Chevrolet - G-VAN - Service Manual - 1986 - 1986

SEC 0 NAME GENERAL INFORMATION 0A OB 1987 1 HEATING AND AIR CONDITIONING 1A 1B 2 LIGHT DUTY TRUCK SERVICE MANUAL Front End Alignment Steering Linkage Manual Steering Power Steering Steering Column Front Suspension and Axle Rear Suspension Wheels and Tires PROPELLER SHAFT AND AXLES 4A Propeller Shaft 4B Rear Axle 4C Front Driving Axle 5 BRAKES 6 ENGINE 6A 6A3 6A4 6A5 6A6 6A7 6B1 6B2 6C 6C1 6C2 6D 6E 6E8 6E9 6F 6H R-V, P-TRUCK AND G-VAN MODELS The Table of C ontents on th is page in­ d icates the sections covered in th is m an­ ual. At the begin nin g of each individual section is a Table of C ontents w hich gives the page n um be r on w hich each m ajor su bject begins. 7 8 Engine 4.3 Liter V6 Small Block 7.4 Liter V8 6.2 Liter Diesel 4.8 Liter L6 Engine Cooling Radiator Fuel System Carburetors Diesel Fuel Injection Engine Electrical Drivability And Emissions Drivability And Emissions - Carburetor Drivability And Emissions - Diesel Exhaust Vacuum Pump TRANSMISSION AND CLUTCH 7A 7B 7C 7D1 7D2 W hen reference is m ade in th is m anual to a brand name, number, or sp e cific tool, an e qu iva len t product m ay be used in place of the recom m ended item. Automatic Transmission Manual Transmission Clutch 205 Transfer Case 208 Transfer Case ELECTRICAL 8A Cab Electrical 8B Chassis Electrical 8C Intrument Panel All inform ation, illustrations, and sp eci­ fica tion s contained in th is M anual are based on th e latest p roduct inform ation available at th e tim e of p ub lica tion ap­ proval. T he rig h t is reserved to m ake changes at any tim e w itho ut notice. P rinted in U.S.A. © 1986 G eneral M otors C orporation Frame and Bumpers Sheet Metal STEERING, SUSPENSION, WHEELS AND TIRES 3A 3B1 3B2 3B3 3B4 3C 3D 3E 4 Heating Air Conditioning FRAME AND CAB 2A 2B 3 General Information Maintenance and Lubrication 9 ACCESSORIES 10 BODY 10A1 10A2 10A3 10A4 10A5 INDEX July, 1986 iii Doors Seats Glass Interior Trim Endgate He knows quality parts make a difference even on simplejobs. Mr. Goodwrench wants you to have the right parts for your truck—whether you see him for service or whether you do the work yourself. So keep that great GM feeling with genuine GM parts at participating independent Mr. Goodwrench dealers selling Chevrolets, Pontiacs, Oldsmobiles, Buicks, Cadillacs, GMC and Chevy Trucks. That’s 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 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. O iN E R A l MOTORS CORPORATION )VA(joodxtrijM C^ B-05884 iv FOREWORD This service manual contains diagnosis, “ On-Vehicle” maintenance, and light repair for Light Duty Truck Models (“ R-V, P-Truck, and G-Van” ). Fuel and emissions related compo­ nents for throttle body injection vehicles are covered in a separate manual. Procedures involving disassem bly and assembly of major components for these vehicles are published in a separate “ Truck Unit Repair M anual.” W iring diagrams for these models are also published in a separate “ Truck W iring 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. ^ L *-/ - vp 'sEtyg. Ho Ipl CAUTION: These vehicles contain some parts dim ensioned in the metric system as well as in the customary system. Some fasteners are metric and are very close in dimension to fam iliar custom ary fasteners in the inch system. It is important to note that, during any vehicle maintenance procedures, replacement fasteners must have the same measurements 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. Customary bolts use radial lines for this purpose, while most custom ary nuts do not have strength markings.) Mis­ matched or incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury. Therefore, fasteners removed from the vehicle 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 m atches the original. For informa­ tion and assistance, see your authorized dealer. CHEVROLET MOTOR DIVISION General Motors Corporation Detroit, Michigan CAUTION To reduce the chance of personal injury and/or property damage, the fo l­ lowing 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 man­ ual 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 pro­ cedure 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 impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions. O A -1 SECTION 0 GENERAL INFORMATION CONTENTS SUBJECT PAGE G eneral In fo r m a t io n ........... ................................................................................................................ ....................................„0A - 1 M aintenance and L u b ric a tio n ............................................................. ............................................... ................................... ,0 8 - 1 SECTION 0A GENERAL INFORMATION CONTENTS SUBJECT PAGE S e rvice Parts Id e n tific a tio n L a b e l ........................................................................................................................ ............0 A - 1 V e hicle Id e n tific a tio n P la te .................................................. ............................................... ............................... ...QA- 1 C e rtific a tio n L a b e l.................................................................. ..................................... ........................ ............................... .0 A - 2 Model R e fe r e n c e ....................................... ................................................................................. ............................................. 0 A - 2 Engine id e n tific a tio n N u m b e r........................................... ........................................ ........................ ................................. 0 A - 2 V ehicle L iftin g P ro c e d u re s ........................................... ............................................................................... ........................ 0 A - 3 E m ergency S ta rtin g Due to a D ischarged B a tte r y ................................................................................................ .. ,0 A - 8 G raphic S y m b o ls .................................................................................................................................................................... .0 A - 8 M etric F a s te n e r s .......................................................................................................................................................................... 0A-1Q Fastener S tre n g th Id e n tific a tio n ............................................................................................. ...........................................0 A -1 0 P re vailin g T orq ue F a s te n e rs ..................................................... .......................................... ............................................... 0A -11 S ix Lobed S o cke t Head F a s te n e rs ............................................................. ............................ ...................... ....................O A -12 RPO L is tin g (R egular P ro d u ctio n O p tio n ).................................................................... .......................................... ...0 A -15 SERVICE PARTS IDENTIFICATION LABEL The Truck Service Parts Identification Labei is provided on all models (figure 1). It is located on the inside of the gloye box door (or on an inner body panel for Forward C o n tro l m odels). The L ab el lists th e V iN (V e h ic le Identification Number), wheelbase, paint information and all Production options or Special Equipm ent on the vehicle when it was shipped from the factory. ALWAYS REFER TO THIS INFORMATION WHEN ORDERING PARTS. VEHICLE IDENTIFICATION NUMBER The VIN is the legal identifier of the vehicle, On all models except Forward Controi, it is located on a plate which is attached to the left top of the instrum ent panel and can be seen through the windshield from the outside of the vehicle (figure 2). On Forward Control models, the plate is on the dash and toe panel. To find out the 15516776 P rinte d in U.S.A SERVICE PARTS IDENTIFICATION THE O P TIO N A L EQ UIPM EN T LISTED 3E LO W H AS BEEN V E H IC L E FOR PROPER ID E N T IF IC A T IO N OF R E P L A C E M E N T $URE TO SPEC IFY THE A P PLIC ABLE OPTION NU M BER S. PARTS. NOTICE: TH IS IN F O R M A T IO N IS SUPPLIED AS AN AID IN '.DENTIFYING PARTS FOR SERVICE. SERVICE PARTS R EQ U IR EM EN TS FOR TH IS VE H IC LE M AY VARY FROM TH O SE LISTED. BEFORE O R D ER IN G ANY OF THE A B O VE PARTS, A LW A YS HAVE YOUR GE NE RA L M OTORS TRUCK DEALER CH EC K THIS V E H IC L E 'S BR OADC AST SU PP LE M E NT FOR PO SSIBLE PART C H AN G ES . IM PO RTAN T: RETAIN TH IS PLATE A S A PERM ANE * 8-05559 F igure 1— S e rvice Parts Id e n tific a tio n Label manufacturer, model and chasis type, engine type, GVW range, model year, plant code, and sequential number, refer to figure 3. OA-2 GENERAL INFORMATION 1GCDC14N4GF100001 o 1. T ypica l VIN F-00687 Figure 2—VIN Location GVWR. Also, the front and rear gross axle weights must not exceed the front and rear GAWRs. The Payload Rating shown on the label is the maximum allowable cargo load (including the weight of the driver and all occupants) that the vehicle can carry based on all factory installed equipm ent on the vehicle. The Payload Rating is reduced if any accessories or other equipm ent is added to the vehicle after final date of manufacture. The weight of these items should be determined and deducted from the Payload Rating. T h e v e h ic le m ay a ls o h a ve a G C W R (G ro s s C o m b in a tio n W e ig h t R a tin g ). T h e G C W (G ro s s Com bination 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 properly inflated for the load which you are carrying. The vehicle Certification Label shows the originally equipped tire size and recommended inflation pressures. For more inform ation on tires, refer to W HEELS AND TIRES (Sec.3E). MODEL REFERENCE CERTIFICATION LABEL The Certification Label shows the GVWR, and the front and rear GAWRs, and the Payload Rating for your vehicle (figure 4). Refer to figures 5 and 6 to determine the vehicle model. For R/V models, a “ R” is a two-wheel drive vehicle and a “ V ” is a four-wheel drive vehicle. Gross Vehicle W eight (GVW) is the w eight of the orginally equipped vehicle and all items added to it after it has left the factory. This would include bodies, winches, booms, etc.; the driver and all occupants; and the load the ve hicle is carrying. The GVW m ust not exceed the Nation of Origin ENGINE IDENTIFICATION NUMBER Refer to figure 7 to determine the location of the engine I.D. number. Ti Code Series 1 V2 Ton 1 = U.S. B u ilt 2 = C a nadian B u ilt 3 = M e xican B u ilt 2 3 Jon A B C h evro let Bus * C h evro let In c o m p le te C h evro let Truck D G M C In c o m p le te E C a d illa c In c o m p le te H GM o f C anada Bus T G M C Truck IGJ G M C Van/Bus IGK G M C MPV IGN C h evro let MPV *Van w ith 4th Seat c Code GVWR/BRAKE SYSTEM GVWR Range Brake System B 3001-4000 C 4001-5000 D 5001-6000 E 6001-7000 F 7001-8000 G* 8001-9000 H 9001-10,000 J 10,001-14,000 K 14,001-16,000 ' In c lu d e s G-Van Bus Code H Code Body Type Code Make H y d ra u lic H y d ra u lic H y d ra u lic H y d ra u lic H y d ra u lic H y d ra u lic H y d ra u lic H y d ra u lic H y d ra u lic J 1 Ton Manufacturers G = G eneral M o to rs Production Sequence Number 0 1 2 3 4 5 6 7 8 9 Assembly Plant Year 1987 B a ltim ore , MD F lin t, M l Ja n e s v ille , W l St. Lou is, MO P o n tia c East, M l P ontiac, Ml F ort W ayne, IN O shaw a, ON M oraine, OH D e tro it, M l S c a rb o ro u g h , ON L o rd s to w n , OH S h re ve p o rt, LA Pontiac, Ml______ P ickup/P ane l D e livery H i-C ube/C u taw ay Van Forw ard C o n tro l Fou r-D oo r Cab Tw o-D oor Cab Van S u burban M o to r H o m e C h a s s is U tility (Jim m y/B lazer) S take Code Line and Chassis Type Chassis Type Line R C o n v e n tio n a l Cab D M ilita ry Truck V C o n v e n tio n a l Cab G Van P Forw ard C o n tro l S Sm Conventional Cab T Sm Conventional Cab M Sm Van 4 4 4 4 4 4 4 4 x x x x x x x x 2 4 4 2 2 2 4 2 Code C E H J K N R Z M W Engine Type and Make Type Producer DDAD P o ntiac C h evro let DDAD C h evro let Chevrolet C h e v ro le t Chevrolet Chevrolet Chevrolet 6.2L 2.5L 5.0L 6.2L 5.7L 7.4L 2.8L 4.3L 5.7L 7.4L V8 D iesel L4 TBI V8 TBI V8 Diesel V8 TBI V8 TBI V6 TBI V6 TBI V8 4BBL V8 4BBL RPO LH6 LN 8 L03 LL4 LOS L19 LL2 LB4 LT9 ✓ LE8 F-02139 Figure 3—Vehicle Identification Number (VIN) GENERAL INFORMATION OA-3 When lifting the R vehicle with a hoist, the rear hoist pads should be positioned under the rear spring front hangers. ' MFD. BY GENERAL MOTORS CORPORATION GVW R g AWR PRT gaw r rr When lifting the V vehicle with a hoist, the front hoist pads should be positioned under the frame, at the front body mount. The rear hoist pads should be positioned under the rear spring front hangers. SEE O W NER'S MANUAL FOR ADDITIONAL INFORMATION When lifting the front of the V vehicle with a floor jack, position the jack pad at the center of the axle, not under the front differential. F-01407 When lifting the P vehicle with a hoist, the rear hoist pads should be positioned under the fram e and inboard of the rear spring front hangers. Figure 4—Certification Label VEHICLE LIFTING PROCEDURES F or liftin g a v e h ic le , v a rio u s lif t p o in ts recommended. Refer to figures 8, 9, 10, and 11. P icku p , R e g u la r C ab a re When lifting the G vehicle with a hoist, the rear hoist pads should be positioned under the rear spring forward hangers. R V MODELS C h a s s is - Cab, R e g u la r C ab C h a s s is - Cab, B o n u s /C re w C ab P ic k u p , B o n u s/C re w C ab S u b u rb a n U tility V e h ic le J im m y (Blazer) F-02281 Figure 5—RV Models OA-4 GENERAL INFORMATION G VAN MODELS V A N D U R A (C H E V Y VAN ) B A LL Y (SPO R TV AN ) CUTAWAY VAN MAGNAVAN (HI-CUBE VAN) MODELS___________ VALUE VAN (STEP VAN) (ALUMINUM) VALUE VAN (STEP VAN) (STEEL) MOTOR HOME CHASSIS FORWARD CONTROL CHASSIS B-09178 Figure 6—G Van and P Models GENERAL INFORMATION OA-5 Figure 7—Engine I.D. Number Location OA-6 GENERAL INFORMATION A. B. C. D. E. F. L ow er c o n tro l arm ; in b o a rd o f th e lo w e r ball jo in t. F ro n t s u s p e n s io n c ro s s m e m b e r; center. F ram e at to w a rd b o d y m o u n t. R ear s p rin g fo rw a rd hanger. R ear axle; b e tw e e n th e s p rin g and brake b a c k in g p la te D iffe re n tia l case; center. V e h ic le J a c k o r F lo o r J a c k F lo o r J a c k H o is t B-07500 Figure 8—Chassis Lift Points — R Model A. B. C. D. E. F. G. F ro n t axle; c lo s e to w h e e l as p o s s ib le . F ro n t axle; at s ta b iliz e r b a r m o u n t. F ro n t axle; at center. Fram e; at fro n t b o d y m o u n t. R ear s p rin g at fro n t m o u n t. R ear a xle; at s p rin g m o u n t. R ear axle, at c e n te r o f d iffe re n tia l. V e h ic le J a c k o r F lo o r J a c k © / \ V e h ic le J a c k Q F lo o r J a c k Two C o lu m n H o is t Two C o lu m n H o is t H o is t B-07501 Figure 9—Chassis Lift Points — V Model GENERAL INFORMATION OA-7 A. B. C. D. E. F. Low er c o n tro l arm ; in b o a rd o f th e lo w e r b all jo in t F ro n t s u s p e n s io n c ro s s m e m b e r; center. Fram e; at in w a rd bend. Rear s p rin g ; at fo rw a rd s p rin g hanger. A xle ; at s p rin g m o u n t. D iffe re n tia l; at center. V e h ic le J a c k o r F lo o r J a c k O F lo o r J a c k f § H H o is t B-07627 Figure 10—Chassis Lift Points — G Model A. B. C. D. E. F ro n t axle; at th e s p rin g m o u n t. Fram e; at th e cro s s m e m b e r, ju s t b e h in d th e s p rin g m o u n t Fram e; at th e c ro ssm e m b e r. Rear a xle; at th e s p rin g m o u n t. R ear axle; at th e d iffe re n tia l. O F lo o r J a c k B-07628 Figure 11—Chassis Lift Points — P Model OA-8 GENERAL INFORMATION Any tim e a vehicl is lifted with a vehicle jack or a floor jack, the wheels at the opposite end of the lifted end should be chocked. Also, jack stands should be used to provide support. When supporting the vehicle with jack stands, the jack stands should be placed under the frame, the front suspension crossm em ber or the axle. When removing m ajor components of the vehicle while the vehicle is on a hoist, the vehicle frame should be chained to the hoist pads in order to prevent tip-off. NOTICE: When jacking or lifting a vehicle, be certain that the lift pads do not contact the catalytic converter, brake lines, brake cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance. EMERGENCY STARTING YOUR VEHICLE DUE TO A DISCHARGED BATTERY If your vehicle will not start due to a discharged battery, it can often be started by using energy from another battery - a procedure called “ jum p starting.” Should your vehicle have an optional diesel engine with two batteries: • P models and G Van models — use only the battery on the driver’s side when jump starting. • R/V models — use only the battery on the passenger’s side when jump starting. These battery locations are closer to the starter, thus reducing electrical resistance. Ignore the second battery. NOTICE: Do not push or tow this vehicle to start it. Under some conditions this may damage the catalytic converter or other parts of the vehicle. Also, since this vehicle has a 12 volt battery, be sure the vehicle or equipm ent used to jum p start your engine is also 12 volt. Use of any other type system may damage the vehicle’s electrical components. At low temperatures, it may not be possible to start your diesel engine from a single battery in another vehicle. However, you can use your vehicle to jum p start another vehicle. JUMP STARTING INSTRUCTIONS CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of personal injury when working near a battery: • Always shield your eyes and avoid leaning over the battery whenever possible. • Do not expose the battery to open flames or sparks. • Be sure any batteries that have filler caps are properly filled with fluid. • Do not allow battery acid to contact eyes of skin. Flush any contacted area with water immediately and throughly, and get medical help. • Follow each step in the jump starting instructions. M ake C on ne ction s in N um erical O rder First Jum per Cable Do NOT Allow Vehicles to Touch I D ischarged B a tte ry Second Jum per Cable Make Last C onnection on Engine or Frame, Away from Battery B a tte ry in V e hicle w ith C harged B a tte ry I © F-02649 F igure 12—J u m p S ta rtin g C on ne ction s 1. Position the vehicle with the good (charged) battery so that the booster (jumper) cables will reach, but never let the vehicles touch. Also, be sure booster cables do not have loose or missing insulation. 2. In both vehicles: • Turn o ff th e ig n itio n and a ll lig h ts and accessories except the hazard flasher or any lights needed for the work area. • Apply the parking brake firmly, and shift the autom atic transm ission to Park (or manual transmission to Neutral). 3. Making sure the cable clamps do not touch any other metal parts, clamp one end of the first booster cable to the positive ( + ) terminal on one battery, and the other end to the positive terminal on the other battery (figure 12). Never connect ( + ) to (-). 4. Clamp one end of the second cable to the negative (-) terminal of the good (charged) battery and make the final connection to a heavy metal bracket (such as the mounting bracket for the generator or air conditioner compressor if so equipped) on the engine about 450 millimeters (18 inches) from the discharged battery. Make sure the cables are not on or near pulleys, fans, or other parts that will move when the engine is started. 5. Start the engine of the vehicle with the good (charged) battery and run the engine at a moderate speed for several minutes. Then, start the engine of the vehicle that has the discharged battery. 6. Remove the booster cables by reversing the above installation sequence exactly. While removing each clamp, take care it does not touch any other metal while the other end remains attached. GRAPHIC SYMBOLS G raphic sym bols are used on som e controls and displays on the vehicle (figure 13). Many of these symbols are used internationally. GENERAL INFORMATION OA-9 ff t t BRAKE 4> POWER TRAIN OIL TEMPERATURE |0 ILLUM INA TION CONTROL FOG LAM P V ENTILATING FAN W IND SHIELD DEFROSTER REAR W IND O W DEFOGGER FASTEN SEAT BELTS FUEL ENGINE OIL PRESSURE o IDENTIFICATION LAM PS A LIGHTS OR HIGH BEAM HORN HAZARD W ARNING FLASHER TURN SIGNALS > CAUSTIC BATTERY ACID COULD CAUSE BURNS BRAKE SPEAKER ------------------------ 1 LIGHTER CHOKE RADIO SELECTOR DOOR LOCK/UNLOCK BATTERY CHARGING SYSTEM HEATER st RADIO VOLUME SPARK OR FLAME COULD EXPLODE BATTERY D a 'I PARKING LIGHTS IIIUII LJ------- 1 CAUTION POSSIBLE INJURY W IND SHIELD WIPER © 0 / h e r t W IND SHIELD W IPER & W ASHER nm ID IPS f W IND SHIE LD W ASHER \\\W O HEADLIGHT LOWER BEAM kPa MANIFOLD V ACUUM TRANSM ISSION OIL TEMPERATURE HOOD RELEASE F-02392 Figure 13—Graphic Symbols 0A-10 GENERAL INFORMATION METRIC FASTENERS 1. 2. 3. 4. 5. 6. 7. G rade 2 (GM 200-M) G rade 5 (GM 280-M) G rade 7 (GM 290-M) G rade 8 (G M 300-M) M a n u fa c tu re r’s Id e n tific a tio n N u t S tre n g th Id e n tific a tio n Id e n tific a tio n M a rks (P o sid riv S crew Head) 1. 2. A. B. C. D. F-00695 C u s to m a ry B o lt— 1/4-20 M e tric B o lt— M6.0x1 1/4-inch 6 mm 20 T h re a d s Per In ch 1 T hre ad Per M illim e te r (25.4 T h re a d s Per In ch) F-00705 Figure 14—Bolt and Nut Identification Figure 15—Thread Notation Models are prim arily dim ensioned in the metric system. Many fasteners are m etric and are very close in dim en­ sion to well-known custom ary fasteners in the inch sys­ tem. It is most important that replacement fasteners be of the correct nominal diameter, thread pitch and strength. the metric M6.0X1 screw which has nearly the same diam ­ eter and has 25.4 threads per inch. The thread pitch is in between the custom ary coarse and fine thread pitches. Original equipm ent metric fasteners (except “ beauty” bolts, such as exposed bum per bolts, and cross recess head screws) are identified by a number marking indica­ ting the strength of the material in the fastener as outlined later. Metric cross recess screws are identified by a Posi­ driv or Type 1A shown in figure 14. Either a Phillips head or Type 1A cross recess screwdriver can be used in Posi­ driv recess screw heads, but Type 1A cross recess screw­ drivers will perform better. FASTENER STRENGTH IDENTIFICATION NOTICE: Most m etric fasteners have a blue color coating. However, this should not be used as positive identification as some fasteners are not color coated. General Motors Engineering Standards, along with other North American Industries, have adopted a portion of the standard metric fastener sizes defined by ISO (In­ ternational Standards Organization). This was done to re­ duce the num ber of fastener sizes used and yet retain the best strength qualities in each thread size. For example, the customary 1/4-20 and 1M-28 screws are replaced by Metric and customary thread notation differ slightly. The difference is shown in figure 15. Most comm only used metric fastener strength property classes are 9.8 and 10.9 with the class identification embossed on the head of each bolt. Custom ary (inch) strength classes range from grade 2 to 8 with radial line identification embossed on each bolt head. M arkings correspond to two lines less than the actual grade (i.e. grade 7 bolt will exhibit 5 embossed radial lines on the bolt head). Some metric nuts will be marked with single digit strength identification numbers on the nut face. Figure 14 shows the different strength markings. When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater than the original fasteners (the same num ber marking or higher). It is likewise important to select replacement fasteners of the correct size. Correct replacement bolts metric fasteners available in the aftermarket parts channels were designed to metric standards of countries other than the United States, and may be of a lower strength, may not have the num bered head m arking system , and may be of a GENERAL INFORMATION OA-11 (I° I) 4 8 Q A 6 & 6.3 8 10 12 14 16 20 N-m 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, N-m 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 .250 .312 .375 .437 .500 .562 .625 .750 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, N-m 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 4 ,5 B 4 ,5 A. M e tric S ize s B. In ch S izes 1. 2. 3. 4. 5. T op L o c k T ype C e n te r L o c k D ry A d h e s iv e C o a tin g O u t O f R ou nd T hre ad D e fo rm e d T h re ad P ro file 6. 7. 8. 9. N y lo n N y lo n N y lo n N y lo n S trip O r P atch W a s h e r In s e rt P atch In s e rt B-02406 Figure 16— T o rq u e N uts and B o lts C hart 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 n u t s u p p lie rs . In g e n e ra l, e x c e p t fo r s p e c ia l applicaitons, the common sizes and pitches are: M6.0 x 1 M 1 0 x 1 .5 M 8 x 1.25 M 12 x 1.75 PREVAILING TORQUE FASTENERS A prevailing torque nut is designed to develop an interference between the nut and bolt threads. This is most often accom plished 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 16). 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 bolts 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 with a new prevailing 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. OA-12 GENERAL INFORMATION T - In te rn a l D rive E - E x te rn a l D rive ______________________________________________ B-02221 Figure 17—Six Lobed Socket Head Fasteners SIX LOBED SOCKET HEAD FASTENERS Six lobed socket head fasteners are used in some applications on vehicles covered in this manual (figure 17). The door striker bolt is of this design. Tools d esign ed fo r th ese fa ste ne rs are availab le commercially. However, in some cases, if the correct tool is not available, a hex socket head wrench may be used. CONVERSION TABLE M u ltip ly by to g e t e q u iv a le n t n u m b e r o f: M u ltip ly LENGTH Inch Foot Yard Mile 25.4 0.304 8 0 .9 1 4 4 1.609 Figure m illim eters2 (m m 2) centim eters2 (cm 2) m eters2 (m2) meters2 VOLUME Inch3 Table Quart 0.946 4 Gallon Yard3 16.387 16.387 0 .01 64 liters 3.785 4 0.764 6 mm3 cm 3 liters (I) liters m eters3(m 3) Foot/sec2 Inch/sec2 0.453 6 907.18 0.907 Pound-inch Pound-foot 9.807 0.278 0 4.448 kilogram s (kg) kilograms (kg) tonne (t) newtons (N) newtons newtons TEMPERATURE Degree Fahrenheit CO "si new ton-m eters (N-m) new ton-m eters POWER Horsepower Inches of water Pounds/sq. in. 0.746 kilow atts (kW) PRESSURE OR STRESS 0.249 1 6 895 kilopascals (kPa) kilopascals ENERGY OR W ORK BTU Foot-pound Kilowatt-hour 1 055 1.355 8 3 600 000 or 3.6 x 106 joules (J) joules joules (J $ one W) Foot candle 1.076 4 lum ens/m eter2 (lm /m 2) FUEL PERFORM ANCE Miles/gal Gal/mile 0.425 1 2.352 7 M iles/hour 1.609 3 kilom eters/liter (km/l) liter/kilom eter (l/km) VELO CITY kilom eters/hr. (km/h) (t°F -3 2 ) -f- 1.8 degree C elsius (C) OA-13 oo 0 01 0.112 98 1.355 8 LIG H T FORCE Kilogram Ounce Pound m eter/sec2 (m /s2) m eter/sec2 TORQUE MASS Pound Ton Ton 0.304 8 0.025 4 GENERAL INFORMATION 18— Conversion Foot2 Yard2 645.2 6.45 0.092 9 0.836 1 to g e t e q u iv a le n t n u m b e r o f: AC C ELER ATIO N m illim eters (mm) meters (m) meters kilom eters (km) AREA Inch2 by OA-14 DECIMAL AND METRIC EQUIVALENTS Decimal In. M etric mm Fractions Decimal In. M etric mm 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 0.015625 0.03125 0.046875 0.0625 0.078125 0.09375 0.109375 0.125 0.140625 0.15625 0.171875 0.1875 0.203125 0.21875 0.234375 0.250 0.265625 0.28125 0.296875 0.3125 0.328125 0.34375 0.359375 0.375 0.390625 0.40625 0.421875 0.4375 0.453125 0.46875 0.484375 0.500 0.39688 0.79375 1.19062 1.58750 1.98437 2.38125 2.77812 3.1750 3.57187 3.96875 4.36562 4.76250 5.15937 5.55625 5.95312 6.3500 6.74687 7.14375 7.54062 7.93750 8.33437 8.73125 9.12812 9.52500 9.92187 10.31875 10.71562 11.11250 11.50937 11.90625 12.30312 12.7000 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 0.515625 0.53125 0.546875 0.5625 0.578125 0.59375 0.609375 0.625 0.640625 0.65625 0.671875 0.6875 0.703125 0.71875 0.734375 0.750 0.765625 0.78125 0.796875 0.8125 0.828125 0.84375 0.859375 0.875 0.890625 0.90625 0.921875 0.9375 0.953125 0.96875 0.984375 1.00 13.09687 13.49375 13.89062 14.28750 14.68437 15.08125 15.47812 15.87500 16.27187 16.66875 17.06562 17.46250 17.85937 18.25625 18.65312 19.05000 19.44687 19.84375 20.24062 20.63750 21.03437 21.43125 21.82812 22.22500 22.62187 23.01875 23.41562 23.81250 24.20937 24.60625 25.00312 25.40000 GENERAL INFORMATION Figure 19—Decimal and Metric Equivalents Fractions GENERAL INFORMATION OA-15 RPO LISTING (REGULAR PRODUCTION OPTION) The RPO list contains RPOs used on R-V Models, G Vans, and Forward Control Chassis Models. Refer to the Service Parts Identification Label for a list of the RPOs used on each specific vehicle. AA3 Windows - Deep Tint, Side Windows Only AC2 Window - Sliding, Right Front Door AD5 Window - Right Rear, Side, Sliding AD8 Door Check AE7 Seat - Front, Split AJ1 Window - Deep Tint, Except Windshield and Doors AM7 Seat - Right Rear Folding AP7 Partition - Sliding Plywood AQ3 Seat - Rear Center AQ4 Seat - Rear AS3 Seat - Right Rear, Suburban AT5 Seat - Center Folding, Suburban AU2 Lock - Cargo Door AU3 Power Lock - Side Door AU6 Power Lock - Tailgate Remote Control AV5 Seat - High Back, Bucket AW4 Door - Sliding Side Extension AX5 Partition - Expanded Metal, Left Side AX7 Partition - Expanded Metal w/Center Sliding Door AX9 Latch - Rear Cargo Door A01 Window - Tinted, All Shaded Windshield A02 Windshield - Tinted, Shaded Upper A07 Window - Body A08 Window - Body, Right Side A12 Window - Stationary, Back Door A13 Window - Stationary, Side Rear Door A17 Window - Left Side Swing-Out A18 Window - Rear Door, Swing-Out A19 Glass - Side Rear Door, Swing-Out A20 Window RR Quarter Vent, Swing Out A28 Window - Right Rear, Full Width, Sliding A31 Window - Side, Power A33 Window - Tailgate, Power A50 Seat - Front Bucket A51 Seat - Front Bucket A52 Seat - Front Bench A57 Seat - Auxiliary, One Passenger, Folding A82 Head Restraints A95 Seat - Front Bucket, High Back, Reclining BA8 Compartment - Front Seat Storage BB5 Ornamentation BF3 Floor Covering - Step Well Mat BG9 Floor Covering, Rubber BW2 Ornamentation - Deluxe Body Side Molding B3D School Bus Equipment B3J Diesel Equipment B30 Floor Carpet B32 Floor Mats - Front B33 Floor Mats - Rear B84 Extra Molding - Body Side B85 Extra Molding - Belt Reveal B93 Extra Molding - Door Edge Guard B96 Extra Molding - Wheel Opening CD4 Wiper System - Pulse C36 Heater - Auxiliary \ C42 C49 C55 C60 C69 C91 C95 DF1 DF2 DG5 D20 D34 D44 D45 D46 D49 D73 D92 E24 E31 E34 E36 E38 E39 E46 E53 E55 E62 E63 E76 E79 E94 F42 F51 F58 F59 F60 G50 G51 G52 G60 G80 KC4 KL7 K05 K09 K22 K34 K46 K60 K68 K81 K99 LB4 LH6 LL4 L03 L05 L19 Heater - Deluxe Outside Air Defogger - Rear Window, Electric Vent - Roof Air Conditioning - Front Manual Controls Air Conditioner - Roof Mounted Lamp - Interior Courtesy Lamp - Interior Courtesy, Dual Reading Mirror - Camper Type, Painted Mirror - Camper Type, SST Mirror - West Coast Type Sunshade - Windshield, Passenger Side Mirror - Visor Vanity Mirror - Outside, Painted Mirror - Outside, SST Mirror - West Coast Type with Clearance Lights Mirror - Chrome Pickup Box Hand Rail Stripe - Lower Decor Door - Cargo Side, Hinged Body - Steel ,10 ft. Body - Steel, 10 ft. Standard Width Body - Aluminum, 10 ft. Body - Steel, 12 ft. x 8 ft. Body - Aluminum, 12 ft. x 8 ft. Door - 66 in., Overhead Sliding w/Window Door - 87 in., Wrap-Around End Gate, Suburban Pickup Box - Stepside (Fenderside) Pickup Box - Fleetside (Wideside) Door. -• 60 in., Rear Door ^ 74 in., Rear, Strap Hinges Rally (Beauville) Equipment Suspension - Front Heavy Duty Shock Absorbers - Front and Rear, Heavy Duty Stabilizer Shaft - Front, Heavy Duty Stabilizer Shaft - Front Spring - Front, Heavy Duty Spring - Rear, Heavy Duty Spring - Rear, Special Heavy Spring - Rear 15000 lbs. Spring - Rear Auxiliary Axle - Rear, Limited Slip Engine Oil Cooler System Gas Conversion - LP Engine Block Heater Generator - 120 Amp Generator - 94 Amp Cruise Control Air Cleaner - Heavy Duty, Pre-Cleaner Generator -100 Amp Generator - 105 Amp Generator - 66 Amp Generator - 85 Amp Engine - 4.3L V6 TBI Engine - 6.2L V8, Diesel Engine - 6.2L V8, Heavy Duty Diesel Engine - 5.0L V8 TBI Engine - 5.7L V8 TBI Engine - 7.4L V8 TBI OA-16 GENERAL INFORMATION LT9 MD8 MY6 M20 M40 M62 M64 NA1 NA4 NA5 NA6 NB2 NE2 NK7 NL2 NL7 NM5 NM8 NY1 N05 N31 N33 N40 N41 N51 N67 N90 PA1 PA6 PF2 P01 P10 P11 P13 P14 P15 P17 QE6 R05 TP2 TR9 TT4 TT5 TVR T63 T84 T85 UA1 UB4 UD4 UF2 UJ1 UM6 UN3 UY1 UY7 U01 U18 U35 U37 U58 U63 U66 U69 Engine - 5.7L V8 4BBL Heavy Duty Transmission - Auto. 4 Speed, THM700 R4 Transmission - Manual 4-Speed w/Overdrive Transmission - Manual 4 Speed, 6.55 1st. Transmission - Auto, 3 Speed, Torque Conv. Var. 1 Transmission - Manual 3 Speed, 2.85 Ratio Transmission - Manual 3 Speed. 3.50 Ratio Emission System - Light Duty Emission System - Heavy Duty Emission System - Federal Requirements Emission System - High Altitude Requirements Emission System - California Requirements Fuel Tank - 40 gal. Fuel Tank - 31 gal. Fuel Tank - Auxiliary Fuel Tank - 33 gal. Emission System - Canadian Requirement Emission System - Leaded Fuel Fuel Tank Shield Fuel Filler Cap Lock Steering Wheel - Custom Steering Column - Tilt Steering - Non-Variable Steering - Power Steering - Manual Wheel - Rally Type Wheel - Aluminum Cast Wheel - Trim Discs, Var. 5 Wheel - Styied, Painted Wheel - 15 x 7 Aluminum Wheel - Trim Discs, Var. 1 Carrier - Spare Tire Carrier - Spare Tire, Glide Out Carrier - Spare Tire, Side-Mounted Carrier - Inside Mounted Spare Tire, Left Side Carrier - Inside Mounted Spare Tire, Right Side Cover - Spare Wheel/Tire Wheel - 16.5 x 6 Wheel Conversion - Dual Rear Battery - Auxiliary Camper Lamp Group Headlamps - Halogen, Pencil Beam Headlamps - Haiogen Lamp - Rear Dome and Reading Headlamps - Warning System Headlamps - Right Rule Headlamps - Left Rule Battery - High Capacity Lamps - Rear Side Marker Alarm - Vehicle Speed Lamp - Cargo Indicator System, Brake Warning Radio - AM/FM Stereo, Seek/Scan, Cassette, Clock Radio - AM/FM Stereo, Cassette Wiring Harness - Camper Wiring Harness - Truck Trailer, Heavy Duty Lamp - Roof Marker Speedometer - Kilometer Electric Clock Cigarette Lighter Radio - AM/FM Stereo R ad io-A M Speaker System - Dual Front, Dual Rear R adio-AM /FM U76 U89 VE5 VF1 VG3 VG5 VR2 VR4 V01 V02 V05 V22 V31 V35 V37 V42 V43 V46 V76 X6W X6Z YE9 YG1 YJ6 ZM2 ZW9 ZY1 ZY2 ZY4 Z53 Z62 Z72 Z73 Z75 Z76 Z80 Z81 Z82 12A 12K 12L 12U 15A 18C 18D 181 18V 18W 19A 191 19K 19L 19U 19W 21L 21U 23D 23G 23I 23V 23W 28A 28L 28U Antenna - Windshield Wiring Harness - Trailer Bumper - Front and Rear Impact Strip Bumper - Rear Chrome Front Bumper Impact Strip Rear Bumper Impact Strip Trailer Hitch Trailer Hitch - Weight Distributing Radiator - Heavy Duty Radiator - Heavy Duty w/Trans. Oil Cooler Radiator - Heavy Duty Radiator Grille - Chrome Bumper Guards - Front, Chrome Bumper, Rear w/Recessed Lighting Bumper - Front and Rear Chrome Bumper - Rear Step, Chrome Bumper - Rear Step, Painted Bumper - Front, Chrome Front Hook Towing Device Hub - Manual Locking Hub - Automatic Locking Equipment Package, Level 3 Molding, Body Side and Wheel Opening Decor Package - Econo Trim Package, Bonaventure Base Body or Chassis Color Combination - Solid Color Combination - Two Tone Color Combination - Deluxe Two Tone Gage Package - Voltmeter, Oil Press, and Temp. Equipment Package - Level 1 Trailering Package - L.D. Ball-Type Hitch Trim - Special Interior Shock Absorbers - Four Front Special Chassis - Camper Package Trim - Special Exterior Camper - Special Trailer Hitch - Special Reese Type Stripe Accent - White Color Combination - White (Auxiliary Top) Secondary Color - White Primary Color - White Stripe Accent - Grey Trim Combination - Charcoal, Stnd Cloth Trim Combination - Charcoal, Velour Cloth Interior Trim - Charcoal Trim Combination - Charcoal, Vinyl Striped Trim Combination - Charcoal, Dual Grain Vinyl Stripe Accent - Black and Grey Two Tone Interior Trim - Black Color Combination - Black (Auxiliary Top) Secondary Color - Black Primary Color - Black Trim Combination - Black, Dual Grain Vinyl Secondary Color - Lt. Blue Metallic Primary Color - Lt. Blue Metallic Trim Combination - Blue, Velour Cloth Trim Combination - Blue Cloth Interior Trim - Blue Vinyl Trim Combination - Blue Vinyl, Striped Trim Combination - Blue Dual Grain Vinyl Stripe Accent - Dk Blue and Lt Blue Secondary Color - Dk. Blue Metallic Primary Color - Dk. Blue Metallic GENERAL INFORMATION OA-17 29A 29K 29L 29U 55L 55U 61K 61L 61U 62C 62D 62G 62I 62V 62W 66K 66L 66U 67L 67U 72A 72L 72U Stripe Accent - Dk. and Lt. Blue Color Combination - Dk. Blue (Auxiliary Top) Secondary Color - Dk. Blue Primary Color - Dk. Blue Second Color - Russet Metallic Primary Color - Russet Metallic Color Combination - Tan (Auxiliary Top) Secondary Color - Tan Primary Color - Tan Trim Combination - Lt. Saddle, Stnd. Cloth Trim Combination - Lt. Saddle, Velour Cloth Trim Combination - Saddle Cloth Interior Trim - Lt. Saddle Trim Combination - Lt. Saddle Vinyl, Striped Trim Combination - Lt. Saddle, Dual Grain Vinyl Color Combination - Dk. Brown Secondary Color - Dk. Brown Metallic Primary Color - Dk. Brown Metallic Secondary Color - Lt. Saddle Metallic Primary Color - Lt. Saddle Metallic Stripe Accent - Bright Red Secondary Color - Bright Red Primary Color - Bright Red 76C 76D 76G 76I 76V 76W 77C 77D 77G 77I 77V 77W 78U 82D 82G 82I 82W 90K 90L 90U 93U 9V8 Trim Combination - Bronze, Stnd. Cloth Trim Combination - Bronze, Velour Cloth Trim Combination - Dk. Claret and Gold, Garnet Red Interior Trim - Bronze Trim Combination - Bronze, Striped Vinyl Trim Combination - Bronze, Dual Grain Vinyl Trim Combination - Dk. Maple, Stnd. Cloth Trim Combination - Dk. Maple, Velour Cloth Trim Combination - Dk. Maple Cloth Interior Trim - Dk. Maple Trim Combination - Dk. Maple, Striped Vinyl Trim Combination - Dk. Maple, Dual Grain Vinyl Primary Color - Med. Rosewood Metallic Trim Combination - Med. Dk. Grey Velour Cloth Trim Combination - Med. Dk. Grey Cloth Interior Trim - Med. Dk. Grey Trim Combination - Dk. Grey, Dual Grain Vinyl Color Combination - Med. Grey (Auxiliary Top) Secondary Color - Grey Metallic Primary Color - Grey Metallic Primary Color - Lt. Driftwood Pearlmist Color Combination - Cardinal Red OA-18 GENERAL INFORMATION OB-1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS SUBJECT PAGE Capacities......................................................................................................................................................................... 08-1 Lubrication....................................................................................................................................................................... 08-6 Maintenance S cheduie...................................................................................................................................................OB-7 CAPACITIES Figures 2 through 6 show the approximate capacities of the differential 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. ENGINE DESCRIPTION VIN Engine Code Liter Displacement Z H K M N W T C J 4.3 5.0 5.7 5.7 7.4 7.4 4.8 6.2 6.2 Type Fuel System Produced In V6 V8 V8 V8 V8 V8 L6 V8 V8 TBI TBI TBI 4 BBL TBI 4 BBL 1 BBL F.l. @ F.l. @ USA USA, Can. USA, Can. USA, Can. USA USA Mexico USA USA Figure 1— 1987 Engine Code Identification Metric Measure Items U.S. Measure Differential 8 V2" Ring Gear 9 V2" Ring Gear IOV2" Ring Gear (Chev.) 93/4" Ring Gear (Dana) 12 Ring Gear (Rockwell) Transmission Automatic 400 — Pan Removal Overhaul 700-R4 — Pan Removal Overhaul Manual 4 Speed 117 mm 4 Speed 89 mm 3 Speed 76 mm 2.0 3.1 3.1 2.8 5.9 L L L L L 4.2 pts. 6.5 pts. 6 V2 pts. 6.0 pts. 12.5 pts. 4.0 L 10.0 L 4.7 L 10.9 L 9.0 pts. 10.0 pts. 23.0 pts. 4.0 L 4.0 L 1.5 L 4.2 qts. 4.2 qts. 1.6 qts. 22.0 pts. Figure 2—Approximate Capacities—All Models OB-2 MAINTENANCE AND LUBRICATION CAPACITIES Items Cooling System (Approx.)▲ Code: H, K, M Without A/C With A/C Code: N Without A/C With A/C Diesel Engines Code: C, J With or Without A/C Crankcase* Gasoline Engines Code: H, K and M Without Filter With Filter Code: N Without Filter With Filter Diesel Enginesf Code: C, J With Filter Metric Measure U.S. Measure 16.5 Liters 17 Liters 17.5 Quarts 18 Quarts 22 Liters 23 Liters 23 Quarts 24.5 Quarts 23 Liters 25 Quarts 3.8 Liters 4.8 Liters 4 Quarts 5 Quarts 4.8 Liters 5.7 Liters 5 Quarts 6 Quarts 6.5 Liters 7 Quarts Fuel Tank (Approx.) Standard, All — Gas — Diesel NK7 Option, All — Gas — Diesel NE2 Option, Suburban Only — Gas — Diesel 95 Liters 102 Liters 117 Liters 121 Liters 25 27 31 32 151 Liters 155 Liters 40 Gallons 41 Gallons Front Axle V15/10-V25/20 V35/30 1.9 Liters 2.8 Liters 2 Quarts 3 Quarts Transfer Case V15/10-V25/20 V35/30 4.9 Liters 2.4 Liters 5.2 Quarts 2.5 Quarts Gallons Gallons Gallons Gallons • After refill, fluid level must be checked as outlined under “ Service and Maintenance,” in Section 5 of this manual, t Oil filter should be changed at EVERY oil change. A Equipped with Auxiliary Heater add 2.68L/2.84 Qts. Figure 3—Approxim ate C apacities-B lazer/Jim m y, Suburban MAINTENANCE AND LUBRICATION OB-3 CAPACITIES Items Cooling System (approx.) 4.8L (L6) Engine Code T P30042 Models With or Without A/C 5.7L (V8) Engine Code M, K P30042 Models With or Without A/C 7.4 L (V8) Engine Code W P30032 Models Without A/C 6.2L (V8) Diesel Engine Code J P30042 Models With or Without A/C P30032 Models Without A/C Crankcase (approx.)* Engine Code: M, K Without Filter With Filter Engine Code: T Without Filter With Filter Engine Code: W Without Filter With Filter Engine Code: J f With Filter Fuel Tank Data P25-35 P30042 School Bus P30032 Motor Home* Metric Measure U.S. Measure 13.1 Liters 13.8 Quarts 14.6' Liters 15.5 Quarts 21.2 Liters 22.5 Quarts 23.5 Liters 25 Quarts 23.4 Liters 24.7 Quarts 3.8 Liters 4.8 Liters 4 Quarts 5 Quarts 4.8 Liters 5.7 Liters 5 Quarts 6 Quarts 5.7 Liters * 6.5 Liters 6 Quarts 7 Quarts 6.5 Liters 7 Quarts 151 Liters 151 Liters 151 Liters 40 Gallons 40 Gallons 40 Gallons * After refill, fluid level should be checked as outlined under “ Service and Maintenance,” in Section 5 of the Owner’s Manual. t Oil Filter should be changed at EVERY oil change. • Optional 60 gallon fuel tank available. Figure 4—Approxim ate C apacities-Forw ard Control OB-4 MAINTENANCE AND LUBRICATION CAPACITIES Items Cooling System (Approx.) Code: Z - V6 With or Without A/C Code: H, K—V-8 Without A/C With A/C Code: N-V-8 Without A/C With A/C Diesel Engines Code: C, J With or Without A/C CrankcaseA Gasoline Engines Code: H, K, Z Without Filter With Filter Code: T Without Filter With Filter Code: N Without Filter With Filter Diesel Engines! Code: C, J Metric Measure U.S. Measure 10.3 Liters 10.9 Quarts 16.5 Liters 17 Liters 17.5 Quarts 18 Quarts 22 Liters 23 Liters 23 Quarts 24.5 Quarts 23 Liters 25 Quarts 3.8 Liters 4.8 Liters 4 Quarts 5 Quarts 4.8 Liters 5.7 Liters 5 Quarts 6 Quarts 4.8 Liters 5.7 Liters 5 Quarts 6 Quarts 6.5 Liters 7 Quarts Fuel Tank (Approx.) Long Bed Single Tank, Gas @*Dual Tanks, Gas Single Tank, Diesel *Dual Tanks, Diesel 76 61 76 76 Front Axle V15/10-V25/20 V35/30 1.9 Liters 2.8 Liters 2 Quarts 3 Quarts Transfer Case V15/10-V25/20 V-35/30 4.9 Liters 2.4 Liters 5.2 Quarts 2.5 Quarts Liters Liters Liters Liters 20 16 20 20 Gallons Gallons Gallons Gallons AAfter refill, fluid level must be checked as outlined under “ Service and Maintenance,” in Section 5 of the Owner’s Manual, t Oil filter should be changed at EVERY oil change. * Listed quantity is for each tank. @Above 8600 GVWR — Both tanks 76 liters, 20 gallons. Figure 5—Approxim ate C apacities-P ickup Models MAINTENANCE AND LUBRICATION OB-5 CAPACITIES Metric Measure US Measure 10.5 L 11 Qts. 16'L 16 L 23 L 24.2 L 17 Qts. 17 Qts. 24 Qts. 25.5 Qts. Crankcase (Approx.)* All engines except diesel Without Filter With Filter Diesel Engines — With Filter 3.8 L 4.8 L 6.5 L 4 Qts. 5 Qts. 7 Qts. Fuel Tank (Approx.) Gasoline and Diesel Engines Standard Optional 83 L 125 L 22 Gal. 33 Gal. Item Cooling System (Approx.)A 4.3 L (Z) V8’s Except Diesel Without A/C With A/C 6.2 L (C) Diesel 6.2 L (J) Diesel * After refill, fluid level should be checked as outlined under “ Service and Maintenance” Section 5 of the Owner’s Manual. A If equipped with Auxiliary Heater add 2.68L/2.84 Qts. t Oil Filter should be changed at EVERY oil change. Figure 6—Approxim ate C apacities-G Van OB-6 MAINTENANCE AND LUBRICATION LUBRICATION Figures 7, 8 and 9 show chassis lubrication points for the R, V, G and P chassis. 1. 2. 3. 4. 5. 6. 7. 8. L ow er C o n tro l A rm s U p p e r C o n tro l A rm s U p p e r and L o w e r C o n tro l A rm Ball J o in ts In te rm e d ia te S te e rin g S h a ft (PA10) T ie Rod E nds W h e el B e a rin g s S te e rin g G ear A ir C le a n e r - E le m e n t 9. M a s te r C y lin d e r 10. T ra n s m is s io n - M an ua l - A u to m a tic 11. T h ro ttle B ell C ra n k - L6 12. C a rb u re to r L in k a g e - V8 13. Brake and C lu tc h Pedal S p rin g s 14. U nive rsa l J o in ts 15. Rear A x le F-00433 F igure 7— L u b ric a tio n P o ints For The C on ven tion a l A nd F orw ard C o n tro l M odels 1. 2. 3. 4. 5. 6. 7. A ir C le a n e r C o n tro l L in k a g e P o in ts T ie Rod E nds W h e el B e a rin g s S te e rin g G ear M a s te r C y lin d e r T ra n s m is s io n - M an ua l - A u to m a tic 8. 9. 10. 11. 12. 13. 14. 15. C a rb u re to r L in k a g e - V8 U nive rsa l J o in ts P ro p e lle r S h a ft S lip J o in ts F ro n t and Rear A x le Drag L in k Brake and C lu tc h Pedal S p rin g s T ra n sfer C ase T h ro ttle B ell C ra nk - L6 F-00434 Figure 8—Lubrication Points For The RV Four Wheel Drive Models MAINTENANCE AND LUBRICATION OB-7 1 1. C o n tro l A rm B u s h in g s and Ball J o in ts 2. T ie Rod E nds 3. W h e el B e a rin g s 4. S te e rin g G e ar C lu tc h C ro s s -S h a ft 5 11 5. T ra n s m is s io n C o n tro l S h a ft 6. A ir C le a n e r - E le m e n t 7. T ra n s m is s io n - M anual - A u to m a tic 8. 9. 10. 11. Rear A x le O il F ilte r Brake M a s te r C y lin d e r P arking Brake L in k a g e F-00435 Figure 9—Lubrication Points For The G Van The information shown on pages OB-8 through OB-25 is the same as shown in the 1987 Light Duty Maintenance Schedule and Log. 1987 GENERAL MOTORS LIGHT DUTY TRUCK MAINTENANCE SCHEDULES This booklet covers the maintenance required for your General Motors vehi­ cle. 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 truck dealer or any other qualified automotive service or repair establishment 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 with the vehicle when sold. The maintenance record, plus maintenance receipts, may be needed for warranty repairs. It is suggested that receipts be kept with this booklet. OB-8 MAINTENANCE AND LUBRICATION SELECTING YOUR VEHICLE’S MAINTENANCE DETERMINING VEHICLE EMISSIONS CLASSIFICATION To determine the emissions classification for your vehicle, refer to the “ En­ gine Emission Classification by VIN Code” chart. This chart classifies your engine as a Light Duty Emissions Engine or Heavy Duty Emissions Engine using the engine code identifier of the Vehicle Identification Number (VIN). The VIN is located on the plate on the top left corner of the instrument panel. (It is also on the Certification Label and the Service Parts Identification Label.) The Engine Code is the eighth character in this number. Locate your vehicle’s Engine Code on the following Engine Emission Classification Chart to determine your vehicle’s emissions class. ENGINE EMISSION CLASSIFICATION BY VIN CODE Engine D escription Engine D ispl./Type 2.5L L4rTBI 2.8L V6/TBI 4.3L V6/TBI 4.8L L6/Carbureted 5.0L V8/TBI 5.7L V8/TBI 5.7L V8/Carbureted 6.2L V8/Diesel 6.2L V8/Diesel 7.4L V8/TBI 7.4L V8/Carbureted VIN Code RPO L ight Duty Em issions LN8 LL2 LB4 L25 L03 L05 LT9 LL4 LH6 L19 LE8 NOTE: TBI is a throttle body injection system. Heavy Duty Em issions E R Z T H K M J C N W MAINTENANCE AND LUBRICATION OB-9 SELECTING THE PROPER MAINTENANCE CHART Select the proper maintenance from pages 6 through 13 depending on your vehicle’s engine (gas or diesel) and engine emissions classification. 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 circle (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 outside tem­ peratures remain below freezing. • Towing a trailer. • Operating in dusty areas. • Idling and/or low-speed operation in stop-and-go traffic. NOTE: Schedule 1 should also be followed if the vehicle is used for delivery service, police, taxi, or other commercial applications. MAINTENANCE SCHEDULE 2 Follow Maintenance Schedule 2 denoted by a black circle ( • ) only if none of the driving conditions specified in Maintenance Schedule 1 apply. 0B-10 SECTION A -S C H E D U LE D MAINTENANCE SERVICES FOR YOUR 1987 VEHICLE Item Miles (000) No. Service Kilometers (000) 3 6 9 12 5 10 o o# 15 20 o om Oil Filter Change * o 0* o o 2A Chassis Lubrication o 0# o om 1 Engine Oil Change * o Maintenance Schedule 1 • Maintenance Schedule 2 15 18 21 24 27 30 25 30 35 40 45 50 o o # o om o o « o o# o o o om o o* o o» om 33 36 55 60 o o* o o o om 39 42 65 70 o o# o om o om 45 48 75 80 o om o o o om om 2B Clutch Fork Ball Stud 3 Engine Idle Speed Adjustment * - At First 6 Months or, o - Refer to Page 9 - Refer to Page 9 o 09 om om om 5 Air Cleaner, A.I.R. and PCV Filter Replacement A * om o om om o om o om o om 7 Transmission Service - Refer to Section B for Service Intervals 8A PCV System Inspection * 9 Fuel Filter Replacement * o om o om o om o o o o om om 11 Vacuum Advance System Inspection * o«1 o#1 om2 o«1 o*1 O * 1'2 o»2 13 Spark Plug Wire Inspection * 14 EGR System Inspection * o*1 o#1 16 Engine Timing Check * A o* o* FOOTNOTES: * An Emission Control Service A Also a Noise Emission Control Service ■ Applicable only to vehicles sold in the United States t To determine the emissions classification of your engine refer to page 4. 1. For vehicles using leaded fuel. 2. For vehicles using unleaded fuel. 60 100 om 10 Carburetor Choke and Hoses Inspection * 12 Spark Plugs * 57 95 o om o 4 Cooling System Service * - Every 24 Months or 6 Front Wheel Bearing Repack 51 54 85 90 o om o om om The maintenance services contained in Maintenance Schedule 1 and 2 are based on the assumption that your vehicle will be used as designed: • To carry passengers and cargo within the limits shown on the tire placard located on the edge of the driver’s door. • On reasonable road surfaces within legal driving limits. • With the proper fuels specified for your vehicle. MAINTENANCE AND LUBRICATION The services shown in this schedule up to 60,000 miles (100 000 km) are to be performed after 60,000 miles (100 000 km) at the same intervals. WITH HEAVY DUTY EMISSIONS - GASOLINE ENGINES t (Continued SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR 1987 VEHICLE WITH HEAVY DUTY EMISSIONS - GASOLINE ENGINES t The services shown in this schedule up to 60,000 miles (100 000 km) are to be performed after 60,000 miles (100 000 km) at the same intervals. Miles (000) 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 Kilometers (000) 5 10 15 20 25 30 35 40 o 45 50 55 60 65 70 75 80 o 85 90 95 100 Item No. Service o Maintenance Schedule 1 - Refer to Page 9 • Maintenance Schedule 2 - Refer to Page 9 17 Fuel Tank, Cap and Lines Inspection * 18 Early Fuel Evaporation System Inspection * 19 Thermostatically Controlled Air Cleaner Inspection * A 20 Engine Accessory Drive Belts Inspection * o om om om om om o om om om o 09 om om om om 23 Air Intake System Inspection A ■ 24 Thermostatically Controlled Engine Cooling Fan Check A " - Every 12 Months or om o« o o om om 21 Evaporative Control System Inspection * 22 Shields and Underhood Insulation Inspection A ■ 09 om om om om 25 Manifold Heat Valve Check A * o om o om o 26 Idle Speed Control Device * - Every 12 Months or o om o om o 27 Throttle Return Control Check * — Every 12 Months or o om o om 28 Engine Idle Mixture Adjustment (4.8 L only) * 29 Governor Check A ■ - Every 48 Months or o om om 31 Tire Rotation - Refer to Section B for Service Intervals FOOTNOTES: * An Emission Control Service ▲ Also a Noise Emission Control Service ■ Applicable only to vehicles sold in the United States t To determine the emissions classification of your engine refer to page 4. 1. For vehicles using leaded fuel. 2. For vehicles using unleaded fuel. The maintenance services contained in Maintenance Schedule 1 and 2 are based on the assumption that your vehicle will be used as designed: • To carry passengers and cargo within the limits shown on the tire placard located on the edge of the driver’s door. • On reasonable road surfaces within legal driving limits. • With the proper fuels specified for your vehicle. MAINTENANCE AND LUBRICATION om OB-11 1987 VEHICLE WITH A 6.2 L DIESEL ENGINE t Miles (000) No. Service Kilometers (000) 1 Engine Oil Change * Oil Filter Change * 2A Chassis Lubrication 2B Clutch Fork Ball Stud 3 Engine Idle Speed Adjustment * 4 Cooling System Service * — Every 24 Months or 2.5 5 4 8 7.5 12 o o# o o» o 09 o o o o Maintenance Schedule 1 - Refer to Page 9 • Maintenance Schedule 2 • Refer to Page 9 10 12.5 15 16 20 24 09 09 09 o o o 09 17.5 20 22.3 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 60 28 32 36 40 44 48 52 56 60 64 68 72 76 80 84 88 92 96 o 09 o o « o 09 o o # o 09 o o # o 09 o o # o 09 09 o 09 o 09 o 09 o o# o 09 o 09 o 09 o o* o 09 09 o o 09 o 09 o o o o o o 09 09 o«1 5 Air Cleaner Element Replacement* 2 6 Front Wheel Bearing Repack 09 09 09 09 09 09 O *1 09 09 09 o«1 09 O• O 09 O 09 7 Transmission Service - Refer to Section B for Service Intervals 8B CDRV System Inspection * 09 20 Drive Belts Inspection 09 22 Shields and Underhood Insulation Inspection ■ ▲ 09 09 09 09 09 09 23 Air Intake System Inspection ■ ▲ 09 09 09 09 09 09 24 Thermostatically Controlled Engine Cooling Fan Check « A —Every 12 Months or 09 09 09 09 09 09 30 Exhaust Pressure Regulator Valve Inspection * 09 31 Tire Rotation - REfer to Section B for Service Intervals FOOTNOTES: 1. In California, thes6 are the minimum Emission Control Maintenance Services an owner must perform according to the California Air Resources Board. General Motors, how­ ever, urges that all Emission Control Maintenance Services shown be performed. To maintain your other new vehicle warranties, all services shown in this booklet should be performed. 2. For vehicles with engine VIN Code J (RPO LL4), replace element every 15,000 miles (24 000 km). * An Emission Control Service ■ Applicable only to trucks sold in the United States. ▲ Also, a Noise Control Service (applicable to vehicles with engine VIN Code J (RPO LL4). t This maintenance schedule applies to all diesel emission classifications. NOTE: Refer to Section 0 of your owner’s manual for VIN code identification information. The maintenance services contained in Maintenance Schedule 1 and 2 are based on the assumption that your vehicle will be used as designed: • To carry passengers and cargo within the limits shown on the tire placard located on the edge of the driver’s door. • With No. 1, blend or No. 2 grade diesel fuel. • On reasonable road surfaces within legal driving limits. MAINTENANCE AND LUBRICATION The services shown in this schedule up to 60,000 miles (100 000 km) are to be performed after 60,000 miles (100 000 km) at the same intervals. Item OB-12 SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR 1987 VEHICLE WITH LIGHT DUTY EMISSIONS - GASOLINE ENGINES t SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR The services shown in this schedule up to 60,000 miles (100 000 km) are to be performed after 60,000 miles (100 000 km) at the same intervals. Miles (000) 3 6 7.5 9 12 Item Kilometers (000) 5 10 12.5 15 20 No. Service 1 Engine Oil Change * Oil Filter Change * 2A Chassis Lubrication o o o o o o • • • o o o o o o o Maintenance Schedule 1 • Maintenance Schedule 2 15 18 21 22.5 24 27 30 25 30 35 37.5 40 45 50 - Refer - Refer 33 36 55 60 o o 09 o o • o o 09 O o o • o o O o o 09 o o • o o 09 o o 2B Clutch Fork Ball Stud 4 Cooling System Service * — Every 24 Months or to Page 9 to Page 9 37.5 39 42 45 48 51 52.5 54 57 60 62.5 65 70 75 80 85 87.5 90 95 100 • o o 09 • o o O • o o 09 o • o o o • o o o o« o o o o • o o o* 09 09 09 09 O o«1 5 Air Cleaner Element* O 6 Front Wheel Bearing Repack O O# 09 7 Transmission Service - Refer to Section B for Service Interval 8A PCV System Inspection * 09 12 Spark Plugs * 09 o«1 09 13 Spark Plug Wire Inspection* 09 15 Electronic Vacuum Regulator Valve (EVRV) Inspection * 09 09 16 Engine Timing Check * O 17 Fuel Tank, Cap and Lines Inspection * 09 09 20 Engine Accessory Drive Belts Inspection * 31 Tire Rotation o • o FOOTNOTES: 1. In California, these are the minimum Emission Control Maintenance Services an owner must perform according to the California Air Resources Board. General Motors, how­ ever, urges that all Emission Control Maintenance Services shown be performed. To maintain your other new vehicle warranties, all services shown in this booklet should be performed. * An Emission Control Service t To determine the emissions classification of your engine refer to page 4. • o • o 09 o • o 9 o • o 09 The maintenance services contained in Maintenance Schedule 1 and 2 are based on the assumption that your vehicle will be used as designed: • To carry passengers and cargo within the limits shown on the tire placard located on the edge of the driver’s door. • On reasonable road surfaces within legal driving limits. • With unleaded fuel. MAINTENANCE AND LUBRICATION 9 Fuel Filter Replacement * O OB-13 OB-14 MAINTENANCE AND LUBRICATION SECTION B — EXPLANATION OF SCHEDULED MAINTENANCE SERVICES The services listed in the preceding Maintenance Schedules are further explained below. After services are completed, fill in the Maintenance Record at the end of this booklet. When the following maintenance services are per­ formed, make sure all parts are replaced and all necessary repairs are done before operating your vehicle. Be sure to use the proper fluids and lubricants as shown in Section E. Item No. 1. ENGINE OIL AND OIL FILTER CHANGE * — ALWAYS USE SF/CC or SF/CD QUALITY, ENERGY CONSERVING OILS OF THE PROPER VISCOSITY Also always change oil and filter as soon as possible after driving in a dust storm. Refer to Section 5 of your Owner’s Manual for further details. 2A. CHASSIS LUBRICATION — Lubricate the front suspension (except when equipped with “ maintenance-free” ball joint), steering linkage, transmission, clutch, and transfer case shift linkage, parking brake ca­ ble guides, propshaft, universal joints, brake pedal springs, and clutch pedal springs. On vehicles without hydraulic clutches lubricate clutch cross shaft every 30,000 miles (50 000 km). 2B. CLUTCH FORK BALL STUD — Refer to the Service Parts Identifica­ tion Label located on the inside of the glove box. Match the three digit/ RPO code to the appropriate RPO code below. Follow the maintenance as detailed for your particular vehicle. RPO codes: MC0, MG5, M20, MY6, M62, M64 — Lubricate the clutch fork ball stud through the fitting on the clutch housing found on some models. Lubricate this bail stud “ sparingly,” as too much lubrication may cause problems with the clutch assembly. 3. ENGINE IDLE SPEED ADJUSTMENT (CARBURETED ENGINES ONLY) * — Adjust to the specifications shown on the underhood label. You must use calibrated test equipment. Check that idle stop solenoid or dashpot work properly (if so equipped). 4. COOLING SYSTEM SERVICE * — Drain, flush and refill system with new coolant. Refer to Section 5 of your Owner’s Manual for further details. 5. AIR CLEANER ELEMENT REPLACEMENT, A.I.R. AND PCV FILTER REPLACEMENT (SOME MODELS) * — Replace at specified intervals. Replace more often under dusty conditions. Ask your dealer for the proper replacement intervals for your driving conditions. 6. FRONT WHEEL BEARING REPACK — Clean and repack the front wheel bearings at each brake relining, or at the specified interval, whichever comes first. * An Emission Control Service 14 MAINTENANCE AND LUBRICATION OB-15 7. TRANSMISSION SERVICE A utom atic Transm ission — Change the transmission fluid and filter every 15,000 miles (25 000 km) for vehicles under 8600 GVWR or every 12.000 miles (20 000 km) for vehicles over 8600 GVWR if the vehicle is mainiy driven under one or more of these conditions: • In heavy city traffic where the outside temperature regularly reaches 90°F (32°C) or higher. • In hilly or mountainous terrain. • Frequent trailer pulling. • Uses such as taxi, police, delivery or other commercial service. If the vehicle is not used mainly under any of these conditions, change the fluid and filter every 30,000 miles (50 000 km) for vehicles under 8600 GVWR or every 24,000 miles (40 000 km) for vehicles over 8600 GVWR. Refer to Section 5 of your Owner’s Manual for further details. Manual Transm ission — Refer to the Service Parts Identification Label located on the inside of the glove box. Match the three digit/RPO code to the appropriate RPO code below. Follow the maintenance schedule recommended for your particular transmission. RPO Code: M73 (4-Speed) — Change transmission fluid at 7,500 miles (12 500 km), then every 30.000 miles (50 000 km). RPO Codes: M62 and M64 (3-Speed) M20, MCO, MC9, and MF2 (4-Speed) MY6 (4-Speed Overdrive) ML2, ML3, MH3 (5-Speed) MG5 (5-Speed Overdrive) — Transmission fluid does not require periodic changing. 8A. PCV SYSTEM INSPECTION * — Check that PCV (Positive Crankcase Ventilation) system works properly. Replace the valve and any worn, plugged or collapsed hoses as necessary. 8B. CDRV System Inspection * — Check the Crankcase Depression Reg­ ulator Valve System for any worn, plugged or collapsed hoses. Have the system checked as described in the Service Manual. 9. FUEL FILTER REPLACEMENT * — Replace the fuel filter at the speci­ fied interval or sooner if clogged. 10. CARBURETOR CHOKE AND HOSES INSPECTION * — Verify that choke and vacuum break work properiy and within specifications. Cor­ rect any binding caused by damage or gum on the choke shaft. Inspect hoses for proper hookup, cracks, chafing, or decay. Correct as neces­ sary. * An Emission Control Service 15 OB-16 MAINTENANCE AND LUBRICATION 11. VACUUM ADVANCE SYSTEM INSPECTION * — Check that the systern works properly. Check hoses for proper hookup, cracks, chafing or decay. Replace parts as needed. 12. SPARK PLUGS * — Replace spark plugs with the type listed in Sec­ tion 6 of your Owner’s Manual. 13. SPARK PLUG WIRE INSPECTION * — Clean wires and inspect for burns, cracks or other damage. Check the wire boot fit at the distributor and at the spark plugs. Replace wires as needed. 14. EGR SYSTEM INSPECTION * — Conduct EGR SYSTEM CHECK as referenced in the Maintenance and Lubrication Section of the Service Manual. 15. ELECTRONIC VACUUM REGULATOR VALVE (EVRV) INSPECTION * — Inspect filter for excessive contamination or plugging. If required, clean element with a solution of biodegradable soap and water, let dry and reinstall element. 16. ENGINE TIMING CHECK AND DISTRIBUTOR CHECK (SOME MODELS)* — Adjust timing to underhood label specifications. Inspect the inside and outside of the distributor cap and rotor for cracks, carbon tracking and corrosion. Clean or replace as needed. 17. FUEL TANK, CAP AND LINES INSPECTION * — Inspect the fuel tank, cap and lines for damage or leaks. Remove fuel cap, inspect gasket for an even filler neck imprint, and any damage. Replace parts as needed. 18. EARLY FUEL EVAPORATION (EFE) SYSTEM INSPECTION * — Check that valve works properly; correct any binding. Check that ther­ mal vacuum switch works properly. Check hoses for cracks, chafing, or decay Replace parts as needed. 19. THERMOSTATICALLY CONTROLLED AIR CLEANER INSPECTION * ▲ — (If so equipped.) Inspect all hoses and ducts for proper hookup. Make sure valve works properly. 20. ENGINE ACCESSORY DRIVE BELTS INSPECTION * — Inspect belts. Look for cracks, fraying, wear, and proper tension. Adjust or replace as needed. 21. EVAPORATIVE CONTROL SYSTEM (ECS) INSPECTION * — Check all fuel and vapor lines and hoses for proper hookup, routing, and con­ dition. Check that bowl vent and purge valves work properly, if equipped. Remove canister, and check for cracks or damage. Replace as needed. 22. SHIELDS AND UNDERHOOD INSULATION INSPECTION A ■ — In­ spect shields and underhood insulation for damage or looseness. Ad­ just or replace as required. * An Emission Control Service AAlso a Noise Emission Control Service ■ Applicable only to vehicles sold in the United States 16 MAINTENANCE AND LUBRICATION OB-17 23. AIR INTAKE SYSTEM INSPECTION — Check the air intake system installation to see that gaskets are seated properly and all hose connections, fasteners, and other components are tight. Also check to be sure that the air cleaner housing is properly seated, that the cover fits tightly, and the wingnut(s) is tight. Tighten connections and fasten­ ers or replace damaged parts as required. 24. THERMOSTATICALLY CONTROLLED ENGINE COOLING FAN IN­ SPECTION A ■ — (If so equipped.) With the engine o ff and below normal operating temperature, check to see that the fan can be rotated by hand on fluid coupling or viscous drives. Replace as necessary. 25. MANIFOLD HEAT VALVE CHECKA ■ — Some engines are equipped with a manifold heat valve which should be inspected and repaired as necessary to insure free operation. 26. IDLE SPEED CONTROL DEVICE * — Check that parts work properly. Replace them as needed. 27. THROTTLE RETURN CONTROL (TRC) SYSTEM INSPECTION * Inspect hoses for proper connections, cracking, abrasion, or deteriora­ tion and replace as necessary. Check for proper operation of system. Check for shorted or broken wires and ensure electrical connectors are fully engaged at distributor, speed switch and vacuum solenoid. 28. ENGINE IDLE MIXTURE ADJUSTMENT (4.8 L ONLY) * — At desig­ nated intervals or in case of a major carburetor overhaul, or when poor idle quality exists, adjust mixture by a mechanical method (lean drop), following the specifications shown on the label under the hood. 29. GOVERNOR CHECK A > — (If so equipped). Check the engine noload governed speed and reset to specifications as required. 30. EXHAUST PRESSURE REGULATOR VALVE INSPECTION * — Check that valve works properly. Correct any binding. Inspect hoses for cracks, chafing or decay. Replace parts as needed. 31. TIRE ROTATION AND WHEEL INSPECTION — Rotate your tires at the specified maintenance service interval as follows: Schedule 1 (O) — Every 6,000 miles (10 000 km). Schedule 2 ( • ) — Every 7,500 miles (12 500 km). Inspect tires and wheels for abnormal wear or damage. Refer to Sec­ tion 5, “ Tires” in your Owner’s Manual for further information. For dual wheels, whenever the vehicle, wheels, or fasteners are new, have the wheel fastener torque set at the first 100,1,000, and 6,000 miles (160, 1 600, and 10 000 km). * An Emission Control Service AAlso a Noise Emission Control Service ■ Applicable only to vehicles sold in the United States 17 OB-18 MAINTENANCE AND LUBRICATION SECTION C — OWNER INSPECTIONS AND SERVICES Listed below are inspections and services which should be made by either you or a qualified technician at the intervals shown to help ensure proper safety, emission performance and dependability of your vehicle. Take any problems promptly to your dealer or another qualified technician for service advice. Whenever repairs are necessary, have them completed at once. For your safety and that of others, any safety-related parts that could have been damaged in an accident should be inspected, and all needed repairs should be done before operating your vehicle. Be sure to use the proper fluids and lubricants as shown in Section E. WHILE OPERATING YOUR VEHICLE Autom atic transm ission sh ift indicator operation — Make sure the indi­ cator points to the gear chosen. Horn operation — Blow the horn occasionally to make sure it works. Check all button locations. Brake system operation — Be alert to abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if a brake warning light goes on, something may be wrong with part of the brake sys­ tem. Exhaust system — Be alert to any changes in the sound of the system or any smell of fumes. These are signs the system may be leaking or overheat­ ing. Have it inspected and repaired at once. Also, refer to Section 2 “ Engine Exhaust Gas Caution (Carbon Monoxide),” and Section 5 “ Catalytic Con­ verter” in your Owner’s Manual. Tire and wheel — Be alert to a vibration of the steering wheel or 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 need for a tire pressure adjustment or wheel alignment. Steering system operation — Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn or has too much free play or if abnormal sounds are noted when turning or parking. Headlight aim — Take note of the light pattern occasionally. If beam aim doesn’t look right, headlights should be adjusted. AT EACH FUEL FILL Engine oil level check t — Check engine oil level and add if necessary. Refer to Section 5 of your Owner’s Manual for further details. t A large loss in these systems may indicate a problem. Have them in­ spected and repaired at once. 18 MAINTENANCE AND LUBRICATION OB-19 Engine coolant level ana co ndition f — Check engine coolant level in coolant reservoir tank and add if necessary. Replace if dirty or rusty. Refer to Section 5 of your Owner’s Manual for further details. W indshield washer flu id level check — Check washer fluid level in con­ tainer and add if necessary. Hood latch operation — When opening hood, note the operation of sec­ ondary latch. It should keep hood from opening all the way when primary latch is released. Make sure that hood closes firmly. AT LEAST MONTHLY Tire pressure check and wheel inspection — Keep pressures as shown on Tire Placard on the driver’s door (including spare). Pressure should be checked when tires are cold. Inspect tires and wheels for abnormal wear or damage. Refer to Section 5, “ Tires” inyour Owner’s Manual for further infor­ mation. L ight operation check — Check operation of license plate light, side marker light, headlights including high beams, parking lights, taillights, brake lights, turn signals, backup lights, instrument panel illumination and hazard warning flashers. Fluid leak check — After the vehicle has been parked for a while, inspect the surface beneath the vehicle for water, oil, fuel or other fluids. Water drip­ ping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, the cause should be found and corrected at once. AT LEAST TWICE A YEAR (FOR EXAMPLE, EVERY SPRING AND FALL) Power steering pump level check t — Check power steering pump fluid in accordance with the instructions in Section 5 of your Owner’s Manual and add fluid if necessary. Brake m aster cylinder reservoir flu id level check t — Check fluid level in accordance with the instructions in Section 5 of your Owner’s Manual, and add fluid if necessary. A low fluid level can indicate that worn disc brake pads may need to be serviced. Clutch pedal free travel (except hydraulic clutch) — Check the clutch pedal free travel. The free travel should be about one inch. Adjust linkage whenever there is little or no free travel. Key lock cylinder — Lubricate key iock cylinders. Lock deicers which con­ tain alcohol may wash away lubricants. It is recommended that you lubricate the lock cylinder after you have used a deicer of this type. Refer to Section E in this booklet for the proper luDricants. t A large loss in these systems may indicate a problem. Have them in­ spected and repaired at once 19 0B-20 MAINTENANCE AND LUBRICATION W eatherstrip lubrication — Clean surface and then apply a thin film of silicone grease with a clean cloth. EACH TIME OIL IS CHANGED Autom atic or manual transm ission flu id level check f — Check trans­ mission fluid level and add as required. Refer to Section 5 of your Owner’s Manual for further details. Steering and suspension t — Inspect front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hookup, bind­ ing, leaks, cracks, chafing, etc. (On vehicles equipped with manual steering gear, check for seal leakage.) Inspect final drive axle output shaft seals for leaking. Brake systems inspection — For convenience the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect disc brake pads for wear and rotors for surface condition. Also inspect drum brake linings for wear and cracks. Inspect other brake parts, including drums, wheel cylinders, parking brake, etc. at the same time. Check parking brake adjustment. In­ spect brakes more often if driving habits or conditions result in frequent braking. Exhaust system inspection * — Inspect complete system including cata­ lytic converter. Inspect body near the exhaust system. Look for broken, dam­ aged, missing or out-of-position parts, as well as, open seams, holes, loose connections or other conditions which could cause a heat buildup in the floor pan or could let exhaust fumes seep into the passenger compartments. T hrottle linkage inspection — Inspect for interference, binding, damaged or missing parts. Replace parts as needed. Engine drive belts inspection — Inspect all belts for cracks, fraying, wear and proper tension. Adjust or replace as needed. Axle rear/front, transfer case (four-wheel drive) — Refer to Section 0 in your Owner’s Manual to determine the GVWR for your vehicle. Check fluid level and add if needed. • Locking differential - under 8600-lbs. GVWR — Drain fluid at first oil change and refill. Check fluid level and add as needed at subsequent oil changes. In dusty areas, or trailer towing applications drain fluid at every oil change and refill, f • Locking differential - over 8600-lbs. GVWR — Drain fluid at first oil change and refill. Change fluid at every other oil change and check and add fluid at subsequent oil changes. In dusty areas, or trailer towing applications, drain fluid at every oil change and refill as specified, f t A large loss in these systems may indicate a problem. Have them in­ spected and repaired at once. * An Emission Control Service 20 MAINTENANCE AND LUBRICATION OB-21 • Standard d ifferential - under 8600-lbs. GVWR — Check fluid level and add as needed at every oil change. In dusty areas, or trailer towing applications, drain fluid every oil change and refill, t • Standard d ifferential - over 8600-lbs. GVWR — Drain fluid every fourth oil change and refill. Check fluid level and add as needed at every oil change. In dusty areas, or trailer towing applications, drain fluid at every oil change and refill, f • Transfer case (four-wheel drive) — Every 12 months or at oil change intervals, check front axle and transfer case and add lubricant when necessary. Lubricate propeller shaft slip joint, constant velocity univer­ sal joint and steering linkage. Oil the control lever pivot point and all exposed control linkage. Check vent hose at transfer case for kinks and proper installation. More frequent lubrication may be required on heavy-duty off-road use. t AT LEAST ONCE A YEAR Starter safety sw itch operation — CAUTION: Before perform ing the follow ing safety sw itch check, be sure to have enough room around the vehicle. Then, firm ly apply both the parking brake (see your O wner’s Manual fo r procedure) and the regular brakes. Do not use the accelerator pedal. If the engine starts, be ready to turn o ff the ig nition prom ptly. Take these precautions because the vehicle could move w ith o ut warning and possibly cause personal injury or property damage. • On automatic transmission vehicles, try to start the engine in each gear. The starter should crank only in “ Park” or “ Neutral.” • On manual transmission vehicles place the shift lever in “ Neutral,” push the clutch halfway and try to start. The starter should crank only when the clutch is fully depressed. Steering colum n lock operation — While parked, try to turn key to “ Lock” position in each gear range. The key should turn to “ Lock” only when 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” without depressing the lever. The key should turn to “ Lock” only with the key lever depressed. On all vehicles, the key should come out only in “ Lock.” t A large loss in these systems may indicate a problem. Have them in­ spected and repaired at once. 21 OB-22 MAINTENANCE AND LUBRICATION Parking brake and transm ission “ Park” mechanism operation— CAUTION: Before checking the holding ability of the parking brake and autom atic transm ission “ Park” mechanism, park on a fairly steep hill with enough room fo r movement in the dow nhill direction; to reduce the risk of personal injury or property damage, be prepared to apply the regular brakes prom ptly if the vehicle begins to move. • To check the parking brake with the engine running and transmission shift lever in “ Neutral,” slowly remove foot pressure from the regular brake pedal until the vehicle is held by only the parking brake. • To check the automatic transmission “ Park” mechanism holding ability, release all brakes after shifting the transmission to “ Park.” Lap and shoulder belts condition and operation — Inspect belt system, including: webbing, buckles, latch plates, retractors, guide loops and an­ chors. Have any defects repaired immediately. Movable head restraint operation — On vehicles with movable head re­ straints, make sure restraints stay in the desired position. Refer to Section 1 in your Owner’s Manual for adjustment instructions in your Owner’s Manual. Seatback latch and recliner operation on vehicles equipped w ith recliner seat — Be sure seatbacks latch on those vehicles with folding seats using mechanical latches. Make sure the recliner is holding by pushing and pulling on the top of the seatback while it is reclined. Refer to Section 1 of your Owner’s Manual for seat operating information. 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 covers or doors are securely stowed at all times. Oil the jack ratchet or screw mechanism after each use. Underbody flushing — At least every spring, flush the underbody with plain water to remove any corrosive materials used for ice and snow removal, and dust control. Take care to thoroughly clean any areas where mud and other debris can collect. Sediment packed in closed areas of the vehicle should be loosened before being flushed. Engine cooling system service * t — Inspect coolant and freeze protec­ tion. If dirty or rusty, drain, flush and refill with new coolant. Keep coolant at the proper mixture as specified in Section 5 of your Owner’s Manual. This provides proper freeze protection, corrosion inhibitor level and engine operat­ ing temperature. Inspect hoses and replace if cracked, swollen or deteriora­ ted. Tighten hose clamps. Clean outside of radiator and air conditioning condenser. Wash radiator filler cap and neck. To help ensure proper opera­ * An Emission Control Service t A large loss in these systems may indicate a problem. Have them in­ spected and repaired at once. 22 MAINTENANCE AND LUBRICATION OB-23 tion, a pressure test of both the cooling system and cap is also recom­ m ended. See m ainten an ce sch ed ule ch arts in Section A for the recommended coolant change interval. Body Lubrication Service — Lubricate all body door hinges including the tailgate (if equipped) also lubricate the body hood, fuel door and rear com­ partment hinges and latches including interior glove box and console doors, and any folding seat hardware. 23 OB-24 MAINTENANCE AND LUBRICATION SECTION E — RECOMMENDED FLUIDS & LUBRICANTS NOTE: Fluids and lubricants identified below by name, part number or speci­ fication may be obtained from your GM Truck Dealer. USAGE FLUID/LUBRICANT Engine Oil GM Goodwrench Motor Oil or equivalent for API Service SF/CC or SF/CD of the recommended vis­ cosity Engine Coolant Mixture of water and a good quality ethylene glycol base antifreeze conforming to GM-1825-M GM Part No. 1052753 Brake and Hydraulic Clutch Systems D e lco S up rem e 1052535 or DOT-3 Parking Brake Cables Chassis grease meeting requirements of GM-6031M GM Part No. 1052497 Power Steering System GM Power Steering Fluid GM Part No. 1050017 or equivalent Manual Steering Gear GM Lubricant Part No. 1052182 or equivalent Automatic Transmission DEXRON ® II Automatic Transmission Fiuid GM Part No. 1051855 11 flu id GM Part No. Manual Transmission: 3-Speed (RPO M62 and M64) SAE-80W GL-5 or SAE-80W-90 GL5 gear lubricant GM Part No. 1052271 (use SAE-80W GL-5 in Can­ ada) 4-Speed (RPO MC9, MF2, and M73) Dexron ® II Automatic Transmission Fluid GM Part No. 1051855 4-Speed (RPO M20) SAE-80W GL-5 or SAE-80W-90 GL5 gear lubricant GM part No. 1052271 (use SAE-80W GL-5 in Can­ ada) 4-S p ee d O ve rd rive (RPO MY6) Dexron ® II Automatic Transmission Fluid GM Part No. 1051855 4-Speed W ithou t C reeper Manual Transmission Fluid GM Part No. 1052931. Gear (RPO MCO) 5-Speed (RPO ML2, ML3 and Dexron ® II Automatic Transmission Fluid GM Part MH3) No. 1051855 5-Speed (RPO MG5) Manual Transmission Fluid GM Part No. 1052931 Differential: Standard - Front and Rear SAE-80W-90 GL-5 gear lubricant GM Part No. Axle 1052271 (use SAE-80W GL-5 in Canada). Locking SAE-80W-90 gear lubricant GM Part No. 1052271 (use SAE-80W GL-5 in Canada) MAINTENANCE AND LUBRICATION OB-25 RECOMMENDED FLUIDS & LUBRICANTS (Cont’d.) Transfer Case Dexron ® II Automatic Transmission Fluid GM Part No. 1051855 Manual Transmission Shift Linkage, Col­ umn Shift, Propeller Shaft Slip Joint Chassis grease meeting requirements of GM-6031-M GM Part No. 1052497 Clutch Linkage (Manual Transmission without hydraulic clutches only) a. Pivot points b. Pushrod to clutch fork joint, and shaft pressure fitting Hood Latch Assembly a. Pivots and spring anchor b. Release pawl a. Engine oil b. Chassis grease meeting requirements of GM-6031-M GM No. 1051344 a. Engine oil or GM Part No. 1050109 b. Chassis Grease m eeting require­ ments of GM-6031-M GM Part No. 1052497 Front Wheel Bearings GM Lubricant Part No. 1051344 Constant Velocity Universal Joint GM Lubricant Part No. 1052497. Automatic Transmission Shift Linkage, Floor Shift Linkage, Hood and Door Hinges, Body Door Hinge Pins, Tailgate Hinge and Linkage, Folding Seat, Fuel Door Hinge Engine oil Key Lock Cylinders Light oil (10W-30) or Dri-Slide lubricant GM Part No. 1052948, or general-pur­ pose silicone lubricant, GM Part No. 1052276. Chassis Lubrication Chassis grease meeting requirements of GM-6031M, GM Part No. 1052497. Windshield Washer Solvent GM Optikleen washer solvent GM Part No. 1051515 or equivalent. Weatherstrip Silicone grease GM Part No. 1052863 or equivalent. NOTE: Silicone lubricants should not be used on lock cylinders with plastic caps. OB-26 MAINTENANCE AND LUBRICATION 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 R/V And G Series Heaters — Description................................................................................................................. 1A - 2 Blower And Air Inlet Assembly................................................................................................................................1A- 2 Heater Distributor Assembly................................................................................................. ...................................1A- 2 Functional T e s t............................................... .............................................................................................................1A - 2 Insufficient Heat Diagnosis.......................................................................................................................................... 1A- 5 Heater Circuit Diagnosis.............................................................................................................................................. 1A- 8 Diagnosis of the Heater S y s te m ............................................. .................................................................................. 1A- 9 R/V Series Heater — On-Vehicle S e rvice ................................................................................................................. 1A-10 Blower Motor Replacement...................................................................................................................................... 1A-10 Heater Hose R outing................................................................................................................................................ 1A-10 Heater Distributor Case and Core Replacement................................................................................................... 1A-10 Control Assembly Replacement................................................................ ............................................................. 1A-11 Control Cable Replacem ent.................................................................................................................................... 1A-12 Cable Adjustment.......................................................................................................................................................1A-14 Blower Switch Replacement......................................................................................... ....................................... 1A-14 Resistor Replacement.............................................................................................................................................. 1A -1 4 Vent Replacement.....................................................................................................................................................1A-14 R/V Series Auxiliary H e a te r........................................................................................................................................ 1A-15 Description.................................................................................................................................................................1A-15 D iagnosis....................................................................................................................................................................... 1A-17 On-Vehicle S e rv ice .................................................................................................................................................... .1A-17 Blower Motor Replacement...................................................................................................................................... 1A -1 7 Heater Core Replacement...................................................................... ...................... ....................................... 1A -1 7 Resistor Replacement............................................................. . .............................................................................. 1A -1 7 Auxiliary Blower Switch Replacement................................................................................................................... 1A-17 Coolant-Control Valve Replacem ent......................................................................................................................1A-17 G Series Heater — On-Vehicle S ervice............................................. ........................................................................1A-18 Blower Motor Replacement.......... ........................................................................................................................... 1A-18 Heater Hose R outing............................................................................................... ............................................. 1A-18 Heater Distributor Case and Core Replacement................................................................................................... 1 A - 1 9 Distributor And Defroster Duct Replacement.............................................................................. ........................ 1A-21 Control Assembly and/or Blower Switch Replacement.......................................................................................1A-22 Control Cable Replacement .................................................................................................................................... 1A-22 Cable Adjustment...................................................................................................................................................... 1A-22 Resistor Replacement.............................................................................................................................................. 1A-22 Vent Replacement.................................................................................................................................................... 1A-22 G Series Auxiliary H eater............................................................................................................................................ 1A- 23 Description.................................................................................................................................................................1A-23 D iagnosis.......................................................................................................................................................................1A-25 On-Vehicle S e rvice ........ ............................................................................................................................................. 1A-25 Blower Motor Replacement......................................................................................................................................1A-25 Heater Core Replacement........................................................................................................................................ 1A-26 Coolant-Control Valve Replacem ent..................................................................................................................... 1A-26 Resistor Replacement.............................................................................................................................................. 1A-26 S pecifications...............................................................................................................................................................IA - 2 6 1A-2 HEATING R/V AND G SERIES HEATERS-DESCRIPTION Heating com ponents are attached to the right side of the cowl. The blower and air inlet assembly and water hoses are located on the forward side of the cowl panel while the heater core and distributor duct are on the pas­ senger side. The heater system is an air-mix type system in which outside air is heated and then mixed in varying amounts with cooler outside air to attain the desired air tempera­ ture. The system consists of (1) a blower and air inlet as­ sembly, (2) a heater distributor assembly and (3) a heater control assembly. BLOWER AND AIR INLET ASSEMBLY The blower and air inlet assembly draws outside air through the outside air inlet grille located forward of the windshield reveal m olding and channels the air into the heater distributor assembly. The operation of the blower motor is controlled by the fan switch on the heater control. The motor is connected in series with the fan switch and the blower resistor assembly. HEATER DISTRIBUTOR ASSEMBLY The heater distributor assem bly houses the heater core and the doors necessary to control mixing and channeling of the air. Since the unit has no water valve, water circulation keeps the core hot at all times. That portion of the air passing through the core receives m axim um heat from the core. A ir entering the distributor assembly is channeled as follows: Air entering the distributor can be directed out the purge door opening on the right end of the distributor assembly by the temperature door. If the temperature door is closed, air is directed through and/or around the heater core by the temperature door. Air is then directed into the passenger com partm ent through the heater (floor) outlets and/or the defroster (dash) outlets by the defroster door. The temperature of the outlet air is dependent on the ratio of heated to unheated air (controlled by the temperature door). FUNCTIONAL TEST Perform this test as one operation: 1. For R/V Series, refer to figure 1. 2. For G Series, refer to figure 2. HEATING 1A-3 FUNCTIONAL TEST-R-V SERIES P e rform th is te s t as o ne o p e ra tio n by o ne in s p e c to r in o n e s ta tio n ro ll-o ff te s t. HI OFF HEATER I J M j 1 $ * ! HOT : o ld V OFF ________________________ 1 CONTROL SETTINGS SYSTEM RESPONSE MODE TEMPERATURE FAN BLOWER HEATER DEFROSTER SEE STEP LEVER LEVER SWITCH SPEED OUTLET OUTLETS REMARKS 1 OFF COLD OFF OFF NO AIR FLOW NO AIR FLOW 2 OFF COLD OFF TO HI OFF TO HI NO AIR FLOW NO AIR FLOW A 3 HEAT HOT HI HIGH AIR FLOW MIN AIR FLOW B, C 4 DEFROST HOT HI HIGH MIN AIR FLOW AIR FLOW B R EM AR KS: A. A ch a n g e in b lo w e r speed m u s t o c c u r fro m Low, M e d iu m to H igh . B. D e te n t e n g a g e m e n t m u s t be fe lt in each m ode. C. C h e c k th e te m p e ra tu re lever fo r e ffo rt and travel (C old to H ot). Figure 1—Functional Test-R/V Trucks F-02037 1A-4 HEATING Heater Functional Test—G Series P erform th is te s t as one o p e ra tio n by o ne in s p e c to r in o n e s ta tio n — o ff ro ll te s t. SYSTEM RESPONSE CONTROL SETTINGS MODE CONTROL TEMPERATURE CONTROL FAN SWITCH 1 HTR COLD (BLUE) 2 HTR COLD 3 HTR 4 DEFROST STEP BLOWER SPEED HEATER OUTLET OFF OFF NO AIR FLOW NO AIR FLOW OFF TO HI OFF TO HI AIR FLOW MIN AIR FLOW A HOT (RED) HI HI AIR FLOW MIN AIR FLOW HOT HI HI MIN AIR FLOW AIR FLOW B, C B DEFROSTER OUTLETS SEE REMARKS REMARKS: A. A n o tic e a b le b lo w e r sp ee d m u s t o c c u r fro m low, m e d iu m to h ig h. B. The e n g a g e m e n t d e te n t m u s t be fe lt in each m ode. C. C h e ck th e te m p e ra tu re lever fo r e ffo rt and fu ll travel (co ld to hot). Hot Air Check W ith th e m o d e lever in d e fro s t th e te m p e ra tu re lever in h ot, th e fan s w itc h in HI, th e te m p e ra tu re fro m th e d e fro s te r o u tle t s h o u ld be above th e te m p e ra tu re o u ts id e th e v e h ic le . F-02134 Figure 2—Functional Test-G Vans HEATING 1A-5 F-02135 Figure 3—Insufficient Heat Diagnosis 1A-6 HEATING CHART A F-02136 Figure 4—Insufficient Heat Diagnosis HEATING 1A-7 CHART B F-02137 Figure 5—Insufficient Heat Diagnosis 1A-8 HEATING HEATER CIRCUIT DIAGNOSIS BLOWER MOTOR INOPERATIVE I CHECK THE FUSE IN THE FUSE PANEL.I X 1 FUSE OK ------1....... TEST WITH THE IGNITION SWITCH IN “ RUN’ POSITION, THE BLOWER SPEED SWITCH “ ON” AND THE LEVER I J THE HEAT POSITION. FUSE BLOWN X WITH THE IGNITION SWITCH IN THE “ RUN” POSITION AND THE BLOWER SPEED SWITCH “ ON” USE A METER TO LOCATE A SHORT IN ONE OF THE FOL­ LOWING WIRES: 1. FROM THE FUSE PANEL TO THE BLOWER SPEED SWITCH. 2. FROM THE BLOWER SPEED SWITCH TO THE HEATER RESISTOR. 3. FROM THE HEATER RESISTOR TO THE BLOWER. NOTE: A SHORT IN THE CIRCUIT MAY BE INTERMITTENT. IF THE METEP DOES NOT INDICATE A SHORT CIRCUIT, MOVE THE HEARNESS AROUND AS MUCH AS POSSIBLE TO RE-CREATE A SHORT CIR­ CUIT. WATCH AND LISTEN FOR ARCING. I CHECK THE BLOWER MOTOR GROUND. X POOR OR NO GROUND GROUND OK ...... ..... i .............: CHECK THE MOTOR CONNECTOR WITH A 12-VOLT TEST LIGHT. REPAIR THE GROUND. r 1 LAMP DOES NOT LIGHT LAMP LIGHTS REPLACE THE MOTOR. CHECKTHE BLOWER FEED WIRE IN THE CONNECTOR ON THE RESIS­ TOR WITH A 12-VOLT TEST LIGHT. X X LAMP DOES NOT LIGHT LAMP LIGHTS USE A 12-VOLT TEST LIGHT AND CHECK THE FEED TERMINAL (BROWN) ON THE BLOWER SPEED SWITCH. X 1. LAMP LIGHTS LAMP DOES NOT LIGHT T X REPAIR THE OPEN IN THE BROWN WIRE FROM THE BLOWER SPEED SWITCH TO THE FUSE PANEL. REPLACE THE SWITCH. ..........I ........ REPAIR THE OPEN IN THE FEED WIRE FROM THE RESISTOR TO THE BLOWER MOTOR. BLOWER MOTOR INOPERATIVE (CERTAIN SPEEDS) ~~ T DISCONNECT THE RESISTOR CONNECTOR, CONNECT ONE LEAD OF A SELF POWERED TEST LIGHT TO ANY ONE TERMINAL AND USE THE OTHER LEAD TO PROBE EACH OF THE OTHER TWO TERMINALS. I X TEST LIGHT DOES NOT LIGHT ON ALL THE TERMINALS. I TEST LIGHT LIGHTS ON ALL THE TERMINALS I WITH THE IGNITION “ OFF,” DISCONNECT THE 3 WIRE CONNECTOR FROM RESIS TOR. CONNECT A JUMPER LEAD FROM THE BATTERY POSITIVE TERMINAL TO ANY WIRE TERMINAL IN CONNECTOR. USE A 12-VOLT TEST LIGHT TO CHECK FOR VOLTAGE AT THE CORRESPONDING WIRE ON THE BLOWER SPEED SWITCH. REPEAT THE SAME TEST ON THE OTHER WIRES. REPLACE THE RESISTOR. X LAMP LIGHTS ON ALL THREE WIRES ............................. I ~ REPLACE THE BLOWER SPEED SWITCH. 1 LAMP LIGHTS ON ALL THREE WIRES LAMP DOES NOT LIGHT ON ALL THREE WIRES I REPAIR THE OPEN IN AFFECTED WIRE. Figure 6—Heater Circuit Diagnosis F-02038 HEATING 1A-9 DIAGNOSIS OF THE HEATER SYSTEM PROBLEM POSSIBLE CAUSE Temperature Of Heater Air At The Outlets Is Too Low To Heat Up Passenger Compartment Refer to “ Insufficient Heat Diagnosis.” Temperature Of Heater Air At The Outlets Is Adequate But The Vehicle Will Not Build Up Sufficient Heat Inadequate Defrosting Action 1. Floor side kick pad ventilators partially open. 2. Leaking grommets in dash. 3. Leaking welded seams along the rocker panel and windshield. 4. Leaks through the access holes and screw holes. 5. Leaking rubber molding around the door and windows. 6. Leaks between the sealing edge of blo­ wer and the air inlet assem bly and cowl, and between the sealing edge of the heater distributor assembly and cowl. 1. Check that the DEFROST lever comple­ tely opens the defroster door in the DEF position. 2. Insure that the temperature and air doors open fully. 3. Look for obstructions in the defroster ducts. 4. Check for air leak in the ducting between the defroster outlet on heater assembly and the defroster duct under the instru­ ment panel. 5. Check the position of the bottom of the nozzle to the heater locating tab. 6. Check the position of the defroster noz­ zle openings relative to instrum ent panel openings. M ounting tabs provide positive position if properly installed. Inadequate Circulation Of Heated Air Through The Vehicle 1. Check the heater outlet for correct instal­ lation. 2. Inspect the floor carpet to insure that the carpet lies flat under the front seat and does not obstruct air flow. Also inspect around the outlet ducts to insure that the carpet is well fastened to floor to prevent cupping of the air flow. Erratic Heater Operation 1. Check the coolant level. 2. Check for kinked heater hoses. 3. Check the operation of all bowden ca­ bles and doors. 4. Sedim ent in the heater lines and radiator causing the engine therm ostat to stick open. 5. Partially plugged heater core. CORRECTION Refer to “ Insufficient Heat D iagnosis.” 1. Check and adjust. 2. Reseal or replace. 3. Clean and rewash. 4. Reseal or replace. 5. Reseal or replace. 6. Reseal or replace. 1. Adjust if necessary. 2. Adjust. 3. Remove any obstructions. 4. Seal area as necessary. 5. Adjust. 6. Adjust the defroster nozzle openings. 1. Remove and install. 2. Correct as necessary. 1. Fill to the proper level. 2. Relieve kinks or replace hoses. 3. Adjust as necessary. 4. Flush the system and clean or replace therm ostat as necessary. 5. Backflush core as necessary. 1A-10 HEATING DIAGNOSIS OF THE HEATER SYSTEM (CONT.) PROBLEM Hard Operating Or Broken Controls POSSIBLE CAUSE CORRECTION 1. Check for loose cable tab screws or misadjusted cables. 2. Check for sticking heater system door(s). 1. Correct as required. 2. Lubricate as required using a silicone spray. R/V SERIES HEATER—ON-VEHICLE SERVICE BLOWER MOTOR REPLACEMENT Remove or Disconnect (Figures 7 and 8) 1 Draw hoses tight to prevent sagging or rubbing against other components. Route hoses through all clamps as installed originally. 1. Battery ground cable. HEATER DISTRIBUTOR CASE AND CORE REPLACEMENT 2. Blower motor wiring harness (3) (figure 7): 3. Motor (13) and fan (15) assembly (figure 8). • Five mounting screws. • Gently pry on the blower flange if the sealer acts like an adhesive. Shaft nut (16). Fan (15) from the motor (13). 0 Remove or Disconnect (Figures 8 through 14) Battery ground cable. Heater hoses (40 and 41) at the core tubes (20) (figures 8, 9, 10 and 11). Install or Connect (Figures 7 and 8) — Drain the engine coolant into a clean pan. — Plug the core tubes to prevent spillage. Screws (31) and nuts (24) from the studs (6) that project into the engine compartment (figures 8 and 12). Instrument panel compartment. Defroster (51) and temperature cables (52) (figure 13). Floor outlet (37). Screw (12) that holds the defroster duct to the heater distributor (figure 14). Heater distributor from the dash panel. Fan (15) from the motor (13). • Locate the open end of the wheel away from the blower motor. Shaft nut (16). Motor (13) and fan (15) assembly to the case (14). • New bead of sealer to the mounting flange. • Five mounting screws. Blower motor wiring harness. Battery ground wire. Test the motor (13). HEATER HOSES ROUTING Heater hoses are routed from the therm ostat housing or in le t m a n ifo ld and w a te r pum p (ra d ia to r on som e automatic transm ission vehicles) to the core inlet and o utlet pipes. Hoses are attached at each end with screw-type clamps. (Refer to figures 9, 10 and 11). REPLACEMENT W hen replacing heater hoses, m aintain a 13 mm (1/2-inch) m inimum clearance between the hose clip and the upper control arm, a 38 mm (11/2-inch) minimum clearance between the hoses and the propshaft, and a 32 mm (11/4-inch) m inimum clearance between the auxiliary heater core lines and the exhaust pipe. The heater core can be dam aged near the tube attachm ent seams if force is applied on them. If the heater hoses do not come off, cut the hoses forward of the core tubes. Cut the hose on core tubes to remove. • Pull the assembly rearward to reach the wiring harness. 9. Wiring harness. Heater case (24). 10. 11. Core retaining clamps (18 and 19). 0 12. Core (20). Install or Connect (Figures 8 through 14) 1. Core (20) to the case (24). 2. Core retaining clamps (18 and 19). 3. Heater case (24) to the vehicle. 4. Screws (31) and nuts to the studs (6). 5. Wiring harness. 6. Floor outlet (37). 7. Defroster (51) and temperature cables (52). 8. Instrument panel compartment. 9. Heater hoses (40 and 41) to the core tubes (20). 10. Battery ground cable. 11. Coolant to the radiator. HEATING 1A-11 7. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. S crew C o n n e c to r S crew M o to r C ase Fan N ut B o lt C la m p C la m p C ore 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. S h a ft Valve Valve C ase S h a ft S h rou d Plate B o lt E lb ow Tube 'E -*— 25 F-02218 Figure 8—Blower Motor Assembly-Component View-R/V CONTROL ASSEMBLY REPLACEMENT 1. 2. 3. 4. 5. Install or Connect (Figures 13) • If a new unit is being installed, transfer the blower switch to the new unit. Remove o r Disconnect (Figure 13) 1. Assembly through the opening above the control. Battery ground cable. Instrument panel bezel. Defroster (51) and temperature cables (52). Blower switch wiring harness. Assembly through the opening above the control. 2. Blower switch wiring harness. 3. Defroster (51) and temperature cables (52). 4. Instrument panel bezel. 5. Battery ground cable. Figure 9—Heater Hose Routing-4.3L, 5.0L and 5.7L Engines 1A-12 HEATING 40. H ose — O u tle t 41. H ose — In le t 42. R a d ia to r B-08618 F igure 10— H eater Hose R o u tin g -6 .2 L Engine Figure 11— H eater Hose R o u tin g -7 .4 L Engine CONTROL CABLE REPLACEMENT |* + [ Remove or Disconnect (Figure 13) Battery ground cable. Instrument panel bezel. Control assembly from the instrument panel. Cable retainers (53) and tab attaching screws (54). • Pull the control out from the instrument panel for access. 5. Instrument panel compartment. 6. Cable retainers (53) and tab attaching screws (54) at the heater case. 7. Cable from the retaining clip (58). 8. Cable (50 or 51). Install or Connect (Figures 13) 1. Cable (51 or 52). HEATING 1A-13 F igure 13— C o n tro l A s se m b ly and C ables 1. 45. 46. 47. 48. 49. C ase G rille N ozzle A s s e m b ly In s tru m e n t Panel O u tle t D e fro s t D u c t B-08617 Figure 14—Floor and Defroster Vents 1A-14 HEATING 50. H e a te r/D e fro s te r C o n tro l A s s e m b ly 55. In s tru m e n t Panel W irin g H a rn e ss 56. B lo w e r S w itc h B-09811 Figure 15—Blower Switch Im portant • Do not kink the cable. Route the cable as removed. Check the adjustment. Cable to the retaining clip (58) at the heater case (24). Cable retainers (53) and the tab screws at the heater case. Instrument panel compartment. Cable (51 or 52) to the control assembly (50). 6. Cable retainers (53) and tab screws (54). 7. Control assembly (50) to the instrument panel. 8. Instrument panel bezel. 4. Control assembly (50) (figure 15). • Pull the control out from the instrument panel. 5. Blower switch wiring harness. 6. Switch (56). |-n-| Install or Connect (Figure 15) 1. 2. 3. 4. 5. CABLE ADJUSTMENT Remove o r Disconnect (Figure 13) 1. 2. 3. 4. m Instrument panel compartment. Retainer (53). Screw (54) from cable tab (57). Cable (51 or 52) from the heater case (24). RESISTOR REPLACEMENT |+ + | Remove or Disconnect (Figures 7 and 16) 1. 2. 3. 4. Adjust Hold the cable with a pair of pliers and rotate the mounting tab (57) to lengthen or shorten the cable. NOTICE: Do not pinch the cable. -H - Install or Connect (Figure 13) Cable (51 or 52) to the heater case (24). Tab (57) to the clip (58). Screw (54). Instrument panel compartment. BLOWER SWITCH REPLACEMENT Remove or Disconnect (Figure 15) 1. Battery ground cable. 2. Instrument panel bezel. 3. Control assembly (50) mounting screws. Switch (56) to the control assembly (50). Wiring harness to the blower switch (56). Control assembly (50) to the instrument panel. Instrument panel bezel. Battery ground cable. Battery ground cable. Connector (4) (figure 16). Screws. Resistor (60). Install or Connect 1. 2. 3. 4. Resistor (60). Screws. Connector (4). Battery ground cable. VENT REPLACEMENT Right and left vents are installed in the kick panels u nd er th e in s tru m e n t p an el. R eplace the vents by removing the attaching screws (figure 17). HEATING 1A-15 65. Bezel 66. Valve A s s e m b ly 67. In s tru m e n t Panel G a rn ish 68 . K ic k p a n e l 69. C o n tro l C able Figure 17—Vent Assembly R/V SERIES AUXILIARY HEATER DESCRIPTION An auxiliary heater provides additional heating capacity for the rear of the Suburban model. T his unit operates in d ep en d en tly of the standard heater, and is regulated through its own controls at the instrum ent panel. This system consists of a separate core and fan unit mounted in the rear of the vehicle. Heater hoses extend from the unit to the front of the vehicle where they are connected to the standard heater hoses with “ tees.” An “ on-off” vacuum operated valve is installed in the heater core inlet line in the engine compartm ent. This valve cuts off coolant flow to the auxiliary core during warm weather and elim inates radiant heat (figure 18). Two control methods are used: COOLANT-CONTROL VALVE When heat is desired, and the blower switch is any position except off, a vacuum operated valve controlled by the switch, opens the coolant line to perm it hot coolant circulation through the heater core. In the OFF position the valve is closed to prevent unwanted heat. BLOWER SWITCH The th re e-sp ee d blow er sw itch is loca te d in the instrum ent panel to the right of the steering column. Figure 7—Blower Motor Assembly Wiring R/V 1A-16 HEATING 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. U p p e r C ase Seal C ore L o w e r C ase S cre w Fan S u p p o rt G ro m m e t W a sh e r S cre w M o to r C la m p S tu d R e s is to r Seal N ut H a rn e ss 92. 93. 94. 95. 96. 97. 98. 99. 100. 101. 102. 103. 104. 105. 106. C la m p A u x ilia ry H e a te r In le t R ear H ose A u x ilia ry H e a te r O u tle t Rear C lip S cre w W a te r H e a te r O u tle t H ose W a te r H e a te r In le t H ose S crew Valve H a rn e s s S crew A u x ilia ry H e a te r S w itc h (S in g le F u n c tio n ) Bezel A u x ilia ry H e a te r C o n tro l S w itc h S crew A u x ilia ry H e a te r/R e ar A ir C o n d itio n in g C o n tro l S w itc h (Dual F u n c tio n ) 107. C o n n e c to r 108. V a cuu m Line F-02222 Figure 18—Auxiliary Heater-Suburban HEATING 1A-17 DIAGNOSIS To diagnose the heater system, refer to “ Insufficient Heat Diagnosis,” “ Heater C ircuit Diagnosis,” and “ Diagnosis of the Heater System .” ON-VEHICLE SERVICE Install or Connect (Figure 18) BLOWER MOTOR REPLACEMENT 4- + 1. 2. 3. 4. 5. 0 1. 2. 3. 4. 5. Remove or Disconnect (Figure 18) Battery ground cable. Blower motor wiring harness (91). Clamp (86). Screws (84) and washer (83). Motor (85). Install or Connect (Figure 18) Motor (85). Screws (84) and washers (83). Clamp (86). Blower motor wiring harness (91). Battery ground cable. HEATER CORE REPLACEMENT Remove or Disconnect (Figure 18) 0 Battery ground cable. Coolant from the radiator. Hoses (93 and 94) from the core (77). Wiring harness (91). Clamp (86). Motor (85), support (81) and fan (80) as an assembly. Upper case (75). Seal (76). Core (77). 0 1. 2. 3. 4. 5. Core (77) to lower case (78). Seal (76). Upper case (75). Motor (85), support (81) and fan (80). Clamp (86). Wiring harness (91). Hoses (93 and 94) to the core (77). Coolant to the radiator. Battery ground cable. Remove or Disconnect (Figure 18) Battery ground cable. Wiring harness (101). Screws. Resistor (88). Resistor (88). Screws. Wiring harness (101). Battery ground cable. AUXILIARY BLOWER SWITCH REPLACEMENT Remove or Disconnect (Figure 18) Battery ground cable. Wiring harness (107) at the switch (104). Screws (102). Bezel (103). Switch (104). Install or Connect (Figure 18) 1. 2. 3. 4. 5. Switch (104) to the bezel (103). Bezel (103) to the instrument panel. Screw (102). Wiring harness (107) to the switch (104). Battery ground cable. COOLANT-CONTROL VALVE REPLACEMENT The coolant-control valve is mounted to the right front fender. To diagnose the vacuum system, refer to AIR CONDITIONING (SEC. 1B). Remove or Disconnect (Figure 18) Install or Connect (Figures 18) RESISTOR REPLACEMENT 1. 2. 3. 4. 1. 2. 3. 4. 1. 2. 3. 4. 5. Coolant from the radiator. Clamps (92). Hoses (93, 94, 97 and 98) from the valve. Vacuum hose (108). Valve (100). Install or Connect (Figure 18) Valve (100). Vacuum hose (108). Hoses (93, 94, 97 and 98). Clamps (92). Coolant to the radiator. Leak test. 1A-18 HEATING G SERIES HEATER—ON-VEHICLE SERVICE 113 110. N u t 111. Fan A s s e m b ly 112. W a s h e r 113. M o to r 114. Tube 115. F ittin g 116. C ase 117. G a s k e t 118. Pin 119. Valve 120. S h a ft 114 121. H o u s in g 122. C ore 123. S tra p 124. C ase 125. B ra c k e t 126. Valve 127. S h a ft A s s e m b ly 128. D u c t B-09761 Figure 19—Blower Motor Assembly Component View BLOWER MOTOR REPLACEMENT Remove or Disconnect (Figure 19) 1. 2. 3. 4. 5. 6. Battery ground cable. Coolant overflow hose from the recovery bottle. Fasteners. Bottle from the vehicle. Blower motor and wiring harness. Motor (113) and fan (111) assembly (figure 19). • Five mounting screws. • Gently pry on the blower flange if the sealer acts like an adhesive. 7. Nut (110). 8. Fan (111) from the motor (113). Install or Connect (Figure 19) 1. Fan (111) to the motor (113). • Locate the open end of the wheel away from the blower motor. 2. Nut (110). 3. Motor (113) and fan (111) assembly. • Bead of sealer to the mounting flange. 4. Blower motor wiring harness. 5. Coolant bottle to the vehicle. 6. Fasteners. 7. Coolant hose. 8. Battery ground cable. 9. Test the motor. HEATER HOSE ROUTING Heater hoses are routed from the therm ostat housing or in le t m a n ifo ld and w a te r p u m p (ra d ia to r on som e automatic transm ission vehicles) to the core inlet and outlet pipes. Hoses are a ttached at each end with screw-type clamps. (Refer to figures 20, 21 and 22). REPLACEMENT W hen replacing heater hoses, m aintain a 13 mm (1/2-inch) m inimum clearance between the hose clip and the upper control arm, a 38 mm (11/2-inch) minimum clearance between the hoses and the propshaft, and a 32 mm (11/4-inch) m inimum clearance between the auxiliary heater core lines and the exhaust pipe. The heater core can be dam aged near the tube attachm ent seams if force is applied on them . If the heater hoses do not come off, cut the hoses forward of the core tubes. Cut the hose on the core tubes to remove. Im portant Draw hoses tight to prevent sagging or rubbing against other components. Route hoses through all clamps as installed originally. HEATING 1A-19 Figure 20—Heater Hose Routing-4.3L, 5.0L and 7.4L Engines HEATER DISTRIBUTOR CASE AND CORE REPLACEMENT + + Remove or Disconnect (Figures 19 through 24) Battery ground cable. Coolant recovery tank. Heater core hoses (140 and 141) (figures 20, 21 and 22). 4. 5. 140. H ose — O u tle t 141. H ose — In le t 142. R a d ia to r 140 8. 9. 10. B-08352 11. Figure 22—Heater Hose Routing-7.4L Engine 12. 13. — Place a clean pan under the vehicle to catch any coolant spillage. — Plug the hoses. — Allow coolant in the core to drain into the pan. Heater distributor duct (134) (figure 23). — Remove the screws that hold the distributor duct to the distributor case and the distributor duct to the engine cover. Engine housing cover. • Refer to INTERIOR TRIM (SEC. 10A4). • Remove the screws at the windshield, all lower screws and the right instrument panel support bracket at the door pillar and the engine housing. Instrument panel. Lower the steering column. • Refer to STEERING COLUMN (SEC. 3B4). • R aise and s u p p o rt the rig h t side of the instrument panel. Defroster duct (130) to distributor case (124) attaching screws. Distributor to heater case (2) screws. Temperature door cable (145) (figure 24). • Fold the cable back for access. Heater case (124) and core (122). • Three nuts at the engine compartment side of the distributor case and one screw on the passenger side. • Tilt the case assembly rearward at the top while lifting up until the core tubes clear the dash openings. Core retaining straps (123). Core (122). 1A-20 HEATING 131. Seal 133. L eft-h a n d O u tle t A s s e m b ly 134. D u c t A s s e m b ly F-00659 Figure 23—Distributor Ducts HEATING 1A-21 F igure 24— C o n tro l A s s e m b ly and C ables Install or Connect (Figures 19 through 24) 1. Core (122) to the heater case (124). • Apply a bead of sealer between the core and the case. DISTRIBUTOR AND DEFROSTER DUCT REPLACEMENT |<-+| Remove or Disconnect (Figure 23) 2. Core retaining straps (123). 1. Battery ground cable. 3. Heater case (124) to the vehicle. 2. Raise the instrument panel at the right side. • Apply a bead of sealer between the heater case and the opening in the vehicle. • Tilt the case until the core tubes clear the cowl opening. 4. Temperature cable (145) to the heater case (124). 5. Distributor duct (134) to the heater case (124). 6. Defroster duct (130) to the heater case (124). 7. Instrument panel. 8. Steering column. • Refer to STEERING COLUMN (SEC. 3B4). 9. Engine housing cover. • Refer to INTERIOR TRIM (SEC. 10A4). 10. Heater core hoses (100 and 141). 11. Coolant recover tank. 3. Engine cover. • Refer to INTERIOR TRIM (SEC. 10A4). • Unsnap the engine cover front latches and remove the two cover-to-floor pan screws. 4. Distributor duct (134) from the heater case (124). • Pull the center distributor duct to the right. 5. Defroster duct (130). • Screws that hold the defroster duct to the instrument panel. Install or Connect (Figure 23) 1. Defroster duct (130). 2. Distributor duct (134) to the heater case (124). 3. Engine cover. • Refer to INTERIOR TRIM (SEC. 10A4). 12. Coolant to the radiator. 4. Instrument panel. 13. Leak test. 5. Battery ground cable. 1A-22 HEATING CONTROL ASSEMBLY AND/OR BLOWER SWITCH REPLACEMENT Remove or Disconnect (Figures 15 and 24) 1. Battery ground cable. 2. Instrument panel bezel. 3. Control assembly (147) from the instrument panel. • Pull the control assembly out to reach the defroster (145) and temperature cables (146). 4. Defroster (145) and temperature cables (146). 5. W irin g h arne ss to th e b low er sw itch and the illumination bulb. 6. Control assembly (147) from the vehicle. 7. Blower switch (56). ♦«“ Install or Connect (Figures 15 and 24) 1. Blower switch (56) to the control assembly (147). 2. Wiring harness to the blower switch (56) and the illumination bulb. 3. Defroster (145) and temperature (146) cables. 4. Control assembly (147) to the instrument panel. 5. Instrument panel bezel. 6. Battery ground cable. CONTROL CABLE REPLACEMENT Remove or Disconnect (Figures 15 and 24) Battery ground cable. Instrument panel bezel. • For additional room, place the transmission shift lever in “ low.” Control assembly (147) from the instrument panel. Cable retainers (148) and tab screws (149). • R aise or lo w e r th e c o n tro l a ss e m b ly as necessary. Cable (145 or 146) from the control assembly (147). Instrument panel compartment. Cable retainer (148) and tab screws at the heater case. -►«* Install or Connect(Figures 15 and 24) 1. Cable (145 or 146) to the heater assembly (124). • Retaining clip (150) and screw (149). • Retainers (148). 2. Instrument panel compartment. 3. Cable (145 or 146) to the control assembly (147). • Retaining clip (150) and screw (149). • Retainer (148). 4. Control assembly (147) to the instrument panel. 5. Instrument panel bezel. 6. Battery ground cable. Figure 25—Resistor Replacement Attach the cable sheath to the heater case (124). Move the temperature lever to full heat. This will require force to slide the inner cable clip to its proper position. RESISTOR REPLACEMENT ++ Remove or Disconnect (Figure 25) 1. 2. 3. 4. Battery ground cable. Wiring harness from the resistor (171) (figure 25). Screws (173). Resistor (171). Install or Connect (Figure 25) 1. 2. 3. 4. Resistor (171). Screws (173). Wiring harness to the resistor (171). Battery ground cable. VENT REPLACEMENT CABLE ADJUSTMENT |+ + l Remove or Disconnect (Figure 26) A djust (Figure 24) 1. Attach the inner cable and sheath to the instrument pane! control. 2. Move the temperature cable (145) to cold. 3. Attach the loop on the inner cable to the temperature door (145 on the heater case (124). 1. Screws (204). 2. Valve assembly (202). Install or Connect (Figure 26) 1. Valve assembly (202). 2. Screws (204). HEATING 1A-23 200. Seal 201. O u tle t 202. Valve A s s e m b ly 203. C lip 204. S crew 205. K n ob 206. Rod 207. G u id e 208. O u tle t 209. Seal 210. In le t A s s e m b ly 211. C ove r F-00657 Figure 26—Vent Replacement G SERIES AUXILIARY HEATER DESCRIPTION An auxiliary heater provides additional heating for the rear area of the vehicle. It operates independently of the standard heater, and is regulated through its own control at the instrum ent panel. This system consists of a separate core fan vent (figures 27 and 28). Heater hoses extend from the unit to the front of the vehicle where they are connected to the standard heater hoses with “ tees.” There are two control methods: COOLANT-CONTROL VALVE An “ o n-off” vacuum -operated, coolant-control valve in s ta lle d in th e h e a te r c o re in le t in th e e n g in e com partm ent controls coolant flow to the auxiliary heater and elim inates radiant heat during warm weather. To d ia g n o s e th e v a c u u m s y s te m re fe r to A IR CONDITIONING (SEC. 1B). BLOWER SWITCH For heating, the blower switch is placed in any position except off. The switch opens the coolant-control valve which permits hot coolant to enter the heater core. In the OFF position, the valve is closed to prevent unwanted heat during warm weather. 1A-24 HEATING 164 150. 151. 152. 153. 154. 155. 156. 157. 158. 159. 160. 161. 162. 163. 164. 165. 166. 167. 168. C over C ore Seal Tube R e s is to r C ase W a sh e r Fan N ut P late S cre w S creen W irin g H a rn e ss S tu d M o to r S tra p T erm in al S crew S crew F-02231 Figure 27—Auxiliary Heater Component View HEATING 1A-25 180 170 185 184 170. 171. 172. 173. 174. 175. 176. 177. 178. 179. 180. 181. 182. 183. 184. 185. 186. 187. H e a te r A s s e m b ly Seal C ia m p S crew W a sh e r cirp S crew S tra p M ate ria l H ose H ose S trap C lip Tee Tee S crew H ose Tee 188. Tank r 189. 190. 191. 192. 193. 194. 195. 196. 197. 198. S crew H ose N ut S w itc h N ut Label Knob H a rn e ss R e ta in e r W ire A s s e m b ly 180 179 176 178 B-09753 Figure 28—Auxiliary Heater Plumbing Component View DIAGNOSIS To diagnose the auxiliary heater, refer to “ Insufficient Heat Diagnosis,” “ Heater Circuit Diagnosis” and “ Diagnosis of the Heater System .” ON-VEHICLE SERVICE BLOWER MOTOR REPLACEMENT ♦«- Install or Connect (Figure 28) 1. Fan (157) to the motor (164). 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove or Disconnect (Figure 27) 2. Nut (158) to the motor (164) shaft. Battery ground cable. Screws (168). Cover (150). Wiring harness to the motor (162). Screws (160). Motor (164) and fan (157) assembly. Nut (158) from the motor (164). Fan (157) from the motor (164). Motor (164). 3. Motor (164), fan (157) and nut (158) to the case (155). • Apply a bead of sealer to the motor (164) flange. 4. Screws (160). 5. Wiring harness (162) to the motor (168). 6. Cover (150). 7. Screws (168). 8. Battery ground cable. 1A-26 HEATING HEATER CORE REPLACEMENT COOLANT CONTROL VALVE REPLACEMENT Remove or Disconnect (Figures 27 and 28) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Coolant from the radiator. Battery ground cable. Clamps (172) from the coolant hoses (179 and 180). Coolant hoses (179 and 180) from the core (151). Studs (163) from the case (155). Screws (168). Cover (150). Wiring harness (162) from the motor (164) and the resistor (154). Case (155) and plate (159) from the vehicle. Screws (160). Plate (159) from the case (155). Seal (152). Core (151). The coolant-control valve is attached to the right side of the cowl in the engine compartm ent. Remove or Disconnect (Figure 28) 1. 2. 3. 4. 5. |+<-| Install or Connect (Figure 28) 1. 2. 3. 4. 5. Install or Connect (Figures 27 and 28) 1. 