interior Trim - Med. Dk. Grey
82W Trim Combination - Dk. Grey, Dual Grain Vinyl
___________________________________________________________________ OB-1
SECTION OB
MAINTENANCE AND LUBRICATION
CONTENTS
SUBJECT PAGE
C a p a citie s.................................................................................................................................................................... OB- 1

L u b ric a tio n .................................................................................................................................................................. OB- 6
Maintenance Schedule and L o g ..............................................................................................................................OB- 7
CAPACITIES
Figures 2 through 6 show the approximate capacities of the dif
ferential gear, the transmission, the cooling system, the crankcase,
the fuel tank, the front axle and the transfer case. Engine code letters
are used in the charts. Refer to figure 1 for an explanation of the code.
VIN E N G IN E D ESCRIPlD ON Produced

Liter Fuel in GM Plant
Engine Code Displacement Type System Operated By:
N 4.3 V6 4 BBL Chevrolet Motor
F 5.0 V8 4 BBL Chevrolet Motor
H 5.0 V8 4 BBL Chevrolet Motor*
L 5.7 V8 4 BBL Chevrolet Motor
M 5.7 V8 4 BBL Chevrolet Motor
W 7.4 V8 4 BBL Chevrolet Motor
T 4.8 L6 1 BBL t
C 6.2 V8 F.l. @ Det. Diesel Allison
J 6.2 V8 F.l. @ Det. Diesel Allison
* or General Motors of Canada

t Produced in Mexico by General Motors de Mexico
@ Diesel
Figure 1-1986 Engine Code Identification
Metric U .S .
Items Measure Measure
Differential
8 V2" Ring Gear 2.0 L 4.2 pts.
9 1/2" Ring Gear 3.1 L 6.5 pts.
IOV2" Ring Gear (Chev.) 3.1 L 6 V2 pts.
93/4" Ring Gear (Dana) 2.8 L 6.0 pts.
12 Ring Gear (Rockwell) 5.9 L 12.5 pts.
Transmission
Automatic
350C Pan Removal 3.3 L 6.3 pts.
Overhaul 9.5 L 20.0 pts.
400 Pan Removal 4.0 L 9.0 pts.
700-R4 Pan Removal 4.7 L 10.0 pts.
Manual
4 Speed 117 mm 4.0 L 4.2 qts.
4 Speed 89 mm 4.0 L 4.2 qts.
3 Speed 76 mm 1.5 L 1.6 qts.
Figure 2Approximate Capacities - All Models

OB-2 MAINTENANCE AND LUBRICATION
Metric U.S.
Cooling System (Approx.)
Code: H, L, M
Without A/C 16.5 Liters 17.5 Quarts
With A/C 17 Liters 18 Quarts
Code: W
Without A/C 22 Liters 23 Quarts
With A/C 23 Liters 24.5 Quarts
Diesel Engines
Code: C, J
With or Without A/C 23 Liters 25 Quarts
Crankcase*
Gasoline Engines
Code: H, L and M
Without Filter 3.8 Liters 4 Quarts
With Filter 4.8 Liters 5 Quarts
Code: W +
Diesel Enginest
Code: C, J With Filter 6.5 Liters 7 Quarts
Fuel Tank
Standard, All Gas 95 Liters 25 Gallons
Diesel 102 Liters 27 Gallons
NK7 Option, All Gas 117 Liters 31 Gallons
NE2 Option, Suburban Only
Gas 151 Liters 40 Gallons
Front Axle
K15/10-K25/20 1.9 Liters 2 Quarts
K35/30 2.8 Liters 3 Quarts
Transfer Case 4.8 Liters 5.0 Quarts
After refill, fluid level must be checked as outlined under Service

and Maintenance in Section 5 of the owners manual.
+ K35/30 Models 5 U.S. quarts (4.8 Liters) Without Filter.
6 U.S. Quarts (5.7 Liters) With Filter,
t Oil filter should be changed at EVERY oil change.
A Equipped with Auxiliary Heater add 2.68L/2.84 Qts.
Figure 3Approxim ate Capacities - Blazer, Suburban

MAINTENANCE AND LUBRICATION OB-3
Metric U.S.
Cooling System (approx.)
4.8L (L6) Engine Code (T)
P30042 Models 13.1 Liters 13.8 Quarts
With or Without A/C
5.7L (V8) Engine Code (M)
With or Without A/C
7.4 L (V8) Engine Code (W)
Without A/C
6.2L (V8) Diesel Engine Code (J)
P30042 Models 23.5 Liters 25 Quarts
With or Without A/C
Without A/C
Crankcase (approx.)*
Engine Code: M
Engine Code: T
Engine Code: W
Engine Code: J (Diesel)t
Fuel Tank Data
P25-35 114 Liters 30 Gallons
P30042 (School Bus) 114 Liters 30 Gallons
P30032 (Motor Home)* 114 Liters 30 Gallons
* After refill, fluid level should be checked as outlined under Service and
Maintenance Section 5 of the owners manual.
t Oil Filter should be changed at EVERY oil change.
Optional 60 gallon fuel tank available.
Figure 4Approximate Capacities - Forward Control

Metric U.S.
ITEMS Measure Measure
Code N-V6
W ith or W ithout A/C 10.3 Liters 10.9 Quarts
Code T-L-6
W ithout A/C 14.7 Liters 15.5 Quarts
With A/C 15.1 Liters 16 Quarts
Code F, H, L & M V-8
W ithout A/C 16.6 Liters 17.5 Quarts
W ith A/C 17 Liters 18 Quarts
Code W V-8
W ithout A/C 22 Liters 23 Quarts
W ith A/C 23 Liters 24.5 Quarts
Diesel
W ith or W ithout A/C 23 Liters 25 Quarts
C rankcaseA
G asoline Engines
Codes: N, F, H, L, M
W ithout Filter 3.8 Liters 4 Quarts
Code: T
Code: W +
Diesel Engines Code C, J t 6.5 Liters 7 Quarts
Fuel Tank (Approx.)
Short Bed
Single Tank, Gas, Diesel 61 Liters 16 Gallons
Dual Tanks, Gas, Diesel 61 Liters 16 Gallons
Long Bed
Single Tank, Gas 76 Liters 20 Gallons
@ *D ual Tanks, Gas 61 Liters 16 Gallons
Single Tank, Diesel 76 Liters 20 Gallons
Dual Tanks, Diesel 76 Liters 20 Gallons
Front Axle
K35/30 2.8 Liters 3 Quarts
Transfer Case
K35/30 2.4 Liters 2.5 Quarts
A A fte r refill, fluid level must be checked as outlined under Service and M aintenance
in Section 5 of the ow ners manual.
+ K30/35 M odels 5 U.S. Q uarts (4.8 Liters) W ithout Filter.
6 U.S. Q uarts (5.7 Liters) W ith Filter,
t Oil Filter should be changed ai EVERY oil change.
* Listed quantity is for each tank.
@ Above 8600 GVWR Both tanks 20 gallons (76 Liters)
Figure 5Approxim ate Capacities - Pickup Models

METRIC U.S.
ITEMS MEASURE MEASURE
4.3 L (N) V6 All 10.5 Liters 11.1 Quarts
V8s Except Diesel
Without A/C 16 Liters 17 Quarts
With A/C 16 Liters 17 Quarts
6.2 L (C) Diesel
With Automatic or 23 Liters 24 Quarts
Manual Transmission
With or w/0 A/C
6.2 L (J) Diesel
With Automatic or 24.2 Liters 25.6 Quarts
Manual Transmission
With or w/o A/C
Crankcase (Approx.)*
All Engines Except Diesel
Diesel Engines
With Filtert 6.5 Liters 7 Quarts
Fuel Tank (Approx.)
Gasoline and Diesel Engines
Standard 83 Liters 22 Gallons
Optional 125 Liters 33 Gallons
* After refill, fluid level should be checked as outlined under Service

and Maintenance Section 5 of the owners manual.
A If equipped with Auxiliary Heater add 2.68L/2.84 Qts.
t Oil Filter should be changed at EVERY oil change.
Figure 6Approxim ate Capacities - G Van

LUBRICATION
Figures 7, 8 and 9 show chassis lubrication points for the C, K, G and P chassis.
1. Lower Control Arms 9. Master Cylinder

2. Upper Control Arms 10. Transmission - Manual
3. Upper and Lower Control Arm Ball Joints - Automatic
4. Intermediate Steering Shaft (PA10) 11. Throttle Bell Crank - L6
5. Tie Rod Ends 12. Carburetor Linkage - V8
6. Wheel Bearings 13. Brake and Clutch Pedal Springs
7. Steering Gear 14. Universal Joints
8. Air Cleaner - Element 15. Rear Axle F-00433
Figure 7Lubrication Points For The Conventional

And Forward Control Models
3 4 11 9 10 9 11
8 1 5 12 3 4 15 1 6 13 2
1. Air Cleaner 8. Carburetor Linkage - V8
2. Control Linkage Points 9. Universal Joints
3. Tie Rod Ends 10. Propeller Shaft Slip Joints
4. Wheel Bearings 11. Front and Rear Axle
5. Steering Gear 12. Drag Link
6. Master Cylinder 13. Brake and Clutch Pedal Springs
7. Transmission - Manual 14. Transfer Case
- Automatic 15. Throttle Bell Crank - L6
F-00434
Figure 8Lubrication Points For The CK Four Wheel Drive Models

1. Control Arm Bushings and Ball Joints 5. Transmission Control Shaft 8. Rear Axle
2. Tie Rod Ends 6. A ir Cleaner - Element 9. Oil Filter
3. Wheel Bearings 7. Transmission - Manual 10. Brake Master Cylinder
4. Steering Gear and Clutch Cross-Shaft - Automatic 11. Parking Brake Linkage
F-00435
Figure 9Lubrication Points For The G Van
MAINTENANCE SCHEDULE AND LOG

The information shown on pages OB-7 through OB-18 is the same as shown in the 1986 Light Duty Mainte
nance Schedule and Log.
1986 GENERAL MOTORS

LIGHT DUTY TRUCK
MAINTENANCE SCHEDULES
This booklet covers the maintenance required for your General Motors
vehicle. It is essential that your vehicle receive this maintenance to
retain the safety, dependability, and emission control performance
originally built into your vehicle.
Maintenance service should be done by your General Motors

tru ck dealer or any other qualified autom otive service or repair
establishm ent which is able to provide such services and which
can be relied upon to use proper parts and practices.
In addition to the in-shop type services shown in Sections A and B,

this booklet also includes owner inspections and services in Section
C which you or a qualified technician should perform periodically.
Always keep this booklet in your vehicle, and leave it w ith the
vehicle when sold. The maintenance record, plus maintenance
receipts, may be needed fo r warranty repairs. It is suggested that
receipts be kept w ith this booklet.
SELECTING YOUR VEHICLES

MAINTENANCE
DETERMINING GVWR AND EMISSIONS

CLASSIFICATION
To determine the emissions classification for gasoline engine
equipped vehicles, refer to the certification label located on the edge
of the drivers door. If the Gross Vehicle Weight Rating (GVWR) in the
u p p e r le ft c o rn e r of the c e rtific a tio n la b e l is less tha n
8600 lbs./3 900 kg, your vehicle is equipped with Light Duty Emis
sions ; if 8600 lbs./3 900 kg or more, your vehicle is equipped with
Heavy Duty Emissions .
SELECTING THE PROPER

MAINTENANCE CHART
Select the proper maintenance from pages 4 through 11 depending
on your vehicles engine (gas or diesel) and engine emissions classifi
cation.
SELECTING THE PROPER
MAINTENANCE SCHEDULE
Select and follow either Maintenance Schedule 1 or Maintenance
Schedule 2 based on how you use your vehicle.
MAINTENANCE SCHEDULE 1
Follow Maintenance Schedule 1 denoted by a white o if you mainly
operate your vehicle under one or more of the following conditions:
When most trips are less than 4 miles (6 kilometers).
When most trips are less than 10 miles (16 kilometers) and out
side temperatures remain below freezing.
Idling for extended periods and/or low-speed operations such as
found in delivery, police, rental or taxi operation.
Towing a trailer.
Operating in dusty areas.
MAINTENANCE SCHEDULE 2
Follow Maintenance Schedule 2 denoted by a black only if none
of the driving conditions specified in Maintenance Schedule 1 apply.
SECTION A -SCH ED U LED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH LIGHT DUTY EMISSIONS - UNDER 8600 GVWR
The corvlroc chnuun in this cchgriylg un In fin nnn mjjoc (inn OOfl kmt o Maintenance Schedule 1
are to be performed after 60,000 miles (100 000 km) at the same intervals. Maintenance Schedule 2
Item Miles (000) 3 6 7.5 9 12 15 18 21 22.5 24 27 30 33 36 37.5 39 42 45 48 51 52.5 54 57 60
No. Service Kilometers (000) 5 10 12.5 15 20 25 30 35 37.5 40 45 50 55 60 62.5 65 70 75 80 85 87.5 90 95 100
1 Engine Oil Change * o o o o om o o o o o o o o o om o o o o o
Oil Filter Change * o o o o o o o o o o o o o o 0 o o o o o
2 Chassis Lubrication * o o o o om o o o o o # o o o o om o o o o o
3 Engine Idle Speed Adjustment * 1 - At 6 Months or o2 o1
4 Cooling System Service * Every 24 Months or om om
5 Air Cleaner Element and PCV Filter Replacement * o m2 om
6 Front Wheel Bearing Repack o om o om
7 Transmission Service - See Explanation for
Service Intervals in Section B
8 PCV System Inspection * om om
9 Fuel Filter Replacement * o1 o#1 o1 om
10 Carburetor Choke and Hoses Inspection * 1
o o#2 o m
- At 6 Months or
11 Carburetor or Throttle Body Mounting Bolt

o2 2 o1 '
Torque Check * - At 6 Months or
12 Vacuum Advance System Inspection *
o o* om
- At 6 Months or
13 Spark Plugs * o#2 o*
14 Wire Service * o# om
15 EGR System Check * o# om
16 Engine Timing Check * o# om
17 Fuel Tank, Cap and Lines Inspection * o1 om o1 om
18 Early Fuel Evaporation System Inspection * 1 o om om
19 Thermostatically Controlled Air Cleaner Inspection * om om
20 Engine Accessory Drive Belts Inspection * o om2 o om
21 Evaporative Control System Inspection * 1 om om
FOOTNOTES:
1. All engines EXCEPT 2.5 L (VIN Engine Code E), 2.8 L (VIN Engine Code R),
The maintenance services contained in Maintenance Schedule 1 and 2 are based on
4.3 L (VIN Engine Code Z)
the assumption that your vehicle will be used as designed:
2. In California, these are the minimum Emission Control Maintenance Services an owner To carry passengers and cargo within the limits shown on the tire placard located
must perform according to the California Air Resources Board. General Motors, how on the edge of the drivers door.
ever, urges that all Emission Control Maintenance Services shown be performed. To On reasonable road surfaces within legal driving limits.
maintain your other new vehicle warranties, all services shown in this booklet should On unleaded gasoline.
be performed.
An Emission Control Service
OB-9
NOTE: To determine the engine code, refer to the Specifications section of your
Owners Manual. 4
SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH HEAVY DUTY EMISSIONS - OVER 8600 GVWR (EXCEPT CALIFORNIA)
0B-10
The services shown in this schedule up to 60,000 miles (100 000 km) o Maintenance Schedule 1
Item Miles (000) 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
No. Service Kilometers (000) 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

1 E n g in e O il C h a n g e o o# o 09 o 09 o o# o o# o 0# o o# o o# o o# o o *
O il F ilter C h a n g e * o o# o O o 09 o o o o# o 0 o o * o o o o o
2 C ha ssis L u b rica tio n o 09 o 09 o O o o o o# o 09 o o * o o * o 09 o o
3 E n g in e Idle S peed A d ju stm e n t * 09 O o# O 09 o
A t 6 M on th s or
4 C o o lin g System S e rv ic e * Every 24 M on th s or 09 09
5 A ir Cleaner, A .I.R . and PCV F ilter 9 9

R e p la ce m e n t * A
6 Front W heel B e a rin g R epack 09 O O9
7 Transm ission S e rvice - See E xp la n a tio n for

S e rvice Intervals in S ection B
8 PC V System In sp ectio n * 09 09
9 Fuel F ilter R e p la ce m e n t o 09 O 09 o
10 C a rbu re to r C hoke and H oses 09 O9 09
In sp ectio n * A t 6 M on th s or
11 C a rbu re to r or T hro ttle B ody M ou n tin g Bolt 09 o O9 O 09 o
Torque C h e ck * At 6 M on th s or
12 Vacuum A d va n ce System In sp ectio n 09 09 09
A t 6 M on th s or
13 S p a rk P lu g s * o* 09 O* 09 o*
14 W ire S e rvice 09
15 EGR System C h e ck * 09 09
16 E n gine T im in g C h e ck * 09 09
17 Fuel Tank, C ap and L ines Insp ectio n * 09 09
18 E arly Fuel E vaporation S ystem In sp ectio n o o 09 o 09 O
19 T h e rm o sta tica lly C o n tro lle d A ir C le a n e r :~t 09 09

Insp ectio n *
20 E n g in e A cce sso ry D rive B elts In sp ectio n o 09 0 09 09
Every 12 M on th s or
21 E vaporative C o n tro l S ystem Inspection 09
22 S h ie ld s and U n d e rh o o d In su la tion In sp ectio n A o# 09 09 09 09
23 A ir Intake System Insp ectio n A 09 09

24 T h e rm o sta tica lly C o n tro lle d E n g in e C o o lin g o# 09
09 09 09
Fan C h e ck A " Every 12 M onths or
25 M an ifo ld H eat Valve C h e ck A * o* 09 09 09 09
FOOTNOTES: The maintenance services contained in Maintenance Schedule 1 and 2 are based
on the assumption that your vehicle will be used as designed:
* An Emission Control Service To carry passengers and cargo within the limits shown on the tire placard lo
Also a Noise Emission Control Service cated on the edge of the drivers door.
Applicable only to vehicles sold in the United States On reasonable road surfaces within legal driving limits. On leaded gasoline.
6
SECTION A -S C H E D U L E D MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH HEAVY DUTY EMISSIONS - OVER 8600 GVWR (CALIFORNIA ONLY)
are io se performed after 60,000 miles (100 000 km) ai the same intervals. m maintenance Schedule 2
Item Miles (000) 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
No. Service Kilometers (000) 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
1 Engine Oil Change * o o* O o o* O om o o* o O* O 0* o 0# O o# o om
Oil Filter Change * o* o o o o# O o o o# o o o 0* o o om o
2 Chassis Lubrication - Every 4 Months or om 09 om om o* om 0* o* om om
3 Engine Idle Speed Adjustment * - At First 4 Months or,
o* om om om o# om
Then Every 12 Months or
4 Cooling System Service * om om om om o
5 Air Cleaner Element Replacement * om om om om om
6 Front Wheel Bearing Repack om om om om om
8 PCV System Inspection * - Every 12 Months or om om om om om
9 Fuel Filter Replacement * - Every 12 Months or om om om om om
10 Carburetor Choke and Hoses Inspection *
om om
- Every 24 Months or
11 Carburetor or Throttle Body Mounting Bolt
om om om om om
Torque Check * Every 12 Months or
o

12 Vacuum Advance System Inspection * - Every 24 Months or
13 Spark Plugs * om om om om om
14 Wire Service * om om om om om
15 EGR System Check * - Every 36 Months or om
16 Engine Timing Check and Distributor Check * om om om om om
17 Fuel Tank, Cap and Lines Inspection * - Every 24 Months or om om
18 Early Fuel Evaporation System Inspection *
om om
19 Thermostatically Controlled Air Cleaner Inspection *
om om om om om
20 Engine Accessory Drive Belts Inspection * om om om om om
21 Evaporative Control System Inspection * - Every 24 Months or om om
22 Shields and Underhood Insulation Inspection om om om om om
23 Air Intake System Inspection A om om om om om
24 Thermostatically Controlled Engine Cooling Fan Check
om cm om om om
25 Manifold Heat Valve Check * Every 12 Months or om om om om om
26 Idle Stop Solenoid Check * - At First 4 Months or
om om om om om om
Then Every 12 Months or
27 Throttle Return Control Check * Every 12 Months or om om om om om
28 Engine Idle Mixture Adjustment (4.8 L only) *
om om
Every 24 Months or
29 Governor Check - Every 48 Months or om
FOOTNOTES: The maintenance services contained in Maintenance Schedule 1 and 2 are based on the assumption that your
OB-11
vehicle will be used as designed:
* An Emission Control Service
To carry passengers and cargo within the lim its shown on the tire placard located on the edge ot the driver s
Also a Noise Emission Control Service door
Applicable only to vehicles sold in the United States On reasonable road surfaces within legal driving lim its .* On leaded gasoline___________________________
8
SECTION A-SCH ED U LED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH A 6.2 L DIESEL ENGINE
Item Miles (000) 2.5 5 7.5 10 12.5 15 18 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5
No. Service Kilometers (000) 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 64 68 72 76
1 Enqine Oil Change * o o o 09 o o o o* o 0# o 09 o 09 o 09 o 09 G
Oil Filter Change * o 0# o o# o o# o o* o 0# o 09 o 09 o 09 o G9 O
2 Chassis Lubrication * o 0# o o o 09 o o o 09 o 09 o 09 o 09 o 09 O
3 Engine Idle Speed Adjustment * o#1 O #1
4 Cooling System Service * Every 24 Months or 0 9
5 Air Cleaner Element Replacement* 2 0 9 1
6 Front Wheel Bearing Repack O 09 O

8 PCV System Inspection * Every 12 Months or O# 09 0 9
22 Shields and Underhood Insulation Inspection A 0 9 o* 09 09
23 Air Intake System Inspection A 09 09 09 09
24 Thermostatically Controlled Engine 09 09 09 09

Cooling Fan Check A " Every 12 Months or
30 Exhaust Pressure Regulator Valve Inspection * 09 o# 09 09
FOOTNOTES: The maintenance services contained in Maintenance Schedule 1 and

1. In California, these are the minimum Emission Control Maintenance Services an owner 2 are based on the assumption that your vehicle will be used as
must perform according to the California Air Resources Board. General Motors, how designed:
ever, urges that all Emission Control Maintenance Services shown be performed. To To carry passengers and cargo within the limits shown on the
maintain your other new vehicle warranties, all services shown in this booklet should tire placard located on the edge of the drivers door.
be performed. On No. 1, blend or No. 2 grade diesel fuel.
2. For engines with Engine Family GGM06.2DABX, replace element every 15,000 miles On reasonable road surfaces within legal driving limits.
(24 000 km).
A Also a Noise Emission Control Service (applicable only to vehicles with Engine Family
GGM06.2DABX).
Applicable only to trucks sold in the United States
NOTE: To determine engine family refer to the Vehicle Emission Control Information label
located in the engine compartment.
10 11
SECTION B EXPLANATION OF 7. TRANSMISSION SERVICE
SCHEDULED MAINTENANCE SERVICES Automatic Transmission Change the transmission fluid and
filter every 15,000 miles (25 000 km) for vehicles under 8600
The services listed in the preceding Maintenance Schedules are GVWR or every 12,000 miles (20 000 km) for vehicles over 8600
further explained below. After services are completed, fill in the Main GVWR if the vehicle is mainly driven under one or more of these
tenance Record at the end of this booklet. When the following mainte conditions:
nance services are performed, make sure all parts are replaced and In heavy city traffic where the outside temperature regularly
all necessary repairs are done before operating you vehicle. Be sure reaches 90F (32C) or higher.
to use the proper fluids and lubricants as shown in Section E.
In hilly or mountainous terrain.
Frequent trailer pulling.
Item No.
1. ENGINE OIL AND OIL FILTER CHANGE * ALWAYS USE Uses such as taxi, police or delivery service.
SF/CC or SF/CD QUALITY, ENERGY CONSERVING OILS OF If the vehicle is not used mainly under any of these conditions,
THE PROPER VISCOSITY Also always change oil and filter as change the fluid and filter every 30,000 miles (50 000 km) for
soon as possible after driving in a dust storm. If following Main vehicles under 8600 GVWR or every 24,000 miles (40 000 km)
tenance Schedule 1, change oil and filter every 6 months or for vehicles over 8600 GVWR. See your Owners Manual for
recommended mileage; otherwise, change the oil and filter ev further details.
ery 12 months or recommended mileage. See your Owners Manual Transmission (S-Truck 4-Speed, 4-Speed O/D, and
Manual for further details. 5-Speed) Change transmission fluid at 7,500 miles (12 500

2. CHASSIS LUBRICATION Lubricate the front suspension, km), then every 30,000 miles (50 000 km).
steering linkage, constant velocity universal joint, transmission, Manual Transmission (Except S-Truck 4-Speed, 4-Speed O/
clutch, transfer case shift linkage, parking brake cable guides, D, and 5-Speed) Manual transmission fluid does not require
propshaft, universal joints, brake pedal springs, and clutch pedal periodic changing.
springs. Lubricate clutch cross shaft every 30,000 miles (50 000
km). 8. PCV SYSTEM INSPECTION * Check that PCV (Positive
Crankcase Ventilation) system works properly. Replace the valve
3. ENGINE IDLE SPEED ADJUSTMENT * Adjust to the specifi as necessary and any worn, plugged or collapsed hoses.
cations shown on the underhood label. You must use calibrated
9. FUEL FILTER REPLACEMENT * Replace the fuel filter at the
test equipment. Check that idle stop solenoid or dashpot work specified interval or sooner if clogged.
properly (if so equipped).
10. CARBURETOR CHOKE AND HOSES INSPECTION * Verify
4. COOLING SYSTEM SERVICE * Drain, flush and refill system that choke and vacuum break work properly and within specifi
with new coolant. See your Owners Manual for further details. cations. Correct any binding caused by damage or gum on the
5 AIR CLEANER ELEMENT REPLACEMENT, A.I.R. AND PCV choke shaft. Inspect hoses for proper hookup, cracks, chafing,
FILTER REPLACEMENT (SOME MODELS) * Replace at or decay. Correct as necessary.
specified intervals. Replace more often under dusty conditions. 11. CARBURETOR OR THROTTLE BODY MOUNTING BOLT
Ask your dealer for the proper replacement intervals for your TORQUE CHECK * Check torque of mounting bolts and/or
driving conditions. nuts.
6. FRONT WHEEL BEARING REPACK Clean and repack the 12. VACUUM ADVANCE SYSTEM INSPECTION * Check that
front wheel bearings at each brake relining, or at the specified the system works properly. Check hoses for proper hookup,
interval, whichever comes first. cracks, chafing or decay. Replace parts as needed.
* An Emission Control Service An Emission Control Service
OB-13
12 13
13. SPARK PLUGS * Replace spark plugs with the type listed in tight. Also check to be sure that the air cleaner housing is prop
OB-14
your Owner's Manual. erly seated on the carburetor, that the cover fits tightly, and the
14. WIRE SERVICE * Clean wires and inspect for burns, cracks wingnut is tight. Tighten connections and fasteners or replace
or other damage. Check the wire boot fit at the distributor and at damaged parts as required.
the spark plugs. Replace wires as needed. 24. THERMOSTATICALLY CONTROLLED ENGINE COOLING

15. EGR SYSTEM CHECK * Conduct EGR SYSTEM CHECK. FAN CHECK A (If so equipped.) With the engine off and
Refer to DRIVEABILITY AND EMISSIONS (SEC. 6E8). below normal operating temperature, check to see that the fan
can be rotated by hand on fluid coupling or viscous drives. Re
16. ENGINE TIMING CHECK AND DISTRIBUTOR CHECK (SOME
place as necessary.
MODELS)* Adjust timing to underhood label specifications.
Inspect the inside and outside of the distributor cap and rotor for 25 MANIFOLD HEAT VALVE CHECKA Some engines are
cracks, carbon tracking and corrosion. Clean or replace as equipped with a manifold heat valve which should be inspected
needed. and repaired as necessary to insure free operation.
17. FUEL TANK, CAP AND LINES INSPECTION * Inspect the 26. IDLE STOP SOLENOID AND/OR DASHPOT CHECK *
fuel tank, cap and lines for damage or leaks. Remove fuel cap, Check that parts work properly. Replace them as needed.
inspect gasket for an even filler neck imprint, and any damage.
Replace parts as needed. 27 THROTTLE RETURN CONTROL (TRC) SYSTEM CHECK *
Check hoses for proper connections, cracking, abrasion, or de
18. EARLY FUEL EVAPORATION (EFE) SYSTEM INSPECTION * terioration and replace as necessary. Check for proper operation
Check that valve works properly; correct any binding. Check of system. Check for shorted or broken wires and ensure electri
that thermal vacuum switch works properly. Check hoses for cal connectors are fully engaged at distributor, speed switch and
cracks, chafing, or decay. Replace parts as needed. vacuum solenoid.
19 THERMOSTATICALLY CONTROLLED AIR CLEANER IN-
SPECTION * A Inspect all hoses and ducts for proper 28. ENGINE IDLE MIXTURE ADJUSTMENT (4.8 L ONLY) * At
hookup. Make sure valve works properly. designated intervals or in case of a major carburetor overhaul, or
when poor idle quality exists, adjust mixture by a mechanical
20. ENGINE ACCESSORY DRIVE BELTS INSPECTION * In method (lean drop), following the specifications shown on the
spect belts. Look for cracks, fraying, wear, and proper tension. label under the hood.
Adjust or replace as needed.
29. GOVERNOR CHECK A (If so equipped). Check the engine
21. EVAPORATE CONTROL SYSTEM (ECS) INSPECTION *
no-load governed speed and reset to specifications as required.
Check all fuel and vapor lines and hoses for proper hookup,
routing, and condition. Check that bowl vent and purge valves 30. EXHAUST PRESSURE REGULATOR VALVE INSPECTION *
work properly, if equipped. Remove canister, and check for Check that valve works properly. Correct any binding. Check
cracks or damage. Replace as needed. hoses for cracks, chafing or decay. Replace parts as needed.
22. SHIELDS AND UNDERHOOD INSULATION INSPECTION
Inspect shields and underhood insulation for damage or * An Emission Control Service
looseness. Adjust or replace as required. AAlso a Noise Emission Control Service
Applicable only to vehicles sold in the United States
23. AIR INTAKE SYSTEM INSPECTION Check the air in
take system installation to see that gaskets are seated properly
and all hose connections, fasteners, and other components are

AAlso a Noise Emission Control Service
Applicable only to vehicles sold in the United States
14 15
SECTION C OWNER AT EACH FUEL FILL
INSPECTIONS AND SERVICES Engine oil ievei check t Check engine oii ievei and add if nec
essary. See your Owners Manual for further details.
Listed below are inspections and services which should be made
by either you or a qualified technician at the intervals shown to help Engine coolant level and condition f Check engine coolant
ensure proper safety, emission performance and dependability of level in coolant reservoir tank and add if necessary. Replace if dirty or
your vehicle. Take any problems promptly to your dealer or a qualified rusty. See your Owners Manual for further details.
technician for service advice. Whenever repairs are necessary, have Windshield washer fluid level check Check washer fluid level
them completed at once. For your safety and that of others, any in container and add if necessary.
safety-related parts that could have been damaged in an accident
should be inspected, and all needed repairs should be done before Hood latch operation When opening hood, note the operation
operating your vehicle. Be sure to use the proper fluids and lubricants of secondary latch. It should keep hood from opening all the way
as shown in Section E. when primary latch is released. Make sure that hood closes firmly
after services are performed.
WHILE OPERATING YOUR VEHICLE AT LEAST MONTHLY

Automatic transmission shift indicator operation Make sure Tire pressure check Keep pressures as shown on Tire Placard
the indicator points to the gear chosen. on the drivers door (including spare). Pressure should be checked
Horn operation Blow the horn occasionally to make sure it when tires are cold.

works. Check all button locations. Light operation check Check operation of license plate light,
side marker light, headlights including high beams, parking lights,
Brake system operation Be alert to abnormal sounds, in
taillights, brake lights, turn signals, backup lights, instrument panel
creased brake pedal travel or repeated pulling to one side when brak illumination and hazard warning flashers.
ing. Also, if a brake warning light goes on, something may be wrong
with part of the brake system. Fluid leak check After the vehicle has been parked for a while,
inspect the surface beneath the vehicle for water, oil, fuel or other
Exhaust system Be alert to any changes in the sound of the fluids. Water dripping from the air conditioning system after use is
system or any smell of fumes. These are signs the system may be normal. If you notice fuel leaks or fumes, the cause should be found
leaking or overheating. Have it inspected and repaired at once. Also, and corrected at once.
see Engine Exhaust Gas Caution (Carbon Monoxide) and Cata
lytic Converter in your Owners Manual.
AT LEAST TWICE A YEAR
Tire and wheel Be alert to a vibration of the steering wheel or (FOR EXAMPLE, EVERY SPRING AND FALL)
seat at normal highway speeds. This may mean a wheel balance is
needed. Also, a pull right or left on a straight, level road may show the Power steering pump level check f Check power steering
need for a tire pressure adjustment or wheel alignment. pump fluid in accordance with Owners Manual instructions and keep
at proper level.
Steering system operation Be alert to changes in steering ac
tion. An inspection is needed when the steering wheel is harder to Brake master cylinder reservoir fluid level check f Check
turn or has too much free play or if abnormal sounds are noted when fluid level in accordance with your Owners Manual, and keep at
turning or parking.
t A large loss in these systems may indicate a problem. Have them
Headlight aim Take note of the light pattern occasionally. If inspected and repaired at once.
beam aim doesnt look right, headlights should be adjusted.
OB-15
17
16
proper level. A low fluid level can indicate worn disc brake pads may cause a heat buildup in the floor pan or could let exhaust fumes seep
OB-16
need to be serviced. into the passenger compartments.
Clutch pedal free travel Note the clutch pedal free travel. It
Throttle linkage inspection Inspect for interference, binding,
should be about 1 . Adjust linkage whenever there is little or no free
damaged or missing parts.
travel.

Engine drive belts inspection Inspect all belts for cracks, fray
EACH TIME OIL IS CHANGED ing, wear and proper tension. Adjust or replace as needed.
Autom atic or manual transm ission fluid level check t Check Axle rear/front, transfer case (four-wheel drive) Check fluid
transmission fluid level and add as required. See your Owners level and add if needed.
Manual for further details.
Locking differential - under 8600-lbs. GVWR Drain fluid at
Tire and wheel inspection and rotation Check tires for abnor
first oil change and refill. Check fluid level and add as needed at
mal wear or damage. Also, check for damaged wheels. To equalize
subsequent oil changes. In dusty areas, or trailer towing applica
tire wear and obtain maximum tire life it is suggested that the tires be
tions drain fluid at every oil change and refill, f
rotated at the first oil change, then at every other oil change thereaf
ter. See Tires in your Owners Manual for further information. For
Locking differential - over 8600-lbs. GVWR Drain fluid at
dual wheels, whenever the truck, wheels, or fasteners are new, have
first oil change and refill. Change fluid at every other oil change
the wheel fastener torque set at the first 100, 1,000 and 6,000 miles
and check and add fluid at subsequent oil changes. In dusty
(160, 1 600 and 10 000 km).
areas, or trailer towing applications, drain fluid at every oil
Steering and suspension Inspect front and rear suspension change and refill as specified, t
and steering system for damage, loose or missing parts, signs of wear
or lack of lubrication. Inspect power steering lines and hoses for Standard differential - under 8600-lbs. GVWR Check fluid
proper hookup, binding, leaks, cracks, chafing, etc. (On vehicles level and add as needed at every oil change. In dusty areas, or
equipped with manual steering gear, check for seal leakage.) Inspect trailer towing applications, drain fluid every oil change and
final drive axle output shaft seals for leaking, t refill, f
Brake system s inspection For convenience the following
Standard differential - over 8600-lbs. GVWR Drain fluid
should be done when wheels are removed for rotation: Inspect lines
every fourth oil change and refill. Check fluid level and add as
and hoses for proper hookup, binding, leaks, cracks, chafing, etc. In
needed at every oil change. In dusty areas, or trailer towing ap
spect disc brake pads for wear and rotors for surface condition. Also
plications, drain fluid at every oil change and refill, t
inspect drum brake linings for wear and cracks. Inspect other brake
parts, including drums, wheel cylinders, parking brake, etc. at the
Transfer case (four-wheel drive) Every 12 months or at oil
same time. Check parking brake adjustment. Inspect brakes more
change intervals, check front axle and transfer case and add
often if driving habits or conditions result in frequent braking.
lubricant when necessary. Lubricate propeller shaft slip joint,
Exhaust system inspection * Inspect complete system includ constant velocity universal joint and steering linkage. Oil the
ing catalytic converter. Inspect body near the exhaust system. Look control lever pivot point and all exposed control linkage. Check
for broken, damaged, missing or out-of*position parts as well as open vent hose at transfer case for kinks and proper installation. More
seams, holes, loose connections or other conditions which could frequent lubrication may be required on heavy-duty off-road
use. f
t A large loss in these systems may indicate a problem. Have them
inspected and repaired at once. t A large loss in these systems may indicate a problem. Have them
* An Emission Control Service inspected and repaired at once.
18 19
AT LEAST ONCE A YEAR Lap and shoulder belts condition and operation Inspect belt
system, including: webbing, buckles, latch plates, retractors, guide
Starter safety switch operation loops and anchors.
Movable head restraint operation On vehicles with movable
CAUTION: Before performing the following safety switch head restraints, make sure restraints stay in the desired position. (See
check, be sure to have enough room around the vehicle. adjustment instructions in your Owners Manual.)
Then, firmly apply both the parking brake (see your Owners Seatback latch and recliner operation on vehicles equipped
Manual for procedure) and the regular brakes. Do not use with recliner seat Be sure seatbacks latch on those vehicles with
the accelerator pedal. If the engine starts, be ready to turn folding seats using mechanical latches. Make sure the recliner is
off the ignition promptly. Take these precautions because holding by pushing and pulling on the top of the seatback while it is
the vehicle could move without warning and possibly cause reclined. See your Owners Manual for seat operating information.
personal injury or property damage.
Spare tire and jack storage Be alert to rattles in the rear of the
vehicle. Make sure the spare tire, all jacking equipment, and any cov
On automatic transmission vehicles, try to start the engine in each
ers or doors are securely stowed at all times. Oil jack ratchet or screw
gear. The starter should crank only in Park or Neutral.
mechanism after each use.
On manual transmission vehicles place the shift lever in Neutral,
push the clutch halfway and try to start. The starter should crank only Underbody flushing At least every spring, flush from the under
when the clutch is fully depressed. body with plain water any corrosive materials used for ice and snow
removal and dust control. Take care to thoroughly clean any areas
Steering column lock operation While parked, try to turn to

where mud and other debris can collect. Sediment packed in closed
Lock in each gear range. The key should turn to "Lock only when areas of the vehicle should be loosened before being flushed.
gear is in Park on automatic or "Reverse on manual transmission.
On vehicles with a key release lever, try to turn the key to Lock Engine cooling system service * f Inspect coolant and freeze
without depressing the lever. The key should turn to Lock only with protection. If dirty or rusty, drain, flush and refill with new coolant.
the key lever depressed. On all vehicles, the key should come out Keep coolant at the proper mixture as specified in your Owners
only in Lock. Manual. This provides proper freeze protection, corrosion inhibitor
Parking brake and transmission Park" mechanism operation level and engine operating temperature. Inspect hoses and replace if
cracked, swollen or deteriorated. Tighten hose clamps. Clean outside
of radiator and air conditioning condenser. Wash radiator filler cap
CAUTION: Before checking the holding ability of the parking and neck. To help ensure proper operation, a pressure test of both the
brake and automatic transmission Park mechanism, park cooling system and cap is also recommended. See maintenance
on a fairly steep hill with enough room for movement in the schedule charts in Section A for the recommended coolant change
downhill direction; to reduce the risk of personal injury or interval.
property damage, be prepared to apply the regular brakes Key Lock Service Lubricate key lock cylinder at least annually.
promptly if the vehicle begins to move.
Body Lubrication Service Lubricate all hody door hinges in
cluding the tailgate (if equipped) also lubricate the body hood, fuel
To check the parking brake with the engine running and transmis door and rear compartment hinges and latches including interior
sion shift lever in Neutral, slowly remove foot pressure from the glove box and console doors, and any folding seat hardware.
regular brake pedal until the vehicle is held by only the parking brake.
To check the automatic transmission Park mechanism holding * An Emission Control Service
ability, release all brakes after shifting the transmission to Park. t A large loss in these systems may indicate a problem. Have them
OB-17
inspected and repaired at once.
20
21
SECTION D MAINTENANCE RECORD SECTION E
OB-18
After each of the preceding Scheduled Maintenance Services is
RECOMMENDED FLUIDS & LUBRICANTS
performed, record the date, odometer reading, services performed Chassis grease m eeting requirem ents
C hassis Lubrication
(list item numbers) and who performed the services in the appropriate

of GM-6031-M (GM Part No. 1052497)
column. In addition, retain copies of your receipts. It is suggested that W inshield W asher Solvent GM O ptikleen washer solvent (GM Part
receipts be kept with this booklet. No. 1051515) or equivalent
Hood Latch Assem bly
SECTION E a. Pivots and spring anchor a. Engine oil or GM Part No. 1050109
b. R elease pawl b. Chassis G rease m eeting requirem ents
RECOMMENDED FLUIDS & LUBRICANTS of GM-6031-M (GM Part No. 1052497)
Front W heel Bearings GM Lubricant Part No. 1051344 or equiva
NOTE: Fluids and lubricants identified below by name, part number
lent
or specification may be obtained from your GM Truck Dealer.
C onstant V elocity Universal Joint GM Lubricant Part No. 1052497 or equiv
USAGE F LU ID /LU B R IC AN T alent.
E ngine Oil GM G oodw rench M otor O il or equivalent Autom atic Transmission Shift Linkage, Engine oil
for API Service SF/CC or SF/CD of the F lo o r S h ift Linkage, Hood and D oor
recom m ended viscosity Hinges, Body Door Hinge Pins, Tailgate
E ngine C oolant M ixture of w ater and a good quality Hinge and Linkage, Folding Seat, Fuel
e th yle ne glyco l base an tifre e ze c o n Door H inge
form ing to GM-1825-M (GM Part No.
Clutch Linkage (Manual Transmission
1052753)
only)
Brake and H ydraulic Clutch Delco Suprem e 11 fluid (GM Part No. a. Pivot points a. Engine oil
System s 1052535) or DOT-3 b. Pushrod to clutch fork joint, and b. Chassis grease m eeting
Parking Brake C ables C hassis grease m eeting requirem ents shaft pressure fitting requirem ents of GM-6031-M (GM
o f GM-6031-M (GM Part No. 1052497) No. 1051344)
Power Steering System GM Power Steering Fluid (GM Part No.

1050017) or equivalent
M anual Steering G ear G M L u b ric a n t P art No. 1052182 o r * See your Owners Manual for further details.
e quivalent
A u to m a tic T ra n sm issio n , 4-S p d O /D DEXRON II Autom atic Transmission
M anual T ransm ission, 5-S pd M anual Fluid (GM Part No. 1051855)
T ransm ission, S-Truck 4-S pd M anual
T ransm ission, Transfer C ase (E xcept
K30/35 Series)
D iffe re n tia l S ta n d a rd , K30/35 Series SAE-80W, or SAE-80W -90 GL-5 gear lu
Transfer C ase, M a n u a l T ra n sm issio n bricant (SAE-80W GL-5 in Canada) (GM
(Except S-Truck 4-Spd, 4-Spd O/D, and Part No. 1052271).
5-Spd)
D ifferential Locking Som e m odels require a special gear lu
bricant additive in addition to (GM Part
No. 1052271).*
M anual Transm ission S hift Linkage, Col C hassis grease m eeting requirem ents
um n Shift, P ropeller Shaft Slip Joint o f GM-6031-M (GM Part No. 1052497)
Key Lock C ylinders Light oil or general-purpose silicone lu
bricant (GM Part No. 1052276)
1A-1
SECTION 1
HEATING AND AIR CONDITIONING

CONTENTS
SUBJECT PAGE
H e a tin g ..................................................................................................................................................................................1A-1
A ir C o n d itio n in g ..................................................................................................................................................................1B-1
SECTION 1A
HEATING
CONTENTS
SUBJECT PAGE
C-K And G Series Heaters General D e scrip tio n ............................................................................................. 1A - 2
Blower And A ir Inlet A ssem bly........................................................................................................................... 1A- 2
Heater D istributor A sse m b ly................................................................................................................................1A - 2
Insufficient Heat D ia g n o sis...................................................................................................................................... 1A- 3
Healer C ircuit D ia g n o s is .......................................................................................................................................... 1A- 4
Diagnosis of Heater S y s te m ....................................................................................................................................1A- 5
C-K Series Heater On-Vehicle S e r v ic e ............................................................................................................ 1A - 6
Blower Motor R eplacem ent.................................................................................................................................. 1A - 6
Heater Hoses Engine R o u tin g ....................................................................................................................... 1A - 6
Heater D istributor And Core A s s e m b ly ............................................................................................................ 1A- 7
Control Assembly R e p lace m e n t......................................................................................................................... 1A- 9
Control Cables Replacem ent................................................................................................................................1A - 9
Cable A d ju stm e n t................................................................................................................................................... 1A - 9
Blower Switch R e p lacem ent................................................................................................................................1A-11
Resistor R e p la ce m e n t...........................................................................................................................................1A-12
Vent R e p la c e m e n t................................................................................................................................................. 1A-12
C-K Series A uxiliary Heater...................................................................................................................................... 1A-12
General D e s c rip tio n ...............................................................................................................................................1A-12
D iagnosis...................................................................................................................................................................... 1A-12
On-Vehicle S ervice..................................................................................................................................................... 1A-14
G Series Heater On-Vehicle S e rv ic e .................................................................................................................1A-15
Blower Motor R eplacem ent..................................................................................................................................1A - 15
Heater Hoses Engine R o u tin g ....................................................................................................................... 1A-15
Heater D istributor And Core A s s e m b ly ............................................................................................................ 1A -1 6
D istributor And Defroster D u c ts ......................................................................................................................... 1A-16
Control Assembly R e placem ent......................................................................................................................... 1A-16
Control C a b le s ....................................................................................................................................................... 1A-19
Cable A d ju stm e n t................................................................................................................................................... 1A-20
Blower Switch R eplacem ent................................................................................................................................1A-20
Resistor R e p la ce m e n t...........................................................................................................................................1A-20
Vent R e p la ce m e n t................................................................................................................................................. 1A-20
G Series Auxiliary H e a te r........................................................................................................................................ 1A-21
General D e s c rip tio n ...............................................................................................................................................1A-21
D iagnosis...................................................................................................................................................................... 1A-21
On-Vehicle S ervice..................................................................................................................................................... 1A-21
Specifications C-K and G S e rie s ....................................................................................................................... 1A-24
1A-2 HEATING
C-K AND G SERIES HEATERS

GENERAL DESCRIPTION
Heating components are attached to the right side of HEATER DISTRIBUTOR

the cowl. The blower and air inlet assembly and water
hoses are located on the forward side of the cowl panel ASSEMBLY
while the heater core and distributor duct are on the
The heater distributor assembly houses the heater
passenger side.
core and the doors necessary to control mixing and
The heater system is an air-mix type system in which
channeling of the air. Since the unit has no water valve,
outside air is heated and then mixed in varying water circulation keeps the core hot at all times. That
amounts with cooler outside air to attain the desired air portion of the air passing through the core receives
temperature. The system consists of (1) a blower and maximum heat from the core. Air entering the
air inlet assembly, (2) a heater distributor assembly distributor assembly is channeled as follows:
and (3) a heater control assembly.
C-K AND G MODELS

BLOWER AND AIR INLET
ASSEMBLY Air entering the distributor can be directed out the
purge door opening on the right end of the distributor
The blower and air inlet assembly draws outside air assembly by the temperature door. If the temperature
through the outside air inlet grille located forward of the door is closed, air is directed through and/or around
windshield reveal molding and channels the air into the the heater core by the temperature door. Air is then
heater distributor assembly. The operation of the directed into the passenger compartment through the
blower motor is controlled by the fan switch on the heater (floor) outlets and/or the defroster (dash) outlets
heater control. The motor is connected in series with by the defroster door. The temperature of the outlet air
the fan switch and the blower resistor assembly. is dependent on the ratio of heated to unheated air
(controlled by the temperature door).
HEATING 1A-3
INSUFFICIENT HEAT DIAGNOSIS

P o s itio n th e c o n tro ls so th a t the:
T e m p e ra tu re lever is on fu ll heat.
S e le c to r o r h e a te r lever is on Heater.
Fan S w itc h is on xHI._
'C H E C K DUM P DOOR O U TLE T FOR A lt i FLO W l
IN O AIR FLOWl I AIR FLOW
A d ju s t d u m p d o o r fo r no a ir flo w .
C H E C K D EFRO STER O U TLE TS FOR AIR FLOW
(If in d o u b t as to H ig h o r Low a ir flo w =L
I HIG H AIR FLOW
se t s e le c tp o r o n DEF w h ic h is H ig h and
c o m p a re . R eset s e le c to r on H eater).__________
|A d ju s t d e fro s te r d o o r fo r lo w a ir flo w "
NO OR LOW AIR FLO W l
| LITT LE OR NO C H A N G E IN AIR FLOW I
C H E C K HEATER O U TLE T AIR FLOW.
I LOW OR NO AIR F L O W l
(If in d o u b le , s w itc h fan i-------------^ ------------
s w itc h fro m Hi to Lo).________________ C h e c k s h u to ff d o o r p o s itio n fo r fu ll
s y s te m a ir flo w . A d ju s t if ne ce ssary.
IC H A N G E IN A IR F LO W
I LOW AIR FLOW ]
I N O R M A L A IR FLOW.l IN O AIR FLOW
C h e c k h e a te r o u t le t te m p e r a
tu r e w it h 2 2 0 F (1 0 4 C ) ra n g e C h e c k h e a te r o u tle t fo r o b s tru c tio n
r^ r
th e r m o m e te r ._____________________ rem ove._______________________________
FUSE BLOW N -
(A p p ro x im a te o u tle t a ir te m p e ra tu re s ). C h e c k m o to r v o lta g e at c lo s e t m o to r th e re p la ce fu s e .
c o n n e c tio n w ith a vo ltm e te r. E
O u tlet A ir 145 F (6 3 C) 1 5 0 F (6 6 C ) 1 5 5 F (6 8 C ) 1 6 5 F (7 4 C ) AIR FLOW -
1U N DER 10 VOLTSl I OVER 10 VOLTS I s y s te m okay.
oo
o
o
A m b ie n t A ir 2 5 F ( -4 C ) 40F(4C ) 7 5F(2 4 C )
O
C h e ck b a tte ry v o lts - u n d e r 10 v o lts ,

re ch a rg e th e n re c h e c k m o to r vo lta g e .
rR c m o v e all o b s tru c tio n s u n d e r fro n t se a t.l
i t C h e ck w irin g and c o n n e c tio n s fo r
C a r d o e s n o t b u ild up h eat - o p e ra te vent
u n d e r 10 v o lts fro m m o to r to fan
c o n tro ls and see th a t th e a ir ve n t d o o rs
s w itc h . R e p a ir o r re p la ce la st p o in t
c lo s e c o m p le te ly , if n o t, a d ju s t.___________ o f u n d e r 10 v o lt rea d in g .
I LOW tem peratureI I BLOW S FUSE
(C h e c k th e s y s te m te m p e ra tu re a fte r
re p a irin g th e ite m ch e c k e d to c o m p le te A p p ly e x te rn a l g ro u n d , (ju m p e r w ire ) to R em ove p o s itiv e lead fro m
th e d ia g n o s is ).__________________ _________ m o to r ca se . IN C R E A S E D AIR FLOW - m o to r and re p la ce fu se .
re p a ir g ro u n d
C h e c k c o o la n t level; if low, fill. L ook fo r IT
o r fe e l all ra d ia to r and h e a te r h o s e s and S A M E AIR FLOW - rem ove m o to r and
FUSE R E M A IN S O K - rem ove m o to r
c o n n e c tio n s fo r leaks. R e p a ir o r rep la ce . c h e c k fo r o b s tru c tio n in syste m
and c h e c k fo r o b s tru c tio n in s y s te m
C h e c k th e ra d ia to r ca p fo r d a m a g e and o p e n in g . If none, R EPLACE MOTOR. If
o p e n in g , if none REPLACE MOTOR.
re p la c e if req u ire d .________________________ o b s tru c tio n , rem ove m a te ria l and
If o b s tru c tio n , rem ove m a te ria l and
re in s ta ll m o to r __________________________
C h e c k h e a te r and ra d ia to r h o s e s fo r k in k s - re -in sta l! m otor._______________________
s tra ig h te n and re p la ce as n e ce ssary._______
BLOW S FUSE - c h e c k fo r s h o rte d
C h e c k te m p e ra tu re d o o r fo r m ax w ire in b lo w e r e le c tric c ir c u it -
he a t p o s itio n . A d ju s t if n e ce ssary. See H e a te r C irc u it D ia g n o s tic C h a rt.
Th e a t e r CORE I
If u s e o k !
Feel te m p e ra tu re s o f h e a te r
FUSE O K - See H e a te r C irc u it
in le t and o u tle t hoses.
D ia g n o s tic C h a rt.______________
W ARM IN LET AN D HOT INLET A N D W ARM
OUTLET HOSES OUTLET HOSES
C h e ck pu lle ys, b e lt te n s io n , e tc. fo r
C h e c k e n g in e th e rm o s ta t
p ro p e r o p e ra tio n . R e p la ce o r se rv ic e
as necessary.
*C H E C K FOR C-K M O D E LS ONLY

R e m ove h o s e s fro m h e a te r c o re . R everse
flu s h w ith ta p w ater. If p lu g g e d , re p a ir o r C H E C K FOR G M O D E LS ONLY
re p la c e . F-00033
Figure 1Insufficient Heat Diagnosis

1A-4
HEATER CIRCUIT DIAGNOSIS*
BLOWER MOTOR INOPERATIVE BLOWER MOTOR INOPERATIVE
HEATING
(ANY SPEED) (CERTAIN SPEEDS)
T = : i z
Check fuse Disconnect resistor connector, connect one lead
in fuse panel. of a self powered test light to any one terminal
....... 1 .... -
and use the other lead to probe each of the other
X two terminals.
FUSE BLOWN FUSE OK I
1
TEST LIGHT DOES NOT TEST LIGHT LIGHTS ON
With ignition switch in The following tests should be made with LIGHT ON ALLTERMINALS ALL TERMINALS
RUN position and blower the ignition switch in RUN position
I
speed switch ON use the blower speed switch ON and the Replace resistor.
meter to locate short in one lever on heat position.
Figure 2Heater Circuit Diagnosis
of the following wires:

1. From fuse panel to blower Check blower motor ground. | With ignition OFF disconnect 3 wire
speed switch. connector from resistor. Connect a
2. From blower speed switch 1POOR OR NO GROUND! j GROUND OK~] jumper lead from battery positive
to heater resistor. terminal to any wire terminal in
3. From heater resistor to | Repair ground. Check motor connector connector. Use 12 volt test light to
blower. with 12 volt test light. check for voltage at the corresponding
wire on blower speed switch. Repeat
Note. Short in circuit may be 1 , " 1 same test on other wires.
intermittent. If meter does | LAMP LIGHTS | |LAMP DOES NOT LIGHT|
not indicate a short circuit,
Replace Motor Check blower feed wire in connector
move harness around as
much as possible to re-create on resistor with 12 volt test light. LAMP LIGHTS ON LAMP LIGHTS ON
short circuit. Watch artd ALL THREE WIRES ALL THREE WIRES
I
listen for arcing. LAMP DOES NOT LIGHT LAMP LIGHTS LAMP DOES NOT
LIGHT ON ALL
Replace blower THREE WIRES
Use 12 volt test light and check feed Repair open in feed wire speed switch.
terminal (brown) on blower speed switch. from resistor to blower motor.
Repair open in
affected wire.
LAMP DOES NOT LIGHT j LAMP LIGKTS
I See heater circuit diagrams.
Repair open in brown wire Replace switch.
from blower speed switch
to fuse panel.
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HEATING 1A-5
DIAGNOSIS OF HEATER SYSTEM

PROBLEM POSSIBLE CAUSE CORRECTION
Temperature Of 1. Refer to Insufficient Heat Diagnostic 1. Refer to Insufficient Heat Diagnostic

Heater A ir At The Chart. Chart.
O utlets Is Too Low
To Heat Up
Passenger
Compartment
Temperature Of 1. Floor side kick pad ventilators partially 1. Check and adjust.
Heater A ir At The open.
O utlets Is Adequate 2. Leaking grommets in dash. 2. Reseal or replace.
But The Vehicle W ill 3. Leaking welded seams along the 3. Clean and rewash.
Not Build Up rocker panel and windshield.
S ufficient Heat 4. Leaks through the access holes and 4. Reseal or replace.
screw holes.
5. Leaking rubber molding around the 5. Reseal or replace.
door and windows.
6. Leaks between the sealing edge of 6. Reseal or replace.
blower and the air inlet assembly and
cowl, and between the sealing edge of
the heater distributor assembly and
cowl.
Inadequate 1. Check that the DEFROST lever com 1. Adjust if necessary.

Defrosting A ction pletely opens the defroster door in the
DEF position.
2. Insure that the temperature and air 2. Adjust.
doors open fully.
3. Look for obstructions in the defroster 3. Remove any obstructions.
ducts.
4. Check for air leak in the ducting be 4. Seal area as necessary.
tween the defroster outlet on heater
assembly and the defroster duct under
the instrument panel.
5. Check the position of the bottom of the 5. Adjust.
nozzle to the heater locating tab.
6. Check the position of the defroster 6. Adjust the defroster nozzle openings.
nozzle openings relative to instrument
panel openings. Mounting tabs provide
positive position if properly installed.
Inadequate 1. Check the heater outlet for correct in 1. Remove and install.
Circulation Of Heated stallation.
A ir Through The 2. Inspect the floor carpet to insure that 2. Correct as necessary.
Vehicle the carpet lies flat under the front seat
and does not obstruct air flow. Also in
spect around the outlet ducts to insure
that the carpet is well fastened to floor
to prevent cupping of the air flow.
1A-6 HEATING
DIAGNOSIS OF HEATER SYSTEM (CONT.)

Erratic Heater 1. Check the coolant level. 1. Fill to the proper level.
Operation 2. Check for kinked heater hoses. 2. Relieve kinks or replace hoses.
3. Check the operation of all bowden ca 3. Adjust as necessary.
bles and doors.
4. Sediment in the heater lines and radia 4. Flush the system and clean or re
tor causing the engine thermostat to place thermostat as necessary.
stick open.
5. Partially plugged heater core. 5. Backflush core as necessary.
Hard Operating Or 1. Check for loose bowden cable tab 1. Correct as required.
Broken Controls screws or mis-adjusted bowden ca
bles.
2. Check for sticking heater system 2. Lubricate as required using a silicone
door(s). spray.
C-K SERIES HEATER ON-VEHICLE SERVICE
BLOWER MOTOR
REPLACEMENT
Remove or Disconnect (Figures 3 and 4)
1. Battery ground cable.

2. Blower motor lead cable (figure 3).
3. Motor and wheel assembly (figure 4).
Five mounting screws.
Gently pry on the blower flange if the sealer
acts like an adhesive.
4. Blower wheel to motor shaft nut.
5. Blower wheel from the motor.
Install or Connect (Figures 3 and 4)
1. Blower wheel to the motor.

Locate the open end of the wheel away from
the blower motor.
1. Heater/Blower Assembly
2. Motor shaft nut.
2. Dash
3. Motor and wheel assembly.
3. Blower Wiring
4. New bead of sealer to the mounting flange.
4. Resistor Connector
5. Blower motor lead wire.
5. Motor Connector
6. Battery ground wire.
7. Test the blower.
F-00625
HEATER HOSES ROUTING Figure 3Blower Motor Assembly W iringCK
Heater hoses are routed from the therm ostat and outlet pipes (figure 5). Hoses are attached at each
housing or inlet manifold and water pump (radiator on end with screw-type clamps,
some automatic transmission vehicles) to the core inlet
HEATING 1A-7
11. Connector 21. Shaft

12. Screw 22. Valve
13. Motor 23. Valve
14. Case 24. Case
15. Fan 25. Shaft
16. Nut 26. Shroud
17. Bolt 27. Plate
18. Clamp 28. Bolt
19. Clamp 29. Elbow
20. Core 30. Tube
B-09826
Figure 4Blower Motor Assem bly Component View
REPLACEMENT 7. Screw that holds the defroster duct to the heater

The heater core can be damaged near the tube distributor (figure 8).
attachment seams if force is applied on them. If the 8. Screws that hold the heater distributor to the
heater hoses do not come off, cut the hoses forward of dash panel.
the core tubes. Cut the hose on core tubes to remove.
Pull the assembly rearward to reach the
wiring harness.
Im portant
9. Wiring harness.
Draw hoses tight to prevent sagging or 10. Heater distributor.
rubbing against other components. Route 11. Core retaining clamps (figure 4).
hoses through all clam ps as installed 12. Core (figure 5).
originally.
Install or Connect (Figures 4, 5, 6, 7, and 8)

HEATER DISTRIBUTOR
1. Core (figure 5).
AND CORE ASSEMBLY
2. Core retaining clamps (figure 4).
3. Heater distributor.
Remove or Disconnect (Figures 4, 5, 6, 7 and 8) 4. Wiring harness.
1. Battery ground cable. 5. Defrost duct to heater distributor (figure 5).

2. Heater hoses at the core tubes (figure 6). 6. Floor outlet (figure 4).
Drain engine coolant into a clean pan. 7. Air-defroster and temperature cables (figure 6).
Plug the core tubes to prevent spillage. 8. Instrument panel compartment.
3. Nuts from the distributor duct studs that project
9. Heater hoses to the core tubes (figure 4).
into the engine compartment (figure 6).
4. Instrument panel compartment assembly. Unplug the hoses.
5. Air defroster and temperature cables (figure 7). 10. Replace coolant.
6. Floor outlet (figure 8). 11. Battery ground wire.
1A-8
HEATING
Figure 5Heater Hoses Routing Diagram
V8 (5.0, 5.7 and 7.4 Liter) Gas Engines V8 (6.2 Liter) Diesel Engine
1. Heater/Blower Assem bly

40. Hose - Inlet
41. Hose - O utlet
V6 (4.3 Liter) Gas Engine L6 (4.8 Liter) Gas Engine 42. Radiator
yi ............. ...........
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HEATING 1A-9
3. Control to instrument panel screws.

4. Cable push nuts and tab attaching screws.
Raise or lower the control as necessary.
5. Instrument panel compartment.
6. Cable push nut and tab attaching screws at the
door end of the cable.
7. Cable from the retaining clip.
8. Cable assembly.
Install or Connect (Figure 7)
1. Cable assembly.
Im portant
Do not kink the cable. Route the cable as

removed. Check adjustment.
2. Cable to retaining clip.
3. Cable push nut and the tabe attaching the screw
at the door.
5. New cable push nuts and the tab attaching screws.
6. Instrument panel to control screws.
7. Instrument panel bezel.
CONTROL ASSEMBLY
REPLACEMENT CABLE ADJUSTMENT
|+ + | Remove or Disconnect (Figures 7 and 9)
1. Battery ground cable. + + Remove or Disconnect (Figure 7)

3. Bowden cables (figure 7). 1. Battery ground cable.
4. Blower switch wiring harness (figure 9). 2. Instrument panel compartment.
5. Assembly through the opening above the control. 3. Eyelet clip.
4. Cable from the door.
-4- Install or Connect (Figures 7 and 9)
If a new unit is being installed, transfer the blower

switch to the new unit.
1. Assembly through the opening above the control. With pliers, hold the cable and rotate the
2. Blower switch wiring harness. mounting tab to lengthen or shorten the
3. Bowden cables. cable.
5. Battery ground cable. NOTICE: Do not pinch the cable.
CONTROL CABLES 0 Install or Connect (Figure 7)
1. Cable to the door.

Remove or Disconnect (Figure 7)
2. Eyelet clip.
1. Battery ground cable. 3. Instrument panel compartment.
2. Instrument panel bezel. 4. Battery ground cable.
1A-10 HEATING
F-00656
Figure 7Control Assembly And Cables

HEATING 1A-11
1. Heater/Blower Assembly
45. Grille
46. Nozzle Assembly
47. Instrument Panel
48. Outlet
B-09822
Figure 8Defroster Vents
BLOWER SWITCH Lower control onto the radio.

REPLACEMENT 4 Switch wiring harness.
5 Switch.
-- Install or Connect (Figure 9)
1 Battery ground cable.
2 Instrument panel bezel. 1 Switch.
3 Control to instrument panel screws. 2 Wiring harness.
4 Control. 3 Control to instrument panel.
50. Heater/Defroster Control Assembly 1. Heater and Blower Assembly

55. Instrument Panel W iring Harness 3. Blower Wiring
56. Blower Switch 60. Resistor
B-09811 B-09812
Figure 9Blower Switch Figure 10Blower Motor Resistor

1A-12 HEATING
65. Bezel
66. Valve Assembly
67. Instrument Panel Garnish
68 . Kickpanel
69. Control Cable
Figure 11Vent Assembly CK
4. Instrument panel bezel. Install or Connect

1. Resistor.
2. Mounting screws.
RESISTOR REPLACEMENT 3. Wiring harness.

VENT
2. Wiring harness. Right and left vents are installed in the kick panels
3. Two resistor mounting screws. under the instrument panel. Replace the vents by
4. Resistor (figure 10). removing the attaching screws (figure 11).
C-K SERIES AUXILIARY HEATER
GENERAL DESCRIPTION WATER VALVE
An auxiliary heater provides additional heating When heat is desired, and the fan switch is any
capacity for the rear of the Suburban model. position except off, a vacuum operated water valve
controlled by the switch, opens the water line to permit
This unit operates independently of the standard hot water circulation through the heater core. In the
heater, and is regulated through its own controls at the OFF position the valve is closed to prevent unwanted
instrument panel. heat.
This system consists of a separate core and fan unit

mounted in the rear of the vehicle. FAN SWITCH
Heater hoses extend from the unit to the front of the The three speed fan switch is located in the
vehicle where they are connected to the standard instrument panel to the right of the steering column.
heater hoses with tee s. An on-off vacuum
operated water valve is installed iin the heater core inlet
line in the engine compartment. This valve cuts off
coolant flow to the auxiliary core during warm weather DIAGNOSIS
and eliminates radiant heat (figure 12).
Refer to C-K and G Model Heaters.
Two control methods are used:
HEATING 1A-13
75. Upper Case 92. Clamp

76. Seal 93. Auxiliary Heater Inlet Rear Hose
77. Core 94. Auxiliary Heater Outlet Rear
78. Lower Case 95. Clip
79. Screw 96. Screw *
80. Fan 97. Water Heater Outlet Hose
81. Support 98. Water Heater Inlet Hose
82. Grommet 99. Screw
83. Washer 100. Valve
84. Screw 101. Harness
85. Motor 102. Screw
86. Clamp 103. Auxiliary Heater Switch (Single Function) Bezel
87. Stud 104. Auxiliary Heater Control Switch
88. Resistor 105. Screw
89. Seal 106. Auxiliary Heater/Rear A ir Conditioning
90. Nut Control Switch (Dual Function)
91. Harness 107. Connector
Figure 12Auxiliary HeaterSuburban

1A-14 HEATING
88. Resistor
101. W iring Harness
108. Auxiliary Heater
109. Platform
F-00662
Figure 13Resistor Location
ON-VEHICLE SERVICE Install or Connect (Figure 13)
1. Resistor.
RESISTOR PRELACEMENT 2. Screws.
3. Wiring connector.
Remove or Disconnect (Figure 13) 4. Battery ground cable.

2. Wiring connector.
3. Screws.
4. Resistor (88).
HEATING 1A-15
G SERIES HEATER ON-VEHICLE SERVICE
113 110. Nut 121. Housing

111. Fan Assem bly 122. Core
112. Washer 123. Strap
113. M otor 124. Case
114. Tube 125. Bracket
115. Fitting 126. Valve
116. Case 127. Shaft Assem bly
114 117. Gasket 128. Duct
118. Pin
119. Valve
120. Shaft
B-09761
Figure 14G-Model Component View
BLOWER MOTOR REPLACEMENT 5. Blower motor lead wire.

6. Coolant bottle to the vehicle.
7. Fasteners.
Remove or Disconnect (Figure 14) 8. Coolant hose.
10. Test the blower.
2. Coolant overflow hose from the recovery bottle.
3. Fasteners.
4. Bottle from the vehicle.
6. Motor and wheel assembly (113).
HEATER HOSESROUTING
Five mounting screws. Heater hoses are routed from the therm ostat
Gently pry on the blower flange if the sealer housing or inlet manifold and water pump (radiator on
acts like an adhesive. some automatic transmission vehicles) to the core inlet
7. Blower sheel shaft nut (112). and outlet pipes (figure 15). Hoses are attached at
8. Blower wheel from the motor (111). each end with screw-type clamps.
Install o r Connect REPLACEMENT

When replacing heater hoses, maintain a 13 mm (V2-
1. Blower wheel to the motor shaft. inch) minimum clearance between the hose clip and
Locate the open end of the wheel away from the upper control arm, a 38 mm ( 1 1/2 -inch) minimum
the blower motor. clearance between the hoses and the propshaft, and a
2. Blower wheel shaft nut. 32 mm (11/4-inch) minimum clearance between the
3. Motor and wheel assembly. auxiliary heater core lines and the exhaust pipe. Refer
4. Bead of sealer to the mounting flange. to figure 15.
1A-16 HEATING
11/4-inch (32 mm) minimum clearance between the 7. Distributor duct to the heater case.
auxiliary heater core lines and the exhaust pipe. Refer 8. Defroster duct to the distributor case.
to figure 15. 9. Instrument panel.
10. Steering column.
11. Engine housing cover.
HEATER DISTRIBUTOR AND
12. Heater distributor duct.
CORE ASSEMBLY 13. Heater core hoses.
14. Coolant recovery tank.
0 Remove or Disconnect (Figures 15, 16 and 17) 15. Battery ground cable.

2. Coolant recovery tank. DISTRIBUTOR AND
3. Heater core hoses (figure 15). DEFROSTER DUCTS
Place a clean pan under the vehicle to catch
any coolant spillage.
Plug the hoses. Remove or Disconnect (Figure 16)
Allow coolant in the core to drain into the
pan. 1. Battery ground cable.
4. Heater distributor duct (figure 16). 2. Raise the instrument panel at the right side.
Remove the screws that hold the distributor Refer to Heater Distributor and Core Assembly.
duct to the d is trib u to r case and the 3. Engine cover.
distributor duct to the engine cover. Unsnap the engine cover front latches and
5. Engine housing cover. remove the two cover-to-floor pan screws.
Remove the screws at the windshield, all 4. Screws that hold the heater distributor duct to the
lower screws and the right instrument panel heater case.
support bracket at the door pillar and the 5. Screw at the left center of the distributor duct.
engine housing. 6. Distributor duct.
6. Instrument panel. Pull the center distributor duct to the right.
7. Lower the steering column. 7. Defroster duct.
* Raise and support the right side of the in
Screws that hold the defroster duct to the
strument panel.
instrument panel.
8. Defroster duct to distributor case attaching
screws.
+ 4 j Install or Connect (Figure 16)
9. Distributor to heater case (2!) screws.
10. Temperature door cable (figure 17).
1. Defroster duct.
Fold the cable back for access.
2. Distributor duct.
11. Heater case and core.
3. Engine cover.
Three nuts at the engine compartment side
of the distributor case and one screw on the 4. Instrument panel.
passenger side. 5. Battery ground cable.
Tilt the case assembly rearward at the top
while lifting up until the core tubes clear the
dash openings.
CONTROL ASSEMBLY
12. Core retaining strap screws (figure 15). REPLACEMENT
13. Core. Remove or Disconnect (Figure 17)
+ 4- Install or Connect (Figures 15, 16 and 17) 1. Battery ground cable.

1. Core to the heater case.
3. Control out of the instrument panel (figure 17).
2. Sealer between the core and case.
Pull the control out to reach the bowden
3. Core retaining strap screws.
cable.
4. Apply new sealer between the heater case and
the opening in the vehicle. 4. Bowden cables.
5. Heater core and case to the vehicle. 5. Control illumination bulb.
Tilt the case until the core tubes clear the 6. Blower switch connector.
cowl opening. 7. Control from the vehicle.
6. Temperature door cable. 8. Blower switch.
HEATING 1A-17
Figure 15Heater Hose Distribution

1A-18 HEATING
133. Left-hand Outlet Assembly

134. Duct Assembly
F-00659
Figure 16Distributor Ducts

HEATING 1A-19
147
124. Heater Assembly
130. Defroster Plenum
145. Temperature Cable
146. Defroster Cable
147. Control Assembly
F-00658
Figure 17Control Assembly And Cables
Install or Connect (Figure 17) 4. Cable push nuts and tab attaching screws.
Raise or lower control as necessary.
1. Blower switch to control assembly (147). 5. Instrument panel compartment.
2. Blower switch connector. 6. Cable push nut and tab attaching screws at the
3. Control illumination bulb. door end of the cable.
4. Bowden cables. 7. Cable from the retaining clip.
5. Control to the instrument panel. 8. Cable assembly.
7. Battery ground cable. -- Install or Connect (Figure 14)
1. Cable assembly.
CONTROL CABLES
REPLACEMENT Im portant
Remove or Disconnect (Figure 14) Do not kink cable. Route the cable as
removed.
1. Battery ground cable. Check adjustment.
2. Instrument panel bezel. 2. Cable to retaining clip.
Place transmission lever in low. 3. Cable push nut and the tab attaching the screw at
3. Control to instrument panel screws. the door.
1A-20 HEATING

5. Cable push nuts and the tab attaching screws.
6. Instrument panel to control assembly screws.
CABLE ADJUSTMENT
f t Adjust (Figure 14)
1. Attach inner cable and sheath to the instrument

panel control.
2. Move the temperature cable to cold.
3. Attach the loop on the inner cable to the
temperature door on the heater case.
4. Attach the cable sheath to the heater case.
5. Move the temperature lever to full heat. This will
require force to slide the inner cable clip to its
proper position.
BLOWER SWITCH
REPLACEMENT
4-+ Remove or Disconnect (Figure 14) Figure 18Resistor Replacement
1. Battery ground cable. VENT REPLACEMENT

2. Blower switch wiring harness connector at the
switch. Remove or Disconnect (Figure 19)
3. Switch attaching screws.
4. Switch assembly. 1. Screws (5).
2. Valve assembly (202).
Install or Connect (Figure 14) +- Install or Connect (Figure 19)
1. Switch. 1. Valve assembly (202).

2. Switch attaching screws. 2. Screws (5).
3. Blower switch wiring harness.
RESISTOR REPLACEMENT
4- + Remove or Disconnect (Figure 18)
1. Screws.
2. Resistor (171).
0 Install or Connect (Figure 18)
1. Resistor.
2. Screws.
HEATING 1A-21
200. Seal 203. Clip 206. Rod 209. Seal

201. Outlet 204. Screw 207. Guide 210. Inlet Assembly
202. Valve Assembly 205. Knob 208. Outlet 211. Cover F-00657
Figure 19Vents
G SERIES AUXILIARY HEATER

GENERAL DESCRIPTION FAN SWITCH
For heating, the fan switch is placed in any position
An auxiliary heater provides additional heating for except off. The switch opens the water valve which
the rear area on some models. permits hot water to enter the heater core. In the OFF
position, the valve is closed to prevent unwanted heat
It operates independently of the standard heater, and during warm weather.
is regulated through its own control at the instrument
panel.
This system consists of a separate core fan vent.

ON-VEHICLE SERVICE
Heater hoses extend from the unit to the front of the
vehicle where they are connected to the standard
heater hoses with tees (figure 21).
2. Wiring harness at the resistor connector.
DIAGNOSIS 3. Resistor mounting screws.
4. Resistor.
Refer to C-K and G Series Heaters.
- Install or Connect (Figure 18)
WATER VALVE 1. Resistor.

An on-off vacuum-operated water valve, installed 2. Mounting screws.
in the heater core inlet in the engine compartment, 3. Wiring harness.
controls coolant flow to the auxiliary core and 4. Battery ground cable.
eliminates radiant heat during warm weather.
1A-22 HEATING
150. Case
151. Core
152. Seal
153. Tube
154. Resistor
155. Case
156. Washer
157. Fan
158. Nut
159. Plate
160. Screw
161. Screen
162. Harness Assembly
163. Stud
164. Motor
165. Strap
166. Terminal
167. Screw
168. Screw
B-09752
Figure 20Auxiliary Heater Component View

HEATING 1A-23
175 185
180
170
182172
176
170. Heater Assembly
171. Seal
172. Clamp
173. Screw
174. Washer
175. Clip
176. Screw
177. Strap
178. Material
179. Hose 189. Screw
180. Hose 190. Hose
181. Strap 191. Nut
182. Clip 192. Switch
183. Tee 193. Nut 180 179 176
184. Tee 194. Label
178
185. Screw 195. Knob
186. Hose 196. Harness
187. Tee 197. Retainer
188. Tank 198. Wire Assembly B-09753
Figure 21 A uxiliary Heater Plumbing Component View

1A-24 HEATING
SPECIFICATIONS
C-K AND G SERIES
HEATER
Amps. RPM
Volts (Cold) (Cold)
Blower Motor
C-K M o d e ls .............................................................................. 13.5 6.25 Max. 2550 Min.
2950 Max.
G M odels.................................................................................. 13.5 7.1 Max. 2850 Min.
3250 Max.
Fuses
C-K M o d e ls .................................................................................................................................... 20 Amp.
G M odels........................................................................................................................................ 20 Amp.
AUXILIARY HEATER
Amps. RPM
Volts (Cold) (Cold)
Blower M o tors......................................................................... 13.5 9.6 Max. 2700 Min.
1B-1
SECTION 1B
AIR CONDITIONING
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................. 1B- 3

CCOT System Components, Temperature and Pressure R elationships.................................................... 1B- 5
Handling Refrigerant-12........................................................................................................................................ 1B- 5
System C o m p o n e n ts .............................................................................................................................................1B- 4
Refrigerant-12 Operating C h a ra c te ris tic s ............................................................................................................ 1B- 5
CCOT System Components and Temperature and Pressure Relationships............................................. 1B- 5
Handling R efrigerant-12........................................................................................................................................ 1B- 5
Handling Refrigerant Lines and F itt in g s .......................................................................................................... 1B- 5
Maintaining Chemical S ta b ility ........................................................................................................................... 1B- 8
D ia g n o s is .................................................................................................................................................................... 1B- 9
Testing The Refrigerant S yste m ......................................................................................................................... 1B- 9
Leak Testing The Refrigerant S y s te m .............................................................................................................. 1B- 9
Pressure Sensing S w itch ...................................................................................................................................... 1B- 9
Electrical/Vacuum Trouble D ia g n o s is ...................................................................................................................1B-16
Operational T e s t..................................................................................................................................................... 1B-16
Vacuum System D ia g n o sis...................................................................................................................................... 1B-21
C-K and G S e r ie s ................................................................................................................................................... 1B-21
A/C Refrigerant System D iagnosis......................................................................................................................... 1B-21
Insufficient Cooling Quick Check P ro c e d u re ............................................................................................. 1B-21
A/C Evacuating and Charging P ro c e d u re s .......................................................................................................... 1B-22
Evacuation and Charging P ro c e d u re s .............................................................................................................. 1B-22
Discharging, Evacuating, Adding Oil, and Charging Procedures fo r CCOT A/C S y s te m ......................1B-22
Discharging the CCOT A/C S y s te m ...................................................................................................................1B-22
CCOT Refrigerant Oil D is trib u tio n .....................................................................................................................1B-24
Evacuating and Charging the CCOT A/C S y s te m ...........................................................................................1B-24
Gage C a lib ra tio n ..................................................................................................................................................... 1B-25
Vacuum System C h e c k ........................................................................................................................................ 1B-25
Charging Station M e tho d ...................................................................................................................................... 1B-25
Disposable Can or Multi-Can M e th o d ................................................................................................................ 1B-25
Refrigerant Drum M e th o d .................................................................................................................................... 1B-25
Charging of the CCOT A/C S ystem .....................................................................................................................1B-25
Accum ulator A s s e m b ly ........................................................................................................................................ 1B-26
Specific Component D iagnosis................................................................................................................................1B-26
Com pressor.............................................................................................................................................................. 1B-26
C ondenser................................................................................................................................................................ 1B-26
Receiver-Dehydrator (Motor Home C h a ssis)....................................................................................................1B-26
Expansion V a lve ..................................................................................................................................................... 1B-27
E vaporator................................................................................................................................................................ 1B-27
Refrigerant Line R e s tric tio n s ............................................................................................................................. 1B-27
Sight Glass Diagnosis (Motor Home Chassis U n its ).......................................................................................1B-27
On-Vehicle S ervice..................................................................................................................................................... 1B-28
Compressor Replacement (C -K )......................................................................................................................... 1B-28
Compressor Replacement (G and Motor Homes Chassis M o d e ls ).............................................................1B-29
Compressor Belt Tension Adjustm ent (G and Motor Home Chassis M o d e ls )......................................... 1B-29
1B-2 AIR CONDITIONING
CONTENTS (CONTINUED)
CCOT A/C SystemC-K S e r ie s ............................................................................................................................. 1P-32

Condenser R e p la ce m e n t......................................................................................................................................1B-33
A ccum ulator Replacement....................................................................................................................................1B-34
Blower Assembly Replacem ent........................................................................................................................... 1B-34
Evaporator Core R e p la c e m e n t........................................................................................................................... 1B-34
O rifice (Expansion Tube) R e p lace m e n t............................................................................................................1B-35
Selector Duct and Heater Core R e p la ce m e n t................................................................................................. 1B-37
Actuator-Plenum Side Vent R e p lace m e n t........................................................................................................1B-38
Plenum Valve Replacem ent..................................................................................................................................1B-39
Control Assem bly R e p la ce m e n t.........................................................................................................................1B-39
Temperature Door Cable A djustm e n t................................................................................................................ 1B-40
Blower Switch R e p lace m e n t............................................................................................................................... 1B-40
Vacuum Tank Replacem ent..................................................................................................................................1B-40
Vacuum Lines-Engine C o m p a rtm e n t................................................................................................................ 1B-40
Vacuum Harness-Dash.......................................................................................................................................... 1B-40
Refrigerant-12 Hose R o u tin g ............................................................................................................................... 1B-40
Blower Motor Resistor R e p la ce m e n t................................................................................................................ 1B-42
Blower Motor Relay Replacem ent.......................................................................................................................1B-45
Fuse R e p la ce m e n t.................................................................................................................................................1B-45
Rear Interior Roof Mounted SystemSuburban................................................................................................. 1B-45
Rear Duct R eplacem ent........................................................................................................................................ 1B-45
Blower Motor Assem bly R eplacem ent.............................................................................................................. 1B-45
Expansion Valve R e p la ce m e n t........................................................................................................................... 1B-46
Blower Motor Switch Replacement.....................................................................................................................1B-49
Fuse R e p la ce m e n t.................................................................................................................................................1B-49
CCOT A/C SystemG S e rie s ..................................................................................................................................1B-49
Condenser R e p lace m e n t......................................................................................................................................1B-49
Accum ulator Replacement....................................................................................................................................1B-49
Heater Core R e p la ce m e n t....................................................................................................................................1B-50
O rifice (Expansion Tube) R e p lace m e n t............................................................................................................ 1B-54
Blower Motor Insulation (w/Diesel) R eplacem ent...........................................................................................1B-54
Evaporator Core (w/Diesel) R e p la c e m e n t........................................................................................................1B-55
Blower Motor R eplacem ent..................................................................................................................................1B-57
Control Assembly R e p la ce m e n t.........................................................................................................................1B-58
Temperature Door Cable A djustm e n t................................................................................................................ 1B-58
Blower Switch R e p lace m e n t............................................................................................................................... 1B-58
Resistor R e p la c e m e n t.......................................................................................................................................... 1B-58
Blower Motor Relay Replacem ent.......................................................................................................................1B-59
A/C Ductwork Replacem ent................................................................................................................................. 1B-59
Defroster Duct R eplacem ent............................................................................................................................... 1B-59
Temperature Door Cable R e p la ce m e n t............................................................................................................1B-59
Vacuum Tank Replacem ent................................................................................................................................. 1B-60
Vacuum Line Engine C o m p a rtm e n t.................................................................................................................. 1B-60
Refrigerant-12 Hose R o u tin g ............................................................................................................................... 1B-60
Rear Interior Roof Mounted SystemsG S eries................................................................................................. 1B-62
CCOT A/C SystemP S e r ie s ................................................................................................................................. 1B-64
AIR CONDITIONING 1B-3
Dash Mounted SystemMotor Home C h a s s is ................................................................................................... 1B-64

Condensor R e p lacem ent...................................................................................................................................... 1B-64
ReceiverDehydrator Replacem ent...................................................................................................................1B-65
Sight Glass Replacement...................................................................................................................................... 1B-65
BlowerEvaporator Assembly R e p la c e m e n t................................................................................................. 1B-66
Blower Assembly Replacement........................................................................................................................... 1B-66
Expansion Valve, Evaporator and/or Evaporator Case R eplacem ent........................................................ 1B-67
Thermostatic and/or Blower Switches Replacem ent...................................................................................... 1B-67
Fuse R e p lace m e n t.................................................................................................................................................1B-67
S pecifica tio ns..............................................................................................................................................................1B-68
DESCRIPTION
CCOT A/C SYSTEM
The CCOT (Cycling Clutch Orifice Tube) A/C system
performs heating and cooling. Air enters the vehicle
and passes through the cooling unit (evaporator) and
through (or around) the heating unit. The system is
called a reheat system. The evaporator cools the air
passing through the core when the air conditioning
system is in the cooling mode.
On C-K and G series, a pressure sensing switch,
located near the top of the accumulator, controls
com pressor operation. The switch responds to
pressure changes to turn the compressor ON or OFF.
System operation:
Outside air or recirculated air enters the system and
is forced through the system by the blower. As the air
passes through the evaporator core, it receives
maximum cooling if the air conditioning controls are
positioned for cooling. 1. Power Element Thermobulb 8. Spring Seat
From the evaporator, the air enters the heater and air 2. Cover 9. Carriage Seat
conditioner selector duct assembly where, by means of 3. Diaphragm Back-up Plate 10. Seat
diverter doors, it passes through or bypasses the 4. Body 11. Actuating Pin
heater core in proportions necessary to provide the 5. Screen 12. Diaphragm
desired outlet temperature. The air enters the vehicle 6. Orifice A. Inlet
through either the floor distributor duct or the dash 7. Carriage Spring B. Outlet
outlets. F-00190
During cooling, the air is cooled by the evaporator to
below comfort level then warmed by the heater to the
desired temperature. During heating only the evapo Figure 1Thermostatic Expansion Valve
rator does not operate, and ambient air is warmed to
the desired level in the same manner. system at OFF. Rear air circulation without the refriger
ant function is possible by operating the rear blower
REAR INTERIOR ROOF control switch.
MOUNTED SYSTEMS These self-contained units operate on inside

(SUBURBAN & G SERIES) (recirculated) air. Air enters the unit and passes
through the evaporator core into the passenger
These systems operate with the front system - they compartment through the air distributor duct. The front
do not operate independently. However, control of the system controls the rear system. A three-speed blower
rear blower motor speed is possible when the front switch controls the rear interior roof mounted system.
passes on to the seat and orifice where it changes into

C a low pressure liquid.
The low pressure liquid leaves the valve and flows
into the evaporator core where it absorbs heat from the
evaporator core and changes to a low pressure vapor
and leaves the evaporator core. The power element
bulb is clamped to the low pressure vapor line just
beyond the outlet of the evaporator.
ACCUMULATOR C-K & G SERIES

The accumulator is located at the evaporator outlet.
It separates liquid retained from vapor, retains the
liquid and releases the vapor to the compressor (figure
2 ).
Flow from the accum ulator to the compressor
consists of vapor, entrained liquid and liquid flow
A. Inlet through the oil bleed hole.
B. Outlet A bag of desiccant (dehydrating agent), located in
C. Refrigerant Vapor Outlet the accumulator, collects moisture.
15. Baffle There is no sight glass in the accumulator with the
16. Internal Tube CCOT system.
17. Desiccant Bag Assembly
18. Filter Assembly
ORIFICE (EXPANSION TUBE) C-K & G SERIES
19. Oil Bleed Hole
Pressure differences and sub-cooling determines
F-00191
expansion tube flow. The orifice is located in the
evaporator inlet line (figure 3).
Figure 2Accum ulator C-K & G Series
PRESSURE CYCLING SWITCH
SYSTEM COMPONENTS This switch controls evaporator temperature. It
cycles the compressor clutch off when the evaporator
THERMOSTATIC EXPANSION VALVE temperature gets too low. It cycles the compressor
Suburban and G rear interior roof mounted and back on after evaporator temperature has increased
motor home chassis systems use a thermostatic ex (figure 4).
pansion valve (figure 1). The cycling pressure switch provides inherent
The valve consists of the power element, body, compressor protection so a separate low pressure
actuating pins, seat and orifice. At the high pressure switch is not necessary. The switch also acts as an
liquid inlet, a fine mesh screen prevents dirt, filings or ambient switch since at ambient freezing temperatures
other foreign matter from entering the valve orifice. it will not allow the compressor to engage. Adjusting
When the valve is connected in the system, high the set screw one-half turn left or right will rise or lower
pressure liquid refrigerant enters the valve through the the settings 20.7 kPa (3 psi) (figure 5).
screen from the receiver-dehydrator or condenser and
25 26 27
/-T.... ..-........... 1 =
I-------------- J-
B jIW
||jn .__1
_ in
|
1 L _ Z . __ .
sia5=j i |I
28
A. Inlet (R-12 From Condenser)
B. Outlet (To Evaporator) 25. Outlet Screen 27. Inlet Screen
D. Dent In Tube (Retains The Expansion Tube) 26. Expansion Tube 28. Seal (O Ring)
F-00192
Figure 3Orifice (Expansion Tube)

CYCLING PRESSURE SWITCH SETTING

(ACCUMULATO R READINGS)
COMPRESSOR CUT OUT COMPRESSOR CUT IN

PRESSURE RANGE PRESSURE RANGE
21-24 43-49
F-00333
Figure 5Cycling Pressure Switch Settings

(Accum ulator Readings)
Figure 4Pressure Cycling Switch
REFRIGERANT-12 OPERATING CHARACTERISTICS

CCOT SYSTEM COMPONENTS, If Refrigerant-12 touches exposed flesh do the
following:
TEMPERATURE AND Treat the area as if it were frost bitten or
PRESSURE RELATIONSHIPS frozen.
Call a doctor or eye specialist and obtain
To review system components and Refrigerant-12 treatment.
flow, refer to figure 6. DO NOT RUB THE EYE. Splash the area
To find the pressure and temperature relationship with cold water to raise temperature above
between Refrigerant-12 and atmospheric pressure, the freezing point.
refer to figure 7. Use an antiseptic oil to provide a protective
To find the relationship between relative humidity, air film over the eyeball to reduce the possibility
temperature, evaporator pressure, engine speed (2000 of infection.
rpm), discharge air temperature and high pressure,
refer to figure 8. HANDLING OF REFRIGERANT
To determine the refrigerant charge for Suburban LINES AND FITTINGS
and G Series front and rear interior roof mounted
systems, refer to figure 9. Tighten tubing connections to the specified torque
(figure 10). Insufficient or excessive torque causes
loose joints or deformed joint parts. Either condition
HANDLING REFRIGERANT-12 can cause refrigerant leakage.
All metal tubing lines should be free of dents
Air conditioning systems contain Refrigerant-12, a or kinks to prevent loss of system capacity
chemical which requires special handling to avoid due to line restriction.
personal injury. Never bend a flexible hose line to a radius of
Always wear goggles and wrap a clean cloth around less than 4 times the diameter oHhe hose.
fittings, valves and connections when opening the Never place a flexible hose line closer than
system. Work in a ventilated area and do not weld or 65 mm (21/2-inch) to the exhaust manifold.
steam clean near air conditioning lines or components. Inspect flexible hose lines regularly for leaks
Refrigerant-12 drums are shipped with a metal screw or brittleness and replace if necessary.
cap that protects the valve and safety plug from When disconnecting any fitting in the
damage. Replace the cap after each use. refrigeration system discharge the system.
Do not carry a container of Refrigerant-12 in the However, proceed with caution. Open
passenger compartment of a vehicle. Never subject slowly. Keep face and hands away to pre
any container to high temperatures. Do not breathe the vent injury if there is liquid Refrigerant-12 in
smoke or fumes produced by burning Refrigerant-12. the line.
606
L. HPV - High pressure vapor leaving compressor.

M. HPL - Vapor is cooled down by condenser air flow
and leaves as high pressure liquid.
N. LPL - O rifice meters the liquid R-12 into evapora-.
33. Accum ulator tor, reducing its pressure and warm blower air
130. Exapansion Tube (Orifice) across evaporator core causes boiling o ff of liquid
124. Evaporator into vapor.
600. Compressor O. LPV - Leaves evaporator as low pressure vapor
601. Condenser and returns with the small amount of . . .
604. Pressure Cycling Switch LPV/lpi - Low pressure liquid that didnt boil o ff
605. Oil Bleed Hole com pletely back to the compressor to be com
606. Dessicant Bag pressed again.
F-00075
Figure 6CCOT A/C System Components
REFRIGERANT - 12 C F kPa PSIG C F kPa PSIG

PRESSURE - TEMPERATURE -29.8 21.7 0 Atmos 12.7 55 358.5 52.0
RELATIONSHIP pheric 15.5 60 397.8 57.7
Pressure 18.3 65 439.2 63.7
The table below indicates the pressure of Refriger -28.8 -20 16.5 2.4 21.1 70 482.7 70.1
ant-12 at various temperatures. For instance, a -23.3 -10 31.0 4.5 23.8 75 530.2 76.9
drum of Refrigerant at a temperature of 26.6C -20.5 -5 46.9 6.8 26.6 80 579.9 84.1
(80F) will have a pressure of 579.9 kPa (84.1 psi). -17.7 0 63.4 9.2 29.4 85 632.3 91.7
If it is heated to 51.6C (125F), the pressure will -15.0 5 81.4 11.8 32.2 90 686.7 99.6
increase to 1 154.9 kPa (167.5 psi). It also can be -12.2 10 101.4 14.7 35.0 95 745.3 108.1
used conversely to determine the temperature at - 9.4 15 122.0 17.7 37.7 100 806.0 116.9
which Refrigerant - 12 boils under various pres - 6.6 20 145.5 21.1 40.5 105 870.2 126.2
sures. For example, at a pressure of 207.5 kPa - 3.8 25 169.6 24.6 43.3 110 937.7 136.0
(30.1 psi), Refrigerant - 12 boils at 0C (32F). - 1.1 30 196.5 28.5 46.1 115 1010.1 146.5
0 32 207.5 30.1 48.8 120 1083.2 157.1
1.6 35 224.8 32.6 51.6 125 1154.9 167.5
4.4 40 255.1 37.0 54.4 130 1234.2 179.0
7.2 45 287.5 41.7 60.0 140 1410.0 204.5
10.0 50 322.0 46.7 F-00177
Figure 7Pressure Temperature Relationship of Refrigerant-12

In Front Of Condenser
Relative Air Discharge A ir High
H um idity Temp. Evaporator Engine Speed Temp. Pressure
(%) C F Pressure (rpm) C F kPa psi
20 21 70 29.5 2000 4 40 1034.25 150
27 80 29.5 7 44 1310.05 190
32 90 30.0 9 48 1689.27 245
38 100 31.0 14 57 2102.97 305
30 21 70 29.5 2000 6 42 1034.25 150
27 80 30.0 8 47 1413.47 205
32 90 31.0 11 51 1827.17 265
38 100 32.0 16 61 2240.87 325
40 21 70 29.5 2000 7 45 1137.67 165
27 80 30.0 9 49 1432.42 215
32 90 32.0 13 55 1930.60 280
38 100 39.0 18 65 2378.77 345
50 21 70 30.0 2000 8 47 1241.10 180
27 80 32.0 12 53 1620.32 235
32 90 34.0 15 59 2034.02 295
38 100 40.0 21 69 2413.25 350
60 21 70 30.0 2000 9 48 1241.10 180
27 80 33.0 13 56 1654.80 240
32 90 36.0 17 63 2068.50 300
38 100 43.0 23 73 2482.20 360
70 21 70 30.0 2000 10 50 1275.57 185
27 80 34.0 14 58 1689.27 245
32 90 38.0 18 65 2102.97 305
38 100 44.0 24 75 2516.67 365
80 21 70 30.0 2000 10 50 1310.05 190
27 80 34.0 15 59 1723.75 250
32 90 39.0 19 67 2137.45 310
90 21 70 30.0 2000 10 50 1379.00 200
27 80 36.0 17 62 1827.17 265
32 90 42.0 22 71 2275.35
330 F-00337
Figure 8Relative Hum idity, Temperature and Pressure Relationships of Refrigerant12

W hen m a kin g stee l to a lu m in u m

REFRIGERANT CHARGE connections, use torque for aluminum
tubing. (Refer to figure 10).
C60 System
C-K Models 3 lbs. 8 ozs.
G Models 3 lbs. 8 ozs. MAINTAINING CHEMICAL
STABILITY
Overhead System
C-K Models 5 lbs. 4 ozs. The efficient operation of the air conditioning
G Models 4 lbs. 8 ozs. refrigeration system is dependent upon the chemical
stability of Refrigerant-12.
F-00652 Foreign m atter can change the s ta b ility of
Refrigerant-12, cause corrosion and wear. Do the
Figure 9CCOT A/C System Refrigerant Capacities following:
1. Before disconnecting a refrigerant connection,
Allow any pressure to bleed off as described remove dirt or oil at and near the connection. Cap
under Discharging, Evacuating, Adding Oil or plug both sides of the connection.
And Charging And Discharging The CCOT 2. Keep tools clean and dry.
A/C System. 3. When adding 525 viscosity refrigerant oil (refer to
ADDING OIL in the Discharging, Evacuating,
Cap or tape any line open to atmosphere to Adding Oil and Charging Procedures for CCOT
prevent dirt and moisture from entering the A/C systems), the transfer device and container
system. should be clean and dry.
Use p ro p e r w re n ch e s when m akin g 4. Have everything ready before opening a line. Do
connections on seal (o-ring) fittings. Use two not leave the A/C system open longer than
wrenches to prevent distorting the lines or necessary.
components. 5. After opening, evacuate before recharging with
W hen c o n n e c tin g the fle x ib le hose Refrigerant-12 according to the Discharging,
connections, hold the swaged fitting, the E va cu a tin g , A d d in g O il, C h a rg in g And
flare nut and the coupling at the same time Discharging The CCOT A/C System.
using three different wrenches to prevent 6. Service parts are dehydrated and seated before
turning the fitting and damaging the ground shipping. Open just before making connections.
seat. Keep at room temperature before uncapping (this
prevents moisture from entering the system). If
Use seals (o-rings) in good condition. A burr
the connections are not made, reseal the parts.
or piece of dirt may cause a leak.
Replace the seal when a connection has
been broken. When replacing the seal first
dip it in clean 525 viscosity refrigeration oil.
Aluminum or
Metal Tube Steel Copper Nominal
Outside Thread and Tubing Tubing Torque
Diameter F itting Size Torque Torque Wrench Span
Nm LB. FT. Nm LB. FT.
1/4 7/l6 14-20 10-15 7-8 5-7 5/s
% 5/s 41-48 30-36 15-18 11-13 3/4
1/2 3/4 41-48 30-36 20-27 15-20 7/s
5/s 7la 41-48 30-36 28-37 21-22 11/l6
3/4 11/l6 41-48 30-36 36-45 28-33 VU
F-00161
Figure 10Pipe and Hose Connections Torque

DIAGNOSIS
NOTICE: When performing air conditioning di Operating Detector

agnosis on vehicles equipped with a catalytic 1. Determine if there is sufficient refrigerant in the
converter, warm the engine to a normal oper sytem for leak testing.
ating temperature before attempting to idle
the engine for periods greater than five (5) CAUTION: Do not breathe the fumes that are
minutes. Make adjustments after the choke is produced by the burning of Refrigerant-12
open and fast idle speed is reduced to a nor gas in the detector flame. These fumes can
mal idle. be toxic in large concentrations.
2. Open control valve until a low hiss of gas is

heard; then light gas at opening in chimney.
TESTING THE 3. Adjust until the blue flame is about 10mm (3/a-
REFRIGERANT SYSTEM inch) above the reactor plate. The reaction plate
will heat to a cherry red.
If a malfuction is suspected due to abnormal system 4. Explore for leaks by moving the end of the
pressures, check the following: sampling hose around possible leak points in the
1. Outer radiator and condensor cores for plugging. system. Do not pinch or kink hose. Since
Check between the condenser and radiator. Refrigerant-12 is heavier than air, place open end
of sampling tube below point being tested.
2. R estrictions or kinks in evaporator core or
5. Watch for color changes. Small leaks will turn the
condensor core, hoses, tubes, etc.
flame to green or yellow-green; large leaks will
3. Refrigerant leaks.
turn the flame a brilliant blue or purple. After
4. Air ducts for leaks or restrictions. Air restriction passing through a leak the flame will turn to a
may indicate a plugged (or partially plugged) c o lo rle s s pale b lu e . Make te s ts in a
evaporator core. semi-darkened area. If the flame remains yellow
5. Compressor clutch slippage. after removing it from a leak, the reaction plate is
6. Improper drive belt tension. dirty or the flame is drawing insufficient air.
7. Plugged accumulator, orifice (expansion tube) or To check a leak in the high pressure side of the
plugged suction inlet screen (A6 compressor). system, operate the system for a minute, shut down
8. Moisture in the refrigerant system. and check. To check a leak on the low pressure, op
erate the system and check several minutes after
turning off the system. This will equalize both sides.
LEAK TESTING THE
REFRIGERANT SYSTEM PRESSURE SENSING SWITCH
A pressure sensing switch located near the top of
Liquid Leak Detectors the accumulator, cycles the compressor clutch on C-K
Check for leaks at fittings and valves with the swab and G series CCOT A/C systems. The switch also
attached to the bottle cap. Bubbles will form if there is shuts off the compressor clutch when there is a low
a leak. refrigerant charge.
For restricted areas, use a leak detector, J-6084 or The A/C system does not have to be discharged to
equivalent. replace the switch. The pressure switch fitting is
equipped with a schrader-type valve.
J-6085 LEAK DETECTOR When replacing the switch, use a new oiled seal
Tool J-6084 is a propane gas-burning torch used to (o-ring), and torque to 10 N m (90 in. lbs.).
locate refrigerant leaks. Refrigerant gas drawn into the Refer to the following trouble shooting charts-
sampling tube attached to the torch will cause the 1. Pressure C ycling CCOT System Diagnosis
torch flame to change color in proportion to the size of (figures 11 and 12).
the leak. Propane gas fuel cylinders used with the 2. System Diagnosis (Dash Mounted Unit) (figures
torch are available commercially. 13, 14 and 15).
3. Compressor Diagnosis (figure 16).
CAUTION: Do not use a lighted detector
where c o m b u s tib le or e xp lo sive gasses,
dusts or vapors may be present.
INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH-EXPANSION TUBE (PRESSURE SENSING)

Move Temp. Lever Rapidly Back And Forth From Hot to Cold. Listen For Door Hitting At Each End
Hitting Not
T .... 1
1 Set Temp Lever Full Cold 4 Open Doors And Hood
2. Set Selector Lever Norm A/C
3 Set Blower Switch On High
5. W arm Engine
6 Run Engine At Idle
H Adjust Temp. Door |
| ---------------------------------------
Feel For Air Flow At Heater And A/C Outlets
Some Or All Air Flow
From Heater Outlet
Air Flow From A/C
Outlets Only [ Repair As Per Service Manual
| Check Visually For Compressor Clutch Operation I
I Engaged Or Cyclingl........... ... I---------------------------------------------------------

----------------------- 1 i .... -............... z
This System Does Not Have A Sight Glass Linder No Circumstances Should A Sight Glass Be Installed |
| Feel Liquid Line Before Expansion Tube |
I Cold l - ------------------------ 1 W arm I

------ LJT J------------
Restriction In High Side Of System. Visually Check For Frost Feel Evaporator Inlet And Outlet Pipes K
Spot To Locate Restriction. Repair As Necessary.
| Evacuate & Charge | | Inlet Pipe And Outlet Pipe Same Temperature Or Outlet Colder Than ln le t| -
System { Install Gage Set And Check Compressor Cycling Press|

(O.K.)
| On At 2 826-3 516 kPa (41-51 PSI) Off At 138-193 kPa (20-28 PSI) |
f - - ............ .......... ................. -I
( Runs Continuously Within Limits | Cycles Within Limits Cycles High Or Low (On Above 51 PSI)
Or Off Below 138 kPa (20 PSI)
Disconnect Blower Wire And Check For
Cycling Off At 138-193 kPa (20-28 PSI) Defective Pressure Switch |
Pressure Falls Cycles Off At 138-193 Replace. Do Not Discharge System.

Below 138 kPa (20 PSI) kPa (20-28 PSI) Or Does There Is A Schrader Valve in The Fitting
________ E_____ , Not Pull Down To Press
Defective Pressure Switch I System
---------------------------------------------- 1 (O.K.)
I Install Thermomete|r In A/C Outlet And Check Performance 1
Replace *Do Not Discharge
System. There Is A Schrader
1. Set Temp. Lever To Full Cold 4. Close Doors and Windows
Valve In The Fitting__________ 2. Set Selector Lever To Max A/C 5. Run Engine At 2000 RPM
,____I ____ t 3. Set Blower Switch On Hi 6. Use Aux. Fan In Front Of Grill
| System (O.K.) |
Ambient Temp. 21 C (70F) 2 7 C (80F) 32C (90F) 3 8 C (100F) 4 3 C (110F)

A/C Pick-Up 5-8 C 5-8C 6-10C 6 -1 1C 6 -1 1C
Outlet (41 -47 F) (41 -47F) (42-50F) (43-57F) (43-51 F)
Temp Suburban 6-9C 6-9 C 10-14C 12-17C 14-19C
(42-48F) (42-48 F) (50-58 F) (54-62F) (57-67 F)
Outlet Temperature Within Limits t j Outlet Temperature High As Per Chart |
3
System (O.K. 1 Check Compressor Cycling |
I j Cycle On And Off Or Remains Off For Long Period Of Time |
| Discharge System And Check For Missing Expansion Tube | \ Discharge System And Check For Plugged Expansion Tube |
| In Place | j Replace j
Install Expansion Tube | Check Compressor Inlet Screen f I Evacuate & Charge
_------t
| Evacuate & Charge j
I System (O.K.) | 1 Repair Or Replace S creen l

4
nrClean |
j System Over Charged |

| SystenT(O.K.) j
| Evacuate & Charge | | Evacuate & Charge j
| Systern (O .K ) | | System (O.K.) \
F-00162
Figure 11Pressure Cycling CCOT System Diagnosis

AIR CONDITIONING 1B -1 1
INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH- EXPANSION TUBE (PRESSURE SENSING)
J Off A lim s Time i

Attach Fused Jum per Wire From Compressor Hot Lead To Positive ( + )
_____________ Battery Post And Check Compressor Operation
I Engaged
Apply External Ground To Compressor, Remove Jumper And Check Refrigerant

If Clutch Is Still Not Engaged Removed Pressure At Accumulator Fitting
4 Inlet Pipe Colder Than Outlet P ip T j Clutch & Repair As Per Service Manual
| Leak Check System | | System (O.K.) |
No Leak Found | Leak Found I | Below 345 kPa (50 PSI) \ Above 345 kPa (50 PSI) !
I '
Add 1 Lb Of Refrigerant 12 I Repair As Necessary I Check High Side Refigerant Jump Pressure Switch
Then Check Clutch Cycle Rate ' I 1 Pressure Does Compressor Run
| Evacuate & Charge |
| System (O.K.) \
| Above 345 kPa (50 PSI) |
| Above 6 Cycles Per Minute | | 8 Cycles Per Min. Or Less | "D isc h arg e System Check For
And Check For Plugged Open Circuit,
"D isc h arg e System And Feel Inlet & Outlet Orifice Or High Side Broken Wire,
Check For Plugged Orifice Pipes Again Restriction etc. Repair
zzxiiz:
X
Repair Or Replace
As Necessary Replace
*Do Not Discharge
I
Evacuate & Charge System System. There Is A
| System (O.K.) |
I (OK.) Schrader Valve
Inlet And Outlet Same Tem p.. Inlet Pipe Colder I

System
Or Outlet Colder Than Inlet Than Outlet Pipe
| Below 345 kPa (50 PSI) I (O.K.)
_ T ' '
Add One More Pound Of
Refrigerant 12____ Inlet & Outlet Pipes ngain Lost Charge
Leak Test & Repair
| System (O .K .)| Evacuate & Charge
I
I System
Inlet And Outlet Same Temp., | Inlet Pipe Colder" Than Outlet Pipe | (O. K. )
Or Outlet Colder Than Inlet
Discharge System And Check
Add One More Pound Of For Plugged Orifice
Refrigerant 12
| System (O.K.
| System (O.K.) |
F-00163
Figure 12Pressure Cycling System Diagnosis (Cont.)

INSUFFICIENT COOLING DIAGNOSIS CHART

D A S H M O U N T E D U N IT (M O TO R H O M E C H AS S IS U N ITS )
THE FOLLOWING PROCEDURES SHOULD BE APPLIED BEFORE PERFORMANCE TESTING AN A/C SYSTEM.
CHECK FOR PROPER BELT INSTALLATION AND TENSION 6. CHECK FOR PROPER AIR DUCTING HOSE CONNECTIONS.
WITH J-23600 7. CHECK HEATER TEMPERATURE DOOR ADJUSTMENT,
CHECK FOR PROPER CLUTCH COIL TERMINAL ADJUST IF INCORRECT.
CONNECTOR INSTALLATION. 8. CHECK EVAPORATOR SEALING FOR AIR LEAK, REPAIR IF
CHECK FOR CLUTCH AIR GAP (0.022-0.057) (.56-1.45 LEAKING.
mm). 9 INSTALL PRESSURE GAGES AND THERMOMETER AND
CHECK FOR BROKEN, BURST, OR CUT HOSES. ALSO MAKE PERFORMANCE TEST.
CHECK FOR LOOSE FITTINGS ON ALL COMPONENTS.
CHECK FOR CONDENSOR AIR BLOCKAGE DUE TO
FOREIGN MATERIAL.
NORMAL AIR FLOW CHECK AIR FLOW NO OR LOW AIR FLOW
CHECK DISCHARGE AIR TEMPERATURE BLOWER NOT OPERATING - CHECK BLOWER OPERATION - NORMAL BLOWER OPERATION
SEE FIGURE 8.
DISCHARGE TEMPERATURE HIGH OUTLET AIR

AT OUTLET COLD TEMPERATURE
CHECK SIGHT GLASS CHECK FOR LOOSE OR DISCONNECTED AIR

REFER TO FIGURE 14 DISTRIBUTION DUCTS, RESTRICTED OR LEAKING
AIR DUCTS, PARTIALLY CLOSED AIR OUTLET
VALVE OR CLOGGED EVAPORATOR CORE, IF
CHECK FOR AIR LEAKS THROUGH DASH PANEL, DOORS, ABOVE CHECK IS OK, CHECK FOR ICE BLOCKING
WINDOWS, OR FROM HEATER. EVAPORATOR.
CHECK FOR BLOW FUSE, INOPERATIVE BLOWER SWITCH, ICE BLOCKING

BROKEN WIRE, LOOSE CONNECTIONS, LOOSE BLOWER EVAPORATOR
MOTOR GROUND WIRE OR INOPERATIVE BLOWER MOTOR.
CHECK FOR LOW EVAPORATOR PRESSURE

1. ALLOW SYSTEM TO W ARM UP.
2 STOP AND RESTART ENGINE
3 CHECK EVAPORATOR PRESSURE
IMMEDIATELY AFTER RESTART AND PULL
DOWN OF EVAPORATOR PRESSURE.
NORMAL EVAPORATOR
LOW EVAPORATOR PRESSURE
PRESSURE
SYSTEM HAS EXCESS MOISTURE. REPLACE CHECK FOR MALFUNCTIONING

RECEIVER DEHYDRATOR AND EVACUATE EXPANSION VALVE. REFER
THOROUGHLY. RECHARGE SYSTEM TO FIGURES 11 AND 12.
F-00164
Figure 13Insufficient Cooling Diagnosis Chart

INSUFFICIENT COOLING DIAGNOSIS CHART (CONTINUED)

D A S H M O U N T E D U N IT (M O TO R H O M E C H AS S IS U N ITS )
FOAMING NO FOAMING
SYSTEM IS PROBABLY LOW ON REFRIGERANT. CHECK SYSTEM MAY BE EITHER FULLY CHARGED OR
FOR LEAKS, REPAIR, AND ADD REFRIGERANT. IF FOAMING EMPTY. FEEL HIGH AND LOWER PRESSURE PIPES AT
STILL OCCURS, CHECK FOR RESTRICTION IN REFRIGERANT COMPRESSOR. HIGH PRESSURE PIPE SHOULD BE
SYSTEM BETWEEN CONDENSER AND SIGHT GLASS. WARM. LOW PRESSURE PIPES SHOULD BE COLD
IF PIPES ARE NOT INDICATING PROPER
TEMPERATURES, RECHARGE SYSTEM AS
RECOMMENDED. IF NOZZLE AIR TEMPERATURE IS
STILL HIGH, CHECK EVAPORATOR PRESSURE.
CHECK EVAPORATOR PRESSURE

LOW EVAPORATOR REFER TO FIGURE 8
PRESSURE
REFER TO FIGURE 8
HIGH EVAPORATOR
PRESSURE
CHECK EVAPORATOR OUTLET LINE
CHECK COMPRESSOR DISCHARGE PRESSURE

EVAPORATOR OUTLET
LINE W ARM
HIGH DISCHARGE PRESSURE
CHECK FOR LIQUID LINE RESTRICTION (FROST SPOT

ON LINE). IF NOT, 1. CHECK ENGINE COOLING SYSTEM, FAN CLUTCH AND
CHECK FOR PLUGGED INLET SCREEN IN EXPANSION CHECK FOR RESTRICTED AIR FLOW THROUGH
VALVE. IF NOT, CONDENSER.
3. CHECK FOR MALFUNCTIONING EXPANSION VALVE BY 2. CHECK EXPANSION VALVE BULB CONTACT. CORRECT
REMOVING VALVE AND BLOWING THROUGH VALVE. IF NECESSARY.
IF UNABLE TO BLOW THROUGH VALVE, BULB IS DIS 3. CHECK FOR REFRIGERANT RESTRICTION IN
CHARGED. REPLACE EXPANSION VALVE. CONDENSER. RETURN BENDS AT EQUAL ELEVATION
SHOULD BE APPROXIMATELY SAME TEMPERATURE.
IF TEMPERATURE OF BENDS IS APPRECIABLY
DIFFERENT, THE COOLER BEND INDICATES A
RESTRICTED CIRCUIT, REPLACE CONDENSER IF
RESTRICTION IS FOUND. IF CONDENSER IS GOOD,
LOW DISCHARGE
PRESSURE CHECK FOR AIR IN SYSTEM. TO CHECK OBSERVE
REFER TO OUTLET AIR TEMPERATURE AND COMPRESSOR
FIGURE 8 DISCHARGE PRESSURE WHILE SLOWLY DISCHARGING
SYSTEM AT RECEIVER INLET CONNECTION.
CHECK FOR MALFUNCTIONING EXPANSION VALVE. OUTLET AIR TEMPERATURE OUTLET AIR TEMPERATURE
DROPS AS COMPRESSOR INCREASES AS COMPRESSOR
DISCHARGE PRESSURE DROPS DISCHARGE PRESSURE DROPS
LEAK TEST SYSTEM, REPAIR REPLACE EXPANSION VALVE

AS NECESSARY. DISCHARGE,
EVACUATE, AND RECHARGE.
F-00165
Figure 14Insufficient Cooling Diagnosis Chart (Cont.)

INSUFFICIENT COOLING DIAGNOSIS CHART (Cont.)

DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS)
DASH MOUNTED UNIT (MOTOR HOME CHASSIS)
Refrigerant Charge 1.474 kg (3 lbs., 4 oz.)
Temperature of
o
o
cir
oo
CVJ
o
Air Entering 21 C - (70 F) 27 C - (80 F) 32 C - (90 F) 38 C - (100 F) 43 C (110 F)

Condenser
Engine rpm 2000
Compressor 758 kPa (110 psi) 931 Kpa (135 psi) 1 1031 kPa (160 psi) 1 310 kPa (190 psi) 1 517 kPa (220 psi) 1 792 kPa (260 psi)
Head Pressure* 827 kPa (120 psi) 1 000 kPa (145 psi) 1 172 kPa (170 psi) 1 379 kPa (200 psi) 1 586 kPa (230 psi) 1 862 kPa (200 psi)
Suction
43 kPa (6 psi) 48 kPa (7 psi) 62 kPa (9 psi) 69 kPa (10 psi) 69 kPa (10 psi) 90 kPa (13 psi)
Pressure psi*
Discharge Air 14 C - (40 F) 16 C - (41 F) 16 C - (41 F) 18 C - (42 F) 22 C - (44 F) 22 C - (44 F)
Temperature* 23 C - (45 F) 25 C - (46 F) 25 C - (46 F) 27 C - (47 F) 31 C - (49 F) 31 C - (49 F)
* Just before compressor clutch disengagement.
f w 2b
F-00468
Figure 15Insufficient Cooling Diagnosis Chart (Cont.)

COMPRESSOR DIAGNOSIS
Check for proper air gap. If previous step does not

Clutch slipping. Correct if necessary correct clutch slippage,
0.56 - 1.45 mm (0.022 - 0.057 in. repair compressor.
I Belt slipping! Check and correct belt tension.

Com pressor engaged
but not operational. Refrigeration charge is depleted. Add one pound refrigerant.
High torque
com pressor (seized). L- System has some refrigerant. Leak test complete Repair compressor.
system before removing Operate and leak
Figure 16Compressor Diagnosis
compressor. test system.
Leaks refrigerant. Repair compressor.

Blow oil seal cavity
Com pressor throws oil. with air hose and leak
test.
J- Does not leak refrigerant. Wipe off oil - OK
Check for refrigerant lines touching Check and adjust Repair compressor
Noisy only when
metal parts. Isolate and re-evaluate belt tension. if noise is
clutch is engaged.
AIR CONDITIONING
noise. objectionable.
Noisy when clutch Remove compressor belt to Check for interference If interference exists,
is not engaged. determine if noise still persits. between coil housing repair compressor.
and pulley hub.
NOTE: A/C system noise is to be evaluated in the vehicle with doors and windows closed and low blower on.
1B-15
F-00166
ELECTRICAL/VACUUM TROUBLE DIAGNOSIS
When diagnosing problems in the electrical and vac 1. Operate the blower at four speeds and check the
uum systems consult electrical wiring diagrams and compressor clutch engagement. This indicates
vacuum diagrams (figures 17, 18, 19, and 20). that the electrical circuits are working.
Ports on rotary vacuum valves are illustrated to pro 2. C heck the hand fe lt te m p e ra tu re of the
vide simplicity in following vacuum schematic lines but evaporator inlet pipe and accumulator surface.
are numbered in consecutive order on the actual valve. The same temperature indicates a properly
(Refer to figures 17 and 20). charged system.
3. Operate the A/C control selector (mode) lever to
distribute air from the outlets. This will check the
OPERATIONAL TEST vacuum and diaphragm function.
To d e te rm in e if the e le c tric a l, vacuum and

refrigeration systems are operating efficiently, do the
following:
45
46
47
\
1 53
/
r Jj" 1 l^
f 1
53 53
z K
/
Port Select Lever Valve Operation Chart

Connection No. Off Max A/C Norm A/C Bi-Level Vent Heat Defrost
Source 4 Vacuum Vacuum Vacuum Vacuum Vacuum Vacuum Vacuum
Bi Level 9 Vent Vacuum Vacuum Vacuum Vacuum Vacuum Vent
Heat/Defrost 3 Vacuum Vacuum Vacuum Vacuum Vacuum Vacuum Vent
OSA/REC 2 Vent Vacuum Vent Vent Vent Vent Vent
AC Mode 5 Vent Vacuum Vacuum Vent Vent Vent Vent
Ports 1,6,7 & 8 Not Used (Sealed On Vacuum Hose Assembly)
45. Vacuum Source - Engine Vacuum Line - Tan (Source)

46. Vacuum Tank - Gas E. Vacuum Line - Gray (Bi Level)
47. Cowl H. Vacuum Line - Dark Blue (A/C)
52. Control K. Vacuum Line - Red (Heat/Defrost)
53. Actuator F. Vacuum Line - Orange (Recirculate)
B-06944
Figure 17G A/C Vacuum Schematic

ELECTRICAL SYSTEM DIAGNOSTIC CHART
BLOW MOTOR INOPERATIVE

(ANY SPEED)
CHECK FOR PROPER

FUSE.
JL
| FUSE B L O W N ""] | FUSE OK
THE FOLLOWING TESTS SHOULD BE MADE WITH

WITH IGNITION SWITCH IN RUN POSITION AND THE IGNITION SWITCH IN RUN POSITION,
HEATER OR A/C ON, LOCATE SHORT IN ONE OF THE HEATER OR A/C ON AND BLOW SWITCH ON
FOLLOWING WIRES: (SEE NOTE) HIGH.
1 FROM FUSE PANEL TO MASTER SWITCH ON Z
CONTROL. CHECK BLOWER MOTOR GROUND.
2. FROM MASTER SWITCH TO COMPRESSOR
[
CLUTCH.
3. MASTER SWITCH TO BLOWER SWITCH. | POOR OR NO GROUND | | GROUND OK 1
4 FROM BLOWER SPEED SWITCH TO RESISTOR
| REPAIR GROUND| CHECK MOTOR CONNECTOR
5. FROM RESISTOR TO BLOWER MOTOR.
WITH 12 VOLT TEST LIGHT
NOTE: SHORT CIRCUIT MAY BE INTERMITTENT. IF
T
TESTER DOES NOT INDICATE A SHORT CIRCUIT,
MOVE HEATER HARNESS AROUND AS MUCH AS LAMP ON | LAMP DOES NOT LIGHT
POSSIBLE TO RECREATE SHORT CIRCUIT WATCH
AND LISTEN FOR ARCING. | REPLACE MOTOR CHECK WIRE CONNECTOR ON BLOWER
RELAY WITH 12 VOLT TEST LIGHT.
.... I
1 1
LAMP ON | | LAMP DOES NOT LIGHT |
REPAIR OPEN IN WIRE CHECK WIRE CONNECTOR ON

FROM BLOWER MOTOR BLOWER RELAY WITH 12 VOLT
TO BLOWER RELAY. TEST LIGHT.
LAMP DOES NOT LIGHT LAMP ON

] [
USE 12 VOLT TEST LIGHT AND REPLACE RELAY.
CHECK WIRE TERMINALS AT
RESISTOR.
1
LAMP OFF LAMP ON
CHECK FEED WIRE FROM REPLACE RESISTOR.

RESISTOR TO BLOWER
SPEED SWITCH.
JL I
LAMP ON | LAMP OFF |
,,.J____1
REPLACE BLOWER REPLACE OPEN IN WIRE
SPEED SWITCH. FROM BLOWER SPEED
SWITCH.
F -0 0 1 6 7
Figure 18Electrical System Diagnostic Chart

AIR CONDITIONING 1B -1 9
ELECTRICAL SYSTEM DIAGNOSTIC CHART (CONTINUED)
F-00168
Figure 19Electrical System Diagnostic Chart (Cont.)

Port Select Lever Valve Operation Chart

Connection No. Off Max A/C Norm A/C Bi-Level Vent Heat Defrost
Source 1 .. vac ............ *
A/C Mode 2 Vent Vacuum ....... vum ^
Heater/Mode 3 Vent Optional Optional Vent Optional Vent Vacuum
OSA/REC 4 Vacuum Vent Vent Vent Vent Vacuum Vacuum
Defroster 5 Vent Vacuum Vacuum Vent Vacuum Vent Vent
Ports 6,7,8 and 9 not used (sealed on vacuum hose assembly)
E. Vacuum Line Gary (Source)

45. Vacuum Source - Engine 49. Mode Door F. Vacuum Line - Orange (Defroster)
46. Vacuum Tank (Gas) 50. Defroster Door H. Vacuum Line - Dark Blue (Heat)
47. Cowl 51. Recirculator Door I. Vacuum Line - Tan (A/C)
48. Plenum Valve 53. Actuator J. Vacuum Line - Black (Defroster)
F-00182
Figure 20C-K A/C Vacuum Schematic

VACUUM SYSTEM DIAGNOSIS
C-K AND G SERIES Vacuum normal at all positions.

If vacuum was normal and even at all
Start the engine and allow it to idle. Move the positions, then the malfunction may be
selector lever to each position and refer to the vacuum caused by improperly connected or plugged
diagrams and operational charts for airflow, air door lines or a malfunctioning vacuum valve or
functioning and vacuum circuits. If air flow is not out of valves.
the proper outlet at each selector lever position do the 3. Specific vacuum circuit check:
following: P lace the s e le c to r le ve r in the
m alfunctioning position and check for
vacuum at the pertinent vacuum actuators.
L* Inspect
If vacuum exists at the actuator but the door
1. The hose connections at the vacuum actuators, does not move, then the a c tu a to r is
control head valve and vacuum tank. defective or the door is jammed.
2. The vacuum source circuit: If low or no vacuum exits at the actuator
Insta ll a vacuum tee and gage (with determine whether the cause is the vacuum
restrictor) at the vacuum tank outlet. Idle the harness or the vacuum valve.
engine and read the vacuum (a normal Check the vacuum harness first.
vacuum is equivalent to manifold vacuum) 4. Vacuum harness circuit check:
at all selector lever positions. Disconnect the vacuum harness at the
Vacuum less than normal at all positions. control head.
Remove the tee and connect the vacuum The black line should show engine vacuum;
gage line to the tank - read the vacuum. If if not, trace back through connector to
still low, then the problem lies in the feed vacuum tank.
circuit, the feed circuit to the tank or in the To check any individual circuit, place the
tank itself. If vacuum is now normal, then selector lever at the involved circuit position
the problem lies downstream. and check for vacuum presence.
Vacuum less than normal at some positions.
If vacuum was low at one or several of the
selector lever positions, a leak is indicated
in these circuits.
A/C REFRIGERANT SYSTEM DIAGNOSIS
INSUFFICIENT COOLING BOTH THE SAME TEMPERATURE AND SOME

DEGREE COOLER THAN AMBIENT Proper
QUICK-CHECK PROCEDURE condition: check for other problems (Refer to A/C
System Diagnostic Procedure).
Use the following CCOT Hand-Feel procedure if INLET PIPE COOLER than accumulator surface
the A/C system has the proper charge of Refrigerant-12 indicates a low refrigerant charge.
(providing ambient temperature is above 21 C (70F). Add a m o un ts 120 ml (4 o u n ce s) of
refrigerant UNTIL BOTH feel the same
1. Engine must be warm (CHOKE OPEN and OFF te m p e ra tu re . A llow s ta b iliz a tio n tim e
FAST IDLE SPEED CAM) and at normal idle between additions.
speed. Diesel engine at normal idle. Then add 420 ml (14 oz.) one can additional
refrigerant. (The 420 ml (14 oz.) disposable
2. Hood and body doors open.
can of Refrigerant-12 is the equivalent to .88
3. Selector (mode) lever set at NORM. lbs.).
4. Temperature lever at COLD.
5. Blower on HI.
6. Hand-Feel the temperature of the evaporator
inlet pipe after the orifice and accumulator with
the compressor engaged.
A/C EVACUATING AND CHARGING PROCEDURES
EVACUATION AND
CHARGING PROCEDURES
Before opening any refrigerant hose or component,
read the information furnished in:
Refrigerant-12 Operating Characteristics.
D is c h a rg in g , E va cu a tin g , A dd in g O il and 55. Gage Set
Charging. 56. Vacuum Pump
57. Empty 3 Lb.
Remove sealing caps from subassemblies before
Coffee Can
making connections for final assembly. Use a small
58. Refrigerant-12
amount of clean 525 viscosity refrigerant oil on all tube
and hose joints.
Use new seal (o-ring) dipped in the clean 525
viscosity refrigerant oil when assembling joints. The oil
will aid in assembly and help provide a leak-proof joint.
When tightening joints, use a second wrench to hold
the stationary part of the connection.
T ig h te n all tu b in g c o n n e c tio n s (fig u re 10).
Insufficient or excessive torque can cause loose joints
or deformed joint parts. Either condition can cause
leakage.
DISCHARGING, EVACUATING F-00169

ADDING OIL AND
CHARGING PROCEDURES FOR Figure 21J-23500-01 Charging System
CCOT A/C SYSTEMS
CAUTION: Never remove a gage line from its
Discharge, evacuate and charge using J-23500-01 adapter when the line is connected to the
air conditioning service Charging Station or the A/C system. Always remove the line adapter
J-5725-04 Manifold Gage Set, and 420 ml (14 oz.) from the service fittin g to disconnect a line.
disposable cans of Refrigerant-12 (figures 21 and 22). Do not remove charging hose at gage set
Use gage adapters to connect the charging lines while attached to service low side fittin g .
from the charging station or manifold and gage set to This w ill discharge the system due to the
system service fittings. A straight gage Adapter J-5420 depressed schrader valve in service low side
and a 90 angle gage Adapter J-9459 is available. fittin g and may cause personal injury due to
Wear goggles and wrap a clean cloth around fittings escaping Refrigerant-12.
and connections.
Discharge the system before removing and
replacing refrigeration lines or components.
DISCHARGING THE CCOT
Use the service valve and pressure gage sets
during evacuation and charging procedures. A/C SYSTEM
Do not charge while the compressor system is
Before replacing any component, discharge the
hot.
system.
Always discharge the system at the low side
service fitting and perform the entire evacuation 1. Discharge at the low side service fitting.
and charging procedure through the low side
service fitting. 2. With the ignition turned OFF, remove the protec
Do not connect the high pressure line or any line tive cap from LOW SIDE service fitting and con
to the high side service fitting during discharging nect Charging Station J-23500-01 Gage Set.
and charging procedures. (Refer to figure 22).
65. Accum ulator

F-00030
Figure 22Charging The System With A Disposable Can Or Drum
a. If charging station J-23500-01 is not being container. If no discharge occurs, check for
used, discharge the system by slowly missing or defective schrader depressor in
connecting a gage hose to the low side the hose fitting.
service fitting on the accumulator and dis
3. With the low side of the system discharged,
charge into a bottle (figure 23).
check the high side system fitting (on the
b. As the hose is SLOWLY tightened down liq u id lin e or m u ffle r) for re m a in in g
onto the schrader valve, Refrigerant-12 will pressure.
d is c h a rg e from the system into the
4. If pressure is found, attempt to discharge
the high side using the same procedure as
used for the low side. (This condition
indicates a restriction on the high side.
Diagnose and correct before evacuating
and charging).
5. After discharging, (no vapor escaping with

the hose fully-tightened down), measure
and record the amount. If 15 ml (.05 ounce)
or more, add this amount of new 525
viscosity refrigerant oil plus any quantity in
removed parts before evacuation and
charging with Refrigerant-12 (refer to CCOT
Refrigerant Oil Distribution for the quantity
of oil normally retained in removed parts).
6. If adding oil is necessary, remove the

suction hose at the accumulator outlet pipe
connection and pour the correct quantity of
Figure 23Discharging The CCOT A/C System refrigerant oil into the hose or pipe and then
W ithout Charging Station J-23500-10 reconnect hose or pipe. (Refer to step
num ber 4 and CCOT R e frig eran t Oil If a new accumulator is installed add 90 ml
D is trib u tio n fo r s p e c ific q u a n tity (3 ounces) additional oil to compensate for
instructions). that absorbed by the original accumulator
dessicant.
R-4 COMPRESSOR
CCOT REFRIGERANT Remove the accumulator. Drain, measure
OIL DISTRIBUTION and record quantity of oil in accumulator. It
is not necessary to remove and drain the
A-6 COMPRESSOR300 ml (10 ounces) of 525 R-4 compressor because the compressor
viscosity refrigerant oil. only retains a minumum quantity of oil.
R-4 COMPRESSOR 180 ml (6 ounces). Add new If less than 90 ml (3 ounces), add 90 ml (3
oil during the following component replacement ounces) of new oil to system.
and conditions:
If more than 90 ml (3 ounces), add the same
1. With no excessive oil leakage, add; amount of new oil as drained.
Compressor - Remove, drain oil, measure If a new accumulator is installed to system,
replace the same amount of new oil plus 30 add 60 ml (2 ounces) additional oil to
ml (1 ounce). compensate for that retained by the original
EvaporatorAdd 90 ml (3 ounces). accumulator dessicant.
CondenserAdd 30 ml (1 ounce).
Accumulator - R-4 Compressor - Remove
drain oil, measure, replace the same EVACUATING AND CHARGING
amount of new oil plus 60 ml (2 ounces) to THE CCOT A/C SYSTEM
compensate for that retained by the original
accumulator dessicant. B efore c h a rg in g , e vacu a te the system if
DA-6 Compressor - Remove, drain oil, Refrigerant-12 is lost or if the system has been opened.
measure, replace same amount of new oil Evacuation and charging is a combined procedure.
plus 90 ml (3 ounces) to compensate for that Purge all gage lines with Refrigerant-12 before
re tained by the o rig in a l a ccu m u la to r charging.
dessicant. If no oil can be drained from old
There are three standard Refrigerant-12 evacuate
accumulator, add 60 ml (2 ounces) new oil to
and charge procedures:
the new accumulator.
2. With signs of excessive oil leakage; J-23500-01 Charging Station Method
A-6 COMPRESSOR Disposable Can Method

Remove Compressor and Accumulator. Drum Method
Drain measure and record total oil from both
components. Use new oil. NOTICE: Do not use alcohol to remove
If less than 180 ml (6 ounces), add 180 ml (6 moisture from the system. Alcohol can
ounces) of new oil to system. damage components.
If more than 180 ml (6 ounces), add same
amount of new oil as drained.
If a new accumulator is installed to A-6 GAGE CALIBRATION
system, add 60 ml (2 ounces) additional oil
to compensate for that held/absorbed by the Before evacuation, check the low pressure gage for
original accumulator dessicant. proper calibration and vacuum system for proper oper
DA-6 COMPRESSOR ation. With the gage disconnected from the refrigera
Remove the accumulator. Drain, measure tion system, be sure that the pointer indicates to the
and record quantity of oil in accumulator. It center of 0. Tap the gage to be sure pointer is not
is not necessary to remove and drain the sticking. If necessary, calibrate as follows:
DA-6 compressor because the compressor Remove the cover from the gage.
only retaines a minimum quantity of oil, it
Holding the gage pointer adjusting screw
doesnt have an oil sump area.
with one hand, carefully force the pointer in
If less than 90 ml (3 ounces) add 90 ml (3 the proper direction to position the pointer at
ounces) of new oil to the system. the 0 position. Tap the gage to be sure
If more than 90 ml (3 ounces) add the same the pointer is not sticking. Replace the gage
amount of new oil as drained. cover.
VACUUM SYSTEM CHECK SLOWLY open high and low side gage
valves and begin vacuum pum p
Before connecting the vacuum pump to the A/C operation. Pump the system until the
system run the pump connected to the low pressure low side gage reaches 459 - 475 mm
gage to determine the vacuum pump capability. If the (28 to 29 inches of mercury [vacuum])
vacuum system is unable to reach 711.2 - 736.6 mm or more.
(28 to 29 inches) or more vacuum check for leaks. If no The evacuation procedure will specify 459 -
leaks are found, check the vacuum pump. 475 mm (28 to 29 inches) of mercury at sea
level. For each 304.8 mm (1,000 ft.) above
sea level, lower the specification by one
CHARGING STATION METHOD inch of vacuum. At 1524 mm (5,000) feet
elevation only 376.9 mm (23 to 24 inches) of
Follow the J-23500-01 Charging Station instructions. mercury (vacuum) is required.
Use with the following exceptions: If the p re scrib e d vacuum c a n n o t be
1. Do not connect the high pressure line to the air reached, close the vacuum control valve,
conditioning system. shut off the pump and look for a leak at
2. Keep the high pressure valve on the charging the connections or the pump.
station closed. 3. When the gage reaches the prescribed vacuum,
3. Perform the evacuate and charge procedure the system is evacuated. Close the high side
through the accum ulator low side pressure gage set valve and turn OFF the vacuum pump.
service fitting. 4. Watch the low side gage to be sure vacuum holds
4. Following these procedures will prevent high side for five minutes. If the vacuum holds, disconnect
pressure from damaging the charging station if the vacuum hose at the gage set and then
an error is made during the sequence. proceed to charging.
5. If the vacuum does not hold for five minutes,
charge the system with 420 ml (8 ounces)
DISPOSABLE CAN OR Refrigerant-12 and leak check. Discharge the
MULTI-CAN METHOD system again and repair any leaks. Repeat the
evacuation procedure.
Tools Required:
J-6271-01 Single Can Refrigerant Dispensing Valve
J-6272-02 Four Can Refrigerant Dispensing Valve CHARGING OF THE CCOT
1. Use tool J-6271-01 for single can or multi-can
A/C SYSTEM
dispensing unit.
2. Use tool J-6272-02 multi-can open valve. When 1. Start the engine, run with the choke open and the
using disposable cans, close the tapping valve fast idle speed reduced to normal idle, set the
and then a tta ch the can(s) fo llo w in g the A/C control lever on OFF.
instructions included with the tapping valve or
2. With the drum or 420 ml (14 ounces) can(s)
tapping manifold adapter.
inverted, open source valve(s) and allow 0.454 Kg
(one (1) pound) or more 420 ml (14 ounces) can of
liquid Refrigerant-12 to enter the system through
REFRIGERANT DRUM METHOD
low side service fitting on accumulator.
Tool required: 3. When one 0.454 Kg (1 pound) or one 420 ml (14
J-23390 Refrigerant Dispensing Valve ounces) can of liquid Refrigerant-12 enters the
1. Use tool J-23390 for a 12 lb. can. system, engage the compressor by setting the
2. A 30 lb. can has a built in opener-valve. Place the A/C control lever to NORM and blower speed on
drum on a scale and note weight before charging. HI to draw in the remainder of the charge.
During charging, watch the scale to determine To speed up the operation, use a fan to pass air over
the amount used. the condenser. If the condenser temperature remains
below the c h a rg in g c y lin d e r te m p e ra tu re ,
Im portant Refrigerant-12 will enter the system faster.
4. Shut off the source valve and run the engine for
Close the outlet valve on the opener 30 seconds to clear lines and gages.
(clockwise) before installing the opener to 5. With the engine running, remove the charging
the R-12 container. low side hose adapter from the accumulator
2. To evacuate the A/C system install Manifold service fittin g . Unscrew rapidly to prevent
Gage Set and Vacuum Pump. Refrigerant-12 from escaping.
CAUTION: Never remove a gage line from its ACCUMULATOR ASSEMBLY

adapter when the line is connected to the
A/C system. Always remove the line adapter The a c c u m u la to r a sse m b ly has a se rv ic e
from the service fittin g to disconnect a line. replacement which includes two seals (o-rings for the
Do NOT remove the charging hose at the inlet and outlet connections). The desiccant is NOT
g a g e s e t w h ile it is a tta c h e d to th e serviced separately - it is part of the sealed
accum ulator. This w ill discharge the system accumulator assembly. Refer to CCOT Refrigerant Oil
because of the depressed schrader valve in and Distribution for presence of refrigerant oil and
service low side fittin g . Also, the escaping service conditions when removing the accumulator
Refrigerant-12 may cause personal injury. from the vehicle to measure the oil.
Replace the accumulator assembly when:
6. Replace the protective cap on the accumulator 1. A physical perforation prduces a leak.
fitting. 2. The (orifice) screen experiences continued or
7. Turn the engine off. repeated plugging.
8. Leak the check system with a J-6084 Leak 3. An evaporator fails because of inside-out internal
Detector. corrosion.
9. Start the engine. DO NOT REPLACE the accumulator assembly
10. With the system charged and leak-checked, where:
operate the system and test for pressures, as 1. A dent is found in the outer shell of the
outlined under Relative Humidity, Temperature accumulator.
and Pressure Relationship of Refrigerant-12 2. A vehicle is involved in a collision and there
(figure 8). is no perforation to the accumulator. Cap or
place a p la s tic bag around an open
refrigerant line.
SPECIFIC COMPONENT DIAGNOSIS
COMPRESSOR RECEIVER-DEHYDRATOR
(MOTOR HOME CHASSIS)
Compressor defects can appear as noise, seizures,
leakage or low discharge pressures. An inlet restriction can cause high head pressure
and an outlet restriction can cause low head pressure,
NOTICE: Resonant compressor noises are or little or no cooling. A restricted outlet can cause a
normal; however, irregular noise or rattles may cold receiver-dehydrator.
indicate broken parts or wear. To check
seizure, de-energize the magnetic clutch and
rotate the drive plate. If rotation is impossible EXPANSION VALVE
the compressor is seized.
There are five expansion valve malfunctions: valve
To check for a leak, refer to Leak Testing The stuck open, valve stuck closed, broken power element,
R efrigerant S ystem . A faulty internal seal, a a restricted screen or an improperly located or installed
restriction or an insufficient refrigerant charge can power elem ent bulb. To correct the first three
cause a low discharge pressure. Check before conditions, replace the valve; to correct the last two,
servicing. replace the valve inlet screen and properly install a
power element bulb.
Operating the system will indicate valve trouble.
CONDENSER 1. Valve stuck open.
Noisy compressor.
A condenser may leak or be restricted. A restriction
No cooling - freeze up.
will cause excessive compressor discharge pressure. If
a partial restriction is present, ice or frost will form after 2. Valve stuck closed, broken power element or
the restriction as the refrigerant expands after passing plugged screen.
through the restriction. Very low suction pressure.
Air flow restrictions through the condenser or No cooling.
radiator can cause high discharge pressures. During 3. Poorly located power element bulb.
normal condenser operation, the outlet pipe will be Normal pressure.
cooler than the inlet pipe. Poor cooling.
DIAGNOSIS FOR MALFUNCTIONING VALVE 2. Discharge LineA restriction will cause the
Use the follo w in g procedure to determ ine a pressure relief valve to open.
malfunctioning valve. 3. Liquid LineA restriction will be caused by low
1. Operate the system at normal idle. If the valve is discharge and suction pressure, and insufficient
m a lfunctioning, the low pressure readings cooling.
(evaporator pressure) will be above specifications
(figure 8).
2. The loss of system performance is not as evident SIGHT GLASS DIAGNOSIS
when the compressor head pressure is below (MOTOR HOME CHASSIS UNITS)
1379 kPa (200 psi). Increase the system head
pressure by partially blocking the condenser. At temperatures above 21 C (70 F), the sight glass
Disconnect the blower lead wire and operate the can indicate if the refrigerant charge is sufficient.
system to determine if the evaporator pressure After operating five minutes, slow-moving bubbles
can be obtained. (vapor) or a broken column of refrigerant under the
3. Bubbles in the sight glass will indicate a low glass may indicate a shortage of liquid refrigerant. On
re frig e ra n t charge (M otor Home C hassis a cool day, continuous bubbles will indicate a properly
Systems). charged system. If the sight glass is clear and
performance is satisfactory, occasional bubbles do not
indicate a refrigerant shortage.
EVAPORATOR If the sight glass shows foaming or a broken liquid
column, observe after partially blocking the air to the
An inadequate supply of cool air can cause the co nd e nse r. If the s ig h t g la ss c le a rs and the
evaporator to malfunction. Check for a plugged core, a performance is satisfactory, the charge is adequate. If
cracked case or a leaking seal. the refrigerant shortage continues, add refrigerant in
120 ml (4 ounces) increments until the sight glass is
clear. Add an additional charge of 240 ml (8 ounces) as
REFRIGERANT LINE a reserve after the glass clears. Do not overcharge the
RESTRICTIONS system.
There are three refrigerant line restrictions:

1. Suction Line - A restriction will cause low suction
pressure at the compressor, low discharge
pressure and little or no cooling.
ON VEHICLE SERVICE
F-00157
Figure 24 C-K C om pressor M o unting C om ponent View L6 (4.8 Liter) Gas Engine
COMPRESSOR REPLACEM ENT Important
(C-K) Use new seals (o-rings) coated with clean

refrigeration oil.
Remove or Disconnect (Figures 24, 25, 26 and 5. Electrical lead to the coil.
27)
6. Compressor belt.
1. Discharge the system.

Adjust
2. Connector attaching bolt.
3. Connector. Belt. Refer to Specifications.
7. Evacuate, charge and check the system.
Cap or plug open connections.
4. Electrical lead to the clutch acutuating coil.
5. Bolt. COMPRESSOR REPLACEMENT
Loosen the bracket and pivot bolts. (G AND MOTOR HOME
6. Compressor. CHASSIS MODELS)
Drain and measure the oil.
Check for contamination.
-- Install or Connect (Figures 24, 25, 26 and 27) 2. Compressor clutch connector.
3. Purge the system of refrigerant.
1. Oil to the compressor. 4. Belt.
Important Important
Replace with fresh oil. If the system was Release the belt tension at the idle pulley to
serviced, install a full, fresh charge of remove.
refrigeration oil. On some vehicles remove the crankshaft
2. Compressor. pulley.
5. Engine cover - G Series.
Position to the mounting bracket.
6. Air cleaner.
3. Nuts, bolts and spring washer. 7. Fitting and muffler assembly.
4. C o n n e c to r a sse m b ly to the rear of the Cap or plug all open connections.
compressor. 8. Compressor bracket.
F-00158
Figure 25C-K Compressor Mounting Component V6 and V8 (4.3 and 5.0 Liter) Gas Engines
9. Engine oil tube support bracket bolt and nut. 6. Compressor belt.
10. Clutch ground lead.
11. Compressor. f t Adjust
Im portant Refer to COOLING (SEC. 6B)
Drain and measure the oil. Check for

contamination. COMPRESSOR BELT TENSION
+- Install or Connect (Figures 28 and 29)
ADJUSTMENT (G AND MOTOR
HOME CHASSIS MODELS)
1. Oil to the compressor.
Adjust the compressor belt to the specifications
Im portant shown in the COOLING (SEC. 6B). On some units
increase idler pulley slack adjustment.
Replace with fresh oil. If the system was
serviced, install a full, fresh charge of f t Adjust
refrigeration oil.
2. Compressor. 1. Remove idler adjustment bolt.
Position to the mounting bracket. 2. Remove idler backing plate.
3. Nuts, bolts and spring washer. 3. Lengthen adjusting slots 13 mm (1/2 -inch)
4. C o n n e c to r a sse m b ly to the rear of the inboard or outboard as required.
compressor. 4. Install backing plate.
5. Install assembly.
9 Im portant If the belt is being replaced it may be necessary to
remove and replace the throttle cable during the belt
Use new seals (o-rings) coated with clean re p la c e m e n t. A d ju s t the th ro ttle ca b le upon
refrigerant oil. completion. It may be necessary to remove the
5. Electrical lead to the coil. crankshaft pulley to install a new compressor belt.
V8 (7.4 Liter) Gas Engine - Federal Emissions
C-K Series Compressor Mounting Component View

V8 (7.4 Liter) Gas Engine - California Emissions
F-00159
Figure 26C-K Compressor Mounting Component View V8 (7.4 Liter) Gas Engine
F-00160
Figure 27C-K Compressor M ounting Component View V8 (6.2 Liter) Diesel Engine
Figure 28G Compressor Mounting Component View V8 (5.7 Liter) Gas Engine
F-00152
Figure 29G Compressor Mounting Component View V8 (6.2 Liter) Diesel Engine
CCOT A/C SYSTEM C-K SERIES
CONDENSER REPLACEMENT

3. Grille assembly.
4. Radiator grille center support.
5. Left grille support to upper fender support (2)
screws.
6. Condenser inlet and outlet lines, and the outlet
tube at the right end of the condenser (figure 30).
Im portant
Cap or plug all open connections.

7. Condenser to radiator support screws.
8. Bend the left grille support outboard to gain
clearance for condenser removal.
9. Condenser assembly by pulling it forward and Im portant
then lowering it from the vehicle.
Use new seals (o-rings) coated with clear
Install or Connect (Figure 30) refrigeration when connecting refrigerant
lines.
1. New condenser.
5. Left grille support to the upper fender support
Important screws.
Add 30 ml (1 ounce) of clean refrigeration oil 6. Radiator center support.

to a new condenser.
2. Left grille support. 7. Grille assembly.
3. Radiator support screws.
4. Condenser inlet and outlet lines. 8. Battery ground cable.
82 83 84 oc
80 81 I 82 I 8,5
109-
80. Harness Assembly 96. Nut

81. Resistor 70. Condenser
82. Screw 97. Hose
83. Screw 98. Clip
84. Tank 99. Screw
85. Screw 100. Clamp
86. Hose 101. Cap
87. Bolt 103. Resistor
88. Washer 104. Switch
89. Fitting 105. Relay
90. Gasket 106. Screw
91. O-ring 107. Evaporator and
92. Tube Blower Assembly
93. Tube 108. Seal
94. Grommet 109. Washer
95. Screw 110. Accum ulator
F-00085
Figure 31 C-K Evaporator and Condenser Component View (Engine Compartment)
ACCUMULATOR REPLACEMENT
2. Compressor clutch connector.
4. Inlet and outlet lines (97).

90. Insulator
91. Stud
Important
92. Nut
F-00087 Cap or plug open connections.
Figure 32Dash Panel Insulator 5. Bracket screws.

Assem bly (Engine Compartment - Diesel)
6. Accumulator (110).
105. Relay
110. Accum ulator Dehydrator Assembly
120. Screw
121 Grommet
122 Case
123. Grommet
124. Core
125. Clamp
126. Screw
127 Rivet
128 Bracket
129. Plate
130. Orifice
131 Gasket 110
132 Motor Assembly
133. Hose
134. Wire Assembly 139
135. Switch Assembly 105
136. Case
137. Seal
81. Resistor
139. Clamp
140. Switch
F-00092
Figure 33C-K Evaporator and Blower Compartment (Engine Compartment)
Im portant 5. Blower assembly.

Case attaching screws.
Drain excess refrigerant oil into a clean Carefully pry the blower flange away from
container. Measure and add new oil. the case if the sealer acts as an adhesive.
6. Blower wheel from motor shaft.
- Install or Connect (Figures 31 and 33) Remove shaft nut.
1. New accumulator. +- Install or Connect (Figures 32 and 33)
Im portant 1. Blower wheel to the motor shaft.

2. Blower assembly.
Add 30 ml (one ounce) of clean refrigerant Use a new bead of sealer on the flange.
oil. PLUS an amount equal to that drained. 3. Blower assembly.
2. Bracket screws. 4. Blower motor cooling tube.
3. Inlet and outlet lines. 5. Blower motor lead and ground wires.
4. Compressor clutch connector. 6. Battery ground cable.
EVAPORATOR CORE
REPLACEMENT
BLOWER ASSEMBLY
REPLACEMENT Remove or Disconnect (Figure 33)
+ + Remove or Disconnect (Figures 32 and 33) 1. Battery ground cable.

1. Battery ground cable. 3. Nuts from the selector duct studs projecting
2. InsulatorDiesel Engine. through the dash panel.
3. Blower motor lead and ground wires (134). 4. Evaporator case cover (122).
4. Blower motor cooling tube. 5. Inlet and outlet lines.
- umiHinumjm
} 47 148 149 ^^<153

150 ^ 152
i 4=^) ^154
157
53. Actuator
145. Valve 154. Connector
146. Housing 155. Screw 163. Valve
147. Screw 156. Bracket 164. Nut
148. Core 157. Shaft 166. Valve 172. Connector
149. Strap 158. Spacer 167. Screw 173. Plate
150. Screw 159. Spring 168. Link 174. Grommet
151. Clamp 160. Shaft 169. Pin 175. Hose
152. Connector 161. Bracket 170. Seal 176. Screw
153. Link 162. Case 171. Vaive 177. Yoke F-00093
Figure 34--C -K A/C ar Heater Component View
Cap or inlet open connections. 7. Evacuate, charge and check the system.
6. Expansion tube. Refer to Orifice (Expansion
Tube) Replacement . ORIFICE (EXPANSION TUBE)
7. Evaporator core assembly.
REPLACEMENT
Install or Connect (Figure 33) The expansion tube is located in the evaporator core
inlet line.
1. New core.
Add 90 ml (3 ounces) of clean refrigeration + Remove or Disconnect (Figures 4 and 33)
oil.
2. Expansion tube. 1. Discharge the system.
3. Inlet and outlet lines. 2. C o n de n ser to the e va p o ra to r lin e at the
Use new seals (o-rings) coated with clean evaporator inlet (figure 35.)
refrigeration oil.
Cap or plug the open line.
4. Bead of sealer to cover.
Remove old sealer before applying new 3. Expansion tube from the evaporator core inlet
bead of sealer. line.
5. Evaporator case cover. Use needle-nose pliers to remove the core.
6. Nuts to the studs that project into the dash panel. 4. Expansion tube seal (o-ring) from the core inlet
6. Battery ground cable. line.
186
196
180. Adapter
181. Screw 193. Retainer
182. Adapter 194. Adapter
183. Hose 195. Felt
184. Duct Assembly 196. Deflector
185. Screw 197. Outlet
186. Duct Assembly 198. A ir Conditioning Assembly
187. Seal 199. Bolt
188. Seal 200. Outlet Assembly
189. Duct Assembly 201. O utlet Assembly
190. Gasket 202. Screw
191. Duct Assembly 203. Deflector
192. Screw 204. Deflector
F-00080
Figure 35C-K A/C and Heater O utlets and Ducts Component View (Passenger Compartment)
Figure 36Actuator-Plenum Side Vent
Install or Connect (Figures 4 and 33) 3. Heater hoses from the core tubes (148).
Plug the core tubes to prevent spillage.
1. Expansion tube seal (o-ring) to the core inlet line. 4. Instrument panel compartment and door.
Use new seal (o-ring) coated with clean 5. Center duct to the selector duct (200).
refrieration oil. 6. Center lower and center upper ducts.
Insert the short screen and end of the orifice
7. Temperature door cable.
into the evaporator inlet line.
8. Nuts from the three selector duct studs that
2. Expansion tube to the evaporator core inlet line.
project into the dash panel.
3. C o n de n ser to the e vap o ra to r line at the
9. Selector duct to dash panel screw (inside the
evaporator inlet.
vehicle).
10. Selector duct assembly.
Pull rearward until the core tubes clear the
SELECTOR DUCT AND HEATER dash panel.
CORE REPLACEMENT Lower the selector assembly to reach the
vacuum and electrical harness.
Remove or Disconnect (Figures 34 and 35) 11. Vacuum and electrical harness.
1. Battery ground cable. 13. Core mounting strap screws.
2. Drain the radiator. 14. Core.
Figure 39C-K Control Assembly
8. Center duct to selector duct.

9. Instrument panel bar and door.
10. Heater hoses.
11. Coolant to the radiator.
f t Adjust
T e m p eratu re d oo r ca b le . R efer to
Temperature Door Cable Adjustment.
1. Core. ACTUATOR-PLENUM SIDE

2. Core mounting strap screws. VENT REPLACEMENT
4. Vacuum and electrical harnesses. Remove or Disconnect (Figure 36)
6. Temperature door cable. 1. Vacuum hose at the actuator.
7. Center lower and center upper ducts. 2. Valve return spring at the actuator end (216).
241 244
VIEW B
240. Cable-Temperature Control
241. Bolt/Screw
242. Retainer
243. Heater Control Assembly
244. Cam VIEW A F-00106
Figure 38Temperature Door Cable Adjustment

3. Actuator bracket mounting screws. CONTROL ASSEMBLY

4. Cam to actuator arm screw (213).
REPLACEMENT
5. Actuator and bracket from the cam.
6. Actuator to bracket nuts. + + Remove or Disconnect
7. Actuator from the bracket (53).
2. Radio. Refer to RADIO (SEC. 9A).
1. Actuator to the bracket (53). 3. Instrument panel bezel.
2. Bracket nuts. 4. Control from the dash.
3. Actuator and bracket to the cam (211).
Lower the control to gain access to the
4. Cam to the actuator arm screw.
control assembly.
5. Actuator bracket mounting screws.
6. Valve return spring at the actuator end (216).
7. Vacuum hose to the actuator. Im portant
Do not kink the cable.

PLENUM VALVE REPLACEMENT 5. Cable.
|+*| Remove or Disconnect (Figure 37) 6. Vacuum harness.

7. Electrical harness.
1. Raise the hood.
8. Control.
2. Cowl plastic grille.
3. Three cowl to valve assembly screws.
Valve assembly from the vehicle. Install or Connect
4. Actuator arm pushnut.
1. Blower switches to the new control.
5. Actuator to valve nuts.
Separate the valve and actuator. 2. Electrical harness.
3. Vacuum harness.
4. Cable.
1. Actuator to valve nuts. 5. Control to the dash.
2. Actuator arm push nut (53).
3. Valve assembly to the vehicle.
4. Cowl plastic grille. 7. Radio. Refer to RADIO (SEC. 9A).
5. Close the hood. 8. Battery ground cable.
TEMPERATURE DOOR
CABLE ADJUSTMENT
A djust (Figure 38)
1. Remove instrument panel compartment and door.

2. Loosen the cable attaching screw at the selector
duct assembly.
Make sure the cable is installed in the
bracket on the selelctor duct assembly.
3. Place the temperature lever in full COLD position
and hold while tightening the cable attaching
screw.
4. Install instrument panel compartment and door.
BLOWER SWITCH
REPLACEMENT
The blower switch is located on the rear of the
control assembly.
+ + Remove or Disconnect (Figure 39)

3. Control to instrument panel screws.
Reset the control on top of the radio. +4* Install or Connect (Figure 40)
4. Switch to control screws.
5. Electrical harness. 1. Tank (251).
6. Vacuum harness at the master switch. 2. Vacuum lines.
7. Switch assembly (235).
VACUUM LINES
+- install or Connect (Figure 39)
ENGINE COMPARTMENT
1. Switch. For vacuum line routing refer to figures 40-43.
2. Vacuum harness. 1. L6 Engine (4.8 Liter) (figure 40).
3. Electrical harness. 2. V6 Engine (4.3 Liter) (figure 41).
4. Switch to control screws. 3. V8 Engines (5.0, 5.7 and 7.4 Liter) (figure 42).
4. V8 Engine (6.2 Liter, Diesel) (figure 43).
5. Control to the instrument panel.
7. Battery ground cable. VACUUM LINE
HARNESS - DASH
VACUUM TANK REPLACEMENT Figure 44 presents the dash vacuum harness and
activator installation.
The vacuum tank is mounted to the cowl behind the
left front fender.
REFRIGERANT-12
Remove or Disconnect (Figure 40) HOSE ROUTING
For Refrigerant-12 hose assemblies, refer to fiqures
1. Vacuum lines at the tank. 45-49.
2. Tank to dash panel screws. 1. L6 Engine (4.8 Liter) (figure 45).
3. Tank (251). 2. V6 Engine (4.3 Liter) (figure 46).
Pi
C36 And C60
7. Vacuum Hose C36, C60 And K34

260. Rear Heater Harness
261. K34 Vacuum Harness C36 Or C60 F-00353
Figure 43C-K Vacuum Hose - Diesel Engine

7. Vacuum Harness 266. Plenum Valve (Actuator)

53. Actuator 267. Recirc A ir Valve (Actuator)
E. Vacuum LineGray To Source 236. Cable 268. Heater Assembly
F. Vacuum LineOrange 244. Cam 269. A ir Cond. Valve (Actuator)
G. Vacuum LineStripe 265. Control Assembly 270. Defrost (Actuator)
H. Vacuum Line Dark Blue
I. Vacuum LineTan F-00234
Figure 44C-K Vacuum Control Hose - Dash
3 V8 Engines (5.0 and 5.7 Liter) (figure 47).
4. V8 Engine (7.4 Liter) (figure 48).
5. V8 Engine (6.2 Liter) (figure 49).
BLOWER MOTOR
The blower motor resistor is located in the blower
side of the blower-evaporator case.
1. Wiring harness at the resistor.
2. Resistor to case attaching screws.
70. Condenser 3. Resistor (81).

97. Refrigerant Hose
107. Evaporator And Blower Assembly
|-<-| install or Connect (Figure 33)
275. Compressor
276. Radiator
1. Resistor (81).
F-00280
2. Screws.
Figure 45C-K L6 (4.8 Liter) Refrigerant
Hose Assembly 3. Wiring harness.
Figure 47C-K V8 (5.0 Liter and 5.7 Liter) Refrigerant Hose Assembly
Figure 49C-K V8 (6.2 Liter - Diesel) Refrigerant Hose Assembly

BLOWER MOTOR RELAY Install or Connect (Figure 31)
REPLACEMENT 1. Relay (105).

2. Mounting screws.
The blower motor relay is located on the blower side 3. Wiring harness.
of the blower-evaporator case.
Remove or Disconnect (Figure 31) FUSE REPLACEMENT

1. Wiring harness at the relay. A 25-amp fuse, located in the junction block, projects
2. Attaching screws. the system except for the blower circuit. The fuse for
3. Relay (105). the blower circuit is located in the electrical wiring
between the junction block and the blower relay.
REAR INTERIOR ROOF MOUNTED SYSTEM SUBURBAN
The rear interior roof mounted system is used with 3. Blower motor ground strap.
the front air conditioning system.
5. Lower to upper blower-evaporator case screws.
REAR DUCT
6. Case and motor assembly (326) (336).
REPLACEMENT
This duct covers the blower-evaporator assembly Im portant
located at the rear of the vehicle. It has four adjustable
air outlets (figure 50). Before removing the case screws, support
the lower case to prevent damage to the
Remove or Disconnect (Figure 50) case or motor assembly.
1. Drain tube from the rear duct. 7. Motor retaining strap.

2. Screws securing the duct to the roof panel and 8. Motor and wheels (330).
rear header brackets.
3. Duct (303). 9. Wheel from the motor shaft.
-4- Install or Connect (Figure 50) Install or Connect (Figures 50 and 51)

1. Duct (303). 1. Wheels to the motor shaft (330).
2. Screws and brackets.
Place the tension springs on the wheel
3. Drain tube.
hubs.
2. Motor and wheels to the case.
BLOWER MOTOR RESISTOR
Align the wheels to prevent contact with the
REPLACEMENT case.
The blower motor resistor is located on the cover 3. Motor retaining strap and foam.
side of the blower-evaporator. To remove, refer to
Blower Motor Resistor, CCOT A/C System (C-K 4. Lower case and blower motor assembly in the
Series). vehicle (336).
5. Lower to upper case screws.
BLOWER MOTOR ASSEMBLY Turn the blower wheels to prevent rubbing
REPLACEMENT against the case.
6. Center ground strap.
I++I Remove or Disconnect (Figures 50 and 51) 7. Blower lead wire.
8. Rear duct.
2. Rear duct (303). 9. Battery ground cable.
303
301. Washer 306. Deflector

302. Screw 307. Outlet
303. Shroud 308. Bracket
304. Screw 309. Nut
305. Clip 310. Screw
F-00224
Figure 50C-K Rear Interior Roof Mounted A/C Shroud
EXPANSION VALVE Im portant
REPLACEMENT Before removing the case screws, support

the lower case and motor assemblies to
This system incorporates an expansion valve which prevent damage to the case or motor
does not utilize and external equalizer line. assembly.
7. Lower case and motor assembly (336).
8. Expansion valve sensing bulb clamps.
9. Valve inlet and outlet lines.
Cap or plug open lines.
10. Expansion valve assembly (342).
Install or Connect (Figure 51).
0
3. Rear duct.
1. New expansion valve assembly (342).
4. Blower motor lead. Remove caps or plug.
Use new seals (o-rings) coated with clean
5. Ground wire. refrigeration oil.
2. Sensing bulb.
6. Lower to upper blower-evaporator case screws. 3. Lower case and blower motor assembly.
320. Screw 333. Bracket

321. Bracket 334. Screw
322. Screw 335. Seal
323. Screw 336. Case
324. Support 337. Clip
326. Case 339. Core Asm.
327. Plate 340. Seal (O-ring)
328. Screw 341. Refrigerant Lines
329. Seal 342. Valve Asm.
330. Motor Asm. 343. Screw
331. Eyelet 344. Clamps
332. Terminal
F-00602
Figure 51C-K Rear Interior Roof Mounted A/C Evaporator and Blower Component View
365
364
366. Clip
351. Fittings 356. Bracket 361. Hose Assembly 367. Clip
352. Clip 357. Screw 362. Seal 368. Screw
353. Screw 358. Clamp 363. Screw 369. Hose Assembly
354. Cover 359. Hose 364. O-ring 370. Hose Assembly
355. Nut 360. Strap 365. O-ring 371. Clip
B-06946
Figure 52C-K Rear Interior Roof Mounted A/C Hoses and Cover Component View
4. Blower motor lead. Cap or plug the open connections.

5. Ground wires. 7. Blower-evaporator support to roof rail screws.
6. Rear duct. 8. Blower-evaporator (339).
7. Battery ground cable. Place the blower-evaporator upside down
8. Evacuate, charge and check the system. on a work bench.
9. Lower case assembly.
10. Upper case from the evaporator core.
EVAPORATOR CORE 11. Expansion valve inlet and outlet lines.
REPLACEMENT Cap or plug open connections.
12. E xp a n sio n valve c a p illa ry bulb from the
evaporator oulet line.
Remove or Disconnect (Figures 51 and 52) 13. Valve.
14. Plastic pins that hold the screen to the core.
1. Battery ground cable. 15. Screen.
3. Rear duct. +- Install or Connect (Figures 51 and 52)
4. Blower motor lead.
5. Ground wire. 1. Wire screen to the front of the core.
6. R e frig e ra n t lin e s at the rear of the 2. Plastic pins.
blower-evaporator assembly (351). 3. Expansion valve inlet and outlet lines (341).
Use new seals (o-rings) coated with clean -- Remove or Disconnect

rerfrigeration oil.
4. Sensing bulb to the evaporator outlet line (342). Battery ground cable.
Bulb must make good contact with the line. Switch retaining screws.
Add 30 ml (3 ounces) of clean refrigeration Wiring harness.
oil to new core. Switch.
5. Upper case and supports to the core.
6. Lower core case and blower assembly. + 4- Install or Connect
7. Blower-evaporator assembly to the roof.
8. Support to roof rail screws. 1. Switch.
9. Refrigerant lines to the blower-evaporator unit. 2. Wiring harness.
Use new se als (o -rin g s ) w ith clean 3. Switch retaining screws.
refrigeration oil. 4. Battery ground cable.
10. Blower lead wire.
11. Ground wire.
12. Rear duct. FUSE REPLACEMENT
14. Evacuate, charge and check the system. A-25 amp fuse at the junction box protects this
system. A 20-amp fuse, located between the junction
block and the rear blower motor switch, protects the
BLOWER MOTOR SWITCH rear blower high speed circuit.
REPLACEMENT
The three-speed (LO-MED-HI) blower motor switch is
located in the instrument panel to the left of the ash
tray.
CCOT A/C SYSTEM G SERIES
CONDENSER REPLACEMENT 5. Condenser inlet and outlet lines at the condenser

(70).
Remove or Disconnect (Figure 53) 6. Grille, hood lock and center hood lock support.
7. Refrigerant.
2. Purge the system of refrigerant. 8. Evacuate, charge and test the system.
3. Grille, hood lock, and center hood lock support.
4. Condenser inlet and outlet lines at the condenser
(70). ACCUMULATOR
5. Screws attaching the left side condenser bracket
to the radiator.
REPLACEMENT
6. Screws attaching the right side condenser
Remove or Disconnect (Figure 53 and 54)
bracket to the condenser.
7. Condenser.
8. Left bracket from the condenser.
2. Compressor clutch cable.
Install or Connect (Figure 53) 3. Discharge the system.
1. Left bracket to condenser. 4. Inlet and outlet lines.

2. Condenser (70).
Add 30 ml (1 ounce) of clean refrigeration oil Important
to a new condenser.
3. Screws attaching the left side of the condenser Cap or plug open connections.
bracket to the condenser.
5. Bracket screws.
4. Screws attaching the right side of the condenser
bracket to the condenser. 6. Accumulator.
^ = a r=
416
70. Condenser Assembly

401. Material (Trim)
402. Hose Assembly 411. Screw
403. Clip 413. Nut
404. Screw 414. Grommet 407
405. Fitting Assembly 415. Strap
406. Fitting Assembly 416. Screw
407. Seal (O-ring) 417. Hose
409. Hose Assembly 418. Compressor F-00086
Figure 53G Condenser and Related Parts Component View
Im portant HEATER CORE

Drain excess refrigerant oil into a clean REPLACEMENT
container. Measure and record amount. Use
fresh oil.
+ Remove or Disconnect (Figure 54)
Install or Connect (Figure 53 and 54)

2. Engine cover.
1. New accumulator.
3. Steering column to instrument panel.
Lower column.
Im portant
4. Upper and lower instrument pane! attaching
screws and radio support bracket attaching
Add 30 ml (1 ounce) of clean refrigerant oil
screw.
PLUS an amount equal to that drained.
5. Raise and support right side of the instrument
2. Bracket screws.
panel.
3. Inlet and outlet lines. 6. Right lower instrument panel support bracket.
4. Compressor clutch connector. 7. Recirculating air door vacuum actuator.
5. Battery ground cable. 8. Temperature cable and vacuum hoses at the
6. Evacuate, charge and check the system. distributor case.
456. Valve Assembly

457. Core
458. Clamp
459. Valve
460. Shaft
461. Connector
462. Link
463. Connector
464. Shaft
465. Valve Assem bly
466. Valve Assembly
467. Case
468. Duct
470. Housing
471. Retainer
472. Duct
473. Seal
474. Valve
475. Shaft Assembly
Nut
Actuator Assembly
Case
Valve
Nut
Fan Assembly
Washer
Terminal
Motor Assembly
Tube
Accum ulator
Dehydrator ^
Assembly
Clamp rjy
Clamp i
Clamp
Case ll> ^
Assembly 4 5 5'
Case
Seal
Seal
Clamp
E vaporator***^
Assembly
Seal
Filter
Retainer
Switch Assembly
Case
O rifice
Gasket 46
Gasket
Bracket
Gasket
Stud
F-00094
Figure 54G A/C Heater and Evaporator-Blower Component View

Figure 55G Blower Motor Cover (Diesel)
9. Heater distributor duct. 17. Heater core (457).

10. Defroster duct to dash panel attaching screws
(below the windshield). Install or Connect (Figure 54)
11. Heater hoses (457).
Plug to prevent spillage. 1. New heater core.
12. Three nuts from the bolts that hold the heater 2. Screws and case.
core case to the dash panel and one screw at the
lower right corner (inside). 3. Temperature cable support bracket.
13. Distributor assembly from the vehicle. 4. Gasket.
14. Gasket to expose the screws attaching the case 5. Distributor assembly.
sections together.
6. Heater core nuts to bolts.
15. Temperature cable support bracket.
16. Case attaching screws and separate the case. 7. Heater hoses.
8. Defroster duct to dash panel screws.
9. Heater distributor duct.
10. Temperature cable and vacuum hoses at the
distributor.
11. Right lower instrument panel support bracket.
12. Right side of the instrument panel.
13. Upper and lower instrument panel screws.
14. Radio support bracket screw.
^ 4 9 0 . Instrument Panel 492
15. Steering column to instrument panel attaching
491. Control
F-00332 bolts and raise the column.
492. Screw
^ ...
16. Engine cover.
Figure 56Control Assembly - A/C and Heater 17. Battery ground cable.

495. Defroster Duct
496. Temperature Cable
497. Heater And Defroster
Assembly
498. Bracket
499. Retainer
F-00324
Figure 57Temperature Control Cable
I s * * '
K. Orange Double Black
Stripe Wire
495. Defroster Duct
501. Body Wiring Harness
502. A/C Wiring Harness
503. Blower Motor Switch
504. Instrument Panel Harness
505. Ignition
F-00348
Figure 58Instrument Panel Wiring Harness

Figure 59Vacuum Harness Assembly
ORIFICE (EXPANSION TUBE) 3. Expansion tube from the evaporator core inlet
line.
REPLACEMENT
Use a needle nose pliers to remove the
The orifice tube is located in the evaporator core orifice from the tube.
inlet line. 4. Expansion tube seal (o-ring) frim the core inlet
line.
0
a Install or Connect (Figure 4)
1. Expansion tube seal (o-ring) to the core inlet line.
2. C o n de n ser to the e vap o ra to r line at the
Use a new seal (o-ring) coated with clean
evaporator inlet.
refrigeration oil.
Cap or plug the open line.
Insert the short screen end of the orifice into
the evaporator inlet line.
491. Control 2. Expansion tube to the evaporator core inlet line.
Assembly 3. C o n de n ser to the e vap o ra to r lin e at the
493. Blower Motor evaporator inlet.
Switch 4. Evacuate, charge and check the system.
BLOWER MOTOR INSULATION

(W/DIESEL) REPLACEMENT
The 6.2 Liter Diesel Engine has extra insulation
around the blower motor on vehicles without air
conditioning and around the blower motor and
Figure 60Blower Switch evaporator core with air conditioning option (figure 55).
433 497 435 502. A/C Harness

418. Compressor 510. Resistor Assembly
433. Motor 511. Relay Assembly
435. Accumulator/Dehydrator Assembly 512. Junction Block
497. Evaporator Blower Motor Assembly 513. Throttle Solenoid
F-00327
Figure 61A/C W iring - Engine Compartment
Remove or Disconnect (Figure 55) im portant
1. Parking lamp assembly. When removing A/C components, cap the

2. Radiator overflow tank. lin e s and o p e n in g s to p re ve n t
contamination.
3. Blower motor insulation (481).
5. Low pressure vapor line and move it out of the
Insulation through the hood opening. way.
4. Blower motor (482). 6. Accumulator.
7. High pressure line inlet to the evaporator and the
4- Install or Connect (Figure 55) connecting bracket.
8. Wiring harness going to the blower motor relay
1. Blower motor (482). and resistor.
9. Blower motor relay and resistor.
2. Insulation (481).
10. Fan shroud upper half.
3. Radiator overflow tank. 11. Radiator.
4. Parking lamp assembly. 12. Heater valve assembly bracket and move it out of
the way.
13. Upper screws of the lower section.
EVAPORATOR CORE Push it down and out of the way.
(W/DIESEL) REPLACEMENT 14. Insulation mounting screws.
15. Insulation through the hood opening.
Remove or Disconnect (Figures 54 and 55) 16. Proceed with the A/C evaporator procedure.
+ 4- Install or Connect (Figures 54 and 55)

1. Cold air intake.
2. Hood latch assembly and cable retainer a. id
1. A/C evaporator core procedure.
place it out of the way.
3. Windshield solvent tank. 3. Insulation mounting screws.
4. Discharge the A/C system. 4. Lower section.
525. Duct Assembly 531. Screw 537. Heater Assembly 543. Seal
526. Screw 532. Seal 538. Support 544. Duct
527. Duct Assembly 533. O utlet Assembly 539. Outlet Assembly 545. Nut
528. Washer 534. Gasket 540. Screw 546. Duct
529. Deflector Assembly 535. Gasket 541. Nut 547. Duct
530. Bezel 536. Duct 542. Inlet Assembly 548. Duct
F-00279
Figure 62A/C O utlets and Ducts
5. Heater valve assembly bracket. 9. Wiring harness.

6. Radiator. 10. High pressure line inlet and bracket.
11. Accumulator.
7. Fan shroud upper half.
12. Low pressure vapor line.
8. Blower motor relay and resistor. 13. Charge the A/C system.
14. Windshield solvent tank.
15. Hood latch assembly and cable retainer.
16. Cold air intake.
EVAPORATOR CORE
REPLACEMENT
550. Vacuum Tank
551. Hood Assembly 1. Battery ground cable.
552. Vacuum Line 2. Purge the system of refrigerant.
F-00356
3. Coolant recovery tank and bracket.
4. E le ctrica l connectors from the core case
Figure 63Vacuum Tank Location assembly.
Vacuum
Hood
Vacuum Line
Vacuum Fitting
Cap
F-00328
Figure 64G - V6 (4.3 Liter) Vacuum Tank Assembly
5. Bracket at the evaporator case. 6. Accumulator inlet and outlet lines.

6. Right marker lamp for access. 7. Two brackets that hold the accumulator to the
7. Accumulator inlet and outlet lines, and the two case.
brackets that attach the accumulator to the case. 8. Right marker lamp.
8. Evaporator inlet line. 9. Bracket to the evaporator case.
9. Three (3) nuts and one (1) screw attaching 10. Electrical connectors.
module to the dash panel. 11. Coolant recovery tank and bracket.
10. Core case assembly from the vehicle. 12. Evacuate, charge and check the system.
11. Screws and separate the case sections. 13. Battery ground cable.
12. Evaporator core.
4- Install or Connect (Figure 54) BLOWER MOTOR

REPLACEMENT
1. New core.
Add 90 ml (3 ounces) or 525 viscosity
refrigeration oil to a new condenser. Remove or Disconnect (Figure 54)
2. Screws and the case sections.
3. Core case assembly to the vehicle. 1. Battery ground cable.
4. Module to the dash panel. 2. Coolant recovery tank.
5. Evaporator inlet line. 3. Power antenna.
4. Blower motor lead wire. 4. Instrument panel bezel.

5. Motor and wheel assembly (433). 5. Headlmap switch control knob.
Five blower motor mounting screws. 6. Battery ground cable.
Pry gently on the blower flange if the sealer
acts as an adhesive.
6. Blower wheel to motor shaft nut. TEMPERATURE DOOR
7. Separate the wheel and motor assemblies. CABLE ADJUSTMENT
Install or Connect (figure 54) J P Adjust (Figure 57)
1. Wheel to the blower motor. 1. Remove instrument panel compartment and door.
Assemble the blower wheel to the motor 2. Loosen the cable attaching screw at the selector
with the open end of the wheel away from duct assembly.
the blower motor.
Make sure the cable is installed in the
2. Blower wheel to the motor shaft nut. bracket on the selector duct assembly.
3. Blower wheel and motor assembly to the vehicle.
3. Place the temperature lever in full HOT position
If the motor mounting flange sealer has
and hold while tightening the cable attaching
hardened or is not intact, remove the old screw.
sealer and apply a bead of sealer to the
4. Install instrument panel compartment and door.
mounting flange.
Check blower operations: blower wheel
should rotate with no interference.
BLOWER SWITCH
4. Blower motor lead wire. REPLACEMENT
5. Coolant recovery tank and power antenna.
6. Battery ground cable. Remove or Disconnect (Figure 60)

CONTROL ASSEMBLY 2. Left-foot cooler outlet assembly at the instrument
REPLACEMENT panel attachment.
Remove or Disconnect (Figures 56, 57, 58 and 4. Mounting screws.
59) 5. Control assembly (491).
6. Switch (493).
2. Headlamp switch control knob. Install or Connect (Figure 60)
4. Control. 1. New switch.
Screws. Mounting screws.
Temperature cable eyelet clip and retainer 2. Electrical harness.
(499). 3. Control Assembly (491).
Control lower right mounting tab through 4. Left-foot cooler outlet assembly.
dash opening. 5. Battery ground cable.
Upper tab.
Lower right tab.
5. Electrical harness. RESISTOR REPLACEMENT
6. Vacuum harness (506).
7. Control assembly.
Install or Connect (Figures 56, 57, 58 and 59)
1. Electrical and vacuum connection to the control. 2. Resistor mounting screws.
2. Control into the opening in the dash panel. 3. Resistor (510).
3. Temperature cable.
-4- install or Connect (Figure 61)
Adjust
1. Resistor (510).
Temperature door operation. Refer to Screws.
Temperature Door Cable Adjustment. 2. Electrical harness.
502. A/C Wiring Harness

550. Vacuum Tank
552. Vacuum Line
552 ^ __ -
C36 And C60
502
Figure 65G - V8 (5.0 and 5.7 Liter) Vacuum Tank
BLOWER MOTOR RELAY Pull the right side of the instrument panel
rearward.
REPLACEMENT 7. Duct (distributor) attaching screws.
8. Center deflector (527).
+- Install or Connect (Figure 62)
2. Relay mounting screw. 1. Center deflector (527).
3. Relay (511). 2. Instrument panel.
3. Radio support bracket.
Install or Connect (Figure 61) 4. Steering column.
5. Engine cover.
1. Relay (511). 6. Battery ground cable.
Screws.
DEFROSTER DUCT
A/C DUCT WORK REPLACEMENT
REPLACEMENT To remove the defroster duct mounting, refer to
figure 64.
|+ + | Remove or Disconnect (Figure 62)
1. Battery ground cable. TEMPERATURE DOOR

2. Engine cover.
CABLE REPLACEMENT
3. S tee rin g colum n to the in stru m e n t panel
attaching screws. To remove the temperature door cable, refer to
4. Radio support bracket screw. Control Assembly Replacement and figure 57.
VACUUM TANK REPLACMENT VACUUM LINES

ENGINE COMPARTMENT
For vacuum line assemblies, refer to figures:
1. Raise the hood. 1. L6 Engine (4.6 Liter) (figure 64).
2. Vacuum harness at the tank (552). 2. V6 - V8 Engine (4.3, 5.0 and 5.7 Liter) (figure 65).
3. Tank attaching screws. 3. V8 Engine (6.2 Liter, Diesel) (figure 66).
4. Tank (551).
[-+[ Install or Connect (Figures 63 and 65) REFRIGERANT-12

1. Tank (551).
HOSE ROUTING
2. Vacuum harness.
For Refrigerant-12 hose assemblies refer to figures:
3. Lower the hood.
1. L6 Engine (4.8 Liter) (figure 67).
2. V8 Engine (5.0 and 5.7 Liters) (figure 68).
3. V8 Engine (6.2 Liter Diesel) (figure 69).
Figure 66G - V8 (6.2 Liter - Diesel) Vacuum Hose Assembly

70. Condenser
97. Refrigerant
Hose
107. Evaporator
and Blower
Assembly
275. Compressor
70
------ 276
276. Radiator F-00325
Figure 67-----L6 (4.8 Liter)

Refrigerant Hose Assembly
70. Condenser
107. Evaporator And Blower Assembly
275. Compressor
276. Radiator
F-00387
Figure 69G - V8 (6.2 Liter - Diesel)

Refrigerant Hose
70. Condenser
107. Evaporator and
Blower Assembl
275. Compressor
276. Radiator
F-00386
Figure 68G - V8 (5.0 and 5.7 Liter)

Refrigerant Hose Assembly
REAR INTERIOR ROOF MOUNTED SYSTEM G SERIES
This system is used in conjunction with the front

mounted air conditioning system, and is almost identi
cal to the C-K rear interior roof mounted system. For
servicing, refer to figure 70 for plumbing and figure 71
for unit component view.
401. Hose Assembly

107. Evaporator and Blower Assembly
565. Rear Evaporator and Blower Assembly
566. Hose Drain
567. Hose Outlet
568. Hose Inlet
569. Hose and Plate
Assembly
F-00283
Figure 70G Rear Interior Roof Mounted A/C Hoses and Drain Component View
575. Screw
576. Screw
577. Washer
578. Pad
579. Screw
580. Shroud
581. Deflector Assembly
582. Clip
583. Screw
584. Seal
585. Evaporator Assembly
586. Support
F-00282
Figure 71G Rear Interior Roof Mounted A/C Evaporator Mounting and Shroud
CCOT A/C SYSTEM P SERIES
F-00369
Figure 72P Truck Condenser Installation Figure 73P Truck Compressor Installation
V8 (5.7 Liter) Engine
The compressor and condenser are installed on the

vehicle during assembly. They are removed and
shipped separately.
For reference refer to the following figures:
1. Condenser Mounting - refer to figure 72.
2. Compressor Installation - refer to figure 73.
DASH MOUNTED SYSTEM MOTOR HOME CHASSIS
This system is installed on the vehicle and checked 70. Condenser /r < r
at assembly. The blower-evaporator is then discon 276. Radiator
nected and shipped with the chassis unit to the body 277. Bracket
supplier. For this reason, it will only be possible to give
basic replacement procedures on some components.
CONDENSER REPLACEMENT
I++I Remove or Disconnect (Figure 74)

3. Condenser inlet and outlet lines.

Cap or plug all open connections.
Figure 74Condenser
4. Condenser to radiator support screws.
5. Condenser (70).
900. Retainer
901. Washer
902. Glass
903. Seal
F-00397
Figure 76Sight Glass Replacement
|+ + | Install or Connect (Figure 75)
1. Bracket and receiver-dehydrator.

2. Screws.
3. Inlet and outlet lines at the receiver-dehydrator.
re frig e ra tio n oil when c o n n e c tin g all
refrigerant lines.
0 Install or Connect (Figure 74) 4. Evacuate, charge and check the system.
1. Condenser.
2. Screws. SIGHT GLASS
3. Condenser inlet and outlet lines. REPLACEMENT
Add 30 ml (1 ounce) of clean refrigeration oil
to new condenser. If the sight glass is damaged, install a new sight
glass kit. The kit contains the sight glass, seal and
retainer.
refrigeration oil when connecting refrigerant
lines.
4. Evacuate, charge and check the system. |+ + | Remove or Disconnect (Figure 76)
1. Purge the system.

RECEIVER-DEHYDRATOR 2. Sight glass retainer nut using a screwdriver (900).
REPLACEMENT 3. Old glass and seal (o-ring) (902 and 903).
|+ + | Remove or Disconnect (Figure 75) - Install or Connect (Figure 76)
1. Battery ground cable. 1. New glass and seal and retainer nut.

9 Important
3. Inlet and outlet lines at the receiver-dehydrator.
Cap or plug the open lines. Do not turn the nut past the face of the
4. Receiver-dehydrator bracket attaching screws. housing. This may damage the seal (o-ring).
5. Bracket and receiver-dehydrator (65). 2. Evacuate, charge and check the system.
Hose Assem blies P. Correct Blower Blade Angle F-0040Q

Evaporator Assembly
Motor Blower Assembly Figure 79Blower Assembly
A/C W iring Harness
F-00398 10. Unit mounting bolts.
11. Unit from the vehicle carefully pulling the
Figure 77Blower - Evaporator Assembly compressor electrical lead through the dash.
-*- Install or Connect (Figures 77 and 78)

BLOWER-EVAPORATOR
ASSEMBLY REPLACEMENT 1. Unit to the vehicle.
2. Mounting bolts.
3. Electrical lead to the connector.
4. Wire from grommet through the slit.
5. Screws that secure the grommet retainer to the
dash.
2. Purge system of refrigerant.
6. Terminal.
3. Inlet and outlet refrigerant lines.
7. Ground wire.
Cap or plug all open connections (401).
8. Electrical connector from the compressor.
4. Drain tube from evaporator case.
5. Electrical connector from the compressor. 9. Drain tube.
6. Terminal (910). 10. Refrigerant lines.
Allow connector to hang on the ground wire. 11. Battery ground cable.
7. Screws securing the grommet retainer to the 12. Evacuate, charge and check the system.
dash panel.
8. Wire from the grommet through the slit.
9. Electrical lead at the connector.
BLOWER ASSEMBLY
REPLACEMENT
1. Cover plate.
Separate the upper and lower case halves.
2. Blower motor mounting strap screw.
3. Blower assembly.
4. Wheels from the motor shaft.
(Narrow Blade) 913. Tang
911. Terminal 914. Groove Install or Connect (Figure 79)
A. Insert screwdriver in groove and press tang
1. Wheels to the motor shaft.
toward terminal to release.
B. Pry tang back out to insure locking when Place the wheels with the lower blades
curved toward the dash panel side of the
reinstalled into connector. F-00399
unit when the motor is placed in the case
(P).
Figure 78Terminal Removal 2. Mounting strap.
920 924
922 923
920. Thermostatic Switch Capillary Tube
922. Bumper
923. Blower Switch
922 923 924. Thermostatic Switch F-00411
920. Thermostatic Switch 922. Bumper
Capillary Tube 923. Expansion Valve Figure 81Therm ostatic and Blower Switches
921. Screen Mesh p 0041Q
THERMOSTATIC AND/OR
BLOWER SWITCHES
Figure 80Therm ostatic and Blower Switches
REPLACEMENT
Place the motor in the bracket with the
electrical connector side of the motor to the
right side of the bracket.
Align the blower wheels so they do not
1. Cover plate assembly from the evaporator case.
touch the case.
2. Switch (923 or 924).
3. Assemble the case halves and attach the cover
plate.
1. Switch (923 or 924).

EXPANSION VALVE, Place the sensing capillary in the same
EVAPORATOR AND/OR position before it was removed.
EVAPORATOR CASE 2. Cover plate.
REPLACEMENT
BLOWER MOTOR
Remove or Disconnect (Figure 80) RESISTOR REPLACEMENT
1. Cover plate. The resistor is located on the top of the unit. Remove
Separate the upper and lower case halves. the unit to replace.
2. Inlet and outlet lines from the expansion valve
(923).
FUSE REPLACEMENT
3. Sensing bulb from the evaporator outlet manifold.
Cap or plug open connections. This unit does not have an in-line fuse. The lead wire
5. Core. is connected to the heater wiring harness and operates
6. Blower motor and harness assembly. off the 20 amp heater fuse.
1. Blower motor and harness assembly.

2. Core.
3. Expansion valve (923).
4. Sensing bulb.
5. Inlet and outlet lines.
refrigeration oil when connecting lines.
Add 90 ml (3 ounces) of new refrigeration oil
to a new core.
SPECIFICATIONS
A-6 COMPRESSOR
Type............................................................................................................................................................. .6 Cylinder Axial

Displacement.......................................................................................................................................................12.6 Cu. In.
Rotation................................................................................................................................................................... Clockwise
SYSTEM CAPACITIES
R efrigerant................................................................................................................... 1 587 6 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O i l ............ ..................................................................................... 330 ml (11 ounces)
TORQUE SPECIFICATIONS
Compressor Suction and Discharge Connector B o lt .....................................................................24 N m (18 ft. Ib.s)
Oil Drain Screw ....................................................................................................................................17 N m (13 ft. lbs.)
Cycling Pressure S w itc h ................................................................................................................... 10 N m (7.5 ft. lbs.)
All Compressor Mounting B olts........................................................................................................ 34 N m (25 ft. lbs.)
DA-6 COMPRESSOR
Type............................................................................................................................................................... 6 Cylinder Axial

Displacement.......................................................................................................................................................10.0 Cu. In.
SYSTEM CAPACITIES
Refrigerant....................................................................................................................... 1 587 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O il.................................................................................................... 240 ml (8 ounces)
Compressor Suction and Discharge Connector B o lt.....................................................................24 N m (18 ft. lbs.)
Shaft N u t.............................................................................................................................................. 16 N m (12 ft. lbs.)
Cycling Pressure Switch . ...............................................................................................................10 N m (7.5 ft. lbs.)
Front Compressor Mounting Bolts.................................................................................................... 43 N m (32 ft. lbs.)
Rear Compressor Mounting B olts....................................................................... .............................30 N m (22 ft. lbs.)
R-4 COMPRESSOR
Type.............................................................................................................................................................4 Cylinder Radial

Displacem ent...................................................................................................................................................... 10.0 Cu. In.
SYSTEM CAPACITIES
R efrigerant................................................................................................................... 1 587 6 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O i l .................................................................................................. 330 ml (11 ounces)
Compressor Suction and Discharge Connector B o lt .....................................................................24 N m (18 ft. Ib.s)
Oil Drain Screw....................................................................................................................................17 N m (13 ft. lbs.)
Cycling Pressure S w itc h ................................................................................................................... 10 N m (7.5 ft. lbs.)
All Compressor Mounting B olts........................................................................................................ 34 N m (25 ft. lbs.)
SPECIFICATIONS (CONT.)
Amps RPM
Volts (Cold) (Cold)
Blower Motor
C-K All Weather 12.0 12.8 Maximum 3400 Minimum
C-K-G Rear Interior Roof Mounted
G Floor and Motor Home Units 12.0 13.7 Maximum 3400 Minimum
Compressor Clutch Coil

Ohms (at 80 F ) ............................................................................................................................................................... 3.70
Amps (at 80 F ).............................................................................................................................................3.33 @ 12 Volts
Belt Tension.............................................................................................................................................See Tune-Up Chart

Fuse Block
C-K System s......................................................................................................................................................... 25 Amps
Motor Home Chassis U n it .................................................................................................................................. 20 Amps
In Line
C-K System s............................................................................................ <>.......................................................... 25 Amps
Motor Home Chassis U n it........................................................................................................................................ None
Circuit Breaker
G Systems............................................................................................................................................................. 45 Amps
SPECIAL TOOL LIST
J-5420...........................................................................................................................................Across Valve Quick Fitting

J-5725-04 .........................................................................................................................................Mainifold and Gage Set
J-6084............................................................................................................................................................... Leak Detector
J-6271-01 ..........................................................................................................................Refrigerant Can Taps-AII Valve
J-6272-02 .................................................................................................................................. Multi-Can Dispensing Valve
J-9459 .........................................................................................................................................Access Valve Quick Fitting
J-23390 ..................................................................................................................... 12 Lb. Disposable Can Control Valve
J-23500-01 ..................................................................... Portable Air Conditioning Evacuation and Recharging Station
J-23600 ..................................................................................................................................................... Belt Tension Gage
2A-1
SECTION 2
FRAME AND CHASSIS SHEET METAL

CONTENTS
SUBJECT PAGE
F ra m e ............................................................................................................................................................................. 2A-1
B u m p e rs .........................................................................................................................................................................2B-1
Sheet M etal.....................................................................................................................................................................2C-1
SECTION 2A
FRAME
CONTENTS
SUBJECT PAGE
C/K And P Model F ra m e s ...........................................................................................................................................2A-1
D e s c rip tio n ................................................................................................................................................................ 2A-1
Diagnosis Of The F ra m e .............................................................................................................................................2A -2
Minim izing Frame S e rv ic e ...................................................................................................................................... 2A -3
Checking Frame A lig n m e n t.................................................................................................................................... 2A -4
Straightening Fram es............................................................................................................................................... 2A -5
Repairing C ra c k s ..................................................................................................................................................... 2A-5
W e ld in g .......................................................................................................................................................................2A -6
G Model U nderbody......................................................................................................................................................2A -7
D e s c rip tio n ................................................................................................................................................................ 2A -7
Underbody A lig n m e n t.............................................................................................................................................2A -7
C/K AND P MODEL FRAMES

DESCRIPTION 1. SECTION MODULUSThis is a measure of the
strength of a frame, based on height, width,
The models covered under this part of the section thickness and shape of the side rails. It does not
include C/K, and P. The service information for the G account for the strength of the material used in
model will be found in the underbody portion of this the frame.
section. 2. YIELD STRENGTHThis is a measure of the
Proper frame alignment is important to assure strength of the material from which the frame is
normal life and functioning of many other parts of the made. It is the maximum load [kPa (psi)] that can
vehicle. If the vehicle has been involved in a fire, be placed on a material and still have it return to
collision, or has been overloaded, there is cause to its original shape.
check the frame alignment. If, for any other reason, 3. RESISTANCE TO B EN D IN G M O M ENT
alignm ent is suspected it should be checked. A (RBM)This is a single measure of frame
procedure for this is described later in this section strength that accounts for both the section
under Checking Frame Alignment. modulus and the strength of the material used. (It
It is possible that certain conditions make the frame is the product of section modulus and yield
appear to be out of alignment when, in fact, it is not. strength.)
These conditions are also described under Checking 4. SAGThis refers to a frame or side rail that is
Frame Alignment. bent down from where it should be.
Terms used later in this section are briefly defined 5. BUCKLEThis refers to a frame or side rail that
below: is bent up from where it should be.
2A-2 FRAME
6. DIAMONDThis refers to the condition where 9. TRACKINGThis refers to the alignment of the
one entire frame rail is moved forward from, or to vehicle axles with each other. A misaligned frame
the rear of, its correct alignment with the other can cause improper tracking. If the vehicle is
rail. tracking correctly, all axles will be parallel to each
7. TWISTThis refers to the condition where the other and perpendicular to the center line of
entire frame has been twisted. One rail will frame.
basically slope up while the other rail will 10. WEBThe vertical part of a channel-type frame
basically slope down. ,vnc rail.
8. SIDESWAYThis refers to a side rail that is bent
to the side of where it should be.
DIAGNOSIS OF THE FRAME

Sag 1. Loads greater than the frame is de 1-7. Straighten and reinforce the frame as
signed to carry. described later in this section. See
2. Uneven load distribution. Straightening Frames and Rein
3. Abrupt changes in section modulus. forcements.
(For a brief definition of section modu
lus, see the Description at the begin
ning of this section.
4. Improper body, or accessory, mount
ing:
Holes drilled in the flange of the frame
rail.
Too many holes in the web section of
the rail.
Holes in the web section which are too
close to each other.
Four or more holes in the same vertical
line of the rail web.
Welds on the flange, p a rticu la rly
across the flange or along its edge.
Cutting holes in the rail with a torch.
Cutting notches anywhere on the rails.
5. A fire involving the vehicle.
6. A collision involving the vehicle.
7. The use of equipment for which the
frame has not been designed or rein
forced.
Buckle 1. The use of equipmient such as snow 1-4. Straighten and reinforce the frame as
plows for which the frame was not de described later in this section. See
signed. Straightening Frames and Rein
2. A collision involving the vehicle. forcements.
3. A fire involving the vehicle.
4. In addition to these causes, refer to
possible causes 3 and 4 under Sag.
These may contribute to Buckle.
FRAME 2A-3
DIAGNOSIS OF THE FRAME (CONT.)

Sidesway 1. A collision involving the vehicle. 1-4. Straighten and reinforce the frame as
2. A fire involving the vehicle. described later in this section. See
3. The use of equipment such as snow Straightening Frames and Rein
plows for which the frame was neither forcements.
designed nor properly reinforced.
4. In addition to these causes, refer to
possible causes 3 and 4 under Sag.
These may be contributing factors.
Diamond 1. A collision involving the vehicle. 1-2. Straighten and reinforce the frame as
2. Towing another vehicle with a chain at described later in this section. See
tached to one corner of the frame. Straightening Frames and Rein
forcements.
Twist 1. An accident or collision involving the 1-2. Straighten and reinforce the frame as
vehicle. described later in this section. See
2. Operating the vehicle in very rough ter Straightening Frames and Rein
rain. forcements.
Improper Tracking 1. Frame is out of alignment. 1. Straighten and reinforce the frame as
described later in this section.
2. Front or rear axle has shifted. 2. Realign and secure the axle.
3. Incorrect wheel alignment may make 3. Align the wheels. Refer to FRONT
the vehicle appear to be tracking incor END ALIGNMENT (SEC. 3A) of this
rectly. manual.
Cracks In The Web 1. Loose crossmember attaching bolts. 1. Replace, or weld and reinforce rail.
Of The Rails Ream bolt holes and replace with
larger bolts if necessary. Retighten
bolts.
2. Concentration of stress that may result 2. Replace, or weld and reinforce the
from many different factors. (See rail. See the appropriate heading,
Sag under Diagnosis previously later in this section.
described in this chart. Also see
M inim izing Frame Damage and
Reinforcements (later in this sec
tion.)
MINIMIZING FRAME SERVICE Take into account the forces that will be
placed on a frame from the operation of
Generally, frame service can be minimized or equipm ent such as snow plows when
eliminated by minimizing the concentration of stress in picking a fram e for a new vehicle or
small areas of the frame. reinforcing a frame.
2. Follow recommended practices when repairing a
1. Vehicles should be used only for those purposes frame or when mounting a body or equipment on
for which they were designed. a frame.
They should not be overloaded. Avoid sudden changes in the section
modulus.
They should be loaded evenly; localized
Do not drill holes in the frame rail flanges.
loads should be avoided.
Space holes in the web section of a rail at
Do not operate the vehicle on extremely least 13 mm (1/2 -inch) from one another.
rough terrain. Use existing holes whenever possible.
2A-4 FRAME
Figure 1C/K And P Model Frames
Do not cut holes with a torch. It is possible to check certain portions of frame
Do not overheat the frame rails. alignment without the proper gages. The procedure is
Avoid welding on the flanges. described later in this section.
Do not allow four or more holes to exist on Whether alignment is checked with or without gages,
the same vertical line of the web. the vehicle must be parked on a level section of floor.
Holes made in a reinforcement should be
Certain conditions call for preliminary checks before
placed a distance of at least two times the
actually checking the frame. Suspension or axle
material thickness from the edge of the
problems may make it appear that the vehicle frame is
reinforcement.
out of alignment. If an axle has shifted, Diamond or
Sidesway may appear to exist when, in fact, they do
CHECKING FRAME ALIGNMENT not. A weak spring may make the vehicle appear to
have a twisted frame.
The main parts of a frame are the side rails and A visual inspection of the top and bottom flanges of
crossmembers. The rails carry the load and the each rail may reveal the specific area where sag or
crossmembers stabilize the rails. buckle exists. In the case of sag, wrinkles may appear
Types of frame misalignment can be divided into five on the top of the upper flange; such wrinkles are
groups. The five groups are sag, buckle, diamond, definite evidence of sag. Wrinkles on the bottom of the
sidesways, and twist. For a brief definition of these lower flange are definite evidence of buckle
terms, refer to Description at the beginning of this
section. DETERMINING THE FRAME CENTERLINE (Figure 1)
A misaligned frame rail may have moved forward 1. Move the vehicle to a level, well-lighted section of
from, up or down from, or to the side of where it should the floor.
be. These possibilities must be checked.
2. Make a diagram of the frame on the floor beneath
The easiest way to check frame alignment is with
the vehicle as follows:
gages made for this purpose. Detailed instructions are
normally supplied with gages at the time of purchase. a. Using a plumb bob, transfer points 1, 2, 11,
Therefore, instructions for gage use are not given in 12 from the inside of the web to the floor.
this manual. Mark the points (figure 1).
FRAME 2A-5
b. Using a plumb bob, transfer the remaining determine the correct sequence of steps in the repair.
points from the outside of the web to the (See Possible Causes under Diagnosis and
floor. Mark the points. The actual placement Minimizing Frame Service previously outlined in this
of these points is not so important as is the section.) Corrective procedures should be set up to
fact that the points must be taken from the reverse the flow of the damaging forces. In many
same place on both the right and left frame instances, to reverse the flow of forces, pressure must
rail. be applied from different directions at the same time.
3. Move the vehicle away from the points on the Careful use of controlled heat is important. Too much
floor. or too little heat, or the improper application of heat, is
4. Measure the distance between points 1 and 2. a major source of trouble. Frame heating should be
This distance should be 704.85 mm (27.75-inch) done with a large sized tip (multi-hole heating tip) and
for the standard front axle, and 847.25 mm a neutral flame should be used (oxygen adjust opened
(33.75-inch) if equipped with a 5000# I-Beam just enough to remove the feathers or stringers from
Front Axle. the blue center at tip of torch). Heat the area that will
5. Measure the distance between points 11 and 12. be stretched as frame is straightened. Heat the area
This distance should be 847.25 mm (33.75-inch). AFTER S U F F IC IE N T PRESSUR E HAS BEEN
If both the measurements in steps 4 and 5 were EXERTED to cause a slight checking, or silvery cracks,
c o rre c t, c o n tin u e the p ro ce d u re . If the to appear on the surface of the metal. Gradually
m e a su re m e n ts are not c o rre c t, re fe r to increase the pressure while heating. Do not heat
H orizontal C h e ck step 2, and mark the beyond 606C (1200F). A red glow indicates that the
centerline through the intersection of two sets of m aterial is overheated. O verheating w ill cause
diagonals that have equal measurements. distortion and stretching, as well as a change in the
6. Make a mark on the floor exactly halfway characteristics of the metal.
between points 1 and 2. Make a similar mark
between points 11 and 12.
7. Use a chalk line to mark a line through the points. REPAIRING CRACKS
This is the centerline of the frame.
Two common types of cracks are shown in figure 2.
HORIZONTAL CHECK The straight crack will normally start from the edge of a
1. Measure the distance between the frame rails, flange. It will go across the flange and through the web
and the centerline at points 3-10. Each pair of section of a rail. Finally, it will continue through the
co rre sp o n d in g points should be an equal other flange. This type of crack may result from high
distance from the ce nte rlin e w ithin 3 mm concentrations of stress in small areas of the frame,
('/s-inch ). Example: Points 3 and 4 should excessive bending moment, and torsional loading.
measure equally from the centerline as should (See Minimizing Frame Service, previously outlined
points 5 and 6, 7 and 8, and points 9 and 10. in this section).
2. Measure diagonally from point 1 to point 6, and Sunburst crack(s) will radiate out from a hole in the
from point 2 to point 5. Mark the floor where the web section of a rail or crossmember. They are caused
diagonals pass the centerline. The diagonals by high loads being applied at a mounting bracket or
should measure the same distance within 5 mm crossm em ber which is not securely or properly
(3/ie-inch), and should cross at the centerline. If attached to the rail.
the frame is within specifications, the frame If cracks occur to both the rail and reinforcement at a
within these points is properly aligned. particular area of the frame, they must be repaired
3. Repeat step 2 on other pairs of diagonals until separately. The flanges must react independently to
the entire frame has been checked. Example: prevent localized stress concentration. Use a copper
Point 3 to point 10 and point 4 to point 9 or point 5 spacer between the flanges of cracked base rail
to point 12 and point 6 to point 11, etc. flanges and reinforcement flanges.
4. Refer to Straightening Frames to repair any
Crossmember mounting flange cracks may be
damage that is found.
repaired in the same manner as side rail cracks.
However, weld bead should be built up to provide a
STRAIGHTENING FRAMES good smooth radius. If a crossmember is greatly
damaged it should be replaced.
Frame straightening can be complicated and usually It may be necessary to align the frame and level the
requires special equipment. It should be attempted by rails before repairing the frame.
competent personnel only. 1. Remove any equipment that will interfere with
A complete analysis of the condition of the frame access to the crack.
should be made before any steps are taken to 2. Locate the extreme end of the crack and drill a 6
straighten it. Analyzing the cause of failure will help mm (0.25-inch) hole.
2A-6 FRAME
Over-welding can be harmful, especially if it is in an

area of the frame that receives high concentrations of
stress.
Small cracks in a crossmember may be welded (see
Repairing Cracks previously outlined in this section).
When welding:
1. Do not use oxyacetylene welding equipment.
2. W henever possible, use sm a lle r diam eter
electrodes and make several passes; this is
preferred to using a large diameter electrode and
making fewer passes.
3. Do not use more heat than is necessary to give
good penetration.
4. Do not run more passes than necessary.
5. Make sure the weld is free from craters and
undercuts.
6. Make sure sca le is rem oved from each
successive pass.
7. If repairing a crack, grind the surface of the weld
flush with the parent material.
8. When mounting accessories, do not weld across
13. Straight Crack the flanges.
9. When mounting accessories, do not weld within
14. Sunburst Cracks
19 mm (3/4-inch) of a flange.
B-09088 10. Do not weld up to the edge of a part being welded
to a frame. Leave 6 mm (0.25-inch) between the
end of the weld and the edge of the part.
Figure 2Types Of Frame Cracks 11. Do not weld cast brackets to the frame.
12. Do not weld the fla n g e s of cracked
3. V grind the entire length of the crack from the reinforcements and base rails together.
starting point to the 6 mm (0.25-inch) hole at the 13. Connect the welding machine ground cables as
extreme end. close to the working area as possible.
4. The bottom of the crack should be opened up 2 14. Avoid direct contact between the welding cables
mm (1/ie-inch) to allow good penetration of the and any part of the vehicle.
weld. (A hack-saw blade may be used for this). 15. Do not get the welding cables near the vehicle
5. Weld with proper electrode and proper welding wiring.
techniques. See Welding outlined later in this
section for tips on welding.
6. Grind the weld smooth on both the inside and the
outside of the rail or crossmember. Be extremely
careful to eliminate weld build-up or notches on
the edge of the flange.
WELDING
Improper welding techniques are the cause of many
weld and/or frame failures. The following information
points out potential areas of difficulty and provides
some general guidelines for successful frame welding.
Most weld failures occur at the end of the weld in
areas of the frame that are under high stress. By
elim inating the ends of a weld, failures can be
reduced; this can be done by making a hole or slot in
the part to be attached and then using a fillet weld
around a slot or plug weld. Do not leave a notch at the
end of a weld.
FRAME 2A-7
G MODEL UNDERBODY
15. Front Gage Holes

16. Rear Gage Holes
A. 789.4 mm (31.08-inch)
B. 1041.4 mm (41.0-inch)
C. 1340 mm (52.76-inch)
D. 1041.4 mm (41.0-inch)
E. 126 mm (4.96-inch)
F. 123 mm (4.8-inch) L. 1465 mm (57.66-inch) 110-inch wheelbase
G. 113.3 mm (4.46-inch) 1845 mm (72.66-inch) 125-inch wheelbase
H. 13 mm (0.51-inch) M. 2772 mm (109.17-inch) 110-inch wheelbase
I. 96 mm (3.78-inch) 3153 mm (124.17-inch) 125-inch wheelbase
J. 145.2 mm (5.72-inch) N. 2833 mm (111.54-inch) 110-inch wheelbase
K. 701 mm (27.6-inch) 3442 mm (135.54-inch) 125-inch wheelbase
B-09120
Figure 3G Model Underbody
DESCRIPTION p o in ts as show n in fig u re 3. C o m pare each

The G Model incorporates a unitized body design measurement with the specifications given in the
comprised of side rails, cross sills, and outriggers figure to determine the damaged areas and the extend
which are all part of the welded underbody. of the damage. When repairing the underbody it will be
A misaligned underbody can affect the opeartion of necessary to return the underbody to these original
many ve hicle com ponents. It is e ssen tia l that specifications within 1.6 mm (1/ie-inch).
underbody alignm ent be exact to within 1.6 mm
(1/i e-inch). Many different types and brands of unibody repair
equipment are available; each system may be slightly
different. A multiple pull system is most desirable in
UNDERBODY ALIGNMENT order to correct the damage in the same direction in
To determine the alignment of the underbody it is which it was created. When making multiple pulls use
necessary to use a good quality traming gage. This the last in, first out procedure. This means that you
gage must be capable of measuring all points of the correct the damage in the reverse sequence by which
underbody up to three quarters of the body length. it was created. It is also important to correct the
Following the instructions given by the manufacturer damage in the opposite direction in which the damage
of your gage, measure the horizontal and vertical was created.
BUMPERS 2B-1
SECTION 2B
BUMPERS
CONTENTS
SUBJECT PAGE
C/K Model B um pers................................................................................................................................................... 2B - 1

Front Bumper Replacement..................................................................................................................................2B - 1
Rear Bumper Replacement (U tility Vehicle and S u b u rb a n )......................................................................... 2B- 4
Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew C a b ) ....................................................2B- 6
Rear Step Bumper Replacem ent......................................................................................................................... 2B- 7
Rear Bumper License Plate Bracket R eplacem ent.........................................................................................2B- 7
Dead Weight Trailer Hitch Replacement (U tility Vehicle and S u b u rb a n )..................................................2B- 8
Weight D istribution Hitch Replacement (Suburban O n ly ) ............................................................................2B-10
Weight D istribution Hitch Replacement (U tility Vehicle O nly)..................................................................... 2B-10
P Model Bum pers....................................................................................................................................................... 2B-12
Front Bumper Replacement..................................................................................................................................2B-12
Front Bumper Replacement (With RPO FS3 Front A x le ) ..............................................................................2B-12
G Model B u m p e rs ..................................................................................................................................................... 2B-14
Front Bumper Replacement............................................................. ................................................................. 2B-14
Rear Bumper R e placem ent..................................................................................................................................2B-15
Rear License Plate Bracket R e p lace m e n t........................................................................................................2B-16
Dead Weight Trailer Hitch R e p lace m e n t..........................................................................................................2B-16
Weight D istribution Hitch Replacem ent............................................................................................................ 2B-17
C/K MODEL BUMPERS
FRONT BUMPER 9. Tow hooks (20) (where used).
REPLACEMENT 10. Brackets (5).
Remove or Disconnect
Install or Connect (Figures 1-4)
1. Brace to bumper nuts (2) (figure 1).
1. Brackets and tow hooks (where used) to the
2. Bracket to bumper nuts (3).
frame rails.
3. Bumper from the vehicle.
4. Guard assemblies (where used) (figure 2).
On vehicles without tow hooks, install the
5. Rub strips from the bumper and guards (where bolts and washers through the brackets and
used) (figure 3). through the outside of the frame rail.
From the rear of the bumper, press the
tangs of the rub strip together, and push the On vehicles with tow hooks, install the tow
strip from the bumper and/or guard. hook bolts and washers from inside the
6. Bumper bolts (6 and/or 8). frame rail, then through the brackets and
7. Brace bolts and washers (17 and 18) (figure 4) the tow hooks. Install the top bracket bolts
from the inside of the frame rail. and washers through the bracket, and into
Braces (4). the top rail flange.
8. Bracket bolts, washers, and nuts (16, 15 and 14)
from the frame. 2. Washers and nuts to the bolts.
2B-2 BUMPERS
Tighten a Tighten
Nuts to 95 N m (70 ft. lbs.). Bolts to 50 N m (37 ft. lbs.).
4. Bumper bolts (6) onto the bumper.

3. Brace bolts and washers (17 and 18) through the
frame rails and into the braces. 5. Rub strips to the bumper and guards (where
used).
Place the tangs of the strips onto the slots in
the bumper or guard. Using a rubber mallet,
set the tangs in place starting at the center
of the strip, and working toward each end.
6. Guard assemblies (where used).
7. Bumper to the vehicle.
Install the bumper with bolts through the

right and left braces, and brackets.
Figure 3C/K Front Bumper Rub Strip

BUMPERS 2B-3
4. Brace
5. Bracket
11. Bolt
12. Washer
13. Nut
14. Nut
15. Washer
16. Bolt
17. Bolt
18. Washer
19. Washer
20. Tow Hook
A. Frame
B. Weld Nut 16
F-00131
Figure 4C/K Front Bumper Brackets, Braces, and Tow Hooks

2B-4 BUMPERS
21. Nut
22. Brace
23. Bracket
24. Nut
25. Washer
26. Nut
27. Nut
28. Washer
29. Bolt
30. Bolt
31. Bumper Bar
32. Bolt
F-00132
Figure 5U tility Vehicle and Suburban Rear Bumper Components
$ Tighten Braces (22).

8. Bracket nuts, washers, and bolts (27, 28 and 29).
Nuts to 90 N m (66 ft. lbs.). Brackets (22).
9. Brace to bumper nuts (2).
Install or Connect (Figures 5-8)
Q Tighten
1. Brackets to the frame rails (22).
Nuts to 90 N m (66 ft. lbs.). Bracket bolts, washers, and nuts (29, 28 and
27).
REAR BUMPER REPLACEMENT
Tighten
(UTILITY VEHICLE AND
SUBURBAN) Nuts to 95 N m (70 ft. lbs.).
Braces to the frame rails (22).
Brace bolts, washers, and nuts (30, 25 and
26).
1. Brace to bumper nuts (21).
& Tighten
3. Rear bumper.
Nuts to 95 N m (70 ft. lbs.).
4. Filler panel bolts (figures 6 and 7).
Filler panel. 3. Bumper bolts to the bumper (32).
5. Rub strips from the bumper (where used) (figure 4. Rub strips to the bumper (where used).
8). Place the tangs of the strips onto the slots in
From the rear of the bumper, press the the bumper guard. Using a rubber mallet,
tangs of the bump strip together, and push set the tangs in place starting at the center
the strip from the bumper. of the strip, working toward each end.
6. Bumper bolts (32). 5. Filler panel supports (Utility vehicle only) (figure
7. Brace nuts, washers, and bolts (26, 25 and 30). 6 ).
BUMPERS 2B-S
31. Bumper Bar

33. Bar
34. U Nut
35. Nut & Washer
36. Support
37. Bolt
38. Filler Panel
37
F-00133
Figure 6Rear Bumper Fiiler Strip
Place the filler panel bolts through the panel Tighten

and into the support U nuts.
Bolts to 2.8 N m (25 in. lbs.).
a Tighten
Bolts to 10 N m (89 in. lbs.). Install the bumper bolts (32) into the braces,
6. Filler panel (Suburban only) (figure 7). and brackets.
Bolts through the filler panel, and into the
platform. 8. Filler Panel (Utility vehicles only).
Figure 7Rear Bumper Center Filler Figure 8Rear Bumper Rub Strip
2B-6 BUMPERS
42. Brace
43. Nut
44. Spring Washer
45. Washer
46. Bracket
47. Washer
48. Spring Washer
49. Nut
50. Nut
51. Nut
52. Spring Washer
53. Bolt
54. Bolt
55. Bumper Bar
56. Bolt F-00128
Figure 9Regular Cab, Bonus Cab, and Crew Cab Rear Bumper Components
Place the filler panel behind the bumper, 2. Bracket nuts (49), spring washers (48), and
and place the supports onto the bumper washers at the bumper.
bolts behind the braces. 3. Rear bumper from the vehicle.
9. Filler panel bracket bolts (Utility vehicle only).
4. Bumper bolts (56).
Tighten 5. Gravel deflector nuts (59) and bolts (57) (where
used) (figure 10).
Bolts to 10 N-m (89 in. lbs.). Gravel deflectors (58).
10. Bracket nuts (24). 6. Brace to frame nuts (50), spring washers (52),
and bolts (54).
$ Tighten
Braces (42).
Nuts to 41 N-m (30 ft. lbs.). 7. Bracket to frame rail nuts (51), spring washers
11. Brace nuts (21). (52) and bolts (53).
Brackets (46).
Tighten
-n - Install or Connect
Nuts to 41 N-m (30 ft. lbs.).
1. Brackets to the frame rails.
REAR BUMPER REPLACEMENT Bolts (53), spring washers (52), and nuts
(51).
(REGULAR CAB, BONUS CAB,
AND CREW CAB) & Tighten

2. Braces to the frame rails.
1. Brace nuts (43), spring washers (44), and Bolts (54), spring washers (52), and nuts
washers (45) at the bumper. (50).
BUMPERS 2B-7
REAR STEP BUMPER

REPLACEMENT
1. Bracket to bumper nuts (63), and bolts (64).

2. Brace to bumper nuts (73), spring washers (72),
washers (71), and bumper bolts.
4. Brace to frame nuts (60) and bolts (62).
Braces (70).
5. Bracket reinforcement nuts (68) and bolts (61)
(and washers (67) where used).
Bracket reinforcements (66).
6. Bracket to frame nuts (60), and bolts (62).
Brackets (65).
+ 4- Install or Connect (Figure 11)
1. Brackets (65) and braces (70) to the frame.

Bolts (62) and nuts (60) loosely.
2. Bracket reinforcements (66).
The reinforcements are marked as right or
left on their inboard sides.
Bolts (61) and nuts (68), and washers (67)
(where used).
$ Tighten
Reinforcement nuts to 70 N m (52 ft. lbs.).
Bracket and brace nuts to 70 N m (52 ft.
3. Gravel deflectors (where used). lbs.).
Nuts (59) and bolts (57). 3. Bumper to the vehicle.
4. Bumper to brace bolts (69), washers (71), spring
washers (72), and nuts (73).
Tighten
Nuts to 10 N m (89 in. lbs.). $ Tighten
4. Bumper bolts (56) onto the bumper. Nuts to 70 N m (52 ft. lbs.).
5. Rear bumper. 5. Bumper to bracket bolts (64), and nuts (63).
Place the bumper bolts through the brackets Tighten

and braces.
6. Bracket washers (47), spring washers (48), and Nuts to 70 N m (52 ft. lbs.).
nuts (49) to the bumper.
REAR BUMPER LICENSE

PLATE BRACKET
Nuts to 90 N m (66 ft. lbs.). REPLACEMENT
7. Brace washers (45), spring washers (44), and
nuts (43) to the bumper. f4 Remove or Disconnect (Figure 12)
Tighten 1. License plate bracket to bumper nuts (78), spring

washers (77), washers (76), and bolts (76).
Nuts to 90 N m (66 ft. lbs.). 2. License plate bracket (75).
2B-8 BUMPERS
60. Nut
61. Bolt
62. Bolt
63. Bolt
64. Bolt
65. Bracket
66. Reinforcement
67. Washer
68. Nut
69. Bolt
70. Brace
71. Washer
72. Spring Washer
73. Nut
74. Bumper Bar
Figure 11Rear Step Bumper Components
+- Install or Connect (Figure 12) DEAD WEIGHT TRAILER

1. License plate bracket (75).
HITCH REPLACEMENT
2. License plate bracket to the bumper bolts (76), (UTILITY VEHICLE AND
washers (76), spring washers (77), and nuts (78). SUBURBAN)
Tighten
1. Bracket assembly nuts, washers, and bolts from
the frame.
2. Support nuts, washers, and bolts from the
75 76 77 bumper.
3. Hitch assembly.
4. Chain bracket nut, washer, and bolt.
Chain bracket.
Support.
5. Bar assembly bolt and washer from the bracket.
Bar assembly.
+4- Install or Connect (Figures 13 and 14)
1. Bracket assem bly to the fram e with bolts,

washers, and nuts.
74. Bumper Bar Nuts to 70 N m (52 ft. lbs.).

75. License Plate Bracket 2. Bar assembly to the support.
76. Washer
Place the bolt through the bar assembly,
77. Spring Washer
support and the chain bracket. Install the
78. Nut
washer and nut loosely.
79. Bolt
3. Support assembly bolts through the support and
the bumper.
F-00119 Washers and nuts loosely.
4. Bar assembly bolt with washer through the bar
Figure 12Rear License Plate Bracket and into the bracket assembly.
BUMPERS 2B-9
31 31. Bumper Bar

31. Bumper Bar
95. Bolt
80. Bolt
96. Washer
81. Washer
97. Nut
82. Nut
98. Washer
83. Washer
99. Bolt
84. Bolt
100. Nut
85. Nut
101. Washer
86. Washer
102. Chain Bracket
87. Chain Bracket
103. Bolt
88. Bolt
104. Support
89. Support
105. Bar Assembly
90. Bar Assembly
106. Bolt
91. Bolt
107. Bracket Assembly
92. Bracket Assembly
108. Washer
93. Washer
F-00120 109. Nut
94. Nut______________
Figure 13Suburban Dead W eight Trailer Figure 14U tility Vehicle Dead W eight
Hitch Components Trailer Hitch
Tighten Install or Connect (Figure 15)
Bar to bracket bolt to 95 N m (70 ft. lbs.). 1. Hitch platform to the vehicle.
Bar to support nut to 70 N m (52 ft. lbs.). There must be no contact between the
Support to bumper nuts to 33 N m (24 ft. platform and the rear bumper.
lbs.). 2. Front bolts, washers, and nuts to the hitch.
Assemble loosely.
3. Rear nuts, washers, and bolts to the hitch.
WEIGHT DISTRIBUTION
Insta ll the nuts w ith the cu t-o ff side
HITCH REPLACEMENT outboard.
(SUBURBAN ONLY)
& Tighten

Rear bolts to 95 N m (70 ft. lbs.).
1. Rear bolts, washers, and nuts from the hitch. Front nuts to 70 N m (52 ft. lbs.).
2. Front nuts, washers, and bolts from the hitch.
3. Hitch platform from the vehicle.
2B-10 BUMPERS
116
31. Bumper Bar 31. Bumper Bar

110. Nut 119. Nut
111. Washer 120. Washer
112. Bolt 121. Nut
114. Spring Washer 123. Washer
115. Bolt 124. Spring Washer
116. Nut 125. Bolt "
117. Washer 126. Bolt
118. Platform 127. Washer
128. Platform
F-00122 F-00123
Figure 15Suburban W eight D istribution Figure 16U tility Vehicle W eight

Hitch Components D istribution Hitch Components
WEIGHT DISTRIBUTION Tighten

HITCH REPLACEMENT
(UTILITY VEHICLE ONLY) Rear bolts to 73 N m (54 ft. lbs.).
Front bolts to 70 N m (51 ft. lbs.).
1. Rear bolts, washers, and nuts from the hitch.

2. Front bolts, washers, and nuts from the hitch.
3. Hitch platform from the vehicle.
1. Hitch platform to the vehicle.

2. Front bolts, washers, and nuts to the hitch.
Assemble loosely.
3. Rear bolts, washers, and nuts to the hitch.
Install nuts with the cut off side inboard.
BUMPERS 2B-11
P MODEL BUMPERS
129. Washer
130. Spring Washer
131. Nut
132. Bracket 143
133. Washer 141 140
134. Spring Washer 138. Washer
135. Nut 139. Brace
136. Nut 140. Washer 142. Spacer
137. Spring Washer 141. Bolt 143. Bumper Bar
Figure 17P-Front Bumper Components
FRONT BUMPER Tighten
REPLACEMENT Nuts to 47 N m (35 ft. lbs.).

5. Brackets to the frame rails with bolts (144),
Remove or Disconnect (Figures 17 and 18) washers (150), spring washers (151), and nuts
(152).
1. Brace to frame nuts (149), spring washers (148),
washers (147), and bolts (145). Tighten
2. Bracket to frame nuts (152), spring washers (151), Bracket to frame nuts to 95 N m (70 ft. lbs.).
washers (150), and bolts (144).
Bracket to bumper nuts to 47 N m (35 ft.
3. Bumper to frame nuts (131), spring washers (130), lbs.).
washers (129), spacers (142) (where used), and 6. Braces to the frame rails with bolts (145), washers
bolts (141). (147), spring washers (148), and nuts (149).
5. Brace to bumper nuts (136), spring washers (137), Tighten
Brace to frame nuts to 85 N m (63 ft. lbs.).
Braces (139).
2. Brace to bumper nuts to 47 N m (35 ft. lbs.).
6. Bracket to bumper nuts (135), spring washers
(134), washers (133), and bolts (141).
FRONT BUMPER
-+ Install or Connect (Figures 17 and 18) REPLACEMENT (WITH
1. Braces to the bumper with bolts (141), washers
RPO FS3 FRONT AXLE)
(138), spring washers (137), and nuts (136).
Assemble loosely. Remove or Disconnect (Figures >9 and 20)
2. Bracket to the bumper with bolts (141), washers
(138), spring washers (137), and nuts (135). 1. Bracket to frame nuts (153) and washers (154).
2. Brace to frame nuts (170), washers (169), and
Assemble loosely.
bolts (167).
3. Bumper to vehicle. 3. Front bumper from the vehicle.
4. Bumper to frame spacers (142) (where used), 4. Bracket to bumper nuts (166 and 171), spring
spring washers (130), washers (129), bolts (141), washers (165 and 172), washers (164 and 173),
and nuts (131). spacers (174), and bolts (161).
2B-12 BUMPERS
Brackets (162).
5. Brace to bumper nuts (155), spring washers (156),
Braces (158).
+- Install or Connect (Figures 19 and 20)
1. Braces to the bumper with bolts (161), washers

(157), spring washers (156), and nuts (155).
Tighten

2. Brackets to the bumper with bolts (161), spacers
(174), spring washers (165 and 172), washers (164
and 173), and nuts (166 and 171).
Tighten

3. Front bumper to the vehicle.
Place the bracket assembly studs into the
frame crossmember.
4. Brace to frame bolts (167), washers (169), and
132. Bracket nuts (170).
139. Brace
144. Bolt $ Tighten
145. Bolt
146. Washer Nuts to 40 N-m (30 ft. lbs.).
147. Washer 5. Bracket to frame washers (154) and nuts (153).
148. Spring Washer
149. Nut Tighten
150. Washer
151. Spring Washer Nuts to 64 N-m (47 ft. lbs.).
152. Nut F-00125
Figure 18P-Front Bumper Braces, and

Brackets
153. Nut
154. Washer
155. Nut
156. Spring Washer
157. Washer
158. Brace
159. Bumper Bar
160. Washer
161. Bolt
162. Bracket
F-00126
Figure 19P-Front Bumper Components (RPO FS3 Front Axle)

BUMPERS 2B-13
158
158. Brace
159. Bumper Bar
160. Washer
161. Bolt
162. Bracket
164. Washer
165. Spring Washer 161
166. Nut
167. Bolt
168. Washer
169. Washer
170. Nut
174 173
171. Nut
172. Spring Washer
173. Washer
174. Spacer
F-00127
Figure 20P-Front Bumper Braces, and Brackets (RPO FS3 Front Axle)
G MODEL BUMPERS
FRONT BUMPER Install or Connect (Figures 21 and 22)
REPLACEMENT 1. Braces to the frame.

Place braces through the holes in the cross
Remove or Disconnect (Figure 21) sill, and install the bolts (179) loosely.
2. Bolts (184) into the guards (where used).
1. Bracket to cross sill bolts (181).
3. Rub strips to the juards (where used).
2. Brace to bumper nuts (180) and bolts (182).
Place the tangs of the strips onto the slots in
3. Bumper from the vehicle. the guard. Using a rubber mallet, set the
4. Bracket to bumper nuts (178), bolts (182), and tangs in place starting at the center of the
guards (where used). strip, and working toward each end.
4. Bracket to bumper bolts (182) or guards (where
Brackets (177).
used), nuts (178), and guard lower bolts.
5. Rub strips from the guards (where used) (figure
22).
From the rear of the guard, press the tangs

of the bump strip together, and push the Nuts to 29 N m (21 ft. lbs.).
strip from the guard. Guard lower bolts to 41 N m (30 ft. lbs.).
6. Brace to frame bolts (179). 5. Bumper to the vehicle.
Braces (176). 6. Bracket to cross sill bolts (181).
2B-14 BUMPERS
176
175. Bumper Bar

176. Brace
177. Bracket
178. Nut
179. Bolt
180. Nut
181. Bolt
182. Bolt
F-00108
Figure 21G-Front Bumper Components
Tighten REAR BUMPER REPLACEMENT

Bolts to 41 N m (30 ft. lbs.).
7. Brace to bumper bolts (182) and nuts (180). Remove or Disconnect (Figure 23)

Tighten 1. Outer brace to bumper nuts (192) and bolts (196).
2. Inner brace to cross sill bolts (194).
Brace to bumper nuts to 29 N m (21 ft. lbs.). 3. Bracket to frame bolts (188) and washers (187).
Brace to frame bolts to 41 N m (30 ft. lbs.). 4. Bumper from the vehicle.
5. Outer brace to cross sill bolts (193).
Outer braces (186).
6. Bracket to bumper nuts and bolts (196).
Brackets (189).
7. Inner brace to bumper nuts (192) and bolts (196).
Inner braces (190).
1. Inner braces (190) to the bumper.

Assemble the top bolts (191) and nuts (192).
Nut to 30 N m (22 ft. lbs.)

Assembly the lower bolts (196) and nuts
(192).
Nut to 30 N m (22 ft. lbs.).

2. Brackets to the frame with washers (187) and
bolts (188).
Assemble loosely.
3. Outer braces (186) to the cross sill with bolts
(193).
BUMPERS 2B-15
191. Bolt
186. Outer Brace 192. Nut
186 187. Washer 193. Bolt
188. Bolt 194. Bolt
189. Bracket 195. Bumper Bar
190. Inner Brace 196. Bolt F-00110
Figure 23G-Rear Bumper Components
$ Tighten Tighten
Bolts to 41 N m (30 ft. lbs.). Nuts to 29 N m (21 ft. lbs.).

Place the inner braces into the inner brace
panel holes. DEAD WEIGHT TRAILER
5. Inner braces to the cross sill with bolts (194). HITCH REPLACEMENT
Tighten
1. Hitch bracket to bumper bracket nuts, washers,
6. Bumper to bracket bolts (196) and nuts.
and bolts.
2. Support to bumper nuts and bolts.
3. Hitch from the vehicle.
4. Chain bracket to bar assembly nut and bolt.
Chain bracket.
Bracket to frame bolts to 68 N m (50 ft. lbs.). Support.
7. Outer bracket to bumper bolts (196) and nuts Bar assembly.
(192). 5. Bar assembly to hitch bracket nut and bolt.
Bar assembly.
Tighten Shim(s).
Hitch bracket.
REAR LICENSE PLATE 1. Hitch bracket to the bumper brackets with bolts,
BRACKET REPLACEMENT washers, and nuts.
Tighten
1. License plate bracket nuts and bolts. 2. Bar assembly with shims (as required) to the
2. License plate bracket. hitch bracket with bolts and nuts.
Assemble loosely.
Install or Connect (Figure 24) 3. Support to the bumper with bolts and nuts.
Assemble loosely.
1. License plate bracket. 4. Bar assembly and chain bracket to the support
2. License plate bracket nuts and bolts. with a bolt and nut.
2B-16 BUMPERS
Tighten WEIGHT DISTRIBUTION

HITCH REPLACEMENT
Bar assembly to chain bracket nut to 68 N m
(50 ft. lbs.).
Bar assembly to hitch bracket bolt to 68 N m
(50 ft. lbs.). 1. Bumper nuts and bolts.
Bumper.
Support to bumper nuts to 29 N m (21 ft. 2. Rear hitch nuts and washers.
lbs.).
189. Bracket
195. Bum per Bar
200. Washer
201. Nut
202. Bolt
203. Bolt
204. Nut
205. Bracket Assem bly
206. Bolt
207. Bar Assem bly
208. Bolt
209. Nut
210. Chain Bracket
211. Support
212. Nut
213. Shim
Figure 25Dead Weight Trailer Hitch

BUMPERS 2B-17
Figure 26W eight D istribution Hitch
3. Front bolts and washers. 3. Rear washers and nuts.

4. Hitch from the vehicle.

1. Hitch to the vehicle. 4. Bumper to the vehicle with nuts and bolts.
2. Front bolts and washers.
Tighten
Nuts to 29 N m (21 ft. lbs.
2C-1
SECTION 2C
SHEET METAL
NOTICE: All hood latch fasteners are im portant attaching parts in that they could affect the perform ance of
vital parts and systems, and/or could result in major repair expense. They must be replaced w ith one of the
same part number of w ith an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during reassembly to
assure proper retention of all parts.
CONTENTS
SUBJECT PAGE
C/K M o d e ls .................................................................................................................................................................. 2C- 2

Hood R eplacem ent................................................................................................................................................. 2C- 2
Spring Assembly R eplacem ent........................................................................................................................... 2C- 2
Hood Hinge R e p la ce m e n t....................................................................................................................................2C- 2
Primary Hood Latch R e p la ce m e n t.....................................................................................................................2C- 3
Secondary Hood Latch And Spring Replacem ent........................................................................................... 2C- 4
Hood Release Cable R e p lace m e n t.....................................................................................................................2C- 4
Hood Ornament Replacem ent............................................................................................................................. 2C- 4
Cowl Vent Grille Replacement............................................................................................................................. 2C- 5
Grille And Molding R e p la c e m e n t....................................................................................................................... 2C- 5
Front Fender R e p la ce m e n t..................................................................................................................................2C- 7
Wheelhouse Panel Replacement......................................................................................................................... 2C- 8
Rear Fender R eplacem ent.................................................................................................................................... 2C- 9
Radiator Support Replacem ent........................................................................................................................... 2C-11
Sheet Metal Unit R e p la ce m e n t........................................................................................................................... 2C-12
Sheet Metal A djustm e n ts...................................................................................................................................... 2C-14
G M odels.......................................................................................................................................................................2C-14
Hood R eplacem ent................................................................................................................................................. 2C-14
Hood Hinge R e p la ce m e n t.................................................................................................................................... 2C-14
Primary Hood Latch R e p la ce m e n t.....................................................................................................................2C-15
Secondary Hood Latch And Spring Replacem ent...........................................................................................2C-16
Hood Release Cable R e p lace m e n t.....................................................................................................................2C-16
Cowl Vent Grille Replacement............................................................................................................................. 2C-16
Grille Replacem ent................................................................................................................................................. 2C-18
Front End Sheet Metal Cross Panel R e p la c e m e n t.........................................................................................2C-18
Sheet Metal Vertical Support R eplacem ent......................................................................................................2C-19
Front End Panel Replacem ent............................................................................................................................. 2C-20
S pe cifica tio ns.............................................................................................................................................................. 2C-21
Special T o o ls .............................................................................................................................................................. 2C-21
2C-2 SHEET METAL
C/K MODELS
Tighten
SPRING ASSEMBLY
REPLACEMENT
Raise and support the front of the hood.

1. Spring assembly to hood bolts (4).
2. Spring assembly to fender bolts (1).
3. Spring assembly from the vehicle.
1. Spring assembly to the vehicle.

2. Spring assembly to fender bolts (1).
Tighten
Bolts to 25 N m (18 ft. lbs.)

3. Spring assembly to hood bolts (4).
Tighten

HOOD REPLACEMENT
Remove or Disconnect (Figure 1) HOOD HINGE
REPLACEMENT
Raise and support the hood at front and rear.
Place protective coverings over the cowl and the Remove or Disconnect (Figure 1)
fenders.
Mark the position of the hinge on the hood. Raise and support the hood at front and rear.
1. Spring assembly to hood bolts (4). 1. Cowl vent grille. Refer to Cowl Vent Grille
2. Hood hinge to hood bolts (5). Replacement.
3. Hood from the vehicle. 2. Hinge to hood bolts (5).
3. Hinge to cowl bolts (6).
Install or Connect (Figure 1) 4. Hinge from the vehicle.
1. Hood to the vehicle. Install or Connect (Figure 1)

Align the hood with the previously made
marks. 1. Hinge to the vehicle.
2. Hood hinge to hood bolts (5). 2. Hinge to cowl bolts (6).
Tighten Tighten
Bolts to 25 N m (18 ft. lbs.). Bolts to 43 N m (32 ft. lbs.).

3. Spring assembly to hood bolts (4). 3. Hinge to hood bolts (5).
SHEET METAL 2C-3
Figure 2Hood Primary Latch Components
Bolts to 25 N m (18 ft. lbs.). 1. Bracket to the radiator support.

4. Cowl vent grille. Refer to Cowl Vent Grille 2. Bracket to support bolts (10) loosely.
Repacement. 3. Primary hood latch to the bracket.
4. Latch to bracket bolts (9) loosely.
PRIMARY HOOD LATCH 5. Hood latch release cable to the latch.
REPLACEMENT
f t Adjust
NOTICE: See Notice on page 2C-1 of this
section. Hood latch bracket left and right until the striker
in the hood easily engages the primary latch.
Raise the hood.
Raise the hood.

1. Hood latch release cable from the latch. Refer to Bracket to radiator support bolts to 27 N m
Hood Release Cable Replacement. (20 ft. lbs.).
2. Bracket to hood latch bolts (9). Hood latch height so that when the hood is
3. Hood latch from the vehicle. closed, the hood is held securely against the front
4. Bracket to radiator support bolts (10). hood bumpers. Mark this height.
5. Bracket from the vehicle. Raise the hood.
Adjust Tighten
Front hood bumpers, so that the top of the hood Bracket to hood latch bolts to 27 N m (20 ft.
is flush with the fenders. lbs.).
2C-4 SHEET METAL
HOOD RELEASE CABLE

REPLACEMENT
If the cable is broken, release the hood by

pressing the primary latch tab on the right side of
the lock assembly. Use a rod to press the tab.
Raise the hood.
1. Cable from the primary latch.
Insert a screwdriver into the clip, and lift the
cable from the lock. Then, carefully pry the
cable grommet from the lock flange.
2. Cable from the ra diator support, and the
wheelhouse retaining strap.
3. Grommet from the cowl.
16 I Cut the grommet down to the cable casing
i
on the engine side of the cowl.
3. Hood
15. Reinforcement Push the cable and grommet through the
16. Spring cowl.
17. Secondary Hood Latch 4. Cable handle to air vent bezel bolts.
18. Bolt
5. Cable from the vehicle.
B-07272
Figure 3Hood Secondary Latch Components 0* l Install or Connect (Figure 4)
1. New cable to the vehicle.

SECONDARY HOOD LATCH 2. Cable through the drivers side of the cowl.
AND SPRING REPLACEMENT Push the grommet into the drivers side of
the cowl.
4 -4 Remove or Disconnect (Figure 3) 3. Cable bolts through the cable handle, and into
the air vent bezel.
Mark the position of the secondary hood latch on
4. Cable through the wheelhouse retaining strap,
the hood.
and the radiator support.
1. Secondary hood latch to hood bolts (18). 5. Cable to the primary latch.
2. Secondary hood latch from the vehicle.
3. Spring from the hood. HOOD ORNAMENT

Twist the spring from the reinforcement.
REPLACEMENT

0 Remove or Disconnect (Figure 5)
Raise hood.
1. Spring to the hood. 1. Hood ornament nuts (21).
Twist the spring into the reinforcement. 2. Hood ornament from the hood.
3. Seal from the hood.
2. Secondary hood latch to the vehicle.
3. Secondary hood latch to hood bolts (18). +4- Install or Connect (Figure 5)
1. Hood seal to the ornament.

Tighten
2. Hood ornament to the hood.
Bolts to 27 N m (20 ft. lbs.). 3. Hood ornament nuts (21).
SHEET METAL 2C-5
COWL VENT GRILLE 3. Cowl vent grille plastic fasteners from the
windshield frame.
REPLACEMENT 4. Cowl vent grille from the vehicle.
+ + Remove or Disconnect (Figure 6) Install or Connect (Figure 6)
1. Wiper arms. 1. Cowl vent grille to the vehicle.

2. Cowl ve nt g rille p la s tic fa s te n e rs to the
2. Cowl vent grille panel screws.
windhsield frame.
3. Cowl vent grille panel screws.
4. Wiper arms.
GRILLE AND MOLDING

REPLACEMENT
1. Lower radiator grille to grille bolt (39).

2. Radiator support to grille bolts (30).
3. Grille from the vehicle.
Slide the bottom of the grille from the
vehicle, and then lower the grille from the
vehicle.
4. Headlamp bezels.
5. Headlamp assemblies.
6. Molding assembly to fender, radiator support, and
lower grille panel nuts (33, 34 and 37).
7. Molding assembly from the vehicle.
8. Right and left moldings from the upper and lower
moldings.
9. Clips from the moldings.
10. Lower radiator grille to fender bolts (38).
11. Lower radiator grille to the sheet metal support
bolts (40).
12. Lower radiator grille from the vehicle.
2C-6 SHEET METAL
29. Radiator Grille

30. Bolt
31. Radiator Support
32. Bolt
33. Nut
34. Nut
35. Bolt
36. Side Molding
37. Nut
38. Bolt
39. Bolt
40. Bolt
41. Lower Molding
42. Lower Radiator Grille
43. Upper Molding
44. Clip
37 36
B-07274
Figure 7Grille Components

SHEET METAL 2C-7
+ + Install or Connect (Figure 7)
Lower radiator grille to the vehicle.

Lower radiator grille to the sheet metal support
bolts (40).
Lower radiator grille to fender bolts (38).
Upper molding to the radiator support with clips
(44), and nuts (33).
Assemble loosely.
5. Lower molding to the radiator support with clips
(44), and nuts (37).
Assemble loosely.
6. Right and left moldings to the fenders.
The moldings must butt against the upper
and lower moldings, and be joined to those
moldings by the clips.
7. Right and left molding nuts (34).
Tighten upper and lower molding nuts (33 and
37).
8. Headlamp assemblies.
9. Headlamp bezels.
10. Grille to the vehicle.
Insert the top of the grille to the underside of
the radiator support, and then slide the
bottom of the grille into place.
11. Lower radiator grille to grille bolt (39).
12. Radiator support to grille bolts (30).
Figure 8Front Fender Attachm ent
FRONT FENDER
17. Fender from the vehicle.
REPLACEMENT
18. Insulator from the fender.
Tool Required: Install or Connect (Figures 8 and 9).

J-24595-B Door Trim Pad Remover.
Raise and support the hood. 1. Insulator to the fender.
1. Head lamp bezel. 2. Fender to the vehicle.
2. Head lamp.
3. Right or left radiator grille molding nuts (34).
4. Upper and lower molding clip nuts (33 and 37).
5. Right or left radiator grille molding (36).
6. Lower radiator grille to fender bolts (38).
7. Cowl vent grille. Refer to Cowl Vent Grille
Replacement.
8. Hood s p rin g assem bly. R efer to S prin g
Assembly Replacement.
9. Radiator support to fender bolts (119).
10. Wheelhouse panel to shield bolts.
11. Shield to underbody retainers using J-24595-B.
12. Shield from the vehicle.
13. Wheelhouse panel to fender bolts (50).
14. Lower door pillar to fender bolt (45) and shim(s) \ 49. Bolt 52. Bolt
(46). 4g 50. Bolt 53. Bolt
15. Fender to cowl bolt (47) and shim(s) (46). 51. Nut 54. Wheelhouse Panel
B-07284
Open the front door.
16. Upper fender to door pillar bolt (48) and shim(s)
(46). Figure 9Wheelhouse Panel Attachment
2C-8 SHEET METAL
3. Upper fender to the door pillar bolt (48) and 7. Wheelhouse panel to underbody shield bolts.
shim(s) (46) as required. 8. Wheelhouse panel reinforcement to underbody
Assemble loosely. bolts (52) and (53).
4. Fender to cowl bolt (47) and shim(s) (46) as 9. Wheelhouse panel to fender bolts (50).
required. 10. Wheelhouse panel from the vehicle.
Assemble loosely.
Slide the panel forward to clear the lower
5. Lower door pillar to fender bolt (45) and shim(s)
back side of the fender well.
(46) as required.
Tilt the wheelhouse panel out of the vehicle.
Assemble loosely.
Install or connect (Figure 9)
$ Tighten
1. Wheelhouse panel to the vehicle.
Bolts to 17 N m (13 ft. lbs.). Tilt the wheelhouse panel into the vehicle.
7. Wheelhouse to fender bolts (50). Slide the panel into position.
Tighten
Wheelhouse to fender bolts (50) to 17 N m

(13 ft. lbs.). Bolts to 17 N m (13 ft. lbs.).
Lower door pillar to fender bolt to 43 N m (31 3. Wheelhouse panel reinforcement to underbody
ft. lbs.). bolts (52) and (53).
8. Shield to the vehicle.
9. Shield to underbody retainers. Tighten
Bolts (52) to 17 N m (13 ft. lbs.).
Tighten Bolt (53) to 47 N m (35 ft. lbs.).
4. Wheelhouse panel to underbody shield bolts.
Fender to cowl bolt (47) to 43 N m (31 ft.
5. Wheelhouse panel to radiator support bolts (49).
lbs.).
Upper fender to door pillar bolt to 43 N m
a Tighten
(31 ft. lbs.).
11. Hood sp rin g assem bly. R efer to S pring
12. Cowl vent grille. Refer to Cowl Vent Grille 6. Right front wheel.
Replacement. Lower the vehicle.
13. Lower radiator grille to fender bolts (38). 7. Air conditioning line retainers (if equipped).
14. Right or left radiator grille molding (36). 8. Coolant recovery reservoir.
15. Upper and lower molding clip nuts (33 and 37). 9. Lug wrench.
16. Right or left radiator grille molding nuts (34). 10. Jack handle.
17. Head lamp.
18. Head lamp bezel. LEFT PANEL REPLACEMENT

WHEELHOUSE PANEL
REPLACEMENT 1. Jack.
2. Windshield washer fluid reservoir.
RIGHT PANEL REPLACEMENT 3. Wiring harness.
4. Hood release cable.
4-+ Remove or Disconnect (Figure 9)
5. Air conditioning hose bracket (if equipped).
Raise and support the vehicle.
1. Jack handle.
2. Lug wrench. 6. Left front wheel.
3. Coolant recovery reservoir. 7. Wheelhouse panel to radiator support bolts (49).
4. Air conditioning line retainers (if equipped). 8. Wheelhouse panel to underbody shield bolts.
Raise and support the vehicle. 9. Wheelhouse panel reinforcement to underbody
5. Right front wheel. bolts (52) and (53).
6. Wheelhouse panel to radiator support bolts (49). 10. Wheelhouse panel to fender bolts (50).
SHEET METAL 2C-9
11. Wheelhouse panel from the vehicle. 3. Cross sill to brace bolt (63).
Slide the panel forward to clear the lower Assemble loosely.
back side of the fender well.
4. Brace (58) to the vehicle.
Tilt the wheelhouse panel out of the vehicle.
5. Side panel to brace bolt (56).
Install or Connect (Figure 9) Assemble loosely.
6. Fender to the vehicle.
1. Wheelhouse panel to the vehicle.
Tilt the wheelhouse panel into the vehicle. 7. Side panel to fender bolts (56).
Slide the panel into position. Assemble loosely.
2. Wheelhouse panel to fender bolts (50). 8. Brace to fender bolts (59).
Tighten
Tighten
Brace to fender bolts to 17 N m (13 ft. lbs.).
3. Wheelhouse panel reinforcement to underbody
bolts (52) and (53). Side panel to fender bolts to 10 N m (7 ft.
lbs.).
Tighten Cross sill to brace bolt to 17 N m (13 ft. lbs.).
9. Parking lamp wiring to the fender.
Bolt (52) to 17 N m (13 ft. lbs.).
Clean excess sealant from the fender.
Bolt (53) to 47 N m (35 ft. lbs.).
4. Wheelhouse panel to underbody shield bolts.
5. Wheelhouse panel to radiator support bolts (49). DUAL REAR WHEEL MODEL FENDER
REPLACEMENT
$ Tighten
6. Left front wheel. 1. Parking lamp wiring from the fender.
Lower the vehicle. 2. Fender to brace bolts (71).
7. Air conditioning hose bracket (if equipped). 3. Fender to side panel bolts (72 and 69) and nuts
8. Hood release cable. ( 68 ).
9. Wiring harness.
4. Side panel to fender nuts (66).
10. Windshield washer fluid reservoir.
11. Jack. 5. Fender from the vehicle.
6. Sealer from the side panel and fender.
REAR FENDER REPLACEMENT -+ Install or Connect (Figure 11)
FENDERSIDE MODEL FENDER REPLACEMENT

1. A medium bodied sealer onto the fender to side
panel flange.
2. Fender to the vehicle.
1. Parking lamp wiring from the fender. 3. Side panel to fender nuts (66).
2. Brace to fender bolts (59).
Assemble loosely.
3. Side panel to fender bolts (56).
4. Fender from the vehicle. 4. Fender to side panel bolts (72 and 69) and nuts
(68 ).
5. Side panel to brace bolt (56).
6. Brace (58). Assemble loosely.
7. Cross sill to brace bolt (63). 5. Fender to brace bolts (71).
8. Brace (62).
9. Sealer from the fender and the side panel.
Tighten
-* Install or Connect (Figure 10)
All of the nuts and bolts to 17 N m (13 ft.
lbs.).
1. A medium bodied sealer onto the fender to side
panel flange. 6. Parking lamp wiring to the fender.
2. Brace (62). Clean excess sealant from the fender.
2C-10 SHEET METAL
Figure 10Fenderside Rear Fender Attachm ent
Figure 11Dual Rear Wheel Rear Fender Attachment

SHEET METAL 2C-11
73. Bolt
74. Washer
75. Retainer
76. Cushion - Upper
77. Bracket
78. Cushion - Lower
79. Retainer
80. Nut
B-07280
Figure 12Radiator Support Mounting
RADIATOR SUPPORT 18. Radiator support to frame nuts (80), lower

re taine rs (79), lower cushions (78), upper
REPLACEMENT cushions (76), retainers (75), bolts (73), and
washers (74).
Remove or Disconnect (Figure 12) 19. Radiator support from the vehicle.
Tilt the radiator support to the rear, and lift it
1. Radiator from the vehicle. Refer to ENGINE up and out of the vehicle.
COOLING (SEC. 6B).
2. Air conditioning condenser from the vehicle. Install or Connect (Figure 12)
Refer to AIR CONDITIONING (SEC. 1B).
3. Battery from the vehicle. 1. Radiator support to the vehicle.
4. Headlamp and parking lamp wires from the Lower the radiator support into the vehicle,
lamps. and tilt it into position.
5. Headlamp and parking lamp wiring harness from 2. Radiator support to frame washers (74), bolts (73),
the radiator support. retainers (75), upper cushions (76), lower
6. Headlamp bezels. cushions (78), lower retainers (79), and frame
7. Headlamp assemblies. nuts (80).
8. Ground wires from the radiator support. Assemble loosely.
9. Fuel vapor canister from the radiator support. 3. Wheelhouse panel to radiator support bolts (49).
10. Air cleaner inlet from the radiator support.
Tighten
11. Primary hood latch bracket to the radiator support
bolts.
12. Grille from the vehicle.
13. Lower radiator grille panel from the vehicle.
14. Sheet metal support to radiator support bolts. Tighten
&
15. Sheet metal support from the vehicle.
16. Radiator support to fender bolts (119). Bolts to 17 N m (13 ft. lbs.).
17. Wheelhouse panel to radiator support bolts (49). 5. Sheet metal support to the vehicle.
2C-12 SHEET METAL
6. Sheet metal support to radiator support bolts. 11. Wheelhouse panel to fender bolts (50).
12. Fender to cowl bolts (47).
Tighten 13. Upper fender to door pillar bolt (48).
Bolts to 17 N-m (13 ft. lbs.). 15. Shield to underbody retainers using J-24595-B.
Radiator support to frame nuts (80) to 47
16. Shield from the vehicle.
N-m (35 ft. lbs.).
17. Lower fender to door pillar bolt (45).
Lower radiator grille panel to the vehicle.
18. Radiator support to frame nuts (80), lower
Grille to the vehicle.
re tainers (79), lower cu shion s (78), upper
Primary hood latch bracket to the radiator support
cushions (76), retainers (75), bolts (73), and
bolts.
washers (74).
19. Sheet metal assembly.
With the aid of a helper, lift the sheet metal
Hood latch left or right so that the hood from the chassis.
properly engages the hood latch.
Install or Connect
1. Sheet metal assembly.

Bracket to radiator support bolts to 27 N-m With the aid of a helper, lift the sheet metal
(20 ft. lbs.). onto the chassis.
10. Air cleaner inlet to the radiator support. 2. Radiator support to frame washers (74), bolts (73),
11. Fuel vapor canister to the radiator support. retainers (75), upper cushions (76), lower
12. Ground wires to the radiator support. cushions (78), lower retainers (79), and nuts (80).
13. Headlamp assemblies. 3. Lower fender to door pillar bolts (45).
14. Headlamp bezels.
15. Headlamp and parking lamp wiring harness to Tighten
the radiator support.
16. Headlamp and parking lamp wires to the lamps. Bolt to 43 N-m (31 ft. lbs.).
17. Battery to the vehicle. 4. Shield to the vehicle.
18. Air conditioning condenser to the vehicle. Refer 5. Shield to underbody retainers.
to AIR CONDITIONING (SEC. 1B). 6. Wheelhouse panel to shield bolts.
19. Radiator to the vehicle. Refer to ENGINE 7. Upper fender to door pillar bolt (48).
COOLING (SEC. 6B).
Tighten
SHEET METAL UNIT
Bolt to 43 N-m (31 ft. lbs.).
REPLACEMENT 8. Fender to cowl bolts (47).
Tool Required:
Tighten
J-24595-B Door Trim Pad Remover.
Bolts to 43 N-m (31 ft. lbs.).
1. Hood from the vehicle.
2. Battery from the vehicle.
3. Radiator from the vehicle. Refer to ENGINE
Wheelhouse panel to fender bolts to 17 N-m
COOLING (SEC. 6B).
(13 ft. lbs.).
4. Air conditioning condenser from the vehicle.
5. Headlamp and parking lamp wires from the 11. Air cleaner inlet to the radiator support.
lamps. 12. Fuel vapor canister to the radiator support.
6. Headlamp and parking lamp wiring harness from 13. Ground wires to the radiator support.
the radiator support. 14. Headlamp and parking lamp wiring harness to
7. Ground wires from the radiator support. the radiator support.
8. Fuel vapor canister from the radiator support. 15. Head lamp and parking lamp wires to the lamps.
9. Air cleaner inlet from the radiator support. 16. Air conditioning condenser to the vehicle. Refer
10. Bumper from the vehicle. to AIR CONDITIONING (SEC. 1B).
SHEET METAL 2C-13
82. Hood
83. Fender
84. Door
85. Cowl Vent Grille
86. Rocker Panel
87. Radiator Support Upper Panel
A. Flush Fit
B. Flush + or - 1mm (0.03-inch)
C. Flush + 0.00 mm or - 1.5 mm (0.00-inch or -0.06-inch)
D. 4.6 mm 1 mm (0.18-inch 0.03-inch)
E. 8 mm 1 mm (0.31-inch 0.03-inch)
F. 5 mm 2.3 mm (0.19-inch 0.09-inch)
F-00183
Figure 13Sheet Metal Gap Specifications

2C-14 SHEET METAL
17. Radiator to the vehicle. Refer to ENGINE 3. Align the hood with the cowl vent grille, so that
COOLING (SEC. 6B). there is a gap of 8 mm 1 mm (0.31-inch
18. Battery to the vehicle. 0.03-inch) between the rear edge of the hood and
19. Hood to the vehicle. the front edge of the cowl vent grille. The hood
surface should be flush with the cowl vent grille
s u rfa c e w ith in + 0.0 m m -1 .5 mm
SHEET METAL ADJUSTEMENTS (+ 0.00-inch-0.06-inch).
4. Align the left and right edges of the hood so that
In o rd e r to have the p ro p e r o p e ra tio n and a gap of 4.6 mm 1 mm (0.18-inch 0.03-inch)
appearance of sheet metal components, it is important exists between the hood and the fenders. The
that certain fits and gaps between components be hood surface should be flush with the fender
maintained. The gaps given in this procedure are surface within + 0.0 mm, -1.5 mm ( + 0.00-inch,
suggested as the best alignment for these components -0.06-inch). If this gap is difficult to obtain, and the
(figure 13). hood appears to be cocked in between the
In aligning sheet metal, it is best to start with the fenders, the radiator support may need to be
rearmost component, and work forward. shifted. By shifting the radiator support, the entire
1. Starting with the fenders, align the rear edge of front end sheet metal can be aligned as a unit.
each fender to the rocker panel, and the door. Loosen the support to the frame bolts, and shift
The gap between these components should be 5 the radiator support to obtain the proper gaps.
mm 2.3 mm (0.19-inch 0.09-inch). This Then, while holding the support in position,
adjustment should be accomplished by moving retighten the radiator support to frame bolts.
the fender forward or rearward. The surface of 5. Align the front face of the hood to obtain a gap of
the fender should be flush with the rocker panel 4.6 mm 1 mm (0.18-inch 0.03-inch) between
and the door. Add or remove shims to perform the hood and the radiator support upper panel.
this adjustment. The hood bumpers on the top of the radiator
2. Align the fender to the cowl vent grille to obtain a support should be adjusted to give the proper
gap of 4.6 mm 1 mm (0.18-inch 0.03-inch). support to hood gap. The surface of the hood
The surface of the cowl vent grille should be flush should be flush with the radiator support upper
with the fender surface. panel (not the grille molding).
G MODELS
HOOD REPLACEMENT HOOD HINGE REPLACEMENT

Remove or Disconnect (Figure 14) 4- + Remove or Disconnect (Figure 14)
Raise and support the hood. Place a protective Raise and support the hood. Also support the
covering over the fenders, and the cowl vent rear corner of the hood.
grille. Mark the position of the hinge on the hood and
Mark the position of the hinges on the hood. the cowl.
1. Hood hinge to hood bolts (89). 1. Hood hinge to hood bolts (89).
2. Hood from the vehicle. 2. Hood hinge to cowl bolts (90).
3. Hood hinge from the vehicle.
1. Hood to the vehicle.
2. Hood hinge to hood bolts (89). 1. Hood hinge to the vehicle.
Align the hood with the previously made marks. 2. Hood hinge to cowl bolts (90).
3. Hood hinge to hood bolts (89).
Tighten Align the hinge with the previously made marks.
Bolts to 17 N m (13 ft. lbs.). Tighten

Remove the protective coverings, and lower the
hood. Bolts to 17 N m (13 ft. lbs.).
SHEET METAL 2C-15
PRIMARY HOOD LATCH

REPLACEMENT
NOTICE: See Notice on page 2C-1 of this
section.

f t Adjust
Raise and support the hood.
1. Hood latch release cable from the latch. 1. Hood latch bracket left and right until the striker
2. Bracket to hood latch bolts (94). in the hood easily engages the primary latch.
3. Hood latch from the vehicle.
4. Bracket to the sheet metal cross panel bolts (91).
5. Bracket from the vehicle.
Tighten
f t A djust
Bracket to radiator support bolts to 27 N m
(20 ft. lbs.)
Front hood bumpers, so that the top of the hood
is flush with the fenders. 2. Hood latch height so that when the hood is
closed, the hood is held securely against the front
I+ + I Install or Connect (Figure 15) hood bumpers.
1. Bracket to the sheet metal cross panel.
2. Bracket to cross panel bolts (91) loosely. Tighten
3. Primary hood latch to the bracket.
4. Latch to bracket bolts (94) loosely. Bracket to hood latch bolts to 27 N m (20 ft.
5. Hood latch release cable to the latch. lbs.).
2C-16 SHEET METAL
HOOD RELEASE CABLE

REPLACEMENT

If the cable is broken, release the hood by
pressing the primary latch tab on the right side of
the lock assembly. Use a rod to press the tab.
1. Cable from the primary latch.
Insert a screwdriver into the clip, and lift the
cable from the lock. Then, carefully pry the
cable grommet from the lock flange.
2. Cable from the sheet metal cross panel clip.
3. Grommet from the cowl.
Cut the grommet down to the cable casing
88. Hood on the engine side of the cowl.
95. Reinforcement
Push the cable and the grommet through
96. Spring
the cowl.
97. Bolt ~
98. Secondary 4. Cable handle to dash screws.
Hood Latch 5. Cable from the vehicle.
98 97
-+ Install or Connect (Figure 17)
B-07283
1. New cable to the vehicle.

Figure 16Secondary Hood Latch Attachm ent
2. Cable through the drivers side of the cowl.
Push the grommet into the drivers side of
SECONDARY HOOD LATCH the cowl, and then push the insert into the
grommet.
AND SPRING REPLACEMENT
3. Cable handle to dash screws.
Remove or Disconnect (Figure 16) 4. Cable into the sheet metal cross panel clip.
5. Cable to the primary latch.
Mark the position of the secondary hood latch on
the hood.
1. Secondary hood latch to hood bolts (97).

COWL VENT GRILLE
REPLACEMENT
2. Secondary hood latch from the vehicle.
3. Spring from the hood.
Twist the spring from the reinforcement. Raise and support the hood.
1. Windshield wiper arms.
2. Cowl vent grille to cowl bolts (104) and screws
|~n-| Install or Connect (Figure 16)
(103).
1. Spring to the hood. 3. Cowl vent grille from the vehicle.
4. Cowl seal from the vehicle.
Twist the spring into the reinforcement.
2. Secondary hood latch to the vehicle. +- Install or Connect (Figure 18)
3. Secondary hood latch to hood bolts (97). 1. Cowl seal to the vehicle.
2. Cowl vent grille to the vehicle.
Q Tighten 3. Cowl vent grille to cowl bolts (104) and screws
(103).
Bolts to 27 N m (20 ft. lbs.). 4. Windshield wiper arms.
SHEET METAL 2C-17
92
101. Bolt
F-07277
Figure 18Cowl Vent Grille Components

20-18 SHEET METAL
107
107. Grille B-07287
108. Nut
Figure 19Radiator Grille
GRILLE REPLACEMENT
4- + Remove or Disconnect (Figures 19 and 20)

1. Headlamp bezels.
2. Sheet metal cross panel to grille bolts.
3. Grille to lower front end panel boits.
Figure 21Front End Sheet Metal Cross
4. Grille from the vehicle. Panel Attachm ent
5. Sheet metal to upper and lower radiator grille

molding nuts (110 and 112).
6. Upper and lower radiator grille moldings from the
vehicle.
1. Upper and lower radiator grille moldings to the

vehicle.
2. Sheet metal to upper and lower radiator grille
molding nuts (110 and 112).
3. Grille to the vehicle.
4. Grille to lower front end panel bolts.
5. Sheet metal cross pane! to grille bolts.
6. Headlamp bezels.
Lower the hood.
FRONT END SHEET METAL

CROSS PANEL REPLACEMENT
109. Front End Sheet Metal Cross Panel
110. Nut Remove or Disconnect (Figure 21)
1 1 1 . Upper Molding
112. Nut Raise and support the hood.
113. Lower Molding 1. Headlamp bezels.
B-07288 2. Grille. Refer to Grille Replacement.
3. Primary hood latch. Refer to Primary Hood
Figure 20Radiator Grille Molding Attachment Latch Replacement.
SHEET METAL 2C-19
4. Air intake snorkel.

5. Upper radiator mount to sheet metal cross panel
bolts.
6. Upper radiator mounts.
7. Sheet metal cross panel to fender bolts (114).
8. Sheet metal cross panel to the hood latch bracket
bolts (91).
9. Sheet metal cross panel to radiator support baffle
panel bolts.
10. Sheet metal cross panel to the headlamp bezel
support bolts.
11. Sheet metal cross panel from the vehicle.
1. Sheet metal cross panel to the vehicle.

2. Sheet metal cross panel to the headlamp bezel
support bolts.
Assemble loosely.
3. Sheet metal cross panel to the radiator support
baffle panel bolts.
Assemble loosely.
4. Sheet metal cross panel to the hood latch bracket
bolts (91).
Assemble loosely.
5. Sheet metal cross panel to the fender bolts (114).
Tighten
Bolts in steps 2 through 5 to 27 N m (20 ft.

lbs.).
6. Upper radiator mounts.
7. Upper radiator mount to sheet metal cross panel
bolts. Figure 22Front End Sheet Metal
8. Air intake snorkel. Vertical Support
9. Primary hood latch. Refer to Primary Hood
Latch Replacement. Install or Connect (Figure 22)
10. Grille. Refer to Grille Repalcement.
1. Vertical support to the vehicle.
11. Headlamp bezels.
Lower the hood. 2. Sheet metal cross panel to vertical support bolts
(115).
SHEET METAL VERTICAL

Tighten
SUPPORT REPLACEMENT
3. Front end panel to vertical support bolts (120).
1. Grille. Refer to Grille Replacement.
2. Vertical support to sill bolts (17).
3. Front end panel to vertical support bolts (120). Tighten
4. Sheet metal cross panel to vertical support bolts

(115).
5. Vertical support from the vehicle. 4. Vertical support to sill bolts (117).
2C-20 SHEET METAL
Tighten

Grille. Refer to Grille Replacement.
FRONT END PANEL

REPLACEMENT
121
1. Headlamp bezels.
2. Grille. Refer to Grille Replacement. 121
3. Front end panel to headlamp bezel support bolts 116. Sheet Metal
(118). Vertical Support 118. Bolt 121. Bolt
4. Front end panel to sill bolts (121). 117. Front End Panel 120. Bolt F-07282
6. Front end panel from the vehicle.
Figure 23Front End Panel Attachm ent
+4- Install or Connect (Figure 23)
1. Front end panel to the vehicle.

Assemble loosely.
3. Front end panel to sill bolts (121).
4. Front end panel to headlamp bezel support bolts
(118).
5. Grille. Refer to Grille Replacement.
6. Headlamp bezels.
SHEET METAL 2C-21
SPECIFICATIONS
TORQUE
Nm Ft. Lbs.
C/K Models
Hood Hinge to Hood B o lts ................................................................................................... 25 18
Hood Hinge to Cowl Bolts..................................................................................................... 43 32
Spring Assembly to Hood B o lts .......................................................................................... 25 18
Spring Assembly to Fender B o lts........................................................................................ 25 18
Primary Hood Latch Bracket to Radiator Support B o lts .................................................. 27 20
Bracket to Primary Hood Latch B olts.................................................................................. 27 20
Secondary Hood Latch to Hood B o lts ................................................................................ 27 20
Sheet Metal Support to Radiator Support Bolts................................................................. 17 13
Radiator Support to Fender B olts........................................................................................ 17 13
Radiator Support to Frame Nuts.......................................................................................... 47 35
Wheelhouse to Fender Bolt................................................................................................... 43 31
Fender to Cowl B o lt............................................................................................................... 43 31
Upper Fender to Door Pillar B o lt ........................................................................................ 43 31
Wheelhouse Panel Reinforcement to Underbody Bolts (52)............................................ 17 13
(53)............................................ 47 35
Wheelhouse to Radiator Support B o lts .............................................................................. 17 13
Fenderside Models
Brace to Rear Fender Bolts................................................................................................... 17 13
Side Panel to Rear Fender B o lts ........................................................................................ 10 7
Side Panel to Brace B olts..................................................................................................... 10 7
Fleetside Models
All Rear Fender to Side Panel Bolts, and N u ts ................................................................. 17 13
G Models
Hood Hinge to Hood B o lts ................................................................................................... 17 13
Primary Hood Latch Bracket to Radiator Support B o lts .................................................. 27 20
Bracket to Primary Hood Latch B olts................................................ ............................. 27 20
Secondary Hood Latch to Hood B o lts ................................................................................ 27 20
Sheet Metal Cross Panel to Headlamp Bezel Support B o lts .......................................... 27 20
Sheet Metal Cross Panel to Radiator Support Baffle Panel Bolts.................................... 27 20
Sheet Metal Cross Panel to Hood Latch Bracket B olts.................................................... 27 20
Sheet Metal Cross Panel to Fender Bolts........................................................................... 28 20
Sheet Metal Cross Panel to Vertical Support B olts........................................................... 27 20
Front End Panel to Vertical Support B olts......................................................................... 18 13
Vertical Support to Sill Bolts................................................................................................ 10 7
SPECIAL TOOLS
J-24595-B Door Trim Pad Remover
3A-1
SECTION 3
STEERING, SUSPENSION,
WHEELS AND TIRES
CONTENTS
SUBJECT PAGE
Front End A lig n m e n t................................................................................................................................................... 3A-1

Steering L in k a g e ........................................................................................................................................................3B1-1
Manual S te e rin g ..........................................................................................................................................................3B2-1
Power S tee rin g ............................................................................................................................................................3B3-1
Steering C o lu m n ........................................................................................................................................................3B4-1
Front S uspension..........................................................................................................................................................3C-1
Rear S u s p e n s io n ..........................................................................................................................................................3D-1
Wheels And T ire s ..........................................................................................................................................................3E-1
SECTION 3A
FRONT END ALIGNMENT

The following Notice applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: NOTICE : See Notice on page 3A-1 on this
section.
NOTICE: Front end alignment fasteners are important attaching parts in that they could affect the perform
ance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace
ment part of lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention of all parts.
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................... 3A-2

D efinition o f T e r m s ................................................................................................................................................. 3A-2
Diagnosis of Front End A lig n m e n t........................................................................................................................... 3A-2
On-Vehicle S e r v ic e ..................................................................................................................................................... 3A-3
In s p e c tio n .................................................................................................................................................................. 3A-3
Front End A lignm ent R equirem ents.....................................................................................................................3A-3
Alignm ent A d ju s tm e n ts .......................................................................................................................................... 3A-4
S pe cifica tio ns................................................................................................................................................................ 3A-6
3A - 2 FRONT END ALIGNMENT
DESCRIPTION
Front End Alignment refers to the angular relation CASTER (Figure 1)
ship between the front wheels, the front suspension Caster is the tilting of the wheel axis either forward
attaching parts and the ground. or backward from the vertical (when viewed from the
Proper front end alignment must be maintained in side of the vehicle). A backward tilt is positive ( + ) and
order to insure efficient steering, good directional sta a forward tilt is negative ().
bility and to prevent abnormal tire wear. On the short and long arm type suspension you
The most important factors of front end alignment cannot see a caster angle without a special instrument,
are wheel toe-in, wheel camber, and axle caster (Fig but if you look straight down from the top of the upper
ure 1). control arm to the ground, the ball joints do not line up
(fore and aft) when a caster angle other than 0 degree
is present. With a positive angle, the lower ball joint
DEFINITION OF TERMS would be slightly ahead (toward the front of the vehicle)
of the upper ball joint center line. Caster is designed
CAMBER into the front axle assembly on all four-wheel drive
Camber is the inward or outward tilting of the front vehicles, and is non-adjustable.
wheels from the vertical. When the wheels tilt outward TOE-IN
at the top, the camber is positive (+ ). When the wheels Toe-in is the turning of the front wheels. The actual
tilt inward at the top, the camber is negative (). The amount of toe-in is normally a fraction of a degree.
amount of tilt measured in degrees from the vertical is Toe-in is measured from the center of the tire treads or
called the camber angle. Camber is designed into the from the inside of the tires. The purpose of toe-in is to
front axle assembly of all four-wheel drive vehicles and insure parallel rolling of the front wheels and to offset
is non-adjustable. any small deflections of the wheel support system
If camber is extreme or unequal between the wheels, which occurs when the vehicle is rolling forward.
improper steering and excessive tire wear will result. Incorrect toe-in results in excessive toe-in and unstable
Negative camber causes wear on the inside tire, while steering. Toe-in is the last alignment to be set in the
positive camber causes wear to the outside. front end alignment procedure.
DIAGNOSIS OF FRONT END ALIGNMENT

Noisy Front End 1. Worn tie rod ends. 1. Replace ends.
2. Loose suspension bolts. 2. Refer to FRONT SUSPENSIO N
(SEC. 3C).
3. Lack of proper lubrication. 3. Refer to MAINTENANCE AND LU
BRICATION (SEC. OB).
4. Loose shock absorbers or worn bush 4. Tighten bolts and/or replace the
ings. bushings.
5. Loose stabilizer bar. 5. Tighten
Wheel Bounce 1. Tire and wheel out of balance. 1. Refer to WHEELS AND TIRES (SEC.
3E).
2. Blister or bump on the tire. 2. Replace the tire.
3. Improper shock absorber action. 3. Replace the shock absorber.
4. Excessive wheel or tire run-out. 4. Refer to WHEELS AND TIRES (SEC.
3E).
5. Tire Lead. 5. Refer to WHEELS AND TIRES (SEC.
3E).
Excessive Tire Wear 1. Incorrect wheel alignment. 1. Align the wheels.

2. Failure to rotate tires. 2. Refer to WHEELS AND TIRES (SEC.
3E).
3. Faulty shock absorbers. 3. Replace shock absorber.
4. Improper tire pressure. 4. Refer to WHEELS AND TIRES (SEC.
3E).
5. Overloaded or improperly loaded vehi 5. Avoid overloading vehicle.
cle.
6. Broken or sagging springs. 6. Replace springs.
FRONT END ALIGNMENT 3A-3
ON-VEHICLE SERVICE
Front View Side View
A minus B .. .Camber (Inches)

C . .Camber (Degrees Positive)
D . . .Caster (Degrees Positive)
E minus F .........Toe-In (Inches)
B-07371
Figure 1Caster - Camber - Toe-In
INSPECTION 8. Control arms or stabilizer bar attachments for

looseness. Refer to FRONT SUSPENSION (SEC.
Before making any adjustments affecting caster, 3C).
camber or toe-in, the following front end inspection 9. Alignment equipment. Follow the manufacturers
should be made: instructions.
10. Level of the vehicle. The vehicle must be on a
Inspect level surface fore and aft and transversely.
1. Tires for proper inflation pressure. Refer to

WHEELS AND TIRES (SEC. 3E).
FRONT END ALIGNMENT
2. Front wheel bearing for proper adjustment. Refer
to FRONT SUSPENSION (SEC. 3C.).
REQUIREMENTS
3. Ball joints, tie rod ends, and relay rods. If exces Satisfactory vehicle operation may occur over a wide
sive looseness is noted, correct before adjusting. range of front end alignment settings. If the settings
Refer to STEERING LINKAGE (SEC. 3B1). vary beyond certain tolerances, adjustments are
4. Wheels and tires for run-out. Refer to WHEELS advisable. The Specifications at the back of this
AND TIRES (SEC. 3E). section is a guideline for vehicle diagnosis or for
repairs.
5. Dimension BC in (figure 3). If not within specifi
cations, the correction must be made before ad Set the front end alignment to specifications while
justing caster. the vehicle is in its no rm a lly loaded condition.
Vehicles which are consistently operated with heavy
6. Steering gear for looseness at the frame.
loads should have toe-in adjusted with the vehicle
7. Shock absorbers for leaks or any noticeable under heavy load. This procedure should result in
noise. Refer to FRONT SUSPENSION (SEC. 3C). longer tire life.
3A-4 FRONT END ALIGNMENT
A.
B. Camber E. Subtract shims here to increase caster
C. Add shims here to increase caster F. Add shims equally to increase camber B-07372
Figure 2Caster - Camber Adjustm ent Pivot Shaft Outboard Of Frame
ALIGNMENT ADJUSTMENTS 3. Determine whether the frame angle is up in

rear or down in rear.
A normal shim pack will leave at least two threads of 4. Determine the caster angle reading from the
the bolt exposed beyond the nut. If two threads cannot alignment equipment.
be obtained, check for control arms and related parts.
5. Refer to figure 3. To determine an actual
The difference between front and rear shim packs must
(corrected) caster reading with various frame
not exceed 7.62 mm (0.03 inch). Front shim pack must
angles and caster readings, one of the following
be at least 2.54 mm (0.10 inch).
rules apply:
ACESS TO SHIM PACKS a. A DOWN IN REAR frame angle must be

Models w ith 3/4-lnch Nut SUBTRACTED from a POSITIVE caster
Jack up the frame to raise the wheel off the ground. reading.
This will allow the proper upper control arm to drop b. An UP IN REAR fram e angle m ust be
down far enough to use a socket on the nuts and ADDED to a POSITIVE caster reading.
permit shim adjustment. Torque to specifications, refer
c. A DOWN IN REAR frame angle must be
to FRONT SUSPENSION (SEC. 3C).
ADDED to a NEGATIVE caster reading.
Models with 7/s-lnch Nut
Remove the upper control arm bumper; then follow d. An UP IN REAR frame angle must be
SUBTRACTED from a NEGATIVE caster
the same procedure as with 3/4-inch Nut. Torque to
specifications. Reinstall the upper control arm bumper reading.
when alignm ent is com pleted. Refer to FRONT 6. Dimension BC measured 90 degrees from the
SUSPENSION (SEC. 3C). lower surface of the crossmember (C) and to the
inboard rear corner of the jounce bumper bracket
CASTER (B).
All caster specifications are given with a frame angle 7. Using dimension BC and the caster, camber,
of zero. Therefore, it will be necessary to know the wheel toe-in chart sheet, find the recommended
angle of the frame (whether up in rear or down in caster angle.
rear) before a corrected caster reading can be
determined. Camber and toe-in can be read as is 8. If the actual (corrected) caster cycle (Step 5) is
from the alignment equipment. not within the recommended caster angle (Step
7) make the necessary shim changes.
How To Determine Caster (Figure 2 and 3)
All caster specifications are given with vehicle frame
angle of zero. CAMBER
1. Position the vehicle on a smooth level surface. 1. Determine the camber angle from the alignment
equipment.
2. Use a bubble protractor or inclinom eter to
measure the frame angle. Frame angle is the 2. Add or subtract shims from both the front and
degree of tilt in the frame from the level position. rear bolts to affect a change.
A. Dimension BC
B. Jounce Bumper Bracket
C. Crossmember
B A
D. A DOWN IN REAR frame angle must be SUB F. A DOWN IN REAR frame angle must be ADDED
TRACTED from a POSITIVE caster reading. to a NEGATIVE caster reading.
_ô
r- HORIZONTAL
HORIZONTAL
FRAME ANGLE = 1- V a " DOWN FRAME ANGLE
= 1/2 DOWN
CASTER ANGLE READING = + (2-1/4) CASTER ANGLE READING = - ( - V a )

ACTUAL (CORRECTED) CASTER ANGLE = + (1)
ACTUAL (CORRECTED) CASTER ANGLE = - ( 1 - 3/ 4 )
E. A UP IN REAR frame angle must be ADDED to a G. An UP IN REAR frame angle must be SUBTRACTED
POSITIVE caster reading. from a NEGATIVE caster reading.
HORIZONTAL HORIZONTAL
FRAME ANGLE
FRAME ANGLE = 1 UP
= 1 1/4 UP
CASTER ANGLE READING = + (2) CASTER ANGLE READING = - ( 1/4 )

ACTUAL (CORRECTED) CASTER ANGLE = + (3) ACTUAL (CORRECTED) CASTER ANGLE = + (1)
B-07373
Figure 3Determining Caster
TOE-IN
1. D eterm ine the toe-in from the a lig n m e n t
equipment.
2. Change the length of both tie rod sleeves to affect
a toe change. Toe-in can be increased or
decreased by changing the length of the tie rod
ends. A threaded sleeve is provided for this
purpose. When the tie rod ends are mounted
ahead of the steering knuckle they must be
decreased in length in order to increase toe-in.
When the tie rod ends are mounted behind the
steering kunckle they must be lenghtened in
order to increase toe-in. Refer to STEERING
LINKAGE (SEC. 3B1) for clamping instructions.
3A-6
P200 + 300 P200 + 300
Dimension Dimension (42) Except (42) W/R05 P300 P300 (32) P30/3500
BC BC C100 C200 + 300 G100 + 200 G300 FS3, R05, Except FS3, w/JB8 or JB9 w/JB8 or JB9 (32,42) K100 + 200
FRONT END ALIGNMENT

MM Inches (00) (00) (00) (00) JB8 or JB9 JB8 or JB9 Except FS3 Except FS3 W/FS3 + 300 (00)
38.1 1.50 - 3.4 3.1 - - - -
44.5 1.75 - 3.2 3.0 - + 5 + 8
50.8 2.00 - 3.0 2.7 3.0 2.5 3.2 - NOMINAL NOMINAL
57.2 2.25 - 2.9 2.4 2.6 2.2 2.9 - (References (References
63.5 2.50 3.7 1.5 2.7 2.1 2.3 1.9 2.6 5.5 only.no o n ly, no
70 2.75 3 .5 1.2 2 .5 1.8 2 .0 1 .6 2 .4 5 .3 m eans o f m eans of

c/>
76.2 3.00 3 .2 0 .9 2 .3 1.5 1.7 1 .3 2 .1 5.0 a d ju stm e n t a d ju stm e n t

g m
w O
82.5 3.25 2 .9 0 .6 2 .2 1.2 1.4 1 .1 1.8 4 .7 p rovided ). p rovided ). m T1
88.9 3.50 2 .6 0 .3 2 .0 1 .0 1 .2 0 .8 1.5 4 .4 = o
S >
95.3 3.75 2 .4 0 .1 1 .8 0 .7 0 .9 0 .5 1.2 4 .1 > 2
3 0
101.6 4.00 2 .1 -0 .0 1 1.7 0 .5 0 .6 0 .3 1.0 3 .8
V)
108 4.25 1 .8 -0 .1 5 1.5 0 .2 0 .4 0 .0 0 .7 3 .5
114.3 4.50 1 .5 -0 .7 1 .4 -0 .0 3 0 .2 -0 .2 0 .5 3 .3
120.7 4.75 1 .3 -1 .0 - -0 .1 -0 .4 0 .2 3 .1
127 5.00 1 .0 -1 .2 -0 .1 2 .9
o
oo
o
133.4 5.25 -1 .4 - -0 .3 2 .6
139.7 5.50 0 .5 -1 .6 - - -0.5 2 .4
146 5.75 0 .3 -1 .8 - - -0 .7 2 .2
152.4 6.00 0 - - - 2 .0
SPECIFICATIONS (CONTINUED)
CAMBER AND TOE-IN CHART
Model Camber Toe Angle Total Toe-In

C100 (00) 0.70 0.36 4.5 mm (0.18 inch)
C200 + 300 (00) 0.25
+ 1.5
K100 + 200 + 300 (00) Nominal
(Reference only
no means of
adjustment provided). 0 0 mm (0 inch)
G100 + 200 (00) 0.50 0.36 4.5 mm (0.18 inch)
G300 (00) 0.25
P200 + 300 (32, 42)
Except FS3 0.25 0.36 4.5 mm (0.18 inch)
P30/3500 (32,42) + 1.5
with FS3 Nominal
(Reference only
no means of
adjustment provided). 0.1 3.0 mm (0.12 inch)
CASTER, CAMBER, WHEEL TOE-IN

ALIGNMENT SETTING TOLERANCES
Check Re-Set
Caster 1.00 0.50
Camber 0.75 0.50
Total 3.0 mm (0.12 inch) 1.5 mm (0.06 inch)
Toe-In 0.232 0.116
STEERING LINKAGE 3B1-1
SECTION 3B1
STEERING LINKAGE
the manual as indicated at appropriate locations by the terminology: NOTICE: See Notice on page 3B1-1 of this
section.
NOTICE: All steering linkage fasteners are im portant attaching parts in that they could affect the perform
ance o f vital parts and systems, and/or could result in major repair expense. They must be replaced w ith one
o f the same part num ber o r w ith an equivalent part if replacement becomes necessary. Do not use a replace
ment part o f lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention o f all parts.
CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 3B1- 1
Diagnosis Of Steering L in kag e ............................................................................................................................. 3B1- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 3B1- 2
Idler Arm Inspection.............................................................................................................................................3B1- 2
Idler Arm Adjustm ent (P30(32) M o to rh o m e )................................................................................................. 3B1- 3
Idler Arm R e p la c e m e n t...................................................................................................................................... 3B1- 3
Relay Rod Replacem ent...................................................................................................................................... 3B1- 5
Pitman Arm R e p la ce m e n t..................................................................................................................................3B1- 6
Steering Shock Absorber In s p e c tio n .............................................................................................................. 3B1 - 7
Steering Shock Absorber Replacem ent.......................................................................................................... 3B1- 8
Tie Rod Replacement (C, G, P20 And 30(42) M o d e ls .................................................................................. 3B1- 8
Tie Rod Replacement (K and P30(00)FS3 M o d e ls ).......................................................................................3B 1- 9
Connecting Rod Replacement (K and P30(00)FS3 M o d e ls)....................................................................... 3B1-11
Connecting Rod Replacement (P30(32) M o to rh o m e ).................................................................................. 3B1-12
S pecifications............................................................................................................................................................3B1 -14
Special T o o ls ............................................................................................................................................................3B1-15
DESCRIPTION
The steering linkage for the C, G, and P20 + 30(42) the frame by support assemblies. The support as
model is composed of a pitman arm, idler arm, relay semblies are adjustable for shaft end play. The
rod, two adjustable tie rods and a steering shock ab steering shock absorber is attached to the frame and
sorber (G-model). When the steering wheel is turned, relay arm (figures 1 through 3).
the gear rotates the pitman arm which forces the relay The K model has a front driving axle assembly and
rod to one side. The tie rods, which are connected to the P30(00) with RPO-FS3 has an I-Beam axle assem
the relay rod by ball studs, transfers the steering force bly. The steering linkage consists of an adjustable con
to the wheels. The tie rods are adjustable and are used necting rod, steering shock absorber, pitman arm and
for toe-in adjustments. The relay rod is supported by a tie rod which connects the two steering knuckles to
the pitman arm and idler arm. The idler arm pivots on a gether (figures 7 and 8).
support attached to the frame rail. On the G-model the The overall condition of the steering linkage affects
steering shock absorber is attached to a relay rod and steering performance. If parts are bent, damaged,
a mounting bracket to the steering gear. worn or poorly lubricated, improper and possibly dan
The P30(32) Motorhome model steering linkage has gerous steering action will result.
a similar adjustable tie rod assembly as described Whenever any steering linkage components are re
above. When the steering wheel is turned, the gear paired or replaced, check the steering geometry and
rotates the pitman arm which forces the nonadjustable front end alignment. Refer to FRONT END ALIGN
connecting rod and relay arm to move the relay rod to MENT (SEC. 3A).
one side. The relay arm and idler arm are attached to
3B1-2 STEERING LINKAGE
DIAGNOSIS OF STEERING LINKAGE

Refer to MANUAL STEERING (SEC. 3B2) or POWER STEERING (SEC. 3B3) in this manual, depending on
vehicle equipment.
ON-VEHICLE SERVICE
1. Idler Arm
2. Relay Rod
3. Tie Rod Assembly
4. Steering Knuckle
5. Pitman Arm
6. Steering Gear B-09657
Figure 1Steering Linkage (C and P20 + 30(42) Models)
IDLER ARM INSPECTION Im portant
Jerking the right wheel and tire assembly back

Inspect (Figures 4 and 5) and forth, causing an up and down movement of
the idler arm, is NOT an acceptable testing
1. Raise the vehicle. Allow the front wheels to rotate procedure. There is no control on the amount of
freely and the steering mechanism freedom to force being applied to the idler arm.
turn. Position the wheels in a straight ahead
position. Care sh o u ld be used w h e n e ve r sh im m y
complaints are suspected of being caused by
2. Place a spring scale near the relay rod end of the loose idler arms. Before suspecting suspension
idler arm. Exert a 110 N (25 lb.) force upward and or steering components, technicians should
then downward (G model the force is forward and consider areas such as dynamic imbalance,
rearward) while measuring the total distance the runout or force variation of wheel and tire
arm moves. The allowable deflection is 3.18mm assemblies and road surface irregularities. Refer
(Vs inch) for a total of 6.35mm (1A> inch) (figures 4 to WHEELS AND TIRES (SEC. 3E).
and 5). Replace the idler arm if it fails this test
with the exception of the P model motorhome.
Refer to Idler Arm Adjustment (P 30(32) Mo
torhome) in this section.
1. Idler Arm
2. Relay Rod
3. Tie Rod Assem bly
4. Steering Knuckle
5. Pitman Arm
6. Steering Gear
7. Shock A bsorber
9. Bracket
B-09659
Figure 2Steering Linkage (G Model)
IDLER ARM ADJUSTMENT IDLER ARM REPLACEMENT

(P30(32) MOTORHOME)
The frame mounted idler support assembly (10) is Important
adjustable for support shaft end play. Check for idler
arm movement as described in Idler Arm Inspection. Do not attempt to free the ball stud by using a
If the idler arm fails this test, adjust the support shaft pickle fork or wedge type tool, because seal or
end-play. bushing damage could result (figure 6). Use the
proper tool to separate all ball joints.

Adjust (Figure 3)
Tool Required:
1. Loosen the support assembly jam nut. J-24319-01 Steering Linkage Puller.
Raise the vehicle.
2. Tighten the adjuster plug to metal-to-metal
1. Idler arm frame bolts.
contact.
2. Nut from the idler arm ball stud.
3. Idler arm (1) from the relay rod (2). Use
3. Back off the adjuster plug 1/b of a turn (V2 of a flat
J-24319-01.
on the square nut).
L* Inspect
Ball stud threads for damage.

Ball stud seal for cuts or other damage.
Jam nut to 40 N m (30 ft. lbs.). The adjusting
plug should not rotate. Clean
Threads on the ball stud and in the ball stud nut.

1. Idler Arm
2. Relay Rod
3. Tie Rod Assembly
4. Steering Knuckle
5. Pitman Arm
6. Steering Gear
7. Shock Absorber
8. Connecting Rod
10. Support Assem blies
11. Relay Arm
12. Washer
13. Grommet
B-09656
Figure 3Steering Linkage (P30(32) Motorhome)
-- Install or Connect (Figures 1 and 2) 3. Prevailing torque nut to the idler arm ball stud.
Tools Required:
J-29193 Steering Linkage Installer (12mm).
Tighten
Nut to Specifications at the end of this
NOTICE: For steps 1 and 3 see Notice on
section.
page 3B1-1 of this section.
Lower the vehicle.
Position the idler arm (1) on the frame.
1. Frame bolts to the idler arm.
Tighten Adjust
Bolts to Specifications at the end of this Toe-in if necessary. Refer to FRONT END
section. ALIGNMENT (SEC. 3A) in this manual.
2. Relay rod (2) to the idler arm ball stud. Make
certain the seal is on the stud. Tighten tool
J-29193 or J-29194 to 54 N-m (40 ft. lbs.) to seat
the tapers. Remove the tool.
RELAY ROD REPLACEMENT
Im portant
Use the proper tool to separate all tie rod and ball
joints.
+ + Remove or Disconnect (Figures 1 through 3)
Tool Required:
J-24319-01 Steering Linkage Puller.
Raise the vehicle.
1. Inner tie rod (3) from the relay rod (2). Refer to Inspect
Tie Rod Replacement in this section.
Threads on the tie rod and the tie rod end for
2. Nuts from the idler arm (1) and pitman arm (5) or
damage.
relay arm (11) ball studs at the relay rod (2).
3. Relay rod (2) from the idler arm (1). Use
J-24319-01. Ball stud seals for excessive wear.
4. Relay rod (2) from the pitman arm (5) or relay arm
(11). Use J-24319-01. 3 Clean
Threads on the ball stud and the ball stud nut.
Install or Connect (Figures 1 through 3)
Tools Required:
1. Relay rod (2) to the idler arm (1) and the pitman
arm (5) or relay arm (11) ball stud. Make certain
the seal is on the stud. Tighten J-29193 or
J-29194 to 54 N m (40 ft. lbs.) to seat the tapers.
Remove the tool.
A. 6.35 mm ( V a " )
NOTICE: See Notice on page 3B1-1 of this
B. Apply Spring Scale
section.
B-07378
2. Nuts to the idler arm and the pitman arm or relay
Figure 5Checking idler Arm Movement (G-Model) arm ball stud.
3. Tie Rod Assembly

4. Steering Knuckle
5. Pitman Arm
6. Steering Gear
7. Shock Absorber
8. Connecting Rod Assembly
B-07367
Figure 7Steering Linkage (P30(00)FS3)
Tighten Mark the pitman arm and the pitman shaft. This
will permit proper alignment at assembly.
Nuts to Specifications at the end of this
section.
3. Inner tie rod (3) to the relay rod. Refer to Tie Rod NOTICE: Do not hammer on pitman arm,
Replacement. pitman shaft, or puller. Damage to pitman arm
Lower the vehicle. or steering gear may result.
4. Pitman arm (5). Use J-6632-01 or J-29107.

PITMAN ARM REPLACEMENT
y | Inspect
Im portant
Use the proper tool to separate all ball joints.
Ball stud seals for excessive wear.
Remove or Disconnect (Figures 1, 2, 3, 7 and
8)
jQJ Clean
Tools Required:
Threads on the ball stud and ball stud nut.
J-24319-01 Steering Linkage Puller.
J-29107 Pitman Arm Puller.
J-6632-01 Pitman Arm Remover. -4- Install or Connect (Figures 1, 2, 3, 7 and 8)
Raise the vehicle.
1. Relay rod nut or connecting rod nut and cotter pin Tools Required:
from the pitman arm ball stud.
2. Relay rod (2) or connecting rod (8) from the J-29193 Steering Linkage Installer (12mm).
pitman arm (5). Use J-24319-01.
3. Pitman arm nut and washer. J-29194 Steering Linkage Installer (14mm).
A. Tie Rod Assem bly (K30)

3. Tie Rod Assembly
4. Steering Knuckle
5. Pitman Arm
7. Shock Absorber
8. Connecting Rod Assembly
B-09660
Figure 8Steering Linkage (K Model)
NOTICE: For steps 2 and 4 see Notice on 3. Relay rod (2) or connecting rod (8) to the pitman
page 3B1-1 of this section. arm ball stud. Make certain the seal is on the
stud. Tighten tool J-29193 or J-29194 to 54 N m
(40 ft. lbs.) to seat the tapers. Remove the tool.
NOTICE: If a clamp type pitman arm is used, 4. Relay rod nut or the connecting rod castellated
spread the pitman arm just enough, with a nut and cotter pin to the pitman arm ball stud.
wedge, to slip the arm onto the pitman shaft.
Do not spread the pitman arm more than
required to slip over the pitman shaft with
hand pressure. Do not hammer, or damage to Castellated nut to S pe cifica tio ns as
the steering gear may result. instructed at the end of this section.
Lower the vehicle.
1. Pitman arm (5) on the pitman shaft. Line up the
marks made at removal.
2. Pitman arm washer and nut. STEERING SHOCK ABSORBER
INSPECTION
S i Tighten
Steering shock absorbers are a sealed assembly
Pitman arm nut to Specifications at the and are non re p airab le . Replace the com plete
end of this section. assembly if damaged.
I? Inspect (Figures 2, 3, 7 and 8) Tighten
1. Shock absorber for fluid leakage. A slight film of Castellated nut to S pecifications as
fluid is allowable near the shaft seal. If there is instructed at the end of this section.
excessive fluid leakage, be sure its from the
shock absorber and then replace the shock
absorber. TIE ROD REPLACEMENT
2. Shock absorber bushing for excessive wear. (C, G, P20 AND 30(42) MODELS)
Replace shock absorber if necessary.
3. Test the shock absorber. There are two tie rod assemblies. Each assembly is
Disconnect the shock absorber from the of a five piece construction, consisting of an adjuster
frame or axle end. tube, two clamps and two tie rod ends. The ends are
threaded into the sleeve and secured with the clamps.
Extend and compress the shock absorber
Right and left hand threads are used for toe-in
usin g as m uch tra ve l as p o s s ib le .
adjustments and steering gear centering. The tie rod
Resistance should be smooth and constant
ends should be replaced when excessive up and down
for each stroking rate. Replace the shock
motion is present, or when excessive end play or loss
absorber if any binding or unusual noises
of motion at the ball stud exists.
are present.
Before servicing, note the position of the tie rod
Install the end of the shock absorber. Torque
adjuster tube and the direction the bolts are installed.
to specifications.
The tie rod adjuster tube components may be rusted. If
the torque required to remove the nut from bolt
exceeds 9 N m (7 ft. lbs.) discard the nuts and bolts.
STEERING SHOCK ABSORBER Apply penetrating oil between the clamp and tube and
REPLACEMENT rotate the clamps until they move freely. Install all
parts, with the correct part number, in the proper
position.
B
Im portant
1. Shock absorber mounting nuts and washers.
Washer (12) and grommet (13) (P30(32) model). Use the proper tool to separate all tie rod and ball
2. Cotter pin and castellated nut. joints.
3. Shock absorber (7).
Remove or Disconnect (Figures 1 through 3)
L * Inspect
Tool Required:
Shock absorber for leaks and damage. J-6627-A Wheel Stud Remover and Tie Rod
Remover.
Shock absorber bushings for wear and damage.
Raise the vehicle.
Grommet (13) for wear.
1. Cotter pins and castellated nuts from the outer tie
+4-
rod ball stud.
Install or Connect
2. Outer tie rod ball studs from the steering knuckle
NOTICE: For steps 2 and 3 see Notice on (4). Use J-6627-A (figure 9).
page 3B1-1 of this section. 3. Inner tie rod ball stud from the relay rod (2). Use
J-6627-A.
1. Shock absorber with bushings to the axle 4. Tie rod ends from the adjuster tube. Loosen the
bracket. clamp bolts and unscrew the end assemblies.
Washer (12) and grommet (13) (P30(32) model). J ? Inspect

2. Shock absorber mounting nuts and washers.
Tie rod end for damage.
Tie rod end seals for excessive wear.
Threads on the tie rod and tie rod end for
Shock absorber nuts to Specifications at damage.
the end of this section. Ball stud threads for damage.
3. Castellated nut and cotter pin. Adjuster tube for bending or damaged threads.
Adjust
Toe-in. Refer to FRONT END ALIGNMENT

(SEC. 3A) in this manual.
6. Adjuster tube clamp bolts (figures 10, 11 and 12).
Before tightening the clamp bolts, be sure the
following conditions have been met:
The clamp must be positioned between the
locating dim ples at e ithe r end of the
adjuster tube.
The clamps must be positioned within the
angular travel shown in figures 10, 11 or 12.
Both inner and outer tie rod ends must
rotate for their full travel. The position of
each tie rod end must be maintained as the
cla m p s are tig h te n e d to e nsure free
movement of each joint.
The clamp ends may touch when nuts are
torqued to specification, but the gap next to
Clean the adjuster tube must NOT be less than the
minimum dimension shown in figures 10, 11
The tapered surfaces. or 12.
Threads on the ball stud and in the ball stud nut.
Tighten
-- Install or Connect (Figures 1 through 3)
A d ju s te r tu b e cla m p b o lts to
Tools Required: Specifications at the end of this section.
J-29194 Steering Linkage Installer (14mm). TIE ROD REPLACEMENT
(K AND P30(00)FS3 MODELS)
If the rod ends were removed, lubricate the tie rod

Tool Required:
threaas with chassis lubricant.
J-6627-A Wheel Stud Remover and Tie Rod
1. Tie rod ends to the adjuster tube. The number of
Remover.
threads on both the inner and outer rod ends
1. Cotter pins and castellated nuts from the rod
must be equal within three threads.
assembly (3).
2. Inner tie rod ball studs to the relay rod (2). The
2. Shock absorber (7) from the tie rod assembly (3).
seal must be on the stud. Tighten J-29193 or
J-29194 to 54 N m (40 ft. lbs.) to seat the tapers. 3. The rod ball studs from the steering knuckle (4).
Remove the tool. Use J-6627-A.
3. Prevailing torque nut to the inner tie rod ball stud. 4. Tie rod end bodies. Count the number of turns
needed to remove the tie rod end bodies.
5. Tie rod ends from the adjuster tube. On K30
models, note the position of the adjuster tube,
Nut to Specifications at the end of this and the direction from which the bolts are in
section. stalled.
4. Outer tie rod ball studs to the steering knuckle.
5. Castellated nuts and cotter pins to the outer rod I? Inspect
ball studs.
Tie rod for bending or damaged threads.
Tie rod end seals for wear.
Castellated nuts to Specifications as Adjuster tube for bending or damaged threads
instructed at the end of this section. (K30).
VIEW A
4. Steering Knuckle
C. Clamps Must Be Between And Clear Of Dimples Before Torquing Nuts
D. Adjuster Tube Slot
E. Slot In Adjuster Tube Must Not Be W ithin This Area Of Clamp Jaws.
F. Rearward Rotation
G. Clamp Ends May Touch When Nuts Are Torqued To Specifications. ki
But The Gap Next To The Adjuster Tube Must Be Visible. Minimum Gap Is 0.127 mm (0.005 Inch).
B-07290
Figure 10Tie Rod Clamp And A djuster Tube Positioning (C Model)
4FRT
4. Steering Knuckle i
C. Clamp Must Be Between And Clear Of Dimples Before Torquing Nuts
D. Slot In A djuster Tube Must Not Be W ithin This Area Of Clamp Jaws
E. Rearward Rotation
F. Adjuster Tube Slot
G. Clamp Ends May Touch When Nuts Are Torqued To Specifications.
But The Gap Next To The Adjuster Tube Must Be Visible. Minimum Gap Is 0.127 mm (0.005-inch).
B-07291
Figure 11Tie Rod Clamp And A djuster Tube P ositioning (G Model)
VIEW A
4. Steering Knuckle
C. Clamps Must Be Between And Clear Of Dimples Before Torquing Nuts
D. Adjuster Tube Slot
E. Slot In Adjuster Tube Must Not Be W ithin This Area Of Clamp Jaws.
F. Rearward Rotation
G. Clamp Ends May Touch When Nuts Are Torqued To Specifications.
But The Gap Next To The Adjuster Tube Must Be Visible. Minimum Gap Is 0.127 mm (0.005 Inch).
B-07292
Figure 12Tie Rod Clamp And Adjuster Tube Positioning (All P Models Excluding FS3)
Clean Remove or Disconnect (Figures 7 and 8)
The tapered surfaces. Tool Required:

Threads on the ball stud and in the ball stud nut. J-24319-01 Steering Linkage Puller.
Raise the vehicle.
1. C astellated nuts and cotter pins from the
+ + Install or Connect (Figures 7 and 8)
connecting rod (8).
2. Connecting rod (8) from the pitman arm (5). Use
If the tie rod ends were removed, lubricate the tie
J-24319-01.
rod threads with chassis lubricant.
3. Connecting rod (8) from the steering knuckle (4).
1. Tie rod end bodies to the tie rod (if removed). Use J-24319-01.
Screw the rod assembly on the same number of
turns as when removed. Im portant
Tie rod ends to the adjuster tube (K30).
2. Outer tie rod ball studs to the steering knuckle B efore rem oving the co n n e c tin g rod
adjuster tube, note the position of the tube
(4).
and the direction from which the bolts are
3. Shock absorber (7) to the tie rod assembly. installed.
4. Connecting rod ends from the adjuster tube.
NOTICE: See Notice on page 3B1-1 of this Loosen the clamp bolts and unscrew the end
section. assemblies.
The c o n n e c tin g rod a d ju s te r tub e
4. Castellated nuts and cotter pins to the tie rod components may be rusted. If the torque
assembly. required to remove the nut from the bolt
exceeds 9 N m (7 ft. lbs.) discard the nuts
and bolts.
& Tighten
Apply penetrating oil between the clamps
Castellated nuts to Specifications as and the tube. Rotate the clamps until they
instructed at the end of this section. move freely.
L* Inspect

Toe-in. Refer to FRONT END ALIGNMENT
Ball stud seals for wear.
(SEC. 3A) in this manual.
Adjuster tube for bending or damaged threads.
Tighten jg ,
Clean
Jam nut at the tie rod end bodies to Threads on the ball stud and ball stud nut.
Specifications at the end of this section.
A d ju s te r tu b e cla m p b o lts to + - Install or Connect (Figures 7 and 8)
Specifications at the end of this section
(K30).
CONNECTING ROD
If the connecting rod ends were removed,
REPLACEMENT lubricate the connecting rod threads with chassis
(K AND P30(00)FS3 MODEL) lubrication.
1. Connecting rod ends to the adjuster tube. The
The adjustable connecting rod is used for centering number of threads on both the inner and outer
the steering gear with the front axle. Replace the connecting rod ends must be equal within three
connecting rod if the rod is bent or if the ball stud is threads.
loose. 2. Inner connecting rod (8) ball stud to the pitman
arm (5) (on K models install the short end). Make
Im portant certain the seal is on the stud.
3. Castellated nut and cotter pin to the inner
Use the proper tool to separate all ball joints. connecting rod ball stud.
l^l Tighten
Castellated nut to S pecifications as
instructed at the end of this section.
4. Outer connecting rod ball stud to the steering
knuckle (4).
5. Castellated nut and cotter pin to the outer
connecting rod ball stud.
Tighten
Castellated nut to S pe cifications as

instructed at the end of this section.
The connecting rod ends to the pitman arm and
steering knuckle must be in correct relationship
to each other after adjustm ent within 2
degrees (K model).
ft Adjust
Steering gear high point centering. Refer to

POWER STEERING (SEC. 3B3) in this
manual.
6. Adjuster tube clamp bolts (figures 13 and 14).
Before tightening the clamp bolts, be sure the
following conditions have been met.
The clamps must be positioned between the
locating dim ples at either end of the
adjuster tube.
The clamps must be positioned within the VIEW A
angular travel shown in figures 13 and 14.
The clamp ends may touch when nuts are
torqued to sp e c ific a tio n , but the gap
adjacent to adjuster tube must NOT be less
than minimum dimension shown in figures
13 and 14.
Both inner and outer connecting rod ends
must rotate for their full travel. The position
of each connecting rod end must be
maintained as the clamps are tightened to
C. Clamps must be between and clear of
ensure free movement of each joint.
dimples before torquing nuts.
D. Outboard Rotation
$ Tighten
E. Adjuster Tube Slot
F. Slot in adjuster tube must not be within
Adjuster tube bolts to Specifications at
this area of clamp jaws.
the end of this section.
G. Clamp ends may touch when nuts
Lower the vehicle.
are torqued to specifications. But the gap
next to the adjuster tube must be visible.
Minim um gap is 0.127 mm (0.005-inch).
CONNECTING ROD
REPLACEMENT
(P30(32) MOTORHOME)
B-07293
The non-adjustable connecting rod is used to
connect the pitman arm to the relay arm. Replace the
connecting rod if the rod is bent or the ball stud is Figure 13Connecting Rod Clamp And Adjuster
loose. Tube Positioning (P30(00)FS3)
C. Slot Of Adjuster Tube May Be In Any Position On Arc Shown But Not Closer Than 2.54 mm (0.10
Inch) To The Edge Of Clamp Jaws Or Between. R_n7 ?q
Figure 14Connecting Rod d a m p And Adjuster Tube P ositioning (K Model)
Im portant Clean
Use the proper tool to separate the ball joints. Threads on the ball stud and ball stud nut.
Remove or Disconnect (Figure 3) Install or Connect (Figure 3)
Tool Required: 1. Connecting rod (8) to the pitman arm (5) and relay
J-24319-01 Steering Linkage Puller. arm (11).
Raise the vehicle. 2. Castellated nuts and cotter pins.
1. C astellated nuts and cotter pins from the
connecting rod (8). Tighten
2. Connecting rod (8) from the pitman arm (5). Use
J-24319-01. Castellated nuts to Specifications as
3. Connecting rod (8) from the relay arm (11). Use instructed at the end of this section.
J-24319-01. Lower the vehicle.
Inspect

Ball stud seals for excessive wear.
3B1-14
SPECIFICATIONS
C Model G Model P20 AND 30(42) P30(32) IVotorhome P30(00)FS3 K Model
STEERING
Nm F t. Lbs. Nm F t. Lbs. Nm F t. Lb s. Nm Ft. Lbs. Nm F t. Lbs. Nm F t. Lb s.
Tie Rod (3) End To Steering Knuckle (4)* 62 46 62 46 62 46 62 46 220 162 55 40
Tie Rod (3) Adjuster Tube Bolts 19 14 19 14 19 14 19 14 55 40
Tie Rod (3) To Relay Rod (2) 90 66 90 66 90 66 90 66
Idler Arm (1) To Relay Rod (2) 90 66 90 66 90 66 90 66
LINKAGE
Idler Arm (1) To Frame 40 30 47 35 40 30
Pitman Arm (5) To Relay Rod (2) 90 66 90 66 90 66
Pitman Arm (5) To Steering Gear (6) 250 184 250 184 250 184 170 125 170 125 125 92
Bolt To Shock Absorber Bracket (9) 100 75
Shock Absorber (7) To Tie Rod (3)* 62 46 62 46 62 46

Shock Absorber (7) To Frame 62 46 11 8 47 35 110 81
Shock Asborber (7) To Idler Arm (1)* 62 46
Connecting Rod (8) To Adjuster Tube Bolts 68 50 54 40

Connecting Rod (8) To Pitman Arm (5)* 95 70 95 70 120 89
Connecting Rod (8) To Steering Knuckle (4)* 95 70 120 89
Connecting Rod (8) To Relay Arm (11)* 95 70
Support Assemblies (10) To Frame 65 48
Idler Arm (1) And Relay Arm (11) To

1/U
i 7 fi
I^D
Support Assemblies (10)
Relay Rod (2) To Relay Arm (11) 90 66
Tie Rod Jam Nut (K10, 20) & P30(00)FS3 375 277 125 92
* Tightening Procedure (Castellated Nuts)

1. Tighten to the specified torque.
2. Advance the nut to align the nut slot with the cotter pin hole. Never back the nut off to align the cotter pin hole.
3. Insert a new cotter pin of the correct size.
SPECIAL TOOLS
J-6627-A Wheel Stud Remover & Tie Rod Remover

J-6632-01 Pitman Arm Remover
J-29107 Pitman Arm Puller
J-24319-01 Steering Linkage Puller
J-29193 Steering Linkage Installer (12mm)
J-29194 Steering Linkage Installer ( 1 4 m m )
3B2-1
SECTION 3B2
MANUAL STEERING GEAR
The following notice applies to one or more steps in the assembly procedure of components in this portion of the
manual as indicated at appropriate locations by the terminology NOTICE: See Notice on page 3B2-1 of this
Section.
NOTICE: These fasteners are important attaching parts in that they could affect the performance of vital
components and systems, and/or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace
to assure proper retention of these parts.
CONTENTS
SUBJECT PAGE
Description .................................................................................................................................................................3B2- 1
Diagnosis Of Manual Steering System ................................................................................................................ 3B2- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 3B2- 3
M a in te n a n ce ..........................................................................................................................................................3B2- 3
Steering Gear Replacem ent................................................................................................................................3B2- 3
Pitman Shaft Seal R e p lace m e n t....................................................................................................................... 3B2- 4
Steering Gear A d ju s tm e n ts ................................................................................................................................3B2- 5
Steering Gear High Point C e n te rin g .................................................................................................................3B2- 6
S pe cifica tio ns............................................................................................................................................................ 3B2- 7
Special T o o ls ............................................................................................................................................................3B2- 7
DESCRIPTION
The steering gear is the recirculating ball nut and
worm type. The worm is located on the lower end of
the steering shaft. The ball nut is mounted on the worm
and the steel balls act as a rolling thread between the
worm and nut to provide a low friction drive between
them.
Teeth on the ball nut engage teeth on the pitman
shaft sector. The teeth on the ball nut are made so that
a tighter fit exists between the ball nut and pitman
shaft sector teeth when the front wheels are in the
straight ahead position. The sector teeth are slightly
tapered so that a proper preload may be obtained by
moving the pitman shaft endways by means of a pre
load adjuster screw which extends through the gear
housing side cover. The head of the preload adjuster
and a selectively fitted shim fit snugly into a T-slot in
the end of the pitman shaft, so that the screw also 1. Ball Nut
controls the end play of the shaft (figure 1). 2. Worm Bearing
3. Seal
4. Wormshaft
5. Balls and Guides
6. Adjuster Plug
7. Nut
8. Worm Bearing (Lower)
9. Pitman Shaft Sector
B-07349
Figure 1Manual Steering Gear

3B2-2 MANUAL STEERING GEAR
DIAGNOSIS OF MANUAL STEERING SYSTEM

Rattle Or Chuckle In 1. Insufficient or improper lubricant in the 1. Add specified lube.

The Steering Gear steering gear.
2. Pitman arm loose on the shaft or the 2. Tighten to specified torque.
steering gear mounting bolts loose.
3. Loose or worn steering shaft bearing. 3. Replace steering shaft bearing.
4. Excessive over-center lash or worm 4. Adjust steering gear to specified pre
thrust bearings adjusted too loose. On loads.
turns a slight rattle may occur, due to
the increased lash between ball nut
and pitman shaft as gear moves off the
center of high point position. This is
normal and lash must not be reduced
to eliminate this slight rattle.
Poor Return Of The 1. Steering column misaligned. 1. Align the column.

Steering Wheel 2. Insufficient or improper lubricant in the 2. Lubricate as specified.
steering gear or front suspension.
3. Steering gear adjusted too tight. 3. Adjust over-center and thrust bearing
preload to specifications.
4. Front w heel a lig n m e n t in c o rre c t 4. Adjust to specifications.
(Caster).
Excessive Play Or 1. Front wheel bearings loosely adjusted. 1. Adjust bearings or replace with new
Looseness In The parts as necessary.
Steering System 2. Steering system out of alignment. 2. Align caster, camber, and toe-in.
3. Worn upper ball joints. 3. Check and replace ball joints if nec
essary.
4. Steering wheel loose on the shaft, 4. Tighten to specification, replace if
loose pitman arm, tie rods, steering worn or damaged.
arms or steering linkage ball nuts.
5. T ire s b ad ly w orn, edge of tire s 5. Install new tires, and check align
rounded off. ment.
6. Excessive over-center lash. 6. Adjust over-center preload to specifi
cations.
7. Worm thrust bearings loosely ad 7. Adjust the worm thrust bearing pre
justed. load to specifications.
Hard Steering 1. Low or uneven tire pressure. 1. Inflate to specified pressures.