2: 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Core (151) to the case (155). Seal (152) to the case (155). Plate (159) to the case (155). Screws (160). Case (155) and plate (159) to the vehicle. Wiring harness (162) to the motor (164) and the resistor (154). Cover (150). Screws (168). Coolant hoses (179 and 180) to the case (155). Clamps (172) to the coolant hoses (179 and 180). Studs (163) to the case (155). Battery ground cable. Coolant to the radiator. Leak test. Coolant from the radiator. Coolant hoses. Vacuum line. Screws. Valve (183). Valve (183). Screws. Vacuum line. Coolant hoses. Coolant to the radiator. RESISTOR REPLACEMENT Remove or Disconnect (Figure 28) Battery ground cable. Screws (168). Cover (150). Wiring harness (162) to the resistor (154). Resistor (154). |-»<-| Install or Connect (Figure 28) 1. 2. 3. 4. 5. Resistor (154). Wiring harness (169) to the ressistor (154). Cover (155). Screws (168). Battery ground cable. SPECIFICATIONS HEATER Volts Amps. (Cold) R/V S eries........................................................................................... 13.5 6.25 Max. G S e r ie s ............................................................................................. 13.5 7.1 Max. RPM (Cold) Blower Motor 2550 2950 2850 3250 Min. Max. Min. Max. Fuses R/V S e r ie s ...................................................................................................................................................... 20 Amp. G S e rie s ...........................................................................................................................................................20 Amp. AUXILIARY HEATER Blower Motor. Volts Amps. (Cold) RPM (Cold) 13.5 9.6 Max. 2700 Min. 1B-1 SECTION 1B AIR CONDITIONING CONTENTS SUBJECT PAGE D e s c rip tio n ...................................................................................................................................................................................... 1 B - 3 CCOT A/C S y s te m .................................................... ...............................................................................................................1 B - 3 Rear In te rio r R oof M ounted S ystem s (S uburban & G S e r ie s ) .................................................................................... 1 B - 3 S ystem C o m p o n e n ts ............................................................................................................................................................... 1 B - 4 P e rio d ic M aintenance and S e r v ic in g ..................................................................................................................................1 B - 4 S ystem O p eratio n — RV & G ................................................................................................................................................1 B - 4 F u n ctio n a l T est — R/V & G . .................................................................................................................................................. 1 B - 4 R efrige ran t-12 O perating C h a ra c te ris tic s ............................................................................................................................. 1 B - 9 S ystem C om po n en ts and T em p eratu re and P ressure R e la tio n s h ip s .......................................................................1 B - 9 R e frig e ra n t and Oil C a p a c ity ..................................................................................................................................................1 B - 9 H andling R efrigerant-12 .........................................................................................................................................................1 B - 9 H an dling R efrige ran t L ines and F it t in g s ........................................................................................................................... 1 B - 9 M ain ta in in g C hem ical S t a b ility ............................................................................................................................................. 1 B - 9 R e frig e ra n t System D ia g n o s is ..................................................................................................................................................1B-11 In s u ffic ie n t C ooling “ Q u ick-C h e ck” P ro c e d u re ............................................................................................................. 1B-11 S ystem P erform ance T e s t...................................................................................................................................................... 1B-11 T e stin g th e R efrigerant S y s te m ......................................... ................................................................. ............................... 1B-11 Leak T e stin g the R efrige ran t S ystem ................................................................................................................................1 B -13 P ressure Sensing S w it c h ...................................................................................................................................................... 1 B -13 E le ctrica l/V a cu u m T ro u ble D ia g n o s is .................................................................................................................................... 1 B -1 8 O p eratio n al T e s t........................................................................................................................................................................ 1 B -18 V acuum S ystem D ia g n o s is .........................................................................................................................................................1 B -23 R/V and G S e r ie s ......................................................................................................................................................................1 B -23 E vacuating and C harging P ro c e d u re s .................................................................................................................................... 1 B -23 E vacuation and C harging P ro c e d u re s ................................................................................................................................1 B -23 D ischa rg ing , E vacuating, A d d in g Oil, C harging P ro c e d u re s .......................................................................................1 B -23 D ischa rg ing the S y s t e m .........................................................................................................................................................1 B -24 R e frig e ra n t Oil D is trib u tio n .................................................................................................................................................... 1 B -24 E va cua tin g and C harging ...................................................................................................................................................... 1 B -25 Gage C a lib ra tio n ..................................................................................................................................................................1 • 1 B -26 Vacuum System C h e c k ........................................................................................................................................................... 1 B -26 C harging S tation M e t h o d ...................................................................................................................................................... 1 B -26 D isposable Can or M ulti-C an M e th o d ..................................................................................................................................1B -26 R efrige ran t Drum M e th o d ...................................................................................................................................................... 1 B -26 C harging th e S y s te m ................................................................................................................................................................1 B -26 A c c u m u la to r A s s e m b ly ........................................................................................................................................................... 1 B -27 S p e cific C om ponent D ia g n o s is ........................................................................................................................................... : .1 B -2 7 C o m p re s s o r............................................................................................................................................................................... 1 B -27 C o n d e n s e r ..................................................................................................................................................................................1B -27 E xpansion V a lv e ........................................................................................................................................................................ 1 B -27 E v a p o r a to r ..................................................................................................................................................................................1 B -27 R efrige ran t Line R e s tric tio n s ............................................................................................................................................... 1 B -28 R efrigerant-11 Flushing P r o c e d u r e .................................................................................................................................... 1 B -28 O n-V ehicle S e r v ic e ...................................................................................................................................................................... 1 B -29 C om pre ssor R eplacem ent (R /V )...........................................................................................................................................1 B -29 C o m pre ssor R eplacem ent (G )................................................................................................................................................1 B -30 1B-2 AIR CONDITIONING CONTENTS (CONTINUED) SUBJECT PAGE A/C System—R/V Series.............................................................................................................................................. 1B-34 Condenser Replacement.......................................................................................................................................... 1B-34 Accumulator Replacem ent...................................................................................................................................... 1B-35 Blower Assembly Replacem ent..............................................................................................................................1B-35 Evaporator Core Replacem ent................................................................................................................................1B-36 Orifice (Expansion Tube) Replacement................................................................................................................. 1B-36 Selector Duct and Heater Core Replacement....................................................................................................... 1B-36 Actuator-Plenum Side Vent Replacement............................................................................................................. 1B-37 Plenum Valve R eplacem ent....................................................................................................................................1B-37 Control Assembly Replacement..............................................................................................................................1B-39 Temperature Door Cable A d ju s tm e n t................................................................................................................... 1B-40 Blower Switch Replacement....................................................................................................................................1B-40 Vacuum Tank R eplacem ent....................................................................................................................................1B-41 Blower Motor Resistor Replacement......................................................................................................................1B-41 Blower Motor Relay R eplacem ent..........................................................................................................................1B-41 Fuse Replacement......................................... ....................................................................................................... 1B-43 Vacuum Line Replacement — Engine Com partm ent...........................................................................................1B-43 Vacuum Line Replacement — Dash........................................................................................................................1B-43 Refrigerant-12 Hose R o u tin g ..................................................................................................................................1B-43 Rear Interior Roof Mounted System—S u b u rb a n ..................................................................................................... 1B-46 Rear Duct Replacement............................................................................................................................................ 1B-46 Blower Motor Resistor Replacement......................................................................................................................1B-46 Blower Motor Assembly Replacement....................................................................................................................1B-49 Expansion Valve Replacement................................................................................................................................1B-49 Evaporator Core Replacement................................................................................................................................1B-49 Blower Motor Switch Replacem ent........................................................................................................................1B-50 Fuse Replacement.................................................................................................................................................... 1B-50 A/C System—G S e rie s ................................................................................................................................................ 1B-50 Condenser Replacement.......................................................................................................................................... 1B-50 Accumulator Replacem ent...................................................................................................................................... 1B-50 Heater Core Replacement........................................................................................................................................ 1B-51 Orifice (Expansion Tube) Replacement................................................................................................................. 1B-53 Blower Motor Insulation (w/Diesel) Replacement................................................................................................. 1B-53 Evaporator Core (w/Diesel) Replacem ent............................................................................................................. 1B-53 Evaporator Core Replacem ent................................................................................................................................ 1B-53 Blower Motor Replacement...................................................................................................................................... 1B-54 Control Assembly Replacement.............................................................................................................................. 1B-55 Temperature Door Cable A d ju s tm e n t....................................................................................................................1B-55 Blower Switch Replacement.................................................................................................................................... 1B-57 Resistor Replacement.............................................................................................................................................. 1B-57 Blower Motor Relay R eplacem ent..........................................................................................................................1B-57 A/C Ductwork Replacem ent.................................................................................................................................... 1B-57 Defroster Duct Replacement.................................................................................................................................... 1B-57 Temperature Door Cable Replacem ent..................................................................................................................1B-57 Vacuum Tank Replacem ent.................................................................................................................................... 1B-57 Vacuum Lines-Engine Com partm ent......................................................................................................................1B-57 Refrigerant-12 Hose Routing .................................................................................................................................. 1B-58 Rear Interior Roof Mounted Systems—G S e rie s ..................................................................................................... 1B-63 A/C System—P Series...................................................................................................................................................1B-65 S pe cifica tio n s............................................................................................................................................................... 1B-66 Special T o o ls ................................................................................................................................................................. 1B-68 AIR CONDITIONING 1B-3 DESCRIPTION 1. 2. 3. 4. 5. 6. 7. P ow er E le m e n t T h e rm o b u lb C ove r D ia p h ra g m B ack-up P late Body S creen O rific e C a rria g e S p rin g 8. 9. 10. 11. 12. A. B. S p rin g S eat C a rria ge Seat Seat A c tu a tin g Pin D iap hrag m In le t O u tle t F-00190 A. B. C. 15. 16. 17. 18. 19. In le t O u tle t R e frig e ra n t V a po r O u tle t B a ffle In te rn a l Tube D e s ic c a n t Bag A s s e m b ly F ilte r A s s e m b ly O il B leed H ole F-00191 Figure 1—Thermostatic Expansion Valve Figure 2—Accumulator R/V & G Series CCOT A/C SYSTEM During cooling, the air is cooled by the evaporator to below comfort level then warmed by the heater to the d e s ire d te m p e ra tu re . D u rin g “ h e a tin g o n ly ” th e evaporator does not operate, and ambient air is warmed to the desired level in the same manner. The CCOT (Cycling Clutch Orifice Tube) A/C system perform s 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 R/V and G series, a pressure sensing switch, lo ca te d n ear the top of the a ccu m u la to r, c o n tro ls compressor operation. The switch responds to pressure changes to turn the compressor ON or OFF. REAR INTERIOR ROOF MOUNTED SYSTEMS (SUBURBAN & G SERIES) These systems operate with the front system - they do not operate independently. However, control of the rear System operation: Outside air or recirculated air enters the system and is forced through the system by the blower. As the air passes throught he evaporator core, it receives maximum cooling if the air conditioning controls are positioned for cooling. From the evaporator, the air enters the heater and air conditioner selector duct assembly where, by means of diverter doors, it passes through or bypasses the heater core in proportions necessary to provide the desired outlet temperature. The air enters the vehicle through either the floor distributor duct or the dash outlets. F. In le t G. O u tle t (To Evaporator) H. D ent On Tube (R e ta in s th e E x p a n s io n Tube) 20. O u tle t S creen 22. In le t S creen 21. E x p a n s io n Tube 23. Seal B-07208 Figure 3—Orifice (Expansion Tube) 1B-4 AIR CONDITIONING blower motor speed is possible when the front system is OFF. Rear air circulation w ithout the refrigerant function is possible by operating the rear blower control switch. T h e s e s e lf-c o n ta in e d u n its o p e ra te on in s id e (recirculated) air. Air enters the unit and passes through the evaporator core into the passenger compartm ent through the air distributor duct. The front system controls the rear system. A three-speed blower switch controls the rear interior roof mounted system. SYSTEM COMPONENTS THERMOSTATIC EXPANSION VALVE Suburban and G rear interior roof mounted and motor home chassis systems use a therm ostatic expansion valve (figure 1). The valve co n sists of the pow er e lem ent, body, actuating pins, seat and orifice. At the high pressure liquid inlet, a fine mesh screen prevents dirt, filings or other foreign matter from entering the valve orifice. When the valve is connected in the system, high pressure liquid refrigerant enters the valve through the screen from the receiver-dehydrator or condenser and passes on to the seat and orifice where it changes into 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 R/V & G SERIES The accum ulator 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 through the oil bleed hole. A bag of desiccant (dehydrating agent), located in the accumulator, collects moisture. There is no sight glass in the accum ulator with the CCOT system. ORIFICE (EXPANSION TUBE) R/V & G SERIES P ressure d iffe re n c e s and su b -co o lin g d ete rm ine s expansion tube flow. The o rifice is located in the evaporator inlet line (figure 3). CYCLING PRESSURE SWITCH This switch controls evaporator temperature. It cycles th e c o m p re s s o r c lu tc h o ff w h e n th e e v a p o ra to r temperature gets too low. It cycles the compressor back on after evaporator tem perature has increased (figure 4). Figure 4—Pressure Cycling Switch T he c y c lin g p re s s u re s w itc h p ro v id e s in h e re n t compressor protection so a separate low pressure switch is not necessary. The switch also acts as an ambient switch since at ambient freezing temperatures it will not allow the compressor to engage. Adjusting the set screw one-half turn left or right will rise or lower the settings 20.7 kPa (3 psi). C ycling Pressure S w itch S e ttin g (A ccu m u la to r Readings) Commpressor Cut Out Pressure R a n g e .................................................71-81 kPa (21-24 psi) Compressor Cut In Pressure R a n g e ......................................145.2-165.4 kPa (43-49 psi) PERIODIC MAINTENANCE AND SERVICING Inspect the system once a year, preferably in the spring before warm weather. Check refrigerant lines for leaks. Check refrigerant charge; evaluate and recharge as necessary. SYSTEM OPERATION — RV & G For information on selector switch, select valve and fan switch operating characteristic, refer to figures 5 and 6. FUNCTIONAL TEST—RV & G To check the operation of the control assembly, perform these tests as one complete operation, refer to figures 7 and 8. AIR CONDITIONING 1B-5 SELECTOR SWITCH OPERATING CHART CONNECTION TERMINAL NUMBER OFF MAX A/C NORM A/C BI-LEV A/C VENT HEATER DEFROST FAN SWITCH 2 NONE 3, 5 3, 5 3, 5 5 5 3, 5 COMPRESSOR 3 NONE 2, 5 2, 5 2, 5 NONE NONE 2, 5 NOT USED 4 BATTERY + 5 2 2 2, 3 NOT USED NONE 2, 3 2, 3 2, 3 SELECT VALUE OPERATING CHART PORT OFF MAX A/C NORM A/C BI-LEV A/C VENT HEATER DEFROST INPUT 1 3 2, 4 2 NONE 2 3 3, 5 A/C MODE 2 VENT 1, 4 1 VENT 1 VENT VENT HTR MODE 3 1 VENT VENT VENT VENT 1 1, 5 OUTSIDE AIR/ RECIRCULATION 4 VENT 1, 2 VENT VENT VENT VENT VENT DEFROST 5 VENT VENT VENT VENT VENT VENT VENT NOT USED 6 CONNECTION SEALED IN THE CONNECTOR BLOWER SWITCH POSITIONS LO MEDIUM 1 MEDIUM 2 HI BATTERY + NONE MEDIUM 1 MEDIUM 2 HI HI NONE NONE NONE BATTERY + MEDIUM 1 NONE BATTERY + NONE NONE NONE NONE BATTERY + NONE TERMINAL MEDIUM 2 B-08404 Figure 5—System Operation — R/V 1B-6 AIR CONDITIONING HI j----------AIRCOND.--------- 1 j-E C O N O M Y -| OFF MAX NORM BI-LEV VENT HEAT DEFM W __ a____! ____ a___ ■____ COLD r — " 1 HOT LO SELECTOR SWITCH OPERATING CHART CONNECTION TERMINAL NUMBER OFF MAX A/C NORM A/C BI-LEV A/C VENT HEATER DEFROST FAN SWITCH 2 NONE 3, 5 3, 5 3, 5 5 5 3, 5 COMPRESSOR 3 NONE 2, 5 2, 5 2, 5 NONE NONE 2, 5 NOT USED 4 BATTERY + 5 NONE 2, 3 2, 3 2 2 2, 3 VENT HEATER DEFROST VENT VENT VENT NOT USED 2, 3 SELECT VALUE OPERATING CHART CONNECTION PORT OFF MAX A/C 1 OUTSIDE AIR/ RECIRCULATION 2 NORM A/C BI-LEV A/C NOT USED - SEALED IN THE CONNECTOR VENT VACUUM VENT VENT HEAT - DEF 3 VACUUM VACUUM VACUUM VACUUM VACUUM VACUUM VENT INPUT 4 VACUUM VACUUM VACUUM VACUUM VACUUM VACUUM VACUUM A/C MODE 5 VENT VACUUM VACUUM VENT VACUUM VENT VENT VENT VENT BI-LEVEL 6 NOT USED - SEALED IN THE CONNECTOR 7 NOT USED - SEALED IN THE CONNECTOR 8 NOT USED - SEALED IN THE CONNECTOR 9 VENT VACUUM VACUUM VACUUM VACUUM BLOWER SWITCH POSITIONS TERMINAL LO MEDIUM 1 MEDIUM 2 BATTERY + NONE MEDIUM 1 MEDIUM 2 HI HI NONE NONE NONE BATTERY + MEDIUM 1 NONE BATTERY + OPTIONAL NONE MEDIUM 2 NONE NONE BATTERY + OPTIONAL HI B-08715 Figure 6—System Operation — G AIR CONDITIONING 1B-7 R/V Functional Test — Air Conditioning P erform th is te s t as o ne o p e ra tio n by o n e in s p e c to r in o n e s ta tio n — o ff roll te s t. SYSTEM RESPONSE CONTROL SETTINGS STEP MODE CONTROL TEMPERATURE CONTROL FAN SWITCH BLOWER SPEED HEATER OUTLETS A/C OUTLETS DEFROSTER OUTLETS 1 OFF COLD OFF OFF NO AIR FLOW NO AIR FLOW NO AIR FLOW 2 MAX COLD LO LOW NO AIR FCOW AIR FLOW NO AIR FLOW A 3 MAX COLD LO TO HI LOW TO HI NO AIR FLOW AIR FLOW NO AIR FLOW B 4 NORM COLD LO TO HI LO TO HI NO AIR FLOW AIR FLOW NO AIR FLOW B 5 BI-LEV COLD HI HI AIR FLOW AIR FLOW MIN AIR FLOW A 6 VENT COLD HI HI NO AIR FLOW AIR FLOW NO AIR FLOW A 7 HTR HOT HI HI AIR FLOW' NO AIR FLOW MIN AIR FLOW A, D HOT HI HI MIN AIR FLOW NO AIR FLOW AIR FLOW A 8 SEE REMARKS REM ARKS A. D e te n t e n g a g e m e n t m u s t be fe lt in each m ode. B. B lo w e r speed in cre a se m u s t o c c u r fro m low, m e d iu m 1, m e d iu m 2, and h ig h. C. L is te n fo r th e re d u c tio n o f a ir n o ise d ue to re c irc u la tio n d o o r c lo s in g . D. ^C heck te m p e ra tu re lever fo r e ffo rt. N O T E ' C h e ck o u tle ts for: 1. Barrel ro ta tio n . 2. Vane o p e ra tio n . 3. Barrel and vanes m u s t h o ld p o s itio n in h ig h blow er. ^ ^ o ld /H o T A i^ 1. W ith th e m od e lever in m a x im u m , th e te m p e ra tu re lever in c o ld , th e -blow e r s w itc h in h ig h , th e te m p e ra tu re fro m th e c e n te r o u tle t s h o u ld d ro p 2 0 ° fro m th e te m p e ra tu re o u ts id e th e v e h ic le (in room te m p e ra tu re o r w a rm e r c o n d itio n s ). 2. W ith th e m od e lever in (d e fro st), th e te m p e ra tu re lever in h o t, th e b lo w e r s w itc h in h ig h , th e te m p e ra tu re fro m th e d e fro s t o u tle t s h o u ld be above th e te m p e ra tu re o u ts id e th e ve h ic le . B-08705 F ig u re 7 — F u n c tio n a l T e s t — R /V 1B-8 AIR CONDITIONING G Functional Test — Air Conditioning P erform th is te s t as o ne o p e ra tio n by o n e in s p e c to r in o n e s ta tio n — o ff roll te s t. CONTROL SETTINGS SYSTEM RESPONSE STEP MODE CONTROL TEMPERATURE CONTROL FAN SWITCH BLOWER SPEED HEATER OUTLETS A/C OUTLETS DEFROSTER OUTLETS 1 OFF COLD OFF OFF NO AIR FLOW NO AIR FLOW NO AIR FLOW 2 MAX COLD LO LOW NO AIR FLOW AIR FLOW NO AIR FLOW A 3 MAX COLD LO TO HI LOW TO HI NO AIR FLOW AIR FLOW NO AIR FLOW B 4 NORM COLD HI HI NO AIR FLOW AIR FLOW NO AIR FLOW A, C 5 BI-LEV COLD HI HI AIR FLOW AIR FLOW NO AIR FLOW A 6 VENT COLD HI HI NO AIR FLOW AIR FLOW NO AIR FLOW A 7 HTR HOT HI HI AIR FLOW NO AIR FLOW MIN AIR FLOW A, D HOT HI HI MIN AIR FLOW NO AIR FLOW AIR FLOW A 8 SEE REMARKS REMARKS A. D eten t e n g a g e m e n t m u s t be fe lt in each m ode. B. B lo w e r sp ee d in cre a se m u s t o c c u r fro m low, m e d iu m 1, m e d iu m 2, and h ig h . C. L iste n fo r th e re d u c tio n o f a ir n o is e d u e to re c irc u la tio n d o o r c lo s in g . D. C h e ck te m p e ra tu re lever fo r e ffo rt. N O TE C h e ck o u tle ts for: 1. Barrel ro ta tio n . 2. Vane o p e ra tio n . 3. Barrel and vanes m u s t h o ld p o s itio n in h ig h blow er. Cold/Hot Air Check 1. W ith th e m o d e lever in m a x im u m , th e te m p e ra tu re lever in c o ld , th e b lo w e r s w itc h in h ig h , th e te m p e ra tu re fro m th e c e n te r o u tle t s h o u ld d ro p 2 0 ° fro m th e te m p e ra tu re o u ts id e th e v e h ic le (in room te m p e ra tu re o r w a rm e r c o n d itio n s ). 2. W ith th e m o d e lever in (d e fro st), th e te m p e ra tu re lever in h o t, th e fan s w itc h in h ig h , th e te m p e ra ­ tu re fro m th e d e fro s t o u tle t s h o u ld be above th e te m p e ra tu re o u ts id e th e v e h ic le . F igure 8-—F u n ctio n a l T est — G AIR CONDITIONING 1B-9 REFRIGERANT-12 OPERATING CHARACTERISTICS SYSTEM COMPONENTS, TEMPERATURE AND PRESSURE RELATIONSHIPS To review system components and Refrigerant-12 flow, refer to figure 9. To find the pressure and tem perature relationship between Refrigerant-12 and atmospheric pressure, refer to figure 10. REFRIGERANT AND OIL CAPACITY The refrigerant system requires refrigerant and oil in quantities listed: 1. Refrigerant-12 — C60 System R/V M o d e ls ............................ 1.588 Kg (3 lbs. 8 ozs.) G M odels.................................1.588 Kg (3 lbs. 8 ozs.) Rear In te rio r S ystem RA?- M o d e ls ............................ 2.381 Kg (5 lbs. 4 ozs.) G M od els.................................2.041 Kg (4 lbs. 8 ozs.) 2. 525 Viscosity Oil — 0.284 Kg (10 oz.). HANDLING REFRIGERANT-12 A ir co nditioning system s contain Refrigerant-12, a c h e m ica l w hich requires sp ecial h an dling to avoid personal injury. Always wear goggles and wrap a clean cloth around fittin g s , valves and co n n e ctio n s when o pening the system. Work in a ventilated area and do not weld or steam clean near air conditioning lines or components. Refrigerant-12 drums are shipped with a metal screw cap that protects the valve and safety plug from damage. Replace the cap after each use. Do not carry a co nta ine r of Refrigerant-12 in the passenger compartment of a vehicle. Never subject any container to high temperatures. Do not breathe the smoke or fumes produced by burning Refrigerant-12. If R e frig e ra n t-1 2 to u c h e s e xp o se d fle sh do th e following: • Treat the area as if it were frost bitten or frozen. • Call a doctor or eye specialist and obtain treatment. • DO NOT RUB THE EYE. Splash the area with cold water to raise temperature above the freezing point. • Use an antiseptic oil to provide a protective film over the eyeball to reduce the possibility of infection. HANDLING OF REFRIGERANT LINES AND FITTINGS Tighten tubing connections to the specified torque (figure 11). Insufficient or excessive torque causes loose joints or deformed joint parts. Either condition can cause refrigerant leakage. • All metal tubing lines should be free of dents or kinks to prevent loss of system capacity due to a line restriction. • Never bend a flexible hose line to a radius of less than 4 times the diameter of the hose. • Never place a flexible hose line closer than 65 mm (2 1/2-inch) to the exhaust manifold. • Inspect flexible hose lines regularly for leaks or brittleness and replace if necessary. • When disconnecting any fitting in the refrigeration system discharge the system. However proceed with caution. Open slowly. Keep face and hands away to prevent injury if there is liquid Refrigerant-12 in the line. Allow any pressure to bleed off as described under “ Discharging, Evacuating, Adding Oil And Charging And Discharging The System .” • Cap or tape any line open to atmosphere to prevent dirt and moisture from entering the system. • Use proper wrenches when making connections on seal (o-ring) fittings. Use two wrenches to prevent distorting the lines or components. • When connecting the flexible hose connections, hold the swaged fittin g , the flare nut and the coupling at the same time using three different w re n c h e s to p re v e n t tu rn in g th e fittin g and damaging the ground seat. • Use seals (o-rings) in good condition. A burr 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. • When making steel to aluminum connections, use the torque for aluminum tubing. (Refer to figure 11). MAINTAINING CHEMICAL STABILITY T he e ffic ie n t o p e ra tio n of th e a ir c o n d itio n in g refrigeration system is dependent upon the chemical stability of Refrigerant-12. F o re ig n m a tte r ca n c h a n g e th e s ta b ility of R efrige ran t-12 , ca use c o rro s io n and wear. Do the following: 1. Before disco nn ectin g a refrigerant connection, remove dirt or oil at and near the connection. Cap or plug both sides of the connection. 2. Keep tools clean and dry. 3. When adding 525 viscosity refrigerant oil (refer to ADDING O IL in the D ischa rg ing , E vacuating, Adding Oil and Charging Procedures for CCOT A/C systems), the transfer device and container should be clean and dry. 4. Have everything ready before opening a line. Do not leave the A/C system open longer than necessary. 5. After opening, evacuate before recharging with R efrigerant-12 a ccordin g to the “ D ischarging, Evacuating, Adding Oil, Charging And Discharging The System .” 6. Service parts are dehydrated and seated before shipping. Open just before making connections. Keep at room temperature before uncapping (this prevents moisture from entering the system). If the connections are not made, reseal the parts. 1B-10 AIR CONDITIONING 33. 130. 124. 600. 601. 604. 605. 606. 606 L. “ H P V ” - H ig h p re s s u re v a p o r lea ving c o m p re s s o r. M. “ HPL” - V a po r is c o o le d d o w n by c o n d e n s e r a ir flo w and leaves as h ig h p re s s u re liq u id . N. “ LPL” - O rific e m e te rs th e liq u id R-12 in to e v a p o ra -. tor, re d u c in g its p re s s u re and w arm b lo w e r a ir a c ro s s e v a p o ra to r co re c a u s e s b o ilin g o ff o f liq u id in to vapor. A c c u m u la to r E xa p a n sio n Tube (O rifice ) E va po rato r C o m p re s s o r C ondenser P ressure C y c lin g S w itc h O il B leed H o le D e s s ic a n t Bag O. “ L P V ” - Leaves e v a p o ra to r as lo w p re s s u re v a p o r and re tu rn s w ith th e s m a ll a m o u n t o f . . . P. “ L P V /lp i” - Low p re s s u re liq u id th a t d id n ’t b o il o ff c o m p le te ly b a ck to th e c o m p re s s o r to be c o m ­ p re ssed a ga in . F-00075 Figure 9— S ystem C om po n en ts REFRiGERANT - 12 PRESSURE - TEMPERATURE RELATIONSHIP The table below indicates the pressure of Refriger­ ant - 12 at various temperatures. For instance, a drum of Refrigerant at a temperature of 26.6°C (80°F) will have a pressure of 579.9 kPa (84.1 psi). If it is heated to 51.6°C (125°F), the pressure will increase to 1 154.9 kPa (167.5 psi). It also can be used conversely to determine the temperature at which Refrigerant - 12 boils under various pres­ sures. For example, at a pressure of 207.5 kPa (30.1 psi), Refrigerant - 12 boils at 0°C (32°F). °C °F kPa PSIG °C °F kPa PSIG -29.8 21.7 0 -28.8 -23.3 -20.5 -17.7 -15.0 -12.2 - 9.4 - 6.6 - 3.8 - 1.1 0 1.6 4.4 7.2 10.0 -2 0 -1 0 -5 0 5 10 15 20 25 30 32 35 40 45 50 16.5 31.0 46.9 63.4 81.4 101 4 17.7 145.5 169.6 196.5 207.5 224.8 255.1 287.5 322.0 Atmos­ pheric Pressure 2.4 4.5 6.8 9.2 11.8 14.7 122.0 21.1 24.6 28.5 30.1 32.6 37.0 41.7 46.7 12.7 15.5 18.3 21.1 23.8 26.6 29.4 32.2 35.0 37.7 40.5 43.3 46.1 48.8 51.6 54.4 60.0 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 140 358.5 397.8 439.2 482.7 530.2 579.9 632.3 686.7 745.3 806.0 870.2 937.7 1010.1 1083.2 1154.9 1234.2 1410.0 52.0 57.7 63.7 70.1 76.9 84 1 91.7 99.6 108.1 116.9 126.2 136.0 146.5 157.1 167.5 179.0 204.5 F igure 10— P ressure T em p eratu re R ela tion ship o f R efrigerant-12 F -00 17 7 AIR CONDITIONING 1B-11 M e ta l T ube O u ts id e D ia m e te r S tee l T u b in g T o rq u e T h re a d and F ittin g Size 7/l6 5/s 3/4 7I& 11/l6 1/4 3/8 1/2 5ls 3/4 A lu m in u m o r C opper T u b in g T o rq u e N-m 14-20 41-48 41-48 41-48 41-48 LB. FT. 10-15 30-36 30-36 30-36 30-36 N-m 7-8 15-18 20-27 28-37 36-45 N o m in a l T o rq u e W re n c h S pan LB. FT. 5-7 11-13 15-20 21-22 28-33 5/s 3/4 7/8 11/l6 1V4 F-00161 Figure 11—Pipe and Hose Connections Torque REFRIGERANT SYSTEM DIAGNOSIS NOTICE: When performing air conditioning di­ agnosis on vehicles equipped with a catalytic converter, warm the engine to a normal operat­ ing temperature before attem pting to idle the engine for periods greater than five minutes. INSUFFICIENT COOLING “QUICK-CHECK” PROCEDURE Use the following “ Hand-Feel” procedure if the system has the pro pe r charge of R efrigerant-12 (provid in g ambient temperature is above 21 °C (70°F). 1. Engine must be warm and at normal idle speed. 2. Hood and body doors open. 3. Selector (mode) lever set at NORM. 4. Temperature lever at COLD. 5. Blower on HI. 6. “ Hand-Feel” the temperature of the evaporator inlet pipe after the orifice and accum ulator with the compressor engaged. — BOTH THE SAME TEMPERATURE AND SOME DEGREE COOLER THAN AM BIEN T — Proper condition: check for other problems (refer to A/C System Diagnostic Procedure). — IN LE T PIPE C O O LER TH AN ACCUM ULATOR SURFACE indicates a low refrigerant charge. • Add amounts 0.113 kg (4 oz.) of refrigerant UNTIL BOTH feel the same temperature. Allow stabilization time between additions. • Then add 0.397 kg (.88 lbs.) one can additional refrigerant. The 0.397 kg/14 oz. disposable can of Refrigerant-12 is the equivalent to .88 lbs.). SYSTEM PERFORMANCE TEST 1. 2. 3. 4. 5. 6. 7. Tool Required: J-21213-A Four Jack-Dual Range Temperature Tester Open doors or windows. Position the right lever in the “ NORM” mode. Place the left lever in the cold (blue) position. Place the blower switch at “ H I.” Install J-21213-A at the instrum ent panel right outlet. Start the engine and run at 2000 rpm. After one minute, the minimum drop in temperature from the center outlet should be: Condenser Inlet Temperature Instrument Panel Right Outlet Temperature (Minimum Drop) 21 °C (70 °F) 26°C (80°F) 32-43°C [90-110°F) -7°C -4°C -1 °C (20 °F) (25 °F) (30°F °) TESTING THE REFRIGERANT SYSTEM If a malfunction is suspected due to abnormal system pressures, check the following: 1. Outer radiator and condensor cores for plugging. Check between the condenser and radiator. 2. R e s tric tio n s o r k in k s in e v a p o ra to r c o re or condensor core, hoses, tubes, etc. 3. Refrigerant leaks. 4. Air ducts for leaks or restrictions. Air restriction may indicate a plugged (or partially plugged) evaporator core. 5. Compressor clutch slippage. 6. Improper drive belt tension. 1B-12 AIR CONDITIONING INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH-EXPANSION TUBE (PRESSURE SENSING) C O N TIN U ED ON FO LLO W ING PAGE F-02215 Figure 12—Insufficient Cooling Diagnosis AIR CONDITIONING 1B-13 F-02653 F igu re 12— In s u ffic ie n t C oo lin g D iagnosis (C ont.) 7. Plugged accumulator, orifice (expansion tube) or plugged suction inlet screen (A6 compressor). 8. Moisture in the refrigerant system. LEAK TESTING THE REFRIGERANT SYSTEM J-29547—AUTO BALANCE REFRIGERANT LEAK DETECTOR Electronic circuitry detects refrigerant or halogen gas leaks as small as 1/2 oz. per year. J-29547 features a slide-type on-off sw itch that also resets the unit in contaminated areas. Audible and visual leak detection is provided by a change in signal tone and flashing LED built into the 45.7 cm (18-inch) flexible probe. A 102 cm (40-inch) coiled extension permits detection in hard to reach places. A green LED battery life monitor glows to indicate sufficient operating voltage when the unit is on. Field service is possible with replacement tips, filters and a sensing element which can be cleaned with common solvent. PRESSURE SENSING SWITCH A pressure sensing switch located near the top of the accumulator, cycles the compressor clutch on R/V and G series systems. The switch also shuts off the compressor clutch when there is a low refrigerant charge. The A/C system does not have to be discharged to replace the switch. The pressure switch fitting is equipped with a schrader-type valve. W hen replacing the switch, use a new oiled seal (o-ring), and torque to 10 N-m (90 in. lbs.). Refer to the following trouble shooting charts: 1. Insufficient Cooling Diagnosis (figures 12, 13, 14, and 15). 2. Compressor Diagnosis (figure 16). 1B-14 AIR CONDITIONING OFF ALL THE TIME CHART “ A” F igure 13— In s u ffic ie n t C oo lin g D iagnosis — C hart A AIR CONDITIONING 1B-15 INLET PIPE COLDER THAN OUTLET PIPE CHART “ B” Figure 14— In s u ffic ie n t C oo lin g D iagnosis — C hart B 1B-16 AIR CONDITIONING CHECK COMPRESSOR CYCLING CHART “ C” B -08574 F ig u re 1 5 — In s u ffic ie n t C o o lin g D ia g n o s is — C h a rt C AIR CONDITIONING 1B-17 COMPRESSOR DIAGNOSIS F -0 2 3 3 3 Figure 16—Compressor Diagnosis 1B-18 AIR CONDITIONING ELECTRICAL/VACUUM TROUBLE DIAGNOSIS When diagnosing problems in the electrical and vac­ uum systems, refer to “ System Operation” and “ Func­ tional Test.” For electrical wiring and vacuum diagrams, refer to figures 17, 18, 19, and 20. Ports on rotary vacuum valves are illustrated to provide simplicity in following vacuum schematic lines but are numbered in consecutive order on the actual valve. OPERATIONAL TEST To determine if the electrical, vacuum and refrigeration systems are operating efficiently, do the following: 1. Operate the blower at four speeds and check the compressor clutch engagem ent. This indicates that the electrical circuits are working. 2. Check the hand felt temperature of the evaporator inlet pipe and accum ula tor surface. The same temperature indicates a properly charged system. 3. Operate the A/C control selector (mode) lever to distribute air from the outlets. This will check the vacuum and diaphragm function. AIR CONDITIONING 1B-19 45 46 47 53 53 A / K / Select Lever Valve Operation Chart Port Max A/C Norm A/C Bi-Level Vent Heat Defrost V a cuu m V a cuu m V a cu u m V a cu u m V a cu u m V a cu u m Vent V a cuu m V a cuu m V a cu u m V a cuu m V a cu u m Vent V a cuu m V a cuu m V a cuu m Vacuum V a cuu m V a cu u m Vent Vent Vent Connection No. Off S o u rce 4 V a cuu m Bi Level 9 H e a t/D e fro s t 3 O S A /R E C 2 Vent V a cuu m Vent Vent Vent Vent AC M od e 5 Vent V a cuu m V a cuu m Vent Vent Vent P o rts 1,6,7 & 8 N o t U sed (Sealed On V a cu u m H o s e A s s e m b ly ) 45. 46. 47. 52. 53. V a cu u m S o u rce - E n g in e V a cu u m Tank - G as C ow l C o n tro l A c tu a to r I. E. H. K. F. V a cuu m V a cuu m V a cu u m V a cu u m V a cuu m L in e Lin e Lin e L in e L in e - Tan (S ource) G ray (Bi Level) D ark B lu e (A/C) Red (H e a t/D e fro s t) O ran ge (R e c irc u la te ) Figure 17—G Vacuum Schematic B-06944 1B-20 AIR CONDITIONING ELECTRICAL SYSTEM DIAGNOSTIC CHART BLOW MOTOR INOPERATIVE (ANY SPEED) CHECK FOR PROPER FUSE. JL r FUSE BLOWN FUSE OK | WITH IGNITION SWITCH IN "R U N ” POSITION AND HEATER OR A/C ON, LOCATE SHORT IN ONE OF THE FOLLOWING WIRES: (SEE NOTE) 1. FROM FUSE PANEL TO MASTER SWITCH ON CONTROL. 2. FROM MASTER SWITCH TO COMPRESSOR CLUTCH. 3. MASTER SWITCH TO BLOWER SWITCH. 4. FROM BLOWER SPEED SWITCH TO RESISTOR. 5. FROM RESISTOR TO BLOWER MOTOR. NOTE: SHORT CIRCUIT MAY BE INTERMITTENT. IF TESTER DOES NOT INDICATE A SHORT CIRCUIT, MOVE HEATER HARNESS AROUND AS MUCH AS POSSIBLE TO RECREATE SHORT CIRCUIT. WATCH AND LISTEN FOR ARCING. THE FOLLOWING TESTS SHOULD BE MADE WITH THE IGNITION SWITCH IN “ RUN" POSITION, HEATER OR A/C ON AND BLOW SWITCH ON HIGH. C CHECK BLOWER MOTOR GROUND. I | POOR OR NO GROUND | | GROUND O K ] CHECK MOTOR CONNECTOR WITH 12 VOLT TEST LIGHT j REPAIR GROUND j LAMP ON LAMP DOES NOT LIGHT REPLACE MOTOR CHECK WIRE CONNECTOR ON BLOWER RELAY WITH 12 VOLT TEST LIGHT. LAMP ON X REPAIR OPEN IN WIRE FROM BLOWER MOTOR TO BLOWER RELAY. LAMP DOES NOT LIGHT C CHECK WIRE CONNECTOR ON BLOWER RELAY WITH 12 VOLT TEST LIGHT. _r LAMP DOES NOT LIGHT I ] USE 12 VOLT TEST LIGHT AND CHECK WIRE TERMINALS AT RESISTOR. 1 LAMP ON T | REPLACE RELAY | 3 [ T r 1 LAMP OFF LAMP ON X I CHECK FEED WIRE FROM RESISTOR TO BLOWER SPEED SWITCH. r LAMP ON — ---------------1 REPLACE RESISTOR. LAMP OFF x REPLACE BLOWER SPEED SWITCH. REPLACE OPEN IN WIRE FROM BLOWER SPEED SWITCH. F -0 0 1 6 7 Figure 18—Electrical System Diagnostic Chart AIR CONDITIONING 1B-21 ELECTRICAL SYSTEM DIAGNOSTIC CHART (CONTINUED) F-00669 Figure 19—Electrical System Diagnostic Chart 1B-22 AIR CONDITIONING Port Connection No. S o u rce 1 A/C M od e Select Lever Valve Operation Chart Off Max A/C 2 V ent V acuum H e a te r/M o d e 3 Vent O p tio n a l O p tio n a l Vent O p tio n a l Vent V a cuu m O S A/R EC 4 V acuum Vent Vent Vent Vent V a cuu m V acuum D e fro s te r 5 V e nt V acuum V acuum Vent V acuum V ent Vent Norm A/C Bi-Level Vent Heat vac Defrost —► P o rts 6,7,8 and 9 n o t used (sealed on v a c u u m h o se a s s e m b ly ) 45. 46. 47. 48. V a cuu m S o u rce - E n gin e V a cuu m Tank (Gas) C ow l P le nu m Valve 49. 50. 51. 53. M od e D o o r D e fro s te r D o o r R e c irc u la to r D o o r A c tu a to r E. F. H. |. J. V a cuu m V a cuu m V a cuu m V a cuu m V a cuu m L in e L in e L in e L in e L in e - G a ry (Source) O ran ge (D e froster) D ark B lue (Heat) Tan (A/C) B la c k (D efroster) F-00182 Figure 20—R/V Vacuum Schematic AIR CONDITIONING 1B-23 VACUUM SYSTEM DIAGNOSIS R/V AND G SERIES Start the engine and allow it to idle. Move the selector lever to each position and refer to the vacuum diagrams and operational charts for airflow, air door functioning and vacuum circuits. If air flow is not out of the proper outlet at each selector lever position do the following: L* Inspect 1. The hose connections at the vacuum actuators, control head valve and vacuum tank. 2. The vacuum source circuit: • Install a vacuum tee and gage (with restrictor) at the vacuum tank outlet. Idle the engine and read the vacuum (a normal vacuum is equivalent to manifold vacuum) at all selector lever positions. • Vacuum less than normal at all positions. Remove the tee and connect the vacuum gage line to the tank - read the vacuum. If still low, then the problem lies in the feed circuit, the feed circuit to the tank or in the tank itself. If vacuum is now normal, then the problem lies downstream. • 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. • Vacuum normal at all positions. If vacuum was normal and even at all positions, then the m alfunction may be caused by im p rop erly connected or plugged lines or a m alfunctioning vacuum valve or valves. 3. Specific vacuum circuit check: • Place the selector lever in the m alfu nctio nin g position and check for vacuum at the pertinent vacuum actuators. • If vacuum exists at the actuator but the door does not move, then the actuator is defective or the door is jammed. • If low or no vacuum exits at the actuator determine whether the cause is the vacuum harness or the vacuum valve. • Check the vacuum harness first. 4. Vacuum harness circuit check: • Disconnect the vacuum harness at the control head. • The black line should show engine vacuum; if not, trace back through connector to vacuum tank. • To check any individual circuit, place the selector lever at the involved circuit position and check for vacuum presence. EVACUATING AND CHARGING PROCEDURES EVACUATION AND CHARGING PROCEDURES Before opening any refrigerant hose or component, read the information furnished in: • Refrigerant-12 Operating Characteristics. • Discharging, Evacuating, Adding Oil and Charging. Remove sealing caps from subassem blies before m aking connections for final assembly. Use a small 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. Tighten all tubing connections (figure 11). Insufficient or excessive torque can cause loose joints or deformed joint parts. Either condition can cause leakage. DISCHARGING, EVACUATING ADDING OIL AND CHARGING PROCEDURES Discharge, evacuate and charge using J-23500-01 air conditioning service Charging Station or the J-5725-04 Manifold Gage Set, and 0.397 kg. (14 oz.) disposable cans of Refrigerant-12 (figures 21 and 22). Use gage adapters to connect the charging lines from the charging station or manifold and gage set to system service fittings. A straight gage Adapter J-5420 and a 90° angle gage Adapter J-9459 is available. Wear goggles and wrap a clean cloth around fittings and connections. • D is c h a rg e th e sys te m b e fo re re m o v in g replacing refrigeration lines or components. and • Use the service valve and pressure gage sets during evacuation and charging procedures. • Do not charge while the compressor system is hot. • Always discharge the system at the low side service fitting and perform the evacuation and charging procedure through the low side service fitting. • Do not connect the high pressure line or any line to the high side service fitting during discharging and charging procedures. CAUTION: Never remove a gage line from its adapter when the line is connected to the A/C system. Always remove the line adapter from the service fitting to disconnect a line. Do not rem ove ch argin g hose at gage set w h ile attached to service low side fitting. This will discharge the system due to the depressed schrader valve in service low side fitting and may cause personal injury due to escaping Refrigerant-12. 1B-24 AIR CONDITIONING 55. G age Set 56. V a cuu m P um p 57. E m p ty 3 Lb. C o ffe e Can 58. R efrigerant-12 quantity in removed parts before evacuation and c h a rg in g w ith R e frig e ra n t-1 2 (re fe r to C C O T 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 accum ulator outlet pipe connection and pour the correct quantity of refrigerant oil into the hose or pipe and then reconnect the hose or pipe. (Refer to step number 4 and Refrigerant Oil Distribution for specific quantity instructions). REFRIGERANT OIL DISTRIBUTION • A-6 COMPRESSOR— 0.284 kg. (10 ounces) of 525 viscosity refrigerant oil. • R-4 COMPRESSOR 0.170 kg. (6 ounces). Add new oil during the following com ponent replacement and conditions: 1. With no excessive oil leakage, add; — C om pressor - Remove, drain oil, measure replace the same am ount of new oil plus 0.0284 kg. (1 ounce). — Evaporator - Add 0.085 kg. (3 ounces). — Condenser - Add 0.0284 kg. (1 ounce). F-00169 Figure 21—J-23500-01 Charging Station DISCHARGING THE SYSTEM B efore re p la cin g any co m p o n e n t, d is c h a rg e the system. 1. Discharge at the low side service fitting. 2. With the ignition turned OFF, remove the protective cap from LOW SIDE service fitting and connect Charging Station J-23500-01 Gage Set. (Refer to figure 21). a. If charging station J-23500-01 is not being u s e d , d is c h a r g e th e sys te m by s lo w ly connecting a gage hose to the low side service fitting on the accum ulator and discharge into a bottle (figure 23). b. As the hose is SLOWLY tightened down onto th e s c h ra d e r v a lv e , R e frig e ra n t-1 2 w ill discharge from the system into the container. If no discharge occurs, check for missing or defective schrader depressor in the hose fitting. 3. With the low side of the system discharged, check the high side system fitting (on the liquid line or muffler) for rem aining pressure. 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 fu lly-tightened down), m easure and record the amount. If 0.0014 kg. (.05 ounce) or more, add this amount of new 525 viscosity refrigerant oil plus any — Accum ulator - R-4 Compressor - Remove drain oil, measure, replace the same amount of new oil plus 0.057 kg. (2 ounces) to compensate for th at retained by the o riginal accum ula tor dessicant. — DA-6 C o m p re s s o r - R em ove, d ra in o il, measure, replace same amount of new oil plus 0.085 kg. (3 ounces) to compensate for that re ta in e d by th e o r ig in a l a c c u m u la to r dessicant. If no oil can be drained from old accumulator, add 0.057 kg. (2 ounces) new oil to the new accumulator. 2. With signs of excessive oil leakage; A-6 COMPRESSOR Remove Compressor and Accumulator. Drain m e a su re and re c o rd to ta l o il fro m both components. Use new oil. • If less than 0.170 kg. (6 ounces), add 180 ml (6 ounces) of new oil to system. • If more than 0.170 kg. (6 ounces), add the same amount of new oil as drained. • If a new a c c u m u la to r is in s ta lle d to A-6 system, add 0.057 kg. (2 ounces) additional oil to compensate for that held/absorbed by the original accum ulator dessicant. DA-6 COMPRESSOR Remove the accumulator. Drain, measure and record quantity of oil in accumulator. It is not necessary to remove and drain the DA-6 com pressor because the com pressor only retains a m inimum quantity of oil, it doesn’t have an oil sump area. • If less than 0.085 kg. (3 ounces) add 0.085 kg. (3 ounces) of new oil to the system. • If more than 0.085 kg. (3 ounces) add the same amount of new oil as drained. AIR CONDITIONING 1B-25 65. A c c u m u la to r F-02407 Figure 22—Charging the System with a Disposable Can or Drum • If a new accum ulator is installed add 0.085 kg. (3 ounces) additional oil to compensate for that absorbed by the original accum ulator dessicant. • If less than 0.085 kg. (3 ounces), add 0.085 kg. (3 ounces) of new oil to system. R-4 COMPRESSOR • If more than 0.085 kg. (3 ounces), add the same amount of new oil as drained. Remove the accumulator. Drain, measure and record quantity of oil in accumulator. It is not necessary to remove and drain the R-4 com pressor because the com pressor only retains a minumum quantity of oil. • If a new accum ulator is installed to system, a dd 0 .0 5 7 (2 o u n c e s ) a d d itio n a l o il to compensate for that retained by the original accum ulator dessicant. EVACUATING AND CHARGING Before charging, evacuate the system if Refrigerant-12 is lost or if the system has been opened. Evacuation and charging is a combined procedure. Purge all gage lines with Refrigerant-12 before charging. There are three standard Refrigerant-12 evacuate and charge procedures: • J-23500-01 Charging Station Method • Disposable Can Method • Drum Method Figure 23—Discharging without Charging Station J23500-01 NOTICE: Do not use alcohol to remove moisture fro m th e s y s te m . A lc o h o l can d a m a g e components. 1B-26 AIR CONDITIONING GAGE CALIBRATION Before evacuation, check the low pressure gage for p ro p e r c a lib ra tio n and vacuum system fo r p ro p e r o p e ra tio n . W ith th e g a g e d is c o n n e c te d from the refrigeration system, be sure that the pointer indicates to the center of “ 0.” Tap the gage to be sure the pointer is not sticking. If necessary, calibrate as follows: • Remove the cover from the gage. • Holding the gage pointer adjusting screw with one hand, carefully force the pointer in the proper direction to position the pointer at the “ 0 ” position. Tap the gage to be sure the pointer is not sticking. Replace the gage cover. VACUUM SYSTEM CHECK Before connecting the vacuum pump to the A/C system run the pump connected to the low pressure gage to determine the vacuum pump capability. If the vacuum system is unable to reach 711.2 - 736.6 mm (28 to 29 inches) or more vacuum check for leaks. If no leaks are found check the vacuum pump. CHARGING STATION METHOD Follow the J-23500-01 Charging Station instructions. Use with the following exceptions: 1. Do not connect the high pressure line to the air conditioning system. 2. Keep the high pressure valve on the charging station closed. 3. P erform th e e vacu ate and ch arge p ro c e d u re through the accum ulator low side pressure service fitting. 4. Following these procedures will prevent high side pressure from dam aging the charging station if an error is made during the sequence. DISPOSABLE CAN OR MULTI-CAN METHOD Tools Required: J-6271-01 Single Can Refrigerant Dispensing Valve J-6272-02 Four Can Refrigerant Dispensing Valve 1. Use tool J-6271-01 for single can or m ulti-can dispensing unit. 2. Use tool J-6272-02 multi-can open valve. When using disposable cans, close the tapping valve and then attach the can(s) following the instructions included with the tapping valve or tapping manifold adapter. REFRIGERANT DRUM METHOD Tool required: J-23390 Refrigerant Dispensing Valve 1. Use tool J-23390 for a 5.443 kg (12 lb.) can. A 13.608 kg (30 lb.) can has a built in opener-valve. Place the drum on a scale and note weight before charging. During charging, watch the scale to determine the amount used. Im portant • C lo s e th e o u tle t v a lv e on th e o p e n e r (clockwise) before installing the opener to the R-12 container. • To evacuate the A/C system install Manifold Gage Set and Vacuum Pump. • SLOWLY open high and low side gage v a lv e s a nd b e g in v a c u u m p u m p operation. Pump the system until the low side gage reaches 459 - 475 mm (28 to 29 inches of mercury [vacuum]) or more. The evacuation procedure will specify 459 475 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 inch of vacuum. At 1524 mm (5,000) feet elevation only 376.9 mm (23 to 24 inches) of vacuum is required. If the prescribed m ercury (vacuum) cannot be reached, close the vacuum control valve, shut off the pum p and look for a leak at the connections or the pump. 2. When the gage reaches the prescribed vacuum, the system is evacuated. Close the high side gage set valve and turn OFF the vacuum pump. 3. Watch the low side gage to be sure vacuum holds for five minutes. If the vacuum holds, disconnect the vacuum hose at the gage set and then proceed to charging. 4. If the vacuum does not hold for five minutes, charge the system with 0.227 kg. (8 ounces) Refrigerant-12 and leak check. Discharge the system again and repair any leaks. Repeat the evacuation procedure. CHARGING THE SYSTEM 1. Start the engine, run with the choke open and the fast idle speed reduced to normal idle, set the A/C control lever on OFF. 2. W ith the drum or 0.397 kg (14 ounces) can(s) inverted, open source valve(s) and allow 0.454 Kg (one (1) pound) or more 0.397 kg (14 ounces) can of liquid Refrigerant-12 to enter the system through low side service fitting on accumulator. 3. When one 0.454 Kg (1 pound) or one 0.397 kg (14 ounces) can of liquid Refrigerant-12 enters the system, engage the compressor by setting the A/C control lever to NORM and blower speed on HI to draw in the remainder of the charge. To speed Up the operation, use a fan to pass air over the condenser. If the condenser temperature remains below the charging cylinder temperature, Refrigerant-12 will enter the system faster. 4. Shut off the source valve and run the engine for 30 seconds to clear lines and gages. 5. With the engine running, remove the charging low side hose adapter from the accum ulator service fitting. Unscrew rapidly to prevent Refrigerant-12 from escaping. AIR CONDITIONING 1B-27 CAUTION: Never remove a gage line from its adapter when the line is connected to the A/C system. Always remove the line adapter from the service fitting to disconnect a line. Do NOT remove the charging hose at the gage set while it is attached to the accumulator. This will discharge the system because of the depressed schrader valve in service low side fitting. Also, th e e sc a p in g R e frig e ra n t-1 2 may cause personal injury. 6. Replace the protective cap on the accum ulator fitting. 7. Turn the engine off. 8. Leak the check system with a J-6084 Leak Detector. 9. Start the engine. 10. With the system charged and leak-checked, operate the system and test for pressures as outlined under R e la tive H um idity, T em p eratu re and P ressure Relationship of Refrigerant-12 (figure 10). ACCUMULATOR ASSEMBLY The accum ulator assem bly has a service replacement which includes two seals (o-rings for the inlet and outlet connections). The desiccant is NOT serviced separately it is part of the sealed accum ulator assembly. Refer to CCOT Refrigerant Oil and Distribution for presence of refrigerant oil and service conditions when removing the accum ulator from the vehicle to measure the oil. Replace the accum ulator assembly when: 1. A physical perforation prduces a leak. 2. The (o rifice ) screen e xpe rie nce s co n tin u e d or repeated plugging. 3. An evaporator fails because of inside-out internal corrosion. DO NOT REPLACE the accum ula tor assem bly where: 1. A dent is found in the outer shell of the accumulator. 2. A vehicle is involved in a collision and there is no perforation to the accum ulator. Cap or place a plastic bag around an open refrigerant line. SPECIFIC COMPONENT DIAGNOSIS COMPRESSOR Com pressor defects can appear as noise, seizures, leakage or low discharge pressures. N O TIC E: R esonant c o m p res so r noises are normal; however, irregular noise or rattles may indicate broken parts or wear. To check seizure, de-energize the magnetic clutch and rotate the d riv e p la te . If ro ta tio n is im p o s s ib le the compressor is seized. To ch eck for a leak, refer to “ Leak Testing The Refrigerant System.” A faulty internal seal, a restriction or an in s u ffic ie n t re frig e ra n t ch arge can cause a low discharge pressure. Check before servicing. 1. Valve stuck open. — Noisy compressor. — No cooling - freeze up. 2. Valve stu ck c lo se d , broken pow er e le m e n t or plugged screen. — Very low suction pressure. —- No cooling. 3. Poorly located power element bulb. — Normal pressure. — Poor cooling. DIAGNOSIS FOR MALFUNCTIONING VALVE CONDENSER A condenser may leak or be restricted. A restriction will cause excessive compressor discharge pressure. If a partial restriction is present, ice or frost will form after the restriction as the refrigerant expands after passing through the restriction. Air flow restrictions through the condenser or radiator can cause high discharge pressures. During normal condenser operation, the outlet pipe will be cooler than the inlet pipe. EXPANSION VALVE There are five expansion valve malfunctions: valve stuck open, valve stuck closed, broken power element, a restricted screen or an improperly located or installed power element bulb. To correct the first three conditions, replace the valve; to correct the last two, replace the valve inlet screen and properly install a power element bulb. Operating the system will indicate valve trouble. U se th e fo llo w in g malfunctioning valve. p ro c e d u re to d e te rm in e a 1. Operate the system at normal idle. If the valve is m a lfu n c tio n in g , th e low p re s s u re re a d in g s (evaporator pressure) will be above specifications (figure 10). 2. The loss of system performance is not as evident when the compressor head pressure is below 1379 kPa (200 psi). Increase the system head pressure by partially blocking the condenser. Disconnect the b lo w e r lead w ire and o p e ra te th e syste m to d e te rm in e if th e e v a p o ra to r p re ssu re can be obtained. EVAPORATOR An inade qu a te su p p ly of cool air can cause the evaporator to m alfunction. Check for a plugged core, a cracked case or a leaking seal. 1B-28 AIR CONDITIONING REFRIGERANT LINE RESTRICTIONS 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. 2. D isch a rg e Lin e - A re s tric tio n w ill ca use the pressure relief valve to open. 3. Liquid Line - A restriction will be caused by low discharge and suction pressure, and insufficient cooling. REFRIGERANT-11 FLUSHING PROCEDURE Tool Required: J-33883 Air Conditioning Flushing Kit Flush the system when: 1. A compressor has failed resulting in debris in the air conditioning system refrigerant components or oil. 2. Inspection of the orifice tube shows the inlet screen to be 25% or more coated with debris. 3. Refrigerant oil is overcharged or contaminated. Follow the kit’s instructions and flush each component separately allowing the Refrigerant-11 to soak in each component for five minutes. Flushing the system requires approximately 6.804 kg (15 lbs.) of R-11 and 1.814 (4 lbs.) of R-12 and up to 0.312 kg (11 oz.) of 525 viscosity refrigerant oil. The actual quantities of R-11, R-12 and oil depends on the system, the number of components flushed and the amount of debris in each component. Remove Refrigerant-11 by purging each components with Refrigerant-12 followed by a system evacuation. Refer to “ On-Vehicle Service” for removal procedures for the system ’s com ponents. Cap or plug all open connections when removing the components. Remove or Disconnect (Figure 24) 1. 2. 3. 4. 5. 6. Battery ground cable. Refrigerant from the system. Compressor. Accumulator. Orifice tube. Evaporator. Inspect Each com ponent for wear or damage. Replace if necessary. Clean • Flush each component with J-38833. Follow the directions included with the kit. + 4- Install or Connect (Figure 24) 1. 2. 3. 4. 5. Evaporator. Orifice tube. Accumulator. Compressor. Refrigerant-12 to the system. • Evacuate, charge and test the system. Figure 24—Flushing a Component with J-33883 • Refer to “ Specifications” for Refrigerant-12 and 525 viscosity refrigerant oil. AIR CONDITIONING 1B-29 ON VEHICLE SERVICE 35 N-m (26 Ft. Lbs.) 3. Connector attaching bolt. 4. Connector. • Cap or plug open connections. 5. Electrical lead to the clutch acutuating coil. 6. Bolt. • Loosen the bracket and pivot bolts. 7. Compressor. • Drain and measure the oil. • Check for contamination. |-n-| Install or Connect (Figures 25, 26, 27 and 28) 1. Oil to the compressor. 1. H o se A s s e m b ly 2. B o lt 7. C o m p re s s o r F-02554 Figure 25—Hose Plate and Bolt Removal — Typical COMPRESSOR REPLACEMENT (R/V) |<-+| Remove or Disconnect (Figures 25, 26, 27 and — 28) 1. Battery negative cable. 2. Refrigerant from the system. | ? | Im portant • Replace with fresh oil. If the system was s e rv ic e d , in s ta ll a fu ll, fre s h c h a rg e of refrigeration oil. 2. Compressor. • Position to the m ounting bracket. 3. Nuts, bolts and spring washer. 4. Connector assembly to the rear of the compressor. Im portant • Use new seals (o-rings) coated with clean refrigeration oil. 5. Electrical lead to the coil. 6. Com pressor belt. 7. Battery negative cable. Figure 26—R/V Compressor Installation — 4.3L, 5.0L, 5.7L Engines 1B-30 AIR CONDITIONING Figure 27—R/V Compressor Installation — 6.2L Engine Adjust • Belt. Refer to ENGINE COOLING (SEC. 6B1). 8. Evacuate, charge and check the system. COMPRESSOR REPLACEMENT (G) ++ Remove or Disconnect (Figures 29, 30 and 31) 1. Battery ground cable. 2. Compressor clutch connector. 3. Refrigerant from the system. 4. Belt. • Loosen the three bolts that hold the idler pulley to the air conditioning support bracket. Refer to ENGINE COOLING (SEC. 6B1). • Back off the idler pulley adjustment screw. 5. Engine cover. 6. Air cleaner. 7. Fitting and m uffler assembly. • Cap or plug all open connections. 8. Compressor bracket. 9. Engine oil tube support bracket bolt and nut. 10. Clutch ground lead. 11. Compressor. Im portant • D ra in and m e a s u re th e o il. C h e c k fo r contamination. |+ + | Install or Connect (Figures 29, 30, and 31) 1. Oil to the compressor. Im portant • Replace with fresh oil. If the system was s e rv ic e d , in s ta ll a fu ll, fre s h c h a rg e of refrigeration oil. 2. Compressor. • Position to the mounting bracket. 3. Nuts, bolts and spring washer. 4. Connector assembly to the rear of the compressor. Im portant • Use new seals (o-rings) coated with clean refrigerant oil. 5. Electrical lead to the coil. 6. Compressor belt. A djust Tighten the idler pulley adjustm ent screw. Measure the belt tention with J-23600-B. Refer to ENGINE COOLING (SEC. 6B1). Tighten the three bolts that hold the idler p u lle y b ra c k e t to th e a ir c o n d itio n in g compressor support bracket. Tighten • Bolts to 33 N m (24 ft. lbs.). • R echeck the belt tension w ith J-23600-B. Refer to ENGINE COOLING (SEC. 6B1). 7. Battery ground cable. 8. Refrigerant to the system. • Evacuate, charge and leak test. AIR CONDITIONING 1B-31 C-K Series Compressor Mounting Component View V8 (7.4 Liter) Gas Engine - Federal Emissions C-K Series Compressor M ounting Component View V8 (7.4 Liter) Gas Engine - California Emissions F-00159 Figure 28—R/V Compressor Installation — 7.4L Engine 1B-32 AIR CONDITIONING 5.0L and 5.7L Engines 4.3L Engine 7. C o m p re s s o r 25. B e lt B-07680 Figure 29—G-Compressor installation — 4.3L, 5.0L and 5.7L Engines (Serpentine Drive) AIR CONDITIONING 1B-33 Figure 31—G-Compressor Installation — 6.2L Engine 1B-34 AIR CONDITIONING A/C SYSTEM—R/V SERIES 1. B lo w e r/E v a p o ra to r A s s e m b ly 2 . R e s is to r 3. S cre w 4. S cre w 5. A u x ilia ry R e s is to r 6. H ose C o n n e c to r 7. C o m p re s s o r 8. U p p e r R e ta in e r 9. S cre w 10. L o w e r R e ta in e r 11. C o n d e n s e r 12. 13. 14. 15. 16. 17. 18. 19. 20. Seal A c c u m u la to r R e frig e ra n t Lin e C ap R elay B o lt B lo w e r M o to r G ro u n d W ire W irin g H a rn e s s B-08670 Figure 32—Air Conditioning System Component View — R/V CONDENSER REPLACEMENT |+ + | Remove or Disconnect (Figures 32 and 33) 1. Battery ground cable. 2. Refrigerant from the system. 3. Grille assembly. 4. Radiator grille center support. 5. Left g rille su pp ort to upper fender support (2) screws. 6. Condenser inlet and outlet lines, and the outlet tube at the right end of the condenser (figure 32). Im portant • Cap or plug all open connections. 7. Condenser to radiator support screws (figure 33). 8. Bend the le ft g rille su pp ort outb oa rd to gain clearance for condenser removal. 9. Condenser assembly by pulling it forward and then lowering it from the vehicle. -►<- Install or Connect (Figures 32 and 33) 1. New condenser. Im portant • Add 30 ml (1 ounce) of clean refrigeration oil to a, new condenser. 2. Left grille support. 3. Radiator support screws. 4. Condenser inlet and outlet lines. Im portant • Use new seals (o-rings) coated with clear re frig e ra tio n w hen co n n e c tin g re frig e ra n t lines. Left grille support to the upper fender support screws. AIR CONDITIONING 1B-35 8. U pper retainer 11. C ondenser 10. Lower retainer 4. Inlet and outlet lines (97). Im portant • Cap or plug open connections. 5. Bracket screws. 6. Accum ulator (13) (figure 34). Im portant • Drain excess re frig e ra n t oil into a clean container. Measure and add new oil. "►+ Install or Connect (Figures 32 and 34) 1. New accumulator. Im portant Figure 33—Conderser Replacement 6. Radiator center support. 7. Grille assembly. 8. Battery ground cable. ACCUMULATOR REPLACEMENT Remove or Disconnect (Figures 32 and 34) 2. 3. 4. 5. 6. • Add 0.028 kg. (one ounce) of clean refrigerant oil. PLUS an amount equal to that drained. Bracket screws. Inlet and outlet lines. Compressor clutch connector. Battery ground cable. Evacuate, charge and check the system. BLOWER ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 32, 34 and 35) 1. Battery ground cable. 2. Insulator - Diesel Engine (figure 35). 3. Blower motor lead and ground wires (134). 1. Battery ground cable. 2. Com pressor clutch connector. 3. Refrigerant from the system. 105. Relay 13. A c c u m u la to r 120. 121. 122. 123. 124. 125. 126. 127. 128. 129. 130. 131. 18. 133. 134. 135. 136. 137. 3. 139. 140. S crew G ro m m e t C ase G ro m m e t C ore C la m p S cre w R ivet B ra cke t P late O rific e G a ske t B lo w e r M o to r H o se W ire A s s e m b ly S w itc h A s s e m b ly C ase Seal R e s is to r C la m p S w itc h 105 139 126 F-02557 Figure 34—Evaporator and Blower Assembly 1B-36 AIR CONDITIONING 5. 6. 7. 8. Evaporator case cover. Nuts to the studs that project into the dash panel. Battery ground cable. Evacuate, charge and check the system. ORIFICE (EXPANSION TUBE) REPLACEMENT The expansion tube is located in the evaporator core inlet line. Remove or Disconnect (Figure 32) 1. Discharge the system. 2. Condenser to the evaporator line at the evaporator inlet (figure 35.) • Cap or plug the open line. 3. Expansion tube from the evaporator core inlet line. • Use needle-nose pliers to remove the core. 4. Expansion tube seal (o-ring) from the core inlet line. 4. Blower motor cooling tube. 5. Blower assembly. • Case attaching screws. • Carefully pry the blower flange away from the case if the sealer acts as an adhesive. 6. Blower wheel from motor shaft. • Remove shaft nut. Install or Connect (Figures 32, 34 and 35) 1. Blower wheel to the motor shaft. 2. Blower assembly. • Use a new bead of sealer on the flange. 3. Blower assembly. 4. Blower motor cooling tube. 5. Blower motor lead and ground wires. 6. Battery ground cable. EVAPORATOR CORE REPLACEMENT Remove or Disconnect (Figures 32 and 34) 1. Battery ground cable. 2. Discharge the system. 3. Nuts from the selector duct studs projecting through the dash panel. 4. Evaporator case cover (122). 5. Inlet and outlet lines. • Cap or inlet open connections. 6. Expansion tube. Refer to ‘‘Orifice (Expansion Tube) R eplacem ent.” 7. Evaporator core assembly. Install or Connect (Figures 32 and 34) 1. New core. • Add 90 ml (3 ounces) of clean refrigeration oil. 2. Expansion tube. 3. Inlet and outlet lines. • Use new seals (o-rings) coated with clean refrigeration oil. 4. Bead of sealer to cover. • Remove old sealer before applying new bead of sealer. |-n-| Install or Connect (Figures 4 and 35) 1. Expansion tube seal (o-ring) to the core inlet line. • Use new seal (o-ring) coated w ith clean refrieration oil. • Insert the short screen and end of the orifice into the evaporator inlet line. 2. Expansion tube to the evaporator core inlet line. 3. Condenser to the evaporator line at the evaporator inlet. 4. Evacuate, charge and check the system. SELECTOR DUCT AND HEATER CORE REPLACEMENT ++ Remove or Disconnect (Figures 36 and 37) 1. Battery ground cable. 2. Drain the radiator. 3. Heater hoses from the core tubes (148) (figure 36). • Plug the core tubes to prevent spillage. 4. Instrument panel com partm ent and door. 5. Center duct to the selector duct (200) (figure 37). 6. Center lower and center upper ducts. 7. Temperature door cable. 8. Nuts from the three selector duct studs that project into the dash panel. 9. Selector duct to dash panel screw (inside the vehicle). 10. Selector duct assembly. • Pull rearward until the core tubes clear the dash panel. • Lower the selector assem bly to reach the vacuum and electrical harness. 11. Vacuum and electrical harness. 12. Selector duct assembly. 13. Core mounting strap screws. 14. Core. Install or Connect (Figures 36 and 37) 1. 2. 3. 4. Core. Core mounting strap screws. Selector duct assembly. Vacuum and electrical harnesses. AIR CONDITIONING 1B-37 J47 148 53. 145. 146. 147. 148. 149. 150. 151. 152. 153. Actuator Valve Housing Screw Core Strap Screw Clamp Connector Link 154. 155. 156. 157. 158. 159. 160. 161. 162. Connector Screw Bracket Shaft Spacer Spring Shaft Bracket Case 163. 164. 166. 167. 168. 169. 170. 171. Valve Nut Valve Screw Link Pin Seal Valve 172. 173. 174. 175. 176. 177. 149 Connector Plate Grommet Hose Screw Yoke F-00093 Figure 36—Air Conditioning and Heater Component View 5. 6. 7. 8. 9. 10. 11. 12. 4. 5. 6. 7. Selector duct assembly. Temperature door cable. Center lower and center upper ducts. Center duct to selector duct. Instrum ent panel bar and door. Heater hoses. Coolant to the radiator. Battery ground cable. ♦«- Install or Connect (Figure 38) Adjust T e m p e ra tu re door c a b le . R e fe r “ Temperature Door Cable A djustm ent.” Cam to actuator arm screw (213). Actuator and bracket from the cam. Actuator to bracket nuts. Actuator from the bracket (53). to ACTUATOR-PLENUM SIDE VENT REPLACEMENT Remove or Disconnect (Figure 38) 1. Vacuum hose at the actuator. 2. Valve return spring at the actuator end (216) (figure 38). 3. Actuator bracket m ounting screws. 1. 2. 3. 4. 5. 6. 7. Actuator to the bracket (53). Bracket nuts. Actuator and bracket to the cam (211). Cam to the actuator arm screw. Actuator bracket m ounting screws. Valve return spring at the actuator end (216). Vacuum hose to the actuator. PLENUM VALVE REPLACEMENT ++ Remove or Disconnect (Figure 39) 1. Raise the hood. 2. Cowl plastic grille. 3. Three cowl to valve assembly screws (226) (figure 39). 1B-38 AIR CONDITIONING 196 180. 181. 182. 183. 184. 185. 186. 187. 188. 189. 190. 191. 192. A d a p te r S cre w A d a p te r H ose D u c t A s s e m b ly S crew D u c t A s s e m b ly Seal Seal D u c t A s s e m b ly G a ske t D u c t A s s e m b ly S cre w 193. 194. 195. 196. 197. 198. 199. 200. 201. 202. 203. 204. R e ta in e r A d a p te r F elt D e fle c to r O u tle t A ir C o n d itio n in g A s s e m b ly B o lt O u tle t A s s e m b ly O u tle t A s s e m b ly S cre w D e fle c to r D e fle c to r F-00080 Figure 37—Duct Assembly Component View AIR CONDITIONING 1B-39 Figure 38—Actuator-Plenum Side Vent • Valve assembly from the vehicle. 4. Actuator arm pushnut. 5. Actuator to valve nuts. • Separate the valve and actuator. "►+ Install or Connect (Figure 39) 1. 2. 3. 4. 5. Actuator to valve nuts. Actuator arm push nut (53). Valve assem bly to the vehicle. Cowl plastic grille. Close the hood. CONTROL ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 40) 1. 2. 3. 4. Battery ground cable. Radio. Refer to RADIO (SEC. 9A). Instrum ent panel bezel. Control from the dash. Lower the control to gain access to the control assembly. Im portant • Do not kink the cable. 5. Cable (236) (figure 40). 6. Vacuum harness. 7. Electrical harness. 8. Control. -►<- Install or Connect (Figure 40) 1. Blower switch to the new control. 2. Electrical harness. 3. Vacuum harness. 4. Cable (236). 5. Control to the dash. 6. Instrument panel bezel. 7. Radio. Refer to RADIO (SEC. 9A). 8. Battery ground cable. 1B-40 AIR CONDITIONING 3. Place the temperature lever in full COLD position and hold while tightening the cable attaching screw. 4. Install instrument panel com partm ent and door. BLOWER SWITCH REPLACEMENT The blower switch is located on the rear of the control assembly. Remove or Disconnect (Figure 40) 1. Battery ground cable. 2. Instrum ent panel bezel. 3. Control to instrument panel screws. • Set the control on top of the radio. 4. Switch to control screws. 5. Electrical harness. 6. Vacuum harness at the master switch. 7. Switch (235). |-n-| Install or Connect (Figure 40) 1. Switch (235). 2. Vacuum harness. 3. Electrical harness. 4. Switch to control screws. 5. Control to the instrum ent panel. 6. Instrum ent panel bezel. 7. Battery ground cable. TEMPERATURE DOOR CABLE ADJUSTMENT Adjust (Figure 41) 1. Remove instrument panel com partm ent and door. 2. Loosen the cable attaching screw at the selector duct assembly. • Make sure the cable is installed in the bracket on the selector duct assembly. Figure 40—Control Assembly Replacement AIR CONDITIONING 1B-41 240 241 244 VIEW B 240. 241. 242. 243. 244. Cable-Temperature Control Bolt/Screw Retainer Heater Control Assem bly Cam VIEW A F-02766 Figure 41—Temperature Door Cable Adjustment VACUUM TANK REPLACEMENT The vacuum tank is mounted to the cowl behind the left front fender. Remove or Disconnect (Figures 42, 43 and 44) 1. Vacuum lines at the tank. 2. Tank to dash panel screws. 3. Tank (251). Install or Connect (Figures 42, 43 and 44) 1. Tank (251). 2. Vacuum hoses. BLOWER MOTOR RESISTOR REPLACEMENT The blower motor resistor is located in the blower side of the blower-evaporator case. |+ + | Remove or Disconnect (Figure 32) 1. W iring harness at the resistor. 2. Resistor to case attaching screws. 3. Resistor (81). I++I Install or Connect (Figure 32) 1. Resistor (81). 2. Screws. 3. W iring harness. BLOWER MOTOR RELAY REPLACEMENT The blower motor relay is located on the blower side of the blower-evaporator case. ++ Remove or Disconnect (Figure 32) 1. W iring harness at the relay. 2. Attaching screws. 3. Relay (105). Install or Connect (Figure 32) 1. Relay (105). 2. Mounting screws. 3. W iring harness. 1B-42 AIR CONDITIONING C 60 7. V a cuu m C o n tro l H o se F-00222 Figure 43—Vacuum Hose — 5.0, 5.7 and 7.4L Engine Figure 44—Vacuum Hose — 6.2L Engine AIR CONDITIONING 1B-43 FUSE REPLACEMENT A 25-amp fuse, located in the junction block, projects the system except for the blower circuit. The fuse for the blower circuit is located in the electrical wiring between the junction block and the blower relay. VACUUM LINE REPLACEMENT— ENGINE COMPARTMENT Rubber vacuum hoses can be repaired by cutting the hose at a leak, inserting a connector and pushing the hoses onto the connector. If the entire hose needs replacing, pull the hose from each connector and thread a new hose into place. Follow the routing of the original hose. For vacuum line routing, refer to figures 42, 43 and 44. 1. 4.3L engine (figure 42). 2. 5.0L, 5.7L and 7.4L engines (figure 43). 3. 6.2L engine (figure 44). REFRIGERANT-12 HOSE REPLACEMENT Refrigerant hoses are replaced as a unit. The hose assembly must be removed from the compressor and the condenser. The hose assem bly has “ captured” seals (o-rings) which are not replaced. New seals are installed on the new hose assembly. For installation, refer to figures 46, 47 and 48. |<-»| Remove or Disconnect (Figures 46, 47 and 48) 1. Refrigerant from the system. 2. Hose plate and bolt from the rear of the compressor (275). 3. Hose connections (97) at the condenser (70) and the accum ulator (107). • Cap or plug all open connections. Install or Connect (Figures 46, 47 and 48) 1. Hose connections (97) at the condenser (70). VACUUM LINE REPLACEMENT — DASH These lines are m olded to a connector w hich is attached to a vacuum control switch on the control assembly. Repair a leaking vacuum hose by cutting the hose at the leak, inserting a connector and pushing the hoses onto the connector. If an entire hose needs replacing, cut the hose off at the connector and attach the hose to the control assembly vacuum switch. To fin d the dash vacuum h a rn e ss and a c tu a to r installation, refer to figure 45. Tighten • Fittings to 24 N m (18 ft. lbs.). 2. Hose connection (97) at the accum ulator (107). Tighten • Fittings to 41 N m (30 ft. lbs.). 3. Hose plate and bolt to the rear of the compressor (275). Tighten • Bolt to 34 N-m (25 ft. lbs.). 4. Refrigerant to the system. • Leak test. 1B-44 AIR CONDITIONING 7. V a cuu m H a rn e s s 53. A c tu a to r E. V a cu u m L in e — G ray To S o u rce F. V a cu u m L in e — O ran ge G. V a cuu m L in e — S trip e 236. C ab le 244. Cam 265- C o n tro l A s s e m b ly 266. 267. P le n u m Valve (A ctu a to r) R e c irc A ir Valve (A ctu a to r) 268. H e a te r A s s e m b ly 269. A ir C o n d . Valve (A ctu ator) 270. D e fro s t (A ctu a to r) H. V a cu u m L in e — D ark B lue I. V a cu u m L in e — Tan F-00234 Figure 45—Vacuum Control Hose — Dash Figure 46—R/V — 4.3L Engine Refrigerant Hose Assembly AIR CONDITIONING 1B-45 Figure 48—R/V — 6.2L Engine Refrigerant Hose Assembly 1B-46 AIR CONDITIONING REAR INTERIOR ROOF MOUNTED SYSTEM—SUBURBAN 303 301. 302. 303. 304. 305. W a sh e r S crew S h rou d S crew C lip 306. 307. 308. 309. 310. D e fle c to r O u tle t B ra cke t N ut S crew F-00224 Figure 49—Rear Interior Roof Mounted System — Shroud The rear interior roof mounted system is used with the front air conditioning system. Refer to figures 49, 50 and 51. Install or Connect (Figure 49) 1. Duct (303). 2. Screws and brackets. REAR DUCT REPLACEMENT T his d uct covers the b lo w er-evaporator a ssem bly located at the rear of the vehicle. It has four adjustable air outlets (figure 49). Remove or Disconnect (Figure 49) 1. Drain tube from the rear duct. 2. Screws securing the duct to the roof panel and rear header brackets. 3. Duct (303). 3. Drain tube. BLOWER MOTOR RESISTOR REPLACEMENT The blower motor resistor is located on the cover side of the blower-evaporator. To remove, refer to “ Blower Motor Resistor, A/C System R/V Series.” AIR CONDITIONING 1B-47 320. 321. 322. 323. 324. 325. 326. 327. 328. 329. 330. 331. 332. S crew B ra cke t S crew S crew S u p p o rt S cre w C ase Plate S crew Seal M o to r A sm . E yelet T erm inal 333. 334. 335. 336. 337. 338. 339. 340. 341. 342. 343. 344. B ra cket S crew Seal Case C lip Seal C ore A sm . Seal (O -ring) R e frig e ra n t L in e s Valve A sm . S crew C la m p s F-00602 Figure 50—Rear Interior Roof Mounted Evaporator and Blower Component View 1B-48 AIR CONDITIONING 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. S crew B ra cket Seal Seal C lip B o lt C lip W ire B ra cket C over B ra cket S crew B ra cket H ose H ose C lip C lip B o lt W a sh er F ittin g 26. L o w e r R e ta in e r 27. 29. 34. 35. 36. 37. 38. 41. 42. 44. Seal P late C lip S cre w B ra cke t 45. 46. 47. 48. 49. 303. 324. E va p o ra to r and B lo w e r A s s e m b ly D e fle c to r O u tle t C la m p Tube S h ro u d S u p p o rt 25. C o n d e n s e r F-00667 Figure 51—Rear Interior Roof Mounted Evaporator Hoses Component View AIR CONDITIONING 1B-49 BLOWER MOTOR ASSEMBLY REPLACEMENT ++ 1. 2. 3. 4. 5. 6. Remove or Disconnect (Figure 50) Battery ground cable. Rear duct (303). Blower motor ground strap. Blower motor lead wire. Lower to upper blower-evaporator case screws. Case and motor assembly (326) (336). ■n- Install or Connect (Figures 50 and 51). 1. New expansion valve assembly (342). • Remove caps or plug. • Use new seals (o-rings) coated with clean refrigeration oil. 2. Sensing bulb. 3. Lower case and blower motor assembly. 4. Blower motor lead. 5. Ground wires. 6. Rear duct. 7. Battery ground cable. 8. Evacuate, charge and check the system. Important • Before removing the case screws, support the lower case to prevent damage to the case or motor assembly. 7. Motor retaining strap. 8. Motor and wheels (330). 9. Wheels from the motor shaft. 0 Install or Connect (Figure 50) 1. W heels to the motor shaft (330). I. Place the tension springs on the wheel hubs. 2. Motor and wheels to the case. • Align the wheels to prevent contact with the case. 3. Motor retaining strap and foam. 4. Lower case and blower motor assem bly in the vehicle (336). 5. Lower to upper case screws. • Turn the blower wheels to prevent rubbing against the case. 6. Center ground strap. 7. Blower lead wire. 8. Rear duct. 9. Battery ground cable. EXPANSION VALVE REPLACEMENT This system incorporates an expansion valve which does not utilize and external equalizer line. Remove or Disconnect (Figures 50 and 51) 1. 2. 3. 4. 5. 6. Battery ground cable. Purge the system of refrigerant. Rear duct. Blower motor lead. Ground wire. Lower to upper blower-evaporator case screws. Im portant • Before removing the case screws, support the lower case and motor assemblies to prevent damage to the case or motor assembly. Lower case and motor assembly (336). Expansion valve sensing bulb clamps. Valve inlet and outlet lines. • Cap or plug open lines. 10. Expansion valve assembly (342). EVAPORATOR CORE REPLACEMENT ++ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Remove or Disconnect (Figures 50 and 51) Battery ground cable. Purge the system of refrigerant. Rear duct. Blower motor lead. Ground wire. Refrigerant lines at the rear of the blower-evaporator assembly (351). • Cap or plug the open connections. Blower-evaporator support to roof rail screws. Blower-evaporator (339). • Place the blower-evaporator upside down on a work bench. Lower case assembly. Upper case from the evaporator core. Expansion valve inlet and outlet lines. • Cap or plug open connections. Expansion valve capillary bulb from the evaporator oulet line. Valve. Plastic pins that hold the screen to the core. Screen. Install or Connect (Figures 50 and 51) 1. Wire screen to the front of the core. 2. Plastic pins. 3. Expansion valve inlet and outlet lines (341). • Use new seals (o-rings) coated with clean rerfrigeration oil. 4. Sensing bulb to the evaporator outlet line (342). • Bulb must make good contact with the line. • Add 30 ml (3 ounces) of clean refrigeration oil to new core. 5. Upper case and supports to the core. 6. Lower core case and blower assembly. 7. Blower-evaporator assembly to the roof. 8. Support to roof rail screws. 9. Refrigerant lines to the blower-evaporator unit. • U se new s e a ls (o -rin g s ) w ith c le a n refrigeration oil. 10. Blower lead wire. 11. Ground wire. 12. Rear duct. 13. Battery ground cable. 14. Evacuate, charge and check the system. 1B-50 AIR CONDITIONING BLOWER MOTOR SWITCH REPLACEMENT The a u xilia ry heater and air c o n d itio n in g blow er switches are located to the right of the steering wheel. Remove or Disconnect (Figure 52) -► 1. 2. 3. 4. Battery ground cable. Switch retaining screws. Wiring harness. Switch. 4- Install or Connect (Figure 52) 1. 2. 3. 4. Switch. Wiring harness. Switch retaining screws. Battery ground cable. 1. 2. 3. 4. FUSE REPLACEMENT S crew N ut Bezel S w itc h F-02555 Figure 52—Blower Switch Replacement 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 rear blower high speed circuit. A/C SYSTEM — G SERIES CONDENSER REPLACEMENT 0 ACCUMULATOR REPLACEMENT Remove or Disconnect (Figure 53) Remove or Disconnect (Figure 53 and 54) 1. Battery ground cable. 2. Refrigerant from the system. 3. Grille, hood lock, and center hood lock support. 4. Condenser inlet and outlet lines at the condenser (70). 1. 2. 3. 4. Battery ground cable. Com pressor clutch cable. Discharge the system. Inlet and outlet lines. 5. Screws attaching the left side condenser bracket to the radiator. 6. Screws attaching the right side condenser bracket to the condenser. 7. Condenser. Im portant • Cap or plug open connections. 5. Bracket screws. 6. Accumulator. 8. Left bracket from the condenser. |-K-| Install or Connect (Figure 53) I 2 I Im portant • D rain excess re frig e ra n t oil into a clean container. Measure and record amount. Use fresh oil. 1. Left bracket to condenser. 2. Condenser (70). • Add 30 ml (1 ounce) of clean refrigeration oil to a new condenser. 3. Screws attaching the left side of the condenser bracket to the condenser. 4. Screws attaching the right side of the condenser bracket to the condenser. 5. Condenser inlet and outlet lines at the condenser (70). Install or Connect (Figure 53 and 54) New accumulator. 9 Im portant • Add 30 ml (1 ounce) of clean refrigerant oil PLUS an amount equal to that drained. 2. Bracket screws. 6. Grille, hood lock and center hood lock support. 3. Inlet and outlet lines. 7. Refrigerant. 4. Compressor clutch connector. 8. Battery ground cable. 5. Battery ground cable. 9. Evacuate, charge and test the system. 6. Evacuate, charge and check the system. AIR CONDITIONING 1B-51 20 12 1. 2. 3. 6. 7. B lo w e r and E va p o ra to r A s s e m b ly S crew R e s is to r H ose C o n n e c to r C ondenser 12. 13. 14. 15. 16. Seal A c c u m u la to r R e frig e ra n t Line Cap R elay 31. 32. 33. B-08467 Figure 53—Air Conditioning System Component View HEATER CORE REPLACEMENT «"► Remove or Disconnect (Figure 54) 1. Battery ground cable. 2 . Engine cover. 3. Steering column to instrument panel. • Lower column. 4. Upper and lower instrument panel attaching screws and radio support bracket attaching screw. 5. Raise and support right side of the instrum ent panel. 6. Right lower instrum ent panel support bracket. 7. Recirculating air door vacuum actuator. 8. Tem perature cable and vacuum hoses at the distributor case. 9. Heater distributor duct. 10. D efroster duct to dash panel attaching screws (below the windshield). 11. Heater hoses (457). • Plug to prevent spillage. 12. Three nuts from the bolts that hold the heater core case to the dash panel and one screw at the lower right corner (inside). 13. Distributor assembly from the vehicle. 14. Gasket to expose the screws attaching the case sections together. 15. Temperature cable support bracket. 16. Case attaching screws and separate the case. 17. Heater core (457). Install or Connect (Figure 54) 1. 2. 3. 4. 5. 6. 7. 8. 9. New heater core. Screws and case. Temperature cable support bracket. Gasket. Distributor assembly. Heater core nuts to bolts. Heater hoses. Defroster duct to dash panel screws. Heater distributor duct. 1B-52 AIR CONDITIONING 425. 53. 427. 428. 429. 430. 431. 432. 433. 434. 435. 436. 437. 438. 439. N ut A c tu a to r A s s e m b ly Case Valve N ut Fan A s s e m b ly W a sh er T erm in al M o to r A s s e m b ly Tube A c c u m u la to r ^ ^ D e h y d ra to r j [ A s s e m b ly C la m p if . C la m p C la m p Case 445. 446. 447. 448. 449. A s s e m b ly 4 5 5 Case Seal Seal C la m p ^ ^ ^ ^ E v a p o ra to r A s s e m b ly Seal F ilte r R e ta in e r S w itc h A s s e m b ly . C ase "* 450. 451. 452. 453. 454. 455. O rific e G a sket G a ske t B ra cke t G a ske t S tud 440. 441. 442. 443. 444. 456. 457. 458. 459. 460. 461. 462. 463. 464. 465. 466. 467. 468. 470. 471. 472. 473. 474. 475. Valve A s s e m b ly C ore C la m p Valve S h a ft C o n n e c to r L in k C o n n e c to r S h a ft Valve A s s e m b ly Valve A s s e m b ly C ase D uct H o u s in g R e ta in e r D uct Seal Valve S h a ft A s s e m b ly 460461 F-02408 Figure 54—Evaporator — Blower Component View AIR CONDITIONING 1B-53 10. Tem perature cable and vacuum distributor. hoses at the EVAPORATOR CORE (W/DIESEL) REPLACEMENT 11. Right lower instrum ent panel support bracket. Remove or Disconnect (Figures 54 and 55) 12. Right side of the instrum ent panel. 13. Upper and lower instrum ent panel screws. 14. Radio support bracket screw. 15. Steering column to instrum ent panel attaching bolts and raise the column. 16. Engine cover. 17. Battery ground cable. ORIFICE (EXPANSION TUBE) REPLACEMENT The orifice tube is located in the evaporator core inlet line. Remove or Disconnect (Figure 53) 1. Discharge the system. 2. Condenser to the evaporator line at the evaporator inlet. • Cap or plug the open line. 3. Expansion tube from the evaporator core inlet line. • Use a needle nose pliers to remove the orifice from the tube. 4. Expansion tube seal (o-ring) from the core inlet line. -►+ Install or Connect (Figure 53) 1. Cold air intake. 2. Hood latch assembly and cable retainer and place it out of the way. 3. W indshield solvent tank. 4. Refrigerant from the system. Im portant 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Install or Connect (Figures 54 and 55) 1. Expansion tube seal (o-ring) to the core inlet line. • Use a new seal (o-ring) coated with clean refrigeration oil. • Insert the short screen end of the orifice into the evaporator inlet line. 2. Expansion tube to the evaporator core inlet line. 3. Condenser to the evaporator line at the evaporator inlet. 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 w ithout air conditioning and around the blower motor and evaporator core with air conditioning option (figure 55). □ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 1. Parking lamp assembly. • Insulation through the hood opening. 4. Blower motor (482). 0 Install or Connect (Figures 54 and 55) 1. Blower motor (482). 2. Insulation (481). 3. Radiator overflow tank. 4. Parking lamp assembly. A/C evaporator core procedure. Insulation (481). Insulation m ounting screws. Lower section. Heater valve assembly bracket. Radiator. Fan shroud upper half. Blower motor relay and resistor. W iring harness. High pressure line inlet and bracket. Accumulator. Low pressure vapor line. Refrigerant to the system. W indshield solvent tank. Hood latch assem bly and cable retainer. Cold air intake. EVAPORATOR CORE REPLACEMENT Remove or Disconnect (Figure2 54 and 55) 2. Radiator overflow tank. 3. Blower motor insulation (481). • W hen rem oving A/C com ponents, cap the lines and openings to prevent contamination. Low pressure vapor line and move it out of the way. Accumulator. High pressure line inlet to the evaporator and the connecting bracket. W iring harness going to the blower motor relay and resistor. Blower motor relay and resistor. Fan shroud upper half. Radiator. Heater valve assembly bracket and move it out of the way. Upper screws of the lower section. • Push it down and out of the way. Insulation mounting screws. Insulation through the hood opening. Proceed with the A/C evaporator procedure. |<"+| Remove or Disconnect (Figure 54) 1. 2. 3. 4. 5. 6. 7. Battery ground cable. Refrigerant from the system. Coolant recovery tank and bracket. Electrical connectors from the core case assembly. Bracket at the evaporator case. Right marker lamp for access. Accum ulator inlet and outlet lines, and the two brackets that attach the accum ulator to the case. 8. Evaporator inlet line. 1B-54 AIR CONDITIONING Figure 55—Blower Motor Insulation — 6.2L Engine 9. Three (3) nuts and one (1) screw attaching module to the dash panel. 10. Core case assembly from the vehicle. 11. Screws and separate the case sections. 12. Evaporator core. 0 Install or Connect (Figure 54) 1. New core. • A dd 90 ml (3 o u n c e s ) or 525 v is c o s ity refrigeration oil to a new condenser. 2. Screws and the case sections. 3. Core case assem bly to the vehicle. 4. Module to the dash panel. 5. Evaporator inlet line. 6. Accum ulator inlet and outlet lines. 7. Two brackets that hold the accum ulator to the case. 8. Right marker lamp. 9. Bracket to the evaporator case. 10. Electrical connectors. 11. Coolant recovery tank and bracket. 12. Evacuate, charge and check the system. 13. Battery ground cable. BLOWER MOTOR REPLACEMENT Remove or D isconnect (Figure 54) 1. Battery ground cable. 2. Coolant recovery tank. 3. Power antenna. 4. Blower motor lead wire. 5. Motor and wheel assembly (433). • Five blower motor m ounting screws. • Pry gently on the blower flange if the sealer acts as an adhesive. 6. Blower wheel to motor shaft nut. 7. Separate the wheel and motor assemblies. Install or Connect (Figure 54) 1. Wheel to the blower motor. • Assemble the blower wheel to the motor with the open end of the wheel away from the blower motor. 2. Blower wheel to the m otor shaft nut. 3. Blower wheel and motor assem bly to the vehicle. • If the m otor m o u n tin g fla n g e se a le r has hardened or is not intact, remove the old sealer and apply a bead of sealer to the mounting flange. • Check blower operations: blower wheel should rotate with no interference. 4. Blower motor lead wire. 5. Coolant recovery tank and power antenna. 6. Battery ground cable. AIR CONDITIONING 1B-55 • Lower right tab. 5. Electrical harness (502) (figure 58). 6. Vacuum harness (506) (figure 59). 7. Control assembly. Install or Connect (Figures 56, 57, 58 and 59) 1. Electrical and vacuum connection to the control. 2. Control into the opening in the dash panel. 3. Temperature cable. ^ 4 9 0 . In s tru m e n t Panel 491. C o n tro l _ 492. S cre w ^ 492 F-00332 CONTROL ASSEMBLY REPLACEMENT T e m p e ra tu re d o o r o p e ra tio n . R e feto r “ Temperature Door Cable A djustm ent.” 6. Battery ground cable. Remove or Disconnect (Figures 56, 57, 58 and 59) Battery ground cable. Headlamp switch control knob. Instrument panel bezel. Control (491) (figure 56). • Screws. • Temperature cable eyelet clip and retainer (499) (figure 57). • Control lower right mounting tab through dash opening. • Upper tab. 491. 495. 496. 497. • 4. Instrument panel bezel. 5. Headlmap switch control knob. Figure 56—Control Assembly Removal 1. 2. 3. 4. Adjust \ TEMPERATURE DOOR CABLE ADJUSTMENT Adjust (Figure 56) 1. Remove instrum ent panel compartm ent and door. 2. Loosen the cable attaching screw at the selector duct assembly. • Make sure the cable is installed in the bracket on the selector duct assembly. 3. Place the temperature lever in full HOT position and hold while tightening the cable attaching screw. Install instrum ent panel com partm ent and door. C o n tro l A s s e m b ly D e fro s te r D u ct T e m p eratu re C able H e a te r A n d D e fro s te r A s s e m b ly 498. B ra cke t 499. R e ta in e r view [1] F-00324 Figure 57—Temperature Control Cable 1B-56 AIR CONDITIONING 495 O ra n g e D o u b le B la c k S trip e W ire 491. C o n tro l A s s e m b ly 495. D e fro s te r D u c t B o d y W irin g H arne ss A/C W irin g H a rn e s s B lo w e r M o to r S w itc h In s tru m e n t Panel H a rn e s s Ig n itio n F-00348 Figure 58—Instrument Panel Wiring Harness I. E. H. K. F. 491. 495. 497. 502. 506. V a cuu m L in e — Tan V a cu u m L in e — G ray V a cu u m L in e — D ark B lue V a cu u m L in e — Red V a cuu m L in e — O ran ge C o n tro l D e fro s te r D u c t H e a te r A n d D e fro s te r A s s e m b ly A/C H a rn e s s A/C V a cuu m H a rn e s s F-00326 Figure 59—Vacuum Harness Assembly AIR CONDITIONING 1B-57 0 491. C o n tro l A s s e m b ly Install or Connect (Figure 61) 1. Relay (511). • Screws. 2. Electrical harness. 493. B lo w e r M o to r S w itc h A/C DUCT WORK REPLACEMENT Remove or Disconnect (Figure 62) L i — 493 F-00355 Figure 60—Blower Switch Wiring Harness BLOWER SWITCH REPLACEMENT — Remove or Disconnect (Figures 56, 57, 58 and 60) 1. Battery ground cable. 2. Left-foot cooler outlet assembly at the instrument panel attachment. 3. Electrical harness (figure 60). 4. M ounting screws. 5. Control assembly (491). 6. Switch (493). 2. Engine cover. 3. Steering column to the instrument panel attaching screws. 4. Radio,support bracket screw. • Pull the right side of the instrument panel rearward. 7. Duct (distributor) attaching screws. 8. Center deflector (527) (figure 62). -►4- Install or Connect (Figure 62) 1. Center deflector (527). 2. Instrument panel. 3. Radio support bracket. 4. Steering column. 5. Engine cover. 6. Battery ground cable. DEFROSTER DUCT REPLACEMENT Install or Connect (Figures 56, 57, 58 and 59) 1. New switch. • Mounting screws. To remove the defroster duct mounting, refer to figure 62. 2. Electrical harness. 3. Control assembly (491). 4. Left-foot cooler outlet assembly. 5. Battery ground cable. RESISTOR REPLACEMENT Remove or Disconnect (Figure 61) 1. Electrical harness. 2. Resistor mounting screws. 3. Resistor (510) (figure 61). Install or Connect (Figure 61) 1. Resistor (510). • Screws. 2. Electrical harness. BLOWER MOTOR RELAY REPLACEMENT «"► Remove or Disconnect (Figure 61) 1. Electrical harness. 2. Relay mounting screw. 3. Relay (511). TEMPERATURE DOOR CABLE REPLACEMENT To remove the temperature door cable refer to “ Control Assembly R eplacem ent” and figure 57. VACUUM TANK REPLACMENT Remove or Disconnect (Figures 63, 64 and 65) 1. 2. 3. 4. Raise the hood. Vacuum harness at the tank (552). Tank attaching screws. Tank (551). Install or Connect (Figures 63, 64 and 65) 1. Tank (551). 2. Vacuum harness. 3. Lower the hood. VACUUM LINES — ENGINE COMPARTMENT For vacuum line assemblies, refer to figures: 1. 4.3L Engine (figure 63). 2. 5.0L and 5.7L Engine (figure 64). 3. 6.2L Engine (figure 65). 1B-58 AIR CONDITIONING 433 418. 433. 435. 497. 497 435 C o m p re s s o r M o to r A c c u m u la to r/D e h y d ra to r A s s e m b ly E v a p o ra to r B lo w e r M o to r A s s e m b ly 502. 510. 511. 512. 513. A/C H a rn e s s R e s is to r A s s e m b ly R elay A s s e m b ly J u n c tio n B lo c k T h ro ttle S o le n o id F-00327 Figure 61—Wiring — Engine Compartment REFRIGERANT-12 HOSE ROUTING For Refrigerant-12 hose assemblies refer to: 1. 4.3L Engine (figure 66). 2. 5.0L and 5.7L Engine (figure 67). 3. 6.2L Engine (figure 68). AIR CONDITIONING 1B-59 525 529 528 530 525. 526. 527. 528. 529. D u ct A s s e m b ly S crew D u c t A s s e m b ly W a sh er D e fle c to r A s s e m b ly 530. Bezel 531. 532. 533. 534. 535. 536. S crew Seal O u tle t A s s e m b ly G a ske t G a ske t D uct 531 536 537. 538. 539. 540. 541. 542. 531 H e a te r A s s e m b ly S u p p o rt O u tle t A s s e m b ly S cre w N ut In le t A s s e m b ly 543. 544. 545. 546. 547. 548. Seal D uct N ut D uct D uct D uct F-00279 Figure 62—Duct Component View 1B-60 AIR CONDITIONING 553. V acuum F ittin g 554. Cap C60 F-00328 Figure 63—Vacuum Tank Assembly — 4.3L Engine AIR CONDITIONING 1B-61 Figure 64—Vacuum Tank Assembly — 5.0 and 5.7L Engine 1B-62 AIR CONDITIONING 552. V a cu u m Line 555. V a cu u m P um p F-00330 Figure 65—Vacuum Tank Assembly — 6.2L Engine 70. C o n d e n s e r 97. R e frig e ra n t H ose 107. E v a p o ra to r and B lo w e r A s s e m b ly 275. C o m p re s s o r 276. R a d ia to r F-00386 Figure 66—4.3L Engine Refrigerant Hose Assembly Figure 67—5.0L and 5.7L Engines Refrigerant Hose Assembly AIR CONDITIONING 1B-63 70. 97. 107. 275. 276. C ondenser R e frig e ra n t H o se E va po rato r A n d B lo w e r A s s e m b ly C o m p re s s o r R a d ia to r F-00387 Figure 68—6.2L Engine 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 identical to the R/V rear interior roof mounted system. For servicing, refer to figure 69. 1B-64 AIR CONDITIONING Figure 69—G-Rear Interior Roof Mounted System — Component View AIR CONDITIONING 1B-65 1. 2. 3. 4. 5. 7. 8. 9. 10. Seal H ose S crew C la m p G ro m m e t E va po rato r B ra cke t B ra cke t H ose 11. 12. 13. 14. 15. 16. 17. 18. 19. S h ie ld P late P late Tube C lip Tube G ro m m e t S cre w C ondenser 20. 21. 22. 23. 26. 27. 28. 29. 30. Tube C ap F ittin g W a sh e r Tube S cre w A c c u m u la to r B ra cke t R e ta in e r 31. 32. 33. 34. 35. 36. 37. 38. Tube S w itc h S cre w R e s is to r C ase S w itc h N ut S cre w 39. 40. 41. 42. 43. 44. 45. 46. W a sh e r S w itc h S h ro u d D e fle c to r S lip S crew S cre w S u p p o rt F-03320 R-Rear Interior Roof Mounted System — Component View A/C SYSTEM — P SERIES Figure 71—P-Compressor Installation The compresser and condenser are installed on the ve­ hicle during assembly. They are removed and shipped separately. For reference refer to the following figures: 1. Condenser M ounting - refer to figure 70. 2. Compressor Installation - refer to figure 71. 1B-66 AIR CONDITIONING SPECIFICATIONS A-6 COMPRESSOR T ype.................................................................................................................................................................................. 6 Cylinder Axial D isplace m en t..........................................................................................................................................................................12.6 Cu. In. R otation.......................................................................................................................................................................................Clockwise SYSTEM CAPACITIES R e frig e ra n t.................................................................................................................................... 1.587 6 kg (3 lbs. 8 ounces) 525 Viscosity Compressor O il.............................................................................................................. 0.284 Kg. (10 ounces) TORQUE SPECIFICATIONS Compressor Suction and Discharge Connector B o l t ....................................................................................24 N m (18 ft. Ib.s) Oil Drain S c re w ......................................................................................................................................................17 N m (13 ft. lbs.) Cycling Pressure S w itc h .................................................................................................................................... 10 N m (7.5 ft. lbs.) Engine Bracket M ounting B o lts ......................................................................................................................... 28 N m (21 ft. lbs.) Compressor Support Bracket B o lts .............................................................................................................. .. .27 N m (20 ft. lbs.) All Other Mounting B o lts .................................................................................................................................... 43 N m (32 ft. lbs.) DA-6 COMPRESSOR T ype ................................... ...............................................................................................................................................6 Cylinder Axial D is p la ce m e n t..........................................................................................................................................................................10.0 Cu. In. R otation.......................................................................................................................................................................................Clockwise SYSTEM CAPACITIES R e frig e ra n t.........................................................................................................................................1.587 kg (3 lbs. 8 ounces) 525 Viscosity Compressor O il................................................................................................................ 0.227 Kg. (8 ounces) TORQUE SPECIFICATIONS Compressor Suction and Discharge Connector B o l t ....................................................................................24 N m (18 ft. lbs.) Shaft N u t................................................................................................................................................................. 16 N m (12 ft. lbs.) Cycling Pressure S w itc h .................................................................................................................................... 10 N m (7.5 ft. lbs.) Front Mounting Bracket Bolts (R /V )...................................................................................................................51 N m (38 ft. lbs.) Front Mount Bracket Nut (R/V)........................................................................................................................... 24 N m (18 ft. lbs.) Rear Brace Bolts (R /V ).........................................................................................................................................33 N m (20 ft. lbs.) Rear Compressor Support Bolt (R/V-6.2L E n g in e ) ...................................................................................... 30 N m (22 ft. lbs.) R-4 COMPRESSOR Type................................................................................................................................................................................ 4 Cylinder Radial D isp la ce m e n t..........................................................................................................................................................................10.0 Cu. In. R otation.......................................................................................................................................................................................Clockwise SYSTEM CAPACITIES R e frig e ra n t.................................................................................................................................... 1.587 6 kg (3 lbs. 8 ounces) 525 Viscosity Compressor O i l .............................................................................................................. 0.312 Kg. (11 ounces) TORQUE SPECIFICATIONS Compressor Suction and Discharge Connector B o l t ....................................................................................24 N m (18 ft. lbs.) Oil Drain S c re w ......................................................................................................................................................17 N m (13 ft. lbs.) Cycling Pressure Switch .....................................................................................................................................10 N m (7.5 ft. lbs.) Front and Rear Compressor Support Belts..................................................................................................... 50 N m (37 ft. lbs.) Support Bracket B olt............................................................................................................................................. 83 N m (61 ft. lbs.) Rear Support Brace Nut and B o lts .................................................................................................................. 33 N m (24 ft. lbs.) AIR CONDITIONING 1B-67 SPECIFICATIONS (CONT.) Blower Motor R/V All Weather R/V-G Rear Interior Roof Mounted G Floor Volts Amps (Cold) RPM (Cold) 12.0 12.8 Maximum 3400 Minimum 12.0 13.7 Maximum 3400 Minimum Compressor Clutch Coil Ohms (at 80° F ) ...................................................................................................................................................................................3.70 Am ps (at 8 0° F )...............................................................................................................................................................3.33 @ 12 Volts Belt T ension...............................................................................................................................................................See Tune-Up Chart Fuse Block R/V S e rie s................................................................................................................................................................................ 25 Amps In Line R/V S e rie s................................................................................................................................................................................ 25 Amps C ircuit Breaker G Series . . . 45 Am ps 1B-68 AIR CONDITIONING SPECIAL TOOLS J-5420 J-6274-01 6 J-23575-01 J-6272-02 J-23600-B J-9459 8 J-29547 J-23500-01 1. 2. 3. 4. 5. 6. 7. 8. S tra ig h t A d a p te r R e frig e ra n t Can “ Taps-AII” Valve M u lti-C a n D is p e n s in g Valve 90 D egree A d a p te r P o rta b le C h a rg in g S ta tio n C o m p le te M a n ifo ld A s s e m b ly B e lt T ension G auge A u to b a la n c e R e frig e ra n t Leak D e te c to r F-02406 2A-1 SECTION 2 FRAME AND SH EET METAL CONTENTS SUBJECT PAGE Frame and B um pers...................................................................................................................................................... 2A-1 Sheet M e ta l.....................................................................................................................................................................2B-1 SECTION 2A FRAME AND BUM PERS CONTENTS SUBJECT PAGE R/V And P Model Fram es............................................................................................................................................ 2A- 2 Description.................................................................................................................................................................2A- 2 Diagnosis Of The Frame.............................................................................................................................................. 2A- 2 Minimizing Frame Service........................................................................................................................................ 2A- 4 Checking Frame Alignm ent...................................................................................................................................... 2A- 4 Straightening F ra m e s.............................................................................................................................................. 2A- 5 Repairing C racks.......................................................................................................................................................2A- 5 W elding.......................................................................................................................................................................2A- 6 G Model U n d erb o dy.....................................................................................................................................................2A- 6 Description.................................................................................................................................................................2A- 6 Underbody A lig nm en t.............................................................................................................................................. 2A- 6 R/V Model Bumpers...................................................................................................................................................... 2A- 7 Front Bumper Replacem ent....................... ......................................................................................................... 2A- 7 Rear Bumper Replacement (Utility Vehicle and Suburban)................................................................................ 2A- 8 Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew C a b )............................................................2A-11 Rear Step Bumper R eplacem ent............................................................................ ........................................... 2A-12 Rear Bumper License Plate Bracket Replacement...............................................................................................2A-13 Dead Weight Trailer Hitch Replacement (Utility Vehicle and Suburban)..........................................................2A - 13 Weight Distribution Hitch Replacement (Suburban O n ly ).................................................................................. 2A-14 Weight Distribution Hitch Replacement (Utility Vehicle Only)............................................................................ 2A - 15 P Model B um pe rs........................................................................................................................................................ 2A-15 Front Bumper Replacement....................................................................................................................................2A-15 Front Bumper Replacement (With RPO FS3 Front A xle ).....................................................................................2A-16 G Model B um pers........................................................................................................................................................ 2A - 18 Front Bumper Replacement....................................................................................................................................2A-18 Rear Bumper Replacement......................................................................................................................................2A-19 Rear License Plate Bracket Replacement............................................................................................................. 2A-19 Dead Weight Trailer Hitch Replacement............................................................................................................... 2A-20 Weight Distribution Hitch Replacement................................................................................................................. 2A-20 S pecifica tio ns.............................................................................................................................................................. 2A-22 2A-2 FRAME AND BUMPERS R/V AND P MODEL FRAMES DESCRIPTION The models covered under this part of the section include R/V, and P. The service information for the G model will be found in the underbody portion of this section. Proper frame alignm ent is important to assure normal life and functioning of many other parts of the vehicle. If the vehicle has been involved in a fire, collision, or has been overloaded, there is cause to check the frame a lig n m e n t. If, fo r any o th e r re a so n , a lig n m e n t is suspected it should be checked. A procedure for this is described later in this section under “ Checking Frame Alignm ent.” It is possible that certain conditions make the frame appear to be out of alignm ent when, in fact, it is not. These conditions are also described under “ Checking Frame Alignm ent.” Terms used later in this section are briefly defined below: 1. SECTION MODULUS—This is a measure of the strength of a frame, based on height, width, thickness and shape of the side rails. It does not account for the strength of the material used in the frame. 2. YIELD STRENGTH—This is a measure of the strength of the material from which the frame is made. It is the maximum load measured in kPa (psi) that can be placed on a material and still have it return to its original shape. 3. RESISTANCE TO BENDING MOMENT (RBM)—This is a single measure of frame strength that accounts for both the section modulus and the strength of the material used. It is the product of section modulus and yield strength. 4. SAG—This refers to a frame or side rail that is bent down from where it should be. 5. BUCKLE—This refers to a frame or side rail that is bent up from where it should be. 6. DIAMOND—This refers to the condition where one entire frame rail is moved forward from, or to the rear of, its correct alignment with the other rail. 7. TWIST—This refers to the condition where the entire frame has been twisted. One rail will basically slope up while the other rail will basically slope down. 8. SIDESWAY—This refers to a side rail that is bent to the side of where it should be. 9. TRACKING—This refers to the alignment of the vehicle axles with each other. A misaligned frame can cause improper tracking. If the vehicle is tracking correctly, all axles will be parallel to each other and perpendicular to the center line of frame. 10. WEB—The vertical part of a channel-type frame rail. DIAGNOSIS OF THE FRAME PROBLEM Sag POSSIBLE CAUSE CORRECTION 1. Loads greater than the fram e is de­ signed to carry. 2. Uneven load distribution. 3. Abrupt changes in section modulus. (For a brief definition of section modulus, see the “ Description” at the beginning of this section. 4. Improper body, or accessory, mounting: — 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, particularly 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 equipm ent for which the frame has not been designed or rein­ forced. 1-7. Straighten and reinforce the frame as described later in this section. See “ S traightening Fram es” and “ R ein­ forcem ents.” FRAME AND BUMPERS 2A-3 DIAGNOSIS OF THE FRAME (CONT.) POSSIBLE CAUSE CORRECTION Buckle 1. The use of equipm ent such as snow plows for which the frame was not de­ signed. 2. A collision involving the vehicle. 3. A fire involving the vehicle. 4. In addition to these causes, refer to pos­ sible causes 3 and 4 under “ S a g .” These may contribute to “ Buckle.” 1-4. Straighten and reinforce the fram e as described later in this section. See “ S tra igh ten ing Fram es” and “ R ein­ forcem ents.” Sidesway 1. A collision involving the vehicle. 2. A fire involving the vehicle. 3. The use of equipm ent such as snow plows for which the frame was neither designed nor properly reinforced. 4. In addition to these causes, refer to pos­ sible causes 3 and 4 under “ S a g .” These may be contributing factors. 1-4. Straighten and reinforce the fram e as described later in this section. Refer to “ S tra igh ten ing Fram es” and “ R ein­ forcem ents.” Diamond 1. A collision involving the vehicle. 2. Towing another vehicle with a chain at­ tached to one corner of the frame. 1-2. Straighten and reinforce the fram e as described later in this section. Refer to “ S tra igh ten ing Fram es” and “ R ein­ forcem ents.” Twist 1. An accident or collision involving the ve­ hicle. 2. Operating the vehicle in very rough ter­ rain. 1-2. Straighten and reinforce the fram e as described later in this section. Refer to “ S tra igh ten ing Fram es” and “ R ein­ forcem ents.” Improper Tracking 1. Frame is out of alignment. PROBLEM 2. Front or rear axle has shifted. 3. Incorrect wheel alignm ent may make the vehicle appear to be tracking incorrectly. Cracks In The Web Of The Rails 1. Loose crossmember attaching bolts. 2. Concentration of stress that may result from many different factors. Refer to “ S a g ” under “ D iag no sis” previously described in this chart. Also refer to “ M inim izing Frame Damage” and “ Rein­ forcem ents” later in this section. 1. Straighten and reinforce the fram e as described later in this section. 2. Realign and secure the axle. 3. Align the wheels. Refer to FRONT END ALIGNM ENT (SEC. 3A) of this manual. 1. Replace, or weld and reinforce rail. Ream b olt holes and rep la ce w ith larger bolts if necessary. R etighten bolts. 2. Replace, or weld and reinforce the rail. See the appropriate heading, later in this section. 2A-4 FRAME AND BUMPERS Figure 1—R/V and P Model Frames MINIMIZING FRAME SERVICE CHECKING FRAME ALIGNMENT G e n e ra lly , fra m e s e rv ic e can be m in im iz e d or eliminated by m inimizing the concentration of stress in small areas of the frame. 1. Vehicles should be used only for those purposes for which they were designed. • They should not be overloaded. • They should be loaded evenly; localized loads should be avoided. • Do not operate the vehicle on extremely rough terrain. • Take into account the forces that will be placed on a frame from the operation of equipment such as snow plows when picking a frame for a new vehicle or reinforcing a frame. 2. Follow recommended practices when repairing a frame or when mounting a body or equipment on a frame. • Avoid sudden changes in the section modulus. • Do not drill holes in the frame rail flanges. • Space holes in the web section of a rail at least 13 mm (1/2-inch) from one another. • Use existing holes whenever possible. • Do not cut holes with a torch. • Do not overheat the frame rails. • Avoid welding on the flanges. • Do not allow four or more holes to exist on the same vertical line of the web. • Holes made in a reinforcement should be placed a distance of at least two times the material thickness from the edge of the reinforcement. The main parts of a fram e are the side rails and c ro s s m e m b e rs . T he ra ils c a rry th e load and th e crossmembers stabilize the rails. Types of fram e m isalignm ent can be divided into five groups. The five groups are sag, buckle, diam ond, sidesways, and twist. For a brief definition of these terms, refer to “ Description” at the beginning of this section. A misaligned frame rail may have moved forward from, up or down from, or to the side of where it should be. These possibilities must be checked. The easiest way to check fram e alignm ent is with gages made for this purpose. Detailed instructions are normally supplied with gages at the tim e of purchase. Therefore, instructions for gage use are not given in this manual. It is p ossible to ch eck c e rta in p o rtio n s of fram e alignm ent w ithout the proper gages. The procedure is described later in this section. W hether alignm ent is checked with or w ithout gages, the vehicle must be parked on a level section of floor. Certain conditions call for prelim inary checks before actually checking the frame. Suspension or axle problems may make it appear that the vehicle frame is out of a lig n m e n t. If an a xle has s h ifte d , “ D ia m o n d ” or “ Sidesway” may appear to exist when, in fact, they do not. A weak spring may make the vehicle appear to have a twisted frame. A visual inspection of the top and bottom flanges of each rail may reveal the specific area where sag or buckle exists. In the case of sag, wrinkles may appear on the top FRAME AND BUMPERS 2A-5 of the upper flange; such w rinkles are definite evidence of sag. W rinkles on the bottom of the lower flange are definite evidence of buckle. DETERMINING THE FRAME CENTERLINE (Figure 1) 1. Move the vehicle to a level, well-lighted section of the floor. 2. Make a diagram of the frame on the floor beneath the vehicle as follows: a. Using a plumb bob, transfer points 1, 2, 11, 12 from the inside of the web to the floor. Mark the points (figure 1). b. Using a plumb bob, transfer the remaining points from the outside of the web to the floor. Mark the points. Be sure to use points from the same place on both the right and left frame rail. 3. Move the vehicle away from the points on the floor. 4. Measure the distance between points 1 and 2. This distance should be 704.85 mm (27.75-inch) for the standard front axle, and 847.25 mm (33.75-inch) if equipped with a 5000# I-Beam Front Axle. 5. Measure the distance between points 11 and 12. This distance should be 847.25 mm (33.75-inch). If both the measurements in steps 4 and 5 were correct, continue the procedure. If the measurements are not correct, refer to “ Horizontal Check” step 2, and mark the centerline through the intersection of two sets of diagonals that have equal measurements. 6. Make a mark on the floor exactly halfway 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. This is the centerline of the frame. HORIZONTAL CHECK 1. Measure the distance between the frame rails, and the centerline at points 3-10. Each pair of corresponding points should be an equal distance from the centerline within 3 mm (Vs-inch). Example: Points 3 and 4 should measure equally from the centerline as should points 5 and 6, 7 and 8, and points 9 and 10. 2. Measure diagonally from point 1 to point 6, and from point 2 to point 5. Mark the floor where the diagonals pass the centerline. The diagonals should measure the same distance within 5 mm (3/ie-inch), and should cross at the ce n te rlin e . If the fram e is w ithin specifications, the frame within these points is properly aligned. 3. Repeat step 2 on other pairs of diagonals until the entire frame has been checked. Example: Point 3 to point 10 and point 4 to point 9 or point 5 to point 12 and point 6 to point 11, etc. 4. Refer to “ Straightening Frames” to repair any damage that is found. STRAIGHTENING FRAMES Frame straightening can be complicated and usually requires special equipment. It should be attempted by competent personnel only. A com plete analysis of the condition of the fram e should be made before any steps are taken to straighten it. Analyzing the cause of failure will help determine the c o rre ct sequence of steps in the repair. (R efer to Figure 2—Types of Frame Cracks “ Possible C auses” under “ Diagnosis” and “ M inim izing Frame S e rvice ” p reviously o utline d in th is section.) Corrective procedures should be set up to reverse the flow of the dam aging forces. In many instances, to reverse the flow of forces, pressure must be applied from different directions at the same time. Careful use of controlled heat is important. Too much or too little heat, or the im proper application of heat, is a m ajor source of trouble. Frame heating should be done with a large sized tip (multi-hole heating tip) and a neutral flame should be used (oxygen adjust opened just enough to remove the feathers or stringers from the blue center at tip of torch). Heat the area that will be stretched as frame is straightened. Heat the area AFTER SU FFIC IEN T PRESSURE HAS BEEN EXERTED to cause a slight checking, or silvery cracks, to appear on the surface of the metal. Gradually increase the pressure while heating. Do not heat beyond 606°C (1200°F). A red glow indicates that the material is overheated. Overheating will cause distortion and stretching, as well as a change in the characteristics of the metal. REPAIRING CRACKS Two common types of cracks are shown in figure 2. The straight crack will norm ally start from the edge of a flange. It will go across the flange and through the web section of a rail. Finally, it will continue through the other flange. This type of crack may result from high concentrations of stress in small areas of the frame, excessive bending moment, and torsional loading. (Refer to “ M inim izing Frame Service,” previously outlined in this section). 2A-6 FRAME AND BUMPERS Sunburst crack(s) will radiate out from a hole in the web section of a rail or crossmember. They are caused by high lo a d s b e in g a p p lie d a t a m o u n tin g b ra c k e t o r crossmember which is not securely or properly attached to the rail. If cracks occur to both the rail and reinforcement at a particular area of the frame, they must be repaired separately. The flanges must react independently to prevent localized stress concentration. Use a copper spacer between the flanges of cracked base rail flanges and reinforcement flanges. Crossmember mounting flange cracks may be repaired in the same m anner as side rail cracks. However, weld bead should be built up to provide a good smooth radius. If a crossm em ber is greatly damaged replace it. It may be necessary to align the frame and level the rails before repairing the frame. 1. Remove any equipment that will interfere with access to the crack. 2. Locate the extreme end of the crack and drill a 6 mm (0.25-inch) hole. 3. “ V” grind the entire length of the crack from the starting point to the 6 mm (0.25-inch) hole at the extreme end. 4. Open up the bottom of the crack 2 mm (V-ie-inch) to allow good penetration of the weld. (A hack-saw blade may be used for this). 5. Weld with proper electrode and proper welding techniques. Refer to “ 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. 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 crossm em ber may be welded. (Refer to “ Repairing Cracks” previously outlined in this section). When welding: 1. Do not use oxyacetylene welding equipment. 2. Whenever possible, use smaller diameter 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 scale is removed 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 the flanges. 9. When mounting accessories, do not weld within 19 mm (3/4-inch) of a flange. 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. 11. Do not weld cast brackets to the frame. 12. Do not weld the flanges of cracked reinforcements and base rails together. 13. Connect the welding machine ground cables as close to the working area as possible. 14. Avoid direct contact between the welding cables and any part of the vehicle. 15. Do not get the welding cables near the vehicle wiring. G MODEL UNDERBODY DESCRIPTION The G Model incorporates a unitized body design comprised of side rails, cross sills, and outriggers which are all part of the welded underbody. A misaligned underbody can affect the operation of many vehicle components. It is essential that underbody alignm ent be exact to within 1.6 mm (1/ie-inch). UNDERBODY ALIGNMENT To determine the alignm ent of the underbody it is necessary to use a good quality tram ing gage. This gage must be capable of m easuring all points of the underbody up to three quarters of the body length. Following the instructions given by the m anufacturer of your gage, measure the horizontal and vertical points as shown in figure 3. Compare each measurement with the s p e c ific a tio n s given in the fig u re to d ete rm ine the damaged areas and the extend of the damage. When repairing the underbody it will be necessary to return the underbody to these original specifications within 1.6 mm (1/ie-inch). Many different types and brands of unibody repair equipm ent are available; each system may be slightly different. A multiple pull system is most desirable in order to correct the damage in the same direction in which it was created. When m aking m ultiple pulls use the last in, first out procedure. This means that you correct the damage in the reverse sequence by which it was created. It is also important to correct the damage in the opposite direction in which the damage was created. FRAME AND BUMPERS 2A-7 15. 16. A. B. C. D. E. F. F ro n t Gage H o le s Rear Gage H ole s 789.4 m m (31.08-inch) 1041.4 m m (41.0-inch) 1340 m m (52.76-inch) 1041.4 m m (41.0-inch) 126 m m (4.96-inch) 123 m m (4.8-inch) 113.3 m m (4.46-inch) 13 m m (0.51-inch) 96 m m (3.78-inch) J. 145.2 m m (5.72-inch) K. 701 m m (27.6-inch) 1465 1845 M. 2772 3153 N. 2806 3415 mm mm mm mm mm mm (57.66-inch) 110-inch w h e e lb a s e (72.66-inch) 125-inch w h e e lb a s e (109.17-inch) 110-inch w h e e lb a s e (124.17-inch) 125-inch w h e e lb a s e (110.46-inch) 110-inch w h e e lb a s e (134.46-inch) 125-inch w h e e lb a s e F-02180 Figure 3—G Model Underbody R/V MODEL BUMPERS FRONT BUMPER REPLACEMENT Remove or Disconnect 1. Brace to bumper nuts (52) (figure 1). 2. Bracket to bumper nuts (53). 3. Bumper from the vehicle. 4. Guard assemblies (where used) (figure 5). 5. Rub strips from the bumper and guards (where used) (figure 6). • From the rear of the bumper, press the tangs of the rub strip together, and push the strip from the bumper and/or guard. Install or Connect (Figures 4-8) 1. Brackets and tow hooks (where used) to the frame rails. • On vehicles without tow hooks, install the bolts and washers through the brackets and through the outside of the frame rail. • On vehicles with tow hooks, install the tow hook bolts and washers from inside the frame rail, then through the brackets and the tow hooks. Install the top bracket bolts and washers through the bracket, and into the top rail flange. 2. Washers and nuts to the bolts. Tighten • Nuts to 95 N m (70 ft. lbs.). Brace bolts and washers (67 and 68) through the frame rails and into the braces. 6. Bumper bolts (56 and/or 58). 7. Brace bolts and washers (67 and 68) (figure 7) from the inside of the frame rail. • Braces (54). 8. Bracket bolts, washers, and nuts (66, 65 and 64) from the frame. 9. Tow hooks (70) (where used). 10. Brackets (55). • Bolts to 50 N m (37 ft. lbs.). 4. Bumper bolts (56) onto the bumper. 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. 2A-8 FRAME AND BUMPERS Figure 4—R/V Front Bumper Components • Install the bumper with bolts through the right and left braces, and brackets. 8. Bracket to bumper nuts (53). Tighten REAR BUMPER REPLACEMENT (UTILITY VEHICLE AND SUBURBAN) Remove or Disconnect (Figure 8) • Nuts to 90 N m (66 ft. lbs.). 9. Brace to bumper nuts (52). Tighten • Nuts to 90 N m (66 ft. lbs.). Figure 5—R/V Front Bumper Guards 1. 2. 3. 4. 5. 6. Brace to bumper nuts (71). Bracket to bumper nuts (74). Rear bumper. Filler panel bolts (figures 9 and 10). Filler panel. Rub strips from the bumper (where used) (figure 24). • From the rear of the bumper, press the tangs of the bump strip together, and push the strip from the bumper. 7. Bumper bolts (82). 8. Brace nuts, washers, and bolts (76, 75 and 80). • Braces (72). 9. Bracket nuts, washers, and bolts (77, 78 and 79). « Brackets (72). Figure 6—R/V Front Bumper Rub Strip FRAME AND BUMPERS 2A-9 54 54. 55. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. A. B. Brace B ra cke t B o lt W a sh er N ut N ut W a sh er B o lt B o lt W a sh er W a sh er Tow H o o k Fram e W eld N ut 66 Figure 7—R/V Front Bumper Brackets, Braces, and Tow Hooks F-02176 2A-10 FRAME AND BUMPERS 51. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 82. B u m p e r Bar N ut Brace B ra cket N ut W a sh er N ut N ut W a sh er B o lt B o lt B o lt F-02175 Figure 8—Utility Vehicle and Suburban Rear Bumper Components |+ + | Install or Connect (Figures 8-11) 1. Brackets to the frame rails (72). Tighten • Nuts to 95 N m (70 ft. lbs.). • Bracket bolts, washers, and nuts (79, 78 and 77). 3. Bumper bolts to the bumper (82). 4. Rub strips to the bumper (where used). Tighten • Place the tangs of the strips onto the slots in the bumper guard. Using a rubber mallet, set the tangs in place starting at the center of the strip, working toward each end. • Nuts to 95 N m (70 ft. lbs.). 2. Braces to the frame rails (72). • Brace bolts, washers, and nuts (80, 75 and 76). 5. Filler panel supports (Utility vehicle only) (figure 9). 51. 83. 84. 85. 86. 87. 88. B u m p e r Bar Bar “ U” N ut N u t and W a sh e r S u p p o rt B o lt F ille r Panel F-02174 Figure 9—Rear Bumper Filler Strip FRAME AND BUMPERS 2A-11 Tighten • Bolts to 10 N-m (89 in. lbs.). 10. Bracket nuts (74). • Nuts to 41 N-m (30 ft. lbs.). 11. Brace nuts (71). Tighten • Nuts to 41 N m (30 ft. lbs.). REAR BUMPER REPLACEMENT (REGULAR CAB, BONUS CAB, AND CREW CAB) Remove or Disconnect (Figure 12) Place the filler panel bolts through the panel and into the support “ U” nuts. Tighten • Bolts to 10 N m (89 in. lbs.). 6. Filler panel (Suburban only) (figure 10). • Bolts through the filler panel, and into the platform. • Bolts to 2.8 N-m (25 in. lbs.). 7. Bumper to the vehicle. • Install the bumper bolts (82) into the braces, and brackets. 8. Filler panel (Utility vehicles only). • Place the filler panel behind the bumper, and place the supports onto the bumper bolts behind the braces. 9. Filler panel bracket bolts (Utility vehicle only). 1. Brace nuts (93), spring washers (94), and washers (95) at the bumper. 2. Bracket nuts (99), spring washers (98), and washers at the bumper. 3. Rear bumper from the vehicle. 4. Bumper bolts (106). 5. Gravel deflector nuts (107) and bolts (81) (where used) (figure 13). 6. Gravel deflectors (105). 7. Brace to frame nuts (100), spring washers (102), and bolts (104). 8. Braces (92). 9. Bracket to frame rail nuts (101), spring washers (102) and bolts (103). 10. Brackets (96). □ Install or Connect 1. Brackets to the frame rails. 2. Bolts (103), spring washers (102), and nuts (101). Tighten • Nuts to 95 N-m (70 ft. lbs.). 3. Braces to the frame rails. 4. Bolts (104), spring washers (102), and nuts (100). $ Tighten • Nuts to 95 N m (70 ft. lbs.). 5. Gravel deflectors (where used). 6. Nuts (107) and bolts (81). Tighten • Nuts to 10 N-m (89 in. lbs.). 7. Bumper bolts (106) onto the bumper. 8. Rear bumper. • Place the bumper bolts through the brackets and braces. 9. Bracket washers (97), spring washers (98), and nuts 99) to the bumper. Tighten • Nuts to 90 N-m (66 ft. lbs.). 10. Brace washers (95), spring washers (94), and nuts (93) to the bumper. 2A-12 FRAME AND BUMPERS 51. 92. 93. 96. 99. 100. 101. 102. 103. 104. 106. B u m p e r Bar Brace N ut B ra cke t N ut N ut N ut S p rin g W a sh er B o lt B o lt B o lt F-02313 Figure 12—Regular Cab, Bonus Cab, and Crew Cab Rear Bumper Components Tighten REAR STEP BUMPER REPLACEMENT • Nuts to 90 N m (66 ft. lbs,). Remove or Disconnect (Figure 14) 1. Bracket to bumper nuts (111), and bolts (112). 2. Brace to bumper nuts (119), spring washers (118), washers (117), and bumper bolts. 3. Bumper from the vehicle. 4. Brace to frame nuts (108) and bolts (110). 5. Braces (54). 6. Bracket reinforcement nuts (115) and bolts (109) (and washers (114) where used). 7. Bracket reinforcements (113). 8. Bracket to frame nuts (108), and bolts (110). 9. Brackets (55). + 4- Install or Connect (Figure 14) Brackets (55) and braces (54) to the frame. Bolts (110) and nuts (108) loosely. Bracket reinforcements (113). • The reinforcements are marked as right or left on their inboard sides. 4. Bolts (109) and nuts (115), and washers (114) (where used). Tighten • Reinforcement nuts to 70 N-m (52 ft. lbs.). • Bracket and brace nuts to 70 N-m (52 ft. lbs.). Bumper to the vehicle. FRAME AND BUMPERS 2A-13 B u m p e r Bar 51. 54. 55. 108. 109. 110. 111. 112. 113. 114. 115. 116. 119. Brace B ra cket N ut B o lt B o lt B o lt B o lt R e in fo rc e m e n t W a sh er N ut B o lt N ut 119 F-02311 Figure 14—Rear Step Bumper Components 6. Bumper to brace bolts (116), washers (117), spring washers (118), and nuts (119). 5. Chain bracket. 6. Support. Tighten 7. Bar assembly bolt and washer from the bracket. • Nuts to 70 N-m (52 ft. lbs.). 7. Bumper to bracket bolts (112) and nuts (111). Tighten • Nuts to 70 N-m (52 ft. lbs.). □ REAR BUMPER LICENSE PLATE BRACKET REPLACEMENT 8. Bar assembly. +«- Install or Connect (Figures 16 and 17) 1. Bracket assembly to the frame with bolts, washers, and nuts. 1 11 Remove or Disconnect (Figure 15) 1. License plate bracket to bumper nuts (123), spring washers (122), washers (121), and bolts (124). 2. License plate bracket (120). 0 Install or Connect (Figure 28) 1. License plate bracket (120). 2. License plate bracket to the bumper bolts (124), washers (121), spring washers (122), and nuts (123). Tighten • Nuts to 29 N-m (21 ft. lbs.). DEAD WEIGHT TRAILER HITCH REPLACEMENT (UTILITY VEHICLE AND SUBURBAN) Remove or Disconnect (Figures 16 and 17) 1. Bracket assembly nuts, washers, and bolts from the frame. 2. Support nuts, washers, and bolts from the bumper. 3. Hitch assembly. 4. Chain bracket nut, washer, and bolt. 51. 120. 121. 122. 123. 124. B u m p e r Bar L ic e n s e Plate B ra cke t W a sh er S p rin g W a sh er N ut B o lt F-02310 Figure 15—Rear License Plate Bracket 2A-14 FRAME AND BUMPERS 125 51. B u m p e r Bar 142 m I32. C ha in B ra c k e t 144 134. Bar A s s e m b ly 145 136. B ra cket A s s e m b ly 14g 139. B o lt 147. 140. W a sh e r 148 141. 86. S u p p o rt 51. 86. 125. 126. 127. 128. 129. 130. 131. 132. 133. B u m p e r Bar S u p p o rt B o lt W a sh er N ut W a sh er B o lt N ut W a sh er C hain B ra cket B o lt Nut 134. 135. 136. 137. 138. B ar A s s e m b ly B o lt B ra cke t A s s e m b ly W a sh er N ut 149' W a sh e r B o lt N ut W asher B o lt B o lt W asher N ut F-02308 Figure 17—Utility Vehicle Dead Weight Trailer Hitch WEIGHT DISTRIBUTION HITCH REPLACEMENT (SUBURBAN ONLY) F-02309 Remove or Disconnect (Figure 18) Figure 16—Suburban Dead Weight Trailer Hitch Components 1. Rear bolts, washers, and nuts from the hitch. 2. Front nuts, washers, and bolts from the hitch. Tighten 3. Hitch platform from the vehicle. • Nuts to 70 N m (52 ft. lbs.). 2. Bar assembly to the support. • Place the bolt through the bar assembly, support and the chain bracket. Install the washer and nut loosely. 3. Support assembly bolts through the support and the bumper. 4. Washers and nuts loosely. 5. Bar assembly bolt with washer through the bar and into the bracket assembly. Q Install or Connect (Figure 18) 1. Hitch platform to the vehicle. • There must be no contact between the platform and the rear bumper. 2. Front bolts, washers, and nuts to the hitch. • Assemble loosely. 3. Rear nuts, washers, and bolts to the hitch. • Install the nuts with the cut-off side outboard. Tighten • Bar to bracket bolt to 95 N m (70 ft. lbs.). Tighten • Bar to support nut to 70 N m (52 ft. lbs.). • Rear bolts to 95 N m (70 ft. lbs.). • Support to bumper nuts to 33 N m (24 ft. lbs.). • Front nuts to 70 N m (52 ft. lbs.). FRAME AND BUMPERS 2A-15 51. 150. 151. 152. 153. 154. 155. B u m p e r Bar N ut W a sh e r B o lt W a sh er S p rin g W asher B o lt “ 156. N ut 157. W a sh e r 158. P la tfo rm 51. 158. 159. 160. 161. 162. 163. Figure 19—Utility Vehicle Weight Distribution Hitch Components Figure 18—Suburban Weight Distribution Hitch Components WEIGHT DISTRIBUTION HITCH REPLACEMENT (UTILITY VEHICLE ONLY) 0 Remove or Disconnect (Figure 19) 1. Rear bolts, washers, and nuts from the hitch. 2. Front bolts, washers, and nuts from the hitch. 3. Hitch platform from the vehicle. B u m p e r Bar P la tfo rm 164. S p rin g W a sh er N ut W a sh e r 165. B o lt ~ B o lt 166. N ut W a sh e r 167. W a sh er W a sh e r ++ Install or Connect (Figure 19) Hitch platform to the vehicle. Front bolts, washers, and nuts to the hitch. • Assemble loosely. Rear bolts, washers, and nuts to the hitch. • Install nuts with the cut off side inboard. Rear bolts to 73 N m (54 ft. lbs.). Front bolts to 70 N m (51 ft. lbs.). P MODEL BUMPERS FRONT BUMPER REPLACEMENT Remove or Disconnect (Figures 20 and 21) 1. Brace to frame nuts (203), spring washers (202), washers (201), and bolts (199). 2. Bracket to frame nuts (206), spring washers (205), washers (204), and bolts (195). 3. Bumper to frame nuts (187), spring washers (186), washers (185), spacers (198) (where used), and bolts (197). 4. Bumper from the vehicle. 5. Brace to bumper nuts (192), spring washers (193), washers (194), and bolts (197). Braces (54). Bracket to bumper nuts (191), spring washers (190), washers (189), and bolts (197). Install or Connect (Figures 20 and 21) Braces to the bumper with bolts (197), washers (194), spring washers (193), and nuts (192). • Assemble loosely. 2. Bracket to the bumper with bolts (197), washers (194), spring washers (193), and nuts (191). • Assemble loosely. Bumper to vehicle. Bumper to frame spacers (198) (where used), spring washers (186), washers (185), bolts (197), and nuts (187). 2A-16 FRAME AND BUMPERS 191 190 v 51. 54. 55. 185. 186. 187. 189. 190. B u m p e r Bar Brace B ra cket W a sh er S p rin g W a sh e r N ut W a sh er S p rin g W a sh e r 51 191. 192. 193. 194. 196. N ut N ut S p rin g W a sh er 197. B o lt W a sh er 198. S p a ce r W a sh er 196 F-02305 Figure 20—P-Front Bumper Components Tighten Tighten • Nuts to 47 N m (35 ft. lbs.). 5. Brackets to the frame rails with bolts (195), washers 204 spring washers (205), and nuts (206). £ • Brace to frame nuts to 85 N m (63 ft. lbs.). • Brace to bumper nuts to 47 N m (35 ft. lbs.). FRONT BUMPER REPLACEMENT (WITH RPO FS3 FRONT AXLE) Tighten • Bracket to frame nuts to 95 N m (70 ft. lbs.). • Bracket to bumper nuts to 47 N m (35 ft. lbs.). 6. Braces to the frame rails with bolts (199), washers (201), spring washers (202), and nuts (203). ++ Remove or Disconnect (Figures 22 and 23) 1. Bracket to frame nuts (207) and washers (208). 2. Brace to frame nuts (222), washers (221), and bolts (219). 3. Front bumper from the vehicle. 4. Bracket to bumper nuts (218 and 223), spring washers (217 and 224), washers (216 and 225), spacers (198), and bolts (215). 5. Brackets (55). 6. Brace to bumper nuts (209), spring washers (210), washers (211), and bolts (213). 7. Braces (54). 199 200 Install or Connect (Figures 22 and 23) 1. Braces to the bumper with bolts (215), washers (211), spring washers (210), and nuts (209). $ Tighten • Nuts to 47 N m (35 ft. lbs.). 55. 72. 195. 199. 200. B ra cket Brace B o lt B o lt W a sh er 201. W a sh er 202. S p rin g W a sh e r 203. N ut 2. Brackets to the bumper with bolts (213), spacers (198), spring washers (217 and 224), washers (216 and 225), and nuts (218 and 223). 204. W a sh er 205. S p rin g W a sh e r • Nuts to 47 N m (35 ft. lbs.). 3. Front bumper to the vehicle. F-02304 • Place the bracket assembly studs into the frame crossmember. Figure 21—P-Front Bumper Braces and Brackets 4. Brace to frame bolts (219), washers (221), and nuts ( 222 ). 206. N ut FRAME AND BUMPERS 2A-17 51. 54. 55. 207. 208. 209. 210. 211. 212. 213. 213 B u m p e r Bar Brace B ra cket N ut W a sh er N ut S p rin g W a sh er W a sh er W a sh er B o lt 212 F-02303 Figure 22—P-Front Bumper Components (RPO FS3 Front Axle) Q Tighten • Nuts to 40 N m (30 ft. lbs.). 5. Bracket to frame washers (208) and nuts (207). Tighten • Nuts to 64 N m (47 ft. lbs.). 51. 54. 55. 198. 214. 215. 216. 217. 218. 219. 220. 221. 222. 223. 224. 225. B u m p e r Bar B race B ra cke t S p a ce r W a sh e r B o lt W a sh e r S p rin g W a sh er N ut B o lt W a sh e r W a sh e r N ut N ut S p rin g W a sh er W a sh e r 198 225 F-02302 Figure 23—P-Front Bumper Braces and Brackets (RPO FS3 Front Axle) 2A-18 FRAME AND BUMPERS G MODEL BUMPERS 51. 54. 55. 239. 240. 241. 242. 243. B u m p e r Bar Brace B ra cket N ut B o lt N ut B o lt B o lt F-02301 Figure 24—G-Front Bumper Components FRONT BUMPER REPLACEMENT 4- + Remove or Disconnect (Figure 24) 1. Bracket to cross sill bolts (242). 2. Brace to bumper nuts (241) and bolts (243). 3. Bumper from the vehicle. 4. Bracket to bumper nuts (239), bolts (243), and guards (where used). 5. Brackets (55). 6. Rub strips from the guards (where used) (figure 38). • From the rear of the guard, press the tangs of the bump strip together, and push the strip from the guard. 7. Brace to frame bolts (240). • Braces (54). 0 • Bolts to 41 N-m (30 ft. lbs.). 7. Brace to bumper bolts (243) and nuts (241). Install or Connect (Figures 24 and 25) 1. Braces to the frame. • Place braces through the holes in the cross sill, and install the bolts (240) loosely. 2. Bolts (245) into the guards (where used). 3. Rub strips to the guards (where used). • Place the tangs of the strips onto the slots in the guard. Using a rubber mallet, set the tangs in place starting at the center of the strip, and working toward each end. 4. Bracket to bumper bolts (243) or guards (where used), nuts (239), and guard lower bolts. Tighten • Nuts to 29 N-m (21 ft. lbs.). • Guard lower bolts to 41 N m (30 ft. lbs.). 5. Bumper to the vehicle. 6. Bracket to cross sill bolts (242). Brace to bumper nuts to 29 N-m (21 ft. lbs.). Brace to frame bolts to 41 N-m (30 ft. lbs.). FRAME AND BUMPERS 2A-19 51. 55. 246. 247. 248. 249. 250. 251. 252. 253. 254. B u m p e r Bar B ra cket O u te r Brace W a sh e r B o lt In n e r Brace B o lt N ut B o lt B o lt B o lt F-02299 Figure 26—G-Rear Bumper Components REAR BUMPER REPLACEMENT Tighten & • Nuts to 29 N-m (21 ft. lbs.). ++ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10 Remove or Disconnect (Figure 26) Outer brace to bumper nuts (251) and bolts (254). Inner brace to cross sill bolts (253). Bracket to frame bolts (248) and washers (247). Bumper from the vehicle. Outer brace to cross sill bolts (252). Outer braces (246). Bracket to bumper nuts and bolts (254). Brackets (55). Inner brace to bumper nuts (251) and bolts (254). Inner braces (249). -►4- Install or Connect (Figure 26) Inner braces (249) to the bumper. • Assemble the top bolts (250) and nuts (251). Tighten Nut to 30 N m (22 ft. lbs.) Assembly the lower bolts (254) and nuts (251). • Nut to 30 N-m (22 ft. lbs.). 2. Brackets to the frame with washers (247) and bolts (248). • Assemble loosely. 3. Outer braces (246) to the cross sill with bolts (252). Tighten • Bolts to 41 N m (30 ft. lbs.). 4. Bumper to the vehicle. • Place the inner braces into the inner brace panel holes. 5. Inner braces to the cross sill with bolts (253). Tighten • Bolts to 41 N-m (30 ft. lbs.). 6. Bumper to bracket bolts (254) and nuts. • Bracket to frame bolts to 68 N m (50 ft. lbs.). 7. Outer bracket to bumper bolts (254) and nuts (251). Q Tighten • Nuts to 68 N-m (50 ft. lbs.). REAR LICENSE PLATE BRACKET REPLACEMENT Remove or Disconnect (Figure 27) 1. License plate bracket nuts and bolts. 2. License plate bracket. Install or Connect (Figure 27) 1. License plate bracket. 2. License plate bracket nuts and bolts. 2A-20 FRAME AND BUMPERS 51. 55. 86. 132. 134. 136. 257. 258. 259. 260. 261. 262. 263. 264. 265. 266. B u m p e r Bar B ra cke t S u p p o rt C ha in B ra cke t Bar A s s e m b ly B ra cke t A s s e m b ly W a sh er N ut B o lt B o lt N ut B o lt B o lt N ut N ut S h im F-02297 Figure 28—Dead Weight Trailer Hitch Q Tighten • Nuts to 29 N m (21 ft. lbs.). DEAD WEIGHT TRAILER HITCH REPLACEMENT 3. Support to the bumper with bolts and nuts. • Assemble loosely. 4. Bar assembly and chain bracket to the support with a bolt and nut. Tighten • 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.). • Support to bumper nuts to 29 N-m (21 ft. lbs.). Remove or Disconnect (Figure 28) 1. Hitch bracket to bumper bracket nuts, washers, 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. • Support. • Bar assembly. 5. Bar assembly to hitch bracket nut and bolt. • Bar assembly. • Shim(s). • Hitch bracket. 0 ~ l Install or Connect (Figure 28) 1. Hitch bracket to the bumper brackets with bolts, washers, and nuts. \$X\ Tighten • Nuts to 24 N-m (18 ft. lbs.). 2. Bar assembly with shims (as required) to the hitch bracket with bolts and nuts. • Assemble loosely. WEIGHT DISTRIBUTION HITCH REPLACEMENT Remove or Disconnect (Figure 29) 1. 2. 3. 4. 5. Bumper nuts and bolts. Bumper. Rear hitch nuts and washers. Front bolts and washers. Hitch from the vehicle. -►4- Install or Connect (Figure 29) 1. Hitch to the vehicle. 2. Front bolts and washers. Tighten • Bolts to 70 N-m (52 ft. lbs.). 3. Rear washers and nuts. FRAME AND BUMPERS 2A-21 Figure 29—Weight Distribution Hitch Tighten * Nuts to 63 N-m (47 ft. lbs.). 4. Bumper to the vehicle with nuts and bolts. Tighten • Nuts to 29 N-m (21 ft. lbs.). FRAME AND BUMPERS 2A-22 SPECIFICATIONS BUMPER TORQUE SPECIFICATIONS FASTENER N m Ft. Lbs. R/V M odels Front Bumper 70 Bracket to Frame Rail N u ts ...................................................................................... .........95 Brace to Frame Rail B o lts ........................................................................................ .........50 37 Bracket to Bumper N uts......................................................................................................90 66 Brace to Bumper N u ts ............................................................................................... .........90 66 Rear Bumper (Utility Vehicle and Suburban) Bracket to Frame Rail N u ts ...................................................................................... .........95 70 Brace to Frame Rail N uts....................................................................................................95 70 Filler Panel to Support Bolts (Utility V e h ic le )..................................................... ........... 10 Filler Panel to Support Bolts (Suburban)................................................................ .........2.8 Filler Panel Bracket N u ts ....................................................................................................41 30 30 Brace to Bum per N u ts ............................................................................................... .........41 Rear Bumper (Regular Cab, Bonus Cab, Crew Cab) Bracket to Frame Rail N u ts ...................................................................................... .........95 70 Brace to Frame Rail N uts....................................................................................................95 70 Gravel Deflector N u ts ................................................................................................. .........10 Bumper to Bracket N uts......................................................................................................90 66 Brace to Bumper N u ts ............................................................................................... .........90 66 Rear Step Bumper Bracket Reinforcement N u t s .............................................................................................70 52 52 Bracket to Brace N u t s ............................................................................................... .........70 Bumper to Brace N u ts ............................................................................................... .........70 52 Bumper to Bracket N uts......................................................................................................70 52 License Plate Bracket to Bum per N u ts................................................................................29 21 Trailer Hitch (Utility Vehicle and Suburban) Bracket to Frame N u ts ............................................................................................... .........70 52 Bar Assembly to Bracket B o lt ...........................................................................................95 70 52 Bar Assembly to Support N u t ...........................................................................................70 Support to Bum per N u t s ....................................................................................................33 24 Weight Distribution Hitch Suburban Hitch to Vehicle Rear B o lts ...................................................................................... .........95 70 Hitch to Vehicle Front N u ts ...................................................................................... .........70 52 Utility Vehicle Hitch to Vehicle Rear B o lts ...................................................................................... .........73 54 Hitch to Vehicle Front B o lts ...................................................................................... .........70 51 P M odels Front Bumper Bumper to Frame N uts............................................................................................... .........47 35 70 Bracket to Frame Rail N u ts ...................................................................................... .........95 Bracket to Bumper N uts..................................................... ....................................... .........47 35 Brace to Frame N u t s ................................................................................................. .........85 63 Brace to Bum per N u ts ............................................................................................... .........47 35 Front Bum per (FS3 Front Axle) Brace to Bum per N u ts ............................................................................................... .........47 35 Bracket to Bumper N uts......................................................................................................47 35 Brace to Frame N u t s ................................................................................................. .........40 30 Bracket to Frame N u ts ............................................................................................... .........64 47 In. Lbs. 89 25 89 2A-23 FRAME AND BUMPERS SPECIFICATIONS (CONT.) BUMPER TORQUE SPECIFICATIONS (CONT.) FASTENER G M odels Front Bumper Bracket to Bum per N uts.............................................................. Bracket to Guard B o lts................................................................ Bracket to Cross Sill B o lts ......................................................... Brace to Bum per N u ts ................................................................ Brace to Frame B o lts .................................................................. Rear Bumper Brace to Bumper Top Nuts................................................. Brace to Bumper Lower N uts..................................................... Bracket to Frame Bolts................................................................ Brace to Cross Sill B o lt s ............................................................ Bumper to Bracket N uts.............................................................. Bracket to Frame Bolts................................................................ Bracket to Bumper N uts.............................................................. License Plate Bracket N u ts ............................................................ Trailer Hitch Hitch Bracket to Bumper Bracket N u t...................................... Bar Assembly to Chain Bracket N u t ........................................ Bar Assembly to Hitch Bracket B o l t ........................................ Support to Bumper N u t s ............................................................ Weight Distribution Hitch Hitch to Vehicle B olts.................................................................. Hitch to Vehicle N u ts .................................................................. Bumper to Vehicle N u ts.............................................................. Nm Ft. Lb ............................. ............................. ............................. ............................. ............................. 29 41 41 29 41 21 30 30 21 30 ............................. ............................. ............................. ............................. ............................. ............................. ............................. ............................. 30 30 41 41 29 68 68 29 22 22 30 30 21 50 50 21 ............................. ............................. ............................. ............................. 24 68 68 29 18 50 50 21 ............................. ............................. ............................. 70 63 29 52 47 21 2B-1 SECTION 2B SH EET 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 o f the same part num ber o f w ith an equivalent part if replacement becomes necessary. Do not use a replacem ent part o f lesser quality or substitute design. Torque values must be used as specified during reassem bly to assure proper retention o f all parts. CONTENTS SUBJECT PAGE R/V M o d e ls ................................................................................................................................................................... 2B - 2 Hood R eplacem ent..................................................................................................................................................2 B - 2 Spring Assembly R eplacem ent.................................................... ....................................................................2B- 2 Hood Hinge R e p la ce m e n t.....................................................................................................................................2B - 2 Primary Hood Latch R e p la c e m e n t..................................................................................................................... 2B - 2 Secondary Hood Latch And Spring Replacem ent........................................................................................... 2B - 3 Hood Release Cable R e p lace m e n t..................................................................................................................... 2B - 3 Hood Ornament R eplacem ent. . ..........................................................................................................................2B - 4 Cowl Vent Grille Replacement.............................................................................................................................. 2B - 4 Grille And Molding R e p la c e m e n t........................................................................................................................2B - 5 Front Fender R e p lace m e n t................................................................. ............................................................. 2B - 6 Wheelhouse Panel Replacement..........................................................................................................................2B - 7 Rear Fender R eplacem ent.....................................................................................................................................2B- 8 Radiator Support R eplacem ent............................................................................................................................ 2B-10 Sheet Metal Unit R e p la ce m e n t............................................................................................................................ 2B-11 Sheet Metal A djustm ents.......................................................................................................................................2B-11 G M odels....................................................................................................................................................................... 2B-13 Hood Replacem ent..................................................................................................................................................2B-13 Hood Hinge R e p la ce m e n t....................................................................................... ............................................. 2B-13 Primary Hood Latch R e p la ce m e n t..................................................................................................................... 2B-13 Secondary Hood Latch And Spring Replacement............................................................... ............................2B-14 Hood Release Cable R e p lace m e n t..................................................................................................................... 2B-15 Cowl Vent Grille Replacement.............................................................................................................................. 2B-15 Grille Replacem ent..................................................................................................................................................2B-15 Front End Sheet Metal Cross Panel R e p la ce m e n t......................................................................................... 2B-17 Sheet Metal Vertical Support R eplacem ent...................................................................................................... 2B-17 Front End Panel Replacement.............................................................................................................................. 2B-17 Cab M ounts...................................................................................................................................................................2B-18 Cab Mount R eplacem ent................................................................................................................................ .... .2B-18 S p e cifica tio n s............................................................................................................................................................... 2B-23 Special T o o ls ............. .................................................................................................................................................2B-23 2B-2 SHEET METAL R/V MODELS SPRING ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 1) • 1. 2. 3. Raise and support the front of the hood. Spring assembly to hood bolts (4). Spring assembly to fender bolts (1). Spring assembly from the vehicle. Install or Connect (Figure 1) 1. Spring assembly to the vehicle. 2. Spring assembly to fender bolts (1). Tighten • Bolts to 25 N-m (18 ft. lbs.) Spring assembly to hood bolts (4). Q Tighten • Bolts to 25 N-m (18 ft. lbs.). HOOD HINGE REPLACEMENT |<~+| Remove or Disconnect (Figure 1) Figure 1—Hood Hinge Components HOOD REPLACEMENT Remove or Disconnect (Figure 1) • Raise and support the hood at front and rear. 1. C owl ve n t g rille . R efer to “ C owl V e nt G rille Replacement.” 2. Hinge to hood bolts (5). 3. Hinge to cowl bolts (6). 4. Hinge from the vehicle. Install or Connect (Figure 1) 1. Hinge to the vehicle. 2. Hinge to cowl bolts (6). Tighten • Raise and support the hood at front and rear. • Place protective coverings over the cowl and the fenders. • Mark the position of the hinge on the hood. 1. Spring assembly to hood bolts (4). 2. Hood hinge to hood bolts (5). • Bolts to 43 N-m (32 ft. lbs.). 3. Hinge to hood bolts (5). ^X Tighten • Bolts to 25 N-m (18 ft. lbs.). 4. C ow l ve n t g rille . R efer to “ C ow l V e n t G ril Repacement.” 3. Hood from the vehicle. |-n-| Install or Connect (Figure 1) 1. Hood to the vehicle. • Align the hood with the previously made marks. 2. Hood hinge to hood bolts (5). Q Tighten • Bolts to 25 N-m (18 ft. lbs.). 3. Spring assembly to hood bolts (4). PRIMARY HOOD LATCH REPLACEMENT Remove or Disconnect (Figure 2) • Raise the hood. 1. Hood latch release cable from the latch. Refer to “ Hood Release Cable Replacement.” 2. Bracket to hood latch bolts (9). 3. Hood latch from the vehicle. 4. Bracket to radiator support bolts (10). 5. Bracket from the vehicle. A djust Tighten Bolts to 25 N m (18 ft. lbs.). Front hood bumpers, so that the top of the hood is flush with the fenders. SHEET METAL 2B-3 Figure 2—Hood Primary Latch Components 0 Install or Connect (Figure 2) 1. Bracket to the radiator support. 2. Bracket to support bolts (10) loosely. SECONDARY HOOD LATCH AND SPRING REPLACEMENT Remove or Disconnect (Figure 3) 3. Primary hood latch to the bracket. 4. Latch to bracket bolts (9) loosely. 5. Hood latch release cable to the latch. Adjust NOTICE: For Steps 1 and 2 refer to “ Notice” on page 2B-1. 1. Hood latch bracket left and right until the striker in the hood easily engages the primary latch. • Raise the hood. • Bracket to radiator support bolts to 27 N-m (20 ft. lbs.). 2. Hood latch height so that when the hood is closed, the hood is held securely against the front hood bumpers. Mark this height. • Raise the hood. • Mark the position of the secondary hood latch on the hood. 1. Secondary hood latch to hood bolts (18). 2. Secondary hood latch from the vehicle. 3. Spring from the hood. • Twist the spring from the reinforcement. Install or Connect (Figure 3) 1. Spring to the hood. • Twist the spring into the reinforcement. 2. Secondary hood latch to the vehicle. 3. Secondary hood latch to hood bolts (18). Q Tighten • Bolts to 27 N-m (20 ft. lbs.). HOOD RELEASE CABLE REPLACEMENT Remove or Disconnect (Figure 4) NOTICE: Refer to “ Notice” on page 2C-1 of this section. Tighten • Bracket to hood latch bolts to 27 N-m (20 ft. lbs.). If the cable is broken, release the hood by pressing the prim ary latch tab on the right side of the lock assembly. Use a rod to press the tab. Raise the hood. Cable from the primary latch. 2B-4 SHEET METAL ++ Install or Connect (Figure 4) 1. New cable to the vehicle. 2. Cable through the drivers side of the cowl. • Push the grommet into the drivers side of the cowl. 3. Cable bolts through the cable handle, and into the air vent bezel. 4. Cable through the wheelhouse retaining strap, and the radiator support. 5. Cable to the primary latch. HOOD ORNAMENT REPLACEMENT Remove or Disconnect (Figure 5) Raise hood. 1. Hood ornament nuts (21). 2. Hood ornament from the hood. 3. Seal from the hood. Install or Connect (Figure 5) 3. 15. 16. 17. H oo d R e in fo rc e m e n t S p rin g S e co n d a ry H oo d L atch 1. Hood seal to the ornament. 2. Hood ornament to the hood. 3. Hood ornament nuts (21). 18. B o lt COWL VENT GRILLE REPLACEMENT B-07272 Figure 3—Hood Secondary Latch Components 2. 3. 4. 5. Remove or Disconnect (Figure 6) • Insert a screwdriver into the clip, and lift the cable from the lock. Then, carefully pry the cable grommet from the lock flange. Cable from the radiator support, and the wheelhouse retaining strap. Grommet from the cowl. • Cut the grommet down to the cable casing on the engine side of the cowl. • Push the cable and grommet through the cowl. Cable handle to air vent bezel bolts. Cable from the vehicle. 11. 13. 14. 19. 20. 1. Wiper arms. 2. Cowl vent grille panel screws. 3. Cowl vent grille plastic fasteners from the windshield frame. 4. Cowl vent grille from the vehicle. P rim a ry H o o d L a tc h C able C ab le C lip B o lt S tra p Figure 4—Hood Release Cable B-07276 SHEET METAL 2B-5 Install or Connect (Figure 6) 1. Cowl vent grille to the vehicle. 2. Cowl vent grille plastic fasteners to the windhsield frame. 3. Cowl vent grille panel screws. 4. Wiper arms. GRILLE AND MOLDING REPLACEMENT ++ Remove or Disconnect (Figure 7) 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). 24. R e ta in e r 25. R e ta in e r 26. C o w l V e n t G rille Panel 27. N u t 28. B o lt B-07269 Figure 6—Cowl Vent Grille Components 2B-6 SHEET METAL 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. R a d ia to r G rille B o lt R a d ia to r S u p p o rt B o lt N ut N ut B o lt S ide M o ld in g N ut B o lt B o lt B o lt L ow er M o ld in g L o w e r R a d ia to r G rille U p p e r M o ld in g 44. C lip 42 B-07274 Figure 7—Grille Components 11. Lower radiator grille to the sheet metal support bolts (40). FRONT FENDER REPLACEMENT Remove or Disconnect (Figures 7, 8 and 9) 12. Lower radiator grille from the vehicle. “►+ Install or Connect (Figure 7) 1. Lower radiator grille to the vehicle. 2. Lower radiator grille to the sheet metal support bolts (40). 3. Lower radiator grille to fender bolts (38). 4. 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). • 1. 2. 3. 4. 5. 6. 7. 8. • 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). 9. 10. 11. 12. 13. 14. 15. • 16. 17. 18. Tool Required: J-24595-B Door Trim Pad Remover. Raise and support the hood. Head lamp bezel. Head lamp. Right or left radiator grille molding nuts (34). Upper and lower molding clip nuts (33 and 37). Right or left radiator grille molding (36). Lower radiator grille to fender bolts (38). C ow l v e n t g rille . R efer to “ C ow l V e n t G rille Replacement.” Hood spring assembly. Refer to “ Spring Assembly Replacement.” Radiator support to fender bolts (119). Wheelhouse panel to shield bolts. Shield to underbody retainers using J-24595-B. Shield from the vehicle. Wheelhouse panel to fender bolts (50). Lower door pillar to fender bolt (45) and shim(s) (46). Fender to cowl bolt (47) and shim(s) (46). Open the front door. Upper fender to door pillar bolt (48) and shim(s) (46). Fender from the vehicle. Insulator from the fender. ♦«- Install or Connect (Figures 8 and 9) 1. Insulator to the fender. 2. Fender to the vehicle. SHEET METAL 2B-7 Tighten • Bolts to 17 N m (13 ft. lbs.). 7. Wheelhouse to fender bolts (50). • Wheelhouse to fender bolts (50) to 17 N m (13 ft. lbs.). • Lower door pillar to fender bolt to 43 N m (31 ft. lbs.). 8. Shield to the vehicle. 9. Shield to underbody retainers. 10. Wheelhouse panel to shield bolts. 11 12 13. 14. 15. 16. 17. 18. 3. Upper fender to the door pillar bolt (48) and shim(s) (46) as required. WHEELHOUSE PANEL REPLACEMENT RIGHT PANEL REPLACEMENT • Assemble loosely. 4. Fender to cowl bolt (47) and shim(s) (46) as required. • Assemble loosely. 5. Lower door pillar to fender bolt (45) and shim(s) (46) as required. • Assemble loosely. 6. Radiator support to fender bolts (119). • Fender to cowl bolt (47) to 43 N m (31 ft. lbs.). • Upper fender to door pillar bolt to 43 N m (31 ft. lbs.). Hood spring assembly. Refer to “ Spring Assembly Replacement.” C owl ve n t g rille . R efer to “ C ow l V e n t G rille Replacement.” Lower radiator grille to fender bolts (38). Right or left radiator grille molding (36). Upper and lower molding clip nuts (33 and 37). Right or left radiator grille molding nuts (34). Head lamp. Head lamp bezel. Remove or Disconnect (Figure 9) □ 1. 2. 3. 4. • 5. 6. 7. 8. Jack handle. Lug wrench. Coolant recovery reservoir. Air conditioning line retainers (if equipped). Raise and support the vehicle. Right front wheel. Wheelhouse panel to radiator support bolts (49). Wheelhouse panel to underbody shield bolts. Wheelhouse panel reinforcement to underbody bolts (52) and (53). 9. Wheelhouse panel to fender bolts (50). 10. Wheelhouse panel from the vehicle. • Slide the panel forward to clear the lower back side of the fender well. • Tilt the wheelhouse panel out of the vehicle. Install or Connect (Figure 9) 1. Wheelhouse panel to the vehicle. • Tilt the wheelhouse panel into the vehicle. • Slide the panel into position. 2. Wheelhouse panel to fender bolts (50). Tighten Figure 9—Wheelhouse Panel Attachment • Bolts to 17 N m (13 ft. lbs.). 3. Wheelhouse panel reinforcement to underbody bolts (52) and (53). 2B-8 SHEET METAL £ Tighten • Bolts (52) to 17 N m (13 ft. lbs.). • Bolt (53) to 47 N-m (35 ft. lbs.). Wheelhouse panel to underbody shield bolts. Wheelhouse panel to radiator support bolts (49). Tighten 6. • 7. 8. 9. 10. • Bolts to 17 N-m (13 ft. lbs.). Right front wheel. Lower the vehicle. Air conditioning line retainers (if equipped). Coolant recovery reservoir. Lug wrench. Jack handle. LEFT PANEL REPLACEMENT |<-+| Remove or Disconnect (Figure 9) 1. 2. 34. 5. • 6. 7. 8. 9. Jack. Windshield washer fluid reservoir. Wiring harness. Hood release cable. Air conditioning hose bracket (if equipped). Raise and support the vehicle. Left front wheel. Wheelhouse panel to radiator support bolts (49). Wheelhouse panel to underbody shield bolts. Wheelhouse panel reinforcement to underbody bolts (52) and (53). 10. Wheelhouse panel to fender bolts (50). 11. Wheelhouse panel from the vehicle. • Slide the panel forward to clear the lower back side of the fender well. • Tilt the wheelhouse panel out of the vehicle. -n - Install or Connect (Figure 9) Wheelhouse panel to the vehicle. • Tilt the wheelhouse panel into the vehicle. • Slide the panel into position. Wheelhouse panel to fender bolts (50). • Bolts to 17 N m (13 ft. lbs.). Wheelhouse panel reinforcement to underbody bolts 52) and (53). Tighten • Bolt (52) to 17 N-m (13 ft. lbs.). • Bolt (53) to 47 N m (35 ft. lbs.). Wheelhouse panel to underbody shield bolts. Wheelhouse panel to radiator support bolts (49). Tighten 6. • 7. 8. 9. 10. 11. • Bolts to 17 N-m (13 ft. lbs.). Left front wheel. Lower the vehicle. Air conditioning hose bracket (if equipped). Hood release cable. Wiring harness. Windshield washer fluid reservoir. Jack. REAR FENDER REPLACEMENT STEPSIDE MODEL FENDER REPLACEMENT Remove or Disconnect (Figure 10) 1. 2. 3. 4. 5. 6. 7. 8. 9. Parking lamp wiring from the fender. Brace to fender bolts (59). Side panel to fender bolts (56). Fender from the vehicle. Side panel to brace bolt (56). Brace (58). Cross sill to brace bolt (63). Brace (62). Sealer from the fender and the side panel. -►4- Install o r Connect (Figure 10) 1. A medium bodied sealer onto the fender to side panel flange. 2. Brace (62). 3. Cross sill to brace bolt (63). • Assemble loosely. 4. Brace (58) to the vehicle. 5. Side panel to brace bolt (56). • Assemble loosely. 6. Fender to the vehicle. 7. Side panel to fender bolts (56). • Assemble loosely. 8. Brace to fender bolts (59). Tighten • Brace to fender bolts to 17 N-m (13 ft. lbs.). • Side panel to fender bolts to 10 N-m (7 ft. lbs.). • Cross sill to brace bolt to 17 N m (13 ft. lbs.). 9. Parking lamp wiring to the fender. • Clean excess sealant from the fender. DUAL REAR WHEEL MODEL FENDER REPLACEMENT 0 1. 2. 3. 4. 5. 6. Remove or Disconnect (Figure 11) Parking lamp wiring from the fender. Fender to brace bolts (71). Fender to side panel bolts (72 and 69) and nuts (68). Side panel to fender nuts (66). Fender from the vehicle. Sealer from the side panel and fender. Install or Connect (Figure 11) 1. A medium bodied sealer onto the fender to side panel flange. 2. Fender to the vehicle. 3. Side panel to fender nuts (66). • Assemble loosely. 4. Fender to side panel bolts (72 and 69) and nuts (68). • Assemble ioosely. 5. Fender to brace bolts (71). • All of the nuts and bolts to 17 N m (13 ft. lbs.). Parking lamp wiring to the fender. Clean excess sealant from the fender. SHEET METAL 2B-9 Figure 10—Stepside Rear Fender Attachment Figure 11—Dual Rear Fender Attachment 2B-10 SHEET METAL 73. 74. 75. 76. 77. 78. 79. 80. 81. B olt W asher R etainer C ushion - Upper Bracket C ushion - Lower R etainer N ut R adiator S upport B-07280 Figure 12—Radiator Support Mounting RADIATOR SUPPORT REPLACEMENT |+ + | Remove or Disconnect (Figure 12) 1. Radiator from the vehicle. • Refer to ENGINE COOLING (SEC. 6B). 2. Air conditioning condenser from the vehicle. • Refer to AIR CONDITIONING (SEC. 1B). 3. Battery. • Refer to ENGINE ELECTRICAL (SEC. 6D). 4. Headlamp and parking lamp wires from the lamps. 5. Headlamp and parking lamp wiring harness from the radiator support. 6. Headlamp bezels. 7. Headlamp assemblies. 8. Ground wires from the radiator support. 9. Fuel vapor canister from the radiator support. 10. Air cleaner inlet from the radiator support. 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. 15. Sheet metal support from the vehicle. 16. Radiator support to fender bolts (119) (figure 8). 17. Wheelhouse panel to radiator support bolts (49) (figure 9). 18. Radiator support to frame nuts (80), lower retainers (79), lower cushions (78), upper cushions (76), retainers (75), bolts (73), and washers (74). 19. Radiator support from the vehicle. • Tilt the radiator support to the rear, and lift it up and out of the vehicle. Install or Connect (Figure 12) Radiator support to the vehicle. • Lower the radiator support into the vehicle, and tilt it into position. 2. Radiator support to frame washers (74), bolts (73), retainers (75), upper cushions (76), lower cushions (78), lower retainers (79), and frame nuts (80). • Assemble loosely. Wheelhouse panel to radiator support bolts (49) (figure 9). • Bolts to 17 N-m (13 ft. lbs.). 4. Radiator support to fender bolts (119) (figure 8). • Bolts to 17 N m (13 ft. lbs.). Sheet metal support to the vehicle. Sheet metal support to radiator support bolts. Tighten • Bolts to 17 N m (13 ft. lbs.). • Radiator support to frame nuts (80) to 47 N-m (35 ft. lbs.). 7. Lower radiator grille panel to the vehicle. 8. Grille to the vehicle. 9. Primary hood latch bracket to the radiator support bolts. SHEET METAL 2B-11 Adjust Hood latch left or right so that the hood properly engages the hood latch. Tighten 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. • Bracket to radiator support bolts to 27 N m (20 ft. lbs.). Air cleaner inlet to the radiator support. Fuel vapor canister to the radiator support. Ground wires to the radiator support. Headlamp assemblies. Headlamp bezels. Headlamp and parking lamp wiring harness to the radiator support. Headlamp and parking lamp wires to the lamps. Battery. • Refer to ENGINE ELECTRICAL (SEC. 6D). Air conditioning condenser. • Refer to AIR CONDITIONING (SEC. 1B). Radiator. • Refer to ENGINE COOLING (SEC. 6B). “►+ Install or Connect 1. Sheet metal assembly. • With the aid of a helper, lift the sheet metal onto the chassis. 2. Radiator support to frame washers (74), bolts (73), retainers (75), upper cushions (76), lower cushions (78), lower retainers (79), and nuts (80) (figure 12). 3. Lower fender to door pillar bolts (45) (figure 8). 4. 5. 6. 7. • Bolt to 43 N m (31 ft. lbs.). 8. Fender to cowl bolts (47). Tighten • Bolts to 43 N-m (31 ft. lbs.). Wheelhouse panel to fender bolts (50) (figure 9). SHEET METAL UNIT REPLACEMENT Tool Required: J-24595-B Door Trim Pad Remover. □ Remove or Disconnect 1. Hood. • Refer to “ Hood Replacement” earlier in this section. 2. Battery. • Refer to ENGINE ELECTRICAL (SEC. 6D). 3. Radiator. • Refer to ENGINE COOLING (SEC. 6B). 4. Air conditioning condenser. • Refer to AIR CONDITIONING (SEC. 1B). • Bolt to 43 N m (31 ft. lbs.). Shield to the vehicle. Shield to underbody retainers. Wheelhouse panel to shield bolts. Upper fender to door pillar bolt (48) (figure 8). 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. • Wheelhouse panel to fender bolts to 17 N-m (13 ft. lbs.). Bumper. • Refer to FRAME AND BUMPERS (SEC. 2A). Air cleaner inlet to the radiator support. Fuel vapor canister to the radiator support. Ground wires to the radiator support. Headlamp and parking lamp wiring harness to the radiator support. Head lamp and parking lamp wires to the lamps. Air conditioning condenser. • Refer to AIR CONDITIONING (SEC. 1B). Radiator to the vehicle. Refer to ENGINE COOLING (SEC. 6B). Battery to the vehicle. Hood to the vehicle. 5 . H e a d la m p a n d p a rk in g la m p w ire s fr o m th e la m p s . 6. Headlamp and parking lamp wiring harness from the radiator support. 7. Ground wires from the radiator support. 8. Fuel vapor canister from the radiator support. 9. Air cleaner inlet from the radiator support. 10. Bumper from the vehicle. • Refer to FRAME AND BUMPERS (SEC. 2A). 11. Wheelhouse panel to fender bolts (50) (figure 9). 12. Fender to cowl bolts (47) (figure 8). 13. Upper fender to door pillar bolt (48). 14. Wheelhouse panel to shield bolts. 15. Shield to underbody retainers using J-24595-B. 16. Shield from the vehicle. 17. Lower fender to door pillar bolt (45). 18. Radiator support to frame nuts (80), lower retainers (79), lower cushions (78), upper cushions (76), retainers (75), bolts (73), and washers (74) (figure 12). 19. Sheet metal assembly. • With the aid of a helper, lift the sheet metal from the chassis. SHEET METAL ADJUSTMENTS In order to have the proper operation and appearance of sheet metal components, it is important that certain fits and gaps between components be maintained. The gaps given in this procedure are suggested as the best alignm ent for these components (figure 13). In aligning sheet metal, it is best to start with the rearmost component, and work forward. 1. Starting with the fenders, align the rear edge of each fender to the rocker panel, and the door. The gap between these components should be 5 mm ± 2.3 mm (0.19-inch ± 0.09-inch). This adjustment should be accom plished by m oving the fender forward or rearward. The surface of the fender should be flush with the rocker panel and the door. Add or remove shims to perform this adjustment. 2. Align the fender to the cowl vent grille to obtain a gap of 4.6 mm ± 1 mm (0.18-inch ± 0.03-inch). The surface of the cowl vent grille should be flush with the fender surface. 2B-12 SHEET METAL 82. 83. 84. 85. 86. 87. A. B. C. D. E. F. Hood Fender Door Cow l V ent G rille R ocker Panel R adiator S upport Upper Panel Flush Fit Flush ± 1 m m (0.03-inch) Flush +0.00 mm or -1.5 mm ( + 0.00-inch or -0.06-inch) 4.6 mm ±1 mm (0.18-inch ± 0.03-inch) 8 mm ±1 mm (0.31-inch ± 0.03-inch) 5 mm ± 2.3 mm (0.19-inch ± 0.09-inch) F -0 2 3 4 8 Figure 13—Sheet Metal Gap Specifications SHEET METAL 2B-13 3. Align the hood with the cowl vent grille, so that there is a gap of 8 mm ± 1 mm (0.31-inch ± 0.03-inch) between the rear edge of the hood and the front edge of the cowl vent grille. The hood surface should be flush with the cowl vent grille surface within + 0.0-1.5 mm (+ 0.00 -0.06-inch). 4. Align the left and right edges of the hood so that a gap of 4.6 mm ±1 mm (0.18-inch ± 0.03-inch) exists between the hood and the fenders. The hood surface should be fiush with the fender surface within +0.0, -1.5 mm ( + 0.00 -0.06-inch). If this gap is difficult to obtain, and the hood appears to be cocked in between the fenders, the radiator support may need to be shifted. By shifting the radiator support, the entire front end sheet metal can be aligned as a unit. Loosen the support to the frame bolts, and shift the radiator support to obtain the proper gaps. Then, while holding the support in position, retighten the radiator support to frame bolts. 5. Align the front face of the hood to obtain a gap of 4.6 mm ±1 mm (0.18-inch + 0.03-inch) between the hood and the radiator support upper panel. The hood bumpers on the top of the radiator support should be adjusted to give the proper support to hood gap. The surface of the hood should be flush with the radiator support upper panel (not the grille molding). G MODELS |-K-| Install or Connect (Figure 14) 1. Hood to the vehicle. 2. Hood hinge to hood bolts (89). • Align the hood with the previously made marks. Tighten • Bolts to 17 N m (13 ft. lbs.). » Remove the protective coverings, and lower the hood. HOOD HINGE REPLACEMENT ++ Remove or Disconnect (Figure 14) • Raise and support the hood. Also support the rear corner of the hood. • Mark the position of the hinge on the hood and the cowl. 1. Hood hinge to hood bolts (89). 2. Hood hinge to cowl bolts (90). 3. Hood hinge from the vehicle. Install or Connect (Figure 14) 1. 2. 3. • 88. H o o d 89. B o lt 90. B o lt Hood hinge to the vehicle. Hood hinge to cowl bolts (90). Hood hinge to hood bolts (89). Align the hinge with the previously made marks. B-07273 Figure 14—Hood Hinge Components HOOD REPLACEMENT Remove or Disconnect (Figure 14) • Raise and support the hood. Place a protective covering over the fenders, and the cowl vent grille. • Mark the position of the hinges on the hood. • Bolts to 17 N m (13 ft. lbs.). PRIMARY HOOD LATCH REPLACEMENT Remove or Disconnect (Figure 15) • Raise and support the hood. 1. Hood latch release cable from the latch. 1. Hood hinge to hood bolts (89). 2. Bracket to hood latch bolts (94). 3. Hood latch from the vehicle. 4. Bracket to the sheet metal cross panel bolts (91). 2. Hood from the vehicle. 5. Bracket from the vehicle. 2B-14 SHEET METAL Tighten £ • Bracket to radiator support bolts to 27 N m (20 ft. lbs.) 92. Primary Latch 93. Bracket 94. Bolt B-07281 2. Hood latch height so that when the hood is closed, the hood is held securely against the front hood bumpers. • Raise and support the hood. Tighten $ Figure 15—Primary Hood Latch Attachment • Bracket to hood latch bolts to 27 N m (20 ft. lbs.). Adjust Front hood bumpers, so that the top of the hood is flush with the fenders. "►«" Install or Connect (Figure 15) 1. Bracket to the sheet metal cross panel. 2. Bracket to cross panel bolts (91) loosely. 3. Primary hood latch to the bracket. 4. Latch to bracket bolts (94) loosely. 5. Hood latch release cable to the latch. NOTICE: For Steps 1 and 2 refer to “ Notice” on page 2B-1. Adjust 1. Hood latch bracket left and right until the striker in the hood easily engages the primary latch. • Raise and support the hood. 0 SECONDARY HOOD LATCH AND SPRING REPLACEMENT < - | Remove or Disconnect (Figure 16) • Mark the position of the secondary hood latch on the hood. 1. Secondary hood latch to hood bolts (97). 2. Secondary hood latch from the vehicle. 3. Spring from the hood. • Twist the spring from the reinforcement. Install or Connect (Figure 16) 1. Spring to the hood. • Twist the spring into the reinforcement. 2. Secondary hood latch to the vehicle. 3. Secondary hood latch to hood bolts (97). Q Tighten • Bolts to 27 N m (20 ft. lbs.). SHEET METAL 2B-15 Figure 17—Hood Release Cable Attachment COWL VENT GRILLE REPLACEMENT HOOD RELEASE CABLE REPLACEMENT □ Remove or Disconnect (Figure 17) Remove or Disconnect (Figure 18) If the cable is broken, release the hood by pressing the prim ary latch tab on the right side of the lock assembly. Use a rod to press the tab. Raise and support the hood. Raise and support the hood. 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. Cable from the sheet metal cross panel clip. Grommet from the cowl. • Cut the grommet down to the cable casing on the engine side of the cowl. • Push the cable and the grommet through the cowl. Cable handle to dash screws. Cable from the vehicle. 1. Windshield wiper arms. 2. Cowl vent grille to cowl bolts (104) and screws (103). 3. Cowl vent grille from the vehicle. 4. Cowl seal from the vehicle. ++ Install or Connect (Figure 18) 1. Cowl seal to the vehicle. 2. Cowl vent grille to the vehicle. 3. Cowl vent grille to cowl bolts (104) and screws (103). 4. Windshield wiper arms. GRILLE REPLACEMENT Remove or Disconnect (Figures 19 and 20) • Raise and support the hood. Install or Connect (Figure 17) 1. Headlamp bezels. New cable to the vehicle. 2. Sheet metal cross panel to grille bolts. Cable through the drivers side of the cowl. • Push the grommet into the drivers side of the cowl, and then push the insert into the grommet. Cable handle to dash screws. Cable into the sheet metal cross panel clip. Cable to the primary latch. 3. Grille to lower front end panel bolts. 4. Grille from the vehicle. 5. Sheet metal to upper and lower radiator grille molding nuts (110 and 112). 6. Upper and lower radiator grille moldings from the vehicle. 2B-16 SHEET METAL 102. 103. 104. 105. 106. C ow l V e n t G rille Panel Screw B o lt/S cre w N ut Seal F-07286 Figure 18—Cowl Vent Grille Components 109. F ro n t End S h ee t M e ta l C ro s s Panel 110. N u t 111. U p p e r M o ld in g 112. N ut 113. L ow er M o ld in g E Figure 19—Radiator Grille Figure 20—Radiator Grille Molding Attachment SHEET METAL 2B-17 +«- Install or Connect (Figure 21) 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.). Upper radiator mounts. Upper radiator mount to sheet metal cross panel bolts. Air intake snorkel. Primary hood latch. Refer to “ Primary Hood Latch Replacement.” 10. Grille. Refer to “ Grille Repalcement.” 11. Headlamp bezels. • Lower the hood. 6. 7. 8. 9. SHEET METAL VERTICAL SUPPORT REPLACEMENT 109. Front End Sheet M etal C ross Panel 114. B olt B-07289 Figure 21—-Front End Sheet Metal Cross Panel Attachment +«- Install or Connect (Figures 19 and 20) Upper and lower radiator grille moldings to the vehicle. Sheet metal to upper and lower radiator grille molding nuts (110 and 112). Grille to the vehicle. Grille to lower front end panel bolts. Sheet metal cross panel to grille bolts. Headlamp bezels. Lower the hood. FRONT END SHEET METAL CROSS PANEL REPLACEMENT Remove or Disconnect (Figure 21) • 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Raise and support the hood. Headlamp bezels. Grille. Refer to “ Grille Replacement.” Primary hood latch. Refer to “ Primary Hood Latch Replacement.” Air intake snorkel. Upper radiator mount to sheet metal cross panel bolts. Upper radiator mounts. Sheet metal cross panel to fender bolts (114). Sheet metal cross panel to the hood latch bracket bolts (91). Sheet metal cross panel to radiator support baffle panel bolts. Sheet metal cross panel to the headlamp bezel support bolts. Sheet metal cross panel from the vehicle. Remove or Disconnect (Figure 22) 1. 2. 3. 4. 5. Grille. Refer to “ Grille Replacement.” Vertical support to sill bolts (17). Front end panel to vertical support bolts (120). Sheet metal cross panel to vertical support bolts (115). Vertical support from the vehicle. Install or Connect (Figure 22) 1. Vertical support to the vehicle. 2. Sheet metal cross panel to vertical support bolts (115). • Bolts to 27 N m (20 ft. lbs.). 3. Front end panel to vertical support bolts (120). Tighten » Bolts to 18 N m (13 ft. lbs.). 4. Vertical support to sill bolts (117). Tighten • Bolt to 10 N m (7 ft. lbs.). 5. Grille. Refer to “ Grille Replacement.” FRONT END PANEL REPLACEMENT Remove or Disconnect (Figure 23) 1. 2. 3. 4. 5. 6. Headlamp bezels. Grille. Refer to “ Grille Replacement.” Front end panel to headlamp bezel support bolts (118). Front end panel to sill bolts (121). Front end panel to vertical support bolts (120). Front end panel from the vehicle. 2B-18 SHEET METAL 121 116. Sheet Metal V ertical Support 117. Front End Panel 118. Bolt 120. Bolt 121. Bolt B-07282 Figure 23—Front End Panel Attachment Install or Connect (Figure 23) 1. Front end panel to the vehicle. 2. Front end panel to vertical support bolts (120). • 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. Q Tighten • Bolts to 18 N m (13 ft. lbs.). Figure 22—Front End Sheet Metal Vertical Support CAB MOUNTS CAB MOUNT REPLACEMENT When changing cab mounts, it is important support the frame while changing the mount. mount is to be changed, the entire side on mount is placed must be lowered enough clearance for the mount. H to properly If only one which the to provide Remove or Disconnect (Figures 24 through 26) • Raise the vehicle slightly on the hoist. • Place jack stands under the body on the side of the vehicle where the m ounts will be replaced. 1. Bolt (279), retainer (278), and lower cushion (277) or nut (283), washer (277), cushion (277) and spacer (281). • Lower the hoist enough to leave the body supported by the jacks. 2. Shim (275) and upper cushion (276). -►4- Install or Connect (Figures 24 through 26) 1. Upper cushion (276) and shim (275). • Raise the frame on the hoist slightly. 2. Lower cushion (277), retainer (278) and bolt (279) or spacer (281), cushion (277), washer (277) and nut (283). • Remove the jacks. & Tighten • Bolts to 75 N m (55 ft. lbs.). • Nuts to 47 N m (35 ft. lbs.). Lower the hoist. SHEET METAL 2B-19 279 277. 278. 279. 280. L ow er C u s h io n R e ta in e r B o lt W eld N u t % A. M o u n t No. 1 B. M o u n t No. 2 C. M o u n t No. 3 F-02294 Figure 24—Cab Mounts for the R/V Chassis with a Bonus or Crew Cab 2B-20 SHEET METAL 279. B o lt 280. W eld N ut F-02295 F igure 25—Cab M ounts fo r th e R/V C hassis w ith a R egular Cab SHEET METAL 2B-21 275 279 279 B 275. 276. 277. 278. 279. 280. 281. 282. 283. S h im U p p e r C u s h io n L o w e r C u s h io n R e ta in e r B o lt W eld N u t A. S p a ce r B. W a sh e r C. N ut D. M ount M ount M ount M ount N o. N o. No. N o. 276 1 2 3 4 F-02293 Figure 26—Cab Mounts for the R/V Pickup 2B-22 SHEET METAL 280 c 275. 276. 277. 278. 279. 280. 283. S h im U p p e r C u s h io n L ow er C u s h io n R e ta in e r B o lt W eld N u t N ut A. B. C. D. E. F. M ount M ount M ount M ount M ount M ount N o. N o. N o. N o. N o. N o. 1 2 3 4 5 6 F-02292 F-02292 Figure 27—Cab Mounts for the Suburban SHEET METAL 2B-23 SPECIFICATIONS N-m TORQUE Ft. Lbs. R/V Models Hood Hinge to Hood B o lts ..........................................................................................................................25 Hood Hinge to Cowl B olts................................................................................................................... .........43 Spring Assem bly to Hood B o lts .................................................................................................................25 Spring Assem bly to Fender B o lts ...............................................................................................................25 Primary Hood Latch Bracket to Radiator Support B o lts .............................................................. .........27 Bracket to Primary Hood Latch B o lts ............................................................................................... .........27 Secondary Hood Latch to Hood B o lts ......................................................................................................27 Sheet Metal Support to Radiator Support B o lt s ........................................................................... .........17 Radiator Support to Fender B o lts...............................................................................................................17 Radiator Support to Frame N uts.................................................................................................................47 W heelhouse to Fender B o l t ........................................................................................................................43 Fender to Cowl B o lt.............................................................................................................................. .........43 Upper Fender to Door Pillar B o lt ...............................................................................................................43 W heelhouse Panel Reinforcement to Underbody Bolts (52 )....................................................... .........17 (53 )....................................................... .........47 W heelhouse to Radiator Support B o lts ....................................................................................................17 Stepside Models Brace to Rear Fender B o lt s .............................................................................................................. ......... 17 Side Panel to Rear Fender B o lts ............................................................................................................... 10 Side Panel to Brace B o lts ................................................................................................................... ......... 10 Fleetside Models All Rear Fender to Side Panel Bolts, and N u ts ............................................................................. ......... 17 G Models Hood Hinge to Hood B o lts .......................................................................................................................... 17 Primary Hood Latch Bracket to Radiator Support B o lts .............................................................. ......... 27 Bracket to Primary Hood Latch B o lts ............................................................................................... ......... 27 Secondary Hood Latch to Hood B o lts ............................................................................................. ......... 27 Sheet Metal Cross Panel to Headlamp Bezel Support B o lts ..................................................... ......... 27 Sheet Metal Cross Panel to Radiator Support Baffle Panel B o lt s ............................................ ......... 27 Sheet Metal Cross Panel to Hood Latch Bracket B o lts ................................................................ ......... 27 Sheet Metal Cross Panel to Fender B o lts ...................................................................................... ......... 28 Sheet Metal Cross Panel to Vertical Support B o lts ................................................................................ 27 Front End Panel to Vertical Support B o lts ...................................................................................... ......... 18 Vertical Support to Sill B o lts........................................................................................................................ 10 Front End Panel to Vehicle B o lts ............................................................................................................... 18 Cab Mounts Cab Mount B o lts .................................................................................................................................. ......... 75 Cab Mount N u t s .................................................................................................................................. ......... 47 18 32 18 18 20 20 20 13 13 35 31 31 31 13 35 13 13 7 7 13 13 20 20 20 20 20 20 20 20 13 7 13 55 35 SPECIAL TOOLS 1. J-24595-B 1. D oo r Trim Pad R em over F-02347 2B-24 SHEET METAL 3A-1 SECTION 3 STEERIN G, SUSPENSION, W HEELS AND TIR ES CONTENTS SUBJECT PAGE Front End A lignm ent.......................................................................................................................................................3A-1 Steering L inkage...........................................................................................................................................................3B1-1 Manual Steering......................................... ................................................................................................................... 3B2-1 Power S te e rin g ............................................................................................................................................................. 3B3-1 Steering C o lu m n ...........................................................................................................................................................3B4-1 Front Suspension And A x le .......................................................................................................................................... 3C-1 Rear Suspension............................................................................................................................................................. 3D-1 Wheels And T ir e 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 term inology: “ NOTICE” : See ‘Notice’ on page 3A-1 on this section.” NOTICE: Front end alignm ent fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in m ajor repair expense. They must be replaced with one o f the same part num ber or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent 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 Description....................................................................................................................................................................... 3A-2 Definition of T e rm s ............................................................ .....................................................................................3A-2 Diagnosis of Front End Alignm ent.............................................................................. ................................................. 3A-3 On-Vehicle S e rvice .........................................................................................................................................................3A-3 Inspection..................................................................................................................................................................... 3A-3 Front End Alignment Requirements..........................................................................................................................3A-3 Alignment Adjustments.............................................................................................................................................. 3A-4 S pe cifica tio ns.................................................................................................................................................................3A-6 3A-2 FRONT END ALIGNMENT DESCRIPTION Side View Front View A C D E m in u s B . . .C a m b e r (Inches) . .C a m b e r (D e gre es P o sitive) . . .C a ste r (D e gre es P o sitive) m in u s F ..........Toe-In (Inches) B-07371 Figure 1—Caster-Camber-Toe-ln “ Front End Alignm ent” refers to the angular relation­ ship between the front wheels, the front suspension atta­ ching parts and the ground. Proper front end alignm ent must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber, and axle caster (Figure 1). DEFINITION OF TERMS CAMBER Camber is the inward or outward tilting of the front wheels from the vertical. When the wheels tilt outward at the top, the camber is positive ( + ). When the wheels tilt inward at the top, the camber is negative (—). The amount of tilt measured in degrees from the vertical is called the camber angle. Camber is designed into the front axle a ss e m b ly of all fo u r-w h e e l d rive v e h ic le s and is non-adjustable. If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside tire, while positive camber causes wear to the outside. CASTER (Figure 1) Caster is the tilting of the wheel axis either forward or backward from the vertical (when viewed from the side of the vehicle). A backward tilt is positive ( + ) and a forward tilt is negative (—). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper 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 would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Caster is designed into the front axle a ssem bly on all fo u r-w h e e l d rive ve h icle s, and is non-adjustable. TOE-IN Toe-in is the turning of the front wheels. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignm ent procedure. FRONT END ALIGNMENT 3A-3 DIAGNOSIS OF FRONT END ALIGNMENT PROBLEM CORRECTION POSSIBLE CAUSE Noisy Front End 1. Worn tie rod ends. 2. Loose suspension bolts. 3. Lack of proper lubrication. 4. Loose shock absorbers or worn bush­ ings. 5. Loose stabilizer bar. Wheel Bounce 1. Refer to 3E). 2. Replace 3. Replace 4. Refer to 3E). 5. Refer to 3E). 1. Tire and wheel out of balance. 2. Blister or bump on the tire. 3. Im proper shock absorber action. 4. Excessive wheel or tire run-out. 5. Tire “ Lead.” Excessive Tire Wear 1. Replace ends. 2. Refer to FRONT SUSPENSION (SEC. 3C). 3. Refer to MAINTENANCE AND LUBRI­ CATION (SEC. OB). 4. Tighten bolts and/or replace the bush­ ings. 5. Tighten 1. Incorrect wheel alignment. 2. Failure to rotate tires. 3. Faulty shock absorbers. 4. Improper tire pressure. 5. Overloaded or improperly loaded vehi­ cle. 6. Broken or sagging springs. WHEELS AND TIRES (SEC. the tire. the shock absorber. W HEELS AND TIRES (SEC. W HEELS AND TIRES (SEC. 1. Align the wheels. 2. Refer to W HEELS AND TIRES (SEC. 3E). 3. Replace shock absorber. 4. Refer to W HEELS AND TIRES (SEC. 3E). 5. Avoid overloading vehicle. 6. Replace springs. ON-VEHICLE SERVICE INSPECTION 9. Alignm ent equipm ent. Follow the m anufacturer’s instructions. B efore m aking any a d ju stm e n ts a ffe ctin g caster, cam ber or toe-in, the following front end inspection should be made: 10. Level of the vehicle. The vehicle must be on a level surface fore and aft and transversely. Inspect (Figure 2) 1. Tires for proper inflation pressure. Refer to WHEELS AND TIRES (SEC. 3E). 2. Front wheel bearing for proper adjustment. Refer to FRONT SUSPENSION (SEC. 3C.). 3. Ball joints, tie rod ends, and relay rods. If excessive looseness is noted, correct before adjusting. Refer to STEERING LINKAGE (SEC. 3B1). 4. Wheels and tires for run-out. Refer to WHEELS AND TIRES (SEC. 3E). 5. D im e n sio n “ B C ” in (fig u re 2). If not w ith in specifications, the correction must be made before adjusting caster. 6. Steering gear for looseness at the frame. 7. Shock absorbers for leaks or any noticeable noise. Refer to FRONT SUSPENSION (SEC. 3C). 8. C ontrol arms or s ta b ilize r bar attachm ents for looseness. Refer to FRONT SUSPENSION (SEC. 3C). FRONT END ALIGNMENT REQUIREMENTS Satisfactory vehicle operation may occur over a wide range of front end alignm ent settings. If the settings vary beyond certain tolerances, adjustm ents are advisable. The “ Specifications” at the back of this section is a guideline for vehicle diagnosis or for repairs. Set the front end alignm ent to specifications w hile the vehicle is in its normally loaded condition. Vehicles w hich are consistently operated with heavy loads should have toe-in adjusted with the vehicle under heavy load. This procedure should result in longer tire life. 3A-4 FRONT END ALIGNMENT A. D im e n s io n “ B C ” B. J o u n c e B u m p e r B ra c k e t C. C ro s s m e m b e r B A D. A “ DOWN IN REAR” frame angle must be SUB­ TRACTED from a POSITIVE caster reading. F. A “ DOWN IN REAR” frame angle must be ADDED to a NEGATIVE caster reading. r- HORIZONTAL FRAME ANGLE = W HORIZONTAL v FRAME ANGLE \ = 1/2° DOWN DOWN CASTER ANGLE READING = + (2-V a ° ) ACTUAL (CORRECTED) CASTER ANGLE = + (1°) C A S T E R A N G L E R E A D IN G = • (-Va °) A C T U A L (C O R R E C TE D ) C A S T E R A N G L E = ■ (1-3/4°) G. An “ UP IN REAR” frame angle must be SUBTRACTED from a NEGATIVE caster reading. E. A “ UP IN REAR” frame angle must be ADDED to a POSITIVE caster reading. HORIZONTAL HORIZONTAL FRAME ANGLE = 1 1/4° UP FRAME ANGLE = 1° UP ■CASTER ANGLE READING = • (1/4°) ACTUAL (CORRECTED) CASTER ANGLE = + (1°) CASTER ANGLE READING = + (2°) ACTUAL (CORRECTED) CASTER ANGLE = + (3°) B-07373 Figure 2—Determining Caster ALIGNMENT ADJUSTMENTS A normal shim pack will leave at least two threads of the bolt exposed beyond the nut. If two threads cannot be obtained, check for control arms and related parts. The difference between front and rear shim packs must not exceed 7.62 mm (0.03 inch). Front shim pack must be at least 2.54 mm (0.10 inch). ACCESS TO SHIM PACKS Models with 3/4-lnch Nut Jack up the frame to raise the wheel off the ground. This will allow the proper upper control arm to drop down far enough to use a socket on the nuts and permit shim adjustment. Torque to specifications, refer to FRONT SUSPENSION AND AXLE (SEC. 3C). Models with 7/s-lnch Nut Remove the upper control arm bumper; then follow the s a m e p ro c e d u re as w ith 3/4 -in ch N u t. T orque to specifications. Reinstall the upper control arm bumper w h e n a lig n m e n t is c o m p le te d . R e fe r to F R O N T SUSPENSION AND AXLE (SEC. 3C). CASTER All caster specifications are given with a frame angle of zero. Therefore, it will be necessary to know the angle of the frame (whether “ up” in rear or “ down” in rear) before a corrected caster reading can be determined. Camber and toe-in can be read “ as is” from the alignm ent equipment. How To Determine Caster (Figure 2 and 3) All caster specifications are given with vehicle frame angle of zero. 1. Position the vehicle on a smooth level surface. 2. Use a bubble protractor or inclinometer to measure the frame angle. Frame angle is the degree of tilt in the frame from the level position. 3. Determine whether the frame angle is “ up in rear” or “ down in rear.” 4. Determine the caster angle reading from the alignment equipment. 5. Refer to figure 3. To determine an “ actual (corrected) caster reading” with various frame angles and caster readings, one of the following rules apply: FRONT END ALIGNMENT 3A-5 A. B. C a m b e r C. A d d s h im s here to in cre a se c a s te r E. S u b tra c t s h im s here to in c re a s e c a s te r F. A d d s h im s e q u a lly to in c re a s e c a m b e r B-07372 Figure 3—Caster-Camber Adjustment a. A “ DOWN IN REAR” frame angle must be SUBTRACTED from a POSITIVE caster reading. b. An “ UP IN REAR” frame angle must be ADDED to a POSITIVE caster reading. c. A “ DOWN IN REAR” frame angle must be ADDED to a NEGATIVE caster reading. d. An “ UP IN REAR” fram e angle m ust be SUBTRACTED from a NEGATIVE c a s te r reading. 6. Dimension “ BC” measured 90 degrees from the lower surface of the crossmember (C) and to the inboard rear corner of the jounce bumper bracket (B). 7. Using dimension “ BC” and the caster, camber, wheel toe-in chart sheet, find the recommended caster angle. 8. If the actual (corrected) caster cycle (Step 5) is not within the recommended caster angle (Step 7) make the necessary shim changes. CAMBER 1. Determine the camber angle from the alignm ent equipment. 2. Add or subtract shims from both the front and rear bolts to affect a change. TOE-IN 1. Determine the toe-in from the alignment 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. - 3.4° 3 .1° — — — — — — 3.2° 3.0° — - — 2.00 — — 3.0° 2.7° 3 .0° 2.5° 57.2 2.25 - — 2.9° 2.4° 2 .6° 63.5 2.50 3.7° 1.5° 2.7° 2.1° 70 2.75 3.5° 1.2° 2.5° 76.2 3.00 3.2° 0.9° 2.3° 38.1 1.50 — 44.5 1.75 50.8 3.25 2.9° 88.9 3.50 2.6° 95.3 3.75 2.4° P300 P300 (32) w/JB8 or JB9 W/JB8 or JB9 Except FS3 Except FS3 P30/3500 (32,42) W/FS3 V100 + 200 + 300 (00) — + 5° + 8° 3.2° — NOMINAL NOMINAL 2.2° 2.9° — (References (References 2.3° 1.9° 2.6° 5.5° only.no only, no 1.8° 2.0° 1.6° 2.4° 5.3° means of means of 1.5° 1.7° 1.3° 2.1° 5.0° adjustment adjustment o CO o 82.5 R200 + 300 (00) 2.2° 1.2° 1.4° 1.1° 1.8° 4.7° 0.3° 2.0° 1.0° 1.2° 0.8° 1.5° 4 .4° 0.1° 1.8° o •^1 o R100 (00) P200 + 300 (42) W/R05 Except FS3, JB8 or JB9 0.9° 0.5° 1.2° 4.1° 1.8° 114.3 4.50 120.7 0.3° 1.0° -0.15° 1.5° 0.2° 0.4° 0.7° 3.5° 1.5° -0.7° 1.4° -0.03° 0.2° -0.2° 0.5° 3.3° 4.75 1.3° -1.0° - — -0.1° 0.2° 3.1° 127 5.00 1.0° -1.2° - - — — -0.1° 2.9° 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° - O 0.6° CO oo o 4.25 0.5° o bo o o o 108 1.7° o 2 .1° o o o 4.00 o 101.6 provided). provided). (0 g m a) O H m 30 = O > > u H H o z <0 FRONT END ALIGNMENT G300 (00) Dimension “ BC” Inches 3A-6 G100 + 200 (00) P200 + 300 (42) Except FS3, R05, JB8 or JB9 Dimension “ BC” MM FRONT END ALIGNMENT 3A-7 SPECIFICATIONS (CONTINUED) CAMBER AND TOE-IN CHART Model Camber Toe Angle Total Toe-In R100 (00) 0.70° 0.36° 4.5 mm (0.18 inch) R200 + 300 (00) 0.25° + 1.5° 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) + 1.5° Nominal (Reference only no means of adjustment provided). 0.1° 3.0 mm (0.12 inch) V100 + 200 +300 (00) P30/3500 (32,42) with FS3 CASTER, CAMBER, WHEEL TOE-IN ALIGNMENT SETTING TOLERANCES Check Re-Set Caster ± 1.00° ± 0.50° Camber ± 0.75° ± 0.50° Total Toe-In ± 3.0 mm (0.12 inch) ± 0.232° ± 1.5 mm (0.06 inch) ± 0.116° 3A-8 FRONT END ALIGNMENT STEERING LINKAGE 3B1-1 SECTION 3B1 STEERING LINKAGE 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 term inology: “ 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 of vital parts and systems, and/or could result in m ajor repair expense. They must be replaced with one o f the same part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of 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 Description...................................................................................................................................................................3B1- 1 Diagnosis Of Steering Linkage.................................................................................................................................. 3B1- 2 On-Vehicle S ervice .....................................................................................................................................................3B1- 2 Idler Arm In sp e ctio n ..................................... ..................................................................................................... 3B1- 2 Idler Arm Adjustment (P30(32) M otorhom e)....................................................................................................... 3B1 - 2 Idler Arm Replacement.......................................................................................................................................... 3B1- 3 Relay Rod Replacem ent........................................................................................................................................ 3B1 - 4 Pitman Arm Replacement...................................................................................................................................... 3B1- 5 Steering Shock Absorber Inspection....................................................................................................................3B1- 6 Steering Shock Absorber Replacement................................................................................................................3B1- 7 Tie Rod Replacement (R, G, P20 and 30(42) M o d e ls).......................................................................................3B1- 7 Tie Rod Replacement (V and P30(00)FS3 Models)............................................................................................. 3B1- 8 Connecting Rod Replacement (V and P30(00)FS3 Models)...............................................................................3B1-10 Connecting Rod Replacement (P30(32) Motorhome).........................................................................................3B1-11 S p e c ific a tio n s .............................................................................................................................................................3B1-13 Special T o o ls ...............................................................................................................................................................3B1-14 DESCRIPTION The steering linkage for the R, G, and P20 + 30(42) model is composed of a pitman arm, idler arm, relay rod, two adjustable tie rods and a steering shock absorber (Gmodel). When the steering wheel is turned, the gear ro­ tates the pitman arm which forces the relay rod to one side. The tie rods, which are connected to the relay rod by ball studs, transfers the steering force to the wheels. The tie rods are adjustable and are used for toe-in adjust­ ments. The relay rod is supported by the pitman arm and idler arm. The idler arm pivots on a support attached to the frame rail. On the G-model the steering shock absor­ ber is attached to a relay rod and a mounting bracket to steering gear. The P30(32) Motorhome model steering linkage has a sim ilar adjustable tie rod assembly as described above. When the steering wheel is turned, the gear rotates the pitman arm which forces the nonadjustable connecting rod and relay arm to move the relay rod to one side. The relay arm and idler arm are attached to the frame by sup­ port assemblies. The support assemblies are adjustable for shaft end play. The steering shock absorber is at­ tached to the fram e and relay arm (figures 1 through 3). The V model has a front driving axle assem bly and the P30(00) with RPO-FS3 has an I-Beam axle assembly. The steering linkage consists of an adjustable connecting rod, steering shock absorber, pitman arm and a tie rod which connects the two steering knuckles together (figures 7 and 8). The overall condition of the steering linkage affects steering performance. If parts are bent, damaged, worn or poorly lubricated, im proper and possibly dangerous steering action will result. Whenever any steering linkage components are re­ paired or replaced, check the steering geometry and front end alignment. Refer to FRONT END ALIGNM ENT (SEC. 3A). 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 A ssem bly 4. Steering Knuckle 5. Pitman Arm 6 . Steering Gear B-09657 F igure 1— S tee rin g L inkage — R, P20, and P30 (42) M odels IDLER ARM INSPECTION In s p e c t (F ig u re s 4 a n d 5) Raise the vehicle. Allow the front wheels to rotate freely and the steering mechanism freedom to turn. Position the wheels in a straight ahead position. Place a spring scale near the relay rod end of the idler arm. Exert a 110 N (25 lb.) force upward and then downward (G model the force is forward and rearward) while measuring the total distance the arm moves. The allowable deflection is ± 3.18mm (1/s inch) for a total of 6.35mm (1/4 inch) (figures 4 and 5). Replace the idler arm if it fails this test with the exception of the P model motorhome. Refer to “ Idler Arm Adjustment (P30(32) Motorhome),” in this section. Im p o rta n t Jerking the right wheel and tire assembly back and forth, causing an up and down movement of the idler arm, is NOT an acceptable testing procedure. There is no control on the amount of force being applied to the idler arm. • Care should be used whenever shimmy complaints are suspected of being caused by loose idler arms. Before suspecting suspension or steering components, technicians should consider areas such as dynamic imbalance, runout or force variation of wheel and tire assemblies and road surface irregularities. Refer to WHEELS AND TIRES (SEC. 3E). IDLER ARM ADJUSTMENT (P30(32) MOTORHOME) The fram e adjustable for movement as idler arm fails mounted idler support assem bly (10) is support shaft end play. Check for idler arm described in “ Idler Arm Inspection.” If the this test, adjust the support shaft end-play. A d ju s t (F ig u re 3) 1. Loosen the support assembly jam nut. 2. Tighten the adjuster plug to metal-to-metal contact. 3. Back off the adjuster plug 1/s of a turn (V2 of a flat on the square nut). STEERING LINKAGE 3B1-3 1. 2. 3. 4. 5. 6. 7. 9. Id le r A rm Relay Rod Tie Rod A s s e m b ly S te e rin g K n u ckle P itm a n Arm S te ering Gear S h o ck A b s o rb e r Bracket B-09659 Figure 2—Steering Linkage — G Model a Tighten • Jam nut to 40 N m (30 ft. lbs.). The adjusting plug should not rotate. |-n-| Install or Connect (Figures 1 and 2) Tools Required: J-29193 Steering Linkage Installer (12mm). J-29194 Steering Linkage Installer (14mm). IDLER ARM REPLACEMENT J~| Im portant Do not attempt to free the ball stud by using a pickle fork or wedge type tool, because seal or bushing damage could result (figure 6). Use the proper tool to separate all ball joints. E3 Remove or Disconnect (Figures 1 and 2) Tool Required: 1. Frame bolts to the idler arm. Tighten • Bolts to “ Specifications” at the end of this section. Idler arm frame bolts. Nut from the idler arm ball stud. 3. Prevailing torque nut to the idler arm ball stud. Raise the vehicle. Idler arm (1) from the relay rod (2). Use J-24319-01. «mjH • Position the idler arm (1) on the frame. 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. J-24319-01 Steering Linkage Puller. L* NOTICE: For steps 1 and 3 see “ N o tice” on page 3B1-1 of this section. Inspect Q Tighten • Nut to “ Specifications” at the end of this section. Ball stud threads for damage. Lower the vehicle. Ball stud seal for cuts or other damage. 0 Clean Threads on the ball stud and in the ball stud nut. A djust • Toe-in if necessary. Refer to FRONT END ALIGNMENT (SEC. 3A) in this manual. 3B1-4 STEERING LINKAGE 7. 8. 10. 11. 12. 13. Idler Arm Relay Rod Tie Rod Assem bly Steering Knuckle Pitman Arm Steering Gear Shock Absorber Connecting Rod Support Assem blies Relay Arm Washer Grommet B-09656 Figure 3—Steering Linkage — P30 (32) Motorhome RELAY ROD REPLACEMENT Inspect • Threads on the tie rod and the tie rod end for damage. 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 “ Tie Rod Replacement” in this section. 2. Nuts from the idler arm (1) and pitman arm (5) or relay arm (11) ball studs at the relay rod (2). 3. Relay rod (2) from the idler arm (1). Use J-24319-01. 4. Relay rod (2) from the pitman arm (5) or relay arm (11). Use J-24319-01. • Ball stud threads for damage. • Ball stud seals for excessive wear. STEERING LINKAGE 3B1-5 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. NOTICE: See “Notice” on page 3B1-1 of this section. 2. Nuts to the idler arm and the pitman arm or relay arm ball stud. • Nuts to “ Specifications” at the end of this section. A. 6.35 m m {AU") B. A p p ly S p rin g S ca le 3. Inner tie rod (3) to the relay rod. Refer to “ Tie Rod Replacement.” B-0737C Figure 5—Checking Idler Arm Movement-G Model jjjjj* • Lower the vehicle. PITMAN ARM REPLACEMENT Clean Im portant • Threads on the ball stud and the ball stud nut. • Use the proper tool to separate all ball joints. |+ + | Install or Connect (Figures 1 through 3) Tools Required: |*"»| Remove or Disconnect (Figures 1, 2, 3, 7 and 8) Tools Required: J-29193 Steering Linkage Installer (12mm). J-24319-01 Steering Linkage Puller. J-29194 Steering Linkage Installer (14mm). J-29107 Pitman Arm Puller. J-6632-01 Pitman Arm Remover. • Raise the vehicle. 1. Relay rod nut or connecting rod nut and cotter pin from the pitman arm ball stud. 2. Relay rod (2) or connecting rod (8) from the pitman arm (5). Use J-24319-01. 3. Pitman arm nut and washer. • Mark the pitman arm and the pitman shaft. This will permit proper alignment at assembly. NOTICE: Donot hammeronpitmanarm, pitman shaft, or puller. Damage to pitman arm or steeringgear mayresult. 4. Pitman arm (5). Use J-6632-01 or J-29107. Inspect • Ball stud threads for damage. • Ball stud seals for excessive wear. jJ 5 Clean • Threads on the ball stud and ball stud nut. +4- Install or Connect (Figures 1, 2, 3, 7 and 8) Tools Required: J-29193 Steering Linkage Installer (12mm). J-29194 Steering Linkage Installer (14mm). 3B1-6 STEERING LINKAGE 3. Tie Rod A sse m b ly 4. S teering K nuckle 5. Pitm an Arm 6 . S teering Gear 7. S hock A bsorbe r 8 . C on n ectin g Rod A ssem bly B-07367 Figure 7—Steering Linkage—P30(00)FS3 NOTICE: For steps 2 and 4 see “ N otice” on page 3B1-1 o f this section. STEERING SHOCK ABSORBER INSPECTION NOTICE: If a clamp type pitman arm is used, spread the pitm an arm ju st enough, with a wedge, to slip the arm onto the pitman shaft Do n o t spread the p itm an arm m ore than required to slip over the pitman shaft with hand pressure. Do not hammer, or damage to the steering gear may re su lt Steering shock absorbers are a sealed assembly and are nonrepairable. Replace the complete assembly if damaged. 1. Pitman arm (5) on the pitman shaft. Line up the marks made at removal. 2. Pitman arm washer and nut. 1? Inspect (Figures 2, 3, 7 and 8) 1. Shock absorber for fluid leakage. A slight film of fluid is allowable near the shaft seal. If there is excessive fluid leakage, be sure it’s from the shock absorber and then replace the shock absorber. 2. Shock absorber bushing for excessive wear. Replace the shock absorber if necessary. • Pitman arm nut to “ Specifications” at the end of this section. 3. Relay rod (2) or connecting rod (8) to the pitman 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. 4. Relay rod nut or the connecting rod castellated nut and cotter pin to the pitman arm ball stud. Tighten • Castellated nut to “ Specifications” as instructed at the end of this section. Lower the vehicle. 3. Test the shock absorber. • Djsconnect the shock absorber from the frame or axle end. • Extend and compress the shock absorber using as much travel as possible. Resistance should be smooth and constant for each stroking rate. Replace the shock absorber if any binding or unusual noises are present. • Install the end of the shock absorber. Torque to specifications. STEERING LINKAGE 3B1-7 A. 3. 4. 5. 7. 8. Tie Rod A ssem b ly (K30) Tie Rod A ssem bly Steering K nuckle Pitm an Arm S hock A bsorbe r C onnectin g Rod A sse m b ly B-09660 Figure 8—Steering Linkage—V Models STEERING SHOCK ABSORBER REPLACEMENT • Washer (12) and grommet (13) (P30(32) model). 2. Shock absorber mounting nuts and washers. Tighten ++ 1. • 2. 3. I? Remove or Disconnect Shock absorber mounting nuts and washers. Washer (12) and grommet (13) (P30(32) model). Cotter pin and castellated nut. Shock absorber (7). Inspect Shock absorber for leaks and damage. Shock absorber bushings for wear and damage. Grommet (13) for wear. Install or Connect NOTICE: For steps 2 and 3 see “ N otice” on page 3B1-1 o f this section. 1. Shock absorber with bushings to the axle bracket. • Shock absorber nuts to “ Specifications” at the end of this section. 3. Castellated nut and cotter pin. Tighten • Castellated nut to “ Specifications” as instructed at the end of this section. TIE ROD REPLACEMENT (R, G, P20 AND 30(42) MODELS) There are two tie rod assemblies. Each assem bly is of a five piece construction, consisting of an adjuster tube, two clam ps and two tie rod ends. The ends are threaded into the sleeve and secured with the clamps. Right and left hand threads are used for toe-in adjustments and steering gear centering. The tie rod ends should be replaced when 3B1-8 STEERING LINKAGE 0 ♦ t l Install or Connect (Figures 1 through 3) Tools Required: J-29193 Steering Linkage Installer (12mm). J-29194 Steering Linkage Installer (14mm). NOTICE: For steps 3 and 5 page3B1-1 of this section. see “Notice” on • If the rod ends were removed, lubricate the tie rod threads with chassis lubricant. 1. Tie rod ends to the adjuster tube. The number of threads on both the inner and outer rod ends must be equal within three threads. 2. Inner tie rod ball studs to the relay rod (2). The seal must be on the stud. Tighten J-29193 or J-29194 to 54 N-m (40 ft. lbs.) to seat the tapers. Remove the tool. 3. Prevailing torque nut to the inner tie rod ball stud. excessive up and down motion is present, or when excessive end play or loss of motion at the ball stud exists. Before servicing, note the position of the tie rod adjuster tube and the direction the bolts are installed. 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.) d isca rd the nuts and bolts. A p ply penetrating oil between the clam p and tube and rotate the clam ps until they move freely. Install all parts, with the correct part number, in the proper position. Im portant Use the proper tool to separate all tie rod and ball joints. Remove or Disconnect (Figures 1, 2, 3, and 9) Tool Required: J-6627-A Wheel Stud Remover and Tie Rod Remover. • Raise the vehicle. 1. Cotter pins and castellated nuts from the outer tie rod ball stud. 2. Outer tie rod ball studs from the steering knuckle (4). Use J-6627-A (figure 9). 3. Inner tie rod ball stud from the relay rod (2). Use J-6627-A. 4. Tie rod ends from the adjuster tube. Loosen the clamp bolts and unscrew the end assemblies. L* Inspect • Nut to “ Specifications” at the end of this section. 4. Outer tie rod ball studs to the steering knuckle. 5. Castellated nuts and cotter pins to the outer rod ball studs. C a s te lla te d n uts to “ S p e c ific a tio n s ” instructed at the end of this section. as Adjust (Figures 10, 11, and 12) • 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 dimples at either end of the adjuster tube. • The clam ps must be positioned w ithin 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 clamps are tightened to ensure free movement of each joint. • The clamp ends may touch when nuts are torqued to specification, but the gap next to the adjuster tube m ust NOT be less than the minimum dimension shown in figures 10, 11 or 12. Tighten • Adjuster tube clamp bolts to “ Specifications” at the end of this section. Tie rod end for damage. Tie rod end seals for excessive wear. Threads on the tie rod and tie rod end for damage. Ball stud threads for damage. TIE ROD REPLACEMENT (V AND P30(00)FS3 MODELS) Adjuster tube for bending or damaged threads. gi Remove or Disconnect (Figures 7 and 8) Clean The tapered surfaces. Threads on the ball stud and in the ball stud nut. Tool Required: J-6627-A Wheel Stud Remover and Tie Rod Remover. STEERING LINKAGE 3B1-9 VIEW A 4. C. D. E. F. G. S te e rin g K n u c k le C la m p s M u st Be B e tw e e n A n d C le a r O f D im p le s B e fo re T o rq u in g N u ts A d ju s te r Tube S lo t S lo t In A d ju s te r Tube M u s t N o t Be W ith in T h is A re a O f C la m p Jaw s. R earw ard R o ta tio n C la m p E nds M ay T ouch W h e n N u ts A re T orqued To S p e c ific a tio n s . B u t T he Gap N e xt To T he A d ju s te r Tube M u s t Be V is ib le . M in im u m G ap Is 0.127 m m (0.005 Inch). B-07290 Figure 10—Tie Rod Clamp and Adjuster Tube Positioning — R Model 4FRT VIEW A 4. S te e rin g K n u c k le i C. C la m p M u s t Be B e tw e e n A n d C le a r O f D im p le s B e fo re T o rq u in g N u ts D. S lo t In A d ju s te r Tube M u s t N o t Be W ith in T h is A re a O f C la m p J a w s E. R earw ard R o ta tio n F. A d ju s te r Tube S lo t G. C la m p Ends M ay T ouch W h e n N u ts A re T orqued To S p e c ific a tio n s . B u t T he G ap N e xt To T he A d ju s te r Tube M u s t Be V is ib le . M in im u m G ap Is 0.127 m m (0.005-inch). ____________________________________________________________________________________________________________ B-07291 Figure 11—Tie Rod Clamp and Adjuster Tube Positioning — G Model VIEW A 4. S te e rin g K n u c k le C. C la m p s M u s t Be B e tw e e n A n d C le a r O f D im p le s B e fo re T o rq u in g N u ts D. A d ju s te r Tube S lo t E. S lo t In A d ju s te r Tube M u s t N o t Be W ith in T h is A re a O f C la m p Ja w s. F. R earw ard R o ta tio n G. C la m p E nds M ay Touch W h e n N u ts Are T orqued To S p e c ific a tio n s . B u t T he G ap N e xt To T he A d ju s te r Tube M u s t Be V is ib le . M in im u m G ap Is 0.127 m m (0.005 Inch). B-07292 Figure 12—Tie Rod Clamp and Adjuster Tube Positioning — All Models, Excluding FS3 3B1-10 STEERING LINKAGE 1. Cotter pins and castellated nuts from the rod assembly (3). 2. Shock absorber (7) from the tie rod assembly (3). 3. The rod ball studs from the steering knuckle (4). Use J-6627-A. 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 V30 models, note the position of the adjuster tube, and the direction from which the bolts are installed. L* Inspect Remove or Disconnect (Figures 7 and 8) Tool Required: J-24319-01 Steering Linkage Puller. • Raise the vehicle. 1. Castellated nuts and cotter pins from the connecting rod (8). 2. Connecting rod (8) from the pitman arm (5). Use J-24319-01. 3. Connecting rod (8) from the steering knuckle (4). Use J-24319-01. Im portant Tie rod for bending or damaged threads. Tie rod end seals for wear. Ball stud threads for damage. Adjuster tube for bending or damaged threads (V30). 4. Connecting rod ends from the adjuster tube. Loosen the clamp bolts and unscrew the end assemblies. • The connecting rod adjuster tube components may be rusted. If the torque required to remove the nut from the bolt exceeds 9 N m (7 ft. lbs.) discard the nuts and bolts. — The tapered surfaces. — Threads on the ball stud and in the ball stud nut. 0 ♦ i l Install or Connect (Figures 7 and 8) • If the tie rod ends were removed, lubricate the tie rod threads with chassis lubricant. 1. Tie rod end bodies to the tie rod (if removed). Screw the rod assembly on the same number of turns as when removed. • Tie rod ends to the adjuster tube (V30). 2. Outer tie rod ball studs to the steering knuckle (4). 3. Shock absorber (7) to the tie rod assembly. NOTICE: See “Notice” on page 3B1-1 of this section. • Apply penetrating oil between the clamps and the tube. Rotate the clamps until they move freely. I? Inspect • Ball stud threads for damage. • Ball stud seals for wear. • Adjuster tube for bending or damaged threads. Clean • Threads on the ball stud and ball stud nut. 4. C astellated nuts and cotter pins to the tie rod assembly. Tighten • C a s te lla te d n uts to “ S p e c ific a tio n s ” instructed at the end of this section. • Before removing the connecting rod adjuster tube, note the position of the tube and the direction from which the bolts are installed. as Install or Connect (Figures 7, 8, 13, and 14) NOTICE: For steps 3 and 5 page3B1-1of this section. see “Notice” on Adjust • If the connecting rod ends were removed, lubricate the connecting rod threads with chassis lubrication. Toe-in. Refer to FRONT END ALIGNMENT (SEC. 3A) in this manual. 1. Connecting rod ends to the adjuster tube. The number of threads on both the inner and outer connecting rod ends must be equal within three threads. Tighten • Jam n ut at th e tie rod end b o d ie s to “ Specifications” at the end of this section. • Adjuster tube clamp bolts to “ Specifications” at the end of this section (V30). 2. Inner connecting rod (8) ball stud to the pitman arm (5) (on V models install the short end). Make certain the seal is on the stud. 3. Castellated nut and cotter pin to the inner connecting rod ball stud. Tighten CONNECTING ROD REPLACEMENT (V AND P30(00)FS3 MODEL) The adjustable connecting rod is used for centering the steering gear with the front axle. Replace the connecting rod if the rod is bent or if the ball stud is loose. Im portant • Use the proper tool to separate all ball joints. • Castellated nut to “ Specifications” 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 “ Specifications” as instructed at the end of this section. STEERING LINKAGE 3B1-11 The connecting rod ends to the pitman arm and steering knuckle must be in correct relationship to each other after adjustment within ± 2 degrees (V model). 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 dimples at either end of the adjuster tube. • The clam ps must be positioned w ithin the angular travel shown in figures 13 and 14. • The clamp ends may touch when nuts are torqued to specification, 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 ensure free movement of each joint. $ Tighten • Adjuster tube bolts to “ Specifications” at the end of this section. • Lower the vehicle. CONNECTING ROD REPLACEMENT (P30(32) MOTORHOME) 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 loose. | 2 | Important • Use the proper tool to separate the ball joints. |<--»| Remove or Disconnect (Figure 3) Tool Required: J-24319-01 Steering Linkage Puller. • Raise the vehicle. 1. Castellated nuts and cotter pins from the connecting rod (8). 2. Connecting rod (8) from the pitman arm (5). Use J-24319-01. C. C la m p s m u s t be b e tw e e n and c le a r o f d im p le s b e fo re to rq u in g n u ts. D. O u tb o a rd R o ta tio n E. A d ju s te r Tube S lo t F. S lo t in a d ju s te r tu b e m u s t n o t be w ith in th is area o f c la m p ja w s. G. C la m p e n d s m ay to u c h w h e n n u ts are to rq u e d to s p e c ific a tio n s . B u t th e gap n e x t to th e a d ju s te r tu b e m u s t be v is ib le . M in im u m gap is 0.127 m m (0.005-inch). 3. Connecting rod (8) from the relay arm (11). Use J-24319-01. I* Inspect — Ball stud threads for damage. — Ball stud seals for excessive wear. jjQ| Clean • Threads on the ball stud and ball stud nut. B-07293 Figure 13—Connecting Rod Clamp and Adjuster Tube Positioning—P30(00)FS3 3B1-12 STEERING LINKAGE C. S lo t O f A d ju s te r Tube M ay Be In A n y P o s itio n On A rc S h o w n B u t N o t C lo s e r T han 2.54 m m (0.10 Inch) To T he E dge O f C la m p Ja w s O r B e tw een. Figure 14—Connecting Rod Clamp and Adjuster Tube Positioning — V Model Install or Connect (Figure 3) 1. Connecting rod (8) to the pitman arm (5) and relay arm ( 11). 2. Castellated nuts and cotter pins. Tighten • C a s te lla te d n uts to “ S p e c ific a tio n s ” instructed at the end of this section. • Lower the vehicle. as Tie Rod (3) End To Steering Knuckle (4)* P20 AND 30(42) G Model R Model P30(00)FS3 P30(32) Motorhome V Model N-m Ft. Lbs. N-m Ft. Lbs. N-m Ft. Lbs. N-m Ft. Lbs. N-m Ft. Lbs. N-m Ft. Lbs. 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 — — — — 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 Bolt To Shock Absorber Bracket (9) — — 89 66 — — — — — — — — 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 ■Tl Connecting Rod (8) To Pitman Arm (5)* — — — — — — 95 70 95 70 120 89 o 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 — — — — 170 125 . — — — — — 125 170 125 125 92 Relay Rod (2) To Relay Arm (11) — — — — — — 90 66 Tie Rod Jam Nut (V10, 20) & P30(00)FS3 — — — — — — — — "0 m o H O CO — 375 — 277 — 125 — 92 LINKAGE * 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. CO STEERING Idler Arm (1) And Relay Arm (11) To Support Assemblies (10) — 170 3B1-13 3B1-14 STEERING LINKAGE SPECIAL TOOLS 1. J-6627-A 2. J-6632-01 3. J-29107 4. J-29193 5. J-29194 1. 2. 3. 4. 5. J-24319-01 Tie Rod P uller Pitm an Arm Puller Pitm an Arm Puller Universal Steering Linkage Puller Steering Linkage In sta lle r (12 mm) GM Torque Prevailing N uts 6. Steering Linkage In s ta lle r (14 mm) GM Torque Prevailing N uts F-02539 Figure 15—Special Tools 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 term inology “ NOTICE: See ‘Notice’ on page 3B2-1 of this Section.” NOTICE: These 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 num ber 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 Description...................................................................................................................................................................3B2Diagnosis Of Manual Steering S y s te m ....................................................................................................................3B2On-Vehicle S e rvice .....................................................................................................................................................3B2Maintenance.............................................................................................................................................................3B2Steering Gear Replacem ent.................................................................................................................................. 3B2Pitman Shaft Seal Replacement............................................................................................................................3B2Steering Gear Adjustments............... ..................................................................................................................3B2Steering Gear High Point Centering......................................................................................................................3B2S pe cifica tio ns.............................................................................................................................................................3B2Special T o o ls ...............................................................................................................................................................3B2- 1 2 3 3 3 5 5 7 7 8 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 posi­ tion. The sector teeth are slightly tapered so that a proper preload may be obtained by moving the pitman shaft end­ ways by means of a preload adjuster screw which extends through the gear housing side cover. The head of the pre­ load adjuster and a selectively fitted shim fit snugly into a T-slot in the end of the pitman shaft, so that the screw also controls the end play of the shaft (figure 1). 