Excessive Effort 2. Insufficient or improper lubricant in the 2. Lubricate as specified. Relubricate at
Required At The steering gear or front suspension. specified intervals.
Steering Wheel 3. Steering shaft flexible coupling mis 3. Align the column and couplings.
aligned.
5. Front wheel alignment incorrect. 5. Check the alignment and correct as
necessary.
MANUAL STEERING GEAR 3B2-3
ON-VEHICLE SERVICE
MAINTENANCE
The steering gear is factory-filled with steering gear
lubricant. Seasonal change of the lubricant should not
be performed and the housing should not be drained.
No additional lubrication is required for the life of the
steering gear.
At intervals specified in MAINTENANCE AND
LUBRICATION (SEC. OB) of this manual, the gear
should be inspected for seal leakage (actual solid
grease not just oily film). If a seal is replaced or the
gear is overhauled, the gear housing should be refilled
with Steering Gear Lubricant meeting GM specification
1051052 (or equivalent).
NOTICE: DO NOT USE EP Chassis Lube to B-07355

lubricate the gear. DO NOT OVER-FILL the
gear housing, or damage may occur. Figure 2Removing Pitman Arm
C-Models
1. F le xib le c o u p lin g onto the ste e rin g gear
STEERING GEAR wormshaft.
REPLACEMENT Align the flat in the coupling with the flat on
the shaft.
Push the coupling onto the shaft until the
+ + Remove or Disconnect
w o rm s h a ft b o tto m s on the c o u p lin g
reinforcement.
Tools Required:
2. Pinch bolt and torque to 41 N m (30 ft. lbs.). The
J-6632-01 Pitman Arm Remover bolt must pass through the shaft undercut.
J-5504-D Pitman Arm Puller Place the steering gear in position, guiding the
Place the front wheels in a straight ahead coupling bolt into the shaft flange.
position. 3. Steering gear to frame bolts and torque to 100
1. F le xib le co u p lin g to ste e rin g sh aft bolts N m (75 ft. lbs.).
(C-Models).
Im portant
2. Lower universal joint pinch bolt (G-Models). Mark
the relationship of the universal yoke to the
If flexible coupling alignment pin plastic
wormshaft.
spacers were used, make sure they are
Mark the relationship of the pitman arm to the bottomed on the pins.
pitman shaft. If flexible coupling alignment pin plastic
3. Pitman shaft nut and washer. spacers were not used, center the pins in
4. Pitman arm from the pitman shaft. Use J-6632-01 the slots in the steeering shaft flange.
or J-5504-D (figure 2). 4. Washer and nut onto the coupling bolts.
5. Frame bolts.
Tighten
6. Pinch bolt, coupling, washers and nuts from the
wormshaft (C-Models).
7. Gear assembly.
G-Models (Figure 4)
-4- Install or Connect (Figure 3) Place the steering gear in position, guiding the
wormshaft into the universal joint assembly and
lining up the marks made at removal. If a new
NOTICE: See Notice on page 3B2-1 of this gear was installed, line up the mark on the
section for steps 3, 5 and 8. wormshaft with the slit in the universal joint yoke.
B-07353
Figure 3Steering Gear Attachm ent (C-Models)
5. Steering gear to frame bolts. PITMAN SHAFT SEAL

REPLACEMENT
Tighten
The pitman shaft seal may be replaced without
Bolts to 100 N m (75 ft. lbs.). removing the steering gear. Remove the pitman arm as
outlined under Steering Gear Replacement or refer
6. Universal joint pinch bolt. The pinch bolt must
to STEERING LINKAGE (SEC. 3B1).
pass through the shaft undercut. Torque to 60
N m (44 ft. lbs.).
ALL MODELS Rotate the steering wheel from stop to stop,

7. Pitman arm onto the pitman shaft. Line up the counting the total number of turns. Then turn
marks made at removal. back exactly halfway, placing the gear on center
8. Washer and nut. (the wormshaft flat should be at the 12 oclock
position).
1. Side cover bolts.
Tighten
2. Pitman shaft and side cover assembly from the
housing.
Nut to 250 N m (185 ft. lbs.)
3. Pitman shaft seal from the gear housing using a
screwdriver. Be careful not to damage the
housing bore.
4. Jam nut (11).
5. Side cover from the pitman shaft assembly. Turn
the adjuster screw (10) clockwise.
Inspect
G ear lu b ric a n t for c o n ta m in a tio n . If

contaminated, the gear must be removed and
overhauled.
+- Install or Connect
Lubricate the new pitman shaft seal with steering

gear lubricant.
1. Pitman shaft seal. Position the seal in the pitman
shaft bore and tap into position using a 25 mm (1
inch) pipe or socket (figure 5).
Figure 6Steering Gear Adjustm ent Points
Place the pitman shaft in the steering gear so Remove or Disconnect

that the center tooth of the pitman shaft sector
enters the center tooth space of the ball nut. Tools Required:
Fill the steering gear housing with Steering Gear J-5504-D Pitman Arm Puller
Lubricant meeting GM Specification 1051052 (or
equivalent).
Raise the vehicle.
2. New gasket onto the gear housing. 2. Pitman arm nut and washer.
Mark the relationship of the pitman arm to the
3. Side cover onto the adjuster screw (10). Reach
pitman shaft.
through the threaded hole in the side cover with a
small screwdriver and turn the adjuster screw 3. Pitman arm using J-6632-01 or J-5504-D (figure
counterclockwise until it bottoms and turns back 2 ).
in 1/4 turn. Loosen the adjuster nut (7) and then back the
adjuster plug (6) off 1/4 turn (figure 6).
4. Side cover bolts and torque to specifications. 4. Horn cap or cover.
5. Jam nut (11). Turn the steering wheel gently in one direction
until stopped by the gear; then turn back one-half
turn.
Adjust
NOTICE: Do not turn the steering wheel hard
Steering gear as outlined under Steering against the stops when the steering linkage is
Gear Adjustments. disconnected from the gear as damage to the
6. Pitman arm. ball guides could result.
Measure
STEERING GEAR
ADJUSTMENTS Bearing drag by applying a torque wrench with
the socket on the steering wheel nut and rotate
Before any adjustments are made to the steering through a 90 degree arc. Do not use a torque
gear, in an attempt to correct such conditions as wrench having a maximum torque reading of
shimmy, loose or hard steering etc., a careful more than 6 N-m (50 in. lbs.) (figure 7).
inspection should be made of the front end alignment,
shock absorbers, wheel balance and tire pressure for
Adjust
the possible steering system problem.
Correct adjustment of the steering gear is very Thrust bearing preload as follows:
im p o rta n t. P erform a d ju stm e n ts fo llo w in g the 1. Tighten the adjuster plug (6) until the proper
sequence listed below. loading preload is 0.6-1 N-m (5-8 in. lbs.).
Important
If maximum torque is exceeded, turn

over ce n te r a d ju s te r screw
counter-clockwise, then come up on
adjustment by turning the jam nut (11)
in a clockwise motion.
-4- Install or Connect
1. Pitman arm onto the pitman shaft. Line up the

marks made during disassembly.
NOTICE: See Notice on page 3B2-1 of this

section.
2. Washer and nut.
Figure 7Checking Torque at Steering Wheel

S i Tighten
NOTICE: See Notice on page 3B2-1 of this Nut to 250 N m (185 ft. lbs.).
section. 3. Horn cap or cover.
Lower the vehicle to the floor.
2. Tighten the adjuster nut (7) to 115 N m (85 ft. 4. Battery ground cable.
lbs.).
3. If the gear feels lumpy after adjustment, STEERING GEAR HIGH

there is probably damage in the bearings POINT CENTERING
due to severe im p a ct or im p ro p e r
adjustment; the gear must be disassembled 1. Set the front wheels in the straight ahead posi
for replacement of damaged parts. tion. This can be checked by driving the vehicle a
short distance on a flat surface.
Over-center preload as follows: 2. With the front wheels set straight ahead, check
the position of the mark on the wormshaft de
1. Turn the steering wheel gently from one stop signating the steering gear high point. This mark
all the way to the other carefully counting should be at the top side of the shaft at 12 oclock
the total number of turns. Turn the wheel position and lined up with the mark in the cou
back exactly half-way to the center position. pling lower clamp.
3. If the gear has been moved off high point when
2. Turn the over center adjuster screw (10) setting wheel in straight ahead position, loosen
clockwise to take out all lash between the adjusting sleeve clamp on both left and right
ball nut (1) and pitman shaft sector (9) teeth hand tie rods. Then turn both sleeves an equal
and then tighten the jam nut (11). number of turns in the same direction to bring
gear back on high point.
Tighten Important
Jam nut (11) to 30 N m (22 ft. lbs.) Turning the sleeves an unequal number of
turns or in different directions will disturb
3. Check the torque at the steering wheel, the toe-in setting of the wheels.
taking the highest reading as the wheel is 4. A djust toe-in as outline d in FRONT END
turned through center position. Refer to ALIGNMENT (SEC. 3A) (if necessary).
Specifications for the proper over-center 5. Orient sleeves and clamps when fastening and
preload. torqueing clamps to specifications. Refer to
STEERING LINKAGE (SEC. 3B1).
4. If necessary, loosen jam nut (11) and adjust
over center adjuster screw to obtain proper
torque. Tighten the jam nut and recheck
torque reading through center of travel.
SPECIFICATIONS
MANUAL STEERING GEAR
Manufacturer......................................................................................................................Saginaw Steering Gear

R a tio ................................................................................................................................................................24 to 1
Type...............................................................................................................................................Recirculating Ball
PRELOAD ADJUSTMENTS
Nm In. Lbs.
Worm Thrust Bearing Preload 0.6-1.0 5-8
Over Center Sector Preload 0.5-1.2* 4-10*
Total Steering Gear Preload 1.8 Max. 16 Max.
In excess of worm bearing preload.
Nm Ft. Lbs.
Steering Gear to Frame Nuts 100 75
Pitman Shaft Nut 250 185
Side Cover Bolts 45 33
Adjuster Screw Jam Nut 30 22
Adjuster Plug Nut 115 85
SPECIAL TOOLS
J-5504-D Pitman Arm Puller
3B3-1
SECTION 3B3
POWER STEERING
the manual as indicated at appropriate locations by the terminology: NOTICE: See Notice on page 3B3-1 of the
section.
NOTICE: All steering fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specific during reassembly to assure
proper retention of all parts.
CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 3B3- 2

Integral Power Steering G e a r........................................................................................................................... 3B3- 2
Hydraulic P u m p s ................................................................................................................................................. 3B3- 2
Diagnosis Of Power Steering S y s te m .................................................................................................................3B3- 5
Oil Leak C h e c k ..................................................................................................................................................... 3B3- 8
Power Steering System T e s t..............................................................................................................................3B3- 8
Power Steering System On-Vehicle S e rv ic e ......................................................................................................3B3-12
M a in te n a n ce ..........................................................................................................................................................3B3-12
Pump Belt Tension A d ju s tm e n t....................................................................................................................... 3B3-12
Fluid Level A d ju s tm e n t........................................................................................... ...........................................3B3-12
Bleeding The Power Steering S y s te m ............................................................................................................ 3B3-13
Flushing The Power Steering S y s te m ............................................................................................................ 3B3-13
Steering Gear High Point C e n te rin g .................................................................................................................3B3-13
Power Steering Gear Replacem ent...................................................................................................................3B3-14
Pitman Shaft Seal R e p lace m e n t....................................................................................................................... 3B3-16
Steering Gear A d ju s tm e n ts ................................................................................................................................3B3-16
Power Steering Pump Replacem ent.................................................................................................................3B3-18
Power Steering H o s e s ........................................................................................................................................ 3B3-23
S pe cifica tio n s............................................................................................................................................................3B3-31
Special T o o ls ............................................................................................................................................................3B3-33
3B3-2 POWER STEERING
DESCRIPTION
1. Pitman Shaft
2. Housing Ball Plug
3. Adjuster Plug
4. Stub Shaft
5. Torsion Bar
6. Adjuster Plug Nut
7. Return Line
8. Stud Bolt O-ring Seals
9. Reservoir
10. Reservoir Cap
11. Reservoir O-ring Seal
12. Pump Shaft Seal
13. Pump Housing
14. Pressure Port Seat
15. Pressure Hose
16. Pressure And Return Port Seat
17. Adjusting Screw Jam Nut
18. End Cover O-ring Seal
19. Side Cover Seal
20. Gear Housing
Figure 1Power Steering System Typical
The hydraulic power steering system consists of a HYDRAULIC PUMPS

pump, an oil reservoir, a steering gear, a pressure
hose, and a return hose (figure 1). The hydraulic pump is a vane-type design. There are
two type s, su b m e rg e d and n o n su b m e rg e d .
INTEGRAL POWER Submerged pump (P models) have a housing and
internal parts that are inside the reservoir and operate
STEERING GEAR submerged in oil. The nonsubmerged pump (TC
The power steering gear (figure 2) has a recirculating models with or without reservoir) function the same as
ball system which acts as a rolling thread between the the submerged pump except that the reservoir is
worm shaft and the rack piston. The worm shaft is separate from the housing and internal parts (figure 3).
supported by a thrust bearing preload and two conical There are two bore openings at the rear of the pump
thrust races at the lower end, and a bearing assembly housing. The larger opening contains the cam ring,
in the adjuster plug at the upper end. When the worm pressure plate, thrust plate, rotor and vane assembly,
shaft is turned right, the rack piston moves up in gear. and end plate. The smaller opening contains the
Turning the worm shaft left moves the rack piston down pressure line union, flow control valve, and spring. The
in gear. The rack piston teeth mesh with the sector, flow control orifice is part of the pressure line union.
which is part of the pitman shaft. Turning the worm The pressure relief valve inside the flow control valve
shaft turns the pitman shaft, which turns the wheels limits the pump pressure (figure 4).
through the steering linkage.
The control valve in the steering gear directs the
power steering fluid to either side of the rack piston.
The rack piston converts the hydraulic pressure into a
mechanical force. If the steering system becomes
damaged and loses hydraulic pressure, the vehicle can
be controlled manually.
POWER STEERING 3B3-3
34
1. Pitman Shaft 26. Adjuster Plug Seal
3. Adjuster Plug 27. Torsion Bar Seal
4. Stub Shaft 28. Stub Shaft Seal
5. Torsion Bar 29. Upper Thrust Bearing
20. Gear Housing 30. Valve Body Seal Rings And Backup O-Rings
21. Side Cover 31. Spool Valve
22. Lower Thrust Bearing And Races 32. Valve Body
23. Inlet Port 33. Worm Shaft
24. Outlet Port 34. Rack Piston
25. Stub Shaft Bearing 35. Rack Piston Seal Ring
B-07321
Figure 2Power Steering Gear
TC MODEL P MODEL
WITHOUT RESERVOIR WITH RESERVOIR B-07322
Figure 3TC And P Pump Models

4. Stub Shaft 48. Exit Hole

9. Reservoir 49. Orifice
10. Reservoir Cap 50. Filter
11. Reservoir O-Ring Seal 51. Pump Union
12. Shaft Seal 52. Seals
13. Pump Housing 53. End Plate
40. Dip Stick 54. Retaining Ring
41. Pump Ring 55. Rotor
42. Thrust Plate 56. Spring
43. Vanes 57. Discharge Cavity
44. Reservoir Hole 58. Retaining Ring
45. Spring 59. Pressure Plate
46. Pressure Relief Valve
47. Flow Control Valve B-07324
Figure 4Power Steering Pump

DIAGNOSIS OF POWER STEERING SYSTEM

O bjectionable H iss 1. Noisy relief valve in the hydraulic 1. There is some noise in all power
pump. steering systems. One of the most
common is a hissing sound most evi
dent at standstill parking. Hiss is a
high frequency noise. The noise is
present in every valve and results
from high velocity fluid passing valve
orifice edges. There is no relationship
between this noise and performance
of the steering. Hiss may be ex
pected when steering wheel is at end
of travel or when slowly turning at
standstill.
Do not replace valve unless hiss
is extremely objectionable. A replace
ment valve will also exhibit slight
noise and is not always a cure for the
objection.
2. Any metal-to-metal contacts through 2. Align the steering shaft and gear so
flexible coupling. the flexible coupling rotates in a flat
plane and is not distorted as the shaft
rotates.
Rattle Or Chuckle 1. Gear loose on the frame. 1. Check the gear m ounting bolts.
Noise In Steering Torque the bolts to specifications.
Gear 2. Steering linkage looseness. 2. Check linkage pivot points for wear.
Replace if necessary.
3. Pressure hose touching other parts of 3. Adjust the hose position. Do not bend
vehicle. tubing by hand.
4. Loose pitman arm. 4. Torque the pitman arm bolt.
5. Improper over-center adjustment. A 5. Adjust to specifications.
slight rattle may occur on turns be
cause of increase clearance off the
high point. This is normal and clear
ance must not be reduced below spe
cified limits to eliminate this slight
rattle.
Excessive Wheel 1. Air in the system. 1. Add oil to the pump reservoir and
Kick-Back Or Loose bleed. Check hose connectors for
Steering proper torque.
2. Steering gear mounting loose. 2. Tighten attaching bolts to specified
torque.
3. Steering linkage joints worn. 3. Replace loose parts.
4. Front wheel bearings incorrectly ad 4. Adjust the bearings or replace with
justed or worn. new parts as necessary.
5. Steering gear improperly adjusted. 5. Adjust to specifications.
6. Worn or missing poppet valve (steering 6. Replace the poppet valve.
gear).
7. Steering gear flexible coupling too 7. Tighten to specifications.
loose on the shaft or the rubber disc
mounting screws loose.
8. Damaged or worn steering gear. 8. Disassemble and repair the steering
gear as outlined in the unit repair
manual.
DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)

Vehicle Leads To 1. Front end misaligned. 1. Adjust to specifications.

One Side Or The 2. Unbalanced steering gear valve. If this 2. Replace the gear valve.
Other (Keep In Mind is cause, steering effort will be very
The Road And Wind light in direction of lead and heavy in
Conditions). Test opposite direction.
The Vehicle, Going 3. Steering shaft rubbing the ID of the 3. Align the column.
In Both Directions, shaft tube.
On A Flat Road. 4. Steering linkage not level. 4. Adjust as required.
Momentary Increase 1. Low oil level in the pump. 1. Add power steering fluid as required.
In Effort When 2. Pump belt slipping (if used). 2. Tighten or replace belt.
Turning The Wheel 3. High internal linkage (steering gear or 3. Refer to Power Steering System
Q uickly To The Right pump). Test in this section.
Or Left
Poor Return Of 1. Tires under-inflated. 1. Inflate to specified pressure.

Steering 2. Lower coupling flange rubbing against 2. Loosen the pinch bolt and assemble
the steering gear adjuster plug. properly.
3. Steering wheel rubbing against direc 3. Adjust the steering jacket.
tional signal housing.
4. Tight or frozen steering shaft bearings. 4. Replace the bearings.
5. Steering linkage or ball joints binding. 5. Replace the affected parts.
6. Steering gear to column misalignment. 6. Align the steering column.
7. Tie rod pivots not centralized. 7. Adjust tie rod ends as required to
center pivots.
8. Lack of lubricant in the suspension 8. Lubricate. Refer to MAINTENANCE
ball joints and the steering linkage. AND LUBRICATION (SEC. OB).
9. Sticky or plugged valve spool. 9. Remove and clean or replace the
valve.
10. Rubber spacer binding in the shift 10. Make certain the spacer is properly
tube. seated. Lubricate inside the diameter
with silicone lubricant.
11. Improper front end alignment. 11. Check and adjust to specifications.
12. Tight steering shaft bearings. 12. Replace the bearings.
13. Steering gear adjusted too tightly. 13. Adjust over-center and thrust bearing
14. Kink in return hose. 14. Replace the hose.
Steering Wheel 1. Low oil level in pump. 1. Add power steering fluid as required.
Surges Or Jerks 2. Loose pump belt. 2. Adjust tension to specification.
When Turning With 3. Sticky flow control valve. 3. Replace or clean the control valve.
Engine Running 4. Insufficient pump pressure. 4. Refer to Power Steering System
Especially During Test in this section.
Parking 5. Faulty gear relief valve. 5. Replace the gear relief valve.
Hard Steering Effort 1. Low tire pressure. 1. Adjust the tire pressure.
In Both Directions 2. Lack of lubricant in suspension or ball 2. Lubricate and relubricate at proper
joints. intervals. Refer to MAINTENANCE
AND LUBRICATION (SEC. OB).
3. Steering gear to column misalignment. 3. Align the steering column.
4. Loose pump belt. 4. Adjust belt tension to specifications.

PRO BLEM POSSIBLE CAUSE CORRECTION
Hard Steering Effort 5. Low fluid level in reservoir. 5. Fill to proper level. Inspect lines and
In Both Directions joints for external leakage.
(Continued) 6. High internal leakage (steering gear or 6. Refer to Power Steering System
pump). Test in this section.
7. Sticky flow control valve. 7. Replace or clean the valve.
8. Lower coupling flange rubbing against 8. Loosen the pinch bolt and assemble
steering gear adjuster plug. properly.
10. Improper front end alignment. 10. Check and adjust to specifications.
F oam ing M ilky P ow er Air in the fluid, and loss of fluid due Check for leak and correct. Bleed
Steering Fluid, Low to internal pump leakage causing over system. Extremely cold temperatures
Level And Possible flow. will cause system aeriation should
Low Pressure the oil level be low. If oil level is cor
rect and pump still foams, remove
pump from vehicle and separate res
ervoir from housing. Check welsh
plug and housing for cracks. If plug is
loose or housing is cracked, replace
housing.
Low Oil Pressure 1. Check for kinks in the hose. 1. Remove the kinks or replace the
Due To Restriction hose.
In The Hose 2. Foreign object stuck in the hose. 2. Remove the foreign object or replace
the hose.
Low Oil Pressure 1. Pressure loss in cylinder due to worn 1. Disassemble the steering gear as
Due To Steering piston ring or scored housing bore. outlined in the unit repair manual. In
Gear. Refer To spect the ring and housing bore. Re
Power Steering place the affected parts.
System Test In 2. Leakage at the valve rings and valve 2. Disassemble steering gear and re
This Section. body to the worm seal. place seals.
3. Leakage at the valve body or a loose 3. Replace the valve.
fitting spool.
4. Damaged poppet valve. 4. Replace the poppet valve.
Low Oil Pressure 1. Flow control valve stuck or inoperative. 1. Replace or clean the valve.
Due To Steering 2. Pressure plate not flat against the cam 2. Replace the pressure plate.
Pump. Refer To ring.
Power Steering 3. Extreme wear of cam ring. 3. Replace and flush the system.
System Test In 4. Scored pressure plate, thrust plate or 4. Replace parts. (If rotor, replace with
This Section. rotor. rotating group), flush the system.
5. Vanes sticking in rotor slots. 5. Free-up by removing burrs, varnish or
dirt.
6. Vanes not installed properly. 6. Install properly. Radius edge to the
outside.
7. Air in oil. 7. Locate source of leak and correct.
Bleed the system.
8. Low oil level. 8. Add power steering fluid as required.
9. Loose belt. 9. Adjust tension to specifications.
10. Damaged hoses or steering gear. 10. Replace as necessary.

Chirp Noise In 1. Loose belt. 1. Adjust belt tension.

Steering Pump
Belt Squeal 1. Loose belt. 1. Adjust belt tension.

(Particularly
Noticeable At Full
Wheel Travel And
Standstill Parking)
Growl Noise In 1. Excessive back pressure in hoses or 1. Locate restriction and correct. Re
Steering Pump steering gear caused by restriction. place part if necessary.
Growl Noise In 1. Scored pressure plates, thrust plate or 1. Replace parts and flush system.
Steering Pump rotor.
(Particularly 2. Extreme wear of cam ring. 2. Replace parts.
Noticeable At
Standstill Parking)
Groan Noise In 1. Low oil level. 1. Add power steering fluid as required.
Steering Pump
2. Air in the oil. Poor pressure hose con 2. Torque the connector. Bleed the sys
nection. tem.
Rattle Or Knock 1. Loose pump pulley nut. 1. Torque nut.

Noise In Steering 2. Pump vanes sticking in rotor slots. 2. Free up by removing burrs, varnish or
Pump dirt.
3. Pressure hose touching other parts of 3. Adjust hose position.
vehicle.
Swish Noise In 1. Faulty flow control valve. 1. Replace part.

Steering Pump
Whine Noise In 1. Pump shaft bearing scored. 1. Replace the housing and shaft. Flush
Steering Pump the system.
OIL LEAK CHECK POWER STEERING

SYSTEM TEST
1. With the vehicles engine off, wipe the complete
power steering system dry (gear, pump, hoses, The power steering system may be tested using
and connections). either J-5176-D, Power Steering Gage, or with J-25323,
Power Steering Analyzer. J-25323 will measure the
2. Check the oil level in the pumps reservoir and
flow rate in addition to the pressure (figure 6).
a djust as dire cted . Refer to Fluid Level
The power steering system test is a method used to
Adjustment in this section.
identify and isolate hydraulic circuit difficulties. Prior to
3. Start the engine and turn the steering wheel from performing this test the following inspection, and
stop to stop several times. Do not hold the wheel corrections if necessary, must be made.
against the stops as this may damage the pump.
Inspect
4. Find the exact areas of leakage and use the
recommended method of repair as shown in Pump reservoir for proper fluid level.
figure 5. Pump belt for proper tension.
60. Replace the drive shaft seal. Make cer

tain that the drive shaft is clean and free
of pitting in the seal area.
61. Replace the resen/oir O-ring seal.
62. Torque hose fittin g nut to 35 N m (25 ft.
lbs.). If leakage persists, replace the O-
ring seal.
63. Torque fittin g to 75 N m (55 ft. lbs.). If
leakage persists, replace the O-ring seal.
64. Torque hose fittin g nut to 48 N m (35 ft.
lbs.). If leakage persists, replace the
brass connector and reface the tube
flare. If nut threads are damaged, replace
the nut.
65. Replace the O-ring seal.
66 . If leakage is observed at (A), following
manufacturers directions apply Loctite
75559 solvent and Loctite 290 adhesive,
or equivalent, to tube-housing connec 71. Torque jam nut to 48 N m (35 ft. lbs.). Re
tion. If leakage is coming from (B), re place the nut if leakage persists.
place the return tube. If com ing from (C), 72. Torque side cover bolts to 60 N m (45 ft.
replace the hose or clamp. lbs.). Replace the side cover seal if leak
67. Seat the plug in the housing. Following age persists.
manufacturers directions apply Loctite 73. Torque hose fittin g nut to 27 N m (20 ft.
75559 solvent and Loctite 290 adhesive, lbs.). If leakage persists, replace the O-
or equivalent, to plug-housing area. ring seal.
68 . Seat the ball in the housing with a blunt 74. Check for seepage between the torsion
punch. Following manufacturers direc bar and stub shaft. Replace the rotary
tions apply Loctite 75559 solvent and valve assembly.
Loctite 290 adhesive, or equivalent, to 75. Seat the ball in the housing with a blunt
area. punch. Apply Loctite 75559 solvent and
69. Check the oil level; if leakage persists Loctite 290 adhesive, or equivalent, to
with the level correct and cap tight, re the ball area.
place the cap. 76. Replace the adjuster plug seals.
70. If a cracked or bent reservoir is detected, 77. Replace both pitman shaft seals.
replace the reservoir. 78. Replace end plug O-ring seal.
B-07323
Figure 5Pump Leak Diagnosis

B-07325
Figure 6Tools For Power Steering System Test
Tires for correct air pressure. Important

Power steering system, replacing parts as
To prevent scrubbing flat spots on the tires,
necessary.
do not turn the steering wheel more than
five times without rolling the vehicle to
Im portant change the tire-to-floor contact area.
6. Start the engine and check the pumps fluid level.
All tests are made with the engine idling at Add power steering fluid if required. When the
normal operating temperature. Check the idle engine is at normal operating temperature, the
adjustment and if necessary adjust the engine initial pressure read on the gage (valve open)
idle speed to the correct specification. Refer to should be in the 550-860 kPa (80-125 psi) range.
FUEL SYSTEMS (SEC. 6C). Should this pressure be in excess of 1380 kPa
(200 psi) check the hoses for restrictions and
Test With J-5176-D the poppet valve for proper assembly.
1. Place a container under the steering gear or
pump to catch the fluid when disconnecting or NOTICE: Do not leave valve fully closed for
connecting the hoses. more than 5 seconds as the pump could be
damaged internally.
2. With the engine NOT running, disconnect the
pressure hose at the steering gear or power 7. Close the gate valve fully 3 times. Record the
steering pump and install J-5176-D to both hoses highest pressures attained each time.
using adapter fitting J-5176-20. The gage must be If the pressures recorded are within the
between the shut-off valve and pump. Open the specifications at the end of this section, and
shut-off valve. the range of readings is within 345 kPa (50
3. Remove the filler cap from the pump reservoir psi), the pump is functioning within its speci
and check the fluid level. Fill the pump reservoir, fications.
with power steering fluid, to the full mark on the If the pressures recorded are high, but do
dipstick. Start the engine and, momentarily not repeat within 345 kPa (50 psi), the flow
holding steering wheel against stop, check the controlling valve is sticking. Remove the
connections at J-5176-D for leakage. valve, clean it and remove any burrs using
crocus cloth or fine hone. If the system
4. Bleed the system. Refer to Bleeding the Power c o n ta in s som e d irt, flu s h it. If it is
Steering System. exceptionally dirty, both the pump and gear
5. Insert thermometer J-5421-02 in the reservoir must be completely disassembled, cleaned,
filler opening. Move the steering wheel from stop flushed and reassembled before further us
to stop several times until the thermometer age.
indicates that the hydraulic fluid in the reservoir If the pressures recorded are constant but
has reached a temperature of 65 to 77C (150 more than 690 kPa (100 psi), below the
to 170F). minimum listed specification, replace the
flow control valve and recheck. If the replace the flow control valve in the pump. If the
pressures are still low, replace the rotating pressure recorded is above the maximum
group in the pump. specification listed, the flow control valve in the
8. If the pump checks within specifications, leave pump should be removed and cleaned or
the valve open and turn (or have turned) the replaced. If the system is exceptionally dirty, both
steering wheel into both corners. Record the the steering gear and pump must be completely
h ig h e st p re ssures and com pare w ith the disassembled and cleaned before reassembly.
maximum pump pressure recorded. If this 9. Increase the engine speed from idle to about
pressure cannot be built in either (or one) side of 1500 rpm. Record the flow (E).
the gear, the gear is leaking internally and must If flow (E) varies more than 1 gpm from flow
be disassembled and repaired. (A), then the flow control valve should be
9. Shut the engine off, remove the testing gage, removed and cleaned or replaced, the same
reconnect the pressure hose, check the fluid level as in step 8.
and/or make the needed repairs. 10. Have the steering wheel turned into the left and
10. If the problem still exists, the steering and front then right corner lightly against the wheel stops.
suspension must be thoroughly examined. Refer Record the pressure and flow (F).
to Diagnosis of Power Steering System. Pressures developed in both corners should
be nearly the same as the maximum pump
Test With J-25323 output (D). At the same time the flow should
1. Place a container under the steering gear or drop below 1.85 L/min. (0.5 gpm).
pump to catch the fluid when disconnecting or If the pressure does not reach maximum
connecting the hoses. output or the flow does not drop below the
2. With the engine NOT running, disconnect the specified value, excessive internal leakage
pressure hose at the steering gear or power is occurring. Remove and disassemble the
steering pump. Thread J-29525 female adapter steering gear and remove the control valve.
into the pressure hose and the male adapter into Repair the steering gear as outlined in the
the gear or pump. Connect J-25323 analyzer Unit Repair Manual.
hoses to the adapters. 11. Have the steering wheel turned slightly in both
3. If the analyzer has never been used, it will be directions and release quickly while watching the
necessary to bleed the power steering system to pressure gage. The needle should move from the
remove all the air. Refer to Bleeding the Power normal back pressure reading and snap back as
Steering System in this section. The analyzer the wheel is released. If it comes back slowly, or
gate must be open during this procedure. sticks, the rotary valve in the steering gear is
4. Add power steering fluid to the pump if required. sticking. Remove, disassemble and clean the
rotary valve. If the system contains a lot of dirt
5. Run the engine at idle speed w ith the gate valve
and foreign material, disassemble the pump the
open and record flow (A) and pressure (B).
gear, clean and reassemble.
If the flow is below 7.4 L/min. (2 gpm), the
12. If the problem still exists, the steering and front
pump appears to be in need of repair, but
suspension must be thoroughly examined. Refer
continue the test.
to Diagnosis of Power Steering System in this
If the pressure is above 1035 kPa (150 psi),
section.
check the hoses for restriction and check
the steering gear.
6. Partially close the gate valve to build 4278 kPa
(620 psi). Record the flow (C).
If the flow (C) drops more than 3.7 L/min. (1
gpm) under flow (A), disassemble the pump
and replace the ring, rotor, and vanes. If the
pressure plates are worn or cracked,
replace them. Replace all O-ring seals when
reassembling the pump. Continue the test.
7. Completely close and partially open the gate
valve three times (do not allow the valve to
rem ain closed fo r more than 5 seconds).
Record the gate closed pressure (D).
8. Check the pressure specifications, at the end of
this section for the correct pump model, and if the
pump pressure recorded is 690 kPa (100 psi)
lower than the minimum specification listed,
POWER STEERING SYSTEM ON-VEHICLE SERVICE
MAINTENANCE 1. Place belt tension gage, J-23600-B or equivalent,

midway between the pulleys on drive belts being
The hydraulic system should be kept clean and at checked.
regular intervals the pump steering fluid level in the Power steering pump driven by a single belt.
reservoir should be checked and fluid added when
re q u ire d . R efer to M A IN TE N A N C E AND Loosen the pump attaching bolts and adjust
LUBRICATION (SEC. OB) of this manual for type of the belt to correct tension by moving the
fluid to be used and intervals for filling. pump outward, away from the engine.
If the system contains some dirt, flush it as detailed Tighten finger tight all pump mounting bolts
later in this section. If it is exceptionally dirty, both the and remove the pry bar.
pump and the gear must be completely disassembled
Tighten all pump mounting bolts. Refer to
before further usage.
Power Steering Pump Replacement in
All tubes, hoses, and fittings should be inspected for this section.
leakage at regular intervals. Fittings must be tight.
Make sure the clips, clamps and supporting tubes and Inspect belt tension and remove the belt
hoses are in place and properly secured. tension gage.
Inspect the hoses with the wheels in the straight 2. Loosen the pivot bolt and pump brace adjusting
ahead position, then turn the wheels fully to the left nuts.
and right, while observing the movement of the hoses.
Correct any hose contact with other parts of the vehicle
that could cause chafing or wear. NOTICE: Do not move the pump by prying
Power steering hoses and lines must not be twisted, against the reservoir or by pulling on the filler
kinked or tightly bent. The hoses should have sufficient neck, or damage may occur.
natural curvature in the routing to absorb movement
and hose shortening during vehicle operation. 3. Move the pump, with the belt in place until the
belt is tensioned to specifications. Refer to
Air in the system will cause spongy action and noisy ENGINE COOLING (SEC. 6B).
operation. When a hose is disconnected or when fluid
is lost, for any reason, the system must be bled after 4. Tighten the pump bracket adjusting nut and the
refilling. Refer to Bleeding the Power Steering pivot bolt nut. Refer to Power Steering Pump
System in this section. Replacement in this section.
5. Inspect the belt tension and remove the belt
tension gage.
FLUID LEVEL ADJUSTMENT

PUMP BELT TENSION
ADJUSTMENT 1. Run the engine until the power steering fluid
reaches normal operating temperature, about
When adjusting a power steering pump belt, never 80C (170F), then shut the engine off.
pry against the pump reservoir or pull against the filler
2. Remove the reservoir cap and check the fluid
neck. Two systems are used for belt adjustment. On
level on the dipstick. On models equipped with a
some models, the pump is loosened from the bracket
remote reservoir, the fluid level should be about
and moved outward to increase the tension. On other
12.7 to 25.4 mm (V2 to 1-inch) from the top when
models, a half-inch square drive hole is located in the
the wheels are in full left turn position.
b ra cke t, and th is hole is used to ro ta te the
pump-and-bracket assembly outward to increase belt 3. If the fluid level is low, add power steering fluid
tension. (GM #1050017 or equivalent) to the proper level
and install the reservoir cap.
Adjust 4. When checking the fluid level after the steering
system has been serviced, air must be bled from
Tool Required: the system. Refer to Bleeding the Power
J-23600-B Belt Tension Gage. Steering System in this section.
BLEEDING THE POWER contact wheel stops or hold the wheel in a corner
or fluid will stop and the pump will be in pressure
STEERING SYSTEM relief mode. A sudden overflow from the reservoir
may develop if the wheel is held at a stop.
When a power steering pump or gear has been
installed, or an oil line has been disconnected, the air 4. Install all the lines, hoses and components (if re
that has entered the system must be bled out before moved) on the vehicle. Fill the system with
the vehicle is operated. If air is allowed to remain in the new power steering fluid and bleed the system as
power steering fluid system, nosiy and unsatisfactory described in Bleeding The Power Steering
operation of the system may result. Bleed air from the System . Operate the engine for about 15
hydraulic system as follows: minutes. Remove the pump return line at the
When bleeding the system, and any time fluid is pump inlet and plug the connection on the pump.
added to the power steering system, be sure to While refilling the reservoir, check the draining
use only power steering fluid as specified in fluid for contamination. If foreign material is still
MAINTENANCE AND LUBRICATION (SEC. OB). evident, replace all lines, disassemble and clean
1. Fill the pump fluid reservoir to the proper level or re p la ce the pow er s te e rin g system
and let the fluid settle for at least two minutes. components. Do not re-use any drained power
2. Start the engine and let it run for a few seconds. steering fluid.
Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level STEERING GEAR HIGH
remains constant after running the engine.
POINT CENTERING
5. Raise the front end of the vehicle so that the
wheels are off the ground.
1. Set the front wheels in the straight ahead
6. Start the engine. Slowly turn the steering wheel
position. This can be checked by driving the
right and left, lightly contacting the wheel stops.
vehicle a short distance on a flat surface.
7. Add power steering fluid if necessary.
8. Lower the vehicle and turn the steering wheel 2. With the front wheels set straight ahead, check
slowly from lock to lock. the position of the mark on the wormshaft
9. Stop the engine. Check the fluid level and refili as designating steering gear high point. This mark
required. should be at the top side of the shaft at the 12
10. If the fluid is extremely foamy, allow the vehicle to oclock position and lined up with the mark in the
stand a few minutes and repeat the above coupling lower clamp.
procedure. 3. On C, G and P models except P30(00)FS3, if the
steering gear has been moved off high point
I* Inspect when setting the wheel in the straight ahead
position, loosen the adjuster tube clamps on both
Belt for tightness. the left and right hand tie rods. Then turn both
Pulley for looseness or damage The pulley adjuster tubes an equal number of turns in the
should not wobble with the engine running. same direction to bring the gear back on high
Hoses so they are not touching any other parts of point.
the vehicle.
Fluid level and fill to the proper level.
Fluid for air and if present attempt to bleed the Im portant
system.
Turning the adjuster tubes an unequal
number of turns or in different directions will
FLUSHING THE POWER disturb the toe-in setting of the wheels.
STEERING SYSTEM 4. On K and P30(00)FS3 models, if the gear has
been moved off high point when setting the
1. Raise the front end of the vehicle off the ground wheels in the straight ahead position, loosen the
until the wheels are free to turn. adjuster tube clamps on the connecting rod.
2. Remove the fluid return line at the pump inlet Then turn the adjuster tube to bring the gear back
connector and plug the connector port on the on high point.
pump. Position the line towards a large container
5. Adjust toe-in. Refer to FRONT END ALIGNMENT
to catch the draining fluid.
(SEC. 3A).
3. While an assistant is filling the reservoir with new
power steering fluid, run the engine at idle. Turn 6. Refer to STEERING LINKAGE (SEC. 3B1) for
the steering wheel from stop to stop. DO NOT adjuster tube clamping instructions.
Figure 7Steering Gear Installation
POWER STEERING GEAR 4. Steering gear frame bolts and the steering gear.
Tap lightly, using a soft mallet, on the flexible
REPLACEMENT coupling to remove the coupling from the steering
gear stub shaft (C, K and P300(32) models).

C, K And P300(32) Models
Place a drain pan below the steering gear.
|-<-| Install Or Connect (Figures 7 and 8)
2. Hoses from the steering gear. Raise the hose up
to prevent oil d rainage. Cap or tape the NOTICE: For steps 2, 3 and 4 see N otice on
ends of the hose and gear fittings to prevent the page 383-7.
entrance of dirt.
Remove the flexible coupling to steering shaft 1. Flexible coupling onto the steering gear stub
flange bolts (C, K and P300(32) models). shaft.
Remove the lower universal joint pinch bolt. Mark Align the flat in the coupling with the flat on
the relationship of the universal yoke to the stub the shaft.
shaft (G and P models). Push the coupling onto the stub shaft until
3. Pitman arm. Refer to STEERING LINKAGE (SEC. the coupling reinforcement bottoms against
3B1). the end of the shaft.
Figure 8Steering Gear Installation
2. Pinch bolt into the split clamp. The pinch bolt 5. Pitman arm. Refer to STEERING LINKAGE (SEC.
must pass through the shaft undercut. 3B1).
Remove the plugs and caps from the steering
Tighten gear and hoses.
6. Hoses to the steering gear. Torque hose fittings to
Pinch bolt to 42 N m (31 ft. lbs.). Specifications at the end of this section.
Place the steering gear into position, guiding the
coupling bolts into the proper holes in the shaft G And P Models
flange.
3. S te e rin g g e a r to fra m e b o lts. Torque to Install or Connect (Figures 7 and 8)
4. Coupling flange nuts and washers. The coupling Place the steering gear in position. Guide the
alignment pins should be centered in the flange stub shaft into the universal joint assembly by
slots. lining up the marks made at removal.
1. Steering gear to the frame bolts. Torque to
& Tighten Specifications at the end of this section.
2. In te rm e d ia te s h a ft p in ch b o lt. Torque to
Coupling flange nuts to 27 N m (20 ft. lbs.). Specifications at the end of this section. The
Maintain a coupling to flange dimension of p in c h b o lt m u st pass th ro u g h th e s h a ft
6.4 to 9.5 mm (0.250 to 0.375-inch). undercut.
3. Pitman arm. Refer to STEERING LINKAGE (SEC. STEERING GEAR

3B1).
Remove the plugs and caps from the steering ADJUSTMENTS
gear and hoses.
4. Hoses to the steering gear. Torque hose fittings to
Specifications at the end of this section. Im portant
Before any adjustments are made to the steering

PITMAN SHAFT SEAL gear, refer to Diagnosis of Power Steering
System for reviewing the possible steering
REPLACEMENT system problems.
The steering gear adjustment is made only as a
correction and not as a periodic adjustment. Adjusting
the steering gear in the vehicle is NOT recommended
for two reasons:
Tools Required:
J-29107 Pitman Arm Puller. 1. The complexity involved in adjusting the worm
J-4245 Internal Snap Ring Pliers. thrust bearing preload.
Mark the position of the pitman arm to the pitman 2. The friction effect provided by the hydraulic fluid
shaft. Remove the pitman arm using J-29107. in the steering gear.
Refer to STEERING LINKAGE (SEC. 3B1). For proper adjustment, remove the steering gear
Position a drain pan under the steering gear. from the vehicle. Drain the power steering fluid from
1. Retaining ring using J-4245. the gear. Mount the gear in a vise and make the
Start the engine and full turn the steering wheel following adjustments.
to the left-turn position for one or two seconds at The steering gear requires two adjustments which
a time. This will force the pitman shaft seals and are: the worm thrust bearing preload and the pitman
washers out of the housing. shaft over-center preload adjustment.
Stop the engine. The worm thrust bearing preload is controlled by the
Pitman shaft seals and washers from the pitman amount of compression force exerted on the conical
shaft. worm bearing thrust races by the adjuster plug.
The pitman shaft over-center preload is controlled by
L* Inspect the pitman shaft adjuster screw which determines the
clearance between the rack piston and the pitman
Pitman shaft seal surfaces for roughness or shaft sector teeth.
pitting. If pitted, replace the shaft.
Housing for burrs. Remove the burrs before
Im portant
installing the new seals.
Adjust the worm thrust bearing preload first,
jQ * Clean then adjust the pitman shaft over-center
preload.
Pitman shaft and seal areas using a crocus cloth.
Worm Bearing Preload
-n - Install or Connect
Adjust (Figures 1, 2, 9 through 13)
Tools Required:
J-6219 Steering Gear Pitman Shaft Oil Seal
Tool Required:
Installer.
J-7624 Adjustable Spanner Wrench.
J-4245 Internal Snap Ring Pliers.
Lubricate the new seals with power steering fluid. 1. Loosen and remove the adjuster plug nut (6)
Apply a single layer of tape to the pitman arm (figure 9).
shaft to avoid damaging the seals. 2. Turn the adjuster plug (3) in (clockwise), using
1. Single lip seal and washer use J-6219. Install far J-7624, until the plug and thrust bearing are firmly
enough to provide clearance for the remaining bottomed in the housing.
seal, washer and retaining ring. DO NOT allow
the seal to bottom on the end of the counter bore.
Double lip seal and washer use J-21553.
Retaining ring use J-4245. Adjuster plug to 27 N m (20 ft. lbs.).
Pitman arm. Refer to STEERING LINKAGE (SEC. 3. Place an index mark on the housing even with
3B1). one of the holes in the adjust plug (figure 10).
5. Rotate the adjuster plug back (counterclockwise)

until the hole in the plug is aligned with the
second mark on the housing (figure 12).
6. Install the adjuster plug nut (6).
Tighten
Nut to 110 N m (81 ft. lbs.). Be sure the

adjuster plug does not turn when tightening
the nut.
7. Use a inch-pound torque wrench and a 12-point

Figure 10Marking Housing Even With deep socket to measure the required torque to
A djuster Plug turn the stub shaft (4). Take the reading with the
handle of the torque wrench near the vertical
4. Measure back (counterclockwise) 4.7-6.3 mm position. Turn the stub shaft to the right stop and
(3/ie-1/4-inch) from the index mark and mark the then back (counterclockwise) 1/4 turn at an even
housing (figure 11). rate (figure 13). Record the torque reading.
Figure 11Remarking The Housing Figure 13Checking Rotational Torque

8. The torque required to turn the stub shaft should

be 0.45-1.13 N m (4-10 in. lbs.). If the reading is
above or below the specified torque; the adjuster
plug may not be tightened properly or may have
4. Stub Shaft
turned when the adjuster plug nut was tightened,
21. Side Cover
or the thrust bearings and races (22) may be
damaged.
Over Center Preload
f t Adjust (Figures 1, 2, 14 through 16)
1. Turn the pitm an shaft adjuster screw (79)

counterclockwise until fully extended, then turn
back V2 turn clockwise.
2. Rotate the stub shaft (4) from stop to stop and
count the number of turns.
3. Starting at either stop, turn the stub shaft back V2 Figure 14A ligning The Stub Shaft
the total number of turns. This is the center of
the gear. POWER STEERING PUMP
When the gear is centered, the flat on the REPLACEMENT
stub shaft should face upward and be
parallel with the side cover (21) (figure 14)
and the master spline on the pitman shaft Remove or Disconnect (Figures 17 through 20)
should be in line with the adjuster screw (79)
(figure 15). Tool Required:
4. Place the torque wrench, in the vertical position, J-29785-A Water Pump and Power Steering
on the stub shaft. Rotate the torque wrench 45 Pulley Remover.
degrees each side of the center and record the Place a drain pan below the pump.
highest drag torque measured on or near center 1. Battery ground cable.
(figure 16). 2. Hoses at the pump. Raise the hose up to prevent
5. Adjust over-center drag torque by loosening the drainage of the oil. Cap or tape the ends of the
adjuster screw jam nut (17) and turning the hose and pump to prevent the entrance of dirt.
pitman shaft adjuster screw (79) clockwise until On m o d els w ith rem ote re se rvo ir,
the correct drag torque is obtained. disconnect the reservoir hose at the pump.
On new steering gears (under 400 miles), Cap the hose pump fittings.
add 0.6-1.2 N m (6-10 in. lbs.) torque to the
previously measured worm bearing preload
torque but do not exceed a total steering
gear preload of 2 N m (18 in. lbs.).
On used steering gears (400 miles or more)
add 0.5-0.6 N m (4-5 in. lbs.) torque to the
previously measured worm bearing preload
torque but do not exceed a total steering
gear preload of 1.5 N m (14 in. lbs.).
Tighten
Adjuster screw jam nut (17) to 47 N m (35 ft.

lbs.).
6. Install the steering gear. Refer to Steering Gear
Installation in this section.
7. Fill the pump reservoir with power steering fluid
and bleed the system. Refer to Bleeding the Figure 15A ligning The Pitman Shaft
Power Steering System in this section. Master Spline
Loosen the pump adjusting bolts and nuts.

3. Pump belt.
4. Pump adjusting bolts, nuts and brackets.
5. Pump assembly.
6. Pulley from the pump.
Install J-29785-A. Be sure the pilot bolt
bottoms in the pump shaft by turning the nut
to the top of the pilot bolt.
Hold the p ilo t b olt and tu rn the nut
counterclockwise (figure 21).
+ 4- Install or Connect (Figures 17 through 20)
Tool Required:
J-25033-B Power Steering Pump Pulley
Installer.
Figure 16Checking Over-Center Rotational 1. Brackets to the pump.
Torque
2. Pulley to the pump.
CK 000(00) V6 (4.3 Liter) V8 (5.0, 5.7 And 7.4 Liter) LS9 And LT9
A. 34 N m (25 Ft. Lbs.)
Figure 17Power Steering Pump Mounting

Figure 18Power Steering Pump Mounting V8 (6.2 Liter)

P300(00) V8 (7.4 Liter)
L6 (4.8 Liter) P000(42) JB6/JB7 CKOOO(OO) NB2 B 07447

GOOO(OO) N40 V8 (5.0 And 5.7 Liter) V6 (4.3 Liter) Excluding V8 (6.2 Liter)
C. 84 N-m (62 Ft. Lbs.)

D. 44 N-m (32 Ft. Lbs.)
E. 34 N-m (25 Ft. Lbs.)
F. 25 N-m (18 Ft. Lbs.)
P000(42) V8 (5.7 Liter)
B-07341

B-07363
Figure 21Installing And Removing Pulley
Place pulley on the end of the pump shaft POWER STEERING HOSES
and install J-25033-B. Be sure the pilot bolt
bottoms in the shaft by turning the nut to the When either a hose is reinstalled or replaced, the
top of the pilot bolt. following points are essential:
Hold the p ilo t b olt and turn the nut Route hoses in the same position they were in
clockwise (figure 21). before removal (figures 22 through 29).
Route hoses smoothly, avoid sharp bends and
On models equipped with a remote power kinking.
steering pump reservoir fill the pump housing Tighten the pump end hose fitting, gear line
with as much fluid as possible before mounting. fitting, and booster line fitting to specifications.
3. Pump assembly and attaching parts loosely to Refer to Specifications at the end of this
the engine. section.
4. Power steering hoses to the pump. Hoses After hoses are installed, check for leaks while
installed out of position may be subjected to the system is being bled. Refer to Bleeding the
chafing or other abuses during sharp turns. Refer Power Steering System in this section.
to Power Steering Hoses in this section.
NOTICE: Do not start the engine with any
Im portant pow er steering hose d isconnected , or
damage to the components could occur.
Do not start the engine with any power
s te e rin g hose d is c o n n e c te d . Af ter
connecting the power steering hoses make
sure there is clearance between the hoses
and the drive belt, sheet metal or any other
components where hose rub or interference
could result.
Fill the reservoir. Bleed the pump by turning the
pulley backwards (counter-clockwise as viewed
Internal Snap Ring Pliers
appear.
Pump belt over the pulley.
Adjust A. 34 N m (25 Ft. Lbs.)

80. Hydro-Boost Assembly
Belt tension. Refer to Pump Belt Tension 81. Clamp
Adjustment in this section. 82. Return Hose B-07333
Fill and bleed the system. Refer to Bleeding the
Power Steering System in this section. Figure 22Hydro-Boost Lines
Figure 23Power Steering Hoses

CK200(00)
L6 (4.8 Liter)
VIEW A
VIEW B
CK300(00)
L6 (4.8 Liter)
VIEW B
CKOOO(OO)
V6 (4.3 Liter) V8 5.0 And 5.7 Liter)
CK300(00)
V8 (5.7 Liter)
B-07448


4 | FRT
VIEW A
G100 + 200 V8 (5.0 And 5.7 Liter) G300 V8 (5.7 Liter) LS9 Or LT9 With JB7
G100 + 200 + 300 V8 (5.0 And 5.7 Liter) G313(03) V8 (5.7 Liter)
B-07345


VIEW C
P300(42) L6 (4.8 Liter) JB8/JF9 P300(42) V8 (7.4 Liter) JB8/JF9

B-07449


SPECIFICATIONS
STEERING GEAR ADJUSTMENTS
Valve Assembly And Seal D rag..............................................................................0.1-0.4 N m (1-4 in. lbs.)

Thrust Bearing Preload (In Excess Of Valve Assembly And Seal Drag).......... 0.3-0.4 N m (3-4 in. lbs.)
Pitman Shaft Over Center Preload
New G ear......................................................................................................... 0.6-1.2 N m (6-10 in. lbs.)
Used G ear......................................................................................................... 0.4-0.5 N m (4-5 in. lbs.)
Final Over Center Reading (Total-Maximum)
New G e a r....................................................................................................................2 N m (18 in. lbs.)
Used G e a r............................................................................................................... 1.6 N m (14 in. lbs.)
TORQUE
Nm Ft. Lbs.
Steering Gear To Frame Nuts (C, K, and G Models)............................................. 102 75
Steering Gear To Frame Nuts (P300(32) andP300(42)FS3)......................... ....... 108 80
Steering Gear To Frame Nuts (P200 + 300(42) Excluding F S 3 ).......................... 95 70
High Pressure Line Fitting (At G e a r)...................................................................... 34 25
Oil Return Line Fitting (At Gear)....................................................................... ....... 34 25
Pitman Shaft Adjuster Screw Jam N ut.................................................................... 47 35
Side Cover To Housing B o lt..................................................................................... 60 45
Adjuster Plug N u t .............................................................................................. ....... 110 81
Reservoir Bolt (At Pump)........................................................................................... 48 35
Flow Control Fitting (At P um p)......................................................................... ....... 48 35
Pressure Hose (At P um p)......................................................................................... 27 20
Power Steering Pump To Booster Line.................................................................... 34 25
Booster To Gear Line.......................................................................................... ....... 34 25
Return Line At Booster And Gear..................................................................... ....... 34 25
Coupling Flange N u ts ........................................................................................ ....... 27 20
Coupling Flange Pinch B o lt ..................................................................................... 42 31
Lower Intermediate Shaft Pinch Bolt (G Model).............................................. ....... 62 46
Upper Intermediate Shaft Pinch Bolt (G M o d e l)............................................ ....... 47 35
Intermediate Shaft Pinch Bolts (P200 + 300(42) Excluding F S 3 )...................... 102 75
Intermediate Shaft Pinch Bolts (P300(42)FS3)................................................ ....... 108 80
PUMP SPECIFICATIONS
Minimum Maximum Relief Valve Settings

Part Output (1) Output (2) Minimum Maximum
Vehicle Number Model G PM L/M in. GPM L/M in. PSI kPa PSI kPa
7838933 132-P-122 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7838934 132-P-123 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7838935 132-P-124 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7838936 132-P-125 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7839797 132-P-143 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7839798 132-P-144 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
C K 7839799 132-P-145 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
Model 7839800 132-P-146 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7839801 132-P-147 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7839802 132-P-148 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7839804 132-P-150 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7839813 132-P-159 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7839816 132-P-161 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7839818 132-P-163 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
26000518 132-P-260 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7841731 132-P-222 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
G 7842049 132-P-228 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
Model 7847616 T115-PT-003 1.15 4.35 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7849229 132-P-253 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998
7839808 132-P-154 1.32 5.00 2.4-2.8 9.1-10.6 1200 8274 1300 8964
7839809 132-P-155 1.32 5.00 2.4-2.8 9.1-10.6 1200 8274 1300 8964
7839812 132-P-158 1.32 5.00 2.4-2.8 9.1-10.6 1350 9308 1450 9998
7839817 132-P-162 1.32 5.00 2.4-2.8 9.1-10.6 1200 8274 1300 8964
P 7842032 132-P-226 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
Model 7842033 132-P-227 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7842489 132-P-230 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
7842490 132-P-231 1.32 5.00 2.4-2.8 9.1-10.6 1350 9308 1450 9998
7842491 132-P-232 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964
1 Output of Power Steering Fluid at 32C (90F) temperature when operating pump at 465 rpm against 4585-
5068 kPa (665-735 psi) pressure.
2 Output of Power Steering Fluid at 32C (90F) temperature when operating pump at 1500 rpm against 345 kPa
(50 psi) pressure.
SPECIAL TOOLS
J-5176-D Power Steering Gage
J-5176-20 Power Steering Gage Adapter 18 mm
J-5421-02 Pocket Thermometer (0-220F)
J-25323 Power Steering Analyzer
J-29525 Power Steering Analyzer Adapter
J-24600-B Belt Tension Gage
J-29107 Pitman Arm Puller
J-4245 Internal Snap Ring Pliers
J-6219 Steering Gear Pitman Shaft Oil Seal Installer
J-7624 Adjustable Spanner Wrench
J-29785-A Water Pump And Power Steering Pulley Remover
J-25033-B Power Steering Pump Pulley Installer
3B4-1
SECTION 3B4
STEERING COLUMN
this manual as indicated at appropriate locations by the terminology See NOTICE on page 3B4-1 of this section.
NOTICE: All steering column fasteners are important attaching parts in that they could affect the perform
ance of vital components and systems, and/or could result in major repair expense. They must be replaced
with one of the same part number or with an equivalent part if replacement becomes necessary. Torque
values must be used as specified during reassembly to assure proper retention of all parts.
CONTENTS
S U B JE C T PAGE
D e s c rip tio n ................................................................................................................................................................ 3B4- 2

Diagnosis Of The Steering C o lu m n .....................................................................................................................3B4- 2
Steering Column Electrical Component A n a lyze r.........................................................................................3B4-10
Steering Column On-Vehicle Service (All M o d e ls)........................................................................................... 3B4-10
In s p e c tio n .............................................................................................................................................................. 3B4-10
Steering Wheel R e p la ce m e n t............................................................................................................................3B4-11
Flexible Coupling R e p la c e m e n t....................................................................................................................... 3B4-11
Intermediate Shaft Replacem ent....................................................................................................................... 3B4-13
Steering Column On-Vehicle Service (C, K And G M odels)............................................................................3B4-15
CK Model Steering Column R e p la ce m e n t......................................................................................................3B4-15
G Model Steering Column R e p la c e m e n t........................................................................................................ 3B4-16
Turn Signal Switch R e p lace m e n t..................................................................... ............................................... 3B4-17
Lock Cylinder Replacement................................................................................................................................3B4-18
Tone Alarm Switch R eplacem ent.....................................................................................................................3B4-19
Ignition Switch Replacement..............................................................................................................................3B4-19
Standard Steering Column Unit Repair (C, K And G M o d e ls )....................................................................... 3B4-20
Standard Steering Column Lower Bearing A d ju s tm e n t.............................................................................. 3B4-24
Tilt Steering Column Unit Repair (C, K And G M o d e ls).................................................................................. 3B4-28
Steering Column On-Vehicle Service P(32) M o d e ls .........................................................................................3B4-34
Turn Signal Switch R eplacem ent..................................................................................................................... 3B4-34
Tilt Steering Column Replacem ent...................................................................................................................3B4-35
Tilt Steering Column Bearing Housing R eplacem ent.................................................................................. 3B4-36
Tilt Steering Column Unit Repair P(32) M o d e ls ............................................................................................... 3B4-40
Steering Column On-Vehicle Service P(42) M o d e ls .........................................................................................3B4-41
Standard Steering Column Replacem ent........................................................................................................3B4-41
Upper Bearing R eplacem ent..............................................................................................................................3B4-42
Lower Bearing R eplacem ent............................................................................................................................. 3B4-42
Steering Column Lower Bearing A d ju s tm e n t............................................................................................... 3B4-44
Shift Tube A d justm e n t........................................................................................................................................ 3B4-44
Standard Steering Column Unit Repair P(42) M o d e ls .................................................................................... 3B4-45
Intermediate Shaft Unit Repair P(42) M o d e ls ....................................................................................................3B4-46
S pecifica tio ns............................................................................................................................................................3B4-47
Special T o o ls ............. .............................................................................................................................................. 3B4-47
3B4-2 STEERING COLUMN
DESCRIPTION
The locking energy absorbing steering column in The column may be disassembled and reassem
cludes three important features in addition to the bled. To insure the energy absorbing action, it is impor
steering function: tant that the specified screws, bolts and nuts be used
1. The column is energy absorbing, designed to only as designated and that they are tightened to the
compress in a front-end collision to minimize the specified torque.
possibility of injury to the driver of the vehicle. When the column is removed from the vehicle, such
2. The ignition switch and lock are mounted conve actions as a sharp blow on the end of the steering
niently on the column. shaft or shift lever, leaning on the column assembly, or
3. With the column mounted lock, the ignition, dropping of the assembly could shear or loosen the
steering and gearshifting operation can be locked plastic fasteners that maintain column rigidity.
to inhibit theft of the vehicle.
DIAGNOSIS OF THE STEERING COLUMN

Lock System Will 1. Lock bolt damaged. 1. Replace the lock bolt.
Not Unlock 2. Faulty lock cylinder. 2. Replace or repair the lock cylinder.
3. Damaged housing. 3. Replace the housing.
4. Damaged or collapsed sector. 4. Replace the sector.
5. Damaged rack. 5. Replace the rack.
Lock System Will 1. Lock bolt spring is broken. 1. Replace the spring.
Not Lock 2. Damaged sector tooth. 2. Replace the sector tooth.
3. Faulty lock cylinder. 3. Replace the lock cylinder.
4. Damaged housing. 4. Replace the housing.
5. Damaged rack. 5. Replace the rack.
6. Interference between the bowl and 6. Adjust or replace.
coupling.
7. Ignition switch stuck. 7. Adjust or replace.
8. Actuator rod restricted or bent. 8. Adjust or replace.
9. Transmission linkage adjustment is in 9. Adjust.
correct.
Lock SystemHigh 1. Lock cylinder is faulty. 1. Replace the lock cylinder.

Lock Effort 2. Ignition switch is faulty. 2. Replace the ignition switch.
3. Rack preload spring is broken or weak. 3. Replace the spring.
4. Burrs on the sector, rack, housing, 4. Remove the burrs.
support, tang of the shift gate or actua
tor rod coupling.
5. Bent sector shaft. 5. Replace the shaft.
6. Distorted rack. 6. Replace the rack.
7. Misalignment of the housing to the 7. Replace either or both.
cover (tilt only).
8. Distorted coupling slot in the rack (tilt 8. Replace the rack.
only).
9. Bent or restricted actuator rod. 9. Straighten or replace the rod.
10. Ignition switch mounting bracket is 10. Straighten or replace the bracket.
bent.
STEERING COLUMN 3B4-3
DIAGNOSIS OF THE STEERING COLUMN (CONT.)

Lock CylinderHigh 1. Burr on tang of shift gate. 1. Remove the burr.
E ffort Between The 2. Distorted rack. 2. Replace the rack.
O ff and
O ff-Lock Positions
Sticks In S tart 1. Actuator rod is deformed. 1. Straighten or replace the rod.

Position 2. Any high effort condition. 2. See correction under the high ef
fort diagnosis.
Key Cannot Be 1. Ignition switch is not set correctly. 1. Adjust ignition switch.
Removed In The 2. Faulty lock cylinder. 2. Replace the lock cylinder.
O ff-Lock Position
The Lock Cylinder 1. Faulty retainer. 1. Replace the lock cylinder.

Can Be Removed 2. Burr over the retainer slot in the hous 2. Remove the burr.
W ithout Depressing ing cover.
The Retainer
Lock Bolt Hits The Ignition switch is not set correctly. Adjust the ignition switch.
Shaft Lock In The
O ff And Park
Positions
Noise In The Column 1. Flexible coupling pulled apart. 1. Align the column and replace the
flexible coupling.
2. Column not correctly aligned. 2. Align the column.
3. One click in Off-Unlock position and 3. Norma! seating of the lock bolt.
when the steering wheel is moved.
4. Horn contact ring not lubricated. 4. Lubricate.
5. Lack of grease on the bearings or 5. Lubricate the bearings.
bearing surface.
6. Lower shaft bearing is tight or frozen. 6. Replace the bearing. Inspect the
shaft and replace if scored.
7. Upper shaft bearing is tight or frozen. 7. Replace the housing assembly.
8. Lock plate retaining ring is not seated. 8. Replace the retaining ring. Inspect
for proper seating in the groove.
9. Steering shaft snap ring is not seated. 9. Replace the snap ring. Inspect for
proper seating in the groove.
10. Shroud or housing is loose. 10. Tighten mounting screws.
11. Sheared intermediate shaft plastic 11. Repair or replace the steering shaft.
joint. Align the column.
High Steering Shaft 1. Column assembly is misaligned in the 1. Align correctly.

Effort vehicle.
2. Tight or frozen upper or lower bear 2. Replace the bearings.
ings.
3. Binding intermediate shaft U-joints. 3. Repair or replace the intermediate
shaft.

High Shift Effort 1. Column assembly is misaligned in the 1. Align correctly.

vehicle.
2. Lower bowl bearing is not aligned cor 2. Align correctly.
rectly.
3. Lack of grease on the bearing or seal 3. Lubricate bearings and seals.
areas.
4. Shift tube is bent or broken. 4. Replace the shift tubes.
Improper 1. Sheared shift tube joint. 1. Replace the shift tube assembly.
Transmission Shifter 2. Improper transmission linkage adjust 2. Adjust the linkage.
ment.
3. Loose lower shift lever. 3. Replace the shift tube assembly.
4. Sheared lower shift lever weld. 4. Replace the shift tube assembly.
Lash In Mounted 1. Column mounting bracket bolts loose. 1. Tighten to specifications.

Column Assembly 2. Broken weld nuts on the jacket. 2. Replace the jacket assembly.
3. Column bracket capsule sheared. 3. Replace the bracket assembly.
4. Loose shoes in the housing (tilt only). 4. Replace the shoes.
5. Loose tilt head pivot pins (tilt only). 5. Replace the pivot pins.
Driver Can Lock 1. Faulty upper shift lever. 1. Replace the shift lever.
Steering In The 2. Faulty shift lever gate. 2. Replace the shift lever gate.
Second Gear (Manual 3. Loose relay lever on the shift tube. 3. Replace the shift tube assembly.
Transmission
Columns)
Excessive Play In 1. Column mounting bracket bolts loose. 1. Tighten to specifications.

The Mounted 2. Loose support screws. 2. Tighten to specifications.
Steering Column 3. Loose tilt head pivot pins. 3. Replace the pivot pins.
Assembly (Tilt 4. Loose lock shoe pin in the support. 4. Replace the pin.
Column)
Housing Loose (Tilt 1. Excessive clearance between the 1. Replace either or both.
Column) holes in the support or the housing
and pivot pin diameter.
2. Faulty anti-lash spring in the cent ring 2. Replace the spring.
spheres.
3. Upper bearing not seating in the bear 3. Replace both.
ing race.
4. Upper bearing inner race seat miss 4. Install the seat.
ing.
5. Bearing preload spring broken. 5. Replace preload spring.
6. Loose support screws. 6. Tighten to specifications.
Housing Scraping Bowl bent or not concentric with the Replace the bowl.
On The Bowl (Tilt hub.
Column)

Steering Wheel Loose fit between the lock shoe and Replace both.
Loose Every Other pivot pin.
Tilt Position (Tilt
Column)
Steering Column 1. Lock shoe grooves may have burrs or 1. Replace lock shoes and clean the
Will Not Lock In Any dirt. grooves.
T ilt Position (Tilt 2. Lock shoe spring is weak or broken. 2. Replace the spring.
Column) 3. Lock shoe seized on its pivot pin. 3. Replace both lock shoes.
Noise When Tilting 1. Tilt spring rubbing in the housing. 1. Lubricate.

The Column (Tilt 2. Tilt bumpers are worn. 2. Replace the tilt bumpers.
Column)
Steering Wheel Fails 1. Pivot pins are bound up. 1. Replace the pivot pins.
To Return To The 2. Wheel tilt spring is faulty. 2. Replace the spring.
Top Tilt Position 3. The turn signal switch wires are too 3. Reposition the wires.
(Tilt Column) tight.
Dimmer Switch Will 1. Loose connector at the dimmer switch. 1. Tighten or replace.
Not Function 2. Improper adjustment. 2. Readjust.
3. Internally damaged or worn switch. 3. Replace.
Turn Signal W ill Not 1. Loose switch mounting screws. 1. Tighten screws to 2.8 N m (25 in.
Cancel lbs.).
2. Switch or anchor bosses broken. 2. Replace the switch.
3. Broken, missing or out of position de 3. Reposition or replace the springs as
tent, return or cancelling spring. required.
4. Uneven or incorrect cancelling cam to 4. Adjust the switch position.
cancelling spring interference. If the interference is correct and
switch will still not cancel, replace
the switch.
If the interference cannot be cor
rected by the switch adjustment,
replace the cancelling cam.
Turn Signal D ifficult 1. Actuator rod loose. 1. Tighten mounting screw to 1.4 N m
To Operate (12 in. lbs.).
2. Yoke broken or distorted. 2. Replace the switch.
3. Loose or misplaced springs. 3. Reposition or replace the springs.
4. Foreign parts and/or materials. 4. Remove the foreign parts and/or ma
terial.
5. Switch mounted loosely. 5. Tighten mounting screws to 2.8 (25
in. lbs.).
Turn Signal W ill Not 1. Broken lane change pressure pad or 1. Replace the switch.
Indicate Lane spring hanger.
Change 2. Broken, missing or misplaced lane 2. Replace or reposition as required.
change spring. 3. Loosen mounting screws, reposition
3. Jammed base or wires. base or wires and tighten the screws
to 2.8 N m (25 in. lbs.).

Turn Signal W ill Not 1. Foreign material or loose parts im 1. Remove material and/or parts.
Stay In Turn Position pending movement of the yoke.
2. Broken or missing detent or cancelling 2. Replace the spring.
springs.
3. None of the above. 3. Replace the switch.
Hazard Switch Foreign material between hazard sup Remove the foreign material.
Cannot Be Turned port cancelling leg and yoke. No foreign material. Replace the
Off turn signal switch.
Hazard Switch W ill 1. Loose switch, mounting screws. 1. Tighten mounting screws to 2.8 N.m
Not Stay On Or (25 in. lbs.).
D ifficu lt To Turn Off 2. Interference with other components. 2. Remove the interference.
3. Foreign material. 3. Remove the foreign material.
4. None of the above. 4. Replace the switch.
No Turn Signal 1. Faulty or blown fuse. 1. Replace fuse and check operation.
Lights 2. Inoperative turn signal flasher. 2. Replace the turn signal flasher.
3. Loose chassis to column connector. 3. Connect securely, check operation.
4. Disconnect column to chassis connec 4. Replace the signal switch.
tor. Connect new switch to chassis and
operate switch by hand. If vehicle
lights now operate normally, signal
switch is inoperative.
5. If vehicle lights do not operate, check 5. Repair the chassis wiring.
chassis wiring for opens, grounds, etc.
Turn Indicator Lights 1. Inoperative turn flasher. 1. Replace the turn flasher.
On, But Not Flashing 2. Loose chassis to column connection. 2. Connect securely and check opera
tion.
3. Inoperative turn signal switch. 3. Replace the turn signal switch.
4. To determine if turn signal switch is 4. Replace the signal switch.
faulty, substitute a new switch into the
circuit and operate the switch by hand.
If the vehicles lights operate normally,
the signal switch is inoperative.
5. If the vehicles lights do not operate, 5. Repair the chassis wiring.
check light sockets for high resistance
connections, the chassis wiring for
opens, grounds, etc.
Front Or Rear Turn 1. Burned out fuse. 1. Replace fuse and check operation.
Signal Lights Are 2. Burned out or damaged turn signal 2. Replace the bulb.
Not Flashing bulb.
3. High resistance connection to ground 3. Remove or repair the faulty connec
at the bulb socket. tion and check operation.
4. Loose chassis to column connector. 4. Connect securely and check opera
tion.

Front Or Rear Turn 5. Disconnect column to the chassis con 5. Replace the turn signal switch.
Signal Lights Are nector. Connect a new switch into the
Not Flashing (Cont.) system and operate the switch by
hand. If turn signal lights are now on
and flash, the turn signal switch is in
operative.
6. If vehicle lights do not operate, check 6. Repair the chassis wiring.
the chassis wiring harness to light
sockets for opens, grounds, etc.
Stop Light Not On 1. Burned out fuse. 1. Replace fuse and check operation.
When Turn Indicated 2. Loose column to chassis connection. 2. Connect securely and check opera
tion.
3. Disconnect column to chassis connec 3. Replace the signal switch.
tor. Connect new switch into system
without removing old. Operate switch
by hand, if brake lights work with
switch in the turn position, signal
switch is faulty.
4. If brake lights do not work, check con 4. Repair connector to stop lights cir
nector to stop light, the sockets for cuits.
grounds, opens, etc.
Turn Indicator Panel 1. Burned out bulbs. 1. Replace the bulbs.

Lights Not Flashing 2. High resistance to ground at the bulb 2. Replace the socket.
socket.
3. Opens, grounds in wiring harness from 3. Locate and repair as required.
the front turn signal bulb socket to the
indicator lights.
Turn Signal Lights 1. Inoperative turn signal flasher. 1. Replace the turn signal flasher.
Flash Very Slowly 2. System charging voltage low. 2. Increase voltage to specifications.
Refer to (SEC. 6D ENGINE ELECTRI
CAL) in this manual.
3. High resistance ground at light sock 3. Repair high resistance grounds at the
ets. light sockets.
4. Loose chassis to column connection. 4. Connect securely and check opera
tion.
5. Disconnect column to chassis connec 5. Replace signal switch.
without removing old. Operate switch
by hand. If flashing occurs at normal
rate, the signal switch is faulty.
6. If the flashing rate is still extremely 6. Locate and repair as required. Refer
slow, check chassis wiring harness to SEC. 8B (CHASSIS ELECTRICAL)
from the connector to the light sockets in this manual.
for high resistance.

Hazard Signal Lights 1. Blown fuse. 1. Replace fuse and check operation.
W ill Not FlashTurn 2. Inoperative hazard warning flasher. 2. Replace the hazard warning flasher.
Signal Functions 3. Loose chassis to column connection. 3. Connect securely and check opera
Normally tion.
4. Disconnect column to chassis connec 4. Replace the turn signal switch.
without removing old. Depress the
hazard warning button and observe
the hazard warning lights. If they now
work normally, the turn signal switch is
faulty.
5. If the lights do not flash, check wiring 5. Replace fuse block. Refer to SEC. 8B
harness K lead (brown) for open be (CHASSIS ELECTRICAL) in this
tween hazard flasher and harmonica manual.
connector. If open, fuse block is faulty.
Tone Alarm Does 1. Loose connection at the tone alarm. 1. Connect securely.
Not Sound With Key 2. Voltage not available to the tone alarm. 2. Check the continuity of the chassis
Fully Inserted In wiring and repair as required.
Lock Cylinder With 3. Faulty tone alarm. 3. Replace the tone alarm.
D rivers Door Open 4. Door jamb switch on the drivers side 4. Adjust or replace as required.
is maladjusted or inoperative.
5. Short in the chassis wiring. 5. Check by separating chassis to col
umn connector. Connect E and F fe
male contacts on the chassis side
(bent paper clip will work). If tone
alarm sounds, continue diagnosis. If
not, locate and repair chassis wiring.
6. Short or fault in the signal switch wir 6. Connect male E and F contacts of
ing. connector with the jumper. Check
buzzer switch pads with the ohmme-
ter. If contact is made, function is nor
mal. If not, replace the signal switch.
7. Chips, burrs, foreign material is pre 7. Remove chips and burrs. Reassem
venting actuator tip function. NOTICE: ble and check.
Key must be removed or the cylinder
in the run position before removing
the lock cylinder.
8. Faulty lock cylinder. 8. With the lock cylinder out (refer to
Notice under step 7), fully insert
and remove the key. The actuator
should extend and retract smoothly.
Total expansion of tip should be
1.25 mm (0.050 inch). If not, replace
the lock cylinder.
9. Chips, foreign material affecting the 9. Remove and clean as requiredre
tone alarm switch operation. assemble and check.
10. Damaged or broken tone alarm switch. 10. Replace the tone alarm switch.
11. Inoperative tone alarm switch (switch 11. Connect the ohmmeter leads to the
appears good but will not make the tone alarm switch probes. Press on
tone alarm switch function check). the actuator pad until the interior
points contact. If contact is not made,
replace the tone alarm switch.
12. Tone alarm switch contact gap is too 12. Reset the contact gap.
large

Tone Alarm Does 13. If the tone alarm fault has not yet been 13. With the fault isolated in the column,
Not Sound With Key detected, connect a continuity meter disassemble the upper end of the col
Fully Inserted In (or light) to the male E and F connector umn until the signal switch mounting
Lock Cylinder With contacts. Insert the key the full depth screws have been removed. Lift the
D rivers Door Open into the lock cylinder. If contact is switch and check the probes of the
(Cont.) made with the key in, and is not made tone alarm switch to ensure good
with it out, the function is normal. Re contact with the pads in the signal
trace the initial diagnostic steps. If con switch. Bend the probes, if required,
tact is not established, the fault is in then reseat the signal switch and in
the column. stall the three screws. Check the
function.
14. If the fault has not yet been isolated 14. Setting the contact gap. Press a
and repaired, connect ohmmeter to the 0.75 mm (0.030 inch) wire type spark
tone alarm switch probes. Fully insert plug gap wire with flat piece of stock
and remove the key from the lock cylin on the actuator pad. If contact is not
der. If contact is made with the key in, made, adjust switch until positive
and is broken with it out, the function is contact is made (use ohmmeter).
normal. Retrace the diagnostic steps. With positive contact at 0.75 mm
If contact is not made, the fault is in (0.030 inch) use a 0.65 mm (0.025
the lock cylinder or tone alarm switch. inch) plug gap wire beneath the flat
stock. No contact should occur. Ad
just. When the switch will make con
tact with the 0.75 mm (0.030 inch)
wire and not with the 0.65 mm (0.025
inch) wire, the tone alarm switch is
set at the low limit.
Tone Alarm 1. Door jamb switch on drivers side mal 1. Adjust or replace as required.
Continues To adjusted or inoperative.
Operate With Key In 2. Wire from signal switch to door jamb 2. If on signal switch side, replace sig
The Lock Cylinder switch shorted. nal switch. If on chassis side, find
W ith The D rivers and repair.
Door Either Opened This condition indicates the lock
Or Closed And cylinder or tone alarm switch is at
Ceases When Key Is fault. To verify, check for continuity at
Removed the E and F male connector contacts
with the key removed from the cylin
der. If continuity exists, the fault is in
the column.
Tone Alarm 1. Lock cylinder binding (turn lock toward 1. Replace the lock cylinder.
Continues To start position. If tone alarm stops in the
Operate With Key run position or when turned past run
Out, But Stops When run towards the start, the problem is a
D rivers Door Is sticky lock cylinder actuator).
Closed 2. Chips, foreign material in lock cylinder 2. Remove, assem ble and recheck
bore. function.
3. Sticky lock cylinder actuator tip. 3. Replace the lock cylinder.
4. Damaged or broken tone alarm switch. 4. Replace the tone alarm switch.
5. Tone alarm switch contact gap is too 5. Adjust as specified.
close.
STEERING COLUMN ELECTRICAL tester will overhang the chassis connector. This does
not affect the test results. These terminals are for
COMPONENT ANALYZER vehicles with cornering lights.
Move the analyzer switch (with the key in the on
Use J-23980-B, the steering column electrical position) to the various functions that may be checked.
component analyzer, for C, K, G models, to analyze the The switch positions are OFF, Horn, Left Turn,
steering column wiring harness for electrical problems. Right Turn, Key Buzzer and Hazard (some
To use J-23980-B, unfasten the harmonica connector vehicles do not use a tone alarm switch). If the system
on the column and plug the harness from J-23980-B functions properly while using the analyzer, then the
into the vehicle chassis harness. Connect the single problem has been narrowed to the column wiring or
black jumper to a good ground and use the analyzer. components. When this is determined the column may
The A , B , and C te rm in a ls on the be serviced.
STEERING COLUMN ON-VEHICLE SERVICE

(ALL MODELS)
INSPECTION
SHIFTER SHAFT
Separation of the shifter shaft sections will be
internal and cannot be visually identified. Hold lower
end of the shifter shaft and move the shift lever on
the column through its ranges and up and down. If
there is little or no movement of the shifter shaft, the
plastic joints are sheared.
STEERING SHAFT
If the steering shaft plastic pins have been sheared,
the shaft will rattle when struck lihtly from the side and
some lash may be felt when rotating the steering wheel 1/
while holding the rag joint. If the steering shaft pins are
sheared due to minor collision without serious damage
to other components, the vehicle can be safely
steered; however, steering shaft replacem ent is
recommended. A. Capsules must be within 1.59 mm (Vie")
from bottom of slots. If not, replace bracket
COLUMN JACKET assembly.
Inspect the jacket section of the colum n for B. The bolt head must not contact surface
looseness, and/or bends. B. If contact is made, the capsule shear
load will be increased Replace bracket.
COLUMN SUPPORT BRACKET B-07380
Damage in this area will be indicated by separation
of the mounting capsules from the bracket. The Figure 1Inspecting The Steering
bracket will have moved forward toward the entire Column For Collapse
compartment and will usually result in collapsing of the
jacket section of the steering column. Inspect (Figures 1 through 3)
STEERING COLUMN FOR ACCIDENT DAMAGE 1. C apsules on the steering colum n bracket
assembly. The capsules must be within 1.59 (1/ie
NOTICE: Vehicles involved in accidents inch) from the bottom of the slots (figure 1). If not,
resulting in frame damage, major body or the bracket should be replaced.
sheet metal damage, or where the steering 2. Contact surface (figure 1). The bolthead must not
column has been impacted may also have a contact surface B or the shear load would be
damaged or misaligned steering column. increased. If contact is made, replace the bracket.
3. Shift lever operation on vehicles with automatic 1. Steering wheel onto the steering shaft. Align the
transmission and column shift. If the shift lever is marks made at removal.
able to move to the Park position without
raising the lever, the upper shift tube plastic Important
bearing is broken.
4. Jacket collapse. Measure the jacket collapse Do not misalign the steering wheel more
dim ensions, depending on the vehicle and than 25.4 mm (1 inch) from the horizontal
steering column, in either of the following ways centerline (figure 5).
(figure 2): 2 . Horn lead assembly (some models).
Measure from the end of the bearing 3. Steering wheel nut.
assembly to the lower edge of the upper
jacket (C). Tighten
Measure from the collar on the toe plate
flange to the lower edge of the upper jacket Nut to 40 N m (30 ft. lbs.).
(E, G and H). Retainer.
Measure from the edge of the back-up Horn button cap.
switch window to the lower edge of the Battery ground cable.
upper jacket (D, F and J).
If the jacket dimensions are not within specifications,
a new jacket must be installed. FLEXIBLE COUPLING
Visually inspect for sheared injected plastic
in the shift tube, and the steering shaft
REPLACEMENT
(figure 3). If either one or both are sheared,
replace with new parts.
5. Any frame damage that could cause a bent
1. Coupling to flange bolt nuts and washers (2).
steering shaft must have the steering shaft
2. Clamp bolt (1).
runout checked in the following manner:
3. Steering gear frame bolts. Lower the steering
Remove intermediate shaft. Hold a ruler
gear far enough to remove the flexible coupling.
against the lower end of steering shaft and
4. F le xib le c o u p lin g from the ste e rin g gear
have the steering wheel rotated. The runout
wormshaft. Tap lightly with a soft mallet.
must not exceed 1.59 mm (Vie inch). A dial
indicator may be used instead of a ruler.
STEERING WHEEL REPLACEMENT

NOTICE: For steps 2, 3 and 4 see Notice on
Remove or Disconnect page 3B4#1.
Tools Required: 1. F le xib le co u p lin g onto the ste e rin g gear

J-1859-03 Steering Wheel Puller wormshaft. Align the flat on the shaft with the flat
Battery ground cable. in the coupling.
Horn button cap. Push the coupling onto the wormshaft until
Retainer and steering wheel nut. the coupling reinforcement bottoms against
Horn lead assembly (some models). the end of the worm.
Mark the relationship of the steering wheel to the 2. Clamp bolt (1) into the split clamp. The bolt must
steering shaft. pass through the shaft undercut.
5. Steering wheel. Use J-1859-03 (figure 4). Do not
hammer on the puller, or damage could result to
the steering column.
Bolt to 42 N m (31 ft. lbs.).
Install or Connect Place the steering gear into position,
guiding the flexible coupling bolts into the
proper holes in the steering shaft flange.
NOTICE: For step 3 see Notice on page 3. Steering gear and frame bolts.
3B4#1.
Tighten
The turn signal control assembly must be in the
neutral position when assembling the steering Bolts to Specifications at the end of this
wheel. section.
, HM IL
Sr
C. 346.7 mm (13.64 inches) CK MODEL (Tilt

Column)
D. 72 mm (2.8 inches) CK MODEL (Standard
Column-Column Shift)
E. 353 mm (14 inches) CK MODEL (Standard I J
Column-Floor Shift)
F. 81.7 mm (3.21 inches) G MODEL (Tilt Col
umn-Column Shift)
G. 144.9 mm (5.70 inches) G MODEL (Tilt Col
umn-4 Speed)
H. 192 mm (7.5 inches) G MODEL (Standard
Column-Column Shift)
J. 80 mm (3.1 inches) G MODEL (Tilt Column-
Floor Shift)
B-07381
Figure 2Inspecting The Steering Column For Collapse

.K
-jE
I 2
K. Inspect for sheared injected plastic in the

A. Capturing Strap
shift tube.
B. Reinforcement
L. Inspect for sheared injected plastic in the 1. Clamp Bolt C. Alignm ent Pins
steering shaft.
2. Nuts And Washers D. Wafer
B-07382 B-07385
Figure 3Inspecting The Steering Column Figure 6Flexible Type Steering Coupling
For Collapse
4. Coupling to flange bolt nuts and washers (2).
The coupling alignment pins should be
centered in the flange slots.
Tighten
Measure
Coupling to flange dimension. Maintain a

6.4 to 9.5 mm (0.250 to 0.375 inch)
dimension.
INTERMEDIATE SHAFT
REPLACEMENT
Set front wheels in the straight ahead position.

Mark the upper universal joint yoke to steering
shaft and the lower yoke to steering gear
wormshaft relationship.
1. Upper and lower universal yoke pinch bolt.
2. Steering gear frame bolts. Lower the steering
gear.
It is not necessary to disconnect the pitman
arm from the steering gear pitman shaft.
3. Intermediate steering shaft and universal joint
assembly.

A. Do not misalign more than 25.4 mm (1 inch)
from the horizontal centerline.
B-07384
Figure 5Steering Wheel Alignment page 3B4#t.
Figure 7Intermediate Shaft Installation
1. Intermediate shaft lower yoke onto the steering

gear worm shaft. Align the marks made at
*F R T removal.
2. Pinch bolt. The pinch bolt must pass through the
shaft undercut.
Tighten
Pinch bolt to Specifications at the end of

this section.
Raise the steering gear into position while
guiding the upper yoke assem bly onto the
steering shaft. The marks on the coupling and
steering shaft must align.
A. Angle must not exceed 39 degrees maximum 3. Steering gear and frame bolts.
or 34 degrees minimum. B-07387
Tighten
Figure 8Carden Joint Angle (G-Model)
Bolt to Specifications at the end of this
section.
4. Pinch bolt to the upper yoke assembly. The pinch Measure

bolt must pass through the shaft undercut.
Carden joint operating angle (G-Model). The
Tighten a ng le m ust not exceed 39 d e g re e s
maximum or 34 degrees minimum (figure
Pinch bolt to Specifications at the end of 8).
this section.

(C, K AND G MODELS)
CK MODEL STEERING
COLUMN REPLACEMENT

2. Transmission control linkage from the column
shift tube levers.
3. Nuts and washers (1) that secure the flanged end
of the steering shaft to the flexible coupling.
4. Nuts (10) and clamp (11).
5. Steering wheel. Refer to S teering Wheel
Replacement in this section.
6. Steering column harness at the connector.
Disconnect the neutral-start switch and
back-up lamp switch connectors (some
models). Refer to SEC. 8B (CHASSIS
ELECTRICAL) in this manual.
7. Transmission indicator cable (some models).
8. Screws (6), upper cover (3), lower cover (5), and
seal (4).
9. Screws (7), nuts (8) and bracket (9).
10. Steering column assembly. Rotate the column so
the shift lever clears the dash opening.
2. Nuts And Washers 9. Bracket

NOTICE: For steps 4 and 12 see Notice on 3. Upper Cover 10. Nuts
page 3B4#1. 4. Seal 1 1 . Clamp
5. Lower Cover 12. Pot Joint
1. Plastic spacers onto the flexible coupling 6. Screws 13. Flexible Coupling
alignment pins. 7. Screws
2. Lower end of the steering column through the 8. Nuts B-07388
dash opening.
3. Lower steering shaft flange onto the flexible
coupling (13). Figure 9Steering Column Installation
(C-K Model)
4. Flange to coupling washers and nuts (1).
Tighten 5. Screws (7) and (8) and bracket (9) loosely. Tighten
screws and nuts finger tight.
The flexible coupling (13) on manual steering 6. Clamp (11) and nuts (10).
must be installed prior to column installation.
Tighten
Nuts (10) to 24 N m (18 ft. lbs.).

Screws (7) and nuts (8) to 30 N m (22 ft.
lbs.).
7. Seal (4) and covers (3, 5) to the dash.
8. Screws (6).
Remove plastic spacers from the flexible
coupling pins.
Measure
Pot joint (12) operating angle must not

exceed 12 degrees.
Flexible coupling (13) must not be distorted
greater than 1.5 mm (0.06 inch) due to pot
joint bottoming, in either direction.
10. Transmission indicator cable (some models).
11. Connectors to the steering column harness. 6. Screws
7. Screws
C onnect the n e u tra l-sta rt sw itch and
8. Nuts
9. Bracket
models). Refer to SEC. 8B (CHASSIS
14. Pinch Bolt
ELECTRICAL) in this manual. B-07389
12. S teering wheel. Refer to S teering Wheel
Replacement in this section. Figure 10Steering Column Installation (G Model)
13. Transmission control linkage.

G MODEL STEERING COLUMN page 3B4H1.
REPLACEMENT
1. Lower end of the steering column through the
Remove or Disconnect (Figure 10) dash opening.
2. Bracket (9), screws (7) and nuts (8) loosely.
1. Battery ground cable. Tighten screws and nuts finger tight.
Guide the steering shaft into the universal yoke,
lining up the marks made at removal.
shift tube levers.
3. Upper universal joint pinch bolt (14). The pinch
3. Upper universal joint pinch bolt (14) from the bolt must pass through the shaft undercut.
intermediate shaft. Mark the relationship of the
universal yoke to the steering shaft. Tighten
4. Screws (7), nuts (8) and bracket (9).
Pinch bolt to 47 N m (35 ft. lbs.).
5. Screws (6) from the cover and seal.
6. S teering wheel. Refer to S teering Wheel Measure
7. Steering column harness at the connectors. Carden joint operating angle. The angle
must not exceed 39 degrees maximum or
Disconnect the neutral-start switch and 34 degrees minimum (figure 8).
models). Refer to SEC. 8B (CHASSIS Tighten
ELECTRICAL) in this manual.
8. Steering column assembly. Rotate the column so Screws (7) and nuts (8) to 30 N m (22 ft.
the shift lever clears the dash opening. lbs.).
Figure 12Removing The Turn Signal

Wire Protector
3. Screws (6) through the cover and seal to the dash
panel. Pull the switch connector out of the bracket on
4. Connectors to the steering column harness. the jacket and feed switch connector through
C onnect the n e u tra l-sta rt sw itch and column support bracket and pull switch straight
back-up lamp switch connectors (some up, guiding the wiring harness through the
models). Refer to SEC. 8B (CHASSIS column housing and protector.
ELECTRICAL) in this manual. 8. Wire protector. Pull downward out of the column
4. S teering wheel. Refer to Steering Wheel with pliers using the tab provided (figure 12).
Replacement in this section. Position the turn signal and shifter housing in the
6. Transmission control linkage. low position. Remove the harness cover by
7. Batter ground cable. pulling toward the lower end of the column, be
careful not to damage the wires (tilt column).
9. Turn signal switch. Pull the switch straight up,
TURN SIGNAL SWITCH guiding the wiring harness and cover through the
REPLACEMENT column housing (figure 13).
Remove or Disconnect (Figures 11 through 13) Install or Connect
Tools Required: Tools Required:

J-23653-A Lock Plate Compressor J-23653-A Lock Plate Compressor
1. Steering wheel. Refer to Steering Wheel
Replacement in this section. Im portant
2. Instrument panel trim cover.
Position a screwdriver blade into the steering Use only the specified screws, bolts and
shaft lock plate cover slot. Pry up and out to free nuts at assembly. The use of overlength
the cover from the lock plate. screws could prevent a portion of the
Screw the center post of J-23653-A onto the assembly from compressing under impact.
steering shaft as far as it will go. Compress the
lock plate by tu rn in g the center post nut
clockwise. Pry the retaining ring out of the shaft
(figure 11). Remove J-23653-A.
Im portant
If the column is being disassembled on a

bench, the shaft could slide out of the end
of the mast jacket when the snap ring is
removed.
3. Lock plate.
4. Turn signal lever screw and lever.
6. Hazard warning knob. Press the knob inward and
then unscrew. Figure 13Removing The Turn Signal
7. Turn signal mounting screws. Switch Assembly
On non-tilt columns, be sure the wiring harness is

on the protector. Feed the connector and cover
down through the housing and under the
mounting bracket.
On tilt columns, feed the connector down through
the housing and under the mounting bracket. A. Hold the lock cylinder sleeve and rotate the
Install the cover on the harness. knob clockwise against the stop.
1. Turn signal mounting screws. B. Lock Cylinder Set
C. Cylinder Key
Clip the connector to the bracket on the
jacket. D. Lock Retaining Screw B 07394
2. Instrument panel trim plate.
3. Hazard warning knob Figure 15Lock Cylinder Installation
4. Turn signal lever and screws.
It is not necessary to completely remove the
Put the turn signal switch in the Neutral
turn signal switch from the column. Pull the
position. Pull out on the hazard warning knob.
switch rearward far enough to slip it over the
5. Washer, upper bearing preload spring and end of the shift. Do not pull the harness out
cancelling cam onto the upper end of the shaft. of the column.
6. Lock plate onto the end of the shaft. 3. Retaining screw and the lock cylinder set.
Screw the center post of J-23653-A onto the
steering shaft as far as it will go. Place a Im portant
NEW retaining ring over the center post.
Place the C bar over the center post and If the retaining screw is dropped on removal,
then compress the lock plate by turning the it could fall into the column, requiring a
nut clockwise. Slide the new retaining ring complete disassembly to retrieve the screw.
down the tapered center post and into the
shaft groove (figure 14). Remove J-23653-A. -" Install or Connect (Figure 15)
7. Cover on the lock plate and snap into position.
8. Steering wheel. Refer to Steering Wheel 1. Lock cylinder set.
Replacement in this section. Align he cylinder key with the keyway in the
housing. Rotate as shown in figure 15.
Push the lock all the way in.
LOCK CYLINDER REPLACEMENT 2. Retaining screw.
Remove or Disconnect (Figure 15) Tighten

$
Place the lock cylinder in the Run position. Screw to 4.5 N m (40 in. lbs.) (Non-Tilt
1. Steering wheel. Refer to S teering Wheel Columns).
Replacement in this section. Screw to 2.5 N m (22 in. lbs.) (Tilt Columns).
2. Turn signal switch. Refer to Turn Signal Switch 3. Turn signal switch. Refer to Turn Signal Switch
Replacement in this section. Replacement in this section.
4. S teering wheel. Refer to S teering Wheel

TONE ALARM SWITCH

REPLACEMENT

Pull the turn signal switch up far enough to
allow access to the tone alarm switch. Refer
to Turn Signal Switch Replacement in this
section.
The tone alarm switch may be removed
without removing the lock cylinder. The lock
cylinder must be in the Run position. Figure 16Ignition Switch Assembly
2. Tone alarm switch assembly.
Pull the tone alarm switch straight out of the Remove or Disconnect
housing using a paper clip or similar tool. A
flat spring wedges the switch toward the Lower the steering column. Refer to CK Model
lock cylinder. or G Model Steering Column Replacement in
this section. It is not necessary to remove the
Im portant steering wheel.
Be careful not to let the flat spring fall down

into the housing and do not pull on the
switch contacts or plastic material of the Properly support the steering column if it is
switch when removing. not removed from the vehicle.
Put the ignition switch in the Lock position.
+ + Install or Connect If the lock cylinder was removed, the
actuating rod to the switch should be pulled
1. Tone alarm switch to the spring clip with the up until there is a definite stop, then moved
formed end of the clip around the lower end of the down one detent, which is the Lock
switch. The spring is bowed away from the position.
switch. 1. Two ignition switch screws.
Lay the spring on the switch opposite the 2. Ignition switch assembly.
contacts.
-4- Install or Connect (Figure 16)
2. Tone alarm switch and spring into the hole with
the contacts toward the lock cylinder bore.
3. Turn signal switch. Refer to Turn Signal Switch Put the ignition switch in the Lock position
Replacement in this section. (figure 16).
4. Steering Wheel. Refer to Steering Wheel 1. Activating rod into the ignition switch.
Replacement in this section. 2 Ignition switch and screws to the column
3. Steering column assembly. Refer to Steering
Column Replacement in this section.
IGNITION SWITCH REPLACEMENT
The ignition switch is mounted on top of the column
jacket near the front of the dash. For anti-theft reasons,
the switch is located inside the channel section of the
brake pedal support.
The switch is actuated by a rod and rack assembly. A
portion of the rack is toothed and engages a gear on
the end of the lock cylinder. This enables the rod and
rack to be moved axially (with respect to the column) to
actuate the switch when the lock cylinder is rotated.
STANDARD STEERING COLUMN UNIT REPAIR

(C, K AND G MODELS)
+ + Remove or Disconnect On floor shift models remove the transmis

sion control lock tube housing and shroud.
Steering column assembly. Refer to CK or G 16. Shift lever spring from the gear shift lever hous
Model Steering Column Replacement in this ing.
section. On floor shift models remove the lock tube
spring.
+ Disassemble (Figures 17 through 25) 17. Steering shaft from the lower end of the jacket
assembly.
Tools Required:
18. Back-up switch or neutral-safety switch. Refer to
J-23074 Steering Column Holding Fixture
SEC. 8B (CHASSIS ELECTRICAL) in this
1. Dash panel bracket and screws from the column.
manual.
Install J-23074 onto the steering column and
19. Lower bearing retaining clip (figure 25).
place the tool in a bench vise.
On Automatic and Floorshift Columns.
Im portant Remove the lower bearing retainer, bearing
adapter assembly, shift tube spring and
Clamping the steering column directly in a washer. The lower bearing may be removed
vise could result in a damaged column. from the adapter by light pressure on the
2. Steering wheel. Refer to Steering Wheel Re bearing outer race.
placement in this section. Slide out the shift tube assembly.
3. Turn signal switch. Refer to Turn Signal Switch On Manual Transmission (Column Shift)
Replacement in this section. Remove the lower bearing adapter, bearing
4. Lock cylinder. Refer to Lock Cylinder Replace and the first reverse shift lever. The lower
ment in this section. bearing may be removed from the adapter
5. Tone alarm switch, if it needs to be serviced. Re by light pressure on the bearing outer race.
fer to Tone Alarm Switch Replacement in this Remove the three screws from the bearing
section. at the lower and slide out the shift tube as
sembly.
Important Remove the gear shift housing lower bear
ing from the upper end of the mast jacket.
The buzzer switch does not have to be re
moved to remove the upper bearing hous
Assemble (Figures 17 through 22, 26 and 27)
ing.
6. Ignition switch. Refer to Ignition Switch Replace
Apply a thin coat of lithium grease to all friction
ment in this section.
surfaces.
7. Shift lever pivot pin and lever. (Column Shift
1. Sector into the turn signal and lock cylinder hous
Models).
ing.
8. Upper bearing washer.
9. Screws attaching the turn signal and ignition lock Install the sector in the lock cylinder hole
housing. over the sector shaft with the tang end to
10. Housing assembly (figure 23). the outside of the hole.
11. Bushing and retainer from the lower side of the Press the sector over the shaft with a blunt
housing. tool.
12. Ignition switch actuating rod, rack assembly, rack 2. Shift lever detent plate onto the housing.
preload spring, shaft lock bolt and spring assem 3. Rack preload spring into the housing from the
bly from the housing. bottom side. The long section should be toward
13. Shift lever detent plate. the handwheel and hook onto the edge of the
14. Ignition switch actuator sector through the lock housing (figure 26).
cylinder hole by pushing firmly on the block tooth 4. Locking bolt onto the crossover arm on the rack
of the sector with a blunt punch or screwdriver and insert the rack and lock bolt assembly into
(figure 24). the housing from the bottom with the teeth up (to
15. Gear shift lever housing and shroud from the ward hand-wheel) and toward the centerline of
jacket assembly. the column.
48 44
49 I 47
B-07396
Figure 17Standard Steering ColumnColumn Shift (CK-Model)

20. Retainer 47. Shaft Lock Bolt 77. Adapter

21. Nut 48. Switch Rack Preload Spring 78. Reinforcement
22. Lock Plate Cover 49. Actuator Rack 79. Adapter Clip
23. Retainer 50. Actuator Pivot Pin 80. Lower Bearing
24. Lock Plate 51. Washer 81. Automatic Transmission
25. Cancelling Cam 52. Shift Lever Gate 82. Shift Tube
26. Bearing Preload Spring 53. Shift Lever Screw 83. Bolt
27. Turn Signal Screws 54. Housing Cover 84. Spacer
28. Tap Screw 55. Cover Screw 85. Lower Shift Lever
29. Actuator Arm 56. Shift Lever Spring 86. Adapter Plate
30. Turn Signal Switch 57. Gear Shift Housing 87. Adapter
31. Turn Signal Housing Screws 59. Gear Shift Shroud 88. Retainer
32. Washer 60. Washer 89. Adapter Clip
33. Tone Alarm Switch 61. G earS hift Housing Bearing 90. Manual Transmission
34. Retainer Clip 62. Jacket 91. Bolt
35. Retainer Screw 63. Wiring Protector 92. Nut
36. Ignition Lock 64. Actuator Rod 93. Coupling
37. Actuator Sector 65. Dimmer Switch 94. Retainer
41. Housing Assembly 66. Ignition Switch Screw 95. Bearing
42. Bearing 67. Ignition Switch 96. Spring
43. Bushing 68. Dash Seal 97. Washer
44. Horn Contact 73. Shaft 98. Pin
45. Upper Bearing Retainer 74. Shift Tube 99. Seal
46. Dimmer Pivot And 75. Washer 100. Intermediate Shaft
Wiper Switch 76. Spring
B-07361
Figure 18Standard Steering ColumnColumn Shift (CK-Model)
Align the first tooth on the sector with the Install the spring and lower bearing adapter
first tooth on the rack; if aligned properly, assembly into the bottom of the jacket.
the block teeth will line up when the rack Hold the adapter in place and install the
assembly is pushed all the way in. lower bearing reinforcement and retainer
5. Retainer and bushing. clip. The clip snaps into the jacket and rein
6. Gear shift housing lower bearing. Insert the bear forcement slots.
ing from the very end of the jacket. On Manual Transmission (Column Shift)
Align the indentations in the bearing with Loosely attach the three screws in the jacket
the projections on the jacket (figure 27). If and shift tube bearing.
the bearing is not installed correctly, it will Assemble the first reverse lever, lower bear
not rest on the stops provided. ing and adapter assembly into the bottom of
7. Shift lever spring into the gear shift lever (or lock the jacket.
tube) housing.
Hold the adapter in place and install the
8. Housing and shroud assemblies onto the upper
bearing reinforcement and retaining clip.
end of the mast jacket.
The clip snaps into the jacket and reinforce
Rotate the housing to be sure it is seated in
ment slots.
the bearing.
Adjust the lower bearing. Refer to the
9. Turn signal and lock cylinder housing onto the
Manual Transmission (Column Shift) Lower
jacket.
Bearing Adjustment in this section.
The gear shift housing should be in the
12. Back-up switch or neutral-safety switch. Refer to
Park position and the rack pulled down
SEC. 8B (CHASSIS ELECTRICAL) in this
ward.
manual.
Seat the turn signal housing and install the
four screws. 13. Steering shaft into the column.
10. Lower bearing into the adapter assembly. 14. Upper bearing washer.
11. Shift tube assembly into the lower end of the 15. Ignition switch. Refer to Ignition Switch Replace
jacket. Rotate until the upper shift tube key slides ment in this section.
into the housing keyway. 16. Tone alarm switch, if removed. Refer to Tone
On Automatic and Floor Shift Columns Alarm Switch Replacement in this section.
Figure 19Standard Steering Column (CK-Model)

20. Retainer 39. Key Release Lever 65. Dimmer Switch

21. Nut 40. Key Release Washer 66. Ignition Switch Screw
22. Lock Plate Cover 41. Housing Assembly 67. Ignition Switch
23. Retainer 42. Bearing 68. Dash Seal
24. Lock Plate 43. Bushing 69. Adapter
25. Cancelling Cam 44. Horn Contact 70. Bearing
26. Bearing Preload Spring 45. Upper Bearing Retainer 71. Reinforcement
27. Turn Signal Screws 46. Dimmer Pivot And Wiper Switch 72. Adapter Clip
28. Tap Screw 47. Shaft Lock Bolt 73. Shaft
29. Actuator Arm 48. Switch Rack Preload Spring 91. Bolt
30. Turn Signal Switch 49. Actuator Rack 92. Nut
31. Turn Signal Housing Screws 50. Actuator Pivot Pin 93. Coupling
32. Washer 51. Washer 94. Retainer
33. Tone Alarm Switch 57. Gear Shift Housing 95. Bearing
34. Retainer Clip 58. Signal Switch Mounting Screws 96. Spring
35. Retainer Screw 59. Gear Shift Housing 97. Washer
36. Ignition Lock 62. Jacket 98. Pin
37. Actuator Sector 63. W iring Protector 99. Seal
38. Key Release Spring 64. Actuator Rod 100. Intermediate Shaft
B-07362
Figure 20Standard Steering Column (CK-Model)
17. Lock cylinder. Refer to Lock Cylinder Replace 2 . Test for rotational drag by turning the shift lever
ment in this section. through the 2-3 shift arc. The drag measured
18. Turn signal switch. Refer to Turn Signal Switch must not be more than 9N (2 lbs.).
Replacement in this section. 3. Loosen the three clamping screws.
Increase clearance by sliding the clamping
19. Steering wheel. Refer to Steering Wheel Re
screws in the direction of arrow B until the
placement in this section.
first reverse lever is free of drag (figure 28)^
20. Shift lever and pivot pin. Decrease clearance by sliding the clamping
Remove the column from the vise and J- screws in the direction of arrow A until a
23074. slight drag is felt at the first reverse shift
21. Dash panel bracket and screws to the column. lever (figure 28).
4. Install a 0.13 mm (0.005 inch) thick shim between
the space and either of the shift levers.
Install or Connect
5. Slide the clamping screws in the direction of
arrow B until the system is loose. Slide the
Steering column assembly. Refer to CK or G
screws in the opposite direction until a drag is felt
Model Steering Column Replacement in this
at the first reverse shift lever.
section.
Tighten the clamping screws.
Remove the shim.
Install the transmission rods.
STANDARD STEERING COLUMN
LOWER BEARING ADJUSTMENT
MANUAL TRANSMISSION (COLUMN SHIFT)
f t A djust (Figure 28)
1. Put the transmission in neutral and disconnect

the transmission rods.
B-07398
Figure 21Standard Steering Column (G-Model)

20. Retainer 41. Housing Assembly 61. Gear Shift Housing

21. Nut 42. Bearing Bearing
22. Lock Plate Cover 43. Bushing 62. Jacket
23. Retainer 44. Horn Contact 63. Wiring Protector
24. Lock Plate 45. Upper Bearing Retainer 64. Actuator Rod
25. Cancelling Cam 46. Dimmer Pivot And 65. Dimmer Switch
26. Bearing Preload Spring Wiper Switch 66. Ignition Switch Screw
27. Turn Signal Screws 47. Shaft Lock Bolt 67. Ignition Switch
28. Tap Screw 48. Switch Rack Preload Spring 68. Dash Seal
29. Actuator Arm 49. Actuator Rack 102. Shift Tube
30. Turn Signal Switch 50. Actuator Pivot Pin 103. Washer
31. Turn Signal Housing Screws 51. Washer 104. Spring
32. Washer 52. Shift Lever Gate 105. Adapter
33. Tone Alarm Switch 53. Shift Lever Screw 106. Bearing
34. Retainer Clip 54. Housing Cover 107, Reinforcement
35. Retainer Screw 55. Cover Screw 108. Adapter Clip
36. Ignition Lock 56. Shift Lever Spring 109. Shaft
37. Actuator Sector 57. Gear Shift Housing 110. Bearing Washer
38. Key Release Spring 58. Signal Switch Mounting 111. Retainer
39. Key Release Lever Screws 112. Automatic Transmission
40. Key Release Washer 59. Gear Shift Shroud 113. Manual Transmission
B-07364
Figure 22Standard Steering Column (G-Model)
B-07400
Figure 24Removing The Ignition Switch

Actuator Sector
Figure 23Removing The Turn Signal Housing

62. Jacket
80. Lower
Bearing
83. Bolt
84. Spacer
85. Lower Shift
B-07401 Lever
88. Retainer
Figure 25Removing The Lower Bearing Retainer 80 88 89. Adapter Clip
C. 2-3 Shift Lever
D. Shim 0.13 mm (0.005 inch) B-07404
Figure 28A djusting The Lower Bearing
B-07402
Figure 26Installing The Rack Preload Spring
Figure 27Installing The Gearshift

Housing Lower Bearing
TILT STEERING COLUMN UNIT REPAIR

(C, K AND G MODELS)
Remove or Disconnect 13. Bearing reinforcement, bearing and bearing

adapter assembly from the lower end of the mast
Steering column assembly. Refer to CK or G jacket.
Model Steering Column Replacement in this 14. Upper bearing housing pivot pins. Use J-21854-01
section. (figure 33).
Install the tilt release lever and disengage the
* Disassemble (Figures 29 through 36) lock shoes.
15. Bearing housing by pulling upward to extend the
Tools Required: rack full down, and then moving the housing to
J-22635 Lock Shoe and Release Lever Pin the left to disengage the ignition switch rack from
Remover and Installer the actuator rod.
J-23074 Steering Column Holding Fixture 16. Steering shaft assembly from the upper end of
J-21854-01 Pivot Pin Remover the column.
J-23072 Shift Tube Remover 17. Steering shaft by removing the centering spheres
1. Dash panel bracket and screws from the column. and the anti-lash spring.
Install J-23074 onto the steering column and 18. Transmission indicator wire, if so equipped.
place the tool in a bench vise. 19. Bearing housing support to gearshift housing
screws and remove the bearing housing support.
Im portant 20. Ignition switch actuator rod.
21. Shift tube retaining ring and washer.
Clamping the steering column directly in a
vise, could result in a damaged column. NOTICE: When removing the shift tube, be
2. Turn signal switch. Refer to Turn Signal Switch sure to guide the lower end through the slot
Replacement in this section. ted opening in the mast jacket. If the tube is
3. Lock cylinder. Refer to Lock Cylinder Replace allowed to interfere with the jacket in any way,
ment in this section. damage to the tube and jacket could result.
4. Tone alarm switch, if it needs to be serviced. Re
fer to Tone Alarm Switch Replacement in this Install J-23072 into the lock plate, making sure
section. that the tool screws have good thread engage
ment in the lock plate. Then, turning the center
Important screw clockwise, force the shift tube from the
housing (Figure 34). Remove the shift tube (trans
The tone alarm switch does not have to be mission control lock tube on floor shift models)
removed to remove the upper bearing hous from the lower end of the mast jacket. Remove J-
ing. 23072.
5. Ignition switch. Refer to Ignition Switch Replace 22. Lock plate and washer.
ment in this section. Slide the lock plate out of the jacket notches
6. Tilt release lever. by tipping it down toward the housing hub
7. Shift lever pivot pin and lever. and sliding it under the jacket opening.
8. Housing cover screws and housing cover. 23. Shift lever housing from the mast jacket.
Install the tilt release lever and place the column (Transmission control lock tube housing on
in the up position. floor shift models).
9. Tilt lever spring retainer, spring and guide. Use a Disassemble the bearing housing as fol
screwdriver to turn the retainer until it aligns with lows:
the grooves in the housing then remove the re 24. Tilt lever opening shield.
tainer. 25. Lock bolt spring. Remove the retaining
10. Pot joint to steering shaft clamp bolt and remove screws and move the spring clockwise to re
the intermediate shaft and pot joint assembly (CK move it from the bolt (figure 35).
Model). 26. Snap ring from the sector drive shaft.
11. Upper bearing inner race and seat. Push the up With a small punch, lightly tap the drive
per steering shaft in enough to remove the race shaft from the sector (figure 36).
and seat. 27. Drive shaft, sector and lock bolt.
12. Lower bearing retainer clip. 28. Rack and rack spring.
Figure 29Tilt Steering Column (CK And G Models)

120. Retainer 146. Tilt Spring 174. Housing Support

121. Nut 147. Spring Guide 175. Pin
122. Lock Plate Cover 148. Screw 176. Shift Lever Gate
123. Retainer 149. Bearing 177. Detent Plate Screw
124. Lock Plate 150. Lock Bolt 179. Retaining Ring
125. Cancelling Cam 151. Lock Bolt Spring 180. Washer
126. Bearing Preload Spring 152. Lock Shoe 181. Lock Plate
127. Turn Signal Screws 153. Lock Shoe 182. Wave Washer
128. Tap Screw 154. Sector Shaft 183. Gear Shift Lever Spring
129. Actuator Arm 155. Lock Shoe Pin 184. Gear Shift Lever Bowl
130. Turn Signal Switch 156. Pivot Pin 185. Shroud
131. Inner Race Seat 157. Actuator Sector 186. Screw
132. Bearing Race 159. Housing Assembly 187. Stud
133. Screw 160. Shoe Release Springs 188. Switch
134. Tone Alarm Switch 161. Spring 189. Dimmer Switch Rod
135. Retainer Clip 162. Shoe Release Lever Pin 190. Nut
136. Lock Retainer Screw 163. Shoe Release Lever 191. Dimmer Switch
137. Ignition Lock 164. Lower Bearing 192. Jacket
138. Housing Cover 165. Rack Preload Spring 193. Dash Seal
139. Dimmer Switch Actuator 166. Actuator Rack 194. Shift Tube
140. Shield 167. Ignition Switch Actuator 195. Adapter
141. Pin Preload Spring 168. Sphere Spring 196. Lower Bearing
142. Pivot Switch 169. Centering Spheres 197. Retainer
143. Actuator Pivot Pin 170. Spring 198. Adapter Clip
144. Cap 172. Lower Steering Shaft
145. Retainer 173. Housing Support Screws B-07365
Figure 30T ilt Steering Column (CK And G Models)
29. Tilt release lever pin. Use J-22635. Apply a thin coat of lithium grease to all friction
30. Release lever and spring. surfaces.
Bearings into the bearing housing, if removed.
9 Im portant Lock shoe springs, lock shoes and shoe pin in
the bearing housing. Use J-22635 or a 4.5 mm
To relieve the load on the release lever, hold (0.180 inch) diameter rod to line up the shoes for
the shoes inward and wedge a block be pin installation.
tween the top of the shoes (over slots) and
bearing housing. Release lever, spring and pin.
31. Lock shoe retaining pin. Use J-22635.
32. Lock shoes and springs. Im portant
33. Bearings from the bearing housing only if they
are to be replaced. To relieve the load on the release lever, hold
the shoes inward and wedge a block be
Remove the separator and balls from the
tween the top of the shoes (over slots) and
bearings.
bearing housing.
Place the housing on a work bench and with
a pointed punch against the back surface of 4. Sector drive shaft into the housing.
the race, carefully hammer the race out of Lightly tap the sector onto the shaft far
the housing until a bearing puller can be enough to install the snap ring.
used. Repeat for the other race. 5. Snap ring.
6. Lock bolt. Engage the bolt with the sector cam
* Assemble (Figures 29 through 32)
surface.
Tools Required:
7. Rack and spring. The block tooth on the rack
J-23073-01 Shift Tube Installer
should engage the block tooth on the sector (fig
J-22635 Lock Shoe and Release Lever Pin
ure 37).
Remover and Installer
If the bearing housing was disassembled, repeat 8. Tilt release lever.
steps 1-9. 9. Lock bolt spring and retaining screw.
Figure 31Tilt Steering ColumnFloor Shift (CK And G Models)

120. Retainer 143. Actuator Pivot Pin 167. Ignition Switch Actuator
121. Nut 144. Cap 168. Sphere Spring
122. Lock Plate Cover 145. Retainer 169. Centering Spheres
123. Retainer 146. T ilt Spring 170. Spring
124. Lock Plate 147. Spring Guide 172. Lower Steering Shaft
125. Cancelling Cam 148. Screw 173. Housing Support Screws
126. Bearing Preload Spring 149. Bearing 174. Housing Support
127. Turn Signal Screws 150. Lock Bolt 175. Pin
128. Tap Screw 151. Lock Bolt Spring 176. Shift Lever Gate
129. Actuator Arm 152. Lock Shoe 177. Detent Plate Screw
130. Turn Signal Switch 153. Lock Shoe 181. Lock Plate
131. Inner Race Seat 154. Sector Shaft 182. Screw
132. Bearing Race 155. Lock Shoe Pin 187. Stud
133. Screw 156. Pivot Pin 188. Switch
134. Tone Alarm Switch 157. Actuator Sector 189. Dimmer Switch Rod
135. Retainer Clip 159. Housing Assembly 190. Nut
136. Lock Retainer Screw 160. Shoe Release Springs 191. Dimmer Switch
137. Ignition Lock 161. Spring 199. Pad
138. Housing Cover 162. Shoe Release Lever Pin 200. Key Release Lever
139. Dimmer Switch Actuator 163. Shoe Release Lever 201. Key Release Spring
140. Shield 164. Lower Bearing 202. Shroud
141. Pin Preload Spring 165. Rack Preload Spring 203. Lower Bearing
142. Pivot Switch 166. Actuator Rack 204. Retainer
205. Screws
B-07368
Figure 32T ilt Steering Column- -Floor Shift

(CK And G Models)
$ Tighten On floor shift models, install the plunger and

slide the gearshift lever housing onto the
Screw to 4 N m (35 in. lbs.). mast jacket.
10. Shift lever spring into the housing. Wind the 11. Washer and lock plate. Slide the lock plate into
spring up with pliers and push it into the housing. the notches in the jacket.
J-2185401
B-07407
Figure 33Removing The Bearing Housing Pivot

Pins
Figure 38 In sta llin g The S h ift Tube A ssem bly

150. Lock Bolt
151. Lock Bolt Spring B-07409 NOTICE: Do not push or tap on the end of the
shift tube. Be sure that teh shift tube lever is
Figure 35Replacing The Lock Bolt Spring aligned with the slotted opening at the lower
end of the mast jacket or damage to the shift
tube and mast jacket could result.
12. Shift tube into the lower end of the mast jacket.
Align the keyway in the tube with the key in
the shift lever housing.
Install the wobble plate end of J-23073-01
into the upper end of the shift tube far
enough to reach the enlarged portion of the
tube.
Install the adapter over the end of the tool,
seating it against the lock plate.
Place the nut on the threaded end of the
tool and pull the shift tube into the housing
(figure 38).
Remove J-23073-01.
13. Bearing support washer and retaining ring. Pull
the shift lever housing up far enough to compress
the lock plate washer.
14. Bearing support. Align the V in the support
with the V in the jacket.
15. Screws through the support and into the lock
plate.
Screws to 6.8 N m (60 in. lbs.).
Align the lower bearing adapter with the
notches in the jacket.
16. Adapter into the lower end of the jacket.
17. Lower bearing, bearing reinforcement and retain
ing clip.
Align the retaining clip with the slots in the
reinforcement, jacket and adapter.
18. Centering spheres and anti-lash spring in the up
Figure 37Installing The Lock Bolt And per shaft.
Rack Assem blies 19. Lower shaft from the same side of the spheres
that the spring ends protrude.
20. Steering shaft assembly into the shift tube from
the upper end. Carefully guide the shaft through
the shift tube and bearing.
26. Tilt lever opening shield.

Remove the tilt release lever.
27. Turn signal housing and retaining screws.
Tighten
Screws to 5 N-m (45 in. lbs.).

28. Tilt release lever and shift lever.
29. Ignition switch. Refer to Ignition Switch Replace
30. Tone alarm switch, if removed. Refer to Tone
Alarm Switch Replacement in this section.
31. Lock cylinder. Refer to Lock Cylinder Replace
32. Turn signal switch. Refer to Turn Signal Switch
Remove the column from the vise and J-23074.
Align the groove across the upper end of the pot
joint with the flat on the steering shaft. Install the
pot joint and intermediate shaft assembly to the
21. Ignition switch actuator rod through the shift lever upper shaft (CK Model).
housing and insert it in the slot in the bearing install the clamp, bolt and nut. The clamp
support. bolt must pass through the shaft undercut.
Extend the rack downward from the bearing
housing. Tighten
22. Bearing housing over the steering shaft.
$
Engage the rack over the end of the actua Nut to 60 N-m (44 ft. lbs ).
tor rod (figure 39). 33. Dash panel bracket and screws to the column.
With the release lever installed, hold the lock
shoes in the disengaged positions. -4- Install or Connect
23. Bearing housing over the steering shaft until the
pivot pin holes line up. Steering column. Refer to CK or G Model
24. Pivot pins. Steering Column Replacement in this section.
Place the bearing in the full up position.
25. Tilt lever spring guide, spring and retainer.
With a suitable screwdriver, push the re
tainer in and turn clockwise to engage it in
the housing.

P(32) MODELS
TURN SIGNAL SWITCH 2. Cancelling cam and spring (standard columns).

3. Instrument panel trim plate (some models).
REPLACEMENT
4. Turn sig n al sw itch w irin g harness at the
half-moon connector.
Remove or Disconnect (Figures 40 and 41) Pry the wiring harness protector out of the
column retaining slots.
Tools Required: Mark the location of each wire in the
J-22727 Electrical Terminal Remover half-moon connector and then remove each
J-22708 Turn Signal Cover Remover individual wire from the connector. Use
1. S teering wheel. Refer to S teering Wheel J-22727 (figure 40). Insert the tool into the
Replacement in this section. lower end of the connector and push in until
Install or Connect
NOTICE: For step 8 see Notice on page

3B4#1.
Wrap the ends of the turn signal switch wires with

tape and then guide them through the opening at
the lower left hand side of the bearing housing
(tilt columns) out the lower end of the shift lever
housing and under the dash seal.
Place the turn signal switch in position.
1. Turn signal switch mounting screws.
Figure 40Removing The Wires
From The Connector Tighten
the tool bottoms on the connector. Remove Screws to 2.8 N m (25 in. lbs.).
the tool and then pull the wire from the On tilt columns.
connector. Align the openings in the turn signal switch
cover with the proper lever positions. Tap
5. Turn signal lever screw and lever.
the cover into place using a plastic hammer.
6. Hazard warning light knob. Press the knob inward Install the tilt release lever.
and unscrew. In sta ll the PRNDL d ia l, pointer, dial
On tilt columns. illu m in a tio n bulb and cap (A utom atic
Transmission Models).
Remove the PRNDL dial screws, dial and 2. Turn signal switch lever and screws.
indicator needle. Remove the cap and dial 3. Hazard warning knob.
illumination bulb from the housing cover Bend the wire retaining tabs, on each wire in the
(Automatic Transmission Model). w iring harness, enough to provide proper
Unscrew and remove the tilt release lever. retention of the wire in the half-moon connector.
4. Each wire in its marked location in the half-moon
Install J-22708 inside the turn signal connector. Push in until the square part of the clip
housing cover and push in until the tangs is flush with the bottom side of the connector.
lock inside the cover flange (figure 41). Turn
5. Turn signal switch wiring harness.
the center screw on the tool clockwise to
6. W iring harness p rotector into the colum n
pull the cover from the housing.
retaining slots.
7. Turn signal switch mounting screws. 7. Cancelling cam and spring (non-tilt column).
8. Turn signal switch assembly from the column. 8. Steering wheel. Refer to S teering Wheel
Guide the wiring harness through the opening in Replacement in this section.
the shift lever housing. 9. Instrument panel trim plate (some models).
TILT STEERING COLUMN

REPLACEMENT

shift tube levers.
3. Nuts and washers that secure the flanged end of
the steering shaft to the flexible coupling.
Figure 41Removing The Turn Signal Replacement in this section.
Housing Cover 5. Turn signal wiring harness.
Adjust the lower bearing preload. Refer to

Steering Column Lower Bearing Adjustment in
this section.
1. Plastic spacers onto the flexible coupling
alignment pins.
2. Lower end of the steering column through the toe
panel opening.
3. Lower steering shaft flange onto the flexible
coupling.
4. Flange to coupling nuts.
$ Tighten

Align the index slot in the steering column jacket
with the protrusion on the column support
bracket.
5. Clamp (210) and screws (211) to the column
support bracket. Tighten bolts finger tight.
Push the column down until the steering shaft
flange bottoms on the plastic spacers on the
flexible coupling.
Tighten
Screws (211) to 25 N m (18 ft. lbs.).

Remove the plastic spacer from the alignment
pins.
Measure
Coupling assembly dimensions (figure 43).

Raise or lower steering column it necessary.
6. Cover and mounting screws to the dash and toe
panel assembly.
7. Turn signal switch wiring harness.
Figure 42Steering Column Installation On an automatic transmission, connect the
P(32) Model single wire to the fuse block and clip it to the
parking brack bracket.
On an automatic transmission, disconnect 8. Steering wheel. Refer to S teering Wheel
the single wire at the fuse block and unclip it Replacement in this section.
from the parking brake bracket. 9. Transmission control linkage.
6. Screws from the cover of the dash and toe panel 10. Battery ground cable.
assembly.
7. Screws (211) and clamp (210) from the column TILT STEERING COLUMN BEARING
support bracket.
HOUSING REPLACEMENT
8. Steering column assembly.
Lower and then w ithdraw the colum n Remove or Disconnect (Figures 44 through 48)
assembly. Rotate the column so the shift
lever cle a rs the dash and toe panel Tools Required:
assembly. J-22635 Lock Shoe and Release Lever Pin
Remover and Installer
+ 4- Install or Connect (Figures 42 and 43) J-22599 Locknut Wrench
J-21854-01 Pivot Pin Remover
J-5822 Steering Gear Shaft Main Bearing
NOTICE: For steps 4 and 8 see Notice on Cup Remover
page 3B4# 1. J-2619-01 Slide Hammer

3. Turn signal switch. Refer to Turn Signal Switch
On column shift models, use a suitable size
punch to drive out the shift lever pivot and remove
the shift lever.
Install the tilt release lever and place the column
in the up position.
4. R e ta in e r (230) and s p rin g (232). Use a
screwdriver to turn the retainer until it aligns with
the grooves in the housing, then remove the
retainer and spring.
5. Upper bearing nut (253). Use J-22599.
6. Seat (254) and race (255).
7. Housing pivot pins (221). Use J-21854-01 (figure
46).
8. Bearing housing (219). Pull up on the tilt release
lever, this will disengage the shoes (224), and
remove the housing.
9. Upper and lower bearings (218, 220).
Remove the bearing races using J-5822 and
J-2619-01 (figure 47).
10. Tilt release lever.
11. Shoe release pivot pin (228). Use J-22635 or a
suitable punch (figure 48).
12. Spring (227) and lever (229).
13. Shoe kit assembly (225).
If the upper steering shaft, lower steering shaft,
or centering spheres are being removed, proceed
as follows.
14. Steering shaft assembly through the upper end of
the column. If it is necessary to disassemble the
shaft, proceed as follows:
D isconnect the shaft at the pot jo in t
coupling clamp and remove the lower
steering shaft.
Turn the upper shaft 90 degrees to the lower
sh a ft and slid e the upper sh aft and
centering sphere from the lower shaft.
Rotate the centering spheres 90 degrees
and remove the centering spheres and
spring from the upper shaft.
If the bearing housing support is being replaced,
proceed as follows:
A. (4.89 0.12 inch) Excluding FS3 15. Screws (231).
B. (4.71 inch) with FS3 16. Support (233).
B-07417 + 4- Install or Connect (Figures 44 and 45)
Figure 43Measuring The Coupling Assembly Tools Required:

J-22599 Locknut Wrench
225 216
235 *
236. * 234 931
247
261
B-07418
Figure 44Tilt Steering Column P(32) Model

215. Housing Cover 229. Lever 243. Guide 257. Spring

216. Turn Signal 230. Retainer 244. Jacket 258. Sphere Assembly
Mounting Screw 231. Screws 245. Bearing 259. Lower Shaft
217. Turn Signal Switch 232. Spring Retainer Clip 260. Shaft Assembly
218. Upper Bearing 233. Support 246. Reinforcement 261. Bolt
219. Bearing Housing 234. Pin 247. Dash Seal 262. Clamp
220. Lower Bearing 235. Detent Plate 248. Seal 263. Nut
221. Pivot Pins 236. Screw 249. Shift Tube 264. Retainer
222. Shoe Spring 237. Retaining Ring 250. Adapter 265. Spring
223. Spacer 238. Washer 251. Bearing 266. CouplingAssembly
224. Shoes 239. Lock Plate 252. Nut 267. Bearings
225. Shoe Kit Assembly 240. Washer 253. Nut 268. Seal
226. Shoe Retaining Pin 241. Gear Shift Lever 254. Seat 269. Intermediate
227. Spring Spring 255. Race Shaft Assembly
228. Pivot Pin 242. Gear Shift Housing 256. Shaft
B-07369
Figure 45Tilt Steering Column P(32) Model
NOTICE: For steps 4 and 11 see Notice on Lubricate and assemble the centering
page 3B4#1. spheres and spring.
Install the spheres into the upper (short)
Lubricate the ID of the bearing housing support shaft and rotate 90 degrees.
and install the support and screws.
Install the lower shaft 90 degrees to the
1. Steering shaft assembly. upper shaft and over the centering spheres.
S lo w ly s tra ig h te n the sh a fts w h ile
compressing the spring.
2. Steering shaft assembly into the housing from the
upper end.
3. Lower steering column shaft to the intermediate
shaft (pot joint) assembly (269).
4. Clamp (262) bolt (261) and nut (263). The bolt
must pass through the shaft undercut.
Tighten

5. Bearing housing (219) assembly.
Press the new upper and lower bearing
Figure 46Removing The Bearing Housing races into the bearing housing.
Pivot Pin
\
AST
1
r
^ B-07421
Figure 48Removing The Release Lever

Pivot Pin
Lubricate and install the bearings into the 7. Spring (232) and retainer (230). Push the retainer
bearing races. into the housing about 5 mm (3/ie inch) and rotate
Place the shoe springs in position in the counterclockwise 1/s turn.
housing. Install each shoe in place and Lubricate the upper bearing race (255), seat (254)
compress the spring in position. Once the and nut (253).
shoes are in place, drive in the shoe 8. Race (255), seat (254) and nut (253). Tighten the
retaining pin (226). nut using J-22599.
Install the shoe release lever (229), spring Remove the tilt release lever.
(227) and pivot pin (228). 9. Turn signal switch. Refer to Turn Signal Switch
Install the tilt release lever. Replacement in this section.
Lubricate the shoes and release lever. 10. Shift lever and pivot pin. (Column Shift Models).
6. Bearing housing assembly to the support (233). 11. Steering Wheel. Refer to Steering Wheel
Hold the tilt release lever in the up Replacement in this section.
position until the shoes have fully engaged 12. Tilt release lever.
the support.
Lubricate and install the bearing housing L* Inspect
pivot pins (221). Press the pins in flush with
the housing. Electrical and mechanical functioning of the
Place the housing in the up position. steering column.
TILT STEERING COLUMN UNIT REPAIR

P(32) MODELS
Remove or Disconnect 6. Neutral-safety or back-up lamp switch screws and

switch. Refer to SEC. 8B (CHASSIS ELECTRI
Steering column assembly. Refer to Tilt Steering CAL) in this manual.
Column Replacement in this section.
7. Shift tube (249) assembly. Use J-23072. Do not
hammer or pull on the shift tube during removal
Disassemble (Figures 44 and 45)
(figure 29).
Tools Required: Insert the hooked end of the tool into the
J-23074 Steering Column Holding Fixture notch in the shift tube just below the shift
J-23072 Shift Tube Remover lever housing key. Pilot the sleeve over the
Install J-23074 onto the steering column and threaded end of the tool and into the upper
place the tool in a bench vise. end of the shift tube. Force the shift tube out
of the housing by turning the nut onto the
Im portant tool. If the shift tube is not completely free
when the nut is bottomed on the threads,
Clamping the steering column directly in a complete the removal by hand.
vise could result in a damaged column.
1. Intermediate shaft assembly (270), with the uni On column shift models, guide the lower
versal joint (pot joint), from the steering column shift lever through the slotted opening in the
shaft. column to prevent damage to the tube or
column.
2. Bearing retainer clip (245) and reinforcement
(246). 8. Lock plate (239) and washer (240). Tip the lock
3. Bearing (251) and adapter (250). plate downward towards the housing, then re
4. Bearing housing assembly and steering shaft as move.
sembly. Refer to Tilt Steering Column Bearing
Housing Replacement in this section. 9. Shift lever housing.
If the shift tube index plate must be removed, re Remove the shift lever spring by winding the
move the two retaining screws and plate. (Col spring up with pliers (Column Shift Models).
umn Shift Models).
5. Shift tube retaining ring (237) and washer (238). 10. Dash panel seal from the column jacket.
* Assemble (Figures 44 and 45) The shift lever housing key must bottom in
the shift tube slot.
Tools Required: 5. Neutral-safety or back-up lamp switch and
J-23073-01 Shift Tube Installer screws. Refer to SEC. 8B (CHASSIS ELECTRI
Apply a thin coat of lithium grease to all friction CAL) in this manual.
surfaces. 6. Washer (238) and retaining ring (237). Pull up on
1. Dash panes seal. the shift lever housing when installing the washer
Press a new shift lever spring into the shift lever and retaining ring.
housing (Column Shift Models). Seat the retaining ring in both slots in the
2. Shift lever housing. Slide the housing over the shift tube.
upper end of the column. 7. Steering shaft assembly and bearing housing as
3. Washer (240) and lock plate (239). sembly. Refer to Tilt Steering Column Bearing
Apply lithium grease to the lock plate and Housing Replacement in this section.
the upper end of the shift tube.
4. Shift tube (249) and seal (248) into the lower end -*- Install or Connect
of the column. Do not hammer or force the shift
tube. Steering column assembly. Refer to Tilt Steering
Align the keyway in the shift tube with the Column Replacement" in this section.
key in the shift lever housing and install the
shift tube using J-23073-01 (figure 38).

P(42) MODELS
STANDARD STEERING COLUMN Install or Connect (Figure 49)
REPLACEMENT
NOTICE: For steps 2, 3, 4 and 9 see Notice
Remove or Disconnect (Figure 40) on page 3B4#7.
1. Battery ground cable. 1. Adjust the lower bearing preload. Refer to

2. Transmission control linkage from the column Steering Column Lower Bearing Adjustment in
shift tube levers (Column Shift Models). this section.
3. Upper universal jo in t pinch bolt from the 2. Lower end of the steering column through the toe
intermediate shaft. Mark the relationship of the panel opening.
universal yoke to the steering shaft. Guide the steering shaft into the universal yoke,
4. Nut (282), bolt (280) and clamp (281). Slide the lining up the marks made at removal.
clamp down the column. Upper universal pinch bolt. The pinch bolt must
5. Screws (277) from the cover (278) and seal (279). pass through the shaft undercut.
Slide the cover and seal up the column.
6. S teering wheel. Refer to Steering Wheel Tighten
Pinch bolt to Specifications at the end of
7. Turn signal wiring harness.
this section.
On an automatic transmission, disconnect
Align the seal (279) and cover (278) with the
the conductor tube at the instrument panel.
floor and dash panel assembly.
8. Bolts (275) and clamp (276) from the column Align the column support bracket protrusion
support bracket. with the index slot in the steering column.
9. Bolt, nut and outer brace (283) from the column 3. Clamp (281), bolt (280) and nut (282). Position the
support bracket (P200 + 300 (42) models). clamp as shown in figure 49.
10. Steering column assembly.
Lower and then w ithdraw the column Tighten
assembly. Rotate the column so the shift
lever cle a rs the dash and toe panel Nut to 15 N m (11 ft. lbs.).
assembly. 4. Clamp (276) and bolt (275).
275. Bolts
276. Clamp
277. Screws
278. Cover
279. Seal
280. Bolt
281. Clamp
282. Nut
283. Outer Brace B-07422
Figure 49Steering Column Installation P(42) Model
Tighten 3. Upper bearing (289).

- Install or Connect (Figure 50).
5. Seal (279), cover (278) and screws (277) to the
dash panel assembly.
6. Outer brace (283), bolt and nut to the column
support bracket (P200 + 300 (42) models). NOTICE: For step 3 see Notice on page
3B4#1.
Tighten
1. New upper bearing (289).
Bolt to 25 N m (18 ft. lbs.). 2. Cancelling cam (286).
7. Transmission control linkage to the shift tube
levers (Column Shift Models). 3. S teering wheel. Refer to Steering Wheel
8. Turn signal wiring harness. Replacement in this section.
On a standard column with autom atic
transmission connect the conductor tube at
the instrument panel.
LOWER BEARING REPLACEMENT
Replacement.
1. In te rm e d ia te s te e rin g s h a ft. R efer to

UPPER BEARING REPLACEMENT Interm ediate Shaft R eplacem ent in this
section.
2. Nut (319), washer (318), bolt (317) and clamp
1. Steering wheel. Refer to S teering Wheel (316).
2. Cancelling cam (286). 3. Bearing assembly (315, 314).
316
285
278. Seal
279. Cover
285. Horn Blow Wire
286. Cancelling Cam
287. Turn Signal Switch Screws
288. Hazard Control Switch
289. Upper Bearing
290. Control Support Switch 296
291. Screw
292. Control Lever
293. Housing 304. Shift Tube
294. Washer 305. Jacket
295. Washer 306. Bolts
296. Shift Lever Housing 307. Washer
297. Pivot Pin 308. Washer 315. Spring
298. Sleeve 309. Nut 316. Clamp
299. Shift Lever 310. Clamp 317. Bolt
300. Knob 311. Bolt 318. Washer
301. Shaft 312. Spacer 319. Nut
302. Bushing 313. Lever 320. Seal
303. Seat 314. Adjusting Pin And Bearing Assembly 321. Cover
B-07423
Figure 50Standard Steering Column P(42) Model

|-<-| Install or Connect (Figures 50 and 51)

page 3B4#1.
1. New adjusting ring and bearing assembly (314, ------

315). A
2. Clamp (316), bolt (317), washer (318) and nut
(319). Maintain the clearance dimension shown in
figure 51. A. 32 0.5 mm (1.26 0.02 inch)
B-07424
$ Tighten
Figure 51Lower Bearing Adjustm ent
3. Intermediate shaft. Refer to Intermediate Shaft
STEERING COLUMN LOWER

BEARING ADJUSTMENT
1. Loosen clamp bolt (317).
2. Apply 222 N (50 lbs.) force to the steering wheel
end of the steering shaft.
3. Adjust the clamp to obtain a clearance of 32
0.5 mm (1.26 0.02 inch) (figure 51).
SHIFT TUBE ADJUSTMENT

3-SPEED MANUAL TRANSMISSION
1. Loosen the adjusting ring bolts (306).
2. Loosen the clamp bolt (317).
3. Rotate the adjusting ring to give a 0.13 mm (0.005 Figure 52Shift Tube A djustm ent
3-Speed Manual Transmission
inch) end play between the adjusting ring and
first and reverse lever (figure 52).
Tighten 304
Adjusting ring bolt (306) to 8 N m (70 in.

lbs.).
Clamp bolt (317) to 14 N m (10 ft. lbs.).
AUTOMATIC TRANSMISSION
1. Place the shift tube lever in Neutral or Drive.
2. Loosen the adjusting ring bolt (306).
3. Rotate the shift tube adjusting ring to obtain a 8.4
to 9.1 mm (0.33 to 0.36 inch) clearance between
the shift tube lever and adjusting ring (figure 53).
A. 8.4 to 9.1 mm (0.33 to 0.36 inch)
Q Tighten B. Adjusting Ring
C. Shift Lever B-07426
Adjusting ring bolt to 8 N m (70 in. lbs.).
Figure 53Shift Tube A d ju s tm e n t-

Autom atic Transmission
STANDARD STEERING COLUMN UNIT REPAIR

P(42) MODELS
Remove or Disconnect Assemble (Figure 50)
Steering column assembly. Refer to Standard Apply a thin coat of lithium grease to all friction
Steering Column Replacement (P42 Model) in surfaces.
this section. 1. Clamp, seal (278) and cover (279) over the end of
the jacket (305).
Disassemble (Figure 50) Apply lithium grease to all bearing surfaces on
Slide the steering shaft assembly from the lower the shift tube.
end of the steering column. 2. Seal (320) onto the shift tube and place the shift
1. Lower bearing bolt (317), washer (318), nut (319), tube in the jacket.
clamp (316) and spring (315). Temporarily install the spacer, first-reverse shift
2. Back-up lamp switch. lever and lower adjusting ring. Place a block of
3. Pivot pin (297) and shift lever (299). wood on top of the adjusting ring and tap until the
4. Cancelling cam (286). shift tube bottoms. Remove the adjusting ring,
shift lever and spacer (3-Speed Columns).
5. Conrol lever screw (291) and lever (292).
Align the three holes in the selector plate with the
6. Column wiring harness cover.
three holes in the jacket. Position the clamping
7. Turn signal switch screws (287). ring and install the three screws. The shift tube
8. Housing (293). Rotate the housing counterclock spring retainer must bottom against the jacket
wise. stops (Automatic Columns).
The housing and switch cannot be comple Lubricate and install the spacer and first-reverse
tely removed from the column until the shift shift lever. The tang of the lever is toward the top
lever housing is removed. of the column (3-Speed Column).
9. Washer assembly (294, 295) and shift lever hous 3. Bearing in the adjusting ring (314).
ing (296) (or extension housing) from the column. 4. Adjusting ring and bearing (314) assembly, clamp
Separate the turn signal switch, switch control (310), washers (308, 307) and bolts (306).
support assembly, turn signal housing and shift 5. Seat (303) and bushing (302) to the upper end of
lever housing (or housing extension) assemblies. the housing.
10. Upper bearing (289). Press the bearing out of the Thread the turn signal switch wiring harness
switch contact support (290). through the switch and lever (or extension) hous
11. Bushing (302) and seat (303). ing.
12. Bolts (306), washers (307, 308) and adjusting ring Lubricate the inner diameter of the shift housing.
clamp (310). 6. Shift lever (or extension) housing onto the upper
13. Adjusting ring and bearing (314) assembly. end of the column.
Press the bearing out of the adjusing ring. 7. Washer assembly (295, 294).
14. First-reverse shift lever and spacer (3-Speed Col 8. Upper bearing into the switch contact support.
umn). 9. Turn signal switch housing (293), contact support,
15. Selector plate clamping screws (Automatic Col bearing, switch and switch screws. Tighten
umns). screws to 2.8 N m (25 in. lbs.).
Place the column upright on the floor, supporting 10. Wiring harness cover and back-up lamp switch.
it with two pieces of wood. Place a block of wood 11. Control lever (292) and the gear shift lever (299).
on the upper end of the shift tube. Press down on
the shift lever with foot while tapping on the wood Adjust
block to withdraw the tube from the column Shift tube. Refer to Shift Tube Adjustment
jacket. in this section.
12. Spring (315), clamp (316), bolt (317), washer (318)
NOTICE: In some tolerance stack-up cases it and nut (319). Tighten the bolt finger tight.
may be necessary to use a press. Be careful Slide the steering shaft assembly up through the
not to damage the tube or jacket. column assembly.
16. Seal (320) and cover (321). Install or Connect

17. Cover (279), seal (278) and clamp from steering Steering column assembly. Refer to Standard
column jacket (305). Steering Column Replacement in this section.
INTERMEDIATE SHAFT UNIT REPAIR P(42) MODELS
Figure 54Intermediate Shaft P(42) Model
Remove or Disconnect Assemble (Figure 54)
Intermediate shaft. Refer to Intermediate Shaft If the yoke trunnions were removed, assemble as
Replacement in this section. follows:
1. Trunnion (326) into the yokes (331, 330).
Disassembly (Figure 54) 2. Trunnion (326) into the yokes (327, 321).
3. Bearing cups (325) into the yokes.
If the upper and lower half of the intermediate Reassemble the intermediate shaft assembly as
shaft is to be replaced, preceed as follows: follows:
Place the intermediate shaft (320) on a bench 4. Dust cap (329) and dust seal (328) over the shaft
and straighten the tangs on the dust cap (329). of the lower yoke (330) assembly.
Separate the upper and lower portions of the Align the arrow on the lower yoke assembly shaft
shaft assembly. with the arrow on the upper yoke assembly tube
1. Dust cap (329) and dust seal (328). and push the two assemblies together.
If the trunnion assembles are to be replaced, pro Push the dust seal (328) and dust cap (329) into
ceed as follows: position on the lower end of the upper yoke as
2. Bearing cups (325). sembly and bend the tangs of the dust cap down
Support the yoke on a bench vise and drive against the yoke tube.
out one bearing cup by tapping on the oppo
site bearing cup. Use a soft drift and ham Install or Connect
mer.

Support the other side of the yoke and drive Intermediate shaft. Refer to Intermediate Shaft
out the re m a in in g b e a rin g cups, as Replacement in this section.
described in the previous step.
3. Trunnion (326) from the yokes (324, 327).
4. Trunnion (326) from the yokes, (331, 330).
SPECIFICATIONS
Nm Ft. Lbs. In. Lbs.
Turn Signal Switch Attaching Screws................................................ 4.0 35
Ignition Switch Attaching Screws...................................................... 4.0 35
Dimmer Switch Attaching Screws...................................................... 4.0 35
Steering Wheel N u t.............................................................................. 40 30
Flexible Coupling Clamp B o lt............................................................. 42 31
Flexible Coupling To Flange Bolt N uts.............................................. 27 20
Steering Gear To Frame Bolts (C, K And G Models)....................... 102 75
Steering Gear To Frame Bolts P300 (32, 42) FS 3........................... 108 80
Steering Gear To Frame Bolts P200 & 300(42) Excluding FS3 . . . 95 70
Upper Intermediate Shaft Pinch Bolt (G M o d e l)............................. 47 35
Lower Intermediate Shaft Pinch Bolt (G Model)............................... 62 46
Intermediate Shaft Pinch Bolt P300 (42) F S 3 ................................. 108 80
Intermediate Shaft Pinch Bolt P200 & 300(42) Excluding FS3. . . . 102 75
Steering Column Support Bracket Screws (C, K And G M odels). . 30 22
Steering Column Support Bracket Clamp Nuts (P M o d e ls ).......... 25 18
Steering Column Shaft To Intermediate Shaft (Pot Joint) Assembly 60 44
SPECIAL TOOLS
J-23980-B Steering Column Electrical Component Analyzer
J-1859-03 Steering Wheel Puller
J-23653-A Lock Plate Compressor
J-21854-01 Pivot Pin Remover
J-23072 Shift Tube Remover
J-22599 Locknut Wrench
J-5822 Steering Gear Shaft Main Bearing Cup Remover
J-2619-01 Slide Hammer
J-22635 Lock Shoe & Release Lever Pin Remover And Installer
J-22727 Electrical Terminal Remover
J-23072 Shift Tube Remover
J-23073-01 Shift Tube Installer
J-23074 Steering Column Holding Fixture
J-22708 Turn Signal Cover Remover
3C-1
SECTION 3C
FRONT SUSPENSION
the manual as indicated at appropriate locations by the terminology NOTICE: Refer to Notice on page 3C-1 of
this section.
NOTICE: All front suspension fasteners are important attaching parts in that they could affect the perform
CONTENTS
SUBJECT PAGE
General D e s c rip tio n ................................................................................................................................................... 3C- 2
Diagnosis of Front S u s p e n s io n ..............................................................................................................................3C- 2
Diagnosis of Wheel B e a rin g s ..................................................................................................................................3C- 3
On-Vehicle Service: Two Wheel Drive Independent Front S usp e nsion ........................................................ 3C- 8
Shock A b s o rb e r..................................................................................................................................................... 3C- 8
Stabilizer B ar............................................................................................................................................................3C- 8
Wheel Hub/Rotor Assem bly..................................................................................................................................3C-12
Wheel Bearing A d ju s tm e n t..................................................................................................................................3C-15
Wheel Hub B o lt........................................................................................................................................................3C-16
Steering K n u c k le ................................................................................................................................................... 3C-16
Coil S p r in g .............................................................................................................................................................. 3C-18
Lower Ball J o in t ..................................................................................................................................................... 3C-19
Upper Ball J o in t ..................................................................................................................................................... 3C-20
Lower Control Arm Pivot Shaft and B ushings................................................................................................. 3C-21
Upper Control Arm Pivot Shaft and B ushings................................................................................................. 3C-25
Lower Control A rm ................................................................................................................................................. 3C-27
Upper Control A rm ................................................................................................................................................. 3C-28
Suspension U n it..................................................................................................................................................... 3C-29
On-Vehicle Service: Two Wheel Drive RPO FS3 (I-Beam) Front S u s p e n s io n ..............................................3C-31
Shock A b s o rb e r..................................................................................................................................................... 3C-31
Stabilizer B ar............................................................................................................................................................3C-33
Wheel Hub/Rotor A ssem bly..................................................................................................................................3C-35
Wheel Bearing A d ju s tm e n t..................................................................................................................................3C-36
Wheel Hub B o lt........................................................................................................................................................3C-36
Steering Arm, Knuckle and S p in d le ...................................................................................................................3C-37
Front A x le ................................................................................................................................................................ 3C-37
Leaf S p rin g .............................................................................................................................................................. 3C-39
On-Vehicle Service: Four Wheel Drive Front S uspension................................................ ............................ 3C-40
Shock A b s o rb e r..................................................................................................................................................... 3C-40
Stabilizer B ar............................................................................................................................................................3C-41
Wheel Hub/Rotor A ssem bly..................................................................................................................................3C-41
Bearing A d ju s tm e n t...............................................................................................................................................3C-47
Wheel Hub B o lt....................................................................................................................................................... 3C-47
S pindle.......................................................................................................................................................................3C-48
Steering Knuckle and A rm .................................................................................................................................... 3C-50
Ball J o in ts ................................................................................................................................................................ 3C-53
Leaf Spring And B ushings....................................................................................................................................3C-55
S pe cifica tio ns.............................................................................................................................................................. 3C-57
Special T o o ls .............................................................................................................................................................. 3C-59
3C-2 FRONT SUSPENSION
GENERAL DESCRIPTION
An independent suspension is standard on the C-G- road bumps. A special heavy duty front suspension is
P series vehicles. This suspension features unequal available on P series vehicles. This suspension (RPO
length control arms (the lower control arm is the load FS3), centered around a solid I-beam axle, includes
carrying member), coil springs and shock absorbers to leaf springs, shock absorbers, and a stabilizer bar.
reduce vibration and shock load, plus a stabilizer bar The K series (four wheel drive) suspension includes
to control sway or roll. Air cylinders inside coil springs leaf springs, shock absorbers, and a stabilizer bar.
are available to minimize crash through on large
DIAGNOSIS OF FRONT SUSPENSION

Hard Steering 1. Ball joints and steering linkage need 1. Lubricate the ball joints and linkage.
lubrication.
2. Low or uneven front tire pressure. 2. Inflate tires to the recommended
pressure.
3. In c o rre c t fro n t w heel a lig n m e n t 3. Check and align the front suspen
(manual steering). sion.
Poor Directional 1. Ball joints and steering linkage need 1. Lubricate the ball joints and linkage.
S tability lubrication.
2. Low or uneven front or rear tire pres 2. Inflate tires to the recommended
sure. pressure.
3. Loose wheel bearings. 3. Adjust the wheel bearings.
4. In c o rre c t fro n t w heel a lig n m e n t 4. Check and align the front suspen
(caster). sion.
5. Broken springs. 5. Replace the springs.
6. Malfunctioning shock absorber. 6. Check and replace the shock absor
ber.
7. Broken stabilizer bar or a missing link. 7. Replace the stabilizer bar or link.
Front Wheel Shimmy 1. Tire and wheel are out of balance or 1. Balance the tires, check run-out.
(Smooth Road out of round.
Shake) 2. Worn or loose wheel bearings. 2. Adjust the wheel bearings.
3. Worn ball joints. 3. Replace the ball joints.
4. Malfunctioning shock absorber. 4. Check and replace the shock absor
ber.
Vehicle Pulls To One 1. Low or uneven tire pressure. 1. Inflate the tires to the recommended
Side (No Braking pressure.
Action) 2. Front or rear brakes dragging. 2. Adjust the brakes.
3. Broken or sagging front spring. 3. Replace the spring.
4. Incorrect front wheel alignment (cam 4. Check and align the front suspen
ber). sion.
FRONT SUSPENSION 3C-3
DIAGNOSIS OF FRONT SUSPENSION (CONT.)

Noise In The Front 1. Ball joints and steering linkage need 1. Lubricate at the recommended inter
End lubrication. vals.
2. Loose shock absorber or worn bush 2. Tighten the bolts or replace the
ings. shock absorber.
3. Worn control arm bushings. 3. Replace the bushings.
4. Worn or loose wheel bearings. 4. Adjust or replace the wheel bearings.
5. Loose stabilizer bar. 5. Tighten all the stabilizer bar attach
ments.
6. Loose wheel nuts. 6. Tighten the wheel nuts.
7. Spring is improperly positioned. 7. Reposition the spring.
8. Loose suspension bolts. 8. Tighten to specifications or replace.
Wheel Tramp 1. Tire and the wheel are out of balance. 1. Balance the wheels.
2. Tire and the wheel are out of round. 2. Replace the tire.
3. Blister or bump on the tire. 3. Replace the tire.
4. Improper shock absorber action. 4. Replace the shock absorber.
Excessive or Uneven 1. Underinflated or overinflated tires. 1. Inflate the tire to the recommended
Tire Wear pressure.
2. Improper toe-in. 2. Adjust toe-in setting.
3. Wheels are out of balance. 3. Balance the wheels.
4. Hard driving. 4. Follow proper driving techniques.
5. Overloading the vehicle. 5. Do not exceed the maximum recom
mended payload rating.
Scuffed Tires 1. Toe-in is incorrect. 1. Adjust toe-in setting.

2. Excessive speed on turns. 2. Follow proper driving techniques.
3. Tires are improperly inflated. 3. Inflate the tires to the recommended
pressure.
4. Suspension arm is bent or twisted. 4. Replace the suspension arm.
Cupped Tires 1. Front shock absorbers are defective. 1. Replace the shock absorbers.
2. Worn ball joints. 2. Replace the ball joints.
3. Wheel bearings are incorrectly ad 3. Adjust or replace the wheel bearings
justed or worn. (also replace the races).
4. Wheel and tire is out of balance. 4. Balance the wheel and tire.
5. Excessive tire or wheel runout. 5. Check and compensate for runout.
DIAGNOSIS OF WHEEL BEARINGS

When diagnosing bearing condition, keep in mind the failure, and follow the recommended repair proce-
the general condition of all parts during disassembly dures.
and inspection. Use Figures 1, 2, 3 and 4 to classify
ABRASIVE ROLLER WEAR ABRASIVE STEP WEAR

Pattern on races and rollers caused by fine Pattern on roller ends caused by fine abra
abrasives. sives.
Clean all parts and housings, check seals and Clean all parts and housings, check seals and
bearings and replace if leaking, rough or bearings and replace if leaking, rough or
noisy. noisy.
GALLING ETCHING
Metal smears on roller ends due to overheat, Bearing surfaces appear gray or grayish black
lubricant failure or overload. in color with related etching away of material
Replace bearing, check seals and check for usually at roller spacing.
proper lubrication. Replace bearings, check seals and check for
proper lubrication.
B-09194
Figure 1Diagnosis Of Front Wheel Bearings

BENT CAGE BENT CAGE

Cage damaged due to improper handling or Cage damaged due to improper handling or
tool usage. tool usage.
Replace bearing. Replace bearing.
CAGE WEAR INDENTATIONS

Wear around outside diameter of cage and Surface d e p re ssio ns on race and rollers
roller pockets caused by abrasive material caused by hard particles of foreign material,
and inefficient lubrication. Clean all parts and housings. Check seals and
Clean related parts and housings. replace bearings if rough or noisy.
Check seals and replace bearings.
B-09195

FRETTAGE SMEARS
Corrosion set up by small relative movement Smearing of metal due to slippage. Slippage
of parts with no lubrication. can be caused by poor fits, lu b rica tio n ,
Replace bearing. Clean related parts. Check overheating, overloads or handling damage.
seals and check for proper lubrication. Replace bearings, clean related parts and
check for proper fit and lubrication.
STAIN DISCOLORATION HEAT DISCOLORATION

Discoloration can range from light brown to Heat discoloration can range from faint yel
black caused by incorrect lubricant or m ois low to dark blue resulting from overload or in -
ture. correct lubricant.
Re-use bearings if stains can be removed by Excessive heat can cause softening of races
light polishing or if no evidence of overheat or rollers. To check for loss of temper on
ing is observed. races or rollers a simple file test may be
Check seals and related parts for damage. made. A file drawn over a tempered part will
grab and cut metal, whereas, a file drawn over
a hard part will glide readily with no metal
cutting.
Replace bearings if over heating damage is
indicated. Check seals and other parts.
F-00531

MISALIGNMENT CRACKED INNER RACE

Outer race m isalignm ent due to foreign ob Race cracked due to improper fit, cocking, or
ject. poor bearing seats.
Clean related parts and replace bearing. Make Replace bearing and correct bearing seats.
sure races are properly seated.
FATIGUE SPALLING BRINELLING

Flaking of surface metal resulting from fa Surface indentations in raceway caused by
tigue. rollers either under impact loading or vibra
Replace bearing, clean all related parts. tion while the bearing is not rotating.
Replace bearing if rough or noisy.
B-09860

ON-VEHICLE SERVICE:
TWO WHEEL DRIVE INDEPENDENT FRONT SUSPENSION
SHOCK ABSORBER Do not clamp the vise jaws on the shocks
reservoir tube.
-- Remove or Disconnect (Figures 5, 6, 7, 8, and 2. Pump the shock absorber at various rates of
speed and observe the rebound force.
9)
Raise the vehicle on a hoist. Rebound force is normally stronger than the
1. Shock absorber (20) from the lower control arm. compression force (approximately two to
Nuts (23), washers (22) and bolts (21) one).
(Figure 9). Rebound force should be smooth and
2. Shock absorber (20) from the frame. constant for each stroke rate.
Nuts (16), washers (17), and bolts (21) 3. Compare with a good shock absorber.
(Figure 9). 4. If one of the following are observed, replace the
shock absorber.
BENCH TEST: SPIRAL GROOVE SHOCK A skip or lag at reversal near mid-stroke.
ABSORBERS A seize (except at the extreme ends of
1. Purge the air from the pressure chamber. travel).
Extend the shock verticallytop end up. A noise (grunt or squeal) after completing
Turn the shock over and co lla p se it one full stroke in both directions.
verticallytop end down. A clicking noise at fast reversal.
Repeat the above step five times.
2. Place the shock absorber in a vise with the jaws Install or Connect (Figures 5 through 9)
clamped onto the shocks bottom mount.
Shock absorber should be positioned NOTICE: Refer to Notice on page 3C#1 of
vertically in the visetop end up. this section.
Do not clamp the vise jaws on the shocks
reservoir tube. 1. Shock absorber (20) onto the vehicle.
3. Pump the shock absorber at various rates of Bolts (21), washers (17, 22), and nuts (16, 23)
speed and observe the rebound force. (figure 9).
Rebound force is normally stronger than the
compression force (approximately two to Tighten
one).
Rebound force should be smooth and C and P series upper mount nuts (16) to 190
constant for each stroke rate. N m (140 ft. lbs.).
4. Compare with a good shock absorber. C and P series lower mount bolts (21) to 80
5. If one of the following are observed, replace the N m (59 ft. lbs.).
shock absorber. G series upper and lower mount bolts (21) to
A skip or lag at reversal near mid-stroke. 103 N m (80 ft. lbs.).
A seize (except at the extreme ends of 2. Lower the vehicle.
travel).
A noise (grunt or squeal) after completing
one full stroke in both directions. STABILIZER BAR
A clicking noise at fast reversal.
Remove or Disconnect (Figures 5-8 and 10)
BENCH TEST: NON-SPIRAL GROOVE
RESERVOIR SHOCK ABSORBERS Raise the vehicle and support with suitable safety
P urging air from non-spiral groove shock stands. Remove the wheel and tire assembly.
absorbers is not necessary. The shock absorbers 1. Stabilizer bar (59) from the frame.
have a gas filled cell in their reservoirs (as Bolts (54), nuts (58), washers (55, 57) and
opposed to the air filled cell in the spiral groove clamps (52).
shock absorber reservoirs). 2. Stabilizer bar (59) from the lower control arm (36).
1. Place the shock absorber in a vise with the jaws Bolts (43), nuts (38), washers (39, 41) and
clamped on the shock absorbers top mount. clamps (42).
Shock absorber should be held vertically in Stabilizer bar (59) drops downremove the
the vise with its bottom end up. bushings (40, 53).
11 12
v / 14 15 16 17
/H
67 66 64 63
62
B-07466
Figure 5C Series Front Suspension

Figure 6G Series Front Suspension

Figure 7P Series Front Suspension

1. Bolt 36. Lower Control Arm Clamps (42), bolts (43), washers (39, 41) and
2. Washer 37. Lower Ball Joint nuts (38).
3. Nut 38. Nut
4. Bolt 39. Washer
5. Washer 40. Bushing
6. Bolt 41. Washer C and P series nuts (38, 58) to 33 N m (24 ft.
7. Washer 42. Bracket lbs.).
8. Reinforcement 43. Bolt G series bolt (54) to 33 N m (24 ft. lbs.).
9. Bracket 44. U-Bolt G series nut (38) to 29 N m (21 ft. lbs.).
10. Nut 45. Rivet 3. Wheel and tire assembly. Lower the vehicle.
11. Rivet 46. Bushing
12. Fitting 47. Bracket
13. Upper Ball Joint 48. Washer WHEEL HUB/ROTOR ASSEMBLY
14. Nut 49. Nut
15. Cotter Pin 50. Pivot Shaft + + Remove or Disconnect (Figures 5 through 8,
16. Nut 51. Rivet and 11)
17. Washer 52. Bracket
18. Shim Pack 53. Bushing Raise the vehicle and support it with suitable
19. Spacer 54. Bolt safety stands. Remove the wheel and tire
20. Shock Absorber 55. Washer assembly.
21. Bolt 56. Bracket 1. Caliper. Refer to BRAKES (SEC. 5).
23. Nut 58. Nut NOTICE: Support the caliper with a piece of
24. Nut 59. Stabilizer Bar wire to prevent damage to the brake line.
25. Retainer 60. Bolt
26. Bushing 61. Washer 2. Wheel Hub/Rotor (81)
27. Nut 62. Washer Dust cap (79).
28. Upper Control Arm 63. Nut Cotter pin (80), nut (78), and washer (77).
29. Pivot Shaft 64. Brace Pull the hub/rotor free, making sure the
30. Bumper 65. Bolt outer wheel bearing (76) comes free of the
31. Steering Knuckle 66. Washer hub/rotor.
32. Coil Spring 67. Nut Do not damage the steering knuckle (70)
33. Bumper 68. Seal spindle threads.
34. Cotter Pin 69. Air Cylinder 3. Inner wheel bearing (73).
35. Nut B-07469 Pry out the seal (72).
4. Races (75, 82).
Drive out each race using a brass drift
Figure 8C-G-P Series Front Suspension inserted behind the race in notches in the
hub.
I* Inspect
Clean
Rubber bushings (40, 53) for excessive
wear, aging, or other damage. Replace as 1. Grease from the hub/rotor (81) and steering
necessary. knuckle spindle.
Remove grease from inside the hub.
Install or Connect (Figures 5, 6, 7, 8 and 10) 2. Grease from the wheel bearings (73, 76) and
races (72 , 75).
1. Bushings (40, 53) to the stabilizer bar (59). Use clean solvent and a small brush (no
Slit on the insulator faces forward. loose bristles).
Do not spin the wheel bearings with
Use rubber lubricant to ease the installation.
compressed air to dry themthe wheel
bearings may be damaged.
NOTICE: Refer to Notice on page 3C#1 of
this section.
1? Inspect
2. Stabilizer bar (59) to the vehicle. 1. Wheel bearings (73, 76) and their races (72 , 75)
Position the stabilizer bar and attach the for damage or wear.
clamps (52), bolts (54), washers (55, 57) and Refer to Diagnosis of Wheel Bearings, in
nuts (58). this section.
B. G Series
16. Nut 21. Bolt
20. Shock Absorber 23. Nut B-07473
Figure 9Shock Absorber Attachm ents
If either a bearing or its race is damaged or Install or Connect (Figures 5 through 8,11 and
worn, replace both. 12)
2. Hub/rotor for damage. Tools Required:

J-8092 Driver Handle
Check for out-of-round or scored conditions. J-8457 Wheel Bearing Race Installer
J-8849 Wheel Bearing Race Installer
Check for pitting or cracks.
J-9746-02 Hub/Rotor Support
Repair or replace as necessary.
38. Nut
39. Washer
40. Bushing
41. Washer
42. Clamp
43. Bolt
52. Clamp
53. Bushing
54. Bolt
55. Washer
57. Washer
58. Nut
59. Stabilizer Bar
B-07475
Figure 10Stabilizer Bar Attachments

70. Steering Knuckle 76. Outer Wheel Bearing 82.

71. Shield 77. Washer 83.
72. Seal 78. Nut 84.
73. Inner Wheel Bearing 79. Dust Cap 85.
74. Wheel Hub Bolt 80. Cotter Pin
75. Outer Race 81. Wheel Hub/Rotor B-07470
Figure 11Steering Knuckle And Hub Assembly
NOTICE: Start the races squarely inside the

hub/rotor to avoid distortion and possible
cracking.
1. Races (72 , 75) into the hub/rotor (81).

Place the hub/rotor on J-9746-02 and rest
this assembly on press bars.
Use J-8457 to drive the outer bearing outer
race (75) into position (figure 12).
Turn over the hub/rotor, remove J-9746-02,
and drive in the inner bearing outer race
(82) with J-8449.
Im portant
Use an approved high-temperature front wheel

bearing grease to lubricate the bearings. Refer to
MAINTENANCE AND LUBRICATION (SEC. OB).
Do not mix different greases as mixing may
change the greases properties resulting in poor
performance.
A. Outer Wheel Bearing Race
2. Apply a thin film of grease to the steering knuckle
B-06955 spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, shoulder, and seal seat.
Figure 12Installing The Outer Wheel 3. Put a small quantity of grease inboard of each
Bearing Race wheel bearing dust cap (79).
NOTICE: Failure to completely pack the wheel WHEEL BEARING ADJUSTMENT

bearing (cones, rollers, and cage) with grease
will result in premature wheel bearing damage Important
and/or wear.
The proper functioning of the front suspension
4. F ill each w heel b e a rin g (cone and ro lle r cannot be maintained unless the front wheel
assembly) full of grease. bearings are correctly adjusted. The bearings
Use a cone-type grease machine that forces must be a slip fit on the spindle and the inside
grease into the bearing. diameter of the wheel bearing must be lubricated
to ensure the bearings will creep. The spindle nut
If a cone-type grease m achine is not
(78) must have a free-running fit on the spindle
available, pack the wheel bearing by hand.
threads.
When packing the wheel bearing by hand,
work the grease into the bearings between
the rollers, cones, and the cage. NOTICE: Never preload the front wheel
bearings. Damage can result by the steady
5. Inner wheel bearing (73) into the hub/rotor (81). thrust on the roller ends which comes from
Put an a d d itio n a l q u a n tity of grease preloading.
outboard of this bearing.
6. New seal (72).
f t Adjust
Use a flat plate or block to install the seal to
insure it is flush with the hub/rotor flange. Raise the vehicle and support it with suitable
Lubricate the seal lip with a thin layer of safety stands under the lower control arms.
grease. 1. Remove the dust cap (79) from the hub/rotor (81).
7. Hub/rotor (81).
2. Remove the cotter pin (80).
Do not damage the steering knuckle spindle
threads.
Tighten
8. Outer wheel bearing (76).
Slide it over the spindle until the wheel Nut (78) to 16 N m (12 ft. lbs.) while rotating the
bearing (76) fully seats against the hub/rotor wheel and tire assembly (this will seat the
outer race (75). bearings).
3. Back off the nut (78) to the just loose position.

this section. 4. Hand tighten the nut (78).
9. Washer (77), nut (78), and cotter pin (80). 5. Back off the nut (78) until the hole in the spindle
lines up with a slot on the nut.
Do not place the cotter pin through the hole
in the spindle until the wheel bearings are Do not back off more than V2 of a flat.
adjusted.
6. New cotter pin (80).
$ Tighten Make sure the bent ends do not interfere

with the dust cap (79).
Nut (78) to 16 N m (12 ft. lbs.) while turning
the hub/rotor assembly in either direction.
Measure
10. Put an additional quantity of grease outboard of
the wheel bearing (76). Endplay in the hub/rotor assembly (81).
11. Adjust the wheel bearings. It should measure between 0.03 mm (0.0012
Refer to Wheel Bearing Adjustment, in inches) and 0.13 mm (0.005 inches) when properly
this section. adjusted.
12. Dust cap (79) on the hub/rotor (81). 7. Install the dust cap (79) on the hub/rotor (81).
13. Caliper. Refer to BRAKES (SEC. 5).
8. Install the wheel and tire assembly if removed
14. Tire and wheel assembly and lower the vehicle. and lower the vehicle.
WHEEL HUB BOLT

Remove or Disconnect (Figures 5 through 8,
and 13)
Tools Required:
1. Hub/rotor from the vehicle. J-9746
Refer to Wheel Hub, Bearing and Race in
this section.
NOTICE: Place J-9746-02 between the press

bars and the hub/rotor to protect the rotor
surfaces.
2. Wheel hub bolts (74) with a press.

Support the hub/rotor (81) using J-9746-02
and press bars (figure 13).
Do not damage the wheel mounting surface
on the hub/rotor flange.
r+| Install or connect (Figures 5 through 8, and

14)
A. Press Bars
NOTICE: Refer to the Notice on page 3C#1
of this section. F-00036
1. Wheel hub bolts (74) into the hub/rotor (81). Figure 13Pressing The Hub Bolt Out
Place four washers onto the bolt, then
fasten a nut onto the bolt until the nut 2. Caliper.
bottoms on the washers (figure 14). Refer to BRAKES (SEC. 5).
Tighten the nut until the bolt fully seats into 3. Hub/Rotor (81).
the hub/rotor (81).
Refer to Wheel Hub, Bearing and Race,
Remove the nut and washers.
in this section.
2. Hub/rotor to the vehicle.
4. Splash shield (71).
Refer to Wheel Hub, Bearing and Race,
in this section. Bolts (83) and washers (84).
3. Wheel and tire assembly. Lower the vehicle. Gaskets (85).
5. Steering knuckle from the tie rod end.
Refer to STEERING LINKAGE (SEC. 3B1).
STEERING KNUCKLE
6. Steering knuckle (70) from the upper ball joint
+ + Remove or Disconnect (Figures 5 through 8, (13).
15 and 16)
Tools Required:
J-23742 Ball Joint Separator
Im portant
It is recommended that the vehicle be raised and

supported as on a twin-post hoist so that the front
coil spring remains compressed, yet the wheel A. Washers
and s te e rin g k n u c k le a sse m b ly rem ain B. Nut
accessible. If a frame hoist is used, support the 81. Hub/Rotor
lower control arm with an adjustable jackstand to
safely retain the spring in its curb height position.
Wheel and tire assembly. Figure 14Installing The Wheel Hub Bolts
B-06961
Figure 15D isconnecting The Upper Ball Joint Figure 16Disconnecting The Lower Ball Joint
From The Steering Knuckle From The Steering Knuckle
Position a floor jack under the lower control If any tap e re d hole is out of round,
arm (36) near the spring seat. deformed, or damaged in any way, replace
Raise the jack until it just supports the lower the steering knuckle (70).
control arm. 2. Spindle for wear or damage.
Use J-23742 to break the upper ball joint The steering knuckle (70) must be replaced
free of the steering knuckle (figure 15). if the spindle is damaged or worn.
Raise the upper co n tro l arm (28) to
disengage the upper ball joint from the Install or Connect (Figures 5 through 8)
steering knuckle.
NOTICE: For steps 3 and 8, refer to the
Im portant Notice on page 3C#1 of this section.
Floor jack must remain under the lower 1. Steering knuckle (70) to the lower ball joint (37).
control arm spring seat during removal and Press the steering knuckle onto the lower
installation to retain the spring and the lower ball joint (37) until it is fully seated.
control arm in position. 2. Steering knuckle (70) to the upper ball joint (13).
7. Steering knuckle (70) from the lower ball joint Lower the upper control arm (28) to seat the
(37). upper ball jo in t (13) into the steering
Use J-23742 to break the lower ball joint free knuckle.
from the steering knuckle (figure 16). 3. Nuts (14, 35).
Lift the steering knuckle off the lower ball
joint.
Inspect Nuts (14, 35) to Specifications at the end

of this section.
1. Tapered holes in the steering knuckle that attach Cotter pins (15, 34).
to the ball joints and the tie rod end. Tighten the nuts (14, 35), if needed, to install
Remove any dirt. the cotter pins.
Nuts (38), bolts (43), washers (41) and clamp

(42).
CAUTION: Failure to secure J-23028 to a

suitable flo o r jack could result in personal
injury.
3. J-23028-02 to a suitable jack.

4. Place J-23028-02 under the lower control arm
shaft (50) as shown in figure 17.
Im portant
Install a chain around the coil spring (32) and

through the lower control arm (36) as a safety
precaution.
5. Raise the jack to remove the tension from the
lower control arm shaft (50) and remove the U
bolts.
5. Remove the floor jack. Nuts (49) and washers (48).
6. Gasket.
6. Lower the control arm by slowly releasing the jack
7. Tie rod end to the steering knuckle (70). until the spring can be removed.
Do not dam age the ball jo in t (37) by
applying too much force on it.
Washers (84) and bolts (83) in position.
7. Spring (32) and safety chain only after all
compression is removed from the spring.
$ Tighten
Proper maneuvering of the spring will allow
Bolts (83) to 13.5 N m (120 in. lbs.). for easy removal.
4. Hub/rotor assembly.
Refer to Wheel Hub, Bearing and Race in Install or Connect (Figures 5 through 8 and 17)
this section.
5. Caliper. Tools Required:
Refer to BRAKES (SEC. 5). J-23028-02 Spring Remover
6. Adjust the wheel bearings.
Refer to Wheel Bearing Adjustment in NOTICE: For steps 3, 5 and 6, refer to the
this section. Notice on page 3C#1 of this section.
7. Check the front alignment and reset as required.
Refer to FRONT END ALIGNMENT (SEC. 1. Coil spring (32) into position on the lower control
3A). arm (36).
8. Wheel and tire assembly, and lower the vehicle to
the ground. Important
Install a chain around the coil spring and through

COIL SPRING the lower control arm as a safety precaution.
+ + Remove or Disconnect (Figures 5 through 8, CAUTION: Failure to secure J-23028 to a

and 17) suitable flo or jack could result in personal
injury.
Tools Required:
J-23028-02 Spring Remover 2. Slowly lift the lower control arm into position.
Raise the vehicle and support it with suitable
Line up the front indexing hole in the shaft
safety stands, allowing the control arms to hang
(50) with the crossmember attaching studs.
free. Remove the wheel and tire assembly.
1. Shock absorber (20) at the lower end and move it Do not damage the lower ball joint (37).
aside. Use J-23028-02 bolted on a floor jack.
2. Stabilizer bar (59) from the lower control arm (36). 3. U-bolts (44), washers (48), and nuts (49).
J-9519-10
J-9519-16
J-9519-22
A. Measure This Distance B-07486 J-21474-13
Figure 18Inspecting The Lower Ball Joint
Tighten
For G 10/1500-20/2500 series vehicles,

torque to 88 N m (65 ft. lbs.).
For all other series vehicles, torque to 115
N m (85 ft. lbs.). 36. Lower Control Arm
4. Lower the floor jack, and remove J-23028-02.
5. Stabilizer bar (59) to the lower control arm (36).
Clamp (42), washers (41), bolts (43) and Figure 19Removing The Lower Ball Joint
nuts (38).
4. Measure the distance as in Step 2.
Tighten If the difference in measurements exceeds
&
2.38 mm ( % 2 inches), for all models, the ball
Nuts (38) to 33 N m (24 ft. lbs.). joint is worn and must be replaced.
6. Shock absorber (20) to the lower control arm (36). 5. If the ball joint seals are cracked, cut, or torn,
Washer (22), bolt (21), and nut (23). replace them.
Tighten Remove or Disconnect (Figures 5 through 8,

and 19)
Nut (23) to Specifications at the end of
this section. Tools Required:
7. Check the front end alignment. J-23742 Ball Joint Separator
Refer to FRONT END ALIGNMENT (SEC. J-9519-10 Ball Joint Fixture
3A). J-9519-16 Ball Joint Installer
8. Wheel and tire and lower the vehicle. J-9519-22 Ball Joint Installer
J-21474-13 Ball Joint Installer
Raise the vehicle on a hoist. If a frame hoist is
LOWER BALL JOINT used it will be necessary to support the lower
control arm with a floor stand. Remove the tire
Inspect (Figures 5 through 8, and 18) and wheel assembly.
1. Cotter pin (34), nut (35), and lube fitting (12).
1. Raise the vehicle and remove the wheel and tire Loosen (two turns) but do not remove the
assembly. Support the weight of the control arms nut (35).
at the wheel hub and drum. 2. Loosen the ball joint in the steering knuckle (31).
2. Measure the distance between the tip of the ball Use J-23742 between the ball joint studs
joint stud and the tip of the grease fitting below (figure 16).
the ball joint (figure 18). It may be necessary to remove the caliper
3. Move the support to underneath the control arm and wire it to the frame to gain clearance for
allowing the wheel hub and drum to hang free. J-23742. Refer to BRAKES (SEC. 5).
Mate the steering knuckle (31) to the lower

ball joint (37).
3. Caliper if it was removed.
Refer to BRAKES (SEC. 5).

this section.
4. Nut (35).
Tighten
Nut (35) to 122 N m (90 ft. lbs.).

5. Cotter pin (34).
Tighten the nut (35) until the hole in the stud
lines up with the slot in the nut.
Do not tighten more than one flat or 175 N m
(130 ft. lbs.) maximum.
5. Fitting (12).
L u b ric a te the ball jo in t (37) w ith
recommended lubricant.
6. Tire and wheel assembly and lower the vehicle to
the floor.
B-07472 UPPER BALL JOINT
Figure 20Installing The Lower Ball Joint

L9 Inspect
The upper ball joint (13) is spring loaded in its

Extend J-23742 until the lower ball joint (37) socket. Replace the ball joint if there is any lateral
breaks free from the steering knuckle (31). shake or if it can be twisted in its socket with the
Remove the nut (35) and J-23742. fingers.
3. Hub/rotor (70) and the knuckle assembly off the The ball joint seals for cuts or tears. Replace the
lower ball joint (37). ball joint if any are found.
Support the upper control arm (28) with a
block of wood to keep it clear of the work + + Remove or Disconnect (Figures 5 through 8,
area. and 15)
4. Ball joint (37) from the lower control arm (36).
Install J-21474-13, J-9519-22, J-9519-16, and Tools Required:
J-9519-10 (figure 19). J-23742 Ball Joint Separator
Turn the hex head screw until the ball joint is Raise the vehicle on a hoist. If a frame hoist
free of the lower control arm. is used, support the lower control arm with a
Remove the tools and the ball joint (37). floor jack.
1. Cotter pin (15) from the upper ball joint (13).
* Install or Connect (Figures 5 through 8, and Loosen the nut (14) two turns, but do not
20) remove the nut.
2. Caliper.
Tools Required: Refer to BRAKES (SEC. 5).
J-9519-9 Ball Joint Installer 3. Upper ball joint (13) from the steering knuckle
J-9519-10 Ball Joint Fixture (31).
1. Ball joint (37) into the lower control arm (36). Use J-23742 to separate the upper ball joint
Start the ball joint into the control arm and from the steering knuckle (figure 15).
install J-9519-9 and J-9519-10 (Figure 20). Nut (14), and lift the upper control arm (28)
Position the bleed vent in the rubber boot free of the ball joint.
facing inward. 4. Ball joint (13) from the upper control arm (28).
Turn the hex head screw until the ball joint is Drill 6.35 mm (1U inch) deep holes in the
seated in the lower control arm. rivet heads using a 3.175 mm (1/s inch)
2. Ball joint into the steering knuckle (31). diameter drill bit.
Figure 22Removing The Lower Control Arm

Bushings (C10/1500, G10/1500-20/2500 Series)
Tighten
All 10/1500 series and G20/2500 series

vehicle nuts (14) to 68 N m (50 ft. lbs.).
All 20/2500 and 30/3500 series (except
G20/2500) vehicles nuts (14) to 122 N m (90
ft. lbs.).
Apply additional torque to align the cotter
pin (15), but do not exceed 120 N m (90 ft.
Drill off the rivet heads using a 12.7 mm (V2 lbs.) for all 10 series and G20/2500 series or
inch) diameter drill bit. 175 N m (130 ft. lbs.) for all other series.
3. Cotter pin (15).
Punch out the rivets and remove the upper
4. Upper ball joint grease fitting (12).
ball joint from the upper control arm.
5. Grease the upper ball joint (13).
Use a recommended lubricant.
|~n~| Install or Connect (Figures 5 through 8, and 6. Caliper.
21 ) Refer to BRAKES (SEC. 5).
7. Tire and wheel assembly.
8. Check the front end alignment.
NOTICE: For steps 1 and 2 refer to the
Refer to FRONT END ALIGNMENT (SEC.
Notice on page 3C#1 of this section.
3A).
1. Upper ball joint (13) into the upper control arm

(28). LOWER CONTROL ARM PIVOT
Position into the upper control arm and SHAFT AND BUSHINGS
install four attaching bolts and nuts (figure
21). C10/1500 SERIES VEHICLES
Remove or Disconnect (Figures 5, 8, 17 and

Tighten
22 )
Attaching nuts to 25 N m (18 ft. lbs.).
Tools Required:
2. Upper ball joint to the steering knuckle (31). J-23028-02 Coil Spring Remover
J-22717 Lower Control Arm Bushing Stake
The upper ball joint must be fully seated into
Remover
the steering knuckle.
J-24435-2 Lower Control Arm Bushing
Nut (14). Spacer

Remover
Spacer
Fixture
If just the bushings (46) or the pivot shaft (50) need
replacement, the lower control arm (36) does not have
to be removed from the vehicle.
Raise the vehicle on a hoist and support the
frame so the lower control arms hang free.
CAUTION: Failure to install J-23028-02 to a

suitable flo o r jack could result in personal
injury.
1. J-23028-02 to a suitable floor jack and raise it into

position [under the lower control arm (26)] Figure 23Installing The Lower Control Arm
inboard of the spring and into the depression of Bushings (C10/1500, G10/1500-20/2500 Series)
the lower control arm.
Im portant Installer
Install a chain over the upper control arm (28) Spacer
inboard of the stabilizer bar (59) and outboard of J-24435-7 Lower Control Arm Bushing
the shock absorber (20).
Fixture
2. Shock absorber (20) from the lower control arm
(28). NOTICE: For steps 3, 4, 5 and 6, refer to the
Nut (23), washer (22), and bolt (21). Notice on page 3C#1 of this section.
3. Stabilizer bar (59) from the lower control arm (28).
Nuts (38), washers (39, 41), clamp (42), and 1. Bushings (46) and the pivot shaft (50).
bolts (43). Use J-24435-4, J-24435-6, and J-24435-7
42. Pivot shaft end nuts (24). (figure 23).
Loosen only, do not remove. Tighten the bolt on J-24435-7 to install the
5. Lower control arm from the frame. bushings.
Nuts (49), washers (48), and U-bolts (44). Install one bushing, then insert the pivot
SLOWLY lower the floor jack until all shaft and install the remaining bushing.
compression is released from the spring Make sure J-24435-6 is in position to
(32). prevent collapsing the control arm.
6. Stakes on the front bushing. 2. Stake the front bushing in at least two places.
Use J-22717 or an equivalent tool.
7. Bushings (46) and the pivot shaft (50) from the CAUTION: Failure to secure J-23028-02 to a
lower control arm (36). suitable flo o r jack could result in personal
Use J-24435-2, J-24435-3, J-24435-6, and injury.
J-24435-7 (figure 22).
Tighten the bolt on J-24435-7 to remove the 3. Lower control arm (36) to the frame.
bushing. Discard the old bushing. SLOWLY raise the floor jack until the front
The pivot shaft (50) will slide out of the lower indexing hole in the pivot shaft (50) lines up
control arm after one bushing is removed. with the crossmember attaching studs.
Leave the pivot shaft (50) inside the lower Do not damage the ball joint (37).
control arm (36) to remove the remaining J-23028-02 is bolted to a suitable floor jack.
bushing. U-bolts (44), washers (48), and nuts (49).
+- Install or Connect (Figure 5, 8 and 23) Tighten
Tools Required: U-bolt nuts (49) to 115 N m (85 ft. lbs.).

J-23028-02 Coil Spring Compressor 4. Pivot shaft end nuts (24).
|-n-| Install or Connect (Figures 6, 8, 23 and 24)
Nuts (24) to 95 N-m (70 ft. lbs.). Tools Required:

5. Stabilizer bar (59) to the lower control arm (28). J-24435-4 Lower Control Arm Bushing
Washers (39, 41), clamp (42), bolts (43), and Installer
nuts (38). J-24435-6 Lower Control Arm Bushing
Spacer
Tighten J-24435-7 Lower Control Arm Bushing
Fixture
Nuts (38) to 34 N-m (25 ft. lbs.). 1. New bushing (46) using J-24435-6, J-24435-4,
and J-24435-7 (figure 23).
6. Shock absorber (20) to the lower control arm (36).
Tighten J-24435-7 until the bushing fully
Washers (22), bolt (21), and nut (23).
seats.
The outer tube hole must be lined up so it
faces to the front or forward to the staked
bushing.
Nut (23) to 81 N-m (60 ft. lbs.). 2. Stake the front bushing in at least two places.
7. Check the front end alignment. 3. Pivot shaft (50) into installed bushing.
Refer to FRONT END ALIGNMENT (SEC. 4. Remaining bushing (46) into the lower control
3A). arm.
8. Wheel and tire and lower the vehicle.
G10/1500-20/2500 SERIES this section.
(EXCEPT 20/2500 SERIES W/6.2L DIESEL)
5. Pivot shaft washers (25) and nuts (24).
|<"+| Remove or Disconnect (Figures 6, 8, and 22)
Tighten
Tools Required:
J-22717 Lower Control Arm Bushing Stake Nuts (24) to 156 N-m (115 ft. lbs.).
Remover 6. Lower control arm (76).
J-24435-2 Lower Control Arm Bushing Refer to Lower Control A rm , in this
Spacer section.
T h is re s u lts w ith the v e h ic le being
completely assembled and lowered to the
Remover
ground.
Spacer
G20/2500 SERIES WITH RPO LH6/LL4
J-24435-7 Lower Control Arm Bushing (6.2L DIESEL ENGINE)
Fixture
1. Lower control arm. 4- + Remove or Disconnect (Figures 5 through 8,
Refer to Lower Control A rm , in this and 25)
section.
2. Pivot shaft nuts (24) and washers (25). Tools Required:
3. Rear bushing (46). J-24435-1 Lower Control Arm Bushing
Place the lower control arm in an arbor Remover
press. J-24435-3 Lower Control Arm Bushing
Remover
Press the front end of the pivot shaft (50) to
remove the rear bushing. Discard the old
Fixture
bushing.
1. Lower control arm (36).
The pivot shaft can be removed at this time.
Refer to Lower Control A rm , in this
4. Front bushing (46). section.
Stakes from the front bushing using J-22717 2. Bushings (46) and the pivot shaft (50) from the
or an equivalent tool. lower control arm (36).
Use J-24435-7, J-24435-3, J-24435-2, and Use J-24435-1, J-24435-3, and J-24435-7
J-24435-6. (figure 25).
Tighten J-24435-7 until the bushing comes Tighten the clamp (J-24435-7) to remove the
free. Discard the old bushing (figure 22). bushing (46).
A. Rear End D. Inner Pivot Shaft G. Washer, Collar and Flange

B. Front End E. Shaft Tube H. Bumper
C. Insulators F. O-Ring I. Shaft Restrictor B-07514
Figure 24Lower Control Arm Pivot Shaft (G10/1500-20/2500 W/O 6.2L Diesel)
The pivot shaft can be slipped out at this Slide the pivot shaft (50) into the lower
time. control arm (36), then install the other
Repeat the procedure on the remaining bushing (36).
bushing (46) to remove it from the lower 2. Lower control arm (36).
control arm (36).
Refer to Lower Control A rm , in this
4- Install or Connect (Figures 5 through 8, and section.
26) T h is re s u lts w ith the v e h ic le being
completely assembled and lowered to the
Tools Required: ground.
Installer
J-24435-5 Lower Control Arm Bushing CP20/2500-30/3500, G30/3500 SERIES VEHICLES
Installer
Fixture
Raise the vehicle and support the frame so the
1. Bushings (46) and the pivot shaft (50) into the
control arms hang free. Remove the tire and
lower control arm (36).
wheel assembly.
Use J-24435-4, J-24435-5, and J-24435-7
(figure 26). 1. Position an adjustable floor jack under the lower
Tighten the clamp (J-24435-7) to install the control arm (36) inboard of the spring and into the
bushing (26). depression in the lower control arm.
Figure 25Removing The Lower Control Figure 26Installing The Lower Control
Arm Bushing (G20/2500 W/6.2L Diesel) Arm Bushing (G20/2500 W/6.2L Diesel)
Tighten
Bushings (46) to 379 N m (280 ft. lbs.)
Pivot shaft (50) for free rotation.

2. Grease fitting (12).
Lubricate the bushings with an approved
grease.
A. 2.96 - 31.9 mm 36. Lower Control Arm R efer to M A IN TE N A N C E AND
(1.16 -1.25 inches) 46. Bushing LUBRICATION (SEC. 0B).
To Properly Center 50. Pivot Shaft 3. Lower control arm (36) to the frame crossmember.
The Pivot Shaft SLOWLY raise the floor jack until the lower
control arm (36) is in position.
B-07478
Im portant
Figure 27Centering The Lower Control Arm
Shaft (CP20/2500-30/3500 And G30/3500 Series) Be sure the hole in the pivot shaft mates
w ith the b o lt head in the fram e
Im portant crossmember saddle.
U-bolts (44), washers (48), and nuts (49).
Install a chain over the upper control arm (28)
inboard of the stabilizer bar (59) and outboard of
& Tighten
the shock absorber (20).
2. Shock absorbers (20) from the lower control arm Nuts (49) to 115 N m (85 ft. lbs.).
(36). 7. Stabilizer bar (59) to the lower control arm (36).
Nut (23), washer (22) and bolt (21). Nuts (38), washers (39, 41), bolts (43), and
3. Stabilizer bar (59) from the lower control arm (36). clamp (42).
Nuts (38), washers (39, 41), bolts (43) and
clamp (42). $ Tighten
4. Low er c o n tro l arm (36) from the fram e
crossmember. Nuts (38) to 33 N m (24 ft. lbs.).
Nuts (49), washer (48), and U-bolts (44). 5. Shock absorbers (20) to the lower control arm
SLOWLY lower the floor jack to access the (36).
pivot shaft (50). Bolt (21), washer (22), and nut (23).
5. Grease fittings (12).
6. Bushings (46) and bushing seals, and pivot
shaft (50).
Unscrew the bushings. Nut (23) to Specifications at the end of
Slide the pivot shaft out of the lower control this section.
arm. 6. Remove the safety chain and the floor jack.
Seals are mounted between the bushings Install the tire and wheel assembly and lower the
and the pivot shaft. Discard the old seals. vehicle to the ground.
+- Install or Connect (Figures 5 through 8, and

27) UPPER CONTROL ARM PIVOT
SHAFT AND BUSHINGS
NOTICE: For steps 1, 3, 4, and 5 refer to the
N otice on page 3C#7 of this section. C10/1500, G10/1500-20/2500 SERIES VEHICLES
1. Pivot shaft (50), seals, and bushings (46), to the |+ + | Remove or Disconnect (Figures 5 through 8,
lower control arm (36). and 28)
New seals onto the pivot shaft.
Pivot shaft into the lower control arm. Attach Tools Required:
the bushings. Center the shaft in the lower J-24435-1 Lower Control Arm Bushing
control arm (figure 27). Remover
J-24435-4
J-24435-5
(Hidden)
B-07481
Figure 28Removing The Upper Control Arm Figure 29Installing The Upper Control Arm
Bushings (C10/1500, G10/1500-20/2500 Series) Bushings (Cl 0/1500, G10/1500-20/2500 Series)
J-24435-3 Lower Control Arm Bushing Tighten the clamp (J-24435-7) to install the
Remover bushing (26).
J-24435-7 Lower Control Arm Bushing Slide the pivot shaft (29) into the upper
Fixture control arm (28), then install the other
1. Upper control arm (28). bushing (26).
Refer to Upper Control A rm , in this Nuts (24) in place.
section.
2. Nuts (24), bushings (26) and the pivot shaft (29) Tighten
from the upper control arm (28).
Use J-24435-1, J-24435-3, and J-24435-7 Nuts (24) to 156 N m (115 ft. lbs.).
(figure 28). 2. Upper control arm (28) to the crossmember.
Tighten J-24435-7 to remove the bushing Refer to Upper Control A rm , in this
(26). section.
Pivot shaft (29) can be pulled free at this 3. Caliper if it was removed.
time. Refer to BRAKES (SEC. 5).
Repeat this procedure on the remaining 4. Check the front end alignment.
bushing (26). Discard the old bushings. Refer to FRONT END ALIGNMENT (SEC.
3A).
Install or Connect (Figures 5 through 8, and 5. Remove the supports and lower the vehicle to the
29) ground.
Tools Required: CP20/2500-30/3500, G30/3500 SERIES VEHICLES

Installer + + Remove or Disconnect (Figures 5 through 8)
Installer Raise the vehicle and support the lower control
J-24435-7 Lower Control Arm Bushing arms with a floor jack positioned under or near
Fixture the ball joint assembly. Remove the wheel and
tire assembly.
NOTICE: Refer to the Notice on page 3C#1 1. Loosen, but do not remove the pivot shaft to
of this section. frame nuts (27).
2. Shim packs (18).
1. Tape each pack together and mark their
Bushings (26) and the pivot shaft (29) into the upper position to assure exact replacement during
control arm (28). installation.
Use J-24435-4, J-24435-5, and J-24435-7 3. Pivot shaft to frame nuts (27), bolts (4), and
(figure 29). spacers (19).
Do not allow the upper control arm (28) to L* Inspect

swing too far from the frame crossmember.
Pivot shaft for free rotation.
Im portant 2. Grease fitting (12).
G rease the b u s h in g s (29). R efer to
Install a chain over the upper control arm MAINTENANCE AND LUBRICATION (SEC.
(28) inboard of the stabilizer bar (59) and OB).
outboard of the shock absorber (20), to
retain the upper control arm in a close NOTICE: Refer to the N otice on page 3C-1
relationship to the frame crossmember. of this section.
4. Pivot shaft (29) and bushings (26). 3. Pivot shaft (29) to the frame.
Grease fitting (12). Bolts (4), shim packs (18), spacers (19), and
nuts (27).
Unscrew the bushings (26).
Shims are positioned into their original
Slide the pivot shaft out of the upper control positions. Make sure the convex and
arm. Remove and discard the inner seals concave sides of the shims are together.
(between the bushings and the pivot shaft).
Tighten
+ 4- Install or Connect (Figures 6 through 8, and
30) Nuts (27) to 142 N m (105 ft. lbs.).
4. Remove the safety chain and install the wheel
1. Pivot shaft (29), seals, and bushings (26) onto the and tire assembly.
upper control arm (28). 5. Check the front end alignment.
New inner seals onto the pivot shaft. 3A).
Slide the pivot shaft into position inside the 6. Lower the vehicle to the ground.
upper control arm. Screw on the new
bushings. Do not tighten.
LOWER CONTROL ARM
Im portant
Remove or Disconnect (Figures 5 through 8,
and 16)
The pivot shaft (29) must be centered in the
upper control arm (28) as shown in figure 30.
Tools Required:
Tighten Raise the vehicle and support it with suitable
safety stands. Remove the wheel and tire
Bushings (26) to 257 N m (190 ft. lbs.). assembly.
1. Caliper. UPPER CONTROL ARM

+ + Remove or Disconnect (Figures 5 through 8,
2. Coil spring (32). and 15)
Refer to Coil Spring, in this section.
Tools Required:
The lower control arm is separated from the J-23742 Ball Joint Separator
frame.
3. Use a jack to support the inboard end of the lower Raise the vehicle and support it with suitable
control arm (36). safety stands. Remove the wheel and tire
assembly. Place an adjustable jackstand under
4. Lower control arm (36) from the steering knuckle the lower control arm for support.
(31). 1. Caliper.
Cotter pin (34), then loosen the nut (35) one Refer to BRAKES (SEC. 5).
turn. 2. Upper control arm (28) from the steering knuckle
(31).
Install J-23742, with the large cup end over
Cotter pin (15).
the upper ball jo in t nut (14). Extend
Loosen the nut (14). Do not remove it.
threaded end until the ball joint stud loosens
from the steering knuckle. Remove J-23742 Install J-23742 with the large cupped end
and the nut (35). over the lower control arm ball joint stud nut
(35). Expand J-23742 until the upper control
arm separates.
Install or Connect (Figures 5 through 8) Nut (14) from the upper ball joint stud and
raise the upper control arm to clear the
1. Lower control arm (36) to the steering knuckle steering knuckle.
(31). 3. Upper control arm (28) from the frame bracket (9).
Position the lower control arm ball joint stud Nuts (27), spacers (19), shims (18), washers
(37) into the steering knuckle (31). (5) and bolts (6).
Nut (35) onto the stud. Do not tighten.

Im portant
2. Coil spring (32).
Tape the shims together in their original
Refer to Coil Spring, in this section. positions and tag for proper relocation.
This step results with the lower control arm
being attached to the frame. + 4- Install or Connect (Figures 5 through 8)
NOTICE: Refer to N otice on page 3C-1 of NOTICE: For steps 2 and 3, refer to Notice
this section. on page 3C-1 of this section.
3. Cotter pin (34). 1. Shims (18) into position on the upper control arm
frame bracket (9).
Tighten Make sure the shims are positioned with
concave and convex sides together.
Nut (35) to 122 N m (90 ft. lbs.). 2. Upper control arm (28) to the frame bracket
(9).
Cotter pin. Tighten further to a maximum of
Spacers (19) and nuts (27), washers (5), and
176 N m (130 ft. lbs.) for c o tte r pin
bolts (6).
installation, if necessary.
4. Caliper. Important
A normal shim pack will leave at least two
5. Check the front end alignment. threads of the bolt (6) exposed beyond the
nut.
If two threads cannot be obtained; check for
3A).
damaged control arm or related parts. The
6. Tire and wheel assembly and lower the vehicle. difference between the front and rear shim
packs must not exceed 7.62 mm (0.30 5. Shock absorbers (20) from the lower control arms
inches). The front shim pack must be at (36).
least 6.09 mm (0.24 inches). Nut (23), washer (22), and bolt (21).
Always tighten the thinner shim packs nut 6. Brake line clip bolts from the front suspension
(27) first for improved shaft to frame crossmember.
clamping force and torque retention. On C series models the clip is located under
the right side engine mount support bracket.
$ Tighten
NOTICE: Failure to disconnect these clips
Nuts (27) to Specifications at the end of from the suspension unit w ill result in severe
this section. damage to the brake line when the unit is
3. Upper control arm (28) to the steering knuckle lowered from the vehicle.
(31).
Insert the upper control arm ball joint stud 7. Suspension crossm em ber from the engine
(13) into the steering knuckle (31). mounts.
Nut (14) and cotter pin (15). Refer to ENGINE (SEC. 6A).
8. Suspension crossmember from the frame rail
Tighten (figure 31).
9. Raise the hoist to support the suspension
Nut (14) to the Specifications at the end of crossmember.
this section. 10. Support the engine.
4. Caliper. Must be done before the suspension unit is
Refer to BRAKES (SEC. 5). lowered from the vehicle.
5. Check the front end alignment. 11. Suspension unit and crossmember from the
Refer to FRONT END ALIGNMENT (SEC. vehicle.
3A). Upper control arm bracket to the frame side
6. Wheel and tire assembly. Lower the vehicle to the rail nuts (10), washer (7), and bolts (6).
ground. Low er the su sp e n sio n u n it and the
crossmember to bring the unit clear of the
vehicle.
SUSPENSION UNIT
Install or Connect (Figures 5 through 8 and 31)
The front suspension and frame crossmember can
be removed or installed as a unit if extensive service is
required. NOTICE: For steps 3, 7, and 8, refer to the
N otice on page 3C-1 of this section.
Rem ove o r D isco n n e ct (F igure 5 th ro u g h 8,
and 31) 1. P o sitio n the new su sp e n sio n u n it and
crossmember and raise it with the hoist to align
Raise the hood and disconnect the battery the suspension crossmember and frame holes.
negative cable. 2. Suspension crossmember to the frame rail bolts
Hoist the vehicle and support it with suitable (figure 31).
safety stands placed at the frame side rails. 3. Upper control arm (28) to the frame bracket bolts
Remove the tire and wheel assembly and then (6).
lower the hoist. Washers (7) and nuts (10). Do not tighten.
1. Front brake hose clip from each upper control
arm.
2. Brake hoses from the calipers.
$ Tighten
Clean the area adjacent to the brake hose Upper control arm to the frame bracket bolts
fittings. (6) to Specifications at the end of this
Discard the special washers (2 on each section.
hose) and cover the disconnected ends of Suspension crossmember to the frame rail
each hose with suitable material. bolts to Specifications at the end of this
Refer to BRAKES (SEC. 5). section.
3. Tie rod ends from the steering knuckle (31).
4. Front stabilizer from the lower control arms (36).
Nuts (38), washers (39, 41), bolts (43), and
clamps (42).
Figure 31Suspension Unit Replacement
The upper control arm to frame bracket

bolts must be tightened first.
a Tighten
The crossmember must be in contact with Nuts (38) to Specifications at the end of
the frame side rails. this section.
4. Remove the engine support and lower the hoist. 9. Tie rod ends to the steering knuckle (31).
5. Engine mount support bracket to the suspension Refer to STEERING LINKAGE (SEC. 3B1).
crossmember. 10. Brake hose to the caliper.
Refer to ENGINE (SEC. 6A). Refer to BRAKES (SEC. 5).
6. Brake line clip to the crossmember. 11. Brake hose clips to the upper control arms.
Refer to BRAKES (SEC. 5). Refer to BRAKES (SEC. 5).
7. Shock absorber to the lower control arm (28). 12. Bleed the brake system.
Washers (22), nuts (23), and bolts (21). Refer to BRAKES (SEC. 5).
13. Tires and wheels and lower the vehicle.
Tighten 14. Battery cable.
Nuts (23) to Specifications at the end of

this section.
Stabilizer bar (59) to the lower control arm (28).
Clamps (42), bolts (43), washers (39) and
nuts (38).
ON-VEHICLE SERVICE: TWO WHEEL

DRIVE RPO FS3 (I-BEAM) FRONT SUSPENSION
SHOCK ABSORBER Shock absorber should be held vertically in
the vise with its bottom end up.
Remove or Disconnect (Figures 32 through 34) Do not clamp the vise jaws on the shocks
reservoir tube.
safety stands. Remove the wheel and tire 2. Pump the shock absorber at various rates of
assembly. speed and observe the rebound force.
1. Shock absorber (113) from the leaf spring spacer Rebound force is normally stronger than the
(158). compression force (approximately two to
Nut (109) and washer (111). one).
2. Shock absorber (113) from the frame.
Rebound force should be smooth and
Nut (109) and washer (111).
constant for each stroke rate.
Pull the shock free from the vehicle.
3. Compare with a good shock absorber.
BENCH TEST: SPIRAL GROOVE SHOCK
4. If one of the following are observed, replace the
ABSORBERS shock absorber.
1. Purge the air from the pressure chamber.
Extend the shock verticallytop end up. A skip or lag at reversal near mid-stroke.
Turn the sh ock over and co lla p se it A seize (except at the extreme ends of
verticallytop end down. travel).
2. Place the shock absorbers in a vise with the jaws A noise (grunt or squeal) after completing
clamped onto the shocks bottom mount. one full stroke in both directions.
Shock absorber should be positioned A clicking noise at fast reversal.
vertically in the visetop end up.
Do not clamp the vise jaws on the shocks
reservoir tube. i l Install or Connect (Figures 32 through 34)
3. Pump the shock absorber at various rates of
1. Shock absorber (113) to the frame (figure 34).
Rebound force is normally stronger than the Insert the shocks upper stud into the hole in
compression force (approximately two to the frame.
one).
Washer (111) and nut (109). Do not tighten.
Rebound force should be smooth and
4. Compare with a good shock absorber. NOTICE: Refer to the Notice on page 3C#1
5. If one of the following are observed, replace the of this section.
shock absorber.
A skip or lag at reversal near mid-stroke. 2. Shock absorber (113) to the leaf spring spacer
A seize (except at the extreme ends of (158) (figure 34).
travel). Position the shocks lower mount onto the
A noise (grunt or squeal) after completing stud.
one full stroke in both directions.
A clicking noise at fast reversal. Washer (111) and nut (109).
BENCH TEST: NON-SPIRAL GROOVE Tighten

RESERVOIR SHOCK ABSORBER
P urging air from n on-spiral groove shock Shock absorber upper nut to 185 N m (136
absorbers is not necessary. The shock absorbers ft. lbs.).
have a gas filled cell in their reservoirs (as
Shock absorber lower nut to 50 N m (37 ft.
opposed to the air filled cell in the spiral groove
lbs.).
shock absorber reservoirs).
1. Place the shock absorber in a vise with the jaws 3. Wheel and tire on the vehicle. Lower the vehicle
clamped on the shock absorbers top mount. to the ground.
Figure 32P Series Front Suspension (RPO FS3)

101. Spring Hanger 126. Spacer 150. Nut

102. Rivet 127. Steering Knuckle 151. Washer
103. Spring Stop 128. Fitting 152. Outer Wheel Bearing And Race
104. Hanger Bushing 129. Nut 153. Wheel Hub Bolt
105. Washer 130. Dust Seal 154. Hub/Rotor
106. Bolt 131. Shim 155. Inner Wheel Bearing And Race
107. Shackle 132. Nut 156. Bearing Seal
108. Nut 133. Washer 157. Front Axle
109. Nut 134. Lock Pin 158. Spring Spacer
110. Nut 135. Nut 159. Spring Leaf
111. Washer 136. Nut 160. Bolt
112. Bumper 137. Thrust Bearing 161. Spacer
113. Shock Absorber 138. Nut 162. Front Spring
114. Spacer 139. Cotter Pin 163. Nut
115. Nut 140. Steering And Third Arm 164. Spacer
116. Stabilizer Link 141. Splash Shield 165. U-Bolt
117. Retainer 142. Brake Caliper 166. Stabilizer Bar
118. Insulator 143. Washer 167. Insulator
119. Bolt 144. Bolt 168. Clamp
120. Washer 145. Anchor Plate 169. Bolt
121. Brake Hose Bracket 146. Stop Bolt 170. Nut
122. Cap 147. Stop Nut 171. Washer
123. Gasket 148. Retainer/Cap 172. Bolt
124. King Pin 149. Cotter Pin 173. Spring Hanger
125. Bushing B-07485
Figure 33P Series Front Suspension (RPO FS3)
STABILIZER BAR
A. Frame |<~+| Remove or Disconnect (Figures 32, 33, and
109. Bolt 35)
111. Washer
113. Shock 1 Tools Required:
Absorber
157. Front Axle J-6627-A Wheel Stud and Tie Rod Remover
158. Spring Spacer Raise the vehicle and support it with suitable
162. Front Spring safety stands. Remove the tire and wheel
assembly.
1. Stabilizer bar (166) from the stabilizer link (116).
Use J-6627-A to separate the stabilizer link
from the stabilizer end.
2. Stabilizer bar (166) from the frame (figure 35).
Nuts (170), washers (171), clamp bolts (169)
and clamps (168).
Slide the insulator (167) from the stabilizer
bar (166).
3. Stabilizer link (116) from the front axle (157)
(figure 35).
B-07487
Nut (136), retainer (117), insulator (118).
Figure 34Shock Absorber Attachments Pull the link from the axle. Another insulator
(118) and retainer (117) will come off the link.
118 \
^1181
A. 166. Stabilizer Bar
11 i j 114. 167. Insulator
115. 168. Clamp
116. 169. Bo*!
117. 170. Nut
118. 171. Washer
136. B-07491
Figure 35Stabilizer Bar Attachm ents
Install or Connect (Figures 32, 33, and 35) Clamps (168), clamp bolts (169), washers
(171), and nuts (170).
NOTICE: For steps 1, 2, and 3, refer to the

Tighten
1. Stabilizer link (116) to the front axle (157) (figure
Nuts (170) to 28 N m (21 ft. lbs.).
35).
Slide a retainer (117) and an insulator (118)
3. Stabilizer bar (166) to the stabilizer link (116).
on to the link and insert the link into the
proper hole in the front axle.
* Washer (114) and nut (115).
Insulator (118), retainer (117) and nut (136).
& Tighten
Tighten
Nut (136) until the distance between each
retainer (117) is 2.08 cm (0.82 inches) (figure Nuts (115) to 68 N m (50 ft. lbs.).
35).
2. Stabilizer bar (166) to the frame (figure 35). 4. Wheel and tire assembly. Lower the vehicle to the
Insulators (167) onto the stabilizer bar (166). ground.
WHEEL HUB/ROTOR ASSEMBLY NOTICE: Start the races squarely inside the
hub/rotor (154) to avoid distortion and
Remove or Disconnect (Figures 32 and 33) possible cracking.
Raise the vehicle and support it with suitable 1. Races into the hub/rotor (154).
safety stands. Remove the tire and wheel Place the hub/rotor on J-9746-02 and rest
assembly. this assembly on press bars.
1. Caliper (142). Use J-29040 to drive the outer bearing race
Refer to BRAKES (SEC. 5). into position.
Remove J-9746-02 and use a 7.6 cm (3 inch)
NOTICE: Support the caliper with a piece of diameter bar, or equivalent tool to drive the
wire to prevent damage to the brake line. inner bearing race into position. If the bar is
larger than 7.6 cm (3 inches), it may damage
2. Wheel hub/rotor (154) (figures 32, 33). the bearing seal seat.
Retainer/cap (148).
9 Im portant
Cotter pin (149), nut (150) and washer (151).
Pull the hub/rotor free from the spindle,
making sure the outer wheel bearing (152) Use an approved high temperature front wheel
comes free. bearing grease to lubricate the bearings. Refer to
Do not damage the steering knuckle spindle MAINTENANCE AND LUBRICATION (SEC. OB).
threads. Do not mix different greases as mixing may
3. Inner wheel bearing (155). change the greases properties resulting in poor
Pry out the seal (156). performance.
4. Races. 2. Apply a thin film of grease to the steering knuckle
Drive out each race using a brass drift. spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, shoulder, and seal seat.
Clean 3. Put a small quantity of grease inboard of each
wheel bearing retainer/cap (148).
1. Grease from the hub/rotor (154) and steering 4. F ill each w heel b ea rin g (cone and ro lle r
knuckle spindle. assembly) full of grease.
Grease from inside the hub. Use a cone-type grease machine that forces
2. Grease from the wheel bearings (152, 155) and grease into the bearing.
races. If a cone-type grease m achine is not
Use clean solvent and a small brush (no available, pack the wheel bearing by hand.
loose bristles). When packing the wheel bearing by hand,
Do not spin the wheel bearings with work the grease into the bearings between
compressed air to dry themthe wheel the rollers, cones, and the cage.
bearings may be damaged.
NOTICE: Failure to completely pack the wheel
Inspect bearing (cones, rollers, and cage) with grease
will result in premature wheel bearing damage
1. Wheel bearings (152, 155) and their races for and/or wear.
damage or wear.
Refer to Diagnosis of Wheel Bearings, in 5. Inner wheel bearing (155) into the hub/rotor (154).
this section. Put an a dd itio n a l q u a n tity of grease
If either a bearing or its race is damaged or outboard of this bearing.
worn, replace both. 6. New seal (156).
2. Hub/rotor (154) for damage or wear. Use a flat plate or block to install the seal to
Check for out-of-round or scored conditions. insure it is flush with the hub/rotor flange.
Check for pitting or cracks. Lubricate the seal lip with a thin layer of
Repair or replace as necessary. grease.
7. Hub/rotor (154).
+- Install or Connect (Figures 32 and 33) Do not damage the steering knuckle spindle
threads.
Tools Required: 8. Outer wheel bearing (152).
J-8092 Driver Handle Slide it over the spindle until the wheel
J-29040 Outer Bearing Race Installer bearing (152) fu lly seats against the
J-9746-02 Hub/Rotor Support hub/rotor outer race.
NOTICE: Refer to the Notice on page 3C#1 If they do not line up, back off the nut until
of this section. they donot more than one additional flat.
9. Washer (151), nut (150) and cotter pin (149).

Measure
Do not place the cotter pin through the hole
in the spindle until the wheel bearings are
E ndplay in the hub/rotor should m easure
adjusted.
between 0.013-0.20 mm (0.0005-0.008 inches)
when properly adjusted.
Tighten
4. Install the retainer/cap (148).
Nut (150) to 16 N m (12 ft. lbs.) while turning
the hub/rotor assembly in either direction. 5. Lower the vehicle to the ground.
10. Put an additional amount of grease outboard of
the wheel bearing (152).
11. Adjust the wheel bearings. WHEEL HUB BOLT
Refer to Wheel Bearing Adjustment, in
this section. Remove or Disconnect
12. Retainer/cap (148) in place.
13. Caliper (142). Tools Required:
Refer to BRAKES (SEC. 5). J-9746-02 Hub/Rotor Support
14. Tire and wheel assembly. Lower the vehicle to the 1. Hub/rotor assembly from the vehicle.
ground. Refer to Wheel Hub/Rotor Assembly, in
this section.
WHEEL BEARING ADJUSTMENT

NOTICE: Place J-9746-02 between the press
Im portant bars and the hub/rotor to protect the rotor
surfaces.
The proper functioning of the front suspension
cannot be maintained unless the front wheel 2. Wheel hub bolts (153) with a press.
bearings are correctly adjusted. The bearings
Support the hub/rotor (153) using J-9746-02
must be a slip fit on the spindle and the inside
and the press bars.
diameter of the wheel bearing must be lubricated
to ensure the bearings will creep. The spindle nut Do not damage the wheel mounting surface
(150) must have a free-running fit on the spindle on the hub/rotor flange.
threads.
NOTICE: Never preload the front wheel -+ Install or Connect

bearings. Damage can result by the steady
thrust on the roller ends which comes from
preloading. NOTICE: Refer to the Notice on page 3C#1
of this section.
JP Adjust 1. Wheel hub bolts (153) into the hub/rotor (154).
Place four washers onto the bolt, then

Raise the vehicle and support it with suitable fasten a nut onto the bolt until the nut
safety stands under the lower control arms. bottoms on the washers.
Remove the retainer/cap (148).
Remove the cotter pin (149). Tighten the nut until the bolt fully seats into
the hub/rotor (154).
Nut (150) to 16 N m (12 ft. lbs.) while rotating 2. Hub/rotor to the vehicle.
the w heel and tire a ssem bly (or the
Refer to Wheel Hub/Rotor Assembly, in
hub/rotor). This will seat the bearings.
this section.
3. Back off the nut (150) one flat.
If the hole in the spindle lines up with the 3. Wheel and tire assembly. Lower the vehicle to the
slot in the nut, insert the cotter pin (149). ground.
STEERING ARM, KNUCKLE AND Do not score the king pin surface. Use a
proper lubricant if necessary.
SPINDLE 3. Lock pin (134).
Washer (133) and nut (132).
Tighten
safety stands. Remove the tire and wheel
Nut (132) to 40 N m (29 ft. lbs.).
assembly.
4. Caps (122) to the steering knuckle (127).
1. Caliper (142).
Gaskets (123) in place.
Brake hose bracket (121).
2. Hub/rotor assembly (154).
Washers (120) and bolts (119).
this section. Tighten
3. Anchor plate (145), splash shield (141), and the
steering arm (140). Bolts (119) to 7 N m (5 ft. lbs.).
Bolts (146), washers (147) and nuts (129), 5. Steering arm (140), splash shield (141), and the
and pull the anchor plate and splash shield anchor plate (145).
off the knuckle. Steering arm hangs by tie Bolts (144) and washers (143) to attach the
rods. splash shield to the anchor plate.
Bolts (144) and washers (143) to separate Bolts (146), washers (147) and nuts (129) to
the anchor plate from the splash shield. attach the anchor plate and steering arm to
Refer to STEERING LINKAGE (SEC. 3B1) to the steering knuckle.
separate the steering arm from the tie rod
and pitman arm. Tighten
4. Caps (122) from the steering knuckle (127).
Bolts (119) and washers (120). Bolts (144) to 16 N m (12 ft. lbs.).
Brake hose bracket (121). Nuts (129) to 312 N m (230 ft. lbs.).
Gaskets (123) come off. 6. Steering arm (140) to the steering linkage.
5. Lock pin (134). Refer to STEERING LINKAGE (SEC. 3B1).
Nut (132) and washer (133). 7. Hub/Rotor assembly (154).
6. King pin (124) from the steering knuckle (127). Refer to Wheel Hub/Rotor Assembly, in
Drive it out using a drift. this section.
Spacers (126) and bushings (125) will also 8. Adjust the wheel bearings.
come out. Refer to Wheel Bearing Adjustment, in
7. Steering knuckle (127) from the axle (157). this section.
Dust seal (130), shim (131), and thrust 9. Caliper (142).
bearing (137) will come free. Refer to BRAKES (SEC. 5).
10. Wheel and tire assembly. Lower the vehicle to the
Install or Connect (Figures 32 and 33) ground.
NOTICE: For steps 3, 4, and 5 refer to the 3A).
1. Steering knuckle (127) to the axle (157). FRONT AXLE

Thrust bearing (137), shim (131), and dust
seal (130) must be properly positioned. Remove or Disconnect (Figures 32 through 36)
Knuckle to axle clearance must be between
0.025-0.25 mm (0.001-0.010 inches). Tools Required:
Prelube the thrust bearing (137). Refer to J-6627-A Wheel Stud and Tie Rod Remover
MAINTENANCE AND LUBRICATION (SEC. Raise the vehicle and support it with suitable
0B). safety stands on the frame. Remove the wheel
Align lube hole in the bearing with the lube and tire assembly. Support the axle with a floor
hole in the steering knuckle. jack to eliminate any load on the springs.
2. King pin (124) into the steering knuckle (127). 1. Steering arm, knuckle, and spindle.
Insert bushings (125) and spacers (126) in Refer to Steering Arm, Knuckle, and
their proper order. Spindle, in this section.
108
101. Spring Hanger

105. Washer
106. Bolt
107. Shackle
108. Nut
135. Nut
157. Front Axle
158. Spring Spacer
162. Front Spring
165. U-Bolt
164. Spacer
173. Spring Hanger B-07492
Figure 36Axle And Leaf Spring Attachm ents
2. Shock absorber (113) from the axle (157) (figure |+<-| Install or Connect (Figures 32 through 36)
34).
3. Stabilizer link (116) from the stabilizer bar (166) NOTICE: For steps 4, 5, and 6, refer to the
(figure 35). Notice on page 3C#1 of this section.
Use J-6627-A to separate the stabilizer bar 1. Line up the axle under the leaf springs.
from the stabilizer link.
Raise it into position using a floor jack.
4. Stabilizer link (116) from the axle (157) (figure 35).
Nut (136), retainer (117) and insulator (118). 2. Steering damper to the axle.
Pull the link free from the axle, making sure
not to loose the other insulator (118) and
retainer (117). 3. Axle (157) to the leaf springs (162).
5. Leaf spring (162) from the axle (157) (figure 36).
Refer to Leaf Spring, in this section.
Nuts (135), washers (105) and U-bolts (165).
Spacer (164), and spring spacer (158). 4. Stabilizer link (116) to the axle (157) (figure 35).
6. Steering damper from the axle.
Link into the hole on the spring spacer (158)
and axle.
7. Lower the floor jack and pull the axle clear of the
vehicle. Insulator (118), retainer (117), and nut (136).
& Tighten Nut (108), washer (105), bolt (106) and

washer (105) to separate the spring from the
Nut (136) until the distance between each rear shackle (107).
retainer (117) is 2.08 cm (0.82 inches) (figure Nut (108), washer (105), bolt (106), and
35). washer (105) to separate the spring from the
5. Stabilizer link to the stabilizer bar (166) (figure front hanger (173).
35). Pull the leaf spring backward and out.
Tighten 0 Install or Connect (Figures 32 through 36).
Nut (115) to 68 N m (50 ft. lbs.).

NOTICE: For steps 1, 2, 3, 4 and 5, refer to the
6. Shock absorber (113) to the axle (157) (figure 34).
N otice on page 3C#7 of this section.
1. Leaf spring (162) to the frame (figure 36).
$ Tighten
Line up the spring with the rear shackle
Nut (109) to 50 N m (37 ft. lbs.). (107) and the front hanger (173). Double
7. Steering arm, knuckle, and spindle. wrap end is toward the front of the vehicle.
Refer to Steering Arm, Knuckle, and Washer (105), bolt (106), washer (105) and
Spindle, in this section. nut (108) to attach the spring to the front
8. Adjust the wheel bearings. hanger (173).
Refer to Wheel Bearing Adjustment in Washer (105), bolt (106), washer (105) and
this section. nut (108) to attach the spring to the rear
9. Wheel and tire assembly. Lower the vehicle to the shackle (107).
ground.
10. Check the front end alignment. Tighten
3B1). Nut (108) to 125 N m (92 ft. lbs.).
2. Leaf spring (162) to the axle (157) (figure 36).
LEAF SPRINGS Position the spring spacer (158) onto the
axle. Either aligning pin can contact the
-- Remove or Disconnect (Figures 32 through 36) edge of the leaf spring after the assembly is
complete.
Tools Required: Spacer (164), U-bolts (165), washers (105)
J-6627-A Wheel Stud and Tie Rod Remover and nuts (135). Tighten nuts to 25 N m (18 ft.
Raise the vehicle and support it with suitable lbs.) in a diagonal sequence (e.g., 1-3-4-2).
safety stands. Support the axle separately to
eliminate any load on the springs. Remove the $ Tighten
tire and wheel assembly.
1. Shock absorber (113) from the axle (157) (figure Nuts (135) in a diagonal sequence (e.g.,
34). 1-3-4-2) to 109 N m (80 ft. lbs.).
Nut (109) and washer (111). 3. Stabilizer link (116) to the axle (157) (figure 35).
2. Stabilizer link (116) from the stabilizer bar (166)
Insert the link into the proper hole in the
(figure 35).
axle after the retainer (117) and insulator
(118) are attached.
Use J-6627-A to separate the stabilizer bar
Insulator (118), retainer (117), and nut (136).
from the stabilizer link.
3. Stabilizer link (116) from the axle (157) (figure 35).
Nut (136), retainer (117), insulator (118). Tighten
Pull the link free from the axle, making sure
not to loose the other insulator (118) and Nut (136) until the distance between each
retainer (117). retainer (117) is 2.08 cm (0.82 inches) (figure
4. Leaf spring (162) from the axle (157) (figure 36). 35).
Nuts (135), washers (105) and U-bolts (165). 4. Stabilizer link (116) to the stabilizer bar (166)
Spacer (164) and spring spacer (158). (figure 35).
5. Leaf spring (162) from the frame (figure 36). Washer (114) and nut (115).
Tighten 6. Wheel and tire assembly. Lower the vehicle to the

ground.
Nut (115) to 68 N m (50 ft. lbs.). 7. Check the front end alignment.
5. Shock absorber (113) to the axle (157) (figure 34). Refer to FRONT END ALIGNMENT (SEC.
Washer (111) and nut (109). 3B1).
Tighten
Nut (109) to 50 N m (37 ft. lbs.).
ON-VEHICLE SERVICE:
FOUR WHEEL DRIVE FRONT SUSPENSION
SHOCK ABSORBER BENCH TEST: NON-SPIRAL GROOVE RESERVOIR
SHOCK ABSORBERS
Remove or Disconnect (Figures 37 through 39) P urging air from non-spiral groove shock
absorbers is not necessary. The shock absorbers
Raise the vehicle on a hoist. have a gas filled cell in their reservoirs (as
1. Shock absorber (220) from the frame. opposed to the air filled cell in the spiral groove
Nut (212), washer (213) and bolt (219) (figure shock absorber reservoirs).
36). 1. Place the shock absorber in a vise with the jaws
2. Shock absorber (220) from the axle. clamped on the shock absorbers top mount.
Nut (212), washer (213) and bolt (225). Shock absorber should be held vertically in
Quad shocks (RPO Z75) have a spacer the vise with its bottom end up.
(246) between them (figure 39). Do not clamp the vise jaws on the shocks
reservoir tube.
BENCH TEST: SPIRAL GROOVE SHOCK 2. Pump the shock absorber at various rates of
ABSORBERS speed and observe the rebound force.
1. Purge the air from the pressure chamber.
Extend the shock verticallytop end up.
compression force (approximately two to one).
Turn the sh ock over and c o lla p se it
verticallytop end down. Rebound force should be smooth and constant
for each stroke rate.
2. Place the shock absorber in a vise with the jaws 3. Compare with a good shock absorber.
clamped onto the shocks bottom mount. 4. If one of the following are observed, replace the
Shock absorber should be positioned shock absorber.
vertically in the visetop end up. A skip or lag at reversal near mid-stroke.
Do not clamp the vise jaws on the shocks A seize (except at the extreme ends of
reservoir tube. travel).
3. Pump the shock absorber at various rates of
A noise (grunt or squeal) after completing
one full stroke in both directions.
compression force (approximately two to A clicking noise at fast reversal.
one).
Rebound force should be smooth and Install or Connect (Figures 37 and 38)
4. Compare with a good shock absorber.
5. If one of the following are observed, replace the NOTICE: For steps 1 and 2, refer to the
shock absorber. Notice on page 3C#7.
A skip or lag at reversal near mid-stroke.
A seize (except at the extreme ends of 1. Shock absorber (220) to the axle.
travel). Bolt (225), washer (213), and nut (212).
A noise (grunt or squeal) after completing Spacer (246) must be positioned between
one full stroke in both directions. the shock absorbers (220) on vehicles with
A clicking noise at fast reversal. quad shocks, RPO Z75 (figure 39).
$ Tighten J-23446 Torque Wrench Adapter

J-26878-A Wheel Bearing Nut Wrench
Nut (212) to 88 N m (65 ft. lbs.). (30/3500 Series)
Nut (212) to 120 N m (89 ft. lbs.) on quad Raise the vehicle and support it with suitable
shocks (RPO Z75). safety stands. Remove the tire and wheel
2. Shock absorber (220) to the frame. assembly.
Bolt (219), washer (213) and nut (212). 1. Caliper
$ Tighten 2. Locking hub (249).
Refer to FRONT AXLE (SEC. 4C).
Nut (212) to 88 N m (65 ft. lbs.). 3. Locking nut (250), ring (251) and adjusting nut
3. Lower the vehicle to the floor. (252).
Use J-6 8 93 -D and J-2 3 44 6 for
10/1500-20/2500 series vehicles.
STABILIZER BAR Use J-26878-A for 30/3500 series vehicles.
4. Hub/Rotor Assembly (257).
4-+ Remove or Disconnect (Figures 37, 38 and 40) Outer wheel bearing (253) will slide off the
spindle (265) ahed of the hub/rotor (257).
Raise the vehicle on a hoist.
Use a brass drift and hammer for the seal
1. Stabilizer bar (230) from the frame brackets (237).
(260) and races (254, 258).
Nuts (231), washers (232), brackets (233),
The inner bearing (259), race (258) are
and bolts (238) (figure 37).
behind the seal (260).
2. Stabilizer bar (230) from the spring plate (224).
Bolts (229), and washers (228).
Stabilizer bar is free of the vehicle. L* Inspect
Bushings (234) can be removed from the

1. Rotor braking surfaces for scoring, pitting, or
stabilizer bar.
cracks.
Repair or replace as necessary.
Install or Connect (Figures 37, 38 and 40)
2. Wheel bearings (253, 259) and races (254, 258).
Refer to Diagnosis of Wheel Bearings, in
1. Stabilizer bar (230) to the frame brackets (237).
this section.
Bushings (234) onto the stabilizer bar.
If either a bearing or its race is damaged or
Use rubber lubricant when installing the
worn, replace both.
b u sh in g s (s lit faces forw a rd ) on the
stabilizer bar.
Install or Connect (Figures 37, 38, and 41
Brackets (233), bolts (238), washers (232),
through 43)
and nuts (231) (figure 37). Do not tighten.
Tools Required:
this section.
J-6368 Bearing Race Installer (Outer)
J-23448 Bearing Race Installer (Inner)
2. Stabilizer bar (230) to the spring plate (224).
Washers (228) and bolts (229) (figure 40). J-6893-D W heel B earing Nut W rench
(10/1500-20/2500 series vehicles)
J-26878-A Wheel Bearing Nut Wrench
$ Tighten
(30/3500 series vehicles)
Nuts (231) to 70 N m (52 ft. lbs.). J-23446 Torque Wrench Adapter
Bolts (229) to 180 N m (133 ft. lbs.). 1. Races (254, 258) into the rotor/hub (257).
3. Lower the vehicle to the ground. Use J-8092 and J-6368 for installation of the
outer bearing outer race (254).
Use J-8092 and J-23448 for installation of
WHEEL HUB/ROTOR ASSEMBLY the inner bearing outer race (258).
Do not damage the hub/rotor during the
Remove or Disconnect (Figures 37, 38, and 41 race installations.
through 43)
Clean
Tools Required:
J-6893-D W heel Bearing Nut W rench Grease from the rotor/hub (257) and spindle
(10/1500-20/2500 Series) (265).
248 223
209
210
211
208 214 215 216
203
217
218
246
B-07494
Figure 37K Series (4 x 4) Front Suspension

201. Bolt 216. Spacer 231. Nut 247. Bracket

202. Shackle 217. Washer 232. Washer 248. Bolt
203. Bushing 218. Nut 233. Bracket A. K3500 Series
204. Nut 219. Bolt 234. Bushing Right Side
205. Washer 220. Shock Absorber 235. Rivet B. Quad Shock
206. Bracket 221. Leaf Spring 236. Rivet RPO Z75
207. Bumper 222. Nut 237. Bracket
208. Rivet 223. Washer 238. Bolt
209. Nut 224. Plate 239. Nut
210. Bracket 225. Bolt 240. Washer
211. Bumper 226. Spacer 241. Hanger
212. Nut 227. Bolt 242. Bolt
213. Washer 228. Washer 243. Reinforcement
214. Hanger 229. Bolt 245. Bracket
215. Rivet 230. Stabilizer Shaft 246. Spacer
B-07495
Figure 38K Series (4 x 4) Front Suspension
A. K Series Standard Shock Absorber Mounting

B. K Series RPO Z75 Quad Shock Absorber Mounting
212. Nut
213. Washer
219. Bolt
220. Shock Absorber
225. Bolt
246. Spacer
B-07493
Figure 39Shock Absorber Attachments

Figure 40Stabilizer Bar Attachm ents
Grease from the wheel bearings (253, 259). 4. F ill the w heel b e a rin g (cone and ro lle r
Use clean solvent and a small brush (no loose assemblies) full of grease.
bristles). Use a cone-type grease packer that forces
Do not spin the wheel bearings with compressed grease into the bearing.
air to dry themthe wheel bearings may be If a cone-type grease packer is not available,
damaged. pack the wheel bearings by hand.
If packing the wheel bearings by hand, work
Im portant
the grease into the bearings between the
rollers, cones, and the cage.
Use an approved high-temperature front wheel
bearing grease. Refer to MAINTENANCE AND
LUBRICATION (SEC. OB). NOTICE: Failure to completely pack the wheel
Do not mix greases as mixing may change the bearings (cones, rollers, and cage) with
g re a s e s p ro p e rtie s re s u ltin g in poor grease will result in premature wheel bearing
performance. damage and/or wear.
2. Apply a thin film of grease to the spindle at the
outer wheel bearing seat and at the inner wheel 5. Inner wheel bearing (259) into the rotor/hub (257).
bearing seat, shoulder, and seal seat. Put an a d d itio n a l q u a n tity of grease
3. Put a small quantity of grease inboard of each outboard of this wheel bearing.
wheel bearing cup, inside the rotor/hub (257). 6. New seal (260).
Use a flat plate to install the seal so it is The hole in the ring must align with the pin
flush with the rotor/hub flange. on the lock nut (250). Move the adjustment
Lubricate the seal lip with a thin layer of nut (252) to align the pin.
grease.
7. Rotor/hub (257). Use J-6893-D or J-26878-A and J-23446.
Do not damage the spindle threads.
8. Outer wheel bearing (253).
Press on the spindle until the wheel bearing & Tighten
fully seats against the rotor/hub outer race.
9. Adjusting nut (252). Lock nut (250) to 217 N m (160 ft. lbs.)
10. Adjust the wheel bearing. minimum.
Refer to Wheel Bearing Adjustment, in
12. Locking hub (249).
this section.
of this section. 13. Caliper.
11. Ring (251) and locking nut (250). Refer to BRAKES (SEC. 5).
Tang on the inside diameter of the ring must
pass onto the slot on the spindle (265). 14. Wheel and tire. Lower the vehicle to the ground.
249
B-07550
Figure 42K30/3500 Series Knuckle, Wheel Hub/Rotor Assembly

249. Locking Hub Assembly 263. Plate 276. Bolt 289. Gasket
250. Locking Nut 264. Bracket 278. Bolt 290. Steering Arm
251. Ring 265. Spindle 279. King Pin 291. Nut
252. Adjusting Nut 266. Shaft Bearing 280. Seal 292. Nut
253. Outer Wheel Bearing 267. Bearing Seal 281. Retainer 293. Lower Ball Joint
254. Outer Race 268. Spacer 282. Race 294. Upper Ball Joint
255. Wheel Hub Nut 269. Seal 283. Bearing 295. Nut
257. Rotor/Hub 270. Oil Deflector 284. Seal 296. Adapter
258. Inner Race 271. Bolt 285. Bearing Cap 297. Steering Arm
259. Inner Wheel Bearing 272. Washer and King Pin 298. Cotter Pin
260. Seal 273. Cap 286. Bolt 299. Nut
261. Nut 274. Steering Knuckle 287. Bushing 300. Adjusting Ring
262. Washer 275. Nut 288. Spring 301. Retainer
B-07464
Figure 43K Series Knuckle, Wheel Hub/Rotor Assembly
BEARING ADJUSTMENT For Manual hubs, back off enough to free

the bearing.
Im portant 4. Ring (251) and lock nut (252).
Tang on the inside diameter of the ring must
The proper functioning of the front suspension pass onto the slot on the spindle (265).
cannot be maintained unless the front wheel The hole in the ring must align with the pin
bearings are correctly adjusted. The cones must on the lock nut (250). Move the adjustment
be a slip fit on the spindle and the inside diameter nut (252) to align the pin.
of the cones must be lubricated to insure the
cones will creep. The adjusting nut must have a Tighten
free-running fit on the spindle threads.
Lock nut (250) to 217 N m (160 ft. lbs.)
minimum.
Adjust
% Measure
Raise the vehicle and support it with safety
stands.
Endplay in the hub/rotor assembly. It should be
1. Remove the locking hub assembly (249), lock nut set between 0.025 to 0.254 mm (0.001 to
(250), and the ring (251). 0.010-inch).
5. Locking hub assembly (249).
a Tighten Refer to FRONT AXLE (SEC. 4C).
6. Lower the vehicle to the ground.
Adjusting nut (252) to 60 N m (50 ft.
lbs.) while rotating the hub/rotor in
order to seat the bearings. WHEEL HUB BOLT
2. Back off the adjusting nut (252) and retighten.
+ + Remove or Disconnect (Figures 37, 38, and
44)
$ Tighten
Tools Required:
For Automatic Hubs, torque the adjusting
nut to 47 N m (35 ft. lbs.) while rotating the
1. Hub/rotor assembly from the vehicle.
wheel.
For Manual Hubs, torque the adjusting nut this section.
to 60 N m (50 ft. lbs.) while rotating the
2. Wheel hub bolts (255) with a press.
wheel.
Support the hub/rotor using J-9746-02 to
3. Back off the adjusting nut (252). prevent damage to the rotor face (figure 44).
For Automatic hubs, back off 3/e of a turn Do not damage the wheel mounting surface
maximum. on the hub/rotor flange.
J-9746
265. Spindle
274. Steering Knuckle
B-07502
Figure 46Removing The Spindle
Tighten the nut until the bolt fully seats into

the hub/rotor.
2. Hub/rotor to the vehicle.
A. Press Bars Refer to Wheel Hub/Rotor Assembly, in
F-00036 this section.
3. Wheel and tire assembly. Lower the vehicle.
Figure 44Pressing The Hub Bolt Out
SPINDLE
Install or Connect (Figures 37, 38, and 45)
Remove or Disconnect (Figures 37, 38, 46 and
Tools Required: 47)
NOTICE: Refer to Notice on page 3C#1 of safety stands. Remove the tire and wheel
this section. assembly.
1. Wheel hub/rotor assembly.
1. New, serrated bolt (255) into the hole in the Refer to Wheel Hub/Rotor Assembly, in
hub/rotor. this section.
Place four washers onto the bolt, then 2. Spindle (265) from the steering knuckle (274).
fasten a nut onto the bolt until the nut N uts (261) and p la te (263) for
bottoms on the washers (figure 45). K10/1500-20/2500 series vehicles.
Nuts (261), washers (262), plate (263) and
the bracket (264) for K30/3500 series
vehicles.
Tap the end of the spindle with a plastic or
rubber mallet to break it loose from the
steering knuckle (274) (figure 46).
NOTICE: The machined surface of the spindle

must not be damaged by vise jaws.
A. Washers 3. Spindle components.

B. Nut Secure the spindle in a vise by locating on
81. Hub/Rotor the high step diameter.
Bearing seal (267) and shaft bearing (266)
Figure 45Installing The Wheel Hub Bolts (figure 47).
Figure 47Spindle Components
Spacer (268), seal (269), and oil deflector Seal (269) onto the oil deflector (270) with
(270) from the axle shaft (figure 47). the deflector lip toward the spindle (265).
Inspect 3. Spacer (268) onto the axle shaft.
The chamfer points toward the oil deflector

Spacer (268). Replace if it is worn.
(270) (figure 48).
Spindle (265) for any heat burns, scoring, or wear.
Replace if necessary. 4. Spindle (265) onto the steering knuckle (274).
+- Install or Connect (Figures 37, 38, 47 and 48)
Tools Required:
J-2 3 4 4 5 -A N eedle B e a rin g In s ta lle r
(K10/1500-20/2500 series)
J-21465-17 Bearing Installer (K30/3500
series)
Relubricate the shaft bearing (266) and the
spindle (265) with a high melting point type wheel
bearing grease. Refer to MAINTENANCE AND
LUBRICATION (SEC. 0B). A. Chamfer Toward
1. Shaft bearing (266) and bearing seal (267) into The Seal
the spindle (265) (figure 47). 265. Spindle
268. Spacer
For K10/1500-20/2500 series vehicles, use
J-8092 and J-23445-A. 269. Seal 269
270. Oil Deflector B-07454
For K30/3500 series vehicles, use J-8092
and J-21465-17.
2. Oil deflector (270) and seal (269) onto the axle Figure 48Installing The Spindle
shaft. Onto The Axle Shaft
4. Tie rod from the steering arm (297).

5. Steering arm (297) from the steering knuckle
(274).
Nuts (295) and adapters (296).
Discard the nuts (295).
NOTICE: Do not remove the adjusting ring

(300) unless new ball joints are being
installed. If it is necessary to loosen the ring to
remove the knuckle, do not loosen it more
than two threads. Use J-23447 (figure 49). The
nonhardened threads in the yoke can be easily
damaged by the hardened threads in the
adjusting ring if caution is not used during
knuckle removal.
6. Steering knuckle (274) from the axle yoke.

Slide the spindle over the axle shaft until it Cotter pin (298), nuts (292, 299).
seats on the steering knuckle. The bolts Insert a wedge-shaped tool between the
(278) must protrude through the spindle. lower ball joint (293) and the yoke. Tap on
the tool to release the knuckle assembly.
NOTICE: Refer to Notice on page 3C#1 of Insert the wedge-shaped tool between the
this section. upper ball joint (294) and the yoke. Tap on
the tool to release the knuckle assembly.
5. Bracket (264) and plate (263).
Only the K30/3500 series vehicles use a
-- Install or Connect (Figure 37, 38 and 49)
bracket (264).
Washers (262) (K30/3500 series only) and
Tools Required:
NEW nuts (261).
J-23447 Ball Stud Nut Wrench
$ Tighten
NOTICE: For steps 2, 3, 4, 6 and 7, refer to
Nuts (261) to 88 N m (65 ft. lbs.). Notice on page 3C#1 of this section.
Refer to Wheel Hub/Rotor Assembly, in 1. Steering knuckle (274) to the axle yoke.
this section. Ball joints (293, 294) into their respective
7. Wheel and tire. Lower the vehicle to the ground. sockets in the axle yoke.
Finger tighten the nuts (292, 299) onto the
ball joints (293, 294). The nut with the cotter
STEERING KNUCKLE AND ARM pin slot goes with the upper ball joint.
K10/1500-20/2500 SERIES VEHICLES 2. Push up on the steering knuckle [to keep the ball
(WITH BALL JOINTS) joint (293) from turning in the knuckle] and
partially torque the lower ball joint nut (292).
|+ + | Remove or Disconnect (Figures 37, 38, and
49) a Tighten
Raise the vehicle and support with suitable safety Nut (292) to 40 N m (30 ft. lbs.).
stands. Remove the tire and wheel assembly. 3. Torque the adjusting ring (300).
1. Locking hub assembly (249).
Use J-23447 (figure 46).
Refer to Wheel Hub/Rotor Assembly, in Tighten
this section.
3. Spindle (265) from the steering knuckle (274). Adjusting ring (300) to 70 N m (50 ft. lbs.).
Refer to Spindle, in this section. 4. Torque the upper ball joint nut (299).
1^1Tighten
Nut (299) to 135 N-m (100 ft. lbs.).
5. Cotter pin (298) into the nut (299).
Do not loosen the nut. Apply additional
torque, if necessary, to line up the hole in
the ball joint with the slot in the nut.
6 . Apply the final torque to the lower ball joint nut
(292).
$ Tighten
Nut (292) to 95 N-m (70 ft. lbs.).

Steering arm (297) to the steering knuckle (274).
Adapters (296) and NEW nuts (295).
Tighten
Figure 50Removing The Cap
Nuts (295) to 120 N-m (90 ft. lbs.). And Steering Arm Fasteners
8. Tie rod to the steering arm (297).
Refer to STEERING LINKAGE (SEC. 3B1). For the steering arm, remove the nuts (291)
9. Spindle (265) to the steering knuckle (274). alternately as the compression spring will
Refer to Spindle, in this section. force the steering arm up (figure 50).
10. Wheel hub/rotor assembly. 5. Gasket (289), and compression spring (288).
Refer to Wheel Hub/Rotor Assembly, in Discard the old gasket (289).
this section. 6. Lower bearing cap and king pin (285).
11. Adjust the wheel bearings. Bolts (271) and washers (272) (figure 51).
Refer to Wheel Bearing Adjustment, in 7. Upper king pin bushing (287).
this section. Pull it out through the steering knuckle
12. Locking hub assembly (249). (274).
Refer to FRONT AXLE (SEC. 4C). 8. Steering knuckle (274) from the axle yoke.
13. Wheel and tire assembly. Seal (301).
14. Check the front end alignment. 9. Upper king pin (279) from the axle yoke.
Refer to FRONT END ALIGNMENT (SEC. Use a large breaker bar and J-26871 (figure
3A). 49).
15. Lower the vehicle to the ground. Apply 677-813 N-m (500-600 ft. lbs.) of
torque to break the king pin free.
K30/3500 SERIES VEHICLES (WITH KING PINS)
Remove or Disconnect (Figures 37, 38, and 50

through 53)
Tools Required:
J-26871 King Pin Socket
Raise the vehicle and support with suitable safety
stands. Remove the tire and wheel assembly.
1. Locking hub (249).
this section.
3. Spindle (265).
274. Steering Knuckle
Refer to Spindle, in this section.
285. Bearing Cap and King Pin B-07453
4. Upper cap (273) and/or steering arm (290).
For the cap, remove the bolts (271) and
w a sh ers (272) a lte rn a te ly as the Figure 51Removing The Lower Bearing
compression spring will force the cap up. Cap And King Pin
Figure 52Removing The Upper King Pin Figure 54Installing The Retainer Into The Axle
Yoke
10. Retainer (281), race (282), bearing (283) and the
seal (284) from the axle yoke. NOTICE: For steps 4, 6, 7, refer to Notice on
page 3C#7 of this section.
Punch all the components out at once
(figure 53).
1. Retainer (281) and the race (282).
Discard the old seal (284).
Use a new retainer.
If the retainer (281) is damaged, discard it.
Use J-7817 (figure 54).
Install or co nn e ct (Figures 38, 39 and 54 2. Fill the area in the retainer (281) and race with an
through 56) approved high temperature bearing lubricant.
Grease the bearing (282).
Tools Required:
Use a cone-type grease packer that forces
J-7817 Front Pinion Bearing Installer grease into the bearing.
J-22301 King Pin Bearing Seal Installer If a cone-type grease packer is not available,
J-28871 King Pin Installer pack the bearing by hand. Work the grease
between the rollers, cones, and cage.
A. Axle Yoke
B-07458
Figure 53Removing The Retainer, Race,

Bearing and Seal
Figure 56Installing The Upper King Pin
NOTICE: Failure to com pletely pack the Q Tighten

bearing (cones, rollers, and cage) with grease
will result in premature bearing damage Nuts (291) alternately and evenly to 108 N m
and/or wear. (80 ft. lbs.).
8. Spindle (265).
R efer to M A IN TE N A N C E AND Refer to Spindle, in this section.
LUBRICATION (SEC. OB). 9. Wheel hub/rotor assembly.
3. Bearing (283) and seal (284). Refer to Wheel Hub/Rotor Assembly, in
Use J-22301 to install the NEW seal (Figure this section.
55). 10. Adjust the wheel bearings.
Do not distort the seal. It will protrude Refer to Wheel Bearing Adjustment in
slightly from the surface of the axle yoke this section.
flange when fully seated. 11. Locking hub (249).
4. Upper king pin (279). Refer to FRONT AXLE (SEC. 4C).
Use J-28871 (figure 56). 12. Wheel and tire assembly.
Tighten Refer to FRONT END ALIGNMENT (SEC.
3A).
King pin (279) to 745 N m (550 ft. lbs.). 14. Lower the vehicle to the ground.
5. Steering knuckle (274) and bushing (287).
Felt seal (280) to the king pin (279) through
the steering knuckle. BALL JOINTS (10/1500-20/2500
Knuckle onto the king pin (279). SERIES VEHICLES ONLY)
Place the bushing (287) over the king pin
(279). Remove or Disconnect (Figures 37, 38, 57 and
6. Bearing cap and king pin (285) to the steering 58)
knuckle (278).
4 bolts (271) and washers (272). Tools Required:
J-9519-10 Ball Joint Fixture
Tighten J-23454-1 Lower Ball Joint Spacer
$
J-23454-3 or
Bolts (271) alternately and evenly to 108 N m J-6382 Upper Ball Joint Spacer
(80 ft. lbs.). J-23454-4 Upper and Lower Ball Joint
7. Steering arm (290) to the steering knuckle (274). Sleeve
Compression ring (288), gasket (289), and Raise the vehicle and support with suitable safety
steering arm (290). stands. Remove the wheel and tire assembly.
Nuts (291). 1. Wheel hub/rotor assembly.
274 J-23454-1 J-6382-3 OR

J-6382-3 OR J-23454-3
23454-3
293
J-9519-10
J-9519-10
A. Flat Washer 274. Steering Knuckle
274. Steering Knuckle B-07509 293. Lower Ball Joint B-07510
Figure 58Removing The Upper Ball Joint Figure 59Installing The Lower Ball Joint
Refer to Wheel Hub/Rotor Assembly, in 2. Upper ball joint (294) into the steering knuckle
this section. (274).
2. Spindle. Use J-9519-10, J-23454-2, and J-23454-3 or
Refer to Spindle, in this section. J-6382-3 (figure 60). Tighten until the ball
3. Steering knuckle (274) and steering arm (290). joint fully seats.
Remove the steering arm (290) only if 3. Steering arm (290) and steering knuckle (274).
removing the left axle yoke ball joints. Steering arm only if removed.
Refer to Steering Knuckle and Arm, in Refer to Steering Knuckle and Arm, in
this section. this section.
Place the steering knuckle in a vise (figure 4. Spindle (265).
57). Refer to Spindle, in this section.
4. Lower ball joint (293). 5. Wheel hub/rotor assembly.
Must be removed before any service can be Refer to Wheel Hub/Rotor Assembly, in
done to the upper ball joint (294). this section.
Snap ring from the lower ball joint (293). 6. Adjust the wheel bearings.
Use J-9519-10, J-23454-1, J-23454-4 or Refer to Wheel Bearing Adjustment, in
equivalent (figuer 57). Tighten until the ball this section.
joint breaks free of the steering knuckle. 7. Wheel and tire assembly.
5. Upper ball joint (294). 8. Check the front end alignment.
Use J-9519-10, J-23454-3 (or J-6382-3) and
J-23454-4 (figure 58). Tighten until the ball
joint breaks free of the steering knuckle. 274 294 J-23454-2
Install or Connect (Figures 37, 38, 59 and 60)
Tools Required: I
J-23454-2 Upper and Lower Ball Joint
Sleeve
J-23454-3 or
J-6382-3 Upper and Lower Ball Joint Spacer
1. Lower ball joint (293) into the steering knuckle J-9519-10
(274).
The ball joint (no cotter pin hole in the J-6382 274. Steering Knuckle
threaded end) must be positioned straight. OR 294. Upper Ball Joint
Use J-9519-10, J-23454-2, and J-23454-3 or J-23454-3
J-6382-3 (figure 59). Tighten until the ball B-07508
joint fully seats.
Snap ring in position. Figure 60Installing The Upper Ball Joint
201. Bolt
202. Shackle 218
203. Bushing
204. Nut
205. Washer
207. Bumper
216. Spacer 217
217. Washer 218
218. Nut
221. Leaf Spring
B-07460
Figure 61Leaf Spring Components
Refer to FRONT END ALIGNMENT (SEC. 4. Shackle (202) from the spring (221).
4C). Nut (218), washer (217), bolt (201), bushings
9. Lower the vehicle to the ground. (203) and spacer (216) (figure 61).
5. Bushing from the spring eye.
Place the spring in a press and press out
LEAF SPRING AND BUSHING the bushing using a suitable rod, pipe, or
tool.
Remove or Disconnect (Figures 37, 38, and
61) Install or Connect (Figures 37, 38, 61 and 62)
Raise the vehicle on a hoist and support the front 1. Bushing into the spring eye.
axle with a floor jack. Raise the floor jack until all
Press in a new bushing, making sure the
tension is relieved from the springs.
tool presses on the steel outer shell of the
1. Spring (221) from the frame.
bushing.
Nut (218), washer (217), shackle (202), bolt
Bushing must protrude an equal amount on
(201), bushings (203) and spacer (216)
either side of the spring eye when properly
(figure 61).
installed.
2. Spring (221) from the hanger (241).
2. Shackle (202) into the spring (221).
Nut (239), washers (240), and bolt (242)
Spacer (216), bushings (203), washers (217),
(figure 61).
bolt (201) and nut (218).
3. Spring (221) from the axle.
Do not tighten.
For K10/1500-20/2500 and the left side of
3. Upper spacer (226) onto the spring (221).
K30/3500 series vehicles, remove nuts
(222), washers (223), U-bolts (227), plate 4. Spring into the hanger (241).
(224) and the spacers (226). Bolt (242), washers (240) and nut (239).
For the right side of K30/3500 series Do not tighten.
vehicles, remove the bolts (248), nuts (222), 5. Spring into the frame.
washers (223), U-bolt (227), plate (224) and Bushings (203) and the spacer (216) into the
the spacers (226) (figure 61). frame.
Shackle (202) into position and attach bolt For the right side of K30/3500 series
(201), washer (217) and nut (218). vehicles, attach the lower spacer (226),
Do not tighten. plate (224), U-bolt (227), washers (223),
bolts (248) and nuts (222) (figure 61).
of this section. Tighten
6. Spring to the axle. Nuts (222) and bolts (248) in sequence

For K10/1500-20/2500 series vehicles and (2-4-1-3) to 203 N m (150 ft. lbs.) (figure 62).
the left side of K30/3500 series vehicles, 6. Torque the spring to frame and hanger fasteners.
attach the lower spacer (226), plate (224), Nuts (239) to 122 N m (90 ft. lbs.).
U-bolts (227), washers (223) and nuts (222) Nuts (218) to 68 N m (50 ft. lbs.).
(figure 61). 7. Lower the floor jack, and lower the vehicle to the
ground.
SPECIFICATIONS
FRONT SUSPENSION BOLT TORQUEN-m (FT. LBS.)
P30
C10 K10 G10 C20 K20 G20 P20 C30 K30 G30 P30 W/FS3
Shock Absorber
To Frame 190 (140) 88 (65) 103 (80) 190 (140) 88 (65) 103 (80) 190 (140) 190 (140) 88 (65) 103 (80) 190 (140) 185 (136)
Shock A bsorber To
Lower Control Arm 80 (59) ___
103 (80) 80 (59) ___
103 (80) 80 (59) 80 (59) ___ 103 (80) 80 (59)
Shock A bsorber
to Axle 88 (65) ___ ___
88 (65) ___ ___ ___ 88 (65) 50 (37)
Stabilizer
To Frame 33 (24) 95 (70) 29 (21) 33 (24) 95 (70) 29 (21) 33 (24) 33 (24) 70 (52) 29 (21) 33 (24) 29 (21)
Stabilizer To
Low er Control Arm 33 (24) ___
33 (24) 33 (24) ___ 33 (24) 33 (24) 33 (24) 33 (24) 33 (24)
Stabilizer To
Stabilizer Link ___ ___ ___ ___ ___ ___ ___ 68 (50)
Stabilizer To
Spring Plate 180 (133) ___ ___
180 (133) ___ ___ 180 (133)
* *
Steering Knuckle To
Upper Ball Joint 68 (50) 135 (100) 68 (50) 122 (90) 135 (100) 68 (50) 122 (90) 122 (90) 122 (90) 122 (90)
* *
Steering Knuckle To
Low er Ball Joint 122 (90) 40 (30) 122 (90) 122 (90) 40 (30) 122 (90) 122 (90) 122 (90) 122 (90) 122 (90)
Splash Shield
To Knuckle 13 (10) 13 (10) 13 (10) ___
13 (10) 13 (10) 13 (10) _ 13 (10) 13 (10)
Splash Shield to
Anchor Plate _ ___ ___ ___ ___ ___ _ 16 (12)
Anchor Plate
To Knuckle 88 (65) ___ ___
88 (65) ___ ___ ___
88 (65) _ _
Steering Arm \
To Knuckle 120 (90) ___
120 (90) ___ ___ ___
120 (90) 312 (230)
Caps To The
Steering Knuckle ___ ___ ___ ___ ___ ___ ___
108 (80) 7 (5 )
Lock Pin To
Steering Knuckle 217 (160) ___ ___
217 (160) ___ ___ ___ 217 (160) 40 (29)
King Pin
To Knuckle _ ___ ___ ___ ___ ___ ___ 745 (550)
A djusting Ring
To Spindle 70 (50) ___ ___
70 (50) ___ ___ ___ ___
Low er Control
Arm Bushings _ ___
379 (280) ___ ___
379 (280) 379 (280) ___ 379 (280) 379 (280) ___
Low er Pivot Shaft

End Nuts 95 (70) _ 156 (115) ___ ___
156 (115) ___ ___ ___
Low er Pivot Shaft

U-Bolt Nuts 115 (85) _ 88 (65) 115 (85) ___
88 (65) 115 (85) 115 (85) ___
115 (85) 115 (85)
Upper Control
Arm Bushings _ _ ___
257 (190) ___
257 (190) 257 (190) ___ 258 (190) 257 (190)
Upper Pivot
Shaft End Nuts 156 (115) _ 156 (115) ___ ___
156 (115) ___ ___ ___ __
Upper Pivot Shaft

Thru Bolt Nuts 95 (70) 95 (76) 142 (105) _ 95 (70) 142 (105) 142 (105) ___
142 (105) 142 (105) ___
Upper Bolt Joint

To Upper Control Arm 25 (18) _ 25 (18) 25 (18) ___
25 (18) 25 (18) 25 (18) ___
25 (18) 25 (18)
Crossm em ber To
B ottom Frame R ail0 122 (90) ' 122 (90) 122 (90) 122 (90) 122 (90) 122 (90) 122 (90) 122 (90)
FRONT SUSPENSION BOLT TORQUEN-m (FT. LBS.)
P30
C10 K10 G10 C20 K20 G20 P20 C30 K30 G30 P30 W/FS3
Crossmember To
Side Frame Rail00 88 (65) _ 88 (65) 88 (65) _ 88 (65) 88 (65) 88 (65) _ 88 (65) 88 (65)
Spring To
Hanger Nuts 122 (90) _ _ 122 (90) _ _ _ 122 (90) _ _ 125 (92)
Spring To
Shackle Nuts _ 68 (50) _ _ 68 (50) _ _ _ 68 (50) 125 (92)
Spring To Axle
U-Bolt Nuts _ 203 (150) _ _ 203 (150) _ _ _ 203 (150) _ 109 (80)
Shackle To
Frame Nuts _ 68 (50) 68 (50) 68 (50) 125 (92)
Suspension Bum per 20 (15) 20 (15) 20 (15) 26 (19) 20 (15) 20 (15) 26 (19) 26 (19) 20 (15) 20 (15) 26 (19) 34 (25)
Crossm em ber To
Brake S upport Struts 81 (60) 81 (60) 81 (60) 81 (60) 81 (60) 81 (60) 81 (60) 81 (60) _
P30 (32) 291 N-m (215 ft. lbs.); P30 (42) and J F 9 -1 7 6 N-m (130 ft. lbs.).
o o P30 (32), P30 (42) and J F 9 -1 3 5 N-m (100 ft. lbs.).
Plus additional torque to align cotter pin. Not to exceed 122 N-m (90 ft. lbs.) m axim um .
Plus additional torque to align co tte r pin. Not to exceed 176 N-m (130 ft. lbs.), m axim um .
Plus additional torque to align cotter pin.
ENDPLAY SPECIFICATIONS
C-G-P Series 0 .0 3 -0 .1 3 m m (0 0 0 1 2 - 0 00 5 inches)
K series 0 .0 2 5 -0 25 m m (0 .0 0 1 - 0 .0 1 0 inches)
P 30 w /FS 3 0 .0 1 3 -0 .2 0 m m (0 .0 0 0 5 -0 .0 0 8 )
SPECIAL TOOLS
Tool Number Tool Name

J-29040 Outer Bearing Race Installer
J-6893-D Wheel Bearing Nut Wrench (K10/1500-20/2500)
J-26878-A Wheel Bearing Nut Wrench (K30/3500)
J-23446 Torque Wrench Adapter
J-6368 Outer Bearing Race Installer
J-23448 Inner Bearing Race Installer
J-24435-A Needle Bearing Installer (K10/1500-20/2500)
J-21465-17 Bearing Installer (K30/3500)
J-23454-1 Lower Ball Joint Separator
J-23454-2 Upper And Lower Ball Joint Sleeve
J-23454-3 or J-6382-3 Upper And Lower Ball Joint Spacer
J-23028-02 Spring Remover
J-6627-A Wheel Stud And Tie Rod Remover
J-23447 Ball Stud Nut Wrench
J-7817 Front Pinion Bearing Installer
J-22301 King Pin Bearing Seal Installer
J-28871 King Pin Installer
J-22717 Lower Control Arm Bushing Stake Remover
J-24435-1 Upper And Lower Control Arm Bushing Remover
J-24435-2 Upper And Lower Control Arm Bushing Spacer
J-24435-3 Upper And Lower Control Arm Bushing Remover
J-24435-4 Upper And Lower Control Arm Bushing Installer
J-24435-5 Upper Control Arm Bushing Installer
J-24435-6 Upper And Lower Control Arm Bushing Spacer
J-24435-7 Upper And Lower Control Arm Bushing Fixture
3D-1
SECTION 3D
REAR SUSPENSION
the manual as indicated at appropriate locations by the terminology Notice: Refer to the Notice on page 3D-1 of
this section.
NOTICE: These rear suspension fasteners are important attaching parts in that they could affect the perform
CONTENTS
S U B JE C T PAGE
General D e scrip tio n ................................................................................................................................................... 3D- 1

On Vehicle S e r v ic e ................................................................................................. ................................................. 3D- 8
Shock A b s o rb e rs ................................................................................................................................................... 3D- 8
Stabilizer Bar............................................................................................................................................................3D- 8
Leaf Spring A s s e m b ly .......................................................................................................................................... 3D-10
Bushing R e p la ce m e n t.......................................................................................................................................... 3D-10
S pecifications..............................................................................................................................................................3D -12
GENERAL DESCRIPTION
All 10/1500 through 30/3500 series vehicles use a tached to the frame by the use of shackles which allow
leaf spring and solid rear axle suspension system (fig the springs to change their length while the vehicle
ures 1 through 7). is in motion.
The rear axle assembly is attached to multi-leaf Ride control is provided by two identical direct dou
springs by U-bolts. The front ends of the springs are ble acting shock absorbers angle-mounted between
attached to the frame at the front hangers, through rub the frame and brackets attached to the axle tubes.
ber bushings. The rear ends of the springs are at
3D-2 REAR SUSPENSION
Figure 1Rear Suspension (C-K 10/1500, 20/2500 Pickup, Suburban, And Blazer/Jimmy)
REAR SUSPENSION 3D-3
Figure 2Rear Suspension (C-K 30/3500 Series Vehicles)

Figure 3Rear Suspension (G 10/1500-30/3500 Series Vehicles)

Figure 4Rear Suspension (G30/3500 Series Cutaway Van With RPO M40)
B-07519
Figure 5Rear Suspension (P20/2500 Series Vehicles)

1. Bracket 12. Spring Lock Washer 23. Bracket 32. Optional Rear
2. Bolt 13. Rear Shock Absorber 24. Cushion Auxiliary Spring
3. Washer 14. Bolt 25. Rear Hanger 33. Bolt
4. Rear Hanger 15. Spring Lock Washer Reinforcement 34. Washer
5. Nut 16. Nut 26. Leaf Spring Eye 35. Nut
6. Rear Shackle 17. Front Hanger Support Bushing 36. Stabilizer Bar
7. Anchor Plate 18. Front Hanger 27. Bolt Anchor
8. U-bolt 19. Axle Bumper 28. Nut 37. Spacer
9. Shim 20. Bumper Bracket 29. Nut 38. Bolt
10. Leaf Spring 21. Washer 30. Bolt 39. Spring Clip
11. Nut 22. Nut 31. Spacer B-07521
Figure 7Rear Suspension Legend

ON-VEHICLE SERVICE
SHOCK ABSORBERS
" Remove or Disconnect (Figures 1 through 7)
Raise the vehicle on a hoist and support the rear

axle independently of the rest of the vehicle.
1. Shock absorber (13) from the frame.
For C-K and P series vehicles; nut (16),

spring-washer (15), and/or washer (21).
For G series vehicles; nut (16), spring

washer (15), washer (3), and bolt (38).
2. Shock absorber (13) from the axle.

Nut (11), spring-washer (12), and bolt (14).
Pull the shock absorber free.
|+ + | Install or Connect (Figures 1 through 7)

Notice on page 3D-1 of this section.
1. Shock absorber (13) to the frame.
For C-K and P s e rie s v e h ic le s ;

spring-washer (15) and/or washer (21), plus
the nut (16).
For G series vehicles; bolt (38), washer (3),

spring-washer (15), and nut (16).
Tighten
Figure 8Rear Stabilizer Attachm ents
Nuts (16) to Specifications at the end of (C30/3500 Series Vehicles)
this section.
2. Shock absorber (13) to the axle. STABILIZER BAR

Line shock absorber up with the axle
bracket.
B" i i Remove or Disconnect (Figures 8, 9, and 10)
Bolt (14), spring-washer (12), and nut (11).
Raise the vehicle on a hoist. Support the rear
axle independently of the rest of the vehicle.
Tighten 1. Stabilizer bar (108) from the frame.
For C 30/3500 series vehicles; nut (120),
For all C-K and P series vehicles; nut (11) to and washer (116). Slide the link bolt (115) out
155 N-m (114 ft. lbs.). along with the grommets (117), washers
(116), and spacer (114).
For all G series vehicles; nut (11) to 102 N-m
(75 ft. lbs.). For P 30/3500 (32) series vehicles; nuts
(105), washers (106), bolts (111), and the
3. Lower the vehicle to the ground. clamp (110).
B-07523
Figure 9Rear Stabilizer Attachm ents (P(32) Series)
2. Stabilizer bar (108) from tê anchor plates (107). Install or Connect (Figures 8, 9 and 10)
Nuts (105), washers (106), bolts (111), and
the clamps (110).
3. Insulators (109) from the stabilizer bar (108). Notice on page 3D-1 of this section.
101. U-bolt 1. Insulators (109) to the stabilizer bar (108).

112. Nut
102. Spacer 113. 2. Stabilizer bar (108) to the anchor plates (107).
Washer
103. Spring Spacer 114. Spacer Clamps (110), bolts (111), washers (106), and
104. Anchor Plate 115. Bolt nuts (105).
105. Nut 116. Washer
106. Spring Lock Washer 117. Grommet Tighten
107. Stabilizer Bar Anchor 118. Link
108. Stabilizer Bar 119. Retainer Refer to Specifications at the end of this
109. Bushing 120. Nut section.
110. Bracket 121. Bracket
111. Bolt Important
B-07524
Route the parking brake cable over the stabilizer
Figure 10Rear Stabilizer Attachments Legend bar.
3. Stabilizer bar (108) to the frame. Tighten

For the C 30/3500 series vehicles; position
the link bolt (115), washers (116), grommets Nuts (22), in a diagonal sequence 1-3-2-4
(117), spacer (114), retainer (119) and nut (figure 11), initially to 25 N m (18 ft. lbs.).
(120). Then final torque in a diagonal sequence
For the P 30/3500 (32) series vehicles; 1-3-2-4 (figure 11) to the Specifications at
attach the clamp (110), bolts (111), washers the end of this section.
(106), and nuts (105) in position. 2. Shackle (6) to the leaf spring (10).
Bolt (2), washers (3), and nuts (5), making
Tighten sure the bolt is positioned correctly (figures
1 through 7).
Nuts (120 and 105) to the Specifications Do not tighten.
at the end of this section. 3. Leaf spring to the front hanger (18).
4. Lower the vehicle to the ground. Bolt (2), washers (3), and nut (5).
Do not tighten.
4. Leaf spring to the rear hanger (25).
LEAF SPRING ASSEMBLY Bolt (2), washers (3), and nut (5).

Nuts (5) and bolts (2), to the Specifications at
Raise the vehicle on a hoist and support the rear the end of this section.
axle independently to relieve tension on the leaf 5. Stabilizer bar to the vehicle if equipped.
springs. Refer to Stabilizer Bar, in this section.
1. Stabilizer bar from the vehicle if equipped. 6. Lower the support on the rear axle. Lower the
vehicle to the ground.
Refer to Stabilizer Bar, in this section.
2. Leaf spring (10) from the rear hanger (25).
Loosen, but do not rem ove, the BUSHING REPLACEMENT
spring-to-shackle nut and bolt.
Nut and the bolt securing the shackle to the
rear hanger (25). PRESS OUT TYPE BUSHINGS
3. Leaf spring (10) from the front hanger (18).
Nut and the bolt securing the leaf spring |<~+| Remove or Disconnect (Figures 1, 3, and 7)
(10) to the front hanger (18).
4. Shackle (6) from the leaf spring (10). 1. Leaf spring (10) from the vehicle.
Nut and bolt securing the shackle to the leaf Refer to Leaf Spring Assembly, in this
spring. section.
5. Leaf spring from the axle. 2. Bushing from the leaf spring (10).
Nuts (22), and washers (21). Place the leaf spring in a press and press
out the bushing.
Rear stabilizer anchor (36) if equipped, the
anchor plate, spacers, shims, and the
|~<-| Install or Connect (Figures 1, 3 and 7)
auxiliary spring (32), if equipped.
U-bolts (8).
1. Bushing into the leaf spring (10).
Leaf spring is free of the vehicle. Use a press to pro pe rly position the
bushings.
|~k ~| Install or Connect (Figures 1 through 7, and 2. Leaf spring (10) to the vehicle.
11) Refer to Leaf Spring Assembly, in this
section.
NOTICE: For steps 1 and 4, refer to the PRY OUT TYPE BUSHINGS
Notice on page 3D-1 of this section.
|<~+| Remvoe or D isco n n e ct (F ig u re s 2 and 4
1. Leaf spring (10) to the rear axle. through 7)
Leaf spring into position.
Spacers, shims, the auxiliary spring (32) if 1. Leaf spring (10) from the vehicle.
equipped, and the anchor plate. Refer to Leaf Spring Assembly, in this
U-bolts (8), washers (21), ^nd nuts (22). section.
2. Bushings (26) from the leaf spring (10).

Pry the bushings out of each side of the
spring eye.
Install or Connect (Figures 2 and 4 through 7)
1. Bushings (26) into the leaf spring (10).

Press each bushing (26) into its side of the
spring eye.
2. Leaf srping (10) onto the vehicle.
Refer to Leaf Spring Assembly, in this
section.
SPECIFICATIONS
FASTENER NAME TORQUE N m (FT. LBS.)
C10/15 C20/25 C30/35 K10/15 K20/25 K30/35 G10/15 G20/25 G30/35 P20/25 P30/35
Shock A bsorber To Fram e Nut 19 0 (1 4 0 ) *1 9 0 (1 40) 7 0 (52) 190 (1 40) 190 (1 40) 70 (52) 102 (75) 102 (75) 102 (75) 33 (24) 70 (52)
Shock A bsorber To Axle Nut 155 (1 1 4 ) *1 5 5 (114) 155 (1 14) 155 (1 14) 155 (1 14) 155 (1 14) 102 (75) 102 (75) 102 (75) 155 (1 14) 155 (114)
Stabilizer Bar To Fram e Nut ** 29 (21)
Stabilizer Bar To A nchor Nut 3 3 (24) 29 (21)
Stabilizer Bar Bracket To H anger - 33 (24)
Stabilizer Bar Bracket To Fram e 33 (24)
Anchor Plate To U-bolt Nut

170 (1 25) 170 (1 25) 170 (1 2 5 ) 170 (1 25) 170 (1 25) 170 (1 25) 155 (114) 155 (1 14) 20 5 (1 51) 170 (1 25) -
(U-bolts Facing Up)
Anchor Plate to U-bolt Nut

2 0 0 (1 4 7 ) 2 0 0 (147) 20 0 (1 47) 2 0 0 (1 47) 2 0 0 (1 47) 2 0 0 (1 47) - - 2 0 5 (1 51) - * * * 2 0 0 (147)
(U-bolts Facing Down)
Spring To Hanger Nut 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) N/A
Spring To H anger Bolt 150 (1 1 0 ) 150 (1 10) 150 (1 10) 150 (110) 150 (110) 150 (110) 185 (136) 185 (1 36) 185 (136) 150 (1 10) 1 5 0 (1 10)
Spring To Shackle Nut 125 (9 2) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 1 2 5 (92)
Spring To Shackle Bolt 15 0 (1 1 0 ) 150 (1 10) 150 (1 10) 15 0 (1 10) 150 (1 10) 150 (1 10) 185 (136) 185 (1 36) 185 (1 36) 150 (1 10) 1 5 0 (1 10)
Shackle To Hanger Nut 125 (9 2) 125 (92) 125 (9 2) 125 (92) 125 (92) 125 (92) N/A N/A N/A 125 (92) 1 2 5 (92)
Shackle To H anger Bolt 15 0 (1 1 0 ) 150 (110) 150 (1 10) 15 0 (110) 150 (110) 15 0 (1 1 0 ) 185 (136) 185 (1 36) 185 (136) 150 (1 10) 1 5 0 (1 10)
For M odels with RPO JF9 or P 3 1 8 (3 2 ) Torque Spring to H anger Bolt to 2 0 0 N m (1 4 7 ft. lbs.) and Tighten Shcakle Fasteners to 135 N m (9 9 ft l b s )
Crew Cab M odel Torque is 7 0 N m (5 2 ft. lbs.) for Shock to Fram e, and 155 N m (1 14 ft. lbs.) for Shock to Axle.
Tighten The Nut To The Unthreaded Portion Of The Link Bolt.
** Torque Is 2 4 0 N m (1 7 7 Ft. Lbs.) W hen Equipped W ith RPO JF9
3E-1
SECTION 3E
WHEELS AND TIRES
the manual as indicated at appropriate locations by the terminology: NOTICE: Refer to the Notice on page 3E-1 of
this section.
NOTICE: These fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of these parts.
CONTENTS
SUBJECT PAGE
General D e s c rip tio n ................................................................................................................................................... 3E- 2

C ertification L a b e l................................................................................................................................................. 3E- 2
Tire Load Lim its And Inflation P re s s u re .......................................................................................................... 3E- 2
Diagnosis Of Wheels And T ir e s ..............................................................................................................................3E- 4
Checking Wheel And Tire R unout....................................................................................................................... 3E- 4
On-Vehicle S ervice..................................................................................................................................................... 3E- 5
Measuring Wheel And Tire R u n ou t..................................................................................................................... 3E- 5
Excessively Tight W h e e ls .................................................................................................................................... 3E- 7
Separating The Tire From The W h e e l............................................................. ..............................................3E- 7
M ounting The Tire On The W heel....................................................................................................................... 3E- 7
Installing The Wheel And Tire A ssem bly..........................................................................................................3E- 9
Alum inum Wheel R e fin is h in g ..............................................................................................................................3E- 9
Wheel And Tire B a la n cin g .................................................................................................................................... 3E-10
O ptional Spare Tire C a rrie rs ................................................................................................................................3E-10
S p e c ific a tio n s .............................................................................................................................................................. 3E-12
Wheel Runout S p e c ific a tio n s ............................................................................................................................. 3E-12
Wheel Stud Nut Torque (Single Front And Rear W h e e ls )............................................................................3E-12
Wheel Stud Nut Torque (Single Front And Dual Rear W h e e ls)................................................................... 3E-12
Tire Load Lim its And Inflation P re s s u re .......................................................................................................... 3E-13
Wheel Codes And Load L im it s ........................................................................................................................... 3E-13
3E-2 WHEELS AND TIRES
GENERAL DESCRIPTION
This section details special service procedures that Correct tire pressures and driving techniques
are not covered in the vehicles Owners Manual. For influence tire life. Underinflated tires can cause
jacking instructions, basic tire changing and rotation handling problems, poor fuel economy, shortened tire
instructions, and a detailed explanation of all other life, and tire overloading. Heavy cornering, excessively
owner-oriented information, refer to the proper section rapid acceleration, and unnecessary braking also
in the vehicles Owners Manual. increase tire wear.
Important
CERTIFICATION LABEL
The use of wheels and/or tires with higher load
The certification label contains information used to capacity ratings than originally equipped on the
determine which tire size and type the vehicle uses. vehicle will not increase the Gross Axle Weight
For fu rth e r in fo rm a tio n , re fe r to G E N ER AL Rating (GAWR) or Gross Vehicle Weight Rating
INFORMATION (SEC. OA). (GVWR) of the vehicle.
TIRE LOAD LIMITS AND

INFLATION PRESSURE
The factory installed wheels and tires are designed
to handle loads up to and including their rated load
capacity when inflated to the recommended inflation
pressures. Refer to Tire Load Limits And Inflation
Pressure at the end of this section.
WHEELS AND TIRES 3E-3
B-07463
Figure 1Radial Tire Lead/Pull Diagnosis Chart

DIAGNOSIS OF WHEELS AND TIRES

The following information (including figure 1) will help to identify certain tire-related durability and drivability
problems.
Excessive Heel And High speed driving, excessive use of Correct as required, rotate tires regu
Toe Wear brakes. larly.
Excessive Tire 1. Underinflated tires. 1 . Inflate to recommended pressure.

Edge(s) Wear 2. Vehicle overloaded. 2 . Correct as requiredrefer to certifi
cation label.
3. High speed cornering. 3. Correct as required.
4. Incorrect toe setting. 4. Set to correct specifications.
Excessive Tire Wear Overinflated tires. Deflate to recommended pressure.

(Center Of Tread)
Uneven Tire Wear 1. Improper tire pressure. 1. Inflate to recommended pressure.

2. Incorrect tire and wheel usage. 2. Install correct tire-wheel combination.
3. Worn shock absorbers. 3. Replace shock absorbers.
4. Front end out of alignment. 4. Align the front end.
5. Loose, worn, or damaged steering link 5. Inspect, repair or replace as required.
age, joints, suspension components,
bushings and/or ball joints.
6 . Out of balance wheel/tire. 6 . Balance wheel/tire.
Radial Tire Waddle Worn tires. Replace worn tires.

(Side To Side
Movement At Speeds
Between 5 and 15
MPH)
Vibration 1. Out of balance wheel/tire. 1. Balance wheel/tire.

2. Tire runout. 2. Replace tire.
3. Wheel runout. 3. Replace wheel.
4. Worn tire. 4. Replace tire.
CHECKING WHEEL AND If the tire and wheel vibration occurs below 40
miles per hour.
TIRE RUNOUT If all wheels are balanced well within one ounce
of static balance and five ounces of dynamic
Some vehicles are sensitive to tire and wheel balance, anda vibration occurs.
assembly runout. Tires that are satisfactory on one If there appears to be a bulge in a tire or an
vehicle might be unsatisfactory on another. When out-of-round condition as a tire rotates on a
analyzing vibration problems, it is important to keep balancer.
this in mind. In addition, different wheel positions on a If any wheel damage is noticed.
vehicle may have different sensitivity levels. You If there is a poor wheel fit on the hub and the
should check for wheel runout or total wheel and tire vehicle exhibits vibration.
runout in the following cases:
WHEELS AND TIRES 3E- 5
ON-VEHICLE SERVICE
MEASURING WHEEL AND

TIRE RUNOUT
Runout m easurem ents of the wheel and tire
assembly can be taken both on and off the vehicle.
These measurements can be taken radially and
laterally. A dial indicator equipped with a roller contact
point, m ounted on a heavy, solid base is the
measurement device.
RADIAL RUNOUT
Radial runout is the egg-shaped difference from a
perfect circle. Measure tire radial runout from the
center tire tread rib although other tread ribs can be
measured as well. The total runout is the reading from
the gage, and the high spot is the location of the
maximum runout. On a rim, if either flange is beyond
specifications, replace the rim (figure 2 ).
LATERAL RUNOUT R otate a ga in to v e rify the low spot

Lateral runout is a sideways variation causing a twist location-the dial indicator must return to
or wobble and is measured on a side surface. On the zero.
tire and wheel assembly, measure the sidewall of the
tire as close to the trend shoulder design edge as
possible. The total runout is the reading from the gage,
and the high spot is the location of the maximum
runout. On a rim, if either flange is beyond guidelines,
replace the rim (figure 3).
MEASUREMENT PROCEDURES
1. Inflate the tires to specifications.
2. Warm up the tires prior to taking measurements
to eliminate flat spotting.
Newly installed tires usually do not require
warming up.
3. Raise the vehicle on a lift.
If m easurem ents will be taken off the
v e h ic le , m ount each tire and w heel
assembly on a dynamic balance machine.
4 Mark the tire and wheel assemblies for exact
replacement.
Mark a wheel hub bolt and its exact position
on the wheel.
Mark each tire and wheel assembly for
re p la c e m e n t on the exact h u b /ro to r A. Tire High Spot 1 . Dial Indicator
assembly. B. Wheel High Spot
5. Take e ith e r a ra d ia l or la te ra l ru n o u t C. Wheel Low Spot
measurement. D. Tire Low Spot
B-07451
Place the dial indicator in position.
Rotate the tire and wheel assembly (or just Figure 3Measuring Lateral Runout
the wheel) to find its low spot. Adjust the dial
indicator to read zero.
2.
3. Tire A. Valve Stem And Tire Reference Mark
A. Tire Reference Mark At 12 Oclock At 12 Oclock
B. First Measurement (High Spot) B. First Measurement (High Spot)
C. Valve Stem At 12 Oclock C. Valve Stem At 12 Oclock
D. Second Measurement (High Spot) D. Second Measurement (High Spot)
E. Tire Reference Mark At 6 Oclock B-07455 E. Tire Reference Mark At 6 Oclock B-07505
Figure 4Checking Tire To Wheel Vectoring Figure 5Tire To Wheel V e c to rin g -

Excessive Tire Runout
Disregard any instantaneous dial jumps due
to welds, paint runs, scratches, etc. on the 3. If la te ra l ru n o u t is the p ro b le m , take a
wheel. measurement on the sidewall just below the edge
Rotate the tire and wheel assembly (or just of the tread shoulder.
the wheel) and note the amount of variance Record the runout magnitude, and mark the
(runout) from zero. Locate and mark the high spot location.
high spot. 4. Mark the tire sidewall at the valve location.
This is the 12 oclock position.
6 . If th e re is a la rg e d iffe re n c e in ru n o u t
The location of the high spot is always with
measurements from ON vehicle to OFF vehicle,
respect to the clock location on the wheel.
the runout problem is likely due to excessive
5. Break the tire and wheel assembly down on a tire
runout of the bolt circle or hub.
mounting machine and rotate the tire 6 hours
7. If measured runouts are not within the guidelines (180) on the rim (figure 4).
(located in Wheel Runout Specifications at the Reinflate the tire and measure the runout in
end of this section), proceed to Vectoring to question.
correct the problem. Record the magnitude and the location of
the high spot. (Valve stem is 12 oclock.)
VECTORING 6 . If the clock location of the high spot remained at
Vectoring is a technique used to reduce radial or or near the clock location of the original high
lateral runoutand even dynamic balance on tire and spot, the rim is the major contributor to the runout
wheel assemblies. Vectoring can be accomplished by problem.
positioning of the tire on the wheel and positioning of Confirm by removing the tire from the wheel
the tire and wheel assembly on the hub/rotor. and check the wheel rim runout.
If the wheel rim runout exceeds guidelines,
Im portant replace the wheel.
7. If the clock position of the high spot is 6 hours
Always rebalance the tire and wheel from the original high spot, the tire is the major
assembly after vectoring. contributor to the runout problem (figure 5).
Replace the tire.
Tire To Wheel Vectoring 8 . After correcting the tire to the wheel vectoring,
1. Determine which runout needs to be minimized. rebalance the wheel and tire assembly.
Determine visually.
Tire And Wheel Assembly To Hub/Rotor Vectoring
2. If ra d ia l ru n o u t is the p ro b le m , take a 1. Mark the wheel hub bolt nearest the valve stem
measurement on the center tread rib. for reference (figure 6 ).
If the trend is uneven, wrap tape tightly 2. Rotate the assembly two wheel hub bolts and
a round the tire , re co rd the ru n o u t recheck the runout (figure 6 ).
magnitude, and mark the high spot location Several positions may have to be tried to
(figure 4). locate the optimum location.
Follow the tire changing machine manufacturers

instructions to properly separate the tire from the
wheel.
MOUNTING THE TIRE ON

THE WHEEL
BIAS PLY TIRES
1. Clean the tire bead area.
2. Clean the rim bead seats with a wire brush or

coarse steel wool to remove lubricants, old
Figure 6 Tire And Wheel Assembly rubber, and light rust.
To Hub/Rotor Vectoring
3. Apply an approved tire lubricant to the tire bead
This can be effective for both radial and area.
lateral runouts.
3. If there is some looseness in the wheel hub bolt 4. Attach the tire to the wheel.
holes, radial runout can be reduced by loosening
Use a tire changing machine. Follow the
the hub bolt nuts slightly, moving the wheel
equipment manufacturers instructions.
position on the bolts and then retightening the
nuts.
4. Balance the tire and wheel to hub/rotor assembly. CAUTION: Do not stand over tire when
Compensates for any imbalance in the inflating. The bead may break when it snaps
brake rotor, drum, or wheel cover. over the safety hump, and cause serious
personal injury. Do not exceed 275 kPa (40
psi) pressure when inflating. If 275 kPa (40
EXCESSIVELY TIGHT WHEELS psi) pressure will not seat beads, deflate,
re-lubricate and reinflate. Overinflation may
Use this procedure to remove the wheel and tire cause the bead to break and result in personal
assembly if it does not break free of the hub using a injury.
standard removal procedure.
5. Install a valve core and inflate to the specified
1. Tighten all the lug nuts on the affected wheel.
pressure (figure 2 ).
Do not torque.
2. Raise the vehicle. The locating rings on each side of the tire
3. Loosen each nut two turns. m u sti show above the rim fla n g e s ,
positioned in direct relation to the wheel (not
4. Lower the vehicle to the floor.
eccentric as compared with the rim).
5. Rock the vehicle from side to side to loosen the
wheel. Or rock the vehicle from forward to reverse 6 . Check the bead seating.
allowing the vehicle to move several feet in each
direction. Apply quick, hard jabs on the brake Tires must be mounted and inflated in
pedal to loosen the wheel. accordance with the safety precautions
included with the tire mounting equipment.
6 . Raise the vehicle and remove the lug nuts and
the wheel.
RADIAL PLY TIRES
SEPARATING THE TIRE NOTICE: Recommended vehicle tire mounting

FROM THE WHEEL and inflation procedures are especially
important with radial tires. Failure to follow
these procedures can cause bead deformation
NOTICE: Use a tire changing machine to in both tube type and tubeless tires due to
demount tires. Do not use hand tools or tire incorrect bead seating. Bead deformation may
irons alone to remove the tire from the wheel. lead to chafing, lower sidewall and bead area
Damage to the tire beads or wheel rim could cracking, eccentric wear, ride vibration and
result. nonretreadable castings.
Tube Type Tires Do not allow the soap solution to run down
into the tire.
Important 5. Follow the standard procedure when mounting
the tube and tire on a drop center rim. Be sure
Only use rims approved for radial tire usage by the tire is centered on the rim so the beads are
the rim manufacturer. out of the rim well before inflating. Do not allow
1. Clean the rim parts. the tire to hang loosely on the wheel while
Remove all rust and other foreign material. inflating.
Make sure the rim parts match and are not 6 . Center the valve and pull it firmly against the rim.
sprung or broken. Hold in this position and inflate until the tire
2. Lubricate the tire beads, the portion of the tube beads are firmly seated on the rim against the
between the beads, and the flaps with an flanges.
approved rubber lubricant. 7. Remove the valve core to completely deflate the
Radial tubes are identifiable by the letter tire.
R in the size designation. A red band in 8 . Reinflate the tire to the recommended pressure.
the valve stem and an R in the flap size
Refer to Tire Load Limits And Inflation
designation also identify radial parts.
Pressure at the end of this section.
NOTICE: Do not use silic o n e base

Tubeless Tires
lubricantsthis could cause the tire to slip on
the wheel.
Important
3. Inflate to operating pressure, deflate completely,
Only use rims approved for radial tire usage by
and reinflate to operating pressure.
the rim manufacturer.
Allows the tube, flap, and tire to fit together
properly. 1. Clean the rim.
4. Check the bead seating. Remove all rust and other foreign material.
Visually check the slot and side ring gap (on 2. Lubricate tire beads and rim bead seats with an
two piece rims) to make sure the bead is approved rubber lubricant.
seated.
5. Check the spacing between the rim flange and NOTICE: Do not use silic o n e base
one of the three lower sidewall rim line rings while lubricantsthis could cause the tire to slip on
the tire is laying flat to verify bead seating. the wheel.
Measurements must be taken each 90
degrees around the circumference of the 3. Inflate the tire to operating pressure.
rim flange. Due to the construction of radial truck tires,
If the spacing is uneven around the bead particularly in the lower sidewall and bead
from side to side, repeat steps 1 through 3, area, it may be difficult to get the tire to take
then recheck. air.
An inflation aid may be necessary to help
Installing Synthetic Tubes seat the bead of tubeless radial tires. Two
types of inflation aids are commercially
NOTICE: When the tube and the flap are not a v a ila b le m etal rin g s w h ich use
properly lubricated, and mounted, they will compressed air to seat beads, and rubber
stretch thin in the tire bead and rim region. rings which seal between the tire bead and
This will cause premature wear. rim bead seat allowing the bead to move out
and seat. Lubrication is necessary with both
1. Clean the inside of the casing. aids.
2. Insert the tube in the tire and inflate until it is 4. Check the spacing between the rim flange and
nearly rounded out. one of the three lower sidewall rim line rings while
3. Inspect the rim for rust scale and bent flanges. the tire is laying flat to verify bead seating.
Clean rust scale and straighten the flanges Measurements must be taken each 90
where necessary. degrees around the circumference of the
4. Apply a solution of neutral vegetable oil soap to rim flange.
the inside and outside of the tire beads, and also If the spacing is uneven around the bead
the rim side of the tube. from side to side, repeat steps 1 through 3,
Use a brush or a cloth swab. then recheck.
Tighten
Nuts to S pecifications at the end of this

section.
Tighten evenly and alternately to avoid excessive
runout (figure 7).
DUAL WHEELS
1. Inner and outer wheel and clamp ring on the rear

wheel, or wheel and clamp ring on the front
wheel.
Be sure the pins on the clamp ring face outward.
Im portant 2. Lub nuts finger tight.
This procedure must be followed to insure proper Tighten

bead s e a tin g in o rd e r to p re ve n t bead
deformation. Nuts to Specifications at the end of this
section.
Radial tires, as well as bias tires, must be For P30 models, tighten to 210 N m (155 ft
mounted and inflated in accordance with safety lbs.), then tighten again to 237 N m (175 ft.
precautions noted in RMA Radial and Bias Truck
lbs.).
Tire Service Manuals.
Tighten evenly and alternately to avoid
excessive runout (figure 7).
INSTALLING THE TIRE AND Measure

WHEEL ASSEMBLY
Lateral runout should not exceed 3.18 mm (0.125
inches) on the front wheel or 4.76 mm (0.187
CAUTION: Before re-installing the wheels, inches) on the rear wheel.
remove any build up of corrosion on the
wheel m ounting surface and brake drum or
disc m ounting surface by scraping and wire ALUMINUM WHEEL REFINISHING
b ru s h in g . In s ta llin g w h e e ls w ith g o o d
m e ta l-to -m e ta l c o n ta c t at the m o u n tin g Remove the tire and wheel assembly from the
surfaces can cause wheel nuts to loosen. vehicle.
This can lead to a wheel com ing o ff while the Mark the position of the wheel weights on the tire
vehicle is moving, possibly causing loss of for correct reinstallation after recoating the wheel.
control. Remove the wheel weights and mask off the tire.
1 . Remove the original clear coating.
Apply a chemical stripper such as 3M brand
SINGLE WHEELS Troubleshooter to the wheel rim surface.
Wait 10 to 15 minutes, then wet scrub the
4* Install or Connect (Figure 7) su rfa ce using a 3M #98 S c o tc h b rite
Cleaning Pad (3M part number 07445).
1 . Wheel and tire assembly in position on the Rinse the surface thoroughly with clean
hub/rotor, and lug nuts installed loosely. water.
2 . Turn the wheel until one nut is at the top of the
bolt circle. Tighten the nut just snug. CAUTION: Use of eye goggles is necessary
to prevent personal injury.
3. Snug up the rem aining nuts criss-cross to
minimize runout. 2. Remove surface oxidation.
Use 3M Superbuff Buffing Pad (3M part
NOTICE: Refer to the Notice on page 3E-1 n um be r 05701) and a m edium type
of this section. compound such as 3M part number 05955
or 05931.
Hose off the rim with water and scrub with a

small brush to remove excess compound,
then air blow dry.
3. Recoat the wheels.
Clean the surface of any contaminants
using Prekleno.
Apply #801 Metal Conditioner, taking care to
use rubber gloves and a clean cloth during
the application. Keep the surface wet while
applying.
Make sure #801 Metal Conditioner is reduced one

part metal conditioner to three parts of water.
Wipe off #801 Metal Conditioner carefully while
the surface is still wet. Use a clean, dry cloth.
4. Apply the clear coat.
Apply R & Ms 893 2K Clear with 894
Urethane Catalyst Hardener. Refer to the
label for specific directions.
Wear proper respiratory protection such as
a 3M Paint Respirator (part number 06984)
or Easi-Air Respirator (part number 06986)
or equivalent.
5. Allow the wheel to air dry overnight (minimum) B-07537
before installing on the vehicle.
6 . Attach balance weights and install the wheel and
Figure 8 Underbody Swing Out Spare Tire
tire assembly on the vehicle.
Carrier (RPO P10)
Mount the weights in the marked positions
and remove the masking from the tire.
Follow the wheel balancer machine instructions
while performing the balancing operation.
WHEEL AND TIRE BALANCING
To insure successful, accurate balancing, the
OPTIONAL SPARE TIRE CARRIERS
following precautions must be observed:
The wheel and tire must be clean and free
UNDERBODY SWING OUT SPARE TIRE CARRIER
of all foreign matter.
(RPO P10)
The tire should be in good condition and
The underbody swing out spare tire carrier is
properly mounted using the balance mark
standard equipment on C-K 10/1500 series pickups. It
on the tire, if any, or lined up with the
is available as an option (RPO P10) on C-K 20/2500
inflation valve.
and 30/3500 series pickups (figure 8 ).
Bent wheels that have a runout over 1.6 mm
(Ve-inch) should be replaced.
UNDERBODY GLIDE OUT SPARE TIRE CARRIER
Inspect the wheel and tire assembly to
(RPO P11)
determ ine if an out-of-round condition
The underbody glide out spare tire carrier is
exists.
available as an option (RPO P11) on all C-K series
pickups (figure 9).
Im portant
SIDE PANEL MOUNTED SPARE TIRE CARRIER
A severe out-of-round condition cannot be
(RPO P13)
balanced out. A wheel and tire assembly
The side panel mounted spare tire carrier is
having an out-of-round condition exceeding 4.7
available as an option on all C-K series pickups (figure
mm (3/ie-inch) is not suitable for the front of the
10).
vehicle. Its use on the rear of the vehicle must be
governed by its general condition and whether
the roundness problem seriously detracts from
overall ride quality.
Figure 10Side Panel Mounted Spare Tire Carrier (RPO P13)

SPECIFICATIONS
WHEEL RUNOUT SPECIFICATIONS

Steel Wheels Alum inum Wheels
Radial Runout 1.01 mm (0.04 inches) 0.76 mm (0.03 inches)
Lateral Runout 1.14 mm (0.045 inches) 0.76 mm (0.03 inches)
WHEEL STUD NUT TORQUE (SINGLE FRONT AND REAR WHEELS)
Series Number Of Studs Nut Torque

C10/1500 5 studs 140 N-m (100 ft. lbs.) (steel wheels)
K10/1500 6 studs 120 N-m (88 ft. lbs.) (steel wheels)
C 10/1500 5 studs 140 N-m (100 ft. lbs.) (aluminum wheels)
K 10/1500 6 studs 140 N-m (100 ft. lbs.) (aluminum wheels)
C-K 20/2500 8 studs 160 N-m (120 ft. lbs.) (all)
G 10/1500-20/2500 5 studs 140 N-m (100 ft. lbs.) (steel wheels)
G 10/1500-20/2500 5 studs 140 N-m (100 ft. lbs.) (aluminum wheels)
G 30/3500 8 studs 160 N-m (120 ft. lbs.) (all)
P20/2500 & 30/3500 8 studs 160 N-m (12 0 ft. lbs.) (all)
WHEEL STUD NUT TORQUE (SINGLE FRONT AND DUAL REAR WHEELS)
Series Number Of Studs Nut Torque

G 30/3500 8 studs 190 N-m (140 ft. lbs.) (all)
P 30/3500 8 studs 190 N-m (140 ft. lbs.) (with RPO JB 8 )
P 30/3500 10 studs 210 N-m (155 ft. lbs.) (with RPO JF9)
TIRE AND WHEEL LOAD LIMIT CHARTS

(TIRE & WHEEL LOAD LIMITS ARE SHOWN BELOW. VEHICLE LOADING MUST BE LIMITED
SUCH THAT NEITHER THE WHEEL OR TIRE INFLATION PRESSURE OR LOAD LIMITS ARE Metric Radial Tires Used As Singles (Cont.)
EXCEEDED).
RADIAL TIRE SIZE AND LOAD LIMITS - kg (LBS) Inflation Pressure - kPa (PSI)
Metric Radial Tires Used As Singles 400 (58) | 450 (65) 500 (73) | 550 (80)
Tire Load Inflation Pressure - kPa (PSI)

Size Range 250 (36) | 300 (44) | 350 (51)
965 1050
LT215/85R16 C 695 790 880
(2127) (2315)
(1532) (1742) (1940)
1100 1190
LT215/85R16 D 695 790 880
(2425) (2623)
(1532) (1742) (1940)
1100 1190 1290 1380
LT235/85R16 D 790 900 1000
(2425) (2623) (2844) (3042)
(1742) (1984) (2205)
LT235/85R16 E 790 900 1000 Metric Radial Tires Used As Duals (Cont.)
(1742) (1984) (2205)
Inflation Pressure - kPa (PSI)
Metric Radial Tires Used As Duals 400 (58) 450 (65) 500 (73) 550 (80)
Size Range 250 (36) | 300 (44) | 350 (51)
LT215/85R16 C 630 720 800 870 955

(1389) (1587) (1764) (1918) (2105)
LT215/85R16 D 630 720 800

(1389) (1587) (1764)
Bias Tires Used As Singles (Cont.)
BIAS TIRE SIZE AND LOAD LIMITS - kg (LBS) Inflation Pressure - kPa (PSI)
Bias Tires Used As Singles 345 (50) 379 (55) | 414 (60) | 448 (65) | 483 (70) 517 (75)

Size Range 207 (30) | 241 (35) | 276 (40) | 310 (45)
993 1048 1107

7 50 16 C 735 803 875 934
(2190) (2310) (2440)
(1620) (1770) (1930) (2060)
993 1048 1107 1161 1211 1261
7 50-16 D 735 803 875 934
(1930) (2190) (2310) (2440) (2560) (2670) (2780)
(1620) (1770) (2060)
7 50-16 E 735 803 875 934 Bias Tires Used As Duals (Cont.)
(1620) (1770) (1930) 2060
___________ _____________ Inflation Pressure - kPa (PSI)_________________________
Bias Tires Used As Duals 345 (50) I 379 (55) | 414 (60) | 448 (65) | 483 (70) [ 517~(75[

Size Range 207 (30) | 241 (35) | 276 (40) | 310 (45)
7 50-16 C 649 710 767 823 875 925 971

(1565) (1690) (1815) (1930) (2040) (2140)
(1430)
7 50-16 D 649 710 767 823

(1430) (1565) (1690) (1815)
B-07548 B-07549
Figure 11Tire Load Lim its And Inflation Figure 12Tire Load Lim its And Inflation
Pressure (C-K) Pressure (C-K)
TIRE LOAD LIMITS AND WHEEL CODES AND LOAD LIMITS

INFLATION PRESSURE
Refer to Figures 13, 16, and 19 for wheel load limits
Refer to Figures 11, 12, 14, 15, 17, and 18 for tire load for each wheel size (coded).
limits given an inflation pressure range.
TIRE AND WHEEL LOAD LIMIT CHARTS

(Tire and wheel load limits are shown below. Vehicle loading must be limited so that neither
the wheel or tire inflation pressure or load limits are exceeded)
_______________ Tire Load Limits: Bias Tires Used As Singles kg (lbs)
Wheel Max. Load Max. Pressure Inflation Pressure kPa (PSI)
Code * Size kg (ibs.) kPa (psi) Tire Load 207 241 276 310 345
Size Range (30) (35) (40) (45) (50)
AA 1 6 x 6 .5 1,381 (3 045) 621 (90)
8 .00 - 617 676 730 785
C
AF 16x6 1,107 (2 440) 517 (75) 16.5 (1 360) (1 490) (1 610) (1 730)
BF 1,261 (2 780) 586 (85) 8.00 - 617 676 730 785 835
16 x 16.5
16.5 (1 360) (1 490) (1 610) (1 730) (1 840 )
BK 15x7 757 (1 670) 276 (40)
8.75- 712 780 839 903 957
D
CF 15 x 7 757 (1 670) 276 (40) 16.5 (1 570) (1 720) (1 850 ) (1 990) (2 110)
8.75 - 712 7 80 839 903 957

CK 15x8 866 (1 910) 276 (40)
16.5 (1 570) (1 720) (1 850) (1 990) (2 110)
DAB 15x8 921 (2 030) 276 (40)
Tire Load L im its: Bias Tires Used As Duals kg (lbs)
DAC 15x8 921 (2 030) 282 (41)
GBA 15x8 900 (1 984) 282 (41) Infla tio n Pressure kPa (PSI)
Tire Load 207 241 276 310 345
GBB 15x7 921 (2 030) 282 (41) Size Range (30) (35) (40) (45) (50)
UA 15 x 7 921 (2 030) 282 (41) 8.00- 542 594 642 689
C
16 5 (1 195) (1 310) 1 41-3 (1 520)
XAH 15x6 900 (1 984) 438 (70)
8 00- 542 594 642 689 735
XH 15x6 719 (1 585) 276 (40) D
16 5 (1 195 (1 310) (1 415) (1 520) (1 620)
CC 15x6 757 (1 670) 379 (55)
Tire Load Lim its: Radial Tires Used As Singles kg (lbs)
XX 15 x 6 925 (2 040) 483 (70)
In fla tio n Pressure kPa (PSI)
* Wheel code is located on the wheel just to the right of the valve stem
Tire Load 207 241 276 310 345
hole. Size Range (30) (35) (40) (45) (50)
8 .7 5 712 780 839 903
E
R 1 6 .5 (1 570) (1 720) (1 850) (1 990)
B-08072 B-08074
Figure 13Wheel Codes And Load Lim its Figure 14Tire Load Lim its And
(C-K) Inflation Pressure (G)
Tire Load Limits: Bias Tire Used As Singles kg (lbs.) (Cont.)

TIRE LOAD LIMIT CH A R TS
Inflation Pressure kPa (PSI)
379 414 (Tire load limits at different inflation pressures are shown below. Vehicle loading must be
448 483 517 552
(55) limited such that neither the tire inflation pressures or load limits are exceeded).
(60) (65) (70) (75) (80)
METRIC RADIAL TIRES - kg (LBS.)
882 928 Inflation Pressure - kPa (PSI)

Tire Load Single
(1 945) (2 045 )
Size Range Dual 250 (36) 300 (44) 350 (51)
1016 1 066
S 695 (1532) 790 (1742) 880 (1940)
(2 240) (2 350) LT215/85R16
D 630 (1389) 720 (1587) 800 (1764)
1016 1066 1120 1166 1216
(2 240) (2 350) (2 470 ) (2 570) S 695 (1532) 790 (1742) 880 (1940)
(2 6 8 0 ) D
LT215/85R16
D 630 (1389) 720 (1587) 800 (1764)
Tire Load Limits: Bias Tires Used As Duals kg (lbs.) (Cont.) 900 (1984) 1000 (2205)
S 790 (1742)
LT235/85R16 D
Inflation Pressure kPa (PSI) -
379 414 448 483 517 552 S 790 (1742) 900 (1984) 1000 (2205)
LT235/85R16 E
(55) (60) (65) (70) (75) (80) -
STANDARD RADIAL TIRES - kg (LBS.)

776 816
(1 710) (1 800)
Tire Load Single
Size Range Dual 310 (45) 345 (50) 379 (55)
Tire Load Limits: Radial Tires Used As Singles kg (lbs.) (Cont.)
S
Inflation Pressure kPa (PSI) On Iy .0 D
D
379 414 448 483 517 552
(55) (60) (65) (70) (75) (80)
BIAS TIRES - kg (LBS.)
957 1016 1 066 1120 1166 1216
(2 110) (2 240) (2 350 ) (2 470 ) (2 570) (2 680) Inflation Pressure kPa (PSI)
Tire Load Single
Size Range Dual 207 (30) 241 (35) 276 (40) 310 (45)
S 735 (1630) 803 (1770) 875 (1930) 934 (2060)

7 50-16
B-08075 0 649 (1430) 710 (1565) 767 (1690) 823 (1815)
s 735 (1620) 803 (1770) 875 (1930) 934 (2060)

7.50-16 0
D 649 (1430) 710 (1565) 767 (1690) 823 (1815)
Figure 15Tire Load Lim its And Inflation 735 (1620) 803 (1770) 875 (1930) 934 (2060)
S
Pressure (G) 7 50-16
-
s
8 -1 9 5
D 839 (1850) 903 (1990)
Wheel Code and Load Limits
E S
8-19 5
Wheel Max. Load Max. Pressure D 839 (1850) 903 (1990)
Code * Size - kg (lbs.) - kPa (PSI)
DAS 15 x 6.5 835 (1 843) 282 (41) B-08077
GBC 15 x 6 5 835 (1 843) 282 (41)
XH 15 x 6 719 (1 585) 276 (40)
XAH 15 x 6 900 (1 984) 483 (70)
Figure 17Tire Load Lim its And
VH 16.5 x 6 1216 (2 680) 586 (85)
Inflation Pressure (P)
XJ 16 5 x 6 75 1216 (2 680) 586 (85)
'W heel code is located on the wheel just to the right ot the valve stem hole.
B-08076
Figure 16Wheel Codes And Load Lim its

(G)
TIRE LOAD LIMIT CHARTS (CONT.)
METRIC RADIAL TIRES (CONT.) - kg (LBS.)
Inflation Pressure - kPa (PSI)

400 (58) 450 (65) 500 (73) 550 (80)
965 (2127) 1050(2315)
870 (1918) 955 (2105)
1100 (2425) 1190 (2623)
1100 (2425) 1190 (2623) 1290 (2844) 1380 (3042)
STANDARD RADIAL TIRES (CONT.) - kg (LBS.)

414 (60) 448 (65) 483 (70) 517 (75) 552 (80)
1030 (2270) 1093 (2410) 1152 (2540) 1216 (2680) 1270 (2800)
1012 (2230) 1066 (2350) 1116 (2460)
BIAS TIRES (CONT.) - kg (LBS.)

345 (50) 379 (55) 414 (60) 448 (65) 483 (70) 517 (75)
993 (2190) 1048 (2310) 1107 (2440)
875 (1930) 925 (2040) 971 (2140)
993 (2190) 1048 (2310) 1107 (2440) 1161 (2560) 1211 (2670) 1261 (2780)
957 (2110) 1030 (2270) 1093 (2410) 1152 (2540) 1216 (2680) 1270 (2800)
957 (2110) 1012 (2230) 1066 (2350) 1116 (2460)
957 (2110) 1030 (2270) 1093 (2410) 1152 (2540) 1216 (2680) 1270 (2800)
957 (2110) 1012 (2230) 1066 (2350) 1116 (2460) 1166 (2570) 1216 (2680)
B-08078
Figure 18 T ire Load L im its And

In fla tio n Pressure (P)
WHEEL CODE AND LIMITS

Wheel Max Load Max Pressure
Code* Size kg (Lbs.) kPa (PSI)
AA 16 x 6.5 L 1381 (3045) 621 (90)
AF 16 x 6 K 1107 (2440) 517 (75)
BF 16 x 6.5 L 1261 (2780) 586 (85)
ZT 19.5 x 6 1261 (2780) 655 (95)
ZY 19.5 x 6 1152 (2540) 552 (80)
W heel co d e is lo ca te d on the w h e e l ju s t to the rig h t o f the

valve ste m hole.
B-08079
Figure 19 W heel Codes And Load L im its

(P)
4A-1
SECTION 4A
PROPELLER SHAFT
this manual as indicated at appropriate locations by the terminology Notice: See NOTICE on page 4A-1 of this
section .
NOTICE: A ll p ro p e lle r s h a ft fa ste n e rs are im p o rta n t a tta ch in g parts in th a t th e y co u ld a ffe ct the perform ance
o f v ita l parts and system s, a n d /o r co u ld re su lt in m ajor repair expense. They m ust be replaced w ith one o f
the sam e part n u m ber o r w ith an e q u iva le n t part if replacem en t becom es necessary. Do n ot use a replace
m ent part o f lesser q u a lity o r s u b s titu te design. T orque values m ust be used as sp e cifie d d u rin g reassem bly
to assure p ro p e r re te n tio n o f all parts.
CONTENTS
SUBJECT PAGE
D e s c rip tio n ............................................. ..........................................................................................................................4 A - 2

P ro p e lle r S h a f t ............................................................................................................................................................. 4 A - 2
C enter B e a r in g ............................................................................................................................................................. 4 A - 2
U niversal J o i n t ............................................................................................................................................................. 4 A - 2
D ia gn osis Of D rive line V ib ra tio n (Road T e s t) ..........................................................................................................4 A - 4
D iagnosis Of P ro p eller S haft and U niversal J o i n t .................................................................................................4 A - 4
O n-V ehicle S e r v ic e ......................................................................................................................................................... 6
P ro p e lle r S haft Balance C h e c k ................................................................................................................................ 6
P ro p e lle r S haft R unout C h e ck...................................................................................................................................4 A - 6
P ro p e lle r S haft R eplacem ent (Rear D riv e )............................................................................................................ 4 A - 8
P ro p e lle r S haft R eplacem ent (F ro nt D r iv e ) ..........................................................................................................4 A - 9
L u b r ic a tio n .........................................................................................................................................................................4A -11
S p e c ific a tio n s .................................................................................................................................................................... 4 A -1 2
S pecial T o o ls .................................................................................................................................................................... 4 A -1 2
4A-2 PROPELLER SHAFT
DESCRIPTION
Figure 1 P ro p eller Shaft A ssem bly Phased
PROPELLER SHAFT shafts have alignment marks or arrows stamped on the

shaft at the time of production.
Torque is transmitted from the transmission to the
rear axle through one or more propeller shafts and
universal joint assemblies. The number of propeller CENTER BEARING
shafts and universal joint assemblies vary with the
Center bearings support the driveline when two or
v e h ic le w heel base, and the c o m b in a tio n of
more propeller shafts are used. The center bearing is a
transmission, transfer case (front drive) and rear axle
ball type bearing mounted in a rubber cushion that is
equipment.
attached to a frame crossmember. The bearing is
All propeller shafts are the balanced tubular type
pre-lubricated and sealed by the manufacturer (figure
(figure 1). A splined slip joint is provided in some
2).
drivelines and others use a companion flange at the
transmission end of the driveline. If two or more
propeller shafts are used on a vehicle the slip joint is UNIVERSAL JOINT
usually at the forward end of the rear propeller shaft.
A universal joint is two Y-shaped yokes connected by
Phasing a crossmember called a spider. The spider is shaped
The propeller shaft is designed and built with the like a cross having arms of equal length called trun
yoke lugs (ears) in line with each other (figure 1). This nions (figure 3).
design produces the smoothest running shaft possible, Universal joints are designed to handle the effects of
and is called phasing. various loadings and rear axle w indup d uring
Vibration can be caused by an out of phase propeller acceleration. Within the designed angle variations the
shaft. The propeller shaft will absorb vibrations from universal joint will operate efficiently and safely. When
speeding up and slowing down each time the universal the design angle is changed or exceeded the
joint goes around. This vibration would be the same as operational life of the joint may decrease.
a person snapping a rope and watching the wave The trunnion bearings used in universal joints are
reaction flow to the end. A propeller shaft working in the needle roller type. The needle rollers are held in
phase would be similar to two persons snapping a rope place on the trunnions by round bearing cups. The
at the same time, and watching the waves meet and bearing cups are held in the yokes by e ith e r
cancel each other out. In comparison this would be the (depending on the manufacturer) snap rings or injected
same as the universal joints on a propeller shaft. A plastic.
total cancellation of vibration produces a smooth flow When a driveline has a large or deep angle a
of power in the driveline. It is very important to constant velocity joint is used. Essentially, the constant
reference mark the propeller shaft before removal, to velocity joint is made of two universal joints coupled by
assure phased installation alignment. Some propeller a yoke and phased for constant velocity. A centering
PROPELLER SHAFT 4A-3
Retainer
Pinion Flange
Yoke and Cross
Assembly
Splined Shaft
Cap
Washer
12. Seal (Cork)
13. Nut
14. Transmission Yoke
15. Washer
Bolt
Universal Joint
Hanger Assembly and Crossmember Slip Yoke
Center Bearing Support
Front Propeller Shaft
Rear Propeller Shaft
Bolt
B-06720
F igure 2 C enter B earing A nd P ro p e lle r S haft Detail
ball socket between the joints keeps a relative position

between the two joints. This centering device causes
each of the two units to operate through one half of the
complete angle between the propeller shaft and the
differential carrier (figure 4). The ball socket on a con
stant velocity universal joint requires periodic lubrica
tion through the fitting provided.
A
A. Ball Socket B-06813
Figure 4C onstant V e lo city J o in t (S im p lifie d )
Figure 3Simple Universal Joint

DIAGNOSIS OF DRIVELINE VIBRATION

(ROAD TEST)
Four major component groups are usually the cause ROAD TEST
of or are related to vibration. When a technician is road A technician should road test the vehicle to diagnose
testing a vehicle for vibration he must remember the exactly what the complaint is. Record the speed and
four major component groups: rpm at which the greatest vibration occurs. The
vibration is likely to be in two places, in the steering
1. Engine and mounts. wheel or in the seat bottom. The road test can be
2. Clutch and transmission. helpful in locating the vibration source either forward or
3. Tires, wheels and brake drums. aft.
4. Propeller shaft and universal joints.
COAST TEST
Before road testing a vehicle, check the following: Drive the vehicle past the vibration speed, shift into
1. In or out of phase propeller shaft. neutral and coast back through the vibration speed. In
2. All fasteners for tightness at universal joints, this test two kinds of vibration normally occur; a
wheel lugs and engine mounts. shaking or a buzzing. A shaking vibration is usually
3. Tire air pressure. tires or a wheel and brake drum /disc assembly
4. Load conditions. problem. A buzzing vibration is usually a driveline
problem.
DIAGNOSIS OF THE PROPELLER SHAFT AND

UNIVERSAL JOINT
Leak A t The F ront 1. Rough su rfa ce on sp lin e d yoke; 1. Replace the seal. Minor burrs can be
S lip Yoke (An burred, nicked or worn. smoothed by careful use of crocus
O ccasional D rop Of cloth or fine stone honing. Replace
L u b rica n t Leaking the yoke if badly burred.
From The S plined 2 . Defective transmission rear oil seal. 2. Replace the transmission rear oil
Yoke Is N orm al And seal and replenish the transmission
R equires No oil.
A tte n tio n )
U niversal J o in t N oise 1. Center bearing. 1. Replace the center bearing.

2. Worn universal joint bearings. 2 . Replace.
3. Improper lubrication. 3. Lubricate as directed.
4. Loose flange bolts. 4. Tighten to Specifications .
Ping, Snap, Or C lick 1 . Loose bushing bolts on the rear 1. Tighten the bolts to specified torque.
In Drive Line (U sually springs or upper and lower control
Heard On In itia l Load arms.
A fte r The 2. Loose or out of phase companion 2. Remove companion flange, turn 180
T ransm issio n Is In flange. degrees from its original position, lu
Gear; Forw ard Or b rica te the s p lin e s and in s ta ll.
Reverse) Tighten the bolts and pinion nut to
specified torque.

UNIVERSAL JOINT (CONTINUED)
PROBLEM I POSSIBLE CAUSE CORRECTION
K nocking Or 1. Worn or damaged universal joint. 1. Replace the worn or damaged uni
Clunking Noise In versal joint.
The D riveline When 2. Side gear hub counterbore in the dif 2. Replace the differential case and/or
Operating The ferential is worn oversize. the sidegears.
Vehicle In A Floating
C ondition In High Or
Neutral Gear At 10
MPH (16 km/h)
Roughness Or 1. Bent or dented propeller shaft. 1. Replace propeller shaft.

V ibration 2. Undercoating on propeller shaft. 2. Clean propeller shaft.
3. Tire unbalance, 30-80 mph (48- 3. Balance or replace as required.
129 km/h). Not throttle conscious.
4. Tight universal joints. 4. Impact yokes with a shaft hammer to
free up. If unable to free up or if joint
feels rough when rotated, replace.
5. Worn universal joints. 5. Replace.
6 . Burrs or gouges on companion flange. 6 . Rework or replace the companion
Check snap ring locating surfaces on flange.
flange yoke.
7. Propeller shaft, parking brake drum or 7. Check for a missing balance weight
companion flange is unbalanced. on the propeller shaft. Rotate the
companion flange 180 degrees.
8 . Incorrect rear joint angle. The angle is 8 . Check and correct trim height at curb
usually too large when it is a factor. weight. Check and correct joint an
gle.
9. Excessive looseness at the slip spline. 9. Replace necessary parts.
10. D istorted or dam aged yokes or 10. Install new yokes or flanges.
flanges.
1 1 . Yokes out of phase. 1 1 . Remove companion flange, turn 180
degrees from the original position, lu
bricate the splines and install.
Tighten bolts to specified torque.
12. Propeller shaft runout at 50 mph (80 1 2 . Check propeller shaft runout at front
km/h). Throttle conscious. and rear. Should be less than speci
fied. If above, rotate propeller shaft
180 degrees and recheck. Replace
the propeller shaft if runout is still
over specification.
Scraping Noise Slinger, companion flange, or end yoke Correct the interference.
rubbing on rear axle or center bearing.
Roughness Above Tires unbalanced or worn. Balance or replace as required.

35 MPH (56 km/h)
Felt And/O r Heard
Squeak 1. Lack of lubricant. 1. Lubricate joints and splines. Also

check for worn or brinelled parts.
2. Center bearing. 2 . Replace or lubricate.