3B2-2 MANUAL STEERING GEAR 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Fram e B o lt S p rin g W a sh e r S p a ce r A d ju s te r S cre w Ja m N u t P in ch B o lt F le x ib le C o u p lin g S p rin g W a sh e r N ut S te e rin g S h a ft W orm S h a ft P itm a n A rm P itm a n A rm N u t S p rin g W a sh e r A d ju s te r N u t A d ju s te r P lug B-07689 Figure 1—Steering Gear - R Models DIAGNOSIS OF MANUAL STEERING SYSTEM PROBLEM Rattle Or Chuckle In The Steering Gear Poor Return Of The Steering Wheel POSSIBLE CAUSE 1. Insufficient or improper lubricant in the steering gear. 2. Pitman arm loose on the shaft or the steering gear m ounting bolts loose. 3. Loose or worn steering shaft bearing. 4. E xcessive o ver-ce nter lash or worm thrust bearings adjusted too loose. On turns a slight rattle may occur, due to the increased lash between ball nut and pit­ man shaft as gear moves off the center of “ high point” position. This is normal and lash must not be reduced to elim i­ nate this slight rattle. 1. Steering column misaligned. 2. Insufficient or improper lubricant in the steering gear or front suspension. 3. Steering gear adjusted too tight. 4. Front wheel alignm ent incorrect (Caster). Excessive Play Or Looseness In The Steering System 1. Front wheel bearings loosely adjusted. 2. Steering system out of alignment. 3. Worn upper ball joints. CORRECTION 1. Add specified lube. 2. Tighten to specified torque. 3. Replace steering shaft bearing. 4. Adjust steering gear to specified pre­ loads. 1. Align the column. 2. Lubricate as specified. 3. Adjust over-center and thrust bearing preload to specifications. 4. Adjust to specifications. 1. Adjust bearings or replace with new parts as necessary. 2. Align caster, camber, and toe-in. 3. Check and replace ball joints if neces­ sary. MANUAL STEERING GEAR 3B2-3 DIAGNOSIS OF MANUAL STEERING SYSTEM (CONT.) POSSIBLE CAUSE CORRECTION 4. Steering wheel loose on the shaft, loose pitman arm, tie rods, steering arms or steering linkage ball nuts. 5. Tires badly worn, edge of tires rounded off. 6. Excessive over-center lash. 4. Tighten to specification, replace if worn or damage. PROBLEM Excessive Play Or Looseness In The Steering System (Cont.) 7. Worm thrust bearings loosely adjusted. Hard Steering — Excessive Effort Required At The Steering Wheel 1. Low or uneven tire pressure. 2. Insufficient or improper lubricant in the steering gear or front suspension. 3. Steering shaft fle xib le co up lin g m is­ aligned. 4. Steering gear adjusted too tight. 5. Front wheel alignm ent incorrect. 5. Install new tires, and check alignm ent. 6. Adjust over-center preload to specifica­ tions. 7. Adjust the worm thrust bearing preioad to specifications. 1. Inflate to specified pressures. 2. Lubricate as specified. Relubricate at specified intervals. 3. Align the column and couplings. 4. Adjust over-center and thrust bearing preload to specifications. 5. Check the alignm ent and correct as necessary. 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. A t in te r v a ls s p e c ifie d in M A IN T E N A N C E A N D LUBRICATION (SEC. OB) of this manual, the gear should be inspected for seal leakage (actual solid grease — not ju s t oily film ). If a seal is replaced or the gear is overhauled, the gear housing should be refilled with S tee rin g G ear L u b rica n t m eeting GM sp e c ific a tio n 1051052 (or equivalent). NOTICE: DO NOT USE EP Chassis Lube to lubricate the gear. DO NOT OVER-FILL the gear housing, or damage may occur. 2. Lower universal joint pinch bolt (6) (G-Models). Mark the relationship of the clamp (20) to the worm shaft (11). • Mark the relationship of the pitman arm (12) to the pitman shaft (21). 3. Pitman shaft nut (13) and washer (14). 4. Pitman arm (12) from the pitman shaft (21). Use J-6632-01 or J-29107 (figure 3). 5. Frame bolts (1) and washers (2). 6. Pinch bolt (6) and coupling (7) from the worm shaft (11) (C-Models). 7. Gear assembly. Install or Connect (Figure 1 and 2) NOTICE: See “ N o tice” on page 3B2-1 o f this section for steps 3, 5 and 8. C-Models STEERING GEAR REPLACEMENT Remove or Disconnect (Figure 1, 2 and 3) Tools R equired: J-6632-01 Pitman Arm Remover J-29107 Pitman Arm Puller • Place the front wheels in a straight ahead position. 1. F le x ib le c o u p lin g to s te e rin g s h a ft n u ts (9) (R-Models). 1. F le x ib le c o u p lin g (7) o n to th e s te e rin g g e a r wormshaft (11). • Align the flat in the coupling with the flat on the shaft. • Push the coupling onto the shaft until the w o rm s h a ft b o tto m s on th e c o u p lin g reinforcement. 2. Pinch bolt (6) and torque to 41 N m (30 ft. lbs.). The bolt must pass through the shaft undercut. • Place the steering gear in position, guiding the coupling bolt into the shaft flange. 3. Steering gear to frame bolts (1) and torque to 100 N m (75 ft. lbs.). 3B2-4 MANUAL STEERING GEAR 1. 2. 4. 5. 6. 11. 12. Fram e B o lt W a sh er A d ju s te r S cre w Jam N ut P in ch B o lt W orm S h a ft P itm a n A rm 13. 14. 15. 20. 21. P itm a n A rm N ut S p rin g W a sh er A d ju s te r N ut L ow er C la m p P itm a n S h a ft B-07688 Figure 2—Steering Gear - G Models Im portant • If fle x ib le c o u p lin g a lig n m e n t pin p la s tic s p a ce rs w ere used, m ake su re th e y are bottom ed on the pins. • If fle x ib le c o u p lin g a lig n m e n t pin p la s tic spacers w ere not used, ce nte r the pins in the slots in the ste ee rin g sh aft flange. 4. Washer (8) and nut (9) onto the coupling bolts. Tighten • N ut to 24 N m (18 ft. lbs.). G-Models • Place the steering gear in position, guiding the worm shaft into the universal joint assembly and lining up the marks made at removal. If a new gear was installed, line up the mark on the wormshaft with the slit in the universal joint yoke. 5. Steering gear to frame bolts (1). MANUAL STEERING GEAR 3B2-5 4. A d ju s te r S crew 5. 11. 15. 16. Jam N ut W orm S h a ft A d ju s te r N ut A d ju s te r Plug 21. 25. 26. 27. 3. Pitm an sh aft seal from the gear housing using a s c re w d riv e r. Be c a re fu l n o t to d a m a g e th e housing bore. P itm a n S h a ft S ide C over B o lt S id e C over W o rm s h a ft Flat 4. Jam nut (5). 5. Side cover (26) from the pitm an sh aft assem bly. Turn the adjuster screw (4) clockw ise. B-07707 Figure 4—Steering Gear Assembly Tighten • Bolts to 100 N-m (75 ft. lbs.). 6. Universal joint pinch bolt. The pinch bolt must pass through the shaft undercut. Torque to 60 N-m (44 ft. lbs.). ALL MODELS 7. Pitman arm (12) onto the pitman shaft. Line up the marks made at removal. 8. Washer (14) and nut (13). Q Tighten • N ut to 250 N-m (185 ft. lbs.) PITMAN SHAFT SEAL REPLACEMENT The pitm an sh aft seal m ay be replaced w ith o u t removing the steering gear. Remove the pitman arm as outlined under “ Steering Gear R eplacem ent” or refer to STEERING LINKAGE (SEC. 3B1). Remove or Disconnect (Figure 4) • R otate th e ste e rin g w heel from stop to stop, co un ting the total n um ber o f turns. Then turn back exactly halfway, pla cing the g ear on center (the w o rm sh a ft fla t (27) sh ou ld be at th e 12 o’clo ck position). 1. Side cover bolts (25). 2. Pitm an sh aft (21) and side cover (26) a ssem bly from the housing. L* Inspect G ear lu b r ic a n t fo r c o n t a m in a t io n . If conta m in ated , th e gear m ust be rem oved and overhauled. -►«- Install or Connect (Figure 4 and 5) • Lubricate the new pitm an sh aft seal w ith steering gear lubricant. 1. Pitm an sh aft seal. Position the seal in the pitm an sh aft bore and tap into position using a 25 mm (1 inch) pipe or socket (figure 5). • Place the p itm an sh aft (21) in the steering g ear so th at the ce nte r tooth o f the pitm an sh aft sector enters the ce nte r tooth space of the ball nut. • Fill the steering g ear housing w ith S teering G ear L ub rica nt m eeting GM S pecification 1051052 (or equivalent). 2. New gasket onto the g ear housing. 3. Side cover (26) onto the adjuster screw (4). Reach through the threaded hole in the side cover w ith a sm all screw driver and tu rn the adjuster screw c o u n terclockw ise until it bottom s and tu rn s back in 1/4 turn. 4. Side cover bolts (25) and torque to sp ecifications. 5. Jam nut (5). A djust • S teering g ear as outlined under “ S teering G ear A d ju s tm e n ts .” 6. Pitman arm. 3B2-6 MANUAL STEERING GEAR A djust (Figure 4) • T hru st bearing preload as follows: 1. Tighten the adjuster plug (16) until the proper “ loading preload” is 0.6-1 N m (5-8 in. lbs.). NOTICE: See “ N otice” on page 3B2-1 of this section. 2. Tighten the adjuster nut (15) to 115 N m (85 ft. lbs.). 3. If the gear feels “ lum py” after adjustment, there is probably damage in the bearings due to severe impact or improper adjustm ent; the gear must be disassembled for replacement of damaged parts. • Over-center preload as follows: 1. Turn the steering wheel gently from one stop STEERING GEAR ADJUSTMENTS Before any adjustments are made to the steering gear, in an attempt to correct such conditions as shimmy, loose or hard steering etc., a careful inspection should be made of the front end alignm ent, shock absorbers, wheel balance and tire pressure for the possible steering system problem. C o rre ct a d ju s tm e n t of th e s te e rin g g e a r is very important. Perform adjustments following the sequence listed below. |+ + | Remove or Disconnect (Figures 1, 2, 3 and 4) 1. • 2. • 3. • 4. • Tools R equired: J-6632-01 Pitman Arm Remover J-29107 Pitman Arm Puller Battery ground cable. Raise the vehicle. Pitman arm nut (13) and washer (14). Mark the relationship of the pitman arm to the pitman shaft. Pitman arm using J-6632-01 or J-5504-D (figure 2). Loosen the adjuster nut (15) and then back the adjuster plug (16) off 1/4 turn. Horn cap or cover. Turn the steering wheel gently in one direction until stopped by the gear; then turn back one-half turn. NOTICE: Do not turn the steering wheel hard against the stops when the steering linkage is disconnected from the gear as damage to the ball guides could result. 1 Measure (Figure 6) “ Bearing d ra g ” by app lyin g a torque w rench w ith the socket on the steering w heel nut and rotate through a 90 degree arc. Do not use a torque w rench having a m axim um torque reading of m ore than 6 N m (50 in. lbs.). all the way to the other carefully counting the total number of turns. Turn the wheel back exactly half-way to the center position. Turn the over c e n te r a d ju s te r screw (4) clockwise to take out all lash between the ball nut and pitman shaft sector teeth and then tighten the jam nut (5). a Tighten • Jam nut (5) to 30 N m (22 ft. lbs.). 3. Check the torque at the steering wheel, taking the highest reading as the wheel is turned th ro u g h c e n te r p o s itio n . R e fe r to “ S pecifications” for the proper over-center preload. 4. If necessary, loosen jam nut (5) and adjust over center adjuster screw (4) to obtain proper torque. Tighten the jam nut (5) and recheck torque reading through center of travel. Im portant If m axim um to rq u e is exceeded, turn o v e r c e n te r a d ju s t e r s c r e w (4 ) c o u n te rc lo c k w is e , th e n com e up on a d ju stm e n t by tu rn in g the jam nut (5) in a clockw ise m otion. Remove or Disconnect (Figures 1 and 2) 1. Pitm an arm (12) onto the p itm an sh aft (21). Line up the m arks m ade d urin g disassem bly. NOTICE: See “ N o tice” on page 3B2-1 of this section. 2. Washer (14) and nut (13). Tighten • N ut to 250 N m (185 ft. lbs.). 3. Horn cap or cover. • Lower the vehicle to the floor. 4. Battery ground cable. MANUAL STEERING GEAR 3B2-7 STEERING GEAR HIGH POINT CENTERING 1. Set the front wheels in the straight ahead position. This can be checked by driving the vehicle a short distance on a fla t surface. 2. With the front wheels set straight ahead, check the position of the mark on the wormshaft designating the steering gear high point. This mark should be at the top side of the shaft at 12 o’clock position and lined up with the mark in the coupling lower clamp. 3. If the gear has been moved off high point when setting wheel in straight ahead position, loosen adjusting sleeve clamp on both left and right hand tie rods. Then turn both sleeves an equal num ber of turns in the same direction to bring gear back on high point. Im portant • Turning the sleeves an unequal n um ber of tu rn s or in d ifferent d irections w ill disturb the toe-in setting of the w heels. 4. A d ju s t to e -in as o u tlin e d in F R O N T EN D ALIGNMENT (SEC. 3A) (if necessary). 5. Orient sleeves and clam ps when fastening and to rq u e in g c la m p s to s p e c ific a tio n s . R efer to STEERJNG LINKAGE (SEC. 3B1). SPECIFICATIONS MANUAL STEERING GEAR M anufacturer...................................................................................................................................... Saginaw Steering Gear R a tio .................................................................................................................................................................................. 24 to 1 Type.................................................................................................................................................................Recirculating Ball PRELOAD ADJUSTMENTS N-m In. Lbs. 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. Worm Thrust Bearing Preload *ln excess of worm bearing preload. TORQUE SPECIFICATIONS N-m 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 3B2-8 MANUAL STEERING GEAR SPECIAL TOOLS 3B3-1 SECTION 3B3 POWER STEERING 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 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 num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent 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 .................................................................................................................................................................................... 3 B 3 - 1 In te g ra l Pow er S tee rin g G e a r ............................................................................................................................................. 3 B 3 - 1 H yd ra u lic P u m p s .................................................................................................................................................................... 3 B 3 - 1 D iag no sis O f Pow er S tee rin g S y s te m .................................................................................................................................. 3 B 3 - 5 O il Leak C h e c k .........................................................................................................................................................................3 B 3 - 8 P ow er S tee rin g System T e s t ............................................................................................................................................. 3 B 3 - 8 P ow er S tee rin g S ystem O n -V ehicle S e rv ic e ...................................................................................................................... 3B3-11 M a in te n a n c e ............................................................................................................................................................................. 3 B 3 -1 1 P um p B e lt Tension A d ju s tm e n t.........................................................................................................................................3B3-11 F luid Level A d ju s tm e n t.........................................................................................................................................................3 B 3 -1 2 B le e d in g The P ow er S te e rin g S y s te m ............................................................................................................................. 3 B 3 -1 2 F lu sh in g The P ow er S te e rin g S y s te m ............................................................................................................................. 3 B 3-1 2 S te e rin g Gear H igh P o in t C e n te rin g .................................................................................................................................. 3 B 3-1 3 P o w er S tee rin g Gear R e p la c e m e n t.................................................................................................................................. 3 B 3-1 3 P itm an S h aft Seal R e p la c e m e n t.........................................................................................................................................3 B 3-1 4 S tee rin g Gear A d ju s tm e n ts ..................................................................................................................................................3 B 3 -1 7 P ow er S teering Pum p R e p la c e m e n t................................................................................................................................3 B 3 -1 9 P ow er S teering H o s e s ........................................................................................................................................................... 3 B 3 -1 9 S p e c ific a tio n s ............................................................................................................................................................................. 3 B 3 -3 4 S pecia l T o o ls ............................................................................................................................................................................... 3 B 3 -3 6 DESCRIPTION The hydraulic power steering system consists of a pump, an oil reservoir, a steering gear, a pressure hose, and a return hose (figure 1). INTEGRAL POWER STEERING GEAR 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 m echanical force. If the steering system becomes damaged and loses h y d ra u lic p re ssure, the v e h ic le can be c o n tro lle d manua"* HYDRAULIC PUMPS The power steering gear (figure 2) has a recirculating ball system which acts as a rolling thread between the worm shaft and the rack piston. The worm shaft is supported by a thrust bearing preload and two conical thrust races at the lower end, and a bearing assembly in the adjuster plug at the upper end. When the worm shaft is turned right, the rack piston moves up in gear. Turning the worm shaft left moves the rack piston down in gear. The rack piston teeth mesh with the sector, which is part The hydraulic pump is a vane-type design. There are two types, submerged and nonsubmerged. Submerged pump (P models) have a housing and internal parts that are inside the reservoir and operate submerged in oil: The n o n s u b m e rg e d p u m p (TC m o d e ls w ith or w ith o u t reservoir) function the same as the submerged pump except that the reservoir is separate from the housing and internal parts (figure 3). of the pitman shaft. Turning the worm shaft turns the pitman shaft, which turns the wheels through the steering linkage. There are two bore openings at the rear of the pump housing. The larger opening contains the cam ring, pressure plate, thrust plate, rotor and vane assembly, and 3B3-2 POWER STEERING 1. Pitm an Shaft 2. H ousing Ball Plug 3. A d ju ste r Plug 4. Stub S ha ft. 5. Torsion Bar 6. A d ju s te r Plug N ut 7. Return Line 8. Stud B olt O-ring Seals 9. Reservoir 10. Reservoir Cap 11. Reservoir O-ring Seal 12. Pump S haft Seal 13. Pump H ousing 14. Pressure Port Seat 15. Pressure Hose 16. Pressure And Return Port Seat 17. A d ju s tin g Screw Jam Nut 18. End Cover O-ring Seal 19. Side Cover Seal 20. Gear H ousing Figure 1—Power Steering System — Typical end plate. The sm aller opening contains the pressure line union, flow control valve, and spring. The flow control orifice is part of the pressure line union. The pressure relief valve inside the flow control valve limits the pump pressure (figure 4). POWER STEERING 3B3-3 « 4 L£J AI c G I —► D /ft n L ‘ ft ... l. i E H ^ n c L IT _ C. 346.7 m m (13.64 in ch e s) RV M O D E L (T ilt C olu m n ) D. 72 m m (2.8 in c h e s ) RV M O D E L (S tandard C o lu m n -C o lu m n S h ift) E. 353 m m (14 in ch e s) RV M O D E L (S tandard C o lu m n -F lo o r S h ift) F. 81.7 m m (3.21 in ch e s) G M O D E L (T ilt C o l­ u m n -C o lu m n S h ift) G. 144.9 m m (5.70 in ch e s) G M O D E L (T ilt C o l­ um n-4 Speed) H. 192 m m (7.5 in ch e s) G M O D E L (S tandard C o lu m n -C o lu m n S h ift) J. 80 m m (3.1 in c h e s ) G M O D E L (T ilt C o lu m n F lo o r S h ift) ___ iu —► J F-02585 Figure 2—Power Steering Gear TC MODEL WITHOUT RESERVOIR WITH RESERVOIR Figure 3—TC and P Pump Models 3B3-4 POWER STEERING 10 11. 12. 13. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. R e se rvo ir O -R ing Seal S h a ft Seal P um p H o u s in g D ip S tic k P um p R ing T h ru s t Plate Vanes R e se rvo ir H ole S p rin g P ressure R e lie f Valve F lo w C o n tro l Valve E xit H ole O rific e 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 300. F ilte r P um p U nio n S eals End Plate R e ta in in g R ing R o to r S p rin g D isch a rg e C a vity R e ta in in g R ing P ressure P late S tu b S h a ft F-02580 Figure 4—Power Steering Pump POWER STEERING 3B3-5 DIAGNOSIS OF POWER STEERING SYSTEM PROBLEM Objectionable “ Hiss” 1. Noisy relief valve in the hydraulic pump. 2. Any metal-to-metal contacts through flex­ ible coupling. Rattle Or Chuckle Noise In Steering Gear 1. Gear loose on the frame. 2. Steering linkage looseness. 3. Pressure hose touching other parts of vehicle. 4. Loose pitman arm. 5. Im p ro p e r o ve r-ce n te r a d ju s tm e n t. A slight rattle may occur on turns because of in crea se clea ra n ce o ff the “ high p o in t.” This is normal and clearance must not be reduced below specified lim ­ its to eliminate this slight rattle. Excessive Wheel Kick-Back Or Loose Steering CORRECTION POSSIBLE CAUSE 1. T here is som e noise in all p ow er steering systems. One of the most com ­ mon is a hissing sound most evident at standstill parking. Hiss is a high fre­ quency noise. The noise is present in every valve and results from high veloc­ ity fluid passing valve orifice edges. There is no relationship between this noise and performance of the steering. “ Hiss” may be expected when steering wheel is at end of travel or when slowly turning at standstill. Do not replace valve unless “ hiss” is extrem ely objectionable. A rep la ce ­ ment valve will also exhibit slight noise and is not always a cure for the objec­ tion. 2. Align the steering shaft and gear so the flexible coupling rotates in a flat plane and is not distorted as the shaft rotates. 1. Check the gear mounting bolts. Torque the bolts to specifications. 2. Check linkage pivot points for wear. Re­ place if necessary. 3. Adjust the hose position. Do not bend tubing by hand. 4. Torque the pitman arm bolt. 5. Adjust to specifications. 1. Air in the system. 1. Add oil to the 2. Steering gear mounting loose. 2. 3. Steering linkage joints worn. 4. Front wheel bearings inco rre ctly ad­ justed or worn. 5. Steering gear improperly adjusted. 6. Worn or missing poppet valve (steering gear). 7. Steering gear flexible coupling too loose on the shaft or the rubber disc mounting screws loose. 8. Damaged or worn steering gear. 3. 4. 5. 6. pum p reservoir and b le ed . C h e ck hose c o n n e c to rs fo r proper torque. T ighten a ttaching bolts to specified torque. Replace loose parts. Adjust the bearings or replace with new parts as necessary. Adjust to specifications. Replace the poppet valve. 7. Tighten to specifications. 8. Disassemble and repair the steering gear as outlined in the unit repair man­ ual. 3B3-6 POWER STEERING DIAGNOSIS OF POWER STEERING SYSTEM (CONT.) PROBLEM POSSIBLE CAUSE Vehicle Leads To One Side Or The Other (Keep In Mind The Road And Wind Conditions). Test The Vehicle, Going In Both Directions, On A Flat Road. 1. Front end misaligned. 2. Unbalanced steering gear valve. If this is cause, steering effort will be very light in direction of lead and heavy in opposite direction. 3. Steering shaft rubbing the ID of the shaft tube. 4. Steering linkage not level. 1. Adjust to specifications. 2. Replace the gear valve. Momentary Increase In Effort When Turning The Wheel Quickly To The Right Or Left 1. Low oil level in the pump. 2. Pump belt slipping (if used). 3. High internal linkage (steering gear or pump). 1. Add power steering fluid as required. 2. Tighten or replace belt. 3. Refer to “ Power Steering System Test” in this section. Poor Return Of Steering 1. Tires under-inflated. 2. Lower coupling flange rubbing against the steering gear adjuster plug. 3. Steering wheel rubbing against direc­ tional signal housing. 4. Tight or frozen steering shaft bearings. 5. Steering linkage or ball joints binding. 6. Steering gear to column misalignment. 7. Tie rod pivots not centralized. 1. Inflate to specified pressure. 2. Loosen the pinch bolt and assemble properly. 3. Adjust the steering jacket. 3. Align the column. 4. Adjust as required. 4. 5. 6. 7. 8. Lack of lubricant in the suspension ball joints and the steering linkage. 9. Sticky or plugged valve spool. 10. Rubber spacer binding in the shift tube. 9. 10. 11. Improper front end alignment. 12. Tight steering shaft bearings. 13. Steering gear adjusted too tightly. 11. 12. 13. 14. Kink in return hose. 14. Steering Wheel 1. Low oil level in pump. Surges Or Jerks When 2. Loose pump belt. Turning With Engine 3. Sticky flow control valve. Running Especially 4. Insufficient pump pressure. During Parking 5. Faulty gear relief valve. Hard Steering Effort In Both Directions CORRECTION 1. Low tire pressure. 2. Lack of lubricant in suspension or ball joints. 3. Steering gear to column misalignment. 4. Loose pump belt. 8. Replace the bearings. Replace the affected parts. Align the steering column. Adjust tie rod ends as required to cen­ ter pivots. Lubricate. R efer to M AIN TEN AN C E AND LUBRICATION (SEC. OB). Remove and clean or replace the valve. Make certain the spacer is properly seated. Lubricate inside the diameter with silicone lubricant. Check and adjust to specifications. Replace the bearings. Adjust over-center and thrust bearing preload to specifications. Replace the hose. 1. 2. 3. 4. Add power steering fluid as required. Adjust tension to specification. Replace or clean the control valve. Refer to “ Power Steering System Test” in this section. 5. Replace the gear relief valve. 1. Adjust the tire pressure. 2. Lubricate and relubricate at proper in­ tervals. Refer to MAINTENANCE AND LUBRICATION (SEC. OB). 3. Align the steering column. 4. Adjust belt tension to specifications. POWER STEERING 3B3-7 DIAGNOSIS OF POWER STEERING SYSTEM (CONT.) PROBLEM Hard Steering Effort In Both Directions (Continued) POSSIBLE CAUSE 5. Low fluid level in reservoir. 6. High internal leakage (steering gear or pump). 7. Sticky flow control valve. 8. Lower coupling flange rubbing against steering gear adjuster plug. 9. Steering gear adjusted too tight. 10. Improper front end alignment. Foaming Milky Power Steering Fluid, Low Level And Possible Low Pressure Air in the fluid, and loss of fluid due to internal pump leakage causing overflow. CORRECTION 5. Fill to proper level. Inspect lines and joints for external leakage. 6. Refer to “ Power Steering System Test” in this section. 7. Replace or clean the valve. 8. Loosen the pinch bolt and assemble properly. 9. Adjust over-center and thrust bearing preload to specifications. 10. Check and adjust to specifications. Check for leak and correct. Bleed system. Extremely cold temperatures will cause system aeriation should the oil level be low. If oil level is correct and pump still foams, remove pump from vehicle and separate reservoir from housing. Check welsh plug and hous­ ing for cracks. If plug is loose or hous­ ing is cracked, replace housing. Low Oil Pressure Due To Restriction In The Hose 1. Check for kinks in the hose. 2. Foreign object stuck in the hose. 1. Remove the kinks or replace the hose. 2. Remove the foreign object or replace the hose. Low Oil Pressure Due To Steering Gear. Refer To “ Power Steering System Test” In This Section. 1. Pressure loss in cylinder due to worn pis­ ton ring or scored housing bore. 1. Disassemble the steering gear as out­ lined in the unit repair manual. Inspect the ring and housing bore. Replace the affected parts. 2. Disassemble steering gear and replace seals. 3. Replace the valve. Low Oil Pressure Due To Steering Pump. Refer To “ Power Steering System Test” In This Section. 2. Leakage at the valve rings and valve body to the worm seal. 3. Leakage at the valve body or a loose fit­ ting spool. 4. Damaged poppet valve. 1. Flow control valve stuck or inoperative. 2. Pressure plate not flat against the cam ring. 3. Extreme wear of cam ring. 4. Scored pressure plate, thrust plate or ro­ tor. 5. Vanes sticking in rotor slots. 6. Vanes not installed properly. 7. Air in oil. 8. Low oil level. 9. Loose belt. 10. Damaged hoses or steering gear. 4. Replace the poppet valve. 1. Replace or clean the valve. 2. Replace the pressure plate. 3. Replace and flush the system. 4. Replace parts. (If rotor* replace with ro­ tating group), flush the system. 5. Free-up by removing burrs, varnish or dirt. 6. Install properly. Radius edge to the out­ side. 7. Locate source of leak and correct. Bleed the system. 8. Add power steering fluid as required. 9. Adjust tension to specifications. 10. Replace as necessary. 3B3-8 POWER STEERING DIAGNOSIS OF POWER STEERING SYSTEM (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Chirp Noise In Steering Pump 1. Loose belt. 1. Adjust belt tension. Belt Squeal (Particularly Noticeable At Full Wheel Travel And Standstill Parking) 1. Loose belt. 1. Adjust belt tension. Growl Noise In Steering Pump 1. Excessive back pressure in hoses or steering gear caused by restriction. 1. Locate restriction and correct. Replace part if necessary. Growl Noise In Steering Pump (Particularly Noticeable At Standstill Parking) 1. Scored pressure plates, thrust plate or rotor. 2. Extreme wear of cam ring. 1. Replace parts and flush system. 2. Replace parts. Groan Noise In Steering Pump 1. Low oil level. 2. Air in the oil. Poor pressure hose con­ nection. 1. Add power steering fluid as required. 2. Torque the connector. Bleed the sys­ tem. Rattle Or Knock Noise In Steering Pump 1. Loose pump pulley nut. 2. Pump vanes sticking in rotor slots. 1. Torque nut. 2. Free up by removing burrs, varnish or dirt. 3. Adjust hose position. 3. Pressure hose touching other parts of vehicle. Swish Noise In Steering Pump 1. Faulty flow control valve. 1. Replace part. Whine Noise In Steering Pump 1. Pump shaft bearing scored. 1. Replace the housing and shaft. Flush the system. OIL LEAK CHECK 1. With the vehicle’s engine off, wipe the complete power steering system dry (gear, pump, hoses, and connections). 2. Check the oil level in the pum p’s reservoir and a d ju s t as d ir e c te d . R e fe r to “ F lu id L e ve l Adjustm ent” in this section. 3. Start the engine and turn the steering wheel from stop to stop several times. Do not hold the wheel against the stops as this may damage the pump. 4. Find the exact areas of leakage and use the recommended method of repair as shown in figure 5. POWER STEERING SYSTEM TEST The power steering system may be tested using either J-5176-D, Power Steering Gage, or with J-25323, Power Steering Analyzer. J-25323 will measure the flow rate in addition to the pressure (figure 6). The power steering system test is a method used to identify and isolate hydraulic circuit difficulties. Prior to p e rfo rm in g th is te s t th e fo llo w in g in s p e c tio n , and corrections if necessary, must be made. & Inspect • Pump reservoir for proper fluid level. • Pump belt for proper tension. • Tires for correct air pressure. • Power steering system, replacing parts as necessary. POWER STEERING 3B3-9 70 69 60. R ep lace th e d rive s h a ft seal. M ake c e r­ ta in th a t th e d rive s h a ft is c le a n and free o f p ittin g in th e seal area. 61. R ep lace th e re s e rv o ir O -rin g seal. 62. Torque h ose fittin g n u t to 35 N m (25 ft. lbs.). If leakage p e rs is ts , re p la ce th e Orin g seal. 63. T orque fittin g to 75 N m (55 ft. lbs.). If lea kag e p e rs is ts , re p la ce th e O -rin g seal. 64. Torque h ose fittin g n u t to 48 N-m (35 ft. lbs.). If le a k a g e p e rs is ts , re p la c e th e b ra s s c o n n e c to r a nd re fa c e th e tu b e fla re . If n u t th re a d s are d a m a g e d , re p la ce th e n ut. 65. R ep lace th e O -rin g seal. 66. If lea kag e is o b se rve d at (A), fo llo w in g m a n u fa c tu re r’s d ire c tio n s a p p ly L o c tite 75559 so lv e n t and L o c tite 290 adhesive, o r e q u iv a le n t, to tu b e -h o u s in g c o n n e c ­ tio n . If leakage is c o m in g fro m (B), re­ p la ce th e retu rn tu b e . If c o m in g fro m (C), re p la ce th e h ose o r clam p. 67. S eat th e p lu g in th e h o u s in g . F o llo w in g m a n u fa c tu re r’s d ire c tio n s a p p ly L o c tite 75559 s o lv e n t and L o c tite 290 adhesive, o r e q u iv a le n t, to p lu g -h o u s in g area. 68. S eat th e b all in th e h o u s in g w ith a b lu n t p u n c h . F o llo w in g m a n u fa c tu re r’s d ire c ­ tio n s a p p ly L o c tite 75559 s o lv e n t and L o c tite 290 adhesive, o r e q u iv a le n t, to area. 69. C h e c k th e o il level; if lea kag e p e rs is ts w ith th e level c o rre c t and ca p tig h t, re­ p la ce th e cap. 70 If a cra cke d o r b e n t re s e rv o ir is d e te c te d , re p la ce th e reservoir. 71. Torque ja m n u t to 48 N-m (35 ft. lbs.). Re­ p la ce th e n u t if lea kag e p e rs is ts . 72. Torque s id e c o v e r b o lts to 60 N-m (45 ft. lbs.). R e p la ce th e s id e c o v e r seal if le a k­ age p e rs is ts . 73. Torque h o s e fittin g n u t to 27 N-m (20 ft. lbs.). If lea kag e p e rs is ts , re p la ce th e Orin g seal. 74. C h e c k fo r se ep ag e b e tw e e n th e to rs io n b a r and s tu b s h a ft. R ep lace th e ro ta ry valve a ssem bly. 75. S eat th e b a ll in th e h o u s in g w ith a b lu n t p u n c h . A p p ly L o c tite 75559 s o lv e n t and L o c tite 290 adhesive, o r e q u iv a le n t, to th e b all area. 76. R ep lace th e a d ju s te r p lu g seals. 77. R ep lace b o th p itm a n s h a ft seals. 78. R ep lace end p lu g O -ring seal. B-07323 Figure 5—System Leak Diagnosis 3B3-10 POWER STEERING J-5176-D J-25323 B-07325 Figure 6—T oo ls fo r P ow er S tee rin g S ystem Test Im p o rta n t • All tests are made with the engine idling at normal operating temperature. Check the idle adjustment and if necessary adjust the engine idle speed to the correct specification. Refer to FUEL SYSTEMS (SEC. 6C). Test W ith J-5176-D 1. Place a container under the steering gear or pump to catch the fluid when disconnecting or connecting the hoses. 2. W ith the engine NOT running, disconnect the pressure hose at the steering gear or power steering pump and install J-5176-D to both hoses using adapter fitting J-5176-20. The gage must be between the shut-off valve and pump. Open the shut-off valve. 3. Remove the fi'ler cap from the pump reservoir and check the fluid level. Fill the pump reservoir, with power steering fluid, to the full mark on the dipstick. Start the engine and, m omentarily holding steering w heel a gainst stop, ch eck the co nn e ctio n s at J-5176-D for leakage. 4. Bleed the system. Refer to “ Bleeding the Power Steering System.” 5. Insert therm om eter J-5421-02 in the reservoir filler opening. Move the steering wheel from stop to stop several times until the thermometer indicates that the hydraulic fluid in the reservoir has reached a temperature of 65° to 77°C (150° to 170°F). Im portant • To prevent scrubbing flat spots on the tires, do not turn the steering wheel more than five tim es without rolling the vehicle to change the tire-to-floor contact area. 6. Start the engine and check the pumps fluid level. Add power steering fluid if required. When the engine is at normal operating temperature, the initial pressure read on the gage (valve open) should be in the 550-860 kPa (80-125 psi) range. Should this pressure be in excess of 1380 kPa (200 psi) — check the hoses for restrictions and the poppet valve for proper assembly. NOTICE: Do not leave valve fully closed for more than 5 seconds as the pum p could be damaged internally. 7. Close the gate valve fully 3 times. Record the highest pressures attained each time. • If the pressures recorded are w ithin the specifications at the end of this section, and the range of readings is within 345 kPa (50 p si), th e pum p is fu n c tio n in g w ith in its specifications. • If the pressures recorded are high, but do not repeat w ithin 345 kPa (50 psi), the flow controlling valve is sticking. Remove the valve, clean it and remove any burrs using crocus cloth or fine hone. If the system contains some dirt, flush it. If it is exceptionally dirty, both the p u m p and g e a r m u s t be c o m p le te ly d is a s s e m b le d , c le a n e d , flu s h e d and reassembled before further usage. • If the pressures recorded are constant but m ore than 690 kPa (100 psi), below the minimum listed specification, replace the flow control valve and recheck. If the pressures are still low, replace the rotating group in the pump. 8. If the pump checks within specifications, leave the valve open and turn (or have turned) the steering w heel into both co rn e rs . R ecord th e h ig h e s t pressures and compare with the maximum pump pressure recorded. If this pressure cannot be built in either (or one) side of the gear, the gear is leaking internally and must be disassembled and repaired. 9. Shut the engine off, rem ove the testing gage, reconnect the pressure hose, check the fluid level and/or make the needed repairs. 10. If the problem still exists, the steering and front suspension must be thoroughly examined. Refer to “ Diagnosis of Power Steering System .” POWER STEERING 3B3-11 Test With J-25323 1. Place a container under the steering gear or pump to catch the fluid when disconnecting or connecting the hoses. 2. W ith the engine NOT running, d isco nn ect the pressure hose at the steering gear or power steering pump. Thread J-29525 fem ale adapter into the pressure hose and the male adapter into the gear or pum p. C onnect J-25323 a nalyzer hoses to the adapters. 3. If the analyzer has never been used, it will be necessary to bleed the power steering system to remove all the air. Refer to “ Bleeding the Power Steering System” in this section. The analyzer gate must be open during this procedure. 4. Add power steering fluid to the pump if required. 5. Run the engine at idle speed with the gate valve open and record flow (A) and pressure (B). • If the flow is below 7.4 L/min. (2 gpm), the pump appears to be in need of repair, but continue the test. • If the pressure is above 1035 kPa (150 psi), 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), disassem ble the pump and replace the ring, rotor, and vanes. If the pressure plates are worn or cracked, replace th e m . R e p la c e a ll O -rin g s e a ls w h e n reassembling the pump. Continue the test. 7. Com pletely close and partially open the gate valve three tim es (do not allow the valve to remain closed for 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, replace the flow 9. 10. 11. 12. control valve in the pump. If the pressure recorded is above the maximum specification listed, the flow control valve in the pump should be removed and cleaned or replaced. If the system is exceptionally dirty, both the steering gear and pump must be c o m p le te ly d is a s s e m b le d and c le a n e d b efo re reassembly. Increase the engine speed from idle to about 1500 rpm. Record the flow (E). • If flow (E) varies more than 1 gpm from flow (A), then the flow control valve should be removed and cleaned or replaced, the same as in step 8. Have the steering wheel turned into the left and then right corner lightly against the wheel stops. Record the pressure and flow (F). • Pressures developed in both corners should be nearly the same as the maximum pump output (D). At the same tim e the flow should drop below 1.85 L/min. (0.5 gpm). • If the pressure does not reach m axim um output or the flow does not drop below the specified value, excessive internal leakage is o c c u rrin g . R em ove and d isa sse m b le the steering gear and remove the control valve. Repair the steering gear as outlined in the Unit Repair Manual. Have the steering wheel turned slightly in both directions and release quickly while watching the pressure gage. The needle should move from the normal back pressure reading and snap back as the wheel is released. If it comes back slowly, or sticks, the rotary valve in the steering gear is sticking. Remove, disassem ble and clean the rotary valve. If the system contains a lot of dirt and foreign material, d is a s s e m b le th e p u m p th e gear, c le a n and reassemble. If the problem still exists, the steering and front suspension must be thoroughly examined. Refer to “ D iagnosis of Power Steering System ” in this section. POWER STEERING SYSTEM ON-VEHICLE SERVICE MAINTENANCE The hydraulic system should be kept clean and at regular intervals the pump steering fluid level in the reservoir should be checked and flu id added when required. Refer to MAINTENANCE AND LUBRICATION (SEC. 0B) of this manual for type of fluid to be used and intervals for filling. If the system contains some dirt, flush it as detailed later in this section. If it is exceptionally dirty, both the pump and the gear must be completely disassembled before further usage. All tubes, hoses, and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Make sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Inspect the hoses with the wheels in the straight-ahead position, then turn the wheels fully to the left 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. Power steering hoses and lines must not be twisted, kinked or tightly bent. The hoses should have sufficient natural curvature in the routing to absorb movement and hose shortening during vehicle operation. A ir in the system will cause spongy action and noisy operation. When a hose is disconnected or when fluid is lost, for any reason, the system must be bled after refilling. Refer to “ Bleeding the Power Steering System” in this section. PUMP BELT TENSION ADJUSTMENT When adjusting a power steering pump belt, never pry against the pum p reservoir or pull against the filler neck. Two systems are used for belt adjustment. On some models, the pump is loosened from the bracket and 3B3-12 POWER STEERING moved outward to lncrea se the tension. On other models, a half-inch square drive hole is located in the bracket, and this hole is used to rotate the pump-and-bracket assembly outward to increase belt tension. ft Adjust Tool Required: J-23600-B Belt Tension Gage. 1. Place belt tension gage, J-23600-B or equivalent, midway between the pulleys on drive belts being checked. • Power steering pump driven by a single belt. • Loosen the pump attaching bolts and adjust the belt to correct tension by moving the pump outward, away from the engine. • Tighten finger tight all pump mounting bolts and remove the pry bar. • Tighten all pum p mounting bolts. Refer to “ Power Steering Pump Replacement” in this section. • Inspect belt tension and remove the belt tension gage. 2. Loosen the pivot bolt and pump brace adjusting nuts. NOTICE: Do not move the pum p by prying against the reservoir or by pulling on the filler neck, or damage may occur. 3. Move the pump, with the belt in place until the belt is tensioned to specifications. Refer to ENGINE COOLING (SEC. 6B1). 4. Tighten the pump bracket adjusting nut and the pivot bolt nut. Refer to “ Power Steering Pump Replacem ent” in this section. 5. Inspect the belt tension and remove the belt tension gage. FLUID LEVEL ADJUSTMENT 1. Run the engine until the power steering fluid reaches normal operating temperature, about 80°C (170°F), then shut the engine off. 2. Remove the reservoir cap and check the fluid level on the dipstick. On models equipped with a remote reservoir, the fluid level should be about 12.7 to 25.4 mm ( 1/2 to 1-inch) from the top when the wheels are in full left turn position. 3. If the fluid level is low, add power steering fluid (GM #1050017 or equivalent) to the proper level and install the reservoir cap. 4. When checking the fluid level after the steering system has been serviced, air must be bled from the system. Refer to “ Bleeding the Power Steering System” in this section. BLEEDING THE POWER STEERING SYSTEM W hen a pow er ste e rin g pum p or gear has been installed, or an oil line has been disconnected, the air that has entered the system must be bled out before the vehicle is operated. If air is allowed to remain in the power steering fluid system, noisy and unsatisfactory operation of the system may result. Bleed air from the hydraulic system as follows: • When bleeding the system, and any tim e fluid is added to the power steering system, be sure to use o n ly p o w e r s te e rin g flu id as s p e c ifie d in MAINTENANCE AND LUBRICATION (SEC. OB). 1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes. 2. Start the engine and let it run for a few seconds. Then turn the engine off. 3. Add fluid if necessary. 4. Repeat the above procedure until the fluid level remains constant after running the engine. 5. Raise the front end of the vehicle so that the wheels are off the ground. 6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops. 7. Add power steering fluid if necessary. 8. Lower the vehicle and turn the steering wheel slowly from lock to lock. 9. Stop the engine. Check the fluid level and refill as required. 10. If the fluid is extremely foamy, allow the vehicle to s ta n d a few m in u te s a nd re p e a t th e a bo ve procedure. Inspect • Belt for tightness. • Pulley for looseness or damage. The pulley should not wobble with the engine running. • Hoses so they are not touching any other parts of the vehicle. • Fluid level and fill to the proper level. • Fluid for air and if present attempt to bleed the system. FLUSHING THE POWER STEERING SYSTEM 1. Raise the front end of the vehicle off the ground until the wheels are free to turn. 2. Remove the fluid return line at the pum p inlet connector and plug the connector port on the pump. Position the line towards a large container to catch the draining fluid. 3. W hile an assistant is filling the reservoir with new power steering fluid, run the engine at idle. Turn the steering wheel from stop to stop. DO NOT contact wheel stops or hold the wheel in a corner or fluid will stop and the pump will be in pressure relief mode. A sudden overflow from the reservoir may develop if the wheel is held at a stop. 4. Install all the lines, hoses and com ponents (if removed) on the vehicle. Fill the system with new power steering flu id and bleed the system as d e s c rib e d in “ B le e d in g T he P ow er S te e rin g System.” Operate the engine for about 15 minutes. Remove the pump return line at the pump inlet and plug the connection on the pump. W hile refilling the reservoir, check the draining fluid for contamination. If foreign material is still evident, replace all lines, POWER STEERING 3B3-13 d is a s s e m b le and cle a n o r rep la ce th e pow er steering system components. Do not re-use any drained power steering fluid. STEERING GEAR HIGH POINT CENTERING 1. Set the front wheels in the straight ahead position. This can be checked by driving the vehicle a short distance on a flat surface. 2. With the front wheels set straight ahead, check the position of the mark on the worm shaft designating steering gear high point. This mark should be at the top side of the shaft at the 12 o’clock position and lined up with the mark in the coupling lower clamp. 3. On R, G and P models except P30(00)FS3, if the steering gear has been moved off high point when setting the wheel in the straight ahead position, loosen the adjuster tube clam ps on both the left and right hand tie rods. Then turn both adjuster tubes an equal number of turns in the same direction to bring the gear back on high point. • Turning the adjuster tubes an unequal number of turns or in different directions will disturb the toe-in setting of the wheels. 4. On V and P30(00)FS3 models, if the gear has been moved off high point when setting the wheels in the straight ahead position, loosen the adjuster tube clam ps on the co n n e ctin g rod. Then tu rn the adjuster tube to bring the gear back on high point. 5. Adjust toe-in. Refer to FRONT END ALIGNMENT (SEC. 3A). 6. R efer to STEER IN G LIN KAG E (SEC. 3B1) for adjuster tube clam ping instructions. POWER STEERING GEAR REPLACEMENT |<-+| Remove or Disconnect (Figures 7, 8, 9, 10, 11, and 12) • Place a drain pan below the steering gear. 1. Battery ground cable. 2. Hoses from the steering gear. Raise the hose up to prevent oil drainage. Cap or tape the ends of the hose and gear fittings to prevent the entrance of dirt. • Remove the flexible co up lin g to steering shaft flange bolts (C, K and P300(32) models). • Remove the lower universal joint pinch bolt. Mark the relationship of the universal yoke to the stub shaft (G and P models). 3. Pitman arm. Refer to STEERING LINKAGE (SEC. 3B1). 4. Steering gear frame bolts and the steering gear. • Tap lightly, using a soft m allet, on the flexible coupling to remove the coupling from the steering gear stub shaft (R, V, and P300(32) models). R, V And P300(32) Models ♦«- Install or Connect (Figures 7, 8 ,1 0 ,1 1 , and 12) NOTICE: For steps 2, 3 and 4 see “ N o tic e ” on page 3B3-1. 1. Flexible coupling onto the steering gear stub shaft. • Align the flat in the coupling with the flat on the shaft. • Push the coupling onto the stub shaft until the coupling reinforcement bottoms against the end of the shaft. 2. Pinch bolt into the split clamp. The pinch bolt must pass through the shaft undercut. Tighten • Pinch bolt to 42 N m (31 ft. lbs.). • Place the steering gear into position, guiding the coupling bolts into the proper holes in the shaft flange. 3. S te e rin g g e a r to fra m e b o lts . T o rq u e “ Specifications” at the end of this section. to 4. Coupling flange nuts and washers. The coupling alignm ent pins should be centered in the flange slots. Tighten • Coupling flange nuts to 27 N m (20 ft. lbs.). Maintain a coupling to flange dimension of 6.4 to 9.5 mm (0.250 to 0.375-inch). 5. Pitman arm. Refer to STEERING LINKAGE (SEC. 3B1). • Remove the plugs and caps from the steering gear and hoses. 6. Hoses to the steering gear. Torque hose fittings to “ Specifications” at the end of this section. G And P Models Install or Connect (Figures 9, 10, 11, and 12) • Place the steering gear in position. Guide the stub shaft into the universal joint assembly by lining up the marks made at removal. 1. S te e rin g g e a r to th e fra m e b o lts . Torque to “ Specifications” at the end of this section. 2. In te rm e d ia te s h a ft p in c h b o lt. T o rq u e to “ Specifications” at the end of this section. The pinch bolt must pass through the shaft undercut. 3. Pitman arm. Refer to STEERING LINKAGE (SEC. 3B1). • Remove the plugs and caps from the steering gear and hoses. 4. Hoses to the steering gear. Torque hose fittings to “ Specifications” at the end of this section. 3B3-14 POWER STEERING 77 76 75 17. 21. 70. 71. 73. 74. 75. 76. 77. 78. 79. 80. A d ju s tin g S cre w Jam N u t S ide C over M o u n tin g B o lt S p rin g W a sh er A d ju s tin g S crew P in ch B o lt / S te e rin g S h a ft C o u p lin g N u t \ \ S p rin g W a sh er C o u p lin g F la n g e C o u p lin g S ide C ove r B o lt B-07602 Figure 7—Steering Gear Installation—R Model PITMAN SHAFT SEAL REPLACEMENT ++ • • 1. • • 2. Remove or Disconnect Tools Required: J-29107 Pitman Arm Puller. J-4245 Internal Snap Ring Pliers. Mark the position of the pitman arm to the pitman shaft. Remove the pitman arm using J-29107. Refer to STEERING LINKAGE (SEC. 3B1). Position a drain pan under the steering gear. Retaining ring using J-4245. Start the engine and full turn the steering wheel to the left-turn position for one or two seconds at a time. This will force the pitman shaft seals and washers out of the housing. Stop the engine. Pitman shaft seals and washers from the pitman shaft. 17. 21. 70. 73. 74. 75. 76. 77. 78. 79. Inspect • Pitman shaft seal surfaces for roughness or pitting. If pitted, replace the shaft. • H ou sing fo r burrs. R em ove th e b urrs b efore installing the new seals. jjjjP Clean • Pitman shaft and seal areas using a crocus cloth. -►+ Install or Connect fo o ls Required: J-6219 Steering Gear Pitman Shaft Oil Seal Installer. J-4245 Internal Snap Ring Pliers. • Lubricate the new seals with power steering fluid. • Apply a single layer of tape to the pitman arm shaft to avoid damaging the seals. A d ju s tin g S cre w Jam N ut S ide C over M o u n tin g B o lt A d ju s tin g S cre w P in ch B o lt S te e rin g S h a ft C o u p lin g N u t S p rin g W a sh e r C o u p lin g F la n g e C o u p lin g 80. S ide C ove r B o lt 81. S p a ce r F-02622 Figure 8—Steering Gear Installation—V Model POWER STEERING 3B3-15 Figure 9—Steering Gear Installation—G Model 17. 21. 70. 71. 73. 74. 75. 76. 77. 78. 79. 80. 81. A d ju s tin g S cre w Ja m N u t S id e C ove r M o u n tin g B o lt S p rin g W a s h e r A d ju s tin g S cre w P in ch B o lt S te e rin g S h a ft C o u p lin g N u t S p rin g W a sh e r C o u p lin g F lan ge C o u p lin g S id e C ove r B o lt Spacer F-02624 Figure 10—Steering Gear Installation—P Model, P300{32) and Solid Front Axle 3B3-16 POWER STEERING 17. 21. 70. 71. 73. A d ju s tin g S cre w Jam N ut S ide C over M o u n tin g b o lt S p rin g W a sh er A d ju s tin g S crew 74. 80. 81. 83. 84. P in c h B o lt S id e C over B o lt S pacer S p rin g W a sh er P in ch B o lt N u t F-02625 Figure 11—Steering Gear Installation—P Model, P300(42) + Solid Front Axle 17. 21. 70. 71. 73. 74. 80. 83. 84. A d ju s tin g S cre w Ja m N u t S id e C ove r M o u n tin g b o lt S p rin g W a s h e r A d ju s tin g S cre w P in ch B o lt S id e C o ve r B o lt S p rin g W a s h e r P in ch B o lt N u t F-02626 Figure 12—Steering Gear Installation—P Model, P200, P300(42) Except FS3 POWER STEERING 3B3-17 1 . Single lip seal and washer use J-6219. Install far enough to provide clearance for the remaining 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. Pitman arm. Refer to STEERING LINKAGE (SEC. 3B1). STEERING GEAR ADJUSTMENTS • Before any adjustments are made to the steering gear, refer to “ Diagnosis of Power Steering System” for reviewing the possible steering system problems. The steering gear adjustm e nt 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: 1. The com plexity involved in adjusting the worm thrust bearing preload. 2. The friction effect provided by the hydraulic fluid in the steering gear. For proper adjustment, remove the steering gear from the vehicle. Drain the power steering fluid from the gear. M ount the gear in a vise and make the fo llo w in g adjustments. The steering gear requires two adjustments which are: the worm thrust bearing preload and the pitman shaft over-center preload adjustment. The worm thrust bearing preload is controlled by the am ount of compression force exerted on the conical worm bearing thrust races by the adjuster plug. The pitman shaft over-center preload is controlled by the pitman shaft adjuster screw which determines the clearance between the rack piston and the pitman shaft sector teeth. • Adjust the worm thrust bearing preload first, then a djust the pitm an sh aft over-center preload. Worm Bearing Preload ^ A djust (Figures 1, 2, 13, 14, 15, 16, and 17) Tool Required: J-7624 Adjustable Spanner Wrench. Loosen and remove the adjuster plug nut (6) (figure 13). 2 . Turn the adjuster plug (3) in (clockwise), using J-7624, until the plug and thrust bearing are firm ly bottomed in the housing. Tighten • Adjuster plug to 27 N m (20 ft. lbs.). Place an index mark on the housing even with one of the holes in the adjust plug (figure 14). 4. Measure back (counterclockw ise) 4.7-6.3 mm (3/ie-1/4-inch) from the index mark and mark the housing (figure 15). 5. Rotate the adjuster plug back (counterclockwise) until the hole in the plug is aligned with the second mark on the housing (figure 16). 6. Install the adjuster plug nut (6). 3B3-18 POWER STEERING 4. Stub Shaft 21. Side Cover B-07330 Figure 16—Aligning the Adjuster Plug to the Second Mark Figure 18—Aligning the Stub Shaft Over Center Preload 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 deep socket to measure the required torque to turn the stub shaft (4). Take the reading with the handle of the torque wrench near the vertical position. Turn the stub shaft to the right stop and then back (counterclockwise) 1/4 turn at an even rate (figure 17). Record the torque reading. 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 turned when the adjuster plug nut was tightened, or the thrust bearings and races (22) may be damaged. Figure 17—Checking Rotational Torque Adjust (Figures 1, 2, 18, 19,, and 20) 1. Turn th e p itm a n s h a ft a d ju s te r s c re w (73) counterclockw ise until fu lly extended, then turn back 1/2 turn clockwise. 2. Rotate the stub shaft (4) from stop to stop and count the number of turns. 3. Smarting at either stop, turn the stub shaft back 1/2 the total number of turns. This is the “ center” of the gear. • When the gear is centered, the flat on the stub shaft should face upward and be parallel with the side cover (21) (figure 14) and the master spline on the pitman shaft should be in line with the adjuster screw (73) (figure 19). 4. Place the torque wrench, in the vertical position, on the stub shaft. Rotate the torque wrench 45 degrees each side of the center and record the highest drag torque measured on or near center (figure 20). Figure 19—Aligning the Pitman Shaft Master Spline POWER STEERING 3B3-19 4. Pump adjusting bolts, nuts and brackets. 5. Pump assembly. 6. Pulley from the pump. • In s ta ll J-29785-A . Be sure the p ilo t b olt bottoms in the pump shaft by turning the nut to the top of the pilot bolt. • H o ld th e p ilo t b o lt and tu rn th e n u t counterclockwise (figure 28). -►+ Install or Connect (Figures 21, 22, 23, 24, 25, 26, 27, and 28) 1. 2. 5. Adjust over-center drag torque by loosening the adjuster screw jam nut (17) and turning the pitman shaft adjuster screw (79) clockwise until the correct drag torque is obtained. • On new steering gears (under 400 miles), add 0.6-1.2 N m (6-10 in. lbs.) to rq u e 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 Power Steering System” in this section. POWER STEERING PUMP REPLACEMENT |<-+| Remove or Disconnect (Figures 21, 22, 23, 24, — 25, 26, 27, and 28) • 1. 2. • 3. Tool Required: J-29785-A Water Pump and Power Steering Pulley Remover. Place a drain pan below the pump. Battery ground cable. Hoses at the pump. Raise the hose up to prevent drainage of the oil. Cap or tape the ends of the hose and pump to prevent the entrance of dirt. • On models with remote reservoir, disconnect the reservoir hose at the pump. Cap the hose pump fittings. Loosen the pump adjusting bolts and nuts. Pump belt. • 3. 4. Tool Required: J-2 5 0 3 3 -B Pow er S te e rin g P um p P u lle y Installer. Brackets to the pump. Pulley to the pump. • Place pulley on the end of the pump shaft and in s ta ll J-25033-B . Be sure th e p ilo t b o lt bottoms in the shaft by turning the nut to the top of the pilot bolt. • Hold the pilot bolt and turn the nut clockwise (figure 28). On models equipped with a remote power steering pump reservoir fill the pump housing with as much fluid as possible before mounting. Pump assembly and attaching parts loosely to the engine. Power steering hoses to the pump. Hoses installed out of position may be subjected to chafing or other abu ses d u rin g s h a rp tu rn s. R efer to “ Power Steering Hoses” in this section. | 9 | Im portant • Do not s ta rt the e ng in e w ith any pow er steering hose disconnected. After 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 from the front) until the air bubbles cease to appear. 5. Pump belt over the pulley. 2 A djust • Belt tension. Refer to “ Pump Belt Tension A djustm ent” in this section. • Fill and bleed the system. Refer to “ Bleeding the Power Steering System” in this section. POWER STEERING HOSES When either a hose is reinstalled or replaced, the following points are essential: • Route hoses in the same position they were in before removal (figures 29 through 36). • Route hoses smoothly, avoid sharp bends and kinking. • Tighten the pump end hose fitting, gear line fitting, and booster line fitting to specifications. Refer to “ Specifications” at the end of this section. 3B3-20 POWER STEERING Figure 21—Power Steering Pump Mounting—RV (4.3, 5.0, and 5.7 Liter) • After hoses are installed, check for leaks while the system is being bled. Refer to “ Bleeding the Power Steering System” in this section. NOTICE: Do not start the engine with any power steering hose disconnected, or damage to the components could occur. POWER STEERING 3B3-21 RV000(00) With A/C A. 44 N-m (32 Ft. Lbs.) B. B a tte ry C a b le (G -M odel) G200 + 300(00) Without A/C P000(00) Without A/C F-02629 Figure 22—Power Steering Pump Mounting (6.2 Liter) 3B3-22 POWER STEERING P300(00) (7.4 Liter) P000(42) (4.8 Liter) F-02631 Figure 23—Power Steering Pump Mounting (4.8 and 7.4 Liter) POWER STEERING 3B3-23 G000(00) (4.3,5.0 And 5.7 Liter) C. D. E. F. 84 44 34 25 N m N m N-m N-m (62 (32 (25 (18 Ft. Ft. Ft. Ft. Lbs.) Lbs.) Lbs.) Lbs.) P000(42) (5.7 Liter) F-02632 Figure 24—Power Steering Pump Mounting (4.3, 5.0, and 5.7 Liter) 3B3-24 POWER STEERING Figure 25—Power Steering Pump Mounting—G Model (4.3, 5.0, and 5.7 Liter) F-02596 Figure 26—Power Steering Pump Mounting—RV 000(00)—(5.0 and 5.7 Liters) with A/C POWER STEERING 3B3-25 B-07363 Figure 28—Installing and Removing Pulley 3B3-26 POWER STEERING Figure 29—Hydro-Boost Lines POWER STEERING 3B3-27 Figure 30—Power Steering Hoses 3B3-28 POWER STEERING Figure 31—Power Steering Hoses—RV (4.3, 5.0, 5.7, and 6.2 Liter) POWER STEERING 3B3-29 G300(00) (5.7 Liter) G000(00) (6.2 Liter) F-02582 Figure 32—-Power Steering Hoses—G Model (4.3, 5.0, 5.7, and 6.2 Liter) 3B3-30 POWER STEERING P000(42) (4.8 Liter) P300(42) (4.8 Liter) With Disc/Drum Brake And 4 Wheel Disc Brake P300(42) (4.8 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake With Front I Beam Axle With Warning Switch P300(42) (4.8 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake With Warning Switch F-02643 Figure 33—Power Steering Hoses—P Model (4.8 Liter) POWER STEERING 3B3-31 P300(42) (5.7 Liter) With Disc/Drum Brakes With 4 Wheel Disc Brakes With Brake Warning Switch P300(42) (5.7 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake With Front I-Beam Axle P300(42) (5.7 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake F-02644 Figure 34—Power Steering Hoses—P Model (5.7 Liter) 3B3-32 POWER STEERING P300(32) (7.4 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake P300(42) (7.4 Liter) With Front I-Beam Axle Figure 35—Power Steering Hoses—P Model (7.4 Liter) F-02645 POWER STEERING 3B3-33 P300(42) (6.2 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake P300(32) (6.2 Liter) With Disc/Drum Brake With 4 Wheel Disc Brake P300(42) (6.2 Liter) With Front I-Beam Axle With Disc/Drum Brake With 4 Wheel Disc Brake F-02646 Figure 36—Power Steering Hoses—P Model (6.2 Liter) 3B3-34 POWER STEERING SPECIFICATIONS STEERING GEAR ADJUSTMENTS Valve Assem bly And Seal D r a g ...........................................................................................0.1-0.4 N m (1-4 in. Thrust Bearing Preload (In Excess Of Valve Assem bly And Seal D ra g )....................0.3-0.4 N-m (3-4 in. Pitman Shaft Over Center Preload New G e a r ....................................................................................................................... 0.6-1.2 N m (6-10 in. Used G e a r ....................................................................................................................... 0.4-0.5 N m (4-5 in. Final Over Center Reading (Total-Maximum) New G e ar.....................................................................................................................................2 N m (18 in. Used G e a r................................................................................................................................ 1.6 N m (14 in. lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) TORQUE SPECIFICATIONS Steering Gear To Frame Nuts (R, V, and G M o d e ls ).............................................. Steering Gear To Frame Nuts (P300(32) andP300(42)FS3)................................... Steering Gear To Frame Nuts (P200 + 300(42) Excluding FS3)............................. High Pressure Line Fitting (At Gear)........................................................................... Oil Return Line Fitting (At G e a r).................................................................................. Pitman Shaft Adjuster Screw Jam N u t....................................................................... Side Cover To Housing B olt........................................................................................... Adjuster Plug N u t............................................................................................................ Reservoir Bolt (At P u m p)............................................................................................... Flow Control Fitting (At P u m p ).................................................................................... Pressure Hose (At P u m p )............................................................................................. Power Steering Pump To Booster L in e ....................................................................... Booster To Gear L in e ...................................................................................................... Return Line At Booster And G e a r................................................................................ Coupling Flange N u t s ................................................................................................... Coupling Flange Pinch B o lt.......................................................................................... Lower Intermediate Shaft Pinch Bolt (G M odel)....................................................... Upper Intermediate Shaft Pinch Bolt (G M odel)....................................................... Intermediate Shaft Pinch Bolts (P200 + 300(42) Excluding F S 3 ) ...................... Intermediate Shaft Pinch Bolts (P300(42)FS3)......................................................... TORQUE N-m Ft. Lbs. 102 75 108 80 95 70 34 25 34 25 47 35 60 45 110 81 48 35 48 35 27 20 34 25 34 25 34 25 27 20 42 31 62 46 47 35 102 75 108 80 POWER STEERING 3B3-35 SPECIFICATIONS (CONTINUED) PUMP SPECIFICATIONS Minimum Output (1) Part Vehicle Number Model GPM L/Min. Maximum Output (2) Relief Valve Settings Minimum Maximum GPM L/Min. 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 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998 R V 7839799 132-P-145 1.32 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 1350 9998 G 7839813 132-P-159 1.32 5.00 3.1-3.5 11.7-13.2 9308 1450 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 7842049 132-P-228 1.32 5.00 3.1-3.5 11.7-13.2 1350 9308 1450 9998 3.1-3.5 11.7-13.2 1350 9308 1450 9998 7847616 T115-PT-003 1.15 4.35 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 Model 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 — O utput of Power Steering Fluid at 32°C (90°F) temperature when operating pump at 465 rpm against 4585-5068 kPa (665-735 psi) pressure. 2 — O utput of Power Steering Fluid at 32°C (90°F) temperature when operating pump at 1500 rpm against 345 kPa (50 psi) pressure. 3B3-36 POWER STEERING SPECIAL TOOLS 1. P ow er S te e rin g P ressure T ester 7. P itm a n A rm P u lle r 2. G a ug e A d a p te r 18m m P ow er S te e rin g 8. S n ap R ing P liers #23 In te rn a l 3. T h e rm o m e te r 9. P itm a n S h a ft Seal In s ta lle r 4. P ow er S te e rin g S ystem A n a lyze r 10. B e a rin g P reload S p a n n e r W re nch 5. Pow er S te e rin g A n a ly z e r 18m m A d a p te r 11. W a te r P um p P u lle y R em ove r 6. V-belt U nive rsa l Tension G auge 12. P ow er S te e rin g P u m p P u lle y In s ta lle r F-02648 3B4-1 SECTION 3B4 STEERIN G COLUMN The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of this m anual as indicated at appropriate locations by the term inology “ 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 com ponents and systems, and/or could result in major repair expense. They must be replaced with one o f the same part num ber or with an equivalent part if replacem ent becomes necessary. Torque values must be used as specified during reassembly to assure proper retention o f all parts. CONTENTS SUBJECT PAGE Description................................................................................................................................................................... 3B4- 2 Diagnosis Of The Steering C olum n.......................................................................................................................... 3B4- 2 Steering Column Electrical Component Analyzer............................................................................................... 3B4-10 Steering Column On-Vehicle Service (All Models)................................................................................................. 3B4-10 Inspection................................................................................................................................................................. 3B4-10 Steering Wheel Replacement.......... ..................................................................................................................3B4-12 Flexible Coupling R eplacem ent............................................................................................................................ 3B4-13 Intermediate Shaft R eplacem ent.......................................................................................................................... 3B4-13 Steering Column On-Vehicle Service (R, V And G M o d e ls ).................................................................................3B4-15 RV Model Steering Column Replacement............................................................................................................3B4-15 G Model Steering Column Replacem ent................................................ .......................................................... 3B4-16 Turn Signal Switch Replacement.......................................................................................................................... 3B4-16 Lock Cylinder Replacem ent.................................................................................................................................. 3B4-17 Tone Alarm Switch Replacement.......................................................................................................................... 3B4-18 Ignition Switch Replacem ent................................................................................................................................ 3B4-18 Standard Steering Column Unit Repair (R, V And G M odels)...............................................................................3B4-19 Standard Steering Column Lower Bearing Adjustm ent.....................................................................................3B4-23 Tilt Steering Column Unit Repair (R, V And G Models)......................................................................................... 3B4-26 Steering Column On-Vehicle Service P(32) Models............................................................................................... 3B4-33 Turn Signal Switch Replacement.......................................................................................................................... 3B4-33 Tilt Steering Column R eplacem ent......................................................................................................................3B4-33 Tilt Steering Column Bearing Housing Replacement......................................................................................... 3B4-35 Tilt Steering Column Unit Repair P(32) M o d els..................................................................................................... 3B4-38 Steering Column On-Vehicle Service P(42) Models............................................................................................... 3B4-38 Standard Steering Column Replacement..............................................................................................................3B4-38 Upper Bearing Replacement.................................................................................................................................. 3B4-39 Lower Bearing Replacement.................................................................................................................................. 3B4-41 Steering Column Lower Bearing A djustm ent..................................................................................................... 3B4-41 Shift Tube A d ju stm e n t..................................... .....................................................................................................3B4-41 Standard Steering Column Unit Repair P(42) M o d e ls........................................................................................... 3B4-42 Intermediate Shaft Unit Repair P(42) M odels......................................................................................................... 3B4-43 S p e cifica tio n s............................................................................................................................................................. 3B4-44 Special T o o ls ............................................................................................................................................................... 3B4-45 3B4-2 STEERING COLUMN DESCRIPTION The locking energy absorbing steering column includes three important features in addition to the steering func­ tion: 1. The column is energy absorbing, designed to com ­ press in a front-end collision to m inimize the possi­ bility of injury to the driver of the vehicle. 2. The ignition switch and lock are mounted on the col­ umn. 3. With the column mounted lock, the ignition, steering and gearshifting operation can be locked to inhibit theft of the vehicle. The column may be disassem bled and reassembled. To insure the energy absorbing action, it is important that the specified screws, bolts and nuts be used only as desig­ nated and that they are tightened to the specified torque. When the column is removed from the vehicle, such actions as a sharp blow on the end of the steering shaft or shift lever, leaning on the column assembly, or dropping of the assembly could shear or loosen the plastic fasten­ ers that maintain column rigidity. DIAGNOSIS OF THE STEERING COLUMN PROBLEM POSSIBLE CAUSE Lock System Will Not Unlock 1. 2. 3. 4. 5. Lock System Will Not Lock 1. 2. 3. 4. 5. 6. Lock System—High Lock Effort Lock bolt damaged. Faulty lock cylinder. Damaged housing. Damaged or collapsed sector. Damaged rack. CORRECTION 1. 2. 3. 4. 5. Replace Replace Replace Replace Replace Lock bolt spring is broken. Damaged sector tooth. Faulty lock cylinder. Damaged housing. Damaged rack. Interference between the bowl and cou­ pling. 7. Ignition switch stuck. 8. Actuator rod restricted or bent. 9. Transmission linkage adjustment is in­ correct. 1. 2. 3. 4. 5. 6. Replace the spring. Replace the sector tooth. Replace the lock cylinder. Replace the housing. Replace the rack. Adjust or replace. 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Lock cylinder is faulty. Ignition switch is faulty. Rack preload spring is broken or weak. Burrs on the sector, rack, housing, sup­ port, tang of the shift gate or actuator rod coupling. Bent sector shaft. Distorted rack. M isalignment of the housing to the cover (tilt only). Distorted coupling slot in the rack (tilt only). Bent or restricted actuator rod. Ignition switch m ounting bracket is bent. the lock bolt. or repair the lock cylinder. the housing. the sector. the rack. 7. Adjust or replace. 8. Adjust or replace. 9. Adjust. Replace Replace Replace Remove the the the the lock cylinder. ignition switch. spring. burrs. 5. Replace the shaft. 6. Replace the rack. 7. Replace either or both. 8. Replace the rack. 9. Straighten or replace the rod. 10. Straighten or replace the bracket. STEERING COLUMN 3B4-3 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Lock Cylinder—High Effort Between The “ O ff” and “ Off-Lock” Positions 1. Burr on tang of shift gate. 2. Distorted rack. 1. Remove the burr. 2. Replace the rack. Sticks In “ Start” Position 1. Actuator rod is deformed. 2. Any high effort condition. 1. Straighten or replace the rod. 2. See “ correction” under the high effort diagnosis. Key Cannot Be Removed In The “ Off-Lock” Position 1. Ignition switch is not set correctly. 2. Faulty lock cylinder. 1. Adjust ignition switch. 2. Replace the lock cylinder. The Lock Cylinder Can Be Removed Without Depressing The Retainer 1. Faulty retainer. 2. Burr over the retainer slot in the housing cover. 1. Replace the lock cylinder. 2. Remove the burr. Lock Bolt Hits The Shaft Lock In The “ O ff” And “ Park” Positions Noise In The Column Ignition switch is not set correctly. 1. Flexible coupling pulled apart. 2. Column not correctly aligned. 3. One click in O ff-U nlock position and when the steering wheel is moved. 4. Horn contact ring not lubricated. 5. Lack of grease on the bearings or bear­ ing surface. 6. Lower shaft bearing is tight or frozen. 7. Upper shaft bearing is tight or frozen. 8. Lock plate retaining ring is not seated. 9. Steering shaft snap ring is not seated. 10. Shroud or housing is loose. 11. Sheared intermediate shaft plastic joint. High Steering Shaft Effort 1. Column assembly is m isaligned in the vehicle. 2. Tight or frozen upper or lower bearings. 3. Binding intermediate shaft U-joints. Adjust the ignition switch. 1. Align the column and replace the flexi­ ble coupling. 2. Align the column. 3. Normal seating of the lock bolt. 4. Lubricate. 5. Lubricate the bearings. 6. Replace the bearing. Inspect the shaft and replace if scored. 7. Replace the housing assembly. 8. Replace the retaining ring. Inspect for proper seating in the groove. 9. R eplace the snap ring. Inspect for proper seating in the groove. 10. Tighten mounting screws. 11. Repair or replace the steering shaft. Align the column. 1. Align correctly. 2. Replace the bearings. 3. R ep air or rep la ce the in te rm e d ia te shaft. 3B4-4 STEERING COLUMN DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM High Shift Effort Improper Transmission Shifter POSSIBLE CAUSE 1. Column assembly is misaligned in the vehicle. 2. Lower bowl bearing is not aligned c o r­ rectly. 3. Lack of grease on the bearing or seal a r­ eas. 4. Shift tube is bent or broken. CORRECTION 1. Align correctly. 2. Align correctly. 3. Lubricate bearings and seals. 4. Replace the shift tubes. 1. Sheared shift tube joint. 2. Im proper transm ission linkage adjust­ ment. 3. Loose lower shift lever. 4. Sheared lower shift lever weld. 1. Replace the shift tube assembly. 2. Adjust the linkage. Lash In Mounted Column Assembly 1. 2. 3. 4. 5. 1. 2. 3. 4. 5. Driver Can Lock Steering In The Second Gear (Manual Transmission Columns) 1. Faulty upper shift lever. 2. Faulty shift lever gate. 3. Loose relay lever on the shift tube. 1. Replace the shift lever. 2. Replace the shift lever gate. 3. Replace the shift tube assembly. Excessive Play In The Mounted Steering Column Assembly (Tilt Column) 1. 2. 3. 4. 1. 2. 3. 4. Housing Loose (Tilt Column) 1. Excessive clearance between the holes in the support or the housing and pivot pin diameter. 2. Faulty anti-lash spring in the centering spheres. 3. Upper bearing not seating in the bearing race. 4. Upper bearing inner race seat missing. 5. Bearing preload spring broken. 6. Loose support screws. Housing Scraping On The Bowl (Tilt Column) Column mounting bracket bolts loose. Broken weld nuts on the jacket. Column bracket capsule sheared. Loose shoes in the housing (tilt only). Loose tilt head pivot pins (tilt only). Column mounting bracket bolts loose. Loose support screws. Loose tilt head pivot pins. Loose lock shoe pin in the support. Bowl bent or not concentric with the hub. 3. Replace the shift tube assembly. 4. Replace the shift tube assembly. Tighten to specifications. Replace the jacket assembly. Replace the bracket assembly. Replace the shoes. Replace the pivot pins. Tighten to specifications. Tighten to specifications. Replace the pivot pins. Replace the pin. 1. Replace either or both. 2. Replace the spring. 3. Replace both. 4. Install the seat. 5. Replace preload spring. 6. Tighten to specifications. Replace the bowl. STEERING COLUMN 3B4-5 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Steering Wheel Loose Every Other Tilt Position (Tilt Column) Loose fit between the lock shoe and pivot pin. Steering Column Will Not Lock In Any Tilt Position (Tilt Column) 1. Lock shoe grooves may have burrs or dirt. 2. Lock shoe spring is weak or broken. 3. Lock shoe seized on its pivot pin. 1. R eplace lock shoes and clean the grooves. 2. Replace the spring. 3. Replace both lock shoes. Noise When Tilting The Column (Tilt Column) 1. Tilt spring rubbing in the housing. 2. Tilt bum pers are worn. 1. Lubricate. 2. Replace the tilt bumpers. Steering Wheel Fails To Return To The Top Tilt Position (Tilt Column) 1. Pivot pins are bound up. 2. Wheel tilt spring is faulty. 3. The turn signal switch wires are too tight. 1. Replace the pivot pins. 2. Replace the spring. 3. Reposition the wires. Dimmer Switch Will Not Function 1. Loose connector at the dim m er switch. 2. Im proper adjustment. 3. Internally damaged or worn switch. 1. Tighten or replace. 2. Readjust. 3. Replace. Turn Signal Will Not Cancel 1. Loose switch mounting screws. 2. Switch or anchor bosses broken. 3. Broken, missing or out of position detent, return or cancelling spring. 4. Uneven or incorrect cancelling cam to cancelling spring interference. 1. Tighten screws to 2.8 N m (25 in. lbs.). 2. Replace the switch. 3. Reposition or replace the springs as re­ quired. 4. Adjust the switch position. • 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, re­ place the cancelling cam. Turn Signal Difficult To Operate 1. Actuator rod loose. 1. Tighten mounting screw to 1.4 N-m (12 in. lbs.). 2. Replace the switch. 3. Reposition or replace the springs. 4. Remove the foreign parts and/or mate­ rial. 5. Tighten mounting screws to 2.8 (25 in. lbs.). 2. Yoke broken or distorted. 3. Loose or misplaced springs. 4. Foreign parts and/or materials. 5. Switch mounted loosely. Turn Signal Will Not Indicate Lane Change 1. Broken lane change pressure pad or spring hanger. 2. B roken, m issin g or m is p la c e d lane change spring. 3. Jammed base or wires. Replace both. 1. Replace the switch. 2. Replace or reposition as required. 3. Loosen m ounting screws, reposition base or wires and tighten the screws to 2.8 N-m (25 in. lbs.). 3B4-6 STEERING COLUMN DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM Turn Signal Will Not Stay In Turn Position POSSIBLE CAUSE 1. Foreign material or loose parts impend­ ing movement of the yoke. 2. Broken or missing detent or cancelling springs. 3. None of the above. Hazard Switch Cannot Be Turned Off Hazard Switch Will Not Stay On Or Difficult To Turn Off No Turn Signal Lights Turn Indicator Lights On, But Not Flashing Front Or Rear Turn Signal Lights Are Not Flashing CORRECTION 1. Remove material and/or parts. 2. Replace the spring. 3. Replace the switch. Foreign material between hazard sup­ port cancelling leg and yoke. Remove the foreign material. • No foreign m aterial. Replace the turn signal switch. 1. Loose switch, mounting screws. 1. Tighten m ounting screws to 2.8 N .m 2. Interference with other components. 3. Foreign material. 4. None of the above. (25 in. lbs.). 2. Remove the interference. 3. Remove the foreign material. 4. Replace the switch. 1. 2. 3. 4. Faulty or blown fuse. Inoperative turn signal flasher. Loose chassis to column connector. Disconnect column to chassis connector. Connect new switch to chassis and oper­ ate switch by hand. If vehicle lights now operate normally, signal switch is inoper­ ative. 5. If vehicle lights do not operate, check chassis wiring for opens, grounds, etc. 1. 2. 3. 4. 1. 2. 3. 4. Inoperative turn flasher. Loose chassis to column connection. Inoperative turn signal switch. To determ ine if turn signal switch is faulty, substitute a new switch into the circuit and operate the switch by hand. If the vehicle’s lights operate normally, the signal switch is inoperative. 5. If the vehicle’s lights do not operate, check light sockets for high resistance c o n n e c tio n s , the ch a s s is w irin g fo r opens, grounds, etc. 1. 2. 3. 4. 1. Burned out fuse. 2. Burned out or damaged turn signal bulb. 3. High resistance connection to ground at the bulb socket. 4. Loose chassis to column connector. 1. Replace fuse and check operation. 2. Replace the bulb. 3. Remove or repair the faulty connection and check operation. 4. Connect securely and check operation. Replace Replace Connect Replace fuse and check operation. the turn signal flasher. securely, check operation. the signal switch. 5. Repair the chassis wiring. Replace Connect Replace Replace the turn flasher. securely and check operation. the turn signal switch. the signal switch. 5. Repair the chassis wiring. STEERING COLUMN 3B4-7 DIAGNOSIS OF THE STEERING COLUMN (CONT.) CORRECTION PROBLEM POSSIBLE CAUSE Front Or Rear Turn Signal Lights Are Not Flashing (Cont.) 5. Disconnect column to the chassis con­ nector. Connect a new switch into the system and operate the switch by hand. If turn signal lights are now on and flash, the turn signal switch is inoperative. 6. If vehicle lights do not operate, check the chassis wiring harness to light sockets for opens, grounds, etc. 5. Replace the turn signal switch. 1. Burned out fuse. 2. Loose column to chassis connection. 3. Disconnect column to chassis connector. 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 n ecto r to stop lig h t, th e sockets for grounds, opens, etc. 1. Replace fuse and check operation. 2. Connect securely and check operation. 3. Replace the signal switch. 1. Burned out bulbs. 2. High resistance to ground at the bulb socket. 3. Opens, grounds in wiring harness from the front turn signal bulb socket to the indicator lights. 1. Replace the bulbs. 2. Replace the socket. 1. Inoperative turn signal flasher. 2. System charging voltage low. 1. Replace the turn signal flasher. 2. Increase voltage to specifications. Re­ fer to (SEC. 6D ENGINE ELECTRICAL) in this manual. 3. Repair high resistance grounds at the light sockets. 4. Connect securely and check operation. 5. Replace signal switch. Stop Light Not On When Turn Indicated Turn Indicator Panel Lights Not Flashing Turn Signal Lights Flash Very Slowly 3. High resistance ground at light sockets. 4. Loose chassis to column connection. 5. Disconnect column to chassis connector. Connect new switch into system 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 slow, check chassis wiring harness from the connector to the light sockets for high re­ sistance. 6. Repair the chassis wiring. 4. Repair connector to stop lights circuits. 3. Locate and repair as required. 6. Locate and repair as required. Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. 3B4-8 STEERING COLUMN DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM Hazard Signal Lights Will Not Flash—Turn Signal Functions Normally Tone Alarm Does Not Sound With Key Fully Inserted In Lock Cylinder With Driver’s Door Open POSSIBLE CAUSE 1. 2. 3. 4. CORRECTION Blown fuse. Inoperative hazard warning flasher. Loose chassis to column connection. Disconnect column to chassis connector. Connect new switch into system without removing old. Depress the hazard warn­ ing button and observe the hazard warn­ ing lights. If they now work normally, the turn signal switch is faulty. 5. If the lights do not flash, check wiring harness “ K” lead (brown) for open be­ tween hazard flasher and harm onica connector. If open, fuse block is faulty. 1. 2. 3. 4. 1. Loose connection at the tone alarm. 2. Voltage not available to the tone alarm. 1. Connect securely. 2. Check the continuity of the chassis w ir­ ing and repair as required. 3. Replace the tone alarm. 4. Adjust or replace as required. 3. Faulty tone alarm. 4. Door jam b switch on the driver’s side is maladjusted or inoperative. 5. Short in the chassis wiring. 6. Short or fault in the signal switch wiring. 7. Chips, burrs, foreign material is prevent­ ing actuator tip function. NOTICE: Key must be removed or the cylinder in the “ run” position before removing the lock cylinder. 8. Faulty lock cylinder. 9. Chips, foreign material affecting the tone alarm switch operation. 10. Damaged or broken tone alarm switch. 11. Inoperative tone alarm switch (switch ap­ pears good but will not make the tone alarm switch function check). 12. Tone alarm switch contact gap is too large. Replace Replace Connect Replace fuse and check operation. the hazard warning flasher. securely and check operation. the turn signal switch. 5. Replace fuse block. Refer to SEC. 8B (CHASSIS ELECTRICAL) in this man­ ual. 5. Check by separating chassis to column connector. C onnect E and F female contacts on the chassis side (bent pa­ per clip will work). If tone alarm sounds, continue diagnosis. If not, locate and repair chassis w iring. 6. Connect male E and F contacts of con­ nector with the jumper. Check buzzer switch pads with the ohmmeter. If con­ tact is made, function is normal. If not, replace the signal switch. 7. Remove chips and burrs. Reassemble and check. 8. With the lock cylinder out (refer to “ No­ tice” under step 7), fully insert and re­ move the key. The actuator should extend and retract smoothly. Total ex­ p an sio n of tip s h o u ld be 1.25 mm (0.050 inch). If not, replace the lock cyl­ inder. 9. Remove and clean as required— reas­ semble and check. 10. Replace the tone alarm switch. 11. C onnect the ohm m eter leads to the tone alarm switch probes. Press on the actuator pad until the interior points contact. If contact is not made, replace the tone alarm switch. 12. Reset the contact gap. STEERING COLUMN 3B4-9 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE Tone Alarm Does Not 13. If the tone alarm fault has not yet been detected, connect a continuity meter (or Sound With Key Fully light) to the male E and F connector con­ Inserted In Lock Cylinder With Driver’s tacts. Insert the key the full depth into the lock cylinder. If contact is made with the Door Open (Cont.) key in, and is not made with it out, the function is normal. Retrace the initial di­ agnostic steps. If contact is not estab­ lished, the fault is in the column. 14. If the fault has not yet been isolated and repaired, connect ohmmeter to the tone alarm switch probes. Fully insert and re­ move the key from the lock cylinder. If contact is made with the key in, and is broken with it out, the function is normal. Retrace the diagnostic steps. If contact is not made, the fault is in the lock cylin­ der or tone alarm switch. Tone Alarm Continues 1. Door jam b switch on driver’s side malad­ justed or inoperative. To Operate With Key 2. Wire from signal switch to door jamb In The Lock Cylinder switch shorted. With The Driver’s Door Either Opened Or Closed And Ceases When Key Is Removed Tone Alarm Continues To Operate With Key Out, But Stops When Driver’s Door Is Closed 1. Lock cylinder binding (turn lock toward start position. If tone alarm stops in the run position or when turned past run run towards the start, the problem is a sticky lock cylinder actuator). 2. Chips, foreign material in lock cylinder bore. 3. Sticky lock cylinder actuator tip. 4. Damaged or broken tone alarm switch. 5. Tone alarm switch contact gap is too close. CORRECTION 13. With the fault isolated in the column, disassem ble the upper end of the col­ umn until the signal switch m ounting screws have been removed. Lift the switch and check the probes of the tone alarm switch to ensure good con­ tact with the pads in the signal switch. Bend the probes, if required, then re­ seat the signal switch and install the three screws. Check the function. 14. S e ttin g th e c o n ta c t gap. P re ss a 0.75 mm (0.030 inch) wire type spark plug gap wire with flat piece of stock on the actuator pad. If contact is not made, adjust switch until positive contact is made (use ohmmeter). With positive contact at 0.75 mm (0.030 inch) use a 0.65 mm (0.025 inch) plug gap wire be­ neath the flat stock. No contact should occur. Adjust. When the switch will make contact 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. 1. Adjust or replace as required. 2. If on signal switch side, replace signal switch. If on chassis side, find and re­ pair. This condition indicates the lock cyl­ inder or tone alarm switch is at fault. To verify, check for continuity at the E and F male connector contacts with the key removed from the cylinder. If continuity exists, the fault is in the column. 1. Replace the lock cylinder. 2. Remove, assemble and recheck func­ tion. 3. Replace the lock cylinder. 4. Replace the tone alarm switch. 5. Adjust as specified. 3B4-10 STEERING COLUMN 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 while holding the rag joint. If the steering shaft pins are sheared due to minor collision w ithout serious damage to other components, the vehicle can be safely steered; however, steering shaft replacement is recommended. 1/ ^ B COLUMN JACKET Inspect the jacket section of the column for looseness, and/or bends. COLUMN SUPPORT BRACKET Damage in this area will be indicated by separation of the mounting capsules from the bracket. The bracket will have moved forward toward the entire com partm ent and will usually result in collapsing of the jacket section of the steering column. A. C a p s u le s m u s t be w ith in 1.59 m m (V ie ") fro m b o tto m o f s lo ts . If n o t, re p la ce b ra c k e t a ssem bly. B T he b o lt head m u s t n o t c o n ta c t s u rfa c e “ B.” If c o n ta c t is m ade, th e c a p s u le s h e a r load w ill be in c re a s e d — R e p la ce b ra cket. B-07380 Figure 1—Steering Column Collapse Inspection STEERING COLUMN FOR ACCIDENT DAMAGE N O T IC E : V e h ic le s in v o lv e d in a c c id e n ts resulting in frame damage, major body or sheet m etal damage, or where the steering column has been im pacted may also have a damaged or misaligned steering column. L* Inspect (Figures 1 through 3) Capsules on the steering column bracket assembly. The capsules must be within 1.59 (Vie inch) from the bottom of the slots (figure 1). If not, the bracket should be replaced. 2. Contact surface (figure 1). The bolthead must not contact surface “ B ” or the shear load would be increased. If contact is made, replace the bracket. 3. Shift lever operation on vehicles with automatic transmission and column shift. If the shift lever is able to move to the “ Park” position w ithout raising the lever, the upper shift tube plastic bearing is broken. 4. Ja cket c o lla p s e . M ea sure th e ja c k e t c o lla p s e dimensions, depending on the vehicle and steering column, in either of the following ways (figure 2): • Measure from the end of the bearing assembly to the lower edge of the upper jacket (C).. STEERING COLUMN 3B4-11 *« ' c uq .-I *1 - 1 IO J Jl G Mr n \ f . H *n I n U C. 346.7 m m (13.64 in c h e s ) RV M O D E L (T ilt C o lu m n ) D. 72 m m (2.8 in c h e s ) RV M O D E L (S tandard C o lu m n -C o lu m n S h ift) E. 353 m m (14 in c h e s ) RV M O D E L (S tandard C o lu m n -F lo o r S h ift) 1 J F. 81.7 m m (3.21 in ch e s) G M O D E L (T ilt C o l­ u m n -C o lu m n S h ift) G. 144.9 m m (5.70 in ch e s) G M O D E L (T ilt C o l­ um n-4 Speed) H. 192 m m (7.5 in ch e s) G M O D E L (S tandard C o lu m n -C o lu m n S h ift) J. 80 m m (3.1 in c h e s ) G M O D E L (T ilt C o lu m n F lo o r S h ift) F-02585 Figure 2—Steering Column Collapse Inspection 3B4-12 STEERING COLUMN ,K tE i 2 f ? K. In s p e c t fo r sh ea re d in je c te d p la s tic in th e s h ift tu b e . L. In s p e c t fo r sh e a re d in je c te d p la s tic in th e s te e rin g s h a ft. B-07382 Figure 3—Steering Column Collapse Inspection • Measure from the collar on the toe plate flange to the lower edge of the upper jacket (E, G and H). • Measure from the edge of the back-up switch window to the lower edge of the upper jacket (D, F and J). • The turn signal control assem bly must be in the neutral position when assem bling the steering wheel. 1. Steering wheel onto the steering shaft. Align the marks made at removal. Im portant If the jacket dim ensions are not within specifications, a new jacket must be installed. • Visually inspect for sheared injected plastic in the shift tube, and the steering shaft (figure 3). If either one or both are sheared, replace with new parts. 5. Any frame dam age that could cause a bent steering shaft must have the steering shaft run ou t checked in the fo llo w in g m anner: R em ove in te rm e d ia te shaft. H old a ruler against the lower end of steering shaft and have the steering wheel rotated. The runout must not exceed 1.59 mm (Vie inch). A dial indicator may be used instead of a ruler. • Do not misalign the steering wheel more than 25.4 mm (1 inch) from the horizontal centerline (figure 5). 2. Horn lead assembly (some models). 3. Steering wheel nut. $ Tighten • Nut to 40 N-m (30 ft. lbs.). 4. Retainer. 5. Horn button cap. 6. Battery ground cable. STEERING WHEEL REPLACEMENT Remove or Disconnect (Figure 4) Tools Required: J-1859-03 Steering Wheel Puller 1. Battery ground cable. 2. Horn button cap. 3. Retainer and steering wheel nut. 4. Horn lead assem bly (some models). • Mark the relationship of the steering wheel to the steering shaft. 5. Steering wheel. Use J-1859-03 (figure 4). Do not hammer on the puller, or damage could result to the steering column. Install or Connect (Figure 5) NOTICE: For step 3 see “ N o tic e ” on page 3B4-1. A. Do n o t m is a lig n m ore th a n 25.4 m m (1 inch) fro m th e v e rtic a l c e n te rlin e . F-02675 Figure 5—Steering Wheel Alignment STEERING COLUMN 3B4-13 !§, Measure • Coupling to flange dimension. Maintain a 6.4 to 9.5 mm (0.250 to 0.375 inch) dimension. INTERMEDIATE SHAFT REPLACEMENT |<-+| Remove or Disconnect (Figure 7) 1 . C la m p B o lt 2. N u ts A nd W ashers A. B. C. D. C a p tu rin g S trap R e in fo rc e m e n t A lig n m e n t P ins W afer B-07385 Figure 6—Flexible Type Steering Coupling • Set front wheels in the straight ahead position. • Mark the upper universal joint yoke to steering shaft and the lower yoke to steering gear worm shaft 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. Interm ediate steering shaft and universal jo in t assembly. + 4- FLEXIBLE COUPLING REPLACEMENT Remove or Disconnect (Figure 6) 1. Coupling to flange bolt nuts and washers (2). 2. Clamp bolt (1). 3. Steering gear frame bolts. Lower the steering gear far enough to remove the flexible coupling. 4. Flexible coupling from the steering gear wormshaft. Tap lightly with a soft mallet. +«- Install or Connect (Figure 6) NOTICE: For steps 2, 3 and 4 see page 3B4-1. ‘N otice” on 1. Flexible coupling onto the steering gear wormshaft. Align the flat on the shaft with the flat in the coupling. • Push the coupling onto the wormshaft until the coupling reinforcement bottoms against the end of the worm. 2. Clamp bolt (1) into the split clamp. The bolt must pass through the shaft undercut. Tighten • Bolt to 42 N-m (31 ft. lbs.). • Place the steering gear into position, guiding the flexible coupling bolts into the proper holes in the steering shaft flange. 3. Steering gear and frame bolts. Tighten • Bolts to “ Specifications” at the end of this section. 4. Coupling to flange bolt nuts and washers (2). • The c o u p lin g a lig n m e n t p in s s h o u ld be centered in the flange slots. Tighten • Nuts to 27 N-m (20 ft. lbs.). Install or Connect (Figure 7) NOTICE: For steps 2, 3 and 4 see “ N otice” on page 3B4-1. 1. Intermediate shaft lower yoke onto the steering gear wormshaft. Align the marks made at 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 assembly onto the steering shaft. The marks on the coupling and steering shaft must align. 3. Steering gear and frame bolts. • Bolt to “ Specifications” at the end of this section. 4. Pinch bolt to the upper yoke assembly. The pinch bolt must pass through the shaft undercut. Tighten Pinch bolt to “ Specifications” at the end of this section. Measure (Figure 8) Carden joint operating angle (G-Model). The angle must not exceed 39 degrees maximum or 34 degrees minimum. 3B4-14 STEERING COLUMN Figure 7—Intermediate Shaft Installation *F R T A. A n g le m u s t n o t e xce e d 39 d e g re e s m a x im u m o r 34 d e g re e s m in im u m . B-07387 Figure 8—Carden Joint Angle (G-Model) STEERING COLUMN 3B4-15 STEERING COLUMN ON-VEHICLE SERVICE (R, V AND G MODELS) 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. Install or Connect (Figure 9) NOTICE: For steps 4 and 12 see “ N o tice” on page 3B4-1. 1. Plastic spacers onto the flexible coupling alignm ent pins. 2. Lower end of the steering column through the dash opening. 3. Lower s te e rin g s h a ft fla n g e onto the fle x ib le coupling (13). 4. Flange to coupling washers and nuts (1). Tighten • Nuts to 27 N m (20 ft. lbs.). • The flexible coupling (13) on manual steering must be installed prior to column installation. 5. Screws (7) and (8) and bracket (9) loosely. Tighten screws and nuts finger tight. 6. Clamp (11) and nuts (10). 2. 3. 4. 5. 6. 7. 8. N u ts A n d W ashers U p p e r C over Seal L o w e r C over S cre w s S cre w s N u ts 9. 10. 11. 12. 13. B ra cket N u ts C la m p Pot J o in t F le x ib le C o u p lin g Q 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). B-07388 • Remove plastic spacers from the flexible coupling pins. Figure 9—Steering Column Installation (RV Model) Measure RV MODEL STEERING COLUMN REPLACEMENT Remove or Disconnect (Figure 9) Battery ground cable. Transmission control linkage from the column shift tube levers. Nuts and washers (1) that secure the flanged end of the steering shaft to the flexible coupling. Nuts (10) and clamp (11). S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l R eplacem ent” in this section. Steering column harness at the connector. • D is c o n n e c t th e n e u tra l-s ta rt sw itc h and b a c k -u p la m p s w itc h c o n n e c to rs (som e m o d e ls ). R e fe r to SEC. 8B (C H A S S IS ELECTRICAL) in this manual. • 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. • Connect the neutral-start switch and back-up iamp switch connectors (some models). Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. 12. S te e rin g w h e e l. R e fe r to Replacem ent” in this section. 13. Transmission control linkage. 14. Battery ground cable. “ S te e rin g W heel 3B4-16 STEERING COLUMN Guide the steering shaft into the universal yoke, lining up the marks made at removal. 3. Upper universal joint pinch bolt (14). The pinch bolt must pass through the shaft undercut. & xnU i 6. 7. 8. 9. 14. Pinch bolt to 47 N-m (35 ft. lbs.). S cre w s S cre w s N u ts B ra cket P in ch B o lt € B-07389 Figure 10—Steering Column Installation (G Model) G MODEL STEERING COLUMN REPLACEMENT Remove or Disconnect (Figure 10) 1. Battery ground cable. 2. Transmission control linkage from the column shift tube levers. 3. U pper universal jo in t pinch bolt (14) from the interm ediate shaft. Mark the relationship of the universal yoke to the steering shaft. 4. Screws (7), nuts (8) and bracket (9). 5. Screws (6) from the cover and seal. 6. S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l R eplacem ent” in this section. 7. Steering column harness at the connectors. • D is c o n n e c t th e n e u tra l-s ta rt s w itc h and b a c k -u p la m p s w itc h c o n n e c to rs (so m e m o d e ls ). R e fe r to SEC. 8B (C H A S S IS ELECTRICAL) in this manual. 8 . Steering column assembly. Rotate the column so the shift lever clears the dash opening. Install or Connect (Figure 10) NOTICE: For steps 3 and 5 page3B4-1. Tighten see Measure Carden joint operating angle. The angle must not exceed 39 d e g re e s m axim um or 34 degrees minimum (figure 8). Tighten • Screws (7) and nuts (8) to 30 N-m (22 ft. lbs.). 3. Screws (6) through the cover and seal to the dash panel. 4. Connectors to the steering column harness. • Connect the neutral-start switch and back-up lamp switch connectors (some models). Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. 4. S te e rin g w h e e l. R e fe r to R eplacem ent” in this section. “ S te e rin g W heel 6. Transmission control linkage. 7. Batter ground cable. TURN SIGNAL SWITCH REPLACEMENT Remove or Disconnect (Figures 11 through 13) Tools Required: J-23653-A Lock Plate Com pressor 1. S te e rin g w h e e l. R e fe r to R eplacem ent” in this section. “ S te e rin g W heel 2. Instrument panel trim cover. “Notice” on 1. Lower end of the steering column through the dash opening. 2. Bracket (9), screws (7) and nuts (8) loosely. Tighten screws and nuts finger tight. • Position a screwdriver blade into the steering shaft lock plate cover slot. Pry up and out to free the cover from the lock plate. • Screw the ce nte r steering shaft as far plate by turning the the retaining ring Remove J-23653-A. post of J-23653-A onto the as it will go. Compress the lock center post nut clockwise. Pry out of the sh aft (figure 11). STEERING COLUMN 3B4-17 Im portant Important • Use only the specified screws, bolts and nuts at assembly. The use of overlength screws could prevent a portion of the assembly from compressing under impact. • If the column is being disassembled on a bench, the shaft could slide out of the end of th e m ast ja c k e t w he n th e sn ap rin g is removed. 3. Lock plate. 4. Turn signal lever screw and lever. 6. Hazard warning knob. Press the knob inward and then unscrew. 7. Turn signal mounting screws. • Pull the switch connector out of the bracket on the jacket and feed switch connector through column support bracket and pull switch straight up, guiding the wiring harness through the column housing and protector. • 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. Install the cover on the harness. 1. Turn signal mounting screws. • Clip the connector to the bracket on the jacket. Instrument panel trim plate. 8. Wire protector. Pull downward out of the column with pliers using the tab provided (figure 12). Hazard warning knob. Turn signal lever and screws. • Position the turn signal and shifter housing in the “ lo w ” position. Remove the harness cover by 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, guiding the wiring harness and cover through the column housing (figure 13). Put the turn signal switch in the “ N eutral” position. Pull “ o ut” on the hazard warning knob. W a sh e r, u p p e r b e a rin g p re lo a d s p rin g a nd cancelling cam onto the upper end of the shaft. 6 . Lock plate onto the end of the shaft. • Screw the center post of J-23653-A onto the steering shaft as far as it will go. Place a NEW retaining ring over the center post. Place the “ C ” bar over the c e n te r p ost and th en compress the lock plate by turning the nut clockwise. Slide the new retaining ring down the tapered center post and into the shaft groove (figure 14). Remove J-23653-A. +«- Install or Connect (Figure 14) Tools Required: J-23653-A Lock Plate Compressor Cover on the lock plate and snap into position. S te e rin g w h e e l. R e fe r to R eplacem ent” in this section. “ S te e rin g W heel LOCK CYLINDER REPLACEMENT ++ Remove or Disconnect (Figure 15) • Place the lock cylinder in the “ Run” position. 1. S te e rin g w h e e l. R e fe r to R eplacem ent” in this section. “ S te e rin g W heel 2. Turn signal switch. Refer to “ Turn Signal Switch R eplacem ent” in this section. 3B4-18 STEERING COLUMN TONE ALARM SWITCH REPLACEMENT Remove or Disconnect 1. S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l R eplacem ent” in this section. • Pull the turn signal switch up far enough to allow access to the tone alarm switch. Refer to “ Turn Signal Switch R eplacem ent” in this section. • The tone alarm sw itch m ay be rem oved w ithout removing the lock cylinder. The lock cylinder must be in the “ Run” position. 2. Tone alarm switch assembly. • Pull the tone alarm switch straight out of the housing using a paper clip or similar tool. A flat spring wedges the switch toward the lock cylinder. Im portant A. Hold the lo ck c y lin d e r sleeve and rotate the knob c lo c k w is e against the stop. B. Lock C ylin de r Set C. C ylinder Key D. Lock R etaining Screw 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 switch when removing. Install or Connect B-07394 Figure 15—Lock Cylinder Installation • It is not necessary to completely remove the turn signal switch from the column. Pull the switch rearward far enough to slip it oyer the end of the shift. Do not pull the harness out of the column. 3. Retaining screw and the lock cylinder set. Im portant • If the retaining screw is dropped on removal, it c o u ld fa ll in to th e c o lu m n , re q u irin g a complete disassem bly to retrieve the screw. +«- Install or Connect (Figure 15) 1. Lock cylinder set. • Align he cylinder key with the keyway in the housing. Rotate as shown in figure 15. • Push the lock all the way in. 2. Retaining screw. 1. Tone alarm switch to the spring clip with the formed end of the clip around the lower end of the switch. The spring is bowed away from the switch. • Lay the spring on the switch opposite the contacts. 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 R eplacem ent” in this section. 4. S te e rin g W h e e l. R e fe r to “ S te e rin g W h e e l R eplacem ent” 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. Remove or Disconnect £ Tighten • S crew to 4.5 N m (40 in. lbs.) (N o n -T ilt Columns). • Screw to 2.5 N m (22 in. lbs.) (Tilt Columns). 3. Turn signal switch. Refer to “ Turn Signal Switch Replacem ent” in this section. 4. S te e rin g w h e e l. R e fe r to Replacem ent” in this section. “ S te e rin g W heel Lower the steering column. Refer to “ CK Model or G M odel S tee rin g C olum n R e p la c e m e n t” in th is section. It is not necessary to remove the steering wheel. Im portant • Properly support the steering column if it is not removed from the vehicle. Put the ignition switch in the “ Lock” position. STEERING COLUMN 3B4-19 • If the lock cylinder was removed, the actuating rod to the switch should be pulled up until there is a definite stop, then moved down one detent, which is the ’ ‘Lock” position. 1. Two ignition switch screws. 2. Ignition switch assembly. *►+ Install or Connect (Figure 16) • Put the ignition switch in the “ Lock” position (figure 16). 1. Activating rod into the ignition switch. 2. Ignition switch and screws to the column. 3. S teering colum n assem bly. Refer to “ Steering Column Replacement” in this section. A A. S w itc h In T he L o ck P o s itio n B-07395 Figure 16—Ignition Switch Assembly STANDARD STEERING COLUMN UNIT REPAIR (R, V AND G MODELS) ++ Remove or Disconnect Steering column assembly. Refer to “ RV or G Model Steering Column Replacem ent” in this section. Disassemble (Figures 17 through 25) 3. 4. 5. 6. Dash panel bracket and screws from the column. Clamp the steering column in a vise. Clamp at the lower end of the jacket. Steering wheel. Refer to “ Steering Wheel Replace­ m ent” in this section. Turn signal switch. Refer to “ Turn Signal Switch Re­ placem ent” in this section. Lock cylinder. Refer to “ Lock Cylinder Replace­ m ent” in this section. Tone alarm switch, if it needs to be serviced. Refer to “ Tone Alarm Switch R eplacem ent” in this sec­ tion. Im portant 7. 8. 9. 10. 11. 12. 13. 14. • The buzzer switch does not have to be re­ moved to remove the upper bearing housing. Ignition switch. Refer to “ Ignition Switch Replace­ m ent” in this section. S h ift lever pivot pin and lever. (C olum n S h ift Models). Upper bearing washer. Screws attaching the turn signal and ignition lock housing. Housing assembly (figure 23). Bushing and retainer from the lower side of the housing. Ignition switch actuating rod, rack assembly, rack preload spring, shaft lock bolt and spring assembly from the housing. Shift lever detent plate. 15. Ignition switch actuator sector through the lock cyl­ inder hole by pushing firm ly on the block tooth of the sector with a blunt punch or screwdriver (figure 24). 16. Gear shift lever housing and shroud from the jacket assembly. • On floor shift models remove the transmission control lock tube housing and shroud. . Shift lever spring from the gear shift lever housing. • On floor shift models remove the lock tube spring. 18. Steering shaft from the lower end of the jacket as­ sembly. 19. Back-up switch or neutral-safety switch. Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. 20 . Lower bearing retaining clip (figure 25). On Automatic and Floorshift Columns. • Remove the lower bearing retainer, bearing a d a p te r assem bly, s h ift tu b e s p rin g and washer. The lower bearing may be removed from the adapter by light pressure on the bear­ ing outer race. • Slide out the shift tube assembly. On Manual Transmission (Column Shift) • Remove the lower bearing adapter, bearing and the first reverse shift lever. The lower bear­ ing may be removed from the adapter by light pressure on the bearing outer race. • Remove the three screws from the bearing at the lower and slide out the shift tube assem­ bly. • Remove the gear shift housing lower bearing from the upper end of the mast jacket. 17 * Assemble (Figures 17 through 22, 26 and 27) Apply a thin coat of lithium grease to all friction sur­ faces. 3B4-20 STEERING COLUMN 48 4* 49 I 47 B-07396 Figure 17—Standard Steering Column—Column Shift (RV Model) STEERING COLUMN 3B4-21 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 41. 42. 43. 44. 45. 46. R e ta in e r N ut L o ck P late C over R e ta in e r L o c k Plate C a n c e llin g C am B e a rin g Preload S p rin g Turn S ig na l S cre w s Tap S crew A c tu a to r A rm Turn S ig na l S w itc h Turn S ig n a l H o u s in g S cre w s W a sh er Tone A la rm S w itc h R e ta in e r C lip R e ta in e r S crew Ig n itio n L ock A c tu a to r S e c to r H o u s in g A s s e m b ly B e aring B u s h in g H o rn C o n ta c t U p p e r B e aring R e ta in e r D im m e r P ivot A n d W ip e r S w itc h 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 73. 74. 75. 76. S h a ft L o c k B o lt S w itc h R ack P reload S p rin g A c tu a to r R ack A c tu a to r P ivot Pin W asher S h ift Lever G ate S h ift Lever S crew H o u s in g C ove r C ove r S cre w S h ift Lever S p rin g G ear S h ift H o u s in g G ear S h ift S h rou d W a sh e r G ear S h ift H o u s in g B e aring Jacket W irin g P ro te c to r A c tu a to r Rod D im m e r S w itc h Ig n itio n S w itc h S crew Ig n itio n S w itc h Dash Seal S h a ft S h ift Tube W asher S p rin g 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. A d a p te r R e in fo rc e m e n t A d a p te r C lip L o w e r B e aring A u to m a tic T ra n s m is s io n S h ift Tube B o lt S p a ce r L ow er S h ift Lever A d a p te r P late A d a p te r R e ta in e r A d a p te r C lip M an ua l T ra n s m is s io n B o lt N ut C o u p lin g R e ta in e r B e aring S p rin g W asher Pin Seal In te rm e d ia te S h a ft B-07361 Figure 18—Standard Steering Column—Column Shift (RV Model) 1. Sector into the turn signal and lock cylinder hous­ ing. • Install the sector in the lock cylinder hole over the sector shaft w ith the tang end to the out­ side of the hole. • Press the sector over the shaft with a blunt tool. 2. Shift lever detent plate onto the housing. 3. Rack preload spring into the housing from the bot­ tom side. The long section should be toward the handwheel and hook onto the edge of the housing (figure 26). 4. Locking bolt onto the crossover arm on the rack and insert the rack and lock bolt assem bly into the hous­ ing from the bottom with the teeth up (toward hand­ wheel) and toward the centerline of the column. • Align the first tooth on the sector with the first tooth on the rack; if aligned properly, the block teeth will line up when the rack assembly is pushed all the way in. 5. Retainer and bushing. 6. Gear shift housing lower bearing. Insert the bearing from the very end of the jacket. • Align the indentations in the bearing with the projections on the jacket (figure 27). If the bearing is not installed correctly, it will not rest on the stops provided. 7. Shift lever spring into the gear shift lever (or lock tube) housing. 8. Housing and shroud assemblies onto the upper end of the mast jacket. 9. 10. 11. • • • Rotate the housing to be sure it is seated in the bearing. Turn signal and lock cylinder housing onto the jacket. • The gear shift housing should be in the “ Park” position and the rack pulled downward. • Seat the turn signal housing and install the four screws. Lower bearing into the adapter assembly. Shift tube assem bly into the lower end of the jacket. Rotate until the upper shift tube key slides into the housing keyway. On Automatic and Floor Shift Columns • Install the spring and lower bearing adapter assembly into the bottom of the jacket. • Hold the adapter in place and install the lower bearing reinforcem ent and retainer clip. The clip snaps into the jacket and reinforcem ent slots. On Manual Transmission (Column Shift) • Loosely attach the three screws in the jacket and shift tube bearing. • Assem ble the first reverse lever, lower bearing and adapter assembly into the bottom of the jacket. • Hold the adapter in place and install the bear­ ing reinforcement and retaining clip. The clip snaps into the jacket and reinforcem ent slots. • Adjust the lower bearing. Refer to the “ Manual Transmission (Column Shift) Lower Bearing A djustm ent” in this section. 3B4-22 STEERING COLUMN Figure 19—Standard Steering Column (RV Model) STEERING COLUMN 3B4-23 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. R e ta in e r N ut L o ck P late C over R e ta in e r L o ck Plate C a n c e llin g Cam B e aring P reload S p rin g Turn S ig na l S cre w s Tap S crew A c tu a to r A rm Turn S ig na l S w itc h Turn S ig na l H o u s in g S cre w s W a sh er Tone A la rm S w itc h R e ta in e r C lip R e ta in e r S crew Ig n itio n L ock A c tu a to r S e c to r Key R elease S p rin g 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 57. 58. 59. 62. 63. 64. Key R elease Lever Key R elease W a sh er H o u s in g A s s e m b ly B e aring B u s h in g H orn C o n ta c t U p p e r B e a rin g R e ta in e r D im m e r P ivo t A n d W ip e r S w itc h S h a ft L o ck B o lt S w itc h R ack P reload S p rin g A c tu a to r R ack A c tu a to r P ivot Pin W asher G e a r S h ift H o u s in g S ig n a l S w itc h M o u n tin g S c re w s G e a r S h ift H o u s in g Jacket W irin g P ro te c to r A c tu a to r Rod 65. 66. 67. 68. 69. 70. 71. 72. 73. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100. D im m e r S w itc h Ig n itio n S w itc h S cre w Ig n itio n S w itc h Dash Seal A d a p te r B e aring R e in fo rc e m e n t A d a p te r C lip S h a ft B o lt N ut C o u p lin g R e ta in e r B e aring S p rin g W a sh er Pin Seal In te rm e d ia te S h a ft B-07362 Figure 20—Standard Steering Column (RV Model) 12. Back-up switch or neutral-safety switch. Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. 13. Steering shaft into the column. 14. Upper bearing washer. 15. Ignition switch. Refer to “ Ignition Switch Replace­ m ent” in this section. 16. Tone alarm switch, if removed. Refer to “ Tone Alarm Switch R eplacem ent” in this section. STANDARD STEERING COLUMN LOWER BEARING ADJUSTMENT MANUAL TRANSMISSION (COLUMN SHIFT) A djust (Figure 28) 1. Put the transm ission in neutral and disconnect the transm ission rods. 2. Test for rotational drag by turning the shift lever through the 2 -3 shift arc. The drag measured must not be more than 9N (2 lbs.). 3. Loosen the three clam ping screws. 17. Lock cylinder. Refer to “ Lock Cylinder Replace­ m ent” in this section. 18. Turn signal switch. Refer to “ Turn Signal Switch Re­ placem ent” in this section. 19. Steering wheel. Refer to “ Steering Wheel Replace­ m ent” in this section. 20. Shift lever and pivot pin. • Remove the column from the vise. 21. Dash panel bracket and screws to the column. • Increase clearance by sliding the clam ping screws in the direction of arrow “ B ” until the first reverse lever is free of drag (figure 28). • Decrease clearance by sliding the clam ping screws in the direction of arrow “ A” until a slight drag is felt at the first reverse shift lever (figure 28). 4. Install a 0.13 mm (0.005 inch) thick shim between the space and either of the shift levers. 5. Slide the clam ping screws in the direction of arrow “ B” until the system is loose. Slide the screws in the opposite direction until a drag is felt at the first reverse shift lever. 6. Tighten the clam ping screws. Install or Connect 7. Remove the shim. Steering column assembly. Refer to “ RV or G Model Steering Column R eplacem ent” in this section. 8. Install the transm ission rods. 3B4-24 STEERING COLUMN Figure 21—Standard Steering Column (G Model) STEERING COLUMN 3B4-25 20. R e ta in e r 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Nut Lock Plate Cover Retainer Lock Plate C ancelling Cam Bearing Preload Spring Turn Signal Screws Tap Screw A ctu a to r Arm Turn Signal S w itch Turn Signal H ousing Screws W asher Tone Alarm S w itch R etainer C lip R etainer Screw Ig n ition Lock A ctua tor S ector Key Release Spring Key Release Lever Key Release W asher 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. H o u s in g A s s e m b ly B e aring B u s h in g H orn C o n ta c t U p p e r B e a rin g R e ta in e r D im m e r P ivot A n d W ip e r S w itc h S h a ft L o c k B o lt S w itc h R ack Preload S p rin g A c tu a to r R ack A c tu a to r P ivot Pin W a sh er S h ift Lever G ate S h ift Lever S crew H o u s in g C over C ove r S cre w S h ift Lever S p rin g G ear S h ift H o u s in g S ig n a l S w itc h M o u n tin g S c re w s G ear S h ift S h rou d 61. G e ar S h ift H o u s in g B e aring 62. 63. 64. 65. 66. 67. 68. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. Jacket W irin g P ro te c to r A c tu a to r Rod D im m e r S w itc h Ig n itio n S w itc h S crew Ig n itio n S w itc h Dash Seal S h ift Tube W a sh er S p rin g A d a p te r B e aring R e in fo rc e m e n t A d a p te r C lip S h a ft B e a rin g W a sh er R e ta in e r A u to m a tic T ra n s m is s io n M an ua l T ra n s m is s io n B-07364 Figure 22—Standard Steering Column (G Model) B-07400 Figure 24—Ignition Switch Actuator Sector Removal Figure 23—Turn Signal Housing Removal B-07401 Figure 25—Lower Bearing Retainer Removal 3B4-26 STEERING COLUMN 80 88 Figure 26—Rack Preload Spring Installtion 62. Jacket 80. Lower Bearing 83. Bolt 84. Spacer 85. Lower S h ift Lever 88. Retainer 89. Adapter C lip C. 2 -3 S h ift Lever D. Shim 0.13 mm (0.005 inch) B-07404 Figure 28—Lower Bearing Adjustment Figure 27—Gearshift Housing Lower Bearing Installation TILT STEERING COLUMN UNIT REPAIR (R, V AND G MODELS) Remove or Disconnect | ? | Im portant Steering column assembly. Refer to “ RV or G Model Steering Column R eplacem ent” in this section. • Disassemble (Figures 29 through 36) Tools Required: J-22635 Lock Shoe and Release Lever Pin Re­ mover and Installer J-21854-01 Pivot Pin Remover J-23072 Shift Tube Remover 10. 1. Dash panel bracket and screws from the column. 2. Clamp the steering column in a vise. • Clamp at the lower end of the jacket. 3. Turn signal switch. Refer to “ Turn Signal Switch Re­ placem ent” in this section. 11. 12. 4. Lock cylinder. Refer to “ Lock Cylinder Replace­ m ent” in this section. 5. Tone alarm switch, if it needs to be serviced. Refer to “ Tone Alarm Switch Replacement” in this sec­ tion. 13. 14. The tone alarm switch does not have to be re­ moved to remove the upper bearing housing. Ignition switch. Refer to “ Ignition Switch Replace­ m ent” in this section. Tilt release lever. Shift lever pivot pin and lever. Housing cover screws and housing cover. Install the tilt release lever and place the column in the “ up” position. Tilt lever spring retainer, spring and guide. Use a screwdriver to turn the retainer until it aligns with the grooves in the housing then remove the retainer. Pot joint to steering shaft clam p bolt and remove the interm ediate shaft and pot jo in t assem bly (RV Model). Upper bearing inner race and seat. Push the upper steering shaft in enough to remove the race and seat. Lower bearing retainer clip. Bearing reinforcement, bearing and bearing adapter assembly from the lower end of the mast jacket. STEERING COLUMN 3B4-27 15. Upper bearing housing pivot pins. Use J-21854-01 (figure 33). • Install the tilt release lever and disengage the lock shoes. 16. Bearing housing by pulling upward to extend the rack full down, and then moving the housing to the left to disengage the ignition switch rack from the actuator rod. 17. Steering shaft assembly from the upper end of the column. 18. Steering shaft by removing the centering spheres and the anti-lash spring. 19. Transmission indicator wire, if so equipped. 20. B earing housing su p p o rt to g e a rsh ift housing screws and remove the bearing housing support. 21. Ignition switch actuator rod. 22. Shift tube retaining ring and washer. NOTICE: When removing the shift tube, be sure to guide the low er end through the slotted opening in the mast jacket. If the tube is al­ lowed to interfere with the jacket in any way, damage to the tube and jacket could result. • Install J-23072 into the lock plate, making sure that the tool screws have good thread engagem ent in the lock plate. Then, turning the center screw clock­ wise, force the shift tube from the housing (Figure 34). Remove the shift tube (transmission control lock tube on floor shift models) from the lower end of the mast jacket. Remove J-23072. 23. Lock plate and washer. • Slide the lock plate out of the jacket notches by tipping it down toward the housing hub and sliding it under the jacket opening. 24 Shift lever housing from the mast jacket. (Transmis­ sion control lock tube housing on floor shift models). • Place the housing on a work bench and with a pointed punch against the back surface of the race, carefully hammer the race out of the housing until a bearing puller can be used. Repeat for the other race. * Assemble (Figures 29 through 39) Tools Required: J-23073-01 Shift Tube Installer J-22635 Lock Shoe and Release Lever Pin Re­ mover and Installer If the bearing housing was disassembled, repeat steps 1-9. Apply a thin coat of lithium grease to all friction sur­ faces. Bearings into the bearing housing, if removed. Lock shoe springs, lock shoes and shoe pin in the bearing housing. Use J-22635 or a 4.5 mm (0.180 inch) diameter rod to line up the shoes for pin instal­ lation. 3. Release lever, spring and pin. Im portant • To relieve the load on the release lever, hold the shoes inward and wedge a block between the top of the shoes (over slots) and bearing housing. Sector drive shaft into the housing. • Lightly tap the sector onto the shaft far enough to install the snap ring. Snap ring. Lock bolt. Engage the bolt with the sector cam sur­ face. Rack and spring. The block tooth on the rack should engage the block tooth on the sector (figure 37). 8. Tilt release lever. 9. Lock bolt spring and retaining screw. Disassemble the bearing housing as follows: 25. Tilt lever opening shield. 26 Lock bolt spring. Remove the retaining screws and move the spring clockwise to remove it from the bolt (figure 35). 27. Snap ring from the sector drive shaft. • With a small punch, lightly tap the drive shaft from the sector (figure 36). 28. Drive shaft, sector and lock bolt. 29. Rack and rack spring. 30. Tilt release lever pin. Use J-22635. 31. Release lever and spring. Im portant • To relieve the load on the release lever, hold the shoes inward and wedge a block between the top of the shoes (over slots) and bearing housing. 32. Lock shoe retaining pin. Use J-22635. 33. Lock shoes and springs. 34. Bearings from the bearing housing only if they are to be replaced. • Remove the separator and balls from the bear­ ings. Tighten • Screw to 4 N-m (35 in. lbs.). 10. Shift lever spring into the housing. Wind the spring up with pliers and push it into the housing. • On floor shift models, install the plunger and slide the gearshift lever housing onto the mast jacket. 11. Washer and lock plate. Slide the lock plate into the notches in the jacket. NOTICE: Do not push or tap on the end o f the shift tube. Be sure that teh shift tube lever is 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. 3B4-28 STEERING COLUMN Figure 29—Tilt Steering Column (RV and G Models) STEERING COLUMN 3B4-29 120. 121. 122. 123. 124. 125. 126. 127. 128. 129. 130. 131. 132. 133. 134. 135. 136. 137. 138. 139. 140. 141. 142. 143. 144. 145. R e ta in e r N ut Lock P late C over R e ta in e r L o ck P late C a n c e llin g Cam B e aring P reload S p rin g Turn S ig na l S cre w s Tap S crew A c tu a to r Arm Turn S ignal S w itc h In n e r Race Seat B e aring Race S crew Tone A la rm S w itc h R e ta in e r C lip L ock R e ta in e r S crew Ig n itio n Lock H o u s in g C over D im m e r S w itc h A c tu a to r S h ie ld Pin Preload S p rin g P ivot S w itc h A c tu a to r P ivot Pin Cap R e ta in e r 146. 147. 148. 149. 150. 151. 152. 153. 154. 155. 156. 157. 159. 160. 161. 162. 163. 164. 165. 166. 167. 168. 169. 170. 172. 173. T ilt S p rin g S p rin g G u id e S cre w B e aring L o c k B o lt L o ck B o lt S p rin g L o ck S hoe L o ck S hoe S e c to r S h a ft L o c k S h oe Pin P ivot Pin A c tu a to r S e c to r H o u s in g A s s e m b ly S h oe R elease S p rin g s S p rin g S h oe R elease Lever Pin S h oe R elease Lever L o w e r B e aring R ack P reload S p rin g A c tu a to r R ack Ig n itio n S w itc h A c tu a to r S p he re S p rin g C e n te rin g S p he res S p rin g L o w e r S te e rin g S h a ft H o u s in g S u p p o rt S cre w s 174. 175. 176. 177. 179. 180. 181. 182. 183. 184. 185. 186. 187. 188. 189. 190. 191. 192. 193. 194. 195. 196. 197. 198. H o u s in g S u p p o rt Pin S h ift Lever G ate D e te n t P la te S cre w R e ta in in g R ing W a sh er L ock Plate W ave W a sh er G ear S h ift Lever S p rin g G ear S h ift Lever B ow l S h rou d S crew S tud S w itc h D im m e r S w itc h Rod N ut D im m e r S w itc h Jacket Dash Seal S h ift Tube A d a p te r L o w e r B earing R e ta in e r A d a p te r C lip B-07365 Figure 30—Tilt Steering Column—(TV and G Models) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. • Place the nut on the threaded end of the tool and pull the shift tube into the housing (figure 38). • Remove J-23073-01. Bearing support washer and retaining ring. Pull the shift lever housing up far enough to compress the lock plate washer. Bearing support. Align the “ V ” in the support with the “ V ” in the jacket. Screws through the support and into the lock plate. • Screws to 6.8 N m (60 in. lbs.). • A lign the lower bearing adapter w ith the notches in the jacket. Adapter into the lower end of the jacket. Lower bearing, bearing reinforcem ent and retaining clip. • Align the retaining clip with the slots in the re­ inforcement, jacket and adapter. Centering spheres and anti-lash spring in the upper shaft. Lower shaft from the same side of the spheres that the spring ends protrude. Steering shaft assembly into the shift tube from the upper end. Carefully guide the shaft through the shift tube and bearing. Ignition switch actuator rod through the shift lever housing and insert it in the slot in the bearing sup­ port. • Extend the rack downward from the bearing housing. Bearing housing over the steering shaft. 23. 24. 25. 26. 27. • Engage the rack over the end of the actuator rod (figure 39). With the release lever installed, hold the lock shoes in the disengaged positions. Bearing housing over the steering shaft until the pivot pin holes line up. Pivot pins. • Place the bearing in the full “ up” position. Tilt lever spring guide, spring and retainer. • With a suitable screwdriver, push the retainer in and turn clockwise to engage it in the hous­ ing. Tilt lever opening shield. Remove the tilt release lever. 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 m ent” in this section. 30. Tone alarm switch, if removed. Refer to “ Tone Alarm Switch R eplacem ent” in this section. 31. Lock cylinder. Refer to “ Lock Cylinder Replace­ m ent” in this section. 32. Turn signal switch. Refer to “ Turn Signal Switch Re­ placem ent” in this section. • Remove the column from the vise. • 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 upper shaft (RV Model). 3B4-30 STEERING COLUMN Figure 31—Tilt Steering Column—Floor Shift (RV and G Models) STEERING COLUMN 3B4-31 120. 121. 122. 123. 124. 125. 126. 127. 128. 129. 130. 131. 132. 133. 134. 135. 136. 137. 138. 139. 140. 141. 142. R e ta in e r N ut L ock P late C over R e ta in e r L o ck P late C a n c e llin g Cam B e a rin g Preload S p rin g Turn S ignal S cre w s Tap S crew A c tu a to r A rm Turn S ig na l S w itc h In n e r Race Seat B e aring Race S crew Tone A la rm S w itc h R e ta in e r C lip L o ck R e ta in e r S cre w Ig n itio n L ock H o u s in g C over D im m e r S w itc h A c tu a to r S h ie ld Pin P reload S p rin g P ivo t S w itc h 143. 144. 145. 146. 147. 148. 149. 150. 151. 152. 153. 154. 155. 156. 157. 159. 160. 161. 162. 163. 164. 165. 166. A c tu a to r P ivot Pin C ap R e ta in e r T ilt S p rin g S p rin g G u id e S crew B e aring L ock B o lt L ock B o lt S p rin g L o ck S hoe L ock S hoe S e c to r S h a ft L o c k S h oe Pin P ivot Pin A c tu a to r S e c to r H o u s in g A s s e m b ly S hoe R elease S p rin g s S p rin g S hoe R elease Lever Pin S hoe R elease Lever L o w e r B e a rin g R ack P reload S p rin g A c tu a to r R ack .... 167. 168. 169. 170. 172. 173. 174. 175. 176. 177. 181. 182. 187. 188. 189. 190. 191. 199. 200. 201. 202. 203. 204. 205. Ig n itio n S w itc h A c tu a to r S phere S p rin g C e n te rin g S p h e re s S p rin g L ow er S te e rin g S h a ft H o u s in g S u p p o rt S cre w s H o u s in g S u p p o rt Pin S h ift Lever G ate D e te n t Plate S cre w L o c k Plate S cre w S tu d S w itc h D im m e r S w itc h Rod N ut D im m e r S w itc h Pad Key R elease Lever Key R elease S p rin g S h ro u d L ow er B e aring R e ta in e r S cre w s B-07368 Figure 32—Tilt Steering Column—Floor Shift (RV and V Models) ■ i Install the clamp, bolt and nut. The clamp bolt must pass through the shaft undercut. Q Tighten • Nut to 60 N m (44 ft. lbs.). 33. Dash panel bracket and screws to the column. 0♦♦I Install or Connect Steering column. Refer to “ RV or G Model Steering Column Replacement” in this section. Figure 33—Bearing Housing Pivot Pins Removal 3B4-32 STEERING COLUMN 157. A c tu a to r S e c to r 166. A c tu a to r Rack B-07411 Figure 37—Lock Bolt and Rack Assemblies Installation STEERING COLUMN 3B4-33 STEERING COLUMN ON-VEHICLE SERVICE P(32) MODELS 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. TURN SIGNAL SWITCH REPLACEMENT Remove or Disconnect (Figure 40) 1. 2. 3. 4. 5. 6. • 7. 8. Tools Required: J-22727 Electrical Terminal Remover S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l Replacem ent” in this section. Cancelling cam and spring (standard columns). Instrument panel trim plate (some models). Turn signal switch wiring harness at the half-moon connector. • Pry the wiring, harness protector out of the column retaining slots. • M ark th e lo c a tio n o f e a ch w ire in th e half-moon connector and then remove each in d iv id u a l w ire from th e co nn ecto r. Use J-22727 (figure 40). Insert the tool into the lower end of the connector and push in until the tool bottoms on the connector. Remove the tool and then pul! the wire from the connector. Turn signal lever screw and lever. Hazard warning light knob. Press the knob inward and unscrew. On tilt columns. • Remove the PRNDL dial screws, dial and indicator needle. Remove the cap and dial illu m in a tio n bulb from the housing cover (Automatic Transmission Model). • Unscrew and remove the tilt release lever. • Remove the turn signal housing cover, using a pulley remover with reversed jaws. Turn signal switch mounting screws. Turn signal switch assembly from the column. Guide the wiring harness through the opening in the shift lever housing. ■n- Install or Connect Wrap the ends of the turn signal switch wires with tape and then guide them through the opening at 4. 5. 6. 7. • Screws to 2.8 N m (25 in. lbs. On tilt columns. • Align the openings in the turn signal switch cover with the proper lever positions. Tap the cover into place using a plastic hammer. • Install the tilt release lever. • In s ta ll th e P R N D L d ia l, p o in te r, d ia l illu m in a tio n b u lb and c a p (A u to m a tic Transmission Models). Turn signal switch lever and screws. Hazard warning knob. Bend the wire retaining tabs, on each wire in the wiring harness, enough to provide proper retention of the wire in the half-moon connector. Each wire in its marked location in the half-moon connector. Push in until the square part of the clip is flush with the bottom side of the connector. Turn signal switch wiring harness. W iring harness protector into the column retaining slots. Cancelling cam and spring (non-tilt column). NOTICE: For step 8 see “ N o tic e ” on page 3B4-1. 8. S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l Replacem ent” in this section. 9. Instrum ent panel trim plate (some models). TILT STEERING COLUMN REPLACEMENT +-► Remove or Disconnect (Figure 41) 4. 5. 6. 7. 8. Battery ground cable. Transmission control linkage from the column shift tube levers. Nuts and washers that secure the flanged end of the steering shaft to the flexible coupling. S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l R eplacem ent” in this section. Turn signal wiring harness. • On an automatic transm ission, disconnect the single wire at the fuse block and unclip it from the parking brake bracket. Screws from the cover of the dash and toe panel assembly. Screws (211) and clam p (210) from the colum n support bracket. Steering column assembly. 3B4-34 STEERING COLUMN • L o w e r a n d th e n w ith d ra w th e c o lu m n assembly. Rotate the column so the shift lever clears the dash and toe panel assembly. Install or Connect (Figures 41 and 42) NOTICE: For steps 4 and 8 see “ N otice” on page 3B4-1. • Adjust the lower bearing preload. Refer to “ Steering Column Lower Bearing A djustm ent” in this section. 1. Plastic spacers onto the flexible coupling alignm ent pins. 2. Lower end of the steering column through the toe panel opening. 3. Low er ste e rin g s h a ft fla n g e onto th e fle x ib le coupling. 4. Flange to coupling nuts. A. (4.89 ± 0.12 in ch ) E x c lu d in g FS3 B. (4.71 in ch ) w ith FS3 B-07417 Figure 42—Coupling Assembly Measurement STEERING COLUMN 3B4-35 • Nuts to 27 N m (20 ft. lbs.). 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. a Tighten • Screws (211) to 25 N m (18 ft. lbs.). Remove the plastic spacer from the alignm ent pins. Measure 6. 7. 8. 9. 10. • Coupling assem bly dim ensions (figure 42). Raise or lower steering column if necessary. Cover and mounting screws to the dash and toe panel assembly. Turn signal switch wiring harness. • On an automatic transm ission, connect the single wire to the fuse block and clip it to the parking brack bracket. S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l Replacem ent” in this section. Transmission control linkage. Battery ground cable. TILT STEERING COLUMN BEARING HOUSING REPLACEMENT ++ 1. 2. 3. • • 4. 5. 6. 7. 8. 9. 10. Remove or Disconnect (Figures 43 through 47) Tools Required: J-22635 Lock Shoe and Release Lever Pin Remover and installer J-21854-01 Pivot Pin Remover J-5822 Steering Gear Shaft Main Bearing Cup Remover J-2619-01 Slide Hammer Battery ground cable. S te e rin g w h e e l. R e fe r to “ S te e rin g W h e e l Replacement” in this section. Turn signal switch. Refer to “ Turn Signal Switch Replacem ent” in this section. 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. Retainer (230) and spring (232). Use a screwdriver to turn the retainer until it aligns with the grooves in the housing, then remove the retainer and spring. Upper bearing nut (253). Seat (254) and race (255). Housing pivot pins (221). Use J-21854-01 (figure 45). Bearing housing (219). Pull up on the tilt release lever, this will disengage the shoes (224), and remove the housing. Upper and lower bearings (218, 220). • Remove the bearing races using J-5822 and J-2619-01 (figure 46). Tilt release lever. 11. Shoe release pivot pin (228). Use J-22635 or a suitable punch (figure 47). 12. Spring (227) and lever (229). 13. Shoe kit assem bly (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 disassem ble the shaft, proceed as follows: • Disconnect the shaft at the pot joint coupling clam p and remove the lower steering shaft. • Turn the upper shaft 90 degrees to the lower shaft and slide the upper shaft 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: 15. Screws (231). 16. Support (233). Install or Connect (Figures 43 and 44) NOTICE: For steps 4 and 11 see “ N otice” on page 3B4-1. • Lubricate the ID of the bearing housing support and install the support and screws. 1. Steering shaft assembly. • Lubricate and assemble the centering spheres and spring. • Install the spheres into the upper (short) shaft and rotate 90 degrees. • Install the lower shaft 90 degrees to the upper shaft and over the centering spheres. Slowly straighten the shafts while compressing the spring. 2. Steering shaft assem bly into the housing from the upper end. 3. Lower steering column shaft to the intermediate shaft (pot joint) assem bly (269). Clamp (262) bolt (261) and nut (263). The bolt must pass through the shaft undercut. Tighten • Bolt to 60 N m (44 ft. lbs.). 5. Bearing housing (219) assembly. • Press the new upper and lower bearing races into the bearing housing. • Lubricate and install the bearings into the bearing races. • Place the shoe springs in position in the hou sin g. In sta ll each shoe in place and compress the spring in position. Once the shoes are in place, drive in the shoe retaining pin (226). • Install the shoe release lever (229), spring (227) and pivot pin (228). • Install the tilt release lever. • Lubricate the shoes and release lever. 6. Bearing housing assem bly to the support (233). 3B4-36 STEERING COLUMN 225 216 247 261 B-07418 Figure 43—Tilt Steering Column—P(32) Model STEERING COLUMN 3B4-37 215. H o u s in g C over 216. Turn S ig n a l M o u n tin g S crew 217. Turn S ig n a l S w itc h 218. U p p e r B e aring 219. B e a rin g H o u s in g 220. L o w e r B earing 221. P ivot Pins 222. S hoe S p rin g 223. S p a ce r 224. S hoes 225. S hoe K it A s s e m b ly 226. S hoe R e ta in in g Pin 227. S p rin g 228. P ivot Pin 229. 230. 231. 232. 233. 234. 235. 236. 237. 238. 239. 240. 241. Lever R e ta in e r S cre w s S p rin g S u p p o rt Pin D e te n t Plate S crew R e ta in in g R ing W a sh er L o ck Plate W a sh er G ear S h ift Lever S p rin g 242. G ear S h ift H o u s in g 243. G u id e 244. J a c k e t 245. B e aring R e ta in e r C lip 246. R e in fo rc e m e n t 247. Dash Seal 248. Seal 249. S h ift Tube 250. A d a p te r 251. B e aring 252. N u t 253. N u t 254. Seat 255. Race 256. S h a ft 257. 258. 259. 260. 261. 262. 263. 264. 265. 266. 267. 268. 269. S p rin g S p h e re A s s e m b ly L o w e r S h a ft S h a ft A s s e m b ly B o lt C la m p N ut R e ta in e r S p rin g C o u p lin g A s s e m b ly B e a rin g s Seal In te rm e d ia te S h a ft A s s e m b ly B-07369 Figure 44—Tilt Steering Column—P(32) Model • Hold the tilt release lever in the “ up” position u n til th e sh o e s have fu lly e n g a g e d th e support. • Lubricate and install the bearing housing pivot pins (221). Press the pins in flush with the housing. Place the housing in the “ up” position. 7. Spring (232) and retainer (230). Push the retainer into the housing about 5 mm (3/ie inch) and rotate counterclockwise Vs turn. • Lubricate the upper bearing race (255), seat (254) and nut (253). 8. Race (255), seat (254) and nut (253). • Remove the tilt release lever. 9. Turn signal switch. Refer to “ Turn Signal Switch R eplacem ent” in this section. 10. Shift lever and pivot pin. (Column Shift Models). 11. S te e rin g W h e e l. R e fe r to “ S te e rin g W h e e l R eplacem ent” in this section. 12. Tilt release lever. L* Inspect E le c tric a l and m e c h a n ic a l fu n c tio n in g steering column. of the B-07421 Figure 47—Release Lever Pivot Pin Removal Figure 46—Bearing Race Removal 3B4-38 STEERING COLUMN TILT STEERING COLUMN UNIT REPAIR P(32) MODELS Remove or Disconnect Steering column assembly. Refer to “ Tilt Steering Column R eplacem ent” in this section. Disassemble (Figures 43 and 44) 1. • 2. 3. 4. 5. • 6. 7. 8. 9. Tool Required: J-23072 Shift Tube Remover Clamp the steering column in a vise. Clamp at the lower end of the jacket. Intermediate shaft assembly (270), with the univer­ sal joint (pot joint), from the steering column shaft. Bearing retainer clip (245) and reinforcement (246). Bearing (251) and adapter (250). Bearing housing assembly and steering shaft as­ sembly. Refer to “ Tilt Steering Column Bearing Housing R eplacem ent” in this section. If the shift tube index plate must be removed, re­ move the two retaining screws and plate. (Column Shift Models). Shift tube retaining ring (237) and washer (238). Neutral-safety or back-up lamp switch screws and switch. Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. Shift tube (249) assembly. Use J-23072. Do not hammer or pull on the shift tube during removal (fig­ ure 29). • Insert the hooked end of the tool into the notch in the shift tube just below the shift lever hous­ ing key. Pilot the sleeve over the threaded end of the tool and into the upper end of the shift tube. Force the shift tube out of the housing by turning the nut onto the tool. If the shift tube is not completely free when the nut is bottomed on the threads, complete the removal by hand. • On column shift models, guide the lower shift lever through the slotted opening in the col­ umn to prevent dam age to the tube or column. Lock plate (239) and washer (240). Tip the lock plate downward towards the housing, then remove. 10. Shift lever housing. • Remove the shift lever spring by winding the spring up with pliers (Column Shift Models). 11. Dash panel seal from the colum n jacket. * Assemble (Figures 43 and 44) • 1. • 2. 3. 4. 5. 6. 7. Tools Required: J-23073-01 Shift Tube Installer Apply a thin coat of lithium grease to all friction sur­ faces. Dash panes seal. Press a new shift lever spring into the shift lever housing (Column Shift Models). Shift lever housing. Slide the housing over the up­ per end of the column. Washer (240) and lock plate (239). • Apply lithium grease to the lock plate and the upper end of the shift tube. Shift tube (249) and seal (248) into the lower end of the column. Do not ham mer or force the shift tube. • Align the keyway in the shift tube with the key in the shift lever housing and install the shift tube using J-23073-01 (figure 38). • The shift lever housing key must bottom in the shift tube slot. Neutral-safety or back-up lamp switch and screws. Refer to SEC. 8B (CHASSIS ELECTRICAL) in this manual. Washer (238) and retaining ring (237). Pull up on the shift lever housing when installing the washer and retaining ring. • Seat the retaining ring in both slots in the shift tube. Steering shaft assembly and bearing housing as­ sembly. Refer to “ Tilt Steering Column Bearing Housing R eplacem ent” in this section. -►<- Install or Connect Steering column assembly. Refer to “ Tilt Steering Column R eplacem ent11 in this section. STEERING COLUMN ON-VEHICLE SERVICE P(42) MODELS STANDARD STEERING COLUMN REPLACEMENT 5. Screws (277) from the cover (278) and seal (279). Slide the cover and seal up the column. Remove or Disconnect (Figure 48) 6. S te e rin g w h e e l. R e fe r to Replacem ent” in this section. Battery ground cable. 7. Turn signal wiring harness. “ S te e rin g W heel 2. Transmission control linkage from the column shift tube levers (Column Shift Models). • On an automatic transm ission, disconnect the conductor tube at the instrum ent panel. 3. U p p e r u n iv e rs a l jo in t p in c h b o lt fro m th e interm ediate shaft. Mark the relationship of the universal yoke to the steering shaft. 8. Bolts (275) and clamp (276) from the column support bracket. 4. Nut (282), bolt (280) and clamp (281). Slide the clamp down the column. 9. Bolt, nut and outer brace (283) from the column support bracket (P200 + 300 (42) models). 10. Steering column assembly. STEERING COLUMN 3B4-39 275. 276. 277. 278. 279. 280. 281. 282. 283. B o lts v C la m p S cre w s C over Seal B o lt C la m p N ut O u te r Brace B-07422 Figure 48—Steering Column Installation—P(42) Model • L o w e r a nd th e n w ith d ra w th e c o lu m n assembly. Rotate the column so the shift lever clears the dash and toe panel assembly. El * t l Install or Connect (Figure 48) NOTICE: For steps 2, 3, 4 and 9 see “ N o tice” on page 3B4-1. 1. Adjust the lower bearing preload. Refer to “ Steering Column Lower Bearing A djustm ent” in this section. 2. Lower end of the steering colum n through the toe panel opening. • Guide the steering shaft into the universal yoke, lining up the marks made at removal. • Upper universal pinch bolt. The pinch bolt must pass through the shaft undercut. Tighten • Pinch bolt to “ Specifications” at the end of this section. Tighten • Bolt to 25 N m (18 ft. lbs.). 5. Seal (279), cover (278) and screws (277) to the dash panel assembly. 6. Outer brace (283), bolt and nut to the colum n support bracket (P200 + 300 (42) models). Tighten • Bolt to 25 N m (18 ft. lbs.). 7. Transmission control linkage to the shift tube levers (Column Shift Models). 8. Turn signal wiring harness. • On a s ta n d a rd c o lu m n w ith a u to m a tic transm ission connect the conductor tube at the instrum ent panel. 9. S te e rin g w h e e l. R eplacem ent.” R e fe r to “ S te e rin g W heel • Align the seal (279) and cover (278) with the floor and dash panel assembly. 10. Battery ground cable. • Align the column support bracket protrusion with the index slot in the steering column. UPPER BEARING REPLACEMENT 3. Clamp (281), bolt (280) and nut (282). Position the clam p as shown in figure 48. Tighten • Nut to 15 N m (11 ft. lbs.). Clamp (276) and bolt (275). |<-+| Remove or Disconnect (Figure 49) 1. S te e rin g w h e e l. R e fe r to R eplacem ent” in this section. 2. Cancelling cam (286). 3. Upper bearing (289). “ S te e rin g W heel 3B4-40 STEERING COLUMN 316 285 278. 279. 285. 286. 287. 288. 289. 290. 291. 292. 293. 294. 295. 296. 297. 298. 299. 300. 301. 302. 303. Seal C over H orn B lo w W ire C a n c e llin g Cam Turn S ig n a l S w itc h S cre w s H azard C o n tro l S w itc h U p p e r B e aring C o n tro l S u p p o rt S w itc h S crew C o n tro l Lever H o u s in g W a sh e r W a sh e r S h ift Lever H o u s in g P ivot Pin Sleeve S h ift Lever Knob S h a ft B u s h in g Seat 296 304. 305. 306. 307. 308. 309. S h ift Tube Ja c k e t B o lts W a sh e r W a sh e r N ut 310. 311. 312. 313. 314. C la m p B o lt Spacer Lever A d ju s tin g Pin A n d B e a rin g A s s e m b ly 315. 316. 317. 318. 319. 320. 321. S p rin g C la m p B o lt W a sh er N ut Seal C over B-07423 Figure 49—Standard Steering Column—P(42) Model STEERING COLUMN 3B4-41 304 A. 32 ± 0.5 m m (1.26 ± 0.02 inch) B-07424 Figure 50—Lower Bearing Adjustment A. 8.4 to 9.1 m m (0.33 to 0.36 inch ) B. A d ju s tin g R ing C. S h ift Lever Install or Connect (Figure 49). NOTICE: For step 3 see “ N o tic e ” on page 3B4-1. B-07426 Figure 52—Shift Tube Adjustment—Automatic Transmission 1. New upper bearing (289). 2. Cancelling cam (286). 3. S te e rin g w h e e l. R e fe r to Replacem ent” in this section. “ S te e rin g W heel 2. Clamp (316), bolt (317), washer (318) and nut (319). Maintain the clearance dimension shown in figure 50. Tighten LOWER BEARING REPLACEMENT 4-+ Remove or Disconnect (Figure 49) 1. Intermediate steering shaft. Refer to “ Intermediate Shaft Replacement” in this section. 2. Nut (319), washer (318), bolt (317) and clamp (316). • Nut to 14 N m (10 ft. lbs.). 3. Intermediate shaft. Refer to “ Intermediate Shaft R eplacem ent” in this section. STEERING COLUMN LOWER BEARING ADJUSTMENT 3. Bearing assembly (315, 314). |-n-| Install or Connect (Figures 49 and 50) NOTICE: For steps 2 and 3 see “ N otice” on page 3B4-1. 1. New adjusting ring and bearing assembly (314, 315). 1. Loosen clam p bolt (317). 2. Apply 222 N (50 lbs.) force to the steering wheel end of the steering shaft. 3. Adjust the clam p 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 clam p bolt (317). 3. Rotate the adjusting ring to give a 0.13 mm (0.005 inch) end play between the adjusting ring and first and reverse lever (figure 51). & Tighten 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 “ N eutral” or “ D rive.” 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 52). Figure 51—Shift Tube Adjustment— 3 Speed Manual Transmission Q Tighten • Adjusting ring bolt to 8 N m (70 in. lbs.). 3B4-42 STEERING COLUMN STANDARD STEERING COLUMN UNIT REPAIR P(42) MODELS ++ Remove or Disconnect Steering colum n assembly. Refer to “ Standard Steering Column Replacem ent” (P42 Model) in this section. Disassemble (Figure 49) • Slide the steering shaft assembly from the lower end of the steering column. 1. Lower bearing bolt (317), washer (318), nut (319), clam p (316) and spring (315). 2. Back-up lamp switch. 3. Pivot pin (297) and shift lever (299). 4. Cancelling cam (286). 5. Conrol lever screw (291) and lever (292). 6. Column wiring harness cover. 7. Turn signal switch screws (287). 8. Housing (293). Rotate the housing counterclock­ wise. • The housing and switch cannot be completely removed from the column until the shift lever housing is removed. 9. Washer assembly (294, 295) and shift lever housing (296) (or extension housing) from the column. • Separate the turn signal switch, switch control sup­ port assembly, turn signal housing and shift lever housing (or housing extension) assemblies. 10. Upper bearing (289). Press the bearing out of the switch contact support (290). 11. Bushing (302) and seat (303). 12. Bolts (306), washers (307, 308) and adjusting ring clam p (310). 13. Adjusting ring and bearing (314) assembly. • Press the bearing out of the adjusing ring. 14. First-reverse shift lever and spacer (3-Speed Col­ umn). 15. Selector plate clam ping screws (Autom atic Col­ umns). • Place the column upright on the floor, supporting it with two pieces of wood. Place a block of wood on the upper end of the shift tube. Press down on the shift lever with foot while tapping on the wood block to withdraw the tube from the column jacket. NOTICE: In some tolerance stack-up cases it may be necessary to use a press. Be careful not to damage the tube or jacket. 16. Seal (320) and cover (321). 17. Cover (279), seal (278) and clam p from steering col­ umn jacket (305). Assemble (Figure 49) • Apply a thin coat of lithium grease to all friction sur­ faces. 1. Clamp, seal (278) and cover (279) over the end of the jacket (305). • Apply lithium grease to all bearing surfaces on the shift tube. 2. Seal (320) onto the shift tube and place the shift tube in the jacket. • Temporarily install the spacer, first-reverse shift lever and lower adjusting ring. Place a block of wood on top of the adjusting ring and tap until the shift tube bottoms. Remove the adjusting ring, shift lever and spacer (3-Speed Columns). • Align the three holes in the selector plate with the three holes in the jacket. Position the clam ping ring and install the three screws. The shift tube spring retainer must bottom against the jacket stops (Auto­ m atic Columns). • Lubricate and install the spacer and first-reverse shift lever. The tang of the lever is toward the top of the column (3-Speed Column). 3. Bearing in the adjusting ring (314). 4. Adjusting ring and bearing (314) assembly, clamp (310), washers (308, 307) and bolts (306). 5. Seat (303) and bushing (302) to the upper end of the housing. • T hread the tu rn sign al sw itch w irin g harness through the switch and lever (or extension) housing. • Lubricate the inner diam eter of the shift housing. 6. Shift lever (or extension) housing onto the upper end of the column. 7. Washer assembly (295, 294). 8. Upper bearing into the switch contact support. 9. Turn signal switch housing (293), contact support, bearing, switch and switch screws. Tighten screws to 2.8 N-m (25 in. lbs.). 10. W iring harness cover and back-up lamp switch. 11. Control lever (292) and the gear shift lever (299). Adjust • Shift tube. Refer to “ Shift Tube A djustm ent” in this section. 12. Spring (315), clamp (316), bolt (317), washer (318) and nut (319). Tighten the bolt finger tight. • Slide the steering shaft assem bly up through the column assembly. -►+ Install or Connect Steering colum n assembly. Refer to “ Standard Steering Column R eplacem ent” in this section. STEERING COLUMN 3B4-43 INTERMEDIATE SHAFT UNIT REPAIR P(42) MODELS Figure 53—Intermediate Shaft—P(42) Model ♦♦ Remove or Disconnect Intermediate shaft. Refer to ‘Intermediate Shaft Replacem ent” in this section. Disassemble (Figure 54) • If the upper and lower half of the intermediate shaft is to be replaced, preceed as follows: • Place the intermediate shaft (320) on a bench and straighten the tangs on the dust cap (329). Separate the upper and lower portions of the shaft assembly. 1. Dust cap (329) and dust seal (328). • If the trunnion assembles are to be replaced, pro­ ceed as follows: 2. Bearing cups (325). • Support the yoke on a bench vise and drive out one bearing cup by tapping on the oppo­ site bearing cup. Use a soft drift and hammer. • Support the other side of the yoke and drive out the remaining bearing cups, as described in the previous step. 3. Trunnion (326) from the yokes (324, 327). 4. Trunnion (326) from the yokes, (331, 330). * Assemble (Figure 53) • If the yoke trunnions were removed, assemble as follows: 1. Trunnion (326) into the yokes (331, 330). 2. Trunnion (326) into the yokes (327, 321). 3. Bearing cups (325) into the yokes. • Reassemble the intermediate shaft assem bly as fol­ lows: 4. Dust cap (329) and dust seal (328) over the shaft of the lower yoke (330) assembly. • Align the arrow on the lower yoke assembly shaft with the arrow on the upper yoke assembly tube and push the two assemblies together. • Push the dust seal (328) and dust cap (329) into position on the lower end of the upper yoke assem­ bly and bend the tangs of the dust cap down against the yoke tube. ++ Install or Connect Intermediate shaft. Refer to “ Intermediate Shaft Re­ placem ent” in this section. 3B4-44 STEERING COLUMN SPECIFICATIONS Turn Signal Switch Attaching S c re w s .................................................................. Ignition Switch Attaching S c re w s ......................................................................... Dimmer Switch Attaching S cre w s......................................................................... Steering Wheel N u t ................................................................................................. Flexible Coupling Clamp B o lt ............................................................................... Flexible Coupling To Flange Bolt N u ts ................................................................ Steering Gear To Frame Bolts (C, K And G M o d e ls )........................................ Steering Gear To Frame Bolts P300 (32, 42) F S 3 ............................................ Steering Gear To Frame Bolts P200 & 300(42) Excluding F S 3...................... Upper Intermediate Shaft Pinch Bolt (G M odel)................................................. Lower Intermediate Shaft Pinch Bolt (G M odel)................................................. Intermediate Shaft Pinch Bolt P300 (42) FS3..................................................... Intermediate Shaft Pinch Bolt P200 & 300(42) Excluding F S 3 ...................... Steering Column Support Bracket Screws (C, K And G M o d e ls ).................. Steering Column Support Bracket Clamp Nuts (P M odels)............................. Steering Column Shaft To Intermediate Shaft (Pot Joint) A s se m b ly............. N-m 4.0 4.0 4.0 40 42 27 102 108 95 47 62 108 102 30 25 60 Ft. Lbs. 30 31 20 75 80 70 35 46 80 75 22 18 44 In. Lbs. 35 35 35 STEERING COLUMN 3B4-45 SPECIAL TOOLS J-1859-03 2 | J - 2 6 1 9 - 0 1 J-5822 6 J-22727 7 J-23072 8 J-23073-01 J-21854-01 J-23653-A J-22635 1. 2. 3. 4. 5. C ra n k s h a ft F ro n t C ove r O il Seal P u lle r S lid e H a m m e r W o rm B e aring A d ju s te r C u p P u lle r P ivo t Pin R em ove r L ock S hoe and R elease Lever Pin R em ove r and In s ta lle r 6. 7. 8. 9. Figure 54—Special Tools T erm in al R em ove r S h ift Tube R em ove r S h ift, Tube In s tlle r L o c k P late C o m p re s s o r F-02652 3B4-46 STEERING COLUMN 3C-1 SECTION 3C FRONT SUSPENSION 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 term inology “ NOTICE: Refer to ‘Notice’ on page 3C-1 of this sec­ tio n .” NOTICE: All front suspension 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 num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention o f these parts. CONTENTS SUBJECT PAGE General Description....................................................................................................................................................... 3C- 2 Diagnosis of Front S uspension.................................................................................................................................. 3C- 2 Shock Absorber Bench T e st.................................................................................................................................... 3C- 3 Diagnosis of Wheel Bearings...................................................................................................................................... 3C- 3 On-Vehicle Service: Independent Front Suspension............................................................................................... 3C- 8 Shock Absorber......................................................................................................................................................... 3C- 8 Stabilizer B a r ............................................................................................................................................................. 3C- 8 Wheel Hub/Rotor A ssem bly.................................................................................................................................... 3C- 8 Wheel Bearing Adjustm ent...................................................................................................................................... 3C-13 Wheel Hub B o lt ......................................................................................................................................................... 3C-15 Steering K nuckle....................................................................................................................................................... 3C-15 Coil S p rin g ................................................................................................................................................................. 3C-17 Lower Ball J o in t......................................................................................................................................................... 3C-17 Upper Ball J o in t......................................................................................................................................................... 3C-19 Lower Control Arm Pivot Shaft and B u sh in g s..................................................................................................... 3C-20 Upper Control Arm Pivot Shaft and B u sh in g s ..................................................................................................... 3C-23 Lower Control Arm ...................................................................................................................................................3C-24 Upper Control Arm ..................................................................................................................................................... 3C-25 Suspension U nit......................................................................................................................................................... 3C-26 On-Vehicle Service: I-Beam (RPO FS3) Front Suspension.....................................................................................3C-28 Shock Absorber........................... ..............................................................................................................................3C-28 Stabilizer B a r ............................................................................................................................................................. 3C-30 Wheel Hub/Rotor A ssem bly.....................................................................................................................................3C-31 Wheel Bearing A djustm ent...................................................................................................................................... 3C-32 Wheel Hub B o lt ......................................................................................................................................................... 3C-33 Steering Arm, Knuckle and Spindle........................................................................................................................ 3C-33 Front A xle ................................................................................................................................................................... 3C-34 Leaf Springs............................................................................................................................................................... 3C-34 On-Vehicle Service: Four Wheel Drive Front Suspension....................................................................................... 3C-36 Shock Absorber......................................................................................................................................................... 3C-36 Stabilizer B a r ............................................................................................................................................................. 3C-36 Wheel Hub/Rotor A ssem bly.................................................................................................................................... 3C-36 Bearing Adjustm ent...................................................................................................................................................3C-37 Wheel Hub B o lt .........................................................................................................................................................3C-41 S p in d le ....................................................................................................................................................................... 3C-41 Steering Knuckle and A r m ..................................................................................................... ................................ 3C-45 Ball Joints (V10/1500 and 20/2500 Models O n ly)................................................................................................. 3C-48 Leaf Spring And B u s h in g s ...................................................................................................................................... 3C-49 S p e c ific a tio n s............................................................................................................................................................... 3C-51 End P la y ..................................................................................................................................................................... 3C-51 Fastener Torque......................................................................................................................................................... 3C-51 Special T o o ls ................................................................................................................................................................. 3C-53 3C-2 FRONT SUSPENSION GENERAL DESCRIPTION An independent suspension is standard on the R-G-P model vehicles. This suspension features unequal length control arms (the lower control arm is the load carrying member), coil springs and shock absorbers to reduce vi­ bration and shock load, plus a stabilizer bar to control sway or roll. Air cylinders inside coil springs are available to minimize “ crash through” on large road bumps. A special heavy duty front suspension is available on P model vehicles. This suspension (RPO FS3), centered around a solid I-beam axle, includes leaf springs, shock absorbers, and a stabilizer bar. The V model (four wheel drive) suspension includes leaf springs, shock absorbers, and a stabilizer bar. DIAGNOSIS OF FRONT SUSPENSION PROBLEM Hard Steering POSSIBLE CAUSE 1. Ball joints and steering linkage need lu­ brication. 2. Low or uneven front tire pressure. 3. Incorrect front wheel alignm ent (manual steering). Poor Directional Stability 1. Ball joints and steering linkage need lu­ brication. 2. Low or uneven front or rear tire pressure. 3. 4. 5. 6. 7. Front Wheel Shimmy (Smooth Road Shake) Vehicle Pulls To One Side (No Braking Action) Noise In The Front End Loose wheel bearings. Incorrect front wheel alignm ent (caster). Broken springs. M alfunctioning shock absorber. Broken stabilizer bar or a missing link. 1. Tire and wheel are out of balance or out of round. 2. Worn or loose wheel bearings. 3. Worn ball joints. 4. M alfunctioning shock absorber. 1. Low or uneven tire pressure. 2. Front or rear brakes dragging. 3. Broken or sagging front spring. 4. Incorrect front wheel alignm ent (cam­ ber). 1. Ball joints and steering linkage need lu­ brication. 2. Loose shock absorber or worn bushings. 1. Lubricate the ball joints and linkage. 2. Inflate tires to the recommended pres­ sure. 3. Check and align the front suspension. 1. Lubricate the ball joints and linkage. 2. Inflate tires to the recommended pres­ sure. 3. Adjust the wheel bearings. 4. Check and align the front suspension. 5. Replace the springs. 6. Check and replace the shock absorber. 7. Replace the stabilizer bar or link. 1. Balance the tires, check run-out. 2. Adjust the wheel bearings. 3. Replace the ball joints. 4. Check and replace the shock absorber. 1. Inflate the tires to the recommended pressure. 2. Adjust the brakes. 3. Replace the spring. 4. Check and align the front suspension. 6. Loose wheel nuts. 7. Spring is improperly positioned. 8. Loose suspension bolts. 1. Lubricate at the recommended inter­ vals. 2. Tighten the bolts or replace the shock absorber. 3. Replace the bushings. 4. Adjust or replace the wheel bearings. 5. Tighten all the stabilizer bar attach­ ments. 6. Tighten the wheel nuts. 7. Reposition the spring. 8. Tighten to specifications or replace. 1. 2. 3. 4. 1. 2. 3. 4. 3. Worn control arm bushings. 4. Worn or loose wheel bearings. 5. Loose stabilizer bar. Wheel Tramp CORRECTION Tire and the wheel are out of balance. Tire and the wheel are out of round. Blister or bump on the tire. Improper shock absorber action. Balance Replace Replace Replace the the the the wheels. tire. tire. shock absorber. FRONT SUSPENSION 3C-3 DIAGNOSIS OF FRONT SUSPENSION (CONT.) E xcessive o r U neven T ire W ear C upped T ires 1. Inflate the tire to the recom m ended pressure. 2. Adjust toe-in setting. 3. Balance the wheels. 4. Follow proper driving techniques. 5. Do not exceed the maximum recom­ mended payload rating. 1. Underinflated or overinflated tires. 2. 3. 4. 5. S cu ffe d Tires CORRECTION POSSIBLE CAUSE PROBLEM Im proper toe-in. W heels are out of balance. Hard driving. Overloading the vehicle. 4. Suspension arm is bent or twisted. 1. Adjust toe-in setting. 2. Follow proper driving techniques. 3. Inflate the tires to the recommended pressure. 4. Replace the suspension arm. 1. Front shock absorbers are defective. 2. Worn ball joints. 3. Wheel bearings are incorrectly adjusted or worn. 4. Wheel and tire is out of balance. 5. Excessive tire or wheel runout. 1. Replace the shock absorbers. 2. Replace the ball joints. 3. Adjust or replace the wheel bearings (also replace the races). 4. Balance the wheel and tire. 5. Check and compensate for runout. 1. Toe-in is incorrect. 2. Excessive speed on turns. 3. Tires are improperly inflated. SHOCK ABSORBER BENCH TEST SPIRAL GROOVE SHOCK ABSORBERS 1. Purge the air from the pressure chamber. • Extend the shock vertically—top end up. • Turn the sh o ck o ver and c o lla p s e it vertically—top end down. • Repeat the above step five times. 2. Place the shock absorber in a vise with the jaws clamped onto the shock’s bottom mount. — Shock absorber should be positioned vertically in the vise—top end up. — Do not clamp the vise Jaws on the shock’s reservoir tube. 3. Pump the shock absorber at various rates of speed and observe the rebound force. — Rebound force is normally stronger than the compression force (approximately two to one). — Rebound force should be smooth and constant for each stroke rate. 4. Compare with a good shock absorber. 5. If one of the following are observed, replace the shock absorber. — A skip or lag at reversal near mid-stroke. — A seize (except at the extreme ends of travel. — A noise (grunt or squeal) after completing one full stroke in both directions. — A clicking noise at fast reversal. NON-SPIRAL GROOVE SHOCK ABSORBERS • Purging air from non-spiral groove shock absorbers is not necessary. The shock absorbers have a gas filled cell in their reservoirs (as opposed to the air filled cell in the spiral groove shock absorber reservoirs). 1. Place the shock absorber in a vise with the jaws clamped on the shock absorber’s top mount. — Shock absorber should be held vertically in the vise with its bottom end up. — Do not clamp the vise jaws on the shock’s reservoir tube.I 2. Pump the shock absorber at various rates of speed and observe the rebound force. — Rebound force is normally stronger than the compression force (approximately two to one). — Rebound force should be smooth and constant for each stroke rate. 3. Compare with a good shock absorber. 4. If one of the following are observed, replace the shock absorber. — A skip or lag at reversal near mid-stroke. — A seize (except at the extreme ends of travel). — A noise (grunt or squeal) after completing one full stroke in both directions. — A clicking noise at fast reversal. DIAGNOSIS OF WHEEL BEARINGS When diagnosing bearing condition, keep in mind the general condition of all parts during disassem bly and inspection. Use Figures 1, 2, 3 and 4 to classify the failure, and follow the recommended repair procedures. 3C-4 FRONT SUSPENSION ABRASIVE ROLLER WEAR ABRASIVE STEP WEAR Pattern on race s and ro lle rs ca u se d by fin e abrasives. C lean all p a rts and h o u s in g s , c h e c k se a ls and b e a rin g s a nd re p la c e if le a k in g , ro u g h o r noisy. Pattern on ro lle r e n d s c a u s e d by fin e a bra­ sives. C lean all p a rts and h o u s in g s , c h e c k s e a ls and b e a rin g s and re p la c e if le a k in g , ro u g h o r noisy. GALLING ETCHING M eta l sm e a rs on ro lle r e n d s due to o verheat, lu b ric a n t fa ilu re o r o verlo a d. R ep lace b e a rin g , c h e c k se a ls and c h e c k fo r p ro p e r lu b ric a tio n . B e aring s u rfa c e s a p p e a r gray o r g ra y is h b la c k in c o lo r w ith related e tc h in g aw ay o f m a te ria l u s u a lly at ro lle r s p a c in g . R ep lace b e a rin g s, c h e c k s e a ls and c h e c k fo r p ro p e r lu b ric a tio n . B-09194 Figure 1—Diagnosis of Front Wheel Bearings FRONT SUSPENSION 3C-5 BENT CAGE BENT CAGE C age d a m a g e d due to im p ro p e r h a n d lin g o r C age d a m a g e d d u e to im p ro p e r h a n d lin g o r to o l usage. R ep lace b e a rin g. to o l usage. R ep lace b e a rin g . CAGE WEAR INDENTATIONS W ear a ro u n d o u ts id e d ia m e te r o f cage and ro lle r p o c k e ts ca use d by a b ra sive m a te ria l and in e ffic ie n t lu b ric a tio n . C lean related p arts and h o u s in g s . C h e c k se a ls and rep la ce b e a rin g s. S u rfa c e d e p r e s s io n s o n ra c e a n d r o lle r s c a u se d by hard p a rtic le s o f fo re ig n m a te ria l. C lean all p a rts and h o u s in g s . C h e c k s e a ls and rep la ce b e a rin g s if rou gh o r noisy. B-09195 Figure 2—Diagnosis of Front Wheel Bearings 3C-6 FRONT SUSPENSION FRETTAGE SMEARS C o rro s io n se t up by sm a ll relative m o ve m e n t o f p a rts w ith no lu b ric a tio n . R eplace b e a rin g . C lean related parts. C h e ck se als and c h e c k fo r p ro p e r lu b ric a tio n . S m e a rin g o f m eta l d ue to s lip p a g e . S lip p a g e c a n be c a u s e d by p o o r f it s , lu b r ic a tio n , o v e rh e a tin g , o v e rlo a d s o r h a n d lin g dam age. R e p la ce b e a rin g s , c le a n re la te d p a rts and c h e c k fo r p ro p e r fit and lu b ric a tio n . STAIN DISCOLORATION HEAT DISCOLORATION D is c o lo ra tio n can range fro m lig h t brow n to b la ck ca u se d by in c o rre c t lu b ric a n t o r m o is ­ ture. Re-use b e a rin g s if s ta in s can be rem oved by lig h t p o lis h in g o r if no e vid e n ce o f o ve rh e a t­ ing is o bse rve d . H eat d is c o lo ra tio n can range fro m fa in t y e l­ low to d ark b lu e re s u ltin g fro m o ve rlo a d o r in c o rre c t lu b ric a n t. E xce ssive heat can ca u s e s o fte n in g o f races o r rollers. To c h e c k fo r lo s s o f te m p e r on C h e ck se a ls and related p a rts fo r dam age. races o r ro lle rs a s im p le file te s t m ay be m ade. A file d ra w n o ver a te m p e re d part w ill grab and c u t m e ta l, w he re a s, a file d ra w n over a hard part w ill g lid e re a d ily w ith no m eta l c u ttin g . R eplace b e a rin g s if o ver h e a tin g d am ag e is in d ic a te d . C h e c k se a ls and o th e r parts. B-00531 Figure 3—Diagnosis of Front Wheel Bearings FRONT SUSPENSION 3C-7 MISALIGNMENT CRACKED INNER RACE O u te r race m is a lig n m e n t d ue to fo re ig n o b ­ Race cra c k e d d u e to im p ro p e r fit, c o c k in g , o r p o o r b e a rin g seats. R eplace b e a rin g and c o rre c t b ea rin g seats. je c t. C lean related p a rts and rep la ce b e a rin g. M ake su re races are p ro p e rly seated. BRINELLING FATIGUE SPALLING F la k in g o f su rfa c e m e ta l re s u ltin g fro m tig u e . R ep lace b ea rin g, cle a n all related parts. fa ­ S u rfa c e in d e n ta tio n s in racew ay ca u s e d by ro lle rs e ith e r u n d e r im p a c t lo a d in g o r v ib ra ­ tio n w h ile th e b e a rin g is n o t ro ta tin g . R eplace b e a rin g if rou gh o r noisy. B-09860 Figure 4—Diagnosis of Front Wheel Bearings 3C-8 FRONT SUSPENSION ON-VEHICLE SERVICE: INDEPENDENT FRONT SUSPENSION SHOCK ABSORBER Remove or Disconnect (Figures 5, 6, 7, 8, and 9) • Raise the vehicle on a hoist. 1. Shock absorber (20) from the lower control arm. • Nuts (23), washers (22) and bolts (21) (Figure 9). 2. Shock absorber (20) from the frame. • Nuts (16), washers (17), and bolts (21) (Figure 9). If Inspect • Shock absorbers for damage and leaking. • Test the shock absorbers. Refer to “ Shock Absorber Bench Test” in this section. El * t i Install or Connect (Figures 5 through 9) NOTICE: Refer to this section. ‘N o tice” on page 3 C - 1 of 2. Stabilizer bar (59) to the vehicle. • Position the stabilizer bar and attach the clamps (52), bolts (54), washers (55, 57) and nuts (58). • Clamps (42), bolts (43), washers (39, 41) and nuts (38). • R and P models. — Nuts (38, 58) to 33 N m (24 ft. lbs.). • G models. — Nut (38) to 29 N-m (21 ft. lbs.). — Bolt (54) to 33 N m (24 ft. lbs.). 3. Wheel and tire assembly. Lower the vehicle. NOTICE: Refer to “ N o tice” on page 3 C - 1 of this section. 1. Shock absorber (20) onto the vehicle. • Bolts (21), washers (17, 22), and nuts (16, 23) (figure 9). Tighten • R models. — Nut (16) to 190 N m (140 ft. lbs.). — Bolt (21) to 80 N m (59 ft. lbs.). • G models. — Bolts (21) to 103 N-m (80 ft. lbs.). • P models. — Nut (16) to 190 N-m (140 ft. lbs.). — Nut (23) to 80 N-m (59 ft. lbs.). 2. Lower the vehicle. STABILIZER BAR Remove or Disconnect (Figures 5 through 8 and 10) • Raise the vehicle and support with suitable safety stands. Remove the wheel and tire assembly. 1. Stabilizer bar (59) from the frame. • Bolts (54), nuts (58), washers (55, 57) and clamps (52). 2. Stabilizer bar (59) from the lower control arm (36). • Bolts (43), nuts (38), washers (39, 41) and clamps (42). • Stabilizer bar (59) drops down— remove the bushings (40, 53). I* 0 Inspect Rubber bushings (40, 53) for excessive wear, a g in g , o r o th e r d a m a g e . R e p la c e as necessary. * i l Install or Connect (Figures 5 through 10) 1. Bushings (40, 53) to the stabilizer bar (59). • Slit on the insulator faces forward. • Use rubber lubricant to ease the installation. 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. B o lt W a sh e r N ut B o lt W a sh e r B o lt W a sh er R e in fo rc e m e n t B ra cke t N ut R ivet F ittin g U p p e r B all J o in t N ut C o tte r Pin N ut W a sh e r S h im Pack S pacer S h o c k A b s o rb e r B o lt W a sh e r N ut N ut R e ta in e r B u s h in g N ut U p p e r C o n tro l A rm P ivo t S h a ft Bum per S te e rin g K n u c k le C o il S p rin g Bum per C o tte r Pin N ut 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. L o w e r C o n tro l A rm L o w e r Ball J o in t N ut W asher B u s h in g W asher B ra c k e t B o lt U -B o lt R ivet B u s h in g B ra c k e t W asher N ut P ivo t S h a ft R ivet B ra cke t B u s h in g B o lt W asher B ra cke t W asher N ut S ta b iliz e r Bar B o lt W a sh e r W a sh e r N ut B race B o lt W asher N ut Seal A ir C y lin d e r B-07469 Figure 5—R-G-P Models Front Suspension FRONT SUSPENSION 3C-9 67 66 64 63 B-07466 Figure 6—R Model Front Suspension Components 3C-10 FRONT SUSPENSION Figure 7—G Model Front Suspension Components FRONT SUSPENSION 3C-11 Figure 8—P Model Front Suspension Components 3C-12 FRONT SUSPENSION WHEEL HUB/ROTOR ASSEMBLY 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. R em ove o r D is c o n n e c t (F ig u re s 5 th ro u g h 8, and 11) • Raise the vehicle and support it with suitable safety stands. Remove the wheel and tire assembly. 1. Caliper. Refer to BRAKES (SEC. 5). NOTICE: Support the caliper with a piece of wire to prevent damage to the brake line. 2. Wheel Hub/Rotor (81) • Dust cap (79). • Cotter pin (80), nut (78), and washer (77). • Pull the hub/rotor free, making sure the outer wheel bearing (76) comes free of the hub/rotor. • Do not damage the steering knuckle (70) spindle threads. 3. Inner wheel bearing (73). • Pry out the seal (72). 4. Races (75, 82). • Drive out each race using a brass drift inserted behind the race in notches in the hub. )QI Clean 1. Grease from the hub/rotor (81) and steering knuckle spindle. • Remove grease from inside the hub. 2. Grease from the wheel bearings (73, 76) and races (72, 75). • Use clean solvent and a small brush (no loose bristles). • Do not spin the wheel bearings with compressed ai'r to dry them—the wheel bearings may be damaged. Inspect 1. Wheel bearings (73, 76) and their races (72, 75) for damage or wear. • Refer to “ Diagnosis of Wheel Bearings,” in this section. • If either a bearing or its race is damaged or worn, replace both. 2. Hub/rotor for damage. • Out-of-round or scored conditions. • Pitting or cracks. -►+ Install or Connect (Figures 5 through 8, 11 and 12) Tools Required: J-8092 Driver Handle J-8457 Wheel Bearing Race Installer J-8849 Wheel Bearing Race Installer J-9746-02 Hub/Rotor Support NOTICE: Start the races squarely inside the h u b /ro to r to avoid d isto rtio n and p o ssible 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. 9 Im portant • Use an approved high-tem perature front wheel bearing grease to lubricate the bearings. Refer to MAINTENANCE AND LUBRICATION (SEC. OB). • Do not mix different greases as mixing may change th e g re a s e ’s p ro p e rtie s r e s u ltin g in p o o r performance. 2. Apply a thin film of grease to the steering knuckle spindle at the outer wheel bearing seat and at the inner wheel bearing seat, shoulder, and seal seat. 3. Put a small quantity of grease inboard of each wheel bearing dust cap (79). NOTICE: Failure to com pletely pack the wheel bearing (cones, rollers, and cage) with grease will result in premature wheel bearing damage and/or wear. 4. Fill each wheel bearing (cone and roller assembly) full of grease. • Use a cone-type grease machine that forces grease into the bearing. • If a cone-type grease machine is not available, pack the wheel bearing by hand. • When packing the wheel bearing by hand, work the grease into the bearings between the rollers, cones, and the cage. 5. Inner wheel bearing (73) into the hub/rotor (81). • Put an additional quantity of grease outboard of this bearing. 6. New seal (72). • Use a flat plate or block to install the seal to insure it is flush with the hub/rotor flange. • Lubricate the seal lip with a thin layer of grease. 7. Hub/rotor (81). • Do not damage the steering knuckle spindle threads. 8. Outer wheel bearing (76). • Slide it over the spindle until the wheel bearing (76) fully seats against the hub/rotor outer race (75). NOTICE: Refer to “ N o tice” on page 3 C - 1 of this section. 9. Washer (77), nut (78), and cotter pin (80). • Do not place the cotter pin through the hole in the spin dle u n til the w heel b ea rin gs are adjusted. Tighten • Nut (78) to 16 N m (12 ft. lbs.) while turning the hub/rotor assembly in either direction. 10. Put an additional quantity of grease outboard of the wheel bearing (76). 11. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment,” in this section. FRONT SUSPENSION 3C-13 21 B. G S e rie s 16. N u t 17. W a sh e r 20. S h o c k A b s o rb e r 21. B o lt 22. W a sh e r 23. N u t B-07473 Figure 9—Shock Absorber Attachment Points 12. Dust cap (79) on the hub/rotor (81). 13. Caliper. Refer to BRAKES (SEC. 5). 14. Tire and wheel assembly and lower the vehicle. be a slip fit on the spindle and the inside diameter of the wheel bearing must be lubricated to ensure the bearings will creep. The spindle nut (78) must have a free-running fit on the spindle threads. WHEEL BEARING ADJUSTMENT | j | Important • The proper functioning of the front suspension cannot be m aintain ed unless the fro n t w heel bearings are correctly adjusted. The bearings must 38. 39. 40. 41. 42. 43. 52. 53. 54. 55. 57. 58. 59. N O T IC E : N e v e r p r e lo a d th e fr o n t w h e e l bearings. Damage can result by the steady thrust on the roller ends which comes from preloading. N ut W a sh e r B u s h in g W a sh e r C la m p B o lt C la m p B u s h in g B o lt W a sh e r W a sh er N ut S ta b iliz e r Bar B-07475 Figure 10—Stabilizer Bar Attachment Points 3C-14 FRONT SUSPENSION 78 70. 71. 72. 73. 74. 75. S te e rin g K n u c k le S h ie ld Seal In n e r W h e e l B e a rin g W h e e l H u b B o lt O u te r Race 76. 77. 78. 79. 80. 81. O u te r W h e e l B e aring W a sh er N ut D u st C ap C o tte r Pin W h e e l H u b /R o to r 79 82. 83. 84. 85. B-07470 Figure 11—Steering Knuckle and Hub Components A djust • Raise the vehicle and support it with suitable safety stands under the lower control arms. 1. Remove the dust cap (79) from the hub/rotor (81). 2. Remove the cotter pin (80). Q Tighten • Nut (78) to 16 N-m (12 ft. lbs.) while rotating the wheel and tire assembly (this will seat the bearings). 3. Back off the nut (78) to the “ just loose” position. 4. Hand tighten the nut (78). 5. Back off the nut (78) until the hole in the spindle lines up with a slot on the nut. • Do not back off more than 1/2 of a flat. 6. New cotter pin (80). • Make sure the bent ends do not interfere with the dust cap (79). $ Measure • Endplay in the hub/rotor assem bly (81). • It should measure between 0.03 mm (0.0012 inches) and 0.13 mm (0.005 inches) when properly adjusted. 7. Install the dust cap (79) on the hub/rotor (81). 8. Install the wheel and tire assembly if removed and lower the vehicle. FRONT SUSPENSION 3C-15 A. W ashers B. N ut 81. H u b /R o to r Figure 14—Installing the Hub Bolts • Remove the nut and washers. 2. Hub/rotor to the vehicle. • Refer to “ Wheel Hub, Bearing and Race,” in this section. 3. Wheel and tire assembly. Lower the vehicle. STEERING KNUCKLE Remove or Disconnect (Figures 5 through 8, 15 and 16) A. Press Bars B-07729 Figure 13—Removing the Hub Bolts Tools Required: J-23742 Ball Joint Separator Important • It is recommended that the vehicle be raised and WHEEL HUB BOLT !<--►[ Remove or Disconnect (Figures 5 through 8, and 13) Tools Required: J-9746-02 Hub/Rotor Support 1. Hub/rotor from the vehicle. • 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. Install or Connect (Figures 5 through 8, and 14) NOTICE: Refer to the “ N otice” on page 3 C - 1 o f this section. 1. Wheel hub bolts (74) into the hub/rotor (81). • Place four washers onto the bolt, then fasten a nut onto the bolt until the nut bottoms on the washers (figure 14). • Tighten the nut until the bolt fully seats into the hub/rotor (81). Figure 15—Disconnecting the Upper Ball Joint 3C-16 FRONT SUSPENSION Steering knuckle (70) from the lower ball joint (37). • Use J-23742 to break the lower ball joint free from the steering knuckle (figure 16). • Lift the steering knuckle off the lower ball joint. Inspect I? 1. Tapered holes in the steering knuckle that attach to the ball joints and the tie rod end. • Remove any dirt. • If any tapered hole is out of round, deformed, or damaged in any way, replace the steering knuckle (70). 2 . Spindle for wear or damage. • The steering knuckle (70) must be replaced if the spindle is damaged or worn. N O TIC E: For step s 3 a n d 8, re fe r to the “ N o tice” on page 3 C - 1 of this section. Install or Connect (Figures 5 through 8) 0 1. Steering knuckle (70) to the lower ball joint (37). • Press the steering knuckle onto the lower ball joint (37) until it is fully seated. 2. Steering knuckle (70) to the upper ball joint (13). • Lower the upper control arm (28) to seat the upper ball joint (13) into the steering knuckle. 3. Nuts (14, 35). supported as on a twin-post hoist so that the front coil spring remains compressed, yet the wheel and steering knuckle assembly remain accessible. If a frame hoist is used, support the lower control arm with an adjustable jackstand to safely retain the spring in its curb height position. Wheel and tire assembly. Caliper. • Refer to BRAKES (SEC. 5). Hub/Rotor (81). • Refer to “ Wheel Hub, Bearing and Race,” in this section. 4. Splash shield (71). • Bolts (83) and washers (84). • Gaskets (85). 5. Steering knuckle from the tie rod end. • Refer to STEERING LINKAGE (SEC. 3B1). 6. Steering knuckle (70) from the upper ball joint (13). • Position a floor jack under the lower control arm (36) near the spring seat. • Raise the jack until it just supports the lower control arm. • Use J-23742 to break the upper ball joint free of the steering knuckle (figure 15). • Raise the upper control arm (28) to disengage the upper ball joint from the steering knuckle. Im portant Floor jack must remain under the lower control arm s p rin g s e a t d u rin g re m o v a l and installation to retain the spring and the lower control arm in position. • R10/1500, G 10/1500 and G20/2500 models. — Nut (14) to 68 N m (50 ft. lbs.). — Nut (35) to 122 N m (90 ft. lbs.). • All other models. — Nuts (14, 35) to 122 N m (90 ft. lbs.). 4. Cotter pins (15, 34). • Tighten the nuts (14, 35), if needed. Im portant 5. 6. 7. 8. • R10/1500, G10/1500 and G20/2500 models. — Nut (14), maximum torque to align the cotter pin is 122 N m (90 ft. lbs.). — Nut (35), maximum torque to align the cotter pin is 175 N m (130 ft. lbs.). • All other models. — Nuts (14, 35), maximum torque to align the cotter pin is 175 N m (130 ft. lbs.). Remove the floor jack. Gasket. Tie rod end to the steering knuckle (70). • Refer to STEERING LINKAGE (SEC. 3B1). Splash shield (71). • Washers (84) and bolts (83) in position. & Tighten • Bolts (83) to 13.5 N-m (120 in. lbs.). 4. Hub/rotor assembly. • Refer to “ Wheel Hub, Bearing and Race” in this section. 5. Caliper. • Refer to BRAKES (SEC. 5). 6. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment” in this section. FRONT SUSPENSION 3C-17 NOTICE: For steps 3, 5 and 6, refer to the “Notice” onpage3C-1 of this section. Install or Connect Connect (Figures 5 through 8 and 17) Tools Required: J-23028-02 Spring Remover 1. Coil spring (32) into position on the lower control arm (36). 2 Important • Install a chain around the coil spring and through the lower control arm as a safety precaution. CAUTION: Failure to secure J-23028 to a suitable floor jack could result in personal injury. 7. Check the front alignment and reset as required. • Refer to FRONT END ALIGNMENT (SEC. 3A). 8. Wheel and tire assembly, and lower the vehicle to the ground. 2 . Slowly lift the lower control arm into position. • Line up the front indexing hole in the shaft (50) with the crossmember attaching studs. • Do not damage the lower ball joint (37). • Use J-23028-02 bolted on a floor jack. 3. U-bolts (44), washers (48), and nuts (49). Tighten COIL SPRING |+ + | Remove or Disconnect (Figures 5 through 8, — and 17) Tools Required: J-23028-02 Spring Remover • Raise the vehicle and support it with suitable safety stands, allowing the control arms to hang free. Remove the wheel and tire assembly. 1. Shock absorber (20) at the lower end and move it aside. 2. Stabilizer bar (59) from the lower control arm (36). • Nuts (38), bolts (43), washers (41) and clamp (42). C A U T IO N : F a ilu re to s e c u re J -2 3 0 2 8 to a s u ita b le flo o r ja c k c o u ld re s u lt in p erso n a l in ju ry. 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. • Nuts (49) and washers (48). 6. Lower the control arm by slowly releasing the jack until the spring can be removed. • Do not damage the ball joint (37) by applying too much force on it. 7. Spring (32) and safety chain only after all compression is removed from the spring. • Proper maneuvering of the spring will allow for easy removal. • G 10/1500-20/2500 models to 88 N m (65 ft. lbs.). • All other m odels to 115 N-m (85 ft. lbs.). Lower the floor jack, and remove J-23028-02. Stabilizer bar (59) to the lower control arm (36). • Clamp (42), washers (41), bolts (43) and nuts (38). • Nuts (38) to 33 N-m (24 ft. lbs.). 6. Shock absorber (20) to the lower control arm (36). • Washer (22), bolt (21), and nut (23). Tighten • R models. — Bolt ( 2 1 ) to 80 N-m (59 ft. lbs.). • G models. — Bolt (21) to 103 N-m (80 ft. lbs.). • P models. — Nut (23) to 80 N m (59 ft. lbs.). 7 . Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 8. Wheel and tire and lower the vehicle. LOWER BALL JOINT Inspect (Figures 5 through 8, and 18) 1. Raise the vehicle and remove the wheel and tire assembly. Support the weight of the control arms at the wheel hub and drum. 2. Measure the distance between the tip of the ball joint stud and the tip of the grease fitting below the ball joint (figure 18). 3. Move the support to underneath the control arm allowing the wheel hub and drum to hang free. 4. Measure the distance as in Step 2. 3C-18 FRONT SUSPENSION • If the difference in measurements exceeds 2.38 mm (3/32 inches), for all models, the ball joint is worn and must be replaced. 5. If the ball joint seals are cracked, cut, or torn, replace them. *” ► Remove or Disconnect (Figures 5 through 8, and 19) Tools Required: J-23742 Ball Joint Separator J-9519-7 Ball Joint Remover J-9519-28 Ball Joint Remover J-21474-30 Ball Joint Fixture • Raise the vehicle on a hoist. If a frame hoist is used it will be necessary to support the lower control arm with a floor stand. Remove the tire and wheel assembly. 1. Cotter pin (34), nut (35), and lube fitting (12). • Loosen (two turns) but do not remove the nut (35). • Use J-23742 between the ball joint studs (figure 16). • It may be necessary to remove the caliper and wire it to the frame to gain clearance for J-23742. Refer to BRAKES (SEC. 5). • Extend J-23742 until the lower ball joint (37) breaks free from the steering knuckle (31). • Remove the nut (35) and J-23742. 3. Hub/rotor (70) and the knuckle assembly off the lower ball joint (37). • Install J-21474-13, J-9519-7, J-9519-28, and J9519-30 (figure 19). 4. Ball joint (37) from the lower control arm (36). • Install J-21474-13, J-9519-22, J-9519-16, and J-9519-10 (figure 19). • Turn the hex head screw until the ball joint is free of the lower control arm. • Remove the tools and the ball joint (37). Install or Connect (Figures 5 through 8, and 20) Figure 19—Removing the Lower Ball Joint Tools Required: J-9519-16 Ball Joint Installer J-9519-30 Ball Joint Fixture 1. Ball joint (37) into the lower control arm (36). • Start the ball joint into the control arm and install J-9519-16 and J-9519-30 (figure 20). • Position the bleed vent in the rubber boot facing inward. • Turn the hex head screw until the ball joint is seated in the lower control arm. 2. Ball joint into the steering knuckle (31). FRONT SUSPENSION 3C-19 • Mate the steering knuckle (31) to the lower ball joint (37). 3. Caliper if it was removed. • Refer to BRAKES (SEC. 5). NOTICE: Refer to “ N o tic e ” on page 3 C - 1 of this section. 4. Nut (35). Tighten • Nut (35) to 122 N-m (90 ft. lbs.). 5. Cotter pin (34). • Tighten the nut (35) if needed. Important • Maximum torque to align the cotter pin is 175 N-m (130 ft. lbs.). 5. Fitting (12). • Lubricate the ball joint (37) with recommended lubricant. 6. Tire and wheel assembly and lower the vehicle to the floor. UPPER BALL JOINT Inspect The upper ball joint (13) is spring loaded in its socket. Replace the ball joint if there is any lateral shake or if it can be twisted in its socket with the fingers. The ball joint seals for cuts or tears. Replace the ball joint if any are found. Remove or Disconnect (Figures 5 through 8, and 15) Tools Required: J-23742 Ball Joint Separator • Raise the vehicle on a hoist. If a frame hoist is used, support the lower control arm with a floor jack. 1. Cotter pin (15) from the upper ball joint (13). • Loosen the nut (14) two turns, but do not remove the nut. 2. Caliper. • Refer to BRAKES (SEC. 5). 3. Upper ball joint (13) from the steering knuckle (31). • Use J-23742 to separate the upper ball joint from the steering knuckle (figure 15). • Nut (14), and lift the upper control arm (28) free of the ball joint. 4. Ball joint (13) from the upper control arm (28). • Drill 6.35 mm (1/4 inch) deep holes in the rivet heads using a 3.175 mm (1/s inch) diameter drill bit. • Drill off the rivet heads using a 12.7 mm (V2 inch) diameter drill bit. • Punch out the rivets and remove the upper ball joint from the upper control arm. NOTICE: For steps 1 and 2 refer to the “ N otice” on page 3 C - 1 of this section. -►4- Install or Connect (Figures 5 through 8, and 21 ) Upper ball joint (13) into the upper control arm (28). • Position into the upper control arm and install four attaching bolts and nuts (A) (figure 21). • Nuts (A) to 25 N m (18 ft. lbs.). 2. Upper ball joint to the steering knuckle (31). • The upper ball joint must be fully seated into the steering knuckle. • Nut (14). Tighten • R10/1500, G10/1500 and G20/2500 models. — Nut (14) to 68 N-m (50 ft. lbs.). • All other models. — Nut (14) to 122 N-m (90 ft. lbs.). 3. Cotter pin (15). • Tighten the nut (14) if needed. Im portant • R10/1500, G 10/1500 and G20/2500 models. — Maximum torque to align the cotter pin is 122 N-m (90 ft. lbs.). • All other models. — Maximum torque to align the cotter pin is 175 N-m (130 ft. lbs.). 4. Upper ball joint grease fitting (12). 5. Grease the upper ball joint (13). • Use a recommended lubricant. 3C-20 FRONT SUSPENSION Figure 22—Removing the Lower Control Arm Bushings (R10/1500, G10/1500 and G20/2500 Models) 6. Caliper. • Refer to BRAKES (SEC. 5). 7. Tire and wheel assembly. 8. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). LOWER CONTROL ARM PIVOT SHAFT AND BUSHINGS R10/1500 SERIES MODELS — Remove or Disconnect (Figures 5, 8, 17 and 22) Tools Required: J-23028-02 Coil Spring Remover J-22717 Lower Control Arm Bushing Stake Remover J-24435-2 Lower Control Arm Bushing Spacer J-24435-3 Lower Control Arm Bushing Remover J-24435-6 Lower Control Arm Bushing Spacer J-24435-7 Lower Control Arm Bushing 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 floor 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)] inboard of the spring and into the depression of the lower control arm. Im portant • Install a chain over the upper control arm (28) inboard of the stabilizer bar (59) and outboard of the shock absorber (20). 2. Shock absorber (20) from the lower control arm (28). Figure 23— Installing the Lower Control Arm Bushings (R10/1500, G10/1500 and G 20/2500 Models) • Nut (23), washer (22), and bolt (21). 3. Stabilizer bar (59) from the lower control arm (28). • Nuts (38), washers (39, 41), clamp (42), and bolts (43). 4. Pivot shaft end nuts (24). • Loosen only, do not remove. 5. Lower control arm from the frame. • Nuts (49), washers (48), and U-bolts (44). • SLOW LY low e r th e flo o r ja c k u n til all compression is released from the spring (32). 6. Stakes on the front bushing. • Use J-22717 or an equivalent tool. 7. Bushings (46) and the pivot shaft (50) from the lower control arm (36). • Use J-24435-2, J-24435-3, J-24435-6, and J-24435-7 (figure 22). • Tighten the bolt on J-24435-7 to remove the bushing. Discard the old bushing. • The pivot shaft (50) will slide out of the lower control arm after one bushing is removed. • Leave the pivot shaft (50) inside the lower control arm (36) to remove the remaining bushing. NOTICE: For steps 3, 4, 5 and 6, refer to the “ N o tice” on page 3 C - 1 of this section. Install or Connect (Figure 5, 8 and 23) Tools Required: J-23028-02 Coil Spring Compressor J-24435-4 Lower Control Arm Bushing Installer J-24435-6 Lower Control Arm Bushing Spacer J-24435-7 Lower Control Arm Bushing Fixture 1. Bushings (46) and the pivot shaft (50). • Use J-24435-4, J-24435-6, and J-24435-7 (figure 23). • Tighten the bolt on J-24435-7 to install the bushings. • Install one bushing, then insert the pivot shaft and install the remaining bushing. • Make sure J-24435-6 is in position to prevent collapsing the control arm. FRONT SUSPENSION 3C-21 Install or Connect (Figures 6, 8, 23 and 24) 2. Stake the front bushing in at least two places. CAUTION: Failure to secure J-23028-02 to a suitable floor jack could result in personal injury. 3. Lower control arm (36) to the frame. • SLOWLY raise the floor jack until the front indexing hole in the pivot shaft (50) lines up with the crossmember attaching studs. • Do not damage the ball joint (37). • J-23028-02 is bolted to a suitable floor jack. • U-bolts (44), washers (48), and nuts (49). 1. 2. 3. 4. Tools Required: J-24435-4 Lower Control Arm Bushing Installer J-24435-6 Lower Control Arm Bushing Spacer J-24435-7 Lower Control Arm Bushing Fixture New bushing (46) using J-24435-6, J-24435-4, and J-24435-7 (figure 23). • Tighten J-24435-7 until the bushing fully seats. • The outer tube hole must be lined up so it faces to the front or forward to the staked bushing. Stake the front bushing in at least two places. Pivot shaft (50) into installed bushing. Remaining bushing (46) into the lower control arm. Tighten • U-bolt nuts (49) to 115 N-m (85 ft. lbs.). Pivot shaft end nuts (24). NOTICE; Refer to “ N otice” on page 3 C - 1 of this section. 5. Pivot shaft washers (25) and nuts (24). • Nuts (24) to 95 N-m (70 ft. lbs.). 5. Stabilizer bar (59) to the lower control arm (28). • Washers (39, 41), clamp (42), bolts (43), and nuts , (38). Tighten • Nuts (38) to 34 N-m (25 ft. lbs.). 6. Shock absorber (20) to the lower control arm (36). • Washers (22), bolt (21), and nut (23). Tighten • Nut (23) to 81 N-m (60 ft. lbs.). 7. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 8. Wheel and tire and lower the vehicle. G10/1500-20/2500 MODELS (EXCEPT 20/2500 MODELS W/6.2L DIESEL) |+-»| Remove or Disconnect (Figures 6, 8, and 22) 1. 2. 3. 4. Tools Required: J-22717 Lower Control Arm Bushing Stake Remover J-24435-2 Lower Control Arm Bushing Spacer J-24435-3 Lower Control Arm Bushing Remover J-24435-6 Lower Control Arm Bushing Spacer J-24435-7 Lower Control Arm Bushing Fixture Lower control arm. • Refer to “ Lower Control Arm,” in this section. Pivot shaft nuts (24) and washers (25). Rear bushing (46). • Place the lower control arm in an arbor press. • Press the front end of the pivot shaft (50) to remove the rear bushing. Discard the old bushing. • The pivot shaft can be removed at this time. Front bushing (46). • Stakes from the front bushing using J-22717 or an equivalent tool. • Use J-24435-7, J-24435-3, J-24435-2, and J-24435-6. • Tighten J-24435-7 until the bushing comes free. Discard the old bushing (figure 22). Tighten • Nuts (24) to 156 N m (115 ft. lbs.). 6. Lower control arm (76). • Refer to “ Lower Control Arm,” in this section. • This results with the vehicle being completely assembled and lowered to the ground. G20/2500 MODELS WITH RPO LH6/LL4 6.2L DIESEL ENGINE) Remove or Disconnect (Figures 5 through 8, and 25) Tools Required: J-24435-1 Lower Control Arm Bushing Remover J-24435-3 Lower Control Arm Bushing Remover J-24435-7 Lower Control Arm Bushing Fixture 1. Lower control arm (36). • Refer to “ Lower Control Arm ,” in this section. 2. Bushings (46) and the pivot shaft (50) from the lower control arm (36). • Use J-24435-1, J-24435-3, and J-24435-7 (figure 25). • Tighten the clamp (J-24435-7) to remove the bushing (46). • The pivot shaft can be slipped out at this time. • Repeat the procedure on the remaining bushing (46) to remove it from the lower control arm (36). Install or Connect (Figures 5 through 8, and 26) Tools Required: J-24435-4 Lower Control Arm Bushing Installer J-24435-5 Lower Control Arm Bushing Installer J-24435-7 Lower Control Arm Bushing Fixture 1. Bushings (46) and the pivot shaft (50) into the lower control arm (36). • Use J-24435-4, J-24435-5, and J-24435-7 (figure 26). • Tighten the clamp (J-24435-7) to install the bushing (26). • Slide the pivot shaft (50) into the lower control arm (36), then install the other bushing (36). 2. Lower control arm (36). • Refer to “ Lower Control Arm,” in this section. 3C-22 FRONT SUSPENSION B A. Rear End B. F ro n t End C. In s u la to rs D. In n e r P ivot S h a ft E. S h a ft Tube F. O -R ing G. W asher, C o lla r and F la n g e H. B u m p e r I. S h a ft R e s tric to r B-07514 Figure 24—Lower Control Arm Pivot Shaft (G10/1500 and G20/2500 Models w/o 6.2L Diesel) • This results with the vehicle being completely assembled and lowered to the ground. • SLOWLY lower the floor jack to access the pivot shaft (50). 5. Grease fittings (12). R-P20/2500-30/3500, G30/3500 MODELS 6. Bushings (46) and bushing seals, and pivot shaft (50). |+ + | Remove or Disconnect (Figures 5 through 8) • Raise the vehicle and support the frame so the control arms hang free. Remove the tire and wheel assembly. 1. Position an adjustable floor jack under the lower control arm (36) inboard of the spring and into the depression in the lower control arm. Important • Install a chain over the upper control arm (28) inboard of the stabilizer bar (59) and outboard of the shock-absorber (20). 2. Shock absorbers (20) from the lower control arm (36). • Nut (23), washer (22) and bolt (21). 3. Stabilizer bar (59) from the lower control arm (36). • Nuts (38), washers (39, 41), bolts (43) and clamp (42). 4. Lower control arm (36) from the frame crossmember. • Nuts (49), washer (48), and U-bolts (44). J-24435-7 • Unscrew the bushings. • Slide the pivot shaft out of the lower control arm. • Seals are mounted between the bushings and the pivot shaft. Discard the old seals. NOTICE: For steps 1, 3, 4, and 5 refer to the “Notice” onpage3C-1 of this section. ++ Install or Connect (Figures 5 through 8, and 27) 1. Pivot shaft (50), seals, and bushings (46), to the lower control arm (36). • New seals onto the pivot shaft. • Pivot shaft into the lower control arm. Attach the bushings. Center the shaft in the lower control arm (figure 27). & Tighten Bushings (46) to 379 N m (280 ft. lbs.). J-24435-7 J-24435-4 J-24435-5 (Hidden) J-24435-3 J-24435-1 B-07479 Figure 25—Removing the Lower Control Arm Bushing (G20/2500 W/6.2L Diesel) B-07481 Figure 26—Installing the Lower Control Arm Bushing (G20/2500 w/6.2L Diesel) FRONT SUSPENSION 3C-23 2.96 • 31.9 mm (1.16 -1.25 inch es) To P ro pe rly C e n te r The Pivot S h a ft 36. L o w e r C o n tro l A rm 46. B u s h in g 50. P ivot S h a ft B. B u s h in g Seal B-07478 Figure 27—Centering the Lower Control Arm Shaft (R-P20/2500, 30/3500 and G30/3500 Models) Inspect • Pivot shaft (50) for free rotation. 2. Grease fitting (12). • Lubricate the bushings with an approved grease. • Refer to MAINTENANCE AND LUBRICATION (SEC. 0B). 3. Lower control arm (36) to the frame crossmember. • SLOWLY raise the floor jack until the lower control arm (36) is in position. Important • Be sure the hole in the pivot shaft mates with the bolt head in the fram e crossm em ber saddle. U-bolts (44), washers (48), and nuts (49). Tighten • Nuts (49) to 115 N-m (85 ft. lbs.). Stabilizer bar (59) to the lower control arm (36). • Nuts (38), washers (39, 41), bolts (43), and clamp (42). Q Tighten • Nuts (38) to 33 N-m (24 ft. lbs.). Shock absorbers (20) to the lower control arm (36). • Bolt (21), washer (22), and nut (23). Tighten Figure 28—Removing the Upper Control Arm Bushings (R10/1500, G10/1500 and G20/2500 Models) UPPER CONTROL ARM PIVOT SHAFT AND BUSHINGS R10/1500, G10/1500-20/2500 MODELS Remove or Disconnect (Figures 5 through 8, and 28) Tools Required: J-24435-1 Lower Control Arm Bushing Remover J-24435-3 Lower Control Arm Bushing Remover J-24435-7 Lower Control Arm Bushing Fixture 1. Upper control arm (28). • Refer to “ Upper Control Arm ,” in this section. 2. Nuts (24), bushings (26) and the pivot shaft (29) from the upper control arm (28). • Use J-24435-1, J-24435-3, and J-24435-7 (figure 28). • Tighten J-24435-7 to remove the bushing (26). • Pivot shaft (29) can be pulled free at this time. • Repeat this procedure on the remaining bushing (26). Discard the old bushings. Install or Connect (Figures 5 through 8, and 29) Tools Required: J-24435-4 Lower Control Arm Bushing Installer J-24435-5 Lower Control Arm Bushing Installer J-24435-7 Lower Control Arm Bushing Fixture NOTICE: Refer to the “ N o tic e ” on page 3 C - 1 of this section. • R models. — Bolt (21) to 80 N-m (59 ft. lbs.). • G models. — Bolt (21) to 103 N-m (80 ft. lbs.). • P models. — Nut (23) to 80 N-m (59 ft. lbs.). Remove the safety chain and the floor jack. Install the tire and wheel assembly and lower the vehicle to the ground. 1. Bushings (26) and the pivot shaft (29) into the upper control arm (28). • Use J-24435-4, J-24435-5, and J-24435-7 (figure 29). • Tighten the clamp (J-24435-7) to install the bushing (26). • Slide the pivot shaft (29) into the upper control arm (28), then install the other bushing (26). 3C-24 FRONT SUSPENSION |-n-| Install or Connect (Figures 6 through 8, and — 30) 1. Pivot shaft (29), seals, and bushings (26) onto the upper control arm (28). • New inner seals onto the pivot shaft. • Slide the pivot shaft into position inside the upper control arm. Screw on the new bushings. Do not tighten. 9 Im portant The pivot shaft (29) must be centered in the upper control arm (28) as shown in figure 30. Tighten Bushings (26) to 257 N-m (190 ft. lbs.). L* Figure 29—Installing the Upper Control Arm Bushings (R10/1500, G10/1500 and G20/2500 Models) Inspect • Pivot shaft for free rotation. 2. Grease fitting (12). • G rease the b u s h in g s (29). R efer to MAINTENANCE AND LUBRICATION (SEC. 0B). • Nuts (24) in place. Tighten • Nuts (24) to 156 N-m (115 ft. lbs.). Upper control arm (28) to the crossmember. • Refer to “ Upper Control Arm,” in this section. Caliper if it was removed. • Refer to BRAKES (SEC. 5). 4. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 5. Remove the supports and lower the vehicle to the ground. R-P20/2500-30/3500, G30/3500 MODELS Remove or Disconnect (Figures 5 through 8) • Raise the vehicle and support the lower control arms with a floor jack positioned under or near the ball joint assembly. Remove the wheel and tire assembly. 1. Loosen, but do not remove the pivot shaft to frame nuts (27). 2. Shim packs (18). • Tape each pack together and mark their position to assure exact replacement during installation. 3. Pivot shaft to frame nuts (27), bolts (4), and spacers (19). • Do not allow the upper control arm (28) to swing too far from the frame crossmember. Im portant • Install a chain over the upper control arm (28) inboard of the stabilizer bar (59) and outboard of the shock absorber (20), to retain the upper control arm in a close relationship to the frame crossmember. 4. Pivot shaft (29) and bushings (26). • Grease fitting (12). • Unscrew the bushings (26). • Slide the pivot shaft out of the upper control arm. Remove and discard the inner seals (between the bushings and the pivot shaft). NOTICE: Refer to the “ Notice” on page 3C-1 of this section. 3. Pivot shaft (29) to the frame. • Bolts (4), shim packs (18), spacers (19), and nuts (27). • Shims are positioned into their original positions. Make sure the convex and concave sides of the shims are together. Tighten • Nuts (27) to 142 N-m (105 ft. lbs.). 4. Remove the safety chain and install the wheel and tire assembly. 5. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 6. Lower the vehicle to the ground. LOWER CONTROL ARM ++ • 1. 2. 3. 4. Remove or Disconnect (Figures 5 through 8, and 16) Tools Required: J-23742 Ball Joint Separator Raise the vehicle and support it with suitable safety stands. Remove the wheel and tire assembly. Caliper. • Refer to BRAKES (SEC. 5). Coil spring (32). • Refer to “ Coil Spring,” in this section. • The lower control arm is separated from the frame. Use a jack to support the inboard end of the lower control arm (36). Lower control arm (36) from the steering knuckle (31). • Cotter pin (34), then loosen the nut (35) one turn. • Install J-23742, with the large cup end over the upper ball joint nut (14). Extend threaded end until the ball joint stud loosens from the steering knuckle. Remove J-23742 and the nut (35). FRONT SUSPENSION 3C-25 Install or Connect (Figures 5 through 8) 1. Lower control arm (36) to the steering knuckle (31). • Position the lower control arm ball joint stud (37) into the steering knuckle (31). • Nut (35) onto the stud. Do not tighten. 2. Coil spring (32). • Refer to “ Coil Spring,” in this section. • This step results with the lower control arm being attached to the frame. NOTICE: Refer to “ Notice” on page 3C-1 of this section. 3. Nut (35) and cotter pin (34). Tighten • Nut (35) to 122 N m (90 ft. lbs.). • Tighten the nut if needed to install the cotter pin. | 9 | Important • Maximum torque to align the cotter pin is 175 N m (130 ft. lbs.). 4. Caliper. • Refer to BRAKES (SEC. 5). 5. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 6. Tire and wheel assembly and lower the vehicle. UPPER CONTROL ARM Remove or Disconnect (Figures 5 through 8, and 15) Tools Required: J-23742 Ball Joint Separator • Raise the vehicle and support it with suitable safety stands. Remove the wheel and tire assembly. Place an adjustable jackstand under the lower control arm for support. 1. Caliper. • Refer to BRAKES (SEC. 5). 2. Upper control arm (28) from the steering knuckle (31). • Cotter pin (15). • Loosen the nut (14). Do not remove it. • Install J-23742 with the large cupped end over the lower control arm ball joint stud nut (35). Expand J-23742 until the upper control arm separates. • Nut (14) from the upper ball joint stud and raise the upper control arm to clear the steering knuckle. 3. Upper control arm (28) from the frame bracket (9). • Nuts (27), spacers (19), shims (18), washers (5) and bolts (6). 9 Im portant • Tape the sh im s to g e th e r in th e ir o rig in a l positions and tag for proper relocation. +«- Install or Connect (Figures 5 through 8) NOTICE: For steps 2 and 3, refer to “ Notice” on page 3C-1 of this section. 1. Shims (18) into position on the upper control arm frame bracket (9). • Make sure the shims are positioned with concave and convex sides together. 2. Upper control arm (28) to the frame bracket (9). • Spacers (19) and nuts (27), washers (5), and bolts (6). Im portant A normal shim pack will leave at least two threads of the bolt (6) exposed beyond the nut. If two threads cannot be obtained; check for damaged control arm or related parts. The difference between the front and rear shim packs must not exceed 7.62 mm (0.30 inches). The front shim pack must be at least 6.09 mm (0.24 inches). Always tighten the thinner shim pack’s nut (27) first for improved shaft to frame clam ping force and torque retention. 3C-26 FRONT SUSPENSION Tighten • R10/1500, G 10/1500 and G20/2500 models. — Nuts (27) to 95 N m (70 ft. lbs.). • All other models. — Nuts (27) to 142 N m (105 ft. lbs.). 3. Upper control arm (28) to the steering knuckle (31). • Insert the upper control arm ball joint stud (13) into the steering knuckle (31). 4. Nut (14) and cotter pin (15). • Tighten the nut if needed to install the cotter pin. Tighten • R10/1500, G 10/1500 and G20/2500 models. — Nut (14) to 68 N m (50 ft. lbs.). • All other models. — Nut (14) to 122 N m (90 ft. lbs.). | ? | Im portant • R10/1500, G10/1500 and G20/2500 models. — Maximum torque to align the cotter pin is 122 N m (90 ft. lbs.). • All other models. — Maximum torque to align the cotter pin is 175 N m (130 ft. lbs.). 5. Caliper. • Refer to BRAKES (SEC. 5). 6. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 7. Wheel and tire assembly. Lower the vehicle to the ground. SUSPENSION UNIT The front suspension and frame crossmember can be removed or installed as a unit if extensive service is required. Remove or Disconnect (Figure 5 through 8, and 31 through 33) • Raise the hood and disconnect the battery negative cable. • Hoist the vehicle and support it with suitable safety stands placed at the frame side rails. Remove the tire and wheel assembly and then lower the hoist. 1. Front brake hose clip from each upper control arm. 2. Brake hoses from the calipers. • Clean the area adjacent to the brake hose fittings. • Discard the special washers (2 on each hose) and cover the disconnected ends of each hose with suitable material. • Refer to BRAKES (SEC. 5). 3. Tie rod ends from the steering knuckle (31). • Refer to STEERING LINKAGE (SEC. 3B1). 4. Front stabilizer from the lower control arms (36). • Nuts (38), washers (39, 41), bolts (43), and clamps (42). 5. Shock absorbers (20) from the lower control arms (36). • Nut (23), washer (22), and bolt (21). 6. Brake line clip bolts from the front suspension crossmember. • On C series models the clip is located under the right side engine mount support bracket. NOTICE: Failure to disconnect these clips from the suspension u nit w ill result in severe damage to the brake line when the unit is lowered from the vehicle. 7. Suspension crossmember from the engine mounts. • Refer to ENGINE (SEC. 6A). 8. Suspension crossmember from the frame rail (figure 31). 9. R a is e th e h o is t to s u p p o r t th e s u s p e n s io n crossmember. 10. Support the engine. • Must be done before the suspension unit is lowered from the vehicle. 11. Suspension unit and crossmember from the vehicle. • Upper control arm bracket to the frame side rail nuts (10), washer (7), and bolts (6). • Lower the suspension unit and the crossmember to bring the unit clear of the vehicle. NOTICE: For steps 3, 7, and 8, refer to the “ Notice” on page 3C-1 of this section. Install or Connect (Figures 5 through 8 and 31 through 33) 1. Position the new suspension unit and crossmember and raise it with the hoist to align the suspension crossmember and frame holes. 2. Suspension crossm em ber to the frame rail bolts (figure 31). 3. Upper control arm (28) and the frame bracket bolts (6 ). • Washers (7) and nuts (10). Do not tighten. Tighten • R models. — Bolts (6) to 87 N m (64 ft. lbs.), except R30/3500 with F42. — Bolts (6) to 135 N m (100 ft. lbs.), R30/3500 with F42. • G models. — Bolts (4) to 125 N m (92 ft. lbs.). • P models. — Bolts (4, 6) to 87 N m (64 ft. lbs.), except P30/3500 motor home. — Bolts (4, 6) to 135 N-m (100 ft. lbs.), P30/3500 motor home. Important • The upper control arm to frame bracket bolts must be tightened first. • The crossmember must be in contact with the frame side rails. 4. C ro ssm em be r to fram e b olts (1), th ro u g h the reinforcement (8). • Washers (2) and nuts (3) as used. Tighten • R30/3500 models with F42. — Nut (3) to 180 N-m (133 ft. lbs.). • P30/3500 motro home. — Bolt (1) to 290 N-m (214 ft. lbs.). FRONT SUSPENSION 3C-27 A. B. C. D. E. 1. 2. 3. 4. 5. 6. 7. 8. 10. 17. 85. 86 . 87. R10/1500 M o d e ls R20/2500 and R30/3500 M o d e ls w ith o u t F42 R30/3500 M o d e ls w ith F42, E xte n d e d C ab and C h a s s is C ab E n g in e M o u n tin g B ra cke t B o lt B o lt W a sh er N ut B o lt W asher B o lt W asher R e in fo rc e m e n t N ut W a sh er B o lt W asher C ro s s m e m b e r B-07727 Figure 31—R Model Suspension Unit Attachment 5. 6. 7. 8. 1. 2. 4. 5. 6. 7. 17. B o lt W a sh e r B o lt W a sh e r B o lt W a sh e r W a sh e r • All other models. — Bolt (1) to 125 N m (92 ft. lbs.). Engine mount support bracket to the suspension crossmember bolts. Remove the engine support and lower the hoist. • Refer to ENGINE (SEC. 6A). Brake line clip to the crossmember. • Refer to BRAKES (SEC. 5). Shock absorber to the lower control arm (28). • Washers (22), nuts (23), and bolts (21). Tighten B-07726 Figure 32—G Model Suspension Unit Attachment • R models. — Bolt (21) to 80 N-m (59 ft. lbs.). • G models. — Bolt (21) to 103 N-m (80 ft. lbs.). • P models. — Nut (23) to 80 N-m (59 ft. lbs.). 9. Stabilizer bar (59) to the lower control arm (28). • Clamps (42), bolts (43), washers (39) and nuts (38). 3C-28 FRONT SUSPENSION A. B. D. E. P20/2500 and 30/3500 M o d e ls P30/3500 M o to rh o m e E n gin e M o u n tin g B ra cket B o lt 1. B o lt 2. W a sh er 5. W a sh er 6. B o lt 7. W a sh er 8. 10. 85. 86. 87. R e in fo rc e m e n t N ut B o lt W a sh er C ro s s m e m b e r B-07724 Figure 33—P Model Suspension Unit Attachment • R and P models. — Nuts (38, 58) to 33 N m (24 ft. lbs.). • G models. — Nut (38) tro 29 N m (21 ft. lbs.). — Bolt (54) to 33 N-m (24 ft. lbs.). 10. Tie rod ends to the steering knuckle (31). • Refer to STEERING LINKAGE (SEC. 3B1). 11. Brake hose to the caliper. • Refer to BRAKES (SEC. 5). 12. Brake hose clips to the upper control arms. • Refer to BRAKES (SEC. 5). 13. Bleed the brake system. • Refer to BRAKES (SEC. 5). 14. Tires and wheels and lower the vehicle. 15. Battery cable. ON-VEHICLE SERVICE: I-BEAM (RPO FS3) FRONT SUSPENSION SHOCK ABSORBER I++I Remove or Disconnect (Figures 34 through 36) • Raise the vehicle and support it with suitable safety stands. Remove the wheel and tire assembly. 1. Shock absorber (113) from the leaf spring spacer (158). • Nut (109) and washer (111). 2. Shock absorber (113) from the frame. • Nut (109) and washer (111). • Pull the shock free from the vehicle. L* Inspect • Shock absorbers for damage and leaking. • Test the shock absorbers. Refer to “ Shock Absorber Bench Test” in this section. Install or Connect (Figures 34 through 36) 1. Shock absorber (113) to the frame (figure 36). • Insert the shock’s upper stud into the hole in the frame. • Washer (111) and nut (109). Do not tighten. NOTICE: Refer to the “ N o tice” on page 3 C - 1 of this section. 2. Shock absorber (113) to the leaf spring spacer (158) (figure 36). • Position the shock’s lower mount onto the stud. • Washer (111) and nut (109). Tighten Shock absorber upper nut to 185 N-m (136 ft. lbs.). FRONT SUSPENSION 3C-29 Figure 34—P Model I-Beam Front Suspension Components 3C-30 FRONT SUSPENSION 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115. 116. 117. 118. 119. 120. 121. 122. 123. 124. 125. Spring Hanger Rivet Spring Stop Hanger B ushing W asher Bolt Shackle Nut Nut Nut W asher Bum per Shock A bsorber Spacer Nut S tabilizer Link Retainer Insulator Bolt W asher Brake H ose Bracket Cap Gasket King Pin Bushing 126. 127. 128. 129. 130. 131. 132. 133. 134. 135. 136. 137. 138. 139. 140. 141. 142. 143. 144. 145. 146. 147. 148. 149. Spacer Steering Knuckle F ittin g Nut Dust Seal Shim Nut W asher Lock Pin Nut Nut Thrust Bearing Nut C otter Pin Steering And Third Arm Splash Shield Brake C aliper W asher Bolt A nchor Plate Stop Bolt Stop Nut Retainer/Cap C otter Pin 150. 151. 152. 153. 154. 155. 156. 157. 158. 159. 160. 161. 162. 163. 164. 165. 166. 167. 168. 169. 170. 171. 172. 173. Nut Washer O uter W heel Bearing And Race W heel Hub Bolt H ub/Rotor Inner W heel Bearing And Race Bearing Seal Front Axle Spring Spacer Spring Leaf Bolt ~ Spacer Front Spring Nut Spacer U-Bolt S tabilizer Bar Insulator Clamp Bolt Nut W asher Bolt Spring Hanger B-07485 Figure 35—P Model I-Beam Front Suspension Components 109 • Shock absorber lower nut to 50 N-m (37 ft. lbs.). A 3. Wheel and tire on the vehicle. Lower the vehicle to the ground. STABILIZER BAR |<"+| Remove or Disconnect (Figures 34, 35, and 37) Tools Required: J-6627-A Wheel Stud and Tie Rod Remover • Raise the vehicle and support it with suitable safety stands. Remove the tire and wheel assembly. 1. Stabilizer bar (166) from the stabilizer link (116). • Nut (115) and washer (114). • Use J-6627-A to separate the stabilizer link from the stabilizer end. 2. Stabilizer bar (166) from the frame (figure 37). • 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 37). • Nut (136), retainer (117), insulator (118). B-07487 Figure 36—Shock Absorber Attachment Points • Pull the link from the axle. Another insulator (118) and retainer (117) will come off the link. NOTICE: For steps 1, 2, and 3, refer to the “ N o tice” on page 3 C - 1 of this section. FRONT SUSPENSION 3C-31 118 \ ^1181 A. n y 114. 166. 167. 168. 169. 170. 171. 115. 116. 117. 118. 136. S ta b iliz e r Bar In s u la to r C la m p B o lt N ut W a sh e r B-07491 Figure 37—Stabilizer Bar Attachment Points 0 Install or Connect (Figures 34, 35, and 37) 1. Stabilizer link (116) to the front axle (157) (figure 37). • Slide a retainer (117) and an insulator (118) on to the link and insert the link into the proper hole in the front axle. • Insulator (118), retainer (117) and nut (136). Tighten • Nut (136) until the distance between each retainer (117) is 2.08 cm (0.82 inches) (figure 37). 2. Stabilizer bar (166) to the frame (figure 37). Tighten • Nuts (115) to 68 N m (50 ft. lbs.). 4. Wheel and tire assembly. Lower the vehicle to the ground. WHEEL HUB/ROTOR ASSEMBLY |<-+| Remove or Disconnect (Figures 34 and 35) • Raise the vehicle and support it with suitable safety stands. Remove the tire and wheel assembly. 1. Caliper (142). • Refer to BRAKES (SEC. 5). • Insulators (167) onto the stabilizer bar (166). • Clamps (168), clamp bolts (169), washers (171), and nuts (170). • Nuts (170) to 28 N m (21 ft. lbs.). 3. Stabilizer bar (166) to the stabilizer link (116). • Washer (114) and nut (115). NOTICE: Support the caliper with a piece of wire to prevent damage to the brake line. 2. Wheel hub/rotor (154) (figures 34, 35). • Retainer/cap (148). • Cotter pin (149), nut (150) and washer (151). • Pull the hub/rotor free from the spindle, making sure the outer wheel bearing (152) comes free. 3C-32 FRONT SUSPENSION • Do not damage the steering knuckle spindle threads. 3. Inner wheel bearing (155). • Pry out the sea! (156). 4. Races. • Drive out each race using a brass drift. 131 Clean 1. Grease from the h ub /ro to r (154) and steering knuckle spindle. • Grease from inside the hub. 2. Grease from the wheel bearings (152, 155) and races. • Use clean solvent and a small brush (no loose bristles). • Do not spin the wheel bearings with compressed air to dry them—the wheel bearings may be damaged. Inspect 1. W heel bearings (152, 155) and th eir races for damage or wear. • Refer to “ Diagnosis of Wheel Bearings,” in this section. • If either a bearing or its race is damaged or worn, replace both. 2. Hub/rotor (154) for damage or wear. • Check for out-of-round or scored conditions. • Check for pitting or cracks. • Repair or replace as necessary. Install or Connect (Figures 34 and 35) Tools Required: J-8092 Driver Handle J-29040 Outer Bearing Race Installer J-9746-02 Hub/Rotor Support NOTICE: Start the races squarely inside the hub/rotor (154) to avoid distortion and possible cracking. 1. Races into the hub/rotor (154). • Place the hub/rotor on J-9746-02 and rest this assembly on press bars. • Use J-29040 to drive the outer bearing race into position. • Remove J-9746-02 and use a 7.6 cm (3 inch) diameter bar, or equivalent tool to drive the inner bearing race into position. If the bar is larger than 7.6 cm (3 inches), it may damage the bearing seal seat. Im portant • Use an approved high tem perature front wheel bearing grease to lubricate the bearings. Refer to MAINTENANCE AND LUBRICATION (SEC. OB). • Do not mix different greases as mixing may change th e g re a s e ’s p ro p e rtie s r e s u ltin g in p o o r performance. 2. Apply a thin film of grease to the steering knuckle spindle at the outer wheel bearing seat and at the inner wheel bearing seat, shoulder, and seal seat. 3. Put a small quantity of grease inboard of each wheel bearing retainer/cap (148). 4. Fill each wheel bearing (cone and roller assembly) full of grease. • Use a cone-type grease machine that forces grease into the bearing. • If a cone-type grease machine is not available, pack the wheel bearing by hand. • When packing the wheel bearing by hand, work the grease into the bearings between the rollers, cones, and the cage. NOTICE: Failure to com pletely pack the wheel bearing (cones, rollers, and cage) with grease will result in premature wheel bearing damage and/or wear. 5. Inner wheel bearing (155) into the hub/rotor (154). • Put an additional quantity of grease outboard of this bearing. 6. New seal (156). • Use a flat plate or block to install the seal to insure it is flush with the hub/rotor flange. • Lubricate the seal lip with a thin layer of grease. 7. Hub/rotor (154). • Do not damage the steering knuckle spindle threads. 8. Outer wheel bearing (152). • Slide it over the spindle until the wheel bearing (152) fully seats against the hub/rotor outer race. NOTICE: Refer to the “ N o tice” on page 3 C - 1 of this section. 9. Washer (151), nut (150) and cotter pin (149). • Do not place the cotter pin through the hole in the sp in d le u ntil the w heel bearings are adjusted. Tighten • Nut (150) to 16 N m (12 ft. lbs.) while turning the hub/rotor assembly in either direction. 10. Put an additional amount of grease outboard of the wheel bearing (152). 11. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment,” in this section. 12. Retainer/cap (148) in place. 13. Caliper (142). • Refer to BRAKES (SEC. 5). 14. Tire and wheel assembly. Lower the vehicle to the ground. WHEEL BEARING ADJUSTMENT | ? | Im portant • The proper functioning of the front suspension ca nn ot be m aintain ed unless the fro n t w heel bearings are correctly adjusted. The bearings must be a slip fit on the spindle and the inside diameter of the wheel bearing must be lubricated to ensure the bearings will creep. The spindle nut (150) must have a free-running fit on the spindle threads. FRONT SUSPENSION 3C-33 N O T IC E : N e v e r p r e lo a d th e fro n t w h e e l bearings. Damage can result by the steady thrust on the roller ends which comes from preloading. ft A djust Raise the vehicle and support it with suitable safety stands under the lower control arms. Remove the retainer/cap (148). Remove the cotter pin (149). Tighten • Nut (150) to 16 N-m (12 ft. lbs.) while rotating the wheel and tire assem bly (or the hub/rotor). This will seat the bearings. 3. Back off the nut (150) one flat. • If the hole in the spindle lines up with the slot in the nut, insert the cotter pin (149). • If they do not line up, back off the nut until they do—not more than one additional flat. Measure % • Endplay in the hub/rotor should measure between 0.013-0.20 mm (0.0005-0.008 inches) when properly adjusted. 4. Install the retainer/cap (148). 5. Lower the vehicle to the ground. WHEEL HUB BOLT □ Remove or Disconnect Tools Required: J-9746-02 Hub/Rotor Support 1. Hub/rotor assembly from the vehicle. • Refer to “ Wheel Hub/Rotor Assembly,” 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 (153) with a press. • Support the hub/rotor (153) using J-9746-02 and the press bars. • Do not damage the wheel mounting surface on the hub/rotor flange. 0 * tl Install or Connect NOTICE: Refer to the “ N o tice” on page 3 C - 1 of this section. 1. Wheel hub bolts (153) into the hub/rotor (154). • Place four washers onto the bolt, then fasten a nut onto the bolt until the nut bottoms on the washers. • Tighten the nut until the bolt fully seats into the hub/rotor (154). • Remove the nut and washers. 2. Hub/rotor to the vehicle. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 3. Wheel and tire assembly. Lower the vehicle to the ground. STEERING ARM, KNUCKLE AND SPINDLE ++ Remove or Disconnect (Figures 34 and 35) • Raise the vehicle and support it with suitable safety stands. Remove the tire and wheel assembly. 1. Caliper (142). • Refer to BRAKES (SEC. 5). 2. Hub/rotor assembly (154). • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 3. Anchor plate (145), splash shield (141), and the steering arm (140). • Bolts (146), washers (147) and nuts (129), and pull the anchor plate and splash shield off the knuckle. Steering arm hangs by tie rods. • Bolts (144) and washers (143) to separate the anchor plate from the splash shield. • Refer to STEERING LINKAGE (SEC. 3B1) to separate the steering arm from the tie rod and pitman arm. 4. Caps (122) from the steering knuckle (127). • Bolts (119) and washers (120). • Brake hose bracket (121). • Gaskets (123) come off. 5. Lock pin (134). • Nut (132) and washer (133). 6. King pin (124) from the steering knuckle (127). • Drive it out using a drift. • Spacers (126) and bushings (125) will also come out. 7. Steering knuckle (127) from the axle (157). • Dust seal (130), shim (131), and thrust bearing (137) will come free. NOTICE: For steps 3, 4, and 5 refer to th e “ N o tice” on page 3 C - 1 of this section. 0 Install or Connect (Figures 34 and 35) 1. Bushings (125). • Ream new b u s h in g s to 29.982-30.022m m (1.1804-1.1820 in.) after installing. 2. Steering knuckle (127). • Thrust bearing (137), shim and the dust seal. • Prelube the thrust bearing. Refer to MAINTE­ NANCE AND LUBRICATION (SEC. 0B). 3. King pin (124) and the lock pin (134). • Insert the spacers in the proper order. • Prelube the king pin. • Washer (133) and the nut (132). • Nut (132) to 40 N-m (29 ft. lbs.). 4. Caps (122) to the steering knuckle (127). 3C-34 FRONT SUSPENSION Gaskets (123) in place. Brake hose bracket (121). Washers (120) and bolts (119). $ Tighten • Bolts (119) to 7 N m (5 ft. lbs.). 5. Steering arm (140), splash shield (141), and the anchor plate (145). • Bolts (144) and washers (143) to attach the splash shield to the anchor plate. • Bolts (146), washers (147) and nuts (129) to attach the anchor plate and steering arm to the steering knuckle. Tighten 6. 7. 8. 9. 10. 11. • Bolts (144) to 16 N-m (12 ft. lbs.). • Nuts (129) to 312 N-m (230 ft. lbs.). Steering arm (140) to the steering linkage. • Refer to STEERING LINKAGE (SEC. 3B1). Hub/Rotor assembly (154). • Refer to “ Wheel Hub/Rotor Assembly,” in this section. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment,” in this section. Caliper (142). • Refer to BRAKES (SEC. 5). Wheel and tire assembly. Lower the vehicle to the ground. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). FRONT AXLE ++ • 1. 2. 3. 4. 5. 6. 7. Remove or Disconnect (Figures 34 through 38) Tools Required: J-6627-A Wheel Stud and Tie Rod Remover Raise the vehicle and support it with suitable safety stands on the frame. Remove the wheel and tire assembly. Support the axle with a floor jack to eliminate any load on the springs. Steering arm, knuckle, and spindle. • Refer to “ Steering Arm, Knuckle, and Spindle,” in this section. Shock absorber (113) from the axle (157) (figure 36). • Nut (109) and washer (111). Stabilizer link (116) from the stabilizer bar (166) (figure 37). • Nut (115) and washer (114). • Use J-6627-A to separate the stabilizer bar from the stabilizer link. Stabilizer link (116) from the axle (157) (figure 37). • Nut (136), retainer (117) and insulator (118). • Pull the link free from the axle, making sure not to loose the other insulator (118) and retainer (117). Leaf spring (162) from the axle (157) (figure 38). • Nuts (135), washers (105) and U-bolts (165). • Spacer (164), and spring spacer (158). Steering damper from the axle. • Refer to STEERING LINKAGE (SEC. 3B1). Lower the floor jack and pull the axle clear of the vehicle. NOTICE: For steps 4, 5, and 6, refer to the “ N o tice” on page 3 C - 1 o f this section. Install or Connect (Figures 34 through 38) □ 1. Line up the axle under the leaf springs. • Raise it into position using a floor jack. 2. Steering damper to the axle. • Refer to STEERING LINKAGE (SEC. 3B1). 3. Axle (157) to the leaf springs (162). • Refer to “ Leaf Spring,” in this section. 4. Stabilizer link (116) to the axle (157) (figure 37). • Link into the hole on the spring spacer (158) and axle. • Insulator (118), retainer (117), and nut (136). $ Tighten • Nut (136) until the distance between each retainer (117) is 2.08 cm (0.82 inches) (figure 37). 5. Stabilizer link to the stabilizer bar (166) (figure 37). • Washer (114) and nut (115). Tighten • Nut (115) to 68 N-m (50 ft. lbs.). 6 . Shock absorber (113) to the axle (157) (figure 36). • Washer (111) and nut (109). Tighten • Nut (109) to 50 N-m (37 ft. lbs.). 7. Steering arm, knuckle, and spindle. • Refer to “ Steering Arm, Knuckle, and Spindle,” in this section. 8. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment” in this section. 9. Wheel and tire assembly. Lower the vehicle to the ground. 10. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3B1). LEAF SPRINGS ++ • 1. 2. 3. 4. Remove or Disconnect (Figures 34 through 38) Tools Required: J-6627-A Wheel Stud and Tie Rod Remover Raise the vehicle and support it with suitable safety stands. Support the axle separately to eliminate any load on the springs. Remove the tire and wheel assembly. Shock absorber (113) from the axle (157) (figure 36). • Nut (109) and washer (111). Stabilizer link (116) from the stabilizer bar (166) (figure 37). • Nut (115) and washer (114). • Use J-6627-A to separate the stabilizer bar from the stabilizer link. Stabilizer link (116) from the axle (157) (figure 37). • Nut (136), retainer (117), insulator (118). • Pull the link free from the axle, making sure not to loose the other insulator (118) and retainer (117). Leaf spring (162) from the axle (157) (figure 38). FRONT SUSPENSION 3C-35 108 101. 105. 106. 107. 108. 135. 157. 158. 162. 165. 164. 173. S p rin g H an g e r W a sh er B o lt S h a ckle N ut N ut F ro n t A xle S p rin g S p a ce r F ro n t S p rin g U -B olt S p a ce r S p rin g H an g e r 135 B-07492 Figure 38—Axle and Leaf Spring Attachment Points Washer (108) to (173). Washer (108) to (107). • Nuts (135), washers (105) and U-bolts (165). • Spacer (164) and spring spacer (158). 5. Leaf spring (162) from the frame (figure 38). • Nut (108), washer (105), bolt (106) and washer (105) to separate the spring from the rear shackle (107). • Nut (108), washer (105), bolt (106), and washer (105) to separate the spring from the front hanger (173). • Pull the leaf spring backward and out. NOTICE: For steps 1, 2, 3, 4 and 5, refer to the “ N o tice” on page 3 C - 1 of this section. -►+ Install or Connect (Figures 34 through 38). 1. Leaf spring (162) to the frame (figure 38). • Line up the spring with the rear shackle (107) and the front hanger (173). Double wrap end is toward the front of the vehicle. $ (105), bolt (106), washer (105) and nut attach the spring to the front hanger (105), bolt (106), washer (105) and nut attach the spring to the rear shackle Tighten • Nut (108) to 125 N m (92 ft. lbs.). 2. Leaf spring (162) to the axle (157) (figure 38). • Position the spring spacer (158) onto the axle. Either aligning pin can contact the edge of the leaf spring after the assembly is complete. • Spacer (164), U-bolts (165), washers (105) and nuts (135). Tighten nuts to 25 N-m (18 ft. lbs.) in a diagonal sequence (e.g., 1-3-4-2). Tighten • N uts (135) in a diagonal se qu en ce (e.g., 1-3-4-2) to 109 N m (80 ft. lbs.). 3. Stabilizer link (116) to the axle (157) (figure 37). 3C-36 FRONT SUSPENSION • Insert the link into the proper hole in the axle after the retainer (117) and insulator (118) are attached. • Insulator (118), retainer (117), and nut (136). Tighten • Nut (115) to 68 N-m (50 ft. lbs.). 5. Shock absorber (113) to the axle (157) (figure 34). • Washer (111) and nut (109). Tighten • Nut (136) until the distance between each retainer (117) is 2.08 cm (0.82 inches) (figure 37). 4. Stabilizer link (116) to the stabilizer bar (166) (figure 37). • Washer (114) and nut (115). • Nut (109) to 50 N-m (37 ft. lbs.). 6. Wheel and tire assembly. Lower the vehicle to the ground. 7. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3B1). ON-VEHICLE SERVICE: FOUR WHEEL DRIVE FRONT SUSPENSION SHOCK ABSORBER STABILIZER BAR |<~+| Remove or Disconnect (Figures 39 through 41) |<~+| Remove or Disconnect (Figures 39, 40 and 42) • Raise the vehicle on a hoist. 1. Shock absorber (220) from the frame. • Nut (212), washer (213) and bolt (219) (figure 38). 2. Shock absorber (220) from the axle. • Nut (212), washer (213) and bolt (225). • Quad shocks (RPO Z75) have a spacer (246) between them (figure 41). Inspect • Shock absorbers for damage and leaking. • Test the shock absorbers. Refer to “ Shock Absorber Bench Test” in this section. N O T IC E : For s te p s 1 a n d 2, re fe r to the “ N o tice” on page 3 C - 1 . Install or Connect (Figures 39 and 40) 1. Shock absorber (220) to the axle. • Bolt (225), washer (213), and nut (212). • Spacer (246) must be positioned between the shock absorbers (220) on vehicles with quad shocks, RPO Z75 (figure 41). $ Tighten • Nut (212) to 88 N-m (65 ft. lbs.). • Nut (212) to 120 N m (89 ft. lbs.) on quad shocks (RPO Z75). 