UNIVERSAL JOINT (CONTINUED)
Whine Or Whistle Center support bearing. Place the vehicle on a hoist with rear
wheels free to rotate and diagnose
for source of noise, replace.
Shudder On 1. Loose or missing bolts at the center 1 . Replace or tighten bolts to specified
Acceleration, (Low bearing or flanges. torque.
Speed) 2. Incorrectly set front joint angle. 2. Shim under the transmission support
mount to change the front joint angle.
3. Worn universal joint. 3. Replace.
ON-VEHICLE SERVICE
PROPELLER SHAFT Install or Connect

BALANCE CHECK 1. Propeller shaft.
Raise the vehicle on a twin post hoist so the Determine the position which gives the best
wheels can spin. balance.
2. Rear drums, wheel and tire assemblies.
Determine the position which gives the best
driveline response by road testing the
vehicle for a final check of the propeller
1 . Tire and wheel assemblies and the brake drums.
shaft balance.
DO NOT APPLY THE BRAKE WITH THE
Unacceptable balance, replace the propeller
DRUMS REMOVED.
shaft.
I* Inspect
PROPELLER SHAFT
P ro p e lle r sh aft, u niversa l jo in ts and
attachments for mud, undercoating or loose RUNOUT CHECK
fasteners. Noise or vibration at high speed could be caused by
(m
j, Clean
a bent propeller shaft. The propeller shaft could have
been damaged by rough handling or a collision. Check
for propeller shaft straightness.
P ro p e lle r sh aft, u niversa l jo in ts and 1 . Raise the vehicle on a twin post hoist so the
attachments. wheels can spin.
2. Attach a dial indicator having a magnetic base to
Tighten a smooth place on the vehicle underbody.
3. Take dial indicator readings at the propeller shaft
Any loose attachments or fasteners. check points shown in figure 5. For runout
specifications, refer to figure 6 .
Im portant
Important
Run the vehicle in gear at the speed where
the disturbance peaks; observe the intensity Do not attach the dial indicator base at a
of the disturbance. weld.
Stop the engine. 4. With the transmission in neutral, hand rotate the
2. Propeller shaft. axle pinion flange or the transmission yoke and
Rotate the propeller shaft 180 degrees from take the necessary dial indicator readings on the
the original position. propeller shaft. Record the readings. Models
JL
=dj \
B
2d . f .
& t \
A. Check Front Runout

B. Check Center Runout
C. Check Rear Runout
D. Check Splined Shaft Runout At Tapered Hole In Splined End
E. Check Front Runout
1. One Piece Propeller Shaft Or Rear Propeller Shaft In A Two-Piece Driveline
2. Front Propeller Shaft In A Two-Piece Driveline
B-07556
Figure 5Checking Propeller Shaft Runout
having a two-piece driveline, measure the rear

propeller shaft runout (figure 5). Reference mark
the position of the rear propeller shaft yoke to the
PROPELLER FRONT CENTER REAR pinion flange, then remove the rear propeller
SHAFT CHECK CHECK CHECK shaft and measure the front propeller shaft
ONE PIECE 0.040 0.050 0.055 runout on the tube and at the tapered hole on the
TWO PIECE 0.020 0.008A splined shaft end (figure 5). If the runout exceeds
FRONT specification, rotate the propeller shaft 180
TWO PIECE degrees at the companion flange and install.
0.030* 0.030 0.035
REAR Check the runout.
5. If the runout is still over specification at one or

more check points, replace the propeller shaft
ANOTE: This measurement must be taken at after checking for vibration or noise. Check the
the tapered hole on the splined shaft after the runout on the replacement propeller shaft.
rear propeller shaft is removed.
6 . If the new p ro p e lle r sh aft runout is over
specification, check for a bent companion flange.
* NOTE: This measurement must be taken
with the rear propeller shaft mounted on the
front shaft which is w ithin specifications. Im portant
The splined end of the front propeller shaft

is critical to the smooth operation of a
B-07557 tw o-piece d rive lin e . Be sure the dial
indicator readings are accurate.
Figure 6Propeller Shaft Runout Specifications
PROPELLER SHAFT 4. For twisted slip yoke splines or possibly the

wrong universal joint.
REPLACEMENT (REAR DRIVE)

One-Piece Propeller Shaft
Tool Required: 1. Propeller shaft (4) into the transmission.
J-33051, Driveshaft Wrench.
Lubricate slip joint.
2. Yoke and cross assembly (8 ) onto the pinion
1. Skid plate if used. flange (7).
Reference mark the propeller shaft (4) to Align the reference marks on the pinion
pinion flange (7) connection. flange (7) and the propeller shaft rear yoke
2. Bolts (5). (8 ). Seat the yoke properly.
3. Retainers(6 ). 3. Retainer (6 ).
4. Bolt (5).
Im portant
Tighten
Do not pound on the original propeller shaft
yoke ears. The injection joints may fracture.
Bolt (5) to torque in Specifications at the
Never pry or place any tool between a yoke end of this section.
and a universal joint.
4. Yoke and cross assembly (8 ). Two-Piece Propeller Shaft
Tape bearing cups to prevent the loss of 1. Propeller shaft (3) into the transmission.
bearing rollers. Be sure joint is lubricated.
5. Propeller shaft (4). Bottom the propeller shaft (3) yoke in the
Slide the propeller shaft (4) forward. transmission.
Lower the propeller shaft (4) and withdraw 2 . Center bearing support (2) onto hanger ( 1 ).
under the rear axle. Align the center bearing support 90 degrees
Do not allow the universal joint (17) to incline to the propeller shaft (3, 4) center lines.
greatly; the joint may fracture. Refer to figure 7.
Models with a two-piece propeller shaft 3. Bolt (16).
6 . Nut (13). 4. Washer (15).
7. Bolt (16) and washer (15). 5. Nut (13).
8 . Center bearing support (2).
Support the propeller shaft (3). NOTICE: SeeNotice on page 4A-1 of this
9. Cap (10). section.
10. Washer (11).
11. Seal (12).
12. Front propeller shaft (3).
Always support the propeller shaft (3).
Do not allow the universal joint (14) to bend Nut (13) to torque specification later in
deeply as the universal joint could fracture. this section. Maintain alignment (figure 7).
Withdraw the propeller shaft (3) with a
rearward movement. Important
IQ* Clean Set the transmission yoke (14) ears in a

vertical position for proper phasing (figure
All parts. 7).
6. Cap (10).
I* Inspect 7. Washer (11).
8. Seal (12).
1. Outer diameter of transmission yoke (14) for Locate the bridged tooth on the splined
burrs. Any burring will damage the transmission shaft (9).
seal. 9. Slip yoke (18) onto the splined shaft (9).
2. For proper installation and uniform seating of Mate the missing tooth in the yoke (18) with
bearing cups. the bridged tooth on the splined shaft (9)
3. Slip yoke (18) splines for wear. figure 7. Support the propeller shaft (4).
Hanger Assembly
Center Bearing Support
Front Propeller Shaft
Rear Propeller Shaft
Transmission Yoke
Slip Yoke
Horizontal Center Line At The Yoke
90 1 Degree Angle For Slotted Hanger Holes
Vertical Center Line At The Yoke B-07562
Figure 7Alignm ent For Two-Piece Propeller Shaft In Phase, G And K Models
Be sure the s lip yoke (18) ears are 1 . Slip yoke (13) from the front axle yoke (12).
horizontal, figure 7.
Nut (10), washer (11) and U-bolt (15).
10. Propeller shaft (4).
Align reference marks. Bolt (20) and retainer (22).
Check bearings for proper fit.
11. Retainer (6 ). Im portant
12. Bolt (5).
Check for proper joint fit. Do not pound on the joint to disconnect.
2. Bolt (18) at the flange (17).
Tighten
3. Boot (21) if used.
Bolts (5) to specified torque. Refer to Release boot retainers using J-22610.
Slide the propeller shaft (14) forward,
Lubricate the slip yoke (18).
enough to disengage, then withdraw the
propeller shaft (14) rearward.
PROPELLER SHAFT Avoid dropping cap assemblies from the
yoke ends.
REPLACEMENT (FRONT DRIVE)
jjjJJ* Clean
|<~+| Remove or Disconnect (Figure 8)
All parts.
Tool Required:
J-22610, Keystone Clamp Pliers.
I? Inspect
Remove skid plate if used.
Splines for damage, wear, burrs and twisting.
Reference mark the relationship of the
propeller shaft (14) to the front axle and the Bearings for wear.
transfer case flange (17). Propeller shaft (14) for straightness.
Front Axle Yoke

Slip Yoke
Propeller Shaft Assembly
U-bolt
Transfer Case
Flange
Bolt
Constant Velocity Joint
Bolt
Boot
Retainer
Front Axle Assembly
Washer Clamp B-07561
Figure 8 Front Propeller Shaft and Driveline Detail
Install or Connect (Figure 8) a Tighten
Tools Required: All fasteners to specified torque. Refer to

J-22610, Keystone Clamp Pliers. Specifications at the end of this section.
J-25512, CV Propshaft Lube Gun (Ve-inch 3. Bolt (18) at the flange (17).
pipe). Mate the joint using reference marks.
J-25512-2, Needle point. Lubricate the Constant Velocity Joint (19).
Lubricate the slip yoke (13) before installing Refer to Lubrication later in this section.
the boot (21). Refer to Lubrication later in 4. Skid plate, if used.
this section.
1. Boot (21) if used. a Tighten
Retainers (24) using J-22610.
2 . Slip yoke (13) to the axle yoke ( 1 2 ). All fasteners to specified torque. Refer to
Adjust propeller shaft (14) length. "Specifications later in this section.
Mate the joint using reference marks.
U-bolt, washer (1 1 ) and nut (10).
Retainer (22) and bolt (20).
Support the propeller shaft (14).
__________________ PROPELLER SHAFT 4A-11
LUBRICATION
The front axle propeller shaft found on four-wheel

drive vehicles requires a special lubricant at two lo
cations: the constant velocity joint, and the slip
yoke.
Constant V elocity Joint (C/V Joint)

The constant velocity (C/V) joint, located at the
transfer case end of the front propeller shaft, must be
lubricated periodically with a special lubricant,
1050679 or equivalent. If the lubrication fitting cannot
be seen from beneath the vehicle refer to figure 9
which shows how the C/V joint may be lubricated from
above, with a special adapter J-25512-2 on the end of a
flex hose.
Slip Spline
Apply chassis lubricant at the slip spline grease
fitting until the grease begins to leave through the vent
hole. Figure 9Lubricating The Constant
If the slip spline is dry or corroded, it may be V elocity Joint Fitting
necessary to disconnect the propeller shaft from the
vehicle, remove the slip yoke, and wire brush the
affected area. Wipe clean before installation.
SPECIFICATIONS
TORQUE
APPLICATION MODEL Nm FT. LBS.
Propeller Shaft:
C, G, P 20* 15*
C, K, G300, P 35 26
Two Piece Propeller Shaft-Front
.P300 27 20
.C, G, P 20 15
K 27 20
Center Bearing Support:
.P300 33 24
.C 20 15
.P 35 26
.K 27 20
.C 33 24
C, G 33 24
Two Piece Propeller Shaft-Rear:
.P 27 20
C, G, P 20 15
C, K, G300, P300 33 24
Propeller Shaft:
.K 100 74
.K100, 200 20 15
.K300 20 15
'Torque Specification Is For Hex Head Bolt.
SPECIAL TOOLS
J-22610 Keystone Clamp Pliers
J-25512 CV Propshaft Lube Gun
J-25512-2 Needle Point
J-33051 Driveshaft Wrench
4B-1
SECTION 4B
REAR AXLE
the manual as indicated at appropriate locations by the terminology: NOTICE: See Notice on page 4B-1 of this
section.
NOTICE: All rear axle fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
proper retention of all parts.
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................. 4B - 2

Rear Axle O peration...............................................................................................................................................4 B - 2
Diagnosis of the Rear A x le ...................................................................................................................................... 4 B - 3
Diagnosis of N o is e ................................................................................................................................................. 4 B - 3
Diagnosis of Tapered Roller B e a rin g s .............................................................................................................. 4B - 6
On-Vehicle Service..................................................................................................................................................... 4B-10
Rear Axle Assem bly R e p la ce m e n t.....................................................................................................................4B-10
Axle Shaft, Oil Seal and Bearing Replacement
(81/2- 91/ 2-lnch Ring Gear-Semi-Floating A xle)............................................................................................... 4B-10
Brake Backing Plate Replacement (81/2- 91/2-inch Ring Gear-Semi-Floating A xles)................................ 4B-13
Wheel Stud Replacement ( 81/2 - 9 V2-lnch Ring Gear-Semi-Floating A x le s )................................................4B-14
Pinion Flange, Dust Deflector/O il Seal Replacement
(81/2- 91/ 2-lnch Ring Gear-Semi-Floating A x le s )...........................................................................................4B-14
Axle Shaft Replacement (93/4- 1 0 1/ 2-lnch Ring Gear-Full Floating A x le s )..................................................4B-16
Hub And Drum Assem bly Replacement (93/4- 1 0 1/ 2-lnch Ring Gear-Full Floating A x le s ) ......................4B-17
Wheel Bearing/Cup Replacement (93/4- 1 0 1/2-lnch Ring Gear-Full Floating A x le s ) .................................4B-18
Non-Demountable Type Drum R eplacem ent....................................................................................................4B-19
Wheel Bolt R eplacem ent...................................................................................................................................... 4B-19
Bearing A d ju s tm e n t...............................................................................................................................................4B-19
Pinion Oil Seal/Companion Flange Replacement
(93/4- 1 0 1/ 2-lnch Ring Gear-Full Floating A x le s )...........................................................................................4B-20
Axle Vent Replacement (12-Inch Ring Gear-Full Floating A x le ) .................................................................4B-21
Axle Shaft Replacement (12-Inch Ring Gear-Full Floating A x le ).................................................................4B-21
Bearing Adjustm ent (12-Inch Ring Gear-Full Floating A x le ) ....................................................................... 4B-21
Drive Pinion Oil Seal Replacement (12-Inch Ring Gear-Full Floating A x le )............................................. 4B-22
S pe cifica tio ns..............................................................................................................................................................4B-24
Special T o o ls ..............................................................................................................................................................4B-25
4B-2 REAR AXLE
DESCRIPTION
Light duty trucks use various rear axles, classed by DANA 9 3/4-INCH RING GEAR AXLE
ring gear diameter such as: This Dana axle is similar to the Chevrolet 1 0 1/2 -inch
ring gear axle however, the differential side bearing
8 V2-INCH AND 9 V2-INCH RING GEAR AXLES shims are located between the case and the side
-SEM I-FLO ATING bearings.
These axles are of the fabricated constructed type
consisting of a cast carrier, bossed at each end into ROCKWELL 12" RING GEAR AXLE
which two welded steel tubes are fitted. An overhung This single-speed, hypoid axle has a straddle
hypoid pinion and the ring gear are housed in the mounted drive pinion which is supported at the rear by
carrier. The differential has a two pinion arrangement. a straight roller bearing. The pinion front bearing has a
Two steel welded tubes pressed into the crossbore of double row ball bearing.
the cast carrier make up the axle housing. Welded-on The differential is a conventional four-pinion type
brackets provide attachment points for the suspension using thrust washers between the side gears and case
components such as leaf springs and shock absorbers. and also between the differential pinions and the
The brake flange plate is attached to a welded-on differential case.
flange.
A thrust pad mounted on the end threaded into the
The overhung hypoid drive pinion is supported by
carrier housing limits the deflection of the ring gear
two preloaded tapered roller bearings. The pinion shaft
under high torque service.
is sealed by means of a molded, spring loaded, rubber
seal. The hypoid ring gear is bolted to a one-piece Involute splines are used in the axle shaft flange and
differential case supported by two preloaded tapered in the wheel hubs. This design gives driving torque
roller bearings. transmission from the axle shaft to the hub through the
The 9 1/2 -inch ring gear axles have the ring gear side mating splines.
bearing preload controlled by a side bearing adjusting
nut threaded into the carrier near the axle tubes.
Backlash is adjusted by increasing or decreasing the REAR AXLE OPERATION
shim thickness.
A basic differential has a set of four gears. Two are
called differential side gears and the other two are
CHEVROLET IOV 2-INCH RING GEAR AXLE
differential pinion gears. Some differentials have more
This axle is the full floating type with a hypoid ring
than two pinions. Each side gear is splined to an axle
gear and drive pinion. The full floating construction
shaft, therefore each axle shaft must turn when its side
allows easy removal of the axle shafts. The differential
gear rotates.
carrier is heavily ribbed to provide rigid support for the
differential assembly. The differential pinion gears are mounted on a
A straddle-mounted drive pinion is supported at the differential pinion shaft, and the gears are free to rotate
front by two opposed tapered roller bearings. The on this shaft. The pinion shaft is fitted into a bore in the
pinion straddle bearing is a roller bearing assembly differential case and is at right angles to the axle
having an outer race and roller assembly. A precision shafts.
ground diameter on the pinion pilot functions as an Power flow through the differential is as follows: the
inner race. drive pinion rotates the ring gear. The ring gear, being
Side bearing preload and ring gear-to-pinion bolted to the differential case, rotates the case. The
backlash are controlled by side bearing adjusting nuts differential pinion, as it rotates with the case, forces the
threaded into the carrier near the axle tubes. Pinion pinion gears against the side gears. When both wheels
depth is controlled by a shim located between the have equal traction, the pinion gears do not rotate on
pinion bearing retainer assembly and the differential the pinion shaft because the input force on the pinion
carrier. gear is equally divided between the two side gears.
Therefore, the pinion gears revolve with the pinion
DANA IOV 2-INCH RING GEAR AXLE shaft, but do not rotate around the shaft itself. The side
The axle is a Salisbury-type design similar to the gears, being splined to the axle shafts and in mesh
8 1 / 2 -inch ring gear axle. The axle shafts are full with the pinion gears, rotate the axle shafts.
floating, and the carrier must be spread to remove the If a vehicle were always driven in a straight line, the
differential, and the drive pinion uses two shim packs. ring and pinion gears would be sufficient. The axle
The inner pack controls pinion depth and the outer shaft could then be solidly attached to the ring gear
pack controls pinion bearing preload. and both driving wheels would turn at equal speed.
REAR AXLE 4B-3
However, if it became necessary to turn a corner, the load developed on the right side clutch pack. This
tires would scuff and slide because the outside wheel induced clutch torque capacity resists motion between
would travel further than the inside wheel. To prevent the side gear and the rear axle differential case. The
tire scuffing and sliding, the differential becomes axle shaft torques developed when turning a corner
effective and allows the axle shafts to rotate at different will overcome this capacity and allow differentiation.
speeds. Also, heavier throttle application will cause differential,
When the vehicle turns a corner, the outer rear but this starts the full-lock feature of the unit.
wheel must turn faster than the inner wheel. The inner Full locking is accomplished through the use of a
wheel turns slower than the outer wheel and slows its heavyweight governor mechanism, cam system, and
rear axle side gear (as the axle shaft is splined to the multi-disc clutch packs. The flyweights on the governor
side gear) and the rear axle pinion gears will roll mechanism move outward to engage a latching
around the slowed rear axle side gear, driving the other bracket whenever the wheel-to-wheel speed varies by
rear axle side gear and wheel faster. approximately 100 rpm or more. This action retards a
cam which, in turn, compresses the multi-disc clutch
LOCKING REAR AXLE packs locking both side gears to the case. The 100 rpm
wheel-to-wheel speed allows for cornering without
Eaton Locking Differential differential lock-up.
The locking rear differential allows for normal At vehicle speeds above approximately 32.2 km/h
differential function as indicated in the standard rear (20 mph), the latching bracket overcomes a spring
axle d escription. A dditionally, the locking rear preload and swings away from the flyweights. At this
differential uses multi-disc clutch packs and a speed vehicle speed or greater, the differential will not lock,
sensitive engagement mechanism that locks both as the added traction is generally not required.
wheels together if one wheel should spin excessively All gear axle parts of vehicles equipped with the
during slow vehicle operation. locking rear axle are interchangeable with those
Under light loads, the clutch plates alone tend to equipped with the conventional rear axle, except for
lock axle shafts to the differential case, and therefore, the case assembly.
each other. This is due primarily to the gear separating
DIAGNOSIS OF THE REAR AXLE
NOISE conditions, or on gear ratio and tire size. This slight

noise is in no way indicative of trouble in the axle
The most essential part of rear axle service, as with assembly.
any mechanical repair, is proper diagnosis of the
Drive lin e noises may b a ffle even the best
problem, and, in axle work one of the most difficult
diagnostician. Vehicle noises coming from tires,
areas to diagnose is noise. Locating a broken axle
transmission, propeller shaft, universal joints, and front
shaft, or broken differential gear, presents little or no
or rear wheel bearings, are often mistaken for axle
problem, but, locating and isolating axle noise can be
noise. Such practices as: raising tire pressure to
an entirely different matter.
eliminate tire noise (although this will not silence tread
noise of mud and snow tires), listening for the noise at
varying speeds and road surfaces, on drive, float, and
Degree of Noise
coast conditions will aid in locating the source of
Any gear driven unit, especially an automotive drive
alleged axle noises. Thus, every effort should be made
axle where engine torque multiplication occurs at a 90
to isolate the noise to a specific drive line component
degree turn in the drive line, produces a certain
instead of making a random guess that could be a
amount of noise. Therefore, an interpretation must be
costly waste of time.
made for each vehicle to determine whether the noise
is normal or if a problem actually exists. A normal
amount of noise must be expected and cannot be
eliminated by conventional repairs or adjustment. DETERMINING TYPE OF NOISE
Acceptable noise can be defined as a slight noise External Noise
heard only at a certain speed or under unusual or When a rear axle is suspected of being noisy, it is
remote conditions. For example, this noise tends to advisable to make a thorough test to determine
reach a peak at speeds from 40 to 60 miles per hour whether the noise originates in the tires, road surface,
(60 to 10 0 km/h) depending on road and load front wheel bearings, engine, transmission, or rear axle
4B-4 REAR AXLE
assembly. Noise which originates in other places Other items that may also contribute to the noise
cannot be corrected by adjustment or replacement of problem are as follows:
parts in the rear axle assembly.
1. U ndercoating or mud on the shaft, causing
Road NoiseSome road surfaces, such as brick or unbalance.
rough-surfaced concrete, cause noise which may be
2 . Shaft or com panion flange balance weights
mistaken for tire or rear axle noise. Driving on a
missing.
different type of road, such as smooth asphalt or dirt,
will quickly show whether the road surface is the cause 3. Shaft damage, such as bending, dents, or nicks.
of noise. Road noise usually is the same on drive or
4. Tire-type roughness. Switch tires from a known
coast.
good vehicle to determine a tire fault.
Tire NoiseTire noise may easily be mistaken for
If, after making a comprehensive check of the
rear axle noise, even though the noisy tires may be
vehicle, all indications point to the rear axle, further
located on the front wheels. Tires worn unevenly, or
diagnostic steps are necessary to determine the axle
having surfaces on non-skid d ivisions worn in
components at fault. True rear axle noise generally
saw-tooth fashion, are usually noisy and may produce
falls into two categories: gear noise and bearing noise.
vibrations which seem to originate elsewhere in the
vehicle. This is particularly true with low tire pressure.
Tire Noise TestTire noise changes with different Rear Axle Noises
road su rfa ce s, but rear axle noise does not. If a careful test of the vehicle shows that the noise is
Temporarily inflating all tires to 345 kilopascals (50 not caused by external items, it is then reasonable to
pounds per square inch) pressure, fo r test purposes assume that noise is caused by the rear axle assembly.
only will materially alter noise caused by tires but will Test the rear axle on a smooth level road to avoid road
not affect noise caused by the rear axle. Rear axle noise. It is not advisable to test the rear axle for noise
noise usually stops when coasting at speeds under 30 by running with the rear wheels jacked up.
miles per hour; however, tire noise continues but with Noise in the rear axle assembly may be caused by a
lower tone as the vehicle speed is reduced. Rear axle faulty propeller shaft, faulty rear wheel bearings, faulty
noise usually changes when comparing pull and differential or pinion shaft bearings, misalignment
coast but tire noise remains about the same. between two U-joints, or worn differential side gears
Engine and Transm ission NoisesSometimes a and p in ion s; noise may also be caused by a
noise which seems to originate in the rear axle is mismatched, improperly adjusted, or scored, ring and
actually caused by the engine or transmission. To pinion gear set.
determine which unit is actually causing the noise, Rear Wheel Bearing NoiseA rough rear wheel
observe approximate car speeds and conditions under bearing produces a vibration or growl which continues
which the noise is most pronounced; then stop the with the vehicle coasting and the transmission in
vehicle in a quiet place to avoid interfering noises. With neutral. A brinelled rear wheel bearing causes a knock
the transmission in neutral, run the engine slowly up or click approximately every two revolutions of the rear
and down through the engine speeds corresponding to wheel, since the bearing rollers do not travel at the
the vehicle speed at which the noise was most same speed as the rear axle and wheel. With the rear
pronounced. If a similar noise is produced with the wheels jacked up, spin the rear wheels by hand while
vehicle standing, it is caused by the engine or listening at the hubs for evidence of a rough or
transmission and not the rear axle. brinelled wheel bearing.
Front Wheel Bearing NoiseLoose or rough front
D iffe r e n tia l S id e G ear and P in io n
wheel bearings will cause noise which may be
NoiseDifferential side gears and pinions seldom
confused with rear axle noise; however, front wheel
cause noise since their movement is relatively slight on
bearing noise does not change when comparing pull
straight ahead driving. Noise produced by these gears
and coast. Light application of the brake, while
will be most pronounced on turns.
holding the vehicle speed steady, will often cause the
wheel bearing noise to diminish, as this takes some P in io n B earing failures can be distinguished
weight off of the bearing. Front wheel bearings may be because they rotate at higher speeds than differential
easily checked for noise by jacking up the wheels and side bearings and axle shaft bearings. Rough or
spinning them, and also by shaking the wheels to brinelled pinion bearings produce a continuous low
determine if the bearings are excessively loose. pitched whirring or scraping noise starting at a low
speed.
Body Boom Noise or VibrationObjectional body
boom noise or vibration at 55-65 mph (90-100 km/h) Side Bearings produce a constant rough noise
can be caused by an unbalanced propeller shaft. pitched lower than pinion bearing noise. Side bearing
Excessive looseness at the spline can contribute to noise may also fluctuate in the above rear wheel
this unbalance. bearing test.
REAR AXLE 4B-5
Gear Noise
There are two basic types of gear noise. The first
type is produced by broken, bent, or forcibly damaged
gear teeth and is usually quite audible over the entire
speed range and presents no particular problem in
diagnosis. For example, hypoid gear tooth scoring
generally results from the following: insufficient
lubricant, improper break-in, improper lubricant,
insufficient gear backlash, improper ring and pinion
gear alignment, or loss of drive pinion nut torque. The
scoring will progressively lead to complete erosion of
the gear tooth, or gear tooth pitting and then eventual
fracture if the initial scoring condition is not corrected
(figure 1). Another cause of hypoid tooth fracture is
extended overloading of the gear set which will
produce fatigue fracture, or shock loading which will
result in sudden failure.
Differential pinion and side gears rarely give trouble.
Common causes of differential failure are shock
loading, extended overloading, and seizure of the
differential pinions to the cross shaft resulting from
excessive wheel spin and consequent lubrication
breakdown. The second type of gear noise pertains to
the mesh pattern of the gear teeth. This form of
abnormal gear noise can be recognized because it
produces a cycling pitch (whine) and will be very
pronounced in the speed range at which it occurs,
appearing under either drive, or float or coast
conditions. Drive is acceleration or heavy pull.
Coast is with a closed throttle and the vehicle in
gear and float is using just enough throttle to keep
the vehicle from driving the engine; the vehicle slows
down gradually but the engine still pulls slightly. Gear
noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch. Bearing noise
will vary in pitch with vehicle speeds.
Refer to figures 2 through 5 for bearing diagnosis.
4B-6 REAR AXLE
ABRASIVE ROLLER WEAR ABRASJVE STEP WEAR

Pattern on races and rollers caused by fine Pattern on roller ends caused by fine abra
abrasives. sives.
Clean all parts and housings, check seals and Clean all parts and housings, check seals and
bearings and replace if leaking, rough or bearings and replace if leaking, rough or
noisy. noisy.
GALLING ETCHING
Metal smears on roller ends due to overheat, Bearing surfaces appear gray or grayish black
lubricant failure or overload. in color with related etching away of material
Replace bearing, check seals and check for usually at roller spacing.
proper lubrication. Replace bearings, check seals and check for
proper lubrication.
B-09194
Figure 2Diagnosis Of Tapered Roller Bearings

REAR AXLE 4B-7
BENT CAGE BENT CAGE

Cage damaged due to improper handling or Cage damaged due to improper handling or
tool usage. tool usage.
Replace bearing. Replace bearing.
CAGE WEAR INDENTATIONS

Wear around outside diameter of cage and Surface d e p re ssio ns on race and rollers
roller pockets caused by abrasive material caused by hard particles of foreign material.
and inefficient lubrication. Clean all parts and housings. Check seals and
Clean related parts and housings. replace bearings if rough or noisy.
Check seals and replace bearings.
B-09195

4B-8 REAR AXLE
FRETTAGE SMEARS
Corrosion set up by small relative movement Smearing of metal due to slippage. Slippage
of parts with no lubrication. can be caused by poor fits, lu b rica tio n ,
Replace bearing. Clean related parts. Check overheating, overloads or handling damage.
seals and check for proper lubrication. Replace bearings, clean related parts and
check for proper fit and lubrication.
STAIN DISCOLORATION HEAT DISCOLORATION

Discoloration can range from light brown to Heat discoloration can range from faint yel
black caused by incorrect lubricant or m ois low to dark blue resulting from overload or in -
ture. correct lubricant.
Re-use bearings if stains can be removed by Excessive heat can cause softening of races
light polishing or if no evidence of overheat or rollers. To check for loss of temper on
ing is observed. races or rollers a simple file test may be
Check seals and related parts for damage. made. A file drawn over a tempered part will
grab and cut metal, whereas, a file drawn over
a hard part w ill glide readily with no metal
cutting.
Replace bearings if over heating damage is
indicated. Check seals and other parts.
F-00531

REAR AXLE 4B-9
MISALIGNMENT CRACKED INNER RACE

Outer race m isalignm ent due to foreign ob Race cracked due to improper fit, cocking, or
ject. poor bearing seats.
Clean related parts and replace bearing. Make Replace bearing and correct bearing seats.
sure races are properly seated.
FATIGUE SPALLING BRINELLING

Flaking of surface metal resulting from fa Surface indentations in raceway caused by
tigue. rollers either under impact loading or vibra
Replace bearing, clean all related parts. tion while the bearing is not rotating.
Replace bearing if rough or noisy.
B-09860

4B-10 REAR AXLE
ON-VEHICLE SERVICE
REAR AXLE ASSEMBLY 8 . Hydraulic brake lines to the connectors. Refer to

BRAKES (SEC. 5).
REPLACEMENT (ALL AXLES)
9. Parking brake cable to the lever and the flange
plate. Refer to BRAKES (SEC. 5).
Raise the vehicle on a hoist and support the axle
assembly with a suitable lifting device. 10. W heel and b ra ke d ru m or hub and drum
For 93/4-inch ring gear and 1 0 1/2-inch ring gear assembly.
axles, raise the vehicle and place jack stands 11. Propeller shaft. Refer to PROPELLER SHAFT
under the frame side rails for support. (SEC. 4A).
Drain the lubricant from the axle housing.
NOTICE: See Notice on page 4B-1 of this
Remove or Disconnect section.
1. Propeller shaft. Refer to PROPELLER SHAFT

(SEC. 4A). Tighten
Tie the propeller shaft to a side rail or
crossmember. All fasteners to Specifications later in this
Tape the bearing cups to prevent loss of the section.
rollers.
2 . W heel and brake drum or hub and drum
Im portant
assembly.
3. Parking brake cable from the lever and at the
Check axle lubricant level at the filler plug hole.
brake flange plate. Refer to BRAKES (SEC. 5).
Lubricate as needed.
4. Hydraulic brake lines from the connectors. Refer
to BRAKES (SEC. 5). Bleed the brake system, check operation and
adjust if necessary. Refer to BRAKES (SEC. 5).
5. Shock absorbers from the axle brackets. Refer to
REAR SUSPENSION (SEC. 3D). Check axle and brake operation.
6 . Vent hose from the axle vent fitting if used. Check for fluid leaks and road test the vehicle.
7. Height sensing and brake proportional valve
linkage if used. Refer to BRAKES (SEC. 5).
8 . S ta b iliz e r s h a ft if used. R efer to REAR AXLE SHAFT, OIL SEAL AND
SUSPENSION (SEC. 3D).
BEARING REPLACEMENT
Support the assembly with a hydraulic floor
jack. (SVa-^/z-INCH RING GEAR
9. Nuts and washers from the U-bolts. SEMI-FLOATING AXLES)
10. U-bolts, spring plates and spacers from the axle
assembly. Raise the vehicle on a hoist.
Lower the jack and the axle assembly. Clean dirt from around the carrier cover.
Install or Connect
-- Remove or Disconnect (Figure 6 )
1. Axle assembly under the vehicle.

Tools Required:
Align the axle assembly with the springs.
J-2619-01 Slide Hammer with Adapter
2 . Spacers, spring plates and U-bolts to the axle
assembly. J-23689 Axle Shaft Bearing Remover (large
Raise the axle assembly. shaft)
3. Washers and nuts to the U-bolts. J-29712 Axle Shaft B earing Remover
Thread the nuts on firmly. (9 1/2 -inch ring gear)
Adjust alignment of semi-float axles. 1. Wheel and tire assembly. Refer to WHEELS AND
4. Stabilizer shaft if used. TIRES (SEC. 3E).
5. Height sensing and brake proportional valve 2 . Brake drum. Refer to BRAKES (SEC. 5).
linkage if used. Refer to BRAKES (SEC. 5).
3. Carrier cover (19).
6 . Vent hose to the axle vent fitting if used.
7. Shock absorbers to the axle brackets. Refer to Catch the oil in a drain pan.
REAR SUSPENSION (SEC. 3D). Remove gasket material if used.
REAR AXLE 4B-11
1 0 . Drum
1 1 . Bolt
1 2 . Shaft
13. Lock
14. Seal
15. Bearing
16. Housing
17. Clip
18. Bolt
19. Carrier Cover
F-00636
Figure 6Axle Shaft And Housing Detail
WITHOUT LOCKING DIFFERENTIAL

4. Screw (A) (figure 7).
5. Pinion shaft (B) (figure 8 ).
Important
Push the flanged axle shaft (12) toward the center

of the vehicle.
6 . Lock (13) from the button end of the axle shaft
( 12).
7. Axle shaft (12).
W ithdraw the axle shaft (12) from the
housing (16).
Be careful not to damage the oil seal (14).
Dont allow the thrust washer in the 9 1/2 -inch
ring gear axle to slide out when removing
the axle shaft ( 1 2 ).
WITH LOCKING DIFFERENTIAL

4. Screw (A). Refer to figures 8 , 9 and 10.
Hold the pinion shaft (B) when loosening the
screw (A).
Withdraw the pinion shaft (B) part way and
then position the differential case (C) for the
best clearance (figure 9). Rotate the case
(C) until the pinion shaft (B) touches the
housing (D).
Use a screwdriver or similar tool to enter the
case (D) and rotate the lock (13) until the
open end points inward (figure 10 ).
Im portant
Do not force or hammer the axle shaft ( 1 2 ) to gain

removal clearance.
Lock (13). Refer to figures 10 and 11.
With the lock (13) correctly positioned, push
the axle shaft ( 1 2 ) inward and remove the
lock (13).
4B-12 REAR AXLE
Figure 9P ositioning The Case Figure 12Removing The Bearing And Seal
For Best Clearance
6 . Axle shaft (12).
B. Pinion Shaft Slide the axle shaft ( 1 2 ) out. Be careful not

E. Thrust Block to damage the seal (14).
F. Side Gear (Locking 7. Seal (14).
Differential) Use the button end of the axle shaft (12) to
G. Lock (C-Lock) pry the seal (14) out or use J-23689.
H. Shaft 8 . Bearing (15).
Use J-23689 for 8 1/2 -inch ring gear axle and
J-29712 for 9 V2-inch ring gear axle. Attach
J-2619-01 to J-23689.
Insert tool into the axle bore so that it grasps
behind the bearing (15) (figure 12). Tighten
nut and washer against the face of the
bearing (15) or seal (14).
F-00640 L* Inspect
All parts. Replace as necessary.

Figure 10 A ligning The C-Lock Correctly
Tools Required:
J-21128 Axle Shaft and Pinion Oil Seal
Installer
J-23690 Axle Shaft Bearing Installer
J-29709 A xle S haft B ea ring In s ta lle r
(9 1/2 -inch ring gear)
J-29713 Axle Shaft Seal Installer (9 1/2 -inch
ring gear)
Lubricate the axle cavity between the seal
(14) lips and the bearing (15) with wheel
bearing lubricant. Refer to MAINTENANCE
AND LUBRICATION (SEC. OB).
1. Bearing (15).
Use J-23690 for the 8 1/2 -inch gear axle and
J-29709 for the 9 1/2 -inch ring gear axle.
REAR AXLE 4B-13
WITHOUT LOCKING DIFFERENTIAL

4. Lock (13).
Lock on the button end of the axle shaft
( 1 2 ), then push the shaft outward to seat the
lock in the counterbore of the differential
side gear.
5. Pinion shaft (B) figure 8 .
Into the differential case (C) and pinion
gears.
Align the hole in the pinion shaft (B) with the
screw hole in the differential case (C).
Thread the screw (A) in and tighten to 18
N m (25 ft. lbs.).
WITH LOCKING DIFFERENTIAL

4. Lock (13).
Keep the pinion shaft (B) partially withdrawn
(figure 9).
Figure 13Installing The Wheel Bearing Place the lock (G) in the position shown in
figure 10 .
Bearing (15) into the axle (16) housing until Carefully withdraw the axle shaft (12) until
the tool bottoms against the tube. Refer to the lock (13) clears the thrust block.
figure 13. Align the pinion shaft (B) hole with the screw
hole in the differential case (C) figure 8 .
2. Seal (14). 5. Screw (A). Refer to figure 8 .
Use J-21128 for 8 1/2 -inch ring gear axle and
J-29713 for the 9 1/2 -inch ring gear axle. Tighten
Drive the tool into the bore until the seal (14) Screw (A) to 18 N m (25 ft. lbs.).
bottoms flush with the end of the tube Gasket if used, otherwise RTV. Be sure sealing
(figure 14). surface is clean.
Carrier cover (19).
3. Axle shaft (12).
Bolts (18) and clip (17).
Be careful not to damage the seal (14) when Tighten bolts (18) in a crosswise pattern to
inserting the axle shaft ( 1 2 ). assure uniform draw on the gasket if used.
Fill axle to filler plug hole level. Refer to
Slide the axle shaft (12) into place allowing MAINTENANCE AND LUBRICATION (SEC.
the splines to engage the differential side OB) for proper lubricant.
gear (F) figure 10. 9. Brake drum. Refer to BRAKES (SEC. 5).
10. Wheel and tire assembly. Refer to WHEELS AND
TIRES (SEC. 3E).
Lower the vehicle and road test.
BRAKE BACKING PLATE

REPLACEMENT (8 V2- AND
9 1 /2-INCH RING GEAR
SEMI-FLOATING AXLES)
+ Remove or Disconnect
1 . Wheel, tire and brake drum. Refer to BRAKES

(SEC. 5).
2. Axle shaft. Refer to Axle Shaft Replacement
earlier in this section.
3. Brake line from the cylinder inlet.
4B-14 REAR AXLE
Brake components from the backing plate. Install or Connect

1. Stud in the axle flange hole. Refer to figure 15.
4. Bolts and washers from the axle.
Start the new stud into the axle flange hole
5. Backing plate. by pressing firmly with your hand.
Thread on a lug nut with the flat side to the
Install or Connect vehicle.
Tighten the lug nut and draw the stud head
1. Backing plate to the axle. into the rear of the flange.
2 . Bolts and washers to the plate. Thread the lug nut off.
Attach components to the backing plate. 2. Wheel, tire and brake drum.
Refer to BRAKES (SEC. 5). Lower the vehicle.
3. Brake line to the cylinder inlet.
Refer to BRAKES (SEC. 5) for bleeding and PINION FLANGE, DUST
adjustment procedure.
DEFLECTOR/OIL SEAL
4. Axle shaft. Refer to Axle Shaft Replacement REPLACEMENT (8 1 /2 - 9 1/2-INCH
earlier in this section.
RING GEAR SEMI-FLOATING
5. Wheel, tire and brake drum.
AXLES)
W HEEL STUD REPLACEMENT
(8 1/2 -9 1/2-INCH RING Remove or Disconnect
GEARSEMI-FLOATING AXLES)
Tool Required:
Raise the vehicle on a hoist and allow the axle to J-8614-01 Companion Flange Holder and
hang free. Remover
1. P ro p e lle r sh a ft from the a xle . R efer to
Remove or Disconnect PROPELLER SHAFT (SEC. 4A).
Tie the propeller shaft to a frame rail or
Tool Required: crossmember.
J-6627-A Wheel Stud Remover
Measure
1. Wheel, tire and brake drum.
2. Stud from the axle flange using J-6627-A (figure The torque required to rotate the pinion (figure
15). 16). Record the torque value for later reference.
REAR AXLE 4B-15
; Im portant
Scribe a line on the pinion stem, pinion nut and

the companion flange and record the number of
exposed threads on the pinion stem. Use the
scribed reference and the exposed threads as a
reinstallation guide (figure 17).
2. Nut using J-8614-01.
Position J-8614-01 on the flange so that the
four notches on the tool face the flange
(figure 18).
3. Flange using J-8614-01
Use the special nut and forcing screw to
remove the flange (figure 19).
4. Oil seal. Use a screw driver to pry the seal out of
the bore.
Inspect
The pinion flange for a smooth oil seal surface,

for worn drive splines, damaged ears and for
smoothness of the bearing contact surface.
5. Dust deflector.
Tap the d e fle c to r from the fla n g e if
replacement is necessary.
Clean up the stake points on the flange.
Clean all foreign material from the contact
area.
Install or Connect
Tools Required:
J-8614-01 Companion Flange Holder and
Remover
J-22388 Pinion Oil Seal Installer (9 1/2 -inch
ring gear)
J-22804-1 Pinion Oil Seal Spacer
J-22836 Pinion Seal Installer (8 1/2 -inch ring
gear)
1. Dust deflector on the flange.
Stake new deflector at three new equally
spaced positions. Staking must be such that
the seal operating surface is not damaged.
2 . Oil seal.
Pack the cavity between the lips of the oil
seal with extreme pressure lithium-base
lubricant.
Position the oil seal in the bore then place
J-22804-1 over the oil seal and flat against
the seal flange (figure 2 0 ).
Use J-22836 or J-22388 for the 9 1/2 -inch
ring gear to press the oil seal into the bore
(figure 2 0 ).
Turn J-22804-1 from installed position 180
degrees to assure proper in sta lla tio n
against the pinion flange.
4B-16 REAR AXLE
Figure 22Installing Or Removing

Flange-To-Hub Bolts
Pack the cavity between the end of the
pinion splines and the pinion flange with a Tighten
non-hardening sealer such as PERMATEX
TYPE A or equivalent. The p in io n nut in a d d itio n a l sm a ll
increments until the torque necessary to
3. Flange onto the pinion using J-8614-01. rotate the pinion exceeds the original
recorded value by 0.35 N-m (3 in. lbs.).
Place washer and nut on the pinion threads 4. Propeller shaft. Refer to PROPELLER SHAFT
and tighten the nut to the original scribed (SEC. 4A).
p o s itio n using the scrib e m arks and
Lower the vehicle and road test.
exposed threads as a reference (figure 2 1 ).
DO NOT ATTEMPT TO HAMMER THE
FLANGE ONTO THE PINION SHAFT.
AXLE SHAFT REPLACEMENT
(93/4-1OVz-INCH RING G E A R -
% Measure
FULL FLOATING AXLES)
The rotating torque of the pinion and compare
This procedure covers the 93/4-inch and 1 0 1/2-inch
with the torque recorded earlier (figure 16).
ring gear, full floating axles.
1 . Bolts (35) (figures 2 2 and 23).

Rap the axle shaft (34) flange with a soft
faced hammer to loosen the shaft.
Grip the rib on the axle shaft (34) flange with
a locking plier and twist, to start shaft
removal.
2. Axle shaft (34) from the tube.
P y l Clean (Figure 23)
Axle shaft (34) flange. Remove old RTV or

gasket (33).
Outside face of the hub assembly (31).
Lubricant in the area w ill loosen the
Figure 21Installing The Pinion Flange shaft-to-hub bolts (35).
REAR AXLE 4B-17
A. Chevrolet
B. Dana
40. Nut
41. Lock
42. Adjusting Nut
43. Washer
44. Outer Bearing
45. Retaining Ring
46. Inner Bearing
47. Oil Seal
48. Drum
49. Hub
50. Stud
51. Gasket
52. Shaft
53. Axle Shaft Flange
54. Washer
55. Bolt
56. Retaining Ring
57. Key
58. Adjusting Nut
59. Outer Bearing
60. Retaining Ring
61. Inner Bearing
62. Oil Seal F-00647
Figure 23Full Floating Axle, Hub And Drum Assem bly Detail
L * Inspect J-2222-C Wheel Bearing Nut Wrench

1 . Wheel and tire.
All parts and replace as necessary. 2. Axle shaft (52) as outlined earlier in this section.
3. Nut (40) use J-2222-C or retaining ring (56). Refer
-+ Install or Connect (Figure 23) to figure 24.
4. Lock (41) or key (57).
1. Axle shaft (34) with a gasket or RTV applied. 5. Adjusting nut (42, 58). Refer to figure 24.
Be sure the shaft splines mesh into the 6 . Washer (43).
differential side gear. 7. Hub and Drum (48, 49).
Align the axle shaft holes with the hub
holes.
2. Bolts (35) figures 2 2 and 23.
Tighten
Bolts (35) to specified torque later in this section.
HUB AND DRUM ASSEMBLY

REPLACEMENT
(9 3/4 -1 0 1/2-INCH RING G E A R -
FULL FLOATING AXLES)
Raise the vehicle until the wheel is free to rotate.

Tool Required:
4B-18 REAR AXLE
Inspect
All parts and replace as necessary.
|~n-| Install or Connect (Figure 23)

page 4B-1 of this section.
Tool Required:
J-2222-C Wheel Bearing Nut Wrench
1. Hub and drum (48, 49) to the tube.
Be sure the bearings and the oil seal are
positioned properly.
Apply a light coat of high melting point EP
bearing lubricant to the contact surfaces
and the outside of the axle tube.
2. Washer (43). Tang into key way.
3. Adjusting nut (42, 58). Refer to figure 24.
6 . Outer bearing (44) or (59) using J-8092 with
J-24426 (figure 25).
Drive the bearing (44, 59) and cup from the
Adjusting nut (42, 58) to specified torque hub (49).
later in this section.
4. Lock (41) or key (57). ay Clean
Bend the tang to the flat of the adjusting nut
(42) or insert the key (57). Old sealing compound from the oil seal (47,
5. Nut (40) or retaining ring (56). Refer to figure 24. 62) bore in the hub (49).
Bearing assemblies in a solvent using a stiff
Tighten brush to remove the old lubricant. Dry the
bearings with compressed air. Do not spin
Nut (40) to specified torque later in this them.
section. Lubricant from the axle housing and inside
6 . Axle shaft (52) earlier in this section. the hub (49).
7. Wheel and tire. Gasket material from the hub (49), axle
Lower the vehicle. shaft (52).
L* Inspect
WHEEL BEARING/CUP
Bearings for wear, chipped edges or other
REPLACEMENT damage. Check for flat or rough spots on
(93/4-1OV2-INCH RING G E A R - the rollers.
FULL FLOATING AXLES) Cups for pits and cracks.
Oil seal for wear or roughness. Replace
|+ + | Remove or Disconnect (Figure 23) parts as necessary.
Raise the vehicle till the wheels are free to rotate. Install or Connect (Figure 23).
Tools Required:
J-8092 Driver Handle Tools Required:
J-24426 Outer Wheel Bearing Cup Installer J-8092 Driver Handle
1. Axle shaft (52) as outlined earlier in this section. J-8608 Pinion Bearing Cup Installer
2. Hub and drum (48, 49) as outlined earlier in this J-24426 Outer Wheel Bearing Cup Installer
section. J-24427 Inner Wheel Bearing Cup Installer
3. Oil seal (47) or (62). Use a drift. J-24428 Axle Shaft Seal Installer
4. Inner bearing (46) or (61). Use a drift to remove 1. Outer bearing (44, 59) into the hub (49).
the bearing and cup. Outer cup into the hub (49) using J-8092
5. Retaining ring (45) or (60). and J-8608. Be sure J-8608 is installed
Use snap ring pliers to remove the ring. upside down on the driver handle J-8092.
REAR AXLE 4B-19
Drive the outer cup beyond the retaining

ring groove.
2. Retaining ring (45) or (60) into the groove.
Drive the outer bearing cup against the
retaining ring (45) or (60) using J-8092 and
J-24426 (figure 25).
3. Inner bearing (46) or (61).
Drive the inner bearing cup into place until
seated against the shoulder of the hub (49)
using J-8092 and J-24427.
4. Oil seal (47) or (62). Use J-24428 to install the
new oil seal (47, 62).
5. Hub and drum (48, 49) as outlined earlier in this
section.
6. Axle shaft (52) as outlined earlier in this section. A. Removing Wheel Bolt
B. Installing Wheel Bolt F-00650
NON-DEMOUNTABLE TYPE Figure 26Wheel Bolt Replacement

DRUM REPLACEMENT
Construction of the non-demountable type drum BEARING ADJUSTMENT
and hub assembly is such that replacement
cannot be done with the hub assembly installed Make sure the brakes are fully released and do
on the vehicle. not drag.
Check the wheel bearing play by grasping the tire
Remove or Disconnect at the top and pulling and pushing back and forth,
or by using a pry bar under the tire. If the wheel

Raise the vehicle. bearings are properly adjusted, movement of the
1 . Hub and drum assembly. Refer to Hub and brake drum in relation to the brake flange plate
Drum Assembly Replacement earlier in this will be barely noticeable and the wheel will turn
section. freely. If the movement is excessive, adjust the
2. Retaining bolts, stud nuts or wheel studs. bearings.
Separate the drum, hub and oil deflector.
Press the wheel studs out of the drum. Remove or Disconnect (Figure 23)
Replace parts as necessary.
Tool Required:
-+ Install or Connect
J-2222-C Wheel Bearing Nut Wrench
1. Drum to the hub. Raise the vehicle until the wheel is free to
Make certain drain holes are in alignment. spin.
2 . Oil deflector to the drum.
1. A xle sh a ft (52). R efer to A xle S ha ft
Apply a light coating of sealing compound to
Replacement earlier in this section.
the oil deflector contact surface.
3. Retaining bolts, stud nuts or wheel studs. Be sure the keyway, threads and adjusting
Press the wheel studs into the drum. nut (42, 58) are clean and free of chips,
burrs and shavings.
2. Nut (40) if used or retaining ring (56).
WHEEL BOLT REPLACEMENT
Disengage the tang from the nut (40).
Wheel bolts are serrated and may also be 3. Lock (41) if used or key (57).
sw aged in p la ce ; how ever, re p la c e m e n t
procedure remains the same for both types of
installation. Press the wheel bolts out of the hub
flange, then press new wheel bolts into place,
Adjusting nut (42, 58) to 70 N m (50 ft. lbs.) using
making sure of a tight fit. When replacing all of
J-2222-C (figures 27 and 28).
the wheel bolts be sure that the hub oil deflector
is in position under the wheel bolt heads. Refer to Be sure the bearings are seated and in contact
figure 26. with the spindle shoulder.
4B-20 REAR AXLE
3. A xle sh a ft (52). R efer to A xle S h a ft

PINION OIL SEAL/COMPANION

FLANGE REPLACEMENT
The pinion oil seal and the companion flange
may be replaced with the carrier assembly
installed in the vehicle.
Tools Required:
Remover
J-22281 Pinion Oil Seal Installer (DANA
Figure 27Tightening The A djusting Nut 93/4-inch ring gear axle)
J-24384 Pinion Oil Seal Installer (DANA
Adjust 1 0 1/2 -inch ring gear axle)
J-2 4 43 4 P in ion O il S eal In s ta lle r
Nut (42, 58). Back the nut (42, 58) off until just (CHEVROLET 1 0 1/2 -inch ring gear axle)
loose using J-2222-C. Align the adjusting nut (58) Raise the vehicle.
slot with the keyway in the axle spindle. Do not 1. Propeller shaft. Refer to PROPELLER SHAFT
back the adjusting nut (58) off more than one slot (SEC. 4A).
to gain alignment. Tie the propeller shaft to a frame rail or
crossmember.
Install or Connect (Figure 23).
Important
1. Key (57) if used or new lock (41).
Key (57) into the keyway and adjusting nut Scribe a line on the pinion stem, pinion nut and
(58) slot. companion flange to be used as a guide for
Bend the lock (41) tang to the flat of the reinstallation (figure 17).
adjusting nut (42). 2. Nut using J-8614-01 (figure 18).
2. Retaining ring (56) or nut (40) if used. 3. Flange using J-8614-01.
Bend the lock (41) tang to the flat of the nut Use the special nut and forcing screw to
(40). remove the flange (figure 19).
Be sure the retaining ring (56) is seated. 4. Oil seal.
Pry the oil seal from the bore. Do not
damage the machined surfaces and then
thoroughly clean foreign material from the
contact area.
Replace parts as necessary.
J-2222-C
0 Install or Connect
1 . Oil seal into the bore.

Lubricate the cavity between the new seal
lips with a high m elting point bearing
lubricant.
Use the proper seal installing tool listed
under tools required.
2 . Flange using J-8614-01.
Use scribed marks for reinstallation.
F-00863 3. Nut, use J-8614-01 (figure 18).
Use s c rib e m ark as an in s ta lla tio n
Figure 28Wheel Bearing Nut Wrench reference.
REAR AXLE 4B-21
4. Propeller shaft. Refer to PROPELLER SHAFT Tap the axle shaft (74) into position using
(SEC. 4A). J-8117 and J-2619-01.
Index the axle shaft (74) splines into the hub
(86 ) splines.
AXLE VENT REPLACEMENT
2. Gasket (73).
(12-INCH RING GEAR-FULL 3. Hub cap (72).
FLOATING AXLE) 4. Washers (71) and bolts (70).
A threaded type axle vent is used on the
Rockwell 12-inch ring gear axle and must be
replaced if the vent cap is damaged or missing.
BEARING ADJUSTMENT (12-INCH
GEARFULL FLOATING AXLE)
Clean
Make sure the brakes are fully released and do
The area around the axle vent. not drag.
Check the wheel bearing play by grasping the tire
Remove or Disconnect at the top and pulling and pushing back and forth,
0
or by using a pry bar under the tire. If the wheel
Axle vent from the housing. bearings are properly adjusted, movement of the
hub or disc will be barely noticeable. If the
Install or Connect movement is excessive, adjust the bearings.
0
Axle vent to the housing.
Tool Required:
AXLE SHAFT REPLACEMENT J-25510 Wheel Bearing Nut Wrench
(12-INCH RING GEARFULL Raise the vehicle until the wheel is free to
FLOATING AXLE) spin.
1. A xle s h a ft (74). R efer to A xle S ha ft
Raise the vehicle and place jack stands under Replacement.
the frame side rails.
2. Nut (90) using J-25510.
" Remove or Disconnect (Figure 29) Release the tang.
3. Lock washer (89).
Tools Required:
J-2619-01 Slide Hammer Adjust
J-8117 Axle Shaft Puller Adapter
1. Bolts (70) and washers (71). Nut (8 8 ) using J-25510. Tighten the nut (88 )
2. Hub cap (72). while the hub is rotating to 68 N m (50 ft.
Thread J-8117 into the tapped hole on the axle lbs.). Make sure the bearing surfaces are in
shaft (74) flange. contact and then back the nut (88 ) off 1/s
Attach J-2619-01 to J-8117. turn.
3. Axle shaft (74) using J-2619-01.
|-n-| Install or Connect (Figure 29)
1. Lock washer (89).

Old gasket material from the hub (86 ) and hub Bend a tang over a flat of the adjusting nut
cap (72) and the axle shaft (74) flange and mating ( 88 ).
surface in the hub (86 ). 2. Nut (90) using J-25510.

Tighten the nut (90) to 339 N m (250 ft. lbs.).
Bend a long tang of the lock washer (89)
Tools Required: over a flat of the nut (90).
J-2619-01 Slide Hammer 3. A xle sh a ft (74). R efer to A xle S ha ft
J-8117 Axle Shaft Puller Adapter Replacement.
1. Axle shaft (74). Lower the vehicle.

4B-22 REAR AXLE
70. Bolt
71. Washer
72. Hubcap
73. Gasket
74. Axle Shaft
75. Axle Housing
76. Bracket
77. Wheel Bolt
78. Hex Bolt

79. Deflector
80. Oil Seal
81. Inner Bearing
82. Brake Disc
83. Retaining Ring
84. Outer Bearing
85. Spacer
86. Hub
87. Thrust Washer
88. Adjusting Nut
89. Lock Washer
90. Nut F-01012
Figure 29Rockwell Axle And Hub Detail
DRIVE PINION OIL SEAL

REPLACEMENT
(12-INCH RING G E A R -
FULL FLOATING AXLE)
A pinion oil seal may be replaced on the Rockwell
1 2 -inch ring gear axle with the carrier assembly
installed in the vehicle.
Tools Required:
Remover
J-22281 Pinion Oil Seal Installer
Raise the vehicle.
(SEC. 4A).
Im portant
91. Cotter Key 95. Oil Seal Retainer
Scribe a reference line on the pinion stem, pinion 92. Nut 96. Oil Seal
nut and companion flange. 93. Pinion Shaft 97. Bolt
2. Cotter key (91) and nut (92) using J-8614-01. 94. Companion Flange F-01013
3. Companion flange (94).
4. Bolts (97).
Figure 30 Drive Pinion Oil Seal Detail
5. Oil seal retainer (95).
REAR AXLE 4B-23
6 . Oil seal (96). bore shoulder.

Pry the oil seal (96) from the bore being 2 . Oil seal retainer (95).
careful not to dam age the m achined 3. Bolts to the retainer (97).
surfaces. 4. Companion flange (94) use the scribed reference
mark.
IQ* Clean 5. Nut (92) using J-8614-01.
The seal contact area. $ Tighten
Install or Connect (Figure 30) Nut (92). Align the castellated nut with the
hole in the pinion shaft (93) stem and the
Lubricate the cavity between the new seal (96) reference mark.
lips with a high melting point bearing lubricant. 6 . Cotter key (91).
Refer to MAINTENANCE AND LUBRICATION 7. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. OB). (SEC. 4A).
Oil seal (96) into the bore using J-22281.
Be sure the seal (96) bottoms against the
4B-24 REAR AXLE
SPECIFICATIONS
TORQUES
DANA CHEVROLET ROCKWELL
8 V2 " RING GEAR- 9 V2 " RING GEAR- RING
93/4 " - 1 0 1/2" IOV2 " RING GEAR 12" RING GEAR
SEMI FLOATING SEMI FLOATING GEAR AXLE-FULL AXLE-FULL AXLE-FULL
AXLE AXLE FLOATING FLOATING FLOATING
Nm FT. LBS. Nm FT. LBS. Nm FT. LBS. Nm FT. LBS. Nm FT. LBS.
Filler Plug 34 25 24 18 14 10 24 18 47 35
Lock Screw 34 25 34 25
Brake Backing
Plate 47 35 142 105 142 105 142 105
Axle Shaft to
Hub Bolts 156 115 156 115
Carrier Cover 27 20 27 20 47 35 41 30
Axle Liters Pints Liters Pints Liters Pints Liters Pints Liters Pints
Lubricant
Capacity 2.0 4.2 2.6 5.5 2.6 5.5 3.4 7.2 6.6 14.0
WHEEL BEARING ADJUSTMENT VALUES
RESULTING
RING GEAR BEARING ADJUSTING ADJUSTING NUT OUTER LOCKNUT BEARING TYPE OF
SIZE NUT TORQUE* BACKOFF* TORQUE ADJUSTMENT BEARING
**
9 % " Ring Gear 68.0 N m 50 ft. lbs. 88.1 N m 65 ft. lbs. 0.0254 to 0.254 mm
TAPERED
10 V2 " Ring Gear 68.0 N m 50 ft. lbs. .001 to .010 inch
ROLLER
12" Ring Gear 68.0 N m 50 ft. lbs. 1/a Turn 339.0 N m 250 ft. lbs. End Play
* W ith wheel rotating.

**B a ck -o ff the nut and retighten to 47 N m (35 ft. lbs.). Then back the nut off 1/4 turn
REAR AXLE 4B-25
1 . J-8117 Axle Shaft Puller Adapter

2 . J-6627-A Wheel Stud Remover
3. J-8092 Driver Handle
4. J-5853 Torque W rench Inch/Pound
5. J-8614-01 Companion Flange Holder And Remover
6 . J-2619-01 Slide Hammer With Adapter
7. J-2222-C Wheel Bearing Nut Wrench
8 . J-24426 Outer Wheel Bearing Cup Installer
9. J-24427 Inner Wheel Bearing Cup Installer
10 . J-8608 Outer Pinion Bearing Cup Installer
1 1 . J-24384 Pinion Oil Seal Installer
1 2 . J-24428 Axle Shaft Seal Installer
13. J-24434 Pinion Oil Seal Installer
14. J-22281 Pinion Oil Seal Installer
15. J-8114 Wheel Bearing Outer Cup Installer
16. J-8093 Wheel Bearing Inner Cup Installer
Figure 31Special Tools

4C-1
SECTION 4C
FRONT AXLE
the manual as indicated at appropriate locations by the terminology: NOTICE: See Notice on page 4C-1 of this
section.
NOTICE: All front axle fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during reassembly to
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................. 4C- 2

Diagnosis Of The Front A xle .................................................................................................................................... 4C- 2
Road T e s t ................................................................................................................................................................ 4C- 2
Tire N o is e s .............................................................................................................. ............................................... 4C- 2
Engine or Exhaust N o is e s .................................................................................................................................... 4C- 2
Test For Wheel Bearing N o is e ........................................................................................................................... 4C- 2
Test For Differential Bearing N o is e ...................................................................................................................4C- 2
Test For Pinion Bearing N o is e ........................................................................................................................... 4C- 2
On-Vehicle Service..................................................................................................................................................... 4C- 3
Axle Shaft Replacement........................................................................................................................................ 4C- 3
Front Axle Assembly Replacement.....................................................................................................................4C- 4
Axle Joint Component R e p la ce m e n t................................................................................................................ 4C- 5
Locking Hub Component R eplacem ent............................................................................................................ 4C- 5
Autom atic Hub To The Wheel A d ju s tm e n t......................................................................................................4C- 8
Manual Locking Hub R eplacem ent.....................................................................................................................4C- 8
Manual Locking Hub Rebuild P ro c e d u re .......................................................................................................... 4C- 8
S pecifica tio ns..............................................................................................................................................................4C-10
Special T o o ls .............................................................................................................................................................. 4C-10
4C-2 FRONT AXLE
DESCRIPTION
The front axle is a hypoid gear axle unit equipped and is rated at 4500 pound capacity. The Dana axle
with steering knuckles and an automatic or manual has a 9 3/4-inch ring gear. Automatic hub locks are used
locking hub. The K10 and 20 models use a Chevrolet on all models to engage the hub whenever four-wheel
front axle having an 8 1/2 -inch ring gear axle rated at drive is selected. A manual locking hub is used on the
3600 pounds for the K-10 and 3800 pounds for the K- K-30 model only and must be engaged manually when
20. A Dana (60 Series) axle is used on the K-30 model ever four-wheel drive is selected.
DIAGNOSIS OF THE FRONT AXLE
ROAD TEST Noise should change due to cornering loads.

Jack-up wheels to verify roughness at the wheels.
Check tires for irregular wear.
Check tire pressure.
*TEST FOR DIFFERENTIAL
Check axle lubricant level.
Drive to warm up the front axle. BEARING NOISE
Test at various speeds in drive, float, coast and
while cornering. Drive the vehicle at low speed on a smooth road.
Verify that the hubs are locked. Constant low pitch bearing noise may be heard.
Noise should not change in reversing turns.
The noise pattern should vary with the wheel
TIRE NOISES speed.
Change the tire pressure to minimize noises.

Drive over different road surfaces. *TEST FOR PINION BEARING
Smooth black-top minimizes tire noise. NOISE
Cross switch the tires, if necessary.
Snow tire treads and studs cause added noises. Rough running or a whine noise should increase
with speed.
Noise pitch should be higher than differential
ENGINE OR EXHAUST NOISES noise.
Perform the test on a smooth road to minimize
Drive slightly above the speed where the noise tire noises.
occurs, place transmission in neutral. Perform test at various speeds in drive, float, and
Let the engine speed drop to idle. coast.
Stop the vehicle. Rear pinion bearing noise may be louder on
Run the engine at various speeds. acceleration.
Front pinion bearing noise may be louder on
deceleration.
TEST FOR WHEEL BEARING NOISE Gear noise tends to peak in a narrow speed
range.
Drive the vehicle at low speed on a smooth road.
Turn the vehicle to develop left and right motions,
traffic permitting.
Bearing tests should be done in 2H (after 4H
selection to lock hubs). This removes the transfer case
whine.
FRONT AXLE 4C-3
ON-VEHICLE SERVICE
2 0 . Hub Lock
2 1 . Ring
2 2 . Retainer
23. Nut
24. Ring
25. Nut
26. Outer Bearing
27. Cup
28. Hub And Disc
30. Cup
31. Inner Bearing
32. Inner Seal
33. Outer Deflector
34. Seal
35. Spacer
36. Seal
37. Bearing
38. Spindle
39. Brake Bracket
40. Brake Caliper
41. Splash Shield
42. Housing
43. Tube
44. Knuckle
46. Axle Shaft
47. U-Joint
48. Washer
49. Nut
F-01015
Figure 1Front Axle Detail
AXLE SHAFT REPLACEMENT 6 . Splash shield (41), brake bracket (39) and spindle
(38).
Remove or Disconnect (Figure 1) 7. Axle shaft (46).
Raise the vehicle. IJI Clean

1 . Wheel and tire.
Inner and outer wheel bearing (31, 26).
2. Brake caliper (40).
Hub and disc (28), spindle (38).
Im portant
Inspect
Support the brake caliper (40) so as not to
stretch or damage the brake hose.
3. Hub lock mechanism (20).
Important
4. Rotor and hub (28).
5. Inner bearing (31) and seal (32). Lube the spindle bearing (37) and spindle (38).
4C-4 FRONT AXLE
Pack the inner and outer wheel bearing (31, 26).
NOTICE: For steps 3, 4 and 5, see Notice on

page 4C#1 of this section.
1. Seal (36) and spacer (35) to the axle shaft (46).

2. Axle shaft (46) into the housing (42).
3. Spindle (38) to the knuckle (44). Be sure the seal
(34) and outer deflector (33) are in place.
4. Brake bracket (39).
New washers (48) and nuts (49) to the studs.
Torque the nuts (49) to 88 N m (65 ft. lbs.).
6 . Hub and disc (28).
Adjust the wheel bearings (26, 31). Refer to
FRONT SUSPENSION (SEC. 3C).
7. Retainer (22) and ring (21).
8 . Hub lock mechanism (20).
NOTICE: See Notice on page 4C#1 of this

section.

Do not stretch or damage the brake hose.
10. Wheel and tire.
Lower the vehicle and test.
L * Inspect
FRONT AXLE ASSEMBLY The a sse m b ly and re p a ir or re p la ce as
REPLACEMENT necessary.
Raise the vehicle until the weight is removed from

the front springs. Support the vehicle with jack NOTICE: For steps 1, 5, 6 and 7, see Notice
stands placed behind the front springs. on page 4C#1 of this section.

1. Propeller shaft. Refer to Propeller Shaft (Sec.
4A). Axle assembly positioned under the vehicle.
2. Connecting rod from the steering arm. Refer to
FRONT SUSPENSION (SEC. 3C). 1. Plates, spacers, U-bolts, washers and nuts.
2. Axle vent tube and clips. Refer to figure 2.
Support the brake caliper (40) so as not to
stretch or damage the brake hose.
3. Front stabilizer bar.
4. Shock absorbers from the axle brackets.
5. Front stabilizer bar.
4. Shock absorbers to the axle brackets.
6 . Axle vent tube and clips (figure 2).
7. Nuts, washers, U-bolts, spacers and plates. 5. Brake caliper (40).
Support the axle with a jack.
8 . Axle assembly out from under the vehicle. 6 . Connecting rod to the steering arm.
Jjj Clean 7. Propeller shaft.
Axle assembly. Lower the vehicle.

FRONT AXLE 4C-5
AXLE JOINT COMPONENT 9. Ring (57) using needle nose plier.

Pull the remaining components from the
REPLACEMENT wheel.
10. Retaining ring (77) from the sleeve (67) groove.
Rotate the drag sleeve (75) until it drops into
engagement with the gear (59).
Raise the vehicle.
Lift and cock the drag sleeve (75) to unlock
1 . A xle s h a ft. R efer to A xle S ha ft
the tangs of the brake band (74) from the
window of the inner cage (72), then move
Support the shaft yoke in a bench vise or on
the drag sleeve (75) and brake assembly
a short piece of pipe.
away.
2. Trunnion
Using a brass drift and soft hammer drive
Important
on the end of a trunnion bearing enough to
drive the opposite bearing from the yoke.
NEVER REMOVE THE BRAKE BAND (74) FROM
Support the other yoke and drive the
THE DRAG SLEEVE (75). The spring tension of
trunnion bearing out in the same manner.
the brake band (74) can be changed if the coils
are over expanded and the operation of the hub
Clean
could be affected.
11. Ring (73) from the groove in the clutch gear (59).
The bearings and yokes.
12. Inner cage (72).
While removing the inner cage (72) use a
L* Inspect
small screw driver to pry the plastic outer
cage (71) away.
The bearings and yokes. Replace parts as
13. Outer cage (71).
necessary.
Pry the plastic outer cage (71) tabs free from
+ + Install or Connect the groove in the clutch gear (59) and move
the outer cage (71) away.
Lubricate the new bearings with a high melting 14. Sleeve (67) from the clutch gear (59).
point type wheel bearing grease. Compress the return spring (64) and hold
1. Bearing in a yoke ear. the assembly in a compressed condition by
2. Trunnion in the bearing. using the clamps shown in figure 4.
3. Another bearing in the opposite yoke ear with the Position the assembly with the clamps in
trunnion aligned. place in a vice and hold both ends of the
4. Bearing in each ear of the companion yoke. sleeve (67).
Press the bearings in beyond the iock ring 15. Ring (61).
grooves. While holding the sleeve (67) in the vise,
5. Lock ring at each bearing. remove the clamps holding the return spring
Tap the yoke lightly to seat the bearings (64) and then open the vise and release the
against the lock rings. return spring (64).
16. Retainer plate (62).
17. Retainer (63).
LOCKING HUB COMPONENT 18. Stop ring (68 ).
REPLACEMENT Align the ends of the stop ring (68 ) with the
legs of the cam (70) to allow removal.
AUTOMATIC HUB COMPONENT 19. Spring (69).
REPLACEMENT 20. Cam (70) from the gear (66 ).
Remove or Disconnect (Figure 3) Inspect
1. Screws (50) and O-ring seals (52). All parts and replace as necessary.
2. Cover (52).
3. Seal (53). Install or Connect (Figure 3)
4. Keeper (60).
5. Spring (54). 1 . Cam (70) over the flats of the gear (66 ).
6. Inner race (55). 2. Spring (69).
7. Bearing (56). Compress the spring (69) and slide the large
8. Retainer (58). diameter end against the gear (66 ).
4C-6 FRONT AXLE
50. Screw
51. O-Ring Seal 67. Sleeve
52. Cover 68. Stop Ring
53. Seal 69. Spring
54. Spring 70. Cam
55. Inner Race 71. Outer Cage
56. Bearing 72. Inner Cage
57. Ring 73. Ring
58. Retainer 74. Brake Band
59. Clutch Gear 75. Drag Sleeve
60. Keeper 76. Spacer
61. Ring 77. Retaining Ring
62. Retainer Plate 78. Washer-K10, K20
63. Retainer 79. Adjusting Nut
64. Return Spring 80. Lock Ring
65. Retainer 81. Nut W ith Pin
66. Gear 82. Ring-K30 F-01017
Figure 3Automatic Hub-Detail K10, K20, K30

FRONT AXLE 4C-7
9. Inner cage (72) into the outer cage (71).

Align the tab of the outer cage (71) with the
window of the inner cage (72).
10. Ring (73).
Into the groove of the clutch gear (59) above
the outer cage (71).
Im portant
Service the brake band (74) and drag sleeve

(75) as an assembly and be sure the original
lu b ric a n t has not been rem oved or
contaminated. Lubricant number 1052750
61. Ring or its equivalent m ust be used in this
67. Sleeve assembly.
70. Cam 11. Brake band (74) tangs.
A. Clamp Place the tangs of the brake band (74) on
B. Vs-inch each side of the lug of the outer cage (71)
C. 1 1/4-inches located in the window of the steel inner
D. 3/8-inch cage (72). Cock these parts to engage the
tangs in this position.
12. Spacer (76) and retaining ring (77).
To the sleeve (67) above the drag sleeve
(75).
13. Hub assembly to the vehicle.
F-01018
14. Ring (57) to the clutch gear (59) unsplined end.
Locate the tangs of the ring (57) pointing
Figure 4Compressing The Return Spring away from the vehicle.
15. Keeper (60).
3. Gear (66 ) over the splines of the sleeve (67). Hold the tangs of the ring (57) together and
Cam (70) should locate at the end of the attach the keeper (60). For K10 and K20
sleeve (67) having no splines. assemble the O-ring seal (53) in the clutch
gear (59) groove and over the keeper (60).
Im portant
16. Bearing (56) over the inner race (55).
Lubricate the bearing (56) with light wheel
The gear (66 ) and spring (69) should slide
bearing grease.
freely over the splines of the sleeve (67).
Steel balls should be visible when bearing
4. Stop ring (68 ) to the groove of the sleeve (67).
(56) is properly installed.
5. Retainers (63 and 65) to each end of the spring
17. Retainer (58) into the outer race (55) hole.
(64).
Retainer (65) to the shoulder of the gear Bearing (56) inner race (55) and retainer
( 66).
(58) into the sleeve (67).
6. Retainer plate (62) to the retainer (63). 18. Spring (54) into the cover (52) bore.
Compress the return spring (64) and hold Align cover (52) screw holes with the screw
the assembly together with clamps (figure thread holes in the clutch gear (59).
4). 19. O-ring seals (51) and screws (50) in the cover
7. Ring (61) in the groove of the sleeve (67). (52).
Place the assembly (steps 1 through 7) into The hub sleeve (67) and attached parts
the clutch gear (59) and support the clutch should turn freely after assembly.
gear (59) above a flat surface allowing the
assembly to drop down so that the tangs of Tighten
the brake band (74) may be assembled later.
8. Outer cage (71) into the clutch gear (59). Screws (50) to 5.1 N m (45 in. lbs.).
The ramps of the outer cage (71) must face
the cam (70). Important
Locate the outside tabs of the outer cage
(71) into the wide grooves of the clutch gear The five cover screw s (50) m ust be
(59). loosened (three or four turns) and then
4C-8 FRONT AXLE
pushed inward to allow the retaining ring L* Inspect

(57) to expand when assem bling the
automatic locking hub to the vehicle. All parts and replace as necessary.
L* Install or Connect (Figure 5)

AUTOMATIC HUB TO THE WHEEL
ADJUSTMENT 1. Body assembly (86 , 87, 88 and 89).
2. Internal snap ring (85) to the hub.
A lock ring (80) is supplied with each new automatic 3. Snap ring (90) onto the axle shaft end.
hub assembly. Assemble this lock ring (80) between 4. Outer hub locking assembly (92, 93, 94, 95, 96,
the nut with pin (81) and the adjusting nut (79) as 97, 98 and 99).
follows: 5. Screws (91).
Use J-6893 to torque the nut with pin (81) to 68 N m
(50 ft. lbs.) to seat the wheel bearings; then back off
the nut with pin (81) and torque to 47 N m (35 ft. lbs.) MANUAL LOCKING HUB REBUILD
while rotating the hub (figure 3). PROCEDURE
Then back the nut with pin (81) off a maximum of 3/8
turn. Assemble the lock ring (80) over the axle shaft Outer hublock knob assembly should be replaced
against the nut with pin (81) so that the inner tang only as a unit, because timing relationships are
enters the axle shaft keyway. One of the holes in the difficult to restore if disassembly occurs. The
lock ring (80) must engage the pin on nut (81). Thread inner body may be disassembled for cleaning
the adjusting nut (79) onto the axle shaft and tighten to and component replacement.
247 N m (183 ft. lbs.).
Align the cut-outs on the drag sleeve (75) with the Remove or Disconnect (Figure 5)
tabs on the lock ring (80) as the splines of the clutch
gear (59) mesh with the splines of the wheel hub. Screws (91).
Loosen the five cover screws (50) three or four turns Hub body (86 ).
and push in on the screws (50) to allow the ring (57) to Spring (88 ).
expand into the groove in the wheel hub. Torque the Internal snap ring (85).
screws (50) to 5.1 N m (45 inch lbs.). Inner drive gear (87) with thrust washers.
Plastic sleeve.
MANUAL LOCKING HUB L* Inspect

REPLACEMENT
1. Screws (91).
2. Outer hub locking assembly (92, 93, 94, 95, 96, Lubricate inner body parts with ATF or a
97, 98, and 99). light coat of wheel bearing grease.
3. Snap ring (90) from the axle shaft end. 1. Plastic sleeve.
4. Internal snap ring (85) from hub. 2. Inner drive gear (87) with thrust washers.
5. Body assembly (86 , 87, 88 and 89). 3. Internal snap ring (85).
4. Spring (8 8 ).
5. Hub body (8 6 ).
6. Screws (91).
FRONT AXLE 4C-9
85. Internal Snap Ring

86. Hub Body
87. Inner Drive Gear
88. Spring
89. Clutch Ring
90. Axle Shaft Snap Ring
91. Screw
92. Hub Cap
93. Compression Spring
94. Clutch Cup
95. O-Ring Seal
96. Dial Screw
97. Clutch Nut
98. Seal
99. Lock Ring
F-01019
Figure 5Manual Locking Hub, K30

4C-10 FRONT AXLE
SPECIFICATIONS
Nut-Splash Shield Retaining 88 N m 65 ft. lbs.
Nut With Pin <Bearin9 Preload) 68 N m 50 ft. lbs.
(Final Torque) 47 N m 35 ft. lbs.
Cover Screw-Automatic Hub 5.1 N m 45 inch lbs.
Adjusting Nut-Axle Shaft 247 N m 183 ft. lbs.
SPECIAL TOOLS
Snap Ring Plier
J-6893-D Wheel Bearing Nut Wrench
5-1
SECTION 5
BRAKES
The following notice applies to one or more steps in the assembly procedure of components in this portion of the
manual as indicated at appropriate locations by the terminology NOTICE: See Notice on page 5-1 of this section.
NOTICE: This fastener is an important attaching part in that it could affect the performance of vital compo
nents and system, and/or could result in major repair expense. It must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
proper retention of this part.
CAUTION: When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by
cleaning wheel brake parts w ith a dry brush or w ith compressed air. (A water dampened cloth should be
used). Many wheel brake parts contain asbestos fibers which can become airborne if dust is created during
servicing. Breathing dust containing asbestos fibers may cause serious bodily harm.
CONTENTS
SUBJECT PAGE
Brake System D ia g n o s is .............................................................................................................................................5 - 2

Road Testing the B ra k e s ........................................................................................................................................ 5 - 2
Hydro-Boost System T e s t s .................................................................................................................................... 5 - 2
Diagnosis o f Brake S y s te m ........................................................................................................................................ 5 - 4
Diagnosis o f Hydro-Boost S y s te m ........................................................................................................................... 5 - 7
On - Vehicle S ervice..................................................................................................................................................... 5 - 8
Bleeding the Brake Hydraulic S y s te m .................................................................................................................5 - 8
Flushing the Brake Hydraulic S ystem ...................................................................................................................5 - 9
Brake Pipes and H o s e s ...........................................................................................................................................5 - 9
Com bination V a lv e ................................................................................................................................................... 5-12
Height Sensing Brake P roportioning V a lv e ........................................................................................................5-13
Brake Pedal A sse m b ly................................................................................................................................................. 5-17
Checking Pedal T ra v e l.............................................................................................................................................5-17
Brake Pedal R e p la ce m e n t...................................................................................................................................... 5-17
Brake Pedal Rod R e p la ce m e n t............................................................................................................................. 5-20
Stoplamp S w itc h ....................................................................................................................................................... 5-20
Parking Brake S y s te m ................................................................................................................................................. 5-22
Parking Brake Pedal or Handle R e p la c e m e n t................................................................................................... 5-22
Cable R eplacem ent................................................................................................................................................... 5-23
Propeller Shaft Brake R e p la ce m e n t.....................................................................................................................5-27
Parking Brake A d ju s tm e n t...................................................................................................................................... 5-27
Master C ylinders............................................................................................................................................................5-30
D e s c rip tio n ................................................................................................................................................................ 5-30
Master Cylinder R e p la ce m e n t................................................................................................................................5-30
Bench B le e d in g ..........................................................................................................................................................5-30
Vacuum B o o s te rs ..........................................................................................................................................................5-32
D e s c rip tio n ................................................................................................................................................................ 5-32
Vacuum Booster R e p la c e m e n t............................................................................................................................. 5-32
5-2 BRAKES
CONTENTS (CONT.)
SUBJECT PAGE
Hydraulic Brake Booster (H ydro-B oost).................................................................................................................. 5-33

D e s c rip tio n ................................................................................................................................................................ 5-33
Hyrdro-Boost R e p la ce m e n t....................................................................................................................................5-33
Bleeding the Hydro-Boost S y s te m .......................................................................................................................5-36
Disc B ra kes................................................................................................. .................................................................. 5-37
D e s c rip tio n ................................................................................................................................................................5-37
Brake Lining In s p e c tio n .......................................................................................................................................... 5-37
Brake Lining Replacem ent...................................................................................................................................... 5-38
Servicing the R o tor...................................................................................................................................................5-41
Rebuilding the C a lip e r............................................................................................................................................ 5-42
Drum B ra kes.................................................................................................................................................................. 5-45
D e s c rip tio n ................................................................................................................................................................5-45
Brake Lining Replacem ent...................................................................................................................................... 5-45
Servicing the Brake D ru m ...................................................................................................................................... 5-45
Brake A d ju s tm e n t..................................................................................................................................................... 5-47
Wheel Cylinder Replacement................................................................................................... ..............................5-47
Rebuilding the Wheel C y lin d e r............................................................................................................................. 5-47
S p e c ific a tio n s ................................................................................................................................................................ 5-49
Special T o o ls ................................................................................................................................................................5-51
BRAKE SYSTEM DIAGNOSIS
ROAD TESTING THE BRAKES 2. V e h ic le L o a d in g When the ve h icle has

unequal loading, the most heavily loaded wheels
require more braking power than the others.
BRAKE TEST
3. F ro n t W heel B e a rin g s Loose front wheel
The brakes should be tested on a dry, clean, bearings permit the disc to tilt and have spotty
reasonably smooth and level roadway. A true test of contact with the linings causing erratic action.
brake performance cannot be made if the roadway is 4. Front End Alignm entMisalignment of the front
wet, greasy, or covered with loose dirt so that all the end, particularly in regard to limits on camber and
tires do not grip the road equally. The testing will be caster, will cause the brakes to pull to one side.
adversely affected if the roadway is crowned so as to
throw the weight of the vehicle toward the wheels on
one side or if the roadway is so rough that the wheels HYDRO-BOOST SYSTEM TESTS
tend to bounce.
The Hydro-Boost system receives its source of
Test the brakes at different vehicle speeds with both power from the power steering system. Therefore a
light and heavy pressure; however, avoid locking the faulty power steering system may affect the operation
wheels and sliding the tires on the roadway. Locked of the booster, just as a problem in the booster may
wheels and sliding tires do not indicate brake efficiency affect the steering system. Prior to performing any
since heavily braked turning wheels will stop the tests the following checks must be made.
vehicle in less distance than locked wheels. More
tire-to-road friction is present with a heavily braked 1. Check all the power steering and brake pipe
turning tire than with a sliding tire. connections for leaks or restriction.
EXTERNAL CONDITIONS THAT AFFECT NOTICE: Power steering fluid and brake fluid
BRAKE PERFORMANCE cannot be mixed. If brake seals contact
steering fluid or steering seals contact brake
1. TiresTires having unequal contact and grip on fluid, seal damage will result.
the road will cause unequal braking. The tires
must be equally inflated and the tread pattern of 2. Check and fill the brake master cylinder with
the right and left tires must be about equal. brake fluid.
BRAKES 5-3
3. Check and fill the power steering reservior with
power steering fluid. If fluid contains air refer to
POWER STEERING (Sec. 3B3) for further diag
nosis.
4. Check power steering pump belt for wear and
tension. Adjust if needed, refer to POWER
STEERING (Sec. 3B3).
5. Check engine idle speed, refer to the vehicles
Emission Control Inform ation label for idle
specifications.
6. Check steering pump pressure. Refer to POWER
STEERING (Sec. 3B3).
NOISE DIAGNOSIS
The following noises are associated with the
Hydro-Boost and may or may not be cause for
customer complaint. Some noises are normal and for
the most part temporary in nature. Other noises may
be a sign of excessive wear or the presence of air in
either the booster or the steering system.
1. A m oan or low fre q u e n c y hum u s u a lly
accompanied by a vibration in the pedal or
steering column may be observed during parking
maneuvers or other low speed maneuvers. This
may be caused by a low fluid level in the power
steering pump or by air in the fluid. Holding the
pump at relief pressure (steering wheel held all
the way in one direction) for more than five
seconds will cause air to enter the system. Check
the fluid level and fill if needed. The system must
then sit for one hour to remove the air. If the
condition persists, refer to POWER STEERING ACCUMULATOR LEAKDOWN TEST
(Sec. 3B3). 1. Start the engine and charge the accumulator by
2. A high speed fluid noise may be heard when the applying the brake pedal or by turning the
brake pedal is fully depressed, this condition is steering wheel from stop to stop. Turn off the
normal. engine and let the vehcile sit for one hour. After
3. Whenever the accumulator pressure is used, a one hour there should be at least two power
assisted applications with the engine off.
slight hiss may be noticed. It is the sound of the
hydraulic fluid escaping through the accumulator 2. If the reserve system will not retain a charge for
valve, and is completely normal. one hour, but functions normally immediately
4. After the accumulator has been emptied, and the following charging, the accumulator valves are at
engine is started again, another hissing sound fault and the booster must be disassembled and
may be heard during the first brake application or the accumulator valves replaced.
the first steering maneuver. This is caused by the 3. If the accumulator can be heard charging and
fluid rushing through the accumulator charging discharging, but it does not hold a charge,
orifice. It is normal and will only be heard once d isassem ble the booster and replace the
after the accumulator is emptied. However, if this accumulator valves.
sound continues, even though no apparent 4. Deplete the accumulator by pressing the brake
accumulator pressure assist was made, it could pedal several times. If the accumulator can has
be an indication that the accumulator is not lost its gas charge, it is possible to rotate or
holding pressure and should be checked using wobble the accumulator can with respect to the
the procedure for the Accumulator Leakdown housing. Replace the accumulator assembly.
Test in this section.
SEAL LEAK DIAGNOSIS (FIGURE 1)
BOOSTER FUNCTIONAL TEST A. INPUT ROD SEAL. A damaged seal will show up
With the engine off, apply the brake pedal several as a fluid leak from the mounting bracket vent
times until the accumulator is completely depleted. hole. The booster must be removed from the
Depress the brake pedal using 180 N (40 lbs.) of force vehicle and disassembled. The input rod bore
and start the engine. The pedal will fall and then push should be checked for any scratches that may
back against your foot. cause the leak. If scratches are present, the
5 -4 BRAKES
housing cover must be replaced. If no excessive D. SPOOL VALVE PLUG SEAL. Damage to this
scratches are present, then the booster seal kit seal will be noticed by fluid leaking out past the
can be used to replace the appropriate seals. plug. The booster need not be removed from the
B. POWER PISTON SEAL. Power piston seal vehicle.
damage will be noticed by fluid leaking out at the E. ACCUMULATOR SEAL. Damage to this seal will
common master cylinder brake booster vent and result in fluid leakage past the accumulator cap.
possible reduction in power assist. The booster The seal can be replaced while the booster is
m ust be rem oved from the v e h ic le and installed on the vehicle.
disassembled. The piston should be checked for F. RETURN PORT FITTING. Tighten the fitting to
any scratches that may be the cause of the leak. 10 N m (7 ft. lbs.). If the leak continues, replace
If scratches are present, then the booster seal kit the seal ring under the fitting.
can be used to replace the appropriate seals.
C. HOUSING SEAL. If the housing seal is damaged,
fluid will leak out from between the two housings.
The booster must be removed from the vehicle
and disassembled. The booster seal kit should be
used to replace the housing and input rod and
power piston seals.
DIAGNOSIS OF BRAKE SYSTEM

Uneven Brake A ction 1. Incorrect tire pressure. 1. Inflate evenly on both sides to manu
(Brakes Pull). facturers specifictions.
2. Front end out of alignment. 2. Check and align to manufacturers
specifications.
3. Loose suspension parts. 3. Check all suspension mountings.
4. Worn out brake lining. 4. Replace with lining of correct mate
rial.
5. Incorrect lining material. 5. Replace with linings of correct mate
rial.
6. Malfunctioning caliper assembly. 6. Check for frozen or sluggish pistons
and the lubrication of the retainer
bolts. Caliper should slide.
7. Loose calipers. 7. Check and torque.
8. Contaminated brake linings. 8. Repair as necessary. Replace linings
in complete axle sets.
9. Malfunctioning rear brakes. 9. Check for inoperative self adjusters.
Weak return springs. Leaking wheel
cylinders.
10. Leaking wheel or piston cylinder seal. 10. Repair as necessary.
11. Restricted brake tubes or hoses. 11. Check for collapsed rubber hoses or
damaged lines. Repair as necessary.
12. Unmatched tires on the same axle. 12. Same style tires with about the same
tread should be used on the same
axle.
BRAKES 5-5
DIAGNOSIS OF BRAKE SYSTEM (CONT.)

Brakes Squeak. 1. Worn out linings. 1. Replace linings.

2. Glazed brake lining. 2. Replace linings.
3. Heat spotted rotors or drums. 3. Check per instructions. If within spec
ifications machine the rotor or drum.
4. Weak or incorrect brake shoe retention 4. Replace with new retention springs.
springs.
5. Contaminated brake linings. 5. Repair as necessary. Replace linings
in complete axle sets.
rial.
7. Brake assembly attachments missing 7. Repair as necessary.
or loose.
8. Excessive brake lining dust. 8. Clean dust from brake assembly.
Brake Pedal 1. Excessive rotor lateral runout. 1. Check per instructions. If within spec
Pulsates. ifications machine the rotor.
2. Rear drums out of round. 2. Check per instructions. If within spec
ifications machine the drum.
3. Heat spotted rotors or drums. 3. Check per instructions. If within spec
ifications machine the rotor or drum.
4. Incorrect wheel bearing adjustments. 4. Repair as necessary.
5. Out of balance wheel assembly attach 5. Repair as necesary.
ments missing or loose.
6. Brake assembly attachments missing 6. Repair as necessary.
or loose.
Excessive Pedal 1. Leaking vacuum system. 1. Repair as necessary.

Effort. 2. Malfunctioning power brake unit. 2. Repair as necessary.
3. Worn out linings. 3. Replace linings.
4. Malfunctioning proportioning valve. 4. Repair as necessary.
rials.
6. Incorrect wheel cylinder. 6. Replace with corrrect size wheel cyl
inder.
Excessive Pedal 1. Insufficient fluid in master cylinder res 1. Fill reservoir with approved brake
Travel. ervoir. fluid. Check for leaks and air in the
system. Check tell-tale light.
2. Air in brake system. 2. Check for leaks in lines, wheel cylin
ders, or master cylinder. Bleed the
system.
3. Malfunctioning self adjusters. 3. Repair as necessary.
4. Master cylinder. 4. Replace or repair as necessary.
5. Incorrect wheel bearing adjustment. 5. Repair as necessary.
6. Improperly adjusted master cylinder 6. Adjust master cylinder pushrod.
pushrod.
5-6 BRAKES
DIAGNOSIS OF BRAKE SYSTEM (CONT.)

Brakes Drag. 1. Malfunctioning caliper assembly. 1. Check for frozen or sluggish pistons
and the lubrication of the retainer
bolts. Caliper should slide.
2. Contaminated or improper brake fluid. 2. Repair as necessary.
3. Improperly adjusted parking brakes. 3. Repair as necessary.
4. Restricted brake tube or hoses. 4. Check for collapsed rubber hoses or
damaged lines. Repair as necessary.
5. Malfunctioning proportioning valve. 5. Replace or repair as necessary.
7. Malfunctioning master cylinder. 7. Repair as necessary.
8. Improperly adjusted master cylinder 8. Adjust pushrod length.
pushrod.
Brake tell-tale light 1. Air in the brake system. 1. Check fluid level. Check for leaks in
comes on. lines, wheel cylinders, or master cyl
inder. Bleed the system.
2. Malfunctioning master cylinder. 2. Check for faulty metering valve, or
leaking. Repair as necessary.
3. Contaminated or improper brake fluid. 3. Repair as necessary.
4. Parking brake on or not fully released. 4. Check parking brake. Repair as nec
essary.
5. Worn out brake lining. 5. Replace linings.
6. Incorrect wheel bearing adjustment. 6. Repair as necessary.
8. Brake assembly attachments missing 8. Replace or repair as necessary.
or loose.
9. Improperly adjusted master cylinder 9. Adjust pushrod length.
pushrod.
Excessive Brake 1. Loose or broken power steering pump 1. Tighten or replace the belt.
Pedal Effort. belt.
2. No fluid in the power steering reser 2. Fill reservoir and check for external
voir. leaks.
3. Leaks at Hydro-Boost tube fittings. 3. Tighten fittings or replace tube seats,
if faulty.
4. External leakage at the accumulator. 4. Replace seal and retainer.
5. Faulty booster piston seal causing 5. Overhaul with new seal or input rod
leakage at the booster flange vent. and piston assembly.
6. Faulty booster input rod seal with 6. Overhaul with new seal kit.
leakage at the input rod end.
7. Fautly booster cover seal with leakage 7. Overhaul with new seal kit.
between the housing and cover.
8. Fautly booster spool plug seal. 8. Overhaul with spool plug seal kit.
BRAKES 5-7
DIAGNOSIS OF HYDRO-BOOST SYSTEM

Slow Brake Pedal 1. Excessive seal friction in booster. 1. Overhaul with new seal kit.
Return. 2. Faulty spool action. 2. Flush steering system while pumping
brake pedal.
3. Restriction in return line from booster 3. Replace line.
to pump reservoir.
4. Damaged input rod end. 4. Replace input rod and piston assem
bly.
Grabby Brakes. 1. Faulty spool action caused by contami 1. Flush steering system while pumping
nation in system. brake pedal.
Booster Chatters - 2. Power steering pump belt slips. 2. Tighten belt.
Pedal Vibrates.
3. Low fluid level in power steering pump. 3. Fill reservoir and check for external
leaks.
4. Faulty spool operation caused by con 4. Flush steering system while pumping
tamination in system. brake pedal.
A ccum ulator Leak- 1. Contamination in steering hydro-boost 1. Flush steering system while pumping
down System does system. brake pedal.
not hold charge. 2. Internal leakage in accumulator sys 2. Overhaul unit using accumulator re
tem. build kit and seal kit.
5-8 BRAKES
ON VEHICLE SERVICE
BLEEDING THE BRAKE 6. If it is known that the calipers and wheel cylinders
do not contain any air, then it will not be
HYDRAULIC SYSTEM necessary to continue. Otherwise bleed each
A bleeding operation is necessary if air has been wheel in the following sequences.
introduced into the hydraulic brake system. Right rear
It may be necessary to bleed the system at all four Left rear
wheels if air has been introduced by a low fluid level Right front.
condition in the master cylinder. Also if the brake pipes Left front
have been disconnected at either the master cylinder 7. Attach a hose to the wheel cylinder/caliper
or the combination valve. If a pipe is disconnected at bleeder screw.
one wheel, then only bleed that particular wheel. Immerse the opposite end of the hose into a
The time required to bleed the hydraulic system container partially filled with clean brake
when the master cylinder is removed can be reduced if fluid.
the master cylinder is filled with fluid and as much air 8. Slowly depress the brake pedal one time and
as possible is bled from the cylinder before installing it hold.
on the vehicle. Loosen the bleeder screw to purge the air
from the wheel cylinder/caliper.
MANUAL BLEEDING
Tighten the bleeder screw and slowly
If the vehicle is equipped with power brakes, deplete
release the pedal.
the vacuum reserve by applying the brakes several
Wait 15 seconds, then repeat this sequence,
times with the engine off.
including the 15 second wait until all the air
Use extreme care to prevent brake fluid from
is purged from the wheel cylinder/caliper.
contacting any painted surface.
1. Fill the master cylinder reservoirs with brake fluid 9. Continue steps 7 and 8 at each wheel until the
specified in MAINTENANCE AND LUBRICATION entire brake system has been bled.
(Sec. OB). 10. Check the brake pedal for sponginess and the
Maintain the fluid level in the reservoir brake warning lamp for an indication of an
during the bleeding operation. unbalanced pressure. Repeat the entire bleeding
2. If the master cylinder is suspected to have air in p ro ced u re to co rre ct e ith e r of these two
the bore, it must be bled before any wheel conditions.
cylinder or caliper.
PRESSURE BLEEDING
Remove the forward brake pipe connection
The pressure bleeding equipment must be of the
at the master cylinder.
diaphragm type. It must have a rubber diaphragm
Allow brake fluid to flow from the connector
between the air supply and the brake fluid to prevent
port.
air, moisture, oil, and other contaminants from entering
Connect the brake pipe but do not tighten.
the hydraulic system. Also adapters are needed,
3. Slowly depress the brake pedal allowing the air to
depending on the type of master cylinder used.
bleed from the loose fitting.
Tools Required:
Tighten the fitting before releasing the
pedal. J-29567 Brake Bleeder Adapter (Plastic
Wait 15 seconds, and repeat this sequence, Reservoir)
including the 15 second wait until all the air J-23518-01 Brake Bleeder Adapter (Cast
is purged from the bore. Iron Reservoir)
4. After all the air has been removed from the J-23709 Combination Valve Depressor
forward connection disconnect the rear pipe.
Allow brake fluid to flow from the connector NOTICE: It is very important that the correct
port. master cylinder bleeder adapter be used to
Connect the brake pipe but do not tighten. avoid possible damage to the master cylinder
5. Slowly depress the brake pedal allowing the air to reservoir.
bleed from the loose fitting.
Tighten the fitting before releasing the 1. Fill the pressure tank at least 1/3 full of brake fluid.
pedal. The bleeder must be re-bled each time fluid is
Wait 15 seconds, and repeat this sequence, added.
including the 15 second wait until all the air Charge the bleeder to 140 - 170 kPa (20 to
is purged from the bore. 25 psi).
BRAKES 5-9
2. Use J-23709 to depress and hold the valve stem

on the combination valve during the bleeding op
eration (figure 2).
Install the correct bleeder adapter (figures 3
and 4).
3. Bleed each wheel in the following sequence.
Right rear
Left rear
Right front
Left front
4. Connect the hose from the bleeder to the adapter
at the master cylinder.
Figure 2 Installing Combination
Open the tank valve.
Valve Depressor
5. Attach a hose to a brake bleeder screw.
Immerse the opposite end of the hose into a
container partially filled with clean brake BRAKE PIPES AND HOSES
fluid.
6. Open the bleeder screw at least 3U of a turn and The hydraulic brake system com ponents are
allow the fluid to flow until no air is seen in the interconnected by special steel piping and flexible
fluid. hoses. Flexible hoses are used between the frame and
the front calipers, and the frame and rear differential.
Close the bleeder screw.
When the hydraulic pipes have been disconnected for
7. Repeat step six at all the wheels. any reason, the brake system must be bled after
8. Check the brake pedal for sponginess , repeat reconnecting the pipe, refer to Bleeding the Brake Hy
the entire bleeding procedure if this condition is draulic System in this section.
found.
9. Remove J-23709.
D isconnect the line form the bleeder
adapter.
Remove bleeder adapter.
10. Fill the master cylinder to the proper level with
brake fluid.
FLUSHING THE BRAKE

HYDRAULIC SYSTEM
It is recommended that the entire hydraulic system
be thoroughly flushed with clean brake fluid whenever
new parts are installed in the hydraulic system.
Flushing is also recommended if there is any doubt
as to the grade of fluid in the system or if fluid has
been used which contains the slightest trace of mineral
oil. Flush the system whenever there is any question of
contamination.
Flushing is performed at each bleeder valve in the
same manner as the bleeding operation, except that
the bieeder valve is opened 1 1/2 turns and the fluid is
forced through the lines and bleeder valves until it
emerges clear in color. Refer to Bleeding the Brake
Hydraulic System , in this section.
Check master cylinder fluid level after flushing at
each valve and replenish if required. When flushing is
Figure 3Plastic Reservoir
completed at all bleeder valves, make certain the
Bleeder Adapter
master cylinder reservoir is filled to proper level.
5-10 BRAKES
Use new copper washers when installing the

hose.
1. Hose (32).
The hose must not be twisted.
2. Washers (33).
Bolt (34).
3. Clip or nut (31).
Steel pipe.
4. Bleed the brakes, refer to Bleeding the Brake
Hydraulic System in this section.
Im portant
The hose installation must not contact any

suspension components.
BRAKE PIPES
When replacing a steel brake pipe, always use steel
piping which is designed to withstand high pressure
and resist corrosion. The same size pipe must be used
as the one removed.
NOTICE: N ever use c o p p e r tubing for

hydraulic brake lines because copper is
subject to fatique cracking, and corrosion
Figure 4Cast Iron Reservoir which could result in brake failure.
Bleeder Adapter
Brake pipes that run parallel to each other must
FLEXIBLE HOSE maintain a 6 mm (1/4-inch) clearance.
On the front brakes the hose is connected to the
caliper with a bolt and copper washers. The fitting at Pipe Flaring (Figure 6)
the other end of the hose is secured at the frame with Tools Required:
either a nut or a clip. J-23530 Flaring Tool.
J-23533-B Tube Cutter.
At the rear differential one end of the hose is
In order to ensure a proper flare, a special flaring tool
connected to the differential with a bolt. The other end
must be used. When using the tool, instruction
is secured at the frame with either a nut or a clip.
furnished by the tool manufacturer should be followed.
Always inspect newly formed flares for cracks or
Flexible Hose Inspeciton
malformations which might cause leaks. After flaring,
The flexible hoses should be inspected for any signs
blow out the brake pipe with compressed air before
of road damage which will cause cracks and chafing of
installing on the vehicle.
the other cover. If any of these conditions are visible,
replace the hose.
NOTICE: Double lap flaring tool must be used,
as single flaring tools cannot produce a flare
Hose Replacement
strong enough to hold the necessary
pressure.
1. Use steel pipe and fittings of the correct size. The
Clean dirt, grease, and other foreign material off
outside diameter of the pipe is used to specify the
the hose fittings at both ends.
size.
1. Steel pipe. 2. Cut the pipe to length. Add 3 mm (Vs-inch) to the
Clip or nut (31). length for each flare.
3. Flare the pipe ends by following the instructions
2. Bolt (34).
with the tool.
Washers (33). 4. Bend the pipe to match the old pipe by using a
Hose (32). pipe bender.
BRAKES 5-11
31. Nut or Clip

32. Flex Hose
33. Washer
34. Bolt
B-07786
Figure 5Flexible Hoses

5-12 BRAKES
in the event of a front brake system malfunction, also

full front pressure is retained in the event of rear mal
function.
The pressure differential warning switch is designed
to constantly compare front and rear brake pressure
from the master cylinder and energize the warning
lamp on the dash in the event of a front or rear system
malfunction. The valve and switch are so designed that
the switch will latch in the warning position once a
malfunction has occured. The only way the lamp can
be turned off is to repair the malfunction and apply a
pedal force as required to develop about 3102 kPa (450
psi) line pressure.
ELECTRICAL CIRCUIT TEST

1. Disconnect the wire from the switch on the valve.
Connect a jumper wire from the switch wire
to ground.
2. Turn the ignition key to ON .
The warning lamp should light.
COMBINATION VALVE If the lamp will not light check the bulb. If
the bulb is good, refer to CHASSIS ELEC
The com bination valve is com prised of three TRICAL (Sec. 8B) for futher diagnosis.
sections, each serving a different function (figure 7).
The metering or hold off section of the valve limits 3. Turn the ignition off.
the p ressure to the fro n t d isc brakes u n til a Disconnect jumper wire and connect the
predetermined front input pressure is reached, enough wire to the switch terminal.
to overcome the rear shoe retractor springs. There is
no restriction to the inlet pressures below 20 kPa (3 psi)
to allow for pressure equalization during the no apply
Valve Warning Switch Test
periods. 1. Raise the vehicle.
The proportioning section of the combination valve Support with suitable safety stands.
proportions outlet pressure to the rear brakes after a
predetermined rear input pressure has been reached.
This is done to prevent rear wheel lock-up on the 2. Attach a hose to a rear brake bleeder screw.
vehicles with light rear wheel loads. Immerse the opposite end of the hose into a
The valve is designed to have a By-Pass feature container partially filled with clean brake
which assures full system pressure to the rear brakes fluid.
Figure 7Combination Valve

BRAKES 5-13
Make sure the master cylinder reservoir is 4. Bleed the brake system. Refer to Bleeding The
full. Brake Hydraulic System in this section.
3. Turn the ignition key to ON .
Open the bleeder screw while a helper
applies moderate pressure to the brake HEIGHT SENSING BRAKE
pedal. PROPORTIONING VALVE
The warning lamp should light.
Close the bleeder screw before the helper The height sensing brake proportioning valve is used
releases the brake pedal. on series 30 models (figure 9). This will provide
4. Reapply the brake pedal with moderate to heavy optimum brake balance and efficiency. The vehicle
pressure. braking force is distributed to the front and rear wheels
The lamp should go out. as determined by either a light or heavy payload
5. Attach a hose to a front brake bleeder screw. condition.
Immerse the opposite end of the hose into a The valve is mounted on the frame, and a linkage
container partially filled with clean brake connects the valve to a bracket that is mounted on the
fluid. axle.
Make sure the master cylinder reservoir is
full. C A U T IO N : A d d in g any s u s p e n s io n
6. Open the bleeder screw while a helper applies accessories or o ther equipm ent (such as
moderate pressure to the brake pedal. load leveling kits, air shocks, suspension lift
The warning lamp should light. kits, additional spring leafs, etc.), or making
Close the bleeder screw before the helper m odification that w ill change the distance
releases the brake pedal. between the axle and the fram e w ith o u t
7. Reapply the brake pedal with moderate to heavy ch a n g in g th e lo a d, w ill p ro v id e a false
pressure. reading to the brake p ro po rtio n ing valve.
The lamp should go out. This could re su lt in u n sa tisfa cto ry brake
8. Turn the ignition key off. perform ance which in turn could result in an
If the warning lamp does not light during accident and possibly personal injury.
steps 3 and 6 but does light when a jumper
is connected to ground, the warning switch
portion of the valve is faulty. Do not VALVE REPLACEMENT
disassemble any portion of the valve. It
must be replaced. Remove or Disconnect (Figure 10)
9. Remove the safety stands.
Lower the vehicle. Raise the vehicle.
Check and fill the master cylinder to the Support the frame with suitable safety stands.
proper level. The axle must be allowed to hang free.
Clean the exterior of the valve to prevent dirt from
VALVE REPLACEMENT contaminating the hydraulic system.
1. Brake pipes (51).
Remove or Disconnect (Figure 8) 2. Nut from the shaft (48).
Lever (49).
The combination valve is not repairable and must 3. Bolts (46) and washers (47).
be replaced as a complete assembly. Valve (50).
Care must be taken to prevent brake fluid from
contacting any painted surface. -+ Install or Connect (Figure 10).
1. Hydraulic pipes.
Plug the pipes to prevent the loss of fluid or 1. Position the valve on the mounting bracket.
the entrance of dirt. Washer (47) and bolts (46).
2. Warning switch harness. 2. Lever (49).
3. Bolts. Refer to Proportioning Valve Adjustment
Combination valve. in this section.
3. Nut (48). Torque to 10 N m (89 in. lbs.).
0 Install or Connect (Figure 8) 4. Brake pipes (51).
5. Bleed brakes. Refer to Bleeding the Brake
1. Position valve on the bracket. Hydraulic System , in this section.
Bolts. 6. Remove the safety stands.
2. Warning switch harness. Lower the vehicle.
3. Hydraulic pipes. Test the brakes.
5-14 BRAKES
A. G-Van
B. C-K Truck
C. P Model (42)
D. P Model (32)
B-07802
Figure 8Combination Valves

BRAKES 5-15
Figure 9Height Sensing Proportioning Valve
PROPORTIONING VALVE ADJUSTMENT ADJUSTMENT GAGE CHART

If a front wheel lockup is experienced when the
vehicle is being operated near the maximum GVWR
Part
with a lower than desired brake application, the valve
Number Code Color Vehicle Combination
adjustment should be checked. Use the following
procedure to check the adjustment. 14061394 A Green C/K 3500 with G52
14061395 B Black C3500 Less G52
1. Raise the vehicle. C2500 all
K 20903
Support the frame with suitable safety G31305/06 with LE3/LS9
stands. The axle must be allowed to hang 14061396 C Blue K3500 Less G52
free. K20906
G31305/06 with LLA/LT9
2. Remove the nut from the valve shaft. RPO G52: Extra Capacity Rear Spring
RPO LS9: 5.7 Liter (Cal. Only)
Remove the lever. RPO LL4: 6.2 Liter
RPO LT9: 5.7 Liter
3. Select the appropriate adjustment gage from the 4. Rotate the valve shaft to permit the installation of
chart. the adjustment gage (figure 11).
The center hole of the adjustment gage
must seat on the D shape of the valve
shaft.
The gage tang must seat in the valve
mounting hole.
NOTICE: Do not drive lever assembly on valve

shaft by using nut or proper valve setting may
be disturbed.
5. Install the nut on the shaft. Torque to 10 N-m (89

51 50 in. lbs.)
46. Bolts 6. Sever the tang on the adjustment gage (figure
47. Washer 48 12).
48. Nut 7. Remove the safety stands.
49. Lever Lower the vehicle.
50. Valve Test the brakes.
51. Brake Pipe B-07783
Figure 10Removing Proportioning Valve

5-16 BRAKES
Figure 12Severing The Adjustment Tang

BRAKES 5-17
BRAKE PEDAL ASSEMBLY
1.
2.
3.
4.
11.
12.
A. Manual Transmission
B. Automatic Transmission
B-06947
Figure 13C-K Brake Pedal Components
CHECKING PEDAL TRAVEL Pin (10) and washer (9).

Pushrod (8).
At frequent intervals the brake pedal should be Return spring (5).
checked for travel. Travel is the distance the pedal 2. Nut (2) and bolt (1).
moves toward the floor from a full released position. 3. Brake pedal (12).
This check should be made with the brakes cold and Clutch pedal (11) (if equipped).
about 122 N (90 lbs.) of force on the pedal. On Bushings (3).
vehicles with power brakes the pedal must be pumped Spacer (4).
at least three times with the engine off before making
the check. Follow the specifications below for the cor Install or Connect (Figures 13 and 14)
rect travel.
C-K-G Manual..................................115 mm (4.5-inches) 1. Spacer (4).
C-K-G Power......................................90 mm (3.5-inches) Bushings (3).
P (Except J F 9 )..................................90 mm (3.5-inches) Brake pedal (12).
P (J F 9 )............................................ 150 mm (6.0-inches) Clutch pedal (11) (if equipped).
NOTICE: See Notice on page 5-1 of this

BRAKE PEDAL REPLACEMENT section.
C-K AND P30 (32) MODELS 2. Bolt (1) and nut (2).
1. Retainer (6). Nut to 34 N m (25 ft. lbs.)

Washer (7). 3. Return spring (5).
5-18 BRAKES
1. Bolt
2. Nut
3. Bushings
4. Spacer
5. Return Spring
6. Retainer
7. Washers
8. Pushrod
9. Washer
10. Pin
12. Brake Pedal
B-07771
Figure 14P30 (32) Brake Pedal Components
4. Washer (9) and pin (10). Install or Connect (Figure 15)

Pushrod (8).
Washer (7) and retainer (6). 1. Bushings (3).
5. Check the stoplamp switch adjustment. Refer to
Brake pedal (12).
Stoplamp Switch.
2. Pin (13) or clutch pedal (11) (if equipped).
G-MODEL
3. Retainer (14) or clutch attaching components (15)
Remove or Disconnect (Figure 15) (if equipped).
1. Retainer (6). 4. Return spring (5).

Washer (9).
5. Washer (7).
Pushrod (8).
Washer (7). Pushrod (8).
2. Return spring. (5).
3. Retainer (14) or clutch attaching components (15) Washer (9).
(if equipped).
Retainer (6).
4. Pin (13) or clutch pedal (11) (if equipped).
5. Brake pedal (12). 6. Check the stoplamp switch adjustment. Refer to
Bushings (3). Stoplamp Switch.
BRAKES 5-19
3. Bushing
5. Return Spring
6. Retainer
7. Washer
8. Push rod
9. Washer
11. Clutch Pedal
12. Brake Pedal
13. Pin
14. Retainer
15. Clutch Attaching Components
B-07770
Figure 15G-Van Brake Pedai Components
P 30 (42) MODEL Brake pedal (12).
Remove or Disconnect (Figure 16) 2. Shaft (17).
1. Retainer and washer. Bolt (18) and nut (16).

Pushrod and washer.
2. Clutch attaching components (15) (if equipped). 3. Clutch pedal (11) (if equipped).
3. Clutch pedal (11) (if equipped).
Return spring (5) (if equipped). Return spring (5) (if equipped).
4. Nut (16) and bolt (18).
Shaft (17). 4. Clutch attaching components (15).
5. Brake pedal (12). I
Bushings (3). 5. Washer and pushrod.
Install or Connect (Figure 16) Washer and retainer.
6. Check the stoplamp switch adjustment, refer to

Lubricate pivot points with Delco Brake Lube or Stoplamp Switch.
equivalent.
1. Bushings (3).
5-20 BRAKES
18. Bolt
B-07772
Figure 16P 30 (42) Brake Pedal Components
BRAKE PEDAL Adjust

ROD REPLACEMENT
Brake rod to 790 mm (31.00-inches) from the
centers of the bolt holes.
P 30 (32) MODEL
2. Brake rod (8).
3. Bolt (19) and washers (20 and 21).
Nut (24) and retainer (23).
1. Retainer (6).
Nut (16).
Bolt (17) and washers (7 and 9).
2. Screws (18).
4. Lower the vehicle.
3. Raise the vehicle and support it with suitable
5. Screws (24).
safety stands.
6. Bolt (17) and washers (9 and 7).
4. Retainer (23).
Nut (16) and retainer (6).
Nut (22).
Bolt (19) and washers (20 and 21).
5. Brake rod (8).
Boot (24). Nut to 35 N m (26 ft. lbs.).
|*<"| Install or Connect (Figure 17) STOPLAMP SWITCH

The design of the switch mounting provides for an
automatic adjustment when the brake pedal is returned
NOTICE: For steps 2 and 6 see N otice on to its stop. There are two styles of switches, the
page 5-1 of this section. determining factor is if the vehicle is equipped with
cruise control. For electrical diagnosis of the stoplamp
1. Boot (24). switch, refer to CHASSIS ELECTRICAL (Sec. 8B).
BRAKES 5-21
SWITCH REPLACEMENT 2. Electrical connectors.

3. Negative battery cable.
" Remove or Disconnect
SWITCH ADJUSTMENT
1. Remove the negative battery cable. 1. Depress the brake pedal and press the switch in
2. Electrical connectors. until it is firmly seated in the clip.
3. Switch. Audible clicks can be heard as the
threaded portion of the switch is pushed
-+ Install or Connect through the clip.
2. Pull the brake pedal against the pedal stop until
1. Switch. the audible click can no longer be heard.
3. Electrical contact should be made when the
Adjust brake pedal is depressed the specified distance.
C-K models 25 - 31 mm (1.0 - 1.24 inches)
Refer to Switch Adjustment . G-P models 11 - 24 mm (0.45 - 0.95 inches)
6. Retainer
7. Washer
8. Brake Rod
9. Washer
16. Nut
17. Bolt
18. Screw
19. Bolt
20. Washer
21. Washer
22. Nut
23. Retainer
24. Boot
B-07775
Figure 17 P30 (32) Brake Pedal Rod Components

5-22 BRAKES
PARKING BRAKE SYSTEM
1. Nuts
2. Bolt
3. Release Rod
B-07774
Figure 18Removing Parking Brake Pedal on C-K, and G Models
PARKING BRAKE PEDAL OR +* Install or Connect (Figure 18)

HANDLE REPLACEMENT
NOTICE: See N otice on page 5-1 o f this
C-K-G MODELS section for steps 2 and 4.
Remove or Disconnect (Figure 18) 1. Parking brake cable.

2. Bolt.
The parking brake must be in the released
position.
Tighten
1. Nuts (1).
2. Release rod (3). Refer to Torque Specifictions in this
3. Bolt (2). section.
4. Brake assembly. 3. Release rod (3).
Parking brake cable. 4. Nuts (1).
BRAKES 5-23
Tighten 4. Cable assembly (36).

Attach a piece of wire to the cable to help in
Refer to Torque Specifications in this installation.
section.
5. Check the parking brake adjustment, refer to Install or Connect (Figure 20 and 21)
Parking Brake Adjustment in this section.
1. Cable assembly (36).
P MODELS Make sure all the retaining fingers are completely
through the holes.
|+ + | Remove or Disconnect (Figure 19) 2. Cable to the pedal assembly.
3. Connector (33).
The parking brake must be in the released 4. Nut (31) onto the equalizer (32).
position.
1. Nuts (10) and washers (11). f t A djust
2. Bolts (12) and washers (13).
Spacers (14). Refer to Parking Brake Adjustment in this
3. Cotter pin (15) and washer (16). section.
Clevis pin (17). 5. Lower the vehicle.
4. Nut (18) and washer (19).
5. Bolt (20). FRONT CABLE REPLACEMENT
Spacer (21). (G AND P MODELS)
Cable (22).
6. Handle assembly. Remove or Disconnect (Figures 20, 22 and 23)
|+<-| Install or Connect (Figure 19) Raise the vehicle and support with suitable safety
stands.
1. Cable (22). 1. Nut (31) from the equalizer (32).
Clevis pin (17). 2. Connector (33) from the front cable.
Washer (16) and cotter pin (15). 3. Bolts (37) and clips (38).
2. Spacer (21). 4. Cable from the pedal/handle assembly.
Bolt (20). 5. Bend retaining fingers (34).
Washer (19) and nut (18). 6. Cable assembly (36).
3. Spacer (14). Attach a piece of wire to the cable to help in
installation.
NOTICE: See Notice on page 5-1 of this
section. +4- Install or Connect (Figures 20,22 and 23)
4. Washer (13) and bolts (12). 1. Cable assembly (36).

Washers (11) and nuts (10). Make sure all the retaining fingers are completely
through the holes.
2. Cable to the pedal/handle assembly.
3. Clips (38) and bolts (37).
Nuts to 24 N m (18 ft. lbs.) 4. Connector (33).
5. Check the parking brake adjustment, refer to 5. Nut (31) onto the equalizer (32).
Parking Brake Adjustment in this section.
Adjust
CABLE REPLACEMENT
Refer to Parking Brake Adjustment , in this
FRONT CABLE REPLACEMENT section.
(C-K MODELS) 6. Lower the vehicle.
|<~+| Remove or Disconnect (Figures 20 and 21) CENTER CABLE REPLACEMENT
Raise the vehicle and support with suitable safety |+ + | Remove or Disconnect (Figure 20)
stands.
1. Nut (31) from the equalizer (32). Raise the vehicle and support with suitable safety
2. Connector (33) from the front cable. stands.
3. Bend retaining fingers (34) and (35). 1. Nut (31) from the equalizer (32).
Cable from the brake pedal assembly. 2. Both front and rear connectors (33).
5-24 BRAKES
Figure 19Removing Parking Brake Lever on P Models

BRAKES 5-25
31. Nut
32. Equalizer
33. Connector
B-07777
Figure 20Equalizer Components
34. Frame Retaining Fingers

35. Pedal Retaining Fingers
36. Cable Assembly
B-07778
Figure 21C-K Front Cable Components

5-26 BRAKES
33. Connector
34. Frame Retaining Fingers
36. Cable Assembly
37. Bolt
38. Clip
B-07780
Figure 22 P Model Front Cable Components
3. Cable.
1. Cable.
2. Connector (33).
3. Nut (31) onto the equalizer (32).
Adjust
Refer to Parking Brake Adjustment in this

section.
REAR CABLE REPLACEMENT

36. Cable Assem bly safety stands.
37. Bolt 1. Nut (31) from the equalizer (32).
38. Clip
2. Connector (33).
3. Brake drum and shoe assembly, refer to Drum
Brakes in this section.
B-07781
4. Bend in retaining fingers at the backing plate.
5. Retaining clip at the frame support.
Figure 23G Model Front Cable Components
Cable assembly.
BRAKES 5-27
Install or Connect (Figure 20) 3. Lever strut (55) and strut spring (57).
4. Washers (63).
1. Cable assembly. Hold down springs (64).
Make sure all the retaining fingers are completely Hold down clips (65).
through the backing plate. 5. Return spring guide (72).
2. Retaining clip at the frame support. Return springs (56 and 57)
3. Brake shoes and drum assembly, refer to Drum 6. Drum (66).
Brakes in this section. 7. Propeller shaft, refer to PROPELLER SHAFT
4. Connector (33). (Sec. 4A) in this manual.
5. Nut (31) onto the equalizer (32).
Adjust
Adjust
Refer to Parking Brake Adjustment in this
Refer to Parking Brake Adjustment in this section.
section. 8. Lower the vehicle.
PROPELLER SHAFT
PARKING BRAKE ADJUSTMENT
BRAKE REPLACEMENT
Remove or Disconnect (Figure 24) The parking brakes must be adjusted whenever the
p a rkin g brake ca b le s have been re p lace d or
Raise the vehicle and support with suitable safety disconnected. Also if the brake holding ability is not
stands. adequate. Before adjusting the parking brakes check
1. Propeller shaft, refer to PROPELLER SHAFT the condition of the service brakes. The service brakes
(Sec. 4A) in this manual. must be adjusted properly before proceeding with the
parking brake adjustment.
CAUTION: See Caution on page 5 - 1 .
CABLE INSPECTION
Check the parking brake system for free operation.
2. Drum (66).
The brake lever must return to the released position
It may be necessary to back off the adjusting
without sticking or binding. If a problem is present
screw.
check the cable routings for kinks or binding. Clean
3. Return springs (56 and 71).
and lubricate the parking brake assembly and cables
Return spring guide (72).
with Delco brake lube or equivalent.
4. Hold down clips (65).
Hold down springs (64). FOOT PEDAL TYPE
Washers (63). 1. Block the front wheels.
5. Lever strut (55). Raise and support the rear axle with
Strut spring (57). suitable safety stands.
6. Lever retaining ring (67). 2. Loosen the equalizer nut.
7. Shoes (68). 3. Set the parking brake pedal to four clicks.
8. Adjusting screw (60).
Adjusting screw spring (58). f t Adjust
Inspect Equalizer nut until the wheels will not

rotate forward without a moderate
All parts for discoloration due to heat, or drag.
stress. Replace if necessary. 4. Release the parking brake and rotate the rear
Brake drum for scoring and heat spots. wheels.
Machine drum if needed. There should be no brake drag.
5. Remove the safety stands and lower the vehicle.
I * * ! Install or Connect (Figure 24) Unblock the front wheels.
Lubricate the shoe pads and adjusting screw LEVER TYPE

threads with a thin coat of white lithum grease. 1. Block the front wheels.
Raise and support the rear axle with
1. Adjusting screw (60) and adjusting screw spring suitable safety stands.
(58) to both shoes (68). 2. Turn the adjusting knob on the parking brake
2. Shoe assembly (68). lever counterclockwise until it stops.
Lever retaining ring (67). Apply parking brake.
5-28 BRAKES
51. Support Plate 63. Washer

52. Washer 64. Hold Down Spring
53. Anchor Pin Nut 65. Hold Down Clip
54. Hold Down Pin 66. Drum
55. Lever Strut 67. Lever Retaining Ring
56. Return Spring 68. Shoe
57. Strut Spring 69. Washer
58. Adjusting Screw Spring 70. Operating Lever
59. Adjusting Screw Socket 71. Return Spring
60. Adjusting Screw 72. Return Spring Guide
61. Adjusting Screw Nut 73. Anchor Pin
62. Cable
B-07779
Figure 24Propeller Shaft Brake Components

BRAKES 5-29
3. Loosen the equalizer nut. Adjust
Adjust Adjusting screw until the drum cannot be

rotated by hand.
Equalizer nut until a light drag is felt Back off the adjusting screw ten notches.
while rotating the wheels forward. The drum should rotate freely.
Knob on the parking brake lever until a 4. Place parking brake lever in the full release
definite snap over center is felt. position.
4. Release the parking brake and rotate the rear 5. Take up the slack in the cable to overcome the
wheels. spring tension.
There should be no brake drag.
5. Remove the safety stands and lower the vehicle. Adjust
Unblock the front wheels.
The clevis of the pull rod to align with the
INTERNAL EXPANDING (PROPELLER SHAFT) hole in the relay lever.
6. Install the clevis pin.
CAUTION: See Caution on page 5-1 of this Install new cover in the drum access hold.
section. 7. Remove the safety stands and lower the vehicle.
1. Block the front wheels. Unblock the front wheels.
Raise and support the rear axle with
suitable safety stands.
2. Remove the clevis pin connecting the pull rod
and relay lever.
3. Rotate the brake drum to align the access hole
with the adjusting screw.
M anual tra n s m is s io n s - the adjusting
screw is located at the bottom of the shoe.
A utom atic transm ission - the adjusting
screw is located at the top of the shoe.
When adjusting the parking brake for the
first time, it will be necessary to remove the
lanced area from the drum. The drum must
be removed to clean out all the metal
shavings. Refer to PROPELLER SHAFTS
(Sec. 4A).
5-30 BRAKES
MASTER CYLINDERS
MASTER CYLINDER
REPLACEMENT
Apply the vehicles parking brakes.
1. Brake pipes.
Cover the ends of the pipes to prevent dirt from
entering the system.
B-07803
2. Mounting nuts.
Figure 25Cast Iron Master Cylinder 3. Master cylinder.
If the vehicle is equipped with manual brakes,
refer to Brake Pedal Replacement for the
DESCRIPTION removal of the pushrod from the pedal.
There are two designs of master cylinders available Install or Connect (Figure 27)
depending on the brake option.
Prior to installation, refer to Bench Bleeding in
One is a full cast iron design incorporating a conven this section.
tional front to rear brake split (figure 25). The primary 1. Master cylinder.
piston provides the fluid pressure to the front brakes, If the vehicle is equipped with manual brakes,
while the secondary piston provides the fluid pressure refer to Brake Pedal Replacement for the
to the rear brakes. If the pressure is lost from either installation of the pushrod to the pedal.
system, the remaining system will function to stop the
vehicle.
NOTICE: See N otice on page 5-1 of this
section.
The second style master cylinder is designed for use
with a system using the low drag calipers (figure 26). In 2. Mounting nuts.
addition to the standard master cylinder functions, a
quick take-up feature is included. This provides a large
Tighten
volume of fluid to the wheels at low pressure with the
initial brake application. This large volume of fluid is
Nuts to 34 N m (25 ft. lbs.), G and P models.
needed to overcome the clearance created by the
Nuts to 44 N-m (32 ft. lbs.), C and K models.
seals retracting the pistons into the front calipers and
the spring retraction of the rear drum brake shoes. 3. Brake pipes.
4. Bleed the brakes, refer to Bleeding the Brake
Hydraulic System in this section.
5. Release the parking brakes.
BENCH BLEEDING
The purpose of bench bleeding is to remove the air
from the master cylinder so when it is installed on the
vehicle the brake system bleeding will be reduced.
1. Plug the outlet ports and mount the master
cylinder in a vise with the front end tilted slightly
down.
2. Fill the reservoir with clean brake fluid.
Figure 26Composite Master Cylinder

BRAKES 5-31
Figure 27Master Cylinder Installations

5-32 BRAKES
Using a smooth rounded end tool, stroke the 4. Reposition the master cylinder in the vise to the
primary piston about 25 mm (1-inch) several level position. Loosen the plugs one at a time and
times. push the piston into the bore to force the air from
As air is bled from the master cylinder, with the the cylinder. To prevent air from being sucked
outlets plugged, the resistance to the primary back into the cylinder, tighten the plug(s) before
piston travel will not allow the full 25 mm (1-inch) allowing the piston to return to its original
stroke. position.
3. Reposition the master cylinder in the vise with the 5. Fill the reservoir.
front end of the master cylinder tilted slightly up. N orm al b le e d in g p ro ce d u re s should be
Again stroke the primary piston about 25 mm followed after the master cylinder is installed.
(1-inch) several times.
VACUUM BOOSTERS
DESCRIPTION
SINGLE DIAPHRAGM MODEL

This booster is a sin g le diaphragm vacuum
suspended unit. It may have a single function vacuum
switch to activate the brake warning light in case of low
booster vacuum or vacuum pump malfunction. In a
normal operating mode, with the service brakes in the
released position, a vacuum suspended booster
operates with vacuum on both sides of its diaphragm.
When the brakes are applied, air at atmospheric 1. Mounting Nuts
pressure is admitted to one side of the diaphragm to 2. Master Cylinder
provide the power assist.
3. Vacuum Booster
4. Booster Mounting Nuts
TANDEM DIAPHRAGM MODEL
5. Booster Pushrod B-07805
This booster is a tandem vacuum suspended unit. It
may have a single dual function vacuum switch to
activate the brake warning light in case of low booster Figure 28Removing Vacuum Boosters
vacuum or vacuum pump malfunction. In a normal
operating mode, with the service brakes in the The mounting nuts must be removed from
released position, a tandem vacuum suspended inside the vehicle.
booster operates with vacuum on both sides of its
Vacuum booster.
diaphragms. When the brakes are applied, air at
atmospheric pressure is admitted to one side of each
diaphragm to provide the power assist.
VACUUM BOOSTER NOTICE: For steps 2 and 6 see Notice on

page 5-1 of this section.
REPLACEMENT
1. Vacuum booster.
Remove or Disconnect (Figure 28) 2. Booster mounting nuts.
Apply the vehicles parking brakes. Tighten

1. Mounting nuts.
2. Master cylinder. Nuts to 34 N m (25 ft. lbs.).
Support the master cylinder. B o o ste r p u sh ro d , re fe r to Brake Pedal
3. Vacuum hose from the check valve. Replacement in this section.
4. B o o ste r p u s h ro d , re fe r to B rake Pedal Vacuum hose.
Replacement in this section. Master cylinder.
5. Booster mounting nut. Mounting nuts.
BRAKES 5-33
Tighten
Mounting nuts to 34 N m (25 ft. lbs.

HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST)
DESCRIPTION 5. Nuts (1).
This system uses a hydraulic pump to power the Tighten

system and a pneumatic accumulator as a reserve
system. Nuts to 34 N m (25 ft. lbs.).
In this system no special fluids are used, however, 6. Hydraulic lines.
care must be taken to use the correct fluids. The 7. Bleed the booster, refer to B leeding the
master cylinder and brake system operate on standard Hydro-Boost System in this section.
hydraulic brake fluid, while the hydraulic pump 8. Release the parking brakes.
operates on power steering fluid. For diagnosis of the
Hydro-Boost System, refer to Hydro-Boost Systems P 30 (42) MODEL
Tests and Diagnosis of Hydro-Boost System in this
Remove or Disconnect (Figure 30 and 31)
section.

HYDRO-BOOST REPLACEMENT 1. Hydraulic lines from the booster.
2. Nuts (1) and washers (7).
3. Master cylinder (2).
C-K AND G MODELS Support the master cylinder.
4. Pushrod retainer (10).
+- Remove or Disconnect (Figure 29) 5. Retaining clip and washer.
Booster pushrod (9).
Apply the vehicles parking brakes. 6. Nuts (4) and washers (8).
1. Hydraulic lines from the booster. 7. Hydro-Boost unit (3).
2. Nuts (1).
3. Master cylinder (2). -+ Install or Connect (Figure 30 and 31)
Support the master cylinder.
4. B o o ste r p u sh ro d , re fe r to Brake Pedal
Replacement in this section. NOTICE: For steps 2 and 6 see Notice on
5. Nuts (4) and (6). page 5-1 of this section.
6. Hydro-Boost unit (3).
Gasket (5). 1. Hydro-Boost unit (3).
2. Washers (8) and nuts (4).
NOTICE: For steps 2 and 5 see Notice on Nuts to 34 N m (25 ft. lbs.).
page 5-1 of this section. 3. Booster pushrod (9).
Washer and retaining clip.
1. Gasket (5). 4. Pushrod retainer (10).
Hydro-Boost unit (3). 5. Master cylinder (2).
2. Nuts (4) and (6). 6. Washers (7) and nuts (1).
Tighten Tighten
Nuts to 34 N m (25 ft. lbs.). Nuts to 34 N m (25 ft. lbs.)

3. B o o ste r p u sh ro d , re fe r to B rake Pedal 7. Hydraulic lines.
Replacement in this section. 8. Bleed the booster, refer to Bleeding the
4. Master cylinder. (2). Hydro-Boost System in this section.
5-34 BRAKES
Figure 29C-K and G Model Hydro-Boost Replacement

BRAKES 5-35
1. Nut
2. Master Cylinder
3. Hydro-Boost
4. Nut
7. Washer
8. Washer B-07809
Figure 30P 30 (42) Hydro-Boost Replacement
P 30 (32) MODEL

1. Hydraulic lines from the booster.
2. Nuts (12) and washers (13).
3. Master cylinder (2).
Support the master cylinder.
4. Brake pedal rod, refer to Brake Pedal Rod
5. Nut (10) and washer (11).
Bolt (16).
6. Nut (14) and washers (15).
Bolt (18).
7. Nuts (12) and washer (13).
Bolts (17).
E Install or Connect (Figure 32)
NOTICE: For steps 2, 3, 4, and 7 see Notice

on page 5-1 of this section.

2. Bolts (17).
5-36 BRAKES
2. Master Cylinder
3. Hydro-Boost
10 . Nut
11 . Washer
12 . Nut
13. Washer
14. Nut
15. Washer
16. Bolt 10
17. Bolts
18. Bolt
19. Nut
B-07811
Figure 32P 30 (32) Hydro-Boost Replacement
Washers (13) and nuts (12). Leave finger NOTICE: The power steering fluid and brake
tight. fluid cannot be mixed. If the brake seals
3. Bolt (18). contact steering fluid or the steering seals
Washer (15) and nut (14). Leave finger tight. contact brake fluid, seal damage will result.
4. Bolt (16).
Washer (11) and nut (10). Leave finger tight. 1. Fill the power steering pump reservoir to the
proper level, let the fluid remain undisturbed for
Tighten at least two minutes.
2. Start the engine and run momentarily.
Nuts (10, 14 and 12) to 34 N m (25 ft. lbs.). Add fluid, if necessary.
5. Brake pedal rod, refer to Brake Pedal Rod 3. Repeat steps 1 and 2 until the fluid level remains
Replacement in this section. constant after running the engine.
6. Master cylinder (2). 4. Raise the front of the vehicle so the wheels are
7. Washers (13) and nuts (12). off the ground.
Support the vehicle with suitable safety stands.
Tighten
5. Turn the wheels from stop to stop, lig h tly
contacting the stops.
Nuts to 34 N m (25 ft. lbs.)
Add fluid, if necessary.
8. Hydraulic lines.
9. Bleed the booster, refer to Bleeding the
Hydro-Boost System in this section. 7. Start the engine and depress the brake pedal
10. Release the parking brakes. serveral times while rotating the steering wheel
from stop to stop.
8. Turn the engine off and then pump the brake
BLEEDING THE pedal 4-5 times.
HYDRO-BOOST SYSTEM 9. Check fluid level, add fluid if necessary.
10. If the fluid is extremely foamy, allow the vehicle to
Whenever the booster is removed and reinstalled, stand a few minutes with the engine off. Then
the steering system should be bled. repeat steps 7, 8 and 9.
BRAKES 5-37
11. Check for the presence of air in the oil. Air in the obvious that the pump will not bleed the air after
oil will have a milky appearance. Air in the system a few attempts, refer to POWER STEERING (Sec.
will also cause the fluid level in the pump to rise 3B3) for futher diagnosis,
when the engine is turned off. If it becomes
DISC BRAKES
DESCRIPTION
The disc brake assembly consists of a caliper and
piston assembly, rotor, linings, and an anchor plate.
The caliper is mounted to the anchor plate, which
allows the caliper to move laterally against the rotor.
The caliper is a one-piece casting with the inboard side
containing the piston bore. A square cut rubber seal is
located in a groove in the piston bore which provides
the hydraulic seal between the piston and the cylinder
wall.
OPERATION
As the brake pedal is depressed, hydraulic pressure
is applied against the piston. This pressure pushes the
inboard brake lining against the inboard braking
surface of the rotor. As the force increases against the
rotor, the caliper assem bly moves inboard thus
providing a clamping action on the rotor.
When the brake pressure is released, the piston seal

returns to its normal position, pulling the piston back
into the caliper bore. This will create a running
clearance between the inner brake lining and the rotor.
BRAKE LINING INSPECTION

Check the outer pad by looking at each end of the
caliper (figure 33). Check the lining thickness on the
inner pad by looking down through the inspection hole
in the top of the caliper housing. Whenever the lining is
worn to about the thickness of the pad, the lining
should be removed for further measurements. The pad
should be replaced anytime the lining is worn to within
0.08 mm (1/32-inch) of a rivet head or the pad itself.
The disc brake pads have a wear indicator that

makes a noise when the linings wear to a degree
where replacement is required (figure 34).
Also check the flatness of the brake pads. Place the

inboard and outboard lining surfaces together and
check for a gap between the lining surfaces. This gap
should not exceed 0.13 mm (.005-inch) at the middle of
the lining surfaces. This applies to new or used brake
pads.
5-38 BRAKES
BRAKE LINING
REPLACEMENT
3000/3100 MODELS
% of the brake fluid from the master cylinder.

safety stands.
Mark the relationship of the wheel to the hub.
1. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
CAUTION: See C aution on page 5-1.
2. Position a C-clamp around the outer pad and cali

per and tighten until the piston bottoms in its bore
(figure 36). 2. Sleeves
C - clamp 3. Bushings
3. Mounting bolts (1) (figure 37). 4. Bushings
5. Retainer Spring
4. Caliper assembly.
6. Inboard Pad
Suspend the caliper from the suspension
7. Outboard Pad
(figure 38). B-07829
Im portant Figure 35Replacing Disc Brake

Linings (3000/3100 Models)
Do not allow the brake components to hang
from the flexible hoses as damage to the Im portant
hoses may occur.
Make sure that the brake hose is not twisted
5. Inboard pad (6).
or kinked since damage to the hose could
Retainer spring (5). result.
6. Outboard pad (7).
7. Sleeves (2). NOTICE: See N otice on page 5-1.
8. Bushings (3 and 4).
5. Mounting bolts (1) (Figure 37).
L* Inspect
The inside of the caliper assembly for signs of

fluid leakage, if found, refer to Rebuilding the
Caliper in this section.
Mounting bolts and sleeves for corrosion. Do not
attempt to polish away corrosion, replace the
bolts.
Lubricate the sleeves and bushings with Delco

Silicone Lube or equivalent.
1. Bushings (3 and 4).
Sleeves (2).
2. Retainer spring (5) onto the inboard pad (6).
Inboard pad (6).
3 Outboard pad (7).
BRAKES 5-39
Tighten
9 Im portant

Bolts to 50 N m (37 ft. lbs.) Before moving the vehicle, pump the brake
pedal several times to make sure that the
6. Compress the pad ears to the caliper (figure 39). pedal is firm. Do not move the vehicle until a
firm pedal is obtained. Check the brake fluid
level in the master cylinder after pumping
Measure (Figure 40) the brakes.
The clearance between the caliper and the BENDIX MODEL

steering knuckle. The clearance at each end of
the caliper should be measured individually and Remove or Disconnect (Figures 41 and 42)
added together, this total should be between 0.26
- 0.60 mm (0.010 - 0.024-inches). % of the brake fluid from the master cylinder.

TIRES (Sec. 3E). Raise the vehicle and support it with suitable
safety stands.
8. Lower the vehicle. Mark the relationship of the wheel to the hub.
Figure 37Removing The Mounting Bolts Figure 40Caliper Clearances

5-40 BRAKES
6. Inboard Pad
Figure 41Replacing Disc Brake Figure 43Compressing The Caliper Piston

Linings (Bendix Models)
3. Bolt (8).
TIRES (Sec. 3E). 4. Support key (9) and spring (10).
Use a brass punch and a hammer to drive the
CAUTION: See C aution on page 5-1. support key out (figure 44).
2. Position C - clamp and tighten until the piston bot
toms in its bore (figure 43). Suspend the caliper from the suspension (figure
C - clamp. 45).
6. Inboard Pad
7. Outboard Pad
8. Bolt
9. Support Key
B-07798
Figure 42 Bendix Disc Brake Assembly

BRAKES 5-41
9 Im portant
Make sure that the brake hose is not twisted

or kinked since damage to the hose could
result.
4. Spring (10) and support key (9).
Use a brass punch and a hammer to drive the
support key in (figure 46).
Im portant
NOTICE: See Notice on page 5-1.
Do not allow the brake components to hang
from the flexible hoses as damage to the 5. Bolt (8).
hoses may occur. The boss on the bolt must fully fit into the circular
6. Inboard pad (6) from the steering knuckle or rear cutout in the key.
caliper support.
Anti-rattle spring (11).
7. Outboard pad (7).
Si Tighten

1* Inspect 6. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
The inside of the caliper assembly for signs of
fluid leakage, if found, refer to Rebuilding the
Caliper in this section.
Im portant
Clean
Before moving the vehicle, pump the brake
pedal several times to make sure that the
Use a wire brush to remove any corrosion from
pedal is firm. Do not move the vehicle until a
the machined surfaces of the steering knuckle
firm pedal is obtained. Check the brake fluid
and caliper.
level in the master cylinder after pumping
0 Install or Connect (Figures 41 and 42)

the brakes.
Lubricate the caliper and steering knuckle (or SERVICING THE ROTOR
support) sliding surfaces and spring with Delco
Silicone Lube or equivalent. In the manufacturing of the brake rotor all the
1. Inboard pad (6) and anti-rattle spring (11). tolerances regarding surface finish, parallelism, and
2. Outboard pad (7) into the caliper assembly. lateral runout are held very closely. The maintenance
5-42 BRAKES
PARALLELISM
Parallelism is the measurement of the thickness of
the ro to r at fo u r or m ore p o in ts a round the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the
rotor. The rotor thickness must not vary more than
0.013 mm (0.0005-inch) from point to point.
MACHINING
Since accurate control of the rotor tolerances is
necessary for proper performance of the disc brakes,
machining of the rotor should be done only with
precision equipment.
A ll brake rotors have a m inim um th ic k n e s s
dimension cast into them. This dimmension is the
m in im um w ear d im e n s io n and not a re fin is h
dimension. Do not use a brake rotor that will not meet
the specifications, after refinishing. Replace with a new
brake rotor. Refer to Specification in this section for
final maching tolerances.
REBUILDING THE CALIPER
3000/3100 MODELS
* Disassemble (Figure 48)
Drain all the fluid from the caliper.

of these tolerances provide the surface necessary to Pad the interior of the caliper with clean shop
prevent brake roughness. towels.
Light scoring of the rotor surface not in excess of
0.38 mm (0.15-inch) in depth is normal. This condition CAUTION: Do not place your fingers in fro n t of
does not affect the brake operation. the piston in an attem pt to catch or protect it
when applying compressed air. This could
LATERAL RUNOUT result in serious injury.
Lateral runout is the movement of the rotor from side
to side as it rotates on the spindle. This could also be
refered to as rotor wobble . NOTICE: Use just enough air to ease the
This movement causes the brake pad and piston to piston out of the bore. If piston is blown
be knocked back into its bore. This results in outeven with padding provided, it may be
additional pedal travel and a vibration during braking. damaged.
1. Piston (22) (figure 49)

Checking Lateral Runout (Figure 47)
1. Tighten the wheel bearings to eliminate all 2. Boot (23) (figure 50).
freeplay. Use care not to scratch the housing bore.
2. Attach a dial indicator to some portion of the 3. Piston seal (21).
suspension. Do not use any type of metal tool.
The point of the styles must contact the rotor face 4. Bleeder valve (20).
about 25 mm (1-inch) from the rotor edge.
3. Move the rotor one complete rotation. Tjjf Clean
The lateral runout should not exceed 0.10 mm
Bleeder valve, caliper bore, caliper passages, and
(0.004-inch).
piston with denatured alcohol. Use dry, filtered
4. Readjust the wheel bearings, refer to FRONT compressed air to dry parts and blow out
SUSPENSION (Sec. 3C). passages.
BRAKES 5-43
Lubricate the new piston seal, caliper bore, and

piston with clean brake fluid.
1. Piston seal (21).
Make sure the seal is not twisted in the caliper
bore groove.
2. Boot (23) onto the piston (22).
Piston (22).
Figure 48Models 3000/3100 3. Boot (23) into the caliper housing counterbore
Caliper Components using tool J-26267 (figure 51).
Inspect
Piston for scoring, corrosion and any damage to

the chrome plating, replace if found.
Caliper bore for scoring, pitting, or corrosion. Use
crocus cloth to polish out any light corrosion.
Replace caliper if corrosion cannot be removed.
* Assemble (Figure 48)
Tool required:
J-26267 Piston Seal Installer
Figure 49Removing The Piston Figure 51Installing The Caliper Boot

5-44 BRAKES
20. Bleeder Valve

21. Piston Seal
22. Piston
23. Boot B-07838
Figure 52Bendix Model

Caliper Components
4. Bleeder valve (20).
BENDIX MODEL
+1+ Disassemble (Figure 52)
Drain all the fluid from the caliper.

Pad the interior of the caliper with clean shop
towels.
Caliper bore for scoring, pitting, or corrosion. Use
CAUTION: Do not place your fingers in fro nt corcus cloth to polish out any light corrosion. Re
o f the piston in an attem pt to catch or protect place caliper if corrosion cannot be removed.
it when applying compressed air. This could
result in serious injury. * Assemble (Figure 52)
Tool required:
NOTICE: Use just enough air to ease the J-24548 Piston Seal Installer
piston out of the bore. If piston is blown Lubricate the new piston seal, caliper bore, pis
outeven with padding provided, it may be ton, and seal lips on boot with clean brake fluid.
damaged. 1. Piston seal (21).
Make sure the seal is not twisted in the caliper
1. Piston (22) (figure 49). bore groove.
2. Boot (23). 2. Boot (23) on tool J-24548.
3. Piston seal (21). Place the large diameter of the boot over the tool
Do not use any type of metal tool. first and ride the smaller diameter onto the tool.
4. Bleeder valve (20). The large diameter must then slide off the tool.
The large lip of the boot into the groove in the
IQI Clean caliper bore.
The lip of the boot must be firmly slated in the
Bleeder valve, caliper bore, caliper passages, and groove.
piston with denatured alcohol. Use dry, filtered 4. Piston (22) inside tool J-24548 (figure 53).
compressed air to dry parts and blow out pas Press the piston half way into its bore.
sages. 5. Remove tool J-24548.
Make sure the boot is firmly seated.
Inspect 6. Bleeder valve (20).
Piston for scoring, corrosion and any damage to

the chrome plating, replace if found.
BRAKES 5-45
DRUM BRAKES
DESCRIPTION Wheel cylinder for signs of leakage, refer to

Rebuilding The Wheel Cylinder.
The drum brake assembly is a duo - servo design. Brake drum for scoring, and machining
With this particular design, the force which is applied tolerance, refer to Servicing The Brake
by the wheel cylinder to the primary shoe is multiplied Drum.
by the primary lining friction to provide a large applied
force to the secondary shoe. The torque from the brake -+ Install or Connect (Figure 54)
shoes is transferred to the anchor pin and through the
backing plate, to the axle flange. Brake adjustments Lubricate the shoe pads and adjusting screw
are automatic and are made during reverse brake threads with a thin coat of white lithium grease.
applications.
1. Adjusting screw (17) and adjusting screw spring
(18) to both shoes (19 and 5).
BRAKE LINING REPLACEMENT The coils of the spring must not touch the
adjusting screw.
2. Shoe assembly.
3. Parking brake lever (3) and washer (4) into the
shoe.
Raise the vehicle and support with suitable safety
Retaining ring (6).
stands.
4. Strut spring (9) onto the parking brake strut (8).
Mark the relationship of the wheel to the hub.
Parking brake strut (8).
1. Wheel and tire assembly, refer to WHEELS AND 5. Actuator lever (10) and lever pivot (15).
TIRES (Sec. 3E). Actuator link (11).
Mark the relationship of the drum to the axle. Lever return spring j[16).
6. Hold down pins (1).
CAUTION: See Caution on page 5-1. Hold down springs (14).
7. Return springs (12 and 13).
2. Drum 8. Drum.
3. Return springs (12 and 13). Align the marks made during disassembly.
Shoe guide (7). 9. Wheel and tire assembly, refer to WHEELS AND
4. Hold down springs (14). TIRES (Sec. 3E).
Hold down pins. (1). Align the marks made during disassembly.
5. Actuator lever (10) and lever pivot (15). 10. Adjust the brakes, refer to Brake Adjustment in
Lever return spring (16). this section.
Actuator link (11).
6. Parking brake strut (8).
Strut spring (9). SERVCING THE
7. Retaining ring (6). BRAKE DRUM
Parking brake lever (4) and washer (4).
8. Shoes (5 and 19). Whenever the brake drums are removed, they
should be thoroughly cleaned and inspected for
Adjusting screw assembly (17).
cracks, scores, deep grooves and out-of-round.
Adjusting screw spring (18).
CRACKED, SCORED, OR GROOVED DRUM
9 Im portant A cracked drum is unsafe for further service and
must be replaced. Do not attempt to weld a cracked
Do not interchange the right and left drum.
adjusting screws. Smooth up any slight scores. Heavy or extensive
scoring will cause excessive brake lining wear, and it
L* Inspect will probably be necessary to machine the drum
braking surface.
All parts for discoloration due to heat, or If the brake linings are slightly worn and the drum is
stress. Replace if necessary. grooved, the drum should be polished with fine emery
All parts for signs of wear. Replace if cloth but should not be machined. At this stage,
necessary. eliminating all the grooves in the drum and smoothing
5-46 BRAKES
Hold Down Spring

Lever Pivot
Lever Return Spring
Adjusting Screw Assembly
Adjusting Screw Spring
Primary Shoe
1. Hold Down Pins

2. Backing Plate
3. Parking Brake Lever
4. Washer
5. Secondary Shoe
6. Retaining Ring
7. Shoe Guide
8. Parking Brake Strut
9. Strut Spring
10. Actuator Lever
11. Actuator Link
12. Return Spring
13. Return Spring
B-07791
Figure 54Drum Brake Components
the ridges on the lining would require the removal of wear can be accurately measured with an inside
too much metal and lining, while if left alone, the micrometer fitted with proper extension rods.
grooves and ridges match and satisfactory service can
be obtained. When measuring a drum for out-of-round, taper and
wear, take measurments at the open and closed edges
If brake linings are to be replaced, a grooved drum
of machined surface and at right angles to each other.
should be machined. A grooved drum, if used with new
lining, will not only wear the lining, but will make it
difficult, if not impossible to obtain efficient brake MACHINING THE DRUM
performance. If a drum is to be machined, only enough metal
should be removed to obtain a true, smooth braking
OUT-OF-ROUND OR TAPERED DRUM surface. If a drum does not clean-up when machined to
An out-of-round drum makes accurate brake shoe a maximum diameter it must be replaced, refer to
adjustment impossible and is likely to cause excessive Specifications in this section. Removal of more
wear of other parts of brake mechanism due to its metal will affect dissipation of heat and may cause
eccentric action. An out-of-round drum can also cause distortion of the drum.
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake All brake drums have a maximum diameter cast into
drum exceeds the specification limits in taper (and/or) them. This diameter is the maximum wear diameter.
out-of-round, the drum should be machined to true up Do not machine a brake drum that will not meet the
the braking surface. Out-of-round as well as taper and specification, refer to Specifications in this section.
BRAKES 5-47
BRAKE ADJUSTMENT
A manual adjustment of the rear brakes is required
after the rear linings have been replaced. The front
disc brakes require not adjustment.
CAUTION: Refer to C aution on page 5-1.
1. Remove the lanced area in the brake backing

plate.
The metal lanced area must be removed
from the brake assembly.
Adjust
Brake adjusting screw until the wheel can

just be turned by hand.
The brake drag should be equal at both
Figure 55Removing The Wheel Cylinder
wheels.
Back off the adjusting screw 33 notches.
5. Bleed brake system, refer to Bleeding the Brake
Hydraulic System.
Im portant
Brakes should have no drag after the screw

has been backed off about 15 notches. If a
REBUILDING THE
heavy drag is present refer to Parking WHEEL CYLINDER
Brake Adjustment.
2. Install an adjusting hole cover in the brake
backing plate.
Disassemble (Figure 56)
3. Check parking brake adjustment.
1. Remove wheel cylinder, refer to Wheel Cylinder
WHEEL CYLINDER Replacement.
2. Boots (54).
REPLACEMENT 3. Pistons (53).
4. Seals (52).
0 Remove or Disconnect (Figure 55) 5. Spring assembly (55).
Inspect
CAUTION: See C aution on page 5-1.
Cylinder bore for scoring and corrosion.
1. B rake lin in g s , re fe r to B rake L in in g
Spring assembly for signs of discoloration
Replacement.
due to heat. Replace if necessary.
2. Brake pipe.
3. Bolts.
[ y l Clean
4. Wheel cylinder.
Inside the cylinder bore with crocus cloth. If
the bore is still scored replace the cylinder.
Cylinder with clean brake fluid.
1. Wheel cylinder.
2. Bolts.
Tighten
Lubricate seals and cylinder bore with clean
Bolts to 18 N m (160 in. lbs.). brake fluid.
3. Brake pipe. 1. Spring assembly (55).
4. B rake lin in g s , re fe r to Brake L in in g 2. Seals (52).
Replacement. 3. Pistons (53).
5-48 BRAKES
51. Bleeder Valve

52. Seal
53. Piston
54. Boot
55. Spring Assembly B-07793
Figure 56Wheel Cylinder Components
4. Boots (54).
5. Wheel cylinder, refer to Wheel Cylinder Replace
ment.
BRAKES 5-49
SPECIFICATIONS
BRAKE SYSTEMS
SYSTEM FRONT BRAKES REAR BRAKES BRAKE ASSIST
GASOLINE ENGINE VEHICLES
C-MODELS
JB1 Low Drag Disc 11.86 x 1.04 Drum 11.0 x 2.00 None (Manual Brakes)
JB3 Low Drag Disc 11.86 x 1.04 Drum 11.0 x 2.00 VacuumSingle Diaphragm
G-MODELS
JB1 Low Drag Disc 11.86 x 1.29 Drum 11.00 x 2.00 None (Manual Brakes)
JB3 Low Drag Disc 11.86 x 1.29 Drum 11.00 x 2.00 VacuumSingle Diaphragm
ALL MODELS
JB5 Low Drag Disc 11.86 x 1.29 Drum 11.15 x 2.75 VacuumDual Diaphragm
JB6 Low Drag Disc 12.50 x 1.28 Drum 11.15 x 2.75 VacuumDual Diaghragm
JB7 Conventional Disc 12.50 x 1.28 Drum 13.00 x 2.50 VacuumDual Diaphragm
JB8 Conventional Disc 12.50 x 1.54 Drum 13.00 x 3.50 HydraulicHydro-Boost
JF9 Conventional Disc 14.25 x.1.54 Disc 13.75 x 1.54 HydraulicHydro-Boost
DIESEL ENGINE VEHICLES

JD3 Low Drag Disc 11.86 x 1.29 Drum 11.00 x 2.00 Hydraulic Hydro-Boost
JD5 Low Drag Disc 11.86 x 1.29 Drum 11.15 x 2.75 HydraulicHydro-Boost
JD6 Conventional Disc. 12.50 x 1.28 Drum 11.15 x 2.75 Hydraulic-Hydro-Boost
JD7 Conventional Disc 12.50 x 1.28 Drum 13.00 x 2.50 HydraulicHydro-Boost
DRUM DIAMETERS ROTOR THICKNESS

REPLACEMENT MINIMUM REPLACEMENT
ORIGINAL MAXIMUM REFINISH (DISCARD) AFTER REFININSHING (DISCARD)
11.000 11.060 11.090 1.480 1.465
11.150 11.210 11.240 1.230 1.215
12.000 12.060 12.090 0.980 0.965
13.000 13.060 13.090
5-50 BRAKES
C K G P
Master Cylinderto Dash or Booster 44 N m (32 ft. lbs.) 44 N-m (32 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.)
Booster to Dash or Frame 44 N m (32 ft. lbs.) 44 N-m (32 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.)
Combination Valve Mounting Bolts 17 N m (150 in. lbs.) 17 N-m (150 in. lbs.) 23 N-m (17 ft. lbs.) 23 N-m (17 ft. lbs.)
Bracket 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.)
CaliperMounting Bolt 48 N m (35 ft. lbs.)
Support Plate to Knuckle 16 N m (140 in. lbs.)
Brake Pedal Bracket to Dash 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 17 N-m (150 in. lbs.) 34 N-m (25 ft. lbs.)
Bracket to I.P. 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.)
Pivot Bolt Nut 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.)
Sleeve to Bracket 9.5 N-m (85 in. lbs.)

Stoplamp Switch Bracket 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.)
Push Rod to Pedal 34 N-m (25 ft. lbs.)

Push Rod Adjusting Nut 30 N-m (22 ft. lbs.)
Parking Brake to Dash 12 N-m (100 in lbs.) 12 N-m (100 in. lbs.) 12 N-m (100 in. lbs.)
to I.P. Kick Panel

or Floorpan 17 N-m (100 in. lbs.) 17 N-m ( 100 in. lbs.) 12 N-m (100 in. lbs.) 24 N-m (18 ft. lbs.)
Cable ClipsScrews 17 N-m (150 in. lbs.) 12 N-m (100 in. lbs.) 17 N-m (150 in. lbs.)
Bolts 17 N-m (150 in. lbs.) 24 N-m (18 ft. lbs.) 6 N-m (55 in. lbs.)
Propshaft Parking Brake
Adjusting Nut 40 N-m (30 ft. lbs.)
Bracket to Trans. 27 N-m (20 ft. lbs.)
Cable Clip to Frame 17 N-m (150 in. lbs.)
Cable Clip to Dash 6 N-m (55 in. lbs.)
Cable Clip to Trans. Brkt. 27 N-m (20 ft. lbs.)
Flange Plate 40 N-m (30 ft. lbs.)
Drum 110 N-m (80 ft. lbs.)
Wheel Cylinder to Flange Plate Bolt 5.5 N-m (50 in. lbs.)/20 N-m (180 in. lbs.) on JB5, JB6, JB7, and JB8
Rear Brake Anchor Pin 190 N-m (140 ft. Ibs.)/312 N-m (230 ft. lbs.) JB7 and JB8
Front Brake Hose to Caliper 44 N-m (32 ft. lbs.)
to Frame Nut 7 N-m (58 in. lbs.)
Bracket Bolt 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.)
Rear Brake Hoseto Axle Bracket 27 N-m (20 ft. lbs.) 27 N-m (20 ft. lbs.) 10 N-m (90 in. lbs.) 17 N-m (150 in. lbs.)
Bracket to Axle 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.)
Brake Line Attaching Nuts 17 N-m (150 in. lbs.)
Retaining ClipsScrews 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 12 N-m (100 in. lbs.) 17 N-m (150 in. lbs.)
Bolts 17 N-m (150 in. lbs.) 24 N-m (18 ft. lbs.)
Brake Bleeder Valves 7 N-m (60 in. lbs.)
HydroBoost
-Pedal Rod - P30 (32) Models 34 N-m (25 ft. lbs.)
Pedal Rod Boot P 30 (32) Models 20 N-m (15 ft. lbs.)
Pivot Lever Rod Retainer 34 N-m (25 ft. lbs.)
Pivot Lever Bolt 60 N-m (45 ft. lbs.)
Booster Brackets 34 N-m (25 ft. lbs.)
Booster Brace at Dash or Rad. Supt. 17 N-m (150 in. lbs.)
Power Steering Pump to Booster Line 34 N-m (25 ft. lbs.)
Booster to Gear Line 34 N-m (25 ft. lbs.)
Return Line at Booster and Gear 34 N-m (25 ft. lbs.)
Return Line Clamp Screw 1.6 N-m (15 in. lbs.)
Line Clamp to Bracket Screw 17 N-m (150 in. lbs.)
-H o se Clamp to Skirt Screw 4.5 N-m (40 in. lbs.)
Line Clamp to Frame Bolt 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.)
BRAKES 5-51
SPECIAL TOOLS
J-29567 Brake Bleeder Adapter

J-23518-01 Brake Bleeder Adapter
J-23709 Combination Valve Depressor
J-23530 Flaring Tool
J-23533-B Tube Cutter
6A-1
SECTION 6
ENGINE
CONTENTS
S U B JE C T PAGE
E ng in e ............................................................................................................................................................................. 6A-1
4.3 Liter V 6 .................................................................................................................................................................. 6A3-1
4.8 Liter L 6 .................................................................................................................................................................. 6A4-1
Small B lo ck.................................................................................................................................................................. 6A5-1
7.4 Liter V 8 .................................................................................................................................................................. 6A6-1
6.2 Liter D ie se l............................................................................................................................................................6A7-1
Engine C o o lin g .............................................................................................................................................................. 6B-1
Fuel S y s te m .................................................................................................................................................................. 6C-1
C arburetors.................................................................................................................................................................. 6C1-1
Diesel Fuel In je c tio n ................................................................................................................................................. 6C2-1
Engine E le c tric a l..........................................................................................................................................................6D-1
D rivability And E m issio n s.......................................................................................................................................... 6E-1
D rivability And Emissions C a rb u re to r.............................................................................................................. 6E8-1
D rivability And Emissions D ie se l....................................................................................................................... 6E9-1
E x h a u s t........................................................................................................................................................................... 6F-1
Vacuum P u m p .............................................................................................................................................................. 6H-1
SECTION 6A
ENGINE
CONTENTS
S U B JE C T PAGE
General In fo rm a tio n ................................................................................................................................................... 6A - 2

Statement on Cleanliness and C a re ................................................................................................................... 6A - 2
Tune-Up In fo rm a tio n .............................................................................................................................................6 A - 2
Use o f RTV Sealer and Anaerobic Gasket E lim ina tor.................................................................................... 6A - 2
Replacing Engine G askets.................................................................................................................................... 6 A - 3
Gasoline Engine Mechanical D iagnosis................................................................................................................ 6 A - 3
Gasoline Engine Compression C h e c k .............................................................................................................. 6A - 6
Diagnosis of Hydraulic L if te r s ................................................................................................................................ 6 A - 7
Diagnosis of Diesel E ngine...................................................................................................................................... 6 A - 9
Compression Check (6.2L Diesel E n g in e )........................................................................................................ 6 A - 1 1
Cranking Speed Check...........................................................................................................................................6A - 1 1
Special T o o ls .............................................................................................................................................................. 6A - 1 1
All new General Motors vehicles are certified by the United States Environmental Protection Agency as
conform ing to the requirem ents of the regulations for the control of air pollution from new m otor vehicles.
This certification is contingent on certain adjustm ents being set to factory standards. In most cases, these
adjustm ent points either have been permanently sealed and/or made inaccessible to prevent indiscrim inate
or routine adjustm ent in the field. For this reason, the factory procedure fo r tem porarily removing plugs,
caps, etc., for purposes of servicing the product must be strictly followed and, wherever practicable, re
turned to the original intent of the design. For vehicles sold in Canada and equipped w ith non-closed loop
engines, also refer to the appropriate Canadian service manual supplement.
6A-2 ENGINE
GENERAL INFORMATION
STATEMENT ON the oil pump screen, jacking against the oil pan
may cause it to be bent against the pump screen
CLEANLINESS AND CARE resulting in a damaged oil pickup unit.
An engine is a combination of many machined,
honed, polished and lapped surfaces with very
fine tolerances.
TUNE-UP INFORMATION
Whenever valve train components, cylinder head, All information required to tune up the vehicles
c y lin d e r, c ra n k s h a ft, or c o n n e c tin g rod engine is given in the Engine Emission Control Label.
components are removed for service, they should This label is located in the engine compartment.
be retained in order. At the time of installation, Information that can be found on the label includes:
they should be installed in the same locations Spark plug type and gap.
and with the same mating surfaces as when
Ignition timing.
removed.
Valve lash (if applicable).
Any time air cleaner, carburetor, or TBI unit is
removed, the intake opening must be covered. If Idle, fast idle, and solenoid screw speeds, as
a d ie s e l e n g in e is being s e rv ic e d , the applicable.
recommended cover (J-29664-2 or J-26996-1) The p ro p e r se q u e n ce for m a kin g the
should be used. This will protect against the adjustments.
entrance of foreign material which could follow Emission hose routing diagram (sometimes on a
the intake passage into the cylinder and cause separate label).
extensive damage when the engine is started.
When any internal engine parts are serviced,
care and cleanliness are important. A liberal USE OF RTV SEALER
coating of engine oil should be applied to friction AND ANAEROBIC
areas during assembly to protect and lubricate GASKET ELIMINATOR
the surfaces on initial operation. Throughout this
section, it should be understood that proper Two types of sealer are commonly used in engines
cleaning and protection of machined surfaces covered by this manual. These are RTV sealer and
and friction areas is part of the repair procedure. anaerobic gasket eliminator sealer.
This is considered standard shop practice even if It is important that these sealers be applied properly
not specifically stated. and in the proper place to prevent oil leaks. THE TWO
On diesel engines, whenever the fuel injection TYPES OF SEALER ARE NOT INTERCHANGEABLE.
pump or lines are removed or disconnected, care Use the sealer recommended in the procedure.
must be taken to prevent the entry of dirt into the RTV (room temperature vulcanizing) sealer is
pump, lines, and injectors. The entry of even used where a non-rigid part is assembled to a
small amount of dirt or other foreign material into rigid part. Common examples are oil pans and
the fuel injection system may cause serious rocker arm covers.
damage. Anaerobic gasket elim inator hardens in the
It should be kept in mind, while working on the absence of air. This sealer is used where two rigid
engine, that the 12-volt electrical system is parts (such as castings) are assembled together.
capable of violent and damaging short circuits. When two rigid parts are disassembled and no
When performing any work where electrical sealer or gasket is readily noticeable, the parts
terminals could possibly be grounded, the ground w ere p ro b a b ly a sse m b le d u sin g gaske t
cable of the battery should be disconnected at eliminator.
the battery.
Battery cables should be disconnected before USING RTV SEALER
any major work is performed on the engine. 1. Dont use RTV when extreme temperatures are
Failure to disconnect cables may result in expected, such as exhaust manifold, head gasket
damage to wire harness or other electrical parts. or where gasket eliminator is specified.
Cover or otherwise protect exposed electrical 2. When separating components sealed with RTV,
connections to prevent damage from oil and fuel. use a rubber mallet and bum p the part
When raising or supporting the engine for any sideways to shear the RTV sealer. Bumping
reason, do not use a jack under the oil pan. Due should be done at bends or reinforced areas to
to the small clearance between the oil pan and prevent distortion of parts. RTV is weaker in
ENGINE 6A-3
shear (lateral) strength than in tensile (vertical) USING ANAEROBIC GASKET ELIMINATOR
strength. 1. Clean surfaces to be resealed with a chlorinated
Attempting to pry or pull components apart solvent to remove all oil, grease and old material.
may result in damage to the part. 2. Apply a continuous bead of gasket eliminator to
3. Surfaces to be resealed must be clean and dry. one flange.
Remove all traces of oil and RTV. Clean with a 3. Spread bead evenly with your finger to get a
chlorinated solvent such as carburetor spray uniform coating on the complete flange.
cleaner. Dont use petroleum cleaners such as 4. Assemble parts in the normal manner and torque
mineral spirits; they leave a film onto which RTV to specifications.
wont stick.
4. Apply RTV to one of the clean surfaces. Use a
bead size as specified in the procedure. Run the REPLACING ENGINE GASKETS
bead to the inside of any bolt holes. Do not allow
the sealer in any blind threaded holes, as it may CAUTION: Composite type gaskets are used
prevent the bolt from seating properly or cause in some areas of the engine assembly. These
damage when the bolt is tightened. gaskets have a thin metal core. Use caution
5. Assem ble w hile RTV is s till wet (w ithin 3 w hen re m o v in g o r h a n d lin g c o m p o s ite
minutes). Dont wait for RTV to skin over. gaskets to help avoid personal injury.
6. Torque bolts to specifications. Dont over-torque.
GASOLINE ENGINE MECHANICAL DIAGNOSIS
The following information pertains to the basic as Cranking and ignition system problems: Refer to
sembly only. For more diagnosis information, refer to ENGINE ELECTRICAL (SEC. 6D).
the following: Starting, driveability, fuel economy, etc. problems:
Overheating or other cooling system problems: Refer to DRIVEABILITY AND EMISSIONS (SEC.
Refer to COOLING (SEC. 6B). 6E).
6A-4 ENGINE
GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.)

Engine W ill Not Turn 1. Battery, cranking system or other elec 1. Refer to ENGINE ELECTRICAL
Over trical problem. (SEC. 6D).
2. Liquid in combustion chamber. 2. Remove with suction gun.
3. Seized engine. 3. Repair.
Engine Cranks 1. Fuel or ignition system problem. 1. Refer to DRIVEABILITY AND EM-
Normally But Does MISSIONS (SEC. 6E) and ENGINE
Not Start ELECTRICAL (SEC. 6D).
2. Restricted exhaust system. 2. Repair.
3. Low compression due to stuck or 3. Perform a compression test, as out
burned valves, stuck rings, blown head lined in this section. Repair engine as
gasket, etc. necessary.
Rough Idle 1. Fuel, ignition system or emissions sys 1. Refer to DRIVEABILITY AND EMIS
tem problem. SIONS (SEC. 6E) and ENGINE
ELECTRICAL (SEC. 6D).
2. Uneven cylinder compression. 2. Perform a compression test, as out
lined in this section. Repair engine as
necessary.
3. Bent pushrod or broken valve spring. 3. Repair.
4. Faulty engine mount. 4. Repair or replace.
White Smoke Usually caused by water vapor, which None required.

is a normal byproduct of combustion.
Usually seen on cold days.
Black Smoke Usually caused by rich fuel mixture. Refer to FUEL SYSTEM (SEC. 6C)
and/or DRIVEABILITY AND EMIS
SIONS (SEC. 6E).
Blue Smoke Usually caused by oil burning in the Refer to Excessive Oil Loss diagno
combustion chambers. sis.
Excessive Oil Loss 1. External oil leaks. 1. Tighten bolts and/or replace gaskets
and seals as necessary.
2. Improper reading of dipstick. 2. Check oil with vehicle on a level sur
face and allow adequate drain down
time.
3. Improper oil viscosity. 3. Use recommended viscosity for pre
vailing temperatures.
4. Continuous high speed driving and/or 4. Continuous high speed operation
severe usage. and/or severe usage will normally
cause decreased oil mileage.
5. Crankcase ventilation or PCV system 5. Service as necessary.
malfunctioning.
6. Valve guides and/or valve stem seals 6. Ream guides and install oversize ser
worn, or seals missing. vice valves and/or new valve stem
seals.
7. Piston rings not seated. 7. Allow adequate time for rings to seat.
8. Broken or worn piston rings. 8. Replace broken or worn rings as nec
essary.
9. Piston improperly installed. 9. Replace piston or repair as neces
sary.
ENGINE 6A-5

Low Oil Pressure 1. Slow idle speed. 1. Set idle speed to specifications.
2. Incorrect or faulty oil pressure switch 2. Replace with proper switch or sensor.
or sensor.
3. Incorrect or faulty oil pressure gage. 3. Replace with proper gage.
4. Improper oil viscosity. 4. Replace with proper oil.
5. Diluted engine oil 5. Change engine oil and filter. Repair
cause of dilution (rich mixture, etc.)
6. Oil pump worn or dirty. 6. Clean pump and replace worn parts
as necessary.
7. Plugged oil filter 7. Replace filter and oil.
8. Oil pickup screen loose or plugged. 8. Clean or replace screen as neces
sary.
9. Hole in oil pickup tube. 9. Replace tube.
10. Excessive bearing clearance. 10. Replace as necessary.
11. Cracked, porous or plugged oil galleys. 11. Repair or replace block.
12. Galley plugs missing or mis-installed. 12. Install plugs or repair as necessary.
Valve Train Noise 1. Low oil pressure. 1. Repair as necessary. (See diagnosis
for low oil pressure).
2. Loose rocker arm attachments. 2. Inspect and repair as necessary.
3. Worn rocker arm and/or pushrod. 3. Replace as necessary.
4. Broken valve spring. 4. Replace spring.
5. Sticking valves. 5. Free valves.
6. Lifters worn, dirty or faulty. 6. Refer to Diagnosis of Hydraulic Lift
ers.
7. Camshaft worn or faulty. 7. Replace camshaft.
8. Worn valve guides. 8. Repair as necessary.
Engine Knocks Cold 1. EFE equipped engines may have valve 1. Replace EFE valve.
And Continues For knock.
Two To Three 2. Flywheel contacting splash shield. 2. Reposition splash shield.
Minutes. Knock 3. Loose or broken torsional damper or 3. Tighten or replace as necessary.
Increases With drive pulleys.
Torque. 4. Excessive piston to bore clearance. 4. Replace piston.
5. Bent connecting rod. 5. Replace connecting rod.
Engine Has Heavy 1. Broken balancer or pulley hub. 1. Replace parts as necessary.
Knock Hot With 2. Loose torque converter bolts. 2. Tighten bolts.
Torque Applied. 3. Accessory belts too tight or nicked. 3. Replace and/or tension to specs as
necessary.
4. Exhaust system grounded. 4. Reposition as necessary.
5. Flywheel cracked or loose rivets on fly 5. Replace flywheel.
wheel.
6. Excessive main bearing clearance. 6. Repair as necessary.
7. Excessive rod bearing clearance. 7. Repair as necessary.
Engine Has Light 1. Faulty EST or ESC system. 1. Refer to DRIVEABILITY AND EMIS
Knock Hot In Light SIONS (SEC. 6E).
Load Conditions. 2. Improper timing. 2. Adjust to specifications.
3. Poor quality fuel. 3. Use fuel of recommended grade.
4. Loose torque converter bolts. 4. Tighten bolts.
5. Exhaust leak at manifold. 5. Tighten bolts and/or replace gaskets.
6. Excessive rod bearing clearance. 6. Replace bearings as necessary.
6A-6 ENGINE

Engine Knocks On 1. Fuel pump. 1. Replace pump.

Initial Start Up But 2. Improper oil viscosity. 2. Install proper oil viscosity for ex
Only Lasts A Few pected temperatures.
Seconds. 3. Hydraulic lifter bleed down. 3. Refer to Diagnosis of Hydraulic Lift
ers.
Engine Knocks At 1. Loose or worn drive belts. 1. Tension and/or replace as necessary.
Idle Hot 2. Compressor generator bearing. 2. Replace as necessary.
3. Fuel pump. 3. Replace pump.
4. Valve train. 4. Refer to Valve Train Noise.
5. Improper oil viscosity. 5. Install proper viscosity oil for ex
pected temperature.
6. Excessive piston pin clearance. 6. Install new piston, pin and/or con
necting rod as needed.
7. Connecting rod alignment. 7. Check and replace rods as neces
sary.
8. Insufficient piston to bore clearance. 8. Hone and fit new piston, if required.
(Cold engine piston knock usually dis
appears when the cylinders spark
plug is grounded out. Cold engine pis
ton knock which disappears in 1.5 min
utes sh o u ld be co n s id e re d
acceptable.)
9. Loose torsional damper. 9. Torque and or replace worn parts.
GASOLINE ENGINE COMPRESSION CHECK
GASOLINE ENGINE than 690 kPa (100 psi). For example, if the
highest pressure in any one cylinder is 1035 kPa
COMPRESSION CHECK (150 psi), the lowest allowable pressure for any
other cylinder would be 725 kPa (105 psi). (1035 x
1. Disconnect the Bat or B + terminal from the
70% = 725) (150 x 70% = 105).
distributor. Refer to ENGINE ELECTRICAL (SEC.
Normal Compression builds up quickly
6D).
and evenly to specified compression on
2. Remove all spark plugs.
each cylinder.
3. Block the throttle plate and choke plate (if used) Piston Rings Leaking compression low
wide open. on first stroke tends to build up on following
4. Make sure the battery is fully charged. stro ke s but does not reach norm a l.
5. Starting with the compression gage at zero, crank Improves considerably with addition of oil.
the engine through four compression strokes Valves Leaking Low on first stroke. Does
(four puffs ). not tend to build up on following strokes.
6. Make the compression check at each cylinder Does not improve much with addition of oil.
and record each reading. If two adjacent cylinders have lower than
7. If some cylinders have low compression, inject normal compression, and injecting oil into
about 15 ml. (one tablespoon or about 3 squirts c y lin d e rs does not in cre a se the
from a pump type oil can) of engine oil into the compression, the cause may be a head
combustion chamber through the spark plug gasket leak between the cylinders.
hole.
8. Minimum compression recorded in any one
cylinder should not be less than 70 per cent of
highest cylinder, and no cylinder should read less
ENGINE 6A -7
DIAGNOSIS OF HYDRAULIC LIFTERS

Momentarily Noisy This condition is normal. Oil drains None needed.

When Engine Is from the lifters which are holding the
Started valves open when the engine is not
running. It will take a few seconds for
the lifter to fill after the engine is
started.
Interm ittently Noisy 1. Dirt in hydraulic lifter. 1. Disassemble and clean.

On Idle Only, 2. Pitted or damaged check ball. 2. Replace the hydraulic lifter.
Disappearing When
Engine Speed Is
Increased
Nofoy At Slow Idle High leak down rate. Replace the hydraulic lifter.
Or W ith Hot Oil;
Quiet At Higher
Engine Speeds Or
W ith Cold Oil
Noisy At High 1. High oil level Oil level above the 1. Drain oil to proper level.
Vehicle Speeds, Full mark allows crankshaft counter
Quiet At Low Speeds weights to churn the oil into foam.
When foam is pumped into the lifters,
they will become noisy since a solid
column of oil is required for proper op
eration.
2. Low oil level Oil level below the 2. Add oil as needed.
Add mark allows the oil pump to
pump air at high speeds which results
in noisy lifters.
3. Oil pan bent against oil pump pickup 3. Repair.
screen.
4. Oil pump screen bent or loose. 4. Repair.
Noisy At Idle, 1. This noise is not connected with lifter 1. Repair as necessary.
Becoming Louder As malfunction. It becomes most notice
Engine Speed Is able in the vehicle at 10 to 15 mph L
Increased To 1500 (Low) range, or 30 to 35 mph D
RPM (Drive) range and is best described as
a hashy sound. At slow idle, it may
be entirely gone or appear as a light
ticking noise in one or more valves. It
is caused by one or more of the follow
ing:
Badly worn or scuffed valve tip and
rocker arm pad.
Excessive valve stem to guide clear
ance.
Excessive valve seat runout.
Off square valve spring.
Excessive valve face runout.
Valve spring damper clicking on rota
tor.
6A-8 ENGINE
DIAGNOSIS OF HYDRAULIC LIFTERS (CONT.)

Noisy At Idle, 2. Off square valve spring. Occasionally 2. If the valve spring is more than
Becoming Louder As this noise can be eliminated by rotat 1.6mm (1/ie-inch) off square, it should
Engine Speed Is ing the valve spring and valve. Crank be replaced.
Increased To 1500 engine until noisy valve is off its seat.
RPM (Continued) Rotate spring. This will also rotate
valve. Repeat until valve becomes
quiet. If correction is obtained, check
for an off square valve spring.
Noisy Regardless Of 1. Incorrect valve adjustment (excessive 1. Adjust as specified.

Engine Speed lash) (engines with adjustable valve
lash).
2. Excessive valve lash. Check for valve 2. Repair engine as needed.
lash by turning the engine so the pis
ton in that cylinder is on TDC of the
firing sroke. If valve lash is present, the
pushrod can be freely moved up and
down a certain amount with rocker arm
held against valve. Excessive lash can
be caused by:
a. Worn pushrod upper end ball. a. Replace pushrod and rocker arm.
b. Bent pushrod. b. Replace pushrod.
c. Improper lubrication of the pushrod. c. Replace pushrod and rocker arm.
Check lubrication system feed to the
pushrod.
d. Loose or damaged rocker arm. d. Replace rocker arm.
e. If pushrod and rocker arm are OK, e. Replace hydraulic lifter.
trouble in the hydraulic lifter is indica
ted.
DIAGNOSIS OF V
DIESEL ENGINE ^ >

a/ A wj ///{&&<
MOST LIKELY/POSSIBLE CAUSES ^ 4d.mmmw % W im
X = UKEUESTCAUSES
= POSSIBLE CAUSES
^m w w w p p lS r
M E C H A N IC A L / M A IN T E N A N C E 1 2 3 4 5 6 7 8 9 10 ii 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 38 37 38 39 40
GASKET BLOW-BY OR SEAL LEAKAGE X X
FAULTY DAMPER/FLYWHEEL BALANCE X
VALVE LEAKAGE X
BROKEN, SCORED OR WORN PISTONS/RINGS
INCORRECT M AIN OR ROD BEARING CLEARANCE
DAMAGED CRANKSHAFT OR MAIN/ROD BEARINGS X X
I
DAMAGED/WORN CAMSHAFT LOBES
FAULTY LIFTER OR GUIDE PLATE
FAULTY PUSHROD OR ROCKER ARM
WORN/MISALIGNED TIMING GEARS, CHAIN OR KEY(S)
LOW CYLINDER COMPRESSION (380 PSI MIN.) X
OIL CHANGE INTERVAL I X
EXTERNAL INJECTION PUMPTHROTTLE LINKAGE
TIMING RETARDED X
TIMING ADVANCED X X X
STARTER CRANKING SPEED/BATTERIES (180 RPM MIN.) X I
ENGINE MOUNTS/BOLTS OR FUEL LINE/OIL FILL TUBE CLAMPS
LONG IDLE PERIODS
CRACKED CYLINDER HEAD OR WALL
MISSING PRECHAMBER(S)
ENGINE OVERLOADED/EXCESSIVE SPEED X X
IMPROPER STARTING PROCEDURES
(1FRRIS/FI y m IN CYUNDEfllS)
E L E C TR IC A L/E M IS S IO N S 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
INOPERATIVE GLOW PLUGS X
FAULTY GLOW PLUG CONTROLLER/IP WIRE GROUNDS X X
FAULTY ALTERNATOR DIODE/STARTER MOTOR WIRE CONNECTIONS
INOPERATIVE GLOW PLUG CONTROLLER/RELAY
SHORTED OR OPEN GLOW PLUG INHIBITOR SWITCH X X X
NO VOLTAGE TO CONTROLLER (KEY ON)
EGRVALVE STUCK OPEN
EPR VALVE STUCK CLOSED
FAULTY EGR/EPR SOLENOIDS
MISADJUSTED OR FAULTY THROTTLE POSITION SWITCH
HOUSING PRESSURE COLD ADVANCE SOLENOID OR SWITCH X
FAULTY CRANKCASE DEPRESSION REGULATOR (CDR) VALVE
CRANKCASE DEPRESSION SYSTEM HOSE CONNECTIONS X X X
MISADJUSTED OR FAULTY VACUUM REGULATOR VALVE
TRANSMISSION CONVERTOR DOES NOT APPLY
ENGINE
FAULTY VACUUM PUMP (21" HG MIN.)
t
A IR S Y S T E M 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
RESTRICTED AIR INTAKE DUCTING OR MANIFOLD X
HIGH EXHAUST BACK PRESSURE
0-1 THIN AIR IN HOT WEATHER OR HIGH ALTITUDE
^ PLUGGED AIR FILTER X X X
6A-9
-vJ LOW AMBIENT TEMPERATURE

6A-10
ENGINE
FU EL SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
PLUGGED, WAXED OR FAULTY FUEL FILTER(S)/ASSEMBLY X X X X
FAULTY WATER IN FUELIWIF) OR VACUUM SENSOR(S)
QUALITY/GRADE OR INCORRECT FUEL (GASOLINE) X X X X X X
AIR LEAKS IN FUEL SUCTION LINES X X X X X X X X
RESTRICTED FUEL RETURN LINE X X X
FUELTANK CAP NOT VENTED
HIGH FUEL TEMPERATURE (ABOVE 90F)
FAULTY INJECTION PUMP OR SHAFT 180 OUT
FUEL INLET RESTRICTION HIGH AT SUPPLY PUMP
FUEL PRESSURE BELOW (2! PSI AT INJECTION PUMP
FAULTY FUEL SUPPLY PUMP 15Vi PSI MIN.)
NOZZLES, LINES OR HOSES X X
LOW IDLE RPM ADJUSTMENT
FAST IDLE RPM ADJUSTMENT/FAULTY SOLENOID
WATER/DEBRIS IN FUELTANK OR FILTER(S) X
EXTERNAL FUEL LEAKS
FAULTY ENGINE SHUTOFF SOLENOID (ESO) X
FAULTY INJECTION PUMP BALL CHECK REG. VALVE
WORN OR STUCK INJECTION PUMP ADVANCE PISTON X
FAULTY INJECTION PUMP WEIGHT RETAINER RING
STICKING INTERNAL GOVERNOR LINKAGE/METERING VALVE
INOPERATIVE FUEL LINE OR FILTER HEATER -
NO FUEL DELIVERY
INJECTION PUMP HOUSING PRESSUREJ8-12 PSIj
LU BR IC ATIO N SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
INTERNAL OIL LEAKS (BLOCK GALLERY/CUP PLUGS)
LOW OIL LEVEL
HIGH OIL LEVEL (OVER-FILLED)
FAULTY REGULATOR OR BY-PASS VALVE
CONTAMINATED LUBE OIL
HIGH LUBE OILTEMPERATURE
QUALITY/GRADE OF LUBE OIL X X
INACCURATE GAGE OR SENSOR
FAULTY OIL COOLER CORE
FAULTY OIL PUMP DRIVE GEAR/SHAFT X
OIL PICKUP TUBE RESTRICTED/CRACK
EXTERNAL OIL LEAKS (PLUGS, SEALS OR GASKETS)
FAULTY OIL PUMP
C O O L IN G S Y S T E M 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
QUALITY/GRADE OF COOLANT
LOW COOLANT LEVEL
FAULTY OR INCORRECT PRESSURE CAP X
INACCURATE TEMPERATURE GAGE/SENSOR
OBSTRUCTED RADIATOR AIR FLOW
INOPERATIVE WATER PUMP
FAULTY OPERATION OF FAN, VISCOUS CLUTCH/BELTS
FAULTY THERMOSTAT
FAULTY COOLANT RECOVERY SYSTEM
RESTRICTED COOLANT FLOW
AIR RECIRCULATION OR FAULTY FAN SHROUD
FAULTY OR INADEQUATE DEAERATION SYSTEM/VENTS
HIGH COOLANT TEMPERATURE

ENGINE 6A-11
COMPRESSION CHECK CRANKING SPEED CHECK

(6.2 DIESEL ENGINE) (6.2L DIESEL ENGINE)
Tools Required: Tool Required:
J-29664-2 or J-26996-1 Intake Manifold J-26999-10 Compression Gage
Cover Cranking speed is critical for a diesel to start, either
J-26999-10 Compression gage. hot or cold. Some tachometers are not accurate at
1. Remove the air cleaner. Install J-29664-2 or cranking speed. An alternate method of checking
J-26996-1 over the mouth of the intake manifold. cranking speed or determining the accuracy of a
2. Disconnect the wire from the fuel solenoid tachometer follows:
terminal of the injection pump. 1. Connect J-26999-10 to any cylinder.
3. Disconnect wires from glow plugs then remove all 2. Disconnect the injection pump fuel solenoid lead
glow plugs. on the top of the injection pump.
4. Screw J-26999-10 into the glow plug hole of the 3. Install the digital tachometer to be checked (if
cylinder that is being checked. desired).
5. Make sure the batteries are fully charged, and the 4. Depress the pressure release valve on the
engine is fully warmed up (engine oil hot). compression gage.
6. Crank the engine. Allow six puffs per cylinder. 5. With the aid of an assistant, crank the engine for
7. Make the compression check at each cylinder 2 or 3 seconds to allow the starter to reach full
and record the readings. speed, then without stopping, count the number
of puffs at the compression gage that occur in
NOTICE: Do not add oil to any cylinder during the next 10 seconds. Multiply the number of
a compression test as extensive engine puffs in the 10 second period by 12 and the
damage can result. resulting number will be the cranking speed in
revolutions per minute (RPM).
8. The lowest reading cylinder should not be less Example:
than 80 percent of the highest reading cylinder. 10 seconds = 1/6 of a minute
No cylinder should read less than 2625 kPa (380 1 puff = 2 RPM
psi). RPM = No. of puffs x 2 x 6 or
Normal: Compression builds up quickly and RPM = No. of puffs x 12
evenly to specified compression on each Minimum cranking speed on the 6.2L diesel engine
c y lin d e r. R e a d in g sh o u ld be in the is 100 RPM cold and 180 RPM hot. The actual cranking
2625-2760 kPa (380-400 psi) range. speed needed will vary depending on the condition of
Leaking: Compression low on first stroke the engine (compression) and nozzles.
tends to build up on following strokes but
does not reach normal.
SPECIAL TOOLS
J-29664-2 or J-26996-1 Intake Manifold Cover

J-26999-10 Compression Gage
6A3-1
SECTION 6A3
4.3 LITER V6
the manual as indicated at appropriate locations by the terminology NOTICE: See Notice on page 6A3-1 of this
section.
NOTICE: All engine fasteners are important attaching parts in that they could affect the performance of vital
to assure proper retention of this part.
CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 6A3- 2

Engine L u b ric a tio n ...............................................................................................................................................6A3- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 6A3- 5
Rocker Arm Cover Replacem ent....................................................................................................................... 6A3- 5
Rocker Arm and Pushrod R eplacem ent.......................................................................................................... 6A3- 6
Valve A d ju s tm e n t................................................................................................................................................. 6A3- 6
Valve Stem Seal and Valve Spring R e p la ce m e n t.........................................................................................6A3- 7
Intake Manifold R e p la ce m e n t........................................................................................................................... 6A3- 8
Hydraulic Lifter R e p lace m e n t........................................................................................................................... 6A3- 9
Rocker Arm Stud Replacem ent......................................................................................................................... 6A3-10
Exhaust Manifold Replacem ent......................................................................................................................... 6A3-11
Cylinder Head R e p la ce m e n t............................................................................................................................. 6A3-12
Torsional Damper And Front Crankshaft Seal R eplacem ent..................................................................... 6A3-12
Front Cover R e placem ent..................................................................................................................................6A3-13
Oil Pan R eplacem ent.......................................................................................................................................... 6A3-14
Oil Pump R e p la ce m e n t...................................................................................................................................... 6A3-15
Rear Crankshaft Oil Seal R e p la ce m e n t.......................................................................................................... 6A3-15
Rear Crankshaft Oil Seal Retainer Replacement...........................................................................................6A3-16
Measuring Camshaft Lobe L i f t ......................................................................................................................... 6A3-17
Camshaft R e p la ce m e n t...................................................................................................................................... 6A3-17
Connecting Rod And Piston Replacement......................................................................................................6A3-20
Main Bearing R eplacem ent................................................................................................................................6A3-22
Oil Filter Adapter And Oil Filter Bypass Valve Replacement (Models With Engine Oil C o o ler).........6A3-23
Crankshaft R eplacem ent....................................................................................................................................6A3-23
Flywheel Replacem ent........................................................................................................................................ 6A3-25
Engine M ountings.................................................................................................................................................6A3-25
Engine R e p la ce m e n t.......................................................................................................................................... 6A3-28
S pecifications............................................................................................................................................................6A3-30
Special T o o ls ............................................................................................................................................................6A3-32
6A3-2 4.3 LITER V6
DESCRIPTION
4.3L engines are 90-degree V6 type, overhead valve, ENGINE LUBRICATION

water cooled, with cast iron block and heads.
Lubrication schematics are shown in figures 1 and 2.
The crankshaft is supported by four precision insert
The gear type oil pump is driven from the distributor
main bearings, with crankshaft thrust taken at the num
shaft, which is gear driven from the camshaft. Oil is
ber four (rear) bearing.
drawn into the oil pump through a pickup screen and
The camshaft is supported by four plain type bear pipe.
ings and is chain driven. Motion from the camshaft is Pressurized oil is routed to the oil filter. In case of
transmitted to the valves by hydraulic lifters, pushrods, excessive oil pressure, a bypass valve is provided.
and ball type rocker arms. The valve guides are inte Filtered oil flows into the main gallery and then to the
gral in the cylinder head. camshaft and crankshaft bearings. The valve lifter oil
gallery supplies oil to the valve lifters. Oil flows from
The connecting rods are forged steel, with precision the hydraulic lifters through the hollow pushrods to the
insert type crankpin bearings. The piston pins are a rocker arms. Oil from the overhead drains back to the
press fit in the connecting rods. crankcase through oil drain holes.
The timing chain is drip fed from the front camshaft
The pistons are cast aluminum alloy. The piston pins bearing. The pistons and piston pins are lubricated by
are a floating fit in the piston. oil splash.
4.3 LITER V6 6A3-3
Figure 1Engine Lubrication Diagram

6A3-4 4.3 LITER V6
A. Regulator Valve (Shown In Open Position)

B. Suction
C. Oil Pressure Switch
D. Valve Lifter Gallery
E. Main Oil Gallery
F. Bypass Valve
Front View Rear View

Showing Path Of Oil To Tim ing Chain. Showing Main Gallery, Oil Filter And Crankshaft Oil Feed.
B-07860

4.3 LITER V6 6A3-5
ON-VEHICLE SERVICE
I* Inspect
Rocker arm cover sealing surfaces for distortion.

i l Install or Connect
1. Rocker arm cover and new gasket.

2. Rocker arm cover bolts and washers.
Tighten
Rocker arm cover bolts to 9.9 N-m (88 in.

lbs.).
3. Wires at choke.
4. AIR pipe retaining screws.
5. PCV valve.
6. Engine oil filler tube.
7. Diverter valve.
8. Air cleaner.
9. Engine cover (G models).
10. Battery negative cable.
LEFT SIDE ROCKER ARM COVER

3. Air cleaner.
ROCKER ARM COVER 4. Air conditioning compressor brace (if used).
REPLACEMENT 5. Accelerator and TVS cable bracket at the intake
manifold.
RIGHT SIDE ROCKER ARM COVER 6. Rocker arm cover bolts.
7. Rocker arm cover gasket.
Clean
All trackes of old gasket from the rocker arm
cover and cylinder head.
3. Air cleaner.
4. Diverter valve. Inspect
6. PCV valve at the rocker arm cover. Rocker arm cover sealing surface for distortion
7. AIR pipe retaining bolts at the left and right and damage. Replace if necessary.
cylinder heads.
8. Wires at the choke and rocker arm cover.
9. Rocker arm cover bolts. 1. Rocker arm cover and new gasket.
10. Rocker arm cover and gasket. 2. Rocker arm cover bolts and washers.
Tighten
All traces of old gasket from the rocker arm cover Rocker arm cover bolts to 9.9 N-m (88 in
and cylinder head. lbs.).
6A3-6 4.3 LITER V6
3. Accelerator and TVS cable bracket.

4. Air conditioning compressor brace (if used).
5. Air cleaner.
ROCKER ARM AND PUSHROD

REPLACEMENT
4-+ Remove or Disconnect
1. Rocker arm cover, as outlined previously.

2. Rocker arm nut.
If only the pushrod is to be replaced, back
the rocker arm nut off until the rocker arm
can be swung away from the pushrod. Then
pull the pushrod out.
3. Rocker arm with ball.
4. Pushrod. VALVE ADJUSTMENT
Im portant 1. Remove the rocker arm cover as outlined
previously.
Store used components in order so they can be 2. Crank the engine until the mark on the torsional
reassembled in the same location. damper lines up with the O mark on the timing
tab and the engine in the number one firing
I* Inspect position. This may be determined by placing
fingers on the number one valve as the mark on
Rocker arms and balls at their mating surfaces. the damper comes near the O mark on the
These surfaces should be smooth and free from timing tab. If the rocker arms are not moving, the
scoring or other damage. engine is in the number one firing position. If the
Rocker arm areas which contact the valve stems rocker arms move as the mark comes up to the
and the sockets which contact the pushrods. timing tab, the engine is in the number four firing
These areas should be smooth and free of position and should be turned over one more time
damage and wear. to reach the number one position.
Pushrods for bending. Roll the pushrod on a flat 3. With the engine in the number one firing position
surface to determine if it is bent. Replace if as determined above, the following valves may be
necessary. adjusted:
Ends of the pushrods for scoring or roughness.
Exhaust: 1, 5, 6.
Intake: 1, 2, 3.
*+ Install or Connect
(Even numbered cylinders are in the right bank;
1. Pushrod. Make sure the pushrod seats properly odd numbered cylinders are in the left bank,
in the hydraulic lifter. when viewed from the rear of the engine).
2. Rocker arm with ball. 4. Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until all
Im portant lash is removed. This can be determined by
rotating the pushrod while turning the adjusting
When new rocker arms and/or balls are nut (figure 4). When the play has been removed,
installed, coat their bearing surfaces with turn the adjusting nut in one full additional turn
Molykote or equivalent. (to center the lifter plunger).
3. Rocker arm nuts. 5. Crank the engine one revolution until the timing
tab O mark and vibration damper mark are
Adjust again in alignment. This is the number four firing
position. The following valves may be adjusted:
Valves as outlined later. Exhaust: 2, 3, 4.
4. Rocker arm cover, as outlined previously. Intake: 4, 5, 6.
4.3 LITER V6 6A3-7
20. Valve Keeper 26.

21. Cap 27.
22. Shield 28.
23. O-Ring Seal 29.
24. Seal
25. Damper
26
JJ, J *
M V \ \ \ 5
29
*
J a 23 21 B-07865
F igure 5 V alves A nd C om ponen ts
6. In s ta ll the rocker arm cover as o u tlin e d

previously.
VALVE STEM SEAL AND

VALVE SPRING
REPLACEMENT
Figure 7T e sting The Valve Seals
Rem ove o r D isco n n e ct (F igures 5 and 6)
Apply compressed air to hold the valves in
Tools Required: place.
J-23590 Air Adapter. Install a rocker arm nut (figure 6).
J-5892-A Spring Compressor. Use J-5892-A to compress the valve spring
1. Rocker arm cover, as outlined previously. (figure 6).
2. Rocker arms, as outlined previously. Remove the valve keepers.
3. Spark plugs. C a re fu lly release the spring tension.
4. Valve keepers (20). Remove J-5892-A.
Install J-23590 into the spark plug hole. 5. Cap (21) and/or rotator (28), shield (22) and
spring (26) with damper (25).
6. O-ring seal (23), and seal (24) (intake valve only).
-n - Install o r C onnect (F igures 5, 6, and 7)
Tools Required:
J-23590 Air Adapter.

J-5892-A Spring Compressor.
J-23738-A Vacuum Pump
1. New seal (24). Install the seal over the intake

valve stem and seat it against the head.
2. Spring (26) with damper (25), sheild (22) and cap
(21) and/or rotator (28).
3. New o-ring seal (23) and valve keepers (20).
With air pressure applied to the cylinder
with J-23590, compress the spring with
J-5892-A (figure 6).
6A3-8 4.3 LITER V6
Figure 8 Intake M anifold In sta lla tio n
Lubricate the o-ring seal with engine oil. INTAKE MANIFOLD

Install the seal on the valve stem. Make sure
the seal is not twisted. REPLACEMENT
Install the valve keepers. Use grease to hold
them in place.
3 Remove or Disconnect
Carefully release spring pressure. Make 1. Battery negative cable.

sure the valve keepers stay in place. 2. Engine cover (G models).
3. Air cleaner.
Remove J-5892-A and J-23590. Drain the cooling system.
Check each o-ring seal for leakage (figure 4. ESC connector.
7). 5. Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
Place the suction cup furnished with J-
23738-A over the shield. 6. TVS and accelerator cables.
Connect J-23738-A to the suction cup 7. Air conditioning compressor rear brace.
and apply a vacuum. Watch the vac 8. Engine oil filler tube at the generator bracket.
uum pump gage. No air should be able 9. Transmission dipstick tube (if used) at the
to leak past the seal. If the seal will not generator bracket.
hold a vacuum, it may have been dam 10. Air conditioning compressor belt idler (if used) at
aged or improperly installed. the generator bracket.
4. Spark plugs. 11. Generator bracket.
12. Fuel and vacuum lines and electrical wiring at the
5. Rocker arms, as outlined previously.
carburetor.
13. AIR hoses and brackets.
Adjust 14. Heater hose at the intake manifold.
15. Carburetor (if required).
Valves, as outlined previously.
16. Intake manifold bolts.
6. Rocker arm cover, as outlined previously. 17. Intake manifold.
4.3 LITER V6 6A3-9
INITIAL TIGHTENING SEQUENCE
FINAL TIGHTENING SEQUENCE

A. Front Of Engine B-07873
F igure 9- -Intake M an ifold B olt T ig h te n in g Figure 10 R em oving The H ydraulic L ifte r

S equence
11. Transmission dipstick tube (if used).
Clean
Old gasket and RTV from the block, heads, and 13. Air conditioning compressor rear brace.
intake manifold. Remove all RTV that is loose or 14. TVS and accelerator cables.
will cause interference at assembly.
15. Distributor. Refer to ENGINE ELECTRICAL (SEC.
Excessive carbon deposits from the exhaust and
6D).
EGR passages.
Excessive scale and deposits from the coolant 16. ESC connector.
passages. 17. Air cleaner.
18. Proper grade and quantity of engine coolant.
L * Inspect
Manifold for cracks and gasket surface damage. 20. Battery negative cable.
|-<-| In stall o r C onnect (F igures 8 and 9)
1. Gaskets to the cylinder head.

HYDRAULIC LIFTER
2. RTV to the front and rear sealing surfaces on the REPLACEMENT
block (figure 8). Apply a 5 mm (3/ie-inch) bead of
RTV (part number 1052366 or equivalent) to the Rem ove o r D isco n n e ct (Figures 10 and 11)
front and rear of the block as shown. Extend the
bead 13 mm (1/2 -inch) up each cylinder head to Tools Required:
seal and retain the gaskets. J-3049 Hydraulic Lifter Remover (Plier Type)
3. Intake manifold to the engine. or
J-9290-01 Hydraulic Lifter Remover (Slide
Hammer Type)
T ig h te n
1. Rocker arm cover, intake manifold, and pushrod,
Intake manifold bolts to 48 N m (36 ft. lbs.). as outlined previously.
Use the tightening sequence shown in 2. Hydraulic lifters.
figure 9.
5. Carburetor (if removed). Remove the hydraulic lifters one at a time
6. Heater hose. and place them in an organizer rack. The
7. AIR hoses and brackets. lifters must be installed in the same bore
8. Fuel and vacuum lines and electrical wiring at the from which they were removed.
carburetor. A stuck hydraulic lifter can be removed
9. Generator bracket. using J-3049 (figure 10) or J-9290-01 (figure
10. Air conditioning compressor belt idler (if used). 11).
6A3-10 4.3 LITER V6
A. N u t
B. F la t W a s h e r B-05245
Figure 11 R em oving The H yd ra ulic L ifte r Figure 12 R em oving The R ocker A rm Stud
(T ypical)
ROCKER ARM STUD
Inspect
REPLACEMENT
Hydraulic lifter body for scuffing or scoring. If the
lifter body wall is worn or damaged, the mating Rem ove o r D isconnect (Figure 12)
bore in the block should also be checked.
Tool Required:
Check the fit of each hydraulic lifter in its mating
J-5802-01 Rocker Arm Stud Remover.
bore in the block. If the clearance is excessive, try
a new lifter. 1. Rocker arm cover and rocker arm, as outlined
previously.
The hydraulic lifter foot must be smooth and
2. Rocker arm stud.
slightly convex. If worn, pitted, or damaged, the
Place J-5802-01 over the rocker arm stud.
mating camshaft lobe should also be checked.
Install a nut and flat washer.
Turn the nut to remove the stud (figure 12).
H ydraulic L ifte r R epair
Refer to the proper unit repair manual.
Install o r C onnect (Figures 13 and 14)
Install o r C onnect
Tools Required:
J-5715 Reamer (0.003-inch oversize) or
1. Hydraulic lifters to the block. Lubricate the lifter
foot and body with Engine Oil Supplement or
equivalent.
When any new hydraulic lifters or a new

c a m s h a ft is in s ta lle d , E ng in e O il
S upplem ent (or equivalent) should be
added to the crankcase oil.
Replace all hydraulic lifters when a new
camshaft is installed.
Intake manifold, as outlined previously.
Pushrod, as outlined previously.
A d ju s t

4. Rocker arm cover, as outlined previously. Stud Bore (Typical)
4.3 LITER V6 6A3-11
EXHAUST MANIFOLD
REPLACEMENT
Rem ove or D isconnect

Raise the vehicle.
3. Exhaust pipe at the manifold.
Lower the vehicle.
4. Oxygen sensor wire (left side manifold). Do not
remove the oxygen sensor from the manifold
unless the sensor is to be replaced.
5. AIR hose at the check valve.
6. AIR pipe at the d ive rte r valve (rig h t side
manifold).
7. AIR pipe bracket at the head (left side manifold).
8. Exhaust m anifold bolts, washers, and tab
washers.
9. Exhaust manifold.
y | Clean
Mating surfaces on the manifold and head.

Threads on the exhaust manifold bolts.
J-6036 Reamer (0.013-inch oversize).
Install o r C onnect
J-6880 Rocker Arm Stud Installer.
1. Exhaust m anifold, bolts, washers, and tab
washers.
NOTICE: Do not attempt to install an oversize
rocker arm stud without reaming the stud hole
as this could damage the cylinder head. T ighten
Ream the hole to the proper size for the Bolts on center exhaust tube to 36 N m (26
replacement oversize rocker arm stud. Use ft. lbs.).
J-5715 for 0.003-inch oversize studs; J-6036 for Bolts on front and rear exhaust tubes to 28
0.013-inch oversize stud (figure 13). N m (20 ft. lbs.).
Bend the tab washers over the heads of all
Coat the lower end (press-fit area) of the rocker
bolts.
arm stud with hypoid axle lubricant.
2. AIR bracket at the head (left side manifold).
1. Rocker arm stud. Use J-6880 (figure 14). Stud is 3. AIR pipe at the d ive rte r valve (rig h t side
installed to proper depth when the tool bottoms manifold).
on the cylinder head.
2. Rocker arm, as outlined previously. 5. Oxygen sensor wire (left side manifold).
Raise the vehicle.
A d ju s t 6. Exhaust pipe to the manifold.
Lower the vehicle.
3. Rocker arm cover, as outlined previously. 8. Battery negative cable.
6A3-12 4.3 LITER V6
CYLINDER HEAD
REPLACEMENT rz

3. Intake manifold, as outlined previously.
4. Exhaust manifold, as described previously. 4 l FRONT
5. AIR pipe at the rear of the head (right cylinder
head). B-07874
6. Generator mounting bolt at the cylinder head
(right cylinder head). Figure 15Cylinder Head Bolt Tightening
7. Power steering pump and brackets from the Sequence
cylinder head, and lay aside (left cylinder head).
8. Air conditioning compressor, and lay aside (left $ Tighten
cylinder head).
9. Rocker arm cover, as outlined previously. Cylinder head bolts, a little at a time, using
10. Spark plugs. the sequence shown in figure 15. Proper
11. Pushrods, as outlined previously. torque is 90 N m (65 ft. lbs.).
12. Cylinder head bolts. 4. Pushrods, as outlined previously.
13. Cylinder head.
f t Adjust
14. Gasket.
Clean
6. Spark plugs.
Carbon deposits from combustion chambers.
All traces of old head gasket from cylinder head
8. Air conditioning compressor (if removed).
and block.
9. Power steering pump and brackets (if removed).
Cylinder head bolt threads and threads in the
10. Generator mounting bolt (if removed).
block.
11. AIR pipe (if removed).
12. Exhaust manifold, as outlined previously.
I* Inspect
13. Intake manifold, as outlined previousy.
Sealing surfaces of the block and cylinder head 14. Engine cover (G models).
for nicks, heavy scratches, or other damage. 15. Battery negative cable.
Cylinder Head Repair

Refer to the proper Unit Repair Manual.
TORSIONAL DAMPER AND
FRONT CRANKSHAFT
-- Install or Connect (Figure 15) SEAL REPLACEMENT
1. Head gasket. + + Remove or Disconnect (Figure 16)
If a steel gasket is used, coat both sides of
the gasket with sealer. Spread the sealer Tool Required:
thin and even. J-23523-E Torsional Damper Puller and
Do not use se a le r on c o m p o s itio n Installer.
steel-asbestos gaskets. 1. Fan belts, fan, and pulley.
Place the gasket over the block dowel pins 2. Fan shroud assembly.
with the bead up. 3. Accessory drive pulley.
2. Cylinder head. Carefully guide the cylinder head 4. Torsional damper bolt.
into place over the dowl pins and gasket. 5. Torsional damper. Use J-23523-E (figure 16).
3. Cylinder head bolts. Coat threads of the cylinder 6. Front crankshaft seal. Pry out with a large
head bolts with sealing compound (GM part screwdriver. Take care not to distort the timing
number 1052080 or equivalent) and install cover.
finger-tight. 7. Crankshaft key, if necessary.
4.3 LITER V6 6A3-13
Figure 16Removing The Torsional Damper Figure 17Installing The Front Crankshaft
Oil Seal
L* Inspect
S i Tighten
Oil seal contact area on the torsional damper
shaft for grooving and roughness. Replace if Bolt to 95 N m (70 ft. lbs.).
necessary. 7. Accessory drive pulley.
8. Fan shroud assembly.
Install or Connect (Figures 17 and 18) 9. Fan pulley, fan, and fan belts.
Tools Required:
J-23042-A Seal Installer. FRONT COVER REPLACEMENT
J-23523-E Torsional Damper Puller and
Installer. Remove or Disconnect
1. Crankshaft key, if removed. 1. Torsional damper, as outlined previously.

2. Front crankshaft seal. Use J-23042-A (figure 17). 2. Water pump.
The open end of the seal faces inside the engine.
3. Front cover bolts.
Coat the seal lips with engine oil.
4. Front cover.
5. Front cover to block gasket.
NOTICE: The inertia weight section of the
torsional damper is assembled to the hub with
a rubber type material. The correct installation
procedures (with the proper tool) must be
followed or movement of the inertia weight
section of the hub will destroy the tuning of
the torsional damper.
3. Stud (item A, figure 18) to the crankshaft. Thread

the stud fully into the tapped hole in the
crankshaft.
4. Torsional damper over the end of the stud. Align
the keyway in the torsional damper shaft with the
crankshaft key.
5. Bearing, washer and nut (figure 18).
A. Installation Stud
Turn the nut to pull the vibration damper into B. Nut
place. C. Washer and Bearing B-07880
Remove the tool.
6. Torsional damper bolt and washer. Figure 18Installing The Torsional Damper
6A3-14 4.3 LITER V6
Figure 19Installing The Front Crankshaft

Oil Seal
6. Front crankshaft oil seal from the front cover. Pry

out with a screwdriver. Take care not to distort the
front cover.
j j | Clean
Old gasket from the front cover, and block.
L * Inspect
Exposed portion of the one-piece oil pan gasket

that contacts the front cover. Inspect for cracks, 70. Gasket
tears, heat checking, and deterioration. If the 71. Reinforcement
gasket is in good condition, it can be re-used. If it B-07884
is unsuitable for reuse, the oil pan gasket must be
replaced.
Figure 20Oil Pan Installation
Front cover for distortion and damage. Replace if
necessary.
Tighten
Install or Connect (Figure 19) Front cover to block bolts to 10.4 N m (92 in.
lbs.).
Tool Required: 4. Water pump.
J-23042-A Seal Installer. 5. Torsional damper, as outlined previously.
1. Front crankshaft oil seal. Use J-23042-A (figure
19). The open end of the seal faces inside the
engine. Coat the seal lips with engine oil. OIL PAN REPLACEMENT
2. Front cover gasket to the front cover. Use gasket
cement to hold them in place. A one piece type oil pan gasket is used.
3. Front cover to the engine. Press the cover down
against the oil pan until the block dowel pins align -- Remove or Disconnect (Figure 20)
with the holes in the cover. Position the cover
against the block so that the dowels enter the 1. Battery negative cable.
cover holes without binding. Do not force the Raise the vehicle.
cover over the holes. Do not distort the cover Drain the engine oil.
flange or dowel pin holes. Hold the front cover in 2. Exhaust crossover pipe.
this position and install the front cover to block 3. Torque converter cover (models with automatic
bolts. transmission).
4.3 LITER V6 6A3-15
4. Strut rods at flywheel cover. OIL PUMP REPLACEMENT

5. Strut rod brackets at the front engine mountings.
6. Starter.
7. Strut rods at engine mounts (K models with 1. Oil pan, as outlined previously.
automatic transmission). 2. Oil pump to main bearing cap bolt.
3. Oil pump.
8. Oil pan bolts, nuts, and reinforcements.
9. Oil pan and gasket. Inspect
Oil pump pickup tube for looseness. If the tube is

j j j ] Clean loose in the oil pump body, replace it, as outlined
in the proper unit repair manual. A loose pickup
Gasket surfaces on the engine and oil pan. tube can result in an air leak and loss of oil
pressure.
I?* Inspect
Oil Pump Repair
Oil pan gasket for damage. Replace if necessary.
Install or Connect

1. Oil pump to the engine. Align the slot in the oil
1. A small amount of RTV sealant (GM part number pump shaft with the tang on the distributor shaft.
1052751 or equivalent) to the front and rear The oil pump should slide easily into place. No
corners of the oil pan. gasket is used.
2. Oil pump to main bearing cap bolt.
Im portant
Tighten
Only a small amount of sealant is required.
Oil pump to main bearing cap bolt to 90 N m
Excessive amounts of sealant may prevent
(65 ft. lbs.).
proper sealing of the oil pan.
3. Oil pan, as outlined previously.
2. Oil pan gasket to the oil pan.
3. Oil pan to the engine. REAR CRANKSHAFT

4. Oil pan bolts, nuts, and reinforcements. OIL SEAL REPLACEMENT
|+"*| Remove or Disconnect (Figure 21)
Tighten
1. Transmission.
Oil pan bolts to 11.3 N m (100 in. lbs.).
2. Clutch and flywheel or flexplate, as equipped.
Oil pan nuts to 22.6 N m (200 in. lbs.).
NOTICE: Care should be taken when removing
5. Strut rods at the engine mounts (K models with
the rear crankshaft oil seal so as not to nick
automatic transmission).
the crankshaft sealing surface.
6. Starter.
3. Rear crankshaft oil seal. Insert a screwdriver into
7. Strut rod brackets at the front engine mountings. the notches provided in the seal retainer and pry
8. Strut rods at the flywheel cover. the seal out (figure 21).
9. Converter housing under pan (models with +- Install or Connect (Figure 22)
automatic transmission).
10. Exhaust crossover pipe. Tool Required:

J-35621 Seal Installer.
Lower the vehicle. 1. Rear crankshaft oil seal (figure 22).
Lubricate the inner and outer diameter of
11. Proper quantity and grade of engine oil.
the seal with engine oil.
12. Battery negative cable. Install the seal on J-35621.
6A3-16 4.3 LITER V6
A. Rear Of Block
81. Seal Retainer
82. Crankshaft
83. Gasket
84. Screw b -07888
Figure 23Rear Crankshaft Oil Seal

Retainer Installation
Position J-35621 against the crankshaft.

Thread the attaching screws into the tapped REAR CRANKSHAFT
holes in the crankshaft. OIL SEAL RETAINER
REPLACEMENT
T ig h te n the scre w s s e c u re ly w ith a
screwdriver. This will ensure that the seal is Remove or Disconnect (Figures 21 and 23)
installed squarely over the crankshaft.
1. Transmission.
Turn the handle until it bottoms. 2. Clutch and flywheel or flexplate, as equipped.
Remove J-35621. 4. Screws (84).
5. Seal retainer (81).
2. Clutch and flywheel or flexplate, as equipped. 6. Gasket (83).
3. Transmission. the notches provided in the seal retainer and pry
the seal out (figure 21).
p y i Clean
Gasket surfaces on block and seal retainer.
|-*-| Install or Connect (Figures 21 and 23)
Whenever the seal retainer is removed, a new

retainer gasket and rear crankshaft oil seal must
be installed.
1. Gasket (83) to the block. It is not necessary to use
sealant to hold the gasket in place.
3. Screws (84).
Screws (84) to 15.3 N-m (135 in. lbs.).

Figure 22Installing The Rear Crankshaft 4. Oil pan, as outlined previously.
Oil Seal 5. Rear cra n ksha ft oil seal (80) as o utline d
previously.
4.3 LITER V6 6A3-17
7. Transmission. CAMSHAFT REPLACEMENT

C AND K MODELS
MEASURING CAMSHAFT
LOBE LIFT -- Remove or Disconnect (Figures 25, 26, and
27)
Tool Required:
Tool Required:
J-8520 Camshaft Lobe Lift Indicator.
J-5825 Crankshaft Sprocket Puller.
1. Remove the rocker arm as outlined previously. 1. Battery negative cable.
2. Refer to figure 24. Position the dial indicator (part 2. Air cleaner.
of J-8520) so the plunger rests on the pushrod 3. Fan, shroud, and radiator. Refer to ENGINE
end, as shown. Make sure the pushrod is in the COOLING (SEC. 6B).
lifter socket. 4. Generator.
3. Rotate the crankshaft slowly in the direction of 5. Rocker arm covers, as outlined previously.
rotation until the lifter is on the heel of the cam 6. Fuel line.
lobe. At this point, the pushrod will be in its lowest 7. Water pump. Refer to ENGINE COOLING (SEC.
position. 6B).
8. Torsional damper, as outlined previously.
4. Set dial indicator on zero, then rotate the
crankshaft slowly, or attach an auxiliary starter 9. Front cover, as outlined previously.
switch and bump the engine over, until the 10. Distributor. Refer to ENGINE ELECTRICAL (SEC.
pushrod is in fully raised position. 6D).
12. Pushrods and hydraulic lifters, as outlined
Im portant
previously.
13. Fuel pump and pushrod.
Whenever the engine is cranked remotely at
the starter, with a special jumper cable or Align the timing marks (figure 25).
other means, the distributor primary lead 14. Camshaft sprocket bolts.
should be disconnected from the distributor 15. Cam shaft sprocket and tim ing chain. The
(coil). sprocket is a lig h t in terfe re n ce fit on the
camshaft. Tap the sprocket on its lower edge to
5. Compare the total lift recorded from the dial
loosen it.
indicator with specifications.
16. Crankshaft sprocket (if required). Use J-5825
6. If camshaft readings for all lobes are within (figure 26).
specifications, remove dial indicator assembly. 17. Engine mount through-bolts.
7. Install the rocker arm and adjust the valves as Raise the engine.
previously outlined. 18. Camshaft.
6A3-18 4.3 LITER V6
B-07892
Figure 27Replacing The Camshaft
Coat the camshaft lobes and journals with a high

quality engine oil supplement (GM Engine Oil
Supplement or equivalent).
1. Two or three 5/ie-18 bolts 100-125 mm (4-5 inches)
B-07891 long into the camshaft threaded holes. Use these
bolts to handle the camshaft.
2. Camshaft to the engine (figure 27). Handle the
Figure 26Replacing The Crankshaft Sprocket
camshaft carefully to prevent damage to the
camshaft bearings.
Install two or three 5/ie-18 bolts 100-125 mm
(4-5 inches) long into the camshaft threaded Lower the engine.
holes. Use these bolts to handle the 3. Engine mount through-bolts.
camshaft (figure 27).
Pull the camshaft from the block. Use care Tighten
to p re ve n t dam age to the c a m s h a ft
bearings. Through-bolts or nuts to specifications.
Refer to figures 35 and 36.
Cleaning, Inspection And Repair
4. Crankshaft sprocket (if removed). Use J-5590
Clean, inspect and repair or replace the camshaft
(figure 26). Make sure the timing mark faces
and related components, as outlined in the proper unit
outside.
repair manual.
5. Camshaft sprocket and timing chain.
The unit repair manual also describes camshaft
bearing replacement.
Im portant
|-+| Install or Connect (Figures 25 through 27, 35,
and 36) Line up the timing marks on the camshaft
sprocket and crankshaft sprocket (figure
Tool Required: 25).
J-5590 Crankshaft Sprocket Installer. 6. Camshaft sprocket bolts.
4.3 LITER V6 6A3-19
Tighten 17. Cam shaft sprocket and tim ing chain. The
sprocket is a lighter interference fit on the
Bolts to 24 N m (18 ft. lbs.). camshaft. Tap the sprocket on its lower edge to
7. Fuel pump and pushrod. loosen it.
8. Hydraulic lifters and pushrods, as outlined 18. Crankshaft sprocket (if necessary). Use J-5825
previously. (figure 26).
19. Camshaft.
Important Install two or three 5/ie-18 bolts 100-125 mm
(4-5 inches) long into the camshaft tapped
Replace all hydraulic lifters and add GM holes. Use these bolts to handle the
Engine Oil Supplement (or equivalent) to camshaft (figure 27).
the engine oil whenever a new camshaft is Pull the camshaft from the block. Use care
installed. to p re ve n t dam age to the c a m s h a ft
bearings.
f t Adjust
Cleaning, Inspection and Repair
Valves, as outlined previously. Clean, inspect and repair or replace the camshaft
9. Intake manifold, as outlined previously. and related components, as outlined in the proper unit
10. Distributor. Refer to ENGINE ELECTRICAL (SEC. repair manual.
6D). The unit repair manual also describes camshaft
11. Front cover, as outlined previously. bearing replacement.
13. Water pump. Refer to ENGINE COOLING (SEC. Install or Connect (Figures 25, 26 and 27)
6B).
14. Fuel line. Tool Required:
15. Rocker arm covers, as outlined previously. J-5590 Crankshaft Sprocket Installer.
16. Generator. Coat the camshaft lobes and journals with a high
17. Fan, shroud, and radiator. Refer to ENGINE quality engine oil supplement (GM Engine Oil
COOLING (SEC. 6B). Supplement or equivalent).
18. Air cleaner. 1. Two or three 5/ie-18 bolts 100-125 mm (4-5 inches)
19. Battery negative cable. long into the camshaft threaded holes. Use these
bolts to handle the camshaft.
G MODELS 2. Camshaft to the engine (figure 27). Handle the
+ + Remove or Disconnect (Figures 25, 26, and camshaft bearings.
27) 3. Crankshaft sprocket. Use J-5590 (figure 26).
Make sure the timing mark faces outside.
Tool Required: 4. Camshaft sprocket and timing chain.
J-5825 Crankshaft Sprocket Puller.
1. Battery negative cable. Im portant
3. Rocker arm covers, as outlined previously. Line up the timing marks on the camshaft
4. Hydraulic lifters and pushrods, as outlined sprocket and crankshaft sprocket (figure
previously. 25).
5. Outside air duct. 5. Camshaft sprocket bolts.
6. Power steering reservoir.
7. Upper fan shroud bolts. Tighten
8. Radiator.
9. Hood release cable at the latch. Bolts to 24 N m (18 ft. lbs.).
10. Upper fan shroud. 6. Fuel pump and pushrod.
11. AIR pum p, g e n e ra to r, a ir c o n d itio n in g 7. Front cover, as outlined previously.
compressor, and power steering pump belts. 8. Water pump.
12. AIR pump and bracket. 9. AIR pump and bracket.
13. Water pump. 10. AIR pum p, g e n e ra to r, a ir c o n d itio n in g
14. Torsional damper, as outlined previously. compressor, and power steering pump belts.
15. Front cover, as outlined previously. 11. Torsional damper, as outlined previously.
16. Fuel pump and pushrod. 12. Front cover, as outlined previously.
Align the timing marks (figure 25). 13. Upper fan shroud.
6A3-20 4.3 LITER V6
Turn the crankshaft until the piston is at

BDC.
Place a cloth on top of the piston.
Perform the cutting operation with a ridge
reamer.
TDC.
Remove the cloth and cuttings.
5. Connecting rod cap. Check the connecting rod
and cap for identification marks. Mark the parts if
required. The connecting rod and cap must be
kept together as mating parts.
6. Connecting rod and piston.
Attach J-5239 to the connecting rod bolts
(figure 28).
Use the long guide rod of J-5239 to push the
connecting rod and piston out of the bore.
7. Connecting rod bearing.
C leaning, In sp e ctio n , And Repair

Clean, inspect and repair or replace the components
as necessary. Measure connecting rod bearing
clearance, piston clearance, ring clearances, etc. Refer
A. Guide Rod to the proper unit repair manual.
B. Thread Protector The unit repair manual contains information on:
B-05269
Connecting rod and piston.
Piston rings.
Figure 28Replacing The Piston And Connecting rod and crankpin.
Connecting Rod (Typical)
Cylinder bores.
- Install or Connect (Figures 28 through 31)
15. Radiator.
16. Upper fan shroud bolts.
Tools Required:
17. Power steering reservoir.
J-5239 Connecting Rod Guide Set.
18. Outside air ducts.
J-8037 Ring Compressor.
19. Hydraulic lifters and pushrods, as outlined
previously. Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
f t Adjust Make sure the piston is installed in the matching
cylinder.
Valves, as outlined previously. 1. Connecting rod bearings.
20. Rocker arm covers, as outlined previously. Be certain that the bearing inserts are of the
21. Intake manifold, as outlined previously. proper size.
22. Battery negative cable. Install the bearing inserts in the connecting
rod and connecting rod cap.
Lubricate the bearings with engine oil.
CONNECTING ROD AND 2. Piston and connecting rod to the proper bore.
PISTON REPLACEMENT With the connecting rod cap removed,
install J-5239 onto the connecting rod studs.
4-- Remove or Disconnect (Figure 28) Locate the piston ring end gaps as shown in
figure 29. Lubricate the piston and rings with
Tool Required: engine oil.
J-5239 Guide Set. W ith o u t d is tu rb in g the ring end gap
1. Cylinder head, as outlined previously. location, install J-8037 over the piston
2. Oil pan, as outlined previously. (figure 30).
3. Oil pump, as outlined previously (if necessary). The piston must be installed so that the
4. Ridge or deposits from the upper end of the notch in the piston faces the front of the
cylinder bores. engine (figure 29).
4.3 LITER V6 6A3-21
o
ENGINE LEFT ENGINE FRONT ENGINE RIGHT
A. Oil Ring Rail Gaps

B. 2nd Compression Ring Gap
C. Notch In Piston
D. Oil Ring Spacer Gap
(Tang In Hole Or Slot W ith Arc)
E. Top Compression Ring Gap B-07895
Figure 29Piston Ring End Gap Locations Figure 31Measuring Connecting Rod Side
Clearance
Place the piston in its matching bore. The

against the block until all rings have entered
connecting rod bearing tang slots must be
the cylinder bore.
on the side opposite the camshaft. Using
Remove J-5239 from the connecting rod
light blows with a hammer handle, tap the bolts.
piston down into its bore (figure 30). At the
same time, from beneath the vehicle guide Im portant
the connecting rod to the crankpin with
J-5239 (figure 28). Hold the ring compressor Each connecting rod and bearing cap
should be marked, beginning at the front of
the engine. Cylinders 1, 3 and 5 are at the
left bank and, 2, 4 and 6 are the right bank.
The numbers on the connecting rod and
bearing cap must be on the same side when
installed in the cylinder bore. If a connecting
rod is ever transposed from block or
cylinder to another, new connecting rod
b e a rin g s sh o u ld be fitte d and the
connecting rod should be numbered to
correspond with the new cylinder number.
Measure
Connecting rod bearing clearance. Refer to

the proper unit repair manual.
3. Connecting rod cap and bearing.
4. Connecting rod cap nuts.
Tighten
Connecting rod cap nuts to 60 N m (45 ft.

lbs.).
Measure
Connecting rod side clearance. Use a feeler

gage between the connecting rod and
crankshaft (figure 31). The correct clearance
is 0.006-0.014-inch.
6A3-22 4.3 LITER V6
5. Oil pump (if removed), as outlined previously.

6. Oil pan and cylinder head, as outlined previously.
MAIN BEARING REPLACEMENT

Tool Required:
J-8080 Main Bearing Remover/Installer.
1. Spark plugs.
3. Oil pump, as outlined previously.
4. Main bearing caps.
Check the main bearing caps for location
markings. Mark the caps if necessary. The
caps must be returned to their original
locations during assembly. Figure 32Removing The Main Bearing Insert
5. Lower main bearing inserts from the main
bearing caps. Measure
6. Upper main bearing inserts.
Main bearing clearance. Refer to the proper
Insert J-8080 into the crankshaft oil hole
unit repair manual. If the engine is in the
(figure 32).
vehicle, the crankshaft must be supported
Rotate the crankshaft to turn the bearing upward to remove any clearance from the
insert out of the block. upper bearing. The total clearance can then
be measured between the lower bearing
Cleaning, Inspection, And Repair and journal.
C le a n, in s p e c t, and re p a ir or re p la ce the
3. Main bearing caps (except rear cap) and bolts to
components as required. Refer to the proper unit repair
the block.
manual. The unit repair manual contains information
on:
Tighten
Crankshaft.
Main and connecting rod bearings.
Main bearing cap bolts to 100 N m (75 ft.
Main bearing cap replacem ent (shim m ing lbs.).
procedure).
4. Rear main bearing cap.
0 Install or Connect (Figures 32 and 33) Apply engine oil to the bearing insert.
Tool Required:
J-8080 Main Bearing Remover/Installer.
Insert J-8080 into a crankshaft main bearing
oil hole (figure 32).
Apply engine oil to inserts of the proper
size.
Insert the plain end (without the bearing
tang) of the insert between the crankshaft
and the notched side of the block.
Rotate the crankshaft to roll the insert into
the block. A. Forward
Remove the tool. B. Feeler Gage
2. Lower main bearing inserts to the main bearing 100. Rear Main Bearing Cap
caps. 101. Crankshaft B-07878
Make sure the inserts are of the proper size.
Apply engine oil to the inserts. Figure 33Measuring Crankshaft End Play
4.3 LITER V6 6A3-23
Install the rear main bearing cap and bolts.

Tighten the bolts temporarily to 14 N m (10
ft. lbs.).
Measure
Crankshaft end play, as follows:

Tap the end of the crankshaft first
rearward then forward with a lead
hammer. This will line up the rear main
b e a rin g and c ra n k s h a ft th ru s t
surfaces.
Tighten the rear main bearing cap
bolts to 100 N m (75 ft. lbs.).
With the crankshaft forced forward,
measure at the front end of the rear
main bearing with a feeler gage (figure
33). The p ro p e r c le a ra n c e is
0.002-0.006-inch.
If correct end play cannot be obtained,
be certain that the correct size rear
main bearing has been installed. 90. Seal
Production engines may have rear 91. Gasket
main bearings that are 0.008-inch 92. Oil Filter Adapter
wider across the thrust faces than 93. Bolt
standard. Refer to the proper unit B-07904
repair manual for more information.
Figure 34Oil Filter Adapter Installation
10. Spark plugs.
Tighten
OIL FILTER ADAPTER AND Bolts (93) to 20 N m (15 ft. lbs.).

3. Oil cooler lines.
OIL FILTER BYPASS VALVE 4. Oil filter.
REPLACEMENT (MODELS WITH Add engine oil as needed.
ENGINE OIL COOLER)
E3 Remove or Disconnect (Figure 34)
CRANKSHAFT REPLACEMENT
1. Oil filter. + + Remove or Disconnect (Figure 28)
Tool Required:
L* Inspect
J-5239 Connecting Rod Guide Set.
Bypass valve spring and fiber valve for 1. Engine, as outlined later.
proper operation, cracks, or other damage. 2. Flywheel (if used) as outlined later.
If replacement is required, the bypass valve Mount the engine in a suitable engine stand.
and oil filter adapter must be replaced as an 3. Spark plugs.
assembly, as outlined following. 4. Oil dipstick tube.
2. Oil cooler lines. 5. Oil pan and oil pump, as outlined previously.
3. Bolts (93). 6. Torsional damper, as outlined previously.
4. Oil filter adapter (92). 7. Front cover, as outlined previously.
5. Gasket (91) and seal (90). 8. Camshaft sprocket and timing chain.
9. Rear crankshaft oil seal retainer, as outlined
Install or Connect (Figure 33) previously.
B 10. Connecting rod caps. Check the connecting rod
1. New gasket (91), new seal (90) and oil filter and cap for identification marks. Mark the parts if
adapter (92) to the block. necessary. The connecting rod and cap are
2. Bolts (93). mating parts.
6A3-24 4.3 LITER V6
11. Connecting rods from the crankshaft. With the crankshaft forced forward,
Attach J-5239 to the connecting rod bolts measure at the front end of the rear
(figure 28). main bearing with a feeler gage (figure
Use the long guide rod to push the pistons 32). The p ro p e r c le ra n c e is
up in the bores. 0.002-0.006-inch.
12. Main bearing caps. Check the main bearing caps If correct end play cannot be obtained,
fo r lo c a tio n m a rkin g s. M ark the p arts if be certain that the correct size rear
necessary. The main bearing caps must be main bearing has been installed.
returned to their original locations at assembly. Production engines may have rear
13. Crankshaft. main bearings that are 0.008-inch
14. Main bearing inserts. wider across the thrust faces than
standard. Refer to the proper unit
Cleaning, Inspection, And Repair repair manual for more information.
Clean, inspect, and repair or replace the parts as
outlined in the proper unit repair manual. Refer to the I* Inspect
unit repair manual for information on:
Crankshaft. Crankshaft for binding. Try turning the
Main and connecting rod bearings. crankshaft to check for binding. If the
Procedures for measuring bearing clearances. crankshaft does not turn freely, loosen the
main bearing cap bolts, one pair at a time,
Install or Connect (Figures 25, 28, and 31) until the tight bearing is located. Burrs on
the bearing cap, foreign matter between the
Tool Required: insert and the block or the bearing cap, or a
J-5239 Guide Set. faulty insert could cause a lack of clearance
1. Upper main bearing inserts to the block. Apply at the bearing.
engine oil to the main bearings. 6. Connecting rods to the crankshaft. Use J-5239 to
2. Crankshaft. pull the connecting rods down (figure 28). Make
3. Lower main bearing inserts to the main bearing sure the connecting rod bearing insert stays in
caps. Apply engine oil to the bearing inserts. place.
% Measure
* Measure
Main bearing clearance. Refer to the proper Connecting rod bearing clearance. Refer to
unit repair manual. the proper unit repair manual.
4. Main bearing caps (except rear cap) and bolts to 7. Connecting rod caps with bearing inserts to the
the block. connecting rods. Apply engine oil to the inserts.
a Tighten
Tighten
lbs.). Connecting rod cap nuts to 60 N m (45 ft.
5. Rear main bearing cap and bolts to the block. lbs.).
Measure
$ Tighten
Rear main bearing cap bolts temporarily to Connecting rod side clearance. Use a feeler
14 N m (10 ft. lbs.). gage between the connecting rod and
crankshft (figure 31) The correct clearance
is 0.006-0.014-inch.
Measure
9. Rear crankshaft oil seal retainer wiht new
Crankshaft end play, as follows: crankshaft rear oil seal, as outlined previously.
Tap the end of the crankshaft first 10. Camshaft sprocket and timing chain.
hammer. This will line up the rear main Im portant
surfaces. Align the timing marks (figure 25).
Tighten the rear main bearing cap 11. Timing cover, as outlined previously.
bolts to 100 N m (75 ft. lbs.). 12. Torsional damper, as outlined previously.
4.3 LITER V6 6A3-25
13. Oil pan and oil pump, as outlined previously. ENGINE MOUNTINGS
14. Oil dipstick tube.
15. Spark plugs. NOTICE: Broken or deteriorated mountings
16. Flywheel (if used), as outlined later. can cause m isa lig n ed and eventual
destruction of certain drive train components.
17. Engine, as outlined later. When a single mounting breakage occurs, the
rem aining m ountings are s u b jected to
abnormally high stresses.
FLYWHEEL REPLACEMENT
Remove or Disconnect INSPECTING ENGINE MOUNTINGS
1. Transmission, flywheel housing, and clutch. Front Engine Mountings
2. Flywheel bolts. NOTICE: When raising or supporting the

3. Flywheel. engine for any reason, do not use a jack under
the oil pan, any sheet metal or crankshaft
pulley. Due to the small clearance between
ay Clean the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent
Mating surfaces of crankshaft and flywheel. against the pump screen, resulting in a
Remove any burrs. damaged oil pickup unit.
1. Raise the engine to remove weight from the

L * Inspect
mountings and to place a slight tension on the
Flywheel for burning, scoring, warping, and wear. rubber cushion. Observe both mountings while
Replace the flywheel if necessary. Do not raising the engine.
machine the flywheel. 2. Replace the mounting if the following conditions
Flywheel ring gear for worn or broken teeth. exist:
Hard rubber surface covered with heat
Flywheel Ring Gear Replacement check cracks.
1. Use a torch to heat the gear around the entire Rubber cushion separated from the metal
circum ference, then drive the gear off the palte of the mounting.
flywheel, using care not to damage the flywheel.
Rubber cushion split through the center.
NOTICE: Never heat starter gear to red heat as 3. If there is movement between a metal plate of the
this will change metal structure. mounting and its attaching points, lower the
engine and tighten the bolts or nuts attaching the
2. Uniformly heat the flywheel gear to temperature mounting to the engine, frame, or bracket.
which will expand the gear to permit installation.
Temperature must not exceed 204C (400F).
Rear Mountings
3. As soon as the gear has been heated, install on 1. Push up and pull down on the transmission
the flywheel. tailshaft. Observe the transmission mounting.
2. Replace the mounting if the following conditions

0 Install or Connect exist:
Rubber cushion separated from the metal
1. Flywheel.
plate of the mounting.
2. Flywheel bolts.
Mounting bottomed out (tailshaft can be
moved up but not down).
Tighten
3. If there is relative movement between a metal
plate of the mounting and its attaching point,
Flywheel bolts to 100 N-m (75 ft. lbs.).
tighten the bolts or nuts attaching the mounting to
3. Clutch, flywheel housing, and transmission. the transmission or crossmember.
6A3-26 4.3 LITER V6
A. Torque Bolt To 95 N-m (70 Ft. Lbs.). Or,

Torque Nut to 55 N-m (40 Ft. Lbs.).
B. 48 N m (36 Ft. Lbs.)
C. Forward
D. 40 N-m (30 Ft. Lbs.)
B-07906
Figure 35Front Engine Mounting (C And K Models)
FRONT MOUNTING REPLACEMENT Tighten
Remove or Disconnect (Figures 35 and 36) Fasteners to specifications. Refer to figures

35 and 36.
3. Engine mount through-bolt and nut. Lower the
NOTICE: When raising or supporting the engine until the bolt can be inserted. Install the
engine for any reason, do not use a jack under nut.
pulley. Due to the small clearance between a Tighten
the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent Through-bolt or nut to specifications. Refer
against the pump screen, resulting in a to figures 35 and 36.
damaged oil pickup unit.
REAR MOUNTING RELACEMENT
Support the engine with a suitable jack. Do not
load the engine mounting. Remove or Disconnect (Figures 37 and 38)
1. Engine mounting through-bolt and nut.
NOTICE: When raising or supporting the
NOTICE: Raise the engine only enough for engine for any reason, do not use a jack under
sufficient clearance. Check for interference the oil pan, any sheet metal or crankshaft
between the rear of the engine and the dash pulley. Due to the small clearance between
panel which could cause distributor damage. the oil pan and the oil pump screen, jacking
Raise the engine only enough to permit removal against the pump screen, resulting in a
of the engine mounting. damaged oil pickup unit.
2. Mounting assembly bolts, nuts, and washers.
Support the rear of the engine to relieve the
3. Mounting assembly. weight on the rear mountings.
1. Mounting to crossmember nut(s) and washer(s).
2. Mounting to transmission bolts and washers.
Raise the rear of the engine only enough to
permit removal of the mounting.
1. Mounting assembly.
3. Mounting.
NOTICE: See Notice on page 6A3-1 of this Install or Connect (Figures 37 and 38)
section.
0
1. Mounting.
2. Mounting assembly bolts, nuts, and washers. Lower the rear of the engine.
4.3 LITER V6 6A3-27
A. Torque Bolt To 95 N m (70 Ft. Lbs.). Or

Torque Nut To 55 N m (40 Ft. Lbs.).
B. 48 N m (36 Ft. Lbs.)
C. Forward
B-07908
Figure 36Front Engine Mounting (G Models)
B. 48 N m (36 Ft. Lbs.)

C MODELS C. 55 N m (40 Ft. Lbs.) K MODELS B-07909
Figure 37Rear Engine Mounting (C And K Models)

6A3-28 4.3 LITER V6
15. Strut rods at the engine mountings ( K models

with automatic transmission).
16. Flywheel or torque converter cover.
17. Wiring along oil pan rail.
18. Starter.
19. Wiring for fuel gage.
20. Converter to flex plate bolts.
Lower the vehicle.
Support the transmission.
Attach a suitable lifting fixture.
21. Bell housing to engine bolts.
22. Engine mounting to frame bo!*s.
23. Hood.
24. Engine.
1. Engine to the vehicle.

2. Mounting to transmission bolts and washers. Raise the vehicle.
NOTICE: See Notice on page 6A3-1 of this NOTICE: See Notice on page 6A3-1 of this
section. section.
3. Mounting to crossmember nut(s) and washer(s). 2. Engine mounting to frame belts.
$ Tighten Tighten
Fasteners to specifications. Refer to figures Fasteners to specifications. Refer to figure

37 and 38. 35.
3. Bell housing to engine bolts. Remove the
transmission support.
ENGINE REPLACEMENT
; f tp 4. Converter to flex plate bolts.
C AND K MODELS 5. Fuel gage wiring.
6. Starter.
|+ + | Remove or Disconnect 7. Wiring along oil pan rail.
1. Battery negative cable. 9. Strut rods at the engine mountings (K models
2. Hood. with automatic transmission).
Drain the cooling system.
10 Exhaust pipes to the manifolds.
3. Air cleaner.
Lower the vehicle.
4. All accessory drive belts.
11. Vacuum lines to the intake manifold.
5. Fan and water pump pulley.
6. R a d ia to r and sh ro u d . R efer to ENG INE 12. Fuel line at the fuel pump.
COOLING (SEC. 1B). 13. Engine wiring harness.
7. Heater hoses at the engine. 14. Power steering pump (if used).
8. Accelerator cruise control, and detent linkage (if 15. Air conditioning compressor (if used).
used) from the carburetor. 16. Accelerator, cruise control, and detent linkages.
9. Air conditioning compressor (if used) and lay 17. Heater hoses.
aside.
18. Radiator and shroud.
10. Power steering pump (if used) and lay aside.
19. Accessory drive belts.
11. Engine wiring harness from the engine.
12. Fuel line at the fuel pump. 20. Air cleaner.
13. Vacuum lines from the intake manifold. 21. Hood.
Raise the vehicle. 22. Proper q uantity and grade of coolant and
Drain the crankcase oil. crankcase oil.
14. Exhaust pipes from the manifolds. 23. Battery negative cable.
4.3 LITER V6 6A3-29
G MODELS NOTICE: See Notice on page 6A3-1 of this

section.
2. Engine mounting through-bolts.
2. Glove box. & Tighten
3. Engine cover.
Drain the coolant. Through-bolts or nuts to specifications.
4. Outside air duct. Refer to figure 36.
5. Power steering fluid reservoir. 3. Bell housing to engine bolts.
6. Hood release cable. 4. Flex plate to torque converter bolts (automatic
7. Upper fan shroud bolts. transmissions).
8. Radiator. Refer to ENGINE COOLING (SEC. 6B). 5. Starter.
9. Upper fan shroud. 6. Torque converter or flywheel cover.
10. Fan and pulley. 7. Strut rods.
11. Air cleaner. 8. Exhaust pipes.
12. Cruise control servo. Lower the vehicle.
13. Vacuum hoses at the intake manifold. 9. Condenser.
14. Accelerator, cruise control, and detent cables (if 10. Hood latch support.
used). 11. Lower fan shroud and filler panel.
15. Carburetor. 12. Upper radiator support.
16. Distributor cap. 13. Headlamp bezels and grille.
17. Diverter valve. 14. Air conditioning idler pulley.
18. Coolant hose at the intake manifold. 15. Power steering pump.
19. PCV valve. 16. Fuel hoses.
20. Other necessary vacuum hoses and wires. 17. Accelerator cable at the dipstick tube.
21. Air conditioning compressor and brace. Refer to 18. Transmission dipstick tube.
AIR CONDITIONING (SEC. 1B). 19. Oil filler tube.
22. Upper half of engine dipstick tube. 20. Upper half of engine dipstick tube.
23. Oil filler tube. 21. Air conditioning compressor and brace. Refer to
24. Transmission dipstick tube. AIR CONDITIONING (SEC. 1B).
22. Vacuum hoses and wires.
25. Accelerator cable at the dipstick tube.
23. PCV valve.
26. Fuel hoses at the fuel pump.
24. Coolant hose at the intake manifold.
27. Power steering pump.
25. Diverter valve.
28. Air conditioning idler pulley.
26. Distributor cap.
29. Headlamp bezels and grille.
27. Carburetor.
30. Upper radiator support.
28. Accelerator, cruise control, and detent cables.
31. Lower fan shroud and filler panel.
29. Vacuum hoses at the intake manifold.
32. Hood latch support.
30. Cruise control servo.
33. Condenser.
31. Air cleaner.
Raise the vehicle. 32. Fan and pulley.
Drain the crankcase. 33. Upper fan shroud.
34. Exhaust pipes at the manifolds. 34. Radiator. Refer to ENGINE COOLING (SEC. 6B).
35. Strut rods at the torque converter or flywheel 35. Upper fan shroud bolts.
underpan. 36. Hood release cable.
36. Torque convertor or flywheel cover. 37. Power steering fluid reservoir.
37. Starter. 38. Outside air duct.
38. Flexplate to torque converter bolts (automatic 39. Glove box.
transmissions). 40. Proper q uantity and grade of coolant and
39. Bell housing to engine bolts. crankcase oil.
40. Engine mounting through bolts. 41. Engine cover.
Lower the vehicle and support the transmission. 42. Battery negative cable.
41. Engine. Evacuate and charge the air conditioning system.

Raise the vehicle.
6A3-30 4.3 LITER V6
SPECIFICATIONS
ENGINE SPECIFICATIONS
All Specifications are in INCHES unless otherwise noted.
GENERAL DATA:
Type V6
Displacement 4.3L (262 Cu. In.)
RPO LB1/LB4
Bore 4.00
Stroke 3.48
Compression Ratio 9.3:1
Firing Order 1-6 - 5 -4 -3 - 2
Oil Pressure 10 psi @ 500 RPM; 30-35 psi @ 2000 RPM
CYLINDER BORE:
Diameter 3.9995-4.0025'
Out Of Production 0.001 (Maximum)
Round Service 0.002 (Maximum)
Production Thrust Side 0.0005 (Maximum)
Taper Relief Side 0.001 (Maximum)
Service 0.001 (Maximum)
PISTON:
Production 0.0007-0.0017
Clearance
Service Limit 0.0027 (Maximum)
PISTON RING:
C
0 Top
Groove Production 0.0012-0.0032
M 2nd
P Clearance
R Service Limit Hi Limit Production + 0.001
E
S Top 0.010-0.020
S Production
I Gap 2nd 0.010-0.025
0
N Service Limit Hi Limit Production + 0.010
0 Clearance Service Limit Hi Limit Production + 0.001
I Production
Gap 0.015-0.055
L Service Limit Hi Production +0.010
PISTON PIN:
Diameter 0.9270-0.09273
Clearance Production 0.00025-0.00035
In Piston Service Limit 0.001 (Maximum)
Fit In Rod 0.0008-0.0016 Interference
B-07911
4.3 LITER V6 6A3-31
SPECIFICATIONS
ENGINE SPECIFICATIONS (CONT.)
All specifications are in INCHES unless otherwise noted.
DISPLACEMENT: 4.3L
CRANKSHAFT:
#1 2.4484-2.4493
Diameter #2, #3 2.4481-2.4490
#4 2.4479-2.4488
Main Production 0.0002 (Maximum)
Taper
Journal Service Limit 0.001 (Maximum)
Round Service Limit 0.001 (Maximum)
#1 0.0008-0.0020
Production #2, #3 0.0011-0.0023
Main #4 0.0017-0.0032
Bearing #1 0.0010-0.0015
Clearance Service Limit #2, #3 0.0010-0.0025
#4 0.0025-0.0035
Crankshaft End Play 0.002-0.006
Diameter 2.2487-2.2497
Production 0.0005
Taper
Crankpin Service Limit 0.001 (Maximum)
Out Production 0.0005
Rod Bearing Production 0.0013-0.0035
Clearance Service Limit 0.0030
Rod Side Clearance 0.006-0.014
CAMSHAFT:
Lobe Intake 0.357
Lift + 0.002 Exhaust 0.390
Journal Diameter 1.8682-1.8692
Camshaft End Play 0.004-0.012
VALVE SYSTEM:
Lifter Hydraulic
Rocker Arm Ratio 1.50:1
Intake One Turn Down From Zero Lash
Valve Lash
Exhaust
Face Angle (Intake & Exhaust) 45
CD
O
Seat Angle (Intake & Exhaust)

Seat Runout (Intake & Exhaust) 0.002 (Maximum)
Intake V 3 2 - V 16
Seat Width
Exhaust 1/ l 6 - 3/3 2
Intake 0.0010-0.0027
Production
Stem Exhaust 0.0010-0.0027
Clearance Intake High Limit Production +0.001
Service
Exhaust High Limit Production +0.002
Free Length 2.03
Valve Pressure Closed 76-84 lbs. @ 1.70-in.
Spring lbs. @ in. Open 194-206 lbs. @ 1.25-in.
(Outer) Installed Height 1 23/3 2
+ V3 2"
Valve Free Length 1 .8 6
Spring
Damper Approx. # of Coils 4
B-07912
6A3-32 4.3 LITER V6
ITEM Nm FT. LBS. IN. LBS.

Rocker Arm Cover B o lts .................................................................................... 9.9 88
Intake Manifold Bolts.......................................................................................... 48 36
Exhaust Manifold Bolts
Center Two B o lts ........................................................................................ 36 26
All O th e rs ..................................................................................................... 28 20
Cylinder Head Bolts............................................................................................ 90 65
Torsional Damper B olt........................................................................................ 95 70
Front Cover Bolts................................................................................................ 10.4 92
Oil Pan Nuts......................................................................................................... 22.6 200
Oil Pan B o lts ....................................................................................................... 11.3 100
Oil Pump Bolt....................................................................................................... 90 65
Rear Crankshaft Oil Seal Retainer S cre w s .................................................... 15.3 135
Camshaft Sprocket Bolts.................................................................................... 24 18
Connecting Rod Cap N u ts .......... ..................................................................... 60 45
Oil Filter Adapter B o lts ...................................................................................... 20 15
Main Bearing Cap B o lts .................................................................................... 100 75
Oil Pump Cover B o lts ........................................................................................ 9.0 80
Flywheel B o lts ..................................................................................................... 100 75
Spark P lu gs......................................................................................................... 30 22
Water Outlet B o lts .............................................................................................. 28 21
Water Pump B o lts .............................................................................................. 40 30
Flywheel Housing Bolts...................................................................................... 44 32
SPECIAL TOOLS
J-23590 Air Adapter
J-5892-A Spring Compressor
J-3049 Hydraulic Lifter Remover (Plier Type)
J-9290-1 Hydraulic Lifter Remover (Slide Hammer
J-5802-01 Rocker Arm Stud Remover
J-5715 Reamer (0.003-inch oversize)
J-6880 Rocker Arm Stud Installer
J-23523-E Torsional Damper Remover and Installer
J-23042-A Front Crankshaft Seal Installer
J-35621 Rear Crankshaft Seal Installer
J-8520 Camshaft Lobe Lift Indicator
J-5239 Guide Set
J-8037 Ring Compressor
J-8080 Main Bearing Remover/Installer
J-5825 Crankshaft Sprocket Puller
J-5590 Crankshaft Sprocket Installer
6A4-1
SECTION 6A4
4.8 LITER L6
this manual as indicated at appropriate locations by the terminology See NOTICE on page 6A4-1 of this section.
the same part number or with an equivalent part if replacement becomes necessary. Torque values must be
used as specified during reassembly to assure proper retention of all parts.
CONTENTS
S U B JE C T PAGE
D e s c rip tio n ................................................................................................................................................................ 6A4- 2

Valve Stem Seal And Valve Spring R eplacem ent.........................................................................................6A4- 5
Pushrod Cover Replacem ent..............................................................................................................................6A4- 6
Intake And Exhaust Manifold R eplacem ent....................................................................................................6A4- 8
Rocker Arm Stud Replacem ent......................................................................................................................... 6A4- 9
Cylinder Head R e p la ce m e n t............................................................................................................................. 6A4-10
Torsional Damper And Front Crankshaft Seal R eplacem ent..................................................................... 6A4-11
Tim ing Gear Cover R e p lace m e n t.....................................................................................................................6A4-12
Oil Pan R eplacem ent.......................................................................................................................................... 6A4-13
Oil Pump R e p la ce m e n t...................................................................................................................................... 6A4-13
Rear Crankshaft Oil Seal R e p la ce m e n t.......................................................................................................... 6A4-13
Checking Valve T im in g ...................................................................................................................................... 6A4-15
Camshaft R e p lace m e n t...................................................................................................................................... 6A4-16
Connecting Rod And Piston Replacement......................................................................................................6A4-17
Main Bearing R eplacem ent................................................................................................................................6A4-19
Crankshaft Gear R e p la ce m e n t......................................................................................................................... 6A4-21
Oil Filter Bypass Valve R eplacem ent.............................................................................................................. 6A4-21
Crankshaft R eplacem ent.................................................................................................................................... 6A4-22
Flywheel R eplacem ent........................................................................................................................................ 6A4-23
Engine M ountings................................................................................................................................................. 6A4-24
Engine R e p la ce m e n t...........................................................................................................................................6A4-29
S pecifications............................................................................................................................................................6A4-30
Special T o o ls ............................................................................................................................................................6A4-33
6A4-2 4.8 LITER L6
DESCRIPTION
The connecting rods are forged steel, with precision

insert type crankpin bearings. The piston pins are a
press fit in the connecting rods.
The pistons are cast aluminum alloy. The piston pins
are a floating fit in the pistons.
ENGINE LUBRICATION
Lubrication schematics are shown in figures 1 and 2.
The gear type oil pump is driven through an extension
shaft from the distributor drive shaft, which is gear
driven from the camshaft. Oil is drawn into the oil
pump through a pickup screen and pipe.
Pressurized oil is routed to the oil filter. In case of
excessive backpressure at the oil filter, a bypass valve
B-05053
is provided. This valve will allow oil flow to the main oil
gallery at the right side of the block. This gallery
Figure 1Lubrication Diagram (Side View) supplies oil to the camshaft bearings, hydraulic lifters,
and main bearings. The connecting rods are supplied
4.8L engines are inline six cylinder type, overhead oil from the main bearings by means of drilled
valve, water cooled, with cast iron block and head. passages in the crankshaft. The valve train is supplied
The crankshaft is supported by seven precision in with oil by the hydraulic lifters. Oil is pumped from the
sert main bearings, with crankshaft thrust taken at the lifters through the hollow pushrods to the rocker arms.
number seven (rear) bearing. Oil drains back to the crankcase through oil drain holes
The camshaft is supported by four plain type bear and the pushrod holes. The piston, piston pin, and
ings and is gear driven. Motion from the camshaft is timing gears are lubricated by oil splash.
transmitted to the valves by hydraulic lifters, pushrods,
and ball-type rocker arms. The valve guides are inte
gral in the cylinder head.
4.8 LITER L6 6A4-3
A. Oil Pressure Sending Unit

B. D istribu tor Shaft O iling
C. Splash O iling
D. F ilte r Bypass System
E. Full Flow Oil F ilte r
B-09222
Figure 2Lubrication Diagram (Front View)

6A4-4 4.8 LITER L6
ON-VEHICLE SERVICE
I? Inspect
Rocker arm cover sealing surfaces for distortion.

Straighten or replace as needed.
|+<-| Install or Connect (Figure 3)
1. New gasket.
2. Rocker arm cover.
3. Bolts, clips, and reinforcements.
Tighten
Bolts to specification.
Rubber gasket - 4.3 N m (38 in. lbs.).
Cork gasket - 5.4 N m (58 in. lbs.).
4. Wiring, fuel and vacuum lines to the clips.
5. Air cleaner.
6. Crankcase ventilation hoses to the rocker arm
cover.
1. Clip 3. Reinforcement ROCKER ARM AND

2. Bolt 4. Rocker Arm Cover PUSHROD REPLACEMENT
5. Gasket
B-07856
Figure 3Rocker Arm Cover Installation
2. Rocker arm nut.
ROCKER ARM COVER If only the pushrod is to be replaced, back
REPLACEMENT the rocker arm nut off until the rocker arm
Remove or Disconnect (Figure 3) 3. Rocker arm with ball.
4. Pushrod.
1. Crankcase ventilation hoses at the rocker arm
cover. Important
2. Air cleaner.
Store used components in order so they can be
3. Wiring, fuel and vacuum lines from the clips. reassembled in the same location.
4. Bolts, reinforcements, and clips.
5. Rocker arm cover. I? Inspect
If the rocker arm cover adheres to the
Rocker arms and balls at their mating surfaces.
cylinder head, try to shear the gasket by
These surfaces should be smooth and free from
bumping the end of the cover with a rubber
scoring or other damage.
mallet. DO NOT DISTORT THE SEALING
Rocker arm areas which contact the valve stems
FLANGE.
and the sockets which contact the pushrods.
6. Gasket. These areas should be smooth and free of
damage and wear.
j j Clean Pushrods for bending. Roll the pushrod on a flat
surface to determine if it is bent. Replace if
All traces of old gasket from the rocker arm cover necessary.
and cylinder head. Ends of the pushrods for scoring or roughness.
4.8 LITER L6 6A4-5
Install or Connect
1. Pushrod. Make sure the pushrod seats properly

in the hydraulic lifter.
Im portant
When new rocker arms and/or balls are

installed, coat their bearing surfaces with
Molykote or equivalent.
3. Rocker arm nut.
Adjust
Valves as outlined later.

Figure 4A djusting The Valves
VALVE ADJUSTMENT
VALVE STEM SEAL AND
1. Remove the rocker arm cover as outlined VALVE SPRING REPLACEMENT
previously.
2. Adjust the valves when the lifter is on the base
circle of the camshaft lobe as follows: Remove or Disconnect (Figures 5 and 6)
a. Mark the distributor housing with chalk, at
#1 and #6 plug wire positions. Remove the Tools Required:
distributor cap and lay aside. J-23590 Air Adapter.
b. Crank the engine until the distributor rotor J-5892-A Spring Compressor.
points to #1 cylinder position. The following 1. Rocker arm cover, as outlined previously.
valves can be adjusted with the engine in
the #1 firing position:
#1 cylinder-Exhaust and Intake 3. Spark plugs.
#2 cylinder-lntake 4. Valve keepers (20).
#3 cylinder-Exhaust Install J-23590 into the spark plug hole.
#4 cylinder-lntake Apply compressed air to hold the valves in
#5 cylinder-Exhaust place.
c. Back out the adjusting nut until lash is felt at Install a rocker arm nut (figure 6).
the pushrod, then turn in the adjusting nut
until all lash is removed. This can be
determined by rotating the pushrod while
turning the adjusting nut (figure 4). When
play has been removed, turn the adjusting
nut in one full additional turn (to center the
lifter plunger).
d. Crank the engine until the distributor rotor
points to #6 position. The following valves
can be adjusted with the engine in #6 firing
position:
#2 cylinder-Exhaust
24. Seal
#3 cylinder-lntake
20. Valve Keeper 25. Damper
#4 cylinder-Exhaust
21. Rotator 26. Spring
#5 cylinder-lntake 22. Shield 27. Intake Valve
#6 cylinder-lntake and Exhaust 23. O-Ring Seal 28. Exhaust Valve
3. Install the distributor cap. B-07859
previously. Figure 5Valves And Components
6A4-6 4.8 LITER L6
Use J-5892-A to compress the valve spring

(figure 6).
Remove the valve keepers.
C a re fu lly release the spring tension.
Remove J-5892-A.
5. Rotator (21), shield (22) and spring (26) with
B-06470
damper (25).
6. O-ring seal (23).
7. Seal (24) (intake valve only). Figure 7Testing The Valve Seals
uum pump gage. No air should be able
Install or Connect (Figures 5, 6, and 7) to leak past the seal. If the seal will not
hold a vacuum, it may have been dam
Tools Required: aged or improperly installed.
J-23590 Air Adapter. 4. Spark plugs.
J-5892-A Spring Compressor. 5. Rocker arms, as outlined previously.
J-23994-01 Adapter Cup.
J-23738-A Vacuum Pump.
Adjust
1. New seal (24) (intake valve only). Install the seal
over the valve stem and seat it against the head.
2. Spring (26) with the damper (25), shield (22) and
rotator (21). 6. Rocker arm cover, as outlined previously.
3. New o-ring seal (23) and valve keepers (20).
With air pressure applied to the cylinder
with J-23590, compress the spring with PUSHROD COVER
J-5892-A (figure 6). REPLACEMENT
Lubricate the o-ring seal with engine oil.
Install the seal on the valve stem. Make sure Remove or Disconnect
the seal is not twisted.
Install the valve keepers. Use grease to hold 1. Battery negative cable.
them in place. 2. Dipstick tube (C-K models if rear pushrod
Carefully release spring pressure. Make cover is to be removed).
sure the valve keepers stay in place.
3. Pushrod cover bolts.
Remove J-5892-A and J-23590.
Check each o-ring seal for leakage (figure 4. Pushrod cover.
7). 5. Gasket.
23738-A over the shield. Clean
Connect J-23738-A to the suction cup
and apply a vacuum. Watch the vac- Old gasket from pushrod cover and block.
4.8 LITER L6 6A4-7
Install or Connect
1. Pushrod cover and new gasket.

2. Pushrod cover bolts.
& Tighten
Pushrod cover bolts to 9.0 N m (80 in. lbs.).

3. Dipstick tube (if removed).
HYDRAULIC LIFTER
REPLACEMENT
-- Remove or Disconnect (Figures 8 and 9)
Tools Required: Figure 8Removing The Hydraulic Lifter

or Replace all hydraulic lifters when a new
J-9290-01 Hydraulic Lifter Remover camshaft is installed.
(Slide Hammer Type) 2. Pushrod cover, as outlined previously.
1. Rocker arm cover, pushrod cover, and pushrod, 3. Pushrod, as outlined previously.
as outlined previously.
2. Hydraulic lifters. f t Adjust
Remove the hydraulic lifters one at a time
and place them in an organizer rack. The Valves, as outlined previously.
lifters must be installed in the same bore 4. Rocker arm cover, as outlined previously.
from which they were removed.
A stuck hydraulic lifter can be removed
using J-3049 (figure 8) or J-9290-01 (figure
9)-
15 Inspect
Hydraulic lifter body for scuffing and scoring. If

the lifter body wall is worn or damaged, the
mating bore in the block should also be checked.
Check the fit of each hydraulic lifter in its mating
bore in the block. If the clearance is excessive, try
a new lifter.
J-9290-01
Hydraulic Lifter Repair
Install or Connect
Hydraulic lifters to the block. Lubricate the lifter

foot and body with Engine Oil Supplement or
equivalent.
When any new hydraulic lifters or a new
B-05064
c a m s h a ft is in s ta lle d , E ngine Oil
Supplem ent (or equivalent) should be
added to the crankcase oil. Figure 9Removing The Hydraulic Lifter
6A4-8 4.8 LITER L6
4. Carburetor (if necessary).

5. Fuel and vacuum lines from the manifold, EGR
valve (if used) and EFE valve.
6. AIR pump and bracket.
7. PCV hose.
8. Exhaust pipe.
9. Manifold heat stove.
10. Clamps (32), bolts (31), nuts (33) and washers.
11. Manifold assembly and gasket.
1. Bolt (35) and nuts (40).

2. Manifolds (34 and 39).
32. Clamp 33. Nut 3. Gasket (38).
B-07861
1^1 Clean
Figure 10Manifold Installation
All manifold bolts and studs. Then apply engine
INTAKE AND EXHAUST oil to the threads.
All traces of old gaskets from the cylinder head
MANIFOLD REPLACEMENT and manifolds.
|<~+| Remove or Disconnect (Figures 10 and 11) Inspect

M anifolds for cracks or dam age to gasket
2. Air cleaner. surfaces.
3. Throttle controls at the bell crank. Operation of EFE or manifold heat valve (if used).
Gaskets, if necessary to diagnose a leakage
problem.
Measure
Manifold distortion. Lay a straight edge along the

full length of the manifold exhaust port faces and
measure any gaps between the straight edge and
the port faces. If at any point a gap of 0.80 mm
(0.030-inch) or more exists, it is likely that the
manifold has distorted to a point where it will not
seal properly. If a good exhaust seal is to be
e xpected, the exhaust m a n ifo ld m ust be
replaced.
1. Gasket (38) to the exhaust manifold (34).

2. Intake manifold (39) to the exhaust manifold.
3. Both (35), washers (36) and nuts (40). LEAVE
FINGER TIGHT.
31. Bolt 36. Washer
32. Clamp 37. Stud
33. Nut 38. Gasket
34. Exhaust Manifold 39. Intake Manifold 1. New gasket, over the manifold studs on the
35. Bolt 40. Nut cylinder head.
B-07866 2. Manifold assembly.
3. Clamps (32).
Figure 11Manifolds And Components 4. Bolts (31), and nuts (33).
4.8 LITER L6 6A4-9
Figure 12Removing The Rocker Arm Stud
Im portant 2. Rocker arm stud.

Always tighten the manifold to cylinder head Install a nut and flat washer.
bolts and nuts (31 and 33) BEFORE Turn the nut to remove the stud (figure 12).
tightening the manifold center bolt and nuts
(35 and 40). Install or Connect (Figures 13 and 14)
& Tighten Tools Required:

J-5715 Reamer (0.003-inch oversize) or
Bolts (31) and nuts (33) to 52 N m (38 ft.
lbs.).
Bolts (35) and nuts (40) to 60 N m (44 ft.
lbs.).
5. Manifold heat stove.
6. Exhaust pipe.
7. PCV hose.
8. AIR pump and bracket.
9. Fuel and vacuum lines from the manifold, EGR
valve (if used) and EFE valve (if used).
10. Carburetor (if removed).
11. Throttle controls.
12. Air cleaner.
Adjust
Engine idle speed, if necessary.
ROCKER ARM STUD

REPLACEMENT
B
*1 Remove or Disconnect (Figure 12)
Tool Required:
1. Rocker arm cover and rocker arm, as outlined
previously. Figure 14Installing The Rocker Arm Stud
6A4-10 4.8 LITER L6

NOTICE: Do not attempt to install an oversize

rocker arm stud without reaming stud hole as
this could damage the cylinder head.
Ream the hole to the proper size for the

replacement oversize rocker arm stud. Use FRONT OF ENGINE
J-5715 for 0.003-inch oversize studs; J-6036 for
0.013-inch oversize stud (figure 13).
B-05258
Coat lower end (press-fit area) of the rocker arm
stud with hypoid axle lubricant.
Figure 15Cylinder Head Bolt
1. Rocker arm stud. Use J-6880 (figure 14). Stud is
Tightening Sequence
installed to proper depth when the tool bottoms
2. Rocker arm, as outlined previously.
L* Inspect
Sealing surfaces of the block and cylinder head

Adjust for nicks, heavy scratches, or other damage.
Valves, as outlined previously. Cylinder Head Repair

3. Rocker arm cover, as outlined previously. Refer to the proper Unit Repair Manual.

CYLINDER HEAD
1. Head gasket.
REPLACEMENT
Remove or Disconnect the gasket with sealer. Spread the sealer
thin and even.
1. Battery ground cable. Do not use se a le r on c o m p o s itio n
2. Manifold assembly, as outlined previously. steel-asbestos gaskets.
Place the gasket over the block dowel pins
3. AIR check valve.
with the bead up.
Cylinder head. Carefully guide the cylinder head
5. Pushrods. Back off the rocker arm nuts. Turn the into place over the dowel pins and gasket.
rocker arms aside, then remove the pushrods. 3. Cylinder head bolts. Coat threads of the cylinder
Place the pushrods in a rack so they can be head bolts with sealing compound and install
returned to their original locations at assembly. finger tight.
6. Spark plug wires at the spark plugs.
7. Vacuum lines at the thermal vacuum switch on Tighten
the water outlet.
Drain the radiator and block. Cylinder head bolts, a little at a time, using
the sequence shown in figure 15, until the
8. Upper radiator hose, heater hose, and water
specified torque is reached.
pump bypass hose.
Left hand front bolt: 115 N m (85 ft.
9. Battery ground strap at the cylinder head.
lbs.).
10. Cylinder head bolts. All other bolts: 130 N m (95 ft. lbs.).
11. Cylinder head and gasket. 4. Battery ground strap at the cylinder head.
Qjj| Clean pump bypass hose. Fill the cooling system with
the proper coolant.
Carbon deposits from combustion chambers. 6. Vacuum lines at the thermal vacuum switch.
All traces of old head gasket from cylinder head 7. Spark plug wires.
and block. 8. Pushrods. Be sure to install them in their original
Cylinder head bolt threads and threads in the locations.
block. 9. Rocker arms to the pushrods.
4.8 LITER L6 6A4-11
f t Adjust

11. AIR check valve.
12. Manifold assembly, as outlined previously.

FRONT CRANKSHAFT SEAL
REPLACEMENT
Tool Required: B-01325

Installer. Figure 16Removing The Torsional Damper
Battery negative cable.
Radiator. Refer to ENGINE COOLING (SEC. 6B).
Drive belts from the crankshaft pulley.
Torsional damper bolt and washer.
Torsional damper. Use J-23523-E (figure 16). J-23042-A
Front crankshaft seal. Pry out with a large
screwdriver. Take care not to distort the timing
gear cover.
Inspect
Oil seal contact area on the torsional damper for

grooving and roughness. Replace if necessary. B-07867
+ + Install or Connect (Figures 17 and 18) Figure 17Installing The Tim ing Gear
Cover And Seal
Tools Required:
J-23523-E Torsional Damper Puller and Turn the nut to pull the torsional damper into
Installer place.
J-23042-A Centering Tool and Seal Installer Remove the tool.
1. Front crankshaft seal. Use J-23042-A (figure 17).
Coat the seal lips with engine oil. The open end
of the seal faces inside the engine.

2. Crankshaft key (if removed).

3. Stud (item C, figure 18) to the crankshaft. Thread
A. Bearing
C
the stud fully into the tapped end of the
B. Washer
crankshaft.
C. Stud
4. Torsional damper over the end of the stud. Align D. Nut B-05254
crankshaft key.
5. Bearing, washer, and nut (figure 18). Figure 18Installing The Torsional Damper
6A4-12 4.8 LITER L6
6. Torsional damper bolt and washer.
Tighten
Torsional damper bolt to 70 N m (50 ft. lbs.).

7. Drive belts to the crankshaft pulley, and tension to
specifications.
8. Radiator. Refer to ENGINE COOLING (SEC. 6B).
Fill the cooling system with the proper coolant.
TIMING GEAR COVER

REPLACEMENT
0 Remove or Disconnect 4. Timing gear cover, with J-23042-A in place, to the

block (figure 17).
2. Torsional damper, as described previously. Important
3. Oil pan to timing gear cover bolts.
4. Timing gear cover to block bolts. The tool is used to align the timing gear
5. Timing gear cover. cover so that the front crankshaft seal is
Pull the cover slightly forward only enough properly centered around the crankshaft.
to permit cutting of the oil pan front seal. The seal must be centered to prevent
Using a sharp knife or other suitable cutting damage during hub installation.
tool, cut the oil pan front seal flush with the 5. Oil pan to timing gear cover bolts. Partially tighten
block at both sides of the oil pan. the bolts.
Remove the cover and attached portion of 6. Timing gear cover to block bolts.
the oil pan front seal.
6. Timing gear cover gasket.
\^X \ Tighten
7. Front crankshaft seal. Pry out with a screwdriver.
Be careful not to distort the timing gear cover. Timing gear cover to block bolts to 9.0 N m
(80 in. lbs.).
ig * Clean
Oil pan to timing gear cover bolts to 5.1 N m
(45 in. lbs.).
Old gasket from the timing gear cover, block, and
oil pan.
|-n-| Install or Connect (Figures 17, 19, and 20)
J-23042-A from the timing gear cover.
Tool Required: 7. Torsional damper, as outlined previously.
J-23042-A Centering Tool and Seal Installer 8. Battery negative cable.
1. Front crankshaft seal to the timing gear cover.
Lubricate the seal lips with engine oil.
Use J-23042-A to press the seal into place
(figure 19).
Leave the tool in position in the seal.
2. Timing gear cover to oil pan seal.
Cut the tabs from a new seal as shown in
figure 20. Use a sharp cutting tool to help
make a clean, straight cut.
Position the seal against the cover. Press
A. Cut This Portion From New Seal
the retaining tips into the holes in the cover.
3. Timing gear cover to block gasket to the timing
gear cover. Use gasket sealer to hold it in place. B-07870
Apply a 3 mm (Vs-inch) bead of RTV sealant to
the joint formed at the oil pan and cylinder block. Figure 20Front Oil Pan Seal Modification
4.8 LITER L6 6A4-13
OIL PAN REPLACEMENT Inspect
Oil pump pickup tube for looseness. If the tube is

loose in the oil pump body, replace it, as outlined
B a Remove or Disconnect
in the proper unit repair manual. A loose pickup
1. Battery negative cable. tube can result in an air leak and loss of oil
pressure.
Drain the engine oil.
2. Starter.
Oil Pump Repair
3. Torque converter or flywheel cover.
4. Front engine mount through-bolts.
Raise the engine and block in position.
Install or Connect
5. Oil pan bolts.
6. Oil pan. 1. Oil pump to the engine. Align the slot in the oil
7. Old gaskets and seals. pump shaft with the tang on the distributor shaft.
The oil pump should slide easily into place. No
Clean gasket is used.
2. Oil pump bolts.
Old gasket and seals from the block and oil pan
sealing surfaces.
Tighten
-j Install or Connect
Oil pump bolts to 13.0 N-m (115 in. lbs.).
1. New rear oil pan seal to the rear main bearing 3. Oil pump pickup tube bracket to main bearing
cap. cap nut.
2. New front oil pan seal to the timing gear cover.
Press the retaining tips into the holes in the cover. Tighten
3. New oil pan to block gaskets to the block. Use
gasket cement to hold them in place. Nut to 34 N-m (25 ft. lbs.).
4. Oil pan bolts. 4. Oil pan, as outlined previously.
Tighten
REAR CRANKSHAFT OIL
1/4-inch oil pan to block bolts to 9.0 N-m (80
in. lbs.).
SEAL REPLACEMENT
5/ie-inch oil pan to block bolts to 18.6 N m
The rear main bearing oil seal can be replaced (both
(165 in. lbs.).
halves) without removal of the crankshaft. Always
Oil pan to timing gear cover to 5.1 N-m (45 replace the upper and lower seal as a unit. Install the
in. lbs.). seal with the lip facing the front of the engine. Extreme
Lower the engine. care should be exercised when installing this seal to
5. Front engine mount through-bolts. protect the sealing bead located in the channel on the
6. Torque converter or flywheel cover. outside diameter of the seal. An installation tool (figure
7. Starter. 23) should be used to protect the seal bead when
positioning the seal. (Some seal kits include the tool as
part of the service kit).

OIL PUMP REPLACEMENT
|+ + | Remove or Disconnect 2. Rear main bearing cap.
3. Lower seal half (figure 21).
2. Oil pump pickup tube bracket to main bearing 4. Upper seal half (figure 22).
cap nut. Tap on the upper seal half, using a small
3. Oil pump bolts. drift and hammer.
4. Oil pump. Remove the upper seal half, using pliers.
6A4-14 4.8 LITER L6
A. 4 mm (11/e4-inch)
B. 13 mm (1/2 -inch)
C. 0.10 mm (0.004-inch) shim stock B-05250
Figure 23Oil Seal Installation Tool
1. Upper seal half.
igi Clean
Sealing surfaces of the main bearing cap and

block.
I* Inspect
Crankshaft, seal channel, and sealing surfaces

for nicks, scratches, etc.
A. Forward
B. Fabricated Tool
C. Oil Seal Lip
80. Upper Seal Half
81. Crankshaft
82. Block
83. Lower Seal Half
84. Main Bearing Cap B-07871
Figure 24Installing The Rear Crankshaft

Figure 22Removing The Upper Seal Half Oil Seal
4.8 LITER L6 6A4-15
Figure 26Checking Valve Tim ing Or

Camshaft Lobe Lift
Im portant
3. Rear main bearing cap with the lower main
An oil seal installation tool (figure 23) bearing.
should be fabricated (if not provided in Apply a brush-on type oil sealing compound
the seal kit) to prevent seal damage to the mating surface of the block and cap
during in sta lla tio n . Extrem e care (figure 25). Do not allow any sealant on
should be taken when installing this either crankshaft or rear oil seal.
seal to protect the sealing bead Apply engine oil to the lower main bearing.
located in the channel on the outside Position the cap to the block. Install the cap
diameter of the seal. bolts.
Coat the seal lips lightly with engine oil.
Keep the oil off of the seal mating ends. Tighten
Position the tip of the tool between the
crankshaft and the seal seat in the block R ear m ain b e a rin g cap b o lts
(figure 24). temporarily to 14 N m (10 ft. lbs.).
P o sitio n the seal h a lf betw een the Tap the end of the crankshaft first rearward
crankshaft and the tip of the tool. Make sure then forward with a lead hammer. This will
that the oil seal lip is positioned toward the line up the rear main bearing and crankshaft
front of the engine. thrust surfaces.
Roll the seal around the crankshaft using
Tighten
the tool as a shoe-horn to protect the seal
bead from the sharp corner of the seal seat
Rear main bearing cap bolts to 90 N m
surface in the block. The installation tool
(65 ft. lbs.).
must remain in position until the seal half is
properly positioned with both ends flush
with the block. 5. The proper quantity and grade of engine oil.
Remove the tool, being careful not to
withdraw the seal half. CHECKING VALVE TIMING
2. Lower seal half.
Coat the seal lips lightly with engine oil. Tool Required:
Keep the oil off of the seal mating ends. J-8520-Dial Indicator Adaptor
Insert the seal half into the rear main When it becomes necessary to make a check of
bearing cap. Use the tool to protect the seal valve timing, the procedure following may be used:
half from the sharp edge of the seal seat. 1. Loosen the nut at the #1 intake valve rocker arm,
Feed the seal half into the rear main bearing swing the rocker arm away from the pushrod,
cap, using light finger pressure. Make sure then remove the pushrod.
the oil seal lip faces the front of the engine 2. Install a dial indicator, along with J-8520 (figure
(figure 24). 26). Turn the crankshaft until the #2 exhaust valve
6A4-16 4.8 LITER L6
opens and the notch on the damper is aligned CAMSHAFT REPLACEMENT

with the 0 mark on the timing tab.
3. Position the dial indicator to measure lifter To ch eck for w orn ca m sh a ft lo b es w ith o u t
movement and set indicator at zero. Turn the disassem bling the engine, refer to M easuring
crankshaft 360 degrees and read the indicator. Camshaft Lobe Lift in this section.
On correctly timed engines the indicator will read
0.012-0.020-inch. Remove or Disconnect (Figures 27 and 28)
4. If the reading is not as shown, reset the indicator

1. Engine assembly, as outlined later.
at zero and turn the crankshaft 360 degrees, then
read the indicator again. If reading is now within Mount the engine in a suitable engine stand.
specifications, the engine is timed properly. 2. Hydraulic lifters, as outlined previously.
3. Timing gear cover, as outlined previously.
5. The chart following shows indicator readings with
gears properly indexed for 4.8L engines and the 4. Fuel pump. Refer to FUEL SYSTEM (SEC. 6C).
indicator readings resulting from improperly 5. Distributor. Refer to ENGINE ELECTRICAL (SEC.
indexed gears. 6D).
Align the timing marks (figure 27).
Engine 4.8L 6. Thrust plate bolts (93) (figure 28).
Camshaft Part Number 3848000 7. Camshaft. Support the camshaft carefully to
Valve Lift 0.405 avoid damage to the camshaft bearings.
Dial Gears Properly Indexed 0.012-0.020
Indicator One Tooth Advanced 0.038 I* Inspect
Readings One Tooth Retarded 0.007
Camshaft lobes and journals for scratches,
pitting, and wear.
Timing gear for damaged teeth.
MEASURING CAMSHAFT
LOBE LIFT IjJ Measure (Figure 29)
Tool Required: Thrust plate to camshaft clearance. Use a feeler

gage (figure 29). The proper clearance is
J-8520 Dial Indicator Adaptor 0.08-0.20mm (0.003-0.008-inch). If the clearance
To check for worn camshaft lobes, use the following is excessive, replace the thrust plate. If the
procedure: clearance is insufficient, replace the spacer ring.
1. Remove the rocker arm as outlined previously.
2. Install a dial indicator (part of J-8520) (figure 26). Camshaft Gear And Thrust Plate Replacement
Position the dial indicator so the plunger rests on Refer to the proper unit repair manual.
the pushrod end, as shown, Make sure the
pushrod is in the lifter socket. Camshaft Bearing Replacement
3. Rotate the crankshaft slowly in the direction of
rotation until the hydraulic lifter is on the heel of
the cam lobe. At this point, the pushrod will be in
its lowest position. Set dial indicator on zero, then
rotate the crankshaft slowly until the pushrod is in Coat the camshaft lobes and journals with a high
the fully raised position. quality engine oil supplement (GM Engine Oil
4. Compare the total lift recorded from the dial 1. C am shaft (90) to the engine. H andle the
indicator with specifications. camshaft carefully to prevent damage to the
5. Continue to rotate the crankshaft until the camshaft bearings.
indicator reads zero. This will be a check on the
accuracy of the original indicator reading. Important
6. Remove the dial indicator and adaptor. Line up the timing marks on the crankshaft
7. Install the rocker arm and adjust the valves as gear and camshaft gear (figure 27).
previously outlined. 2. Thrust plate bolts (94).
4.8 LITER L6 6A4-17
Tinning Marks
90. Camshaft
91. Thrust Plate
92. Camshaft Gear
93. Thrust Plate Bolts
94. Crankshaft Gear
B-07863
Figure 27Camshaft And Components
a Tighten Measure
Thrust plate bolts to 9.0 N m (80 in. lbs.). Camshaft and crankshaft gear run-out. Use
a dial indicator. Camshaft gear run-out
should not exceed 0.10 mm (0.004-inch),
crankshaft gear run-out should not exceed
0.08 mm (0.003-inch). If gear run out is
excessive, the gear will have to be removed
and any burrs cleaned from the shaft or the
gear will have to be replaced.
Timing gear backlash. Use a dial indicator.
The correct backlash is 0.10-0.15 mm
(0.004-0.006-inch) with new parts, 0.20 mm
(0.008-inch) maximum with used parts.
6D).
6. Fuel pump. Refer to FUEL SYSTEM (SEC. 6C).
Figure 28Removing The Camshaft Thrust
7. Hydraulic lifters, as outlined previously.
Plate Bolts
Im portant
Replace all hydraulic lifters and add GM En

gine Oil Supplement (or equivalent) to the
engine oil whenever a new camshaft is in
stalled.
8. Engine assembly in the vehicle, as outlined later.
CONNECTING ROD AND

PISTON REPLACEMENT
Tool Required:
Figure 29Measuring Camshaft To Thrust J-5239 Guide Set.
Plate Clearance
1. Cylinder head, as outlined previously.
3. Oil pump, as outlined previously (if necessary).
6A4-18 4.8 LITER L6
Figure 30Removing Or Installing The Figure 31Piston Ring Gap Location

Connecting Rod And Piston
Make sure the cylinder walls are clean. Lubricate
4. Ridge or deposits from the upper end of the the cylinder wall lightly with engine oil.
cylinder bores. Make sure the piston is installed in the matching
Turn the crankshaft until the piston is at cylinder.
BDC. 1. Connecting rod bearings.
Place a cloth on top of the piston. Be certain that the bearings are of the
Perform the cutting operation with a ridge proper size.
reamer. Install the bearing inserts in the connecting
Turn the crankshaft until the piston is at rod and connecting rod cap.
TDC. Lubricate the bearings with engine oil.
Remove the cloth and cuttings. 2. Piston and connecting rod to the proper bore.
5. Connecting rod cap. Check the connecting rod With the connecting rod cap removed,
and cap for identification marks. Mark the parts if install J-5239 onto the connecting rod studs
required. The connecting rod and cap must be (figure 30).
kept together as mating parts. Locate the piston ring end gaps as shown in
6. Connecting rod and piston. figure 31. Lubricate the piston and rings with
engine oil.
W ith o u t d is tu rb in g the ring end gap
(figure 30).
location, install J-8037 over the piston
(figure 32).
connecting rod and piston out of the bore.
The piston must be installed so that the
piston crown depressions flat side faces to
the engines left side (figure 33).
Cleaning, Inspection, And Repair
Place the piston in its matching bore. Using
light blows with a hammer handle, tap the
same time, from beneath the vehicle guide
to the proper unit repair manual.
The unit repair manual contains information on: J-5239 (figure 30). Hold the ring compressor
Connecting rod and piston. against the block until all rings have entered
Piston rings. the cylinder bore.
Connecting rod and crankpin. Remove J-5239 from the connecting rod
Cylinder bores. bolts.
Install or Connect (Figures 30 through 34) Measure
Tools Required: Connecting rod bearing clearance. Refer to

J-5239 Connecting Rod Guide Set the proper unit repair manual.
J-8037 Ring Compressor 3. Connecting rod cap and bearing.
4.8 LITER L6 6A4-19
Figure 34Measuring Connecting Rod Side

Clearance

6 Oil pan and cylinder head, as outlined previously.
MAIN BEARING
REPLACEMENT
+ + Remove or Disconnect (Figures 35 and 36)
Tool Required:
1. Spark plugs.
4. Connecting rod cap nuts. 2. Oil pan, as outlined previously.
$ Tighten 4. Main bearing caps.
Connecting rod cap nuts to 60 N m (44 ft. Check the main bearing caps for location
lbs.). markings. Mark the caps if necessary. The
caps must be returned to their original
locations during assembly.
m Measure
5. Lower main bearing inserts from the main
bearing caps.
gage between the connecting rod and 6. Rear crankshaft oil seal, if necessary, as outlined
crankshaft (figure 34). The correct clearance previously.
is 0.006-0.017-inch. 7. Upper rear main bearing insert.
Use a small brass drift and hammer. Tap on
the insert, on the side opposite the bearing
tang, until the insert rotates out of position
(figure 35).
Use a pair of pliers with the jaws taped to
prevent damage to the crankshaft. Clamp
the insert to the crankshaft flange (figure
35). Rotate the crankshaft to remove the
bearing insert.
A. Front of Engine 8. Upper main bearing inserts.
B. Flywheel Side of Engine Insert J-8080 into the crankshaft oil hole
C. Piston Depression Flat Side B-05256 (figure 36).
Rotate the crankshaft to turn the bearing
Figure 33Pistons Installed insert out of the block.
6A4-20 4.8 LITER L6
Figure 35Removing The Upper Rear Main Bearing Insert
Cleaning, Inspection, And Repair Main bearing cap replacem ent (shim m ing
C le a n , in s p e c t, and re p a ir or re p la ce the procedure).
manual. The unit repair manual contains information Install or Connect (Figures 25, 35, 36, and 37)
on:
Crankshaft. Tool Required:

J-8080-Main Bearing Remover/Installer
1. Upper rear main bearing insert.
A. Forward
B. Feeler Gage
100. Rear Main Bearing Cap
101. Crankshaft B-07878
Figure 36Removing The Upper Main Bearing

Insert Figure 37Measuring Crankshaft End Play
4.8 LITER L6 6A4-21
Apply engine oil to an insert of the proper Install the rear main bearing cap and bolts.
size. Tighten the bolts temporarily to 14 N m (10
Insert the plain end (without the bearing ft. lbs.).
journal and the notched side of the block. Measure
Use pliers with taped jaws to clamp the
bearing to the crankshaft as shown in figure Crankshaft end play, as follows:
35. Rotate the crankshaft to roll the insert Tap the end of the crankshaft first
into the block. Then seat the insert using a rearward then forward with a lead
small drift and hammer. hammer. This will line up the rear main
2. Lower rear main bearing insert. b e a rin g and c ra n k s h a ft th ru s t
Apply engine oil to an insert of the proper surfaces.
size.
Press the insert into the rear main bearing bolts to 90 N m (65 ft. lbs.).
cap.
Insert tool J-8080 into a crankshaft main
bearing oil hole (figure 36).
37). The proper clearance is 0.05-0.15
mm (0.002-0.006-inch).
size.
tang) of the insert between the crankshaft 9. Oil pan, as outlined previously.
and the notched side of the block. 10. Spark plugs.
the block.
Remove the tool. CRANKSHAFT GEAR
4. Lower main bearing inserts to the main bearing REPLACEMENT
caps.
Make sure the inserts are of the proper size. 4-+ Remove or Disconnect (Figure 38)
Apply engine oil to the inserts.
Tool Required:
% Measure J-24420-A Puller.
unit repair manual. If the engine is in the 2. Crankshaft gear. Use J-24220-A (figure 38).
vehicle, the crankshaft must be supported
upward to remove any clearance from the | - n - | Install or Connect (Figures 2 7 and 38)
upper bearing. The total clerance can then
be measured between the lower bearing Tool Required:
and journal. J-5590 Crankshaft Gear Installer.
5. Main bearing caps (except rear cap) and bolts to 1. Crankshaft gear. Use J-5590 (figure 38). Make
the block. Make sure the special bolt which sure the timing mark faces out.
retains the oil pump screen bracket is installed in
the proper position. (#5 main bearing cap,
Im portant
camshaft side hole.)
a Tighten
lbs.).
6. Rear crankshaft oil seal to the block and main OIL FILTER BYPASS
bearing cap, as outlined previously. VALVE REPLACEMENT
7. Rear main bearing cap to the block.
Apply a brush-on type oil sealing compound 4 Remove or Disconnect (Figure 39)
to the mating surface of the block and cap
(figure 25). Do not allow any sealant on 1. Oil filter.
either crankshaft or rear oil seal. 2. Oil filter relief valve. Pry it from the block with a
Apply engine oil to the bearing insert. screwdriver (figure 39).
6A4-22 4.8 LITER L6
1. Oil pressure relief valve. Tap into place. Use a

9/ie-inch thin wall deep socket as a driver (figure
39).
2. Oil filter.
3. Engine oil, as necessary.
- Remove or Disconnect (Figures 30 and 38)
Tools Required:
J-24420-A Puller.
J-5239 Guide Set.
1. Engine, as outlined later.
2. Flywheel (if necessary), as outlined later.
The crankshaft can be removed from the
block without removing the flywheel. If the
flywheel is removed, the dowel holes must
be reamed oversize and oversized dowel
pins installed, as outlined later.
Mount the engine in a suitable engine stand.
3. Spark plugs.
4. Dipstick and tube.
6. Oil pan and oil pump, as outlined previously.
7. C rankshaft tim in g gear (if required). Use
J-24420-A (figure 38).
8. Connecting rod caps. Check the connecting rod
B-05249 necessary. The connecting rod and cap are
mating parts.
Figure 38Replacing The Crankshaft Gear 9. Connecting rods from the crankshaft.
(figure 30).
Use the long guide rod to push the pistons
up in the bores.
10. Main bearing caps. Check the main bearing caps
fo r lo c a tio n m a rkin g s. M ark the p a rts if
necessary. The main bearing caps must be
returned to their original locations at assembly.
11. Crankshaft.
12. Main bearing inserts.
13. Rear crankshaft seal, as outlined previously.
VALVE REMOVAL VALVE INSTALLATIO N
B-03497 Cleaning, Inspection, And Repair
Clean, inspect, and repair or replace the parts as
Figure 39Replacing The Oil Filter outlined in the proper unit repair manual. Refer to
Bypass Valve the unit repair manual for information on:
Crankshaft.
P ro ce d u re s fo r m e a su rin g b e a rin g
clearances.
4.8 LITER L6 6A4-23
Install or Connect (Figures 25, 27, 30, 34, 37, main bearing cap bolts, one pair at a time,
and 38) until the tight bearing is located. Burrs on
Tools Required: insert and the block or the bearing cap, or a
J-5239 Guide Set. faulty insert could cause a lack of clearance
J-5590 Crankshaft Gear Installer. at the bearing.
1. Upper main bearing inserts to the block. Apply 7. Connecting rods to the crankshaft. Use J-5239 to
engine oil to the bearing inserts. pull the connecting rods down (figure 30). Make
2. Crankshaft. sure the connecting rod bearing insert stays in
3. Lower main bearing inserts to the main bearing place.
caps. Apply engine oil to the bearing inserts.
Measure
Measure
Main bearing clearance. Refer to the proper the proper unit repair manual.
unit repair manual. 8 . Connecting rod caps with bearing inserts to the
Main bearing caps (except rear cap) and bolts to connecting rods. Apply engine oil to the inserts.
the block. Make sure the special bolt which 9. Connecting rod cap nuts.
retains the oil pump screen bracket is installed in
the proper position. (#5 main bearing cap, $ Tighten
camshaft side hole.)
Tighten lbs.).
Main bearing cap bolts to 90 N m (65 ft. Measure

lbs.).
5. Rear crankshaft oil seal to the block and main Connecting rod side clearance. Use a feeler
bearing cap, as outlined previously. gage between the connecting rod and
6. Rear main bearing capto the block.
is 0.006-0.017-inch.
Apply a brush-on type oil sealing compound
10. Crankshaft timing gear (if removed). Use J-5590
to the mating surface of the block and cap
(figure 38). Make sure the timing mark faces out.
(figure 25). Do not allow any sealant on
either crankshaft or rear oil seal.
Im portant
Install the rear main bearing cap and bolts.
ft. lbs.).
Measure
13. Spark plugs.
14. Flywheel (if used), as outlined later.
15. Engine, as outlined previously.
rearward then forward with, a lead
hammer. This will line up the rear main FLYWHEEL REPLACEMENT
surfaces. Remove or Disconnect (Figure 40)
bolts to 90 N m (65 ft. lbs.). 1. Transmission, clutch housing, and clutch.
With the crankshaft forced forward, 2. R ear m ain b e a rin g cap. R efer to R ear
measure at the front end of the rear Crankshaft Oil Seal Replacement in this section.
main bearing with a feeler gage (figure Mark the flywheel and crankshaft so the dowel
37). The proper clearance is 0.05-0.15 pin holes can be aligned in their original positions
mm (0.002-0.006-inch). at assembly (figure 40).
Loosen the flywheel bolts a few turns.
I? Inspect 3. Flywheel dowel pins.
Turn the crankshaft so that a dowel pin is at
Crankshaft for binding. Try turning the the 6 oclock position.
crankshaft to check for binding. If the Drive the dowel pin out, using a hammer
crankshaft does not turn freely, loosen the and drift.
6A4-24 4.8 LITER L6
NOTICE: Never heat starter gear to red heat as

this will change metal structure.
2. Uniformly heat the flywheel gear to temperature

3. As soon as the gear has been heated, install on
the flywheel.
1. Flywheel to the crankshaft. Align the marks made

at disassembly. Make sure the dowel holes in the
crankshaft and flywheel are aligned.
2. Flywheel.
Tighten

3. Dowel pins.
The interference fit dowel pins must be
replaced with an oversized dowel pin when
installing the flywheel.
Ream the dowel pin holes to the proper size
(0.4510-0.4517-inch).
Tap the dowl pins into place, flush with the
Figure 40Flywheel Dowel Pin Hole Locations flywheel retaining bolt surface.
4. Rear m ain b e a rin g cap. Refer to Rear
Repeat the preceding steps to drive out the Crankshaft Oil Seal Replacement in this section.
remaining dowel pins. The crankshaft must 5. Transmission, clutch housing, and clutch.
be turned each time so that the pin can be
driven out without contacting the block.
ENGINE MOUNTINGS
4. Flywheel bolts.
NOTICE: Broken or deteriorated mountings
5. Flywheel. can cause m isalig n ed and e ven tu al
When a single mounting breakage occurs, the
a y Clean rem aining m ountings are su b jec te d to
Mating surfaces of crankshaft and flywheel.
Remove any burrs.
INSPECTING ENGINE MOUNTINGS
Inspect Front Engine M ountings

Flywheel for burning, scoring, warping, and wear. mountings and to place a slight tension on the
Replace the flywheel if necessary. Do not rubber cushion. Observe both mountings while
machine the flywheel. raising the engine.
Flywheel ring gear for worn or broken teeth. exist:
check cracks.
Flywheel Ring Gear Replacement
1. Use a torch to heat the gear around the entire Rubber cushion separated from the metal
circum ference, then drive the gear off the plate of the mounting.
flywheel, using care not to damage the flywheel. Rubber cushion split through the center.
4.8 LITER L6 6A4-25
3. If there is movement between a metal plate of the

mounting and its attaching points, lower the
engine and tighten the bolts or nuts attaching the
mounting to the engine, frame, or bracket.
Rear M ountings
1. Push up and pull down on the transmission
tailshaft. Observe the transmission mounting.
exist:
3. If there is relative movement between a metal
the transmission or crossmember.
FRONT MOUNTING REPLACEMENT
|<-+| Remove or Disconnect (Figures 41 through 44)
Support the engine with a suitable lifting fixture.

Do not load the engine mounting.
Figure 41Front Engine Mounting Brackets
1. Engine mounting through-bolt and nut. All Models
Raise the engine only enough to permit removal
of the engine mounting. REAR MOUNTING REPLACEMENT (EXCEPT
P-MODELS WITH FLYWHEEL
HOUSING MOUNTING)
Install or Connect (Figures 41 through 44) 47)

NOTICE: See Notice on page 6A4-1 of this weight on the rear mountings.
section for steps 2 and 3. 1. Mounting to crossmember nut(s) and washer(s).
2. Mounting assembly bolts, nuts, and washers. permit removal of the mounting.
3. Mounting.
$ Tighten
Fasteners to specifications. Refer to figures * l Install or Connect (Figures 45, 46, and 47)
41 through 44.
1. Mounting.
engine until the bolt can be inserted. Install the Lower the rear of the engine.
nut. 2. Mounting to transmission bolts and washers.
Tighten NOTICE: See Notice on page 6A4-1 of this

section.
Through-bolt or nut to specifications. Refer
to figure 41. 3. Mounting to crossmember nut(s) and washer(s).
6A4-26 4.8 LITER L6
A. 40 N-m (30 Ft. Lbs.)

B. Torque Bolt To 48 N-m (36 Ft. Lbs.) Or,
Torque Nut To 40 N-m (30 Ft. Lbs.).
B-07882
Figure 42Front Engine M ountings (C Models)
Tighten
Fasteners to specifications. Refer to figures

45, 46, and 47.
REAR MOUNTING REPLACEMENT (P-MODELS

WITH FLYWHEEL HOUSING MOUNTING
4-+ Remove or Disconnect (Figure 48)
1. Bolt, cushion and spacer.

A. 40 N-m (30 Ft. Lbs.) 2. Mounting.
B. Forward
B-07887 -4- Install or Connect (Figure 48)
1. Mounting. Align the hole in the mounting with the

Figure 43Front Engine Mountings (K Models)
hole in the crossmember.
Lower the rear of the engine.
4.8 LITER L6 6A4-27
MODELS WITH I-BEAM AXLE (RPO-FS3)
MODELS WITHOUT I-BEAM AXLE
A. 40 N m
B. Forward
150. Mounting Assembly
152. Frame Bracket
B. 48 N m (36 Ft. Lbs.) f in --------- B
B-07894 C. Forward
B-07897
Figure 44Front Engine Mountings (P Models)

Figure 46Rear Engine Mounting (K Models)
6A4-28 4.8 LITER L6
MODELS WITH PROPSHAFT PARKING BRAKE
A. Forward
B. 68 N m (50 ft. lbs.
C. 48 N m (36 ft. lbs.
D. 60 N m (44 ft. lbs.
MODELS WITHOUT PROPSHAFT PARKING BRAKE

B-07901
Figure 47Rear Engine Mounting (P Models With Transmission Tail Type Mounting)
4.8 LITER L6 6A4-29
17. Strut rods at engine mountings (4 wheel drive

models).
S upport the tra n sm issio n with a chain or
transmission jac.
18. Bell housing to engine bolts.
19. Engine. Move the engine forward to disengage
the transmission and remove.
I* Install or Connect (Figure 41)
1. Engine. Move the engine rearward to engage the

transmission.
2 . Bell housing to engine bolts. Remove the
transmission jack or support chain.
3. Front engine mounting through-bolts and nuts.
Tighten
Figure 48Rear Engine Mounting (P Models Fasteners to specifications. Refer to figure

With Flywheel Mousing Type Mounting) 41.
Remove the lifting device.
NOTICE: See Notice on page 644-7 of this 4. Strut rods (4 wheel drive models).
section. 5. Torque converter to flywheel bolts (automatic
transmission).
2. Spacer, cushion and bolt. 6. Flywheel cover.
7. Exhaust pipe and new packing to the exhaust
$ Tighten manifold.
8. Starter.
Bolt to 90 N m (65 ft. lbs.). 9. Engine wiring.
10. Vacuum hoses.
11. Fuel lines.
ENGINE REPLACEMENT 12 . Fan and water pump pulley.
13. Transmission detent cable (if used).
The procedure outlined applies specifically to C
14. Accelerator cable.
and K models. Additional steps may be necessary
15. Heater hoses.
on P models depending on body design.
16. Radiator.
17. Air cleaner.
18. Hood.
20 . Proper quantity and grade of coolant.
2. Hood.
3. Air cleaner.
4. Radiator.
5. Heater hoses from the engine.
7. Transmission detent cable (if used).
9. Fuel lines from the fuel pump.
10. Evaporate emission and other vacuum hoses.
11. Engine wiring.
12. Starter.
13. Exhaust pipe at the exhaust manifold. Wire the
pipe out of the way.
14. Flywheel cover.
15. Flywheel to torque converter bolts (automatic
transmission).
Attach a suitable lifting device to the engine.
Remove the weight from the engine mountings.
16. Front engine mounting through-bolts.
6A4-30 4.8 LITER L6
SPECIFICATIONS
GENERAL DATA:
Type In Line
No. Of Cylinders 6
Bore 3.876
Stroke 4.12
Firing Order 1-5-3-6 -2-4
CYLINDER BORE:
Diameter 3.8750-3.8780
Thrust Side 0.0005 (Maximum)
Production
PISTON:
Clearance
PISTON RING:
C Top
o Groove Production 0.0020-0.0040
M 2nd
p niparanrp
R Service Limit Hi Limit Production 0.001
ct
S Top 0.010-0.020
s Production
1 Gap 2nd 0.010-0.020
0
1 Production 0.015-0.055
PISTON PIN:
Diameter 0.9270-0.09273
B-07896
4.8 LITER L6 6A4-31
SPECIFICATIONS

CRANKSHAFT:
All
Diameter
2.2979-2.2994
Taper
Out of Production 0.0002 (Maximum)
#1-#6: 0.0010-0.0024
Main Production #7: 0.0016-0.0035
Bearing
#1-#6: 0.0010-0.0025
Clearance Service Limit #7: 0.0015-0.0035
Diameter 2.099-2.100
Production 0.0005 (Maximum)
Taper
Out Production 0.0005 (Maximum)
Clearance Service Limit 0.0030 (Maximum)
CAMSHAFT:
Lobe Intake 0.2315
Lift 0.002 Exhaust 0.2315
Camshaft Runout 0.020 (Maximum)
VALVE SYSTEM:
Lifter Hydraulic
Intake One Turn Down From Zero Lash
Valve Lash
Exhaust
CO CO
O O
Face Angle (Intake & Exhaust)

I- - -

Intake 0.035-0.060
Seat Width
Exhaust 0.062-0.093
Intake 0.0010-0.0027
Production
Service
Free Length 2.08
Valve Pressure Closed 78-86 lbs. @ 1.66"
Spring lbs. @ in. Open 170-180 lbs. @ 1.26"
(Outer) Installed Height 1 21/3 2
+ 1/ 3 2 "
Valve Free Length 1.94
Spring
Damper Approx. # of Coils 4
B-07898
6A4-32 4.8 LITER L6
Item Nm Ft. Lbs. In. Lbs.
Flywheel Bolts 150 110
Main Bearing Cap Bolts 90 65
Camshaft Thrust Plate Screws 9.0 80
Timing Gear Cover Bolts To Block 9.0 80
Torsional Damper Bolt 70 50
Connecting Rod Cap Nuts 60 44
Oil Pump Bolts 13.0 115
Oil Pump Pickup Tube Bracket Nut (To Main Bearing Cap Bolt) 34 26
Oil Pump Cover Bolts 7.9 70
Oil Pan Bolts (To Front Cover) 5.1 45

(To Block [1/4-20]) 9.0 80
(To Block [5/i 6-18]) 18.6 165
Cylinder Head Bolts (Left-Hand Front Bolt) 115 85
(All Others) 130 95
Rocker Arm Cover Bolts (Cork Gasket) 5.4 58

(Rubber Gasket) 4.3 38
Pushrod Cover Bolts 9.0 80
Water Pump Bolts 20 15
Thermostat Housing To Block Bolts 38 28
Water Outlet to Thermostat Housing Bolts 28 20
Intake Manifold To Exhaust Manifold Bolts And Nuts 60 44
Manifold To Cylinder Head Bolts And Nuts 52 38
Spark Plug 20 15
4.8 LITER L6 6A4-33
SPECIAL TOOLS
J-23590 Air Adapter

J-5892 Spring Compressor
J-9290-01 Hydraulic Lifter Remover (Slide Hammer Type)
J-5715 Reamer (0.003-inch Oversize)
J-6036 Reamer (0.013-inch Oversize)
J-23523-E Torsional Damper Puller And Installer
J-8520 Dial Indicator Adaptor
J-5239 Guide Set
J-24420-A Crankshaft Gear Puller
J-5590 Crankshaft Gear Installer
SMALL BLOCK 6A5-1
SECTION 6A5
SMALL BLOCK
section.
CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 6A5- 2

Engine L u b ric a tio n ............................................................................................................................................... 6A5- 2
intake Manifold R e p la ce m e n t........................................................................................................................... 6A5- 8
Hydraulic L ifte r R e p lace m e n t........................................................................................................................... 6A5- 8
Rocker Arm Stud Replacem ent......................................................................................................................... 6A5-10
Exhaust Manifold Replacem ent......................................................................................................................... 6A5-11
Cylinder Head R e p la ce m e n t..............................................................................................................................6A5-11
Torsional Damper and Front Crankshaft Seal R e p la ce m e n t..................................................................... 6A5-12
Front Cover R ep lace m e n t..................................................................................................................................6A5-13
Oil Pan R eplacem ent...........................................................................................................................................6A5-14
Oil Pump R e p la c e m e n t...................................................................................................................................... 6A5-14
Rear Crankshaft Oil Seal R e p la ce m e n t........................ ..................................................................................6A5-15
Rear Crankshaft Oil Seal Retainer Replacem ent........................................................................................... 6A5-16
Connecting Rod and Piston Replacem ent......................................................................................................6A5-19
Oil Filter Bypass V alve........................................................................................................................................ 6A5-21
Main Bearing R e p lace m e n t................................................................................................................................6A5-21
Crankshaft R eplacem ent.................................................................................................................................... 6A5-22
Engine R e p la c e m e n t.......................................................................................................................................... 6A5-27
S pe cifica tio ns............................................................................................................................................................6A5-34
Special T o o ls ............................................................................................................................................................6A5-36
6A5-2 SMALL BLOCK
DESCRIPTION
Small block engines covered by this manual are ENGINE LUBRICATION

available in two displacements; 5.0L (305 cu. in.) and
5.7L (350 cu. in.). Lubrication schematics are shown in figures 1 and 2.
Small block engines are 90-degree V8 type, over The gear type oil pump is driven from the distributor
head valve, water cooled, with cast iron block and shaft, which is gear driven from the camshaft. Oil is
heads. drawn into the oil pump through a pickup screen and
The crankshaft is supported by five precision insert pipe.
main bearings, with crankshaft thrust taken at the num Pressurized oil is routed to the oil filter. In case of
ber five (rear) bearing. excessive oil pressure, a bypass valve is provided.
The camshaft is supported by five plain type bear Filtered oil flows into the main gallery and then to the
ings and is chain driven. Motion from the camshaft is camshaft and crankshaft bearings. The valve lifter oil
transmitted to the valves by hydraulic lifters, pushrods, gallery supplies oil to the valve lifters. Oil flows from
and ball type rocker arms. The valve guides are inte the hydraulic lifters through the hollow pushrods to the
gral in the cylinder head. rocker arms. Oil from the overhead drains back to the
The connecting rods are forged steel, with precision crankcase through oil drain holes.
insert type crankpin bearings. The piston pins are a The timing chain is drip fed from the front camshaft
press fit in the connecting rods. bearing. The pistons and piston pins are lubricated by
The pistons are cast aluminum alloy. The piston pins oil splash.
are a floating fit in the piston.
SMALL BLOCK 6A5-3
B-07913

6A5-4 SMALL BLOCK

SMALL BLOCK 6A5-5
ON-VEHICLE SERVICE
ROCKER ARM COVER 0 Install or Connect (Figure 3)
REPLACEMENT 1. Rocker arm cover and new gasket.

2. Reinforcements, wire clips, nuts, and special bolt
(7) (if used).
Tighten
2. Engine cover (G models). Nuts to 7.3 N m (65 in. lbs.).
Special bolt (7) (if used) to 6.2 N m (55 in.
3. Air cleaner.
lbs.).
4. Crankcase ventilation hoses at the rocker arm 3. Air co nd itio n ing com pressor rear brace (if
covers. necessary).
5. Wiring harnesses from the rocker arm clips. 4. Heat stove pipe (if removed).
5. Wiring harness support (6) (if used).
6. Wiring harness support (6) (G modelsleft rocker 6. Wiring harnesses to the rocker arm clips.
arm cover). 7. Crankcase ventilation hoses.
7. Heat stove pipe (right side rocker arm cover). 8. Air cleaner.
8. A ir co nd itio n ing com pressor rear brace (if
equipped) (left side rocker arm cover).
9. Rocker arm cover nuts, special bolt (7) (if used),
reinforcements, and wire clips. ROCKER ARM AND PUSHROD
10. Rocker arm cover and gasket. REPLACEMENT
Clean Remove or Disconnect
All traces of old gasket from the rocker arm cover 1. Rocker arm cover, as outlined previously.
and cylinder head. 2. Rocker arm nut.
If only the pushrod is to be replaced, back
1* Inspect the rocker arm nut off until the rocker arm
Rocker arm cover sealing surface for distortion. pull the pushrod out.
Replace if necessary. 3. Rocker arm with ball.
6A5-6 SMALL BLOCK
4. Pushrod.
Im p o rta n t
Store used components in order so they can be

reassembled in the same location.
L* Inspect

These surfaces should be smooth and free from
scoring or other damage.
Rocker arm areas which contact the valve stems
These areas should be smooth and free of
damage and wear.
Pushrods for bending. Roll the pushrod on a flat
necessary.
Ends of the pushrods for scoring or roughness.
Exhaust: 1, 3, 4, 8
0 Insta ll o r C onnect Intake: 1, 2, 5, 7
1. Pushrod. Make sure the pushrod seats properly odd numbered cylinders are in the left bank,
in the hydraulic lifter. when viewed from the rear of the engine).
2. Rocker arm with ball. 4. Back out the adjusting nut until lash is felt at the
Im p ortan t lash is removed. This can be determined by
When new rocker arms and/or balls are nut (figure 4). When the play has been removed,
installed, coat their bearing surfaces with turn the adjusting nut in one full additional turn
Molykote or equivalent. (to center the lifter plunger).
3. Rocker arm nut. 5. Crank the engine one revolution until the timing
tab O mark and vibration damper mark are
A d ju s t again in alignment. This is the number six firing
position the following valves may be adjusted:
Valves as outlined later. Exhaust: 2, 5, 6, 7
Rocker arm cover, as outlined previously. Intake: 3, 4, 6, 8
6. In sta ll the rocker arm cover as o u tlin e d
previously.
VALVE ADJUSTMENT
1. Remove the rocker arm cover as outlined VALVE STEM SEAL AND
previously.
2. Crank the engine until the mark on the vibration
VALVE SPRING REPLACEMENT
damper lines up with the O mark on the timing
Remove or D isconnect (Figures 5 and 6)
position. This may be determined by placing
Tools Required:
the damper comes near the O mark on the
J-23590 Air Adapter.
timing tab. If the rocker arms are not moving, the
engine is in the number one firing position. If the J-5892-A Spring Compressor.
rocker arms move as the mark comes up to the 1. Rocker arm cover, as outlined previously.
timing tab, the engine is in the number six firing 2. Rocker arms, as outlined previously.
position and should be turned over one more time 3. Spark plugs.
to reach the number one position. 4. Valve keepers (20).
3. With the engine in the number one firing position Install J-23590 into the spark plug hole.
as determined above, the following valves may be Apply compressed air to hold the valves in
adjusted: place.
SMALL BLOCK 6A5-7
20. Valve Keeper 26. Spring

21. Cap 27. Intake Valve
22. Shield 28. Rotator
23. O-Ring Seal 29. Exhaust Valve
24. Seal
25. Damper
A 26
29
linn B-07865
Figure 5 Valves A nd C om ponen ts
Install a rocker arm nut (figure 6).

(figure 6).
C a re fu lly release the spring tension.
Remove J-5892-A.
5. Cap (21) and/or rotator (28), shield (22) and
spring (26) with damper (25).
6. O-ring seal (23), and seal (24). Figure 7Testing The Valve Seals
Insta ll o r C onn ect (F igures 5, 6, and 7) 2. Spring (26) with damper (25), shield (22) and cap
(21) and/or rotator (28).
Tools Required: 3. New o-ring seal (23) and valve keepers (20).
J-23590 Air Adapter With air pressure applied to the cylinder
J-5892-A Spring Compressor with J-23590, compress the spring with
J-23738-A Vacuum Pump J-5892-A (figure 6).
1. New seal (24). Install the seal over the valve stem Lubricate the o-ring seal with engine oil.
and seat it against the head. Install the seal on the valve stem. Make sure
the seal is not twisted.
them in place.
J-5892
Carefully release spring pressure. Make
Check each o-ring seal for leakage (figure
7).
J-23590 23738-A over the shield.
Connect J-23738-A to the suction cup
and apply a vacuum. Watch the vac
uum pump gage. No air should be able
to leak past the seal. If the seal will not
hold a vacuum, it may have been dam
B-07868 aged or improperly installed.
4. Spark plugs.
Figure 6Compressing The Valve Springs 5. Rocker arms, as outlined previously.
6A5-8 SMALL BLOCK
A d ju s t front and rear of the block as shown. Extend the

bead 13 mm (1/2 -inch) up each cylinder head to
Valves, as outlined previously. seal and retain the gaskets.
6. Rocker arm cover, as outlined previously. 3. Intake manifold to the engine.
INTAKE MANIFOLD
Tighten
REPLACEMENT
Intake manifold bolts to 48 N m (36 ft. lbs.).
Use the tightening sequence shown in
-- Rem ove o r D isco nn ect figure 9.
5. Carburetor (if removed).
6. Brake booster vacuum pipe.
3. Air cleaner. 7. Air conditioning compressor and bracket (if
Drain the cooling system. equipped). Refer to AIR CONDITIONING (SEC.
1B).
4. AIR crossover hose.
5. Heater hose and upper radiator hose at the intake 8. Distributor. Refer to ENGINE ELECTRICAL (SEC.
manifold. 6D).
6. Generator upper bracket. 9. Accelerator, cruise control, and TV cables, as
7. Vacuum hoses at the intake manifold. equipped.
8. Electrical wiring at the carburetor and intake 10. Fuel line to the carburetor.
manifold. 11. Electrical wiring.
9. Fuel line at the carburetor. 12. Vacuum hoses.
10. Accelerator, cruise control, and TV cables, as 13. Generator upper bracket.
equipped.
14. Heater hose and upper radiator hose.
6D). 15. AIR crossover hose.
12. Air conditioning compressor and bracket (if 16. Air cleaner.
equipped). Refer to AIR CONDITIONING (SEC. 17. Engine cover (G models).
1B). 18. Battery negative cable.
13. Brake booster vacuum pipe. Fill the cooling system with the proper quantity
14. Carburetor. and grade of coolant.
16. Intake manifold.
17. Gaskets. HYDRAULIC LIFTER
REPLACEMENT
Clean
Old gasket and RTV from the block, heads, and Remove o r D isconnect (F igures 10 and 11)
intake manifold. Remove all RTV that is loose or
will cause interference at assembly. Tools Required:
Excessive carbon deposits from the exhaust and J-3049 Hydraulic Lifter Remover (Plier Type)
EGR passages. or
Excessive scale and deposits from the coolant
J-9290-01 Hydraulic Lifter Remover (Slide
passages.
Hammer Type)
I* Inspect
Manifold for cracks and gasket surface damage. 2. Hydraulic lifters.
-4- Install o r C onnect (F igures 8 and 9) and place them in an organizer rack. The
lifters must be installed in the same bore
Gaskets to the cylinder head. from which they were removed.
RTV to the front and rear sealing surfaces on the A stuck hydraulic lifter can be removed
block (figure 8). Apply a 5 mm (3/ie-inch) bead of using J-3049 (figure 10) or J-9290-01 (figure
RTV (part number 1052366 or equivalent) to the 11).
SMALL BLOCK 6A5-9
C. Forward
D. RTV Sealant
B-07915
Figure 8Intake Manifold Installation
Lv Inspect Hydraulic Lifter Repair

mating bore in the block should also be checked. Install or Connect
Check the fit of each hydraulic lifter in its mating 1. Hydraulic lifters to the block. Lubricate the lifter
bore in the block. If the clearance is excessive, try foot and body with Engine Oil Supplement or
a new lifter. equivalent.

B-09569
Figure 9Intake Manifold Bolt Tightening

Sequence Figure 10Removing The Hydraulic Lifter
6A5-10 SMALL BLOCK
A. N u t
B. F la t W a s h e r B-05245
Figure 11Removing The Hydraulic Lifter (Typical) Figure 12Removing The Rocker Arm Stud
Important NOTICE: Do not attempt to install an oversize

rocker arm stud without reaming stud hole as
When only new hydraulic lifters or a new this could damage the cylinder head.
c a m s h a ft is in s ta lle d , E ngine Oil
S upplem ent (or equivalent) should be Ream the hole to the proper size for the
added to the crankcase oil. replacement oversize rocker arm stud. Use
Replace all hydraulic lifters when a new J-5715 for 0.003-inch oversize studs; J-6036 for
camshaft is installed. 0.013-inch oversize studs (figure 13).
2. Intake manifold, as outlined previously. Coat lower end (press-fit area) of rocker arm stud
3. Pushrod, as outlined previously. with hypoid axle lubricant.
1. Rocker arm stud. Use J-6880 (figure 14). Stud is
Adjust installed to proper depth when the tool bottoms
Valves, as outlined previously. 2. Rocker arm, as outlined previously.
Adjust
ROCKER ARM STUD Valves, as outlined previously.

REPLACEMENT 3. Rocker arm cover, as outlined previously.
Tool Required:
1. Rocker arm cover and rocker arm, as outlined
previously.
2. Rocker arm stud.
Install a nut and flat washer.
Turn the nut to remove the stud (figure 12).
4- Install or Connect (Figures 13 and 14)
Tools Required:
J-5715 Reamer (0-003-inch oversize) or
J-6880 Rocker Arm Stud Installer Figure 13Reaming The Rocker Arm Stud Bore
SMALL BLOCK 6A5-11
Ijjjl Clean
Mating surfaces on the manifold and head.

Install or Connect
1. Exhaust manifold to the cylinder head.

2. Exhaust manifold fasteners and spark plug heat
shields (where used).
Cast manifolds: Install the flat washers
against the manifold, then the tab washers
and bolts.
Tighten
Two center bolts to 36 N-m (26 ft. lbs.).

Outside bolts to 28 N m (20 ft. lbs.).
Bend the tab washers against the bolt
heads.
Tubular (stainless steel) manifolds: Install
the bolts and flat washers.

3. AIR bracket at the manifold stud (left side
manifold).
5. Oxygen sensor wire (if used).
EXHAUST MANIFOLD
Raise the vehicle.
REPLACEMENT 6. Exhaust pipe.
Lower the vehicle.
7. Engine cover.
2. Engine cover (G models). CYLINDER HEAD
Raise the vehicle. REPLACEMENT
3. Exhaust pipe at the manifold.
Lower the vehicle.
4. Oxygen sensor wire (if used) (left side manifold).
0 Remove or Disconnect
Do not remove the oxygen sensor unless 1. Battery negative cable.

replacement is required. 2. Engine cover (G models).
5. AIR hose at the check valve. Drain the cooling system.
6. AIR pipe bracket at the manifold stud (left side 3. Intake manifold, as outlined previously.
manifold). 4. Generator, and lay aside.
7. Exhaust manifold bolts, washers, tab washers
6. Air conditioning compressor and front bracket (if
and spark plug heat shields, as equipped.
equipped). Lay the compressor aside.
Cast manifolds are retained by bolts, tab 7. Rocker arm cover, as outlined previously.
washers, and plain washers. Remove the
8. Spark plugs.
outside bolts first, then the center bolts.
9. Pushrods, as outlined previously.
Tubular (stainless steel) m anifolds are 10. Cylinder head bolts.
retained by bolts and plain washers. 11. Cylinder head.
8. Exhaust manifold. 12. Head gasket.
6A5-12 SMALL BLOCK
0 r '" . 0
0 0
^
00000000
B-09572
Figure 15Cylinder Head Bolt Tightening

Sequence
y | Clean
Figure 16Removing The Torsional Damper
Carbon deposits from combustion chambers.
All traces of old head gasket from cylinder head f t Adjust
and block.
Cylinder head bolt threads and threads in the Valves, as outlined previously.
block. 5. Rocker arm cover, as outlined previously.
6. Spark plugs.
L* Inspect 7. Air conditioning compressor and front bracket (if
equipped).
Sealing surfaces of the block and cylinder head 8. Exhaust manifold, as outlined previously.
for nicks, heavy scratches, or other damage.
9. Generator.
Refer to the proper Unit Repair Manual. 11. Engine cover (G models).
-- Install or Connect (Figure 15) Fill the cooling system with the proper quantity
and grade of coolant.
1. Head gasket.
the gasket with sealer. Spread the sealer
thin and even. FRONT CRANKSHAFT SEAL
Do not use se a le r on c o m p o s itio n REPLACEMENT
seal-asbestos gaskets.
"* Remove or Disconnect (Figure 16)
with the bead up.
2. Cylinder head. Carefully guide the cylinder head Tool Required:
into place over the dowel pins and gasket. J-23523-E Torsional Damper Puller and
3. Cylinder head bolts. Coat threads of the cylinder Installer
head bolts with sealing compound (GM part 1. Fan belts, fan, and pulley.
number 1052080 or equivalent) and install
finger-tight.
3. Accessory drive pulley.
Tighten 4. Torsional damper bolt.
5. Torsional damper. Use J-23523-E (figure 16).
Cylinder head bolts, a little at a time, using 6. Front crankshaft seal. Pry out with a large
the sequence shown in figure 15. Proper screwdriver. Take care not to distort the timing
torque is 90 N m (65 ft. lbs.). cover.
4. Pushrods, as outlined previously. 7. Crankshaft key, if necessary.
SMALL BLOCK 6A5-13


the stud fu lly into the tapped hole in the
crankshaft.
crankshaft key.
Turn the nut to pull the vibration damper into
place.
Remove the tool.
L* Inspect
$ Tighten
Oil seal contact area on the torsional damper
shaft for grooving and roughness. Replace if Bolt to 95 N m (70 ft. lbs.).
necessary. 7. Accessory drive pulley.
El Install or Connect (Figures 17 and 18) 9. Fan pulley, fan, and fan belts.
Tools Required:
FRONT COVER REPLACEMENT
J-23042-A Seal Installer

Installer 0 Remove or Disconnect
1. Crankshaft key, if removed. 1. Torsional damper, as outlined previously.
2. Front crankshaft seal. Use J-23042-A (figure 17). 2. Water pump.
The open end of the seal faces inside the engine. 3. Front cover bolts.
Coat the seal lips with engine oil. 4. Front cover.
5. Front cover to block gasket.
6. Front crankshaft seal from the front cover. Pry out
with a screwdriver. Take care not to distort the
front cover.
Clean
Old gasket from the front cover and block.
I? Inspect
Exposed portion of the one-piece oil pan gasket

that contacts the front cover. Inspect for cracks,
tears, heat checking, and deterioration. If the
A. Installation Stud
gasket is in good condition, it can be re-used. If it
B. Nut
is unsuitable for reuse, the oil pan gasket should
C. Washer and Bearing B-07880 be replaced.
Figure 18Installing The Torsional Damper necessary.
6A5-14 SMALL BLOCK

Tool Required:
J-23042-A Seal Installer
1. Front crankshaft seal. Use J-23042-A (figure 19).
The open end of the seal faces inside the engine.
2 . Front cover gasket to the front cover. Use gasket
cement to hold it in place.
against the oil pan until the block dowel pins align
against the block so that the dowels enter the
cover holes without binding. Do not force the
cover over the holes. Do not distort the cover
flange or dowel pin holes. Hold the front cover in
this position and install the front cover to block
bolts.
Tighten Im portant
Front cover to block bolts to 11.3 N m (100 Only a small amount of sealant is required.
in. lbs.). Excessive amounts of sealant may prevent
4. Water pump. proper sealing of the oil pan.
5. Torsional damper, as outlined previously. 2. Oil pan gasket to the oil pan.
3. Oil pan to the engine.
OIL PAN REPLACEMENT
Tighten
A one piece type oil pan gasket is used.
Oil pan bolts to 11.3 N-m (100 in. lbs.).
Oil pan nuts to 22.6 N-m (200 in. lbs.).
5. Strut rods at the engine mount (K models with
automatic transmissions).
6. Flywheel/torque converter cover.
Raise the vehicle. 7. Exhaust crossover pipe.
Drain the engine oil. Lower the vehicle.
2. Exhaust crossover pipe. 8. Proper quantity and grade of engine oil.
3. Flywheel/torque converter cover. 9. Battery negative cable.
4. Strut rods at the engine mountings (K models
with automatic transmissions).
6. Oil pan and gasket.
j ] Clean
Gasket surfaces on the engine and oil pan. 2. Nuts (73) (if equipped).
3. Bolt (72).
I? Inspect 4. Oil pump (70) and baffle (71) (if equipped).
Oil pan gasket for damage. Replace if necessary. L* Inspect
-- Install or Connect (Figure 20) Oil pump pickup tube for looseness. If the tube is
loose in the oil pump body, replace it, as outlined
1. A small amount of RTV sealant (GM part number in the proper unit repair manual. A loose pickup
1052751 or equivalent) to the front and rear tube can result in an air leak and loss of oil
corners of the oil pan. pressure.
SMALL BLOCK 6A5-15
B-07885
Figure 21Seal Removal Notches
Oil Pump Repair

4- Install or Connect (Figure 20)

73 pump shaft with the tang on the distributor shaft.
74 The oil pump should slide easily into place. No
i
i gasket is used.
2. Baffle (71) (if equipped) and bolt (72).
Tighten
Bolt (72) to 90 N m (65 ft. lbs.).

3. Nuts (73) (if equipped).
Tighten
Nuts (73) to 36 N m (26 ft. lbs.).

4 Oil pan, as outlined previously.
REAR CRANKSHAFT OIL SEAL

REPLACEMENT
70. Oil Pump 1. Transmission.

71. Baffle (Some 5.7L Engines) 2. Clutch and flywheel or flexplate, as equipped.
72. Bolt
73. Nut (Some 5.7L Engines)
NOTICE: Care should be taken when removing
74. Gasket the rear crankshaft oil seal so as not to nick
75. Reinforcement the crankshaft sealing surface.
B-07916
Figure 20Oil Pan Installation the notches provided in the seal retainer and pry
the seal out (Figure 21).
6A5-16 SMALL BLOCK
Tool Required:
J-35621 Seal Installer
1. Rear crankshaft oil seal (figure 22).
Lubricate the inner and outer diameter of
the seal with engine oil.
Install the seal on J-35621.
Position J-35621 against the crankshaft.
Thread the attaching screws into the tapped
holes in the crankshaft.
T ig h te n the scre w s s e c u re ly w ith a
screwdriver. This will ensure that the seal is
installed squarely over the crankshaft.
Turn the handle until it bottoms.
Remove J-35621.
3. Transmission.
REAR CRANKSHAFT OIL SEAL MEASURING CHAMSHAFT

RETAINER REPLACEMENT LOBE LIFT
Tool Required:
Remove or Disconnect (Figures 21 and 23).
1. Transmission.
2. Clutch and flywheel or flexplate, as equipped. 1. Remove the rocker arm as outlined previously.
2. Refer to figure 24. Position the dial indicator (part
4. Screws (84).
of J-8520) so the plunger rests on the pushrod
end, as shown. Make sure the pushrod is in the
6. Gasket (83).
lifter socket.
the notches provided in the seal retainer and pry 3. Rotate the crankshaft slowly in the direction of
the seal out (figure 21). normal rotation until the lifter is on the heel of the
cam lobe. At this point, the pushrod will be in its
? | Clean lowest position.
Gasket surfaces on block and seal retainer.
* Install or Connect (Figure 23)
Whenever the seal retainer is removed, a new

retainer gasket and rear crankshaft oil seal must
be installed.
1. Gasket (83) to the block. It is not necessary to use
sealant to hold the gasket in place.
3. Screws (84).
A. Rear Of Block
Tighten
81. Seal Retainer
82. Crankshaft
Screws (84) to 15.3 N m (135 in. lbs.).
83. Gasket
5. Rear cra n ksha ft oil seal (80) as o utline d 84. Screw B-07888
previously.
6. Clutch and flywheel or flexplate, as equipped. Figure 23Rear Crankshaft Oil Seal Retainer
7. Transmission. Installation
SMALL BLOCK 6A5-17
4. Set dial indicator on zero, then rotate the

crankshaft slowly, or attach an auxiliary starter
switch and bump the engine over, until the
pushrod is in fully raised position.
Im portant
Whenever the engine is cranked remotely at

the starter, with a special jumper cable or
other means, the distributor primary lead
should be disconnected from the distributor
(coil).
5. Compare the total lift recorded from the dial
indicator with specifications.
6. If camshaft readings for all lobes are within
specifications, remove dial indicator assembly.
7. Install the rocker arm and adjust the valves as
previously outlined.
CAMSHAFT REPLACEMENT
4- + Remove or Disconnect (figures 25, 26, and 27)

Tool Required:
3. Air cleaner.
4. Grille (G models).
5. Air conditioning condenser from its mounting and
swing it forward (G models).
6. Fan, shroud, and radiator. Refer to ENGINE
COOLING (SEC. 6B).
7. Generator.
8. Rocker arm covers, as outlined previously.
9. Fuel line.
10. Water pump. Refer to ENGINE COOLING (SEC. Figure 26Replacing The Crankshaft Sprocket
6B).
6A5-18 SMALL BLOCK
Install two or three 5/ie-18 bolts 100-125

mm (4-5 inches) long into the camshaft
threaded holes. Use these bolts to handle
the camshaft (figure 27).
Pull the camshaft from the block. Use care
to p re ve n t dam age to the ca m s h a ft
bearings.
Cleaning Inspection and Repair

repair manual.
Install or Connect (Figures 25 through 27 and

35 through 38)
Tool Required:
B-07892 1. Two or three 5/ie-18 bolts 100-125 mm (4-5

inches) long into the camshaft threaded holes.
Use these bolts to handle the camshaft.
camshaft bearings.
12. Front cover, as outlined previously.
Lower the engine.
6D). 3. Engine mount through-bolts.
15. Pushrods and hydraulic lifters, as outlined S i Tighten
previously.
16. Fuel pump and pushrod. Through-bolts to specifications. Refer to
Align the timing marks (figure 25). figures 35 through 38.
17. Camshaft sprocket bolts. 4. Crankshaft sprocket (if removed). Use J-5590
18. Cam shaft sprocket and tim ing chain. The (figure 26). Make sure the timing mark faces
sprocket is a lig h t in te rfe re n ce fit on the outside.
camshaft. Tap the sprocket on its lower edge to 5. Camshaft sprocket and timing chain.
loosen it.
19. Crankshaft sprocket (if required). Use J-5825 Im portant
(figure 26).
20. Front engine mounting through bolts. Line up the timing marks on the camshaft
sprocket and crankshaft sprocket (figure
NOTICE: When raising or supporting the en 25).
gine for any reason, do not use a jack under 6. Camshaft sprocket bolts.
the oil pan, any sheet metal or crankshaft pul
ley. Due to the small clearance between the
oil pan and the oil pump screen, jacking
against the pump screen, resulting in a dam
aged oil pickup unit. 7. Fuel pump and pushrod.
8. Hydraulic lifters and pushrods, as outlined
21. Camshaft previously.
SMALL BLOCK 6A5-19
Im portant
Replace all hydraulic lifters and add GM

Engine Oil Supplement (or equivalent) to
the engine oil whenever a new camshaft is
installed.
/> Adjust

6D).
13. Water pump. Refer to ENGINE COOLING (SEC.
6B).
14. Fuel line.
16. Generator.
COOLING (SEC. 6B).
18. Air conditioning condenser (G models).
19. Grille (G models).
20. Air cleaner.
Fill the cooling system with the proper quantity Figure 28Replacing The Piston and
and grade of coolant. Connecting Rod

CONNECTING ROD AND (figure 28).
PISTON REPLACEMENT connecting rod and piston out of the bore.
Cleaning, Inspection, and Repair
Tool Required: Clean, inspect and repair or replace the components
J-5239 Guide Set as necessary. Measure connecting rod bearing
Cylinder head, as outlined previously.
Oil pan, as outlined previously.
The unit repair manual contains information on:
Oil pump, as outlined previously (if necessary).
Ridge or deposits from the upper end of the
cylinder bores. Piston rings.
Turn the crankshaft until the piston is at Connecting rod and crankpin.
BDC. Cylinder bores.
Perform the cutting operation with a ridge +4- Install or Connect (Figures 28 through 31)
reamer.
Turn the crankshaft until the piston is at Tools Required:
TDC. J-5239 Connecting Rod Guide Set
Remove the cloth and cuttings. J-8037 Ring Compressor
5. Connecting rod cap. Check the connecting rod Make sure the cylinder walls are clean. Lubricate
and cap for identification marks. Mark the parts if the cylinder wall lightly with engine oil.
required. The connecting rod and cap must be Make sure the piston is installed in the matching
kept together as mating parts. cylinder.
6. Connecting rod and piston. 1. Connecting rod bearings.
6A5-20 SMALL BLOCK
o
o
B-04580
C. Notch In Piston
D. Oil Ring Spacer Gap Figure 31Measuring Connecting Rod Side
(Tang In Hole Or Slot W ith Arc) Clearance
E. Top Compression Ring Gap B-07895
Locate the piston ring end gaps as shown in
figure 29. Lubricate the piston and rings.
Figure 29Piston Ring End Gap Locations
Be certain that the bearings are of the
proper size. (figure 30).
Install the bearings in the connecting rod
notch in the piston faces the front of the
and connecting rod cap.
engine (figure 29).
Lubricate the bearings with engine oil. Place the piston in its matching bore. The
2. Piston and connecting rod to the proper bore. connecting rod bearing tang slots must be
With the connecting rod cap removed, on the side opposite the camshaft. Using
install J-5239 onto the connecting rod studs. light blows with a hammer handle, tap the
J-5239 (figure 28). Hold the ring compressor
against the block until all rings have entered
the cylinder bore.
Remove J-5239 from the connecting rod
bolts.
Important
Each connecting rod and bearing cap should be

marked, beginning at the front of the engine.
Cylinders 1, 3, 5 and 7 are the left bank and, 2, 4,
6, and 8 are the right bank. The numbers on the
connecting rod and bearing cap must be on the
same side when installed in the cylinder bore. If a
connecting rod is ever transposed from one block
or cylinder to another, new connecting rod
bearings should be fitted and the connecting rod
should be numbered to correspond with the new
cylinder number.
Measure

SMALL BLOCK 6A5-21
Q Tighten Tighten
Connecting rod cap nuts to 60 N m (45 ft. Bolts (94) to 26 N m (20 ft. lbs.).
lbs.). 3. Oil filter.
4. Engine oil, as needed.
Measure
Connecting rod side clearance. Use a feeler MAIN BEARING

gage between the connecting rods (figure REPLACEMENT
31). The c o rre c t c le a ra n c e is
0.006-0.014-inch.
5. Oil pump (if removed), as outlined previously. + + Remove or Disconnect (Figure 33)
Tool Required:
OIL FILTER BYPASS VALVE 1. Spark plugs.
Remove or Disconnect (Figure 32) 3. Oil pump, as outlined previously.
Oil filter. Check the main bearing caps for location
Inspect caps must be returned to their original
locations during assembly.
Bypass valve spring and valve disc for 5. Lower main bearing inserts from the main
proper operation, cracks, and damage. If bearing caps.
replacement is needed, the oil filter bypass 6. Upper main bearing inserts.
valve (93) must be replaced, as follows: Insert J-8080 into the crankshaft oil hole
Bolts (94). (figure 33).
Oil filter bypass valve. Rotate the crankshaft to turn the bearing
I
insert out of the block.
Clean
Valve chamber in the block. C le a n , in s p e c t, and re p a ir or re p la c e the
Install or Connect (Figure 32) manual. The unit repair manual contains information
on
Oil filter bypass valve (93). Crankshaft.
Bolts (94). Main and connecting rod bearings.
6A5-22 SMALL BLOCK
Tighten
Main bearing cap bolts to specifications.

Outer bolts on #2, #3, and #4 main
bearing caps: 95 N-m (70 ft. lbs.).
All others: 110 N m (80 ft. lbs.).
4. Rear main bearing cap and bolts.
$ Tighten
Rear main bearing cap bolts temporarily to

14 N-m (10 ft. lbs.).
A. Forward
B. Feeler Gage Measure
100. Rear Main Bearing Cap
101. Crankshaft B-07878 Crankshaft end play, as follows:
Figure 34Measuring Crankshaft End Play
Main bearing cap replacem ent (shim m ing surfaces.
procedure). Tighten the rear main bearing cap
bolts to 110 N-m (80 ft. lbs.).
Install or Connect (Figures 33 and 34) With the crankshaft forced forward,
Tool Required: main bearing with a feeler gage (figure
J-8080 Main Bearing Remover/Installer 34). The p ro p e r cle a ra n c e is
0.002-0.006-inch.
1. Upper main bearing inserts. If correct end play cannot be obtained,
Insert tool J-8080 into a crankshaft main be certain that the correct size rear
bearing oil hole (figure 33). main bearing has been installed.
Production engines may have rear
main bearings that are 0.008-inch
size.
wider across the thrust faces than
Insert the plain end (without the bearing standard. Refer to the proper unit
tang) of the insert between the crankshaft repair manual for more information.
and the notched side of the block. 8. Oil pump, as outlined previously.
Rotate the crankshaft to roll the insert into 9. Oil pan, as outlined previously.
the block. 10. Spark plugs.
Remove the tool.
2. Lower main bearing inserts to the main bearing CRANKSHAFT REPLACEMENT
caps.
Make sure the inserts are of the proper size.
Tool Required:
Measure J-5239 Guide Set
Main bearing clearance. Refer to the proper 2. Flywheel (if used) as outlined later.
unit repair manual. If the engine is in the Mount the engine in a suitable engine stand.
vehicle, the crankshaft must be supported 3. Spark plugs.
upward to remove any clearance from the 4. Torsional damper, as outlined previously.
upper bearing. The total clearance can then 5. Front cover, as outlined previously.
be measured between the lower bearing 6. Camshaft sprocket and timing chain.
and journal. 7. Oil pan and oil pump, as outlined previously.
3. Main bearing caps (except rear cap) and bolts to 8. Rear crankshaft oil seal retainer, as outlined
the block. previously.
SMALL BLOCK 6A5-23
9. Connecting rod caps. Check the connecting rod Measure

necessary. The connecting rod and cap are Crankshaft end play, as follows:
mating parts.
10. Connecting rods from the crankshaft.
Attach J-5239 to the connecting rod bolts hammer. This will line up the rear main
(Figure 28). b e a rin g and c ra n k s h a ft th ru s t
Use the long guide rod to push the pistons surfaces.
up in the bores.
11. Main bearing caps. Check the main bearing caps
for lo c a tio n m a rkin g s. M ark the p arts if
necessary. The main bearing caps must be With the crankshaft forced forward,
returned to their original locations at assembly. measure at the front end of the rear
12. Crankshaft. main bearing with a feeler gage (figure
13. Main bearing inserts. 34). The p ro p e r cle a ra n c e is
0.002-0.006-inch.
Cleaning, Inspection, and Repair If correct end play cannot be obtained,
Clean, inspect, and repair or replace the parts as be certain that the correct size rear
outlined in the proper unit repair manual. Refer to main bearing has been installed.
the unit repair manual for information on: Production engines may have rear
Crankshaft. main bearings that are 0.008-inch
Main and connecting rod bearings. wider across the thrust faces than
standard. Refer to the proper unit
P ro c e d u re s fo r m e a su rin g b e a rin g
repair manual for more information.
clearances.
Install or Connect (Figures 25, 28, 31, and 34) L* Inspect
Tool Required: Crankshaft for binding. Try turning the

J-5239 Guide Set crankshaft to check for binding. If the
crankshaft does not turn freely, loosen the
1. Upper main bearing inserts to the block. Apply
engine oil to the main bearings.
until the tight bearing is located. Burrs on
2. Crankshaft. the bearing cap, foreign matter between the
3. Lower main bearing inserts to the main bearing insert and the block or the bearing cap, or a
caps. Apply engine oil to the bearing inserts. faulty insert could cause a lack of clearance
at the bearing.
Measure
6. Connecting rods to the crankshaft. Use J-5239 to
pull the connecting rods down (figure 28). Make
sure the connecting rod bearing insert stays in
unit repair manual.
place.
4. Main bearing caps (except rear cap) and bolts to
the block.
Measure

Main bearing cap bolts to specifications. the proper unit repair manual.
Outer bolts on #2, #3, and #4 main 7. Connecting rod caps with bearing inserts to the
bearing caps: 95 N m (70 ft. lbs.). connecting rods. Apply engine oil to the inserts.
All others: 110 N m (80 ft. lbs.).
5. Rear main bearing cap and bolts to the block.
Tighten
Rear main bearing cap bolts temporarily to Connecting rod cap nuts to 60 N m (45 ft.
14 N m (10 ft. lbs.). lbs.).
6A5-24 SMALL BLOCK
Measure Install or Connect
Connecting rod side clearance. Use a feeler 1. Flywheel.

gage between the connecting rods (figure 2. Flywheel bolts.
31). The correct clearance is 0.006-0.014-
inch. Tighten
9. Rear oil seal retainer with new crankshaft rear oil
seal, as outlined previously. Flywheel bolts to 100 N m (75 ft. lbs.).
10. Camshaft sprocket and timing chain 3. Clutch, flywheel housing, and transmission.
Im portant
ENGINE MOUNTINGS
11. Front cover, as outlined previously. NOTICE: Broken or deteriorated mountings
12. Oil pan and oil pump, as outlined previously. can cause m isalig n ed and e ve n tu a l
13. Torsional damper, as outlined previously. destruction of certain drive train components.
14. Spark plugs. When a single mounting breakage occurs, the
rem aining m ountings are su b jec te d to
15. Flywheel (if used), as outlined later.
INSPECTING ENGINE MOUNTINGS

FLYWHEEL REPLACEMENT
Front Engine Mountings
+ + Remove or Disconnect NOTICE: When raising or supporting the

engine for any reason, do not use a jack under
1. Transmission, flywheel housing, and clutch. the oil pan, any sheet metal or crankshaft
2. Flywheel bolts. pulley. Due to the small clearance between
3. Flywheel. the oil pan and the oil pump screen, jacking
131 Clean
against the pump screen, resulting in a
damaged oil pickup unit
Mating surfaces of crankshaft and flywheel.
Remove any burrs.
rubber cushion. Observe both mountings while
1? Inspect raising the engine.
Flywheel for burning, scoring, warping, and wear. exist:
Replace the flywheel if necessary. Do not
machine the flywheel.
check cracks.
Flywheel ring gear for worn or broken teeth. Rubber cushion separated from the metal
Flywheel Ring Gear Replacement Rubber cushion split through the center.
1. Use a torch to heat the gear around the entire 3. If there is movement between a metal plate of the
circum ference, then drive the gear off the mounting and its attaching points, lower the
flywheel, using care not to damage the flywheel. engine and tighten the bolts or nuts attaching the
NOTICE: Never heat starter gear to red heat as
this will change metal structure. Rear Mountings
2. Uniformly heat the flywheel gear to temperature tailshaft. Observe the transmission mounting.
which will expand the gear to permit installation. 2. Replace the mounting if the following conditions
Temperature must not exceed 204C (400F). exist:
3. As soon as the gear has been heated, install on Rubber cushion separated from the metal
the flywheel. plate of the mounting.
S M A LL BLO CK 6A5-25
Mounting bottomed out (tailshaft can be REAR MOUNTING REPLACEMENT (EXCEPT

moved up but not down). P-MODELS WITH FLYW HEEL HOUSING
3. If there is relative movement between a metal MOUNTING)
tighten the bolts or nuts attaching the mounting to Rem ove o r D isconnect (Figures 39 th ro u g h 42)
the transmission or crossmember.
FRONT MOUNTING REPLACEMENT

R em ove o r D isco n n e ct (F igures 35 th ro u g h 38) the oil pan, any sheet metal or crankshaft
NOTICE: When raising or supporting the against the oil pan may cause it to be bent
engine for any reason, do not use a jack under against the pump screen, resulting in a
the oil pan, any sheet metal or crankshaft damaged oil pickup unit
the oil pan and the oil pump screen, jacking Support the rear of the engine to relieve the
against the oil pan may cause it to be bent weight on the rear mountings.
against the pump screen, resulting in a 1. Mounting to crossmember nut(s) and washer(s).
Support the engine with a suitable jack. Do not permit removal of the mounting.
load the engine mounting. 3. Mounting.
1. Engine mounting through-bolt and nut. -+ Install o r C onnect (F igures 39 th ro u g h 42)
NOTICE: Raise the engine only enough for 1. Mounting.

sufficient clearance. Check for interference Lower the rear of the engine.
between the rear of the engine and the dash 2. Mounting to transmission bolts and washers.
panel which could cause distributor housing
damage. NOTICE: See Notice on page 6A5-1 of this
section.
of the engine mounting. 3. Mounting to crossmember nut(s) and washer(s).
3. Mounting assembly. T ighten
+- In stall o r C onnect (F igures 35 th ro u g h 38) Fasteners to specifications. Refer to figures

39 through 42.
REAR MOUNTING REPLACEMENT
(P MODELS WITH FLYWHEEL
NOTICE: See Notice on page 6A5-1 of this
HOUSING MOUNTING)
section.
Rem ove o r D isco n n e ct (Figure 43)
1. Bolt, cushion, and spacer.
T ig h te n
Fasteners to specifications. Refer to figures engine for any reason, do not use a jack under
35 through 38. the oil pan, any sheet metal or crankshaft
3. Engine mount through-bolt and nut. Lower the pulley. Due to the small clearance between
engine until the bolt can be inserted. Install the the oil pan and the oil pump screen, jacking
nut. against the oil pan may cause it to be bent
T ig h te n damaged oil pickup unit.
Through-bolt nut to specifications. Refer to Raise the rear of the engine only enough to
figures 35 through 38. permit removal of the mounting.
6A5-26 SMALL BLOCK
A. Forward
B. 40 N m (30 Ft. Lbs.)
C. Torque Bolt To 115 N m (85 Ft. Lbs.) Or, Torque Nut
To 75 N m (55 Ft. Lbs.)
D. 48 N m (36 Ft. Lbs.)
E. Torque Bolt To 48 N m (36 Ft. Lbs.) Or, Torque Nut To 40 N m (30 Ft. Lbs.)
150. Transmission Strut Bracket (Automatic Transmission) Or Spacer (Manual Transmission)
B-07917
Figure 35Front Engine Mounting (C Models)

SMALL BLOCK 6A5-27
ENGINE REPLACEMENT
C AND K MODELS

2. Hood.
3. Air cleaner.
4. All accessory drive belts.
6. R a d ia to r and sh ro u d . R efer to ENG INE
COOLING (SEC. 1B).
7. Heater hoses at the engine.
8. Accelerator, cruise control, and detent linkage (if
used) from carburetor.
9. Air conditioning compressor (if used) and lay
aside.
10. Power steering pump (if used) and lay aside.
11. Engine wiring harness from the engine.
12. Fuel line at the fuel pump.
13. Vacuum lines from the intake manifold.
Raise the vehicle.
Drain the crankcase oil.
14. Exhaust pipes from the manifolds.
15. Strut rods at the engine mountings ( K models
C D with automatic transmission).
16. Flywheel or torque converter underpan.
A. 40 N m (30 Ft. Lbs.) 17. Wiring along oil pan rail.
B. Forward 18. Starter.
C. Torque Bolt To 115 N-m (85 Ft. Lbs.) Or, Torque 19. Wiring for fuel gage.
Nut To 75 N-m (55 Ft. Lbs.) 20. Converter to flex plate bolts.
D. 48 N-m (36 Ft. Lbs.) Lower the vehicle.
B-07918
Figure 36Front Engine Mounting (K Models) 21. Bell housing to engine bolts.
22. Front engine mounting to frame bolts.
2. Engine mounting. 23. Engine.
4- Install or Connect (Figures 35 and 36)

1. Engine mounting. Align the hole in the mounting Raise the vehicle.
with the hole in the crossmember.
Lower the engine. section.
2. Front engine mounting to frame bolts.

section. Tighten
2. Spacer, cushion, and bolt. Fasteners to specifications. Refer to figures

35 and 36.
3. Bell housing to engine bolts. Remove the
Tighten transmission support.
4. Converter to flex plate bolts.
Bolt to 90 N-m (65 ft. lbs.). 5. Fuel gage wiring.
6A5-28 SMALL BLOCK
A. Forward
B. Torque Bolt To 100 N m (75 Ft. L b s .) Or, Torque Nut To 48 N m (36
C. 48 N m (36 Ft. Lbs.)
D. Torque Bolt To 52 N m (38 Ft. Lbs.) Or, Torque Nut To 40 N m (30 Ft. Lbs.)
E. Torque Bolt Or Nut to 40 N m (30 Ft. Lbs.)
150. Spacer OR Power Steering Pump Bracket (Left Side Only) B-07919
6. Starter. G MODELS
7. Wiring along oil pan rail.
8. Flywheel or torque converter underpan.
9. Strut rods at the engine mountings (K models 1. Battery negative cable.
with automatic transmission). Drain the cooling system.
2. Coolant reservoir bottle.
10. Exhaust pipes to the manifolds.
3. Grille and lower grille valance.
Lower the vehicle. 4. Upper radiator support.
11. Vacuum lines to the intake manifold. 5. Air conditioning condenser. Refer to AIR CONDI
TIONING (SEC. 1B).
12. Fuel line at the fuel pump.
13. Engine wiring harness. 7. Power steering pump, and lay aside.
14. Power steering pump (if used). 8. Engine cover.
9. Air cleaner.
15. Air conditioning compressor (if used).
10. Carburetor.
16. Accelerator, cruise control, and detent linkages. 11. Engine wiring harness from the conductor on the
17. Heater hoses. dash panel.
12. Vacuum hoses and electrical wiring, as required.
18. R a d ia to r and sh ro u d . R efer to ENG INE
13. Heater hoses at the engine.
COOLING (SEC. 1B).
14. Thermostat housing.
19. Accessory drive belts. 15. Oil filler tube.
20. Air cleaner. 16. Cruise control servo, bracket, and transducer (if
equipped).
21. Hood.
Raise the vehicle.
22. Proper q uantity and grade of coolant and 17. Exhaust pipes at the exhaust manifolds.
crankcase oil.
18. Propeller shaft at the transmission. Plug the
23. Battery negative cable. transmission end.
SMALL BLOCK 6A5-29
A. Front
B. 100 N m (75 Ft. Lbs.)
C. 48 N m (36 Ft. Lbs.)
D. 40 N m (30 Ft. Lbs.) B
MODELS WITHOUT I-BEAM AXLE MODELS WITH I-BEAM AXLE (RPO-FS3)

B-07920
19. Transmission shift linkage and speedometer 24. Front engine mounting frame brackets. Raise the
cable. engine slightly to allow removal of the mounting
20. Fuel and vapor return hoses at the engine. bracket. Block the engine in place with wood
Drain the engine oil. blocks.
21. Rear engine mounting bolts.

Lower the vehicle.
NOTICE: When raising or supporting the Install a suitable lifting fixture.

the oil pan, any sheet metal or crankshaft 25. Engine and transmission from the vehicle.
Support the engine with a suitable jack.

22. Front engine mounting bracket to frame bolts and
nuts.
23. Front engine mounting through bolts.
6A5-30 SMALL BLOCK
Figure 39Rear Engine Mounting (C Models)

SMALL BLOCK 6A5-31

Support the engine with a suitable jack.

section.
2. Engine mounting frame brackets.

Raise the engine slightly and position the
brackets against the engine mountings.
Install the through-bolts finger tight.
Lower the engine.
A. 54 N m (40 Ft. Lbs.) Install the mounting bracket to frame bolts
B. 48 N m (36 Ft. Lbs.) B and nuts.
C. Forward
B-07897 Tighten
E ng in e m o u n tin g fa s te n e rs to
specifications. Refer to figure 37.
Remove the jack.
Rear engine mounting bolts.
& Tighten
Engine mounting to transmission bolts to 48

N m (36 ft. lbs.).
4. Fuel and vapor return lines.
5. Transmission shift linkage and speedometer
cable.
6. Propeller shaft.
7. Exhaust pipes.
Lower the vehicle.
8. Cruise control servo, bracket, and transducer (if
equipped).
9. Oil filler tube.
10. Thermostat housing.
11. Heater hoses.
12. Vacuum hoses and electrical wiring.
13. Engine wiring harness connector.
14. Carburetor.
15. Air cleaner.
18. Air conditioning condenser (if equipped). Refer to
AIR CONDITIONING (SEC. 1B).
19. Upper radiator support.
20. Grille and lower grille valance.
21. Coolant reservoir bottle.
6A5-32 SMALL BLOCK
Figure 42Rear Engine Mounting (P Models with Transmission Tail Type Mounting)
SMALL BLOCK 6A5-33
Figure 43Rear Engine Mounting (P Models with

Flywheel Housing Type Mounting)

23. Proper quantities and grades of coolant and
engine oil.
Evacuate and charge the air conditioning system.
6A5-34 SMALL BLOCK
SPECIFICATIONS
GENERAL DATA:
Type V8
Displacement 5.0L (305 Cu. In.) 5.7L (350 Cu. In.)
RPO (VIN Code) LF3 (F) LE9 (H) LS9 (L) LT9 (M)
Bore 3.736 4.00
Stroke 3.480
Compression Ratio 8.6:1 9.2:1 8.2:1 8.3:1
Firing Order 1-8-4-3-6-5-7-2
CYLINDER BORE:
Diameter 3.7350-3.7385 3.9995-4.0025
Production Thrust Side 0.0005 (Maximum)
PISTON:
Clearance
PISTON RING:
C
0 Top
M 2nd
P Clearance
R Service Limit Hi Limit Production +0.001
E
S Top 0.010-0.020
S Production
1 Gap 2nd 0.010-0.025
0
1 Production
Gap 0.015-0.055
PISTON PIN:
Diameter 0.9270-0.09273
B-07927
SMALL BLOCK 6A5-35
SPECIFICATIONS
DISPLACEMENT 5.0L (305 Cu. In.) 5.7L (350 Cu. In.)

CRANKSHAFT:
#1 2.4484-2.4493
Diameter #2, #3, #4 2.4481-2.4490
#5 2.4479-2.4488
Taper
#1 0.0008-0.0020
Production #2, #3, #4 0.0011-0.0023
Main #5 0.0017-0.0032
Bearing #1 0.0010-0.0015
Clearance Service Limit #2, #3, #4 0.0010-0.0025
#5 0.0025-0.0035
Diameter 2.0988-2.0998
Production 0.0005 (Maximum)
Taper
Out Production 0.0005 (Maximum)
CAMSHAFT:
Lobe Intake 0.2484 0.2600
Lift + 0.002 Exhaust 0.2667 0.2733
VALVE SYSTEM:
Lifter Hydraulic
Intake
Valve Lash
Exhaust
0
Face Angle (Intake & Exhaust)

cn
CD

O

Intake V 3 2 - V 16
Seat Width
Exhaust 1/ l 6 3/3 2
Intake 0.0010-0.0027
Production
Service
Free Length 2.03
Valve Pressure Closed 76-84 lbs. @ 1.70"
Spring lbs. @ in. Open 194-206 lbs. @ 1.25"
(Outer) Installed Height
123/3 2
+ V32"
Valve Free Length 1.86

Spring
Damper Approx. # of Coils 4 B-07928
6A5-36 SMALL BLOCK
Item Nm Ft. Lbs. In. Lb:

Rocker Arm Cover N u ts .......................................... 7.3 65
Rocker Arm Cover B o lt............................................ 6.2 55
Intake Manifold Bolts................................................ 48 36
Exhaust Manifold B o lts............................................
Cast Manifolds:
Two Center Bolts:................... 36 26
All O th e rs:............................. 28 20
Tubular (Stainless Steel) Manifolds (All Bolts) 36 26
Cylinder Head Bolts.................................................. 90 65
Torsional Damper B olt.............................................. 95 70
Front Cover Bolts...................................................... 11.3 100
Oil Pan Nuts............................................................... 22.6 200
Oil Pan B o lts ........................................................... 11.3 100
Oil Pump Bolt............................................................. 90 65
Oil Pan Baffle Nuts (Some 5.7L E ng in e s)............. 36 26
Rear Crankshaft Oil Seal Retainer S cre w s.......... 15.3 135
Camshaft Sprocket Bolts.......................................... 24 18
Connecting Rod Cap N u ts ...................................... 60 45
Oil Filter Bypass Valve Bolts................................... 26 20
Main Bearing Cap Bolts
Outer Bolts on #2, #3, and #4 C a p s ............... 95 70 __
All O th e rs ........................................................... 110 80

Oil Pump Cover B o lts .............................................. 9.0 80
Flywheel B o lts ........................................................... 100 75
Spark P lugs............................................................... 30 22
Water Outlet B o lts .................................................... 28 21
Water Pump B o lts .................................................... 40 30
Flywheel Housing Bolts............................................ 44 32
SPECIAL TOOLS
J-23590 Air Adapter
J-23042-A Front Crankshaft Seal Installer
J-35621 Rear Crankshaft Seal Installer
J-5239 Guide Set
6A6-1
SECTION 6A6
7.4 LITER V8
section.
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................. 6A6-2

Engine L u b ric a tio n ................................................................................................................................................. 6A6-2
On-Vehicle S e r v ic e ................................................................................................................................................... 6A6-4
Rocker Arm Cover Replacem ent......................................................................................................................... 6A6-4
Rocker Arm and Pushrod R eplacem ent............................................................................................................ 6A6-4
Valve A d ju s tm e n t................................................................................................................................................... 6A6-5
Valve Stem Seal and Valve Spring R e p la ce m e n t........................................................................................... 6A6-5
Intake Manifold R e p la ce m e n t..............................................................................................................................6A6-6
Hydraulic Lifter R e p lace m e n t..............................................................................................................................6A6-7
Rocker Arm Stud Replacem ent........................................................................................................................... 6A6-8
Exhaust Manifold Replacem ent........................................................................................................................... 6A6-8
Cylinder Head R e p la ce m e n t................................................................................................................................6A6-8
Torsional Damper and Front Crankshaft Seal R e p la ce m e n t........................................................................6A6-9
Front Cover R e p lace m e n t.................................................................................................................................. 6A6-10
Oil Pan R e p lace m e n t...........................................................................................................................................6A6-12
Oil Pump R e p la c e m e n t...................................................................................................................................... 6A6-13
Rear Crankshaft Oil Seal R e p la c e m e n t.......................................................................................................... 6A6-13
Connecting Rod and Piston R eplacem ent......................................................................................................6A6-17
Oil Filter Bypass Valve........................................................................................................................................ 6A6-19
Main Bearing R e p lace m e n t................................................................................................................................6A6-20
Crankshaft R e p lace m e n t.................................................................................................................................... 6A6-21
S pe cifica tio ns............................................................................................................................................................6A6-31
Special T o o is ............................................................................................................................................................6A6-33
6A6-2 7.4 LITER V8
DESCRIPTION
7.4L engines are 90-degree V8 type, overhead valve, ENGINE LUBRICATION

water cooled, with cast iron block and heads.
The crankshaft is supported by five precision insert Lubrication schematics are shown in Figure 1. The
main bearings, with crankshaft thrust taken at the num gear type oil pump is driven from the distributor shaft,
ber five (rear) bearing. which is gear driven from the camshaft. Oil is drawn
The camshaft is supported by five plain type bear into the oil pump through a pickup screen and pipe.
ings and is chain driven. Motion from the camshaft is Pressurized oil is routed to the oil filter. In case of
transmitted to the valves by hydraulic lifters, pushrods, excessive oil pressure, a bypass valve is provided.
and ball type rocker arms. The valve guides are inte Filtered oil flows into the main gallery and then to the
gral in the cylinder head. camshaft and crankshaft bearings. The valve lifter oil
The connecting rods are forged steel, with precision gallery supplies oil to the valve lifters. Oil flows from
insert type crankpin bearings. The piston pins are a the hydraulic lifters through the hollow pushrods to the
press fit in the connecting rods. rocker arms. Oil from the overhead drains back to the
The pistons are cast aluminum alloy. The piston pins crankcase through oil drain holes.
are a floating fit in the piston. The timing chain is drip fed from the front camshaft
bearing. The pistons and piston pins are lubricated by
oil splash.
7.4 LITER V8 6A6-3
Cylinder walls are oiled by oil thrown

off pressure fed connecting rod bearings.
CYLINDER WALL AND

CAMSHAFT LOBE OILING
FUEL PUMP PUSH OIL FILTER AND
ROD OILING DISTRIBUTOR OILING
CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILING

B-09187

6A6-4 7.4 LITER V8
ON-VEHICLE SERVICE
Inspect
Rocker arm cover sealing surface for distortion.

1. Rocker arm cover and new gasket.

2. Reinforcements, clips, and nuts.
Tighten
Nuts to 5.4 N-m (48 in. lbs.).

3. Air co nd itio n ing com pressor rear brace (if
removed).
4. Heat stove pipe (if removed).
5. Wiring harnesses.
6. Crankcase ventilation hoses.
7. Air cleaner.
ROCKER ARM AND PUSHROD

REPLACEMENT

Rocker arm cover, as outlined previously.
Rocker arm nut.
ROCKER ARM COVER If only the pushrod is to be replaced, back
REPLACEMENT the rocker arm nut off until the rocker arm
Remove or Disconnect (Figure 2) Rocker arm with ball.
Pushrod.
Important
2. Air cleaner.
3. Crankcase ventilation hoses at the rocker arm Store used components in order so they can be
cover. reassembled in the same location.
4. Wiring harnesses from the rocker arm clips.

L* Inspect
5. Heat stove pipe (right side rocker arm cover).
6. A ir co nd itio n ing com pressor rear brace (if These surfaces should be smooth and free from
equipped) (left side rocker arm cover). scoring or other damage.
7. Rocker arm cover nuts, reinforcements, and clips. Rocker arm areas which contact the valve stems
8. Rocker arm cover and gasket.
These areas should be smooth and free of
damage and wear.
? | Clean Pushrods for bending. Roll the pushrod on a flat
All traces of old gasket from the rocker arm cover necessary.
and cylinder head. Ends of the pushrods for scoring or roughness.
7.4 LITER V8 6A6-5
1. Pushrod. Make sure the pushrod seats properly

in the hydraulic lifter.
Important
When new rocker arms and/or balls are

installed, coat their bearing surfaces with
Molykote or equivalent.
Rocker arm nut.
Adjust
Valves as outlined later.

VALVE ADJUSTMENT
1. Remove the rocker arm cover as outlined
previously.
2. Crank the engine until the mark on the vibration
damper lines up with the O mark on the timing
position. This may be determined by placing
the damper comes near the O mark on the
timing tab. If the rocker arms are not moving, the
engine is in the number one firing position. If the VALVE STEM SEAL AND
rocker arms move as the mark comes up to the VALVE SPRING REPLACEMENT
timing tab, the engine is in the number six firing
position and should be turned over one more time
to reach the number one position. Remove or Disconnect (Figures 4 and 5)
3. With the engine in the number one firing position
as determined above, the following valves may be Tools Required:
adjusted: J-23590 Air Adapter
Exhaust: 1, 3, 4, 8 J-5892-A Spring Compressor
Intake: 1, 2, 5, 7
odd numbered cylinders are in the left bank,
when viewed from the rear of the engine).
4. Back out the adjusting nut until lash is felt at the
iash is removed. This can be determined by
nut (figure 3). When the play has been removed,
turn the adjusting nut in Wa additional turn (to
center the lifter plunger).
5. Crank the engine one revolution until the timing
tab O mark and vibration damper mark are 23. Spring With Damper
again in alignment. This is the number six firing 20. Intake Valve 24. Seal
position the following valves may be adjusted: 21. Exhaust Valve 25. Cap
22. Rotator 26. Valve Keeper
Exhaust: 2, 5, 6, 7
B-07931
Intake: 3, 4, 6, 8
previously. Figure 4Valves And Components
6A6-6 7.4 LITER V8

them in place.
Carefully release spring pressure. Make
4. Spark plugs.
Adjust

INTAKE MANIFOLD
REPLACEMENT

2. Air cleaner.
pump bypass hose.
B-07932 4. Accelerator, cruise control, and TVS cables, as
equipped.
Figure 5Compressing The Valve Spring 5. Fuel line at the carburetor.
6. Crankcase ventilation hoses.
1. Rocker arm cover, as outlined previously. 7. Vacuum hoses, as necessary.
2. Rocker arms, as outlined previously. 8. Distributor. Refer to ENGINE ELECTRICAL (SEC.
3. Spark plugs. 6D).
4. Valve keepers (26). 9. Air conditioning compressor and bracket (if
Install J-23590 into the spark plug hole. equipped) and lay aside.
10. Accelerator bellcrank, return spring, and bracket.
Apply compressed air to hold the valves in
place. 11. Upper generator bracket.
Install a rocker arm nut (figure 5).
14. Gaskets and seals.
(figure 5).
jQjj] Clean
C a re fully release the sp rin g tension.
Remove J-5892-A.
Old gaskets from the block, heads, and intake
5. Cap (25) and spring with damper (23).
manifold.
6. Seal (24). Excessive carbon deposits from the exhaust and
EGR passages.
+ 4- Install or Connect (Figures 4 and 5) Excessive scale and deposits from the coolant
passages.
Tools Required:
J-23590 Air Adapter
L* Inspect
1. New seal (24). Install the seal over the valve stem Manifold for cracks and gasket surface damage.
and seat it against the head.
2. Spring with damper (23), and cap (25). Install or Connect (Figure 6)
3. Valve keepers (26).
With air pressure applied to the cylinder 1. Front and rear intake manifold seals to the block.
with J-23590, compress the spring with 2. Side gaskets to the cylinder heads.
J-5892-A (figure 5). 3. Intake manifold and bolts.
7.4 LITER V8 6A6-7
Figure 6Intake Manifold Bolt Tightening

Sequence
Tighten
Figure 7Removing The Valve Lifter
Bolts to 40 N m (30 ft. lbs.). Use the
tightening sequence shown in Figure 6.
Inspect
4. Upper generator bracket.
5. Accelerator bellcrank, return spring, and bracket.
6. Air conditioning compressor and bracket (if
equipped).
mating bore in the block should also be checked.
6D). Check the fit of each hydraulic lifter in its mating
8. Vacuum hoses. bore in the block. If the clearance is excessive, try
9. Crankcase ventilation hoses. a new lifter.
10. Fuel line. The hydraulic lifter foot must be smooth and
11. Accelerator, cruise control, and TV cables. slightly convex. If worn, pitted, or damaged, the
12. Water pump bypass hose, heater hose, and upper mating camshaft lobe should also be checked.
radiator hose.
13. Air cleaner. Hydraulic Lifter Repair
14. Battery negative cable. Refer to the proper unit repair manual.
Fill the cooling system with the proper quantity
Install or Connect
HYDRAULIC LIFTER 1. Hydraulic lifters to the block. Lubricate the lifter
REPLACEMENT
Tools Required:
J-3049 Lifter Remover (Plier Type) or
J-9290-01 Lifter Remover (Slide Hammer
Type)
2. Hydraulic lifters.
and place them in an organizer rack. The
lifters must be installed in the same bore
from which they were removed.
A stuck hydraulic lifter can be removed
using J-3049 (figure 7) or J-9290-01 (figure
8 ). Figure 8Removing The Valve Lifter
6A6-8 7.4 LITER V8
foot and body with Engine Oil Supplement or 7. Exhaust manifold.

equivalent.
Clean
Im portant
Mating surface on the manifold and head.
When any new hydraulic lifters or a new Threads on the exhaust manifold bolts.
c a m s h a ft is in s ta lle d , E ng in e O il
Supplem ent (or equivalent) should be +- Install or Connect
added to the crankcase oil.
Replace all hydraulic lifters when a new 1. Exhaust manifold.
camshaft is installed. 2. Exhaust manifold bolts and spark plug shields (if
2. Intake Manifold, as outlined previously. used).
3. Pushrod, as outlined previously.
Tighten
Adjust
Exhaust manifold bolts to specifications.
Valves, as outlined previously. Tighten the center bolts first, then continue
4. Rocker arm cover, as outlined previously. outward each way.
Models with stainless steel manifolds
(RPO-NA5): 54 N m (40 ft. lbs.).
ROCKER ARM STUD M odels with cast iron m anifolds
REPLACEMENT (RPO-NB2): 24 N m (18 ft. lbs.).
3. Exhaust pipe.
4. Spark plugs.
5. AIR hose.
1. Rocker arm cover and rocker arm, as outlined 6. Air cleaner and heat stove pipe.
previously. 7. Battery negative cable.
2. Rocker arm stud. Use a deep socket.
Install or Connect CYLINDER HEAD

REPLACEMENT
1. Rocker arm stud.
Tighten Remove or Disconnect
Rocker arm stud to 68 N m (50 ft. lbs.). 1. Battery negative cable.

2. Rocker arm, as outlined previously. Drain the cooling system.
Adjust 3. Generator, and lay aside.
Valves, as outlined previously. 5. Air conditioning compressor and front bracket (if
3. Rocker arm cover, as outlined previously. equipped). Lay the compressor aside.
EXHAUST MANIFOLD 7. Spark plugs.
8. Pushrods, as outlined previously.
REPLACEMENT
9. Cylinder head bolts.
10. Cylinder head.
Remove or Disconnect 11. Head gasket.
1. Battery negative cable. j y | Clean

2. Air cleaner and heat stove pipe.
3. AIR hose at the check valve. Carbon deposits from combustion chambers.
4. Spark plugs. All traces of old head gasket from cylinder head
5. Exhaust pipe at the manifold. and block.
6. Exhaust manifold bolts and spark plug heat Cylinder head bolt threads and threads in the
shields (if used). block.
7.4 LITER V8 6A6-9
B-09570
Figure 9Cylinder Head Bolt Tightening Sequence
L* Inspect
Sealing surfaces of the block and cylinder head

for nicks, heavy scratches, or other damage.
Refer to the proper Unit Repair Manual.
|-n -| Install or Connect (Figure 9) TORSIONAL DAMPER AND

1. Head gasket. FRONT CRANKSHAFT SEAL
If a steel gasket is used, coat both sides of REPLACEMENT
the gasket with sealer. Spread the sealer
thin and even.
. Do not use s e a le r on c o m p o s itio n
steel-asbestos gaskets.

"*l Remove or Disconnect (Figure 10)
Tool Required:
with the bead up. J-23523-E Torsional Damper Puller and
2. Cylinder head. Carefully guide the cylinder head Installer
into place over the dowel pins and gasket. 1. Fan belts, fan, and pulley.
3. Cylinder head bolts. Coat threads of the cylinder 2. Fan shroud assembly.
head bolts with sealing compound (GM part 3. Accessory drive pulley.
num ber 1052080 or equivalent) and install
4. Torsional damper bolt.
finger-tight.
5. Torsional damper. Use J-23523-E (figure 10).
Tighten 6. Front crankshaft seal. Pry out with a large
screwdriver. Take care not to distort the front
cover.
Cylinder head bolts, a little at a time, using
the sequence shown in figure 9. Proper 7. Crankshaft key, if necessary.
torque is 130 N m (95 ft. lbs.).
4. Pushrods, as outlined previously. I* Inspect
Adjust Oil seal contact area on the torsional damper

shaft for grooving and roughness. Replace if
Valves, as outlined previously. necessary.
6. Spark plugs. -4- Install or Connect (Figures 11 and 12)
7. Air conditioning compressor and front bracket (if
equipped). Tools Required:
8. Exhaust manifold, as outlined previously. J-22102 Seal Installer
9. Generator. J-23523-E Torsional Damper Puller and
10. Intake manifold, as outlined previously. Installer
11. Battery negative cable. 1. Crankshaft key, if removed.
6A6-10 7.4 LITER V8
Figure 11Installing The Front Crankshaft Seal Figure 13Cutting The Front Oil Pan Seal
(Typical)
2. Front crankshaft seal. Use J-22102 (figure 11). Turn the nut to pull the vibration damper into
The open end of the seal faces inside the engine. place.
Remove the tool.
a rubber type material. The correct installation $ Tighten
followed or movement of the inertia weight Bolt to 115 N m (85 ft. lbs.).
section of the hub will destroy the tuning of 7. Accessory drive pulley.
the torsional damper. 8. Fan shroud assembly.
9. Fan pulley, fan, and fan belts.
the stud fully into the tapped hole in the
crankshaft. FRONT COVER REPLACEMENT
crankshaft key. -- Remove or Disconnect (Figures 13 through 16)

6B).
4. Oil pan to front cover bolts.
5. Front cover to block bolts.
6. Front cover.
Pull the cover forward enough to permit
cutting of the front oil pan seal (figure 13).
Cut the front oil pan seal flush with the block
on both sides (figure 13). Use a sharp
cutting tool to ensure a clean cut.
Pull off the front cover.
7. Gasket and front oil pan seal.
8. Front crankshaft oil seal from the front cover. Pry
out with a screwdriver. Take care not to distort the
front cover.
7.4 LITER V8 6A6-11
Clean
Old gasket from the front cover, block, and oil

pan.
L* Inspect

necessary.
0 Install or Connect (Figures 14, 15, and 16)
Tool Required:

1. Front crankshaft seal. Use J-22102 (figure 14).
Figure 14Installing The Front Crankshaft Seal The open end of the seal faces inside the engine.
(Typical) Coat the seal lips with engine oil.
2. Front oil pan seal.
Cut the tabs from a new seal (figure 15). Use

a sharp cutting tool to ensure a clean cut.
Position the seal on the front cover. Push

the seal locating tips into the holes in the
front cover.
3. Front cover to block gasket to the front cover. Use

gasket sealer to hold it in position.
Apply a 3 mm (Vs-inch) bead of RTV sealant (GM

part number 1052366 or equivalent) to the front
oil pan to block joint (figure 16).

against the oil pan until the block dowel pins align
against the block so that the dowels enter the
cover holes without binding. Do not force the
cover over the holes. Do not distort the cover
flange or dowel pin holes. Hold the front cover in
this position. Install and partially tighten the oil
pan to front cover bolts.
5. Front cover to block bolts.
Front cover to block bolts to 10.8 N m (96 in.

lbs.).
B-03463 Oil pan to front cover bolts to 7.9 N m (70 in.

lbs.).
Figure 16Applying Sealer 6. Torsional damper, as outlined previously.

6B).

6A6-12 7.4 LITER V8
NOTICE: Oil pressure line must be removed

from the side of the block to prevent crushing
of the line when the engine is raised.
8. Oil pressure line from the side of the block.

Support the engine with a suitable lifting fixture.

9. Engine mounting through-bolts.
Raise the engine only enough to permit oil pan
removal.
10. Oil pan bolts, timing marker (if used), clips, and
reinforcements.
11. Oil pan.
12. Gaskets and seals.
i y | Clean
70. Rear Oil Pan Seal Gasket surfaces on the engine and oil pan.
71. Gasket
72. Reinforcement Install or Connect (Figure 17)
73. Tim ing Marker (Some P Models)
74. Front Oil Pan Seal 1. Gaskets (71) to the block. Use gasket sealer to
75. Clip hold them in place.
B-07933
2. Rear oil pan seal (70) to the groove in the rear
main bearing cap, with the ends mating against
Figure 17Oil Pan Installation the gaskets (71).
3. Front oil pan seal (74). Press the locating tips into
OIL PAN REPLACEMENT the holes in the front cover. The ends should
mate against the gaskets (71).
4. Oil pan.
Remove or Disconnect (Figure 17) 5. Oil pan bolts, timing marker (if used), clips, and
reinforcements.
2. Fan shroud from the radiator and push rearward. Tighten
3. Air cleaner. Oil pan to front cover bolts to 7.9 N m (70 in.
lbs.).
4. Distributor cap.
Oil pan to block bolts to 15.3 N m (135 in.
Raise the vehicle. lbs.).
Drain the engine oil. Lower the engine.
5. Starter (vehicles with manual transmission). NOTICE: See Notice on page 6A6-1 of this
6. Torque converter or clutch cover. section.
7. Oil filter. 6. Engine mounting through bolts.

7.4 LITER V8 6A6-13
l$ l Tighten
Through-bolts to specifications. Refer to

figures 35, 36, and 37.
7. Oil pressure line.
8. Oil filter.
9. Torque converter or clutch cover.
10. Starter (if removed).
Lower the vehicle.
11. Distributor cap.
12. Air cleaner.
13. Fan shroud.
outside diameter of the seal. An installation tool should
be used to protect the seal bead when positioning the
seal. (Some seal kits include the tool as part of the
2. Oil pump to main bearing cup bolt.
service kit).
3. Oil pump.

L* Inspect
Oil pump pickup tube for damage and looseness.
If the tube is loose or damaged, the entire oil 2. Rear main bearing cap.
pump must be replaced, because the tube is
welded to the pump body.
Oil Pump Repair

Install or Connect

pump shaft with the tang on the distributor shaft.
The oil pump should slide easily into place. No
gasket is used.
2 . Oil pump to main bearing cap bolt.
Oil pump bolt to 90 N m (65 ft. lbs.).

REAR CRANKSHAFT OIL

SEAL REPLACEMENT
The rear main bearing oil seal can be replaced (both
halves) without removal of the crankshaft. Always
replace the upper and lower seal as a unit. Install the
B-03487
seal with the lip facing the front of the engine. Extreme
care should be exercised when installing this seal to
protect the sealing bead located in the channel on the Figure 19Removing The Upper Oil Seal Half
6A6-14 7.4 LITER V8
3. Lower seal half (figure 18).

4. Upper seal half (figure 19).
Tap on the upper seal half, using a small
drift and hammer.
Remove the upper seal half, using pliers.
Clean
Sealing surfaces of the main bearing cap and A. 4 mm (11/e4-inch)

block. B. 13 mm (1/2 -inch)
C. 0.10 mm (0.004-inch) shim stock B-05250
L* Inspect
Figure 20Oil Seal Installation Tool
Crankshaft, seal channel, and sealing surfaces
for nicks, scratches, etc.
Apply a brush-on type oil sealing compound
Install or Connect (Figures 20, 21, and 22) to the mating surface of the block and cap
(figure 22). Do not allow any sealant on
1. Upper seal half. either crankshaft or rear oil seal.
Im portant
An oil seal installation tool (figure 20) should

be fabricated (if not provided in the seal kit)
to prevent seal damage during installation.
E xtrem e care should be taken when
installing this seal to protect the sealing
bead located in the channel on the outside
diameter of the seal.
Coat the seal lips lightly with engine oil. Keep the
oil off of the seal mating ends.
Position the tip of the tool between the crankshaft
and the seal seat in the block (figure 21).
Position the seal half between the crankshaft and
the tip of the tool. Make sure that the oil seal lip is
positioned toward the front of the engine.
Roll the seal around the crankshaft using the tool
as a shoe-horn to protect the seal bead from
the sharp corner of the seal seat surface in the
block. The installation tool must remain in
position until the seal half is properly positioned
with both ends flush with the block.
Remove the tool, being careful not to withdraw
the seal half.
Lower seal half.
Coat the seal lips lightly with engine oil.
Keep the oil off of the seal mating ends. A. Forward
Insert the seal half into the rear main B. Fabricated Tool
bearing cap. Use the tool to protect the seal C. Oil Seal Lip
half from the sharp edge of the seal seat. 80. Upper Seal Half
Feed the seal half into the rear main bearing 81. Crankshaft
cap, using light finger pressure. Make sure 82. Block
the oil seal lip faces the front of the engine 83. Lower Seal Half
(figure 21). 84. Main Bearing Cap B-07871
Rear main bearing cap with the lower main
bearing. Figure 21Installing The Rear Crankshaft Oil Seal
7.4 LITER V8 6A6-15
Apply engine oil to the lower main bearing. 4. Set dial indicator on zero, then rotate the
crankshaft slowly, or attach an auxiliary starter
Position the cap to the block. Install the cap
switch and bump the engine over, until the
bolts.
pushrod is in fully raised position.
Tighten Im portant
Rear m ain b e a rin g cap b o lts Whenever the engine is cranked remotely at
temporarily to 14 N m (10 ft. lbs.). the starter, with a special jumper cable or
Tap the end of the crankshaft first rearward other means, the distributor primary lead
then forward with a lead hammer. This will should be disconnected from the distributor
line up the rear main bearing and crankshaft (coil).
thrust surfaces. 5. Compare the total lift recorded from the dial indi
cator with specifications.
Tighten 6. If camshaft readings for all lobes are within speci
fications, remove dial indicator assembly.
Rear main bearing cap bolts to 150 7. Install the rocker arm and adjust the valves as
N m 110 ft. lbs.). previously outlined.

5. The proper quantity and grade of engine oil.
CAMSHAFT REPLACEMENT
MEASURING CAMSHAFT Remove or Disconnect (Figures 24, 25, and

LOBE LIFT 26)
Tools Required: Tool Required:

J-8520 Camshaft Lobe Lift Indicator J-1619 Crankshaft Sprocket Puller
1. Remove the rocker arm as outlined previously.
2. Air cleaner.
2. Refer to figure 23. Position the dial indicator (part 3. Grille.
of J-8520) so the plunger rests on the pushrod 4. Air conditioning condensor from its mounting and
end, as shown. Make sure the pushrod is in the swing it forward.
lifter socket. 5. Fan, shroud, and radiator. Refer to ENGINE
3. Rotate the crankshaft slowly in the direction of COOLING (SEC. 6B).
rotation until the lifter is on the heel of the cam 6. Generator and bracket.
lobe. At this point, the pushrod will be in its lowest 7. Rocker arm covers, as outlined previously.
position. 8. Fuel line.
6A6-16 7.4 LITER V8
Figure 24Tim ing Marks
B-07892

6B).
6D).
14. Pushrods and hydraulic lifters, as outlined
previously.
16. Camshaft sprocket bolts.
17. Cam shaft sprocket and tim ing chain. The
sprocket is a lig h t in te rfe re n ce fit on the
camshaft. Tap the sprocket on its lower edge to
loosen it.
18. Crankshaft sprocket (if required). Use J-1619
(figure 25).
19. Camshaft.
J-22102
Install two or three 5/ie-18 bolts 100-125 mm (4-5
B-05279 Use these bolts to handle the camshaft (figure
26).
Figure 25Replacing The Crankshaft Sprocket Pull the camshaft from the block. Use care to
prevent damage to the camshaft bearings.
7.4 LITER V8 6A6-17
Cleaning Inspection and Repair

repair manual.
-4- Install or Connect (Figures 24, 25, and 26)
Tool Required:
1. Two or three 5/ie-18 bolts 100-125 mm (4-5
Use these bolts to handle the camshaft.
camshaft bearings.
3. Crankshaft sprocket (if removed). Use J-22102
(figure 25). Make sure the timing mark faces
outside.
4. Camshaft sprocket and timing chain.
Im portant
Line up the timing marks on the camshaft Figure 27Replacing The Connecting Rod And
sprocket and crankshaft sprocket (figure Piston
24).
5. Camshaft sprocket bolts. 15. Generator and bracket.
a Tighten COOLING (SEC. 6B).
17. Air conditioning condensor.
Bolts to 27 N m (20 ft. lbs.). 18. Grille.
19. Air cleaner.
7. H ydraulic lifters and pushrods, as outlined
previously.
Im portant
Replace all hydraulic lifters and add GM

CONNECTING ROD AND
Engine Oil Supplement (or equivalent) to
the engine oil whenever a new camshaft is PISTON REPLACEMENT
installed.
Adjust Remove or Disconnect (Figure 27)
Valves, as outlined previously. Tool Required:

8. Intake manifold, as outlined previously. J-5239 Guide Set
9. Distributor. Refer to ENGINE ELECTRICAL (SEC. 1. Cylinder head, as outlined previously.
6D). 2. Oil pan, as outlined previously.
10. Front cover, as outlined previously. 3. Oil pump, as outlined previously (if necessary).
11. Torsional damper, as outlined previously. 4. Ridge or deposits from the upper end of the
12. Water pump. Refer to ENGINE COOLING (SEC. cylinder bores.
6B). Turn the crankshaft until the piston is at
13. Fuel line. BDC.
14. Rocker arm covers, as outlined previously. Place a cloth on top of the piston.
6A6-18 7.4 LITER V8
Perform the cutting operation with a ridge

reamer. O
TDC.
5. Connecting rod cap. Check the connecting rod
required. The connecting rod and cap must be
kept together as mating parts.
6. Connecting rod and piston.
(figure 27).
Use the long guide rod of J-5239 to push the C. Oil Ring Spacer Gap
connecting rod and piston out of the bore. (Tang In Hole Or Slot With Arc)
7. Connecting rod bearing. D. Top Compression Ring Gap B-07935
Clean, inspect and repair or replace the components Figure 28Ring End Gap Location
clearance, piston clearance, ring clearances, etc. Refer Place the piston in its matching bore. Using
light blows with a hammer handle, tap the
The unit repair manual contains information on: piston down into its bore (figure 29). At the
Connecting rod and piston. same time, from beneath the vehicle guide
Piston rings. the connecting rod to the crankpin with
Connecting rod and crankpin. J-5239 (figure 27). Hold the ring compressor
Cylinder bores. against the block until all rings have entered
the cylinder bore.
Install or Connect (Figures 27 through 31)
Tools Required:
J-5239 Connecting Rod Guide Set
Make sure the piston is installed in the matching
cylinder for which it was fitted. Used pistons must
be installed in the cylinder they were removed
from.
1. Connecting rod bearings.
Be certain that the bearings are of the
proper size.
and connecting rod cap.
2. Piston and connecting rod to the proper bore.
With the connecting rod cap removed,
install J-5239 onto the connecting rod studs.
Locate the piston ring end gaps as shown in
figure 28. Lubricate the piston and rings with
engine oil.
(figure 29).
valve clearance notches are towards the
center of the engine (figure 30).
7.4 LITER V8 6A6-19
Figure 31Measuring Connecting Rod Side

Clearance
OIL FILTER BYPASS VALVE

Figure 30Pistons Installed
Remove J-5239 from the connecting rod + + Remove or Disconnect (Figure 32)
bolts.
1. Oil filter.
Im portant
Each connecting rod and bearing cap Inspect

should be marked, beginning at the front of
the engine. Cylinders 1, 3, 5 and 7 are the Bypass valve spring and valve disc for
left bank and 2, 4, 6 and 8 are the right proper operation, cracks, and damage. If
bank. The numbers on the connecting rod replacement is needed, the oil filter bypass
and bearing cap must be on the same side valve (93) must be replaced, as follows:
when installed in the cylinder bore. If a 2. Bolts (94).
connecting rod is ever transposed from one
block or cylinder to another, new connecting 3. Oil filter bypass valve.
rod and bearings should be fitted and the
connecting rod should be numbered to
correspond with the new cylinder number. *3* Clean
Measure Valve chamber in the block.

Tighten

lbs.).
Measure

is 0.013-0.023-inch.
6A6-20 7.4 LITER V8

C le a n, in s p e c t, and re p a ir or re p la ce the
manual. The unit repair manual contains information
on:
Crankshaft.
Main bearing cap replacement (shimming
procedure).
-+ Install or Connect (Figures 22, 33, and 34)
Tool Required:
Insert tool J-8080 into a crankshaft main
bearing oil hole (figure 33).
size.
+4-
and the notched side of the block.
1. Oil filter bypass valve (93).
2. Bolts (94).
the block.
Remove the tool.
$ Tighten
2. Lower main bearing inserts to the main bearing
Bolts (94) to 26 N m (20 ft. lbs.). caps.
3. Oil filter. Make sure the inserts are of the proper size.
4. Engine oil, as needed. Apply engine oil to the inserts.
Spark plugs.
Flywheel (if used), as outlined later. Measure
Engine, as outlined later.
Main bearing clearance. Refer to the
proper unit repair manual. If the
MAIN BEARING REPLACEMENT engine is in the vehicle, the crankshaft
must be supported upward to remove
any clearance from the upper bearing.
Remove or Disconnect (Figure 33) The total clearance can then be
measured between the lower bearing
Tool Required: and journal.
J-8080 Main Bearing Remover/Installer 3. Main bearing caps (except rear cap) and bolts to
1. Spark plugs. the block.
3. Oil pump, as outlined previously. Tighten
Check the main bearing caps for location Main bearing cap bolts to 150 N-m (110 ft.
markings. Mark the caps if necessary. The lbs.).
caps must be returned to their original 4. Rear crankshaft oil seal to the block and main
locations during assembly. bearing cap, as outlined previously.
5. Lower main bearing inserts from the main 5. Rear main bearing cap.
bearing caps. Apply a brush-on type oil sealing compound
6. Rear crankshaft oil seal, if necessary, as outlined to the mating surface of the block and cap
previously. (figure 27). Do not allow any sealant on
8. Upper main bearing inserts. either crankshaft or rear oil seal.
Insert J-8080 into the crankshaft oil hole Apply engine oil to the bearing insert.
(figure 33). Install the rear main bearing cap and bolts.
Rotate the crankshaft to turn the bearing Tighten the bolts temporarily to 14 N m (10
insert out of the block. ft. lbs.).
7.4 LITER V8 6A6-21
8. Connecting rod caps. Check the connecting rod

necessary. The connecting rod and cap are
mating parts.
9. Connecting rods from the crankshaft.
(figure 27).
Use the long guide rod to push the pistons
up in the bores.
10. Main bearing caps. Check the main bearing
caps for location markings. Mark the parts if
necessary. The main bearing caps must be
A. Forward returned to the ir o rig in al locations at
B. Feeler Gage assembly.
100. Rear Main Bearing Cap 11. Crankshaft.
101. Crankshaft B-07878 12. Main bearing inserts.
13. Rear crankshaft seal, as outlined previously.
Figure 34Measuring Crankshaft End Play
C leaning, In sp e ctio n , and Repair
Measure Clean, inspect, and repair or replace the parts as
outlined in the proper unit repair manual. Refer to
Crankshaft end play, as follows: the unit repair manual for information on:
Tap the end of the crankshaft first Crankshaft.
rearward then forward with a lead Main and connecting rod bearings.
hammer. This will line up the rear main P ro ce d u re s for m e a su rin g b e a rin g
b e a rin g and c ra n k s h a ft th ru s t clearances.
surfaces.
Tighten the rear main bearing cap - Install or Connect (Figures 22, 24, 27, 31, and
bolts to 150 N m (110 ft. lbs.). 34)
measure at the front end of the rear Tool Required:
main bearing with a feeler gage (figure J-5239 Guide Set
34). The p ro p e r c le a ra n c e is 1. Upper main bearing inserts to the block. Apply
0.006-0.010-inch. engine oil to the main bearings.
6. Oil pump, as outlined previously. 2. Crankshaft.
7. Oil pan, as outlined previously. 3. Lower main bearing inserts to the main bearing
8. Spark plugs. caps. Apply engine oil to the bearing inserts.
Measure
unit repair manual.
Remove or Disconnect (Figure 27) 4. Main bearing caps (except rear cap) and bolts to
the block.
Tool Required:
J-5239 Guide Set Tighten
2. Flywheel (if used) as outlined later. Main bearing cap bolts to 150 N m (110 ft.
lbs.).
Mount the engine in a suitable engine stand.
5. Rear crankshaft oil seal to the block and main
3. Spark plugs.
bearing cap, as outlined previously.
6 . Rear main bearing cap to the block.
5. Front cover, as outlined previously. Apply a brush-on type oil sealing compound
6. Camshaft sprocket and timing chain, as outlined to the mating surface of the block and cap
previously. (figure 22). Do not allow any sealant on
7. Oil pan and oil pump, as outlined previously. either crankshaft or rear oil seal.
6A6-22 7.4 LITER V8
Install the rear main bearing cap and bolts. Important

ft. lbs.). Align the timing marks (figure 24).
m Measure 12. Oil pan and oil pump, as outlined previously.
14. Spark plugs.
rearward then forward with a lead 15. Flywheel (if equipped) as outlined later.
hammer. This will line up the rear main 16. Engine, as outlined later.
surfaces.
Tighten the rear main bearing cap FLYWHEEL REPLACEMENT
measure at the front end of the rear Remove or Disconnect
34). The p ro p e r cle a ra n c e is 1. Transmission, flywheel housing, and clutch.
0.006-0.010-inch. 2. Flywheel bolts.
3. Flywheel.
I? Inspect
13 1 Clean
Crankshaft for binding. Try turning the
crankshaft to check for binding. If the Mating surfaces of crankshaft and flywheel.
crankshaft does not turn freely, loosen the Remove any burrs.
main bearing cap bolts, one set at a time,
until the tight bearing is located. Burrs on
L* Inspect
insert and the block for the bearing cap, or a

Flywheel for burning, scoring, warping, and wear.
faulty insert could cause a lack of clearance
Replace the flywheel if necessary. Do not
at the bearing.
machine the flywheel.
7. Connecting rods to the crankshaft. Use J-5239 to
Flywheel ring gear for worn or broken teeth.
pull the connecting rods down (figure 27). Make
sure the connecting rod bearing insert stays in
place. Flywheel Ring Gear Replacement
1. Use a torch to heat the gear around the entire
circum ference, then drive the gear off the
Measure
flywheel, using care not to damage the flywheel.
the proper unit repair manual. NOTICE: Never heat starter gear to red heat as
this will change metal structure.
8. Connecting rod caps with bearing inserts to the
connecting rods. Apply engine oil to the inserts.
2. Uniformly heat the flywheel gear to temperature
$ Tighten
3. As soon as the gear has been heated, install on
the flywheel.
lbs.).
+ + Install or Connect
| ^ | Measure
1. Flywheel.
Connecting rod side clearance. Use a feeler 2. Flywheel bolts.
crankshaft (figure 31). The correct clearance Tighten
is 0.013-0.023-inch.
10. Camshaft sprocket and timing gears, as outlined Flywheel bolts to 90 N m (65 ft. lbs.).
previously. 3. Clutch, flywheel housing, and transmission.
7.4 LITER V8 6A6-23
ENGINE MOUNTINGS FRONT MOUNTING REPLACEMENT

NOTICE: Broken or deteriorated mountings 37)
can cause m isa lig n ed and e ven tu al
When a single mounting breakage occurs, the NOTICE: When raising or supporting the
rem aining m ountings are su b jec te d to engine for any reason, do not use a jack under
abnormally high stresses. the oil pan, any sheet metal or crankshaft
INSPECTING ENGINE MOUNTINGS against the oil pan may cause it to be bent
Front Engine M ountings damaged oil pickup unit.
NOTICE: When raising or supporting the Support the engine with a suitable jack. Do not
engine for any reason, do not use a jack under load the engine mounting.
pulley. Due to the small clearance between 1. Engine mounting through-bolt and nut.
NOTICE: Raise the engine only enough for
sufficient clearance. Check for interference
between the rear of the engine and the dash
panel which could cause distributor damage.
rubber cushion. Observe both mountings while
of the engine mounting.
raising the engine.
2. Replace the mounting if the following conditions 2. Mounting assembly bolts, nuts, and washers.
exist:
check cracks.
plate of the mounting. 1. Mounting assembly.

3. If there is movement between a metal plate of the section.
engine and tighten the bolts or nuts attaching the 2. Mounting assembly bolts, nuts, and washers.
Rear M ountings a Tighten

35, 36, and 37.
exist:
Rubber cushion separated from the metal engine until the bolt can be inserted. Install the
plate of the mounting. nut.
3. If there is relative movement between a metal Tighten
tighten the bolts or nuts attaching the mounting to Through-bolt nut to specifications. Refer to
the transmission or crossmember. figures 35, 36, and 37.
6A6-24 7.4 LITER V8
A. Forward
B. 40 N m (30 Ft. Lbs.)
C. Torque Bolt To 115 N m (85 Ft. Lbs.) Or, Torque Nut To 75 N-m (55 Ft. Lbs.)
D. 48 N m (36 Ft. Lbs.)
E. Torque Bolt To 48 N m (36 Ft. Lbs.) Or, Torque Nut To 40 N m (30 Ft. Lbs.)
151. Heat Shield (Engines With Federal Emissions Left Side Only)
B-07937
Figure 35Front Engine Mounting (C Models)

7.4 LITER V8 6A6-25

section.
3. Mounting to crossmember nut(s) and washer(s).
& Tighten

38, 39, and 40).
REAR MOUNTING REPLACEMENT

(P-MODELS WITH FLYWHEEL
HOUSING MOUNTING)
40 N m (30 Ft. Lbs.). 4- + Remove or Disconnect (Figure 41)

Forward Q
Torque Bolt 1. Bolt, cushion, and spacer.
to 115 N m cr
(85 Ft. Lbs.) NOTICE: When raising or supporting the
or, Torque Nut engine for any reason, do not use a jack under
to 75 N m (55 Ft. Lbs.) the oil pan, any sheet metal or crankshaft
D. 48 N m (36 Ft. Lbs.) pulley. Due to the small clearance between
151. Heat Shield (Engines the oil pan and the oil pump screen, jacking
E m issions Left Side Only)
Figure 36Front Engine M ounting (K Models)
REAR MOUNTING REPLACEMENT permit removal of the mounting.
(EXCEPT P-MODELS WITH FLYWHEEL 2. Engine mounting.
HOUSING MOUNTING)
|-+-| Install or Connect (Figure 41)
|<"| Remove or Disconnect (Figures 38, 39, and
40) 1. Engine mounting. Align the hole in the mounting
with the hole in the crossmember.
Lower the engine.
engine for any reason, do not use a jack under NOTICE: See Notice on page 6A6-1 of this
section.
the oil pan and the oil pump screen, jacking 2. Spacer, cushion, and bolt.
against the pump screen, resulting in a Tighten
weight on the rear mountings.
1. Mounting to crossmember nut(s) and washer(s). ENGINE REPLACEMENT
permit removal of the mounting. Remove or Disconnect
3. Mounting.

1. Hood.
0 Install or Connect (Figures 38, 39, and 40) 2.
3.
Air cleaner.
1. Mounting. 4. Radiator and fan shroud. Refer to ENGINE
Lower the rear of the engine. COOLING (SEC. 6B).
6A6-26 7.4 LITER V8
A. Front
B. 100 N m (75 Ft. Lbs.) 4 b .
C. 48 N m (36 Ft. Lbs.) A
D. 40 N m (30 Ft. Lbs.)
151. Heat Shield (Engines with Federal Emissions - Left
Side Only)

B-07939
Figure 37Front Engine Mounting (P Models)
5. Necessary engine wiring: 12. Starter.

Starter and solenoid wires. 13. Flywheel or torque converter cover.
Generator wires. 14. Flex plate to torque converter bolts (automatic
TRC solenoid and switch (if used) wires. transmission).
Temperature sensor wire. Lower the vehicle.
Oil pressure sender wire.
Distributor wires.
Any other necessary wiring.
6. Accelerator, cruise control and TVS linkages, as 15. Bell housing to engine bolts.
equipped. 16. Front engine mounting through bolts.
7. Fuel supply line from fuel pump. 17. Engine.
8. Necessary vacuum hoses:
Evaporative emission hoses. Install or Connect (Figures 36, 37, and 38)
Vacuum booster hose (if used).
Cruise control hose (if used). 1. Engine in the vehicle.
Any other necessary vacuum hoses.
9. Power steering pump, and lay aside. NOTICE: See Notice on page 6A6-1 of this
10. Air conditioning compressor, and lay aside. section.
Raise the vehicle.
11. Exhaust pipes at the manifolds. 2. Engine mounting through bolts and nuts.
7.4 LITER V8 6A6-27
ALL MODELS EXCEPT WITH THM 400 TRANSMISSION (RPQ-M40)
MODELS WITH THM 400 TRANSMISSION (RPQ M40)
A. Forward
B. 48 N m (36 Ft. Lbs.) B-07921
Figure 38Rear Engine Mounting (C Models)

6A6-28 7.4 LITER V8
A. 54 N m (40 Ft. Lbs.)

B. 48 N m (36 Ft. Lbs.)
C. Forward
B-07897
Tighten

36, 37, and 38.
3. Bell housing bolts.
Remove the lifting fixture and transmission jack.
Raise the vehicle.
4. Flex plate to torque converter bolts (automatic
transmission).
6. Starter.
7. Exhaust pipes at the manifolds.
8. Air conditioning compressor.
10. Vacuum hoses.
11. Fuel supply line.
12. Accelerator, cruise control, and TVS linkages, as
equipped.
13. Engine wiring.
14. Radiator and fan shroud: Refer to ENGINE
COOLING (SEC. 6B).
15. Air cleaner.
16. Hood.
18. Proper quantity and grade of coolant.
7.4 LITER V8 6A6-29
Figure 40Rear Engine Mounting (P Models with Transmission Tail Type Mounting)
6A6-30 7.4 LITER V8
Figure 41Rear Engine Mounting (P Models with

Flywheel Housing Type Mounting)
7.4 LITER V8 6A6-31
SPECIFICATIONS
GENERAL DATA:
Type V8
RPO LE8
Bore 4.25
Stroke 4.00
Firing Order 1-8-4-3-6-5-7-2
Oil Pressure 10 psi @ 500 RPM Minimum; 40-60 psi @ 2000 RPM
CYLINDER BORE:
Diameter 4.2495-4.2525
Thrust Side 0.0005 (Maximum)
Production
PISTON:
o ied icm isc;
PISTON RING:
C Top 0.0017-0.0032
0 o iu u v t ; Production
M 2nd 0.0017-0.0032
p n io a r a n r p
R Service Limit Hi Limit Production +0.001
t
S Top 0.010-0.018
s Production
I Gap 2nd 0.016-0.024
0
0 Hi Limit Production + 0.001
Clearance Service Limit
I Production 0.015-0.055
L Vjctp
Service Limit Hi Limit Production + 0.010
PISTON PIN:
Diameter 0.9895-0.9898
B-07940
6A6-32 7.4 LITER V8
SPECIFICATIONS

DISPLACEMENT 74L
CRANKSHAFT:
#1, #2, #3, #4 27481-2.7490
Diameter
#5 27476-2.7486
Taper
Main #1,#2, #3, #4 0.0013-0.0025
Production
Bearing #5 0.0024-0.0040
Clearance #1, #2, #3, #4 0.0010-0.0025
Service Limit
#5 0.0025-0.0035
Diameter 2.1990-2.200
Production 0.0005
Taper
Crankpin Service Limit 0.001
Out Production 0.0005
Round Service Limit 0.001
CAMSHAFT:
Lobe Intake 0.2343
Lift + 0.002 Exhaust 0.2530
VALVE SYSTEM:
Lifter Hydraulic
Intake 3/4 Turn Down From Zero Lash
Valve Lash
Exhaust
CD
0

Seat Runout (Intake & Exhaust 0.002 (Maximum)
Intake V32-V16
Seat Width
Exhaust 1/l 6-3/32
Intake 0.0010-0.0027
Production
Service
Free Length 2.12
Pressure Closed 74-86 lbs. @ 1.80 in.
Valve lbs. @ in. Open 195-215 lbs. @ 1.40 in.
Spring Installed Height 151/64
+ V32"
Valve Spring Fit In Damper 0.042-0.094 Interference
B-07941
6A6-33 7.4 LITER V8
Item N-m Ft. Lbs. In. Lbs.

Rocker Arm Cover N u ts ..................................................................... ............ 5.4 48
Intake Manifold Bolts........................................................................... ............ 40 30
Rocker Arm S tud s................................................................................ ............ 68 50
Exhaust Manifold Bolts
Models with stainless steel manifolds (RPO-NA5)................... ............ 54 40
Models with cast iron manifolds (RPO-NB2)............................. ............ 24 18
Cylinder Head Bolts.............................................................................. ............ 130 95
Torsional Damper B o lts....................................................................... ............ 115 85
Front Cover to Block B o lts ................................................................. ............ 10.8 96
Oil Pan to Front Cover B olts............................................................... ............ 7.9 70
Oil Pan to Block B o lts ......................................................................... ............ 15.3 135
Oil Pump Bolt........................................................................................ ............ 90 65
Main Bearing C a p s .............................................................................. ............ 150 110
Camshaft Sprocket Bolts..................................................................... ............ 26 20
Connecting Rod Cap N u ts ................................................................. ............ 66 48
Oil Filter Bypass Valve Bolts............................................................... ............ 26 20
Flywheel B o lts ...................................................................................... ............ 90 65
Oil Pump Cover B o lts ......................................................................... ............ 9.0 80
Flywheel Housing Bolts....................................................................... ............ 40 30
Water Pump B o lts ................................................................................ ............ 40 30
Water Outlet B o lts................................................................................ ............ 40 30
Spark P lu gs.......................................................................................... ............ 30 22
SPECIAL TOOLS
J-23590 Air Adapter

J-22102 Front Crankshaft Seal and Crankshaft Sprocket Installer
J-5239 Guide Set
6A7-1
SECTION 6A7
6.2L DIESEL
section.
CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 6A7- 2

On-Vehicle S e r v ic e .................................................................................................................................................6A7- 3
Intake Manifold R e p la ce m e n t........................................................................................................................... 6A7- 3
Exhaust Manifold Replacem ent......................................................................................................................... 6A7- 3
Rocker Arm, Shaft, and Pushrod Replacement.............................................................................................6A7- 6
Cylinder Head R e p la ce m e n t............................................................................................................................. 6A7- 9
Oil Pump Drive R e p la c e m e n t........................................................................................................................... 6A7-13
Torsional Damper and Front Crankshaft Seal R e p la ce m e n t..................................................................... 6A7-13
Front Cover R e p lace m e n t..................................................................................................................................6A7-14
Tim ing Chain and Sprocket R eplacem ent......................................................................................................6A7-15
Dipstick Tube Replacement............................................................................................................................... 6A7-18
Oil Pan Replacement (C and K M o d els)..........................................................................................................6A7-19
Oil Pump Replacement (C and K M o d e ls )......................................................................................................6A7-20
Oil Pan and Oil Pump Replacement (G M o d e ls )...........................................................................................6A7-20
Rear Crankshaft Oil Seal R e p la ce m e n t..........................................................................................................6A7-21
Connecting Rod and Piston R eplacem ent..................................................................................................... 6A7-23
Main Bearing R e p lace m e n t............................................................................................................................... 6A7-25
Crankshaft R e p lacem ent....................................................................................................................................6A7-27
Engine M ountings.................................................................................................................................................6A7-28
S pe cifica tio ns........................................................................................................................................................... 6A7-38
Special T o o ls ........................................................................................................................................................... 6A7-40
6A7-2 6.2L DIESEL
DESCRIPTION
Rocker Arm
Camshaft Bearings
Oil Cooler Bypass Valve
Oil Filter Bypass Valve
Oil Filter
A. Forward Cup Plug
B. To Oil Cooler Plug
C. From Oil Cooler Valve Lifters
D. From Oil Pump Pushrod
F-08022
Figure 1Lubrication Diagram
6.2L diesel engines are 90 degree V8 type, naturally ENGINE LUBRICATION

aspirated, with indirect type combustion chambers.
A lubrication schematic is shown in figure 1.
The crankshaft is supported by five precision insert
The gear type oil pump is driven from either the
main bearings, with crankshaft thrust taken at the num
vacuum pump shaft or from a drive gear, depending on
ber three (center) main bearing.
engine application. The vacuum pump or drive gear is
The camshaft is supported by five plain type bear driven by the camshaft. Oil is drawn into the pump
ings and is chain driven. Motion from the camshaft is through a pickup screen and pipe.
transmitted to the overhead valves by roller type hy Pressurized oil is routed to the oil cooler, located in
draulic lifters, pushrods, and spindle mounted rocker the radiator. A bypass valve is provided should the oil
arms. The valve guides are integral in the cylinder cooler become clogged. Oil flows from the cooler to a
head. full flow oil filter. An oil filter bypass valve is provided
should the oil filter become clogged.
The connecting rods are forged steel, with precision Oil flows from the oil filter to the oil galleries,
insert type crankpin bearings. The piston pins are re p ro v id in g p re s s u riz e d lu b ric a tio n to v a rio u s
tained by snap ring retainers. components.
6.2L DIESEL 6A7-3
The hydraulic valve lifters receive oil from the oil The pistons, rings, piston rings, cylinder walls, and
galleries. Oil flows from the hydraulic lifters through connecting rod small end bearing are lubricated by oil
hollow pushrods to the rocker arms. Oil from the splash.
overhead drains back to the crankcase through oil
drain holes.
ON-VEHICLE SERVICE
INTAKE MANIFOLD Tighten
REPLACEMENT Intake manifold bolts to 42 N m (32 ft. lbs.).

Use the tightening sequence shown in
Remove or Disconnect figure 2.
Rotate the vacuum pump to the proper position
Tool Required:
and tighten the clamp bolt (gear driven vacuum
J-29664-1 Intake Port Covers pumps).
1. Battery cables. 4. Fuel filter bracket (G models).
2. Engine cover (G models). 5. Fuel line bracket and ground strap.
3. Air cleaner. 6. Rear air conditioning compressor bracket (if
4. EGR/EPR solenoids with bracket from the intake equipped).
manifold studs. 7. EGR and crankcase ventilation hoses.
5. CDR valve (G models). 8. CDR valve (G models).
6. EGR and crankcase ventilation hoses. 9. EGR/EPR solenoids with bracket.
7. Rear air conditioning compressor bracket (if 10. Air cleaner.
equipped). 11. Engine cover (G models).
8. Fuel line bracket and ground strap. 12. Battery cables.
9. Fuel filter bracket at the intake manifold (G
models).
10. Intake manifold bolts and fuel line clips. On EXHAUST MANIFOLD
models with gear driven vacuum pumps, it may REPLACEMENT
be necessary to loosen the vacuum pump clamp
bolt and turn the pump to provide access to an C AND K MODELS (RIGHT SIDE)
intake manifold bolt.
11. Intake manifold and gasket. Remove or Disconnect
Important 1. Battery cables.

Raise the vehicle.
If any further service work is to be done, 2. Exhaust pipe from the manifold.
cover the intake ports with J-29664-1.
Lower the vehicle.
3. Glow plug wires.
Clean
4. Air cleaner duct bracket.
Gasket surfaces on intake manifold and cylinder 5. Glow plugs.
heads. 6. Exhaust manifold bolts and exhaust manifold.
-4- Install or Connect (Figure 2) y | Clean
1. New gaskets. Be sure to use the correct gasket. Sealing surfaces on exhaust manifold and
The gaskets for light duty emissions models have cylinder head.
openings for the EGR, the gaskets for heavy duty Threads on manifold bolts.
emissions models do not. Be sure to remove
J-29664-1 from the intake ports, if necessary. Install or Connect
2. Intake manifold.
3. Intake manifold bolts and fuel line clips. 1. Exhaust manifold and bolts.
6A7-4 6.2L DIESEL
Figure 2intake Manifold Installation
Tighten 3. Rem aining exhaust m anifold bolts and air

conditioning compressor rear bracket (if used).
2. Glow plugs. Tighten
3. Air cleaner duct bracket.
4. Glow plug wires. Bolts to 35 N m (26 ft. lbs.).
Raise the vehicle. 4. Glow plugs.
5. Exhaust pipe to the manifold. 5. Dipstick tube.
Lower the vehicle.
6. Battery cables.
6. Battery cables.
G MODELS (BOTH SIDES)
C AND K MODELS (LEFT SIDE)
4- + Remove or Disconnect
1. Battery cables.
1. Battery cables.
2. Dipstick tube. Raise the vehicle.
3. Glow plugs. 2. Exhaust pipe at the manifold.
4. Air conditioning compressor rear bracket (if Lower the vehicle.
equipped). 3. Engine cover.
5. Exhaust manifold bolts. 4. Glow plug wires. np
Raise the vehicle. 5. Air conditioning compressor rear bracket (if
6. Exhaust pipe at the manifold. equipped) (left side exhaust manifold).
7. Exhaust manifold, from below the vehicle.
6. Exhaust manifold bolts and exhaust manifold.
jm j|
Clean
Clean
Sealing surfaces on the exhaust manifold and
cylinder head. Stealing surfaces on the exhaust manifold and
cylinder head.
Threads on the manifold bolts.
0 Install or Connect +4- Install or Connect

1. Exhaust manifold, from below the vehicle.
Loosely install two or three bolts to hold the 1. Exhaust manifold.
manifold in place. 2. Exhaust manifold bolts and air conditioning
2. Exhaust pipe to the manifold. compressor rear bracket (if equipped) (left side
Lower the vehicle. exhaust manifold).
6.2L DIESEL 6A7-5
Tighten

3. Glow plug wires.
4. Engine cover.
Raise the vehicle.
5. Exhaust pipe to the manifold.
Lower the vehicle.
6. Battery cables.
ROCKER ARM COVER

REPLACEMENT
Figure 3Apply Sealant To The
C AND K MODELS (BOTH SIDES) Rocker Arm Cover
G MODELS (RIGHT SIDE)
cylinder head, inboard of the bolt holes. Refer to
0 Remove or Disconnect figure 3. The sealer must be wet to the touch
when the bolts are torqued.
1. Intake manifold, as outlined previously. 1. Rocker arm cover.
2. Fuel injection lines. Refer to DIESEL FUEL
INJECTION (SEC. 6C2). (Injection lines for #5 2. Rocker arm cover bolts.
and #7 cylinders do not have to be removed for
right side rocker arm cover replacement).
3. Glow plug wires (G models).
4. Wiring harness from wiring harness clip. Bolts to 22 N m (16 ft. lbs.).
5. Wiring harness bracket (left rocker arm cover). 3. Wiring harness bracket.
6. Rocker arm cover bolts. 4. Wiring harness to the wiring harness clip.
5. Glow plug wires (G models).
NOTICE: Do not pry on the rocker arm cover. 6. Fuel injection lines. Refer to DIESEL FUEL
Damage to sealing surfaces may result. INJECTION (SEC. 6C2).
Clean G MODELS (LEFT SIDE)
1. RTV from the rocker arm cover and cylinder Remove or Disconnect
head. All loose RTV, or pieces that will cause
installation interference, must be removed. 1. Intake manifold, as outlined previously.
2. Oil and grease from the sealing surfaces on the 2. Fuel injection lines. Refer to DIESEL FUEL
rocker arm cover and cylinder head. Use a INJECTION (SEC. 6C2).
suitable solvent.
3. Upper fan shroud (vehicles with air conditioning).
L* Inspect 4. Air conditioning compressor belt (if equipped).

5. Left exhaust manifold, as outlined previously
Rocker arm cover sealing flanges for distortion. (vehicles with air conditioning).
Replace as necessary.
6. Air conditioning compressor (if equipped). Refer
to AIR CONDITIONING (SEC. 1B).
7. Dipstick tube front bracket from stud.
NOTICE: Do not allow RTV sealant into the 8. Wiring harness brackets.
rocker arm cover bolt holes. This may cause a
hydraulic lock condition when the bolts are 9. Rocker arm cover bolts and fuel return bracket.
tightened, dam aging the cylinder head
casting. NOTICE: Do not pry on the rocker arm cover.
Damage to the sealing surfaces may result.
Apply a 5 mm (3/ie-inch) bead of RTV sealant
(GM part number 1052915 or equivalent) to the 10. Rocker arm cover.
6A7-6 6.2L DIESEL
|mj| Clean degree of hardness at each end. A paint

stripe identifies the upper end of the
1. RTV from the rocker arm cover and cylinder pushrod. If the paint stripe is not visible,
head. All loose RTV, or pieces that will cause mark the pushrods on the upper end as they
installation interference, must be removed. are removed.
2. Oil and grease from the sealing surfaces on the The pushrods should be installed in the
rocker arm cover and cylinder head. Use a same location at assembly.
suitable solvent. 5. Rocker arms, if required.
Insert a screwdriver into the rocker arm
Inspect
shaft bore, and break off the end of the
Rocker arm cover sealing flanges for distortion. nylon rocker arm retainers.
Replace as necessary. Remove the rocker arm retainers with pliers
(figure 5).
Install or Connect (Figure 3) Slide the rocker arms from the shaft.
NOTICE: Do not allow RTV sealant into the Install or Connect (Figures 4 and 6)
rocker arm cover bolt holes. This may cause a
hydraulic lock condition when the bolts are 1. Rocker arms to the rocker arm shaft. One type of
tightened, dam aging the cylinder head rocker arm is used at all locations.
casting.
Important
2. Rocker arm cover bolts and fuel return bracket.
Lubricate the rocker arms with engine oil
before installing.
Tighten
2. Rocker arm retainers.
Bolts to 22 N m (16 ft. lbs.). C e n te r the ro cke r arm s on the
3. Wiring harness brackets. corresponding holes in the rocker arm shaft.
4. Dipstick tube front bracket. Install new retainers. Use a drift of at least
5. Air conditioning compressor (if equipped). Refer 13 mm (1/2 -inch) diameter.
6. Left exhaust manifold, as outlined previously (if NOTICE: The pushrods must be installed with
removed). the marked or painted end up. Failure to do so
7. Air conditioning compressor belt (if equipped). may result in damage or premature wear.
8. Upper fan shroud (if removed).
9. Fuel injection lines. Refer to DIESEL FUEL 3. Pushrods, with the painted or marked end up.
INJECTION (SEC. 6C2).
4. Rocker arm shaft assembly. Make sure the ball
10. Intake manifold, as outlined previously. ends of the pushrods seat in the rocker arms.
ROCKER ARM, SHAFT, AND NOTICE: Improper installation of the rocker

arm shaft bolts may cause rocker arm shaft
PUSHROD REPLACEMENT breakage and/or piston to valve contact.

5. Rocker arm shaft bolts.
1. Rocker arm cover, as outlined previously. Rotate the engine until the mark on the
torsional damper aligns with the 0 mark
2. Rocker arm shaft nuts.
on the timing tab.
3. Rocker arm shaft with rocker arms. Mark the
assemblies so they can be returned to the Rotate the engine counterclockwise 88 mm
original location at assembly. (3 1/2-inches), measured at the torsional
4. Pushrods. dam per. T h is m e a su re m e n t can be
estimated by aligning the torsional damper
Im portant mark with the first lower water pump bolt
(figure 6). This procedure will position the
The pushrods must be installed in the engine so no valves are close to a piston
original direction at assembly. This is crown.
because the pushrods have a different Install both bolts snug on the shaft.
6.2L DIESEL 6A7-7
Figure 4Valve Train Components
a Tighten Cylinder head, as outlined later (G models).

Clamps (32).
Bolts alternately to 55 N m (40 ft. lbs.). Guide plates (33). Use mechanical fingers, if
6. Rocker arm cover, as outlined previously. necessary.
Hydraulic lifters, through the access hole in the
cylinder head. On C and K Models, use J-29834
HYDRAULIC LIFTER and a magnet. Place the lifters in an organizer
REPLACEMENT rack. The lifters must be installed in the same
bore from which they were removed.

L* Inspect
Tool Required:
J-29834 Hydraulic Lifter Remover (C and K Hydraulic lifter body for scuffing and scoring.
Models) Replace the lifter if present.
Roller for looseness and excessive play. Check
1. Rocker arm covers, as outlined previously. for missing or broken needle bearings. Replace if
2. Rocker arm shaft with rocker arms and pushrods, necessary.
as outlined previously. Roller surface for pits and roughness. If present,
the m ating cam shaft lobe should also be
Im portant checked. If the lobe is pitted or rough, replace
both camshaft and lifter.
Rocker arm assemblies and pushrods must
be marked for proper assembly, as outlined Hydraulic L ifte r Repair
previously. Refer to the proper unit repair manual.
Some engines will have both standard and

0.010-inch oversize hydraulic lifters. The oversize
lifter will have a 10 etched on the side. The
block will be stamped O.S. on the cast pad
adjacent to the lifter bore and on the top rail of the
cylinder case above the lifter bore.
NOTICE: New hydraulic lifters must be primed

before installation. Damage to the lifters may
result if dry when the engine is started.
6A7-8 6.2L DIESEL
B-08027
Figure 6A ligning The Tim ing Mark
1. Hydraulic lifters to the engine. On C and K in the guide plates. If the engine will not turn
models, fabricate an in stallatio n tool from over by hand, one or more of the lifters may
mechanics wire. be binding in the guide plate.
4. Cylinder head, as outlined later (G models).
5. Rocker arm shaft with rocker arms and pushrods,
in their original locations, as outlined previously.
P rim e new h y d ra u lic lifte rs befo re Hardened ends of the pushrods must face up.
installation by working the lifter plunger 6. Rocker arm covers, as outlined previously.
while submerged in clean kerosene or
diesel fuel.
Coat the lifter roller and bearings with VALVE STEM SEAL AND
lubricant (GM part number 1052365 or VALVE SPRING REPLACEMENT
equivalent).
Lifters MUST be installed in their original Remove or Disconnect (Figures 7 and 8)
locations.
Tools Required:
2. Guide plates (33). J-29666 Air Line Adapter
3. Clamps (32). J-26513 Valve Spring Compressor Or
J-5892-A Valve Spring Compressor
Tighten 1. Rocker arm covers, as outlined previously.
$ 2. Rocker arm shaft with rocker arms, as outlined
Clamp bolt to 26 N m (18 ft. lbs.). previously. Mark the assemblies so they can be
returned to their original locations.
Im portant 3. Glow plugs.
4. Valve keepers (42).
After all clamps are installed, turn the Rotate the engine until the piston for the
crankshaft by hand 720 degrees (two full cylinder being serviced is at TDC.
turns), to insure free movement of the lifters Install J-29666 into the glow plug hole.
6.2L DIESEL 6A7-9
41 42
40. Cap 45. Shield
41. Intake Valve 43 46. Valve Spring
42. Exhaust Valve 44 With Damper
43. Valve Keepers 47. Shim
44. Valve Seal 45 48. Rotator
IN T A K E EX H A U S T
B-08028
Figure 7Valves And Components
Apply compressed air to hold the valves in 3. Valve keepers (42).

place. With air pressure applied to the cylinder
Use J-26513 (or J-5892-A) to compress the with J-29666, compress the valve spring
valve spring (figure 8). If the spring will not with J-26513 (or J-5892-A) (figure 8).
compress, tap on the tool lightly with a Install the valve keepers. Use grease to hold
mallet to break the cap (40) or rotator (48) them in place.
loose from the valve keepers. Carefully release spring pressure. Make
Remove the valve keepers. sure the valve keepers stay in place.
Carefully release spring tension. Remove Remove J-26513 (or J-5892-A) and J-29666.
J-29666 or J-5892-A. 5. Glow plugs.
5. Cap (40) or rotator (48), shield (45), and valve 6. Rocker arm shaft with rocker arms, as outlined
spring with damper (46). previously.
6. Valve seal (44). 7. Rocker arm covers, as outlined previously.
+ 4- Install or Connect (Figures 7 and 8)

CYLINDER HEAD
Tools Required: REPLACEMENT
J-29666 Air Line Adaptor
J-26513 Valve Spring Compressor Or REMOVAL (C AND K MODELS) (BOTH SIDES)
1. New valve seal (44). 4- + Remove or Disconnect
2. Valve spring with damper (46), shield (45) and
cap (40) or rotator (48). 1. Intake manifold, as outlined previously.
2. In je c tio n lin e s . R efer to D IE SE L FUEL
J-26513 3. Rocker arm covers, as outlined previously.
4. Dipstick tube (left cylinder head).
5. Ground wire at the cowl (right cylinder head).
6. Glow plug relay (left cylinder head).
Raise the vehicle.
7. Exhaust pipe from the manifold.
Lower the vehicle.
8. Air conditioning compressor (if equipped) and lay
B-08029 aside (left cylinder head).
9. Generator, and lay aside (right cylinder head).
Figure 8Compressing The Valve Spring 10. Glow plug wires.
6A7-10 6.2L DIESEL
11. Glow plug temperature inhibit switch wire (right REMOVAL (G MODELS) (LEFT SIDE)
cylinder head).
12. Rocker arm assem blies and pushrods, as Remove or Disconnect
outlined previously.
Im portant 2. Injection lines at the injection pump. Refer to
DIESEL FUEL INJECTION (SEC. 6C2).
Rocker arm assemblies and pushrods must 3. Transducer (cruise control equipped vehicles).
be marked for proper assembly, as outlined 4. U pper fan sh ro ud and a ir c o n d itio n in g
previously. compressor belt (vehicles with air conditioning).
13. Radiator, bypass and heater hoses. Raise the vehicle.
14. Ground strap. 5. Left exhaust manifold, as outlined previously.
15. W ater cro sso ver p ip e /th e rm o s ta t housing 6. Power steering pump lower adjusting bolts.
assembly. 7. Glow plug wires.
16. Cylinder head bolts. Rear bolt in left cylinder 8. Glow plug temperature inhibit switch.
head may have to remain in the head during 9. In je c tio n lin e s. R efer to D IE SE L FUEL
removal. INJECTION (SEC. 6C2).
17. Cylinder head. Lower the vehicle.
REMOVAL (G MODELS) (RIGHT SIDE) to AIR CONDITIONING (SEC. 1B).
11. Upper power steering pump brackets. Lay the
Remove or Disconnect pump aside.
12. Dipstick tube front bracket from the stud.
13. Transmission detent cable.
2. In je c tio n lin e s. R e fer to D IE S E L FUEL
14. Glow plug controller, bracket, and relay.
15. Wiring harness bracket.
3. Transducer (cruise control equipped vehicles).
16. Vacuum line clip, at the cylinder head.
4. U p p er fan sh ro ud and a ir c o n d itio n in g
compressor belt (vehicles with air conditioning). 17. Fuel return line bracket.
Raise the vehicle. 18. Rocker arm cover, as outlined previously.
5. Exhaust pipe at the manifold. 19. Rocker arm assem blies and pushrods, as
6. Rear air conditioning compressor bracket at the
exhaust manifold (if equipped).
Important
7. Glow plug wires.
Lower the vehicle.
Rocker arm assemblies must be marked for
8. Air conditioning compressor (if equipped). Refer proper assembly, as outlined previously.
9. Dipstick tube front bracket from the stud.
20. Air cleaner resonator and bracket.
10. Oil fill tube upper bracket.
21. Transmission dipstick tube at the front attaching
11. Rocker arm cover, as outlined previously. stud and lay aside.
12. Rocker arm assem blies and pushrods, as 22. Generator upper bracket.
23. Water crossover pipe/thermostat assembly.
24. Cylinder head bolts.
Im portant
25. Cylinder head.
Rocker arm assemblies must be marked for
proper assembly, as outlined previously. CLEANING AND INSPECTION
Clean
14. Transmission dipstick tube. Carbon deposits from combustion chambers.
15. Heater, radiator and bypass hoses at the engine. All traces of old head gasket from cylinder head
16. Generator upper bracket. and block. Use of a motorized wire brush is not
17. Water crossover pipe/thermostat assembly. recommended.
18. Cylinder head bolts. Cylinder head bolt threads using a wire brush.
19. Cylinder head. Metal chips and dirt from the threads in the block.
6.2L DIESEL 6A7-11
If the engine has 0.030-inch oversize

pistons, the oversize type head gasket must
be used.
DO NOT use a sealer on the head gasket.
The head gasket is manufactured with the
proper amount of sealant printed on its
surface. A dd itional sealer may cause
leakage or malfunction. In addition, some
sealers may attack the sealant already on
the head gasket.
2. Rear cylinder head bolt to the cylinder head (left
B-08030 cylinder head). Apply sealant to the bolt as
described in step 4. Due to clearances, the bolt
Figure 9Head Bolt Tightening Sequence must be installed at this time.
3. Cylinder head. Make sure the gasket surfaces are
inspect clean. Guide the head carefully into place over
L*
the dowel pins.
Cylinder head for cracks between the intake and 4. Cylinder head bolts.
exhaust ports. Use the magnaflux or dye method Make sure the bolt threads are clean.
if available. Apply sealant (GM part number 1052080 or
Sealing surfaces of the block and cylinder head equivalent) to the bolt threads and under the
for nicks, heavy scratches, or other damage. bolt heads.
Block for missing or damaged dowel pins, or
dowel pins in the wrong location. Tighten
Measure Cylinder head bolts, as follows:

Using the sequence shown in Figure 9,
Cylinder head warpage. If warped more than 0.15 tighten all bolts to 25 N-m (20 ft. lbs.).
mm (0.006-inch) lo n g itu d in a lly or 0.08 mm In sequence, tighten all bolts to 65 N-m (50
(0.003-inch) transversely, replace the cylinder ft. lbs.).
head. Resurfacing is not recommended. In sequence, tighten all bolts an additional
Pre-chamber installed depth. The pre-chamber 90 degrees (1/4 turn).
should be flush to a maximum of 0.05 mm 5. Water crossover pipe/thermostat assembly. Use
(0.002-inch) protrusion. new gaskets.
Make the measurement at two or more
points on the pre-cham ber where the Tighten
prechamber seats on the head gasket shield
and sealing ring. Bolts to 42 N-m (31 ft. lbs.).
Measure the difference between the flat of 6. Ground strap.
the pre-chamber and the flat surface of the 7. Radiator, bypass, and heater hoses.
cylinder head. 8. Pushrods and rocker arm assemblies, in their
The pre-chamber must not protrude out of original locations, as described previously.
the cylinder head more than 0.05 mm Hardened ends of the pushrods must face up.
(0.002-inch). 9. Glow plug temperature inhibit switch wire (right
The pre-chamber must not be recessed into cylinder head).
the cylinder head. 10. Glow plug wires.
11. Generator (right cylinder head).
CYLINDER HEAD REPAIR
12. Air conditioning compressor (left side cylinder
head).
INSTALLATION (C AND K MODELS) (BOTH SIDES) Raise the vehicle.
13. Exhaust pipe to the manifold.
Install or Connect (Figure 9) Lower the vehicle.
14. Glow plug relay (left cylinder head).
1. Head gasket to the block, over the dowel pins. 15. Ground wire at the cowl (right cylinder head).
16. Dipstick tube (left cylinder head).
Im portant 17. Rocker arm covers, as outlined previously.
18. In je c tio n lin e s. R efer to D IE SE L FUEL
The block gasket surfaces must be clean. INJECTION (SEC. 6C2).
6A7-12 6.2L DIESEL
19. Intake manifold, as outlined previously. 13. Air conditioning compressor (if equipped). Refer
Fill the cooling system with the proper quantity to AIR CONDITIONING (SEC. 1B).
and grade of coolant. Raise the vehicle.
14. Glow plug wires.
INSTALLATION (G MODELS) (RIGHT SIDE) 15. Rear air conditioning compressor bracket (if
equipped).
Install or Connect (Figure 9) 16. Exhaust pipe.
Lower the vehicle.
1. Head gasket to the block, over the dowel pins.
17. U pper fan sh ro ud and a ir c o n d itio n in g
compressor belt (vehicles with air conditioning).
Im portant
18. Transducer (if equipped).
The block gasket surfaces must be clean. 19. In je c tio n lin e s. R efer to D IE S E L FUEL
If the engine has 0.030-inch oversize INJECTION (SEC. 6C2).
pistons, the oversize type head gasket must 20. Intake manifold, as outlined previously.
be used. Fill the cooling system with the proper quantity
DO NOT use a sealer on the head gasket. and grade of coolant.
proper amount of sealant printed on its INSTALLATION (G MODELS) (LEFT SIDE)
surface. A dditional sealer may cause
leakage or malfunction. In addition, some -n - Install or Connect (Figure 9)
sealers may attack the sealant already on
the head gasket. 1. Head gasket to the block, over the dowel pins.
2. Cylinder head. Make sure the gasket surfaces are
clean. Guide the head carefully into place over Important
the dowel pins.
3. Cylinder head bolts. The block gasket surfaces must be clean.
Make sure the bolt threads are clean. If the engine has 0.030-inch oversize
Apply sealant (GM part number 1052080 or pistons, the oversize type head gasket must
equivalent) to the bolt threads and under the be used.
bolt heads. DO NOT use a sealer on the head gasket.
Tighten proper amount of sealant printed on its
surface. A dditional sealer may cause
Cylinder head bolts, as follows: leakage or malfunction. In addition, some
Using the sequence shown in figure 9, sealers may attack the sealant already on
tighten all bolts to 25 N-m (20 ft. lbs.). the head gasket.
In sequence, tighten all bolts to 65 N-m 2. Cylinder head. Make sure the gasket surfaces are
(50 ft. lbs.). clean. Guide the head carefully into place over
In sequence, tighten all bolts an the dowel pins.
additional 90 degrees (1/4 turn). 3. Cylinder head bolts.
4. Water crossover pipe/thermostat assembly. Use Make sure the bolt threads are clean.
new gaskets. Apply sealant (GM part number 1052080 or
equivalent) to the bolt threads and under the
bolt heads.
Bolts to 42 N-m (31 ft. lbs.). Tighten

5. Generator upper bracket.
6. Heater, radiator, and bypass hoses. Cylinder head bolts, as follows:
7. Transmission dipstick tube. Using the sequence shown in figure 9,
8. Air cleaner resonator and bracket. tighten all bolts to 25 N-m (20 ft. lbs.).
9. Pushrods and rocker arm assemblies, in their In sequence, tighten all bolts to 65 N-m
original locations, as described previously. (50 ft. lbs.).
Hardened ends of the pushrods must face up. In sequence, tighten all bolts an
10. Rocker arm cover, as outlined previously. additional 90 degrees (1/4 turn).
11. Oil fill tube upper bracket. 4. Water crossover pipe/thermostat assembly. Use
12. Dipstick tube front bracket. new gaskets.
6.2L DIESEL 6A7-13
A. Forward
60. Oil Pump Drive 60
Bolts to 42 N-m (31 ft. lbs.). 61. C la m p ----------------L__
5. Generator upper bracket. 62. Bolt / J j\
6. Transmission dipstick tube. 63. Gasket 61
8. Pushrods and rocker arm assemblies, in their
original locations; as described previously.
Hardened ends of the pushrods must face up. /I -------- 62
10. Fuel return line bracket. 63 / / B-08031
11. Vacuum line clip.
12. Wiring harness bracket. Figure 10Oil Pump Drive Installed
13. Glow plug controller, bracket, and relay.
15. Dipstick tube front bracket.
s Install or Connect (Figure 10)
1. New gasket to the oil pump drive.

16. Power steering pump and brackets.
2. Oil pump drive to the engine. Index the drive with
17. Air conditioning compressor (if equipped). Refer the camshaft gear and oil pump drive shaft. Make
to AIR CONDITIONING (SEC. 1B). sure the drive seats fully.
Raise the vehicle. 3. Clamp and bolt.
18. In je c tio n lin e s. R efer to D IE S E L FUEL
INJECTION (SEC. 6C2). Tighten
19. Glow plug temperature inhibit switch.
20. Glow plug wires. Bolt to 42 N-m (31 ft. lbs.).
21. Power steering pump lower adjusting bolts.
22. Left exhaust manifold, as outlined previously. TORSIONAL DAMPER AND
Lower the vehicle.
FRONT CRANKSHAFT SEAL
23. U pper fan sh ro u d and a ir c o n d itio n in g
compressor belt (vehicles with air conditioning). REPLACEMENT
24. Transducer (if equipped).
Fill the cooling system with the proper quantity Tools Required:
and grade of coolant. J-23523-E Torsional Damper Puller
Evacuate and charge the air conditioning system. J-29788 Pilot
Refer to AIR CONDITIONING (SEC. 1B). 1. Battery cables.
2. Upper fan shroud (G models).
OIL PUMP DRIVE Raise the vehicle (G models).
REPLACEMENT 4. Bolts and crankshaft pulley.
For gear driven vacuum pump replacement, refer to 6. Torsional damper. Use J-23523 and J-29788.
VACUUM PUMP (SEC. 6H). 7. Front crankshaft seal. Pry out with a screwdriver.
NOTICE: Do not run the engine without the -n - Install or Connect (Figure 11)
gear driven vacuum pump or oil pump drive in
place. This will cause extensive engine Tool Required:
damage. J-22102 Seal Installer
1. New front crankshaft seal. Use J-22102. Lubricate
the seal lips with engine oil.
Remove or Disconnect (Figure 10) Apply engine oil to the crankshaft stub.
2. Torsional damper. Tap into place with a mallet.
1. Bolt and clamp. Make sure the key is in place. Make sure the
2. Oil pump drive. damper is all the way on the crankshaft.
3. Gasket. 3. Torsional damper bolt and washer.
6A7-14 6.2L DIESEL
Torsional Damper
Crankshaft Pulley
Bolt
Bolt
Washer
B-08032
Figure 11Torsional Damper And Crankshaft Pulley
Q Tighten Clean
Bolt to 270 N m (200 ft. lbs.)
4. Crankshaft pulley and bolts. RTV from oil pan sealing surface.
Sealing surfaces on front cover.
Tighten
Inspect
Front cover for cracks or damage to sealing
Lower the vehicle, if necessary. surfaces.
5. Accessory drive belts. Tension as outlined in
ENGINE COOLING (SEC. 6B). Install or Connect (Figures 12 and 13)
6. Upper fan shroud (G models).
7. Battey cables. Tool Required:
1. New front crankshaft seal to the front cover. Use
FRONT COVER J-22102.
REPLACEMENT Apply a 2 mm (3/32-inch) bead of anaerobic
sealant (GM part number 1052357 or equivalent)
|+ + | Remove or Disconnect (Figures 12 and 13) to the front cover sealing area shown in Figure
12.
Drain the cooling system. Apply a 5 mm (3/ie-inch) bead of RTV sealant to
the front cover sealing surface that mates against
the oil pan.
6B).
2. Front cover to the engine. Install the attaching
Rotate the engine until the timing marks on the bolts.
pump gear and camshaft gear are aligned (figure
13). Tighten
Scribe a mark aligning the injection pump flange
and front cover. Front cover to block bolts to 45 N m (33 ft.
2. Torsional damper, as outlined previously. lbs.).
3. Four front cover to oil pan bolts. Oil pan to front cover bolts to 10.0 N m (84
4. Two fuel return line clips. in. lbs.).
5. Injection pump gear. 3. Baffle.
6. Injection pump retaining nuts at the front cover.
Tighten
7. Baffle.
8. Front cover bolts. Baffle bolts and nut to 45 N m (33 ft. lbs.).
9. Front cover. Align the scribe marks on the front cover and
10. Front crankshaft seal. Pry out with a screwdriver. injection pump.
6.2L DIESEL 6A7-15
A. Apply Anaerobic Sealer 80. Front Cover 82. Probe Holder

B. Minimum Clearance 1.0 mm (0.040-inch) 81. Baffle 83. Camshaft Gear B-08033
Figure 12Front Cover And Components
4. Injection pump nuts. a minimum of 1.0 mm (0.040-inch) between

the gear and baffle, or noise may result.
Si Tighten 6.
7.
Fuel return line bolts.
Torsional damper, as outlined previously.
Nuts to 42 N m (31 ft. lbs.). 8. Water pump. Refer to ENGINE COOLING (SEC.
5. Injection pump gear and bolts. Align the timing 6B).
marks (figure 13). Fill the cooling system with the proper quantity
Tighten
TIMING CHAIN AND SPROCKET
Injection pump gear bolts to 23 N m (17 ft.
lbs.).
REPLACEMENT
Measure
1. Front cover, as outlined previously,
Clearance between injection pump gear and
baffle (figure 12). It is necessary to maintain tjj M easure
Timing chain free play as follows:

Mount a dial indicator to the front of
the block.
Position the dial indicator so that the
plunger contacts the timing chain
between the two gears.
Pull the chain outward (parallel to the
front face of the block) the maximum
amount with finger pressure on the
inside of the chain.
Set the dial indicator to zero.
Move the chain inward (parallel to the
front face of the block) the maximum
A. Timing Marks
amount with finger pressure on the
83. Camshaft Gear
outside of the chain.
84. Injection Pump Gear B-08034
The total indicator travel can be noted.
With used parts, the deflection must
Figure 13Injection Pump Gear And not exceed 20.3 mm (0.800 inch). If the
Timing Marks deflection exceeds this limit, the gears
6A7-16 6.2L DIESEL
83 90
100. Bolt
101. Thrust Plate
102 102. Key
103. Spacer
104. Camshaft
B-08036
A. Tinning Marks
83. Camshaft Gear
Figure 15Camshaft And Components
90. Camshaft Sprocket
91. Crankshaft Sprocket
B-08035 CAMSHAFT REPLACEMENT
Figure 14Tim ing Chain And Sprockets C AND K MODELS
and timing chain must be inspected for + + Remove or Disconnect (Figure 15)
wear and replaced as necessary. With
new parts the maximum deflection Battery cables.
must not exceed 12.7 mm (0.500 inch). Drain the cooling system.
2. Injection pump gear. 2 . Radiator, shrouds, and fan. Refer to ENGINE
3. Camshaft gear. COOLING (SEC. 6B).
Align the timing marks (figure 14). 3. Vacuum pump. Refer to VACUUM PUMP (SEC.
4. Camshaft sprocket with timing chain. 6H).
5. Crankshaft sprocket. Power ste e rin g pum p, generator, and air
conditioning compressor and position aside.
* i l Install or Connect (Figures 13 and 14) Rocker arm covers, as outlined previously.
Rocker arm assem blies and pushrods, as
1. Crankshaft sprocket. outlined previously.
2. Camshaft sprocket with timing chain.
Im portant
Im portant
Rocker arm assemblies and pushrods must
Align the timing marks (figure 14). be marked for proper assembly, as outlined
3. Camshaft gear, bolt, and washer. previously.
7. Hydraulic lifters, as outlined previously. Place the
a Tighten lifters in an organizer rack. The lifters must be
installed in the same bore from which they were
Bolt to 100 N m (75 ft. lbs.). removed.
4. Injection pump gear and bolts. 8. Front cover, as outlined previously.
9. Timing chain and camshaft sprocket, as outlined
Im portant previously.
10. Fuel pump (lift pump).
Align the timing marks (figure 13). 11. Front engine mounting through bolts.
$ Tighten NOTICE: When raising or supporting the

Bolts to 23 N m (17 ft. lbs.). the oil pan, any sheet metal or crankshaft
5. Front cover, as outlined previously. pulley. Due to the small clearance between
Adjust against the oil pan may cause it to be bent
Injection pump timing, if new gears, sprockets, or damaged oil pickup unit.
timing chain were installed. Refer to DIESEL
FUEL INJECTION (SEC. 6C2). Raise the engine and block in position.
6.2L DIESEL 6A7-17
12. Air conditioning condensor mounting bolts (if 10. Rocker arm assemblies and pushrods, in their
equipped). Lift the condensor with the aid of an o rig in a l lo ca tion s, as o u tlin e d previously.
assistant. Hardened ends of the pushrods must face up.
13. Bolts and thrust plate. 11. Rocker arm covers, as outlined previously.
14. Camshaft. Pull the camshaft from the block 12. Power ste e rin g pum p, generator, and a ir
carefully to avoid damage to the cam shaft conditioning compressor, as equipped.
bearings. 13. Vacuum pump. Refer to VACUUM PUMP (SEC.
15. Spacer (if necessary). 6H).
14. Fan, radiator, and radiator shrouds. Refer to
Cleaning, Inspection and Repair ENGINE COOLING (SEC. 6B).
Clean, inspect and repair or replace the camshaft 15. Battery cables.
and related components, as outlined in the proper unit Fill the cooling system with the proper quantity
repair manual. and grade of coolant.
bearing replacement. G MODELS
Install or Connect (Figures 14, 15, 30, and 31). Remove o r D isco n n e ct (Figure 15)
When a new camshaft is installed, replacement 1. Battery cables.

of all hydraulic lifters, engine oil, and oil filter is 2. Headlight bezels.
recommended. 3. Grille, bumper, and lower valence panel.
1. Spacer, w ith the ID cham fer tow ards the 4. Hood latch.
camshaft.
5. Coolant recovery bottle.
2. Camshaft.
6. Upper tie bar.
Coat the camshaft lobes with Molykote or
7. Air co nd itio n ing compressor. Refer to AIR
equivalent.
CONDITIONING (SEC. 1B).
Lubricate the camshaft bearing journals
with engine oil.
8. Radiator and fan. Refer to ENGINE COOLING
Insert the camshaft carefully into the block
(SEC. 6B).
to avoid damage to the camshaft bearings.
9. Oil pump drive, as outlined previously.
3. Thrust plate and bolts.
10. Cylinder heads, as outlined previously.
11. Generator lower bracket.
S i Tighten
Bolts to 23 N-m (17 ft. lbs.). 6B).
Lower the engine. 13. Torsional damper, as outlined previously.
NOTICE: See Notice on page 6A7-1 of this 15. Fuel pump (lift pump).
section. 16. Rocker arm covers, as outlined previously.
17. Rocker arm assem blies and pushrods, as
4. Engine mounting through bolts and nuts. outlined previously.
Tighten Im portant
Fasteners to specifications. Refer to figures Rocker arm assemblies and pushrods must
30 and 31. be marked for proper assembly, as outlined
5. T im in g chain and sp ro ckets, as o u tlin e d previously.
previously. 18. Hydraulic lifters, as outlined previously. Place the
lifters in an organizer rack. The lifters must be
Im portant installed in the same bore from which they were
removed.
Align the timing marks (figure 14). 19. Timing chain and camshaft sprocket, as outlined
6. Air conditioning condensor (if equipped). previously.
7. Fuel pump (lift pump). 20. Bolts and thrust plate.
8. Front cover, as outlined previously. 21. Camshaft. Pull the camshaft from the block
9. Hydraulic lifters, as outlined previously. Used carefully to avoid damage to the camshaft
lifters must be installed in the same bore from bearings.
which they were removed. 22. Spacer, if necessary.
6A7-18 6.2L DIESEL

repair manual.
-- Install or Connect (Figures 14 and 15).
When a new camshaft is installed, replacement

of all hydraulic lifters, engine oil, and oil filter is
recommended.
1. Spacer, w ith the ID cham fer tow ards the
camshaft.
2. Camshaft.
Coat the camshaft lobes with Molykote or
equivalent.
Lubricate the camshaft bearing journals Figure 16Oil Dipstick Tube (C and K Models)
with engine oil.
Insert the camshaft carefully into the block Evacuate and charge the air conditioning system
to avoid damage to the camshaft bearings. (if equipped). Refer to AIR CONDITIONING (SEC.
3. Thrust plate and bolts. 1B).
& Tighten
DIPSTICK TUBE REPLACEMENT
4. Timing chain and camshaft sprocket, as outlined C AND K MODELS
previously.
5. Hydraulic lifters, as outlined previously. Used
1. Battery cables.
lifters must be installed in the same bore from
2. Dipstick tube bracket, nut and washer, at the
which they were removed.
exhaust manifold.
6 . Rocker arm assemblies and pushrods, in their
3. Dipstick tube.
o rig in a l lo ca tion s, as o utline d previously.
4. O-ring from the dipstick tube.
Hardened ends of the pushrods must face up.
7. Rocker arm covers, as outlined previously. |~<-| Install or Connect (Figure 16)
8 . Fuel pump (lift pump).
9. Front cover, as outlined previously. 1. New o-ring to the dipstick tube.
10. Torsional damper, as outlined previously. 2. Dipstick tube to the engine.
11. Water pump. Refer to ENGINE COOLING (SEC. 3. Dipstick tube bracket nut and washer.
6B). 4. Battery cables.
12. Generator lower bracket.
13. Cylinder heads, as outlined previously. G MODELS
14. Oil pump drive, as outlined previously.
15. Radiator and fan. Refer to ENGINE COOLING Remove or Disconnect (Figure 17)
(SEC. 6B).
1. Battery cables.
16. A ir co nd itio n ing compressor. Refer to AIR
2. Engine cover.
CONDITIONING (SEC. 1B).
3. Air cleaner.
17. Upper tie bar.
4. Dipstick tube bracket, at the thermostat housing.
5. Dipstick tube bracket, at the rocker arm cover
19. Hood latch. bracket.
20. Grille, bumper, and lower valence panel. Raise the vehicle.
21. Headlight bezels. 6. Left exhaust manifold, as outlined previously.
22 Battery cables. 7. Dipstick tube from the oil pan.
Fill the cooling system with the proper quantity Lower the vehicle.
and grade of coolant. 8. Dipstick tube from the vehicle.
6.2L DIESEL 6A7-19
Figure 17Oil Dipstick Tube (G Models) Figure 18Oil Pan And Oil Pump
9. O-ring. NOTICE: When raising or supporting the

+ + Install or Connect (Figure 17) the oil pan, any sheet metal or crankshaft
1. New o-ring to the dipstick tube. the oil pan and the oil pump screen, jacking
2. Dipstick tube to the vehicle. against the oil pan may cause it to be bent
Raise the vehicle.
3. Dipstick tube to the oil pan.
4 Left exhaust manifold, as outlined previously. Raise the engine.
Lower the vehicle. 4. Oil pan bolts.
5. Dipstick tube bracket at the rocker arm cover 5. Oil pan.
6. Dipstick tube bracket at the thermostat housing. 6. Oil pan rear seal.
7. Air cleaner.
8. Engine cover. Clean
9. Battery cables.
1. Old RTV from the oil pan and block.
2. All oil and grease from the gasket surfaces.
OIL PAN REPLACEMENT
Install or Connect (Figure 18, 30, and 31)
(C AND K MODELS)
Apply a 5 mm (3/ie-inch) bead of RTV sealant
(GM part number 1052915 or equivalent) to the oil
pan sealing surface, inboard of the bolt holes
1. Battery cables. (figure 18). The sealer must be wet to the touch
Raise the vehicle. when the oil pan is installed.
Drain the engine oil. 1. Oil pan rear seal.
2. Flywheel cover. 2. Oil pan to the engine. Be sure to connect the oil
3. Left front engine mounting through-bolt. dipstick.
6A7-20 6.2L DIESEL
3. Oil pan bolts. OIL PAN AND OIL PUMP

REPLACEMENT (G MODELS)
Tighten
All except rear two bolts to 10.0 N m (84 in.
lbs.). 1. Battery cables.
Rear two bolts to 23 N m (17 ft. lbs.). 2. Engine cover.
Lower the engine. 3. Engine oil dipstick.
4. Engine oil dipstick tube at the rocker arm cover.
NOTICE: See Notice on page 6A7-1 of this 5. Transmission. Refer to TRANSMISSION (SEC. 7).
section. Drain the engine oil.
6. Engine oil cooler lines at the block.
4. Engine mounting through-bolt and nut. 7. Starter.
8. Oil pan bolts.
9. Oil pan and oil pump.
Tighten
Lower the oil pan from the engine.
Fasteners to specifications. Refer to figures Rotate the crankshaft so that the forward
30 and 31. crankshaft throw and numbers 1 and 2
connecting rod journals are up.
5. Flywheel cover. Oil pump to main bearing cap bolt.
Lower the vehicle. Let the oil pump and extension shaft fall into
6. Proper quantity and grade of engine oil. the oil pan.
7. Battery cables. Remove the oil pan and oil pan rear seal.
Clean
OIL PUMP REPLACEMENT 1. Old RTV from the oil pan and block.
(C AND K MODELS) 2. All oil and grease from the gasket surfaces.
L* Inspect
1. Oil pan, as outlined previously. Oil pump pick up tube and screen for damage.
2. Oil pump to main bearing cap bolt. Oil pump extension shaft bushing for cracks.
3. Oil pump and extension shaft.
Oil Pump Repair
L* Inspect
Oil pump pick up tube and screen for damage.
Oil pump extension shaft bushing for cracks. Apply a 5 mm (3/ie-inch) bead of RTV sealant
(GM part number 1052915 or equivalent) to the oil
Oil Pump Repair pan sealing surface, inboard of the bolt holes
Refer to the proper unit repair manual. (figure 18). The sealer must be wet to the touch
when the oil pan is installed.
Install or Connect 1. Oil pan rear seal to the oil pan.
2. Oil pan and oil pump to the engine.
1. Oil pump and extension shaft to the engine. Align Lay the oil pump and extension shaft in the
the extension shaft hex with the drive hex on the oil pan.
oil pump drive or vacuum pump. The oil pump Hold the oil pan and position the oil pump to
should push easily into place. the main bearing cap.
Align the extension shaft hex with the drive
2. Oil pump bolt.
hex on the oil pump drive or vacuum pump.
The oil pump should push easily into place.
$ Tighten Install the oil pump bolt and tighten.
Position the oil pan against the engine. Be
Oil pump bolt to 90 N m (65 ft. lbs.). sure to connect the dipstick tube.
3. Oil pan, as outlined previously. 3. Oil pan bolts.
6.2L DIESEL 6A7-21
All except rear two oil pan bolts to 10.0 N m

(84 in. lbs.).
Rear two oil pan bolts to 23 N m (17 ft. lbs.).
4. Starter.
5. Engine oil cooler lines.
6. Transmission. Refer to TRANSMISSION (SEC. 7).
7. Engine oil dipstick tube at the rocker arm cover.
8. Engine oil dipstick.
9. Engine cover.
11. Battery cables.
REAR CRANKSHAFT OIL SEAL

REPLACEMENT
The production rear crankshaft oil seal is a rope
type seal. The rope seal can be replaced with a two
piece type seal, if desired. Repair procedures for both
types of seal follow.
The CDR and crankcase ventilation system should
be thoroughly inspected and crankcase pressure
should be checked before a new seal is installed. Refer
A. Upper Seal Groove B-08040
to DRIVEABILITY AND EMISSIONSDIESEL (SEC.
6E9).
Figure 19Packing The Upper Rear Crankshaft
ROPE TYPE SEAL Oil Seal
Remove or Disconnect Install J-33154-1 onto the cylinder block

(figure 21).
Oil pan and oil pump, as outlined previously.
Rear main bearing cap. Use J-33154-2 to work the short pieces of
Old rope seal from the main bearing cap. Do not seal cut previously onto the guide tool and
discard. into the seal groove in the block (figure 21).
It may help to use engine oil on the seal
Clean pieces. The tools have been machined to
Main bearing cap and block mating surfaces.

Rope seal groove in the main bearing cap.
|~n-| Install or Connect (Figures 19 through 22)
Tools Required:
J-33154 Rear Oil Seal Packer
J-33153 Rear Oil Seal Installer
1. Rope seal pieces to the upper seal groove.
Use J-33154-2 and gently drive the upper
seal into the groove about 6 mm (1/4-inch).
Do this on both sides. Refer to figure 19.
Measure the amount the seal was driven up
on one side. Add 1.5 mm (Vie-inch). Cut this
length from the old seal removed from the
main bearing cap. Use the main bearing cap
as a holding fixture when cutting the seal
(figure 20). Use a sharp tool. Repeat this
procedure for the other side. Figure 20Cutting The Rope Seal
6A7-22 6.2L DIESEL
specification, check the ends of the seal for

fraying that may prevent the main bearing
cap from seating. Correct as necessary.
Remove the gaging material from the
bearing and journal.
NOTICE: The main bearing caps are to be

tapped into place with a brass or leather
mallet before the attaching bolts are installed.
Do not use the attaching bolts to pull the main
bearing caps into their seats, as this may
damage the bearing cap and/or block.
3. Main bearing cap to the block.

Apply a thin film of anaerobic sealant (GM
part number 1052756 or equivalent) to the
bearing cap as shown in figure 22. Keep the
sealant off the seal and bearing. Do not put
sealant in the bearing cap oil relief slot.
Apply a light coat of engine oil to the
provide a built-in stop. Use this procedure crankshaft surface that will contact the seal.
for both sides.
Apply engine oil to the main bearing cap
2 . New rope seal to the main bearing cap.
bolt threads.
Apply adhesive (GM part number 1052621 Tap the main bearing cap into place with a
[Loctite 414] or equivalent) to the seal brass or leather mallet. Then install the
groove. , bolts.
Position the rope seal on the bearing cap.
Use J-33153 to install the seal (figure 22). Tighten
After correctly positioning the seal, rotate
J-33153 slightly and cut the seal ends flush Bolts to specifications, in the following
with the bearing cap surface. Use a sharp sequence:
tool, (figure 22). Inner bolts: 150 N m (110 ft. lbs.).
Outer bolts: 135 N m (100 ft. lbs.).
Measure Re-tighten all bolts in the same
sequence.
Rear main bearing clearance, using plastic
4. Oil pump and oil pan, as outlined previously.
gaging material. Refer to the proper unit
repair manual. If the clearance is out of
TWO PIECE TYPE SEAL
A. Apply Anaerobic Sealer + + Remove or Disconnect

B. A fter Correctly Positioning
Seal, Rotate Tool Slightly 1. Oil pan and oil pump, as outlined previously.
And Cut Off Each End Of 2. Rear main bearing cap.
Seal Flush With Cap. 3. Upper and lower rope seal.
igi Clean
J-33153
Upper and lower seal grooves and bearing cap
slot with a chlorinated solvent, such as carburetor
spray cleaner.
Main bearing cap and block mating surfaces.
Measure
Rear main bearing clearance, using plastic gage

material. Refer to the proper unit repair manual. If
Figure 22Installing The Lower Rear the clearance is outside specifications, correct as
Crankshaft Oil Seal necessary.
6.2L DIESEL 6A7-23
Figure 23A pplying Sealer To The

Rear Main Bearing Cap A. Use short pieces of 10 mm (3/8-inch) hose to
protect the crankshaft journal. B-08045
Figure 24Replacing The Connecting Rod

1. Seal halves to the block. And Piston
Apply a light coat of engine oil to the seal
lips where they contact the crankshaft.
Tighten
Roll one seal half into the block seal
groove until 13 mm (1/2 -inch) of the seals
M ain b e a rin g cap b o lts to
one end is extending out of the block.
s p e c ific a tio n s , in the fo llo w in g
Insert the other seal half into the opposite sequence:
side of the seal groove in the block. Inner bolts: 150 N m (110 ft. lbs.).
Outer bolts: 135 N m (100 ft. lbs.).
\~l~\ Im portant Re-tighten all bolts using the
same sequence.
The contact ends of the seal halves should 3. Oil pump and oil pan, as outlined previously.
now be at the four and ten oclock positions,
or at the eight and two oclock positions.
This is necessary to align the rear main CONNECTING ROD AND PISTON
bearing cap and seal lips.
REPLACEMENT
NOTICE: To prevent damage to the main Remove or Disconnect (Figure 24)
bearing caps, the caps are to be tapped into

the block using a brass or leather hammer. 1. Cylinder head, as outlined previously.
The new seal is used as a guide. The cap must 2. Oil pan, as outlined previously.
NOT be pulled into the block with the bolts.
4. Ridge or deposits from the upper end of the
2. Main bearing cap to the block.
cylinder bores.
Lightly coat the seal groove in the main Turn the crankshaft until the piston is at
bearing with adhesive (GM part number BDC.
1052621 [Loctite 414] or equivalent).
Apply a thin film of anaerobic sealant (GM Perform the cutting operation with a ridge
part number 1052756 or equivalent) to the reamer.
main bearing cap as shown in figure 23. Do Turn the crankshaft until the piston is at
not put sealant in the bearing cap oil relief TDC.
slot.
Apply engine oil to the main bearing cap 5. Connecting rod cap. Check the connecting rod
bolt threads. and cap for identification makrs. Mark the parts if
Tap the main bearing cap into place with a required. The connecting rod and cap must be
brass or leather mallet. Then install the kept together as mating parts.
bolts. 6. Connecting rod and piston.
6A7-24 6.2L DIESEL
Attach two short pieces of 10 mm (3/a-inch)

hose to the connecting rod bolts (figure 24).
This will protect the crankshaft journal
during removal.
Push the connecting rod and piston out of
the bore.
7. Connecting rod bearings. Place the bearings in a
rack if they are to be reused, so they can be
returned to their original locations.

The unit repair manual contains information on:
Piston rings.
Connecting rod and crankpin.
Cylinder bores.
-- Install or Connect (Figures 24 through 27)
Tool Required:
Figure 25Ring Gap Location
Make sure the piston is installed in the matching
cylinder. Install new pistons in the cylinders for
which they were fitted. Install used pistons in the pieces of hose (figure 24). Hold the ring
cylinder from which they were removed. compressor against the block until all rings
1. Connecting rod bearings. have entered the cylinder bore.
Be certain that the bearings are the proper Remove the hoses from the connecting rod
size. bolts.
and connecting rod cap. Important
2. Piston and connecting rod to the proper bore. Each connecting rod and bearing cap
With the connecting rod cap removed, should be marked, beginning at the front of
install two short pieces of 10 mm (3/s-inch) the engine. Cylinders and 1, 3, 5 and 7 are
hose onto the connecting rod studs. the left bank and, 2, 4, 6 and 8 are the right
Locate the piston ring end gaps as shown in bank. The numbers on the connecting rod
figure 25. Lubricate the piston and rings with and bearing cap must be on the same side
engine oil. when installed in the cylinder bore. If a
W ith o u t d is tu rb in g the ring end gap connecting rod is ever transposed from one
location, install J-8037 over the piston block or cylinder to another, new connecting
(figure 26). rod bearings should be fitted and the
The piston must be installed so that the connecting rod should be numbered to
depression in the piston crown is towards correspond with the new cylinder number.
the outside of the engine. The connecting
rod bearing tang slots must be opposite the
camshaft.
Place the piston in its matching bore. Using Connecting rod bearing clearance. Refer to
light blows with a hammer handle, tap the the proper unit repair manual.
the connecting rod to the crankpin with the 4. Connecting rod cap nuts.
6.2L DIESEL 6A7-25
MAIN BEARING REPLACEMENT

[<-[ Remove or Disconnect (Figure 28)
Tool Required:
Figure 26Installing The Piston And
Connecting Rod J-8080 Main Bearing Remover/Installer
$ Tighten 1. Glow plugs.

lbs.). 3. Oil pump, as outlined previously.
Measure Check the main bearing caps for location
Connecting rod side clearance. Use a feeler caps must be returned to their original
gage between the connecting rod and locations during assembly.
is 0.17-0.63 mm. 5. Lower main bearing inserts from the main
5. Oil pump (if removed), as outlined previously. bearing caps.
6. Rear crankshaft oil seal, if necessary, as outlined
previously.
Insert J-8080 into the crankshaft oil hole
(figure 28).
Rotate the crankshaft to turn the bearing
insert out of the block.

as required. Refer to the proper unit repair manual.
The unit repair manual contains information on
Crankshaft.
Figure 27Checking Connecting Rod
Side Clearance Main and connecting rod bearings.
6A7-26 6.2L DIESEL
NOTICE: The main bearing caps are to be

tapped into place with a brass or leather
mallet before the attaching bolts are installed.
bearing caps into their seats, as this may
damage the bearing cap and/or block.
4. Number 5 (rear) main bearing cap.

Apply a thin film of anaerobic sealant (GM
part number 1052756 or equivalent) to the
bearing cap as shown in figure 23. Keep the
A. Forward sealant off the seal and bearing. Do not put
B. Feeler Gage sealant in the bearing cap oil relief slot.
120. Number 3
Apply a light coat of engine oil to the
Main Bearing Cap
crankshaft surface that will contact the seal.
121. Crankshaft
B-08047 Apply engine oil to the main bearing cap
bolt threads.
Figure 29Measuring Crankshaft End Play Tap the main bearing cap into place with a
brass or leather mallet. Then install the
bolts.
+ 4- Install or Connect (Figures 23, 28, and 29)
Tool Required: $ Tighten
J-8080 Main Bearing Remover/Installer Bolts to specifications, in the following

sequence:
1. Upper main bearing inserts. Inner bolts: 150 N m (110 ft. lbs.).
Insert tool J-8080 into a crankshaft main Outer bolts: 135 N m (100 ft. lbs.).
bearing oil hole (figure 28). Re-tighten all bolts in the same
sequence.
5. Numbers 1, 2, and 4 main bearing caps and bolts.
size.
Insert the plain end (without the bearing Tighten

and the notched side of the block. Bolts to specifications. Refer to step 4.
6. Number 3 (center) main bearing cap and bolts.
Tighten the bolts temporarily to 14 N m (10 ft.
the block.
lbs.).
Remove the tool.
Measure
2. Lower main bearing inserts to the main bearing
caps.
Make sure the inserts are of the proper size. Tap the end of the crankshaft first
Measure surfaces.
Main bearing clearance. Refer to the proper bolts to specifications. Refer to step 4.
unit repair manual. If the engine is in the With the crankshaft forced forward,
vehicle, the crankshaft must be supported m easure at the fro nt end of the
upward to remove any clearance from the number 3 main bearing with a feeler
upper bearing. The total clearance can then gage (figure 29). The proper clearance
be measured between the lower bearing is 0.10-0.25 mm.
and journal. 7. Oil pump, as outlined previously.
3. Rear crankshaft oil seal (if necessary) as outlined 8. Oil pan, as outlined previously.
previously. 9. Glow plugs.
6.2L DIESEL 6A7-27
CRANKSHAFT REPLACEMENT 2. New rope seal to the main bearing cap (if a rope
type seal is to be installed).
+ + Remove or Disconnect (Figure 24) Apply adhesive (GM part number 1052621
[Loctite 414] or equivalent) to the seal
1. Engine, as outlined later. groove.
2. Flywheel as outlined later. Position the rope seal on the bearing cap.
Mount the engine in a suitable engine stand. Use J-33153 to install the seal (figure 22).
3. Oil dipstick tube. After correctly positioning the seal, rotate
4. Glow plugs. J-33153 slightly and cut the seal ends flush
5. Torsional damper, as outlined previously. with the bearing cap surface. Use a sharp
6. Front cover, as outlined previously. tool, (figure 22).
7. Timing chain, as outlined previously. 3. Upper main bearing inserts to the block. Apply
8. Oil pan and oil pump, as outlined previously. engine oil to the main bearings.
9. Connecting rod caps. Check the connecting rod 4. Crankshaft.
and cap for identification marks. Mark the parts if 5. Lower main bearing inserts to the main bearing
necessary. The connecting rod and cap are caps. Apply engine oil to the bearing inserts.
mating parts.
10. Connecting rods from the crankshaft. m Measure
Attach short pieces of 10 mm (3/e-inch) hose
to the connecting rod bolts (figure 24). Main bearing clearance. Refer to the proper
Push the pistons up in the bores. unit repair manual. If clearance is out of
11. Connecting rods bearings. If the bearings are to specification at the rear main bearing, and a
be re-used, mark them so they can be re-installed rope type seal is being installed, check for
in the original location. fraying that may prevent the bearing cap
12. Main bearing caps. Check the main bearing caps from seating.
fo r lo c a tio n m a rkin g s. M ark the p a rts if 6. Rear crankshaft oil seal halves to the block and
necessary. The main bearing caps must be main bearing cap as outlined previously (if a two
returned to their original locations at assembly. piece type seal is to be installed).
13. Crankshaft.
14. Main bearing inserts. NOTICE: The main bearing caps are to be
15. Rear crankshaft oil seal, from the block and main tapped into place with a brass or leather
bearing cap. mallet before the attaching bolts are installed.
Cleaning, Inspection and Repair bearing caps into their seats, as this may
Clean, inspect and repair or replace the parts as damage the bearing cap and/or block.
outlined in the proper unit repair manual. Refer to
the unit repair manual for information on: 7. Number 5 (rear) main bearing cap.
Crankshaft. Apply a thin film of anaerobic sealant (GM
Main and connecting rod bearings. part number 1052756 or equivalent) to the
P ro c e d u re s fo r m e a su rin g b e a rin g bearing cap as shown in figure 22. Keep the
sealant off the seal and bearing. Do not put
clearances.
sealant in the bearing cap oil relief slot.
0 Install or Connect (Figures 14, 22, 27, and 29) Apply engine oil to the main bearing cap
bolt threads.
Tool Required: Tap the main bearing cap into place with a
J-33153 Rear Oil Seal Installer (for rope type brass or leather mallet. Then install the
seal) bolts.
1. New upper rope seal piece to the seal groove in
the block (if a rope type seal is to be installed). & Tighten
Apply a drop of adhesive (GM part number
1052621 [Loctite 414] or equivalent) to the Bolts to specifications, in the following
seal groove in the block. sequence:
install the new rope seal piece. The seal Inner bolts: 150 N m (110 ft. lbs.).
must be firmly installed in place, completely Outer bolts: 135 N m (100 ft. lbs.).
filling the groove. Re-tighten all bolts in the same
Cut the seal clean and flush with the block sequence.
surface. Use a sharp tool. 8. Numbers 1, 2, and 4 main bearing caps and bolts.
6A7-28 6.2L DIESEL
Tighten [11Measure
Bolts to specifications. Refer to step 7. Connecting rod side clearance. Use a feeler
9. Number 3 (center) main bearing cap and bolts.
Tighten the bolts temporarily to 14 N m (10 ft.
is 0.17-0.63 mm.
lbs.).
14. Oil pump and oil pan, as outlined previously.
15. Timing chain, as outlined previously.
Measure
Important
Tap the end of the crankshaft first Align the timing marks (figure 14).
rearward then forward with a lead 16. Torsional damper, as outlined previously.
hammer. This will line up the rear main 17. Glow plugs.
b e a rin g and c ra n k s h a ft th ru s t 18. Oil dipstick tube.
surfaces.
19. Flywheel.
Tighten the rear main bearing cap 20. Engine.
bolts to specifications. Refer to step 7.
m easure at the front end of the ENGINE MOUNTINGS
number 3 main bearing with a feeler
gage (figure 29). The proper clearance NOTICE: Broken or deteriorated mountings
is 0.10-0.25 mm. can cause m isaligned and e ven tu al
When a single mounting breakage occurs, the
L* Inspect rem aining m ountings are sub jected to
Crankshaft for binding. Try turning the
crankshaft to check for binding. If the
crankshaft does not turn freely, loosen the INSPECTING ENGINE MOUNTINGS
until the tight bearing is located. Burrs on Front Engine Mountings
insert and the block or the bearing cap, or a NOTICE: When raising or supporting the
faulty insert could cause a lack of clearance engine for any reason, do not use a jack under
at the bearing. the oil pan, any sheet metal or crankshaft
10. Connecting rod bearing inserts. Used inserts pulley. Due to the small clearance between
must be installed in their original locations. the oil pan and the oil pump screen, jacking
against the oil pan may cuase it to be bent
11. Connecting rods to the crankshaft. Pull the against the pump screen, resulting in a
connecting rods down. Make sure the connecting damaged oil pickup unit.
rod bearing insert stays in place. Remove the
hose pieces. 1. Raise the engine to remove weight from the
Measure rubber cushion. Observe both mountings while
raising the engine.
Connecting rod bearing clearance. Refer to 2. Replace the mounting if the following conditions
the proper unit repair manual. exist:
12. Connecting rod caps with bearing inserts to the
check cracks.
connecting rods. Apply engine oil to the inserts.
13. Connecting rod cap nuts. plate of the mounting.
Tighten 3. If there is movement between a metal plate of the
Connecting rod cap nuts to 65 N m (48 in. engine and tighten the bolts or nuts attaching the
lbs.). mounting to the engine, frame, or bracket.
6.2L DIESEL 6A7-29
Rear Mountings NOTICE: See Notice on page 6A7-1 of this

1. Push up and pull down on the transmission section.
3. Through bolts and nuts.
exist:
moved up but not down). Fasteners to specifications. Refer to figures
3. If there is relative movement between a metal 30 through 33.
the transmission or crossmember. REAR MOUNTING REPLACEMENT
(EXCEPT P MODEL FLYWHEEL
FRONT MOUNTING REPLACEMENT HOUSING MOUNTING)
Remove or Disconnect (Figures 30 through 33) Remove or Disconnect (Figures 34 through 37)

engine for any reason, do not use a jack under NOTICE: When raising or supporting the
the oil pan, any sheet metal or crankshaft engine for any reason, do not use a jack under
pulley. Due to the small clearance between the oil pan, any sheet metal or crankshaft
the oil pan and the oil pump screen, jacking pulley. Due to the small clearance between
against the oil pan may cause it to be bent the oil pan and the oil pump screen, resulting
against the pump screen, resulting in a in a damaged oil pickup unit.
damaged oil pickup unit
Support the engine with a suitable jack. Do not
weight on the rear mountings.
load the engine mounting.
1. Engine mounting through-bolt and nut. 1. Mounting to crossmember nut(s) and washer(s).
of the engine mounting. 2. Mounting to transmission bolts and washers.
3. Mounting assembly. Raise the rear of the engine only enough to
+- Install or Connect (Figures 30 through 33)
3. Mounting.
1. Engine mounting assembly to the vehicle.
On K, G, and P models, the through-bolt
must be inserted from the rear of the right Install or Connect (Figures 34 through 37)
side mounting before the mounting is
installed in the vehicle. 1. Mounting.
NOTICE: See Notice on page 6A7-1 of this Lower the rear of the engine.
section.

section.
30 through 33.
On K, G, and P models (right side), make sure
there is 25 mm (1 inch) clearance between the Tighten
through bolt head and mounting assembly.
Lower the engine until the through bolts can be Fasteners to specifications. Refer to figures
inserted. 34 through 37.
6A7-30 6.2L DIESEL
A. Forward
B. 40 N m (30 Ft. Lbs.)
C. Torque Bolt To 115 N-m (85 Ft. Lbs.) Or, Torque Nut
To 75 N-m (55 Ft. Lbs.)
D. 48 N-m (36 Ft. Lbs.)
E. Torque Bolt To 48 N-m (36 Ft. Lbs.) Or, Torque Nut To 40 N-m (30 Ft. Lbs.)
B-08048
Figure 30Front Engine Mountings (C Models)

6.2L DIESEL 6A7-31
150
A. Forward
B. 40 N m (30 Ft. Lbs.)
C. Torque Bolt To 115 N-m (85 Ft. Lbs.) Or, Torque Nut
To 75 N-m (55 Ft. Lbs.)
D. 48 N-m (36 Ft. Lbs.)
B-08049
Figure 31Front Engine Mountings (K Models)

6A7-32 6.2L DIESEL
B. Torque Bolt To 100 N m (75 Ft. Lbs. ) Or, Torque Nut To 48 N m (36
C. 48 N m (36 Ft. Lbs.)
D. Torque Bolt To 52 N m (38 Ft. Lbs.) Or, Torque Nut To 40 iN m (30 Ft. Lbs.)
E. Torque Bolt Or Nut to 40 N m (30 Ft. Lbs.)
150. Spacer OR Power Steering Pump Bracket (Left Side Only) B-07919
Figure 32Front Engine Mountings (G Models)
REAR MOUNTING REPLACEMENT NOTICE: See Notice on page 6A7-1 of this

(P MODELS FLYWHEEL HOUSING MOUNTING) section.
Remove or Disconnect (Figure 38) 2. Spacer, cushion, and bolt.
1. Bolt, cushion, and spacer. Tighten
Bolt to 90 N m (65 ft. lbs ).

the oil pan, any sheet metal or crankshaft ENGINE REPLACEMENT
the oil pan and the oil pump screen, jacking C AND K MODELS
against the pump screen, resulting in a + + Remove or Disconnect
1. Battery cables.
Raise the rear of the engine only enough to Raise the vehicle.
permit removal of the mounting. 2. Flywheel cover.
2. Engine mounting. transmission).
5. Starter.
+4- Install or Connect (Figure 38) 6. Bell housing bolts.
7. Front engine mounting through-bolts.
1. Engine mounting. Align the hole in the mounting 8. Block heater.
with the hole in the crossmember. 9. Wiring harness, transmission cooler lines, and
front battery cable clamp at the oil pan.
Lower the engine. 10. Fuel return lines at the engine.
6.2L DIESEL 6A7-33
A. Front
B. Tighten Bolt to 115 N m (85 Ft. Lbs.) or,
Tighten Nut to 75 N m (55 Ft. Lbs.).
C. 48 N m (36 Ft. Lbs.).
D. 40 N m (30 Ft. Lbs.).

B-08050
Figure 33Front Engine Mountings (P Models)
11. Oil cooler lines at the engine. 26. Accelerator, detent, and cruise control cables at
12. Lower fan shroud bolts. the injection pump.
Lower the vehicle. 27. Heater hose at the engine.
13. Hood. 28. Radiator. Refer to ENGINE COOLING (SEC. 6B).
Drain the cooling system. Support the transmission with a suitable jack.
14. Air cleaner with resonator. 29. Engine.
15. Fuel filter.
16. Ground cable at the generator bracket. -- Install or Connect (Figures 30 and 31)
17. Generator wires and clips.
18. Wiring at the injection pump. 1. Engine to the vehicle.
19. Wiring from rocker arm clips, including glow plug 2. Radiator. Refer to ENGINE COOLING (SEC. 6B).
wires. 3. Heater hose.
20. EGR-EPR solenoids, glow plug controller and 4. Accelerator, detent, and cruise control cables.
temperature sensor. Move the harness aside. 5. Vacuum hose at the transducer.
21. Left side ground strap. 6. Power steering pump and reservoir.
22. Fan. 7. Fan shroud.
23. Fan shroud. 8. Fan.
24. Power steering pump and reservoir and lay aside. 9. Left side ground strap.
25. Vacuum hose at the cruise control transducer (if 10. EGR-EPR, glow plug controller, and temperature
equipped). sensor.
6A7-34 6.2L DIESEL
ALL MODELS EXCEPT WITH THM 400 TRANSMISSION (RPO-M40)
MODELS WITH THM 400 TRANSMISSION (RPO-M40)
A. Forward
B. 48 N m (36 Ft. Lbs.) B-07921
Figure 34Rear Engine Mountings (C Models)

6.2L DIESEL 6A7-35
11. Wiring at the rocker arm clips, including glow

plug wires.
12. Injection pump wiring.
13. Generator wires and clips.
14. Ground cable at the generator bracket.
15. Fuel filter.
16. Air cleaner and resonator.
17. Hood.
Raise the vehicle.
18. Lower fan shroud bolts.
19. Oil cooler and fuel return lines.
20. Wiring harness, transmission cooler lines, and
front battery cable clamp at the oil pan.
21. Block heater.

section.
22. Engine mounting through bolts.
Tighten
A. 54 N m (40 Ft. Lbs.)
B. 48 N m (36 Ft. Lbs.) B 30 and 31.
C. Forward
23. Bell housing bolts.
B-07897 24. Starter.
25. Exhaust pipes.
Figure 35Rear Engine M ountings (K Models) 26. Flywheel to torque converter bolts (automatic
transmission).
27. Flywheel cover.
Lower the vehicle.
28. Battery cables.
G MODELS
Tool Required:
J-33888 Lifting Fixture
1. Battery cables.
2. Headlight bezels, grille, bumper, and lower
valence panel.
3. Hood latch.
5. Upper fan shroud.
6. Upper tie bar.
7. Engine cover.
8. Condenser (vehicles with air conditioning). Refer
9. Radiator and fan. Refer to ENGINE COOLING
(SEC. 6B).
10. In je c tio n pum p. R efer to D IE SE L FUEL
Raise the vehicle.
12. Flywheel cover.
6A7-36 6.2L DIESEL
MODELS WITH PROPSHAFT PARKING BRAKE
A. Forward
B. 68 N m (50 ft. lbs.
C. 48 N m (36 ft. lbs.
D. 60 N-m (44 ft. lbs.
MODELS WITHOUT PROPSHAFT PARKING BRAKE

B-07901
Figure 37Rear Engine Mountings (P ModelsTransmission Tail Type Mountings)

6.2L DIESEL 6A7-37
3. Water crossover/thermostat assembly. Use new

gaskets.
Tighten

5. Heater hoses.
6 . Transmission dipstick tube.
8. Oil pressure sender harness.
9. Glow plug relay.
10. Oil fill tube upper bracket.
13. Cruise control transducer (if equipped).
Raise the vehicle.
Figure 38Rear Engine M ountings 14. Starter.
(P ModelsFlywheel Housing Type Mounting) 15. Bellhousing bolts.
16. Block heater wires.
transmission). NOTICE: See Notice on page 6A7-1 of this
14. Engine mounting through bolts. section.
15. Block heater wires.
16. Bellhousing bolts. 17. Engine mounting through bolts.
17. Starter.
Lower the vehicle.
Tighten
18. Cruise control transducer (if equipped).
19. Air conditioning compressor (if equipped). Refer Fasteners to specifications. (Refer to figure
to AIR CONDITIONING (SEC. 1B). 32).
20. Power steering pump, and lay aside. 18. Flywheel to torque converter bolts (automatic
21 . Oil fill tube upper bracket. transmission).
22 . Glow plug relay. 19. Flywheel cover.
23. Oil pressure sender harness. 20. Exhaust pipes.
24. Air cleaner resonator and bracket. Lower the vehicle.
25. Transmission dipstick tube and move aside. 21. In je c tio n pum p. R efer to D IE SE L FUEL
26. Heater hoses at the engine. INJECTION (SEC. 6C2).
27. Generator upper bracket. 22. Radiator and fan. Refer to ENGINE COOLING
28. Water crossover/thermostat assembly. (SEC. 6B).
29. Fuel lines at the fuel pump (lift pump). 23 C o n d e n se r (if e q u ip p e d ). R efer to AIR
30. Engine CONDITIONING (SEC. 1B).
Attach J-33888 to the center intake manifold 26 Engine cover.
bolt holes. The two pieces of the tool should 27. Upper tie bar.
extend down into the valley between the 28. Upper fan shroud.
cylinders. 29. Coolant recovery bottle.
Support the transmission. 30. Hood latch.
Use a suitable lifting device to remove the 31. Lower valence panel, bumper, g rille , and
engines. headlight bezels.
32. Battery cables.
Install or Connect (Figure 32) Fill the cooling system with the proper quantity
1. Engine to the vehicle. Evacuate and charge the air conditioning system.
J-33888, and lifting device.

Transmission support.
2. Fuel lines to the fuel pump (lift pump).
6A7-38 6.2L DIESEL
SPECIFICATIONS
All Specifications are in m illim eters (mm) unless otherwise noted.
GENERAL DATA:
Type 90-degree V8 Diesel
Displacement 6.2L
RPO LH6 LL4
Bore 101
Stroke 97
Firing Order 1-8-7-2-6-5-4-3
Oil Pressure 10 psi at idle (hot); 40-45 psi at 2000 RPM
CYLINDER BORE:
Diameter 100.987-101.065
Diameter 0.02 (Maximum)
Taper (Thrust Side) 0.02 (Maximum)
PISTON:
Bores 1 through 6 0.089-0.115
Bohn Pistons
Bores 7 and 8 0.102-0.128
Clearance
Bores 1 through 6 0.112-0.138
Zollner Pistons
Bores 7 and 8 0.125-0.151
PISTON RING:
Groove Top 0.076-0.178
Clearance 2nd 0.039-0.080
Compression
Top 0.30-0.55
Gap
2nd 0.75-1.00
Groove Clearance 0.040-0.096
Oil
Gap 0.25-0.51
PISTON PIN:
Diameter 30.9961-31.0039
Clearance 0.0101-0.0153
Fit in Rod 0.0081-0.0309
CRANKSHA :T
#1, 2, 3, 4 74.917-74.941
Diameter
Main #5 74.912-74.936
Journal Taper 0.005 (Maximum)
Out of Round 0.005 (Maximum)
Main Bearing #1, 2, 3, 4 0.045-0.083
Clearance #5 0.055-0.093
Diameter 60.913-60.939
Crankpin Taper 0.005 (Maximum)
Out-of-Round 0.005 (Maximum)
Rod Bearing Clearance 0.045-0.100
B-08051
6.2L DIESEL 6A7-39
SPECIFICATIONS
All Specifications are in m illim eters (mm) unless otherwise noted.
DISPLACEMENT 6.2 L
CAMSHAFT:
Intake 7.133
Lobe Lift 0.05
Exhaust 7.133
#1, 2, 3, 4 54.975-55.025
Journal Diameter
#5 50.975-51.025
Journal Clearance 0.026-0.101
VALVE SYSTEM:
Lifter Hydraulic Roller
Rocker Arm Ratio 1.5 : 1
Intake
Valve Lash Not Adjustable
Exhaust
CD
't
o
Seat Runout (Intake & Exhaust 0.05
Intake 0.89-1.53
Seat Width
Exhaust 1.57-2.36
Intake 0.026-0.069
Stem Clearance
Exhaust 0.026-0.069
Pressure Closed 356 N @ 46.0 mm
Valve
Newtons @ mm Open 1025 N @ 35.3 mm
Spring
Installed Height 46
New Chain 12.7 mm (0.500-inch)
Timing Chain Free Play
Used Chain 20.3 mm (0.800-inch)
6A7-40 6.2L DIESEL
Item Nm Ft. Lbs. In. Lbs.
Intake Manifold Bolts 42 31
Exhaust Manifold Bolts 35 26
Rocker Arm Cover Bolts 22 16
Rocker Arm Shaft Bolts 55 40
Hydraulic Lifter Guide Plate Clamp Bolts 26 18
Cylinder Head BoltsRefer to Procedure
Oil Pump Drive Clamp Bolt 42 31
Torsional Damper Bolt 270 200
Crankshaft Pulley Bolts 40 30
Front Cover to Block Bolts 45 33
Oil Pan Bolts (all except rear two bolts) 10.0 84
(rear two bolts) 23 17
Front Cover Baffle Bolts and Nut 45 33
Injection Pump Nuts 42 31
Injection Pump Gear Bolts 23 17
Camshaft Gear Bolt 100 75
Camshaft Thrust Plate 23 17
Oil Pump Bolt 90 65
Main Bearing Cap BoltsInner 150 110
Outer 135 100
Connecting Rod Cap Nuts 65 48
Glow Plugs 14 10
Water Crossover/Thermostat Housing Bolts 42 31
Fuel Pump to Block 34 25
Flywheel Bolts 40 30
Bell Housing Bolts 40 30
SPECIAL TOOLS
J-29834 Hydraulic Lifter Remover

J-29666 Air Line Adapter
J-26513 Valve Spring Compressor or
J-23523-E Torsional Damper Puller
J-29788 Pilot
J-33154 Rear Oil Seal Packer
J-33153 Rear Oil Seal Installer
J-33888 Lifting Fixture
J-29664-1 Intake Port Covers
6B-1
SECTION 6B
ENGINE COOLING
CONTENTS
S U B JE C T PAGE
General D e s crip tio n ................................................................................................................................................... 6B- 1

General D ia g n o s is ......................................................................................................................................................6B- 2
System C h e cks........................................................................................................................................................6B - 2
Fan Clutch D ia g no sis.............................................................................................................................................6B - 3
Thermostat D ia g n o s is ...........................................................................................................................................6B - 3
Coolant Level Indicator D ia g n o s is ..................................................................................................................... 6B - 3
Cooling System D iagnosis.................................................................................................................................... 6B - 3
Uncommon Cooling System P roblem s...............................................................................................................6B - 3
On Vehicle S ervice......................................................................................................................................................6B - 6
Flushing The Cooling S yste m ..............................................................................................................................6B - 6
Coolant Recovery T a n k .........................................................................................................................................6B - 6
Deaeration T a n k ......................................................................................................................................................6B - 6
T h e rm o s ta t.............................................................................................................................................................. 6B - 6
Therm ostat Housing C ro s s o v e r......................................................................................................................... 6B-10
Drive B e lts ................................................................................................................................................................ 6B-11
Fan S h ro u d .............................................................................................................................................................. 6B-14
Fan And Fan C lu tc h ............................................................................................................................................... 6B-19
A uxiliary Cooling Fan............................................................................................................................................. 6B-21
Water P u m p ............................................................................................................................................................ 6B-23
R a d iato r.....................................................................................................................................................................6B-28
Alum inum Radiator R e p a ir...................................................................................................................................... 6B-36
General D e s c rip tio n ............................................................................................................................................... 6B-36
Alum inum Radiator D iagnosis..............................................................................................................................6B-37
Alum inum Radiator S ervice .................................................................................................................................. 6B-39
S pe cifica tio ns.............................................................................................................................................................. 6B-44
Drive Belt Tension S pecifications....................................................................................................................... 6B-44
Radiator M ounting Torque S p e c ific a tio n s ........................................................................................................ 6B-44
Accessory Drive Component Torque S p e c ific a tio n s .....................................................................................6B-45
Therm ostat And Reservoir Related Torque S p e c ific a tio n s ..........................................................................6B-45
GENERAL DESCRIPTION
All C-K, G, and P series vehicles have pressure type center of the cap without building unnecessary pres
engine cooling systems with thermostatic control of the sure. This expanding coolant flows into the coolant res
coolant circulation. The cooling system is sealed by a ervoir. The vent valve closes due to expansion and
pressure type radiator cap that causes the system to coolant flow (the nominal 105 kPa (15 psi) pressure will
operate at higher than atmospheric pressure. This not be reached until the system is working at maximum
higher pressure operation raises the boiling point of capacity). Any air or vapor in the cooling system will be
the coolant, thereby increasing the cooling efficiency forced to the coolant reservoir and leave through the
of the radiator. The 105 kPa (15 psi) pressure cap vent tube at the top of the reservoir. As the system
raises the boiling point of the coolant to approximately cools, the extra coolant in the reservoir will be drawn
125C (258F) at seal level. back to the radiator through the vent valve. In this man
The pressure-vacuum valve radiator cap allows the ner, the radiator will keep itself full at all times.
coolant to expand through the pressure valve in the
6B-2 ENGINE COOLING
GENERAL DIAGNOSIS
SYSTEM CHECKS Heater core may gurgle or surge.
Radiator hoses may collapse and expand.
EXHAUST LEAKS Heater hoses may vibrate and thump.
To check for exhaust leaks into the cooling system, Overheat light may or may not come on.
drain the system until the coolant level stands just Symptoms are the result of coolant boiling at some
above the top of the cylinder head(s), then disconnect localized area and may be noticed after extending
the radiator upper hose and remove the thermostat idling and/or while driving. Determine which side of the
and fan belt(s). Start the engine and quickly accelerate engine is involved and whether it is more at the front or
several times. At the same time note any appreciable rear of the engine.
coolant rise or the appearance of bubbles which are
indicative of exhaust gases leaking into the cooling Diagnosis/Inspection
system. 1. Isolate the area from which the localized boiling
is originating. This can be done by probing the
NOTICE: A worn head gasket may allow engine with a sounding bar (large screwdriver).
exhaust gases to leak into the cooling system. 2. With the radiator cap removed, observe the water
This is particularly damaging to the cooling being circulated in the radiator. Feel the front area
system as the gases combine with the water of the radiator for cold spots which indicate
to form acids which are harmful to the radiator blockage. Blocked radiators generally occur on
and engine. units that have accrued miles and not on new
vehicles.
WATER PUMP C A U TIO N : The ra d ia to r cap s h o u ld be

Water pump operation may be checked by running removed from a cool engine only. If the
the engine while squeezing the radiator upper hose. radiator cap is removed from a hot cooling
When the engine warms a pressure surge should be system, serious personal injury may result.
felt. Check for a plugged venthole in the pump.
3. Inspect the the rm o sta t to see if it opens
RADIATOR completely.
Test for restriction in the radiator by warming the 4. Inspect the thermostat housing to make sure it is
engine up and then turning the engine off and feeling completely free of obstructions.
the radiator. The radiator should be hot along the left 5. Remove water pump from the vehicle and remove
side and warm along the right side, with an even the back cover on the pump. All in ternal
temperature rise from right to left. Cold spots in the passages can be inspected using a flash light.
radiator indicate clogged sections. 6. Inspect the cross over at the front of the inlet
manifold. This entire passage can be seen with
THERMOSTAT only the thermostat removed.
An operational check of the thermostat can be made 7. Remove heads, but lay them aside for now and
by hanging the thermostat on a hook in a 33% glycol check the block first because the heads are the
solution, 25C (4F) above the temperature stamped most complex pieces as far as coolant passages
on the th e rm o sta t valve. Subm erge the valve are concerned.
completely and agitate the solution thoroughly. Under 8. With the water pump and heads removed, ALL
this condition the valve should open. Remove the coolant passages CAN be inspected by using a
thermostat and place in a 33% glycol solution, -12C pen light flash light. All water jacket areas can be
(10F) below the temperature indicated on the valve. seen directly and a block should never be
With the valve completely submerged and coolant replaced as being suspect unless the restricted
agitated thoroughly, the valve should close completely. area can be DIRECTLY SEEN.
9. If none of the above inspections reveal the
OVERHEAT AND/OR NOISE problem area, the heads must be considered
Engine overheat and/or cooling system noise may prime suspect. Heads with blocked coolant
be caused by restrictions in the cooling system. passages generally have more than one area that
Components which may be prone to this condition is blocked. Inspect the heads for signs of
are the cylinder head, water pump, block, thermostat overheat discoloration (a dark blue or black area).
housing and inlet manifold. Symptoms of this condition If none are found, look in the coolant passages
are: for blockage and probe all the passages that are
Engine may make snapping/cracking noises. accessible.
ENGINE COOLING 6B-3
The head is very intricate and all the passages COOLANT LEVEL INDICATOR
cannot be reached. Use a probe that is fairly
substantial as a tag wire may go through or DIAGNOSIS
around a partially blocked area. If nothing is
found by visual inspection and probing, inspect INDICATOR LAMP WILL NOT ILLUMINATE
the passages for a rough, ragged appearance. 1. Turn the ignition switch to the CRANK position.
The roughest internal passages are probably the If the lamp illuminates, the lamp is OK and
ones that are blocked. the connector is properly installed on the
module. Go to Step 2.
Replace a blocked or suspect head and inspect
If the lamp does not illuminate, check the
the replacement head in the same manner before
bulb, socket and wiring between the socket
installation.
and the m o d ule c o n n e c to r and the
connector on the module. Replace or repair
as required.
FAN CLUTCH DIAGNOSIS 2. Turn the ignition switch to the ON position and
disconnect the electrical lead at the coolant level
NOISE sensor on the radiator.
Fan noise is sometimes evident under the following If the lamp fails to illuminate, check the
normal conditions.
wiring between the coolant level sensor
When the clutch is engaged for maximum connector and the module for a short circuit
cooling. to ground. If the circuit is OK, replace the
During the first few minutes after start-up until the module.
clutch can re-distribute the silicone fluid back to
its normal disengaged operating condition (after INDICATOR LAMP REMAINS ILLUMINATED
overnight settling). 1. Turn the ignition switch to ON.
Fan noise or an excessive roar will generally occur Check the coolant level. Add coolant if
continuously, however, under all high engine speed necessary.
conditions (2500 rpm and up) if the clutch assembly is If the lamp remains illuminated, go to Step
locked up due to an internal failure. If the fan cannot be 2.
rotated by hand or there is a rough grating feel as the 2. Disconnect the electrical lead at the coolant level
fan is turned, the clutch should be replaced. sensor on the radiator (use a jumper wire and
G type electrical connector).
If the lamp does not illuminate, replace the
LOOSENESS
sensor.
An excessively loose fan assembly must be checked
If the lamp remains illuminated, connect the
for any wear and be replaced if necessary. Under
electrical lead and go to Step 3.
various temperature conditions, there is a visible lateral
3. Check for an open circuit between the sensor and
movement that can be observed at the tip of the fan
the module.
blade. This is a normal condition due to the type of
If an open circuit is found, repair it.
bearing used. A p p ro xim a te ly 6.5 mm ( 1/4-inch)
If no open circuit is found, replace the
maximum lateral movement measured at the fan tip is
module.
allowable. This is not cause for replacement.
SILICONE FLUID LEAKS COOLING SYSTEM DIAGNOSIS

The fan clutch operation is generally not affected by
small fluid leaks which may occur in the area around Refer to the cooling system diagnosis chart (figure 2)
the bearing assembly. If leakage appears excessive, for detailed cooling system diagnostic procedures.
replace the fan clutch (see below).
ENGINE OVERHEATING UNCOMMON COOLING SYSTEM

If the fan and clutch assembly free-wheel with no PROBLEMS
drag (revolves more than five times when spun by
hand), the clutch should be replaced. PROBLEMS NOT REQUIRING DISASSEMBLY OF
THE COOLING SYSTEM
1. Large obstructions blocking the radiator or
THERMOSTAT DIAGNOSIS condenser should be relocated or removed.
Auxiliary oil cooler.
Refer to the thermostat diagnostic chart (figure 1) for License plates.
detailed thermostat diagnosis procedures. Spare tires.
6B-4 ENGINE COOLING
*N0TE: THE TEMPERATURE STICK IS A PENCIL LIKE DEVICE WHICH HAS A WAX MATERIAL CONTAINING
CERTAIN CHEMICALS WHICH MELT AT A GIVEN TEMPERATURE. TEMPERATURE STICKS CAN BE USED TO
DETERMINE A THERMOSTATS OPERATING TEMPERATURE BY RUBBING 86.6C (188F) AND 96.6C
(206F) STICKS ON THE THERMOSTAT HOUSING. THE MARKS MADE BY THE STICKS SHOULD MELT WHEN
COOLANT TEMPERATURES OF 86.6C (188F) AND 96.6C (206F) ARE REACHED, RESPECTIVELY. THESE
TEMPERATURES ARE THE NORMAL OPERATING RANGE OF THE THERMOSTAT, THEREFORE, IF THE
COOLANT FLOWS AS INDICATED ON THE DIAGNOSIS CHART, THE THERMOSTAT MAY BE WORN. B-07540
Figure 1Therm ostat Diagnosis Chart
Ice, mud, or snow obstructing the grille. W orn or dam aged b e a rin g a n d /o r
2. Engine oil is overfilled. seal-check for shaft or bearing play.
3. Incorrect radiator for the application. 5. Plugged radiator tubes.
Check the part number. Perform a flow check.
4. Loose, damaged, or missing air seals. 6. Internal system leaks.
5. Missing or damaged lower air baffle. Head gasket.
6. Incorrect ignition timing. Cracked block.
Timing chain cover.
PROBLEMS REQUIRING DISASSEMBLY OF THE Intake manifold gasket.
COOLING SYSTEM 7. Plugged coolant passages in the cylinder heads.
1. Incorrect or damaged fan. Visual check.
2. Worn or damaged emission system components.
Could cause overheating at idle.
Damaged PCV valve, TVS or TCS.
3. Pressure check the cooling system with the
pressure cap installed.
Shows if the pressure cap leaks because of
radiator filler neck damage.
4. Worn or damaged water pump.
Impeller vanes eroded or broken.
DIAGNOSIS CHART
HOT LIG H T BO ILING CO O LAN T LO SS

(OR T E M P GAGE)
BAD
. x zz - BAD
BAD CHECK THE B U LB -i CHECK THE PRESSURE CAP CHECK PRESSURE CAP
" O N " OR ~T~ I

HOT TE M P OK REPLACE
REPLACE OK OK REPLACE
C HECK THE SEN D IN G UNIT CHECK THE C O O LAN T LEVE L

AN TI-FREE ZE V IS U A L S Y S TE M CHECK
NO W PR O TECTION TO
SPEC IFIC ATIO N S OK
OK L E A K S -C H E C K HO SES, R AD IATO R ,
I C LA M P S , W A TE R P U M P , TH E R M O S TA T
Figure 2Cooling System
ADD 'OFF' HOT LIG H T HOUSING, R AD IATO R D R A IN , SOFT OR

YES (OR T E M P GAGE) CORE P LU G S, HEATER W A T E R V A LV E S ,
GO TO 'B O IL IN G '' OR LO W -------r------- HEATER CORE
ON TH IS C H A R T TEM P?
FOAM ING C O O L A N T -O B S E R V E IN THE
ON" OR FILLER NECK AFTER ENGINE W A R M U P
HOT T E M P OVERFLO W S Y S T E M (S E M I-S E A LE D
C HECK THE SEN D IN G U NIT
S YSTE M )
REPLACE
A CHECK FOR G ASKET IN PRESSURE CAP
ON VEH IC LE SEE TH E R M O S TA T
B C H E * FOR L E A K S -H O S E S , C LA M P S ,
T H E R M O S T A T CHECK DIAG N O SIS CHART
O VER FLO W BO TTLE. FILLE R NECK
S Y S TE M ...................J _______ 1 __ L " NIPPLE.
IS OK TIG H TEN TO LOOSE FAN BELT TEN SIO N __ OK BAD C CHECK FOR O B STR U C TIO N S OR
SP EC IFIC ATIO N S PLUG GING IN THE HOSE BETW EEN THE
RADIATO R A N D BO TTLE.
Diagnosis Chart
OK REPLACE
R EPAIR OR
C O LLA P S E D UPPER OR SYST EM REPLACE DEFECTS
R EPLACE NO
LO W ER R AD IATO R HOSE? IS OK
PRESSURE CHECK S Y S TE M
ENGINE COOLING
YES IN S T A LL PR ESSUR E CAP - LEAK S
CHECKER ON THE R AD IATO R
FILLER NECK AN D PR ESSUR IZE
D IR T, BUG S, BEN T FINS, ETC.
C LEAN OR THE S YSTE M TO RATED
- YES BLO C KIN G R AD IATO R OR
STR AIG H TEN PRESSURE. IF THE S Y S TE M
A /C C O NDENSER? REPAIR
DOES NOT HO LD PR ESSURE,
LOOK FOR THE LE A K LO CATIO N
NO
T
OK
S Y S TE M YES A N Y FIXES ABO VE?
IS OK
I
NO A N Y R EPAIRS?
NO
00 =3=
O IF NONE OF THE ABO VE REQ UIR ED R EPAIR , THE P R O BLEM IS
YES
6B-5
-v l
cn OUT OF THE O R D IN A R Y OR OF A M A JO R N ATU R E. REFER TO
"U N C O M M O N COO LING S Y S T E M P R O B L E M S , IN TH IS SECTION S Y S TE M IS OK
6B-6 ENGINE COOLING
ON VEHICLE SERVICE
The deaeration tank (10) is free of the

FLUSHING THE COOLING
vehicle.
SYSTEM
Various methods and equipment can be used to
flush the cooling system. If special equipment such as 1. Deareation tank (10) to the vehicle.
a back flu s h e r is used, follow the equipm ent For C-K and P series vehicles; deaeration
manufacturers instructions. tank (10) onto the support brackets (9).
Attach the retaining straps with bolts/screws
Im portant around the tank and the lip on the support
brackets (9).
Remove the thermostat before flushing the For G series vehicles; deaeration tank (10)
cooling system. into position and attach with bolts/screws (7)
and the nut (6 ).
COOLANT RECOVERY TANK Tighten
B o lt/s c re w s (7) and nut ( 6 ) to

Remove or Disconnect (Figures 3, 4 and 5) Specifications at the end of this section.
2. Return hose (12) to the deaeration tank (10).
1. Battery negative cable. 3. Overflow hose to the filler neck.
2. Drain the coolant from the recovery tank (1). 4. Coolant into the deaeration tank (10).
3. Coolant overflow hose from the recovery tank ( 1 ). 5. Battery negative cable.
4. Coolant recovery tank ( 1 ) from the vehicle.
Bolt/screw (2).
THERMOSTAT
0 Install or Connect (Figures 3 and 4)
1 . Coolant recovery tank ( 1 ), to tne vehicle. ALL MODELS EXCEPT THOSE WITH 6.2L DIESEL
Bolt/screw (2). ENGINES
4-+ Remove or Disconnect (Figures 9 through 12)

Tighten
Bolt/screw (2) to 2.0 N m (1.5 ft. lbs.).
2. Drain the cooling system until the radiator coolant
2 . Coolant overflow hose to the recovery tank ( 1 ).
level is below the thermostat.
3. Coolant to the recovery tank ( 1 ). 3. Thermostat (23) from the vehicle.
4. Battery negative cable. Bolts (20) and the water outlet (21).
Thermostat from its housing.
Discard the old gasket.
DEAERATION TANK
Remove or Disconnect (Figures 6, 7 and 8)

0 Install or Connect (Figures 9 through 12)
Make sure the thermostat housing and water

outlet sealing surfaces are clean.
1. Thermostat (23) in its housing.
2. Drain the coolant from the deaeration tank (10).
2. New gasket (22) into position.
3. Overflow hose from the filler neck. 3. Water outlet (21).
4. Return hose (12) from the deaeration tank (10). Bolts (20).
5. Deaeration tank (10) from the vehicle.
For C-K and P series vehicles; bolts/screws Tighten
(7), and the retaining straps (8 ) from the
support brackets (9) (figures 6 and 8 ). For bolts (20), refer to Specifications at
For G series vehicles; bolts/screws (7) and the end of this section.
nut (6 ) (figure 7). Battery negative cable.
ENGINE COOLING 6B-7
A. G Series Arrangement W ithout A ir Conditioning

B. G Series Arrangement With Air Conditioning (Not 6.2L Diesel)
1. Recovery Tank
2. Bolt/Screw B
3. Cap
4. Return Hose
5. Radiator Assembly
B-07543
Figure 4G Series Coolant Recovery Bottle

6B-8 ENGINE COOLING
8 . Radiator cap to the radiator, making sure the

arrows line up with the overflow tube.
MODELS WITH THE 6.2L DIESEL ENGINE

2. Upper fan shroud ONLY from G Van models.
Refer to Fan Shroud in this section.
3. Drain the cooling system until the radiator coolant
level is below the thermostat.
4. Engine oil dipstick tube brace and the oil fill brace
ONLY on G Van models.
Refer to 6.2L DIESEL (SEC. 6A7).
5. Thermostat (23) from the vehicle.
Studs (26) and the water outlet (21).
Upper radiator inlet hose.
Thermostat from its housing.
Discard the old gasket (22).
Install Or C onnect (Figures 13 and 14)
Make sure the thermostat housing and water

outlet sealing surfaces are clean.
1. Thermostat (23) into its housing.
2. Gasket (22) into position.
3. Water outlet (21).
Studs (26) and the upper radiator inlet hose.
5. Fill the cooling system.

$ Tighten
Refer to the vehicle Owners Manual.
Studs (26) to 47 N m (35 ft. lbs.).
6 . Start the engine and run, with the radiator cap
4. Engine oil dipstick tube brace and the oil fill brace
removed, until the radiator upper hose becomes ONLY on G Van models.
hot (thermostat is open). Refer to 6.2L DIESEL (SEC. 6A7).
7. With the engine idling, add coolant to the radiator 5. Upper fan shroud ONLY on G Van models.
until the coolant level reaches the bottom of the Refer to Fan Shroud, in this section.
filler neck. 6 . Battery negative cable.
5. Radiator Assembly
6. Nut
7. Bolt/Screw
8. Retaining Strap
9. Support Bracket
10. Deaeration Tank
Figure 6C-K Series Deaeration Tank

ENGINE COOLING 6B-9
7. Fill the cooling system. 10. Radiator cap to the radiator, making sure the
8 . Start the engine and run, with the radiator cap
removed, until the radiator upper hose becomes
hot (thermostat is open).
9. With the engine idling, add coolant to the radiator
until the coolant level reaches the bottom of the
filler neck.
Figure 9C-K And G Series Vehicle

5. Radiator Assembly 11. Clamp
Thermostat Replacement (4.3L V6)
7. Bolt/Screw 12. Return Hose
8 . Retaining Strap 14. Radiator Support
9. Support Bracket Brace
10. Deaeration Tank B-07547
Figure 8P Series Deaeration Tank

6B-10 ENGINE COOLING
2 0 . Bolt
2 1 . Water Outlet
(G, P Series)
21 A. Water Outlet
(C-K Series)
2 2 . Gasket
20. Bolt 25. Bolt
23. Thermostat
21. Water Outlet 26. Stud
24. Inlet Manifold
22. Gasket 27. Thermostat Housing
26. Stud B-08082
23. Thermostat 28. Gasket B-08081
Figure 10C-K And P Series Vehicle Figure 11C-K, G, And P Series Vehicle
Thermostat Replacement (4.8L L6) Therm ostat Replacement (5.0L & 5.7L V8)
THERMOSTAT HOUSING Tighten
CROSSOVER Bolts (27) to 47 N m (35 ft. lbs.).

3. Heater hose, upper radiator hose, and bypass
hose.
C-K SERIES VEHICLE WITH 6.2L DIESEL ENGINE 4. Generator upper bracket.
5. Crankcase depression regulator valve.
Remove or Disconnect (Figure 15) Battery negative cable.
Fill the cooling system.
2. Drain the cooling system. Start the engine and run, with the radiator cap
3. Crankcase depression regulator valve. removed, until the radiator upper hose becomes
4. Generator upper bracket. hot (thermostat is open).
5. By pass hose, upper radiator hose, and heater 9. With the engine idling, add coolant to the radiator
hose. until the coolant level reaches the bottom of the
6 . Crossover (32) from the vehicle. filler neck.
Bolts (27) from the vehicle. 10. Radiator cap to the radiator, making sure the
Thermostat (23) and water outlet (21) are arrows line up with the overflow tube.
attached to the crossover along with the
thermal bypass nipple. G AND P SERIES VEHICLES WITH 6.2L DIESEL
ENGINES
Make sure the crossover sealing surfaces are
clean. 1. Battery negative cable.
1. New gaskets (28) into position. 2. Drain the cooling system.
2. Crossover (32) to the vehicle. 3. Engine cover from G Van models ONLY.
Bolts (27). 4. Air cleaner.
ENGINE COOLING 8B-11
20A
20. Bolt 22. Gasket

20A. Bolt (With NA5 23. Thermostat
Emissions Only) 24. Inlet Manifold
21. Water Outlet 26. Stud B-08083
Figure 12C-K And P Series Vehicle Figure 13C-K Series Vehicle Thermostat
Therm ostat Replacement (7.4L V8) Replacement (6.2L V8 Diesel)
5. Air cleaner resonator and its bracket. 7. Air cleaner.

6. Upper fan shroud. 8 . Engine cover on G Van models ONLY.
8. Bypass hose, upper radiator hose, and heater
hose. 10. Fill the cooling system.
9. Crossover (32) from the vehicle. Refer to the vehicle Owners Manual.
Bolts (27), studs (26) and discard the old 1 1 . Start the engine and run, with the radiator cap
gaskets (28). removed, until the radiator upper hose becomes
Thermostat (23) and the water outlet (21) are hot (thermostat is open).
attached.
12. With the engine idling, add coolant to the radiator
until the coolant level reaches the bottom of the
-+ Install or Connect (Figure 14) filler neck.
Make sure the crossover sealing surfaces are 13. Radiator cap to the radiator, making sure the
clean. arrows line up with the overflow tube.
1. New gaskets (28) into position.
2. Crossover (32) to the vehicle.
Bolts (27) and studs (26). DRIVE BELTS
Tighten
PULLEY INSPECTION
Bolts (27) to 47 N m (35 ft. lbs.). Examine the pulleys for chips, nicks, tool marks,
cracks, bent sidewalls, corrosion, or other damage.
Studs (26) to 47 N m (35 ft. lbs.).
3. Heater hose, upper radiator hose, and the bypass 1 . Place a straightedge or position a cord across the
hose. two pulleys so they touch at all points (figure 16).
4. Generator upper bracket. 2. Turn each pulley one half revolution and recheck
5. Upper fan shroud. with a straightedge or cord. Full contact at all
6. Air cleaner resonator and its bracket. points must be made. If contact is not made at all
31. Hose
27. Bolt 29. Nipple 32. Crossover
28. Gasket 30. Clamp Hose B.08086
Figure 14G, P Series Vehicle Therm ostat & Figure 15C-K Series Vehicle Crossover
Crossover Replacement (6.2L V8 Diesel) Replacement (6.2L V8 Diesel)
points, the pulley may be warped or its shaft

could be bent. Replace any parts found to be
damaged.
DRIVE BELT INSPECTION
Frayed or cracked belts must be replaced and

tensioned to the proper specification. Do not use drive
belt dressings to extend the belt life.
A. Correct Alignment
B. Incorrect Alignment
C. Cord Or Straight Edge B-08087
Figure 16Inspecting Pulley Alignment

CAUTION: A void over or under-tightening Place the gage at the center of the greatest
drive belts. Loose belts result in slippage span.
which can lead to belt and pulley glazing
The belt tension should be at the maximum
and inefficient com ponent operation. Once a
used belt specifications from the chart in
b e lt has b e c o m e g la z e d , it w ill be
Specifications, at the end of this section.
necessary to replace the belt. Loose belts
can also place high im pact loads on driven
com ponent bearings due to the w hipping DRIVE BELT ADJUSTMENT
action of a loose belt. Over tightening belts A used belt must never be tensioned to more than its
can lead to bearing damage and early belt specified tension limit.
failure. 1. Check the belt tension.
Belt should be cool or at least warm to the
DRIVE BELT REPLACEMENT touch. Not hot.
1. Remove the old belt. Use BT-33-95 ACBN to measure v-belt
Loosen the component driven by the belt tension, and BT-33-97M to measure poly
(figures 17 through 21). v-belt tension.
Place the gage at the center of the greatest
NOTICE: Place the belts into the pulley
span.
grooves by hand. Do not force a belt into a
pulley groove by prying with a screwdriver, If the belt is below the minimum used belt
crowbar, or other wedge type tool. Prying a tension specification, adjust the belt.
belt into position can damage both the belt 2. Loosen the component in its mounting bracket
and the belt drive components. (figures 17 through 21).
2. Install the new belt. 3. Tension the belt to the maximum used belt
Tension the new belt to the Specifications specification from the chart in Specifications,
at the end of this section. at the end of this section.
Use BT-33-95 ACBN to measure v-belt
tension, and BT-33-97M to measure poly Tighten
v-belt tension.
Place the gage at the center of the greatest Component to mounting bracket fasteners
span. to the specifications at the end of this
section.
$ Tighten 4. Run the engine at idle for a minimum of 15

minutes.
Component to mounting bracket fasteners
This allows the belt to reseat itself in the
to the specifications at the end of this
pulleys.
section.
3. Run the engine at idle speed for a minimum of 15 5. Allow the drive belt to cool.
minutes. Should be at most warm to the touch. Not
This allows the belt to seat itself in the hot.
pulleys, causing the belt fibers to relax, or
6 . Check the belt tension.
stretch.
4. Allow the drive belt to cool until it is cool or at Use BT-33-95 ACBN to measure v-belt
most, warm to the touch. Not hot. tension, and BT-33-97M to measure poly
v-belt tension.
NOTICE: A used belt is one that has been Place the gage at the center of the greatest
rotated at least one complete revolution on span.
the engine pulleys. This begins the seating
of the belt and it must never be tensioned to If not within the used belt specifications
new belt specifications. from the chart in Specifications, at the
end of this section, re-adjust.
5. Check the belt tension.
Use BT-33-95 ACBN to measure v-belt DRIVE BELT ROUTING
tension, and BT-33-97M to measure poly Refer to the drive belt routing diagrams (figures 22
v-belt tension. through 31) if belt replacement becomes necessary.
VIEW A
A. 4.8L L6 Engine
B. 4.3L V 6 , 5.0/5.7L V8 Engines
C. 7.4L V 8 Engine
40. Adjustm ent Bolt
41. Pivot Bolt
Figure 17C-K, G, And P Series Vehicle Generator Adjustm ent
FAN SHROUD |+<-| Install or Connect (Figures 32 and 33)
1. Lower fan shroud (64) and the fan clutch.

C-K SERIES VEHICLE Position along the back of the radiator (63).
Remove or Disconnect (Figures 32 and 33) Make sure the lower edge fits into the lower
retaining clips.
2. Fan clutch to water pump hub attachments.
2. Fan shroud to radiator retainer attaching bolts
Refer to Fan And Fan Clutch, in this
(60).
section.
3. Fan clutch to water pump hub attachments.
3. Shroud (61) to the radiator retainer attaching bolts
Refer to Fan And Fan Clutch, in this (60).
section.
4. Fan shroud assembly (61 and 64). Tighten
Pull up and out of the lower retaining clips.
Bolts (60) to 6 N m (53 in. lbs.)
The fan shroud and fan clutch assembly
must be removed together. 4. Battery negative cable.
' * o
ms
A 4 3 L |_6 Engine
^ J* B. 4.3L V6 , 5.0/5.7L V 8 Engin es (Not P or G Series)
C. 4.3L V6 5.0/5.7L V 8 Engine>s (P and G Series)
D. 7.4L V 8 Engine
41. Pivot Bolt B-08089
Figure 18C-K, G, And P Series Vehicle Power Steering Pump Adjustm ent
G, P SERIES VEHICLE WITH GASOLINE ENGINES Install or Connect (Figures 34 through 37)
4- + Remove or Disconnect (Figures 34 through 37) 1. Fan and the fan shroud together.
2. Fan to the water pump.
2. Vacuum re se rvo ir, if e q u ip p e d w ith air Refer to Fan And Fan Clutch in this
conditioning. section.
Refer to AIR CONDITIONING (SEC. 1B). 3. Radiator hose strap to the fan shroud.
3. Windshield washer jar and its bracket.
4. Fan shroud retaining bolts (60). 4. Dipsticks into the engine, and transmission if
applicable.
5. Radiator support bracket (67).
6 . Dipstick from the engine. 5. Radiator support bracket (67).
7. Dipstick from the automatic transmission, if
Bolts (60).
equipped.
8 . Radiator hose strap from the fan shroud (61).
9. Fan from the water pump. $ Tighten
Leave the pulley in place.
Bolts (60) to 6 N m (53 in. lbs.).
Refer to Water Pump, in this section.
10. Fan and the fan shroud together. 6 . Fan shroud retaining bolts (60).
A. 4.8L L6 Engine
B. 4.3 V6, 5.0/5.7L
V8 Engines (Not G Van)
C. 4.3 V6, 5.0/5.7L
V8 Engines
D. 7.4L V8 Engine
41. Pivot Bolt
42. Brace
43. Support
41 " V -
40
B-08090
Figure 19C-K, G, And P Series Vehicle A ir Conditioning Compressor Adjustm ent
Tighten 4. Hood latch cable.

5. Windshield washer bottle.
Bolts (60) to 6 N m (53 in. lbs.). 6. Upper fan shroud (61).
Bolts (60) for 4.3L V6 engines to 27 N-m (20
ft. lbs.). |-n-| Install or Connect (Figures 35 and 37)
7. Windshield washer jar and its bracket.
8. Vacuum re se rvo ir, if e q u ip p e d w ith a ir 1. Upper fan shroud (61).
conditioning. Bolts (60).
G, P SERIES VEHICLE (DIESEL ENGINE Bolts (60) to 6 N-m (53 in. lbs.).
EQUIPPED) 2. Windshield washer bottle.
3. Hood latch cable.
0 Remove or Disconnect (Figures 35 and 37) 4. Fan shroud bolts (60).
1. Battery negative cable. Tighten

2. Air cleaner intake.
Rotate the snorkel up. Bolts (60) to 6 N-m (53 in. lbs.).
3. Fan shroud bolts (60). 5. Air cleaner intake.
Figure 20C-K, G, And P Series Vehicle Air Conditioning And A.i.R. Adjustment
^ j
42 f Wd
D IE S E L D IE S E L
41
4 1 ------------- V'
B-08092
Figure 21C-K, G, And P Series Vehicle 6.2L Diesel Drive Belt Adjustment
A. 1st Track
B. 2nd Track
53
C. 3rd Track
50. Water Pump Pulley
51. Crankshaft Pulley
A
52. Generator Pulley
53. A.I.R. Pump Pulley B
54. Power Steering Pump
Pulley
55. A ir Conditioning 52
Compressor Pulley
55
Figure 22C-K Series 4.8L L6 Engine Accessory Drive
6. Battery negative cable. Install or Connect (Figure 38)
All mating surfaces (the water pump hub and the

fan c lu tc h hub) m ust be in s p e c te d for
FAN AND FAN CLUTCH smoothness and reworked as necessary to
eliminate any burrs or other imperfections.
2. Radiator fan shroud.
Refer to Fan Shroud, in this section.
3. Fan (73) and fan clutch (74) from the water

pump pulley (70).
Nuts (75).
4. Fan (73) from the fan clutch (74).
Bolts (72).
A. 1st Track 50
B. 2nd Track
C. 3rd Track
D. 4th Track
53. A.I.R. Pump Pulley
54. Power Steering
Pump Pulley
55. A ir Conditioning
Compressor Pulley
B-08094
Figure 23C-K Series V6 & V8 Engine Accessory Drive
A. 1st Track 51. Crankshaft Pulley

B. 2nd Track 52. Generator Pulley
C. 3rd Track 53. A.I.R. Pump Pulley
D. 4th Track 54. Power Steering Pump Pulley
50. Water Pump Pulley 55. Air Conditioning Compressor Pulley B-08095
Figure 24C-K Series 5.7L V8 Engine (With Heavy Duty Emissions) Accessory Drive
A. 1st Track
B. 2nd Track
C. 3rd Track
54. Power Steering
Pump Pulley
Compressor Pulley
B-08096
Figure 25C-K Series 7.4L V8 Engine Accessory Drive (Federal Emissions)
CAUTION: If a fan blade is bent or damaged 2. Fan and clutch assembly to the water pump
in any way, no attem pt should be made to pulley (70).
repair and/or reuse the damaged part. A bent Nuts (75), making sure to align the yellow
or damaged fan assembly must be replaced reference marks on the water pump hub and
w ith a new fan assembly. the fan clutch hub (figure 38).
It is essential that the fan assembly remain
in p ro p e r b a la n c e . B a la n ce c a n n o t be
assured once a fan assembly has been bent
or damaged. A fan assembly that is not in Nuts (75) to 25 N m (18 ft. lbs.).
proper balance could fail and fly apart during 3. Radiator fan shroud.
use, creating a dangerous condition to both Refer to Fan Shroud in this section.
the vehicle and the owner. 4. Battery negative cable.
1. Fan (73) to the fan clutch (74). AUXILIARY COOLING FAN

The Auxiliary Cooling Fan is available only when a
Tighten 7.4L V8 engine (RPO LE8) and Air Conditioning (C60,
C69) are ordered. Its purpose is to provide additional
Bolts (72) to 25 N m (18 ft. lbs.). cooling at low speed vehicle operations, extended idle,
54
B. 2nd Track 52. Generator Pulley

C. 3rd Track 53. A.I.R. Pump Pulley
50. Water Pump Pulley 54. Power Steering Pump Pulley
51. Crankshaft Pulley 55. Air Conditioning Compressor Pulley B-08097
Figure 26C-K Series 7.4L V8 Engine Accessory Drive (California Emissions)

50
.51
C 56 55
A. 1st Tract 50
B. 2nd Track
C. 3rd Track
D. 4th Track
51. Crankshaft Pulley 54
52 Generator Pulley
53 A.I.R. Pump Pulley
54 Power Steering
Pump Pulley
55. Air Conditioning
Compressor Pulley
56. Idler Pulley
B-09164
Figure 27G Series V6 And V8 Engine Accessory Drive
C. 3rd Track 51. Crankshaft Pulley 54

D. 4th Track 52. Generator Pulley 55 A ir Conditioning Compressor Pulley
50. Water Pump Pulley 53. A.I.R. Pump Pulley 56 Idler Pulley F-00911
Figure 28G Series 5.7L V8 Engine Accessory Drive (Heavy Duty Emissions)
51
A. 1st Track
B. 2nd Track
C. 3rd Track
54. Power Steering
Pump Pulley
55. Air Conditioning
Compressor Pulley
F-00912
Figure 29P Series 4.8L L6 Engine Accessory Drive
stop and go conditions, and when running the air WATER PUMP
conditioning system.
|*"| Remove or Disconnect (Figure 39) 4.8L L6 ENGINE
1. Battery negative cable. |+-+| Remove or Disconnect (Figures 38 and 40)

2. Grille assembly.
Refer to SHEET METAL (SEC. 2C).
3. Fan harness connector (83).
4. Fan assembly (81) from the radiator support (80). Refer to Drive Belts, in this section.
Bolts/screws (82). 2. Fan (73) and fan clutch (74) (figure 38).
Nuts (75).
3. Water pump pulley (70).
1. Fan assembly (81) to the radiator support (80). Pulley off the water pump studs (71), but do
not damage the threads.
Bolts/screws (82).
4. Lower radiator hose and the heater hose
from the water pump (91).
5. Water pump (91) from the engine block
Bolt/screw (82) to 6 N m (53 ft. lbs.). (figure 40).
2. Fan harness connector (83). Bolts (92, 93), and gasket (94).
3. Grille assembly. Loosen the generator adjusting bolt to allow

the brace to be moved away on vehicles
Refer to SHEET METAL (SEC. 2C).
where the brace will inhibit water pump
4. Battery negative cable. removal.
A. 1st Track
B. 2nd Track
C. 3rd Track
D. 4th Track
54. Power Steering
Pump Pulley
Compressor Pulley
56. Idler Pulley 51 A
F-00913
Figure 30P Series 5.7L V8 Engine Accessory Drive (Heavy Duty Emissions)
[+[ Install or Connect (Figures 38 and 40) Tighten
Clean the mating surfaces on the water pump Nuts (75) to 25 N m (18 ft. lbs.).
and the engine block.
4. Drive belts and adjust.
1. Water pump (91) to the engine block (figure 40).
Refer to Drive Belts, in this section.
New gasket (94) onto the water pump (91).
Place the generator adjusting brace back
into position if moved. 6. Cooling system.
Bolts (92 and 93). Refer to the Owners Manual.
7. Start the engine and run, with the radiator cap
Tighten removed, until the radiator upper hose (12)
becomes hot (thermostat is open).
Bolts (92 and 93) to the specifications at the
end of this section. 8. Add coolant to the radiator until the level reaches
the bottom of the filler neck.
2. Lower radiator hose and the heater hose to the
water pump (91). Engine must be running at idle speed.
3. Water pump pulley (70), fan (73), and fan clutch 9. Radiator cap, making sure the arrows line up with
(74) on the water pump hub (figure 38). the overflow tube.
A. 1st Track
B. 2nd Track
C. 3rd Track
50. Water Pump
54. Power Steering
Pump Pulley
Compressor Pulley F-00914
Figure 31P Series 7.4L V8 Engine Accessory Drive
V6 AND V8 GASOLINE ENGINES + + Install or Connect (Figures 41, 42 and 43)
|*"| Remove or Disconnect (Figures 41, 42 and 43) Clean the mating surfaces on the water pump
and the engine block.
Battery negative cable. 1. Water pump (91) to the engine block.
Drain the cooling system. New gaskets (94).
1. Accessory drive belts. Place the pump against the block and retain
Refer to Drive Belts, in this section. it with bolts (92, 93 and 95).
2. Fan (73), the fan clutch (74), and the pulley (70)
from the water pump (91) (figure 38). & Tighten
Nuts (75).
3. Generator lower brace attaching bolts and swing Bolts (92 and 93) and studs (95) to the
the brace down and out of the way. Specifications at the end of this section.
4. Generator upper brace attaching bolts. 2. Lower radiator hose and the heater hose to the
5. Lower radiator hose and heater hose from the water pump (91).
water pump (91). Bypass hose with 7.4L V8 engine.
On the 7.4L engine, remove the bypass 3. Generator upper and lower braces to the water
hose. pump (91).
6. Water pump (91) from the engine block. 4. Water pump pulley (70), fan (73) and fan clutch
Bolts (92, 93) and studs (95). (74) to the water pump hub (figure 38).
Figure 32C-K Series V6, Small Block VIB Engine Fan Shrouds
Nuts (75). Refer to Fan Shroud, in this section.

3. Air conditioning hose bracket nuts.
$ Tighten 4. Oil fill tube.
5. Generator drive belt.
Nuts (75) to 25 N m (18 ft. lbs.). Generator pivot bolt.
5. Accessory belt drive and adjust. Refer to Drive Belts, in this section.
Refer to Belt Drive in this section. 6. Generator lower bracket.
6. Battery negative cable. 7. Power steering belt.
7. Fill the cooling system. Refer to Drive Belts, in this section.
Refer to the Owners Manual. 8 . Power steering pump.
8. Start the engine and run, with the radiator cap 9. Air conditioning compressor belt, if equipped.
removed, until the radiator upper hose (12) Refer to Drive Belts, in this section.
becomes hot (thermostat is open). 10. Bypass hose and the lower radiator hose.
9. Add coolant to the radiator until the level reaches 11. Water pump (91) (figure 44).
the bottom of the filler neck. Bolts (96 and 97), water pump plate (99) and
Engine must be running at idle speed. the water pump (91).
10. Radiator cap, making sure the arrows line up with 12. Water pump plate (99) from the water pump (91).
the overflow tube. Bolts (92 and 93) and the gasket (94).
6.2L V8 DIESEL ENGINE Install or Connect (Figure 44)
H Remove or Disconnect (Figures 38 and 44)

Important
Drain the cooling system. Flanges must be free of oil. Clean the mating
1. Fan. surfaces on the water pump, both sides of the
Refer to Fan And Fan Clutch, in this water pump plate, and the engine block.
section. 1. Water pump (91) to the water pump plate (99).
2. Fan shroud. Gasket (94) and bolts (92 and 93).
A. 4.8L L6 Engine Fan Shroud

63 Jo
66
B. 7.4L V8 Engine Fan Shroud
C. 6.2L V8 Diesel Engine Fan Shroud
60. Bolt
63. Radiator
65. Clip Nut
66 . Radiator Support
69. Complete Fan Shroud
100. Radiator Mounting Panel F-00916
Figure 33C-K Series L6, 6.2L Diesel, And 7.4L V8 Engine Fan Shrouds
Tighten Refer to Drive Belts, in this section.

7. Oil fill tube.
Bolts (92 and 93) to Specifications, at the 8. Fan shroud.
end of this section.
2. Water pump (91) to the engine block.
A p p ly a n e ro b ic s e a le r #1052357 or 9. Fan (73) assembly.
equivalent as shown in figure 44. Refer to Fan And Fan Clutch, in this
The sealer must be wet to the touch when section.
the bolts are tightened. 10. Battery negative cable.
Bolts (96 and 97). 11. Fill the cooling system.
Refer to the Owners Manual.
Tighten
12. Start the engine and run, with the radiator cap
removed, until the radiator upper hose (12)
Bolts (96 and 97) to Specifications, at the
becomes hot (thermostat is open).
3. Bypass hose and lower radiator hose. 13. Add coolant to the radiator until the level reaches
4. Power steering pump. the bottom of the filler neck.
5. Generator in place. Engine must be running at idle speed.
Generator lower bracket. 14. Radiator cap, making sure the arrows line up with
6. Drive belts and adjust. the overflow tube.
60. Bolt
61. Upper Fan Shroud
62. Insulator
63. Radiator
64. Lower Fan Shroud
65. Clip Nut
67. Radiator Mounting Bracket 60 62
F-00917
Figure 34G Series 4.3L V6 Engine Fan Shroud
RADIATOR
C-K, G, AND P SERIES VEHICLE (WITHOUT

A 6.2L DIESEL ENGINE)

2. Radiator hoses from the radiator.
Radiator inlet hose and radiator outlet hose.
3. Overflow hose from the radiator.
4. Fan shroud.
5. Transmission cooler lines.
6. Radiator from the vehicle.
Retainers from the radiator support.
60. Bolt 65. Clip Nut Retainers from the upper mounting panel on
61. Upper Fan Shroud 66 . Radiator Support C-K series vehicle.
63. Radiator 67. Radiator Mounting
64. Lower Fan Shroud Bracket
|-n-| Install or Connect (Figures 45, 46 and 47)
F-00918
1. Radiator on the vehicle.
Figure 35G Series Small Block V8 And Radiator support on the upper mounting
6.2L Diesel Engine Fan Shroud panel.
A. Fan Shroud For 4.8L L6 Or 5.7L V 8

(Heavy Duty Emissions) Engine
B. Fan Shroud for The 5.7L V8 (Heavy Duty
Emissions) Engine With Air Conditioning
60. Bolt
63. Radiator
65. Clip Nut
66 . Radiator Support
67. Radiator Mounting Bracket
68. Clip
69. Complete Fan Shroud B
F-00919
Figure 36P Series (42) 4.8L L6 And 5.7L V8 Fan Shroud
65. Clip Nut 0

6 6 . Radiator Support A. P(32) Series Vehicles Fan Shroud
6 8 . Clip B. P(42) Series Vehicles Fan Shroud
F-00920
Figure 37P Series (32 & 42) 6.2L Diesel And 7.4L V8 Fan Shroud
75

71. Stud
72. Bolt
73. Fan
74. Fan Clutch
75. Nut A. Yellow Paint Marks For Proper
76. Crankshaft Pulley Alignm ent Of The Fan Clutch
77. Water Pump Hub To The Water Pump Hub
F-00921
Figure 38Fan And Fan Clutch Attachm ent
Figure 39Auxiliary Cooling Fan Attachment

90. Engine Block

91. Water Pump
92. Bolt
93. Bolt
94. Gasket
Figure 404.8L L6 Engine Water Pump Attachm ents
a Tighten 8. Remove the radiator pressure cap, start the

engine, and let it run until the upper radiator hose
Fasteners to the Specifications, at the becomes hot thermostat is open.
2. Transmission cooler lines. 9. Add coolant, with the engine running at idle
3. Fan shroud. speed, until the coolant level reaches the bottom
Refer to Fan Shroud, in this section. of the filler neck.
4. Overflow hose to the radiator.
5. Radiator hoses to the radiator. 10. Install the radiator pressure cap, making sure the
Radiator inlet hose and radiator outlet hose.
7. Fill the cooling system.
90. Engine Block

91. Water Pump
92. Bolt
94. Gasket
95. Stud
F-00924
Figure 414.3L V6 Engine Water Pump Attachments

Figure 425.0L/5.,7L V8 Engine Water Pump Attachm ents
C-K SERIES VEHICLE WITH A 6.2L DIESEL ENGINE 0 Install or Connect (Figures 45, 46 and 47)
0 Remove or Disconnect (Figures 45, 46 and 47) 1. Radiator to the vehicle.

2. Radiator supports and/or mounting panel.
1. Battery negative cable. & Tighten
2. Fan shroud. Fasteners to the Specifications at the end

of this section.
3. Overflow hose to the radiator.
3. Engine and transmission oil cooler lines. 4. Upper radiator hose and lower radiator hose to
the radiator.
Upper radiator hose and lower radiator hose from
5. Engine and transmission oil cooler lines.
the radiator.
6. Fan shroud.
5. Overflow hose from the radiator. Refer to Fan Shroud, in this section.
6. Upper radiator supports. 8. Fill the cooling system.
7. Radiator from the vehicle. Refer to the vehicle Owners Manual.
9. Remove the radiator pressure cap, start the
engine, and let it run until the upper radiator hose
90. Engine Block becomes hot thermostat is open.
91. Water Pump 10. Add coolant, with the engine running at idle
92. Bolt speed, until the coolant level reaches the bottom
94. Gasket of the filler neck.
11. Install the radiator pressure cap, making sure the
G AND SERIES VEHICLE WITH A 6.2L DIESEL

ENGINE

2. Air intake snorkel.
F-00932 3. Windshield washer bottle.
Figure 437.4L V8 Engine Water Pump 5. Upper fan shroud.
Attachments Refer to Fan Shroud, in this section.
Figure 446.2L V8 Diesel Engine Water Pump Attachm ents
6. Upper radiator hose from the radiator. 2. Master cylinder to the booster.
7. Transmission cooler lines from the radiator. Refer to BRAKES (SEC. 5).
8. Low coolant sensor. 3. Raise the vehicle.
9. Overflow hose from the radiator. 4. Lower radiator hose to the radiator.
10. Engine oil cooler lines from the radiator.
5. Lower the vehicle. j
11. Raise the vehicle.
6. Engine oil cooler lines to the radiator.
12. Lower radiator hose from the radiator.
13. Lower the vehicle. 7. Overflow hose to the radiator.
14. Master cylinder from the booster. 8. Low coolant sensor.
Refer to BRAKES (SEC. 5). 9. Transmission oil cooler lines to the radiator.
15. Radiator from the vehicle. 10. Upper radiator hose to the radiator.
* * i Install or Connect (Figures 45, 46, and 47) Refer to Fan Shroud, in this section.
1. Radiator into the vehicle.
Tighten 14. Air intake snorkel.
$ 15. Battery negative cable.
Fasteners to the Specifications, at the 16. Fill the cooling system.
end of this section. Refer to the vehicle Owners Manual.
F-00934
Figure 45C-K, G, P(42) Series Vehicle Radiator Attachment

Figure 46P(32) Series Vehicle Radiator Attachments

A. Radiator Mounting For C-K Series With 4.8L L6 (Exc. C60), P(42) Series With 4.8L L6 And 5.7L V8
B. Radiator Mounting For C-K Series With 4.8L L6 With C60
C. Radiator Mounting For C-K And G Series With 4.3L V6
D. Radiator Mounting For C-K Series With 5.0L, 5.7L; G Series (Exc. 4.3L V6); P(42) Series With 5.7L
V8
E. Radiator Mounting For C-K Series W ith 7.4L V8, 6.2L Diesel; P(42) Series With 7.4L V8, 6.2L Diesel
60. Bolt
62. Insulator
63. Radiator
65. Clip Nut
67. Radiator Mounting Bracket
68. Clip
69. Complete Fan Shroud
100. Radiator Mounting Panel
101. Radiator Upper Mounting Panel
102. Radiator Lower Mounting Panel
103. Washer
104. Nut
105. Washer
106. Nut
107. Insulator
108. Extension Assembly
109. Radiator Support Brace F-00936
Figure 47Radiator Attachm ent Legend
ALUMINUM RADIATOR REPAIR

17. Remove the radiator pressure cap, start the If the damage to a tube is too severe, a tube can be
engine and let it run until the upper radiator hose blocked or plugged as explained in Tube Blocking.
(12) becomes hot thermostat is open. No more than two tubes should ever be blocked on a
18. Add coolant, with the engine running at idle core. Also replace the core if more than three tabs are
speed, until the coolant level reaches the bottom broken on one side or if two adjacent tabs are broken.
of the filler neck.
TANKS
19. Install the radiator pressure cap, making sure the
The tanks are attached to the core by the use of
clinched tabs attached to the sides of the core. The
clinched tabs can be bent back if the tanks need to be
GENERAL DESCRIPTION removed from the core. Bend the tabs back only
enough to remove the tank. Overbending will weaken
This radiator utilizes an aluminum core with plastic the tabs.
side tanks. The core and side tanks can be replaced
separately and core repair is easily made with the hot A high temperature rubber gasket is used to seal the
melt adhesive method. A transmission oil cooler is mating surface between the core and the tank (figure
located in one of the side tanks. The oil coolers can be 48). The gasket must be replaced any time a tank is
replaced. The drain cock is located on the lower part of removed from the core.
one of the tanks. The drain cock is also serviceable. TRANSMISSION OIL COOLER
CORE The oil cooler can be replaced by removing the tank
The core is made of aluminum and is of the from the core.
crossflow design. It utilizes large tubes that resist
plugging, and repairs to the tubes and core are easily A leaking oil cooler gasket can be replaced without
made using the hot melt adhesive method. removing the tank from the core.
DRAIN COCK
The core is attached to the tanks by clinched tabs on
the core that can be bent back if tank or core The aluminum/plastic radiator utilizes a two piece
replacement is required. plastic drain cock and a rubber seal. The drain cock is
serviceable (figure 49).
113
110. Core
111. Outlet Tank
112. Inlet Tank
113. Side Tank Gasket
114. Engine Oil Cooler (Diesel Only)
115. Transmission Oil Cooler
116. Cooler Gasket
117. Cooler Retaining Nut
118. Drain Cock
Figure 48Alum inum Radiator Assembly
ALUMINUM RADIATOR
DIAGNOSIS
LEAK TESTING
Some core leaks can be detected by merely adding
water to the radiator. It is helpful to clean the core so
that the damaged area can be more easily found.
1. Remove dirt and insects from the fins with a
common water hose without a nozzle. Excessive
water pressure could damage the fins.
2. Scrub the core with a soft-bristle brush using
clean, hot water or hot water with a mild detergent
solution.
On-Vehicle Pressure Testing

You can pressure-test the aluminum-plastic radiator
with a common pump and gage, such as BT-7002-3, or
J-24460-01 with J-23699 (figure 50). With the system at
a cool temperature, remove the radiator cap, connect
the gage, and apply normal system operating pressure.
Do not exceed 138 kPa (20 psi). Watch the gage
needle for an indication of a leak, and examine the
radiator and other cooling system parts for signs of
F-00938 escaping coolant.
Repair all hose and hose connections as required.
Figure 49Aluminum Radiator Drain Cock Also check the radiator cap to ensure that it will
maintain the correct pressure.
113A 121 113B
Figure 50Pressure Testing The Radiator
If the radiator is found to be leaking during the

pressure test, mark the leak area so that it is easily
found once the radiator has been removed from the
113A. Inlet Tank Gasket
vehicle.
121. Core Tubes
113B. Outlet Tank Gasket
Off-Vehicle Leak Testing
118B. Drain Cock Gasket
122. Oil Cooler Gaskets
NOTICE: Do not use boil-out tanks or vats or
123. Joint Between Tube And Header
other tanks that have been used for copper
and brass radiators. The flux, acid, and
caustic cleaners remaining in these tanks will F-00941
attack the aluminum and cause radiator
failure. A separate test tank containing clean Figure 52Possible Leak Areas
water is strongly recommended for servicing
aluminum/plastic radiators.
If a large water tank is available, the radiator can
be submerged, and a check for air bubbles can
1. Install test fittings or rubber test caps in the inlet
be made.
and outlet necks and seal the oil cooler fittings
with metal plugs to protect the cooler and keep
the fluid from running out (figure 51). REPAIRABLE LEAKS
2. Attach the pressure tester and gradually apply air There are two types of leaks that can be repaired on
pressure until 138 kPa (20 psi) is attained. Do not the aluminum-plastic radiator: core leaks and gasket
exceed 138 kPa (20 psi). Check the pressure leaks. Leaks in the plastic tanks cannot be repaired
gage to see if there is a pressure loss. To ensure (figure 52).
that there are no small leaks, run water over the
repair area and look for bubbles. (A mild Core leaks can occur in a tube or in the joints
detergent is very helpful). between the tubes and headers. Gasket leaks can
occur in the joints between the plastic tanks and the
headers or in the joints between the oil cooler fittings
and the tank. Some leaks can be repaired while the
radiator is on the vehicle; however, it is usually best to
remove the radiator.
Repair Methods
There are several methods that can be used to repair
the radiator core, but the hot melt adhesive method
has been found to be the most simple and effective.
The kit contains adhesive sticks, cotton swabs, a

wire brush and the primer. The adhesive stick is
reusable, has an indefinite shelf life, and is waste-free.
Figure 51Alum inum Radiator And Oil The sticks must be stored in a sealed container to keep
Cooler Plugs them dry (figure 53).
NOTICE: DO NOT USE BOIL OUT TANKS OR

VATS. Common service methods may actually
124 125 destroy an aluminum radiator. Caustic or lye
cleaning solutions must NOT be used for
aluminum radiators. USE CLEAN WATER ONLY
WHEN SERVICING ALUMINUM RADIATORS.
Do not open the hood if you can see or hear

steam or coolant escaping from the engine
compartment.
Do not remove radiator cap if the radiator feels
warm.
Do not remove the radiator cap or coolant
recovery tank cap if the coolant in the recovery
tank looks like it is boiling.
Wear eye protection.
Wear gloves to protect your hands against
excessive heat or the effects of chemicals on your
124. Adhesive Sticks skin.
125. Kit Container
Prevent d irt and w ater from e nte rin g the
126. Cotton Swabs
transmission oil cooler.
127. Primer
128. Wire Brush Do not use boil-out tanks or vats or other tanks
F-00942 that have been used for copper and brass
radiators. The flux, acid, and caustic cleaners
remaining in these tanks will attack the aluminum
Figure 53Hot Melt Adhesive Repair Kit
and cause radiator failure. A separate test tank
containing clean water is strongly recommended
ALUMINUM RADIATOR SERVICE for servicing aluminum/plastic radiators.
The aluminum-plastic radiator can be repaired at the NOTICE: Never use shop air to pressure test
dealership. The following components are easily radiators that is not regulated at 138 kPa (20
replaced: psi). Pressures over 138 kPa (20 psi) will
damage the radiator.
Core
Tanks and gaskets

SPECIAL PREPARATION
For damaged areas that are between the cooling
Oil coolers and gaskets
fins, it may be necessary to remove some of the fins.
Drain cock and gasket Do not remove more fins than necessary. Usually 6
mm (1/4-inch) beyond the leak or damage area is
The tanks cannot be repaired if broken or cracked. enough to make an effective repair (figure 54).
The radiator core can be replaced and the new core
used with the original tanks and oil cooler. TUBE BLOCKING
If a tube is severely damaged, it can be blocked off
(figure 55).
PRECAUTIONS
As with all cooling system service, take measures to
prevent personal injury and damage to the system. NOTICE: Do not block off more than two tubes
in a radiator. Blocking off more than two tubes
will reduce the cooling capability of the
CAUTION: To help avoid the danger o f being system.
burned, do not remove the radiator cap while
the engine and radiator are still hot. Scalding The tube should be cut off 6 mm (1/4-inch) from the
flu id and steam can be blow n out under header and pinched shut before it is cleaned and
pressure if the cap is taken o ff too soon. sealed. Refer to General Core Sealing.
iMUM, JUUUUUIJUUUUUUUUUVUUVUUUUUUUI/UU/i/i/ui/uuuuwui/viyuimjuutjuuuumiu
IIII I I l W l/M iIlill/Iillf m iiiEiiii
muiMilMlMlEil mmmmiii a
mimmmimimimaimmim
IB M i i M i i P i i i p r w mmmaiiimm!
iff mmmmmmmmmmm
WillM M M M M M mini? mm
IIIIII1IM11m uuim m m
A. 6mm (1/4-inch) Beyond^ mmmr.. * " ....
The Damaged Area
F-00946
Figure 54Removing Fins From Damaged Area Figure 56Using A Wet Cloth To Cool
The Side Tank
HEADER REPAIR
2. Apply a wet cloth if you are working near the
If the header or a tube near the header requires a
plastic tanks or the joints between the core tubes
repair, the side tank does not have to be removed. A
and header (figure 56); or submerge the tank in
damp cloth can be placed against the side tank where
water (figure 57).
the repair has to be made (figure 56). The side tank
can also be submerged in a tank of water up to the
header (figure 57). 3. Heat the repair area slightly with a small torch or
heat gun to be sure it is dry. Do not use a blow
torch.
NOTICE: One of these procedures have to be
used when repairs are made on or near the 4. Brush the area to be repaired with the small steel
header to prevent damage to the tank or brush that is supplied in the kit and blow dust
gasket. away from the repair area (figure 58).
5. Open the tube of primer, using the spurred cap or

a pin, and apply primer to the repair area only.
GENERAL CORE REPAIR
Use of the primer produces a stronger repair. Do
Preparation of the surface in the repair area cannot not heat the primer.
be overemphasized. If the leak area surface is not
clean, none of the repair materials will stick to the
surface.
1. Position the core so the repair area is accessible.
A. Submerge The Tank Keep The Header

Above The Water Line F-00949
Figure 55Tube Blocking Figure 57Submerging The Side Tank

Figure 58Cleaning The Repair Area With Figure 59Scrubbing The Area With A
A Steel Brush Cotton Swab
C A U T IO N : The p rim e r c o n ta in s
trichlorethane.
It could be harful or fatal if swallowed. If
swallowed, get medical attention.
Use with adequate ventilation.
In case of eye contact, flush with plenty
of water and get medical attention.
In c a se o f b o d y c o n ta c t, w a sh
thoroughly w ith soap and water.
Do not mix the prim er w ith water.
6. Scrub the repair area with a cotton swab until a

fresh swab stays clean. The clear, yellow-brown Figure 60Heating The Repair Area
coating does not have to be removed (figure 59).
7. Heat the repair area with a heat gun or by moving TANK GASKET LEAK REPAIR
the torch in a circular pattern (figure 60). Use a Tank gasket leaks can easily be mistaken for tank or
soft, small blue flame (like a gas stove flame). header leaks. If a plactic tank leaks from the header
8. Withdraw the torch and rub the adhesive stick on joint gasket, tighten the clinch tabs with locking-type
the repair area (figure 61). The adhesive will flow pliers (figure 62). If this method doesnt seal the leak,
at a tem pe ra ture of a pp ro xim a te ly 260C remove the tank for further inspection.
(500F). If the stick doesnt start to melt, remove
1. Pry open the clinch tabs, except those under the
it and reapply the heat. Do not heat the stick
inlet, outlet, and filler necks, using J-33419-1 or a
directly with a flame. High heat w ill burn and screwdriver (figure 63). Lift the tabs only enough
char the adhesive. to allow removal.
9. Continue heating until the adhesive flows and
wets the entire repair area and fills the joint. If a
hole is in the center of a tube, heat the tube and
let the hot surface melt and pull in the adhesive.
The force of the flame or heat gun will also tend
to guide the adhesive toward the hole. For leaks
between a tube and header, flow the adhesive
completely around the tube and header joint with
the tank installed.
10. Heat the repair area until the adhesive is
bubble-free and smooth, with a light yellow color.
Curing is not required.
11. Test the radiator for leaks when cool. If the repair
area still leaks, reheat it gently to dry it. Heat and
reflow the adhesive or apply more as necessary Figure 61Apply Hot Melt Adhesive To
to repair the leak. The Repair Area
NOTICE: Care should be taken not to 10. Clamp remaining clinch tabs around the header
overbend the tabs. Overbending could result using the clinching tool or pliers (figure 65).
in breakage. If there are more than 3 tabs
broken on one side of the header, or more NOTICE: Tighten the clinch tabs as you would
than 2 adjacent tabs together, the core must cylinder head bolts, starting at the center and
be replaced. working out to the ends.
2. Lift the tank and slide it out from under the 11. Replace the core if there are more than three
remaining clinched tab. You may have to tap the tabs broken on one side or two adjacent tabs
tank with your hand to dislodge the gasket. Lift broken.
the remaining tab(s) with pliers. 12. Install the drain cock, if removed.
3. Remove and discard the gasket. 13. Test the radiator for leaks.
4. Clean the header and gasket groove of all dirt
and old rubber. OIL COOLER GASKET REPLACEMENT
The outlet tank must be removed to replace the oil
5. Clean the sealing edge of the plastic tank.
cooler, but the oil cooler gaskets can be replaced
6. Examine the header gasket surface and tank
without removing the tank.
flange for evidence of leakage, and clean or
1. Remove the radiator and lay it on a flat surface.
repair the surface to remove dirt, burrs, and
2. Remove the bottom oil cooler nut and loosen the
bumps.
top nut.
7. Remove the oil cooler, if equipped, and install it in 3. Press the oil cooler into the hole and remove the
the new tank, if used. gasket using a small hook (figure 66).
8. Dip or coat the new tank gasket in engine coolant 4. Flow-dry ail surfaces on the tank and oil cooler.
and position it on the header surface. The coolant 5. Install a new gasket w ithout lubrication. Be sure
helps hold the gasket in place. it is seated properly inside the tip of the fitting.
9. Position the tank and gasket to the header, clamp 6. Reach into the oil cooler and push it into position
it in place and secure it by bending four clinch against the tank.
tabs as shown in figure 64. 7. Assemble the oil cooler nut loosely.
A. Pry Up The Clinch Tab
F-00956
Figure 63Opening The Clinch Tabs Figure 65Clinching Sequence

9. Install the oil cooler nuts and torque to 20 N m (15

ft. lbs.). Do not overtighten, as damage to the
gasket could result.
10. Leak-test the radiator.
OIL COOLER REPLACEMENT

1. Remove the outlet tank as previously outlined.
2. Remove nuts from the oil cooler fittings.
3. Remove the oil cooler and gaskets from the tank.
4. Remove the old rubber gaskets, throw away, then
clean and dry seal areas.
5. Place rubber gaskets on a new oil cooler and
place onto the outlet tank fitting holes. Be careful
not to loosen or misalign the gaskets. Gaskets
must be installed dry and be free of dirt and oil.
6. Install and tighten nuts snugly onto the fittings.
7. Torque nuts to 20 N-m (15 ft. lbs.). Overtorquing
could cut the rubber gaskets.
Figure 66Removing The Oil Cooler Gasket 8. Replace the tank as previously described.
9. Test the radiator.
8. Replace the other gasket by following the same
procedure. RECORE
If the radiator core is damaged beyond repair and
the other parts are serviceable, install the original inlet
and outlet tanks, oil cooler, radiator cap, and drain
valve, along with the new core and new gaskets.
SPECIFICATIONS
DRIVE BELT TENSION SPECIFICATIONS i
Power Steering Air Conditioning A.I.R.

Engine Tension Requirement Generator Pump Compressor Pump
Before Operating The Engine (New Belt) 750 N (169 lb.) 750 N (169 lb.) 750 N (169 lb.) 750 N (169 lb.)
4.8L L6
A fter Operating The Engine (Old Belt) 400 N (90 lb.) 400 N (90 lb.) 400 N (90 lb.) 400 N (90 lb.)
Before Operating The Engine (New Belt) 600 (135 lb.) 650 N (146 lb.) 750 N (169 lb.) 650 N (146 lb.)
4.3L V6
Before Operating The Engine (New Belt) 600 N (135 lb.) 650N (146 lb.) 750 N (169 lb.) 650 N (146 lb.)
5.0L V8
Before Operating The Engine (New Belt) 600 N (135 lb.) 650 N (146 lb.) 750 N (169 lb.) 650 N (146 lb.)
5.7L V8
Before Operating The Engine (New Belt) 600 N (135 lb.) 650 N (146 lb.) 650 N (146 lb.) *650 N (146 lb.)
7.4L V8
A fter Operating The Engine (Old Belt) 400 N (90 lb.) 400 N (90 lb.) 400 N (90 lb.) MOO N (90 lb.)
6.2L V8 Before Operating The Engine (New Belt) 650 N (146 lb.) 650 N (146 lb.) 750 N (169 lb.)
(Diesel) A fter Operating The Engine (Old Belt) 300 N (67 lb.) 300 N (67 lb.) 400 N (90 lb.) -
* When equipped w ith a right hand mounted pum p and/or Federal Emissions (NAS) ONLY.
DO NOT exceed the New B elt tension specification when tensioning any belt, especially a used belt.
RADIATOR MOUNTING TORQUE SPECIFICATIONS
Fastener Name 4 .8 L L6 4 .3 L V6 5 .0 L V8 5 .7 L V8 6 .2 L V8 7 .4 L V8
Com plete Fan Shroud To

6 N m (4 ft. lbs.) - 16 N m (1 2 ft. lbs.) 16 N m (12 ft. lbs.) 9 N m (7 ft. lbs.) 6 N m (4 ft. l b s )
The Radiator Support
Upper Fan Shroud To

*6 N m (4 ft. lbs.) 27 N m (2 0 ft. lbs.) - * 1 6 N m (12 ft. lbs.) *6 N m (4 ft. lbs.) * * 1 0 N-m (8 ft. lbs.)
Low er Fan Shroud To

- 6 N m (4 ft. lbs ) - - - -
Upper Fan Shroud To

- 6 N m (4 ft lbs.) - - *6 N m (4 ft lbs.) -
The Low er Fan Shroud
Radiator M ounting Panel

17 N m (1 3 ft. lbs.) - - - -
To The Bracket
R adiator M ounting Panel To

- - - - 17 N m (1 3 ft. lbs.) 17 N -m (1 3 ft lbs.)
Upper M ounting Panel To

- - - - 17 N m (13 ft l b s ) 17 N -m (13 ft. lbs.)
The Low er M ounting Panel
Low er M ounting Panel

- - - 25 N -m (18 ft lbs ) 25 N m (18 ft lbs.)
To The Fram e
Radiator Bracket
- - 17 N m (1 3 ft lbs.) 17 N m (1 3 ft. lbs.) - -
To The Support
S upport Brace To The

- - - - 17 N m (1 3 ft lbs.) 17 N -m (13 ft. lbs.)
Upper M ounting Panel
* For G Series Vehicles ONLY

* For P Series Vehicles ONLY
ACCESSORY DRIVE COMPONENT TORQUE SPECIFICATIONS
Fastener Name 4.8L L6 4.3L V6 5.0L V8 5.7L V8 6.2L V8 7.4L V8

Generator 25 N m 25 N-m 25 N-m 25 N-m 27 N-m *25 N-m
A djustm ent Bolt (18 ft. lbs.) (18 ft. lbs.) (18 ft. lbs.) (18 ft. lbs.) (20 ft. lbs.) (18 ft. lbs.)
Generator 23 N-m 47 N-m 47 N-m 47 N m 43 N-m 50 N-m
Pivot Bolt (17 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (32 ft. lbs.) (37 ft. lbs.)
Power Steering Pump 43 N m 33 N-m 33 N-m 33 N-m 43 N-m 88 N-m
Power Steering Pump 24 N-m 33 N-m 33 N-m 33 N-m 43 N-m 50 N-m
Air Conditioning Condenser 34 N-m 34 N-m 34 N-m 34 N-m 34 N-m 34 N-m
Air Conditioning Condenser 34 N m 34 N-m 34 N-m 34 N-m 34 N-m 34 N-m

Air Injection Reactor (A I R.) 25 N-m 25 N-m 25 N-m 25 N-m 33 N m

-
Pump A djustm ent Bolt (18 ft. lbs.) (18 ft. lbs.) (18 ft. lbs.) (18 ft. lbs.) (24 ft. lbs.)
Air Injection Reactor (A I R.) 24 N-m 24 N-m 24 N-m **2 4 N-m 33 N-m
-
Pump Pivot Bolt (17 ft. lbs.) (17 ft. lbs.) (17 ft. lbs.) (17 ft. lbs.) (24 ft. lbs.)
* For P series vehicles, torque is 64 N m (47 ft. lbs.) w ith the K97 Generator.
** For the 5.7L V8 w ith Federal Em issions (RPO NA5), torque is 50 N m (37 ft. lbs.)
THERMOSTAT AND RESERVOIR RELATED TORQUE SPECIFICATIONS

C-K C-K C-K G G G P P
Fastener Name 10/1500 20/2500 30/3500 10/1500 20/2500 30/3500 20/2500 30/3500
Coolant Recovery Tank 2 N-m 2 N-m 2 N-m 2 N-m 2 N-m 2 N-m
B olt/Screw (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) - -
Deaeration Tank Bolts/ 5 N-m 5 N-m 5 Nm 10 N-m 17 N-m
Screws And Nuts (44 in. lbs.) (44 in. lbs.) (44 in. lbs.) (88 in. lbs.) (12 ft. lbs.)
W ater Outlet To The * 2 7 N-m * 2 7 N-m * 2 7 N m * 2 7 N-m * 2 7 N-m * 2 7 N-m * 2 7 N-m *2 7 N-m
Therm ostat Housing Bolts (20 ft. lbs.) (20 ft. lbs.) (20 ft. lbs.) (20 ft. lbs.) (20 ft. lbs.) (20 ft. lbs.) (20 ft. lbs.) (20 ft lbs.)
Therm ostat Crossover
47 N-m 47 N-m 47 N-m 47 N m 47 N-m 47 N-m 47 N-m 47 N-m
To The Engine Bolts
(35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft lbs.)
(6.2L Diesel ONLY)
W ater Outlet To The
47 N m 47 N-m 47 N-m 47 N m 47 N-m 47 N-m 47 N-m 47 N m
Therm ostat Housing
(35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft. lbs.) (35 ft lbs.)
Bolts (6.2L Diesel ONLY)
* On vehicles w ith a 6.2L Diesel, torque to 47 N-m (35 ft. lbs.)

On vehicles w ith a 7.4L V8, torque to 41 N m (30 ft. lbs.)
6C-1
SECTION 6C
FUEL SYSTEM
CONTENTS
SUBJECT PAGE
A ir C le a n e r.................................................................................................................................................................. 6C- 2
A ir Filter Element R e p la c e m e n t......................................................................................................................... 6C- 2
Gasoline Engine Fuel F ilte rs ....................................................................................................................................6C- 2
Fuel Filter Replacem ent........................................................................................................................................ 6C- 2
Diagnosis Of WATER IN FUEL Light (Diesel Engine O n ly )..........................................................................6C- 3
Diesel Engine Fuel F ilte rs ........................................................................................................................................ 6C- 4
Draining The Fuel F ilte r........................................................................................................................................ 6C- 4
Diesel Fuel Filter R eplacem ent........................................................................................................................... 6C- 5
Diesel Fuel Filter Assem bly Component Replacem ent.................................................................................. 6C- 5
Fuel Pum p.................................................................................................................................................................... 6C- 6
Fuel Pump Tests (Gasoline E n g in e )...................................................................................................................6C- 6
Fuel Pump Tests (Diesel E n g in e )....................................................................................................................... 6C- 6
Fuel Pump R e p la ce m e n t...................................................................................................................................... 6C- 7
Fuel T a n k .................................................................................................................................................................... 6C- 9
Draining The Fuel T a n k ........................................................................................................................................ 6C- 9
Fuel System Cleaning (Gasoline E ngine).......................................................................................................... 6C- 9
Diesel Fuel System C ontam ination.....................................................................................................................6C-10
Fuel System Cleaning (Diesel E n g in e ).............................................................................................................. 6C-10
Fuel Tank P u r g in g ................................................................................................................................................. 6C-11
Fuel Tank Leak T e st...............................................................................................................................................6C-11
Fuel Tank R eplacem ent........................................................................................................................................ 6C-12
Fuel Tank Filler N e c k .............................................................................................................................................6C-12
Fuel L in e s ................................................................................................................................................................ 6C-12
Fuel Gage Sending U n i t .......................................................................................................................................... 6C-15
Fuel Gage Sending Unit R eplacem ent.............................................................................................................. 6C-15
Fuel Tank Selector V a lv e ........................................................................................................................................ 6C-15
Diagnosis Of Selector V a lv e ................................................................................................................................6C-15
Fuel Tank Selector Valve R eplacem ent............................................................................................................ 6C-17
Accelerator C o n tro ls ................................................................................................................................................. 6C-18
Accelerator Control C a b le ....................................................................................................................................6C-18
Accelerator P e d a l................................................................................................................................................... 6C-19
S pe cifica tio ns..............................................................................................................................................................6C -19
Special T o o ls ..............................................................................................................................................................6C-19
All new GM vehicles are certified by the United States Environmental Protection Agency as conforming to the
requirements of the regulations for the control of air pollution from new motor vehicles. This certification is contin
gent on certain adjustments being set to factory standards. In most cases, these adjustment points either have been
permanently sealed and/or made inaccessible to prevent indiscriminate or routine adjustment in the field. For this
reason, the factory procedure for temporarily removing plugs, cap, etc., for purposes of servicing the product, must
be strictly followed and, wherever practicable, returned to the original intent of the design. For vehicles sold in
Canada and equipped with non-closed loop engines, also refer to the appropriate Canadian service manual supple
ment.
6C-2 FUEL SYSTEM
AIR CLEANER
CAUTION: The air cleaner also functions as a AIR FILTER ELEMENT

flame arrestor in the event of engine back
fire. The air cleaner should be installed at all
REPLACEMENT
tim es unless its removal is necessary fo r re
pair or maintenance. To help reduce the risk
of personal injury and property damage, be NOTICE: Extreme care should be taken when
sure that no one is near the engine com part removing the filter element. Remove the filter
ment before starting the engine w ith the air element slowly to prevent dirt from falling into
cleaner removed. If engine backfire occurs the engine.
w ith the air cleaner removed, there could be
a burst of flame and possibly other fire in the
engine com partm ent. + + Remove or Disconnect
On vehicles w ith diesel engines, do not
use starting flu id simmediate engine dam 1. Wing nut.
age can result. Also take care not to let ob 2. Air cleaner cover from the base.
jects fall into the engine if the air cleaner is 3. Air filter element.
removed. If the engine is running, suction 4. All accumulated dirt from the base.
can pull loose objects into the engine. Ob
jects pulled or dropped into the engine can I? Inspect
cause costly engine damage.
Filter element for damage or excessive dirt
When replacement of the air cleaner filter element is accumulation. Replace as necessary.
necessary, an AC air filter element is recommended. Seals or gaskets for damage.
Refer to MAINTENANCE AND LUBRICATION
- Install or Connect
(SEC. OB) for change intervals. Operation of the vehicle
in dusty areas will necessitate more frequent replace
ment. 1. Air filter element.
2. Air cleaner cover.
3. Wing nut.
GASOLINE ENGINE FUEL FILTERS
placed in the inlet hole with the gasket (2) surface out
ward. A spring (4) pushes out against the element and
compresses the gasket (2) against the fuel inlet nut (1).
A check valve is also built into the filter element.
FUEL FILTER REPLACEMENT

1. Fuel Inlet Nut
2. Gasket Remove or Disconnect
3. Filter With Check Valve
4. Spring B-08098 1. Fuel line connection at the fuel inlet nut (1).
2. Fuel inlet nut (1).
Figure 1Carburetor Fuel Filter 3. Filter element (3), gasket (2), and spring (4).

The fuel filter element should be replaced at the in
tervals shown in MAINTENANCE AND LUBRICATION
1. Spring (4).
(SEC. OB). Fuel filter elements are of the throw away
2. Filter element (3).
type and should be replaced, not cleaned.
The inlet check valve must be installed in
Internal fuel filters are located in the inlet fitting of the filter element to meet Motor Vehicle
the carburetor (Figure 1). The filter element (3) is Safety Standards (M.V.S.S.) for roll-over.
FUEL SYSTEM 6C-3
The new filter element must include the Tighten

check valve.
The check valve end of the filter element Fuel inlet nut to 24 N-m (18 ft. lbs.).
must face toward the fuel line. 4. Fuel line.
3. Fuel inlet nut (1). Start the engine and check for leaks.
DIAGNOSIS OF WATER IN FUEL LIGHT

(DIESEL ENGINE ONLY)
Interm ittent Light Water in fuel filter. Drain water from the fuel filter.
Light Stays On With Fuel filter is clogged or contains water. Drain the fuel filter. If no water is
Engine Running drained and the light stays on, re
(Temperature Above place the filter element.
Freezing)
Light Stays On With Fuel filter is clogged with ice. Drain the fuel filter. If no water is
Engine Running drained, open the air bleed and
(Temperature Below check for fuel pressure. Replace the
Freezing) filter element if there is no pressure.
Light Comes On At Plugged fuel filter. Replace the filter element.

High Speed Or
During Heavy
Acceleration
Light Stays On Fuel filter or lines plugged. Replace the filter element or check
C ontinuously And the lines.
Engine Stalls And
W ill Not Restart
(A fter Initial
Start-Up).
Light Stays On Large amounts of water pumped into Purge the fuel tank.
Continuously And the tank.
Engine Stalls And
W ill Not Restart
(After Refueling).
6C-4 FUEL SYSTEM
DIESEL ENGINE FUEL FILTERS
7. Water Drain Valve

8. Bail Wires
9. Fuel Filter Element
10. Air Bleed
11. Filter Adapter
12. Air Bleed Port
13. Restriction Switch
14. Fuel Heater
15. Water Sensor
F-00796
Figure 2Diesel Fuel Filter
The diesel engine fuel filter is an inline type filter A water drain is located in the bottom of the fuel filter
which combines several different functions. It acts as a assembly. By opening the water drain valve, water that
filter, water separator, water detector, water drain, and a has collected in the bottom of the filter element can be
fuel heater (Figure 2). drained.
The first stage of the filter element is a water coale-
A fuel heater is located in the fuel filter assembly to
sor. The coalesor element combines small droplets of
help prevent fuel waxing. The heater thermostat turns
water into larger drops. The water collects in the bot
the heater on at about 0C (32F) and off at about
tom of the filter element for draining. The fuel then pas
30C (80F). The heater uses 7 to 13 amps depending
ses through the second stage of the filter element
which is a paper filter. on fuel temperature.
The filter acts as a water detector by turning on the

WATER IN FUEL light on the instrument panel. The
probe of the water detector will touch water when 65
ml. (2.2 fluid ounces) of water has collected in the filter.
DRAINING THE FUEL FILTER
This completes a circuit through the water to the cover
1. Turn off the engine and apply the parking brake.
assembly which turns on the WATER IN FUEL light.
2. Remove the fuel filler cap to release any pressure
NOTICE: If the WATER IN FUEL light comes or vacuum in the fuel tank.
on and the fuel system is not purged of water,
fuel injection system damage may result. 3. Place a suitable container under the filter drain
hose.
When the light comes on, the filter should be drained
as soon as practical, but within one to two hours of
engine operation.
FUEL SYSTEM 6C-5
CAUTION: The water/diesel fuel m ixture is 3. A 3 mm (Ve-inch) inside diameter hose to the air
flammable, and could be hot. To help avoid bleed port (12).
personal injury and/or property damage, do 4. The other end of the hose into a suitable
not touch the fuel com ing from the drain container.
hose, and do not expose the fuel to open Disconnect the fuel injection pump shut-off
flames or sparks. solenoid wire.
Be sure you do not overfill the container.
Heat (such as from the engine) can cause the NOTICE: If the engine is to be cranked or
fuel to expand. If the container is too full, started with the air cleaner removed, take care
fuel could be forced out of the container. not to let objects fall into the engine. If the
This could lead to a fire and the risk of engine is running, suction can pull loose
personal injury and/or vehicle damage. objects into the engine. Objects pulled or
dropped into the engine can cause costly
4. Open the drain valve (7) two to three turns (figure engine damage.
2).
5. Start the engine and allow it to idle for one to two Crank the engine for 10 to 15 seconds and then
minutes or until clear fuel is observed. wait one minute for the starter motor to cool.
6. Stop the engine and close the drain valve (7). Repeat until clear fuel is observed coming from
7. Install the fuel filler cap. the air bleed.
8. Dispose of the drained mixture in a proper Close the air bleed.
manner 5. Injection pump solenoid wire.
6. Fuel filler cap.
Start the engine and allow it to idle for five
DIESEL FUEL FILTER minutes.
REPLACEMENT Check the fuel filter for leaks.
Remove or Disconnect (Figure 2) DIESEL FUEL FILTER ASSEMBLY

COMPONENT REPLACEMENT
1. Fuel filler cap to release any pressure or vacuum
in the fuel tank. All component parts of the fuel filter assembly are
2. Both bail wires (8). serviceable. These components include the filter
Drain fuel from the filter by opening the air adapter, restriction switch, fuel heater, and the water
bleed (10) and the water drain valve (7). sensor (figure 2).
Allow the fuel to drain into a suitable Always replace any damaged or worn O-rings,
container. gaskets, or seals. After replacing components, bleed
3. Fuel filter element (9). air from the filter to save cranking time. Start the
e n g in e and ch e ck fo r leaks a fte r re p la c in g
5 | Clean components.
Any dirt from the fuel sealing surfaces of the filter

element and the filter adapter (11).
1. New filter element.

2. Bail wires.
Close the drain valve (7).
6C-6 FUEL SYSTEM
FUEL PUMP
All engines use a mechanical fuel pump located on 4. If the flow is insufficient, check for a restriction.
the front right side of the engine. The pump is a dia 5. If there are no restrictions, check fuel pump
phragm type pump and is actuated by a rocker arm vacuum and/or pressure.
through a link and pull rod.
Some engines have a special fuel pump that has a FUEL PUMP PRESSURE TEST
metering outlet for a vapor return system. Any vapor 1 . Disconnect the fuel inlet line at the carburetor.
that forms is returned to the fuel tank along with hot
2. Install a low pressure gage to the line.
fuel. This reduces the chance of vapor lock because
cool fuel from the tank is always circulated through the 3. Start the engine.
fuel pump. 4. Fuel pump pressure should be 27.5 to 44.8 kPa (4
The fuel pump rocker arm is moved back and forth to 6 V2 psi).
by a rod which rides on an eccentric on the engine 5. If the pressure is low, check for restrictions in the
camshaft. The rocker arm pulls down on the pump dia fuel tank sender unit filter, lines, and hoses.
phragm against spring pressure. This causes a vac
uum in the pump chamber which draws fuel from the NOTICE: Hold the carburetor fuel inlet nut
tank through the inlet valve. The camshaft rotates and while tightening the fuel line fitting to prevent
releases pressure on the rocker arm. This allows the carburetor damage.
spring to act on the diaphragm and force fuel out of the
pump chamber through the outlet valve and into the 6 . Connect the fuel inlet line to the carburetor.
fuel line to the carburetor.
When the carburetor float rises and closes the nee FUEL PUMP VACUUM TEST
dle valve, fuel cannot leave the pump chamber. The 1. Disconnect the inlet hose at the fuel pump and
spring is held compressed by the fuel pressure in the connect a vacuum gage.
pump chamber. The rocker arm idles on the cam ec
2. Crank or run the engine until the maximum
centric and only moves enough to maintain pressure
vacuum is reached.
on the spring. A constant pressure is maintained on
the fuel in the line to the carburetor. This pressure is 3. If the vacuum is less than 50.6 kPa (15-inches
proportional to the force of the spring. Hg), replace the fuel pump.
4. If the vacuum is 50.6 kPa (15-inches Hg), check
the fuel lines and hoses for leaks, kinks, or splits
FUEL PUMP TESTS by disconnecting each section of line and
(GASOLINE ENGINE) connecting a vacuum gage. Crank or run the
engine until the maximum vacuum is reached.
If the fuel system is suspected of not delivering The vacuum should be at least 50.6 kPa
enough fuel, it should be inspected as follows. (15-inches Hg).
L * Inspect
FUEL PUMP TESTS
Make certain that there is fuel in the tank. (DIESEL ENGINE)
For leaks at all fuel connections from the fuel tank
to the carburetor. If the fuel system is suspected of not delivering
The engine should be running. enough fuel, it should be inspected as follows.
Tighten any loose connections.
All hoses for flattening or kinks that would restrict Inspect
the flow of fuel.
Air leaks or restrictions on the suction side of the Make certain that there is fuel in the tank.
fuel pump will seriously affect pump output. For leaks at all fuel connections from the fuel tank
to the injection pump.
FUEL PUMP FLOW TEST
The engine should be running.
1 . Remove the fuel supply line from the carburetor
and insert it into a suitable container. Tighten any loose connections.
2 . Crank the engine. All hoses for flattening or kinks that would restrict
3. The fuel pump should supply 237 ml ( 1/2 -pint) or the flow of fuel.
more in 15 seconds. Air leaks or restrictions on the suction side of the
fuel pump will seriously affect pump output.
FUEL SYSTEM 6C-7
FUEL PUMP FLOW TEST
1. Fuel line at the fuel filter inlet.

2. Fuel injection pump electric shut-off solenoid wire
(pink wire).
Place a suitable container at the end of the fuel
filter inlet line.
Crank the engine for 15 seconds.
The fuel pump should supply 237 ml (1/2 -pint) or
more in 15 seconds.
FUEL PUMP PRESSURE TEST

1. Disconnect the fuel line at the inlet to the fuel
filter assembly.
2. Install a low pressure gage to the line.
3. Crank or run the engine for 10 to 15 seconds.
4. Fuel pressure should be 38 to 45 kPa (5.5 to 6.5
psi).
Tighten
FUEL PUMP VACUUM TEST
1. Disconnect the inlet line at the fuel pump. Bolts to specification.
Plug the hose or position it so fuel does not
leak. 5. New gasket (27).
2. Connect a vacuum gage to the fuel pump inlet.
6. Fuel pump (25).
3. Start the engine.
The engine will use fuel from the filter 7. Bolts (26).
assembly.
4. Vacuum should be 41 kPa (12-inches Hg) or
greater.
5. Replace the pump if vacuum is less than 41 kPa
(12-inches Hg).
FUEL PUMP REPLACEMENT

ALL ENGINES EXCEPT 7.4L
|+ + | Remove or Disconnect (Figures 3 through 6)
1. Fuel pipes and hoses from the fuel pump (25).

2. Bolts (26).
3. Fuel pump (25).
4. Gasket (27).
5. Bolts (28).
6. Mounting plate (29).
7. Gasket (30). 25. Fuel Pump
8. The push rod (31) (if necessary). 26. Bolt
27. Gasket
Install or Connect (Figures 3 through 6) 28. Bolt
29. Mounting Plate
1. The push rod (if removed). 30. Gasket
Apply some chassis grease to the rod to 31. Push Rod
hold it up against the camshaft.
F-00798
2. New gasket (30).
3. Mounting plate (29).
4. Bolts (28). Figure 4Fuel Pump4.3L Engine
6C-8 FUEL SYSTEM
Si Tighten
Bolts to specification.
8. Fuel pipes and hoses to the fuel pump.
26. Bolt 31. Push Rod If it is difficult to start the outlet fitting,
27. Gasket F-00799 disconnect the line at the carburetor.
Start the engine and check for leaks.
Figure 5Fuel Pump5.0L and

7.4L ENGINE
5.7L Engines
25. Fuel Pump
26. Bolt 1. Fuel pipes and hoses from the fuel pump (35).
27. Gasket 2. Bolts (36).
28. Bolt 3. Fuel pump (35).
29. Mounting Plate 4. Gasket (37).
30. Gasket 5. Plug (38).
31. Push Rod 6. The push rod (39).
1. The push rod (39).

Apply some chassis grease to the rod and
hold it up against the camshaft.
2. Gasket sealer to the threads on the plug (38).
3. Plug (38).
4. Gasket (37).
5. Fuel pump (35).
6. Bolts (36).
S i Tighten
Bolts alternately and evenly to 37 N m (27 ft.

lbs.).
7. Fuel pipes and hoses to the fuel pump.
F-00800 If it is difficult to start the outlet fitting,
disconnect the line at the carburetor.
Figure 6Fuel Pump6.2L Engine Start the engine and check for leaks.
FUEL SYSTEM 6C-9
FUEL TANK
The fuel tank is located under the rear or the sides of FUEL SYSTEM CLEANING
the vehicle. The fuel tank is held in place by two metal
straps that are attached to the underbody. Anti-squeak
(GASOLINE ENGINE)
strips are used between the tanks and straps to reduce
rattles and squeaks.
CAUTION: This procedure w ill not remove all
The fuel tank, filler cap, and fuel lines should be fuel vapor. Do not attem pt any repair on the
checked for damage which could cause leakage. Re tank or fille r neck where heat or flame is
place any damaged or worn parts. re q u ire d , as an e x p lo s io n re s u ltin g in
personal injury could occur.
Before servicing the fuel tank or lines:
Disconnect the negative battery cable from the Contaminated fuel or other foreign material in the
battery. tank can usually be removed by cleaning; however, if
the fuel tank is rusted internally, it should be replaced.
Place NO SMOKING signs near work areas.
Have a C 0 2 fire extinguisher nearby. Remove or Disconnect

Wear safety glasses. Tool Required:
Siphon or pump fuel into an explosion proof con J-24187 Fuel Gage Sending Unit Tool
tainer. 1. Negative battery cable.
2. Engine harness connector at the distributor.
Have a dry ch e m ic a l (C lass B) fire
DRAINING THE FUEL TANK extinguisher near the work area.
3. Fuel from the fuel tank.
Refer to Draining the Fuel Tank.
Remove or Disconnect 4. Fuel tank.
Refer to Fuel Tank Removal.
5. Fuel filter. Replace the filter if it is plugged.
There are two batteries in diesel engine 6. Fuel gage sending unit using J-24187.
vehicles. Locate the tank away from heat, flame, or
Have a dry c h e m ic a l (C lass B) fire other sources of ignition.
extinguisher in the work area. If the strainer is contaminated or clogged, a
new strainer should be installed upon
2. Fuel filler cap.
reassembly.
7. Remaining fuel from the tank by rocking the tank.
CAUTION: Never drain or store gasoline or Flush the fuel tank with hot running water for at
diesel fuel in an open container due to the least five minutes.
possibility of fire or explosion. 8. Water from the fuel tank by rocking the tank.
Make sure that the water is completely
3. Fuel through the filler tube using a hand operated
removed.
pump.
9. Fuel feed pipe at the fuel pump.
If a hand operated pump cannot be used to
complete the draining, use a siphon at the ay Clean
main (not return) fuel pipe at the fuel pump
or the fuel gage sending unit. Fuel lines by applying air pressure in the opposite
direction of fuel flow in the line.
q
Install or Connect
1. Any lines or hoses.
Tool Required:
2. Fuel filler cap.
J-24187 Fuel Gage Sending Unit Tool
3. Negative battery cable. 1. Lines and pipes.
6C-10 FUEL SYSTEM
diesel fuel biocide to sterilize the fuel system. Do not

exceed the dosage recommended on the label.
Fittings to 30 N m (22 ft. lbs.). Discontinue the use of a biocide when towing a trailer.
2. New strainer on the fuel gage sending unit (if It is permissible to have biocide in the fuel when
necessary). starting to tow, but do not add any biocide while
Use low air pressure to clean the pipes of towing.
the fuel gage sending unit. Steam cleaning may be necessary if most of the
3. New fuel gage sending unit gasket. fungus growth cannot be removed with biocides.
NOTICE: Take care not to fold or twist the

strainer when installing the sending unit as FUEL SYSTEM CLEANING
this will restrict fuel flow. (DIESEL ENGINE)
4. Fuel gage sending unit. CAUTION: Never drain or store diesel fuel in
5. Fuel tank. an open container due to the possibility of
6. Fuel gage wire harness to the body harness. fire or explosion.
7. All fuel lines.
8. A hose to the carburetor inlet line.
Disconnect the inlet line from the carburetor. WATER IN THE FUEL SYSTEM
9. The other end of the hose into a four liter (one
gallon) fuel can. Remove or Disconnect
10. Battery cable.
11. Six gallons of clean gasoline into the fuel tank. 1. Fuel from the tank.
Crank the engine until the fuel can is about Refer to Draining the Fuel Tank.
one-half full. This will purge the fuel pump. 2. Fuel tank.
Do not overheat the starter. 3. Fuel gage sending unit.
12. Carburetor inlet line to the carburetor.
Check all connections for leaks and tighten all igi Clean
hose clamps.
13. Engine harness connector to the distributor. Fuel tank.
The tank should be replaced if it is
rusted internally.
DIESEL FUEL SYSTEM The pick-up filter or replace if necessary.
CONTAMINATION The check valve assembly.
4. Main fuel hose at the fuel pump.
Fungi and other micro-organisms can survive and 5. Fuel return line at the injection pump.
multiply in diesel fuel if water is present. The fungi can Use low air pressure to blow out the lines toward
be present in any part of the fuel handling system. the rear of the vehicle.
These fungi grow into long strings and will form into R eplace the pipes if they are rusted
large globules. The growths appear slimy and are internally.
usually black, green, or brown. The fungi may grow 6. Fuel filter.
anywhere in the fuel but are most plentiful where
diesel fuel and water meet. As the fuel is agitated Install or Connect
(when service station tanks are being filled), fungi are
distributed throughout the tank and may be pumped 1. Fuel gage sending unit.
into a vehicle. 2. Fuel tank.
Fungi use the fuel as their main energy supply and 3. Fuel lines to the tank.
need only trace amounts of water and minerals. As 4. Clean diesel fuel into the tank until it is 1/4 full.
they grow and multiply, they change fuel into water, 5. Fuel tank cap.
sludge, acids, and products of metabolism. The most 6. Fuel hoses to the fuel pump.
common symptom is fuel filter plugging; however, 7. Battery cables.
various metal components (fuel tank, lines, and Crank the engine for 15 seconds with one minute
injection pump) can corrode. cooling periods until clean fuel is pumped out.
Use a suitable container to catch the fuel.
CAUTION: To avoid personal injury, do not 8. New fuel filter.
come into physical contact w ith biocides. 9. A hose from the return line at the fuel injection
pump to a closed metal container with a capacity
If fungi have caused fuel system problems, use a of at least 8L (2-gallons).
FUEL SYSTEM 6C-11
If the engine temperature is above 52C (125F), done by disconnecting the two lead connectors at
activate the HPCA (Housing Pressure Cold the Engine Temperature Switch and bridging the
Advance) on the injection pump. This can be connector with a jumper wire.
done by disconnecting the two lead connectors at 8. Start the engine and remove the jumper wire.
the Engine Temperature Switch and bridging the 9. Connect the two lead connector.
connector with a jumper wire. 10. Run the engine for 15 minutes.
Crank the engine for 15 seconds with one minute
cooling periods until clean fuel appears at the
return line. FUEL TANK PURGING
10. Two lead connectors to the Engine Temperature
Switch. The fuel tank should be purged before being
Remove the jumper wire. repaired.
Disconnect the lead to the HPCA solenoid (on the
injection pump). Remove or Disconnect
Crack open each injection line at the nozzle. Use
two wrenches to prevent nozzle damage. 1. Fuel tank from the vehicle.
Crank the engine for 15 seconds with one minute 2. Fuel gage sending unit.
cooling periods until clean fuel appears from 3. All remaining fuel from the tank.
each nozzle.
11. HPCA lead to the injection pump. I? Inspect
& Tighten Fuel tank for any remaining fuel.
Injection line to nozzle fitting to 25 N m (20 |-n-| Install or Connect

ft. lbs.).
Use two wrenches to prevent nozzle 1. Tap water into the tank until it is full.
damage. Move the tank to the flushing area (wash
Start the engine and allow it to idle for 15 rack).
minutes. Agitate the water vigorously and then drain it.
Make sure the fuel return line is in the metal 2. Gasoline emulsifying agent into the tank.
container and that the container does not Use an available emulsifying agent such as
overflow. Product-Sol No. 913 or equivalent.
Remove the hose from the metal container. 3. Water to the fuel tank.
12. Fuel return line to the injection pump. R efer to the e m u ls ify in g a gent
Check for leaks. specifications for the mixture ratio.
Agitate the mixture for ten minutes.
GASOLINE IN THE FUEL SYSTEM Drain the tank completely.
Fill the tank with water until it overflows.
Engine W ill Run Or Start Completely flush out any remaining mixture.
1. Drain the fuel tank. Drain the fuel tank.
2. Fill the tank with diesel fuel. Use an explosion meter (if available) to check for
3. Run the engine for 15 minutes. a negative reading.
Perform the required service work.
Engine W ill Not Run
1. Drain the fuel tank.
2. Fill the tank with diesel fuel. FUEL TANK LEAK TEST
3. Remove the fuel line between the fuel filter and
the injection pump. If fuel is leaking from the tank, the tank should be
4. Connect a hose to the fuel filter outlet and run it replaced. Make sure that the fuel lines are not leaking
to a closed metal container. onto the tank.
5. Crank the engine for 15 seconds with one minute 1. Remove the fuel tank.
cooling periods to purge gasoline from the 2. Drain the tank.
system. 3. Plug all of the outlets.
6. Install the fuel line between the fuel filter and the 4. Apply 7 to 10 kPa (1 to IV 2 psi) air pressure
injection pump. through the vent tube.
7. If the engine temperature is above 52C (125F), 5. Test for leaks with a soap solution or by
activate the HPCA (Housing Pressure Cold submersion.
Advance) on the injection pump. This can be 6. Replace the tank if a leak is found.
6C-12 FUEL SYSTEM
FUEL TANK REPLACEMENT allows fuel tank pressure to escape while the cap is
being removed. A torque limiting device prevents
CAUTION: To help avoid personal in ju ry overtightening. To install, turn the cap clockwise until a
w h e n a v e h ic le is on a h o is t, p ro v id e clicking noise is heard.
a dd itio n a l su pp o rt fo r the vehicle at the
opposite end from which com ponents are NOTICE: If a fuel fille r cap requires
b e in g re m o v e d . T h is w ill re d u c e th e replacement, use only a cap with the same
possibility of the vehicle falling o ff the hoist. features. Failure to use the correct cap can
result in a serious malfunction of the system.
1. Fuel from the tank.

FUEL LINES
2. Fuel tank retaining straps.
NOTICE: Fuel and vapor hoses and pipes are
Support the fuel tank.
specially manufactured. It is important to use
3. Sending unit wire, hoses, and ground straps.
replacem ent hose or pipe m eeting GM
Lower the tank.
Specifications. Hoses and pipes not meeting
4. Fuel tank from the vehicle.
GM Specification could cause early failure or
failure to meet emission standards.
When replacing fuel feed and return pipes, always
1. Fuel tank into the vehicle.
use welded steel tubing meeting GM Specification 124
Support the tank.
M or its equivalent. The replacement pipe must have
2. Sending unit wire, hoses, and ground straps.
the same type fittings as the original pipes to ensure
3. Fuel tank retaining straps with the anti-squeak
integrity of the connection.
pieces.
Never replace fuel pipe with copper or aluminum
Cement the anti-squeak material securely to
tubing.
the tank with 25 mm (1-inch) wide coverage
Check and replace any damaged O-rings or
for 10 cm (4-inches) on each end.
washers.
Fuel pipes should be inspected occasionally for
$ Tighten
leaks, dents, or kinks.
Follow the same routing as the original pipe.
Retaining strap bolts or nuts to specifications.
Pipes must be properly secured to the frame to
prevent chafing. A minimum clearance of 6 mm
FUEL TANK FILLER NECK (1/4-inch) must be maintained to prevent contact
and chafing.
A restrictor and deflector is built into the fuel filler
neck on gasoline engine vehicles to help prevent FUEL AND VAPOR HOSES
refueling with leaded gasoline. The opening in the
restrictor will only admit the smaller unleaded gas NOTICE: Fuel and vapor hoses are specially
nozzle spout. The nozzle must be fully inserted to m anu factu red . It is im p o rta n t to use
bypass the deflector (figure 11 through 13). re p la c em e n t hoses that m eet GM
Specification 6163-M. These hoses are
FUEL FILLER CAP identified by the word Fluoroelastomer
The fuel tank filler neck is equipped with a screw marked on them. Hoses not so marked could
type cap. The cap re q u ire s se veral tu rn s cause early failure or failure to meet emission
counterclockwise to remove. The long threaded area standards.
Do not use rubber hose within 10 cm (4-inches) of

any part of the exhaust system or within 25 cm
(10-inches) of the catalytic converter.
FUEL SYSTEM 6C-13
Figure 8Fuel Tank M ountingC/K Pickup
Figure 9Fuel Tank M o u n tin g -

U tility Vehicle and Suburban
Figure 10Fuel Tank MountingG-Van

6C-14 FUEL SYSTEM
Figure 13G-Van Filler Neck

FUEL SYSTEM 6C-15
FUEL GAGE SENDING UNIT
Diesel engine vehicles have a check valve that will

permit fuel to pass if the tank filter becomes plugged
50. Locking Cam with paraffin during cold weather operation.
51. Fuel Gage When this plugging occurs, the last four gallons of
Sending Unit fuel will not be used due to the location of the check
52. Gasket valve. Therefore it is important to keep the fuel tank
53. In-Tank Fuel above the 1/4 mark at temperatures below -6C (-20F)
52 Filter when using number two diesel fuel.
FUEL GAGE SENDING UNIT

B-08104 REPLACEMENT
Figure 14Fuel Gage Sending Unit
The fuel gage sending unit is mounted in the top of
the fue! tank. It is held in place by a cam lock ring. A Tool Required:
gasket is used between the tank and the sending unit. J-24187 Fuel Gage Sending Unit Tool
Sending units have either two or three nipples to at Fuel from the tank.
tach hoses. These hoses are the fuel feed, fuel return, Fuel tank from the vehicle.
and vapor hoses. Locking cam (50) using J-24187.
On some sending units a wire is attached to the unit; Fuel gage sending unit (51).
while on other sending units, connectors attach directly 5. Gasket (52).
to the sender.
IN TANK FUEL FILTER
A woven plastic filter is located on the lower end of Tool Required:
the fuel pickup tube in the fuel tank (figure 14). This J-24187 Fuel Gage Sending Unit Tool
filter prevents dirt and water from entering into the fuel New gasket.
line unless it becomes completely submerged in water. Fuel gage sending unit.
The filter is self cleaning and normally requires no Take care not to fold or twist the strainer or
maintenance. Fuel stoppage at this point indicates that fuel flow will be restricted.
the fuel tank contains an abnorm al am ount of Locking cam using J-24187.
sediment or water and should be thoroughly cleaned. Fuel tank into the vehicle.
FUEL TANK SELECTOR VALVE
The fuel tank selector valve is operated by a switch CHECKING THE SELECTOR VALVE SIDE
on the instrument panel. The switch controls fuel tank OF THE HARNESS
switching and fuel gage indication in a single opera 1. Make sure there is about 40 liters (10 gallons) of
tion. fuel in one tank and about 20 liters (5 gallons) in
the other tank.
A simple check can be made to determine if the fuel
tank selector valve is working by listening for selector 2. Remove the harness connector from the fuel tank
valve motor operation when the switch is pressed. selector valve.
3. Install a known good selector valve.
4. Activate the fuel tank selector switch and note the
gage readings of the right and left tanks.
DIAGNOSIS OF SELECTOR VALVE 5. The system is operating properly if a change is
indicated between the tanks. Therefore, the
CHECKING THE INSTRUMENT PANEL
original selector valve was the problem.
SIDE OF THE HARNESS
6. If a change is not indicated, there is an open in
Refer to figures 15 through 17 to diagnose the the harness between the connector on the cowl
instrument panel side of the selector valve harness. and the selector valve.
6C-16 FUEL SYSTEM
DISCONNECT SELECTOR VALVE HARNESS AT THE CONNECTOR

ON THE COWL.
WITH IGNITION ON, CONNECT ONE LEAD OF A TEST LIGHT TO

THE FEMALE HARNESS CONNECTOR AND PROBE THE REMAINING
TERMINAL.
TEST LIGHT SHOULD LIGHT IN BOTH SWITCH POSITIONS.
TEST LIGHT LIGHTS. TEST LIGHT DOES NOT LIGHT.

I
CHECK FOR PROPER GROUND CONNECTION (BLACK OR
BLACK WITH PINK WIRE) AT THE BUSS BAR.
--- -------------- --------- I ----- -----------------------
CHECK FOR A PROPER CONNECTION TO THE IGNITION
RECEPTICAL IN THE FUSE PANEL.
I
CHECK FOR PROPER CONNECTION AT THE SELECTOR
VALVE SWITCH. CHECK FOR BENT TERMINAL ON THE
BACK OF THE SWITCH AND IN THE SWITCH
CONNECTOR. CHECK FOR VOLTAGE AT THE PINK WIRE
AND FOR GROUND AT THE BLACK WIRE.
--------------------------- --------------- ----------------------------------------------
WITH IGNITION ON, CONNECT ONE LEAD OF A TEST LIGHT

TO GROUND AND PROBE THE LIGHT GREEN WIRE OF THE
FEMALE CONNECTOR ON THE COWL. THE TEST LIGHT
SHOULD LIGHT IN ONE SWITCH POSITION ONLY.
TEST LIGHT LIGHTS. TEST LIGHT DOES NOT LIGHT.
REPLACE THE SELECTOR VALVE SWITCH.
WITH IGNITION ON, CONNECT ONE LEAD OF A TEST

LIGHT TO THE FEMALE HARNESS CONNECTOR AND
PROBE THE REMAINING TERMINAL.
TEST LIGHT SHOULD LIGHT IN BOTH SWITCH POSITIONS.
IF THE TEST LIGHT DOES NOT LIGHT, THERE IS AN

OPEN IN THE HARNESS BETWEEN THE SWITCH AND
THE CONNECTOR.
I
IF A PROBLEM STILL EXISTS, PERFORM A CHECK ON
THE SELECTOR VALVE SIDE OF THE HARNESS.
F-00807
Figure 15Diagnosis Of The Instrument Panel Side Of The Selector Valve Harness
FUEL SYSTEM 6C-17
> 9 1 7253 H I lilt OOJ7

.8 PNK - 3 0 - 1- - p 0 } : - ?-.5 PNK - 3 0 ------- 30 30
BULKHEAD 1 INST
connector -*
CONN7 " INST CLUSTER (BASE)
(BASE) ( SEE ALS0 G * GES)
5)
u r i
-------- (AUXILIARY
R I G H T T ANK
1
3
----- 1 PM
> VALVE
>-
1CMT ,
------ L T
F U E L T AN K
SELECTOR VALVE
ME T E R S W I T C H
.8 P N K / B L K - 8 3 0 ( SXL )
8 PNK/WHT-930(HDT
(PRODUCTION)
L E F T TANK
B-08116
Figure 16A uxiliary Fuel Tank W iring
7. Refer to INSTRUMENT PANEL (SEC. 8C) if the

fuel gage does not register accurately.
FUEL TANK SELECTOR VALVE

REPLACEMENT
* l l Remove or Disconnect (Figure 18)

2. Hose shield (60) and brace (61).
3. Electrical connector from the selector valve (62).
4. Fuel and vapor hoses.
Note the p o s itio n of the hoses for
installation.
5. Screws (63).
6. Valve (62).
To Fuel Tank Selector Valve
And Sending Unit Install or Connect (Figure 18)
54. Fuse Panel
55. Selector Valve Switch 1. Valve (62).
56. Instrument Panel Side Of Harness 2. Screws (63).
57. Connector 3. Fuel and vapor hoses in the correct position.
58. Selector Valve Side Of Harness B-08117
4. Electrical connector.
5. Brace (61) and hose shield (60).
Figure 17Auxiliary Fuel Tank Instrument Panel
Wiring 6. Battery negative cable.
6C-18 FUEL SYSTEM
B
A. 4.8L Engine Only
B. Fuel Feed
C. Fuel Return
D. Right Feed (Orange)
E. Left Feed (Yellow)
F. Right Return (Pink)
G. Left Return (Blue)
60. Shield
61. Brace
62. Selector Valve
63. Bolt B-08119
Figure 18Selector Valve
ACCELERATOR CONTROLS
The accelerator pedal controls the throttle through a

cable. There are no linkage adjustments. The throttle
cable must be replaced with an identical replacement
part.
All linkages and cables must be checked to assure
free movement with no rubbing, chafing, or binding.
The throttle must operate freely without binding be
tween full closed and wide open throttle.
ACCELERATOR CONTROL CABLE

Observe the following when performing service on
the accelerator control cable.
The retainer must be installed with the tangs
secured over the head of the stud (figure 19).
The conduit fitting at both ends of the cable must
have the locking tangs expanded and locked into
the attaching holes.
The braided portion of the cable must not come
into contact with the front of dash sealer during
replacement.
FUEL SYSTEM 6C-19
Flexible components (hoses, wires, conduit, etc.)

must not be routed within 50 mm (2-inches) of the
moving parts of the accelerator linkage unless
routing is positively controlled.
Lube all pivot points with Accelerator Linkage
Lubricant (1052541 or equivalent).
ACCELERATOR PEDAL
Observe the following when performing service on
the accelerator pedal.
The mounting surface between the support and
the dash panel must be free of insulation. The
carpet and padding in the pedal and tunnel area
must be positioned to lay flat and be free of
wrinkles and bunches.
Slip the accelerator control cable through the slot
in the rod before installing the retainer in the rod.
Make sure it is seated properly. Use care in
pressing the retainer into the hole so the cable is
not kinked or damaged (figure 20).
The linkage must operate freely without binding 75. Retainer (Must Bear Against Pedal Rib)
between closed throttle and full throttle. 76. Spring
Wire, hoses, cable, and other flexible components 77. Rod
must not be placed within 13 mm (0.52-inch) of 78. Reinforcement B-08122
the cable or rod at any point in their travel.
Figure 20Accelerator Pedal Assembly
SPECIFICATIONS
FUEL PUMP BOLT TORQUE

4.8L E ngine.................................................................................................23 N m (17 ft. lbs.)
4.3L Engine (Top B o lt) ..................................................................................4 N m (3 ft. lbs.)
4.3L Engine (Bottom Bolts)....................................................................... 22 N m (16 ft. lbs.)
5.0L and 5.7L Engines (Top Bolts)...........................................................37 N-m (27 ft. lbs.)
5.0L and 5.7L Engines (Bottom Bolts).........................................................4 N m (3 ft. lbs.)
6.2L Engine (Top B o lts )........................................................................... 33 N-m (24 ft. lbs.)
6.2L Engine (Bottom Bolts)........................................................................... 8 N-m (6 ft. lbs.)
7.4L E n g in e .............................................................................................. (37 N-m (27 ft. lbs.)
FUEL TANK MOUNTING STRAP FASTENERS

C/K Model With Base Tank N uts................................................................. 6 N-m (4 ft. lbs.)
C/K Model With RPO NL2 B o lts .............................................................33 N-m (24 ft. lbs.)
Utility Vehicle And Suburban Nuts...........................................................16 N-m (12 ft. lbs.)
G-Van With Base Tank B olts..................................................................... 5 N-m (45 in. lbs.)
G-Van With RPO NL7 Bolts..................................................................... 11 N-m (95 in. lbs.)
G-Van N u ts ................................................................................................ 13 N-m (10 ft. lbs.)
SPECIAL TOOLS
J-24187 Fuel Gage Sending Unit Tool
6C1-1
SECTION 6C1
CARBURETORS
CONTENTS
SUBJECT PAGE
Carburetor Model 1MEF.......................................................................................................................................... 6C1- 2
D e s c rip tio n ............................................................................................................................................................6C1- 2
Diagnosis of 1MEF Rochester C a rb u re to r.......................................................................................................... 6C1- 7
On-Vehicle Service (1M E F)....................................................................................................................................6C1-13
Electric Choke....................................................................................................................................................... 6C1-13
Idle S o le n o id ......................................................................................................................................................... 6C1-13
Carburetor R e p la ce m e n t....................................................................................................................................6C1-14
Carburetor A djustm ents...................................................................................................................................... 6C1-15
Carburetor Models M4ME, M4MED and M 4M E F............................................................................................... 6C1-19
D e s c rip tio n ............................................................................................................................................................6C1-19
Carburetor Id e n tific a tio n ....................................................................................................................................6C1-23
On-Vehicle Service (M4ME, M4MED, and M 4M EF)...........................................................................................6C1-28
Float Level C heck.................................................................................................................................................6C1-28
Choke and H o s e s ................................................................................................................................................. 6C1-28
Dual Capacity Pump Check (M4MED O n ly )................................................................................................... 6C1-29
Idle Stop Solenoid C h e c k ..................................................................................................................................6C1-30
Throttle Kicker C h e c k ........................................................................................................................................ 6C1-30
Carburetor R e p la ce m e n t....................................................................................................................................6C1-30
Idle Mixture A djustm ent (Light-Duty Emission Vehicles O n ly ) ................................................................. 6C1-31
Idle Mixture Adjustm ent (Heavy-Duty Emission Vehicles O n ly ) ...............................................................6C1-33
Idle Speed A djustm e n t........................................................................................................................................ 6C1-33
Throttle Kicker A d ju s tm e n t................................................................................................................................6C1-33
Float A d ju s tm e n t................................................................................................................................................. 6C1-33
Pump A d ju stm e n t.................................................................................................................................................6C1-34
A ir Valve Spring A d ju stm e n t............................................................................................................................. 6C1-34
Choke Coil Lever A d ju s tm e n t........................................................................................................................... 6C1-34
Choke Rod and Fast Idle Cam A d ju s tm e n t................................................................................................... 6C1-36
Primary Side Vacuum Break A d ju stm e n t........................................................................................................6C1-36
Secondary Side Vacuum Break A d ju s tm e n t................................................................................................. 6C1-36
A ir Valve Rod A d ju s tm e n t..................................................................................................................................6C1-37
Unloader A d ju s tm e n t.......................................................................................................................................... 6C1-38
Secondary Lockout A d ju s tm e n t.......................................................................................................................6C1-38
Carburetor Models E4ME and E4MED (California O n ly )............. .....................................................................6C1-40
D e s c rip tio n ............................................................................................................................................................6C1-40
Model Id e n tific a tio n .............................................................................................................................................6C1-45
On-Vehicle S e r v ic e .................................................................................................................................................6C1-45
Float Level C heck.................................................................................................................................................6C1-45
Choke C heck......................................................................................................................................................... 6C1-45
Dual Capacity Pump Check (E4MED O nly)..................................................................................................... 6C1-46
Idle Stop Solenoid C h e c k ..................................................................................................................................6C1-46
Throttle Kicker C h e c k ........................................................................................................................................ 6C1-47
Carburetor A djustm ents...................................................................................................................................... 6C1-47
Carburetor R e p lace m e n t......................................................................................................................... .......... 6C1-47
6C1-2 CARBURETORS
CONTENTS (CONT.)
SUBJECT PAGE
S pe cifica tio ns........................................................................................................................................................... 6C1 -47

Special T o o ls ........................................................................................................................................................... 6C1-50
All new GM vehicles are certified by the United States Environmental Protection Agency as conforming to the
requirements of the regulations for the control of air pollution from new motor vehicles. This certification is contin
gent on certain adjustments being set to factory standards. In most cases, these adjustment points either have been
permanently sealed and/or made in accessible to prevent indiscriminate or routine adjustment in the field. For this
reason, the factory procedure for temporarily removing plugs, cap, etc., for purposes of servicing the product, must
be strictly followed and, wherever practicable, returned to the original intent of the design. For vehicles sold in
Canada and equipped with non-closed loop engines, also refer to the appropriate Canadian service manual supple
ment.
CARBURETOR MODEL 1MEF
DESCRIPTION
Model 1MEF carburetors are single bore downdraft
carburetors using a trip le venturi along with a
discharge tube nozzle (figure 1).
A power valve piston assembly and metering rod
control the fuel flow in the main metering and power
systems of the carburetor. The tapered metering rod is
attached to the power piston and moves in a fixed
metering jet to provide the fuel flow for varying engine
demands. On 1MEF carburetors, a factory set metering
rod adjusting screw controls the position of the
metering rod in the jet. This screw is located in the air
horn and should not be turned as this could result in
engine damage or increased exhaust emissions.
Model 1MEF incorporates an integral automatic
choke system which uses an electrically heated choke
coil. The vacuum diaphragm unit is mounted externally
on the air horn and connects to the thermostatic coil
lever through a connecting link.
The electric choke coil is contained in a choke
housing, which is mounted on a bracket attached to
the float bowl. Special rivets are installed to retain the
factory setting of the choke coil and provide a
non-adjustable design.
An integral, pleated-paper fuel inlet filter is mounted B-01358
in the fuel bowl behind the fuel inlet nut to give
maximum filtration of incoming fuel. A check valve is
Figure 11 MEF Carburetor
used in the filter inlet to prevent fuel draining from the
fuel system after rollover.
insulator gasket keeps excessive engine heat from the
To improve hot engine starting and meet evaporative
emission requirements, fuel vapors from the carburetor float bowl.
bowl are vented to a vapor canister on some models. A All 1MEF models have seals added in the float bowl
tube (location F) is added to the air horn to connect the to seal the power piston drive rod and the pump lever.
air horn and canister. T h is p re ve n ts fu e l va po rs from e sc a p in g to
O ther features of the carburetors include an atmosphere. During unit repair, the seals and retainer,
aluminum throttle body for decreased weight and where used, must be removed prior to immersion of
improved heat distribution. A thick throttle body to bowl the float bowl in carburetor cleaner.
CARBURETORS 6C1-3
The throttle lever has a spun-in plastic bushing

which is used as a bearing surface. The bushing will
withstand normal cleaning time in an approved cold
immersion type carburetor cleaner. The bushing is not
serviced separately and should not be removed from
the carburetor throttle lever.
Six basic systems of operation are used (figures 3
through 8).
Float Power
Idle Pump
M odel N um be Main Metering Choke
Day Of Year
S ource Code
Year
A s s e m b ly P lant Code
S h ift Id e n tific a tio n B-06647
Figure 2Carburetor Identification
The carburetor model identification is stamped on a

vertical portion of the foat bowl, adjacent to the fuel
inlet nut (figure 2).
If replacing the float bowl, follow the manufacturers
instructions contained in the service package so that
the identification number can be transferred to the new
float bowl.
An electrically operated idle stop solenoid and dual
throttle return springs are used on all carburetors.
226
226. Float
228. Float Hinge Pin
231. Float Needle
234. Needle Seat
215. Fuel Inlet Filter
218. Filter Spring
A. Internal Vent
B. Vent Tube to Canister
C. Check Valve Seat
D. Fuel In
E. Check Valve
F. Valve Closing Spring
B-06641
Figure 3Float System

6C1-4 CARBURETORS
240. Rod - Pump

247. Cup - Pump Plunger
248. Spring - Pump Plunger
252. Spring - Pump Return
256. Guide - Pump Discharge Spring
258. Spring - Pump Discharge Ball
260. Ball - Pump Discharge
310. Lever - Pump and Power Rod
317. Link - Pump
A. Pump Plunger Head
B. Pump Duration Spring
C. Pump Discharge Channel
D. Pump Jet
248
B-06645
Figure 4Pump System
266. Rod - Power Piston K J

274. Power Valve Piston Assembly
276. Spring - Power Piston
279. Metering Rod and Spring Assembly
282. Jet - Main Metering
A. Throttle Valve
B. Vacuum Channel
C. Main Venturi
D. Boost Venturi
E. Main Discharge Nozzle
F. Lower Idle A ir Bleed
G. Main Well
H. Fuel Feed Orifice
I. Part Throttle Adjusting Screw
J. Main Well to Aspirator Bleed
B-06643
Figure 5Main Metering System 1 MEF

CARBURETORS 6C1-5
266. Rod - Power Piston

276. Spring - Power Piston
279. Metering Rod and Spring Assembly
282. Jet - Main Metering
310. Lever - Pump and Power Rod
314. Link - Power Rod
A. Throttle Valve
B. Vacuum Channel
C. Main Discharge Nozzle
D. Lower Idle A ir Bleed
E. Main Well
F. Metering Rod Adjusting Screw
G. Setscrew
H. Metering Rod Adjusting Screw Plug
I. Top Main Well A ir Bleed
J. Main Well to Aspirator Bleed
E B
B-06644
Figure 6Power System 1 MEF
10. Cam - Fast Idle

15. Link - Fast Idle Cam
20 . Choke Shaft, Lever
and Link Assem bly
40. Choke Shaft and Lever
Assem bly
43. Lever - Choke Stat
65. Vacuum Break Assem bly 15
- Bowl Side
69. Vacuum Break Leve
and Link Assem bly
A. Choke Valve
B. Therm ostatic Coil
B-06646
Figure 7Choke System

6C1-6 CARBURETORS
282. Jet-M ain Metering

286. Idle Tube Assembly
326. Needle-Idle Mixture
333. Plug-Idle Mixture Needle
A. Throttle Valve
B. Idle Channel Restriction
C. Top Idle Air Bleed
E. O ff-Id le Port
F. Idle Discharge Orifice
G. Timed Vacuum Port
B-06642
Figure 8Idle System 1 MEF

CARBURETORS 6C1-7
DIAGNOSIS OF 1MEF ROCHESTER

CARBURETOR
The following diagnostic procedures are for carburetor related problems and their effects on vehicle performance
Other systems of the vehicle can also cause problems and should be checked when listed on the chart.
Engine Cranks 1. Improper starting procedure used. 1. Check with the customer to deter
Normally W ill Not mine if proper starting procedure is
Start used, as outlined in the Owners
and Drivers Manual.
2. Choke valve not operating properly. 2. Check the choke valve and/or linkage
as necessary. Replace parts if faulty.
If caused by foreign material and
gum, clean with suitable solvent.
3. No fuel in carburetor. 3. Remove fuel line at carburetor. Con
nect hose to fuel line and run into
metal container. Remove the wire
from the BAT terminal of the dis
tributor. Crank over engineif there
is not fuel discharge from the fuel
line, test fuel pump as outlined in
FUEL SYSTEM (SEC. 6C). If fuel
supply is okay, check the following:
a. Inspect fuel inlet filter. If plugged,
replace.
b. If fuel filter is okay, remove air
horn and check for a bind in the float
mechanism or a sticking inlet needle.
If okay, adjust float as specified.
4. Engine flooded. To check for flooding, 4. Remove the air horn.
remove the air cleaner with the engine Check fuel inlet needle and seat for
immediately shut off and look into the proper seal. If a needle and seat
carburetor bore. Fuel will be dripping tester is not available, apply vacuum
off nozzle. to the needle seat with needle in
stalled. If the needle is leaking, re
place.
Check float for free movement.
If foreign material is in fuel system,
clean the system and replace fuel fil
ters as necessary. If excessive for
eign material is found, completely
disassemble and clean.
Engine Starts Will 1. Fuel pump. 1. Check fuel pump pressure and vol
Not Keep Running ume, replace as necessary.
2. Idle speed. 2. Adjust idle to specifications.
3. Electric choke system malfunctioning 3. Check choke for proper operation.
(may cause loading).
6C1-8 CARBURETORS

CARBURETOR (CONT.)
Engine Starts Will 4. Loose, broken or incorrect vacuum 4. Check condition and routing of all
Not Keep Running hose routing. vacuum hoses correct as neces
(Cont.) sary.
5. Engine does not have correct fast idle 5. Check for free movement of fast idle
speed when cold. cam. Clean and/or realign as neces
sary. Adjust fast idle.
6. Choke vacuum break units are not ad 6. Adjust vacuum break assembly to
justed to specification or are faulty. specification. If adjusted okay, check
the vacuum break unit as outlined
under Electric Choke later in this
section.
7. Choke valve sticking and/or binding. 7. Clean and align linkage or replace if
n ecessary. R e a d ju st all choke
settings, if part replacement or re
alignment is necessary.
8. Not enough fuel in carburetor. 8. Check fuel pump pressure and vol
ume.
Check for partially plugged fuel in
let filter. Replace if plugged.
Check the float level adjustment.
Engine Starts Hard 1. Loose, broken or incorrect vacuum 1. Check condition and routing of vac
(Cranks Normally) hose routing. uum hoses correct as necessary.
2. Incorrect starting procedure. 2. Check to be sure customer is using
the starting procedure outlined in
Owners and Drivers Manual.
3. Malfunction in accelerator pump sys 3. Check accelerator pump operation.
tem. Check pump discharge ball for
sticking or leakage.
4. Choke valve not closing. 4. Check choke valve and linkage for
binds and alignment. Clean and re
pair or replace as necessary.
5. Vacuum bre ak m is a d ju s te d or 5. Check for adjustment and function of
malfunctioning. vacuum break as outlined under
Electric Choke later in this section.
Correct as necessary.
6. Not enough fuel in carburetor. 6. Check fuel pump pressure and vol
ume. Check for partially plugged fuel
inlet filter. Replace if dirty. Check float
level. Adjust as specified.
7. Flooding. 7. Check float and needle and seat for
proper operation.
8. Slow engine cranking speed. 8 Refer to starting circuit diagnosis.
CARBURETORS 6C1-9

CARBURETOR (CONT.)
Engine Idles 1. Incorrect idle speed. 1. Reset idle speed.

Abnorm ally (Too 2. Air leaks into carburetor bores beneath 2. Check all vacuum hoses and restric-
Fast Or Too Slow) throttle valve, manifold leaks, or vac tors leading into the manifold or car
uum hoses disconnected or installed buretor base for leaks or being
improperly. disconnected. Install or replace as
necessary.
Torque carburetor to manifold bolts
to specifications. Using a pressure oil
can, spray light oil or kerosene
around manifold to head surfaces
and carburetor throttle body.
Do not spray at throttle shaft ends.
If engine RPM changes, tighten or
replace the carburetor or manifold
gaskets as necessary.
3. PCV system not working. 3. Check PCV system. Clean and/or re
place as necessary.
4. Carburetor flooding. 4. Remove air horn and check float ad
justment.
Check float needle and seat for
proper seal. If a needle and seat
tester is not available, apply vacuum
to the needle seat with needle in
stalled. If the needle is leaking or
damaged, replace.
Check float for free movement.
If foreign material is found in the
carburetor, clean the fuel system and
carburetor. Replace fuel filter as nec
essary.
5. Restricted air cleaner element. 5. Replace as necessary.
6. idle system plugged or restricted. 6. Clean carburetor.
7. Incorrect idle mixture adjustment. 7. Readjust per specified procedure.
8. Misadjusted idle solenoid. Faulty idle 8. Check solenoid and wiring.
solenoid or wiring.
9. Throttle valve or linkage sticking and/ 9. Check throttle linkage and throttle
or binding. valve for smooth and free operation.
Correct problem areas.
Engine Diesels (After 1. Loose, broken or improperly routed 1. Check condition and routing of all
Run) Upon Shut Off vacuum hoses. vacuum hoses. Correct as necessary.
2. Incorrect idle speed. 2. Reset idle speed.
3. Faulty or misadjusted idle solenoid. 3. Check for correct adjustment and op
eration of idle solenoid. Check for
sticky or binding solenoid.
4. Fast idle cam not fully off. 4. Check fast idle cam for freedom of
operation. Clean, repair, or adjust as
required. Check choke linkage for
binding. Clean and correct as neces
sary.
6C1-10 CARBURETORS

CARBURETOR (CONT.)

Engine Diesels (After 5. Excessively lean condition caused by 5. Adjust carburetor idle mixture.
Run) Upon Shut Off misadjustment of carburetor idle mix
(Continued) ture.
6. Ignition timing retarded. 6. Set to specifications.
Engine Hesitates On 1. Loose, broken or incorrect vacuum 1. Check condition and routing of all
Acceleration hose routing. vacuum hoses correct or replace.
2. Inoperative accelerator pump system. 2. Remove air horn and check pump
A quick check of the pump system cup. If cracked, scored or distorted,
can be made as follows: With the en replace the pump plunger cup and
gine off, look into the carburetor bores spring. Check the pump discharge
and observe pum p nozzle w hile ball for proper seating and location.
quickly opening throttle lever. A full
stream of fuel should emit from pump
jet.
3. Foreign matter in pump passages. 3. Clean and blow out with compressed
air.
4. Float level too low. 4. Check and reset float level to specifi
cation.
5. Vacuum break diaphragm not function 5. Check adjustment and operation of
ing properly. vacuum break diaphragm.
6. Power enrichment system not operat 6. Check for sticking power piston
ing correctly. correct as necessary.
7. Inoperative Thermae system. 7. Check operation. Repair as needed.
8. Fuel filter dirty or plugged. 8. Replace filter and clean fuel system
as necessary.
9. Distributor vacuum or mechanical ad 9. Check for proper operation.
vance malfunctioning.
10. Timing not to specifications. 10. Adjust to specifications.
11. Incorrect metering rod adjustment. 11. Adjust to specifications.
Engine Has Less 1. Loose, broken or incorrect vacuum 1. Check condition and routing of all
Than Normal Power hose routing. vacuum hoses.
At Normal 2. Clogged or faulty PCV system. 2. Clean or replace as necessary.
Accelerations 3. Choke sticking. 3. Check complete choke system for
sticking or binding. Clean and realign
as necessary.
Check jet and channels for plug
ging; clean and blow out passages.
4. Clogged or inoperative power system. 4. Remove air horn and check for free
operation of power piston.
5. Air cleaner temperature regulation im 5. Check regulation and operation of
proper. Thermae system.
6. Transmission malfunction. 6. Refer to transmission diagnosis.
7. Ignition system malfunction. 7. Check ignition system. Refer to HEI
diagnosis.
8. Exhaust system restricted. 8. Check for restrictions. Correct as re
quired.
CARBURETORS 6C1-11

CARBURETOR (CONT.)
Less Than Normal 1. Carburetor throttle valve not going 1. Correct throttle linkage to obtain wide
Power On Heavy wide open. open throttle in carburetor.
Acceleration Or At Check for free movement of fast
High Speed idle cam.
(Continued) 2. Spark plugs fouled, incorrect gap. 2. Clean, regap, or replace plugs.
3. Plugged air cleaner element. 3. Replace element.
4. Plugged fuel inlet filter. 4. Replace with a new filter element.
5. Insufficient fuel to carburetor. 5. Check fuel pump and system, run
pressure and volume test.
6. Power enrichment system not operat 6. Remove the air horn and check for
ing correctly. free operation of power piston. Clean
and correct as necessary.
7. Choke closed or partially closed. 7. Free choke valve or linkage.
cation.
9. Transmission malfunction. 9. Refer to transmission diagnosis.
10. Ignition system malfunction. 10. Check ignition system.
11. Fuel metering jets restricted or loose. 11. If the fuel metering jets are restricted
and an excessive amount of foreign
material is found in the fuel bowl, the
carburetor should be completely dis
assembled and cleaned.
12. Faulty fuel pump. 12. Check fuel pump pressure and vol
ume, inspect lines or leaks and re
strictions.
13. Restricted exhaust system. 13. Check for restrictions. Correct as re
quired.
Engine Surges 1. Loose, broken or incorrect vacuum 1. Check condition and routing of all
hose routing. vacuum hoses. Correct as necessary.
2. PCV system clogged or malfunction 2. Check PCV system. Clean or replace
ing. as necessary.
3. Loose carburetor or intake manifold 3. Torque carburetor to manifold bolts.
bolts and/or leaking gaskets. Using a pressure oil can, spray light
oil or kerosene around manifold to
head mounting surface and carbure
tor base. If engine rpm changes,
tighten or replace the carburetor or
manifold gaskets as necessary.
4. Low or erratic fuel pump pressure. 4. Check fuel delivery and pressure.
5. Contaminated fuel. 5. Check for contam inants in fuel.
Clean system if necessary.
6. Fuel filter plugged. 6. Check and replace as necessary.
cation.
8. Malfunctioning float and/or needle and 8. Check operation of system. Repair or
seat. replace as necessary.
9. Power piston sticking. 9. Check for free movement of power
piston. Clean and correct as neces
sary.
6C1-12 CARBURETORS

CARBURETOR (CONT.)
Engine Surges 10. Fuel jets or passages plugged or re 10. Clean and blow out with compressed
(Continued) stricted. air.
11. Faulty ignition system. 11. Check ignition system.
12. Restricted exhaust system. 12. Check for restrictions. Correct as
necessary.
Poor Gas Mileage 1. Customer driving habits. 1. Run mileage test with customer driv
* Black Smoke From ing if possible. Make sure vehicle has
Tail Pipe 2000-3000 miles (3 200-4 800 km) for
the break-in period.
2. Loose, broken or improperly routed 2. Check condition of all vacuum hose
vacuum hoses. routings. Correct as necessary.
3. Engine in need of service. 3. Check engine compression, examine
spark plugs; if fouled or improperly
gapped, clean and regap or replace.
Check ignition wire condition and
check and reset ignition timing. Re
place air cleaner element if dirty.
Check for restricted exhaust system
and intake manifold for leakage.
Check carburetor m ounting bolt
torque. Check vacuum and mechani
cal advance.
4. Fuel leaks. 4. Check fuel tank, fuel lines and fuel
pump for any fuel leakage.
*5. Incorrect float setting. 5. Adjust.
*6. Incorrect metering rod adjustment. 6. Adjust.
*7. Loose main metering jet. 7. Tighten.
*8. Faulty electric choke. 8. Refer to Electric Choke later in this
section.
9. Restricted exhaust system. 9. Repair.
10. Low tire pressure or incorrect tire size. 10. Inflate tires to specifications and use
correct size tires.
11. Transmission malfunction or in wrong 11. Refer to transmission diagnosis.
gear.
Gasoline Odor 1. Fuel feed or vapor return line leaking. 1. Correct as required.
2. Leak in fuel tank. 2. Purge tank and repair or replace tank
as required.
3. Disconnected fuel tank vent lines or 3. Connect lines or hoses as required.
hoses.
4. Purge lines not connected, improperly 4. Check, connect and open lines as re
routed, plugged or pinched. quired.
5. Faulty fill cap. 5. Install new cap.
Fuel Starvation 1. Fuel line pinched, plugged or mis- 1. Check open or reroute as required.
routed.
2. Fuel pump not operating. 2. Test and replace if necessary.
CARBURETORS 6C1-13
ON-VEHICLE SERVICE (1MEF)
ELECTRIC CHOKE
L* Inspect
Remove the air cleaner. With the engine off, hold

the throttle half open. Open and close the choke
several times. Watch linkage to be certain all links
are connected and there are no signs of damage.
If the choke or linkage binds, sticks, or works
sluggishly, clean it with Choke Cleaner X-20-A or
equivalent. Use cleaner as directed on the can.
Refer to the d isa ssem b ly in stru c tio n s for
additional direction if cleaning does not correct
the problem. Do not lubricate the linkage.
Visually inspect the carburetor to be certain all
vacuum hoses are connected. Inspect hoses for
cracks, abrasions, hardness or other signs of
deterioration. Replace or correct as necessary.
The vacuum break diaphragm shaft should be Align a #21 drill (0.156 inch) on the rivet
fully extended when the engine is off. If the shaft head and drill only enough to remove the
is not fully extended, replace the vacuum break rivet head (figure 9).
assembly. Start engine the vacuum break Use a drift and a small hammer to drive the
diaphragm shaft should fully retract within 10 remainder of the rivets from the choke
seconds. If the unit fails to retract, replace the housing.
vacuum break assembly. Use care in drilling to prevent damage to the
Allow the choke to cool so that when the throttle choke cover or housing.
is opened slightly, the choke blade fully closes. 4. The choke cover assembly from the housing.
This check must be performed at an ambient 5. The choke coil from the housing.
temperature of about 21 C (70F).
Start the engine and determine the time required Install or Connect
for the choke blade to reach its full open position.
(Start timing when the engine starts). If the choke 1. The choke cover and coil assembly in the choke
plate fails to open fully within five minutes, housing.
proceed with the remaining steps. Align the notch in the cover with the raised
Check voltage at the choke heater connection casting projection on the housing cover
with the engine running. If the voltage is flange.
approximately 12-15 volts, replace the electric Make sure the coil pick-up tang engages the
choke unit. If the voltage is low or zero, check all inside choke coil lever.
wires and connections. If the connections at the 2. Retainers and rivets using a suitable blind rivet
oil pressure switch are dirty or corroded, the oil installing tool (figure 10).
warning lamp will be off with the ignition switch 3. Electrical connector.
On and the engine off. If the fuse is blown, the Start the engine and check the operation of the
radio or turn signal indicator will be inoperative. choke.
Repair wires or replace fuses as necessary. 4. Air cleaner.
If all wiring and fuses are good, replace the oil
pressure switch.
IDLE SOLENOID
I? Inspect
1. Air cleaner.
2. The choke electrical connector. 1. Turn on the engine control switch, but do not start
3. Rivet heads and retainers. the engine.
6C1-14 CARBURETORS
450
Figure 10Installing The Choke Coil Rivets
2. Open the throttle to allow the solenoid plunger to

extend.
3. Hold the throttle lever wide open, feel the end of
the plunger and disconnect the wire at the
solenoid.
4. Plunger should move. Some spring tension
should be felt.
5. If the plunger did not move, back out 1/s hex
screw (counter clockwise) one full turn and repeat
step 3 and 4.
6. If the plunger moves in step 5, connect the wire to 450. Nut
the solenoid and adjust the idle speed. 451. Insulator Gasket
7. If the plunger did not move in step 5, insert test 452. Heat Shield
light (1893 bulb or smaller) between the solenoid 453. Intake Manifold B-09229
feed wire and ground.
8. If the light lights, replace the solenoid. Figure 11Carburetor Installation
9. If the light does not light, locate the cause of the
open circuit in the solenoid feed wire. CARBURETOR REPLACEMENT
Remove or Disconnect Flooding, stum ble on acceleration and other
performance complaints are, in many instances,
1. Air cleaner. caused by the presence of dirt, water or other foreign
matter in the carburetor. To aid in diagnosing the
2. Electrical connector from the solenoid.
cause, the carburetor should be removed carefully
3. Solenoid from the float bowl assembly. from the engine without draining fuel from the bowl.
Contents of the fuel bowl may then be examined for
0 Install or Connect foreign materials as the carburetor is disassembled.
1. Solenoid. Remove or Disconnect (Figure 11)

Hold the choke valve wide open so the fast
idle cam follower clears the fast idle cam. 1. Air cleaner assembly.
2. Fuel and vacuum lines from the carburetor.
Turn the solenoid until it contacts the lever
Make note of the vacuum hose routing.
tang.
3. Electrical connectors for the choke and idle
2. Electrical connector. solenoid.
3. Air cleaner. 4. Accelerator linkage.
Check and adjust the idle speed. 5. Carburetor attaching nuts.
CARBURETORS 6C1-15
6. Carburetor. manifold, vacuum hoses and connections for leaks and

7. Insulator gaskets and heat shield. check torques of carburetor mounting bolts/nuts.
Make all adjustments with the engine at normal
5 | Clean operating temperature, choke full open, and the air
cleaner installed. Except as noted, air conditioning
All traces of the old gasket from the carburetor should be off and all vacuum lines and all electrical
flange and intake manifold. leads connected. Refer to Specifications at the end
of this section for carburetor adjustment specifications.
Install or Connect (Figure 11) Gages and tools for making adjustments are included
in the Universal Gage J-9789D.
1. Heat shield and insulator gaskets to the intake
manifold. IDLE MIXTURE ADJUSTMENT
In the case of a major carburetor overhaul, throttle
body replacement, or high idle CO as indicated by an
CAUTION: Extinguish all open flames while
em issions inspection, the idle m ixture may be
fillin g and testing carburetor with gasoline to
adjusted. Adjusting the mixture by other than the
avoid personal injury.
following method may violate Federal and/or state
laws.
2. Carburetor.
Tool Required:
It is good shop practice to fill the carburetor
J-29030-B Idle Mixture Needle Socket
float bowl before installing the carburetor.
1. Set parking brake and block the drive wheels.
This reduces the strain on the starting motor
and battery and reduces the possibility of 2. Remove the air cleaner.
backfiring while attempting to start the 3. Remove carburetor from the engine.
engine. Operate the throttle several times 4. Invert the carburetor and drain fuel into a
and check the discharge from pump jets container. Dispose of the fuel in an approved
before installing the carburetor. container.
3. Carburetor attaching nuts. 5. Place the carburetor on a suitable holding fixture
with the manifold side up.
Tighten 6. Make two parallel cuts in the throttle body, one on
each side of the locator point with a hack saw.
Both nuts to 4.1 N-m (36 in. lbs.) and then The cuts should reach down to the steel plug but
both nuts to 22 N m (16 ft. lbs.). should not extend more than 3 mm (Ve-inch)
beyond the locator points (figure 12).
4. Accelerator linkage.
7. Place a small flat punch at a point near the ends
5. Electricai connectors for the choke and idle
of the saw marks in the throttle body. Holding the
solenoid.
punch at a 45 degree angle, drive it into the
6. Fuel and vacuum lines. Refer to the Emission
throttle body until the casting breaks away,
Control Label, if necessary, for vacuum line
exposing the steel plug.
routing information.
8. Hold a center punch vertically and drive it into the
7. Air cleaner.
steel plug. Hold the punch at a 45 degree angle
and drive the plug out of the casting. The plug
jP Adjust will break rather than remain intact. It is not
necessary to remove the plug completely, but
Idle speed, as outlined later. remove all loose pieces.
9. Use J-29030-B to lightly seat the idle mixture
needle, then back the needle out three turns.
CARBURETOR ADJUSTMENTS 10. Install the carburetor as outlined previously.
A carburetor is designed to meet the particular 11. Disconnect and plug hoses, as directed on
requirements of the engine, transmission and vehicle Vehicle Emission Control Information label under
and although they may look alike, they are not usually the hood.
interchangeable. Refer to carburetor part number 12. Place the transmission in Neutral or Park.
and/or specifications when making adjustments. 13. Start the engine and bring it to normal operating
Before suspecting the carburetor as the cause of temperature, choke open, air conditioning off.
poor engine performance or rough idle; check the 14. Connect an ACCURATE tachom eter to the
ignition system including distributor, timing, spark engine.
plugs and wires. Check the air cleaner, evaporative 15. Disconnect the vacuum advance and plug the
emission system, EFE System, PCV system, EGR hose. Check ignition timing. If necessary, adjust
valve and engine compression. Also inspect intake to the specification shown on Vehicle Emission
6C1-16 CARBURETORS
Figure 13Idle Speed Adjustm ent

C
4. Turn a 1/a Hex screw to adjust the low idle speed
A. Idle Mixture Needle Plug to 450 RPM.
B. Locator Point
The solenoid should not be energized.
C. Hacksaw Slots
D. Flat Punch
FAST IDLE ADJUSTMENT (Figure 14)
E. Center Punch B-G6212
1. Prepare the vehicle for adjustments according to
the Emission Control Information label.
Figure 12Removing The Idle Mixture
Ignition timing must be set per label.
Needle Plug
C ontrol Inform ation Label. R econnect the

vacuum advance.
16. Use J-29030-B to turn the mixture needle to
obtain the highest RPM (best idle).
17. Adjust the idle stop screw to obtain the base idle
speed s p e cifie d on the E m ission C ontrol
Information Label.
18. Readjust the mixture needle to obtain the highest
idle RPM.
19. If necessary, readjust the idle stop screw to
obtain the specified base idle speed.
20. If necessary, adjust the fast idle speed and the
idle stop solenoid activated speed to the
specification shown on the Emission Control
Information Label.
21. Turn the engine off and reconnect the vacuum
hoses.
22. Install the air cleaner.
23. Remove the block from the wheels.
IDLE SPEED ADJUSTMENT (Figure 13)

1. Engine must be warm with the choke wide open.
2. The fast idle cam follower must be off the steps of
the cam.
See the Emission Control Information label.
3. Set the curb idle to specification. Turn the
solenoid in or out to adjust RPM.
The solenoid should be energized.
CARBURETORS 6C1-17
2. Adjust the curb idle speed with the idle stop

solenoid.
3. Place the cam follower tang on the high step of
the cam.
4. Support the lever with pliers and bend the tang in
or out to obtain the specified fast idle RPM.
CHOKE COIL LEVER ADJUSTMENT (Figure 15)

1. Place the fast idle cam follower on the highest
step of the fast idle cam.
2. Hold the choke valve completely closed.
3. Bend the link to adjust.
A 3 mm (0.120-inch) plug gage must pass
through the hole in the lever and enter the
hole in the casting.
CHOKE ROD (FAST IDLE CAM) ADJUSTMENT

(Figure 16)
1. With the fast idle adjustment made, the fast idle Figure 15Choke Coil Lever Adjustm ent
cam follower must be held firmly on the second
step of the fast idle cam and against the highest 3. Place J-34817-3 in the base with the contact pin
step. resting on the edge of the float lever.
2. Hold down on the choke valve so the rod is in the 4. Measure the distance from the top of the casting
end of the slot. to the top of the index at the toe of the float.
3. Gage between the lower edge of the choke valve
Use J-9789-90.
(at the center) and the inside air horn wall.
Refer to Specifications. 5. If more than 2/32 from specification, use
4. Bend the rod at point A to adjust. J-34817-30 to bend the lever up or down. Remove
J-34817-30 and measure, repeating until within
CHOKE UNLOADER ADJUSTMENT (Figure 17) specification.
1. If the choke coil is warm, cool it down to the point
where the choke valve will close fully.
2. Hold the throttle valve wide open.
and the inside of the air horn.
4. Bend the tang to adjust.
VACUUM BREAK ADJUSTMENT (Figure 18)

1. Place the fast idle cam follower on the highest
step of the cam.
2. Use an outside vacuum source to seat the
vacuum break diaphragm.
On delay feature models, cover the plug and
the purge bleed hole with a 1 inch square of
m asking tape. Remove the tape after
adjustment.
3. Push down on the choke valve (compress the
plunger bucking spring and seat the plunger
stem on models so equipped).
and the inside of the air horn wall.
Hold the gage vertical.
5. Bend the link at point A to adjust.
FLOAT ADJUSTMENT (Figure 19)

Tool Required:
J-34817 Float Positioning Tool Kit A. Bend rod here to adjust
B-09233
1. Remove the air horn and gasket.
2. Attach J-34817-2 to the float bowl using an air
horn attaching screw. Figure 16Choke Rod (Fast Idle Cam) Adjustment
6C1-18 CARBURETORS
Slide the metering rod out of the slot in the

holder.
2. Back out the idle stop solenoid.
Hold the throttle valve completely closed.
3. Hold the power piston down and swing the
metering rod holder over the flat surface of the
bowl casting next to the carburetor bore.
The gasket must be removed.
4. Gage between the end of the metering rod holder
and the top of the casting.
6. Check float alignment. Use the specified plug gage.
7. Install the air horn and gasket, Gage should have a slide fit.
5. Bend at point A to adjust.
METERING ROD ADJUSTMENT (Figure 20)
1. Remove the metering rod.
Hold the throttle valve wide open.
Push down on the metering rod against
spring tension.
A. Bend Here To Adjust

B-09237
Figure 20Metering Rod Adjustment
B. Plug Gage B-09235
Figure 18Vacuum Break Adjustment

CARBURETORS 6C1-19
CARBURETOR MODELS M4ME, M4MED AND M4MEF
/uV_fl__fl
A. Fixed Idle A ir By-Pass

B. Low er Idle A ir Bleed
C. EGR T im ed V acuum P orts
D. O ff - Idle O pe ra tio n
E. T h ro ttle Valve 4 22
F. Idle D isch a rg e H ole
G. O ff - Idle Port
H. Idle Tube 248. P rim ary M e te rin g Jet
J. Idle C hannel R e s tric tio n 420. Idle M ixtu re N eedle
K. Idle A ir Bleed 422. Idle M ixtu re N eedle Plug
B-09239
Figure 21Idle System M4ME, And M4MED
DESCRIPTION F has an adjustable wide open throttle mixture

control.
All these m odels are four barrel, two stage
carburetors with three major assemblies: the air horn,
METERING SYSTEMS
float bowl, and throttle body. They have six basic
A single float chamber supplies fuel to all carburetor
operating systems (figures 21 through 33).
bores. A float, float needle with pull clip, and a float
Float Power needle seat, are used to control the level of fuel in the
Idle Pump float chamber. A vacuum-operated power piston and
Main Metering Choke metering rods control the air/fuel metering in the
The first M indicates this carburetor is of a primary bores of the carburetor. Tapered metering rods
Modified primary metering open loop design. are attached to the power valve piston assembly, and
The 4M is the model designation, indicating it is a move in fixed metering jets, to provide the fuel flow for
four barrel carburetor. The remaining letters designate varying engine demands. A factory-set adjustable part
specific features. throttle screw, used on all models, precisely positions
E uses an electric choke. the tapered portion of the metering rods in the jets. (On
D has a dual capacity pump. M4MEF models, the factory-set rich stop adjusting
6C1-20 CARBURETORS

237. Float
238. Float Needle Pull Clip
239. Float Needle
240. Float Needle Seat
377. Fuel Filter Spring
B-06771
A. Idle Tube
B. Idle A ir Bleed
C. Idle Channel Restriction
E. O ff - Idle Port
420
F. Idle Discharge Orifice
G. Fixed Idle A ir By-Pass 248. Primary Metering Jet
H. Primary Throttle Valve 420. Idle Mixture Needle
J. Timed Vacuum Ports 422. Idle Mixture Needle Plug B-09240
Figure 23Idle System M4MEF

CARBURETORS 6C1-21
A. A ir Valves (Open) 32. Secondary Metering Rods

B. Eccentric Cam 212. Power Valve Piston Assembly
C. Secondary Throttle Valves 213. Primary Metering Rod
D. Main Discharge Nozzles 218. Power Piston Spring
E. Metering Discs 248. Primary Metering Jet
F. Throttle Valves
G. Vacuum Passage
31. Secondary Metering Rod Holder
B-09243
Figure 24Power System M4ME And M4MED
248 K G. Main Discharge Nozzle

A. Part Throttle A djusting Screw (Do Not Turn Or Remove) H. Boost Venturi
B. Rich Stop A djusting Bushing J. Main Venturi
C. Rich Stop A djust Plug K. Primary Throttle Valve
D. Vacuum Channel 213. Primary Metering Rod
E. Main Well 218. Power Piston Spring
F. Main Well A ir Bleeds 248. Primary Metering Jet B-09242
Figure 25Main Metering System M4MEF

6C1-22 CARBURETORS
A. Metering Adjustm ent Screw (Factory Set)

B. Main Well A ir Bleeds
C. Boost Venturi
D. Main Venturi
E. Main Fuel Wells
F. Vacuum Passage
213. Primary Metering Rod
218. Power Piston Spring
248. Primary Metering Jet
B-09241
Figure 26Main Metering System M4ME And M4MED
bushing precisely positions the enrichment portion of When the engine is cold, more fuel is necessary to
the metering rods in the jets.) insure a smooth transition from idle to part throttle
operation. When the engine is warm, less fuel is
Air valves and tapered metering rods control the
needed. The dual capacity pump solenoid is activated
a ir/fu e l m ixture in the secondary bores during
by a coolant temperature sensor. When coolant
increased engine air flow at wide open throttle. On
tem perature is approxim ately 170F, the pump
M4MEF models, the factory-set secondary well air
solenoid is energized. The pump solenoid opens the
bleed adjusting screw provides additional control of the
dual capacity pump valve, reducing the capacity of the
air/fuel mixture during wide open throttle.
pump by about one-half.
PUMP SYSTEMS
CHOKE SYSTEMS
The pump system on all models uses a throttle
actuated pump plunger, operating in the pump well. A choke coil is used to provide the choke valve
The pump provides extra fuel during quick throttle closing force for cold startup and for correct opening
openings. timing during warmup. Vacuum break assemblies
control initial choke valve openings at startup and
DUAL CAPACITY PUMP (M4MED ONLY) during warmup. An unloader tang on the throttle lever
M4MED carburetors have a float bowl-mounted dual forces the choke valve open to purge a flooded engine
capacity pump valve assembly and a dual capacity when the accelerator is pressed to the floor. The fast
pump solenoid assembly. idle cam, following choke valve movement, acts as a
CARBURETORS 6C1-23
A. Rich Stop Adjusting

Bushing (Do not turn or ^48
remove)
c l
P. Secondary Well Bleed Adjust Screw (Do not
B. Rich Stop Adjusting Plug turn or remove)
C. Primary Throttle Valve Q. Secondary Well Bleed Adjust Spring
D. Secondary Throttle Valve R. Secondary Well Bleed Adjust Plug
E. Air Valve S. Secondary Discharge Nozzle
F. Eccentric Cam T. Baffle
G. Metering Disc 31. Secondary Metering Rod Holder
H. Secondary Fuel Well 32. Secondary Metering Rod
J. Accelerator Well Inlet Orifice 50. Air Horn Baffle
K. Accelerator Well and Tube 212. Power Valve Piston Assembly
L. Accelerator Well Discharge Orifice 213. Primary Metering Rod
M. Secondary Well Bleed Tube 218. Power Piston Spring
N. Clean Air Inlet 248. Primary Metering Jet
B-09245
Figure 27Power System M4MEF
graduated throttle stop to provide increased idle speed CARBURETOR IDENTIFICATION

during warmup.
Refer to the carburetor identification before servicing
the carburetor. The number is stamped vertically on
THROTTLE KICKER AND IDLE SPEED SOLENOID
the float bowl near the secondary throttle lever (figure
Depending on engine displacement and vehicle
34). Follow the instructions in the service package
application, a throttle kicker assembly or an idle speed
when replacing the float bowl assembly. Stamp or
solenoid may be used.
engrave the identification number on the new float
On vehicles without air conditioning, the idle speed bowl.
solenoid provides desired engine speed and prevents
dieseling when the ignition is turned off. On vehicles
with air conditioning, the idle speed solenoid maintains
e ng in e idle speed when the air c o n d itio n in g
com pressor clutch is engaged. The solenoid is
energized by the air conditioning switch.
The vacuum-operated throttle kicker holds the

throttle open during deceleration, to reduce emissions.
On the 4.3 liter engine, it is also used to increase
engine idle speed based on accessory load.
6C1-24 CARBURETORS
A. Pump Suction Breaker

B. Pump Jets
C. Discharge Passage
D. Pump Plunger
r Cup Seal
F. Expancer Sprinn
G. Duration Sprir,,j
41. Pump Lever
67. Pump Stem Seal Retainer
68. Pump Stem Seal
206. Pump Return Spring
250. Pump Discharge Plug
251. Pump Discharge Ball
B-09246
Figure 28Pump System M4ME And M4MEF

C. Pump Duration Spring Retainer
D. Pump Plunger Cup
E. Pump Plunger Spring
F. Pump Discharge Orifice
G. Pump Suction Breaker
H. Check Ball
260
41. Pump Lever 250. Pump Discharge Plug (Retainer)

205. Pump Assembly 251. Pump Discharge Ball
206. Pump Return Spring 260. Dual C a p a c ity P um p S o le n o id
245. Dual Capacity Pump Valve (S how n Energized)
Assembly (Shown Open)
B-09248
Figure 29Dual Capacity Pump System M4MED

CARBURETORS 6C1-25
A. Choke Valve 55. Primary Side Vacuum Break Assembly

B. Thermostatic Coil 58. Primary Side Vacuum Break To A ir Valve Link
C. Unloader Tang 320. Secondary Side Vacuum Break Assembly
D. Fast Idle Cam Follower 322. Secondary Side Vacuum Break to Choke Link
E. Plunger Bucking Spring (Not Used On All Models) 356. Choke Link
F. A ir Valve 360. Secondary Throttle Lockout Lever
G. Hot Air Inlet 425. Fast Idle Adjusting Screw R-oq?4 q
Figure 30Hot Air Choke System With Front And Rear Vacuum Breaks
D. Fast Idle Cam Follower

E. Plunger Bucking Spring (Not Used On All Models)
F. A ir Valve
320. Secondary Side Vacuum Break Assembly
322. Secondary Side Vacuum Break To Choke Link
323. Secondary Side Vacuum Break to A ir Valve Lever
Link
360. Secondary Throttie Lockout Lever
425. Fast Idle A djusting Screw B-09251
Figure 31Electric Choke With Rear Vacuum Break

6C1-26 CARBURETORS
322 360 D 425

A. Choke Valve 55. Primary Side Vacuum Break Assembly
B. Thermostatic Coil 58. Primary Side Vacuum Break To A ir Valve Lever
C. Unloader Tang 320. Secondary Side Vacuum Break Assembly
D. Fast Idle Cam Follower 322. Secondary Side Vacuum Break To Choke Link
E. Plunger Bucking Spring 356. Choke Link
(Not Used On All Models) 360. Secondary Throttle Lockout Lever
F. A ir Valve 425. Fast Idle Adjusting Screw
B-09252
Figure 32Electric Choke With Front And Rear Vacuum Breaks

CARBURETORS 6C1-27
A. Choke Valve
B. Adjustm ent Screw
C. Unloader Tang
D. Fast Idle Cam Follower
E. A ir Valve
55. Primary Side Vacuum Break Assembly
58. A ir Valve Link Rod
330. Choke Cover Attaching Rivet
335. Electric Choke Cover and Stat Assembly
356. Choke Link
360. Secondary Throttle Lockout Lever
425. Fast Idle Adjusting Screw
B-09250
Figure 33Electric Choke System With

Front Vacuum Break
B-09586
Figure 34Carburetor Identification

6C1-28 CAR BU R ETO R S
ON*VEHICLE SERVICE (M4ME, M4MED AND M4MEF)
Figure 36 P lugging The Vacuum Break

A ir Bleed H oles
1. Remove the air cleaner. With the engine off, hold

the throttle half open. Open and close the choke
several times. Be sure all links are connected,
and are not damaged.
2. If choke or linkage binds or is sluggish, clean
them with choke cleaner X-20-A or equivalent.
Refer to the Light Duty Truck Unit Repair
Manual if cleaning does not correct the problem.
3. Inspect all carburetor vacuum hoses for proper
connections, cracks, cuts, hardness, or other
FLOAT LEVEL CHECK signs of deterioration. Replace or correct as
1. With the engine idling and the choke wide open, necessary.
insert J-34935-1 in the vent slot or vent hole
VACUUM BREAK CHECKING PROCEDURE
(figure 35).
1. If the vacuum break has an air bleed hole, plug it
Allow the gage to float freely. during this checking procedure (figure 36).
2. Use hand held vacuum pump J-23738-A or
NOTICE: Do not press down on the gage. equivalent, to apply -51 kPa (15 in. Hg.) vacuum
Flooding or float damage could result. to the vacuum break.
The vacuum break plunger should retract
2. Observe the mark on the gage that lines up with fully w ithin ten seconds. Apply fin ge r
the top of the casting. The setting should be pressure to see if the plunger has moved
within 1.588 mm (2/32-inch) of the specified float through its full travel. If it fails to retract
level setting. within ten seconds, or if it fails to move
Incorrect fuel pressure will adversely affect through full travel, replace the vacuum
the fuel level. break assembly.
The vacuum break diaphragm should hold
3. If not within specification, remove the air horn vacuum for at least twenty seconds. If it
and adjust the float. does not, replace the vacuum break.
ELECTRIC CHOKE CHECKING PROCEDURE

CHOKE AND HOSES 1. Allow the choke to cool so that when the throttle
Check the choke mechanism and vacuum break(s) is opened slightly, the choke valve closes fully.
for proper operation at recommended maintenance Ambient temperature should be 15-27C
intervals. (60-80F).
CARBURETORS 6C1-29
2. Start the engine and find the time that the choke
222
valve takes to open fully.
Start timing when the engine starts.
3. If the choke fails to open fully within five minutes,
check the voltage at the choke heater connection
with the engine running.
221
If approximately 12-15 volts, replace the
electric choke assembly.
If low or zero, check all connections and
wires. Repair wires or replace fuses as
required.
DUAL CAPACITY PUMP CHECK

(M 4M ED ONLY)
1. B rin g the e n g in e to n orm a l o p e ra tin g 245
tempearture.
2. With the ignition off, actuate the throttle lever
several times and observe the fuel stream. The
stream should be strong and consistent. 221. Screw
3. Run the engine to refill the float bowl. 222. Gasket
4. With the ignition on, actuate the throttle lever 245. Dual Capacity Pump
several times and observe the fuel stream. Less Valve Assembly
fuel should be coming from the pump because 246. Gasket
the solenoid is energized. 260. Dual Capacity Pump Solenoid F-00861
5. If the pump stream does not change and appears
to be strong and consistent, fuel is not being Figure 37Dual Capacity Pump
bypassed by the pump circuit.
Disconnect the solenoid (260) (figure 37) Remove the air horn assembly and the
coolant temperature switch connector and gasket.
jump it to ground.
Fill the float bowl and the pump well with
Repeat step 4.
clean fuel.
If less fuel comes from the pump,
check cooling system operation and Seal the two pump discharge passages on
the coolant temperature switch for the top surfaces of the float bowl with two
fingers while pushing the pump assembly
opens.
slowly into the pump well.
If the pump stream remains the same,
check wiring for opens or shorts. The pump assembly should not travel
Disconnect the dual capacity pump solenoid to the bottom of the well. The only
connector. movement should be the compressing
Remove the air horn assembly and gasket. of the duration spring.
Remove the dual capacity solenoid from the If the pump assembly moves down in
flo a t bowl and co nn e ct the so le no id the well, the pump cup may be worn,
connector. hardened or damaged, the pump well
With the ignition on and the coolant switch may be worn or scored, the pump
lead grounded, the solenoid should be discharge plug may be leaking, the
energized and the solenoid plunger should dual capacity pump solenoid plunger
extend. Replace the solenoid if it does not may be stuck, the pump valve may not
extend. be seating correctly, or the valve
Check the pump valve (245) and passages gasket may be leaking.
for dirt or obstructions. Connect the dual capacity pump solenoid
Check pump system operation. connector.
6. If the pump stream does not change and appears Disconnect the dual pump solenoid coolant
to be weak or irregular, fuel is leaking in the pump temperature switch connector and jump it to
circuit. ground.
Disconnect the dual capacity pump solenoid With the ignition on and the engine off,
(260) (figure 37) connector. slowly move the pump assembly into the
6C1-30 CARBURETORS
pump well until fuel is visible at the top of matter in carburetor. To aid in diagnosing the cause,
the passages. the carburetor should be removed carefully from the
Remove the pump assembly and continue engine without draining fuel from the bowl. Contents of
to watch fuel in the passages. The fuel level the fuel bowl may then be examined for foreign
should not go down. materials as carburetor is disassembled.
If the level b eg in s to drop, the
discharge ball may be missing or not Remove or Disconnect
seating correctly, damaged, or needs
to be restaked. It may also indicate 1. Air cleaner and gasket.
that the check ball in the pump valve is
2. Electrical connectors at the idle speed solenoid
not seating properly.
and dual capacity pump solenoid (if equipped).
C heck dual c a p a c ity pum p system
operation. 3. Fuel line and vacuum hoses.
4. Choke system.
IDLE STOP SOLENOID CHECK
6. Downshift cable (automatic transmission only).
A non-functioning idle stop solenoid (if equipped) 7. Cruise control linkage (if equipped).
could cause stalling or rough idle when the air
8. Carburetor attaching bolts.
conditioning (if equipped) is turned on.
1. Turn the ignition on but do not start the engine. 9. Carburetor and insulator.
Turn the air conditioning switch on.
2. Open the throttle momentarily to allow the -+ Install or Connect
solenoid plunger to extend.
3. Disconnect the wire at the solenoid. The plunger Clean the sealing surfaces on the intake manifold
should pull back from the throttle lever. and carburetor.
4. Connect the solenoid wire. The plunger should
move out and contact the throttle lever. CAUTION: Extinguish all open flames while
5. If the plunger does not move in and out, check for fillin g and testing carburetor with gasoline to
voltage across the feed wire. avoid personal injury.
If the voltage is 12 to 15 volts, replace the
solenoid. 1. Carburetor and insulator.
If the voltage is low, locate the cause of the
It is good shop practice to fill the carburetor
open circuit in the solenoid feed wire.
float bowl before installing the carburetor.
This reduces the strain on starting motor
THROTTLE KICKER CHECK and battery and reduces the possibility of
backfiring while attempting to start the
Tool Required: engine. Operate the throttle several times
J-23738-A, Hand Held Vacuum Pump. and check the discharge from pump jets
1. Hold the throttle half way open to allow the before installing the carburetor.
plunger to extend fully. 2. Carburetor attaching bolts.
2. Apply 68 kPa (20-inches Hg) vacuum to the
throttle kicker.
Tighten
3. Apply finger pressure to the plunger to see if it is
fully extended. If not, replace the throttle kicker.
Bolts to 16 N m (144 in. lbs.) in a criss-cross
4. Observe the vacuum gage. The vacuum should
pattern.
hold for at least 20 seconds. If not, replace the
throttle kicker. 3. Downshift cable (automatic transmission only).
5. Release the vacuum to the throttle kicker. 4. Cruise control cable (if equipped).
6. Apply finger pressure to the plunger to see if it 5. Accelerator linkage.
has returned to its retracted position. If not,
6. Choke system.
replace the throttle kicker.
7. Fuel line and vacuum hoses.
8. Electrical connectors at the idle speed solenoid
CARBURETOR REPLACEMENT and/or the dual capacity pump solenoid (if
equipped).
F looding, stum ble on acceleration and other
performance complaints are, in many instances, 9. Air cleaner.
caused by the presence of dirt, water or other foreign Check and adjust the idle speed.
CARBURETORS 6C1-31
IDLE MIXTURE ADJUSTM ENT

(LIGHT-DUTY EMISSION
VEHICLES ONLY)
Idle mixture needles were preset and sealed at the
factory. Idle mixture should only be adjusted during
major carburetor overhaul, throttle body replacement,
or if high em issions are determined by official
inspection.
Because of the sealed idle mixture needles, the idle
m ixture ch ecking procedure requires a rtific ia l
enrichment by adding propane. Adjusting mixture by
o th e r than the fo llo w in g m ethod may vio la te
government regulations.
1. Set the parking brake and block the drive wheels.
Engine must be at normal operating temperature
with the air conditioning off.
2. Disconnect and plug hoses as directed on the A. Push Valve
Emission Control Information label under the B. Flow Meter
hood. C. Control Valve
3. Connect an accurate tachometer to the engine. D. Propane Cylinder
4. Disconnect the vacuum advance and set timing
to the sp ecificatio n shown on the V ehicle
Emission Control Information label. Reconnect
the vacuum advance. F-00401
5. Set carburetor idle speed to the specification
show n on the V e h ic le E m issio n C o n tro l
Figure 38Idle Mixture Check With
Information label. Propane Enrichment
6. Disconnect the crankcase ventilation tube from
the air cleaner. l Use a hacksaw to make two parallel cuts in
7. Insert the hose with the rubber stopper into the the throttle body, one on each side of the
crankcase ventilation tube opening in the air locator point by each idle mixture needle
cleaner using tool J-26911 or equivalent (figure plug. Cut down to the steel plug but not
38). more than 3.1 mm (Ve-inch) beyond the
The propane cartridge must be vertical. locator point.
8. With the engine idling in Drive (Neutral for
Place a flat punch at a point near the ends
manual transmissions), slowly open the propane
of the saw marks. Hold the punch at a 45
control valve while pressing the button. Continue
degree angle and drive it into the throttle
to add propane until the engine speed drops, due
body u n til the ca stin g breaks away,
to over-richness. Note the maximum engine
exposing the steel plug.
speed (enriched speed). If rich speed drop
cannot be obtained, check for an empty propane Hold a center punch vertically and drive it
cartridge or propane system leaks. into the steel plug.
9. If the enriched idle speed is within the enriched Hold the punch at a 45 degree angle and
idle specification, the mixture is correct. Go to drive the plug out of the casting.
Step 18. Remove all loose pieces.
10. If the e n ric h e d id le speed is not w ith in Repeat the procedure for the other plug.
specifications, remove the idle mixture needles:
11. Install the carburetor on the engine.
Remove the carburetor from the engine
using normal service procedures. 12. Use J-29030-B or equivalent to lightly seat the
Invert the carburetor and drain the fuel into mixture needles, then back out equally, just
an approved container. enough so the engine will run.
Place the carburetor on a holding fixture 13. Place the transmission in Drive (automatic) or
with the manifold side up. Neutral (manual).
Use care to avoid dam aging the 14. Back each needle out (richen 1/8 turn at a time),
linkage, tubes, and parts protruding until the maximum idle speed is obtained. Set the
from the air horn. idle speed to the enriched idle specification.
6C1-32 CAR BU R ETO R S
352. Fast Idle Cam Assembly n n

425. Fast Idle Adjusting Screw
r~ c z j
r H A lllit
P V I
352
B-09590
Figure 39 Fast Idle A d ju stm e n t
A. Idle Speed Screw

B-09283
Figure 40 Idle Speed A d ju stm e n t W ith o u t Idle Speed S olenoid
A. Solenoid Screw
B. Idle Speed Screw
C. Electrical Connection
B-09284
Figure 41Idle Speed Adjustment With Idle Speed Solenoid

CARBURETORS 6C1-33
15. Turn each mixture needle in (1/8 turn at a time), Hold the punch at a 45 degree angle and
until the idle speed reaches the value given on drive the plug out of the casting.
the Emission Control Information label. Remove all loose pieces.
16. Re-check the enriched speed with propane. If not Repeat the procedure for the other plug.
within specification, repeat the adjustment, Replace the carburetor on the engine.
starting at step 12. 2. Connect a tachometer and a vacuum gage to the
17. After adjustments are made, seal the idle mixture engine.
needles with RTV rubber or equivalent. Sealing is 3. As a preliminary adjustment, lightly seat each
required to retain the setting and to prevent loss mixture needle and back it out two turns.
of fuel vapors. 4. Adjust the idle speed screw to the idle speed
18. Check, and if necessary, adjust the fast idle as specified on the Vehicle Emission Control
described on the Emission Control Information Information label.
label. Engine should be running with the choke
19. Turn the engine off. Remove the propane tool and wide open and the transmission in neutral.
connect the crankcase ventilation tube. Unplug 5. Adjust each idle mixture needle to obtain the
and reconnect the vacuum hoses. Install the air highest RPM.
cleaner. 6. Repeat steps 4 and 5 until b est idle is
obtained.
20. Remove the wheel blocks.
7. Reset the curb idle speed to specifications on the
Vehicle Emission Control Information label (if
necessary).
IDLE MIXTURE ADJUSTM ENT
8. After adjustments are made, seal idle mixture
(HEAVY DUTY EMISSION needles with RTV rubber or equivalent. Sealing is
VEHICLES ONLY) required to retain the setting and to prevent loss
of fuel vapors.
Idle mixture needles were preset at the factory and 9. Check, and if necessary, adjust the throttle lever
sealed. Idle mixture should be adjusted only during actuator.
major carburetor overhaul, throttle body replacement, 10. Check, and if necessary, adjust the fast idle
or if high em issions are determ ined by official speed as described on the Emission Control
inspection. Infomation label.
Perform this adjustment with the engine at operating 11. Turn off the engine, remove gages, unplug and
temperature, parking brake applied, drive wheels reconnect vacuum hoses. Install the air cleaner.
blocked, and the transmission in Park or Neutral. 12. Remove block from the drive wheels.
1. Remove the air cleaner.
2. Remove the idle m ixture needle plugs (if
equipped). IDLE SPEED ADJUSTM ENT
Remove the carburetor from the engine Refer to the Emission Control Information label to
using normal service procedures.
adjust idle speed and fast idle.
Invert the carburetor and drain the fuel into
an approved container.
Place the carburetor on a holding fixture THROTTLE KICKER ADJUSTM ENT
with the manifold side up.
Use care to avoid dam aging the Refer to D R IV E AB ILITY AND EM ISSIO NS -
linkage, tubes, and parts protruding CARBURETED (SEC. 6E8) to adjust the throttle kicker.
from the air horn.
Use a hacksaw to make two parallel cuts in
FLOAT ADJUSTM ENT
the throttle body, one on each side of the
locator point by each idle mixture needle Tools Required:
plug. Cut down to the steel plug but not J-9789-90, Float Level T Scale
more than 3.1 mm (Vs-inch) beyond the J-34817, Float Positioning Tool Kit
locator point. 1. Remove the air horn, gasket, power piston and
Place a flat punch at a point near the ends metering rod assembly, and the float bowl insert.
of the saw marks. Hold the punch at a 45 2. Attach J-34817-1 to the float bowl (figure 42).
degree angle and drive it into the throttle 3. Place J-34817-3 in J-34817-1 with the contact pin
body u n til the c a stin g breaks away, resting on the outer edge of the float lever.
exposing the steel plug. 4. Measure the distance from the top of the casting
Hold a center punch vertically and drive it to the top of the float at a point 3/16-inch from the
into the steel plug. large end of the float.
6C1-34 CARBURETORS
A. Scale
B. Bend Here
380. Throttle Stop Screw
410. Pump Link
B-09286
Figure 42Float Adjustm ent Figure 43Pump Adjustm ent
Use J-9789-90. AIR VALVE SPRING

5. If more than 2/32-inch from specification, use ADJUSTM ENT
J-34817-25 to bend the lever up or down.
1. Loosen the lock screw using a 3/32-inch hex
6. Remove J-34817-25 and measure, repeating until wrench (figure 44).
within specification. 2. Turn the te n sio n a d ju s tin g screw
counterclockwise until the air valve opens part
7. Check the float alignment. way.
8. Reassemble the carburetor. 3. Turn the tension adjusting screw clockwise until
the air valve just closes. Then turn the adjusting
screw clockwise the specified number of turns.
4. Tighten the lock screw.
PUMP ADJUSTM ENT
5. Apply lithium base grease to lubricate the contact
1. The pump link (410) must be in the specified hole area.
(figure 43). 6. Bend the choke rod to adjust.
2. Be sure the fast idle cam follower lever is off the

steps of the fast idle cam. Back off the throttle CHOKE COIL LEVER
stop screw (380) from contact with the throttle
lever. ADJUSTM ENT
3. Gage from the top of the choke valve wall next to 1. Drill out and remove rivets (if riveted). Remove
the vent stack, to the top of the pump stem as the electric choke cover and stat assembly.
specified. 2. Place the fast idle cam follower on the high step
of the fast idle cam.
4. Bend the pump lever (41) at the notch to adjust.
3. Push up on the choke coil lever to close the
Support the lever with a screwdriver while choke valve.
bending it. 4. Insert a 0.120-inch plug gage (figure 45).
CARBURETORS 6C1-35
A. Apply Lithium Base Grease Here

B. Lock Screw
C. Tension A djusting Screw
B-09287
Figure 44A ir Valve Spring Adjustm ent
A. Bend Here to Adjust

B. 0.120 - Inch Plug Gage
B-09573
Figure 45Choke Coil Lever Adjustment

6C1-36 CARBURETORS
NOTICE: Final Fast Idle Speed Adjustm ent

J-26701 m ust be p e rfo rm e d a c c o rd in g to the
Underhood Em ission C ontrol Inform ation
Label.
5. Adjust by bending the tang of the fast idle cam

until the bubble is centered.
PRIM ARY SIDE VACUUM

BREAK ADJUSTM ENT
Tool Required:
J-26701, Choke Valve Angle Gage
1. Attach rubber band to the green tang of the
intermediate choke saft.
2. Open the throttle to allow the choke valve to
close.
3. Set up J-26701 and set angle to specifications
(figure 47).
Rotate the degree scale until zero is
opposite the pointer.
Center the leveling bubble.
425 Rotate the scale to the specified angle.
A. Pliers on Tang Refer to Specifications.
425.Fast Idle Adjusting Screw B-09574 4. Retract the vacuum break plunger using a
vacuum source of at least 61 kPa (18 in. Hg.).
Figure 46Choke Rod And Fast Idle Plug the air bleed holes where applicable (figure
Cam Adjustm ent 36).
The air valve rod must not restrict the plunger
5. The lower edge of the lever should just contact from retracting fully. If necessary, bend the rod to
the gage. permit full plunger travel. Final rod clearance
must be set after the vacuum break setting has
6. Bend the choke rod to adjust.
been made.
5. With at least 61 kPa (18 in. Hg.) still applied,
adjust the screw to center the bubble (figure 48).
CHOKE ROD AND FAST Bucking spring must be seated against
IDLE CAM ADJUSTM ENT lever (if used).
Tool Required:
J-26701, Choke Valve Angle Gage SECONDARY SIDE VACUUM
1. Attach a rubber band to the green tang of the BREAK ADJUSTM ENT
intermediate choke shaft (figure 46).
Tool Required:
close.
1. Attach a rubber band to the green tang of the
3. Set up J-26701 and set the angle to specification intermediate choke shaft.
(figure 47). 2. Open the throttle to allow the choke valve to
Rotate the degree scale until zero is close.
opposite the pointer. 3. Set up J-26701 and set angle to specification
Center the leveling bubble. (figure 47).
Rotate the scale to the specified angle. opposite the pointer.
Refer to Specifications. Center the leveling bubble.
4. Place the cam follower on the second step of the Rotate the scale to the specified angle.
cam against the high step. If the cam follower Refer to Specifications.
does not contact the cam, turn in the fast idle 4. Retract the vacuum break plunger using a
speed screw additional turn(s). vacuum source of at least 61 kPa (18 in. Hg.).
CARBURETORS 6C1-37
A. Magnet
B. Leveling Bubble
B-09575
Figure 47Choke Valve Angle Gage
Plug the air bleed holes where applicable (figure

36).
The air valve rod must not restrict the

plunger from retracting fully. If necessary,
bend the rod to permit full plunger travel.
The plunger stem must be extended fully to
compress the plunger bucking spring.
5. Center the bubble by adjusting with a 1/s inch hex

wrench (vacuum still applied) or support at point
A and bend the vacuum break rod (vacuum still
applied) (figure 49).
323- AIR VALVE ROD

ADJUSTMENT
1. Use a vacuum source of at least 61 kPa (18 in.
Hg.) to seat the vacuum break plunger.
Plug the air bleed holes where applicable

(figure 36).
A. Bucking Spring (If Used)
2. The air valve must be completely closed.
B. Rubber Band
323.Air Valve Lever B-09576 3. Use a 0.025-inch plug gage between the rod and
the end of the slot (figures 50 and 51).
Figure 48Primary Side Vacuum Break
Adjustment 4. Bend the rod to adjust clearance to 0.025-inch.
6C1-38 CARBURETORS
UNLOADER ADJUSTMENT
Tool Required:
1. Attach a rubber band to the green tang of the
intermediate choke shaft (figure 52).
close.
3. Set up J-26701 and set angle to specification
(figure 47).
opposite the pointer.
Center the leveling bubble.
Rotate the scale to the specified angle.
Refer to Specifications.
4. Hold the secondary lockout lever away from the
pin.
5. Hold the throttle lever wide open.
6. Adjust by bending the tang of the fast idle lever
until the bubble is centered.
SECONDARY LOCKOUT
ADJUSTMENT
1. The choke valve and throttle valves must be
closed.
2. Secondary lockout lever side clearance should be
A. Support Here a maximum of 0.015-inch (figure 53).
B. Bend Here 3. Bend the pin to adjust.
C. Hex Wrench 4. Hold the choke valve wide open by pushing down
D. Rubber Band on the tail of the fast idle cam.
5. Check the secondary lockout opening clearance
with a 0.015-inch gage.
B-09577 6. File the end of the pin for clearance.
Check for burrs after filing.
Figure 49Secondary Side Vacuum Break

Adjustm ent
c
A. 0.025-inch
Plug Gage
B. Bend Rod Here
To Adjust
F-00402
Figure 50Front Air Valve Adjustment

CARBURETORS 6C1-39
A. Rubber Band
B. Bend Tang to Adjust
C. Lockout Lever
D. Pin
352. Fast Idle Cam
B-09580
Figure 52Unloader Adjustment

6C1-40 CARBURETORS
A. 0.015-inch Plug Gage

B. Bend Here
F-00404
Figure 53Secondary Lockout Adjustm ent
CARBURETOR MODELS E4ME AND E4MED

(CALIFORNIA ONLY)
DESCRIPTION signals received frm the Electronic Control Module

(ECM).
The M odels E4ME and E4M ED Q u a d ra je t
Carburetors are of the four barrel, two stage design. TWO POINT ADJUSTMENT
They are used with the Computer Command Control The two points of fuel control adjustment are:
System of fuel control, which is further described in 1. The mixture control solenoid adjusting screw.
DRIVABILITY AND EMISSIONS CARBURETED 2. The idle mixture needles.
(SEC. 6E8). A single mixture control solenoid adjusting screw
The carburetor has three major assemblies: the air replaces the separate rich stop and lean stop screws.
horn, the float bowl, and the throttle body. It has six The solenoid adjusting screw positions the solenoid in
basic operating systems (figures 54 through 60). the float bowl. A rich limit stop is assembled with the
adjusting screw to hold the solenoid plunger travel to a
Float Power
fixed limit.
Idle Pump
Main Metering Choke DUAL CAPACITY PUMP (E4MED MODELS ONLY)
A single float chamber supplies fuel to the four E4MED model carburetors have a dual capacity
carburetor bores. Fuel level is controlled by a closed pump valve and a combined mixture control/dual
cell rubber float, brass needle seat, and a rubber capacity pump solenoid assembly mounted on the
tipped float needle with pull clip. float bowl (figure 59).
Air/fuel mixture in the primary bores is controlled by When the engine is cold, more fuel is necessary to
an electrically operated mixture control solenoid. The insure a smooth transition from idle to part throttle.
solenoid is mounted in the float bowl. The plunger in When the engine is warm, less fuel is required. The
the solenoid is controlled (or pulsed ) by electrical dual capacity pump is controlled by the coolant
CARBURETORS 6C1-41

237. Float
238. Float Needle Pull Clip
239. Float Needle
240. Float Needle Seat
377. Fuel Filter Spring
B-06771
422 420 G 12. A ir Bleed Valve Cover

A. Solenoid Plunger (G. Off-Idle Port 15. A ir Bleed Valve Assembly
B. Idle Tube H. Idle Discharge Orifice 213. Primary Metering Rod
C. Idle Channel Restriction J. Fixed Idle Air By-Pass 225. Mixture Control Solenoid Assembly
D. Clean Air Inlet (Some Models) 255. Primary Metering Jet Assembly
E. Idle Air Bleed K. Primary Throttle Valve 420. Idle Mixture Needle
F. Lower Idle A ir Bleed L. Timed Vacuum Ports 422. Idle Mixture Needle Plug
F-00405
Figure 55Idle System

6C1-42 CARBURETORS
226 70 15
A. Main Well
B. Solenoid Plunger
C. Clean A ir Inlet
D. Main Well Air Bleeds 15. Air Bleed Valve Assembly 226. Solenoid Adjusting Screw
E. Main Discharge Nozzle 70. Solenoid Adjusting Screw Plug (Lean Mixture)
F. Boost Venturi 213. Primary Metering Rod 227. Rich Limit Stop
G. Main Venturi 225. Mixture Control Solenoid 255. Primary Metering Jet
H. Primary Throttle Valve Assembly Assembly
F-00406
Figure 56Main Metering System
A. Primary Throttle Valve

B. Secondary Throttle Valve
C. A ir Valve
D. Eccentric Cam
E. Metering Disc J. Accelerator Well Inlet Orifice 31. Secondary Metering Rod
F. Secondary Fuel Well K. Secondary Discharge Nozzle Holder
G. Accelerator Well & Tube L. Secondary Well Bleed Tube 32. Secondary Metering Rod
H. Accelerator Well Discharge Orifice M. Baffle 50. Air Horn Baffle
F-00407
Figure 57Power System

CARBURETORS 6C1-43
A. Pump Suction Breaker

B. Pump Jets
C. Discharge Passage
D. Pump Plunger
E. Cup Seal
F. Expander Spring
G. Duration Spring
41. Pump Lever
67. Pump Stem Seal Retainer
68. Pump Stem Seal
206. Pump Return Spring
250. Pump Discharge Plug
251. Pump Discharge Ball
B-09246
Figure 58Pump System
205
260
245

C. Pump Duration Spring Retainer 251 250. Pump Discharge
D. Pump Plunger Cup 41. Pump Lever Plug (Retainer)
E. Pump Plunger Spring 205. Pump Assembly 251. Pump Discharge Ball
F. Pump Discharge Orifice 206. Pump Return Spring 260. Dual Capacity Pump
G. Pump Suction Breaker 245. Dual Capacity Pump Valve Solenoid (Shown
H. Check Ball Assembly (Shown Open) Energized)
B-09595
Figure 59Dual Capacity Pump System

6C1-44 CARBURETORS
F 58 356 A
A. Choke Valve 55. Primary Side (Front) Vacuum Break Assembly

B. Therm ostatic Coil 58. Primary Side Vacuum Break To Air Valve Lever Link
C. Unloader Tang 320. Secondary Side (Rear) Vacuum Break Assembly
D. Fast Idle Cam Follower 322. Secondary Side Vacuum Break To Choke Link
E. Plunger Bucking Spring 356. Choke Link
(Not Used On All Models) 360. Secondary Throttle Lockout Lever
F. Air Valve 425. Fast Idle Adjusting Screw
F-00408
Figure 60Electric Choke System With Front And Rear Vacuum Breaks
temperature sensor. When coolant temperature is to changes in throttle position. TPS input is used by the
approximately 170F (77C), a solenoid within the ECM to regulate the mixture control solenoid, EST, idle
carburetor is energized, opening a bypass valve. This speed control, and TCC. The sensor is adjustable and
lowers the capacity of the pump by about one-half. the specific adjustment procedure must be followed.
SECONDARY OPERATION
THROTTLE POSITION SENSOR (TPS)
Air valves and metering rods control the air/fuel
The float bowl mounted throttle position sensor is a
metering in the secondary bores.
pump lever actuated variable resistor (figure 61). It
Additional fuel flow during wide open throttle is
sends a varying voltage signal to the ECM in response
provided by a pair of tapered metering rods. The
metering rods are attached to a holder. The holder
A 62 61 operates by cam action resulting from the air valve
210. Throttle angle.
Position
Sensor (TPS) CHOKE
An electrically heated thermostatic coil provides the
choke valve closing force for cold start-up and for
correct opening time during warmup. Vacuum break
units control initial choke valve opening at start and
during warmup. An unloader tang on the fast idle lever
211 forces the choke valve open to purge a flooded engine
Sensor
Adjustm ent
Adjusting when the accelerator is pressed to the floor. A fast idle
Lever
Spring cam follows the choke valve movement. This acts as a
41. Pump Lever
graduated throttle stop and provides increased idle
60. Sensor Actuator Plunger
61. TPS A djusting Screw Plug speed during warmup.
62. TPS A djusting Screw
THROTTLE KICKER AND IDLE SPEED SOLENOID
66 . TPS Plunger Seal B-09597
Depending on engine displacement and vehicle
application, either a throttle kicker assembly or an idle
Figure 61Throttle Position Sensor (TPS) speed solenoid (ISS) is used.
CARBURETORS 6C1-45
A throttle kicker is vacuum operated and ECM

controlled to maintain primary throttle position during
deceleration above a specified rpm as an emission
requirement.
On vehicles with V-8 engines and air conditioning,
an idle speed solenoid is used to maintain curb idle
speed whenever the air conditioning compressor
clutch is engaged. The idle speed solenoid is
energized by the air conditioning switch.
MODEL IDENTIFICATION
The carburetor model identification number (figure
62) is stamped vertically on the float bowl near the
secondary throttle lever. Refer to this part number
when servicing the carburetor. If replacing the float
bowl assembly, follow instructions contained in the
service package. Stamp or engrave the model number
on the new float bowl.
ON-VEHICLE SERVICE
the top of the casting. Setting should be within

2/32 (1.588 mm) of the specified float level.
Incorrect fuel pressure will adversely affect
J-34935-1
the fuel level.
3. If not within specifications, remove the air horn
and adjust the float.
CHOKE CHECK
Check the unloader and idle setting adjustments.
The choke linkage and fast idle cam must operate
freely.
Bent, dirty or otherwise damaged linkage must be
cleaned, repaired or replaced as necessary. Do not
lubricate the linkage, since lubricant will collect dust
F-00409
and cause sticking.
Figure 63External Float Checking Gage I? Inspect
FLOAT LEVEL CHECK This check should be performed at an ambient

temperature of 15 to 27C (60 to 80F).
Tool Required: Allow the choke to cool so that when the throttle
J-34935-1, Float Gage is opened slightly, the choke valve closes fully.
1. With the engine idling and the choke wide open, Start the engine and determine the time required
insert J-34935-1 in the vent slot or vent hole. for the choke valve to open fully.
Allow the gage to float freely (figure 63). Start timing when the engine starts.
Check the voltage at the choke heater connection
NOTICE: DO NOT PRESS DOWN ON THE with the engine running.
GAGE. FLOODING OR FLOAT DAMAGE COULD If the voltage is approximately 12-15 volts,
RESULT. replace the electric choke unit.
If the voltage is low or zero, check all wires
2. Observe the mark on the gage that lines up with and connections.
6C1-46 CARBURETORS
The oil pressure warning lamp will be on Remove the air horn assembly and the
with the engine running if there is a problem gasket.
in the oil pressure switch circuitry or if the Fill the float bowl and the pump well with
pressure switch is open. clean fuel.
5. If step 4 does not correct the problem, replace the Seal the two pump discharge passages on
oil pressure switch. the top surfaces of the float bowl with two
No gasket is used between the choke cover and fingers while pushing the pump assembly
the choke h o u sin g due to g ro u n d in g slowly into the pump well.
requirements. The pump assembly should not travel
to the bottom of the well. The only
movement should be the compressing
DUAL CAPACITY PUMP CHECK of the duration spring.
(E4MED ONLY) If the pump assembly moves down in
the well, the pump cup may be worn,
1. B rin g the e n g in e to n orm al o p e ra tin g hardened or damaged, the pump well
temperature. may be worn or scored, the pump
2. With the ignition off, actuate the throttle lever discharge plug may be leaking, the
several times and observe the fuel stream. The dual capacity pump solenoid plunger
stream should be strong and consistent. may be stuck, the pump valve may not
3. Run the engine to refill the float bowl. be seating correctly, or the valve
4. With the ignition on, actuate the throttle lever gasket may be leaking.
several times and observe the fuel stream. Less Connect the dual capacity pump solenoid
fuel should be coming from the pump because connector.
the solenoid is energized. Disconnect the dual pump solenoid coolant
5. If the pump stream does not change and appears temperature switch connector and jump it to
to be strong and consistent, fuel is not being ground.
bypassed by the pump circuit. With the ignition on and the engine off,
D is c o n n e c t the s o le n o id c o o la n t slowly move the pump assembly into the
temperature switch connector and jump it to pump well until fuel is visible at the top of
ground. the passages.
Repeat step 4. Remove the pump assembly and continue
If less fuel comes from the pump, to watch fuel in the passages. The fuel level
check cooling system operation and should not go down.
the coolant temperature switch for If the level b e g in s to drop, the
opens. discharge ball may be missing or not
If the pump stream remains the same, seating correctly, damaged, or needs
check wiring for opens or shorts. to be restaked. It may also indicate
Disconnect the mixture control solenoid and that the check ball in the pump valve is
the d ua l c a p a c ity pum p s o le n o id not seating properly.
connectors. C heck dual c a p a c ity pum p system
Remove the air horn assembly and gasket. operation.
Remove the dual capacity solenoid from the
flo a t bowl and co nn e ct the so le no id
connector. IDLE STOP SOLENOID CHECK
With the ignition on and the coolant switch
lead grounded, the solenoid should be A non-functioning idle stop solenoid (if equipped)
energized and the solenoid plunger should could cause stalling or rough idle when the air
extend. Replace the solenoid if it does not conditioning (if equipped) is turned on.
extend. 1. Turn the ignition on but do not start the
Check the pump valve and passages for dirt engine. Turn the air conditioning switch on.
or obstructions. 2. Open the throttle momentarily to allow the
Check pump system operation. solenoid plunger to extend.
6. If the pump stream does not change and appears 3. Disconnect the wire at the solenoid. The
to be weak or irregular, fuel is leaking in the pump plunger should pull back from the throttle
circuit. lever.
Disconnect the mixture control solenoids 4. Connect the solenoid wire. The plunger
and the dual capacity pump solenoid should move out and contact the throttle
connectors. lever.
CARBURETORS 6C1-47
5. If the plunger does not move in and out, 3. Accelerator linkage.

check for voltage across the feed wire. 4. Transmission detent cable.
If the voltage is 12 to 15 volts, replace the 5. Cruise control linkage (if equipped).
solenoid. 6. All necessary vacuum hoses.
If the voltage is low, locate the cause of the Make note of the hose routing.
open circuit in the solenoid feed wire. 7. Fuel line at the carburetor inlet.
8. All necessary electrical connectors.
THROTTLE KICKER CHECK 10. Carburetor from the engine.
11. Insulator gasket.
Tool Required:
J-23738-A, Hand Held Vacuum Pump.
Install or Connect
1. Hold the throttle half way open to allow the
plunger to extend fully.
1. Insulator gasket.
Apply 68 kPa (20-inches Hg) vacuum to the
2. Carburetor on the engine.
throttle kicker.
3. Apply finger pressure to the plunger to see if it is
fully extended. If not, replace the throttle kicker. Tighten
4. Observe the vacuum gage. The vacuum should
hold for at least 20 seconds. If not, replace the
Long bolts to 9 N m (7 ft. lbs.).
throttle kicker.
Short bolts to 15 N m (11 ft. lbs.
Release the vacuum to the throttle kicker.
4. All necessary electrical connectors.
Apply finger pressure to the plunger to see if it
5. Fuel line to the carburetor inlet.
has returned to its retracted position. If not,
6. Vacuum hoses.
replace the throttle kicker.
7. Cruise control linkage (if equipped).
CARBURETOR ADJUSTMENTS
10. Air cleaner.
All on-vehicle adjustments are in DRIVEABILITY 11. Negative battery cable.
AND EMISSIONS CARBURETED (SEC. 6E8).
CARBURETOR REPLACEMENT
Raise the hood and cover the fenders.