2. Shock absorber (220) to the frame. • Bolt (219), washer (213) and nut (212). Tighten • Nut (212) to 88 N-m (65 ft. lbs.). 3. Lower the vehicle to the floor. • Raise the vehicle on a hoist. 1. Stabilizer bar (230) from the frame brackets (237). • Nuts (231), washers (232), brackets (233), and bolts (238) (figure 39). 2. Stabilizer bar (230) from the spring plate (224). • Bolts (229), and washers (228). • Stabilizer bar is free of the vehicle. • Bushings (234) can be removed from the stabilizer bar. Install or Connect (Figures 39, 40 and 42) 1. Stabilizer bar (230) to the frame brackets (237). • Bushings (234) onto the stabilizer bar. • Use rubber lu b ric a n t when in s ta llin g the bushings (slit faces forward) on the stabilizer bar. • Brackets (233), bolts (238), washers (232), and nuts (231) (figure 39). Do not tighten. NOTICE: Refer to “ N o tic e ” on page 3 C - 1 of this section. 2. Stabilizer bar (230) to the spring plate (224). • Washers (228) and bolts (229) (figure 42). • Nuts (231) to 70 N-m (52 ft. lbs.). • Bolts (229) to 180 N-m (133 ft. lbs.). 3. Lower the vehicle to the ground. WHEEL HUB/ROTOR ASSEMBLY |+ + | Remove or Disconnect (Figures 39, 40, and 43 through 45) Tools Required: J-68 93 -D W heel B e a rin g N ut W rench (V10/1500-20/2500 Models) J-23446 Torque Wrench Adapter J-26878-A Wheel Bearing Nut Wrench (V30/3500 Models) FRONT SUSPENSION 3C-37 • Raise the vehicle and support it with suitable safety stands. Remove the tire and wheel assembly. 1. Caliper • Refer to BRAKES (SEC. 5). 2. Locking hub (249). • Refer to FRONT AXLE (SEC. 4C). 3. Locking nut (250), ring (251) and adjusting nut (252). • Use J-6893-D and J-23446 for V10/1500-20/2500 models. • Use J-26878-A for V30/3500 models. 4. Hub/Rotor Assembly (257). • Outer wheel bearing (253) will slide off the spindle (265) ahed of the hub/rotor (257). • Use a brass drift and hammer for the seal (260) and races (254, 258). • The inner bearing (259), race (258) are behind the seal (260). L* Inspect 1. Rotor braking surfaces for scoring, pitting, or cracks. • Repair or replace as necessary. 2. Wheel bearings (253, 259) and races (254, 258). • Refer to “ Diagnosis of Wheel Bearings,” in this section. • If either a bearing or its race is damaged or worn, replace both. Install or Connect (Figures 39, 40, and 43 through 45) Tools Required: J-8092 Driver Handle J-6368 Bearing Race Installer (Outer) J-23448 Bearing Race Installer (Inner) J-68 93 -D W h e el B e a rin g N ut W rench (V10/1500-20/2500 models) J-26878-A Wheel Bearing Nut Wrench (V30/3500 models) J-23446 Torque Wrench Adapter 1. Races (254, 258) into the rotor/hub (257). • Use J-8092 and J-6368 for installation of the outer bearing outer race (254). • Use J-8092 and J-23448 for installation of the inner bearing outer race (258). • Do not damage the hub/rotor during the race installations. Clean • Grease from the rotor/hub (257) and spindle (265). • Grease from the wheel bearings (253, 259). • Use clean solvent and a small brush (no loose bristles). • Do not spin the wheel bearings with compressed air to dry them —the wheel bearings may be damaged. Im portant • Use an approved high-tem perature front wheel bearing grease. Refer to M AIN TEN AN C E AND LUBRICATION (SEC. 0B). • Do not mix greases as mixing may change the grease’s properties resulting in poor performance. 2. Apply a thin film of grease to the spindle at the outer wheel bearing seat and at the inner wheel bearing seat, shoulder, and seal seat. 3. Put a small quantity of grease inboard of each wheel bearing cup, inside the rotor/hub (257). 4. Fill the wheel bearing (cone and roller assemblies) full of grease. • Use a cone-type grease packer that forces grease into the bearing. • If a cone-type grease packer is not available, pack the wheel bearings by hand. • If packing the wheel bearings by hand, work the grease into the bearings between the rollers, cones, and the cage. NOTICE: Failure to com pletely pack the wheel bearings (cones, rollers, and cage) with grease will result in premature wheel bearing damage and/or wear. 5. Inner wheel bearing (259) into the rotor/hub (257). • Put an additional quantity of grease outboard of this wheel bearing. 6. New seal (260). • Use a flat plate to install the seal so it is flush with the rotor/hub flange. • Lubricate the seal lip with a thin layer of grease. 7. Rotor/hub (257). • Do not damage the spindle threads. 8. Outer wheel bearing (253). • Press on the spindle until the wheel bearing fully seats against the rotor/hub outer race. 9. Adjusting nut (252). 10. Adjust the wheel bearing. • Refer to “ Wheel Bearing Adjustment,” in this section. NOTICE: Refer to the “ N o tic e ” on page 3 C - 1 of this section. 11. Ring (251) and locking nut (250). • Tang on the inside diameter of the ring must pass onto the slot on the spindle (265). • The hole in the ring must align with the pin on the lock nut (250). Move the adjustment nut (252) to align the pin. • Use J-6893-D or J-26878-A and J-23446. Tighten • Lock nut (250) to 217 N m (160 ft. lbs.) minimum. 12. Locking hub (249). • Refer to FRONT AXLE (SEC. 4C). 13. Caliper. • Refer to BRAKES (SEC. 5). 14. Wheel and tire. Lower the vehicle to the ground. BEARING ADJUSTMENT Im portant • The proper functioning of the front suspension ca nn ot be m ain ta in e d unless the fro n t w heel bearings are correctly adjusted. The cones must be a slip fit on the spindle and the inside diam eter of the cones must be lubricated to insure the cones w ill c re e p . T h e a d ju s tin g n u t m u s t h a ve a free-running fit on the spindle threads. 3C-38 FRONT SUSPENSION 248 209 210 211 208 214 215 216 203 232 / 231 246 B-07494 Figure 39—V Model Front Suspension FRONT SUSPENSION 3C-39 201. 202. 203. 204. 205. 206. 207. 208. 209. 210. 211. 212. 213. 214. 215. 216. 217. 218. 219. 220. 221. 222. 223. 224. 225. 226. 227. 228. 229. 230. B olt Shackle B ushing N ut W asher Bracket Bum per Rivet Nut Bracket B um per Nut W asher Hanger Rivet Spacer W asher Nut Bolt S hock A bsorber Leaf Spring Nut W asher Plate Bolt Spacer Bolt W asher Bolt S tabilizer Shaft 231. 232. 233. 234. 235. 236. 237. 238. 239. 240. 241. 242. 243. 245. 246. Nut W asher Bracket Bushing Rivet Rivet Bracket Bolt Nut W asher Hanger Bolt R einforcem ent Bracket Spacer 247. Bracket 248. Bolt A. K3500 Series Right Side B. Quad S hock RPO Z75 B-07495 Figure 40—V Model Front Suspension 212 213 212 213 219 219 225 246 B A. B. 212. 213. 219. 220. 225. 246. K Series Standard Shock A bsorber M ounting K Series RPO Z75 Quad Shock A bsorber M ounting Nut W asher B olt S hock A bsorber Bolt Spacer Figure 41—Shock Absorber Attachment Points B-07493 3C-40 FRONT SUSPENSION Figure 42—Stabilizer Bar Attachment Points Adjust • Raise the vehicle and support it with safety stands. 1. Remove the locking hub assembly (249), lock nut 250), and the ring (251). Tighten • Adjusting nut (252) to 60 N m (50 ft. lbs.) while rotating the hub/rotor in order to seat the bearings. 2. Back off the adjusting nut (252) and retighten. £ Tighten • For Automatic Hubs, torque the adjusting nut to 47 N m (35 ft. lbs.) while rotating the wheel. • For Manual Hubs, torque the adjusting nut to 60 N m (50 ft. lbs.) while rotating the wheel. 3. Back off the adjusting nut (252). • For Autom atic hubs, back off 3/s of a turn maximum. • For Manual hubs, back off enough to free the bearing. 4. Ring (251) and lock nut (252). • Tang on the inside diameter of the ring must pass onto the slot on the spindle (265). • The hole in the ring must align with the pin on the lock nut (250). Move the adjustment nut (252) to align the pin. Tighten • Lock nut (250) to 217 N m (160 ft. lbs.) minimum. Measure Endplay in the hub/rotor assembly. It should be set between 0.025 to 0.254 mm (0.001 to 0.010-inch). 5. Locking hub assembly (249). • Refer to FRONT AXLE (SEC. 4C). 6. Lower the vehicle to the ground. FRONT SUSPENSION 3C-41 WHEEL HUB BOLT Remove or Disconnect (Figures 39, 40, and 46) Tools Required: J-9746-02 Hub/Rotor Support 1. Hub/rotor assembly from the vehicle. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 2. Wheel hub bolts (255) with a press. • Support the hub/rotor using J-9746-02 to prevent damage to the rotor face (figure 46). • Do not damage the wheel mounting surface on the hub/rotor flange. Install or Connect (Figures 39, 40, and 47) Tools Required: J-9746-02 Hub/Rotor Support NOTICE: Refer to “ N o tice” on page 3 C - 1 of this section. 1. New, serrated b olt (255) into the hole in the hub/rotor. • Place four washers onto the bolt, then fasten a nut onto the bolt until the nut bottoms on the washers (figure 47). • Tighten the nut until the bolt fully seats into the hub/rotor. • Remove the nut and washers. 2. Hub/rotor to the vehicle. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 3. Wheel and tire assembly. Lower the vehicle. SPINDLE Remove or Disconnect (Figures 39, 40, 48 and 49) Raise the vehicle and support it with suitable safety stands. Remove the tire and wheel assembly. 3C-42 FRONT SUSPENSION 249 B-07550 Figure 44—Knuckle and Hub/Rotor Components (V30/3500 Models) FRONT SUSPENSION 3C-43 249. 250. 251. 252. 253. 254. 255. 257. 258. 259. 260. 261. 262. Locking H ub A ssem bly Locking Nut Ring A d ju s tin g Nut O uter W heel Bearing O ute r Race W heel Hub Nut R otor/H ub Inner Race Inner W heel Bearing Seal Nut W asher 263. 264. 265. 266. 267. 268. 269. 270. 271. 272. 273. 274. 275. Plate Bracket S pindle Shaft Bearing Bearing Seal Spacer Seal Oil D eflector Bolt W asher Cap Steering K nuckle Nut 276. 278. 279. 280. 281. 282. 283. 284. 285. B olt Bolt King Pin Seal R etainer Race Bearing Seal Bearing Cap and King Pin 286. B olt 287. B ushing 288. Spring 289. 290. 291. 292. 293. 294. 295. 296. 297. 298. 299. 300. 301. G asket S teering Arm N ut N ut Lower Ball J o in t Upper Ball J o in t Nut A dapter Steering Arm C o tte r Pin Nut A d ju s tin g Ring R etainer B-07464 Figure 45—Knuckle and Hub/Rotor Components (V30/3500) 1. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 2. Spindle (265) from the steering knuckle (274). • Nuts (261) and plate (263) for V 10/1500-20/2500 models. • Nuts (261), washers (262), plate (263) and the bracket (264) for V30/3500 models. • Tap the end of the spindle with a plastic or rubber mallet to break it loose from the steering knuckle (274) (figure 48). A. W ashers B. Nut 81. H ub/R otor Figure 47—Installing the Hub Bolts NOTICE: The m achined surface of the spindle must not be dam aged by vise jaws. 3. Spindle components. • Secure the spindle in a vise by locating on the high step diameter. A. Press Bars B-07729 Figure 46—Removing the Hub Bolts Figure 48—Removing the Spindle 3C-44 FRONT SUSPENSION A. 265. 267. 268. 269. 270. 2.54mm (0.10-inch) depth S pindle Bearing Seal Spacer Seal Oil D eflector B-07465 Figure 49—Spindle Components • Bearing seal (267) and shaft bearing (266) (figure 49). • Spacer (268), seal (269), and oil deflector (270) from the axle shaft (figure 49). 4. Spindle (265) onto the steering knuckle (274). • Slide the spindle over the axle shaft until it seats on the steering knuckle. The bolts (278) must protrude through the spindle. Inspect Spacer (268). Replace if it is worn. • Spindle (265) for any heat burns, scoring, or wear. Replace if necessary. Install or Connect (Figures 39, 40, 49 and 50) • 1. 2. 3. Tools Required: J -2 3 4 4 5 -A N ee dle B e a rin g In s ta lle r (V10/1500-20/2500 models) J-8092 Driver Handle J-21465-17 Bearing Installer (V30/3500 models) Relubricate the shaft bearing (266) and the spindle (265) with a high melting point type wheel bearinq g re a s e . R e fe r to M A IN T E N A N C E AND LUBRICATION (SEC. 0B). Shaft bearing (266) and bearing seal (267) into the spindle (265) (figure 47). • For V10/1500-20/2500 models, use J-8092 and J-23445-A. • For V 3 0 /3 5 0 0 m o d e ls, use J-80 92 and J-21465-17. Oil deflector (270) and seal (269) onto the axle shaft. • Seal (269) onto the oil deflector (270) with the deflector lip toward the spindle (265). Spacer (268) onto the axle shaft. • The chamfer points toward the oil deflector (270) (figure 50). NOTICE: Refer to “ N o tice” on page 3 C - 1 of this section. 5. Bracket (264) and plate (263). • Only the V30/3500 models use a bracket (264). A. C ham fer Toward The Seal 265. S pindle 268. Spacer 269. Seal 269 270. Oil D eflector Figure 50—Installing the Spindle B-07454 FRONT SUSPENSION 3C-45 • Insert a wedge-shaped tool between the lower ball joint (293) and the yoke. Tap on the tool to release the knuckle assembly. • Insert the wedge-shaped tool between the upper ball joint (294) and the yoke. Tap on the tool to release the knuckle assembly. NOTICE: For steps 2, 3, 4, 6 and 7, refer to “ N otice” on page 3C - 1 o f this section. 0 Figure 51—Tightening the Adjusting Ring • Washers (262) (V30/3500 models only) and NEW nuts (261). Install or Connect (Figure 39, 40 and 51) Tools Required: J-23447 Ball Stud Nut Wrench Steering knuckle (274) to the axle yoke. • Ball joints (293, 294) into their respective sockets in the axle yoke. • Finger tighten the nuts (292, 299) onto the ball joints (293, 294). The nut with the cotter pin slot goes with the upper ball joint. 2 . Push up on the steering knuckle [to keep the ball joint (293) from turning in the knuckle] and partially torque the lower ball joint nut (292). Tighten Tighten • Nuts (261) to 88 N m (65 ft. lbs.). 6. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 7. Wheel and tire. Lower the vehicle to the ground. STEERING KNUCKLE AND ARM V10/1500-20/2500 MODELS (WITH BALL JOINTS) Remove or Disconnect (Figures 39, 40, and 51) • Raise the vehicle and support with suitable safety stands. Remove the tire and wheel assembly. 1. Locking hub assembly (249). • Refer to FRONT AXLE (SEC. 4C). 2. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 3. Spindle (265) from the steering knuckle (274). • Refer to “ Spindle,” in this section. 4. Tie rod from the steering arm (297). • Refer to STEERING LINKAGE (SEC. 3B1). 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 k n u c kle, do n ot loo sen it m o re than two th re a d s . U se J -2 3 4 4 7 (fig u r e 5 1 ). The nonhardened threads in the yoke can be easily d am ag ed by the h a rd e n e d thread s in the adjusting ring if caution is not used during knuckle removal. 6. Steering knuckle (274) from the axle yoke. • Cotter pin (298), nuts (292, 299). • Nut (292) to 40 N-m (30 ft. lbs.) 3. Torque the adjusting ring (300). • Use J-23447 (figure 48). ^X Tighten • Adjusting ring (300) to 70 N m (50 ft. lbs. Torque the upper ball joint nut (299). ^X Tighten • 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 • Nuts (295) to 120 N m (90 ft. lbs.). 8 . Tie rod to the steering arm (297). • Refer to STEERING LINKAGE (SEC. 3B1). 9. Spindle (265) to the steering knuckle (274). • Refer to “ Spindle,” in this section. 10. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 11. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment,” in this section. 12. Locking hub assembly (249). • Refer to FRONT AXLE (SEC. 4C). 13. Wheel and tire assembly. 14. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). 15. Lower the vehicle to the ground. 3C-46 FRONT SUSPENSION Figure 52—Removing the Cap and Steering Arm Fasteners V30/3500 MODELS (WITH KING PINS) Remove or Disconnect (Figures 39, 40, and 5 2 through 5 5 ) • 1. 2. 3. 4. Tools Required: J-26871 King Pin Socket Raise the vehicle and support with suitable safety stands. Remove the tire and wheel assembly. Locking hub (249). • Refer to FRONT AXLE (SEC. 4C). Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. Spindle (265). • Refer to “ Spindle,” in this section. Upper cap (273) and/or steering arm (290). • For the cap, remove the bolts (271) and washers (272) alternately as the compression spring will force the cap up. Figure 53—Removing the Lower Bearing Cap and King Pin 5. 6. 7. 8. 9. 10. • For the steering arm, remove the nuts (291) alternately as the compression spring will force the steering arm up (figure 52). Gasket (289), and compression spring (288). • Discard the old gasket (289). Lower bearing cap and king pin (285). • Bolts (271) and washers (272) (figure 53). Upper king pin bushing (287). • Pull it out through the steering knuckle (274). Steering knuckle (274) from the axle yoke. • Seal (301). Upper king pin (279) from the axle yoke. • Use a large breaker bar and J-26871 (figure 54). • Apply 677-813 N m (500-600 ft. lbs.) of torque to break the king pin free. Retainer (281), race (282), bearing (283) and the seal (284) from the axle yoke. • Punch all the components out at once (figure 55). • Discard the old seal (284). • If the retainer (281) is damaged, discard it. Figure 55—Removing the Retainer, Race, Bearing and the Seal FRONT SUSPENSION 3C-47 NOTICE: For steps 4, 6, 7, refer to “ N otice” on page 3 C - 1 of this section. |- n - | Install or Connect (Figures 4 0 , 41 and 56 through 58) Tools Required: J-7817 Front Pinion Bearing Installer J-22301 King Pin Bearing Seal Installer J-28871 King Pin Installer 1. Retainer (281) and the race (282). • Use a new retainer. • Use J-7817 (figure 56). 2. Fill the area in the retainer (281) and race with an approved high temperature bearing lubricant. Grease the bearing (282). • Use a cone-type grease packer that forces grease into the bearing. • If a cone-type grease packer is not available, pack the bearing by hand. Work the grease between the rollers, cones, and cage. NOTICE: Failure to com pletely pack the bearing (cones, rollers, and cage) with grease will result in premature bearing damage and/or wear. • Refer to MAINTENANCE AND LUBRICATION (SEC. OB). 3. Bearing (283) and seal (284). • Use J-22301 to install the NEW seal (Figure 57). • Do not distort the seal. It will protrude slightly from the surface of the axle yoke flange when fully seated. 4. Upper king pin (279). • Use J-28871 (figure 58). £ Tighten • King pin (279) to 745 N m (550 ft. lbs.). 5. Steering knuckle (274) and bushing (287). • Felt seal (280) to the king pin (279) through the steering knuckle. • Knuckle onto the king pin (279). • Place the bushing (287) over the king pin (279). 6. Bearing cap and king pin (285) to the steering knuckle (278). • 4 bolts (271) and washers (272). Tighten • Bolts (271) alternately and evenly to 108 N-m (80 ft. lbs.). 7. Steering arm (290) to the steering knuckle (274). • Com pression ring (288), gasket (289), and steering arm (290). • Nuts (291). £ Tighten • Nuts (291) alternately and evenly to 108 N-m (80 ft. lbs.). 8. Spindle (265). • Refer to “ Spindle,” in this section. 9. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 10. Adjust the wheel bearings. 3C-48 FRONT SUSPENSION J-6382-3 OR J-23454-3 274 » i)i i' 293 j mill) J-23454-2 J-9519-10 274. Steering K nuckle 293. Lower Ball Jo in t B-07510 Figure 61— Installing the Lower Ball Joint 11. 12. 13. 14. • Refer to “ Wheel Bearing Adjustment” in this section. Locking hub (249). • Refer to FRONT AXLE (SEC. 4C). Wheel and tire assembly. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 3A). Lower the vehicle to the ground. BALL JOINTS (V10/1500-20/2500 MODELS ONLY) — Remove or Disconnect (Figures 39, 40, 59 and 60) Tools Required: J-9519-10 Ball Joint Fixture J-23454-1 Lower Ball Joint Spacer J-23454-3 or J-6382 Upper Ball Joint Spacer J-23454-4 Upper and Lower Ball Joint Sleeve 274 J-23454-1 J-6382-3 OR J-23454-3 J-9519-10 A. Flat W asher 274. S teering K nuckle B-07509 Figure 60—Removing the Upper Ball Joint • Raise the vehicle and support with suitable safety stands. Remove the wheel and tire assembly. 1. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. 2. Spindle. • Refer to “ Spindle,” in this section. 3. Steering knuckle (274) and steering arm (290). • Remove the steering arm (290) only if removing the left axle yoke ball joints. • Refer to “ Steering Knuckle and Arm,” in this section.” > Place the steering knuckle in a vise (figure 59). 4. ' *er ball joint (293). • Must be removed before any service can be done to the upper ball joint (294). • Snap ring from the lower ball joint (293). • Use J-9519-10, J-23 45 4-1, J-2 3 4 5 4 -4 or equivalent (figure 59). Tighten until the ball joint breaks free of the steering knuckle. 5. Upper ball joint (294). • Use J-9519-10, J-23454-3 (or J-6382-3) and J-23454-4 (figure 60). Tighten until the ball joint breaks free of the steering knuckle. +«- Install or Connect (Figures 39, 40, 61 and 62) Tools Required: J-9519-10 Ball Joint Fixture 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 (274). • The ball joint (no cotter pin hole in the threaded end) must be positioned straight. • Use J-9519-10, J-23454-2, and J-23454-3 or J-6382-3 (figure 61). Tighten until the ball joint fully seats. • Snap ring in position. 2. Upper ball joint (294) into the steering knuckle (274). • Use J-9519-10, J-23454-2, and J-23454-3 or J-6382-3 (figure 62). Tighten until the ball joint fully seats. 3. Steering arm (290) and steering knuckle (274). FRONT SUSPENSION 3C-49 274 294 J-23454-2 I J-6382 OR J-23454-3 274. S te e rin g K n u c k le 294. U p p e r Ball J o in t B-07508 Figure 62—Installing the Upper Ball Joint 4. 5. 6. 7. 8. 9. • Steering arm only if removed. • Refer to “ Steering Knuckle and Arm,” in this section. Spindle (265). • Refer to “ Spindle,” in this section. Wheel hub/rotor assembly. • Refer to “ Wheel Hub/Rotor Assembly,” in this section. Adjust the wheel bearings. • Refer to “ Wheel Bearing Adjustment,” in this section. Wheel and tire assembly. Check the front end alignment. • Refer to FRONT END ALIGNMENT (SEC. 4C). Lower the vehicle to the ground. LEAF SPRING AND BUSHINGS — Remove or Disconnect (Figures 39, 40, and 63) • Raise the vehicle on a hoist and support the front axle with a floor jack. Raise the floor jack until all tension is relieved from the springs. 1. Spring (221) from the frame. • Nut (218), washer (217), shackle (202), bolt (201), bushings (203) and spacer (216) (figure 61). 2. Spring (221) from the hanger (241). • Nut (239), washers (240), and bolt (242) (figure 61). 3. Spring (221) from the axle. • For V 10/1500-20/2500 and the left side of V30/3500 models, remove nuts (222), washers (223), U-bolts (227), plate (224) and the spacers (226). • For the right side of V30/3500 models, remove the bolts (248), nuts (222), washers (223), U-bolt (227), plate (224) and the spacers (226) (figure 63). 4. Shackle (202) from the spring (221). • Nut (218), washer (217), bolt (201), bushings (203) and spacer (216) (figure 63). 5. Bushing from the spring eye. 0 • Place the spring in a press and press out the bushing using a suitable rod, pipe, or tool. Install or Connect (Figures 39, 40, 63 and 64) 1. Bushing into the spring eye. • Press in a new bushing, making sure the tool presses on the steel outer shell of the bushing. • Bushing must protrude an equal amount on either side of the spring eye when properly installed. 2. Shackle (202) into the spring (221). • Spacer (216), bushings (203), washers (217), bolt (201) and nut (218). • Do not tighten. 3. Upper spacer (226) onto the spring (221). 4. Spring into the hanger (241). • Bolt (242), washers (240) and nut (239). • Do not tighten. 5. Spring into the frame. • Bushings (203) and the spacer (216) into the frame. • Shackle (202) into position and attach bolt (201), washer (217) and nut (218). • Do not tighten. NOTICE: Refer to the “ N o tice” on page 3 C - 1 of this section. 6. Spring to the axle. • For V 10/1500-20/2500 models and the left side of V30/3500 models, attach the lower spacer (226), plate (224), U-bolts (227), washers (223) and nuts (222) (figure 63). • For the right side of V30/3500 models, attach the lower spacer (226), plate (224), U-bolt (227), washers (223), bolts (248) and nuts (222) (figure 63). Tighten • N uts (222) and b olts (248) in se q u e n c e (2-4-1-3) to 203 N m (150 ft. lbs.) (figure 64). 6. Torque the spring to fram e and hanger fasteners. • Nuts (239) to 122 N m (90 ft. lbs.). • Nuts (218) to 68 N m (50 ft. lbs.). 7. Lower the floor jack, and lower the vehicle to the ground. 3C-50 FRONT SUSPENSION 218. N ut 221. Leaf S p rin g B-07460 Figure 63—Leaf Spring Attaching Parts Figure 64—U-Bolt Tightening Order FRONT SUSPENSION 3C-51 SPECIFICATIONS ENDPLAY R-G-P Models 0.03-0.13 mm (0.0012-0.005 inches) V Models 0.025-0.25 mm (0.001-0.010 inches) P Motorhome w/FS3 0.013-0.20 mm (0.0005-0.008 inches) FASTENER TORQUE IN D EP EN D E N T FR O N T SU S PEN SIO N R a n d P M o d e ls N -m Shock Absorber to F ra m e ............................................................................. ........ 190 Shock Absorber to Lower Control A r m ....................................................... ........ 80 Stabilizer to F ra m e ................................................................................................... 33 Stabilizer to Lower Control A rm ............................................................................. 33 Steering Knuckle to Upper Ball Joint R10/1500 ............................................................................................................ 68 All Other M o d e ls ...................................................................................... ........ 122 Steering Knuckle to Lower Ball J o in t .................................................................. 122 Ball Joint Cotter Pin Alignm ent R10/1500 Upper Ball Joint — M a x im u m ............................................ ........ 122 All Other Ball Joints — M a x im u m ....................................................... ........ 176 Splash Shield to K nuckle........................................................................................ 13 Lower Control Arm Bushings (Exc. R 10/1500).......................................... ........ 379 Lower Pivot Shaft End Nuts (R10/1500 o n ly ) ............................................ ........ 95 Lower Pivot Shaft U-Bolt N u ts ............................................................................... 115 Upper Control Arm Bushings (Exc. R 10/1500).......................................... ........ 257 Upper Pivot Shaft End Nuts (R10/1500 o n ly ) ............................................ ........ 156 Upper Pivot Shaft Thru-Bolt Nuts R 10/1500 ............................................................................................................ 95 All Other M o d e ls ...................................................................................... ........ 142 Upper Bolt Joint to Upper Control A rm ....................................................... ........ 25 Crossm em ber to Bottom Frame Rail Motorhome................................................................................................. ........ 291 Van Models with JF 9 ............................................................................... ........ 176 All Other M o d e ls ...................................................................................... ........ 122 Crossmember to Frame Side Rails P Models with J F 9 .......................................................................................... 135 All Other M o d e ls ...................................................................................... ........ 88 Suspension Bumper R10/1500 M odels...................................................................................... ........ 20 All Other M o d e ls ...................................................................................... ........ 26 Crossmember to Support S tr u ts .................................................................. ........ 81 G M odels Shock Absorber to F ra m e ............................................................................. ........ 103 Shock Absorber to Lower Control A r m ....................................................... ........ 103 Stabilizer to F ram e................................................................................................... 29 Stabilizer to Lower Control A rm ............................................................................. 33 Steering Knuckle to Upper Ball Joint G 30/3500............................................................................................................ 122 All Other M o d e ls ...................................................................................... ........ 68 Steering Knuckle to Lower Ball J o in t ......................................................... ........ 122 Ball Joint Cotter Pin Alignm ent G10/1500 and G20/2500 Models Upper Ball Joint — Maximum . . 122 All Other Ball Joints — M a x im u m ....................................................... ........ 176 F t. L b s . 140 59 24 24 50 90 90 90 130 10 280 70 85 190 115 70 105 18 215 130 90 100 65 15 19 60 80 80 21 24 90 50 90 90 130 3C-52 FRONT SUSPENSION SPECIFICATIONS (CONT.) G M odels (C ont.) N-m Splash Shield to K nuckle............................................................................... ........ 13 Lower Control Arm Bushings (G30/3500 o n ly ).......................................... ........ 379 Lower Pivot Shaft End Nuts (Exc. G 30/3500)............................................ ........ 156 Lower Pivot Shaft U-Bolt Nuts G 30/3500................................................................................................... ........ 115 All Other M o d e ls ...................................................................................... ........ 88 Upper Control Arm Bushings (G30/3500 o n ly ).......................................... ........ 258 Upper Pivot Shaft End Nuts (Exc. G 30/3500)............................................ ........ 156 Upper Pivot Shaft Thru-Bolt Nuts G30/3500 M o d e ls ............................................................................................ 142 All Other M o d e ls ...................................................................................... ........ 95 Upper Bolt Joint to Upper Control A rm ....................................................... ........ 25 Crossmember to Bottom Frame R a il........................................................... ........ 122 Crossmember to Side Frame R a il........................................................................ 88 Suspension B um per........................................................................................ ........ 20 Crossmember to Support S tru ts .............................................................. . 81 Ft. Lbs. 10 280 115 85 65 190 115 105 70 18 90 65 15 60 I-BE AM (RPO FS3) FR O N T SU S PEN SIO N P30 M odels Shock Absorber to F ra m e ............................................................................. ........ 185 Shock Absorber to A x le .......................................................................................... 50 Stabilizer to F ra m e .......................................................................................... ........ 29 Stabilizer to Stabilizer L in k ........................................................................... ........ 68 Splash Shield to Anchor Plate............................................................................... 16 Steering Arm to K n u c k le ............................................................................... ........ 312 Caps to Steering K n u c k le ............................................................................. ........ 7 Lock Pin to Steering K n u c k le ............................................................................... 40 Spring to Hanger N u ts ............................................................................................ 125 Spring to Shackle N u t s .......................................................................................... 125 Spring to Axle U-Bolt N uts............................................................................. ........ 109 Shackle to Frame N u t s .......................................................................................... 125 Suspension B um per........................................................................................ ........ 34 136 37 21 50 12 230 5 29 92 92 80 92 25 FOUR W H E EL DRIVE FR O N T SU S PEN SIO N V M odels Shock Absorber to F ra m e ............................................................................. ........ 88 Shock Absorber to A x le .......................................................................................... 88 Stabilizer to Frame V 3 0 /3 5 0 0 ................................................................................................... ........ 70 All Other M o d e ls ...................................................................................... ........ 95 Stabilizer to Spring P la te ............................................................................... ........ 180 Steering Knuckle to Upper Ball Joint (Exc. V30/3500)..................................... 135 Steering Knuckle to Lower Ball Joint (Exc. V30/3500)..................................... 40 Ball Joint Cotter Pint Alignm ent (Exc. V30/3500) Upper Ball Joint — M a x im u m ...................................................................... 176 Adjusting Ring to Spindle (Exc. V30/3500)......................................................... 70 Caps to Steering Knuckle (V30/3500 o n ly )......................................................... 108 King Pin to Knuckle (V30/3500 only).................................................................... 745 Anchor Plate to K n u c k le ............................................................................... ........ 88 Steering Arm to K n u c k le ............................................................................... ........ 120 Lock Pin to Steering K n u c k le ............................................................................... 217 Spring to Hanger N u ts ............................................................................................ 122 Spring to Shackle N u t s .......................................................................................... 68 Spring to Axle U-Bolt N uts............................................................................. ........ 203 Shackle to Frame N u t s ................................................................................. ........ 68 Suspension B um per........................................................................................ ........ 20 65 65 52 70 133 100 30 130 50 80 550 65 90 160 90 50 150 50 15 FRONT SUSPENSION 3C-53 SPECIAL TOOLS 1. J-24435-A 2. J-23448 9. J-9519-D 10. J-23742 . J-22301 12 . J-21365-17 13. J-8092 14. J-23447 15. J-9746-02 16. J-23028-01 J-23454-D 3. 11 1 4. 5, J-6368 6. 7. 8. 1. 2. 3. 4. 5. 6. 7. 8. J-26878-A J-7817 J-6893-D J-6627-A Needle Bearing In sta lle r Inner Bearing Race In sta lle r Ball J o in t Remover and Installer W heel Bearing N ut W rench O uter Bearing Race In stalle r Front Pinion Bearing In sta ller W heel Bearing N ut W rench W heel Stud and Tie Rod Remover 9. 10. 11. 12. 13. 14. 15. 16. Ball Jo in t Remover and In staller Ball Jo in t Separator King Pin Bearing Seal In staller Bearing In staller Driver Handle Ball Stud N ut W rench H ub/R otor S upport Spring Remover Tools Not Shown A. J-8457 B. J-8849 C. J-29040 W heel Bearing Race In staller W heel Bearing Race In sta lle r Outer Bearing Race In staller D. J-23446 E. J-28871 F. J-22717 Torque W rench A dapter King Pin In sta lle r Lower C ontrol Arm B ushing Stake Remover B-07725 REAR SUSPENSION 3D-1 SECTION 3D REAR SUSPENSION 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 term inology “ Notice: Refer to the ‘Notice’ on page 3D-1 of this section. NOTICE: Theserearsuspension fastenersareimportant attachingparts in that theycouldaffect theperform­ anceof vital parts andsystems, and/or couldresult in major repair expense. Theymust bereplacedwith one of thesamepart number or withanequivalent part if replacement becomesnecessary. Donot useareplace­ ment part of lesser quality or substitute design. Torque valuesmust beusedasspecifiedduring reassembly to assureproper retention of theseparts. CONTENTS SUBJECT PAGE General D e scrip tio n ....................................................................................................................................................3D - 1 On Vehicle S e r v ic e ....................................................................................................................................................3D - 8 Shock Absorber Replacem ent.............................................................................................................................. 3D - 8 Stabilizer Bar R eplacem ent...................................................................................................................................3D - 8 Leaf Spring Assem bly Replacem ent.................................................... ...............................................................3D - 9 Bushing R e p lace m e n t........................................................................................................................................... 3D-10 S pecifica tio ns...............................................................................................................................................................3D -12 GENERAL DESCRIPTION All 10/1500 through 30/3500 series vehicles use a leaf spring and solid rear axle suspension system (figures 1 through 7). The rear axle assembly is attached to multi-leaf springs by U-bolts. The front ends of the springs are attached to the frame at the front hangers, through rubber bushings. The rear ends of the springs are attached to the frame by the use of shackles which allow the springs to “ change their length” while the vehicle is in motion. Ride control is provided by two identical direct double acting shock absorbers angle-m ounted between the frame and brackets attached to the axle tubes. 3D-2 REAR SUSPENSION Figure 1—Rear Suspension (R/V 10/1500, 20/2500 Pickup, Suburban, and Blazer/Jimmy) REAR SUSPENSION 3D-3 Figure 2—Rear Suspension (R/V 30/3500 Series Vehicles) 3D-4 REAR SUSPENSION Figure 3—Rear Suspension (G 10/1500-30/3500 Series Vehicles) REAR SUSPENSION 3D-5 Figure 4—Rear Suspension (G30/3500 Series Cutaway Van with RPO M40) 3D-6 REAR SUSPENSION Figure 5—Rear Suspension (P20/2500 Series Vehicles) REAR SUSPENSION 3D-7 Figure 6—Rear Suspension (P30/3500 Series Vehicles) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. B ra cke t B o lt W a sh e r R ear H a n g e r N ut R ear S h a c k le A n c h o r P late U -b olt S h im Leaf S p rin g N ut 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. S p rin g L ock W a sh er R ear S h o c k A b s o rb e r B o lt S p rin g L o ck W a sh er N ut F ro n t H a n g e r S u p p o rt F ro n t H a n g e r A x le B u m p e r B u m p e r B ra cket W a sh e r N ut 23. B ra cket 24. C u s h io n 25. Rear H a n g e r R e in fo rc e m e n t 26. Leaf S p rin g Eye B u s h in g 27. B o lt 28. N ut 29. N ut 30. B o lt 31. S p a ce r Figure 7—Rear Suspension Legend 32. O p tio n a l Rear A u x ilia ry S p rin g 33. B o lt 34. W a sh er 35. N ut 36. S ta b iliz e r Bar Anchor 37. S p a c e r 38. B o lt 39. S p rin g C lip B-07521 3D-8 REAR SUSPENSION ON-VEHICLE SERVICE SHOCK ABSORBER REPLACEMENT |+ + | Remove or Disconnect (Figures 1 through 7) • Raise the vehicle on a hoist. 1. Shock absorber (13) from the frame. • For R/V and P series ve hicles; 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) N O T IC E : For s te p s 1 a n d 2, re fe r to the “ N o tice” on page 3D-1 of this section. 1. Shock absorber (13) to the frame. • For R/V and P series vehicles; 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 • Nuts (16) to “ Specifications” at the end of this section. Shock absorber (13) to the axle. • Line shock absorber up with the axle bracket. • Bolt (14), spring-washer (12), and nut (11). St Tighten • For all R/V and P series vehicles; nut (11) to 155 N m (114 ft. lbs.). • For all G series vehicles; nut (11) to 102 N-m (75 ft. lbs.). 3. Lower the vehicle to the ground. Figure 8—Rear Stabilizer A ttachm ents (R30/3500 Series Vehicles) Install or Connect (Figures 8, 9 and 10) STABILIZER BAR REPLACEMENT Remove or Disconnect (Figures 8, 9, and 10) • Raise the vehicle on a hoist. 1. Stabilizer bar (108) from the frame. • For R 30/3500 series vehicles; nut (120), and washer (116). Slide the link bolt (115) out along with the grommets (117), washers (116), and link (118). • For P 30/3500 series vehicles; nuts (105), washers (106), bolts (111), and the clamp (110). 2. Stabilizer bar (108) from the anchor plates (107). • Nuts (105), washers (106), bolts (111), and the clam ps (110). 3. Insulators (109) from the stabilizer bar (108). N O T IC E : For s tep s 2 a n d 3, r e fe r to the “ N o tice” on page 3D-1 of this section. 1. Insulators (109) to the stabilizer bar (108). 2. Stabilizer bar (108) to the anchor plates (107). • Clamps (110), bolts (111), washers (106), and nuts (105). Tighten • Refer to “ Specifications” at the end of this section. Im portant • Route the parking brake cable over the stabilizer bar. 3. Stabilizer bar (108) to the frame. REAR SUSPENSION 3D-9 For the R 30/3500 series vehicles; position the link bolt (115), washers (116), grommets (117), link (118), retainer (119) and nut (120). For the P 30/3500 series vehicles; attach the clamp (110), bolts (111), washers (106), and nuts (105) in position. Tighten Nuts (120 and 105) to the “ Specifications” at the end of this section. 4. Lower the vehicle to the ground. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. U -b olt S p a ce r S p rin g S p a ce r A n c h o r Plate N ut S p rin g L ock W a sh er S ta b iliz e r Bar A n c h o r S ta b iliz e r Bar B u s h in g B ra cket B o lt 112. 113. 114. 115. 116. 117. 118. 119. 120. 121. N ut W a sh er S p ace r B o lt W a sh er G ro m m e t L in k R e ta in e r N ut B ra cket B-07524 LEAF SPRING ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 1 through 7) • Raise the vehicle on a hoist and support the rear axle independently to relieve tension on the leaf springs. 1. Stabilizer bar from the vehicle if equipped. • Refer to “ Stabilizer Bar Replacement,” in this section. 2. Leaf spring (10) from the rear hanger (25). • Loosen, but do n ot re m o v e , th e spring-to-shackle nut and bolt. • Nut and the bolt securing the shackle to the rear hanger (25). 3. Leaf spring (10) from the front hanger (18). • Nut and the bolt securing the leaf spring (10) to the front hanger (18). 4. Shackle (6) from the leaf spring (10). • Nut and bolt securing the shackle to the leaf spring. 5. Leaf spring from the axle. • Nuts (22), and washers (21). • Rear stabilizer anchor (36) if equipped, the anchor plate, spacers, shims, and the auxiliary spring (32), if equipped. • U-bolts (8). Figure 10—Rear Stabilizer Attachments Legend • Leaf spring is free of the vehicle. 3D-10 REAR SUSPENSION Install or Connect (Figures 1 through 7, and 11) N O T IC E : For s tep s 1 and 4, re fe r to the “ N o tice” on page 3D-1 o f this section. 1. Leaf spring (10) to the rear axle. • Leaf spring into position. • Spacers, shims, the auxiliary spring (32) if equipped, and the anchor plate. • U-bolts (8), washers (21), and nuts (22). Q Tighten • Nuts (5) and bolts (2), to the “ Specifications” at the end of this section. 5. Stabilizer bar to the vehicle if equipped. • Refer to “ Stabilizer Bar R eplacem ent,” in this section. 6. Lower the support on the rear axle. Lower the vehicle to the ground. BUSHING REPLACEMENT Tighten • Nuts (22), in a diagonal sequence as shown in figure 11, initially to 25 N m (18 ft. lbs.). Then final torque in a diagonal sequence as shown in figure 11 to the “ Specifications” at the end of this section. 2. Shackle (6) to the leaf spring (10). • Bolt (2), washers (3), and nuts (5), making sure the bolt is positioned correctly (figures 1 through 7). • Do not tighten. 3. Leaf spring to the front hanger (18). • Bolt (2), washers (3), and nut (5). • Do not tighten. 4. Leaf spring to the rear hanger (25). • Bolt (2), washers (3), and nut (5). PRESS OUT TYPE BUSHINGS Remove or Disconnect (Figures 1, 3, and 7) 1. Leaf spring (10) from the vehicle. • R e fe r to “ Leaf S p rin g R eplacem ent,” in this section. A s s e m b ly 2. Bushing from the leaf spring (10). • Place the leaf spring in a press and press out the bushing. Install or Connect (Figures 1, 3 and 7) 1. Bushing into the leaf spring (10). • Use a press to properly position the bushings. 2. Leaf spring (10) to the vehicle. • R e fe r to “ Leaf S p rin g Replacem ent,” in this section. A s s e m b ly REAR SUSPENSION 3D-11 PRY OUT TYPE BUSHINGS |+ + | Rem ove o r D is c o n n e c t (F ig u re s 2 and 4 through 7) 1. Leaf spring (10) from the vehicle. • R e fe r to “ Leaf S p rin g A s s e m b ly R eplacem ent,” in this 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 spring (10) onto the vehicle. • R e fe r to “ Leaf S p rin g A s s e m b ly R eplacem ent,” in this section. 3D-12 REAR SUSPENSION SPECIFICATIONS FASTENER NAME TORQUE N m (FT. LBS.) R10/15 R20/25 R30/35 V10/15 V20/25 V30/35 G10/15 G20/25 G30/35 P20/25 P30/35 70 (52) 102 (75) 102 (75) 102 (75) 33 (24) 70 (52) 102 (75) 102 (75) 102 (75) 155 (114) 155 (114) Shock Absorber To Frame Nut 190 (140) *190 (140) Shock Absorber To Axle Nut 155 (114) *155 (114) 155 (114) 155 (114) 155 (114) 155 (114) 70 (52) 190 (140) 190 (140) Stabilizer Bar To Frame Nut — — ** Stabilizer Bar To Anchor Nut — — 33 (24) — — Stabilizer Bar Bracket To Hanger — — — — — Stabilizer Bar Bracket To Frame — — — — — — — — — — 29 (21) — — 29 (21) — — 33 (24) — — 33 (24) — — — — — — — — — — — Anchor Plate To U-bolt Nut (U-bolts Facing Up) 170 (125) 170 (125) 170 (125) 170 (125) 170 (125) 170 (125) 155 (114) 155 (114) 205 (151) 170 (125) Anchor Plate to U-bolt Nut (U-bolts Facing Down) 200 (147) 200 (147) 200 (147) 200 (147) 200 (147) 200 (147) - - 205 (151) - - ***200 (147) Spring To Hanger Nut 125 (92) Spring To Hanger Bolt 150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 185 (136) 185 (136) 185 (136) 150 (110) •150 (110) Spring To Shackle Nut 125 (92) 125 (92) •125 (92) Spring To Shackle Bolt 150 (110) 150(110) 150 (110) 150 (110) 150 (110) 150(110) 185 (136) 185 (136) 185 (136) 150 (110) •150 (110) Shackle To Hanger Nut 125 (92) 125 (92) •125 (92) Shackle To Hanger Bolt 150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 150 (110) 185 (136) 185 (136) 185 (136) 150 (110) •150 (110) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) 125 (92) N/A 125 (92) 125 (92) N/A 125 (92) 125 (92) N/A 125 (92) N/A • For M odels w ith RPO JF9 o r P318(32) Torque Spring to Hanger B olt to 200 N m (147 ft. lbs.) and Tighten Shcakle Fasteners to 135 N m (99 ft. lbs ). * Crew Cab M odel Torque is 70 N m (52 ft. lbs.) fo r Shock to Frame, and 155 N m (114 ft. lbs.) fo r S hock to Axle. * * Tighten The N ut To The Unthreaded Portion Of The Link Bolt. * * * Torque Is 240 N m (177 Ft. Lbs.) W hen Equipped W ith RPO JF9. WHEELS AND TIRES 3E-1 SECTION 3E W HEELS AND TIR ES CONTENTS SUBJECT PAGE General Description.......................................................................................................................................................3E- 1 Certification L a b e l.................................................................................................................................................... 3E- 1 Tire Load Limits And Inflation P re ssure ............................................................................................................... 3E- 1 Diagnosis Of Wheels And T ire s ..................................................................................................................................3E- 3 Checking Wheel And Tire R u n o u t......................................................................................................................... 3E- 3 On-Vehicle S e rv ic e ...................................................................................................................................................... 3E- 4 Measuring Wheel And Tire Runout..........................................................................................................................3E- 4 Excessively Tight W heels........................................................................................................................................ 3E- 5 Separating The Tire From The W h e e l................................................................................................................... 3E- 6 Mounting The Tire On The W h e e l..........................................................................................................................3E- 6 Installing The Wheel And Tire Assembly............................................................................................................... 3E- 7 Aluminum Wheel R e fin ishing ..................................................................................................................................3E- 8 Wheel And Tire Balancing........................................................................................................................................ 3E- 8 Optional Spare Tire C arriers....................................................................................................................................3E- 8 Specifications.................................................................................................................................................................3E-11 Wheel Runout.............................................................................................................................................................3E-11 Wheel Stud Nut Torque (Single Front And Rear W h e e ls).................................................................................. 3E-11 Wheel Stud Nut Torque (Single Front And Dual Rear W heels).......................................................................... 3E-11 Tire Load Limits And Inflation P ressure............................................................................................................... 3E-12 Wheel Codes And Load L im its ................................................................................................................................3E-12 GENERAL DESCRIPTION This section details special service procedures that are not covered in the vehicle’s O wner’s Manual. For jacking instructions, basic tire changing and rotation instructions, and a detailed explanation of all other owner-oriented in­ formation, refer to the proper section in the vehicle’s Own­ e r’s Manual. CERTIFICATION LABEL The certification label contains information used to determine which tire size and type the vehicle uses. For further information, refer to GENERAL INFORMATION (SEC. OA). 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. Correct tire pressures and driving techniques influence tire life. Underinflated tires can cause handling problems, p o o r fu e l e co n o m y , s h o rte n e d tire life , and tire o v e rlo a d in g . H ea vy c o rn e rin g , e x c e s s iv e ly ra p id acceleration, and unnecessary braking also increase tire wear. | 9 | Im p o rta n t • The use of wheels and/or tires with higher load capacity ratings than originally equipped on the vehicle will not increase the Gross Axle Weight Rating (GAWR) or Gross Vehicle Weight Rating (GVWR) of the vehicle. 3E-2 WHEELS AND TIRES B-07463 Figure 1—Radial Tire Lead/Pull Disgnosis Chart WHEELS AND TIRES 3E-3 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 Toe Wear Excessive Tire Edge(s) Wear CORRECTION POSSIBLE CAUSE PROBLEM 1. Inflate to recommended pressure. 2. Correct as required— refer to certifica­ tion label. 3. Correct as required. 4. Set to correct specifications. 1. Underinflated tires. 2. Vehicle overloaded. 3. High speed cornering. 4. Incorrect toe setting. Excessive Tire Wear (Center Of Tread) Uneven Tire Wear Deflate to recommended pressure. Overinflated tires. 1. 2. 3. 4. 5. Im proper tire pressure. Incorrect tire and wheel usage. Worn shock absorbers. Front end out of alignment. Loose, worn, or damaged steering link­ age, joints, suspension com ponents, bushings and/or ball joints. 6. Out of balance wheel/tire. Radial Tire Waddle (Side To Side Movement At Speeds Between 5 and 15 MPH) Vibration Correct as required, rotate tires regu­ larly. High speed driving, excessive use of brakes. 1. 2. 3. 4. 5. 6. Balance wheel/tire. Replace worn tires. Worn tires. 1. 2. 3. 4. Out of balance wheel/tire. Tire runout. Wheel runout. Worn tire. CHECKING WHEEL AND TIRE RUNOUT Some vehicles are sensitive to tire and wheel assembly runout. Tires that are satisfactory on one vehicle might be unsatisfactory on another. W hen analyzing vibration problems, it is important to keep this in mind. In addition, different wheel positions on a vehicle may have different sensitivity levels. You should check for wheel runout or total wheel and tire runout in the following cases: Inflate to recommended pressure. Install correct tire-wheel combination. Replace shock absorbers. Align the front end. Inspect, repair or replace as required. 1. 2. 3. 4. Balance Replace Replace Replace wheel/tire. tire. wheel. tire. — If the tire and wheel vibration occurs below 40 miles per hour. — If all wheels are balanced well within one ounce of static balance and five ounces of dynamic balance, and a vibration occurs. — If there appears to be a bulge in a tire or an out-of-round condition as a tire rotates on a balancer. — If any wheel damage is noticed. — If there is a poor wheel fit on the hub and the vehicle exhibits vibration. 3E-4 WHEELS AND TIRES ON-VEHICLE SERVICE Figure 2—Measuring Radial Runout MEASURING WHEEL AND TIRE RUNOUT Runout measurements of the wheel and tire assembly can be taken both on and o ff th e ve h ic le . These measurements can be taken radially and laterally. A dial indicator equipped with a roller contact point, mounted 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 Lateral runout is a sideways variation causing a twist or wobble and is measured on a side surface. On the 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 Inflate the tires to specifications. 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 measurements will be taken off the vehicle, mount each tire and wheel assembly on a dynamic balance machine. Mark the tire and w heel a ssem blies for exact replacement. • Mark a wheel hub bolt and its exact position on the wheel. A. B. C. D. T ire H ig h S p o t W h e e l H ig h S p o t W h e e l Low S p o t T ire Low S p o t 1. Dial In d ic a to r B-07451 Figure 3—Measuring Lateral Runout • M ark each tire and w heel a s s e m b ly fo r replacement on the exact hub/rotor assembly. 5. Take either a radial or lateral runout measurement. • Place the dial indicator in position. • Rotate the tire and wheel assembly (or just the wheel) to find its low spot. Adjust the dial indicator to read zero. • Rotate again to verify the low spot location—the dial indicator must return to zero. • Disregard any instantaneous dial jumps due to welds, paint runs, scratches, etc. on the wheel. • Rotate the tire and wheel assembly (or just the wheel) and note the amount of variance (runout) from zero. Locate and mark the high spot. 6. If there is a large difference in runout measurements from ON vehicle to OFF vehicle, the runout problem is likely due to excessive runout of the bolt circle or hub. 7. If measured runouts are not within the guidelines (located in “ Wheel Runout Specifications” at the end of this section), proceed to “ Vectoring” to correct the problem. VECTORING Vectoring is a technique used to reduce radial or lateral runout— and even dynamic balance on tire and wheel a s s e m b lie s . V e c to rin g c a n be a c c o m p lis h e d by positioning of the tire on the wheel and positioning of the tire and wheel assembly on the hub/rotor. WHEELS AND TIRES 3E-5 B 2. 3. A. B. C. D. E. T ire T ire R eferen ce M ark A t 12 O ’c lo c k F irs t M e a su re m e n t (H ig h S p ot) Valve S tem A t 12 O ’c lo c k S e co n d M e a su re m e n t (H ig h S pot) T ire R eference M ark A t 6 O ’c lo c k B-07455 Valve S tem and T ire R eferen ce M ark at 12 O ’c lo c k F irs t M e a s u re m e n t (H ig h Spot) Valve S tem at 12 O ’c lo c k S e con d M e a s u re m e n t (H ig h Spot) T ire R eferen ce M ark at 6 O ’c lo c k F-02342 Figure 4 — Checking Tire to Wheel Vectoring Figure 5—Tire to Wheel Vectoring—Excessive Runout | j I Important Tire And Wheel Assembly To Hub/Rotor Vectoring • Always rebalance the tire and wheel assembly after vectoring. Tire To Wheel Vectoring 1. Determine which runout needs to be minimized. • Determine visually. 2. If radial runout is the problem, take a measurement on the center tread rib. • If the trend is uneven, wrap tape tightly around the tire, record the runout magnitude, and mark the high spot location (figure 4). 3. If lateral runout is the problem, take a measurement on the sidewall just below the edge of the tread shoulder. • Record the runout magnitude, and mark the high spot location. 4. Mark the tire sidewall at the valve location. • This is the 12 o’clock position. • The location of the high spot is always with respect to the clock location on the wheel. 5. Break the tire and wheel assembly down on a tire mounting machine and rotate the tire 6 hours (180°) on the rim (figure 4). • Reinflate the tire and measure the runout in question. • Record the magnitude and the location of the high spot. (Valve stem is 12 o’clock.) 1. Mark the wheel hub bolt nearest the valve stem for reference (figure 6). 2. Rotate the assembly two wheel hub bolts and recheck the runout (figure 6). • Several positions may have to be tried to locate the optimum location. • This can be effective for both radial and lateral runouts. 3. If there is some looseness in the wheel hub bolt holes, radial runout can be reduced by loosening the hub bolt nuts slightly, moving the wheel position on the bolts and then retightening the nuts. 4. Balance the tire and wheel to hub/rotor assembly. • Compensates for any imbalance in the brake rotor, drum, or wheel cover. EXCESSIVELY TIGHT WHEELS Use this procedure to remove the wheel and tire assembly if it does not break free of the hub using a standard removal procedure. 1. Tighten all the lug nuts on the affected wheel. • Do not torque. 2. Raise the vehicle. 6. If the clock location of the high spot remained at or near the clock location of the original high spot, the rim is the major contributor to the runout problem. • Confirm by removing the tire from the wheel and check the wheel rim runout. • If the wheel rim runout exceeds guidelines, replace the wheel. 7. If the clock position of the high spot is 6 hours from the original high spot, the tire is the major contributor to the runout problem (figure 5). • Replace the tire. 8. After correcting the tire to the wheel vectoring, rebalance the wheel and tire assembly. Figure 6—Tire and Wheel Assembly to Hub/Rotor Vectoring 3E-6 WHEELS AND TIRES 3. Loosen each nut two turns. 4. Lower the vehicle to the floor. 5. Rock the vehicle from side to side to loosen the wheel. Or rock the vehicle from forward to reverse allowing the vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal to loosen the wheel. 6. Raise the vehicle and remove the lug nuts and the wheel. SEPARATING THE TIRE FROM THE WHEEL N O TIC E: Use a tire c h a n g in g m a c h in e to demount tires. Do not use hand tools or tire irons alone to remove the tire from the wheel. Damage to the tire beads or wheel rim could result. • Follow the tire changing machine m anufacturer’s instructions to properly separate the tire from the wheel. MOUNTING THE TIRE ON THE WHEEL BIAS PLY TIRES 1. Clean the tire bead area. RADIAL PLY TIRES NOTICE: Recomm ended vehicle tire mounting a n d in fla tio n p ro c e d u re s a re e s p e c ia lly im portant with radial tires. Failure to follow these procedures can cause bead deformation in both tube type and tubeless tires due to incorrect bead seating. Bead deformation may lead to chafing, lower sidewall and bead area cracking, eccentric wear, ride vibration and nonretreadable castings. Tube Type Tires | 9 | Im portant • Only use rims approved for radial tire usage by the rim manufacturer. 1. Clean the rim parts. • Remove all rust and other foreign material. • Make sure the rim parts match and are not sprung or broken. 2. Lubricate the tire beads, the portion of the tube between the beads, and the flaps with an approved rubber lubricant. • Radial tubes are identifiable by the letter “ R” in the size designation. A red band in the valve stem and an “ R” in the flap size designation also identify radial parts. N O T IC E : Do not u se s ilic o n e b as e lubricants— this could cause the tire to slip on the wheel. 2. Clean the rim bead seats with a wire brush or coarse steel wool to remove lubricants, old rubber, and light rust. 3. Inflate to operating pressure, deflate completely, and reinflate to operating pressure. 3. Apply an approved tire lubricant to the tire bead area. • Allows the tube, flap, and tire to fit together 4. Attach the tire to the wheel. • Use a tire ch an ging m achine. Follow the equipment manufacturer’s instructions. CAUTION: Do not stand over tire when inflating. The bead may break when it snaps over the safety hump, and cause serious personal injury. Do not exceed 275 kPa (40 psi) pressure when inflating. If 275 kPa (40 psi) pressure will not seat beads, deflate, re-lubricate and reinflate. Overinflation may cause the bead to break and result in personal injury. 5. Install a valve core and inflate to the specified pressure (figure 2). • The locating rings on each side of the tire must show above the rim flanges, positioned in direct relation to the wheel (not eccentric as compared with the rim). 6. Check the bead seating. • T ire s m ust be m ounted and in fla te d in accordance with the safety precautions included with the tire mounting equipment. p r o p e r ly . 4. Check the bead seating. • Visually check the slot and side ring gap (on two piece rims) to make sure the bead is seated. 5. Check the spacing between the rim flange and one of the three lower sidewall rim line rings while the tire is laying flat to verify bead seating. • Measurements must be taken each 90 degrees around the circumference of the rim flange. • If the spacing is uneven around the bead from side to side, repeat steps 1 through 3, then recheck. Installing Synthetic Tubes NOTICE: When the tube and the flap are not properly lubricated, and m ounted, they will stretch thin in the tire bead and rim region. This will cause premature wear. 1. Clean the inside of the casing. 2. Insert the tube in the tire and inflate until it is nearly rounded out. 3. Inspect the rim for rust scale and bent flanges. • Clean rust scale and straighten the flanges where necessary. WHEELS AND TIRES 3E-7 4. Apply a solution of neutral vegetable oil soap to the inside and outside of the tire beads, and also the rim side of the tube. • Use a brush or a cloth swab. • Do not allow the soap solution to run down into the tire. 5. Follow the standard procedure when mounting the tube and tire on a drop center rim. Be sure the tire is centered on the rim so the beads are out of the rim well before inflating. Do not allow the tire to hang loosely on the wheel while inflating. 6. Center the valve and pull it firmly against the rim. Hold in this position and inflate until the tire beads are firmly seated on the rim against the flanges. 7. Remove the valve core to completely deflate the tire. 8. Reinflate the tire to the recommended pressure. • R efer to “ Tire Load Lim its And In fla tio n Pressure” at the end of this section. Tubeless Tires | j | Im portant • Only use rims approved for radial tire usage by the rim manufacturer. 1. Clean the rim. • Remove all rust and other foreign material. 2. Lubricate tire beads and rim bead seats with an approved rubber lubricant. N O T IC E : Do not u se s ilic o n e base lubricants— this could cause the tire to slip on the wheel. 3. Inflate the tire to operating pressure. • Due to the construction of radial truck tires, particularly in the lower sidewall and bead area, it may be difficult to get the tire to take air. • An inflation aid may be necessary to help seat the bead of tubeless radial tires. Two types of inflation aids are commercially available—metal rings which use compressed air to seat beads, and rubber rings which seal between the tire bead and rim bead seat allowing the bead to move out and seat. Lubrication is necessary with both aids. 4. Check the spacing between the rim flange and one of the three lower sidewall rim line rings while the tire is laying flat to verify bead seating. • Measurements must be taken each 90 degrees around the circumference of the rim flange. • If the spacing is uneven around the bead from side to side, repeat steps 1 through 3, then recheck. Im portant • This procedure must be followed to insure proper bead seating in order to prevent bead deformation. • Radial tires, as well as bias tires, must be mounted and inflated in accordance with safety precautions noted in RMA Radial and Bias Truck Tire Service Manuals. INSTALLING THE TIRE AND WHEEL ASSEMBLY CAUTION: Before re-installing the wheels, remove any build up of corrosion on the wheel m ounting surface and brake drum or disc m o u n tin g s u rfa c e by s c ra p in g and w ire b ru s h in g . In s ta llin g w h e e ls w ith goo d m e ta l-to -m e ta l c o n ta c t at th e m o u n tin g surfaces can cause wheel nuts to loosen. This can lead to a wheel coming off while the vehicle is moving, possibly causing loss of control. SINGLE WHEELS +«- Install or Connect (Figure 7) 1. Wheel and tire assembly in position on the hub/rotor, and lug nuts installed loosely. 2. Turn the wheel until one nut is at the top of the bolt circle. Tighten the nut just snug. 3. Snug up the remaining nuts criss-cross to minimize runout. Tighten • Nuts to “ Specifications” at the end of this section. • Tighten evenly and alternately to avoid excessive runout (figure 7). DUAL WHEELS Install or Connect (Figure 7) 1. Inner and outer wheel and clam p ring on the rear wheel, or wheel and clam p ring on the front wheel. • Be sure the pins on the clam p ring face outward. 2. Lub nuts finger tight. Tighten • Nuts to “ Specifications” at the end of this section. • For P 3 0 models, tighten to 210 N m (155 ft. lbs.), then tighten again to 237 N m (175 ft. lbs.). • T ig h te n e v e n ly and a lte rn a te ly to avoid excessive runout (figure 7). 3E-8 WHEELS AND TIRES 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. Im portant • Make sure #801 Metal C onditioner is reduced one part metal conditioner to three parts of water. • Wipe off #801 Metal C onditioner carefully w hile the surface is still wet. Use a clean, dry cloth. 4. Apply the clear coat. • Apply R & M’s 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) before installing on the vehicle. 6. Attach balance weights and install the wheel and tire assembly on the vehicle. • Mount the weights in the marked positions and remove the masking from the tire. WHEEL AND TIRE BALANCING Figure 8- -Underbody Swing Out Spare Tire Carrier (RPO P10) Measure • Lateral runout should not exceed 3.18 mm (0.125 inches) on the front wheel or 4.76 mm (0.187 inches) on the rear wheel. ALUMINUM WHEEL REFINISHING • Remove the tire and wheel assembly from the vehicle. • Mark the position of the wheel weights on the tire for correct reinstallatio n after recoating the wheel. Remove the wheel weights and mask off the tire. 1. Remove the original clear coating. • Apply a chemical stripper such as 3M brand Troubleshooter to the wheel rim surface. • Wait 10 to 15 minutes, then wet scrub the surface using a 3M #98 Scotchbrite Cleaning Pad (3M part number 07445). • Rinse the surface thoroughly with clean water. CAUTION: Use of eye goggles is necessary to prevent personal injury. 2. Remove surface oxidation. • Use 3M Superbuff Buffing Pad (3M part number 05701) and a medium type 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. To insure successful, accurate balancing, the following precautions must be observed: • The wheel and tire must be clean and free of all foreign matter. • The tire should be in good condition and properly mounted using the balance mark on the tire, if any, or lined up with the inflation valve. • Bent wheels that have a runout over 1.6 mm (Ve-inch) should be replaced. • Inspect the wheel and tire assembly to determine if an out-of-round condition exists. Im portant A s e v e re o u t-o f-ro u n d c o n d itio n c a n n o t be “ balanced o ut.” A wheel and tire assembly having an o u t-o f-ro u n d c o n d itio n e xce e d in g 4.7 mm (3/i6-inch) is not suitable for the front of the 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. Follow the wheel balancer m achine instructions while performing the balancing operation. OPTIONAL SPARE TIRE CARRIERS UNDERBODY SWING OUT SPARE TIRE CARRIER (RPO P10) The underbody swing out spare tire carrier is standard equipm ent on RV 10/1500 series pickups. It is available as an option (RPO P10) on RV 20/2500 and 30/3500 series pickups (figure 8). WHEELS AND TIRES 3E-9 Figure 9—Underbody Glide Out Spare Tire Carrier (RPO P11) UNDERBODY GLIDE OUT SPARE TIRE CARRIER (RPO P11) SIDE PANEL MOUNTED SPARE TIRE CARRIER (RPO P13) The underbody glide out spare tire carrier is available as an option (RPO P11) on all RV series pickups (figure The side panel mounted spare tire carrier is available as an option on all C-K series pickups (figure 10). 9). 3E-10 WHEELS AND TIRES WHEELS AND TIRES 3E-11 SPECIFICATIONS WHEEL RUNOUT Steel Wheels Aluminum 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 studs studs studs studs studs studs 140 N m (100 ft. lbs.) (steel wheels) 120 N m (88 ft. lbs.) (steel wheels) 140 N m (100 ft. lbs.) (aluminum wheels) 140 N m (100 ft. lbs.) (aluminum wheels) 160 N-m (120 ft. lbs.) (all) 160 N m (120 ft. lbs.) (all) G 10/1500-20/2500 G 10/1500-20/2500 G30/3500 5 studs 5 studs 8 studs 140 N m (100 ft. lbs.) (steel wheels) 140 N m (100 ft. lbs.) (aluminum wheels) 160 N m (120 ft. lbs.) (all) P20/2500 & 30/3500 8 studs 160 N m (120 ft. lbs.) (all) R 10/1500 V10/1500 R10/1500 V10/1500 RV20/2500 RV30/3500 5 6 5 6 8 8 WHEEL STUD NUT TORQUE (SINGLE FRONT AND DUAL REAR WHEELS) Series Number Of Studs Nut Torque RV30/3500 8 studs 190 N m (140 ft. lbs.) (all) G 30/3500 8 studs 190 N m (140 ft. lbs.) (all) P 30/3500 P 30/3500 8 studs 10 studs 190 N-m (140 ft. lbs.) (with RPO JB8) 210 N-m (155 ft. lbs.) (with RPO JF9) 3E-12 WHEELS AND TIRES 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 EXCEEDED). RADIAL TIRE SIZE AND LOAD LIMITS - kg (LBS) Metric Radial Tires Used As Singles Metric Radial Tires Used As Singles (Cont.) Inflation Pressure - kPa (PSI) 400 (58) Tire Load Size Range 2 5 0 (3 6 ) LT215/85R16 C 695 (1532) 790 (1742) (1940) LT215/85R16 D 695 (1532) 790 (1742) 880 (1940) LT235/85R16 D 790 (1742) 900 (1984) 1000 (2205) LT235/85R16 E 790 (1742) 900 (1984) 1000 (2205) [ 450 (65) 500 (73) 550 (80) 1290 (2844) 1380 (3042) Inflation Pressure - kPa (PSI) | 3 0 0 (4 4 ) | 3 5 0 (5 1 ) 880 965 (2127) 1050 (2315) 1100 (2425) 1190 (2623) 1100 (2425) 1190 (2623) Metric Radial Tires Used As Duals (Cont.) Inflation Pressure - kPa (PSI) 400 (58) 450 (65) 870 (1918) 955 (2105) 500 (73) 550 (80) Metric Radial Tires Used As Duals Tire Load Size Range 250 (36) LT215/85R16 C 630 LT215/85R16 D Inflation Pressure - kPa (PSI) | 300 (44) | 350 (51) (1389) 720 (1587) 800 (1764) 630 (1389) 720 (1587) 800 (1764) Bias Tires Used As Singles (Cont.) Inflation Pressure - kPa (PSI) BIAS TIRE SIZE AND LOAD LIMITS - kg (LBS) 345 (50) 379 (55) 993 (2190) 1048 (2310) 1107 (2440) 993 (2190) 1048 (2310) 1107 (2440) | 414 (60) | 448 (65) | 483 (70) 517 (75) 1211 (2670) 1261 (2780) Bias Tires Used As Singles Tire Load Size Range 207 (30) 7 50 16 C 735 (1620) 803 (1770) 875 (1930) 7 50-16 D 735 (1620) 803 (1770) 875 (1930) (2060) 7 50-16 E 735 (1620) 803 875 (1930) 934 2060 Inflation Pressure - kPa (PSI) | 241 (35) | (1770) 276 (40) | 310 (45) 934 (2060) 934 1161 (2560) Bias Tires Used As Duals (Cont.) Inflation Pressure • kPa (PSI) 345 (50) [ 379 (55) [ 414 (60) | 448 (65) | 483 (70) [ 5 17 ^75 ^ Bias Tires Used As Duals Tire Load Size Range 207 (30) 7 50-16 C 649 (1430) 710 767 823 (1565) (1690) (1815) 7 50-16 D 649 (1430) 710 (1565) 767 (1690) 823 (1815) Inflation Pressure - kPa (PSI) | 241 (35) | 276 (40) | 310 (45) B-07548 875 (1930) 925 (2040) 971 (2140) ______________________________________________ B-07549 Figure 11—Tire Load Limits and Inflation Pressure (RV) Figure 12—Tire Load Limits and Inflation Pressure (RV) TIRE LOAD LIMITS AND INFLATION PRESSURE WHEEL CODES AND LOAD LIMITS Refer to Figures 11, 12, 14, 15, 17, and 18 for tire load limits given an inflation pressure range. Refer to Figures 13, 16, and 19 for wheel load limits for each wheel size (coded). WHEELS AND TIRES 3E-13 Code * AA Wheel Size Max. Load kg (lbs.) 16 x 6.5 Tire Load Limits: Bias Tire Used As Singles — kg (lbs.) (Cont.) Max. Pressure kPa (psi) 1,381 (3 045) 621 (90) AF 16x6 1,107 (2 440) 517 (75) BF 16 x 16.5 1,261 (2 780) 586 (85) BK 15x7 757 (1 670) 276 (40) CF 15x7 757 (1 670) 276 (40) CK 15x8 866 (1 910) 276 (40) DAB 15x8 921 (2 030) 276 (40) Inflation Pressure — kPa (PSI) 414 (60) 379 (55) 448 (65) 8 82 928 (1 9 45 ) (2 0 4 5 ) 1016 1 066 (2 240 ) (2 3 50 ) 552 (80) 517 (75) 483 (70) 1016 1066 1120 1166 1216 (2 240 ) (2 3 5 0 ) (2 4 7 0 ) (2 5 70 ) (2 6 80 ) DAC 15x8 921 (2 030) 282 (41) GBA 15x8 900 (1 984) 282 (41) GBB 15 x 7 921 (2 030) 282 (41) UA 15x7 921 (2 030) 282 (41) XAH 15 x 6 900 (1 984) 438 (70) XH 15x6 719 (1 585) 276 (40) 7 76 816 CC 1 5x,6 757 (1 670) 379 (55) (1 710) (1 8 00 ) XX 15x6 925 (2 040) 483 (70) Tire Load Limits: Bias Tires Used As Duals — kg (lbs.) (Cont.) Inflation Pressure — kPa (PSI) 448 (65) 414 (60) 379 (55) 552 (80) 517 (75) 483 (70) Tire Load Limits: Radial Tires Used As Singles — kg (lbs.) (Cont.) * W heel code is located on the wheel ju s t to the rig h t o f the valve stem hole. Inflation Pressure — kPaJPSI) 379 (55) 448 (65) 414 (60) 552 (80) 517 (75) 483 (70) 9 57 1016 1066 1120 1166 1216 (2 110) (2 240 ) (2 3 50 ) (2 4 70 ) (2 570 ) (2 6 8 0 ) B-08072 B-08075 Figure 15—Tire Load Limits and Inflation Pressure (G) Figure 13—Wheel Codes and Load Limits (RV) TIRE AND WHEEL LOAD UMIT CHARTS (Tire and wheel load limits are shown below. Vehicle loading must be limited so that neither Wheel Code and Load Limits the wheel or tire inflation pressure or load limits are exceeded) Tire Load Limits: Bias T im Used As Singles — kg (lbs) Inflation Pressure — kPa (PSI) Tire Size 8.0016.5 8.0016.5 8.7516.5 8 .7 5 16.5 Load Range C D D E 207 (30) 345 (50) 310 (45) 276 (40) 241 (35) Code * 617 676 730 785 (1 3 60 ) (1 4 90 ) (1 610) (1 730 ) 617 676 730 7 85 835 (1 3 60 ) (1 4 9 0 ) (1 610) (1 730) (1 8 4 0 ) 712 7 80 839 903 957 (1 5 70 ) (1 720 ) (1 8 5 0 ) (1 990 ) (2 110) 712 780 839 903 957 (1 5 70 ) (1 720 ) (1 8 5 0 ) (1 990 ) (2 110) Inflation Pressure — kPa (PSI) 8 00165 8 0016.5 Load Range C D 207 (30) 542 594 (1 195) (1 310) 689 642 . il 345 (50) 310 (45) 276 (40) 241 (35) ... (1 520) 542 594 642 689 735 (1 195 (1 310) (1 415) (1 520) (1 620) Tire Load Limits: Radial Tires Used As Singles — kg (lbs) Inflation Pressure — kPa (PSI) Tire Size 8 .7 5 R 1 6.5 Load Range E 207 (30) 241 (35) 276 (40) Max. Load - kg (lbs.) Max. Pressure - kPa (PSI) DAS 15 x 6.5 835 (1 843) 282 (41) GBC 15 x 6.5 835 (1 843) 282 (41) XH 15 x 6 719 (1 585) XAH 15 x 6 900 (1 984) 483 (70) VH 16 5 x 6 1216 (2 680) 586 (85) XJ 16.5 x 6.75 1216 (2 680) 586 (85) 276 (40) 'W heel code is located on the wheel just to the right of the valve stem hole. B-08076 1 ire Load Limits: Bias Tires Used As Duals — kg (lbs) Tire Size Wheel Size 345 (50) 310 (45) 712 780 839 903 (1 5 70 ) (1 7 20 ) (1 8 50 ) (1 9 9 0 ) B-08074 Figure 14—Tire Load Limits and Inflation Pressure (G) Figure 16—Wheel Codes and Load Limits (G) 3E-14 WHEELS AND TIRES TIRE LOAD LIMIT CHARTS TIRE LOAD LIMIT CHARTS (CONT.) (Tire load limits at different inflation pressures are shown below. Vehicle loading must be limited such that neither the tire inflation pressures or load limits are exceeded) METRIC RADIAL TIRES Tire Size Load Range LT215/85R16 c LT215/85R16 METRIC RADIAL TIRES (CONT.) - Inflation Pressure - kPa (PSI) Single Dual 250 (36) 300 (44) 350 (51) S 695 (1532) 790 (1742) 880 (1940) D 630 (1389) 720 (1587) 800 (1764) S 695 (1532) 790 (1742) 880 (1940) D 630 (1389) 720 (1587) 800 (1764) S 790 (1742) 900 (1984) 790 (1742) 900 (1984) D o LT235/85R16 kg (LBS.) kg (LBS.) Inflation Pressure ■ kPa (PSI) 400 (58) 450 (65) 965 (2127) 1050(2315) 870 (1918) 955 (2105) 1000 (2205) 1100 (2425) 1190 (2623) 1000 (2205) 1100 (2425) 1190 (2623) 500 (73) 550 (80) 1290 (2844) 1380 (3042) - LT235/85R16 S E - STANDARD RADIAL TIRES Tire Load Size Range Single Dual 8R19.5 o kg (LBS.) STANDARD RADIAL TIRES (CONT.) - Inflation Pressure - kPa (PSI) 310 (45) 345 (50) Inflation Pressure — kPa (PSI) 379 (55) 414 (60) 448 (65) 483 (70) 517 (75) 552 (80) S 1030 (2270) 1093 (2410) 1152 (2540) 1216 (2680) 1270 (2800) D 1012 (2230) 1066 (2350) 1116 (2460) BIAS TIRES - kg (LBS.) BIAS TIRES (CONT.) - Inflation Pressure — kPa (PSI) Load Single Range Dual 207 (30) 241 (35) 276 (40) 310 (45) 7.50-16 c S 735 (1630) 803 (1770) 875 (1930) 934 (2060) 823 (1815) 7.50-16 D 7.50-16 kg (LBS.) Inflation Pressure — kPa (PSI) Tire Size E kg (LBS.) 345 (50) 379 (55) 414 (60) 1107 (2440) 448 (65) 483 (70) 517 (75) D 649 (1430) 710 (1565) 767 (1690) S 735 (1620) 803 (1770) 875 (1930) 934 (2060) 993 (2190) 1048 (2310) D 649 (1430) 710 (1565) 767 (1690) 823 (1815) 875 (1930) 925 (2040) 971 (2140) S 735 (1620) 803 (1770) 875 (1930) 934 (2060) 993 (2190) 1048 (2310) 1107 (2440) 1161 (2560) 1211 (2670) 1261 (2780) 957 (2110) 1030 (2270) 1093 (2410) 1152 (2540) 1216 (2680) 1270 (2800) 839 (1850) 903 (1990) 957 (2110) 1012 (2230) 1066 (2350) 1116 (2460) 957 (2110) 1030 (2270) 1093 (2410) 1152 (2540) 1216 (2680) 1270 (2800) 839 (1850) 903 (1990) 957 (2110) 1012 (2230) 1066 (2350) 1116 (2460) 1166 (2570) 1216 (2680) - 8-19 5 D S D 8-19.5 E S D B-08077 Figure 17—Tire Load Limits and Inflation Pressure (P) B-08078 Figure 18—Tire Load Limits and Inflation Pressure (P) WHEEL CODE AND LIMITS Code* Wheel Size Max Load kg (Lbs.) Max Pressure 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) ‘ Wheel code is located on the wheel just to the right of the valve stem hole. B-08079 Figure 19—Wheel Codes and Load Limits (P) PROPELLER SHAFT 4A-1 SECTION 4A \ PRO PELLER SHAFT The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of this manual as indicated at appropriate locations by the term inology “ Notice: See ‘NOTICE’ on page 4A-1 of this section” . NOTICE: All propeller shaft to pinion flange fasteners are important attaching parts in that they could affect the performance o f vital parts and systems, and/or could result in major repair expense. They must be replaced with one o f the same part number or with an equivalent part if replacem ent becomes necessary. Do not use a replace­ m ent 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 Description..................................................................................................................................................................... 4A- 1 Propeller S h a ft...........................................................................................................................................................4A- 1 Center B earing...........................................................................................................................................................4A- 1 Universal J o in t...........................................................................................................................................................4A- 1 Diagnosis Of Driveline Vibration (Road Test)........................................................................................................... 4A- 3 Diagnosis Of Propeller Shaft and Universal J o in t................................................................................................... 4A- 4 On-Vehicle S e rv ic e ...................................................................................................................................................... 4A- 5 Propeller Shaft Balance Check................................................................................................................................4A- 5 Propeller Shaft Runout C h e c k ................................................................................................................................4A- 5 Propeller Shaft Replacement (Rear Drive)............................................................................................................. 4A- 6 Propeller Shaft Replacement (Front D rive)............................................................................................................4A- 7 Lubrication.....................................................................................................................................................................4A- 9 S p e cifica tio n s...............................................................................................................................................................4 A - 10 Special T o o ls .................................................................................................................................................................4A-10 DESCRIPTION PROPELLER SHAFT Torque is transmitted from the transm ission to the rear axle through one or more propeller shafts and universal joint assemblies. The num ber of propeller shafts and universal joint assemblies vary with the vehicle wheel base, and the combination of transm ission, transfer case (front drive) and rear axle equipment. All propeller shafts are the balanced tubular type (figure 1). A splined slip joint is provided in some 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 usually at the forward end of the rear propeller shaft. Phasing The propeller shaft is designed and built with the yoke lugs (ears) in line with each other (figure 1). This design produces the smoothest running shaft possible, and is called phasing. Vibration can be caused by an out of phase propeller shaft. The propeller shaft will absorb vibrations from speeding up and slowing down each tim e the universal joint goes around. This vibration would be the same as a person sn ap ping a rope and w atch in g the “ w ave” reaction flow to the end. A propeller shaft working in phase would be sim ilar to two persons snapping a rope at the same time, and watching the “ waves” meet and cancel each other out. In comparison this would be the same as the universal joints on a propeller shaft. A total cancellation of vibration produces a smooth flow of power in the driveline. It is very important to reference mark the p ro p e lle r s h a ft b efo re rem oval, to a ssure pha sed in s ta lla tio n a lig n m e n t. Som e p ro p e lle r shafts have alignm ent marks or arrows stamped on the shaft at the tim e of production. CENTER BEARING Center bearings support the driveline when two or more propeller shafts are used. The center bearing is a ball type bearing mounted in a rubber cushion that is attached to a frame crossmember. The bearing is pre-lubricated and sealed by the m anufacturer (figure 2). UNIVERSAL JOINT A universal joint is two Y-shaped yokes connected by a crossm em ber called a spider. The spider is shaped like a cross having arms of equal length called trunnions (figure 3). 4A -2 PROPELLER SHAFT Universal joints are designed to handle the effects of v a rio u s lo a d in g s a n d re a r a x le w in d u p d u rin g acceleration. W ithin the designed angle variations the universal joint will operate efficiently and safely. When the design angle is changed or exceeded the operational life of the joint may decrease. The trunnion bearings used in universal joints are the needle roller type. The needle rollers are held in place on the trunnions by round bearing cups. The bearing cups are held in the yokes by e ithe r (depending on the manufacturer) snap rings or injected plastic. When a driveline has a large or deep angle a constant velocity joint is used. Essentially, the constant velocity joint is made of two universal joints coupled by a yoke and phased for constant velocity. A centering 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 6. R e ta in e r 7. P in io n F la n g e 8. Yoke and C ro s s A s s e m b ly S p lin e d S h a ft C ap W a sh e r Seal (Cork) N ut T ra n s m is s io n Yoke W asher B o lt U nive rsa l J o in t 1. 2. 3. 4. 5. H a n g e r A s s e m b ly and C ro s s m e m b e r C enter Bearing S u pp o rt F ro n t P ro p e lle r S h a ft Rear P ro p e lle r S h a ft B o lt S lip Yoke B-06720 Figure 2—Center Bearing and Propeller Shaft Detail PROPELLER SHAFT 4A-3 A. Ball S o c k e t Figure 3—Simple Universal Joint B-06813 Figure 4—Constant Velocity Joint (figure 4). The ball socket on a constant velocity universal join t requires periodic lubrication through the fitting provided. DIAGNOSIS OF DRIVELINE VIBRATION (ROAD TEST) Four major component groups are usually the cause of or are related to vibration. When a technician is road test­ ing a vehicle for vibration he must remember the four ma­ jor component groups: 1. Engine and mounts. 2. Clutch and transmission. 3. Tires, wheels and brake drums. 4. Propeller shaft and universal joints. Before road testing a vehicle, check the following: 1. In or out of phase propeller shaft. 2. All fasteners for tightness at universal joints, wheel lugs and engine mounts. 3. T ire a ir pressure. 4. Load conditions. ROAD TEST A technician should road test the vehicle to diagnose exactly what the com plaint is. Record the speed and rpm at which the greatest vibration occurs. The vibration is likely to be in two places, in the steering wheel or in the seat bottom. The road test can be helpful in locating the vibration source either forward or aft. COAST TEST Drive the vehicle past the vibration speed, shift into neutral and coast back through the vibration speed. In this test two kinds of vibration normally occur; a shaking or a buzzing. A shaking vibration is usually tires or a wheel and brake drum /disc assembly problem. A buzzing vibration is usually a driveline problem. 4A-4 PROPELLER SHAFT DIAGNOSIS OF THE PROPELLER SHAFT AND UNIVERSAL JOINT PROBLEM Leak At The Front Slip Yoke (An Occasional Drop Of Lubricant Leaking From The Splined Yoke Is Normal And Requires No Attention) POSSIBLE CAUSE CORRECTION 1. Rough surface on splined yoke; burred, nicked or worn. 1. Replace the seal. Minor burrs can be sm oothed by careful use of crocus cloth or fine stone honing. Replace the yoke if badly burred. 2. Replace the transm ission rear oil seal and replenish the transm ission oil. 2. Defective transm ission rear oil seal. Universal Joint Noise 1. 2. 3. 4. Ping, Snap, Or Click In Drive Line (Usually Heard On Initial Load After The Transmission Is In Gear; Forward Or Reverse) 1. Loose bushing bolts on the rear springs or upper and lower control arms. 2. Loose or out of phase companion flange. Knocking Or Clunking Noise In The Driveline When Operating The Vehicle In A Floating Condition In High Or Neutral Gear At 10 MPH (16 km/h) 1. Worn or damaged universal joint. Roughness Or Vibration Center bearing. Worn universal joint bearings. Improper lubrication. Loose flange bolts. 2. Side gear hub counterbore in the dif­ ferential is worn oversize. 1. Bent or dented propeller shaft. 2. Undercoating on propeller shaft. 3. Tire unbalance, 30-80 mph (48-129 km/ h). Not throttle conscious. 4. Tight universal joints. 5. Worn universal joints. 6. Burrs or gouges on companion flange. Check snap ring locating surfaces on flange yoke. 7. Propeller shaft, parking brake drum or companion flange is unbalanced. 8. Incorrect rear joint angle. The angle is usually too large when it is a factor. 9. Excessive looseness at the slip spline. 10. Distorted or damaged yokes or flanges. 11. Yokes out of phase. 12. Propeller shaft runout at 50 mph (80 km/ h). Throttle conscious. 1. 2. 3. 4. Replace the center bearing. Replace. Lubricate as directed. Tighten to “ Specifications” later in this section. 1. Tighten the bolts to specified torque. 2. Remove companion flange, turn 180 degrees from its original position, lubri­ cate the splines and install. Tighten the bolts and pinion nut to specified torque. 1. Replace the worn or damaged univer­ sal joint. 2. Replace the differential case and/or the sidegears. 1. Replace propeller shaft. 2. Clean propeller shaft. 3. Balance or replace as required. 4. Impact yokes with a shaft hammer to free up. If unable to free up or if joint feels rough when rotated, replace. 5. Replace. 6. R ew ork or re p la c e th e co m p a n io n flange. 7. Check for a missing balance weight on the propeller shaft. Rotate the com pan­ ion flange 180 degrees. 8. Check and correct trim height at curb weight. Check and correct joint angle. 9. Replace necessary parts. 10. Install new yokes or flanges. 11. Remove companion flange, turn 180 degrees from the original position, lu­ bricate the splines and install. Tighten bolts to specified torque. 12. Check propeller shaft runout at front and rear. Should be less than specified. If above, rotate propeller shaft 180 de­ grees and recheck. Replace the propel­ le r s h a ft if r u n o u t is s till o v e r specification. PROPELLER SHAFT 4A-5 DIAGNOSIS OF THE PROPELLER SHAFT AND UNIVERSAL JOINT (CONTINUED) PROBLEM POSSIBLE CAUSE CORRECTION Scraping Noise Slinger, companion flange, or end yoke rubbing on rear axle or center bearing. Correct the interference. Roughness Above 35 MPH (56 km/h) Felt And/Or Heard Tires unbalanced or worn. Balance or replace as required. Squeak 1. Lack of lubricant. 1. Lubricate joints and splines. Also check for worn or brinelled parts. 2. Replace or lubricate. 2. Center bearing. Whine Or Whistle Shudder On Acceleration, (Low Speed) Center support bearing. Place the vehicle on a hoist with rear wheels free to rotate and diagnose for source of noise, replace. 1. Loose or m issing bolts at the center bearing or flanges. 2. Incorrectly set front joint angle. 3. Worn universal joint. 1. Replace or tighten bolts to specified torque. 2. Shim under the transmission support mount to change the front joint angle. 3. Replace. ON-VEHICLE SERVICE PROPELLER SHAFT BALANCE CHECK • Raise the vehicle on a twin post hoist so the wheels can spin. B Remove or Disconnect 1. Tire and wheel assemblies and the brake drums. • DO NOT APPLY THE BRAKE W ITH THE DRUMS REMOVED. L* Inspect Propeller shaft, universal joints and attachments for mud, undercoating or loose fasteners. igi Clean • Propeller shaft, universal joints and attachments. U Tighten • Any loose attachments or fasteners. Important • Run the vehicle in gear at the speed where the disturbance peaks; observe the intensity of the disturbance. • Stop the engine. 2. Propeller shaft. Rotate the propeller shaft 180 degrees from the original position. B Install or Connect 1. Propeller shaft. • Determine the position which gives the best 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 shaft balance. • Unacceptable balance, replace the propeller shaft. PROPELLER SHAFT RUNOUT CHECK Noise or vibration at high speed could be caused by a bent propeller shaft. The propeller shaft could have been damaged by rough handling or a collision. Check for propeller shaft straightness. 1. Raise the vehicle on a twin post hoist so the wheels can spin. 2. Attach a dial indicator having a magnetic base to a smooth place on the vehicle underbody. 3. Take dial indicator readings at the propeller shaft c h e c k p o in ts show n in fig u re 5. For ru n o u t specifications, refer to figure 6. 4A-6 PROPELLER SHAFT F ro n t R u n o u t C e n te r R u n o u t Rear R u n o u t S p lin e d S h a ft R u n o u t at Tapered H o le in S p lin e d End O ne Piece P ro p e lle r S h a ft Rear P ro p e lle r S h a ft F ro n t P ro p e lle r S h a ft B-07678 Figure 5—Checking Propeller Shaft Runout Im portant • Do not attach the dial indicator base at a weld. 4. With the transmission in neutral, hand rotate the axle pinion flange or the transmission yoke and take the necessary dial indicator readings on the propeller shaft. Record the readings. Models 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 pinion flange, then remove the rear propeller shaft and measure the front propeller PR O PELLER SHAFT FR O N T CHECK CEN TER CHECK REAR CHECK O N E PIECE .040 .050 .055 TW O PIECE FR O N T .020 TW O PIECE REAR .030* .008A .030 shaft runout on the tube and at the tapered hole on the splined shaft end (figure 5). If the runout exceeds specification, rotate the propeller shaft 180 degrees at the companion flange and install. Check the runout. 5. If the runout is still over specification at one or more check points, replace the propeller shaft after checking for vibration or noise. Check the runout on the replacement propeller shaft. 6. If the new propeller shaft runout is over specification, check for a bent companion flange. Im portant The splined end of the front propeller shaft is critical to the smooth operation of a two-piece driveline. Be sure the dial indicator readings are accurate. PROPELLER SHAFT REPLACEMENT (REAR DRIVE) Remove or Disconnect (Figure 2) .035 • 1. A N O T E : T h is m e a s u re m e n t m u s t be ta ken at th e ta p e re d h o le on th e s p lin e d s h a ft a fte r th e rear p ro p e lle r s h a ft is rem oved. 2. 3. Tool Required: J-33051, Driveshaft Wrench. Raise the vehicle on a hoist. Skid plate if used. • Reference mark the propeller shaft (4) to pinion flange (7) connection. Bolts (5). Retainers(6). Im portant * NOTE: T h is m e a s u re m e n t m u s t be ta ken w ith th e rear p ro p e lle r s h a ft m o u n te d on th e fro n t s h a ft w h ic h is w ith in s p e c ific a tio n s . B-07557 Figure 6—Propeller Shaft Runout Specifications • Do not pound on the original propeller shaft yoke ears. The injection joints may fracture. Never pry or place any tool between a yoke and a universal joint. 4. Yoke and cross assembly (8). • Tape bearing cups to prevent the loss of bearing rollers. 5. Propeller shaft (4). • Slide the propeller shaft (4) forward. PROPELLER SHAFT 4A-7 • Lower the propeller shaft (4) and withdraw under the rear axle. • Do not allow the universal joint (17) to incline greatly; the joint may fracture. Tighten $ Nut (13) to torque specification later in this section. Maintain alignment (figure 7). Models with a two-piece propeller shaft 6. Nut (13). 7. Bolt (16) and washer (15). 8. Center bearing support (2). • Support the propeller shaft (3). 9. Cap (10). 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 deeply as the universal joint could fracture. • Withdraw the propeller shaft (3) with a rearward movement. Im portant 6. 7. 8. 9. 10. Clean All parts. Inspect 1. Outer diameter of transmission yoke (14) for burrs. Any burring will damage the transmission seal. 2. For proper installation and uniform seating of bearing cups. 3. Slip yoke (18) splines for wear. 4. For twisted slip yoke splines or possibly the wrong universal joint. |~n-| Install or Connect (Figures 2 and 7) One-Piece Propeller Shaft 1. Propeller shaft (4) into the transmission. • Lubricate slip joint. 2. Yoke and cross assembly (8) onto the pinion flange (7). • Align the reference marks on the pinion flange (7) and the propeller shaft rear yoke (8). Seat the yoke properly. 3. Retainer (6). NOTICE: See “ N otice” on page 4A-1 of this section. 4. Bolt (5). Tighten • Bolt (5) to torque in “ Specifications” at the end of this section. Two-Piece Propeller Shaft 1. Propeller shaft (3) into the transmission. • Be sure joint is lubricated. • Bottom the propeller shaft (3) yoke in the transmission. 2. Center bearing support (2) onto hanger (1). • Align the center bearing support 90 degrees to the propeller shaft (3, 4) center lines. Refer to figure 7. 3. Bolt (16). 4. Washer (15). 5. Nut (13). 11. • Set the transmission yoke (14) ears in a vertical position for proper phasing (figure 7). Cap (10). Washer (11). Seal (12). • Locate the bridged tooth on the splined shaft (9). Slip yoke (18) onto the splined shaft (9). • Mate the missing tooth in the yoke (18) with the bridged tooth on the splined shaft (9) figure 7. Support the propeller shaft (4). • Be sure the slip yoke (18) ears are horizontal, figure 7. Propeller shaft (4). • Align reference marks. • Check bearings for proper fit. Retainer (6). NOTICE: See “ N o tic e ” on page 4A-1 of this section. 12. Bolt (5). • Check for proper joint fit. £ Tighten • B o lts (5) to s p e c ifie d to rq u e . R e fe r to “ Specifications” at the end of this section. • Lubricate the slip yoke (18). PROPELLER SHAFT REPLACEMENT (FRONT DRIVE) Remove or Disconnect (Figure 8) Tool Required: J-22610, Keystone Clamp Pliers. • Raise the vehicle on a hoist. • Remove skid plate if used. • Reference mark the relationship of the propeller shaft (14) to the front axle and the transfer case flange (17). 1. Slip yoke (13) from the front axle yoke (12). — Nut (10), washer (11) and U-bolt (15). — Bolt (20) and retainer (22). Im portant • Do not pound on the joint to disconnect. 2. Bolt (18) at the flange (17). 3. Boot (21) if used. • Release boot retainers using J-22610. • Slide the propeller shaft (14) forward, enough to disengage, then withdraw the propeller shaft (14) rearward. • Avoid dropping cap assemblies from the yoke ends. ijj| Clean • All parts. 4A-8 PROPELLER SHAFT H a n g e r A s s e m b ly C e n te r B e aring S u p p o rt F ro n t P ro p e lle r S h a ft Rear P ro p e lle r S h a ft T ra n s m is s io n Yoke S lip Yoke H o riz o n ta l C e n te r Lin e A t T he Yoke 90 ± 1 D egree A n g le F or S lo tte d H a n g e r H o le s V e rtic a l C e n te r L in e A t T he Yoke B-07562 Figure 7—Alignment for Two-Piece Propeller Sahft In Phase, G and V Models ' 12 I* ' 11. W a sh e r 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. Figure 8—Front Propeller Shaft and Driveline Detail F ro n t A x le Yoke S lip Yoke P ro p e lle r S h a ft A s s e m b ly U -b olt T ra n sfe r C ase F lan ge B o lt C o n s ta n t V e lo c ity J o in t B o lt Boot R e ta in e r F ro n t A x le A s s e m b ly C la m p B-07561 PROPELLER SHAFT 4A-9 IP Inspect • Splines for damage, wear, burrs and twisting. • Bearings for wear. • Propeller shaft (14) for straightness. • Mate the joint using reference marks. — U-bolt, washer (11) and nut (10). — Retainer (22) and bolt (20). • Support the propeller shaft (14). NOTICE: See “ N o tic e ” on page 4A-1 of this section. Install or Connect (Figure 8) Tools Required: J-22610, Keystone Clamp Pliers. J-25512, CV Propshaft Lube Gun (Vs-inch pipe). J-25512-2, Needle point. • Lubricate the slip yoke (13) before installing the boot (21). Refer to “ Lubrication” later in this section. 1. Boot (21) if used. • Retainers (24) using J-22610. 2. Slip yoke (13) to the axle yoke (12). • Adjust propeller shaft (14) length. Tighten • All fasteners to specified torque. Refer to “ Specifications” at the end of this section. 3. Bolt (18) at the flange (17). • Mate the joint using reference marks. • Lubricate the Constant Velocity Joint (19). Refer to “ Lubrication” later in this section. 4. Skid plate, if used. Tighten All fasteners to specified torque. Refer to “ Specifications” later in this section. LUBRICATION The front axle propeller shaft found on four-wheel drive vehicles requires a special lubricant at two locations: the constant velocity joint, and the slip yoke. Constant Velocity Joint (C/V Joint) The constant velocity (C/V) joint, located at the transfer case end of the front propeller shaft, must be lubricated p e rio d ic a lly w ith a s p e c ia l lu b ric a n t, 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 (figure 9). Slip Spline Apply chassis lubricant at the slip spline grease fitting until the grease begins to leave through the vent hole. If the slip spline is dry or corroded, it may be necessary to disconnect the propeller shaft from the vehicle, remove the slip yoke, and wire brush the affected area. Wipe clean before installation. Figure 9—Lubricating the Constant Velocity Joint Fitting 4A-10 PROPELLER SHAFT SPECIFICATIONS APPLICATION P ropeller Shaft: To Rear A xle (R etainer or S tra p ) ..................................... To Rear A x le .......................................................................... Two Piece Propeller S h a ft-F ro n t To Brake Hub S tu d s ............................................................ To Transm ission F lan ge /Y o ke ............................................ To Transfer Case Yoke (N u t).............................................. C enter B earing Support: To TORQUE FT. LBS. MODEL Nm R, G, P R, V, G300, P 2 0* 35 15* 26 R, G, P V 27 20 27 20 15 20 P300 R P V R R, G 33 20 35 27 33 33 24 15 26 20 24 24 P R, G, P R, V, G300, P300 27 20 33 20 15 24 V V100, 200 V300 100 20 20 74 15 15 P300 Two Piece P ropeller S h a ft-R e a r: To Rear Axl Propeller Shaft: T o rq u e S pecification Is For Hex Head Bolt. SPECIAL TOOLS 1. 2. 3. 4. J-22610 3. J-25512-2 J-25512 4. J-33051 K e ysto n e C la m p P liers CV P ro p s h a ft Lube G un N ee dle P oint D rive s h a ft W re nch Figure 10—Special Tools B-07708 REAR AXLE 4B1-1 SECTION 4B1 REAR AXLE 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 term inology: “ 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 o f 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 replacem ent becom es necessary. Do not use a replacem ent part o f lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of all parts. CONTENTS SUBJECT PAGE Description................................................................................................................................................................... 4B1- 1 Rear Axle O p e ra tio n .............................................................................................................................................. 4B1- 1 Diagnosis of the Rear A xle........................................................................................................................................ 4B1- 2 Determining the Type of Noise..............................................................................................................................4B1- 2 On-Vehicle S e rv ic e .................................................................................................................................................... 4B1- 8 Rear Axle Assembly Replacement (All Axles)..................................................................................................... 4B1 - 8 Semi Floating Axle (81/2-91/2>lnch Ring Gear)......................................................................................................... 4B1 - 9 Axle Shaft, Oil Seal and Bearing Replacement................................................................................................... 4B1- 9 Brake Backing Plate Replacement........................................................................................................................4B1-11 Wheel Stud Replacem ent...................................................................................................................................... 4B1-11 Pinion Flange, Dust Deflector/Oil Seal Replacement.........................................................................................4B1-12 Full Floating Axle (93/4-101/2-lnch Ring Gear)......................................................................................................... 4B1-14 Axle Shaft Replacement.................................................................. ......................................................................4B1-14 Hub And Drum Assembly Replacement............................................................................................................... 4B1-14 Wheel Bearing/Cup Replacement..........................................................................................................................4B1-15 Non-Demountable Type Drum Replacement................................................................ .......................................4B1-16 Wheel Bolt Replacement........................................................................................................................................ 4B1-16 Bearing A djustm e n t................................................................................................................................................4B1-16 Pinion Oil Seal/Companion Flange Replacement............................................................................................... 4B1-17 Full Floating Axle (12-Inch Ring G e a r)................................................................................................................... 4B1-18 Axle Vent Replacement.......................................................................................................................................... 4B1-18 Axle Shaft Replacem ent........................................................................................................................................ 4B1-18 Bearing Adjustm ent................................................................................................................................................ 4B1 -18 Drive Pinion Oil Seal R eplacem ent..................................................................................................................... 4B1-19 S pe cifica tio n s.............................................................................................................................................................4B1-20 Special T o o ls ...............................................................................................................................................................4B1-21 DESCRIPTION Light duty trucks use various rear axles. These axles can be identified by ring gear size in inches, by m anufac­ turer (Corporate, Dana, or Rockwell) and by the type of axle shaft used (Semi-Floating or Full Floating). Corporate axles include the 8 V2 , 91fe and 101/2-inch ring gear axles. Dana also supplies a 101/2-inch ring gear axle as well as a 9 3/4-inch ring gear axle. The 12-inch ring gear axle is sup­ plied by Rockwell, and uses rear wheel disc brakes. REAR AXLE OPERATION A basic differential has a set of four gears. Two are called differential side gears and the other two are differential pinion gears. Some differentials have more than two pinions. Each side gear is splined to an axle shaft, therefore each axle shaft must turn when its side gear rotates. The d iffe re n tia l p in io n g ea rs are m ou nte d on a differential pinion shaft, and the gears are free to rotate on this shaft. The pinion shaft is fitted into a bore in the differential case and is at right angles to the axle shafts. Power flow through the differential is as follows: the drive pinion rotates the ring gear. The ring gear, being bolted to the differential case, rotates the case. The differential pinion, as it rotates with the case, forces the pinion gears against the side gears. When both wheels have equal traction, the pinion gears do not rotate on the pinion shaft because the input force on the pinion gear is equally divided between the two side gears. Therefore, the pinion gears revolve with the pinion shaft, but do not 4B1-2 REAR AXLE rotate around the shaft itself. The side gears, being splined to the axle shafts and in mesh with the pinion gears, rotate the axle shafts. If a vehicle were always driven in a straight line, the ring and pinion gears would be sufficient. The axle shaft could then be solidly attached to the ring gear and both driving wheels would turn at equal speed. However, if it became necessary to turn a corner, the tires would scuff and slide because the outside wheel would travel further than the inside wheel. To prevent tire scuffing and sliding, the differential becomes effective and allows the axle shafts to rotate at different speeds. When the vehicle turns a corner, the outer rear wheel must turn faster than the inner wheel. The inner wheel turns slower than the outer wheel and slows its rear axle side gear (as the axle shaft is splined to the side gear) and the rear axle pinion gears will roll around the slowed rear axle side gear, driving the other rear axle side gear and wheel faster. LOCKING REAR AXLE Eaton Locking Differential T he lo c k in g re a r d iffe re n tia l a llo w s fo r n o rm a l differential function as indicated in the standard rear axle description. Additionally, the locking rear differential uses m u lti- d is c c lu tc h p a c k s and a s p e e d s e n s itiv e engagem ent mechanism that locks both wheels together if one wheel should spin excessively during slow vehicle operation. Under light loads, the clutch plates alone tend to lock axle shafts to the differential case, and therefore, each other. This is due prim arily to the gear separating load developed on the right side clutch pack. This induced clutch torque capacity resists motion between the side gear and the rear axle differential case. The axle shaft torques developed when turning a corner will overcome this capacity and allow differentiation. Also, heavier throttle application will cause differential, but this starts the full-lock feature of the unit. Full locking is accom plished through the use of a heavyweight governor m echanism , cam system , and multi-disc clutch packs. The flyweights on the governor m echanism move outward to engage a latching bracket w h e n e v e r th e w h e e l-to -w h e e l s p e e d v a rie s by approximately 100 rpm or more. This action retards a cam which, in turn, compresses the multi-disc clutch packs locking both side gears to the case. The 100 rpm w he el-to -w he e l speed allo w s fo r co rn e rin g w ith o u t differential lock-up. At vehicle speeds above approximately 32.2 km/h (20 mph), the latching bracket overcomes a spring preload and swings away from the flyweights. At this vehicle speed or greater, the differential will not lock, as the added traction is generally not required. All gear axle parts of vehicles equipped with the locking rear axle are interchangeable with those equipped with the conventional rear axle, except for the case assembly. DIAGNOSIS OF THE REAR AXLE The most essential part of rear axle service, as with any m echanical repair, is proper diagnosis of the problem, and, in axle work one of the most difficult areas to diag­ nose is noise. Locating a broken axle shaft, or broken differential gear, presents little or no problem, but, locat­ ing and isolating axle noise can be an entirely different matter. Degree of Noise Any gear driven unit, especially an automotive drive axle where engine torque m ultiplication occurs at a 90 degree turn in the drive line, produces a certain amount of noise. Therefore, an interpretation must be made for each vehicle to determine w hether the noise is normal or if a problem actually exists. A normal amount of noise must be expected and cannot be elim inated by conventional repairs or adjustment. Acceptable noise can be defined as a slight noise heard only at a certain speed or under unusual or remote conditions. For example, this noise tends to reach a “ peak” at speeds from 40 to 60 miles per hour (60 to 100 km/h) depending on road and load conditions, or on gear ratio and tire size. This slight noise is in no way indicative of trouble in the axle assembly. D riv e lin e n o is e s m a y b a ffle e ven th e b e s t d ia g n o s tic ia n . V e h ic le n o is e s co m in g from tire s , transmission, propeller shaft, universal joints, and front or rear wheel bearings, are often mistaken for axle noise. Such practices as: raising tire pressure to 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 coast conditions will aid in locating the source of alleged axle noises. Thus, every effort should be made to isolate the noise to a specific drive line component instead of m aking a random guess that could be a costly waste of time. DETERMINING THE TYPE OF NOISE External Noise When a rear axle is suspected of being noisy, it is advisable to make a thorough test to determ ine whether the noise originates in the tires, road surface, front wheel bearings, engine, transm ission, or rear axle assembly. N oise w h ic h o rig in a te s in o th e r p la c e s c a n n o t be corrected by adjustment or replacement of parts in the rear axle assembly. Road Noise— Some road surfaces, such as brick or rough-surfaced concrete, cause noise which may be mistaken for tire or rear axle noise. Driving on a different type of road, such as smooth asphalt or dirt, will quickly show whether the road surface is the cause of noise. Road noise usually is the same on drive or coast. Tire Noise—Tire noise may easily be mistaken for rear axle noise, even though the noisy tires may be located on the front wheels. Tires worn unevenly, or having surfaces on non-skid divisions worn in saw-tooth fashion, are REAR AXLE 4B1-3 usually noisy and may produce vibrations which seem to originate elsewhere in the vehicle. This is particularly true with low tire pressure. Tire Noise Test—Tire noise changes with different road surfaces, but rear axle noise does not. Temporarily inflating all tires to 345 kilopascals (50 pounds per square inch) pressure, for test purposes only will materially alter noise caused by tires but will not affect noise caused by the rear axle. Rear axle noise usually stops when coasting at speeds under 30 miles per hour; however, tire noise continues but with lower tone as the vehicle speed is reduced. R ear axle noise usually changes when comparing “ p u ll” and “ coast” but tire noise remains about the same. Engine and Transmission Noises—Som etim es a noise which seems to originate in the rear axle is actually caused by the engine or transm ission. To determ ine w h ich u n it is a c tu a lly c a u s in g th e noise, o b se rve approximate car speeds and conditions under which the noise is most pronounced; then stop the vehicle in a quiet place to avoid interfering noises. With the transm ission in neutral, run the engine slowly up and down through the engine speeds corresponding to the vehicle speed at which the noise was most pronounced. If a sim ilar noise is produced with the vehicle standing, it is caused by the engine or transm ission and not the rear axle. Front Wheel Bearing Noise— Loose or rough front wheel bearings will cause noise which may be confused with rear axle noise; however, front wheel bearing noise does not change when com paring “ p ull” and “ coast.” Light application of the brake, while holding the vehicle speed steady, will often cause the wheel bearing noise to dim inish, as this takes some weight off of the bearing. Front wheel bearings may be easily checked for noise by jacking up the wheels and spinning them, and also by shaking the wheels to determ ine if the bearings are excessively loose. Body Boom Noise or Vibration—Objectional “ body boom” noise or vibration at 5 5 -6 5 mph (90-100 km/h) can be caused by an unbalanced propeller shaft. Excessive looseness at the spline can contribute to this unbalance. O ther items that may also contribute to the noise problem are as follows: 1. Undercoating or mud on the shaft, causing unbalance. 2. Shaft or companion flange balance weights missing. 3. Shaft damage, such as bending, dents, or nicks. 4. Tire-type roughness. Switch tires from a known good vehicle to determine a tire fault. If, after making a comprehensive check of the vehicle, all indications point to the rear axle, further diagnostic steps are necessary to determine the axle components at fa u lt. True rear axle noise g e n e ra lly fa lls into two categories: gear noise and bearing noise. Rear Axle Noises If a careful test of the vehicle shows that the noise is not caused by external items, it is then reasonable to assume that noise is caused by the rear axle assembly. Test the rear axle on a smooth level road to avoid road noise. It is not advisable to test the rear axle for noise by running with the rear wheels jacked up. Noise in the rear axle assem bly may be caused by a faulty propeller shaft, faulty rear wheel bearings, faulty d iffe re n tia l or p in io n sh a ft b e a rin g s , m is a lig n m e n t Figure 1—Causes of Gear Noise between two U-joints, or worn differential side gears and pinions; noise may also be caused by a mism atched, improperly adjusted, or scored, ring and pinion gear set. Rear Wheel Bearing Noise—A rough rear w heel bearing produces a vibration or growl which continues with the vehicle coasting and the transm ission in neutral. A brinelled rear wheel bearing causes a knock or click approximately every two revolutions of the rear wheel, since the bearing rollers do not travel at the same speed as the rear axle and wheel. W ith the rear wheels jacked up, spin the rear wheels by hand while listening at the hubs for evidence of a rough or brinelled wheel bearing. Differential Side Gear and Pinion Noise— Differentia! side gears and pinions seldom cause noise since their movement is relatively slight on straight ahead driving. Noise produced by these gears will be most pronounced on turns. Pinion Bearing failures can be distinguished because th e y rotate at h ig h e r sp ee ds than d iffe re n tia l side bearings and axle shaft bearings. Rough or brinelled pin ion b e a rin g s p ro du ce a c o n tin u o u s low p itch e d w hirring or scraping noise starting at a low speed. Side Bearings produce a constant rough noise pitched lower than pinion bearing noise. Side bearing noise may also fluctuate in the above rear wheel bearing test. 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, im proper break-in, improper lubricant, insufficient gear backlash, im proper 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). A nother 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. 4B1-4 REAR AXLE ABRASIVE ROLLER WEAR ABRASIVE STEP WEAR Pattern on race s and ro lle rs ca u se d by fin e abrasives. C lean all p a rts and h o u s in g s , c h e c k se a ls and b e a rin g s and re p la c e if le a k in g , ro u g h o r noisy. Pattern on ro lle r e n d s c a u s e d by fin e a b ra ­ sives. C lean all p a rts and h o u s in g s , c h e c k se a ls and b e a rin g s and re p la c e if le a k in g , ro u g h o r noisy. GALLING ETCHING M etal sm e a rs on ro lle r e n d s due to overheat, lu b ric a n t fa ilu re o r o ve rlo a d . R eplace b e a rin g , c h e c k se a ls and c h e c k fo r p ro p e r lu b ric a tio n . B e aring s u rfa c e s a pp ea r gray o r g ra y is h b la c k in c o lo r w ith related e tc h in g aw ay o f m a te ria l u s u a lly at ro lle r s p a c in g . R eplace b ea rin gs, c h e c k s e a ls and c h e c k fo r p ro p e r lu b ric a tio n . B-09194 Figure 2—Diagnosis of Tapered Roller Bearings REAR AXLE 4B1-5 BENT CAGE C age dam ag ed d u e to im p ro p e r h a n d lin g o r to o l usage. R ep lace b ea rin g. BENT CAGE C age d a m a g e d d u e to im p ro p e r h a n d lin g o r to o l usage. R ep lace b e a rin g . CAGE WEAR INDENTATIONS W ear a ro u n d o u ts id e d ia m e te r o f ca ge and ro lle r p o c k e ts ca u se d by a b rasive m a te ria l and in e ffic ie n t lu b ric a tio n . C lean related p a rts and h o u s in g s . C h e c k se a ls and re p la ce b e a rin g s. S u rfa c e d e p r e s s io n s o n ra c e a nd r o lle r s ca u s e d by hard p a rtic le s o f fo re ig n m a te ria l. C lean all p a rts and h o u s in g s . C h e c k s e a ls and rep la ce b e a rin g s if ro u g h o r noisy. B-09195 Figure 3—Diagnosis of Tapered Roller Bearings 4B1-6 REAR AXLE FRETTAGE SMEARS C o rro s io n se t up by sm a ll relative m o ve m e n t o f p a rts w ith no lu b ric a tio n . R eplace b e a rin g . C lean related parts. C h e c k seais and c h e c k fo r p ro p e r lu b ric a tio n . S m e a rin g o f m eta l due to s lip p a g e . S lip p a g e c a n be c a u s e d by p o o r f it s , lu b r ic a tio n , o v e rh e a tin g , o ve rlo a d s o r h a n d lin g dam age. R e p la c e b e a rin g s , c le a n re la te d p a rts and c h e c k fo r p ro p e r fit and lu b ric a tio n . STAIN DISCOLORATION HEAT DISCOLORATION D is c o lo ra tio n can range fro m lig h t b row n to b la c k ca u se d by in c o rre c t lu b ric a n t o r m o is ­ ture. Re-use b e a rin g s if s ta in s can be rem oved by lig h t p o lis h in g o r if no e vid e n ce o f o ve rh e a t­ ing is o bse rve d . H eat d is c o lo ra tio n can range fro m fa in t y e l­ low to d ark b lu e re s u ltin g fro m o ve rlo a d o r in c o rre c t lu b ric a n t. E xce ssive heat can ca u s e s o fte n in g o f races o r rollers. To c h e c k fo r lo s s o f te m p e r on C h e ck se a ls and related p a rts fo r dam age. races o r ro lle rs a s im p le file te s t m ay be m ade. A file dra w n o ver a te m p e re d part w ill grab and c u t m eta l, w he re a s, a file d ra w n over a hard part w ill g lid e re a d ily w ith no m eta l c u ttin g . R eplace b e a rin g s if o ver h e a tin g d am ag e is in d ic a te d . C h e c k se als and o th e r parts. F-00531 Figure 4—Diagnosis of Tapered Roller Bearings REAR AXLE 4B1-7 MISALIGNMENT O u te r race m is a lig n m e n t d ue to fo re ig n o b ­ je c t. C lean related p a rts and re p la ce b ea rin g. M ake CRACKED INNER RACE Race cra c k e d d u e to im p ro p e r fit, c o c k in g , o r p o o r b e a rin g seats. R eplace b e a rin g and c o rre c t b e a rin g se ats. su re races are p ro p e rly seated. FATIGUE SPALLING F la k in g o f s u rfa c e m e ta l re s u ltin g fro m fa ­ tig u e . R ep lace b e a rin g , clea n all related parts. BRINELLING S u rfa c e in d e n ta tio n s in racew ay c a u se d by ro lle rs e ith e r u n d e r im p a c t lo a d in g o r v ib ra ­ tio n w h ile th e b e a rin g is n o t ro ta tin g . R eplace b e a rin g if rou gh o r noisy. B-09860 Figure 5—Diagnosis of Tapered Roller Bearings 4B1-8 REAR AXLE 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 te e th . T h is fo rm of a b n o rm a l g e a r n o ise 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 “ flo at” or “ coast” conditions. “ Drive” is acceleration or heavy pull. “ Coast” is with a closed throttle and the vehicle in gear and “ flo at” 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. ON-VEHICLE SERVICE REAR AXLE ASSEMBLY REPLACEMENT (ALL AXLES) Raise the vehicle on a hoist and support the axle assembly with a suitable lifting device. For 93/4-inch ring gear and 101/2-inch ring gear axles, raise the vehicle and place jack stands under the frame side rails for support. Drain the lubricant from the axle housing. Remove or Disconnect 1. Propeller shaft. Refer to PROPELLER SHAFT (SEC. 4A). • Tie the p ro p e lle r sh a ft to a side rail or crossmember. • Tape the bearing cups to prevent loss of the rollers. 2. Wheel and brake drum or hub and drum assembly. 3. Parking brake cable from the lever and at the brake flange plate. 4. Hydraulic brake lines from the connectors. 5. Shock absorbers from the axle brackets. 6 . V e n t h o s e f r o m t h e a x l e v e n t f it t in g if u s e d . 7. Height sensing and brake proportional valve linkage if used. 8. Stabilizer shaft if used. • Support the assembly with a hydraulic floor jack. 9. Nuts and washers from the U-bolts. 10. U-bolts, spring plates and spacers from the axle assembly. • Lower the jack and the axle assembly. 0 hM j Install or Connect 1. Axle assembly under the vehicle. • Align the axle assembly with the springs. 2. Spacers, spring plates and U-bolts to the axle assembly. • Raise the axle assembly. 3. Washers and nuts to the U-bolts. • Thread the nuts on firmly. • Adjust alignment of semi-float axles. 4. Stabilizer shaft if used. 5. Height sensing and brake proportional valve linkage if used. 6. Vent hose to the axle vent fitting if used. 7. Shock absorbers to the axle brackets. 8. Hydraulic brake lines to the connectors. 9. Parking brake cable to the lever and the flange plate. 10. Wheel and brake drum or hub and drum assembly. 11. Propeller shaft. NOTICE: See “ N otice” on page 4B1-1 of this section. T ig h te n • All fasteners to “ Specifications” later in this section. | ? | Im portant • Check axle lubricant level at the filler plug hole. Lubricate as needed. • Bleed the brake system, check operation and adjust if necessary. Refer to BRAKES (SEC. 5). • Check axle and brake operation. • Check for fluid leaks and road test the vehicle. REAR AXLE 4B1-9 SEMI-FLOATING AXLE (8 V2- AND 91/2-INCH RING GEAR) 10 . Drum 11 . B o lt 1 2 . S h aft 13. 14. 15. 16. 17. 18. 19. Lock Seal B e aring H o u s in g C lip B o lt C a rrie r C over F-00636 Figure 6—Axle Shaft and Housing Components AXLE SHAFT, OIL SEAL AND BEARING REPLACEMENT Raise the vehicle on a hoist. Clean dirt from around the carrier cover. ++ 1. 2. 3. 4. 5. 6. 7. 8. Remove or Disconnect (Figure 6) Tools Required: J-2619-01 Slide Hammer with Adapter J-23689 Axle Shaft Bearing Remover (large shaft) J-29712 Axle Shaft Bearing Remover (91/2-inch ring gear) Wheel and tire assembly. Brake drum. C arrier cover (19). • Catch the oil in a drain pan. • Remove gasket material if used. Screw (A) (figures 7 and 8). Pinion shaft (B). • Remove the shaft from the case on vehicles without a locking differential. • With a locking differential remove the shaft (B) part way and rotate the case until the pinion shaft touches the housing (figure 9). • Use a screwdriver or similar tool to enter the case and rotate the lock until it aligns with the thrust block (figure 10). Lock (13) (figure 11). • Push the flange of the axle shaft towards the differential. Do not force or hammer the shaft to move the shaft. • Remove the lock from the button end of the axle shaft. Axle shaft (12). • Slide the axle shaft out, being careful not to damage the seal. Seal (14) using J-23689. 9. Bearing (15). • Use J-23689 for 8 1/2-inch ring gear axle or J-29712 for 9 1/2-inch ring gear to pull the bearing from the axle. • Insert the tool into the axle bore so that it grasps behind the bearing (15) (figure 12). Tighten the nut and washer against the face of the bearing (15). Inspect All parts. Replace as necessary. 0 Install or Connect (Figures 6 and 10) Tools Required: J-8092 Driver Handle J-21128 Axle Shaft and Pinion Oil Seal Installer J-23690 Axle Shaft Bearing Installer 4B1-10 REAR AXLE J-29709 Axle Shaft Bearing Installer (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 lu b ric a n t. R efer to M A IN T E N A N C E 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. • Bearing (15) into the axle (16) housing until the tool bottoms against the tube. Refer to figure 13. 2. Seal (14). • Use J-21128 for 8 1/2-inch ring gear axle and J-29713 for the 9 1/2-inch ring gear axle. • Drive the tool into the bore until the seal (14) bottoms flush with the end of the tube (figure 14). 3. Axle shaft (12). • Be careful not to damage the seal (14) when inserting the axle shaft ( 12). B. P in io n S h a ft E. T h ru s t B lo c k F. S id e G ear (L o c k in g D iffe re n tia l) G. L ock (C-Lock) H. S h a ft F-00640 Figure 10—Aligning the Lock F-00642 Figure 12—Removing the Bearing and Seal REAR AXLE 4B1-11 8. Carrier cover (19). 9. Bolts (18) and clip (17). • Tighten bolts (18) in a crosswise pattern. 10. Brake drum. 11. Wheel and tire assembly. • Lower the vehicle. 12. Axle lubricant. Fill to the filler plug hole level. Refer to MAINTENANCE AND LUBRICATION (SEC. OB). BRAKE BACKING PLATE REPLACEMENT • Raise the vehicle on a hoist. Remove or Disconnect 1. Wheel, tire and brake drum. 2. Axle shaft. Refer to “ Axle Shaft R eplacem ent” earlier in this section. 3. Brake line from the cylinder inlet. • Slide the axle shaft (12) into place allowing the splines to engage the differential side gear (F) figure 10. 4. Lock (13). — Without locking differential: • Place the lock on the button end of the axle shaft (12), then pull the shaft flange outward to seat the lock in the differential side gear. — With locking differential. • Keep the pinion shaft partially withdrawn (figure 9). • Place the lock in the position shown in figure 10. Pull the shaft flange outward to seat the lock in the differential side gear. 5. Pinion shaft (figure 8). • Align the hole in the pinion shaft with the screw hole in the differential case. 6. Screw (A). Tighten • Screw to 34 N m (25 ft. lbs.). 7. Carrier cover gasket or RTV (if used). 4. Brake com ponents from the backing plate. Refer to BRAKES (SEC. 5). 5. Bolts and washers from the axle. 6. Backing plate. Install or Connect 1. Backing plate to the axle. 2. Bolts and washers to the plate. 3. Brake com ponents to the backing plate. Refer to BRAKES (SEC. 5). 4. Brake line to the cylinder inlet. • Refer to BRAKES (SEC. 5) for bleeding and adjustment procedure. 5. Axle shaft. Refer to “ Axle Shaft Replacement” earlier in this section. 6. Wheel, tire and brake drum. WHEEL STUD REPLACEMENT • Raise the vehicle on a hoist and allow the axle to hang free. Remove or Disconnect Tool Required: J-6627-A Wheel Stud Remover Wheel, tire and brake drum. Stud from the axle flange using J-6627-A (figure 15). Install or Connect 1. Stud in the axle flange hole. Refer to figure 15. • Start the new stud into the axle flange hole by pressing firmly with your hand. • Thread on a lug nut with the flat side to the vehicle. • Tighten the lug nut and draw the stud head into the rear of the flange. • Thread the lug nut off. 2. Wheel, tire and brake drum. • Lower the vehicle. 4B1-12 REAR AXLE PINION FLANGE, DUST DEFLECTOR/OIL SEAL REPLACEMENT • Raise the vehicle on a hoist. |+-+| Remove or Disconnect Tool Required: J-8614-01 Remover C om panion Flange H older and 1. Propeller shaft from the axle. • Tie the pro pe lle r shaft to a fram e rail or crossmember. | l j | | Measure • The torque required to rotate the pinion (figure 16). R e c o rd th e to rq u e v a lu e fo r la te r reference. Figure 16—Measuring Pinion Rotating Torque 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). 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). Flange using J-8614-01 • Use the special nut and forcing screw to remove the flange (figure 19). Oil seal. Use a screw driver to pry the seal out of the bore. I? Inspect • The pinion flange for a smooth oil seal surface, for worn drive splines, dam aged ears and for smoothness of the bearing contact surface. Replace if necessary. Dust deflector. Figure 18—Removing the Drive Pinion Nut REAR AXLE 4B1-13 • Tap the deflector from the flange 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 C om panion Flange H older and Remover J-22388 Pinion Oil Seal Installer (9 1/2-inch ring gear) J-22804-1 Pinion Oil Seal Spacer Measure The rotating torque of the pinion and compare with the torque recorded earlier (figure 16). Tighten • The p in io n nut in a d d itio n a l s m a ll increments until the torque necessary to rotate the pinion exceeds the original recorded value by 0.35 N m (3 in. lbs.). 4. Propeller shaft. • Lower the vehicle and road test. 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 20 ). • Use J-22836 for the 8 1/ 2-inch ring gear or J-22388 for the 9 1/2-inch ring gear to press the oil seal into the bore (figure 20 ). • Turn J-22804-1 from installed position 180 degrees to assure proper installation against the pinion flange. • Pack the cavity between the end of the pinion s p lin e s and th e p in io n fla n g e w ith a non-hardening sealer such as PERMATEX TYPE A or equivalent. 3. Flange onto the pinion using J-8614-01. • Place washer and nut on the pinion threads and tighten the nut to the original scribed position using the scribe marks and exposed threads as a reference (figure 21). DO NOT ATTEMPT TO HAMMER THE FLANGE ONTO THE PINION SHAFT. Figure 21—Installing the Pinion Flange 4B1-14 REAR AXLE ( 9 3/4- FULL FLOATING AXLE AND 101/2-INCH RING GEAR) HUB AND DRUM ASSEMBLY REPLACEMENT + + Remove or Disconnect (Figure 23) • Raise the vehicle until the wheel is free to rotate. Tool Required: J-2222-C Wheel Bearing Nut Wrench 1. Wheel and tire. 2. Axle shaft (52) as outlined earlier in this section. 3. Nut (40) use J-2222-C or retaining ring (56). Refer to figure 24. 4. Lock (41) or key (57). 5. Adjusting nut (42, 58). Refer to figure 24. 6. Washer (43). Figure 22—Removing or Installing Flange-to-Hub Bolts AXLE SHAFT REPLACEMENT 7. Hub and Drum (48, 49). y Inspect • All parts and replace as necessary. ♦«- Install or Connect (Figure 23) |<"*| Remove or Disconnect (Figures 22 and 23) 1. Bolts (55). • Rap the axle shaft (53) flange lightly with a soft faced hammer to loosen the shaft. • Grip the rib on the axle shaft (53) flange with a locking plier and twist, to start shaft removal. 2. Axle shaft (53) from the tube. Clean • Axle shaft (53) flange. Remove old RTV or gasket (51). • Outside face of the hub assembly. I* NOTICE: For steps 3, 4 and 5 see “ N o tice” on page 4B-1 o f 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. Inspect • All parts and replace as necessary. Install or Connect (Figure 23) 1. Axle shaft (53) with a gasket or RTV applied. • Be sure the sh aft sp lin e s mesh into the differential side gear. • Align the axle shaft holes with the hub holes. 2. Bolts (55) figures 22 and 23. Q\ Tighten • Bolts (35) to specified torque later in this section. • Adjusting nut (42, 58) to specified torque later in this section w hile turning the hub. 4. Lock (41) or key (57). • Bend the tang to the flat of the adjusting nut (42) or insert the key (57). 5. Nut (40) or retaining ring (56). Refer to figure 24. • N ut (40) to s p e c ifie d to rq u e la te r in th is section. 6. Axle shaft (52) earlier in this section. 7. Wheel and tire. • Lower the vehicle. REAR AXLE 4B1-15 A. C he vro let B. Dana 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. N ut Lock A d ju s tin g N u t W a sh er O u te r B e a rin g R e ta in in g R ing In n e r B e aring O il Seal D rum H ub S tud G a sket S h a ft A x le S h a ft F lange W a sh er B o lt R e ta in in g R ing Key A d ju s tin g N ut O u te r B e aring R e ta in in g R ing In n e r B e aring O il Seal F-00647 Figure 23—Full Floating Axle, Hub and Drum Assembly Components WHEEL BEARING/CUP REPLACEMENT + + Remove or Disconnect (Figure 23) • Raise the vehicle till the wheels are free to rotate. Tools Required: J-8092 Driver Handle J-24426 Outer Wheel Bearing Cup Installer 1. Axle shaft (52) as outlined earlier in this section. Figure 24—Removing or Installing Bearing Adjusting Nut 2 Hub and drum (48, 49) as outlined earlier in this section. 3. Oil seal (47) or (62). 4. Inner bearing (46) or (61). Use a drift to remove the bearing and cup. 5. Retaining ring (45) or (60). • Use snap ring pliers to remove the ring. 6. Outer bearing (44) or (59) using J-8092 with J-24426 (figure 25). • Drive the bearing (44, 59) and cup from the hub Figure 25—Removing the Outer Bearing and Cup 4B1-16 REAR AXLE Clean Old sealing com pound from the oil seal (47, 62) bore in the hub (49). Bearing assem blies in a solvent using a stiff brush to remove the old lubricant. Dry the bearings with compressed air. Do not spin them. Lubricant from the axle housing and inside the hub (49). Gasket material from the hub (49), axle shaft (52). L* Inspect • Bearings for wear, chipped edges or other damage. Check for flat or rough spots on the rollers. • Cups for pits and cracks. • Oil seal for wear or roughness. Replace parts as necessary. Figure 26—Wheel Bolt Replacement Install or Connect (Figure 23) Tools Required: J-8092 Driver Handle J-8608 Pinion Bearing Cup Installer J-24426 Outer Wheel Bearing Cup Installer J-24427 Inner Wheel Bearing Cup Installer J-24428 Axle Shaft Seal Installer 1. Outer bearing cup (44, 59) into the hub (49). • Drive the cup into the hub using J-8092 and J-8608. Be sure J-8608 is installed upside down on J-8092 so that the chamfer does not contact the bearing cup. Drive the cup beyond the retaining ring groove. 2. Retaining ring into the groove. • Drive the cup back onto the retaining ring using J-24426. 3. Inner bearing cup using J-8092 and J-24427. • Drive the cup into place until it is seated against the hub shoulder. 4. Inner bearing (46) or (61). 5. New oil seal using J-24428. 6. Hub and drum assembly. 7. Outer bearing (44) or (59). A djust • Bearing preload. Refer to “ Bearing Adjustment.” 8. Axle shaft (52). NON-DEMOUNTABLE TYPE DRUM REPLACEMENT • Construction of the non-demountable type drum and hub assem bly is such that replacement cannot be done with the hub assem bly installed on the vehicle. Remove or Disconnect • Raise the vehicle. 1. Hub and drum assembly. Refer to “ Hub and Drum Assembly Replacem ent” earlier in this section. 2. Retaining bolts, stud nuts or wheel studs. • Separate the drum, hub and oil deflector. • Press the wheel studs out of the drum. Replace parts as necessary. □ Install or Connect 1. Drum to the hub. • Make certain drain holes are in alignment. 2. Oil deflector to the drum. • Apply a light coating of sealing compound to the oil deflector contact surface. 3. Retaining bolts, stud nuts or wheel studs. • Press the wheel studs into the drum. WHEEL BOLT REPLACEMENT • Wheel bolts are serrated and may also be swaged in place; however, replacement 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, m aking sure of a tight fit. When replacing all of the wheel bolts be sure that the hub oil deflector is in position under the wheel bolt heads. Refer to figure 26. BEARING ADJUSTMENT • Make sure the brakes are fully released and do not drag. • Check the wheel bearing play by grasping the tire at the top and pulling and pushing back and forth, or by using a pry bar under the tire. If the wheel bearings are properly adjusted, movement of the brake drum in relation to the brake flange plate will be barely noticeable and the wheel will turn freely. If the movement is excessive, adjust the bearings. Remove or Disconnect (Figure 23) Tool Required: J-2222-C Wheel Bearing Nut Wrench • Raise the vehicle until the wheel is free to spin. 1. Axle shaft (52). Refer to “ Axle Shaft Replacement” earlier in this section. REAR AXLE 4B1-17 0 Install or Connect (Figure 23). 1. Key (57) if used or new lock (41). • Key (57) into the keyway and adjusting nut (58) slot. • Bend the lock (41) tang to the flat of the adjusting nut (42). 2. Retaining ring (56) or nut (40) if used. • Bend the lock (41) tang to the flat of the nut (40). • Be sure the retaining ring (56) is seated. 3. Axle shaft (52). Refer to “ Axle Shaft Replacement” earlier in this section. 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. • Be sure the keyway, threads and adjusting nut (42, 58) are clean and free of chips, burrs and shavings. 2. Nut (40) or retaining ring (56). • Disengage the tang from the nut (40). 3. Lock (41) or key (57). Tighten 0 Remove or Disconnect Tools Required: J-8614-01 C om panion Flange H older and Remover • Raise the vehicle. Propeller shaft. Refer to PROPELLER SHAFT (SEC. 4A). • Tie the pro pe lle r shaft to a fram e rail or crossmember. Im portant Adjusting nut (42, 58) to 70 N m (50 ft. lbs.) using J-2222-C (figures 27 and 28). Be sure the bearings are seated and in contact with the spindle shoulder. Adjust Nut (42, 58). Back the nut (42, 58) off until just loose, but not more than one slot of the lock or the axle spindle using J-2222-C. Align the adjusting nut (58) slot with the keyway in the axle spindle. • Scribe a line on the pinion stem, pinion nut and companion flange to be used as a guide for reinstallation (figure 17). Nut using J-8614-01 (figure 18). Flange using J-8614-01. • Use the special nut and forcing screw to remove the flange (figure 19). 4. Oil seal. • Pry the oil seal from the bore. Do not damage the machined surfaces. Thoroughly clean foreign material from the contact area. • Replace parts as necessary. 0 Install or Connect J-2222 C \ \ F-00863 Figure 28—Wheel Bearing Nut Wrench Tools Required: J-8614-01 C om panion Flange H older and Remover J-24384 Pinion Oil Seal Installer (Dana 101/2-inch ring gear axle). J-24434 Pinion Oil Seal Installer (Chevrolet 101/2-inch ring gear axle). Oil seal into the bore using J-24384 or J-24434. • Lubricate the cavity between the new seal lips with a high melting point bearing lubricant. Flange using J-8614-01. • Use scribed marks for reinstallation. Nut, use J-8614-01 (figure 18). • Use scribe mark as an installation reference. Propeller shaft. Refer to PROPELLER SHAFT (SEC. 4A). 4B1-18 REAR AXLE FULL FLOATING AXLE (12-INCH RING GEAR) 70. 71. 72. 73. 74. 75. 76. 77. B o lt W a sh er H u b ca p G a sket A x le S h a ft A x le H o u s in g B racket W heel B o lt H ex B o lt D e fle c to r O il Seal In n e r B e aring Brake D isc R e ta in in g R ing O u te r B earing Spacer 86 . H ub 87. T h ru s t W a sh e r 88 . A d ju s tin g N u t 89. L ock W a sh er 90. N ut F-01012 78. 79. 80. 81. 82. 83. 84. 85. Figure 29—Rockwell 12-Inch Ring Gear Axle and Hub Components AXLE VENT REPLACEMENT • A threaded type axle vent is used on the Rockwell 12-inch ring gear axle and must be replaced if the vent cap is dam aged or missing. Clean The area around the axle vent. Remove or Disconnect • Axle vent from the housing. -►4- Install or Connect • Axle vent to the housing. AXLE SHAFT REPLACEMENT • Raise the vehicle and place jack stands under the frame side rails. Remove or Disconnect (Figure 29) 1. 2. • 3. Tools Required: J-2619-01 Slide Hammer Bolts (70) and washers (71). Hub cap (72). Thread J-8117 into the tapped hole on the axle shaft (74) flange. Axle shaft (74) using J-2619-01. Clean Old gasket material from the hub (86) and hub cap (72) and the axle shaft (74) flange and m ating surface in the hub (86). + + Install or Connect (Figure 29) Tools Required: J-2619-01 Slide Hammer 1. Axle shaft (74). • Tap the axle shaft (74) into position using J-2619-01. • Index the axle shaft (74) splines into the hub (86) splines. 2. Gasket (73). 3. Hub cap (72). 4. Washers (71) and bolts (70). BEARING ADJUSTMENT • Make sure the brakes are fully released and do not drag. • Check the wheel bearing play by grasping the tire at the top and pulling and pushing back and forth, or by using a pry bar under the tire. If the wheel bearings are properly adjusted, movement of the hub o r d is c w ill be b a re ly n o tic e a b le . If the m ovement is excessive, adjust the bearings. REAR AXLE 4B1-19 Remove or Disconnect (Figure 29) Tool Required: J-25510 Wheel Bearing Nut Wrench • Raise the vehicle until the wheel is free to spin. Axle shaft (74). Refer to “ Axle Shaft Replacement.” Nut (90) using J-25510. • Release the tang. Lock washer (89). Adjust • Nut (88) using J-25510. Tighten the nut (88) while the hub is rotating to 68 N-m (50 ft. lbs.). Make sure the bearing surfaces are in contact and then back the nut (88) off 1/s turn. E3 Install or Connect (Figure 29) 1. Lock washer (89). • Bend a tang over a flat of the adjusting nut (88). 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) over a \ flat of the nut (90). Axle shaft (74). Refer to “ Axle Shaft Replacement.” • Lower the vehicle. DRIVE PINION OIL SEAL REPLACEMENT E3 * l l Remove or Disconnect (Figure 30) Tools Required: J-8614-01 C om panion Flange H older and Remover • Raise the vehicle. 1. Propeller shaft. Refer to PROPELLER SHAFT (SEC. 4A). Im portant 2. 3. 4. 5. 6. • Scribe a reference line on the pinion stem, pinion nut and companion flange. Cotter key (91) and nut (92) using J-8614-01. Companion flange (94). Bolts (97). Oil seal retainer (95). Oil seal (96). • Pry the oil seal (96) from the bore being careful not to damage the machined surfaces. Clean • The seal contact area. Install or Connect (Figure 30) • Lubricate the cavity between the new seal (96) lips with a high m elting point bearing lubricant. Refer to MAINTENANCE AND LUBRICATION (SEC. 0B). 1. Oil seal (96) into the bore using a suitable tool. • Be sure the seal (96) bottoms against the bore shoulder. 2. Oil seal retainer (95). 3. Bolts to the retainer (97). 91 . 92 . 93 . 94 . C o tte r Key N ut P in io n S h a ft C o m p a n io n F la n g e 95. 96. 97. O il Seal R e ta in e r O il Seal B o lt F-01013 Figure 30—Drive Pinion Oil Seal Components 4. Companion flange (94) use the scribed reference mark. 5. Nut (92) using J-8614-01. • Nut (92). Align the castellated nut with the hole in the pinion shaft (93) stem and the reference mark. 6. Cotter key (91). 7. Propeller shaft. Refer to PROPELLER SHAFT (SEC. 4A). 4B-20 REAR AXLE SPECIFICATIONS TORQUES 8V2 " RING GEAR- SEMI FLOATING AXLE Filler Plug Lock Screw Brake Backing Plate Axle Shaft to Hub Bolts Carrier Cover Axle Lubricant Capacity 91/2" RING GEARSEMI FLOATING AXLE DANA 9% "-10 1fe" RING GEAR AXLE-FULL FLOATING CHEVROLET IOV2 " RING GEAR AXLE-FULL FLOATING ROCKWELL 12" RING GEAR AXLE-FULL FLOATING Nm FT. LBS. N-m FT. LBS. Nm FT. LBS. N-m FT. LBS. N-m FT. LBS. 34 34 25 25 24 34 18 25 14 10 24 18 47 35 — — — — — — 47 35 142 105 142 105 142 105 — — — — — — — 27 20 27 20 156 47 115 35 156 41 115 30 — Liters Pints Liters Pints Liters Pints Liters Pints Liters Pints 2.0 4.2 2.6 5.5 2.6 5.5 3.4 7.2 6.6 14.0 WHEEL BEARING ADJUSTMENT VALUES RING GEAR SIZE 93/4" Ring Gear 10 V2 " Ring Gear 12" Ring Gear BEARING ADJUSTING NUT TORQUE* ADJUSTING NUT BACKOFF* OUTER LOCKNUT TORQUE 68.0 N-m 50 ft. lbs. 68.0 N-m 50 ft. lbs. 68.0 N-m 50 ft. lbs. * * 88.1 N-m 65 ft. lbs. 1/s Turn RESULTING BEARING ADJUSTMENT 0.0254 to 0.254 mm .001 to .010 inch 339.0 N-m 250 ft. lbs. End Play ‘ With wheel rotating. **Back-off the nut and retighten to 47 N m (35 ft. lbs.). Then back the nut off V* turn. TYPE OF BEARING TAPERED ROLLER REAR AXLE 4B1-21 1. J-24428 11. J-6627-A 12. 2. j- J-8092 J-23689 14. J-5853-B 3. 15. cm m J-21128 16. ((((( 55 ) J-23690 17. (1 J-29709 J-8614-01 4. J-2919-01 5. cnglt 1 8 - 6. 7. 24434 | r ~ T l ( a j *2 9 7 1 3 J-2222-C J-24426 20. J-22804-1 8. J-24427 9. J-8608 21. (J J-22836 10. J-24384 22. J-25510 B-07587 Figure 31—Special Tools 4B1-22 REAR AXLE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. W heel Stud Remover Driver Handle Inch/Pound-Torque W rench C om panion Flange H older and Remover Slide H am m er w ith A dapter W heel Bearing N ut W rench O uter W heel Bearing Cup In staller Inner W heel Bearing Cup In sta lle r O uter Pinion Bearing Cup In sta lle r Pinion Oil Seal In sta lle r A xle Shaft Seal In sta lle r 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Pinion O il Seal In sta lle r W heel Bearing Inner Cup In sta lle r A xle Shaft Bearing Remover A xle Shaft and Pinion Oil Seal In s ta lle r A xle Shaft Bearing In sta lle r A xle Shaft Bearing In sta lle r (91/2-lnch Ring Gear) A xle Shaft Seal In sta lle r (91/2-lnch Ring Gear) Pinion O il Seal In sta lle r (91/2-lnch Ring Gear) Pinion O il Seal Spacer Pinion Seal In sta lle r (81/2-lnch Ring Gear) W heel Bearing N ut W rench B-07586 Figure 32—Special Tools FRONT AXLE 4C-1 SECTION 4C FRONT AXLE 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 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 num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent 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 ........................................................................................................................................................................................ 4C-1 D iag no sis Of The F ront A x l e ...................................................................................................................................................... 4 C -2 Road T e s t ...................................................................................................................................................................................... 4 C -2 Tire* N o is e s .................................................................................................................................................................................... 4 C -2 E ngine o r Exhaust N o is e s .........................................................................................................................................................4 C -2 T est For Wheel Bearing N o is e ................................................................................................................................................4 C -2 T est For D iffe re ntia l B earing N o is e ...................................................................................................................................... 4 C -2 T est For Pinion Bearing N o is e ................................................................................................................................................4 C -2 O n -V ehicle S e r v ic e .........................................................................................................................................................................4 C -2 A xle S haft R e p la c e m e n t........................................................................................................................................................... 4 C -2 F ront Axle A ssem bly R e p la c e m e n t...................................................................................................................................... 4 C -3 A xle J o in t C om ponent R e p la c e m e n t.................................................................................................................................... 4 C -4 L o ckin g Hub C om po n en t R e p la c e m e n t........................................................................................... .................................... 4 C -4 A u to m a tic Hub To The W heel A d ju s tm e n t.........................................................................................................................4 C -7 M anual Locking Hub R e p la c e m e n t.........................................................................................................................................4 C -7 Manual Locking Hub R ebuild P ro c e d u re ............................................................................................................................. 4 C -8 S p e c ific a tio n s ..................................................................................................................................................................................4 C -8 S pecial T o o ls .................................................................................................................................................................................... 4 C -8 DESCRIPTION The front axle is a hypoid gear axle unit equipped with steering knuckles and an automatic or manual locking hub. The V-10/15 and 20/25 models use a Chevrolet front axle having an 8 1/2-inch ring gear axle rated at 3600 pounds for the V-10/15 and 3800 pounds for the V-20/25. A Dana (60 Series) axle is used on the V-30/35 model and is rated at 4500 pound capacity. The Dana axle has a 9 3/4inch ring gear. Automatic hub locks are used on all models to engage the hub whenever four-wheel drive is selected. A manual locking hub is used on the V-30/35 model only and must be engaged manually whenever four-wheel drive is selected. 4C-2 FRONT AXLE DIAGNOSIS OF THE FRONT AXLE ROAD TEST • • • • • Check tires for irregular wear. Check tire pressure. Check axle lubricant level. Drive to warm up the front axle. Test at various speeds in drive, float, coast and while cornering. • Verify that the hubs are locked. TIRE NOISES • • • • • Change the tire pressure to minimize noises. Drive over different road surfaces. Smooth black-top minimizes tire noise. Cross switch the tires, if necessary. Snow tire treads and studs cause added noises. ENGINE OR EXHAUST NOISES • Drive slightly above the speed where the noise occurs, place transmission in neutral. • Let the engine speed drop to idle. • Stop the vehicle. • Run the engine at various speeds. TEST FOR WHEEL BEARING NOISE • Drive the vehicle at low speed on a smooth road. • Turn the vehicle to develop left and right motions, traffic permitting. • Noise should change due to cornering loads. • Jack-up wheels to verify roughness at the wheels. ‘ TEST FOR DIFFERENTIAL BEARING NOISE • • • • Drive the vehicle at low speed on a smooth road. Constant low pitch bearing noise may be heard. Noise should not change in reversing turns. The noise pattern should vary with the wheel speed. *TEST FOR PINION BEARING NOISE • Rough running or a whine noise should increase with speed. • Noise pitch should be higher than differential noise. • Perform the test on a smooth road to m inimize tire noises. • Perform test at various speeds in drive, float, and coast. • Rear pin ion b earing noise m ay be lo u d e r on acceleration. • Front p in ion b earing noise m ay be lo u d e r on deceleration. • Gear noise tends to peak in a narrow speed range. ‘ Bearing tests should be done in 2H (after 4H selection to lock hubs). This removes the transfer case whine. ON-VEHICLE SERVICE AXLE SHAFT REPLACEMENT Remove or Disconnect (Figure 1) • Raise the vehicle. 1. Wheel and tire. 2. Brake caliper (40). Im portant • Support the brake caliper (40) so as not to stretch or dam age the brake hose. 3. Hub lock mechanism (20). 4. Rotor and hub (28). 5. Inner bearing (31) and seal (32). 6. Splash shield (41), brake bracket (39) and spindle (38). 7. Axle shaft (46). «gi Clean Inner and outer wheel bearing (31, 26). Hub and disc (28), spindle (38). L9 Im portant • Lube the spindle bearing (37) and spindle (38). • Pack the inner and outer wheel bearing (31, 26). NOTICE: For steps 3, 4 and 5, see “ N o tic e ” on page 4 C - 1 of this section. Install or Connect (Figure 1) 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). 5. Splash shield (41). • 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). Inspect 7. Retainer (22) and ring (21). All parts and replace as necessary. 8. Hub lock mechanism (20). FRONT AXLE 4C-3 20. 21. 22. 23. 24. 25. 26. 27. 28. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 46. 47. 48. 49. H u b Lock R ing R e ta in e r N ut R ing N ut O u te r B e aring C up H ub A n d D is c C up In n e r B earing In n e r Seal O u te r D e fle c to r Seal S p a ce r Seal B e aring S p in d le Brake B ra c k e t Brake C a lip e r S p la sh S h ie ld H o u s in g Tube K n u c k le A x le S h a ft U -Jo in t W a sh e r N ut F-01015 Figure 1— F ront A xle C om ponents NOTICE: See “ N otice” on page 4 C - 1 of this section. • S u p p o rt the brake ca lip e r (40) so as not to stretch or da m a g e th e brake hose. 4. S ho ck ab so rb e rs from the axle brackets. 9. Brake ca lip e r (40). 5. Front s ta b iliz e r bar. • Do not stretch or d a m ag e th e brake hose. 6. A xle vent tu b e and clip s (figu re 2). 7. Nuts, w ashers, U-bolts, spa cers and plates. 10. W hee l and tire. • S u p p o rt th e axle w ith a ja ck. • Lower the ve h icle and test. 8. A xle a sse m b ly out from un de r th e veh icle . C lean FRONT AXLE ASSEMBLY REPLACEMENT Axle assembly. I? ++ R e m o ve o r D is c o n n e c t (F ig u re 1) • Raise the vehicle until the weight is removed from the front springs. Support the vehicle with jack stands placed behind the front springs. In s p e c t The assembly and repair or replace as necessary. NOTICE: For steps 1, 5, 6 and 7, see “ N o tice” on page 4 C - 1 of this section. 1. Propeller shaft. Refer to “ Propeller Shaft” (Sec. 4A). 2. Connecting rod from the steering arm. Refer to FRONT SUSPENSION (SEC. 3C). 3. Brake caliper (40). +4- In s ta ll o r C o n n e c t (F ig u re 1) • Axle assembly positioned under the vehicle. 1. Plates, spacers, U-bolts, washers and nuts. 4C-4 FRONT AXLE 0 Install or Connect • Lubricate the new bearings with a high melting point type wheel bearing grease. 1. Bearing in a yoke ear. 2. Trunnion in the bearing. 3. Another bearing in the opposite yoke ear with the trunnion aligned. 4. Bearing in each ear of the companion yoke. • Press the bearings in beyond the lock ring grooves. 5. Lock ring at each bearing. • Tap the yoke lightly to seat the bearings against the lock rings. LOCKING HUB COMPONENT REPLACEMENT AUTOMATIC HUB COMPONENT REPLACEMENT 4- + Remove or Disconnect (Figure 3) 1. Screws (50) and O-ring seals (52). 2. Cover (52). 3. Seal (53). 4. Keeper (60). 5. Spring (54). 6. Inner race (55). 7. Bearing (56). 8. Retainer (58). 2. 3. 4. 5. 6. 7. • Axle vent tube and clips. Refer to figure 2. Front stabilizer bar. Shock absorbers to the axle brackets. Brake caliper (40). Connecting rod to the steering arm. Propeller shaft. Lower the vehicle. AXLE JOINT COMPONENT REPLACEMENT Remove or Disconnect • Raise the vehicle. 1. Axle shaft. Refer to “ Axle Shaft Replacement” earlier in this section. • Support the shaft yoke in a bench vise or on a short piece of pipe. 2. Trunnion • Using a brass drift and soft hammer drive on the end of a trunnion bearing enough to drive the opposite bearing from the yoke. • Support the other yoke and drive the trunnion bearing out in the same manner. Clean The bearings and yokes. Inspect The bearings and yokes. Replace parts as necessary. 9. Ring (57) using needle nose plier. • Pull the remaining components from the wheel. 10. Retaining ring (77) from the sleeve (67) groove. • Rotate the drag sleeve (75) until it drops into engagement with the gear (59). • Lift and cock the drag sleeve (75) to unlock the tangs of the brake band (74) from the “ window” of the inner cage (72), then move the drag sleeve (75) and brake assembly away. Im portant • NEVER REMOVE THE BRAKE BAND (74) FROM THE DRAG SLEEVE (75). The spring tension of the brake band (74) can be changed if the coils are over expanded and the operation of the hub could be affected. 11. Ring (73) from the groove in the clutch gear (59). 12. Inner cage (72). • While removing the inner cage (72) use a small screw driver to pry the plastic outer cage (71) away. 13. Outer cage (71). • Pry the plastic outer cage (71) tabs free from the groove in the clutch gear (59) and move the outer cage (71) away. 14. Sleeve (67) from the clutch gear (59). • Compress the return spring (64) and hold the assembly in a compressed condition by using the clamps shown in figure 4. • Position the assembly with the clamps in place in a vice and hold both ends of the sleeve (67). FRONT AXLE 4C-5 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. S crew O -R ing Seal C over Seal S p rin g In n e r Race B e aring R ing R e ta in e r C lu tc h G ear Keeper R ing 62. 63. 64. 65. 66. R e ta in e r Plate R e ta in e r R eturn S p rin g R e ta in e r G ear 67. 68. 69. 70. 71. 72. 73. Sleeve S to p R ing S p rin g Cam O u te r Cage In n e r Cage R ing 74. 75. 76. 77. 79. 80. 81. 82. Brake Band Drag Sleeve S p ace r R e ta in in g R ing A d ju s tin g N ut Lock R ing N u t W ith Pin R ing A. S h ie ld Figure 3—Automatic Hub Components, V10/15, V20/25 and V30/35 F -03523 4C-6 FRONT AXLE 7. 8. 9. 61. 67. 70. A. Ring Sleeve Cam C la m p 10. B. Vs-inch C. 11/4-inches Im portant D. 3/e-inch • Service the brake band (74) and drag sleeve (75) as an assem bly and be sure the o riginal lubricant has not been removed or contaminated. Lubricant number 1052750 or its equivalent m ust be used in this assembly. Brake band (74) tangs. • Place the tangs of the brake band (74) on each side of the lug of the outer cage (71) located in the “ window” of the steel inner cage (72). Cock these parts to engage the tangs in this position. Spacer (76) and retaining ring (77). • To the sleeve (67) above the drag sleeve (75). Hub assembly to the vehicle. Ring (57) to the clutch gear (59) unsplined end. • Locate the tangs of the ring (57) pointing away from the vehicle. Keeper (60). • Hold the tangs of the ring (57) together and attach the keeper (60). For K10 and K20 assemble the O-ring seal (53) in the clutch gear (59) groove and over the keeper (60). Bearing (56) over the inner race (55). — Lubricate the bearing (56) with light wheel bearing grease. — Steel balls should be visible when bearing (56) is properly installed. Retainer (58) into the outer race (55) hole. • Bearing (56) inner race (55) and retainer (58) into the sleeve (67). Spring (54) into the cover (52) bore. • Align cover (52) screw holes with the screw thread holes in the clutch gear (59). O-ring seals (51) and screws (50) in the cover (52). • The hub sleeve (67) and attached parts should turn freely after assembly. 11. F-01018 Figure 4—Compressing the Return Spring 15. Ring (61). • While holding the sleeve (67) in the vise, remove the clamps holding the return spring (64) and then open the vise and release the return spring (64). 16. Retainer plate (62). 17. Retainer (63). 18. Stop ring (68 ). • Align the ends of the stop ring (6 8 ) with the legs of the cam (70) to allow removal. 19. Spring (69). 20. Cam (70) from the gear (66 ). I* 12. 13. 14. 15. 16. Inspect • All parts and replace as necessary. ++ • Compress the return spring (64) and hold the assembly together with clamps (figure 4). Ring (61) in the groove of the sleeve (67). • Place the assembly (steps 1 through 7) into the clutch gear (59) and support the clutch gear (59) above a flat surface allowing the assembly to drop down so that the tangs of the brake band (74) may be assembled later. Outer cage (71) into the clutch gear (59). • The ramps of the outer cage (71) must face the cam (70). • Locate the outside tabs of the outer cage (71) into the wide grooves of the clutch gear (59). Inner cage (72) into the outer cage (71). • Align the tab of the outer cage (71) with the “ window” of the inner cage (72). Ring (73). • Into the groove of the clutch gear (59) above the outer cage (71). Install or Connect (Figure 3) Cam (70) over the flats of the gear (6 6 ). Spring (69). • Compress the spring (69) and slide the large diameter end against the gear (66 ). Gear (66 ) over the splines of the sleeve (67). • Cam (70) should locate at the end of the sleeve (67) having no splines. 17. 18. 19. Im portant • The gear (6 6 ) and spring (69) should slide freely over the splines of the sleeve (67). Stop ring (6 8 ) to the groove of the sleeve (67). Retainers (63 and 65) to each end of the spring (64). • Retainer (65) to the shoulder of the gear (66 ). Retainer plate (62) to the retainer (63). % Tighten • Screws (50) to 5.1 N m (45 in. lbs.). Im portant • The five cover screws (50) must be loosened (three or four turns) and then pushed inward to FRONT AXLE 4C-7 85. In te rn a l S nap R ing 86. H u b B ody 87. In n e r Drive G ear 88 . S p rin g 89. C lu tc h R ing 90. A x le S h a ft S nap R ing 91. S crew 92. H u b Cap 93. C o m p re s s io n S p rin g 94. C lu tc h C up 95. O -R ing Seal 96. D ial S crew 97. C lu tc h N ut 98. Seal 99. L ock R ing Figure 5—Manual Hub Components, V30/35 AUTOMATIC HUB TO THE WHEEL ADJUSTMENT Align the cut-outs on the drag sleeve (75) with the tabs on the lock ring (80) as the splines of the clutch gear (59) mesh with the splines of the wheel hub. Loosen the five cover screws (50) three or four turns and push in on the screws (50) to allow the ring (57) to expand into the groove in the wheel hub. Torque the screws (50) to 5.1 N-m (45 inch lbs.). A lock ring (80) is supplied with each new automatic hub assembly. Assemble this lock ring (80) between the nut with pin (81) and the adjusting nut (79) as follows: MANUAL LOCKING HUB REPLACEMENT allow the retaining ring (57) to expand when assembling the automatic locking hub to the vehicle. Use J-6893 to torque the nut with pin (81) to 6 8 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.) while rotating the hub (figure 3). Then back the nut with pin (81) off a maximum of 3/8 turn. Assemble the lock ring (80) over the axle shaft against the nut with pin (81) so that the inner tang enters the axle shaft keyway. One of the holes in the lock ring (80) m ust engage the pin on nut (81). Thread the adjusting nut (79) onto the axle shaft and tighten to 247 N-m (183 ft. lbs.). Remove or Disconnect (Figure 5) 1 . Screws (91). 2. Outer hub locking assembly (92, 93, 94, 95, 96, 97, 98, and 99). 3. Snap ring (90) from the axle shaft end. 4. Internal snap ring (85) from hub. 5. Body assem bly (8 6 , 87, 8 8 and 89). L * Inspect All parts and replace as necessary. 4C-8 FRONT AXLE Install or Connect (Figure 5) Spring (8 8 ). Internal snap ring (85). Inner drive gear (87) with thrust washers. Plastic sleeve. 1. 2. 3. 4. Body assembly (8 6 , 87, 88 and 89). Internal snap ring (85) to the hub. Snap ring (90) onto the axle shaft end. Outer hub locking assembly (92, 93, 94, 95, 96, 97, 98 and 99). 5. Screws (91). I9 All parts and replace as necessary. + 4- MANUAL LOCKING HUB REBUILD PROCEDURE Install or Connect (Figure 5) • Lubricate inner body parts with ATF or a light coat of wheel bearing grease. Plastic sleeve. Inner drive gear (87) with thrust washers. Internal snap ring (85). Spring (88 ). Hub body (8 6 ). Screws (91). • Outer hublock knob assembly should be replaced only as a unit, because tim ing relationships are difficult to restore if disassembly occurs. The inner body m ay be d isa sse m b le d fo r c le a n in g and component replacement. □ Inspect Remove or Disconnect (Figure 5) 1. Screws (91). 2. Hub body (8 6 ). SPECIFICATIONS Nut-Splash Shield Retaining IS X T 1 Cover Screw-Automatic Hub Adjusting Nut-Axle Shaft N-m Ft. Lbs. 88 68 65 50 35 45 (inch lbs.) 183 47 5.1 247 SPECIAL TOOLS Figure 6—Special Tools 5A-1 SECTION 5 BRAKES CONTENTS SUBJECT PAGE H yd ra u lic B ra k e s ............................................................................................................................................................................. 5A -1 H yd ra u lic Brake B o o ste r S y s te m s ........................................................................................................................................... 5A 1-1 H yd ra u lic F oundation B ra k e s .................................................................................................................................................... 5A 2-1 SECTION 5A HYDRAULIC BRAKES t )C 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 term inology NOTICE: See ‘Notice’ on page 5A-1 of this section. NOTICE: This fastener is an important attaching part in that it could affect the performance of vital components and system, and/or could result in major repair expense. It must be replaced with one of the same part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part. CAUTION: W hen se rv ic in g w he el brake parts, do n o t crea te d u s t by g rin d in g o r sa nd in g brake lin in g s o r by cle a n in g w heel brake p a rts w ith a d ry brush o r w ith co m p re ssed air. (A w a te r dam pened clo th s h o u ld be used). M any w heel brake p arts co n ta in a sbe stos fib e rs w h ic h can becom e a irb o rn e if d u s t is crea ted d u rin g s e rv ic in g . B re a th in g d u st co n ta in in g a sb e sto s fib e rs m ay cause se rio u s b o d ily harm . CONTENTS SUBJECT PAGE Brake System Diagnosis..............................................................................................................................................5A- 2 Road Testing the Brakes..........................................................................................................................................5A- 2 Diagnosis of Brake S y s te m ........................................................................................................................................ 5A- 2 On - Vehicle S ervice.................................................................................................................................................... 5A- 5 Bleeding the Brake Hydraulic S ystem ................................................................................................................... 5A- 5 Flushing the Brake Hydraulic S yste m ................................................................................................................... 5A- 6 Brake Pipes and Hoses............................................................................................................................................ 5A- 6 Combination Valve.................................................................................................................................................... 5A- 7 Height Sensing Brake Proportioning Valve........................................................................................................... 5A- 9 Brake Pedal A sse m b ly................................................................................................................................................ 5A-13 Checking Pedal Travel.............................................................................................................................................. 5A-13 Brake Pedal Replacement........................................................................................................................................5A-13 Brake Pedal Rod Replacement................................................................................................................................5A-15 Stoplamp S w itc h ...................................................................................................................................................... 5A-16 Parking Brake System.................................................................................................................................................. 5A-17 Parking Brake Pedal or Handle Replacement.......................................................................................................5A-17 Cable Replacem ent.................................................................................................................................................. 5A-18 Propeller Shaft Brake Replacement....................................................................................................................... 5A-22 Parking Brake A d ju stm e n t......................................................................................................................................5A-22 Master C ylinders.......................................................................................................................................................... 5A-24 D escription................................................................................................................................................................ 5A-24 Master Cylinder Replacement..................................................................................................................................5A-24 Bench B leeding........................................................................................................................................................ 5A-26 S pe cifica tio ns.............................................................................................................................................................. 5A-26 Special T o ols................................................................................................................................................................ 5A-28 5A -2 HYDRAULIC BRAKES BRAKE SYSTEM DIAGNOSIS ROAD TESTING THE BRAKES EXTERNAL CONDITIONS THAT AFFECT BRAKE PERFORMANCE BRAKE TEST The brakes should be tested on a dry, clean, reasonably s m o o th and le ve l roa dw a y. A tru e te s t of b ra ke perform ance cannot be made if the roadway is wet, greasy or covered with loose dirt so that all the tires do not grip the road equally. The testing will be 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 tend to bounce. Test the brakes at different vehicle speeds with both light and heavy pressure; however, avoid locking the wheels and sliding the tires on the roadway. Locked wheels and sliding tires do not indicate brake efficiency since heavily braked turning wheels will stop the vehicle in less distance than locked wheels. More tire-to-road friction is present with a heavily braked turning tire than with a sliding tire. 1. Tires—Tires having unequal contact and grip on the road will cause unequal braking. The tires must be equally inflated and the tread pattern of the right and left tires must be about equal. 2. Vehicle Loading—When the vehicle has unequal loading, the most heavily loaded wheels require more braking power than the others. 3. F ro n t W heel B e a rin g s — L o o s e fr o n t w h e e l bearings permit the disc to tilt and have spotty contact with the linings causing erratic action. 4. Front End Alignment—M isalignm ent of the front end, particularly in regard to limits on camber and caster, will cause the brakes to pull to one side. DIAGNOSIS OF BRAKE SYSTEM PROBLEM U neven Brake A ctio n (Brakes Pull) POSSIBLE CAUSE 1. Incorrect tire pressure. 2. 3. 4. 5. 6. Front end out of alignment. Loose suspension parts. Worn out brake lining. Incorrect lining material. Malfunctioning caliper assembly. 7. Loose calipers. 8 . Contaminated brake linings. 9. M alfunctioning rear brakes. 10. Leaking wheel or piston cylinder seal. 11. Restricted brake tubes or hoses. 12. Unmatched tires on the same axle. CORRECTION 1. Inflate evenly on both sides to specifictions. 2. Check and align to specifications. 3. Check all suspension mountings. 4. Replace with lining of correct material. 5. Replace with linings of correct material. 6 . Check for frozen or sluggish pistons and the lubrication of the retainer bolts. Caliper should slide. 7. Check and torque. 8 . Repair as necessary. Replace linings in complete axle sets. 9. Check for inoperative self adjusters. Weak return springs. Leaking wheel cylinders. 10. Repair as necessary. 11. Check for collapsed rubber hoses or damaged lines. Repair as necessary. 12 . Same style tires with about the same tread should be used on the same axle. HYDRAULIC BRAKES 5-3 DIAGNOSIS OF BRAKE SYSTEM (CONT.) Brakes Squeak 1. Worn out linings. 2. Glazed brake lining. 3. Heat spotted rotors or drums. 4. Weak or incorrect brake shoe retention springs. 5. Contaminated brake linings. 6. Incorrect lining material. 7. Brake assembly attachm ents missing or loose. 8. Excessive brake lining dust. Brake Pedal Pulsates 1. Excessive rotor lateral runout. 2. Rear drum s out of round. 3. Heat spotted rotors or drums. 4. Incorrect wheel bearing adjustments. 5. Out of balance wheel assembly attach­ ments missing or loose. 6. Brake assembly attachments missing or loose. Excessive Pedal Effort 1. 2. 3. 4. 5. Leaking vacuum system. M alfunctioning power brake unit. Worn out linings. M alfunctioning proportioning valve. Incorrect lining material. 6. Incorrect wheel cylinder. Excessive Pedal T ravel CORRECTION POSSIBLE CAUSE PROBLEM 1. Insufficient fluid in master cylinder reser­ voir. 2. Air in brake system. 3. 4. 5. 6. M alfunctioning self adjusters. Master cylinder. Incorrect wheel bearing adjustment. Im p ro p e rly a djusted m aster c y lin d e r pushrod. 1£' 1. Replace linings. 2. Replace linings. 3 3. Check per instructions. If within specifi­ cations machine the rotor or drum. 4. Replace with new retention springs. 5. Repair as necessary. Replace linings in complete axle sets. 6. Replace with linings of correct material. 7. Repair as necessary. i ■1 ■ 8. Clean dust from brake assembly. 1. Check per instructions. If within specifi­ cations machine the rotor. 2. Check per instructions. If within specifi­ cations machine the drum. 3. Check per instructions. If within specifi­ cations machine the rotor or drum. 4. Repair as necessary. 5. Repair as necesary. 6. Repair as necessary. 1. 2. 3. 4. 5. Repair as necessary. Repair as necessary. Replace linings. Repair as necessary. Replace with linings of correct m ateri­ als. 6. Replace with corrrect size wheel cylin­ der. 1. Fill reservoir with approved brake fluid. Check for leaks and air in the system. Check indicator light. 2. Check for leaks in lines, wheel cylin­ ders, or master cylinder. Bleed the sys­ tem. 3. Repair as necessary. 4. Replace or repair as necessary. 5. Repair as necessary. 6. Adjust master cylinder pushrod. 5-4 HYDRAULIC BRAKES DIAGNOSIS OF BRAKE SYSTEM (CONT.) PROBLEM Brakes Drag POSSIBLE CAUSE 1. M alfunctioning caliper assembly. 2. Contaminated or improper brake fluid. 3. Improperly adjusted parking brakes. 4. Restricted brake tube or hoses. 5. Malfunctioning proportioning valve. ‘. 11 9 Brake In d ica to r L ig h t Com es On 1. Check for frozen or sluggish pistons and the lubrication of the retainer bolts. C aliper should slide. 2. Repair as necessary. 3. Repair as necessary. 4. Check for collapsed rubber hoses or damaged lines. Repair as necessary. 5. Replace or repair as necessary. 6. M alfunctioning self adjusters. 7. M alfunctioning master cylinder. 8. Im pro pe rly a djusted m aster c y lin d e r pushrod. 6. Repair as necessary. 7. Repair as necessary. 8. Adjust pushrod length. 1. Air in the brake system. 1. Check fluid level. Check for leaks in lines, wheel cylinders, or master cylin­ der. Bleed the system. 2. Check for faulty metering valve, or leak­ ing. Repair as necessary. 3. Repair as necessary. 4. Check parking brake. Repair as neces­ sary. 5. Replace linings. 6. Repair as necessary. 7. Repair as necessary. 8. Replace or repair as necessary. 2. M alfunctioning master cylinder. 3. Contaminated or improper brake fluid. 4. Parking brake on or not fully released. 5. 6. 7. 8. Worn out brake lining. Incorrect wheel bearing adjustment. Malfunctioning self adjusters. Brake assembly attachments missing or loose. 9. Im pro pe rly a djusted m aster cylin d e r pushrod. Excessive Brake Pedal Effort CORRECTION 1. Loose or broken power steering pump belt. 2. No fluid in the power steering reservoir. 3. Leaks at Hydro-Boost tube fittings. 4. External leakage at the accumulator. 5. Faulty booster piston seal causing leak­ age at the booster flange vent. 6. Faulty booster input rod seal with leakagae at the input rod end. 7. Fautly booster cover seal with leakage between the housing and cover. 8. Fautly booster spool plug seal. 9. Adjust pushrod length. 1. Tighten or replace the belt. 2. Fill reservoir and check for external leaks. 3. Tighten fittings or replace tube seats, if faulty. 4. Replace seal and retainer 5. Overhaul with new seal or input rod and piston assembly. 6. Overhaul with new seal kit. 7. Overhaul with new seal kit. 8. Overhaul with spool plug seal kit. HYDRAULIC BRAKES 5A-5 ON VEHICLE SERVICE BLEEDING THE BRAKE HYDRAULIC SYSTEM A bleeding operation is necessary if air has been introduced into the hydraulic brake system. It may be necessary to bleed the system at all four wheels if air has been introduced by a low fluid level condition in the master cylinder or if the brake pipes have been disconnected at either the master cylinder or the com bination valve. If a pipe is disconnected at one wheel, then only bleed that particular wheel. The tim e required to bleed the hydraulic system when the master cylinder is removed can be reduced if the master cylinder is filled with fluid and as much air as possible is bled from the cylinder before installing it on the vehicle. MANUAL BLEEDING If the vehicle is equipped with power brakes, deplete the vacuum reserve by applying the brakes several tim es with the engine off. Use extreme care to prevent brake fluid from contacting any painted surface. 1. Fill the master cylinder reservoirs with brake fluid specified in MAINTENANCE AND LUBRICATION (Sec. OB). • Maintain the fluid level in the reservoir during the bleeding operation. 2. If the master cylinder is suspected to have air in the bore, it must be bled before any wheel cylinder or caliper. • Remove the forward brake pipe connection at the master cylinder. • Allow brake fluid to flow from the connector port. • Connect the brake pipe but do not tighten. 3. Slowly depress the brake pedal allowing the air to bleed from the loose fitting. • Tighten the fitting before releasing the pedal. • Wait 15 seconds, and repeat this sequence, including the 15 second wait until all the air is purged from the bore. 4. After all the air has been removed from the forward connection disconnect the rear pipe. • Allow brake fluid to flow from the connector port. • Connect the brake pipe but do not tighten. 5. Slowly depress the brake pedal allowing the air to bleed from the loose fitting. • Tighten the fitting before releasing the pedal. • Wait 15 seconds, and repeat this sequence, including the 15 second wait until all the air is purged from the bore. 6. If it is known that the calipers and wheel cylinders do not contain any air, then it will not be necessary to continue. Otherwise bleed each wheel in the following sequence. • Right rear • Left rear • Right front • Left front 7. Attach a hose to the wheel cylinder/caliper bleeder screw. • Immerse the opposite end of the hose into a container partially filled with clean brake fluid. 8. Slowly depress the brake pedal one tim e and hold. • Loosen the bleeder screw to purge the air from the wheel cylinder/caliper. • Tighten the bleeder screw and slowly release the pedal. • Wait 15 seconds, then repeat this sequence, including the 15 second wait until all the air is purged from the wheel cylinder/caliper. 9. Continue steps 7 and 8 at each wheel until the entire brake system has been bled. 10. Check the brake pedal for “ sponginess” and the bra ke w a rn in g la m p fo r an in d ic a tio n o f an unbalanced pressure. Repeat the entire bleeding procedure to correct either of these two conditions. PRESSURE BLEEDING The pressure bleeding equipm ent m ust be of the d ia ph rag m type. It m ust have a rub be r d ia p h ra g m between the air supply and the brake fluid to prevent air, moisture, oil, and other contaminants from entering the hydraulic system. Also adapters are needed, depending on the type of master cylinder used. Tools Required: J -2 9 5 6 7 B rake B le e d e r A d a p te r (P la s tic Reservoir) J-23518-01 Brake Bleeder Adapter (Cast Iron Reservoir) J-23709 Com bination Valve Depressor NOTICE: It is very important that the correct m aster cylinder bleed er adapter be used to avoid possible damage to the master cylinder reservoir. 1. Fill the pressure tank at least 1/3 full of brake fluid. The bleeder must be re-bled each tim e fluid is added. • Charge the bleeder to 140 - 170 kPa (20 to 25 psi). 2. Use J-23709 to depress and hold the valve stem on the combination valve during the bleeding operation (figure 1). • Install the correct bleeder adapter (figures 2 and 3). 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. • Open the tank valve. 5. Attach a hose to a brake bleeder screw. • Immerse the opposite end of the hose into a container partially filled with clean brake fluid. 5A-6 HYDRAULIC BRAKES B-07785 Figure 1—Installing Combination Valve Depresser 6. Open the bleeder screw at least 3/4 of a turn and allow the fluid to flow until no air is seen in the fluid. • Close the bleeder screw. 7. Repeat step six at all the wheels. 8. Check the brake pedal for “ sponginess” , repeat the entire bleeding procedure if this condition is found. 9. Remove J-23709. • Disconnect the line from the bleeder adapter. • Remove bleeder adapter. 10. Fill the master cylinder to the proper level with brake fluid. ______________________________________________ B-07783 Figure 3— Cast Iron Reservoir Bleeder Adapter 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 bleeder 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 re p le n is h if re q u ire d . W hen flu s h in g is completed at all bleeder valves, make certain the master cylinder reservoir is filled to proper level. BRAKE PIPES AND HOSES T h e h y d r a u lic b ra k e s y s te m c o m p o n e n ts are interconnected by special steel piping and flexible hoses. Flexible hoses are used between the frame and the front calipers, and the frame and rear differential. When the hydraulic pipes have been disconnected for any reason, the brake system must be bled after reconnecting the pipe, refer to “ Bleeding the Brake Hydraulic System” in this section. HYDRAULIC BRAKES 5A-7 FLEXIBLE HOSE On the front brakes the hose is connected to the caliper with a bolt and copper washers. The fitting at the other end of the hose is secured at the frame with either a nut or a clip. At the rear differential one end of the hose is connected to the differential with a bolt. The other end is secured at the frame with either a nut or a clip. Flexible Hose Inspection The flexible hoses should be inspected for any signs of road damage which will cause cracks and chafing of the other cover. If any of these conditions are visible, replace the hose. Hose Replacement Remove or Disconnect (Figure 4) • Clean dirt, grease, and other foreign material off the hose fittings at both ends. 1. Steel pipe. 2. Clip or nut (31). 3. Bolt (34). 4. Washers (33). 5. Hose (32). 0 Install or Connect (Figure 4) • Use new copper washers when installing the hose. 1. Hose (32). • The hose must not be twisted. Important 2. 3. 4. 5. • • The hose installation must not contact any suspension components. Washers (33). Bolt (34). Clip or nut (31). Steel pipe. Bleed the brakes, refer to “ Bleeding the Brake Hydraulic System” in this section. 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: Never use copper tubing for hydraulic brake lines because copper is subject to fatique cracking, and corrosion which could result in brake failure. Brake pipes that run parallel to each other must maintain a 6 mm (1/4-inch) clearance. Pipe Flaring (Figure 5) Tools Required: J-23530 Flaring Tool. J-23533-B Tube Cutter. In order to ensure a proper flare, a special flaring tool must be used. When using the tool, instruction furnished by the tool manufacturer should be followed. Always inspect newly formed flares for cracks or malformations which m ight cause leaks. After flaring, blow out the brake pipe with compressed air before installing on the vehicle. NOTICE: Double lap flaring tool must be used, as single flaring tools cannot produce a flare strong enough to hold the necessary pressure. 1. Use steel pipe and fittings of the correct size. The outside diameter of the pipe is used to specify the size. 2. Cut the pipe to length. Add 3 mm (Vs-inch) to the length for each flare. 3. Flare the pipe ends by following the instructions with the tool. 4. Bend the pipe to match the old pipe by using a pipe bender. COMBINATION VALVE The combination valve is comprised of three sections, each serving a different function (figure 6). The metering or hold off section of the valve limits the pressure to the front disc brakes until a predetermined front input pressure is reached, enough 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 periods. The proportioning section of the com bination valve 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 vehicles with light rear wheel loads. The valve is designed to have a By-Pass feature which assures full system pressure to the rear brakes in the event of a front brake system malfunction, also full front pressure is retained in the event of rear m alfunction. 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 “ w arning” position once a malfunction has occured. The only way the lamp can be turned off is to repair the m alfunction and apply a pedal force 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 jum per wire from the switch wire to ground. 2. Turn the ignition key to “ O N ” . • The warning lamp should light. • If the lamp will not light check the bulb. If the bulb is good, refer to Chasis Electrical (Sec. 8B) for further diagnosis. 3. Turn the ignition off. • Disconnect jum per wire and connect the wire to the switch terminal. Valve Warning Switch Test 1. Raise the vehicle. • Support with suitable safety stands. 2. Attach a hose to a rear brake bleeder screw. • Immerse the opposite end of the hose into a container partially filled with clean brake fluid. • Make sure the master cylinder reservoir is full. 5A -8 HYDRAULIC BRAKES 31. 32. 33. 34. N ut or C lip F le x H ose W asher B o lt B-07786 Figure 4—Flexible Hoses HYDRAULIC BRAKES 5A-9 8. Turn the ignition key off. • If the warning lamp does not light during steps 3 and 6 but does light when a jum per is connected to ground, the w arning sw itch p o rtio n o f th e v a lv e is fa u lty . Do n o t disassem ble any portion of the valve. It must be replaced. 9. Remove the safety stands. • Lower the vehicle. • C heck and fill the m aster c y lin d e r to the proper level. VALVE REPLACEMENT Remove or Disconnect (Figure 7) 3. Turn the ignition key to “ O N ” . • Open the bleeder screw while a helper applies moderate pressure to the brake pedal. • The warning lamp should light. • Close the bleeder screw before the helper releases the brake pedal. 4. Reapply the brake pedal with moderate to heavy pressure. • The lamp should go out. 5. Attach a hose to a front brake bleeder screw. • Immerse the opposite end of the hose into a container partially filled with clean brake fluid. • Make sure the master cylinder reservoir is full. 6. Open the bleeder screw while a helper applies moderate pressure to the brake pedal. • The warning lamp should light. • Close the bleeder screw before the helper releases the brake pedal. 7. Reapply the brake pedal with moderate to heavy pressure. • The lamp should go out. • The combination valve is not repairable and must be replaced as a complete assembly. • Care must be taken to prevent brake fluid from contacting any painted surface. 1. Hydraulic pipes. • Plug the pipes to prevent the loss of fluid or the entrance of dirt. 2. Warning switch harness. 3. Bolts. 4. Com bination valve. Install or Connect (Figure 7) 1. 2. 3. 4. • Position valve on the bracket. Bolts. Warning switch harness. Hydraulic pipes. Bleed the brake system. Refer to “ Bleeding Brake System” in this section. HEIGHT SENSING BRAKE PROPORTIONING VALVE The height sensing brake proportioning valve is used on series 30 models (figure 8). This will provide optimum brake balance and efficiency. The vehicle braking force is distributed to the front and rear wheels as determ ined by either a light or heavy payload condition. Figure 6—Combination Valve 5A-10 HYDRAULIC BRAKES A. B. C. D. G-Van R-V Truck P M o d e l (42) P M o d e l (32) ^ D B-09427 Figure 7—Combination Valves HYDRAULIC BRAKES 5A-11 The vaive is mounted on the frame, and a linkage connects the valve to a bracket that is mounted on the axle. CAUTION: Adding any suspension accessories or other equipment (such as load leveling kits, air shocks, suspension lift kits, additional spring leafs, etc.), or making modification that will change the distance between the axle and the frame w ithout changing the load, w ill p ro v id e a fa lse re a d in g to the brake p ro p o rtio n in g valve. T his could re su lt in unsatisfactory brake performance which in turn could result in an accident and possibly personal injury. 0 VALVE REPLACEMENT Remove or Disconnect (Figure 9) Raise the vehicle. Support the frame with suitable safety stands. The axle must be allowed to hang free. • Clean the exterior of the valve to prevent dirt from contam inating the hydraulic system. 1. Brake pipes (51). 2. Nut from the shaft (48). 3. Lever (49). 4. Bolts (46) and washers (47). 5. Valve (50). Install or Connect (Figure 9). 1. Position the valve on the mounting bracket. 2. Washer (47) and bolts (46). 3. Lever (49). • Refer to “ Proportioning Valve A djustm ent” in this section. 4. Nut (48). Torque to 10 N-m (89 in. lbs.). 5. Brake pipes (51). • B le ed b ra ke s. R e fe r to “ B le e d in g th e B rake Hydraulic System” , in this section. • Remove the safety stands. • Lower the vehicle. • Test the brakes. PROPORTIONING VALVE ADJUSTMENT If a front wheel lockup is experienced when the vehicle is being operated near the maximum GVWR with a lower than desired brake application, the valve adjustm ent should be checked. Use the following procedure to check the adjustment. 1. Raise the vehicle. • Support the frame with suitable safety stands. The axle must be allowed to hang free. 2. Remove the nut from the valve shaft. » Remove the lever. 3. Select the appropriate adjustment gage from the chart. 5A-12 HYDRAULIC BRAKES 5. Install the nut on the shaft. Torque to 10 N m (89 in. lbs.) 6. Sever the tang on the adjustm ent gage (figure 11). 7. Remove the safety stands. • Lower the vehicle. • Test the brakes. A. A d ju s tm e n t G age B-07794 Figure 10—Installing Adjustment Gage ADJUSTMENT GAGE CHART Part Number CodeColor 14061394 A Green 14061395 B Black 14061396 C Blue 15592484 D Red 15548904 E Yellow RPO RPO RPO RPO RPO Vehicle Combination R/V 3500 with G52 R20903 R3500 Less G52 R/V20903 G30005/06 with LB4/L05 V3500 Less G52 G31305/06 with LL4/LT9 R/V20903 with VD1 V20906 with VD1 V20906 G52: Extra Capacity Rear Spring LB4: 4.3 Liter L05: 5.7 Liter _ LL4: 6.2 Liter LT9: 5.7 Liter H.D. 4. Rotate the valve shaft to permit the installation of the adjustment gage (figure 10). • The center hole of the adjustment gage must seat on the “ D” shape of the valve shaft. • The g a g e ta n g mounting hole. m u st se a t in th e va lv e NOTICE: Do not drive the lever assembly onto the valve shaft by using nut or proper valve setting may be disturbed. HYDRAULIC BRAKES 5A-13 BRAKE PEDAL ASSEMBLY 1. 2. 3. 4. 6. 7. 11. 12. A. B. B o lt N ut B u s h in g s S p a ce r R e ta in e r W a sh er C lu tc h Pedal Brake Pedal M anual T ra n sm issio n A u to m a tic T ra n s m is s io n B-09428 Figure 12—R-V Brake Pedal Components CHECKING PEDAL TRAVEL 8. Clutch Pedal (11) (if equipped). 9. Bushings (3). At frequent intervals the brake pedal should be checked for travel. Travel is the distance the pedal moves toward the floor from a full released position. This check should be made with the brakes cold and about 122 N (90 lbs.) of force on the pedal. On vehicles with power brakes the pedal must be pumped at least three times with the e n g in e o ff b e fo re m a k in g th e c h e c k . F o llo w th e specifications below for the correct travel. R-V-G M a n u a l........................................115 mm (4.5-inches) R-V-G P o w e r............................................ 90 mm (3.5-inches) P (Except J F 9 ) ........................................90 mm (3.5-inches) P (JF9).....................................................150 mm (6.0-inches) BRAKE PEDAL REPLACEMENT 10. Spacer (4). Install or Connect (Figures 12 and 13) 1. Spacer (4). 2. Bushings (3). 3. Brake pedal (12). 4. Clutch pedal (11) (if equipped). NOTICE: See “ N otice” on page 5A-1 of this section. 5. Bolt (1) and nut (2). Tighten R-V AND P-30 (32) MODELS Remove or Disconnect (Figures 12 and 13) 1. 2. 3. 4. 5. 6. Retainer (6). Washer (7). Pin (10) and washer (9). Pushrod (8). Return spring (5). Nut (2) and bolt (1). 7. Brake pedal (12). • Nut to 63 N m (46 ft. lbs.) for P30 (32) Models. • Nut to 34 N m (25 ft. lbs.) for R-V Models. 6. Return spring (5). 7. Washer (9) and pin (10). 8. Pushrod (8). 9. Washer (7) and retainer (6). • Check the stoplamp switch adjustment. Refer to “ Stoplamp Sw itch.” 5A-14 HYDRAULIC BRAKES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 12. B o lt N ut B u s h in g s S p a ce r R eturn S p rin g R e ta in e r W a sh ers P u shro d W a sh e r Pin Brake Pedal B-07771 Figure 13—P30(32) Brake Pedal Components G-Model 4- + Remove or Disconnect (Figure 14) 1. 2. 3. 4. 5. 6. Retainer (6). Washer (9). Pushrod (8). Washer (7). Return spring (5). Retainer (14) or clutch attaching components (15) (if equipped). 7. Pin (13) or clutch pedal (11) (if equipped). 8. Brake pedal (12). 9. Bushings (3). |-»<-| Install or Connect (Figure 14) 1. 2. 3. 4. B ushings (3). Brake pedal (12). Pin (13) or clutch pedal (11) (if equipped). R etainer (14) or clutch attaching com ponents (15) (if equipped). 5. R eturn sp ring (5). 6. W asher (7). 7. 8. 9. • Pushrod (8). W asher (9). R etainer (6). C heck the stoplam p sw itch a djustm e nt. Refer to “ S toplam p S w itc h .” P 30 (42) MODEL 4- + 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove or Disconnect (Figure 15) Retainer and washer. Pushrod and washer. Clutch attaching components (15) (if equipped). Clutch pedal (11) (if equipped). Return spring (5) (if equipped). Nut (16) and bolt (18). Shaft (17). Brake pedal (12). Bushings (3). Install or Connect (Figure 15) • Lubricate the pivot points with Delco Brake Lube or equivalent. HYDRAULIC BRAKES 5A-15 3. B u s h in g B-07770 Figure 14—G-Van Brake Pedal Components 1. 2. 3. 4. 5. 6. 7. 8. 9. • Bushings (3). Brake pedal (12). Shaft (17). Bolt (18) and nut (16). Clutch pedal (11) (if equipped). Return spring (5) (if equipped). Clutch attaching components (15). Washer and pushrod. Washer and retainer. Check the stoplamp switch adjustment, refer to “ Stoplamp Sw itch.” BRAKE PEDAL ROD REPLACEMENT P 30 (32) MODEL Remove or Disconnect (Figure 16) 1. Retainer (6). 2. Nut (16). 3. Bolt (17) and washers (7 and 9). 4. Screws (18). 5. Raise the vehicle and support it with suitable safety stands. 6. Retainer (23). 7. Nut (22). 8. Bolt (19) and washers (20 and 21). 9. Brake rod (8). 10. Boot (24). Install or Connect (Figure 16) NOTICE: For steps 4 and 7 see “ N o tice” on page 54-7 of this section. 1. Boot (24). f t Adjust • Brake rod to 790 mm (31.00-inches) from the centers of the bolt holes. 2. Brake rod (8). 3. Bolt (19) and washers (20 and 21). 4. Nut (22) and retainer (23). 5A-16 HYDRAULIC BRAKES 18. Bolt B-07772 Figure 15— P30(42) Brake Pedal C om po n en ts Tighten • Nut to 35 N m (26 ft. lbs.). • Lower the vehicle. 5. Screws (18). 6. Bolt (17) and washers (9 and 17). 7. Nut (16) and retainer (6). Tighten • Nut to 35 N m (26 ft. lbs.). STOPLAMP SWITCH The design of the switch m ounting provides for an automatic adjustment when the brake pedal is returned to its stop. There are two styles of switches, the determining factor is if the vehicle is equipped with cruise control. For electrical d iagnosis of the stoplam p sw itch refer to CHASSIS ELECTRICAL (SEC. 8B). SWITCH REPLACEMENT |<"»| Remove or Disconnect 1. Remove the negative battery cable. 2. Electrical connectors. 3. Switch. Install or Connect 1. Switch. Adjust • Refer to “ Switch A djustm ent.” 2. Electrical connectors. 3. Negative battery cable. SWITCH ADJUSTM ENT 1. Depress the brake pedal and press the switch in until it is firm ly seated in the clip. • Audible “ clicks” can be heard as the threaded portion of the switch is pushed through the clip. 2. Pull the brake pedal against the pedal stop until the audible “ click” can no longer be heard. 3. Electrical contact should be made when the brake pedal is depressed the specified distance. • R-V models 25-31 mm (1.0-1.24 inches). • G-P models 11-24 mm (0.45-0.95 inches). HYDRAULIC BRAKES 5A-17 6. 7. 8. 9. 16. 17. 18. 19. 20. 21. 22. 23. 24. Retainer W asher Brake Rod W asher Nut B olt Screw B olt W asher W asher N ut R etainer Boot B-07775 Figure 16—P30(32) Brake Pedal Rod Components PARKING BRAKE SYSTEM PARKING BRAKE PEDAL OR HANDLE REPLACEMENT “►+ Install or Connect (Figure 17) NOTICE: See “ N otice” on page 5A-1 of this section for steps 2 and 4. R-V-G MODELS 4* + Remove or Disconnect (Figure 17) • The parking brake must be in the released position. 1. Nuts (1). 2. Release rod (3). 3. Bolt (2). 4. Brake assembly. 5. Parking brake cable. 1. Parking brake cable. 2. Bolt. $ Tighten • Refer to “ Torque Specifictions” in this section. 3. Release rod (3). 4. Nuts (1). Tighten • R efer to “ Torque S p e c ific a tio n s ” in th is section. 5. C heck the p a rkin g brake a d ju stm e n t, refer to “ Parking Brake A djustm ent” in this section. 5A-18 HYDRAULIC BRAKES 6. Washer (19) and nut (18). 7. Spacer (14). NOTICE: See “ N otice” on page 5A-1 of this section. 8. Washer (13) and bolts (12). 9. Washers (11) and nuts (10). Tighten Q • Nuts to 24 N m (18 ft. lbs.) • C heck the p arkin g brake a djustm e nt, refer to “ Parking Brake A djustm ent” in this section. CABLE REPLACEMENT FRONT CABLE REPLACEMENT (R-V MODELS) |++| Remove or Disconnect (Figures 19 and 20) • Raise the vehicle and support with suitable safety stands. 1. Nut (31) from the equalizer (32). 2. Connector (33) from the front cable. 3. Bend retaining fingers (34) and (35). 4. Cable from the brake pedal assembly. 5. Cable assembly (36). • Attach a piece of wire to the cable to help in installation. 0 1. N uts 2. B olt 3. Release Rod B-09421 Install or Connect (Figures 19 and 20) 1. Cable assembly (36). • M ake su re all th e re ta in in g fin g e rs are completely through the holes. 2. Cable to the pedal assembly. 3. Connector (33). 4. Nut (31) onto the equalizer (32). Adjust Figure 17—Removing Parking Brake Pedal on R-V and G Models P MODELS ++ • 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove or Disconnect (Figure 18) The parking brake must be in the released position. Nuts (10) and washers (11). Bolts (12) and washers (13). Spacers (14). Cotter pin (15) and washer (16). Clevis pin (17). Nut (18) and washer (19). Bolt (20). Spacer (21). Cable (22). Handle assembly. Install or Connect (Figure 18) 1. 2. 3. 4. 5. Cable (22). Clevis pin (17). Washer (16) and cotter pin (15). Spacer (21). Bolt (20). • Refer to “ Parking Brake A djustm ent” in this section. • Lower the vehicle. FRONT CABLE REPLACMENT (G AND P MODELS) Remove or Disconnect (Figures 19, 21 and 22) • Raise the vehicle and support with suitable safety stands. 1. Nut (31) from the equalizer (32). 2. Connector (33) from the front cable. 3. Bolts (37) and clips (38). 4. Cable from the pedal/handle assembly. • Bend the retaining fingers (34). 5. Cable assembly (36). • Attach a piece of wire to the cable to help in installation. Install or Connect (Figures 19, 21 and 22) 1. Cable assembly (36). • M ake sure all th e re ta in in g fin g e rs are completely through the holes. 2. Cable to the pedal/handle assembly. HYDRAULIC BRAKES 5A-19 Figure 18—Removing Parking Brake Lever on P Models 5A-20 HYDRAULIC BRAKES 31. N u t 32. E q u a lize r 33. C o n n e c to r B-07777 Figure 19—Equalizer Components 34. Fram e R e ta in in g F in g e rs 35. Pedal R etaining Fingers 36. C ab le A s s e m b ly B-07778 Figure 20—R-V Front Cable Components HYDRAULIC BRAKES 5A-21 Figure 21—P Model Front Cable Components 3. Clips (38) and bolts (37). 4. Connector (33). 5. Nut (31) onto the equalizer (32). ft Adjust • P arking brake. R efer to “ P arking Adjustm ent” , in this section. Brake • Lower the vehicle. CENTER CABLE REPLACEMENT Remove or Disconnect (Figure 19) • Raise the vehicle and support with suitable safety stands. 1. Nut (31) from the equalizer (32). 2. Both front and rear connectors (33). 3. Cable. -►+ Install or Connect (Figure 19) 36. 37. 38. 1. Cable. C able A ssem bly B olt C lip 2. Connector (33). 3. Nut (31) onto the equalizer (32). B-07781 Figure 22—G Model Front Cable Components Adjust • P arking brake. R efer to “ P a rkin g Brake A djustm ent” in this section. • Lower the vehicle. 5A-22 HYDRAULIC BRAKES REAR CABLE REPLACEMENT Remove or Disconnect (Figure 19) • Raise the vehicle and support it with suitable safety stands. 1. Nut (31) from the equalizer (32). 2. Connector (33). 3. B ra ke d ru m a nd s h o e a s s e m b ly . R e fe r to HYDRAULIC FOUNDATION BRAKES (SEC. 5A2). • Bend in retaining fingers at the backing plate. 4. Retaining clip at the frame support. 5. Cable assembly. -►+ Install or Connect (Figure 19) 1. Cable assembly. • M ake su re a ll th e re ta in in g fin g e rs are completely through the backing plate. 2. Retaining clip at the fram e support. 3. B ra k e s h o e s a nd d ru m a s s e m b ly . R e fe r to HYDRAULIC FOUNDATION BRAKES (SEC. 5A2). 4. Connector (33). 5. Nut (31) onto the equalizer (32). Adjust • P a rkin g brake. R efer to “ P arking Brake Adjustm ent” in this section. Lower the vehicle. PROPELLER SHAFT BRAKE REPLACEMENT Install or Connect (Figure 23) • L u b rica te the shoe pads and a d ju s tin g screw threads with a thin coat of white lithium grease. 1. Adjusting screw (60) and adjusting screw spring (58) to both shoes (68). 2. Shoe assembly (68). 3. Lever retaining ring (67). 4. Lever strut (55) and strut spring (57). 5. Washers (63). 6. Hold down springs (64). 7. Hold down clips (65). 8. Return spring guide (72). 9. Return springs (56 and 57) 10. Drum (66). 11. Propeller shaft, refer to PROPELLER SHAFT (Sec. 4A) in this manual. A djust • P arking brake. R efer to “ P arking Brake A djustm ent” in this section. • Lower the vehicle. PARKING BRAKE ADJUSTMENT The parking brakes must be adjusted whenever the p a rk in g b ra k e c a b le s h ave b e e n re p la c e d o r disconnected. Also if the brake holding ability is not adequate. Before adjusting the parking brakes check the condition of the service brakes. The service brakes must be adjusted properly before proceeding with the parking brake adjustment. CABLE INSPECTION Remove or Disconnect (Figure 23) • Raise the vehicle and support with suitable safety stands. 1. Propeller shaft, refer to Propeller Shaft (Sec. 4A). CAUTION: See “ Caution” on page 5A-1 of this section. 2. Drum (66). • It may be necessary to back off the adjusting screw. 3. Return springs (56 and 71). 4. Return spring guide (72). 5. Hold down clips (65). 6. Hold down springs (64). 7. Washers (63). 8. Lever strut (55). 9. Strut spring (57). 10. Lever retaining ring (67). 11. Shoes (68). 12. Adjusting screw (60). 13. Adjusting screw spring (58). Inspect All parts for discoloration due to heat, or stress. Replace if necessary. Brake drum for scoring and heat spots. Machine drum if needed. Check the parking brake system for free operation. The brake lever must return to the released position without sticking or binding. If a problem is present check the cable routings for kinks or binding. Clean and lubricate the parking brake assembly and cables with Delco brake lube or equivalent. FOOT PEDAL TYPE 1. Block the front wheels. • Raise and support the rear axle with suitable safety stands. 2. Loosen the equalizer nut. 3. Set the parking brake pedal to four clicks. A djust • Equalizer nut until the wheels rotate forward with a moderate drag. 4. Release the parking brake and rotate the rear wheels. There should be no brake drag. 5. Remove the safety stands and lower the vehicle. 6. Unblock the front wheels. LEVER TYPE 1. Block the front wheels. • Raise and support the rear axle with suitable safety stands. 2. Turn the adjusting knob on the parking brake lever counterclockwise until it stops. • Apply parking brake. 3. Loosen the equalizer nut. HYDRAULIC BRAKES 5A-23 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. Support Plate W asher A n ch o r Pin Nut Hold Down Pin Lever S trut Return Spring S trut Spring A d ju stin g Screw Spring Adjusting Screw Socket A d ju s tin g Screw A d ju s tin g Screw Nut Cable 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. W asher Hold Down Spring Hold Down C lip Drum Lever R etaining Ring Shoe W asher O perating Lever Return Spring Return Spring G uide A nchor Pin B-07779 Figure 23—Propeller Shaft Brake Components 5A-24 HYDRAULIC BRAKES ft Adjust • Equalizer nut until a light drag is felt while rotating the wheels forward. • Knob on the parking brake lever until a definite snap over center is felt. Release the parking brake and rotate the rear wheels. There should be no brake drag. Remove the safety stands and lower the vehicle. Unblock the front wheels. INTERNAL EXPANDING (PROPELLER SHAFT) CAUTION: See “ Caution” on page 5A-1 of this section. 1. Block 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. • Manual transmissions - the adjusting screw is located at the bottom of the shoe. • Automatic transmission - 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 m ust be removed to clean out all the metal shavings. Refer to PROPELLER SHAFTS (Sec. 4A). Adjust • Adjusting screw until the drum cannot be rotated by hand. • Back off the adjusting screw ten notches. The drum should rotate freely. Place parking brake lever in the full release position. Take up the slack in the cable to overcome the spring tension. ft A djust • The clevis of the pull rod to align with the hole in the relay lever. Install the clevis pin. Install new cover in the drum access hold. Remove the safety stands and lower the vehicle. Unblock the front wheels. MASTER CYLINDERS Figure 25—Composite Master Cylinder DESCRIPTION There are two designs of master cylinders available depending on the brake option. O ne is a fu ll c a s t iro n d e s ig n in c o rp o ra tin g a conventional front to rear brake split (figure 24). The primary piston provides the fluid pressure to the front brakes, while the secondary piston provides the fluid pressure to the rear brakes. If the pressure is lost from either system, the remaining system will function to stop the vehicle. The second style master cylinder is designed for use with a system using the low drag calipers (figure 25). In addition to the standard master cylinder functions, a quick take-up feature is included. This provides a large volume of fluid to the wheels at low pressure with the initial brake application. This large volum e of fluid is needed to overcome the clearance created by the seal retracting the pistons into the front calipers and the spring retraction of the rear drum brake shoes. MASTER CYLINDER REPLACEMENT Remove or Disconnect (Figure 26) • Apply the vehicles parking brakes. 1. Brake pipes. • Cover the ends of the pipes to prevent dirt from entering the system. 2. M ounting nuts. 3. Master cylinder. HYDRAULIC BRAKES 5A-25 Figure 26—Master Cylinder Installations 5A-26 HYDRAULIC BRAKES 0 If the vehicle is equipped with manual brakes, refer to “ Brake Pedal Replacem ent” for the removal of the pushrod from the pedal. BENCH BLEEDING ♦ ± l Install or Connect (Figure 26) • Prior to installation, refer to “ Bench Bleeding” in this section. 1. Master cylinder. • If the vehicle is equipped with manual brakes, refer to “ Brake Pedal R eplacem ent” for the installation of the pushrod to the pedal. NOTICE: See “ Notice" section. on page 5A-1 of this 2. Mounting nuts. Tighten • Nuts to 27 N m (20 ft. lbs.), G and P models. Brake pipes. Bleed the brakes, refer to “ Bleeding the Brake Hydraulic System” in this section. Release the parking brakes. 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 m ount the master cylinder in a vise with the front end tilted slightly down. 2. Fill the reservoir with clean brake fluid. Using a tool with a smooth rounded end tool, stroke the prim ary piston about 25 mm (1-inch) several times. As air is bled from the master cylinder, with the outlets plugged, the resistance to the prim ary piston travel will not allow the full 25 mm (1-inch) stroke. 3. Reposition the master cylinder in the vise with the front end of the master cylinder tilted slightly up. Again stroke the prim ary piston about 25 mm (1-inch) several times. 4. Reposition the master cylinder in the vise to the level position. Loosen the plugs one at a time and push the piston into the bore to force the air from the cylinder. To prevent air from being sucked back into the cylinder, tighten the plug(s) before allowing the piston to return to its original position. 5. Fill the reservoir. Normal bleeding procedures should be followed after the master cylinder is installed. SPECIFICATIONS BRAKE SYSTEMS SYSTEM FRONT BRAKES REAR BRAKES BRAKE ASSIST GASOLINE ENGINE VEHICLES R-MODELS JB1 Low Drag JB3 Low Drag Disc 11.86 x 1.04 Disc 11.86 x 1.04 Drum 11.0 x 2.00 Drum 11.0 x 2.00 None (Manual Brakes) Vacuum— Single Diaphragm Drum 11.00 x 2.00 Drum 11.00 x 2.00 None (Manual Brakes) Vacuum— Single Diaphragm Drum 11.15 x 2.75 Drum 11.15 x 2.75 Drum 13.00 x 2.50 Drum 13.00 x 3.50 Disc 13.75 x 1.54 Vacuum— Dual Diaphragm Vacuum— Dual Diaghragm Vacuum— Dual Diaphragm Hydraulic— Hydro-Boost Hydraulic— Hydro-Boost G-MODELS JB1 Low Drag JB3 Low Drag Disc 11.86 x 1.29 Disc 11.86 x 1.29 ALL MODELS JB5 JB6 JB7 JB8 JF9 Low Drag Low Drag Conventional Conventional Conventional Disc Disc Disc Disc Disc 11.86 x 1.29 12.50 x 1.28 12.50 x 1.28 12.50 x 1.54 14.25 x.1.54 DIESEL ENGINE VEHICLES JD3 JD5 JD6 JD7 Low Drag Low Drag Conventional Conventional Disc 11.86 x 1.29 Disc 11.86 x 1.29 Disc. 12.50 x 1.28 Disc 12.50 x 1.28 Drum Drum Drum Drum 11.00 x 11.15 x 11.15 x 13.00 x 2.00 2.75 2.75 2.50 Hydraulic— Hydro-Boost Hydraulic— Hydro-Boost Hydraulic-Hydro-Boost Hydraulic— Hydro-Boost BRAKES 5A-27 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS R V G P Master Cylinder—to Dash or Booster 27 N m (20 ft. lbs.) 27 N-m (20 ft. lbs.) 27 N-m (20 ft. lbs.) 27 N-m (20 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.) 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 — — 34 N m (25 ft. 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.) — 63 N-m (46 ft. lbs.) — — 9.5 N-m (85 in. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) Brake Pedal —Bracket to Dash —Sleeve to Bracket —Stoplamp Switch Bracket — 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.) 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.) —Cable Clips—Screws 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.) — Bracket to Trans. — — — —Cable Clip to Frame — — — 17 N-m (150 in. lbs.) —Cable Clip to Dash — — — 6 N-m (55 in. lbs.) — — 27 N-m (20 ft. lbs.) Parkinq Brake —to Dash Propshaft Parking Brake —Adjusting Nut — 24 N-m (18 ft. lbs.) 40 N-m (30 ft. lbs.) 27 N-m (20 ft. lbs.) —Cable Clip to Trans. Brkt. — — Flange Plate — — — 40 N-m (30 ft. lbs.) — Drum — — — 110 N-m (80 ft. lbs.) 44 N m (32 ft. lbs.) Front Brake Hose —to Caliper 7 N m (58 in. lbs.) —to Frame Nut —Bracket Bolt 17 N-m (150 in. lbs.) — 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 10 N-m (90 in. lbs.) 17 N-m (150 in. lbs.) — 17 N-m (150 in. lbs.) Rear Brake Hose—to Axle Bracket 27 N m (20 ft. lbs.) 27 N-m (20 ft. lbs.) — Bracket to Axle 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 17 N-m (150 in. lbs.) 12 N-m (100 in. lbs.) — 17 N-m (150 in. lbs.) Brake Line —Attaching Nuts —Retaining Clips—Screws — Bolts — 17 N-m (150 in. lbs.) 24 N-m (18 ft. lbs.) 5A-28 HYDRAULIC BRAKES SPECIAL TOOLS 1. 2. 3. 4. 5. Brake B le e d e r A d a p te r Brake B le e d e r A d a p te r C o m b in a tio n Valve D e p re sso r F la rin g Tool Tube C u tte r J-23533-B B-09305 Figure 27—Special Tool Chart 5A1-1 SECTION 5A1 HYDRAULIC BRAKE BOOSTER SYSTEM S 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 term inology NOTICE: See ‘Notice’ on page 5A1-1 of this section. NOTICE: This fastener is an im portant attaching part in that it could affect the performance of vital com ponents and system, and/or could result in major repair expense. It must be replaced with one o f the same part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part o f lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part. CONTENTS SUBJECT PAGE Diagnosis of Hydro-Boost System..............................................................................................................................5A1-1 Hydro-Boost System T e sts...................................................................................................................................... 5A1-2 Vacuum B o o s te rs.........................................................................................................................................................5A1-3 Description................................................................................................................................................................. 5A1-3 Vacuum Booster Replacement................................................................................................................................ 5A1-3 Hydraulic Brake Booster (H ydro-B oost)....................................................................................................................5A1-4 Description................................................................................................................................................................. 5A1-4 Hydro-Boost R eplacem ent...................................................................................................................................... 5A1-4 Bleeding the Hydro-Boost System .......................................................................................................................... 5A1-7 S pe cifica tio n s...............................................................................................................................................................5A1-8 DIAGNOSIS OF HYDRO-BOOST SYSTEM PROBLEM Slow Brake Pedal Return POSSIBLE CAUSE 1. Excessive seal friction in booster. 2. Faulty spool action. 3. Restriction in return line from booster to pum p reservoir. 4. Damaged input rod end. Grabby Brakes Booster Chattters Pedal Vibrates 1. Overhaul with new seal kit. 2. Flush steering system while pum ping brake pedal. 3. Replace line. 4. Replace input rod and piston assembly. 1. Faulty spool action caused by contam i­ nation in system. 2. Power steering pump belt slips. 1. Flush steering system while pumping brake pedal. 2. Tighten belt. 3. Low fluid level in power steering pump. 3. Fill reservoir and check for external leaks. 4. Flush steering system while pum ping brake pedal. 4. Faulty spool operation caused by con­ tamination in system. Accumulator Leak-Down System Does Not Hold Charge CORRECTION 1. Contamination in steering hydro-boost system. 2. Internal leakage in accum ulator system. 1. Flush steering system while pum ping brake pedal. 2. Overhaul unit using accum ulator re­ build kit and seal kit. 5A1-2 HYDRAULIC BRAKE BOOSTER SYSTEMS HYDRO-BOOST SYSTEM TESTS The Hydro-Boost system receives its source of power fro m th e p o w e r s te e r in g s y s te m . T h e re fo re a m alfunctioning power steering system may affect the operation of the booster, just as a problem in the booster may affect the steering system. Prior to performing any tests, the following checks must be made. 1. C heck all the pow er ste ering and brake pipe connections for leaks or restriction. NOTICE: Power steering fluid and brake fluid cannot bemixed. If brakesealscontact steering fluid or steering seals contact brake fluid, seal damage will result. 2. Check and fill the brake master cylinder with brake fluid. 3. Check and fill the power steering reservior with power steering fluid. If fluid contains air refer to P O W E R S T E E R IN G (S e c. 3 B 3 ) fo r fu r th e r diagnosis. 4. Check power steering pump belt for wear and te n s io n . A d ju s t if n e e d e d , re fe r to PO W ER STEERING (Sec. 3B3). 5. Check engine idle speed, refer to the vehicles E m is s io n C o n tro l In fo rm a tio n la b e l fo r id le specifications. 6. Check steering pump pressure. Refer to POWER STEERING (Sec. 3B3). A. B. C. D. E. F. Input Rod Seal Power Piston Seal H ousing Seal Spool Valve Plug Seal A c cu m u la to r Seal Return Port F ittin g B-07849 Figure 1-H ydro-B oost Seal Leak Diagnosis NOISE DIAGNOSIS T h e fo llo w in g n o is e s a re a s s o c ia te d w ith th e Hydro-Boost and may or may not be cause for custom er 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 moan or low frequency hum usually 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 (Sec. 3B3). 2. A high speed fluid noise may be heard when the brake pedal is fully depressed, this condition is normal. 3. Whenever the accum ulator pressure is used, a slight hiss may be noticed. It is the sound of the hydraulic fluid escaping through the accumulator valve, and is completely normal. 4. After the accum ulator has been emptied, and the engine is started again, another hissing sound may be heard during the first brake application or the first steering maneuver. This is caused by the fluid rushing through the accum ulator charging orifice. It is normal and will only be heard once after the accum ulator is em ptied. However, if this sound continues, even though no apparent accum ulator pressure assist was made, it could be an indication that the accum ulator is not holding pressure and should be checked using the procedure for the “ Accum ulator Leakdown Test” in this section. BOOSTER FUNCTIONAL TEST With the engine off, apply the brake pedal several times until the accum ulator is completely depleted. Depress the brake pedal using 180 N (40 lbs.) of force and start the engine. The pedal will fall and then push back against your foot. ACCUMULATOR LEAKDOWN TEST 1. Start the engine and charge the accum ulator by applying the brake pedal or by turning the steering wheel from stop to stop. Turn off the engine and let the vehcile sit for one hour. After one hour there should be at least two power assisted applications with the engine off. 2. If the reserve system will not retain a charge for one hour, but functions norm ally immediately following charging, the accum ulator valves are at fault and th e b o o s te r m u st be d is a s s e m b le d and th e accum ulator valves replaced. 3. If the accum ulator can be heard charging and d is c h a rg in g , b u t it d o e s not hold a c h a rg e , d is a s s e m b le th e b o o s te r and re p la c e th e accum ulator valves. HYDRAULIC BRAKE BOOSTER SYSTEMS 5A1 -3 4. Deplete the accum ulator by pressing the brake pedal several times. If the accum ulator can has lost its gas charge, it is possible to rotate or wobble the a ccu m u la to r can w ith resp ect to the housing. Replace the accum ulator assembly. C. SEAL LEAK DIAGNOSIS (FIGURE 1) A. INPUT ROD SEAL. A dam aged seal will show up as a fluid leak from the mounting bracket vent hole. The booster must be removed from the vehicle and d isa sse m b le d . T he in p u t rod bore s h o u ld be checked for any scratches that may cause the leak. If scratches are present, the housing cover must be replaced. If no excessive scratches are present, then the booster seal kit can be used to replace the appropriate seals. B. POWER PI&TON SEAL. Power piston seal damage will be noticed by fluid leaking out at the common master cylinder brake booster vent and possible reduction in power assist. The booster must be D. E. F. removed from the vehicle and disassembled. The piston should be checked for any scratches that may be the cause of the leak. If scratches are present, then the booster seal kit can be used to replace the appropriate seals. 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. SPOOL VALVE PLUG SEAL. Damage to this seal will be noticed by fluid leaking out past the plug. The booster need not be removed from the vehicle. ACCUMULATOR SEAL. Damage to this seal will result in fluid leakage past the accum ulator cap. The seal can be replaced w hile the booster is installed on the vehicle. RETURN PORT FITTING. Tighten the fitting to 10 N m (7 ft. lbs.). If the leak continues, replace the seal ring under the fitting. VACUUM BOOSTERS DESCRIPTION SINGLE DIAPHRAGM MODEL This booster is a single 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 pum p m alfunction. In a norm al 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 pressure is admitted to one side of the diaphragm to provide the power assist. TANDEM DIAPHRAGM MODEL 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 vacuum or vacuum pump malfunction. In a normal operating mode, with the service brakes in the released position, a tandem vacuum suspended booster operates with vacuum on both sides of its diaphragm s. W hen the brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide the power assist. VACUUM BOOSTER REPLACEMENT ++ Remove or Disconnect (Figure 2) • Apply the vehicles parking brakes. 1. Mounting nuts. 2. Master cylinder. • Support the master cylinder. 3. Vacuum hose from the check valve. 4. B o o s te r p u s h ro d , re fe r to “ B ra k e P e d a l R eplacem ent” in HYDRAULIC BRAKES (SEC. 5A). 1. 2. 3. 4. 5. M o u n tin g N u ts M a s te r C y lin d e r V a cu u m B o o s te r B o o s te r M o u n tin g N u ts B o o s te r P u sh ro d B-07805 Figure 2—Removing Vacuum Boosters 5. Booster m ounting nuts. • The mounting nuts must be removed from inside the vehicle. 6. Vacuum booster. +4* Install or Connect (Figure 2) NOTICE: For steps 2 and 6 page5A1-1 of this section. see “Notice” on 1. Vacuum booster. 2. Booster m ounting nuts. Nuts to 29 N m (21 ft. lbs.) for R-V-G Models. Nuts to 24 N-m (18 ft. lbs.) for P Models. 5A1-4 HYDRAULIC BRAKE BOOSTER SYSTEMS 3. Booster pushrod, refer to HYDRAULIC BRAKES (SEC. 5A). 4. Vacuum hose. 5. Master cylinder. 6. Mounting nuts. Tighten • Mounting nuts to 27 N m (20 ft. lbs.) 7. Release the parking brakes. HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST) DESCRIPTION P 30 (42) MODEL 44 Remove or Disconnect (Figures 4 and 5) This system uses a hydraulic pump to power the system and a pneum atic accum ulator as a reserve system. In this system, no special fluids are used, however, care must be taken to use the correct fluids. The master cylinder and brake system operate on standard hydraulic brake fluid, while the hydraulic pump operates on power steering fluid. For diagnosis of the Hydro-Boost System, refer to “ Hydro-Boost Systems Tests” and “ Diagnosis of Hydro-Boost System” in this section. HYDRO-BOOST REPLACEMENT R-V AND G MODELS Remove or Disconnect (Figure 3) • 1. 2. 3. 4. 5. 6. 7. Apply the vehicles parking brakes. Hydraulic lines from the booster. Nuts (1). Master cylinder (2). • Support the master cylinder. Booster pushrod. Refer to HYDRAULIC BRAKES (SEC. 5A). Nuts (4) and (6). Hydro-Boost unit (3). Gasket (5). Apply the vehicles parking brakes. Hydraulic lines from the booster. Nuts (1) and washers (7). Master cylinder (2). • Support the master cylinder. Pushrod retainer (10). Retaining clip and washer. Booster pushrod (9). Nuts (4) and washers (8). Hydro-Boost unit (3). 44- Install or Connect (Figures 4 and 5) NOTICE: For steps 2 and 7 see “ N o tic e ” on page 5A1-1 of this section. 1. Hydro-Boost unit (3). 2. Washers (8) and nuts (4). Tighten 3. 4. 5. 6. 7. Tighten Install or Connect (Figure 3) NOTICE: For steps 3 and 6 see “ N o tice” on page 5A1-1 of this section. 1. Gasket (5). 2. Hydro-Boost unit (3). 3. Nuts (4) and (6). • Nuts to 29 N-m (21 ft. lbs.). Booster pushrod (9). Washer and retaining clip. Pushrod retainer (10). Master cylinder (2). Washers (7) and nuts (1). • Nuts to 27 N m (20 ft. lbs.) 8. Hydraulic lines. • Bleed the booster, refer to “ Bleeding the Hydro-Boost System” in this section. 9. Release the parking brakes. P 30 (32) MODEL Remove or Disconnect (Figure 6) • Nuts to 24 N-m (18 ft. lbs.) for R-V Models. • Nuts to 29 N-m (21 ft. lbs.) for G Models. 4. Booster pushrod. Refer to HYDRAULIC BRAKES (SEC. 5A). 5. Master cylinder. (2). 6. Nuts (1). Tighten • Nuts to 27 N-m (20 ft. lbs.). 7. Hydraulic lines. • Bleed the booster, refer to “ Bleeding the Hydro-Boost System” in this section. • Release the parking brakes. • 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Apply the vehicles parking brakes. Hydraulic lines from the booster. Nuts (12) and washers (13). Master cylinder (2). • Support the master cylinder. Brake pedal rod. Refer to HYDRAULIC BRAKES (SEC. 5A). Nut (10) and washer (11). Bolt (16). Nut (14) and washers (15). Bolt (18). Nuts (12) and washer (13). Bolts (17). Hydro-Boost unit (3). HYDRAULIC BRAKE BOOSTER SYSTEMS 5A1-5 A. B. 1. 2. 3. 4. 5. 6. R-V M odel G -M odel N ut M a ste r C y lin d e r H yd ro -B o o st N ut G asket N ut B-09429 Figure 3—R-V and G Model Hydro-Boost Replacement 5A1-6 HYDRAULIC BRAKE BOOSTER SYSTEMS 1. 2. 3. 4. 7. 8. N ut M aste r C y lin d e r H yd ro -B o o st N ut W asher W asher B-07809 Figure 4—P30(42) Hydro-Boost Replacement |~K-| Install or Connect (Figure 6) NOTICE: For steps 2, 4, 6, and 9 see “ N o tice” on page 5A1-1 of this section. 1. Hydro-Boost unit (3). 2. Bolts (17). 3. Washers (13) and nuts (12). Leave finger tight. 4. Bolt (18). 5. Washer (15) and nut (14). Leave finger tight. 6. Bolt (16). 7. Washer (11) and nut (10). Leave finger tight. Tighten • Nuts (10, 14 and 12) to 34 N m (25 ft. lbs.). 8. Brake pedal rod. Refer to HYDRAULIC BRAKES (SEC. 5A). 9. Master cylinder (2). 10. Washers (13) and nuts (12). ^ Tighten • Nuts to 34 N m (25 ft. lbs.) 11. Hydraulic lines. • Bleed the booster, refer to “ Bleeding the Hydro-Boost System” in this section. • Release the parking brakes. HYDRAULIC BRAKE BOOSTER SYSTEMS 5A1-7 2. 3. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. M a ste r C y lin d e r H yd ro -B o o st N ut W a sh er N ut W a sh er N ut W a sh er B o lt B o lts B o lt N ut 10 B-07811 Figure 6—P30(32) Hydro-Boost Replacement BLEEDING THE HYDRO-BOOST SYSTEM Whenever the booster is removed and reinstalled, the steering system should be bled. NOTICE: The pow er steering fluid and brake fluid cannot be mixed. If the brake seals contact steering fluid or the steering seals contact brake fluid, seal damage will result. 1. Fill the power steering pump reservoir to the proper level and let the fluid remain undisturbed for at least two minutes. 2. Start the engine and run momentarily. • Add fluid, if necessary. 3. Repeat steps 1 and 2 until the fluid level remains constant after running the engine. 4. Raise the front of the vehicle so the wheels are off the ground. • Support the vehicle with suitable safety stands. 5. Turn the wheels from stop to stop, lightly contacting the stops. • Add fluid, if necessary. 6. Lower the vehicle. 7. Start the engine and depress the brake pedal several times while rotating the steering wheel from stop to stop. 8. Turn the engine off and then pump the brake pedal 4-5 times. 9. Check fluid level, add fluid if necessary. 10. If the fluid is extremely foamy, allow the vehicle to stand a few minutes with the engine off. Then repeat steps 7, 8 and 9. 11. Check for the presence of air in the oil. Air in the oil will have a milky appearance. Air in the system will also cause the fluid level in the pump to rise when the e n g in e is tu rn e d o ff. If it beco m e s obvious that the pump will not bleed the air after a few attempts, refer to POWER STEERING (Sec. 3B3) for further diagnosis. 5A1 -8 HYDRAULIC BRAKE BOOSTER SYSTEMS SPECIFICATIONS BRAKE SYSTEMS SYSTEM FRONT BRAKES REAR BRAKES BRAKE ASSIST GASOLINE ENGINE VEHICLES R-MODELS JB1 Low Drag JB3 Low Drag Disc 11.86 x 1.04 Disc 11.86 x 1.04 Drum 11.0 x 2.00 Drum 11.0 x 2.00 None (Manual Brakes) Vacuum— Single Diaphragm Drum 11.00 x 2.00 Drum 11.00 x 2.00 None (Manual Brakes) Vacuum— Single Diaphragm Drum 11.15 x 2.75 Drum 11.15 x 2.75 Drum 13.00 x 2.50 Drum 13.00 x 3.50 Disc 13.75 x 1.54 Vacuum— Dual Diaphragm Vacuum— Dual Diaghragm Vacuum— Dual Diaphragm Hydraulic— Hydro-Boost Hydraulic— Hydro-Boost G-MODELS JB1 Low Drag JB3 Low Drag Disc 11.86 x 1.29 Disc 11.86 x 1.29 ALL MODELS JB5 JB6 JB7 JB8 JF9 Low Drag Low Drag Conventional Conventional Conventional Disc Disc Disc Disc Disc 11.86 x 1.29 12.50 x 1.28 12.50 x 1.28 12.50 x 1.54 14.25 x.1.54 DIESEL ENGINE VEHICLES JD3 JD5 JD6 JD7 Low Drag Low Drag Conventional Conventional Disc 11.86 x 1.29 Disc 11.86 x 1.29 Disc. 12.50 x 1.28 Disc 12.50 x 1.28 Drum Drum Drum Drum 11.00 x 2.00 11.15 x 2.75 11.15 x 2.75 13.00 x 2.50 Hydraulic— Hydro-Boost Hydraulic— Hydro-Boost Hydraulic-Hydro-Boost Hydraulic— Hydro-Boost TORQUE SPECIFICATIONS Master Cylinder to Booster R 27 N-m (20 ft. lbs.) V 27 N-m (20 ft. lbs.) G 27 N-m (20 ft. lbs.) P 27 N-m (20 ft. lbs.) Booster to Dash or Frame 29 N-m (21 ft. lbs.) 29 N-m (21 ft. lbs.) 29 N-m (21 ft. lbs.) 24 N-m (18 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.) Hydro— Boost -P e d a l Rod - P30 (32) Models 34 N-m (25 ft. 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.) —Hose 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.) —Booster to Dash or Frame 24 N-m (18 ft. lbs.) 24 N-m (18 ft. lbs.) 29 N-m (21 ft. lbs.) 29 N-m (21 ft. lbs.) 5A2-1 SECTION 5A2 HYDRAULIC FOUNDATION 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 term inology NOTICE: See ‘Notice’ on page 5A2-1 of this section. NOTICE: This fastener is an important attaching part in that it could affect the performance of vital components and system, and/or could result in major repair expense. It must be replaced with one of the same part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure 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 with a dry brush or with 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 Disc B ra ke s................................................................................................................................................................ 5A2- 1 Description...............................................................................................................................................................5A2- 1 Brake Lining In s p e c tio n ........................................................................................................................................ 5A2- 1 Brake Lining Replacem ent....................................................................................................................................5A2- 2 Servicing the R o to r................................................................................................................................................ 5A2- 6 Rebuilding the Caliper............................................................................................................................................ 5A2- 6 Drum B ra k e s .............................................................................................................................................................. 5A2- 9 Description.............................................................................................................................................................. 5A2- 9 Brake Lining Replacem ent....................................................................................................................................5A2- 9 Servicing the Brake Drum ......................................................................................................................................5A2-10 Brake A d ju s tm e n t.................................................................................................................................................. 5A2-10 Wheel Cylinder Replacement................................................................................................................................5A2-11 Rebuilding the Wheel Cylinder..............................................................................................................................5A2-11 S pe cifica tio ns............................................................................................................................................................ 5A2-12 Special T o ols.............................................................................................................................................................. 5A2-13 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 c a lip e r a sse m b ly m oves in b o a rd th u s p ro v id in g a clam ping 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 1). 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 0.80 mm (1/32-inch) of a rivet head or the pad itself. 5A2-2 HYDRAULIC FOUNDATION BRAKES Suspend the caliper from the suspension (figure 6 ). Im portant • Do not allow the brake components to hang from the flexible hoses as damage to the hoses may occur. 5. Inboard pad (6). 6. Retainer spring (5). 7. Outboard pad (7). The disc brake pads have a wear indicator that makes a n o ise w he n th e lin in g s w e a r to a d e g re e w h e re replacement is required (figure 2). 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. BRAKE LINING REPLACEMENT 3000/3100 MODELS |*"*| Remove or Disconnect (Figure 3) • Two-thirds of the brake fluid from the master cylinder. • Raise the vehicle and support it with suitable 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 “Caution” on page 5A2-1 of this section. • Position a C-clamp around the outer pad and caliper and tighten until the piston bottoms in its bore (figure 4). 2. C - clamp 3. Mounting bolts (figure 5). 4. Caliper assembly. 2 . Sleeves 3. Bushings 4. Bushings 5. R etainer Spring 6 . Inboard Pad 7. O utboard Pad B-07829 Figure 3—Replacing Disc Brake Linings (3000/3100 Models) HYDRAULIC FOUNDATION BRAKES 5A2-3 Figure 4—Compressing the Caliper Piston 8. Sleeves (2). 9. Bushings (3 and 4). 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. Install or Connect (Figure 3) • Lubricate the sleeves and bushings with Delco Silicone Lube or equivalent. 1. Bushings (3 and 4). 2. Sleeves (2). 3. Retainer spring (5) onto the inboard pad (6). 4. Inboard pad (6). 5. Outboard pad (7). 6. Caliper assembly. Im portant Make sure that the brake hose is not twisted or kinked since damage to the hose could result. NOTICE: See “ N o tice” on page 5A2-1 of this section. 7. Mounting bolts (Figure 5). Tighten • Bolts to 48 N m (35 ft. lbs.) Compress the pad ears to the caliper (figure 7). tj| Measure (Figure 8) • The clearance between the caliper ana the steering knuckle. The clearance at each end of the caliper should be measured individually and added together, this total should between 0.26 0.60 mm (0.010 - 0.024-inches). 8. Wheel and tire assembly, refer to WHEELS AND TIRES (Sec. 3E). • Lower the vehicle. 5A2-4 HYDRAULIC FOUNDATION BRAKES Im portant • Before moving the vehicle, pump the brake pedal several times to make sure that the 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 the brakes. 6. 7. 8. 9. In bo ard Pad O u tb o a rd Pad B o lt S u p p o rt Key B-07798 BENDIX MODEL Figure 10—Bendix Disc Brake Assembly Remove or Disconnect (Figures 9 and 10) • Two-thirds of the brake fluid from the master cylinder. • Raise the vehicle and support it with suitable safety stands. • Mark the relationship of the wheel to the hub. 1. Wheel and tire assembly, refer to WHEELS AND TIRES (Sec. 3E). 6. 7. 8. 9. 10. CAUTION: See “ Caution” on page 5A2-1 of this section. • Position C - clamp and tighten until the piston bottoms in its bore (figure 11). 2. C - clamp. 3. Bolt (8). 4. Support key (9) and spring (10). • Use a brass punch and a hammer to drive the support key out (figure 12). 5. Caliper assembly. Inboard Pad O u tb oa rd Pad B o lt S u p p o rt Key S pring A n ti-R a ttle S pring B-07831 Figure 9—Replacing Disc Brake Linings (Bendix Models) Figure 11—Compressing the Caliper Piston HYDRAULIC FOUNDATION BRAKES 5A2-5 Figure 13—Suspending the Caliper Suspend the caliper from the suspension (figure 13). im portant • Do not allow the brake components to hang from the flexible hoses as damage to the hoses may occur. 6. Inboard pad (6) from the steering knuckle or rear caliper support. 7. Anti-rattle spring (11). 8. Outboard pad (7). Inspect igi The inside of the caliper assembly for signs of fluid leakage, if found, refer to “ Rebuilding the Caliper” in this section. Clean Use a wire brush to remove any corrosion from the machined surfaces of the steering knuckle and caliper. Install or Connect (Figures 9 and 10) • Lubricate the caliper and steering knuckle (or support) sliding surfaces and spring with Delco Silicone Lube or equivalent. 1. Inboard pad (6) and anti-rattle spring (11). 2. Outboard pad (7) into the caliper assembly. 3. Caliper assembly. Important 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 14). NOTICE: See “ N o tic e ” on page 5A2-1 o f this section. 5. Bolt (8). • The boss on the bolt must fully fit into the circular cutout in the key. 5A2-6 HYDRAULIC FOUNDATION BRAKES l§l Tighten • Bolt to 20 N m (15 ft. lbs.). 6. Wheel and tire assembly, refer to WHEELS AND TIRES (Sec. 3E). • Lower the vehicle. Important • Before moving the vehicle, pump the brake pedal several times to make sure that the 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 the brakes. SERVICING THE ROTOR In the m a n u fa c tu rin g of the brake rotor all the tolerances regarding surface finish, parallilism, and lateral runout are held very closely. The maintenance of these tolerances provide the surface necessary to prevent brake roughness. Light scoring of the rotor surface not in excess of 0.38 mm (0.15-inch) in depth is norm al. This condition does not affect the brake operation. LATERAL RUNOUT 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” . This movement causes the brake pad and piston to be knocked back into it’s bore. This results in additional pedal travel and a vibration during braking. Checking Lateral Runout (Figure 15) 1. Tighten the wheel bearings to eliminate all freeplay. 2. Attach a dial ind icato r to some portion of the suspension. • The point of the styles must contact the rotor face about 25 mm (1-inch) from the rotor edge. 3. Move the rotor one complete rotation. • The lateral runout should not exceed 0.10 mm (0.004-inch). 4. A d ju s t th e w he el b e a rin g s , re fe r to FR O N T SUSPENSION (Sec. 3C). PARALLELISM Parallelism is the measurem ent of the thickness of the rotor at four or more points around the circum ference 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 a ccurate co n tro l of the rotor to leran ces is necessary for proper perform ance of the disc brakes, machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dim m ension is the minimum wear dimension and not a refinish dimension. Do not use a brake rotor that will not meet the specifications, after refinishing. Replace with a new brake rotor. Refer to “ S p e c ific a tio n s ” in th is se ctio n fo r fin a l m ach in g tolerances. REBUILDING THE CALIPER 3000/3100 MODELS Remove or Disconnect (Figure 16) • Drain all the fluid from the caliper. • Pad the interior of the caliper with clean shop towels. CAUTION: Do not place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in serious injury. NOTICE: Use just enough air to ease the piston out of the bore. If the piston is blown out— even with padding provided, it may be damaged. 1. Piston (22) by directing compressed air into the caliper fluid inlet (figure 17) • Use just enough air pressure to ease the piston out of the bore. 2. Boot (23) (figure 18). • Use care not to scratch the housing bore. 3. Piston seal (21). • Do not use any type of metal tool. 4. Bleeder valve (20). j j ] Clean • Bleeder valve, caliper bore, caliper passages, and piston with denatured alcohol. Use dry, filtered compressed air to dry parts and blow out passages. HYDRAULIC FOUNDATION BRAKES 5A2-7 Figure 18—Removing the Boot 20. Bleeder Valve 21. Piston Seal 22. Piston 23. Boot 2. Boot (23) onto the piston (22). 3. Piston (22). 4. Boot (23) into the caliper housing counterbore using J-26267 (figure 19). 5. Bleeder valve (20). B-07834 BENDIX MODEL |*"*| Remove or Disconnect (Figure 20) Figure 16—Models 3000/3100 Caliper Components L* • Drain all the fluid from the caliper. • Pad the interior of the caliper with clean shop towels. 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. Install or Connect (Figure 16) Tool required: J-26267 Piston Seal Installer • 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. Figure 17—Removing the Piston Figure 19—Installing the Caliper Boot 5A2-8 HYDRAULIC FOUNDATION BRAKES 20. Bleeder Valve 21. Piston Seal 22. Piston 23. Boot Figure 20—Bendix Model Caliper Components CAUTION: Do not place your fingers in front of the piston in an attempt to catch or protect it when applying compressed air. This could result in serious injury. NOTICE: Use just enough air to ease the piston out of the bore. If piston is blown out— even with padding provided, it may be damaged. 1. Piston (22) by directing compressed air into the caliper fluid inlet (figure 17). • Use just enough air pressure to ease the piston out of the bore. Boot (23). Piston seal (21). • Do not use any type of metal tool. B le e d e r valve (20). IJI Clean Bleeder valve, caliper bore, caliper passages, and piston with denatured alcohol. Use dry, filtered compressed air to dry parts and blow out passages. IP Inspect Piston for scoring, corrosion and any damage to the chrome plating, replace if found. Caliper bore for scoring, pitting, or corrosion. Use corcus cloth to polish out any light corrosion. Replace caliper if corrosion cannot be removed. -►+ Install or Connect (Figure 20) Tool required: J-24548 Piston Seal Installer Lubricate the new piston seal, caliper bore, piston, and seal lips on boot with clean brake fluid. Piston seal (21). • Make sure the seal is net twisted in the caliper bore groove. 