2. Air cleaner.
SPECIFICATIONS
CAR BURETOR MODE LS 1ME AND 1MEF

CARBURETOR FLOAT METERING CHOKE ROD VACUUM UNLOADER
PART LEVEL ROD CAM ADJ BREAK
NUMBER m/(lnches) mm/(lnches) mm/(lnches) mm/(lnches) mm/(lnches)
17081009 8.7/(11/32) 2.3/(.090) 7.0/(.275) 10.0/(.400) 13.2/(.520)
17084329 8.7/(11/32) 2.3/(.090) 7.0/(.275) 10.0/(.400) 13.2/(.520)
17085009 8.7/(11/32) 2.3/(090) 7.0/(.275) 10.0/(.400) 13.2/(.520)
17085036 8.7/(11/32) 2.3/(.090) 7.0/(.275) 10.0/(.400) 13.2/(.520)
17085044 8.7/(11/32) 2.3/(.090) 7.0/(.275) 10.0/(.400) 13.2/(.520)
6C1-48 CARBURETORS
MODEL M4MC/M4ME CARBURETORS
FAST
CARBU FLOAT PUMP PUMP AIR CHOKE IDLE VACUUM VACUUM AIR UN- PROPANE
RETOR LEVEL ROD ROD VALVE COIL CAM BREAK BREAK VALVE LOAD ENRICH
PART mm (Inches) SETTING LOCA SPRING LEVER (CHOKE FRONT REAR ROD ER MENT
NO. 2/32 mm (Inches) TION (Turns) ROD) mm (Inches) 4 SPEED
2.5 2 .5 3 .5
17085000 9.5 (12/32) 7.0 (9/32) INNER 7/8 .120 46 24 30 0.6 (.025) 40
17085001 9.5 (12/32) 7.0 (9/32) INNER 1 .120 46 23 30 0.6 (.025) 40
17085003 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 23 0.6 (.025) 35
17085004 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 23 0.6 (.025) 35
17085206 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 26 0.6 (.025) 39 20
17085208 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 38 0.6 (.025) 39 10
17085209 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 20 26 36 0.6 (.025) 39 50
17085210 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 38 0.6 (.025) 39 10
17085211 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 20 26 36 0.6 (.025) 39 50
17085212 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 23 0.6 (.025) 35
17085213 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 23 0.6 (.025) 35
17085215 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 26 0.6 (.025) 32
17085216 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 38 0.6 (.025) 39
17085217 10.0 (13/32) 7.0 (9/32) INNER 1/2 .120 20 26 36 0.6 (.025) 3 9
17085219 10.0 (13/32) 7.0 (9/32) INNER 1/2 .120 20 26 36 0.6 (.025) 39
17085220 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 20 26 0.6 (.025) 3 2 75
17085221 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 20 26 0.6 (.025) 32 75
17085222 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 36 0.6 (.025) 39 20
CARBURETORS 6C1-49
MODEL M4MC/M4ME CARBURETORS
FAST
CARBU FLOAT PUMP PUMP AIR CHOKE IDLE VACUUM VACUUM AIR UN- PROPANE
RETOR LEVEL ROD ROD VALVE COIL CAM BREAK BREAK VALVE LOAD ENRICH
PART mm (Inches) SETTING LOCA SPRING LEVER (CHOKE FRONT REAR ROD ER MENT
NO. 2/32 mm (Inches) TION (T urns) ROD) mm (Inches) 4 SPEED
2.5 2.5 3.5
17085223 10.0 (13/32) 9.5 (3/8) OUTER 1/2 .120 20 26 36 0.6 (.025) 39 50
17085224 10.0 (13/32) 7.0 (9/32) INNER 1/2 .120 20 26 36 0.6 (.025) 39 20
17085225 10.0 (13/32) 9.5 (3/8) OUTER 1/2 .120 20 26 36 0.6 (.025) 39 50
17085226 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 24 0.6 (.025) 32 20
o
17085227 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 24 0.6 (.025) 32 20
ro

o
17085228 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 24 0.6 (.025) 39 30
17085229 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 24 0.6 (.025) 39 30
17085230 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 0.6 (.025) 32 20
17085231 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 0.6 (.025) 32 40
17085235 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 26 0.6 (.025) 39 80
17085238 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 20 26 0.6 (.025) 32 75
C\J
O
o
17085239 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 26 0.6 (.025) 32 75
17085283 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 24 0.6 (.025) 32 20
17085284 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 26 0.6 (.025) 32 20
17085285 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 20 24 0.6 (.025) 32 20
17085290 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 24 0.6 (.025) 39 30
17085291 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 46 26 0.6 (.025) 39 100
17085292 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 24 0.6 (.025) 39 30
17085293 10.0 (13/32) 9.5 (3/8) OUTER 7/8 .120 46 p 26 0.6 (.025) 39 100
17085294 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 26 0.6 (.025) 39
CVJ
to
o
17085298 10.0 (13/32) 7.0 (9/32) INNER 7/8 .120 46 0.6 (.025) 39
6C1-50 CARBURETORS
MODEL E4ME CARBURETOR
IDLE AIR
MIXTURE IDLE VALVE CHOKE CHOKE VACUUM VACUUM
CARBU FLOAT LEAN NEEDLE AIR SPRING STAT LINK BREAK BREAK AIR UN
RETOR LEVEL MIXTURE (NO. OF BLEED (NO. OF LEVER CAM FRONT REAR VALVE LOADER
NUMBER 2/32 SCREW TURNS) VALVE TURNS) 2.5 2.5 3.5 ROD 4
14/32 1.304 SEE 1.756 .120
C\J
O
17085502
o
7/8 26 36 .025 39
(11.0 mm) Gage NOTE Gage Gage
14/32 1.304 SEE 1.756 .120

17085503 7/8 20 26 36 .025 39
14/32 1.304 SEE 1.756 .120

17085506
CO
CO
o
(11.0 mm)
1 20 27 36 .025
Gage NOTE Gage Gage
14/32 1.304 SEE 1.756 .120

17085508 1 20 27 36 .025 36
14/32 1.304 SEE 1.756 .1 2 0
17085524
CVJ
O
o
CO
CD
O
(11.0 mm)
1 25 .025 36
Gage NOTE Gage Gage
14/32 1.304 SEE 1.756 .1 2 0

17085526
CO
to
1
0
(11.0 mm) 20 25 36 .025
Gage NOTE Gage Gage
NOTE: Preset 3 Turns, Final Adjustm ent On Vehicle
TH R O rrLE POSITION SENSO R (TPS)

TPS VOLTAGE
ENGINE THROTTLE
0.1 VOLT
F (LF3) .41 Volts Curb Idle
L (LS9) .41 Volts Curb Idle
N (LB1) .25 Volts Curb Idle
SPECIAL TOOLS
J-9789-D Carburetor Gage Set

J-9789-90 Float Level T Scale
J-9789-111 Bending Tool
J-9789-118 Carburetor Stand
J-23738-A Hand Held Vacuum Pump
J-26701-A Carburetor Choke Angle Gage
J-26911 Propane Enrichment Device
J-29030-B Idle Mixture Socket
J-34817 Float Positioning Tool Kit
J-34935-1 Float Level Gage
6C2-1
SECTION 6C2
DIESEL FUEL INJECTION
CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 6C2- 2
On-Vehicle S ervice................................................................................................................................................... 6C2- 2
Fuel Filter Replacem ent...................................................................................................................................... 6C2- 2
Idle Speed A djustm e n t........................................................................................................................................ 6C2- 3
Throttle Position Switch Adjustm ent
(LH6 Engine With 700 R4 T ra n s m is s io n )....................................................................................................6C2- 4
Vacuum Regulator Valve Adjustm ent
(LL4 Engine W ith Autom atic Transm ission)............................................................................................... 6C2- 4
Housing Pressure Cold A d v a n c e .....................................................................................................................6C2- 5
Injection Line R eplacem ent................................................................................................................................6C2- 5
Injection Pump R e p la c e m e n t............................................................................................................................6C2- 5
Injection Tim ing A d ju s tm e n t..............................................................................................................................6C2- 9
Marking TDC On The Front H o u s in g .............................................................................................................. 6C2- 9
Injection N o z z le s ..................................................................................................................................................... 6C2-10
Injection Nozzle Replacem ent........................................................................................................................... 6C2-10
Injection Nozzle T e s ts ........................................................................................................................................ 6C2-10
Injection Pump On-Vehicle S e rv ic e .....................................................................................................................6C2-12
Pump Cover And/O r Guide Stud Seal Replacem ent.................................................................................... 6C2-12
Throttle Shaft Seal R e p la ce m e n t..................................................................................................................... 6C2-14
Shutdown And/Or Cold Advance Solenoid Replacement............................................................................6C2-16
Side Cover Gasket Replacement....................................................................................................................... 6C2-17
Injection Pump Off-Vehicle Service ...................................................................................................................6C2-17
Advance Pin Hole Plug Seal Replacement......................................................................................................6C2-17
Advance Piston Seals Replacem ent.................................................................................................................6C2-17
Hydraulic Head Seal R eplacem ent...................................................................................................................6C2-18
Drive Shaft Seal Replacement........................................................................................................................... 6C2-19
Pressure Testing The Injection Pump .............................................................................................................6C2-19
Special T o o ls ............................................................................................................................................................6C2-20
6C2-2 DIESEL FUEL INJECTION
DESCRIPTION
The 6.2 L diesel engine fuel system is composed of: The injection pump is mounted on top of the engine
Fuel tank under the intake manifold. The pump is driven by the
Mechanical fuel pump camshaft through two gears, one attached to the front
Fuel filter with water sensor and heater of the camshaft and the other attached to the end of
Fuel filter restriction switch the injection pump shaft. These gears are the same
Injection distributor pump size and have the same number of teeth; therefore, the
High pressure lines injection pump shaft turns at the same speed as the
Fuel injection nozzles camshaft. The pump turns in the opposite direction of
Fuel is drawn from the fuel tank by the mechanical the camshaft and crankshaft.
pump which is located on the right side of the engine. The injection pump is a high pressure rotary type
The pump is driven by an eccentric lobe on the cam pump that meters, pressurizes, and distributes fuel to
shaft through a push rod. Fuel is then pumped through the eight injector nozzles. The eight high pressure
the filter/water separator. The filer/water separator is lines are all the same length although their shape may
located on the engine side of the cowl (C-K models) or be different. This prevents timing differences between
under the rear of the air cleaner (G-P models). The fuel cylinders. Injection lines should not be bent to ease
is then transferred to the injection pump. removal.
ON-VEHICLE SERVICE
FUEL FILTER REPLACEMENT
The fuel filter on C-K models is located on the en
gine side of the cowl.
The fuel filter on G-P models is mounted on the rear
of the inlet manifold under the air cleaner. It is accessi
ble by removing the engine cover.
The fuel tank cap to release pressure or vacuum

in the tank.
The bail wires (1) using a screwdriver.
Drain fuel from the filter by opening both the air
bleed and water drain valves and allowing fuel to
drain into an appropriate container.
Filter.
Clean
Any dirt from the fuel port sealing surface of the A. A ir Bleed
filter adapter and the new filter. B. Fuel Filter/Water Separator
C. Water Drain
|~H| Install or Connect (Figures 1 and 2) 1. Bail Wires
1. New filter. B-08123

2. The bail wires.
Close the water drain valve and open the air Figure 1Fuel Filter on C-K Truck
bleed.
3. A 3.18 mm (1/a inch) inside diameter hose to the NOTICE: If the engine is to be cranked, or
air bleed port and the other end into a suitable starting attem pted with the air cleaner re
container. moved, care must be taken to prevent material
Disconnect the fuel injection pump shut off sole from being pulled into the air inlet manifold
noid wire. which could result in engine damage.
DIESEL FUEL INJECTION 6C2-3
A. Front
B. Clockwise Rotation
C. Power Test Light Or Ohmmeter
D. IGN (Pink Wire)
E. EGR (Yellow Wire)
F. Optional Test Location
G. EPR (Blue or Violet Wire)
F-0008
Figure 4Testing The TPS For Continuity
Crank the engine for 10-15 seconds and then wait ]? Inspect
one minute for the starter motor to cool. Repeat
until clear fuel is observed coming from the air Fuel filter for leaks.
bleed.
Close the air bleed.
4. Injection pump solenoid wire. IDLE SPEED ADJUSTMENT
5. Fuel tank cap.
CURB IDLE SPEED (Figure 3)
Start the engine and allow it to idle for five min
Tool Required: J-26925, Tachometer
utes.
2. Engine must be at normal operating temperature
with the air cleaner on and all accessories turned
off.
3. Install J-26925 or equivalent per manufacturers
instructions.
4. Adjust the low idle speed screw (2) on the fuel
injection pump to obtain the curb idle speed
shown on the Emission Control Information label.
FAST IDLE SPEED (Figure 3)

Tool Required: J-26925, Tachometer
2. Engine must be at normal operating temperature
with the air cleaner on and all accessories turned
off.
3. Install J-26925 or equivalent per manufacturers
instructions.
4. Remove the connector from the fast idle solenoid.
2. Loosen the mounting screws that hold the TPS.
3. Connect an ohmmeter or test light to the IGN
(pink) and EGR (yellow) terminals of the TPS (fig
ure 4).
4. Insert the proper switch closed gage block
between the gage boss on the injection pump
and the wide open stop screw on the throttle shaft
(figure 5).
Refer to the Emission Control Information
label for correct gage block.
5. Rotate the throttle lever and hold the wide open
stop screw against the gage block.
6. Rotate the TPS until there is continuity between
the terminals.
7. Hold the TPS and tighten the mounting screws to
6 N m (53 in. lbs.).
8. Return the throttle lever to the idle position and
remove the gage block.
9. Insert the proper switch open gage block and
rotate the throttle lever against the block. There
5. Connect an insulated jum per wire from the should be no continuity. If there is continuity,
positive battery terminal to the solenoid terminal. repeat steps 1 through 9.
This will energize the solenoid. Refer to the Emission Control Information
6. Open the throttle momentarily to energize and label for correct gage block size.
fully extend the fast idle solenoid plunger.
10. Remove the gage block and ohmmeter.
7. Adjust the extended plunger (3) by turning the
11. Connect the TPS connector.
hex head to obtain the fast idle speed shown on
the Emission Control Information label.
8. Remove the jumper wire and install the connector
to the fast idle solenoid.
VACUUM REGULATOR VALVE
ADJUSTMENT (LL4 ENGINE WITH
AUTOMATIC TRANSMISSION)
THROTTLE POSITION SWITCH
ADJUSTMENT (LH6 ENGINE WITH Tool Required: J-33043, Gage Block
700 R4 TRANSMISSION) 1. Loosen the vacuum regulator valve (VRV) so it is
free to rotate on the pump.
Tool Required: J-33043, Gage Block 2. Attach a vacuum source of 67 5 kPa (20 inches
1. Disconnect the throttle position switch (TPS) Hg 1.5 inch Hg) to the bottom vacuum port of
connector. the VRV.
3. Attach a vacuum gage to the top vacuum port
(figure 6).
4. Insert the proper gage block between the gage
boss on the injection pump and the wide open
stop screw on the throttle lever (switch on
position) (figure 5).
label for correct gage block size.
5. Rotate the throttle shaft and hold it against the
gage block.
NOTICE: Valve must be set while rotating the

valve body clockwise only.
6. Slowly rotate the vacuum regulator valve body

clockwise (facing the valve) until the vacuum
gage reads 27 + 2 kPa (8 0.6 inches Hg). Hold
the valve body at this position and tighten the
mounting screws to 6 N m (54 in. lbs.).
A. Left Bank
B. Right Bank
B-08130
Figure 7Fuel Injection Lines
Check by allowing the throttle shaft to return to INJECTION LINE

the idle stop position. Then rotate the throttle
shaft back against the gage block and read the
REPLACEMENT
vacuum gage. The gage should read 27 2 kPa
Clean
(8 0.6 inches Hg). If vacuum is outside of limits,
reset the valve.
All line fittings that will be loosened or removed.
HOUSING PRESSURE Tool Required: J-29664-1, Protective Covers

COLD ADVANCE 1. Battery negative cables.
2. Engine cover (G-Van only).
The Housing Pressure Cold Advance feature 3. Air cleaner at the valve cover.
advances the injection timing about four degrees 4. Crankcase ventilator bracket.
during cold operation. This provides better cold starts, 5. Intake manifold bolts.
improved cold idle, and emission control.
It may be necessary to loosen the vacuum
pump hold down clamp and rotate the pump
The circuit is actuated by a coolant temperature
to gain access to all intake manifold bolts.
switch on the rear of the right cylinder head. The
6. Injection line clips.
switch is calibrated to open the circuit at 35C (95F).
7. Intake manifold.
Below the switching point, timing is advanced by
decreasing housing pressure from 68.95 kPa (10 psi) to Install J-29644-1 to the intake ports.
zero. Above the switching point, the housing pressure 8. Injection line clips at the loom brackets.
is returned to 68.95 kPa (10 psi). The fast idle solenoid Raise the vehicle (left bank of G-Van only).
is energized by the same switch. 9. Injection lines at the nozzles.
Cap the lines and nozzles immediately.
Do not bend injection lines.
10. Injection lines at the pump.
Cap the lin e s and the pum p fittin g s

immediately.
Tag the lines for installation.
[*[ Install or Connect (Figures 7 and 8)
1. Injection lines at the pump.

Uncap the lines and pump fittings.
Refer to the tags for correct installation.
Raise the vehicle (left bank of G-Van only).
2. Injection lines at the nozzles.
Uncap the lines and nozzles.
Tighten
Fittings to 25 N m (19 ft. lbs.).

3. Injection line clips at the loom brackets.
4. Intake manifold.
Remove J-29664-1.
5. Injection line clips.
Tighten

7. Crankcase ventilator bracket.
8. Air cleaner.
9. Engine cover (G-Van only).
10. Battery negative cables.
INJECTION PUMP
REPLACEMENT
C-K TRUCK
Tool Required: J29664-1, Protective Covers

2. Intake manifold.
Refer to 6.2 LITER DIESEL (SEC. 6A7).
3. Injection lines.
A. Cyl nder Number 8 4. Accelerator cable at the injection pump (figure 9).
B. Cyl nder Number 7 5. Detent cable (if equipped).
C. Cyl nder Number 2 6. Fuel return line at the top of the injection pump.
nder Number 6 7. Fuel inlet line from the injection pump.
D. Cyl
nder Num ber 5 8. All necessary wires and hoses from the injection
E. Cyl
nder Number 4 pump.
F. Cyl
nder Number 3 9. A ir co n d itio n in g hose re taine r bracket (if
G. Cyl
nder Number 1 equipped).
H. Cyl
10. Oil fill tube (includes CDR valve vent hose).
11. Grommet.
Scribe or paint a mark on the front cover
B-08131
and the injection pump flange.
Rotate the engine to gain access to the bolts
Figure 8Injection Line Routing that hold the driven gear to the injection
pump.
4. Drive gear to injection pump bolts (10) (figure 11).

A. Accelerator Cable
B. Detent Rod (700-R4 Only)
a Tighten

5. Grommet.
6. Oil fill tube including the CDR valve vent hose.
7. A ir co n d itio n in g hose re taine r bracket (if
equipped).
8. Fuel feed line at the injection pump.
Tighten
Fitting to 25 N m (20 ft. lbs.).

9. Fuel return line to the top of the injection pump.
B-08132 10. Detent cable (if equipped).
11. All necessary wires and hoses.
Figure 9Accelerator Linkage
13. Injection lines.
Access is gained through the oil filler
neck hole (figure 10).
12. Bolts (10).
13. Nuts (11) (figure 11). G-VAN
14. Pump.
Cap all open lines and nozzles. + + Remove or Disconnect
15. Gasket (12).
Tool Required: J-29664-1, Protective Covers
0 Install or Connect 1.
2.
Engine cover.
1. New gasket (12). 3. Intake manifold.
2. Injection pump to the front cover. Refer to 6.2 LITER DIESEL (SEC. 6A7).
Align the locating pin on the pump hub (14) 4. Air cleaner inlet hose.
with the slot in the injection pump driven Rotate the snorkel up.
gear (13) (figure 12). 5. Hood latch.
Align the timing marks (figure 13). 6. Hood latch cable and move it aside.
3. Nuts (11) (figure 11). 7. Windshield washer bottle.
8. Fan shroud bolts.
$ Tighten 9. Upper fan shroud.
10. Rubber hose from the oil fill tube.
Nuts to 40 N m (30 ft. lbs.). 11. The oil fill tube nuts.
Check the tim ing mark alignm ent 12. The oil fill tube.
before fully torquing the nuts. 13. The oil fill tube grommet.
14. The drive gear to injection pump bolts (10) (figure
10).
Rotate the engine as necessary.
15. Fuel filter and bracket including the line to the
injection pump.
16. Wire looms from the injection lines.
17. Injection lines from the brackets.
18. The oil pan dipstick tube at the left cylinder head.
19. Electrical connections at the injection pump.
20. Detent cable (if equipped).
22 . Injection lines.
10. B-08133
23. Fuel return line.
Scribe or paint a mark on the front cover and the
Figure 10Pump Drive Gear Bolts injection pump flange.
A. Injection Pump Gear ^

B. Alignm ent Mark
C. Cam Gear
10. Bolt
11. Nut
12. Gasket
14. Pump Hub B-08134
Figure 11Injection Pump Installation
24. Pump to front cover attaching nuts (11) (figure 11).

25. Injection pump.
Cap all open discharge fittings.
26. Gasket (12).
Install or Connect

1. New gasket.
2. Injection pump to the front cover.
Align the locating pin on the pump hub with
the slot in the injection pump driven gear
(figure 12).
\
3. Nuts (11).
13. Driven Gear
14. Pump Hub B-08135 a Tighten

Figure 12Injection Pump Locating Pin Check the tim ing mark alignm ent
before fully torquing the nuts.
4. Drive gear to injection pump bolts (10).
Tighten

6. Injection lines.
8. Detent cable (if equipped).
9. Electrical connections at the injection pump.
10. The oil pan dipstick tube at the left cylinder head.
11. Injection lines to the brackets.
12. Wire looms to the injection lines.
13. Fuel filter and bracket including the line to the
injection pump.
14. The oil fill tube grommet.
15. The oil fill tube.
16. The oil fill tube nuts.
17. Rubber hose to the oil fill tube.

19. Fan shroud bolts.
21. Hood latch cable.
22. Hood latch.
23. Air cleaner inlet hose.
25. Engine cover.
INJECTION TIMING
ADJUSTMENT
For the engine to be properly timed, the marks on 9. Strike the scriber with a mallet to mark TDC on
the top of the engine front cover must be aligned with the front housing.
the marks on the injection pump flange (figure 13). The 10. Remove J-33042.
engine must be off when the timing is reset. On
Federal models, align the scribe marks. On California +- Install or Connect
models, align the half circles.
1. Gasket.
Adjust 2. Injection pump.
3. Nuts (finger tight).
1. Injection timing. 4. One 8 mm bolt to attach the gear to the pump
Loosen the three pump retaining nuts. hub.
Align the mark on the injection pump with
the mark on the front cover. Tighten
Tighten Bolt to 25 N m (20 ft. lbs.).

Injection pump nuts to 40 N-m (30 ft. lbs.).
Pump retaining nuts to 40 N m (30 ft. lbs.). Align the timing mark on the injection
2. Throttle rod. pump flange with the mark on the front
cover.
5. Remaining pump gear attaching bolts.
MARKING TDC ON THE Rotate the engine to gain access to the
FRONT HOUSING bolts.
Tool Required: J-33042, Timing Fixture Tighten

1. Set the engine so that number 1 cylinder is at
TDC (firing). Bolts to 25 N-m (20 ft. lbs.).
2. Install J-33042 in the injection pump location.
Do not use the gasket.
3. The slot in the injection pump gear should be in
the vertical 6 oclock position (figure 14). If not,
remove J-33042 and rotate the engine crankshaft
360 degrees. The timing marks on the gears will
be aligned.
4. Fasten J-33042 to the gear and tighten.
5. Install one 10 mm nut to the upper housing stud
to hold the tool flange.
The nut should be finger tight.
6. Tighten the large bolt (18 mm head) clockwise
(looking at the front of the engine) to 48 N m (35
ft. lbs.).
7. Tighten the 10 mm nut.
8. Check that the crankshaft has not rotated and
that the tools did not bind.
INJECTION NOZZLES
Nozzles used in G models are shorter than nozzles

used on C-K and P models. Attempts to use the incor
rect nozzle will damage the cylinder heads. When re
placing nozzles, reference should be made to the part
number which is stamped on the side of the nozzle
(figure 15).
INJECTION NOZZLE
REPLACEMENT
Remove or Disconnect(Figure 16)
Tool Required: J-29873, Nozzle Socket

2. Fuel line clip.
3. Fuel return hose.
4. Fuel injection line.
INJECTION NOZZLE TESTS
Cap the nozzle and lines.
Nozzle testing is comprised of the following checks:
NOTICE: When removing an injection nozzle, Nozzle opening pressure
use J-29873. Remove the nozzle using the 30 Leakage
mm hex portion (figure 15). Failure to do so
w ill result in damage to the injection nozzle.
5. Injection nozzle using J-29873.
Tool Required: J-29873, Nozzle Socket
NOTICE: When installing an injection nozzle,

use J-29873. Install the nozzle using the 30
mm hex portion (figure 15). Failure to do so
w ill result in damage to the injection nozzle.
1. Injection nozzle using J-29873.
Tighten
Nozzle to 70 N m (50 ft. lbs.).

2. Fuel injection line.
Tighten
A. Cap
Nut to 25 N m (20 ft. lbs.). B. Gasket
3. Fuel return hose. B-08138
4. Fuel line clip.
5. Negative battery cable. Figure 16Injection Nozzles
Chatter Some nozzles may pop while other nozzles

Spray pattern may drip down (this is not leakage).
Each test should be considered independent of the 3. The opening pressure should not fall below the
others (for example, when checking opening pressure, lower limit of 105 bar (1500 psi) on used nozzles.
do not check for leakage). 4. Replace nozzles which fall below the lower limit.
If all of the above tests are satisfied, the nozzle
holder assembly can be re-used. If any one of the tests LEAKAGE TEST
is not satisfied, the complete nozzle holder assembly 1. Further open the shutoff valve at the pressure
must be replaced. The nozzle holder will then be gage 1/2 to 1 1/2 turns).
checked and repaired at a centralized location. 2. Blow-dry the nozzle tip.
Test Lines - 6 x 2 x 400 mm (1.5 mm bore).
Test Fluid - per ISO 4113 (Example: Shell V 1399, CAUTION: When te stin g nozzles, do not
Viscosity 1487C or equivalent). place your hands or arms near the top of the
Kinetic Viscosity at 40 - per ISO 3104: 2,45 - 2.75 nozzle. The high pressure atom ized fuel
mm 7second. s p ra y fro m a n o z z le has s u f f ic ie n t
Test oil temperature during test: 20 - 25C (68F - p en etrating pow er to p un cture fle sh and
77 F). d e s tro y tis s u e and may re s u lt in b lo o d
R efer to the e q u ip m e n t m a n u fa c tu re rs poisoning. The nozzle tip should always be
instructions for exact test procedures. e n c lo s e d in a re c e p ta c le p r e fe r a b ly
1. Connect the nozzle holder assembly to the test transparent, to contain the spray.
line.
2. Place clear plastic tubes on overflow connections
3. Depress the lever of the manual test stand slowly
to prevent leakoff from being confused with actual
until the gage reads a pressure of 95 bar (1400
leak.
psi). Observe the nozzle tip. A drop may form on
3. Close the shutoff valve to the pressure gage.
the end of the nozzle but should not drop off
within a period of 10 seconds.
CAUTION: When te stin g nozzles, do not
4. Replace the nozzle assembly if a drop falls
place your hands or arms near the tip of the
during the 10 seconds.
nozzle. The high pressure atom ized fuel
s p ra y fro m a n o z z le has s u f f ic ie n t CHATTER TEST
penetrating pow er to p un cture flesh and When testing for chatter, it should be noted that the
d e s tro y tis s u e and may re s u lt in b lo od sound (chatter) for new and used nozzles may vary.
poisoning. The nozzle tip should always be This is due to carbonized fuel deposits on the pintle
e n c lo s e d in a r e c e p ta c le , p r e fe r a b ly and nozzle tip of used nozzles. With some used
transparent, to contain the spray. nozzles, chatter is difficult to detect during slow
actuation of the hand lever.
4. Fill and flush the nozzle holder assembly with test Some nozzles may chatter louder than others. As
oil by activating the lever briskly and repeatedly. long as there is chatter, the nozzle is acceptable.
This will apply test oil to all functionally important 1. Close the shutoff lever at the pressure gage.
areas of the nozzle and purge it of air. CAUTION: When te stin g nozzles, do not
place your hands or arms near the top of the
OPENING PRESSURE TEST nozzle. The high pressure atom ized fuel
1. Open the shutoff valve at the pressure gage s p ra y fro m a n o z z le has s u f f ic ie n t
one-quarter turn. p en etrating pow er to pun cture fle sh and
d e s tro y tis s u e and may re s u lt in b lo o d
CAUTION: When te stin g nozzles, do not poisoning. The nozzle tip should always be
place your hands or arms near the top of the e n c lo s e d in a r e c e p ta c le p r e fe r a b ly
nozzle. The high pressure atom ized fuel transparent, to contain the spray.
s p ra y fro m a n o z z le has s u f f ic ie n t
p en etrating pow er to p uncture flesh and 2. Depress the lever of the test stand slowly and
d e s tro y tis su e and may re s u lt in b lo o d note whether chatter noise can be heard.
poisoning. The nozzle tip should always be 3. If no chattter is heard, move the lever faster until
e n c lo s e d in a re c e p ta c le p r e fe r a b ly it chatters. At fast lever movement, the nozzle
transparent, to contain the spray. may make a hissing or squealing sound
rather than the normal chatter. This is acceptable.
2. Depress the tester lever slowly. Note at what 4. These sounds indicate that the nozzle needle
pressure the needle of the pressure gage moves freely and that the nozzle seat, guide, and
stopped. The maximum observed pressure is the pintle are OK.
opening pressure. 5. Replace nozzles that do not chatter.
A pop tester will not deliver fuel fast enough for

SPRAY PATTERN
proper spray pattern analysis. Based on this, this type
This nozzle features a longer nozzle overlap, greater
of nozzle should not be rejected for spray pattern.
pintle to body clearance, greater needle to body
clearance, and an internal wave washer between the
nozzle nut and the nozzle. These features make
objective spray pattern testing difficult.
INJECTION PUMP ON-VEHICLE SERVICE
Refer to figure 17 for injection pump components lo 10. Pump cover seal from the pump cover.
cation.
Install or Connect
PUMP COVER SEAL AND/OR 1. The guide stud with a new washer.
GUIDE STUD SEAL Make sure that the upper extension of the
metering valve spring rides on top of the
REPLACEMENT guide studs.
I Remove or Disconnect Tighten
Tool Required: J-29664, Manifold Cover Set The guide stud to 9.5 N m (85 in. lbs.).
1. Negative battery cables. Overtightening the guide stud may
2. Air cleaner and intake manifold. strip the aluminum threads in the
housing.
Install J-29664 in the cylinder heads.
2. New pump cover seal in the pump cover.
3. Injection pump fuel solenoid wire.
3. The pump cover.
4. Housing pressure cold advance wire.
The screws should not be in the pump
cover.
6. Top attaching bolt and loosen the lower attaching
Position the cover about 6 mm (1/4-inch)
bolt on the fast idle solenoid. Move the solenoid
forward (toward the shaft end) and about 3
aside.
mm (Ve-inch) above the pump (figure 19).
7. Injection pump cover screws.
Move the cover rearward and downward into
position, being careful not to cut the seal.
Clean Hold throttle in the idle position.
4. The cover screws.
Injection pump cover. Be careful not to drop or lose the flat washer
Upper portion of the pump. and spring washer on each screw.
The guide stud area. The flat washer must be against the pump
Place several rags in the engine valley to cover.
catch fuel.
Tighten
NOTICE: Extreme care must be used to keep
foreign material out o f the pump when the Screws to 3.7 N m (33 in. lbs.).
cover is off. If any objects are dropped into 5. Battery negative cables.
the pump, they must be removed before the
engine is started or in je ctio n pum p and Inspect
engine damage could occur.
Turn the ignition switch to the run position
8. Injection pump cover. and touch the pink wire to the solenoid
9. The guide stud and washer. connector. A clicking noise should be heard
Note location of parts prior to removal. as the wire is connected and disconnected.
Observe the position of the metering valve If this clicking is not heard, the linkage may
spring over the top of the guide stud (figure be jammed in the wide open throttle position
18). This position must be exactly duplicated and the engine MUST NOT BE STARTED.
during assembly. If clicking is not heard, remove the cover
^____

/n n
A. Pump Cover
B. Head And Rotor Assembly
C. Cam Advance Screw
D. Timing Line Side Cover
E. Guide Stud
F. Advance Screw Hole Plug
B-08139
Figure 17Injection Pump Components Location
Figure 18Metering Valve Spring Position Figure 19Installing The Injection Pump Cover
and ground the solenoid lead (opposite the

hot lead) and connect the pink wire. With
the ignition switch in the run position, the
solenoid in the cover should move the
linkage. If not, the solenoid must be
replaced. Minimum voltage across the
terminals must be 12.0. Install the cover and
repeat the inspection.
6. Fuel return line, throttle cable, and the return
springs.
7. Fast idle solenoid.
Idle roughness may be observed due to air in the
pump. Engine idling will allow the air to purge.
It may be necessary to shut the engine
down for several minutes to allow air
bubbles to rise to the top of the pump.
10. Intake manifold and air cleaner. Clean
Remover J-29664.
Injection pump cover.
Upper portion of the pump.
THROTTLE SHAFT SEAL The guide stud area.
Place several rags in the engine valley to
REPLACEMENT catch fuel.
+ + Remove or Disconnect NOTICE: Extreme care must be used to keep

foreign material out fo the pump when the
Tools Required: cover is off. If any objects are dropped into
J-29601, Injection Pump Timing Adapter the pump, they must be removed before the
engine is started or injection pump and
J-29664, Manifold Cover Set
engine damage could occur.
1. Negative battery cables.
2. Air cleaner and intake manifold 10. Injection pump cover.
Install J-29664 in the cylinder heads. 11. The guide stud and washer.
3. Injection pump fuel solenoid, housing pressure Note location of parts prior to removal.
cold advance wires, and the fuel return line. Observe the position of the metering valve
4. Throttle rod and the return springs. spring over the top of the guide stud (figure
Mark the position of the TPS switch or VRV 18). This position must be exactly duplicated
for installation. during assembly.
5. Top attaching bolt on the fast idle solenoid. Move 12. Min - max governor assembly (figure 21).
the soleniod aside. R otate the a sse m b ly up to p ro vid e
6. Throttle cable bracket. clearance.
If the idle g ove rn o r s p rin g becom es
7. Throttle shaft advance cam and fiber washer.
disengaged from the throttle block, it must
Install J-29601 over the throttle shaft with
be reinstalled with the tightly wound coils
the slots on the tool engaging the pin (figure
toward the throttle block.
20). Put the spring clip over the throttle shaft
13. The throttle shaft assembly.
advance cam and tighten the wing nut. Pull
the tool off of the shaft without loosening the
wingnut This provides proper advance cam L* Inspect
alignment for assembly.

Throttle shaft ror unusual wear or damage.
Loosen the face cam screw. Throttle shaft bushings for damage or
Drive the pin from the throttle shaft. unusual wear or leaks.
8. Any burrs from the throttle shaft that may have Remove the pump and send it to the
resulted from pin removal. local Stanadyne dealer if bushing
9. Injection pump cover screws. replacement is necessary.
Figure 22Setting Advance Cam To

Housing Clearance
A. Min - Max Governor Assembly Tighten

B. Min - Max Governor Sleeve
C. Seal Cam screw to 3.1 N-m (30 in. lbs.).
D. Throttle Shaft Squeeze the throttle shaft.
Secure the screw with Loctite 290 or
B-08140
equivalent.
Remove J-29601.
Figure 21Injection Pump Cover Removed 7. The guide stud with a new washer.
Make sure that the upper extension of the
14. The throttle shaft seals. metering valve spring rides on top of the
Do not attempt to cut the seals, as nicks in guide stud.
the seal seat will cause leakage.
Tighten
The guide stud to 9.5 N m (85 in. lbs.).
Tools Required: Overtightening the guide stud may
strip the aluminum threads in the
J-29601, Injection Pump Timing Adapter
housing.
J-33198, Synkut Oil Seal Lubricant
8. New pump cover seal in the pump cover.
1. New throttle shaft seals. 9. The pump cover.
Use care not to cut the seal on the sharp The screws should not be in the pump
edges of the shaft. cover.
Apply J-33198 or a light coating of clean Position the cover about 6 mm (1/4-inch)
chassis grease to the seals. forward (toward the shaft end) and about 3
2. The throttle shaft to the point where the min - max mm (Vs-inch) above the pump (figure 19).
governor assembly will slide back onto the shaft. Move the cover rearward and downward into
3. Throttle shaft and governor into position. position, being careful not to cut the seal.
10. The cover screws.
Rotate the min - max governor assembly
Be careful not to drop or lose the flat washer
downward (figure 21).
and spring washer on each screw.
4. New mylar washer, the throttle shaft advance
The flat washer must be against the pump
cam, and a new throttle shaft drive pin (figure 20).
cover.
Do not tighten the cam screw.
5. J-29601 over the throttle shaft with the pin in the $ Tighten
slots and the spring clip over the advance cam.
6. A 0.005-inch feeler gage between the white Screws to 3.7 N-m (33 in. lbs.).
washer on the throttle shaft and the pump 11. TPS switch or VRV.
housing (figure 22). 12. Battery negative cables.
Inspect
Turn the ignition switch to the run position

and touch the pink wire to the solenoid
connector. A clicking noise should be heard
as the wire is connected and disconnected.
If this clicking is not heard, the linkage may
be jammed in the wide open throttle position
and the engine MUST NOT BE STARTED.
If clicking is not heard, remove the cover
and ground the solenoid lead (opposite the
hot lead) and connect the pink wire. With
the ignition switch in the run position, the
solenoid in the cover should move the
linkage. If not, the solenoid must be
replaced. Minimum voltage across the
terminals must be 12.0. Install the cover and
repeat the inspection.
13. Fuel return line, throttle cable, and the return
springs.
14. Fast idle solenoid.
A. Shutdown Solenoid Assembly
B. Cold Advance Solenoid
Idle roughness may be observed due to air in the
pump. Engine idling will allow the air to purge. B-08146
It may be necessary to shut the engine
down for several minutes to allow air Figure 23Cold Advance And
bubbles to rise to the top of the pump. Shutdown Solenoids
17. Intake manifold and air cleaner.
Remove J-29664.
Tighten
Nuts to 1.2 N-m (12 in. lbs.).
SHUTDOWN AND/OR COLD
ADVANCE SOLENOID 4. Pump cover.
REPLACEMENT Refer to Pump Cover Seal And/Or Guide

Stud Seal Replacement.
1. Pump cover.
Refer to Pump Cover Seal And/Or Guide
Stud Seal Replacement.
2. Terminal contact nuts.
3. Solenoid.
Note the positions of the insulating washers.
1. Solenoid in the pump cover.

On the shutdown solenoid, make sure that
the linkage is free.
On the cold advance solenoid, make sure
40. Screws
that the plunger is centered so that it will
41. Cover
contact the check ball in the fitting.
42. Gasket B-08147
2. Insulating washers on the terminal studs (where
used).
3. Terminal nuts. Figure 24Side Housing and Drive Group
Inspect Install or Connect (Figure 24)

I*
Solenoid operation prior to installing the 1. Gasket.
pump cover. Use a 12V DC power source. 2. Cover.
3. Screws.
SIDE COVER GASKET Tighten

REPLACEMENT
Screws to 2 N m (18 in. lbs.).
[++I Remove or Disconnect (Figure 24)
1. The two screws (40).

2. Cover (41).
3. Gasket (42).
INJECTION PUMP OFF-VEHICLE SERVICE
Refer to Injection Pump Replacement. Off-vehicle

service operations require a leak test after the repair
has been made. Refer to Pressure Testing The Injec
tion Pump.
ADVANCE PIN HOLE PLUG

SEAL REPLACEMENT
|<-+| Remove or Disconnect (Figure 25)
1. Injection pump.
2. Plug (50).
Tap the plug lightly with a hammer to loosen
it.
3. Seal (51).

49. Cam Advance Pin
1. New seal. 50. Plug
Lubricate the seal. 51. Seal
2. Plug. 52. Spring Side Plug
53. Seal
Tighten 54. Seal
55. Power Side Plug B-08148
Plug to 10 N m (90 in. lbs.).
3. Injection pump.
Figure 25Advance Piston Group
4. Power side advance piston hold plug (55).

ADVANCE PISTON SEALS
5. Seal (4).
REPLACEMENT
|+<-| Install or Connect (Figure 25)
1. New seal (54).
1. Injection pump. Lubricate the seal.
2. Spring side advance piston hold plug (52). 2. Plug (55).
3. Seal (53). 3. Seal (53).
4. Plug (52).
5. Injection pump.
HYDRAULIC HEAD SEAL

REPLACEMENT
1. Injection pump.
2. Throttle shaft and seals.
R efer to T h ro ttle S ha ft Seal
Replacement.
3. Metering valve (figure 26)
4. Housing vent screw assembly (figure 27).
5. Cam advance pin hold plug (50) (figure 25).
6. Seal from the plug.
7. Cam advance pin (49) (figure 25).
8. Head locking screws (figure 28).
Locate the pump assembly so the rear of
the pump is sloping down.
9. Head locating screw and seal (figure 29).
10. Hydraulic head assembly using a twisting motion.
11. O-ring seal.
Install or Connect
1. New o-ring seal to the hydraulic head.

Lubricate the seal.
2. Hydraulic head assembly into the pump housing.
3. Head locking screws loosly (figure 28).
Lubricate the screws.
4. New seal on the head locating screw.
5. Head locating screw (figure 29).
Turn the pump upside down.
Screw to 23 N m (17 ft. lbs.).

6. The advance pin (49) (figure 25).
7. New seal on the advance pin hole plug.
Lubricate the seal.
8. The advance pin hold plug.
Plug to 10 N m (90 in lbs.).

9. Housing vent screw assembly (figure 27).
10. Metering valve (figure 26).
11. Throttle shaft and seals.
R efer to T h ro ttle S h a ft Seal
Replacement.
12. Injection pump.
1. One black seal on the shaft using J-29745-A.

Lubricate the seal protector with J-33198 or
equivalent.
2. The red seal using J-29745-A.
equivalent.
3. The other black seal using J-29745-A.
equivalent.
4. New o-ring retaining clip on the shaft.
5. Drive shaft into the pump.
Make sure the drill points on the drive shaft
end match up with the rotor.
6. Fast idle solenoid bracket.
7. Injection pump.
PRESSURE TESTING THE

INJECTION PUMP
DRIVE SHAFT SEAL Drain all fuel from the pump.
Connect an air line to the pump inlet connection.
REPLACEMENT Make sure the air supply is clean and dry.
Completely immerse the pump in a bath of clean
Remove or Disconnect (Figure 30) test oil.
Seal off the return line fitting.
Tool Required: J-29692-B, Holding Fixture 4. Raise the air pressure in the pump to 137.9 kPa
1. Injection pump. (20 psi). Keep the pump immersed in the oil for 10
2. Fast idle solenoid bracket. minutes to allow any trapped air to escape.
Mount the pump in J-29692-B and tilt it. 5. Watch for leaks after the ten minutes. If the pump
3. The drive shaft from the pump using a rotating is not leaking, reduce the air pressure to 13.8 kPa
motion (alignment pin at the top). (2 psi) for 30 seconds. If there is still no leakage,
increase the pressure to 137.9 kPa (20 psi). If
The shaft is retained by an o-ring.
there are no leaks, the pump is ready for use.
Make sure that no pieces of the o-ring have
broken off in the pump.
4. The drive shaft seals.
Tools Required:
J-29692-B, Holding Fixture
J-29745-A, Shaft Seal Protector
J-33198, Synkut Lubricating Oil
A. Drive Shaft Seals

B-08149
Figure 30Drive Shaft Seals

SPECIAL TOOLS
J-26925 Tachometer
J-29601 Injection Pump Timing Adapter
J-29664-1 Protective Covers
J-29692-B Holding Fixture
J-29745-A Shaft Seal Protector
J-29873 Nozzle Socket
J-33042 Timing Fixture
J-33043 Gage Block
J-33198 Synkut Lubricating Oil
6D-1
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
SUBJECT PAGE
Electrical S y s te m ....................................................................................................................................................... 6D- 2
Electric Choke Heater - Oil Pressure S w itch ........................................................................................................6D- 2
D e s c rip tio n ..............................................................................................................................................................6D- 2
Choke Heater Check...............................................................................................................................................6D- 2
B attery...........................................................................................................................................................................6D- 3
D e s c rip tio n .............................................................................................................................................................. 6D- 3
General In fo rm a tio n ...............................................................................................................................................6D- 4
Diagnosis of B a tte ry ................................................................................................................................................. 6D- 4
Visual In s p e c tio n ................................................................................................................................................... 6D- 4
Hydrometer T e st..................................................................................................................................................... 6D- 4
Load T e s t ................................................................................................................................................................ 6D- 4
Battery On-Vehicle S e rvice ...................................................................................................................................... 6D - 6
Battery Charging P ro c e d u re s ..............................................................................................................................6D- 6
Current Drain T e s t ................................................................................................................................................. 6D- 6
Battery C a b le s ........................................................................................................................................................6D- 6
Battery R e p lace m e n t.............................................................................................................................................6D- 7
Charging S y s te m ........................................................................................................................................................6D- 8
D e s c rip tio n ................................................................................................................................................................ 6D- 8
Diagnosis of Charging S yste m ................................................................................................................................6D-11
Noisy G e n e ra to r..................................................................................................................................................... 6D-11
Electrical T e s ts ........................................................................................................................................................6D-11
Generator On-Vehicle S e r v ic e ................................................................................................................................6D-14
Generator R eplacem ent........................................................................................................................................ 6D-14
Diesel Glow Plug Electrical S yste m ....................................................................................................................... 6D-15
D e s c rip tio n .............................................................................................................................................................. 6D-15
Diagnosis of Glow Plug Electrical S y s te m .......................................................................................................... 6D-18
Circuit C h e c k ..........................................................................................................................................................6D-18
Glow Plug Inhibit S w itc h ...................................................................................................................................... 6D-18
Glow Plug S y s te m ................................................................................................................................................. 6D-18
Glow Plug A fte rsta rt............................................................................................................................................... 6D-18
Glow Plug On-Vehicle S e rv ic e ................................................................................................................................6D-21
Cranking S y s te m ........................................................................................................................................................6D-21
D e s c rip tio n .............................................................................................................................................................. 6D-21
Diagnosis of Cranking S y s te m ................................................................................................................................6D-23
Cranking C ir c u it..................................................................................................................................................... 6D-23
Starter Motor N o is e ............................................................................................................................................... 6D-23
Cranking System On-Vehicle S e r v ic e ...................................................................................................................6D-30
M a in ten a nce ............................................................................................................................................................6D-30
Starter M o tor............................................................................................................................................................6D-30
Starter Motor R eplacem ent.................................................................................................................................. 6D-30
Ignition S y s te m ..........................................................................................................................................................6D-30
D e s c rip tio n .............................................................................................................................................................. 6D-32
Diagnosis of Ignition S y s te m .................................................................................................................................. 6D-38
High Energy Ignition (HEI) S yste m ..................................................................................................................... 6D-38
Electronic Spark Tim ing (HEI/EST) S yste m ......................................................................................................6D-38
Electronic Spark Control (HEI/ESC) S y s te m ....................................................................................................6D-38
Ignition System On-Vehicle S ervice....................................................................................................................... 6D-48
Service P re cau tio ns...............................................................................................................................................6D-48
D istributor R e p la ce m e n t...................................................................................................................................... 6D-48
Ignition T im in g ....................................................................................................................................................... 6D-49
6D-2 ENGINE ELECTRICAL
SUBJECT PAGE
Ignition System On-Vehicle Service (Cont.)
Spark Plug W ire s ...................................................................................................................................................6D-49
Spark Plug Wire R e p la c e m e n t........................................................................................................................... 6D-49
Engine Wire H arness.................................................................................................................................................6D-54
S p e c ific a tio n s .............................................................................................................................................................6D-64
Special T o o ls ..............................................................................................................................................................6D-69
ELECTRICAL SYSTEM
Engine electrical system diagnosis includes the bat a Check Engine or Service Engine Soon lamp on
tery, charging system (generator and related wiring), the instrument panel. Refer to the emissions material
cranking system (starter and related wiring), ignition in Section 6E of this manual for a detailed description
system (distributor, spark plugs, and wiring), and glow of the lamps operation and use as a diagnostic indica
plug system (diesel electrical). tor.
Some vehicles are equipped with an electronic Com For vehicles sold in Canada and equipped with non
puter Command Control system. These vehicles have closed loop engine electrical systems, refer to the ap
propriate Canadian Service Manual Supplement.
ELECTRIC CHOKE HEATER-OIL

PRESSURE SWITCH
DESCRIPTION 4. Check the voltage at the choke heater connection

with the engine running. If the voltage is
All carbureted engines without gage instrumentation approximately 12 to 15 volts, replace the electrical
have a 2-terminal oil pressure switch to control current choke unit.
to the electric choke heater. This switch also provides 5. If the voltage is low or zero, check all wires and
for the lighting of the Oil or Choke indicator lamp. connections. No gasket is used between the
No choke heater relay is used on these vehicles. Refer choke cover and the choke housing because of
to the Body and Chassis Electrical Diagram for choke grounding requirements. If any connections in the
heater and associated indicator lamp circuitry. oil pressure switch circuitry are bad or if the oil
pressure switch is stuck open, the oil warning
lamp will be on with the engine running. Repair
wires or connections as required.
CHOKE HEATER-OIL 6. If all wiring and connections are good, replace
the oil pressure switch.
PRESSURE SWITCH CHECK
1. Allow the choke to cool so that when the throttle
is opened slightly the choke blade fully closes. Do
this with the engine not running and at an
ambient temperature of 27 to 60 C (80 to 140
F).
2. Start the engine and determine the time for the

choke blade to reach full open position. Start the
timer when the engine starts.
3. If the choke blade fails to open fully within 3.5

minutes, proceed with steps 4-5-6 below.
ENGINE ELECTRICAL 6D-3
BATTERY
degree angle in any direction can allow a small amount

of electrolyte to leak out the vent hole.
Do not exceed this 45 degree angle when carrying or
installing the battery.
Evidence of electrolyte leakage does not always
mean the battery is defective.
RATINGS
Batteries are rated according to their reserve
capacity in minutes and their cold cranking power in
amperes. Both methods involve measuring the battery
terminal voltage after a specified time period and
discharge current.
The reserve capacity is defined as the maximum
length of time it is possible to travel at night with
minimum electrical load and no generator output.
Expressed in minutes, it is the time required for a fully
charged 12-volt battery, at a temperature of 27 C (80
F), being discharged at a constant current of 25
amperes, to reach a terminal voltage of 10.5 volts.
The cold cranking ampere (CCA) test measures
the amperage delivered by the battery at -1 8 C (0 F)
for 30 seconds.
1. Built In Hydrometer
Refer to the Specifications at the end of this
section for battery ratings.
B-02396
BUILT-IN HYDROMETER
Figure 1Sealed Battery with The sealed battery has a special temperature
Side Terminals compensated hydrometer built into the cover to show
at a glance the b a tte ry s state -o f-ch arge . The
DESCRIPTION hydrometer has a green ball within a cage which is
attached to a clear plastic rod. The green ball will float
The battery has three major functions in the at a predetermined specific gravity of the electrolyte.
electrical system: first, it provides a source of energy When the green ball floats, it rises within the cage and
for cranking the engine; second, it acts as a voltage positions itself under the rod. Visually a green dot then
stabilizer for the electrical system; and third, it can, for shows in the center of the hydrometer (figure 2). The
a limited time, provide energy when the electrical load built-in hydrometer provides a guide for battery testing
used exceeds the output of the generator. and charging.
When looking at the hydrometer, make sure that the
The sealed battery as shown in figure 1 is standard.
battery has a clean top. A lamp may be needed in
Refer to Specifications at the end of this section for
some poorly-lit areas.
specific application.
1. GREEN DOT VISIBLE: The state of charge is 65
Water never needs to be added to the sealed battery. percent or more of the full charge.
There are no filler caps in the cover. The battery is 2. DARK; GREEN DOT NOT VISIBLE: The state of
sealed, except for small vent holes in the cover. The charge is below 65 percent. Charge the battery
vents allow what small amount of gasses that are until the green dot appears. (Shake the battery
produced in the battery to escape. The special slightly to make the green dot appear after
chemical composition inside the battery reduces charging).
gassing to a very small amount at normal charging 3. CLEAR OR LIGHT YELLOW: The fluid level has
voltages. Besides reducing gassing, the special dropped below the bottom of the hydrometer. This
chemistry greatly reduces the possibility of overcharge can be caused by a broken case, tipping of the
damage. battery, normal wearout, or overcharging because
Keep the battery in an upright position to prevent of a problem in the electrical system. Check the
electrolyte leakage. Tipping the battery beyond a 45 system and replace the battery.
4. Problems in the charging system such as shorts,

o
slipping fan belt, or worn generator or regulator
parts.
& d> 5. Loose or poor battery cable-to-post connections,
previous improper charging of a rundown battery,
or loose hold-downs.
6. High-resistance connections in the cranking
system.
7. Electronic devices draining the battery when the
vehicle is parked for a long period of time.
A B Disconnect the negative cable if the vehicle will
2. Green Dot
3. Dark be stored for more than 30 days.
4. Clear
A. 65% or Above State of Charge Electrolyte Freezing
B. Below 65% State of Charge The freezing point of electrolyte depends on its
C. Low Level Electrolyte B-06941 specific gravity. Since freezing may ruin a battery,
protect it against freezing by keeping it in a charged
condition.
Figure 2Built-In Hydrometer
Carrier And Hold-Down
GENERAL INFORMATION The carrier and hold-down should be clean and free
from corrosion before battery installation.
COMMON CAUSES OF MALFUNCTION The carrier should be in a sound mechanical
If testing shows the battery to be in good condition condition so that it will support the battery securely and
but the battery doesnt perform satisfactorily, check for keep it level. Make certain there are no foreign objects
the following: in the carrier before installation.
1. Vehicle accessories left on overnight. To prevent the battery from shaking in its carrier,
2. E xten d ed slo w -sp e ed d riv in g w ith many tighten the hold-down bolts. However, do not tighten
accessories turned on. the bolts to where the battery case or cover is placed
3. The vehicle electrical load is more than the under a severe strain.
generator output, particularly with the addition of
aftermarket equipment.
DIAGNOSIS OF BATTERY
In a diesel-equipped vehicle, check and test each LIGHT OR BRIGHT INDICATOR: Do not charge,
battery separately. test, or jump start the battery. Replace the battery.
VISUAL INSPECTION LOAD TEST

Check for obvious damage such as a cracked or If the battery is in the vehicle, make sure the engine
broken case or cover that could perm it loss of control switch is off. If there is more than one battery,
electrolyte. If damaged, replace the battery. Determine check each separately.
the cause of the damage and correct.
1. Disconnect the battery cables from the terminals.
2. Install adapter AC-Delco ST 1201 or equivalent
(figure 3).
HYDROMETER TEST
3. If adapters are not available, use a 3/e-inch 16
GREEN DOT VISIBLE: If the hydrometer has a UNC bolt and stainless steel nut (figure 4). Finger
GREEN DOT visible the battery is ready for testing. tighten. Contact must be made through the lead
Proceed to Load Test . pads at the face of the terminals, not through the
threads of the bolt.
DARK; GREEN DOT NOT VISIBLE: Charge the
battery as outlined under the heading Battery 4. Install a voltmeter and battery load tester to the
Charging Procedure later in this section. adapters.
7. Case
8. 3/a-inch 16 UNC Nut
9. 3/8-inch 16 UNC Bolt
10. Electrical Contact
B-09715
Figure 3Testing and Charging Figure 4Testing and Charging Using

Terminal Adapter Bolt and Nut
5. Remove the surface charge from recently

charged batteries by applying a 300-ampere load Voltage And Temperature Chart
across the adapters for 15 seconds.
6. Do not remove the surface charge from batteries
which have been in storage. MINIMUM
7. Turn the load off and wait 15 seconds for the TEMPERATURE ________ ___ VOLTAGE
battery to recover. 21 C (70 F & Above)................................................ 9.6
8. Apply the specified load selected from the chart 10 C (50 F ) ............................................................... 9.4
in Specifications . Observe the battery voltage -1 C (30 F ) ............................................................... 9.1
after 15 seconds with the load connected, then -10 C (15 F ) ............................................................. 8.8
turn off the load. -18 C (0 F ) ............................................................... 8.5
9. If the battery voltage does not drop below the
minimum voltage as shown in the Voltage and
Temperature Chart following, the battery is good
and should be returned to service. (The battery
temperature must be estimated by feel and by the
temperature the battery has been exposed to for
the preceeding few hours.) If the battery voltage
drops below the minimum voltage listed, replace
the battery.
BATTERY ON-VEHICLE SERVICE
BATTERY CHARGING charging current causes the electrolyte acid

content to increase, the charging current will
PROCEDURES likewise increase,
d. Charger Capacity Example: A charger
The following basic rules apply to any sealed battery
which can supply only 5 amperes will
charging situation:
require a much longer period of charging
1. Do not charge a battery if the hydrometer is clear
than a charger that can supply 30 amperes
or light yellow replace the battery.
or more.
2. Charge rates between 3 and 50 amperes are
satisfactory as long as spewing of electrolyte
does not occur or the battery does not feel over CURRENT DRAIN TEST
52 C, (125 F). If spewing occurs or temperature
exceeds 52 C (125 F), the charging rate must If a battery needs recharging and no cause is
be reduced or tem porarily halted to permit evident, check the vehicle for excessive current drain.
cooling.
Estimate battery temperature by touching or + + Remove or Disconnect
feeling the battery case.
3. The battery is sufficiently charged when the Negative battery cable (both negative cables on
green dot in the built-in hydrometer is visible. No diesels).
further charging is required. Shake or tilt the
batter at hourly intervals during charging to mix
Install or Connect
the electrolyte and see if the green dot appears.
4. Battery charging consists of a charge current in Tool Required:
amperes for a period of time in hours. Thus a
J-29125 Multimeter.
25-ampere charging rate for 2 hours would be 50
1. Battery side terminal adapter in the negative
ampere-hour charge to the battery. In most cases,
terminal or nut and bolt as described earlier in
batteries whose load test values are less than
this section.
200 amperes will have the green dot visible after
at least a 50 ampere-hour charge. Most batteries 2. A 3/a-inch 16 UNC nut on the negative battery
whose load test values are greater than 200 cable terminal attaching screw.
amperes will have the green dot visible after at 3. Clip of a jumper wire to the negative battery
least a 75 ampere-hour charge. In the event that terminal adapter (figure 5).
the green dot does not appear after this amount 4. Clip at the other end of the jumper wire to digital
of charging, continue charging for another 50 or multimeter J-29125 or equivalent.
75 ampere-hours. If the green dot still does not 5. Clip from the second jumper wire to the end of
appear, replace the battery. the negative battery cable.
5. The time required for a charge will vary according 6. Clip at the other end of the wire to the multimeter.
to: Set the multimeter on the DC, MA and 2000
a. Size of battery Example: A discharged scale.
large heavy-duty battery requires more than Take the reading with the engine control
twice the recharging as a discharged small switch and all accessories off.
passenger car battery. 7. If current draw is more than 50 milliamps, check
b. Temperature Example: A longer time will the system for causes such as a shorted wire or a
be needed to charge any battery at -18 C compartment lamp that does not shut off when it
(0 F) than at 27 C (80 F). When a fast should.
charger is connected to a cold battery, the
current accepted by the battery will be very
low at first; then, as the battery warms, it will BATTERY CABLES
accept a higher rate.
c. State-of-charge Example: A discharged Excessive resistance caused by poor terminal
battery requires more than twice as much connections and partial short circuits through defective
charge as a one-half-charged battery. cable insulation will result in an abnormal voltage drop
Because the electrolyte is nearly pure water in the starter cable. Low voltage at the starter will
and therefore a poor conductor, the current prevent normal starter operation and cause hard
accepted is low at first. Later, as the starting.
cables are frayed or the clamps corroded, the

cables should be replaced. When selecting new
cables, be sure they are at least as large as the
ones being replaced.
BATTERY
REPLACEMENT
When handling a battery, observe the following
safety precautions.
1. Hydrogen gas is produced by the battery. A flame
or spark near the battery may cause the gas to
ignite.
2. Battery fluid is highly acidic. Avoid spilling on
clothing or skin. Any spilled electrolyte should be
12. Battery (Disconnect Negative Cable From flushed with large quantities of water and cleaned
Other Battery On Diesel Vehicles) immediately.
13. Multimeter J-29125 Or Equivalent Set On
DC, MA and 2000 Scale
14. Meter Test Leads Remove or Disconnect
15. End of Negative Battery Cable
16. Jumper Wires 1. Negative cable from the negative battery
terminal.
2. Positive cable from the positive battery terminal.
3. Battery hold-down clamp.
B-09979 4. Battery.
Inspect
Figure 5Battery Drain Test Circuit
1. Battery for damage.
CAUTION: To p re ven t p o ssib le personal
2. Cables and connectors.
injury from a moving vehicle or operating
3. Carrier for damage or foreign objects.
engine do the follow ing before perform ing
If damage is noted, find and correct the
the checks:
cause.
1. Engage the parking brakes and block
the wheels.
Install or Connect
2. Place the manual transm ission in the
n e u tra l p o s itio n o r th e a u to m a tic
1. Battery into cleaned carrier.
transm ission in park.
2. Hold-down retainer or top bar, as equipped.
3. On gas engines disconnect the battery
fee d at th e d is tr ib u to r . On d ie s e l
Tighten
engines disconnect the battery feed at
the engine sh utoff (ESO) solenoid.
1. Retainer to 15 N m (135 in. lbs.).
2. Top bar to 10 N m (90 in. lbs.).
1. Check the vo ltag e drop between ground
3. Positive cable to the positive terminal.
(negative battery terminal) and the vehicle frame.
4. Negative cable to the negative terminal.
Place one prod of the test voltmeter on the
grounded battery post (not on the cable clamp)
Tighten
and the other on the frame. Operate the starter
and note the voltage reading.
Terminals to 13 N-m (120 in. lbs.).
2. Check the voltage drop between the positive
battery terminal and starter terminal stud with
starter operating.
3. Check the voltage drop between the starter
housing and frame with the starter operating.
4. If the voltage drop in any of the above is more
than 1.0 volt, there is excessive resistance in the
circuit. To eliminate resistance, the cables should
be disconnected and connections cleaned. If
CHARGING SYSTEM
DESCRIPTION
The charging system consists of the battery, the
generator, the regulator, and the charging system
indicator lamp circuitry. The generator supplies
electrical power for charging the battery and operating
accessories.
The generators shown in figures 6 through 11 are of
the System Intergral series (generator with built-in
regulator).
The generator features a solid state regulator that is
m o u nte d in s id e the g en e ra to r. All re g u la to r
components are enclosed into a solid mold* and this
unit along with the brush holder assembly is attached
to the slip ring end frame. The regulator voltage setting
cannot be adjusted.
The generator rotor bearings contain enough grease
to eliminate the need for periodic lubrication. Two
brushes carry current through the two slip rings to the
field coil mounted on the rotor, and under normal
conditions will provide long periods of attention-free
service.
The stator windings are assembled on the inside of a
laminated core that forms part of the generator frame.
A rectifier bridge connected to the stator windings
contains six diodes, and electrically changes the stator
AC voltages to a DC voltage which appears at the
generator output (BAT) terminal. The output varies lamp goes out since approximately the same voltage is
from 37 to 80 amperes, depending on the model. Refer present at both sides of the lamp. On vehicles with
to S p e c ific a tio n s at the end of this section. gages a voltmeter indicates voltage.
Generator field current is supplied thorugh a diode trio
which also is connected to the stator windings. A
capacitor or condenser, mounted in the end frame,
protects the rectifier bridge and diode trio from high
voltages, and suppresses radio noise.
No periodic adjustments or maintenance of any kind
are required on the entire generator assembly.
CIRCUIT OPERATION
When the engine control switch is turned to Run
or Start , the switch closes and current from the
battery flows through the charging system indicator
lamp, the number 1 terminal, the regulator, ground,
and back to the battery. Current also flows through the
generator field coil and back to the battery. The charge
indicator lamp then turns on.
With the generator operating, direct current (DC)
voltage is applied to the battery through the BAT
terminal. Some of the output flows through the diode
trio to the field coil, then through the brown wire at
terminal number 1 to the charge indicator lamp. The
54
51. BAT Terminal
51. BAT Terminal
52. No. 1 Terminal
52. No. 1 Terminal
53. No. 2 Terminal
53. No. 2 Terminal
54. Field Ground Hole
F-00013 54. Field Ground Hole
Figure 712-SI Series 100 Generator Figure 927-SI Series 100 Generator
51. BAT Terminal

52. No. 1 Terminal
53. No. 2 Terminal
54. Field Ground Hole
F-00014
Figure 815-SI Series 100 Generator Figure 10Generator Schematic

51. BAT Terminal 59. Diode Trio

52. No. 1 Terminal 60. Rectifier Bridge
53. No. 2 Terminal 61. Seal
55. Drive End Frame 62. Slip Rings
56. Bearing 63. Brushes
57. Rotor 64. Regulator
58. Stator Assembly 65. Slip Ring End Frame
B-08205
Figure 11SI Series Generator

DIAGNOSIS OF CHARGING SYSTEM
NOISY GENERATOR 1. Check that the undercharged condition has not

been caused by accessories having been left on
Noise from a generator may be caused by a loose for extended periods.
drive pulley, loose mounting bolts, worn or dirty 2. Check the drive belt for proper tension. Refer to
bearings, worn diode or stator. If the pulley and E NG INE C O O LIN G (SEC. 6B) for b elt
mounting bolts are snug and the noise continues, specifications.
remove the generator for inspection and repair. Refer 3. If the battery is suspected as defective, refer to
to Generator Replacement later in this section. Battery covered previously in this section.
4. Inspect the wiring for cracks or breaks. Check all
circuit connections, cable clamps and battery
ELECTRICAL TESTS terminals for tightness and cleanliness.
5. With the engine control switch on and all wiring
Before performing the diagnosis procedures on the harness leads connected, use a voltmeter for the
vehicle, be certain that the system wiring is good and following checks:
generator belts are not slipping. Also, the battery must
be fully charged for a valid test of the charging system. Install or Connect (Figures 6 through 11)
1. Voltm eter from the g enerator battery

NOTICE: To avoid damage to the vehicle
terminal to ground.
electrical system, observe the following
Should read 12 volts.
precautions:
2. Voltmeter from the number 1 terminal to
Do not polarize the generator.
ground.
Do not short across or ground any of the
terminals in the charging circuit except Should read one volt or more.
as specifically instructed herein. 3. Voltmeter from the number 2 terminal to
NEVER operate the generator with the ground.
output terminal open-circuited. Should read 12 volts.
Make sure the generator and battery have A zero reading on any of the above indicates an
the same ground polarity. open between the voltmeter connection and the
When connecting a charger or booster battery. If checks 1 through 5 are normal perform the
battery to the vehicle battery, connect generator output test.
negative to negative and positive to
positive. OVERCHARGED BATTERY
If the battery feels hot, is spewing electrolyte, or
Trouble in the charging system will show up as one lam ps seem too b rig h t when tu rn e d on, an
or more of the following conditions: overcharged condition may exist.
1. On vehicles without gages, unusual operation of To check the voltage, install a voltmeter across the
the charging indicator lamp. battery. Run the engine at moderate speed with all
accessories off. If the voltage reads 15.5 or more,
2. An undercharged battery, indicated by slow
remove the generator for repair.
cranking or a dark battery hydrometer.
3. An overcharged battery, indicated by spewing of GENERATOR OUTPUT TEST
electrolyte from the vents. 1. Disconnect the battery ground cable.
2. Connect an ammeter in the circuit at the battery
CHARGING SYSTEM INDICATOR terminal of the generator.
LAMP OPERATION 3. Reconnect battery ground cable.
Check the indicator lamp for normal operation (figure 4. Turn on the radio, windshield wipers, headlamps
12). If normal, proceed to Undercharged Battery . (high beam) and blower motor high speed.
5. Connect a carbon pile across the battery.
UNDERCHARGED BATTERY 6. Run the engine at moderate speed (about 2,000
Slow cranking or a dark battery hydrometer can be rpm) and adjust the carbon pile to obtain
caused by one or more of the following conditions even maximum current output.
though the indicator lamp may be operating normally. 7. If the ampere output is within 10 amperes of the
The following procedures also apply to vehicles rated ouput as stamped on the generator frame,
equipped with a voltmeter. the generator is probably all right.
6D-12
C H A R G IN G S Y S T E M IN D IC A T O R L A M P O P E R A T IO N
I . I
E n g in e R u n n in g E n g in e S to p p e d E n g in e C o n t r o l
T E S T NO. 1 E n g in e C o n t r o l T E S T NO. 2 E n g in e C o n t r o l T E S T NO. 3 S w itc h O F F
ENGINE ELECTRICAL
S w it c h O N S w itc h O N i
L a m p O ff Lam p On Lam p On L a m p O ff
NORM AL Lam p On NORM AL D IM L a m p O ff NORMAL Lam p On
S e e T est 2 S ee T est 3 1
If th e in d ic a to r la m p o p e ra tio n
C o n n e c t v o ltm e te r to BAT. C h e c k 10 am p. C h e c k d riv e b e lt a n d D is c o n n e c t N o . 1 and 2 c o n n e c t o r is n o rm a l fo r a ll th re e te s ts ,
te rm in a l o n g e n e r a to r a n d GAGES w irin g c o n n e c tio n s at a t g e n e ra to r. G ro u n d N o . 1 w ire . re fe r to SI g e n e r a to r d ia g n o s i s
c h a s s is g ro u n d . Turn T R A N S . fu s e g e n e ra to r a n d b a tte r y D o N O T g ro u n d N o . 2 w ire .
ig n itio n key o n . in fu s e b lo c k ca b le s .
D is c o n n e c t N o . 1 a n d 2
C h e c k 10 am p. c o n n e c to r at g e n e ra to r.
Figure 12Charging System
1
j B a tte ry v o lt a g e Z e r o v o lt a g e GAGES
T R A N S . fu s e L a m p O ff Lam p On
in fu s e b lo c k Lam p On L a m p O ff
D is c o n n e c t N o . 1 a n d N o . 2 c o n n e c to r R e p a ir o p e n c ir c u it b e tw e e n
at g e n e ra to r. C o n n e c t v o ltm e te r fro m BAT. te rm in a l o n g e n e r a to r
and ju n c tio n b lo c k o r b a tte ry . R e p a ir s h o rt b e tw e e n
N o . 1 c o n n e c to r to c h a s s is g ro u n d . 1. L a m p b u r n e d o u t .
2. O p e n in N o . 1 w ire fro m No. 1 and 2
A p p r o x im a te ly g e n e r a t o r t o e n g in e c o n t r o l w ir e s in h a rn e s s .
In s ta ll N o. 1 and 2 c o n n e c to r .
2 t o 4 v o lt s s w it c h . ____
...................... r ................. R e p la c e r e c t i f ie r
1. D is c o n n e c t b a tte ry g ro u n d s tra p . 1. C o n n e c t N o . 1 a n d N o . 2 b r id g e in g e n e r a to r .;
Z e ro v o lta g e
2. D is c o n n e c t w ire fr o m BAT.
r c o n n e c to r to g e n e ra to r.
R e p a ir o p e n c ir c u it in N o . 1 w ire te rm in a l on g e n e ra to r. 2. In s e rt s c r e w d r iv e r in to
f r o m c o n n e c t o r t o e n g in e c o n t r o l 3. C o n n e c t a m m e te r b la c k le a d to te s t h o le to g ro u n d r o to r
BAT. te rm in a l w ire s a n d red SW ITCH EN G IN E LAM P
s w it c h . w in d in g .
Diagnosis
lead to BAT. te rm in a l.
O FF STO PPED O FF
4. C o n n e c t b a tte ry g ro u n d s tra p .
ON STOPPED ON
* l f b a tte ry is fu lly c h a rg e d , u s e th e 5. T u rn o n a ll a c c e s s o r ie s , la m p s o n Lam p On L a m p O ff ON O FF
R U N N IN G
h ig h b e a m , and b lo w e r o n h ig h s p e e d .
s ta r te r to p a r tia lly d is c h a rg e it b e fo re
6. Run e n g in e as re q u ire d to o b ta in
re c o rd in g m a x im u m c u rr e n t o u tp u t. N O R M A L L A M P O P E R A T IO N
m a x im u m c u rre n t o u tp u t a n d re c o rd R e p la c e r e g u la t o r
a m m e te r re a d in g .*
X
O u tp u t w it h in 10 a m p s o f ra te d o u t
O u tp u t NOT w ith in 10 a m p s o f ra te d 1. M a ke s u re N o . 1 w ire
p u t s ta m p e d o n g e n e ra to r fra m e .
o u tp u t s ta m p e d o n g e n e r a to r fra m e . c o n n e c to r is m a k in g
NORMAL
g o o d c o n ta c t o n te rm in a l.
I I
'C h e c k b a tte r y c o n n e c tio n s a n d b a tte ry In s e rt s c re w d riv e r in to te s t h o le . 2. D is a s s e m b le g e n e ra to r
End o f s c re w d riv e r m u s t to u c h ta b a n d s id e a n d c h e c k b ru s h e s , s lip
c o n d itio n .
o f s c re w d riv e r g ro u n d a g a in s t e n d fra m e . rin g s a n d r o to r w in d in g
O u tp u t w it h in 10 a m p s o f ra te d o u t Run e n g in e as b e fo re a n d r e c h e c k o u tp u t. fo r o p e n .
00 p u t s ta m p e d o n g e n e ra to r fra m e .
o
co O u tp u t NOT w ith in 10 a m p s o f ra te d R e m o v e g e n e ra to r. R e fe r to
R e p la c e r e g u la to r g e n e r a t o r d is a s s e m b ly .
co o u tp u t s ta m p e d o n g e n e r a to r fra m e .
66. Battery
70. Generator 54. Field Ground
71. Carbon Pile 73. Tab
72. Ammeter A. Insert screwdriver, ground tab to end frame.
F-00010 F-00011
Figure 13Connections For Generator Figure 14Generator Field

O utput Test Ground Tab
8. If the vehicle is equipped with a charging system 11. Run the engine at moderate speed and adjust the
indicator lamp, and the lamp remains on while the carbon pile to get maximum current ouput.
engine runs, and ampere output is normal,
12. If the output is within 10 amperes of the rated
remove the generator for repair. Check the diode
ouput, remove the generator for repair. Refer to
trio and rectifier bridge.
the Light Duty Truck Unit Repair Manual to check
9. If the ampere output is not within 10 percent of the field winding and regulator.
the rated ouput in amperes, see if the test hole is
13. If the output is not within 10 amperes of rated
accessible (figure 14). If it is not accessible go to
output, remove the generator and check the field
step 14.
winding, diode trio, rectifier bridge and stator.
10. G round the fie ld w in d in g by in s e rtin g a 14. If the test hole is not accessible, remove the
screwdriver into the test hole. generator for repair.
NOTICE: The tab is within 19 mm (3M inch) of GENERATOR DIAGNOSTIC

the casting surface. Do not force the TESTER INDICATIONS
screwdriver deeper than 25 mm (1 inch) into If a tester is available, check the generator following
the end frame or the generator may be the tester manufacturers instructions. It will indicate
damaged. about 98 percent of the charging system problems.
TRANSISTORIZED VOLTAGE
REGULATOR TEST
Connect a fast charger and a voltmeter to the battery
as shown in figure 15. With the engine control switch
on run and the engine off, slowly increase the
charge rate. The charging system indicator lamp (on
vehicles w ithout gages) will dim at the voltage
regulator setting. The setting should be at a minimum
of 13.5 volts and a maximum of 16.0 volts.
This test works if the rotor circuit is good, even if the
stator, rectifier bridge or diode trio is bad.
74. Fast Charger

75. Voltmeter
66. Battery
F-00012
Figure 15On-Vehicle Regulator Test
GENERATOR ON-VEHICLE SERVICE
GENERATOR REPLACEMENT Im portant
The removal and installation instructions serve only Cover the tube opening to prevent dirt
as a guide. Additional operations may be required on particles form entering the tube.
some vehicles to remove other equipment to gain 5. Engine oil dipstick.
access to the generator, drive belts and brackets. 6. Bolt through the bracket holding the dipstick tube
However, specific instructions are given below for G to the engine oil fill tube.
vans equipped with air conditioning. 7. Engine oil dipstick tube.
Cover the opening.
CAUTION: Failure to observe step 1 in this 8. Bolt holding the oil fill tube to the generator
procedure may result in an injury from the bracket.
hot battery lead at the generator. 9. Oil fill tube from the rubber grommet in the valve
cover.
Cover the opening.
111 Remove or Disconnect All Models:
10. Terminal plug and battery lead from the back of
All Models
the generator.
1. Negative battery cable at the battery. Loosen the adjusting bolt on the generator
G Van: mounting.
11. Generator drive belt.
2. Air intake hoses on the bulkhead side.
\ 12. Lower mounting through-bolt from the generator
3. Air intake and hoses. flange.
4. Transmission fluid dipstick from the tube. 13. Adjusting bolt and the generator.
Install or Connect 4. Terminal plug and battery lead to the back of the
generator.
All Models G Van:
1. Generator to the mounting bracket with the bolt. 5. Oil fill tube to the rubber grommet after removing
Do not tighten. the cover.
2. Lower mounting bolt through the generator 6. Oil fill tube to the generator bracket with the bolt.
flange, flange extension, emission hose bracket 7. Engine oil dispatch tube bracket to the oil fill tube
and into the cylinder head. with a bolt after removing the cover.
3. Generator drive belt. 8. Dipstick.
9. Air intake hoses.
$ Tighten 10. Air intake and bolt to core support.
All Models:
Belt. Refer to ENGINE COOLING (SEC. 6B) 11. Negative battery cable to the battery.
for belt specifications. Refer to the Light Duty Truck Unit Repair Manual for
Adjusting bolt. off-vehicle service.
DIESEL GLOW PLUG ELECTRICAL SYSTEM
DESCRIPTION
In the diesel engine, air alone is compressed in the

cylinder; then after the air has been compressed a
charge of fuel is sprayed into the cylinder and ignition
occurs due to the heat of compression. Eight glow
plugs are used to preheat the chamber as an aid to
starting (figure 16).
The diesel glow plug system consists of an

intergral-electronic control/glow plug relay assembly,
6-volt glow plugs, a glow plug inhibit temperature
switch and a glow plug lamp.
GLOW PLUGS
These are 6-volt heaters (operated at 12 volts) that
turn on when the engine control switch is turned to the
run position prior to starting the engine. They remain
pulsing a short time after starting, then automatically
turn off.
INSTRUMENTATION
Figure 16Diesel Engine Glow
Vehicles with the diesel engine have special
Plug Location
instrumentation indicators to permit the operator to
properly apply the starting procedure. A glow plug
lamp on the instrument panel provides this information ELECTRONIC CONTROLLER/GLOW PLUG
on engine starting conditions. RELAY ASSEMBLY (FIGURES 17 AND 18)
The assembly contains the circuitry which monitors
Vehicles equipped with diesel engines have a water and controls glow plug relay operation. Information is
in fuel lamp and low engine coolant lamp. Refer to the received at pins B and C which is used by the
engine fuel and engine cooling sections for information c o n tro lle r to d e te rm in e glow plug o p e ra tin g
on these systems. requirements. Pin B senses voltage at the starting
GLOW PLUG INHIBIT SWITCH

The switch is temperature controlled and opens
above 51.5 C (125 F) to prevent glow plug operation
above this temperature. It is mounted at the rear of the
right cylinder head.
CIRCUIT OPERATION
A normal functioning system operates as follows:
A. Key on - Engine not running and at room
temperature.
1. Glow plugs ON for 4 to 6 seconds, then OFF
for about 4.5 seconds.
2. Then cycle; ON for about 1.5 seconds, OFF
for about 4.5 seconds, and continue to cycle
1.5 O N/4.5 OFF, for a tota l d u ra tio n
(including the initial 4 to 6 seconds) of about
20 seconds.
B. If the engine is cranked during or after the above
sequence, the glow plugs will cycle ON/OFF for a
total duration of 25 seconds after the engine
control switch is returned from the crank position,
whether the engine starts or not. The engine
does not have to be running to terminate the glow
plug cycling.
All the times shown above are approximate because
they vary with initial engine temperature. The initial ON
time and cycling ON/OFF times vary also with system
voltage and/or temperature. Lower temperatures cause
longer duration of cycling.
motor solenoid. Pin C senses glow plug voltage

through the glow plug inhibit switch which is wired in
series with the glow plug voltage sense lead to the
glow plugs. The controller is mounted at the rear of the
left cylinder head on two 10 mm studs.
631. Glow Plugs Lamp

632. Glow Plug Inhibit Temperature Switch
633. Starter Solenoid
634. Engine Cranking Sense Input (Purple) 637. Ground (Black)
635. Glow Plug Voltage Sense Input (Yellow) 638. Ignition Switch
636. Igniton (Pink) 639. Battery
F-00230
Figure 18Electronic Glow Plug System

DIAGNOSIS OF GLOW PLUG ELECTRICAL SYSTEM
CIRCUIT CHECK 12. Replace the switch if it is closed.

13. When installing the switch, use a socket wrench.
If the system does not operate as described, check
the following: Tighten
&
L * Inspect Switch to 23 N m (17 ft. lbs.).
1. All connectors.
2. Engine harness ground connection to engine. GLOW PLUG SYSTEM
& Tighten If all connections are intact, but the glow plug system
does not operate as stated, do the system diagnosis
Nut to 11 N m (8 ft. lbs.). shown in figure 19. It provides a fast way to find if the
3. Four-wire connector at controller. It must be fully glow plug system is working properly. Use this
seated and latched. procedure whenever there is doubt about correct
4. Both controller copper stud upper nuts. system oepration. Then refer to the diagnostic chart in
figure 20 to pinpoint the condition.
Tighten
NOTICE: Do not manually bypass the relay in
Nuts to 5 N m (48 in. lbs.). the glow plug controller. Do not jump start
Do not tighten lower nuts. with more than a 12-volt system. The glow
5. Temperature switch connector at top rear right plugs could be damaged.
cylinder head.
6. Glow plug lamp on instrument panel for tight
connection and operation.
GLOW PLUG AFTERSTART
GLOW PLUG The glow plug co ntro lle r provides glow plug
INHIBIT SWITCH operation after starting a cold engine. This after-start
operation is initiated when the engine control switch is
Check the temperature-controlled switch to make returned to RUN from the START position. While
sure it is closed at low temperatures and open at high loss of this function may not cause a cold start
temperatures. complaint, it may result in excessive white smoking
1. Remove the connector from the inhibit switch and/or poor idle quality after start. To check for proper
when the engine temperature is below 38C operation of this circuit proceed as follows:
(100F). 1. With the engine cold 27 C (80 F), turn the
2. Set the ohmmeter on a low range or use a engine control switch to the RUN position and let
self-powered test lamp. the glow plugs cycle.
3. Test across the terminals. 2. After 2 minutes crank the engine for 1 second. (It
4. The switch should be closed (test lamp on or a is not important that the engine starts.) Return the
reading of less than 0.1 ohm on the meter). engine control switch to RUN. Glow plugs should
5. Test terminals to ground with a test lamp or the cycle at least once after cranking.
ohmmeter on a high range. The lamp should be
off or the meter show greater than 1.0 megohm. 3. If the plugs do not turn on, disconnect the
controller connector, and check the connector
6. Replace the switch if it tests open across the
harness terminal B with a grounded 12-volt test
terminals or if either terminal is closed to ground.
light. The light should be off with the engine
7. Disconnect the plug from the switch terminals
control switch in RUN, and on when the engine is
when the engine is above 52 C (125 F).
cranked.
8. Set the ohmmeter on the highest scale or use a
self-powered test light. 4. If the light does not operate as just described,
9. Test across the terminals. repair a short or open in the engine harness
10. Test from each teminal to ground. purple wire.
11. Switch should be open (test light off or high ohm 5. If the light works right, but the afterstart glow plug
reading of greater than 1 megohm on the meter). feature does not, replace the controller.
* If using an in line ammeter read both banks at once. Do not cut wire.
(Snap-on meter MT552, VAT-40, or equivalent)
F-00231
Figure 19-Preliminary Diagnosis With An Ammeter

Figure 20Diesel Electrical System Diagnosis

GLOW PLUG ON>VEHICLE SERVICE
Check the system and its components on the vehi sure that connections are tight and torque values are
cle. used. Torque the glow plugs to 17 N m (12 ft. lbs.) when
None of the components are serviceable. When in installed.
stalling new components and making connections, be
CRANKING SYSTEM
426. Bulkhead Connector 435. Flywheel

427. To D istributor BAT Terminal 436. Pinion
428. BAT. 437. Shift Lever
429. Engine Control Switch 438. Plunger
430. Battery 439. Hold In Coil
431. Starter Motor 440. Pull In Coil
432. Shift Collar 441. Solenoid
433. Pinion Compression Spring 442. Solenoid Switch Contacts
434. Clutch
B-08263
Figure 21Cranking Circuit
DESCRIPTION STARTER MOTOR
CRANKING CIRCUIT Two types of starter motors are used in the vehicles
covered in this manual (figures 22 and 23). Both have
The basic cranking circuit consists of the battery, the shift lever mechanism and the solenoid plunger
starter motor, engine control switch, and related enclosed in the drive housing to protect them from
electrical wiring (figure 21). exposure to dirt, icing conditions and splash.
438 437. Shift Lever

438. Plunger
444. Bearing
446. Grommet
449. Overrunning Clutch
451. Armature
444 444
F-00840
Figure 2210MT Starting Motor
437. Shift Lever 462 457. Bronze-Graphite Bushing

449. Overrunning Clutch 458. Grease Reservoir
450. Center Bearing 459. Sealing Grommet
451. Center Bearing 460. Sealing Washers
Retaining Screw 461. Cadmium-Copper
452. Conductor Banding Contact Disc
462. Gasket
458
458
450 449 B-08267
Figure 2327MT Starting Motor

In the basic circuit (figure 21), the solenoid windings disengage. To prevent excessive overrun, open the
are energized when the switch is closed (in the Start engine control switch (release from the S tart
position). The resulting plunger and shift lever position) immediately when the engine starts,
movement causes the pinion to mesh with the engine
flywheel ring gear and the solenoid main contacts to
close, and engine cranking takes place. When the
engine starts, pinion overrun protects the armature
from excessive speed until the switch is opened, at
which time the return spring causes the pinion to
DIAGNOSIS OF CRANKING SYSTEM
Refer to figures 24, 25 and 26 for a diagnosis of the engine off and rotate the flywheel so that the
cranking system. Before removing any unit in the sys marked teeth are in the area of the starter pinion
tem for repair, make the following checks. gear.
4. Disconnect the negative battery cable to prevent
accidental cranking of the engine.
CRANKING CIRCUIT 5. Insert a screwdriver in the small hole in the
bottom of the starter (shown by the arrow in figure
BATTERY 27) and move the starter pinion and clutch
Determine the condition of the battery. Refer to assembly so that the pinion teeth and flywheel
Battery earlier in this section for battery diagnosis teeth are meshed. If necessary, rotate the
and testing. flywheel so that a pinion tooth is directly in the
center of two flywheel teeth and on the centerline
WIRING of the two gears (figure 28).
Inspect the circuit wiring for damage. Inspect all 6. Measure the clearance between the top of the
connections to the starter motor, solenoid, engine pinion tooth and the bottom of the flywheel tooth
control switch, and battery, including all ground using the width of the wire gage (figure 28).
connections. Clean and tighten all connections as Normal clearance is 0.5 to 1.5 mm (0.02 to 0.06
required. inch).
7. If the clearance is less than 0.5 mm (0.02 inch)
SOLENOID AND CONTROL SWITCHES and the starter whines after firing, shim the
Check all switches to determine their condition. A starter away from the flywheel.
vehicle equipped with an automatic transmission and a Gas engines (figure 29):
computerized ignition system (Electronic Control Add 1.0 mm (0.04 inch) shims, one at a time,
Module) has a neutral start switch which allows the to both long bolts between starter mounting
vehicle to be started in Park or Neutral. It is located on pads and engine until noise problem is
the steering column near the floor. A vehicle with a corrected. Do not use more than 2 shims
manual transm ission has a neutral start switch total.
attached to the clutch. Diesel engine (figure 30):
Add shims as required. Total shim stack
must not exceed 4.0 mm (0.016 inch). If
STARTER MOTOR NOISE starter shims are not available, washers
made of shim stock can be used.
Refer to the starter noise diagnostic chart. 8. If the pinion clearance is more than 1.5 mm (0.06
inch) and the starter whines during cranking,
PINION CLEARANCE shim the starter towards the flywheel.
1. Remove the lower flywheel housing cover. Gas engines (figure 29):
2. Inspect the flywheel for signs of unusual wear Add 0.38 mm (0.015 inch) shims between the
such as chipped or missing gear teeth or the outboard starter mounting pad and engine
flywheel being bent. If the flywheel needs mount until the noise stops. Do not add
replacing, refer to Engine Mechanical earlier in more than 4 shims total.
this manual.
3. Start the engine and gently touch the outside
diameter of the rotating flywheel ring gear with
chalk or crayon to show the high point of tooth
runout after the engine is turned off. Turn the
NO CRANKING, NO SOUND FROM SOLENOID

TURN HEADLAMPS AND DOME
LAMP ON. TURN KEY TO START.
LAMPS DIM OR GO OUT
CHECK BATTERY STATE-OF-CHARGE
EYE DARK | GREEN EYE SHOWING
CHARGE BATTERY, CHECK FOR CHECK CRANKING VOLTAGE

DRAIN, AND CHECK GENERATOR. AT BATTERY POSTS.
r
X 1
LESS THAN 9.6 VOLTS 9.6 VOLTS OR MORE |
CHECK VOLTAGE FROM ENGINE BLOCK TO BATTERY

TEST BATTERY; IF OK,
NEGATIVE POST, KEY IN START POSITION, VOLTMETER
REPAIR STARTER.
POSITIVE LEAD ON BLOCK.
0.5 VOLT OR MORE LESS THAN 0.5 VOLT
CLEAN AND TIGHTEN GROUND CABLE CONNECTION CHECK CRANK NG VOLTAGE

AND/OR REPLACE CABLE. AT STARTER B " TERMINAL.
LESS THAN 9.0 VOLTS 9 .0 VOLTS OR MORE
CLEAN AND TIGHTEN POSITIVE BATTERY CABLE REPAIR STARTER

TERMINALS AND/OR REPLACE CABLE.
B-06799
Figure 24Cranking System Diagnosis
Diesel engine (figure 30):

Tighten
Add a 1.0 mm (0.014 inch) shim at A
between the starter motor mounting pad
and the engine. If a starter shim is not 1. Gas engine starter motor mounting bolts to
38 N-m (28 ft. lbs.) (figure 29).
available, a washer made of shim stock can
2. Diesel engine starter motor:
be used.
9. When shimming is done, torque the mounting Through bolt to 38 N-m (28 ft. lbs.)
(figure 30).
bolts.
Nut to 10 N-m (7.4 ft. lbs.).
NO CRANKING, NO SOUND FROM SOLENOID

TURN HEADLAMPS AND DOME LAMP ON. TURN KEY TO START.
i
LAMPS STAY BRIGHT.
TURN ON RADIO, HEATER AND TURN SIGNALS.
OPERATE OK W ONT OPERATE.
WITH AUTOMATIC WITH MANUAL CHECK BULKHEAD

TRANSMISSION TRANSMISSION CONNECTOR, FUSEABLE LINK
AND ENGINE CONTROL
SWITCH CONNECTIONS.
NO ECM WITH ECM
CHECK VOLTAGE AT NEUTRAL SENSE CHECK VOLTAGE AT NEUTRAL - START

SWITCH (ON STEERING COLUMN NEAR SWITCH (ATTACHED TO CLUTCH) -
FLOOR) WITH TRANSMISSION IN CLUTCH DEPRESSED.
NEUTRAL OR PARK.
1
9 6 VOLTS LESS THAN MORE THAN 9.6 MORE THAN 9.6 MORE THAN 9.6
OR MORE 9 .6 VOLTS VOLTS ON BOTH VOLTS ON BOTH VOLTS ON ONE
TERMINALS. TERMINALS. TERMINAL.
CHECK CONNECTIONS AND REPLACE

VOLTAGE AT S TERMINAL
SWITCH
OR STARTER SOLENOID.
CHECK CONNECTIONS AND CHECK CLUTCH SWITCH
VOLTAGE AT SOLENOID S " ADJUSTMENT AND
9.6 VOLTS LESS THAN TERMINAL. CONNECTOR. IF OK,
OR MORE 9.6 VOLTS REPLACE SWITCH.
I ,
9.6 VOLTS LESS THAN

REPAIR
OR MORE 9.6 VOLTS
STARTER
WITH KEY IN START, REPAIR WITH KEY IN START, CHECK

CHECK VOLTAGE AT STARTER. VOLTAGE AT ENGINE CONTROL
ENGINE CONTROL SWITCH SWITCH SOLENOID TERMINAL.
SOLENOID TERMINAL.
9.6 VOLTS LESS THAN 9.6 VOLTS OR MORE LESS THAN 9.6 VOLTS. (
OR MORE 9.6 VOLTS
REPAIR PURPLE REPAIR YELLOW FEED WIRE REPLACE ENGINE

WIRE FROM REPLACE ENGINE FROM ENGINE CONTROL CONTROL SWITCH
SWITCH TO CONTROL SWITCH. SWITCH.
STARTER.
F-00249

S LO W C R A N K IN G , S O LE N O ID CLICKS O R C H A T T ER S
Figure 27Meshing Starter and Flywheel Teeth

463
435. Flywheel
436. Pinion
463. Suggested Wire Gage
A. 0.058 mm (0.020-inch) Wire Gage
6.355-12.7mm 76.2mm
(1/4"-1/2")
APPROXIMATE
463
436 436
B-08268
Figure 28Flywheel To Pinion Clearance
464
A. 38 N m (28 Ft. Lbs.)

464. Shim 0.38 mm (0.015-inch)
465. Shim 1.0 mm (0.04-inch)
B-08269
Figure 29Shimming Gas Engine Starter Motors

466, 467
466. Shim A = 1.0 mm (0.014-inch)

467. Shim B = 2.0 mm (0.08-inch)
A. 38 N m (28 ft. lbs.)
B. 10 N m (7.4 ft. lbs.)
C. 32 N m (24 ft lbs.)
F-00248
Figure 30Shimming Diesel Engine Starter Motors

DIAGNOSIS OF STARTER MOTOR NOISE

High-pitched whine Distance too great between starter pin Remove shims at starter mount. Re
during cranking ion and flywheel. fer to Starter Motor Noise .
(before engine fires)
but engine cranks
and fires normally.
High-pitched whine Distance too small between starter pin Add shims at starter mount. Refer to
after the engine fires ion and flywheel. Flywheel runout con Starter Motor Noise .
as key is being tributes to the intermittent nature of the
released. The engine problem.
cranks and fires
normally. This
com plaint is often
diagnosed as
starter hang-in or
solenoid weak .
A loud w h o op Usually due to a worn starter motor Remove starter motor and check
after the engine fires clutch. clutch. Refer to the Light Duty Truck
but while the starter Unit Repair Manual.
is still held engaged.
Sounds like a siren
if the engine is
revved while the
starter is engaged.
A rum ble g ro w l Usually due to a bent or unbalanced Remove starter motor and check the
or (in severe cases) starter armature. armature. Refer to the Light Duty
a knock as the Truck Unit Repair Manual.
starter is coasting
down to a stop after
starting the engine.
CRANKING SYSTEM ON-VEHICLE SERVICE
MAINTENANCE STARTER MOTOR REPLACEMENT

Keep starter terminals and all other terminals in the Remove or Disconnect
electrical system clean and tight. A loose or corroded
connection or terminal will cause excessive resistance 1. Negative battery cable.
in the system which will result in hard starting. 2. Starter braces or shields if equipped.
At regular intervals, inspect the starting system to 3. Wires from the starter solenoid.
locate and correct potential causes of trouble before Raise the vehicle.
the system performance is affected. 4. Two bolts, nuts, washers and shims holding the
Starting motors do not require lubrication except starter to the engine.
during overhaul. 5. Starter from the engine.
Install or Connect
STARTER MOTOR
1. Two bolts, nuts, washer and shims through the
If the battery, wiring and switches are in satisfactory starter to the engine.
condition, and the engine is functioning properly,
remove the motor and refer to the Light Duty Truck Unit Tighten
$
Repair Manual.
Never operate the starter motor more than 15 Bolts to 38 N m (28 ft. lbs.).
seconds at a time without pausing to allow it to cool for Lower the vehicle.
at least two m inutes. O verheating, caused by 2. Wires to the solenoid terminals.
excessive cranking, will damage the motor. 3. Negative battery terminal.
IGNITION SYSTEM
DESCRIPTION Energy Ignition system is basically identical in

operation to conventional ignition except the module
All ignition systems include a battery, a distributor, and pick-up coil replace the contact points.
an engine control switch, spark plugs, and the primary The High Energy Ignition is a magnetic pulse
and secondary wiring. Information on the battery is triggered, transistor controlled, inductive discharge
loca te d e a rlie r in th is se ctio n . Refer to CAB ignition system. The magnetic pick-up assembly
ELECTRICAL (SEC. 8A) for information on the engine located inside the distributor contains a permanent
control switch. magnet, a pole piece with internal teeth, and a pick-up
coil. When the teeth of the timer core rotating inside
There are three ignition systems used on light duty the pole piece line up with the teeth of the pole piece,
vehicles: the High Energy Ignition (HEI) system, the an induced voltage in the pick-up coil signals the
HEI/ESC system, and the HEI/EST system. electronic module to trigger the coil primary circuit.
The primary current decreases and a high voltage of
HEI SYSTEM up to 35,000 volts is induced in the ignition coil
The High Energy Ignition distributor used on these secondary winding which is directed through the rotor
gasoline engines combines all ignition components in and secondary leads to fire the spark plugs. The
one unit (figures 31 and 32). The external electrical ca p a cito r in the d is trib u to r is for radio noise
connections are the engine control switch feed wire, suppression.
the tachometer pickup, and the six or eight spark plug The magnetic pick-up assembly is mounted over the
leads. The engine control switch feed connector to the main bearing on the distributor housing, and is made
distributor has full battery voltage when the engine to rotate by the vacuum control unit, thus providing
control switch is in the RUN and START positions. vacuum advance. The distributor shaft is mounted on
There is NO RESISTOR WIRE FROM THE ENGINE the camshaft at the rear of the engine, and rotates at
CONTROL SWITCH TO THE DISTRIBUTOR. The one-half the rpm of the engine. The force of rotation
ignition coil is in the distributor cap and connects moves the advance weights against the springs, and
through a resistance brush to the rotor. The High provides cetrifugal advance to the timer core.
The module automatically controls the dwell period,

stretching it with increasing engine speed. 158
The HEI system also features a longer spark
duration, made possible by the higher amount of
energy stored in the coil primary. This is desirable for
firing lean mixtures.
When making compression checks, disconnect the
engine control switch connector (pink wire) from HEI
system.
No periodic lubrication is required. Engine oil
lubricates the lower bushing and an oil-filled reservoir
provides lubrication for the upper bushing.
ELECTRONIC SPARK CONTROL

(HEI/ESC) SYSTEM (Figures 33, 34 and 35)
ESC is a closed loop system that controls engine
knock by retarding spark timing. In addition to the
com ponents of the HEI system, it includes an
electronic controller, a sensor, and switches. This
system is used with LBI (4.3 L V6) and LE9 (5.0 L)
engine equipped trucks.
Controller (Figures 36 and 37)

The controller is contained in a plastic box mounted
behind the instrument panel compartment on the
passenger side on CK models and under the drivers
seat in the G van. It contains micro-electronic circuits
which process signals from the sensor and switches
and send a voltage signal to the distributor module to 152. Battery Terminal
retard spark tim ing. The retard command is in
(Connected to Ignition Switch)
proportion to the number and intensity of knock
153. Vacuum Unit
signals. It does not have memory storage.
156. Tach Terminal
158. Ground Terminal
Sensor (Figure 38)
The piezoelectric device is mounted in the engine B-09832
block. It detects the presence and intensity of
detonation by the vibration characteristics of the Figure 31High Energy Ignition
engine and sends a voltage signal to the controller.
command sent to the distributor in response to the
ESC Vacuum Switch knock sensor. Some detonation is then permitted
On LE9 and LB1 engine-equipped vehicles with during first gear acceleration to gain power.
automatic transmissions a tip in vacuum switch is
used. It provides a brief contact closure (signal) to the ELECTRONIC SPARK TIMING (HEI/EST) SYSTEM
controller to retard spark timing to minimize knock California vehicles use an HEI/EST distributor. All
during a throttle tip in condition. spark timing changes in the distributor are done
The switch contacts are normally open under steady electronically by the Electronic Control Module (ECM)
engine vacuum conditions including no vacuum, and which monitors information from various engine
all brief increasing vacuum conditions. The switch sensors, computes the desired spark timing and
closes during rapidly decreasing vacuum conditions s ig n a ls the d is trib u to r to ch a n g e the tim in g
such as those encountered on rapid throttle operation. accordingly. No vacuum or mechanical advance is
The switch is mounted on the right side of the cowl used. F u rth e r EST in fo rm a tio n is fo u n d in
in the engine compartment (figure 39). DRIVABILITY AND EMISSIONS (SEC. 6E).
CARL Switch IGNITION TIMING

H E I/E S C -e q u ip p e d v e h ic le s w ith m anual Timing specifications for each engine are listed on
transmissions (except the M20) use a Clutch Activated the Vehicle Emissions Control Information label on the
Retarded Limiting (CARL) switch (figures 40 and 41). It radiator support. When using a timing light, connect an
sends a signal to the controller to limit the retard adapter between the number 1 spark plug and the
number 1 spark plug wire, or use an inductive type

pick-up. Do not pierce the plug lead. Once the
insulation of the spark plug cable has been broken,
voltage will jump to the nearest ground, and the spark
plug will not fire properly. The timing procedure
remains the same as the conventional ignition system.
Always follow Vehicle Emissions Control Information
label procedures when adjusting timing.
SECONDARY WIRING
The spark plug wiring used with the HEI system is a
carbon impregnated cord conductor encased in an 8
mm or 7 mm diameter silicone rubber jacket. The
silicone wiring withstands high temperatures and
provides an insulator for the higher voltage of the HEI
system. The silicone spark plug boots form a tight seal
on the plug and the boot should be twisted V2 turn
before removing. Be cafeful when connecting a timing
light or other pick-up equipment. Do not force contacts
between the boot and wiring or through the silicone
jacket. Make connections in parallel using an adapter.
DO NOT pull on the wire to remove. Pull on the boot, or
use a tool designed for this purpose.
SPARK PLUGS
Resistor type, tapered seat spark plugs are used on
all gasoline engines. No gasket is used on these
tapered seat plugs. Refer to fig u re 42 for an
explanation of letter coding on spark plugs. Refer to
the Vehicle Emissions Control Information label on the
radiator support for correct gap information.
Normal or average service is assumed to be a
m ixture of idling, slow speed, and high speed
operation with some of each making up the daily total
driving. Occasional or intermittent high-speed driving
153 is essential to good spark plug performance as it
provides increased and sustained combustion heat
that burns away any excess deposits of carbon or
oxide that may have accumulated from frequent idling
or continual stop-and-go or slow-speed driving. Spark
plugs are protected by an insulating nipple made of
special heat-resistant material which covers the spark
plug terminal and extends downward over a portion of
154 the plug insulator. These nipples prevent flash-over
with resultant missing of engine, even though a film is
allowed to accumulate on exposed portion of plug
porcelains.
153. Vacuum Unit 161. Cap Do not mistake corona discharge for flash-over or a
154. Connector 162. Rotor shorted insulator. Corona is a steady blue light
159. Cover 163. Gear appearing around the insulator, just above the shell
160. Coil crimp. It is the visible evidence of a high-tension field,
and has no effect on ignition performance. Usually it
can be detected only in darkness. This discharge may
B-09833
repel dust particles, leaving a clear ring on the
insulator just above the shell. This ring is sometimes
Figure 32HEI System Components mistakenly regarded as evidence that combustion
gases have blown out between shell and insulator.
00
co
OD
CO
o
Figure 33Electronic Spark Control Schematic - Automatic Transmission
o>
CD
CD
cn
o
Figure 34Electronic Spark Control Schematic - Manual Transmission (Except M20)
165. Tachometer Terminal A. Black Figure 36Electronic Spark Control C ontroller (CK)
173. Pickup Coil B. White
174. Module C. Green
175. Ignition Switch Terminal D. Brown
B-09841
Figure 35HEI/ESC Distributor

Figure 37Electronic Spark Control

C ontroller (G Van)
Figure 39Tip In Vacuum Switch Mounting

R = Resistor
4 = 14 mm Thread
6 = Heat Range
T = Taper Seat
5 = Extended Tip
B-09847
Figure 42Spark Plug Coding
177
177. Transmission
178. CARL Switch
B-09846
Figure 41-CARL Switch on M62/M64 Transmissions

DIAGNOSIS OF IGNITION SYSTEM
HIGH ENERGY IGNITION to ESC. There can be a number of other causes for
these conditions. Before replacing an ESC system
(HEI) SYSTEM component, check for other causes as listed below.
1. Refer to figures 43, 44 and 45 for system ENGINE CRANKS BUT DOES
diagnosis. NOT START (FIGURES 46, 47 and 48)
2. Refer to the Light Duty Truck Unit Repair Manual Other possible causes:
for distributor component checks. 1. A component in the electrical system (refer to
3. Performance figures for centrifugal advance and Cranking System Diagnostic Charts earlier in this
vacuum advance are listed in Specifications at section).
the end of this section. 2. Exhaust restriction or low compression. Refer to
ENGINE (SEC. 6A).
3. Fuel system component. Refer to DRIVABILITY
NOTICE: If the module is removed from the
AND EMISSIONS (SEC. 6E).
distributor be sure to completely coat it with
silicone grease or an equivalent heat transfer
POOR ENGINE PERFORMANCE
substance before reinstallation. Failure to do
(FIGURE 49)
so could result in heat damage to the module.
Other possible causes:
1. Poor quality fuel.
2. Carburetor condition. Refer to FUEL SYSTEM
CAUTION: To p re ve n t p o ssible personal
(SEC. 6C).
injury from a moving vehicle or operating
3. Mechanical noises causing false spark retard.
engine do the follow ing before perform ing
Fuel pump noise. Refer to FUEL SYSTEM
the checks:
(SEC. 6C).
1. Engage the parking brake and block the
Abnormally loud valve lifters.
wheels.
Loose accessory mounting brackets.
2. Place the autom atic tra nsm issio n in
4. Ignition system.
park or the manual tra nsm issio n in
Timing - Set timing to specifications.
neutral.
Distributor - Check that centrifugal advance
and vacuum a d va n ce m eet the
specifications given at the end of this
ELECTRONIC SPARK TIMING ; section.
Spark Plugs - Inspect and replace if
(HEI/EST) SYSTEM n ece ssa ry. Be sure to use the
recommended plugs.
1. Refer to figures 43, 44 and 45 for system checks.
Plug Wiring - Route plug wires and knock
2. Refer to the Light Duty Truck Unit Repair Manual sensor wire away from the generator.
for distributor component checks. 5. Mobile phone or radio (if equipped). Run separate
3. Refer to DRIVEABILITY AND EMISSIONS (SEC. power and ground wires directly to battery
6E) in this manual for further checks, including terminals.
diagnostic use of the Check E ngine or 6. CARL switch inoperative.
Service Engine Soon lamp.
4. Refer to the Notice and Caution given for the HEI ENGINE DETONATION (FIGURE 50)
System. Other possible causes:
1. Low octane fuel.
2. High load on engine.
3. Exhaust Gas Recirculation (EGR) valve, Early
Fuel Evaporation (EFE) valve, or THERMAC valve
(HEI/ESC) SYSTEM in o p e ra tiv e . R efer to D R IV A B ILITY AND
EMISSIONS (SEC. 6E8).
Refer to the Notice and Caution given for the HEI 4. Mechanical condition in engine. Refer to ENGINE
System. (SEC. 6A).
The charts and wiring diagrams in figures 46 through 5. Low coolant level. Refer to ENGINE COOLING
50 show how to identify and correct no start, spark (SEC. 6B).
knock and poor engine performance conditions related 6. Tip in switch inoperative.
E N G IN E C R A N K S , B U T W IL L N O T S T A R T
(D IS TR IB U TO R W ITH IN T E G R A L COIL)
IF A TACHOMETER IS CONNECTED TO THE TACHOMETER TERMINAL, DISCONNECT IT BEFORE PROCEEDING WITH THE TEST.
1. CHECK SPARK AT PLUG WITH ST-125 WHILE CRANKING (VIEW A, B, FIGURE 44), IF NO SPARK ON ONE WIRE, CHECK A
SECOND W IR E .1 A FEW SPARKS AND THEN NOTHING IS CONSIDERED NO SPARK.
SPARK NO SPARK
= H
CHECK FUEL, SPARK PLUGS, ETC. ON COMPUTER EQUIPPED VEHICLES DISCONNECT THE 4-TERMINAL
EST CONNECTOR AND SEE IF ENGINE W ILL RUN.
DOESN'T RUN RUNS
2. CHECK VOLTAGE AT DISTRIBUTOR BAT TERMINAL WHILE CRANKING. REFER TO CODE 42

CHART IN SECTION 6E8.
7 VOLTS OR MORE UNDER 7 VOLTS
I
3. W ITH ENGINE CONTROL SWITCH O N REPAIR PRIMARY CIRCUIT TO ENGINE CONTROL SWITCH
CHECK TACH TERMINAL VOLTAGE.
I 1
UNDER 1 VOLT 10 VOLTS OR MORE 1 TO 10 VOLTS
------------ 1........
------ I
4. CHECK FOR SPARK AT COIL OUTPUT TERMINAL
REPLACE IGNITION COIL REPLACE MODULE AND CHECK FOR
WITH ST-125 WHILE CRANKING (VIEW C, FIGURE
SPARK FROM COIL AS IN STEP 6.
44).
SPARK 1 MO QrH
IMU o P AnRfNtf SPARK NO SPARK
REMOVE PICKUP COIL LEADS FROM MODULE. CHECK TACH. I

INSPECT CAP FOR SYSTEM
TERMINAL VOLTAGE W/ENGINE CONTROL SWITCH ON .
WATER, CRACKS, OK
WATCH VOLTMETER AS TEST LIGHT IS MOMENTARILY CON
ETC. IF OK, RE
NECTED FROM BATTERY TO MODULE P (VIEW D, FIGURE 44)
PLACE ROTOR.
NOT MORE THAN 5 SECONDS.
NO DROP IN VOLTAGE VOLTAGE DROPS
CHECK MODULE GROUND AND FOR OPEN IN WIRES FROM 6. CHECK FOR SPARK FROM COIL WITH ST-125 AS TEST
CAP TO DISTRIBUTOR. IF OK, REPLACE MODULE. LIGHT IS REMOVED FROM MODULE TERMINAL.
NO SPARK SPARK
I
1
IF MODULE TESTER IS AVAILABLE, TEST MODULE. IF NO MODULE TESTER IS AVAILABLE. REPLACE PICKUP COIL.
r~ 1 7. CHECK IGNITION COIL GROUND CIRCUIT. IF OK,

OK BAD REPLACE IGNITION COIL AND REPEAT STEP 6.
REPLACE I
MODULE SPARK NO SPARK
CHECK IGNITION COIL GROUND. IF SYSTEM OK COIL REMOVED IS OK. REINSTALL ORIGINAL
OK, REPLACE IGNITION COIL. COIL AND REPLACE MODULE.
F-00250
Figure 43HEI System Diagnosis

-<-------188
CUT BOOT HERE
11 mm (7/ie IN.)
FROM TIP OF
SPARK PLUG
VIEW A
VIEW B
194
VIEW C
VIEW D
188. Spark Plug Boot
189. Discard
191. Insert Boot Over Porcelain End Of ST-125
192. Connect To Ground
193. Leave Harness Connected
194. Remove Leads To Module
195. To BAT +
196. Test Light
197. Connect Voltmeter And Tach Terminal To Ground
F-00251

IN T E R M IT T E N T O P E R A T IO N OR M ISS
r~
NOT OK OK
| REPLACE PICKUP COIL | CHECK FOR DWEL.L INCREASE FROM

LOW TO HIGH RP M WITH A DWELL
METER OR OSCIL LOSCOPE.
CHECK FUEL, PLUG ON N O N -E S T V E H IC L E S FOR EST VEHICLES REFER TO

WIRES, CAP AND R E P LA C E D IS T R IB U T O R SECTION 6E
PLUGS. MODULE.
F-00252

E N G IN E C R A N K S B U T D O ES N O T S TA R T
With engine control switch on, check fe NOT OK

male connector at d istributor for battery [ Repair electrical circuit to distributor. |
voltage (pink wire).
OK
Disconnect 4-pin connector at distributor Check for other possible causes. Refer to
and jumper pins A and C together in d is NO START text. A lso refer to d ia g n o stic charts in
trib u to r connector. Cranking System earlier in this section.
START
Shut off engine and remove jumper and

reconnect 4-pin connector to distributor. UNDER
With engine control switch on, use m u lti 11.6 VOLTS Repair circuit between engine control
meter J-29125-A to check voltage from pin switch and pin F.
F wire on 10-pin connector at controller to
ground. Set voltm eter on DC, 20 range.
OVER 11.6 VOLTS
Turn engine control switch off and discon

nect 10-pin connector from controller. With
ohmmeter set on DC, 200 scale, check pins NOT OK
Repair harness.]
G, H, J and K for opens or short circuits. K
is a ground wire and should measure - 0.3
ohms.
OK
Replace ESC controller.
Figure 46Electronic Spark Control System Diagnosis
SWITCHES
Vacuum Controlled Tip In Switch

1. Run the engine at idle speed.
2. Disconnect the vacuum line at the switch.
3. Connect a vacuum gage to the vacuum line.
Vacuum should reach -5 7 kPa (17 in. Hg.).
4. W ith the gage still attached, depress the
accelerator pedal rapidly. Vacuum should drop to
approximately -10 kPa (3 in. Hg.).
5. With the engine again at idle speed, disconnect
the vacuum gage. Depress the accelerator pedal
rapidly. There should be noticeable engine knock.
6. With the engine again at idle speed, reconnect
the vacuum line.
7. Depress the accelerator pedal rapidly. A slight
amount of engine detonation may still be heard (a
few pings ).
8. If engine detonation does not decrease with the
vacuum line attached, replace the tip in switch.

Figure 48High Resistance Test Light

PO O R E N G IN E P E R FO R M A N C E
Disconnect 4-pin controller at d istributor Check for other possible causes. Refer to
TROUBLE
and jum per pins A and C together at dis C M IKIO text.
n tM AlINo
a
tributor connector. Test drive vehicle.
TROUBLE GONE
Turn engine off, remove jum per and recon

nect 4-pin connector. D isconnect 10-pin
connector from controller. Make sure term i NOT OK r - ----- :----------------------
nals are seated in c onnector and connec-
tion to controller is cjood. Check connector
pins B and K for opein or short circuits.
OK
W tih m ultim eter J-29125-A set on DC in D is c o n n e c t s e n s o r w ire fro m sensor.

2000 range, check resistance from pin B to NOT OK Check resistance from terminal on sensor
pin K. Should be approximately 98 or 99 to ground. Should be approximately 98 or
ohms. 99 ohms.
OK OK NOT OK
Reconnect connector to controller. Mea Repair circuit from sensor to pin B.

sure voltage from connector pin F wire to
Rep ace sensor
connector pin K wire with engine control
sw itch on.
OVER 11.6 VOLTS UNDER 11.6 VOLTS
Measure voltage from pin H wire to pin K Repair c irc u it betw een engine c o n tro l
wire with engine control switch on and volt switch and pin F._________________________
meter on the AC, 20 range. Shold be more
than 0.2 volts.
OK NOT OK
Test drive vehicle. If trouble remains, re Repair harness

place ESC controller.
F-00215

E N G IN E D E T O N A T IO N
Before attempting any diagnosis, check

connection at knock sensor and make
sure that all connections are clean and
tight.
With engine running at least 1200 RPM and RETARD
transmission in park or neutral, tap exhaust Check for other engine detonation causes.
manifold lightly and repeatedly and check Refer to text.
for spark timing retard with timing light.
NO RETARD
Turn engine off. Disconnect 10-pin connec Disconnect sensor wire from knock sen
tor from ESC controller. With multimeter J- sor. Measure voltage from terminal on
NOT OK
29125 A, check resistance from pin B to pin sensor to ground with engine running at
K with ohmmeter set on DC, 2000 range. approxim ately 2000 rpm. Should be
Should be approximately 98 or 99. greater than 80 millivolts (0.08 volts).
OK LOW
Replace sensor, j
OK
With engine off, check wires in 10-pin con

nector from pin B for open or short and
pin K for ground.
With ohmmeter set on DC, 200 range,
measure resistance from pin H to pin K. OK NOT OK
Should be 14 to 16 ohms.
Repair sensor connector. Repair harness.
___________ OK NOT OK
Replace ESC controller. Repair open circuit to pin H of connector
harness.
Some occasional trace-to-light detonation

is acceptable. F-00216

DIAGNOSIS OF SPARK PLUGS

Brown to grayish-tan Normal wear. Clean, regap, reinstall.

deposits and slight
electrode wear.
Dry, flu ffy black 1. Carburation is too rich. 1. Check fuel mixture. Replace air
carbon deposits. cleaner if clogged.
2. Sticking EFE valve or manifold heat 2. Replace if necessary.
valve.
3. Sticking automatic choke. 3. Refer to DRIVABILITY AND EMIS
SIONS (SEC. 6E).
4. Poor ignition output. 4. Check distributor coil connections
and cables (discussed in this sec
tion).
Wet, oily deposits 1. Break-in of new or recently over 1. Degrease, clean and reinstall plugs.
w ith very little hauled engine.
electrode wear. 2. Excessive valve stem guide clear 2. Refer to ENGINE (SEC. 6A).
ances.
3. Worn intake valve seals. 3. Replace seals.
Red, brown, yellow By-products of combustion. Clean, regap, and reinstall. If heavily
and white colored coated, replace.
coatings on
insulator. Engine
misses interm ittently
under severe
operating conditions.
Colored coatings Leaking seals if condition is found in Check seals. Replace if necessary.
heavily deposited on only one or two cylinders. Clean, regap, and reinstall plugs.
portion of plug
projecting into
chamber and on side
facing intake valve.
Shiny yellow glaze Melted by-products of combustion. Avoid sudden acceleration with wide-
coating on insulator. open throttle after long periods of low
speed driving. Replace plugs.
Burned or blistered Excessive overheating. 1. Check cooling system.

insulator tips and 2. Check for sticking heat riser valves.
badly eroded Refer to ENGINE (SEC. 6A).
electrodes. 3. Check air-fuel mixture. May be too
lean.
4. Check heat range of plugs. May be
too hot.
5. Check ignition timing. May be over
advanced.
6. Check torque value of plugs to en
sure good plug-engine seat contact.
DIAGNOSIS OF SPARK PLUGS (CONT.)

Broken or cracked Heat shock from sudden rise in tip Replace plugs. Gap correctly.
insulator tips. temperature under severe operating
conditons. Improper gapping of plugs.
IGNITION SYSTEM ON-VEHICLE SERVICE
SERVICE PRECAUTIONS DISTRIBUTOR REPLACEMENT

Some service tachometers and electronic diagnostic
equipment may NOT be compatible with the High Remove or Disconnect
Energy Ignition system. Consult your representative of
such equipm ent to update your equipm ent for 1. Engine cover (G-Van only).
compatibility with the HEI system. 2. Engine control switch battery feed wire from the
1. When making compression checks, disconnect distributor cap.
the engine control switch feed wire at the 3. Tachometer lead (if equipped) from the cap.
distributor. When disconnecting this connector 4. Ignition coil connector from the cap.
release the locking tab while pulling downward on Do not use a screwdriver or tool to release
the connector body; do not use a screwdriver or the locking tabs.
tool to release the locking tab as it may break the 5. Distributor cap by pressing down on the four
tab. spring-loaded screws and turning the latches to
2. No periodic lubrication is required. Engine oil the left.
lubricates the lower bushing and an oil-filled 6. Vacuum hose from the vacuum advance unit (if
reservoir provides lubrication for the upper equipped).
bushing. 7. Distributor clamp bolt and hold-down clamp from
3. The tachometer (TACH) terminal is next to the the engine.
engine control switch (BAT) connector on the Note the position of the rotor, then pull the
distributor cap. distributor up until the rotor just stops
turning to the left and again note the
NOTICE: the tachometer terminal must NEVER position of the rotor.
be allowed to touch ground, as damage to the 8. Distributor.
module and/or ignition coil can result.
Install or Connect
4. There is no dwell adjustm ent since this is
controlled by the module. To ensure correct timing of the distributor it must be
5. The centrifugal advance and vacuum advance installed with the rotor correctly positioned as noted in
are similar to the conventional ignition. Step 7 of the removal procedure.
If the engine was accidentally cranked after the
6. The material used to construct the spark plug
distributor was removed, the following procedure can
wires is very pliable and soft. This wire will
be used for installation:
withstand more heat and carry a higher voltage.
Due to the more pliable wire, scuffing and cutting Remove the number 1 spark plug.
become easier. Route the spark plug wires Place finger over the number 1 spark plug
correctly to prevent chaffing or cutting. When hole and crank the engine slowly until
removing a spark plug wire from a spark plug, compression is felt.
twist the boot on the spark plug and pull on the Align the timing mark on the pulley to 0
boot to remove the wire. on the engine timing indicator.
change is necessary, loosen the distributor

hold-down clam p bolt at the base of the
distributor. While observing the mark with the
timing light, slowly rotate the distributor until the
line indicates the correct timing. Tighten the
hold-down bolt, and re-check the timing.
5. Turn off the engine and remove the timing light.
Reconnect the number 1 spark plug wire, if
removed.
6. Connect the vacuum hose to the distributor if so
equipped.
SPARK PLUG WIRES

Use care when removing spark plug wire boots from
spark plugs. Twist the boot V2 turn before removing,
and pull on the boot only to remove the wire.
When replacing plug wires, route the wires correctly
and through the proper retainers. Failure to route the
Turn the rotor to point between number 1 wires properly can lead to radio ignition noise and
and number 8 spark plug towers on the crossfiring of the plugs, or shorting of the leads to
distributor cap. ground.
1. Distributor.
If the distributor shaft wont drop into the
engine, first insert a screwdriver into the SPARK PLUG WIRE
hole for the distributor and turn the oil pump REPLACEMENT
drive shaft.
2. Distributor hold-down clamp and clamp bolt. Wire routings must be kept intact during service, and
3. Vacuum hose to the vacuum unit (if equipped). followed exactly when wires have been disconnected,
4. Cap on the distributor. or when replacement of the wires is necessary. For the
The aligning tab on the cap should engage correct wiring routing for each engine, refer to figures
with the notch in the housing. 52 through 57.
5. Four hold-down spring latches. Some distributors have spark plug wire retainer
6. Ignition coil connector to the cap. harness assemblies with the engine firing order
7. Engine control switch battery feed wire. marked on them. If the firing order is not indicated,
8. Tachometer lead (if so equipped). install the plug wires according to the firing order as
Set ignition timing as described later in this shown in figures 58, 59 and 60. When the wiring is
section. completed, the plug wire from cylinder number 1
should lead to the distributor tower at the front and on
the same side of the engine as cylinder number 1. The
IGNITION TIMING plug wire from cylinder number 6 (in 6 cylinder
engines) or from cylinder number 8 (in V8 engines)
1. R efer to the V e h ic le E m issio n s C o n tro l should lead to the distributor tower at the front of the
Information label located on the radiator support. engine next to the number 1 tower.
Follow all instructions on the label. On the LE8 (7.4 L V8) engine, the spark plug harness
2. With the engine control switch off, connect the assembly and a dielectric paper insulator are fitted to a
pick-up lead of a timing light to the number 1 shield which is installed over the spark plug (figure 61).
spark plug. Use a jumper lead between the wire The insulator grounds the shield to the engine block. If
and plug or an inductive type pick-up. DO NOT the assembly is removed from the shield, make sure
pierce the wire or attempt to insert a wire between that the insulator is present and undamaged before
the boot and the wire. Connect the timing light reinstallation.
pow er leads a cco rd in g to m a n u fa c tu re rs
instructions.
3. Disconnect the vacuum hose from the distributor
if so equipped.
4. Start the engine and aim the timing light at the
timing mark (figure 51). The line on the balancer
or pulley wiil line up at the timing mark. If a
184
179. Cyl nder No. 1

180. Cyl nder No. 2
181. Cyl nder No. 3
182. Cyl nder No. 4
183. Cyl nder No. 5
184. Cyl nder No. 6
F-00255
Figure 52Spark Plug Wire Routing For Engine L25
179. C y lin d e r N o. 1 182. C y lin d e r N o . 4

180. C y lin d e r N o. 2 183. C y lin d e r N o. 5
181. C y lin d e r N o. 3 184. C y lin d e r N o. 6
F-00256
Figure 53Spark Plug Wire Routing For Engine LB1

179. Cylinder No. 1 183. Cylinder No. 5

F-00257
Figure 54Spark Plug Wire Routing For Engine LT9
184 182 180

179 181
182. Cylinder No. 4 186. Cylinder No. 8 F-00258
Figure 55Spark Plug Wire Routing For Engines LE9, LF3, LS9 and LT9, CK
180
182
181
186 184 182 180 179 181 183 185

179. Cyl nder No. 1
180. Cyl nder No. 2
181. Cyl nder No. 3
182. Cyl nder No. 4
183. Cyl nder No. 5
184. Cyl nder No. 6
185. Cyl nder No. 7
186. Cyl nder No. 8
F-00259
Figure 56Spark Plug Wire Routing For Engines LE9, LF3, LS9 and LT9, G Van
179. Cyl nder No. 1

180. Cyl nder No. 2
fy j-.
181. Cyl nder No. 3
182. Cyl nder No. 4
183. Cyl nder No. 5
184. Cyl nder No. 6
185. Cyl nder No. 7
186. Cyl nder No. 8
F-00260
Figure 57Spark Plug Wire Routing For Engine LE8
r\
FIRING
ORDER
1-6-5-4-3-2
KJ
F-00262
Figure 58Spark Plug Wire Figure 59Spark Plug Wire Schematic

Schematic (L6 Engines) (V6 Engines)
Figure 60Spark Plug Wire Schematic

(V8 Engines)
ENGINE WIRE HARNESS
Refer to figures 62 through 71.

166. Grommet
200. Starter Motor
201. ESC Module
202. Tip In Switch
203. Generator
204. Engine Harness Ground
F-00265
Figure 62Engine Wiring, CK Series For LB1 (4.3 L V6)

245
249
200 . Starter Motor

207. Battery Cable
222. Throttle Position Sensor
224. EGR/EPR Solenoid 254
245. Bulkhead Connector
246. Carburetor Fuel Solenoid Connector
247. Choke
248. M.A.P. Sensor
249. A ir Diverter Valve
253
250. A.I.R. Pump
251. Fuel Vapor Cannister
252. Solenoid Cannister Purge
253. Coolant Temperature Sensor Connector
254. Accelerator Pump Temperature Switch Connector
F-00266
Figure 63Engine Wiring, G Series, For ECM-Equipped LB1 (4.3 L V6)

205 204 206

205. Engine Lift Bracket
206. W indshield Wiper Motor
F-00267
Figure 64Engine Wiring, CK Series, For L25 (4.8 L L6)

200. Starter Motor

206. W indshield Wiper Motor
240. A ir Divert Module
241. Generator
242. Electric Choke
243. Hydraulic Clutch Reservoir Hose
244. Speedometer Cable
F-00268
Figure 65Engine Wiring, CK Series, For LE8 (7.4 L V8)

207. Battery Cable

208. Red
209. Purple
210. Headlamps
211. Taillamps
212. Oil Pressure Switch
213. Fuel Solenoid Temperature Switch
F-00269
Figure 66Engine Wiring, CK Series, for LE9 (5.0 L V8), LF3 (5.0 V8) and LS9 (5.7 L V8)
227
228
212. Oil Pressure Switch
215. Diagnostic Connector
224. EGR/EPR Solenoid
225. Fuel Meter Wire
226. Low Coolant Connector
227. EGR Solenoid Connector
229. EPR Solenoid Connector
230. Glow Plug Controller Connector
231. EPR/EGR Solenoid
F-00270
Figure 67Engine Wiring, CK Series For LH6, LL4 Engines (6.2 L Diesel)
ENGINE ELEC TR IC AL 6D-61
204
233 238

232. Fast Idle Switch
233. Transmission Switch
234. Fast Idle Solenoid
235. Water Sensor Connector 239
236. Fuel Heater Connector
237. Fuel Filter
238. Speed Sensor
239. Engine Temperature Switch
F-00271
Figure 68Engine Wiring, CK Series For LH6, LL4 Engines (6.2 L Diesel)
216
214. Vacuum
215. Diagnostic Connector
216. Differential Pressure Sensor
219
217. Electronic Control Module
218. EGR Bleed Solenoid
219. A ir Control Valve
220. Purge Solenoid
221. Carburetor A ir Fuel Solenoid
222. Throttle Position Sensor
223. Coolant Temperature Sensor
221 222
223
F-00272
Figure 69Engine Wiring, CK Series For ECM-Equipped LF3 (5.0 L V8) and LS9 (5.7 L V8)
ENGINE ELEC TR IC AL 6D-63
F igure 70 E ngine W irin g , CK Series, For LB1 (4.3L V6)

203
200 200. Starter Motor

203. Generator
207. Battery Cable
256. Spark Plug Wires
F-00273
Figure 71 E ngine W iring, P Series, For LT9 (5.7L V8)
SPECIFICATIONS
BATTERY SPECIFICATIONS
Reserve
Cold Cranking Capacity
Amperes Rating (Minutes at Load Test
Part No. Application Description Volts @ - 1 8 C (0 F) 25 Amps) (Amperes)
1981103 CK Delco 103 12 405 75 200
1981104 CK, G Delco 104 12 500 90 250
1981105 CK, G, P Delco 105 12 540 115 250
1981610 G, P Delco 610 12 430 90 210
GENERATOR APPLICATIONS
9
Mountim Torque
Top Bracket Bolt Bottom Bracket Bolt
Engine Generator Part Number N m Ft. Lbs. Nm Ft. Lbs.
CK
LB1 4.3 L (262 cu. in.) K81 1105706 25 18 47 35
K85 1105703 25 18 47 35
LE9 5.0 L (305 cu. in.) K64 1105708 25 18 47 35
K81 1105707 25 18 47 35
K85 1105704 25 18 47 35
LF3 5.0 L (305 cu. in.) K81 1105707 25 18 47 35
K85 1105704 25 18 47 35
LT9 5.7 L (350 cu. in.) K64 1101155 25 18 47 35
K64 1105708 25 18 47 35
K81 1101156 25 18 47 35
K81 1105707 25 18 47 35
K85 1101155 25 18 47 35
K85 1105704 25 18 47 35
L25 4.8 L (292 cu. in.) K81 1100207 25 18 23 17
K81 1100242 25 18 23 17
K85 1100203 25 18 23 17
K85 1100225 25 18 23 17
Diesel 6.2 L (379 cu. in.) K64 1105628 27 20 43 32
K81 1105632 27 20 43 32
LE8 7.4 L (454 cu. in.) K22 1105629 25 18 50 37
K85 1105691 25 18 50 37
LS9 5.7 L (350 cu. in.) K64 1105708 25 18 *47 35
K81 1105707 25 18 47 35
K85 1100704 25 18 47 35
G Van
LB1 4.3 L (263 cu. in.) K81 1105706 25 18 47 35
K85 1105703 25 18 47 35
LE9 5.0 L (305 cu. in.) K81 1105707 25 18 47 35
K85 1105704 25 18 47 35
LF3 5.0 L (305 cu. in.) K85 1105704 25 18 47 35
LS9 5.7 L (305 cu. in.) K81 1105707 25 18 47 35
K85 1105704 25 18 47 35
LT9 5.7 L (350 cu. in.) K81 1105707
K85 1105704 25 18 47 35
Diesel 6.2 L (379 cu. in.) K81 1105632 27 20 43 32
P Truck
L25 4.8 L (292 cu. in.) K79 1100229 25 18 24 17
K81 1100207 25 18 24 17
K97 1101064 33 44 33 44
GENERATOR APPLICATIONS (CONT.)
Mountin; Torque
Top Bracket Bolt Bottom Bracket Bolt
Engine Generator Part Number N m F t. Lbs. Nm F t. Lbs.
P Truck (Cont.)
LT9 5.7 L (350 cu. in.) K79 1101159 25 18 47 35
K81 1105707 25 18 47 35
K81 1101156 25 18 47 35
K97 1105709 26 19 47 35
LE8 7.4 L (454 cu. in.) K81 1105692 25 18 47 35
K97 1105693 64 47 50 37
LL4 6.2 L (379 cu. in.) K81 1105632 27 20 43 32
K09 1101215 27 20 43 32
GENERATOR SPECIFICATIONS
Field Current
Rotation @ 12 Volts Cold Ouput Hot Output
Series Viewing (2 7 C, 80 F) AM PS @
Part No. (Type 100) Dr. End AM P S 2000 R PM AM PS R PM AM PS
1100203 10SI CW 4 .0 -5 .0 22 33 5000 37
1100207 12SI cw 4 .5 -5 .0 38 70 7000 66
1100225 10SI CW 4 .0 -5 .0 22 33 5000 37
1100229 10SI cw 4 .0 -5 .0 25 38 5000 42
1100242 12SI cw 4 .5 -5 .0 38 70 7000 66
1101064 27SI cw 4.4 - 4.9 55 76 5000 80
1101155 10SI cw 4.0 - 5.0 22 33 5000 37
1101156 12SI CW 4 .5 -5 .0 38 70 7000 66
1101157 12SI CW 4.5 - 5.0 51 81 7000 78
1101159 10SI CW 4 .0 -5 .0 25 38 5000 42
1105628 12SI CW 4 .5 -5 .0 51 81 7000 78
1105629 12SI CW 4 .5 -5 .0 56 103 7000 94
1105632 12SI CW 4 .5 -5 .0 38 70 7000 66
1105691 10SI CW 4 .0 -5 .0 22 33 5000 37
1105692 12SI CW 4.5 - 5.0 38 70 7000 66
1105693 27SI CW 4.4 - 4.9 55 76 5000 80
1105703 10SI CW 4 .0 -5 .0 22 33 5000 37
1105704 10SI CW 4 .0 -5 .0 22 33 5000 37
1105706 12SI CW 4 .5 - 5.0 38 70 7000 66
1105707 12SI CW 4 .5 -5 .0 38 70 7000 66
1105708 12SI CW 4 .5 -5 .0 51 81 7000 78
1105709 27SI CW 4.4. - 4.9 55 76 5000 80
STARTER SPECIFICATIONS
No Load Tesl @ 10 Volts

Truck Engine Starter AM PS R PM
Model Application Part No. Series Type Minimum Maximum Minimum Maximum
C, G, P LH6.LL4 1113589 27MT 136 120 210 9000 13400
K LH6,LL4 1113590 27MT 136 120 210 9000 13400
C L25 1998559 10MT 101 60 90 6500 10500
K L25
P L25
K LE9, LS9,LT9, L25 1998560 10MT 101 70 110 6500 10700
C, G LE9, LF3, LS9, LT9 1998561 10MT 101 70 110 6500 10700
K LE9, LS9, LT9

G LE9, LF3
P LT9
C LB1, LE8 1998562 10MT 101 70 110 6500 11070
K LB1, LE8
G LB1, L59, LT9
P LT9, LE8
P LT9 1998563 10MT 100 70 110 6500 10700
K LB1, LE8 1998565 10MT 101 70 110 6500 10700
STARTER SHIMS
Gas Engines Diesel Engines

Shim Part No. Shim Part No.
0.38 mm (0.015 ) 1246249 1.0 mm (0.014 ) 23500396
1.0 mm (0.04 ) 14036090 2.0 mm (0.08 ) 23500397

DISTRIBUTOR SPECIFICATIONS
T h e v a lu e s g iv e n in th e s e d a ta a re d istrib u to r rpm a n d d is trib u to r d e g r e e s of a d v a n c e . T h e c e n trifu g a l a u to m a tic

a d v a n c e s h o u ld b e c h e c k e d at e a c h of th e d istrib u to r s p e e d s listed . N O T E : D is trib u to r rpm a n d d e g r e e s o f a d v a n c e
a re o n e -h a lf e n g in e rpm a n d d e g r e e s of a d v a n c e .
A d v a n c e c u rv e in fo rm a tio n for th e H E I / E S T d istrib u to r is not g iv e n . T h e a d v a n c e is p ro v id e d by a se p a ra te

e le c tro n ic co n tro l d e v ic e .
C E N T R IF U G A L A D V A N C E
Start Intermediate Intermediate Maximum

Ignition Distributor Distributor Distributor Distributor Vacuum
Model No. System R PM Degree R PM Degree R PM Degree R PM Degree Model
CK
1103436 HEI 650 0-4 1200 7-9 2300 10-12 1973691
1103460 HEI/EST
1103456 HEI/ESC 700 0-2 1000 3-5 2100 9-11 1973691
1103572 HEI 800 0-2 1200 4-6 1600 5-7 200 8-10 1973691
1103573 HEI/EST
1103604 HEI 700 0-2 1000 3-5 2100 9-11 1973591
1103631 HEI/ESC 800 0-2 1200 4-6 1600 5-7 2000 8-10 1973644
1103641 HEI/ESC 700 0-2 1000 3-5 2100 9-11 1973644
G Van
1103436 HEI 650 0-4 1200 7-9 2300 10-12 1973691
1103460 HEI/EST
1103465 HEI/ESC 700 0-2 1000 3-5 2100 9-11 1973691
1103572 HEI 800 0-2 1200 4-6 1600 5-7 2000 8-10 1973626
1103573 HEI/EST 1973691
1103604 HEI 700 0-2 1000 3-5 2100 9-11 1973591
1103631 HEI/ESC 800 0-2 1200 4-6 1600 5-7 2000 8-10 1973644
1103641 HEI/ESC 700 0-2 1000 3-5 2100 9-11 1973644
P Truck
1103376 HEI 700 0-3 1400 6-8 2100 9-11 1973682
1103384 HEI 500 0-4 800 5-8 2000 9-11 1973620
1103420 HEI 1000 0-3 800 5-8 2000 11-13 1973681
1103606 HEI 600 0-3 1850 4-6 1900 9-11 1973626
1103636 HEI 700 0-2 1000 3-5 2100 9-11 1973682
VACUUM ADVANCE SPECIFICATIONS
M ax.
Start Maximum Dist.
Vacuum Inches Inches
Model Hg. -k P a Hg. -k P a (Deg.)
1973591 3-4 10-14 11-13 37-44 10
1973620 3-6 10-21 10-13 33-44 12
1973626 3-6 10-21 7-9 23-31 5
1973644 3-4 7-14 6-7 18-25 8
1978681 9-11 30-38 12-13 40-48 5
1973682 7-9 24-32 13-14 42-46 5
1973691 3-4 8-14 6-9 20-30 10
SPECIAL TOOLS
AC Delco ST 1201 Battery Terminal Adapters

AC ST-125 Spark Plug Tester
J 29125-A Multimeter
DRIVEABILITY AND EMISSIONS - 6E-1
SECTION 6E
DRIVEABILITY AND EMISSIONS
CONTENTS
General In fo rm a tio n - Section 6E
D riveability and Emissions - Carbureted - Section 6E8
Diesel Emissions - 6.2L E n g in e Section 6E9
CONTENTS OF SECTION 6E
G eneral Inform ation .................................6E-1 Section B - D riveability Sym ptom s ...... 6E-7
D r iv e a b ility .................................................6E-1 Section C - C om ponent-System s ............ 6E-7
E m issions .................................................... 6E-1 C om puter Com m and C ontrol ............. 6E-7
M aintenance S ch ed u le ..........................6E-1 Fuel Control System ................................6E-7
V ehicle Em ission Control E vaporative E m ission C o n tr o l............ 6E-8
Inform ation L a b e l............................... 6E-1 E lectronic Spark T im ing ...................... 6E-8
Introduction Air Injection R e a c tio n ............................ 6E-8
G eneral ...................................................... 6E-3 D eceleration C ontrol ............................. 6E-8
Section A - D iagnostic C h a rts.............. 6E-3 E xh aust G as R e c ir c u la tio n ................... 6E-8
D iagnostic P roced ure Sum m ary.....6E-4 Early Fuel E vaporation .........................6E-8
V isual U nderhood In sp ection ..........6E-5 E lectronic Spark C ontrol ..................... 6E-8
Basic K now ledge R eq u ired .............. 6E-5 T ransm ission C onverter C lu tc h .......... 6E-8
D iagnostic In form ation ..................... 6E-5 A/C Clutch Control .................................. 6E-9
Service E ngine Soon L ight............... 6E-5 P ositive C ran k case V e n tila tio n ........... 6E-9
Trouble C odes ...................................... 6E-6 T herm ostatic Air C lea n er...................... 6E-9
ALCL C o n n e c to r ..................................6E-6 A b b reviation s and G lossary .................. 6E-9
D iagnostic M ode ..................................6E-6 Wiring H arness S ervice ..........................6E-12
C learing Trouble C o d e s ....................6E-7 S pecial T ools ............................................... 6E-14
ECM Learning A b ility ....................... 6E-7 G eneral S p ecification s ............................ 6E-20
GENERAL INFORMATION
DRIVEABILITY
The driveab ility d ia g n o sis p roced u res apply MAINTENANCE SCHEDULE
to variou s system s in current GM veh icles. The
p roced u res assum e that the veh icle w orked right R efer to the G eneral M otors M aintenance
S ch ed u le in Section OB o f the C h assis Service
at one tim e and the problem is due to tim e, w ear,
dirt or other cau ses. Start w ith the introdu ction M anual for the m ain ten an ce serv ice that sh ou ld
that follow s. This w ill d escrib e a system atic be perform ed to retain em ission con trol
d iagn ostic procedure. perform ance.
Any system d iscon n ected d u ring d iagn osis VEHICLE EMISSION CONTROL INFORMATION
sh ou ld be recon nected. T his in clu d es w ires, LABEL
h oses, link age, etc. When rem oving air cleaner,
plug hose fittings that could cau se an air leak. The V ehicle E m ission Control Inform ation
label (F ig.l) co n ta in s im portant em ission
Diesel Driveability sp ecifica tio n s and settin g p roced u res. In the
The d riveab ility d iagn osis inform ation that upper left corn er is ex h a u st em ission inform ation
ap p lies to a veh icle w ith a d iesel en gin e can be w hich id en tifies the year, the m an ufacturing
found in Section 6 o f this Service M anual. d ivision of the en gin e, the d isp la cem en t in liters
EMISSIONS of the en gin e, tne cla ss o f v eh icle and type o f fuel
m etering. A lso there is an illu strated em ission
The ex h a u st em ission control system s used on
com p on en t and vacuum hose sch em atic. T his
G eneral M otors en gin es perform a sp ecific
fu n ction to low er exh au st em ission s w hile label is located in the en g in e com p artm en t o f
m aintainin g good fuel econom y and d riveab ility. every G eneral M otors C orporation veh icle. If the
label has been rem oved, it can be ordered from
Diesel Emissions the parts d ivision . (WDDGM)
The system d iagn osis and repair for
em ission s that apply to a d iesel en gin e can be
found in the ap p licab le D iesel E m issions-S ection
6E9.
6E-2 - DRIVEABILITY AND EMISSIONS
ENGINE ADJUSTMENT
SPECIFICATIONS \
PROCEDURE
ENGINE SIZE
LABEL CODE
EMISSION COMPONENT
AND VACUUM HOSE SCHEMATIC
LABEL PART NUMBER
AREA OF CERTIFICATION
" A L W A Y S REFER TO THE V E H IC L E EMISSION CO NT RO L IN F O R M A T IO N L A B E L

FOR THE CORRECT A N D MOST C U RRE NT SPEC IFICAT IONS".
EVAPORATIVE EMISSION SYSTEM
EXHAUST EMISSION SYSTEM

G2G25T5NBAX.
DIVISION DISPLACEMENT
1G ~ Chevrolet Liters Larqest Gasoline Vehicle E ngine F a m ily S u ffix Code
2G = Pontiac if more thjn one Calif. Std. Gasoline Vehicle (D e s c r ib e s E m i s s i o n S y s t e m )
3G - Oldsmobile Gasoline Truck
4G = Buick Diesel Vehicle
6G Cadillac 100K Cahf. Std. Diesel Vehicle
Diesel Truck C A T A L Y S T DESCRIPTION
FUEL METERING
1 Ibtal
2 - 2bbl
4 4bbl
5 TBI
7 MFI
8 PFI
9 PF1 Tu rbo
4 19 84
5S-2871-6E
Figure 1 V ehicle E m ission Control Inform ation Label

INTRODUCTION
GENERAL
Each G eneral M otors engine has system properly. This section d ia g n o sis the fuel system
controls to red u ce exh au st em ission s w hile controlled by the ECM and has ch arts to
m aintaining good d riveab ility and fuel econom y. d ia g n o sis a circu it w hen the ECM has d isp la y ed a
trou ble code.
This Section exp lain s how to use the
D riveability and E m ission S ection s for gasolin e The w ay to ap p roach a problem is to follow
engines. The p rocedure in Section A starts w ith three basic step s (sh ow n in F igure 2):
ch eck in g the C om puter Com m and Control for
codes on C alifornia 4.3L, 5.0L, and 5.7L en gin es. 1. Are the O n-V ehicle D iagn ostics w orking?
We find this out by perform in g the
These en gin es have an E lectronic Control "D iagnostic C ircuit Check". S ince th is is
M odule (ECM) to control the fuel system . The the startin g p oint for the d ia g n o stic
ECM varies the air/fuel ratio. In addition, the procedure, alw ays begin here.
ECM controls the ignition tim ing system as w ell
as other system s su ch as exh au st gas If the O n-V ehicle D iagn ostics a ren t w orking, the
recirculation and can ister purge. "D iagnostic C ircuit Check" w ill lead you to a
chart in Section A to co rrect th e problem . If the
It is im portant to review the com p on en t
veh icle w ill not start, see "Ignition System
section s and w iring diagram s for a sp ecific
Check" in Chart C-4A or C-4E. If the O n-V ehicle
engine to determ in e w h at is controlled by the
D iagn ostics are OK, the next step is:
ECM and w hat system s are non-ECM controlled .
2. Is there a T rouble Code stored? If a trou ble
This Section has a b rief d escription of
code is stored , go d irectly to the num bered
system s used to control fuel and em issions.
code ch art in Section A. T his w ill determ in e if
A b breviations that are used in D riveability the fault is still presen t. If no trouble cod e is
and E m issions are listed in this Section. stored, the third step is:
Wiring h arn ess service inform ation for 3. Is the Fuel System con trollin g correctly? We
h arn esses used with the ECM is also provided in find this out in the "System P erform ance
this Section. Check". If the fuel system is not con trollin g
Special tools used to d iagn osis and repair a correctly, a chart in Section A will be u sed to
system . correct the problem . If the fuel system goes
closed loop and o p erates norm ally, go to the
The D riveability and E m issions Section s are
D riveability Sym ptom s in Section B. Section
subd ivided into three sub sections:
B lists variou s d riveab ility sym p tom s w h ich
may be found, and su g g e sts ch eck s o f related
SECTION A - DIAGNOSTIC CHARTS com p on en ts, m any o f w h ich are found in
Section "C.
The D iagnostic C ircuit C heck in Section A is
This p roced u re will help lead you to repair
the starting point for the d iagn ostic p rocedure to
the problem in the least am ount o f tim e.
be used on C alifornia 4.3L, 5.0L, or 5.7L en gin es
with an E lectronic Control M odule (ECM). If an Before ch eck in g the system , ob serve the
engine d oes not use an ECM, start the d iagn osis follow in g inform ation:
with D riveability Sym ptom s in Section B.
Blocking Drive Wheels
The d iagn ostic charts are related to the ECM
The veh icle drive w h eels should a lw a y s be
and w ill determ ine if the ECM is w orking
block ed ,an d P ark in g Brake firm ly set, w h ile
ch eck in g the system .
E AS Y-TO -FO LLO W T R O U B L E S H O O T I N G PATH
OWNER COMPLAI NT: E X C E S S I V E SPARK D E T O N A T I O N , 3.8L V6 ENGINE
START HERET1 r
C H E C K C OD E D I S P L A Y S Y S T E M . !
i r i ... i dii
Figure 2 Diagnostic Proced ure
NO ADDITIONAL CODES
| S O U R C E OF C O M P L A I N T L O C A T E D ! 1
NO C OD E F O U N D .
CHECK F U EL C O N T R O L SYS TE M
FIELD SERVICE
CODE CHECK
FU E L SYSTEM
OPER ATING
N O R M A L L Y . SEE
D R IV E R COMPLAI
SECTION B.
VISUAL/PHYSICAL UNDERHOOD DIAGNOSTIC INFORMATION

INSPECTION 4.3L, 5.0L, or 5.7L in California
One of the m ost im portant ch eck s that m ust The E lectronic Control M odule (ECM) is
be done as part o f any d iagn ostic p rocedure is a eq u ip p ed w ith a self- d ia g n o sis system w h ich
careful visu al/p h ysical underhood in sp ection . d etects system failure and aids the tech n icia n by
This can often lead to fixing a problem w ithout id en tifyin g the fault via a trou b le code. B elow is
further steps. In sp ect all vacuum h oses for inform ation ab ou t th e w ay the ECM d isp la y s a
correct routing, p in ch es, cuts, or d isco n n ects. Be problem and how this co rresp o n d s to a trou b le
sure to in sp ect h oses that are difficu lt to see cod e in the ECM.
beneath the air cleaner, com p ressor, generator,
etc. Inspect all the w ires in the en gin e "CHECK ENGINE" or "SERVICE ENGINE SOON" LIGHT
com partm ent for correct and good con n ection s,
burned or chaffed sp ots, pinched w ires, or A lthough this ligh t may in d icate eith er
con tact with sharp ed ges or hot exh au st w ord in g d ep en d in g on the veh icle, it h as the
m anifolds. T his v isu al/p h ysical inspection is sam e function in eith er case. The term s are
very im portant. It m ust be done carefully and in terch an geab le. T his ligh t is on the in stru m en t
thoroughly. p an el and has tw o functions:
It is used to tell the driver that a problem has
BASIC KNOWLEDGE REQUIRED occu red , and that the v eh icle sh ou ld be taken
for service as soon as reason ab ly p o ssib le.
Before u sin g this section o f the Service It is used by the tech n ician to read out
M anual, there are som e areas that you should be "Trouble Codes" to help d ia g n o sis system
fam iliar with. W ithout this basic k n ow led ge, you problem s.
w ill have trouble u sin g the d iagn ostic proced u res
contained in this section. A s a bulb and system ch eck , the ligh t w ill
com e "ON" w ith the key "ON" and the en gin e not
running. When the en gin e is started , the ligh t
Basic Electric Circuits w ill turn off. If the light rem ains on, the s e lf
d iagn ostic system has d etected a problem . If the
You should un d erstan d the basic theory of problem goes aw ay, the light w ill go out in m ost
electricity, and know the m eaning o f voltage, c a ses after 10 se co n d s, but a T rouble Code w ill
am ps, and ohm s. You sh ou ld und erstand w hat rem ain stored in the ECM.
h ap p en s in a circu it w ith an open or a shorted
w ire. You should be able to read and und erstand
a w irin g diagram . A short to ground is referred INTERMITTENT "CHECK ENGINE" or "SERVICE ENGINE
to as a ground to d istin gu ish it from a short SOON" LIGHT
betw een w ires.
The D iagnostic C harts in Section A are set up
to ch eck w h ether or not a stored trou ble cod e is
Use of Circuit Testing Tools "interm ittent" or "hard".
You sh ou ld know how to use a test light, how An "interm ittent" cod e is one w h ich d o es not
to con n ect and u se a tachom eter, and how to use reset itself, and is not p resen t w h ile you are
jum per w ires to by-pass com p onents to test w orking on the veh icle. T his is often cau sed by a
circuits. loose con n ection . If a chart lead s you to an
interm ittent con d ition , go to "INTERM ITTENTS
in Section B.
Use of Digital Volt-Ohm Meter (DVM)
A "hard" cod e is on e w h ich is p resen t w hen
You should be fam iliar w ith the Digital Volt- you are w orking on the v eh icle and rep eats itse lf
Ohm Meter, particularly essen tia l tool J-29125-A, in the Chart P roced u res. The ch art with the
J34029A, or equivalent. You sh ou ld be able to stored trouble code num ber w ill lead you to the
m easure voltage, resistan ce, and cu rren t and c a u se o f the problem .
k n ow how to use the m eter correctly.
The Digital Volt-Ohm M eter is covered in the
"Special Tools" portion of this section.
Trouble Codes Diagnostic Mode

The E lectronic Control M odule, (ECM), is If the D iagnostic term inal is grou n d ed with
really a com puter. It u ses sen sors to look at m any the ignition "ON" and the en gin e sto p p ed , the
engine operating con d ition s. It has a m em ory system w ill enter the D iagn ostic M ode. In this
and it k now s w h at a certain sen sor readin gs m ode the ECM will:
should be und er certain con ditions. T hese 1. D isplay a cod e "12" by fla sh in g the "CHECK
conditions are d escrib ed on the facing page of ENGINET SERVICE ENGINE SOON" light
each Trouble Code Chart. If a sen sor read in g is (ind icating the system is operating). A code
not w hat the ECM thin ks it should be, the ECM "12" co n sists of one flash , follow ed by a short
will turn on the "CHECK ENGINET S E R VICE pause, then tw o fla sh es in q uick su ccessio n .
ENGINE SOON light on the instrum ent panel, T his code will be flash ed three tim es. If no
and will store a Trouble Code in the memory. The other co d es are stored, cod e 12 w ill con tin u e
Trouble Code tells w h ich CIRCUIT the trouble is to flash until the D iagn ostic term inal is
in. A circuit con sists o f a sen sor (such as coolan t ungrounded:
tem perature), the w iring and con n ectors to it,
and the ECM. The en gin e should not be started w ith the
To get a Trouble Code out of the ECM, we use D iagnostic term inal grou n d ed , b ecau se it may
the A ssem bly Line C om m unication Link (ALCL) con tin u e to flash a Code 12 w ith the en gin e
connector. running. A lso, if the test term ina' is grounded
after the en gin e is running, any stored cod es
w ill flash, but Code 12 w ill flash only if there
ALCL Connector is a problem with the d istrib u tor referen ce
signal.
The A ssem bly Line C om m unication Link
(ALCL) is a d iagn ostic conn ector located in the
p assenger com partm ent (Figure 3). It has 2. D isplay any stored trou b le c o d es by flash in g
term inals w hich are used in the assem bly plant to the "CHECK ENGINE/"SERVICE ENGINE
check that the en gin e is op erating properly SOON light. Each code w ill be flash ed three
before it leaves the plant. Term inal "B" is the tim es, then cod e "12" w ill be flash ed again.
D iagnostic term inal, and it can be con n ected to If a trou ble cod e is d isp la y ed , the m em ory is
term inal "A", or ground, to enter the D iagnostic cleared, then the en gin e is run to see if the
mode. code is a "hard" or "interm ittent" failure. If it
is a "hard" failure, a D iagn ostic Code Chart is
used to find the problem . If it is an
interm ittent failure, the ch arts are not used.
A p h ysical in sp ection o f the ap p lica b le
system is m ade.
TERMINAL IDENTIFICATION
M GROUND [j T J T.C.C . (IF USED) 3. Energize all ECM con trolled relays and
0 DIAGNOSTIC TERMINAL
so len o id s (with som e ex cep tio n s, as noted in
"Com ponent System s").
A.I.R. (IF USED)
The M ixture Control S olen oid is pulsed for 25
[ d ~] SERVICE ENGINE SOON LAMP seco n d s or until the e n g in e is started,
3-26-85 6S2614-6E w h ich ever occurs first.
Figure 3 ALCL C onnector
ALCL Mode SECTION B - DRIVEABILITY SYMPTOMS

Tools are available from various su p p liers for A lw ays start w ith S ection A D iagn ostic
reading inform ation from the ALCL con n ector. C ircuit C h eck on C om puter Com m and C ontrol
With a tool con n ected , the ECM w ill be in the veh icles before p ro ceed in g to the d riveab ility
ALCL m ode. The inform ation w h ich can be sym ptom s. Section A c h e c k s the ECM w h ich may
obtained, and how it can be used in d ia g n o sis, is be the d riveab ility problem . On all other
found in "Special T ools. veh icles, start w ith Section B. A d efin ition of
each sym ptom is d escrib ed for that con d ition .
Clearing Trouble Codes
This w ill then lead to the m ost probable c a u se s o f
When the ECM sets a trou ble code, the the d riveab ility problem .
"CHECK EN G IN E/"SERVICE ENGINE SOON
light w ill com e "ON and a trou ble cod e w ill be SECTION C - COMPONENT SYSTEMS
stored in m em ory. If the problem is interm ittent, There are m any com p on en t system s that are
the light w ill go out after 10 se co n d s, w hen the used to control fuel and em issio n s. Section C
fault goes aw ay. H ow ever, the trou ble cod e will in trod u ces each com p on en t system or con trol
stay in the ECM m em ory until the battery voltage w ith a general d escrip tion . Inclu ded in each
to the ECM is rem oved. R em oving battery voltage system is d ia g n o sis and on- veh icle service.
for 10 seco n d s will clear all stored trou ble codes.
Trouble C odes sh ou ld be cleared after repairs Computer Command Control
have been com p leted . A lso, som e D iagnostic
This Section d e sc rib e s the E lectronic C ontrol
Charts w ill tell you to clear the cod es before
M odule (ECM) and the inform ation sen so rs in the
u sing the chart. T his allow s the ECM to set the
system .
cod e w h ile goin g thru the chart, w h ich w ill help
to find the cau se o f the problem m ore quickly. F igure 4 sh o w s the op eratin g co n d ition s
w h ich the ECM may se n se and the system s that
NOTICE: To prevent ECM damage, the key must
the ECM may control.
be "OFF" when disconnecting or reconnecting
power to ECM (for example battery cable, ECM Fuel Control System
pigtail, ECM fuse, jumper cables, etc.).
The ECM con trols the air/fuel d elivery to the
com b ustion cham ber.
ECM Learning Ability
The ECM has a learning" ability. If the Fuel delivery is controlled by a m ixture
battery is d iscon n ected to clear d iagn ostic cod es, control solen oid in the carburetor.
or for repair, the "learning" p ro cess has to begin The ECM, on som e en g in es, con trols the idle
all over again. A ch an ge may be noted in the sp eed .
veh icles perform ance. To "teach" the veh icle,
m ake sure the veh icle is at op eratin g
tem perature, and drive at part throttle, with
m oderate acceleration and id le con d ition s, until
norm al perform ance returns.
6E-8- DRIVEABILITY AND EMISSIONS
Air M anagem ent

A/C "O n" or "O ff"
Canister Purge
Engine Coolant "Tem perature
ELECTRONIC Exhaust Gas Recirculation (EGR)
Engine crank signal
(ENGINE) Electronic Spark Timing
Exhaust Oxygen ( 0 2) Sensor
CONTROL Fuel Control
Distributor Reference
MODULE Transmission Converter Clutch (TCC)
Crankshaft Position
(ECM) Air Conditioning
Engine Speed (RPM)
Diagnostics
System Voltage
Service Engine Soon" Light
Throttle Position (TPS)
Diagnostic Terminal (ALCL)
Transmission Gear Position
Data O utput (ALCL)
Fuel Pump Voltage
Electronic Spark Control (ESC) 4.3L
EGR Vacuum
Engine Knock (ESC)
D ifferential Pressure (VAC)
'ALL SYSTEMS NOT USED ON ALL ENGINES
3-22-85
f6S 2612-6E
Figure 4 ECM O perating C onditions S en sed and S ystem s C ontrolled

Evaporative Emission Control Exhaust Gas Recirculation (EGR)
This system has a can ister w h ich stores fuel The EGR system u ses a valve to feed a sm all
vapor from the fuel tank and the carburetor (if am ount o f ex h a u st gas back into the intake
used). The fuel vapor is rem oved from the m anifold to control form ation o f NOx. This
canister and consum ed in the norm al com b ustion system is used on m ost en g in es and may or may
process w hen the en gin e is running. T his system not be controlled by the ECM.
is used on all en g in es and may or may not be Early Fuel Evaporation (EFE)
controlled by the ECM.
The EFE system heats the e n g in e in d u ction
Electronic Spark Timing (EST) system or w ith exh au st gas d u rin g cold
This system is controlled by the ECM w hich driveaw ay. T his system is not con trolled by the
controls distributor spark ad van ce (timing) and ECM.
is used on all en gin es. Electronic Spark Control (ESC)
Air Injection Reaction (AIR) This system u ses a a K nock S en sor in
The system provid es additional oxygen to the con n ection with the ECM to con trol spark
exh aust gases to con tin u e the com b ustion tim ing on som e en g in es to allow the en gin e to
process. The A I R system is not on all en gin es have m axim um spark a d van ce w ith ou t spark
and may or may not be controlled by the ECM. knock. T his im proves d riv ea b ility and fuel
Deceleration Control econom y.
The deceleration control u ses a d eceleration Transmission Converter Clutch (TCC)

valve to control em ission s and back-fire on The TCC is ECM controlled on C alifornia
deceleration. When deceleration ca u ses a sudd en 4.3L, 5.0L, and 5.7L en g in es and is used on all
rise in m anifold vacuum , the deceleration valve en gin es with an autom atic tran sm ission . This
will open to adm it fresh air to the inlet m anifold. system red u ces slip p age lo sse s in the torque
A fter a calibrated tim e delay, the valve will close. converter in an autom atic tran sm ission by
The system is m ainly used with m anual cou p lin g the en gin e flyw h eel to the ou tp u t shaft
tran sm ission eq u ip p ed veh icles. o f the tran sm ission . R efer to S ection 7A for TCC
service inform ation w ithout ECM control.
A/C Clutch Control

The ECM may control the A/C clu tch on the CALPAK - A d ev ice u sed w ith fuel injection to
com p ressor to im prove id le quality. T his control allow fuel d elivery in the ev en t of a PROM or
is not on all en gin es. ECM m alfunction.
A/C Wide Open Throttle (WOT) Control CALIBRATOR - (PROM ). An electro n ic
The ECM con trols the A/C com p ressor clu tch com p on en t w h ich can be sp e c ific a lly
to d isen gage clu tch during hard acceleration . On program m ed to m eet en gin e op p eratin g
som e en gin es, the ECM d isen g a g es the clu tch requirem en ts for each veh icle m odel. It p lu gs
du ring en gin e start-up on a warm en gine. T his into the E ngine C ontrol M odule (ECM).
control is not on all en gin es. CCC - COM PUTER COMMAND CONTROL -
has an electron ic control m odule to con trol
A/C Constant Run Control air/fuel and em ission system s.
The ECM controls a relay to keep the A/C
com p ressor clu tch from cy clin g at idle for three C3I - C om putor C ontrolled Coil Ignition.
m inutes. This control is not on all en gin es. P rod u ces the ignition sp ark w ith ou t the aid o f an
ignition distributor.
Positive Crankcase Ventilation (PCV) CCP - CONTROLLED CA NISTER PURG E -
The PCV system p a sse s cran k case vapors ECM con trolled so len o id valve that perm its
into the intak e m anifold. T his system is not m anifold vacuum to purge the evap orative
controlled by the ECM and is u sed on all en gin es. em ission s from the ch arcoal can ister.
Thermostatic Air Cleaner (THERMAC) CE - CHECK ENGINE - Lights w h en a
The THERMAC system regu lates heated air m alfunction occu rs in C om puter Com m and
through the air clean er to provide uniform inlet Control.
air tem perature w h ich gives good d riveab ility CII) - Cubic Inch D isp lacem en t
u nd er variou s clim atic co n d ition s. This system is
not controlled by the ECM and is used on all C L O O P -C losed Loop
en gin es. CLCC - CLOSED LOOP CARBURETO R
ABBREVIATIONS AND GLOSSARY OF TERMS CONTROL - Used to d e sc rib e oxygen sen so r to
ECM to M/C solen oid circu it operation.
A b b reviation s used in this Section are listed
below in alp h ab etical order w ith an explanation COOLANT TE M PER A TU R E SENSO R -
of the abbreviation. There are som e variations in D evice that se n se s the en gin e coolan t
the use of p eriod s and in capitalization (as mph, tem perature, and p a sse s that inform ation to the
m .p.h., Mph, and MPH) for ab b reviation s used in electron ic control m odule.
this Section but all typ es are accep tab le.
CONV.. - CATALYIC CO NVERTER, THREE-
WAY - EXHAUST CO NVERTER. C on taining
A/F - A ir/Fuel (A/F Ratio)
platinum and p allad ium to sp eed up con version
AIR - AIR INJECTOR REACTION SYSTEM - o f HC and CO, and rhodium to a ccelerate
Air flow from pum p is directed into en gin e con version o f NOx.
exh au st m anifold and/or con verter to reduce
CO - CARBON M ONOXIDE - One o f the
exhaust.
p ollu tants found in en gin e exh au st.
ALCL - A ssem b ly Line C om m unication Link -
DIS - D irect Ignition System . P rod u ces the
Used at assem bly to evalu ate C om puter
ignition spark w ith ou t the aid o f an ignition
Com m and Control and for service to flash the
distributor.
"SERVICE ENGINE SOON" light if there are
trouble cod es. DIAGNOSTIC CODE - Pair of num bers
obtain ed from flash in g "SERVICE ENGINE
ATS - Air T em perature Sensor. M easures
SOON" light. T his cod e can be u sed to determ in e
tem perature o f am bient air.
the system m alfunction.
BARO - BAROM ETRIC ABSOLUTE
DIAGNOSTIC TERM. - Lead of ALCL
PR E SSU R E SENSOR - R eads atm ospheric C onnector w h ich is grou n d ed to get a T rouble
pressu re. Code. On EFI it is grou n d ed w ith the en gin e
Bat + - Battery P ositive T erm inal (12 Volts) running to en ter the "Field Service M ode.
6E-10-DRIVEABILITY AND EMISSIONS
DVM (10 Meg.) - Digital V oltm eter w ith 10 HIGH IM PEDANCE VOLTMETER - H as high
M illion ohm s resistan ce - u sed for m easurem en t op p osition to the flow o f electrical cu rren t. Good
in electronic system s. for read in g circu its w ith low cu rren t flow , su ch
as found in electron ic system s b eca u se it allow s
DWELL - The am ount o f tim e (recorded on a tests to be m ade w ith ou t affectin g the circuit.
d w ellm eter in d egrees o f cran k sh aft rotation)
that current p asses through a closed sw itch; for HEI - HIGH ENERGY IGNITION - is a
exam ple, ignition con tact points or in ternal distrib u tor that u ses an electron ic m odule and
sw itch in an electronic control m odule. pick-up coil in place o f con tact points.
EAC - E lectric Air Control - Used on AIR Hg - M ercury, a calibration m aterial used as a
System to direct air flow to Air S w itch in g valve stan dard for vacuum m easurem ent.
or air cleaner.
IAC - IDLE AIR CONTROL - in stalled in the
EAS - E lectric Air S w itch in g - used to d irect throttle body o f fuel injected system s and
air flow to catalytic con verter or ex h a u st ports of controlled by the ECM to regu late id le sp eed .
the engine.
IDEAL MIXTURE - The air/fuel ratio w h ich
ECM - ELECTRONC (ENGINE) CONTROL p rovid es the b est p erform ance, w h ile
MODULE - A m etal cased box (located in m aintainin g m axim um con version o f ex h a u st
p assen ger com partm ent) con tain in g electron ic em ission s, typ ically 14.7/1.
circuitry w hich electrically con trols and
IDLE AIR BLEED VALVE - C ontrols the
m onitors air/fuel and em ission system s on
am ount of air let into the idle fuel m ixture prior to
Com puter Command Control, and turns on the
the m ixture en tering the carb u retor id le system ,
"SERVICE ENGINE SOON light w h en a
w hen the M/C solen oid is en ergized.
m alfunction occurs in the system .
EFI - E lectronic Fuel Injection is C om puter IGN -IG N ITIO N
Com m and Control u sin g throttle body fuel ILC - IDLE LOAD CO M PENSATOR - is used
injection. to control throttle angle d u ring lon g d eceleration
EGR - EXHAUST GAS RECIRCULATION - su ch as co astin g dow n a long grade and exten d s
at w ide open throttle position or to prevent
M ethod o f reducin g NOx em ission levels.
en gin e stalls at idle.
EECS - EVAPO RATIVE EM ISSIO NS
CONTROL SYSTEM - Used to preven t g asolin e IN PU TS - Inform ation from so u rces (coolant
vapors in the fuel tank and carburetor from tem peratu re sen so rs, e x h a u st oxygen sen sor,
en tering the atm osphere. etc.) that tells the ECM how the en gin e is
perform ing.
EFE - EARLY FUEL EVAPO RATIO N (EFE) -
M ethod o f w arm ing the intak e m anifold d u rin g INTERM ITTENT - O ccurs now and then; not
cold en gin e operation. P rovides efficien t air/fuel con tin u ou sly. In electrical circu its, refers to
m ixing. occa sio n a l open, short, or ground.
ENERGIZE/DE-ENERGIZE - When cu rren t I.P. - INSTRUM ENT PA N EL

is p assed through a coil su ch as the M/C solen oid , ISC - IDLE SPE E D CONTROL - R egulates
the m etering control arm ature is pulled into the throttle valve p osition , is con trolled by the ECM.
solen oid (energized). When the voltage to the
solenoid is turned off, a sp rin g raises the KM/HR - KILOMETER PER HOUR - A
m etering control arm ature (de- energized). m etric unit m easuring d ista n ce (1000 m eters) in
one hour.
ESC - E lectronic Spark Control - Used to
m odify spark advance w hen d etonation occu rs. L - LITER - A m etric unit o f cap acity.
EST - ELECTRONIC SPA R K TIMING - ECM L4 - Four C ylinder In-Line Engine

controlled tim ing o f ignition spark. M ALFUNCTION - A problem th at c a u se s the
EVRV - E lectronic V acuum R egulator V alve. system to operate in correctly. T ypical
C ontrols EGR vacuum . m alfunctions are; w irin g h arn ess o p en s or sh orts,
failed sen so rs, or circu it com p on en ts.
FED - FEDERAL - V eh icle/E ngine availab le
in all states excep t C alifornia. M ANIFOLD VACUUM SEN SO R - R eads
p ressu re c h a n g es in in tak e m anifold in relation
GROUND - A Wire shorted to ground. to barom etric p ressu re. May be called a
d ifferen tial p ressu re sen sor.
HC - HYDROCARBONS (HC) - One o f the
p ollu tan ts found in en gin e exhaust.
MAP - M ANIFOLD ABSOLUTE PR ESSU R E RPM - REVO LUTIONS PER MINUTE - A

SENSO R - R eads p ressu re ch a n g es in intak e m easure o f rotational sp eed .
m anifold w ith referen ce to zero or ab solute
RVB - REAR VACUUM BRAKE - is u sed to
vacuum .
control ch ok e op eration d u rin g cold en gin e
MAF - M ASS AIR FLOW con ditions.
MAT - M anifold Air T em perature Sensor. SELF-DIAGNOSTIC CODE - The ECM can
M easures air tem peratu re in the intake m anifold. d etect m alfunctions in the system . If a
m alfunction occu rs, the ECM turns on the
M/C - MIXTURE CONTROL "SERVICE ENGINE SO O N light. A d iagn ostic
MFI - M ULTIPORT FUEL INJECTION. code can be obtain ed from the ECM through the
Individual injectors for each cylin d er are "SERVICE ENGINE SO ON light. This cod e will
m ounted in the intake m anifold. The injectors are indicate the area of the m alfunction.
fired in groups rather than in d ividu ally. SERVICE ENGINE SOON Light - Lights
MIXTURE CONTROL (M/C) SOLENOID - w hen a m alfunction occu rs in C om puter
D evice, in stalled in carburetor, w h ich regulates Com m and Control system . See "CHECK
the air/fuel ratio. ENGINE.
MODE - A particular state o f operation. TACH - TACHOM ETER
MPH - MILES PER HOUR - A unit m easuring TBI - THROTTLE BODY INJECTION (Unit) -
d istan ce (5280 feet) in one hour. is controlled by the ECM to su p p ly p recise
air/fuel m ixture into the in tak e m anifold.
N.C. - NORMALLY CLOSED. State o f relay
con tacts or solenoid plu n ger w hen no voltage is TCC - TR A N SM ISSIO N / TRANSAXLE
applied. CONVERTER CLUTCH - ECM con trolled
solen oid in tran sm ission w h ich p o sitively cou p les
N.m - NEWTON M ETERS (Torque) - A m etric the tran sm ission to the en gin e.
unit w h ich m easures force.
THERM AC - THERM OSTATIC AIR
N.O. - NORMALLY O PEN . State of relay CLEANER- provid es p reheated air to intak e
c on tacts or solenoid p lunger w hen no voltage is m anifold to provide better driveab ility w hen
applied. en gin e is cold.
NOx - NITROGEN, OXIDES OF (NOx) - One of TPS - THROTTLE PO SITIO N SENSO R -
the p ollu tan ts found in en gin e exh au st. D evice that tells the ECM the throttle position.
O 2 - OXYGEN (Sensor) - M onitors the oxygen TVS - THERM AL VACUUM SWITCH. U sed
con ten t o f the exh au st system and gen erates a to control vacuum in relation sh ip to en gin e
voltage sign al to the ECM. tem perature.
O PEN LOOP - D escrib es ECM fuel control V - VOLT
w ithout use o f oxygen sen so r inform ation.
V-6 - SIX CYLINDER ENGINE - A rranged in
O UTPUT - F un ctions, typ ically solen oid s, that a "V
are controlled by the ECM.
V-8 - EIGHT CYLINDER ENGINE - A rranged
OXYGEN SENSO R, EXHAUST - D evice that in a "V
d etects the am ount of oxygen (O2 ) in the exh au st
stream . VACUUM - N egative pressure; less than
atm ospheric pressu re.
PAIR - PULSE AIR INJECTION REACTOR
system - p u lsed air directed into en g in e to reduce VACUUM, M ANIFOLD - V acuum so u rce in
ex h a u st em ission s. m anifold below throttle plate.
PCV - POSITIVE CRANKCASE VACUUM , PORTED - A vacuum sou rce
VENTILATION - P reven t fum es in cran k case above (atm ospheric sid e ) of clo sed throttle plate.
from p a ssin g into atm osphere. VAC SENSO R - A b b reviation for D ifferential
PFI - PORT FUEL INJECTION P ressu re Sen sor w h ich is a vacuum sen sor.
P/N -PA R K /N E U T R A L VIN - VEHICLE IDENTIFICATIO N
NUM BER.
PORT - E xhaust Port
VSS - VEHICLE SPE E D SENSO R (VSS) -
PROM - PROGRAM ABLE READ ONLY Sen sor in sp eed o m eter clu ster w h ich sen d s
MEMORY- an electronic term used to d escrib e veh icle speed inform ation to the ECM.
the en gin e calibration u n it .
WOT - WIDE OPEN THROTTLE.
WIRING HARNESS SERVICE FEMALE Ma l e

CONNECTOR CONNECTOR
BODY BODY
GENERAL DESCRIPTION
The ECM wire harness electrically con n ects
the ECM to the various solen oid s, sw itch es, and
sen sors in veh icle en gin e com partm ent. The ECM
is located in sid e the v eh icle p assen ger 1. OPEN SECONDARY LOCK HINGE ON CONNECTOR
com partm ent.
M ost con n ectors in the en gine com partm ent
are protected against m oisture and dirt w hich
could create oxidation and d ep o sits on the
term inals. This protection is im portant b ecau se
o f the very low voltage and cu rren t levels found
in the electron ic system . As sh ow n in Figure 5, 2. REMOVE TERMINAL USING TOOL
the con n ectors have a lock w h ich secu res the PUSH TO
RELEASE
male and fem ale term inals together. A secon d ary
lock holds the seal and term inal into the
connector.
TERMINAL REMOVAL
ON-VEHICLE SERVICE TOOL J-28742
GENERAL 3. CUT WIRE IMMEDIATELY BEHIND CABLE SEAL
M olded-on con nectors (like m etro pack)

require com plete replacem ent o f the con n ector. WIRE
This m eans sp licin g a new con n ector assem b ly EAL
into the harness. Figure 7 has in stru ction s on REPLACE TERMINAL
sp licin g w ires. A. SLIP NEW SEAL ONTO WIRE.
B. STRIP 5 mm (.2") OF IN S U L A T IO N FROM WIRE.
Use care w hen probing the co n n ector or C. CRIMP T E R M I N A L O ^ E R W 'R E A N D SEAL.
rep lacin g term inals in them . It is p o ssib le to
short betw een op p osite term inals. If this EAL
hap p en s to the w rong term inal pair, it is p ossib le
to dam age certain com p onents. A lw ays use 5. PUSH TERMINAL AND CONNECTOR AND
jum per w ires betw een con n ectors for circuit ENGAGE LOCKING TANGS.
ch eck in g. NEVER probe through the W eather- 6. CLOSE SECONDARY LOCK HINGE
Pack seals.
04 09 8 4 5S 1 5 5 5 -6 E
When d iagnosin g, open circu its are often Figure 5 W eather-Pack T erm inal Repair
d ifficu lt to locate by sigh t b ecau se oxidation or
term inal m isalignm ent are hidden by the id en tified by the rubber seal at the rear o f the
con n ectors. M erely w igglin g a con n ector on a con n ector. Figure 5 sh o w s a W eather-Pack
sen sor or in the w iring h arness may correct the term inal and the tool (J-28742) required to service
open circu it condition. T his should alw ays be it. This tool is used to rem ove the pin and sleeve
con sid ered w hen an open circu it or failed sen sor term inals. If rem oval is attem pted w ith an
is indicated. Interm ittent problem s may also be ordinary pick, there is a good ch a n ce that the
caused by oxidized or loose con n ection s. term inal will be bent or d eform ed, and, unlike
standard blade type term in als, th ese term in als
Before m aking a con n ector repair, be certain
can n ot be straigh ten ed on ce they are bent.
of the type of connector. W eather-Pack and
Com pact Three con n ectors look sim ilar but are Make certain that the co n n ecto rs are
serviced differently. properly seated and all o f the sea lin g rings in
place w hen con n ectin g lead s. The hinge type flap
R eplacem ent con n ectors and term in als are
p rovides a backup, or seco n d a ry lock in g feature
listed in Group 8.965 of the Standard Parts
for the con nector. T hey are u sed to im prove the
Catalog.
con n ector reliability by retain in g the term in als if
CONNECTORS the sm all term inal lock tan gs are not position ed
properly.
WEATHER-PACK W eather-Pack c o n n e c tio n s can n ot be
Som e conn ectors used w ith an ECM are replaced with stan dard con n ection s.
called W eather-Pack. T hese con n ectors can be In struction s are provided w ith W eather-Pack
con n ector and term inal p ack ages.
J _ CABLE [T ] L OCKING TANG WITH T OO L IN PLACE, G E N T L Y PULL

2J T E R M IN A L '"T " TOOL J33095 ON THE CABLF. TO REMOVE T E R M IN A L .
V I S U A L L Y CHECK T E R M I N A L A ND
REPLACE IF T E R M I N A L C A V I T Y OR TANG
IS DAMAGED.
IN S T A L L T E R M I N A L INTO CONNECTOR
1. GRASP CA BLE A N D PUSH T E R M I N A L C A V I T Y U N T I L LO CKING TANG HAS
TO THE MOST F O R W ARD POSITION. SNAPPED INTO POSITION.
2. INSERT TOOL J33095 S T R A IG H T INTO
THE FRONT OF THE CONNECTOR C A V IT Y .
DO NOT USE C O N V E N T IO N A L PICK TO REMOVE
T E R M IN A L .
03 21 84 5S 1418-6E
Figure 6 M icro Pack T erm inal R eplacem ent
COMPACT THREE SPECIAL TOOLS

The C om pact T hree con n ector w h ich looks TOOLS NEEDED TO SERVICE THE SYSTEM
sim ilar to a W eather-Pack con n ector not sealed
The system d oes not require sp ecia l testers
and is used w h ere resista n ce to the en viron m en t for d iagn osis. A tach om eter, test light,
is not required. This type of con n ector m ost ohm m eter, digital voltm eter w ith 10 m egohm s
likely is used at the air control solen oid . Use the
im p ed an ce (J-29125A), vacuum gage and jum p er
standard m ethod w hen repairing a term inal. Do w ires are required for d ia g n o sis. A test light or
not use the W eather-Pack term inal tool J-28742. voltm eter m ust be used w h en sp ecified in the
p rocedures. T hey m ust NOT be in terch an ged .
MICRO-PACK See F igures 8 through 11 for S p ecial T ools need ed
to d ia g n o sis or repair a system .
Som e c o n n ecto rs used on harness to con n ect
to the ECM are called M icro-Pack. Term inal
rep lacem en t req u ires the use of a sp ecial tool. ALCL "SCAN" Tools
Refer to Figure 6 for M icro-Pack term inal
replacem ent. The ALCL co n n ector u nd er the d ash has a
variety of inform ation availab le on term inal "D"
(called Serial Data). T here are several tools
WIRE HARNESS availab le for read in g this inform ation.
Wire h a r n e sses should be replaced with "SCAN tools do not m ake the use o f
proper part num ber h arn esses. When sign al d iagn ostic charts u n n ecessary. T hey do not tell
w ires are sp liced into a harness, use w ire w ith exactly w here a problem is in a given circuit.
high tem perature in su lation only. H ow ever, w ith an u n d ersta n d in g o f w h at each
position on the eq u ip m en t m easu res, and
With the low cu rren t and voltage levels found
k n ow led ge o f the circu it in volved , the tools can
in the system , it is im portant that the best
be very u sefu l in gettin g inform ation w h ich
p o ssib le bond at all w ire sp lices be m ade by
w ould be more tim e con su m in g to get w ith other
sold erin g the sp lices as sh ow n in Figure 7.
equipm ent.
6E-14- DRIVEABILITY AND EMISSIONS
TWISTED/SHIELDED CABLE TWISTED LEADS

D R A IN WIRE
z OUTER JA C K E T
MYLAR
1. REMOVE OUT ER JACK ET . 1. LOCAT E D A M A G E D WIRE.

2. UNWRAP A L U M I N U M / M Y L A R TAPE. DO NOT 2. REMOVE IN S U L A T IO N AS REQ U IR E D .
REMOVE M Y L A R .
SPLICE & SOLDER
I
3. UNTWIST CONDUCTORS. STRIP IN S U L A T IO N AS 3. SPLICE TWO WIRES TOG ETHER USING SPLICE
NECESSARY. CLIPS A N D ROSIN CORE SOLDE R.
DR A IN WIRE
I 2
4. SPLICE WIRES USING SPLICE CLIPS A N D ROSIN CORE 4. CO VE R SPLICE WITH TAPE TO IN S U L A T E
SOLDER. WRAP EACH SPLICE TO INSULA TE . FROM OTHER WIRES.
5. WRAP WITH M Y L A R A N D D R A IN (U N IN S U L A T E D ) WIRE. 5. RETWIST AS BEFORE A ND TAPE WITH
E L E C T R IC A L TAPE A N D HO LD IN PLACE.
I
6. TAPE O VER WHOLE BUN DLE TO SECURE AS BEFORE. 4S 0570-6 E
Figure 7 Wire H arness Repair
In som e cases, SCAN Tools will provide Intermittent Conditions

inform ation that is either extrem ely difficu lt or
im p ossib le to get with other equipm ent. The SCAN tool is helpful in c a ses of
When a chart calls for a sensor reading, the interm ittent operation. The tool can be plugged
SCAN tool can be used to read the follow ing in and ob served w hile driving the v eh icle und er
directly: the condition w here the light com es "ON
m om entarily, or the en gin e d riveab ility is poor
Throttle Position S ensor in volts m om entarily. If the problem seem s to be related
Vacu um S ensor in volts to certain areas that can be ch eck ed on the
C oolant T em perature Sensor in C SCAN tool, then those are the p o sitio n s that
O xygen S ensor Voltage should be ch eck ed w h ile d riving the veh icle. If
M/C Solenoid dw ell. there d o es not seem to be any correlation
betw een the problem and any sp ecific circuit, the
SCAN tool can be ch eck ed on each p osition,
When the SCAN tool is plugged in, the w atching for a period o f tim e to se e if th ere is any
"CHECK ENGINE/"SERVICE ENGINE SOON ch ange in the readin gs that in d icates in term ittent
light w ill flash rapidly on a carbureted engine. operation.
This in d icates that inform ation is being
For more com plete inform ation on the
transm itted to the tool.
operation o f th ese tools, see the m an u factu rers
When the tool is plugged in on every system , it in structions.
takes out the tim er that k eep s the system in open
loop for a certain period o f tim e. T herefore, it
w ill go closed loop as soon as the veh icle is
started, if all other closed loop con d ition s are
met.On som e v eh icles w ith ESC, it w ill ad vance
the spark 8 to 10 degrees.
SPECIAL TOOLS
V O L T M E T E R -V o lta g e Position Measures amount
FUSE of voltage. Connected parallel to exiting circuit.
Replace w ith ? im p 3AG fast blow (BUSS
AGO 2 LitHefuse 312002 o ' equivalent)
Verify ihat fuse holder cap is securely
A digital voltmeter with a 10 meg ohm input
snapped into place
POWER
impedence is used because some circuits require
accurate low voltage readings, and some circuits
HIGH IMPEDANCE
have a very high resistance in the ECM.
MULTIMETER
J 1 A This meter also accurately measures extremely low
current flow. Refer to meter for more information.
Both function and range switch must be set properly,
VOLTS
OHMS MA and the DC or AC position selected. DC is used for
(()) + most measurements.
OHMMETER-Resistance Position Measures resistance
of circuit directly in ohms. Refer to meter for more
information.
L_ PROBE Function Range switch:
To replace probe leads
rmo*e sfram
witch |1. I display in all ranges indicates open circuit.
relief clamp and
pull out leads Power twitch Zero display in all ranges indicates a short circuit.
Intermittent connection in circuit may be indicated
HIGH IM PEDANCE M U LT IM E TE R by digital reading that will not stabilize on circuit.
(D IG IT A L V O L T M E T E R -D V M ) Range Switch.
J29125-A or J34029 20012 - Reads ohms directly
2, 20, 200, 2 ,0 0 0 1 2 - Reads ohms in thousands
20M12 - Reads ohms in millions
Amps - Reads in thousandths of an amp.
Volts - Reads directly
VACUUM PUMP (20 IN. HG. MINIMUM)

Use gage to m o n ito r m a n ifo ld engine vacuum . Check vacuum sensors,
so le n o id s and valves w ith hand pum p.
J23738
UNPOWERED TEST LIGHT
Used to check w irin g fo r co m plete circuit. Connect lead w ire to good
g ro u n d . Probe w ith test prod to connector o r co m p o n e n t te rm in a l.
B ulb w ill lig h t if vo ltag e is present.
TACHOMETER
Use e ith e r a crankshaft h a rm o n ic balance pickup type or e le ctronic coil
trig g e r signal pickup type
HEI SPARK TESTER

Use to check HEI spark voltage. Also called ST125.
J26792/BT7220-1
DWELL METER (SET ON 6 CYL. SCALE)

Used to monitor the carburetor fuel control delivery
determined by the ECM command.
05 24 84 5S 1469-6E
Figure 8 S p ecial T ools (1 of 4)
I SPECIAL TOOLS
JUMPER WIRES (#16, 18 OR 20 GAGE WIRE)
Clip ju m p e r w ire used to com plete a circu it by bypassing an open.
Set o f ju m p e r w ires used to insert between W eather Pack
co nn e cto rs to p e rm it access to the connector term in a ls fo r circu it
checking. Six w ire s a p p ro xim a te ly 6 " long. Use te rm in a ls 12014836
and 12014837. One set - fem ale term in a ls both ends, one set - m ale
at both ends and fo u r sets - m ale term in a ls at one end and fem ale
te rm in a ls at the opposite end.
CIRCUIT TESTER
Used to check all relays and solenoids before connecting
them to a new ECM. Measures the circuit resistance and
indicates pass or fail via green or red LED. Amber LED
indicates current polarity. Can also be used as a non
J34636 powered continuity checker.
OIL PRESSURE SWITCH WRENCH

U sed to re m o ve o r in stall o il pressure gage sw itch on engine.
J28687-A/BT8220
WEATHER PACK TERMINAL REMOVER
Used to rem ove te rm in a ls fro m W eather Pack connectors. Refer to
w irin g harness service fo r rem oval procedure.
J28742/BT8234-A
ECM CONNECTOR TERMINAL REMOVER
Use to extract a terminal from edgeboard connectors at the
J22727/BT8234-A ECM.
ECM CONNECTOR TERMINAL REMOVER

Used to remove terminal from Micro-Pack connectors. Refer
to wiring harness service for removal procedure.
J33095/BT8234-A
OXYGEN SENSOR WRENCH

Used to remove or install the oxygen sensor.
J2953^/B T8127
ISC MOTOR TESTER

Used to test operation of ISC motor on carburetor in either
direction and condition of the internal switch.
J34025/BT8256A
ISC ADJUSTING WRENCH
Used to adjust ISC plunger on carburetor to obtain
J29607/BT8022 maximum specification RPM speed.
I 05 24 84 5S 1470-6E
Figure 9 S p ecial T ools (2 of 4)
SPECIAL TOOLS
FLOAT LEVEL GAGE SET
Used to check float level on 2SE or E2SE carburetor.
J9789-135/BT8104
FLOAT LEVEL GAGE

Used to check float level or M/C solenoid plunger travel on
E2ME or E4ME carburetor.
J34935/BT8420A
IDLE MIXTURE SOCKET

Used to adjust idle mixture needle on a E2SE carburetor.
J29030-B/BT761 OB
Xx
J28696-B/BT7928
MIXTURE ADJUSTMENT TOOL
Used to adjust lean mixture and rich mixture stop screws
on E2SE, E2ME or E4ME carburetor.
CARBURETOR ADJUSTMENT WRENCH

Used to remote adjust idle mixture needle on carburetor.
't t
J22646-02
M/C SOLENOID GAGING TOOL
Used to adjust the mixture control solenoid plunger on
E2ME or E4ME carburetor.
J33815-1 /BT8253-A
AIR BLEED VALVE GAGING TOOL

Used to adjust idle air bleed valve on E2ME or E4ME
carburetor.
PUMP LEVER PIN PUNCH

\ Used to drive pump lever pin inward to allow removal of
the pump lever on E2ME carburetor.
J25322/BT7523
BANJO BOLT WRENCH

Used to disconnect or connect fuel inlet on 2.0L TBI engine.
J34062
05 24 84 5S 1471-6EA
Figure 10 S p ecial T ools (3 o f 4)

SPECIAL TOOLS
FUEL LINE WRENCH
Used to connect or disconnect fuel lines at TBI unit by holding fuel nut
at throttle body.
J2969^^T 8251
IDLE AIR CONTROL WRENCH

Used to remove or install IAC valve on throttle body.
IDLE AIR PASSAGE PLUGS

Used to block idle air passages when adjusting m inim um idle speed
on TBI unit. Also may be used to check ECM idle control.
J33047/BT8207-A
MINIMUM AIR RATE ADJUSTING WRENCH

Used to adjust throttle stop screw on TBI unit.
FUEL PRESSURE GAGE

Used to check fuel pressure on TBI engines.
J29658/BT8205
PORT FUEL INJECTION DIAGNOSTIC KIT
5H Used to diagnosis and service port fuel injection systems.

The kit includes:
Fuel Pressure Gage to check fuel pump pressure and
compare injectors for equal fuel distribution.
Test Light to check electrical impulses to an injector.
J 34730-A Injector Tester to evaluate an injector.
FUEL PRESSURE GAGE

Used to check and monitor fuel line pressure
of port fuel system.
J34730-1
i
C9
J 34730-2
%
INJECTOR TEST LIGHT
Used to check port fuel injector signal from ECM.
INJECTOR TESTER
>* Used to perform injector balance test in CHART C-2A.
34730-3
05 24 84 5S 1472-6E
Figure 11 S p ecial Tools (4 o f 4)

GENERAL SPECIFICATIONS
Many of the specifications used in this section are located on the Vehicle Emission Control
Inform ation label under the hood.
Listed on the chart below are locations o f specifications used in this Section.
Carburetor specifications can be found in the appropriate 6C Section of this Service Manual.
SPECIFICATION LOCATION OF INFORMATION
Engine Timing Vehicle Emission Control inform ation label.
Idle Speed, ECM Not adjustable. ECM controls idle.

Controlled
Idle Speed, Non-ECM Vehicle Emission Control Inform ation label.

Controlled-
Carbureted
Idle Speed, M inim um - Vehicle Emission Control Inform ation Label.

Carbureted
Fast Idle Speed- Vehicle Emission Control Inform ation label.

Carbureted
Spark Plug Type See Owner's Manual, Section 7.
Spark Plug Gap Vehicle Emission Control Inform ation Label.
Engine Code 8th d ig it o f VIN number. See Section OA. Also Owner's Manual,
Section 7.
Engine Family Vehicle Emission Control Inform ation label.
Filter Part Numbers See Owner's Manual, Section 7.
Part Numbers of WDD-GM Parts Book.

Major Components
Replacement of WDD-GM Label Catalog.

Vehicle Emission
Control Inform ation
Label
DRIVEABILITY AND EMISSIONS - CARBURETED 6E8-1
SECTION 6E8
DRIVEABILITY AND EMISSIONS
CARBURETED VEHICLE
LIGHT DUTY EMISSIONS HEAVY DUTY EMISSIONS
4.3L ENG. CODE N (RPO LB1) 4.8L ENG. CODE T (RPO L25)
5.0L ENG. CODE F (RPO LF3) 5.7L ENG. CODE M (RPO LT9)
5.0L ENG. CODE H (RPO LE9) 7.4L ENG. CODE W (RPO LE8)
5.7L ENG. CODE L (RPO LS9)
Note: All 5.7L (LS9) engines, in K 10/15 Pick-Ups, K 10/15 Blazers/Jimmys and C 20/25
Pick-Ups, are California engines w ith Computer Command Control.
CONTENTS
INTRODUCTION
G eneral D e sc r ip tio n ........................................6E8-4 Code 45, Rich E xh aust Indication ....... 6E8-62
E ngine E m ission C om ponents ..................6E8-4 Code 51, PROM ...........................................6E8-64'
Code 54, M/C Solenoid High ..................... 6E8-66
S E C T IO N A - D I A G N O S T I C - C H A R T S
G eneral ............................................................ 6E8-24 SECTION B-DRIVEABILITY

D iagnostic C ircuit C heck ...................... 6E8-26 SYMPTOMS
System P eform ance C heck ....................6E8-28 I n te r m itte n ts ................................................... 6E8-68
Chart A -l, D w ell Fixed U nder 10 ..........6E8-30 Wont Start - Engine C ranks O K ............. 6E8-69
Chart A-2, D w ell Fixed B etw een 10 Hard Start - C old.............................................6E8-69
and 50 ...................................................... 6E8-32 Hard Start - Hot ...........................................6E8-70
Chart A-3, D w ell fixed Over 50 .............. 6E8-34 Stall A fter Start - Cold .............................. 6E8-70
Chart A-5, "SERVICE ENGINE SOON" Stall A fter Start -- Hot ............................... 6E8-71
Light Inop erative .............................. 6E8-36 H esitation, Sag, Stum ble ..........................6E8-71
Chart A-6, W ont F lash Code 12 ............. 6E8-38 S u rges and/or C huggle ............................. 6E8-72
Code 12, No R eferen ce P u lse ................ 6E8-40 Lack o f P ow er, S lu ggish or Spongy ...... 6E8-72
Code 13, 02 S en sor Circuit ....................6E8-42 B ackfire ......................................................... 6E8-73
Code 14, C oolant S en sor Circuit M isses ............................... ........................... 6E8-74
Shorted ................................................... 6E8-44 Cuts Out ......................................................... 6E8-74
Code 15, C oolant S en sor Circuit R ough, U n stable or Incorrect Idle;
O pen ..................................... .................... 6E8-46 S tallin g .......................................................6E8-74
Code 21, T hrottle Position Sensor W ont Idle ......................................................6E8-75
C ircuit ......................................................6E8-48 Poor Fuel Econom y ..........................*.........6E8-75
Code 23, M/C Solen oid Circuit Low .....6E8-50 D ieseling, Run-On ...................................... 6E8-75
C ode 34, D ifferential P ressu re S en sor D etonation/Spark Knock ..........................6E8-76
C ircuit ......................................................6E8-52 E xcessive E xhaust E m issions (Odors) .. 6E8-76
Code 41, No D istributor R eference R estricted E xh aust System C heck ....... 6E8-77
C ircuit ......................................................6E8-54
Code 42, E lectron ic Spark T im ing ...... 6E8-56
Code 43, E lectron ic Spark Control ...... 6E8-58
Code 44, Lean E xh aust Indication .........6E8-60
6E8-2 DRIVEABILITY AND EMISSIONS - CARBURETED
SECTION C-COMPONENT Rem ote Lamp D river ...........................6E8-84

SYSTEMS Wiring H arn ess...........................................6E8-84
D iagnosis Chart Sum m ary C oolant T em perature Sensor ............. 6E8-84
ECM R ep lacem ent C heck - D ifferential P ressu re S ensor ............6E8-84
CHART C-l ......................................... 6E8-90 O xygen S e n s o r ........................................... 6E8-84
V acuum S ensor C heck - ECM R eplacem ent Check -
CHART C-1E ...................................... 6E8-92 CHART C-l ...........................X .............6E8-90
TPS E nrichm ent C heck - Vacuum Sensor Check -
CHART C-2F ......................................6E8-108 CHART C-1E ..................................... 6E8-92
Idle Speed S olenoid - Fuel Control System ...................................6E8-94
CHART C-2T ....................................6E8-U0 G eneral D escription ............................. 6E8-94
Idle Speed Solenoid - O xygen S en sor ....................................... 6E8-94
CHART C-2W ...................................6E8-114 ECM Com m and ..................................... 6E8-94
Solenoid V alve C heck - Closed Loop .............................................6E8-94
CHART C-3 ....................................... 6E8-126 Open Loop ............................................... 6E8-95
Ignition System C heck - Throttle P osition Sensor ..................... 6E8-95
CHART C-4A ....................................6E8-130 Idle Speed Control .................................... 6E8-95
EST P erform ance Check - D iagnosis ......................................................6E8-96
CHART C-4D ....................................6E8-132 TPS E nrichm ent C heck -
Ignition System Check - CHART C-2F........................................ 6E8-108
CHART C-4E ...................................... 6E8-132 Idle Speed Control -
ESC C h e c k - CHART C-2T .................................... 6E8-110
CHART C-5 ....................................... 6E8-136 Idle Speed Control -
Air M anagem ent Check - CHART C-2W ...................................6E8-114
CHART C-6C ......................................6E8-146 O n-V ehicle Service ..................................... 6E8-97
CHART C-64I) ....................................6E8-159 C arburetor Calibration ..................... 6E8-97
P ulse Width M odulated EGR - M/C Solenoid ......................................... 6E8-99
CHART C-7E ....................................6E8-167 T hrottle Position S e n s o r ..................... 6E8-104
EGR Control - Idle Speed Control ............................. 6E8-105
CHART C-7C ....................................6E8-168 E vaporative E m ission Control System
EGR Bleed Solenoid Check - (EECS) ............................................... 6E8-116
CHART C-7D ...................................... 6E8-165 W ithout an ECM ..................................... 6E8-116
TCC C heck - With an ECM ............................................6E8-I16
CHART C-8B ....................................6E8-172 D iagn osis .............................................. 6E8-119
EFE System C heck - C anister Purge C heck -
CHART C-9C ....................................6E8-179 CHART C-3 ..................................6E8-122
On- V ehicle Service ............................. 6E8-120
COMPUTER COMMAND CONTROL .............6E8-79 E lectronic Spark Tim ing (EST) ...........6E8-124
E lectronic Control M odule (ECM) ... 6E8-79 G eneral D escription ..........................6E8-112
P R O M ....................................................... 6E8-79 D iagnosis ............................................... 6E8-125
Rem ote Lamp Driver ........................ 6E8-80 Ignition System C heck -
Inform ation S en sors ............................6E8-80 CHART C-4A ................................6E8-126
Engine C oolant Tem perature ....... 6E8-80 EST P erform ance C heck -
D ifferential P ressu re (Vacuum ) CHART C-4D .................................6E8-128
Sen sor .............................................6E8-81 Ignition System C heck -
O xygen (02) S en sor ..........................6E8-81 CHART C-4E ................................6E8-128
Throttle P osition Sensor (TPS) .....6E8-81 O n-V ehicle Service .........................6E8-125
D istributor (EST) .............................. 6E8-82 E lectronic Spark Control (ESC) ...........6 E 8 -130
D ia g n o sis...........................................................6E8-82 G eneral D escription ............................ 6E8-130
O n-V ehicle S ervice ............................... 6E8-82 D iagnosis ............................................... 6E8-130
E lectronic C ontrol M odule (ECM) .... 6E8-82 ESC C h eck -C H A R T C -5 ............... 6E8-132
PROM .......................................................6E8-84 O n-V ehicle S ervice ............................. 6E8-130
Air M anagem ent System T ransm ission C onverter Clutch

(U nder 8600 GVW )............................. 6E8-134 (TCC) System ....................................... 6E8-169
G eneral D escription ............................. 6E8-134 G eneral D escription ...........................6E8-169
AIR System .............................................6E8-134 D iagnosis ............................................... 6E8-169
D eceleration C o n tr o l....................... 6E8-136 T ransm ission C onverter Clutch -
D ia g n o sis.................................................... 6E8-136 CHART C-8B ............................... 6E8-172
E lectric D ivert - CHART C-6C .....6E8-142 O n-V ehicle Service ............................. 6E8-170
O n-V ehicle S e r v ic e ................................ 6E8-137 Early Fuel E vaporation (EFE)
Air M anagem ent System System ............................................... 6E8-175
(Over 8600 GVW)................................. 6E8-144 G eneral D escription ............................ 6E8-175
G eneral D e sc r ip tio n ............................... 6E8-144 D iagnosis .............................................. 6E8-175
Diagn o s is .................................................... 6E8-145 EFE System C heck -
"Service E ngine S oon Light CHART C-9C ............................... 6E8-178
is "ON - CHART C -6H D ....................... 6E8-155 O n-V ehicle Service ............................. 6E8-176
O n-V ehicle S ervice .............................6E8-146 P ositive C rank case V entilation
E xhaust Gas R ecirculation (EGR) (PCV) ................................................. 6E8-180
System .............................................. 6E8-160 G eneral D escription ............................ 6E8-180
G eneral D escription ...................... 6E8-160 D iagn osis ............................................... 6E8-180
D iagn osis ...........................................6E8-161 O n-V ehicle Service ............................. 6E8-181
PWM - EGR D iagn osis - T h erm ostatic Air C leaner
CHART C-7E .................................... 6E8-166 (THERMAC) ...................................... 6E8-182
EGR Valve C heck - G eneral D escription ............................6E8-182
CHART C-7C ................ ............. 6E8-168 D iagn osis ............................................... 6E8-183
EGR Bleed S olenoid C heck O n-V ehicle S ervice ............................. 6E8-184
CHART C-7D....................................6E8-165 T hrottle R eturn Control
O n-V ehicle Service ............................. 6E8-162 (TRC) ........................................................6E8-185
C leaning M anifold P a ssa g e ..........6E8-162 G eneral D escription ............................6E8-185
EGR V alve .........................................6E8-162 D iagn osis ................................................6E8-185
EGR V acuum Solenoid ................ 6E8-163 O n-V ehicle Service ............................. 6E8-187
EGR B leed S o le n o id ...........................6E8-163
T h erm ostatic V acuum S w itch .... 6E8-164
ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF
THE REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES.
THIS CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO
FACTORY STANDARDS. IN MOST CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE TO PREVENT INDISCRIMINATE OR
ROUTINE ADJUSTMENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR
TEMPORARILY REMOVING PLUGS, CAPS, ETC., FOR PURPOSES OF SERVICING THE
PRODUCT, MUST BE STRICTLY FOLLOWED AND, WHEREVER PRACTICABLE, RETURNED TO
THE ORIGINAL INTENT OF THE DESIGN.
6E8-4 DRIVEABIUTY AND EMISSIONS - CARBURETED
INTRODUCTION
GENERAL DESCRIPTION
Fuel Control System

The en gin e has controls to reduce ex h a u st
Air Injection R eaction (AIR)
em ission s w h ile m aintaining good d riveab ility
and fuel econom y. E xh aust G as R ecirculation (EGR)
E vaporative E m ission Control System (EECS)
R efer to Section 6E for inform ation to E lectronic Spark Tim ing (EST)
d iagn osis and repair system s in this section . E lectronic Spark Control (ESC) (4.3L Cal.)
The follow in g em ission con trols are on all T ran sm ission C onverter C lutch (TCC)
engines: An E lectronic Control M odule (ECM) is the
P ositive C rank case V entilation (PCV) heart o f the C om puter Com m and Control system .
E xhaust G as R ecirculation (EGR) The ECM u ses sen sors to get inform ation ab ou t
T herm ostatic Air C leaner (THERM AC) en gin e op eration w h ich the ECM u ses to vary
Air Injection R eaction (AIR) system s it con trols. D etails o f b asic operation,
Early Fuel Evaporation (EFE) (except 4.8L) d iagn osis, and service are covered in Section C -
C om ponent System s.
All en gin es in C alifornia have an E vap orative The ECM has the ability to do som e d ia g n o sis
Em ission Control System . The 4.3L, 5.0L and 5.7L o f itself. When it recogn izes a problem , it lights a
(LS9) en gin es ou tsid e o f C alifornia have an "SERVICE ENGINE SOON" lam p on the
Evaporative E m ission Control System . in strum ent panel. This d oes not mean that the
A Throttle Return Control (TRC) system is en gin e sh ou ld be stopped right aw ay, but that the
used on heavy duty em ission s - 4.8L, and 5.7L cau se o f the ligh t com ing on should be ch eck ed as
(LT9) veh icles. soon as reason ab ly possib le.
U nder the instrum ent panel on a CK truck or
COMPUTER COMMAND CONTROL und er the d rivers seat on a G-Truck, is an
California Only A ssem b ly Line C om m unication Link (ALCL)
The 4.3L, 5.0L (RPO LF3) and 5.7L (RPO LS9) con n ector that is u sed by the assem b ly p lant for a
en gin es in C alifornia have a C om puter Com m and com p uterized ch eck-ou t o f the system . This
Control system w hich controls: con n ector is u sed in service to help d iagn ose the
system (see "D iagnostic P roced ure Terms").
ENGINE COMPONENTS
ENGINE EMISSION COMPONENTS C om ponent L ocations - 5.0L/5.7L (G Series)-
California Only Figures 9, 10, and 12
A top view location o f em ission com p on en ts C om ponent Locations - - 5.7L (P Series) -
for each en gin e are sh ow n in the follow in g Figure 13
illustrations: C om ponent L ocations - 7.4L (CK Series) -
Figure 14
C om ponent L ocations - 4.3L (CK Series) -
C om ponent L ocations - 7.4L (P Series) -
Figu res 1 and 2
F igure 15
C om ponent L ocations - 4.3L (G Series) -
Figures 3 and 4 R efer to F igure 16 and 18 for Com puter
C om ponent L ocations - 4.8L (CK Series) - Com m and C ontrol w irin g sch em atic diagram s.
Figure 5 R efer to F igures 17 and 19 for Com puter
C om ponent L ocations - 4.8L ( P Series) - Com m and C ontrol (ECM) co n n ector term inal
Figure 6 end w ires. V oltage valu es that are taken at the
C om ponent Locations - 5.0L/5.7L (CK Series)- ECM should be very close to the chart. There
F igures 7 ,8 , and 11 may be a slig h t variation due to low battery.
DRIVEABILITY AND EMISSIONS-CARBURETED 6E8-5
' C / K 's e r i e s rpo:LB 1 v in c o d e :N 4 . 3 L V 6 4BBL
COMPUTER HARNESS ECM CONTROLLED O INFORMATION SENSORS

C1 Electronic Control Module (ECM) 1 Mixture control solenoid A Manifold differential pressure
C2 ALCL diagnostic connector 5 Trans. Conv. Clutch connector B Exhaust oxygen
C3 "SERVICE ENGINE SOON" light 6 Electronic Spark Timing C Throttle position
C5 ECM harness ground 7 Electronic Spark Control module D Coolant temperature
C6 Fuse panel 9 Air injection divert valve J ESC knock
C7 Lamp driver 12 Exhaust Gas Recirculation solenoid
C10 Diagnostic dwell connector 17 Fuel vapor canister solenoid
17a Auxiliary fuel vapor canister
Rem is s io nsystem s 18 Throttle kicker
(NOT ECM CONTROLLED) 18a Throttle kicker solenoid
N1 Crankcase vent valve (PCV)
xhaust Gas Recirculation valve
N2 EFE valve
N3 Deceleration valve
N4 Accelerator pump solenoid
N8 Air injection pump
11-27-84
*5S 2133-6E
Figure 1 C om ponent Locations - 4 .3L (CK Series) - C alif

'C/K' SERIES r p o :LB 1 v i n c o d e :N 4.3L V6 4BBL
EMISSIONS DEVICES
1 Crankcase vent valve (PCV)
2 Air injection pump
2a Air injection divert valve
3 Deceleration valve
4 EFE valve
6 Fuse panel
7 Electronic Spark Control module
7a ESC knock sensor
8 Accelerator pump solenoid
12 EGR control valve solenoid
17 Fuel vapor canister solenoid
17a Auxiliary fuel vapor canister
18 Throttle kicker
18a Throttle kicker solenoid
11-27-84
Exhaust Gas Recirculation valve
*5S 2134-6E
Figure 2 C om ponent Locations - 4 .3L (CK Series) - Fed

' G ' s er ie s rpo:LB 1 v in c o d e . N 4 . 3 L V 6 4BBL
COMPUTER HARNESS ECM CONTROLLED O INFORMATION SENSORS

C1 Electronic Control Module (ECM) 1 Mixture control solenoid A Manifold differential pressure
C2 ALCL connector (Data Access) 5 Trans. Conv. Clutch connector B Exhaust oxygen
C3 "SERVICE ENGINE SOON" light 6 Electronic Spark Timing Throttle position
C5 ECM harness ground 7 Electronic Spark Control module , ,D Coolant temperature
C6 Fuse panel 9 Air injection divert solenoid J ESC knock
C7 Lamp driver 12 Exhaust Gas Recirculation solenoid
C10 Diagnostic dwell connector 17 Fuel vapor canister solenoid
18 Throttle kicker
.i EMISSION SYSTEMS j)ExhaustG as Recirculation valve
(NOT ECM CONTROLLED)
N2 EFE valve
N4 Accelerator pump solenoid
11-27-84
*5S 2146-6E
Figure 3 - C om ponent Locations - 4.3L (G Series) - Calif.

EMISSIONS DEVICES
4 EFE valve
6 Fuse panel
7 Electronic Spark Contol module
7a ESC knock sensor
8 Accelerator pump solenoid
12 EGR solenoid
17 Fuel vapor canister
18 Throttle kicker
Exhaust Gas Recirculation valve 11-27-84

*5S 2147-6E
Figure 4 C om ponent Locations - 4 .3L (G Series) - Fed

' C / K 's e r i e s rp o:L 2 5 v in c o d e :T 4 . 8 L L6 4BBL
EMISSIONS DEVICES
1 Crankcase v e n t va lve (PCV)
2 A ir in je c tio n p u m p
2a A ir in je c tio n d iv e rt va lve
3 D e ce le ra tio n va lve
6 Fuse pa n el
17 Fuel v a p o r ca n iste r
17 a A u x ilia ry fu e l v a p o r ca n iste r
19 T h ro ttle re tu rn c o n tro l
20 T h ro ttle va lve re la y
E xhaust Gas R e circu la tion va lve
11-27-84
*5S2135-6E
Figure 5 C om ponent Locations - 4 .8L (CK Series)

'P' SERIES r p o :L 2 5 v i n c o d e :T 4.8L L6 4BBL
EMISSIONS DEVICES
6 Fuse panel
17 a Auxiliary fuel vapor canister
19 Throttle return control
20 Throttle valve relay
11-27-84
*5S 2151-6E
Figure 6 C om ponent Locations - 4.8L (P Series)

' C / K ' series r p o :LF3/LS 9 v i n c o d e :F/L 5 . 0 / 5 . 7 L V 8 4BBL
COMPUTER HARNESS c o n tr o lled devices O INFORMATION SENSORS

C1 Electronic Control Module (ECM) 1 Mixture control solenoid A Manifold differential prerssure
C5 ECM harness ground 9 Air injection divert valve D Coolant temperature
C6 Fuse panel 12 Exhaust Gas Recirculation solenoid
C7 Lamp driver 15 Fuel vapor canister solenoid
C10 A/F dwell connector 17 Fuel vapor canister
NOT ECM CONNECTED

N2 EFE valve
11-27-84
*5S 2136-6E
Figure 7 Com ponent Locations - 5.0L/5.7L (CK Series) - Calif

6E8-12 DRIVEABIUTY AND EMISSIONS-CARBURETED
'C/K' series rpo:LE9/LS9 v i n c o d e :H /L 5.0/5.7LV8 4BBL
...i EMISSIONS DEVICES

4 EFE valve
6 Fuse panel
7a ESC knock sensor
12 EGR control valve solenoid
17 Fuel vapor canister solenoid
11-27-84
*5S2137-6E
Figure 8 C om ponent Locations - 5.0L/5.7L (CK S eries)-F ed

' G ' s er ie s rpo:LF3/LS 9 v in c o d e :F /L 5 . 0 / 5 . 7 L V 8 4BBL
COMPUTER HARNESS CONTROLLED DEVICES O INFORMATION SENSORS

C1 Electronic Control Module (ECM) 1 Mi xture control solenoid A Manifold differential prerssure
C5 ECM harness ground 9 Air injection divert valve D Coolant temperature
C6 Fuse panel 12 Exhaust Gas Recirc. solenoid (PWM)
C7 Lamp driver 15 Fuel vapor canister solenoid
C10 A/F dwell connector 17 Fuel vapor canister

:::: em is s io n systems
(NOT ECM CONTROLLED)
N2 EFE valve
11-26-84
*5S 2145-6E
Figure 9 Com ponent Locations - 5.0L/5.7L (G Series) - Calif.

6E8-14 DRIVEABILITY AND EMISSIONS-CARBURETED
' G 's e r i e s rpo:LE9/LS9 v in c o d e :H /L 5 . 0 / 5 . 7 L V 8 4BBL
Federal only

3 Air injection divert valve
4 EFE valve
5a ESC knock sensor
10 Fuse panel
12 EGR solenoid
11-27-84
*5S 2148-6E
Figure 10 C om ponent Locations - 5.0L/5.7L (G Series) - Fed

'C/K' series rp o :L T 9 v in c o d e :M 5 .7 L V 8 4BBL
EMISSIONS DEVICES
4 EFE va lve
6 Fuse panel
12 EGR c o n tro l va lve so lenoid
17a Fuel v a p o r ca n iste r so lenoid
20 T h ro ttle v a lv e re la y
Exhaust Gas R e circulation va lve
8-01-84 *5S2138-6E
Figure 11 C om ponent Locations - 5.7L (CK Series) - H.D. Emissions

' G ' seri es rp o :L T 9 v in c o d e :M 5 . 7 L V 8 4BBL
Heavy D uty
EMISSIONS DEVICES
4 EFE va lve
6 Fuse panel
17 Fuel va p o r ca n iste r
17a Fuel v a p o r ca n iste r so le n o id
20 T h ro ttle va lve re la y
E xhaust Gas R ecircu la tion va lve
11-27-84
*5S 2149-6E
Figure 12 C om ponent Locationms - 5.7L (G Series) - H.D. Emissions

DRIVEABIUTY AND EMISSIONS - CARBURETED 6E8-17
' P ' series r p o :L T 9 v in c o d e :M 5.7L V 8 4BBL
Heavy D uty
EMISSIONS DEVICES
1 Crankcase v e n t v a lv e (PCV)
4 EFE va lve
6 Fuse panel
17 Fuel v a p o r ca n iste r so le n o id
20 T h ro ttle v a lv e re la y
21 Engine speed re la y
Exhaust Gas R e circu la tion va lve
11-27-84
*5S 2 1 50-6E
Figure 13 Com ponent Locations - 5 .7L (P Series)

'C / K ' seri es rp o :L E 8 v in c o d e :W 7 . 4 L V 8 4BBL

4 EFE va lve
6 Fuse panel
17 Fuel va p o r ca n iste r s o le n o id
20 T h ro ttle va lve relay
Exhaust Gas R ecirculation va lve
11-27-84
t 5S2158-6E
Figure 14 Com ponent Locations - 7.4L (CK Series)

EMISSIONS DEVICES
>50
4 EFE valve
6 Fuse panel
19 Throttle return control
20 Throttle valve relay
11-27-84
*5S 2152-6E
Figure 15 Com ponent Locations - 7.4L (P Series)

Figure 16 ECM W irin g D iagram - 4.3L - CALIF.

ECM TERMINAL VOLTAGE

This ECM voltage chart is fo r use w ith a digital voltm eter to fu rth e r aid in diagnosis. The voltages
you get may vary due to lo w battery charge or other reasons, but they should be very close.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
Engine at operating tem perature
Engine idling in closed loop (fo r "Engine Run" column)
Engine at 1000 RPM fo r "engine run" column
Test term inal not grounded
ALCL tool (scanner) not installed
2 WD
VOL1 AGE VO LTAGE
KEY ENG. WIRE KEY ENG. WIRE

"O N " RUN COLOR "O N " RUN COLOR
NOT USED 22 1 NOTUSED
TPS SENSOR *1 .0
5 5 GRA 5V REFERENCE
SIGNAL + 5.0 .... *2.Q ....... DK. BLU
COOLANT TEMP.
.5 .6 5 2-3 LT. GRN VAC. SENS. SIG. SENSOR SIG. *3 .0 *2 .5 YEL
12 14 GRA EGR NOTUSED
DIAGNOSTIC "TEST"
12 5-10 LT. BLU M/C SOLENOID TERMINAL 5 _ 5 WHT/BLK
(VAR )
NOTUSED NOTUSED
NOTUSED COOLANT RETURN 0 0 BLK
NOTUSED NOTUSED
0 2 SENSOR- HI .3 -4 5 .1 .9 PPL
*.5 *.5 TAN 0 2 SENS.-LO
(VAR)
DIST.REF. PULSE-HI *.5 1-2 PPL/WHT
*.5 *5 BLK/RED DIST. REF.-LO
h LVAJU
*.5 1-2 WHT EST IGN. M O D. BY-PASS *.5 3.7 TAN/BLK

12 11
(VAR.)
NO TUSED
NOTUSED J K
ESC SIGNAL 7-10 7-10 BLK
NOTUSED
10 *.5 WHT/GRN SERVICE ENGINE NO TUSED
SOON LAMP
4TH GEAR SWITCH *.5 *.5 LT. BLU
NOTUSED
TRANS. CONVERTER 12 14 BLU/BLK1
CLUTCH SOLENOID TAN/BLK2
12 14 BRN THROTTLE KICKER
CONTINUOUS 12 14 ORN
BATTERY
NOTUSED -----
NOTUSED
12 14 PNK/BLK IGN 1 POWER
PURGE 12 .12 GRN/YEL
12 .14 BRN AIR DIVERT SOL.

0 0 TAN/WHT GROUND (TO GROUND TO 0 0 BLK/WHT
ENGINE)
A U ENGINE
vt
1 - FOUR WHEEL DRIVE - 4W D
2 - TW O WHEEL DRIVE - 2W D
* = VALUE SHOWN, OR LESS THAN THAT VALUE.

(VAR.) = VARIABLE
ENGINE 4JL_ *6S2556 6E
+ = WIDE OPEN THROTTLE VEHICLE C.K.GJRK 3 20-85
Figure 17 ECM Connector Term inal End V ie w - 4.3L - CALIF.

Figure 18 ECM W irin g Diagram - 5.0L/5.7L - CALIF.

ECM TERMINAL VOLTAGE

This ECM voltage chart is fo r use w ith a digital voltm eter to fu rth e r aid in diagnosis. The voltages
you get may vary due to lo w battery charge or other reasons, but they should be very close.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
Engine at operating tem perature
Engine idling in closed loop (fo r "Engine Run" column)
Engine at 1000 RPM fo r "engine ru n " column
Test term inal not grounded
ALCL tool (scanner) not installed
2 WD
VOLT AGE VO LTAGE
KEY ENG. WIRE KEY ENG. WIRE

"O N " RUN COLOR "O N " RUM CQLQR
0 0 BLK SENSOR 22 1 NOTUSED
RETURN
TPS SENSOR *1.0
5 5 GRA 5V REFERENCE
SIGNAL 5..Q *2,0 . DK BLU
COOLANT TEMP.
.5 .6 5 2 3 LT. GRN VAC. SENS. SIG. *3.0 *2.5 YEL
SENSOR SIG.
12 14 GRA EGR NO TUSED
DIAGNOSTIC "TEST"
12 5-10 LT. BLU M/C SOLENOID
TERMINAL 5 5 WHT/BLK
(VAR.)
NOT USED NOTUSED
NOTUSED NOTUSED
NOT USED NOTUSED
0 2 SENSOR-HI .3 .4 5 .1-.9 PPL

*.5 *.5 TAN 0 2 SENS.-LO
VAR
DIST.REF. PULSE -HI *5 1-2 PPL'WHT
*.5 * 5 BLK/RED DIST.REF.-LO
MAR.
*.5 1-2 W HT EST IGN. M O D BY-PASS *.5 3.7 TAN/BLK

12 11
VAR.
NOTUSED
NO TUSED J K
NOTUSED
NO TUSED
10 *.5 WHT/GRN SERVICE ENGINE NOTUSED
SOON LIGHT
4TH GEAR SWITCH *.5 *.5 LT BLU
NOTUSED TRANS. CONVERTER 12 14 BLU/BLK1

CLUTCH SOLENOID TAN/BLK 2
CONTINUOUS 12 14 ORN
NO TUSED
BATTERY
NOTUSED
12 14 PNK/BLK IGN 1 POWER
12 .14 BRN AIR DIVERT SOL. PURGE 12 .12 GRN YEL
0 0 TAN/W HT GROUND (TO GROUND TO 0 0 BLK W H T

A U ENGINE
ENGINE)
1FOUR WHEEL DRIVE -4 W D

2TW 0 WHEEL DRIVE -2 W D
* = VALUE SHOWN, OR LESS THAN THAT VALUE. ENGINE 5.0/5.7L

(VAR.) = VARIABLE *6S 2557-6E
+ = WIDE OPEN THROTTLE VEHICLE C,K,G,TRK 3-20 85
Figure 19 ECM Connector Term inal End V ie w - 5.0L/5.7L - CALIF.

6E8-24 DRIVEABIUTY AND EMISSIONS -CARBURETED
SECTION A
DIAGNOSTIC CHARTS
4.3L, 5.0L (RPO LF3) 5.7L (RPO LS9) ENGINE
CALIFORNIA ONLY
GENERAL STARTING POINT

The d iagn ostic inform ation for S ection A The "D iagnostic C ircuit Check" is the startin g
should only be used for C alifornia v eh icles w ith p oint for driveab ility or em ission d ia g n o sis on
C om puter Com m and Control and an E lectronic veh icles w ith C om puter C om m and Control. It
Control M odule. R eview the Introduction in verifies the system is fu n ctio n in g correctly. Som e
Section 6E before u sin g this Section. sp ecia l c o n sid era tio n s to k eep in m ind w h ile
m aking the "D iagnostic C ircuit Check" are:
Trouble Code Identification
Blocking Drive Wheels
The trouble code id en tification chart (Figure
20) is a b rief explanation of w hy a trou ble cod e The veh icle drive w h eels sh ou ld a lw ays be
w as set by the ECM. Before referring to a trou ble blocked w h ile ch eck in g the system .
code chart, perform a "D iagnostic C ircuit
Check".
PERFORMANCE CHARTS
When the perform ance of the system has

in d icated a problem w ith a fixed d w ell reading, a
diagn ostic "A" chart w ill check and lead to the
correction.
When ch eck in g the D iagnostic C ircuit
C heck, Chart A-5 w ill determ ine w hy the
"service en gin e soon" lam p is in operative.
Chart A-6 w ill correct the reason for the
"service en gin e soon" lamp bein g "ON" all the
tim e or w hy the ECM w ill not flash trou b le code
12.
DRIVEABILITYAND EMISSIONS -CARBURETED 6E8-25
TROUBLE CODE IDENTIFICATION

4.3L, 5.0L OR 5.7L ENGINE - CALIFORNIA
The SERVICE ENGINE SOON light w ill only be ON if the m alfunction ex ists u n d er the
con d itions listed below . It takes up to five seco n d s m inim um for the ligh t to com e on w h en a
problem occurs. If the m alfunction clears, the light will go out and a trou b le cod e w ill be se t in
the ECM. Code 12 d oes not store in m em ory. If the light com es o n in term itten tly, but no cod e
is stored, go to Section B - Sym ptom s. Any cod es stored w ill be era sed if no problem reoccu rs
w ithin 50 en gin e starts. A sp ecific en gin e may not use all available co d es.
The trouble cod es ind icate problem s as

follow s:
TROUBLE CODE 12 No distributor referen ce
sign al to the ECM. This TROUBLE CODE 41 No d istrib u tor referen ce
cod e is not stored in sign al to the ECM at
m em ory and w ill only sp ecified en gin e vacuum .
flash w hile the fault is I n i s cod e w ill store in
p resen t. Norm al cod e with m em ory.
ignition on, en gin e not
running. TROUBLE CODE 42 E lectronic sp ark tim ing
TROUBLE CODE 13 O xygen S ensor C ircuit - (EST) b yp ass circu it or
The en gin e m ust run up to EST circu it grou n d ed or
four m inutes at part open.
throttle, und er road load,
before this cod e w ill set. TROUBLE CODE 43 E lectron ic Spark C ontrol
(ESC) retard sign al for too
TROUBLE CODE 14 Shorted coolan t sen sor lon g a time; ca u ses retard
circu it - The en gin e m ust in EST sign al.
run tw o m inutes before
this cod e w ill set. TROUBLE CODE 44 Lean ex h a u st in d ication -
T h e en g in e m ust run tw o
TROUBLE CODE 15 O pen coolan t sen sor m in u tes, in closed loop
circuit - The en gin e m ust and at part throttle, before
run five m inutes before th is c o a e w ill set.
this cod e w ill set. TROUBLE CODE 45 R ich ex h a u st in d ication -
T he en g in e m ust run tw o
TROUBLE CODE 21 T hrottle P osition S ensor m inu tes, in closed loop
(TPS) circu it voltage high and at part throttle, before
(open circu it or th is c o a e w ill set.
m isadjusted TPS). The TROUBLE CODE 51 F aulty or im properly
en gin e m ust run 10 in sta lled calibration u n it
secon d s, at sp ecified curb (PROM ). It tak es up to 30
idle sp eed , before this code se c o n d s before this cod e
w ill set. w ill set.
TROUBLE CODE 54 M/C solen oid voltage high
TROUBLE CODE 23 M/C solen oid circu it open at ECM as a resu lt o f a
or grounded. sh orted M/C solen oid
TROUBLE CODE 34 D ifferential P ressu re circu it and/or faulty ECM.
(Vacuum ) sen so r c ir c u it-
The en gin e m ust run up to
tw o m inutes, at sp ecified
curb idle, before this code
w ill set.
2 -3 -8 5
6S 2 5 5 2 -6 E
Figure 20 Trouble Code Identificatio n

DIAGNOSTIC CIRCUIT CHECK

4.3L, 5-OLOR 5.7L ENGINE
CARBURETED-CALIF.
The p u rp ose o f the D iagnostic Circuit Check is to 1)
m ake sure the "SERVICE ENGINE SOON" light w orks, 2)
the ECM is op eratin g and can recogn ize a fault, and 3) to
d eterm ine if any cod es are stored. If cod es are stored, it
also ch eck s to see if they in d icate an interm ittent problem .
This is the startin g point for any d iagn osis. If there are no
cod es in d icated , go to the System Perform ance Check. If no
additional ch eck s are called out from the System
P erform ance C heck, go to the D riveability Sym ptom s,
Section "B."
C heck for proper operation o f the If the light is "ON," fault is still present;
"SERVICE ENGINE SOON" light with the therefore, go to the a p p licab le trou ble code
key "ON," en gin e not running. The light chart.
should be on steady.
If the light is "OFF," the fault is either
G rounding the test term inal will flash a interm ittent, or it is a cod e that can n ot be
Code 12 and any stored trouble cod es. The set in the stall in tw o m inutes. For cod es
light m ust go "ON" and "OFF" for a proper that cannot be set in the stall d u ring the
code. If the ligh t goes from "Bright" to D iagnostic Circuit C heck, the ap p licab le
"Dim" this is not con sid ered a code. See trouble code chart will d eterm in e if those
Chart A-6 in that case. cod es are interm ittent.
T his step is to determ in e if any cod es, other
than Code 12 that w as recorded before, are
still present, or w ere interm ittent and are
no longer there. M emory is cleared and
vehicle run for tw o m inutes to see if trouble
code(s) w ill reset.
ECM
REMOTE LAMP DRIVER

IGNITION "SERVICE ENGINE SOON'
SWITCH GAU/IDLE LAMP E ID
FUSE
487 WHT/
+ 12 V 39 PNK/BLK 489 YEL ---- - SESLAMP
DKGRN
451 WHT/
DIAGNOSTIC TEST DIAG.
BLK
TEST TERM
TERMINAL
150 BLK + 12 440 ORN
ECM B CONTIN.
FUSE BATT.
n
O O ALCL CONNECTOR
2-13-85
6S 2553-6E
DRIVEABILITY AND EMISSIONS -CARBURETED 6E8-27
DIAGNOSTIC CIRCUIT
CHECK
o Key "O N ", engine stopped, "te s t"
term .ungrounded.
Note "Service Engine S oon"light.
4.3L, 5.0L or 5.7L ENGINE
CARBURETED-CALIF.
Light "O N " Steady Light flashes (in te rm itte n tly or a code) Light "OFF'
X 1 ..... .
Ground "te s t" term, and

note "Service Engine Soon" light.
Check fo r gn'ded w ire to ECM term.
"5 " If not gn'ded, it is fa u lty ECM.
See Chart
A-5
Flashes code 12 (This is Does not flash code 12

not a "trouble code 12")
I
Note and record any See Chart A-6
additional codes.
No Code 51 Code 51
i
Turn ignition "OFF". Remove "te s t" term, ground. Check th a t all PROM pins are
0 Clear Codes.t fu lly seated in socket. If OK,
Set parking brake and block drive wheels. replace PROM. Clear memory
Place a .075" to .100" d rill or equivalent as a spacer and recheck. If code 51
between the accelerator and pump lever and TPS reappears, replace ECM.
plunger and run to warm up engine (drive, A.T.) fo r tw o
(2) minutes and note "Service Engine Soon" light. If ALCL CONNECTOR
engine w o n 't run and Code 42 is stored, see Chart 42. If n
no Code 42, see "Ig n itio n System Check" Chart. .GROUND
Remove Spacer.
F E D C 8| o
4 \
'SERVICE ENGINE SOON" LIGHT TE! TERM.
Light "OFF' Light "ON'

I
Refer to the additional codes

recorded above (not code 12). Ground "te s t" term , and
note codes.
No additional codes A dditional codes Flashes Codes Flashes but no code.
1
1 4,2 1,23,34,41, A ll others Replace ECM,
42*, 43, 54 See Chart C-1
1 =
Trouble is in te rm itte n t so code charts See applicable Trouble Code Chart(s).
cannot be used. Make physical check
o f circuit indicated by trouble code.
See System Performance Check on fo llo w in g page.

To clear codes, remove pow er to 'R' term, o f ECM fo r 10 sec. by removing ECM
connector w ith ig n itio n "OFF", or ECM B fuse, or disconnect ECM pow er feed
at battery. Verify codes have been cleared. The System Performance Check
should be perform ed a fte r any repairs to the System have been made.
It is possible to set a false Code 42 on starting, but the "Service Engine Soon" 3-20-85
lig h t w ill not be "O N ". No corrective action is necessary. * 5S 1790 6EA
RELATIONSHIP OF DWELLMETER READINGS TO

MIXTURE CONTROL SOLENOID CYCLING
DWELL FIXED STARTING// WARM-IJP

WOT
DWELL VARYING ACCELERATION CRUISING DECELERATION

IDLE
A/F MIXTURE RICH VARYING LEAN
DWELLMETER 15 30 45 54 60
READING
DUTY CYCLE 0% 10% 25% 50% 75% 90% 100%
t .
MIXTURE ON
CONTROL
SOLENOID OFF U L iM r m j u iT m "
' ^ ONE * 4S0691-6E
CYCLE
3-20-85 6-22-84
SYSTEM PERFORMANCE CHECK

4.3L, 5.0L, OR 5.7L ENGINE
CARBURETED-CALIF.
1. Checks for ability of carburetor main 2B. There is an open loop condition. It can be
metering system to change the Air/Fuel caused by:
mixture. Disconnecting M/C solenoid makes 1. An open oxygen sensor circuit or bad
carburetor operate full-rich and sensor.
reconnecting it with the dwell lead grounded 2. An open in coolant sensor circuit.
makes it operate full-lean. Normal response - 3. An open in wire from ECM term. "14" to
RPM drops as M/C solenoid is reconnected. ground.
Usually 400-1000 RPM, but should be at least 2C. This is a full lean command. It can be caused
300 RPM. by:
1A. If plugging the PCV, Purge, or Bowl Vent 1. Rich engine condition caused by:
vacuum hose causes RPM to drop over 300 a. M/C Solenoid wire connections
RPM, that hose leads to the souce of the reversed.
problem. If RPM increases as M/C solenoid b. Leaking Bowl Vent valve, excessive
is connected, it indicates the system is fuel in vapor canister, fuel in
running extremely rich. This can sometimes crankcase, faulty carburetor
be caused by incorrect valve timing. calibration or carburetor, or silicone
contaminated oxygen sensor.
2. Checks for proper control of idle circuit. 2D. Normal reading - operates in closed loop -
dwell is between 10-50, but varying.
2A. This is a full-rich command to the carburetor Running for 1 minute at fast idle is to make
and can be caused by: sure the oxygen sensor is warm.
1. Lean engine condition. 3. Checks for proper control of main metering
2. Grounded oxygen sensor wire or bad system. RPM must be at least 3000 to get into
sensor. the main metering system operation.
3. Open in wire from ECM term. "14" to Removing and plugging the hose may set a
ground. Code 34 so memory will have to be cleared.
4. Open wire to ECM term. "22".
5. Open in coolant sensor circuit. 3A. A missing "O" ring between the switching
valve solenoid and the valve, or a faulty
valve, may cause air to leak to the exhaust
ports at higher RPM only.
SYSTEM PERFORMANCE
CHECK
1. START ENGINE.
2. GROUND "TEST" TERM. (MUST NOT BE GROUNDED
BEFORE ENGINE IS STARTED).
3. CONNECT TACHOMETER.
4.3L, 5.0L OR 5.7L ENGINE
4. DISCONNECT MIXTURE CONTROL (M/C) SOLENOID AND CARBURETED-CALIF.
GROUND M/C SOLENOID DWELL TERM.
5. RUN ENGINE AT 3,000 RPM AND, WHILE KEEPING
THROTTLE CONSTANT, RECONNECT M/C SOLENOID AND
NOTE RPM.
6. REMOVE GROUND FROM M/C SOLENOID DWELL TERM.
BEFORE RETURNING TO IDLE.
300 RPM DROP OR MORE LESS THAN 300 RPM DROP OR RPM INCREASES

CONNECT DWELL METER TO M/C SOL. DWELL
TERM. (6 CYL. SCALE).
SET CARB. ON HIGH STEP OF FAST IDLE CAM.
CHECK EVAPORATOR CANISTER FOR BEING LOADED W ITH
FUEL AND RELATED VALVES, SUCH AS PURGE AND BOWL
AND RUN FOR ONE (1) MINUTE ORUNTIL VENTS WHICH WOULD CAUSE RICHNESS. ALSO CHECK
DWELL STARTS TO VARY, WHICHEVER FOR FUEL IN CRANKCASE. IF OK. SEE CARB. ON-VEHICLE
HAPPENS FIRST. SERVICE. SECTION 6C-10.
PLACE A SPACER (.075" TO .100") BETWEEN
ACCELERATOR PUMP LEVER AND TPS PLUNGER
AND NOTE DWELL*
RETURN ENGINE TO IDLE AND NOTE DWELL.
I I I
2D ) VARYING t? B ) l FIXEP I 0-50 FIXED UNDER 10 FIXED 50 OR OVER
CHOKE ENGINE. SEE CHART A-1 SEE CHART A-3

NOTE DWELL.
VARYING FIXED 10-50
REMOVE SPACER ANDCHECK

DWELL AT 3000 RPM
SEE CHART A-2
BETWEEN 10-50 UNDER 10 50 OR OVER
CHECK AIR MANAGEMENT CHECK AIR SWITCHING VALVE

SYSTEM. LEAKING TO FXHAUST PORTS AT 3000
RPM. IF NOT LEAKING..........
NO TROUBLE FOUND IN SEE CARB. CALIBRATION

THE "SYSTEM". PROCEDURE "FUEL
CLEAR LONG TERM CONTROL SYSTEM".
M E M O R Y .** SECTION C. INCLUDING
SEE DRIVEABILITY TPS ADJUSTMENT.
SYMPTOMS. SECTION "B".
* AN OXYGEN SENSOR M AY COOL OFF AT IDLE AND THE DWELL CHANGE FROM VARYING TO FIXED. IF THIS HAPPENS,
RUNNING THE ENGINE AT FAST IDLE WILL W ARM IT UP AGAIN.
** BY DISCONNECTING POWER FROM ECM TERMINAL "R" OR ECM B FUSE FOR 10 SECONDS WITH IGNITION SWITCH OFF.
6-27-85
6S2554-6E
Inf "T rrF rT m nrr

FfM
i
BACK VIEW OF ECM CONNECTOR
0 2 SENSOR
4112 PPL - SIGNAL
0 2 CIRCUIT
GROUND
SV REFERENCE
COOLANT
OXYGEN TEMPERATURE 4.3 L
( 0 2) SENSOR SENSOR
EXHAUST 416 GRA - 21 5V REFERENCE

W -
4 1 7D K B LU - - TPS SIGNAL
3
THROTTLE
POSITION 452 BLK 22 2-13-85
3-20-85 SENSOR (5.0L/5.7L) 6S 2555-6EA
CHART A-1
DWELL FIXED UNDER 10
CARBURETED-CALIF.
1. Determines if the problem is Computer 3. Checks for normal coolant sensor circuit
Command Control related or engine related. condition. Voltage on a normalized hot
Dwell should start increasing as soon as engine should be under 2.5V.
engine is choked, and go higher as it is
choked more, until it goes over 50. With 4. This step checks for an open in the ground
severe choking, the dwell could move up circuit to ECM Term. "14" and grounded O 2
scale momentarily even if it is not engine sensor circuit.

related, but it will move right back to a low
dwell. If dwell responds, the problem is a Terminal "2" voltage should be under 1.0
lean engine. volt at idle. A high voltage could be caused
by an open in circuit 452. Normally, this
1A. Checks for cause of lean condition that would cause Codes 21 and 34 but, wont set
resulted in full rich command. them on some engines.
2. Checks for ECM response to input to O 2
sensor circuit. The voltmeter is used to put a

voltage on the oxygen sensor circuit to
simulate a rich condition. Dwell should
increase (a lean command) if ECM and
harness are good.
CHART A-1
DWELL FIXED UNDER 10
(LEAN EXHAUST INDICATION)
CARBURETED-CALIF.
DO NOT USE AN ORDINARY VOLTMETER OR JUMPER IN PLACE OF DIGITAL VOLTMETER. BECAUSE THEY HAVE TOO LITTLE
RESISTANCE. A VOLTAGE SOURCE OF 1.0V TO 1.7V (SUCH AS A FLASHLIGHT BATTERY) CAN BE CONNECTED WITH THE
POSITIVE TERMINAL TO THE PURPLE WIRE AND THE NEGATIVE TERMINAL TO GROUND AS A JUMPER. IF THE POLARITY IS
REVERSED, IT W O N 'T WORK.
2-13-85
M S 0 2 8 4 -6 E A
CHART A-2
DWELL FIXED BETWEEN 10 AND 50
CARBURETED-CALIF.
1. Running engine at part throttle for one 2. This step grounds O sensor circuit at ECM
2
minute warms up the oxygen sensor. to check for opens in wiring, to ECM
Terminals "9" and "14".
Grounding O sensor input checks ECM
2
response to a "lean" signal. Normal response to "lean" signal, dwell

decreases; that is a rich command.
Normal response-dwell decreases to full rich
command. 3. This step checks for voltage to the coolant
sensor. Normal reading on a warm engine is
IA. On some ECMs, an open in circuit to Term. less than 2.5 volts.
"14" can cause open loop.
An open circuit would cause a reading of
IB. Checks output of O sensor with full rich
2 approximately 5 volts.
command from ECM caused by grounded O 2
sensor input.
Normal response, voltage at O sensor over
2
.8 volt.
CHART A-2
DWELL FIXED BETWEEN 10 - 50
(OPEN COOLANT OR OXYGEN SENSOR CIRCUIT)
CARBURETED-CALIF.
* CHECKING COOLANT SENSOR RESISTANCE M AY REQUIRE USE OF CONNECTOR AND WIRE ASSEMBLY
NO. 12026621 FOR ACCESSIBILITY. 2-14-85
5S1791-6E
I I H iV f l I T~R
I I H I I I 1 ITFT
i
0 2 SENSOR
412 PPL
SIGNAL
413 TAN 14 0 2 CIRCUIT

GROUND
I
11-17-84 2-14-85
4S 0362-6E
CHART A-3
DWELL FIXED OVER 50
CARBURETED-CALIF.
1. Determines whether problem is related to 3. Checks ECM response to a "lean" O signal.

2
engine or electronics. Normal response - low dwell (rich command)

No dwell change says it is bad ECM. It
Normal response - dwell decreases (rich couldnt be an open wire because that would
command) - says electronics (O sensor,
2 cause open loop operation and may set Code
harness and ECM) are OK; problem is a 13.
rich engine condition.
4. Checks for excessive voltage in O line.
2
This may require a large air leak if engine

is very rich. When it is lean enough, the If under .55V, wire and ECM are OK; fault is
engine will start to run rough. in O sensor which could be the result of
2
silicone contamination. If over .55V, wire is

2. If plugging the PCV or bowl vent vacuum shorted to B + or a faulty ECM.
hose causes the dwell to decrease, that hose
leads to the source of the problem.
CHART A-3
DWELL FIXED OVER 50
RICH EXHAUST INDICATION
CARBURETED-CALIF.
2-14-85
5S 1792-6E
CHART A -5
"SERVICE ENGINE SOON" LIGHT INOPERATIVE
CARBURETED-CALIF.
1. This checks for open gage fuse or open in This indicates a bad ground or faulty lamp
"SERVICE ENGINE SOON light circuit, driver.
including IP connector, printed circuit, and
"SERVICE ENGINE SOON" lamp. 4. This step checks for an open in the wire to
terminal "B".
Normal response is lamp "ON".
Normal voltage is approximately battery
2. This checks for a shorted ECM. voltage.
Grounded ECM terminal "G" will turn the 4A. This checks for an open wire to terminal "E"
"SERVICE ENGINE SOON" light "OFF". If from the "SERVICE ENGINE SOON lamp.
disconnecting ECM turns light "ON", ECM is With terminal "E" grounded, the lamp
shorted. should normally light. Lamp "OFF"
Normal response is lamp "ON". indicates an open, and lamp "ON" indicates
3. This checks for grounded wire from faulty lamp driver connection or lamp
terminal "C" of lamp driver to terminal "G" driver.
of ECM, an open circuit to terminal "B" of 5. This checks for a grounded wire from driver
lamp driver, a bad ground or faulty lamp terminal "C" to ECM terminal "G". Normal
driver. response is light "ON".
A normal reading is about 9 to 11 volts
because of the drop through the upper
resistor in the lamp driver. Over II volts
indicates there is no drop in the lamp driver.
CHART A-5
"SERVICE ENGINE SOON" LIGHT
INOPERATIVE
CARBURETED-CALIF.
3-21-85
6S2559-6E
U o --------------
/ ---------------------------
fl "N
O id
|a | |c| 1 1 |G | m |1 2 | I I I I I I I I |2 2 |
,GN- 1 BATTERY
M 1 M 1 1 1 M Ini I I I I |s| II |i | A
ECM
^-----------------------------
ECM CONNECTORS BACK VIEW -r
'SERVICE ENGINE GAGES ECM ECM/BAT
SOON" LAMP FUSE FUSE FUSE
20 AMP 10 AMP 10 AMP
F E D C B e
G K M

/ A 440 ORN -
LONGTERM.
MEMORY
J GROUND
B
439
PNK/BLK IGN.
'SERVICE ENGINE 'TEST*'TERM. REMOTE
LAMP 487
SOON" LIGHT C
DRIVER WHT/GRN
UNDER-DASH CONNECTOR
MODULE 1
D
E
1
F
DIAGNOSTIC
487
- 5 TEST
WHT/BLK TERMINAL
3-21-85
2-14-85 4S 0380-6E
CHART A-6
WON'T FLASH CODE 12
CARBURETED-CALIF.
1. This step checks for short to battery voltage 4. This step checks for open in wire from ECM to
in wire to Terminal "C" or faulty lamp driver. test terminal in ALCL connector. The lamp
should flash Code 12 when Terminal "5" is
Normal voltage reading is 9-11 volts. grounded.
2. This step checks to see if problem is related to 5. Checks for proper voltage supply to ECM.
the ECM or the lamp driver. Both should read over 9 volts. Terminal *C* is
ignition and Terminal *R is constant battery
Normally, grounding Terminal "C" should for long term memory.
turn lamp "OFF". If it does, the problem is
related to the ECM and its wiring. If not, it is 6. Checks for a bad ground to ECM - Terminals
related to the lamp driver and its wiring. A and U are connected together in the ECM.
3. Grounding Terminal G at ECM and finding 7. This step distinguishes between a faulty ECM
light "ON" indicates an open in the wire to and PROM. Normal response is for Code 51 to
Terminal C of lamp driver. flash even though the PROM is not installed
in the ECM. If it doesnt, it means that the
Normally, grounding Terminal G should ECM is faulty.
turn lamp "OFF".
CHART A-6
SERVICE ENGINE SOON" LIGHT ON
AT ALL TIMES OR
WON'T FLASH CODE 12
Check ECM supply fuses.
B attery voltage m ust be above 11 volts
Disconnect ground from ' tes t' term inal.
Key "o n ", engine stopped.
Check voltage from lamp driver term inal "C" to ground.
CARBURETED-CALIF.
1.
Under 11 Volts 11 volts or more
Ground lamp driver term inal "C" and note

"Service Engine Soon" light.
Check for short from term inal "C" w ire to B + .
If not shorted, replace lamp driver.
1
Light " O ff' Light "O n'
I I
Ground term inal "G" a t ECM and note "Service Engine Disconnect driver and note "Service Engine
Soon" light.
Soon" light.
I
Light "O ff" Light "O n" Light "O ff' Light "O n"
1
zz I
Ground te r m .5 at
Repair open in w ire from It is fau lty conn, to Repair gnd in w ire from
ECM and note
ECM term inal "G" to driver term . "C" or driver term " E" to
"Service Engine
driver term inal "C". fau lty driver "Service Engine Soon"
Soon" light.
light.
1
"O n" steady Flashes
~1 I

Disconnect ground from term inal "5 ".
Check voltage from ECM term inals "C"
and "R" to ground.
Repair open in w ire from ECM
term inal "5 " to test term inal.
1
Both 9 volts or over Either under 9 volts
L
Check voltage from ECM term inal "U " to ground. Repair poor connection or open in
[ circuit to term inal th a t reads low .
1
Under 1 volt 1 volt or over
I
Turn ign. "OFF". Repair open or poor connection from
Remove PROM. term inals "A " and "U " to ground.
Turn ign. "O N ".
A fter 30 secs.,
check for Code 51.
NO Code 51 Code 51
See ECM Replacement Check fo r proper PROM installation.

Check, Chart C-1. If OK, install n ew PROM and recheck for Code 12.
If Code 12 does not flash. See ECM replacem ent Check, Chart C-1.
11-17-84
REPEAT DIAGNOSTIC CIRCUIT CHECK AFTER A N Y REPAIR *4S 0291-6EA
DISTRIBUTOR
HEI MODULE
ECM 4.3L
PRIMARY 19
IGN. COIL EST
430 PPL/WHT REFRENCE
424 TAN/BLK 10 BY-PASS
453 BLK/RED
GROUND
ECM
5.0L/5.7L
PRIMARY
IGN. COIL WHT 19
EST
PPL/WHT REFRENCE
10 BY-PASS
453 BLK/RED
GROUND
DISTRIBUTOR EST CONNECTOR
HEI MODULE
85 6S2571 6E
CODE 12
NO DISTRIBUTOR REFERENCE SIGNAL
CARBURETED-CALIF.
Code 12 means the ECM is "ON" and sees no reference pulse from the
distributor. This is a normal code with the ignition "ON and engine not running.
Code 12 is not stored and will only flash when the fault is present. With the engine
running, Code 12 could mean an open or ground in the distributor reference
circuit. Code 41 will appear with Code 12 if the engine is running with no
distributor reference signal. If the problem clears, Code 41 will store.
1. This step checks for a poor connection at the signal is being generated by the module and fault
EST connector as being the source of no is a bad connection at the ECM, or faulty ECM.
distributor reference pulse. Check for To check the connection at the ECM, the terminal
corrosion, connector terminals not fully must be removed from the connector.
seated, or terminal not properly attached to
the wire. The terminal must be removed from 3. With an open circuit, there is still a small
the connector and carefully inspected. amount of voltage at the ECM. It will not
increase when the throttle is opened. If the
circuit from Terminal "10" to the module is
2. This step determines if a reference pulse is not opened or grounded, the source of no
being sent to the ECM. Voltage should signal is the module itself.
normally be above .5V indicating that the
CODE 12
TO THE ECM
CARBURETED-CALIF.
84-85
4-2-85
* 65 2638-6E
---------ItUJ-------- ,
I I h i I I I I I I M ECM
I I ................................. h i
i
0 2 SENSOR
4 1 2 PPL __ 9
SIGNAL

GROUND
I
11-10-84 2-14-85
4S 0362-6E
CODE 13
OXYGEN SENSOR CIRCUIT
CARBURETED-CALIF.
Code 13 means an open in the oxygen sensor circuit with the following conditions:
Oxygen sensor voltage is within a specified range.
Above a specified TPS value.
More than a specified time after the engine has warmed up.
The ECM supplies a voltage of about .45V between Terminals 9 and 14. (Voltage may read
as low as .32V when measured with a 10 megohm DVM.) The O sensor varies the voltage within
2
a range from about 1 volt if the exhaust is rich down through about .IV if exhaust is lean.
1. This step is to determine if the problem is still it is functional, since the exhaust is rich. If the
present. O sensor functions, fault is in the connections
2
A Normal dwell will vary indicating the fault to the sensor.

is not present, while a fixed dwell indicates 4. This step checks for an open in the ECM O 2
the fault is still present. sensor ground circuit. Normal voltage is
below 1 volt if the circuit is complete. The
2. By grounding the O sensor circuit to the
2
worse the connection is, the higher the
ECM, a "low voltage (lean) signal" is sent to voltage will read.
the ECM. If the ECM is not faulty and the
circuit is complete a "low voltage signal" 5. This step grounds the O signal wire at the 2
should result in a full rich command (low ECM. If the ECM is functional, dwell should
dwell) from the ECM. go to below 10, since this is a "low voltage
signal" indicating lean exhaust. No change
3. This step determines if the O sensor is
2
indicates a problem at the ECM connections,
functioning. With the rich command, the O or the ECM.
2
sensor should read a high voltage, over .8V if

CODE 13
OPEN OXYGEN SENSOR CIRCUIT
CARBURETED-CALIF.
Check fo r sticking or misadjusted th ro ttle p o sitio n

sensor.(If 13 a n d z l are displayed, g o to 21 first.)
Connect dw ell meter to M/C sol., use 6-cyl. scale.
Ground "te s t" term inal and note dw ell at 2000 rpm's.
-
I !
Varying w ith in 10- 50 Fixed under 10 Fixed A bout 30
Trouble is interm itten t.

Oxygen sensor circuit is
See Chart #A-1
vvI iiI e n g in e l u i m y ,
disconnect oxygen
sensor and around
OK at present.
Check oxygen sensor purple w ire le a d in g
circuit fo r in te rm itte n t to ECM (not oxygen
connection. Clear sensor).
memory.
J
Under 10 dw ell. 10 dw ell or over
Leave purple w ire grounded.

Check volxage from oxygen sensor
to around w ith digital voltm eter
Check voltage from ECM
term inal "1 4 " to ground.
on 2 vo lt scale. It should read over
.8 volts.
Under 1 vo lt 1 vo lt or over
OK Not OK
Connect jum per
between ECM
term inals "9 " and
Repair open
between ECM
term inal "1 4 "
" 14 " . and ground.
Faulty oxygen Replace
sensor oxygen
connections or sensor.
sensor.
10 dw ell or over Under 10 dw ell.

1
Faulty conn, at Repair open in
ECM terms. "9 or oxygen sensor
14" or ECM. See harness lead from
Chart C-1 connector to ECM.
84-85
*6S 2632-6E
4-2-85
CODE 14
COOLANT SENSOR CIRCUIT SHORTED
CARBURETED-CALIF.
Code 14 means the ECM has seen low resistance of the coolant
sensor circuit as follows:
Low resistance (high engine temperature)
Or low voltage (at ECM Terminal 3")
For a time longer than specified
1. This step determines whether the fault is at the 2. This step checks for a grounded circuit
coolant sensor or elsewhere in the circuit. between the ECM and the coolant sensor. Test
Normal voltage shoud be about 5 volts in the light to B + should be "OFF" in an ungrounded
circuit. circuit. The coolant sensor is not connected
during the test.
CODE 14
COOLANT SENSOR CIRCUIT SHORTED
CARBURETED-CALIF.
84-85
*6S 2633 -6E
4-2-85
2-16-85
11-10-84 *5S 1364-6EA
CODE 15
COOLANT SENSOR OPEN
CARBURETED-CALIF.
Code 15 means the ECM has seen the resistance of the Coolant
Sensor Circuit too high as follows:
High resistance (Cold Engine Temperature)
Or high voltage (at ECM Terminal "3")
This could cause detonation on a warm engine due to too much
spark advance or poor driveability due to wrong fuel control.
1. Checks to see if problem is still present. If it is, 3. Determines whether the low voltage at the
the "SERVICE ENGINE SOON" light will sensor connector is due to opens in the
come "ON" and Code 15 will be set. coolant sensor wires, or in another part of the
5V ref. circuit. Normal voltage should be
2. Checks to see if the fault is the coolant sensor about 5V from ECM Terminals "3" to "7".
or lack of voltage to the coolant sensor.
Normally you should have 5 volts across the 4. Checks resistance of the coolant sensor. If the
coolant sensor connector terminals. resistance is within the chart specifications,
coolant sensor is not faulty; therefore, check
for corrosion at the connector, or low coolant
level.
CODE 15
COOLANT SENSOR CIRCUIT OPEN
CARBURETED-CALIF.
COOLANT SENSOR
TEMPERATURE TO RESISTANCE VALUES

(APPROXIMATE)
F C OHMS
210 100 185
160 70 450
100 38 1,600
70 -20 3,400
40 4 7,500
20 -7 13,500
0 -18 25,000
-40 -40 100,700
CODE 21
TPS OPEN OR MISADJUSTED
CARBURETED-CALIF.
Code 21 means that the ECM has seen a high TPS voltage
for:
Over about 10 seconds
Below a specified RPM (normally curb idle).
Below a specified engine load.
Due to the pull-up resistor between Terms. "21' and "2"
within the ECM, an open in the TPS circuit will place about 5 volts
(high TPS signal) at Term. 2" of the ECM.
1. Checks the circuits from the TPS connector 2. Checks to see if the low voltage at the TPS
back to the ECM. The circuit should read connector is an open in the circuit or a faulty
about 5V because of the pull-up resistor in the ECM. A normal reading at the ECM is about
ECM. A 10 Meg. ohm resistence meter must be 5V.
used. A lower resistence voltmeter would 3. This step simulates closed throttle, so dwell
read virtually zero at terminal B. should increase if the ECM is good.
4. This step tests the resistance of the TPS
switch itself. A normal reading is under 20,000
*
ohms.
CODE 21
TPS OPEN OR MISADJUSTED
CARBURETED-CALIF.
A f t e r a n y re p a ir , c le a r lo n g te rm m e m o ry b y
r e m o v in g ECM fu se f o r 10 seconds. 4-2-85
6 S 2 6 3 5 -6 E
n \
T n r r r e " I I H
lnl T T T ' T T T L U l I,
...... .
DWELL |------1
CONNECTOR |___ |-----
GREEN
4 1 1 LT.BLU
M/C
SOLENOID
439 PNK/BLK
ECM/IGN
FUSE
I
IGN. 1
11-10-84
CODE 23
M/C SOLENOID VOLTAGE LOW TO ECM
CARBURETED-CALIF.
Code 23 says the ECM has seen the voltage at ECM Term. "18"
stay low instead of rising and falling as the M/C solenoid is turned
"ON" and "OFF". This could be caused by an open in the M/C
solenoid circuit or a ground on the ECM side of the M/C solenoid.
An open would cause a full rich condition and cause poor
economy, odor, smoky exhaust or poor driveability. A ground
would cause a full lean condition and cause poor driveability.
1. Checks for a complete circuit from the 3. This step determines whether the fault is in
battery to the M/C solenoid dwell lead. It the M/C solenoid, a ground in the circuit to
should be battery voltage. Battery voltage the ECM, or the ECM. A light would indicate
means there might be an open circuit a ground in circuit to Terminal "18" or a
between the dwell connector and ground. No faulty ECM. A voltmeter cant be used
voltage could be either an open between the because it is normal to have enough current
connector and battery or a ground on the flow through the ECM even with the circuit
ECM side of the M/C solenoid. open to make a voltmeter read, but not
2. Checks for B + on the pink ignition source enough to light a test light.
wire. Test light should light between the 4. This checks for ground in the wire to ECM
ignition source and ground. Term. "18". If it is grounded, the light will
stay "ON".
2A. Checks for an open in the solenoid to ECM
circuit. A normal circuit would read about
battery voltage at the ECM Terminal "18".
CODE 23
M/C SOLENOID VOLTAGE LOW TO ECM
CARBURETED-CALIF.
84-85
6S2637-6E
4-2-85
6E8-52 DRIVEABIUTY AND EMISSIONS -CARBURETED
CODE 34
DIFFERENTIAL PRESSURE (VAC) SENSOR
CARBURETED-CALIF.
Code 34 says that the ECM has seen the following:
Pressure outside a specified voltage range (seen by ECM as
voltage at Term. 20).
Engine RPM less than a given value (normally curb idle).
Engine at operating temperature.
All the above for a time greater than specified.
The VAC sensor is a differential pressure sensor that measures
the difference in pressure between atmosphere and manifold. The
VAC sensor supplies high voltage at high vacuum. High voltage
increases spark advance while low voltage reduces advance.
1. Checks output of sensor at idle to determine if 3. Check for a ground in wire from Term. B of
sensor is within specification. Normal sensor VAC sensor to ECM. This would be the case if
will read less than 1 volt with key "ON, the voltage went up over 2 volts when the line
engine "OFF and over 3 volts with engine was opened.
idling with a minimum of 15 vacuum. 4. Checks to see if the fault is in the sensor, or in
2. A normal sensor should drop below 1 volt the ECM wiring, or in the ECM. If the voltage
when vacuum is removed. This step tests for goes over 2 volts with the sensor
that drop at the sensor. disconnected, the sensor or sensor
connections are faulty.
CODE 34
DIFFERENTIAL PRESSURE (VAC) SENSOR
(SIGNAL VOLTAGE INCORRECT)
CARBURETED-CALIF.
* This requires use o f three jumpers between the sensor and the connector.
They can be made using term inals 12014836 and 12014837.
2-18-85
6S2569-6E
iii iti
PICK-UP
COIL
DISTRIBUTOR M1111h u m
HEI MODULE l"l 1111ii 11iii,
E
ECM4.3L
IGN BACK VIEW OF ECM CONNECTOR
- f
PRIMARY < 19
423 WHT EST
IGN. COIL<
n
453 BLK/RED j
GROUND
ECM
IGN 5.0L75.7L
PRIMARY <
IG N .C O IK 423 WHT 19
EST
430 PPL/WHT - REFRENCE
453 BLK/RED _
GROUND
HEI MODULE
2-18-85 3-7-85 6S2571 6E
CODE 41
4.3L, 5.0LOR 5.7L ENGINE
CARBURETED-CALIF.
Code 41 says that there are no distributor references pulses to the ECM at a
specified engine vacuum. This code could set with the key "ON", engine "Not
Running" if the VAC sensor was defective by indicating "Engine Running"
voltage with just the key "ON". With a constant open or ground in the reference
signal circuit, Code 12 would be set along with a 41. Use Chart 12 if 12 and 41 are
set. Code 41 alone indicates the problem is intermittent. When the distributor
reference line signal is lost, the engine runs full rich and with retarded (base)
spark timing. The result is poor performance, poor fuel economy, and possibly
rotten egg odor from exhaust.
1. Checks to see if VAC sensor voltage changes 2. Checks for cause of an intermittent open or
with loss of vacuum supply. A good sensor ground in the distributor circuit. Fault could
will change voltage at Terms. A to B by 1 also be an intermittent stuck Vacuum sensor
volt or more. that has the same voltage output as an engine
"running" with only the key "ON", thus, no
1A. Since the voltage change was less than 1 volt, reference signal. Terminals must be removed
the problem is in the Vacuum system. The from connectors to properly check them. The
ECM has "seen" engine running vacuum distributor pick-up coil should also be
equivalent with no distributor reference checked.
signal, with the key "ON", engine not running.
CODE 41
NO DISTRIBUTOR
REFERENCE SIGNAL
CARBURETED-CALIF.
2-18-85
6S2570-6E
U m i
PICK-UP
COIL
DISTRIBUTOR
h i 11 M i i i n ^ f i
MODULE i i i i i i i i m rr
ECM 4.3L
IGN BACK VIEW OF ECM CONNECTOR
GBRE
PRIMARY < 19
423 WHT EST
IGN. COIL*
1J m rm r
453 BLK/RED
GROUND
ECM
IGN 5.0L/5.7L
- f
PRIMARY <
IGN. COIH 423 W HT 19
EST
430 PPL/WHT - REFRENCE

453 BLK/RED
GROUND
HEI MODULE
2-16-85 3-7-85 6S2571 6E
CODE 42
ELECTRONIC SPARK TIMING (EST)
CARBURETED-CALIF.
Code 42 says that the ECM has seen:
Open or grounded By-pass Circuit (Term. 11)
Open or grounded EST Circuit (Term. 12)
A grounded EST may sometimes not set a code unless
cranked 10 seconds or longer with circuit grounded.
1. This checks operation of EST. Grounding the By putting voltage through the test light on
test terminal causes timing to go to a fixed Terminal C of the harness, the module is
value which is normally different from that switched to the EST mode and the vehicle
obtained with EST operating. Therefore, the should run. If the engine stops, there is no
EST signal reaching the module due to open
timing should change. Usually the change or poor connections, or the module is faulty.
can be heard in engine RPM. If so, the timing 3. By removing the jumper, you are opening the
change does not have to be checked. If timing EST signal and the engine should stop.
varies with increase in engine RPM, problem
is indicated. 4. Since the engine ran when the module was
jumpered, it says the problem is not in the
2. This step eliminates the ECM and ECM distributor (if the correct HEI module is
connections from the module input. By installed). The wrong HEI module can set a
jumpering Terminals A and B, the Code 42.
distributor ref. signal is fed directly into the
EST line of the module.
3^
ESC
= 2 = 3
MODULE
= >
J &
........................... J
5-9-84
CODE 43
ESC VOLTAGE LOW TO ECM
(ELECTRONIC SPARK CONTROL)
4.3 L ENGINE
CARBURETED-CALIF.
Code 43 says that the Electronic Spark Control (ESC) retard
signal has been seen by the ECM for too long a period of time.
When voltage at Terminal L at the ECM is low, spark is retarded.
Normal voltage in non-retard mode is about 7.5V or more.
Normal voltage would be over 7.5 volts. If 7.5 5. Checks for proper 12V ignition source to ESC
volts is present at Term. "L", the reason for a Term. B. Term. B should be battery voltage.
Code 43 is a poor connection to ECM or faulty
ECM. 6. Checks to see if spark retard is due to engine
knock or a faulty knock sensor. If by
2. Over 6 volts indicates an overly sensitive disconnecting the knock sensor spark
knock sensor or controller, or noise in the advances, fault is in engine "noise" or sensor.
engine that fools the knock sensor. Normally no increase would be noted.
3. Checks for grounded ECM. 7. Checks to see if spark retard is due to "noise"
on ESC to knock sensor line or a faulty ESC
4. Checks for an open in wire from ESC to ECM. controller. By removing terminal "E" from the
If over 6 volts was obtained at Term. "C" of connector, the determination can be made. If
the ESC, the fault is an open to Term. "L" of spark advances, check for improper routing
ECM. of knock sensor signal wire.
CODE 43
ESC VOLTAGE LOW TO ECM
(ELECTRONIC SPARK CONTROL)
4.3L ENGINE
CARBURETED-CALIF.
4-2-85
65 2640-6E
i i m 1 1 1 1 r r m
I I hi I I I I I I FT i
0 2 SENSOR
412 PPL
SIGNAL

GROUND
I
11-10-84 2-14-85
4S 0362-6E
CHART 44
LEAN EXHAUST INDICATION
CARBURETED-CALIF.
Code 44 says that the ECM has seen O sensor voltage under
2
the following conditions:

Voltage lower than specified
Closed loop
Above a specified TPS value
1. Checks to see if the condition is still present. 3. If dwell increases to over 50 with heavy
A fixed dwell of under 10 indicates the choking the fault is an air leak, since the ECM
problem is still present. A fixed dwell under was able to respond. If air is going to exhaust
10 at idle, with dwell varying at 3000 RPM, ports, disconnect the solenoid(s) for the air
usually indicates an intake leak. Check these control valve. If air still goes to the ports, it is
areas prior to replacing the O sensor.
2 a faulty valve.
2. Checks to see if the ECM is able to respond to 4. This step puts a rich O signal (about 1 volt)
2
a rich condition caused by choking the into Terminal "9" of the ECM. Dwell should
engine. If it does, the problem is a lean engine increase (lean command).
condition, NOT electrical.
CODE 44
LEAN EXHAUST INDICATION
CARBURETED-CALIF.
*Do not use an ordinary voltm eter or jum per in place of the digital voltm eter because they have too
little resistance. A voltage o f 1 .OV to 1.7v (such as a flashlight Dattery) can be connected w ith the
Positive term inal to the purple w ire and the negative term inal to ground as a jum per. If the polarity is
reversed, it w o n 't work.
If chart does not resolve problem, see D riveability Symptoms, Section "B ".
4-2-85
* 65 2636-6E
I I H I I I I ITT5T ECM
I I hi I I I I I ITT
i
0 2 SENSOR
412 PPL
SIGNAL

GROUND
I
11-12-84 2-14-85
4S 0362-6E
CODE 45
RICH EXHAUST INDICATION
CARBURETED-CALIF.
Code 45 says that the ECM has seen:
High oxygen sensor voltage
More than specified time (about 2 minutes)
Above a specified TPS value
Closed loop
A high voltage can be caused by a rich exhaust or O sensor 2
contaminated with silicone.
1. Checks to see if fault is still present. A dwell of 3. This step tests to see if ECM is able to respond
under 50 indicates engine should be checked to a lean exhaust O signal (low voltage). If no
2
for cause of intermittent rich condition: i.e., dwell change with a grounded lead to O 2
sensor Term. 9", fault is in ECM. It couldnt

Purge or bowl vent valves leaking. be an open O wire because that would set
2
Fuel in crankcase. Code 13.
Fuel in evaporative canister.
Sticking mixture control solenoid or 4. This step checks the voltage from the ECM at
metering rods. the O sensor harness. Normal voltage at this
2
point is the ECM bias voltage for no O signal 2

2. This step causes a lean condition by putting which is approximately .45V. If voltage is
an air leak into the engine to see if ECM can high, the wire to the ECM could be shorted to
respond. A drop in the dwell indicates ECM B +, or it is a faulty ECM.
and O sensor are not faulty. Look for source
2
of constant rich condition. See step one

examples.
CODE 51
PROM
4.3L, 5.0L.OR5.7L ENGINE
CARBURETED-CALIF.
Code 51 sets if any one of the following occur:
Faulty PROM unit
PROM unit improperly installed (may not set a code if installed backwards)
Some PROM pins not making contact (i.e., bent)
Always check to see that the PROM pins are not bent and are inserted properly into
the ECM.
Make certain the PROM is installed in the proper direction as shown in the chart.
THE IGNITION SHOULD ALWAYS BE OFF WHEN
INSTALLING OR REMOVING THE ECM CONNECTORS
4-- Remove or Disconnect (Figures 1 and 2) Im portant
1. Connectors from ECM Using the rocker-type PROM removal tool, engage one
2. ECM mounting hardware end of the PROM carrier with the hook end of the tool.
Press on the vertical bar end of the tool and rock the
engaged end of the PROM carrier up as far as possi
Important ble. Engage the opposite end of the PROM carrier in
the same manner and rock this end up as far as possi
ELECTRONIC CONTROL MODULE (ECM) MOUNTING ble. Repeat this process until the PROM carrier and
HARDWARE NOT ILLUSTRATED. HARDWARE CON PROM are free of the PROM socket. The PROM carrier
FIGURATION WILL VARY WITH CAR DIVISION. with PROM in it should lift off of the PROM socket
easily. PROM carrier should only be removed by using
the pictured PROM removal tool (Figure 2). Other
methods could cause damage to the PROM or PROM
3. ECM from passenger compartment socket.
4. ECM access cover
5. PROM
ACCESS COVER
F ig u re 2
Im portant
REPLACEMENT ELECTRONIC CONTROL MODULE

(ECM) IS SUPPLIED WITHOUT AN ENGINE CALIBRA
TION UNIT (PROM) SO CARE SHOULD BE TAKEN
F ig u re 1 WHEN REMOVING THE PROM AS IT WILL BE REUSED
IN THE NEW ECM IF THE ORIGINAL ECM IS FOUND
TO BE DEFECTIVE.
04 26 85 4S 1027-6EB
CODE 51
CHECK THAT ALL PINS ARE FULLY INSERTED IN THE PROM PROBLEM
SOCKET. IF OK, REPLACE PROM AND RECHECK.
IF CONDITION IS NOT CORRECTED, REPLACE ECM. 4.3L, 5.0L, OR 5.7L ENGINE
SEE CHART C-1. CARBURETED-CALIF.
| I nspect (Figure 3) Install or C onnect (Figures 1 and 3)

For correct indexing of reference end of the 1. PROM in PROM socket.
PROM carrier and carefully set aside. Do
not remove PROM from carrier to conform
PROM correctness. Im p o rta n t
DO NOT PRESS ON PROM - ONLY CARRIER.
Small notch of carrier should be aligned

with small notch in socket. Press on
PROM carrier until it is firmly seated in
the socket. Do not press on PROM; only
NOTCH IN PROM REFERENCED the carrier.
TO SMALLER NOTCH IN 2. Access cover on ECM.
3. ECM in passenger compartment.
CARRIER AND THE PIN #1 END
| 1 [ REFERENCE END 4. Connectors to ECM.

Functional Check
|T]
[~2~| PROM
1. Turn ignition on.
PROM CARRIER
2. Enter diagnostics.
a. Code 12 should flash four times. (No
other codes present.) This indicates
the PROM in installed properly.
b. If trouble code 51 occurs or if the
check engine light is on constantly
Im p o r ta n t with no codes, the PROM is not fully
(B efore in s ta llin g n e w PROM) seated, installed backwards, has bent
pins, or is faulty.
If not fully seated, press firmly on
ANYTIME THE PROM IS INSTALLED BACKWARDS PROM carrier.
AND THE IGNITION SWITCH IS TURNED ON, THE If it is necessary to remove the
PROM IS DESTROYED. PROM, follow instructions in
steps A & B.
If installed backwards, REPLACE
THE PROM.
If pins bend, remove PROM,
straighten pins, and reinstall. IF1
bent pins break or crack during
straightening, discard PROM and
replace it.
5-20-85
*4S 0317-6EE
CODE 54
M/C SOLENOID VOLTAGE HIGH TO ECM
CARBURETED-CALIF.
Code 54 will be set if there is constant high voltage at ECM
Term. 18.
A shorted solenoid or a wiring short to 12V on circuit to ECM
would cause the solenoid to remain in the full rich position,
resulting in potential ECM damage, excessive fuel consumption,
and excessive exhaust odor.
L Checks the M/C solenoid resistance to 2. Checks to see if reason for high voltage to
determine if the fault is in the solenoid or Term. 18 is a faulty ECM or a short to 12V on
ECM harness/ECM. A normal solenoid has that wire. If the test light illuminates with
about 20 to 32 ohms of resistance. both ends of harness disconnected, there is a
short to 12V in the wire.
CODE 54
M/C SOLENOID VOLTAGE
HIGH TO ECM
CARBURETED-CALIF.
4-2-85
6S2641-6E
SECTION B - SYMPTOMS
BEFORE STARTING CARBURETOR ADJUSTMENT
C alifo rn ia O nly Carburetor adjustment and specification can
Before using this section you should have be found in Section 6C10 for the E4ME
performed the DIAGNOSTIC CIRCUIT carburetor, Section 6C7 for the 1ME
CHECK and found out that: carburetor or Section 6C10 for the
M4ME/M4MC carburetor.
1. The ECM and "SERVICE ENGINE SOON"
light are operating. VISUAL CHECK
Several of the symptom procedures below
2. There are no trouble codes stored, or only
intermittent codes. call for a careful visual check. This check
3. The fuel control system is operating OK (by should include:
performing SYSTEM PERFORMANCE Vacuum hoses for splits, kinks, and proper
CHECK). connections, as shown on Emission Control
Information label.
Federal and C alifornia Air leaks at carburetor throttle body
Verify the customer complaint, and locate mounting and intake manifold.
the correct SYMPTOM below. Check the items Ignition wires for cracking, hardness,
indicated under that symptom. proper routing, and carbon tracking.
If the ENGINE CRANKS BUT WILL NOT Wiring for proper connections, pinches,
RUN, see "No Start - Engine Cranks OK" and cuts.
below. The importance of this step cannot be
stressed too strongly - it can lead to correcting
DISTRIBUTOR INFORMATION a problem without further checks and can save
Refer to Section 6D, Engine Electrical, for valuable time.
Ingnition System including distributor
information.
INTERMITTENTS
CALIFORNIA ONLY - 4.3L. 5.0L OR 5.7L ENGINE
Problem may or may not turn "on the "SERVICE ENGINE SOON light, or set a code.
DO NOT use the Code Charts in Section A Open Ignition coil ground and arcing at
for intermittent problems. The fault must be spark plug wires or plugs.
present to locate the problem. If a fault is "SERVICE ENGINE SOON" light wire
intermittent, use of Code Charts may result in to ECM for short to ground.
replacement of good parts. Diagnostic "Test" Terminal wire to
ECM, for short to ground.
Most intermittent problems are caused by ECM terminals A and U to engine
faulty electrical connections or wiring. ground.
Perform careful check as described at start Loss of trouble code memory. To check,
of Section B. Check for: ground the dwell lead for 10 seconds with
Poor mating of the connector halves, or ' Test" terminal left ungrounded. Code 23
terminals not fully seated in the should be stored after engine is stopped,
connector body (backed out). and ignition turned to "run" position. If not,
Improperly formed or damaged the ECM is faulty.
terminals. All connector terminals in Check for an electrical system interference
problem circuit should be carefully caused by a defective relay, ECM driven
reformed to increase contact tension. solenoid, or switch. They can cause a sharp
Poor terminal to wire connection. This electrical surge. Normally, the problem will
requires removing the terminal from the occur when the faulty com ponent is
connector body to check. See operated.
Introduction in Section 6E. Check for improper installation of
If a visual (physical) check does not find the electrical options, such as lights, 2-way
cause of the problem, the car can be driven radios, etc.
with a voltmeter connected to a suspected EST wires should be kept away from spark
circuit. An abnormal voltage reading when plug wires, distributor wires, distributor
the problem occurs indicates the problem housing, coil, and generator. Wire from
may be in that circuit. ECM terminal 13 to distributor, should be a
Check for intermittent connection in circuit good ground.
from: Check for open diode or resistor across A/C
compressor clutch, and for other open
diodes (see wiring diagrams).
WON'T START - ENGINE CRANKS OK

Definition: Engine cranks OK, but does not start. May fire a few times.
Perform "Diagnostic Circuit Check". (Cal.) Check fuel pump capacity.
Make sure proper starting procedure is If fuel pump checks OK, check float
being used. See Owners Manual. needle for sticking in seat, or
Visual Check: binding float.
Vacuum hoses for splits, kinks and If there is a pump squirt,
proper connections, as shown on Crank engine and check for
Vehicle Emission Control Information flooding.
label. If not flooding, see "Ignition System
Ignition wires for cracking, hardness Check", Chart C-4A in Section C,
and proper connections at both Remove spark plugs. Check for wet plugs,
distributor cap and spark plugs. cracks, wear, improper gap, burned
Remove air cleaner: electrodes, or heavy deposits. Repair or
Check carburetor choke valve, replace as necessary.
vacuum break(s), linkage and unloader Visually check distributor cap inside and
operation. See Section 6C. Set to out for moisture, dust, cracks, burns, and
specifications. Choke valve should arcing to coil mounting screws.
move smoothly and be closed when Try to turn distributor shaft by hand. Drive
cold, and open when hot. pin may be broken.
Check for presence of fuel by noting After starting engine, perform the
carburetor accelerator pump operation. "System Performance Check." (Cal.)
Look for gas squirt in carburetor bore Very cold temperatures:
while quickly opening throttle lever. Check that the proper viscosity oil is
If no pump squirt, being used, and crank case oil is not
Check for fuel in tank. contaminated with gasoline.
Check carburetor fuel inlet filter.
Replace if dirty or plugged.
HARD START-COLD
Definition: Engine cranks OK, but does not start for a long time. Does
eventually run. If the engine starts but immediately dies (as soon as key is
released from start position), See "No Start, Engine Cranks OK" symptom.
Perform "Diagnostic Circuit Check" (Cal.) Check EGR system for sticky operation that
Perform the "System Performance Check" could cause valve to stick open.
(Cal.) Check float level using external float gage.
Make sure driver is using correct Adjust float to specification if required. See
starting procedure. See Owners Manual. Section 6C.
Visual Check: Check carburetor fuel inlet filter. Replace if
Vacuum hoses for splits, kinks and dirty or plugged.
proper connections, as shown on Check ignition system - see Chart C-4,Check
Vehicle Emission Control Information distributor for:
label. Worn shaft
Air leaks at carburetor mounting and Bare and shorted wires
intake manifold. Pick-up coil resistance and connections
Ignition wires for cracking, hardness, Loose ignition coil ground
and proper connections, at both the Moisture in distributor cap.
distributor cap and spark plu gs. Remove spark plugs; check for wet plugs,
Wiring for proper connections, pinches wear, improper gap, burned electrodes or
and cuts. heavy deposits. Repair or replace as
Check the choke valve, throttle and fast necessary.
idle cam for sticking. Replace any Check ignition timing per Vehicle Emission
malfunctioning parts. If caused by foreign Control Information label.
material and gum, clean with suitable non Verify proper engine oil viscosity per
oil base solvent. See Section 6C. recommendations in M aintenance Schedule.
Check choke and vacuum break operation Check fuel pump volume, pressure and
and adjustment. Choke should be closed vacuum.
cold. See Section 6C.
HARD START-HOT
Definition: Engine cranks OK, but does not start for a long
time. Does eventually run. If the engine starts but immediately
dies (as soon as key is released from start position), see
Ignition System Check", Chart C-4,
Perform "Diagnostic Circuit Check." Check fuel line routing.
Perform the "System Performance Check." Check EFE valve. EFE valve should be
Visual (physical) Check: open.
Vacuum hoses for splits, kinks, and Check EGR for sticky operation that could
proper connections, as shown on cause valve to stick open.
Vehicle Emission Control Information Check for obvious overheating problems.
label. Low coolant.
Ignition wires for cracking, hardness, Loose water pump belt.
and proper connections, at the Restricted air flow to radiator, or
distributor cap and spark plugs.
Wiring for proper connections, pinches Check ignitionwater
restricted flow thru radiator.
system, Section 6D. Check
and cuts. distributor for:
Make sure driver is using correct starting Worn shaft.
procedure. See Owners Manual. Bare and shorted wires.
Check choke valve, throttle linkage and Intermittent pickup coil or connections,
fast idle cam for sticking. module, ignition coil ground and
Check choke and vacuum break operation condenser. Repair or replace as
and adjustment. Choke should be open hot. necessary.
See Section 6C. Remove spark plugs. Check for cracks,
Check for carburetor flooding. wear, improper gap, burned electrodes,
Check fuel inlet filter. If plugged replace. heavy deposits. Repair or replace as
Check float level using external float gage. necessary.
Adjust float to proper specification if Check ignition timing. See Vehicle
required. See Section 6C. Emission Control Information label.
Check fuel pump volume, pressure and
vacuum.
STALL AFTER START - COLD

Definition: Engine at room or outside temperature, within
three minutes after start. (1) Stalls after brief idle; (2) dies as
soon as any load is placed on engine (such as A/C turned "ON"
or transmission engaged); or (3) Dies on initial driveaway.
If symptom is present cold and hot, go to With engine "OFF", check all choke
symptom "Stall After Start - Hot". adjustments, including vacuum breaks and
Perform "Diagnostic Circuit Check." TVS if used. See Section 6C.
(Cal.) Check fast idle speed setting, if applicable,
Perform "System Performance Check." and curb idle speed.
(Cal.) Check carburetor accelerator pump
Visual (physical) Check: operation.
Vacuum hoses for splits, kinks and Check EFE valve for proper operation.
proper connections, as shown on EFE valve should be closed cold. See Chart
Vehicle Emission Control C-9C.
Information label. Check EGR valve for proper operation. See
Make sure hot air tube is connected to air Chart C-7.
cleaner Check engine timing. See Vehicle
Check proper operation of THERMAC. Emission Control Information label.
Check carburetor choke valve, throttle Poor or contaminated gasoline. Suggest
linkage and fast idle cam for sticking. owner try different brand.
With engine running, visually check
vacuum break linkage for movement
while removing and re-installing vacuum
hoses to vacuum breaks. If the linkage
does not move and vacuum is at hose,
check for binding linkage. If linkage OK,
replace vacuum break unit.
STALL AFTER START - HOT

Definition: The engine starts OK, but (1) dies after brief idle; (2)
dies as soon as any load is placed on engine (such as A/C turned
"ON or transmission engaged); (3) dies on initial driveaway.
Perform "Diagnostic Circuit Check."(Cal.) Check float level using external float gage.
Perform "System Performance Check." See Section 6C.
Vacuum hoses for splits, kinks and Check EGR valve for proper operation -
proper connections, as shown on Chart C-7A in Section C.
Vehicle Emission Control Information Check for overcharged A/C System.
label. Check for obvious overheating problems:
Make sure hot air tube is connected to air Low coolant
cleaner. Loose water pump belt
Check proper operation of THERMAC. Restricted air flow to radiator or
Check carburetor choke and vacuum restricted water flow thru radiator.
breaks for proper operation. See Section
6C for check procedure.
HESITATION/ SAG, STUMBLE

Definition: Momentary lack of response as the accelerator is
pushed down. Can occur at all vehicle speeds. Usually most
severe when first trying to make vehicle move, as from a stop
sign. May cause the engine to stall if severe enough.
Perform "Diagnostic Circuit Check."(Cal.) Check float level using external float gage.
Perform "System Performance Check." See Section 6C.
Vacuum hoses for splits, kinks and Check vacuum hose to vacuum sensor for
proper connections, as shown on leaks, restrictions, and proper connections
Vehicle Emission Control Information (should be
label. manifold vacuum).
Ignition wires for cracking, hardness, Check EGR valve operation, Chart C-7A
and proper connections, at both Section C.
distributor and spark plugs. Check TPS adjustment in Section C. Use
Wiring for proper connections, ALCL tool if available.
pinches and cuts. Check canister purge system for proper
Make sure hot air tube is connected to air operation, Chart C-3 in Section C.
cleaner. Check for open ignition coil ground and for
Check proper operation of THERMAC intermittent ECM ground.
See Section C.. Check engine timing. See Vehicle Emission
Note: Cold engine only - check the Control Information label.
following for sticking or faulty operation: Poor or contaminated gasoline. Try a
Carburetor choke, including vacuum different brand of gasoline.
break, throttle linkage and fast idle
cam.
Check choke TVS if used.
Check all choke adjustments,
including vacuum breaks.
SURGES AND/OR CHUGGLE

Definition: Engine power variation under steady throttle or cruise. Feels like
the car speeds up and lows down with no change in the accelerator pedal.
Perform "Diagnostic Circuit Check." (Cal.) Check for intermittent open, or short to
Perform "System Performance Check." ground in TCC circuit, term. "N" at ECM, to
(Cal.) terminal "B" at transmission.
Visual (physical) Check: Check for proper operation of EGR. See
Vacuum hoses for splits, kinks and
proper connections, as shown on Chart C-7A.
Vehicle Emission Control Information Check carburetor fuel inlet filter, replace if
label. dirty or plugged.
Ignition wires for cracking, hardness, Check carburetor float level using external
and proper connections, at both float gage. See Section 6C.
distributor cap and spark plugs. Test fuel pump capacity. See Section 6C.
Wiring for proper connections, pinches Remove spark plugs, check for cracks,
and cuts. wear, improper gap, burned electrodes or
4-Terminai EST connector and wires heavy deposits.
near spark plug wires. Check condition of distributor cap, rotor
Have driver read explanation of and spark plug wires.
transmission converter clutch and A/C Check for arcing to coil attaching screws in
compressor operation in Owners Manual. distributor cap.
Make sure hot air tube is connected to air Check for intermittent ground connection
cleaner. on integral ignition coil.
Check proper operation of THERMAC in Poor or contaminated gasoline. Try a
Section C. different brand of gasoline.
LACK OF POWER, SLUGGISH OR SPONGY
Definition: Engine delivers less than expected power, little
or no increase in speed when accelerator pedal is pushed down
part way.
Perform "Diagnostic Circuit Check." (Cal.) Check EGR operation. See Chart C-7A.
Perform "System Performance Check." Check EST operation. If ALCL tool is
(Cal.) available, check for excessive retard.
Visual Check: Excessive retard may be caused by carbon
Vacuum hoses for splits, kinks and build-up in cylinders which can be removed
proper connections, as shown on with "Top Engine Cleaner."
Vehicle Emission Control Information Check VAC sensor output as applicable, see
label. Chart C-1E.
Ignition wires for cracking, harness, Check EFE Valve
and proper connections, at both the Remove spark plugs. Check for cracks,
distributor cap and spark plugs. wear, improper gap, burned electrodes,
Wiring for proper connections, pinches heavy deposits. Repair or replace as
and cuts. necessary.
Compare customers vehicle to similar Check for an exhaust system restriction:
unit. Make sure the customers vehicle has 1. With engine at normal operating
an actual problem. Was the customers old temperature, connect a vacuum gage to
vehicle much more powerful? any convenient vacuum port on intake
Make sure hot air tube is connected to air manifold.
cleaner. 2. Run engine at 1000 RPM and record
Remove air cleaner and check air filter for vacuum reading.
dirt. 3. Increase RPM slowly to 2500 RPM.
Check for proper operation of THERM AC. Note vacuum reading at steady 2500
Check for full throttle valve opening in RPM.
carburetor by depressing accelerator 4. If vacuum at steady 2500 RPM is more
pedal to floor. than 3 lower than 1000 RPM, exhaust
Check carburetor float level using external system should be inspected for
float gage. retstrictions, See CHART B-l.
Check for proper operation of carburetor Check engine valve timing and compression.
air valve (if equipped). See Section 6C. Check engine for proper or worn camshaft,
Check ignition timing. See Vehicle see Section 6A.
Emission Control Information label. Poor or contaminated fuel. Try a different
Check transmission for proper downshift brand of gasoline.
and TCC operation.
BACKFIRE
Definition: Fuel ignites in intake manifold, or exhaust
system, making a loud popping noise.
Perform "Diagnostic Circuit Check." (Cal.) Check vacuum sensor hose for restriction, or
Perform "System Performance Check." (CA1.) for fuel or water in hose.
Visual Check: Check for proper operation of EGR valve.
- Vacuum hoses for splits, kinks and proper Perform a com pression check - look for
connections, as shown on Vehicle Emission sticking or leaking valves.
Control Information label. Check for restricted exhaust system, see
- Ignition wires for cracking or hardness CHART B-l at end of Section B.
proper connection, at both the distributor cap Check output voltage of ignition coil. See
and spark plugs. Chart C-4A in Section C.
- Chaffed wiring harness by pulleys or metal Check operation of decel (gulp) valve if so
edges. equipped.
Make sure hot air tube is connected to air Check for crossfire between spark plugs,
cleaner. distributor cap, spark plug wires and proper
Check proper operation of THERMAC in routing of plug wires. Wires for cylinders
Section C. which fire in sequence on the same side of the
Note: Cold engine only - check the following engine should not be routed next to each other;
for sticking or faulty operation: i.e., 8 and 4, and 5 and 7. See Section 6D.
- Carburetor choke, including vacuum break Check for intermittent condition in ignition
and throttle linkage. Check choke TVS if used. system.
Check EFE Valve. - Pick-up coil
Check carburetor accelerator pump - EST wire (to ECM Terminal 12)
operation. - Ignition coil ground on integral coil
- Ignition coil primary connections
Check for proper valve timing.
MISSES (CUTS OUT)

Definition: Pulsation or jerking that follows engine speed, usually
more pronounced as engine load increases. The exhaust may have a
steady spitting sound at idle or low speed. Not normally felt above 1500
RPM or 30 MPH (48 Km/h).
Perform "Diagnostic Circuit Check." (Cal.) Visually check distributor cap inside and out
Perform "System Performance Check." for moisture,dust, cracks, burns and check
(Cal.) for to coil arcing mounting screws. With
Visual (Physical) Check: engine running, spray cap and plug wires
Vacuum hoses for splits, kinks and with fine water mist to check for shorts.
proper connections, as shown on Check for poor ground on integral ignition
Vehicle Emission Control Information coil.
label. Check EGR valve for sticking partially open.
Ignition wires for cracking, hardness Remove spark plugs and check for cracks,
and proper connections at both wear, improper cap, burned electrodes and
distributor cap and spark plugs. heavy deposits.
Wiring for proper connections, pinches Check pickup coil in distributor with
and cuts. (Verify good connections ohmmeter, and check for proper connections
grounding of ECM terminals "A and at module. Pickup coil should be 500-1500
"U). OHMS and not grounded. See Sec. 6D.
Check spark plug wire routing for correct If pickup coil checks OK,
firing order. Check for ignition dwell increase
Check for misfiring at spark plugs: from low to high RPM by connecting
1. Disconnect and plug air cleaner and dwell meter -to distributor "TACH"
EGR vacuum hoses. terminal. If dwell doesnt increase,
2. Check spark at all plug wires with replace ECM.
J26792 (ST-125). Remove rocker covers, check for bent
If there is no spark on any cylinder, pushrods, worn rocker arms, broken valve
see "Ignition System Check", Chart springs, worn camshaft lobes. Repair as
C-4, necessary. See Section 6A.
Spark at all cylinders
ROUGH, UNSTABLE OR INCORRECT IDLE; STALLING

Definition: The engine runs unevenly at idle. If bad enough, the car may
shake. Also, the idle may vary in RPM (called "hunting"). Either condition
may be bad enough to cause stalling. Engine idles at incorrect speed.
Perform "Diagnostic Circuit Check." (Cal.) Check EGR System. See Chart C-7A, There
Perform "System Performance Check." should be no EGR at idle. Pulse Width
(Cal.) Modulated Systems do not work in Park or
Visual (physical) Check: Neutral.
Vacuum hoses for splits, kinks and If rough idle occurs hot, perform these
proper connections as shown on additional checks:
Vehicle Emission Control Information Check PCV valve for proper operation
label. by placing finger over inlet hole in valve
Ignition wires for cracking, hardness, end several times. Valve should snap
or proper connections, at both back. If not, replace valve.
distributor cap and spark plugs. Check canister purge and bowl vent
Check throttle linkage for sticking or control system. See Chart C-3 in Section
binding. C..
Check carburetor for flooding. Remove carbon with top engine cleaner.
Check float level using external float gage. Follow instructions on can.
See Section 6C. Check for proper spark plug gap.
Check engine idle speed, See Vehicle Run a cylinder compression check. See
Emission Control Information label. Section 6.
Check ignition timing. See Vehicle Emission
Control Information label.
Check for exhaust system restriction. See
Chart B-l.
WON'T IDLE
Definition: Engine starts OK, but dies at idle. Will run if accelerator
pedal is held at part throttle.
Perform "Diagnostic Circuit Check." If sticking operation is found, clean or
Perform "System Performance Check." if replace valve. There should be no EGR at
possible. idle. It may be necessary to remove the
Visual (physical) Check: valve to check for leaking.
Vacuum hoses for splits, kinks and Check engine idle speed, See Vehicle
proper connections as shown on Emission Control Information label.
Vehicle Emission Control Information Check carburetor idle adjustment. If unable
label. to adjust, check carburetor idle system. See
Air leaks at carburetor mounting and Section 6C.
intake manifold. Check spark plug condition and gap.
Check carburetor float level using external
float gage. See Section 6C. Check for exhaust system restriction. See
Check for carburetor flooding. See Section Chart BI.
6C.
Check EGR system, See Chart C-7A in
Section C.. Check for a loose valve or
sticking EGR plunger.
POOR FUEL ECONOMY
Definition: Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is noticeably lower than it
was on this car at one time, as previously shownlby an actual road test.
Check owners driving habits. Ignition wires for cracking, hardness
Is A/C on full time (Defroster mode on)? and proper connections.
Are tires at correct pressure? Check ignition timing. See Vehicle Emission
Are excessively heavy loads being
carried? Control Information label.
Is acceleration too much, too often? Check EST operation, Chart C-4C. (Cal.)
Suggest driver read "Important Facts Check ESC operation, Chart C-5. If ALCL
on Fuel Economy" in Owners Manual. tool is available, check for excessive retard.
Perform "Diagnostic Circuit Check." (Cal.) (Cal.)
Perform the ' System Performance Check." Remove spark plugs. Check for cracks,
(Cal.) wear, improper gap, burned electrodes or
Check air cleaner damper door operation. heavy deposits. Repair or replace as
(Thermal) necessary.
Check air cleaner element (filter) for dirt or Check compression. See Section 6A.
being plugged. Check TCC for proper operation. See Chart
Check for proper calibration of C-8B, Use ALCL tool if available. (Cal.)
speedometer. Check for dragging brakes.
Visual Check: Suggest owner fill fuel tank and recheck fuel
Vacuum hoses for splits, kinks and economy.
proper connections as shown on Check for exhaust system restriction. See
Vehicle Emission Control Information Chart B-1.
label.
DIESELING, RUN-ON
Definition: Definition: Engine continues to run after key is turned "OFF", but
runs very roughly. If engine runs smoothly, check ignition switch and adjustment.
Visually Check: Check engine idle speed,
Vacuum hoses for splits, kinks and Check ignition timing. See Vehicle Emission
proper connections as shown on Vehicle Control Information label.
Emission Control Information Label. Remove carbon with top engine cleaner.
Carburetor choke, throttle linkage and Follow instructions on can.
fast idle cam for sticking. Check for engine overheating. Use ALCL
Check carburetor choke, vacuum break tool if available. Normal coolant
linkage, throttle linkage and fast idle cam temperature is 85 C- 100C (185F-215"F).
for proper adjustment. See Section 6C. Low coolant:
Check cruise control for proper adjustment. Loose fan belt
See Section 9. Restricted air flow
Inoperative fan clutch.
DETONATION/SPARK KNOCK
Definition: A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change with throttle
opening. Sounds like popcorn popping.
Check EGR System for proper operation. Check for poor fuel quality, proper octane
See Chart C-7A, rating.
Check Vacuum sensor hose for fuel in hose Check TPS enrichment operation. See
or restrictions, and Vacuum sensor for low Chart C-2F. (Cal.)
output and proper connections or vacuum Remove carbon with top engine cleaner.
sensor for high output. (Cal.) Follow instructions on can.
Check ignition timing. See Vehicle If excessive carbon in cylinders, check for
Emission Control Information label. leaking valve seals.
Check for obvious overheating problems. Check for incorrect PROM. (Cal.)
Use ALCL tool if available. 85C-100C Check for improper operation of
(185F-215F) is normal. transmission (i. e., linkage adjustment) and
Low coolant: TCC. Use ALCL tool if available. (Cal.)
Loose water pump belt. Check for incorrect basic engine parts, such
Restricted air flow to radiator, or as cam, heads, pistons, etc.
restricted water flow thru radiator.
Check for air leaks at carburetor mounting
and intake manifold.
EXCESSIVE EXHAUST EMISSIONS (ODORS)

Definition: Car fails an emission test. May also have excessive "rotten
egg" smell (hydrogen sulfide).
Perform "Diagnostic Circuit Check." (Cal.) Check carburetor for flooding.
Perform "System Performance Check." Check float level using external float
(Cal.) gage. See Section 6C.
If test shows excessive CO and HC, (also Check canister for loading and check
has excessive odors): purge system for proper operation.
Check items which cause car to run See Chart C-3 in Section C..
rich. Check for incorrect idle speed.
Make sure engine is at normal Check for incorrect timing. See
operating temperature. Vehicle Emission Control
Visually check hoses for splits, Information label.
kinks and proper connections, as Check condition of spark plugs, plug
shown on Vehicle Emission Control wires and distributor cap.
Information label. If test shows excessive NOx:
Remove air cleaner and check air Check items which cause vehicle to run
filter for dirt or being plugged. lean, or to run too hot.
Replace as necessary. Check EGR valve for not opening.
Check for misadjusted idle mixture See Chart C-7A in Section C..
if plugs are removed. Check for vacuum leaks.
Check choke valve and linkage for Check for inoperative THERMAC.
sticking of faulty operation. Check coolant system and coolant
Check choke, vacuum breaks and fan for proper operation.
fast idle adjustments. Remove carbon with top engine
Check for stuck PCV valve or cleaner. Follow instructions on can.
obstructed hose. Check ignition timing for excessive
Check for lead contamination of base advance. See Vehicle Emission
catalytic converter. Check for Control Information label.
absence of filler neck restrictor.
Check operation of air management
system. See Chart C-6C or Chart C-
6D in Section C.
CHART B-1
RESTRICTED EXHAUST SYSTEM CHECK
Proper diagnosis for a restricted exhaust system is essential before any components are
replaced. The following diagnostic procedure is recommended:
1. Remove the rubber hose at the

exhaust manifold A.I.R. pipe check
valve. Remove check valve.
2. Connect a fuel pump pressure gage
to a hose and nipple from a Propane
Enrichment Device (J26911) (see
illustration).
3. Insert the nipple into the exhaust
manifold A.I.R. pipe.
4. With the engine at normal operating
temperature and running at 2500
rpm, observe the exhaust system
backpressure reading on the gage.
5. If the backpressure exceeds 2 3/4
psi, 19 kPa a restricted exhaust
system is indicated.
6. Inspect the entire exhaust system
for a collapsed pipe, heat distress,
or possible internal muffler failure.
7. If there are no obvious reasons for
the excessive backpressure, a
Q U f UEL PUMP PRESSURE GAUGE
restricted catalytic converter C T J h OSE A N D NIPPLE FROM PROPANE EN R IC H
should be suspected, and replaced

M ENT DEVICE (J-26911)
using current recommended

procedures.
3-22 85
SECTION C
COMPONENT SYSTEMS
Section C provides on-vehicle service for the Air Management System (under 8500 GVW)
following systems: Air Management System (over 8500 GVW)
Computer Command Control (Calif. Only) Exhaust Gas Recirculation
Fuel Control (Calif. Only) Transmission Converter Clutch (Calif. Only)
Throttle Return Control Early Fuel Evaporation
Evaporative Emission Control Positive Crankcase Ventilation
Electronic Spark Timing (Calif. Only) Thermostatic Air Cleaner
Electronic Spark Control (Calif. Only) Throttle Return Control - V8 engine (over 8500
GVW)
The following are diagnostic charts used in Section C:

Chart C-l ECM Replacement Check
Chart C-1A Differential Pressure Sensor Check
Chart C-2F TPS Enrichment Check
Chart C-2T Idle Speed Solenoid - 4.3L with A/C (Calif.)
Chart C-2W Idle Speed Solenoid - 4.3L without A/C (Calif.)
Chart C-3 Solenoid Valve Check
Chart C-4A Ignition System Check - with EST
Chart C-4D EST Performance Check
Chart C-4E Ignition System Check - without EST
Chart C-5 Electronic Spark Control Check
Chart C-6C Air Management Check
Chart C-6HD Air Management Check
Chart C-7D EGR Bleed Solenoid Check
Chart C-7E PWM Exhaust Gas Recirculation Check - with ECM
Chart C-7C Exhaust Gas Recirculation Check - without ECM
Chart C-8B Transmission Converter Clutch Electrical Check
Chart C-9C Early Fuel Evaporation System Check
COMPUTER COMMAND CONTROL

4.3L, 5.0L (RPO LF3) OR 5.7L (LS9) ENGINE
CALIFORNIA ONLY
GENERAL DESCRIPTION
The Computer Command Control system in
California is an electronically controlled exhaust o
f
U -
Ej Dj Ci Bj Aj Hr
emission system which consists of an electronic I l I M l-'
control module and various information sensors

to control the following systems:
Fuel Control
Evaporative Emission Control
Electronic Spark Timing
Electronic Spark Control (4.3L only)
Air Injection Reaction
Exhaust Gas Recirculation
Transmission Converter Clutch
Electronic C o n tro l M o d u le (ECM)
The Electronic Control Module (ECM) (Figures

21 and 27) is the control center of the Computer Q j A LC LC O N N E C T O R
Command Control system. It constantly looks at ~A~ GROUND TERM IN A L
the information from various sensors, and j~B~ T E S T TERM IN A L
controls the various systems that affect vehicle f i r , LAMP D R IV ER
performance. [ i n ELEC TR O N IC CO N TRO L MODULE

[ T ] SEAT RISER (DRIVER'S SIDE)
The ECM performs the diagnostic function of
the system. It can recognize operational 5 18 84 5S 1448-6E
problems, alert the driver through the SERVICE Figure 21 Electronic Control Module (ECM) - G
ENGINE SOON light, and store a code or codes
which identify the problem areas to aid the The PROM allows one model controller to be
technician in making repairs. Refer to Section 6E used for many different vehicles. It is located
and Section A for more information. inside the ECM and has information on the
An ECM used for service (called a Controller) vehicles weight, engine, transmission, axle ratio,
comes without program information (a PROM) and several others. While one ECM part number
for specific engine and vehicle. can be used by many engines, a PROM is very
specific and must be used for the right vehicle.
PROM (FIGURE 23) For this reason, it is very important to check the
latest parts book and Service Bulletin
The program information is programed in the information for the correct part number when
ECM using an intergrated circuit called a PROM replacing a PROM.
(Programmable Read-Only Memory). In the
parts book, it is listed as a calibrator.
[T] E LEC TRO N IC CON TRO L MODULE

I 2 |R ET A IN ER
m P LA STIC CON TAIN ER
l~3~! ECM MOUNTING HOUSING
| 2 | PRIN TED C IR C U IT BOARD
E plen u m p a n e l
m ECM HARNESS
05 18 84 5S 1447-6E 4S 1145-6E
Figure 22 Electronic Control Module (ECM) - CK Figure 24 Remote Lamp Driver
INFORMATION SENSORS
Engine C o o la n tT e m p e ra tu re Sensor
(FIGURE 25)
The coolant sensor is a thermistor (a resistor

which changes value based on temperature)
mounted in the engine coolant stream. Low
coolant temperature produces a high resistance
(100,000 ohms at -40C/-40F) while high
temperature causes low (resistance (70 ohms at
130C/266F).
The ECM supplies a 5-volt signal to the coolant
sensor thru a resistor in the ECM and measures
the voltage. The voltage will be high when the
engine is cold, and low when the engine is hot. By
measuring the voltage, the ECM knows the
engine coolant temperature. Engine coolant
Remote Lamp D river ( f ig u r e 24)
temperature affects most system s the ECM
The Remote Lamp Driver controls the controls.
"SERVICE ENGINE SOON" Light It is a small
circuit board located in a plastic holder taped to
the harness near the ECM. It turns the
"SERVICE ENGINE SOON" Light "ON" any time
the ignition is "ON" and the ECM is not pulling
Terminal "C" of the Lamp Driver to ground. This
normally occurs with the ignition "ON", engine
not running. The main advantage of the Remote
Lamp Driver is if the ECM looses power, the
"SERVICE ENGINE SOON" Light will come
"ON" to indicate a fault.
Figure 25 Engine Coolant Temperature Sensor
D iffe re n tia l Pressure (Vacuum ) Sensor

(FIGURE 26)
The Differential Pressure (Vacuum on VAC)

sensor located under the hood- It measures
engine vacuum directly. It has a high voltage
output (near 5 volts) at high vacuum, and a low
output at low vacuum. It is called a Differential
Pressure sensor since it measures the difference
between outside air pressure and manifold
vacuum, rather than an absolute pressure.
m EXH A U ST O XYG EN
(O2) SENSOR 4S 0619-6E
Figure 27 Exhaust Oxygen (O ) Sensor

2
T h r o ttle Position Sensor (TPS)

(FIGURE 28)
The Throttle Position Sensor (TPS) is a

variable resistor that is mounted in the
carburetor float bowl. The TPS plunger is under
the pump lever. As the TPS varies position, so
does the signal to the ECM. The ECM measures
the voltage output of the TPS. As closed throttle,
the voltage is about 1 volt or less and as the
throttle opening is increased, the voltage is
increased to about 5 volts at wide-open throttle.
Exhaust O x yg e n (O 2 ) Sensor The ECM used the TPS information to regulate
(FIGURE 27)
the M/C solenoid, idle speed, EST and TCC.
The exhaust oxygen (O 2 ) sensor is mounted in
the exhaust system where it can monitor the
oxygen content of the exhaust gas stream. The
oxygen content in the exhaust reacts with the
oxygen sensor to produce a voltage output. This
voltage ranges from approximately .1 volt (high
O - lean mixture) to .9 volts (low O - rich
2 2
mixture).
By monitoring the voltage output of the O 2
sensor, the ECM will know what fuel mixture

command to give to the carburetor injector (lean
mixture-low O voltage-rich command, rich
2
mixture-high O voltage-lean command).

2
The O sensor, if open, should set a Code 13. A

2
shorted sensor circuit should set a Code 44. A

high voltage in the circuit should set a Code 45.
Figure 28 Throttle Position Sensor
INPUT SIGNALS OXYGEN SENSOR

D is trib u to r
Code 13 will set if there is an open in the
The distributor not only controls engine oxygen sensor circuit. A shorted sensor circuit
timing, but acts as a sensor to tell the ECM the will set a Code 44. A high voltage in the circuit
crankshaft position and engine RPM. See will set a Code 45. Refer to Section A for
"Electronic Spark Timing." for service diagnosis.
information. THROTTLE POSITION SENSOR
DIAGNOSIS An open TPS circuit or a misadjusted throttle
ELECTRONIC CONTROL MODULE
position sensor will set a Code 21. Refer to
Section A for diagnosis. Chart C-2F will
Since the ECM can have a failure which may diagnosis the throtte position sensor circuit.
effect only one circuit, following the Diagnostic DISTRIBUTOR REFERENCE SIGNAL
Procedures starting with the Diagnostic Circuit
Check in Section A which will indicate if the ECM Code 42 chart will diagnosis the electronic
requires replacement. Refer to Chart C-1 before spark timing circuit. Refer to Section A.
replacing the ECM. Refer to C hart C-4A for diagnosis of the
PROM
Ignition System.
ON-VEHICLE SERVICE
A PROM failure will generally set a Code 51.
Code 51, also indicates that the PROM may have ELECTRONIC CONTROL MODULE (ECM)
been installed improperly. Check the PROM Replacement of the electronic control module
installation for bent pins or pins not fully seated. (ECM) consists of a service controller without a
Replace the PROM if installation is correct and PROM.
there is still a Code 51. Refer to Section A for Refer to General Description in Section C for
diagnosis. location of the ECM and additional information.
REMOTE LAMP DRIVER Service of the ECM should normally consist of
Refer to Chart A-5 or Chart A-6 in Section A for either replacement of the ECM or a PROM
diagnosis of the remote lamp driver. change (Figure 29).
If the diagnostic procedures requires the ECM
COOLANTTEMPERATURE SENSOR to be replaced, the engine calibrator (PROM) and
A failure in the coolant sensor circuit should ECM should be checked first to see if they are the
set either a Code 14 or Code 15. Remember, these correct parts. If they are, remove the PROM from
codes indicate a failure in the coolant the faulty ECM and install it in the service
temperature circuit, so proper use of the chart controller.
will lead to either repairing a wiring problem or Im p o r ta n t
replacing the sensor, to properly repair a
problem. Refer to Section A for diagnosis. When replacing the production ECM with a new
DIFFERENTIAL PRESSURE SENSOR ECM, it is important to transfer the Production
Broadcast Code and Production ECM number to
A Code 34 will set if the ECM has seen an the new ECM Label. Please do not record on
incorrect signal voltage in the differential ECM Cover. This will enable positive
pressure sensor circuit. Refer to Section A for identification of ECM Components throughout
diagnosis. the service life of the vehicle.
Chart C-1E will diagnosis the differential
pressure sensor circuit. NOTICE: To prevent internal ECM damage, the
ignition must be "OFF when disconnecting or
reconnecting p o w er to ECM (for example , battery
positive cable, ECM pigtail, ECM fuse, jum per cables,
etc.).
1. R e m o v e EC M access cover. 4. If a service c o n t r o l l e r is bein g in s ta lle d , c h e c k th e

service n u m b e r o n t h e c o n t r o l l e r t o m a k e sure it is t h e
same as t h e r e m o v e d EC M . R e m o v e access cover.
2. R e m o v e P R O M using t h e r o c k e r - t y p e P R O M r e m o v a l 5. In s ta ll P R O M . If a service P R O M is being in sta lle d , m a ke

t o o l s h o w n . Engage o n e e n d o f t h e P R O M c a rr ie r w i t h sure i t has the same part number as the removed
t h e h o o k end o f t h e t o o l . Press o n t h e v e r t ic a l bar end PROM.
o f t h e t o o l and r o c k t h e engaged e n d o f t h e P R O M c a r
T l
rie r u p as f a r as possib le . Engage t h e o p p o s i t e end o f * I m p o r t a n t (B e f o re in s t a llin g P R O M )
t h e P R O M c a rr ie r in t h e same m a n n e r and r o c k t h is end
u p as f a r as possible. R e p e a t t h is process u n t i l t h e A N Y T I M E T H E P R O M IS I N S T A L L E D B A C K W A R D S
P R O M ca rr ie r and P R O M are fr e e o f t h e P R O M s o c ke t. A N D T H E I G N I T I O N S W IT C H T U R N E D O N , T H E P R O M
T h e P R O M ca rr ie r w i t h P R O M in it s h o u ld l i f t o f f o f IS D E S T R O Y E D .
t h e P R O M so ck e t easily.
DO NOT press on PROM O N LY C A R R IE R .
Sm a ll n o t c h o f c a r r ie r m u s t be alig n e d w i t h sm all n o t c h
in so c k e t. Press o n P R O M c a rr ie r u n t i l it is f i r m l y
seated in t h e so c ke t. D o n o t press o n P R O M , o n l y th e
ca rrie r.
6. In sta ll ECM access cover.

1 In s ta ll E C M in passenger c o m p a r t m e n t and p e r f o r m a
" D I A G N O S T I C C IR C U I T C H E C K to c o n firm p roper
i n s t a lla t io n .
3. In s p e c t reference end o f t h e P R O M c a rr ie r and c a re

f u l l y set aside. D o n o t re m o v e P R O M f r o m t h e c a rr ie r
t o c o n f i r m P R O M co rre ctn e s s. N o t c h in JEJROM r e
fe re n c e d t o sm alle r n o t c h in c a rr ie r a n d t h e ( l J
PROM
04 26 85 6S 2590 6E
Figure 29 Replacem ent o f PROM

DIFFERENTIAL PRESSURE SENSOR

PROM REPLACEMENT
(FIGURE 30)
Before replacing a PROM, check it for proper
installation and correct alignment of the locator The differential pressure sensor is retained in a
marks. The PROMs pins should be fully inserted bracket on the air cleaner.
in their sockets when the PROM is plugged into
the ECM. The CODE 51 chart has PROM 4-+ Remove or Disconnect
replacement instructions, and replacement 1. Electrical connector.
package also has instructions included. 2. Vacuum hose.
Refer to Figure 29 for replacement of the 3. Sensor.
PROM.
REMOTE LAMP DRIVER (FIGURE 23)
Install o r Connect
Replace remote lamp driver only if diagnosis - f 4-
has determined that it has failed. The driver is 1. Sensor.

inside a container, taped to the harness near the 2.Vacuum hose.
ECM. Open container and replace remote lamp 3. Electrical connector.
driver as required.
WIRING HARNESS
The wiring harness routings and component
locations for the Computer Command Control
used in California are shown in Figure 35
through 37.
INFORMATION SENSORS
ENGINE COOLANTTEMPERATURE SENSOR
Refer to Figures 35 through 37 fo r location o f the
coolant tem perature sensor. P jj HARNESS CONNECTOR [T] AlR CLEANER
Li_ CARB P0RT
[~2J D I F F E R E N T IA L PRESSURE
NOTICE: Care must be taken when handling SENSOR I 5 1MANIFOLD VACUUM
coolant sensor. Damage to coolant sensor w ill affect 4-22-85 HOSE 5s 1551-6E
proper operation o f the Fuel Control system. See Figure 30 Diff. Press. Sensor
Wire Harness views in Introduction for location of
OXYGEN SENSOR (FIGURES 31 THRU 34)
coolant sensor.
Remove or Disconnect NO TICE: The oxygen sensor uses a perm anently

attached pigtail and connector. This pigtail should
1. Negative battery cable. not be removed from the oxygen sensor. Damage or
2. Drain cooling system below level of sensor. removal o f the pigtail or connector could affect
3. Electrical connector. proper operation o f the oxygen sensor.
4. Carefully back out sensor. Take care when handling the oxygen sensor. The in
line electrical connector and louvered end must be
Install o r C onnect kept free o f grease, dirt or other contaminants. Also,
1. Sensor in engine. avoid using cleaning solvents o f any type. Do not
2. Electrical connector. drop or roughly handle the oxygen sensor.
3. Refill coolant system if necessary.
Figure 33 O2 Sensor - V8 - (CK)
New or service sensors will already have the

compound applied to the threads. If a sensor is
Figure 31 O Sensor - V6 (CK) removed from an engine, and, if for any reason it
2
is to be reinstalled, the threads must have anti-
Remove o r D isconnect seize compound applied before reinstallation.
1. Coat threads of oxygen sensor with anti-seize
The oxygen sensor may be difficult to remove compound P/N 5613695 or equivalent if
when engine temperature is below 48C (120F). necessary.
Excessive force may damage threads in exhaust 2. Sensor, and torque to 40 N-m (30 ft. lbs.).
manifold or exhaust pipe.
1. Negative battery cable. 3. Electrical connector.
2. Raise vehicle if necessary for access. 4. Lower vehicle if necessary.
3. Electrical connector. 5. Negative battery cable.
4. Carefully back out Oxygen Sensor.
PARTS INFORMATION
Install o r C onnect PART NAME .....................................................GROUP
Controller, ECM ............................................3.670
Important Calibrator, PROM ....................................... 3.670
A special anti-seize compound is used on the Sealer, Exhaust Oxygen Sender
oxygen sensor threads. The compound consists of (Anti-Seize Compound) .................................3.671
a liquid graphite and glass beads. The graphite Sensor, Coolant Temp .................................3.760
will tend to burn away, but the glass beads will Sensor, Exhaust Oxygen ...............................3.670
remain, making the sensor easier to remove. Sensor, Manif. Diff. Press ............................ 3.670
Figure 32 O Sensor - V6 - (G)

2 Figure 34 O Sensor - V8 - (G)
2
r r ~ j CANISTE R PURGE SOLENOID [ T ] O IL PRESSU RE SWITCH f ie ; ENGINE CO O LAN T SWITCH

f~2~| F U E L VA POR CANISTE R [To] ESC MODULE [TT] M/C SO LEN OID
m A IR D IV E R T SOLENOID |TT| EST CONNECTOR pT8~l A C C E LE R A T O R PUMP SO LENOID
[~4~| A IR D IV E R T V A L V E jjlT j TCC SO LENOID pl9~l T H R O TT LE POSITION SENSOR
|~5~1 EGR SOLENO ID [~T3~] O XYG EN SENSOR |~20~| A C C E LE R A T O R PUMP
TEM PERA TU RE SWITCH
| 6 | V A C U U M SENSOR [TTj GROUND CONNECTOR
COO LANT SENSOR
p r i A/C HARNESS CONNECTOR [T5J ESC KNOCK SENSOR
[22i GROUND CONNECTOR
| 8 1 DW E LL METER CONNECTOR
5S 1449-6E
Figure 35 Wiring Harness - V6
COMPUTER SYSTEM IG N IT IO N SYSTEM SENSORS/SWITCHES

fc T I Electronic Control Module (ECM) }6 ] Electronic Spark Timing Connector Vacuum Sensor

|C2 | A L C L Connector A IR INJECTION SYSTEM Exhaust Oxygen Sensor
|C51 System Ground
|9 ' Air Divert Solenoid Valve
|C 8 1 Computer Control Harness Throttle Position Sensor
EXHAUST GAS R EC IR C U LA TIO N
|C91 Remote Lamp Driver CO NTRO L SYSTEM Coolant Sensor
jciOl Dwell Connector j 12 j Exhaust Gas Recirculation Solenoid Valve
A IR /F U E L SYSTEM FUEL VAPOR CO NTRO L SYSTEM
]1 j Mixture Control Solenoid j 13 j Canister Purge Solenoid Valve
TRA NSM ISSIO N CO N VE R TE R CLUTCH

CONTROL SYSTEM
| 5 | Trans. Conv. Clutch Connector
85
5 02 84 5S 1730-6E
Figure 36 Wiring Harness - Yr8 (CK Series)

COMPUTER SYSTEM A IR INJECTIO N SYSTEM SENSORS/SWITCHES
|C l | Electronic Control Module (ECM)

System Ground
1 9 | Air Divert Solenoid Valve
EXHAUST GAS R EC IR C U LA TIO N
Manifold Pressure Sensor
CO NTROL SYSTEM Exhaust Oxygen Sensor

Computer Control Harness
A IR /F U E L SYSTEM
|1 j Mixture Control Solenoid
|11 j
[ 12 1
Exhaust Gas Recirculation Valve
Exhaust Gas Recirculation Solenoid Valve Throttle Position Sensor
Coolant Sensor
TRA NSM ISSIO N C O NVERTER CLUTCH IG N IT IO N SYSTEM

CO NTRO L SYSTEM |6 | Electronic Spark Timing Connector
| 5 1 Trans. Conv. Clutch Connector
85
5 02 84 5S 1729-6E
Figure 37 Wiring Harness - V8 (G Series)
EMISSIONS-CARBURETED 6E8-89
BLANK
CHART C-1
ECM REPLACEMENT CHECK
CARBURETED-CALIF.
Prior to replacing an ECM, the circuit involved m ust be tested for:
Poor connector term inal to ECM contact;
D irect battery voltage on an ECM ground circuit from a short to B +; or
Shorted solenoid or relay. If a short is found, the circuit m ust be repaired prior to rep la cin g the
ECM to prevent repeat ECM failures
1. Check for good term inal con tact due to w eak the cau se o f "drivers com plaint." A ny circu it
or dirty term inals. Rem ove term inal to testin g below 20 ohm s is sh orted to ignition,
inspect. R eplace if broken or dirty. If coolan t or sh orted across the relay or solen oid .
is present, replace coolan t sen sor and 3. C heck for shorted TCC solen oid . Som e
connector. Also, replace ECM connector tra n sm issio n s have a norm ally open 4th gear
term inal and blow coolant out o f harness. sw itch in series w ith the solen oid . The
Clean connector with alcohol or spray ohm m eter w ill read infin ite resista n ce (open
contact cleaner and replace ECM. circuit) in th ese ca ses. If the read in g is less
2. C heck for a short to ignition or shorted than 20 ohm s, a short to ign ition or faulty
solenoid or relay. All term inals m ust be tested solen oid exists. A norm al solen oid will read
sin ce several are connected internally in the b etw een 20 - 50 ohm s.
ECM. A short in one circuit may cau se 4. C heck for shorted TCC circu it in units w ith a
another circuit in the ECM to be inoperative 4th gear sw itch . The veh icle m ust be in 4th
that d oes not have an external fault, but w as gear to clo se the sw itch to obtain a resista n ce
reading. A norm al solen oid w ill read b etw een
20-50 ohm s.
Remove or D isc o n n e c t (Figures 1 and 2) Im portant
N e w e le c tro n ic c o n tr o l m o d u le o u t o f its p a cka g in g and R E P L A C E M E N T E L E C T R O N IC C O N T R O L M O D U L E

c h e c k th e service n u m b e r t o m a ke sure it is th e same as (E C M ) IS S U P P L IE D W IT H O U T A N E N G IN E C A L I B R A
th e f a u lt y EC M . T IO N U N IT (P R O M ) SO C A R E S H O U L D BE T A K E N
W H E N R E M O V IN G T H E P R O M F R O M T H E D E F E C
2 Access c o v e r so th a t P R O M fr o m f a u lty EC M m a y be
in s ta lle d in re p la c e m e n t E C M . T IV E EC M A S IT W I L L BE R E U S E D IN T H E N E W E C M .
R EFER TO PROM R E P L A C E M E N T PR O C E D U R E AS
D E T A I L E D IN S E C T IO N " A " , C O D E 51.
06 18 84 5S 1511-6E
CHART C-1
ECM REPLACEMENT CHECK
4.3L,5.0L OR 5.7L ENGINE
o ALWAYS CHECK PROM FOR THE CORRECT
APPLICATION AND INSTALLATION BEFORE CARBURETED
REPLACING AN "ECM".
REMOVE BOTH ECM CONNECTORS.
VERIFY GOOD CONNECTOR TERMINAL TO ECM
CONTACT AND INSPECT FOR FOREIGN MATERIAL.
GOOD TERMINAL CONTACT POOR TERMINAL CONTACT
CONNECT OHMMETER BETWEEN ECM HARN.

TERM. "C" & THE FOLLOWING ECM TERMS:
CLEAN OR REPLACE DIRTY TERMINALS.
REPAIR SOURCE OF FOREIGN MATERIAL.
"B'Y'E", "T", "4", "6"," 18" AND "19" REPAIR OR REPLACE POOR CONTACT TERMINAL
NOTE ANY CIRCUIT BELOW 20 OHMS. RECONNECT AND RETEST ECM.
ALL 20 OHMS OR ABOVE BELOW 20 OHMS
CONNECT OHMMETER BETWEEN

ECM HARN. TERMS. "C" 8. "P".
DISCONNECT CONN. FROM SOLENOID OR
RELAY INVOLVED.
NOTE RESISTANCE. RECHECK RESISTANCE IN CIRCUIT.
20 OHMS OR ABOVE BELOW 20 OHMS
I
REPLACE SOLENOID REPAIR SHORT TO IGN.
OR RELAY IN CIRCUIT. REPLACE ECM. A
REPLACE ECM. A
50 OHMS OR OVER UNDER 20 OHMS 20-50 OHMS
I

DISCONNECT TCC SOLENOID CONNECTOR.
CONNECT OHMMETER ACROSS TERMS.
DISCONNECT CONN.
FROM TCC SOLENOID.
SOLENOID OK.
REPLACE ECM. A
"A" 8. "D" OF SOLENOID. RECHECK RESISTANCE
HOIST DRIVE WHEELS AND RUN VEHICLE IN CIRCUIT.
TO ENGAGE HIGH GEAR.
NOTE RESISTANCE.
BELOW 20 OHMS 20 OHMS OR ABOVE 20 OHMS OR ABOVE BELOW 20 OHMS
REPLACE TCC REPLACE TCC REPAIR SHORT TO

SOLENOID AND ECM. A SOLENOID AND ECM. A IGNITION.
REPLACE ECM. A
1- IF REPLACING AN ORIGINAL EQUIPMENT ECM, TRANSFER THE ORIGINAL BROADCAST CODE

TO THE LABEL ON THE REPLACEMENT ECM. 4-20-85
2. IF AFTER REPLACING THE "ECM', THE PROBLEM STILL EXISTS, THE"PROM" MAY BE FAULTY. * 4S 0191-6EA
CHART C-1E
DIFFERENTIAL PRESSURE (VAC) SENSOR CHECK
CARBURETED-CALIF.
1. T his ch eck s the output o f the sensor. The VAC 2. T his c h e c k s the rate of ch a n g e o f the output
sen so r is a d ifferen tial p ressu re sen so r that w ith vacuum . A gain, the norm al readin g
m easu res the d ifferen ce in p ressu re betw een w ou ld be about in the m iddle of the range
atm osphere and m anifold. The voltage output in d icated . A lso, the voltage should ch an ge as
norm ally w ith en gin e stop ped and key O N soon as the vacuum ch a n g es. If it d o e sn t, it
is less than 1 volt, w h ile at idle it sh ou ld be could resu lt in deton ation or a sa g on
above 3 volts. H igh voltage in crea ses spark acceleration . It could also be cau sed by poor
ad van ce, w h ile low voltage red u ces spark fuel or a restriction in the h o se to the sensor.
advance.
CHART C-1 E
DIFFERENTIAL PRESSURE (VAC)
SENSOR CHECK
CARBURETED-CALIF.
* This requires use o f three jum pers between the sensor & the connector.
They can be made using term inals 12014836 and 12014837.
* * lf voltage does not im m ediately fo llo w vacuum change, sensor is faulty.
[A fte r any repair clear long term memory by removing ECM fuse fo r 10 seconds.
11-17-84
* 4S 0293-6EA
FUEL CONTROL SYSTEM

CALIFORNIA ONLY
GENERAL DESCRIPTION
The basic function o f the fuel control system When the solen oid is d e-en ergized , th ere is m ore
is to control fuel delivery to the engine. fuel flow provid in g a rich er fuel m ixture. The
The Electronic Control M odule (ECM) controls solen oid is turned on and o ff at a rate o f 10 tim es
the fuel delivery from inform ation received per secon d .
regarding: The M/C solen oid "on" tim e verse o f f tim e is
Coolant tem perature varied to ch an ge the m ixture. T his is called ECM
C rankshaft RPM com m and.
Am ount of oxygen in the exh au st stream
Throttle position OXYGEN SENSOR
Intake M anifold P ressu re
The ECM controls fuel delivery to an E4ME An ex h a u st oxygen (O 2 ) sen so r, m ounted in the
carburetor through an electrically operated ex h a u st system , m onitors the oxygen con ten t o f
M ixture Control (M/C) solenoid (Figure 38) the ex h a u st gas stream .
m ounted in the float bowl. A plunger in the The oxygen con ten t in the ex h a u st reacts with the
solenoid is pulsed by the ECM to allow more or oxygen sen so r to p roduce a voltage output. This
less fuel to mix with the air en terin g the voltage ran ges from ap p roxim ately 0.100 volts
carburetor. When the solenoid is energized, there (high O 2 - lean m ixture) to 0.900 volts (low O2 -
is less fuel flow providing a leaner fuel m ixture. rich m ixture).
By m onitoring the voltage ou tp u t o f the O 2
sen sor, the ECM w ill k n ow w h at fuel m ixture
com m and to give to the so len o id (lean m ixture-
low voltage-rich com m and, rich m ixture-high
voltage-lean com m and).
ECM COMMAND
The ECM com m and d eterm in es the fuel control

d elivery and can be m onitored w ith a d w ell m eter
set on the 6 cylin d er scale. It is con n ected to the
M/C S olenoid d w ell co n n ecto r (green) located in
the h arn ess near the solen oid (F igure 39).
CLOSED LOOP { F I G U R E 40)
On a norm al op eratin g en gin e the d w ell m eter

n eedle, at part throttle, w ill be b etw een 10 and
50 d w ell and varying. T his is called "CLOSED
LOOP" operation. T his m eans that the oxygen
sen sor affects control of the fuel d elivery.
T h rottle P osition S en sor - sen d s voltage sig n a l

to ECM affectin g fuel d elivery.
ECM Com m and - visu al view o f fuel d eliv ery
usin g d w ell m eter.
Idle S p eed C ontrol - The throttle lever actu ator
plu n ger exten d s to m aintain idle sp eed w ith A/C
and in crease idle sp eed du rin g cold starts.
THROTTLE POSITION SENSOR
The throttle position sen so r (TPS) c h a n g e s
position as the throttle valve angle ch a n g es. The
TPS is a p otentim eter, m ounted in the cab u retor,
w ith one end con n ected to 5 volts from the ECM
I 1 DW ELL METER (SET ON 6-C YL SCALE) and the other end to ground. A third w ire is
|~2~ M /CSOLENOID DW ELL CONNECTOR
con n ected to the ECM to m easure voltage from
[~3~j CARB U RETO R 4S 0422-6E
the TPS. At a closed throttle p osition , the ou tp u t
Figure 39 D w ell M eter o f the TPS is app roxim ately .31 volts. A s the
OPEN LOOP throttle valve op en s, the ou tp u t voltage in c re a se s
so that at w id e-op en throttle the o u tp u t is
The oxygen sen sor does not affect fuel control in approxim ately 5 volts.
"OPEN LOOP" operation and the dw ell reading
w ill not vary. This condition is w hen the en gin e is IDLE SPEED CONTROL
cold, the oxygen sen sor is below 316C (600F) at FIGURES 41 or 42
idle or at w ide-open throttle (WOT). An idle sp eed control is used on a 4.3L e n g in e
to in crease idle sp eed d u rin g cold start and to
m aintain idle sp eed w ith air co n d ition in g "on or
pow er steerin g d u rin g a full turn. Idle sp eed
control is called step p ed sp eed control on the
V ehicle E m ission Control Inform ation label.
When the en gin e coolan t tem peratu re is b elow
85C (185F) and the en g in e is started, a vacuum
solen oid is en ergized , w h ich o p en s m anifold
vacuum to a throttle kick er (stepped sp eed
control actuator). The throttle kick er p lu n g er
exten d s onto the throttle lever and idle sp e e d is
in creased . When coolan t tem peratu re is a b ove
85C (185F), the ECM o p en s the circu it to the
solen oid and actu ator retracts.
m M/C SO LENOID [T ] ECM
jT j C A RB U RETO R [][] O XYG EN SENSOR
If the en gin e coolan t tem p eratu re is a b ove 85C
3 j VA RIO U S INPUTS 4S 0421-6E (185F) and en g in e is started , the so len o id w ill
energize for 30 seco n d s and then the ECM o p e n s
Figure 40 Closed Loop Cycle
the circuit.
The fuel control system in clu d es the follow ing: When air con d itio n in g is turned "on, the
An E lectronic Control M odule (ECM) - the vacuum solen oid is energized through a relay
control center. and rem ains on d u rin g this m ode to m aintain id le
M ixture Control (M/C) solenoid - p u lses to m eter sp eed .
more or less fuel. D uring full steerin g turn on a pow er ste e r in g
O xygen (O 2 ) sen sor - sen d s voltage signal to eq u ip p ed veh icle, the solen oid is en ergized
ECM d ep en d in g on the am ount o f oxygen in through a sw itch to m aintain idle sp eed d u rin g a
exh au st stream . static full turn load.
System Performance Check

The M/C solen oid , w h ich is con trolled by the
ECM, ch a n g es the air/fuel m ixture to the en gin e
by allow in g m ore or less fuel to flow through the
carburetor.
The System P eraform ance C heck is used to
ch eck the operation o f the m ixture control
solen oid , the main m etering circu it in the
carburetor, and the operation o f the C om puter
Com m and Control by use of a d w ell meter.
The dw ell read in g is u sed to d eterm in e
carburetor calibration and is se n sitiv e to ch a n g es
in fuel m ixture su ch as heat, air leak s, or lean and
i 2 C ARB P O R T "B " rich con d ition . A norm al d w ell w ill in crea se and
04 0584 L A J T H R O T T LE K IC K E R 5S 1543-6E d ecrease over a narrow d w ell range. H ow ever, it
Figure 41 Idle Speed Control - G Series may occa sio n a lly vary as m uch as a 10 to 15
d w ell range m om entarily b ecau se o f a tem porary
m ixture ch an ge. A dw ell read in g is the average
o f the m ost co n sista n t variation w ithin the 10 to
50 scale o f the meter.
The carb u retor has been calibrated at the
factory and sh ou ld not norm ally need adjustm ent
in the field. If d u rin g d ia g n o sis, the System
Perform ance C heck in d icates that carburetor
calibration is required, refer to ON-VEHICLE
SERVICE.
Throttle Position Sensor
n~1 VACUUM SO LENOID If the T PS is out of adjustm ent, idle quality
f T ] E L E C T R IC A L CONNECTOR
may be affected and perform ance may be poor. If
i 3 | VACUUM HOSES
the TPS circu it is open, the ECM w ill think the
PH CARB PORT "B
veh icle is at w id e-op en throttle, and c a u se the
C l ] T H R O T T LE K IC K E R 6S 2750-6E
ECM to go full rich, and set a C ode 21. R efer to
Figure 42 Idle Speed Control - CK Series
Section A for d iagn osis.
R efer to Chart C-2F for throttle p osition sen sor
DIAGNOSIS en rich m en t ch eck .
FUEL CONTROL SYSTEM IDLE SPEED CONTROL
The fuel control system d iagn osis is in R efer to Chart C-2T or C-2W for d ia g n o sis of
SECTION A. the Idle Speed Control.
Also, refer to SECTION B for driveab ility
sym ptom s related to the fuel control system .
If during d iagn osis, code d ia g n o sis in d icates
that carburetor calibration is req uired, refer to
ON-VEHICLE SERVICE.
ON-VEHICLE SERVICE
CARBURETOR CALIBRATION 1. E lectrical connectors; M/C solen oid and T PS
1. C heck float level, u sin g gage J-34935-1, BT- assem bly.
8420-A, or eq u ivalen t (Figure 43). If settin g is 2. Air horn:
not w ithin 14/32" sp ecified float level, float a. U pper ch ok e lever from end o f ch ok e sh aft
adjustm ent is required. A fter rem oving air by rem oving attach in g screw . R otate
horn, refer to Figure 48 for adjustm ent. u pp er ch ok e lever to rem ove lever from
ch ok e link.
b. C hoke link form low er lever in sid e the
float bow l castin g. R em ove link by
1 W ITH ENG IN E IDLING AND CHOKE W IDE OPEN.
INSERT GAGE IN VENT SLOT OR VENT HOLE
h old in g low er lever outw ard with sm all
A LLO W GAGE TO FLOAT FREELY
screw d river and tw istin g link c o u n te r
NO TICE: DO NOT PRESS DOWN ON GAGE clock w ise.
FLOODING OR FLO AT DAMAGE COULD RESULT.
c. The retainer from the pum p link, and
2 OBSERVE THE MARK ON GAGE THA T LIN ES UP
WITH TOP OF C ASTIN G SETTING SHO ULD BE rem ove link from lever. DO NOT rem ove
W ITH IN + 2 /3 2 (1 .5 8 8 m m ) OF S P E C IFIE D FLOAT
LEVEL SETTIN G pum p lever from air horn, (Figure 44).
IN C O R R E C T F U E L P R E S S U R E W IL L A D V E R S E L Y Front vacuum break hose from tu b e on
AFFE C T FUEL L E V E L .
3. IF NOT W ITHIN S P E C IFIC A TIO N . REMOVE AIR

float bowl.
HORN AND A D JU S T FLOAT.
e. S econdary m etering rod holder screw .
Lift the holder w ith the m etering rods
straight up out of the air horn.
f. Air horn-to-bow l screw s; then rem ove the
07 12 84 4S 0933-6EA tw o cou n tersu n k attach in g screw s located
next to the venturi.
Figure 43 External Float Gage Check
g- Air horn from bow l by lifting it straigh t
2. If system perform ance ch eck in d icates that the up. (G asket sh ou ld rem ain on float bow l).
M/C solen oid d w ell is incorrect, DO NOT 3. Solenoid adju stin g screw and rich lim it stop
attem pt any carburetor calibration ch an ges, (Figure 45), u sin g tool J-28696-10, BT-7928, or
until ALL p ossib le c a u se s listed on System eq u ivalen t.
P erform ance Chart have been thoroughly 4. Solen oid -m eterin g rod p lunger by lifting
ch eck ed . straigh t up (Figure 46).
a. If the M/C d w ell at 3000 rpm is still 5. Air horn gask et by lifting it from the d ow el
incorrect, adjustm ent o f the M ixture locatin g pins on the float bow l. DISC AR D
Control Solenoid is required. GASKET.
b. If the M/C d w ell at idle w as incorrect, 6. Float bow l insert.
refer to: Idle M ixture A djustm ent, w h ich
follow s in this Section. The air horn
assem b ly m ust be rem oved to adjust the
M/C Solenoid.
AIR HORN ASSEMBLY REMOVAL
The follow in g op eration s are n ecessary to
perform rem oval of the air horn,
1. Float adjustm ent.
2. M/C solen oid and plu n ger adjustm ents.
3. TPS replacem ent.
rn air horn [ 3] R E T A IN E R
RH PUMP LE V E R [T j p UMP L IN K
4S 1200-6 EA
Figure 44 R em oving Pum p Link From Lever
m SC REW-
SO LENO ID
AD JUSTING
art
(LE AN M IX T U R E ]
HR ST O P -R IC H
L IM IT vu - ^
S SOLENOID
PLUNGER
m R O D -P R IM A R Y
MET ER ING J
m S P R IN G -
P R IM A R Y
METERING ROD Y
( 6 | IN SE R T-FLO A T
BOWL
m TPS PLUNGER SEAL
m M/C SOLENO ID
R ET AIN E R
cu PLUNGER
La J T H R O T T L E POSITION SENSOR
e ADJU STIN G SPRING 6S 2751-6E
Figure 47 Throttle Position Sensor
Inspect
METERING COMPONENTS
1. If the carburetor interior has ob viou s sign s of
dirt or contam ination, it sh ou ld be com p letely
d isassem b led and clean ed .
2. E xam ine all M/C solen oid parts.
06 15 84 5S 1429-6E
a. M/C solenoid; bore and p lu n ger for sign s
Figure 45 M/C Solenoid and R elated Parts o f stick in g or w ear.
b. P lu nger return sp rin g for d am age or
distortion and for correct assem b ly on
solen oid body.
c. M etering rod and sp rin g assem b lies.
(1) Any dam age to rods; bent or burred.
(2) M etering rod sp rin gs for: distortion,
co lla p se, and for correct installation
on rods.
(3) C orrect part num bers.
d. M etering jets.
(1) For lo o se n e ss in bow l.
(2) Any dam age, su ch as bent gu id e that
could cau se a bind.
(3) Any dam age or foreign m aterial in
m etering jet orfice.
P H S O L E N O ID -M E T E R I N G (4) C orrect part num bers.
PLUNGER
| 2 | A IR HORN G ASKET 4S 0428-6E
Float Adjustment, If Necessary
Figure 46 Solenoid-M etering P lunger 1. Refer to Figure 48 for p roced u re and tools
required for m aking float adjustm ent.
2. Set float to sp ecification 14/32" 2/32".
7. M etering rods and sp rin gs.
8. Throttle Postition S en sor (TPS) Rem oval Remove or Disconnect
(Figure 47), if required for replacem ent:

MIXTURE CONTROL SOLENOID
Push up from bottom on electrical REPLACEMENT
connector and rem ove TPS and con n ector 1. If d ia g n o sis or in sp ection in d ica tes that a new
assem b ly from bow l. M/C solen oid assem b ly is required, install a
Service R ep lacem en t P ackage. The solen oid
and p lunger MUST be in stalled as a m atched
set.
1. REMOVE AIR HORN & GASKET. J-9789-90

2. REMOVE SOLENOID PLUNGER, METERING RODS,
FLOAT BOWL INSERT. IF NECESSARY TO REMOVE
SOLENOID (LEAN MIXTURE) ADJUSTING SCREW,
COUNT AND MAKE RECORD OF NUMBER OF TURNS
IT TAKES TO LIGHTLY BOTTOM SCREW, USING
J -2 8 6 9 6 -1 0 OR B T -7928. (RETURN TO EXACT
POSITION WHEN REASSEMBLING.) J-34817-1
OR
3. ATTACH J -3 4817-1 OR B T -8227A -1 TO FLOAT BOWL. B T -8 2 2 7 A-1
4. PLACE J -3 4 8 1 7 -3 OR B T -8 2 2 7 A IN BASE WITH

CONTACT PIN RESTING ON OUTER EDGE OF
FLOAT LEVER.
5. MEASURE DISTANCE FROM TOP OF CASTING TO TOP

OF FLOAT. AT POINT 3/16 FROM LARGE END OF
FLOAT. USE J-9789-90 OR BT-8037.
6. IF MORE THAN 2 / 3 2 FROM SPECIFICATION,

USE J-34817-15 OR B T -8 2 3 3 TO BEND LEVER
UP OR DOWN. REMOVE BENDING TOOL AND
MEASURE, REPEATING UNTIL WITHIN
SPECIFICATION.
7. CHECK FLOAT ALIGNMENT.
8- REASSEMBLE CARBURETOR.
6S 2725-6E
FLOAT ADJUSTMENT (E2M, E4M)
Figure 48 Float Adjustm ent
a. U sing tool J28696-10, or BT-7928, or
eq u ivalen t, rem ove Solenoid ad justing
screw and Rich Limit Stop.
b. Remove solen oid assem b ly attach in g
screw and lift the M/C solenoid and
con n ector assem b ly from the float bow l.
2. Proceed to M/C solen oid assem bly.
+ - Install or Connect
MIXTURE CONTROL SOLENOID ASSEMBLY
Figure 49
1. Be certain large M/C solen oid ten sion sp rin g
is properly p ositioned over boss on bottom o f
float bow l.
2. Be certain lean stop screw ten sion sp rin g is
properly position ed betw een raised b o sses p n SOLENOID ADJUSTING
----- (LEAN MIXTURE) SCREW
next to float hinge pin.
PH RICH LIMIT STOP
3. M ixture control solen oid gaging tool,
|"3~| SOLENOID PLUNGER
J-33815-1, BT-8253-A, or eq u ivalen t, over
m GAGING TOOL J33815-1 OR
throttle sid e m etering jet rod guide. ' BT823-A
4. M/C solen oid assem b ly in the float cham ber, [~5~j THROTTLE SIDE PRIMARY
METERING JET
align in g pin on end o f solen oid with hole in
n n SOLENOID ASSEMBLY
raised boss at bottom o f bow l.
a. Press d ow n on M/C solen oid body
4-29-85 5S 1466-6E
(com p ressin g ten sion sp rin g under the
solenoid) and hold dow n. Figure 4^ In stallin g M ixture Control S olenoid
b. Solenoid ad justing screw through rich lim it G aging Tool
stop and ten sion sprin g.
c. Carefully start en gagem ent o f solen oid screw 2b. Remove:

threads. Use adjusting tool J28696-10 or BT- Solenoid ad justing (lean m ixture) screw
7928 or equivalent, to turn screw . R ich lim it stop
Align solen oid con n ector w ires in slot in bow l M/C Solenoid p lunger
and in stall con n ector attach in g screw and Solenoid adjustm ent screw sp rin g
tighten secu rely.
G aging tool
HP] Adjust 2c. Reinstall:
MIXTURE CONTROL SOLENOID Solenoid ad justing screw sp rin g
1. H olding the solen oid plunger dow n a gain st M/C Solenoid
the solenoid stop, use Tool J-28696-10, BT- P lastic filler block
7928, or eq u ivalen t, to turn the adju stin g Prim ary m etering rods w ith sp rin gs
screw (lean stop screw ), until the solen oid M/C Solenoid plunger
plunger ju st co n tacts the gaging tool. The R ich lim it stop
adjustm ent is correct w hen the solen oid Solenoid ad justing (lean m ixture) screw
plunger is con tactin g BOTH the solen oid stop
3. Turn solen oid adju stin g (lean m ixture) screw
and the gaging tool, (Figure 50). __________
c lo ck w ise until M/C solen oid bottom s out
a gain st float bow l, then cou n ter c lo c k w ise the
exact num ber o f turns recorded in step 2a.
4. Rem ove lean m ixture screw p lu g from air
horn. (Figure 51).

AIR HORN ASSEMBLY TO BOWL
1. Install pum p p lunger sp rin g and pum p
plunger.
2. Install TPS plunger by p u sh in g up through
seal in air horn.
3. H olding pum p p lunger d ow n , p osition new
air horn gask et over pum p p lu n ger stem and
over tw o locatin g pins on float bow l.
m TO O L J28696-10/BT7928
[T~l SO LEN OID AD JUSTIN G SCREW
[T 1 PLUNGER CONTACTING SO LENOID
STOP AND GAGING TO O L
m GAGING TO O L
J33815-1 /BT8253-A (1.304" HIGH)
4S 0576-6E
Figure 50 A djusting Solenoid Screw
2a. Note exact p osition o f solen oid adju stin g

screw tool tee h an d le and record the num ber
of turns as solen oid adjusting screw is turned |1 j SO LEN OID ADJUSTING SCREW PLUG
clo ck w ise until M/C solenoid bottom s out l~2~l PUNCH
again st float bow l. 6S 2752-6E
Figure 51 Removing Plug
4. C arefully low er air horn assem b ly onto float 6. Pum p link to pum p lever and in stall retainer.
bow l w h ile p o sition in g the TPS A djustm ent 7. Secon d ary m etering rods to m etering rod
Lever o f the TPS sen so r, and gu id in g pum p holder (upper en d s o f rods p oint tow ard each
p lunger stem through seal in air horn. To other). C arefully low er rods into air horn
ea se installation , in sert a thin screw d river o p en in gs and place the h old er onto th e air
b etw een air horn g a sk et and float bow l to valve cam follow er. Install retain in g screw .
raise the TPS ad justm ent Lever over the TPS Work Air V alves up and d ow n, to m ake su re
sen sor, (Figure 52). they m ove freely in both d irection s, w ith no
Be certain that the bleed tu b es and binds.
acceleratin g w ell tu b es are p osition ed 8. C hoke link into low er ch ok e lever in sid e bow l
properly through the holes in the air horn cavity. Install ch ok e link into upp er ch o k e
gasket. DO NOT force the air horn assem b ly lever and p osition lever on end o f ch ok e shaft,
onto the bow l, low er it lightly into place. being su re flats on end o f ch ok e sh aft align
w ith flats in lever. Install attach in g screw
and tighten.
9. Front vacuum break h ose to tube on front o f
float bow l.
IDLE AIR BLEED VALVE SETTING
F ollow in g M ixture Control S olen oid
rep lacem en t and/or adjustm ents, it is
n ecessa ry to m ake the Idle Air Bleed V alve
setting.
1. Idle Air Bleed V alve Cover R em oval.
a. Cover in ternal bow l vents and air in lets to
idle air bleed valve w ith m ask ing tap e or
eq u ivalen t.
b. C arefully drill out pop rivet h ead s in valve
5. All air horn screw s and tighten even ly and cover (Figure 54).
secu rely, follow in g tigh ten in g seq u en ce sh ow n c. Drive out rem aining portion o f the rivets
in Figure 53. w ith a drift p u n ch and sm all ham m er.
d. D iscard the bleed valve cover. Use a sm all
m agnet if n ecessa ry to rem ove rivet and
ch ip s rem aining on air horn su rface.
R em ove m ask in g tape.
e. R em ove the idle air bleed valve assem b ly
by carefu lly tu rn in g cou n ter-clo ck w ise
until the valve a ssem b ly can be lifted from
air horn.
2. Idle Air Bleed V alve

a. In sp ect the bleed valve for any d am age or
con tam ination that could p reven t free and
unrestricted m ovem ent o f valve plunger.
b. If the tw o O -rings are dam aged, h ard en ed ,
or sw ollen they m ust be rep laced .
05 24 84 5S 1464-6E
Figure 53 A ir Horn Tightening Sequence

, 3
IT D R IL L #35 (.110")
r r ~ l RIVET
FT!MASKING TAPE p n G AG ING T O O L -J -3 3 8 1 5 -2 /B T 8 2 5 3 -B
S id le a ir b leed v a l v e c o ve r [T 1 G UIDE
|T 1 ID L E A IR BLEED V A L V E
f~4~l SOLENO ID PLUNGER
\T } M ETER IN G ROD 4S 0S S 3S E
6 S 2 6 0 5 -6 E
Figure 54 Idle Air Bleed Cover Rem oval Figure 55 In stallin g Idle A ir B leed V alve G aging
Tool
Install or Connect
3. Idle Air Bleed V alve.
a. Cavity in the air horn m ust be clean and
free of any foreign m aterial.
b. Install new O -rings, if n ecessary. Lightly
coat the tw o O -rings w ith autom atic
tran sm ission fluid, to aid in in stallation .
Install the valve assem b ly, m aking sure
there is proper thread en gagem ent.
4. Setting the Idle Air Bleed V alve.
a. Install air bleed valve gagin g Tool J-
33815-2, BT-8253-B, or eq u ivalen t, in
throttle sid e "D shap ed vent hole in the
air horn casting. The upper end o f the tool
sh ou ld be p osition ed over the open cavity
next to the idle air bleed valve.
b. While h olding the gagin g tool dow n
lightly, so that the solen oid p lu n ger is ED TO O L CO N TAC TIN G V A L V E
again st the solen oid stop, adjust the idle m G UIDE
air bleed valve so that the gagin g tool w ill D ID LE A IR BLEED V A L V E
pivot over and ju st con tact the top o f the E G AG ING TO O L - J-33815-2/BT8253B
(1.7 5 6 " HIG H)
valve. No further adjustm ent is req uired,
cn PLUNGER A G A IN S T STOP
(Figure 56). 4S 0584-6E
c. R em ove gagin g tool. Figure 56 Positioning Idle A ir Bleed Valve
5 a. D iscon n ect and plug can ister purge hose f. Use a cen ter p u n ch to break the p lu g for
at canister. a c c ess to the id le m ixture need le. R em ove
b. P lace a sp a cer (.75 to .10") betw een p ieces of plug. R epeat this p roced u re w ith
a ccelerator pum p lever and T PS plunger. the other m ixture needle.
c. Start en gin e and allow it to reach norm al
op eratin g tem peratu re, (closed loop). 0 Adjust
d. If the idle d w ell is not w ithin 25 - 35, the 7. IDLE MIXTURE NEEDLES
idle need le p lugs w ill have to be rem oved
a. U sing tool J-29030, BT-7610-B, or
and the idle n eed les adjusted.
eq u ivalen t, rem ove both idle m ixture
Remove or Disconnect n eed les and sp rin gs for inspection:
(1) N eed les m ust not be bent, burred or
6. IDLE MIXTURE NEEDLE PLUG
oth erw ise dam aged.
a. C arburetor from the en gin e, follow in g
(2) In sp ect both id le need le o p en in g s in
norm al service p roced u res, to gain access
the throttle body for any dam age or
to the plugs coverin g the idle m ixture
foreign m aterial. Clean as n ecessa ry .
n eedles.
b. Install idle m ixture n eed les and sp rin g s in
b. Invert carburetor and drain fuel into a
the throttle body.
su itab le container.
(1) U sing tool J-29030-B, BT-7610-B, or
c. P lace carbu retor on a su itab le holding
eq u ivalen t, turn both m ixture n e e d les
fixture, with m anifold sid e up. Use care to
c lo ck w ise until lightly seated .
avoid dam agin g link age, tu b es, and parts
(2) Turn each m ixture n eed le co u n ter
protru din g from air horn.
clo c k w ise 3 turns.
d. With a h a ck saw , m ake tw o parallel cuts in
c. R einstall carb u retor on en gin e u sin g a
the throttle body, one on each sid e of the
n ew flange gask et, but do not in stall air
locator p oin ts beneath the idle m ixture
clean er at this tim e.
n eed le plug (m anifold side), (Figure 57).
d. D iscon n ect vacuum h ose to can ister p urge
The cuts should reach dow n to the steel
valve and plug it.
plug, but sh ou ld not extend more than 1/8
e. Place a sp a cer (.75 to. 10") b etw een
beyond the locator points. The d istan ce
accelerator pum p lever and TPS p lu nger.
betw een the saw cuts d e p e n d s on the size
Start en gin e and allow it to reach norm al
o f the p un ch to be used.
op eratin g tem perature.
e. P lace a flat p u n ch near the en d s o f the saw
8. While id lin g in D rive (N eutral for m anual
m arks in the throttle body. Hold the
tran sm ision) adjust both m ixture n e e d les
pun ch at a 45 an gle and d rive it into the
eq u ally, in 1/8 turn in crem en ts, until d w ell
throttle body until the ca stin g breaks
read in g varies w ithin the 25-35 range,
aw ay, ex p o sin g the steel plug.
attem pting to be as clo se to 30 as p o ssib le . If
read in g is too low , turn m ixture n e e d les
co u n terclo ck w ise. If read in g is too high, turn
m ixture n eed les c lo c k w ise . A llow tim e for
d w ell readin g to stab ilize after each
adjustm ent.
9. A fter ad ju stm en ts are com p lete, seal the idle
m ixture n eed le o p en in g in the throttle body,
u sin g silico n e sealan t, RTV rubber, or
eq u ivalen t. The sealer is required to
d iscou rage u n n ecessa ry readju stm en t o f the
settin g, and to p reven t fuel vapor loss in that
area.
( jF ) RECESSED ID L E M IX T U R E [~4~| F LA T PUNCH
NEEDLE A N D PLUG LO C ATIO N S j~y~| CENTER PUNCH
fT I LO C ATO R POINTS Q f ] PLUG
[ 3 j HACKSAW S LO T S _____________________________ 4S 0585-6E
Figure 57 R em oving Idle N eed le P lugs

1. TPS A djustm ent is required only if voltage

-*4- Install readin gs are not w ithin a range o f .31 .1
Volts on a 5.0L, 5.7L, or 4.3L (w ith A/T) en gin e
8. P lug on solen oid adjusting screw . (Figure 58)
or .25 + .1 V olts on a 4.3L en g in e w ith M/T.
a. Install plug, hollow end d ow n , into the
a. C onnect a 10 m eg d igital voltm eter such as
a ccess hole to solenoid screw , and use
J-29125-A from TPS co n n ector cen ter
suitably sized pun ch to drive plug into the
term inal "B to bottom term inal "C,
air horn until the top of p lug is even w ith
(Jum p ers for a c c ess can be m ade u sing
the low er ed ge off cham fer. P lug m ust be
term inals 12014836 and 12014837) or use
installed to retain the screw settin g and to
Scan tool.
prevent fuel vapor loss.
b. Read TPS voltage, und er th ese conditions:
(1) Ignition ON.
(2) Engine stop ped.
(3) D iscon n ect electrical con n ector from
Idle Solenoid , (p lu nger retracted).
(4) Throttle lever aga in st idle speed
screw .
c. If adjustm ent is required, rem ove TPS
plug to allow adjustm ent.
2. TPS Plug Removal and Adjustment
a. U sing a 2mm (5/64") drill, drill a 1/16" to
1/8" deep hole in alum inum plug coverin g
TPS adjustm ent screw , (F igure 59). Use
care in drillin g to p reven t dam age to
adjustm ent screw head.
f~1~| SO LENOID STOP SCREW PLU G -N O T

USED ON A L L M ODELS (TOP OF
PLUG SHOULD BE 1/16" BELOW
SU RFACE)
[ 2 | SO LEN OID AD JUSTIN G SCREW PLUG
(TOP OF PLUG SHOULD BE FLUSH
WITH BOTTOM OF CHAM FER)
_______________________________________________ 6S 2753-6E
Figure $8 Installing Solenoid Adjusting Screw Plug
f t Adjust
Curb idle speed and fast idle speed as m PLUG (TH R O TTLE POSITION
SENSOR ADJUSTM ENT SCREW)
described on the V ehicle Em ission Control
|~2~] D R IL L
Inform ation label. 4S 0425-6E
Figure 59 TPS Plug
THROTTLE POSITION SENSOR
b. Start a No. 8, 1/2" long self-tap p in g screw
Before the Throttle Postitin S en sor (TPS)
in drilled hole turning, screw in only
voltage output settin g can be accu rately
en ough to en su re good thread
checked or adjusted, the idle rpm settin gs m ust
engagem ent in hole.
be set to sp ecification s as show n on the V ehicle
Em ission Control Inform ation label.
c. P lacing a w id e-b lad e screw d river

b etw een screw head and air horn casting,
pry again st screw head to rem ove plug.
DISCARD PLUG.
d. U sing tool J-28696, BT-7967-A, or
eq u ivalen t, adjust T PS screw to obtain
correct voltage, (F igure 60).
e. A fter adjustm ent, install new plug
(supplied in serv ice kits) in air horn,
d rivin g plug in p lace until flu sh with
raised pum p lever b o ss on casting.
NOTICE: Plug m u s t be installed to retain the
TPS adjustment screw setting. If plug is not
available, remove screw and apply GM
ENGINE A T OPERATING TEM PERATU RE
1052624 Threadlock or equivalent to screw
CHOKE WIDE OPEN
threads, then repeat adjustment.
CAM FO LLOW ER STEPS OF FA ST ID LE CAM
f. Clear trou ble cod e m em ory after H H A D JU ST ID LE SPEED SCREW TO OBTAIN SPEC IFIED
CURB ID LE R.P.M. (SEE LA B E L)
adjustm ent.
|~2~| A PPLY 68 kPa (20 ) WITH OUTSIDE VACUUM SOURCE
TO F U L L Y EXTEN D PLUNGER
H T ] M AN U ALLY OPEN T H R O T T LE S L IG H T L Y AND THEN
R E L E A S E AG AIN ST PLUNGER
m WITH PLU N GER H ELD INWARD, TURN PLUN GER IN OR
OUT TO OBTAIN SP EC IFIED R.P.M. (SEE LA B E L)
4S 1061-6E
Figure 61 Throttle Kicker Adjustm ent
|4--) Remove or Disconnect

Figure 62
1. V acuum hose.
2. B racket and throttle kicker.
3. Tab lock in g w ash er.
4. Throttle K icker.
+ 4- Install or Connect
1. T hrottle Kicker.
2. Tab lock in g w ash er - do not lock.
IDLE SPEED CONTROL
Throttle Kicker 4. A djust throttle kicker.
5. Lock tab w asher.
f t Adjust 6. V acuum hose.
Refer to F igure 61 and V ehicle E m ission
Control Inform ation label for adjustm ent o f the
throttle kicker.
Throttle Kicker Relay

Figure 63 or 64
1. E lectrical C onnector.
2. T hrottle K icker relay.
1. T hrottle K icker relay.
2. E lectrical con nector.
P H ATTACH IN G NUT
H H t a b l o c k in g w a s h e r
m BR A C K ET
H T H R O T T LE K IC K E R 6S 2754-6E
Figure 62 T hrottle K icker
Vacuum Solenoid
Figure 42 or 63
2. Vacuum h oses.
3. V acuum Solenoid . m T H R O T T LE K IC K E R R E L A Y
| 2 j E L E C T R IC A L CONNECTOR 6S 2755-6E
F igure 64 Throttle K icker R elay - CK Series
1. V acuum Solenoid.
2. V acuum hoses. Power Steering Switch
2. P ow er steerin g sw itch .
Install or Connect
1. P ow er steerin g sw itch .
2. E lectrical con nector.
n~| T H R O T T LE K IC K E R R E L A Y
H H VACUUM SO LENOID 6S 2756-6E
Figure 63 V acuum Solenoid

and R elay - G Series
PARTS INFORMATION
PA RT N A M E ............................... G RO UP
C arburetor ........................... . ...3 .7 2 5
Sen sor Kit, T hrottle P osition ...3 .7 6 4
S olenoid Kit, M ixture Control . . .3.440
I 1 j E L E C T R IC A L CONNECTOR
POWER STEERIN G SWITCH
|~3~i IN LE T HOSE
STEERIN G GEAR 6S 2757-6E
Figure 65 P ow er S teerin g Sw itch
CHART C-2F
TPS ENRICHMENT CHECK
CARBURETED-CALIF.
1. This step ch eck s that the TPS will cau se an 3. This step ch eck s for 5V. ref. at TPS. It should
ECM "Rich" com m and w hen fully d ep ressed be about 5 volts. If loss o f V. Ref. w ere in the
m anually. On som e veh icles, this w ill ca u se a ECM, it sh ou ld set C odes 21, 32 and 34 sin ce
low d w ell (full rich). On others it w ill not. this is the sam e 5V to VAC S en sor. T herefore,
it m ust be an open in the w ire.
Code 21 should norm ally be set.
4. This step ch eck s for a grou n d ed circuit.
2. T his step d istin g u ish es b etw een a faulty TPS Norm al circu it should read a b ou t 5 volts.
or ECM harness/ECM . C h ecking for grounded T PS output to
Term inal 2" o f ECM, or sh ort in CKT 417 and
Code 21 should norm ally be set, if en gin e 452 from TPS, in d icates w h eth er fault is in
RPM is not set above sp ecification s. w irin g or ECM. A voltm eter w ith a 10
m egohm s resistan ce m ust be used for an
accurate reading.
CHART NO. C-2F

TPS ENRICHMENT CHECK
CARBURETED-CALIF.
2-26-85
A fte r any repair clear long term memory by removing ECM fuse fo r 10 seconds
M S 0 2 8 9 -6 E A
mm M
n
is lu n r m T F T
n i
VAC. KICKER
A B RELAY CONN. 18 PIN ECM CONN. (BACK VIEW)
'THROTTLE KICKER"
VAC. SOL. CONN.
POWER
A/C SELECT A/C PRESSURE STEERING A/C CLUTCH
A/C FUSE
25 A SWITCH CYCLING SWITCH SWITCH COIL
959 GRN/WHT -----------150
IGN 50 BRN 66 LT. GRN. 59 GRN
N.C. "T ftR T blk -|
150
14 - 59 GRN
"THROTTLE
'Ih BLK
KICKER"
-RELAY N,C, 439 PNK/BLK IGN
I---- ----- - -J:
MANIFOLD
VACUUM - _____, VACUUM SOLENOID - f
r|; - ---- - i ECM
439 PNK/BLK
I
! n >
449 BRN
6-27-85
THROTTLE KICKER
6-27-85 (RETRACTS WITHOUT VACUUM) w* 5S 1588-6E
CHART C-2T-1
IDLE SPEED CONTROL CHECK
"THROTTLE KICKER"
4.3L WITH A / C - CALIFORNIA
CARBURETED-CALIF.
The throttle k ick er is m anifold vacuum operated and exten d s under the follow in g
conditions:
C oolant tem peratu re b elow 85C (185F).

For 30 se co n d s after startin g en gin e, if coolan t tem perature is above 85C
(185F).
If A/C eq u ip p ed , A/C "on and p ressu re cyclin g sw itch closed (clutch "ON).
If p ow er steerin g eq u ip p ed , full steerin g turn w ill open sw itch and solenoid
w ill en ergize (with A/C " o ff).
1. C h ecks ECM control o f solenoid and for an 3. C hecks for open relay coil circuit to ECM.
open in relay coil circuit. 4. C hecks for open ignition circuit to solenoid.
5. C hecks vacuum sou rce to solen oid , then
2. C h ecks to see that p ow er steerin g sw itch ch eck s for faulty throttle kicker,
o p en s, and the relay con tact circu it is not
open.
CHART C - 2 T - 1
IF AIR CONDITIONING (A/C) IS NOT OPERATING, REPAIR
SYSTEM BEFORE CHECKING THROTTLE KICKER.
"THROTTLE KICKER"
MAKE VISUAL INSPECTION OF HOSES AND ELECTRICAL
HARNESS FOR CONDITION AND MAKE CORRECTIONS AS
4.3L ENGINE WITH A/C
REQUIRED. CARBURETED-CALIF.
:.. :r"~:i " _ ~::~zzz
o WITH A/C "OFF". START ENGINE AND NOTE THROTTLE KICKER. IT SHOULD
EXTEND FOR 30 SECONDS AND THEN RETRACT.
OK DOES NOT EXTEND DOES NOT RETRACT
I
TURN STEERING WHEEL TO FULL TURN A/C "ON". KICKER SHOULD SEE CHART C - 2T -2
TURN. KICKER SHOULD EXTEND. EXTEND.
RETURN WHEEL TO STRAIGHT
AHEAD.
EXTENDS DOESN'T EXTEND EXTENDS DOESN'T EXTEND
NO CHECK FOR OPEN TO CHECK FOR OPEN IN CONNECT TEST LIGHT

TROUBLE RELAY TERMS. "A" WIRE TO ECM TERM. FROM SOLENOID
FOUND AND "D". IF NOT "E". IF NOT OPEN, TERM. "A" TO
OPEN, IT IS FAULTY CHECK CONNECTION GROUND AND NOTE
RELAY CONNECTION AT ECM TERM. "E". IF LIGHT.
OR RELAY. OK, SEE CHART C-1.
LIGHT "ON" LIGHT "OFF"
CHECK FOR VACUUM

AT SOLENOID, IF
PRESENT, CONNECT
REPAIR OPEN IN
CIRCUIT TO SOLENOID
TERMINAL "A .
KICKER DIRECTLY TO
VACUUM.
EXTENDS DOESN'T EXTEND
IT IS SOLENOID REPLACE THROTTLE KICKER

CONNECTION OR
SOLENOID.
6-27-85
'5S 1587-6E
r
IA IB I C| D| L
M
U N IT I TITT
n Iu I I l l l l l~FT
VAC. KICKER
A B RELAY CONN. 18 PIN ECM CONN. (BACK VIEW)
"THROTTLE KICKER"
VAC. SOL CONN.
POWER
A/C SELECT A/C PRESSURE STEERING A/C CLUTCH
A/C FUSE
25 A SWITCH CYCLING SWITCH SWITCH COIL
IGN 959 GRN/WHT 150
66LT.GRN. 59GRN BLK
N.C. BlK 1
150 ----------- 59GRN

R N -------------- 1
l|f~ BLK
8 "THROTTLE
I KICKER"
RELAY N.C. 439 PNK/BLK IGN
MANIFOLD
VACUUM g L -.- VACUUM SOLENOID - f
ECM
439 PNK/BLK
449 BRN
6-27-85
THROTTLE KICKER
6-27-85 (RETRACTS WITHOUT VACUUM) w* 5S 1588-6E
CHART C-2T-2
"THROTTLE KICKER"
4.3LWITH A /C
CARBURETED-CALIF.
The d iagn osis is con tin u ed from Chart C-2T-1
6. If throttle kicker retracts, relay or circu it is 8. C hecks for ignition voltage to relay,
c a u se of the problem .
9. C hecks for grounded w ire from solen oid
7. "Light o f f in d ica tes an open relay coil circuit. term inal "B to relay term inal "D or ECM
term inal "E.
CHART C - 2T - 2
CONTINUED FROM CHART C-2T-1 "THROTTLE KICKER"
4.3L ENGINE WITH A/C
CARBURETED-CALIF.
WITH A/C "OFF", START ENGINE AND NOTE THROTTLE KICKER. IT SHOULD
EXTEND FOR 30 SECONDS AND THEN RETRACT.
KICKER DOES NOT RETRACT
DISCONNECT RELAY AND NOTE KICKER, IT SHOULD RETRACT
RETRACTS DOES NOT RETRACT
CONNECT TEST LIGHT BETWEEN DISCONNECT SOLENOID ELECTRICAL CONNECTOR

RELAY HARNESS CONNECTOR AND CONNECT TEST LIGHT BETWEEN SOLENOID
TERMINALS "B" AND "C". NOTE
LIGHT. IT SHOULD BE "ON". HARNESS CONNECTOR TERMINALS "A" AND "B"
AND NOTE LIGHT.
LIGHT "ON' LIGHT "OFF" LIGHT "ON'

LIGHT "OFF'
REPLACE SOLENOID. CHECK FOR
CONNECT TEST LIGHT

FROM RELAY HARNESS
CONNECTOR TERMINAL
REPLACE RELAY. GROUNDED WIRE TO
SOLENOID TERMINAL
"B". IF NOT
"C" TO GROUND AND GROUNDED, SEE
NOTE LIGHT. CHART C-1.
LIGHT "OFF" LIGHT "ON'
REPAIR OPEN IN REPAIR OPEN IN

IGNITION CIRCUIT TO WIRE FROM RELAY
RELAY TERMINAL TERMINAL "B" TO
c
A/C CIRCUIT.
6-27-85
*5S 1585-6E
n r ,n
p e r
ii ii
f M M i l TTJTj
M I M M I ft ;
A B
18 PIN CCC CONN. (BACK VIEW)
VAC. SOL. CONN.
IGN
POWER STEERING SW. -

(IF USED) N.O. 6-27-85
* 5S 1590-6E
CHART C-2W
"THROTTLE KICKER"
4.3L WITHOUT A /C
CARBURETED-CALIF.
The throttle lever actuator is m anifold vacuum operated and extend s und er the
follow in g conditions:
C oolant tem peratu re below 85C (185F).

For 30 seco n d s after startin g en gin e, if coolan t tem perature is above 85C
(185F).
If p ow er steerin g eq u ip p ed , full steerin g turn will close sw itch and energize
the solen oid .
1. This c h eck s the ECM operation o f the throttle 3. C hecks for an open ignition circu it to the
kicker and d eterm in es if there is an open or solen oid .
grounded circuit.
4. C hecks for m anifold vacuum to the throttle
2. This c h eck s the pow er steerin g sw itch circu it kicker or faulty kicker as reason for an
to d eterm in e if the sw itch is w orking properly in op erative kicker.
or if th is is an open circuit. S in ce the en gin e is
loaded d ow n by an extrem e turn, the solenoid 5. C hecks solenoid and ground circu it to the
is en ergized to increase idle to com p en sate solen oid .
the load.
CHART C - 2 W
"THROTTLE KICKER"
MAKE VISUAL INSPECTION OF HOSES AND ELECTRICAL HARNESS 4.3L ENGINE WITHOUT A/C
FOR CONDITION AND MAKE CORRECTIONS AS REQUIRED. CARBURETED-CALIF.
START ENGINE AND NOTE THROTTLE KICKER MOVEMENT.

o KICKER SHOULD EXTEND FOR 30 SECONDS AND THEN RETRACT.
I
SYSTEM OK DOES NOT RETRACT
DOES NOT EXTEND
X
CONTINUE FOR POWER STEERING
ONLY
I
CONNECT TEST LIGHT FROM
' DISCONNECT SOLENOID

TURN STEERING WHEEL TO FULL
TURN. KICKER SHOULD EXTEND.
RETURN WHEEL TO STRAIGHT
SOLENOID TERMINAL
GROUND AND NOTE LIGHT.
"A" TO ELECTRICAL CONNECTOR.
KICKER SHOULD RETRACT.
AHEAD.
I----------- ----------------- 1 ' ' 1

EXTENDS DOESN'T EXTEND LIGHT "ON' LIGHT "OFF' RETRACTS DOES NOT
RETRACT
Q l
SYSTEM CHECK FOR OPEN CHECK FOR CHECK FOR OPEN IN 1
OK WIRE TO POWER VACUUM AT WIRE TO ECM TERM. CHECK FOR REPLACE
STEERING SOLENOID, IF "E". IF NOT OPEN, GROUNDED VACUUM
SWITCH. PRESENT. CHECK CONNECTION WIRE TO SOLENOID
CHECK FOR POOR CONNECT KICKER AT ECM TERM. "E". IF SOLENOID
CONNECTION AT DIRECTLY TO OK, SEE CHART C-1. TERM. "B".
SWITCH. VACUUM. IF NOT
CHECK POWER GROUNDED
STEERING SEE CHART
SWITCH. C-1.
REPAIR OR
REPLACE AS DOESN'T EXTEND EXTENDS
REQUIRED.
REPLACE
THROTTLE
IT IS KICKER
KICKER SOLENOID
CONNECTION OR
SOLENOID.
6-27-85
^s i s s e - e E
EVAPORATIVE EMISSION CONTROL SYSTEM (EECS)

ALL ENGINES
GENERAL DESCRIPTION
PURPOSE
V apor vent valve m ounted on the canister.
The E vaporative Em ission Control System A therm al bow l vent valve (som e applications).
(EECS) (Figure 66 and 67) lim its fuel vapor into A therm ostatic vacuum sw itch (TVS) in stalled in
the atm osphere. The system traps fuel vapor the intake m anifold to se n se en gin e coolan t
from the fuel tank and carburetor float bow l into tem perature.
a fuel vapor canister. The fuel tank has a non- When the en gin e is sh u t off, m anifold vacuum
vented fuel cap and a sin gle ven t pipe to the is lost at the vapor vent valve. The sp rin g loaded
canister. The can ister absorbs and stores the fuel valve in the vapor vent valve now co n n ects the
vapor in a carbon elem en t until it can be rem oved carburetor bow l vent to the can ister. C arburetor
and burned d u ring the norm al com b ustion float cham ber vapors now p a ss into the can ister
process. When the en gine is running, a for storage. When the en gin e is restarted,
therm ostatic vacuum sw itch or a solenoid valve m anifold vacuum d raw s the vapor vent
determ in es w h en the fuel vapor is purged into the con trolling valve again st sp rin g p ressu re, closin g
intak e air flow . off the bow l vent. Ported vacuum from the
EVAPORATIVE EMISSION SYSTEM WITHOUT carburetor is con n ected to the TVS. When the
AN ECM TVS op en s, ported vacuum o p en s the purge
(Figures 66 or 67) control valve. When the valve o p en s, m anifold
vacuum draw s vapors from the can ister into the
T his system u ses the follow ing control valves:
intak e m anifold.
P urge control valve m ounted on the canister.
PH CANISTER
[ 2 | BOWL VE N T V A L V E
[~3~1 CANISTE R PURGE V A L V E
m A U X F U E L VAPOR CANISTER
PICK UPS WITH A U X . F UEL T A N K
VA NS WITH 33 G A L L O N F U E L T A N K
| 5 | FUELTANK
|in AUX FU E LTA N K
r n F U E L T A N K V E N T LINE RESTR IC TIO N
| 8 | VENT
RT1 VA C U U M S IG N A L FOR BOWL V E N T
[T o l VAPOR PURGE LINE
( F U L L M A N I F O L D V A CUUM )
fTT] PORTED M A N I F O L D V A C U U M
12A |TVS ' WITHOUT ECM
12B |PURGE SOLENOID-WITH ECM
pf3~| TO EGRVALVE
|TT| CARBURETOR
|~1~5] CARBURETOR BOWL VENT LINE
nsl AIR CLEANER
4S 1165-6E
Figure 66 E vaporative E m ission System - V6 and L6

The therm al bow l vent valve (TBVV) is located Ported m anifold vacuum from the carb u retor
in the section o f hose that con n ects the is con n ected to the can ister purge solen oid valve.
carburetor bow l vent fitting to the can ister When the purge solen oid valve is d e-en ergized by
control valve. the ECM, vacuum will be applied to the ca n ister
The TBVV will close and prevent vapor purge valve, ca u sin g the valve to open and
m ovem ent at 32C (90F) and below . The TBVV vapors from the can ister to purge through the
will open at 49C (120F) to perm it vapor flow to carburetor purge port.
the can ister control valve. The ECM w ill d e-en ergize the purge solen oid
*#
valve and allow can ister purge to occur w h en the
EVAPORATIVE EMISSION SYSTEM follow in g co n d itio n s have been met:
WITH AN ECM (Figure 66 or 67) Engine has been running for a period o f tim e
after starting.
The con trolling valves in this system are: System is in closed loop.
P urge control valve m ounted on the canister. E ngine RPM ab ove idle sp eed .
Vapor vent valve m ounted on the canister. System not in ALCL m ode.
C anister purge solenoid valve controlled by the E ngine at norm al operating-tem perature.
ECM.
When the en gin e is sh u t off, full m anifold FUEL VAPOR CANISTER, PRIMARY (Figure 68)
vacuum is lost at the vapor vent valve. The sprin g
loaded valve in the vapor vent valve now The basic large size, tw o cham ber clo sed
con n ects the carburetor bow l vent to the bottom ca n ister is used on all system s and
canister. C arbureter float cham ber vapors now operates as follow s:
pass into the can ister for storage. When the
en gin e is restarted, full m anifold vacuum draw s
the valve again st sprin g p ressu re, clo sin g off the
bow l vent.
Q ] CANISTER
[ H b o w l VENT VALVE
Q ]CAN ISTER PURGE VALVE
[~4~1f UEL TANK
[~~5~l AUX. FUEL TANK
[j G f UELTANK VENT LINE RESTRICTION
Q ]V A C U U M SIGNALFOR BOWL VENT VALVE
[j G VAPOR PURGE LINE (FULL MANIFOLD VACUUM)
E l]PO R TED MANIFOLD VACUUM
rTo~l PCV VALVE
I H A l TVS -WITHOUT ECM
11 i e I p URGE SOLENOID - WITH ECM
112 I CARBURETOR BOWL VENT LINE
H Y l CARBURETOR
P u l AIR CLEANER
h 5 1 FUEL VAPOR CANISTER VENT
R 6 l TO EGR VALVE AND TCC
4S 1166-6E
Figure 67 E vaporative E m ission System

M J LA RG E SIZE TWO CHAMBER

' CLO SED BOTTOM CAN ISTER
F T ! VAPOR V EN T CO N TRO L V A LV E
f~3~i PURGE CO N TRO L V A LV E
f T l CLEAN AIR TUBE
"A IR C LN R "
[~5~] VAPOR FROM F U E L TAN K
[ 6 J VAPOR FROM BOWL VEN T
[~T~j TO M ANIFOLD VACUUM SIG N A L
[~8~! TO PORTED VACUUM
|~9~; VAPOR TO PURGE LIN E
H0~! F IL T E R
{ j j j CARBON
[T2j BOTTOM COVER
pi~3~j DUST CAP
p 4 j AIR FLOW
04 16 84 5S 1RRQ-RE
Figure 68 Fuel Vapor Canister
G asoline vapors from the fuel tank flow into VAPOR VENT CONTROL VALVE (FIGURE 68)
the tube labeled "Fuel Tank", and vapors from The vapor vent control valve p reven ts venting
the carburetor float bow l flow into the tube o f the carburetor float bow l d u rin g en gin e
labeled "CARB BOWL",and are ab sorb ed by the operation. A sp rin g-b iased diap h ragm valve,
carbon. The can ister is purged w hen the en g in e is norm ally open, allow s (or p revents) fuel vapors
running above idle sp eed . The closed bottom from the float bow l to en ter the can ister. When
d esign k eep s w ater from entering the bottom of the en gin e is off, sp rin g ten sion h old s the valve
the canister, freezing, and restricting purge air open, allow in g norm al venting.
flow . D uring purge, air is draw n from the clean
When the en gin e is turned on, h ow ever, m anifold
sid e of the air cleaner, to the tube on the can ister
vacuum p u lls the diaphragm up to clo se the
labeled "AIR CLNR", through the carbon and
valve.
into the intake m anifold to be burned. Som e
closed bottom can isters draw purge air d irectly FUEL VAPOR CANISTER, AUXILIARY
from the atm osphere. (Figure 69)
CANISTER PURGE CONTROL VALVE An A uxiliary Fuel V apor C anister is added to a
(Figure 68) prim ary closed bottom ca n ister to in crease
cap acity w hen a dual (aux.) fuel tank is used. On
The C anister Purge Control Valve is a spring-
the bottom is a hose w h ich c o n n ects to the
biased diaphragm valve, norm ally clo sed , w h ich
prim ary ca n isters purge air inlet. On top is a
allow s or prevents p u rging of the can ister. When
purge air inlet. V apor o v erflow in g from the
the engine is off or idling, the sprin g h old s the
prim ary ca n ister is stored in the auxiliary
valve closed , p reven tin g canister purge. When
canister. D uring purge, vapor flow s through the
the en gin e is off- idle, how ever, tim ed m anifold
auxiliary can ister, the prim ary ca n ister and into
vacuum pulls the diaphragm upw ard, op ening
the intake m anifold for b urning during
the valve and allow in g the canister to be purged.
com b ustion.
VAPOR VENT CONTROL VALVE

Functional Test
A pply a sh ort len gth o f hose to the carb u retor
bow l vapor tube o f the ca n ister (low er tube), and
blow into it to d eterm in e that air will p a ss the
vapor vent valve into the can ister. If not p o ssib le
to blow into the can ister, it m ust be replaced.
With a hand vacuum pum p, apply vacuum
51kPa (15" Hg) to the vacuum sign al tube on the
diaphragm assem b ly cover. The d iaphragm
sh ou ld hold vacuum for at least 20 seco n d s. If it
d oes not, d iaphragm is leak ing, and the ca n ister
m A U X IL IA R Y |~4~| A IR FLOW
C AN ISTER DURING PURGE m ust be rep laced .
|~2~| CARBON [~5~| DUST CAP With vacuum still ap plied to the vacuum sig n a l
m F IL T E R S f~6~| VAPOR FROM tube, again attem pt to blow in toth e carb u retor
PRIM A RY CAN ISTER bow l vapor tube o f the canister. N ow air sh ou ld
4S 1018-6 E not pass the vapor vent valve into the can ister,
Figure 69 A uxiliary Vapor Canister in d icatin g that the valve is sea lin g p ro p erly.If air
d oes enter the ca n ister p ast the vapor vent valve,
DIAGNOSIS the valve is not fu n ction in g properly, and the
can ister m ust be rep laced .
SYSTEM DIAGNOSIS PURGE CONTROL VALVE
Poor idle, stallin g and poor d riveab ility can be Functional Test
caused by: A pply a short len gth of hose to the PCV tu b e o f
Inoperative vapor vent valve purge valve assem b ly (low er tube), and attem pt
Inoperative purge control valve to blow through it. Little or no air should p a ss
Dam aged can ister into the can ister. (A sm all am ount of air w ill p ass
H oses split, crack ed and, or, not con n ected if the can ister has a co n sta n t purge hole.)
to the proper tubes. With a hand vacuum pum p, apply vacuum
E vidence of fuel loss or fuel vapor odor can be 51kPa (15" Hg) through the control vacuum
caused by: sign al tube to the purge valve diaphragm . If the
Liquid fuel leak in g from fuel lines, fuel pum p diaphragm d o es not hold vacuum for at least 20
or carburetor secon d s, the diaphragm is leak in g, and the
Cracked or dam aged can ister can ister m ust be rep laced .
Inoperative bowl vapor vent valve
If the diaphragm h olds vacuum , again try to
Inoperative purge control valve
blow through the hose con n ected to the PCV tube
D isconnected, m isrouted, kinked,
w hile vacuum is still bein g applied. An in creased
deteriorated or dam aged vapor hoses, or
flow of air sh ou ld be ob served . If not, the ca n ister
control h oses
m ust be replaced.
Bowl vent hose m isrouted
Air cleaner or air clean er gask et inproperly THERMOSTATIC VACUUM SWITCH (TVS)
seated REPLACEMENT
Therm al vacuum sw itc h e s opens, c lo se s, or
FUEL VAPOR CANISTER
sw itch es vacuum sou rce w hen the calib ration
V isually ch eck can ister and rep lace if crack ed , tem peratu re is reach ed . The follow in g gen eral
dam aged or satu rated with fuel. A pply a short ch eck in g p roced u res can be used for all therm al
length o f hose to the carb uretor bow l vapor tube vacuum sw itch es. Refer to num ber stam ped on
of the can ister (low er tube), and blow into it,to base o f valve or sw itch for calib ration
determ ine that air w ill p ass the vapor vent valve tem perature.
into the canister. If not p o ssib le to blow into the 1. A llow TVS to cool below calibration
canister, it m ust be replaced. tem perature.
2. In spect sw itch to m ake sure it is in good could ca u se early failure or failure to m eet
condition. em ission stan dard.
3. C onnect hand vacuum pum p(s) to output Do not use cop p er or alum inum tu b in g to
port(s) of the TVS. (See vacuum hose sch em atic rep lace steel tubing. T h ose m aterials do not
on V ehicle Control E m ission Inform ation have satisfactory d u rab ility to w ithstand
label.) norm al v eh icle vibrations.
4. A pply 51 kP a (15 Hg) vacuum . Do not use ru b b er hose w ithin 4 (100 mm) of
5. H eat TVS to a tem peratu re above the any part o f the exh au st system or w ithin 10
calibration tem perature. N ever apply a torch (254 mm) of the catalytic converter. H ose
or open flam e d irectly to the TVS. in sid e diam eter m ust m atch steel tubing
ou tsid e diam eter.
6. Com pare vacuum gage read in g to the correct
reading indicated on sw itch or valve base. 1. In rep airab le areas, cu t a p iece o f fuel h ose 4"
(100 mm) longer than portion o f the line
NO TICE: Leakage of u p to 7 kPa (2" H G ) v a c u u m
rem oved. If more than a 6 in ch (152 mm) length
in 2 minutes is allowable a n d does not m e a n a
o f pipe is rem oved, use a com b ination o f steel
defective part.
tu b in g and h ose so that h ose len gth s w ill not be
7. If operation is satisfactory, reinstall valve or more than 10 in ch es (254 mm). F ollow the sam e
sw itch. If valve or sw itch is d efective, replace routing as the original pipe.
with a new part.
2. Cut en d s of pipe rem aining on v eh icle square
SOLENOID VALVE with a tube cutter. U sing the first step of a
If the solenoid valve is open, or is not receivin g d ou b le flaring tool, form a bead on the end of
pow er, the can ister can purge to the in tak e both pipe sectio n s. If pipe is too corroded to
m anifold at all tim es. T his can allow extra fuel at w ith stan d bead operation w ithout dam age, the
idle or during warm -up, w h ich can cau se rough pipe sh ou ld be rep laced . If a n ew section of
or unstable idle, or too rich operation d u ring pipe is used, form a bead on both en d s of it
warm -up. also.
SOLENOID VALVE CHECK 3. Use screw type hose clam p, Part N um ber
2494772, or eq u ivalen t. Slid e clam ps onto pipe
The solenoid valve ch eck is covered in Chart
and p u sh h ose 2 (51 mm) onto each portion of
C-3 at the end o f this system section.
fuel pipe. T ighten clam ps on each sid e of
repair.
ON-VEHICLE SERVICE
4. P ip es m ust be properly secu red to the fram e to
SYSTEM HOSES
p revent chafing.
R efer to V ehicle E m ission Control Inform ation
label for routing of system hoses. FUEL CAP
If a fuel tank tiller cap req u ires replacem ent,
When replacing h oses, u se hose id en tified with
use only a cap w ith the sam e features. Failure to
the w ord "Fluoroelastrom er".
use the correct cap can resu lt in a m alfunction of
VAPOR PIPE the system .
The vapor pipe is secu red to the und erbod y CANISTER
w ith clam p and screw assem b lies. F lexible h oses Replacement
are connected at the fuel tank and the fuel vapor
1. D iscon n ect h oses from can ister. Mark h oses
canister. The pipe sh ou ld be in sp ected
for in stallation on new can ister. A lso refer to
occasion ally for leak s, kin k s or d en ts and
the V ehicle E m ission Control Inform ation
repaired as required.
label.
Repair
2. R em ove screw from bracket and rem ove
Repair vapor pipe in sectio n s u sin g brazed
canister.
seam less steel tu b in g m eeting GM Specification
123M or its eq u ivalen t or h ose id en tified w ith the 3. Install can ister and bracket screw .
word Fluoroelastom er. H ose not so m arked
4. C onnect h oses to canister.
AUXILIARY VAPOR CANISTER PARTS iNFORMATION

Replacement PART NAME ............. .............. GROUP
1. D iscon n ect hose from canister. C anister, Fuel V apor ......... .....3.130
S olenoid , Fuel V apor C anister .....3.140
2. R em ove screw from bracket and rem ove
canister.
3. Install can ister and con n ect hose.
SOLENOID VALVE
ECM CONTROLLED
1. D isconnect electrical con nector.
2. D iscon n ect vacuum hoses.
3. R em ove solen oid valve.
4. Install rep lacem ent valve.
5. C onnect vacuum h oses and electrical
connector.
THERMOSTATIC VACUUM SWITCH
NOT ECM CONTROLLED
1. Drain coolan t below level o f sw itch.
3. R em ove sw itch.
4. A pply a soft settin g sealan t to the th read s of
therm ostatic vacuum sw itch . Sealan t should
not be on the end of the sw itch .
5. Install sw itch , tighten to 14 N-m (120 in. Ibs.)
and then turn c lo ck w ise as required to align
with hoses.
6. C onnect hoses.
7. Add coolan t as required.
CHART C-3
SOLENOID VALVE CHECK
4.3L, 5.0L#o r 5.7L ENGINE
CARBURETED - CALIFORNIA
C anister purge is controlled by a solenoid valve that allow s
m anifold vacuum to purge the can ister w hen de-energized. The
ECM su p p lies a ground to energize the solenoid (purge off). The
solen oid is energized (no purge) by grounding the test term inal
w ith the ingition "ON" and en gin e stop ped, or with the engine
run n in g if the follow in g are met:
E ngine run tim e less than specified.
Coolant tem perature below a given value.
T PS below a given value.
If the above are not met, the solenoid valve is not energized.
1. C hecks to see if solen oid is energized and will 3. C hecks to see if solenoid p a sses vacuum w hen
not allow vacuum to p ass. "test term inal is ungroun ded (solenoid d e
energized). It should open and keep the pum p
2. C hecks to see if sign al to energize solenoid from bu ild in g up a vacuum .
(Light "ON") is p resen t at the solen oid . Light
"ON" is norm al and w ould ind icate no fault in
ECM or circu it to solenoid.
CHART C-3
SOLENOID VALVE CHECK
4.3L, 5.0L, or 5.7L ENGINE
5S 1687-6E
3-1-85
ELECTRONIC SPARK TIMING (EST) SYSTEM

4.3L, 5.0L, o r 5.7L ENGINE
CALIFORNIA ONLY
GENERAL DESCRIPTION
PURPOSE
The High E nergy Ignition (HEI) system
controls fuel com b u stion by provid in g a spark to
ignite the com p ressed air/fuel m ixture at the
correct tim e. To provide im proved en gin e
perform ance, fuel econom y, and control of
exh au st em ission s, the ECM controls distrib u tor
spark ad vance (tim ing) w ith the E lectronic Spark
DISTRIBUTOR
Tim ing (EST) system . HEI MODULE IGN. COIL TERMINALS
Only the E lectronic Spark T im ing (EST)

system w ill be d escrib ed here. A dditional
inform ation on the HEI system is found in
EST TERMINALS
PICK-UP COIL TERMINALS
3-15-85
Section 6D. *6S 2535-6E
Figure 71 D istributor HEI M odule (5.0/5.7L)

GENERAL DESCRIPTION
The high en ergy ignition (HEI) system The EST system co n sists of a distrib u tor HEI
(described in Section 6D) with EST has a m odule, an ECM, and c o n n ectin g w ires. The
distributor HEI m odule (F igu res 70 & 71) with con n ector four term inals for EST are lettered as
four term inals for the EST system . sh ow n in F igures 70 & 71.
To properly control ign ition/com bustion T hese circu its perform the fo llo w in g functions:
tim ing the ECM n eed s to know: TERM INAL A -E ST
crankshaft p osition T his circu it triggers the HEI m odule. The ECM
engine sp eed (rpm) d oes not k n ow w h at the actu al tim ing is, but it
engine load (m anifold p ressu re or vacuum ) d oes know w h en it gets the referen ce sign al. It
atm ospheric (barom etric) p ressu re then ad v a n ces or retards the sp ark from that
en gine coolan t tem peratu re point. T herefore, if the b ase tim ing is set
in correctly, the entire spark curve w ill be
incorrect.
TERM INAL B - DISTRIBUTO R REFERENCE
HI
This p rovid es the ECM w ith RPM and
cran k sh aft p osition inform ation.
TERM INAL C -B Y -P A SS
At ab out 400 RPM, the ECM a p p lies 5 volts to
this circu it to sw itch spark tim in g control from
the HEI m odule to the ECM. An open or
grounded b yp ass circuit will set a Code 42 and
the en gin e w ill run at base tim ing, p lus a sm all
am ount o f ad van ce built into the HEI m odule.
TERM INAL D -R E F E R E N C E G RO UND LO
T his w ire is grounded in the d istrib u tor and
m akes sure the ground circu it has no voltage
drop w h ich could affect p erform ance. If it is
Figure 70 D istributor HEI M odule (4.3L) open, it may ca u se poor perform ance.
DIAGNOSIS If the EST line is grounded, the m odule w ill

HEI SYSTEM sw itch to EST but b eca u se the line is grounded
there w ill be no EST sign al and the en gin e w ill
The d escrip tion and operation o f the HEI
not run. A Code 42 may or may not be set.
system can be found in Section 6D.
An open in the EST circu it will set a Code 42
Refer to Chart C-4A for Ignition System C heck
and cau se the en gin e to run on the d istrib u tor
w ith EST.
HEI m odule tim ing. This w ill cau se poor
R efer to Chart C-4E for Ignition System C heck perform ance and poor fuel econom y. A ground
w ithout EST. may set a Code 42, but the en gin e w ill not run.
EST SYSTEM The ECM u ses inform ation from the VAC
Code 12 is used d u rin g the D iagnostic Circuit sen sor and co o la n t se n so rs in addition to RPM to
C heck in Section A p roced u re to test the cod e calcu late spark ad van ce as follow s.
d isp la y ability o f the ECM. T his cod e in d ica tes Cold E n gine = m ore spark ad vance
that the ECM is not receivin g the en gin e RPM H igh V acuum S en so r O utput V oltage = m ore
(REFERENCE) sign al. T his occu rs w ith the spark advan ce
ignition key "ON and the en gin e not running. Low V acuum S en sor O utput V oltage = less
The " R eference sign al also triggers the fuel spark ad van ce
injection system . W ithout the " R eference sign al Hot E ngine = le ss spark ad van ce
the en gin e can n ot run.
EST PERFORMANCE CHECK

ON-VEHICLE SERVICE
Refer to EST P erform ance C heck, Chart C-4E
Refer to Section 6D for O n-V ehicle service o f the
Results of Incorrect EST Operation HEI d istributor, pick-up coil, d istributor cap,
D etonation could be cau sed by high vac. ignition coil, rotor, or distrib u tor HEI m odule,
sen so r output, or high resista n ce in the coolan t EST System .
sen so r circuit. Refer to Section 6D for rep lacem en t o f the
Poor p erform ance could be cau sed by low d istributor HEI m odule.
VAC sen so r ou tp u t or low resista n ce in the Refer to Section 6E for repair o f the EST w ires or
coolan t sen so r circuit. con n ectors.
CODE 42 Refer to Section C for rep lacem en t of the ECM.
A fault in the EST system w ill u su ally set a SETTING TIMING

Code 42 as d iagn osed in S ection A. A lw ays
Set tim ing a cco rd in g to in stru ction s on V eh icle
perform a D iagnostic C ircuit C heck before
E m ission C ontrol Inform ation label.
d ia g n o sin g Code 42.
When the system is run n in g on the distrib u tor
HEI m odule, that is, no voltage on the b y-pass PARTS INFORMATION
line, the HEI m odule grou n d s the EST sign al. The PART NAME ...................................................GROUP
ECM ex p ects to see no voltage on the EST line
D istributor .......................................................... 2.361
du rin g this con d ition . If it se es a voltage, it sets
M odule, Distr ...................................................... 2.383
Code 42 and w ill not go into the EST m ode.
Coil, Distr .............................................................. 2.170
When the RPM for EST is reach ed (about 400
RPM) the ECM ap p lies 5 volts to the by-pass line
and the EST sh ou ld no lon ger be grounded in the
m odule so the EST voltage sh o u ld be varying.
If the b y-pass line is op en , the m odule w ill not
sw itch to EST m ode so the EST voltage w ill be
low and Code 42 w ill be set.
CHART C-4A
IGNITION SYSTEM CHECK
4.3L, 5.0L OR 5.7L ENGINE WITH EST
CARBURETED-CALIF.
1. C hecks for proper output from the ignition 4. C hecks the voltage ou tp u t w ith the pick-up
system . The J26792 (ST-125) spark tester coil triggerin g the m odule. A spark in d icates
requires a m inim um o f 25,000 volts to fire. that the ignition system has su fficien t output,
h ow ever interm ittent no-starts or poor
This check can be used in case o f an ignition p erform ance could be the resu lt o f in correct
m iss b ecau se the system may provide enough polarity betw een the ignition coil and the
voltage to run the en gin e but not enou gh to pick-u p c o il .
fire a spark plug und er heavy load. The color o f the pick-up coil co n n ector has to
1A. If the en gin e w ill start with the con n ector be y ello w if one o f the ignition coil lead s is
d iscon n ected , it in d icates the problem is yello w . If the ignition coil h as a w h ite lead,
related to the EST circuit. The problem any pick-u p coil co n n ecto r color excep t
w ould u su ally be a grounded EST line or no yellow is OK.
ground to the ECM. 5. C h ecks for an open m odule or circu it to it. 12
2. Normal readin g d u rin g cran k in g is about 8-10 volts app lied to the m odule "P" term inal
volts. sh ou ld turn the m odule "ON" and the voltage
3. C hecks for a sh orted m odule or grounded sh ou ld drop to about 7-9 volts.
circuit from the ignition coil to the m odule. 6. This sh ou ld turn off the m odule and cau se a
The distributor m odule should be turned off spark. If no spark occu rs, the fault is m ost
so normal voltage should be about 12 volts. If likely in the ignition coil b eca u se m ost m odule
the m odule is turned "ON", the voltage w ould problem s w ould have been found before this
be low but ab ove I volt. This could c a u se the point in the procedure. A m odule tester could
ignition coil to fail from ex cessiv e heat. With determ in e w h ich is at fault.
an open ignition coil prim ary w inding, a sm all
am ount o f voltage will leak through the
m odule from the "Bat." to the tach. term inal.
Perform diagnostic circuit check before proceeding with this

CHART C-4A
test.
If a tachometer is connected to the "Tach." term., disconnect it IGNITION SYSTEM CHECK
before proceeding with the test. (Intermittent no start may be
caused by wrong pick-up or ign. coil) 4.3L, 5.0L, or 5.7L ENGINE
Check spark at plug with spark tester J-26792 or equivalent (ST- WITH EST
125) while cranking (if no spark on one wire, check a second
wire). A few sparks and then nothing, is considered no spark.
I
No Spark Spark 4.3L MIL LI
Disconnect 4 term. EST Check fuel,spark plugs, etc.
@ connector and check for spark. See section "B" symptoms. TEST X 4 RBG
V ---------------------- ---------- -------- LIGHT L ... U
No spark Spark
~T~T + 12V-^S^-
Check voltage at distributor Replace pick-up coil
"Bat." terminal while cranking.
3L
7 Volts or more Under 7 volts
l ......
5.0L/5.7L f
With ignition on, check

voltage at "Tach." terminal
Repair primary circuit
to ignition switch
Figure
OverlO volts Under 1 volt 1 to 10 volts

r X
Check for spark at coil output terminal

with spark tester while cranking.
Repair faulty coil connection
or replace faulty ignition coil
Replace module and check for
spark from coil as in Step 6.
L. ~
No spark Spark Spark No Spark

I xz
Remove pick-up coil leads from module.
Ignition "on". Engine stopped.
Observe voltage at "Tach." terminal as
Check color match of pick-up coil
connector and ign. coil lead. (See Below)
Inspect cap for w ater, cracks, etc.
System
OK
Replace ign.
coil, it too is
faulty
test light is momentarily connected If ok replace rotor.
from Bat. + to module term. "P". (Fig. 1)
Don't touch for more than 5 seconds.
1
Voltage drops No drop in voltage
I
Check for spark from coil wire with spark tester

as test light is removed from module term.
Check module ground and for
open in wires from coil to
module. If OK, replace module.
No Spark Spark
If no module tester is available; If module tester is Check pick-up coil or

Replace ign. coil and repeat Step 5. available: test module conns. (Coil resistance
should be 500-1500 ohms
X. and not grounded).
Spark OK Not OK
~1------
Ign. coil removed is OK, System OK Check coil wire Replace
reinstall original coil and from cap to coil. If module
replace dist. module. OK, replace coil.
IGN.
COIL
YELLOW
WIRE s a r :YELLOW
3-25-85
P/N 1876209 P/N 1875894
L -------------------------------------------------------------------------------------------------------------------------------------------------- 4 '6S2521-6EB
2. Checks to see if fa u lt is in VAC system.
3 -1 1 -8 5 3 -2 5 -8 5 6S 25 27-6 E
CHART C-4E
IGNITION SYSTEM CHECK WITHOUT EST
1. C h ecks for proper outp u t from the ignition that the ignition system has su fficien t
system . The J26792 (ST-125) spark tester ou tp u t,h ow ever interm ittent no-starts or poor
req uires a m inim um o f 25,000 volts to fire. perform ance could be the resu lt o f incorrect
T his ch eck can be used in case of an ignition polarity betw een the ignition coil and the
m iss b ecause the system may provide enough pick-up coil.
voltage to run the en gin e but not enou gh to The color o f the pick-up coil co n n ecto r has to
fire a spark plug u nd er heavy load. be yellow if one o f the ignition coil lead s is
yellow . If the ignition coil has a w h ite lead,
2. Norm al reading d u rin g cranking is ab ou t 8-10
andy pick-up coil con n ector color excep t
volts.
yellow is OK.
3. C h eck s for a sh orted m odule or grounded
5. C hecks for an open m odule or circu it to it. 12
circu it from the ignition coil to the m odule.
volts applied to the m odule "P term inal
The d istributor m odule should be turned off
should turn the m odule "ON and the voltage
so norm al voltage sh ou ld be about 12 volts. If
should drop to about 7-9 volts.
the m odule is turned "ON, the voltage w ould
be low but above 1 volt. T his could cau se the 6. This should turn o ff the m odule and ca u se a
ignition coil to fail from ex cessiv e heat. With spark. If no spark occu rs, the fault is m ost
an op en ignition coil prim ary w inding, a sm all likely in the ignition coil b ecau se m ost m odule
am ount of voltage w ill leak through the problem s w ould have been found before this
m odule from the "Bat. to the tach. term inal. point in the p rocedure. A m odule tester could
determ ine w h ich is at fault.
4. C h ecks the voltage output with the pick-up
coil triggering the m odule. A spark in d icates
P e rfo rm d ia g n o s tic c irc u it check b e fo re p ro ce e d in g w ith th is

CHART C-4E
te st.
If a ta c h o m e te r is co n n ecte d to th e "T a c h ." te rm ., d isco n n ect it
b e fo re p ro ce e d in g w it h th e te s t. ( In te r m itte n t no s ta rt m ay be
IGNITION SYSTEM CHECK
caused by w ro n g p ick-u p o r ign. co il)
Check spark a t p lu g w ith spark te s te r J-26792 o r e q u iv a le n t (ST-
WITHOUT EST
125) w h ile c ra n kin g ( if no spark on o ne w ire , check a second
w ire ). A f e w sparks and th e n n o th in g , is co n sid e re d no spark.
CARBURETED
No spark Spark
Check v o lta g e a t d is trib u to r

" B a t." te rm in a l w h ile cra n kin g .
Tcheck fu e l,s p a rk plugs, etc.
See section " B " sym p to m s.
7 V o lts o r m ore U nder 7 V olts
W ith ig n itio n on, check

v o lta g e a t "T a c h ." te rm in a l Repair p rim a ry circu it
to ig n itio n s w itc h
Figure 1
X
j C v e rlO v o lts U nder 1 v o lt 1 to 10 v o lts
T
Check fo r spark a t coil o u tp u t te rm in a l
w ith spark te s te r w h ile cra n kin g .
Repair fa u lty coil co n n e ctio n
o r replace fa u lty ig n itio n coil
Replace m o d u le and check fo r
spark fro m coil as in Step 6.
[ No spark Spark Spark No Spark
Rem ove p ic k-u p coil leads fro m m od u le .

Ig n itio n " o n " . Engine sto p p e d .
O bserve v o lta g e a t "T a c h ." te rm in a l as
Check color m atch o f p ick-u p coil
co n n e cto r a nd ign. coil lead. (See B e lo w )
Inspect cap fo r w a te r, cracks, etc.
System
OK
Replace ign.
coil, it to o is
fa u lty
te s t lig h t is m o m e n ta rily co n n ecte d If ok replace ro to r.
fro m Bat. + to m o d u le te rm . " G " . (Fig.
1) D o n 't to u ch fo r m ore th a n 5 seconds.
V o lta g e d rops No d ro p in v o lta g e

i ....:
* Check fo r spark fro m coil w ire w ith spark te s te r
as te s t lig h t is re m o v e d fro m m o d u le te rm .
Check m o d u le g ro u n d and fo r
o p e n in w ire s fro m coil to
m o d u le . If OK, replace m od u le .
1
No Spark Spark
I
If no m o d u le te s te r is a v a ila b le ; If m o d u le te s te r is Check p ick-u p coil or
Replace ign. coil and re p e a t Step 5. a v a ila b le : te s t m od u le conns. (Coil resistance
sh o u ld be 500-1500 ohm s
and n o t g ro u n d e d ).
No Spark Spark OK N o t OK
zr ~ z n i
Ign. coil re m o v e d is OK, [~System
^y~ OK Check coil w ire Replace
re in s ta ll o rig in a l coil and fro m cap to coil. If m o d u le
replace d ist. m o d u le . OK, replace coil.
PICK-UP
COIL
CLEAR
OR.BLACK
WHITE
WIRE
X, YELLOW
WIRE YELLOW
3-15-85
P/N 1876209 P/N 1875894
L ------------------------------- -------------------------------------------------------------------------------------------------------------------4 r6S 2536-6E
ELECTRONIC SPARK CONTROL (ESC) SYSTEM

4.3L ENGINE
CALIFORNIA ONLY
GENERAL DESCRIPTION DIAGNOSIS

PURPOSE ESC SYSTEM
V arying octane levels in todays gasolin e can Loss of the ESC k n ock sen sor sign al or loss of
cau se detonation in an engine. D etonation is ground at ESC m odule w ould c a u seth e sign al to
called spark knock. the ECM to rem ain high. T his con d ition w ould
To control spark knock on a 4.3L en gin e, an cau se the ECM to control EST as if no spark
Electronic Spark Control (ESC) system has been k n ock in g w ere hap p en in g. No retard w ould
added. This system is d esign ed to retard spark occur, and spark k n ock in g could becom e severe
tim ing up to 20 to reduce spark knock in the under heavy en gin e load con d ition s.
engine. This allow s the engine to use m axim um
Spark retard w ith ou t the k n ock sen sor
spark advance to im prove driveab ility and fuel
con n ected could in d icate a n oise sign al on the
econom y.
w ire to the ECM or a m alfu n ction in g ESC
OPERATION m odule.
The ESC system has tw o major com ponents: Loss of the ESC sign al to the ECM w ould cau se
ESC M odule the ECM to con stan tly retard EST. This could
ESC K nock Sensor Fig. 72) resu lt in slu ggish perform ance and cau se a
CODE 43 to be set.
The ESC knock sen so r (Figure 72) d etects
abnorm al vibration (spark knocking) in the When no CODE 43 is p resen t but the ESC
en gine. The sensor is m ounted in the en gin e block system is a p o ssib le cau se of ex c esisiv e spark
near the cylinders (Fig. 73). The ESC m odule knock, refer to CHART C-5 for ESC system
receives the knock sen so r inform ation and sen d s check.
a sign al to the ECM. The ECM then adjusts the
electron ic spark tim ing (EST) to red u ce spark CODE 43
knocking. CODE 43 in d icates that the ECM is receivin g
The ESC m odule (Fig. 74) sen d s a voltage less than 6 volts for a 4 secon d period w ith the
sign al (8 to 10 volts) to the ECM w hen no spark en gin e running. If cod e is p resen t after
k n o ck in g is detected by the ESC k n ock sen sor, perform ing the D iagnostic C ircuit C heck, refer to
and the ECM provides norm al spark ad van ce. CODE 43 chart in Section A for d ia g n o sis.
When the knock sen so r detects spark k n ock,

the m odule turns off the circuit to the ECM. The
ON-VEHICLE SERVICE
ECM then retards EST to reduce spark knock.
ESC KNOCK SENSOR
F IG U R E 7 3
The ESC K nock S en sor is located to the low er

left o f the en gin e block, b elow the sp ark plugs.
4S 0712-6E
Figure 72 ESC Knock Sen sor

JE S C m o d u le
[~2~| H ARNESS CONNECTOR
[ T ] e s c KN O CK SENSOR |~3~ BO LTTIG H TEN TO 34 N-m (25 FT. LBS.)
[ T ] h arn ess co n n ecto r 5S 1535-6E [T ]B R A C K E T
04 06 84
04 06 84 [IJ A IR P IP E 5S 1536-6E
Figure 73 ESC Knock Sensor - 4.3L Figure 74 ESC Module - 4.3L
ESC MODULE AND BRACKET

FIGURE 74
Remove or Disconnect The ESC m odule is located at the top rear o f
1. N egative battery cab le the engine.
2. ESC w iring h arn ess con n ector from ESC
sen sor Remove or Disconnect
3. Knock sen sor from en gin e block
1. ESC m odule con n ector
Install or Connect 2. A ttach in g screw s

3. ESC m odule
1. Knock sen sor into en gin e block. A pply
thread sealer, su ch as soft sealin g tape, to
ESC sen sor threads.
+1- Install or Connect
2. ESC w irin g h arn ess con n ector to the ESC 1. ESC m odule
sen sor 2. A ttach in g screw s
3. N egative battery cab le 3. ESC m odule co n n ector
PARTS INFORMATION
PART NAME .............................................. GROUP
S ensor, ESC K nock ..................................... 3.682
M odule, Elek Spark Cont ............................ 2.383
B racket, Elek Spark Cont Md ....................2.383
Shield , Elek Spark Cont K nock .................2.383
CHART C-5
4.3L ENGINE
If the tim ing is retarded at idle, it may be due to ESC operating.
ESC should not operate u n less a knock is presen t.
1. T his is the ESC fu n ctional ch eck . Sim u latin g 5. C hecks to se e if knock sen so r is reason for
an en gin e k n ock by tap p in g the en gin e block retard sign al. If en gin e k n ock is not p resen t,
should norm ally cau se an RPM drop and tim ing in crea ses w hen knock sen so r is
(d ecrease tim ing). If it d o e sn t drop, either the d iscon n ected , fault is an over sen sitiv e knock
tim ing is not retard in g or is retarded all the sensor. T im ing should not norm ally in crease.
tim e.
6. C hecks to see if retard sign al is d ue to "noise
2. T his sh ou ld c a u se full retard by d rop p in g the on sign al w ire or faulty controller. If tim ing
voltage at ECM term . "L." R etarded tim ing in creases w hen w ire is d isco n n ected from
sh ou ld c a u se an RPM drop. controller, fault is due to knock sen so r sign al
wire running too clo se to an ignition or
3. N orm ally, voltage should be .08V AC or chargin g system w ire. R eroute w ire to
h igher for a good k n ock sen sor circuit. correct.
4. C heck en g in e light sh ou ld be "on" and a Code

43 set b e c a u se ESC system w ould be retarded
too long. If no light com es on, the ECM is not
retard in g the spark b ecau se o f a voltage on
the circu it to term inal "L" or the ECM is
faulty.
CHART C-5
ELECTRONIC SPARK CONTROL (ESC) CHECK
4.3L ENGINE
o Engine knock, poor performance or poor economy - no Code 43.

This chart should only be used after all other causes of Spark Knock have been
checked, i.e., Timing, EGR, MAP, Engine Temperature or Excessive Engine
Noise, etc.
"Test" terminal ungrounded.
Connect tachometer.
Engine running at about 1500 RPM.
Transmission in park or neutral and at normal operating temperature.
Tap Engine Block in area of knock sensor and check for RPM drop.
X
RPM Drop No RPM Drop
I
System OK

Disconnect ESC.
Check for RPM change.
I
^3^ j RPM Drops No RPM Change
Note "Service Engine

Run engine at 2000 RPM.

--- 1
Check voltage between ESC harness Soon" light.
connector pins "E" and "D" with
r
digital voltmeter and controller
disconnected. Should be over .08 volts
on A.C. scale at 2000 RPM + 100 RPM.
Light OFF [ Light ON
I
X
Not OK
X
OK
"Ignition ON," engine
stopped. Check voltage from
ESC Term. "C" to ground.
Reconnect ESC controller.
Engine idling, disconnect
knock sensor.
Note timing change
x z ZE
Check for open in Faulty ESC X 1
circuit from ESC connection or Under 2 Volts 2 Volts or over
connector pin "D" ESC controller.
to ground. I
Replace ECM. Correct short to B + in
wire from ESC conn,
i term. "C" to ECM conn,
Open Not Open term. "L '\
n z z IZ X Z Z
Repair and Check for faulty i
recheck. connection, open or Increases No Increase
ground in wire from
sensor to ESC term. I ...........I- ~
"E".
If circuit is OK, it is
faulty sensor
connection or sensor.
Check for source of engine
knock
If no knock present, replace
Disconnect term ."E"
from ESC controller conn.
Note timing change.
knock sensor.
Increases No Increase
~~l
Retard is due to a Replace ESC
"false" signal on wire controller
from knock sensor to
controller. Reroute
wire away from other
wires sucn as spark
plug, etc.
84-85
* 4S 0330-6EA
3-25-85
AIR MANAGEMENT SYSTEM

ALL VEHICLES UNDER 8500 GVW
GENERAL DESCRIPTION The system co n sists of an air pum p, a diverter

PURPOSE valve or an electric air con trol valve, ch eck
The air m anagem ent system is used to reduce valve(s), and n ecessa ry plum bing.
carbon m onoxide and hydrocarbon em ission s. The 4.3L, 5.0L (RPOLF3) or 5.75L (LS9) en gin e
One part o f the system is called air injection in C alifornia have an electric air control valve
reaction (AIR) and the other is a d ecelera tion controlled by an ECM and all other en g in es use a
control. d iverter valve w ith ou t an ECM.
AIR SYSTEM Operation W ithout ECM

FIGURES 75 AND 76
This system , und er certain con d ition s, adds
A belt driven air pum p su p p lies com p ressed
air (oxygen) to the ex h a u st m anifold to continu e
air through a centrifu gal filter fan to a diverter
com bustion after the ex h a u st g a ses leave the
valve (Figure 77). T his valve, d u rin g norm al
com bustion cham ber. T his added air also brings
operation, allo w s air to go to the exh au st
the catalytic con verter up to op erating
m anifold or ports. At high en gin e sp eed s, air is
tem perature more q u ick ly w hen the en gin e is
directed to the air clea n er/silen cer through a
cold.
pressu re relief valve. D uring en gin e d ecel, w hen
there is a rise in the m anifold vacuum signal, air
is d irected to the air clean er/silen cer.
AIR PUMP
AIR TO DIVERTER VALVE

AIR PUMP
DIVERTER VALVE
AIR TO DIVERTER VALVE
AIR TO SILENCER
DIVERTER VALVE
SILENCER
MANIFOLD VACUUM SIGNAL
MANIFOLD VACUUM SIGNAL
AIR TO AIR CLEANER
AIR TO EXHAUST PORTS
AIR TO EXHAUST PORTS
CHECK VALVE
CHECK VALVES
AIR INJECTION PIPES (AIR TO EXHAUST PORTS)
AIR INJECTION PIPES (AIR TO EXHAUST PORTS)
3-18-85 *6S 2540-6E -85 *6S 2595-6E
Figure 75 AIR System (L6) Figure 76 AIR System - W ithout ECM (V6/V8)
Operation With ECM

FIGURE 78
A belt driven air pum p su p p lies air through a

cen trifu gal filter fan to the electric air control
EAC) valve (Figure 79). T his valve directs the air
to either the en gin e ex h a u st m anifold ports or to
the air clean er. When the en gin e is cold or in
w ide open throttle con d ition , the ECM en ergizes
the solen oid on the valve and air is d irected to the
ex h a u st m anifold ports. When the coolan t
tem peratu re in creases, the solen o id is d e
STAN D ARD D IV E R T E R [~5~| VEN T energized and air goes into the air clean er w h ich
V A LV E m PUMP A IR IN LE T also acts as a silen cer. At h igh er en gin e sp eed s,
s M ETERING V A LV E [~~7~j EXH A U ST PORT O U TLET air is directed to the air clean er through the
GO DIAPHRAGM |~8~l R E L IE F V A LV E p ressu re r e lief valve even though the solen oid
l TIMING V A LV E [~9~! VACUUM SIG N A L TUBE
may be en ergized . D uring en gin e d ecel, w hen
4S 1019' 6E
there is a rise in the m anifold vacum n sign al, air
Figure 77 D iverter V alve
is d irected to the air cleaner.
One ch eck valve is used on an L6 en gin e and
the V6 or V8 en gin e has tw o ch eck valves on A Check valve on either sid e o f the en gin e
either sid e o f the en gin e. The ch eck valves p revents back flow of ex h a u st into the air pum p if
preven t back flow o f ex h a u st into the air pum p if there is an ex h a u st backfire or pum p drive belt
there is an ex h a u st b ack fire or pum p d rive belt failure.
failure.
[T ] ELECTRICAiR CONTROL [ 6 I DECEL TIM ING CHAMBER

(EAC) VALVE pH AIR TO AIR CLEANER
[~2~| DECEL TIMING ASSEMBLY | 8 | AIR FROM AIR PUMP
m MANIFOLD VACUUM p ep AIR TO EXHAUST PORTS
SIGNALTUBE OR MANIFOLD
[ T ] ELECTRICAL TERMINAL p O l PRESSURE RELIEF

|~5~] EACSOLENOID ASSEMBLY f is 2 6 0 9 . 6E
Figure 78 AIR S ystem - With ECM <V6/V8) Figure 79 EAC V alve

If the en gin e is op eratin g u nd er a rich NOTICE: If the engine or underhood

condition or the "SERVICE ENGINE SOON" c o m p a r t m e n t is to b e cleaned with s t e a m or high-
lamp lights, the solen oid is d e-en ergized and air pressure detergent, the centrifugal filter fan
goes to the air cleaner. should be m a s k e d off to prevent liquids from
entering the p u m p .
DECELERATION CONTROL
The AIR System is not com p letely n o iseless.
FIGURE 80
U nder norm al con d ition s, n oise rises in pitch
To help p reven t back firin g d u rin g high as en gin e sp eed in creases. To determ in e if
vacuum con d itions a d ecelera tio n (gulp) valve is e x c essiv e n oise is the fault o f the AIR System
used to allow air to flow into the intak e m anifold. pum p, operate the en gin e w ith the pum p drive
This air enters the air/fuel m ixture to lean the belt rem oved.
rich condition created by high vacuum w h en the If noise is cau sed by the AIR System pum p,
throttle valve c lo se s on d eceleration . ch eck f o r :
The vacuum d ra w s the d eceleration valve A seized air pum p.
diaphragm dow n and op en s the valve allow in g Proper m ounting and Bolt torq ue o f pum p.
air from the air clean er to flow into the intak e Proper routine and co n n ectio n s o f h oses.
m anifold. NOTICE; D o not oil air air p u m p
Replace p u m p if there is excessive noise.
DIAGNOSIS
AIR SYSTEM Air Pump
R efer to CHART C-6C for the d iagn osis of the The air pum p is a positive d isp la cem en t vane
AIR System with an electric air control valve and type w hich is perm anently lu b ricated and
an ECM. req uires no period ic m aintenance.
A ccelerate en gin e to ap p roxim ately 1500 RPM
and ob serve air flow from hose. If air flow
in crea ses as en gin e is accelerated , pum p is
op eratin g satisfactorily. If air flow d o es not
in crease or is not p resen t, p roceed as follow s:
t?
Inspect
1. For proper d rive b elt ten sion .
2. For a leak y p ressu re r elief valve. Air may be
heard lea k in g with the pum p running.
Check Valve
Ip ' Inspect
l. A check valve should be in sp ected w h en ever
the hose is d iscon n ected from a ch eck valve
[T] a ir flo w AIR CLEANER or w h en ever ch eck valve failure is su sp ected
[~2~] EXHAUST GAS [ 9 | DECELERATION (A pum p that had becom e inop erative and
F T ] EXHAUST VALVE VALVE had sh ow n in d ication s o f havin g exh au st
H P INTAKE FLOW F 10 1MANIFOLD gases in the pum p w ould in d icate check
VACUUM valve failure).
U Q INTAKE VALVE
[~6~1 COMBUSTION
R t~I DIAPHRAGM
Blow through the ch eck valve (tow ard the
CHAMBER R F | VALVE cylin d er head) then attem pt to su ck back
f~7~| VACUUM BLEED through the ch eck valve. Flow sh ou ld only
VALVE 4S 0507-6E
be in on e d irection (tow ard the exh au st
Figure 80 D eceleration Control m anifold). R eplace valve w h ich d oes not
operate properly.
Hoses and Pipes
Inspect
1. H ose or pipe for d eterioration or holes.
2. All h o ses or pipe co n n ectio n s, and clam p
tig h tn ess.
3. H ose or pipe routing. In terference may
c a u se w ear.
4. If a leak is su sp ected on the p ressu re sid e of
the system or if a h ose or pipe has been
d isco n n ected on the p ressu re sid e, the
co n n ectio n s should be ch eck ed for leak s
w ith a soap y w ater solu tion . With the pum p
running, b u b b les w ill form if a ieak exists.
DECELERATION VALVE
Functional Check
1. R em ove air clean er, p lu g air clean er vacuum
so u rce and co n n ect tach om eter.
2. With the en gin e ru n n in g at sp ecified idle
sp eed , rem ove the sm all d eceleration valve
sign al h ose from the m anifold vacuum
sou rce.
3. R econ n ect the sign al h ose and listen for air
flow through the ven tilation pipe and into
the d eceleration valve. T here should also be CAUTION: C entrifugal fan should not be
a n oticeab le speed drop w hen the signal rem oved from pum p u n less it is dam aged, as
h ose is recon n ected . rem oval w ill destroy the fan.
4. If the air flow d oes not con tin u e for at least Before startin g rep lacem en t note the
one secon d or the en g in e sp eed d oes not follow ing:
drop noticeab ly, ch eck the deceleration
Do not allow any filter fragm ents to en ter the
valve h o ses for resitriction s or leaks.
air pum p intak e hole.
5. If no restriction s or lea k s are found, replace
the d ecelera tion valve. Do not rem ove filter fan by in sertin g a
screw d river b etw een pum p and filter fan.
ON-VEHICLE SERVICE Air dam age to sea lin g lip pum p will result.
DRIVE BELT Do not rem ove m etal drive hub from filter
fan.
Remove or Disconnect It is seldom p o ssib le to rem ove the filter fan
In sp ect drive belt for w ear, crack s or w ithout d estro y in g it.
deterioration and rep lace if required. When
in sta llin g n ew belt, it m ust be seated and
*-- Remove or Disconnect
fully secu red in grooves o f A/C com p ressor,
air pum p, generator, and cran k sh aft pulleys. FIGURE 81
PUMP CENTRIFUGAL FILTER FAN 1. Air pump

2. Pum p pulley
The cen trifu gal filter fan should not be 3. Insert n eedle n ose p liers and pull filter fan
clean ed , either w ith com p ressed air or from pum p hub.
solven ts.
-<- Install or Connect

1. N ew filter fan on pum p hub.
2. Spacer and pum p p u lley again st centrifu gal
filter fan.
3. Pum p pulley b olts and tighten eq u al to 10
N-m (90 in.lbs.). T his w ill com p ress the
cen trifu gal filter fan onto the pum p hole. Do
not drive filter fan on with a ham m er. A
sligh t am ount o f in terferen ce w ith the
h ou sin g bore is norm al. A fter a n ew filter
fan has been in sta lled , it may sq u eal upon
initial operation or until O.D. sealin g lip has
worn in. This m ay require a short period of
pum p operation at variou s en gin e sp eed s.
4. Air pum p.
AIR PUMP
FIGURE 82
-- Remove or Disconnect
1. Hold pum p p u lley from tu rnin g by
com p ressin g d rive belt, then loosen pum p
pulley bolts.
2. Loosen bolt, h old in g pum p to m ounting
b rackets, release ten sion on drive belts.
3. Move belts out o f the w ay, then rem ove
pum p hoses, vacuum and electrical
con n ection s, and con trol valve.
4. P ulley, then pum p.
5. If required, in sert n eed le nose p liers and
pull filter fan from hub (see Figure 81).
H ~ ]P U L L E Y m SUPPORT m AIR PUMP

m B O LT T IG H T E N TO [ T ] A IR PUMP QHDIVERTER VALVE OR EAC VALVE
10 N-m (90 IN. LBS.) [~7~| BRACKET [ T I t O AIR CLEANER
P [ ] B O LT T IG H T E N TO [ j j BRACE QGlNJECTlON PIPE - TIGHTEN TO 30 N-m
45 N-m (32 FT. LBS.)
[T ] n u t - t ig h t e n
TO [j l Jc HECK VALVE -TIGHTEN TO 23 N m (17 FT. LBS.)
r~4 ~ |B O L T -T IG H T E N TO 34 N m (25 FT. LBS.)
84 N-m (25 FT. LBS.) C]PIPE ASSEMBLY
04 06 84 5S 1528-6E
______________________________________________ 5S 1741-6E
Figure 82 Air Pum p - T ypical
Figure 84 A I R System - V8
(Lt. Duty E m issions - CK)
[T] AIR PUMP [TjDIVERTER VALVE OR EAC VALVE

[ T ] ADAPTER AND SEAL - TIGHTEN SCREWS TO 25 N m (18 FT. LBS) [T ]A lR CLEANER
[ T ] AIR INJECTION PIPE - TIGHTEN NUTS TO 28 N m (20 FT. LBS.) [7JBO LT - TIGHTEN TO 34 Nm (25 FT. LBS.)
E C H E C K VALVE - TIGHTEN TO 85 N m (26 FT. LBS.)
04 06 84 5S 1532-6E
Figure 85 A I R System - V6
Install or Connect
1. Air pum p assem b ly, and tighten m ounting
bolts.
2. H ose.
3. N ew filter fan on pum p hub.
4. S p acer and pum p p u lley aga in st centrifu gal
filter fan.
5. Pum p p u lley bolts and tighten eq u ally to 13
N m (10 Ib.-ft.). This w ill com p ress the
cen trifu gal filter fan onto the pum p hole. Do
not drive filter fan on w ith a ham m er. A
sligh t am ount of in terferen ce w ith the
h ou sin g bore is norm al. A fter a new filter fan
has been in stalled , it may sq u ea l upon initial
op eration or until O.D. se a lin g lip has worn
in. T his may require a sh ort period o f pum p
[ T ] A I R PUMP
op eration at variou s en gin e sp eed s.
[~2~] AD A PTER
6. Pum p d rive belt and adjust. [ T ] d iv e r t e r valve
V A C U U M HOSE
7. C heck air m anagem ent system w ith an ECM
C H E C K VALVE
for prop er operation (see C hart C- 6C).
IN J E C T IO N p ip e
05 03 84 5S 1738-fiE
Figure 86 AIR System - 7.4L

DIVERTER OR EAC VALVE

FIGURES 83 THRU 88
2. E lectrical con n ector on EAC valve.
3. M anifold vacuum sign al hose.
4. Air in let and ou tlet h o ses from valve.
5. D iverter or EAC valve.
1. D iverter or EAC valve.
2. Air in let and ou tlet h oses to valve.
3. M anifold vacuum sign al hose.
4. E lectrical con n ector on EAC valve.
PH a I R PUMP
f~2~[ D IV E R TE R V A L V E
m CHECK V A L V E
f~4~l V A C U U M HOSE
j~5~] INJECTIO N PIPE
05 04 84
4S 1087-6EA
Figure 88 AIR System - V8

(H eavy Duty E m issions)
6. C heck system operation (C alifornia 4.3L,

5.0L, or 5.7L only, Chart C-6C).
CHECK VALVE
FIGURES 83 THRU 88
1. Any parts required for a ccess.
2. R elease clam p and d isco n n e ct air h oses
from ch eck valve.
3. U nscrew ch eck valve from air injection pipe.
Install or Connect
1. Screw ch eck valve onto air injection pipe.
2. Position air hose on check valve and secu re
with clam p.
VIEW A 3. Any parts rem oved for a ccess.
m A I R PUMP
[ T ] D IV E R T E R V A L V E OR
A IR C O N T R O L V A L V E
i~3~l TU BE TO A CLEA N ER
f~4~l CHECK V A L V E
[~5~~1 IN JEC TIO N PIPE
G C ] D E C E LE R A TIO N V A L V E 4S 1088-6EA
Figure 87 AIR System - V8

(Lt. Duty E m issions - G)
AIR INJECTION PIPE ASSEMBLY

FIGURES 83 THRU 88
|<-+| Remove or Disconnect

1. H ose.
2. C heck V alve.
3. N uts attach in g pipes-to-m anifold.
4. P ipe A ssem bly.
El Install or Connect
1. N uts attaching pipes-to-m anifold.
2. C heck Valve.
3. H ose.
DECELERATION VALVE
FIGURE 89 or 90
1. V acuum h oses from valve.
2. S crew s secu rin g valve to en gin e bracket. f T l BR A C K E T
3. D eceleration valve.
PH D E C E LE R A TIO N VALVE
m B O LT T IG H T E N TO 17 N-m (12 FT. LBS.)
E B O LT T IG H T E N TO 14 N-m (12 LBS.)
Install or Connect 05 04 84 5S 1740-6E
Figure 90 D eceleration V alve - V8
2. S crew s secu rin g valve to en gin e bracket.
3. V acuum h oses to valve.
PARTS INFORMATION
PART NAME GROUP
A dapter, AIR Inj Cont Vlv ............................... 3.671
Bracket, AIR Inj Pum p S up t ...........................3.655
Bracket, AIR Inj Pum p .....................................3.655
Fan, AIR Pum p ................................................... 3.665
G asket, AIR Inj Dvtr Vlv El .............................3.671
H arness, AIR Inj Cont Vlv Vac ...................... 3.675
H ose, AIR Inj Cont Vlv ....................................3.675
H ose, AIR Inj Cont Vlv D vtr ...........................3.675
fT~j B R A C KE T P ulley, AIR Inj Pum p ......................................3.650
fTl D E C E LE R A TIO N VALVE
Pum p, AIR Inj ................................................... 3.660
l~3~] B O LT T IG H T E N TO
3.5 N m (30 IN . LBS.) Valve, AIR Inj Cont ............................................3.670
04 17 84 5S 1657-6E Valve, AIR Inj Eng Chk .................................. 3.670
Figure 89 D eceleration Valve - V6 V alve, AIR Inj Control (D ivert) .....................3.620
V alve, AIR Inj Sw itchin g ............................... 3.670
SOLENOID CONNECTOR
flnfl J !
I a I 11 i ei i i h r I ] GDIHIh]
m
s, ,
r r m 'K i J I.P. HARNESS CONNECTOR
A B ECM CONNECTORS (BACK VIEW)
ELECTRIC
AIR CONTROL
TO AIR AIR
SOLENOID
CLEANER PUMP
V JX X I
CHECK CHECK
/ww\ VALVE
TT
VALVE
TO TO
EXHAUST EXHAUST
PORTS ECM
B PORTS
A I
439 PNK/BLK
436 BRN
IGNITION-
ECM I n
FUSE c
o O
3-25-85 / ALCL CONNECTOR 3-11-85 6S2528-6E
CHART C-6C
AIR MANAGEMENT CHECK (EAC)
The air m anagem ent system has a sin gle bed catalytic converter.
An electric air control valve solenoid that directs air into the exh au st
ports or the air cleaner. D uring cold start, the ECM com p letes ground
circuit, the EAC solenoid is energized, and air is directed to the exh au st
ports. As "coolant tem perature in crea ses, or system goes to "closed
loop , th e ECM open s the ground circu it, the EAC solenoid is d e
en ergized , and air goes to the air cleaner.
1. T his is a system perform ance test. When 3. C h ecks for an open control circuit. G rounding
veh icle goes to "closed loop , air w ill sw itch test term inal will energize the solen oid if ECM
from the ports and d ivert to the air cleaner. and circuits are norm al. In this step , if test
light is ON, circuits are norm al and fault is in
2. T ests for a grounded electric divert circuit.
valve con n ection s or valve.
Norm al system light w ill be OFF.
4. C hecks for voltage from battery through a fuse
to the solen oid .
CHART C-6C
AIR MANAGEMENTCHECK
(ELECTRIC AIR CONTROL(EAC) VALVE)
6-27-85
*6S 2530-6EB
AIR INJECTION REACTION (A I R) SYSTEM

(VEHICLE OVER 8500 GVW)
GENERAL DESCRIPTION
The heavy duty em ission en gin es with veh icle to the exh au st m anifold. D uring an en gin e d ecel,
w eigh t over 8500 GVW have an AIR System w ith w hen there is a rise in the m anifold vacuum
in creased air flow . The system is used to reduce sign al, air is directed to the air clean er or silen cer
carbon m onoxide (CO), and hydrocarbon (HC) even though the solenoid is energized. The
em issions. The air injection reaction (AIR) system solenoid is de-en ergized w hen there is high
provides additional oxygen to con tin u e the en gin e RPM over a prolonged period or a
com bustion p rocess after the ex h a u st gases leave m alfunction o f the electrical circuit.
the com bustion cham ber. The system diverts air
from the exh au st m anifold at increased en gin e
sp eed or w hen an electrical m alfunction is
detected in the system .
The system used on a 4.8L en gin e co n sists o f
an air pum p, an air filter, an air control valve, a
ch eck valve, a silen cer, an air tem perature
sw itch , a control m odule and n ecessary
plum bing.
The system used on a 5.7L or 7.4L en gin e
c o n sists of two AIR pum ps, an air filter, tw o air
control valves, tw o ch eck valves, a control
m odule and n ecessary plum bing. The 7.4L
en gin e also u ses a control relay to operate the
"SERVICE ENGINE SOON light.
AIR OPERATION H H HIGH FL0W e l e c t r i c j T 1 D ECEL TIMING

AIR CO N TRO L V A LV E CHAMBER
The air pump(s) is belt driven on the front o f m d e c e l t im in g m D IV E R T A IR TO AIR
the engine and su p p lies the air to the system . ASSEM BLY "J C LE A N E R OR SILE N C E R
[ 3J V E R Y HIGH VACUUM [~8~] A IR FROM PUMP
Intake air p asses through an external air filter SIG N A L PORT
rg - 1AIR TO EXH AU ST
to the air pum p(s). r~4~j E LE C T R IC A L 1 PORTS
TERM IN AL
Air flow from the pum p(s) p a sse s through a !T0l PRESSURE R E L IE F
I 5 [SO LENOID ASSEM BLY
control valve(s) to a check valve(s) and an AIR 09 25 84 5S 1934-6E
pipe(s) and into the exh au st manifold* Figure 91 Air Control Valve (HFEAC)
The check valve preven ts back flow o f e xh au st
into the pum p in the even t o f an ex h a u st SERVICE ENGINE SOON LIGHT
backfire or pum p drive belt failure. If there is a m alfunction in the control
AIR CONTROL VALVE (HFEAC) m odule, w iring harn ess or solenoid(s), an am ber
F I G U R E 91 "service en gin e so o n light will illum inate on the
instrum ent panel. The "SERVICE ENGINE
T his valve is a high flow electric air control
SOON light is "ON with the ignition key "ON
(HFEAC) valve that has an electric solenoid to
and the en gin e not running as a bulb ch eck
com b in e electron ic control w ith norm al diverter
(except 7.4L). When the engine is started, the light
valve function.
will rem ain on for three to six seco n d s and then
With ignition "ON, the solenoid is energized turn off. On a 7.4L system , with ignition "ON
through the control m odule and the air control and the en gin e not running, the "SERVICE
valve operates like a stan dardized diverter ENGINE SOON light will com e "ON and stay
valve.W ith the solen oid energized, air is directed "ON for 1-2 seco n d s and then go "OFF as a bulb
check.
DECELERATION CONTROL
FIGURE 92
The AIR System is not com p letely n o iseless.
To help prevent b ackfiring during high U nder norm al con d ition s, noise rises in pitch as
vacuum con d ition s a d eceleration (gulp) valve is en gin e speed in creases. To d eterm in e if e x c essiv e
used w ith th ese AIR system s. Thge high vacuum n oise is the fault o f the Air Injection R eactor
draw s the d eceleration valve diaphragm dow n System , operate the en g in e with the pum p d rive
and op ens the valve a llow in g air from the air belt rem oved. If e x c essiv e n oise d oes not ex ist
cleaner to flow into the intak e m anifold. T his air w ith the belt rem oved proceed as follow s:
enters the air/fuel m ixture to lean the rich A seized air pum p.
condition created by high vacuum w hen the
Proper m ounting and bolt torq ue o f pum p.
throttle valve clo ses on d eceleration .
Proper routing and c o n n ectio n s o f hoses.
The vacuum draw s the d eceleration valve
CAUTION: Do not oil air, pum p.
diaphragm dow n and op en s the valve allow in g
air from the air clean er to flow into the intake R eplace pum p if there is e x c essiv e noise.
m anifold. "SERVICE ENGINE SOON" LIGHT
If the "service en gin e so o n light is on w ith the
en gin e running, refer to the proper C-6HD
CHART for d iagn osis.
AIR PUMP
The air pum p is p erm an en tly lubricated and
requires no p eriod ic m aintenence.
A ccelerate en gine and ob serve air flow from
hoses(s). If air flow in crea ses as en g in e is
accelerated , pum p is op eratin g satisfactory. If air
flow d oes not in crease or is not presen t, proceed
as follow s:
Inspect
f T | AIR FLOW AIR CLEANER 1. For proper drive belt ten sion .
l~2~1 EXHAUST GAS | 9 | DECELERATION
VALVE 2. For a leak y p ressu re r elief valve. Air may be
G O EXHAUST VALVE
heard leak in g w ith the pum p running.
f T l INTAKE FLOW H o l MANIFOLD
HT1 INTAKE VALVE VACUUM
I 11 I DIAPHRAGM
AIR CONTROL VALVE
[~6~1 COMBUSTION
CHAMBER f l T ] VALVE Air pum p should be w ork in g properly.
1~7~| VACUUM BLEED D iscon n ect solen oid co n n ecto r at valve. With
VALVE 4S 0507-6E
ignition "on ch eck for 12 volts at the con n ector.
If there is no voltage, refer to the proper C-6HD
Figure 92 Deceleration Control
CHART for d iagn osis. Start en gin e. Air sh ou ld go
to the air clean er or silen cer. C on nect the
DIAGNOSIS solen oid con n ector and air should go to the
AIR SYSTEM e xh au st ports. C heck for m anifold vacuum sign al
at valve with en gin e idling. Vacuum sh ou ld be
NOTICE: If the engine or under h o o d c o m p a r t m e n t
10 Hg (34kpa). D uring d eeel and high vacuum
is to be cleaned with s t e a m or high-pressure
sign al, air sh ou ld go to the air clean er and
detergent, the intake air filter should be m a s k e d
silen cer. R eplace valve if any o f the co n d itio n s
off to prevent liquids from entering the p u m p .
are not correct.
CHECK VALVE ON-VEHICLE SERVICE

I? Inspect AIR WIRING DIAGRAM
1. A ch eck valve should be in sp ected w h en ever Refer to the proper C-6HD CHART for the
the h ose is d iscon n ected from a ch eck valve or w iring diagram for L6 and V8 en gin es.
w h en ever check valve failure is su sp ected (A DRIVE BELT
pum p that had becom e inoperative and had
sh ow n indications o f having ex h a u st g a ses in
4- + Remove or Disconnect
the pum p would in d icate check valve failure).
1. In spect drive belt for w ear, crack s or
2. Blow through the ch eck valve (tow ard the
cylinder head) then attem pt to su ck back deterioration and rep lace if required. When
through the check valve. Flow should only be in stallin g new belt, it m ust be seated and fully
in one direction (tow ard the ex h a u st m anifold). secu red in grooves o f A/C com p ressor, AIR
R eplace valve w h ich d oes not operate pum p, generator, and cran k sh aft p u lleys.
properly. AIR INJECTION PUMP
HOSE AND PIPES FIGURES 93 T H R U 97
15 Inspect *-- Remove or Disconnect

1. H ose or pipe for deterioration or holes. l. Hold pum p pulley from tu rnin g by
2. All h oses or pipe con n ection s, and clam p com p ressin g drive belt, then loosen pum p
tigh tn ess. pulley bolts.
3. H ose or pipe routing. Interference may cau se I. Loosen bolt, holding pum p to m ounting
w ear. brackets, release ten sion on drive belts.
R em ove belt from pulley.
4. If a leak is su sp ected on the pressu re sid e o f the
system or if a h ose or pipe has been 3. D iscon n ect h oses at rear o f pum p.
d iscon n ected on the pressu re sid e, the 4. D iscon n ect vacuum and electrical
con n ection s should be check ed for leak s w ith a con n ection s if control valve is attached to the
soapy w ater solu tion . With the pum p running, pum p.
b u b b les will form if a leak exists. 5. R em ove pum p pulley.
CONTROL MODULE 6. Rem ove pum p.
R efer to the proper C-6HD CHART for 7. R em ove control valve if attached.
d ia g n o sis o f the control m odule.
DECELERATION VALVE Install or Connect
1. R em ove air clean er, plug air clean er vacuum 1. Install pum p with control valve if attached.
sou rce and con n ect tachom eter. 2. C onnect vacuum and electrical co n n ectio n s if
2. With the engine run n in g at sp ecified idle control valve is attached to pum p.
sp eed , rem ove the sm all deceleration valve 3. C on nect h oses at rear o f pum p.
sign al h ose from the m anifold vacuum source. 4. Install pum p pulley bolts and tighten eq u ally
3. R econ n ect the sign al h ose and listen for air to 15 N.m (10 lb.-ft.). T ighten again w ithin 10
flow through the ventilation pipe and into the m inutes to 15 N.m (10 lb.-ft.). u sin g a click
d eceleration valve. There should also be a w rench, port-a-torque or other eq u iv a len t
n oticeab le speed drop w hen the sign al hose is tool.
recon n ected . 6. Install pum p drive belt and adjust ten sion.
4. If the air flow d oes not con tin u e for at least one AIR CONTROL VALVE
secon d or the en gin e speed d o es not drop
FIGURES 93 T H R U 97
noticeab ly, ch eck the deceleration valve h oses
for resitriction s or leak s.
5. If no restriction s or leak s are found, rep lace
1. E lectrical conn ector from solen oid .
the d eceleration valve.
2. Air outlet hoses from valve.
3. M anifold vacuum hose.
4. Air control valve, g ask ets and adapter.
Install or Connect FILTER

F I G U R E 93 T H R U 97
1. G ask ets, adapter and air control valve.
2. M anifold vacuum hose.
3. Air outlet h oses to valve w ith clam ps.
1. Filter from bracket.
4. E lectrical con n ector to solenoid.
2. H ose from air in tak e and pum p.
CHECK VALVE
F IGURES 93 T H R U 97
Install or Connect
1. H ose from air in tak e and pum p.
1. A ny parts required for a ccess to valve.
2. Filter to bracket.
2. R elease clam p and d isco n n ect air h o ses from
ch eck valve.
3. V alve from bracket. SILENCER-4.8L
FIG UR E 93
4. U n screw ch eck valve from air injection pipe.
1. H ose from silen cer.
2. silen cer from bracket.
1. Screw check valve onto air injection pipe.
2. V alve to bracket
Install or Connect
3. Position air h ose on ch eck valve and secu re
1. silen cer to brack et
w ith clam p.
2. H ose to silen cer.
4. A ny parts rem oved for access.
DECELERATION VALVE
AIR INJECTION PIPE ASSEMBLY FIGURES 98 O R 101
FI G U R E 93 T H R U 97
1. Vacuum h oses from valve.
1. H ose from ch eck valve.
2. S crew s secu rin g valve to bracket.
2. C heck Valve
3. N uts attach in g pipes-to-m anifold
4. P ipe A ssem bly -*+ Install or Connect
2. S crew s secu rin g valve to bracket.
1. N uts attach in g pipes-to-m anifold
3. Vacuum h oses to valve.
2. C heck Valve
3. H ose to ch eck valve with clam p.
P T l A .I.R . PUMPT IG H T E N M O U N TIN G f l T ] HOSESILENCER TO A IR C O NTRO L V A L V E

----- SCREWS TO 25 N-m (18 FT. LBS.)
n n HIGH FLOW ELECTRIC A IR CO N TR O L V A L V E -
|~ 2 l CHECK V A L V E T IG H T E N NUT TO T IG H T E N A T T A C H IN G BOLTS TO 10 N-m (94 IN . LBS.)
35 N-m (26 FT. LBS.)
[T~| SILENCER
| 3 [ A IR INJECTIO N PIPET IG H T E N NUTS
[~ 8 l F ILT E R
TO 28 N-m (20 FT. LBS.)
| 9 | DUCT (D R A IN HOLE MUST PO INT DOWNWARD)
|~4~| H O S E -A IR C O NTRO L V A L V E TO CHECK V A L V E
PTol HOSEF IL T E R TO PUMP
10 15 84 5S 1958-6E
Figure 93 AIR System - 4.8L E ngine

| ~ n P U L L E Y T IG H T E N SCREWS TO 15 N-m (10 FT. LBS.). | 6 | H O S E -A IR C O N TR O L V A L V E TO A IR CLEA N ER

T IG H T E N A G A IN W IT H IN 10 M INUTES TO 15 N-m [~7~| CHECK V A L V E T IG H T E N N U T TO 35 N-m (25 FT. LBS.)
(10 FT. LBS.)
f~8~] A IR INJECTIO N PIPET IG H T E N NUTS TO 25 N-m
[~ 2 ] A .I.R . PUMPT IG H T E N M O U N TIN G SCREWS (18 FT. LBS.)
----- TO 50 N-m (36 FT. LBS.)
n r i F IL T E R -D R A IN HO LE ON IN L E T HOSE MUST PO INT
| T 1 A D A P T E R T IG H T E N SCREWS TO 25 N-m (18 FT. LBS.) ----- DOWNWARD
[~ 4 l A IR CO N TR O L V A L V E T IG H T E N SCREWS TO [T o ] HOSEF ILT E R TO PUMP
25 N-m (18 FT. LBS.)
|~5~l H O S E -A IR CO N TR O L V A L V E TO CHECK V A L V E
10 15 84 5S 1959-6E
Figure 94 AIR System - 5.7L (CK)

6E8-150 DRIVEABIUTY AND EMISSIONS-CARBURETED
[T J p U L L E Y -T IG H T E N SCREWS TO 15 N-m (10 FT. LE ) | 5 | HO SE-PUM P TO A IR CONTRO L V A L V E

T IG H T E N A G A IN W IT H IN 10 M INUTES TO 15 N-m
(10 FT. LBS.). f~6~] CHECK V A L V E T IG H T E N NUT TO 35 N m
(26 FT. LBS.)
m A .I.R . PUM P-TIGHTEN M O UNTING
----- SCREWS TO 25N-m (18FT.LBS). 7~1 H O S E -A IR
[~ CO NTRO L V A L V E TO CHECK V A L V E
[~8~| AIR INJECTIO N PIPET IG H T E N NUTS TO 28 N-m
f T l A D A P T E R T IG H T E N SCREWS TO 25 N m
(20 FT. LBS.)
(18 FT. LBS.)
m A IR C O N TR O L V A L V E T IG H T E N SCREWS TO
RT| F IL T E R -D R A IN
HOLE IN IN L E T HOSE MUST
PO INT DOWNWARD
25 N-m (18 FT. LBS.)
10 15 84 [TO] H O S E -F IL T E R TO PUMP 5S 1960-6E
Figure 95 AIR System - 5.7L (G)

r n P U L L E Y TIG H TEN SCREWS TO 15 N m (10 FT. LBS.) f T I H O S E -A IR CO N TRO L V A LV E TO CH ECK V A LV E

TIG H TEN AGAIN WITHIN 10 MINUTES TO 15 N m f T I CH ECK V A L V E TIG H TEN NUT TO 35 N-m
(10 FT. LBS.)
(26 FT. LBS.).
f T I A.I.R. PUMPTIG H TEN MOUNTING SCREWS TO | 8 |A IR INJECTION PIPETIG H TEN NUTS TO 28 N-m
50 N m (36 FT. LBS.) (20 FT. LBS.)
flT ] A IR CO N TRO L V A L V E TIG H TEN SCREWS |~ 9 l F IL T E R -D R A IN HOLE ON IN L E T HOSE MUST
----- TO 25 N m (18 FT. LBS.) POINT DOWNWARD
[~4~1 HOSE-PUM P TO A IR CO N TRO L V A LV E fT0~| HOSEF IL T E R TO PUMP
| 5 |H O S E -A IR CO N TRO L V A LV E S TO A IR C LE A N E R
10 1584 5S 1971-6E
Figure 96 AIR S y stem -5 .7 L (P)
m C H ECK V A L V E TIG H TEN TO A.I.R. PUMPTIGH TEN MOUNTING SCREWS

35 N-m (26 FT. LBS.) TO 25 N m (18 FT. LBS.)
H O S E -V A L V E TO CH ECK V A LV E
D H O S E -V A L V E TO A IR C LEA N ER
A IR CO N TRO L V A L V E TIG H TEN MOUNTING A IR INJECTION PIPE (TIGHTEN NUTS TO 28 N m/
SCREWS TO 25 N m (18 FT. LBS.) 20 FT. LBS.) RIG H T SH O W N -LE FT SIM ILAR
10 1584
5S 1961-6E
Figure 97 AIR System - 7.4L E ngine
CONTROL MODULE CONTROL RELAY (7.4L ONLY)
FIGURES 102 OR 106 FIGURES 103, 105, or 106
|++| Remove or Disconnect Remove or Disconnect

1. E lectrical connector. 1. E lectrical connector.
2. Control m odule. 2. Control m odule.
-4- Install or Connect + 4- Install or Connect

1. Control m odule. 1. Control m odule.
2. E lectrical con nector. 2. E lectrical connector.
[ T ] H O SE-M A N IFO LD [T ]D E C E L E R A T IO N V A LV E
VACUUM [ T ] H O S E - A IR C LEA N ER -TO
\~T\ HOSEV A LV E-TO -IN TA KE V A LV E
M ANIFOLD
10 15 84 5S 1965-6E
Figure 100 D eceleration V alve - 4.8L
IT ] D EC ELER A TIO N [~3~1 H O S E -V A LV E -T O

----- V A LV E IN TA KE M ANIFOLD
m H O SE-M A N IFO LD [~4j H O S E -A IR CLEA N ER -
----- VACUUM TO -V A LV E
10 15 84 5S 1963-6E
F igure 98 D eceleration Valve
PH D E CELER A TIO N f n H O SE-M A N IFO LD

V A LV E -----VACUUM
[ T ] H O S E -A IR C LE A N E R - [ T I h o s e - v a l v e -t o -
TO -V A LV E IN TA KE M ANIFOLD
10 15 84 5S 1962-6E
Figure 101 D eceleration Valve - 7.4L
H I D EC ELER A TIO N [TJ H O S E -V A L V E TO

VA LV E IN TA KE M ANIFOLD
r y i H O S E -A IR C LE A N ER - [ T ] H O SE-M A N IFO LD
----- -TO -V ALVE VACUUM
10 15 84 5S 1964-6E
Figure 99 D eceleration V alve - 4.3L
[ T j CO N TRO L MODULE
f Y lN U T (TIGHTEN TO
-----20 N-m/15 FT. LBS.)
5S 1968-6E
Figure 104 Control M od u le-4.8L
r n CONTROL M ODULE Q T] BRACKET

[T 1 ENGINE W IRING [T ] CO NTRO L RELAY
HARNESS (7.4L ENGINE)
10-7-85 5S 1966-6E
Figure 105 Control M odule - 5.7L/7.4L (CK)
[~H CONTROL M O D ULE [T ] BRACKET

m ELECTRICAL [T ] DASH A N D TOE PANEL
CONNECTOR j- y j CONTRO L RELAY
(7.4L ENGINE)
10-7-85 5S 1969-6E
Figure 103 Control M odule - 5.7L/7.4L (P42)
r n CONTROL M O DULE m BRACKET

m ELECTRICAL r~4~| CONTROL RELAY
CONNECTOR
10-7-85 5S 1970-6E
Figure 106 Control M odule - 7.4L (P32)

CHART C-6HD-1
5.7L ENGINE
SERVICE ENGINE SOON" LIGHT IS ON
The illum ination o f the "Service E ngine S oon ligh t in d ica tes that
there is a m alfunction in the solen oid , control m odule, or w iring.
C heck solenoid and m odule con n ectors for proper con n ection .
1. D iscon n ect Air T em perature Sw itch and 3. C on nect solen oid co n n ecto rs and d isco n n e ct
in stall a jum p er w ire across the term inals. both co n n ecto rs at C ontrol M odule. C heck for
a light b etw een term in als "A and "B o f the 5
2. With ignition on, d isco n n e ct each solenoid
pin con n ector.
con n ector and w ith a test light, check for a
light from the p ink/black w ire to ground. If the test light d oes not illu m in ate, ch eck for
an open circu it to the m odule.
If ligh t d oes not illum inate, check for an
open in circu it 39 to the solen oid . If the test ligh t illu m in ates, ch eck for a ligh t
betw een 5 pin co n n ecto r h arn ess term in als
If light illum inates, ch eck for a light across
"A and "D.
term inals. Circuit is O.K. if there is a light.
C heck solen oid coil resistan ce and if less If the test light illu m in ates, ch eck for a
than 20 ohm s, replace solenoid and valve. If short to ground in circu it 419.
there is no light, ch eck for an open in circuit If the test ligh t d o es not illum inate, ch eck
900 to the Air T em perature Sw itch, an open for an open in circu it 900 b etw een the
in circuit 436 or faulty Control M odule. solen oid term inal "B and the m odule 2
pin con n ector term in al "A. If circu it 900
is not open, rep lace the Control M odule.
CHART C-6HD-2
7.4L ENGINE
(Vehicle Over 8500 GVW)
"SERVICE ENGINE SOON" LIGHT IS "ON"
The illum ination o f the "Service E ngine Soon light in d icates that there is a
m alfunction in the solen oid , control m odule, control relay or w iring.
B efore d ia g n o sis, check the solen oid and m odule con n ectors for proper
con n ection .
1. T his step is to determ in e if there is p ow er to 4. This step w ill determ in e if the problem is a
the Air T em perature Sw itch. short to ground in the "Service E ngine S oon
light circu it or a m alfunction in the Air
2. T his step will in su re th at there is p ow er to the
M anagem ent System .
circu it by elim in atin g the Air T em perature
Sw itch. 5. This step ch eck s for Bat. ( + ) at "A and a
ground at "B, to pow er up the Control
This step will also ch eck the w irin g betw een
M odule.
the Air T em perature Sw itch and the
S olen oid s. 6. This step w ill determ in e if a ground sign al is
sent to the relay b ecau se CKT 919 is grounded
3. T his step w ill ch eck the w irin g b etw een the ou tsid e the m odule.
so len o id s and ground in clu d in g the circu it
in sid e the Control M odule. 7. This step ch eck s for a Tach sign al to the
Control M odule
DISCONNECT AIR TEMPERATURE SWITCH

IGNITION "ON," ENGINE STOPPED
WITH A TEST LIGHT, CHECK FOR A LIGHT FROM THE
PINK/BLACK WIRE TO GROUND.
CHART C-6HD-2
SERVICE ENGINE SOON" LIGHT
"O N " AT ALL TIMES
LIGHT "OFF"
LIGHT "ON" 7.4L ENGINE

........... I'
INSTALL A JUMPER WIRE ACROSS THE AIR
TEMP. SWITCH CONNECTOR TERMINALS.
' DISCONNECT EACH SOLENOID CONNECTOR
AND WITH A TEST LIGHT. CHECK FOR A LIGHT
__ L___
REPAIR OPEN
IN CKT 39 TO
THE SWITCH
CARBURETED
FROM THE YELLOW WIRE TO GROUND.
LIGHT " O N " A T B O T H LIGHT "OFF" AT ONE OR BOTH

X
CHECK FOR A LIGHT ACROSS THE REPAIR OPEN IN CKT 900 TO THE
TERMINALS (BOTH CONNECTORS) SOLENOID
LIGHT " O N " A T B O T H C O N N E C T O R S LIGHT " O F F " A T O N E OR B O T H
I
USING AN OHM METER, CHECK THE CHECK FOR OPEN IN CKT 436
RESISTANCE OF EACH SOLENOID COIL IF OK, REPLACE CONTROL MODULE
20 OHMS OR GREATER LESS THAN 20 OHMS

I ZZ ZZ Z X Z Z Z Z I
RECONNECT BOTH SOLENOID CONNECTORS REPLACE THE VALVE ASSEMBLY
START ENGINE AND DISCONNECT CONTROL RELAY
NOTE "SERVICE ENGINE SOON" LIGHT
LIGHT "OFF' LIGHT "ON'

f
USING AN OHM METER, CHECK FOR CONTINUITY REPAIR SHORT TO

BETWEEN TERMINALS "A" AND "D" OF THE HARNESS. GROUND IN CKT 419
NO CONTINUITY CONTINUITY
DISCONNECT CONTROL MODULE CONNECTOR REPLACE CONTROL RELAY

USING A TEST LIGHT, CHECK FOR A LIGHT BETWEEN
TERMINALS "A" AND "B" OF THE HARNESS
| ................ L_...
LIGHT" ON" LIGHT "OFF"
CHECK FOR A LIGHT BETWEEN TEMINALS CHECK FOR OPEN IN CKT 900
"A" AND "D" OF THE HARNESS. OR CKT 150 TO THE MODULE
1
LIGHT "OFF" LIGHT "ON'
I ...........T ....
START ENGINE
USING A TEST LIGHT, CHECK FOR A FLICKERING LIGHT
BETWEEN HARNESS TERMINAL "C" AND GROUND
REPAIR SHORT TO
GROUND IN CKT 919
1
LIGHT "FLICKERS' LIGHT DOES NOT"FLICKER'
r
REPLACE CONTROL MODULE REPAIR OPEN IN CKT 121
10-18-85
6S 2994
CONTROL
MODULE
10-18-85
*6S 2919-6EA
CHART C-6HD-3
4.8L ENGINE
SERVICE ENGINE SOON" LIGHT IS ON
The illum ination of the "Service E ngine S oon light in d icates that
there is a m alfunction in the solen oid , control m odule, or w iring.
C heck solen oid and m odule con n ectors for proper con n ection .
1. D isconnect Air T em perature S w itch and 3. C on nect solen oid co n n ector and d isco n n e ct
install a jum per wire across the term inals. both co n n ecto rs at C ontrol M odule. C heck for
a light b etw een term in als "A and "B o f the 5
2. With ignition on, d isco n n e ct solenoid
pin con n ector.
con n ector and w ith a test light, ch eck for a
light from the p ink/black w ire to ground. If the test light d o es not illum inate, ch eck for
an open circu it to the m odule.
If light d oes not illum linate, ch eck for an
open in circuit 39 to the solen oid . If the test light illu m in ates, ch eck for a light
b etw een 5 pin co n n ector h arn ess term in als
If light illum inates, ch eck for a light across
"A and "D.
term inals. Circuit is O.K. if there is a light.
C heck solenoid coil resistan ce and if less If the test ligh t illu m in ates, ch eck for a
than 20 ohm s, rep lace solenoid and valve. If sh ort to ground in circu it 419.
there is no light, ch eck for an open in circuit If the test light d o es not illum inate, ch eck
936 to the Air T em perature Sw itch, an open for an open in circu it 936 b etw een the
in circuit 436 or faulty Control M odule. solen oid term inal "B and the m odule 2
pin co n n ector term inal "A. If circu it 936
is not open, replace the Control M odule.
BLANK
. J
' i - ; 'V
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

ALL ENGINES EXCEPT 4.8L & 7.4L FED
GENERAL DESCRIPTION
PURPOSE
The EGR system is used to lower NOx (oxides
of nitrogen) emission levels caused by high
combustion temperatures. It does this by
decreasing combustion temperature.
The EGR system has a negative backpressure
EGR valve (Figure 107), hose from a ported
manifold vacuum source and a method to control
the vacuum source. On an engine without an
ECM, a coolant temperature TVS is used to HI EGR VALVE m
DQ
VACUUM CHAMBER
control vacuum and on an engine with an ECM, a m EXHAUST GAS VALVE RETURN SPRING
solenoid is used to control vacuum.

H INTAKE FLOW MO I THERMAL VACUUM SWITCH
n n VACUUM PORT ITT! COOLANT
[ 7 1 THROTTLE VALVE I
(12 DIAPHRAGM
OPERATION '----- AS 0002-6 E
On an engine without an ECM, the Figure 108 EGR System w ith TVS
thermostatic vacuum switch (TVS) blocks On an engine with an ECM, a vacuum solenoid
vacuum to the EGR valve during cold engine energized by a signal from the ECM block
operation (Figure 108). vacuum to the EGR valve during cold engine
operation, cranking and at wide-open throttle
(Figure 109).
H I EGR VALVE ' 1 VACUUM SENSOR

I D EXHAUST GAS
n n COOLANT TEMPERATURE
f~3~i INTAKE AIR SENSOR
[~4~ DIAPHRAGM ~ THROTTLE POSITION
[T 1 EGR VALVE | 6 | AIR BLEED
HOLE [j5 ~ j MANIFOLD VACUUM SENSOR
1 2 | EXHAUST GAS [ I T VACUUM SOLENOID [TcT ELECTRONIC CONTROL
[X I INTAKE AIR |T1 SMALL SPRING MODULE
G O VACUUM PORT f i n LARGE SPRING 6S 2607-6E
m DIAPHRAGM 4S 0 1 13-6E
Figure 107 N egative B ack p ressu re EGR V alve Figure 109 EGR System - with Solenoid
EGR Bleed Solenoid

When the en gin e is warm , the TVS op en s or the
On 5.0L and 5.7L Federal en g in es w ith light
solen oid d e-en ergizes w hich op en s the vacuum
duty em ission s and autom atic tran sm ission , an
sou rce to the EGR valve. At idle or w ide-open
EGR bleed solen oid is con n ected in the
throttle, there is little or no vacuum from the
transm ission converter clutch circuit. When the
vacuum sou rce, the EGR pintle is closed and
transm ission converter clu tch ap p lies, the
there is no ex h a u st gas recircu lation . When the
solenoid is energized and the vacuum to the EGR
en gin e is ab ove idle sp eed , the pintle valve rises
valve is reduced to about h alf norm al value.
and a sm all am ount o f exh au st gas goes into the
com b ustion cham ber. The negative
b ack p ressu re valve varies the am ount of exh au st DIAGNOSIS
gas flow into the m anifold d e p e n d in g on m anifold EGRSYSTEM
vacuum and variations in exh au st b ack p ressu re. Too m uch EGR flow ten ds to w eak en
com bustion, cau sin g the en gin e to run roughly or
The diaphragm on the valve has an internal air stop. With too m uch EGR flow at idle, cru ise, or
bleed hole w h ich is held closed by a sm all sprin g cold operation, any of the follow in g co n d ition s
w hen there is no ex h a u st b ack p ressu re. may happen:
E ngine vacuum op en s the EGR valve again st E ngine stop s after cold start.
the p ressu re o f a large spring. When m anifold E ngine stop s at idle after deceleration .
vacuum com b in es w ith n egative exh au st V ehicle su rges d u ring cruise.
b ack p ressu re, the vacuum bleed hole op en s and
the EGR valve closes. Rough idle.
If the EGR valve sh ou ld stay open all o f the
T his cycle occu rs ap p roxim ately forty tim es tim e, the en gin e may not idle.
per secon d d u rin g norm al en gin e operation.
Too little or no EGR flow allow s com b ustion
tem peratures to get too high during acceleration
If there is en ou gh vacuum sign al from the
and load con d ition s. This could cause:
vacuum sou rce to op erate the EGR valve, the
pintle valve cy cles at a greater vaive op en in g Spark knock (detonation).
w hen ex h a u st m anifold p ressu re is high, and E ngine overheating.
intak e m anifold vacuum is fairly low , and will
Em ission test failure.
cycle at a low er valve op en in g w hen exh au st
m anifold p ressu re is low , and intak e m anifold System Check
vacuum is high.
D iagnosis o f the EGR system is covered in
charts at the end of this system .
On en g in es w ith an ECM, the EGR System is
called "P ulse Width M odulation (PWM), w h ich CHART C-7A for P u lse Width M odulated
m eans the ECM turns the solen oid "ON and EGR System C heck - ECM C ontrolled.
"OFF m any tim es a secon d and varies the C H A R T C-7C for EGR System C heck - Non-
am ount of "ON time (P u lse Width) to vary the ECM Controlled.
am ount o f ex h a u st gas recircu lation .
EGR VALVE ON-VEHICLE SERVICE

Refer to EGR System C h ecks at the end of this CLEANING MANIFOLD PASSAGE
section for d ia g n o sis o f the EGR valve.
The valve w ill open if vacuum is ap plied with I? Inspect
the en gin e not running. If EGR p assages in the inlet m anifold indicate
ex cessiv e build-up of d ep osits, the p a ssa g es
VACUUM SOLENOID should be cleaned. Care should be taken to
ensu re that all loose particles are com p letely
Refer to EGR System C heck in CHART C-7E
rem oved to prevent them from cloggin g the EGR
for d iagn osis of the vacuum solenoid.
valve or from being in gested into the engine.
EGR BLEED SOLENOID Do not w ash EGR valve in so lv en ts or
d egreaser - perm anent dam age to valve
Refer to EGR Bleed S olenoid in Chart C-7D to
diaphragm may result. A lso, sand b lasting o f the
check d ia g n o sis of the solen oid . valve is not recom m ended sin ce this can affect
the operation of the valve.
System Hoses
A therm al vacuum sw itch opens, clo ses, or
sw itch es vacuum sou rce w hen the calibration Refer to V ehicle Em ission Control Inform ation
tem perature is reach ed . The follow in g general label for routing of system hoses.
ch eck in g p roced u res can be used for all therm al When rep lacin g h oses, use hose id en tified with
vacuum sw itch es. R efer to num ber stam ped on the word "Fluoroelastrom er.
base o f valve or sw itch for calibration EGR VALVE
tem perature.
Identification
1. A llow TVS to cool below calibration Refer to Figure 110 to identify a n egative
tem perature. b ack p ressu re EGR valve.
2. In spect sw itch to m ake sure it is in good
condition. Remove or Disconnect
3. C on nect vacuum gage(s) to output port (s) 1. Air Cleaner.
o f the TVS. (See vacuum hose sch em atic 2. EGR valve vacuum hose at valve. (Figure
on V ehicle Control E m ission Inform ation 111 or 112).
label). 3. Bolts.
4. Com pare vacuum gage reading(s) w ith the 4. EGR valve from m anifold.
proced u res and in the TVS d escrip tio n s
given under each valve nam e.
5. H eat TVS to a tem perature ab ove the
calibration tem perature. N ever apply a
torch or open flam e d irectly to the TVS.
6. C om pare vacuum gage read in g to the
correct readin g indicated on sw itch or
valve base.
NOTICE; Leakage of up to 7 kPa (2" H G )
v a c u u m in 2 minutes is allowable a n d does [T 1 ASSEMBLY PLA N T CODE
not m e a n a defective part. j 2 | PART NUMBER

j 3 1 DATE B U ILT
7. If operation is satisfactory, re-install valve f T I LOOK HERE FOR LETTER
or sw itch . If valve or sw itch is d efective, P = POSITIVE BACK PRESSURE
N = N E G A TIV E BACK PRESSURE
rep lace w ith a n ew part. B L A N K = PORTED V A L V E
4S 0538-6E
Figure 110 EGR V alve Identification
U J EGR V A L V E
I 2 ! V A C U U M SO LE N O ID
04 06 84 [~3~] CARB PORT J " 5S 1538-6E
Figure 111 EGR V alve & Solenoid - 4.3L Cal. Figure 113 EGR Bleed Solenoid
-*+ Install or Connect Install or Connect

1. Solenoid and bracket. T ighten nut to
1. EGR valve to m anifold (use n ew gasket).
24 N-m (17 ft. lbs.).
2. Bolts.
2. Vacuum hoses.
3. V acuum h ose to EGR valve.
4. Air cleaner. 3. E lectrical con n ector.
EGR VACUUM SOLENOID 4. Air cleaner.

FIGURE 111 OR 112 5. N egative battery cable.
Remove or Disconnect EGR BLEED SOLENOID

1. N egative battery cable. FIGURE 113
2. Air cleaner.
3. E lectrical co n n ector at solen oid . Remove or Disconnect
4. V acuum h oses. 1. N egative battery cable.
5. Nut and solen oid .
2. Air cleaner.
3. Electrical con n ector at solen oid .
4. Vacuum h oses.
5. Nut and solen oid .
Solenoid and bracket. T ighten nut to
24 N-m (17 ft. lbs.).
2. Vacuum h oses.
3. E lectrical con n ector.
4. Air cleaner.
5. N egative battery cable.
m EGR V A L V E [~2~| VA C U U M SO LENO ID
04 26 85 6S 2606 6E
Figure 112 EGR V alve & Solenoid - 5.0L/5.7L Cal.


FIGURES 114TO 116
Replacement
1. Drain coolan t b elow level of therm ostatic
vacuum sw itch (TVS).
3. R em ove TVS.
4. Install rep lacem en t TVS w ith soft settin g
sealan t applied to male th read s. Sealan t
should not be on end of TVS.
5. Tighten TVS to 14 N-m (120 in. lbs.) then m EGR V A L V E m TVS (DIST) EFE
turn c lo c k w ise as required to align with l"y~l TVS (EGR) 4S 1049-6 E
hoses. Figure 115 TVS Location,5.0L-LE9, Federal,

6. C onnect vacuum hoses. 5.7L-LS9, Federal, 5.7L-LT9,California
7. Add coolan t as required.
4S 1050-6 E
Figure 114 TVS Location, 4.3L, Federal Figure 116 TVS Location, 7.4L-LE8, C alifornia
PARTS INFORMATION
PARTS NAME GROUP
V a l v e ................................................................. 3.670
Solenoid, EGR cont VLV RLY ( 1 4 ) .......... 3.670
G asket, EGR Valve (1 5 )................................ 3.680
CHART C-7D
EGR BLEED SOLENOID CHECK
5.0L or 5.7L ENGINE - FEDERAL WITH
LIGHT DUTY EMISSIONS AND AUTOMATIC
TRANSMISSION
1. D isco n n ect EGR bleed solen oid connector.

6. Start en gin e. There sh ou ld be no vacuum
2. C on nect a test ligh t from solen oid term inal reading. R ep lace solen oid if there is a
"A to ground. reading.
3. With the ignition "ON and en gin e stop p ed , 7. C onnect a test light from solenoid term inal
the test ligh t sh ou ld illum inate. If not, there is "B to ground. Solenoid should energize and
an open in the circu it to the ignition sw itch. there should be a full vacuum reading.
R eplace solen oid as required.
4. C onnect solen oid con n ector.
8. C on nect a test ligh t from term inal "D at the
5. D isco n n ect vacuum h ose from solen oid to the TCC solen oid to ground. Solenoid sh ou ld
EGR valve and co n n ect a vacuum gage to en ergize and there sh ou ld be a full vacuum
solen oid . readin g. If not, there is an open in circu it 386.
_____________i l l J1_____________
m i mi l im
! ] j| m i i i i i i i i rr
A
m
B
SOLENOID
I.P. CONNECTOR (FRONT CONNECTOR
FRONT VIEW
VIEW)
CHART C-7E
PULSE WIDTH MODULATED (PWM) EGR SYSTEM CHECK
PWM EGR is an ECM control that p u lses the vacuum sign al to
the EGR. This is accom p lish ed through a norm ally open EGR
solen oid w h ich w hen energized by the ECM sh u ts o ff the vacuum
to the EGR valve diaphragm . T his system can p u lse the solen oid
m any tim es per secon d (PWM). The EGR solen oid is alw ays
energized (EGR off) w hen any one o f the follow in g co n d ition s are
m e t:
Throttle Position greater than sp ecified .
C oolant tem perature less than sp ecified .
1. C hecks to see if the EGR p a ssa g es are valve sh ou ld m ove if EGR control system is
restricted or if the valve is stu ck open. fu n ction in g properly.
2. A cold engine is sim ulated by d isco n n ectin g 5. If vacuum is b elow 23.6 k P a ( 7 Hg ) at 2000
the coolan t tem peratu re sen sor w h ich will RPM w ith EGR solen oid electrical con n ector
also energize the EGR solen oid . d isco n n ected , a leak or restriction betw een
3. With the 4 w ire EST con n ector d isco n n ected , test p oint ( EGR diaphragm ) and so u rce is
the ECM thin ks the en gin e is not running. e v id e n t.
G rounding the test term inal, und er this 6. C h ecks EGR solen oid electrical control
condition, c a u se s the ECM to pu lse the EGR circuit. T he test light sh ou ld "flicker faintly" if
solenoid "ON" and "OFF" for testin g w h ich the ECM, h arn ess and co n n ectio n s are OK.
will resu lt in a con trolled vacuum su p p ly to "Flicker faintly" refers to a sligh tly p u lsin g
the EGR valve diaphragm at 2000 RPM. glow as op p osed to a "bright ste a d y glow
4. By d isco n n ectin g EGR solen oid electrical from a con tin u ou s ground path .
connector , control by the ECM is overridden
and the norm ally opened EGR solen oid will
I Steps 1, 2, and 3 rep resen t an EGR system I
p ass available v a c u u m . At 2000 RPM EGR
I operation check.
CHART C-7E
r ---------------------------------------------------------------------------------------------------------------------------1
INSTALL TACHOMETER PWM EGR SYSTEM CHECK
o START ENGINE D O N O T GROUND DIAGNOSTIC "TEST" TERMINAL ..
WITH ENGINE AT NORMAL OPERATING TEMPERATURE CHECK FOR
(PULSE WIDTH MODULATED
PORTED VACUUM ON SOURCE (ENGINE) SIDE OF EGR SOLENOID . EXHAUST GAS RECIRCULATION)
SHOULD BE OVER 23.6 kPa { 7" HG ) AT 2000 RPM .(IF NOT OK ,
REPAIR .THEN CONTINUE). 4.3L, 5.0L, or 5.7L SERIES
WITH ENGINE IDLING , RPM SHOULD DROP AS EGR VALVE IS OPENED
BY PUSHING UP ON UNDERSIDE OF EGR DIAPHRAGM . CARBURETED - CALIFORNIA
\------------------- 1
i RPM DROPS i NO CHANGE
L j: : :: : : J 1 ______
' ^CONNECT VACUUM GAGE IN PLACE OF EGR VALVE DIAPHRAGM .

J TRANSMISSION IN NEUTRAL.
i GROUND DIAG. "TEST" TERMINAL AND DISCONNECT COOLANT SENSOR,
CLEAN EGR PASSAGES, OR
REPLACE VALVE IF NECESSARY
i OBSERVE VACUUM READING AT 2000 RPM . IT SHOULD BE ZERO .
i OK ' NOT OK
T I
REPEAT ABOVE CHECK WITH 4 TERMINAL EST CONNECTOR DISCONNECT EGR SOL. ELECT. CONNECTOR
DISCONNECTED AND DIAG. "TEST" TERMINAL GROUNDED.
MANUAL TRANSMISSION RECONNECT COOLANT SENSOR.
INSTALL TEST LIGHT BETWEEN CONN.TERMS
OBSERVE TEST LIGHT WITH ENGINE RUNNING
VACUUM SHOULD BE AT LEAST 10 kPa (3" HG) AT 2000 RPM
f -------- 1 1 LIGHT "ON" LIGHT OFF'

' OK i NOT OK
T REPLACE EGR
RECONNECT VACUUM
HOSE TO EGR VALVE .
DISCONNECT EGR
SOLENOID ELECTRICAL
DISCONNECT EGR
SOLENOID CONNECTOR .
OBSERVE VACUUM GAGE
READING AT 2000 RPM.
SOLENOID
CONNECTOR. SHOULD BE OVER 23.6

CHECK FOREGRVALVE kPa (7" HG).
MOVEMENT AT 2000 RPM
EGRVALVE SHOULD CONNECT TEST LIGHT FROM
MOVE . EACH EGR CONN. TERM. TO
GRD. AND NOTE LIGHT.
r ---- 1 1
t
:i
OK i NOT OK
1
NOT OK
X OK
nz LIGHT "ON" LIGHT "OFF"
NO
TROUBLE
FOUND
FAULTY
EGR VALVE
REPEAT TEST
WITH GAGE
CONNECTED
CONNECT TEST LIGHT
BETWEEN EGR SOLENOID
HARNESS CONN. TERMS
ONE OR BOTH
TERMS.
EITHER
TERMINAL
** ON EGR SIDE OBSERVE TEST LIGHT.
OF SOLENOID CHECK CKT REPAIR
FROM ECM OPEN IGN
TERM. "1 9 ". CKT. TO
TO EGR SOL. EGR SOL.
IF NO TROUBLE OK NOT OK BRIGHT LIGHT TERM. "B" TERM. "A"
FOUND AND STEADY FLICKERS ,FOR OPEN
ROUGH IDLE STILL LIGHT FAINTLY . OR SHORT
EXISTS, MAKE TO "B" + , IF
PHYSICAL CHECK OK, SEE
FOR LOOSE EGR CHART C-1
VALVE REPAIR REPLACE CHECK FOR CHECK
ASSEMBLY. VACUUM EGR SOL. GND CIRCUIT. CONN. AT
HOSE FROM ECM EGR SOL.
TO EGR ERM. "B"
FROM
SOL.TERM. IF CONN. IS
SOL. TO "B" AND GOOD
EGR CHECK CONN. REPLACE
VALVE. IFCKT. AND FAULTY
CONNS ARE SOLENOID.
GOOD,
REPLACE
FAULTY EGR
SOLENOID.
85' 3-26-85
6S2538-6E
CHART C-7C
EGR SYSTEM CHECK
ALL ENGINES
WITHOUT ECM
CARBURETED HOLD TOP OF EGR VALVE AND TRY TO ROTATE
TOP OF VALVE BACK AND FORTH.
1
NO LOOSENESS F E L T IF LOOSENESS IS FELT
I
PLACE TRANSMISSION IN P/N. REPLACE EGR VALVE
RUN WARM ENGINE AT IDLE, ENGINE TEMP ABOVE 910C/195F.
PUSH UP ON UNDERSIDE OF EGR VALVE DIAPHRAGM. RPM SHOULD DROP.
1
RPM DROPS NO RPM CHANGE
I
* CHECK FOR MOVEMENT OF EGR VALVE DIAPHRAGM CLEAN EGR PASSAGES OR
AS RPM IS CHANGED FROM APPROX. 2000 RPM TO IDLE. REPLACE VALVE AS NEEDED
X
DOESN'T MOVE MOVES
I
CHECK VACUUM AT EGR VALVE AS ENGINE RPM IS NO TROUBLE FOUND
CHANGED TO APPROXIMATELY 2000 RPM.
1.
UNDER 20 kPa (6 INCHES HG) OVER 20 kPa (6 INCHES HG)
CHECK VACUUM HOSES FOR RESTRICTIONS, REPLACE EGR VALVE

LEAKS, AND CONNECTIONS.
X
OK NOT OK-REPAIR
CHECK TVS OPERATION.

REMOVE CARB. TO TVS SWITCH HOSE FROM SWITCH
AND CONNECT HOSE TO VACUUM GAGE.
CHECK VACUUM AT APPROX. 2000 RPM.
UNDER 33 kPa (10 INCHES HG) OVER 33 kPa (10 INCHES HG)
CHECK FOR PLUGGED HOSE OR REPLACE TVS

CARBURETOR PASSAGE.
10-22-85 4S0611 -6E

TRANSMISSION CONVERTER CLUTCH (TCC) SYSTEM

CALIFORNIA ONLY
GENERAL DESCRIPTION
PURPOSE Throttle P osition S en sor (TPS). A fter the
The T ran sm ission C onverter C lutch (TCC) converter clu tch a p p lies, the ECM u ses the
System u ses a solen oid op erated valve in the inform ation from the TPS to release the clutch
autom atic tran sm ission to co u p le the en gin e
w hen the veh icle is a cceleratin g or
fly w h eel to the outp u t sh aft o f the tran sm ission
d eceleratin g at a certain rate.
thru the torq ue converter. T his red u ces the
slip p a g e lo sse s in the con verter, w h ich in crea ses G ear S elect S w itch. The transm ission u ses a
fuel econom y. 4th gear sw itch to sen d a sign al to the ECM
OPERATION tellin g it w h at gear the tran sm ission is in. The
ECM u ses this inform ation to vary the
For the con verter clu tch to apply, tw o
con d ition s u nd er w h ich the clu tch ap p lies or
co n d ition s m ust be met:
releases. H ow ever, the tran sm ission d oes not
Internal tran sm ission fluid p ressu re m ust be
have to be in high gear in order for the ECM to
correct. For inform ation on in tern al tran sm ission
turn the clu tch on. T ran sm ission s u sin g gear
op eration, see Section 7A. T his section w ill cover
select sw itch es can be identified by three w ires
only the electrical op eration o f the TCC system .
com ing out of TCC connector. On 4 w h eel
The ECM com p letes a ground circu it to drive, the 4th gear sw itch is externally m ounted
en ergize a TCC apply solen oid in the on tran sm ission.
tran sm ission w h ich m oves a ch eck ball in a fluid
A nother sw itch u sed in the TCC circu it is a
line (Figure 117). T his allow s the converter clutch
brake sw itch w h ich op en s the 12 volt su p p ly to
to apply, if the h yd rau lic p ressu re is correct, as
the TCC solen oid w h en the brake is d ep ressed .
d escrib ed above.
A lso, the tra n sm issio n s use a 4-3 pulse sw itch
The ECM con trols the TCC apply solen oid by
to open the TCC solen oid circuit m om entarily
look in g at several sensors:
d u rin g a dow n sh ift.
C oolant T em perature Sen sor. Engine m ust be
The d iagn ostic ch arts w ill cover the sw itc h e s
w arm ed up before clu tch can apply.
u sed w ith each en gin e/tran sm ission com b ination.
DIAGNOSIS
TCC System
If the converter clu tch is applied at all tim es,
the en gin e will stall im m ediately, ju st as in a
m anual tran sm ission with the clutch ap plied .
If the converter clu tch does not apply, fuel
ecom ony may be low er than exp ected . If the
V ehicle Speed S en sor fails, the TCC will not
apply. If the 4th gear sw itch does not operate, the
TCC w ill not apply at the right time.
The T ransm ission C onverter Clutch (TCC)
Q j TCC SO LE N O ID j~3~1 CHECK B A L L SEAT system has differen t op eratin g ch aracteristics
j 2 j CHECK B A L L than an autom atic tran sm ission w ithout TCC. If
4S 0548-6 E
the driver com p lain s o f a "chuggle" or "surge"
F igure 117 TCC Solenoid con d ition , the veh icle sh ou ld be road tested and
com pared to a sim ilar veh icle to see if a real
ON-VEHICLE SERVICE
problem exists. The O w ners M anual section on See Section 7A for TCC Solenoid rep lacem ent.
TCC operation sh ou ld be review ed w ith the See Section 8C for brake sw itch rep lacem ent.
driver. A n other TCC com plaint may be a
d ow n sh ift felt w h en g oin g up a grade, esp ecially
PARTS INFORMATION
with cru ise control. T his may not be a d ow nshift,
PA R T N A M E G RO UP
but a clu tch d isen g a g em en t due to the change in
TPS to m aintain c ru isin g sp eed . Sensor, VSS (I) ..................................................... 9.761
The electrical d ia g n o sis o f the TCC system is V alve, Clutch and Cruise Vac. Sw ................ 3.885
covered in CHART C-8B. Solenoid , TCC ...................................................... 4.122
DRIVEABIUTY AND EMISSIONS -CARBURETED 6E8-171
W iring Diagram - TCC 2W [) V8 - (C)

Wiring Diagram - TCC - V6 or V8 - G
CHART C-8B
TRANSMISSION CONVERTER CLUTCH(TCC)
ELECTRICAL DIAGNOSIS
The tran sm ission converter clu tch is activated by a TCC solen oid located
in sid e the tran sm ission . The solen oid is su p p lied voltage by the ignition and
the ECM com p letes the ground to en ergize the solen oid .
1. C hecks for com p lete circu it from ignition 4. C hecks for ground in circu it to ECM term inal
through TCC solen oid to ALCL TCC test "P. Norm ally light should be "OFF.
term inal. Norm ally the light should be ON if 5. C hecks for open in w ire to tran sm ission from
circuit is not grounded or open. TCC test point or open in TCC solenoid
2. C hecks to see if ECM com p letes ground to co n n ection s or solen oid . If w irin g is com plete,
energize TCC solen oid . Light should go test light should be ON.
OUT.
3. This in creases throttle op en in g to in crease
TPS output. If T PS output is too low, the
clutch w on t apply. On som e app lication s,
running free d o e sn t require enou gh throttle
op ening to allow the tran sm ission to shift.
MECHANICAL CHECKS, SUCH AS LINKAGE. OIL LEVEL, ETC., SHOULD CHART C-8B
BE PERFORMED PRIOR TO USING THIS CHART.
TRANSMISSION CONVERTER CLUTCH
CONNECT TEST LIGHT FROM TCC TEST POINT IN
TERM. "F" IN ALCL CONNECTOR TO GROUND. * 4.3L, 5.0L, or 5.7L ENGINE
O FOUR WHEEL DRIVE VEHICLE SHOULD BE IN TWO-WHEEL DRIVE. CARBURETED - CALIFORNIA
DRIVE WHEELS OFF FLOOR, KEY "ON". ENGINE NOT RUNNING.
NOTE LIGHT
LIGHT "ON" LIGHT "OFF'
TEST LIGHT SHOULD GO OUT AS BRAKE PEDAL IS MOMENTARILY DEPRESSED
L
OK NOT OK o CHECK FOR BLOWN FUSE. IF OK. DISCONNECT
CONNECTOR AT TRANS. AND CONNECT TEST
LIGHT FROM HARNESS CONNECTOR "A" TO"D'
START ENGINE AND INCREASE IT IS FAULTY BRAKE TERMINAL.
SPEED TO 50-55 MPH (80 Km/h SW. OR ADJUSTMENT WITH IGNITION "ON" AND ENGINE STOPPED,
TO 88 Km/h) AND NOTE LIGHT NOTE TEST LIGHT.

JL LIGHT "OFF" LIGHT "ON"
LIGHTLY DEPRESS PARKING TCC ELECTRICAL
BRAKE AND OPEN THROTTLE SYSTEM OK. I
TO MAINTAIN 50-55 mph (80 CONNECT TEST LIGHT CHECK FOR GROUND IN
Km/h TO 88Km/h) FOR 5 FROM TERM. "A" TO WIRE TO ECM TERM. "P"
SECONDS AND NOTE LIGHT GROUND IF NOTGROUNDED.SEE
ECM REPLACEMENT
CHECK. CHART C-1.
1
......... I ........ LIGHT "OFF'
0 CHECK VOLTAGE FROM ECM CHECK TPS

TERM. "B" TO GROUND WITH ADJUSTMENT.
CONNECT TEST LIGHT REPAIR OPEN IN TCC
DIGITAL V.M. WITH IGNITION IF OK, NO
"ON", ENG. STOPPED, AND TROUBLE BETTWEEN HARNESS BRAKE SWITCH
CONNECTOR TERM'S CIRCUIT OR ADJUST
THROTTLE WIDE OPEN FOUND.
AGAIN. GROUND SWITCH.
TRANS. TEST POINT 8.
1 NOTE LIGHT.
OVER1 VOLT UNDER 1 VOLT
I
CHECK TPS CHECK FOR LIGHT "OFF" LIGHT "ON"
ADJUSTMENT, GROUND IN WIRE
CHECK FOR LOW TO TERM. "2" .
REPAIR OPEN IN WIRE IT IS FAULTY
COOLANT LEVEL IF NOT
FROM TRANS. TO TEST CONN. AT TRANS.
AND HIGHERTHAN GROUNDED,
POINT OR FAULTY 4WD OR TRANS. SOL.
NORMAL REPLACE ECM.
RELAY. CIRCUIT.
RESISTANCE IN
COOLANT SENSOR
CIRCUIT.
A LOW RESISTANCE LIGHT BULB COULD RESULT IN IMMEDIATE TCC APPLY DUE TO
3-26-85
GROUNDING OF TEST TERMINAL "F". TO AVOID THIS POSSIBILITY, A HIGH RESISTANCE
BULB SHOULD BE USED. 4S 0680-6E
BLANK PAGE
EARLY FUEL EVAPORATION SYSTEM (EFE)

GENERAL DESCRIPTION
vacuum is ap plied to the actuator, the valve
PURPOSE clo ses, ca u sin g the intak e m anifold to heat up.
The EFE system used on all en gin es excep t When coolan t tem peratu re in creases, the TVS
4.8L, provid es a sou rce o f rapid heat to the en gin e stop s vacuum to the actuator.
induction system d u rin g cold driveaw ay. Rapid
h eating is d esira b le b eca u se it provid es quick Results of Incorrect EFE Operation
fuel evaportion and m ore uniform fuel No EFE w h en cold:
distribution to aid cold d riveab ility. It also
red u ces the length of tim e cab u retor ch ok in g is E ngine may stu m ble and stall d u ring w arm -up.
required, so it red u ces ex h a u st em ission s. Engine takes lon ger tim e to warm up.
Choke may heat up and be off before en g in e is
OPERATION
warm.
The EFE system is a V acuum Servo type that
u ses a valve and vacuum actuator w h ich
in creases the ex h a u st gas flow u nd er the intake
m anifold d u rin g cold en gin e operation. The valve m -
is located in the ex h a u st and the vacuum actuator
is vacuum op erated (Figure 118) by a Therm al
Vacuum S w itch (TVS) (Figure 119). When
ED
IT ] V E N T (F IL T E R E D )
| 2 | TO EFE V A L V E
H r] M A N IF O L D V A C U U M
4S 0550-6 E
Figure 119 T herm al V acuum Sw itch
EFE stays on:
Poor perform ance.
Lack o f p ow er w h en warm due to su p erh eated
gases.
Engine may overheat.
DIAGNOSIS
GENERAL
The operation o f the EFE system is to be
ch eck ed at regular m aintenance intervals. R efer
to Section OB for m aintenance interval
inform ation.
VACUUM SERVO EFE DIAGNOSIS

TVS c o n tr o lle d -S e e CHART C-9C.
ON-VEHICLE SERVICE
VALVE AND ACTUATOR

FIGURES 120,121, AND 122
1. V acuum h ose at EFE valve.
2. E xhaust pip e to m anifold nuts, and
ten sion sp rin gs.
3. Lower right hand ex h a u st (crossover) pipe
and seal - com p lete rem oval o f pipe is not
alw ays n ecessa ry .
4. EFE valve and actu ator
Install or Connect
1. EFE valve (rep lace sea ls and g a sk ets if
used). p jj N U T -T IG H T E N TO 20 N-m (15 FT. LBS.)
2. E xhaust (crossover) pipe and seal. |~2~| TENSIO N SPRING

j 3 [ R IG H T H AN D EXHAUST PIPE
3. E xhaust pipe to m anifold nuts and ten sion
f T l SEAL
sp rin gs. Tighten nuts to 20 N.m (15 ft.lbs.). [~5~j V A L V E A N D ACTU ATO R
4. V acuum hose at EFE valve. [ 6 | EX H AU S T M A N IF O L D

[ T j M A N IF O L D VA CUUM PIPE 4S i 028
Figure 121 V alve and A ctuator - 7.4L
fT~1 NUT-TIGHTEN TO 20 N-m (15 FT. LBS.)

[ T ] STUD-EXHAUST MANIFOLD P H N U T -T IG H T E N TO N-m (15 FT. LBS.)
[1 ~ | M ANIFOLD VACUUM PIPE [ 2 I TENSIO N SPRING
f T l VALVE AND ACTUATOR n R IG H T H AN D EX HAUST PIPE
|~5~| VALVE ACTUATOR ARM [T ]S E A L
n LEFT HAND EXHAUST MANIFOLD n V A L V E A N D ACTU ATO R
4-22-85 5S 1534-I3E [IF] S T U D -E X H A U S T M A N IF O L D
Figure 120 V alve and A ctuator - 4.3L [ T ] M A N IF O L D VA C U U M PIPE
Figure 122 Valve and A ctuator - V8 (E xcept 7.4L)

COOLANT THERMAL VACUUM SWITCH (TVS)

FIGURE 123
The TVS is located on the en gin e coolan t outlet
housing.
Drain coolan t b elow level of engine
coolan t ou tlet housing.
2. H oses at TVS ports.
3. TVS. R efer to num ber stam ped on base of
TVS for calibration tem perature.
PH E F E -T V S SWITCH
+ 4- Install or Connect l~2~l E G R -T V S SWITCH
4S 0549-6E
A pply a soft settin g sea la n t uniform ly on Figure 123 EFE Coolant TVS
rep lacem en t TVS m ale thread s. No
sealan t sh ou ld be app lied to sen sor end of
PARTS INFORMATION
TVS.
PART NAME GROUP
TVS. T ighten to 14 N.m (120 lbs. in.) and
then hand torque c lo c k w ise as required to V alve, w /A ctuator, EFE ................................... 3.140
align TVS to accom m odate hoses. S w itch, EFE Vlv Therm o Vac ........................ 3.140
H oses to TVS ports.
C oolant as required.
VAAAAAAA J
VAAAJ
ENGINE COOLANT
TEMPERATURE
M S 0614-6E
3-19-85 3-26-85
CHART C-9C
EFE SYSTEM CHECK - WITH TVS
CARBURETED
1. Engine coolan t tem peratu re should be below 4. Valve may be seized up. It may be freed up by
40C (105F). using heat valve lubricant (part # 1052627 or
equivalent). If valve does not free up, it m ust
2. EFE valve should open above 40C (105F).
be replaced.
3. There should be at least 34 kP a (10" Hg.)
vacuum availab le to EFE actuator
diaphragm .
CHART C-9C
EFE SYSTEM CHECK - WITH TVS
CARBURETED
M S 0 3 4 6 -6 E A
3-19-85
POSITIVE CRANKCASE VENTILATION (PCV)

ALL ENGINES
GENERAL DESCRIPTION A leak in g valve or hose w ould cause:
PURPOSE Rough idle.
A P ositive C ran k case V entilation (PCV) Stalling.

system is used to provide more com p lete High idle speed.
scaven gin g of cra n k ca se vapors.
DIAGNOSIS
OPERATION If an en gine is id lin g rough, ch eck for a clogged
Fresh air from the air clean er is su p p lied to PCV valve or plugged hose. R eplace as required.
the cran k case, m ixed w ith blow -by gases and U se the follow in g procedure:
then p assed throu gh a positive cra n k ca se 1. R em ove PCV valve from rocker arm
ventilation (PCV) valve into the intak e m anifold
cover.
(Figure 125).The prim ary control is through the
PCV valve (Figure 124) w h ich m eters the flow at a 2. Run the engine at idle.
rate d ep en d in g on m anifold vacuum .
Figure 124 PCV V alve Cross Section
To m aintain idle quality, the PCV valve

restricts the flow w h en intak e m anifold vacuum
is high. If abnorm al op eratin g con d ition s arise,
the system is d esig n ed to allow ex c esisiv e
am ounts of blow -by g a se s to back flow through
the cran k case vent tu b e into the air clean er to be
con su m ed by norm al com b ustion.
Results of Incorrect PCV Operation =S> CLEAN AIR
A plugged valve or h ose may cause: VOLATILE OIL FUMES

R ou gh idle. MIXTURE OF AIR AND FUMES
S tallin g or slow idle speed.
m PCV V A L V E
Oil leak s. CE A IR CLEANER
Oil in air clean er. ry i CRANKCASE
1------1 VE N T HOSE
Slu d ge in en gin e. [~4~~1 PCV V A L V E
------ HOSE 4S 0067-6E
Figure 125 PCV Flow

3. P lace your thum b over end o f valve to

ch eck for vacuum . If th ere is no vacuum at
valve, ch eck for plugged h oses or
m anifold port, or PCV valve. R eplace
plugged or d eteriorated hoses.
4. Turn off the en gin e and rem ove PCV
valve. Shak e valve and listen for the rattle
o f ch eck n eed le in sid e the valve. If valve
d oes not rattle, rep lace valve.
With this system , any blow -by in e x c ess o f the
system cap acity (from a badly-w orn engine,
su stain ed heavy load, etc.) is exh au sted into the
air clean er and is draw n into the en gine.
P roper operation o f the PCV System (Figure
116) is d ep en d en t upon a sealed engine. If oil
slu d gin g or d ilu tion is noted, and the PCV System
is fu n ction in g properly, ch eck en gin e for p ossib le
ca u se and correct to en su re that system w ill [ T j PCV V A LV E
function as in ten d ed . [T~i AIR CLEAN ER
m CRANKCASE VENT
TUBE
ON-VEHICLE SERVICE j~4~i PCV V A LV E HOSE
~5~1 HOSE TO CANISTER
See F igure 126 for rep lacem en t o f PCV system VIEW A H r] GROMMET
com p on en ts. _____________4S 06 54-6 E
Figure 126 P ositive C rankcase V entilation
An en g in e w h ich is operated w ithout any System
c ran k case ventilation can be dam aged.
T herefore, it is im portant to replace the PCV
valve and air clean er breath er at intervals show n PARTS INFORMATION
in Section O.B. PART NAME GROUP
P eriod ically, in sp e ct the h o ses and clam ps and Air C leaner ......................................................... 3.402
rep lace any sh o w in g sig n s o f deterioration.
Tube, C/Case V ent ............................................ 1.762
H ose, C/Case V ent Vlv ......................................1.762
THERMOSTATIC AIR CLEANER (THERMAC)

ALL ENGINES
GENERAL DESCRIPTION sen so r allow s vacuum to the motor and

PURPOSE the dam per door w ill be up, sh u tin g off
ou tsid e air and allow in g only heated air
A heated in tak e air system is used to give
good d riveab ility u n d er varyin g clim atic from the exh au st m anifold to enter the air
con d ition s. By h avin g a uniform inlet cleaner.
tem perature, the fuel system can be calib rated to B REGULATING MODE. Betw een 86F
reduce ex h a u st em issio n s and to elim inate (30C) and 131F (55C) the dam per door
throttle blade icing. a llow s both heated and ou tsid e air to
OPERATION enter the air cleaner.
The THERM AC air clean er op erates by heated C O UTSIDE AIR DELIVERY MODE. When
air and m anifold vacuum (Figure 127). Air can the tem peratu re is above 131F (55C), the
enter the air clean er from o u tsid e the en gin e dam per door drops dow n and only ou tsid e
com partm ent or from a heat stove built around air en ters the air cleaner.
the exh au st m anifold. A vacuum diaphram THERMAC Delay Valve
motor, built into the air clean er sn ork el, m oves a
Som e ap p lication s use a d elay valve on the
dam per door, to adm it hot air from the exh au st
hose co n n ectin g the vacuum motor to the
m anifold, ou tsid e air, or a com b ination of both.
tem peratu re sen sor (Figure 128). When vacuum
Insid e the air clean er is a tem peratu re sen sor
in this h ose d rop s for any reason, the ch eck valve
that reacts to air in tak e tem peratu re and controls
w ill bleed o ff the vacuum to the vacuum motor
the am ount o f vacuum g oin g to the motor.
slow ly.
A HOT AIR DELIVERY MODE. When the
tem peratu re is below 86F (30C), the
m VACUUM DIAPHRAGM MOTOR

m DIAPHRAGM SPRING
CHI TEMPERATURE SENSOR
4AJ AIR BLEED VALVE-CLOSED
4B~ AIR BLEED V ALVE-
PARTIALLY OPEN
|~4C] AIR BLEED VALVE-OPEN
[~5~1 VACUUM HOSES
[~6~| DIAPHRAGM
f~7~] HEAT STOVE
[~8~| HOT AIR (EXHAUST MANIFOLD)
(~9~| DAMPER DOOR
110 I OUTSIDE INLET AIR
Q D SNORKEL
A - HOT AIR DELIVERY MODE

B - REGULATING MODE
C -OUTSIDE AIR DELIVERY MODE
4S 0073-6E
Figure 127 THERM AC O peration

5. If the air clea n er fails to operate as

d escrib ed above, perform vacuum motor
ch eck . If it op erates, the door may not be
m oving at the right tem perature. If the
driveab ility problem is during warm -up,
m ake the tem peratu re sen sor ch eck
below .
VACUUM MOTOR CHECK

1. With en g in e off, d isco n n ect vacuum hose
4S 0651-6E
at vacuum diaphragm motor.
F igure 128 THERM AC Delay V alve 2. A pply at least 23 k P a (7 in. Hg.) o f vacuum
to the vacuum diaphragm motor. Dam per
Results of Incorrect THERMAC operation
door sh ou ld com p letely block off ou tside
H esitation d u ring warm -up can be cau sed by: air w hen vacuum is applied. If not, check
H eat stove tube d iscon n ected . to see if lin k age is hooked up correctly.
V acuum diaphram m otor in op erative 3. With vacuum still applied , trap vacuum in
(open to Snorkel). vacuum d iaphragm m otor by bending
No m anifold vacuum . hose. D am per door should rem ain closed.
Dam per door d oes not m ove. If not, rep lace vacuum diaphragm motor
assem bly. (Failure of the vacuum
M issing air c lean er to carburetor seal. diaphragm m otor assem bly is more likely
M issing air clean er cover seal or loose to be cau sed from binding linkage or a
cover. corroded sn ork el than from a failed
Loose air cleaner. diaphragm . T his should be ch eck ed first,
before rep la cin g the diaphragm .)
Lack o f pow er, slu g g ish , or sp ongy, on a hot
en gin e can be cau sed by: 4. If vacuum m otor ch eck s OK, ch eck
vacuum h o ses and con n ection s. If OK,
D am per door d oes not open to o u tsid e air.
replace the tem peratu re sensor.
T em perature sen so r d o e sn t bleed off
vacuum . TEMPERATURE SENSORCHECK
1. Start test w ith air clean er tem perature
DIAGNOSIS
below 30C (86F). If en gin e has been run
THERMAC AIR CLEANER CHECK recently, rem ove air clean er cover and
1. In spect system to be sure all h oses and p lace therm om eter as close as p ossib le to
heat stove tube are con n ected . C heck for the sen sor. Let air clean er cool until
k inked, plugged or d eteriorated hoses. therm om eter reads below 30C (86F)
about 5 to 10 m inutes. R einstall air cleaner
2. C heck for p resen ce and con dition o f air
on en gin e and con tin u e to Step 2.
cleaner-to-carbu retor gask et seal.
2. Start and idle en gine. Dam per door should
3. With air clean er assem bly installed,
m ove to clo se off ou tsid e air im m ediately
dam per door should be open to ou tsid e
if en gin e is cool enough. When dam per
air.
door starts to open the snorkel p assage (in
4. Start en gin e. Watch dam per door in air a few m inutes), rem ove air clean er cover
clean er snork el. When en gin e is first and read therm om eter. It m ust read a b ou t,
started, dam per door should m ove and 55C (131F).
clo se o ff ou tsid e air. As air clean er w arm s
3. If the d am per door is not open to ou tsid e
up, dam per door should open slow ly to
air at tem p eratu re in d icated, tem perature
o u tsid e air.
sen sor is m alfu n ction in g and m ust be
replaced.
p ackage to secu re m otor to the snorkel

ON-VEHICLE SERVICE
tube.
AIR CLEANER ELEMENT M ake sure the screw d oes not interfere
with the operation o f the dam per
Remove or Disconnect assem bly. Shorten screw if required.
1. Air clean er cover. 4. Vacuum hose to m otor and install air
cleaner.
2. Old elem ent.
SENSOR (FIGURE 130)
-4- Install or Connect Remove or Disconnect
1. N ew elem ent. 1. Air cleaner.
2. Air clean er cover. Do not over-torque nuts 2. H oses at sensor.
(install finger- tight). 3. Pry up tabs on sen sor retaining clip.
Rem ove clip and sen sor from air cleaner.
VACUUM DIAPHRAGM MOTOR (Figure 129) Note position o f sen sor for installation.
1. Air cleaner.
2. Vacuum hose from motor.
3. Drill out the tw o spot w eld s with a I. 6mm
(1/16") drill, then enlarge as required to
rem ove the retaining strap. Do not
dam age the sn ork el tube.
4. M otor retain in g strap.
5. Lift up m otor, cock in g it to one sid e to P H SENSOR RETA IN IN G CLIP
4S 0650-6E
unhook the m otor link age at the control 08 14 84
dam per assem b ly. Figure 130 R eplacin g THERM AC Sensor
R etaining Clip
- + Install or Connect PARTS INFORMATION
1. Driil a 2.8mm (7/64) hole in snork el tube
PART NAME GROUP
at center o f vacuum motor retaining strap.
Air C leaner ...........................................................3.402
2. Elem ent(Paper) ....................................................3.410

V acuum m otor link age into control
dam per assem b ly. Nut, A/Cl ................................................................. 3.403
3. Use the m otor retaining strap and sh eet Seal, Air C leaner ..................................................3.403
m etal screw p rovided in the m otor service Sensor, A/Cl ...........................................................3.415
Motor,A/Cl Vac Diaph ...................................... 3.415
T ube,E ng Air H eat Stove .................................3.417
Stove,E ng Air Heat ............................................3.417
p r i SPOT WELDS
[T 1 MOTOR ASM.
FT] RETA IN IN G STRAP
m IN ST A LL REPLACEM EN T SENSOR ASM.
IN SAME POSITION AS O R IG IN A L ASM.
08 14 84 4S 0649-(3E
Figure 129 R ep lacin g V acuum D iaphragm Motor

THROTTLE RETURN CONTROL (TRC) SYSTEM

California V-8 Engines W ith Heavy D uty Emissions
GENERAL DESCRIPTION
PURPOSE
The TRC system (Fig. 131), used on V8 heavy 5. If the actu ator d oes not operate at any sp e e d ,
duty em ission v eh icles in C alifornia, c o n sists o f p roceed w ith the fo llo w in g steps.
three major com ponents: a. With a voltm eter, ch eck for voltage at the
T hrottle Lever A ctuator - M ounted as part of control valve and sp eed sw itch . T his is
the carbu retor assem bly, this d ev ice op en s accom p lish ed by co n n ectin g the n eg a tiv e
the prim ary throttle p lates a p reset am ount probe o f the voltm eter to the en g in e
in e x c ess o f curb idle, w hen en gin e vacuum "ground and in ser tin g the positive prob e
is applied to it. This actu atin g vacuum is in the co n n ector cavity o f the voltage
controlled by a sep arate solen oid vacuum sou rce w ire. A voltage of 12-14 volts
control valve. sh ou ld be m easured at this term inal on
Solenoid Vacuum Control Valve - M ounted both the valve and sp eed sw itch . W hen
sep arately from the carburetor, this off-on m aking this m easurem en t, it is not
valve is held open, above a p resen t nom inal n ecessary to u n p lu g the con n ector from
en gin e sp eed , by a sign al from an en gin e its com p onent. T he voltm eter p robe can
sp eed sen sor. The valve, w hen open, allow s be in serted in the co n n ector body on the
a vacuum signal to be ap plied to the throttle wire sid e of the co n n ector to con tact the
lever actu ator as long as the p resen t en g in e m etal term inal.
speed is exceed ed . b. If voltage is p resen t at one d evice and not
E ngine S p eed Sw itch - M ounted sep arately the other, repair the en gin e w irin g
from the solen oid vacuum control valve, this h arn ess as req uired.
sw itch in g d evice m onitors en gin e sp eed at c. If voltage is not p resen t at either d ev ice,
the d istrib u tor and su p p lies a co n tin u o u s ch eck the en g in e h a rn ess co n n ectio n s at
electrical sign al to the solen oid vacuum the d istrib u tor and/or b u lk h ead
control valve as long as the p reset en gin e con n ector. R epair as required.
speed is exceed ed . d. If the proper voltage ex ists at each d evice,
to ch eck for prop er solen oid valve
DIAGNOSIS operation, "ground the valve-to-sw itch
Check h oses for crack ing, abrasion , or co n n ectin g w ire term inal at the solen oid
deterioration and replace as n ecessa ry . C heck con n ector, u sin g a ju m p er wire. The
for shorted or broken w ires and en su re that throttle lever actu ator sh ou ld exten d
electrical con n ectors are fully en gaged at the (en gine running).
distributor, sp eed sw itch , and control valve. e. If it d o es not exten d , rem ove the hose from
Check system function for proper op eration and the solen oid sid e port that co n n ects to the
adjust as n ecessary. actu ator hose. V isu ally, ch eck the orifice
1. C on nect precision tach om eter (cap able of in this port for p lu ggin g. Clear the orifice
resolvin g 10 RPM) to the distrib u tor "TACH as required. If n ot p lugged, rep lace the
term inal. solen oid vacuum con trol valve.
2. Start en gin e and ad vance throttle to in dicated f. If the actu ator ex ten d s in Step D, ground
1890 RPM. T hrottle lever actu ator sh ou ld be the valve-to-sw itch w ire term inal at the
exten d ed at this speed. sp eed sw itch . If it d oes not extend , repair
3. R edu ce throttle op en in g to indicated 1700 the w ire c o n n ectin g the sp eed sw itch and
RPM. T hrottle lever actu ator should be valve. If it d oes exten d , ch eck the sp eed
retracted at this speed. sw itch ground w ire for "ground - it
4. If the throttle lever actuator op erates ou tsid e should read 0 volts w h en ch eck ed w ith a
o f the 1700 to 1890 RPM lim its, the sp eed voltm eter, w ith the en gin e running, ch eck
sw itch is out of calibration and sh ou ld be the speed sw itch -to-d istrib u tor w ire for
replaced.
proper con n ection . With both the ground

and distributor w ires properly con n ected ,
and if the actu ator d oes not exten d w hen
operating above 1890 RPM, rep lace the
speed sw itch.
Throttle Lever Actuator-Checking Procedure
1. D iscon n ect valve to actuator h ose at valve
and con n ect to an external vacuum source
equ ip p ed with a vacuum gage.
2. A pply 68 kP a (20 Hg) vacuum to the actuator
and seal off the vacuum source. If the
vacuum gage read in g d rops, then the
actuator is leak in g and m ust be rep laced .
3. To check the actu ator for proper operation:
a. C heck the throttle lever, shaft, and
linkage to be sure that they op erate freely ENGINE A T O PERATING TEM PER A TU R E
w ithout b in d in g or sticking. CHOKE WIDE OPEN
b. Start en gin e and run until w arm ed up and CAM FOLLOW ER STEPS OF FAST ID LE CAM
idle is stable. Note idle rpm. pj | ADJU ST ID LE SPEED SCREW TO O B T A IN SPECIFIED
c. Apply 68 k P a (20 Hg) vacuum to the CURB ID LE R.P.M. (SEE LA B E L)
actuator. M anually, open the throttle |~2~1 APPLY 68 kPa (2 0 ") W ITH O UTSIDE VA C U U M SOURCE
TO F U L L Y EX TE N D PLUNGER
slightly and allow to close again st the
extend ed actuator plunger. Note the | 3 | M A N U A L L Y OPEN T H R O T T L E S L IG H T L Y A N D THEN
RELEASE A G A IN S T PLUNGER
engine rpm. m W ITH PLUNGER HELD INW A R D , TU R N PLUNGER IN OR
d. R elease and reapply 68 kP a (20 Hg) OUT TO O B T A IN SPECIFIED R.P.M. (SEE LA B E L)
vacuum to the actuator and note the rpm
4S 1061-6E
to w hich the en gine sp eed in crea sed (do
not a ssist the actuator). Figure 132 - T hrottle Lever A ctuator
A djustm ent
e. If the rpm obtain ed in Step D is not w ithin

150 rpm o f that obtain ed in Step C, then
the actu ator p lunger may be bin d in g d ue
to dirt, corrosion, varnish, etc., or the
actuator diaphragm may be too w eak. If
b in d in g is not in d icated , or can n ot be
corrected, then the actuator m ust be
replaced.
f. R elease the vacuum from the actu ator and
the en gin e sp eed should return to w ithin
50 rpm o f the idle sp eed noted in Step 2. If
it d oes not, the plunger may be bin d in g
due to dirt, corrosion, varnish , etc. If the
problem can n ot be corrected , the actu ator
m ust be replaced.
g. If the en gin e rpm noted in Step 3 is not
w ithin the sp ecified TRC sp eed range, the
TRC actu ator m ust be adjusted. Refer to
Figure 131 and V ehicle E m ission control
Inform ation label for adjustm ent o f the ENGINE SPEED SWITCH
throttle lever actuator. Figure 134
ON-VEHICLE SERVICE Remove or Disconnect

THROTTLE KICKER 1. E lectrical con n ector.
2. Engine sp eed sw itch .
f t Adjust
Refer to Figure 131 and V ehicle E m ission Install or Connect
Control Inform ation label for adjustm ent o f the
1. E ngine sp eed sw itch .
throttle kicker.
2. E lectrical con n ector.
4- - * Remove or Disconnect
Figure 133
1. V acuum hose.
2. Bracket and throttle kicker.
3. Tab lock in g w asher.
4. T hrottle K icker.
Install or Connect
1. Throttle K icker.
2 . Tab lock in g w ash er - do not lock.
4. A djust throttle kicker.
5. Lock tab w asher.
6. V acuum hose.
SOLENOID VACUUM CONTROL VALVE PARTS INFORMATION

Figure 135 PART NAME GROUP
T hrottle K icker .....................................Carb. Chart
Engine S p eed Sw itch .....................................3.440
Solenoid V acuum Control Valve ................. 3.440
2. Vacuum hoses.
3. Solenoid vacuum control valve.
1. Solenoid vacuum control valve.
2. Vacuum hoses.
*>
PR T H R O T T L E LEVER AC TU ATO R
[T ~ l VA C U U M HOSE
RT| N U T T IG H T E N TO 28 N-m (20 FT. LBS.)
i~4~1 SO LENO ID V A C U U M CO N TR O L V A L V E
4S 1063-6 E
Figure 135 - Solenoid Vacuum Control Valve

6E9-1
SECTION 6E9
DRIVABILITY AND EMISSIONS DIESEL

CONTENTS
SUBJECT PAGE
D e s c rip tio n ................................................................................................................................................................ 6E9- 2

Crankcase Ventilation S y s te m ..............................................................................................................................6E9- 4
CDR Valve C h e c k ................................................................................................................................................. 6E9- 4
CDR Valve R e p la c e m e n t.................................................................................................................................... 6E9- 5
Exhaust Gas Recirculation S y s te m .....................................................................................................................6E9- 6
EGR System Check...............................................................................................................................................6E9- 6
EGR Valve R e p la c e m e n t.................................................................................................................................... 6E9- 6
EPR Vacuum A ctuator R e p la c e m e n t.............................................................................................................. 6E9- 7
EPR/EGR Solenoid R e p la c e m e n t.....................................................................................................................6E9- 8
Throttle Position Switch A d ju s tm e n t.............................................................................................................. 6E9- 9
Vacuum Regulator V a lve ........................................................................................................................................ 6E9-10
VRV A d ju s tm e n t................................................................................................................................................... 6E9-10
All new General Motors vehicles are certified by the United States Environmental Protection Agency as
conform ing to the requirem ents of the regulations fo r the control of air pollution from new m otor vehicles.
This certification is contingent on certain adjustments being set to factory standards. In most cases, these
adjustm ent points either have been permanently sealed and/or made inaccessible to prevent indiscrim inate
or routine adjustm ent in the field. For this reason, the factory procedure for tem porarily removing plugs,
caps, etc., fo r purposes of servicing the product must be strictly follow ed and, wherever practicable, re
turned to the original intent of the design.
For vehicles sold in Canada, also refer to the appropriate Canadian Service Manual Supplement.
6E9-2 DRIVABILITY AND EMISSIONSDIESEL
DESCRIPTION
A
*
A. Front of Vehicle A. Front of Vehicle
B. EGR Valve B. Vacuum Pump
C. Vacuum Pump C. Crankcase Depression Regulator Valve
D. EPR Solenoid D. EGR Valve
E. EPR Valve E. Engine Speed Sensor
F. EGR Solenoid F. EPR Solenoid
G. Injection Pump G. EPR Valve
H. Fast Idle Solenoid H. EGR Solenoid
J. Oil Fill Pipe J. Injection Pump
K. Throttle Position Switch K. Fast Idle Solenoid
L. Crankcase Depression Regulator Valve L. Oil Fill Pipe
M. Throttle Position Switch
F-00017 F-00024
Figure 1C-K Emission System With Figure 2G-Van Emission System

Light Duty Emissions W ith Light-Duty Emissions
The 6.2L diesel engine has controls to reduce ex Gas Recirculation (figures 1 and 2). The heavy duty
haust emissions while maintaining good drivability emission engine (RPO LL4) has Crankcase Ventilation
and fuel economy. The light duty emission engine and a Vacuum Regulator Valve (figure 3).
(RPO LH6) has Crankcase Ventilation and Exhaust
DRIVABILITY AND EMISSIONSDIESEL 6E9-3
*
A. Front of Vehicle
B. Crankcase Depression Regulator Valve
C. Vacuum Pump (G-P Series)
D. Injection Pump
E. Fast Idle Solenoid
F. Oil Fill Pipe
G. Vacuum Regulator Valve
H. Vacuum Pump (C-K Series)
F-00023
Figure 3Heavy Duty Emission System

CRANKCASE VENTILATION SYSTEM
A. Hose to Intake
B. Blowby Gases from the Crankcase
1. Clamps
2. Bolts
3. CDR Valve
F-00022
Figure 4Crankcase Ventilation System
The crankcase ventilation system is used on all 6.2L CDR VALVE CHECK
diesel engines to reduce crankcase pressure at idle
(figure 4). This reduced pressure reduces engine oil The purpose of the CDR valve is to maintain 0.75-1.0
leaks. The system consists of connecting hoses and a kPa (3-4 inches of water) vacuum in the crankcase. Too
Crankcase Depression Regulator (CDR) valve located little vacuum may force oil leaks while too much
at the front right cylinder head. vacuum will pull oil into the air crossover.
The CDR valve is checked with a water manometer.
The CDR valve is used to regulate the flow of crank The U-tube manometer indicates pressure or vacuum
case gases back into the engine. The valve limits vac by the difference in the height of the two columns of
uum in the crankcase as the gases are drawn from the the fluid (figure 6).
oil fill pipe and into the intake manifold.
Inspect
Intake manifold vacuum acts against a spring loaded
diaphragm to control the flow of crankcase gases (fig
1. Connect one end of the manometer to the oil
ure 5). Higher intake vacuum pulls the diaphragm
dipstick hole
closer to the top of the outlet tube. This reduces the
The other end of the manometer is vented to
amount of gases being drawn from the crankcase and
atmosphere.
also decreases the vacuum in the crankcase. As the
intake vacuum decreases, the spring pushes the dia 2. Run the engine at idle.
phragm away from the top of the outlet tube. This al 3. The reading should be about 0.25 kPa (1-inch of
lows more crankcase gases to flow to the intake water) pressure at idle to 0.5-1.25 kPa (2-5 inches
manifold. of water) vacuum at full load.
Add the amount that the manometer column
Refer to MAINTENANCE AND LUBRICATION (SEC. travels up to the amount the other column
OB) for diesel crankcase ventilation system mainte travels down to get the total pressure or
nance requirements. vacuum.
As an example; 12.7 mm (one-half

in ch ) above zero plu s 12.7 mm
(one-half inch) below zero gives a 25.4
(one-inch) vacuum reading (figure 6).
CDR VALVE REPLACEMENT
1. Clamps (1) from the hoses.

2. Hoses.
3. Bolts (2).
4. CDR valve (3).
A. Cover 1. CDR valve to the bracket.

B. Diaphragm 2. Bolts.
C. Body 3. Hoses.
D. Spring 4. Clamps.
E. O utlet Tube (Gases To Intake Manifold)
F. Mounting Bracket
G. Inlet Port (Gases From Crankcase)
F-00021
Figure 5CDR Valve Operation
A. Front
B. Engine Oil Dipstick Tube
C. Vent To Atmosphere
C. 1/2 -lnch Above Zero
D. 1/2 -lnch Below Zero
F-00028
Figure 6CDR Valve Test

EXHAUST GAS RECIRCULATION SYSTEM
The Exhaust Gas Recirculation (EGR) system is 2. Remove the air cleaner cover to observe EGR
used on 6.2 L diesel engines with Federal light duty valve operation.
emissions. The EGR system (figure 7) consists of: 3. With the engine at idle, the EGR valve should be
EGR valve. open (valve head in the up position and
Exhaust Pressure Regulator (EPR). noticeable exhaust noise). If not, check and
EGR solenoid. correct any electrical and hose connection which
EPR solenoid. may be loose and/or disconnected.
Throttle Position Switch (TPS). 4. Remove the vacuum hose from the EGR valve.
Vacuum Pump. The valve head should drop with a noticeable
Nitrogen oxides (NOx) are formed at high combus reduction in noise. Connect the hose.
tion temperatures. The purpose of the EGR system is 5. The hose to the EGR valve should have 6.75 kPa
to reduce these emissions. (20-inches of water) vacuum at idle. If vacuum is
Exhaust gases are introduced into the intake mani not present, check the output of the vacuum
fold through the EGR valve (figure 8). These exhaust pump at the pump. The pump should produce a
gases act as an inert (non-combustible) ingredient in m inim um of 6.75 kPa (20-inches of water)
the combustion chamber. This reduces NOx through vacuum.
lower combustion temperatures. 6. If vacuum is present at the EGR valve, but the
The EPR valve is located between the exhaust mani valve does not operate as the hose is put on and
fold and the exhaust pipe (figure 9). It increases ex taken off, the EGR valve is stuck and should be
haust backpressure during idle to increase exhaust checked and replaced if necessary.
flow through the EGR system. The EPR valve is nor 7. Manually operate the throttle lever at the injection
mally open. pump through about 15 to 20 degrees of travel.
The TPS is mounted on the throttle shaft of the injec The EGR valve should close when the TPS
tion pump. As the throttle is opened, one switch con reaches the calibrated point.
tact opens a circuit and another switch closes a circuit 8. Check the pink wire to the TPS for 12 volts (key
at calibrated throttle angles. on). If 12 volts is not present, check for loose
At idle, the EPR solenoid is energized through the connections, open wires, or a blown fuse.
TPS, allowing vacuum to close the EPR valve. This 9. With the key on, the blue wire from the TPS
increases exhaust backpressure. At a calibrated throt should also have 12 volts. The blue wire feeds the
tle angle, the EPR soleniod is de-energized and the EPR solenoid. If the pink wire has 12 volts at idle,
EPR valve is opened. but the blue wire does not, the TPS is inoperative
At idle, the EGR solenoid is de-energized, allowing and should be changed.
vacuum to open the EGR valve. At a calibrated throttle 10. With the engine off and the key on, operate the
angle, the EGR solenoid is energized. This cuts off throttle through 20 degrees of travel. At about 15
vacuum to the EGR valve and the valve closes. degrees, the TPS will stop sending 12 volts to the
The EPR solenoid is normally de-energized arid the blue wire (EPR). At about 20 degrees, the TPS
EGR solenoid is normally energized. The EPR sole will supply 12 volts to the yellow wire (EGR). If
noid is de-energized before, or at the same time that not, the TPS is inoperative.
the EGR solenoid is energized. 11. Make sure the electrical connections are made at
There are three different cams used to change the the EGR/EPR solenoid assembly and that the
time when the EPR valve opens and the EGR valve hoses are routed correctly.
closes. 12. If there is vacuum at the solenoid assembly and
Blue Cam 0 degree difference. the solenoids are receiving the proper electrical
Black Cam 5 degree difference. signal but operation of the TPS does not operate
Red Cam 10 degree difference. the EGR and/or EPR valve(s), the solenoid
Refer to figure 10 for a summary of EGR and EPR assembly is inoperative and should be replaced.
operation.
EGR VALVE REPLACEMENT

EGR SYSTEM CHECK
Heavy black exhaust smoke during acceleration 4-4 Remove or Disconnect (Figure 8)
usually indicates a problem in the system.
1. Start the engine and bring it to operating 1. Air cleaner cover.
temperature. 2. Vacuum hose from the EGR valve.
A. EGR Valve
B. Intake Runner
C. Exhaust Gases
D. EPR Valve
E. Injection Pump
F. 12 Volts (Pink Wire)
G. Throttle Position Switch
H. EGR Wire (Yellow)
J. Vacuum Pump
K. EGR Solenoid
L. EPR Solenoid
M. EPR Wire (Blue)
N. To 700 R4 Transm ission Converter
Clutch
F-00027
Figure 7EGR System
3. Studs. 3. Vacuum hose.

4. EGR valve.
1. EGR valve.
EPR VACUUM ACTUATOR
2. Studs.
Seal the stu d s w ith L o ctite 272 or
REPLACEMENT
equivalent.
1. The vacuum hose from the actuator.
2. Clip from the valve lever.
3. Bolt holding the actuator to the valve.
4. Actuator from the EPR valve.

A. Intake Manifold
B. Front 1. Actuator to the EPR valve.
10. Stud
11. EGR Valve 2. Bolt.
12. Vacuum Hose (To Air Cleaner) F-00025
3. Clip.
Figure 8EGR Valve 4. The vacuum hose.

/"I , r-
tigpr
B
A r A.
B.
C.
Front
Connector
EGR Solenoid
A. EPR Valve
D. EPR Solenoid
B. Normally Spring Loaded Open
15. Bolt
F-00026 F-00031
Figure 9EPR Valve Figure 11 EGR/EPR Solenoid Assembly
EPR/EGR SOLENOID
REPLACEMENT
Throttle EGR EGR EPR EPR
Position Valve Solenoid Valve Solenoid
Idle to Not Energized Energized
15 Open (Vacuum Closed (Vacuum
Throttle to Valve) To Valve)
1. The vacuum hoses.
Observe the hose routings for proper
15 to Not Energized Not Energized installation.
20 Open (Vacuum to Open (No Vacuum
2. Electrical connectors.
Throttle Valve) to Valve)
3. Bolt (15).
20 to Energized Not Energized 4. Solenoid assembly.
Full Closed (No Vacuum Open (No Vacuum
Throttle to Valve) to Valve) -4- Install or Connect (Figure 11)
F-00001 1. Solenoid assembly.

2. Bolt (15).
Figure 10EGR System Operation 3. Electrical connectors.
4. The vacuum hoses.
THROTTLE POSITION
SWITCH ADJUSTM ENT
Tool Required:
J-33043, Gage Block.
1. Disconnect the throttle position switch (TPS)
connector.
2. Loosen the mounting screws that hold the TPS.
3. Connect an ohmmeter or test light to the IGN
(pink) and EGR (yellow) terminals of the TPS
(figure 12).
4. Insert the proper switch closed gage block
between the gage boss on the injection pump
and the wide open stop screw on the throttle shaft
(figure 13).
Refer to the Emission Control Information C
5. Rotate the throttle lever and hold the wide open A. Front
stop screw against the gage block. B. Clockwise Rotation
6. Rotate the TPS until there is continuity between C. Power Test Light Or Ohmmeter
the terminals. D. IGN (Pink Wire)
7. Hold the TPS and tighten the mounting screws to E. EGR (Yellow Wire)
6 N m (53 in. lbs.). F. Optional Test Location
8. Return the throttle lever to the idle position and G. EPR (Blue or Violet Wire)
remove the gage block.
9. Insert the proper switch open gage block and F-00008
rotate the throttle lever against the block. There
should be no continuity. If there is continuity, Figure 12Testing The TPS For C ontinuity
repeat steps 1 through 9.
10. Remove the gage block and ohmmeter.
11. Connect the TPS connector.
Figure 13TPS Adjustment Block

6 E 9 -1 0 DRIVABILITY AND EMISSIONS DIESEL
VACUUM REGULATOR VALVE
7. Check by allowing the throttle shaft to return to

the idle stop position. Then rotate the throttle
shaft back against the gage block and read the
vacuum gage. The gage should read 27 2 kPa
(8 0.6 inches Hg). If vacuum is outside of limits,
reset the valve.
A vacuum regulator valve is used on engines with

heavy duty emissions and automatic transmission. The
valve regulates the vacuum signal to the vacuum mo
dulator of a 400 automatic transmission. The valve is
mounted to the injection pump and vacuum is supplied
by the vacuum pump.
VRV ADJUSTM ENT

Tool Required:
J-33043, Gage Block.
1. Loosen the vacuum regulator valve so it is free to
rotate on the pump.
2. Attach a vacuum source of 67 5 kPa (20-inches
Hg. 1.5-inch Hg.) to the bottom vacuum p>ort.
3. Attach a vacuum gage to the top vacuum port
(figure 14).
4. Insert the proper gage block between the gage
boss on the injection pump and the wide open
stop screw on the throttle lever (switch on
position) (figure 13).
5. Rotate the throttle shaft and hold it against the
gage block.
NOTICE: Valve must be set while rotating the

valve body clockwise only.
6. Slowly rotate the vacuum regulator valve body

clockwise (facing the valve) until the vacuum
gage reads 27 2 kPa (8 0.6 inches Hg.) Hold
the valve body at this position and tighten the
mounting screws to 6 N m (54 in. lbs.).
EXHAUST 6F-1
SECTION 6F
EXHAUST
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................. 6F- 1

Diagnosis of Exhaust S y s te m ..................................................................................................................................6F- 2
On-Vehicle S ervice..................................................................................................................................................... 6F- 3
In s p e c tio n ................................................................................................................................................................ 6F- 3
Installing Exhaust P a rts ........................................................................................................................................ 6F- 3
Catalytic Converter R e p lace m e n t....................................................................................................................... 6F- 3
Bottom Cover Replacem ent..................................................................................................................................6F- 4
S p e cifica tio n s.............................................................................................................................................................. 6F-12
DESCRIPTION
Exhaust system designs will vary according to model The catalytic converter is an emission control device
designation and intended use of the vehicle. added to the gasoline engine exhaust system to re
The exhaust pipe(s), muffler(s) and tailpipe(s) are duce hydrocarbon and carbon monoxide pollutants
standard equipment. The exhaust system uses a ball from the exhaust gas stream. The converter contains
joint coupling to secure the exhaust pipe to the engine beads which are coated with a catalytic material con
manifold. The ball joint will allow angular movement for taining platinum and palladium. The catalytic converter
alignment purposes. The other connections use a slip for the computer command control emission system
joint coupling design with a clamp and U-bolt. will also contain rhodium to reduce the level of nitrogen
The exhaust system is suspended by hangers at oxides. The catalyst in the converter is not serviceable.
tached to the frame members. This will permit some THE CATALYTIC CONVERTER REQUIRES THE
movement of the exhaust system, but should not per USE OF UNLEADED FUEL ONLY.
mit the transfer of noise and vibration into the vehicle. The diesel engine does not use a catalytic converter,
Heat shields are used to protect both the vehicle and and uses only diesel fuel.
the environment from the high temperatures developed
from the exhaust system, especially the catalytic con
verter.
6F-2 EXHAUST
DIAGNOSIS OF EXHAUST SYSTEM

Exhaust system performance complaints, such as excessive back pressure, are noticeable by their effect on
engine performance. However, other malfunctioning vehicle components have similar effects on engine perform
ance and are characterized by the same symptoms or complaints. Therefore, it is necessary to refer to the engine
diagnosis procedure when attempting to diagnose this type of problem.
NOTICE: Replacement oi exhaust system parts MUST be OEM standard.
Vibrating or Rattling Loose and/or misaligned components. A lign, then tighten connections.
From Exhaust Check for damaged hanger or mount
System ing brackets and clamps.
Restricted Exhaust 1. Kinked exhaust tubing. 1. If possible, repair the damaged con
System dition, otherwise replace the compo
nent.
2. Restriction within the muffler. 2. if restriction is suspected, remove the
muffler and visually check it. Replace
muffler if condition is doubtful.
3. End of tail pipe obstruction. 3. Remove the obstruction, or if end is
crimped, straighten outlet.
4. Plugged catalytic converter (may result 4. Replace the catalytic converter.
from serious engine malfunction).
Exhaust Leakage 1. Leakage at exhaust component joints 1. Tighten clamps or couplings to speci
and/or Noise and couplings. fied torque.
2. Improperly installed or misaligned. 2. Align, then tighten connections.
3. Exhaust manifold cracked or broken. 3. Replace the manifold.
4. Leak between exhaust manifold and 4. Tighten the manifold to cylinder head
cylinder head. nuts and bolts to specifications.
5. Damaged or worn seals or packing. 5. Replace the seals or packing as nec
essary.
6. Burned or rusted out exhaust pipe 6. Replace the heat tube extensions as
heat tube extension. required.
7. Burned or rusted out exhaust pipe. 7. Repiace the exhaust pipe.
8. Burned or blown out muffler. 8. Replace the muffler assembly.
9. Broken or loose clamps and/or brack 9. Repair or replace as necessary.
ets.
EXHAUST 6F-3
ON-VEHICLE SERVICE
INSPECTION
Inspect exhaust pipes, catalytic converters (if
equipped), mufflers and tailpipes for cracked joints,
broken welds and corrosion damage that would result
in a leaking exhaust system. Inspect the clamps,
brackets and insulators for cracks and stripped or cor
roded bolt threads.
The exhaust system, including heat shields, must be
free of leaks, binding, grounding and excessive vibra
tion. These conditions are usually caused by damaged
or loose flange bolts, heat shields, brackets or pipes. If
any of these conditions exist, check the exhaust sys
tem components and alignment. Align and replace as
necessary.
INSTALLING EXHAUST PARTS

When installing a new exhaust pipe or muffler and
tailpipe, on any model, check for proper alignment.
Rattles and noise vibrations in the exhaust system are
usually caused by m isalignment of parts. When
aligning the system, leave all bolts or nuts loose until
all parts are properly aligned, then tighten, working 2. Sea! Assembly
from the front to the rear. 3. Flange
Exhaust system hangers, hanger brackets, and 4. Exhaust Pipe
5. EFE Valve B-07304
clamps which are damaged should be replaced to
maintain exhaust system alignment.
Figure 1Exhaust Pipe to Manifold
Important (Typical) CK-Model
When jacking or lifting the vehicle from the frame 3. C o n ve rte r p ip e -to -fro n t-e x h a u s t pipe and
side rails, be certain lift pads do not contact the converter pipe-to-rear-exhaust pipe.
catalytic converter as damage to the converter
will result.
Sealer 9985020 or equivalent is to be applied to install or Connect (Figure 8)
all slip joint connections.
When replacing a muffler, the tailpipe should also Apply sealer 9985020 or equivalent at the slip
be replaced. joint connection.
When installing the exhaust pipe to the engine
manifold, always use new packings and nuts. 1. New catalytic converter into the exhaust pipe.
Clean the engine manifold stud threads with a
wire brush before installing the new nuts. 2. New U-bolts and clamps at the front and rear of
Refer to figures 1 through 18 for component the converter.
replacement of the engine exhaust system.
Check for clearance and alignment.
CATALYTIC CONVERTER
R E PLA C EM E N T
& Tighten
Remove or Disconnect (Figure 8) Clamps and support to 40 N-m (30 ft. lbs.).
Raise the vehicle on a hoist. 3. Heat shield.

1. Heat shield.
2. Clamps at the front and rear of the converter. 4. Lower the vehicle.
6F-4 EXHAUST
damaged the converter assem bly must be

replaced.
-4- Install or Connect (Figures 21 through 24)
Place new insulation in the replacement cover.

Apply sealing compound 9985020 or equivalent,
all around the cover after the insulation is in
position (figure 21). Apply extra sealer at the front
and rear opening for the pipes. On the dual bed
converter, also apply extra sealer around the air
inlet tube.
1. Cover on the converter (figure 22).
2. Cover retaining channels on both sides of the
converter (figure 23).
On the single bed converter, attach two clamps
over the retaining channels at each end of the
converter (figure 24).
On the dual bed converter, attach two clamps
over the retaining channels at each end of the
converter plus one clamp without a retaining
channel between the air inlet tube and exhaust
inlet pipe. Position the air inlet tube clamps.
Figure 2Exhaust Pipe to Manifold

G-Model
BOTTOM COVER R EPLAC EM EN T

If, for any reason, the bottom cover of a bead type
converter is torn or punctured, it can be replaced with a
repair kit.
-- Remove or Disconnect (Figures 19 and 20)
1. Bottom cover.
Cut close to the bottom outside edge
(Figures 19 and 20). Do not remove the fill
plug. The depth of the cut must be very
shallow to prevent damage to the inner shell
of the converter.
2. Insulator.
g | Inspect
Inner shell of the converter for damage. If

EXHAUST 6F-5
P300(00) V8 (7.4 Liter)

P300(42) V8 (5.7 Liter) M20 & JF9 P200 + 300(00) V8 (6.2 Liter)
A. 20 N m (15 Ft. Lbs.)

B. 34 N m (25 Ft. Lbs.)
C. 15 N-m (11 Ft. Lbs.) V8 (5.7 Liter)
1. Manifold
2. Seal Assembly
3. Flange Left Hand Manifold
4. Exhaust Pipe Typical
V8 (7.4 And 5.7 Liter)
6. Extension
7. Seal
8. Valve And Actuator Assembly
B-07306
Figure 3Exhaust Pipe to Manifold P-Model

6F-6 EXHAUST
Figure 4Exhaust Pipe Hangers

(Typical) CK-Model
Figure 5Exhaust Pipe Hangers (Typical) P-Model

EXHAUST 6F-7
C. 15 N m (11 Ft. Lbs.)

E. 36 N m (27 Ft. Lbs.)
12. Clamp
13. Cross Member
14. Side Member
15. Exhaust Pipe Extension B-07309
Figure 6Exhaust Pipe Extension Hanger P-Model
15 or 16
4 or 15
F. 40 N m (30 Ft. Lbs.)

G. Sealer
H. Key
Sealer
4. Exhaust Pipe
Exhaust Pipe
15. Exhaust Pipe Extension
'18. Clamp
16. M uffler 19. Catalytic Converter
17. U Bolt
20. M uffler Inlet Pipe b -07311
18. Clamp B-07310
Figure 7Exhaust Pipe Clamping (Typical) Figure 8Catalytic Converter Clamping

(Typical)
6F-8 EXHAUST
C. 15 N m (11 Ft. Lbs.)

D. 60 N-m (44 Ft. Lbs.)
12. Clamp
16. M uffler
21. Tail Pipe
22. Hanger
B-07312
Figure 9M uffler Hangers (Typical) CK-Model
C. 15 N m (11 Ft. Lbs.)

23. Bracket
24. Cross Sill
Figure 10Front and Rear M uffler Hangers (Typical) G-Model
Figure 11Tail Pipe Hanger (Typical) CK-Model

EXHAUST 6F-9
VIEW B
C. 15 N m (11 Ft. Lbs

J. 11 N m (8 Ft. Lbs.
21. Tail Pipe
25. Hanger
26. Bracket
VIEW A B-07316
Figure 12Tail Pipe Hanger (Typical) G-Model
B. 34 N m (25 Ft. Lbs.)

C. 15 N m (11 Ft. Lbs.)
13. Cross Member
14. Side Member C (REAR HANGER)
21. Tail Pipe
22. Hanger B-07317
Figure 13Tail Pipe Hanger (Typical) P-Model

6F-10 EXHAUST
C100 + 200 V8
(5.0 And 5.7 Liter)
A. 20 N m (15 Ft. Lbs.)
27. Transmission
28. Support
29. Clamp B-07318
Figure 14Catalytic Converter Support C-Model
E. 36 N-m (27 Ft. Lbs.)

J. 11 N-m (8 Ft. Lbs.) K100+ 200(03) V8
K. 18 N-m (13 Ft. Lbs.) (7.4, 5.0 And 5.7 Liter) K100(06) V8 (5.7 Liter)
30. Heat Shield B-08286
Figure 16Converter Heat Shield K-Model
30. Heat Shield B-08285
Figure 17-Heat Shield Attachment (CK 200)

EXHAUST 6F-11
CK-MODEL G-MODEL
P-MODEL 313 + 316(00) L B-08284
Figure 18Exhaust Heat Shields (Typical)
P
G
G. Sealer
P. Insulation
B-08289
Figure 21Insulation and Sealer on New Cover
Figure 20Removing Bottom CoverHand

6F-12 EXHAUST
Q. New Cover Q B-08288
Figure 24Retaining Channel Clips
Figure 23Retaining Channels
SPECIFICATIONS
N-m Ft. Lbs.
Exhaust Pipe to M a n ifo ld .......................................................................................... 20 15

Exhaust Pipe Hanger C la m p ........................................................................... ........ 15 11
Exhaust Pipe Hanger Bracket to Frame (CK-Model).............................................. 60 44
Exhaust Pipe Extension Hanger to Bracket (P-M odel)................................. ........ 36 27
Exhaust Pipe C la m p .................................................................................................. 40 30
Catalytic Converter C la m p ............................................................................... ........ 40 30
Muffler Hanger Clamp................................................................................................ 15 11
Muffler Hanger to Frame................................................................................... ........ 60 44
Tail Pipe Hanger C la m p ............................................................................................ 15 11
Tail Pipe Hanger to Bracket/Side Member (P -M odel)............................................ 34 25
Catalytic Converter Support (C-Model)..................................................................... 20 15
Catalytic Converter Heat S hield ....................................................................... ........ 18 13
Heat Shield A tta ch m e nt............................................................................................ 11 8
Heat Shield Attachment (CK200(00))....................................................................... 60 44
Exhaust Heat Shields (CK-Model)............................................................................. 8 6
Exhaust Heat Shields (G-Model)....................................................................... ........ 4 3
Exhaust Heat Shields (P-Model)....................................................................... ........ 11 8
6H-1
SECTION 6H
VACUUM PUMPS
CONTENTS
SUBJECT PAGE
General D e s crip tio n ..................................................................................................................................................... 6H-1
Belt Driven Vacuum Pum p...................................................................................................................................... 6H-1
Gear Driven Vacuum P u m p .................................................................................................................................... 6H-1
Diagnosis of Vacuum P u m p ...................................................................................................................................... 6H-1
On-Vehicle S e r v ic e ..................................................................................................................................................... 6H-4
Belt Driven Pump R e p la ce m e n t........................................................................................................................... 6H-4
Gear Driven Pump Replacem ent........................................................................................................................... 6H-5
S pe cifica tio ns................................................................................................................................................................ 6H-6
Special T o o ls ................................................................................................................................................................ 6H-7
GENERAL DESCRIPTION
The vacuum pump is mounted on diesel engines G EAR DRIVEN VACUUM PU M P

and supplies power for operating emission controls,
transmission modulators, cruise control, and air condi The gear driven model is mounted at the top rear of
tioning controls. It may be belt driven or gear driven. the engine. It is driven by a cam inside the drive
Refer to figure 1 for model breakdown. The pump is a assembly to which it mounts. The drive housing
diaphram pump which does not require periodic main assembiy has a drive gear on the lower end which
tenance. meshes with the camshaft gear in the engine. This
drive gear causes the cam in the drive housing to
rotate. The drive gear also powers the engine oil
BELT DRIVEN VACUUM PU M P lubricating pump.
The belt driven model is bracket mounted at the right
front of the engine. It has a pulley attached which is
driven by the generator belt. With the exception of the
pulley, the vacuum pump is replaced as an assembly.
DIAGNOSIS OF VACUUM PUMP
Refer to figures 1 and 2 for diagnosis of the vacuum

pump.
6H-2 VACUUM PUMPS
AUTOMATIC TRANSMISSION (VACUUM MODULATED) WILL NOT SHIFT OUT OF FIRST

(LOW) GEAR. BLOCK WHEELS, APPLY PARKING BRAKE AND PLACE TRANSMISSION SE
LECTOR LEVER IN PARK OR NEUTRAL BEFORE STARTING ENGINE.
VACUUM PUMP
MINIMUM ACCEPTABLE vs ALTITUDE
kPa 0 -17 -34 -51 -68 -84
B-05764
Figure 1On-Vehicle Diagnosis of Vacuum Pump

VACUUM PUMPS 6H-3
VEHICLE VACUUM SYSTEM DIAGNOSIS
VACUUM PUMP
VACUUM GAGE
B-06869
Figure 2On-Vehicle Diagnosis of Vacuum Pump

6H-4 VACUUM PUMPS
ON-VEHICLE SERVICE
1.
2.
3.
B-05872
Figure 3Belt Driven Vacuum Pump Assembly
BELT DRIVEN PUMP * Assemble (Figure 5)
REPLACEMENT Tool Required:

J-25033-B Pump Pulley Installer
Pulley to the pump with J-25033-B until the pulley
B is flush with the end of the shaft.

NOTICE: Do not tap pulley back onto pump
2. Generator belt.
shaft. The pump could be damaged.
3. Upper vacuum pump attaching bolts.
Raise the vehicle.
4. Engine coolant. - Install or Connect (Figure 3)
5. Lower radiator hose.
6. Vacuum hose. 1. Vacuum pump assembly to the engine.
7. Lower vacuum pump attaching bolt. 2. Vacuum pump lower attaching bolt.
8. Vacuum pump including the pulley.
Tighten
Bolts to 27 N-m (20 ft. lbs.)
Tool Required: 3. Vacuum hose.
J-29785-A Pump Pulley Remover 4. Bottom radiator hose.
Pulley from the pump with J-29785-A. Lower the vehicle.
5. Upper vacuum pump attaching bolts.
NOTICE: Do not pry from the back of the 6. Generator belt and tighten it.
pulley. Damage could occur to the pulley or Refer to ENGINE COOLING (SEC. 6B) for
pump. belt specifications.
VACUUM PUMPS 6H-5
5. Inlet M a n ifo ld
6. C e n te rlin e o f E ngine ^
7. Rear Face o f Case
B-05876
Figure 7Vacuum Pump Positioned
1-05873 7. Battery cable.

8. Engine coolant.
Figure 4Removing The Pulley
GEAR DRIVEN PUMP

REPLACEMENT
Tool Required:
J-29664 Manifold Cover Set
1. Air cleaner.
Im portant
Cover the air intake with J-29664 to prevent

foreign m aterial from fa llin g into the
manifold.
2. Vacuum hose from the pump inlet.
3. Bolt and bracket holding the drive assembly to
Figure 5Installing The Pulley the engine block.
4. Pump and drive assembly.
NOTICE: Do not run the engine without the

vacuum pump installed. Since the oil pump is
powered by the vacuum pump drive gear, no
oil would circulate through the engine. The
engine could be damaged.
L* Inspect
Gasket on the pump assembly. Replace if

necessary.
[++I Install or Connect (Figure 6)
1. New pump assembly making sure that the gear

on the drive assembly meshes with the gear on
Figure 6Gear Driven Vacuum Pump Assembly the engine camshaft.
6H-6 VACUUM PUMPS
A djust (Figure 7) Tighten
Rotate the pump so the inlet tube faces the Bolt to 27 N-m (20 ft. lbs.)
front of the engine. 3. Vacuum hose to the inlet port.
Pump should be on a 20-degree angle 4. Air cleaner.
(figure 7). Remove J-29664 from the air cleaner inlet.
2 . Bolt and bracket. Install the air cleaner.
SPECIFICATIONS
VACUUM PUMP APPLICATIONS
6.2 L V8 Vacuum
Model (379 Cu. In.) Pump Pump
Designation Diesel Engine Type P/N
CK Series
Federal LH6, LL4 Gear Driven 7839416
California LL4 Gear Driven 7839416
G Series
Federal LH6, LL4 Belt Driven 7841746
California LL4 Belt Driven 7841746
P Series
Federal LL4 Belt Driven 7841746
California LL4 Belt Driven 7841746
VACUUM PUMPS 6H-7
SPECIAL TOOLS
(/ I)
1 1 >
ciLift
B
A. J-29785-A Pump Pulley Remover

B. J-25033-B Pump Pulley Installer
C. J-29664 Manifold Cover
B-05879
6H-8 VACUUM PUMPS
7A-1
SECTION 7A
AUTOMATIC TRANSMISSIONS
CONTENTS
SUBJECT PAGE
D e s c rip tio n ...................................................................................................................................................................7 A - 2

Torque C o n ve rte r..................................................................... ............................................................ .................7A - 2
Torque Converter Clutch (T C C )......................................................................................................................... 7 A - 2
Transmission And C o n trols.................................................................................................................................. 7A - 3
Inspection Of C om ponents...................................................................................................................................... 7A - 8
Transmission F lu id ................................................................................................................................................. 7A - 8
Shift Linkage............................................................................................................................................................ 7A - 8
Transmission M ount............................................................................................................................................... 7A - 9
Vacuum M o d u la to r................................................................................................................................................. 7A - 9
TV C a b le ...................................................................................................................................................................7A-10
Detent (Downshift) Cable...................................................................................................................................... 7A - 11
Detent (Downshift) S w itch .................................................................................................................................... 7A-12
EGR S y s te m ............................................................................................................................................................ 7A-12
Fluid Leak P re c a u tio n s .............................................................................................................................................7A-13
Causes....................................................................................................................................................................... 7A-13
Diagnosis Of Fluid Leaks...................................................................................................................................... 7A-15
Diagnosis Of Torque C o n v e rte r............................................................................................................................. 7A-15
THM 350-C Prelim inary C hecking........................................................................................................................... 7A-18
Diagnosis o f THM 3 5 0 -C ...........................................................................................................................................7A-19
Oil And W iring C ir c u its .........................................................................................................................................7A-26
THM 400 Prelim inary C h e c k in g ..............................................................................................................................7A-33
Diagnosis Of THM 4 0 0 ..............................................................................................................................................7A-35
Oil C ir c u its .............................................................................................................................................................. 7A-45
THM 700-R4 Prelim inary C hecking......................................................................................................................... 7A-51
Diagnosis Of THM 700-R4........................................................................................................................................ 7A-53
Oil And W iring C ir c u its ........................................................................................................................................ 7A-61
On Vehicle S e r v ic e ................................................................................................................................................... 7A-81
General Service P ro c e d u re s ................................................................................................................................7A-81
Oil Cooler L in e s ..................................................................................................................................................... 7A-82
Checking And Adding Fluid.................................................................................................................................. 7A-82
Fluid And F ilte r........................................................................................................................................................7A-83
S hift Linkage............................................................................................................................................................7A-83
TV Detent Cable (THM 350-C And THM 700-R 4)............................................................................................. 7A-85
Detent Switch (THM 4 00)...................................................................................................................................... 7A-85
Vacuum Modulator (THM 350-C And THM 400)............................................................................................... 7A-86
Speedometer Driver Gear Vehicle Speed S ensor.......................................................................................7A-87
G o v e rn o r.................................................................................................................................................................. 7A-88
1-2 A ccum ulator (THM 350-C)............................................................................................................................. 7A-90
2-4 Servo (THM 700-R4)........................................................................................................................................ 7A-91
Rear Extension Oil S e a l........................................................................................................................................ 7A-94
Transm ission R eplacem ent..................................................................................................................................7A-94
S pe cifica tio ns.............................................................................................................................................................. 7A-97
Fastener T o rq u e ..................................................................................................................................................... 7A-97
L u b ric a tio n ..............................................................................................................................................................7A-98
Special T o o ls ..............................................................................................................................................................7A-98
7A -2 AUTOMATIC TRANSMISSIONS
DESCRIPTION
100. Cover 102. Turbine 104. Pump 106. Spring

101. Pressure Plate 103. Stator 105. Thrust Bearing 107. Thrust Spacer b Q9166
Figure 1Torque Converter Components
TORQUE CONVERTER A converter clutch apply (control) valve is used to

control the direction of oil flow throughout the torque
The torque converter is of welded construction and converter and therefore the apply or release of the
is serviced as an assembly. The unit is made up of two converter clutch.
vaned sections, or halves, that face each other in an oil All apply valves are moved to the apply position by
filled housing. The pump half of the converter is oil pressure through an orifice to an area between the
connected to the engine and the turbine half is valve and a bleed (TCC) solenoid. The restriction is
connected to the transmission. smaller than the bleed in the solenoid so no pressure
is available to move the valve when the solenoid is not
When the engine makes the converter pump revolve, energized electrically.
it sends oil against the turbine, making it revolve also. There are two types of pressure plates in the present
The oil then returns in a circular flow back to the converter assemblies. Both types have spring type
converter pump, continuing this flow as long as the torsional dampening. The unit used on diesel engines
engine is running. has additional valves in the plate. These valves are
used to equalize oil pressure on both sides of the
The converter also has a smaller vaned section,
pressure plate during a disengagement. Since the
called a stator, that funnels oil back to the converter
diesel engine is compressing a full charge of air on
pump through smaller openings, at increased speed.
every stroke, during deceleration as well as any other
The speeded up oil directs additional force to the
time, engine braking is greater and torsional shock is
engine-driven converter pump, thereby multiplying
greater. The rapid slowing of the diesel engine causes
engine torque (figure 1).
a reverse rotation of the plate on the hub and opens
two valves which allows oil to move to the front side of
the plate effecting a quicker release. This results in
TORQUE CONVERTER CLUTCH less RPM drop and less feel during clutch release.
(TCC) Other converter clutches do not use the poppet valves
in the pressure plate.
The converter clutch assem bly consists of a The THM 350-C apply valve is a one piece valve
3-element torque converter with the addition of a located in an auxiliary valve body on the front of the
converter clutch. The converter clutch is splined to the separator plate. The valve is held in the release
turbine assembly, and when operated applies against position by spring pressure. 2-3 clutch oil, acting on
the converter cover providing a mechanical direct drive the ring land difference, moves the valve to the apply
coupling of the engine to the transmission planetary position.
gears. When the converter clutch is released, the The THM 700-R4 uses a one piece valve spring
assembly operates as a conventional torque converter loaded to the release position. Oil to move it to the
(figure 1). apply position is controlled by a TCC shift valve that
AUTOMATIC TRANSMISSIONS 7 A -3
1 112 113 114 115 116
120 118 Oil Pump

119
Intermediate Roller Clutch
Intermediate Clutch
INT. LO-REV.
INT INT. ROLLER DIRECT FORWARD L0 REV. ROLLER Intermediate Band
RANGE GEAR CLUTCH BAND CLUTCH CLUTCH CLUTCH CLUTCH CLUTCH Direct Clutch
FIRST ON ON Forward Clutch
DRIVE S EC O N D ON ON ON
Lo And Reverse Clutch
THIRD ON ON ON
Lo And Reverse Roller Clutch
FIRST ON ON ON
MAN
SECO ND ON ON ON ON
Output Shaft
REV ON ON
Planetary Gears
Input Shaft
B-09167
Torque Converter
Figure 2THM 350-C Clutches And Operation

operates like any shift valve. Governor pressure must THM 400 (RPO M 40)
rise to move the shift valve before oil called signal can The THM 400 is a fully automatic transmission for
move the apply valve. The 1-2 shift must also be made rear wheel drive vehicles which provides three forward
to supply 2nd clutch oil to the TCC shift valve. The gear ranges and a reverse (figure 3).
screen in the signal oil passages helps to keep the The major components of this transmission are:
apply valve and the solenoid bleed clean. Torque Converter.
Gear Type Oil Pump.
Two Bands.
TRANSMISSION AND CONTROLS
Three Multiple Disc Clutches.
THM 350-C (RPO MV4) Two Planetary Gear Sets.
The THM 350-C is a fully automatic transmission for Two Roller Clutches.
rear wheel drive vehicles which provides three forward Valve Body Assembly.
gear ranges and a reverse (figure 2). External control connections to the transmission are:
The major components of this transmission are: Manual Linkage To select the desired
Clutch Type Torque Converter. operating range.
Gear Type Oil Pump. Engine Vacuum To operate the vacuum
Intermediate Overrun Band. modulator.
Four Multiple Disc Clutches. 12 Volt Electrical Signals To operate an
Two Planetary Gear Sets. electrical detent solenoid.
Two Roller Clutches.
THM 700-R4 (RPO MD8)
Valve Body Assembly.
The THM 700-R4 is a fully automatic transmission
External control connections to the transmission are: for rear wheel drive vehicles which provides four
M anual Linkage To select the desired forward gear ranges and a reverse (figure 4).
operating range.
The major components of this transmission are:
Engine Vacuum To operate the vacuum Clutch Type Torque Converter.
modulator.
Vane Type Oil Pump.
Detent Cable To operate the detent valve.
2-4 Band Assembly.
Five Multiple Disc Clutches.
Two Planetary Gear Sets.
122 . Front Band

110. Oil Pump 114. Direct Clutch 119. Planetary Gears 123. Rear Band
111. Intermediate Roller Clutch 115. Forward Clutch 120. Input Shaft 124. Lo Roller Clutch
112. Intermediate Clutch 118. Output Shaft 121. Torque Converter 125. Main Shaft
INT. L0
FORWARD DIRECT FRONT INT. ROLLER ROLLER REAR
RANGE GEAR CLUTCH CLUTCH BAND CLUTCH CLUTCH CLUTCH BAND
PARK - N EU TR AL
FIRST ON EFFECTIVE
DRIVE SECOND ON ON EFFECTIVE

TH IR D ON ON ON
INT. FIRST ON EFFECTIVE

SECOND ON ON ON EFFECTIVE
FIRST ON EFFECTIVE ON
L0
SECOND ON ON ON EFFECTIVE
REV. ON ON
B-09168
Figure 3THM 400 Clutches And Operation

One Sprag Clutch. DETENT (DOWNSHIFT) SWITCH
One Roller Clutch. While operating the THM 400 at speeds below
Valve Body Assembly. approximately 70 mph, a forced or detent downshift is
External control connections to the transmission are: possible by depressing the accelerator fully. This
Manual Linkage To selected the desired engages an e le ctrica lly operated switch at the
operating rang. accelerator pedal that activates the detent solenoid.
Throttle Valve (TV) Cable To control shift points The detent solenoid opens an orifice that allows line oil
by throttle opening. at the detent valve to be exhausted, thus permitting the
The transmission identification number is located on detent regulator valve to downshift the transmission.
the right side of the transmission on the pan rail (figure
5 ). VACUUM MODULATOR
A vacuum modulator is used to automatically sense
DETENT (DOWNSHIFT) CABLE SYSTEM any change in torque input to the transmission. The
The detent valve in the THM 350-C is activated by vacuum modulator transmits this signal to the pressure
the dow nshift cable which is connected to the regulator, which controls line pressure, so that all
carburetor linkage. When the throttle is half open, the torque requirements of the transmision are met and
detent valve is actuated, causing a part throttle smooth shifts are obtained at all throttle openings.
downshift at speeds below 80 km/h (50 mph). When
the throttle is fully opened, the detent valve is actuated
causing the transmission to downshift
AUTOMATIC TRANSMISSIONS 7A-5
110. Oil Pump 124. Lo Roller Clutch

115. Forward Clutch 126. 2-4 Band
117. Lo And Reverse Clutch 127. Reverse Input Clutch
118. Output Shaft 128. Overrun Clutch
119. Planetary Gears 129. 3-4 Clutch
120. Input Shaft 130. Forward Sprag Clutch
121. Torque Converter
REVERSE FORWARD
GEAR 2-4 INPUT OVERRUN FORWARD SPRAG CL. 3-4 LO ROLLER LO-REV.
RANGE BAND CLUTCH CLUTCH CLUTCH ASSEMBLY CLUTCH CLUTCH CLUTCH
1ST
ON ON ON
DR4
2ND
ON ON ON
DR4
3RD
DR4 ON ON ON
4TH
ON ON ON
DR4
3RD
ON ON ON ON
DR3
2ND
ON ON ON ON
DR2
1ST
ON ON ON ON ON
LO
REV. ON ON
B-09169
Figure 4THM 700-R4 Clutches And Operation

THROTTLE VALVE (TV) CABLE SYSTEM The TV cable operates the throttle lever and bracket
The TV C a b le used w ith the THM 700-R4 assembly (figures 6 and 7).
transmission should not be thought of as an automatic The Throttle Lever and Bracket Assembly serves two
downshift cable. The TV cable used on the THM (2) basic functions:
700-R4 controls line pressure, shift points, shift feel, 1. The primary function of this assembly is to
part throttle downshifts and detent downshifts. The transfer the carburetor throttle plate movement to
function of the cable is similar to the combined the TV plunger in the control valve assembly as
functions of the vacuum modulator and the detent related by the TV cable and linkage (figure 6).
cable used on the THM 350-C.
7A-6 AUTOMATIC TRANSMISSIONS
TH M 350-C
TH M 400
M O D E L YEAR
(3 = 1983) J U L IA N DATE
(4 = 1984) (OR DAY OF TH E YEAR)
(5 = 1985 etc.)
1MD137A

MODEL
S H IF T B U ILT
A & B = F IR S T S H IF T
C & H = S E C O N D S H IF T
D = DAY
N = N IG H T
TH M 700-R4
B-09170
Figure 5Transmission Identification

This causes TV pressure and line pressure to

increase according to engine throttle opening and
144 also controls part throttle and detent downshifts.
The proper adjustment of the TV cable is based
140. Carburetor Lever on the TV plunger being fully depressed to flush
141. Cable Adjuster with the TV bushing at engine wide open throttle,
142. TV Cable 2. The second function of the assembly involves the
143. Throttle Lever And Bracket TV exhaust valve lifter rod, spring and the TV
144. TV Link exhaust ball. The function of this system is to
145. Valve Body prevent the transmission from operating at low
B-08890 (idle position) pressures, if the TV cable should
become broken or disconnected. If the cable is
not connected or broken, the TV lifter rod will not
move from its normal spring loaded up position
which holds the TV exhaust check ball off its
seat. The TV lifter rod will drop down to allow the
TV exhaust bail to seat only if the cable is broken,
disconnected or extremely out of adjustment.
With the transmission pan removed, it should be
possible to pull down on the TV exhaust valve
lifter rod and the springs should return the rod to
its normal up position, If the throttle lever and
bracket assembly or lifter rod binds or sticks so
that the TV lifter rod cannot lift the exhaust ball
off its seat, high line pressures and delayed shifts
will result. The normal shape of the TV lifter rod is
shown in figure 8. The right angle leg must not be
bent to any other angle or it will not function
properly.
144. TV Link
150. Throttle Lever Spring
152. TV Plunger
153. TV Bushing
154. TV Exhaust Valve Lifter Rod
B-08354
Figure 7Throttle Lever And Bracket Assembly

INSPECTION OF COMPONENTS
Before diagnosing transmission complaints, first
check any related components for problems to be sure
the transmission itself is not at fault. A
Engine for proper tune.
Transmission fluid condition and level.
Manual linkage for dirt, corrosion and damage.
Be sure the linkage is adjusted properly.
Transmission mount for looseness and damage.
Engine and transmission vacuum lines. A. Cool
TV and detent cable for damage and adjustment. B. Warm
Detent switch and solenoid for damage and ad
justment. B-08696
Transmission wiring for loose connections, corro
sion and damage. Figure 9Transmission Dipstick
EGR system for proper operation.
Transmission for fluid leaks. 1. Apply the parking brake and block the vehicle
wheels.
2. With the selector lever in the PARK position, start
TRANSMISSION FLUID engine. DO NOT RACE ENGINE. Move the
selector lever through each range.
Before diagnosis of any transmission complaint is
3. Immediately check the fluid with the selector
attempted, there must be understanding of fluid
lever in PARK, engine running at SLOW IDLE and
checking procedure and what appearance the fluid
the vehicle on a LEVEL surface.
should have. Many times a transmission malfunction
4. Remove the dipstick and touch the transmission
can be traced to low fluid level or improper reading of
end of the dipstick cautiously to find out if the
the dipstick. Due to the transmission fluid that is now
fluid is cool, warm or hot.
being used it may appear to be darker and have a
stronger odor. This is normal, and not a positive sign of 5. Wipe it clean and re-insert it until the cap seats.
required maintenance or transmission failure. Remove the dipstick and note the reading.
Also when the dipstick is removed, it should be 6. If the fluid feels cool, about room temperature,
noted whether the fluid is free of air bubbles or not. 18-29C (6 5 -8 5F ), the level should be
Fluid with air bubbles gives an indication of an air leak between the two dimples below the ADD mark.
in the suction lines, which can cause inconsistent 7. If it feels warm, the level should be close to the
operation and slipping. Water in the fluid gives a milky, ADD mark (either above or below).
pink color to the fluid and can cause spewing. Water in 8. If it feels hot (cannot be held comfortably), the
the fluid can also cause swelling of nylon parts. level should be between the ADD and FULL
The automatic transmission is designed to operate marks.
at the FULL HOT mark on the dipstick at normal 9. If additional fluid is needed, add enough fluid to
operating temperatures of 88-93C (190-200F) and bring the level to the proper mark.
should be checked under these conditions. The normal Overfilling can cause foaming and loss of fluid
operating temperature is obtained only after at least 24 through the vent. Slippage and transmission failure
km (15 miles) of highway type driving. can result.
Automatic transmissions are frequently overfilled Fluid level too low can cause slipping, particularly,
because ihe fluid level is checked when the fluid is when the transmission is cold or the vehicle is on a hill.
cold and the dipstick indicates fluid should be added.
However, the low reading is normal since the level will
rise as the fluid temperature increases. A level change SHIFT LINKAGE
of over 19.05 mm (3/4-in.) will occur as fluid temperature
rises from 16-82C (60-180F) (figure 9). Shift linkage should be adjusted so that the engine
If the vehicle has recently been operated for an will start in the Park and Neutral positions only.
extended period at high speed or in city traffic in hot With the selector lever in the Park position, the
weather or the vehicle is being used to pull a trailer, an parking pawl should freely engage w ith in the
accurate fluid level cannot be determined until the fluid rear/reaction internal gear lugs or output ring gear
has cooled down, usually about 30 minutes after the lugs. The pointer on the indicator quandrant should
vehicle has been parked. line up properly with the range indicators in all ranges.
If the linkage is not adjusted properly, an internal

leak could occur at the manual valve which could GAGE
cause a clutch and/or band failure. IN D IC A TO R J -24466
CAUTION: W ith the se le cto r lever in the

P ark" position, the parking pawl should
fre e ly e n g a g e w ith in th e re a r/re a c tio n
internal gear lugs or output ring gear lugs
and prevent the vehicle from rolling, which
could cause personal injury.
Check the linkage for:

1. Proper adjustment.
2. Loose swivels and fittings. Figure 10Checking The M odulator
3. Dirt and corrosion.
4. Bent or damaged rods.
c. Restricted orifice or incorrect orifice size.
d. Carbon build up at modulator vacuum
TRANSMISSION MOUNT fitting.
e. Pinched line.
1. Raise the vehicle. Push up and pull down on the f. Grease in pipe (delayed or no upshift-cold).
tra n s m is s io n ta ils h a ft w h ile w a tch in g the
transmission mount. VACUUM DIAPHRAGM CHECK
2. If there is movement between a metal plate of the 1. Raise the vehicle and disconnect the vacuum line
mount and its attaching point, thighten the at the modulator.
screws or nuts attaching the mount to the
2. Turn the modulator so the vacuum line stem
transmission or crossmember.
points downward.
3. If the rubber separates from a metal plate of the
3. If transmission oil comes out, the modulator must
mount or the tailshaft moves up but not down
be replaced.
(mount bottomed out) replace the mount.
4. If gasoline and/or water vapor are found in a
vehicle which may be exposed to -12C (10F)
VACUUM MODULATOR temperatures or below, the modulator must be
changed.
A vacuum modulator can cause one or more of the 5. If oil is not found in the vacuum side of the
following complaints. modulator, but the transmission oil level is
1. Harsh upshifts and downshifts. continually low, and no external leaks are found,
2. Delayed upshifts. there is a possibility that a pin hole leak exists in
3. Soft upshifts and downshifts. the diaphragm and the modulator should be
4. Slips in low, drive and reverse. replaced.
5. Transmission overheating.
6. Engine burning transmission oil. ATMOSPHERIC LEAK CHECK
If any one of the above com plaints are 1. Apply a thick coating of soap bubble solution to
encountered, the modulator must be checked. the vacuum connector pipe seam and the
crimped upper to lower housing seam.
CAUSES OF IMPROPER VACUUM AT MODULATOR
2. Using a short piece of rubber hose, apply air
1. Engine.
pressure to the vacuum pipe by blowing into the
a. Tune up.
tube.
b. Loose vacuum fittings or improperly routed
3. If bubbles appear, replace the modulator.
hoses/lines.
c. Vacuum operated accessory leak (hoses, Do not use any method other than human lung
vacuum valve, etc.). power for applying air pressure, as pressures
d. Engine exhaust system restricted. over 41.37 kPa (6 psi) may damage the modulator.
e. D ie s e l Vacuum R e g u la to r Valve
a d ju s tm e n t (re fe r to D IE SE L FUEL LOAD CHECK
INJECTION, SEC. 6C6). 1. Install a modulator that is known to be good on
2. Vacuum line to the modulator. either end of tool J-24466.
a. Leak. 2. Install the moduator in question on the opposite
b. Loose fitting. end of the gage (figure 10).
3. Holding the modulators in a horizontal position,

bring them slowly together under pressure. If the
modulator in question is bad, the gage line will
remain blue. If the modulator is good, the yage
line will be white. When making the comparison,
make sure that both modulators are of the same
type. The part numbers are stamped on the dome
of the modulator.
SLEEVE ALIGNMENT CHECK

1. Roll the main body of the modulator on a flat
surface.
2. If the sleeve is not concentric to the can, replace
the modulator.
3. If the plunger is not free, replace the modulator.
The following items should also be checked as a
possible cause of the problem.
1. C heck fre e n e s s of m o d u la to r valve in Figure 11TV Cable At Carburetor Lever
transmission case.
2. Check the vacuum line from the manifold or 4. Misalignment of the throttle lever and bracket
vacuum pump to modulator for holes, cracks or assembly on the coiled pin in the control valve
dents. Check the rubber hose connection at the assembly (figure 13).
modulator and at the intake manifold or vacuum 5. Damaged or binding throttle lever and bracket
pump for leaks. assembly. Correct by straightening or replace as
required.
6. Throttle lever spring unhooked or damaged.
TV CABLE Correct by assembling the spring properly or
replace the throttle lever and bracket assembly as
If the TV cable is broken, sticky, misadjusted or the required.
incorrect part for the model, the vehicle may exhibit If the TV cable is adjusted too long, it may result in
various malfunctions. one of the two following conditions:
Sticking or binding TV linkage can result in delayed 1. Early and slipping shifts and/or no detent
or full throttle shifts. The TV cable must be free to downshifts.
travel to the full throttle position and return to the 2. Delayed or full throttle shifts by causing the
closed throttle position without binding or sticking. transmission to operate in the high pressure
Some binding or sticking of the TV cable and mode. The transmission senses a malfunction of
associated parts may only occur with the engine the TV cable and associated parts; and to prevent
running and will not be noted or obtained with the burning the clutches and band due to low line
engine off.
Inspection of the TV linkage for sticking or binding
should be made with engine running at idle speed,
with the transmission selector in Neutral and the
parking brakes set. Pull the TV cable full travel through
the cable terminal and then release the cable; it should
return to the closed throttle position against the cable
terminal (figure 11). If the TV cable sticks, and remains
ahead of the cable terminal (figure 12), it may be
caused by one or more of the following:
1. Sharp bends or a damaged TV cable housing.
Correct by rerouting the cable or replace it if
required.
2. Sharp end or burr on the TV link, dragging in the
TV cable housing. Correct by making end
smooth, using a file or stone. DO NOT SHORTEN
LINK.
3. Bent TV link. Correct by straightening or replace
as required. Figure 12Sticking TV Cable
DETENT (DOWNSHIFT) CABLE

Figure 13A lignm ent Of Throttle Lever If the detent cable is broken, sticky, misadjusted or
And Bracket Assembly incorrect part for the model, the vehicle may exhibit
various malfunctions. Check for:
pressures, it will go into the high pressure mode.
Line pressures checked under the minimum TV 1. Sharp bends or a damaged cable housing.
conditions in Neutral and Drive will be in the Correct by rerouting the cable or replace it if
range of the f u l l TV p re ssu re s if the required.
transmission is in high pressure mode. The
complaint could be described as no upshifts, 2. Damaged or binding throttle lever and bracket
delayed or sharp upshifts. assembly. Correct by straightening or replace as
required.
If the TV cable is adjusted too short or not adjusted
at all, it will result in raising the line pressure and shift 3. Throttle lever spring unhooked or damaged.
points. It may also limit the carburetor or injection Correct by assembling the spring properly or
pump opening to prevent full throttle operation. replace the throttle lever and bracket assembly as
required.
CHECK TV CABLE OPERATION
1. Check the transmission oil level and correct as CHECK DETENT CABLE OPERATION
required. 1. Check the transmission oil level and correct as
2. Be sure the engine is operating properly and the required.
brakes are not dragging.
2. Be sure the engine is operating properly and the
3. Check for correct cable, according to the parts
brakes are not dragging.
catalog.
4. Check that the cable is connected at both ends. 3. Check for correct cable, according to the parts
catalog.
5. Adjust the cable.
6. Check to insure the cable is not sticking or 4. Check that the cable is connected at both ends.
binding.
5. Adjust the cable.
7. Road test the vehicle.
6. Check to insure the cable is not sticking or
8. If delayed or only full throttle shifts still occur,
binding.
remove the oil pan and inspect the throttle lever
and bracket assembly (figure 12). Check that the 7. Road test the vehicle.
TV exhaust valve lifter rod is not distorted and not
binding in the control valve assembly or spacer The 3-1 detent downshift may be obtained
plate. The TV exhaust check ball must move up when the vehicle speed is approximately 9-19
and down as the lifter rod does. Also, be sure km/h (6-12 mph) below the maximum throttle 1-2
lifter spring holds the lifter rod up against the upshift point. The 3-2 detent downshift may be
bottom of the control valve assembly. Make sure o b ta in e d when the v e h ic le speed is
TV plunger is not stuck. Inspect transmission for approximately 6-13 km/h (4-8 mph) below the
correct throttle lever to cable link (figure 14). maximum throttle 2-3 upshift point.
DETENT (DOWNSHIFT) SWITCH 7. Check the black striped orange feed wire at the
transmission downshift switch with the test light.
Check the detent downshift switch and wires for: If the thest lig h t lights, replace the
transmission downshift switch. Recheck the
1. Sharp bends or a damaged wire casing. Replace
system.
and reroute the wires if needed.
8. Check the transmisison control fuse in the fuse
2. Damaged or binding accelerator pedal and
panel.
bracket assembly. Correct by straightening or
a. If necessary to replace the fuse, recheck the
replace as required.
system.
3. Loose or corroded wires. Clean or replace as
b. If the fuse is all right, it will be necessary to
needed.
locate the open in the wiring. Test the circuit
4. Loose or broken switch. Tighten or replace as continuity from the black-striped orange
needed. wire at the downshift switch to the battery.
9. Remove the air cleaner. Remove the black-striped
CHECKING DETENT SWITCH OPERATION orange wire connector at the transm ission
1. Check the transmission oil level and correct as downshift switch. Use the test light to check from
required. the bare terminal at the switch with the throttle
2. Be sure the engine is operating properly and the closed.
brakes are not dragging. If the test light fails to light, the orange
3. Check the wire connections at both ends. wire is shorted. C orrect the sh orting
4. Adjust the switch. condition.
5. Road test the vehicle. 10. With the throttle in the closed position, check the
A detent 3-2 downshift is possible at 117.5-109.5 b la ck s trip e d o range feed w ire at the
km/h (73-68 mph) by depressing the accelerator transmission downshift switch.
fu lly , and a 2-1 d o w n s h ift can also be a. If the test light fails to light, replace the
accomplished at 51.5-45 km/h (32-28 mph). transmission downshift switch. Recheck the
system.
CHECKING DETENT SOLENOID CIRCUIT b. If the test light lights, it will be necessary to
1. With the transmission shift lever in Park, turn the locate the short in the wiring. Test the circuit
ignition switch to ON position, but do not start from the black striped orange wire at the
the car. Leave the ig n itio n sw itch O N downshift switch to the battery.
throughout the checking procedure.
2. Working under the hood, slowly advance the
throttle linkage to the wide open position. One EGR SYSTEM
click should be heard from the transmission.
With Exhaust Gas Recirculation (EGR), the throttle is
3. Allow the throttle to return to the closed position.
open enough in Drive range (1000 rpm) to cause the
One click should be heard from the transmission.
EGR valve to open. When the EGR valve opens,
4. If the system performed as described above, the
exhaust gas enters the intake manifold which lowers
downshift circuit is operating properly.
intake m anifold vacuum. When intake manifold
5. Use a test light to check the brown wire at the vacuum is lowered, the transmission line oil pressure
connector on the side of the transmission case.
raises and may go above the upper specification limit,
The test light should light with the throttle wide for this reason, if high line pressures are found,
open and go out when the throttle is released.
proceed as follows:
a. If the system operates as described above, 1. Disconnect the EGR vacuum line at the EGR
but did not perform properly during steps valve and plug the vacuum line.
1-3, replace the solenoid after first checking 2. Recheck line pressures as indicated on the
to see that the internal wiring is operational. proper oil pressure chart.
b. If the light fails to light with the throttle in the 3. If high line pressures are still found, it may be that
wide open position, the circuit is open. the engine is not producing enough vacuum to
Proceed to step 6. lower the transmisison line pressure within
c. If the light lights with the throttle closed, the specifications. The newer engines with emission
circuit is shorted. Proceed to step 9. controls characteristically have lower engine
6. Remove the air cleaner. Remove the orange wire vacuum than older past model engines. To obtain
connector located at the transmission downshift line pressures suitable for evaluation, it is
switch. Use the test light to check from the bare recommended that vacuum be applied to the
terminal at the switch with the throttle wide open. modulator, using an external vacuum source such
If the test light lights, replace the brown as J-23738 hand operated vacuum device or its
wire. Recheck the system. equivalent. The unit allows definite amounts of
vacuum to be applied to the modulator so that 6. Recheck line pressures according to the proper
consistent line pressures may be obtained for oil pressure chart.
evaluation as follows: 7. If line pressures are still high, proceed to the
4. Disconnect the vacuum hose to the modulator at specific diagnosis chart that applies to the
the modulator and plug the vacuum hose. malfunction encountered.
5. Attach the hand operated vacuum device and 8. If line pressures are normal with external vacuum
apply 20" of vacuum. applied, check engine vacuum and vacuum
systems for leaks.
FLUID LEAK PRECAUTIONS

The precautions that must be observed to prevent B. Modulator assembly O ring seal damaged
fluid leaks are as follows: or improperly installed.
1. Use new gaskets and O ring seals whenever C. Connector O ring seal damaged or
there is a disassembly. improperly installed.
2. Use a very small amount of petrolatum to hold D. G o ve rn o r cover, gaske t and screw s
gaskets and thrust washers in place during as damaged, loose; case face leak.
sembly, or to seal gaskets. Never use gasket E. D am aged or porous. Leak at the
paste or shellac. speedometer driven gear housing or seal.
3. Make sure that composition cork and paper gas Leak at the speedometer hole plug.
kets are not wrinkled or creased when installed. F. Manual shaft seal damaged, improperly
Make sure that gaskets have not stretched or installed.
shrunk during storage. G. Line pressure tap plug stripped, lacking
4. Make sure the square type O ring seals are compound.
installed squarely and are not twisted during as H. Vent Pipe (refer to item 5).
sembly. I. Porous case, or cracked at the pressure
5. Make sure that mating surfaces of castings are plug boss.
flat and smooth, free of deep scratches, chips, 4. Front end leak.
and burrs. A. Front seal damaged, (check the converter
6. Torque fasteners to proper torque. When check neck for nicks, etc., also for the pump
ing for oil leaks, first determine whether leak origi bushing moved forward) garter spring
nates from transmission or engine. The original missing.
factory fill fluid in the transmission is formulated B. Pum p a tta c h in g screw s, and se als
with a red aniline dye to assist in locating leaks. damaged, missing, screws loose.
Red dye appearing in the leaking oil will give pos C. Converter leak in the weld.
itive identification as to the location of the leak D. Pump O ring seal damaged. (Also check
(figure 15). the pump oil ring groove and the case bore).
E. Porous casting (pump or case).
F. Pump drain back hole not open.
CAUSES
1. Transmission oil pan leaks. 5. Oil comes out the vent pipe.
A. Attaching screws not correctly torqued. A. Transmission over-filled.
B. Im p ro pe rly in sta lle d or dam aged pan B. Water in the oil.
gasket. C. Filter O ring seal damaged or improperly
C. Oil pan gasket mounting face not flat. assembled causing the oil to foam.
2. Case extension leak. D. Foreign material between the pump and
A. Attaching screws not correctly torqued. case or between the pump cover and body
B. Rear seal assembly damaged or improperly E. Case porous, the pump face improperly
installed. (Propeller shaft yoke damaged). machined.
C. Gasket (Extension to case) damaged or F. Pump insufficient metal, porous.
improperly installed. G. Pump to case gasket mispositioned.
D. Porous casting. H. Pump breather hole blocked or missing.
E. Output shaft O ring damaged. I. Hole in intake pipe.
3. Case leak. 6. Oil cooler lines.
A. Filler pipe O ring seal damaged or A. C o n ne ctio ns at the ra d iato r loose or
m issing; m isposition of the fille r pipe stripped.
bracket to the engine loading one side of B. Connections at the case loose or stripped.
the O ring. 7. Modulator assembly. Diaphragm leaking.
D E F L M N
A. Oil Pan F. Oil Fill Tube Seal L. Manual Shaft Seal

B. Case G. Oil Pump Seal Assembly M. Governor Cover
C. Cooler Connectors & H. Oil Pump To Case Seal N. Speedo Seal
Plugs I. Converter 0. Extension To Case Seal
D. TV Cable Seal J. Vent P. Extension Oil Seal
E. Servo Cover K. Electrical Connector Seal Assembly
B-08659
Figure 15Possible Leak Points

DIAGNOSIS OF FLUID LEAKS

CONDITION INSPECT COMPONENT FOR CAUSE
Fluid Leak 1. Oil pan. 1. a. Low bolt torque.

b. Cut or damaged oil pan gasket.
To Correctly Identify 2. TV cabie connector. 2. a. Connector cocked and interfering
Fluid Leaks, Perform with mount.
The Following b. Connector cracked.
Procedure: c. Seal missing, cut or damaged.
3. Fill tube. 3. a. Fill tube cracked or damaged.
Clean all residual b. Seal missing, cut, or damaged.
oil from the 4. Electrical connector. 4. a. Electrical connector cracked.
transm ission with b. Seal missing, cut or damaged.
electram otive 5. Manual shaft. 5. a. Manual shaft nicked or damaged.
cleanser or b. Manual shaft seal assembly miss
equivalent. ing, cut or damaged.
6. Governor cover. 6. Gaps in sealant. (Remove & reseal).
Dust the 7. Speedo fitting. 7. a. Low bolt torque.
transm ission with b. Seal missing, cut or damaged.
leak tracing 8. Servo cover. 8. a. Porosity.
powder or spray b. Sharp edges on case cut seal.
foot powder. 9. Cooler fittings. 9. a. Low torque.
b. Cracked fitting.
Bring the engine 10. Converter assembly. 10. Hub or seam weld leak.
to normal 11. Vent. 11. a. Oil overfill.
operating b. Engine coolant in transmission oil.
tem perature. 12. Oil pump assembly. 12. a. Low bolt torque.
b. Cut or damaged oil pump to case
Turn the engine seal.
o ff and let the c. Damaged seal. (Restricted drain-
vehicle set for back passage).
th irty minutes. d. Porosity.
13. Rear extension. 13. a. Damaged extension to case seal.
Check fo r leaks. b. Porosity.
c. Damaged oil seal assembly.
DIAGNOSIS OF TORQUE CONVERTER

Converter Shudder 1. Torque converter assembly. 1. Internal damage.

2. Valve body. 2. Converter clutch shift valve stuck.
3. Oil pump assembly. 3. a. C onverter clutch apply valve
stuck.
b. Restricted oil passage.
4. Oil filter. 4. a. Crack in filter body.
b. Flash restricting filter neck.
c. Seal cut or damaged.
5. Miscellaneous. 5. a. Low oil pressure.
b. Engine not tuned properly.
6. Input housing and shaft assembly. 6. a. Turbine shaft seal cut or dam
aged.
b. Turbine shaft retainer and ball as
sembly damaged.
DIAGNOSIS OF TORQUE CONVERTER (CONT.)

No Converter Clutch 1. Solenoid 1. External ground.

Release 2. Converter. 2. Internal damage.
3. Oil pump assembly. 3. Converter clutch apply valve stuck.
No Converter Clutch 1. Electrical. 1. a. 12 volts not supplied to transmis

Apply sion.
b. Outside electrical connector dam
aged.
c. Inside electrical connector, wiring
harness or solenoid damaged.
d. Electrical short (pinched solenoid
wire).
e. Solenoid not grounded.
f. Incorrect or damaged pressure
switches.
2. Converter. 2. Internal damage.
3. Oil pump assembly. 3. a. Converter clutch apply valve stuck
or assembled backwards.
b. Converter clutch apply valve re
taining ring mispositioned.
c. Pump to case gasket misposi
tioned.
d Orifice cup plug plugged.
e. Solenoid seal cut or damaged.
f. O rifice cup plug om itted from
cooler in passage.
g. High or uneven bolt torque (pump
body to cover).
4. Valve body assembly. 4. Valves stuck.
a. Converter clutch shift valve.
b. Throttle valve.
5. Input housing and shaft. 5. a. Turbine shaft seal cut or dam
aged.
sembly plugged.
STATOR ASSEMBLY FREEWHEELS STATOR ASSEMBLY REMAINS LOCKED UP

If the stator assembly remains locked up at all times,
If the stator roller clutch becomes ineffective, the the engine rpm and vehicle speed will tend to be
stator assembly freewheels at all times in both limited or restricted at high speeds. The vehicle
directions. With this condition, the vehicle tends to performance when accelerating from a standstill will be
have poor acceleration from a standstill. At speeds normal. Engine overheating may be noted. Visual
above 48 to 56 km/h (30-35 mph), the vehicle may act examination of the converter may reveal a blue color
normal. If poor acceleration problems are noted, it from the overheating that will result.
should first be determined that the exhaust system is
not blocked, the engine is running properly and the
transmission is in first (1st) gear when starting out.
If the engine will free acclerate to high rpm in Neutral

(N), it can be assumed that the engine and exhaust
system are normal.
TORQUE CONVERTER CLUTCH (T.C.C.)

M E C H A N IC A L C H EC K S , S U C H AS L IN K A G E , O IL L E V E L , E T C .,
S H O U L D BE P E R F O R M E D P R IO R TO U S IN G TH IS C H A R T .
B-08583
Figure 16TCC Diagnosis

THM 350-C PRELIMINARY CHECKING
CHECK TRANSMISSION OIL LEVEL

----------- ------- ------ I _______
CHECK OUTSIDE MANUAL LINKAGE AND CORRECT
I
CHECK ENGINE TUNE
_________ I _________
INSTALL OIL PRESSURE GAGE (FIGURE 18)
_______________ I _______________
CONNECT VACUUM GAGE TO MODULATOR LINE & TACHOMETER TO ENGINE
CHECK O IL PRESSURES IN FOLLOW ING MANNER

_ p
Modulator* Sl Modulator**
RANGE MODELS Line Connected Line Disconnected
kPa PSI kPa PSI
XA 467-607 68-88 1020-1179 148-171
DRIVE - BRAKES APPLIED
XX 379-441 55-64 1020-1193 148-173
XA 614-756 89-111 1020-1186 148-172
L2 or L1 - BRAKES APPLIED
XX 552-641 80-93 1020-1193 148-173
XA 703-924 102-134 1558-1786 226-259

REVERSE - BRAKES APPLIED
XX 572-667 83-97 1634-1862 237-270
XA 467-593 68-86 1020-1172 148-170

NEUTRAL - BRAKES APPLIED
XX 379-427 55-62 1020-1193 148-173
DRIVE IDLE - SET ENGINE

XA 467-607 68-88
IDLE TO SPECIFICATIONS
XX 379-441 55-64
BRAKES APPLIED
DRIVE - 30 MPH
XA 467-607 68-88
CLOSED THROTTLE
XX 379-441 55-64
OR ON HOIST*
^MODULATOR LINE CONNECTED: Run engine to 1,000 RPM, close throttle and check PSI
* "MODULATOR LINE DISCONNECTED: Check PSI at 1,000 RPM, throttle open
***TOTAL RUNNING TIME FOR THIS COMBINATION NOT TO EXCEED 2 MINUTES.
F-00836
Figure 17Preliminary Check Procedure
The key to correcting any complaint is to make use transmission from the vehicle. Remember, THE VEHI
of all the available symptoms and logically letting them CLE IS THE BEST TEST STAND AND DIAGNOSITC
direct you to the cause. Symptoms or conditions that TOOL AVAILABLE TO YOU, if the transmission is oper
will help are determined by subjective road test, oil able. Once the transmission is on the bench, it cannot
pressure checks or noise evaluation. tell you what hurts and quite frequently the correc
When dealing with automatic transmission com tion of the cause of the complaint does not require re
plaints, it is best to gather as many symptoms as possi moval of the transmission from the vehicle.
ble before m aking the decision to remove the
DIAGNOSIS OF THM 350-C

No Drive Range 1. Low oil level. 1. Correct level-check for external leaks
(Install Pressure or vacuum modulator (leaking dia
Gage). phragm will evacuate oil from unit).
2. Manual linkage adjustment. 2. See manual linkage adjustment.
3. Low oil pressure. 3. a. Filter assembly-blocked.
b Pump assembly-pressure regula
tor, pump drive gear-tangs dam
aged by converter,
c. Case-porosity in intake bore.
4. Control valve assembly. 4. Manual valve disconnected from in
ner lever.
5. Forward clutch. 5. a. Forward clutch does not apply-
piston cracked; seals missing,
damaged; clutch plates burned,
b. Pump feed circu it to forward
clutch oil seal rings missing or
broken on pump cover; leak in
feed circuits; pump to case gasket
m is p o s itio n e d or dam ag e d.
Clutch drum ball check stuck or
missing.
6. Roller clutch assembly. 6. Broken spring or damaged cage.
DIANOSIS OF THM 350-C (CONT.)

Oil Pressure 1. High oil pressure. 1. a. Vacuum line or fittings leaking.

High-Low b. Vacuum modulator.
c. Modulator valve.
d. Pressure regulator.
e. Oil pump.
2. Low oil pressure. 2. a. Vacuum line or fittings obstructed.
b. Vacuum modulator.
c. Modulator valve.
d. Pressure regulator.
e. Governor.
f. Oil pump.
1-2 S hift-F u ll 1. Detent valve misadjusted. 1. Sticking or linkage.

Throttle Only 2. Vacuum leak. 2. Vacuum line or fittings leaking.
3. Control valve assembly. 3. a. Valve body gaskets-leaking, dam
aged, incorrectly installed.
b. Detent valve train stuck.
c. 1-2 valve stuck.
4. Case assembly. 4. Porosity.
First Speed O nly-N o 1. Governor assembly. 1. a. Governor valve sticking.

1-2 Shift b. Driven gear loose, damaged or
worn (check for pin in case and
length of pin showing); also, check
output shaft drive gear for nicks or
rough finish, if driven gear shows
damage.
2. Control valve assembly. 2. a. 1-2 shift valve train stuck closed.
b. Governor feed channels blocked.
c. Valve body gaskets-leaking, dam
aged, incorrectly installed.
3. Case 3. a. Porosity between channels.
b. Governor feed channel blocked,
governor bore scored or worn, al
lowing cross pressure leak.
4. Intermediate clutch. 4. a. Clutch piston seals-missing, im
properly assembled, cut.
b. Intermediate roller clutch.
c. Broken spring or damaged cage.
First And Second 1. Control valve assembly. 1. a. 2-3 shift train stuck.
Speeds Only, No 2-3 b. Valve body gaskets-leaking, dam
Shift aged, incorrectly installed.
2. Direct clutch. 2. a. Pump hub-direct clutch oil seal
rings-broken, missing,
b. Clutch piston seals-missing, im
properly assembled, cut, piston
ball check stuck or missing.
DIAGNOSIS OF THM 350-C (CONT.)

Drive In Neutral 1. Manual linkage. 1. Misadjusted.

2. Forward clutch. 2. Clutch does not release-(this condi
tion will also cause No Reverse ).
No Motion In 1. Low oil level. 1. Add oil.

Reverse , Or Slips 2. Manual linkage. 2. Misadjusted.
In Reverse -(ln sta ll 3. Oil pressure. 3. a. Modulator valve stuck.
Pressure Gage) b. Modulator and reverse boost valve
stuck.
c. Pump hub-direct clutch oil seal
rings broken.
d. Direct clutch piston seal cut or
missing.
e. Low and reverse clutch piston seal
cut or missing.
f. No. 1 check ball missing.
4. Control valve assembly. 4. a. Valve body gaskets-leaking, dam
aged, incorrectly installed (other
malfunctions may also be indica
ted).
b. 2-3 valve train stuck in upshifted
position. This will also cause 1-3
upshift in drive range.
c. 1-2 valve train stuck in upshifted
position.
5. Intermediate servo. 5. Piston or pin stuck so intermediate
overrun band is applied.
6. Low and reverse clutch. 6. Piston out or seal damaged or miss
ing.
7. Direct clutch. 7. a. Outer seal damaged or missing,
b. Clutch plates b urned-m ay be
caused by stuck ball check in pis
ton.
8. Forward clutch. 8. Clutch does not release (will also
cause Drive in Neutral ).
Slips In All Ranges, 1. Oil level low. 1. Add oil.

Slips On 2. Oil pressure. 2. a. Vacuum modulator inoperative.
T ake-O ff-(lnstall b. Vacuum modulator valve sticking.
Pressure Gage) c. Filter assembly-plugged or leaks.
3. a. Pressure regulator valve stuck.
3. Case. b. Pump to case gasket damaged or
incorrectly installed.
4. Forward clutch slipping. 4. Cross leaks, porosity.
Slips 1-2 1. Oil level low. 1. Add oil.

S h ift-(ln sta ll 2. Oil pressure. 2. a. Vacuum modulator assembly in
Pressure Gage) operative.
b. Modulator valve sticking.
c. Pump pressure regulator valve.
3. 2-3 accumulator. 3. Oil ring damaged or missing.

Slips 1-2 4. 1-2 accumulator. 4. Oil ring missing or damaged, case

Shift-(lnstaH bore damaged.
Pressure Gage) 5. Pump to case gasket. 5. Mispositioned.
(Continued) 6. Case. 6. Porosity between channels.
7. Intermediate clutch. 7. Piston seals missing or damaged;
clutch plates burned.
Rough 1-2 1. Oil pressure. For loose fittings, restric 1. a. Vacuum modulator-check.
S hift-(ln sta ll tions in line. b. Modulator valve stuck.
Pressure Gage) c. Valve body-regulator or boost
valve stuck.
d. Pump to case gasket-off location
or damaged.
2. Case. 2. Porosity between channels.
3. 1-2 accumulator assembly. 3. a. Oil rings damaged.
b. Piston stuck.
c. Broken or missing spring.
d. Bore damaged.
e. Check accumulator feed hole in
valve body plate.
Slips 2-3 1. Oil level low. 1. Add oil.

S h ift-(ln sta ll 2. Oil pressure low. 2. a. Modulator assembly.
Pressure Gage) b. Modulator valve.
c. Pump pressure regulator valve or
boost valve; pump to case gasket
off location.
3. Case. 3. Porosity.
4. Direct clutch. 4. Piston seals leaking, or ball check
leak.
Rough 2-3 1. Oil pressure high. 1. a. Vacuum leak.

S hift-(ln sta ll b. Modulator valve sticking.
Pressure Gage) c. Valve body-pressure regulator or
boost valve inoperative.
2. 2-3 accumulator assembly. 2. a. 2-3 accumulator spring missing,
broken.
b. Accumulator piston stuck.
No Engine 1. Intermediate servo and 2-3 accumula 1. a. Servo or accumulator oil rings or
Braking-L2-2nd Gear tor. bores leaking,
b. Servo piston stuck.
2. Intermediate overrun band. 2. Intermediate overrun band broken,
burned (check for cause).
3. Oil pressure low. 3. Pressure regulator and/or boost valve
stuck.
No Engine 1. Manual low control valve assembly. 1. Stuck.

B raking-L1-1st Gear 2. Oil pressure low. 2. Pressure regulator and/or boost valve
stuck.
3. Low and reverse clutch. 3. Piston inner seal damaged or miss
ing.

No Part Throttle 1. Oil pressure. 1. Vacuum modulator assembly, modu

D ow nshift-(lnstall lator valve, pressure regulator valve
Pressure Gage) train (other malfunctions may also be
noticed).
2. Detent valve and linkage. 2. Sticks or disconnected or broken.
3. 2-3 shift valve. 3. Stuck.
No Detent 1. Control valve assembly. 1. 2-3 valve stuck.

Downshifts 2. Detent valve and linkage. 2. Sticks or disconnected or broken.
Low Or High Shift 1. Oil pressure. 1. a. Engine vacuum-check at trans

P oints-(lnstall mission end of the m odulator
Pressure Gage) pipe.
b. Vacuum modulator assembly vac
uum line connections at engine
and tra n s m is s io n , m o d u la to r
valve, pressure regulator valve
train.
2. Governor. 2. a. Valve sticking.
b. Feed holes restricted or leaking,
pipes damaged or mispositioned.
3. Detent valve and linkage. 3. Stuck open. (Will cause late shifts).
4. Control valve assembly. 4. a. 2-3 valve train sticking.
b. 1-2 shift valve train sticking.
5. Case. 5. Porosity.
W ont Hold In 1. Manual linkage. 1. Misadjusted.

Park 2. Internal linkage. 2. a. Parking brake lever and actuator
assembly. Check for chamfer on
actuator rod sleeve,
b. Parking pawl broken or inopera
tive.
Locks Up In Manual 1. Converter pressure leaking into direct 1. Check stator shaft position.
Low (Usually Hot clutch through stator shaft.
Only) 2. Direct clutch. 2. a. Direct clutch bore undersize or
piston oversize,
b. Direct clutch feed hole shy small
chamber.
3. Lo and reverse clutch. 3. Lo and reverse clutch piston center
seal missing or cut.
Second Gear Start Intermediate clutch. Wrong number of clutch plates or

Or Slips Second wrong piston.
Gear Only
Locks Up In Reverse 1. Forward clutch. 1. Bore undersize or piston oversize.

(Usually Hot Only) 2. Direct clutch. 2. Direct clutch feeding forward clutch
through stator shaft. (Check stator
shaft position.)

Locks In Reverse Parking pawl. Parking pawl staying in due to a burr

From Park To on leading edge.
Reverse Only
Cold Morning Pressure regulator bore or sleeve tight. Remove and repair.
Reverse No Drive
Till Engine Warms
Up
Shifts Cold But Not Governor assembly. Nylon gear roll pin shy.
Warm
No D rive-B ut Has Low and reverse roller clutch. Low and reverse roller clutch in
Manual Low stalled backwards.
No 1-2 Shift-M akes Intermediate roller clutch. Intermediate roller clutch not locking.
1-3 Shift And 3-1
S hift, But Has All
S hifts Manually
Governor Nylon Gear 1. Case pin missing. 1. Governor case pin.

Stripped 360 2. Output shaft. 2. Output shaft rough or worn.
Governor Gear Governor seizing in bore. Repair or replace as necessary.

Stripped One Side
Slow Reverse (Cold Low oil level. Adjust oil level.

Only)
Harsh 1-2 Shift 1-2 accumulator. a. Piston or spring.

b. Accumulator feed hole in valve body
plate.
Slow Reverse (Hot 1. Valve body. 1. Leaking valve body support plate.
Only) 2. Shift selector lever. 2. a. Bent or S-hook hole off location.
b. S-hook bent.
c. Detent roller spring hole off loca
tion.
d. Manual valve S-hook hole off loca
tion.
THM 350-C AUTOMATIC TRANSMISSION
DIAGNOSIS CH ART
PROBLEM
CAR ROAD TEST >
LEGEND
XPROBLEM AREA V.S. CAUSE
*-<a, 0" VACUUM ONLY
O-BALLS *2/3/4 ONLY
2 Q- c//\ v / v / 0 / 0 / ry / ry/o o / v y <?y 0 7 ^ /
LLOCKED
S-STUCK <5
4 wwM/M
't/a1
nU/Vna y / yV yrv7c S>/ ?>/
//of/S>/<v/<<ZS/ / &
XV-/ \ /
/ fryer, / j / / A / n:y o
' f ' // V v/ s/ /
POSSIBLE CAUSE S'/ 0/&
V'r - V / 7V' / s/
LOW OIL LEVEL/WATER IN OIL X X X X X X X X X X X X
VACUUM LEAK X X X X X X X X X X
Figure 19THM 350-C Diagnosis Chart
MODULATOR & / OR VALVE X X * X X X X X X X X

STRAINER &/ OR GASKET X X X X X X X X X
GOVERNOR-VALVE/SCREEN X X X X X
VALVE BODY-GASKET/PLATE X X X X X X X X X X X X X
PRES. REG. & / OR BOOST VALVE X X X X X X X X X X X X X X X X X
BALL (#1) SHY X X X X X X X o X X
1-2 SHIFT VALVE X X X X X X X
2-3 SHIFT VALVE X X X X X X
MANUAL LOW CONT'L VALVE X
AUTOMATIC
DETENT VALVE & LINKAGE X X X X X X
DETENT REG. VALVE X
2-3 ACCUMULATOR X X X
MANUAL VALVE/LINKAGE X X X X X X X
POROSITY/CROSS LEAK X X X X X X X X X X X X X X X X X X X X X X
PUMPGEARS X X X X X X X X
PRIMING VALVE SHY X X X s
COOLER VALVE LEAK X X
CLUTCH SEAL RINGS X X X X X X X X X X X X X
POROUS/CROSS LEAK X X X X X X X X X X X X X X X
TRANSMISSIONS
GASKET SCREEN-PRESSURE X X X X X X X
j BANDINTERM. O.R. X
1 CASE-POROUS/X LEAK X X X X X X X X X X X X X X X X X X X X X
1-2 ACCUMULATOR X X X X X X X
INTERMED. SERVO X X X X X
FORWARD CLUTCH ASS'Y X X X X L
DIRECT CLUTCH ASS'Y X X X X X X
I INTERMED. CL. ASS'Y X X X X
L & REV. CL. ASS'Y X X X
| INT. ROLLER CL. ASSY X X X
1 L. & R. ROLLER CL. ASSY X
1 PARK PAWL/LINKAGE X
1 CONVERTER ASS'Y X X
CD
1 GEAR SET & BEARINGS X X 1
6
7A -25
CD
cn
o
o
7A-26
TRANSMISSION TRANSMISSION
AUTOMATIC
110
TRANSMISSIONS
Figure 20THM 350-C Oil Circuit
>
Z
o
S
30
Z
0
O
33
O
c
H
(/>
SLOT IN GASKET -
187^
186
110. Oil Pump 185. Manual Valve
170. Oil Cooler 175. 2-3 Clutch Pressure Tap 180. 1-2 S hift Valve 186. Detent Valve
171. Screen 176. 1-2 Clutch Pressure Tap 181. 2-3 S hift Valve 187. Detent Pressure Regulator
co 172. TCC Solenoid 177. M odulator Valve 182. Governor 188. 1-2 Accum ulator
o 173. TCC Apply Valve 178. Vacuum M odulator 183. 2-3 Accum ulator 189. Filter
oo
CD 174. Line Pressure Tap 179. Manual Low Control Valve 184. 3rd Gear Pressure Switch 190. Pressure Regulator
O
ro
215
AA. Reverse
AB. 2-3 Clutch
AC. Converter
Apply
AD. Converter
Feed
AE. Converter
Release
AF. Cooler In
AG. Void
B-08608
Figure 22THM 350-C Auxiliary Valve Body

Oil Passages
172 216
172. TCC Solenoid

215. Connector
216. Governor Pressure Switch
N.O.
GOV
[ a t .c .c . s o l
SW
POSITIVE >.
(TO PORTED LO VAC SW) In O.OILPATHl
>----- --------------------- 1 I
Ld _________________ |
5.0 L C- TRUCK
5.0 L G -VAN-SHO RT
5.0 L G-VAN-LONG
B-08604
Figure 21THM 350-C Wiring Diagram

AH AJ
AA. Reverse (Direct

Clutch Outer)
AC. Converter Clutch
Apply
IDENTIFICATION OF OIL CHANNELS IN PUMP COVER AE. Converter Release
AF. Cooler In
AJ AH AH. Cooler Out
AJ. Exhaust
AK. Pump Pressure
AL. Suction
AM. Forward Clutch
(Drive)
AN. Direct Clutch
AO. Intermediate Clutch
A P. Lip Seal Drain
IDENTIFICATION OF OIL CHANNELS IN PUMP BODY FRONT FACE

B-08611
Figure 23THM 350-C Oil Pump Passages

AN AM AE AA AK AL AE AM AN AO AC
Bolt Holes
Bolt Holes Reverse (Direct Clutch Outer)
AA.
AA. Reverse (Direct Clutch Outer)
AC. Converter Apply
AC. Converter Apply Converter Release
AE.
AE. Converter Release AF. Cooler In (To Radiator)
AF. Cooler In AH. Cooler Out (From Radiator)
AH. Cooler Out AK. Pump Pressure
AK. Pump Pressure AL. Suction
AL. Suction AM. Forward Clutch
AM. Forward Clutch AN. Direct Clutch
AN. Direct Clutch AO. Intermediate Clutch Apply
AO. Intermediate Clutch Apply AP. Drain (4) Cast Open Ports
AQ. Breather AQ. Breather
B-08626 B-08332
Figure 24THM 350-C Pump Rear Face Figure 25THM 350-C Case To Pump
Oil Passages Oil Passages
AA. Reverse AN. Direct Clutch (2-3) AX. Exhaust, Intermediate Clutch
AC. Converter Apply AO. Intermediate Clutch (1-2) AY. Detent Regulator.
AD. Converter Feed A P. Drain AZ. Governor
AE. Converter Release AR. Exhaust, 1-2 Clutch BA. Modulator
AF. Cooler In AS. Intermediate Service BB. Detent 2
AG. Void Release (RND) BC. Lo
AJ. Exhaust AT. Line BD. Detent Modulator (3 2)
AK. Pump Pressure AU. 2-3 Clutch BE. Modulator Thru Detent Valve
AL. Suction AV. Drive BF. Lo/Reverse Clutch
AM. Drive Forward Clutch AW. Modulator Or Detent Regulator BG. Manual Lo Control
B-08351
Figure 26THM 350-C Case Face Oil Passages

Bolt Hole AT. Line BJ. Reverse Orifice

AA. Reverse AV. Drive BK. Drive Orifice
AD. Converter Feed AW. Modulator Or BL. Converter Feed
AJ. Exhaust Detent Orifice
AK. Pump Pressure Regulator BM. Modulator
AL. Suction AY. Detent Thru Detent
AN. Direct Clutch Regulator Valve
2-3 AZ. Governor BN. Detent
AO. Intermediate BA. Modulator BO. Manual Lo
Clutch 1-2 BC. Lo Control
A P. Drain BD. Detent BP. Governor
AR. Exhaust 1-2 Modulator (3-2) Orifice
Clutch BF. Lo Reverse BR. Intermediate
AS. Intermediate Clutch Servo (RND)
Servo Release BH. Pump Pressure
(RND) Orifice B-08353
Figure 27THM 350-C Valve Body Spacer Plate

HO,C
AA. Reverse AU. 2-3 Clutch BG. Manual Lo Control
AD. Converter Feed AV. Drive BS. Speed Release
AG. Void AW. Modulator Or BT. Pressure Regulator
AJ. Exhaust (*-To Sump) Detent Regulator BU. Manual
AL. Suction AY. Detent Regulator BV. Detent 1
AN. Intermediate (L2) AZ. Governor BW. 1-2 Shift
AO. 1-2 Clutch BA. Modulator BX. 2-3 shift
AS. Intermediate BB. Detent 2 BY. Detent
Servo Release BC. Lo BZ. Detent Pressure
AT. Line BF. Lo Or Reverse Regulator
B-08400
Figure 28THM 350-C Valve Body Oil Passages

THM 400 PRELIMINARY CHECKING
CAUTION: TOTAL RUNNING

CHECK ENGINE TIMING AND IDLE (See Section 6-C & 6-D.)
TIME FOR THIS COMBINATION
NOT TO EXCEED 2 MINUTES.
INSTALL OIL PRESSURE GAGE (FIGURE 30)
CONNECT TACHOMETER TO ENGINE
CHECK O IL PRESSURES IN FOLLOW ING M ANNER

NORMAL NORMAL OIL PRESSURE PATTERN
RANGE LO W -N O R M A L-H IG H
kPa P.S.I.
1 N E U TR AL-BR A KES APPLIED

ENGINE AT 1000 RPM
379 TO 483 55 TO 70
DRIVE ID L E -S E T ENGINE
CM
414 TO 586 60 TO 85
IDLE TO SPECIFICATIONS
D R IV E -B R A K E S APPLIED
3 ENGINE AT 1000 RPM
414 TO 621 60 TO 90*
INTERMEDIATE OR LO -BR AKES

4 APPLIED ENGINE AT 1000 RPM
931 TO 1103 135 to 160*
REVERSE-BRAKES APPLIED 655 TO 1034 95 TO 150*

D R IV E -B R A K E S APPLIED
DOWNSHIFT SWITCH ACTIVATED
621 TO 758 90 TO 110
GOVERNOR C H EC K- DROP OF 69 DROP OF

7 FOR UPSHIFT PROBLEM PSI OR MORE 10 PSI OR MORE
8 D R IV E -3 0 MPH-CLOSED THROTTLE
ON ROAD, OR ON HOIST**
379 TO 483 55 TO 70
* IF HIGH LINE PRESSURES ARE EXPERIENCED REFER TO CAUSES OF HIGH LINE PRESSURE IN THIS
SECTION.
** VEHICLE ON HOIST, DRIVING WHEELS OFF GROUND, SELECTOR IN DRIVE, BRAKES RELEASED, RAISE
ENGINE TO 3000 R.P.M., CLOSE THROTTLE AND READ PRESSURE BETWEEN 2000 AND 1200 R.P.M.
B-08660
Figure 29Preliminary Checking Procedure

ROAD TEST
1. Connect a portable tachometer to the engine. En
gine rpm will identify the shift points.
2. Place the selector in Drive position and accel
erate the vehicle from a rest at a minimum throttle
opening. The specifications for the shifts points
are:
Downshifts should occur (3-2 and 2-1) as the
vehicle speed decreases to 0 mph. Stop the
vehicle.
3. Place the selector in Intermediate position and
accelerate the vehicle from a rest. A 1-2 shift
should occur at all throttle openings. No 2-3 shift
can be obtained in this range. Stop the vehicle.
4. Place the selector in Low . No upshift should
occur in this range regardless of the throttle
opening.
5. Position the selector in Drive and accelerate
the vehicle to 35 mph and move the selector to
Intermediate . A 3-2 downshift should occur, in
creasing the engine rpm and an engine braking
UPSHIFT MINIMUM effect should be noticed on deceleration.
1-2 15 MPH 6. With the selector in Intermediate at approxi
2-3 30 MPH mately 25 mph, but not over 40 mph, at closed
UPSHIFT MAXIMUM throttle, move the selector to Low. A 2-1 down
1-2 44-48 MPH shift should occur, increasing the engine rpm and
2-3 77-83 MPH an engine braking effect should be noticed on de
celeration. Stop the vehicle.
DETENT DOWNSHIFT MINIMUM 7. Place the selector in Reverse and check for re
3-2 68-73 MPH verse operation.
2-1 28-32 MPH
B-08325
Figure 31THM 400 Shift Points

DIAGNOSIS OF THM 400
1 2 3 4 5 6 7 8
Drive Drive Left

Neutral Drive-R Reverse Pressure Drop Drive
Left Brakes Applied
Brakes Drive Brakes Brakes Occurs while 30 mph
Brakes 1000 rpm
Applied Idle Applied Applied Engine rpm Closed Possible Cause
Applied Downshift
Malfunction 1000 rpm 1000 rpm 1000 rpm Increases from Throttle of Malfunction
1000 rpm Switch Activated
1000 to 3000 rpm
Wheels Free
Oil Oil Oil Oil Oil Oil to Move* Oil
Pressure Pressure Pressure Pressure Pressure Pressure Pressure
Malfunction in
10 psi Drop
Normal Normal Normal Normal Normal Normal Normal Control Valve
or More
Assembly
Malfunction in
Less than Governor or
Normal Normal Normal Normal Normal Normal Normal
10 psi Drop Governor Feed
System
No 1-2 Upshift
a n d/or Delayed Malfunction in
Normal High High Normal Normal Normal High
Upshift Detent System
Malfunction in
Modulator or
High High High Normal High - - - Vacuum Feed
System to
Modulator
Oil Leak in Feed

Slipping-Reverse Normal Normal Normal Normal Low Normal Normal System to the
Direct Clutch
Oil Leak in Feed

Low to Low to Low to Low to Low to
Slipping-1 st Gear Normal Normal - System to the
Normal Normal Normal Normal Normal
Forward Clutch
Downshift with
Stator and
Zero Throttle
Normal High Normal Normal Normal - - High Detent Wires
and No Engine
Switched
Braking in Drive
No Detent Malfunction in
Normal Normal Normal Normal Normal Low Normal
Downshifts Detent System
*Drive range, vacuum line disconnected from modulator.

A dash ( - ) in the above chart means that the oil pressure reading has no meaning under the test condition.
Pressures obtained by the Preliminary Checking procedure
B-08741
Figure 32THM 400 Oil Pressure Check Chart

DIAGNOSIS OF THM 400
B-08739
Figure 33No 1-2 Upshift And/Or Delayed Upshift

DIAGNOSIS OF THM 400 (CONT.)
B-08737
Figure 34102 Shift Feel Complaint Firm Shift

B-08735
Figure 3 5 -1 -2 Shift Feel Complaint Soft Shift

AUTOMATIC TRANSM ISSIONS 7 A -3 S
B-08336
Figure 3 6 -2 -3 Shift Complaint

Figure 37Drive In Neutral Figure 39No Engine B raking-Lo Range-

1st Gear
Figure 38W ill Not Holt In Park Or Will

Not Release From Park
B-08629
Figure 41No Reverse Or Slips In Reverse
Figure 421st And 2nd Speeds Only, No

2-3 Upshift
Figure 43No Drive In Drive Range
B-08675
Figure 44No Detent Downshift


NOTE: BEFORE CHECKING TRANSMISSION FOR WHAT IS BELIEVED TO BF TRANSMISSION NOISE, MAKE CERTAIN THE NOISE IS
NOT FROM THE WATER PUMP, GENERATOR, AIR CONDITIONER, POWER STEERING, ETC. THESE COMPONENTS CAN BE ISOLATED
BY REMOVING THE PROPER BELT AND RUNNING THE ENGINE NO MORE THAN TWO MINUTES AT ONE TIME.
B-08669
Figure 45Transmission Noisy

CAUSES OF LOW LINE PRESSURE Detent switch actuated (plunger stuck) or

1. Low transmission oil level. shorted.
2. Modulator Assembly. Detent wiring shorted.
3. Filter. Detent solenoid stuck open.
Blocked or restricted. (There is no approved Detent feed orifice in the spacer plate
service procedure for checking or cleaning blocked.
the filter. If the filter is suspected or being Detent solenoid loose.
plugged or restricted, it must be replaced). Detent valve bore plug damaged.
O ring on intake pipe and / or grommet Detent regulator valve pin short.
omitted or damaged. 4. Pump.
Split or leaking intake pipe. Pressure regulator and/or boost valve stuck.
Wrong filter assembly. Incorrect pressure regulator spring.
4. Pump. Too many pressure regulator valve spacers.
Pressure regulator or boost valve stuck. Pump casting bad.
Gear clearance, damaged, worn. (Pump will Pressure boost valve installed backwards or
become damaged if drive gear is installed malfunctioning.
backwards, or if converter pilot does not
enter crankshaft freely). CONTROL VALVE ASSEMBLYGOVERNOR LINE
Pressure regulator spring, too week. PRESSURE CHECK
Not enough spacers in pressure regulator. 1. Install an oil pressure test gage.
Pump to case gasket mispositioned. 2. Install a tachometer.
Malfunctioning pump body and/or cover. 3. Disconnect the vacuum line to the modulator.
Mismatched pump cover/pump body. 4. With the vehicle on a hoist driving wheels off the
5. Internal circuit leaks. ground, foot off the brake, in drive, check the line
Forward clutch leak (pressure normal in pressure at 1000 rpm.
neutral and reverse-pressure low in drive). 5. Slowly increase the engine rpm to 3000 rpm and
determine if a line pressure drop occurs (69 kPa
Check pump rings.
[10 psi] or more).
Check forward clutch seals.
6. If pressure drop of 69 kPa (10 psi) or more occurs,
Direct clutch leak (pressure normal in
disassemble, clean and inspect the control valve
n e u tra l, low, in te rm e d ia te , and
assembly.
drive-pressure low in reverse).
7. If the pressure drop is less than 69 kPa (10 psi):
Check center support oil seal rings.
Inspect the governor.
Check direct clutch outer seal for
Stuck valve.
damage.
Weight freeness.
C heck rear servo and fro n t
Restricted orifice in the governor
accum ulator pistons and rings for
valve.
damage or missing.
Check the governor valve entry and
6. Case assembly.
exhaust (0.50 mm [0.20-in.] min.).
Porosity in intake bore area.
Governor feed system.
Check case for intermediate clutch plug
Check the screen in the control valve
leak or missing plug.
assembly or case.
Lo-reverse check ball mispositioned or
Check for restrictions in the governor
missing (this will cause no reverse and no
pipe.
overrun braking in Lo range).
Check for fit of the governor pipes in
the case holes.
CAUSES OF HIGH LINE PRESSURE
1. Vacuum leak.
Full leak (vacuum line disconnected).
Partial leak in the line from the engine
modulator.
Improper engine vacuum.
Vacuum operated accessory leak. (Hoses,
vacuum advance, etc.).
2. Damaged modulator.
Stuck valve.
Water in the modulator.
Not operating properly.
3. Detent system.
TRANSMISSION
_ _ _ _ _
Figure 46THM 400 Oil Circuit
AUTOMATIC
TRANSMISSIONS
110. Oil Pump 181. 2-3 Shift Valve 190. Pressure Regulator
170. Oil Cooler 182. Governor 191. Front Servo
171. Screen 185. Manual Valve 192. Pressure Switch
177. M odulator Valve 187. Detent Pressure Regulator 193. Rear Servo
7 A -4 5
178. Vacuum M odulator 188. 1-2 A ccum ulator 194. 3-2 Shift Valve
180. 1-2 S hift Valve 189. Filer 195. Detent Solenoid
1986 THM 400 CLUTCH PLATE APPLICATION CHART

FORWARD CLUTCH
NO. OF NO. OF NO. OF NO. OF
MODELS FLAT STEEL WAVED STEEL DISHED COMPOSITION
PLATES PLATES PLATES PLATES
THICKNESS 2.32 MM 1.97 MM 1.54 MM 1.37 MM
(.0915") (.0775") (.0605") (.054")
EV, FI, FS, HR, MA 5 5
FG, RC, RR, RT, RV, ZD, ZV 5 1 5
ALL OTHERS 4 1 5
1986 THM 400 CLUTCH PLA TE APPLICATION CHART

DIRECT CLUTCH
NO. OF NO. OF NO. OF NO. OF
MODELS FLAT STEEL WAVED STEEL DISHED COMPOSITION
PLATES PLATES PLATES PLATES
THICKNESS 2.32 MM 1.97 MM 1.54 MM 1.37 MM
(.0915") (.0775") (.0605") (.054")
FA. FB, FC, FD, FF, FJ, FK, FM
5 5
FN. FP, FR, FT, FV, FW, FX, FZ
FG, ZD, ZV 2 3 1 5
EV, FT, FS, HR, MA, RV 6 6
FL, FQ, HZ, RC, RR 4 1 5
LR, LS 3 1 4
RT 5 1 6
1986 THM 400 (ILUTCH PLATE APPLICATION CHART

IN TERMEDIATE CLUTCH
NO. OF NO. OF NO. OF
MODELS FLAT STEEL WAVED STEEL COMPOSITION
PLATES PLATES PLATES
THICKNESS 2.51 MM 1.74 MM
(.099") (.0685")
EV, FG, FI, FS, HR, MA
3 3
RV, ZD, ZV
ALL OTHERS 2 1 3
B-08647
Figure 47THM 400 Clutch Usage Chart

AA. Drive AG
AB. Modulator AH. Line AA. Drive AH. Line
Or Intermediate AJ. Pressure AB. Modulator AL. Intake (Pump)
AC. To Cooler Regulator Feed Or Intermediate AN. Reverse
AD. From Cooler AK. Converter AC. To Cooler AP. Intermediate
AE. Breather AL. Intake AD. From Cooler Clutch Cup Plug
AF. Lubrication AM. Exhaust AG. Vent
AG. Vent AN. Reverse B-08635 B-08630
Figure 48THM 400 Pump Cover Oil Passages Figure 50THM 400 Case Oil Passages
AA. Drive
AB. Modulator Or Intermediate
AC. To Cooler
AD. From Cooler
AG. Vent
AH. Line
AK. Converter
AL. Intake
AN. Reverse
AO. Seal Drain Back Hole B-08641
Figure 49THM 400 Pump Body Oil Passages

AF. Lubrication
AN. Reverse
AQ. Direct Clutch
AR. Intermediate
B-08655
Figure 51THM 400 Center Support Oil

Passages
AA. Drive
AH. Line
AM. Exhaust
AN. Reverse
AQ. Direct Clutch
AR. Intermediate
AS. Servo
AT. Detent
AU. M odulator
AV. Governor
AW. Lo
AX. 1-2 Accum ulator
AY. Void
185. Manual Valve B-08322
Figure 52THM 400 Valve Body Oil Passages

(TO F SERVO) AZ (EXH AA. Drive

AH. Line
AM. Exhaust
AN. Reverse
AR. Intermediate
AT. Detent
AU. Modulator
AV. Governor
AW. Lo
AZ. Rnd
BA. 3rd Clutch
BB. 2nd Clutch
2-3 DR O IL TO F. SERVO
q O I
AN AA<2' 3) 1J r AA / / A W AW
AA (2-3) (2-3 DR TO 2nd C L)
q O (2ND CL. FEED)
0 Q 0*U (TO 3RD CL.)
a t aa
Q AH
0
AT
AT
B-08320
Figure 53THM 400 Valve Body Spacer Plate (Typical)

AA AM AT AR AH AN
AS AQ AP AX
AA. Drive AS. Servo

AB. Modulator or Intermediate AT. Detent
AH. Line AU. Modulator
AM. Exhaust AV. Governor
AN. Reverse AW. Lo
AP. Intermediate Clutch AX. 1-2 Accum ulator
Direct Clutch BC. Reverse or Lo
AR. Intermediate
B-08323
Figure 54THM 400 Case Oil Passages Bottom View

THM 700-R4 PRELIMINARY CHECKING
CHECK TRANSMISSION OIL LEVEL

CHECK AND ADJUST T V CABLE * NOTICE Total running time for this
CHECK OUTSIDE MANUAL LINKAGE AND CORRECT combination not to exceed 2 minutes.
CHECK ENGINE TUNE
INSTALL OIL PRESSURE GAGE (FIGURE 57) CAUTION Brakes must be
CONNECT TACHOMETER TO ENGINE applied at all times.
CHECK OIL PRESSURE AS FOLLOWS:
Minimum T V Line Pressure Check
Set the T V cable to specification; and with the brakes applied, take the line pressure readings in the ranges
and at the engine r.p.m.'s indicated in the chart below.
Full T V Line Pressure Check
Full T V line pressure readings are obtained by tying or holding the T V cable to the full extent of its travel; and
with,the brakes applied, take the line pressure readings in the ranges and at the engine r.p.m.'s indicated in the
chart below.
AUTOMATIC TRANSMISSION OIL PRESSURES

NORMAL OIL PRESSURE NORMAL OIL PRESSURE
RANGE MODEL AT MINIMUM T.V. AT FULL T.V.
kPa PSI kPa PSI
YC 384-443 56-64 1019-1387 148-201
YT,YX 451-514 65-75 945-1253 137-182
PARK,
NEUTRAL, YA, YD, YK, YL, YN, YP, YR, YS, YW, YZ 384-443 56-64 878-1182 127-171
OVERDRIVE & MH,TN,TR 451-514 65-75 885-1175 128-170
MANUAL 3RD FA, MA, MC, MD, MF, MK, MM, MP,
@ 1000 RPM MR, MT, MW, MX, PL, PR, TA, TB, 451-514 65-75 885-1175 128-170
TC,TD,TF,TJ,TK,TS,TW, YF
YC 631-728 92-106 *1674-2278 243-330
YT, YX 740-845 107-123 *1552-2058 225-298
REVERSE YA, YD, YK, YL, YN, YP, YR, YS, YW, YZ 631-728 92-106 *1443-1942 209-282
@ 1000 RPM MH,TN,TR 740-845 107-123 *1453-1929 211-280
*@ 2000 RPM FA, MA, MC, MD, MF, MK, MM, MP,
MR, MT, MW, MX, PL, PR, TA, TB, 740-845 107-123 *1454-1930 211-280
YC 704-813 102-118 704-813 102-118
YT, YX 709-808 103-117 709-808 103-117
MANUAL 2ND YA, YD, YK, YL, YN, YP, YR, YS, YW, YZ 704-813 102-118 704-813 102-118
& MANUAL LO MH,TN,TR 644-734 93-106 644-734 93-106
@ 1000 RPM FA, MA, MC, MD, MF, MK, MM, MP,
MR, MT, MW, MX, PL, PR, TA, TB, 709-808 103-117 709-808 103-117
Line pressure is basically controlled by pump output and the pressure regulator valve. In addition,
line pressure is boosted in Reverse, Second and Lo by the reverse boost valve.
Also, in the Neutral, Drive, Intermediate and Reverse positions of the selector lever, the line pressure should
increase with throttle opening because of the T V system. The pressure is controlled by the T V cable, the
throttle lever and bracket assembly and the T V link, as well as the control valve assembly.
The main line pressure tap plug is located on the left side of the transmission above the outside manual lever.
B-08640
Figure 55Oil Pressure Check Procedure

DIAGNOSIS OF THM 700-R4
IMPORTANT
As a diagnosis aid, you can check the oil pressure differential between line pressure and the
2nd, 3rd, and 4th clutch pressure while driving the vehicle. If the pressure differential be
tween line pressure and any of the clutch circuits is more than 10 P.S.I. (provided your gages
are accurate), there is a possible leak in that clutch oil circuit.
A. Line Pressure
B. Third Pressure
C. Fourth Pressure
D. Second Pressure
B-08331
Figure 56THM 700-R4 Pressure Tap Locations

DIAGNOSIS OF THM 700-R4

PROBLEM INSPECT COMPONENT FOR CAUSE
Oil Pressure High Or 1. Oil pump assembly. 1. a. Pressure regulator valve stuck.
Low b. Pressure regulator valve spring
(Check With Gage - damaged.
Check Oil Level & c. Rotor guide missing or misas-
Engine Tune) sembled.
d. Rotor cracked or broken.
e. TV valve, reverse boost valve or
bushing stuck, damaged or incor
rectly assembled.
f. Orifice hole in pressure regulator
valve plugged.
g. Sticking slide or excessive rotor
clearance.
h. Pressure relief ball not seated or
damaged.
j. Porosity in pump cover or body.
k. Wrong pump cover.
I. Pump faces not flat.
2. Oil filter. 2. a. Intake pipe restricted by casting
flash.
b. Cracks in filter body or intake
pipe.
c. Seal missing, cut or damaged.
3. TV exhaust ball. 3. Stuck or damaged.
4. Throttle lever and bracket assembly. 4. Misassembled, binding or damaged.
5. Throttle link. 5. Misassembled, binding or damaged.
6. Valve body. 6. a. Manual valve scored or damaged.
b. Spacer plate or gaskets incorrect,
misassembled or damaged.
c. Face not flat.
d. Throttle valve sticking.
e. Throttle valve sleeve rotated in
bore or retaining pin not seated.
f. TV limit valve sticking.
g. Modulated downshift valve stuck.
h. Line bias valve stuck.
j. 2-3 shift valve stuck.
k. Check balls missing or misas
sembled.
7. Case. 7. Case to valve body face not flat.
High Or Low Shift 1. TV cable. 1. Binding or not correctly adjusted.

Points 2. TV exhaust ball. 2 . Stuck or damaged.
3. Throttle lever and bracket assembly. 3. Misassembled, binding or damaged.
4. Oil pump assembly. 4. a. Stuck pressure regulator valve or
TV boost valve.
b. Sticking pump slide.
5. Valve body assembly. 5. a. Sticking throttle valve or plunger.
b. Modulated TV up or down valves
sticking.
c. TV limit valve sticking.
d. Spacer plate or gaskets misas
sembled, damaged or incorrect.
DIAGNOSIS OF THM 700-R4 (CONT.)

1st Gear Range Only 1. Governor assembly. 1. a. Governor valve sticking.

No Upshift b. Governor driven gear loose or
damaged.
c. Governor driven gear retaining pin
missing.
d. Nicks or burrs on output shaft.
e. Nicks or burrs on governor sleeve
or case bore.
f. Governor support pin in case too
long or short.
g. Governor weights or springs miss
ing binding or damaged.
2. Valve body. 2. a. 1-2 shift valve sticking.
b. Spacer plate or gaskets misposi
tioned or damaged.
3. Case. 3. a. Case to valve body face not flat or
damaged,
b. Governor screen restricted or
damaged.
4. 2-4 servo assembly. 4. a. Restricted or blocked apply pas
sages in case.
b. Nicks or burrs on servo pin or pin
bore in case.
c. Missing or damaged piston or pin
seals.
d. 4th servo piston in backwards.
5. 2-4 band assembly. 5. a. 2-4 band worn or damaged.
b. Band anchor pin not engaged.
Slips In 1st Gear 1. Forward clutch assembly. 1. a. Clutch plates worn.

b. Porosity or damage in forward
clutch piston.
c. Forward clutch piston inner and
outer seals missing, cut or dam
aged.
d. Input housing to forward clutch
housing seal missing, cut or dam
aged.
e. Damaged forward clutch housing.
f. Forward clutch housing retainer
and ball assembly not sealing or
damaged.
2. Input housing and shaft assembly. 2. Turbine shaft seals missing, cut or
damaged.
3. Valve body. 3. a. Accumulator valve stuck.
b. Face not flat, damaged lands or
interconnected passages.
c. Spacer plate or gaskets incorrect,
mispositioned or damaged.
4. TV cable. 4. Binding or broken.

Slips In 1st Gear 5. 1-2 accumulator piston assembly. 5. a. Porosity in piston or 1-2 accumula
(Continued) tor cover and pin assembly.
b. Damaged ring grooves on piston.
c. Piston seal missing, cut or dam
aged.
d. 1-2 accum ulator cover gasket
missing or damaged.
e. Leak between piston and pin.
f. Broken 1-2 accumulator spring.
6. Oil pressure. 6. Refer to Causes of High or Low Oil
Pressure.
7. 2-4 servo assembly. 7. 4th servo piston in backwards.
1-2 S hift Speed 1. TV cable. 1. a. Binding or broken.

High Or Low b. Not correctly adjusted.
2. Governor assembly. 2. Refer to 1st Gear Range Only No
Upshift.
3. Throttle lever and bracket assembly. 3. a. Misassembled, binding or dam
aged.
b. TV link missing, binding or dam
aged.
4. Valve body. 4. a. TV exhaust check ball stuck.
b. TV plunger sticking.
c. Face not flat.
5. Oil pump assembly or case. 5. Face not flat.
Slipping Or rough 1. Throttle lever and bracket assembly. a. Incorrectly installed or damaged.
1-2 Shift b. TV cable broken or binding.
2. Valve body assembly. a. Throttle valve sticking.
b. TV bushing turned in its bore.
c. 1-2 shift valve train stuck.
d. Gaskets or spacer plate incorrect,
Line bias valve stuck.
Accumulator valve stuck.
TV limit valve stuck.
Face not flat.
3. 2-4 servo assembly. 3. a. Apply pin too long or too short.
b. Servo seals missing, cut or dam
aged.
Restricted or missing oil pas
sages.
Servo bore in case damaged.
4. 2nd Accumulator. 4. Porosity in 1-2 accumulator hous
ing or piston.
b. Piston seal or groove damaged.
c. Nicks or burrs in 1-2 accumulator
housing.
d. Missing or restricted oil passage.
5. 2-4 band. Worn or mispositioned.
6. Oil pump assembly or case. Faces not flat.

No 2-3 Shift Or 2-3 1. Converter. 1. Internal damage.

Shift Slipping, Rough 2. Governor assembly. 2. a. Valve stuck.
Or Hunting b. Drive gear retaining pin missing or
loose.
c. Governor weights binding.
d. Governor drive gear damaged.
e. Governor support pin in case too
long or too short.
3. Oil pump. 3. Stator shaft sleeve scored or off loca
tion.
4. Valve body. 4. a. 2-3 valve train stuck.
b. Accumulator valve stuck.
c. Spacer plate or gaskets incorrect,
d. Throttle valve stuck.
e. TV limit valve stuck.
5. Input housing assembly. 5. a. Clutch plates worn (3-4 or for
ward).
b. Excessive clutch plate travel.
c. Cut or damaged piston seals (3-4
or forward).
d. Porosity in 3-4 clutch housing or
piston.
e. 3-4 piston check ball stuck, dam
aged or not sealing.
f. Restricted apply passages.
g. Forward clutch piston retainer and
ball assembly not seating.
h. Sealing balls loose or missing.
6. Case. 6. 3rd accumulator retainer and ball as
sembly not seating.
7. 2-4 servo assembly. 7. a. 2nd apply piston seals missing,
cut or damaged,
b. Servo pin seals missing, cut or
damaged.
No. 3-4 S hift/S lipping 1. Governor. 1. a. Governor weights binding.

Or Rough 3-4 Shift b. Governor valve stuck.
c. Governor drive gear retaining pin
missing or loose.
d. Governor drive gear damaged.
e. Governor support pin in case too
long or too short.
2. Oil pump assembly. 2. a. Faces not flat.
b. Pump cover retainer and ball as
sembly missing or damaged.
AUTOMATIC TRANSM ISSIONS 7A-57

No 3-4 Shift/Slipping 3. Valve body assembly. 3. a. Valves stuck.

Or Rough 3-4 Shift -2-3 shift valve train.
(Continued) -Accumulator valve.
-Throttle valve.
-TV limit valve.
-1-2 shift valve train.
-3-2 control valve.
b. Manual valve link bent or dam
aged.
c. Spacer plates or gaskets incorrect,
4. 2-4 servo assembly. 4. a. Incorrect band apply pin.
b. Missing or damaged servo seals.
c. Porosity in pistons, cover or case.
d. Damaged piston seal grooves.
e. Plugged or missing orifice cup
plug.
5. Case. 5. a. 3rd accumulator retainer and ball
assembly leaking.
b. Porosity in 3-4 accumulator piston
or bore.
c. 3-4 accumulator piston seal or
seal grooves damaged.
d. Plugged or missing orifice cup
plug.
e. Restricted oil passage.
6. Input housing assembly. 6. Refer to Slipping 2-3 Shift.
7. 2-4 band assembly. 7. Worn or misassembled.
1
No Reverse Or Slips 1. Input housing assembly. 1. a. 3-4 apply ring stuck in applied po
In Reverse sition.
b. Forward clutch not releasing.
c. Turbine shaft seals missing, cut or
damaged.
2. Manual linkage. 2. Not adjusted.
3. Oil pump assembly. 3. a. Retainer and ball assembly miss
ing or damaged.
b. Stator shaft seal rings or ring
grooves damaged.
c. Stator shaft sleeve scored or dam
aged.
d. Reverse boost valve stuck, dam
aged or misassembled.
e. Cup plug missing.
f. Restricted oil passage.
g. Faces not flat.
h. Converter clutch apply valve
stuck.
4. Valve body assembly. 4. a. 2-3 shift valve stuck.
b. Manual linkage not adjusted.
c. Spacer plate and gaskets incor
rect, mispositioned or damaged.

No Reverse Or Slips 5. Reverse input clutch. 5. a. Clutch plates worn.

In Reverse b. Reverse input housing and drum
(Continued) assembly cracked at weld.
c. Clutch plate retaining ring out of
groove.
d. Return spring assembly retaining
ring out of groove.
e. Piston deformed or dished.
f. Seals cut or damaged.
g. Reatiner and ball assembly not
sealing.
6. Lo and reverse clutch. h. Restricted apply passage.
6. a. Clutch plates worn.
b. Clutch plate retaining ring mispo-
sitioned.
c. Porosity in piston.
d. Seals damaged.
e. Return spring assembly retaining
ring mispositioned.
7. Case. f. Restricted apply passage.
7. a. Cover plate gasket missing or
damaged.
b. Cover plate not torqued correctly.
c. Porosity.
No Part Throttle Or 1. External linkage. 1. Not adjusted.

Delayed Downshifts 2. 2-4 servo assembly. 2. a. Apply pin seal cut or damaged.
b. Servo cover retaining ring missing
or misassembled.
c. 4th apply piston damaged or mis
assembled.
d. Servo inner housing damaged or
misassembled.
3. Governor assembly. 3. a. Governor weights binding,
b. Governor valve stuck.
4. Valve body assembly. 4. a. Valves stuck.
-Throttle valve.
-3-2 control valve.
-TV modulated downshift.
b. TV sleeve turned in bore.
c. 4-3 sequence valve body channel
blocked.
d. #5 check ball missing from valve
body.
No Overrun Braking 1. External linkage. 1. Not adjusted properly.

Manual 3-2-1 2. Valve body assembly. 2. a. Valves stuck.
-4-3 sequence valve.
-Throttle valve.
b. Check ball #3 mispositioned.
c. Spacer plate and gaskets incor
rect, damaged or mispositioned.

No Overrun Braking 3. Input clutch assembly. 3. a. Turbine shaft oil passages

Manual 3-2-1 plugged or not drilled.
(Continued) b. Turbine shaft seal rings damaged.
c. Turbine shaft sealing balls loose or
missing.
d. Porosity in forward or overrun
I clutch position.
i
e. Overrun piston seals cut or dam
aged.
f. Overrun piston check ball not seal
ing.
No Converter Clutch 1. Electrical. 1. a. 12 volts not supplied to transmis

Apply sion.
b. Outside electrical connector dam
aged.
c. Inside electrical connector, wiring
harness or solenoid damaged.
d. Electrical short (pinched solenoid
wire).
e. Solenoid not grounded.
f. Incorrect or damaged pressure
switches.
2. Converter. 2. Internal damage.
3. Oil pump assembly. 3. a. Converter clutch apply valve stuck
or assembled backwards.
b. Converter clutch apply valve re
taining ring mispositioned.
I c. Pump to case gasket misposi
I
t
tioned.
d. Orifice cup plug plugged.
e. Solenoid 0 ring seal cut or
damaged.
f. Orifice cup plug omitted from
cooler in passage.
g. High or uneven bolt torque (pump
body to cover).
4. Valve body assembly. 4. Valves stuck.
-Converter clutch shift valve.
-Throttle valve.
5. Input housing and shaft. 5. a. Turbine shaft 0 ring seal cut or
damaged,
sembly plugged.
Converter Shudder 1. Torque converter assembly. 1. Internal damage.

2. Valve body. 2. Converter clutch shift valve stuck.
3. Oil pump assembly. 3. a. Converter clutch apply valve
stuck.
b. Restricted oil passage.
4. Oil filter. 4. a. Crack in filter body.
b. Flash restricting filter neck.
c. Seal cut or damaged.

Converter Shudder 5. Miscellaneous. 5. a. Low oil pressure.

(Continued) b. Engine not tuned properly.
6. Input housing and shaft assembly. 6. a. Turbine shaft seal cut or dam
aged.
sembly damaged.
No Converter Clutch 1. Solenoid. 1. External ground.

Release 2. Converter. 2. Internal damage.
3. Oil pump assembly. 3. Converter clutch apply valve stuck.
Drives In Neutral 1. Forward clutch. 1. Not releasing.

2. Manual linkage. 2. a. Incorrectly adjusted,
b. Disconnected.
3. Case. 3. a. Face not flat.
b. Internal leakage.
2nd Gear Start (Drive 1. Governor assembly. 1. a. Valve stuck.

Range) b. Governor support pin too long or
missing.
2. Forward sprag clutch. 2. Sprag assembly installed backwards.
No Park 1. Parking linkage. 1. a. Acutator rod assembly bent or

damaged.
b. Actuator rod spring binding or im
properly crimped.
c. Actuator rod not attached to inside
detent lever.
d. Parking bracket damaged or not
torqued properly.
e. Inside detent lever not torqued
properly.
f. Detent roller mispositioned or not
torqued properly.
g. Parking pawl binding or damaged.
Racheting Noise Parking pawl. Parking pawl return spring weak,

damaged or misassembled.
Oil Out The Vent 1. Oil pump. 1. Chamfer in pump body rotor pocket
too large.
2. Valve body. 2. TV Imiit valve stuck.
Vibration In Reverse Oil pump. Broken vane rings.

And Whining Noise
In Park
OIL AND WIRING CIRCUITS

TRANSMISSION TRANSMISSION
:2"'1ciuich
110. Oil Pump 184. 3rd C lutch 197. TCC S hift Valve 205. Throttle Valve
170. Oil C ooler Pressure S w itch Train (TV)
172. TCC Solenoid 185. Manual Valve 198. MTV Up Valve 206. TV Exhaust Lifter
173. TCC A pply Valve 188. 1-2 A ccum ulator Train 207. A ccum ulator
174. Line Pressure 189. F ilter 199. MTV Down Valve Valve Train
Tap 190. Pressure Train 208. 3-4 A ccum ulator
175. 3rd A ccum ula tor R egulator 200. 3-4 S hift Valve 209. TV Lim it Valve
Pressure Tap 191. 2-4 Servo Train Train
176. 2nd C lutch 192. 4-3 D ow nshift 201. 4th C lutch 210. Line Bias Valve
Pressure Tap S w itch Pressure S w itch Train
180. 1-2 S hift Valve 194. 3-2 C ontrol Valve 202. 3-4 Relay Valve 211. Pressure Relief
Train Train 203. 4-3 Sequence Valve
181. 2-3 S h ift Valve 196. TCC Signal Valve 212. 4th C lutch
Train S w itch 204. TV Plunger Pressure Tap
182. G overnor Check Balls
B-08461
Figure 57THM 700-R4 Oil Circuits

AA. Vent
AB. Line
AC. Dec.
AD. Exhaust
AE. Rev. Clutch
AF. D-2
AG. MTV
AH. 3-4 Clutch
AJ. O.R. Clutch
AK. Seal Drain
AL. Void
AM. Conv. Clu. Sig.
AN. To Cooler
AO. Conv. Clu. Rel.
A P. Lube
AQ. Conv. Feed
Figure 58THM 700-R4 Pump Cover Oil Passages
AQ. Conv. Feed

AA. Vent
A P. Lube
AD. Exhaust
AO. Conv. Clu. Rel.
AN. To Cooler
AM. Conv. Clu. Sig.
AL. Void
AK. Seal Drain
AJ. O.R. Clu.
AH. 3-4 Clutch
AG. MTV
AF. D-2
AE. Rev. Clutch
AB. Line
AC. Dec.
Figure 59THM 700-R4 Pump Body Oil Passages

AD. Exhaust 229. Seal, O Ring

AR. 4th Oil 230. H ousing, Servo Piston Inner
AS. 3rd A ccu m u la to r Oil 231. Ring, Oil Seal Inner (2nd Apply Piston)
AT. 2nd Oil 232. Ring, Oil Seal O uter (2nd A pply Piston)
220. Valve Body Face 233. Piston, 2nd A pply
221. Oil Pan Flange 234. Spring, Servo C ushion
222. Seal, 0 Ring (2-4 Servo Cover) 235. Retainer, Servo C ushion Spring
223. Cover, 2-4 Servo 236. Ring, Retainer (2nd A pply Piston)
224. Piston, 4th Supply 237. Pin, 2nd A pply Piston
225. Ring, Oil Seal O uter (4th A pply Piston) 238. Seal, 2nd A pply Piston Pin
226. Ring, Retainer (Apply Pin) 239. Spring, Servo Return
227. Washer, Servo A pply Pin 240. Retainer & Ball Assem bly, 3rd Accum.
228. Spring, Servo A pply Pin 241. Plug, Case Servo
B-08561
Figure 60THM 700-R4 Servo Assembly

AE. Reverse
AF. D-2 AF BH BJ AT BK AE A AU AVAW AX
AU. Lo
AV. Lo-1
AW. D-4
AX. G overnor
AY. Lo Reverse
AS. 3 A ccum u la to r
AZ. TV
AH. 3-4 C lutch
AG. MTV
AH. A ccu m u la to r (4th) *#1
BA. 4th Signal
AL. Void
BB. 3-4 A ccu m u la to r
AD. TV-Ex
AB. Line
BC. Part Throttle-D rive 3 *#3
AT. 2nd (1-2) #8
BD. TVF
AR. 4th
AM. C onv Clu. Sig.
n . . AR AZ B D AT BC AB AD BB AL AH
BE. MTV Down BG. Detent
BF. MTV Up BH. Det./Lo *#9 BK. RND 4-3
AJ. O.R. C lutch BJ. 3-4 C lutch (3-2 Ex.) #10 Check Balls
B-08462
Figure 61THM 700-R4 Chase Oil Passages And Check Ball Locations
BL. Fwd. Clutch AL. Void BP AD

AG. MTV AA. Vent
AH. 3-4 Clutch BN. From Cooler AD. Servo Exhaust Hole
AE. Reverse AN. To Cooler BO. 3rd Accumulator Pressure Tap Passage
AB. Line AM. Conv. Clu. Sig. BP. 2-4 Servo Bore
AF. D-2 AJ. O.R. Clutch BQ. 2nd & 4th Band Apply Passage
BM. Pressure Tap 240. Retainer & Ball Assembly, 3rd Accum.
241. Plug, Case Servo
B-08465 B-08464
Figure 62THM 700-R4 Pump To Case Oil Figure 63THM 700-R4 Servo Oil Passages
Passages
AB. Line Bolt Holes BU. 4th C lutch

AW. D4 BR. A ccum ulator AM. Conv. Clu. Sig.
AE. Reverse BA. 4th Signal BF. MTV Up
AF. D2 AT. 2nd C lutch BE. MTV Down
AU. Lo BB. 3-4 A ccum ulator BG. Detent
AV. Lo-1 BD. TVF AH. 3-4 C lutch
AX. G overnor AJ. Overrun C lutch BH. Detent/Lo
AY. Lo/Reverse AD. TV Ex. BK. Rnd. 4-3
AS. 3rd A ccum u la to r BC. DC3/Part T hrottle BX. 3rd C lutch
AZ. TV BS. Part th ro ttle By. Id e n tifica tio n
AG. MTV BT. D3
B-08831
Figure 64THM 700-R4 Spacer Plate To Case Gasket

<v?

O AF
AU BG
O O ^ AB AU o AE AX
AE O C 3 AU
O Q BH W 6 Q DAE
AZ AT AX ASD O AY
^ 0 A
BX
P Z je
BG . & y e *

a
a AW AX
BG BA

AS BG BB U q j ,
O AB ^ /J
AM AJ / BA
O B R -^ -Q
AT
C3 O O
AT BS BT
BC AD
AB. Line Bolt Holes BU. 4th C lutch

AW. D4 BR. A ccum ulator AM. Conv. Clu. Sig.
AF. D2 BA. 4th Signal BF. MTV Up
AU. Lo AT. 2nd C lutch BE. MTV Down
AE. Reverse BB. 3-4 A ccum ulator BG. Detent
AX. Governor BD. TVF AH. 3-4 C lutch
AV. Lo-1 AJ. Overrun C lutch BH. Detent/Lo
AY. Lo/Reverse AD. TV Ex. BK. RND. 4-3
AS. 3rd A ccu m u la to r BC. D3/Part Throttle BX. 3rd C lutch
AZ. TV BS. Part T hrottle BY. Id e n tifica tio n
AG. MTV BT. D3
B-08798
Figure 65THM 700-R4 Spacer Plate To Valve Body Gasket

AUTOMATIC TRANSMISSIONS 7A -67
GAS MODELS
ONLY
AF
AE DIESEL MODELS
cA
0
^5 AU
AU<W ' AX
AF
o
AU BG
O C> AV o AW "
AE 0 0 AWO n QAX - ^ AE
o
AZ
Q
AS
BH AB
BX X *S O O
AHD a
AH AZ *
s . 0
AG AW m BG
BG a AX
a ag
AZ
BA
AJ 0 AG
AS BG BB O O q 'U-BY
BF
D Q
AM
^ScBF 0
BU
AB
AT_ BS
A AZ ATC3 O OBT
AB. Line Bolt Holes

AW. D4 BR. Accumulator BU. 4th Clutch
AF. D2 BA. 4th Signal AM. Conv. Clu. Sign.
AU. Lo AT. 2nd Clutch BF. MTV Up
AE. Reverse BB. 3-4 Accumulator BE. MTV Down
AX. Governor BD. TVF BG. Detent
AV. Lo-1 AJ. Overrun clutch AH. 3-4 Clutch
AY. Lo/Reverse AD. TV Ex. BH. Detent/Lo
AS. 3rd Accumulator BC. D3/Part Throttle BK. RND. 4-3
AZ. TV BS. Part Throttle BX. 3rd Clutch
AG. MTV BT. D3 BY. Identification
rc F-00910
Figure 66THM 700-R4 Typical Spacer Plate

n s n [
AB. Line AZ. TV BC. D3/Part Throttle BH. Detent/Lo

AW. D4 AG. MTV BS. Part T hrottle BK. Rnd. 4-3
AF. D2 BR. A ccu m u lator BT. D3 BX. 3rd clu tch
AU. Lo BA. 4th Signal BU. 4th C lutch BY. Id e n tifica tio n
AE. Reverse AT. 2nd C lutch AM. Conv. Clu. Sig. AL. Void
AX. Governor BB. 3-4 A ccum ulator BF. MTV Up AD. Exhaust
AV. Lo-1 BD. TVF BE. MTV Down BZ. SF
AY. Lo/Reverse AJ. Overrun C lutch BG. Detent CA. 4-3
AS. 3rd A ccu m ulator AD. TV Ex. AH. 3-4 C lutch
B-08520
Figure 67THM 700-R4 Valve Body Oil Passages

B A
205. T h ro ttle Valve (& Bushing)
204. T V P lunger (& Bushing) 181. 2-3 S hift Valve Train
203. 4-3 Sequence Valve 200. 3-4 S hift Valve Train
202. 3-4 Relay Valve 197. TCC S hift Valve Train
209. T V Lim it Valve Train 198. M TV Up Valve Train
207. A ccu m ula tor Valve Train 199. M T V Down Valve Train
210. Line Bias Valve Train A. Converter C lutch TV B ushing Bore
194. 3-2 C ontrol Valve Train Plug (ECM C ontrolled Vehicles)
185. Manual Valve B. Converter C lutch S h ift Valve Bore
180. 1-2 S hift Valve Train Plug (ECM C ontrolled Vehicles)
B-08521
Figure 68THM 700-R4 Valve Trains

TC C SOL
(N.O. OIL PATH
0.5 am ps! * \ f
+ 12 V - > r ~* *-------- P ^ V i
0.5 AMPS i B 4TH CL
+ 12V (N.O.) I
0.28 AMPS ' D ^ ^ |
+ 12V i / \ ^ |
T ------ \ --------------- '

3RD CL TC C SIG
(N.O.) (N.O.)
NORMALLY OPEN (N.O.)
NORMALLY CLOSED (N.C.)
TYPE 1
MODELS: MD, MK, TK
Component Color ID Wire Color ID

172. TCC Solenoid White A. Connector A To Red
184. 3rd Clutch Switch Black/Green Dot 4-3 Shift Switch
Terminals Lt. Green B. Connector B To White
192. 4-3 Shift Switch Black Body 4th Clutch Switch
Terminals Yellow D. Connector D To White
196. TCC Signal Switch Black 3rd Clutch Switch
Terminal Lt. Green E. 4-3 Shift Switch To White
201. 4th Clutch Switch Black/Green Dot 4th Clutch Switch
Terminals Blue F. TCC Signal Switch To White
215. Connector 3rd Clutch Switch
G. TCC Solenoid To Red
4-3 Shift Switch
B-08516
Figure 69THM 700-R4 Wiring Type 1

4-3 SHIFT
(N.C.f TCC_SOL____
0.5 AMPS, (N.O. OIL PATH)
+ 12V
0.5 AMPS iB
^ 5 ^
+ 12V 4TH CL
D (N.O.)

TYPE 2
MODELS: MF, MR, MX,

TC, TD, TF, TR
201

172. TCC Solenoid Yellow A. Connector A To Red
192. 4-3 Shift Switch Black 4-3 Shift Switch
Terminal Yellow B. Connector B To White
Terminals Blue E. 4-3 Shift Switch To White
215. Connector 4th Clutch Switch
G. TCC Solenoid To Red
4-3 Shift Switch
B-08517

|T C C SOL
I(N.O. OIL PATH)|
0.5 AMPS
+ 12V :.>A
,4 3 SHIFT'c w
(N.C.)

192
TYPE 3
MODELS: TS, YF, YL,
MH, TN

172. TCC Solenoid Black A. Connector A To Red
192. 4-3 Shift Switch Black Body 4-3 Shift Switch
Terminals Yellow G. TCC Solenoid ( + ) To Red
215. Connector 4-3 Shift Switch
B-08513


4-3 SHIFT I C C SOL

(N.C. (N.O. OIL PATH)
1
0.5 AMPS i a
+ 12V ~>>
0.28 AMPS,B
+ 12V
E .C .M .-S * a xT C C SIG
GRD (N.O.) j
3RD CL
(N.O.)
(N.O.) 4TH CL
NORMALLY CLOSED (N.C.
TYPE-5
5.0L GAS 2 W.D. (C) TRUCK
5.7L GAS 2 W.D. (C) &
4 W.D. (T) TRUCK
4.1 L GAS 2 W.D. (C) TRUCK &
(G) VAN WITH EMISSION
SYSTEM FOR CALIFO R N IA

172. TCC Solenoid Blue A. Connector A To Red
184. 3rd Clutch Switch Black/Green Dot 4-3 Shift Switch
Terminals Lt. Green B. Connector B To White
192. 4-3 Shift Switch Black Body 3rd Clutch Switch
Terminals Yellow D. Connector D To Black
196. TCC Signal Switch Black 4th Clutch Switch
Terminal Lt. Green F. TCC Signal Switch To White
201. 4th Clutch Switch Black 3rd Clutch Switch
Terminals Blue G. TCC Solenoid ( + ) To Red
H. TCC Solenoid (-) To Black
3rd Clutch Switch B-085C

T.C.C. SOL
(N.O. O IL PATH)
----------------\ T
0.5 AMPSi a
+ 12V -*> --------------
GROUND>C-

TYPE 6
MODELS: MP, PL, TA, TB

172. TCC Solenoid Dk. Green A. Connector A To Red
215. Connector TCC Solenoid ( + )
D. Connector D To Black
TCC Solenoid (-)
B-08510

4TH CL T C C SO L
21 (N.O.) (N.O. O IL PATH)
0.5 AM PS
+ 12V
0.5 AM PS
+ 12V
0.28 AM PS
+ 12V
T C C S IG N A L
(N.O.)
NO R M ALLY OPEN (N.O.)

NO R M ALLY CLOSED (N.C.)
TYPE-7
2.0L GAS 2 W.D. (S) TR UCK W ITH
EM ISSION SYSTEM FOR H IG H
ALTITUDE U.S.A.
EXCEPT C A L IF O R N IA

172. TCC Solenoid Gray A. Connector A To Red
196. TCC Signal Switch Black 4th Clutch Switch
Terminal Lt. Green B. Connector B To Red
Terminals Blue D. Connector D To White
215. Connector TCC Signal Switch
J. TCC Solenoid To Red
4th Clutch Switch
B-08509


172. TCC Solenoid Lt. Green A. Connector A To Red
201. 4th Clutch Switch Black 4th Clutch Switch
Terminals Blue B. Connector B To Red
215. Connector 4th Clutch Switch
J. TCC Solenoid To Red
4th Clutch Switch
------------------------------------------------ .. B-08505

215
TC C SOL
(N.O. OIL PATH)
\ n
0.5 AMPS i
+ 12V
0.010 AMPS ig
B + 12V
g r o u n d -4-0
4TH DISCREET
SW (N.C.)
201
BC
TYPE 9
MODELS: YC, YD, YW, YX,

YZ, YA, YR, YS
______Component______ Color ID Wire_____________ Color ID

172. TCC Solenoid Orange A. Connector A To Red
Terminal ( + ) Red TCC Solenoid ( + )
201. 4th Clutch Switch Metallic/White B. Connector B To White
Terminal Blue 4th Clutch Switch
D. Connector D To Black
*Optional Metallic/Black TCC Solenoid (-)**
**CCC Ground
B-08493

T C C SOL

172. TCC Solenoid Brown A. Connector A to Red
192. 4-3 Shift Switch Black 4-3 Switch
Terminals Yellow D. Connector D To Black
201. 4th Clutch Switch Black 4th Clutch Switch
Terminal Blue G. TCC Solenoid ( + ) To
215. Connector 4-3 Shift
B-08526

3RD CLU. 4-3 SHIFT

(N.O.) (N.C.)
+12V r 1
0.5 AMPS
T C C SOL.
ECM (N.O. O IL PATH)
GROUND>
|D

172
TYPE 14
MODELS: MC, MT, PR

172. TCC Solenoid Pink A. Connector A To Red
184. 3rd Clutch Switch Black/Green Dot 3rd Clutch Switch
Terminals Lt. Green D. Connector D To Black
192. 4-3 Shift Switch Black Body TCC Solenoid (-)
Terminals Yellow G. TCC Solenoid ( + ) To
B-08527

ON-VEHICLE SERVICE
GENERAL SERVICE PROCEDURES SERVICE METHODS

When servicing the transmission, it is recommended
ENGINE COOLANT IN TRANSMISSION that upon disassembly of a unit, all parts should be
If the transmission oil cooler, located in the radiator cleaned and inspected as outlined under PARTS
assembly, has developed a leak allowing engine CLEANING AND INSPECTION. The unit should be
coolant to enter the transmission, use the following assembled before disassembly of other units to avoid
procedure: confusion and interchanging of parts.
1. Before disassembly of the unit, thoroughly clean
1. Remove the transmission from the vehicle. the exterior.
2. Disassemble the transmission and replace all 2. Disassembly and reassembly of the unit and the
rubber type seals. (The coolant will attack the subassemblies must be made on a clean bench.
seal material causing leakage.) As in repairing any hydraulically operated unit,
cleanliness is of the utmost im portance;
3. Replace the composition-faced clutch plate therefore, the bench, tools, and parts must be
assemblies. (The facing material may become kept clean at all times.
separated from the steel center portion). 3. Before installing cap screws into aluminum parts,
ALWAYS DIP THE SCREWS INTO
4. Replace the nylon washers, speedometer gears
TRANSMISSION OIL to prevent cap screws from
and governor gear. (The nylon can swell and
galling the aluminum threads and also to prevent
become damaged.)
the screws from seizing.
5. Flush the converter, including TCC types. 4. Always use a torque wrench when installing cap
screws into aluminum parts to prevent the
6. Thoroughly clean and rebuild the transmission,
possibility of stripping the threads.
using new gaskets and oil filter.
5. If tapped threads in aluminum parts are stripped
7. Flush the cooler lines after the transmission or damaged, the part can be made serviceable by
cooler has been properly repaired or replaced. the use of Heli-Coils or equivalent.
6. Seal protecting tools must be used when
assembling the units to prevent damage to the
CASE POROSITY REPAIR
seals. The slightest flaw in the sealing surface of
External leaks caused by case porosity can be
the seal can cause an oil leak.
repaired with the transmission in the vehicle by using
7. The aluminum castings and the valve parts are
the following recommended procedures:
very susceptible to nicks, burrs, etc., and care
1. Road test and bring the transmission to operating should be exercised when handling them.
temperature, about 93C (200F). 8. The internal snap rings should be expanded and
the external snap rings compressed if they are to
2. Raise the vehicle on a hoist or jack stand, with
be reused. This will insure proper seating when
engine running and locate the source of the oil
installed.
leak. Check for leaks in all operating positions. A
9. Replace all O ring seals, gaskets and oil seals
mirror may be helpful in finding leaks.
that are removed. Oil seal rings should not be
3. Shut the engine off and thoroughly clean the area removed unless damaged.
to be repaired with a cleaning solvent and air dry. 10. During assembly of each unit, all internal parts
must be lubricated with oil.
4. Using the instructions of the manufacturer, mix a
sufficient amount of epoxy, GM Part No. 1052533,
PARTS CLEANING AND INSPECTION
or equivalent to make repair. Observe the
Cleanliness is an important factor in the overhaul of
cautions of the manufacturer in handling.
the transmission. Before attempting any disassembly
5. While the transmission case is still HOT, apply the operation, the exterior of the transmission should be
epoxy to the area to be repaired. A clean, dry thoroughly cleaned to prevent the possibility of dirt
soldering acid brush can be used to clean the entering the transmission internal mechanism. During
area and also to apply the epoxy cement. Make inspection and reassembly, all parts should be
certain the area to be repaired is fully covered. thoroughly cleaned with cleaning fluid and then air
dried. Wiping cloths or rags should not be used to dry
6. Allow the cement to cure for three hours before
parts. Do not use solvents on neoprene seals,
starting the engine.
composition-faced clutch plates or thrust washers. All
7. Road test and check for leaks. oil passages should be blown out ahd checked to make
sure that they are not obstructed. Small passages

should be checked with tag wire. All parts should be
inspected to determine which parts are to be replaced.
The various inspections of parts are as follows:
1. Inspect linkage and pivot points for excessive
wear.
2. Bearing and thrust surfaces of all parts should be
checked for excessive wear and scoring.
3. Check for broken seal rings, damaged ring lands
and damaged threads.
4. Inspect all seals.
5. Mating surfaces of castings and end plates
should be checked for burrs and irregularities
may be removed by lapping the surface with
crocus cloth. The crocus cloth should be laid on a CHECKING AND ADDING FLUID
flat surface, such as a piece of plate glass.
6. Castings should be checked for cracks and sand The automatic transmission is designed to operate
holes. at the FULL HOT mark on the dipstick at normal
operating temperatures of 88C-93C (190F-200F),
and should be checked under these conditions.
OIL COOLER LINES The normal operating temperature is obtained only
after at least 24 km (15 miles) of highway type driving.
If replacement of transmission steel tubing cooler If the vehicle has recently been operated for an
lines is required, use only double wrapped and brazed extended period at high speed or in city traffic in hot
steel tubing meeting GM specification 123M or weather or the vehicle is being used to pull a trailer, an
equivalent. Under no condition use copper or accurate fluid level cannot be determined until the fluid
aluminum tubing to replace steel tubing. Those has cooled down, usually about 30 minutes after the
materials do not have satisfactory fatigue durability to vehicle has been parked.
withstand normal vehicle vibrations. Steel tubing
should be flared using the double flare method.
Inspect (Figure 80)
COOLER LINE FLUSHING Check the transmission fluid level with the engine
In a major transmission failure, where particles of running, the shift lever in park, and the vehicle
metal have been carried with the oil throughout the level.
units of the transmission, it will be necessary to flush 1. Apply the parking brake and block the vehicle
out the oil cooler and connecting lines. To flush the oil wheels.
cooler and lines, use the following procedure:
2. With the selector level in the PARK position, start
1. D isconnect both cooler lines from the the engine. DO NOT RACE THE ENGINE. Move
transmission. the selector lever through each range.
2. Place a hose over the end of the cooler inlet line 3. Remove the dipstick and touch the transmission
(from the bottom of the cooler) and insert the end of the dipstick cautiously to find out if the
hose into an empty container. fluid is cool, warm or hot. Wipe it clean and
3. Flush clean oleum solvent or equivalent through re-insert it until the cap seats.
the return line (from the top of the cooler) using 4. Remove the dipstick and note the reading.
an oil suction gun until clean solvent comes out If the fluid feels cool, about room
of the hose. This will "back flush the cooler. temperature, 18 to 29C (65 to 85F), the
4. Remove the hose from the inlet cooler line and level should be between the two dimples
place it on the return line. below the ADD mark.
5. Flush clean oleum solvent or equivalent through If it feels warm, the level should be close to
the inlet line until clean solvent comes out the the ADD mark (either above or below).
return line. Remove remaining solvent from If it feels hot (cannot be held comfortably),
cooler with compressed air applied to the return the level should be between the ADD and
line and flush with transmission fluid. FULL marks.
6. Reconnect oil cooler lines and torque nuts to 17 5. If additional fluid is required, add enough fluid to
N m (12 ft. lbs.). bring it to the correct mark on the dipstick.
ty Clean (Figure 81)
Drain remaining fluid from the pan.

Gasket m aterial from the pan and the
transmission case.
Pan, and the filter screen if used, with solvent.
Dry with clean compressed air.
1. New filter (181) and new seal (223) or screen and

new gasket, if used.
Screws or c'ips as needed.
2. New gasket (220) and the pan (221).
3. Screws (222). Refer to Specifications for the
proper torque.
Lower the vehicle.
4. New fluid. Refer to Specifications for the
proper amount.
Check the fluid level and add as needed to bring
the fluid to the proper level.
SHIFT LINKAGE
|++| Remove or Disconnect (Figure 82)
Apply the parking brake.

1. Retaining pin (226).
2. Rod (240) from the column lever.
Important Note the position of any washers, spacers
and insulators removed.
DO NOT OVERFILL. 3. Rod (240) from the equalizer lever (238).
To bring fluid level from ADD mark to FULL mark C, K and P Models.
requires 0.5 liter (one pint) of fluid. Screw (242) and the washer.
Overfilling can cause foaming and loss of fluid Swivel (232).
through the vent. Slippage and transmission failure G Models.
can result. Nut (236), washers and the insulator.
Fluid level too low can cause slipping, particularly, Swivel (232).
when the transmission is cold or the vehicle is on a hill. Spacer and the retainer.
4. Retaining pin (227) and the equalizer lever (238).
Insulator, washer and the spring.
FLUID AND FILTER
Clean
0 Remove or Disconnect (Figure 81) Metal parts using solvent. Wipe dry using a
clean, dry rag.
Raise the vehicle. Rubber or nylon parts using soapy water. Wipe
1. Screws (222) from the front and sides of the pan dry using a clean, dry rag.
(221).
Loosen the screws at the rear of the pan about -+ Install or Connect (Figure 82)
four turns.
2. Pan (220) part way. 1. Equalizer lever (238) and a new retaining pin
Pry the front loose and drain the fluid into a pan. (227).
3. Screws (222) from the rear of the pan (221). Spring, washer and the insulator.
4. Pan (221) and the gasket (220). 2. Rod (240) to the equalizer lever (238).
5. Filter (181) and the seal (223), or screen and the C, K and P Models.
gasket, if used. Swivel (232).
Screws or clips as needed. Washer and the screw (242).
244 U ---- 226
P MODELS
226. R etaining Pin
227. Retaining Pin
228. Nut
229. Spring
230. Washer
231. Insulator
232. Swivel
233. Retainer 240. Rod
234. Insulator 241. Washer
235. Spring Washer 242. Screw G MODELS
236. Nut 243. Spacer 240
237. Washer 244. Insulator
238. Equalizer Lever A. Shift Lever / Jr^
239. Spacer B. Steering Column 232 /
233 B-08491
Figure 82Shift Linkage
G Models. Move the shift lever (A) to the forward

Retainer and the spacer. position, the back to the second detent.
Swivel (232). (Figure 83).
Insulator, washers and the nut (236). 4. Hold the rod (240) tightly in the swivel (232).
3. Rod (240) to the column lever.
Insulators, spacers and washers in the Tighten
positions they were removed from.
Nut (236) or the screw (242) to 23 N m (17 ft.
4. New retaining pin (226).
lb.).
Adjust 5. Put the column selector lever in the P (Park)
position.
Apply the parking brake. 6. Check the adjustment.
1. Loosen the screw (242) or the nut (236), as used. The column selector lever must go into all
2. Put the column selector lever in the N (Neutral) positions.
position.
The engine must start in the P (Park) or
Put the lever into the neutral gate, do not N (Neutral) positions only. Adjust if
use the indicator to find the neutral position. needed, refer to Neutral Start Switch in
3. Put the transmission in neutral. this section.
0 l Install or Connect (Figure 84)
1. New seal (254).

2. Cable (142) to the transmission.
Link.
Washer and the screw.
Screw to 10 N m (8 ft. lb.).

3. Routing clips or straps as used.
The cable must be routed in the position it
was removed from.
Raise the transmission if needed, refer to
Transmission R eplacem ent in this
section.
Lower the vehicle.
Figure 83Shift Positions 4. Cable (142) to the throttle lever.
Both lock tabs must be through the bracket.
CAUTION: With the selector lever in the Cable terminal to the throttle lever.
Park position, the parking pawl should
freely engage w ith in the rear (reaction) Important
internal gear lugs or output ring gear lugs
and prevent the vehicle from rolling, which The cable must not be kinked or damaged.
could cause personal injury.
^ Adjust (Figure 84)
Align the indicator, if needed.
Release the parking brake. Remove the air cleaner if needed.
1. Push the re-adjust tab (250) in and puis :\e slider
(251) back against the fitting.
TV-DETENT CABLE
Important
(THM 350-C AND THM 700-R4)
Do not press the lock tabs in.
2. Move the throttle lever to the full throttle position,
and release it.
1. Air cleaner, if needed.
Important
2. Cable (142) from the throttle lever.
Push the re-adjust tab (250) in and pull the Do not use the accelerator pedal to open the
slider (251) through the fitting (141). throttle.
Cable terminal from the throttle lever. 3. Install the air cleaner if needed.
Push the lock tabs in and pull the fitting

(141) from the bracket. DETENT SWITCH (THM 400)
3. Routing clips or straps as used.
Raise the vehicle.
Lower the transmission if needed for
clearance. Refer to Transm ission 1. Wire connector.
Replacement in this section. 2. Screw.
Note the routing of the cable (142). 3. Switch (260).
4. Cable (142) from the transmission.
Screw and the washer.
1. Switch (260).
Raise the cable and disconnect the link. 2. Screw.
5. Seal (254). 3. Wire connector.
250
HE
140. Throttle Lever

141. Cable Adjuster (Fitting)
140 142. Cable
255 144. Link
250. Re-Adjust Tab
251. Slider
252. Screw
253. Washer
254. Seal
255. Terminal
A. ID Number B-08654
Figure 84TV-Detent Cable (THM 350-C And THM 700-R4)
ft Adjust (Figure 85)
1. Press the plunger (A) as far forward as possible.

2. Press the accelerator pedal to the floor.
VACUUM MODULATOR
(THM 350-C AND THM 400)
Raise the vehicle.

1. Pipe (267) from the modulator port.
Hose.
2. Vacuum modulator (178).
Screw and the retainer.
Seal.
3. Pipe (267) if needed.
Hose.
Note the position of the pipe and any clips.
jQ* Clean (Figure 86)
All parts using soapy water. Air dry.

178. Vacuum Modulator

265. Manifold Fitting
266. Hose
267. Pipe
268. Clip
269. Seal
270. Retainer
271. Screw B-08653
Figure 86Vacuum Modulator (THM 350-C And THM 400)
L* Inspect SPEEDOMETER DRIVEN GEAR

Modulator and pipe for kinks, cracks and VEHICLE SPEED SENSOR
damage.
Hoses for cracks, wear and dry rot. Remove or Disconnect (Figure 87)
Apply the parking brake.

Install or Connect (Figure 86) 1. Speedometer cable (277).
1. Pipe (267) if removed. 2. Screw and the retainer.
3. Sleeve and the seal.
Seat the pipe against the manifold fitting. 4. Driven gear or speed sensor (280), as used.
The pipe must be routed in the position it
was removed from. y Inspect (Figure 87)
2. Vacuum modulator (178). Gear teeth for nicks and burrs.

All parts for wear and damage.
New seal.
Retainer and the screw. Install or Connect (Figure 87)
3. Pipe (267) onto the modulator port. 1. Driven gear or speed sensor (280) as used.
2. New seal and the sleeve.
Important 3. Retainer and the screw.
4. Speedometer cable (277).
The pipe must not be twisted or bent.
Release the parking brake.
4. Transmission fluid if needed. Refer to Checking 5. Transmission fluid if needed. Refer to Checking
and Adding Fluid in this section. and Adding Fluid in this section.
Or Speed Sensor
B-08637
Figure 87Speedometer Driven Gear
GOVERNOR Important
Do not damage the governor cover. If the

Remove or Disconnect (Figure 88) cover is damaged it must be replaced.
2. Governor (182).
Raise the vehicle.
y | Clean (Figure 88)
Lower the transmission if needed for clearance,
refer to Transmission Replacement*1 in this Governor using solvent. Air dry and blow out all
section. passages using dry compressed air.
1. Governor cover (287) and the seal or gasket as
used. L * Inspect (Figure 88)
THM 350-C and THM 700-R4 All parts for nicks, burrs, scoring and galling.
Tap around the cover flange with a Governor sleeve for binding.
punch. Governor valve for binding.
Driven gear for loose fit.
THM 400
Weight springs for kinks or damage.
Remove the screws. Weights for binding.
B-08676
Figure 88Governor
Valve entry opening. With the weights held all the

way outward, the opening should be 5.1 mm
(0.020 in.) (Figure 89).
Valve exhaust opening. With the weights held all
the way inward, the opening should be 5.1 mm
(0.020 in.) (Figure 90).
If the weights, sleeve, or valve do not operate
freely, disassemble and clean the governor.
If the driven gear must be replaced, the governor
must be disassembled.
Important
All the governor parts are a select fit. Except

for the driven gear, the governor must be
replaced as an assembly if repair is needed.
Diassemble (Figures 91 and 92) Figure 89Measuring The Governor

Value Entry Opening
1. Remove the governor weight pins (310).
Cut off one end of each pin to remove them.
2. Remove the thrust cap (317), the weights (315 and
316) and the springs (314).
3. Remove the valve (311) from the sleeve.
4. Remove the driven gear, if needed.
Drive out the retaining pin using a punch or
1/s in. drill.
Press the gear out of the sleeve using a
punch, with the gear supported in a press
with two 2.778 mm (7/e4 in.) plates in the
exhaust slots.
5. Clean the governor parts and inspect for damage.
* Assemble (Figures 92, 93 and 94)
1. New driven gear into the sleeve, if needed.

Press the gear in until it is almost seated Figure 90Measuring The Governor
using a socket with the governor supported Value Exhaust Opening
in a press with two 2.778 mm (7/e4 in.) plates
in the exhaust slots.
Remove any shavings from the gear hub
and press the gear in until it is seated.
Drill a new pin hole 90 from the old one
using a 1/s in. drill in a press.
New retaining pin through the new pin hole
so the ends are just below the top of the
hole.
Stake both ends of the pin hole in two
places, and wash the governor.
2. Valve (311) into the sleeve.
3. Springs (314), the weights (315 and 316) and the
thrust cap (317) onto the governor, aligning the
pin holes.
4. New weight pins (310) and crimp both ends of
each pin.
310. Weight Pins

311. Valve Figure 94Drilling The Driven Gear
312. Retaining Pin
313. Driven Gear Tap the cover into place using a brass
314. Spring drift.
315. Primary Weight THM 400.
316. Secondary Weight Screws.
317. Thrust Cap Raise the transmission if needed. Refer to
B-08523 Transmission R eplacem ent in this
section.
Figure 92Governor Lower the vehicle.
3. Transmission fluid if needed. Refer to Checking
-4- Install or Connect (Figure 88) and Adding Fluid in this section.
1. Governor (182).
2. Governor cover (287) and a new seal or gasket as 1-2 ACCUMULATOR (THM 350-C)
used.
THM 350-C and THM 700-R4.
Put a thin coat of Loctite Cup Plug
Sealant II, or equivalent, on the cover.
Tool Required:
J-23069 Accumulator Cover Remover and
Installer
Raise the vehicle.
Lower the transmission, if needed for clearance.
Refer to Transmission Replacement in this
section.
1. Retaining ring and the cover (290) using J-23069.
Seal from the cover.
2. Spring (292).
3. Piston (295).
Important
Do not remove the teflon seal rings from the

piston.
y | Clean (Figure 96)

Figure 93Installing The
Governor Driven Gear All parts using solvent. Air dry.
A. J-23069
290. Cover B-08524
Figure 95Removing The Figure 97Removing The Servo Cover

Accumulator Cover (THM 350-C) (THM 700-R4)
Inspect (Figure 96) |-n-| Install or Connect (Figures 95 and 96)

L*
All parts for wear and damage. Tool Required:

J-23069 Accumulator Cover Remover and
Cover seal groove for nicks and burrs. Installer.
Piston seal rings for scoring. If the seal rings are 1. Piston (295).
worn or scored, the piston and rings must be 2. Spring (292).
replaced as a unit. 3. Cover (290) and the retaining ring using J-23069.
New seal on the cover.
Raise the transmission if needed. Refer to
Transmission R eplacem ent in this
section.
Lower the vehicle.
and Adding Fluid in this section.
2-4 SERVO (THM 700-R4)
Tool Required:
J-29714 Servo Cover Compressor.
Raise the vehicle.
Lower the transmission if needed for clearance.
Refer to Transmission Replacement in this
290. Cover section.
291. Teflon Seal Rings 1. Retaining ring and the cover (223) using J-29714.
292. Spring 2. Seal from the cover.
293. Seal 3. 4th apply piston (224).
294. Retaining Ring 4. 2nd apply piston assembly (301).
295. Piston 5. Spring (239).
Disassemble (Figures 99 and 100)

B-08532
Tool Required:
Figure 9 6 -1 -2 Accumulator (THM 350-C) J-22269-01 Piston Compressor.
226. Ring, Retainer (Apply Pin)

227. Washer, Servo Apply Pin
228. Spring, Servo Apply Pin
229. Seal, O Ring
A. Case Servo Bore 230. Housing, Servo Piston Inner
222. Seal, O Ring (2-4 Servo Cover) 231. Ring, Oil Seal Inner (2nd Apply Piston)
223. Cover, 2-4 Servo 232. Ring, Oil Seal Outer (2nd Apply Piston)
224. Piston, 4th Apply 233. Piston, 2nd Apply
225. Ring, Oil Seal Outer (4th Apply Piston) 234. Spring, Servo Cushion
229. Seal, O Ring 235. Retainer, Servo Cushion Spring
232. Ring, Oil Seal Outer (2nd Apply Piston) 236. Ring, Retainer (2nd Apply Piston)
238. Seal, 2nd Apply Piston Ring 237. Pin, 2nd Apply Piston
239. Spring, Servo Return 238. Seal, 2nd Apply Piston Pin
300. Ring, Servo Cover Retaining
301. 2nd Apply Piston Assembly
B-08536 B-08530
Figure 9 8 -2 -4 Servo (THM 700-R4) Figure 992nd Apply Piston Assembly

(THM 700-R4)
A. Gage Slot
A. J-22269-01 B. J-33037
233. Piston, 2nd Apply
236. Ring, Retainer (2nd Apply Piston) B.08729 Pin Is Preset At Factory And Must Not Be Re
adjusted
Figure 100Removing The Retainer Ring 2-4 SERVO PIN SEL ECTION
(THM 700-R4) PIN I.D.
PIN LENGTH
1. Housing (230) from the piston (233). mm INCH
Seal from the housing. 66.37-66.67 2.61-2.62 2 Rings
2. Retainer ring from the pin (237). 67.74-68.04 2.67-2.68 3 Rings
Washer and the spring. 69.11-69.41 2.72-2.73 Wide Band
3. Pin (237).
B-08731
Seals from the pin.
4. Retainer ring from the piston (233) using
J-22269-01. Figure 101 -Measuring The Servo Pin Length
Retainer and the spring. (THM 700-R4)
Seals from the piston.
Install pin and J-33037 as shown.
J ] Clean (Figures 98 and 99) Apply 11.0 N-m (110 in. lbs.) torque and
check the gage slot (A).
All parts using solvent. Air dry. If the white line is seen in the slot, the
pin is correct.
L* Inspect (Figures 98 and 99) If the white line is not seen in the slot,
replace the pin using the chart.
Pistons for porosity and damage. Remove the pin and J-33037.
Seal grooves for damage. 2. Piston and housing dimension (Figure 102).
Cover for porosity and damage.
Measure the piston dimension (C).
Seals for nicks and cuts and binding in the seal
Measure the housing dimension (D).
grooves.
If damage is found, check for the cause of Check the chart for the proper dimensions.
the damage.
Springs for kinks and bending. * Assemble (Figures 99 and 100)
Pin for wear and burrs.
Tool Required:
Important J-22269-01 Piston Compressor
1. Retainer and the spring in the piston (233).
Check the case servo bore for damage and New seals on the piston.
sharp edges. Retainer ring using J-22269-01.
2. Pin (237).
Measure (Figures 101 and 102)
New seals on the pin.
Tools Required: 3. Retainer ring on the pin.
J-33037 Band Apply Pin Tool Spring and the washer.
Vernier calipers or micrometer 4. Housing (230) on the piston (233).
1. Servo pin length (Figure 101). New seal on the housing.
2ND APPLY PISTON & HOUSING APPLICATION

PISTON HOUSING
MODEL DIMENSION DIMENSION
*A **B
63.10 mm 64.00 mm
YT, Y6, YK
(2.48") (2.52")
44.64 mm 45.54 mm
YC, YX
(1.78") (1.79")
57.85 mm 58.74 mm
ALL OTHERS
(2.28") (2.31")
Figure 103Rear Extension Oil Seal

and Adding Fluid in this section.
REAR EXTENSION OIL SEAL
[++I Remove or Disconnect (Figure 103)
Raise the vehicle.

1. Transmission fluid.
(SEC. 4A).
3. Seal.
230. Housing, Servo Piston (Inner) Tool Required:

233. Piston, 2nd Apply J-21426 Extension Housing Oil Seal Installer
B-08730
(THM 350-C and THM 700-R4)
J-24057 Extension Housing and Pump Oil
Figure 1022nd Apply Piston And Seal Installer (THM 400)
Housing Dimensions (THM 700-R4)
1. New seal using J-21426 or J-24057 as needed.
Important Coat the outer edge of the seal case with a
non hardening sealer.
Be sure the proper seals are in the proper 2. Propeller shaft. Refer to PROPELLER SHAFT
positions (Figure 98). (SEC. 4A).
Lower the vehicle.
Install or Connect (Figures 97 and 98). 3. New transmission fluid. Refer to Specifications
for the proper amount.
Tool Required:
J-29714 Servo Cover Compressor
1. Spring (239).
TRANSMISSION REPLACEMENT
2. 2nd apply piston assembly (301). If the transmission is being lowered for clearance, do
3. 4th apply piston (224). steps 1-8 only.
4. New seal on the cover.
5. Cover (223) and the retaining ring using J-29714. Remove or Disconnect (Figure 104)
Raise the transmission if needed. Refer to
Transmission R eplacem ent in this Tool Required:
section. J-21366 Converter Holding Strap
Lower the vehicle. 1. Negative battery cable.
220
232
x^ ^ ---^ p :226
220. Harness
221. Dipstick Tube
222. Support Brace
223. Cooler Lines
224. Seal
225. Transmission
226. Screws, Transmission To Engine
227. Exhaust Bracket
228. Converter Housing Cover 228 227
229. Flywheel
230. Screw, Flywheel To Torque Converter
231. Dampener
232. Insulator
233. Support
B-08535
Figure 104Transmission And Components (Typical)

2. Air cleaner, and the TV or detent cable as used iiP| Clean (Figure 104)
from the throttle linkage, if the transmission is
being removed. Transmission case using a solvent dampened
Raise the vehicle. cloth, do not allow solvent to enter the
3. Transmission fluid. transmission. Air dry.
All hardware and flywheel cover using solvent. Air
4. Shift linkage.
dry.
5. Propeller shaft, refer to PROPELLER SHAFT
(SEC. 4A). Inspect (Figure 104)
Front propeller shaft, if used, from the
transfer case. All parts for wear and damage.
6. The support bracket at the catalytic converter. All seals and fittings for signs of leakage.
Any other components as needed for Torque converter for stripped or broken weld nuts
clearance. or screw holes.
Support the transmission, and the transfer Transmission case for porosity.
case, if used, with a transmission jack.
7. Transmission crossmember.
Tool Required:
Important J-21366 Converter Holding Strap
Do not stretch or damage any cables, wires If the transmission was lowered for clearance
or other components when lowering the only, do steps 13-20.
transmission. 1. Transmission (225).
8. Transmission far enough for clearance to reach Be sure the torque converter is seated
other components. properly and that J-21366 is in place.
9. Dipstick tube (221) and the seal. Support the transmission, and the transfer
Cover the opening in the transmission. case if used, with a transmission jack.
10. Speedometer cable. Raise the transmission into place and
remove J-21366.
11. Vacuum modulator line, if used.
Slide the transmission straight onto the
12. Electrical connectors from the transmission. locating pins (A) while lining up the marks
13. Cooler lines (223). on the flywheel and the torque converter.
Cap all openings in the transmission and
the lines. Important
14. Transfer case shifter and move it aside, refer to
TRANSFER CASE (SEC. 7D). The torque converter must be flush onto the
flywheel and rotate freely by hand.
15. Dampener and the support, if used.
2. Screws (226).
16. Transmission support braces (222). All brackets, clips and harnesses must be in
Note the location of the braces, they must the positions they were removed from.
be installed in the same positions. Do not install the dipstick tube or the
17. Converter housing cover (228). transmission support brace screws.
Mark the flywheel and the torque converter 3. Screws (230).
alignment.
18. Screws (230). Tighten
Screws finger tight to insure proper

Important
converter seating.
Screws to 65 N m (50 ft. lbs.).
Support the engine with a jack or hoist
Remove the engine hoist or jack.
before disconnecting the transmission.
4. Converter housing cover (228).
19. Screws (226).
Hook the cover under the lip of the engine
Note the location of any brackets or clips oil pan.
and move them aside. 5. The support and dampener, if used.
Slide the transmission straight back off the 6. Transmission support braces (222).
locating pins (A) and install J-21366. The braces must be installed in the
Transmission (225) from the vehicle. positions they were removed from.
7. Transfer case shifter, refer to TRANSFER CASE 14. Transmission crossmember and the transmission
(SEC. 7D). mount.
8. Cooler lines (223). Any components that were removed for
Uncover the openings. clearance.
Do not twist or bend the lines. Remove the transmission jack.
9. Vacuum modulator line, if used. 15. The support bracket at the catalytic converter.
10. Speedometer cable. 16. Propeller shaft, refer to PROPELLER SHAFT
11. Electrical connectors to the transmission. (SEC. 4A).
12. Dipstick tube (221) with a new seal. Front propeller shaft to the transfer case, if
Uncover the opening and install the seal used.
first. 17. Shift linkage.
Screw (226). Lower the vehicle.
13. Transmission into place. 18. New transmission fluid.
19. Air cleaner, and the TV or detent cable, if
Important removed.
Do not pinch or damage any cables, wires
or other components when raising the
transmission.
SPECIFICATIONS
FASTENER TORQUE
Nm Ft. Lbs.
Shift Linkage................................................................................................. ........25 19
TV-Detent Cable............................................................................................. ........10 7
Cooler Lines to Transmission....................................................................... ........22 16
Cooler Lines to Radiator............................................................................... ........27 20
Dipstick Tube to Alternator Bracket (G models)
Except with LBI Engine......................................................................... ........43 32
With LBI Engine..................................................................................... ........ 3.5 2.5
Transmission Support Braces
C and K Models..................................................................... ....................... 95 70
G Models (to Engine)............................................................................. ........ 57 42
(to Transmission)................................................................... ........ 37 27
Dampener S upport....................................................................................... ........ 41 30
Dampener to Support................................................................................... ........ 87 65
Converter Housing Cover
C and G Models Except with LBI Engine...................................................... 10 7
With LBI Engine..................................................................................... ........ 35 25
K Models
Except 30/3500 with L25 Engine........................................................... ........ 35 25
30/3500 with L25 Engine....................................................................... ........ 10 7
P Models................................................................................................. ........ 10 7
Transmission to Engine................................................................................. ........ 47 34.5
Converter to Flywheel................................................................................... ........ 65 50
Crossmember to Frame
C, G and P Models................................................................................. ........ 85 63
K Models................................................................................................. ........ 70 52
Note:
LBI Engine - 4.3L (262 CID V6) Carbureted
L25 Engine - 4.8L (292 CID L6)
LUBRICATION
Capacity
Pan Removal
THM 350-C................................................... ........................................... 3.3 I. 6.3 pts.
THM 400....................................................... ........................................... 4 I. 9 pts.
THM 700-R4................................................. ........................................... 4.7 I. 10 pts.
Overhaul
THM 350-C.................................................... ........................................... 9.5 I. 20 pts.
THM 400........................................................ ........................................... 10 I. 22 pts.
THM 700-R4.................................................. ........................................... 10.9 I. 23 pts.
Type Recommended DEXRON II or equivalent
Note:
DO NOT OVERFILL. Refer to Checking And Adding Fluid in this section.
SPECIAL TOOLS
1. J-21366 Converter Holding Strap

2. J-21426 Extension Housing Oil Seal Installer (THM 350-C And THM 700-R4)
3. J-22269-01 Piston Compressor (THM 700-R4)
4. J-23069 Accumulator Cover Remover And Installer (THM 350-C)
5. J-24057 Extension Housing Oil Seal Installer (THM 400)
6. J-29714 Servo Cover Compressor (THM 700-R4)
7. J-33037 Band Apply Pin Tool (THM 700-R4)
B-08534
7B-1
SECTION 7B
MANUAL TRANSMISSION
CONTENTS
S U B JE C T PAGE
D escription......................................................................................................................................................... 7B- 1
Inspection........................................................................................................................................................... 7B- 2
Control L in k a g e s ........................................................................................................................................... 7B- 2
Transmission Shift E ffort...............................................................................................................................7B- 2
Diagnosis of Manual T ransm ission................................................................................................................ 7B- 3
3-Speed 76mm Transm ission.........................................................................................................................7B1- 1
4-Speed 89mm Transm ission.........................................................................................................................7B2- 1
4-Speed 117mm Transm ission.......................................................................................................................7B3- 1
DESCRIPTION
Manual transmissions are identified by: (A) the num The countershaft is not a press fit and is sealed in
ber of forward gears, and (B) the measured distance the front of the case with an expansion plug.
between centerlines of the mainshaft and the counter Gear shifting is done with a floor mounted shift
gear. control.
3-SPEED 76MM 4-SPEED 117MM

The three speed 76mm transmissions (RPOs M62 The four speed 117mm transmission (RPO M20)
and M64) are in constant mesh and fully synchronized uses a constant mesh first gear and synchronized
in all forward speeds with two sliding synchronizer second, third and fourth gears.
sleeves. Gear shifting is done with a transmission cover
Gearshift levers are either a floor-type or a steering mounted shift lever. The cover has a ball pin type
column-type shift lever. interlock which stops the transmission from being
shifted into two gears at one time.
4-SPEED 89MM
The four speed 89mm transmission (RPO MY6) is an
overdrive unit and is fully synchronized in all forward
speeds.
7B -2 M AN U AL TRANSMISSION
INSPECTION
Before repairing the transmission, check the 6. Connect the control rods and check the steering
clutch and shifting linkages to be sure the prob column control levers for alignment. In neutral,
lem is in the transmission. the column control lever tangs should line up with
If a hydraulic clutch is used, there are no adjust the slot in the relay lever.
ments for linkage or clutch pedal.
CLUTCH SPIN DOWN TIME
1. Run the engine at a normal idle with the
CONTROL LINKAGES transmission in neutral and the clutch engaged.
2. Disengage the clutch, wait nine seconds and shift
1. Check the clutch and shift linkage for dirt, wear, the transmission into reverse.
or damage. 3. If a grinding noise is heard, check the clutch for
2. Check clutch free pedal travel adjustment and the problem. Refer to CLUTCH (SEC. 7C).
adjust as necessary. Refer to CLUTCH (SEC. 7C).
3. Check the shift linkage for worn swivels,
mounting brackets or damaged cordon shaft. TRANSMISSION SHIFT
4. Check the shift linkage adjustment and adjust as EFFORT
necessary.
1. Remove the shift rods at the transmission.
STEERING COLUMN SHIFT CONTROL 2. Line up the problem gear by shifting into the gear
1. Remove the shift control rods from the column and back to neutral.
levers. 3. Check the effort needed to shift into the problem
2. Check shift effort at the shift control lever knob. gear using a torque wrench.
3. If the effort is more than 9 N (2 lb.), adjust the 4. If the shift effort is more than 5 N-m (50 in. lbs.)
steering column lower bearing. Refer to and the shift lever shaft is clean and not
STEERING (SEC. 4B). dam aged, add an a n ti-ch a tte r lu bricant,
4. Lubricate all rod and swivel connections and re (positraction additive) to the transmission.
check shift effort. 5. If the shift effort is still high, repair the
5. If shift linkage is free from binding, check for transmission as needed.
0.13m mm (0.005 in.) end play between the col
umn levers and control lever.
M A N U A L TRANSMISSION 7B -3
DIAGNOSIS OF MANUAL TRANSMISSION

The following diagnosis information is to be used only as a guide to locating a transmission problem.

Leaks Lubricant 1. Lubricant level too high. 1. Drain to correct level.
2. Main drive bearing retainer or gasket 2. Tighten or replace.
loose or damaged.
3. Side cover or gasket loose or dam 3. Tighten or replace.
aged.
4. Rear extension seal damaged. 4. Replace.
5. Countershaft loose in case. 5. Replace case.
Hard Shifting, 1. Levers binding dirty or damaged. 1. Clean and lubricate or replace.
Column Shift 2. Lever end play more than 0.13mm 2. Adjust. Refer to STEERING COL
Refer to (0.005 in.). UMN (SEC. 3B4).
Transmission Shift
Effort 7B-2
Noisy Shifting 1. Shift linkage out of adjustment or dam 1. Adjust or replace.

aged.
2. Clutch linkage out of adjustment or 2. Adjust or replace. Refer to CLUTCH
damaged. (SEC. 7C).
3. Synchronizers or gears worn or dam 3. Repair the transmission.
aged.
Noisy Neutral 1. Shift linkage out of adjustment or dam 1. Adjust or replace.

aged.
2. Pilot bearing worn or damaged. 2. Replace. Refer to CLUTCH (SEC.
3. Main drive gear or countergear bear 7C).
ings worn or damaged. 3. Repair the transmission.
Noisy Operation 1. Lubricant level low. 1. Fill to correct level.

2. Shift linkage damaged. 2. Replace.
3. Synchronizers worn or damaged. 3. Repair the transmission.
4. Bearings worn or damaged. 4. Repair the transmission.
5. Gears worn or damaged. 5. Repair the transmission.
Slips Out Of Gear 1. Shift lever seal stiff. 1. Replace.

2. Shift linkage out of adjustment or bind 2. Adjust or replace.
ing.
3. Pilot bearing loose or damaged. 3. Replace. Refer to CLUTCH (SEC.
7C).
4. Dirt betwen the clutch housing and 4. Clean the mating surfaces.
transmission.
5. Transmission loose. 5. Tighten.
6. Main drive gear retainer loose or dam 6. Tighten or replace.
aged.
7. Transmission not aligned. 7. Align.
7B1-1
SECTION 7B1
3 SPEED 76MM TRANSMISSION

CONTENTS
S U B JE C T PAGE
On Vehicle S e rv ic e ......................................................................................................................................... 7B1- 1

Drain and F ill................................................................................................................................................. 7B1- 1
Rear Extension Seal..................................................................................................................................... 7B1- 1
Speedometer Driven G ear...........................................................................................................................7B1 - 2
Shift Linkage................................................................................................................................................. 7B1- 2
Shift Linkage A d ju stm e n t...........................................................................................................................7B1- 5
Side Cover..................................................................................................................................................... 7B1- 5
Transmission Replacement.........................................................................................................................7B1- 5
Specifications................................................................................................................................................... 7B1- 7
Fastener T orque........................................................................................................................................... 7B1- 7
L u b ric a tio n ................................................................................................................................................... 7B1- 7
Special T o o ls ................................................................................................................................................... 7B1- 7
ON VEHICLE SERVICE
DRAIN AND FILL
1. The filler plug (102).

2. The drain plug (103).
3. Transmission oil.
Catch the oil in a pan.

2. New transmission oil.
Fill to the level o* the fill plug hole. Refer to
MAINTENANCE AND LUBRICATION (SEC.
0B0.
100. Spring Washer 108. Gear
REAR EXTENSION SEAL 102. Filler Plug 110. Sleeve
103. Drain Plug 111. Adapter
104. Transmission 112. Cable
Remove or Disconnect (Figure 1) 105. Seal 113. Seal
106. Retainer 114. Plug
107. Screw
Raise the vehicle.
B-08744
(SEC. 4A). Figure 1Transmission and Components
7B1-2 3-SPEED 76MM TRANSMISSION
4. Retainer (106) and the screw (107) if used.

5. Adapter (111) if used.
6. New seal (113) and the speedometer cable (112).
Lower the vehicle.
SHIFT LINKAGE
STEERING COLUMN LINKAGE
|<-+| Remove or Disconnect (Figures 3 and 4)
Raise the vehicle.

1. Retainer (123).
2. Shift rod (120 or 124) from the column.
3. Spring (122) and the spacer (121).
4. Screw (129) and the washer (130).
5. Shift rod (120 or 124) and the swivel (131) from
the transmission.
3. Seal (105). 6. Swivel (131).
7. Retainer (127).
Install or Connect (Figure 1) 8. Nuts (136), the spring washers (137) and the
screws (138).
Tool Required: 9. Bracket (135).
J-21426, Rear Extension Seal Installer. 10. Insulator (134), the washer (133) and the spring
1. Locking compound on the outside of a new seal (132).
(105). 11. Cross lever (125).
2. New seal (105), use J-21426 (figure 2).
Fill between the seal lips with chassis Install or Connect (Figure 3)
nrfiase.
3. Propeller shaft. Refer to PROPELLER SHAFT Put a thin coat of grease on the insulator.
(SEC. 4A). 1. Cross lever (125).
4. New transmission oil. Refer to MAINTENANCE 2. The spring (132), the washer (133) and the
AND LUBRICATION (SEC. OB). insulator (134).
Lower the vehicle. 3. Bracket (135).
4. Screws (138), new spring washers (137) and the
nuts (136).
SPEEDOMETER DRIVEN 5. New retainer (127).
GEAR 6. Swivel (131) onto the shift rod (120 or 124).
7. Shift rod (120 or 124) and the swivel (131) to the
transmission.
Important
Raise the vehicle.
1. Speedometer cable (112) and the seal (113). The washer must stand off the lever as shown.
2. Adapter (111) if used. 8. Washer (130) and the screw (129) loosely.
3. Retainer (106) and the screw (107) if used. 9. Spacer (121) and the spring (122).
4. Sleeve (110). 10. Shift rod (120 or 124) to the column.
5. Seal (109). 11. New retainer (123).
6. Gear (108). Lower the vehicle.
FLOOR SHIFT LINKAGE

0* t l Install or Connect (Figure 1)
Put a thin coat of transmission oil on the gear and Remove or Disconnect (Figure 5)
the seal.
1. Gear (108). 1. Retainer (148).
2. New seal (109) onto the sleeve (110). 2. Washer (149).
3. Sleeve (110). 3. Shift rod (150 or 156) from the shift control (146).
3-SPEED 76MM TRANSMISSION 7B1-3
127
136 135 / / %
120. Shift Rod 134/ 7
121. Spacer 133 /
122. Spring 132
123. Retainer 130. Washer
124. Shift Rod 131. Swivel
125. Cross Lever 132. Spring 130
126. Shift Lever 133. Washer
127. Retainer 134. Insulator
128. Shift Lever 135. Bracket 137. Spring Washer
129. Screw 136. Nut 138. Screw B-08748
Figure 3Column Shift Linkage
4. Retainer (154).
5. Washer (155).
141 \
6. Shift rod (150 or 156) from the transmission.
140
7. Nuts (151 and 153) and the swivel (152).

Y 139 A
120. Shift Rod 1. Nuts (151 and 153) and the swivel (152).
/ L 120 124. Shift Rod Do not tighten.
139. Lever
140. Lever 2. Shift rod (150 or 156) to the transmission.
H J l2 4
141. Relay Lever 3. Washer (155).
A. Gage Pin 4. New retainer (154).
B-08742 5. Shift rod (150 or 156) to the shift control (146).
6. Washer (149).
Figure 4Column Linkage Adjustment 7. New retainer (148).
Adjust the shift rods.
7B 1-4 3-SPEED 76MM TRANSMISSION
126. Shift Lever

128. Shift Lever
145. Control Lever
146. Shift Control
147. Control Lever
148. Retainer
149. Washer
150. Shift Rod
151. Nut
152. Swivel
153. Nut
154. Retainer
155. Washer
156. Shift Rod
A. Gage Pin
149 148
126 128 153 152 B-08743
Figure 5Floor Shift Linkage
FLOOR SHIFT CONTROL

145. Shift Lever
Remove or Disconnect (Figure 6) 146. Shift Control
160. Knob
161. Nut
1. Knob (160) and the nut (161).
162. Boot
2. Screws (170) and the boot (162). 163. Bracket
3. Shift lever (145). 164. Spring Washer
Slide a piece of shim stock between the 165. Nuts
lever and the control to release the lever. 166. Spring Washer
4. Shift rods at the control (figure 5). 167. Screw
5. Screws (168) and the fitting (169). 168. Screw
6. Shift control (146). 169. Fitting 1fi
7. Screws (167) and the spring washers (166). 170. Screw ,DO
8. Nuts (165) and the spring washers (164).
9. Bracket (163).
1. Bracket (163).
2. New spring washers (164) and the nuts (165).
3. New spring washers (166) and the screws (167).
4. Shift control (146).
Important
The screw with the lubrication fitting must go into B-08745

the top hole.
5. Fitting (170) and the screws (168). Figure 6Floor Shift Control
6. Shift rods at the control (figure 5).
7. Shift lever (145). 6. Remove the gage pin and lubricate the shift
Wipe the lever with a damp rag and slide it control. Refer to MAINTENANCE AND LUBRICA
into place. TION (SEC. 0B).
8. Boot (162) and the screws (171).
9. Nut (161) and the knob (160).
10. Lubricate the shift control and the shift linkage. SIDE COVER
Refer to MAINTENANCE AND LUBRICATION
(SEC. OB).
Adjust the shift rods. 0 Remove or Disconnect (Figure 7)
Raise the vehicle.
Transmission oil.
SHIFT LINKAGE
Harness connectors (178).
ADJUSTMENT Shift rods (figure 3 or 5).
Move the shift levers into neutral, to the
COLUMN SHIFT LINKAGE front detent then back one.
Screws (183), spring washers (182) and the
ft Adjust (Figure 3)
brackets (181).
The first and reverse shift rod (120) must be Side cover (180) and the gasket (179).
adjusted before the second and third shift rod Scrape all gasket material from the cover
(124). and the case.
1. Loosen the screw (129) if needed.
2. Put the transmission lever in place. -+ Install or Connect (Figure 7)
For shift rod (120), move the shift lever (128)
into reverse, the front detent. 1. New gasket (179) and the side cover (180).
For shift rod (124), move the shift lever (126) The shift levers must be in neutral.
into neutral, to the front detent then back 2. Brackets (181), new spring washers (182) and the
one. screws (183).
3. Put the column lever in place. 3. Harness connectors (178).
For shift rod (120), move the column lever 4. Shift rods (figures 3 or 5).
into Reverse and lock the steering
5. New transmission oil. Refer to MAINTENANCE
column.
AND LUBRICATION (SEC. 0B).
For shift rod (124), move the column lever
Lower the vehicle and adjust the shift rods.
into Neutral and put a 0.249-0.250 in.
gage pin through the levers (139 and 140)
and the relay lever (141) (figure 4).
4. Hold the shift rod (120 or 124) down tightly in the
swivel (131) and tighten the screw (129).
Unlock the steering column, or take the [< [ Remove or Disconnect (Figure 1)
gage pin out.
5. Lubricate all rod and swivel connections. Refer to Raise the vehicle.
MAINTENANCE AND LUBRICATION (SEC. 0B). 1. Transmission oil.
2. Shift rods.
FLOOR SHIFT LINKAGE
Floor shift control is used.
Adjust (Figure 5) 3. Parking brake lever and controls if used, refer to
BRAKES (SEC. 5).
1. Loosen the nuts (151 and 153) if needed. 4. Propeller shaft. Refer to PROPELLER SHAFT
2. Move the shift control level (145) into Neutral . (SEC. 4A).
3. Move the shift levers (126 and 128) into neutral, to 5. Speedometer cable (112) and the seal (113).
the front detent then back one.
6. Wiring harness.
4. Put a 0.249-0.250 in. gage pin through the control
7. Exhaust pipes. Refer to EXHAUST (SEC. 6F).
levers (147).
5. Hold the shift rods (150 and 156) forward tightly in Support the transmission with a jack.
the swivels (152) and tighten the nuts (151 and 8. Any parts if needed for clearance.
153). 9. Crossmember.
178. Harness Connector

179. Gasket
180. Side Cover
181. Bracket
182. Spring Washer
183. Screw
178
v* ^ ' 1 8 3 B-08746
Figure 7Side Cover
9 Important Remove the jack.

5. Any parts that were removed for clearance.
Do not let the transmission hang from the clutch. 6. Exhaust pipes. Refer to EXHAUST (SEC. 6F).
Pull the transmission straight back on the clutch 7. Wiring harness.
hub splines. 8. New seal (113) and the speedometer cable (112).
10. Screws (101) and the spring washers (100). 9. Propeller shaft. Refer to PROPELLER SHAFT
Support the clutch release bearing. (SEC. 4A).
11. Transmission (104). 10. Parking brake lever and controls if used. Refer to
12. Plugs (114), if they are loose or damaged. BRAKES (Sec. 5).
Note the location of the plugs before 11. Shift rods.
removing. Floor shift control, if used..
Install or Connect (Figure 1) 12. New transmission oil. Refer to MAINTENANCE
AND LUBRICATION (SEC. 0B).
1. New plugs (114) if needed. Lower the vehicle.
Put a thin coat of high temperature grease
on the main drive gear splines.
Important
Do not force the transmission into the clutch.

Do not let the transmission hang from the clutch.
2. Transmission (104).
Shift the transmission into high gear before
installing.
Leave the jack under the transmission to
support it.
4. Crossmember.
3-SPEED 76MM TRANSMISSION 7B 1-7
SPECIFICATIONS
FASTENER TORQUE
Plug, Drain and Fill....................................................... ...................... 23 Nm 17 ft. lbs.
Cross Lever Bracket S crew .......................................... ...................... 25 Nm 18 ft. lbs.
Shift Rod Swivel Screw (Column Shift)........................ ...................... 25 Nm 18 ft. lbs.
Shift Rod Swivel Screw (Floor S hift)............................ ...................... 14 Nm 10 ft. lbs.
Control Bracket S crew .................................................. ...................... 33 Nm 24 ft. lbs.
Control Mounting Screw............................................... ...................... 32 Nm 23 ft. lbs.
Control Lubrication S crew ........................................... ...................... 45 Nm 33 ft. lbs.
Side Cover Screw.......................................................... ...................... 20 Nm 15 ft. lbs.
Transmission to Clutch Housing Screw........................ ...................... 100i Nm 74 ft. lbs.
Transmission to Mount S cre w ...................................... ...................... 47 Nm 35 ft. lbs.
Crossmember to Mount Screw...................................... ...................... 54 Nm 40 ft. lbs.
Crossmember to Frame Screw..................................... ...................... 75 Nm 55 ft. lbs.
LUBRICATION
Capacity................................................................................................. 1.5 L 1.6 qts.

Type Recommended..................................................................................... API GL5 SAE 80W90
SPECIAL TOOLS

7B2-1
SECTION 7B2
4-SPEED 89MM TRANSMISSION

CONTENTS
S U B JE C T PAGE

Drain And F i l l ...............................................................................................................................................7B2- 1
Rear Extension Seal..................................................................................................................................... 7B2- 1
Speedometer Driven G ear........................... ............................................................................................ 7B2- 2
Shift R ods..................................................................................................................................................... 7B2- 2
Shift Rod Adjustment...................................................................................................................................7B2- 3
Shift C o n tro l................................................................................................................................................. 7B2- 3
Side Cover..................................................................................................................................................... 7B2- 3
Specifications................................................................................................................................................... 7P?- 7
Fastener Torque........................................................................................................................................... 7B2- 7
L u b rica tio n ................................................................................................................................................... 7B2- 7
Special T o o ls ................................................................................................................................................... 7B2- 7
ON VEHICLE SERVICE
DRAIN AND FILL


2. New transmission oil.
Fill to the level of the filler plug hole. Refer
to Lubrication in this section.
108 109 109. Adapter
REAR EXTENSION SEAL 101. Transmission 110. Sleeve
102. Spring Washer 111. Seal
103. Screw 112. Gear
104. Filler Plug 113. Drain Plug
Remove or Disconnect (Figure 1) 105. Rear Extension Seal 114. Expansion Plug
106. Retainer 115. Plug
Raise the vehicle. 107. Screw 116. Seal
1. Transmission oil. 108. Speedometer Cable B-06
(SEC. 4A).
Figure 1Transmission and Components
3. Seal (105).
7B2-2 4-SPEED 89M M TRANSMISSION
120. Shift Lever

121. Shift Control
122. Retainer
123. Washer
124. Control Lever
125. Shift Rod, 1st/2nd
126. Shift Rod, 3rd/OD
127. Shift Rod, Rev.
128. Nut
129. Swivel
130. Nut
131. Shift Lever
132. Washer
133. Retainer
A. Gage Pin Hole
- 4 - Install or Connect (Figure 1)
Tool Required:
J-21426, Rear Extension Seal Installer.
1. Locking compound on the outside of a new seal
(105). 130 B-09896
2. New seal (105), use J-21426 (figure 2).
Fill between the seal lips with chassis
grease. Figure 3Shift Rods
(SEC. 4A). 6. New seal (116) and the speedometer cable (108).
4. New transmission oil. Refer to Drain and Fill in Lower the vehicle.
this section.
Lower the vehicle.
SHIFT RODS
SPEEDOMETER DRIVEN 4 -+ Remove or Disconnect (Figure 3)
GEAR
1. Retainer (122).
2. Washer (123).
++ Remove or Disconnect (Figure 1)
3. Shift rod (125, 126 or 127) from the shift control
Raise the vehicle. lever (124).
1. Speedometer cable (108) and the seal (116). 4. Retainer (133).
2. Adapter (109) if used. 5. Washer (132).
3. Retainer (106) and the screw (107) if used. 6. Shift rod (125, 126 or 127) from the shift lever
4. Sleeve (110). (131).
5. Seal (111). 7. Nuts (128 and 130) and the swivel (129).
6. Gear (112).
|~fr4-| install or Connect (Figure 3)
- 4 - Install or Connect (Figure 1)
1. Nuts (128 and 130) and the swivel (129).
Put a thin coat of transmission oil on the gear and Do not tighten.
the seal. 2. Shift rod (125, 126 or 127) to the shift lever (131).
1. Gear (112). 3. Washer (132).
2. New seal (111) onto the sleeve (110). 4. New retainer (133).
3. Sleeve (110). 5. Shift rod (125, 126 or 127) to the shift control lever
4. Retainer (106) and the screw (107) if used. (124).
5. Adapter (109) if used. 6. Washer (123).
Wipe the lever with a damp rag and slide it

into place.
10. Boot (142) and the screws (151).
The plate (152) if used.
11. Nut (141) and the knob (140).
12. Lubricate the shift control and the shift rods, refer
to MAINTENANCE AND LUBRICATION (SEC.
0B).
SHIFT ROD
ADJUSTMENT
Figure 4Transmission Shift Pattern
7. New retainer (122). ft Adjust (Figure 3)

1. Loosen the nuts (128 and 130) if needed.
2. Move the shift control lever (120) into Neutral.
SHIFT CONTROL 3. Move the shift levers (125, 126 and 127) into
neutral, (figure 4).
++ Remove or Disconnect (Figures 4, 5 and 6) 4. Put a 0.249-0.250 in. gage pin through the control
levers (124).
1. Knob (140) and the nut (141). 5. Hold the shift rods (125, 126 and 127) forward
2. Screws (151) and the boot (142). tightly in the swivels (129) and tighten the nuts
3. Plate (152) if used. (128 and 130).
4. Shift lever (120). 6. Remove the gage pin and lubricate the shift
Slide a piece of shim stock between the control. Refer to MAINTENANCE AND
lever and the control to release the lever. LUBRICATION (SEC. 0B).
5. Shift rods at the control (figure 3).
6. Gear sensing switch (145).
7. Screws (143) and the fitting (144).
SIDE COVER
8. Washers (153) if used.
9. Shift control (121). Remove or Disconnect (Figure 7)
10. Screws (146) and the spring washers (147).
11. Nuts (149) and the spring washers (148) if used. Raise the vehicle.
12. Bracket (150). 1. Transmission oil.
2. Harness (160).
Install or Connect (Figures 4, 5, and 6) 3. Shift rods (figure 3).
Move the shift levers into neutral.
1. Bracket (150).
4. Nut (166) and the washer (165).
2. New spring washers (148) and the nuts (149) if
used. 5. Reverse shift lever (164).
3. New spring washers (147) and the screws (146). 6. Seal (163).
4. Shift control (121). 7. Screws (173), the spring washers (174) and the
brackets (175).
Important 8. Side cover (169).
9. Reverse detent ball (162) and the spring (161).
The screw with the lubrication fitting must
go into the top hole. Important
The lubrication fitting must point in the
direction shown (A). Note the positions of the shift forks before
5. Washers (153) if used. removing.
6. Fitting (144) and the screws (143). 10. Shift forks (167).
7. Gear sensing switch (145). 11. Gasket (168).
8. Shift rods at the control (figure 3). Scrape all gasket material from the cover
9. Shift lever (145). and the case.
120. Shift Lever

121. Shift Control
140. Knob
141. Nut
142. Boot
143. Screw
144. Fitting
145. Gear Sensing Switch
146. Screw
147. Spring Washer
148. Spring Washer
149. Nut
150. Bracket
151. Screw
A. Fitting Direction
B-09897
Figure 5G Truck Shift Control

120.
121.
Shift Lever
Shift Control
145-Â s
140. Knob C
141. Nut
142. Boot 147. Spring Washer
143. Screw 150. Bracket
144. Fitting 151. Screw
145. Gear Position Switch 152. Plate N T
146. Screw 153. Washer B-08783
Figure 6C-K Truck Shift Control
Install or Connect (Figure 7) 8. Washer (165) and the nut (166).

9. Shift rods (figure 3).
1. New gasket (168). 10. Harness (160).
2. Shift forks (167).
11. New transmision oil. Refer to Drain and Fill in
Install the shift forks in the position they
this section.
were removed.
3. Reverse detent spring (161) and the ball (162). Lower the vehicle and adjust the shift rods.
4. Slide cover (169).
Lift the reverse interlock lever to seat the
cover.
Important Remove or Disconnect (Figure 1)
The screw with the large shoulder is a Raise the vehicle.

locating screw and must be installed in the
rear-center hole (A).
5. Brackets (175), new spring washers (174) and the 2. Shift rods.
screws (173). 3. Shift control.
6. New seal (163). 4. Parking brake lever and controls if used. Refer to
7. Reverse shift lever (164). BRAKES (SEC. 5).
160. Harness 170. Shift Lever

161. Spring 171. Washer
162. Detent Ball 172. Nut
163. Seal 173. Screw
164. Shift Lever 174. Spring Washer
165. Washer 175. Bracket
166. Nut A. Locating Hole
167. Shift Fork
168. Gasket
169. Side Cover
175
B-08778
Figure 7Side Cover
5. Propeller shaft. Refer to PROPELLER SHAFT Important

(SEC. 4A).
6. Speedometer cable (108) and the seal (116). Do not force the transmission into the clutch.
7. Wiring harness. Do not let the transmission hang from the clutch.
8. Exhaust pipes. Refer to EXHAUST (SEC. 6F).
Shift the transmission into high gear before
Support the transmission with a jack.
installing.
9. Any parts if needed for clearance. Leave the jack under the transmission to
10. Crossmember. support it.
Important 4. Crossmember.
Remove the jack.
Do not let the transmission hang from the 5. Any parts that were removed for clearance.
clutch. 6. Exhaust pipes. Refer to EXHAUST (SEC. 6F).
Pull the transmission straight back on the 7. Wiring harness.
clutch hub splines. 8. New seal (116) and the speedometer cable (108).
11. Screws (103) and the spring washers (102). 9. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
Support the clutch release bearing.
10. Parking brake lever and controls if used, refer to
12. Transmission (101). BRAKES (SEC. 5).
13. Plugs (115), if they are loose or damaged. 11. Shift control.
Note the location of the plugs before 12. Shift rods.
removing. Adjust the shift rods.
13. New transmission oil. Refer to Drain and Fill in
Install or Connect (Figure 1) this section.
Lower the vehicle.
1. New plugs (115) if needed.
Put a thin coat of high temperature grease
on the main drive gear splines.
SPECIFICATIONS
FASTENER TORQUE
Plug, Drain and Fill............................................................................... ....23 N m 17 ft. lbs.
Cross Lever Bracket Screw 25 N-m 18 ft. lbs.
Shift Rod Swivel S cre w ....................................................................... ....25 N-m 18 ft. lbs.
Control Bracket S crew ......................................................................... ....32 N-m 23 ft. lbs.
Control Mounting Screw....................................................................... .... 45 N-m 33 ft. lbs.
Side Cover Screw................................................................................. ....20 N-m 15 ft. lbs.
Transmission to Clutch Housing Screw....................................................100 N-m 74 ft. lbs.
Transmission to Mount S cre w ............................................................. ....54 N-m 40 ft. lbs.
Crossmember to Mount Screw............................................................. ....54 N-m 40 ft. lbs.
Crossmember to Frame Screw............................................................. ....75 N-m 55 ft. lbs.
LUBRICATION
Capacity................................................................................................. 4.0 L 4.2 qts.

Type Recommended........................................................Dexron II Automatic Transmission Fluid
SPECIAL TOOLS

SECTION 7B3
4-SPEED 117MM TRANSMISSION

CONTENTS
S U B JE C T PAGE

Drain and F ill................................................................................................................................................. 7B3- 1
Rear Retainer Oil S e a l................................................................................................................................. 7B3- 1
Speedometer Driven G ear...........................................................................................................................7B3- 2
Shift Control Lever....................................................................................................................................... 7B3- 3
Specifications................................................................................................................................................... 7B3- 5
Fastener T orque........................................................................................................................................... 7B3- 5
L u b ric a tio n ................................................................................................................................................... 7B3- 5
Special T o o ls ................................................................................................................................................... 7B3- 5
ON VEHICLE SERVICE
DRAIN AND FILL 5. Nut (124) and the flange (123).

6. Transmission mount.
Remove or Disconnect (Figure 1) 7. Screws (125) and the retainer (121).
8. Gasket (120).
The fill plug (112). Scrape all gasket material from the retainer
The drain plug (103). and the case.
Transmission oil. 9. Seal (122).
Tool Required:
1. The drain plug (103). J-22834, Rear Retainer Seal Installer
2. New transmission oil. 1. Locking compound on the outside of the a new
Fill to the level of the fill plug hole, refer to seal (122).
MAINTENANCE AND LUBRICATION (SEC. 2. New seal (122), use J-22834-2 (figure 3).
OB). Use J-22834-1 if a parking brake is used.
3. The fill plug (112). Fill between the seal lips with chassis
grease.
3. New gasket (120).
R EAR RETAINER OIL S E A L 4. Retainer (121) and the screws (125).
5. Transmission mount.
Remove the jack.
Remove or Disconnect (Figure 2) 6. Flange (123) and the nut (124).
7. New seal (110) and the speedometer cable (111).
Raise the vehicle. 8. Parking brake if used, refer to BRAKES (SEC. 5).
Transmission oil. 9. Propeller shaft, refer to PROPELLER SHAFT
Propeller shaft, refer to PROPELLER SHAFT (SEC. 4A).
(SEC. 4A). 10. New transmisssion oil, refer to MAINTENANCE
Parking brake if used, refer to BRAKES (SEC. 5). AND LUBRICATION (SEC. 0B).
Speedometer cable (111) and the seal (110). Lower the vehicle.
100. Screw
101. Clip
102. Transmission
103. Drain Plug
104. Speedometer Driven Gear
105. Seal
106. Retainer
107. Screw
108. Sleeve
109. Adapter
110. Seal
112. Fill Plug
113. Screw
1.14. Spring Washer
115. Plug
107 106 B-08800
Figure 1Transmission and Components
SPEEDOMETER DRIVEN GEAR 4. Sleeve (108).

5. Seal (105).
I | 6. Gear (104).
I* * -! Install or Connect (Figure 1)
Raise the vehicle.
1. Speedometer cable (111) and the seal (110). Put a thin coat of transmission oil on the gear and
2. Adapter (109) if used. the seal.
3. Retainer (106) and the screw (107) if used. 1. Gear (104).
102. Transmission
110. Seal
120. Gasket
121. Rear Bearing Retainer
122. Seal
123. U-joint Flange
124. Nut
125. Screw
124
125 B-08788
Figure 2Rear Retainer and Seal

4. Retainer (136) and the screws (137) if used.

5. Transfer case shift lever boot if used, refer to
TRANSFER CASE (SEC. 7D).
TRANSMISSION
REPLACEMENT
Tool Required:
J-1126, Transmission Guide Pin
Raise the vehicle.
2. Propeller shaft, refer to PROPELLER SHAFT
(SEC. 4A).
3. Transfer case if used, refer to TRANSFER CASE
(SEC. 7D).
4. Parking brake and controls if used, refer to
BRAKES (SEC. 5).
5. Shift control lever.
6. Screw (100) and the connector (101).
7. Speedometer cable (111) and the seal (110).
8. Exhaust pipes, refer to EXHAUST (SEC. 6F).
9. Any parts if needed for clearance.
10. Crossmember.
2. New seal (105) onto the sleeve (108). Important

3. Sleeve (108).
4. Retainer (106) and the screw (107) if used. Do not let the transmission hang from the clutch.
5. Adapter (109) if used. Use guide pins to pull the transmission straight
6. New seal (110) and the speedometer cable (111). back on the clutch hub splines.
Lower the vehicle. 11. Screws (113) and the spring washers (114).
Remove the top two first and install guide
pins J-1126.
SHIFT CONTROL LEVER Support the clutch release bearing.
Remove or Disconnect (Figure 4) 13. Plugs (115), if they are loose or damaged.
Note the location of the plugs before
1. Transfer case shift lever boot if used, refer to removing.
TRANSFER CASE (SEC. 7D).
2. Screws (137) and the retainer (136) if used. - 4 - Install or Connect (Figure 1)
3. Screws (135) if used.
4. Boot (133). Put a thin coat of high temperature grease on the
5. Lever (132). main drive gear splines.
Push the cap (134) down and turn 1. New plugs (115) if needed.
counter-clockwise (A).
Important
|-n-1 Install or Connect (Figure 4)
Do not force the transmission into the clutch.
1. Lever (132). Do not let the transmission hange from the
Push the cap (134) down and turn clockwise clutch.
(B). Transmission (102).
2. Boot (133). Shift the transmission into high gear before
3. Screws (135) if used. installing.
130. Knob
131. Nut
132. Control Lever
133. Boot
134. Cap
135. Screw
136. Retainer 135
137. Screw
A. Remove
B. Install
B-08802
Figure 4Shift Control Lever
Leave the jack under the transmission to 8. Connector (101) and the screw (100).
support it. 9. Shift control lever.
3. New spring washers (114) and the screws (113). 10. Parking brake and controls if used, refer to
Install the two bottom screws before BRAKES (SEC. 5).
removing the guide pins. 11. Transfer case if used, refer to TRANSFER CASE
4. Crossmember. (SEC. 7D).
Remove the jack. 12. Propeller shaft, refer to PROPELLER SHAFT
5. Any parts that were removed for clearance. (SEC. 4A).
6. Exhaust pipes, refer to EXHAUST (SEC. 6F). 13. New transmission oil, refer to MAINTENANCE
7. New seal (110) and the speedometer cable (111). AND LUBRICATION (SEC. 0B).
Lower the vehicle.
4-SPEED 117MM TRANSMISSION 7B 3 -5
SPECIFICATIONS
FASTENER TORQUE
Plug, Drain and Fill................................................................................ 23 N m 17 ft. lbs.

U-joint Flange Nut.................................................................................. 135 N-m 100 ft. lbs.
Rear Retainer Screw (Top).................................................................... 27 N m 20 ft. lbs.
Rear Retainer Screw (Bottom).............................................................. 40 N-m 30 ft. lbs.
Transmission to Clutch Housing Screw................................................ 100 N m 74 ft. lbs.
Transmission to Mount S cre w .............................................................. 47 N-m 35 ft. lbs.
Crossmember to Mount Screw.............................................................. 54 N-m 40 ft. lbs.
Crossmember to Frame Screw.............................................................. 75 N-m 55 ft. lbs.
LUBRICATION
Capacity................................................................................................. 4.0 L 4.2 qts.
Type Recommended..................................................................................... API GL5 SAE 80W90
SPECIAL TOOLS

7C-1
SECTION 7C
CLUTCH
CONTENTS
S U B JE C T PAGE
D escription......................................................................................................................................................... 7C- 2
C lu tc h ..............................................................................................................................................................7C- 2
Clutch Controls............................................................................................................................................... 7C- 2
Inspection........................................................................................................................................................... 7C- 2
L in k a g e ........................................................................................................................................................... 7C- 2
Clutch P e d a l................................................................................................................................................... 7C- 2
Release B e aring............................................................................................................................................. 7C- 2
Hydraulic C lutch............................................................................................................................................. 7C- 2
Diagnosis of C lu tc h ........................................................................................................................................... 7C- 3
On-Vehicle Service............................................................................................................................................. 7C- 5
Hydraulic Clutch Pedal...................................................................................................................................7C- 5
Mechanical Clutch P edal...............................................................................................................................7C- 5
Master Cylinder and R eservoir.....................................................................................................................7C- 6
Secondary Cylinder and Hydraulic Line...................................................................................................... 7C- 8
Clutch L in ka g e ............................................................................................................................................... 7C- 9
Cross Lever..................................................................................................................................................... 7C-10
Hydraulic Clutch Bleeding.............................................................................................................................7C-12
Clutch Pedal Free Travel Adjustment.......................................................................................................... 7C-12
Clutch Assembly and Pilot B e a rin g ............................................................................................................ 7C-13
Specifications..................................................................................................................................................... 7C-17
Fastener T orque............................................................................................................................................. 7C-17
Clutch Pedal Free T ravel...............................................................................................................................7C-17
L u b ric a tio n ..................................................................................................................................................... 7C-17
Special T o o ls ..................................................................................................................................................... 7C-18
7C -2 CLUTCH
DESCRIPTION
CLUTCH CLUTCH CONTROLS

The principal components on a clutch are the driven
plate, pressure plate, diaphragm-type spring and a HYDRAULIC CONTROLS - C-K MODELS
release bearing. The hydraulic clutch has a master cylinder with a
The driven plate is splined on the transmission separate reservoir. The clutch pedal moves the master
clutch shaft so that it can move back and forth when cylinder push rod and a secondary cylinder at the
the clutch is disengaged, and can turn the shaft when clutch housing moves the clutch fork and the release
the clutch is engaged. The driven plate has friction bearing.
pads riveted to both sides of it, and a flexible center
MECHANICAL CONTROLS - G AND P MODELS
with springs to absorb vibration.
G models have a pull rod from the clutch pedal that
The pressure plate has a machined surface that fits
moves a cross lever. The cross lever moves the clutch
against the driven plate and a diaphragm-type spring
fork and the release bearing with an adjustable rod.
mounted in a cover on the pressure plate. The spring
P models have an upper pull rod from the clutch
holds the pressure plate and driven plate together
pedal to a bell crank lever and a lower pull rod from the
against the engine flywheel when the clutch is
bell crank lever to a cross lever. The cross lever moves
engaged.
the clutch fork and the release bearing with an
The release bearing is a ball-thrust bearing on a
adjustable rod.
sleeve that pushes in on the center of the diaphragm
spring, releasing pressure on the pressure plate and
driven plate to disengage the clutch.
INSPECTION
Before repairing the clutch, check the transmission Adjust the clutch linkage and repeat, if
and shift linkage, and the engine mounts to be sure the needed.
problem is in the clutch.
RELEASE BEARING
LINKAGE
1. Check the clutch fork for dirt, wear and damage.
1. Check the clutch rods for bending and damage. 2. Check the clutch fork for proper installation and
2. Check for worn swivels and loose or damaged lubrication.
mounting brackets. 3. Check the release bearing and clearance
3. Check the clutch lever for bending, wear and between the spring fingers and the transmission.
damage.
Be sure there is some clearance between
the clutch lever and the mounting brackets
HYDRAULIC CLUTCH
and ball studs. 1. Check the hoses for cracks and wear.
4. Lubricate the clutch linkage. 2. Check the cylinders for loose mounting screws
and signs of leakage.
3. Check the clutch pedal travel, it should be 210.8
CLUTCH PEDAL mm (8.3 in).
4. Check the secondary push rod travel at the clutch
1. Check the bushings for dirt, wear and damage.
fork, it should be at least 25.4 mm (1.0 in).
2. Check the clutch release. 5. Bleed the controls and repeat as needed.
Hold the clutch pedal 12.7 mm (1/2 in.) above
the floor mat with the engine running and
the parking brake on.
Move the shift lever from first gear to
reverse gear and back several times.
If the shift is sm ooth, the clutch is
disengaging fully.
CLUTCH 7C -3
DIAGNOSIS OF CLUTCH
Will Not Disengage 1. Linkage loose or out of adjustment. 1. Tighten or adjust.

(Pedal to the floor 2. Air in the hydraulic system. 2. Bleed and check for damage.
and hard to shift 3. Master or secondary hydraulic cylinder 3. Repair.
into reverse). seals worn.
4. Not enough pedal travel. 4. Adjust the linkage or trim the pedal
bumper.
5. Release bearing worn or damaged. 5. Replace.
6. Driven plate worn or damaged. 6. Replace.
7. Clutch fork off the ball stud. 7. Install correctly and lubricate.
8. Driven plate binding. 8. Repair or replace the plate or clutch
gear.
9. Driven plate warped-run-out more than 9. Replace.
5.08 mm (0.20 in.).
Slipping. 1. Linkage out of adjustment. 1. Adjust.

2. Driven plate friction pads worn or oil 2. Replace. Check for leaks as needed.
soaked.
3. Pressure plate or flywheel warped. 3. Replace as needed.
4. Diaphragm spring weak. 4. Replace.
5. Driven plate overheated or not seated. 5. Allow to cool and make 30-40 normal
starts - DO NOT OVERHEAT.
Grabbing 1. Engine mounts loose or damaged. 1. Tighten or replace.

(Chattering). 2. Driven plate friction pads oil soaked. 2. Replace and check for leaks.
3. Pressure plate or flywheel warped. 3. Replace as necessary.
4. Driven plate friction pad material 4. Clean off or replace as needed.
burned or smeared onto the pressure
plate or flywheel.
5. Clutch gear worn. 5. Repair the transmission.
Rattling 1. Diaphragm spring weak. 1. Replace the pressure plate.

(Transmission Click). 2. Clutch fork loose or off the ball stud. 2. Replace the retaining spring or install
the fork correctly.
3. Driven plate springs weak or oil in the 3. Replace and check for leaks as
damper. needed.
Release Bearing 1. Linkage out of adjustment. 1. Adjust.

Noisy With The 2. Release bearing binding. 2. Clean, or replace if damaged, and lu
Clutch Engaged bricate.
3. Clutch fork off the ball stud or loose 3. Install, and lubricate.
spring tension.
4. Linkage return springs weak. 4. Replace.
Noisy 1. Release bearing worn or damaged. 1. Replace.

2. Clutch fork off the ball stud. 2. Install correctly and lubricate.
3. Pilot bearing loose. 3. Replace. Refer to ENGINE (Sec. 6A).
7C -4 CLUTCH
DIAGNOSIS OF CLUTCH (Cont.)

Pedal Stays On The 1. Linkage or release bearing binding. 1. Free up, or replace, and lubricate.
Floor When 2. Diaphragm spring weak. 2. Replace the pressure plate.
Disengaged. 3. Return springs being over traveled. 3. Adjust the linkage or replace the
pedal bumper if worn.
Pedal Is Hard To 1. Linkage binding. 1. Free up, or replace and lubricate.

Push. 2. Hydraulic line blocked or crimped. 2. Clean out or replace.
3. Master or secondary cylinders binding. 3. Repair or replace as needed.
4. Driven plate worn. 4. Replace.
CLUTCH 7C -5
ON-VEHICLE SERVICE
10. Bushings (104) and the spacer (110).
11. Bumper (111) if it is worn or damaged.
-4- Install or Connect (Figure i)
New bumper (111) if needed.

New spacer (110) and new bushings (104).
Coat with grease before installing.
Important
The rod must be installed as shown.

3. Spring (103), the pedal (109) and the stud (101).
R em ove th e long scre w or rod w h ile
installing the stud.
4. Braces (102 and 112).
5. Nuts (100).
6. New wave washer (108) and the push rod (107).
The washer must stand off the pedal as
shown.
7. Washer (106) and the retainer (105).
8. Neutral start switch.
100. Nut ^
9. The lower left side air conditioning duct, if used.
101. Stud
Outboard Brace 10. The lower steering column covers.
102.
103. Spring 11. Negative battery cable.
104. Bushing Bleed the clutch system. Refer to Hydraulic
105. Retainer Clutch Bleeding in this section.
106. Washer L u b ric a te th e c lu tc h p e d a l. R e f e r to
107. Pushrod MAINTENANCE AND LUBRICATION (Sec. 0B).
108. Wave Washer
109. Pedal
110. Spacer
MECHANICAL CLUTCH PEDAL
111. Bumber
112. Inboard Brace Remove or Disconnect (Figure 2)
B-08845

Figure 1Hydraulic Clutch Pedal 2. Cotter pin (132) and the washer (131).
3. Wave washer (130).
HYDRAULIC CLUTCH PEDAL 4. Pedal rod (128) and the bushing (129).
0
5. Neutral start switch (125).
Note the direction the switch is mounted in.
Remove or Disconnect (Figure 1) 6. Nut (120) and the spring washer (121).
7. Screw (133) and the washer (136).
1. Negative battery cable. Note the direction the screw is mounted in.
2. The lower steering column covers. Remove the washer (134) if used.
3. The lower left side air conditioning duct if used. 8. Arm (135) and the wave washer (122).
4. Neutral start switch. 9. Spring (127).
5. Retainer (105) and the washer (106). Push the pedal down, move it to the side
6. Push rod (107) and the wave washer (108). and let it up to release the spring.
7. Nuts (100). 10. Pedal (126).
8. Braces (102 and 112). Slide a long screw or rod through the
9. Stud (101), the pedal (109) and the spring (103). bracket while removing the pedal to keep
Slide a long screw or rod into the bracket the brake pedal in place.
while removing the stud. 11. Bushings (123).
7C -6 CLUTCH
126
120. Nut 129. Bushing

121. Spring Washer 130. Wave Washer
122. Wave Washer 131. Washer
123. Bushing 132. Cotter Pin
124. Bumper 133. Screw
125. Neutral Start Switch 134. Washer
126. Pedal 135. Arm
127. Spring 136. Washer
128. Pedal Rod B-08846
Figure 2Mechanical Clutch Pedal
12. Bumper (124) if it is worn or damaged. Install the screw in the direction it was
removed from.
Clean (Figure 2) 7. New spring washer (121) and the nut (120).
8. Neutral start switch (125).
Metal parts with solvent. Wipe dry. Install the switch in the position it was
Plastic and rubber parts with a dry rag. removed from.
9. Bushing (129) and the pedal rod (128).
I? Inspect (Figure 2) 10. New wave washer (130).
11. Washer (131) and a new cotter pin (132).
Pedal (126) for wear and bending. 12. Negative battery cable.
Bushings (123 and 129) for cracks and wear. Adjust the clutch linkage. Refer to Free Travel
Adjustment in this section.
l-Mj Install or Connect (Figure 2) Lubricate the clutch pedal. Refer to
MAINTENANCE AND LUBRICATION (Sec. 0B).
1. New bumper (124) if needed.
2 . Bushings (123).
Coat the bushings with petroleum jelly. MASTER CYLINDER
Pedal (126). AND RESERVOIR
Slide the screw or rod out while installing
the pedal.
Spring (127). Remove or Disconnect (Figure 3)
Hold the pedal up, next to the pedal stop to
hook the spring. 1. Negative battery cable.
Push the pedal down, slide it to the side and 2. The lower steering column covers.
let it up against the pedal stop. 3. The lower left side air conditioning duct, if used.
New wave washer (122) and the arm (135). 4. Retainer (105) and the washer (106).
Washer (136) and the screw (133). 5. Push rod (107) and the wave washer (108).
Install the washer (134) if used. 6. Reservoir hose (145).
CLUTCH 7C -7
105
Retainer
Washer
144 Pushrod
Wave Washer
Reservoir
Gasket
Hydraulic Line,
Secondary Cylinder
Nut
Master Cylinder
Reservoir Hose
Screw
143 142 B-08847
Figure 3Master Cylinder and Reservoir
7. Secondary cylinder hydraulic line (142) from the * Assemble (Figure 4)

master cylinder (144).
8. Nuts (143) and the master cylinder (144). Lubricate all seals with clean brake fluid.
9. Gasket (141). Install the shim (223) and a new seal (225) with
Scrape all gasket material from the master the flat against the shim (223). Install the support
cylinder and the cowl. (222) and the spring (230).
Install a new seal (226).
10. Screws (146) and the reservoir (140).
Coat the cylinder bore with clean brake fluid and
slide the plunger (224) and the push rod (107) in.
$ Disassemble (Figure 4)
Push the push rod (107) in and install the snap
ring (227). Coat the inside of the dust cover (228)
1. Remove the adapter (221) and the seal (220). with grease and slide it into place.
2. Pull the dust cover (228) back and remove the 5. Install a new seal (220) and the adapter (221).
snap ring (227).
3. Shake the push rod (107) and the plunger (224) Install or Connect (Figure 3)
out.
4. Remove the seal (226). Remove the spring (230), 1. Reservoir (140) and the screws (146).
the support (222), the seal (225) and the shim 2 . New gasket (141).
(223). 3. Master cylinder (144) and the nuts (143).
4. Secondary cylinder hydraulic line (142) to the
P y l Clean (Figure 4) master cylinder (144).
5. Reservoir hose (145).
All parts with clean brake fluid. 6. New wave washer (108) and the push rod (107).
7. Washer (106) and the retainer (105).
I? Inspect (Figure 4) 8. The lower left side air conditioning duct, if used.
9. The lower steering column covers.
The cylinder bore and the plunger for scratches, 10. Negative battery cable.
ridges, and pitting. Fill the reservoir. Refer to Specifications in this
The dust cover for wear and cracking. section.
7C -8 CLUTCH
Install the nut (150) to hold the speedometer

cable (B) in place.
Important
Cover all hydraulic line openings to keep dirt

and moisture out of the components.
* Disassemble (Figure 6)
1. Remove the push rod (241) and the dust cover

(240).
2 . Remove the snap ring (238) and shake the
plunger (239) out.
228 227 229
3. Remove the spring (242) and the seal (237).
X
Clean (Figure 6)
All parts with clean brake fluid.
Inspect (Figure 6)
144. Master Cylinder
The cylinder bore and the plunger for scratches
220. Seal
ridges and pitting.
221. Adapter
The dust cover for wear and cracking.
222. Support
223. Shim
224. Plunger * Assemble (Figure 6)
225. Seal
226. Seal Coat a new seal (237) with clean brake fluid and
227. Snap Ring slide it into place and install the spring (242).
228. Dust Cover Coat the cylinder bore with clean brake fluid and
229. Push Rod slide the plunger (239) in.
230. Spring Push the plunger (239) in and install the snap
B-08848 ring (238).
Coat the inside of the dust cover (240) with
grease and slide it into place. Install the push rod
Figure 4Master Cylinder Components (241).
Bleed the clutch system. Refer to Hydraulic Install or Connect (Figure 5)

Clutch Bleeding in this section.
Uncover the hydraulic line openings.
1. Hydraulic line (142).
SECONDARY CYLINDER AND Remove the nut (150).
HYDRAULIC LINE Hydraulic line (142) onto the master cylinder
(144).
Hydraulic line (142) and the nut (150).
1. Negative battery cable. Important

Raise the vehicle.
i'i'C The hydraulic line must be upright, as shown.
2. Hydraulic line (142) from the secondary cylinder Secondary cylinder (153) and the nuts (151).
(153).
Hydraulic line (142) onto the secondary cylinder
3. Nuts (151) and the secondary cylinder (153). (153).
4. Hydraulic line (142). Lower the vehicle.
Hydraulic line (142) from the master cylinder 4. Negative battery cable.
(144). Bleed the clutch system. Refer to Hydraulic
Nut (150) and the hydraulic line (142). Clutch Bleeding in this section.
CLUTCH 7C -9
Figure 5Secondary Cylinder and Hydraulic Line
CLUTCH LINKAGE 8. Adjusting rod (170).

Note the direction the rod was removed
from.
IQ* Clean (Figures 7 and 8)
2. Cotter pins (132), the washers (131) and the wave All metal parts with solvent. Wipe dry.
washers (130).
All nylon and rubber parts with a clean, dry rag.
3. Pedal rod (128) and the bushing (129).
Note the direction the rod was removed
from. Inspect (Figures 7 and 8)
4. Screws (172) and the boot (171).
All metal parts for wear, damage and bending.
5. The lower pedal rod (163), (P models only).
Cotter pins (160), the washers (161) and the All nylon and rubber parts for wear and cracks.
wave washers (162).
6. The pull back spring (166). Install or Connect (Figures 7 and 8)
Retaining spring (164) if used.
7. Cotter pin (167), the washer (168) and the wave 1. Adjusting rod (170).
washer (169). Install the rod in the direction it was
The nut (165), if used. removed from.
7C-10 CLUTCH
CROSS LEVER
152
2. Springs and the adjusting rod (170), (Figures 7

and 8).
3. Pedal rod or the lower pedal rod (A), (Figures 7

and 8).
2 4 1 4. Screws (185) and the spring washers (189).
/ 239 Nuts (190), (P models only).

240 238 5. Bracket (186) and the cross lever (191).
152. Bleeder Screw 6. Ball stud (181), the nut (188) and the star washer
153. Secondary Cylinder (187) from the bracket (186).
236. Cap
237. Seal 7. Engine side ball stud (181) if it is worn or
238. Snap Ring damaged.
239. Plunger
240. Dust Cover
241. Pushrod 3 2 Clean (Figure 9)
242. Spring B-08850
All metal parts with solvent. Wipe dry.
Figure 6Secondary Cylinder Components All nylon and plastic parts with a clean, dry rag.
2. New wave washer (169), the washer (168) and a

new cotter pin (167). L* Inspect (Figure 9)
The jam nut (165), if used. All metal parts for wear, damage and bending.
3. The pull back spring (166). All nylon and plastic parts for wear and cracks.
The retaining spring (164), if used.
4. The iower pedal rod (163), (P models only). Install or Connect (Figure 9)
New wave washers (162), the washers (161) 1. Engine side ball stud (181) if needed.
and new cotter pins (160).
2. New star washer (187), the nut (188) and the ball
5. The boot (171) and the screws (172). stud (181) onto the bracket (186).
The dimple must face the rear of the vehi 3. Cross lever (191) and the bracket (186).
cle, (P models only).
6. The bushing (129) and the pedal rod (128).
Nuts (190), (P models only).
Install the rod in the direction it was
removed from. 5. Pedal rod or the lower pedal rod (A), (Figures 7
7. New wave washers (130), the washers (131) and and 8).
new cotter pins (132). 6. Adjusting rod (170) and the springs, (Figures 7
8. Negative battery cable. and 8).
Adjust the clutch, if needed. Refer to Free Travel Adjust the clutch linkage. Refer to Free Travel
Adjustment in this section. Adjustment in this section.
Lubricate the clutch linkage. Refer to Lubricate the clutch linkage. Refer to
MAINTENANCE AND LUBRICATION (Sec. OB). MAINTENANCE AND LUBRICATION (Sec. 0B).
CLUTCH 7C-11
128. Pedal Rod

129. Bushing
130. Wave Washer
131. Washer
132. Cotter Pin
160. Cotter Pin
161. Washer
162. Wave Washer
163. Lower Pedal Rod
164. Retaining Spring (Except JF9)
165. Nut
166. Pull Back Spring
167. Cotter Pin
168. Washer
169. Wave Washer
170. Adjusting Rod
171. Boot
172. Screw B-08840
Figure 7Clutch Linkage - P Models

7C-12 CLUTCH
HYDRAULIC CLUTCH BLEEDING
C-K MODELS
131 Bleed (Figures 3 and 5)
1. Fill the reservoir (140) with new DOT 3 brake fluid
to the level of the diaphragm.
NOTICE: Never, under any circumstances, use

fluid which has been bled from a system to fill
the reservoir, as it may be aerated, have too
much moisture content and possibly be
contaminated.
2. Remove the secondary cylinder (153) and hold it
with the bleeder screw (152) the highest.
3. Hold the clutch pedal down, open the bleeder
screw (152) to let air and fluid escape, and close
the bleeder screw (152). Let the clutch pedal up.
4. Repeat step 3 unti all air is out of the system.
Important
Check and refill the reservoir as needed

while bleeding so that air is not drawn into
the system.
Install the secondary cylinder (153) and refill the
reservoir (140) if needed.
CLUTCH PEDAL FREE

TRAVEL ADJUSTMENT
P MODELS
128. Pedal Rod
129. Bushing ft Adjust (Figures 7 and 10)
130. Wave Washer
131. Washer 1. Remove the pull back spring (166).
132. Cotter Pin 2. Loosen the nut (201) at the swivel (202).
164. Retaining Spring Take the swivel (202) out of the cross lever
166. Pull Back Spring (191), (models without JF9).
167. Cotter Pin 3. Move the clutch fork (200) back until the clutch
168. Washer spring pressure is felt, and adjust the rod length.
169. Wave Washer Models without JF9.
170. Adjusting Rod Hold the clutch pedal against the bumper.
171. Boot (Two Piece) Turn the nut (201) until the swivel (202) fits
172. Screw into the gage hole (A), then remove all lash.
Install the swivel (202) with a new wave
washer (169) and cotter pin (167).
Models with JF9.
Hold the clutch pedal against the bumper.
Loosen the jam nut (165) and turn the nut
B-08839
(203) until it is 0.29 in (7.37 mm) from the rod
shoulder (B).
Figure 8Clutch Linkage - G Models Tighten the jam nut (165) and turn the nut
(201) to remove all lash.
CLUTCH 7C-13
170. Adjusting Rod

180. Seat
181. Ball Stud
182. Seal
183. Spring
184. Retainer
185. Screw
186. Bracket
187. Star Washer
188. Nut
189. Spring Washer
190. Nut
191. Cross Lever
A. Pedal Rod (G Models) 185 189
Lower Pedal Rod (P Models)
B-08841
Figure 9Cross Lever
4. Install the pull back spring (166). CLUTCH ASSEMBLY AND

5. Check the clutch pedal free travel and re-adjust if PILOT BEARING
needed. Refer to Clutch Pedal Free Travel in
this section.
6. Lubricate the clutch linkage. Refer to CAUTION: When servicing clutch parts, do
MAINTENANCE AND LUBRICATION (Sec. OB). not create dust by grinding or sanding clutch
disc or by cleaning parts with a dry brush or
G MODELS with compressed air. (A water dampened
clothNOT SOAKEDshould be used). The
Adjust (Figures 8 and 10) clutch disc contains asbestos fibers which
can become airborne if dust is created during
1. Remove the pull back spring (166). s e rv ic in g . B re a th in g d u s t c o n ta in in g
asbestos fibers may cause serious bodily
2. Loosen the nut (203). harm.
3. Move the clutch fork (200) back until the clutch
spring pressure is felt.
4. Hold the clutch pedal against the bumper and
turn the nut (201) until it is 0.28 in. (7.11 mm) from
Tool Required:
the cross lever (191).
J-5824-01 Clutch Alignment Tool
5. Tighten the nut (203) against the cross lever
J-1448 Pilot Bearing Puller (Gas Engine
(191).
Only)
6. Install the pull back spring (166). J-23907 Pilot Bearing Puller (6.2 L Diesel
7. Check the clutch pedal free travel and re-adjust if Only)
needed. Refer to Clutch Pedal Free Travel in 1. Transmission. Refer to TRANSMISSION (Sec.
this section. 7B).
8. Lubricate the clutch linkage. Refer to 2. Adjusting rod (170) or the secondary cylinder
MAINTENANCE AND LUBRICATION (Sec. 0B). (153), (Figure 5, 7 or 8).
7C-14 CLUTCH
Pull back spring (166) if used.

Retaining spring (164) if used.
3. Screws (216) and the cover (215).
4. Screws (208) and the flywheel housing (207).
5. Boot (210), the clutch fork (200) and the release
bearing (212).
Pry the clutch fork (200) off the ball stud
200 (209).
Pry the retainer (211) out of the clutch fork
(200) if it is worn or damaged.
6. Ball stud (209).
P Models (without JF9)

Install J-5824-01 clutch alignment tool or a used
clutch drive gear to support the clutch.
Mark the flywheel, clutch cover and a pressure
plate lug for alignment when installing.
7. Screws (206) and the spring washers (205).
Important
Loosen each screw one turn at a time to avoid

warping the clutch cover.
8. Cover assembly (213) and the driven plate (214).
Remove the clutch alignment tool.
9. Pilot bearing (217) if it is worn or damaged.
Use J-1448 or J-23907 as needed (figure 12).
1. Remove the screws (218) and straps (219).

Note the location of the retracting springs.
2. Remove the pressure plate (220).
IQ* Clean (Figure 11)

203
1. All parts with a clean, water dampened cloth to
remove any asbestos fibers.
G Models
2. Clutch fork (200), the flywheel housing (207) and
the ball stud (209) with solvent. Wipe dry.
NOTICE: The release bearing is permanently

165. Jam Nut
packed with lubricant and should not be
170. Adjusting Rod
soaked in cleaning solvent as this will dissolve
191. Cross Lever
the lubricant.
200. Clutch Fork
201. Nut
Inspect (Figure 11)
202. Swivel
203. Nut
- All parts for wear and damage.
A. Gage Hole
Contact surfaces for scoring, and flatness with a
B. Rod Shoulder
straight edge. Driven plate run-out must not be
more than 0.20 in (5.08 mm).
B-08842 Friction pads for scoring, gouges, and loose
rivets. Check to see if they are oil soaked.
Figure 10Clutch Linkage Adjustment All splines for nicks, burrs and sliding fit.
All springs for bending and breaks.
CLUTCH 7C-15
\2 0 5
@ C > 206
213
200. Clutch Fork
205. Spring Washer
206. Screw
207. Flywheel Housing 215. Cover
208. Screw 216. Screw
209. Ball Stud 217. Pilot Bearing
210. Boot 218. Screw
211. Retainer 219. Strap
212. Release Bearing 220. Pressure Plate
213. Cover Assembly A. Lubrication Fitting
214. Driven Plate (CK Models Only)
B-08833
Figure 11Clutch Assembly and Pilot Bearing
Boot for tears and brittleness. * Assemble (Figure 11)
1., Install the pressure plate (220).

Measure (Figure 11)
Important
Transmission pilot hole in the clutch housing for Line up the marks made during removal.
run out using a dial indicator. Run out should not 2. Straps (219) and the screws (218).
be more than 0.015 in. (0.380 mm). Install the retracting springs in the positions
they were removed from.
Tool Required:
J-5824-01 Clutch Alignment Tool
J-1522 Pilot Bearing Driver (Gas Engine
Only)
J-34140 Pilot Bearing Driver (6.2 L Diesel
Only)
1. New pilot bearing (217) if needed. Use J-1522 or
J-34140 as needed to drive the bearing in until
the tool bottoms out.
Gas Engine
Lubricate the bearing with a few drops of
machine oil.
6.2 L Diesel Engine
The bearing is sealed and does not need any
lubrication.
2. Driven plate (214) and the cover assembly (213).
7C-16 CLUTCH
5. Coat the rounded end of the ball stud (209) with

high temperature grease.
Pack the ball stud seat from the lubrication
fitting (A) on the flywheel housing (207) (C-K
models only).
6. New retainer (211) if needed.
The retainer must be installed so the fingers
and tabs fit into the release bearing groove
and the retainer wraps around the flat side
of the ball stud head.
7. Release bearing (212), the clutch fork (200) and
the boot (210).
Pack the inside recess (A) and the outside
groove (B) of the release bearing (212) with
A. Recess high temperature grease as shown. (Figure
B. Groove B-08844 10).
8. Flywheel housing (207) and the screws (216).
9. Cover (215) and the screws (216).
Figure 13Release Bearing 10. Adjusting rod (170) or the secondary cylinder
(153) as needed. (Figure 5, 7 or 8).
Important Retaining spring (164) if used.
Pull back spring (166) if used.
Install J-5824-01 clutch alignment tool or a used Transmission. Refer to TRANSMISSION (Sec.
clutch drive gear to support the clutch. 7B).
Align the marks made during removal. Adjust the clutch linkage or bleed the hydraulic
3. New spring washers (205) and the screws (206). system as needed.
Remove the clutch alignment tool.
Important
Tighten each screw one turn at a time to

avoid warping the clutch cover.
NOTICE: Be careful not to use too much

lubricant. Excessive lubricant may get on
clutch fingers and cause slippage or damage
may result to the clutch.
4. Ball stud (209).
Pack the seat with high temperature grease.
CLUTCH 7C-17
SPECIFICATIONS
FASTENER TORQUE
Flywheel Housing to E n gin e.................................................. .................................. 54 Nm 40 ft. lb.

Clutch Pedal Stud................................................................... .................................. 39 Nm 29 ft. lb.
Master Cylinder....................................................................... .................................. 18 N-m 13 ft. lb.
Secondary C ylinder............................................................... .................................. 18 N-m 13 ft. lb.
Cross Lever Ball Stud -
Bracket S id e ....................................................................... .................................. 27N-m 20 ft. lb.
Engine Side (G Models)...................................................... .................................. 54 N-m 40 ft. lb.
(P Models)...................................................... .................................. 46 N-m 34 ft. lb.
Adjusting Rod Swivel (G Models)........................................ .................................. 43 N m 32 ft. lb.
(P Models)........................................ .................................. 27 N-m 20 ft. lb.
CLUTCH PEDAL FREE TRAVEL
G Models....................................................................... ............................................ 34 mm 1.375 in

P Models (Without J F 9 )............................................... ............................................ 34 mm 1.375 in
P Models (With JF9)...................................................... ............................................ 38 mm 1.500 in
LUBRICATION
Hydraulic Clutch -
Capacity................ Fill to level of diaphragm.
Type recommended Brake fluid meeting DOT 3.
7C-18 CLUTCH
SPECIAL TOOLS

7D1-1
SECTION 7D1
205 TRANSFER CASE

CONTENTS
SU B JE C T PAGE
General Description........................................................................................................................................... 7D1-2

Maintenance And Adjustment...........................................................................................................................7D1-2
Diagnosis Of Transfer C a s e .............................................................................................................................7D1-3
On-Vehicle S e rv ic e ........................................................................................................................................... 7D1-4
Transfer Case R em oval.................................................................................................................................7D1-4
Specifications..................................................................................................................................................... 7D1 -6
7D1-2 205 TR A N SFER C A S E
GENERAL DESCRIPTION
F. Rear Output Assembly

G. Fill Plug
H. Idler Shaft Cover
A. Shift Rail Link I. Front Output Shaft Rear Bearing Retainer
B. Poppet Nuts J. Drain Plug
C. Front Input Shaft Assembly
D. Idler and Rear Output Shaft Nut
E. Front Output Shaft Assembly
F-00044 F-00045
Figure 1Front View Figure 2Rear View
The 205 transfer case mounts behind the transmis available in two modes, 2H for two-wheel drive or 4H
sion and allows drive torque to be transmitted in a pro for four-wheel drive. Gear reduction (1.96:1 ratio) is
portional split to both the front axle and the rear axle, used in the 4L position. This unit uses constant mesh
resulting in four-wheel drive (figures 1 and 2). helical gears to connect the input shaft, idler gear and
The shift control lever for the transfer case is floor- two output gears, thus allowing gear selection to match
mounted in the passenger compartment. driving conditions.
The? model 205 is a two-speed unit which offers two- When driving in a four-wheel mode (4L or 4HI), turn
wheel or four-wheel drive Direct drive (1:1 ratio) is the hubs on the front wheels to the Locked position.
MAINTENANCE AND ADJUSTMENT

LUBRICATION INFORMATION LINKAGE ADJUSTMENT AND INSPECTION
Refer to Section OB for information on intervals and Periodically inspect the linkage system for freedom
types of lubricant. of operation, proper engagement, loose attaching
bolts, foreign material, etc. Adjust, clean and tighten as
necessary (figure 3).
205 TR AN SFER CA SE 7D1-3
1. Knob
2. Nut
3. Screw
4. Plate
5. Lever
6. Retainer
7. Boot
8. Pin
9. Washer
10. Washer
11. Link
12. Rod
13. Grommet
14. Fitting
15. Bolt V
F-00035
Figure 3Shift Control Component View
DIAGNOSIS OF TRANSFER CASE

Before servicing a malfunction, check the front hubs, axles, propeller shafts, wheels and tires, transmission or
clutch.
Excessive Noise 1. Lubricant level low. 1. Fill as required.

2. Worn or damaged bearings. 2. Replace.
3. Misalignment of drive shafts or univer 3. Align.
sal joints.
4. Yoke bolts loose. 4. Refer to Specifications.
5. Loose adapter bolts. 5. Refer to Specifications.
Shift Lever Difficult Binding inside transfer case. Repair as required.

To Move
Shifter Lever 1. Gears worn or damaged. 1. Replace.

Disengages From 2. Shift rod bent. 2. Replace.
Position 3. Missing detent ball or spring. 3. Replace.
Lubricant Leaking 1. Excessive lubricant in case. 1. Adjust level.

2. Leaking seals or gaskets. 2. Replace.
3. Loose bolts. 3. Tighten
4. Scored yoke in seal contact area. 4. Refinish or replace.
7D 1-4 205 TR A N SFER C A SE
ON-VEHICLE SERVICE
TRANSFER CASE REMOVAL
Raise and support the vehicle on a suitable hoist.

Drain the transfer case.
1. Speedometer cable.
2. Skid plates and crossmembers (figure 4).
3. Strut rod (automatic transmissions) (figure 5).
4. Rear propshaft from the case.
Mark propshaft for assembly reference.
Tie it up and move it away from the work
area.
5. Shift lever rod from the shift rail link.
6. Bolts attaching the transfer case to the transmis
sion adapter (figure 6).
Support the transfer case with a suitable
stand.
7. Transfer case.
Move the transfer case to the rear until the
input shaft clears the adapter.
I Install or Connect
Support the transfer case in a suitable stand and

position the case to the transmission adapter.
1. Bolts attaching the case to the adapter (figure 6).

^X Tighten

Bolts to 61 N m (45 ft. lbs.). 6. Strut rod (automatic transmission) (figure 5).
Remove the stand.
2. Connecting rod to the shift rail link or connect the
shift lever to transfer case as required (figure 3).
Tighten

3. Front propshaft to the transfer case front output
flange or yoke.
Tighten

4. Rear propshaft to the transfer case rear output
yoke.
Tighten
B-06918
5. Crossmember support and skid plate, if removed Figure 5Strut Rod Support
(figure 4). (Automatic Transmissions)
205 T RAN SFER C A SE 7D1-5
MANUAL TRANSMISSION
F-00037
Figure 6Transmission Adapters

7D1-6 205 TR A N SFER CA SE
8. Fill the transfer case to the proper level with

lubricant. Refer to Section OB.
Transmission end bolts to 47 N m (35 ft. lbs.). 9. Filler plug.
Transfer case end bolts to 175 N m (129 ft.
lbs.). Tighten
Plug to 44 N m (32 ft. lbs.).
10. Lower and remove the vehicle from hoist.
SPECIFICATIONS
N-m Ft. Lbs. In. Lbs.
Nut, Shift Lever-To-Shifter Assembly 23 17
Nut, Knob Assembly-To-Shift Lever 33 24
Bolt, Shifter Assembly-To-Transfer Case 135 100
Nut, Shift Arms-To-Case 17 13
Screw, Shift Lever Boot Retainer 2.7 31
Bolt, Adapter-To-Transmission 33 24
Bolt, Adapter-To-Transfer Case 33 24
Drain Plug 44 32
Filler Plug 44 32
Bolts P.T.O. Cover 22 16
Nut, Skid Plate-To-Crossmember 63 46
Bolt, Support Strut Rod
Transmission End 47 35
Transfer Case End 175 129
Propeller Shaft
Transfer Case (Front) 75 55
Transfer Case (Rear) 15 11
MODEL NO. 205 (PART TIME)

AVAILABILITY All K30 Series
RATIOS: Hi Range 1.00 To 1
Lo Range 1.96 To 1
LEVER POSITIONS 4-Lo (All Wheel Underdrive)
N (Neutral)
2-Hi (Rear Wheel Drive)
4-Hi (All Wheel Direct Drive)
LEVER LOCATION Rear Of Transmission Shift Lever
POWER TAKE-OFF DATA:
Opening and Location SAE 6-Bolt; Left Side
LUBRICANTS:
Oil Capacity 5.2 Pints*
Type, Grade Dexron II
*To Be Filled Within One Inch Of Fill Plug.

G EN ER A L INFORMATION 7D2-1
SECTION 7D2
208 TRANSFER CASE

CONTENTS
SU B JE C T PAGE
General Description...........................................................................................................................................7D2-1
Diagnosis of Transfer Case...............................................................................................................................7D2-3
Maintenance and Adjustm ent...........................................................................................................................7D2-4
On-Vehicle S e rvice ........................................................................................................................................... 7D2-5
Transfer Case R em oval.................................................................................................................................7D2-5
Specifications..................................................................................................................................................... 7D2-9
GENERAL DESCRIPTION
range and a neutral position. The model 208 is a part-
time four-wheel drive unit. Torque input in four-wheel
high and low ranges is the same.
A two-piece aluminum case contains front and rear
output shafts, two drive sprockets, a shift mechanism
and a planetary gear assembly. The drive sprockets
are connected and operated by the drive chain. The
planetary assembly, which consists of a four pinion
carrier and an annulus gear, provides the four-wheel
drive low range when engaged. Reduction ratio is
2.61:1 in this range.
SHIFT CONSOLE AND LEVER CONTROLS

A floor mounted shift lever is used to select the
operating range (figure 2). The shift lever is located on
the floorpan transmission tunnel adjacent to the
transmission gearshift lever. The shift pattern is not in a
straight line for 208 models (figure 3).
FOUR-WHEEL DRIVE INDICATOR LAMP

An indicator lamp mounted in the instrument panel
alerts the driver whenever the vehicle is being
operated in four-wheel range. An indicator switch in
the transfer case controls the lamp (figure 2).
The switch is a ball and plunger unit activated by the
range selector when four-wheel range is selected.
IDENTIFICATION
Figure 1Indicator Switch, Identification For servicing, an identification tag attached to the
Tag, and Drain and Fill Plug Location rear half of the transfer case provides the transfer case
model number, low range reduction ratio and assembly
The Model 208 transfer case (figure 1) is an alumi number. If the tag is removed or becomes dislodged
num case, chain driven, four position unit providing during service operations, reattach using an adhesive
four-wheel drive high and low ranges, a two-wheel high sealant such as Loctite 312 or equivalent (figure 1).
7D2-2 G E N E R A L DECSRIPTION
V \ 46
45
20. Knob 40. Guide

21. Rod 31. Boot 41. Lever
22. Grommet 32. Seal 42. Pin
23. Lever 33. Nut 43. Swivel
24. Washer 34. Washer 44. Bolt
25. Pin 35. Bushing 45. Nut
26. Lever 36. Housing 46. Washer
27. Nut 37. Fork 47. Bolt
28. Plate 38. Washer 48. Nut
29. Screw 39. Spring 49. Nut
B-08867
Figure 2Console and Shift Controls Component View

G EN ER A L DESCRIPTION 7D2-3
LUBRICATION
Change the lubricant at the intervals specified in
Section OB. when adding lubricant or refilling the trans
fer case after servicing, use DEXRON II. Refer to the
maintenance and adjustments section for lubricant
change procedures and fill level.
Figure 3Shift Pattern
DIAGNOSIS OF TRANSFER CASE

Before repairing a suspected transfer case problem check the driveline components. The problem may be related
to the front hubs, axles, propeller shafts, wheels and tires, transmission or clutch.
Transfer Case 1. Vehicle speed too great to permit shift 1. Stop vehicle and shift into desired
Difficult To Shift Or ing. range. Or reduce speed to 2-3 mph
Will Not Shift Into (3-4 km/h) before attempting to shift.
Desired Range 2. If vehicle was operated for extended 2. Stop vehicle, shift transmission to
period in 4H mode on dry paved sur neutral, shift transfer case to 2H
face, driveline torque load may cause mode and operate vehicle in 2H on
difficult shifting. dry paved surfaces.
3. Transfer case external shift linkage 3. Lubricate or repair or replace linkage,
binding. or tighten loose components as nec
essary.
4. Insufficient or incorrect lubricant. 4. Drain and refill to edge of fill hole with
DEXRON II only.
5. Internal components binding, worn or 5. Disassemble unit and replace worn
damaged. or damaged components as neces
sary.
Transfer Case Noisy 1. Insufficient or incorrect lubricant. 1. Drain and refill to edge of fill hole with
In All Drive Modes DEXRON II only. Check for leaks
and repair if necessary. Note: If unit
is still noisy after drain and refill, dis
assembly and inspection may be re
quired to locate source of noise.
Noisy In Or Jumps 1. Transfer case not completely engaged 1. Stop vehicle, shift transfer case in
Out Of Four Wheel in 4L position. Neutral, then shift back into 4L posi
Drive Low Range tion.
2. Shift linkage loose or binding. 2. Tighten, lubricate or repair linkage as
necessary.
7D2-4 G E N E R A L INFORMATION
DIAGNOSIS OF TRANSFER CASE (CONT.)

Noisy In Or Jumps 3. Range fork cracked, inserts worn, or 3. Disassemble unit and repair as nec
Out Of Four Wheel fork is binding on shift rail. essary.
Drive Low Range 4. Annulus gear or lockplate worn or 4. Disassemble unit and repair as nec
(Continued) damaged. essary.
Lubricant Leaking 1. Transfer case overfilled. 1. Drain to correct level.

From Output Shaft 2. Vent closed or restricted. 2. Clear or replace vent if necessary.
Seals Or From Vent 3. Output shaft seals damaged or in 3. Replace seals. Be sure seal lip faces
stalled incorrectly. interior of case when installed. Also
be sure yoke seal surfaces are not
scored or nicked. Remove scores,
nicks with fine sandpaper or replace
yoke(s) if necessary.
Abnormal Tire Wear 1. Extended operation on dry hard sur 1. Operate in 2H on hard surface
face (paved) roads in 4H range. (paved) roads.
MAINTENANCE AND ADJUSTMENT

CASE-OIL CHANGE LINKAGE ADJUSTMENTS (FIGURES 1 AND 4)
Remove or Disconnect ft Adjust (Figures 1 and 4)
Raise the vehicle. 1. Put the transfer case lever into the 4H detent
Position a drain pan under the transfer case. (figure 4).
Drain and fill plugs. 2 . Push the lower shifter lever (26) forward into the
Drain the lubricant. 4H detent.
3. Install the rod swivel (21) into the shift lever hold.
n- Install or Connect 4. Hang a 129 mm (0.200) gage (F) with a 6 mm
(0.25 inch) radius over the rod behind the swivel.
1. Drain plug. 5. Run the rear rod nut (27) against the gage with
the shifter against the 4H detent.
6. Remove the gage and push the swivel rearward
against the nut (27).
Plug to 24 N-m (18 ft. lbs.) 7. Run the front rod nut (49) against the swivel and
Remove the drain pan. tighten.
Fill the transfer case to the edge of fill plug
opening with DEXRON II.
2. Fill plug.
Plug to 24 N-m (18 ft. lb.).

Lower the vehicle.
INSPECTION
Periodically inspect the linkage system for freedom
of operation, proper engagement, loose attaching bolts
and foreign material.
G EN ER A L INFORMATION 7D2-5
F. Gage 129 mm (0.200)

21. Rod
22. Grommet
23. Lever
26. Lever
27. Nut
49. Nut B-08895
Figure 4Linkage Adjustment
ON-VEHICLE SERVICE
TRANSFER CASE REMOVAL Move the transfer case rearward until it is

free of the transmission output shaft.
10. Gasket material.
Remove or Disconnect (Figures 2, 5, 6 and 7)
E
Place the transfer case in 4H detent.
Raise the vehicle. Place the transfer case in 4H detent.
Drain the lubricant from the transfer case.
1. Cotter pin from the shift lever swivel (figure 2). Place the transfer case in a support stand.
2. Speedometer cable. 1. Gasket to the transmission (figure 6).
3. Indicator switch wire. 2. Output shaft.
4. Front and rear propeller shafts.
Rotate the transfer case output shaft (turn
Mark the shafts and yokes for assembly
yoke) until the ouput shaft gear engages the
alignment reference.
transfer case input shaft.
5. Parking brake cable guide from the pivot located
on the right frame rail. Move the transfer case forward until the
6. Engine strut rod on automatic transmission case seats against the transmission.
models (figure 5).
7. Transfer case-to-transmission adapter bolts NOTICE: Place the transfer case flush against
(figure 6). the transmission. The case can be damaged if
Support the transfer case with a suitable the attaching bolts are tightened when the
stand. case is cocked or in a bind.
8. Skid plates (figure 7).
9. Case. 3. Attaching bolts.
7D2-6 G E N E R A L DECSRIPTION
Transmission bolts to 47 N-m (35 ft. lbs.).

Transfer case bolts to 175 N m (129 ft. lbs.).
10. Fill the transfer case with DEXRON II.
Lower the vehicle.
Figure 5Strut Rod Support - Automatic

Transmissions
Tighten

5. Front and rear propeller shafts.
Tighten
Front flange belts to 20 N-m (75 ft. lbs.

Rear strap nuts to 20 N-m (15 ft. lbs.).
9 Important
Line up the reference marks made during

removal.
6. Skid plate (figure 7).
Tighten

Remove the support stand from under the
transfer case.
7. Parking brake cable if disconnected.
8. Cotter pin to the shift lever swivel (figures 2 and
4).
9. Strut rod support to the transfer case on auto
matic transmissions (figure 5).
G E N E R A L DESCRIPTION 7D2-7
VIEW H
WITH MANUAL TRANSMISSION
B-08899
Figure 6Transmission Adapters

t
7D2-8 G E N ER A L DECSRIPTION
Figure 7Skid Plate

208 TRAN SFER C ASE 7D2-9
SPECIFICATIONS
N-m Ft. Lbs.

Nut, Shift Lever-To-Shifter Assembly 23 17
Nut, Knob Assembly-To-Shift Lever 33 24
Bolt, Shifter Assembly-To-Transfer Case 130 96
Nut, Shift Arms-To-Case 17 13
Screw, Shift Lever Boot Retainer 2.7 24*
Bolt, Detent Retainer 31 23
Switch, Indicator 149 111
Bolt, Adapter-To-Transmission 33 24
Bolt, Adapter-To-Transmission Case 33 24
Filler Plug 47 35
Nut, Skid Plate-To-Crossmember 63 47
Bolt, Support Strut Rod
Transmission End 47 35
Transfer Case End 175 129
Bolts, Yoke Steps
Transfer Case, Front 75 55
Transfer Case, Rear 15 11
* Inch Pounds
Model No. 208 (Part Time)

Ratios: Hi Range
Lo Range 2.61 to 1
Lever Positions 4-Lo (All Wheel Underdrive)
2-Hi (Rear Wheel Drive)
4-Hi (All Wheel Drive)
Lever Location Rear of Trans. Shift Lever
Lubricants:
Oil Capacity 10 Pints*
Type, Grade DEXRON II
* Fill To The Edge Of The Plug Hole.

8 A-1
SECTION 8
ELECTRICAL
CONTENTS
S U B JE C T PAGE
Cab E lectrical..................................................................................................................................................... 8A- 1
Chassis Electrical............................................................................................................................................... 8B- 1
Instrument Panel and Gages.............................................................................................................................8C- 1
SECTION 8A
CAB ELECTRICAL
CONTENTS
S U B JE C T PAGE
Basic Electrical................................................................................................................................................... 8A- 2

C irc u its ........................................................................................................................................................... 8A- 2
Wire Size Conversion T a b le .........................................................................................................................8A- 4
Circuit M alfunctions.......................................................................................................................................8A- 4
Circuit D ia g n o sis........................................................................................ 0 ............................................. 8A- 4
Diagnostic Tools.......................................................................................... V '...............................................8A- 5
Circuit Maintenance and R e pair.................................................................................................................. 8A- 6
Cab Electrical S ystem s.....................................................................................................................................8A-10
CK Cab Harness R outings.............................................................................................................................8A-10
CK Fuse B lo c k ............................................................................................................................................... 8A-10
G Van Cab Harness R o u tin g s...................................................................................................................... 8A-10
G Van Fuse Block........ .................................................................................................................................. 8A-18
Power Door Lock S yste m .............................................................................................................................8A-18
Diagnosis of Power Door Lock System.......................................................................................................... 8A-25
On-Vehicle Service.........................................................................................................................................8A-26
Power Window S yste m .................................................................................................................................8A-26
Diagnosis of Power Window System.............................................................................................................. 8A-26
Windshield WiperCK and G M odels............................................................................................................ 8A-28
D escription..................................................................................................................................................... 8A-28
Diagnosis C h a rt................................................................................................................................................. 8A-31
On-Vehicle Service........................................................................................................................................ 8A-28
Windshield WasherCK and G Models.......................................................................................................... 8A-36
D e scription..................................................................................................................................................... 8A-36
Windshield Washer D iagn osis........................................................................................................................ 8A-37
Wiper Motor Unit R epair...................................................................................................................................8A-38
Replacement of C om ponents...................................................................................................................... 8A-38
Windshield Wiper Delay C irc u it...................................................................................................................... 8A-40
D e scription..................................................................................................................................................... 8A-40
Diagnosis of the Wiper Delay C ircuit.............................................................................................................. 8A-42
Windshield Wiper and WasherP M o d e ls .................................................................................................... 8A-43
D e scription...................................................................................................... ...........................................8A-43
Diagnosis.........................................................................................................................................................8A-44
8A -2 C A B ELECTRICAL
CONTENTS (CONT.)
S U B JE C T PAGE
Diagnosis of the WiperO n-Vehicle.............................................................................................................. 8A-45

Diagnosis of the WiperO ff-Vehicle.............................................................................................................. 8A-46
Diagnosis of the Washer System .................................................................................................................... 8A-47
Unit R epair......................................................................................................................................................... 8A-48
Wiper Motor Disassem bly............................................................................................................................ 8A-48
Inspection....................................................................................................................................................... 8A-48
Wiper Motor Assembly...................................................................................................................................8A-48
Windshield Washer Disassem bly................................................................................................................ 8A-50
Windshield Washer Assembly...................................................................................................................... 8A-51
Heater System C irc u its .....................................................................................................................................8A-51
D escription..................................................................................................................................................... 8A-51
Diagnosis......................................................................................................................................................... 8A-51
Air Conditioning Electrical S y s te m ................................................................................................................ 8A-51
D escription..................................................................................................................................................... 8A-51
Diagnosis......................................................................................................................................................... 8A-51
Special T o o ls ..................................................................................................................................................... 8A-52
BASIC ELECTRICAL
CIRCUITS
An electrical circuit starts from a supply of electricity,
conducts the electricity back to the supply of electricity.
There should be a device to open and close the circuit,
and a protective device to open the circuit in case too
much current flows in the circuit.
Electrical circuits can be set up as series circuits or
parallel circuits. The circuits in trucks are usually
parallel circuits.
SERIES CIRCUITS (Figure 1)

In series circuits, each electrical device is connected
in the circuit so that the current can only go along one
path as it flows from the power supply, around the
circuit and back to the power supply.
PARALLEL CIRCUITS (Figure 1)

In parallel circuits, the electrical devices are
connected by parallel wires that are joined at the start
of the circuit. The current divides: part of it flows into
one device, part into another.
With circuits in parallel, each circuit can be switched
on and off by itself since each circuit receives
electricity directly from the power supply.
CIRCUIT COMPONENTS (Figure 2)

The usual circuit path starts at the power supply
which is the battery/generator system. Next in the
circuit is the circuit protection component which can be goes into the circuit load. The circuit load can be one
a fusible link, a fuse, or a circuit breaker. Then the light or many lights in parallel, an electric motor or a
circuit goes to the circuit controller which can be a solenoid. After the electricity has passed through the
switch or a relay. From the circuit controller the circuit load it must return to the power supply via the ground
C A B ELECTRICAL 8A -3
and closes until the excess current condition is

corrected or the circuit is disconnected from the power
supply.
The remote reset circuit breaker has a heating wire
wound around the bimetallic strip. When an excess
current happens, the strip heats, bends, and opens the
contacts. Then a small current flows through the heat
wire, keeping the strip hot and the contacts open. This
type of breaker will stay open until either the power
supply is disconnected from the circuit or the breaker
is removed from the circuit. Then the breaker can cool
and reset.
CIRCUIT CONTROLLERS
Circuit controllers consist of switches or relays.
Switches are usually operated by a mechanical means
such as a hand or lever. Switches are usually at the
beginning of a circuit but can be used to control a
Figure 2Circuit Components ground path. For example, the switch controlling the
headlights is at the power end of the circuit while the
path. The ground path can be a wire in the harness or door switch controlling the domelight completes the
it could be through the load housing into the body or ground path.
frame, thus returning the electricity to the power Relays are remotely controlled switches. They are
supply. The body and frame are connected by flexible used in high current circuits and in circuits controlled
ground straps. by sensors.
Relays are designed so that a small current circuit
FUSIBLE LINK will be able to control a large current circuit.
A fusible link is a section of wire that is usually four
gage sizes smaller than the circuit it protects. A special
WIRING HARNESS AND WIRES
insulation is used that swells when heated by the wire.
Every wire is a specific size with colored or striped
Fusible links are usually found in the engine
insulation that is indicated on the wiring diagrams.
compartment harnesses. The function of the fusible
Insulation colors help to trace circuits and to make
link is to melt open when an overload occurs, thus
proper connections. Abbreviations and symbols used
preventing any damage to the circuit.
for indicating wire insulation colors and patterns are as
follows:
FUSES
BLK......................Black ORG . . . . ........Orange
The most common protector in the vehicle circuit is a
BRN........ ..........Brown PPL........ ..........Purple
fuse. A fuse consists of a fine wire or strip of metal
CH.......... ..........Check T R .......... ..........Tracer
inside a glass tube or plastic housing. The strip melts
C R .......... ..........Cross Y E L ........ .........Yellow
and interrupts the flow of current in the circuit when
GRN ..........Green / / ............ ........Parallel
there is an overload caused by an unwanted short or
NAT........ ........Natural WHT........ ..........White
ground. The fuse is designed to melt before the wiring
LT............ ............Light B L U ........ ............Blue
or electrical components in a circuit can be damaged.
SGL........ ..........Single S T R ........ ..........Stripe
Naturally, the cause must be located and corrected
ORN ........Orange P N K ........ ............Pink
before the fuse is replaced or the new fuse will also
GRA........ ............Gray D K .......... ............Dark
blow.
Since different circuits handle different amounts of Some wires are grouped and taped together or
current, fuses of various ratings are used. Fuses are encased in a split plastic casing. This grouping of
rated in amperes. Be sure to replace a blown fuse with wires is called a harness. For some purposes, it is
a fuse of the connecting rating. more practical to use a single wire protected by a
braided tubing called a loom.
CIRCUIT BREAKERS Wiring harnesses are joined by using a multiple plug
Circuit breakers are another form of circuit protector. and receptacle connector block, or a terminal post
There are two types of circuit breakers; automatic reset chassis junction block. In the instrument panel area
and remote reset. plastic insulated blade-type connectors and screw-type
The automatic reset breaker opens when excess terminals are used.
current heats a bimetallic strip, causing the strip to Each harness or wire must be held securely in place
bend and open a set of contacts. Then the strip cools by clips or other holding devices to prevent chafing of
and closes the contacts. So the circuit breaker opens the insulation.
8A -4 C A B ELECTR ICAL
WIRE SIZE
Wire size in a circuit is determined by the amount of
current, the length of the circuit and the voltage drop
allowed. Wire size is specified using the metric gage.
The metric gage describes the wire size directly in
cross section area measured in square millimeters.
WIRE SIZE CONVERSION TABLE

METRIC AWG
SIZE SIZE
(mm)2
0.22 24
0.5 20
0.8 18
1.0 16
2.0 14
3.0 12
5.0 10
8.0 8
13.0 6
19.0 4
32.0 2
40.0 1
50.0 0
62.0 00
CIRCUIT MALFUNCTIONS may also be caused by deposits of oil, dirt and

moisture around connections or terminals, which
There are three electrical conditions that can cause provide a good path to ground.
a nonworking circuit; an Open Circuit, a Short
Circuit, and a Ground Circuit.
CIRCUIT DIAGNOSIS
OPEN CIRCUIT (Figure 3)
An open circuit occurs whenever there is a break in A clear understanding of the circuit and a wiring
the circuit. The break can be corrosion at the diagram are needed for effective diagnosis. Use a
connector, a wire broken off in a device, or a wire that logical sequence of testing to find the trouble. Use the
burned open from too much current. diagnostic tools. After the trouble is fixed, make sure
the circuit works correctly.
SHORT CIRCUIT (Figure 4)

A short circuit happens when the current bypasses
part of the normal circuit. This bypassing is usually
caused by wires touching, salt water in or on a device
such as a switch or a connector or solder melting and
bridging conductors in a device.
GROUNDED CIRCUIT (Figure 5)

A ground circuit is like a short circuit but the current
flows directly into a ground circuit that is not part of the
original circuit. This may be caused by a wire rubbing
against the frame or body. Sometimes a wire will break
and fall against metal that is connected electrically to
the ground side of the power supply. A ground circuit
C A B ELECTRICAL 8 A -5
DIAGNOSTIC TOOLS 33
UNPOWERED TEST LAMP

This tool consists of a 12 volt lamp with leads. The
ends of the leads usually have alligator clamps, but
various kinds of probes, terminal spades, and special
connectors are used also.
The unpowered test lamp is used on an open circuit.
One lead of the test lamp is grounded and the other
lead is moved around the circuit to find the open. 30. Power Source
Depending on the physical layout of the circuit, 31. Circuit Breaker
sometimes it will be easier to start at the power supply 32. Switch (Closed)
and other times it is easier to start at the circuit load or 33. Ammeter
ground circuit. 34. Load
B-06086
POWER TEST LAMP

This lamp is a pencil shaped unit with a self con Figure 6Ammeter Circuit
tained battery, a 1.5 volt lamp bulb, a sharp probe and
a ground lead fitted with an alligator clip. AMMETER (Figure 6)
Disconnect the circuit from the power source before
This test lamp is used mainly for testing components connecting the ammeter. The ammeter measures the
that are disconnected from the vehicle power supply. amount of electrical current, amperes, moving through
The power test lamp is also useful for testing a conductor. The ammeter must be placed in series
suspected high resistance points in a circuit such as with the circuit being tested. Be sure that the
connectors and ground circuits that are corroded or ammeters positive terminal is connected to the
loose. positive (battery) side of the circuit and the ammeters
negative terminal is connected to the negative (ground)
JUMPER side of the circuit.
The jumper is usually a long wire with alligator
clamps. A version of the jumper has a fuse holder in it OHMMETER (Figure 7)
with a 10 Amp fuse. This will prevent damaging the The ohmmeter is an instrument designed to indicate
circuit if the jumper is connected in the wrong way. resistance in ohms. It is used to test the condition of a
The jumper is used to locate opens in a circuit. One unit disconnected from the circuit.
end of the jumper is attached to a power source and
then the other end is attached to the load in the circuit, Ohmmeter Calibration
i.e.; lamp, motor. If the load works, try jumping to When the ohmmeter probes are connected together,
circuit points that are progressively closer to the power a circuit is completed causing the meter needle to
supply. When the circuit load stops working, the open
has been located.
The jumper is also used to test components in the
circuit such as connectors, switches, and suspected
high resistance points.
NOTICE: The following instruments: Ammeter,

Voltmeter, and Ohmmeter, each have a
particular application for trouble shooting
electrical circuits.
When using an ammeter or voltmeter, and
the value being tested is unknown, always use
the highest scale first and work downward to a
midscale reading whenever possible. This will
avoid damage to the instrument.
Never use an ohmmeter in a power circuit,
or as a substitute for a voltmeter or ammeter,
as damage to the instrument will result. Figure 7Ohmmeter Circuit
Figure 9Removing Terminals

From The Connector
To splice a wire or repair one that is frayed or broken,

always use rosin flux solder to bond the splice and
insulating tape to cover all splices or bare wires.
When replacing wire, it is important that the correct
deflect. The needle should read ZERO ohms, if it does
size wire be used as shown on applicable wiring
not, rotate the CAL or ADJ knob to ZERO the needle.
diagrams or parts book. Each harness or wire must be
When the probes are held apart, the needle moves
held securely in place to prevent chafing or damage to
to the maximum (infinite) resistance side of the scale.
the insulation due to vibration.
The meter is now ready for use.
Never replace a wire with one of a smaller size or
replace a fusible link with a wire of a larger size.
VOLTMETER (Figure 8)
The voltmeter (properly observed) will give the WIRING CONNECTOR TERMINAL
technician more information than the ammeter, REPLACEMENT (BLADE TYPE)
ohmmeter and test lamp combined. Its application for
troubleshooting here is to measure the electrical Remove or Disconnect (Figure 9)
pressure (voltage) drop in a resistance circuit.
To use a voltmeter for troubleshooting an electrical 1. Terminal lock tang.
problem, connect it in parallel with the existing circuit. 2. Terminal (61).
If the voltmeter is connected in series with the circuit
being tested, the nature of the circuit would be Install or Connect (Figure 10)
changed and the reading would have no particular
value or use. Connect the meter terminals according to 1. Pry up on the tang (70).
polarity as shown. 2. Terminal into the connector.
The dash mounted voltmeter (in the vehicle) should
also be observed for monitoring proper operation of the
generator battery cranking motor, and cranking circuit.
In this application, battery voltage drop can be
monitored while the engine is cranking; and after the
engine is running, generator output voltage can be
monitored. This can be a valuable first step prior to
diagnosing other electrical problems.
CIRCUIT MAINTENANCE
AND REPAIR
MAINTENANCE AND REPAIR
All electrical connections must be kept clean and 71
tight. Loose or corroded connections may cause a 70. Terminal Lock Tang
discharged battery, difficult starting, dim lamps, and 71. Terminal
possible damage to the generator and regulator. Wires B-06227
must be replaced if insulation becomes burned,
cracked, or deteriorated. Figure 10Resetting The Lock Tang
WIRING CONNECTOR TERMINAL

REPLACEMENT (TWIN LOCK TYPE)
Tool Required:
J-22727 Terminal Remover
1. Connector lock tangs.
2. Terminal locks using J-22727.
3. Terminal.
Install or Connect
1. Pry out the tangs.

2. Terminal into the connector.
WEATHER-PACK CONNECTORS (Figure 12)

Special connectors known as Weather-Pack
connectors require a special tool J-28742 for servicing.
This special tool is required to remove the pin and
sleeve terminals. If removal is attempted with an
ordinary pick, there is a good chance that the terminal
Tool Required:
will be bent or deformed. Unlike standard blade-type
terminals, these terminals cannot be straightened once J-28742 Terminal Remover
they are bent. 1. Primary lock (121) by lifting.
Make sure that the connectors are properly seated
2. Connector sections.
and all of the sealing rings are in place when
connecting the leads. The hinge-type flap provides a 3. Secondary lock (125) by spreading the sides of
back-up, or secondary locking feature for the terminals. the hasp, thus clearing the staples and rotating
They are used to improve the connector reliability by the hasp (127).
retaining the terminals if the small terminal lock tangs 4. Terminal (131) by using J-28742 (128).
are not positioned properly.
Snip off the old terminal assembly.
M olded-on-connectors require com plete
replacement of the connection. This means splicing a 5. 5 mm of the wire insulation (130).
new connector assem bly into the harness.
Environmental connections cannot be replaced with Clean
standard connections. Instructions are provided with
the Weather-Pack connector and terminal packages. Terminal Barrel (124).
With the low current and voltage levels found in
some circuits, it is important that the best possible
+" Install or Connect (Figure 12)
bond at all wire splices be made by soldering the
splices.
1. Terminal insulator (134) on the wire. Slide the
Use care when probing the connections or replacing
insulator back on the wire about 8 cm (3 inches).
terminals in them, it is possible to short between
opposite terminals. If this happens to the wrong 2. Terminal (131) on the wire.
terminal part, it is possible that damage may be done Roll crimp (132) and solder the terminal.
to certain components. Always use jumper wires
3. Terminal insulator (134) and roll crimp (133).
between connectors for circuit checking. Never probe
through the Weather-Pack seals. 4. Terminal into the connector.
When diagnosing for possible open circuits, it is 5. Secondary lock (125).
often difficult to locate them by sight because oxidation
6. Connector sections until the primary lock (121)
or terminal misalignment are hidden by the connectors.
Merely wiggling a connector on a sensor or in the engages.
wiring harness may correct the open circuit condition.
This should always be considered when an open WIRING REPAIR
circuit is indicated while troubleshooting. Intermitten The wire repair is very important for the continued
problems may also be caused by oxidized or loose reliable operation of the vehicle. This repair must be
connections. done as described in the following procedures.
122
123
125
126
t= f , ...
128
129
120. Connector Seal 128. J 28742 Terminal Remover

121. Primary Lock 129. Wire
122. Secondary Lock Staple 130. 5 mm (.2 inch)
123. Secondary Lock 131. Terminal
124. Terminal Barrel 132. Roll Crimp
125. Secondary Lock 133. Roll Crimp
126. Lock Opened 134. Terminal Insulator
127. Lock Opened
B-06232
Figure 12Weather-Pack Terminals

CA B ELECTRICAL 8A -9
90. Jacket 77 7 / / f t / /
91.
92.
Twisted Wires
Splice Clip
V(106
93. Crimp and Solder
94. Electrical Tape Wrap \
95. Outer Electrical Tape Wrap.
107
Figure 13Twisted Lead Repair 100. Jacket

101. Aluminum/Mylar Tape
102. Drain Wire
WIRING REPAIR 103. Splice Clip
The wire repair is very important for the continued 104. Crimp and Solder
reliable operation of the vehicle. This repair must be 105. Electrical Tape Wrap
done as described in the following procedures. 106. Drain Wire Splice Clip, Crimped And Sol
dered.
Twisted Leads (Figure 13) 107. Outer Electrical Tape Wrap. B-06231
Remove or Disconnect Figure 14Twisted/Shielded Lead Repair
Jacket (90). 5. Insulation on the leads.

Twisted wires (91).
Insulation from the wire. Install or Connect
Install or Connect 1. Splice clips (103).

2. Crimp and solder the splice clips (104).
Splice clip (93). 3. Electrical tape (105) on the splices.
Crimp. 4. Aluminum/mylar tape by wrapping and taping.
Solder. 5. Drain wire with a splice clip (106). Crimp and
Electrical tape wrap (94) on wires. solder the splice clip.
Outer electrical tape wrap (95). 6. Outer jacket electrical tape wrap (107).
Twisted Leads/Shielded Cable (Figure 14)
|<-+| Remove or Disconnect
1. Jacket (100).
2. Unwrap aluminum/mylar tape (101).
3. Drain wire (102).
4. Leads.
CAB ELECTRICAL SYSTEMS
CK CAB HARNESS ROUTINGS At the rear door frame, the harness is connected to a
contact assembly on the right rear door frame. This
There are several w iring harnesses routed contact assembly is aligned with a contact assembly
throughout the cab which provide continuity between mounted on the right rear door. From the contact
the electrical components. These harnesses consist of: assembly on the door, the harness then goes to the
the instrument panel harness, the power door locks lock motor.
and power window harness, the radio harness, the
heater harnesses, the air conditioning harnesses and CARGO LAMP HARNESS (Figure 19)
the interior lighting harnesses. The harness starts from the instrument panel
harness and routes under the left front door sill. The
INSTRUMENT PANEL HARNESS (Figure 15) harness then goes up the left front door latch frame,
This harness is located along the upper back edge through a connector, and into a control switch.
of the instrument panel. It starts from the fuse panel From the control switch, the harness goes down the
which is located at the left side of the dash panel, and frame, back along the rear door sill and then up the
goes up to the left side of the instrument panel and rear door latch frame. From the top of the frame the
across the instrument panel to the right side of the cab. harness goes to the cargo lamp.
As the instrument panel harness is routed across the
instrument panel, various circuits branch off to the CK FUSE BLOCK
switches, indicators, and the instrument panel. The
harness is held in place with bendable clips. The fuse block holds the fuses and circuit breakers
Other harnesses are carried in the same supports as that protect the circuits. The fuse block is located on
the instrument panel harness. These harnesses the left side of the dash panel and is fastened to the
consist of the power door locks, power window, radio, dash panel connector block with two screws. The fuse
heater and air conditioning. panel connects to the engine compartment harness.
Power leads from the various circuits plug into the fuse
POWER DOOR LOCKS AND POWER WINDOWS block.
HARNESS (Figures 16 and 17) The fuses are encased in plastic and have twin
This harness starts at the fuse block and routes to blade connectors. The fuses are printed and color
the left and right along the instrument panel. At the coded with the amperage rating. Refer to Figure 20.
middle of the instrument panel, the harness branches
off to the relay assembly. The relay assembly is located
on the inside of the dash panel, just above the steering G VAN CAB HARNESS ROUTINGS
column. The harness then goes to a set of connectors
on the inner wheel housing. From the connectors the INSTRUMENT PANEL HARNESS (Figure 21)
harness passes through a grommet in the front door The instrument panel harness in the G van includes
opening trim panel and then through a flexible the circuits for the instrument panel gages, indicators,
coupling to the door. Inside the door the harness main light switch, windshield wiper and washer, and
branches off to the control switches, the door lock the steering column controls. The harness is held in
motors, and the power window motors. The harness place with clips that plug into brackets which are
connectors are fastened to the control switches with mounted on the instrument panel.
retaining nuts.
FRONT DOOR POWER LOCK SYSTEM
REAR DOOR POWER LOCK HARNESS (Figure 18) (Figure 22 and 23)
The rear door power lock harness starts at a connec The harness starts from the fuse block, which is
tor in the fuse block. The harness is routed along the located under the far left side of the instrument panel.
instrument panel harness, with a branch going to the The left branch of the harness has a connector at the
power door lock switch assembly in the instrument left door hinge frame. Then the harness passes into
panel. The harness then drops down the right front the frame and routes down to a flexible conduit to the
door hinge frame and routes back along the right door door. Inside the door, the harness branches; one
sill to the right front door latch frame. The harness then branch going down to the door lock motor, and the
travels up the right front door latch frame to its mid other branch going up to the door lock switch.
point where a connector is located. The harness then The right branch of the harness routes across the
goes to the roof halo panel and back to the rear door top of the instrument panel to the right door hinge
frame. frame. The harness passes through a connector and
C A B ELECTRICAL 8A-11
1. Heater Control Lamp Bulb

2 . Heater Connector
3. Instrument Panel Cluster Connector
4. Instrument Panel Ground Connector
5. Ground Connector
6 . Ground Circuit Wire
7. Main Lamp Switch Connector
8 . Engine Function Diagnosis Connector
9. Door Jamb & Dome Lamp Connector
10. Parking Brake Switch Connector
11. Dash Panel Connector
12. Horn Relay
13. Dome Lamp And Door Jamb Harness Connector
14. Convenience Center
15. Radio Connector
16. Cigarette Lighter Connector
17. Courtesy Lamp
F-00728
Figure 15CK Instrument Panel Harness

8A-12 C A B ELECTRICAL
20. Instrument Panel Harness 27. Power Window Connector

21. Power Lock And Window Harness 28. Dash Panel Connector
22. Door Harness Connector 29. Power Door Lock Relay
23. Power Window Connector 30. Brake Pedal Bracket
24. Ground 31. Side Front Door Harness
25. Fuse Block 32. Rear Panel Door Harness Connector
26. Power Lock Connector 33. Rear Panel Door Power Lock Connector
F-00729
Figure 16Power Door Locks And Power Window Harness

39. Nut
40. Power Window Switch Connector
41. Retainer Bezel
42. Power Window Switch
43. Power Door Lock Switch Connector
44. Retainer Bezel
45. Power Door Lock Switch
46. Power Door Lock Motor
47. Power Window Motor
48. Front Door Harness F-00730
Figure 17Power Door Locks And Power Window Harness-ln Doors

60. Fuse Block

61. Power Door Lock Switch
62. Lock Motor
63. Pop Rivet
F-00731
Figure 18Rear Door Power Lock Harness

C A B ELECTR ICAL 8A-15
Figure 19Cargo Lamp Harness
continues into the door frame. The harness routes REAR DOOR POWER LOCK CIRCUIT (Figure 25)
down to a flexible conduit. The harness passes The rear power door lock harness is routed from the
through the flexible conduit into the door. Inside the connector on the left front door hinge frame. The
door, the harness branches; one branch going up to harness goes up the frame to the roof, rearward along
the door lock switch, and the other branch going to the the roof halo panel and then crosses over to the right
door lock. rear corner, using the rear roof halo panel. The
harness goes down the right rear corner to a connector
just below the upper door hinge. The harness then
SIDE DOOR POWER LOCK CIRCUIT (Figure 24) passes through grommets and into the right rear door.
Inside the door the harness connects to the power lock
The side door power lock circuit branches off from motor.
the left roof halo harness just behind the front door
latch frame. It goes across the roof frame and down POWER WINDOW SYSTEM
the right front door latch frame, where it connects to (Figures 22, 23, 24 and 25)
the door frame contact assembly. The door frame This harness starts at the fuse block and routes to
contact assembly aligns with the door contact the left and right along the instrument panel. The
assembly so that electrical contact is made when the harness then routes into the left and right front doors.
door is closed. In this way, electricity is conducted to At the left door hinge pillar, the harness routes up to
the side door power lock motor. the left roof halo panel, back to the first roof frame,
branches to the right side of the van and rearward to
70. Clock, Dome Lamp, Door Jam Switch 86 85

71. Cruise Control, Radio/Window Defogger, Diesel Indicator Circuit, Automatic Transmission Con
verter Switch, Tachometer, Overspeed Indicator Circuit
72. Power Window, Power Door Locks
73. Automatic Transmission Converter Clutch, 4 Wheel Drive Indicator Lamp, Auxiliary Battery
74. 4 Wheel Drive Indicator Lamp, Radio/Window Defogger
75. Power Door Lock, Power Windows, Radio/Window Defogger
76. Rear Air Conditioning Circuit, Auxiliary Heater 85. Choke Heater
77. Instrument Panel Lamps 86. Fuse/'PLR
78. Power Accessories Circuit Breaker, Power Windows 87. Turn, Back Up Lamps
79. Stop/Hazard Lamps 88. Gages, Idle Solenoid
80. Auxiliary Heater, Air Conditioning 89. Fuse
81. Radio 90. Tail Lamps, Courtesy Lamps
82. Heater, Air Conditioning 91. Ignition Circuit
83. Wiper 92. Horn, Dome Lamps
84. Power Window Circuit Breaker 93. Spare Fuses
Figure 20CK Fuse Block
the rear door. The branch that went to the right side When the harness reaches the first roof frame, it
routed down the side door hinge pillar and into the side goes into a connector. There are two branches coming
door. out of the connector. One branch goes to the center
lamp assembly in the roof. This branch, after
connecting to the center lamp assembly, continues on
INTERIOR LIGHTING SYSTEM (Figures 26 and 27)
to the right side of the roof, where it goes into a
This circuit starts at the fuse block and routes to the
connector. From this connector, one lead goes to the
body harness connector. The standard harness is then
side door grounding switch. The other leads are routed
routed up the left front door hinge frame and back
down the right front door lock frame to the stepwell
along the left roof halo panel. The harness branches at
lamp assembly.
the first and third roof frames, with connectors located
next to the left roof halo panel. The harnesses then go
The other branch, coming out of the roof frame
to the roof lamps and terminate in bulb clips. The
connector, goes back along the left roof halo panel,
standard harness also branches off to the door
across the rear halo panel and terminates at the rear
switches.
door ground switch. Also coming from this connector is
The optional harness is routed from the body a branch that goes down the left front door lock frame
harness connector to a control switch on the to the left stepwell lamp assembly.
instrument panel. The harness then goes from the
switch to the left front door hinge frame, up the frame,
and back along the left roof halo panel.
79
70. Heater Lamp Connector 81. Back Up Switch Connector

71. Heater Controls Assembly 82. Instrument Panel Harness Ground Connector
72. Instrument Cluster Connector (Telltale) 83. Steering Column Connector
73. Instrument Cluster Connector (Gages) 84. Windshield Wiper Connector
74. Neutral Switch (Manual Transmission) 85. Stop Lamp Connector
75. Light Switch Connector 86. Stop Lamp Switch
76. Body Wiring Harness Connector 87. Torque Converter Clutch Connector
77. Horn Relay 88. Blower Motor Connector
78. Park Brake Switch Connector 89. Windshield Wiper And Washer Harness Connector
79. Test Connector
80. Ground Bus
F-00734
Figure 21 G Van Instrument Panel Harness

100. Power Lock Relay 103. Power Door Lock Connector 106. Power Window Circuit Breaker
101. Right Door Harness 104. Ground Connector 107. Left Door Harness
102. Power Window Connector 105. Power Door Lock Circuit
F-00735
Figure 22G Van Power Door Lock And Power Window Harness
G VAN FUSE BLOCK supply voltage polarity. Each switch will lock all the
doors.
The fuse block holds the fuses and circuit breakers Each motor has a self-resetting circuit breaker built
that protect the circuits. The fuse block is located on in. Voltage is present at the door lock switches at all
the left side of the dash panel and is fastened to the times. Voltage is also present on the open contacts of
dash panel connector block with two screws. The fuse the door lock relay at all times.
block connects to the engine compartment harness. When a door switch is moved to Lock, current
Power leads from the various circuits plug into the fuse flows through the switch and lock relay coil to ground.
block. The relay closes, causing current to flow through the
The fuses are encased in plastic and have twin lock relay contacts, door lock motor, the unlock relay
blade connectors. The fuses are printed and color contacts, and then to ground.
coded with the amperage rating. Refer to Figure 28. When a door lock switch is moved to Unlock,
current flows through the switch, the unlock relay
contacts, the door lock motor, the lock relay contacts,
POWER DOOR LOCK SYSTEM and to ground. This causes the lock motor to unlock
the door.
DESCRIPTION For CK models, the door lock relay is located on the
Individual motors operate each door lock. The dash panel, above the steering column. For G van
direction the motor turns depends on the polarity of the models the door lock relay is located on front left door
supply voltage. The door lock switches control the hinge pillar.
CA B ELECTR ICAL 8A-19
Figure 23G Van In-Door Harness

8A - 20 C A B ELECTRICAL
130. Power Window Motor Connector

131. Power Window Motor
132. Contacts Assembly
133. Power Windows Harness Connector
134. Power Lock Motor Connector
135. Power Lock Motor
Figure 24G Van Side Door Harness

Figure 26Door Jamb Switch And Dome Lamp Switch Harness

F-00740
Figure 27G Van Interior Lighting Harness

161 163 164 165 167
165. Radio Feed Power Door Locks Door Locks Circuit Breaker
166. Front Auxiliary Battery 171. Overspeed Alarm System 175. Audio Alarm Center
167. Radio Dial Lamp 172. Power Windows And Power 176. Check Engine 3C Jumper
168. Auxiliary Heater Door Locks Circuit Breaker 177. TransmissionController Switch
169. Rear Air Conditioning 173. Directional Signal Flasher 178. Theft Deterrent Harness
F-00741
Figure 28G Van Fuse Block

DIAGNOSIS OF POWER DOOR LOCK SYSTEM

One door lock will 1. No power at lock motor. 1. Check for voltage at the lock motor. If
not work. no voltage at lock motor, check for
voltage at the connector which is lo
cated at the front door hinge pillar. If
there is no voltage at the connector,
check for an open between the con
nector and the door lock relay.
2. Open ground circuit between the 2. Move a door switch to Lock. Back-
motor and the relay. probe the TAN wire at the motor. If
there is voltage, find the open be
tween the motor and the relay.
None of the door 1. No power. 1. Check for power at the fuse block
locks function; all (ORN/BLK). Check for power at the
switches tried. door lock relay (ORN/BLK). If power
is present at the fuse block but not
present at the relay, find the open in
the harness.
2. Relay not working. 2. Hold a switch to Lock. Backprobe
the LT BLU wire at the relay. If there
is no voltage, find the open in the har
ness. If there is voltage, check the re
lay case to ground path. If the ground
is OK, check the relay coil for con
duction. If the relay coil is OK, check
for voltage on the TAN wire. If there is
no voltage, replace the relay. If there
is voltage, find the open in the har
ness.
One switch wont 1. No power to the switch. 1. Check for voltage on the ORN wire at
lock the doors. the switch. If there is no voltage, find
the open between the switch and the
fuse block.
2. Switch has internal open. 2. Move the switch to Lock. Check for
voltage on the LT BLU wire at the
switch. If there is no voltage, replace
the switch.
ON-VEHICLE SERVICE Install or Connect

POWER DOOR LOCK MOTOR REPLACEMENT 1. Switch.
2. Switch connector.
Remove or Disconnect 3. Retaining nut.
4. Door panel. Refer to SHEET METAL AND
1. Battery ground cable from the battery. FIBERGLASS (SEC. 2C).
2. Door paneling. Refer to SHEET METAL AND 5. Battery ground cable to the battery.
FIBERGLASS (SEC. 2C).
3. Motor. Refer to SHEET METAL AND
POWER WINDOW SYSTEM
DESCRIPTION
Install or Connect
Each power window is moved by a single permanent
magnet motor. The direction the motor turns depends
on the polarity of the supply voltage. The control
switches control the supply voltage polarity.
2. Door Paneling. Refer to SHEET METAL (SEC.
Switches for controlling all the power windows are
2C).
located at the drivers door. Each passengers window
3. Battery ground cable to the battery.
switch controls only the window at that passengers
position.
SWITCH REPLACEMENT
The motors have a self resetting circuit breaker built
in. The circuit breaker allows the motor to be stalled
|+~| Remove or Disconnect
without damage. There are no travel-limit switches.
When a window switch is moved to UP, current
1. Battery ground cable from the battery.
flows through the circuit breaker, the window switch,
the DK BLU wire, the motor, the circuit breaker, the
BRN wire, the DN contacts in the switch, and into
3. Switch connector. The connector is secured with
the BLK wire which goes to ground.
a retaining nut.
4. Switch. Press in both retaining tabs at the same
time.
DIAGNOSIS OF POWER WINDOW SYSTEM

Passenger Window 1. No power at the passenger switch. 1. Ignition switch at RUN or ACC.
Will Not Work, Using Check for voltage at the PNK wire on
Either Passenger the passenger switch. If there is no
Switch Or Driver voltage, find the open between the
Switch switch and the fuse block.
2. Passenger switch is not working. 2. With the voltage on the PNK wire at
the switch, move the switch to UP.
There should be voltage on the DK
BLU wire at the switch. If there is no
voltage on the DK BLU wire, replace
the switch.
DIAGNOSIS OF POWER WINDOW SYSTEM (CONT.)

Passenger Window 3. Motor has an internal open. 3. With the window switch moved to the
Will Not Work, Using UP position, check for voltage on
Either Passenger the DK BLU wire at the motor. If there
Switch Or Driver is no voltage, find the open between
Switch (Continued) the switch and the motor. If there is
voltage on the DK BLU wire, back-
probe a jumper ground at the BRN
wire at the motor. If the motor does
not run, replace the motor. If the
motor does run, find the open in the
ground circuit. Note: The ground cir
cuit does run back through the pas
senger window DN contacts and
the driver window switch DN con
tacts before reaching ground.
Passenger Window 1. No power at the passenger switch. 1. Check for voltage on the PNK wire at
Will Not Work Using the passenger switch. If voltage is not
The Passenger present, find the open in the circuit
Switch. The Window between the switch and the 1.P har
Will Work Using the ness connector.
Driver Switch 2. Switch has internal open. 2. If voltage is present, replace the
switch.
Passenger Window 1. No power. 1. Check driver window action. If the dri

Wont Work Using ver window works, power is at the
The Driver Switch switch.
2. Open in driver switch. 2. With the driver switch moved to
UP, check for voltage on the DK
BLU wire at the driver switch. If volt
age is not present, replace the
switch.
3. Open in harness. 3. With voltage present on the DK BLU
wire at the driver switch, find the
open between the driver switch and
the passenger switch.
Driver Window Wont 1. Switch wont work. 1. Switch moved to UP. Check for
Work. Passenger voltage at the DK BLU wire at the
Window Works. switch. If voltage is not present, re
place the switch.
2. Motor has internal open. 2. Switch moved to UP. Check for
voltage on the DK BLU wire at the
motor. If voltage is present, back-
probe a jumper ground at the BRN
wire at the motor. If the motor wont
run, replace the motor.
3. Motor ground circuit is open. 3. Backprobe a jumper ground at the
BRN wire at the motor. Move the dri
ver switch to UP. If the motor runs,
find the open in the ground circuit.
SWITCH REPLACEMENT
ON-VEHICLE SERVICE
POWER WINDOW MOTOR REPLACEMENT
++ Remove or Disconnect
3. Switch connector. The connector is secured with
2. Door paneling. Refer to SHEET METAL AND
a retaining nut.
4. Switch. Press in both retaining tabs at the same
time.
Install or Connect
1. Motor. Refer to SHEET METAL AND Switch.

Switch connector.
2. Door paneling. Refer to SHEET METAL (SEC. Retaining nut.
Door panel. Refer to SHEET METAL AND
2C).
3. Battery ground cable to the battery. FIBERGLASS (SEC. 2C).
Battery ground cable to the battery.
WINDSHIELD WIPER-CK AND G MODELS
DESCRIPTION their park position, the cam on the gear opens the
normally closed park switch, which turns off the wiper.
A permanent magnet type wiper is used on CK and Refer to Figures 29 and 30.
G Series. The motor parts-field magnets, armature,
drive gear etc. are enclosed in a two piece sheet metal
housing. For purposes of explanation the housing ON-VEHICLE SERVICE
halves are referred to as upper and lower housings.
WIPER MOTOR REPLACEMENT
The two housings are attached to each other by ten
extrusions which are staked over.
C-K Truck
The wiper motor is protected by an automatic reset
type circuit breaker located on the motor brush holder Remove or Disconnect (Figure 36)
assembly. A fuse located in the fuse block protects the
vehicle wiring. Wiper motor is in the Park position.
The wiper motor can be operated only when the 1. Ground cable from the battery.
ignition switch is in the run or accessory position. 2. Electrical harness (38) from the wiper motor.
The wiper motor has three brushes; the common, 3. Drive rod (34) from the wiper motor crank arm
the low speed, and the high speed. When the ignition (36).
switch is ON, power is applied to the common brush. Reach down through the access hole (32) in
The low speed and high speed brushes are connected the plenum and loosen the wiper drive rod
to their respective ground via the control switch. When attaching nuts (33) before removing the
the control switch is positioned at HI or LO speed, drive rod (34).
a ground path is connected to the high or low speed 4. Wiper motor to dash panel attaching screws (40).
brush in the motor. The motor runs at the switch 5. Wiper motor.
selected speed.
- 4- Install or Connect (Figure 36)
In order to have the wiper blades stop in their normal
park position and the wiper motor shut off properly, the
motor must run in LO speed. When the control switch 1. Wiper motor.
is moved to the OFF position, the low speed brush 2. Wiper motor to dash panel attaching screws (40).
circuit goes through a park switch located in the gear 3. Drive rod (34) the wiper motor crank arm (36).
housing and then to ground at the control switch. The Lubricate wiper motor crank arm pivot ball
park switch is normally closed and this allows the (35) prior to installing the drive rod (34).
wiper to keep running. When the wiper blades reach 4. Electrical harness (38) to the wiper motor.
rm
18. Terminal No. 2
1. Gear Cam 6. BLK 12. HIGH Position 19. Terminal No. 1
2. Park Switch 7. LT BLU 13. Power 20 . Circuit Breaker
(Normally Closed) 8. BLK 14. Ignition Switch 21. Common Brush
3. Terminal No. 5 9. Movable Contact 15. Fuse 22 . High Speed Brush
4. Terminal No. 4 10. OFF Position 16. BLK w/dbl YEL Tracer 23. Low Speed Brush
5. BLK w/dbl LT BLU Tracer 11. LOW Position 17. Terminal No. 3 F-00668
Figure 29CKG Windshield Wiper Diagram
5. Ground cable to the battery. 9. Three screws (30) securing the wiper motor to the
cowl.
G Van 10. Wiper motor.
Remove or Disconnect (Figure 37) Install or Connect (Figure 37)
Wiper motor must be in Park position. 1. Wiper motor.

Ground cable from the battery. 2. Three screws (30) securing the wiper motor to the
Wiper arms. cowl.
Cowl panel cover. 3. Heater duct in and up.
Drive arm (34) to the wiper motor crank arm (36). 4. Screw securing the left hand heater duct to the
Loosen nuts (33) holding the drive bar (34) to the engine cover shroud.
wiper motor crank arm (36) removing the drive 5. Left dash defroster outlet to the flex hose.
bar (34). 6 . Electrical harness (38) to the wiper motor.
Electrical harness (38) from the wiper motor. 7. Drive bar (34) to the wiper motor crank arm (36).
Left dash defroster outlet from the flex hose. Lubricate the wiper motor crank arm pivot ball
Screw securing the left hand heater duct to the (35).
engine cover shroud. 8 Cowl panel cover.
Heater duct down and out. 9. Wiper arms.
10. Ground cable to the battery.
12V(
17
3. Ground Park
4. JumperPark
17. GroundHigh Speed
18. GroundLow Speed
19. Power Motor
F. High Speed Operation
G. Low Speed Operation
H. Park Operation
F-00792
Figure 30Diagnosis Connections

DIAGNOSIS CHART
S Y M P TO M PRO CED URE

NO.
1) W IP E R IN O P E R A T IV E BOTH LO W A N D HIGH SPEED 1
2) LO W SPEED O N L Y -IN O P E R A T IV E IN HIGH SPEED 2
3) HIGH SPEED O N L Y -IN O P E R A T IV E IN LO W SPEED 3
4) ONE S P E E D -S A M E IN BOTH LO W A N D HIGH SPEED 4
5) B LA D E S STO P A T R A N D O M P O SITIO N S W H E N W IP E R IS TU R N E D OFF. (DO NOT 5

R ETU R N TO P AR K P O S ITIO N .)
6) W IP E R W IL L NOT S H U T OFF 6
7) IN T E R M IT T E N T O PER ATIO N 7
8) W IP E R M O TO R R UN S BUT B LA D E S D O N T MOVE 8
PROCEDURE 1 (WIPER INOPERATIVE)
GO TO STEP 5 GO TO STEP 2
STEP 2 CHECK FUSE
FUSE BLOWN ..... _...... _ ..___ ............. . J FUSE OK |
GO TO STEP 3 LOCATE AND REPAIR OPEN

IN WIRE FROM FUSE BLOCK
TO WIPER.
F-00715
Figure 31Windshield Wiper Diagnosis

PROCEDURE 1 (CONT.)
GO TO STEP 4 REPLACE FUSE AND

RECHECK SYSTEM
LOCATE AND REPAIR PROBLEM IS IN THE

SHORTED OR GROUNDED MOTOR. REFER TO
CONDITION IN WIRING. WIPER REPAIR".
PROBLEM IS IN THE
CHECK THE WIPER SWITCH
MOTOR. REFER TO WIPER
GROUND WIRE
REPAIR .
CONNECTION. IF OK,
REPLACE THE WIPER SWITCH.
PROCEDURE 2 (LO SPEED ONLY) (INOP IN HI)
PROBLEM IS AN REPAIR THE WIPER

OPEN WIRE FROM MOTOR. (LOOK FOR A
TERMINAL NO. 17 HIGH SPEED HUNG
TO THE DASH BRUSH.)
SWITCH.
F-00742

PROCEDURE 3 ( HI SPEED ONLY) (INOP IN LO)
PROBLEM IS ON OPEN REPAIR THE WIPER MOTOR

WIRE FROM WIPER (LOOK FOR LO SPEED
TERMINAL NO. 2 TO THE HUNG BRUSH).
WIPER SWITCH.
PROCEDURE 4 (ONE SPEED-SAME IN BOTH LO AND HI).
PROBLEM IS IN THE WIRING REPAIR THE WIPER MOTOR.

BETWEEN THE WIPER SWITCH AND CHECK FOR LO AND HI SPEED
WIPER OR A FAULTY WIPER BRUSH LEADS SHORTING
SWITCH. TOGETHER INTERNALLY.
PROCEDURE 5 (WIPER SHUTS OFF BUT BLADES DONT RETURN TO PARK POSITION)
WIRE FROM THE WIPER

REPLACE THE WIPER PARK
TERMINAL NO. 3 TO THE
SWITCH ASSY.
WIPER SWITCH IS OPEN OR
THE SWITCH IS FAULTY.
F-00743

PROCEDURE 6 (WIPER WILL NOT SHUT OFF)
REPAIR THE WIPER MOTOR GO TO STEP 2

(REPLACE THE PARK SWITCH
ASSY.)
LOCATE AND REPAIR THE REPAIR THE WIPER MOTOR

GROUND CONDITION IN THE (LOOK FOR INTERNAL GRD.
WIRES FROM THE WIPER CONDITION IN LO OR
TERMINALS 18 OR 17 TO H I BRUSHES)
THE WIPER SWITCH.
PROCEDURE 7 (INTERMITTENT OPERATION)

(WIPER HAS BOTH SPEEDS)
A WEAK CIRCUIT BREAKER GO TO STEP 2

IS INDICATED. REPLACE
MOTOR END CAP ASSY.
REPLACE BLADE ELEMENTS GO TO STEP 3
CHECK WIPER LINKAGE FOR PROBLEM IS IN THE WIPER

A BINDING CONDITION AND MOTOR. CHECK FOR
REPAIR OR REPLACE AS ARMATURE END PLAY,
REQD. SHORTED OR GROUNDED
ARMATURE.
F -0 0 7 4 4

PROCEDURE 8 (WIPER RUNS BUT BLADES DONT MOVE)
STEP 1 CHECK THE WIPER LINKAGE CONNECTION TO THE WIPER CRANK ARM
LINKAGE
LINKAGE CONNECTED
DISCONNECTED
WIPER GEAR IS STRIPPED. CHECK THE LINKAGE AND
REPLACE THE WIPER MOTOR. CHECK THE SYSTEM.
F-00745
Figure 36Windshield Wiper Motor Mounting-CK

8A-36 CA B ELECTRICAL
F-00747
Figure 37Windshield Wiper Mounting-G Van
WINDSHIELD WASHER CK AND G MODELS
DESCRIPTION turn signal and multi-function lever. Two wires go to the

washer. The white wire is power coming from the fuse
The washer motor is located in the bottom of the box. The same fuse that protects the washer motor
windshield washer fluid reservoir. The washer is also protects the wiper motor. The pink wire is the
controlled by a washer switch, which is located on the ground circuit that goes through the washer switch to
ground. Refer to Figures 38 and 39.
CAB ELECTRICAL 8A-37
53 51
54
54
50. Dash Panel
51. Windshield Washer Motor Connector
51. Windshield Washer Motor Connector 52. Reservoir Retaining Screw
52. Reservoir Retaining Screw 53. Washer Fluid Reservoir
53. Washer Fluid Reservoir 54. Windshield Washer Motor
54. Windshield Washer Motor F-00748 F-00749
Figure 38CK Windshield Washer Figure 39G Van Windshield Washer
WINDSHIELD WASHER DIAGNOSIS

Washer Fluid Does 1. No fluid. 1. Check the fluid reservoir. Refill, if

Not Spray On The necessary.
Windshield 2. Clogged jets. 2. Using a fine pin, carefully clear the
jets.
3. Clogged filter in the reservoir. 3. Remove the filter and back flush it.
Also clean the reservoir.
4. Washer motor is not running. 4. Check for power on the WHT wire at
the motor. If there is no power, and
the wipers work, find the open in the
power circuit. If there is power, check
the PNK wire at the washer motor for
ground. If the ground circuit is good,
replace the washer motor.
ON-VEHICLE SERVICE 4. Reservoir.

5. Two reservoir retaining screws.
WASHER MOTOR REPLACEMENT 6. Battery ground cable to the battery.
CK Truck G Van
Remove or Disconnect Remove or Disconnect (Figure 39)

2. Two reservoir retaining screws. 2 . Electrical connector at the motor.
3. Reservoir. 3. Fluid tubes from the motor.
4. Electrical connector at the motor. 4. Motor from the bracket.
5. Fluid tube at the motor.
6. Motor from the reservoir.
+ 4- Install or Connect (Figure 38) Motor onto the bracket.

Fluid tubes to the motor.
Motor to the reservoir. Electrical connector to the motor.
Fluid tube at the motor. Battery ground cable to the battery.
Electrical connector at the motor.
WIPER MOTOR UNIT REPAIR
2. Cover.
END CAP-BRUSH HOLDER,

ARMATURE ASSEMBLY
1. Retainer tabs.
2. End cap assembly.
Rotate crank arm clockwise.
3. Armature.
60. Connector
61. Tang
62. Cam Follower ++ Install or Connect (Figure 41 and 42)
63. Points F-00753 1. Armature in the end cap assembly.
Release the brush spring tension (65).
Figure 40Park Switch
Slide the brushes back in the brush holders.
REPLACEMENT OF COMPONENTS Put the armature in the end cap assembly.

Reposition the brush spring legs behind
PARK SWITCH their respective notches (66).
Tie the armature to the end cap assembly
Remove or Disconnect (Figure 40) with small wire.
1. Cover 2. Armature in the wiper housing.
2. Park switch. 3. End cap into the slot area of the wiper housing.
Depress tang (61). Remove the wire.
4- Install or Connect (Figure 40) 4. End cap assembly into the housing until it
bottoms.
1. Park switch. 5. Retainer tabs.
65. Brush Spring Leg Released

from Retainer Notch
66. Rotate Brush Spring in Direction of Arrow
to Reposition it Behind Retainer Notch
67. Retainer Notch
F-00754
Figure 41Brush Spring Release Position Figure 43Crank Arm, Spacer, and Seal
CRANK ARM, SPACER, SEAL Install or Connect (Figure 43, 44 and 45)
-- Remove or Disconnect (Figure 43) 1. Spacer (73).

2. Shaftseal (72).
1. Crank arm retaining nut (71). 3. Crank arm (70).
Have the crank arm clamped in a vise. Be sure the wiper motor is in Park.
2. Crank arm (70). Install the crank arm according to figure 44
3. Shaft seal (72). or 45, depending on the vehicle model.
4. Spacer (73). 4. Crank arm retaining nut (71).
Figure 42End Cap Assembly Figure 44Crank Arm PositionCK Models

81. Identification Code

82. Crank Arm Park Position
G Van Models F-00759
Figure 45Crank Arm PositionG Van Model
WINDSHIELD WIPER DELAY CIRCUIT
DESCRIPTION Install or Connect
The wiper pulse control circuit is an option on CK 1. Module (91).

and G models. This option allows the wiper to operate 2. Harness connectors.
at a slower rate than the low speed setting on the
standard control. REPLACEMENT OF THE SWITCH.
The optional module is inserted into the harness Refer to STEERING COLUMN (SEC. 3B5).
under the steering column. Refer to figure 46.
ON-VEHICLE SERVICE
REPLACEMENT OF THE MODULE
|<--| Remove or Disconnect (Figure 46)
1. Harness connectors.
2. Module (91) by sliding it off the bracket.
CA B ELECTRICAL 8A-41
90. Steering Column

91. Windshield Wiper Delay Module
92. Instrument Panel Harness F-00818
Figure 46Windshield Wiper Pulse Module

DIAGNOSIS OF THE WIPER DELAY CIRCUIT
F-00819
Figure 47Diagnosis Of The Wiper Delay Module

WINDSHIELD WIPER AND WASHER P MODELS
J L -V
18 17 16 15
1. Motor 9. Moving Contact 17. LOW Position
2. Shunt Resistor 10. Rachet 18. HIGH Position
3. Series Resistor 11. Washer 19. Power
4. GRA Wire 12. Terminal #1 20. RED Wire
5. Terminal No. 3 13. Terminal #2 21. PARK Switch
6. Terminal No. 1 14. Solenoid 22. Resistor
7. Terminal No. 2 15. Pawl 23. Armature
8. Instrument Panel Switch 16. OFF Position 24. Brush F-00814
Figure 48P-Model Wiper Diagram
DESCRIPTION and 3. The shunt field current then flows via terminal
No. 3 through the resistor to terminal No. 1 to the
The system consists of a compound wound switch, to ground.
rectangular-shaped motor attached to a gear box The parking circuit covers that portion of wiper
containing a parking switch in addition to the gear operation when the wiper switch is turned off and
train. The gear train consists of a motor armature the wiper blades have not reached the park position.
helical gearshaft which drives an intermediate gear When the wiper blades are not in the normal park
and pinion assembly. The pinion gear of the position, the parking switch contacts are still closed.
intermediate gear and pinion drives an output gear and The wiper will continue to operate until the wiper
shaft assembly. output gear is turned to a position where its cam opens
the park switch. The wiper motor circuits are
Turning the wiper switch to the LO speed position
completed to ground through the parking switch.
completes the circuits from the wiper terminals 1 and 3
to ground (Figure 48). Current then flows from the The wiper motor must be securely grounded to body
battery via wiper terminal No. 2 through the series field metal.
and divides; (1) part passes through the armature to The shunt field circuit is completed from terminal No.
ground via wiper terminal No. 1 to the wiper switch and 3 via the switch to terminal No. 1 through the parking
(2) the second part passes through the shunt field to switch to ground. The series field and armature circuit
ground through wiper terminal No. 3 to the wiper is also completed from terminal No. 1 through the
switch. The wiper switch must be securely grounded to parking switch to ground.
body metal. The shunt field is connected direct to ground,
Moving the wiper switch to the HI speed position by-passing the resistor. This results in LO speed
opens the shunt field circuit to ground at the switch. operation during the parking operation.
However, the shunt field is connected to a 20 ohm When the output gear cam opens the park switch
resistor which is connected across wiper terminals 1 contacts, the wiper is OFF.
30. Terminal No. 2 30. Terminal No. 2

33. Ammeter; 0-30 Ampere Range 33. Ammeter; 0-30 Ampere Range
34. Gear Shaft In The Park Position 34. Gear Shaft In The Park Position
35. Wiper Ground Strap 35. Wiper Ground Strap
F-00808 F-00809
Figure 49Wiper Motor Jumper Connections Figure 50Wiper Motor Jumper Connections
Low Speed High Speed
6. If wiper fails to operate correctly independently of

DIAGNOSIS linkage, remove wiper motor from vehicle and
refer to DIAGNOSIS CHARTWIPER OFF
WIPER SYSTEM CHECKS
VEHICLE.
1. Inspect for the following items:
a. Wiring harness is securely connected to
wiper and switch.
b. Wiper motor is securely grounded to body.
c. Wiper switch is securely mounted and
grounded.
d. Check fuse.
2. If items in Step 1 check out, try operating wiper in
both LO and HI speeds, then turn wiper off
(blades should return to park position). If wiper
fails to operate correctly, proceed to Step 3.
3. Disconnect wiring harness from wiper and try
operating wiper as shown in Figures 49, 50, and
51.
4. If wiper operates correctly independently of
switch and vehicle wiring, refer to DIAGNOSIS
CHARTWIPER ON VEHICLE.
5. If wiper still fails to operate correctly in Step 3,
disconnect wiper linkage from motor crank arm
and try operating wiper again. If wiper operates
correctly independently of linkage, check linkage
for cause of wiper malfunction.
30. Terminal No. 2

31. Terminal No. 1
32. Terminal No. 3
33. Ammeter; 0-30 Ampere Range
34. Gear Shaft In The Park Position
35. Wiper Ground Strap F-00810
Figure 51Wiper Motor Jumper ConnectionsOff
DIAGNOSIS OF THE WIPERON VEHICLE

Wiper Not Working 1. Blown fuse 1. Locate short circuit and repair. Re
Or Intermittent place fuse.
2. Open circuit in feed wire (No. 2 termi 2. Locate broken wire and repair.
nal on wiper motor)
3. Loose mounting of wiper switch. 3. Tighten switch mounting.
4. Faulty wiper switch. 4. Replace switch.
5. Open circuit in wire to wiper switch 5. Locate broken wire and repair.
(No. 1 terminal on wiper motor)
Wiper Will Not Shut 1. Grounded wire (No. 1 terminal on 1. Locate short circuit and repair.
Off. Wiper has Both wiper motor) to wiper switch.
Lo And Hi
Speeds
Wiper Will Not Shut 1. Defective wiper switch. 1. Replace wiper switch.
Off. Wiper Has Lo 2. Grounded wire (No. 3 terminal on 2. Locate and repair short circuit.
Speed Only. wiper motor) to wiper switch.
8A -46 CA B ELECTRICAL
DIAGNOSIS OF THE WIPERON VEHICLE (CONT.)

Wiper Will Not Shut 1. Defective wiper switch. 1. Replace wiper switch.
Off. Wiper has Hi 2. Open circuit in wire (No. 3 terminal on 2. Locate and repair broken wire.
Speed Only wiper motor) to wiper switch.
Wiper Has Hi Open circuit in wire (No. 3 terminal on Locate broken wire and repair.
Wiper Has Lo 1. Grounded wire (No. 3 terminal on 1. Locate short circuit and repair.
2. Defective wiper switch. 2. Replace wiper switch.
Blades Do Not Loose wiper ground strap connection. Tighten strap connection.
Return To Full Park
Position
DIAGNOSIS OF THE WIPEROFF VEHICLE

Wiper Not Working 1. Broken or damaged gear train (only if 1. Replace gears as required.
or Intermittent not working).
2. Poor solder connections at terminal 2. Resolder wires at terminals.
board.
3. Loose splice joints at brush plate. 3. Recrimp or solder splice joints.
4. Brushes binding in brush holder. 4. Clean holder or replace brush, spring
or brush plate assembly.
5. Open circuit in armature. 5. Replace armature.
Wiper Will Not 1. Faulty part switch. 1. Replace terminal board assembly.
Shut-Off. Wiper Has 2. Grounded red lead wire. 2. Repair short circuit in red wire.
Normal Hi and
Lo Speed
Wiper Will Not Shut 1. Grounded shunt field coil. 1. Replace frame and field assembly.
Off. Wiper Has Lo 2. Grounded black wire. 2. Repair short circuit in black wire.
Speed Only
Wiper Will Not Shut 1. Open circuit in shunt field coil. 1. Replace frame and field assembly.
Off. Wiper Has Hi 2. Open circuit in black wire. 2. Repair broken wire or poor solder
Speed Only connection.
Wiper Shuts OffBut Park switch faulty or contacts dirty. Replace terminal board assembly or
Not In Park Position clean contacts.
Hi Speed Too Resistor faulty. Replace terminal board assembly.

Fast
CA B ELECTRICAL 8A -47
DIAGNOSIS OF THE WASHER SYSTEM

Washers Inoperative 1 Inadequate quantity of washer solu 1. Add washer solution.

tion.
2. Hoses damaged or loose. 2. Cut short length off end of hose to
insure air tight connection or replace
hose.
3. Plugged screen at end of jar cover 3. Clean screen.
hose.
4. Loose electrical connection to washer 4. Check electrical connections and re
pump or wiper switch. pair if necessary.
5. Open circuit in feed wire to ratchet re 5. Locate open circuit and repair.
lay coil.
6. Wiper switch faulty. 6. Replace wiper switch.
7. Ratchet relay coil defective. 7. Replace ratchet relay.
8. Washer nozzles plugged. 8. Clean washer nozzles.
9. Ratchet wheel tooth missing. 9. Replace ratchet wheel.
10. Ratchet pawl spring missing. 10. Replace ratchet pawl spring.
11. Faulty pump valve assembly. 11. Replace pump valve assembly.
Washer Pumps 1. Grounded wire from ratchet relay to 1. Locate grounded wire and repair.
Continuously When switch. 2. Replace wiper switch.
Wipers Are 2. Wiper switch faulty. 3. Replace ratchet wheel.
Operating 3. Ratchet wheel tooth missing.
4. Ratchet wheel dog broken or not con 4. Replace of repair ratchet wheel dog.
tacting ratchet wheel teeth.
5. Lock-out tang broken or bent on piston 5. Replace piston actuating plate.
actuating plate.
ON-VEHICLE SERVICE
WIPER MOTOR
Wiper motor replacement procedures are not
included here since installation is performed by the
individual body manufacturers; however, disassembly
of the unit will be covered in Unit Repair.
UNIT REPAIR
6. Seal cap (56).

7. Retaining ring (55).
8. Spacer (54).
9. Gear box cover retaining rivets.
Drill out the rivets.
10. Gear box cover (53).
11. Output gear and shaft assembly (52).
12. Intermediate gear and pinion assembly off the
shaft (51).
13. Terminal board and park switch assembly, if
necessary.
U nsolder the motor leads from the
terminals.
Label the motor leads.
Drill out the rivets securing the terminal
board and the park switch ground strap to
the mounting plate.
14. Motor through bolts (42).
15. Motor from the mounting plate.
Tap motor frame lightly.
WIPER MOTOR DISASSEMBLY 16. Brush spring tension (61).
17. Armature (46) and end plate (43) from the motor
GEAR BOX AND MOTOR frame (44).
18. End plate (43) from the armature (46).
Remove or Disconnect (Figure 52, 53, and 54) There is a thrust plug (45) between the
armature shaft and the end plate.
1. Two washer pump mounting screws (72). 19. End play adjusting washers (47 and 41) from
2. Pump (71) from the gear box cover. the armature.
3. Washer pump drive cam (75). Note the washers positions.
Wedge off the cam and the plate using two
screwdrivers.
4. Crank arm retaining nut (58). INSPECTION
Clamp the crank arm (57) in a vise before
removing the nut (58). Inspect all the parts for wear or damage. All the parts
5. Crank arm (57). can be replaced individually except the motor frame
and field, which is serviced as an assembly. Service
kits provide screws, nuts and washers to replace the
gear cover and terminal board rivets.
WIPER MOTOR ASSEMBLY

GEAR BOX AND MOTOR
Install or Connect (Figure 52, 53, 54, and 55)
1. End play adjusting washers (41 and 47) on the

armature (46).
2. End plate (43) on the armature (46).
Make sure the thrust plug (45) is between
the armature shaft and the endplate.
Lubricate the bearing with light machine oil.
3. Armature and the end plate assembly on the
motor frame (44).
4. Brush spring tension (60).
40. Brushes 47. Flat Washers

41. Wave Washers 48. Brush Plate Assembly And Mounting Brackets
42. Motor Through Bolt 49. Gear Box Housing
43. End Plate 50. Wave Washer
44. Frame And Field 51. Intermediate Gear
45. Thrust Plug
46. Armature
47. Flat Washers
Output Gear And Shaft Assembly 57. Crank Arm

Gear Box Cover 58. Nut
Spacer 59. Brush Holder
Retaining Ring 60. Slot
Seal Cap 61. Groove For Brush Spring
F-00811
Figure 54Wiper Motor And Gear Box Assembly
5. Motor to the mounting plate (49).

6. Motor through bolts (42).
7. Terminal board and park switch assembly, if
removed.
Secure the terminal board and park switch
with the screws, washers and nuts supplied
in the rebuild kits.
Solder the motor leads to the terminals.
8 . Intermediate gear and pinion assembly on the
shaft (51).
Lubricate the gear teeth with Delco Cam
and Ball Bearing Grease (or equivalent).
9. Output gear and shaft assembly (52).
10. Gear box cover (53).
11. Gear box cover screw, washers, and nuts.
12. Spacer (54).
13. Retaining ring (55).
14. Seal cap (56).
15. Crank arm (57).
Place the wiper in the park position.
Install the crank arm on the output shaft.
57. Crank Arm Rotate the crank so that the alignment
80. Gear Case Alignment Marks marks line up with those on the cover (80
81. Crank Arm Alignment Marks and 81).
16. Crank arm retaining nut (58).
F-00834 Clamp the crank arm in a vise before
tightening the retaining nut.
Figure 55Crank Arm Park Alignment 17. Washer pump drive cam (75).
Press the cam on the shaft.
8A-50 CA B ELECTRICAL
85. Valve Assembly Mounting Screw 93. Rachet Pawl Spring

86. Valve Assembly 94. Cam Follower Upper Pin
87. Pump 95. E Ring
88. Rachet Dog 96. Cam Follower
89. Rachet Dog Retaining Screw 97. Frame
90. Solenoid Coil 98. Rachet Pawl
91. Solenoid Plunger 99. Rachet Wheel Spring
92. Rachet Wheel 100. Retaining Groove
F-00835
Figure 56Washer Pump Assembly
18. Pump on the gear box cover. 6. Ratchet pawl (98) from the cam follower Upper
19. Two pump mounting screws (72). Pin.
7. Ratchet wheel spring (99) out of the shaft groove.

WINDSHIELD WASHER
DISASSEMBLY 8. Ratchet wheel (92) from the shaft.
9. Pump and actuator plate assembly.

i Remove or Disconnect (Figure 56)
B Pull the pump housing away from the drive
1. Washer pump cover cam until the housing grooves (100) clear
the frame.
2. Ratchet dog retaining screw (89).
3. Solenoid assembly (90) and ratchet dog (88) off Lift the cam follower (96) from the ratchet
the pump frame (97). wheel and cam follower shafts.
Hold the spring loaded solenoid plunger (91)
in position while liftin g the solenoid 10. Four valve assembly screws (85).
assembly.
4. Ratchet pawl spring (93). 11. Valve assembly (86) from the pump housing.
5. Ratchet pawl retaining ring (94).
WINDSHIELD WASHER ASSEMBLY 3. Pump (87) and cam follower (96) assembly to the
frame (97).
4. Ratchet wheel (92) to the shaft.
5. Ratchet wheel spring (99) into the shaft groove.
6. Ratchet pawl (98) onto the cam follower upper pin
1. Valve assembly (86). To the pump housing (87). (94).
Be sure that the seal between the pump 7. Ratchet pawl retaining E ring (95).
housing and the valve plate is properly 8. Ratchet pawl spring (93).
positioned in the pump housing and valve 9. Solenoid assembly (90) and ratchet dog (88) on
plate grooves. the pump frame (97).
Be sure that the triple seal is properly Hold the spring loaded solenoid plunger (91)
installed between the valve body and the in position while installing the solenoid
pipe assembly. assembly.
2. Four valve assembly screws (85). 10. Ratchet dog retaining screw (89).
11. Washer pump cover.
HEATER SYSTEM CIRCUITS
DESCRIPTION From the resistor block, the harness then goes to the
blower motor. The wire colors can be found in the
The heater blower motor is controlled by the blower wiring diagrams which are at the back of this manual.
switch. The blower switch is a four position switch; off,
low, medium, and high. This switch controls the speed
of the blower motor by connecting different resistances
DIAGNOSIS
into the motor circuit, thereby dropping the voltage
For diagnosis of the heater blower circuit, refer to
available to the motor.
HEATER (SEC. 1A).
The blower switch is located on the control
assembly. The harness from the switch goes to the
dash panel connector and into the engine ON-VEHICLE SERVICE
compartment. The harness is then routed to the
resistor block, which is located on the blower housing. For on-vehicle service of the heater blower circuit,
refer to HEATER (SEC. 1A).
AIR CONDITIONING ELECTRICAL SYSTEM
DESCRIPTION DIAGNOSIS
The compressor electro-magnetic clutch is turned on For diagnosis of the A/C electrical system, refer to
and off by the pressure sensing switch. When AIR CONDITIONING (SEC. 1B).
re frig e ra n t pressure drops below a certain
predetermined level, the switch opens the compressor
clutch circuit, which causes the refrigeration system to ON-VEHICLE SERVICE
stop working. The pressure sensing switch is located
near the top of the accumulator. For on-vehicle service of the air conditioning, refer to
AIR CONDITIONING (SEC. 1B).
SPECIAL TOOLS
CHASSIS ELECTRICAL 8B-1
SECTION 8B
CHASSIS ELECTRICAL
CONTENTS
SUBJECT PAGE
Front Lighting System ....................................................................................................................................... 8B- 1

Headlamp System........................................................................................................................................... 8B- 1
Diagnosis Of Headlamp..................................................................................................................................... 8B- 6
On-Vehicle Service......................................................................................................................................... 8B- 7
Front Parking Lamps S y s te m ...................................................................................................................... 8B- 7
Diagnosis Of The Front Parking Lamps.......................................................................................................... 8B- 9
On-Vehicle Service......................................................................................................................................... 8B- 9
Front Side Marker Lamp System.................................................................................................................. 8B-10
Diagnosis Of The Front Side Marker Lam ps.................................................................................................. 8B-11
On-Vehicle Service......................................................................................................................................... 8B-11
Rear Lighting S y s te m s ..................................................................................................................................... 8B-12
Rear Running Lamps And Marker L a m p s .................................................................................................. 8B-12
Rear Park L a m p s ........................................................................................................................................... 8B-12
Rear Turn, Stop And Hazard System s........................................................................................................ 8B-12
Back-Up Lamp System...................................................................................................................................8B-12
Rear Lamp Harness Layouts.........................................................................................................................8B-13
Diagnosis Of The Rear Side Marker Lamps.................................................................................................... 8B-18
Diagnosis Of The Running, Park And License Lam ps..................................................................................8B-19
Diagnosis Of The Turn Signal And Hazard S ystem s....................................................................................8B-20
Diagnosis Of The Stoplamp S y s te m .............................................................................................................. 8B-21
Diagnosis Of The Back Up Lamp S ystem ...................................................................................................... 8B-22
On-Vehicle Service......................................................................................................................................... 8B-23
Fuses, Circuit Breakers S pecifications.......................................................................................................... 8B-30
Lamp S p e cifica tio n s......................................................................................................................................... 8B-32
FRONT LIGHTING SYSTEMS
The front lighting system includes the headlamps, HEADLAMP SYSTEM

the front parking lamps, and the front side marker
lamps. The circuit starts at the fuse block and goes to The headlamp system has two options. One option is
the light switch in the instrument panel. From the light two headlamps, each headlamp having a parking lamp
switch the circuit goes to the dash panel connector and located under it. The other option is four headlamps,
then to the front lamps. with the parking lamps located in the grill. On the four
headlamp option, when the low bea n circuit is
energized, only the upper headlamps will be on. When
the high beam circuit is energized, only the lower
headlamps will be on. Refer to figures 1, 2, 3, and 4.
8 B -2 CHASSIS ELECTRICAL
Figure 1Headlamp HarnessTwo Headlamp OptionCK

Figure 2Headlamp HarnessFour Headlamp OptionCK

8 B -4 CHASSIS ELECTRICAL
11. Parking Lamp Assembly

40. Front Marker Lamp
41. Headlamp
42. Ground
43. Two Headlamp Harness
45. Dash Panel Connector
46. Four Headlamp Harness
47. Lower Headlamp
F-00862
Figure 3Front Lighting HarnessG Van

CHASSIS ELEC TRIC AL 8B -5
10. Retained Nut

11. Parking Lamp F-00750
Figure 4Two Unit Headlamp AssemblyCKG

8B -6 CH ASSIS ELECTRICAL
DIAGNOSIS OF HEADLAMP
One Headlamp 1. Loose connection. 1. Secure the connections to the

Inoperative Or headlamp including the ground
Intermittent. (black wire).
2. Defective sealed beam unit. 2. Replace the headlamp.
One Or More 1. Open ground connection at the 1. Repair the black wire connection be
Headlamps Are Dim. headlamp. tween headlam p and the body
ground.
2. Black ground wire mislocated in the 2. Relocate the black wire in the con
headlamp connector (three-wire, hi-lo, nector.
connector only).
One Or More Charge circuit problem. Refer to ENGINE ELECTRICAL

Headlamps Short (SEC. 6D), charging system diagno
Life. sis.
All Headlamps 1. Loosen connection. 1. Check and secure the connections at

Inoperative Or the dimmer switch and the lamp
Intermittent. switch.
2. Defective dimmer switch. 2. Check the voltage at the dimmer
switch with a test lamp. Refer to CAB
ELECTRICAL (SEC. 8A) for the test
points.
3. Open wiringlamp switch to the dim 3. Check the yellow wire with a test
mer switch. lamp. If the bulb lights at the lamp
switch yellow wire terminal but not at
the dimmer switch, repair the open
wire.
4. Open wiringlamp switch to the bat 4. Check the red wire terminal at the
tery. lamp switch with a test lamp. If the
bulb does not light, repair the open
red wire circuit to the battery (possi
ble open fusible link).
5. Shorted ground circuit. 5. If, after a few minutes operation, the
headlamps flicker ON and OFF
and/or a thumping noise can be
heard from the lamp switch (circuit
breaker opening and closing), repair
the short to ground in the circuit be
tween the lamp switch and the
headlamps. After repairing the short,
check for headlamp flickering after
i
one minute operation. If flickering oc
curs, the circuit breaker has been
damaged and the lamp switch must
be replaced.
6. Defective switch. 6. Check the red and yellow wire termi
nals at the lamp switch with the test
lamp. If the bulb lights at the red wire
terminal but not at the yellow termi
nal, replace the lamp switch.
CHASSIS ELECTRICAL 8B -7
DIAGNOSIS OF HEADLAMP (CONT.)

Upper Or Lower 1. Open connection or defective dimmer 1. Check the dimmer switch terminals
Beam Will Not Light switch. with a test lamp. If the bulb lights at
Or Intermittent. the light green or tan wire terminals,
repair the open wiring between the
dimmer switch and the headlamps. If
the bulb will not light at either of
these terminals, depending upon
switch position, replace the dimmer
switch.
2. Short circuit to ground. 2. Follow the diagnosis above (all
headlamps inoperative or intermit
tent).
ON-VEHICLE SERVICE HEADLAMP ADJUSTMENT (Figure 6)

Horizontal and vertical aiming of each headlamp is
HEADLAMP UNIT REPLACEMENT done by two (2) adjusting screws which move the
mounting ring against the tension of the coil spring.
++ Remove or Disconnect (Figure 4 and 5) Some state and local authorities have specific
requirements for aiming headlamps and these
1. Battery ground cable from the battery. requirements should be followed.
2. Headlamp bezel retaining screws. Replacement of a headlamp will normally not require
3. Bezel. aiming adjustment. However, do check the aim.
4. Retaining ring screws. Be careful not to move the Use the safety aimer J-6878-01 or equivalent.
adjustment screws. Instructions for using the safety aimer are supplied by
5. Retaining ring spring, using a hooked tool. the instrument manufacturer.
6. Retaining ring from the mounting ring.
7. Headlamp unit. DIMMER SWITCH REPLACEMENT
8. Headlamp electrical connector. Refer to STEERING COLUMNS (SEC. 3B5).
Install or Connect (Figure 4 and 5) LAMP SWITCH REPLACEMENT

Refer to Rear Lighting Systems.
1. Headlamp electrical connector.
On the dual headlamp option, the 2A1
headlamp is the upper unit and the 1A1
FRONT PARKING LAMPS SYSTEM
headlamp is the lower unit.
DESCRIPTION
2. Headlamp.
The front parking lamps circuit is in the headlamp
3. Retaining ring.
harness. The circuit starts from the fuse block, goes to
4. Retaining ring screws. Make sure that the
the lamp switch, and then forward to the front parking
headlamp is properly seated.
lamps. The circuit also includes the rear parking
5. Retaining ring spring.
lamps, which are covered later in this section. The
6. Bezel.
parking lamp system is turned on when the lamp
7. Bezel retaining screws.
switch is pulled out to the first detent.
Figure 5Four Unit Headlamp Assembly-
CKG
Figure 6-H eadlam p Aiming Screw

Locations
DIAGNOSIS OF THE FRONT PARKING LAMPS

One Side Not 1. Bulb burnt out. 1. Replace the bulb.

Working. 2. Open connection at the bulb socket or 2. Jumper the bulb base socket connec
the ground wire terminal. tion to ground. If the bulb lights, re
pair the open ground circuit.
Both Sides Not 1. Fuse blown. 1. Replace the fuse. If the new fuse
Working. blows, repair the short to ground in
the brown wire circuit between the
fuse panel through the lamp switch to
the lamps.
2. Loose connection. 2. Secure the connector at the lamp
switch.
3. Open wiring. 3. Using a test lamp, check the circuit
on both sides of the fuse. If the test
bulb does not lamp on either side, re
pair the open circuit between the fuse
panel and the battery (possible open
fusible link). If the test bulb lamps at
the lamp switch brown wire terminal,
lamp switch and the lamps.
4. Multiple bulb burnout. 4. If the test bulb lights at the lamp
socket brown wire terminal, replace
the bulb(s).
5. Defective lamp switch. 5. If the test bulb lamps at the lamp
switch orange wire but not at the
brown wire, replace the defective
lamp switch.
ON-VEHICLE SERVICE Install or Connect (Figures 3 and 4)
REPLACEMENT OF THE LAMP SWITCH 1. Electrical connector to the parking lamp.

Refer to INSTRUMENT PANEL (SEC. 8C). 2. Parking lamp.
3. Three parking lamp retaining screws.
REPLACEMENT OF THE FRONT PARKING LAMP 4. Bezel.
5. Four bezel retaining screws.
CK and G ModelsTwo Headlamp Option
|++| Remove or Disconnect (Figures 3 and 4)
CK and G ModelsFour Headlamp Option
2. Four bezel retaining screws.
, 3. Bezel. 1. Radiator grille (27). Refer to SHEET METAL
(SEC. 2C).
4. Three park lamp retaining screws.
2. Electrical connector from the parking lamp.
5. Parking lamp. 3. Two nuts (26) at the top of the housing (25).
6. Electrical connector from the parking lamp. 4. Housing by lifting it up from the radiator grille.
8B-10 CHASSIS ELECTR ICAL
25. Park Lamp

26. Nut
27. Radiator Grille B-00824
Figure 7Parking Lamp AssemblyCKG Models
|~n~| Install or Connect (Figure 7) FRONT SIDE MARKER LAMP

1. Park lamp housing (25) on the radiator grille (27). SYSTEM
2. Two nuts (26) at the top of the housing (25).
3. Electrical connector into the parking lamp. DESCRIPTION
4. Radiator grille (27). Refer to SHEET METAL The front side marker lamp circuit is included in the
(SEC. 2C). headlamp harness. The circuit starts at the lamp
switch. It goes to the dash panel connector and out to
the front side marker lamps. The circuit also branches
at the lamp switch and goes to the rear side marker
lamps. This part of the circuit is covered later in this
section.
DIAGNOSIS OF THE FRONT SIDE MARKER LAMPS

One Lamp Wont 1. Turn signal bulb burnt out (front lamp). 1. Switch turn signals on. If the signal
Work bulb does not light, replace the bulb.
(Bulb filament provides ground path
for marker lamp bulb through the
dark blue or brown wires.)
2. Side marker bulb burnt out. 2. Replace the bulb.
3. Loose connection or open in wiring. 3. Using a test lamp, check the brown
wire terminal at the bulb socket. If the
test bulb lights, repair the open
ground circuit. If the bulb does not
light, repair the open in the brown
wire circuit.
Front or Rear Lamps 1. Loose connection or open ground cir 1. If the associated tail or park lamps do
Wont Work cuit. not operate, check all the connectors
in the brown wire circuit. If the park
and turn lamps are not working, re
pair the open ground connections.
2. Multiple bulbs burnt out. 2. Replace the burnt out bulbs.
All Lamps Wont 1. Blown fuse. 1. If the park and tail lamps do not oper
Work ate, replace the blown fuse. If the
new fuse blows, check for a short to
ground between the fuse panel and
the lamps.
2. Loose connection. 2. Secure the connector to the lamp
switch.
3. Open in wiring. 3. Check the tail lamp fuse with a test
lamp. If the test bulb lights, repair the
open wiring between the fuse and the
light switch. If not, repair the open
wiring between the fuse and the bat
tery. (Possible open fusible link.)
4. Defective lamp switch. 4. Check the lamp switch with a test
light. If the test bulb lights at the or
ange wire but not at the brown wire,
replace the lamp switch.
ON-VEHICLE SERVICE Install or Connect (Figures 8 and 9)
REPLACEMENT OF THE FRONT SIDE 1. Bulb (33) into the lamp (31).
MARKER LAMP 2. Side marker lamp (31) into the fender (30).
3. Two screws (32).
|++| Remove or Disconnect (Figures 8 and 9)
1. Two screws (32).

2. Side marker lamp (31).
3. Bulb (33) from the lamp (31).
30. Front Fender

31. Side Marker Lamp
32. Screw
34. Nut
F-00871
Figure 8Front Side Marker Lamp Assembly Figure 9Front Side Marker Lamp Assembly
CK Models G Van
REAR LIGHTING SYSTEMS
The rear lighting systems contain the circuits for the REAR TURN, STOP, AND
running, park, turn, stop and license lamps. One bulb
may function for more than one circuit. The harness for HAZARD SYSTEMS
the rear lighting systems starts at the fuse block, goes
to the various switches and then back along the left These three systems use the same bulb in the rear
frame to the various lamps. lamps. When the rear turn system is turned on, a
thermal oscillator is turned on, which causes the
system to flash. The front park lamps are also a part of
REAR RUNNING LAMPS AND the turn system.
MARKER LAMPS The stop lamp system is turned on by a brake switch
closing. The two rear bright lamps are then turned on.
This circuit starts at the lamp switch. The lamps will The hazard system is turned on by the hazard
be on when the lamp switch is in the first and second switch. The hazard system thermal oscillator is then
detents. The front park lamps and front marker lamps turned on which causes the front park lamps and the
will also be on when the lamp switch is in the first rear bright lamps to flash.
detent.
BACKUP LAMP SYSTEM

REAR PARK LAMPS
This circuit is turned on when the transmission is
These lamps will be on when the lamp switch is in shifted into reverse. The backup switch is closed, thus
the first detent. The front park lamps will also be on. turning on the backup lamps. The backup lamps are
The side marker lamps will also be on. located in the rear lamp assemblies.
CHASSIS ELECTR ICAL 8B-13
1. Ignition Switch Connector 5. Steering Column

2. Neutral Switch Connector 6. Turn Signal Indicator Connector
3. Dimmer Switch Connector 7. Stop Lamp Switch ConnectorWith Cruise Control
4. Back Up Switch Connector 8. Stop Lamp Switch ConnectorWithout Cruise Control
F-00837
Figure 10Lamp Systems Connectors At The Steering ColumnCK Models
REAR LAMP HARNESS LAYOUTS

Refer to Figures 10, 11, 12, 13, 14, 15, 16, 17, 18 and
19.
8B -14 CHASSIS ELECTRICAL
10. Marker Lamp (Cream)

11. Running, Turn, Stop Lamp (Gray)
12. Ground
13. Left Harness Connector
14. Right Harness Connector
15. License Lamp
16. Back Up Lamp F-00838
Figure 12Rear Lamp HarnessSuburban


11. Running, Turn, Stop Lamp (Gray) 15
12. Ground
15. License Lamp
16. Back Up Lamp
F-00841
Figure 13Rear Lamp HarnessPickup (Fleetside)

15. License Lamp
F-00842
Figure 14Rear Lamp Harness Pickup (Stepside)


11. Running, Turn, Stop Lamp
12. Ground
16. Back Up Lamp
F-00843
Figure 15Rear Lamp HarnessUtility Vehicle
50. Rear Lighting Harness Connector

51. Rear Lamp Assemblies
52. Run, Stop, Turn Lamp Connector
53. Back Up Lamp Connector
54. License Lamp Connector
55. Fuel Tank Sender Connector
56. Side Marker Lamp Connector
57. Ground
58. Run, Stop, Turn, Back Up
Lamps Connector
59. LT GRN Wire
60. GRN Wire
61. BRN Wire
62. License Lamp, Fuel Tank
Sender Connector
63. WH Wire
64. ORG Wire
65. PNK Wire
66 . BRN Wire
67. Rear Lamp Harness
68. YEL Wire
69. DK GRN Wire
70. LT GRN Wire
71. Instrument Panel Harness
F-00872
Figure 16Rear Lamp HarnessG Van

Figure 17Side Fender Marker Lamp Harness Pickup
Figure 18Tailgate Lamp HarnessPickup

8B-18 CHASSIS ELECTRICAL
30. Instrument Panel Harness Connector 33. Back Up Switch

31. Connector 4 Speed Manual Transmission 34. Manual Transmission
32. Automatic Transmission F-00860
Figure 19Back Up Lamp Switch HarnessesCK
DIAGNOSIS OF THE REAR SIDE MARKER LAMPS

One Lamp Wont 1. Turn signal bulb burnt out (front lamp). 1. Switch turn signals on. If the signal
Work bulb does not light, replace the bulb.
(Bulb filament provides ground path
for marker lamp bulb through the
dark blue or brown wires.)
2. Side marker bulb burnt out. 2. Replace the bulb.
3. Loose connection or open in wiring. 3. Using a test lamp, check the brown
wire terminal at the bulb socket. If the
test bulb lights, repair the open
ground circuit. If the bulb does not
light, repair the open in the brown
wire circuit.
Front Or Rear Lamps 1. Loose connection or open ground cir 1. If the associated tail or park lamps do
Wont Work cuit. not operate, check all the connectors
in the brown wire circuit. If the park
and turn lamps are not working, re
pair the open ground connections.
2. Multiple bulbs burnt out. 2. Replace the burnt out bulbs.
DIAGNOSIS OF THE REAR SIDE MARKER LAMPS (CONT.)

All Lamps Wont 1. Blown fuse. 1. If the park and tail lamps do not oper
Work ate, replace the blown fuse. If the
new fuse blows, check for a short to
ground between the fuse panel and
the lamps.
2. Loose connection. 2. Secure the connector to the lamp
switch.
3. Open in wiring. 3. Check the taillamp fuse with a test
lamp. If the test bulb lights, repair the
open wiring between the fuse and the
lamp switch. If not, repair the open
wiring between the fuse and the bat
tery. (Possible open fusible link.)
4. Defective lamp switch. 4. Check the lamp switch with a test
lamp. If the test bulb lights at the or
ange wire but not at the brown wire,
replace the light switch.
DIAGNOSIS OF THE RUNNING, PARK

AND LICENSE LAMPS
One Side Not 1. Bulb burnt out. 1. Replace the bulb.

Working 2. Open connection at the bulb socket or 2. Jumper the bulb base socket connec
the ground wire terminal. tion to ground. If the bulb lights, re
pair the open ground circuit.
Both Sides Not 1. Tail lamp fuse blown. 1. Replace the fuse. If the new fuse
Working blows, repair the short to ground in
the brown wire circuit between the
fuse panel through the lamp switch to
the lamp.
2. Loose connection. 2. Secure the connector at the lamp
switch.
3. Open wiring. 3. Using a test lamp, check a circuit on
both sides of the fuse. If the test bulb
does not light on either side, repair
the open circuit between the fuse
panel and the battery (possible open
fusible link). If the test bulb lights at
the lamp switch brown wire terminal,
lamp switch and the lamps.
4. Multiple bulb burnout. 4. If the test bulb lights at the lamp
socket brown wire terminal, replace
the bulb(s).
5. Defective lamp switch. 5. If the test bulb lights at the lamp
switch orange wire but not at the
brown wire, replace the defective
lamp switch.
DIAGNOSIS OF THE TURN SIGNAL AND

HAZARD SYSTEMS
Turn Signals Not 1. Bulb(s) burnt out (flasher cannot be 1. Turn the hazard warning system
Working On One heard). ON. If one or more bulbs are inop
Side erative, replace the bulbs as neces
sary.
2. Open wiring or loose ground connec 2. Turn the hazard warning system on. If
tor. one or more bulbs are inoperative,
use the test lamp and check the cir
cuit at the bulb socket. If the test bulb
lights, repair the open ground con
nection. If not, repair the open wiring
between the bulb socket and the turn
signal switch.
3. Improper bulb or defective turn signal 3. Turn the hazard warning system on. If
switch. all the front lamps and rear lamps op
erate, check for an improper bulb
(see bulb chart). If the bulbs are OK,
replace the defective turn signal
switch.
4. Short to ground. (Flasher can be 4. Locate and repair the short to ground
heard, no bulbs operate). by disconnecting the front and rear
circuits separately.
Turn Signals Not 1. Blown turn signal fuse. 1. Turn the hazard warning system on. If
Working all the lamps operate, replace the
blown fuse. If the new fuse blows, re
pair the short to ground between the
fuse and the lamps.
2. Defective flasher (located in conven 2. If the turn signal fuse is OK and the
ience center near steering column). hazard warning system will operate
the lamps, replace the defective turn
signal flasher.
3. Loose connection. 3. Secure the steering column connec
tor.
*\ .
DIAGNOSIS OF THE TURN SIGNAL AND

HAZARD SYSTEMS (CONT.)
Hazard Warning Not 1. Blown stop-hazard fuse. 1. Switch the turn signals ON. If the
Working lights operate, replace the stop-haz
ard fuse if blown. If the new fuse
blows, repair the short to ground.
(Could be in stop lamp circuit).
2. Faulty hazard warning flasher. (Lo 2. If the stop-hazard fuse is OK, switch
cated in the convenience center). the turn signals on. If the lamps oper
ate, replace the defective hazard
flasher.
3. Open in the wiring or a defective turn 3. Using the test lamp, check the brown
signal switch. wire in the turn signal steering col
umn connector. If the test bulb does
not light, repair the open circuit oe-
tween the flasher and the connector.
If the test lamp indicates power on
the brown wire and connection is
good, use a test lamp to check the
output terminals (It. blue, blue, yellow
and dark green wires).
DIAGNOSIS OF THE STOPLAMP SYSTEM

One Bulb Not Bulb burnt out. Replace bulb.
Working
One Side Not 1. Loose connection, open wiring or 1. Turn on the directional signal. If lamp
Working (Multi-Bulb faulty bulbs. does not operate, check the bulbs. If
Design) the bulbs are OK, check all connec
tions. If the lamp still does not oper
ate, use the test lamp and check for
open wiring.
2. Faulty directional signal switch or can 2. If the lamp will operate by turning the
celling cam. directional signal on, the switch is not
centering properly during the cancel
ling operation. Replace faulty cancel
ling cam or directional signal switch.
All Stoplamps 1. Stop-hazard fuse is blown. 1. Replace the fuse. If the new fuse
Inoperative blows, repair the short to ground in
the circuit between the fuse and the
lamps.
1. Open in the wire from the fuse to the 2. Check for power at the brown wire at
stop-switch. the stop-switch and at the fuse. If
there is power at the fuse but not at
the switch, check for an open in the
brown wire.
DIAGNOSIS OF THE STOPLAMP SYSTEM (CONT.)

All Stoplamps Not 3. Stop-switch misadjusted or faulty. 3. With the brake pedal pressed, check
Working (cont.) the white wire terminal in the steering
column connector with a test lamp. If
the bulb does not light, check the
stop switch for proper adjustment. If
the adjustment is OK, jumper the
stop switch. If the stop lamps oper
ate, replace the stop switch.
Will Not Turn Off 1. Stop switch misadjusted or faulty. 1. Readjust the switch. If the switch still
malfunctions, replace the switch.
DIAGNOSIS OF THE BACKUP LAMP SYSTEM

One Lamp Not 1. Loose or burnt out bulb. 1. Secure or replace the bulb.
Working Or 2. Loose connection.
Intermittent 3. Open ground connections. 2. Tighten the connectors.
3. Repair the bulb ground circuit.
Both Lamps Not 1. Gear selector switch is misadjusted 1. Readjust the gear selector switch.
Working Or (open when shifter lever is in reverse
Intermittent position).
2. Loose connection or open circuit. 2. Check all connectors. If OK, check
the continuity of the circuit from the
fuse to the lamp on either side of the
fuse. Correct the open circuit from
the battery to the fuse.
3. Blown fuse. 3. Replace the fuse. If the new fuse
blows, repair the short to ground in
the circuit from the fuse through the
gear selector or the backup lamp
switch to the backup lamps.
4. Faulty gear selector or backup lamp 4. With the ignition ON, check the
switch. switch terminals in the backup posi
tion with the test lamp. If the test bulb
lights at the dark blue wire terminal
but not at the light green wire termi
nal, replace the switch.
5. Faulty ignition switch. 5. If the test bulb lights at the ignition
switch battery terminal, but not at the
output terminal, replace the ignition
switch.
Lamp Will Not Turn 1. Gear selector switch misadjusted 1. Readjust the gear selector switch.
Off (closed when the shift lever is not in
the reverse position).
CHASSIS ELEC TR IC AL 8B-23
Figure 20Rear Lamp AssemblyCK Models
ON-VEHICLE SERVICE 4. Housing retaining screws (81).

5. Housing (82).
REAR LAMP BULB REPLACEMENTCK MODELS 6. Lamps (10, 11 and 16).
7. Seal (84).
2. Lens retaining screws (86). 1. Seal (84).
Install the seal with the tabs (83) pointed
3. Lens (80).
forward.
4. Bulb (10, 11 or 16).
Apply adhesive at the four corners of the
seal in order to hold the seal in place.
2. Lamps (10, 11 and 16).
3. Housing (82).
1. Bulb (10, 11 or 16).
4. Housing screws (81).
2. Lens (80). 5. Lens (80).
3. Lens retaining screws (86). 6. Lens screws (86).
4. Battery ground cable to the battery. 7. Battery ground cable to the battery.
REAR LAMP HOUSING AND LICENSE LAMP REPLACEMENT-

SEAL REPLACEMENT-CK MODELS CK MODELS
|*"| Remove or Disconnect (Figures 20) Remove or Disconnect (Figure 21)
1. Battery ground cable from the battery. 1. Battery ground cable from the battery.
2. Lens retaining screws (86). 2. Housing retaining screws (92) or bolts (97).
3. Lens (80). 3. Lens.
4. Bulb. 4. Trim panel (120).

5. Bezel (132).
Install or Connect (Figure 21) 6. Light switch harness (130).
7. Light switch (133).
1. Bulb.
2. Lens. -4- Install or Connect (Figures 24 and 25)
3. Housing retaining screws (92) or bolts (97).
4. Battery ground cable from the battery. 1. Light switch (133).
2. Light switch harness (130).
REAR LAMP BULB REPLACEMENT-G VAN 3. Bezel (132).
4. Trim panel (120).
|<"| Remove or Disconnect (Figures 22 and 16) 5. Trim panel screws (121).
6. Knob assembly (131).
1. Battery ground cable from the battery. 7. Battery ground cable to the battery.
2. Lens housing retaining screws (101).
3. Lamp housing (100). G-Van
4. Bulb socket (52 and 53) by squeezing the
retention lock and rotating the socket + + Remove or Disconnect (Figures 26 and 27)
counterclockwise.
5. Bulb from the bulb socket (52 and 53). 1. Battery ground cable from the battery.
0 1.
Install or Connect
Bulb into the bulb socket.
2. Knob assembly (141).
Press the knob assembly retaining pin on
the switch.
2. Bulb socket (52 and 53) into the housing. Pull out the knob assembly.
3. Lamp housing (100). 3. Trim plate retaining screws (142).
4. Lens housing retaining screws (101). 4. Trim plate (140).
5. Battery ground cable to the battery. 5. Bezel (143).
6. Light switch (144).
REAR MARKER LAMP BULB 7. Light switch harness (145).
REPLACEMENTG VAN
|<+| Remove or Disconnect (Figure 23)

El Install or Connect
1. Light switch harness (145) from the light switch

1. Battery ground cable from the battery. (144).
2. Housing retaining screws (113). 2. Light switch (144).
3. Housing (112). 3. Bezel (143).
4. Bulb socket (56). 4. Trim plate (140).
5. Bulb. 5. Trim plate retaining screws (142).
6. Knob assembly (141) into the switch (144).
Install or Connect 7. Battery ground cable to the battery.
1. Bulb. BACK UP SWITCH REPLACEMENT

2. Bulb socket (56) into the housing (112).
3. Housing (112). CKG ModelsManual Transmission
4. Housing retaining screws (113).
5. Battery ground cable from the battery. ++ Remove or Disconnect (Figure 28)
LIGHT SWITCH REPLACEMENT 1. Battery ground cable from the battery.

2. Backup switch harness (164).
C-K Models 3. Backup switch (163).
4. Seal (162).
2. Knob assembly (131). 1. Seal (162).
Push in retainer pin on the switch body. 2. Backup switch (163).
Pull out the knob assembly. 3. Backup switch harness (164).
3. Trim panel screws (121). 4. Battery ground cable to the battery.
CHASSIS ELEC TRIC AL 8B-25
94. Toothed Washer

95. Bolt
96. Nut
F-00875
Figure 21License LampCK Models

8B -26 CHASSIS ELECTR ICAL
CKG ModelsAutomatic Transmission Install or Connect
Remove or Disconnect (Figure 28) 1. Switch assembly.

Place gear selector in neutral.
1. Battery ground cable from the battery. Align the actuator (157) with the cutout (159)
in the steering column jacket (158).
2. Switch assembly harness. Insert the tangs (151) into the rectangular
3. Switch assembly. holes (150).
Push down on the switch assembly (152).
Place gear selector in neutral.
ft Adjust
Squeeze the switch tangs (151) together.
Switch by moving the gear selector to park.
Lift out the switch assembly (152).
The actuator will rachet, providing proper
switch adjustment.
2. Switch assembly harness.
Figure 23Rear Marker LampG Van

CHASSIS ELEC TR IC AL 8B-27
120. Trim Plate

121. Screw
F-00878
Figure 24Instrument Panel Trim PlateCK Models
121. Screw
130. Light Switch Harness
131. Light Switch
132. Bezel
133. Knob Assembly
B-06910
Figure 25Light Switch AssemblyCK Models

Figure 27Light Switch AssemblyG Van

150. Rectangular Hole

151. Tang
152. Switch Assembly (Auto Trans.
153. Back Up Switch Terminal
154. Back Up Switch Terminal
155. Park, Neutral Switch Terminal
156. Park, Neutral Switch Terminal
157. Actuator
158. Steering Column Jacket
159. Cutout
160. Shift Tube
161. Manual Transmission
162. Seal
163. Switch
164. Harness
F-00881
Figure 28Back Up Lamp Switch Assembly

FUSESCIRCUIT BREAKERS SPECIFICATIONS

The wiring circuits are protected from short circuits Dome Lamp* ............................................... 15 Amp
by a combination of fuses, circuit breakers, and fusible Auxiliary Battery*, Back-up Lamp,
thermal links in the wiring itself. This greatly reduces Radio............................................................. 15 Amp
the hazard of electrically caused fires in the vehicles. Idle Stop Solenoid, Cruise Control*,
The headlamp circuits are protected by a circuit Directional Signal Lamp, Time Delay
breaker in the light switch. An electrical overload on Relay, Emission Control Solenoid,
the breaker will cause the lamps to go on and off, or in Transmission Downshift (M40)......................10 Amp
some cases to remain off. In-line fuses are located in the auxiliary heater
In addition to a fuse, the windshield wiper motor is circuits (C-K-P models) and underhood lamp, front and
also protected by a circuit breaker. If the motor over rear A/C circuits (C-K models).
heats, due to overloading caused by heavy snow, etc.,
*When incorporated by body builder.
the wipers will remain stopped until the motor cools.
Fuses located in the Junction Block beneath the Do not use fuses of higher amperage than those
dash on the drivers side are: recommended above.
The following wiring harnesses are protected by a
C-K TRUCK fusible link which is a special wire incorporated in
Heater, Front A/C, Generator Warning the circuit headlamp hi-beam indicator, horn, air
Lamp............................................................. 20 Amp conditioning high blower, ignition circuits (C-K-P
Idle Stop Solenoid, Aux. Battery, Radio,
models) starter solenoid (pull-in and hold) circuit (C-K
Time Delay Relay, Emission Control
models). Should an electrical overload occur, this wire
Solenoid, Transmission Downshift
will fail and prevent damage to the major harness.
(M40)............................................................. 15 Amp
Cigarette Lighter, Clock, Dome Lamp,
Cargo Lam p..................................................20 Amp G TRUCK
Fuel Gage, Brake Warning Lamp, Heater, A/C....................................................... 25 Amp
Temperature Warning Lamp, Oil Idle Stop Solenoid, Cruise Control,
Pressure Warning L a m p ................................4 Amp Directional Signal Lamp, Directional
Courtesy Lamp, Roof Marker Lamp, Signal Indicator Lamp, Transmission
License Plate Lamp, Parking Lamp, Downshift (M-40)........................................... 10 Amp
Side Marker Lamp, Tail Lamp, Cigarette Lighter, Dome Lamp, Spot Lamp... .15 Amp
Clearance Lamp............................................20 Amp Fuel Gage, Brake Warning Lamp,
Directional Signal Indicator Lamp, Stop Temperature Warning Lamp, Generator
Lamp, Traffic Hazard......................................15 Amp Warning Lamp, Oil Pressure Warning Lamp. .3 Amp
Instrument Cluster Lamp, Heater Dial Stop Lamp, Traffic Hazard................................15 Amp
Lamp, Radio Dial Lamp, Cruise Control Auxiliary Battery, Backing Lamp,
Lamp, Windshield Wiper Switch Lamp..........4 Amp Radio Dial Lamp, Radio................................15 Amp
Windshield Wiper/Washer................................25 Amp Instrument Cluster Lamp, Heater Dial
Cruise Control, Rear Window Aux., Lamp, Transmission Control Lamp
Fuel Tank, Tachometer, Back-up Lamp, with Tilt Wheel, Cruise Control
Directional Signal Indicator Lamp, Lamp, W/S Wiper Switch Lamp,
Directional Signal Lamp, Headlamp Headlamp Buzzer........................................... 3 Amp
Buzzer........................................................... 15 Amp License Lamp, Parking Lamp, Side
Marker Lamp, Tail Lamp................................15 Amp
P TRUCK Windshield Wiper............................................. 25 Amp
Heater*, Air Conditioning*..............................25 Amp An in-line fuse is located in the ammeter and the
Instrument Cluster Lamp, Windshield auxiliary heater circuits.
Wiper Switch L a m p ........................................3 Amp
Do not use fuses of higher amperage rating than
Directional Signal Indicator Lamp, Stop
those recommended above.
Lamp, Traffic Hazard......................................15 Amp
Fuel Gage, Brake Warning Lam p......................3 Amp The following wiring harnesses are protected by a
License Plate Lamp, Parking Lamp, fusible link which is a special wire incorporated in
Side Marker Lamp, Tail Lamp, the circuit, ignition, horn and headlamp hi-beam
Clearance Lamp, Identification Lam p..........15 Amp indicator circuits, air conditioning high blower. Should
Windshield Washer/Wiper................................25 Amp an electrical overload occur, this wire will fail and
Cigarette Lighter*, Clock*, Courtesy*, prevent damage to the major harness.
CHASSIS ELEC TRIC AL 8B-31
CIRCUIT BREAKERS
DEVICE OR
CIRCUIT MODELS AMPS. LOCATION
PROTECTED
Headlamp and
Lamp
parking lamp C-K-P-G 15
switch
circuit
Tailgate window Dash
C-K 30
motor (forward side)
Rear A/C Dash
G 35
(C69 overhead) (forward side)
8B-32 CH ASSIS ELECTRICAL
LAMP SPECIFICATIONS
LAMP BULB DATA LAMP BULB DATA

C-K-P TRUCK G TRUCK
USED IN QUAN. TRADE # POWER USED IN QUAN.TRADE # POWER

Dome Lamps: Dome lamps 2 211-2 12 CP
Cab 1 1004 15 CP Oil pressure indicator lamp 1 161 1 CP
Utility & Surburban 1 211-2 12 CP
Generator indicator lamp 1 194 2 CP
Oil Pressure indicator lamp 1 168 3 CP
Instrument cluster lamps" 1 161 1 CP
Generator indicator lamp1 1 168 3 CP
Headlamp beam indicator
Instrument cluster lamps2 5 168 3 CP lamp 1 161 1 CP
Headlamp beam indicator Park, directional signal
lamp 1 168 3 CP lamps 2 1157 3-32 CP
Lamp assemblytail & Tail, stop lamps 2 1157 3-32 CP
stop lamp 2 1157 3-32 CP
License lamp 1 67 4 CP
License Lamp4 1 67 4 CP
Head lamps'2 2 6014 50-60 W
Directional signal
(front park lamps)6 2 1157 3-32 CP
Temperature indicator lamp 1 194 2 CP
Head Lamps 2 6014 50-60 W Directional signal indicator
lamp 2 194 2 CP
Temperature indicator lamp 1 168 3 CP
Marker lamps 4 168 3 CP
Directional signal indicator
lamp 2 168 3 CP
Brake warning indicator lamp 1 194 2 CP
Clearance and marker lamps 4 168 3 CP
Back-up lamp 2 1156 32 CP
Roof marker lamps5 5 194 2 CP Radio dial lamp 1 1893 2 CP
Brake warning indicator lamp 1 168 3 CP Heater or A/C Ilium, lamp 1 194 2 CP
Transmission control (auto) 1 1445 0.7 CP Transmission control w/tilt
Backing lamp (exc. wheel Ilium, lamp 1 1445 0.7 CP
motor home) 2 1156 32 CP W/S wiper switch lamp 1 161 1 CP
Backing lamp (motor home) 2 1295 50 CP Transmission control Ilium, lamp 1 73 .3 CP
Heater or A/C Ilium, lamp 1 161 1 CP Choke heater indicator lamp 1 1893 2 CP
Corner marker lamps Seat belt warning lamp 1 194 2 CP
(platform) 7 67 4 CP Instrument cluster lamps9 5 194 2 CP
Cargo lamp (C-K cab) 1 1142 21 CP Instrument cluster lamps'0 1 168 3 CP
Radio dial lamp AM 1 216 1 CP 'On CA, KA 10-35 instrument clusters only.
AM/FM 1 216 1 CP 23 lamps used on instrument cluster on P models or C-K w/o
Courtesy lamp 1 1003 15 CP gages.
Windshield wiper switch lamp 1 3Double filament sealed beam 60W high beam, 50W low
161 1 CP
beam.
Clock lamp 1 168 3 CP 42 lamps used with step bumper and P models.
Rear identification7 lamp 10 1895 2 CP 54 required on P models.
Underhood lamp 1 93 15 CP 61157 NA, 2.2-24 CP on C-K models.
7Wideside Pickup.
Seat belt warning lamp 1 168 3 CP
8P truck only.
Cargo/dome lamp 2 211-2 12 CP 9G model w/o gages; 1 lamp with gages.
Four wheel drive indicator lamp 1 161 1 CP 'G model w/o gages; 3 lamps with gages.
Choke heater indicator lamp 1 168 3 CP G model with gages only.
'2Double filament sealed beam 60W high beam, 50W low
beam.
8C-1
SECTION 8C
INSTRUMENT PANEL AND GAGES

CONTENTS
SUBJECT PAGE
D escription..........................................................................................................................................................8C- 2
Speedometer................................................................................................................................................... 8C- 2
Fuel G a g e ....................................................................................................................................................... 8C- 2
Oil Pressure Gage........................................................................................................................................... 8C- 2
Temperature G age......................................................................................................................................... 8C- 2
Engine Control (Ignition) S w itc h .................................................................................................................8C- 2
Lamp S w itch ................................................................................................................................................... 8C- 2
Diagnosis Of Speedometer S ystem .................................................................................................................8C- 3
Diagnosis Of The Fuel Gage............................................................................................................................. 8C- 4
Diagnosis Of The Oil Pressure G age...............................................................................................................8C- 5
Diagnosis Of The Temperature Gage...............................................................................................................8C- 6
On Vehicle Service............................................................................................................................................. 8C- 7
Speedometer Replacement...........................................................................................................................8C- 7
Speedometer Cable Core Replacement...................................................................................................... 8C- 9
Fuel Gage Replacement................................................................................................................................. 8C-10
Fuel Sender Unit Replacement.....................................................................................................................8C-13
Temperature Gage R eplacem ent.................................................................................................................8C-13
Temperature Gage Sender Replacement.................................................................................................... 8C-14
Oil Pressure Gage Replacement...................................................................................................................8C-14
Oil Pressure Gage Sender Replacem ent.................................................................................................... 8C-15
Voltmeter Replacement................................................................................................................................. 8C-15
Instrument Cluster R eplacem ent.................................................................................................................8C-16
Laminated (Printed) Circuit Replacem ent.................................................................................................. 8C-17
Engine Control (Ignition) Switch Replacement.......................................................................................... 8C-17
Lamp Switch Replacem ent...........................................................................................................................8C-17
Special T o o ls ..................................................................................................................................................... 8C-17
8C -2 INSTRUMENT PA N E L AND G AG ES
DESCRIPTION
SPEEDOMETER ENGINE CONTROL

(IGNITION) SWITCH
The speedometer on the instrument panel is a
mechanical type that is driven by a cased cable which
On the CK and G models, the engine control
is connected to the transmission. The speedometer is (ignition) switch is located in the steering column on
located in the center of the instrument panel. Refer to
the right hand side just below the steering wheel. The
figure 1 for diagnosis.
electrical switching portion of the assembly is separate
from the key and lock cylinder. However, both are
FUEL GAGE synchronized and work in conjunction with each other
through the action of the actuator rod assembly.
For a complete explanation of the key and lock
The fuel gage is an electrical, current sensing type
cylinder, and the actuator rod assembly, see
of indicator. It has two coils in it. One coil sets up a
STEERING, (Sec. 3B4).
constant magnetic field. The other coil has a varying
The engine control (ignition) and starting switch is
magnetic field which is varied by the rheostat attached
key operated through the actuator rod assembly to
to a float in the fuel tank. A magnet, attached to a
close the ignition primary circuit and to energize the
pointer, is located between the two coils. The magnet
starting motor solenoid for cranking.
will establish a position which is controlled by the mag
On the P models the engine control (ignition) switch
netic fields of the two coils. Refer to figure 2 for diagno
is located on the instrument panel. The switch controls
sis.
the engine run and start functions, and the
accessories.
OIL PRESSURE GAGE The connections to the engine control (ignition)
switch are shown in the Wiring Diagrams at the end of
The oil pressure gage displays the engine oil this manual. The charts included on the diagrams
pressure. The gage is electrical. The sender is a show how the switches are internally connected in
variable resistance which controls the current passing each switch position.
through the gage. Refer to figure 3 for diagnosis.
LAMP SWITCH
TEMPERATURE GAGE The lamp switch controls the headlamps, marker
lamps, running lamps and parking lamps. The switch
This gage displays the temperature of the engine also controls the dome lamps and the light level of the
coolant. It is an electrical gage. The gages sender is a instrument illumination lamps.
variable resistance that controls the current passing
through the gage. Refer to figure 4 for diagnosis.
INSTRUMENT PA N E L AND G AG ES 8C -3
DIAGNOSISSPEEDOMETER SYSTEM
Noisy Kinked, pinched or Replace both the cable and

burned casings. casing. Recheck for noise.
n
Bent cable tips. Replace both the cable and
casing. Recheck for noise.
ft
Im proper or insufficient Lubricate cable core with P/N
lubrication of cable. 6 4 7 8 5 3 5 or equivalent. Pack
ferrule with grease.
n
Faulty driven gear or Remove driven gear assem bly
rough drive gear. from transmission. Check for
free rotation of gear in sleeve.
Check for burrs, flash or
unusual worn spots. If gears
appear faulty, replace and
recheck for noise.
W hine Oversize driven gear stem Replace driven gear and stem .
in transmission binds with
adapter.
Buzzing sound with Shift linkage vibration. Adjust transmission shift

manual transmission. linkage.
Tick or ringing sound Faulty speedom eter head. Remove speedom eter head for
with jum py pointer repair.
between 0 and 30 M PH .
Sticky speedom eter Speedom eter pointer is Remove speedom eter cluster
pointer. bent and rubs. or lens and straighten pointer.
Recheck speedom eter operation.
Incorrect W rong transmission Check speedom eter gear

calibration. adapter, drive gear or reference for correct
sleeve. application and replace if
necessary.
n
Oversize or undersize Check calibration using
tires. correct tire size.
n
Faulty speedom eter head. Remove speedom eter for repair.
F-00930
Figure 1Diagnosis Of The Speedometer System

8C -4 INSTRUMENT PA N EL AND G AG ES
Figure 2Diagnosis Of The Fuel Gage

INSTRUMENT P A N E L AND G A G ES 8C -5
Figure 3Diagnosis Of The Oil Pressure Gage

8C-6 INSTRUMENT PA N EL AND G AG ES
DIAGNOSIS OF THE TEMPERATURE GAGE
DISCONNECT TEMP. GAGE

SENDER WIRE
TURN
ENGINE CONTROL SWITCH GO TO STEP 2
ON
CONNECT J-24538-A TESTER TO
SENDER WIRE & TO GROUND
GAGE RESPONDS TO TESTER ACCURATELY REPLACE SENDER
GAGE DOES NOT RESPOND OR IS INACCURATE GO TO STEP 3
GAGE INDICATES WELL BEYOND HOT END OF SCALE GO TO STEP 5
CHECK WIRING
GAGE RESPONDS BETWEEN SENDER
DISCONNECT TEMP. GAGE TO TESTER ACCURATELY CONNECTOR &
LEAD AT ENGINE HARNESS ENGINE HARNESS
CONNECTOR. CONNECT J-24538-A CONNECTOR
TESTER TO LEAD THAT GAGE DOES
GOES TO THE GAGE NOT RESPOND GO TO STEP 4
GOOD REPLACE GAGE

CHECK FOR BAD
CONNECTIONS
CONNECTIONS AT GAGE
TERMINALS OR INST.
REMOVE REPAIR
CLUSTER CONNECTOR
GAGE CONNECTIONS &
OR LOOSE NUTS AT BAD
GAGE TERMINALS CONNECTIONS REINSTALL GAGE
GOOD REPLACE GAGE

CHECK FOR LOOSE CONNECTIONS
NUTS AT GAGE
REMOVE TERMINALS OR
GAGE LACK OF GROUND
REPAIR
CONNECTION TO GAGE BAD
CONNECTIONS &
CONNECTIONS
REINSTALL GAGE
F-00931
Figure 4Diagnosis Of The Temperature Gage

INSTRUMENT P A N E L AND G A G ES 8C -7
ON VEHICLE SERVICE
SPEEDOMETER REPLACEMENT G MODELS
Servicing of the speedometer assembly should only Remove or Disconnect (Figure 7)

be performed by trained technicians having the proper
test equipment. 1. Battery ground cable from the battery.
2. Instrument cluster. Refer to Instrument Cluster
When replacing a speedom eter or odom eter
assembly, the law requires the odometer reading of the
3. Speedometer dial retaining screws.
replacement unit to be set to register the same mileage
4. Two hex head screws and rubber grommets
as the prior odometer. If the same mileage cannot be
securing the speedom eter assem bly to the
set, the law requires the replacement odometer be set
cluster cover.
to zero and a label be installed on the drivers door
5. S p e e d o m e te r ca b le a sse m b ly from the
frame to show the previous odometer reading and the
speedometer.
date of replacement.
6. Speedometer (80).
C-K MODELS -- Install or Connect
+ + Remove or Disconnect (Figures 5 and 6) 1. Speedometer (80).

2. Speedometer cable assembly.
3. Two hex head screws and rubber grommets that
2. Headlamp switch knob assembly. Refer to hold the speedometer assembly to the cluster
CHASSIS ELECTRICAL (SEC. 8B). cover.
3. Radio control knobs. 4. Speedometer dial retaining screws.
4. Clock adjuster stem. 5. Instrument cluster. Refer to Instrument Cluster
5. Instrument cluster bezel (43). Replacement in this section.
6. Steering column cover.
7. Instrument cluster lens (42). P MODELS
8. Transmission shift indicator (41).
9. Retainer (44). Remove or Disconnect
Depress spring clip (30).
Rem ove ca b le and case from the Replacement in this section.
speedometer (36). 3. Lamp socket assemblies.
4. Laminated circuit retaining nuts.
Install or Connect (Figures 5 and 6) 5. Laminated circuit.
6. Cluster case retaining screws.
1. Speedometer (36). 7. Cluster case from the bezel.
2. Speedometer cable assembly. 8. Speedometer retaining bolts.
Push the ca b le a sse m b ly in to the 9. Speedometer from the cluster case.
speedom eter head, rotating the cable
assembly, until the spring clip engages. Install or Connect
3. Retainer (44).
1. Speedometer to the cluster case.
4. Transmission shift indicator (41). 2. Speedometer retaining bolts.
5. Instrument cluster lens (42). 3. Cluster case to the bezel.
6. Steering column cover. 4. Cluster case retaining screws.
7. Instrument cluster bezel (43). 5. Laminated circuit.
8. Clock adjuster stem.
7. Lamp socket assemblies.
9. Radio control knobs.
10. Headlamp switch knob assembly. Replacement in this section.
11. Battery ground cable to the battery. 9. Battery ground cable from the battery.
8C -8 INSTRUMENT PA N E L AND G AG ES
30. Speedometer Cable Spring Clip

31. Lamp Bulb Socket
32. Laminated Circuit
33. Cluster Case
34. Indicator Lamp Filter (Turn Signal)
35. Fuel Gage
36. Speedometer
37. Temperature Gage
38. Brake Warning Lamp Filter
39. Ammeter
40. Oil Pressure Gage
41. Transmission S hift Indicator
42. Instrument Cluster Lens
43. Instrument Cluster Bezel
44. Retainer
F-00945
Figure 5Instrument Panel CK Models

INSTRUMENT PA N E L AND G A G ES 8C-9
64 63 ^ -6 0
32. Laminated Circuit

33. Cluster Case 57. Charging System Lamp
50. Fuel Gage Clip 58. Instrument Cluster Connector
51. Lamp Socket Hole 59. Ammeter Clip
52. Speedometer Hole 60. Brake Warning Lamp/Clock
53. High Beam Indicator Lamp 61. Temperature Gage Clip
54. Oil Pressure Indicator I amp 62. Fuel Gage Clip
55. Engine Temperature Warning Lamp 63. Turn Signal Indicator Lamp
56. Brake Warning Lamp 64. Brake Warning Lamp
F-00953
Figure 6Laminated C ircuit CK Models
SPEEDOMETER CABLE CORE Pull the core out of the speedometer end of
the casing. If the cable core is broken,
REPLACEMENT remove the lower piece of the core from the
transmission end of the casing.
ALL VEHICLES
Remove or Disconnect (Figures 5, 8, 9, and Install or Connect (Figures 5, 8, 9, and 10)

10)
1. Lubricant in the casing and on the core.
2. Core into the speedometer end of the casing.
2. S p e e d o m e te r c a b le a sse m b ly from the Turn the core to engage the drive gear in the
speedometer. transmission.
Compress the spring clip (30). 3. S p e e d o m e te r ca b le a sse m b ly in to the

speedometer head until the spring clip (30)
P ull the ca b le a sse m b ly from the engages.
speedometer.
3. Cable core.
70. Bolt (#8-32 x 7/ie") 80. Speedometer

71. Speedometer Mounting Bushing 81. Gage Mask
72. Nut 82. Lens Retainer
73. Flat Washer 83. Lens
74. Laminated Circuit 84. Bezel
75. Screw (#8-18 x 7he") 85. Fuel Gage
76. Engine Coolant Temperature Gage 86. Lamp
77. Voltmeter 87. Engine Oil Pressure Gage
78. Screw (#8-16 x 7/ie") 88. Instrument Cluster With Gages
79. Retainer 89. Instrument Cluster W ithout Gages
F-00960
Figure 7Instrum ent Panel G Van
FUEL GAGE REPLACEMENT Install or Connect (Figures 5 and 6)
1. Fuel gage (35).

Remove or Disconnect (Figures 5 and 6) 2. Fuel gage attaching screws.
1. Battery ground cable from the battery. 3. Case front cover (44).
2. Headlamp switch knob assembly. Refer to 4. Transmission shift indicator (41).
CHASSIS ELECTRICAL (SEC. 8B).
5. Instrument cluster lens (42).
4. Clock adjuster stem. 6. Steering column cover.
5. Instrument cluster bezel (43). 7. Instrument cluster bezel (43).
8. Transmission shift indicator (41). 9. Radio control knobs.
9. Case front cover (44). 10. Headlamp switch knob assembly. Refer to
10. Fuel gage attaching screws. CHASSIS ELECTRICAL (SEC. 8B).
11. Fuel gage (35). 11. Battery ground cable to the battery.
INSTRUMENT PA N EL AND G AG ES 8C-11
Figure 9Speedometer Cable Assem bly

Four Wheel Drive
G MODELS

2. In s tru m e n t c lu s te r a ssem bly. R efer to
Instrum ent C luster R eplacem ent in this
section.
3. Lens (83).
4. Lens retainer (82).
1. Speedometer 5. Laminated circuit retaining nuts.
2. Speedometer Cable Connector 6. Laminated circuit (74) from the retainer (79).
3. Seal 7. Fuel gage retaining nuts (72).
8. Fuel gage.
F-00882
E
Figure 8Speedometer Cable Assembly 1. Fuel gage to the laminated circuit.
Two Wheel Drive 2. Fuel gage retaining nuts (72).
8C-12 INSTRUMENT PA N E L AND G AG ES
12o^ r
19 11
12 10
14
14 5 X6 7
12 10
2. Speedometer Cable Connector

4. Transfer Case
5. Sleeve 13. Adapter Assem bly Position for All Transmissions Except SM465
6. Gear 14. Adapter Assem bly Position For SM465 Transmission
7. Transmission 15. Output Key
8. Retainer 16. Adapter Assem bly Right Angle
9. Seal 17. Adapter Assembly
10. Retainer 18. In-Line Adapter Assembly (With SM465 Transmission)
11. Sleeve Assembly 19. Parallel Adapter Assembly (Except SM465 Transmission)
12. Bolt 20. In-Line Adapter
F-00884
Figure 10Speedometer Adapter Assemblies

INSTRUMENT PA N E L AND G AG ES 8C-13
3. Laminated circuit (74) to the retainer (79). 4. Clock adjuster stem.

4. Laminated circuit retaining nuts. 5. Instrument cluster bezel (43).
6. Lens (83).
7 In s tru m e n t c lu s te r a ssem bly. R efer to 7. Instrument cluster lens (42).
Instrum ent C luster R e p lacem ent in this 8. Transmission shift indicator (41).
section. 9. Retainer (44).
8. Battery ground cable to the battery. 10. Temperature gage attaching screws.
11. Temperature gage (37).
P MODELS
Remove or Disconnect Install or Connect (Figure 5)
1. Battery ground cable from the battery. 1. Temperature gage (37).

2. Instrument cluster. Refer to Instrument Cluster 2. Temperature gage attaching screws.
Replacement in this section. 3. Retainer (44).
Lamp socket assemblies. 4. Transmission shift indicator (41).
Laminated circuit retaining nuts.
Laminated circuit.
Cluster case retaining screws. 6. Steering column cover.
7. Cluster case from the bezel. 7. Instrument cluster bezel (43).
8. Fuel gage retaining bolts. 8. Clock adjuster stem.
9. Fuel gage from the cluster case.
Install or Connect 10. Headlamp switch knob assembly. Refer to

1. Fuel gage to the cluster case. 11. Battery ground cable to the battery.
2. Fuel gage retaining bolts.
3. Cluster case to the bezel. G MODELS
5. Laminated circuit. Remove or Disconnect (Figure 7)
7. Lamp socket assemblies. 1. Battery ground cable from the battery.
8. Instrument cluster. Refer to Instrument Cluster 2. In s tru m e n t c lu s te r assem bly. R e fer to
Replacement in this section. Instrum ent C luster R eplacem ent in this
9. Battery ground cable from the battery. section.
3. Lens (83).
FUEL SENDER UNIT 4. Lens retainer (82).
REPLACEMENT 5. Laminated circuit retaining nuts.
6. Laminated circuit (74) from the retainer (79).
7. Temperature gage retaining nuts (72).
ALL MODELS 8. Temperature gage (76).
Refer to FUEL SYSTEMS (SEC. 6C).

TEMPERATURE GAGE
1. Temperature gage (76) to the laminated circuit.
REPLACEMENT
2. Temperature gage retaining nuts (72).
3. Laminated circuit (74) to the retainer (79).
CK MODELS 4. Laminated circuit retaining nuts.
|+"| Remove or Disconnect (Figure 5)
6. Lens (83).
1. Battery ground cable from the battery. 7. In s tru m e n t c lu s te r a ssem bly. R efer to
2. Headlamp switch knob assembly. Refer to Instrum ent C luster R eplacem ent in this
CHASSIS ELECTRICAL (SEC. 8B). section.
3. Radio control knobs. 8. Battery ground cable to the battery.
P MODELS 3. Coolant to return the coolant level to the proper

level.
1. Battery ground cable from the battery. OIL PRESSURE GAGE

2. Instrument cluster. Refer to Instrument Cluster REPLACEMENT
4. Laminated circuit retaining nuts. CK MODELS
5. Laminated circuit.
6. Cluster case retaining screws. Remove or Disconnect (Figure 5)
7. Cluster case from the bezel.
8. Temperature gage retaining bolts. 1. Battery ground cable from the battery.
9. Temperature gage from the cluster case. 2. Headlamp switch knob assembly. Refer to
Install or Connect 3. Radio control knobs.
1. Temperature gage to the cluster case. 5. Instrument cluster bezel (43).
2. Temperature gage retaining bolts.
3. Cluster case to the bezel.
6. Laminated circuit retaining nuts. 9. Retainer (44).
7. Lamp socket assemblies. 10. Oil pressure gage attaching screws.
8. Instrument cluster. Refer to Instrument Cluster 11. Oil pressure gage (40).
9. Battery ground cable from the battery. Install or Connect
1. Oil pressure gage (40).

TEMPERATURE GAGE SENDER 2. Oil pressure gage attaching screws.
REPLACEMENT 3. Retainer.
ALL MODELS
CAUTION: Do n ot rem ove cap w ith the 7. Instrument cluster bezel (43).
engine hot. A llow the vehicle to cool o ff first. 8. Clock adjuster stem.
10. Headlamp switch knob assembly. Refer to
+ + Remove or Disconnect CHASSIS ELECTRICAL (SEC. 8B).
1. Radiator cap.
Loosen the cap to the first stop. This will G MODELS
relieve the cooling system pressure.
Tighten the cap. This will minimize the loss Remove or Disconnect (Figure 7)
of coolant when replacing the temperature
sender. 1. Battery ground cable from the battery.
2. Sender harness connector. 2. In s tru m e n t c lu s te r assem bly. R efer to
3. Sender. Instrum ent C luster R eplacem ent in this
Have the new sender ready to install or section.
close the sender hole with a cork in order to 3. Lens (83).
minimize coolant loss.
6. Laminated circuit (74) from the retainer (79).
1. Sender. 7. Oil pressure gage retaining nuts (72).
2. Sender harness connector. 8. Oil pressure gage (87).
-- Install or Connect (Figure 7) 3. Sender.

Use Tool J-21757
1. Fuel gage (87) to the laminated circuit.
2. Fuel gage retaining nuts (72). -n - Install or Connect
Laminated circuit (74) to the retainer (79). Tool Required: J-21757
Laminated circuit retaining nuts. 1. Sender.
Lens retainer (82). Use Tool J-21757.
Lens (83). 2. Wiring harness connector to the sender.
In s tru m e n t c lu s te r a ssem bly. R efer to 3. Battery ground cable to the battery.
Instrum ent C luster R e p lacem ent in this
section.
8. Battery ground cable to the battery. VOLTMETER REPLACEMENT
P MODELS
CK MODELS
2. Instrument cluster. Refer to Instrument Cluster 1. Battery ground cable from the battery.
Replacement in this section. 2. Headlamp switch knob assembly. Refer to
5. Instrument cluster bezel (43).
8. Oil pressure gage retaining bolts.
9. Oil pressure gage from the cluster case.
9. Retainer (44).
10. Voltmeter attaching screws.
11. Voltmeter.
1. Oil pressure gage to the cluster case.
|-+| Install or Connect (Figure 5)
2. Oil pressure gage retaining bolts.
3. Cluster case to the bezel.
1. Voltmeter.
2. Voltmeter attaching screws.
5. Laminated circuit. 3. Retainer (44).
6. Laminated circuit retaining nuts. 4. Transmission shift indicator (41).
7. Lamp socket assemblies. 5. Instrument cluster lens (42).
8. Instrument cluster. Refer to Instrument Cluster 6. Steering column cover.
Replacement in this section. 7. Instrument cluster bezel (43).
9. Battery ground cable from the battery. 8. Clock adjuster stem.
10. Headlamp switch knob assembly.
OIL PRESSURE GAGE 11. Battery ground cable to the battery.
SENDER REPLACEMENT
G MODELS
ALL MODELS Remove or Disconnect (Figure 7)
+ + Remove or Disconnect 1. Battery ground cable from the battery.

Tool Required: J-21757 2. In s tru m e n t c lu s te r assem bly. R efer to
1. Battery ground cable from the battery. Instrum ent C luster R eplacem ent in this
2. Wiring harness connector from the sender. section.
L-6 engines the sender is located in the 3. Lens (83).
block above the starter. 4. Lens retainer (82).
V-8 engines the sender is located at the 5. Laminated circuit retaining nuts.
left front side of the distributor. 6. Laminated circuit (74) from the retainer (79).
V-8 (454) engines the sender is located at 7. Voltmeter retaining nuts (72).
the rear left side of the block. 8. Voltmeter.
8C-16 INSTRUMENT PA N E L AND G AG ES
Install or Connect (Figure 7) P ress the s p rin g c lip (30) at the

speedometer (36).
1. Voltmeter to the laminated circuit. Pull the cable from the speedometer head.
2. Voltmeter retaining nuts (72). 9. Four cluster retaining screws.
3. Laminated circuit (74) to the retainer (79). 10. Cluster harness connector.
4. Laminated circuit retaining nuts. 11. Cluster.
6. Lens (83). Install or Connect (Figure 5)
7. In s tru m e n t c lu s te r assem bly. R efer to
Instrum ent C luster R e p lace m e n t in this 1. Cluster.
section. 2. Cluster harness connector.
8. Battery ground cable to the battery. 3. Four cluster retaining screws.
4. Speedometer drive cable.
P MODELS 5. Instrument bezel (43).
6. Eight instrument bezel retaining screws.
Remove or Disconnect 7. Steering column cover.
8. Four steering column cover retaining screws.
1. Battery ground cable from the battery. 9. Radio control knobs.
2. Instrument cluster. Refer to Instrument Cluster 10. Headlamp switch knob assembly.
Replacement in this section. 11. Battery ground cable to the battery.
4. Laminated circuit retaining nuts. G MODELS
6. Cluster case retaining screws. |+ + | Remove or Disconnect (Figure 7)
8. Voltmeter retaining bolts. 1. Battery ground cable from the battery.
9. Voltmeter from the cluster case. 2. Speedometer drive cable.
Press in the tang on the speedometer head.
-- Install or Connect Pull out the drive cable.
3. Clock set stem knob.
1. Voltmeter to the cluster case. 4. Instrument cluster bezel retaining screws.
2. Voltmeter retaining bolts. 5. Instrument bezel (84).
3. Cluster case to the bezel. 6. Two lower cluster retaining screws.
4. Cluster case retaining screws. 7. Cluster.
5. Laminated circuit. Pull the top of the cluster away from the
6. Laminated circuit retaining nuts. instrument panel.
7. Lamp socket assemblies. Lift out the bottom of the cluster.
8. Instrument cluster. Refer to Instrument Cluster 8. Instrument cluster harness connnector.
9. Battery ground cable from the battery. Install or Connect (Figure 7)
1. Cluster harness connector into the cluster.

INSTRUMENT CLUSTER 2. Cluster.
REPLACEMENT 3. Two lower cluster retaining screws.
4. Instrument bezel (84).
5. Instrument cluster bezel retaining screws.
CK MODELS 6. Clock set stem knob.
7. Speedometer drive cable.
|+ + | Remove or Disconnect (Figure 5) 8. Battery ground cable to the battery.
1. Battery ground cable from the battery. P MODELS

2. Headlamp switch knob assembly.
3. Radio control knobs. |+ + | Remove or Disconnect
4. Four steering column cover retaining screws.
5. Steering column cover. 1. Battery ground cable from the battery.
6. Eight instrument bezel retaining scerws. 2. Speedometer drive cable.
7. Instrument bezel (43). Press in the tang on the speedometer head.
8. Speedometer drive cable. Pull out the drive cable.
3. Instrument cluster harness connector. Temperature gage terminal nuts.

4. Instrument cluster bezel screws. Ammeter terminal nuts.
0
5. Instrument cluster from the dash panel. 5. Laminated circuit from the cluster case (33).
Install or Connect Install or Connect (Figures 5, 6, and 7)
1. Instrument cluster to the dash panel. 1. Laminated circuit (51) to the cluster case (33).
2. Instrument cluster bezel screws. 2. Laminated circuit retaining screws.
3. Instrument cluster harness connector. 3. G and P models.
4. Speedometer drive cable. Fuel gage terminal nuts.
5. Battery ground cable from the battery. Ammeter terminal nuts.
Instrument cluster lamp bulb assemblies (57).
In s tru m e n t c lu s te r a ssem bly. R e fer to
LAMINATED (PRINTED) Instrum ent C luster R eplacem ent in this
CIRCUIT REPLACEMENT section.
ALL MODELS IGNITION SWITCH

REPLACEMENT
|<"*| Remove or Disconnect (Figures 5, 6, and 7)
Refer to STEERING COLUMN (SEC. 3B4).
1. In s tru m e n t c lu s te r a ssem bly. R efer to
Instrum ent C luster R e p lacem ent in this
section. LAMP SWITCH REPLACEMENT
2. Instrument cluster lamp bulb assemblies (57).
3. Laminated circuit retaining screws. Refer to CHASSIS ELECTRICAL (SEC. 8B).
4. G and P models.
Fuel gage terminal nuts.
SPECIAL TOOLS
Tool J-21757-03 Oil Pressure Sending Unit Socket
9A-1
SECTION 9A
RADIO
CONTENTS
SUBJECT PAGE
D e s c rip tio n .................................................................................................................................................................. 9 A - 1
D ia g n o s is .....................................................................................................................................................................9 A - 6
Chart 1 System Diagnosis and A n a ly s is .......................................................................................................... 9 A - 7
Chart 2 Noisy Part 1 .............................................................................................................................................9 A - 8
Chart 3 Noisy Part 2 .............................................................................................................................................9 A - 9
Chart 4 ECM or Digital Dash N o is e ...................................................................................................................9A-10
Chart 5 Ignition N oise.............................. ............................................................................................................9A-11
Chart 6 Antenna Noise Part 1 ........................................................................................................................... 9A-12
Chart 7 Antenna Noise Part 2 ........................................................................................................................... 9A-13
Chart 8 W e a k..........................................................................................................................................................9A-14
Chart 9 A lternator W h in e .................................................................................................................................... 9A - 15
Chart 10 D e a d ........................................................................................................................................................9A-16
Chart 11 T a p e ........................................................................................................................................................9A-17
Accessory N oise..................................................................................................................................................... 9A - 18
Diagnostic RF S n iffe r............... .............................................................................................................................9A-20
Radio Receiver R e p la ce m e n t..................................................................................................................................9A-21
CK M o d e ls................................................................................................................................................................ 9A-21
G V a n ......................................................................................................................................................................... 9A-21
Antenna R eplacem ent...............................................................................................................................................9A-23
CK M o d els................................................................................................................................................................ 9A-23
G V a n ......................................................................................................................................................................... 9A-23
Speaker R e p lace m e n t...............................................................................................................................................9A-24
CK M o d e ls................................................................................................................................................................ 9A-24
G V a n ......................................................................................................................................................................... 9A-25
DESCRIPTION
For operation of the factory installed standard and The power, antenna, and speaker harnesses con
optional radios available, refer to the Owners Manual nect to the rear of the receiver.
or radio supplement supplied with the vehicle. Depending on the system, the speakers can be
The receiver is mounted using the front support mounted at the center or end of the dash, in the side
tubes surrounding the control shafts, and a rear sup panels or in the rear corners of the cab.
port bracket. The front support tubes are secured with The antenna may be mounted in the windshield, or
nuts. The rear support bracket is secured with a screw. on the right front corner of the vehicle.
9A-2 RADIO
A. G Van
B. CK Truck
50. Receiver
51. Support Tube
52. Nut
53. Knob Bezel
54. Knob
55. Support Bracket Screw
B-06949
Figure 1Receiver Installation CK & G

w l C K ^ de'S
9 p\cKOp
O sut>viân
9 A -4 RADIO
Figure 3G Speaker Harness

RADIO 9A - 5
Figure 4G Antenna System

9A -6 RADIO
DIAGNOSIS
Since radio problems are most often repaired at 90% of the noises enter via the antenna.
authorized warranty repair stations, the tendency is to A small amount of ignition noise may be normal
remove the set when a problem is reported, without when the HEI is located near the cowl (windshield
any preliminary diagnosis. This results in a large num antennas only).
ber of radios showing up as NO TROUBLE FOUND Coated screws or bolts CAN act as a poor
units when received by the warranty repair stations. ground.
Many times, when this is the case, the trouble usually Windshield antennas are more prone to noise
could have been corrected without removal of the ra and station directivity.
dio, such as noise complaints. Most hoses are conductive unless they have a
The inconvenience of driving without a radio, while white stripe.
the set is being serviced at a warranty repair station, When shielding the dash, wire, hose, etc., use foil
can frequently be avoided if the following quick checks or screen and ground it.
are used to eliminate external radio system problems Weak or fading AM is often caused by improp
before removing the radio for repair: erly adjusted antenna trimmer (when present).
Test the radios outside, with the hood down. Always determine the exact nature of the radio prob
Most noise can be found on weak AM stations lem as an aid to diagnosis. Knowing whether the condi
near the low frequency and end of the band tion is intermittent or constant, whether it occurs with
Ignition noise on FM indicates a possible faulty engine off or running, and whether it occurs with car
HEI system. stationary or moving, will help to pinpoint the problem.
If a test antenna is used, ground the base to the Use Chart 1 to isolate radio problems, then proceed to
car body and DO NOT HOLD THE MAST. the diagnostic charts.
RADIO 9A -7
B-06920
Figure 5Chart 1
9A -8 RADIO
Figure 6Chart 2 (Noisy Part 1)

RADIO 9A -9
CHART 3
NOISY - PART 2
W ith radio powered up
and all speakers and an
tenna connected, slowly
pull radio in and out of
the instrum ent panel and N o is e re m a in s e ith e r
Noise elim inated when
check for noise. way. ____
out. ________________
Shield the entire wiring Noise is entering on one

harness next to the radio of the power lines - igni
u s in g a lu m in u m tap e . tion or memory. (Memory
T h e a lu m in u m ta p e line is used only w ith
MUST BE GROUNDED ETRs).
Insta ll a 1224205 filte r

Noise remains.
package on the ignition
line. Try the black wire of
the filte r package con
| Noise eliminated n e c te d and d is c o n
n e c te d , and use
w hichever works better.
Noise
Noise eliminated. remains.
In sta ll a 1224205 filte r
package on the memory
line. ETRs are the only
radios with memory lead.
(Memory lead is orange
wire in the two or three
wire connector).
Noise
Noise eliminated. I remains.
Determine which of the
follow ing three noises is
present and suppress the
n o is e at th e s o u rc e ,
using inform ation from
REFER TO IG N IT IO N the appropriate chart.
NOISE REFER TO
Ig n itio n noise may be ALTERNATOR WHINE
REFER TO
id e n tifie d as a bacon Alternator whine may be
ACCESSORY NOISE
frying or constant pop identified as a siren type Accessory noise may be
ping noise th a t varies n o ise o r h ig h p itch e d id e n ifie d as a tu rn -o n
with engine RPM. whine that varies with en pop or a blower m otor
gine RPM. noise.___________________
B-06922
Figure 7Chart 3 (Noisy Part 2)

9A -10 RADIO
CHART 4
ECM OR DIGITAL DASH NOISE
Noise eliminated. Remove the fuse to the Noise remains.

digital dash.
Noise in digital dash. Noise in ECM.
Try the follow ing fixes in Try the following fixes in

the given order: the given order.
1. Install 1224205 filte r 1. Install a 1224205 filte r
packages on BOTH package to the igni
the battery and igni tion power line (pink
tion power leads to and black wire) of the
th e d ig it a l d a s h . ECM. The black wire
These should be tried of the filte r package
with and without the s h o u ld fa c e aw ay
1224205s black lead from the ECM. The
attached to ground, filte r should be tried
to determine best re with the filte rs black
sults. Also, the black lead g ro unded and
wire of the filte r pack ungrounded to deter
age must face away m in e b est re s u lts .
from the dash. The black wire of the
2. Install one-piece an filte r must face away
tenna lead-in and run from the ECM.
a b ra id e d g ro u n d 2. Install a 1224205 filte r
strap from the base package to the mem
of the antenna to the ory lead (orange wire,
negative battery ter te rm in a l R) o f th e
minal. ECM. Again, face the
b la c k w ire o f th e
1224205 away from
the ECM.
B-06923
Figure 8Chart 4 (ECM or Digital Dash Noise)

RADIO 9A - 11
CHART 5
IGNITION NOISE
Determine the source of
the ignition noise. ___
1 or 2 cylinders. All cylinders.
I .............................. ...............................................
Try the following fixes in Try the following fixes in

the given order: the given order:
1. Check fo r loose or 1. C h e c k th e g ro u n d
defective spark plug from engine to bulk
wire. head; in s ta ll a
2. Reroute spark plug braided ground strap
wires laying against if necessary.
anything that could 2. In s ta ll a b ra id e d
p o s s ib ly tr a n s m it ground strap on the
n o ise to th e rad io hood.
(w irin g o r s e n s o r 3. C h e ck h e a te r core
leads that travel into ground; clean or in
the passenger com stall braided ground
partment). strap if necessary.
3. Check fo r fa u lty 4. Check air conditioner
spark plug. accum ulator ground;
4. Replace d is trib u to r c le a n o r in s ta ll a
cap and rotor. braided ground strap
if necessary.
5. Move all wiring away
from HEI and spark
plug vvlres.
6. Inspect HEI for the
following and replace
if necessary:
D is trib u to r cap
c a rb o n b a ll
eroded away, or
cracked or loose
cap.
A ro to r w ith
b u rn e d b la c k
spot on wiper or
pits in wiper sur
face.
A faulty coil.
An o ily film on
some of the lead
te rm in a ls o r in
side the cap.
Faulty HEI mod
ule; can cause ig
n itio n noise on
FM only.
B-06924
Figure 9Chart 5 (Ignition Noise)

9A-12 RADIO
I CHART61
ANTENNA NOISE - PART 1
W indshie d antenna Pluo antenna back into the radio.
Place aluminum foil

over the entire dash
top and ground it
Noise eliminated.
w ith c lip leads to
each door and jam
sw itch.
Noise remains
Unplug antenna at Noise remains.
Use a sniffer to lo the cowl.
c a te fro m w h ic h Noise eliminated.
part of the dash the M e a su re g ro u n d
Check the mounting
n o is e is b e in g from lead-in shield
(g ro u n d ) c o n n e c
generated. (at radio end of lead- Good ground.
tio n s o f the co w l
shield. It m ust be in) to good ground,
grounded. using lowest scale Less than
on a digital ohmme 0.2 Ohms
A fte r lo c a tin g the ter.
a rea o f th e d a sh G re a te r th a n 0.2
G ro u n d th e hoo d Ohms
where the noise is
with a short ground
b e in g g e n e ra te d , Check antenna lead-
strap from the cowl.
the follow ing fixes in screws at cowl.
(Scrape the surface
are possible. Scrape area and in
around the m ount
stall shiny screws
ing holes for good
to in s u re a g oo d
contact).
ground.
Noise remains
A g a in m e a su re Less than
Suppress the noise
ground from the an 0.2 Ohms
at the source using
tenna lead-in shield
th e a p p ro p ria te
c h a rt: IG N IT IO N to a good ground.
NOISE, ALTERNA IG re a te r 7 la n 0.2 Ohms
TOR W H IN E , A C R e p la ce th e a n
tenna lead-in. Noise remains.
CESSORY NOISE.
T
Line the underside If a noisy wire or If all else fails, in Suppress the noise
of the dash with alu- c a b le can be lo stalling an outside at the source using
m in u m ta p e , th e cated w it the sniffer, antenna w ill often th e a p p ro p ria te
ta p e M UST BE re-route it or ground elim ina te the c u s c h a rt: IG N IT IO N
GROUNDED. the s h ie ld o f any tom ers complaint. NOISE, ALTERNA
noisy cable. TOR W H IN E , A C
CESSORY NOISE.
B-06925
Figure 10Chart 6 (Antenna Noise Part 1)

RADIO 9A-13
B-06926
Figure 11Chart 7 (Antenna Noise Part 2)

9A -14 RADIO
CHART 8
I WEAK I
AM and FM weak or |Only FM is weak.
only AM is weak.
Compare the FM re
Trim the Antenna* ception to another
See Procedure Be car with an FM ra
low d io . Tune in to a
weak station.
W ont trim or s till
Radio weak.
Works
Check the antenna
STOP system with a test C u s to m e rs ra d io Both radios have rel
antenna. has c o n s id e ra b ly a tiv e ly s im ila r re
weaker reception. ception capabilities.
S till Weak
Return to Normal Remove the Radio. Explain to the cus

Repair the antenna tom er that the radio
Remove t he Radio |
system. Retrim. is normal.
*ETR and 2000 series radios do not have an an

tenna trimmer. Try a substitute antenna.
ANTENNA TRIMMER ADJUSTMENT

The antenna trim m er adjustment matches the
antenna coil in the radio to the antenna. Only
AM radios, or the AM part of AM/FM radios,
need this adjustment. (ETR models and all 2000
series radios use self adjusting circuits, and
do not have an antenna trimmer).
1. Tune the radio to a weak AM station or noise

near 1400 kHz. Turn the volume all the way
up. You should barely hear the station.
2. Remove the right inner and outer knobs.
3. Use a small screwdriver to adjust the trim
mer screw. Adjust the screw for the loudest
volume.
4. Reinstall the control knobs.
B-06927
Figure 12Chart 8 (Weak)

RADIO 9A-15
CHART 9
ALTERNATOR WHINE
I
Noise Remains U n p lu g a n te n n a Noise Eliminated
from the back of the
radio.
Try th e fo llo w in g Try th e fo llo w in g

fixes in the given or fixes in the given or
der: der:
1. In s ta ll a 250 1. In s ta ll a 250
MFD, 100V capa MFD, 100V capa
cito r on the al cito r on the al
terna to r o u tp u t ternator o u tp u t
lead and/or the lead and/or the
brown field wire brown field wire
of the alternator at the alternator.
to ground. 2. Install a 1224205
f ilt e r p a cka g e
on the existing
2. Exchange radio ground wire for
w ith a k n o w n the radio.
g o o d ra d io . If 3. E x c h a n g e th e
th is e lim in a te s ra d io w ith a
the noise, send known good ra
the faulty radio . dio. If this elim i
to an authorized nates the noise,
repair shop. send the faulty
3. D e d i c a t e d ra d io to an
ground fo r the a u th o riz e d re
ra d io receiver. pair shop.
C u t th e b la c k 4. Replace the al
wire of the black ternator.
plug in back of
the radio. Attach
a b ra id e d
g ro u n d s tra p
from the case of
th e ra d io to a
g o o d c h a s s is .
y
'J i t
4. Run a w ire d i
rectly from the
positive battery
term inal to the
alternator.
5. Replace the al
ternator.
B-06928
Figure 13Chart 9 (Alternator Whine)

9A -16 RADIO
CHART 10
DEAD
C h e c k th e ra d io .
Check to see if all
speakers are dead.
(Use fader to check.)
Test the speakers. All modes are dead.

.............l :
Using an ohmmeter, I Check the fuse.
measure from all 8 Fuse Fu se Blown
speaker terminals of i
b lu e and w h ite Check the radio 14V U n p lu g th e ra d io
plugs at the back of at cavity F on the power lead. Replace
radio, to ground. black plug of the ra the fuse.
O ne o r m o re dio. Also, check for
All open shorted 14V on the orange
________ 1 ........ wire of the memory
M e a s u re a c ro s s R e p air o r re p la ce c o n n e c to r on th e
each speaker (A-C, harness. R echeck back of radio. Also,
B-D, etc.) radio. check the speaker
ot open | Open or Shorted Not O K| OK connections at the
w h ite and b lu e
Replace Remove STOP plugs on the back of
Remove speaker or radio. the radio. Refer to
radio. repair diagram below).
connection.
Bad Good
__ C X
Repair Remove radio
AM and FM dead or
AM only dead. Check all the acces
Fuse Blows
I sories on the fuse
Check the antenna for the problem. Re Again
connection. fe r to S e rv ic e Fuse
Good Bad Manual. Test drive if Doesnt
necessary). Blow
Check antenna and Repair the connec-
T
lead-in with a sub tion. P lu g th e ra d io
C o rre c t th e prob-
s t it u t e a n te n n a . power lead back in.
lem.
Radio Works Fuse
Radio Works
No Reception B low s
Stop. Remove the radio.
Remove the radio.* R e p la ce th e
m a lfu nctio n ing an- FM only is dead.
+ 14V ANT.
tenna or lead-in. Re-
trim. Remove the unit. F
BLACK
*When radio has been determined Front and rear speaker harnesses, G
to be defective, be sure to describe and pow er plug c o n n e c to r pin nn
the symptom s to aid the radio tech views.
nician.
L.R.
WHITE BLUE B-06929
Figure 14Chart 10 (Dead)

RADIO 9A-17
*NOTE: Jammed tape cannot be removed from

the search and repeat tape deck. Send the radio
to authorized repair shop.
CLEANING PARTS OF TAPE PLAYER

TO REDUCE TAPE NOISE
There are two parts that you clean on a tape
player; the head and the capstan. Since you can
reach them through the tape door, you can leave
the tape player in the car.
To clean the head and capstan, use a cotton swab
dipped in ordinary rubbing alcohol. Wipe the head
and capstan as shown.
B-06930
Figure 15Chart 11 (Tape)

9A-18 RADIO
B-06950
1. Low Vacuum Switch
2. Solenoid
Figure 16Blower M otor Noise Capacitor 3. EGR Assembly
4. High Vacuum Switch
B-06990
ACCESSORY NOISE
Figure 18Diesel EGR
BLOWER MOTOR NOISE High Vacuum Switch
Install a blower motor feed through capacitor. Attach
one end to the blower motor ana the other end to the
3) Check the system for any vacuum leaks and
hot lead from the blower motor switch. Also, ground the repair.
capacitor ground tab. 4) If the noise still remains, change the EGR control
assembly.
BLOWER SWITCH POP (HIGH SETTING TO OFF)
Install a diode (diode num ber IN4001, or the CRUISE CONTROL POP (TRANSDUCER TYPE)
equivalent diode to withstand a 50V inverse peak For cruise control engage and disengage pops,
voltage) from the high speed switch wire (orange) to install a 0.5 MFD capacitor from the hold line at the
ground on the high speed blower relay under the hood. transducer to ground. If disengage pops are still
present, splice a 0.5 MFD capacitor across the
BRAKE SWITCH POP contacts of the disengage switch at the brake pedal.
Install a 0.5 MFD capacitor between the two wires
going to the brake switch at the brake pedal. Also, HORN BLOW-THRU NOISE OR HASH (STATIC IN
install a 0.5 MFD capacitor from the 14V lead to ground RADIO SPEAKERS WHEN USING HORN)
at the brake switch. Splice blower motor capacitors into each lead. Install
the capacitors as close to the horn as possible. Ground
CLICKING OR POPPING NOISE (DIESEL ENGINE) the case of the capacitor to chassis ground using the
1) The problem will sound similar to ignition noise. metal ground tab on the capacitor. The technician
However, it wont vary with engine speed. Also should solder all connections instead of using quick
the noise will most likely be noticeable only in the connects.
idle condition.
HORN SWITCH POPS
2) The noise is being generated by the high vacuum
1) Install a 0.5 MFD capacitor between the switched
switch in the EGR assembly.
14 volt lead and horn lead at the horn delay.
2) If pop persists, install a 0.5 MFD capacitor from
the switched 14 volt lead of the horn relay to
ground and a 0.5 MFD capacitor from the horn
lead to ground.
MIXTURE CONTROL SOLENOID POPPING

Complaint:
A popping noise which sounds like ignition noise
occuring on the AM band. This noise will NOT vary
w ith engine speed. Also this noise should be
noticeable with the ignition on , and engine off , but
not in accessory position.
Figure 17Diode IN4001

RADIO 9A-19
Figure 19Cruise Transducer Figure 21Horn Switch Capacitors
Problem: REAR DEFOGGER NOISE OR HASH

A broken grid in the defogger in the rear glass may
Noise is being radiated from the mixture control cause a hash in the radio. Repairing this break will
solenoid duty cycle lead to the ALDL connector. eliminate the noise. A break in the rear defogger grid
Fix: can be found by touching each line of the grid while
the rear defogger is on. The cold grid is the one
1) Locate the breakout harness extending from the broken.
main harness, about six inches from the ECM
harness connector. TACHOMETER NOISE
Locate the wire from the distributor cap to the
2) Locate the light blue wire. It should connect to
tachometer and shield the wire by wrapping it with
Pin D on the 15 pin breakout connector.
aluminum tape. The tape must also be connected to a
3) Cut the light blue wire on the vehicle side of the good ground.
connector at the connector.
TORQUE CONVERTER LOCK-UP NOISE
Model:
17
Diesel Engines
16 \ 18 1.9 Complaint:
'f \ V \ >1 Hash or popping noise on AM band after torque

converter lock-up (35-45 mph).
Fix:
1) Install a 1224205 filter package in series with
15. Lead from the Horn Switch green lead on the VRV sw itc h (see the
16. .5 MFD Feed through Capacitor instructions in filter package). For this application,
17. Horn No. 1 connect the ground lead in the filter package to
18. .5 MFD Feed through Capacitor the blue lead on the VRV switch, instead of to
19. Horn No. 2 B-06994 ground.
Install a capacitor (0.5 MFD) from the blue lead
Figure 20Horn Capacitors on VRV switch to ground.
9A-20 RADIO
40 41 /2
^ / /
HUM\
'/
43
40. Antenna Lead In

41. Center Wire
42. White Plastic Insulator
43. 50 mm (2 in.) of Coax Shield Removed
B-09197
Figure 23RF Sniffer
OTHER SWITCH POPS (BLOW ER SWITCHES,

POW ER LO C K S , POW ER M IR R O S , P A R K -
NEUTRAL SWITCH, POWER WINDOWS, WIPERS,
REAR WINDOW DEFOGGER)
Install a 0.5 MFD capacitor rated at 50 VDC across
the contacts of the switch, from the hot side of the
switch to ground or both.
31. To a Test Terminal

32. To the Brake Switch and Fuse Block DIAGNOSTIC RF SNIFFER
33. Filter Package. 1224205
The antenna sniffer can be used along with the cars
34. 4-3 Shift (Momentary open)
radio to locate Hot Spots which are generating radio
35. TCC Solenoid
noise interference. These Hot Spots will be found in
36. 4th Gear Switch (Closed when engaged)
37. Filter Ground Wire the harnesses, in the upper part of the dash or even
B-09193 between the hood and windshield.
The sniffer is made from an old piece of antenna
Figure 22Torque Converter lead-in from a mast or power antenna. The longer the
Lock Up Noise lead-in the better, since it will make the sniffer more
flexible as a diagnostic tool.
Fix: Make the sniffer as shown in figure 23. The 50 mm (2
inch) section with the black coating and braided shield
2) Install a 220 MFD capacitor rated at 50 VDC stripped back becomes the antenna when the sniffer is
across the VRV switch between the green and plugged into the radios antenna socket. It can then be
blue wires. used to probe and search out Hot Spots .
Procedure:
WIPER SWISH WINDSHIELD ANTENNA 1. While listening to the complaint noise, disconnect
the antenna and plug the sniffer into the antenna
The swish sound encountered when the wipers pass socket.
over the windshield antenna is due to a static buildup 2. Turn the radio volume up.
between the windshield and the wiper. Try cleaning the 3. When searching for the noise source, keep
windshield with Opticlean or add a tablespoon of dish fingers off of the probe, otherwise erroneous
soap to the washer bottle. results will be received.
When checking for noise on a wire, the best results
OTHER ELECTRIC MOTOR NOISES (POWER will be achieved when the sniffer is placed parallel to
WINDOWS, BLOWER MOTORS) the wire.
The sniffer can also be used to determine from what
Install a 0.5 MFD capacitor rated at 50 VDC across area of the dash the noise is being generated onto a
o.ich motor. c windshield antenna.
RADIO 9A-21
The sniffer can also be used to locate Hot Spots It must be noted that the sniffer will also locate
between the windshield and the hood that may be normal hot spots. However, the technician who
directing noise onto the windshield antenna. becomes familiar with the sniffers capabilities will find
it the most useful diagnostic tool in noise suppression
work.
RADIO RECEIVER REPLACEMENT
C-K MODELS Retaining nuts (52)
0
Rear mounting bracket screws (55)
Power, speaker and antenna leads
Remove or Disconnect (Figure 24) Push receiver forward.
Lower receiver.
1. Battery ground cable Disconnect leads.
2. Control knobs (54) 10. Receiver (50)
3. Knob bezels (53)
4. Nuts (52) from the support tubes (51) Install or Connect (Figure 24)
5. Support bracket retainer screws (55)
6. Harnesses 1. Power, speaker and antenna leads.
Lift up the rear edge of the receiver. 2. Receiver (50)
Push the receiver forward until the control Raise receiver into place.
shafts clear the instrument panel. Move receiver rearward so that the control
Lower the control shafts. shafts are in the mounting holes.
Remove the power feed, speaker and 3. Rear mounting bracket screws (55).
antenna connectors. 4. Retaining nuts (52) on the supporting tubes (51).
7. Receiver (50) 5. Knob bezel (53).
6. Control knobs (54).
-+ Install or Connect (Figure 24) 7. Air cleaner element.
1. Receiver (50) 9. Engine cover.
Position the receiver under the instrument 10. Battery ground cable.
panel.
NOTICE: Always connect the speaker wiring
Connect the power, speaker and antenna
harness to the receiver before applying power
leads.
to the receiver in order to prevent receiver
Lift the rear of the receiver into place.
damage.
Move the receiver rearward so that the
control shafts slide through the control shaft
holes in the instrument panel.
Support bracket screws (55)
Nuts (52) on the support tubes (51)
Knob bezels (53)
Control knobs (54)
Battery ground cable
G VAN
1. Battery ground cable

2. Engine cover
3. Air cleaner cover
4. Air cleaner element
5. Control knobs (54)
6. Knob bezels (53)
9A-22 RADIO
52. Nut
53. Knob Bezel
54. Knob
55. Support Bracket Screw
B-06949
Figure 24Receiver Installation CK & G

RADIO 9A-23
ANTENNA REPLACEMENT
"+ Install or Connect
1. Washer (51)
2. Body and cable assembly (50)
3. Seal (52)
4. Seal (54) and bezel (53)
5. Nut (55)
6. Nast (57)
7. Mast retaining nut (56)
CK MODELS

2. Antenna cable connector
3. W indow . R e fer to Sec. 10 W in d s h ie ld
Replacement .
1. W indow . R e fer to Sec. 10 W in d s h ie ld

Replacement .
2. Antenna cable connector
G VAN
|<--| Remove or Disconnect (Figure 26)

2. Mast retaining nut (56)
3. Mast (57)
4. Nut (55)
5. Seal (54) and bezel (53)
6. Seal (52)
7. Body and cable assembly (50)
8. Washer (51)
9A -24 RADIO
50. Body and Cable Assembly

51. Washer
52. Seal
53. Bezel
54. Seal
55. Nut
56. Mast Retaining Nut
57. Mast
B-09198
Figure 26G Van Antenna System
SPEAKER REPLACEMENT
A
C-K MODELS 7. Battery ground cable
REAR SPEAKER
FRONT SPEAKER
|<-+| Remove or Disconnect (Figure 27)
2. Grill retaining screws (90)
2. Instrument cluster bezel upper four screws
3. Instrument panel pad screws 3. Grill (80)
4. Pad (70) 4. Speaker retaining screws (82)
5. Speaker to dash panel screws (72) 5. Speaker harness from the speaker (81)
6. Speaker harness
6. Speaker (81)
Lift up speaker (71)
7. Speaker (71)
Install or connect (Figure 28)
0 Install or connect (Figure 27)

1. Speaker harness to the speaker
1. Speaker harness to speaker (71) 2. Speaker (81)
2. Speaker (71) 3. Speaker retaining screws (82)
3. Speaker to dash panel screws (72)
4. Grill (80)
4. Pad (70)
5. Instrument panel pad screws 5. Grill retaining screws (82)
6. Instrument cluster bezel upper four screws 6. Battery ground cable
RADIO 9A-25
G VAN 5. Instrument panel bezel

FRONT SPEAKER REAR CORNER SPEAKER
|+ + | Remove or Disconnect (Figure 29) Remove or Disconnect (Figure 30)
1. Battery ground cable 1. Battery ground cable.

2. Instrument panel bezel 2. Lower corner trim panel (114).
3. Instrument cluster 3. Lower edge screws of the upper corner trim panel
4. Speaker screws (102) (110).
5. Speaker connector (101) 4. Trim strip (115) screws.
6. Speaker (100)
5. Rear door upper molding (113) screws.
6. Upper corner trim panel (110) upper screws.
7. Upper corner trim panel assembly (110).
1. Speaker connector (101) to the speaker (100) 8. Horness connector from the speaker.
2. Speaker (100) 9. Insulation retaining screws.
3. Speaker screws (102) 10. Insulation (112).
4. Instrument cluster 11. Speaker retaining screws.
9 A -2 6 RADIO
A. CK Pickup 84. Insulator

B. U tility 85. Insulator
C. Suburban 86. Bracket
80. Grille 87. Bracket Retaining Screw
81. Speaker 88. Speaker Retaining Screw
82. Speaker M ounting Screw 89. Trim Panel
83. Clip Nut 90. Grille Retaining Screw
B-09205
Figure 28CK Rear Speakers
12. Speaker (111) from the upper corner trim panel

(110).
1. Speaker (111) to the upper corner trim panel (110).

2. Speaker retaining screws.
4. Inslulation retaining screws.
5. Harness connector to the speaker.
6. Upper corner trim panel assembly (110).
7. Upper corner trim panel screws.
8. Rear door upper molding (113) screws.
9. Trim strip (115).
10. Trim strip (115) screws.
11. Lower corner trim panel (114).
RADIO 9A-27
120. Speaker
121. Nut
122. Harness Connector
B-09247
Figure 31G Van Rear Side Speakers

110. Upper Corner Trim Panel
111. Speaker REAR SIDE SPEAKER
112. Speaker Insulation
113. Rear Door Upper Molding Remove or Disconnect (Figure 31)
114. Lower Corner Trim Pane!
115. Trim Strip B-09219 1. Battery ground cable.
2. Four forward lower screws retaining the rear trim
panel.
Figure 30G Van Rear Corner Speakers
Pull the trim panel out to reach the speaker.
3. Harness connector from the speaker.
4. Speaker retaining nuts.
5. Speaker.
1. Speaker.
2. Speaker retaining nuts.
3. Harness connector to the speaker.
4. Rear trim panel screws.
C-K-G-P TRUCK CRUISE CONTROL 9B-1
SECTION 9B
CRUISE CONTROL
CONTENTS
Cruise Control ...................................................... ....................................................................... 9B-1
General Description ........................................ ....................................................................... 9B-1
Operation ........................................................... ....................................................................... 9B-1
Diagnosis ........................................................... ....................................................................... 9B-3
On-Vehicle Service ........................................... ....................................................................... 9B-4
GENERAL DESCRIPTION slider switch is released, the speed the vehicle

accelerated to becomes the new cruise speed. In order
Cruise control is a speed control system which to use the Accel mode, the cruise
maintains a desired vehicle speed under normal driving Off/On/Resume/Accel switch must be in the "On"
conditions. However, steep grades up or down may position and the vehicle must be above the low speed
cause variations in the selected speeds. The electronic inhibit lockout (25 mph). The slide switch can also be
cruise control system has the capability to cruise, coast, used to "tap-up" vehicle speed. In order to do this the
resume speed, accelerate, and "tap-up" and cruise must be engaged and operating. "Tapping-up"
"tap-down". is done by quickly pressing the slide switch, not more
The main parts of the cruise control system are than one second, toward the R /A position and quickly
the mode control switches, controller (module), servo releasing it, or "tap" the lever. Do not hold the lever
unit, speed sensor, vacuum supply, electrical and in the R /A position or the system will revert to the
vacuum release switches, and electrical harness. Accel mode. "Tap-up" is a function in which cruise
The cruise control system uses vacuum to operate speed can be increased by 1 mph increments (one tap
a throttle servo unit. The servo unit maintains a desired = 1 mph increase) up to ten times, after 10 times the
vehicle speed by trapping vacuum in the servo unit at system must be reset to a new speed to continue this
the proper servo position. The controller monitors function.
vehicle speed and servo position and operates the
vacuum and vent valves in the servo to maintain
desired speed. The controller contains a low speed limit
which will prevent system engagement below a
minimum speed, about 25 mph. The operation of the
controller is controlled by mode control switches
located in the end of the directional signal lever. To
disengage the system, two release switches are
provided. An electrical release switch mounted on the
brake pedal bracket (and clutch pedal bracket on
vehicles equipped with manual transmission)
disengages the system electrically when the brake pedal fTI D IR E C T IO N A L [ T ) OFF/O N/R ES UME /A CCE L SWITCH
(or clutch pedal) is depressed. A vacuum release valve, SIG NA L LEVER [ T ] S E T /C 0 AST SWITCH . . QR1
mounted on the brake pedal bracket, vents the trapped
vacuum in the servo to atmosphere when the brake Figure 9B-1 M ulti-Function Lever
pedal is depressed, allowing the servo unit to quickly
return the throttle to idle position.
SET/COAST BUTTON SWITCH
OPERATION (Figure 9B-1)
OFF/ON/RESUME/ACCEL SWITCH The cruise control Set/Coast Switch (located in
the end of the turn signal lever) has two positions -
(Figure 9B-1) "Normal" and "Depressed".
The Off/On/Resume/Accel Switch has three T h e S e t P o s itio n - With the button switch
positions. This switch turns the cruise control system depressed and then released (vehicle speed must
ON and O FF and also returns cruise control operation exceed the low speed limit point, and the
to the last speed setting when MOMENTARILY Off/On/Resume/Accel Switch must be in the
moved towards the R /A position after braking. (Do ON position) the cruise speed will be set at the
not hold the slider in the R /A position ... release it particular speed the vehicle was at when the
immediately.) If the slider is held in the R /A position button was released. Vehicle cruise speed will be
for more than one second, the system reverts to the within + 1 mph of the actual speed at engaged
Accel mode. To accelerate the vehicle, move the slider speed. The system will cruise until either the
switch to the R /A position and hold it there until the Off/On/Resume/Accel Switch is moved to OFF,
vehicle reaches the desired increased speed. When the the ignition switch is turned off, and/or the
9B-2 CRUISE CONTROL C-K-G-P TRUCK
Set/Coast Button is pushed in fully and held.

Pushing the brake pedal (or clutch pedal) releases
the cruise but not the resume capability.
The Coast (Trim) Position - With the button
switch fully depressed, the driver can raise or
lower his control speed. To increase control
speed, the driver would accelerate to a new speed,
fully depress the switch (controller releases
previously set speed) and release the button.
Upon releasing the button a new speed is set. An
increased control speed can also be more easily
set by the Off/On/Resume/Accel Switch as
previously described. To decrease cruise speed,
the button switch is held in (depressed position)
disengaging the cruise system, and allowing the
throttle to return to the idle position. When the
vehicle has slowed to the desired lower cruise
speed, releasing the switch will re-engage the
system. Figure 9B-2 C ontroller (Module)
The "Tap-Down" Position - In order to do

this the cruise must be engaged and operating.
"Tapping-down" is done by quickly pressing the
Set/Coast Button (not more than .4 second) to
the depressed position and quickly releasing it, or
"tap" the button. Do not hold the button in the
depressed position or the system will revert to the
"coast" mode. "Tap-down" is a function in which
cruise speed can be decreased by 1 mph
increments (one tap = 1 mph decrease). The
system can "tap-down" until it reaches the low
speed lockout (25 mph), after this cruise will not
operate.
The accelerator may be depressed at any
time to override the cruise system. TO V A C U U M
Release of the accelerator w ill return the SUPPLY
TO VA C U U M BRAKE
RELEASE V A L V E
vehicle to the previous set cruise speed.
m SERVO
m V A CUUM SOLENO ID AND

V A L V E ( N O R M A L L Y CLOSED)
NOTICE: To keep the vehicle under control, and
to prevent possible vehicle damage, it is not m coil
advisable to use the Resume Cruise Control on [T ] V A R I A B L E INDUCTANCE

POSITION SENSOR
slippery roads. It is not recommended to use the
| 5 | VE NT SOLENOIO A ND V A L V E
cruise control in conditions such as on winding
roads or in traffic of heavy or varying volume. (N O R M A L L Y OPEN)
When traveling down a steeply graded hill, the [ 6 1 STEEL CORE

cruise control should be disengaged by depressing [~7~~| T H R O T T L E A T T A C H M E N T
the brake pedal lightly. The transmission can then 449B3
be shifted into a lower gear range to help control
Figure 9B-3 Servo U nit
vehicle speed.
ELECTRONIC CONTROLLER (MODULE) SERVO UNIT

(Figure 9B-3)
(Figure 9B-2)
The servo consists of a vacuum operated
The controller interprets the position of the servo, diaphragm, a normally open solenoid valve to vent the
the position of the mode control switches and the diaphragm chamber to atmosphere, a normally closed
output of the speed sensor. In response to these inputs, solenoid valve to connect the diaphragm chamber to
the controller electrically signals the opening or closing the vacuum source, and a variable inductance position
of the vent and vacuum solenoid valves in the servo. sensor. The servo operates the throttle in response to
signals from the electronic controller as follows:
For mounting location, turn to the On-Vehicle Service Steady Cruise State (system engaged and
portion of this section. operating) - Both vacuum and vent valves are
closed or sealed. The servo has a constant vacuum
on the diaphragm and places no-flow

requirements on the vacuum source. Vacuum is
trapped in diaphragm chamber.
Vehicle Losing Speed (due to steep grades or
driver wishes to increase speed by operating mode
control switches) - The controller energizes the
vacuum solenoid to open the vacuum valve to the
vacuum source. This increases the vacuum level
in the servo to increase the throttle opening. The
vent remains closed.
Vehicle Gaining Speed (due to steep grades
or driver wishes to decrease speed by operating
mode control switches) - The controller
de-energizes the vent solenoid to open the vent
valve to the atmosphere which reduces vacuum
in the servo and allows the throttle return spring
to decrease the throttle opening. The vacuum
valve remains closed.
When the cruise system is engaged and operating
(without any interference from the driver via the mode
control switches), no speed correction will be made from a L.E.D. in the optic head. As each blade enters
until the vehicle exceeds approximately + 1 / 4 mph of the L.E.D. light beam, light is reflected back to a
set speed. photocell in the optic head causing a low power speed
When the controller senses an over or underspeed signal to be sent to a buffer for amplification and signal
condition it will pulse the opening of the vent or conditioning. This amplified signal is then sent to the
vacuum valve. The average duration of one pulse will controller.
be 10 milliseconds. The pulse will be repeated, as
required, until the speed correction required brings the VACUUM SUPPLY
vehicle to the set speed. From any set speed, under
normal road load conditions, the vacuum valve will The vacuum supply to operate the Cruise Control
remain in a completely open position when vehicle system is routed to the servo. This can be done by
speed has dropped 5 mph below set speed. Likewise, routing manifold vacuum straight to the servo or from
when vehicle speed has exceeded 3 mph over the set manifold through a vacuum storage tank.
speed, such as down a steep grade, the vent will go into
constant open position. ELECTRICAL AND VACUUM RELEASE
The servo incorporates a steel core which moves SWITCHES
within a coil. Its resulting variable inductance provides
These switches are used to disengage the cruise
a continuous (voltage) servo position signal to the
control system. An electrical release switch mounted
controller. This voltage signal is constantly compared
to the vehicle speed signal. This comparison on the brake pedal bracket (and clutch pedal bracket
on vehicles equipped with manual transmission)
determines if the pulses issued have corrected the speed
disengages the system electrically when the brake (or
error or if additional pulses are required. This
clutch) pedal is depressed. This is done by interrupting
comparison is also used to lengthen the average pulse
when it is not enough to compensate for the speed the flow of current to the controller. A vacuum release
error, such as a steep grade. valve, mounted on the brake pedal bracket vents the
trapped vacuum in the servo to atmosphere when the
The servo will go into an open vent valve position brake pedal is depressed, allowing the servo unit to
under the following conditions: more quickly retain the throttle to idle position. This
When the brake (or clutch) pedal is depressed. is done by routing a separate hose directly to the servo
An open variable inductance position sensor coil from the normally closed vacuum switch. These two
in the servo. types of switches will also sometimes be combined with
A loss of electrical power to the system. stop light switch, TCC switch, etc. See On-Vehicle
The ignition is turned off. Service.
SPEED SENSORS DIAGNOSIS

VSS Buffer Amplifier PRELIMINARY INSPECTION
(Figure 9B4) An undesirable cruise control performance
symptom can be mechanical, vacuum, electrical or a
This is the device that will supply the vehicle combination of the three. In all cases perform a visual
speed input to the controller. The optic head portion
inspection of all components in the cruise system.
of the VSS is located in the speedometer frame. A
Things to check are:
reflective blade is attached to the speedometer
cable/head assembly. The reflective blade spins like a Disconnected or damaged wiring
propeller, with its blades passing through a light beam Pinched, cracked or disconnected vacuum hoses
Cracked or broken vacuum fittings at the servo Follow the servo test, Figures 9B-5, 9B-7 and
or accumulator 9B-8. Replace the servo if required.
Correct positioning of the check valve in the If no system problem is noted, replace the
servo and accumulator line electronic controller (module).
Damaged Components
CRUISE SET SPEED HIGH OR LOW
NOTICE: To avoid breaking vacuum ports, care Check vacuum hoses for proper routing,
must be exercised in removing vacuum hoses from restrictions or leaks. Adjust or replace as
fittings. If necessary cut hose. required.
Check servo linkage for excess slack and adjust
TEST PROCEDURES as described in the On-Vehicle Service portion of
CRUISE SYSTEM INOPERATIVE this section.
Incorrect module usage, check module for
1. Perform the voltage and resistance checks shown correct part number.
in Figure 9B-5. Servo resistance measurement If no system problem is noted, replace the
(vent valve control or vacuum valve control) can electronic controller (module).
be made at the servo as shown in Figure 9B-7.
2. Perform the following vacuum servo tests: EXCESSIVE CRUISE SPEED LOSS ON HILLS
Perform preliminary inspection
Check hoses for vacuum leaks.
Disconnect the bead chain, cable (or rod)
Determine if check valve is functional.
and electrical connector at servo
Check vacuum hose routing. Correct as
Start the engine or apply vacuum to the necessary.
servo vacuum port
Proceed to Figure 9B-8 Vacuum Servo CRUISE "TAP-UP" & "TAP-DOWN"
Tests DOES NOT OPERATE
3. Check electrical operation of the mode control
switches by replacing the switch with a known If all other functions of cruise cont rol are working
good switch . Perform the tests shown in 9B-9 except "tap-up" and "tap-down" the controller
Mode Control Switch Test. (module) is at fault.
A quick check box is available through ON-VEHICLE SERVICE
Kent-Moore Tool Company under Tool Number
J-34185 (or equivalent). This quick check box will plug Servo Mounting
in in place of the controller and determine which part See particular engine application.
of the system has a problem. Instructions on the
operation of this tool will be provided with the tool. Vacuum Hose Routing
CRUISE SYSTEM SURGES See particular engine application.
The servo and throttle linkages should operate Controller (Module) Location
freely and smoothly. This linkage should be
adjusted as described in the On-Vehicle Service See Figure 9B-10.
portion of this section.
Check for dry speedometer cable, lubricate as Release Switch and Valve Adjustments
required. See Figure 9B-11.
Check for high voltage spikes on B + line, repair
as required. Engagement Switch
Check for excessive grease in speedometer head, The cruise control engagement switch is part of
replace speedometer. the turn signal lever assembly and is not serviceable by
Check hose routing for pinches, leaks or itself. The turn signal lever must be replaced as an
restrictions, including three way check valve. assembly as shown in Figure 9B-12.
VOLTAGE CHECK MODULE CONNECTED
SPECIFIED
VOLTAGE TO
TEST TER M INA L FUNCTION GROUND CO NDITIO NS
BRAKE INPUT 12V ...................... BRAKE/CLUTCH NOT APPLIED

Vi G OV ...................... BRAKE/CLUTCH APPLIED
CRUISE ON-OFF 12V ...................... SLIDER SWITCH ON

v2 A INPUT OV ...................... SLIDER SWITCH OFF, SET/COAST DEPRESSED
OR NORMAL
RESUME/ACCEL 12V ...................... SLIDER SWITCH IN R/A POSITION

V3 M INPUT OV ...................... SLIDER SWITCH ON, SET/COAST DEPRESSED
OR NORMAL
OV ...................... SLIDER SWITCH OFF, SET/COAST
DEPRESSED OR NORMAL
SET/COAST 12V ...................... SLIDER SWITCH ON, SET/COAST DEPRESSED

V4 L INPUT OV ...................... SLIDER SWITCH ON, SET/COAST NORMAL
OV ...................... SLIDER SWITCH OFF, SET/COAST NORMAL
CRUISE
Vs B LAMP 12V ...................... CRUISE ENGAGED
SPEED GREATER THAN DRIVE WHEELS ROTATING ON

V. D SIGNAL 4V HIGH, APPLICATIONS LISTED
NEAR OV LOW
RESISTANCE CHECK MODULE DISCONNECTED
SPECIFIED
TEST TERMINAL FUNCTION RESISTANCE CONDITIONS
C TO VENT VALVE 30-5511 ................ MEASURED TO GROUND, SERVO CONNECTED

Ri GROUND CONTROL OPEN CIRCUIT . . . MEASURED TO GROUND, SERVO DISCONNECTED
F TO H SPS HIGH, 15-250 ................ MEASURED F TO H, SERVO CONNECTED

F TO
GROUND
r2 H TO SPS LOW OPEN CIRCUIT . .. MEASURED F AND H TO GROUND,
GROUND SERVO DISCONNECTED
K TO VACUUM VALVE 30-55(1 ................ MEASURED TO GROUND, SERVO CONNECTED

Ra GROUND CONTROL OPEN CIRCUIT . .. MEASURED TO GROUND, SERVO DISCONNECTED
J TO
R4 GROUND GROUND on .................. MEASURED TO VEHICLE GROUND
Figure 9B-5 Custom Cruise III Voltage and Resistance Values

CONTROL
MODULE NORMALLY OPEN
CONNECTOR CRUISE MOOE CONTROL
JG N_1_
GND
SPEED SIGNAL (C 3l
SPEED SIGNAL (CRUISE)
CUSTOM CRUSE III
Figure 9B-6 Custom Cruise III System Schem atic (Typical)

SERVO CONNECTOR DISCONNECTED MEASURE AT SERVO PINS
PIN FUNCTION RE SIS TA N CE CONDITIONS
D lo B SPS 15-25 n MEASURED BETWEEN PINS D AND B

(IF MEASURED RESISTANCE IS NOT STATED VALUE, REPLACE SERVO)
A to C VENT VALVE 30-55 n MEASURED BETWEEN PINS A AND C
E toC VACUUM VALVE 30-55 n MEASURED BETWEEN PINS E AND C
Figure 9B-7 Servo Resistance M easurem ent
Test Action Reaction
1 Apply 12 volts to A and E, then ground C Servo should full stroke. If not, check
(A-C closes the normally open vent vacuum hoses to the vacuum supply.
valve E-C opens the normally closed
vacuum valve)
2 Remove voltage from E The servo should hold a full stroke. If not,
go to the next step. If servo holds, go
to step 4.
3 Disconnect the vacuum brake release at If the servo holds its position, adjust the
the servo and plug the servo. Momen brake vacuum release valve or replace
tarily apply 12 volts to E to allow the the valve.
servo to full stroke.
4 Turn Ignition ON Vacuum release valve should engage.

Turn Ignition "OFF and With a properly adjusted brake switch,
disconnect vacuum valve connector battery voltage should be present
at the valve. Turn Ign. ON across the (2) connector terminals.
No battery voltage indicates an open circuit.
Figure 9B-8 Vacuum Servo Tests

SET/COAST POSITION 1-2 1-3 1-4 2-3 2-4 3-4

(S/C ) SW SUDER C-B C-D C-A B-D B-A D-A
Normal Off O 0 0 0 0 0
Normal On 0 0 0 0 c 0
Normal R/A c o c 0 c 0
Depressed Off o o 0 c 0 0
Depressed On 0 0 0 c c c
Depressed R/A c c c c c c
C C losed
O Open
TERMINAL "B"
GREEN WIRE. TOP, #2
TERMINAL C
YELLOW WIRE. BOTTOM, #1 C
\ ___r;
1*
c
-
\
TERMINAL "A" N
BLUE WIRE, TOP, #4 TERMINAL D"
RED WIRE. BOTTOM. #3
Figure 9B-9 Mode Control Sw itch Test
Figure 9B-10 C ontroller (Module) M ounting

R ETAIN E R
CLUTCH RELEASE SWITCH
CLUTCH PEDAL
BRAKE PEDAL BRACKET
l/P W IR IN G HARNESS
ACTUATO R
V A L V E ASM (A U TO M A TIC )
V A L V E ASM (M A N U A L)
STOP LAMP SWITCH
IN S T A L L A T IO N OF SELF AD JU STIN G CRUISE IN S T A L L A T IO N OF SELF ADJU STING

C O N TRO L CLUTCH RELEASE SWITCH (G V A N ) V A C U U M RELEASE V A L V E
1. Install retainer m 1. Install retainer .

2. With clutch pedal depressed, insert switch [ 2 | into 2. With brake pedal depressed, insert valve I 7 | or | 8 [
tubular clip until switch body seats on clip. Note that into tubular retainer u n til valve seats on retainer. Note
audible "c lic k s " may be heard as threaded portion of that audible "c lic k s can be heard as threaded portion
switch is pushed through the clip toward the clutch o f valve is pushed through the retainer toward the brake
pedal. pedal.
3. Pull clutch pedal fu lly rearward against pedal stop, until 3. Pull brake pedal fu lly rearward against pedal stop, until
audible " c lic k " sounds can no longer be heard. Switch audible " c lic k " sounds can no longer be heard. Valve
w ill be moved in tubular clip providing adjustment. w ill be moved in tubular retainer providing adjustment.
4. Release clutch pedal and then repeat step # 3 to assure 4. Release brake pedal, and then repeat step # 3 , to assure
that no audible " c lic k " sounds remain. that no audible " c lic k " sounds remain.
CRUISE C O NTRO L CLUTCH RELEASE SWITCH

AD JU STM EN T PROCEDURE (C-K TRUC K)
1. Install switch asm w ith slider (A) in the "as received"

position.
2. Care must be taken that the clutch pedal is not moved in

such a manner th a t the slider is moved u n til all mats
and/or carpets are installed in the vehicle.
3. When all mats and/or carpets are in place the clutch

pedal should be depressed to the flo o r mat and/or carpet
in order to adjust the switch by moving the slider (A)
along the shaft (B) a "c lic k in g " noise can be heard when
CW' this is happening.
4. If the slider is moved prem aturely or accid e n ta lly

resulting in an "a djustm e n t p rior to what has been
specified, the slider can be easily moved rearward along
the shaft to a fu lly unadjusted "as received" position.
5. Failure to observe these requirements w ill result in a

tru ck needing excessive clutch pedal to actuate the
neutral start switch; or in some cases, a "n o s ta rt
co n d itio n.
Figure 9B-1 1 Release Sw itches and Valves

ATTACH TERMINAL TO MUSIC INSTALL LEVER BY ALIGNING TANG

WIRE & PULL THROUGH COLUMN AND PUSH STRAIGHT IN UNTIL
UNTIL SLACK IS REMOVED SEATED IN SPRING RETAINER
MUSIC
WIRE
TOOL
INSERT TOOL INTO

OPENING & ROUTE
THROUGH COLUMN AS
SHOWN SLIDE PROTECTOR OVER
LEAD FROM LEVER,
THEN SLIDE PROTECTOR
OVER RIB ON MAIN WIRE
CONDUIT UNTIL LOWER
ENDS OF BOTH
PROTECTOR & MAIN
WIRE CONDUIT ARE EVEN
POSITION COLUMN AS FOLLOWS:
1. SHIFT LEVER IN LOW POSITION
2. TURN SIGNAL SWITCH IN RIGHT TURN POSITION
FOR TILT COLUMN INSTALLATION, COLUMN IS TO

BE IN FULL UP POSITION 1B9B1
Figure 9B-1 2 Cruise Control Lever Assem bly (Turn Signal Lever)
1.0 TO 0
B
V IE W 0 g van
1. SERVO ASM 0.2 TO

2. ROD
3. R ETAIN E R
4. STUD (17 N-m)
5. NUT V IE W [ a ] C-K TRUCK
6. BOLT/SCREW (2.0 N m)
7. TAB (SERVO ASM)
8. LEVER (CARB)
9. SERVO BR ACKET
SERVO ASM TO CARBURETO R ADJU STM EN T
W ith ignition o ff and fast idle cam o ff and th ro ttle com pletely
closed, hook [ 2] through tab on servo asm. Adjust length so
that [ 2] assembles over end o f [4~] as shown (see View A).
Install [T ] .
C A U TIO N Flexible components (hoses, wires, conduits, v i e w (b ]

e;c.) must not be routed w ith in 50.0m m o f moving parts
o f accelerator linkage forw ard o f servo asm unless routing
is positively controlled.
Figure 9B-13 Servo M ounting (V8 Gas)

V IE W 0
V IE W ff]
SERVO ASM TO C AR BURETO R ADJU STM EN T

1. SERVO ASM 5. NUT (8-12 N-m)
2. R E T A IN E R 6. BOLT/SCREW (2.0 N-m) With ignition o ff and fast idle cam o ff and th ro ttle com pletely
3. ROD ASM. 7. SERVO BR ACKET closed, hook | 3) through tab on servo asm. Adjust length so
4. STUD 8. LEVER that |_3] assembles over end o f [_4j as shown (see View A).
Install [ 2] .
Figure 9B-14 Servo M ounting (V6)
1. HOSE ASM
2. CRUISE CABLE ASM
3. STRAP
4. CONNECTOR
5. HOSE
6. AC C ELER A TO R CABLE
7. R ETAIN E R
8. SERVO ASM
9. SERVO BRACKET
10. R A D IA T O R SUPPORT
CRUISE CO NTRO L CABLE ADJUSTM ENT
W ith cable installed to cable bracket and th ro ttle , install cable

to servo bracket. Using th ird ball o n ly on servo chain, install
servo chain on cable w ith th ro ttle com pletely closed (ignition
o ff & fast idle cam o ff) adjust cable jam nuts u n til cable sleeve
at th ro ttle lever is tig h t but not holding th ro ttle open. Tighten
jam nuts to specified torque. Pull rubber boot over washer on
cable.
C A U TIO N Having secured all components o f the accelerator,

detent and cruise linkage as specified, linkage must operate
freely w ith o u t bind between fu ll closed th ro ttle and fu ll wide
open th ro ttle .
Figure 9B-15 Servo M ounting (G Van Diesel)

1 . HOSE ASM
2. R E T A IN E R V IE W 0
3. ROD L IN K
4. SERVO ASM
5. BOLT/SCREW
6 . SERVO BR ACKET
7. ACC ELERATO R CABLE
8 . LEVER
SERVO ROD L IN K ADJU STM EN T
W ith engine not running and idle bolt/screw against stop,

assemble rod lin k QF] to th ro ttle lever stud and then to servo.
Choose hole closest to servo which w ill provide a m aximum o f
1.0 mm slack. See View C.
C A U T IO N . Having secured all components o f accelerator,

detent, and cruise linkage as specified, linkage must operate
freely w ith o u t bind between fu ll closed th ro ttle , and fu ll wide
open th ro ttle .
Figure 9B-16 Servo M ounting (C-K Diesel)
l~ T ] | NOTE | MUST BE ROUTED HOSE ASM

B I NOTE~l TAPERED END MUST REA R W AR D OF WSW M OTOR. STRAP
BE TO W ARD V A C U U M SOURCE.
CAP W/O C36/C60
A /C VA C U U M HOSE
VA C U U M T A N K
SERVO ASM.
V A C U U M F IT T IN G
CHECK V A L V E
V IEW A
Figure 9B-17 Vacuum Hose Routing C-K Truck (V8 Gas)

I NOTE I IN S T A L L HOSE
ASM TO S M A LLE R F IT T IN G
ON SERVO ASM.
1. HOSE ASM
2. STRAP
3. CAP W/O C36/C60
4. SERVO ASM
5. VA CUUM T A N K
6. A /C VA C U U M HOSE
7. VA C U U M F IT T IN G
Figure 9B-18 Vacuum Hose Routing G Van (V8 Gas)
NOTE | TAPERED END

MUST BE TO W ARD VA C U U M
SOURCE. 1. HOSE ASM
2. STRAP
3. HOSE
4. CAP W/O C60/C36
5. VA CUUM F IT T IN G
6. SERVO ASM.
7. VA CUUM T A N K
8. CHECK V A L V E
V IE W B 9. A /C VA C U U M HOSE
[ NOTE I MUST BE ROUTED

R EA R W AR D OF WSW MOTOR.
V IEW A
Figure 9B-19 Vacuum Hose Routing C-K Truck (V6)

1. HOSE ASM
2. STRAP
3. HOSE
4. CAP W/O C36/C60
5. O IL F IL L TUBE
6. VA C U U M F IT T IN G
7. VA C U U M T A N K
8. SERVO ASM.
9. A /C VACUUM HARNESS
Figure 9B-20 Vacuum Hose Routing G Van (V6)

10A1-1
SECTION 10
BODY
CONTENTS
SUBJECT PAGE
D oors........................................................................................................................................................................... 10A1-1
S e a ts ........................................................................................................................................................................... 10A2-1
G la s s ........................................................................................................................................................................... 10A3-1
Interior T r im .............................................................................................................................................................. 10A4-1
End G a te .................................................................................................................................................................... 10A5-1
SECTION 10A1
DOORS
CONTENTS
SUBJECT PAGE
C/K Model Side Front D o o r..................................................................................................................................10A1- 4

Door And Hinge Replacem ent......................................................................................................................... 10A1- 4
Door A d ju s tm e n t...............................................................................................................................................10A1- 4
Door Trim Panel R e p la ce m e n t...................................................... ................................................................ 10A1- 4
Door Vent/W indow Run Channel Assembly Replacem ent....................................................................... 10A1- 6
Vent Glass R eplacem ent..................................................................................................................................10A1- 7
Vent Window A d ju s tm e n t................................................................................................................................10A1- 7
Door Window Replacem ent............................................................................................................................. 10A1- 7
Inner W indow W eatherstrip R eplacem ent....................................................................................................10A1- 8
Outer W indow W eatherstrip Replacement....................................................................................................10A1- 8
Rear Glass Run Channel Replacement.......................................................................................................... 10A1- 9
W indow Regulator Replacem ent.....................................................................................................................10A1- 9
Door Lock R e p la c e m e n t....................................... .......................................................................................... 10A1-11
Power Door Lock Motor R eplacem ent..........................................................................................................10A1-11
Door Outside Handle R e p la ce m e n t.............................................................................................................. 10A1-12
Door Lock Cylinder Replacem ent...................................................................................................................10A1-12
Door Inside Handle R eplacem ent...................................................................................................................10A1-12
Door W eatherstrip Replacem ent.....................................................................................................................10A1-13
Outside Rear View Mirror Replacem ent........................................................................................................10A1-13
Below Eyeline Outside Rear View Mirror R e placem ent............................................................................10A1-14
West Coast Outside Rear View Mirror R e p la ce m e n t................................................................................ 10A1-14
Door A ir Valve R eplacem ent........................................................................................................................... 10A1-15
C/K Model Side Rear D o o r s ................................................................................................................................10A1-15
Door And Hinge Replacement......................................................................................................................... 10A1-15
Door A d ju s tm e n t...............................................................................................................................................10A1-16
Door Trim Panel R e p la ce m e n t.......................................................................................................................10A1-17
10A1-2 DOORS
SUBJECT PAGE
C/K Model Side Rear Doors (Continued)

Stationary Glass/W indow Run Channel Assembly R e p la c e m e n t.......................................................... 10A1-18
Door Window Replacement............................................................................................................................. 10A1-18
Inner W indow W eatherstrip R eplacem ent................................................................................................... 10A1-19
Outer W indow W eatherstrip Replacement................................................................................................... 10A1-20
Front Glass Run Channel R eplacem ent........................................................................................................10A1-20
W indow Regulator Replacement.....................................................................................................................10A1-20
Door Lock R e p la ce m e n t..................................................................................................................................10A1-21
Power Door Lock Motor R eplacem ent......................................... ................................................................ 10A1-21
Door Inside Handle R eplacem ent.................................................................................................................. 10A1-23
Remote Control R eplacem ent......................................................................................................................... 10A1-23
Door W eatherstrip Replacem ent.....................................................................................................................10A1-23
Door A ir Valve Replacem ent........................................................................................................................... 10A1-23
C/K Model Rear D o o rs.......................................................................................................................................... 10A1-25
Door And Hinge Replacement.........................................................................................................................10A1-25
Striker Replacement.......................................................................................................................................... 10A1-26
Bumper Wedge R eplacem ent.........................................................................................................................10A1-27
Door Trim Panel R e p la ce m e n t.......................................................................................................................10A1-27
W indow R e p la ce m e n t...................................................................................................................................... 10A1-27
Right Door Lower Latch R eplacem ent..........................................................................................................10A1-29
Right Door Upper Latch R eplacem ent..........................................................................................................10A1-29
Right Door Control Assembly R e p lace m e n t............................................................................................... 10A1-30
Left Door Lower Latch R eplacem ent............................................................................................................ 10A1-30
Check Strap R eplacem ent............................................................................................................................... 10A1-31
Right Door W eatherstrip Replacement..........................................................................................................10A1-31
Left Door W eatherstrip Replacem ent............................................................................................................ 10A1-32
Secondary W eatherstrip Replacem ent..........................................................................................................10A1-33
G Model Side Front D o o r ....................................................................................................................................10A1-34
Door And Hinge Replacement......................................................................................................................... 10A1-34
Door A d ju s tm e n t.............................................................................................................................................. 10A1-34
Door Trim Panel R e p la ce m e n t.......................... ............................................................................................ 10A1-36
Door Vent/W indow Run Channel Assembly Replacem ent....................................................................... 10A1-36
Vent Glass R eplacem ent..................................................................................................................................10A1-36
Vent Window A d ju s tm e n t............................................................................................................................... 10A1-37
Door Window Replacem ent............................................................................................................................. 10A1-37
W indow Stop Assembly A d ju s tm e n t............................................................................................................ 10A1-38
Inner W indow W eatherstrip R eplacem ent................................................................................................... 10A1-39
Outer Window W eatherstrip Replacement................................................................................................... 10A1-40
Rear Glass Run Channel Replacement..........................................................................................................10A1-40
W indow Regulator Replacement.....................................................................................................................10A1-40
Door Lock R e p la c e m e n t................................................................................................................................. 10A1-42
Power Door Lock Motor R eplacem ent..........................................................................................................10A1-42
Door Lock Cylinder Replacem ent.................................................................................................................. 10A1-43
Door Lock Control Assembly Replacement................................................................................................. 10A1-43
Door W eatherstrip Replacement.....................................................................................................................10A1-44
Below Eyeline Outside Rear View M irror R e placem ent........................................................................... 10A1-44
G Model Intermediate D o o rs............................................................................................................................... 10A1-45
Door And Hinge Replacement.........................................................................................................................10A1-45
Door A d ju s tm e n t.............................................................................................................................................. 10A1-46
DOORS 10A1-3
SUBJECT PAGE
G Model Intermediate Doors (Continued)

Bumper Wedge R e p lace m e n t......................................................................................................................... 10A1-47
Door Trim Panel R e p la ce m e n t....................................................................................................................... 10A1-47
W indow R e p la c e m e n t...................................................................................................................................... 10A1-48
Intermediate Front Door Lock R eplacem ent............................................................................................... 10A1-49
Intermediate Front Door Lock Control R e p la ce m e n t................................................................................ 10A1-50
Door Lock Cylinder R eplacem ent...................................................................................................................10A1-51
Door Outside Handle R e p la c e m e n t.............................................................................................................. 10A1-51
Intermediate Rear Door Lower Latch R e p la ce m e n t.................................................................................. 10A1-53
Intermediate Rear Door Upper Latch R e p la ce m e n t.................................................................................. 10A1-53
Intermediate Rear Door Control Assembly Replacem ent..........................................................................10A1-54
Power Door Lock Motor R eplacem ent.......................................................................................................... 10A1-54
Intermediate Front Door W eatherstrip R e p la ce m e n t................................................................................ 10A1-55
Intermediate Rear Door W eatherstrip R eplacem ent.................................................................................. 10A1-57
G Model Sliding Side D o o r..................................................................................................................................10A1-57
Door R e p lace m e n t.............................................................................................................................................10A1-57
Hinge Assem bly R e p la c e m e n t....................................................................................................................... 10A1-57
Lower Roller Assem bly Replacement............................................................................................................ 10A1-57
Upper Front Roller R e p la c e m e n t...................................................................................................................10A1-58
Front Lock R eplacem ent..................................................................................................................................10A1-65
Rear Lock Replacem ent.................................................................................................................................... 10A1-65
Lock Cylinder Replacement............................................................................................................................. 10A1-67
Sliding Side Door W eatherstrip Replacem ent............................................................................................. 10A1-67
G Model Rear D o o r s .............................................................................................................................................10A1-69
Door And Hinge Replacem ent......................................................................................................................... 10A1-69
S triker Replacem ent.......................................................................................................................................... 10A1-71
Bumper Wedge R e p lace m e n t......................................................................................................................... 10A1-71
Swing Out W indow .............................................................................................................................................10A1-73
Left Door Lower Latch R e p lacem ent............................................................................................................ 10A1-73
Right Door Lower Latch R eplacem ent.......................................................................................................... 10A1-74
Right Door Upper Latch R eplacem ent.......................................................................................................... 10A1-75
Right Door Control Assem bly R e p la ce m e n t............................................................................................... 10A1-75
Door Outside Handle R e p la c e m e n t.............................................................................................................. 10A1-76
Door Lock Cylinder Replacem ent...................................................................................................................10A1-76
Check Strap R eplacem ent................................................................................................................................10A1-76
Check Assem bly R e p lace m e n t.......................................................................................................................10A1-77
Left Door W eatherstrip R eplacem ent............................................................................................................ 10A1-77
Right Door W eatherstrip Replacement.......................................................................................................... 10A1-78
Power Door Lock Motor R eplacem ent.......................................................................................................... 10A1-78
Special T o o ls ......................................................................................................................................................... 10A1-79
10A1-4 DOORS
C/K MODEL SIDE FRONT DOOR
DOOR AND HINGE

REPLACEMENT
1. Cowl
2. Door
Open the door.
Lower
1. Electrical wiring harness (if equipped).
Hinge
Refer to Door Trim Panel Replacement,
Bolt
for access to the wiring harness.
Upper
Mark the position of the hinges on the door.
Hinge
2. Door hinge to door bolts (4).
6. Bolt
3. Door from the vehicle.
Mark the position of the hinges on the body side
pillar.
4. Hinge to door pillar bolts (6).
2 F-00444
5. Door pillar to hinge bolt (7).
6. Hinges from the vehicle.
Figure 1Door Hinge Components
3. Adjust the door to obtain a gap of 5 mm 2 mm
1. Hinges to the vehicle. (0.19-inch 0.09-inch) between the doors rear
Align the hinges to the marks on the body side edge and the rear door pillar.
pillars. 4. The gap between the door and the windshield
2. Hinge to door pillar bolts (6). pillar should be 2 mm 1.5 mm (0.08-inch
3. Door pillar to hinge bolt (7). 0.06-inch).
4. Door to the vehicle. 5. The door surface should be flush with the other
Align the marks on the door to the hinges. panels within 1.5 mm ( 0.06-inch) except for
5. Door hinge to door bolts (4). the door to roof panel surface which should be
6. Electrical wiring harness (if equipped). flush within +1.5 mm (+ 0.06-inch).
Refer to Door Trim Panel Replacement, 6. Tighten the hinge bolts.
for access to the wiring harness.
0
DOOR ADJUSTM ENT 1. Door striker bolt.

Adjust
Tools Required:
Bolt to properly engage the door lock.
J-22585-01 Door Hinge Bolt Wrench.
2. Tighten the striker bolt.
J-23457-A Wrench.
Door striker bolt using J-23457-A.
Tighten
Use tool J-22585-01 when loosening the door
hinge to body side pillar bolts. The rear fender
Striker bolt to 63 N m (46 ft. lbs.).
bolts may need to be loosened for access to
these bolts.
DOOR TRIM PANEL
f t Adjust
REPLACEMENT
The door up or down, forward or rearward, and in
or out, at the door hinges. Remove or Disconnect (Figures 4 and 5)
1. Adjust the door to obtain a gap of 6 mm
(0.24-inch 0.09-inch) between the rocker panel Tools Required:
and the door. J-9776-01 Door Handle Clip Remover.
2. The gap between the door and the roof panel J-24595-B Door Trim Pad Clip Remover.
should be 5 mm 2 mm (0.19-inch 0.09-inch). 1. Window regulator handle using J-9886-01.
DOORS 10A1-5
A. 2 mm 1.5 mm (0.08-inch 0.06-inch)

B. 5 mm 2 mm (0.19-inch 0.09-inch)
C. 5 mm 2 mm (0.19-inch 0.09-inch)
D. 6 mm 2 mm (0.24-inch 0.09-inch)
W indshield Pillar
Door Assembly
Roof Panel
Rocker Panel
Front Door Rear Pillar
F-00445
Figure 2Door Adjustm ents
2. Lock knob.
3. Arm rest to arm rest bracket screws (77).
4. Arm rest from the door.
5. Strap assembly covers (if equipped).
6. Strap assembly screws (24) (if equipped).
7. Strap assembly (if equipped).
8. Door trim panel to door screws (22).
9. D oor trim panel to d oo r re ta in e rs using
J-24595-B.
10. Door trim panel from the door.
Pry the top of the panel away from the door
side window seal clips.
18
18. Inside Handle The Arrow

F-01227
Figure 3Door Striker

Figure 4Handle Clip Removal
10A1-6 DOORS
-20
19. Retainer
21 20. Door Trim
21. Arm Rest
22 22. Screw
23. Cover
24. Screw
25. Strap
^25 77. Screw
F-00446
Figure 5Trim Panel Components
EEI Install or Connect (Figures 4 and 5) Pull the top of the vent backwards away
from the door frame.
Check that all the trim retainers are securely Lift and rotate the assembly out of the door.
fastened, and are not damaged. Replace any
damaged fasteners. - Install or Connect (Figure 6)
1. Door trim panel onto the door side window seal
clips. 1. Door vent/window run chanrel assembly to the
2. Door trim retainers into the door panel. vehicle.
4. Strap assembly onto the door (if equipped).
5. Strap assembly screws (if equipped).
6. Strap assembly covers (if equipped).
7. Arm rest to the door.
8. Arm rest to arm rest bracket screws (77).
9. Lock knob.
10. Window regulator handle.
DOOR VENT/W INDOW RUN

CHANNEL ASSEM BLY
REPLACEMENT
The door vent and the front window run channel are
one assembly. This assembly is fit into the front of the
door frame.
Place the window in the lowered position.

1. Door trim panel. Refer to Door Trim Panel
Replacement. 26. Screw
2. Run channel molding. 27. Spacer
Pull the molding out of the vent assembly 29. Door Vent/Window Glass Run Assembly
only. 30. Run Channel Molding
3. Door panel to run channel bolt (31). 31. Bolt F-00447
4. Door to ventilator screws (26) and spacers (27).
5. Door vent/window run channel assembly from the Figure 6Door Vent/Window Run Channel
vehicle. Components
DOORS 10A1-7
Rotate the vent assembly into the door.

Fit the assembly into the door frame.
2. Door to ventilator screws (26) and spacers (27).
e Start with the screw at the top of the door,
and work downward.
3. Door panel to run channel bolts (31).
4. Run channel molding.
Seat the clip into the vent, then push the
remainder of the molding into the run
channel.
Replacement.
VENT GLASS REPLACEMENT
CAUTION: Always wear heavy gloves when

handling glass to minim ize the risk of injury. Firjure 7Vent W indow Adjustm ent
3. Adjust the vent by placing a wrench on the

REMOVAL (Figure 6) adjusting nut, and then turning the vent window
1. Open the vent window. to the proper tension.
2. Squirt solvent on the tar-paper-like filler all 4. Bend the tabs over the adjustment nut.
around the glass channel, on both sides of the 5. Install the door trim panel. Refer to Door Trim
glass. Panel Replacement.
3. When the filler and sealer soften, pull the glass
and the old filler from the channel.
DOOR WINDOW REPLACEMENT
INSTALLATION (Figure 6)
1. Thoroughly clean the inside of the glass channel Remove or Disconnect (Figure 8)
with sandpaper to remove all rust and foreign
matter.
2. Cut the new piece of glass channel filler 51 mm CAUTION: Always wear heavy gloves when
(2-inches) longer than required. handling glass to minimize the risk of injury.
3. Position the filler (soap stoned side away from the
glass) evenly around and over the edge of the Lower the glass to the bottom of the door.
glass that will be inserted in the channel. Press 1. Door trim panel. Refer to Door Trim Panel
the filler firmly onto the edge of the glass to Replacement.
ensure a good bond. (Usually this is done with a 2. Door vent/window run channel assembly. Refer to
mechanical window press.) Squeeze together the Door Vent/Window Run Channel Assembly
doubled ends of the filler which project beyond Replacement.
the edge of the glass. Mask or cover any sharp edges that could
4. Brush the inner channel with soap solution. DO scratch the glass.
NOT USE GREASE OR OIL. 3. Door window glass.
5. Press the glass and the filler into the channel Slide the glass forward until the front roller
until firmly seated. is in line with the notch in the sash channel.
6. Trim off excess filler material around, and at the Disengage the roller from the channel.
end of the channel. Push the window forward, then tilt it up until
the rear roller is disengaged.
Place the iwndow in a level position, and
VENT W INDOW ADJUSTM ENT raise it straight up and out of the door.
^ Adjust (Figure 7)
1. Remove the door trim panel. Refer to Door Trim 1. Door window glass.
Panel Replacement. Lower the window into the door frame.
2. Bend the tabs on the adjustment nut away from Push the window forward, then tilt it up, and
the nut. slide the rear roller into the sash channel.
10A1-8 DOORS
32. Glass
33. W indow Sash
34. Regulator Assembly
35. Regulator Rail
36. Notch
F-00449
Figure 8W indow Assem bly Components
Slide the glass backward until the front - Install or Connect (Figure 9)
roller is in line with the notch in the sash
channel. Engage the roller to the sash 1. Weatherstrip (37) to the trim panel.
channel.
Push the weatherstrip clips onto the trim
Slide the glass rearward into the glass run panel shoulder.
channel.
Remove any masking or covering. Replacement.
2. Door vent/window run channel assembly. Refer to

Door Vent/Window Run Channel Assembly
Replacement. OUTER WINDOW
W EATHERSTRIP REPLACEMENT
Replacement.
Lower the window.

INNER WINDOW
Weatherstrip (38) from the door.
WEATHERSTRIP REPLACEMENT
Pry the weatherstrip clips from the door
|*"| Remove or Disconnect (Figure 9) panel.

Replacement. Install or Connect (Figure 10)
2. Weatherstrip (37) from the trim panel. Weatherstrip (38) to the door.
Pry the clips on the weatherstrip from the Push the weatherstrip clips onto the door
trim panel shoulder. panel.
DOORS 10A1-9
Figure 10Outer W indow W eatherstrip
REAR GLASS RUN

CHANNEL REPLACEMENT
33. W indow Sash
1 . Door trim panel. Refer to Door Trim Panel 34. Regulator Assembly
Replacement. 35. Regulator Rail
Lower the window completely. 42. Bolt
2. Inner and outer window weatherstrips.
3. Door to run channel bolts (41). F-00453
4. Run channel from the vehicle.
Pull the run channel upwards while twisting
Figure 12Manual W indow Regulator
to clear the lower bracket.
Install or Connect (Figure 11) 5. Door trim panel. Refer to Door Trim Panel
Replacement.
1. Run channel to the vehicle.
Work the run channel into the door frame.
Be certain that the glass is in the channel. WINDOW REGULATOR
2. Lower door to run channel bolt (41).
REPLACEMENT
Raise the window completely.
3. Upper door to run channel bolt (41).
MANUAL REGULATOR
4. Inner and outer window weatherstrips.
Raise the window and tape the glass in the full up

position using cloth body tape.
Replacement.
2. Door panel to regulator bolts (42).
3. Window regulator.
Slide the regulator rearward to disengage
the rear roller from the sash channel. Also
disengage the lower roller from the regulator
rail.
Disengage the forward roller from the sash

channel at the notch inthe sash channel.
C ollapse the regulator, and remove it

through the access hole in the door.
10A1-10 DOORS

Replacement.
3. Remove control to door trim panel bolts.
Lay the control aside.
4. Regulator to door panel bolts (45) and nuts (44).
5. Wiring harness from the regulator.
rail.
channel at the notch in the sash channel.
CAUTION: The next step must be performed

when the re g ula to r is rem oved from the
d oo r. The re g u la to r lift arm s are under
43. R egulator A ssem bly tension from the counterbalance spring and
44. Nut can cause serious in ju ry if the m otor is
45. B olt removed w ithout locking the sector gear in
46. W iring Harness position.
F-00454 Drill a hole through the regulator sector gear and

back plate. Drill the hole at least 12.7 mm
Figure 1 3 Power Window Regulator (1/2 -inch) away from the edge of the sector gear or
back plate. Install a pan head sheet metal
|+<*| Install or Connect (Figure 12) tapping screw at least 19 mm (3/4-inch) long into
the drilled hole to lock the sector gear in place.
Lubricate the regulator and the sash and 7. Motor to regulator attaching bolts (28).
regulator rails with lubriplate or equivalent. 8. Motor from the regulator.
Collapse the regulator, and insert it through Install or Connect (Figures 12 and 13)
the access hole in the door.
Unfold the regulator, and engage the Lubricate the motor drive gear and regulator
forward roller to the sash channel at the sector teeth.
sash channel notch. 1. Regulator motor to regulator.
Slide the regulator rearward to engage the The motor pinion gear teeth must mesh
rear roller to the sash channel. Also engage properly with the sector gear teeth before
the lower roller to the regulator rail. installing the motor to regulator screws.
Slide the regulator into its proper position, 2. Regulator motor to regulator bolts (28).
and insert the regulator drive through the Remove the sheet metal screw from the back
door panel. plate and sector gear.
2. Door panel to regulator bolts (42). 3. Window regulator to the door.
3. Door trim panel. Refer to Door Trim Panel Collapse the regulator, and insert it through
Replacement. the access hole in the door.
Remove the tape from the window. Unfold the regulator, and engage the
forward roller to the sash channel at the
POWER REGULATOR sash channel notch.
For the diagnosis of power window circuits, refer to Slide the regulator rearward to engage the
CAB ELECTRICAL (SEC. 8A). rear roller to the sash channel. Also engage
the roller to the regulator rail.
|++| Remove or Disconnect (Figures 12 and 13) Slide the regulator into its proper position.
4. Wiring harness to the regulator.
Raise the window and tape the glass in the full up 5. Regulator to door panel bolts (45) and nuts (44).
position using cloth body tape. 6. Remote control to door trim panel bolts.
DOORS 10A1-11
48
47 Lock Knob 48. Inside Door Lock Rod

48 Inside Door Lock Rod 49. Clip
49 Clip 50. Lock Assembly
50 Lock Assembly 53. Motor Assembly
51 Inside Door Handle Rod 78. Screw
52 Screw F-00455 F-00456
Figure 14Door Lock Components Figure 15Power Door Lock Motor
7. Door trim panel. Refer to Door Trim Panel Install or Connect (Figure 14)
Replacement.
8. Battery ground cable. 1. Lock assembly to the door.
Remove the tape from the window. Align the inside lock rod to the hole in the
door panel. Tilt the lock assembly onto the
outside lock cylinder.
DOOR LOCK REPLACEMENT 2. Door to lock assembly screws (52).
3. Inside door lock knob.
|+-| Remove or Disconnect (Figure 14) 4. Outside door handle to lock rod onto the lock
assembly.
Raise the window completely. 5. Clip onto the lock rod.
1. Door trim panel. Refer to Door Trim Panel Pivot the clip up and onto the lock rod.
Replacement. 6. Inside door handle to lock rod onto the lock
2. Inside door handle to lock rod clips (49). assembly.
7. Clip onto the lock rod.
Using a flat bladed screwdriver, push on the
Pivot the clip up and onto the lock rod.
top of the clip where it is connected to the
rod. Pivot the clip away from the rod.
Replacement.
3. Inside door handle to lock rod from the lock.
4. Outside door handle to lock rod clip.
Use the procedure given under step 2. POWER DOOR LOCK
5. Outside door handle to lock rod from the lock. MOTOR REPLACEMENT
6. Inside door lock knob.
7. Door to lock assembly screws (52). Refer to CAB ELECTRICAL (SEC. 8A) for electrical
8. Lock assembly from the door. diagnosis of the door lock motor.
Tilt the lock assembly away from the outside
lock cylinder. Pull the lock assem bly |<~+| Remove or Disconnect (Figure 15)
downward to make clearance for the inside
lock rod. 1. Battery ground cable.
10A1-12 DOORS
5. Handle with the control rod from the door.

6. Gaskets from the door.
1. Large gasket over the lock rod and onto the

handle.
2. Handle with the lock rod onto the door.
3. Door to outside handle screw (54) to the push
button side of the handle.
Do not tighten.
4. Small gasket between the door and the handle.
5. Door to outside handle screw (54) to the other
side of the handle.
59 Tighten both screws.
54. Bolt 59. Lock Cylinder 6. Outside door handle to lock rod to the lock
55. Outside Handle Rod 60. Gasket assembly.
56. Small Gasket 61. Large Gasket 7. Clip onto the lock rod.
57. Handle Assembly 62. Retainer Pivot the clip up and onto the lock rod.
58. Key 63. Clip F-00457 8. Door trim panel. Refer to Door Trim Panel
Replacement.
Figure 16Outside Handle And Lock
Cylinder Components
DOOR LOCK CYLINDER
REPLACEMENT
Replacement.
3. Electrical connector from the motor. Remove or Disconnect (Figure 16)
4. Door to motor screws (78). Raise the window completely.

5. Motor from the lock rod. 1. Door trim panel. Refer to Door Trim Panel
Slide the rubber mount at the top of the Replacement.
motor off of the door lock rod. 2. Lock cylinder retaining clip (62) from the cylinder.
6. Motor from the door. Slide the clip off the cylin d er with a
screwdriver.
Install or Connect (Figure 15) 3. Lock cylinder and gasket from the door.
1. Motor into the door.
2. Motor to the lock rod. Install or Connect (Figure 16)
Slide the rubber mount at the top of the 1. Lock cylinder with gasket to the door.
motor onto the door lock rod.
The cylinder rod must engage the lock
3. Door to motor screws (78).
assembly lever.
4. Electrical connector to the motor.
2. Lock cylinder (62) retaining clip onto the cylinder.
Replacement.
Replacement.
DOOR OUTSIDE HANDLE DOOR INSIDE HANDLE

REPLACEMENT REPLACEMENT
Remove or Disconnect (Figure 16) Remove or Disconnect (Figure 17)
Raise the window completely. 1. Door trim panel. Refer to Door Trim Panel
1. Door trim panel. Refer to Door Trim Panel Replacement.
Replacement. 2. Door handle seal.
2. Outside door handle to lock rod clip. 3. Handle to door screws (65).
Using a flat bladed screwdriver, push on the 4. Control rod from the inside handle.
top of the clip where it is connected to the Slide the clip so that the large diameter slot
rod. Pivot the clip away from the rod. is in line with the lock rod. Then, pull the rod
3. Outside door handle to lock rod from the lock. from the handle.
4. Door to outside handle screws (54). 5. Inside handle from the door.
DOORS 10A1-13
Figure 17Door Inside Handle
Install or Connect (Figure 17) OUTSIDE REAR VIEW

1. Control rod to the inside handle. MIRROR REPLACEMENT
Place the rod into the clip and the lever.
Slide the clip so that the small diameter slot Remove or Disconnect (Figure 19)
is in line with the lock rod.
2. Handle to door screws (65). 1. Mirror to bracket screw.
3. Door handle seal. 2. Mirror from the door.
4. Door trim panel. Refer to Door Trim Panel 3. Bracket to door bolts.
Replacement.
DOOR WEATHERSTRIP
REPLACEMENT
Open the door.

1. Sill plate from the vehicle.
2. Weatherstrip from the pinchweld flange.
Pull the weatherstrip away from the flange.
1. Weatherstrip to the pinchweld flange.

Start at the bottom center of the door
opening.
Trim the weatherstrip, and butt the ends together.
2. Sill plate to the vehicle.
10A1-14 DOORS
Figure 19Outside Rear View M irror

Components
4. Bracket and gasket from the vehicle.
1. Bracket and gasket to the vehicle.

2. Bracket to door bolts.
3. Mirror to the bracket.
4. Mirror to bracket screw.
BELOW EYELINE OUTSIDE

REAR VIEW MIRROR Figure 20Below Eyeline And West Coast
REPLACEMENT Style Mirrors
* l Remove or Disconnect (Figure 20) 4. Brackets from the door.
1. Mirror cover screw.

Lift the cover, and pivot the mirror towards the + 4- Install or Connect (Figure 20)
window.
2. Mirror to door bolts. 1. Door brackets to the door.
3. Mirror and seal from the door.
2. Door bracket nuts and bolts.
Install or Connect (Figure 20) 3. Mirror bracket to the door brackets.
1. Mirror and seal to the door. 4. Mirror bracket to door bracket nuts, bolts, and
2. Mirror to door bolts. bushings.
Pivot the mirror away from the window, and lower
the mirror cover.
WEST COAST OUTSIDE

REAR VIEW MIRROR
REPLACEMENT
1. Mirror bracket to door bracket nuts, bolts, and

bushings.
2. Mirror bracket from the vehicle.
3. Door bracket nuts and bolts.
DOORS 10A1-15
DOOR AIR VALVE install or Connect (Figure 21)
REPLACEMENT 1. Air valve to the door.

2. Door to air valve screws.
Remove or Disconnect (Figure 21) 3. Door trim panel. Refer to Door Trim Panel
Replacement.
Replacement.
3. Air valve from the door.
C/K MODEL SIDE REAR DOORS
Hinge to door pillar bolts (80).

DOOR AND HINGE
Door from the vehicle.
REPLACEMENT Hinge to door bolts (80).
Hinges from the door.
Open the door.
1. Electrical wiring harness (if equipped). 1. Hinges to the door.
Refer to Door Trim Panel Replacement for Align the hinges with the previously made
access to the wiring harness. marks.
2. Inner hinge pillar cover screws (78) and covers Hinge to door bolts (80).
(79). Door to the vehicle.
Mark the position of the hinges on the door and Align the hinges with the previously made
on the door pillar. marks.
10A1-16 DOORS
F-00467
4. Hinge to door pillar bolts (80). 1. Adjust the door to obtain a gap of 6 mm 2
5. Inner hinge pillar covers (79) and screws (78). mm (0.24-inch 0.09-inch) between the
6. Electrical wiring harness (if equipped). rocker panel and the door.
Refer to Door Trim Panel Replacement for 2. The gap between the door and the roof
access to the wiring harness. panel should be 5 mm 2 mm (0.19-inch
0.09-inch).
DOOR ADJUSTMENT 3. Adjust the door to obtain a gap of 5 mm 2

mm (0.19-inch 0.09-inch) between the
Remove or Disconnect doors rear edge and the rear door pillar.
Tool Required: 4. The gap between the door and the center
J-23457-A Wrench. pillar should be 5 mm 2 mm (0.19-inch
0.09-inch).
Door striker bolt using J-23457-A.
5. The door surface should be flush with the
Adjust (Figure 23) other panels within 1.5 mm ( 0.06-inch)
except for the door to roof panel surface
The door up or down, forward or rearward, which should be flush within + 1.5 mm ( +
and in or out, at the door hinges. 0.06-inch).
DOORS 10A1-17
Figure 24Door Trim Panel Components
Install or Connect 9. D oor trim panel to d oo r re ta in e rs u sing

J-24595-B.
Door striker bolt.
10. Door trim panel from the door.
Adjust Pry the top of the panel away from the door
side window seal clips.
Bolt to properly engage the door lock.

Tighten
Check that all the trim retainers are securely

Striker bolt to 63 N m (46 ft. lbs.).
fastened, and are not damaged. Replace any
damaged fasteners.
DOOR TRIM PANEL 1. Door trim panel onto the door side window seal
REPLACEMENT clips.
2. Door trim retainers into the door panel.
Tools Required:
J-9886-01 Door Handle Clip Remover. 4. Strap assembly onto the door (if equipped).
J-24595-B Door Trim Pad Clip Remover. 5. Strap assembly screws (if equipped).
1. Window regulator handle using J-9886-01.
2. Lock knob. 6. Strap assembly covers (if equipped).
3. Arm rest to arm rest bracket screws (91). 7. Arm rest to the door.
4. Arm rest from the door.
5. Strap assembly covers (if equipped). 8. Arm rest to arm rest bracket screws (91).
6. Strap assembly screws (if equipped).
9. Lock knob.
7. Strap assembly (if equipped).
8. Door trim panel to door screws (93). 10. Window regulator handle.
10A1-18 DOORS
5. Stationary glass/window run channel assembly

from the door.
Pull the top of the channel backwards away
Lift and rotate the assembly out of the door.

107
1. Stationary glass/window run channel assembly to
the door.
2 . Run channel molding.
Push the molding into the run channel. The
slot at the top of the molding must be on top
of the run channel.
3. Door frame to run channel screw (97).
108 The screw must pass through the run
channel molding slot.
Door panel to run channel bolt (99).
Door trim panel. Refer to Door Trim Panel
109 Replacement.
DOOR WINDOW REPLACEMENT

96. Run Channel Molding

97. Screw
handling glass to minimize the risk of injury.
98. Stationary Glass/Window Run Channel
99. Bolt
Lower the window to the bottom of the door.
107. Bolt
108. Front Glass Run Channel
Replacement.
109. Nut F-00469
2. Stationary glass/window run channel assembly.
Refer to Stationary Glass/Window Run Channel
Figure 25Stationary Glass/W indow Run Assembly Replacement.
Channel Components Mask or cover any sharp edges that could
scratch the glass.
STATIONARY GLASS/WINDOW 3. Door window glass (100).
Slide the glass rearward until the rear roller
RUN CHANNEL ASSEMBLY
is in line with the notch in the sash channel.
REPLACEMENT Disengage the roller from the channel.
Push the window rearward, then tilt it up
The stationary glass and the rear window run until the front roller is disengaged.
channel are one assembly. This assembly fits into the Place the window in a level position, and
rear of the door frame. raise it straight up and out of the door.
I Remove or Disconnect (Figure 25) - Install or Connect (Figure 26)
Place the window in the lowered position. 1. Door window glass (100).
1. Door trim panel. Refer to Door Trim Panel Lower the window into the door frame.
Replacement. Push the window rearward, then tilt it up,
2. Run channel molding (96). and slide the front roller into the sash
channel.
Pull the molding out of the run channel only.
Slide the glass forward until the rear roller is
3. Door panel to run channel bolt (99). in line with the notch in the sash channel.
4. Door frame to run channel screw (97). Engage the roller to the sash channel.
DOORS 10A1-19
100. Glass
101. Filler
102. Sash Channel
103. Regulator
104. Bolt
A. Notch
Figure 26W indow Assembly Components
Slide the glass forward into the glass run

channel.
Remove any masking or covering.
2. Stationary glass/window run channel assembly.
Refer to Stationary Glass/Window Run Channel
Replacement.
INNER WINDOW
|*"| Remove or Disconnect (Figure 27)

Replacement.
2. Weatherstrip from the trim panel.
Pry the clips on the weatherstrip from the
trim panel shoulder.
1. Weatherstrip to the trim panel.

Push the weatherstrip clips onto the trim
panel shoulder.
Replacement.
10A1-20 DOORS
WINDOW REGULATOR
REPLACEMENT
MANUAL REGULATOR
" Remove or Disconnect (Figure 26)

Replacement.
2. D oor w indow . R efer to D oor W indow
Replacement.
OUTER WINDOW
WEATHERSTRIP REPLACEMENT Install or Connect (Figure 26)
Remove or Disconnect (Figure 28) Lubricate the regulator and the sash and
regulator rails with lubriplate or equivalent.
Lower the window. 1. Window regulator.
Collapse the regulator, and insert it through
1. Weatherstrip from the door.
Pry the weatherstrip clips from the door 2. Door panel to regulator bolts (104).
panel. 3. D oor w in d ow s. R efer to D oor W indow
Replacement.
Replacement.
1. Weatherstrip to the door.
POWER REGULATOR
Push the weatherstrip clips onto the door For the diagnosis of power window circuits, refer to
panel. CAB ELECTRICAL (SEC. 8A).

FRONT GLASS RUN
CHANNEL REPLACEMENT
B Remove or Disconnect (Figure 25) Replacement.
3. D oor w indow . R efer to D oor W indow
Lower the window completely. Replacement.
4. Regulator to door panel bolts (110) and nuts (112).
1. Outer window weatherstrip. 5. Wiring harness from the regulator.
2. Door to run channel bolt (107) and nut (109). 6. Window regulator.
Pull the run channel upwards while twisting
to clear the lower bracket. CAUTION: The next step must be perform ed
when the re g ula to r is rem oved from the
d o o r. The re g u la to r lift arm s are under
E
t ^ Install or Connect (Figure 25)
tension from the counterbalance spring and
can cause serious in ju ry if the m o to r is
1. Run channel to the vehicle.
removed w ithout locking the sector gear in
Work the run channel into the door frame. position.
Be certain that the glass is in the channel.
Drill a hole through the regulator sector gear and
2. Door to run channel bolt (107) and nut (109).
3. Outer window weatherstrip. (1/2 -inch) away from the edge of the sector gear or
DOORS 10A1-21
110. Bolt DOOR LOCK REPLACEMENT

111. W iring Harness
112. Nut + + Remove or Disconnect (Figure 30)
113. Regulator Assembly
Replacement.
2 . Inside door handle to lock rod clip (115).
Inside door handle to lock rod from the lock.
Outside door handle to lock rod clip.
Use the procedure given under step 2.
Outside door handle to lock rod from the lock.
6. Remove control to lock assembly clip and rod.
7. Door to lock assembly screws (116).
8. Lock assembly from the door.
Tilt the lock assembly away from the outside
lock cylinder. Pull the lock assem bly
downward to make clearance for the inside
lock rod.

F-00475 1. Lock assembly to the door.
Tilt the lock assembly onto the outside lock
Figure 29Power Regulator cylinder.
2. Door to lock assembly screws (116).
back plate. Install a pan head sheet metal 3. Remote control to lock assembly rod and clip.
tapping screw at leat 19 mm (3/4-inch) long into 4. Outside door handle to lock rod onto the lock
the drilled hole to lock the sector gear in place. assembly.
7. Motor to regulator attaching screws. 5. Clip onto the lock rod.
8. Motor from the regulator.
6. Inside door handle to lock rod onto the lock
assembly.
B 7. Clip onto the lock rod.
Lubricate the motor drive gear and regulator
sector teeth.
Replacement.
1. Regulator motor to regulator.
The motor pinion gear teeth must mesh
properly with the sector gear teeth before POWER DOOR LOCK
installing the motor to regulator screws. MOTOR REPLACEMENT
1. Regulator motor to regulator screws.
Remove the sheet metal screw from the back Refer to CAB ELECTRICAL (SEC. 8A) for electrical
plate and sector gear. diagnosis of the door lock motor.
3. Window regulator to the door.
Collapse the regulator, and insert it through |<-+| Remove or Disconnect (Figure 30)
4. Wiring harness to the regulator.
5. Regulator to door panel bolts (110) and nuts (112). Replacement.
6. D oor w indow . R efer to D oor W indow 3. Electrical connector from the motor.
Replacement. 4. Door to motor screws.
7. Door trim panel. Refer to Door Trim Panel 5. Motor from the lock rod.
Replacement. Slide the rubber mount at the top of the
8. Battery ground cable. motor off of the door lock rod.
10A1-22 DOORS
117. Remote Control To Lock Rod

118. Inside Door Handle To Lock Rod
119. Power Door Lock Motor
F-00476
Figure 30Door Lock Components
6. Motor from the door.

2. Motor to the lock rod.
Slide the rubber mount at the top of the
3. Door to motor screws.
4. Electrical connector to the motor.
Replacement.
DOOR OUTSIDE
HANDLE REPLACEMENT 120. Screws
125 121. Outside Handle
Remove or Disconnect (Figure 31) To Lock Rod
122. Small Gasket
Raise the window completely. 123. Outside Handle
1. Door trim panel. Refer to Door Trim Panel 124. Large Gasket
Replacement. 125. Clip
top of the clip where it is connected to the F-00477
3. Outside door handle to lock rod from the lock. Figure 31Door Outside Handle Components
4. Door to outside handle screws (120).
DOORS 10A1-23
5. Handle with the control rod from the door. Using a flat bladed screwdriver, push on the
6. Gaskets from the door. top of the clip where it is connected to the
Install or Connect (Figure 31) Pull the rod from the remote control.
3. Door panel to remote control bolts (129).
1. Large gasket over the lock rod and onto the 4. Remote control levers and rods through the
handle. access hole.
2. Handle with the lock rod onto the door.
Do not tighten. 1. Remote control levers and rods through the

4. Small gasket between the door and the handle. access hole.
5. Door to outside handle screw (120) to the other 2. Door panel to remote control bolts (129).
side of the handle. 3. Remote control to lock assembly rod.
Tighten both screws. Pivot the clip up and onto the lock rod.
6. Outside door handle to lock rod to the lock 4. Door trim panel. Refer to Door Trim Panel
assembly. Replacement.
7. Clip onto the lock rod.
8. Door trim panel. Refer to Door Trim Pansl
DOOR WEATHERSTRIP
Replacement. REPLACEMENT
DOOR INSIDE HANDLE
REPLACEMENT Open the door.
1. Sill plate from the vehicle.
Remove or Disconnect (Figure 32) 2. Weatherstrip from the pinchweld flange.
Pull the weatherstrip away from the flange.
Replacement. -4- Install or Connect (Figure 33)
2. Door handle seal.
3. Handle assembly to door screws (131). 1. Weatherstrip to the pinchweld flange.
4. Control rod from the inside handle. Start at the bottom center of the door
Slide the clip so that the large diameter slot opening.
is in line with the lock rod. Then, pull the rod Trim the weatherstrip, and butt the ends together.
from the handle. 2. Sill plate to the vehicle.
5. Inside handle from the door.

DOOR AIR VALVE
REPLACEMENT
1. Control rod to the inside handle.
Place the rod into the clip and the lever. Remove or Disconnect (Figure 34)
Slide the clip so that the small diameter slot
is in line with the lock rod. 1. Door trim panel. Refer to Door Trim Panel
2. Handle assembly to door screws (131). Replacement.
3. Door handle seal. 2. Door to air valve screws.
4. Door trim panel. Refer to Door Trim Panel 3. Air valve from the door.
Replacement.
El Install or Connect (Figure 34)
REMOTE CONTROL 1. Air valve to the door.

REPLACEMENT 3. Door trim panel. Refer to Door Trim Panel
Replacement.

Replacement.
2. Remote control to lock assembly rod.
10A1-24 DOORS
Figure 32Door Inside Handle Components
Figure 33Door Weatherstrip

DOORS 10A1-25
C/K MODEL REAR DOORS
140
Bolt
Hinge
Bolt
Screw
Cover
F-00464
Figure 35Hinge Components
DOOR AND HINGE Align the hinge with the previously made
mark.
REPLACEMENT 4. Door to hinge bolts (139).
5. Rear door hinge access plug and screw (if
Remove or Disconnect (Figure 35) equipped).
Mark the position of the door and the door
Refer to Door Trim Panel for access to the
opening on the hinges.
wiring harness.
1. Strap pin.
7. Strap pin.
Refer to Door Trim Panel Replacement for
access to the wiring harness. DOOR ADJUSTMENT
3. Rear door hinge access plug screw, and the
access plug (if equipped). Each of the two doors must first be adjusted in the
4. Door to hinge bolts (139). door opening before adjusting the door to door
5. Door from the vehicle. clearance.
6. Door opening to hinge bolts (137).
7. Hinges from the door opening. Adjust (Figure 36)
+4- Install or Connect (Figure 35) 1. The door height so that there is a gap of 5 mm
2.3 mm (0.190-inch 0.09-inch) between the roof
1. Hinges to the door opening. panel and the rear door panel.
Align the hinge with the previously made 2. The gap between the bottom of the door panel
mark. (not the bottom of the outer panel) and the
2. Door opening to the hinge bolts (137). platform panel should be 7 mm (0.280-inch). This
3. Door to the vehicle. measurement should be taken on each door
10A1-26 DOORS
individually from the side of the door. The door

should be in its normal closed position. (The
outer rear door panel is 14 mm + 1.5 mm
(0.560-inch 0.06-inch) away from the rear
platform panel when normally closed).
3. The rear door outer panel to the body side outer
panel gap to 5 mm 2.3 mm (0.190-inch
0.09-inch).
4. The door to door clearance between the left and
right outer door panels should be 5 mm 2.3
mm (0.190-inch + 0.09-inch).
STRIKER REPLACEMENT
1. Striker to door frame bolts (150).

147. Spacer
2. Striker from the door frame. 148. Bumper
3. Spacer (if equipped). 149. Screw
150. Bolt
151. Striker
152. Spacer
1. Spacer (as required). F-00470
2. Striker to the door frame.

Figure 37Striker Components
DOORS 10A1-27
DOOR TRIM PANEL

152 REPLACEMENT
1. Lower garnish molding to door screws (158).

2. Lower garnish molding.
3. Check strap from the door.
5. Door trim panel.
6. Upper garnish molding to door screws (153).
7. Upper garnish molding.
1. Upper garnish molding.

2. Upper garnish molding to door screws (153).
3. Door trim panel.
5. Check strap to the door.
6. Lower garnish molding.
7. Lower garnish molding to door screws (158).
151. Striker
152. Spacer
F-00471
WINDOW REPLACEMENT
If a glass is cracked but still intact, it should be
Figure 38S triker Adjustm ent crisscrossed with masking tape to reduce the risk of
injury and/or damage to the vehicle. If a crack extends
Adjust (Figure 38) to the edge of the glass, mark the door with a piece of
chalk at the point where the crack meets the
The striker to door latch clearance so that there weatherstrip. Later, when examining the flange of the
are 4.4 mm (0.172-inch) between the striker and opening for a cause of the crack, start at the point
the door latch when the door is in the secondary marked.
latched position. (The door is latched but not fully It is important that the cause of the crack be
closed.) An 11/e4-inch diameter drill bit may be determined and the condition corrected, before the
used to gage this clearance. new glass is installed. The cause of the crack may be
an obstruction or high spot somewhere around the
flange of the opening; cracking may not occur until
BUMPER WEDGE REPLACEMENT pressure from the high spot or obstruction becomes
p a rtic u la rly high due to w in d s, e xtre m e s of
Remove or Disconnect (Figure 37) temperature, or rough terrain.
1. Bumper to upper door frame screws (149). Remove or Disconnect (Figure 40)
2. Bumper and spacer.
Install or Connect (Figure 37) CAUTION: Always wear heavy gloves when
1. Spacer (as required).
2. Bumper. 1. W eatherstrip seal by running a putty knife
3. Bumper to upper door frame screws (149). between the flange and the weatherstrip (inside
and outside the door).
Adjust Have an assistant outside the cab by the
window.
The bumper to door clearance so that there is 1 2. Weatherstrip and glass from the flange.
mm (0.04-inch) between the bumper and the door Force the weatherstrip from the flange from
when the door is in the secondary position. (The the inside with a putty knife.
door is latched but not fully closed). 3. Window from the weatherstrip.
10A1-28 DOORS
Figure 40Window Components

DOORS 10A1-29
Figure 42Right Door Upper Latch

162. Screw
163. Bumper Install or Connect
164. Spacer
165. Screw 1. Lower latch with the rod to the door.
162
166. Latch Assembly 2. Lower latch to door screws (165).
167. Lower Latch Rod 3. Lower latch to control assembly rod into the
F-00474 control assembly.
Pivot the clip onto the rod.
4. Door lock access cover.
Figure 41Right Door Lower Latch
Replacement.
H" Install or Connect (Figure 40)
1. Weatherstrip to the glass. RIGHT DOOR UPPER

2. A six mm (1/4-inch) cord in the weatherstrip
groove. The ends should overlap about 5 cm LATCH REPLACEMENT
(6-inches) at the window bottom.
3. Window and weatherstrip on the flange from Remove or Disconnect (Figure 42)
outside the cab.
Brush soapy water on the flange. 1. Door trim panel. Refer to Door Trim Panel
Have an assistant pull the cord from inside Replacement.
the cab to seat the lip of the weatherstrip on 2. Door lock access cover.
the flange. 3. Upper latch to control assembly rod from the
control assembly.
RIGHT DOOR LOWER top of the clip where it is connected to the
LATCH REPLACEMENT rod. Pivot the clip away from the rod.
4. Upper latch to door bolts (168).
Remove or Disconnect (Figure 41) 5. Upper latch with the rod from the door.
1. Door trim panel. Refer to Door Trim Panel -+ Install or Connect

Replacement.
2. Door lock access cover. 1. Upper latch with the rod to the door.
3. Lower latch to control assembly rod from the 2. Upper latch to door bolts (168).
control assembly. 3. Upper latch to control assembly rod into the
Using a flat bladed screwdriver, push on the control assembly.
top of the clip where it is connected to the Pivot the clip onto the rod.
rod. Pivot the clip away from the rod. Door lock access cover.
4. Lower latch to door screws (165). Door trim panel. Refer to Door Trim Panel
5. Lower latch with the rod from the door. Replacement.
10A1-30 DOORS
DOOR OUTSIDE HANDLE

REPLACEMENT

Replacement.
4. Outside door handle to lock rod from the lock.
6. Handle with the control rod from the door.
4f Install or Connect
170. Upper Latch Rod
171. Control Assembly 1. Large gasket over the lock rod and onto the
172. Clip handle.
173. Bolt 2. Handle with the lock rod onto the door.
F-00826
Figure 43Right Door Control Assembly Do not tighten.
RIGHT DOOR CONTROL 5. Door to outside handle screw (174) to the other
ASSEMBLY REPLACEMENT side of the handle.
Tighten both screws.
6. Outside door handle to lock rod to the lock
1 . Door trim panel. Refer to Door Trim Panel assembly.
Replacement. 7. Clip onto the lock rod.
2 . Door lock access cover. Pivot the clip up and onto the lock rod.
3. Upper and lower door latch rods from the control
assembly.
Using a flat bladed screwdriver, push on the 9. Door trim panel. Refer to Door Trim Panel
top of the clip where it is connected to the Replacement.
4. Electric door actuator (if equipped).
5. Door to control assembly bolts (173). LEFT DOOR LOWER
6. Control assembly through the access hole. LATCH REPLACEMENT
Install or Connect (Figure 43) Remove or Disconnect (Figure 45)
1. Control assembly through the access hole. Open the door.

2 . Door to control assembly bolts (173).
1. Latch to door screws (182).
3. Electrical door actuator (if equipped).
2. Latch from the door.
4. Upper and lower door latch rods to the control
assembly.
Pivot the clips onto the rods. Install or Connect (Figure 45)
6. Door trim panel. Refer to Door Trim Panel 1. Latch to the door.
Replacement. 2. Latch to door screws (182).
DOORS 10A1-31
174. Screw
175. Small Gasket
176. Outside Handle
177. Large Gasket
178. Key
179. Door Lock Cylinder
180. Seal
181. Retainer
F-00829
Figure 44Door Outside Handle Components
CHECK STRAP REPLACEMENT Install or Connect (Figure 46)
Remove or Disconnect (Figure 46) 1. Bracket.
2. Bracket to inner panel bolts (187).

1. Pin.
2. Strap to door bolts (184). 3. Strap to the door.
3. Strap. 4. Strap to door bolts (184).
5. Bracket. 5. Pin.
RIGHT DOOR WEATHERSTRIP

REPLACEMENT
182 1. Weatherstrip from the door using 3M Release

Agent (or equivalent).
162. Screw jp] Clean

163. Bumper
164. Spacer The door and weatherstrip of all the old cement.
182. Screw
183. Latch Assembly
1. Weatherstrip to the door using 3M Weatherstrip

Figure 45Left Door Lower Latch Adhesive (or equivalent).
10A1-32 DOORS
184. Bolt
185. Strap Assembly
186. Bracket
187. Bolt
188. Pin
F-00479
Figure 46Check Strap Components
LEFT DOOR WEATHERSTRIP

REPLACEMENT
I*"*! Remove or Disconnet (Figure 48)
Tool Required:
J-24595-B Door Trim Pad Clip Remover.
1. Weatherstrip to door fasteners using J-24595-B.
2. Weatherstrip from the door using 3M Release

agent (or equivalent).
P] Clean
The door and weatherstrip of all the old cement.

189. Weatherstrip
190. Plastic Nails 1. Weatherstrip to the door using 3M Weatherstrip
F-00480 Adhesive (or equivalent).
Figure 47Right Door Weatherstrip 2. Weatherstrip to door fasteners.

DOORS 10A1-33
189. Weatherstrip
190. Plastic Nails
191. Fastener
F-00481
Figure 48Left Door W eatherstrip
SECONDARY WEATHERSTRIP -+ Install or Connect (Figure 49)
REPLACEMENT 1. Weatherstrip to the door using 3M Weatherstrip

Adhesive (or equivalent).

JQ* Clean
Figure 49Door Secondary Weatherstrip

10A1-34 DOORS
G MODEL SIDE FRONT DOORS
191. Upper Hinge

192. Bolt
193. Screw
194. Cover
195. Lower
Hinge
DOOR AND HINGE

REPLACEMENT
1. E lectrical w iring harness from the door (if

equipped).
Refer to Door Trim Pad Replacement for
access to the wiring harness.
2. Kick panel (if equipped). 196. Screw
3. Hinge bolt cover screw (193). 197. Spring
4. Hinge bolt cover. 198. Striker
Mark the position of the hinges on the door and 199. Spacer
door pillar. 200. Protector
F-00827
Support the door.
5. Door frame to hinge bolts (192).
6. Door from the vehicle. Figure 51Striker Components
7. Hinge to door bolts.
8. Hinges from the door. 7. Kick panel (if equipped).
8. Electrical wiring harness to the door (if equipped).
E Install or Connect (Figure 50) Refer to Door Trim Panel Replacement for
1. Hinges to the door.
2. Hinge to door bolts.
Align the hinges to the previously made DOOR ADJUSTMENT
mark.
3. Door to the vehicle. |+ + | Remove or Disconnect (Figure 51)
Align the hinges with the previously made
mark. Tool Required:
Support the door. J-23457-A #50 Torx Wrench.
4. Door frame to hinge bolts (192). 1. Lock striker protector screw (196).
5. Hinge bolt cover. 2. Lock striker protecter.
Place the tab on the cover into the slot. 3. Spring.
6. Hinge bolt cover screws (193). 4. Door striker using J-23457-A.
DOORS 10A1-35
201. Roof Panel I

202. Door
203. Front Fender I
204. Rocker Panel \ o ()4 -
205. Lock Pillar \
A. 4.5 mm 0.5 mm \
(0.18-inch 0.02-inch)
B. 6 mm 0.5 mm (0.25-inch 0.02-inch) -00485
5. Spacer. 4. The gap between the doors front edge and the
6. Kick panel (if equipped). rear edge of the fender should be 4.5 mm 0.5
7. Hinge bolt cover screw (193). mm (0.18-inch 0.02-inch).
8. Hinge bolt cover. Tighten the door hinge bolts that were loosened.
Loosen the door hinge bolts as needed to adjust
the door.
A djust (Figure 52)
1. Hinge bolt cover.
The door up or down, forward or rearward and in Place the tab on the cover into the slot.
or out, at the door hinges.
2. Hinge bolt cover screw (193).
1. Adjust the door to obtain a gap of 4.5 mm 0.5
mm (0.18-inch 0.02-inch) between the front 3. Kick panel (if equipped).
door and the roof panel. 4. Spacer to the door striker.
2. The gap between the rocker panel and the front
door at its base should be 6 mm 0.5 mm 5. Door striker.
(0.25-inch 0.02-inch). 6. Spring.
3. Adjust the door to obtain a gap of 4.5 mm 0.5
7. Lock striker protecter.
mm (0.18-inch + 0.02-inch) between the doors
rear edge and the rear door pillar. 8. Lock striker protecter screw (196).
10A1-36 DOORS
DOOR TRIM PANEL 5. Door vent/window run channel assembly from the
vehicle.
REPLACEMENT Pull the top of the vent backwards away
Lift and rotate the assembly out of the door.
Tool Required:
|-<-| Install or Connect (Figure 56)
J-9886-01 Door Handle Clip Remover.
1. Window regulator handle using J-9886-01.
1. Door vent/window run channel assembly to the
2. Window regulator handle bezel.
vehicle.
3. Door lock co ntro l assem bly handle using
J-9886-01.
4. Control assembly handle bezel.
2. Door to ventilator screws (223).
5. Assist handle (if equipped).
Start with the screw at the top of the door,
6. Arm rest (if equipped) (figure 55).
and work downward.
7. Door trim outer panel screws (if equipped).
3. Door panel to run channel bolt (228).
8. Door trim outer panel (if equipped).
4. Run channel molding.
Pull the panel away from the retainers.
9. Door trim inner panel screws. Push the corner of the molding into the run
10. Door trim inner panel. channel.
E3 Install or Connect (Figures 53 and 54) Replacement.
1. Door trim inner panel.

2. Door trim inner panel screws.
VENT GLASS REPLACEMENT
3. Door trim outer panel (if equipped).
Push the panel into the retainer.
4. Door trim outer panel screws (if equipped).
handling glass to minimize the risk o f injury.
5. Arm rest (if equipped) (figure 55).
6. Assist handle (if equipped).
7. Control assembly handle bezel. REMOVAL (Figure 57)
8. Window regulator handle bezel. 1. Open the vent window.
9. The clips to the window regulator handle and the 2. Squirt solvent on the tar-paper-like filler all
door lock control assembly handle. around the glass channel, on both sides of the
10. Window regulator handle. glass.
Push the handle onto the shaft. 3. When the filler and sealer soften, pull the glass
11. Door lock control assembly handle. and the old filler from the channel.
Push the handle onto the shaft.
INSTALLATION
1. Thoroughly clean the inside of the glass channel
DOOR VENT/WINDOW RUN with sandpaper to remove all rust and foreign
CHANNEL ASSEMBLY matter.
REPLACEMENT 2. Cut the new piece of glass channel filler 51 mm
(2-inches) longer than required.
The door vent and the front window run channel are 3. Position the filler (soap stoned side away from the
one assembly. This assembly is fit into the front of the glass) evenly around and over the edge of the
door frame. glass that will be inserted in the channel. Press
the filler firmly onto the edge of the glass to
Remove or Disconnect (Figure 56) ensure a good bond. (Usually this is done with a
mechanical window press.) Squeeze together the
Place the window in the lowered position. doubled ends of the filler which project beyond
1. Door trim panel. Refer to Door Trim Panel the edge of the glass.
Replacement. 4. Brush the inner channel with soap solution. DO
2. Run channel molding. NOT USE GREASE OR OIL.
Pul! the molding out of the vent assembly 5. Press the glass and the filler into the channel
only. until firmly seated.
3. Door panel to run channel bolt (228). 6. Trim off excess filler material around, and at the
4. Door to ventilator screws (223). end of the channel.
DOORS 10A1-37
206. Inner Panel

207. Seal
208. Screw
209. Bezel
210. Door Handle
211. W indow Handle
Figure 53Door Trim Inner Panel
VENT WINDOW ADJUSTMENT 2. Door vent/window run channel assembly. Refer to

2 A djust (Figure 58) Replacement.
Mask or cover any sharp edges that could
Remove the door trim panel. Refer to Door Trim scratch the glass.
Panel Replacement. 3. Door window glass (230).
Bend the tabs on the adjustment nut away from Slide the glass forward until the front roller
the nut. is in line with the notch in the sash channel.
Disengage the roller from the channel.
Adjust the vent by placing a wrench on the
adjusting nut, and then turning the vent window Push the window forward, then tilt it up until
to the proper tension. the rear roller is disengaged.
Place the window in a level position, and
Bend the tabs over the adjustment nut.
raise it straight up and out of the door.
Install the door trim panel. Refer to Door Trim
Panel Replacement.
1. Door window glass (230).

DOOR WINDOW REPLACEMENT Lower the window into the door frame.
|+-+| Remove or Disconnect (Figure 59) Push the window forward, then tilt it up, and
slide the rear roller into the sash channel.
Slide the glass backward until the front
CAUTION: Always wear heavy gloves when roller is in line with the notch in the sash
handling glass to minim ize the risk of injury. channel. Engage the roller to the sash
channel.
Lower the glass to the bottom of the door. Slide the glass rearward into the glass run
1. Door trim panel. Refer to Door Trim Panel channel.
Replacement. Remove any masking or covering.
10A1-38 DOORS
Inner Panel
Screw
Screw
Top Retainer
Screw
Rear Retainer
Door Trim Panel
Screw
Assist Strap
Screw
Bezel F-00487
Figure 54Door Trim Outer Panel
2. Door vent/window run channel assembly. Refer to

Replacement.
Replacement.
WINDOW STOP ASSEMBLY

ADJUSTMENT
1. Remove the door trim panel. Refer to Door Trim
Panel Replacement.
2. Lower the window until it is flush with the window
sill.
3. Loosen the glass stop bolt, and adjust the stop
until the glass is completely flush with the window
sill (figure 59).
4. Tighten the bolt.
5. Install the trim pad. Refer to Door Trim Panel
Replacement.
DOORS 10A1-39
26. Screw
27. Spacer
29. Door Vent/Window Glass Run Assembly
30. Run Channel Molding
31. Bolt F-00447
223. Screw
224. Run Channel Molding Figure 57Door Vent/W indow Run Channel
225. Bolt Components
226. Rear Run Channel Assembly
227. Bolt OUTER WINDOW
228. Bolt
229. Door Vent/Run Channel Assembly
WEATHERSTRIP
F-00491
REPLACEMENT
Figure 56Door Run Channel Assemblies
Lower the window.
INNER WINDOW
WEATHERSTRIP
REPLACEMENT
Lower the window.
Weatherstrip from the door.
Pry the weatherstrip clips from the door

panel.
Push the weatherstrip clips onto the door

panel.
10A1-40 DOORS
230. Glass H" Install or Connect (Figure 56)

231. Sash Assembly
232. Outer W indow Weatherstrip 1. Run channel to the vehicle.
233. Inner W indow Weatherstrip Work the run channel into the door frame.
234. Regulator Rail Be certain that the glass is in the channel.
235. Bolt 230 232 2. Lower door to run channel bolt (227).
236. Washer Raise the window completely.
237. Bolt
3. Upper door to run channel bolt (225).
238. Regulator
239. Stop 4. Inner and outer window weatherstrips.
Replacement.
WINDOW REGULATOR
REPLACEMENT
MANUAL REGULATOR
Raise the window and tape the glass in the full up

position using cloth body tape.
234 Replacement.
F-00492
3. Window regulator (238).
Figure 59Door W indow Components
1. Weatherstrip from the door. disengage the lower roller from the regulator
Pry the weatherstrip clips from the door rail.
panel. Disengage the forward roller from the sash
Collapse the regulator, and remove it
Install or Connect
Push the weatherstrip clips onto the door
panel. Lubricate the regulator and the sash and
regulator rails with lubriplate or equivalent.
1. Window regulator (238).
REAR GLASS RUN Collapse the regulator, and insert it through
CHANNEL REPLACEMENT the access hole in the door.
Unfold the regulator, and engage the
Remove or Disconnect (Figure 56) forward roller to the sash channel at the
sash channel notch.
1. Door trim panel. Refer to Door Trim Panel Slide the regulator rearward to engage the
Replacement. rear roller to the sash channel. Also engage
the lower roller to the regulator rail.
Lower the window completely.
Slide the regulator into its proper position,
2. Inner and outer window weatherstrips. and insert the regulator drive through the
door panel.
3. Door to run channel bolts (225 and 227).
Pull the run channel upwards while twisting Replacement.
to clear the lower bracket. Remove the tape from the window.
DOORS 10A1-41
S.ide the regulator rearward to disengage

rail.
Collapse the regulator, and remove it
CAUTION: The next step must be performed

when the re g u la to r is rem oved from the
d o o r. The re g u la to r lift arm s are under
tension from the counterbalance spring and
can cause serious in ju ry if the m otor is
removed w ithout locking the sector gear in
position.
Drill a hole through the regulator sector gear and

(1/2 -inch) away from the edge of the sector gear or
back plate. Install a pan head sheet metal
tapping screw at least 19 mm (3/4-inch) long into
the drilled hole to lock the sector gear in place.
7. Motor to regulator attaching screws.
0
231. Sash Channel
240. Bumper
241. Stop Install or Connect (Figure 60)
242. Bolt
243. Washer Lubricate the motor drive gear and regulator
244. Bolt sector teeth.
245. Nut 1. Regulator motor to regulator.
246. Power Regulator The motor pinion gear teeth must mesh
properly with the sector gear teeth before
F-00493 installing the motor to regular screws.
2. Regulator motor to regulator screws.
Figure 60Power W indow Regulator Remove the sheet metal screw from the back
plate and sector gear.
POWER REGULATOR 3. Window regulator to the door.
For the diagnosis of power window circuits, refer to Collapse the regulator, and insert it through
CAB ELECTRICAL (SEC. 8A). the access hole in the door.
Unfold the regulator, and engage the
|+ + | Remove or Disconnect (Figure 60) forward roller to the sash channel at the
sash channel notch.
Raise the window and tape the glass in the full up Slide the regulator rearward to engage the
position using cloth body tape. rear roller to the sash channel. Also engage
1. Battery ground cable. the lower roller to the regulator rail.
2. Door trim panel. Refer to Door Trim Panel Slide the regulator into its proper position.
Replacement. 4. Wiring harness to the regulator.
3. Remote control to door trim panel bolts. 5. Regulator to door panel bolts (244) and nuts
(245).
Lay the control aside.
6. Remote control to door trim panel bolts.
4. Regulator to door panel bolts (244) and nuts 7. Door trim panel. Refer to Door Trim Panel
(245). Replacement.
5. Wiring harness from the regulator. 8. Battery ground cable.
6. Window regulator (246). Remove the tape from the window.
10A1-42 DOORS
DOOR LOCK REPLACEMENT 247 247. Lock Assembly

248. Clip
249. Inside Handle Rod
250. inside Lock Rod
251. Clip
252. Power Lock Rod
Replacement.
2. Door lock knob.
3. Remove control assembly. Refer to Remote
Control Replacement.
4. Rear glass run channel. Refer to Rear Glass 249
Run Channel Replacement.
5. Door to lock screws (267).
6. Lock from the door.
Lower the lock in the door far enough to
provide clearance for the inside lock rod.
install or Connect (Figures 61 and 62)
1. Lock to the door.

Align the lock rod with the hole in the top of
the door panel.
3. Rear glass run channel. Refer to Rear Glass
Run Channel Replacement.
4. Remote control assembly. Refer to Remote F-00494
Control Assembly.
5. Door lock knob. Figure 61Door Lock With Lock Rods
Replacement.
POWER DOOR LOCK

MOTOR REPLACEMENT
Refer to CAB ELECTRICAL (SEC. 8A) for electrical
diagnosis of the door lock motor.

Replacement.
3. Electrical connector from the motor.
5. Motor from the lock rod.
motor off of the door lock rod.
Install or Connect (Figure 62) 247. Lock Assembly

252. Power Lock Rod
1. Motor into the door. 266. Power Door Lock Motor
2. Motor to the lock rod. 267. Bolt
Slide the rubber mount at the top of the 268. Bolt 266 F-00495
4. Electrical connector to the motor. Figure 62Door Lock Attachments
DOORS 10A1-43

Replacement.
DOOR OUTSIDE
HANDLE REPLACEMENT
|*"| Remove or Disconnect (Figure 63)

Replacement.
2. Door to outside handle screws (253). :
\
3. Handle from the door.
253. Bolt 257. Retainer

1. Large gasket onto the handle.
254. Small Gasket 258. Key
2. Door to outside handle screw (253) to the push 255. Door Handle 259. Lock Cylinder
button side of the handle. 256. Large Gasket 260. Gasket
Do not tighten. F-00496
4. Door to outside handle screw (253) to the other Figure 63Outside Handle And Lock
side of the handle. Cylinder Components
5. Door trim panel. Refer to Door Trim Panel DOOR LOCK CONTROL
Replacement. ASSEMBLY REPLACEMENT
DOOR LOCK CYLINDER
REPLACEMENT 1. Door trim panel. Refer to Door Trim Panel
Replacement.
2. Door panel to control assembly screws (262).
3. Control assembly from the lock assembly rod.
Pivot the clip away from the rod at the
Door trim panel. Refer to Door Trim Panel
control assembly.
Replacement.
Twist the control assembly off the rod.
Lock cylinder retaining clip from the cylinder.
4. Control from the vehicle.
0
Slide the clip off the cylin d er with a
screwdriver.
Lock cylinder and gasket from the door. + 2 Install or Connect (Figure 64)
Lock cylinder with gasket to the door.

1. Control to the vehicle.
2. Control assembly to the lock assembly rod.
Twist the control assembly (with clip) onto
the rod.
assembly lever. Pivot the clip onto the rod.
2. Lock cylinder retaining clip onto the cylinder. 3. Door panel to control assembly screws (262).
3. Door trim panel. Refer to Door Trim Panel 4. Door trim panel. Refer to Door Trim Panel
Replacement. Replacement.
10A1-44 DOORS

262. Screw 248
263. Clip
_ 261
F-00497
Figure 64Door Lock Control

264. Weatherstrip
265. Plastic Nail
DOOR WEATHERSTRIP
REPLACEMENT
|+ + | Remove or Disconnect (Figure 65) F-00498

Figure 65Door W eatherstrip
2. Plastic nails from the door. BELOW EYELINE OUTSIDE

REAR VIEW MIRROR
REPLACEMENT
Clean
The door of all the old cement.


Lift the cover, and pivot the mirror towards the
Install or Connect (Figure 65) window.
2. Mirror to door bolts and nut.
1. Weatherstrip adhesive to the door. Use 3M 3. Mirror and seal from the door.
Weatherstrip Adhesive (or equivalent).
1. Mirror and seal to the door.
Locate the weatherstrip part number, and 2. Mirror to door bolts and nut.
place it at the top of the vent window. Pivot the mirror away from the window, and lower
the mirror cover.
Press the plastic nails into the door. 3. Mirror cover screw.
DOORS 10A1-45
G MODEL INTERMEDIATE DOORS
269 269. Cap

270. Bolt
271. Hinge
272. Grommet 273
273. Seal
274. Retainer
272
F-00499
DOOR AND HINGE Support the door.
REPLACEMENT 4. Hinge to the body pillar bolts (270).

5. Door from the vehicle.
* t l Remove or Disconnect (Figures 66 and 67)

6. Hinge to door bolts (270).
Open the door. 7. Hinges from the door.
1. Electrical wiring harness (if equipped). 8. Retainers (274), seals (273), and grommets (272)
Refer to Door Trim Panel Replacement for from the door or the hinges.
Mark the position of the door on the hinges using
a wax pencil.
2. Hinge hole plugs on the body side pillar.
1. Grommet to the door.
3. Strap pin (275) from the bracket.
Remove the snap ring from the pin, and pull 2. Hinge to the door.
the pin. 3. Hinge to door bolts (270).
Align the hinge to the previously made
mark.
4. The seals and retainers to the body half of the
hinge.
5. Door to the vehicle.
Support the door.
6. Hinge to body pillar bolts (270).
mark.
275
7. Strap pin (275) to the bracket.
276. Bracket
277. Bolt 8. Snap ring to the pin.
278. Ring 9. Hinge hole plugs on the body side pillar.
279. Strap
280. Pin F-00500 10. Electrical wiring harness (if equipped).
Refer to Door Trim Panel Replacement for
Figure 67Check Strap Components access to the wiring harness.
10A1-46 DOORS
281. Front Door

282. Rear Door
283. Roof Panel
284. Rocker Panel
286. Lock Pillar Or Body Side Outer Panel
A. 4.5 mm 0.5 mm (0.18-inch 0.020-inch)
B. 6 mm 0.5 mm (0.24-inch 0.020-inch)
C. 4 mm 0.5 mm (0.16-inch 0.020-inch) F-00501
DOOR ADJUSTMENT 1. The door height so that there is a gap of 4.5 mm

0.5 mm (0.18-inch 0.020-inch) between the
Remove or Disconnect (Figure 68) doors and the roof panel.
2. The gap between the door and the rocker panel
Tool Required: to 6 mm 0.5 mm (0.24-inch 0.020-inch).
J-23457-A Wrench. 3. The gap between the doors and the body at the
1. Door lock striker from the rear intermediate door hinge pillars to 4 mm 0.5 mm (0.16-inch
using J-23457-A. 0.020-inch).
2. Upper and lower rear intermediate door strikers. 4. The gap between the front and rear intermediate
Loosen the hinge bolts as necessary to adjust the doo rs to 6 mm 0.5 mm (0 .2 5 -in ch
doors. 0.020-inch).
Tighten the hinge bolts that were loosened.
A djust
Install or Connect
Each of the two doors must first be adjusted in
the door opening before adjusting the door to 1. Upper and lower rear intermediate door strikers to
door clearance. the body.
The door up or down, forward or rearward, and in 2. Door lock striker to the rear intermediate door
or out, at the door hinges. using J-23457-A.
DOORS 10A1-47
A djust (Figure 69)
The upper and lower rear intermediate door

striker to door clearance so that there is 4.4 mm
(0.172-inch) between the striker and the door latch
when the door is in the secondary latched
position. (The door is latched but not fully closed.)
An 11/64-inch diameter drill bit may be used to
gage this clearance.
The front intermediate striker on the rear door.
Adjust it so that the front door lock properly
engages the rear door, and so the front door is
flush with the rear door.
BUMPER WEDGE
REPLACEMENT
1. Bumper to upper and lower door frame screws

(308).
2. Bumper and spacer.
287. Striker
Install or Connect (Figure 70) 288. Latch
A. 4.4 mm (0.172-inch) F-00503
2. Bumper. Figure 69S triker Adjustm ents
3. Bumper to upper and lower door frame screws
(308). |-n-| Install or Connect (Figure 71)
Adjust 1. Door garnish molding to the door.

2. Door garnish molding screws (289).
The bumper to door clearance so that there is 1 3. Retainers to the door.
mm (0.04-inch) between the bumper and the door 4. Retainer to door screws (293).
when the door is in the secondary position. (The 5. Door trim panel.
door is latched but not fully closed). Push the edge of the panel into the
retainers.
DOOR TRIM PANEL 7. Door handle bezel and lock knob to the vehicle.
REPLACEMENT Place the lock knob onto the lock rod.
8. Door handle bezel screws.
INTERMEDIATE FRONT DOOR 9. Door strap.
|+ + | Remove or Disconnect (Figure 71) INTERMEDIATE REAR DOORS
1. Door strap. Remove or Disconnect (Figure 72)

Pry the lock knob off of the lock rod, when the
knob is in the unlocked position. 1. Door trim panel to door screws (305).
2. Door handle bezel screws. 2. Door trim panel.
3. Bezel and lock knob from the vehicle. Pull the panel from the retainers.
4. Door trim panel to door screws (295). 3. Side door garnish molding screws (304) and bolt
5. Door trim panel. (302).
Pull the panel from the retainers. 4. Side door garnish molding from the door.
6. Retainer to door screws (293). 5. Retainer to door screws (301).
7. Retainers from the door. 6. Retainer from the door.
8. Door garnish molding screws (289). 7. Upper door garnish molding screws (298).
9. Door garnish molding from the doors. 8. Upper door garnish molding from the door.
10A1-48 DOORS
WINDOW REPLACEMENT
crisscrossed with masking tape to reduce the risk of
to the edge of the glass, mark the door with a piece of
weatherstrip. Later, when examining the flange of the
opening for a cause of the crack, start at the point
marked.
It is important that the cause of the crack be

determined and the condition corrected, before the
new glass is installed. The cause of the crack may be
pressure from the high spot or obstruction becomes
p a rtic u la rly high due to w in d s, e xtre m e s of
temperature, or rough terrain.
STATIONARY GLASS
312
313 CAUTION: Always wear heavy gloves when

307. Bolt handling glass to minimize the risk of injury.
308. Screws
309. Bumper 1. W eatherstrip seal by running a putty knife
310. Spacer between the flange and the weatherstrip (inside
311. Upper Latch and outside the door).
312. Lower Latch 314 Have an assistant outside the cab by the
313. Screw
window.
314. Drain Hole Plug
F-00506
2. Weatherstrip and glass from the flange.
Figure 70Bumper Wedge Components Force the weatherstrip from the flange from
the inside with a putty knife
- Install or Connect (Figure 72) 3. Window from the weatherstrip.
1. Upper door garnish molding to the door.

2. Upper door garnish molding screws (298).
1. Weatherstrip to the glass.
3. Retainer to the door. The seam of the weatherstrip must be
located at the bottom centerline of the glass.
4. Retainer to door screws (301).
2. A six mm (1/4-inch) cord in the weatherstrip
5. Side door garnish molding to the door. groove. The ends should overlap about 5 cm
6. Side door garnish molding screws (304) and bolt
(302). 3. Window and weatherstrip on the flange from
outside the cab.
7. Door trim panel. Brush soapy water on the flange.
Push the edge of the panel into the retainer. Have an assistant pull the cord from inside
the cab to seat the lip of the weatherstrip on
8. Door trim panel to door screws (305). the flange.
DOORS 10A1-49
Figure 71Intermediate Front Door Trim Panel
SWING OUT WINDOW H" Install or Connect (Figures 74 and 75)
Remove or Disconnect (Figures 74 and 75) 1. Hinge and hinge seal to the door.
2. Hinge to door screws (320).
3. Window latch to the window.
CAUTION: Always wear heavy gloves when Place the cover and spacer through the
handling glass to minim ize the risk of injury. window.
Place the washer and spring onto the cover.
1. Window latch to door screws (327). Twist the latch onto the cover with of a
turn.
2. Window latch from the window. 4. Window latch to door screws (327).
Twist the latch V* of a turn to release the
latch components from the window.
INTERMEDIATE FRONT DOOR
Lift the window for access to the hinge screws. LOCK REPLACEMENT
4. Hinge from the door.
1. Door trim panel. Refer to Door Trim Pane'
5. Hinge seal from the door. Replacement.
10A1-50 DOORS
Figure 72Intermediate Rear Door Trim Panel
2. Door lock control. Refer to Door Lock Control INTERMEDIATE FRONT

Replacement.
3. Power door lock motor (if equipped). Refer to
DOOR LOCK CONTROL
Power Door Lock Motor Replacement. REPLACEMENT
4. Door to remote control screws (330).
5. Door to lock screws (331). Remove or Disconnect (Figure 77)
6. Lock and remote control with rods from the door.
Replacement.
2. Lock control to door screw (337).
1. Lock and remote control with rods to the door.
3. Lock control from the door.
3. Door to remote control screws (330). Slide the control towards the front of the
4. Power door lock motor (if equipped). Refer to door.
Power Door Lock Motor Replacement.
4. Lock rod from the lock control.
5. Door lock control. Refer to Door Lock Control
Replacement. Slide the clip so that the large diameter slot
6. Door trim panel. Refer to Door Trim Panel is in line with the lock rod. Then, pull the rod
Replacement. from the control.
DOORS 10A1-51
+ + Install or Connect (Figure 77)
1. Lock rod to the lock control.

Place the rod into the clip and the lever.
Slide the clip so that the small diameter slot
is in line with the lock rod.
315 2. Lock control to the door.
Slide the control towards the rear of the
door.
3. Lock control to door screws (337).
Replacement.
DOOR LOCK CYLINDER

REPLACEMENT

Replacement.
2. Lock cylinder retaining clip from the cylinder.
Slide the clip off the cylin d e r with a
screwdriver.
3. Lock cylinder and gasket from the door.
4- Instali or Connect (Figure 78)
1. Lock cylinder with gasket to the door.

315. Weatherstrip
316. Glass
assembly lever.
2. Lock cylinder retaining clip onto the cylinder.
Replacement.
F-00507
Figure 73W indow Components DOOR OUTSIDE

HANDLE REPLACEMENT
327
322 |+ + | Remove or Disconnect (Figure 78)

323 1. Door trim panel. Refer to Door Trim Panel
Replacement.
3. Handle from the door.
318. Glass 4. Gaskets from the door.
322. Cover 326. Spring
323. Spacer 327. Screw - Install or Connect (Figure 78)
325. Washer 328. Latch
1. Large gasket onto the handle.
Figure 74Swing Out Latch Components 2. Door to outside handle screw (341) to the push
Do not tighten.
4. Door to outside handle screw (341) to the other
side of the handle.
10A1-52 DOORS
Figure 75Swing Out W indow Attachm ent
329. Remote Control

330. Bolt
331. Bolt
332. Lock Assembly
333. Clip
334. Remote Control Rod
336. Inside Lock Rod
F-00510
Figure 76Intermediate Front Door Lock Components

DOORS 10A1-53
Figure 77Intermediate Front Door Lock Control
5. Door trim panel. Refer to Door Trim Panel. -+ Install or Connect (Figure 79)
1. Lower latch with the rod to the door.

INTERMEDIATE REAR DOOR 2. Lower latch to door screws (349).
LOWER LATCH REPLACEMENT 3. Lower latch to control assembly rod into the
control assembly.
+ + Remove or Disconnect (Figure 79) Pivot the clip onto the rod.
1. Door trim panel. Refer to Door Trim Panel Replacement.
Replacement.
2. Lower latch to control assembly rod from the
control assembly. INTERMEDIATE REAR DOOR
Using a flat bladed screwdriver, push on the UPPER LATCH REPLACEMENT
rod. Pivot the clip away from the rod. Remove or Disconnect (Figure 80)
3. Lower latch to door screws (349).

4. Lower latch with the rod from the door. Replacement.
339. Outside Handle

340. Large Gasket
341. Bolt
342. Retainer
343. Key
344. Lock Cylinder
345. Gasket
346. Small Gasket
Figure 78Outside Handle And Lock Cylinder Components

10A1-54 DOORS

347. Lower Latch Rod
assembly.
348. Lower Latch - i-------- 347 Using a flat bladed screwdriver, push on the
349. Bolt
I L -------- 348 rod. Pivot the clip away from the rod.
jo 3. Electric door actuator (if equipped).

4. Lock knob (356).
5. Rear door inside handle screw (364) and handle
4^34$ 1-4 (365).

6. Rear door lock rod clip at the door panel.
Pivot the clip away from the rod.
F-00513 7. Door to control assembly bolts (363).
8. Control assembly with lock rod through the
Figure 79Intermediate Rear Door Lower Latch access hole.
2 . Upper latch to control assembly rod from the |-n-| Install or Connect (Figure 81)
control assembly.
Using a flat bladed screwdriver, push on the 1. Control assembly with lock rod through the
top of the clip where it is connected to the access hole.
rod. Pivot the clip away from the rod. 2. Door to control assembly bolts (363).
U pper latch to door bolts (350). 3. Rear door lock rod clip at the door panel.
Upper latch with the rod from the door. Pivot the clip onto the rod.
4. Rear door inside handle (365) and screw (364).
Install or Connect (Figure 80) 5. Lock knob (356).
1. Upper latch with the rod to the door. 7. Upper and lower door latch rods to the control
2. Upper latch to door bolts (350). assembly.
3. Upper latch to control assembly rod into the Pivot the clip onto the rod.
control assembly. 8. Door trim panel. Refer to Door Trim Panel
Replacement.
Replacement. POWER DOOR LOCK
MOTOR REPLACEMENT
INTERMEDIATE REAR DOOR
Refer to CAB ELECTRICAL (SEC. 8A) for electrical
CONTROL ASSEMBLY diagnosis of the door lock motor.
REPLACEMENT
1. Door trim panel. Refer to Door Trim Panel 2. Door trim panel. Refer to Door Trim Panel
3 50

350. Bolt
351. Upper Latch 1. Motor into the door.
352. Upper Latch Rod 2. Motor to the lock rod.
F-00514 motor onto the door lock rod.
Figure 80Intermediate Rear Door Upper Latch 4. Electrical connector to the motor.
DOORS 10A1-55
.353
356 353. Control Assembly
/ 354. Clip
r 355. Lock Rod
357 356. Lock Knob
/ 357. Ferrule
358. Screw
359. Protector
355 360. Spring
361. Striker
362. Washer
363. Bolt
364. Screw
365. Handle
F-00515
Figure 81Intermediate Rear Door Control Assembly
5. Door trim panel. Refer to Door Trim Panel INTERMEDIATE FRONT DOOR
Replacement.
367 1. Weatherstrip from the door using 3M Release

332. Lock Assembly
2. Plastic nails from the door.
367. Clip
368. Lock Motor Rod
368 369. Lock Motor
370. Screws jQJ Clean
370 The door of all the old cement.
1. Weatherstrip adhesive to the door. Use 3M

Figure 82Power Door Lock Motor Attachments 2. New weatherstrip to the door.
Press the plastic nails into the door.

10A1-56 DOORS
371. Weatherstrip
372. Plastic Nail
F-00518
Figure 83Intermediate Front Door W eatherstrip
373. Weatherstrip
374. Plastic Nail
375. Screw
373
373
F-00519
Figure 84Intermediate Rear Door Weatherstrip

DOORS 10A1-57
INTERMEDIATE REAR DOOR Clean
WEATHERSTRIP REPLACEMENT The door of all the old cement.
+ + Remove or Disconnect (Figure 84) Install or Connect (Figure 84)
1. Weatherstrip to door panel screws (375). 1. Weatherstrip adhesive to the door. Use 3M
2. WeatherstriD from the door using 3M Release Weatherstrip adhesive (or equivalent).
Agent (or equivalent). 2. New weatherstrip to the door.
3. Plastic nails from the door. Press the plastic nails into the door.
3. Weatherstrip to door panel screws (375).
G MODEL SLIDING SIDE DOOR
DOOR REPLACEMENT HINGE ASSEMBLY

REPLACEMENT
1. Upper rear track cover and hinge cover. Remove or Disconnect (Figure 88)
Open the door completely. Close the door completely.

1. Hinge cover (figure 85).
2. Upper front roller assembly (381) from the door. 2. Track cover (figure 86).
Mark the position of the roller assembly on 3. Hinge retainer plate (393).
the door. Mark the position of the hinge on the door.
4. Nut (390), washer (389), and retainer (380).
3. Upper rear hinge retainer (393) from the hinge.
5. Hinge to door screw (391).
4. Upper rear hinge (394) from the upper rear track. 6. Hinge to door bolt (388).
7. Hinge from the vehicle.
Lift the hinge off of the track.
5. Lower front roller (398) from the track. Install or Connect (Figure 88)
Pivot the door away from the vehicle to
1. Hinge to the vehicle.
disengage the rollers.
Place the roller on the track.
6. Door from the vehicle. Align the hinge to the previously made mark.
2. Hinge to door bolt (388).
Install or connect (Figures 85 through 89) 3. Hinge to door screw (391).
4. Retainer (380), washer (389) and nut (390).
1. Door to the vehicle. 5. Hinge retainer plate (393).
6. Track cover (figure 86).
2. Lower front roller (398) to the track.
7. Hinge cover (figure 85).
Pivot the door away from the vehicle to
engage the rollers to the track. Then pivot
the door towards the vehicle. LOWER ROLLER ASSEMBLY
3. Upper rear hinge (394) to the upper rear track.
REPLACEMENT
Lift the hinge roller onto the track. Remove or Disconnect (Figure 89)
4. Upper rear hinge retainer (393) to the hinge.
Mark the position of the assembly to the bracket
5. Upper front roller assembly (381) to the door. on the roller assembly.
1. Roller assembly to door bracket bolts (401).
Align the roller assembly to the previously
2. Catch clip (400) and rod from the catch.
made mark.
3. Pivot the roller assembly out of the lower door
6. Upper rear track cover and hinge cover. track.
10A1-58 DOORS
1. Roller into the track.
2. Bracket to door bolts (386).
3. Plastic cap (if equipped).
4. Roller molding (if equipped).
1. Pivot the roller assembly into the lower door

track.
2. Roller assembly to door bracket bolts (401).
Align the roller assembly to the previously

made mark.
3. Catch clip (400) and rod to the catch.

381. Front Roller Bracket
415. Upper Roller
UPPER FRONT ROLLER 416. Spacer
417. Spring Washer
REPLACEMENT 418. Nut
A. Center The Roller
Remove or Disconnect (Figure 87) In The Track
1. Roller molding (if equipped).
2. Plastic cap (if equipped).
3. Bracket to door bolts (386). F-00522
4. Roller from the track.

Figure 87Upper Front Roller Components
Figure 86Upper Hinge Cover

DOORS 10A1-59
395 387 380. Cover Retainer

387. Spring
388. Bolt
389. Washer
390. Nut
391. Screw
392. Bolt
393. Retainer
394. Hinge Assembly
395. Striker
A. Lubrication Points
392 393 A 394 A 391 380 389 390 F-00523
Figure 88Upper Rear Hinge Components
DOOR ADJUSTMENT mm (0.25-inch 0.02-inch) between the bottom

of the door and the rocker panel. To accomplish
UP AND DOWN ADJUSTMENT this adjustment, loosen the upper rear hinge to
door bolts (figure 88), and align the rear edge
Remove or Disconnect (Figure 90) ofthe door up or down. Next, tighten the upper
rear hinge to door bolts (figure 88).
Tool Required: 2. The front edge of the door by loosening the upper
J-23457 #50 Torx Wrench. front roller bracket to door bolts (figure 87) and
Upper rear hinge cover. the lower hinge to door bolts (figure 89). Align the
Front lock striker (404). door to obtain the same gap as in step 1, then
Rear lock striker (405) using J-23457. tighten the lower hinge to door bolts (figure 89).
Rear door wedge assembly (407). 3. The upper front roller bracket up or down so that
the roller is centered in the track. The roller must
f t A djust (Figure 91) not touch the top or bottom of the track. Tighten
the upper front roller bracket to door bolts (figure
1. The rear edge of the door to obtain a gap of 4.5 92).
mm + 0.5 mm (0.18-inch 0.02-inch) between
the top of the door and the roof side rail. This Install or Connect (Figure 90)
adjustment should provide a gap of 6 mm 0.5
1. Rear door wedge assembly (407).
396. Bolt 2. Rear lock striker (405) using J-23457.
397. Striker 3. Front lock striker (404).
398. Roller Assembly 4. Upper rear hinge cover.
399. Catch
400. Clip IN AND OUT ADJUSTMENT (Figures 90 through 92)
401. Bolt 1. Remove the front lock striker (404).
2. Loosen the nut (418) retaining the upper front
roller (415) to the upper roller bracket (381).
3. Loosen the lower front roller assembly to roller
assembly bracket bolts (figure 89).
398 4. Loosen the rear door lock striker.
5. Adjust the door in or out until the surface of the
door is flush with the surface of the body.
6. Tighten the rear door lock striker.
7. Tighten the lower front roller assembly to roller
assembly bracket bolts (figure 89).
F-00524
8. Tighten the nut (418) retaining the upper front
roller (415) to the upper roller bracket (381).
Figure 89Lower Front Roller Assembly 9. Install the front lock striker.
10A1-60 DOORS
Figure 90Front And Rear Lock Striker
FORWARD AND REARWARD ADJUSTMENT 7. Close the door to make an impression of the lock
1. Mark the position of the front and rear latch on the striker.
strikers on the body pillars.
8. Open the door and measure the distance from
2. Remove the front (404) and rear (405) lock
the rear of the striker head to the impression. The
strikers (figure 90).
distance should be between 5 mm and 8 mm
3. Remove the upper front track over.
(0.20-inch and 0.30-inch).
4. Loosen the upper rear hinge striker (figure 88).
5. Adjust the door forward or rearward to obtain a 9. Adjust the striker by adding or deleting shims.
gap of 4.5 mm 0.5 mm (0.18-inch 0.02-inch) Align the striker to the previously made marks.
between the left and right door edge and the door
pillars (figure 91). 10. Tighten the striker using J-23457
6. Tighten the upper rear hinge striker (figure 88).
7. Install the upper front track cover. UPPER REAR HINGE ADJUSTMENT (Figure 93)
8. Install the front (404) and rear (405) lock strikers 1. The lower hinge lever (419) should have a gap of
at the position previously marked (figure 90). 2.5 mm to 4 mm (0.10-inch to 0.16-inch) between
the outer edge of the lower lever and the striker
FRONT STRIKER ADJUSTMENT (Figure 90)
latch edge. This adjustment is made by adding
1. Loosen the front latch striker bolts (403). an equal amount of shims between the guide
2. Slide the door towards the striker.
block (420) and the hinge assembly, and between
3. The guide on the door must fit snugly into the
the roller and the hinge assembly.
rubber lined opening in the striker assembly.
4. Check that the latch fully engages the striker. Add 2. Adjust the striker up or down to obtain a gap of
or delete shims behind the striker to accomplish 1.5 mm (0.06-inch) between the lower edge of the
this adjustment. striker plate (395) and the lower edge of the lower
5. Tighten the striker bolts (403). hinge lever (419).
3. Adjust the guide up or down to obtain a gap of 0.5

REAR STRIKER ADJUSTMENT (Figure 90)
mm (0.02-inch) between the track and the guide.
Tool Required:
J-23457 Wrench.
1. Loosen the striker using J-23457 DOOR HOLD OPEN CATCH ADJUSTMENT (Figure
2. Loosen the rear wedge assembly. 89)
3. Center the striker vertically so that the striker 1. Mark the position of the lower roller assembly to
properly engages the door lock. Mark the vertical the bracket.
position of the striker.
4. Adjust the striker in or out to align the surface of 2. Loosen the lower roller assembly bolts (401).
the door flush with the body surface. Mark the 3. Pivot the lower roller assembly to properly
position of the striker. engage the latch striker.
5. Tighten the striker using J-23457.
6. Open the door, and apply grease to the striker. 4. Tighten the lower roller assembly bolts (401).
DOORS 10A1-61
Figure 91Door Adjustments

10A1-62 DOORS
381. Front Roller

Assembly
382. Molding
383. Screw
384. Screw
385. Cap
386. Bolt
F-00535
Figure 92Upper Front Roller Adjustm ent
REAR WEDGE ASSEMBLY ADJUSTMENT (Figure

94)
1. Loosen the rear wedge assembly screws (408).
2. Completely close the door.
3. From inside the vehicle, center the wedge
394 419 assembly (407) onto the door wedge.
4. Mark the position of the wedge assembly.
395 5. Open the door, and move the wedge assembly
forward 4.7 mm (3/ie-inch).
6. Tighten the rear wedge assembly screws (408).
DOOR TRIM PANEL

REPLACEMENT
420 394 Remove or Disconnect (Figure 95)
1. Inside door handle screw (429).

2. Inside door handle (422).
3. Inside door handle cover (430).
4. Lock knob (428).
Pull the knob from the door.
421 H. 4.7 mm (3/a-inch)
Y
407. Wedge Assembly
394. Hinge Assembly H 408. Bolt
395. Striker
419. Lower Hinge Lever jU
420. Guide Block J__ IT
421. Track
A. 2.5 mm to 4 mm (0.10-inch to 0.16-inch)
B. 1.5 mm (0.06-inch)
C. 0.5 mm (0.02-inch) F-00539
F-00540
Figure 93Upper Rear Hinge Adjustments
Figure 94Rear Wedge Adjustment
DOORS 10A1-63
422. Inside Handle

423. Assist Strap
424. Door Trim Panel
425. Screw
426. Cover
427. Screw
428. Lock Knob
429. Screw
430. Cover
429 428 F-00541
5. Door assist strap screws (425), and assist strap STATIONARY GLASS
(423).
6. Trim panel to door screws (427).
7. Trim panel from the door.
E3 Install or Connect (Figure 95) handling glass to minim ize the risk o f injury.
f
1. Trim panel to the door. 1. W eatherstrip seal by running a putty knife
between the flange and the weatherstrip (inside
2. Trim panel to door screws (427).
and outside the door).
3. Door assist strap (423) and assist strap screws
(425). Have an assistant outside the cab by the
window.
4. Lock knob (428).
5. Inside door handle cover (430). 2. Weatherstrip and glass from the flange.
6. Inside door handle (422). Force the weatherstrip from the flange from
7. Inside door handle screw (429). the inside with a putty knife.
3. Window from the weatherstrip.
WINDOW REPLACEMENT
Install or Connect
crisscrossed with masking tape to reduce the risk of 1. Weatherstrip to the glass.
The seam of the weatherstrip must be
to the edge of the glass, mark the door with a piece of
located at the bottom of the glass.
weatherstrip. Later, when examining the flange of the 2. Asix mm (1/4-inch) cord in the weatherstrip
opening for a cause of the crack, start at the point groove. The ends should overlap about 5 cm
marked. (6-inches) at the window bottom.
It is im portant that the cause ofthe crack be
3. Window and weatherstrip on the flange from
determined and the condition corrected, before the
outside the cab.
an obstruction or high spot somewhere around the Brush soapy water on the flange.
pressure from the high spot or obstruction becomes Have an assistant pull the cord from inside
p a rtic u la rly high due to w in d s, e xtre m e s of the cab to seat the lip of the weatherstrip on
temperature, or rough terrain. the flange.
10A1-64 DOORS
SWING OUT WINDOW 3. Hinge to door screws (435).

4. Hinge from the door.
5. Hinge seal from the door.
CAUTION: Always wear heavy gloves when -<- Install or Connect (Figure 97)
1. Hinge and hinge seal to the door.
1. Window latch to door screws (441). 2. Hinge to the door screws (435).
2. Window latch from the window. 3. Window latch to the window.
Twist the latch 1A* of a turn to release the Place the cover and spacer through the
latch components from the window. window.
Lift the window for access to the hinge screws. Place the washer and spring onto the cover.
4. Glass 439. Spacer

5. Screw 440. Washer 437
6. Hinge 441. Screw
7. Weatherstrip 442. Latch
8. Cover 443. Spring 435
436
434
438 439 440 441
442
F-00543
Figure 97Swing Out Window Components

DOORS 10A1-65
Figure 98Door Lock Access Panel
Twist the latch onto the cover with 1A of a install or Connect (Figures 98 and 99)
turn.
4. Window latch to door screws (441). 1. Lock assembly to the door.
2. Lock cylinder rod clip.
3. Lower latch rod to the lock.
FRONT LOCK REPLACEMENT Pivot the clip onto the rod.
4. Rear door lock rods to the front lock.
Remove or Disconnect (Figures 98 and 99) Pivot the clip onto the rod.
5. Lock to door screws (449 and 451).
1. Door trim panel. Refer to Door Trim Panel 6. Outside door handle (422).
Replacement. 7. Lock access panel (444) and panel screws (445).
2. Lock access panel screws (445) and the panel
(444). Replacement.
Pull the panel upwards to disengage the

clips. REAR LOCK REPLACEMENT
3. Outside door handle (422).
4. Lock to door screws (449 and 451). Remove or Disconnect (Figure 100)
5. Rear door lock rods from the front lock.

1. Lock rods from the lock.
Pivot the clips from the rods, and pull the Pivot the clip from the rod, and pull the rod
rods from the lock. from the lock.
6. Lower latch rod from the lock. 2. Lock to door screws (457).
Pivot the clip from the rod and pull the rod 3. Lock from the door through the access hole.
from the lock.
7. Lock cylinder rod clips.
Slide the clip to release the rod. 1. Lock to the door through the access hole.
8. Lock assembly from the door. 2. Lock to door screws (457).
10A1-66 DOORS
Figure 99Door Lock Attachm ent
Upper Lock Rod

Lower Lock Rod
Latch Rod Retainer
Clip
Rear Lock Assembly
Screw
Bumper
Screw
F-00546
Figure 100Rear Lock Attachment

DOORS 10A1-67
450. Lock Cylinder Rod

460. Outside Handle
461. Washer
462. Retainer
463. Gasket
464. Cylinder
465. Key F-00547
Figure 101Outside Handle And Lock Cylinder Attachm ents
Lock rods to the lock. SLIDING SIDE DOOR

Pivot the clip onto the rod. WEATHERSTRIP REPLACEMENT
LOCK CYLINDER
REPLACEMENT Agent (or equivalent).
2. Plastic nails from the door.
*] Clean
1 . Door trim panel. Refer to Door Trim Panel
Replacement.
The door of all the old cement.
2 . Door lock cylinder rod (450).
3. Cylinder retainer (462).
Pry the retainer from the lock. 1. Weatherstrip adhesive to the door. Use 3M
4. Cylinder (464) and seal (463) from the door. Weatherstrip Adhesive (or equivalent).
2. New weatherstrip to the door.
Press the plastic nails into the door.
1. Cylinder (464) and seal (463) to the door.

2 . Cylinder retainer (462).
Push the retainer onto the cylinder.
3. Door lock cylinder rod (450).
Replacement.
10A1-68 DOORS
466. Weatherstrip
467. Plastic Nails
F-00548
Figure 102Sliding Side Door W eatherstrip

DOORS 10A1-69
G MODEL REAR DOORS
468. Hinge
469. Pin
470. Bolt
471. Bolt
472. Strap Assembly
473. Bracket
474. Bolt
475. Bolt
477. Seal
478. Retainer
479. Grommet
472
468
F-00549
Figure 103Hinge Components

DOOR AND HINGE
mark.
REPLACEMENT 4. The seals and retainers to the body half of the
hinge.
f4 Remove or Disconnect (Figure 103)
5. Door to the vehicle.
Support the door.
Open the doors.
1. Electrical wiring harness (if equipped). Refer to
Door Trim Panel Replacement for access to the
mark.
wiring harness.
7. Strap pin (469).
Mark the position of the door on the hinges using
a wax pencil. 8. Electrical wiring harness.
2. Strap pin (469). Refer to Door Trim Panel Replacement for
Support the door.
4. Door from the vehicle. DOOR ADJUSTMENT
5. Hinge to door bolts (470).
6. Hinges from the door. Each of the two doors must first be adjusted in the
7. Retainers (478), seals (477), and grommets (479) door opening before adjusting the door to door
from the door or the hinges. clearance.

E Adjust (Figure 104)
1. Grommet to the door. The door height so that there is a gap of 6 mm

2. Hinge to the door. 0.5 mm (0.25-inch 0.02-inch) between the roof
3. Hinge to door bolts (470). panel and the rear door panel.
10A1-70 DOORS
481
480
Roof Panel
Roof Side Rail
Left Door
Right Door
Body Side Panel
Floor Extension Panel
A. 6 mm 0.5 mm (0.25-inch 0.02-inch)
485 B. 15.25 mm 0.5 mm (0.60-inch 0.02-inch)
C. 4 mm 0.5 mm (0.16-inch 0.02-inch)
F-00550
Figure 104Door Adjustments

DOORS 10A1-71
487
486. Bolt
487. Striker
488. Spacer
A. 4.4 mm
(0.172-inch)
486
,*^3l^F-00552
Figure 106Striker Components
2. Striker to the door frame.

Adjust (Figure 106)
The striker to door latch clearance so that there

are 4.4 mm (0.172-inch) between the striker and
the door latch when the door is in the secondary
latched position. (The door is latched but not fully
2. The gap between the bottom of the door panel closed.) An 11/e4-inch diameter drill bit may be
(not the bottom of the outer panel) and the used to gage this clearance.
platform panel should be 6 mm 0.5 mm
(0.25-inch 0.02-inch). This measurement
should be taken on each door individually from DOOR TRIM PANEL
the side of the door. Thedoor should be in its REPLACEMENT
normal closed position. (The outer rear door
panel is 15.25 mm 0.5 mm (0.60-inch Remove or Disconnect (Figure 107)
0.02-inch) away from the rear platform panel
when normally closed). 1. Door trim panel to door screws (489).
3. The rear door outer panel to the body side outer
2. Door trim panel from the vehicle.
panel gap to 4 mm 0.5 mm (0.16-inch
0.02-inch). Slide the panel out of the retainers.
4. The door to door clearance between the left and
right outer door panels should be 6 mm 0.5 Install or Connect (Figure 107)
mm (0.25-inch 0.02-inch).
1. Door trim panel to the vehicle.
Slide the panel into the retainers.
STRIKER REPLACEMENT 2. Door trim panel to door screws (489).

BUMPER WEDGE
2. Striker from the door frame. REPLACEMENT
3. Spacer (if equipped).
1. Bumper to upper door frame screws (495).
1. Spacer (as required). 2. Bumper and spacer.
10A1-72 DOORS
489. Screw
490. D oor Trim Panel
491. Side Retainer
492. Screw
493. Side R etainer
494. Top R etainer
F-00553
Figure 107 D oor Trim Panel C om ponents
Insta ll o r C onnect (F igure 108) WINDOW REPLACEMENT

2. Bumper. crisscrossed with masking tape to reduce the risk of
3. Bumper to upper door frame screws (495). to the edge of the glass, mark the door with a piece of
ch a lk at the p o in t w here th e c ra ck m eets the
A d ju s t weatherstrip. Later, when examining the flange of the
opening for a cause of the crack, start at the point
The bumper to door clearance so that there is 1 marked.
mm (0.04-inch) between the bumper and the door
when the door is in the secondary position. (The It is im portant that the cause of the crack be
door is latched but not fully closed). determined and the condition corrected, before the
496 pressure from the high spot or obstruction becomes
p a r tic u la r ly h ig h d u e to w in d s , e x tre m e s of
temperature, or rough terrain.
Remove o r D isconnect (Figure 109)
CAUTION: A lw ays w ear heavy g lo ve s when

h a ndlin g glass to m inim ize the risk o f in ju ry .
1. Using a 3/ie-inch drill bit, drill the rivets from the

Figure 108Bumper Wedge Components weatherstrip (if equipped).
DOORS 10A1-73
2. W e a th e rs trip seal by ru n n in g a p u tty knife Lift the window for acess to the hinge screws.
between the flange and the weatherstrip (inside
and outisde the door).
Have an assistant outside the cab by the 4. Hinge from the door.
window.
5. Hinge seal from the door.
3. W eatherstrip and glass from the flange.
Force the weatherstrip from the flange from
the inside with a putty knife. +4- Install o r C onnect (F igure 110)
4. W indow from the weatherstrip.
1. Hinge and hinge seal to the door.
++ In sta ll o r C on ne ct (F igure 109)
1. W eatherstrip to the glass. 3. Window latch to the window.

2. A six mm ( 1/4-inch) cord in the w eatherstrip
Place the cover and spacer through the
groove. The ends should overlap about 5 cm
window.
3. W indow and w eatherstrip on the flange from Place the washer and spring onto the cover.
outside the cab.
Twist the latch onto the cover with 1/4 of a
Brush soapy water on the flange.
turn.
Have an assistant pull the cord from inside
the cab to seat the lip of the weatherstrip on 4. W indow latch to door screws (509).
the flange.
4. Rivets (if equipped) to the weatherstrip with a
rivet gun.
LEFT DOOR LOWER
Use 3/ie-inch blind rivets.
LATCH REPLACEMENT
SWING OUT WINDOW Rem ove o r D isco n n e ct (Figure 111)
++ R em ove o r D isco n n e ct (F igure 110) Open the door.
1. Latch to door screws (511).
CAUTION: A lw a ys w ear heavy g lo v e s w hen 2. Latch from the door.

h a n dlin g glass to m in im ize th e ris k o f in ju ry .
Install o r C onnect (Figure 111)

1. W indow latch to door screws (509).
2. W indow latch from the window.
1. Latch to the door.
Twist the latch 1/4 of a turn to release the
latch components from the window. 2. Latch to door screws (511).
10A1-74 DOORS
510 510
501. W eatherstrip
502. Screw
503. Latch A sse m b ly 506
504. Cover
505. W indow
506. Spacer
507. W asher
508. Spring 505 510
509. Screw 503 505
510. H inge
F-00556
Figure 110 S w ing O ut W indow C om ponents
RIGHT DOOR LOWER

LATCH REPLACEMENT
Rem ove o r D isconnect (Figure 112)

Replacem ent.
2. Lower latch to control assembly rod from the
control assembly.
4. Lower latch with the rod from the door.
|+<-| Install o r C onnect (Figure 112)
1. Lower latch with the rod to the door.

DOORS 10A1-75
513. Screw
514. Lower Latch
515. Lower Lock Rod
516. Drain Hole C lip
516
F-00558
Figure 112 R ight D oor L ow e r Latch
3. Lower latch to control assem bly rod into the

control assembly.
Replacem ent.
RIGHT DOOR UPPER

Figure 114 R ight D oor C ontrol A ssem bly
LATCH REPLACEMENT A tta ch m e n t
Rem ove o r D isco n n e ct (F igure 113)

4. Upper latch with the rod from the door.
Replacem ent.
2. Upper latch to control assembly rod from the
control assembly.
1. Upper latch with the rod to the door.
G. Upper latch to control assem bly rod into the
control assembly.
Replacement.
RIGHT DOOR CONTROL

ASSEMBLY REPLACEMENT
++ Rem ove o r D isco n n e ct (Figure 114)

Replacem ent.
assembly.
517. Bolt
518. Upper Latch
519. Upper Lock Rod F-00559 rod. Pivot the clip away from the rod.
Figure 113Right Door Upper Latch 4. Door to control assembly bolts (520).
10A1-76 DOORS
522. Screw
523. Sm all G asket
524. O u tsid e Handle
525. Key
526. Lock C ylin d er
527. Large Gasket
528. R etainer
529. Gasket
Figure 115 O utside Handle And Lock C ylin d e r C om ponents
5. Control assembly through the access hole. DOOR LOCK CYLINDER

|-n -| Insta ll o r C onnect (Figure 114)
REPLACEMENT
|<~+| Rem ove o r D isconnect (Figure 115)
1. Control assembly through the access hole.
2. Door to control assembly bolts (520). 1. Door trim panel. Refer to Door Trim Panel
3. Electrical door actuator (if equipped). Replacement.
4. Upper and lower door latch rods to the control 2. Lock cylinder retaining clip from the cylinder.
assembly.
S lid e the c lip o ff the c y lin d e r w ith a
Pivot the clips onto the rods. screwdriver.
5. Door trim panel. Refer to Door Trim Panel 3. Lock cylinder and gasket from the door.
Replacem ent.
|-n -| Install o r C onnect (Figure 115)
DOOR OUTSIDE HANDLE 1. Lock cylinder with gasket to the door.

REPLACEMENT The cylinder rod must engage the lock
assembly lever.
2. Lock cylinder retaining clip onto the cylinder.
Replacem ent.
Replacem ent.
3. Handle from the door. CHECK STRAP REPLACEMENT
Insta ll o r C onnect (F igure 115)
1. Pin (469).
1. Large gasket onto the handle. 2. Strap to door bolts (474).
2. Door to outside handle screw (502) to the push 3. Strap (472).
button side of the handle. 4. Bracket to inner panel bolts (471).
Do not tighten. 5. Bracket (473).
4. Door to outside handle screw (522) to the other Install o r C onnect (F igure 103)
side of the handle.
Tighten both screws. 1. Bracket (473).
5. Door trim panel. Refer to Door Trim Panel. 2. Bracket to inner panel bolts (471).
DOORS 10A1-77
530. Pin
531. C heck A ssem bly
532. B olt
533. B olt
534. Bracket
530
534
533
535. Fastener
536. W eatherstrip
537. P lastic Nail
F-00562
F igure 116 C heck A sse m bly C om ponents
3. Strap to the door.

4. Strap to door bolts (474).
5. Pin (469).
F-00563
CHECK ASSEMBLY F igure 117 Le ft D oor W e atherstrip

REPLACEMENT
Rem ove o r D isco n n e ct (F igure 116) LEFT DOOR WEATHERSTRIP
REPLACEMENT
1. Pin (530).
2. Check assembly to door bolts (532). Remove o r D isco n n e ct (Figure 117)
3. Check assembly (531). Tool Required:

J-24595-B Door Trim Pad Clip Remover.
5. Bracket (534).
1. W eatherstrip to door fasteners using J-24595-B.
-n - Insta ll o r C onnect (F igure 116) 2. Weatherstrip from the door using 3M Release
1. Bracket (534).
3. Plastic nails from the door frame.
3. Check assembly (531).

Clean
4. Check assembly to door bolts (532).
5. Pin (530). The door and weatherstrip of all the old cement.
10A1-78 DOORS
POWER DOOR LOCK

MOTOR REPLACEMENT

Replacem ent.

2. Motor to the lock rod.
538. W eatherstrip 4. Electrical connector to the motor.
539. P lastic Nail 5. Door trim panel. Refer to Door Trim Panel
Replacement.
F-00564
F igure 118 R ight D oor W e ath erstrip
|~n~| Install o r C onnect (Figure 117)
1. N ew w e a th e r s tr ip to th e d o o r u s in g 3M
Push the plastic nails into the door frame.
2. W eatherstrip to door fasteners.
RIGHT DOOR WEATHERSTRIP

REPLACEMENT
|+ + | Rem ove o r D isco n n e ct (Figure 118)
1. W eatherstrip from the door using 3M Release

2. Plastic nails from the door frame.
jQ * Clean
|~n-| Insta ll o r C onnect (F igure 118)
1. N ew w e a th e r s tr ip to th e d o o r u s in g 3M
W eatherstrip Adhesive (or equivalent).
Push the plastic nails into the door frame.
DOORS 10A1-79
F igure 119 Pow er D oor Lock M otor A tta ch m e n t
SPECIAL TOOLS
J-22585-01 Door Hinge Bolt Wrench

J-23457-A #50 Torx Wrench
J-9886-01 Door Handle Clip Remover
J-24595-B Door Trim Pad Clip Remover
10A2-1
SECTION 10A2
SEATS
section.
NOTICE: All seat belt fasteners are important attaching parts in that they could affect the performance of all
vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the
same part num ber or with an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser q u d ity or substitute design. Torque values must be used as specified during reassembly to
CONTENTS
SUBJECT PAGE
D iag no sis O f Manual Seat A d ju s te r ....................................................................................................................... 10 A 2 - 2
Seat A d ju s te r A d ju s tm e n t.....................................................................................................................................10 A 2 - 3
C/K M odel F ront S e a t ................................................................................................................................................ 10A 2- 3
F ront Seat A nd Seat A d ju s te r R e p la c e m e n t..................................................................................................1 0 A 2 - 3
U tility V ehicle P assenger F ront B ucket Seat R e p la c e m e n t........................................................................ 10A 2- 5
F ront P ivo t B racke t D is a s s e m b ly ....................................................................................................................... 10A 2- 5
B ench S eatback And C atch R e p la c e m e n t....................................................................................................... 10A 2- 6
Seat B elt R ep la cem e n t........................................................................................................................................... 10A 2- 6
H igh Back B ucke t Seat B elt R e p la c e m e n t....................................................................................................... 10A 2- 7
C/K M odel S uburba n C enter S e a t ......................................................................................................................... 10A 2- 9
C enter Seatback R e p la c e m e n t............................................................................................................................10A 2- 9
C enter Seat B ottom R e p la c e m e n t.....................................................................................................................10A 2- 9
C enter Seat B o tto m S u p p o rt B racket R e p la c e m e n t..................................................................................... 10A 2-10
C enter Seatback B um per And S trike r R e p la ce m e n t..................................................................................... 10A 2-10
C enter Seat B ottom S trik e r R e p la c e m e n t....................................................................................................... 10A 2-10
C enter Seatback Latch R e p la c e m e n t................................................................................................................ 10A 2-12
C enter Seat B ottom Latch R e p la c e m e n t..........................................................................................................10A 2-12
C enter Seat B elt R e p la c e m e n t............................................................................................................................10A 2-14
C/K M odel Rear S e a ts ................................................................................................................................................10A 2-14
Crew Cab Rear Seat R e p la c e m e n t................................................................................................... ................. 10A 2-14
C rew Cab Rear S eatback And C atch R e p la ce m e n t........................................................................................10A 2-14
C rew Cab Rear Seat B elt R e p la c e m e n t............................................................................................................ 10A 2-14
U tility V ehicle Rear Seat R e pla cem en t.............................................................................................................. 10A 2-15
U tility V e hicle Rear Seat C over Rod R e p la c e m e n t........................................................................................10A 2-15
U tility V ehicle Rear Seat S torage S tru t R e p la ce m e n t................................................................................... 10A 2-15
U tility V ehicle Rear Seat B elt R e pla ce m en t..................................................................................................... 10A 2-17
U tility V ehicle A nd S uburba n S eatback And Hinge R e p la ce m e n t.............................................................10A 2-17
U tility V e hicle A nd S uburba n Latch A nd S u p p o rt A ssem bly R e p la c e m e n t...........................................10A 2-17
S uburban Rear Seat R e p la c e m e n t.....................................................................................................................10A 2-19
S uburban Rear Seat B elt R e p la c e m e n t............................................................................................................10A 2-19
C/K M odel T op S trap B elt A n c h o r In s ta lla tio n ...................................................................................................10A 2-20
P ickup A nd C rew Cab M o d e ls ..............................................................................................................................10A 2-20
U tility V ehicle Rear S e a t .......................................................................................................................................10A2-21
S uburban F ront S e a t ........................................................................................................................... ..............10A 2-22
S uburban S econd S e a t .........................................................................................................................................10A 2-22
S uburban T h ird S e a t ............................................................................................................................................. 10A 2-22
10A2-2 SEATS
SUBJECT PAGE
G M odel F ro nt S e a t .................................................................................................................................................... 10A 2-24
F ront Seat R e p la c e m e n t.......................................................................................................................................10A 2-24
F ront Seat D is a s s e m b ly .........................................................................................................................................10A 2-26
F ront Seat B elt R e p la c e m e n t..............................................................................................................................10A 2-26
G M odel C enter And Rear S e a ts..............................................................................................................................10A 2-27
C enter And Rear Seat R e p la c e m e n t.................................................................................................................. 10A 2-27
C enter And Rear Seat D is a s s e m b ly .................................................................................................................. 10A 2-27
C enter And Rear Seat A rm re st R e p la c e m e n t................................................................................................ 10A 2-28
C enter And Rear Seat B elt R e p la c e m e n t......................................................................................................... 10A 2-29
G M odel Top Strap B elt A n c h o r In s ta lla tio n ....................................................................................................... 10A2-31
V ehicle s W ith A 125-Inch W he e lba se................................................................................................................ 10A2-31
V ehicle s W ith A 110-Inch W he e lba se................................................................................................................ 10A 2-33
S p e c ific a tio n s ............................................................................................................................................................... 10 A 2 -3 5
DIAGNOSIS OF MANUAL SEAT ADJUSTER

A d ju s te r W ill Not 1. Locking wire too tight. 1. Loosen the lo ckin g w ire tension
Lock enough to provide full engagement of
the lock bar in the locking slots of the
a d ju ste r low er channe l. R efer to
Seat Adjuster Adjustm ent.
2. Adjuster lock bar spring disconnected 2. Connect the spring or install a new
or broken. spring.
3. Adjuster lock bar sticking or binding. 3. Lubricate the lock bar pivot. If the bar
is binding, elim inate the cause of
binding or replace the adjuster.
A d ju s te r W ill Not 1. Locking w ire too loose or d isco n 1. Tighten the locking wire enough to al
U nlock nected. low the lock bar to disengage from
the locking slots in the adjuster lower
channel when the lock control lever is
activated. Refer to Seat Adjuster Ad
justm ent.
2. Adjuster lock bar sticking or binding. 2. Lubricate the lock bar pivot. If the bar
is binding, elim inate the cause of
binding or replace the adjuster.
W hen The L e ft 1. Right adjuster either rearward or for 1. Loosen the adjuster to floor pan bolts
A d ju s te r L ocks, The ward of the left adjuster. or nuts move one adjuster forward
R ight A d ju s te r Is or rearward as far as possible and
Betw een Lock the other adjuster in the opposite di
P ositio n s rection. Refer to Seat Adjuster Ad
justm ents.
SEATS 10A2-3
DIAGNOSIS OF MANUAL SEAT ADJUSTER (CONT.)

Seat Hard To Move 1. Adjusters new, not broken in. 1. Operate the seat to the full forward
Forw ard Or Rearward and full rearward positions several
times to work the new tightness out
of the channels.
2. Adjuster(s) improperly lubricated. 2. Lubricate the adjuster channels with
Lubriplate or equivalent.
3. Adjuster(s) binding due to bent or dam 3. Replace the adjuster.
aged channels.
4. Adjusters not in parallel alignm ent with 4. Loosen the floor pan attaching bolts
each other. or nuts, align the adjusters parallel on
the floor pan and tighten nuts. Refer
to Seat Adjuster Adjustm ents.
SEAT ADJUSTER
ADJUSTMENT
A d ju s t
Remove the seat. Refer to Front Seat and Seat

Adjuster Replacem ent.
Leave the adjuster on the seat.
Loosen the adjuster to seat bolts.
1. The adjuster rails forward or rearward so that
both rails are the same distance from the front of
the seat.
2. The adjuster rails so they are parallel to each
other.
Tighten the adjuster to seat bolts.
3. W ire assem bly tension. Three holes on the Move the hook to a forward hole to loosen
s e c o n d a ry a d ju s te r ra il a llo w fo r te n s io n the wire, move the hook to a rearward hole
to tighten it.
adjustment of the wire assembly (figure 1).
Close the hook, and slide the spring over
Slide the spring off of the hook.
Open the hook, and remove it from the hole. the hook.
Install the seat. Refer to Front Seat and Seat
Adjuster Replacem ent.
C/K MODEL FRONT SEATS
FRONT SEAT AND SEAT 3. Seat (10) with adjuster (2) from the vehicle.
4. Adjuster to seat bolts (8).
ADJUSTER REPLACEMENT
5. Adjuster (2) from the seat (10).
This procedure applies to all C/K Model front seats,
whether bench or bucket type with the exception of the
utility vehicle passenger front bucket seat. Refer to Install o r C onnect (Figures 2 and 3)
U tility V e h ic le P a s s e n g e r F ro n t B u c ke t S eat
Replacem ent for information on this type of seat. 1. Adjuster (2) to the seat (10).
2. Adjuster to seat bolts (8).
R em ove o r D isco n n e ct (F igures 2 and 3)
3. Seat (10) with adjuster (2) to the vehicle.
1. Bolt cover (5) (if equipped). 4. Seat adjuster to floor panel bolts (7).
2. Seat adjuster to floor panel bolts (7). 5. Bolt cover (5) (if equipped).
10A2-4 SEATS
1. W ire A ssem bly

2. A d ju ste r
6. Spring
7. Bolt
8. Bolt
9. Bracket
10. Seat
F-00588
Figure 3Bucket Seat Components

SEATS 10A2-5
11. Seat 18. Nut

12. Bolt 19. Cable
13. Spring Retaining 20. Bolt
Bracket 21. Spring
14. Upper Bracket 22. B olt W
15. Bolt 23. Lower Bracket
16. Bolt 24. Sleeve
17. Washer 25. Pivot Stud
F-00589
Figure 4 U tility V ehicle P assenger Seat C om ponen ts
7. Spring retaining bracket (13) onto the springs

UTILITY VEHICLE
(21), and the spring retaining bracket bolts (12).
PASSENGER FRONT BUCKET 8. Restraint cable (19) to the floor panel bolts (22).
SEAT REPLACEMENT
B Rem ove o r D isco n n e ct (F igure 4) FRONT PIVOT BRACKET

DISASSEMBLY
Place the seat in its forward position.
1. Restraint cable (19) to the floor panel bolt (22). This pro ce d u re a p p lie s only to U tility V e hicle
Allow the seat to tip forward. passenger front bucket seats.
2. Spring retaining bracket bolts (12) and the bracket
(13). Remove o r D isco n n e ct (Figure 4)
3. Lower seat bracket (23) to the floor panel bolts
(20 ). 1. Seat. Refer to Utility Vehicle Passenger Front
4. Seat from the vehicle. Bucket Seat Replacem ent.
5. Upper seat bracket bolts (15). 2. Nut (18).
6. Seat brackets (14) from the seat. 3. Washer (17).
7. Latch assembly to seat bolts. 4. Pivot stud (25).
8. Latch assembly from the seat. 5. Sleeve (24).
6. Springs (21).
In sta ll o r C onnect (F igure 4) 7. Upper bracket (14) from the lower bracket (23).
1. Latch assembly to the seat. Install o r C onnect (F igure 4)

2. Latch assembly to seat bolts.
3. Seat brackets (14) to the seat. 1. Upper bracket (14) to the lower bracket (23).
4. Upper seat bracket bolts (15). 2. Springs (21) onto the sleeve (24).
5. Seat to the vehicle. 3. Brackets (14 and 16) to the sleeve.
6. Lower seat bracket (22) to the floor panel bolts 4. Pivot stud (25).
(20). 5. Washer (17).
10A2-6 SEATS
6. Nut (18). SEAT BELT REPLACEMENT

Tighten each nut until it bottoms out.
This procedure covers belts for all seats except high
7. Seat. Refer to Utility Vehicle Passenger Front back bucket seats.
Bucket Seat Replacem ent.
++ Rem ove o r D isconnect (Figures 6 and 7)
BENCH SEATBACK AND 1. Upper seat belt anchor plate cover (42).
Pry the top of the cover away from the
CATCH REPLACEMENT
anchor plate.
Rem ove o r D isco n n e ct (Figure 5) 2. Anchor plate bolt (36).
3. Anchor plate (35).
1. Seat back trim cover (32). 4. Plug (39) (except regular cab).
5. Retractor (33) to floor bolt (40).
2. Striker (27).
6. Seat belt wire (left side only).
3. Catch (28) with bushing (29). 7. Retractor from the vehicle.
4. Washer (30). 8. Plug (37).
9. Buckle (34) to floor bolt (38).
5. Seatback to seat base bolt (26).
10. Buckle from the floor.
6. Washer (30).
NOTICE: For steps 2, 6, and 9 see N otice on
7. Seatback from the vehicle.
page 10A2-1 of this section.

-n - Install o r C onnect
1. Seatback to the vehicle.
1. Buckle (38) to the floor.
2. W asher (30) between the seat base and the 2. Buckle to floor bolt (38).
seatback frame.
3. Seatback to seat base bolt (26). $ Tighten
4. Washer (30). Bolt to 50 N-m (37 ft. lbs.).

5. Catch (28) with bushing (29). 3. Plug (37).
4. Retractor to the vehicle.
6. Striker (27).
7. Seat back trim cover (32). 6. Retractor to floor bolt (40).
SEATS 10A2-7
P ^ 35
33. R etractor
34. Buckle
35. A n ch o r Plate
36. Bolt
37. Plug
38. B olt
39. Plug
40. Bolt
41. W ire A ssem bly
F-00591
42. Cover
Figure 6 B ucket Seat Belt C om ponents
T ig hte n HIGH BACK BUCKET SEAT

BELT REPLACEMENT
7. Plug (39) (except regular cab). |+ + | Rem ove o r D isco n n e ct (Figure 8)
8. Anchor plate (35) to the door pillar. 1. Upper seat belt anchor plate cover (49).
Pry the top of the cover away from the
9. Anchor plate bolt (36). anchor plate.
2. Anchor plate bolt (48).
3. Anchor plate (45).
4. Retractor lower flap (54).
& T ig hte n
5. Retractor (44) to pillar bolt (47).
6. Lower anchor bolt (53).
7. Lower anchor (46).
10. Upper seat belt anchor plate cover (42). 8. Retractor from the vehicle.
9. Plug (51).
Pivot the cover upwards, and press it into 10. Buckle (43) to floor bolt (50).
place. 11. Seat belt wire (left side only).
33. R etractor
34. B uckle
36. B olt
38. B olt
40. B olt
42. Cover
F-00592
Figure 7Bench Seat Belt Components

10A2-8 SEATS
45
43. B uckle
44. R etractor
45. A n c h o r Plate
46. Lower A n ch o r
47. B olt
48. B olt
49. Cover
50. B olt
51. Plug
53. B olt
54. Flap F-00593
Figure 8 High Back B ucket Seat Back C om ponents
12. Buckle from the floor. 10. Anchor plate (45).

NOTICE: For steps 3, 7, 8 and 11 see Notice
on page 10A2-1 of this section. T ig h te n
B Insta ll o r C onnect 12. Upper seat belt anchor plate cover (49).
1. Buckle to the floor.

3. Buckle (43) to floor bolt (50).
T ig h te n

4. Plug (51).
5. Retractor to the vehicle.
6. Lower anchor (46) to the pillar.
7. Lower anchor bolt (53).

8. Retractor (44) to pillar bolt (47).

9. Retractor lower flap.
__________________________________________ SEATS 10A2-9
C/K MODEL SUBURBAN CENTER SEAT
Figure 9 C enter Seat Back M ounting
CENTER SEATBACK CENTER SEAT BOTTOM

REPLACEMENT REPLACEMENT
R em ove o r D isco n n e ct (F igure 9) + + Remove o r D isconnect (Figure 10)
Fold the seatback forward. Fold the seat bottom forward.
1. Hinge (57) to floor panel bolts (58).

1. Bracket (105) to floor panel bolts (61).
2. Seatback (55 or 56) from the vehicle.
2. Seat bottom (55 or 56) from the vehicle.
3. Seal (59).
3. Center stop bracket bolts (103) and bracket (64).
4. Hinge (57) to seatback bolts (60).
5. Hinge (57) from the seatback (55 or 56). 4. Side stop bracket bolts (104) and brackets (63).
in s ta ll o r C onnect (F igure 9)
H" Install o r C onnect
1. Hinge (57) to the seatback (55 or 56).

1. Side stop bracket (63) and bolts (104).
2. Hinge (57) to seatback bolts (60).
2. Center stop bracket (64) and bolts (103).
3. Seal (59).
3. Seat bottom (55 or 56) to the vehicle.
4. Seatback (55 or 56) to the vehicle.
5. Hinge (57) to floor panel bolts (58). 4. Bracket (105) to floor panel bolts (61).
10A2-10 SEATS
F igure 10 C enter Seat B ottom M ounting
CENTER SEAT BOTTOM 3. Bumpers (75).

4. Striker bolts (76).
SUPPORT BRACKET
5. Striker (77).
REPLACEMENT
6. Spacer (78).
Rem ove o r D isco n n e ct (Figure 11) 7. Plate (79).
Fold the seat bottom forward. -4- Install o r C onnect (Figure 12)
1. Trim panel bolts (69) and the panel (68).
2. Bracket to seat bolts (67).
1. Plate (79).
3. Bracket to floor panel bolts.
2. Spacer (78) as required.
0
4. Bracket (105) from the vehicle.
3. Striker (77).
In sta ll o r C onnect (F igure 11) 4. Striker bolts (76).
5. Bumpers (75).
1. Bracket (105) to the vehicle.
2. Bracket to floor panel bolts. 6. Bumper (75) to seat bolts (74).
3. Bracket to seat bolts (67). 7. Bumper covers (73).
4. Trim panel (68) and bolts (69) to the seat.
CENTER SEAT BOTTOM

CENTER SEATBACK BUMPER
STRIKER REPLACEMENT
AND STRIKER REPLACEMENT
Fold the seat bottom forward.
Fold the seatback forward.
1. Bumper covers (73). 1. Striker (65) to seat bolts (66).
2. Bumper (75) to seat bolts (74). 2. Striker (65) from the seat.
10A2-12 SEATS
72. Screw
73. Cover
74. Bolt
75. Bum per
76. Bolt
76 77 77. S triker
78. Spacer
79. Plate B-07257
F igure 12 C enter S eatback B um per A nd S trik e r C om ponen ts
Insta ll o r C onnect (F igure 11) CENTER SEAT BOTTOM

1. Striker (65) to the seat. LATCH REPLACEMENT
2. Striker (65) to seat bolts (66).
Rem ove o r D isconnect (F igure 14)
CENTER SEATBACK Fold the seat bottom forward.

LATCH REPLACEMENT
1. Latch to floor panel bolts (89).
2. Latch (88) from the vehicle.
Fold the seatback forward.
1. Latch bolts (83).
2. Latch from the vehicle. -+ Install o r C onnect
In sta ll o r C onn ect (F igure 13) 1. Latch (88) to the vehicle.
1. Latch to the vehicle. 2. Latch to floor panel bolts (89).

2. Latch bolts (83).
SEATS 10A2-13
80. Screw
81. Handle
82. Bracket A ssem bly
83. Bolt
84. B um per
85. Screw
B-07258
Figure 13 C enter S eatback Latch
92. R etractor
93. Bolt
94. Flap
95. Buckle
96. Guide
97. Bolt
98. Bolt
99. Latch Plate
B-07260
Figure 15Center Seat Belt Components

Figure 14Center Seat Bottom Latch
10A2-14 SEATS
CENTER SEAT BELT Install o r C onnect (Figure 15)
REPLACEMENT
Rem ove o r D isco n n e ct (F igure 15) page 10A2-1 of this section.
Fold the seat bottoms forward. 1. Buckle and latch plate assemblies to the vehicle.
Note the position of the belts. 2. Buckle and latch plate assembly bolts (98).
1. Retractor flaps (94).
2. Retractor bolts (93). T ighten
3. Retractor (92) from the vehicle.
a
4. Guide assembly bolts (97) and the guides (96). Bolts to 50 N-m (37 ft. lbs.).
5. Buckle (95) and latch plate (99) assembly bolts 3. Guide assemblies (96) and guide bolts (97).
(98). 4. Retractor (92) to the vehicle.
6. Buckle and latch plate assem blies from the 5. Retractor bolts (93).
vehicle.
T ig h te n
Retractor bolts to 50 N-m (37 ft. lbs.).

1i rr 6. Retractor flaps (94).
C/K MODEL REAR SEATS
7. Seatback from the vehicle.

CREW C A B REAR
SEAT R E PLA C EM E N T Install o r C onnect (Figure 5)

1. Seatback to the vehicle.
2. Washer (30) between the seat base and the
1. Rear bracket (107) to floor bolts (106).
seatback frame.
2. Front bracket (109) to floor bolts (110).
3. Seat from the vehicle.
4. Washer (30).
4. Front and rear bracket to seat bolts (108).
5. Rear bracket (107). 5. Catch (28) with bushing (29).
6. Front bracket (109). 6. Striker (27).
7. Seat back trim cover (32).
In stall o r C onnect (F igure 16)
1. Front bracket (109) and bolts (108). CREW CAB REAR SEAT
2. Rear bracket (107) and bolts (108). BELT REPLACEMENT
3. Seat to the vehicle.
4. Front bracket (109) to floor bolts (110). RETRACTOR REPLACEMENT
5. Rear bracket (107) to floor bolts (106).
CREW CAB REAR SEATBACK 1. Retractor to floor panel bolts (115).

AND CATCH REPLACEMENT 2. Retractor (112).
Rem ove o r D isco n n e ct (Figure 5) - Install o r C onnect (Figure 17)
1. Seat back trim cover (32). 1. Retractor (112) to the floor panel.
2. Striker (27).
3. Catch (28) with bushing (29). NOTICE: See Notice on page 10A2-1 of this
4. Washer (30). section.
6. Washer (30). 2. Retractor to floor panel bolts (115).
SEATS 10A2-15

section.
2. Belt to floor panel bolts (114).
T ighten

3. S e a t. R e fe r to C re w C ab Rear Seat
Replacement.
UTILITY VEHICLE REAR

SEAT REPLACEMENT
Remove o r D isco n n e ct (Figure 18)
Fold the seat forward.

1. Hinge to floor bolt (116) and spring washer (117).
|-n -| Install o r C onnect (Figure 18)
1. Seat to the vehicle.

2. Spring washer (117) and bolt (116).
UTILITY VEHICLE REAR SEAT

COVER ROD REPLACEMENT
1. Actuator rod clip (123).

2. Actuator rod (124).
|+ + | Install o r C onnect (Figure 19)
1. Actuator rod (124).

T ig h te n 2. Actuator rod clip (123).

UTILITY VEHICLE REAR
CENTER BUCKLE AND LATCH PLATE SEAT STORAGE STRUT
REPLACEMENT
REPLACEMENT
Rem ove o r D isco n n e ct (F igure 17) ++ Rem ove o r D isco n n e ct (Figure 20)
1. S e a t. R e fe r to C re w Cab R ear Seat Tilt the seat forward.

Replacem ent. 1. Strut (125) to floor bolts (126).
Note the position of the belts. 2. Strut (125) to seat bolts (127).
2. Belt to floor panel bolts (114). 3. Strut from the vehicle.
3. Left belt (113) and right belt (113) from the vehicle.
0
iJ Install o r C onnect (Figure 20)
In stall o r C onnect (F igure 17) 1. Strut (125) to the vehicle.

2. Strut (125) to seat bolts (127).
1. Left belt (113) and right belt (113) to the vehicle. 3. Strut (125) to floor bolts (126).
10A2-16 SEATS
Figure 18Utility Vehicle Rear Seat Components

SEATS 10A2-17
- Install o r C onnect (Figure 21)
1. Seat belts (130) to the latch.

2. Seat belts (130) to latch bolts (131).
$ T ig h te n

3. Latch and support assembly to the seat. Refer to
Utility Vehicle and Suburban Latch and Support
Assembly Replacem ent.
4. Rear seat cover rod.
5. Side latch plate (128) to the vehicle.
6. Side latch plate (128) to floor panel bolts (129).
a T ig h te n
UTILITY VEHICLE REAR UTILITY VEHICLE AND

SEAT BELT REPLACEMENT SUBURBAN SEATBACK AND
HINGE REPLACEMENT
Rem ove o r D isco n n e ct (Figures 22 and 23)
Fold the seat forward.
1. Side latch plate (128) to floor panel bolts (129). 1. Seatback to hinge bolts (139).
2. Side latch plate (128) from the vehicle. 2. Seatback (154) from the vehicle.
3. Rear seat cover rod. 3. Hinge (153) to seat bottom bolts (137).
4. Latch and support assembly from the seat. Refer 4. Hinge from the vehicle.
to U tility V ehicle and Suburban Latch and 5. Armrest to hinge bolt (136).
Support Assembly Replacem ent. 6. Armrest support (138) from the hinge.
5. Seat belt (130) to latch bolts (131).
6. Seat belts from the latch. Install o r C onnect
NOTICE: For steps 2 and 6 see N otice on 1. Armrest (133) to the hinge.
page 10A2-1 of this section. 2. Armrest to hinge bolt (136).
3. Hinge to the vehicle.
4. Hinge (153) to seat bottom bolts (137).
5. Seatback (154) to the vehicle.
6. Seatback to hinge bolts (139).
UTILITY VEHICLE AND

SUBURBAN LATCH AND
SUPPORT ASSEMBLY
REPLACEMENT
Rem ove o r D isco n n e ct (Figures 24 and 25)
Fold the seat forward (Utility vehicle only).

1. The seat (Suburban only). Refer to Suburban
Seat Replacem ent.
2. Latch cover rod (Utility vehicle only).
3. Latch cover (Suburban only) (141).
4. Latch to seat bolts (145).
5. Latch (144) from the seat.
10A2-18 SEATS
6. Latch cover (143) (Utility vehicle only).

132. Ash Tray
133. A rm rest
134. Spring W asher
135. Bolt " |-<-| Install o r C onnect
136. Bolt
137. Bolt 1. Latch cover (141) to the seat (Utility vehicle only).
138. S upport
139. Bolt 2. Latch (144) to the seat.
153. Hinge
154. Seatback 3. Latch to seat bolts (145).
4. Latch cover (Suburban only).
5. Latch cover rod (Utility vehicle only).
6. The seat (Suburban only). Referr to Suburban

Seat Replacem ent.
154
136. Screw
137. Screw
138. Support
137 B-07267
139. Bolt
140. Hinge And Latch B-07268
Figure 22Left Seatback Hinge Figure 23Right Seatback Hinge

SEATS 10A2-19
SUBURBAN REAR 4. Push back and forth on the seat to be sure it is

latched.
SEAT REPLACEMENT
REMOVAL SUBURBAN REAR SEAT
1. Unlatch the seat, and pull towards the rear of the BELT REPLACEMENT
vehicle.
2. Remove the seat from the vehicle. Rem ove o r D isco n n e ct (Figure 26)
INSTALLATIO N 1. Rear seat latch cover (figure 24).

1. Place the seat in the vehicle. 2. Seat belts (151 and 152) to latch bolts (150).
3. Seat belts from the seat.
2. Place the hooked retainers onto the anchor pins.
4. Side buckle (148) to floor panel bolts (149).
3. Latch the seat. 5. Buckle (148) from the vehicle.

++ Install o r C onnect
1. Buckle (148) to the vehicle.

2. Buckle (148) to floor panel bolts (149).
T ighten

3. Seat belts (151 and 152) to the seat.
4. Seat belt to latch bolts (150).

5. Rear seat latch cover (figure 24).
Figure 25Rear Seat Latch Components

10A2-20 SEATS
148. Buckle
149. B olt
150. Bolt
151. Buckle
A ssem bly
152. Latch Plate
148
B-09076
F igure 26 S uburban Rear Seat B elts
C/K MODEL TOP STRAP BELT ANCHOR INSTALLATION
All hardware discussed in this procedure should be

supplied or available from the child seat manufacturer.
Be sure the child seat position does not conflict with
any additional requirements provided by its manufac
turer, or with any recommendations in the Child Re
straint section of the O wners Manual.
The child seat may be used only in a forward facing
seating location.
PICKUP AND CREW CAB MODELS 158

1. Place the Child Seat in the front seating position
(rear seating position on crew cab models) (figure 159
27).
2. Secure the vehicle lap belt over the armrests of
the Child Seat in the position which the Child
Seat will be used.
3. S ele ct a s u ita b le a n ch o r bracket m o u n tin g
location on the cab back panel. The location must 155. Center Line
be: 156. W indow
L o c a te d near th e re a r w in d o w 157. Sealer
reinforcement. The angle between the Child 158. A nchor Plate
Seat top strap and horizontal should not 159. Nut
exceed 45. 160. A n ch o r Bracket
As close to the center line of the Child Seat 161. Bolt
as possible, but in no case more than 50 B-09152
mm (2-inches) towards the passenger side
of the cab, and 150 mm (6-inches) towards
Figure 27Pickup Top Strap Belt Components
the drivers side of the cab.
In a position clear of the fuel tank, fuel lines,
brake lines, exhaust systems, etc.
4. Drill an 8 mm (5/ie-inch) diameter hole through
the cab panel at the selected location.
SEATS 10A2-21
F igure 28 U tility V ehicle Second Seat Top S trap B elt C om ponen ts
NOTICE: See N otice on page 10A2-1 of this mm (52.25-inches) inboard of the right quarter
section. inner panel. Mark the position where these
measurements meet.
5. Install the bolt (161), anchor bracket (160), anchor
plate (158), and lock nut (159) to the hole with an 2. Drill an 8 mm (5/ie-inch) hole at the mark.
appropriate sealant.
3. To insure proper sealing of the hole, remove any
6. Tighten the nut to 31 N m (23 ft. lbs.).
dirt or foreign matter from around the hole on the
Use the Child Seat only in the seating position for underside of the floor pan where the seaier is to
which the anchor bracket has been installed, be applied.
latching the Child Seat top strap hook to the
anchor bracket as shown.
CAUTION: In th e e ve n t th a t th e C hild Seat section.
anch orag e asse m bly is rem oved, th e 8 mm
( 5/ie -in c h ) d ia m e te r hole m ust be p ro p e rly 4. Place sealer on the hole from the underside of
resealed to p re ve n t to x ic e xh a ust fu m e s fro m the vehicle and assembly the bolt (162), anchor
e n te rin g th e cab. plate (163), washer (165), and lock nut (166) to the
floor pan.
5. Tighten the nut to 31 N m (23 ft. lbs.). Use the

UTILITY VEHICLE Child Seat only in the seating position for which
REAR SEAT the anchor bracket has been installed.
1. D e te rm in e th e lo c a tio n fo r th e a n c h o r by
measuring 140 mm (51/2-inches) forward from the N O T IC E : In th e e v e n t th e C h ild S eat
rear edge of the floor pan (figure 28). Make this anchorage assembly is removed, the 8 mm
m e a s u re m e n t in th e c e n te r of one of the (5/ie inch) diameter hole must be properly
depressed floor pan ribs. Next, measure 1330 resealed.
10A2-22 SEATS
Bolt
A n ch o r Plate
Sealer
W asher
Nut
B-09026
Figure 29 S uburba n F ront Seat Top Strap B elt C om ponents
SUBURBAN FRONT SEAT the vehicle and assemble the bolt (167), anchor
plate (168), washer (170), and lock nut (171) to the
This procedure applies to vehicles not equipped with floor pan.
a second seat or vehicles with the second seat in the 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the
down position. Child Seat only in the seating position for which
1. D e te rm in e th e lo c a tio n fo r th e a n c h o r by the anchor bracket has been installed.
measuring 51 mm (2-inches) rearward from the
rear edge of the kick up molding. Make this NOTICE: In the event the child seat anchorage
m e a s u re m e n t in the c e n te r of one of the assembly is removed, the 8 mm (5/i e-inch)
depressed floor pan ribs (figure 29). diameter hole must be properly resealed.
A. Measure 360 mm (14.6-inches) inboard of
the right quarter inner panel for the right
seating position.
SUBURBAN SECOND SEAT
B. Measure 895 mm (35.25-inches) inboard of
the right quarter inner panel for the center 1. D e te rm in e th e lo c a tio n fo r th e a n c h o r by
seating position. measuring 650 mm (251/2-inches) rearward from
M a rk th e p o s itio n w h e re th e the rear edge of the kick-up molding (figure 30).
measurements meet. Next:
2. Drill an 8 mm (5/ie-inch) hole at the mark. A. Measure 55 mm (2.12-inches) inboard of the
3. To insure proper sealing of the hole, remove any rig h t w heelho use for the rig h t se a tin g
dirt or foreign matter from around the hole on the position.
underside of the floor pan where the sealer is to B. Measure 590 mm (23.25-inches) inboard of
be applied. the right wheelhouse for the center seating
position.
NOTICE: See Notice on page 10A2-1 of this C. Measure 55 mm (2.12-inches) inboard of the
section. left wheelhouse for the left seating position.
Mark the position where the measurements for
4. Place sealer on the hole from the underside of the desired seating position meet.
SEATS 10A2-23
172. B olt
174. Sealer
175. W asher
176. Nut
(55mm)
2 . 12"
(590mm) 23.25
55mm (2.12")
174 175 176 B-09129
F igure 30 S uburban Second Seat Top S trap Belt C om ponen ts
2. Drill an 8 mm (5/ie-inch) hole at mark. SUBURBAN THIRD SEAT

3. To insure proper sealing of the hole, remove any 1. D e te rm in e th e lo c a tio n fo r th e a n c h o r by
dirt or foreign matter from around the hole on the measuring 127 mm (5-inches) forward from the
underside of the floor pan where the sealer is to re a r e d g e o f th e flo o r p a n . M ake th is
be applied. m e a su re m e n t in the ce n te r of one of the
depressed floor pan ribs (figure 31).
Next:
NOTICE: See N otice on page 10A2-1 of this A. Measure 535 mm (21-inches) inboard of the
section. right quarter inner panel for the right seating
position.
4. Place sealer on the hole from the underside of B. Measure 805 mm (31.75-inches) inboard of
the vehicle and assemble the bolt (172), anchor the right quarter inner panel for the center
plate (173), washer (175), and lock nut (176) to the seating position.
floor pan. C. Measure 1,160 (45.75-inches) inboard of the
right quarter inner panel for the left seating
5. Tighten the nut to 31 N-m (23 ft. lbs.). Use the position.
C hild Seat only in the second seat seating
2. Drill an 8 mm (5/ie-inch) hole at the mark.
position for which the anchor bracket has been
3. To insure proper sealing of the hole, remove
installed.
anydirt or foreign matter from around the hole on
the underside of the floor pan where the sealer is
to be applied.
NOTICE: In the event the child seat anchorage
assembly is removed, the 8 mm (5/ie-inch) NOTICE: See N otice on page 10A2-1 of this
diameter hole must be properly resealed. section.
4. Place sealer on the hole from the underside of

10A2-24 SEATS
1,160mm (45.75")
177. Bolt
178. A n cho r Plate
179. Seaier
181 180. W asher
181. Nut B-09029
F igure 31 S uburban T h ird Seat Top Strap B elt C om ponents
the vehicle and assemble the bolt (177), anchor NOTICE: If the hole penetrates to the exterior
plate (178), washer (180), and lock nut (181) to the of the vehicle, apply a sealant between the
floor pan. anchor bolt washer and the sheet metal to
5. Tighten the nut to 31 N m (23 ft. lbs.). Use the prevent carbon monoxide from entering the
Child Seat only in the third seat seating position vehicle. Suitable sealers include silicone,
for which the anchor bracket has been installed. butyl or acrylic type caulking.
In the event that the child seat anchorage
N O T IC E : In th e e v e n t th e C h ild S e at a s s e m b ly is re m o v e d , a ll b o lt h o le s
anchorage assembly is removed, the 8 mm penetrating to the exterior of the vehicle must
( 5/ i e-inch) diam eter hole must be properly be resealed to prevent exhaust fumes from
resealed. entering the vehicle.
G MODEL FRONT SEAT
FRONT SEAT REPLACEMENT Install o r C onnect (Figure 32)
Rem ove o r D isco n n e ct (F igure 32 1. Seat (182) to floor panel nuts (185), washers
(186), and reinforcements (187) to the underside
1. Seat belts. Refer to Seat Belt Replacem ent. of the vehicle.
Raise and support the vehicle. Lower the vehicle.
2. Seat riser (183) to floor panel nuts (185), washers 3. Seat belts. Refer to Seat Belt R eplacem ent.
(186), and reinforcements (187) from underneath
the vehicle.

SEATS 10A2-25
182. Seat
183. Seat Riser
184. Nut
185. Nut
186. W asher
187. R einforcem ent
B-09027
F igure 32 F ront B ucket Seat C om ponen ts
B-09028
Figure 33Bucket Seat Adjusters

10A2-26 SEATS
Figure 34 B ucket Seat Belt C om ponents
FRONT SEAT DISASSEMBLY FRONT SEAT BELT

REPLACEMENT
Rem ove o r D iscon ne ct (F igures 32 and 33)
Remove o r D isconnect (Figure 34)
1. Seat. Refer to Front Seat Replacem ent.
2. Seat riser to adjuster nuts (184). 1. Anchor plate (194) to the roof side rail bolt (198).
3. Seat (182) and adjuster (190) from the riser (183). 2. Anchor plate (194).
3. Seat belt warning wire (left side only).
4. Adjuster to seat bolts (193) and spacers (191).
4. Retractor (195) to seat riser bolt (199).
5. Adjuster (190) from the seat (182). 5. Retractor (195) and anchor plate (194) from the
vehicle.
Insta ll o r C onnect (F igures 32 and 33) 6. Plug (200).
7. Buckle (196) to seat riser bolt (201) and washer
1. Adjuster (190) to the seat (182). (202 ).
2. Adjuster to seat spacers (191) and bolts (193). 8. Buckle (196) from the vehicle.
3. Seat (182) and adjuster (190) to the riser (183).
NOTICE: For steps 2, 5, and 7 see Notice on
4. Seat riser to adjuster nuts (184). page 10A2-1 of this section.
5. Seat. Refer to Seat Replacem ent.
SEATS 10A2-27
In stall o r C onnect (F igure 34) T ig h te n
1. Buckle (196) to the vehicle. Bolt to 60 N m (44 ft. lbs.).

2. Buckle (196) to seat riser washer (202) and bolt 6. Seat belt warning wire (left side only).
(201). 7. Anchor plate (194) to the roof side rail.
$ T igh ten
T ig h te n
3. Plug (200). Bolt to 60 N-m (44 ft. lbs.).
4. Retractor (195) and anchor plate (194) to the
vehicle.
5. Retractor (195) to seat riser bolt (199).
G MODEL CENTER AND REAR SEATS
CENTER AND REAR SEAT CENTER AND REAR

REPLACEMENT SEAT DISASSEMBLY
REMOVAL (F igure 35) |*"| Rem ove o r D isco n n e ct (Figures 36 and 37)
1. Unlatch the seat, and pull towards the rear of the
vehicle. 1. Seat from the vehicle. Refer to Center and Rear
Seat Replacem ent.
2. Remove the seat from the vehicle. 2. Support (210) and leg assembly (209) to seat
bolts (207 and 208).
3. Support assembly (210) to leg assembly (209),
IN STALLATIO N (F igure 35)
bolts (206) and spring washers (205).
1. Place the seat in the vehicle.
4. Support assembly (210) from the legs (209).
2. Place the hooked retainers onto the anchor pins.
|-<-| Install o r C onnect (Figures 36 and 37)
3. Latch the seat.
1. Support assembly (210) to the legs (209).
4. Push back and forth on the seat to be sure it is 2. Support assembly (210) to leg assembly (209),
latched. springs washers (205) and bolts (206).
10A2-28 SEATS
T ig h te n 4. Armrest bracket (217) to armrest nuts (215) and

washers (214).
3. Support (210) and leg assembly (209) to seat 5. Armrest bracket (217) from the armrest (212).
bolts (207 and 208).
4. Seat to the vehicle. Refer to Center and Rear
Seat Replacem ent. Install o r C onnect
1. Armrest bracket (217) to the armrest (212).

CENTER AND REAR SEAT
ARMREST REPLACEMENT 2. Armrest bracket (217) to armrest washers (214)
and nuts (215).
Rem ove o r D iscon ne ct (F igures 38 and 39) 3. Armrest cover (218) (if equipped).
1. Armrest bracket (217) to seat bolts (216). 4. Armrest to seatback bolts (213).
2. Armrest to seatback bolts (213).
5. Armrest bracket (217) to seat bolts (216).
3. Armrest cover (218) (if equipped).
205. W asher
206. Bolt
207. Bolt
208. Bolt
209. Leg A ssem bly
210. S upport A ssem bly
B-09110
Figure 37Rear Seat Components

SEATS 10A2-29
211. Ash Tray

212. Arm Rest
213. Bolt
214. W asher
212 215. Nut
216. Bolt
B-09108
Figure 39 Rear Seat A rm re st
CENTER AND REAR SEAT

BELT REPLACEMENT
|+"| Rem ove o r D isco n n e ct (Figures 40, 41, and

42)
211. Ash Tray
212. Arm Rest 1. Retractor to support assembly bolts (221).
213. B olt 2. Retractor (220) from the seat.
214. W asher 3. Buckle (219) and latch plate (225) (if equipped) to
215. Nut support assembly bolts (222).
216. B olt
4. Buckle (219) and latch plate (225) (if equipped)
from the seat.
218. Cover

B-08586
Figure 38Center Seat Armrest 1. Buckle (219) and latch plate (225) (if equipped) to
the seat.
10A2-30 SEATS
219. Buckle
220. R etractor
221. Bolt
222. Bolt
225. Latch Plate
B-09132
Figure 41Rear Seat Belt Components

SEATS 10A2-31
Screw
Cover
B-09106
Figure 42Seat Leg Cover
2. Buckle (219) and latch plate (225) (if equipped) 3. Retractor (220) to the seat.
bolts (222). 4. Retractor to support assembly bolts (221).
The shoulder of the bolt must bottom on the
weld nut. & T ighten
T ig h te n Bolts to 50 N m (37 ft. lbs.).
G MODEL TOP STRAP BELT ANCHOR INSTALLATION
All hardware discussed in this procedure should be front edge of the left wheelhouse. Measure 60
supplied or available from the child seat manufacturer. mm (2 3/s -in c h e s ) in b o a rd fro m th e le ft
Be sure the child seat position does not conflict with wheelhouse. Mark the position on top of the rib
any additional requirements provided by its manufac where these measurements meet (figure 43).
turer, or with any recommendations in the Child Re
straint section of the O w ners manual. 2. Drill an 8 mm (5/ie-inch) hole at the mark.
The child seat may be used only in a forward facing
seating location. 3. To insure proper sealing of the hole, remove any
Installation of top strap belts is not recommended in dirt or foreign matter from around the hole on the
the front passenger seat of G Vans. The second seat underside of the floor pan where sealer is to be
offset which allows passenger entry does not position applied.
a second seat lap belt within the recommended zone
for attachm ent to the top strap hook. Also, a floor an
chorage is impractical since the top strap length is in NOTICE: See N otice on page 10A2-1 of this
sufficient to directly connect the restraint to the floor section.
with high back bucket seats.
the vehicle and assemble the bolt (227), anchor
VEHICLES WITH A bracket (228), two 35 mm (13/s-inch) outside
125-INCH WHEELBASE diameter spacer washers (230), anchor plate
(231) and lock nut (232) to the floor pan.
SECOND SEAT LEFT SEATING POSITION
This procedure is for vehicles not having a third seat. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the
1. D e te rm in e th e lo c a tio n fo r th e a n c h o r by Child Seat only in the seating position for which
measuring 76 mm (3-inches) rearward from the the anchor bracket has been installed.
10A2-32 SEATS

section.

bracket (237), two 35 mm (13/s-inch) outside
diam eter spacer washers (240), anchor plate
(237) and lock nut (238) to the floor pan.

Child Seat only in the seating position for which
the anchor bracket has been installed.
N O T IC E : In th e e v e n t th e C h ild S eat
anchorage assembly is removed, the 8 mm
( 5/ i e-inch) diameter hole must be properly
226. R ight W heelhouse
resealed.
227. Bolt
228. A n ch o r Bracket
229. Sealer
230. Spacer W ashers THIRD SEAT
232. Lock Nut It is recommended that only the left seating position
233. Front Edge Of The Left W heelhouse be used for the third seat.
B-09127
1. D e te rm in e the lo c a tio n fo r th e a n c h o r by
measuring 76 mm (3-inches) rearward from the
Figure 43 Second Seat T op Strap
left w h e elho use. M easure 10 mm (3/s-inch)
C o m p o n e n ts L e ft P osition
inboard from the left wheelhouse. Mark the
position where those measurements meet (figure
N O T IC E : In th e e v e n t th e C h ild S e at 45).
( 5/ie-in ch ) diam eter hole must be properly 2. Drill an 8 mm (5/ie-inch) hole at the mark.
resealed.
3. To insure proper sealing of the hole, remove any
dirt or foreign matter from around the hole on the
SECOND SEAT CENTER OR RIGHT underside of the floor pan where sealer is to be
SEATING POSITIONS applied.
This procedure is for vehicles not having a third seat.
1. D e te rm in e th e lo c a tio n fo r th e a n c h o r by
measuring 35 mm (13/s-inch) rearward from the NOTICE: See N otice on page 10A2-1 of this
front edge of the left wheelhouse (figure 44). section.
Next:
A. M easure 580 mm (227/e-inches) inboard 4. Place sealer on the hole from the underside of
from the right wheelhouse for the center the vehicle and assemble the bolt (241), anchor
seating position. bracket (242), anchor plate (244) and lock nut
B. Measure 395 mm (151/2-inches) inboard of (245) to the floor pan.
the right wheelhouse for the right seating
position. 5. Tighten the nut to 31 N-m (23 ft. lbs.). Use the
Child Seat only in the seating position for which
Mark the position where the measurements for
the anchor bracket has been installed.
the desired seating positions meet.
2. Drill an 8 mm (5/ie-inch) hole at the mark.
3. To insure proper sealing of the hole, remove any N O T IC E : In th e e v e n t th e C h ild S eat
dirt or foreign matter from around the hole on the anchorage assembly is removed, the 8 mm
underside of the floor pan where sealer is to be (5/ie-inch) diameter hole must be properly
applied. resealed.
SEATS 10A2-33

234. Bolt
235. A n ch o r Bracket
236. Sealer
238. Lock Nut
239. Front Edge Of The R ight W heelhouse
240. Spacer W ashers
A. Right S eating P osition
B. C enter Seating P osition
B-09128
F igure 44 Second Seat Top Strap C om p o n e n tsC enter And R ight P osition
VEHICLES WITH A C. Measure 546 mm (211/2 -inches) rearward

from the front edge of the right wheelhouse.
110-INCH WHEELBASE N ext, m e a su re 395 mm (1 5 1/2-inches)
inboard from the right wheelhouse for the
SECOND SEAT right seating position.
This procedure is for vehicles without a third seat
(figures 46 and 47). Mark the position where the measurements for
1. Determine the location of the anchor by: the desired seatings positions meet.
A. Measuring 457 mm (18-inches) rearward 2. Drill an 8 mm (5/ie-inch) hole at the mark.

from the front edge of the left wheelhouse.
Measure 50 mm (2-inches) inboard of the 3. To insure proper sealing of the hole, remove any
left wheelhouse for the left seating position. dirt or foreign matter from around the hole on the
underside of the floor pan where sealer is to be
B. Measuring 546 mm (211/2-inches) rearward
applied.
from the front edge of the left wheelhouse.
Make this measurement in the center of one
of the depressed floor pan ribs. Next, NOTICE: See Notice on page 10A2-1 of this
measure 580 mm (227/8-inches) inboard of section.
the left wheelhouse for the center seating
position. 4. Place sealer on the hole from the underside of
241. Bolt
242. A n c h o r Bracket
243. Sealer
244. A n c h o r Plate
245. Nut
247. Left W heelhouse
Figure 45Third Seat Top Strap ComponentsLeft Position

10A2-34 SEATS
N O T IC E : In th e e v e n t the C h ild S eat

( 5/ 1 6 -inch) diameter hole must be properly
resealed.
SECOND SEAT VEHICLES EQUIPPED WITH

A THIRD SEAT
Use the C hild Seat as dire cte d in the usage
instructions furnished with the Child Seat, in any
second seating position. Latch the Child Seat top strap
hook to the third seat lap belt tongue located most
directly behind the Child Seat.
THIRD SEAT
The Child Seat is not recommended for use in the
third seat of a 110-inch wheelbase model.
249. A n ch o r
250. Sealer
252. Lock Nut
253. Front Edge Of The Left W heelhouse
B-09131
F igure 46 S econd Seat T op Strap

C om p on en ts Left P ositio n

bracket (249), anchor plate (251) and lock nut
(252) to the floor pan.

Child Seat only in the second seat seating
position for which the anchor bracket has been
installed.
248. Bolt
249. A nch or Bracket
250. Sealer
252. Lock Nut
253. Front Edge Of The Left W heelhouse
A. R ight Seating Position
B. Center Seating P osition
Figure 47Second Seat Top Strap ComponentsCenter And Right Position

10A2-35 SEATS
SPECIFICATIONS
TORQUE
ITEM N m FT. LBS.
C/K Models
All Seat Belt Fasteners Except Top S tra p ........................................................................ 50 37
G Models
Front Seat Belt F aste n ers......................................................................................................... 60 44
Center And Rear Seat Belt Fasteners Except Top S tr a p .............................................. 50 37
Top Strap Fasteners

All M odels..................................................................................................................................... 31 23
10A3-1
SECTION 10 A3
GLASS
CONTENTS
SUBJECT PAGE
C/K M o d e ls .................................................................................................................................................................... 10A 3- 1

W in d sh ie ld R e p la c e m e n t....................................................................................................................................... 10 A 3 - 1
S ta tio n a ry Glass R e p la c e m e n t............................................................................................................................10 A 3 - 5
G M o d e ls ......................................................................................................................................................................... 10 A 3 - 7
W in d sh ie ld R e p la c e m e n t.......................................................................................... .............................................10A 3- 7
S ta tio n a ry Glass R e p la c e m e n t............................................................................................................................10A3-11
A ll M o d e ls .......................................................................................................................................................................10A 3-13
G lass P o lis h in g ......................................................................................................................................................... 10A 3-13
C/K MODELS
WINDSHIELD REPLACEMENT
CAUTION: A lw a ys w ear heavy g lo ve s w hen

h a n dlin g glass to m in im ize th e ris k o f in ju ry.
When replacing a cracked windshield, it is important

that the cause of the crack be determined and the
condition corrected, before a new glass is installed.
The cause of the crack may be an obstruction or high
spot somewhere around the flange of the opening;
cracking may not occur until pressure from the high
spot or obstruction becomes particularly high due to 1. W eatherstrip
winds, extremes of tem perature, or rough terrain. 2. Cap
i
Suggestions of what to look for are described later in 3. Glass
this section under Inspection . 4. W indshield Reveal M olding B-09049
F igure 1W in d sh ie ld C om ponents
REMOVAL (F igures 1 and 2)
If a windshield is broken, the glass may already have
The higher the temperature of the work area, the
fallen or been removed from the weatherstrip. Often,
more pliable the weatherstrip will be. The more pliable
however, it is necessary to remove a cracked or
the weatherstrip, the more easily the windshield can be
otherwise imperfect windshield that is still intact. In this
removed.
case, it is a good practice to crisscross the glass with
strips of masking tape before removing it; this will help Before removing the glass, cover the instrument
hold the glass together and minimize the risk of injury. panel, and the surrounding sheet metal with protective
covering. Remove the wiper arms. Disconnect the
If a crack extends to the edge of the glass, mark the antenna lead if the vehicle has a windshield antenna.
point where the crack meets the weatherstrip. (Use a 1. Remove the reveal molding cap (2) and the reveal
piece of chalk and mark the point on the cab, next to molding (lock strip) (4).
the weatherstrip.) Later, when examining the flange of 2. From inside the cab, remove the weatherstrip and
the opening for a cause of the crack start at the point glass from the pinchweld flange by applying a
marked. firm controlled pressure to the edge of the glass
10A3-2 GLASS
the ends of the wire to avoid an abrupt change in

c o n to u r w h ic h c o u ld re s u lt, later, in a broken
windshield.
INSTALLATIO N (F igures 3 and 4)

To replace a urethane adhered w indshield, GM
adhesive service kit No. 9636067 contains some the
materials needed, and must be used to insure the
original integrity of the windshield design. Materials in
the kit include:
1. One tube of adhesive material.
2. One dispensing nozzle.
3. Steel music wire.
Figure 2 F orcin g The W e a th e rstrip Over 4. Rubber cleaner.
The Flange 5. Rubber primer.
6. Pinchweld primer.
while forcing the weatherstrip from the flange 7. Blackout primer.
with a flat bladed tool. 8. Filler strip (for use on windshield installations for
3. With the aid of an assistant from outside the vehicles equipped with em bedded windshield
vehicle, remove the windshield from the opening. antenna).
4. Remove any excess urethane and remaining 9. Primer applicators.
weatherstrip from the pinchweld flange. O th e r m a te ria ls are re q u ire d fo r w in d s h ie ld
installation which are not included in the service kit.
INSPECTION These include:
An inspection of the flange of the w in dshield 1. GM Rubber lubricant No. 1051717.
opening, the weatherstrip, and the glass may reveal
2. Alcohol for cleaning the edge of the glass.
the cause of a broken windshield. This can help
3. Adhesive dispensing gun J-24811 or
prevent future breakage. If there is no apparent cause
4. A s ta n d a rd h o u s e h o ld c a rtrid g e ty p e gun
of breakage, the weatherstrip should be removed from
reworked as follows:
the flange of the opening and the flange inspected.
Look for high weld or solder spots, hardened spot weld a. Widen the end slot to fit the diameter ofthe
sealer, or any other obstruction or irregularity in the dispensing nozzle of the adhesive tube.
flange. Check the weatherstrip for irregularities or b. Reduce the diameter of the plunger disc so
obstructions in it. that the disc will enter the large end of the
Check a windshield that is to be installed to make adhesive tube.
sure it does not have any chipped edges. Chipped 5. Commercial type razor knife (for cutting along the
edges can be ground off, restoring a smooth edge to edge of the glass).
the glass, and minimizing concentrations of pressure 6. Weatherstrip Tool J-2189-02.
th a t c a u s e b re a k a g e . R e m o ve no m o re th a n W indshield installation requires a number of timed
necessary, in an effort to maintain the original shape of steps because of the cure times involved with the
the glass and the proper clearance between it and the p rim e rs , s o lv e n ts , and a d h e s iv e s used in th is
fla n g e of the o p e n in g . See G la ss-T o-O pe ning procedure. This tim ing is im portant and must be
Clearance C heck later in this section. followed.
GLASS-TO-OPENING CLEARANCE CHECK CAUTION: A lw ays w ear heavy g loves when

B efore in s ta llin g a w in d s h ie ld , the c le a ra n c e han d lin g glass to m inim ize the ris k o f in ju ry.
between the edge of the glass and the flange of the
opening should be checked. On C/K Models the glass 1. Wipe the pinchweld clean with a dry cloth. Make
and flange overlap by 5 mm (0.2-inch). If the windshield sure the previous urethane has been removed.
is too big, rework the metal flange or grind off the edge 2. Apply the pinchweld primer with a new applicator
of the glass. If the glass is to be ground off, place a to the pinchweld as shown in view B. The primer
strip of tape on the glass and use the edge of the tape must be thoroughly stirred and agitated prior to
as a guide. application. Allow the prim er to cure for 30
If there is too much clearance between the glass and minutes.
the flange of the opening, the flange can be built up. 3. Apply rubber cleaner with a new applicator to
Braze a piece of 3 mm (Va-inch) diameter wire to the both channels of the rubber weatherstrip as
edge of the flange. Usually, building up one side and shown in view A. Wait 5 minutes before wiping
half way around one corner will be enough. Taper off the channels with a clean dry cloth.
GLASS 10A3-3
5. Prim er Location
6. Rubber Cleaner And Prim er Location
7. Cleaner Location
8. B lackout P rim er Location
9. 10 mm (0.40-inch)
10. Urethane Location
11. Rubber Lubricant Location
B-09055
Figure 3 P rim er And A dhesive A p p lic a tio n L o ca tio n s
4. Apply rubber prim er to both channels of the NOTICE: When cleaning windshield glass,
rubber weatherstrip which were cleaned in the avoid contacting the edge of the plastic
previous step. Allow 30 minutes for the primer to laminate material (on the edge of the glass)
cure. with volatile cleaner. Contact may cause
5. Thoroughly clean the surface of the glass to discoloration and deterioration of the plastic
which the blackout primer will be applied (around laminate by wicking action. Do not use a
the edge of the inside surface) by wiping the petroleum based solvent such as kerosene or
window with a clean alcohol dampened cloth. gasoline. The presence of oil will prevent
Allow the alcohol to air dry. adhesion of new material.
6. Apply the blackout primer to the inside face of the

windshield starting 10 mm (0.40-inch) from the
edge and working outward to the edge. Apply the
primer to the edge of the glass also. Allow the
primer to dry to the touch.
7. Apply a 6.0 mm (0.25-inch) diameter bead of

urethane adhesive in the center of the pinchweld
flange around the entire windshield opening. The
w indshield glass must be installed w ithin 20
minutes of performing this step.
8. Apply a mist of plain water to the urethane bead

on the pinchweld flange, wetting it fully.
9. Install the rubber weatherstrip to the pinchweld

flange.
10. Apply a 4.5 mm (0.18-inch) diam eter bead of

urethane adhesive to the rubber weatherstrip
Figure 4Installing The Reveal Molding glass channel as shown in view D.
10A3-4 GLASS
12. Glass
13. W eatherstrip
14. Lower Reveal M olding
15. Upper Reveal M olding
16. Cap
B-09083
F igure 5 Back W indow C om ponents
11. On w indshields equipped with an em bedded 14. Install the lockstrip to the weatherstrip using
antenna, tape the pigtail to the inside of the J-2189-02.
windshield.
15. Install the lockstrip cap at the lockstrip joint.
12. With the aid of a helper, lift the glass into the
16. Install the antenna pigtail to the antenna lead of
window opening.
the radio (if equipped).
13. Apply rubber lubricant to the lockstrip channel. 17. Install the windshield wiper arms.
The w in d s h ie ld m ust be seated before the
lubricant is applied. 18. Install the rear view mirror to the windshield.
17. S liding Back W indow A ssem bly
B-09084
Figure 6Sliding Back Window Components

GLASS 10A3-5
18. Glass
19. Cap
20. W eatherstrip
21. Reveal M olding
B-09087
F igure 7 Body Side W indow C om ponents
STATIONARY GLASS 2. Pull the insert out of the weatherstrip.

3. Insert a putty knife between the glass and the
REPLACEMENT weatherstrip. Pull it around the entire edge of the
window to make sure the glass is not stuck to the
When replacing a cracked window, it is important weatherstrip.
that the cause of the crack be determined and the 4. Have an assistant stand outside the cab near the
condition corrected, before a new glass is installed. window.
The cause of the crack may be an obstruction or high
5. From inside the cab, push the window from the
spot somewhere around the flange of the opening; weatherstrip.
cracking may not occur until pressure from the high
6. Have an assistant remove the window.
spot or obstruction becomes particularly high due to
winds, extremes of temperature, or rough terrain.
INSPECTION
Suggestions of what to look for are described later in
An inspection of the flange of the window opening,
this section under Inspection .
the weatherstrip, and the glass may reveal the cause of
a broken w indow . T h is can help prevent fu tu re
REMOVAL (F igures 5 th ro u g h 9) breakages. If there is no apparent cause of breakage,
If a window is broken, the glass may already have the weatherstrip should be removed from the flange of
fallen or been removed from the weatherstrip. Often, the opening and the flange inspected. Look for high
however, it is necessary to remove a cracked or weld or solder spots, hardened spot weld sealer, or any
otherwise imperfect window that is still intact. In this other obstruction or irregularities or obstructions in it.
case, it is a good practice to crisscross the glass with Check a window that is to be installed to make sure it
strips of masking tape before removing it; this will help does not have any chipped edges. Chipped edges can
hold the glass together and minimize the risk of injury. be ground off, restoring a smooth edge to the glass,
If a crack extends to the edge of the glass, mark the and minimizing concentrations of pressure that cause
point where the crack meets the weatherstrip. (Use a breakage. Remove no more than necessary, in an
piece of chalk and mark the point on the cab, next to effort to maintain the original shape of the glass and
the weatherstrip.) Later, when examining the flange of the proper clearance between it and the flange of the
the opening for a cause of the crack start at the point opening.
marked.
The higher the temperature of the work area, the INSTALLATION (F igures 5 th ro u g h 9)
more pliable the weatherstrip will be. The more pliable To ease installation, the weatherstrip can be heated
the weatherstrip, the more easily the window can be with a non-flame source. At higher temperatures, the
removed. weatherstrip is more pliable. Do not heat above 52C
(125F) and/or for longer than 1-1/2 hours.
CAUTION: A lw a ys w ear heavy g lo ve s w hen Avoid hitting the glass on anything that may chip its
h a n dlin g glass to m in im ize the ris k o f in ju ry. edge. P ressure on th e w in d s h ie ld w ill tend to
concentrate at the chipped areas, causing cracks. If
1. Push the clip that covers the ends of the reveal the glass is chipped, the edge should be ground
insert to one side, freeing the ends. smooth.
10A3-6 GLASS
CAUTION: A lw a ys w ear heavy g lo ve s w hen 3. Brush the weatherstrip with soapy water.
han d lin g glass to m in im ize the ris k o f in ju ry . 4. Set the window in place on the weatherstrip.
5. Insert the hook end of tool J-2189-02 between the
1. Place a 120 mm (six-inch) strip of sealing tape on weatherstrip and the edge of the glass.
the outside upper corners of opening. This will 6. Pull the tool around the glass in such a way as to
help hold the weatherstrip in place. slip the edge of the glass into the groove of the
2. Push the weatherstrip onto the flange of opening. weatherstrip.
Start at the center of the bottom edge of the 7. Thread the end of insert through the handle of
opening. the loop of tool J-2189-02.
Figure 9Suburban Rear Stationary Window Components

GLASS 10A3-7
8. Push the loop of the tool and the end of the insert 10. If the insert is longer than required, cut it, but
into the groove of the weatherstrip at the center of allow the ends to overlap by 25 mm (one-inch).
the bottom edge. 11. Slip one end of the retaining clip over one end of
9. Move the tool around the window, while feeding the insert; butt the ends of the insert together and
the insert (figure 6). Use a hitching motion to secure them with a clip.
avoid stretching the insert. 12. Push the ends of the insert, with clip, into the
groove of the weatherstrip.
G MODELS
WINDSHIELD REPLACEMENT When using the extended method of windshield

replacem ent, all the urethane adhesive m ust be
removed from the pinchweld flange so, the process of
CAUTION: A lw ays w ear heavy g lo ve s when cutting the window from the adhesive is less critical.
h a n dlin g glass to m inim ize the ris k o f in ju ry. Tool Required:
J-24402-A Glass Sealant Remover Knife.
When replacing a cracked windshield, it is important 1. Place protective coverings around the area where
that the cause of the crack be determined and the the glass will be removed.
condition corrected, before a new glass is installed. 2. Remove the windshield wiper arms, and the
The cause of the crack may be an obstruction or high interior garnish moldings.
spot somewhere around the flange of the opening; 3. Remove the exterior reveal moldings and the
cracking may not occur until pressure from the high support molding from the urethane adhesive by
spot or obstruction becomes particularly high due to prying one end of the molding from the adhesive.
winds, extremes of temperature, or rough terrain. Pull the free end of the molding away from the
Suggestions of what to look for are described later in w indshield and/or pinchw eld flange until the
this section under Inspection . molding is completely free of the windshield.
4. Using J-24402-A cut the windshield from the
REMOVAL (F igures 10 and 11) urethane adhesive. If the short method of glass
If a windshield is broken, the glass may already have replacement is to be used, keep the knife as
fallen or been removed from the weatherstrip. Often, close to the glass as possible in order to leave a
however, it is necessary to remove a cracked or base for the replacement glass.
otherwise imperfect windshield that is still intact. In this 5. With the help of an assistant, remove the glass.
case, it is a good practice to crisscross the glass with 6. If the original glass is to be reinstalled, place it on
strips of masking tape before removing it; this will help a protected bench or holding fixture. Remove any
hold the glass together and minimize the risk of injury. remaining adhesive with a razor blade or sharp
If a crack extends to the edge of the glass, mark the scraper. Any re m a in in g tra ce s of adhesive
point where the crack meets the weatherstrip. (Use a material can be removed with denatured alcohol
piece of chalk and mark the point on the cab, next to or lacquer thinner.
the weatherstrip.) Later, when examining the flange of
the opening for a cause of the crack start at the point NOTICE: When cleaning windshield glass,
marked. avoid contacting the edge of the plastic
The higher the temperature of the work area, the laminate material (on the edge of the glass)
more pliable the weatherstrip will be. The more pliable with volatile cleaner. C ontact may cause
the weatherstrip, the more easily the windshield can be discoloration and deterioration of the plastic
removed. laminate by wicking action. Do not use a
Before removing the glass, cover the instrument petroleum based solved such as kerosene or
panel, and the surrounding sheet metal with protective gasoline. The presence of oil will prevent
covering. Remove the wiper arms. adhesion of new material.
There are two m ethods of w indshield removal,
depending on the method of windshield replacement
chosen. When using the short method of installation, it INSPECTION
is im po rta nt to cut the glass from the urethane An inspection of the flange of the w indshield
adhesive as close to the glass as possible. This is due opening, the weatherstrip, and the glass may reveal
to the fact that the urethane adhesive will be used to the cause of a broken windshield. This can help
provide a base for the replacement windshield. prevent future breakage. If there is no apparent cause
10A3-8 GLASS
Glass
Cap
Reveal M olding
Spacer Block
S upport M olding
B-09092
Figure 10W in d sh ie ld C om ponents
of breakage, the weatherstrip should be removed from The second of the two methods is the extended
the flange of the opening and the flange inspected. method. This method should be used when work must
Look for high weld or solder spots, hardened spot weld be done to the windshield frame such as straightening
sealer, or any other obstruction or irregularity in the or repairing sheet metal or repainting the windshield
flange. Check the weatherstrip for irregularities or frame. In this method, all of the urethane adhesive
obstructions in it. must be removed from the pinchweld flange.
Check a windshield that is to be installed to make
sure it does not have any chipped edges. Chipped INSTALLATION (Figures 12 th ro u g h 16)
edges can be ground off, restoring a smooth edge to To replace a urethane adhered windshield, GM
the glass, and minimizing concentrations of pressure adhesive service kit No. 9636067 contains some of the
th a t c a u s e b re a k a g e . R e m o ve no m o re th a n materials needed, and must be used to insure the
necessary, in an effort to maintain the original shape of original integrity of the windshield design. Materials in
the glass and the proper clearance between it and the the kit include:
flange of the opening. 1. One tube of adhesive material.
2. One dispensing nozzle.
3. Steel music wire.
INSTALLATIO N METHODS
4. Rubber cleaner.
T h e re are tw o m e th o d s used fo r w in d s h ie ld
5. Rubber primer.
replacement. The short method described previously
6. Pinchweld primer.
in the removal procedure is used when the urethane
7. Blackout primer.
adhesive can be used as a base for the new glass. This 8. Filler strip (for use on windshield installations for
method would be used in the case of a cracked glass, vehicles equipped with embedded windshield
if, no other service needs to be done to the windshield
antenna).
frame such as sheet metal or repainting work.
9. Primer applicators.
O th e r m a te ria ls are re q u ire d fo r w in d s h ie ld
installation which are not included in the service kit.
These include:
1. GM Rubber lubricant No. 1051717.
2. Alcohol for cleaning the edge of the glass.
3. Adhesive dispensing gun J-24811 or
4. A s ta n d a rd h o u s e h o ld c a rtrid g e ty p e gun
reworked as follows:
a. Widen the end slot to fit the diameter of the
dispensing nozzle of the adhesive tube.
b. Reduce the diameter of the plunger disc so
that the disc will enter the large end of the
adhesive tube.
5. Commercial type razor knife.
6. Two rubber support spacers.
GLASS 10A3-9
Extended M ethod
1. Clean all the metal surrounding the windshield
opening with a clean alochol dampened cloth.
Allow the alcohol to air dry.
2. Apply the pinchweld primer found in the service
kit to the pinchweld area (figure 12). Do not let
any of the prim er touch any exposed paint
because damage to the finish will occur. Allow
thirty minutes for the primer to dry.
3. Follow the steps listed under Short Method for the
remainder of the procedure.
S h o rt M ethod
1. Install the support molding onto the pinchweld
flange from inside the vehicle. The joint of the
molding should be located at the bottom center of
the molding.
2. Thoroughly clean the edge of the glass to which
the adhesive material will be applied with a clean
alcohol dampened cloth. Allow the alcohol to dry.
3. Apply the clear glass primer in thekit to the inner
edge of the windshield from the edge of the glass
inward 10 mm (0.40-inch). Apply the prim er
around the entire perimeter of the glass. Allow the
primer to cure for 30 minutes.
4. Apply the blackout primer to the glass in the
same area as the clear primer. Allow the blackout
primer to dry to the touch.
10A3-10 GLASS
32
30
Figure 14 U rethane A p p lic a tio n
5. Place two rubber blocks onto the base of the

pinchweld flange. Place the blocks in line with the
last screw on either side of the cowl grille cover.
6. With the aid of a helper, lift the glass into the
opening. Center the glass in the opening, on top
of the support molding.
7. Check the fit of the reveal molding. If necessary,
rem ove the glass and cut away a d d itio n a l
urethane to give the proper windshield height.
Place the glass in the window opening.
8. C u t th e tip o f th e a d h e s iv e c a r tr id g e
approximately 5 mm (3/ie-inch) from the end of
the tip.
9. Apply the adhesive first in and around the spacer 31
blocks. Apply a sm ooth continuous bead of
adhesive into the gap between the glass edge
and the sheet metal. Use a flat-bladed tool to
paddle the material into position if necessary. Be
sure that the adhesive contacts the entire edge of
the glass, and extends to fill the gap between the
glass and the primed sheet metal (extended
m ethod) or s o lid ifie d u rethane base (short
method).
10. Spray a mist of water onto the urethane. Water
will assist in the curing process. Dry the area
where the reveal molding will contact the body or
glass.
11. In s ta ll new re ve al m o ld in g s . R em ove the
protective tape covering the butyl adhesive on the 30. Glass
underside of the molding. Push the molding caps 31. Cap
onto each end of one of the reveal moldings. 32. Reveal M olding
Press the lip of the molding into the urethane 34. S upport M olding
adhesive while holding it against the edge of the 36. Urethane Adhesive
windshield. Take care to seat the molding in the
corners. The lip must fully contact the adhesive
B-09104
and the gap must be entirely covered by the
crown of the molding. Slide the molding caps
onto the adjacent moldings. Use tape to hold the Figure 15Reveal Molding
molding in position until the adhesive cures.
GLASS 10A3-11
CAUTION: A lw ays w ear heavy g lo ve s w hen

ha ndlin g glass to m in im ize th e ris k o f in ju ry.
1. Drill out the rivets (if equipped) with a 5 mm

(3/ie-inch) drill bit.
2. Run a putty knife around the edge of the window,
between the weatherstrip and the cab panels
(inside and outside the cab). This is to make sure
the weatherstrip is not stuck to the cab.
3. Have an assistant stand outside the cab next to
the window.
4. Use the putty knife, or other blunt tool, to force
the edge of the weatherstrip off the flange of the
opening inside the cab. W hile doing this, push
out on the glass.
5. C o n tin u e a ro u n d th e w in d o w , fo rc in g the
weatherstrip off the flange, until the glass and
F igure 16 W in d sh ie ld S u p p o rt M olding
weatherstrip are free of the opening.
S h o rt M ethod
6. Have an a s s is ta n t rem ove th e g la s s and
12. Install the wiper arms and the interior garnish weatherstrip from outside the vehicle.
moldings.
13. The vehicle should not be driven and should INSPECTION
remain at room temperature for six hours to allow An inspection of the flange of the w indshield
the adhesive to cure. opening, the weatherstrip, and the glass may reveal
the cause of a broken windshield. This can help
prevent future breakage. If there is no apparent cause
STATIONARY GLASS of breakage, the weatherstrip should be removed from
REPLACEMENT the flange of the opening and the flange inspected.
Look for high weld or solder spots, hardened spot weld
sealer, or any other obstruction or irregularity in the
REMOVAL (F igures 17, 18 and 19) flange. Check the weatherstrip for irregularities or
If the glass is cracked but still intact, it should be obstructions in it.
crisscrossed with masking tape to reduce the risk of Check a windshield that is to be installed to make
injury and/or damage to the vehicle. If a crack extends sure it does not have any chipped edges. Chipped
to the edge of the glass, mark the cab with a piece of edges can be ground off, restoring a smooth edge to
ch a lk at th e p o in t w h e re th e c ra c k m eets the the glass, and minimizing concentrations of pressure
weatherstrip. This will aid the inspection later. th a t c a u s e b re a k a g e . R e m o ve no m o re th a n
37. W eatherstrip
38. Glass
38
B-09112
Figure 17Body Side Front Window

10A3-12 GLASS
39. W eatherstrip
40. Glass
B-09118
F igure 18 Body Side Rear W indow
necessary, in an effort to maintain the original shape of CUATION: A lw ays w ear heavy g lo ve s w hen
the glass and the proper clearance between it and the handlin g glass to m inim ize the risk o f in ju ry.
flange of the opening.
1. Place the weatherstrip around the edge of the
INSTALLATIO N (F igures 17, 18, and 19) glass to be installed.
Before a new glass is installed, the cause of the 2. Place a lengthof cord about 6 mm (1/4-inch) thick
breakage should be determined. This may require an around the weatherstrip. It should be in the
inspection of the weatherstrip and the flange of the groove of the weatherstrip where the flange of the
window opening. See Inspection , previously outlined opening will fit. The ends of the cord should
in this section. overlap about 152 mm (6-inches) and be located
To ease installation, the weatherstrip can be heated at the bottom of the window.
with a non-flame source. At higher temperatures, the
weatherstrip is more pliable. Do not heat above 52 C 3. Brush a soapy solution of water around the
(125F), or for more than 1-1/2 hours. outside edge of the cab opening.
Avoid hitting the glass on anything that may chip its 4. Have an assistant hold the glass and weatherstrip
edges. Pressure on the glass will tend to concentrate (with the cord around it) up to the w indow
at the chipped areas, causing cracks. If the glass is opening from the outside of the cab; the ends of
accidentally chipped, the edge should be ground the cord should have been placed through the
smooth. opening and hang loosely inside the cab.
Figure 19Body Side Rear Window Riveted

GLASS 10A3-13
5. W hile the assistant holds the glass firm ly in 6. Continue pulling the cord until it is free from the
place, pull one end of the cord, forcing the lip of weatherstrip and the lip of the entire weatherstrip
the weatherstrip up and over the flange of the is over the flange of the opening.
opening. 7. Install rivets (if equipped) to the weatherstrip and
the side panel with a rivet installing gun.
ALL MODELS
GLASS POLISHING
MINOR SCRATCH AND ABRASION REMOVAL
Minor scratches and abrasions can be removed or
reduced by following the procedure outlined below.
P recautions m ust be taken, however, to prevent
distortions of vision; double vision may result if an
attempt is made to remove deep scratches. Deep
scratches should not be removed from an area in the
drivers line of vision; in such cases, the glass should
be replaced.
The procedure that follows was developed using a
ce riu m o xid e co m p o u n d . Follow m a n u fa c tu re rs
directions if other materials are used.
R ecom m ended E qu ip m e n t
1. A low speed (600-1300 rpm) rotary polisher.
2. A w o o l, fe lt, ro ta ry p o lis h in g pad 76 mm
(th r e e - in c h e s ) in d ia m e te r and 51 mm
(two-inches) thick.
3. Powdered cerium oxide mixed with water. This is
the abrasive compound.
4. A wide mouth container to hold the abrasive
compound.
Figure 20 G lass P olish in g G uidelines

P o lish in g P rocedure (F ig u re 20)
1. Mix at least 44 ml (1.5 oz.) of cerium oxide with
enough water to obtain a creamy consistency. (If NOTICE: Never hold the tool in one spot or
the mixture is too thick it will cake on the felt pad operate the tool on the glass any longer than
more quickly. If it is too runny, more polishing 30 to 45 seconds. If the glass becomes hot to
time will be needed.) touch, let it air cool before proceding further.
Cooling with cold water may crack heated
2. Draw a circle around the scratches on the
glass. Avoid excessive pressure. It may cause
opposite side of the glass with a marking crayon,
overheating of the glass.
or equivalent.
3. Draw a line directly behind the scratch(es) to 6. Polish the scratched area, but note the following:
serve as a guide for locating the scratch while
polishing. a. Agitate the mixture as often as needed to
m aintain the creamy consistency of the
4. Cover the surrounding area with masking paper compound.
to catch the drippings or spattered polish.
b. Use moderate but steady pressure.
5. Dip the felt pad attached to the polisher into the
mixture. Do not submerge the pad or allow the c. Hold the pad flat against the glass.
pad to stay in the mixture as it may loosen the
bond between the pad and the metal plate. d. Use a feathering-out motion.
10A3-14 GLASS
e. Dip the pad into the m ixture every 15

seconds to ensure that the wheel and the
glass are always wet during the polishing
operation. (A dry pad causes excessive heat
to develop.)
f. Keep the pad free of dirt and other foreign
substances.
7. After removing the scratch, wipe the area clean of
any polish.
8. Clean the polishing pad.
10A4-1
SECTION 10A4
INTERIOR TRIM
CONTENTS
SUBJECT PAGE
C/K M odel In te rio r T rim ..............................................................................................................................................10A 4- 1
F ront T rim R e p la c e m e n t............................................................. ..........................................................................10A 4- 1
Pick Up M o d e ls ........................................................................................................................................................... 10A 4- 3
C arpet R e p la ce m e n t................................................................................................................................................ 10A 4- 3
H eadliner A nd T rim R e p la c e m e n t....................................................................................................................... 10A 4- 3
B onus Cab M o d e ls .......................................................................................................................................................10A 4- 6
C arpet R e p la ce m e n t................................................................................................................................................10A 4- 6
H eadliner A nd T rim R e p la c e m e n t............................................. ..........................................................................10A 4- 6
U tility V ehicle M o d e ls .......................................................................................... ..................................................10A 4- 9
C arpet R ep la ce m e n t................................................................................................................................................ 10A 4- 9
H eadliner And T rim R ep la ce m e n t....................................................................................................................... 10A 4- 9
F ront Floor C om partm ent R eplacem en t............................................................................................................ 10A4-11
Suburban M o d e ls ......................................................................................................................................................... 10A4-14
Carpet R e placem en t................................................................................................................................................ 10A4-14
H eadliner And Trim R e placem en t....................................................................................................................... 10A4-14
R oof Rear Header T rim Panel R e p la c e m e n t................................................................................................... 10A4-15
G M odel In te rio r T r i m ................................................................................................................................................ 10A4-19
Carpet R e placem en t................................................................................................................................................ 10A4-19
H eadliner R e p la c e m e n t.................................................................................................................................. . .10A 4-20
In te rio r Trim R eplacem en t.....................................................................................................................................10A4-23
Engine C over R e p la ce m e n t.................................................................................................................................. 10A 4-26
C/K MODEL INTERIOR TRIM

The following procedure covers the trim located at
the front of the cab, and applies to all C/K models.
FRONT TRIM REPLACEMENT

Rem ove or D isconnect (Figures 1 th ro u g h 4)
1. Sill plate screws (1).

2. Sill plate (2).
3. Kick panel screws (3).
4. Kick panel (4).
5. Instrument panel outer filler screws (5).
6. Instrument panel outer filler (6).
7. Upper garnish molding screws (7).
8. Upper garnish molding (8).
9. Windshield side garnish molding screws (9).
10. Windshield side garnish molding (10).
Install o r C onnect (Figures 1 th ro u g h 4)

6. Instrument panel outer filler screws (5).
1. W indshield side garnish molding (10). 7. Kick panel (4).
2. Windshield side garnish molding screws (9). 8. Kick panel screws (3).
3. Upper garnish molding (8). 9. Sill plate (2).
4. Upper garnish molding screws (7). 10. Sill plate screws (1).
5. Instrument panel outer filler (6).
10A4-2 INTERIOR TRIM
Figure 3Instrument Panel Outer Filler Figure 4Sill Plate

INTERIOR TRIM 10A4-3
PICK UP MODELS
7. Seats and seat belts. Refer to SEATS (10A2).

CARPET REPLACEMENT
++ R em ove o r D isco n n e ct (F igures 5 th ro u g h 8)

HEADLINER AND TRIM
REPLACEMENT
1. Seats and seat belts. Refer to SEATS (SEC.
10A2).
2. Kick panel. ++ Rem ove o r D isco n n e ct (F igure 9)
3. Front door scuff plate (12).
4. Rear panel nails (13). 1. W indshield upper garnish molding screws (23).
Pull the nails from the panel. 2. W indshield upper garnish molding (17).
5. Rear panel (14). 3. Side window garnish molding screws (21).
6. Dash panel retainers (15). 4. Side window garnish molding (22).
7. Carpet (16) from the vehicle. 5. W indshield garnish molding screws.
6. W indshield garnish molding (24).
- Insta ll o r C on n ect (F igures 5 th ro u g h 8) 7. Back window garnish molding screws.
8. Back window garnish molding (25).
1. Carpet (16) to the vehicle. 9. Headliner (20).
2. Dash panel retainers (15).
3. Rear panel (14). Install o r C onnect (Figure 9)
4. New rear panel nails (13).
Push the nails through the panel and into 1. Headliner (20).
the body panels. 2. Back window garnish molding (25).
5. Front door scuff plate (12). 3. Back window garnish molding screws.
6. Kick panel. 4. W indshield garnish molding (24).
5. Windshield garnish molding screws.

6. Side window garnish molding (22).
7. Side window garnish molding screws (2 1 ).
8. Windshield upper garnish molding (17).
9. Windshield upper garnish molding screws (23).
Figure 7Carpet Retainers

16. Carpet
Figure 8Carpet
17. Windshield Upper Garnish Molding

18. Screw
19. Back Window Upper Garnish Molding
20. Headliner
21. Screw
22 . Side Window Garnish Molding
23. Screw
24. Windshield Garnish
Molding
25. Back Window Garnish
Molding
B-09067
Figure 9Headliner And Interior Trim

BONUS CAB MODELS
Figure 10Front Door Sill Plate
CARPET REPLACEMENT 6. Rear panel nails (figure 6).

Push the nails through the panel and into
the body panels.
Remove or Disconnect (Figures 10 through 12) 7. Front and rear door scuff plates (27).
8. Kick panel.
1. Seats and seat belts. Refer to SEATS (Sec. 10A1 ). 9. Seats and seat belts. Refer to SEATS (SEC.
2. Kick panel. 10A1).
3. Front and rear door scuff plates (27).
4. Rear panel nails (figure 6).
Pull the nails from ther panel. HEADLINER AND TRIM
5. Rear panel (figure 6). REPLACEMENT
6. Dash panel retainers (figure 7).
7. Lock pillar garnish molding screws (41) and the
molding (42). Remove or Disconnect (Figures 13 and 14)
8. Carpet to floor pane! bolts (28) (if equipped).
9. Carpet (29) from the vehicle. Windshield upper garnish molding screws (39)
and the molding (31).
Install or Connect (Figures 10 through 12) 2. Side window garnish molding screws (40) and the
molding (38).
1. Carpet (29) to the vehicle. 3. Windshield garnish molding screws and the
2 . Carpet to floor panel bolts (28) (if equipped). molding (30).
3. Lock pillar garnish molding (42) and the screws 4. Back window garnish molding screws and the
(41). molding (35).
4. Dash panel retainers (figure 7). 5. Lock pillar garnish molding screws and the
5. Rear panel (figure 6). molding.
6. Sunshade screws (44) and sunshade (43).

7. Headliner (32) from the vehicle.
1. Headliner (32) to the vehicle.

2. Sunshade (43) and screws (44).
3. Lock pillar garnish molding and screws.
4. Back window garnish molding (35) and screws.
5. Windshield garnish molding (30) and screws.
6. Side window garnish molding (38) and screws
(40).
7. Windshield upper garnish molding (31) and
screws (39).
Figure 11Lock Pillar Garnish Molding
Figure 12Carpet
30. Windshield Garnish Molding

32. Headliner
33. Screw
34. Back Window Upper Garnish Molding
35. Back Window Garnish Molding
36. Screw
37. Cap
38. Side Header Molding
39. Screw
40. Screw B-09135
43. Sunshade
44. Screw
B-09065
Figure 14Sunshade
UTILITY VEHICLE MODELS
CARPET REPLACEMENT 6. Side trim carpet panel (46) and screws (45).
7. Front door scuff plate.
8. Kick panel.
Remove or Disconnect (Figures 15 through 19) 9. Seats and seat belts. Refer to SEATS (Sec. 10A2).
1 . Seats and seat belts. Refer to SEATS (SEC.

10A2). HEADLINER AND TRIM
2. Kick panel. REPLACEMENT
3. Front door scuff plate.
4. Side trim carpet panel screws (45) and the panel
(46). Remove or Disconnect (Figure 20)
5. Side trim panel screws (47) and the panel (48).
6. Floor panel trim plate screws (49) and the trim 1 . Windshield upper garnish molding screws (56)
plate (50). and the molding (55).
7. Rear scuff plate screws (51) and the plate (52). 2 . Side window garnish molding screws (58) and the
8. Dash panel retainers (figure 7). molding (59).
9. Carpet (53) from the vehicle.
3. Windshield garnish molding screws and the

molding (57).
4. Roof rear header molding screws (60) and the.
1. Carpet (53) to the vehicle. molding (53).
2. Dash panel retainers (figure 7). 5. Lock pillar garnish molding screws and the
3. Rear scuff plate (52) and screws (51). molding (61).
4. Floor panel trim plate (50) and screws (49). 6. Sunshade screws and sunshade (figure 14).
5. Side trim panel (48) and screws (47). 7. Headliner (54) from the vehicle.
u i6o- 8
/dUp
7. Windshield upper garnish molding (55) and

screws (56).
FRONT FLOOR COMPARTMENT

REPLACEMENT
Open the compartment door.

1. Compartment to floor bolts (74).
2. Compartment from the vehicle.
1. Compartment to the vehicle.

2. Compartment to the floor bolts (74).

2. Sunshade and screws (figure 14).
3. Lock pillar garnish molding(61) and screws.
4. Roof rear header molding (53) and screws (60).
5. Windshield garnish molding (57) and screws.
6. Side window garnish molding (59) and screws
(58).
53. Carpet
B-09149
Figure 19Carpet Assemblies

53. Rear Header Molding

54. Headliner
56. Screw
57. Windshield Garnish Molding
58. Screw
59. Side Window Garnish Molding
60. Screw
61. Lock Pillar Garnish Molding
B-09071

62. Lock Cylinder

63. Bezel
64. Case Assembly
65. Door Assembly
66. Door Stop
67. Screw
68. Hinge
69. Striker
70. Nut
71. Bolt
72. Bumper
73. Compartment Assembly
74. Bolt
75. Bolt
76. Support B-09072
Figure 21 Floor Compartment

SUBURBAN MODEL
CARPET REPLACEMENT
" Remove or Disconnect (Figures 22 through 27)

10A1).
2. Front and rear door scuff plates (figure 5).
3. Kick panel.
4. Rear corner garnish molding screws (77) and the
molding (78).
5. Rear lock pillar garnish molding screws (79) and
the molding (80).
6. Front lock pillar garnish molding screws (81) and
the molding (82).
7. Body side trim panel screws (83) and the panel
(84).
8. Front scuff plate screws (85) and the plate (86).
9. Rear scuff plate screws (87) and the plate (88).
1 1 . Carpet (89) from the vehicle.
" Install or Connect (Figures 22 through 27)
1. Carpet (89) to the vehicle.

3. Rear scuff plate (88) and the screws (87). Figure 22Corner Garnish Molding
4. Front scuff plate (86) and the screws (85).
5. Body side trim panel (84) and the screws. 4. Rear roof header molding screws (95) and the
6. Front lock pillar garnish molding (82) and the molding (96).
screws (81). 5. Side header rear garnish molding screws (97)
7. Rear lock pillar garnish molding (80) and the and the molding (98) (if equipped).
screws (79).
6. Upper side garnish molding screws (99) and the
8. Rear corner garnish molding (78) and the screws molding (100) (if equipped).
(77).
7. Roof inner trim panel screws (101) and the panei
9. Kick panel. ( 102).
10. Front and rear door scuff plates (figure 5).
10A1).
-*- Install or Connect (Figures 28 and 29)
HEADLINER AND TRIM 1. Headliner (103) to the vehicle.

2. Roof inner trim panel (102) and screws (101).
REPLACEMENT 3. Upper side garnish molding (100) and screws (99)
(if equipped).
Remove or Disconnect (Figures 28 and 29) 4. Side header rear garnish molding (98) and
screws (97) (if equipped).
1. Windshield upper garnish molding screws (90) 5. Rear roof header molding (96) and screws (95).
and the molding (91). 6. Windshield garnish molding (94) and screws.
2 . Side header garnish molding screws (92) and the 7. Side header garnish molding (93) and screws
molding (93). (92).
3. Windshield garnish molding screws and the 8. Windshield upper garnish molding (91) and
molding (94). screws (90).
ROOF REAR HEADER

TRIM PANEL
1. Lower trim panel screws (104) and the lower

panel (105).
2. Upper trim panel screws (106) and the upper
panel (107).
1. Upper trim panel (107) and the screws (106).

2. Lower trim panel (105) and the scerws (104).
Figure 23Rear Lock Pillar Molding
Figure 24Front Lock Pillar Molding

Figure 26Scuff Plates

89. Carpet
B-09093
Figure 27Carpet
90. Screw 96. Rear Roof Header Molding

91. Windshield Upper Garnish Molding 97. Screw
92. Screw 98. Side Header Rear Garnish Molding
93. Side Header Garnish Molding 101. Screw
94. Windshield Garnish Molding 102. Roof Inner Trim Panel
95. Screw 103. Headliner B-09039

Figure 30Rear Header Lower Trim Panel

G MODEL INTERIOR TRIM
CARPET REPLACEMENT 4. Front step panel mat (if equipped) (114).

5. Carpet from the dash retainers (108).
Bend the retainers away from the dash.
|<+| Remove or Disconnect (Figures 32 through 41) 6. Front carpet (115) from the vehicle.
7. Side door scuff plate (116).
1 . Seats. Refer to SEATS (SEC. 10A2). 8. Side door mat (if equipped) (118).
2 . Front carpet retainer (110). 9. Carpet to side door screws (119).
3. Front door scuff plate (112 ). 10. Rear door scuff plate (12 1 ).
Figure 35Side Door Scuff Plates
11. Front trim panel (123).

12. Rear trim panel (125).
13. Rear corner panel (127).
14. Rear carpet from the vehicle.
111. Screw
112. Scuff Plate B-09109 Install or Connect (Figures 32 through 41)
1. Rear carpet to the vehicle.

Figure 33Scuff Plate
2. Rear corner panel (127).
3. Rear trim panel (125).
4. Front trim panel (123).
5. Rear door scuff plate (121).
6. Carpet to side door screws (119).
7. Side door mat (if equipped) (118).
8. Side door scuff plate (116).
9. Front carpet (115) to the vehicle.
10. Carpet to the dash retainers (108).
Bend the retainers over the carpet.
11. Front step panel mat (if equipped) (114).
12 . Front door scuff plate (112).
13. Front carpet retainer (110).
14. Seats. Refer to SEATS (SEC. 10A2).
HEADLINER REPLACEMENT
1. Upper window trim that supports the headliner.

Refer to Interior Trim Replacement.
2. Headliner retainer bow (if equipped).
Pull the bow (128) from the retainer.
3. Retainer bolts (129) and the retainers (130).
Shift the headliner from side to side to
disengage the headliner from the clips.
119. Screws B-09095
Figure 37Floor Carpet Bolts
" Install or Connect (Figure 42)
Place the headliner into the roof clips.
2. Retainers (130) to the headliner, and the retainer

bolts (129).
3. Headliner retainer bow (if equipped).
Push the bow (128) onto the retainer.
4. Upper window trim that supports the headliner.

Refer to Interior Trim Replacement.
Figure 38-Rear Door Scuff Plates

122. Screw
123. Front Trim Panel B-09123
Figure 39Front Trim Panel
124. Screw
125. Rear Trim Panel
B-09137
Figure 40Rear Trim Panel

Figure 42Headliner Retainer
INTERIOR TRIM REPLACEMENT Install or Connect
1. Body side trim rear panel and screws (figure 41).
0
a Remove or Disconnect 2.
3.
Body side rear trim panel and screws (figure 40).
Body side front trim panel and screws (figure 39).
1. Lock pillar garnish molding screws and the lock 4. Body side rear garnish molding and screws
pillar garnish molding (figure 43). (figure 52).
2. Front door hinge pillar molding screws and the 5. Body rear corner garnish molding and screws
front door hinge pillar molding (figure 44). (figure 51).
3. Sunshade screws and the sunshade (figure 45).
4. Front header garnish molding screws and the
front header garnish molding (figure 46).
5. Roof side rail garnish molding (figure 47). For
vehicles with intermediate doors only.
6. Roof side header garnish molding (figure 48). For
vehicles with the sliding side door only.
7. Lower lock pillar garnish molding screws and the
molding (figure 49).
8. Body side front garnish molding screws and the
9. Roof rear header garnish molding screws and the
10. Body rear corner garnish molding screws and the
1 1 . Body side rear garnish molding screws and the
12. Body side front trim panel screws and the trim
panel (figure 39).
Pull the panel from the retainers.
13. Body side rear trim panel screws and the trim
panel (figure 40).
14. Body side trim rear corner panel screws and the
panel (figure 41).
6. Roof rear head garnish molding and screws

(figure 50).
7. Body side front garnish molding and screws
(figure 49).
Figure 46Front Header Garnish Molding

8. Lower lock pillar garnish molding and screws

(figure 49).
9. Roof side header garnish molding and screws
(figure 48). For vehicles with the sliding side door
only.
10. Roof side rail garnish molding and screws (figure
47). For vehicles with intermediate doors only.
144 1 1 . Front header garnish molding and screws (figure
144. Screw
145. Lower Lock Pillar
Garnish Molding
146. Screw
147. Front Side
Garnish Molding
145 B-09070
Figure 49Front Garnish Moldings
Figure 50Rear Header Garnish Molding Figure 51Rear Corner Garnish Molding
12 . Sunshade and screws (figure 45).

13. Front door hinge pillar molding and screws (figure
44).
14. Lock pillar garnish molding and screws (figure
43).
ENGINE COVER REPLACEMENT
++ Remove or Disconnect (Figures 53 and 54)
1. Instrument panel lower extension screws (150),

washers (151), and shims (152).
2. Instrument panel lower extension (153).
3. Engine cover (158) to floor panel bolts (156).
4. Clamp (157) from the pin (155).
5. Engine cover (158) from the vehicle.
1. Engine cover (158) to the vehicle.

2. Clamp (157) to the pin (155).
3. Engine cover (158) to floor panel bolts (156).
4. Instrument panel lower extension (153).
5. Instrument panel lower extension screws (150),
washers (151) and shims (152).
Figure 53Instrument Panel Lower Extension

157
155
155. Pin
156. Bolt
157. Clamp
158. Engine Cover B-09053
Figure 54Engine Cover

-- 77 r
---------- - ---- ' ------------
10A5-1
SECTION 10A5
END GATE
CONTENTS
SUBJECT PAGE
Fender Side Models....................................................................................................................................... 10A5- 2

End Gate R eplacem ent.............................................................................................................................10A5- 2
Fleet Side M o d e ls ......................................................................................................................................... 10A5- 2
Handle And Latch Replacement.............................................................................................................. 10A5- 3
Utility Vehicle M o d e ls................................................................................................................................... 10A5- 4
Torque Rod Replacem ent.........................................................................................................................10A5- 5
Hinge Replacem ent...................................................................................................................................10A5- 6
End Gate Cover Replacement...................................................................................................................10A5- 6
Handle And Control Assembly Replacement.......................................................................................... 10A5- 6
Latch Replacement..................................................................................................................................... 10A5- 6
Regulator Replacement.............................................................................................................................10A5- 7
Window Motor And Blockout Switch R eplacem ent..............................................................................1QA5-11
Sash Assembly Replacem ent...................................................................................................................10A5-11
Run Channel Replacem ent.......................................................................................................................10A5-12
End Gate Outside Crank Replacement.................................................................................................... 10A5-12
Window Glass Seal Replacement............................................................................................................ 10A5-12
Weatherstrip R eplacem ent.......................................................................................................................10A5-12
Utility Vehicle Removable T o p .....................................................................................................................10A5-13
Removable Top Replacement...................................................................................................................10A5-13
Suburban Models........................................................................................................................................... 1QA5-14
End Gate R eplacem ent.............................................................................................................................10A5-14
Torque Rod Replacem ent.........................................................................................................................10A5-14
Hinge Replacem ent...................................................................................................................................10A5-15
End Gate Trim And Cover Panel Replacement......................................................................................10A5-16
Handle And Control Assembly Replacement.......................................................................................... 10A5-16
Latch Replacement..................................................................................................................................... 10A5-17
Regulator Replacement.............................................................................................................................10A5-18
Blockout Switch Replacem ent................................................................................................................ 10A5-19
Sash Assembly Replacem ent.................................................................................................................. 10A5-19
Run Channel Replacem ent.......................................................................................................................10A5-19
End Gate Outside Crank Replacement.................................................................................................... 10A5-19
Window Glass Seal Replacement............................................................................................................ 10A5-19
Weatherstrip Replacem ent.......................................................................................................................10A5-20
10A5-2 END GATE
FENDER SIDE MODELS
END GATE REPLACEMENT

Open the end gate and support it with a table or

other suitable support.
1. Fender to end gate bolt (6) and washer (7).
2. End gate (4), and bushing (5) from the vehicle.
3. Chain (3) to fender nut (1), washer (2), and eye
bolt.
1. Chain (3) with eye bolt to the fender.

2. Washer (2) and nut (1) to the eye bolt.
3. End gate (4) and bushing (5) to the vehicle.
4. Fender to end gate washer (7), and bolt (6).
1. Nut
2 . Spring Washer
3. Chain Assembly
4. End Gate
5. Bushing
6 . Bolt
7. Washer B-09020
Figure 1Fender Side End Gate Components
FLEET SIDE MODELS
END GATE REPLACEMENT n- Install or Connect (Figure 2)
++ Remove or Disconnect (Figure 2) 1. Bumpers (10) to the vehicle.

2. Bumper (10) to fastener screws (11).
Open the end gate and support it with a table or
other suitable support. 3. Outer hinge half (B).
1. Link and striker plate (8) to fender bolts (17). 4. Hinge (14) to fender bolts (16).
2. Link and striker (8) from the end gate. 5. Inner hinge half (A).
Rotate the link until it aligns with the tab (9)
6. End gate (12) to the vehicle.
on the end gate, and pull it from the end
gate. 7. Hinge (14) to end gate bolts (13).
3. Hinge (14) to end gate bolts (13). 8. Link and striker (8) to the end gate.
4. End gate (12) from the vehicle.
Place the slot on the link in line with the tab
5. Inner hinge half (A). * (9) on the end gate, and place the link onto
6. Hinge (14) to fender bolts (16). the end gate. Pivot the link into its proper
position.
7. Outer hinge half (B).
8. Bumper (10) to fender screws (11). 9. Link and striker to the fender.
9. Bumpers (10) from the vehicle. 10. Link and striker to fender bolts (17).
END GATE 10A5-3
8. Link And
Striker Plate
9. Tab
10. Bumper
11. Screw
12. End Gate
13. Bolt
14. Hinge
16. Bolt
17. Bolt
A. Inner Hinge
B. Outer Hinge
B-09023
Figure 2Fleet Side End Gate Components
HANDLE AND LATCH 3. Link to the end gate.

Refer to End Gate Replacement.
REPLACEMENT 4. Handle (21) to the end gate.
5. End gate to handle bolts (22).
++ Remove or Disconnect (Figure 3) 6. Latch rods (19) to the clips (20).
Lower and support the end gate with a table or

other suitable support.
1. Latch rods (19) from the clips (20).
2. End gate to handle bolts (22).
3. Handle (21) from the end gate.
4. Link from the end gate.
Refer to End Gate Replacement.
5. Latch (18) to end gate bolts (23).
6. Latch (18) from the vehicle.
Latch (18) to the vehicle.

Latch (18) to end gate bolts (23).
10A5-4 END GATE
18. Latch Assembly

19. Latch Rod
20. Clip
21. Handle
22. Bolt
23. Bolt B-09033
Figure 3Handle And Latch Components
UTILITY VEHICLE MODELS
END GATE REPLACEMENT + + Install or Connect (Figures 4, 5, and 6)
Remove or Disconnect (Figures 4, 5, and 6) 1 . End gate to the vehicle.

Guide the torque rods over the gravel
The end gate must be in the closed position. deflectors to prevent damage.
1. Torque rod to frame stud (30) and nut (32).
Allow the torque rod to swing down. Insert the hinges into the floor panel slots.
Open the end gate, and support it with a table or 2. Hinge (49) to floor pan bolts (48) to the under side
other suitable support. of the vehicle.
2. Electrical wiring harness (if equipped). Refer to
End Gate Cover Replacement for access to the 3. Torque rod brackets (25) and bolts (24).
harness. 4. Cable (34) to the end gate opening with bolts (37),
3. Cable (34) to end gate opening bolts (37), spacers spacers (36), and washers (35).
(36), and washers (35).
4. Torque rod bracket bolts (24) and brackets (25). 5. Electrical wiring harness (if equipped). Refer to
End Gate Cover Replacement for access to the
5. Hinge (49) to floor panel bolts (48) from the under
harness.
side of the vehicle.
6. End gate from the vehicle. Close the end gate.
Lift the end gate from the body.
6. Torque rod to frame stud (30) and nut (32).
Guide the torque rods over the gravel
deflectors to prevent damage. 7. Torque rods onto the studs.
END GATE 10A5-5
25 ^
24 . 24. Bolt
25. Outer Bracket
26. Torque Rod
27. Bolt
28. Silencer
29. Inner Bracket
30. Stud
31. Frame
32. Nut
33. Silencer
B-09034
Figure 4Utility VehicleTorque Rod
TORQUE ROD REPLACEMENT 5. Inner bracket (29) from the end gate.
4- + Remove or Disconnect (Figure 4) +- Install or Connect (Figure 4)
1. End gate. Refer to End Gate Replacement. 1. Torque rod (26) with silencers (28) to the end
2. End gate cover. gate.
3. End gate to torque rod inner bracket bolts (27). 2. Inner bracket (29) to the torque rod.
4. Torque rod (26) with silencers (28) from the end 3. End gate to torque rod inner bracket bolts (27).
gate. 4. End gate cover.
34. Cable
35. Washer
36. Spacer
37. Bolt
38. Washer
39. Spring
40. Washer
41. Bolt
42. Screw
43. Guide
B-09035
Figure 5Cable Assembly Components

i
10A5-6 END GATE
END GATE COVER

REPLACEMENT
1. End gate cover screws (51).

2. End gate cover (50).
1 . End gate cover (50).

2. End gate cover screws (51).
HANDLE AND CONTROL

1. End gate cover.

2. Control rod (64) from the handle (61).
3. Handle to end gate screws (62).
4. Handle (61) from the end gate.
5. Right and left latch rods (65) from the control
assembly.
6. Control assembly to end gate bolts (60).
7. Control assembly (55) from the end gate.
8. Window lockout rod spring (54).
5. End gate. Refer to End Gate Replacement. 9. Lockout rod (53) to end gate bolts (52).
10. Lockout rod (53) from the end gate.
HINGE REPLACEMENT Install or Connect (Figure 8)
Remove or Disconnect (Figure 6) 1. Lockout rod (53) to the end gate.

The bottom of the rod must fit into the clip at
Lower the end gate. the base of the end gate.
1. Hinge to body bolts (48) for the hinge to be 2. Lockout rod (53) to end gate bolts (52).
removed only. 3. Window lockout rod spring (54).
Loosen the hinge to body bolts (48) on the 4. Control assembly (55) to the end gate.
opposite hinge. 5. Control assembly to end gate bolts (60).
2. Hinge to end gate bolts (47) for the hinge to be 6. Right and left latch rods (65) from the control
removed. assembly.
Pull the end gate away from the body several 7. Handle (61) to the end gate.
inches and remove the hinge from the body. 8. Handle to end gate screws (62).
Lift tlhe end gate slightly to allow removal of the 9. Control rod (64) to the handle (61).
hinge from the end gate. 10. End gate cover.

LATCH REPLACEMENT
Lift the end gate slightly and install the hinge to
the end gate. Remove or Disconnect (Figure 9)
Pull the end gate away from the body several
inches, and insert the hinge into the body. 1 . End gate cover.
1. Hinge to end gate bolts (47). 2. Right or left latch rod (65) from the control
2. Hinge to body bolts (48). assembly.
Tighten the hinge to body bolts on the opposite 3. Latch (66) to end gate screws (67).
hinge. 4. Latch (66) from the end gate.
END GATE 10A5-7
Figure 1End Gate Cover
Install or Connect (Figure 9) REGULATOR REPLACEMENT

1. Latch (66) with rod to the end gate. MANUAL REGULATOR
2. Latch (66) to end gate screws (67). Remove or Disconnect (Figure 10)
3. Right or left latch rod (65) to the control assembly. 1 . End gate cover.
2 . Control assembly. Refer to Handle And Control
4. End gate cover. Assembly Replacement.
Figure 8Handle And Control Assembly

10A5-8 END GATE
Figure 9Latch Components
3. Sash assembly (73). Refer to Sash Assembly 3. Sash assembly (73). Refer to Sash Assembly
4. Regulator (69) to end gate bolts (70).
5. Regulator (69) from the end gate. 4. Control assembly. Refer to Handle And Control
*4- Install or Connect (Figure 10)
5. End gate cover.
1. Regulator (69) to the end gate.
Figure 10Regular And Sash Components

END GATE 10A5-9
76. Regulator
77. Cable Assembly
78. Bolt
79. Motor Assembly
80. Gear Assembly
B-09143
Figure 11Power Regulator Components
POWER REGULATOR
1. End gate cover.

2. Control assembly. Refer to Handle And Control
3. Sash assembly (73). Refer to Sash Assembly
Replacement.
CAUTION: Step 4 must be performed if the

gear box is removed or disengaged from the
regulator lift arms. The left arms are under
tension from the counterbalance spring, and
can cause personal injury if the gear box is
removed without locking the sector gears in
place.
4. Drill a 3.1 mm (Ve-inch) diameter hole through the
sector gear and back plate. Install a sheet metal
tapping screw into the hole to lock the sector
gears in position.
103. Bolt 5. Drive cable (77) at regulator (76).
104. Motor
105. Bolt 6. Regulator (76) to end gate bolts (78).
106. Blockout Switch B-09146 7. Regulator (76) from the end gate.
8. Gear assembly (80) to regulator bolts.
Figure 12End Gate Electrical Components
9. Gear assembly (80) from the regulator (76).
10A5-10 END GATE
Install or Connect (Figures 10 and 11) 6. Sash assembly (73). Refer to Sash Assembly
Replacement.
1 . Gear box (80) to the regulator (76).
2. Gear box (80) to regulator bolts. 7. Control assembly. Refer to Handle and Control
4. Regulator (76) to end gate bolts (78). 8. End gate cover.
5. Drive cable (77) to the regulator (76).
Remove the sheet metal screw.
85. Nut 92. Cover

86. Bezel 93. Gasket
87. Gasket 94. Lock Cylinder
88. Handle Assembly 95. Retainer
89. Clip 96. Clutch
90. Bezel 97. Pawl
91. Gasket 98. Spring
B-09058
Figure 14Window Control Components

END GATE 10A5-11
WINDOW MOTOR AND BLOCKOUT SASH ASSEMBLY REPLACEMENT

SWITCH REPLACEMENT
1. Window run channel caps (figure 13).
1. End gate panel. 2. Inner and outer window glass seals. Refer to
2. Wiring harness from the motor and switch. Window Glass Seal Replacement.
3. Cable from the motor. 3. End gate cover.
4. End gate to motor bolts (103).
Regulate the window so that the sash channel
5. Motor (104) from the end gate.
bolts (72) are accessable.
6. Latch containing the blockout switch from the end
gate. Refer to Latch Replacement. 4. Sash (73) to sash channel bolts (72).
7. Blockout switch (106) to latch bolts (105). 5. Sash (73) with glass (75) from the end gate.
8. Blockout switch (106) from the latch.
6. Sash rails (71) from the regulator (69).

1 . Blockout switch (106) to the latch.
1 . Sash rails (71) to the regulator (69).
2. Blockout switch (106) to latch bolts (105).
3. Latch to the end gate. Refer to Latch 2. Sash (73) with glass (75) to the end gate.
Replacement.
3. Sash (73) to sash channel bolts (72).
4. Motor (104) to the end gate.
4. End gate cover.
5. End gate to motor bolts (103).
6. Cable to the motor. 5. Inner and outer window glass seals. Refer to
7. Wiring harness to the motor and the switch. Window Glass Seal Replacement.
8. End gate panel. 6. Window run channel caps (figure 13).
10A5-12 END GATE
RUN CHANNEL REPLACEMENT

1. Window run-channel caps (83).

Completely lower the window.
2. Run-channel (81) from the end gate.
Pull the channel from the end gate. Twist the
channel to clear the window opening.
1. Run-channel (81) to the end gate.

Twist the channel into the window opening.
2. Run-channel (81) to end gate bolts (82). Remove or Disconnect (Figure 16)
3. Window run-channel caps (83). Weatherstrip from the end gate using 3M Release
END GATE OUTSIDE CRANK |-n-| Install or Connect (Figure 16)

REPLACEMENT
W eatherstrip to the end gate using 3M
1. Handle and control assembly. Refer to Handle

And Control Assembly Replacement.
2. Crank to end gate nuts (85).
3. Crank (88) and bezel (86) from the end gate.
1. Crank (88) and bezel (86) to the end gate.

WINDOW GLASS SEAL

REPLACEMENT
B Remove or Disconnect (Figure 15)
Lower the window.

Inner or outer seal by prying the clips from the
end gate.
Inner or outer seal by pressing the clips into the

holes in the end gate.
END GATE 10A5-13
UTILITY VEHICLE REMOVABLE TOP

Pull the panel away only far enough to gain ac
cess to the hidden top boit.
6. Hidden bolts (115).
7. The removable top (111).
With the assistance of helpers, carefully lift
the top from the vehicle. Do not allow the
sides to bend.
To prevent damage to the top and to ensure proper

weatherstrip sealing, the following procedure must be
followed.
Remove the upper spare tire brace.
1. The top onto the vehicle.
Use the two rear guide pins as locators.
2. Top to roof mounting bolts (114).
3. Top to side panel mounting bolts (112).
Figure 17Removable TopAccess Plate Start with the bolts nearest the end gate,
Components and work towards the cab.
Do not install the second bolt from the rear
REMOVABLE TOP REPLACEMENT on the right side at this time.
Do not install the bolts (113) nearest the cab.
Remove or Disconnect (Figures 17 and 18) Loosen the top (111) to roof mounting bolts (114).
4. Top to side panel mounting bolts (113).
1. Access plate (108) and dome lamp wiring har 5. Top to roof mounting bolts (110) and (114).
ness. 6. Hidden bolts (115).
Lower the end gate. 7. Trim panel screws to the right and left trim panels.
2. Top (111) to roof mounting bolts (110) and (114). 8. The upper spare tire brace with the remaining
3. Top (111) to side panel mounting bolts (113) and bolt.
(112).
9. Dome lamp wiring harness, and access plate
4. Upper tire brace bolt and the upper brace. (108).
Reinstall the brace after the top is removed.
5. Side trim panel rear attaching screws.
Remove twelve screws on the left side.
Remove eleven screws on the right side.
10A5-14 END GATE
Figure 18Removable Top Components
SUBURBAN MODELS
END GATE REPLACEMENT 6. Torque rod bracket (119).
++ Remove or Disconnect (Figures 19, 20, and

21 ) TORQUE ROD REPLACEMENT
Lower the end gate. Remove or Disconnect (Figure 19)

1. Torque rod bracket (119).
2. Wiring harness (if equipped). Refer to End Gate 1. End gate. Refer to End Gate Replacement.
Trim And Cover Panel Replacement for access 2. Trim panel (if equipped) and the cover panel.
to the wiring harness. 3. End gate to torque rod inner bracket bolts (126).
3. Hinge access cover (131) and seal (132).
4. End gate to torque rod outer bracket bolts (122).
4. End gate to hinge bolts (133).
Lift the end gate to the almost closed position. 5. Inner (118) and outer (119) brackets from the end
5. Support cable (136) to end gate bolt (142) and gate.
washer (143). 6. Torque rod (117) from the end gate.
6. End gate with torque rod from the vehicle.
0 Install or Connect (Figures 19, 20 and 21)
1. Torque rod (117) to the end gate.
1. End gate with torque rod (117) to the vehicle.
2. Outer brackets (117) to the end gate.
2. Support cable (136) to end gate washer (143) and
bolt (142). 3. Outer bracket bolts (122).
3. End gate to hinge bolts (133). 4. Inner bracket (118) to the end gate.
4. Hinge cover seal (132) and access cover (131). 5. Inner bracket bolts (126).
5. Wiring harness (if equipped). Refer to End Gate
Trim And Cover Panel Replacement for access 6. The cover panel and trim panel (if equipped).
to the wiring harness. 7. End gate. Refer to End Gate Replacement.
END GATE 10A5-15
Figure 19SuburbanTorque Rod Components
HINGE REPLACEMENT
128. Striker
129. Washer ++ Remove or Disconnect (Figure 20)
130. Screw
131. Cover Lower the end gate.
132. Seal 1. Hinge to body bolts (134) for the hinge to be
133. Bolt removed.
134. Bolt
135. Hinge Loosen the hinge to body bolts (134) on the
opposite hinge.
2 . Hinge cover screws (130) and covers (131).
3. Hinge to end gate bolts (133) for the hinge to be
removed.
Pull the end gate away from the body several
inches and remove the hinge from the body.
Lift the end gate slightly to allow removal of the
hinge from the end gate.
|++| Install or Connect (Figure 20)
Lift the end gate slightly and install the hinge to

the end gate.
B-09078 Pull the end gate away from the body several
inches, and insert the hinge into the body.
Figure 20Hinge Components 1. Hinge to end gate bolts (133).
10A5-16 END GATE
136. Cable
137. Bolt
138. Washer
139. Spring
140. Plug
141. Washer
142. Bolt
143. Washer
Figure 21Cable Assembly Components
2. Hinge to body bolts (134). 3. Trim panel (144).

Tighten the hinge to body bolts on the opposite 4. Trim panel screws (145).
hinge.
3. Hinge covers (131) and cover screws (130). HANDLE AND CONTROL
END GATE TRIM AND COVER < Remove or Disconnect (Figures 23 and 24)
PANEL REPLACEMENT
1. Trim panel (if equipped) and the cover panel.
Remove or Disconnect (Figures 22 and 23) 2. Control rod (154) from the handle (159).
1. Trim panel screws (145). 4. Handle (159) from the end gate.
2. Trim panel (144). 5. Right and left latch rods (150) from the control
assembly.
Slide the panel away from the glass
opening. 6. Control assembly to end gate bolts (148).
7. Control assembly (149) from the end gate.
Note the position of the cover panel screws. Five
of the holes in the cover panel are also holes for +- Install or C o rre ct (Figures 23 and 24)
the trim panel.
3. Cover panel screws (146). 1. Control assembly (149) to the end gate.
4. Cover panel (147). 2. Control assembly to end gate bolts (148).
3. Right and left latch rods (150) from the control
assembly.
Install or Connect (Figures 22 and 23) 4. Handle (159) to the end gate.
1. Cover panel (147).
6. Control rod (154) to the handle (159).
2 . Cover panel screws (146). 7. End gate cover and trim panel (if equipped).
END GATE 10A5-17
Figure 22Trim Panel Components
LATCH REPLACEMENT Install or Connect (Figure 24)

Remove or Disconnect (Figure 24) 1. Latch (153) with rod to the end gate.
2. Latch (153) to end gate screws (152).
1. Trim panel (if equipped) and the cover panel.
3. Right or left latch rod (150) to the control
2 . Right or left latch rods (150) from the control
assembly.
assembly.
4. Cover panel and trim panel (if equipped).
3. Latch (153) to end gate screws (152).
4. Latch (153) from the end gate.
146. Screw
147. Cover
148. Bolt
150. Latch Rod
151. Lever Assembly
B-09081
Figure 23End Gate Cover And Control Assembly Components

10A5-18 END GATE

150. Latch Rod
152. Bolt
153. Latch Assembly
154. Control Rod
159. Handle
160. Clip 150
161. Screw
B-09082
Figure 24Handle And Latch Components
REGULATOR REPLACEMENT 4. Wiring harness from the motor.

MANUAL. REGULATOR
6. Regulator (76) from the end gate.
CAUTION: Step 7 must be performed if the
Remove or Disconnect (Figure 10) gear box is removed or disengaged from the
regulator lift arms. The lift arms are under
1. Trim panel (if equipped) and cover panel. tension from the counterbalance spring, and
2. Control assembly. Refer to Handle And Control can cause personal injury if the gear box is
Assembly Replacement. removed without locking the sector gears in
3. Sash assembly (73). Refer to Sash Assembly place.
Replacement.
4. Regulator (69) to end gate bolts (70). 7. Drill a 3.1 mm (Vs-inch) diameter hole through the
5. Regulator (69) from the end gate. sector gear and back plate. Install a sheet metal
tapping screw into the hole to lock the sector
gears in position.
H" Install or Connect (Figure 10) 8. Motor to regulator bolts.

Replacement.
1. Motor to the regulator.
Assembly Replacement. 2. Motor to regulator bolts.
5. End gate cover and trim panel (if equipped).
Remove the sheet metal screw.
POWER REGULATOR
Remove or Disconnect (Figures 10 and 11) 5. Wiring harness to the motor.

1. Trim panel (if equipped) and end gate cover. Replacement.
Assembly Replacement. 7. Control assembly. Refer to Handle And Control
Replacement. 8. Trim panel (if equipped) and end gate cover.
END GATE 10A5-19
BLOCKOUT SWITCH
REPLACEMENT
1. Trim panel (if equipped) and the end gate cover.

2. The right latch assembly. Refer to Latch
Replacement.
3. Wiring harness from the switch.
4. Switch from the latch.
Install or Connect
1. Switch to the latch.

2. Wiring harness to the switch.
3. The right latch assembly to the end gate. Refer to
Latch Replacement.
4. End gate cover and trim panel (if equipped).
SASH ASSEMBLY REPLACEMENT

END GATE OUTSIDE
CRANK REPLACEMENT
1. Inner and outer window glass seals. Refer to
Window Glass Seal Replacement. ++ Remove or Disconnect (Figure 14)
2. Trim panel (if equipped) and cover panel.
Regulate the window so that the sash channel
bolts (72) are accessable.
2 . Crank to end gate nuts (85).
3. Crank (88) and gasket (87) from the end gate.
4. Sash (73) with glass (75) from the end gate.
5. Sash rails (71) from the regulator (69). -4- Install or Connect (Figure 14)
1. Crank (88) and gasket (87) to the end gate.
1. Sash rails (71) to the regulator (69).
2. Sash (73) with glass (75) to the end gate.
4. End gate cover and trim panel.
5. Inner and outer window glass seals. Refer to WINDOW GLASS SEAL
Window Glass Seal Replacement.
REPLACEMENT
RUN CHANNEL REPLACEMENT +- Remove or Disconnect (Figure 15)
Remove or Disconnect (Figure 25) Lower the window.

1. Trim panel (if equipped).
Completely lower the window. The inner seal is attached to the trim panel,
1 . Run-channel (156) to end gate bolts (155). when equipped, and replacement is not
2. Run-channel (156) from the end gate. recommended.
Pull the channel from the end gate. Twist the 2. Inner or outer seals by prying the clips from the
channel to clear the window opening. end gate.
-4- Install or Connect (Figure 25) -4- Install or Connect (Figure 15)
1. Run-channel (156) to the end gate. 1. Inner or outer seal by pressing the clips into the
Twist the channel into the window opening. holes in the end gate.
2 . Run-channel (156) to end gate bolts (155). 2. Trim panel (if equipped).
10A5-20 END GATE
1. Weatherstrip screws (158).

2. Weatherstrip from the end gate using 3M Release
-- Install or Connect (Figure 26)
1. W eatherstrip to the end gate using 3M

2. Weatherstrip screws (158).
Figure 26Weatherstrip Components

SECTION PAGE SECTION PAGE
A Thermostatic Switch Replacement..................1B-67

A/C Electric/Vacuum (A/C) Trouble Diagnosis .. .1B-16
Accelerator Control Cable....................................6C-18 A/C Evacuating And Charging Procedures........1B-22
Accelerator Pedal..................................................6C-19 A/C Pressure Sensing Switch......................1B-4, 1B-9
Accessory Drive Component Torque A/C Rear Interior Roof Mounted
Specifications....................................................6B-45 SystemSuburban..........................................1B-45
A/C Compressor Belt Tension Adjustment Blower Motor Assembly Replacement............1B-45
(G and Motor Home)........................................1B-29 Blower Motor Resistor Replacement..............1B-45
A/C Compressor Diagnosis..................................1B-15 Blower Motor Switch Replacement..................1B-49
A/C Compressor Replacement............................1B-28 Evaporator Core Replacement........................1B-48
A/C Components-GK Series................................1B-32 Expansion Valve Replacement........................1B-46
Accumulator......................................................1B-33 Fuse Replacement............................................1B-49
ActuatorPlenum Side Vent Replacement.. .1B-38 A/C Refrigerant-12 Operating Characteristics . . . .1B-4
Blower Assembly..............................................1B-34 A/C Refrigerant System Diagnosis......................1B-21
Blower Motor Relay Replacement..................1B-45 A/C Sight Glass Diagnosis (Motor Home)..........1B-27
Blower Motor Resistor Replacement..............1B-43 A/C Specific Component Diagnosis....................1B-26
Blower Switch Replacment..............................1B-40 A/C System Description........................................1B-3
Condenser........................................................1B-32 A/C System Diagnosis..........................................1B-9
Control Assembly Replacement......................1B-39 A/C Vacuum System Diagnosis..........................1B-21
Evaporator Core................................................1B-34 A/C Clutch C ontrol................................................6E-9
Fuse Replacement............................................1B-45 Accumulator (THM 350-C)....................................7A-90
Orifice (Expansion Tube)..................................1B-35 Adjustment Brakes............................................5-47
Plenum Valve Replacement............................1B-39 Air C leaner............................................................6C-2
Refrigerant-12 Hose Routing............................1B-40 Air Conditioning Circuits......................................8A-52
Selector Duct and Heater Core Replacement .1B-37 Air Conditioning Electrical System......................8A-52
Temperature Door Cable Adjustment..............1B-40 Air Conditioning Electrical System Diagnosis .. .8A-52
Vacuum Line HarnessDash..........................1B-40 Air Filter Element Replacement............................6C-2
Vacuum LinesEngine Compartment............1B-40 Air Injection Reaction............................................6E-8
Vacuum Tank Replacement..............................1B-40 Air Valve Rod Adjustment
A/C ComponentsG Series................................1B-49 (M4ME, M4MED, And M4MEF)......................6C1-37
Accumulator Replacement..............................1B-49 Air Valve Spring Adjustment
Blower Motor Insulation (Diesel) (M4ME, M4MED, And M4MEF)......................6C1-34
Replacement....................................................1B-54
ALCL Connector....................................................6E-6
Blower Motor Replacement..............................1B-57
Aluminum Radiator Repair..................................6B-36
Blower Motor Relay Replacement..................1B-59
Aluminum Wheel Refinishing................................3E-9
Blower Switch Replacement............................1B-58
Antenna ReplacementCK Models....................9A-24
Condenser Replacement..................................1B-49
Antenna ReplacementG Van............................9A-24
Control Assembly Replacement......................1B-58
Automatic Hub To the Wheel Adjustment............4C-8
Defroster Duct Replacement............................1B-59
Auxiliary Cooling F a n ..........................................6B-21
Ductwork Replacement....................................1B-59
Evaporator Core Replacement........................1B-56 Axle Joint Component Replacement....................4C-5
Evaporator Core (Diesel) Replacement..........1B-55 Axle Shaft, Oil Seal And Bearing Replacement
Orifice (Expansion Tube) Replacement..........1B-54 (81/2-91/2-lnch Ring Gear Semi-Floating Axles).4B-10
Refrigerant-12 Hose Routing........................... 1B-60 Axle Shaft Replacement........................................4C-3
Resistor Replacement......................................1B-58 Axle Shaft Replacement (93/4-10 1/2-lnch
Tempearture Door Cable Adjustment..............1B-58 Ring Gear Full Floating Axles)....................4B-16
Temperature Door Cable Replacement..........1B-59 Axle Shaft Replacement (12-Inch Ring
Vacuum Lines Engine Compartment..............1B-60 GearFull Floating A xle )................................4B-21
Vacuum Tank Replacement..............................1B-60 Axle Vent Replacement (12-Inch Ring G e a r-
A/C ComponentsMotor Home..........................1B-64 Full Floating A xle)............................................4B-21
Blower Assembly Replacement......................1B-66
BlowerEvaporator Assembly Replacement. .1B-66
Blower Motor Resistor Replacement..............1B-67 B
Blower Switch Replacement............................1B-67
Condenser Replacement..................................1B-64 Back-Up Lamp System........................................8B-12
Evaporator Case Replacement........................1B-67 Back-Up Lamp System Diagnosis......................8B-22
Evaporator Core Replacement........................1B-67 Ball Joints........................................................... 3C-53
Expansion Valve Replacement........................1B-67 Basic Electrical......................................................8A-2
Fuse Replacement............................................1B-67 Battery................................................................... 6D-3
ReceiverDehydrator Replacement..............1B-65 Battery Cables....................................................... 6D-6
Sight Glass Replacement.............................. 1B-65 Battery Charging Procedures................................6D-6
Battery Diagnosis..................................................6D-4 Camshaft Replacement
Battery Replacement..............................................6D-7 (4.3L Engines)................................................. 6A3-17
Bearing Adjustment ( 4 x 4 ) ..................................3C-47 (4.8L Engines)................................................. 6A4-16
Bearing Adjustment (12-Inch Ring (Small Block Engines)....................................6A5-17
GearFull Floating A x le )................................4B-21 (7.4L Engines)................................................. 6A6-15
Below Eyeline Outside Rear View Mirror (6.2L Engines)................................................. 6A7-16
Replacement (C/K Model Side Front Door). .10A1-14 Carburetor Adjustments (1 MEF)........................6C1-15
Below Eyeline Outside Rear View Mirror Carburetor Adjustments (E4ME And E4MED). .6C1-47
Replacement (G Model Side Front Door). . .10A1-44 Carburetor Models E4ME And E4MED
Bench Seatback And Catch Replacement (California Only)............................................. 6C1-40
(C/K Model Front Seat)..................................10A2-6 Carburetor Model 1 M EF..................................... 6C1-2
BleedingBrake System..........................................5-8 Carburetor Models M4ME, M4MED,
Blockout Switch Replacement And M4MEF................................................... 6C1-19
(Suburban Model)..........................................10A5-18 Carburetor Replacement (1M EF)......................6C1-14
Brakes Carburetor Replacement (E4ME And
Adjustment......................................................... 5-47 E4MED)......................................................... 6C1-47
Bleeding The System..........................................5-36 Carburetor Replacement
Cable Replacement............................................5-23 (M4ME, M4MED, And M4MEF)......................6C1-30
Combination Valve..............................................5-12 Carpet Replacement (Bonus Cab Models)........10A4-6
Carpet Replacement (G Model)........................10A4-19
Disc B rakes....................................................... 5-37
Carpet Replacement (Pick Up M odels)............10A4-3
Drum EJrakes....................................................... 5-45
Carpet Replacement (Suburban Models)........10A4-14
Flushing The Hydraulic S ystem ..........................5-9
Carpet Replacement (Utility Vehicle Models) . .10A4-9
Hydraulic Brake Booster....................................5-33
Center And Rear Seats (G Model)..................10A2-27
Master Cylinders................................................5-30
Center And Rear Seat Disassembly
Parking Brake Adjustment..................................5-27
(G Model)..................................................... 10A2-27
Parking Brake Pedal............................................5-22 Center And Rear Seat Replacement
Pedal Replacement..............................................5-17 (G Model)..................................................... 10A2-27
Pedal Rod Replacement....................................5-20 Center And Rear Seat Armrest Replacement
Pipes And Hoses..................................................5-9 (G Model)..................................................... 10A2-28
Propeller Shaft Brake..........................................5-27 Center And Rear Seat Belt Replacement
Road Testing......................................................... 5-2 (G Model)..................................................... 10A2-29
Stoplamp S w itch ............................................... 5-20 Center Bearing..................................................... 4A-2
Vacuum Boosters................................................5-32 Center Seat Belt Replacement
Wheel Cylinder................................................... 5-47 (Suburban Center Seat)................................10A2-14
Brake Backing Plate Replacement (8V2- Center Seat Bottom Latch Replacement
91/2-lnch Ring Gear-Semi-Floating Axles) .. . .4B-13 (Suburban Center Seat)................................10A2-12
Bumpers (C/K M odels)..........................................2B-1 Center Seat Bottom Replacement
Bumpers (G Models)............................................2B-14 (Suburban Center S eat..................................10A2-9
Bumpers (P M odels)............................................2B-12 Center Seat Bottom Striker Replacement
Bumper Wedge Replacement (Suburban Center Seat)................................10A2-10
(C/K Model Rear Doors)................................10A1-27 Center Seat Bottom Support Bracket Replacement
(G Model Intermediate Doors)......................10A1-47 Center Seatback Bumper And Striker Replacement
(G Model Rear D oors)..................................10A1-71 Center Seatback Latch Replacement
(Suburban Center Seat)................................10A2-12
Center Seatback Replacement
c (Suburban Center Seat)..................................10A2-9
Certification Label................................................. OA-2
Charging System Diagnosis................................6D-11
CDR Valve C heck............................................... 6E9-4 Charging System Electrical Tests........................6D-11
CDR Valve Replacement....................................6E9-5 Chart A-1, Dwell Fixed Under 1 0 ....................6E8-30
Cab Harness R outings........................................8A-10 Chart A-2, Dwell Fixed Between
Cable Replacement-Parking Brake........................5-23 10 And 5 0................................................... 6E8-32
Caliper Rebuilding..................................................5-42 Chart A-3, Dwell Fixed Over 5 0 ......................6E8-34
Camshaft Lobe Lift, Measuring Chart A-5, SERVICE ENGINE SOON
(4.3L Engines)................................................. 6A3-17 Light Inoperative........................................... 6E8-36
(4.8L Engines)..................................................6A4-16 Chart A-6, Wont Flash Code 12........................6E8-38
(Small Block Engines)....................................6A5-16 Check Assembly Replacement
(7.4L Engines)..................................................6A6-15 (G Model Rear D oors)..................................10A1-77
Check Strap Replacement (Small Block Engines)....................................6A5-22
(C/K Model Rear Doors................................10A1-31 (7.4L Engines)..................................................6A6-21
Check Strap Replacement (6.2L Engines)............................................... 6A7-27
(G Model Rear D oors)..................................10A1-76 Cross Lever, Clutch............................................. 7C-10
Choke And Hoses (M4ME, Cruise Control Clutch Release
M4MED, And M4MEF)....................................6C1-28 Switch Adjustment............................................. 9B-9
Choke Check (E4ME And E4MED)..................6C1-45 Cruise Control Clutch Release
Choke Coil Lever Adjustment Switch Installation..............................................9B-9
(M3ME, M4MED, And M4MEF)......................6C1-34 Cruise Control Diagnosis......................................9B-3
Choke Rod And Fast Idle Cam Adjustment Cruise ControlElectrical Switches......................9B-3
(M4ME, M4MED, And M4MEF)......................6C1-36 Cruise Control Mode Control
Circuit Diagnosis....................................................8A-4 Switch Test......................................................... 9B-6
Circuit Maintenance And R e p a ir..........................8A-6 Cruise Control On-Vehicle Service........................9B-4
Circuit Malfunctions................................................8A-4 Cruise Control Resistance C h e ck........................9B-5
Clearing Trouble Codes..........................................6E-7 Cruise Control Schematic..................................... 9B-6
Clutch....................................................................10,-2 Cruise ControlServo Mounting
Clutch Assembly And Pilot Bearing....................7C-13 (C-K D iesel)......................................................9B-12
Clutch Bleeding, Hydraulic..................................7C-12 Cruise Control Servo Mounting
Clutch Diagnosis....................................................7C-3 (G Van Diesel)....................................................9B-11
Clutch Inspection..................................................7C-2 Cruise ControlServo Mounting (V6) . ............... 9B-11
Clutch Linkage......................................................7C-9 Cruise ControlServo Mounting (V8 Gas)..........9B-10
Clutch Pedal Free Travel Cruise Control Servo Resistance..........................9B-7
Adjustment........................................................7C-12
Cruise Control Vacuum Hose Routing
Clutch Pedal, Hydraulic........................................7C-5
CK Truck (V6) ....................................................9B-13
Clutch Pedal, Mechanical......................................7C-5
Cruise ControlVacuum Hose Routing
Clutch Specifications............................................7C-17
CK Truck (V8 Gas)............................................9B-12
Coil Spring............................................................3C-18
Cruise Control Vacuum House Routing
Combination Valve..................................................5-12
G Van (V6) ........................................................9B-14
Compression Check
Cruise ControlVacuum Hose Routing
(Gasoline Engine)..............................................6A-6
(6.2L Diesel Engine)........................................6A-20 G Van (V8 G a s )................................................9B-13
Computer Command C ontrol................................6E-7 Cruise ControlVacuum Release
Connecting Rod And Piston Replacement Switches..............................................................9B-3
(4.3L Engines)................................................6A3-20 Cruise ControlVacuum Release Valve
(4.8L Engines)..................................................6A4-17 Installation..........................................................9B-9
(Small Block Engines)....................................6A5-19 Cruise Control Vacuum Servo Tests......................9B-7
(7.4L Engines)..................................................6A6-17 Cruise Control Voltage Checks..............................9B-5
(6.2L Engines)..................................................6A7-21 Cylinder Head Replacement
Connecting Rod Replacement (4.3L Engines)..................................................6A3-12
K And P30(00) Models....................................3B1-11 (4.8L Engines)..................................................6A4-10
Connecting Rod Replacement (Small Block Engines)....................................6A5-11
P30(32) Motorhome........................................3B1-12 (7.4L Engines)..................................................6A6-8
Conversion Table..................................................OA-12 (6.2L Engines)..................................................6A7-9
Coolant Level Indicator Diagnosis........................6B-3
Coolant Recovery Tank..........................................6B-6
Coolant Temperature Gage....................................8C-2 D
Cooling System Diagnosis....................................6B-3
Cooling System Problems......................................6B-3 Dead Weight Trailer Hitch Replacement
Cowl Vent Grille Replacement (G Model)......................................................... 2B-16
(C/K M odel)........................................................2C-5 Dead Weight Trailer Hitch Replacement
Cowl Vent Grille Replacement (Utility Vehicle And Suburban)..........................2B-8
(G Model)......................................................... 2C-16 Deaeration Tank..................................................... 6B-6
Crankcase Ventilation System (Diesel)..............6E9-4 Deceleration Control..............................................6E-8
Cranking C irc u it..................................................6D-23 Decimal And Metric Equivalents..........................OA-13
Cranking Speed Check (6.2L Engine)................6A-20 Diagnosis Of:
Cranking System Diagnosis................................6D-23 Air Conditioning Electrical System..................8A-52
Crankshaft Gear Replacement A/C Electrical/Vacuum..................................... 1A-16
(4.8L Engines)............................................... 6A4-21 A/C Vacuum System ........................................1B-21
Crankshaft Replacement Automatic Transmission Fluid Leaks................7A-15
(4.3L Engines)............................................... 6A3-23 Auxiliary HeaterC-K Series............................1A-12
(4.8L Engines).................... ........................6A4-22 Auxiliary Heater G........................................1A-21
Back Up Lamp System....................................8B-22 Diagnostic RF S niffer......................................... 9A-20
Battery............................................................... 6D-4 Diagnostic T oo ls................................................... 8A-5
Brake System....................................................... 5-4 Diesel Engine Fuel Filters..................................... 6C-4
Charging System..............................................6D-11 Diesel Fuel Filter Assembly
Clutch................................................................. 7C-3 Component Replacement..................................6C-5
Cranking System..............................................6D-23 Diesel Fuel Filter Replacement............................6C-5
Diesel Engine......................................................6A-9 Diesel Fuel System Contamination......................6C-10
Driveline Vibration (Road Test)..........................4A-4 Diesel Idle Speed Adjustment............................6C2-3
Front Axle........................................ ................4C-2 Dipstick Tube Replacement
Front End Alignment..........................................3A-2 (6.2L Engines)................................................. 6A7-18
Front Parking Lamps..........................................8B-9 Disc BrakesReplacement....................................5-37
Front Side Marker Lam ps................................8B-11 Distributor Replacement......................................6D-48
Front Suspension..............................................3C-2 Door Adjustment (C/K Model
Fuel G a g e ..........................................................8C-4 Rear Doors)................................................. 10A1-25
Gasoline Engine M echanical............................6A-3 Door Adjustment (C/K Model
Glow Plug Electrical System............................6D-18 Side Front Door)............................................. 10A1-4
Headlamp........................................................... 8B-6 Door Adjustment (C/K Model Side
Heater System....................................................1A-5 Rear Doors)................................................... 10A1-16
Hydraulic Lifters..................................................6A-7 Door Adjustment (G Model
Hydro-Boost......................................................... 5-7 Intermediate Doors)......................................10A1-46
Ignition System ................................................6D-38 Door Adjustment (G Model Rear Doors)..........10A1-69
Insufficient Heat..................................................1A-3 Door Adjustment (G Model Side
Manual Steering System..................................3B2-2 Front Door)................................................... 10A1-34
Oil Pressure Gage..............................................8C-5 Door Adjustment (G Model Sliding
1 MEF Carburetor..............................................6C1-7 Side Door)..................................................... 10A1-59
Power Door Lock System..................................8A-15 Door Air Valve Replacement
Power Steering System....................................3B3-5 (C/K Model Side Front Door)........................10A1-15
Power Window System ....................................8A-27 Door Air Valve Replacement
Propeller Shaft And Universal Jo in t..................4A-5 (C/K Model Side Rear Doors........................10A1-23
Rear Axle........................................................... 4B-3 Door And Hinge Replacement
Rear Side Marker Lamps..................................8B-18 (C/K Model Rear Doors)................................10A1-25
Refrigerant System............................................1B-9 Door And Hinge Replacement
Running, Park And License Lamps..................8B-19 (C/K Model Side Front Door)..........................10A1-4
Speedometer System ........................................8C-3 Door And Hinge Replacement
Steering Linkage..............................................3B1-2 (C/K Model Side Rear D oors)......................10A1-15
Stoplamp System..............................................8B-21 Door And Hinge Replacement
Tapered Roller Bearings....................................4B-6 (G Model Intermediate Doors)......................10A1-45
Temperature Gage..............................................8C-6 Door And Hinge Replacement
THM 350-C....................................................... 7A-19 (G Model Rear Doors)..................................10A1-69
THM 400 ..........................................................7A-35 Door And Hinge Replacement
THM 700-R4......................................................7A-53 (G Model Side Front D o o r)..........................10A1-34
Torque Converter..............................................7A-15 Door Inside Handle Replacement
Transmission, M anual........................................7B-3 (C/K Model Side Front Door)........................10A1-12
Turn Signal And Hazard Systems....................8B-20 Door Inside Handle Replacement
Washer SystemP-Model................................8A-48 (C/K Model Side Rear Doors)......................10A1-23
Wheel Bearings..................................................3C-3 Door Lock Control Assembly Replacement
Wheels And T ire s ..............................................3E-4 (G Model Side Front D o o r)..........................10A1-43
Windshield Washer CK And Door Lock Cylinder Replacement....................10A1-12
G M odels......................................................8A-38 (C/K Model Side Front Door)
Windshield Wiper CK And Door Lock Cylinder Replacement
G M odels................................................... .8A-32 (G Model Intermediate Doors)......................10A1-51
Windshield Wiper And Washer Door Lock Cylinder Replacement
P Models........................................................8A-45 (G Model Rear Doors....................................10A1-76
Windshield Wiper Off Vehicle Door Lock Cylinder Replacement
P Models................................................. 8A-47 (G Model Side Front D o o r)..........................10A1-43
Windshield Wiper On Vehicle Door Lock Replacement
P Models................................................. 8A-46 (C-K Model Side Front Door)........................10A1-11
Wiper Delay C ircuit..........................................8A-43 Door Lock Replacement
Vacuum Pum p....................................................6H-1 (C/K Model Side Rear Doors)......................10A1-21
Diagnostic Circuit C h e c k ..............................*. .6E8-26 Door Lock Replacement
Diagnostic M ode....................................................6E-6 (G Model Side Front D o o r)..........................10A1-42
Door Outside Handle Replacement E
(C/K Model Rear Doors)................................10A1-30
Door Outside Handle Replacement Early Fuel Evaporation..........................................6E-8
(C/K Model Side Front Door)........................10A1-12 ECM Learning Ability..............................................6E-7
Door Outside Handle Replacement EGR System Check (Diesel)................................6E9-6
(C/K Model Side Rear Doors)......................10A1-22 EGR Valve Replacement (Diesel)........................6E9-6
Door Outside Handle Replacement Electrical Systems............................................... 8A-10
(G Model Intermediate Doors)......................10A1-51 Electric Choke (1MEF)........................................6C1-13
Door Outside Handle Replacement Electric Choke Heater........................................... 6D-2
(G Model Rear D oors)..................................10A1-76 Electronic Controller (Module)
Door Outside Handle Replacement Cruise Control................................................... 9B-2
(G Model Side Front Door............................10A1-43 Electronic Spark Control........................................6E-8
Door Replacement (G Model Electronic Spark Control (HEI/ESC) System . . . .6D-38
Sliding Side D oor)........................................10A1-57 Electronic Spark Tim ing........................................6E-8
Door Trim Panel Replacement Electronic Spark Timing (HEI/EST) System........6D-30
(C/K Model Rear Doors)................................10A1-27 Emergency Starting............................................... OA-2
Door Trim Panel Replacement Emissions............................................................... 6E-1
(C/K Model Side Front Door)..........................10A1-4 Engine Emission Components............................6E8-4
Door Trim Panel Replacement Engine Identification..............................................OA-2
(C/K Model Side Rear Doors........................10A1-17 Engine Lubrication
Door Trim Panel Replacement (4.3L Engines)................................................. 6A3-2
(G Model Intermediate Doors)......................10A1-47 (4.8L Engines)................................................. 6A4-2
Door Trim Panel Replacement (Small Block Engines)..................................... 6A5-2
(G Model Rear D oors)..................................10A1-71 (7.4L Engines)..................................................6A6-2
Door Trim Panel Replacement (6.2L Engines)................................................. 6A7-2
(G Model Sliding Side Door)........................10A1-62 Engine Mountings
Door Trim Panel Replacement (4.3L Engines)............................................... 6A3-25
(4.8L Engines)............................................... 6A4-24
(G Model Side Front D o o r)..........................10A1-36
(Small Block Engines)....................................6A5-24
(7.4L Engines)............................................... 6A6-23
Replacement (C/K Model Side Front Door) . .10A1-6
(6.2L Engines)............................................... 6A7-28
Engine Or Exhaust Noises....................................4C-2
Replacement (G Model Side Front Door). . .10A1-36
Engine Replacement
Door Weatherstrip Replacement
(4.3L Engines)................................................6A3-28
(C/K Model Side Front Door)........................10A1-13
(4.8L Engines)................................................6A4-29
Door Weatherstrip Replacement
(C/K Model Side Rear Doors)......................10A1-23 (7.4L Engines)................................................6A6-25
Door Weatherstrip Replacement Engine Wire Harness..........................................6D-54
(G Model Side Front D o o r)..........................10A1-44 EPR/EGR Solenoid Replacement......................6E9-8
Door Window Replacement End Gate Cover Replacement
(C/K Model Side Front Door)..........................10A1-7 (Utility Vehicle M odels)..................................10A5-6
Door Window Replacement End Gate Outside Crank Replacement
(C/K Model Side Rear D oors)......................10A1-18 (Suburban Model)......................................... 10A5-19
Door Window Replacement End Gate Outside Crank Replacement
(G Model Side Front D o o r)..........................10A1-37 (Utility Vehicle M odel)................................. 10A5-12
Draining The Diesel Fuel Filter..............................6C-4 End Gate Replacement
Draining The Fuel Tank..........................................6C-9 (Fender Side Models)......................................10A5-2
Driveability............................................................. 6E-1 End Gate Replacement (Fleet Side Models) .. .10A5-2
Driveability Symptoms........................................6E8-68 End Gate Replacement (Suburban Models). . .10A5-14
Drive B e lts ........................................................... 6B-11 End Gate Replacement (Utility
Drive Belt Tension Specifications........................6B-44 Vehicle M odels)........................................... 10A5-14
Driveline Capacity Charts......................................OB-1 End Gate Trim And Cover Panel Replacement
Drive Pinion Oil Seal Replacement (12-Inch (Suburban Models)........................................10A5-16
Ring Gear Full-Floating A xle)..........................4B-22 Engine Cover Replacement (G Model)............10A4-26
Drum BrakesReplacement..................................5-45 Engine C ooling..................................................... 6B-1
Dual Capacity Pump Check (E4MED O nly)... .6C1-46 Evaporative Emission Control............................... 6E-8
Dual Capacity Pump Check (M4MED Only) .. .6C1-29 Exhaust Gas Recirculation................................... 6E-8
Detent Switch (THM 400)....................................7A-85 Exhaust Gas Recirculation System
(Diesel)............................................................. 6E9-6
Exhaust Manifold Replacement
(4.3L Engines)................................................. 6A3-11
(Small Block Engines)....................................6A5-11 Front Lock Replacement
(7.4L Engines)................................................. 6A6-8 (G Model Sliding Side Door)........................10A1-65
(6.2L Engines)................................................. 6A7-3 Front Parking Lamps Diagnosis............................8B-9
Front Parking Lamps On Vehicle
Service............................................................... 8B-9
F Front Parking Lamps System................................8B-7
Front Pivot Bracket Disassembly
Fan And Fan Clutch..............................................6B-19 (C/K Model Front Seat)..................................10A2-5
Fan Clutch Diagnosis............................................. 6B3 Front Seat (C/K Model)..................................... 10A2-3
Fan Shroud........................................................... 6B-14 Front Seat (G Model)....................................... 10A2-24
Fastener Strength Identification............................OA-9 Front Seat And Adjuster Replacement
Float Adjustment (M4ME, M4MEO, (C/K Model Front Seat)..................................10A2-3
And M4MEF)................................................. 6C1-33 Front Seat Belt Replacement (G M odel)........10A2-26
Float Level Check (E4ME And E4MED)............6C1-45 Front Seat Disassembly (G Model)..................10A2-26
Float Level Check (M4ME, M4MED, Front Seat Replacement (G Model)................10A2-24
And M4MEF)................................................. 6C1-28 Front Side Marker Lamps Diagnosis..................8B-11
Fluid And Filter, Automatic Front Side Marker Lamps On Vehicle
Transmission................................................... 7A-83 Service............................................................. 8B-11
Fluid Checking, Automatic Transmission............7A-82 Front Side Marker Lamp System .................. .8B-10
Fluid Leak Causes, Automatic Front Trim Replacement (C/K Model)................10A4-1
Transmission..................................................... 7A-13 Fuel Control System............................................. 6E-7
Fluid Leak Diagnosis, Automatic Fuel Filters (Gasoline Engines)............................6C-2
Transmission..................................................... 7A-15 Fuel G age........................................... ................. 8C-2
Fluid Leak Precautions, Automatic Fuel Gage Diagnosis........................................... 8C-4
Transmission..................................................... 7A-13 Fuel Gage Replacement..................................... 8C-10
Flushing The Cooling System................................6B-6 Fuel Gage Sending U n it..................................... 6C-15
Flywheel Replacement Fuel Gage Sending Unit .,,-
(4.3L Engines)............................................... 6A3-25 Replacement ................................................... 6C-15
(4.8L Engines)............................................... 6A4-23 Fuel L in e s ........................................................... 6C-12
(Small Block Engines)....................................6A5-24 Fuel Pump............................................................. 6C-6
(7.4L Engines)............................................... 6A6-22 Fuel Pump Replacement..................................... 6C-7
(6.2L Engines)............................................... 6A7-28 Fuel Pump Tests (Diesel Engine)..........................6C-6
Frames (C/K And P Models)..................................2A-1 Fuel Pump Tests (Gasoline Engine)......................6C-6
Frame, Checking Alignment..................................2A-4 Fuel Sender Unit Replacement............................8C-13
Frame, Diagnosis Of, (C/K And P )........................2A-2 Fuel System Cleaning (Diesel Engine)................6C-10
Frame, Minimizing Service....................................2A-3 Fuel System Cleaning (Gasoline Engine)............6C-9
Frame, Repairing C racks..................................... 2A-5 Fuel Tank............................................................... 6C-9
Frame, Straightening............................................. 2A-5 Fuel Tank Filler Neck........................................... 6C-12
Front A x le ........................................................... 3C-37 Fuel Tank Leak Test............................................. 6C-11
Front Axle Assembly Replacement......................4C-4 Fuel Tank Purging............................................... 6C-11
Front Bumper Replacement (C/K Models)............2B-1 Fuel Tank Replacement....................................... 6C-12
Front Bumper Replacement (G Model)................2B-14 Fuel Tank Selector Valve..................................... 6C-15
Front Bumper Replacement (P Model)................2B-12 Fuel Tank Selector Valve Diagnosis....................6C-15
Front Bumper Replacement Fuel Tank Selector Valve Replacement..............6C-17
(P Models With RPO FS3 Front Axle)..............2B-12 Fuse Block C K ............................................... 8A-10
Front Cover Replacement Fuse Block G Van........................................... 8A-18
(4.3L Engines)................................................. 6A3-13 Fuses, Circuit Breakers Specifications................8B-30
(7.4L Engines)................................................. 6A6-10
(6.2L Engines)................................................. 6A7-14 G
Front End Alignment Adjustments........................3A-4
Front End Panel Replacement (G M odel)..........2C-20 Gaskets, Replacing (Engine)................................. 6A-3
Front End Sheet Metal Cross Generator Noise................................................... 6D-11
Panel Replacement (G M odel)........................2C-18 Generator Replacement..................................... 6D-14
Front Fender Replacement (C/K M odel)..............2C-7 Glass Polishing................................................. 10A3-13
Front Floor Compartment Replacement Glow Plug Afterstart............................................. 6D-18
(Utility Vehicle Models)..................................10A4-11 Glow Plug Circuit Check..................................... 6D-18
Front Glass Run Channel Replacement Glow Plug Electrical System Diagnosis..............6D-18
(C/K Model Side Rear Doors)......................10A1-20 Glow Plug Inhibit Switch..................................... 6D-18
Front Housing Marking (Diesel)..........................6C2-9 Glow Plug System............................................... 6D-18
Governor, Automatic Transmission......................7A-88 Hinge Assembly Replacement
Graphic Symbols....................................................OA-6 (G Model Sliding Side Door)........................10A1-57
Grille And Molding Replacement Hinge Replacement (Suburban Models)..........10A5-16
(C/K M odel)........................................................2C-5 Hinge Replacement (Utility Vehicle Models) . . .10A5-6
Grille Replacement (G M odel)............................2C-18 Hood Hinge Replacement (C/K Model)................2C-2
Hood Hinge Replacement (G Model)..................2C-14
Hood Ornament Replacement (C/K Model)..........2C-4
H Hood Release Cable Replacement (C/K Model). .2C-4
Hood Release Cable Replacement (G Model).. .2C-16
Hood Replacement (C/K Model)............................2C-2
Hands And Control Assembly
Hood Replacement (G M odel)............................2C-14
Replacement (Suburban Models)................10A5-16
Hood Spring Assembly Replacement
Handle And Control Assembly
(C/K M odel)....................................................... 2C-2
Replacement (Utility Vehicle
Housing Pressure Cold Advance........................6C2-5
Models)........................................................... 10A5-6
Hub And Drum Assembly Replacement
Hands And Latch Replacement
(9 3/4-10 1/2-lnch
(Fleet Side Models)........................................10A5-3
Headlamp Diagnosis..............................................8B-6 Ring GearFull Floating A xles)......................4B-17
Hydraulic Brake BoosterDiagnosis ..................... 5-7
Headlamp On-Vehicle Service..............................8B-7
Hydraulic Brake BoosterReplacement..............5-33
Headlamp System..................................................8B-1
Hydraulic Brake BoosterSystem Tests...............5-2
Headliner And Trim Replacement
Hydraulic Lifter Replacement
(Bonus Cab M odels)......................................10A4-6
(4.3L Engines)..................................................6A3-9
(4.8L Engines)..................................................6A4-7
(Pick Up Models)............................................10A4-3
(Small Block Engines)......................................6A5-8
(7.4L Engines)....................................................6A6-7
(Suburban Models)........................................10A4-14
(6.2L Engines)....................................................6A7-7
(Utility Vehicle Models)..................................10A4-9
Headliner Replacement
(G Model)......................................................10A4-20 I
Heating ComponentsC-K....................................1A-6
Blower Motor Replacement....................................1A-6 Idle Mixture Adjustment (M4ME,
Heater Hoses..........................................................1A-6 M4MED, M4MEF With Light-Duty
Distributor Assembly..............................................1A-7 Emissions).......................................... ........6C1-31
Core Assembly....................................................... 1A-7 Idle Mixture Adjustment
Control Assembly Replacement............................1A-9 (M4ME, M4MED, M4MEF With Heavy-Duty
Cable Replacement................................................1A-9 Emissions)......................................................6C1-33
Cable Adjustment..................................................1A-9 Idle Solenoid (1 MEF)..........................................6C1-13
Blower Switch Replacement................................1A-11 Idle Speed Adjustment (M4ME,
Resistor Replacement..........................................1A-12 M4MED, And M4MEF)....................................6C1-33
Vent Replacement................................................1A-12 Idle Stop Solenoid Check
Auxiliary Heater....................................................1A-12 (E4ME And E4MED)......................................6C1-46
Heating Components-G Series............................1A-15 Idle Stop Solenoid Check (M4ME,
Blower Motor Replacement..................................1A-15 M4MED, And M4MEF)....................................6C1-30
Blower Switch Replacement................................1A-20 Idler Arm Adjustment P30 (32)
Cable Adjustment................................................1A-20 Motorhome....................................................... 3B1-3
Control Assembly Replacement..........................1A-16 Idler Arm Inspection........................................... 3B1-2
Control Cables......................................................1A-19 Idler Arm Replacement....................................... 3B1-3
Core Assembly..................................................... 1A-16 Ignition Switch............................................... .. .8C-2
Defroster D u ct......................................................1A-16 Ignition Switch Replacement........................ .8C-17
Distributor Assembly............................................1A-16 Ignition System Diagnosis..................................6C-38
Distributor D u c t................................................... 1A-16 Ignition Timing..................................................... 6D-48
Heater Hoses....................................................... 1A-16 Injection Line Replacement................................6C2-5
Resistor Replacement..........................................1A-20 Injection Nozzle Replacement..........................6C2-10
Heater System Circuits........................................8A-52 Injection Nozzles............................................... 6C2-10
Height Sensing Brake Proportioning Injection Nozzle Tests....................................... 6C2-10
Valve................................................................... 5-13 Injection Pump Advance Pin Hole
High Back Bucket Seat Belt Plug Seal Replacement..................................6C2-17
Replacement (C/K Model Front Seat)............10A2-1 Injection Pump Advance Piston
High Energy Ignition (HEI) S ystem ....................6D-38 Seals Replacement........................................6C2-17
m

Injection Pump Cover And/Or Latch Replacement (Utility Vehicle
Guide Stud Seal Replacement......................6C2-12 Models)........................................................... 10A5-6
Injection Pump Drive Shaft Seal Leaf Spring (RPO FS3)....................................... 3C-39
Replacement..................................................6C2-19 Leaf Spring And Bushings ( 4 x 4 ) ......................3C-55
Injection Pump Hydraulic Head Seal Left Door Lower Latch Replacement
Replacement..................................................6C2-18 (C/K Model Rear Doors)................................10A1-30
Injection Pump Replacement..............................6C2-5 Left Door Lower Latch Replacement
Injection Pump Side Cover (G Model Rear Doors)................................. 10A1-73
Gasket Replacement......................................6C2-17 Left Door Weatherstrip Replacement
Injection Timing Adjustment................................6C2-9 (C/K Model Rear Doors)................................10A1-32
Inner Window Weatherstrip Replacement Left Door Weatherstrip Replacement
(C/K Model Side Front Door)..........................10A1-8 (G Model Rear Doors)..................................10A1-77
Inner Window Weatherstrip Replacement Lock Cylinder Replacement
(C/K Model Side Rear D oors)......................10A1-19 (G Model Sliding Side Door)........................10A1-67
Inner Window Weatherstrip Replacement Locking Hub Component Replacement................4C-5
(G Model Side Front D o o r)..........................10A1-39 Lower Ball Joint ( 2 x 4 ) ....................................... 3C-19
Intake And Exhaust Manifold Replacement Lower Control A r m ............................................. 3C-27
(4.8L Engines)..................................................6A4-8 Lower Control Arm Pivot Shaft
Intake Manifold Replacement And Bushings................................................... 3C-21
Lower Roller Assembly Replacement
(4.3L Engines)..................................................6A3-8
(Small Block Engines)......................................6A5-8
(G Model Sliding Side Door)........................10A1-57
Lubrication............................................................. OB-6
(7.4L Engines)..................................................6A6-6
(6.2L Engines)..................................................6A7-3
Interior Trim (C/K Model)....................................10A4-1
Interior Trim Replacement (G Model)..............10A4-23
M
Intermediate Doors (G Model)..........................10A1-45 Main Bearing Replacement
Intermediate Front Door Lock Control (4.3L Engines)............................................... 6A3-22
Replacement (G Model Intermediate (4.8L Engines)................................................. 6A4-19
Doors)........................................................... 10A1-50 (Small Block Engines)................................... 6A5-21
Intermediate Front Door Lock Replacement (7.4L Engines)............................................... 6A6-20
(G Model Intermediate Doors)......................10A1-49 (6.2L Engines)............................................... 6A7-25
Intermediate Front Door Weatherstrip Maintenance Schedule And Log............................OB-7
Replacement (G Model Intermediate Doors) 10A1-55 Manual Locking Hub Rebuild
Intermediate Rear Door Control Assembly Procedure........................................................... 4C-8
Replacement (G Model Intermediate Manual Locking Hub Replacement......................4C-8
Doors)........................................................... 10A1-54 Manual Seat Adjuster, Diagnosis Of..................10A2-2
Intermediate Rear Door Lower Latch Master CylinderReplacement............................5-30
Replacement (G Model Intermediate Master Cylinder And
Doors)........................................................... 10A1-53 Reservoir, Clutch............................................... 7C-6
Intermediate Rear Door Upper Latch Metric Fasteners................................................... OA-9
Replacement (G Model Intermediate Model Identification (E4ME And
Doors)........................................................... 10A1-53 E4MED)......................................................... 6C1-45
Intermediate Rear Door Weatherstrip Model Reference................................................... OA-2
Replacement (G Model Intermediate
Doors)........................................................... 10A1-51
o
Installing The Wheel And Tire
Assembly............................................................3E-9 Off/On/Resume/Accel Switch................................9B-1
Instrument Cluster Replacement........................8C-16 Oil Cooler Lines, Automatic
Transmission................................................... 7A-82
Oil Filter Adaptor And Oil Filter
L Bypass Valve Replacement
(4.3L Engines)............................................... 6A3-23
Laminated (Printed) Circuit Oil Filter Bypass Valve
Replacement....................................................8C-17 Replacement
(4.8L Engines)............................................... 6A4-21
Lamp Specifications............................................8B-32
Lamp Switch......................................................... 8C-2
(7.4L Engines)................................................. 6A6-19
Lamp Switch Replacement..................................8C-17
Oil Pan Replacement
Lamp Systems On-Vehicle Service....................8B-23
(4.3L Engines)................................................. 6A3-14
Latch Replacement (Suburban Models)..........10A5-16
(4.8L Engines)................................................. 6A4-13
(Small Block Engines)....................................6A5-14 Power Door Lock System-Component
(7.4L Engines)..................................................6A6-12 Replacement................................................... 8A-26
(6.2L Engines, C And K Models)....................6A7-19 Power Door Lock SystemDiagnosis................8A-25
Oil Pan And Oil Pump Replacement Power Window System........................................8A-26
(6.2L EnginesG Models)..............................6A7-20 Power Window SystemComponent
Oil Pressure Gage..................................................8C-2 Replacement....................................................8A-29
Oil Pressure Gage Diagnosis................................8C-5 Power Window System Diagnosis......................8A-27
Oil Pressure Gage Replacement ...................... 8C-14 Pressure Testing The
Oil Pressure Gage Sender Replacement............8C-15 Ignition Pump..................................................6C2-19
Oil Pressure Switch............................................... 6D-2 Prevailing Torque Fasteners..................................0A-9
Oil Pump Drive Replacement Primary Hood Latch Replacement
(6.2L Engines)................................................. 6A7-13 (C/K Model)....................................................... 2C-3
Oil Pump Replacement Primary Hood Latch Replacement
(4.3L Engines)..................................................6A3-15 (G Model)......................................................... 2C-15
(4.8L Engines)..................................................6A4-13 Primary Side Vacuum Break Adjustment
(Small Block Engines)....................................6A5-14 (M4ME, M4MED, And M4MEF)......................6C1-36
(7.4L Engines)..................................................6A6-13 Propeller Shaft....................................................... 4A-2
(6.2L EnginesC And K Models)..................6A7-20 Propeller Shaft Balance Check..............................4A-7
Propeller Shaft BrakeReplacement....................5-27
Outer Window Weatherstrip Replacement
Propeller Shaft Replacement
(C/K Model Side Front Door)..........................10A1-8
(Front Drive)........................................................4A-9
Outer Window Weatherstrip
Propeller Shaft Replacement
Replacement (C/K Model Side Rear Doors). 10A1-20
(Rear Drive)........................................................4A-8
Outer Window Weatherstrip Replacement
Propeller Shaft Runout C heck..............................4A-7
Pushrod Cover Replacement
Outside Rear View Mirror Replacement
(4.8L Engines)..................................................6A4-6
(C/K Model Side Front Door)........................10A1-13 Pump Adjustment
(M4ME, M4MED, And M4MEF)......................6C1-34
P
R
Parking Brake Adjustment......................................5-27
Parking Brake PedalReplacement......................5-22 RPO Listing..........................................................OA-15
Passenger Front Bucket Seat Replacement RTV Sealer And Anaerobic
(Utility Vehicle)................................................10A2-5 Gasket Eliminator (Use O f)................................6A-2
Pedal ReplacementBrakes..................................5-17 Radiator................................................................6B-28
Pedal Rod ReplacementBrakes..........................5-20 Radiator Mounting Torque
Pinion Flange, Dust Deflector/Oil Seal Specification....................................................6B-44
Replacement (81/2- 91/2-lnch Ring Gear- Radiator Support Replacement
Semi-Floating A xles)........................................4B-14 (C/K Model)....................................................... 2C-11
Pinion Oil Seal/Companion Flange Radio Diagnosis....................................................9A-6
Replacement (9 3/4-10 1/2-lnch Ring Radio Receiver ReplacementCK Models........9A-22
GearFull Floating A xles)..............................4B-20 Radio Receiver ReplacementG Van................9A-22
Pitman Arm Replacement....................................3B1-6 Rear Axle Assembly Replacement......................4B-10
Pitman Shaft Seal Replacement Rear Axle Operation..............................................4B-2
Rear Bumper License Plate
(Manual G ear)..................................................3B2-4
Bracket Replacement (C/K Models)..................2B-7
Pitman Shaft Seal Replacement
Rear Bumper Replacement (G Model)................2B-15
(Power Gear)....................................................3B3-16
Rear Bumper Replacement (Regular
Positive Crankcase Ventilation..............................6E-9
Cab, Bonus Cab, And Crew Cab)......................2B-6
Power Door Lock Motor Replacement
Rear Bumper Replacement (Utility
(C/K Model Side Front Door)..........................10A1-1
Vehicle And Suburban)......................................2B-4
Rear Crankshaft Oil Seal Replacement
(C/K Model Side Rear Door)........................10A1-21 (4.3L Engines)................................................. 6A3-15
Power Door Lock Motor Replacement (4.8L Engines)....................................................6A4-13
(G Model Intermediate Doors)......................10A1-54 (Small Block Engines)........................................6A5-15
Power Door Lock Motor Replacement (7.4L Engines)..................................................... 6A6-13
(G Model Rear D oors)..................................10A1-78 (6.2L Engines)................................................... 6A7-21
Power Door Lock System ....................................8A-18
Rear Crankshaft Oil Seal Retainer Replacement Remote Control Replacement
(4.3L Engines)..................................................6A3-16 (C/K Model Side Rear Doors)......................10A1-23
(Small Block Engines)....................................6A5-16 Right Door Control Assembly
Rear Doors (C/K M odel)..................................10A1-25 Replacement (C/K Model Rear Doors)........10A1-30
Rear Doors (G Model)......................................10A1-69 Right Door Control Assembly
Rear Duct Replacement......................................1B-45 Replacement (G Model Rear Doors)............10A1-75
Rear Extension Oil Seal, Automatic Right Door Lower Latch
Transmission....................................................7A-94 Replacement (C/K Model Rear Doors)........10A1-29
Rear Extension Oil Seal, Right Door Lower Latch
3 Speed Transmission......................................7B1-1 Replacement (G Model Rear Doors)............10A1-74
Rear Extension Seal, 89 mm Right Door Upper Latch Replacement
4 Speed Transmission......................................7B2-1 (C/K Model Rear Doors)................................10A1-29
Rear Fender Replacement Right Door Upper Latch
(C/K M odel)........................................................2C-9 Replacement (G Model Rear Doors)............10A1-75
Rear Glass Run Channel Replacement Right Door Weatherstrip
(C/K Model Side Front Door)..........................10A1-9 Replacement (C/K Models Rear Doors) . . . .10A1-31
Rear Glass Run Channel Replacement Right Door Weatherstrip
(G Model Side Front D o o r)..........................10A1-40 Replacement (G Model Rear Doors)............10A1-78
Rear Interior Roof Mounted System Road Test............................................................... 4C-2
G Series........................................................... 1B-62 Rocker Arm And Pushrod Replacement
Rear Lamp Harness Layouts..............................8B-13 (4.3L Engines)................................................. 6A3-6
Rear Leaf Spring....................................................3-10 (4.8L Engines)................................................. 6A4-4
Rear Leaf Spring Bushing....................................3D-10 (Small Block Engines)..................................... 6A5-4
Rear License Plate Bracket (7.4L Engines)................................................. 6A6-4
Replacement (G Model)....................................2B-16 Rocker Arm Cover Replacement
Rear Lock Replacement (4.3L Engines)................................................. 6A3-5
(G Model Sliding Side Door)........................10A1-65 (4.8L Engines)................................................. 6A4-4
Rear Marker Lamps..............................................8B-12 (Small Block Engines)..................................... 6A5-5
Rear Park Lamps..................................................8B-12 (7.4L Engines)................................................. 6A6-4
Rear Retainer Oil Seal, 117 mm (6.2L Engines)................................................. 6A7-5
4 Speed Transmission......................................7B3-1 Rocker Arm, Shaft, And Pushrod Replacement
Rear Running L a m p s..........................................8B-12 (6.2L Engines)................................................. 6A7-6
Rear Seats (C/K Model)....................................10A2-14 Rocker Arm Stud Replacement
Rear Seat Belt Replacement (4.3L Engines)................................................. 6A3-10
(Crew C a b)................................................... 10A2-14 (4.8L Engines)................................................. 6A4-9
Rear Seat Belt Replacement (Suburban)........10A2-19 (Small Block Engines)....................................6A5-10
Rear Seat Cover Rod Replacement (7.4L Engines)................................................. 6A6-8
(Utility Vehicle)..............................................10A2-15 Roof Rear Header Trim Panel Replacement
Rear Seat Replacement (Crew Cab)..................10A-14 (Suburban Models)........................................10A4-15
Rear Seat Replacement (Suburban)................10A2-19 Rotor-Disc B rake................................................... 5-41
Rear Seat Replacement Run Channel Replacement
(Utility Vehicle)..............................................10A2-15 (Suburban Model)......................................... 10A5-19
Rear Seat Storage Strut Run Channel Replacement
Replacement (Utility Vehicle)........................10A2-15 (Utility Vehicle M odel)..................................10A5-12
Rear Seatback And Catch Running, Park And License Lamps
Replacement (Crew Cab)..............................10A2-14
Diagnosis......................................................... 8B-19
Rear Side Marker Lamps Diagnosis....................8B-18
Rear Shock Absorbers..........................................3D-8
Rear Stabilizer B a r ................................................. 3-8
Rear Step Bumper Replacement s
(C/K M odel)....................................................... 2B-7
Rear Suspension................................................... 3D-1 Sash Assembly Replacement
Rear Suspension Specifications..........................3D-12 (Suburban Model)......................................... 10A5-18
Rear Turn, Stop, And Sash Assembly Replacement
Hazard Systems............................................... 8B-12 (Utility Vehicle Models)..................................10A5-11
Regulator Replacement Seat Adjuster Adjustment..................................10A2-3
(Surburban Model)........................................10A5-16 Seat Belt Replacement
Regulator Replacement (C/K Model Front Seat)..................................10A2-6
(Utility Vehicle M odels)..................................10A5-7 Seat Belt Replacement
Relay Rod Replacement......................................3B1-5 (Utility Vehicle Rear Seat)............................10A2-17
Seat Latch And Support Assembly Spark Plug W ire s............................................... 6D-49
Replacement (Utility Vehicle And Speaker ReplacementCK Models....................9A-25
Suburban)..................................................... 10A2-17 Speaker Replacement-G Van..............................9A-26
Seatback And Hinge Replacement Specifications, Automatic Transmission..............7A-97
(Utility Vehicle And Suburban Specifications, C lutch..........................................7C-17
Seatback)..................................................... 10A2-17 Specifications, 89 mm 4 Speed
Secondary Cylinder And Hydraulic Transmission..................................................... 7B2-7
Line, C lutch....................................................... 7C-8 Specifications, 3 Speed Transmission................7B1-7
Secondary Hood Latch And Spring Specifications, 117 mm 4 Speed
Replacement (C/K Model)................................. 2C-4 Transmission................................................... 7B3-5
Secondary Hood Latch And SpecificationsFuses, Circuit
Spring Replacement (G Model)........................2C-16 Breakers........................................................... 8B-30
Secondary Lockout Adjustment SpecificationsLamps....................................... 8B-32
(M4ME, M4MED, And M4MEF)......................6C1-38 Special Tools....................................................... 8C-17
Secondary Side Vacuum Break Speedometer......................................................... 8C-2
Adjustment (M4ME, M4MED ANd M4MEF). .6C1-36 Speedometer Cable Core
Secondary Weatherstrip Replacement Replacement..................................................... 8C-9
(C/K Model Rear Doors)................................10A1-33 Speedometer Driven Gear,
Service Parts Identification Label..........................OA-2 3 Speed Transmission......................................7B1-2
Separating The Tire From Speedometer Driven Gear, 89 mm
The W heel......................................................... 3E-7 4 Speed Transmission..................................... 7B2-2
Service Engine Soon Light....................................6E-5 Speedometer Drive Gear, 117 mm
Servo (THM 700-R4)............................................7A-91 4 Speed Transmission......................................7B3-2
Servo UnitCruise Control....................................9B-2 Speedometer Driven GearVehicle Speed
Set/Coast Button Switch........................................9B-1 Sensor, Automatic Transmission......................7A-87
Sheet Metal Adjustments Speedometer Replacement..................................8C-7
(C/K M odel)..................................................... 2C-14 Speed SensorVSS Buffer Am plifier..................9B-3
Sheet Metal Unit Replacement Speedometer System Diagnosis..........................8C-3
(C/K M odel)..................................................... 2C-12 Spindle................................................................. 3C-48
Sheet Metal Vertical Support Stabilizer Bar ( 2 x 4 ) ............................................. 3C-8
Replacement (G Model)....................................2C-19 Stabilizer Bar (RPO FS3)....................................3C-33
Shift Control, 89 mm 4 Speed Stabilizer Bar ( 4 x 4 ) ........................................... 3C-41
Transmission................................................... 7B2-3 Starter Motor Noise............................................. 6D-23
Shift Control Lever, 117 mm 4 Speed Starter Motor Replacement................................6D-30
Transmission................................................... 7B3-3 Stationary Glass/Window Run
Shift Linkage, 3 Speed Channel Assembly Replacement
Transmission..................................................... 7B1-2 (C/K Model Side Rear D oors)......................10A1-18
Shift Linkage Adjustment, 3 Speed Stationary Glass Replacement
Transmission..................................................... 7B1-5 (C/K Models)................................................... 10A3-5
Shift Linkage, Automatic Stationary Glass Replacement
Transmission................................................... 7A-83 (G M odel)..................................................... 10A3-11
Shift Rods, 89 mm 4 Speed Steering Arm, Knuckle And Spindle
Transmission................................................... 7B2-2 (RPO FS3)....................................................... 3C-37
Shift Rod Adjustment, 89 mm Steering Gear Adjustments
4 Speed Transmission......................................7B2-3 (Manual G ear)................................................. 3B2-5
Shock Absorber ( 2 x 4 ) ......................................... 3C-8 Steering Gear Adjustments
Shock Absorber (RPO FS3)................................3C-31 (Power Gear)................................................... 3B3-16
Shock Absorber ( 4 x 4 ) ....................................... 3C-40 Steering Gear High Point
Shutdown And/Or Cold Advance Centering (Manual Gear)................................. 3B2-6
Solenoid Replacement....................................6C2-16 Steering Gear High Point
Side Cover, 3 Speed Transmission......................7B1-5 Centering (Power Gear)..................................3B3-13
Side Cover, 89 mm 4 Speed Transmission........7B2-3 Steering Gear Replacement
Side Front Door (C/K Model)..............................10A1-4 (Manual G ear)................................................. 3B2-3
Side Front Door (G M odel)..............................10A1-34 Steering Gear Replacement
Side Rear Doors (C/K M odel)..........................10A1-15 (Power Gear)................................................... 3B3-14
Six Lobed Socket Head Fasteners........................OA-9 Steering Hoses................................................. 3B3-23
Sliding Side Door (G Model)............................10A1-57 Steering Knuckle ( 2 x 4 ) ..................................... 3C-16
Sliding Side Door Weatherstrip Steering Knuckle And Arm ( 4 x 4 ) ......................3C-50
Replacement (G Model Sliding Steering Pump Belt Tension
Side Door)..................................................... 10A1-67 Adjustment..................................................... 3B3-12
Spare Tire C arriers............................................. 3E-10 Steering Pump Replacement............................3B3-18
Steering Shock Absorber Inspection..................3B1-7 Top Strap Belt Anchor Installation
Steering Shock Absorber Replacement..............3B1-8 (C/K M odel)................................................. 10A2-20
Steering System Bleeding................................. 3B3-13 Top Strap Belt Anchor Installation
Steering System (Power) (G Model)..................................................... 10A2-31
Diagnosis......................................................... 3B3-5 Top Strap Belt Anchor Installation
Steering System T e s t..........................................3B3-8 (Pickup And Crew Cab Models)..................10A2-20
Stoplamp SwitchReplacement............................5-20 Top Strap Belt Anchor Installation
Stoplamp System Diagnosis................................8B-21 (Suburban Front Seat)................................. 10A2-22
Striker Replacement Top Strap Belt Anchor Installation
(C/K Model Rear Doors)................................10A1-26 (Suburban Second Seat)............................. 10A2-22
Striker Replacemen Top Strap Belt Anchor Installation
(G Model Rear D oors)..................................10A1-71 (Suburban Third Seat)................................. 10A2-22
Suburban Center S e a t......................................10A2-9 Top Strap Belt Anchor Installation
Suspension U n it..................................................3C-29 (Utility Vehicle Rear Seat)........................... 10A2-21
Swing Out Window Replacement Torque Converter Diagnosis................................7A-15
(G Model Rear D oors)..................................10A1-73 Torque Rod Replacement
System Performance Check..............................6E8-28 (Suburban Models)........................................10A5-14
Torque Rod Replacement
(Utility Vehicle M odels)................................. 10A5-5
T Torsional Damper And Front Crankshaft
Seal Replacement
Temperature Gage Diagnosis................................8C-6 (4.3L Engines)................................................. 6A3-12
Temperature Gage Replacement........................8C-13 (4.8L Engines)................................................. 6A4-11
Temperature Gage Sender (Small Block Engines)................................... 6A5-12
Replacement................................................... 8C-14 (7.4L Engines)................................................. 6A6-9
Test For Differential Bearing N o is e ......................4C-2 (6.2L Engines)................................................. 6A7-13
Test For Pinion Bearing N oise..............................4C-2 Transmission, Automatic....................................... 7A-1
Test For Wheel Bearing Noise..............................4C-2 Transmission Component Inspection,
Thermostat............................................................. 6B-6 Automatic........................................................... 7A-8
Thermostat And Reservoir Related Transmission Diagnosis, M anual..........................7B-3
Torque Specifications..................................... 6B-45 Transmission Diagnosis, THM 350-C..................7A-19
Thermostat Diagnosis........................................... 6B-3 Transmission Diagnosis, THM 400......................7A-35
Thermostat Housing Crossover............................6B-10 Transmission Diagnosis, THM 700-R4................7A-53
Thermostatic Air Cleaner..................................... 6E-9 Transmission General Service Procedures,
Throttle Kicker Adjustment Automatic......................................................... 7A-81
(M4ME, M4MED, And M4MEF)......................6C1-33 Transmission Inspection, Manual..........................7B-2
Throttle Kicker Check Transmission, Manual........................................... 7B-1
(E4ME And E4MED)..................................... 6C1-47 Transmission Oil And Wiring
Throttle Kicker Check Circuits, THM 350-C ....................................... 7A-26
(M4ME, M4MED, And M4MEF)......................6C1-30 Transmission Oil And Wiring
Throttle Position Switch Adjustment Circuits, THM 700-R4....................................... 7A-61
(LH6 Engine With 700R4 Transmission)..........6C2-4 Transmission Oil Circuits,
Throttle Shaft Seal Replacement THM 4 0 D ......................................................... 7A-45
(Diesel)........................................................... 6C2-14 Transmission Oil Drain And Fill,
3 S peed........................................................... 7B1-1
Transmission Converter Clutch..............................6E-8
Transmission Oil Drain And Fill,
Throttle ValveDetent Cable (THM 350-C And
89 mm 4 Speed............................................... 7B2-1
THM 700-R4)................................................... 7A-85
Trouble Codes....................................................... 6E-6
Tie Rod Replacement C, G And
Transmission Oil Drain And Fill,
P20 + 30 (42) Models......................................3B1-8
117 mm 4 Speed Transmission .. .1..................7B3-1
Tie Rod Replacement K And P30(00)
Transmission Replacement,
FS3 M odels..................................................... 3B1-9
3 Speed........................................................... 7B1-5
Tight Wheels......................................................... 3E-5
Transmission Replacement, 117 mm
Tire Certification Label......................................... 3E-2
4 Speed........................................................... 7B3-3
Tire Load Limits And Inflation
Transmission Replacement, 89 mm
Pressure........................................................... 3E-15
4 Speed........................................................... 7B2-5
Timing Chain And Sprocket
Transmission Replacement, Automatic..............7A-94
Replacement (6.2L Engines)..........................6A7-15
Tune-Up Information (Engine)................................6A-2
Timing Gear Cover Replacement
Turn Signal And Hazard System
(4.8L Engines)................................................. 6A4-12 Diagnosis......................................................... 8B-20
Tire N oises........................................................... 4C-2
u Weatherstrip Replacement
(Utility Vehicle M odel)..................................10A5-12
Underbody Alignment............................................2A-7 Weight Distribution Hitch Replacement
Underbody, G Model..............................................2A-7 (G M odel)..........................................................2B-17
Unit RepairWindshield Wiper Motor Weight Distribution Hitch Replacement
CK And G Models............................................8A-39 (Suburban Only)................................................2B-10
Unit RepairWindshield Wiper And Weight Distribution Hitch Replacement
WasherP M odel............................................8A-49 (Utility Vehicle Only)..........................................2B-10
Universal Joint........................................................4A-2 Welding..................................................................2A-6
Unloader Adjustment (M4ME, West Coast Outside Rear View Mirror
M4MED, And M4MEF)....................................6C1-38 Replacement (C/K Model Side Front Door). .10A1-14
Upper Ball J o in t..................................................3C-20 Wheels And T ire s ..................................................3E-1
Upper Control A rm ..............................................3C-28 Wheel And Tire Balancing....................................3E-10
Upper Front Roller Replacement Wheel And Tire R unout........................................3E-5
(G Model Sliding Side Door)........................10A1-58 Wheel Bearing Adjustment ( 2 x 4 ) ......................3C-15
Utility Vehicle Wheel Bearing Adjustment (RPO FS3)..............3C-36
Removable Top Replacement......................10A5-13 Wheel Bearing/Cup Replacement
(9 3/4-10 1/2-lnch Ring Gear
Full Floating A xle s)..........................................4B-18
V Wheel Bolt Replacement......................................4B-19
Wheel Codes And Load Limits ............................ 3E-15
Vacuum Booster-Replacement........ . .5-32 Wheel Cylinder Rebuilding....................................5-47
Vacuum Modulator (THM 350-C And Wheel Cylinder Replacement................................5-47
THM 400)...................................... 7A-86 Wheelhouse Panel Replacement
Vacuum Pump Replacement.......... .6H-4 (C/K M odel)....................................................... 2C-8
Vacuum Pumps................................ .6H-1 Wheel Hub Bolt ( 2 x 4 ) ........................................3C-16
Vacuum Regulator Valve Adjustment Wheel Hub Bolt (RPO FS 3)................................3C-36
(LL4 Engine With Automatic Wheel Hub Bolt ( 4 x 4 ) ........................................3C-47
Transmission)................................ 6C2-4 Wheel Hub/Rotor Assembly ( 2 x 4 ) ....................3C-12
Valve Adjustment Wheel Hub/Rotor Assembly (RPO F S 3 )............3C-35
(4.3L Engines).............................. 6A3-6 Wheel Hub/Rotor Assembly ( 4 x 4 ) ....................3C-41
(4.8L Engines).............................. .6A4-5 Wheel Runout Specifications..............................3E-14
(Small Block Engines).................. .6A5-6 Wheel Stud Nut Torque........................................3E-14
(7.4L Engines).............................. .6A6-5 Wheel Stud Replacement (8 1/2-
Valve Stem Seal And Valve Spring 9 1/2-lnch GearSemi-Floating
Replacement Axles)............................................................... 4B-14
(4.3L Engines).............................. . .6A3-7 Window Glass Seal Replacement
(4.8L Engines).............................. . .6A4-5 (Suburban Model)..........................................10A5-19
(Small Block Engines).................. . .6A5-6 Window Glass Seal Replacement
(7.4L Engines).............................. . .6A6-5 (Utility Vehicle M odel)..................................10A5-12
(6.2L Engines).............................. . .6A7-8 Window Motor And Blockout Switch
Valve Timing, Checking Replacement (Utility Vehicle Models)..........10A5-11
(4.8L Engines)................................ .6A4-15 Window Regulator Replacement
Vehicle Identification Number.......... . . .OA-2 (C/K Model Side Front Door)..........................10A1-9
Vent Glass Replacement Window Regulator Replacement
(C/K Model Side Front Door)........ .10A1-7 (C/K Model Side Rear Doors)......................10A1-20
Vent Glass Replacement Window Regulator Replacement
(G Model Side Front D o o r).......... 10A1-36 (G Model Side Front D o o r)..........................10A1-40
Vent Window Adjustment Window Replacement
(C/K Model Side Front Door)........ .10A1-7 (C/K Model Rear Doors)................................10A1-27
Vent Window Adjustment Window Replacement
(G Model Side Front D o o r).......... 10A1-37 (G Model Intermediate Doors)......................10A1-48
Voltmeter Replacement.................... . .8C-15 Window Replacement (G Model
Rear Doors)....................................................10A1-72
Window Replacement (G Model
w Sliding Side D oor)........................................10A1-63
Window Stop Assembly Adjustment
WATER IN FUEL Light Diagnosis......................6C-3 (G Model Side Front D o o r)..........................10A1-38
Water Pump..........................................................6B-23 Windshield Replacement
Weatherstrip Replacement (C/K Models)................................................... 10A3-1
(Suburban Model)..........................................10A5-19 Windshield Replacement (G Model)..................10A3-7
Windshield WasherCK And G M odels............8A-37
Windshield WasherCK And G Models
Component Replacement................................8A-39
Windshield Washer Diagnosis
CK And G Models............................................8A-38
Windshield Washer System
Unit RepairP M odel......................................8A-49
Windshield Wiper And Washer
P M odels..........................................................8A-44
Windshield Wiper And Washer Diagnosis
P M odels..........................................................8A-45
Windshield WiperCK And G Models................8A-29
Windshield Wiper Component
ReplacementCK And G M odels..................8A-29
Windshield Wiper Delay C ircu it..........................8A-41
Windshield Wiper Delay Circuit Diagnosis........8A-43
Windshield Wiper Delay Circuit
Module Replacement....................................... 8A-41
Windshield Wiper Diagnosis
CK And G Models........................................... 8A-32
Windshield Wiper Off Vehicle
Diagnosis, P M o d e ls .............................................. 8A-47
Windshield Wiper On-Vehicle
Diagnosis, P-Model..........................................8A-46
Wiper Motor Unit Repair
CK And G Models............ .............................. 8A-39
Wire Size Conversion Table..................................8A-4
Wiring Harness Service........................................6E-12
*/%

1986 GM CK Service Manual

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1986 GM CK Service Manual

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LIGHT DUTY TRUCKS

GMC TRUCK & COACH OPERATION

The service procedures recommended and described in this service

Accordingly, anyone who intends to use a replacement part, service proce

It is important to note that this manual contains various Cautions and No

FRAME AND CAB

LIGHT DUTY STEERING, SUSPENSION,

MANUAL PROPELLER SHAFT AND AXLES

C-K, P-TRUCK ENGINE

Printed in Canada 10 BODY

Service Parts Identification L ab e l....................................................................................................................... OA- 2

models, the plate is on the dash and toe panel. To find

VEHICLE IDENTIFICATION NUMBER

Figure 3Vehicle Identification Number (VIN)

These battery locations are closer to the starter, thus

THU VENICLf EOUmO FOR 1000/453 L IS PAYLOAD

SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION

Figure 4Certification Label

Pickup, Regular Cab C-K MODELS Chassis - Cab, Regular Cab

Chassis - Cab, Bonus/Crew Cab

Pickup, Bonus/Crew Cab Suburban

Figure 5 C-K Models

RALLY (SPORTVAN) VANDURA (CHEVY VAN)

CUTAWAY VAN MAGNAVAN (HI-CUBE VAN)

VALUE VAN (STEP VAN) FORWARD CONTROL CHASSIS

Figure 6G Van and P Models

1 2 L6 ENGINE 4. Engine I.D. {0[Dtional Location)

Figure 7Engine I.D. Number Location

Figure 8Jump Starting Connections

PARKING LIGHTS CHOKE

Figure 9Graphic Symbols

1. Grade 2 (GM 200-M)

1. Customary B olt 1/4-20

Figure 10Bolt and Nut Identification Figure 11Thread Notation

nuts w ill be marked with single d ig it strength SIX LOBED SOCKET

PREVAILING TORQUE FASTENERS

RECOMMENDATIONS FOR REUSE:

Figure 12Torque Nuts and Bolts Chart

Figure 13Six Lobed Socket Head (Torx)

VOLUME Inches of water 0.249 1 kilopascals (kPa)

DECIMAL AND METRIC EQUIVALENTS

1/64 .015625 .39688 33/64 .515625 13.09687

Decimal and Metric Equivalents

G51 Spring - Rear, Special Heavy UA1 Battery - High Capacity

C a p a citie s.................................................................................................................................................................... OB- 1

VIN E N G IN E D ESCRIPlD ON Produced

* or General Motors of Canada

Figure 2Approximate Capacities - All Models

After refill, fluid level must be checked as outlined under Service

Figure 3Approxim ate Capacities - Blazer, Suburban

Figure 4Approximate Capacities - Forward Control

Figure 5Approxim ate Capacities - Pickup Models

* After refill, fluid level should be checked as outlined under Service

Figure 6Approxim ate Capacities - G Van

1. Lower Control Arms 9. Master Cylinder

Figure 7Lubrication Points For The Conventional

Figure 8Lubrication Points For The CK Four Wheel Drive Models

Figure 9Lubrication Points For The G Van

MAINTENANCE SCHEDULE AND LOG

1986 GENERAL MOTORS

Maintenance service should be done by your General Motors

In addition to the in-shop type services shown in Sections A and B,

SELECTING YOUR VEHICLES

DETERMINING GVWR AND EMISSIONS