2. Boot (23) on tool J-24548. • Place the large diameter of the boot over the tool first and ride the smaller diameter onto the tool. • The large diameter must then slide off the tool. 3. The large lip of the boot into the groove in the caliper bore. • The lip of the boot must be firmly slated in the groove. 4. Piston (22) inside J-24548 (figure 21). 5. Piston half way into its bore. • Remove J-24548. • Make sure the boot is firmly seated. 6. Bleeder valve (20). HYDRAULIC FOUNDATION BRAKES 5A2-9 DRUM BRAKES H old Down Spring Lever Pivot Lever Return Spring A d ju s tin g Screw A ssem bly A d ju s tin g Screw Spring Prim ary Shoe 1. Hold Down Pins 2. Backing Plate 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Parking Brake Lever W asher S econdary Shoe Retaining Ring Shoe Guide Parking Brake S trut S trut Spring A ctu ato r Lever A ctu ato r Link Return Spring Return Spring B-07791 F igure 22— Drum Brake C om po n en ts DESCRIPTION The drum brake assembly is a duo - servo design. With this particular design, the force which is applied by the wheel cylinder to the prim ary shoe is multiplied by the prim ary lining friction to provide a large applied force to the secondary shoe. The torque from the brake shoes is transferred to the anchor pin and through the backing plate, to the axle flange. Brake adjustments are automatic and are made during reverse brake applications. BRAKE LINING REPLACEMENT Remove or Disconnect (Figure 22) • Raise the vehicle and support with suitable 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 “ Caution" on page 5A2-1 of this section. 2. Drum • Mark the relationship of the drum to the axle. 3. Return sp ring s (12 and 13). 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Shoe guide (7). Hold down springs (14). Hold down pins (1). Actuator lever (10) and lever pivot (15). Lever return spring (16). Activator link (11). Parking brake strut (8). Strut spring (9). Retaining ring (6). Parking brake lever (4) and washer (4). 5A2-10 HYDRAULIC FOUNDATION BRAKES 14. Shoes (5 and 19). 15. Adjusting screw assembly (17). 16. Adjusting screw spring (18). 9 Im portant Do not interchange right and left adjusting screws. Inspect 0 All parts for discoloration due to heat, or stress. Replace if necessary. All parts for signs of wear. Replace if necessary. W heel c y lin d e r fo r sign s of leakage, refe r to “ Rebuilding The Wheel Cylinder.” Brake drum for scoring, and machining tolerance, refer to “ Servicing The Brake Drum.” H I Install or Connect (Figure 22) • Lubricate the shoe pads and adjusting screw threads with a thin coat of white lithium grease. 1. Adjusting screw (17) and adjusting screw spring (18) to both shoes (19 and 5). • 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. 4. Retaining ring (6). 5. Strut spring (9) onto the parking brake strut (8). 6. Parking brake strut (8). 7. Actuator lever (10) and lever pivot (15). 8. Actuator link (11). 9. Lever return spring (16). 10. Hold down pins (1). 11. Hoid down springs (14). 12. Return springs (12 and 13). 13. Drum. • Align the marks made during disassembly. 14. Wheel and tire assembly, refer to WHEELS AND TIRES (Sec. 3E). • Align the marks made during disassembly. • Adjust the brakes, refer to “ Brake Adjustment” in this section. SERVICING THE BRAKE DRUM Whenever the brake drum s are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves and out-of-round. CRACKED, SCORED, OR GROOVED DRUM A cracked drum is unsafe for further service and must be replaced. Do not attempt to weld a cracked drum. Sm ooth up any slig h t scores. Heavy or extensive scoring will cause excessive brake lining wear, and it will probably be necessary to machine the drum braking surface. If the brake linings are slightly worn and the drum is grooved, the drum should be polished with fine emery cloth but sh o u ld not be m ach in e d. A t th is stage, elim inating all the grooves in the drum and smoothing the ridges on the lining would require the removal of too much metal and lining, while if left alone, the grooves and ridges match and sataisfactory service can be obtained. If brake linings are to be replaced, a grooved drum should be machined. A grooved drum, if used with a new lining, will not only wear the lining, but will make it d iffic u lt, if not im p ossib le to o bta in e ffic ie n t brake performance. OUT-OF-ROUND OR TAPERED DRUM An out-of-round drum makes accurate brake shoe adjustment impossible and is likely to cause excessive wear of other parts of the brake m echanism due to its eccentric action. An out-of-round drum can also cause severe and irregular tire tread wear as well as a pulsing brake pedal. When the braking surface of a brake drum e x c e e d s th e s p e c ific a tio n lim its in ta p e r a n d /o r out-of-round, the drum should be machined to true up the braking surface. Out-of-round as well as taper and wear can be accurately measured with an inside micrometer fitted with proper extension rods. When measuring a drum for out-of-round, taper and wear, take measurments at the open and closed edges of machined surface and at right angles to each other. MACHINING THE DRUM If a drum is to be machined, only enough metal should be removed to obtain a true, smooth braking surface. If a drum does not clean-up when m achined to a maximum diameter, it must be replaced. Refer to “ Specifications” in this section. Removal of more metal will affect dissipation of heat and may cause distortion of the drum. All brake drum s have a maximum diameter cast into them. This diameter is the maximum wear diameter. Do not m achine a brake drum th a t w ill not m eet the specification. Refer to “ Specifications” in this section. BRAKE ADJUSTMENT A manual adjustment of the rear brakes is requireed after the rear linings have been replaced. The front disc brakes require no adjustment. CAUTION: Refer to “ Caution” on page 5A2-1 of this section. 1. Remove the lanced area in the brake backing plate. • The metal lanced area must be removed from the brake assembly. jP Adjust Brake adjusting screw until the wheel can just be turned by hand. The brake drag should be equal at both wheels. Back off the adjusting screw 33 notches. Im portant Brakes should have no drag after the screw has been backed off about 15 notches. If a heavy drag is p re se n t re fe r to “ P arking Brake Adjustment” in HYDRAULIC BRAKES (SEC. 5A). HYDRAULIC FOUNDATION BRAKES 5A2-11 53 54 B-07792 Figure 23—Removing the Wheel Cylinder 2. Install an adjusting hole cover in the brake backing plate. 3. Check parking brake adjustment. WHEEL CYLINDER REPLACEMENT 51. 52. 53. 54. 55. 1. Brake linings, refer to “ Brake Lining Replacement.” 2. Brake pipe. 3. Bolts. 4. Wheel cylinder. ■H" Install or Connect (Figure 23) 1. Wheel cylinder. 2. Bolts. Tighten • Bolts to specification. 3. Brake pipe. 4. Brake linings, refer to “ Brake Lining Replacement.” 5. Bleed brake system. Refer to HYDRAULIC BRAKES (SEC. 5A).” REBUILDING THE WHEEL CYLINDER |+ + | Remove or Disconnect (Figure 24) 1. Boots (54). 2. Pistons (53). 3. Seals (52). 4. Spring assembly (55). B-07793 Figure 24—Wheel Cylinder Components +-► Remove or Disconnect (Figure 23) CAUTION: See “ Caution” on page 5A2-1 in this section. B le e d e r Valve Seal P is to n Boot S p rin g A s s e m b ly L* Inspect Cylinder bore for scoring and corrosion. Spring assembly for signs of discoloration due to heat. Replace if necessary. Clean Inside the cylinder bore with crocus cloth. If the bore is still scored replace cylinder. Cylinder with clean brake fluid. +3 Install or Connect (Figure 24) • Lubricate seals and cylinder bore with clean brake fluid. 1. Spring assembly (55). 2. Seals (52). 3. Pistons (53). 4. Boots (54). 5A2-12 HYDRAULIC FOUNDATION BRAKES SPECIFICATIONS BRAKE SYSTEMS SYSTEM FRONT BRAKES REAR BRAKES BRAKE ASSIST GASOLINE ENGINE VEHICLES C -M O D ELS JB1 Low Drag JB3 Low Drag Disc 11.86 x 1.04 Disc 11.86 x 1.04 Drum 11.0 x 2.00 Drum 11.0 x 2.00 None (M anual Brakes) Vacuum — S ingle D iaphragm Drum 11.00 x 2.00 Drum 11.00 x 2.00 None (M anual Brakes) Vacuum — S ingle D iaphragm Drum 11.15 x 2.75 Drum 11.15 x 2.75 Drum 13.00 x 2.50 Drum 13.00 x 3.50 Disc 13.75 x 1.54 Vacuum — Dual D iaphragm Vacuum — Dual D iaghragm Vacuum — Dual D iaphragm H yd rau Ii c— H yd ro- Boost H y d ra u lic -H y d ro -B o o s t G-M O DELS JB1 Low Drag JB3 Low Drag Disc 11.86 x 1.29 Disc 11.86 x 1.29 ALL M ODELS JB5 JB6 JB 7 JB8 JF9 Low Drag Low Drag C onventional C onventional C onventional Disc Disc Disc Disc Disc 11.86 12.50 12.50 12.50 14.25 x 1.29 x 1.28 x 1.28 x 1.54 x.1.54 DIESEL ENGINE VEHICLES JD 3 JD 5 JD 6 JD 7 Low Drag Low Drag C onventional C onventional Disc Disc Disc. Disc 11.86 x 1.29 11.86 x 1.29 12.50 x 1.28 12.50 x 1.28 Drum Drum Drum Drum DRUM DIAMETERS O R IG IN A L M AXIM U M REFINISH 11.000 11.150 12.000 13.000 11.060 11.210 12.060 13.060 11.00 11.15 11.15 13.00 x x x x 2.00 2.75 2.75 2.50 H y d ra u lic -H y d ro -B o o s t H y d ra u lic -H y d ro -B o o s t H ydraulic-H ydro-B oost H y d ra u lic -H y d ro -B o o s t ROTOR THICKNESS R EP LAC E M E N T (DISCARD) 11.090 11.240 12.090 13.090 M IN IM U M AFTER R EFIN IN SH IN G R E P LA C E M E N T (DISC AR D ) 1.480 1.230 0.980 1.465 1.215 0.965 HYDRAULIC FOUNDATION BRAKES 5A2-13 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Nm Caliper M ounting B o lt.......................................................................................................................................48 Support Plate to K n u c k le ......................................................................... .............................................. .........16 Wheel Cylinder to Flange Plate Bolt (All Except JB5, JB6, JB76, and J B 8 ) ............................... .........5.5 Wheel C ylinder to Flange Plate Bolt (JB5, JB6, JB7 and J B 8 ) ..................................................... .........20 Rear Brake Anchor Pin (All Except JB7 and J B 8 ) ........................................................................... .........190 Rear Brake Anchor Pin (JB7 and J B 8 ) ........................................................................................................312 Brake Bleeder V a lv e s .......................................................................................................................................7 SPECIAL TOOLS Figure 25—Special Tool Chart Ft. Lbs. 35 10 4 15 140 230 5 5A2-14 HYDRAULIC FOUNDATION BRAKES ENGINE 6-1 SECTION 6 ENGINE CONTENTS SUBJECT PAGE Engine............................................................................................................................................................................... 6A-1 4.3 Liter V6..................................................................................................................................................................... 6A3-1 Small B lo c k ................................................................................................................................................................... 6A4-1 7.4 Liter V8..................................................................................................................................................................... 6A5-1 6.2 Liter Diesel...............................................................................................................................................................6A6-1 4.8 Liter Diesel...............................................................................................................................................................6A7-1 Engine C o o lin g .............................................................................................................................................................6B1-1 R a d iato r......................................................................................................................................................................... 6B2-1 Fuel S ystem ..................................................................................................................................................................... 6C-1 C a rburetors................................................................................................................................................................. .6C1-1 Diesel Fuel In je ctio n .....................................................................................................................................................6C2-1 Engine E le ctrica l.............................................................................................................................................................6D-1 Drivability And Emissions.............................................................................................................................................. 6E-1 Drivability And Emissions — Carburetor................................................................................................................... 6E8-1 Drivability And Emissions — Diesel............................................................................................................................6E9-1 Exhaust............................................................................................................................................................................. 6F-1 Vacuum P um p.................................................................................................................................................................6H-1 GENERAL INFORMATION Following are brief outlines of the information contained in Section 6. Use them as a guide to help locate informa­ tion more quickly. SECTION 6A ENGINE T his section c o n ta in s in fo rm a tio n com m on to all engines, including: • Use of gasket sealers. • Diagnosis (for engine mechanical). • Compression check procedure. SECTIONS 6A3 THROUGH 6A7 4.3L V6, SMALL BLOCK, 7.4L V8, 6.2L DIESEL, 4.8L L6 These sections contain information for “ on-vehicle” servicing of the basic engine, such as manifold, cylinder head, camshaft, and piston replacement. Detailed repair information on components such as oil pump, cylinder head, etc. is not included. Refer to the “ L ig h t D u ty Truck U n it R e p a ir M a n u a l” fo r th is information. SECTION 6B1 ENGINE COOLING T his s e c tio n has in fo rm a tio n on c o o lin g system components, including: • Diagnosis • Water Pump • Fan and Fan Clutch • Auxiliary Fan • Belts • Thermostat. SECTION 6B2 RADIATORS This section contains inform ation on radiators and shrouds, including aluminum radiator repair procedures. SECTION 6C FUEL SYSTEM This section contains inform ation on fuel system components, including: • Accelerator controls • Fuel tanks • Air cleaners • Fuel filters (carbureted vehicles) • Fuel pump (carbureted vehicles) • Fuel tank sending unit (carbureted vehicles) 6-2 ENGINE • For fuel filter, pump, and sending unit information on TBI equipped vehicles, refer to the “ Fuel and Emissions Service Manual.” SECTION 6C1 CARBURETORS T his se ction c o n ta in s in fo rm a tio n fo r c a rb u re to r “ on-vehicle” service and adjustm ents. For overhaul information, refer to the “ Light Duty Truck Unit Repair M anual.” SECTION 6C2 DIESEL FUEL INJECTION SECTIONS 6E AND 6E8 EMISSIONS AND DRIVEABILITY AND EMISSIONS (CARBURETED) This section contains information on the emissions systems on carbureted engines, including diagnosis and c o m p o n e n t re p la c e m e n t. For in fo rm a tio n on T B I emissions systems, refer to the “ Fuel and Emissions Service M anual.” SECTION 6E9 DRIVEABILITY AND EMISSIONS (DIESEL) This section contains information on the fuel injection system used on 6.2L diesel engines, including: • Timing adjustment and other adjustment procedures. • Injection nozzle replacement and testing. • Injection pump replacement and repairs. This section contains information on the emissions systems of 6.2L diesel engines, including com ponent repair. Driveability diagnosis can be found in ENGINE (SEC. 6A). SECTION 6D ENGINE ELECTRICAL SECTION 6F EXHAUST T h is se c tio n c o n ta in s in fo rm a tio n on e le c tric a l components associated with engine operation, including: • Spark plug wires • Block heaters • Battery • Glow plug system • Starters • Generators • Distributors. “ O n -v e h ic le ” se rv ic e p ro ce d u re s are give n. For overhaul information, refer to the “ Light Duty Truck Unit Repair M anual.” This section contains inform ation on the exhaust system, including component replacement. SECTION 6H VACUUM PUMPS This section contains information on vacuum pumps, including replacement procedures and diagnosis. ENGINE 6A-1 SECTION 6A ENGINE CONTENTS SUBJECT PAGE General In fo rm a tio n .................................................................................................................................................... 6A- 1 Statement on Cleanliness and Care....................................................................................................................... 6A- 1 Tune-Up Inform ation................................................................................................................................................ 6A- 2 Use of RTV Sealer and Anaerobic Gasket Eliminator...........................................................................................6A- 2 Replacing Engine G a ske ts...................................................................................................................................... 6A- 2 Gasoline Engine Mechanical Diagnosis..................................................................................................................... 6A- 2 Gasoline Engine Compression C h e c k ................................................................................................................... 6A- 5 Diagnosis of Hydraulic L ifte rs ....................................................................................................................................6A- 6 Diagnosis of Diesel Engine.......................................................................................................................................... 6A- 8 Compression Check (6.2L Diesel Engine)............................................................................................................. 6A-10 Cranking Speed Check (6.2L Diesel Engine)......................................................................................................... 6A-10 Special T o ols.................................................................................................................................................................6A-11 All new General Motors vehicles are certified by the United States Environmental Protection Agency as con­ forming 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 adjust­ ment 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. For vehicles sold in Canada and equipped with non-closed loop engines, also refer to the appropriate Canadian service manual supplement. GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE • An engine is a combination of many machined, honed, polished and lapped surfaces with very fine tolerances. • Whenever valve train components, cylinder head, cylinder, crankshaft, or connecting rod components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. • Any time air cleaner, carburetor, or TBI unit is removed, the intake opening must be covered. If a diesel engine is being serviced, the recommended cover (J-29664-2 or J-26996-1) should be used. This will protect against the entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the engine is started. • When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initia l operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. • On diesel engines, whenever the fuel injection pump or lines are removed or disconncted, care must be taken to prevent the entry of dirt into the pump, lines, and injectors. The entry of even small amount of dirt or other foreign material into the fuel injection system may cause serious damage. • It should be kept in mind, while working on the engine, that the 12-volt electrical system is capable of violent and damaging short circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. • Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. • Cover or o th e rw is e p ro te ct exposed e le c tric a l connections to prevent damage from oil and fuel. • When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause it to be bent against the pump screen resulting in a damaged oil pickup unit. 6A-2 ENGINE TUNE-UP INFORMATION All information required to tune up the vehicle’s engine is given in the Engine Emission Control Label. This label is located in the engine compartment. Information that can be found on the label includes: • Spark plug type and gap. • Ignition timing. • Valve lash (if applicable). • Idle, fast idle, and solenoid screw speeds, as applicable. • The proper sequence for making the adjustments. • Emission hose routing diagram (sometimes on a separate label). USE OF RTV SEALER AND ANAEROBIC GASKET ELIMINATOR Two types of sealer are commonly used in engines covered by this m anual. These are RTV sealer and anaerobic “ gasket elim inator” sealer. It is important that these sealers be applied properly and in the proper place to prevent oil leaks. THE TWO TYPES OF SEALER ARE NOT INTERCHANGEABLE. Use the sealer recommended in the procedure. • RTV (room temperature vulcanizing) sealer is used where a non-rigid part is assembled to a rigid part. Common examples are oil pans and rocker arm covers. • Anaerobic gasket eliminator hardens in the absence of air. This sealer is used where two rigid parts (such as castings) are assembled together. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using gasket eliminator. USING RTV SEALER 1. Don’t use RTV when extreme temperatures are expected, such as exhaust manifold, head gasket or where gasket eliminator is specified. 2. When separating components sealed with RTV, use a rubber mallet and “ bump” the part sideways to shear the RTV sealer. “ Bumping” should be done at bends or reinforced areas to prevent distortion of parts. RTV is weaker in shear (lateral) strength than in tensile (vertical) strength. Attempting to pry or pull components apart may result in damage to the part. 3. Surfaces to be resealed must be clean and dry. Remove all traces of oil and RTV. Clean with a chlorinated solvent such as carburetor spray cleaner. Don’t use petroleum cleaners such as mineral spirits; they leave a film onto which RTV won’t stick. 4. Apply RTV to one of the clean surfaces. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer in any blind threaded holes, as it may prevent the bolt from seating properly or cause damage when the bolt is tightened. 5. Assemble while RTV is still wet (within 3 minutes). Don’t wait for RTV to skin over. 6. Torque bolts to specifications. Don’t over-torque. USING ANAEROBIC GASKET ELIMINATOR 1. Clean surfaces to be resealed with a chlorinated solvent to remove all oil, grease and old material. 2. Apply a continuous bead of gasket eliminator to one flange. 3. Spread bead evenly with your finger to get a uniform coating on the complete flange. 4. Assemble parts in the normal manner and torque to specifications. REPLACING ENGINE GASKETS CAUTION: Composite type gaskets are used in some areas of the engine assembly. These gaskets have a thin metal core. Use caution when removing or handling composite gaskets to help avoid personal injury. GASOLINE ENGINE MECHANICAL DIAGNOSIS The following information pertains to the basic assem­ bly only. For more diagnosis information, refer to the fol­ lowing: • Overheating or other cooling system problems: Refer to COOLING (SEC. 6B). • Cranking and ignition system problems: Refer to EN­ GINE ELECTRICAL (SEC. 6D). • Starting, driveability, fuel economy, etc. problems: Re­ fer to DRIVEABILITY AND EMISSIONS (SEC. 6E) for carbureted engines, or to the “ Fuel and Emissions Ser­ vice Manual” for TBI engines. ENGINE 6A-3 GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.) POSSIBLE CAUSE CORRECTION Engine Will Not Turn Over 1. Battery, cranking system or other electri­ cal problem. 2. Liquid in combustion chamber. 3. Seized engine. 1. Refer to ENGINE ELECTRICAL (SEC. 6D). 2. Remove with suction gun. 3. Repair. Engine Cranks Normally But Does Not Start 1. Fuel or ignition system problem. 1. Refer to DRIVEABILITY AND EM IS­ SIONS (SEC. 6E) (carbureted engines) or “ Fuel and Emissions Service Man­ ual” (TBI engines) and ENGINE ELEC­ TRICAL (SEC. 6D). 2. Repair. 3. Perform a compression test, as out­ lined in this section. Repair engine as necessary. PROBLEM 2. Restricted exhaust system. 3. Low compression due to stuck or burned valves, stuck rings, blown head gasket, etc. Rough Idle 1. Fuel, ignition system or emissions sys­ tem problem. 2. Uneven cylinder compression. 3. Bent pushrod or broken valve spring. 4. Faulty engine mount. 1. Refer to DRIVEABILITY AND EM IS­ SIONS (SEC. 6E) (carbureted engines) or “ Fuel and Emissions Service Man­ ual” (TBI engines) and ENGINE ELEC­ TRICAL (SEC. 6D). 2. Perform a compression test, as out­ lined in this section. Repair engine as necessary. 3. Repair. 4. Repair or replace. White Smoke Usually caused by water vapor, which is a normal byproduct of combustion. Usu­ ally seen on cold days. None required. Black Smoke Usually caused by rich fuel mixture. Refer to FUEL SYSTEM (SEC. 6C) and/ or DRIVEABILITY AND EM ISSIONS (SEC. 6E) (c a rb u re te d e n g in e s ) or “ Fuel and Emissions Service M anual” (TBI engines). Blue Smoke Usually caused by oil burning in the combustion chambers. Refer to Excessive Oil Loss diagnosis. Excessive Oil Loss 1. External oil leaks. 2. Im proper reading of dipstick. 3. Im proper oil viscosity. 4. Continuous high speed driving and/or severe usage. 5. Crankcase ventilation or PCV system malfunctioning. 6. Valve guides and/or valve stem seals worn, or seals missing. 7. Piston rings not seated. 8. Broken or worn piston rings. 9. Piston improperly installed. 1. Tighten bolts and/or replace gaskets and seals as necessary. 2. Check oil with vehicle on a level sur­ face and allow adequate drain down time. 3. Use recommended viscosity for prevail­ ing temperatures. 4. Continuous high speed operation and/ or severe usage will normally cause de­ creased oil mileage. 5. Service as necessary. 6. Ream guides and install oversize ser­ vice valves and/or new valve stem seals. 7. Allow adequate tim e for rings to seat. 8. Replace broken or worn rings as nec­ essary. 9. Replace piston or repair as necessary. 6A-4 ENGINE GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.) PROBLEM Low Oil Pressure POSSIBLE CAUSE CORRECTION 1. Slow idle speed. 2. Incorrect or faulty oil pressure switch or sensor. 3. Incorrect or faulty oil pressure gage. 4. Improper oil viscosity. 5. Diluted engine oil 1. Set idle speed to specifications. 2. Replace with proper switch or sensor. 6. Oil pump worn or dirty. 7. 8. 9. 10. 11. 12. Valve Train Noise Plugged oil filter Oil pickup screen loose or plugged. Hole in oil pickup tube. Excessive bearing clearance. Cracked, porous or plugged oil galleys. Galley plugs missing or mis-installed. 1. Low oil pressure. 2. 3. 4. 5. 6. Loose rocker arm attachments. Worn rocker arm and/or pushrod. Broken valve spring. Sticking valves. Lifters worn, dirty or faulty. 7. Camshaft worn or faulty. 8. Worn valve guides. Engine Knocks Cold And Continues For Two To Three Minutes. Knock Increases With Torque. 1. EFE equipped engines may have valve knock. 2. Flywheel contacting splash shield. 3. Loose or broken torsional dam per or drive pulleys. 4. Excessive piston to bore clearance. 5. Bent connecting rod. Engine Has Heavy Knock Hot With Torque Applied. 1. Broken balancer or pulley hub. 2. Loose torque converter bolts. 3. Accessory belts too tight or nicked. 4. Exhaust system grounded. 5. Flywheel cracked or loose rivets on fly­ wheel. 6. Excessive main bearing clearance. 7. Excessive rod bearing clearance. Engine Has Light Knock Hot In Light Load Conditions. 1. Faulty EST or ESC system. 2. 3. 4. 5. 6. Im proper timing. Poor quality fuel. Loose torque converter bolts. Exhaust leak at manifold. Excessive rod bearing clearance. 3. Replace with proper gage. 4. Replace with proper oil. 5. Change engine oil and filter. Repair cause of dilution (rich mixture, etc.) 6. Clean pump and replace worn parts as necessary. 7. Replace filter and oil. 8. Clean or replace screen as necessary. 9. Replace tube. 10. Replace as necessary. 11. Repair or replace block. 12. Install plugs or repair as necessary. 1. Repair as necessary. (See diagnosis for low oil pressure). 2. Inspect and repair as necessary. 3. Replace as necessary. 4. Replace spring. 5. Free valves. 6. Refer to “ Diagnosis of Hydraulic Lift­ ers.” 7. Replace camshaft. 8. Repair as necessary. 1. Replace EFE valve. 2. Reposition splash shield. 3. Tighten or replace as necessary. 4. Replace piston. 5. Replace connecting rod. 1. Replace parts as necessary. 2. Tighten bolts. 3. Replace and/or tension to specs as necessary. 4. Reposition as necessary. 5. Replace flywheel. 6. Repair as necessary. 7. Repair as necessary. 1. Refer to D RIVEABILITY AND EM IS­ SIONS (SEC. 6E) (carbureted engines) or “ Fuel and Emissions Service Man­ ual” (TBI engines). 2. Adjust to specifications. 3. Use fuel of recommended grade. 4. Tighten bolts. 5. Tighten bolts and/or replace gaskets. 6. Replace bearings as necessary. ENGINE 6A-5 GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.) CORRECTION POSSIBLE CAUSE PROBLEM Engine Knocks On Initial Start Up But Only Lasts A Few Seconds. 1. Fuel pump. 2. Improper oil viscosity. Engine Knocks At Idle Hot 1. 2. 3. 4. 5. 1. Replace pump. 2. Install proper oil viscosity for expected temperatures. 3. Refer to “ Diagnosis of Hydraulic Lift­ ers.” 3. Hydraulic lifter bleed down. 1. 2. 3. 4. 5. Loose or worn drive belts. Compressor generator bearing. Fuel pump. Valve train. Im proper oil viscosity. 6. Excessive piston pin clearance. 7. Connecting rod alignment. 8. In sufficie nt piston to bore clearance. (Cold engine piston knock usually disap­ pears when the cylinder’s spark plug is grounded out. Cold engine piston knock which disappears in 1.5 minutes should be considered acceptable.) 9. Loose torsional damper. Tension and/or replace as necessary. Replace as necessary. Replace pump. Refer to “ Valve Train Noise.” Install proper viscosity oil for expected temperature. 6. Install new piston, pin and/or connect­ ing rod as needed. 7. Check and replace rods as necessary. 8. Hone and fit new piston, if required. 9. Torque any or replace worn parts. GASOLINE ENGINE COMPRESSION CHECK GASOLINE ENGINE COMPRESSION CHECK 1. Disconnect the primary lead from the distributor or ignition coil. Refer to ENGINE ELECTRICAL (SEC. 6D). 2. Remove all spark plugs. 3. Block the throttle plate and choke plate (if used) wide open. 4. M a k e s u r e t h e b a t t e r y is f u ll y c h a r g e d . 5. Starting with the compression gage at zero, crank the engine through four com pression strokes (four “ puffs” ). 6. Make the compression check at each cylinder and record each reading. 7. If some cylinders have low compression, inject about 15 ml. (one tablespoon or about 3 squirts from a pump type oil can) of engine oil into the combustion chamber through the spark plug 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 than 690 kPa (100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa (150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa (105 psi). (1035 x 70% = 725) (150 x 70% = 105). • Normal — Compression builds up quickly and evenly to s p e cifie d com pression on each cylinder. • Piston Rings Leaking — compression low on first stroke tends to build up on following strokes but does not reach normal. Improves considerably with addition of oil. • Valves Leaking — Low on first stroke. Does not tend to build up on following strokes. Does not improve much with addition of oil. • If two adjacent cylinders have lower than normal compression, and injecting oil into cylinders does not increase the compression, the cause may be a head gasket leak between the cylinders. 6A-6 ENGINE DIAGNOSIS OF HYDRAULIC LIFTERS PROBLEM Momentarily Noisy When Engine Is Started Intermittently Noisy On Idle Only, Disappearing When Engine Speed Is Increased Noisy At Slow Idle Or With Hot Oil; Quiet At Higher Engine Speeds Or With Cold Oil Noisy At High Vehicle Speeds, Quiet At Low Speeds Noisy At Idle, Becoming Louder As Engine Speed Is Increased To 1500 RPM POSSIBLE CAUSE This condition is normal. Oil drains from the lifters which are holding the valves open when the engine is not running. It will take a few seconds for the lifter to fill after the engine is started. 1. Dirt in hydraulic lifter. 2. Pitted or damaged check ball. High leak down rate. CORRECTION None needed. 1. Disassemble and clean. 2 . Replace the hydraulic lifter. Replace the hydraulic lifter. 1 . High oil level — Oil level above the 1 . Drain oil to proper level. “ Full” mark allows crankshaft counter­ 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 operation. 2. Low oil level — Oil level below the “ A dd” mark allows the oil pump to pump air at high speeds which results in noisy lifters. 3. Oil pan bent against oil pump pickup screen. 4. Oil pump screen bent or loose. 2. Add oil as needed. 1. This noise is not connected with lifter malfunction. It becomes most noticeable in the vehicle at 10 to 15 mph “ L” (Low) range, or 30 to 35 mph “ D” (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 following: • 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 dam per clicking on rotator. 3. Repair. 4. Repair. 1. Repair as necessary. ENGINE 6A-7 DIAGNOSIS OF HYDRAULIC LIFTERS (CONT.) POSSIBLE CAUSE CORRECTION Noisy At Idle, Becoming Louder As Engine Speed Is Increased To 1500 RPM (Continued) 2. Off square valve spring. Occasionally this noise can be eliminated by rotating the valve spring and valve. Crank engine until noisy valve is off its seat. Rotate spring. This will also rotate valve. Repeat until valve becomes quiet. If correction is obtained, check for an off square valve spring. 2. If the valve spring is more than 1.6mm ( 1/ie-inch) off square, it should be re­ placed. Noisy Regardless Of Engine Speed 1. Incorrect valve adjustm ent (excessive lash) (en gin es w ith a d ju s ta b le valve lash). 2. Excessive valve lash. Check for valve lash by turning the engine so the piston in that cylinder is on TDC of the firing sroke. If valve lash is p re s e n t, 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. b. Bent pushrod. c. Im proper lubrication of the pushrod. 1. Adjust as specified. PROBLEM d. Loose or damaged rocker arm. e. If pushrod and rocker arm are OK, trou­ ble in the hydraulic lifter is indicated. 2. Repair engine as needed. a. Replace pushrod and rocker arm. b. Replace pushrod. c. R e p la ce p u sh ro d and rocke r arm . Check lubrication system feed to the pushrod. d. Replace rocker arm. e. Replace hydraulic lifter. X = LIKELIEST CAUSES • = POSSIBLE CAUSES M E C H A N IC A L /M A IN T E N A N C E GASKET BLflW -BY OR SEAL LEAKAGE FAULTY DAMPER/FLYWHEEL BALANCE VALVE LEAKAGE BROKEN, SCORED OR WORN PISTONS/RINGS INCORRECT M A IN OR ROD BEARING CLEARANCE DAMAGED CRANKSHAFT OR M AIN/ROD BEARINGS D A M AG ED /W O RN CAMSHAFT LOBES FAULTY LIFTER OR GUIDE PLATE FAULTY PUSHROD OR ROCKER ARM W O R N /M IS A LIG N E D T IM IN G GEARS, CHAIN OR KEY(S) LOW CYLINDER COMPRESSION (380 PSI M IN .) OIL CHANGE INTERVAL__________________________ EXTERNAL INJECTION PUM P THROTTLE LINKAGE T IM IN G RETARDED T IM IN G ADVANCED_________________________________________ STARTER CRANKING SPEED/BATTERIES (180 RPM M IN .) ENGINE MOUNTS/BOLTS OR FUEL L IN E /O ILFILLTUBE CLAMPS LONG IDLE PERIODS________________ CRACKED CYLINDER HEAD OR WALL M IS SIN G PRECHAMBER(S)______________ ENGINE OVERLOADED/EXCESSIVE SPEED IMPROPER STARTING PROCEDURES DEBRIS/FLUID IN CYLINDER(S) E L E C T R IC A L /E M IS S IO N S INOPERATIVE GLOW PLUGS______________ FAULTY GLOW PLUG CONTROLLER/IP W IRE GROUNDS____________ FAULTY ALTERNATOR DIODE/STARTER MOTOR WIRE CONNECTIONS INOPERATIVE GLOW PLUG CONTROLLER/RELAY__________________ SHORTED OR OPEN GLOW PLUG INHIBITO R SWITCH NO VOLTAGE TO CONTROLLER (KEY ON) EGR VALVE STUCK OPEN EPR VALVE STUCK CLOSED FAULTY EGR/EPR SOLENOIDS MISADJUSTED OR FAULTY THROTTLE POSITION SWITCH HOUSING PRESSURE COLD ADVANCE SOLENOID OR SWITCH FAULTY CRANKCASE DEPRESSION REGULATOR (CDR) VALVE CRANKCASE DEPRESSION SYSTEM HOSE CONNECTIONS M ISADJUSTED OR FAULTY V ACUUM REGULATOR VALVE TR A N SM ISS IO N CONVERTOR DOES NOT APPLY_________ FAULTYVACUUM PU M P(21"HG M IN .)________________ AIR S Y STEM RESTRICTED AIR INTAKE DUCTING OR MANIFOLD HIGH EXHAUST BACK PRESSURE_____________ CD THIN AIR IN HOT WEATHER OR HIGH ALTITUDE O PLUGGED AIR FILTER_________________________ ^ LOW A M B IE N T TEMPERATURE_______________ -P* HlfiHAMRIFNTTFMPFRATIIRF r\D mr i in' mi ENGINE MOST LIKELY/POSSIBLE CAUSES 6A-8 DIAGNOSIS OF DIESEL ENGINE M E C H A N IC A L /M A IN T E N A N C E 1 GASKET BLOW-BY OR SEAL LEAKAGE • 2 3 4 5 6 9 10 11 12 13 14 15 16 • • • • • • • • • • 7 8 • 17 18 19 20 21 22 23 24 25 • • • • X X • • • 26 27 28 29 30 31 32 33 34 35 • • X FAULTY DAMPER/FLYWHEEL BALANCE VALVE LEAKAGE • • • • BROKEN, SCORED OR W ORN PISTONS/RINGS • • • • • • • • X • • • • • • • DAM AG ED /W O RN CAMSHAFT LOBES • FAULTY LIFTER OR GUIDE PLATE • FAULTY PUSHROD OR ROCKER ARM • W O R N /M IS A LIG N E D T IM IN G GEARS, CHAIN OR KEY(S) • LOW CYLINDER COMPRESSION (380 PSI M IN .) • • X • X • • • • • • • • • • • • • • • • • • • • • • • • OIL CHANGE INTERVAL EXTERNAL INJECTION PUMP THROTTLE LINKAGE • • • T IM IN G RETARDED • • • • • • T IM IN G ADVANCED • • • • • • X • STARTER CRANKING SPEED/BATTERIES (180 RPM M IN .) • • • • X • • • X • X • X • • • X • X • • ENGINE MOUNTS/BOLTS OR FUEL LINE/OIL FILL TUBE CLAMPS • LONG IDLE PERIODS • • • • • • • • CRACKED CYLINDER HEAD OR WALL M IS SIN G PRECHAMBER(S) • ENGINE OVERLOADED/EXCESSIVE SPEED • • • • • • • • X • 2 3 • INOPERATIVE GLOW PLUGS • • X • 1 • • • IMPROPER STARTING PROCEDURES • • • DAMAGED CRANKSHAFT OR MAIN /R OD BEARINGS • • • INCORRECT M A IN OR ROD BEARING CLEARANCE E L E C T R IC A L /E M IS S IO N S 36 37 38 39 40 • 4 X 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 • FAULTY GLOW PLUG CONTROLLER/IP WIRE GROUNDS X FAULTY ALTERNATOR DIODE/STARTER MOTOR WIRE CONNECTIONS • • ! • • • X X • INOPERATIVE GLOW PLUG CONTROLLER/RELAY • X SHORTED OR OPEN GLOW PLUG INHIBITOR SWITCH • • • • • • • • • • • • • EGR VALVE STUCK OPEN • EPR VALVE STUCK CLOSED FAULTY EGR/EPR SOLENOIDS, ECM, OR M AP SENSOR 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 • FAULTY V ACUUM PUM P (21" HG M IN .) • • 1 2 X • HIGH EXHAUST BACK PRESSURE • THIN AIR IN HOT WEATHER OR HIGH ALTITUDE • PLUGGED AIR FILTER X • 3 4 5 6 7 8 • • • • • • 9 10 11 12 13 14 15 16 • • • • • • • • • • • • X • • • 17 18 19 20 21 22 23 24 25 • • • • • • • • • • • • 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 • • X • • • • • • 6A-9 RESTRICTED AIR INTAKE DUCTING OR MANIFOLD • • ENGINE • TRA N SM ISS IO N CONVERTOR DOES NOT APPLY HIGH A M B IE N T TEMPERATURE • • • MISADJUSTED OR FAULTY V ACUUM REGULATOR VALVE LOW AM B IEN T TEMPERATURE • • NO VOLTAGE TO CONTROLLER (KEY ON) AIR SYSTEM X • 6A-10 ENGINE 6 . Crank the engine. Allow six “ puffs” per cylinder. 7. Make the compression check at each cylinder and record the readings. NOTICE: Do not add oil to any cylinder during a compression test as extensive engine damage can result. 8 . The lowest reading cylinder should not be less than 80 percent of the highest reading cylinder. No cylinder should read less than 2625 kPa (380 psi). • Normal: Compression builds up quickly and evenly to s p e c ifie d co m pression on each cylinder. Reading should be in the 2625-2760 kPa (380-400 psi) range. • Leaking: Compression low on first stroke tends to build up on following strokes but does not reach normal. CRANKING SPEED CHECK (6.2L DIESEL ENGINE) COMPRESSION CHECK (6.2L DIESEL ENGINE) 1. 2. 3. 4. 5. Tools Required: J-29664-2 or J-26996-1 Intake Manifold Cover J-26999-10 Compression Gage Adapter Remove the air cleaner. Install J-29664-2 or J-26996-1 over the mouth of the intake manifold. Disconnect the wire from the fuel solenoid terminal of the injection pump. Disconnect wires from glow plugs then remove all glow plugs. Screw J-26999-10 into the glow plug hole of the cylinder that is being checked. Connect to a suitable compression gage (figure 1). Make sure the batteries are fully charged, and the engine is fully warmed up (engine oil hot). Tool Required: J-26999-10 Compression Gage Cranking speed is critical for a diesel to start, either hot or cold. Some tachometers are not accurate at cranking speed. An alternate method of checking cranking speed or determ ining the accuracy of a tachom eter follows: 1. Connect J-26999-10 to any cylinder. 2. Disconnect the injection pump fuel solenoid lead on the top of the injection pump. 3. Install the digital tachometer to be checked (if desired). 4. D e p re ss th e p re s s u re re le a s e valve on the compression gage. 5. With the aid of an assistant, crank the engine for 2 or 3 seconds to allow the starter to reach full speed, then without stopping, count the number of “ puffs” at the compression gage that occur in the next 10 seconds. Multiply the number of “ puffs” in the 10 second period by 12 and the resulting number will be the cranking speed in revolutions per minute (RPM). Example: 10 seconds = 1/6 of a minute 1 puff = 2 RPM RPM = No. of puffs x 2 x 6 or RPM = No. of puffs x 12 Minimum cranking speed on the 6.2L diesel engine is 100 RPM cold and 180 RPM hot. The actual cranking speed needed will vary depending on the condition of the engine (compression) and nozzles. ENGINE 6A-11 SPECIAL TOOLS '• • 'K , J-26999-10 2. j . 29664 1. C o m p re s s io n G auge A d a p te r (6.2L E n gin es) 2. M a n ifo ld C ove r Set (6.2L E n gin es) B-07603 6A-12 ENGINE 6A3-1 SECTION 6A3 4.3 LITER V6 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 term inology “ 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 o f 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 replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention o f this part. CONTENTS SUBJECT PAGE Description...................................................................................................................................................................6A3- 2 Engine Lubrication.................................................................................................................................................. 6A3- 2 On-Vehicle S ervice .................................................................................................................................................... 6A3- 5 Rocker Arm Cover R eplacem ent..........................................................................................................................6A3- 5 Rocker Arm and Pushrod Replacement............................................................................................................... 6A3- 5 Valve Adjustment.................................................................................................................................................... 6A3- 6 Valve Stem Seal and Valve Spring Replacement...............................................................................................6A3- 6 Intake Manifold Replacement................................................................................................................................6A3- 7 Hydraulic Lifter Replacement................................................................................................................................6A3- 9 Rocker Arm Stud Replacem ent............................................................................................................................6A3-10 Exhaust Manifold R eplacem ent............................................................................................................................6A3-11 Cylinder Head Replacement..................................................................................................................................6A3-12 Torsional Damper And Front Crankshaft Seal Replacem ent........................................................................... 6A3-13 Front Cover Replacement...................................................................................................................................... 6A3-14 Oil Pan Replacement........................................................................................................... .................................. 6A3-15 Oil Pump Replacement.......................................................................................................................................... 6A3-15 Rear Crankshaft Oil Seal Replacement............................................................................................................... 6A3-16 Rear Crankshaft Oil Seal Retainer R eplacem ent...............................................................................................6A3-16 Measuring Camshaft Lobe L if t ..............................................................................................................................6A3-17 Camshaft Replacement.......................................................................................................................................... 6A3-17 Connecting Rod And Piston R eplacem ent......................................................................................................... 6A3-20 Main Bearing Replacement....................................................................................................................................6A3-22 Oil Filter Adapter And Oil Filter Bypass Valve Replacement (Models With Engine Oil Cooler)...................6A3-23 Crankshaft Replacement........................................................................................................................................ 6A3-23 Flywheel R eplacem ent.......................................................................................................................................... 6A3-23 Engine M o u ntin g s.................................................................................................................................................. 6A3-23 Engine Replacement.............................................................................................................................................. 6A3-24 S pe cifica tio ns............................................................................................................................................................ 6A3-28 Special T o o ls .............................................................................................................................................................. 6A3-31 6A3-2 4.3 LITER V6 DESCRIPTION 4.3L engines are 90-degree V 6 type, overhead valve, water cooled, with cast iron block and heads. The crankshaft is supported by four precision insert main bearings, with crankshaft thrust taken at the number four (rear) bearing. The camshaft is supported by four plain type bearings and is chain driven. Motion from the camshaft is transm it­ ted to the valves by hydraulic lifters, pushrods, and ball type rocker arms. The valve guides are integral in the cyl­ inder head. The connecting rods are forged steel, with precision in­ sert 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 piston. ENGINE LUBRICATION Lubrication schem atics are shown in figures 1 and 2. The gear type oil pump is driven from the distributor 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 oil pressure, a bypass valve is provided. Filtered oil flows into the main gallery and then to the camshaft and crankshaft bearings. The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the hydraulic lifters through the hollow pushrods to the rocker arms. Oil from the overhead drains back to the crankcase through oil drain holes. The tim ing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oil splash. 4.3 LITER V6 6A3-3 6A3-4 4.3 LITER V6 Front View Rear View Showing Path Of Oil To Tim ing Chain. Showing Main Gallery, Oil Filter And Crankshaft Oil Feed. B-07860 Figure 2—Engine Lubrication Diagram 4.3 LITER V6 6A3-5 DESCRIPTION 7. Power brake vacuum pipe, and move out of the way (R and V models). 8 . Crankcase ventilation pipe at the rocker arm cover. 9. Rocker arm cover bolts. 10. Rocker arm cover and gasket. CLEANING AND INSPECTION • All traces of old gasket from the rocker arm cover and cylinder head. L * Inspect • Rocker arm cover sealing surface for distortion and damage. Replace if necessary. INSTALLATION — RIGHT SIDE -►«- Install or Connect (Figure 3) 1. Rocker arm cover and gasket. 2. Rocker arm cover bolts and washers. Tighten • Rocker arm cover bolts to 11.3 N m (100 in. lbs.). Wiring harness to the rocker cover. Spark plug wires, clips, and brackets (G models). Diverter valve, hoses, and bracket (G models). Air cleaner and heat stove tube. Engine cover (G models). Battery negative cable. INSTALLATION — LEFT SIDE ROCKER ARM COVER REPLACEMENT REMOVAL — RIGHT SIDE -►+ Install or Connect (Figure 3) 1 . Rocker arm cover and gasket. 2. Rocker arm cover bolts and washers. Tighten Remove or Disconnect (Figure 3) 1. 2. 3. 4. 5. 6. 7. 8. 9. Battery negative cable. Engine cover (G models). Air cleaner and heat stove tube. Diverter valve, bracket and hoses (G models). Spark plug wire bracket at the side of the cylinder head (G models). Spark plug wires and clip at the rear of the cylinder head (G models). Wiring harnesses at the rocker arm cover. Move out of the way. Rocker arm cover bolts. Rocker arm cover and gasket. REMOVAL — LEFT SIDE Remove or Disconnect (Figure 3) 1. 2. 3. 4. 5. 6. Battery negative cable. Engine cover (G models). Oil fill tube (G models). AIR pipe and check valve (G models). Generator rear bracket (G models). Air conditioning compressor, and lay aside (R and V models). 7. 8. 9. 10. • Rocker arm cover bolts to 11.3 N m (100 in. lbs.). Crankcase ventilation pipe. Power brake vacuum pipe (R and V models). Air conditioning compressor (R and V models). Generator rear bracket (G models). AIR pipe and check valve (G models). Oil fill tube (G models). Engine cover (G models). Battery negative cable. 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. 6A3-6 4.3 LITER V6 Important Store used components in order so they can be reassembled in the same location. I Inspect Rocker arms and balls at their mating surfaces. These surfaces should be smooth and free from scoring or other damage. Rocker arm areas which contact the valve stems and the sockets which contact the pushrods. These areas should be smooth and free of damage and wear. Pushrods for bending. Roll the pushrod on a flat surface to determine if it is bent. Replace if necessary. Ends of the pushrods for scoring or roughness. Install or Connect 1. Pushrod. Make sure the pushrod seats properly in the hydraulic lifter. 2. Rocker arm with ball. Im portant • When new rocker arms and/or balls are installed, coat their bearing surfaces with “ Molykote” or equivalent. 3. Rocker arm nuts. — Exhaust: 2, 3, 4. — Intake: 4, 5, 6 . 6 . Install the rocker arm cover as outlined previously. VALVE STEM SEAL AND VALVE SPRING REPLACEMENT Adjust • Valves as outlined later. Rocker arm cover, as outlined previously. VALVE ADJUSTMENT Remove the rocker arm cover as outlined previously. Crank the engine until the mark on the torsional damper lines up with the “ O” mark on the timing tab and the engine in the number one firing position. This may be determined by placing fingers on the number one valve as the mark on 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 rocker arms move as the mark comes up to the timing tab, the engine is in the number four firing position and should be turned over one more time to reach the number one position. With the engine in the number one firing position as determ ined above, the follow ing valves may be adjusted: — Exhaust: 1, 5, 6 . — Intake: 1, 2, 3. (Even numbered cylinders are in the right bank; 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 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 the play has been removed, turn the adjusting nut in one full additional turn (to center the lifter plunger). Crank the engine one revolution until the timing tab “ O ” mark and vibration damper mark are again in alignment. This is the number four firing position. The following valves may be adjusted: ++ Remove or Disconnect (Figures 5 and 6) Tools Required: J-23590 Air Adapter. J-5892-B Spring Compressor. 1. 2. 3. 4. Rocker arm cover, as outlined previously. Rocker arms, as outlined previously. Spark plugs. Valve keepers (20). • Install J-23590 into the spark plug hole. • Apply compressed air to hold the valves in place. • Install a rocker arm nut (figure 6 ). 2 0 . Valve K e ep e r 21 . C ap 2 2 . S h ie ld 23. O -R ing Seal 24. Seal 25. D am pe r I 20 oo ? 22 23 26. 27. 28. 29. 25 B-07609 Figure 5—Valves and Components 4.3 LITER V6 6A3-7 +«- Install or Connect (Figures 5, 6, and 7) 1. 2. 3. F igure 6—C om pre ssin g th e V alve S p rin gs • Use J-5892-B to compress the valve spring (figure 6). • Remove the valve keepers. • Carefully release the spring tension. Remove J-5892-B. 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). 5. Tools Required: J-23590 Air Adapter. J-5892-B Spring Compressor. J-23994-01 Adapter Cup. J-23738-A Vacuum Pump. New seal (24) (intake valve only). Install the seal over the intake valve stem and seat it against the head. Spring (26) with damper (25), sheild (22) and cap (21) and/or rotator (28). 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-B (figure 6). • Lubricate the O-ring seal with engine oil. Install the seal on the valve stem. Make sure the seal is not twisted. • Install the valve keepers. Use grease to hold them in place. • Carefully release spring pressure. Make sure the valve keepers stay in place. • Remove J-5892-B and J-23590. • Check each O-ring seal for leakage (figure 7). • Place the suction cup furnished with J-23738-A over the shield. • Connect J-23738-A to the suction cup and apply a vacuum. Watch the vacuum pump gage. No air should be able to leak past the seal. If the seal will not hold a vacuum, it may have been damaged or improperly installed. Spark plugs. Rocker arms, as outlined previously. E3 Adiust • Valves, as outlined previously. 6. Rocker arm cover, as outlined previously. INTAKE MANIFOLD REPLACEMENT Remove or Disconnect B-07869 Figure 7—Testing the Valve Seals 1. Battery negative cable. 2. Engine cover (G models). 3. Air cleaner and heat stove tube. Drain the cooling system. 4. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 5. Accelerator, cruise control, and TVS cables and bracket. %. Cruise control transducer, if equipped. 7. Air conditioning compressor, and lay aside (G models). 8 . Air conditioning compressor rear brackets at the manifold (R and V models). 9. Generator bracket at the manifold. 10. Idler pulley bracket at the manifold (G models). 11. Fuel and vacuum lines and electrical connections at the TBI unit and manifold. 12. Heater pipe. 13. Upper radiator hose. 14. Power brake vacuum pipe. 15. Coil wires. 16. EGR vacuum line. 6A3-8 4.3 LITER V6 C. RTV Sealant B-07872 Figure 8—Intake Manifold 17. 18. 19. 20. 21. Sensors with bracket on right side. Wiring harness on right side. Move out of the way. Transmission dipstrick tube (if equipped) (G models). Intake manifold bolts. Intake manifold and gaskets. Clean Old gasket and RTV from the block, heads, and intake manifold. Remove all RTV that is loose or will cause interference at assembly. Excessive carbon deposits from the exhaust and EGR passages. Excessive scale and deposits from the coolant passages. 5. 6. 7. 8. 9. 10. 11. 12. 13. Transmission dipstick tube (if equipped) (G models). Wiring harness. Sensors with bracket. EGR vacuum line. Coil wires. Power brake vacuum pump. Upper radiator hose. Heater pipe. Fuel and vacuum lines and electrical connections at the TBI and manifold. 14. Idler pulley bracket (G models). Inspect Manifold for cracks and gasket surface damage. □ ♦ a Install or Connect (Figures 8 and 9) 1. Gaskets to the cylinder head. 2. RTV to the front and rear sealing surfaces on the block (figure 8). Apply a 5 mm (3/i6-inch) bead of RTV (part number 1052366 or equivalent) to the front and rear of the block as shown. Extend the bead 13 mm (1/2-inch) up each cylinder head to seal and retain the gaskets. 3. Intake manifold to the engine. 4. Intake manifold bolts. Tighten Intake manifold bolts to 48 N m (35 ft. lbs.). Use the tightening sequence shown in figure 9. INITIAL TIGHTENING SEQUENCE FINAL TIGHTENING SEQUENCE A. Front Of Engine B-07873 Figure 9—Intake Manifold Bolt Tightening Sequence 4.3 LITER V6 6A3-9 40. 41. 42. 43. 44. 45. 46. 47. Bolt Retainer N uts Balls Rocker A rm s Pushrods R e stricto r H ydrualic L ifte r B-07611 Figure 10—Hydraulic Lifters and Components 15. Generator bracket. 16. Air conditioning compressor rear brackets (R and V models). 17. A ir c o n d itio n in g c o m p re s s o r (G m odels). 18. C ruise co n tro l tran sdu ce r, if e quipped. 19. Accelerator, cruise control, and TVS cables and bracket. 20. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 21. Air cleaner and heat stove tube.' 22. Engine cover (G models). 23. Battery negative cable. • Fill the cooling system with the proper coolant. HYDRAULIC LIFTER REPLACEMENT Remove or Disconnect (Figures 10) 1. Rocker arm cover, intake manifold, and pushrods, as outlined previously. 2. Bolts (40). 3. Retainer (41) with restrictors (46). 4. Hydraulic lifters. • Remove the hydraulic lifters one at a time and place them in an organizer rack. The lifters must be installed in the same bore from which they were removed. I* Inspect — Hydraulic lifter body for scuffing or 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. — Roller for freedom of movement. — Roller for flat spots, pits and missing or broken needle bearings. If worn, pitted, or damaged, the mating camshaft lobe should also be checked. Hydraulic Lifter Repair • Refer to the proper unit repair manual. Install or Connect (Figure 10) 1. Hydraulic lifters to the block. Lubricate the lifter rolleran d body w ith Engine O il S u p p le m e n t or equivalent. Im portant • W hen any new hydraulic lifte rs or a new camshaft is installed, change the engine oil and filter. Engine Oil Supplement (or equivalent) should be added to the engine oil. • R eplace all h yd ra u lic lifte rs when a new camshaft is installed. 2. Retainer (41) with restrictors (46). 3. Bolts (40). Tighten • Bolts (40) to 16.4 N m (145 in. lbs.). 4. Intake manifold, as outlined previously. 5. Pushrod, as outlined previously. 6A3-10 4.3 LITER V6 Adjust • Valves, as outlined previously. 6. Rocker arm cover, as outlined previously. ROCKER ARM STUD REPLACEMENT |+ + | Remove or Disconnect (Figure 11) Tool Required: J-5802-01 Rocker Arm Stud Remover. 1. Rocker arm cover and rocker arm, as outlined previously. 2. Rocker arm stud. |~n~| Install or Connect (Figures 12 and 13) Tools Required: J-5715 Reamer (0.003-inch oversize) or J-6036 Reamer (0.013-inch oversize). • Place J-5802-01 over the rocker arm stud. • Install a nut and flat washer. J-6880 Rocker Arm Stud Installer. • Turn the nut to remove the stud (figure 11). NOTICE: Do not attem pt to install an oversize rocker arm stud without reaming the stud hole as this could damage the cylinder head. • Ream the hole to the proper size for the replacement oversize rocker arm stud. Use J-5715 for 0.003-inch oversize studs; J-6036 for 0.013-inch oversize stud (figure 12). • Coat the lower end (press-fit area) of the rocker arm stud with hypoid axle lubricant. 1. Rocker arm stud. Use J-6880 (figure 13). Stud is installed to proper depth when the tool bottoms on the cylinder head. 2. Rocker arm, as outlined previously. Adjust • Valves, as outlined previously. Figure 12—Reaming the Rocker Arm Stud Bore (Typical) 3. Rocker arm cover, as outlined previously. 4.3 LITER V6 6A3-11 CAST IRON MANIFOLD (TYPICAL) STAINLESS STEEL MANIFOLD 60. 61. 62. 63. Heat Shield W asher Tab W asher Bolt/Stud 62 61 B-07612 Figure 14—Exhaust Manifold EXHAUST MANIFOLD REPLACEMENT □ Remove or Disconnect (Figure 14) 1. Battery negative cable. 2. Engine cover (G models). • Raise the vehicle. Support with suitable safety stands. 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 it is to be replaced. 5. Air conditioning com pressor rear bracket at the manifold, if equipped (R and V models - left side manifold). 6. Power steering pump bracket at the manifold (G models - left side manifold). 7. Heat stove pipe (right side manifold). 8. AIR pipe at the diverter valve (R and V models - right side manifold). 9. Diverter valve bracket (R and V models - right side manifold). 10. Dipstick tube bracket at the manifold (G models — right side manifold). 11. AIR hose at the check valve. 12. Exhaust manifold bolts, washers, heat shield (left side manifold), and tab washers. 13. Exhaust manifold. j y l Clean — Mating surfaces on the manifold and head. — Threads on the exhaust manifold bolts. Install or Connect (Figure 14) 1. Exhaust manifold, bolts, washers, heat shield (left side manifold), and tab washers. • Bolts on center exhaust tube to 36 N-m (26 ft. lbs.). • Bolts on front and rear exhaust ubes to 28 N-m (20 ft. lbs.). 6A3-12 4.3 LITER V6 • Bend the tab washers over the heads of all bolts. 2. AIR hose at the check valve. 3. Dipstick tube bracket at the manifold (G models - right side manifold). 4. Diverter valve bracket (R and V models - right side manifold). 5. AIR pipe at the diverter valve (R and V models - right side manifold). 6. Heat stove tube (right side manifold). 7. Power steering pump bracket at the manifold (G models - left side manifold). 8. Air conditioning compressor rear bracket, if equipped (R and V models - left side manifold). 9. Oxygen sensor wire (left side manifold). • Raise the vehicle. Support with suitable safety stands. 10. Exhaust pipe to the manifold. • Lower the vehicle. 11. Engine cover (G models). 12. Battery negative cable. CYLINDER HEAD REPLACEMENT REMOVAL — R AND V MODELS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 1. 2. 3. 4. 5. 6. 0 ® 0 0 0 0 0 0 0 B-07874 Figure 15—Cylinder Head Bolt Tightening Sequence 9. Wiring harness, clip and ground strap at the rear of the head (right cylinder head). 10. Fuel pipes and bracket at the rear of the cylinder head (left cylinder head). 11. Coolant sensor wire (left cylinder head). 12. Cruise control transducer bracket (left cylinder head). 13. Rocker arm cover, as outlined previously. 14. Spark plugs. 15. Pushrods, as outlined previously. Battery negative cable. Intake manifold, as outlined previously. Exhaust manifold, as described previously. AIR pipe at the rear of the head. Generator mounting bolt at the cylinder head (right cylinder head). Power steering pump and brackets from the cylinder head, and lay aside (left cylinder head). Air conditioning compressor and brackets, and lay aside (left cylinder head). Rocker arm cover, as outlined previously. Spark plug wires from the brackets. Coolant sensor wire (left cylinder head). Cruise control transducer bracket (left cylinder head). Dipstick tube at the cylinder head, and move aside (right cylinder head). Spark plugs. Pushrods, as outlined previously. Cylinder head bolts. Cylinder head. Gasket. 16. Cylinder head bolts. Remove or Disconnect Battery negative cable. Engine cover. Intake manifold, as outlined previously. Exhaust manifold, as described previously. AIR pipe at the rear of the head. AIR pump mounting bolt and spacer at the cylinder head (right cylinder head). 7. Engine accessory bracket bolts and studs at the cylinder head. For left cylinder head removal, it may be necessary to loosen the remaining bracket bolts to provide clearance for head removal. 8. Spark plug wires at the brackets. © 4 i FRONT Remove or Disconnect REMOVAL - G MODELS ++ I 17. Cylinder head. 18. Gasket. CLEANING, INSPECTION, AND REPAIR Clean — Carbon deposits from combustion chambers. — All traces of old head gasket from cylinder head and block. — Cylinder head bolt threads and threads in the block. Inspect • Sealing surfaces of the block and cylinder head for nicks, heavy scratches, or other damage. Cylinder Head Repair • Refer to the proper Unit Repair Manual. INSTALLATION — R AND V MODELS -►+ Install or Connect (Figure 15) 1. Head gasket. • If a steel gasket is used, coat both sides of the gasket with sealer. Spread the sealer thin and even. • Do not use sealer on composition steel-asbestos gaskets. • Place the gasket over the block dowel pins with the bead up. 2. Cylinder head. Carefully guide the cylinder head into place over the dowel pins and gasket. 3. Cylinder head bolts. Coat threads of the cylinder head bolts with sealing com pound (GM part num ber 1052080 or equivalent) and install finger-tight. 4.3 LITER V6 6A3-13 • Cylinder head bolts, a little at a time, using the sequence shown in figure 15. Proper torque is 90 N m (65 ft. lbs.). 4. Pushrods, as outlined previously. A djust 9. 10. 11. 12. 13. 14. 15. 16. 17. • Valves, as outlined previousiy. Rocker arm cover, as outlined previously. Spark plugs. Dipstick tube (right cylinder head). Cruise control transducer bracket (left cylinder head). Coolant sensor wire (left cylinder head). Spark plug wires. Air conditioning compressor and brackets (left cylinder head). Power steering pump and brackets (left cylinder head). Generator mounting bolt (right cylinder head). AIR pipe. Exhaust manifold, as outlined previously. Intake manifold, as outlined previously. Battery negative cable. Figure 16—Removing the Torsional Damper 18. Battery negative cable. TORSIONAL DAMPER AND FRONT CRANKSHAFT SEAL REPLACEMENT IN STALLATIO N — G MODELS -►«" Install or Connect (Figure 15) 1. Head gasket. • If a steel gasket is used, coat both sides of the gasket with sealer. Spread the sealer thin and even. • Do not use sealer on composition steel-asbestos gaskets. • Place the gasket over the block dowel pins with the bead up. 2. Cylinder head. Carefully guide the cylinder head into place over the dowel pins and gasket. 3. Cylinder head bolts. Coat threads of the cylinder head bolts with sealing com pound (GM part num ber 1052080 or equivalent) and install finger-tight. Tighten • Cylinder head bolts, a little at a time, using the sequence shown in figure 15. Proper torque is 90 N m (65 ft. lbs.). 4. Pushrods, as outlined previously. A djust • Valves, as outlined previously. 5. Rocker arm cover, as outlined previously. 6. Spark plugs. 7. Cruise control transducer bracket (left cylinder head).I 8. Coolant sensor wire (left cylinder head). 9. Fuel pipes and bracket (left cylinder head). 10. Wiring harness, clip, and ground strap (right cylinder head). 11. Spark plug wires. 12. Engine accessory bracket bolts and studs. 13. AIR pump mounting bolt and spacer (right cylinder head). 14. AIR pipe. 15. Exhaust manifold, as outlined previously. 16. Intake manifold, as outlined previously. 17. Engine cover. +-► Remove or Disconnect (Figure 16) 1. 2. 3. 4. 5. 6. Tool Required: J-23523-E Torsional Damper Puller and Installer. Fan belts, fan, and pulley. Fan shroud assembly. Accessory drive pulley. Torsional damper bolt. Torsional damper. Use J-23523-E (figure 16). Front crankshaft seal. Pry out with a large screwdriver. Take care not to distort the timing cover. Crankshaft key, if necessary. Inspect Oil seal contact area on the torsional damper shaft for grooving and roughness. Replace if necessary. Install or Connect (Figures 17 and 18) Tools Required: J-35468 Seal Installer. J-23523-E Torsional Damper Puller and Installer. 1. Crankshaft key, if removed. 2. Front crankshaft seal. Use J-35468 (figure 17). The open end of the seal faces inside the engine. Coat the seal lips with engine oil. NOTICE: The in ertia w e ig h t s ectio n o f the torsional dam per is assembled to the hub with a rubber type material. The correct installation procedures (w ith the p ro p er tool) m ust be follow ed or m ovem ent o f the inertia w eight section o f the hub will destroy the tuning o f the torsional damper. 3. Stud (item A, figure 18) to the crankshaft. Thread the stud fully into the tapped hole in the crankshaft. 6A3-14 4.3 LITER V6 4. Torsional damper over the end of the stud. Align the keyway in the torsional dam per shaft with the crankshaft key. 5. Bearing, washer and nut (figure 18). FRONT COVER REPLACEMENT ++ Remove or Disconnect 1. Torsional damper, as outlined previously. • Turn the nut to pull the vibration damper into place. 2. Water pump. Refer to ENGINE COOLING (SEC. 6B1). • Remove the tool. 4. Front cover bolts. 3. Oil pan, as outlined later. • Use a small amount of RTV sealant to seal the torsional damper key to crankshaft joint. 5. Front cover. 6. Torsional damper bolt and washer. 7. Front crankshaft oil seal from the front cover. Pry out with a screwdriver. Take care not to distort the front cover. Q Tighten • Bolt to 95 N m (70 ft. lbs.). 6. Front cover to block gasket. Clean 7. Accessory drive pulley. Old gasket from the front cover, and block. 8. Fan shroud assembly. Inspect 9. Fan pulley, fan, and fan belts. • Front cover for distortion and damage. Replace if necessary. Install or Connect (Figure 19) Tool Required: J-35468 Seal Installer. 1. Front crankshaft oil seal. Use J-35468 (figure 19). The open end of the seal faces inside the engine. Coat the seal lips with engine oil. 2. Front cover gasket to the front cover. Use gasket cement to hold them in place. 3. Front cover and bolts. Q Tighten • Front cover bolts to 11.3 N m (100 in. lbs.). 4. Oil pan, as outlined later. 5. Water pump. 6. Torsional damper, as outlined previously. 4.3 LITER V6 6A3-15 I* Inspect 0 Oil pan gasket for damage. Replace if necessary. Install or Connect (Figure 20) • Apply sealant (GM part number 1052080 or equivalent) to the front cover to block joint and to the rear crankshaft seal to block joint. Apply the sealant for about 25 mm (1-inch) in both directions from each of the four corners. 1. Oil pan gasket to the oil pan. 2. Oil pan to the engine. 3. Oil pan bolts, nuts, and reinforcements. Tighten — Oil pan bolts to 11.3 N m (100 in. lbs.). — Oil pan nuts at corners to 22.6 N m (200 in. lbs.). 4. Strut rods at the engine mounts (V models with automatic transmission). 5. Starter. 6. Strut rod brackets at the front engine mountings. 7. Strut rods at the flywheel cover. 8. Converter housing under pan (models with automatic transmission). 9. Exhaust crossover pipe. • Lower the vehicle. 10. Proper quantity and grade of engine oil. 11. Battery negative cable. OIL PUMP REPLACEMENT 70. G a ske t 71. R e in fo rc e m e n t |+"»| Remove or Disconnect B-07884 Figure 20—Oil Pan 1. Oil pan, as outlined previously. 2. Oil pump to main bearing cap bolt. 3. Oil pump. OIL PAN REPLACEMENT A one piece type oil pan gasket is used. Remove or Disconnect (Figure 20) 1. • • 2. 3. 4. 5. 6. 7. 8. 9. Battery negative cable. Raise the vehicle. Support with suitable safety stands. Drain the engine oil. Exhaust crossover pipe. Torque converter cover (m odels with autom atic transmission). Strut rods at flywheel cover. Strut rod brackets at the front engine mountings. Starter. Strut rods at engine mounts (V models with automatic transmission). Oil pan bolts, nuts, and reinforcements. Oil pan and gasket. Clean • Gasket surfaces on the engine and oil pan. 1 * Inspect • Oil pump pickup tube for looseness. If the tube is loose in the oil pump body, replace it, as outlined in the proper unit repair manual. A loose pickup tube can result in an air leak and loss of oil pressure. Oil Pump Repair • Refer to the proper unit repair manual. -►+ Install or Connect 1. Oil pump to the engine. Align the slot in the oil 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 to main bearing cap bolt to 90 N m (65 ft. lbs.). 3. Oil pan, as outlined previously. 6A3-16 4.3 LITER V6 REAR CRANKSHAFT OIL SEAL REPLACEMENT REAR CRANKSHAFT OIL SEAL RETAINER REPLACEMENT Remove or Disconnect (Figure 21) 1. Transmission. 2. Clutch and flywheel or flexplate, as equipped. NOTICE: Care should be taken when removing the rear crankshaft oil seal so as not to nick the crankshaft sealing surface. Remove or Disconnect (Figures 21 and 23) 1. Transmission. 2. Clutch and flywheel or flexplate, as equipped. 3. Oil pan, as outlined previously. 4. Screws (80) and nuts (81). 3. Rear crankshaft oil seal. Insert a screwdriver into the notches provided in the seal retainer and pry the seal out (figure 21). Take care not to damage the crankshaft sealing surface. L* Inspect Chamfer on crankshaft for grit, loose rust, and burrs. Correct as necessary. Clean Seal running surface on the crankshaft with a non-abrasive cleaner. Install or Connect (Figure 22) 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. • Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft. • Turn the handle until it bottoms. • Remove J-35621. 2. Clutch and flywheel or flexplate, as equipped. 3. Transmission. 5. Seal retainer (82). 6. Gasket (84). 7. Rear crankshaft oil seal. Insert a screwdriver into the notches provided in the seal retainer and pry the seal out (figure 21). 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 (84) to the block. It is not necessary to use sealant to hold the gasket in place. 2. Seal retainer (82). 3. Screws (80) and nuts (81). Tighten • Screws (80) and nuts (81) to 15.3 N m (135 in. lbs.). 4. Oil pan, as outlined previously. 5. Rear crankshaft oil seal as outlined previously. 6. Clutch and flywheel or flexplate, as equipped. 7. Transmission. 4.3 LITER V6 6A3-17 A. 80. 81. 82. 83. 84. Rear o f B lock Screw Nut Retainer Stud Gasket B-07614 Figure 23—Rear Crankshaft Oil Seal Retainer MEASURING CAMSHAFT LOBE LIFT Tool Required: J-8520 Camshaft Lobe Lift Indicator. 1. Remove the rocker arm as outlined previously. 2. Refer to figure 24. Position the dial indicator (part of J-8520) so the plunger rests on the pushrod end, as shown. Make sure the pushrod is in the lifter socket. 3. Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the cam lobe. At this point, the pushrod will be in its lowest position. 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 ignition coil. 5. Compare the total lift recorded from the dial indicator with specifications. 6 . If c a m s h a ft re a d in g s for all lob es are w ith in specifications, remove dial indicator assembly. Install the rocker arm and adjust the valves as previously outlined. CAMSHAFT REPLACEMENT R AND V MODELS ++ 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. • 12. 13. 14. 15. 16. 17. Remove or Disconnect (Figures 25 through 28) Tool Required: J-5825-A Crankshaft Sprocket Puller. Battery negative cable. Air cleaner. Fan, shroud, and radiator. Refer to ENGINE COOLING (SEC. 6B1) and RADIATOR (SEC. 6B2). Generator. Rocker arm covers, as outlined previously. Water pump. Refer to ENGINE COOLING (SEC. 6B1). Torsional damper, as outlined previously. Front cover, as outlined previously. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). Intake manifold, as outlined previously. Pushrods and hydraulic lifters, as outlined previously. Align the timing marks (figure 26). Camshaft sprocket bolts. Camshaft sprocket and timing chain. The sprocket is a light interference fit on the camshaft. Tap the sprocket on its lower edge to loosen it. Screws (88) and thrust plate (87). Crankshaft sprocket (if required). Use J-5825-A (figure 27). Engine mount through-bolts. Raise the engine. Camshaft. 6A3-18 4.3 LITER V6 87. T h ru s t Plate 88. S crew B-07615 Figure 25—Camshaft and Components • 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 28). • Pull the camshaft from the block. Use care to prevent damage to the camshaft bearings. Cleaning, Inspection And Repair Clean, inspect and repair or replace the camshaft and related components, as outlined in the proper unit repair manual. The u nit rep air m anual also d escrib e s ca m sh aft bearing replacement. -►«- Install or Connect (Figures 25 through 28, 36, and 37) T o o l R e q u ir e d : J-5590 Crankshaft Sprocket Installer. Coat the camshaft lobes and journals with a high q u a lity engine oil su p p le m e n t (GM Engine Oil Supplement or equivalent). B-09549 Figure 27—Replacing the Crankshaft Sprocket 4.3 LITER V6 6A3-19 Replace all hydraulic lifters, change the engine oil and filter, and add GM Engine Oil Supplement (or equivalent) to the engine oil whenever a new camshaft is installed. ft Adjust • Valves, as outlined previously. Intake manifold, as outlined previously. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). Front cover, as outlined previously. Torsional damper, as outlined previously. Water pump. Rocker arm covers, as outlined previously. Generator. Fan, shroud, and radiator. Refer to ENGINE COOLING (SEC. 6B1) and RADIATOR (SEC. 6B2). 17. Air cleaner. 18. Battery negative cable. 9. 10. 11. 12. 13. 14. 15. 16. G MODELS |+ + | Remove or Disconnect (Figures 25 through 28) 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. 2. Camshaft to the engine (figure 28). Handle the camshaft carefully to prevent damage to the camshaft bearings. • Lower the engine. 3. Engine mount through-bolts. Tighten • Through-bolts or nuts to specifications. Refer to figures 36 and 37. 4. Crankshaft sprocket (if removed). Use J-5590 (figure 27). Make sure the timing mark faces outside. 5. Thrust plate (87) and screws (88). • Screws (88) to 11.9 N m (105 in. lbs.). 6. Camshaft sprocket and timing chain. Im portant • Line up the tim ing marks on the camshaft sprocket and crankshaft sprocket (figure 26). 7. Camshaft sprocket bolts. Q Tighten • Bolts to 23 N m (17 ft. lbs.). 8. Hydraulic lifters and pushrods, as outlined previously. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. • 14. 15. 16. 17. Tool Required: J-5825-A Crankshaft Sprocket Puller. Battery negative cable. Intake manifold, as outlined previously. Rocker arm covers, as outlined previously. Hydraulic lifters and pushrods, as outlined previously. Outside air duct. Power steering reservoir. Upper fan shroud bolts. Radiator. Refer to RADIATOR (SEC. 6B2). Hood release cable at the latch. Upper fan shroud. Water pump. Torsional damper, as outlined previously. Front cover, as outlined previously. Align the timing marks (figure 26). Camshaft sprocket and timing chain. The sprocket is a light interference fit on the camshaft. Tap the sprocket on its lower edge to loosen it. Screws (88) and thrust plate (87). Crankshaft sprocket (if necessary). Use J-5825-A (figure 27). Camshaft. • Install two or three 5/ie-18 bolts 100-125 mm (4-5 inches) long into the camshaft tapped holes. Use these bolts to handle the camshaft (figure 28). • Pull the camshaft from the block. Use care to prevent damage to the camshaft bearings. Cleaning, Inspection and Repair Clean, inspect and repair or replace the camshaft and related components, as outlined in the proper unit repair manual. The unit re p air m anual also d e scrib e s ca m sh aft bearing replacement. Install or Connect (Figures 25 through 28) Tool Required: J-5590 Crankshaft Sprocket Installer. 6A3-20 4.3 LITER V6 Coat the camshaft lobes and journals with a high q u a lity engine oil su p p le m e n t (GM Engine Oil Supplement or equivalent). Two or three 5/is-18 bolts 100-125 mm (4-5 inches) long into the camshaft threaded holes. Use these bolts to handle the camshaft. 2. Camshaft to the engine (figure 28). Handle the camshaft carefully to prevent damage to the camshaft bearings. 3. Crankshaft sprocket. Use J-5590 (figure 27). Make sure the timing mark faces outside. 4. Thrust plate (87) and screws (88). Tighten • Screws (88) to 11.9 N m (105 in. lbs.). 5. Camshaft sprocket and timing chain. Im portant • Line up the tim ing marks on the camshaft sprocket and crankshaft sprocket (figure 26). Camshaft sprocket bolts. Tighten 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. • Bolts to 23 N m (17 ft. lbs.). Front cover, as outlined previously. Water pump. Torsional damper, as outlined previously. Front cover, as outlined previously. Upper fan shroud. Hood release cable. Radiator. Refer to RADIATOR (SEC. 6B2). Upper fan shroud bolts. Outside air ducts. Hydraulic lifters and pushrods, as outlined previously. ft A djust • Valves, as outlined previously. 17. Rocker arm covers, as outlined previously. 18. Intake manifold, as outlined previously 19. Battery negative cable. CONNECTING ROD AND PISTON REPLACEMENT Remove or Disconnect (Figure 29) 1. 2. 3. 4. 5. Tool Required: J-5239 Guide Set. Cylinder head, as outlined previously. Oil pan, as outlined previously. Oil pump, as outlined previously (if necessary). Ridge or deposits from the upper end of the cylinder bores. • 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. • Turn the crankshaft until the piston is at TDC. • Remove the cloth and cuttings. 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. A. G uide Rod B. Thread P rotector B-05269 Figure 29—Replacing the Connecting Rod and Piston (Typical) 6. Connecting rod and piston. • Attach J-5239 to the connecting rod bolts (figure 29). • Use the long guide rod of J-5239 to push the connecting rod and piston out of the bore. 7. Connecting rod bearing. Cleaning, Inspection, And Repair Clean, inspect and repair or replace the components as necessary. Measure connecting rod bearing clearance, piston clearance, ring clearances, etc. Refer to the proper unit repair manual. The unit repair manual contains information on: — Connecting rod and piston. — Piston rings. — Connecting rod and crankpin. — Cylinder bores. -►+ Install or Connect (Figures 29 through 32) Tools Required: J-5239 Connecting Rod Guide Set. J-8037 Ring Compressor. • Make sure the cylinder walls are clean. Lubricate the cylinder wall lightly with engine oil. • Make sure the piston is installed in the matching cylinder. 1. Connecting rod bearings. • Be certain that the bearing inserts are of the proper size. • Install the bearing inserts in the connecting rod and connecting rod cap. 4.3 LITER V6 6A3-21 6 ENGINE LEFT ENGINE FRONT ENGINE RIGHT A. B. C. D. Oil Ring Rail Gaps 2nd Compression Ring Gap Notch In Piston Oil Ring Spacer Gap (Tang In Hole Or Slot W ith Arc) E. Top Compression Ring Gap B-07895 Figure 30—Piston Ring End Gap Locations Figure 32—Measuring Connecting Rod Side Clearance The piston must be installed so that the notch in the piston faces the front of the engine (figure 30). Place the piston in its matching bore. The connecting rod bearing tang slots must be on the side opposite the camshaft. Using light blows with a hammer handle, tap the piston down into its bore (figure 31). At the same time, from beneath the vehicle guide the connecting rod to the crankpin with J-5239 (figure 29). Hold the ring compressor against the block until all rings have entered the cylinder bore. Remove J-5239 from the connecting rod bolts. • Lubricate the bearings with engine oil. 2 Pistpn 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 30. Lubricate the piston and rings with engine oil. • Without disturbing the ring end gap location, install J-8037 over the piston (figure 31). Im portant 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 bearings should be fitted 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 (fig u re 32). 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. 6A3-22 4.3 LITER V6 Figure 33—Removing the Main Bearing Insert 6. Oil pan and cylinder head, as outlined previously. MAIN BEARING REPLACEMENT • Remove the tool. 2. Lower main bearing inserts to the main bearing caps. • Make sure the inserts are of the proper size. • Apply engine oil to the inserts. Remove or Disconnect (Figure 33) 1. 2. 3. 4. 5. 6. Tool Required: J-8080 Main Bearing Remover/Installer. Spark plugs. Oil pan, as outlined previously. Oil pump, as outlined previously. 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. Lower main bearing inserts from the main bearing caps. Upper main bearing inserts. • Insert J-8080 into the crankshaft oil hole (figure 33). • Rotate the crankshaft to “ turn” the bearing insert out of the block. Cleaning, Inspection, And Repair Clean, inspect, and repair or replace the components as required. Refer to the proper unit repair manual. The unit repair manual contains information on: • Crankshaft. • Main and connecting rod bearings. -►+ Install or Connect (Figures 33 and 34) Tool Required: J-8080 Main Bearing Remover/Installer. 1. Upper main bearing inserts. • Insert J-8080 into a crankshaft main bearing oil hole (figure 33). • 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. Measure • Main bearing clearance. Refer to the proper unit repair manual. If the engine is in the vehicle, the crankshaft must be supported upward to remove any clearance from the upper bearing. The total clearance can then be measured between the lower bearing and journal. 3. Main bearing caps (except rear cap) and bolts to the block. a • 4. Rear • • % Tighten Main bearing cap bolts to 100 N m (75 ft. lbs.). main bearing cap. Apply engine oil to the bearing insert. 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 lin e up th e re a r m ain b e a rin g and crankshaft thrust surfaces. • Tighten the rear main bearing cap bolts to 100 N-m (75 ft. lbs.). • W ith the c ra n k s h a ft fo rce d fo rw a rd , measure at the front end of the rear main bearing with a feeler gage (figure 34). The proper clearance 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. Production engines may have rear main bearings that are 0.008-inch wider across the thrust faces than standard. Refer to the proper unit repair manual for more information. 4.3 LITER V6 6A3-23 Tighten • Bolts (93) to 20 N m (15 ft. lbs.). 3. Oil cooler lines. 4. Oil filter. • Add engine oil as needed. CRANKSHAFT REPLACEMENT 1. Remove the engine, as outlined later. 2. Refer to the proper unit repair manual for crankshaft replacement procedures. FLYWHEEL REPLACEMENT Rembve or Disconnect Transmission, flywheel housing, and clutch. Flywheel bolts. Flywheel. Clean 90. 91. 92. 93. Seal Gasket Oil Filter Adapter Bolt Mating surfaces of crankshaft and flywheel. Remove any burrs. L* Flywheel for burning, scoring, warping, and wear. Replace the flywheel if necessary. Do not machine the flywheel. B-07904 Flywheel ring gear for worn or broken teeth. Figure 35—Oil Filter Adapter 8. Oil pump, as outlined previously. 9. Oil pan, as outlined previously. 10. Spark plugs. OIL FILTER ADAPTER AND OIL FILTER BYPASS VALVE REPLACEMENT (MODELS WITH ENGINE OIL COOLER) Remove or Disconnect (Figure 35) Inspect Flywheel Ring Gear Replacement 1. Use a torch to heat the gear around the entire circumference, then drive the gear off the flywheel, using care not to damage the flywheel. NOTICE: Never heat starter gear to red heat as this will change metal structure. 2. Uniformly heat the flywheel gear to temperature which will expand the gear to permit installation. Temperature must not exceed 204°C (400°F). 3. As soon as the gear has been heated, install on the flywheel. 1. Oil filter. + 4- Inspect • Bypass valve spring and fiber valve for proper o p e ra tio n , cra cks, or o th e r d am ag e. If replacement is required, the bypass valve and oil filter adapter must be replaced as an assembly, as outlined following. 2. Oil cooler lines. 3. Bolts (93). 4. Oil filter adapter (92). 5. Gasket (91) and seal (90). -►«- Install or Connect (Figure 33) 1. New gasket (91), new seal (90) and oil filter adapter (92) to the block. 2. Bolts (93). Install or Connect 1. Flywheel. 2. Flywheel bolts. £ Tighten • Flywheel bolts to 100 N m (75 ft. lbs.). 3. Clutch, flywheel housing, and transmission. ENGINE MOUNTINGS NOTICE: Broken or deteriorated mountings can cause misaligned and eventual destruction of certain drive train components. When a single m o u n tin g b re ak ag e occurs, the re m ain in g mountings are subjected to abnormally high stresses. 6A3-24 4.3 LITER V6 INSPECTING ENGINE MOUNTINGS Front Engine Mountings NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be b en t against the pum p screen, resulting in a dam aged oil pickup unit. 1. Raise the engine to remove weight from the mountings and to place a slight tension on the rubber cushion. Observe both mountings while raising the engine. 2. Replace the mounting if the following conditions exist: — Hard rubber surface covered with heat check cracks. — Rubber cushion separated from the metal palte of the mounting. — Rubber cushion split through the center. 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 Mountings 1. Push up and pull down on the transmission tailshaft. Observe the transmission mounting. 2. Replace the mounting if the following conditions exist: — Rubber cushion separated from the metal plate of the mounting. — Mounting bottomed out (tailshaft can be moved up but not down). 3. If there is relative movement between a metal plate of the mounting and its attaching point, tighten the bolts or nuts attaching the mounting to the transmission or crossmember. FRONT MOUNTING REPLACEMENT Remove or Disconnect (Figures 36 and 37) NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be bent against the pum p screen, resulting in a dam aged oil pickup unit. -►+ Install or Connect (Figures 36 and 37) 1. Mounting assembly. NOTICE: See “ N otice” on page 6A3-1 of this section. 2. Mounting assembly bolts, nuts, and washers. Tighten • Fasteners to specifications. Refer to figures 36 and 37. 3. Engine mount through-bolt and nut. Lower the engine until the bolt can be inserted. Install the nut. Tighten • Through-bolt or nut to specifications. Refer to figures 36 and 37. REAR MOUNTING RELACEMENT 4-+ Remove or Disconnect (Figures 38 and 39) NOTICE: When raising or supporting the engine for any reason, do not use a ja ck under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be b en t against the pum p screen, resulting in a dam aged oil pickup unit. • Support the rear of the engine to relieve the 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. 3. Mounting. -■*3 in s ta ll o r C o n n e c t (F ig u re s 38 a n d 39) 1. Mounting. • Lower the rear of the engine. 2. Mounting to transmission bolts and washers. NOTICE: See “ N o tice” on page 6A3-1 of this section. 3. Mounting to crossmember nut(s) and washer(s). Tighten • Fasteners to specifications. Refer to figures 38 and 39. • Support the engine with a suitable jack. Do not load the engine mounting. 1. Engine mounting through-bolt and nut. ENGINE REPLACEMENT “ R” AND “ V” MODELS 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. • Raise the engine only enough to permit removal of the engine mounting. 2. Mounting assembly bolts, nuts, and washers. 3. Mounting assembly. Remove or Disconnect 1. 2. • 3. 4. 5. 6. Battery negative cable. Hood. Drain the cooling system. Air cleaner. All accessory drive belts. Fan and water pump pulley. Radiator and shroud. Refer to RADIATOR (SEC. 6B2). 4.3 LITER V6 6A3-25 7. Heater hoses at the engine. 8. Accelerator cruise control, and detent linkage (if used) from the 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. 13. • • Fuel line. Vacuum lines from the intake manifold. Raise the vehicle. Support with suitable safety stands. Drain the crankcase oil. 14. Exhaust pipes rom the manifolds. 15. Strut rods at the engine mountings (“ V” 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 (automatic transmission). • Lower the vehicle. • Support the transmission. Figure 37—Front Engine Mounting (G Models) 6A3-26 4.3 LITER V6 R” MODELS C. 55 N m (40 Ft. Lbs.) ‘V” MODELS B-07616 Figure 38—Rear Engine Mounting (R and V Models) • Attach a suitable lifting fixture to the engine. 21. Bell housing to engine bolts. 22. Engine mounting to frame bolts. NOTICE: See “ N o tice” on page 6A3-1 o f this section. 2. Engine mounting to frame bolts. 23. Hood. 2 4 . E n g in e . Install or Connect (Figure 36) 1. Engine to the vehicle. • Raise the vehicle. Support with suitable safety stands. • Fasteners to specifications. Refer to figure 36. 3. Bell housing to engine bolts. Remove the transmission support. 4. Converter to flex plate bolts. 5. Fuel gage wiring. 6. Starter. 7. Wiring along oil pan rail. 8. Flywheel or torque converter cover. 9. Strut rods at the engine mountings (V models with automatic transmission). 10. Exhaust pipes to the manifolds. • Lower the vehicle. 11 . Vacuum lines to the intake manifold. 12. Fuel line. 13. Engine wiring harness. 14. Power steering pump (if used). 15. Air conditioning compressor (if used). 16. Accelerator, cruise control, and detent linkages. 17. Heater hoses. 18. Radiator and shroud. Refer to RADIATOR (SEC. 6B2). 19. Accessory drive belts. 20. Air cleaner. 21. Hood. 22. Proper quantity and grade of coolant and crankcase oil. 23. Battery negative cable. 4.3 LITER V6 6A3-27 “ G ” MODELS |+ + | Remove or Disconnect 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. Battery negative cable. Glove box. Engine cover. Drain the coolant. Outside air duct. Power steering fluid reservoir. Hood release cable. Upper fan shroud bolts. Radiator. Refer to RADIATOR (SEC. 6B2). Upper fan shroud. Fan and pulley. Air cleaner. Cruise control transducer. Vacuum hoses at the intake manifold. Accelerator, cruise control, and TVS cables (if used). TBI unit. Distributor cap. Diverter valve. Coolant hose at the intake manifold. PCV valve. Other necessary vacuum hoses and wires. Air conditioning compressor and brace. Refer to AIR CONDITIONING (SEC. 1B). Upper half of engine dipstick tube. Oil filler tube. Transmission dipstick tube. Accelerator cable at the dipstick tube. Fuel hoses at the fuel pump. Power steering pump. Headlamp bezels and grille. Upper radiator support. Lower fan shroud and filler panel. Hood latch support. Condenser. Raise the vehicle. Support with suitable safety stands. Drain the crankcase. Exhaust pipes at the manifolds. S tru t rods at the to rq ue co nve rte r or flyw he el underpan. Torque convertor or flywheel cover. Starter. F lexplate to torque co n ve rte r bolts (autom atic transmissions). Bell housing to engine bolts. Engine mounting through bolts. Lower the vehicle and support the transmission. Engine. Install or Connect (Figure 37) 1. Engine to the vehicle. • Raise the vehicle. Support with suitable safety stands. NOTICE: See “ N o tice” on page 6A3-1 of this section. 2. Engine mounting through-bolts. Tighten • Through-bolts or nuts to specifications. Refer to figure 37. 3. Bell housing to engine bolts. 4. Flex plate to torque converter bolts (autom atic transmissions). 5. Starter. 6. Torque converter or flywheel cover. 7. Strut rods. 8. Exhaust pipes. • Lower the vehicle. 9. Condenser. 10. Hood latch support. 11. Lower fan shroud and filler panel. 12. Upper radiator support. 13. Headlamp bezels and grille. 14. Pump. 15. Fuel hoses. 16. Accelerator cable at the dipstick tube. 17. Transmission dipstick tube. 18. Oil filler tube. 19. Upper half of engine dipstick tube. 20. Air conditioning compressor and brace. Refer to AIR CONDITIONING (SEC. 1B). 21. Vacuum hoses and wires. 22. PCV valve. 23. Coolant hose at the intake manifold. 24. Diverter valve. 25. Distributor cap. 26. TBI unit. 27. Accelerator, cruise control, and detent cables. 28. Vacuum hoses at the intake manifold. 29. Cruise control servo. 30. Air cleaner. 31. Fan and pulley. 32. Upper fan shroud. 33. Radiator. Refer to RADIATOR (SEC. 6B2). 34. Upper fan shroud bolts. 35. Hood release cable. 36. Power steering fluid reservoir. 37. Outside air duct. 38. Glove box. 39. Proper quantity and grade of coolant and crankcase oil. 40. Engine cover. 41. Battery negative cable. • Evacuate and charge the air conditioning system. Refer to AIR CONDITIONING (SEC. 1B). 6A3-28 4.3 LITER V6 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement RPO Bore Stroke Compression Ratio Firing Order Oil Pressure V6 4.3L (262 Cu. In.) LB4 4.00 3.48 9.3:1 1-6-5-4-3-2 10 psi @ 500 RPM; 30-35 psi @ 2000 RPM CYLINDER BORE: Diameter Out Of Round Service 3.9995-4.0025 0.001 (Maximum) 0.002 (Maximum) 0.0005 (Maximum) 0.001 (Maximum) 0.001 (Maximum) Production Service Limit 0.0007-0.0017 0.0027 (Maximum) Production Service Thrust Side Relief Side Taper PISTON: PISTON RING: C o M P R F S c 0 1 O N 0 1 L Groove Production Top Clearance Service Limit Production Gap Groove Clearance Gap 0.0012-0.0032 2nd Hi Limit Production + 0.001 Top 0.010-0.020 2nd 0.010-0.025 Service Limit Hi Limit Production + 0.010 Production Service Limit Production Service Limit 0.002-0.007 Hi Limit Production + 0.001 0.015-0.055 Hi Production +0.010 Production Service Limit 0.9270-0.09273 0.0002-0.0007 0.001 (Maximum) 0.0008-0.0016 Interference PISTON PIN: Diameter Clearance In Piston Fit In Rod 4.3 LITER V6 6A3-29 SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. 4.3L DISPLACEMENT: CRANKSHAFT: #1 #2, #3 #4 Production Service Limit Production Service Limit #1 #2, #3 #4 #1 #2, #3 #4 Diameter Main Journal Taper Out Of Round Production Main Bearing Clearance Service Limit Crankshaft End Play Diameter Production Service Limit Production Service Limit Production Service Limit Taper Crankpin Out Round Rod Bearing Clearance Rod Side Clearance 2.4484-2.4493 2.4481-2.4490 2.4479-2.4488 0.0002 (Maximum) 0.001 (Maximum) 0.0002 (Maximum) 0.001 (Maximum) 0.0008-0.0020 0.0011-0.0023 0.0017-0.0032 0.0010-0.0015 0.0010-0.0025 0.0025-0.0035 0.002-0.006 2.2487-2.2497 0.0005 0.001 (Maximum) 0.0005 0.001 (Maximum) 0.0013-0.0035 0.0030 0.006-0.014 CAMSHAFT: Intake Exhaust Lobe Lift + 0.002 Journal Diameter Camshaft End Play 0.357 0.390 1.8682-1.8692 0.004-0.012 VALVE SYSTEM: Hydraulic 1.50:1 Lifter Rocker Arm Ratio Valve Lash Intake Exhaust One Turn Down From Zero Lash Intake Exhaust Intake Exhaust Intake Exhaust 45° 46° 0.002 (Maximum) 1/32-1/l 6 1/l6-3/32 0.0010-0.0027 0.0010-0.0027 High Limit Production +0.001 High Limit Production +0.002 2.03 76-84 lbs. @ 1.70-in. 194-206 lbs. @ 1.25-in. Face Anqle (Intake & Exhaust) Seat Angle (Intake & Exhaust) Seat Runout (Intake & Exhaust) Seat Width Stem Clearance Valve Spring (Outer) Valve Spring Damper Production Service Free Length Pressure lbs. @ in. Closed Open Installed Height + 1/32" Free Length Approx. # of Coils 123/32 1.86 4 6A3-30 4.3 LITER V6 SPECIFICATIONS (CONTINUED) TORQUE SPECIFICATIONS ITEM Rocker Arm Cover B o lt s ........................................................................... Intake Manifold B o lts .................................................................................. Exhaust Manifold Bolts Center Two B o lts.................................................................................. All O th e r s ............................................................................................. Cylinder Head B o lts .................................................................................... Torsional Damper B o lt............................................................................... Front Cover B o lts ........................................................................................ Oil Pan N u ts ................................................................................................. Oil Pan Bolts................................................................................................. Oil Pump B o lt............................................................................................... Rear Crankshaft Oil Seal Retainer Screws and N u t s ........................ Camshaft Sprocket B o lts ........................................................................... Connecting Rod Cap N uts......................................................................... Oil Filter Adapter Bolts ........................................................................................................................................... Main Bearing Cap B o lts . ................................................................................................................................... Oii Pump Cover B o lt s ............................................................................... Flywheel B o its ............................................................................................. Spark P lu g s ................................................................................................. Water Outlet B o lts ...................................................................................... Water Pump B o lt s ...................................................................................... Flywheel Housing B o lts ............................................................................. Camshaft Thrust Plate S c re w s ................................................................ Hydraulic Lifter Restrictor Retainer B o lts .............................................. Oil Pan Studs to Oil Seal Retainer or C ra n k c a s e ...................................................... .................. .................. .................. .................. .................. .................. .................. ............................... .................. .................. .................. .................. .................. ............................... .................. .................. .................. .................. .................. .................. .................. ............................... ............................... Nm 11.3 48 FT. LBS. — 35 IN. LBS. 100 — 36 28 90 95 11.3 22.6 11.3 90 15.3 23 60 20 100 9.0 100 30 28 40 44 11.9 16.4 1.7 26 20 65 70 — — — — — — — 65 — 100 200 100 — 135 17 45 15 75 — — 80 75 22 21 30 32 — — — — — — — — — — — 105 145 15 4.3 LITER V6 6A3-31 SPECIAL TOOLS J-23523-E J-5802 01 J-5892-B 10 J-5715 11 J-6036 12 0) J-6880 J-23590 13 J-35468 1. 2. 3. 4. 5. 6. 7. 8. Torsional Dam per Remover and In staller Valve S pring C om pressor A ir A dapter C rankshaft Seal In sta lle r and C entering Tool Main Bearing Replacer P iston Ring C om pressor G uide Set Vacuum Pump 9. 10. 11. 12. 13. 14. 15. 16. J-5825-A Stud Remover Reamer (0.003-inch oversize) Reamer (0.013-inch oversize) Stud In sta lle r C rankshaft Gear Puller C rankshaft Gear In staller Dial In d ica to r A dapter Rear C rankshaft Seal In staller B-07617 6A3-32 4.3 LITER V6 6A4-1 SECTION 6A4 SMALL BLOCK The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the m anual as indicated at appropriate locations by the term inology “ NOTICE: See ‘Notice’ on page 6A4-1 of this section.” NOTICE: All engine fasteners are important attaching parts in that they could affect the perform ance of vital com ponents and systems, and/or could result in m ajor repair expense. They must be replaced with one of the same part number or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part. CONTENTS SUBJECT PAGE Description................................................................................................................................................................... 6A4- 2 Engine Lubrication................................................................................................................................................... 6A4- 2 On-Vehicle S ervice ..................................................................................................................................................... 6A4- 5 Rocker Arm Cover Replacem ent.......................................................................................................................... 6A4- 5 Rocker Arm and Pushrod Replacement................................................................................................................6A4- 6 Valve Adjustment..................................................................................................................................................... 6A4- 6 Valve Stem Seal and Valve Spring Replacement.......................................................... .....................................6A4- 7 Intake Manifold Replacement................................................................................................................................ 6A4- 8 Hydraulic Lifter Replacement................................................................................................................................ 6A4- 9 Rocker Arm Stud R eplacem ent............................................................................................................................ 6A4-10 Exhaust Manifold R eplacem ent............................................................................................................................ 6A4-11 Cylinder Head Replacement.................................................................................................................................. 6A4-12 Torsional Damper and Front Crankshaft Seal Replacement.............................................................................6A4-13 Front Cover Replacement.......................................................................................................................................6A4-14 Oil Pan Replacement...............................................................................................................................................6A4-14 Oil Pump Replacement...........................................................................................................................................6A4-15 Rear Crankshaft Oil Seal Replacem ent................................................................................................................6A4-15 Rear Crankshaft Oil Seal Retainer R eplacem ent............................................................................................... 6A4-16 Measuring Camshaft Lobe L if t .............................................................................................................................. 6A4-17 Camshaft Replacement...........................................................................................................................................6A4-17 Connecting Rod and Piston Replacement............................................................................................................6A4-19 Oil Filter Bypass V a lv e ...........................................................................................................................................6A4-20 Main Bearing Replacement.................................................................................................................................... 6A4-21 Crankshaft Replacement........................................................................................................................................ 6A4-22 Flywheel R eplacem ent...........................................................................................................................................6A4-22 Engine M o u n tin g s...................................................................................................................................................6A4-22 Engine Replacem ent........................................................ ...................................................................................... 6A4-23 S pe cifica tio n s............................................................................................................................................................. 6A4-32 Special T o o ls............................................................................................................................................................... 6A4-35 6A4-2 SMALL BLOCK DESCRIPTION Small block engines covered by this manual are availa­ ble in two displacements; 5.0L (305 cu. in.) and 5.7L (350 cu. in.). Small block engines are 90-degree V8 type, overhead valve, water cooled, with cast iron block and heads. The crankshaft is supported by five precision insert main bearings, with crankshaft thrust taken at the number five (rear) bearing. The camshaft is supported by five plain type bearings and is chain driven. Motion from the camshaft is transm it­ ted to the valves by hydraulic lifters, pushrods, and ball type rocker arms. The valve guides are integral in the cyl­ inder head. The connecting rods are forged steel, with precision in­ sert type crankpin bearings. The piston pins are a press fit in the connecting rods. The pistons are cast alum inum alloy. The piston pins are a floating fit in the piston. ENGINE LUBRICATION Lubrication schem atics are shown in figures 1 and 2. The gear type oil pump is driven from the distributor 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 oil pressure, a bypass valve is provided. Filtered oil flows into the main gallery and then to the camshaft and crankshaft bearings. The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the hydraulic lifters through the hollow pushrods to the rocker arms. Oil from the overhead drains back to the crankcase through oil drain holes. The tim ing chain is drip fed from the front camshaft bearing. The pistons and piston pins are lubricated by oil splash. SMALL BLOCK 6A4-3 Figure 1—Engine Lubrication Diagram 6A4-4 SMALL BLOCK Figure 2—Engine Lubrication Diagram SMALL BLOCK 6A4-5 ON-VEHICLE SERVICE 5. Bolt 6. W a sh er R o cke r A rm C over 8. G a sket 9. R e in fo rc e m e n t 10. N u t TBI ENGINES CARBURETED ENGINES B-07620 Figure 3—Rocker Arm Cover ROCKER ARM COVER REPLACEMENT REMOVAL — TBI ENGINES R e m o ve o r D is c o n n e c t (F ig u re 3) □ 1. 2. 3. 4. 5. 6. Battery negative cable. Engine cover (G models). Air cleaner. Crankcase ventilation hoses at the rocker arm covers. Wiring harnesses from the clips, and move aside. Components as follows for right rocker arm cover: • AIR hose from check valve (G models). • D iverter valve and hoses from bracket (G models). • PCV valve. • Upper dipstick bracket (G models). • Heat stove pipe. Components as follows for left rocker arm cover.: • Generator rear brace (G models). • Oil fill tube (G models). • Power brake vacuum pipe and move aside (R and V models). • Air conditioning compressor, and lay aside (R and V models). 8. AIR pipe at manifold (G models). 9. Rocker arm cover bolts and washers. 10. Rocker arm cover and gasket. REMOVAL — CARBURETED ENGINES Remove or Disconnect (Figure 3) 1. 2. 3. 4. 5. Battery negative cable. Engine cover (G models). Air cleaner. Crankcase ventilation hoses at the rocker arm covers. Wiring harnesses from the clips, and move aside. 6A4-6 SMALL BLOCK 6. 7. 8. 9. 10. Diverter valve with bracket and hoses. AIR check valve. Oil fill tube (right side cover). Heat stove pipe (right side cover). Components as follows for left rocker arm cover: • Decel valve and bracket (G models). • Vacuum pipe from EFE valve. • Power brake vacuum pipe, and move aside. • Air co nd itio nin g com pressor rear brace (if equipped). 11. Rocker arm cover nuts, reinforcements, and wire clips. 12. Rocker arm cover and gasket. CLEANING AND INSPECTION Clean All traces of old gasket from the rocker arm cover and cylinder head. Inspect I* • Rocker arm cover sealing surface for distortion. Replace if necessary. 5. 6. 7. 8. 9. 10. 11. 12. ROCKER ARM AND PUSHROD REPLACEMENT ++ 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. INSTALLATION — TBI ENGINES Im portant -►+ Install or Connect (Figure 3) 1. Rocker arm cover and new gasket. 2. Rocker arm cover bolts and washers. Oil fill tube (right side cover). AIR check valve. Diverter valve, bracket, and hoses. Wiring harnesses to the rocker arm clips. Crankcase ventilation hoses. Air cleaner. Engine cover (G models). Battery negative cable. • Store used components in order so they can be reassembled in the same location. Inspect 6. 7. 8. 9. 10. • Bolts to 11.3 N m (100 in. lbs.). AIR pipe at manifold (G models). Components as follows for left rocker arm cover: • Air conditioning compressor (R and V models). • Power brake vacuum pipe (R and V models). • Oil fill tube (G models). • Generator rear brace (G models). Components as follows for right rocker arm cover: • Heat stove pipe. • Upper dipstick bracket (G models). • PCV valve. • Diverter valve and hoses (G models). • AIR hose to check valve (G models). Wiring harnesses to the rocker arm clips. Crankcase ventilation hoses. Air cleaner. Engine cover (G models). Battery negative cable. INSTALLATION — CARBURETED ENGINES Install or Connect (Figure 3) 1. Rocker arm cover and new gasket. 2. Reinforcements, wire clips, nuts, and stud (if used). & Tighten — Nuts to 7.3 N m (65 in. lbs.). 3. Components as follows for left rocker arm cover: • A ir co nd itio nin g com pressor rear brace (if equipped). • Power brake vacuum pipe. • Vacuum pipe to EFE valve. • Decel valve and bracket. 4. Heat stove pipe (right side cover). 0 Rocker arms and balls at their mating surfaces. These surfaces should be smooth and free from scoring or other damage. Rocker arm areas which contact the valve stems and the sockets which contact the pushrods. These areas should be smooth and free of damage and wear. Pushrods for bending. Roll the pushrod on a flat su rfa ce to dete rm ine if it is bent. R eplace if necessary. Ends of the pushrods for scoring or roughness. Install or Connect Pushrod. Make sure the pushrod seats properly in the hydraulic lifter. 2. Rocker arm with ball. Important • When new rocker arms and/or balls are installed, coat their bearing surfaces with “ Molykote” or equivalent. 3. Rocker arm nut. ft Adjust • Valves as outlined later. 4. Rocker arm cover, as outlined previously. 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 tab and the engine in the number one firing position. This may be determined by placing fingers on the number SMALL BLOCK 6A4-7 20. 21. 22. 23. 24. 25. Valve Keeper Cap Shield O-Ring Seal Seal Damper 26. 27. 28. 29. Spring Intake Valve R otator Exhaust Valve Figure 5— Valves and Components 3. 4. 5. 6. one valve as the mark on 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 rocker arms move as the mark comes up to the 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. With the engine in the number one firing position as determ ined above, the follow ing valves may be adjusted: — Exhaust: 1, 3, 4, 8 — Intake: 1, 2, 5, 7 (Even numbered cylinders are in the right bank; odd numbered cylinders are in the left bank, when viewed from the rear of the engine). Back out the adjusting nut until lash is felt at 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 the play has been removed, turn the adjusting nut in one full additional turn (to center the lifter plunger). Crank the engine one revolution until the timing tab “ O” mark and vibration damper mark are again in alignment. This is the number six firing position the following valves may be adjusted: — Exhaust: 2, 5, 6, 7 — Intake: 3, 4, 6, 8 Install the rocker arm cover as outlined previously. VALVE STEM SEAL AND VALVE SPRING REPLACEMENT Remove or Disconnect (Figures 5 and 6) 1. 2. 3. 4. Tools Required: J-23590 Air Adapter. J-5892-B Spring Compressor. Rocker arm cover, as outlined previously. Rocker arms, as outlined previously. Spark plugs. Valve keepers (20). • • • • Install J-23590 into the spark plug hole. Apply compressed air to hold the valves in place. Install a rocker arm nut (figure 6). Use J-5892-B to compress the valve spring (figure 6). • Remove the valve keepers. • Carefully release the spring tension. Remove J-5892-B. 5. Cap (21) and/or rotator (28), shield (22) and spring (26) with damper (25). 6. O-ring seal (23). 7. Seal (24) (intake valve only). Install or Connect (Figures 5, 6, and 7) Tools Required: J-23590 Air Adapter J-5892-B Spring Compressor J-23738-A Vacuum Pump 1. New seal (24) (intake valve only). Install the seal over the valve stem and seat it against the head. 2. Spring (26) with damper (25), shield (22) and cap (21) and/or rotator (28). 6A4-8 SMALL BLOCK INTAKE MANIFOLD REPLACEMENT Remove or Disconnect 3. • 4. 5. 7. 14. Figure 7—Testing the Valve Seals 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-B (figure 6). • Lubricate the O-ring seal with engine oil. Install the seal on the valve stem. Make sure the seal is not twisted. 15. 16. 17. 18. Clean Old gasket and RTV from the block, heads, and intake manifold. Remove all RTV that is loose or will cause interference at assembly. Excessive carbon deposits from the exhaust and EGR passages. Excessive scale and deposits from the coolant passages. • Install the valve keepers. Use grease to hold them in place. • Carefully release spring pressure. Make sure the valve keepers stay in place. • Remove J-5892-B and J-23590. • Check each O-ring seal for leakage (figure 7). • Place the suction cup furnished with J-23738-A over the shield. • Connect J-23738-A to the suction cup and apply a vacuum. Watch the vacuum pump gage. No air should be able to leak past the seal. If the seal will not hold a vacuum, it may have been damaged or improperly installed. 4. Spark plugs. 5. Rocker arms, as outlined previously. ft Adjust • Valves, as outlined previously. 6. Rocker arm cover, as outlined previously. Battery negative cable. Engine cover (G models). Air cleaner. Drain the cooling system. AIR crossover hose (G m odels with TBI engines). Heater hose and upper radiator hose at the intake manifold. Generator bracket at the manifold. Vacuum hoses at the m anifold, carburetor or TBI unit, and EGR valve. E le c tr ic a l c o n n e c tio n s a t th e m a n ifo ld and carburetor or TBI unit. Fuel line(s) at the carburetor or TBI unit. Accelerator, cruise control, and TVS cables, as equipped. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). Air conditioning compressor and bracket and lay aside (if equipped) (except G m odels with TBI engines). Brake booster vacuum pipe. Components as follows on TBI engines: • Coil wires. • Emission control sensors and bracket on right side. • Cruise control trandsucer and bracket. • Fuel line bracket at rear of manifold. Move the fuel lines aside. • Bracket at rear of belt idler (G models). Carburetor or TBI unit (if necessary). Intake manifold bolts. Intake manifold. Gaskets and clips (some TBI engines). L* Inspect Manifold for cracks and gasket surface damage. Install or Connect (Figures 8 and 9) 1. Gaskets to the cylinder head' On TBI engines so equipped, also install the clips over the gaskets to the rib between the intake port^. Then apply a dot of RTV to the upper side of the clip. 2. RTV to the front and rear sealing surfaces on the block (figure 8). Apply a 5 mm (3/ie-inch) bead of RTV (part number 1052366 or equivalent) to the front and rear of the block as shown. Extend the bead 13 mm (1/2-inch) up each cylinder head to seal and retain the gaskets. 3. Intake manifold to the engine. 4. Intake manifold bolts. SMALL BLOCK 6A4-9 C. Forw ard D. RTV S ealant B-07915 Figure 8—Intake Manifold Tighten • Intake manifold bolts to 48 N-m (35 ft. lbs.). Use the tightening sequence shown in figure 9. Carburetor or TBI unit (if removed). Components as follows on TBI engines: • Bracket at rear of belt idler (G models). • Fuel line bracket at rear of manifold. • Cruise control transducer and bracket. • E m ission c o n tro l se n so rs and brackets. • Coil wires. Brake booster vacuum pipe. Air conditioning compressor and bracket (if removed). Refer to AIR CONDITIONING (SEC. 1B). Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 10. Accelerator, cruise control, and TVS cables, as equipped. 11. Fuel line(s) at the TBI unit or carburetor. 12. Electrical connections. 13. Vacuum hoses. 14. Generator bracket. 15. Heater hose and upper radiator hose. 16. AIR crossover hose (G models with TBI engines). 17. Air cleaner. 18. E ng in e cove r (G m odels). 19. Battery negative cable. • Fill the cooling system with the proper quantity and grade of coolant. HYDRAULIC LIFTER REPLACEMENT Remove or Disconnect (Figures 10 and 11) B-09569 Figure 9—Intake Manifold Bolt Tightening Sequence Tools Required: J-3049 Hydraulic Lifter Remover (Plier Type) or J-9290-01 H ydraulic Lifter Remover (Slide Hammer Type) Rocker arm cover, intake manifold, and pushrod, as outlined previously. 2. Hydraulic lifters. — Remove the hydraulic lifters one at a time and place them in an organizer rack. The lifters must be installed in the same bore from which they were removed. 6A4-10 SMALL BLOCK Figure 10—Removing the Hydraulic Lifter — A stuck hydraulic lifter can be removed using J-3049 (figure 10) or J-9290-01 (figure 11). L * 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. The hydraulic lifter foot must be smooth and slightly convex. If worn, pitted, or damaged, the mating camshaft lobe should also be checked. Hydraulic Lifter Repair • R efer to the p ro p e r u n it rep air m anual. Install or Connect 1. Hydraulic lifters to the block. Lubricate the lifter foot and body with Engine Oil Supplement or equivalent. Im portant • When any new hydrau lic lifte rs or a new camshaft is installed, change the engine oil and filter. Engine Oil Supplement (or equivalent) should be added to the crankcase oil. • R eplace all h y d ra u lic lifte rs when a new camshaft is installed. 2. Intake Manifold, as outlined previously. 3. Pushrod, as outlined previously. A djust • Valves, as outlined previously. Rocker arm cover, as outlined previously. ROCKER ARM STUD REPLACEMENT Remove or Disconnect (Figure 12) Tool Required: J-5802-01 Rocker Arm Stud Remover 1. Rocker arm cover and rocker arm, as outlined previously. 2. Rocker arm stud. • Place J-5802-01 over the rocker arm stud. • Install a nut and flat washer. • Turn the nut to remove the stud (figure 12). -►«- Install or Connect (Figures 13 and 14) Tools Required: J-5715 Reamer (0-003-inch oversize) or J-6036 Reamer (0.013-inch oversize) J-6880 Rocker Arm Stud Installer NOTICE: Do not attem pt to install an oversize rocker arm stud without reaming stud hole as this could damage the cylinder head. Figure 11—Removing the Hydraulic Lifter (Typical) • Ream the hole to the proper size for the replacement oversize rocker arm stud. Use J-5715 for 0.003-inch oversize studs; J-6036 for 0.013-inch oversize studs (figure 13). SMALL BLOCK 6A4-11 EXHAUST MANIFOLD REPLACEMENT Remove or Disconnect Figure 13—Reaming the Rocker Arm Stud Bore (Typical) • Coat lower end (press-fit area) of rocker arm stud with hypoid axle lubricant. 1. Rocker arm stud. Use J-6880 (figure 14). Stud is installed to proper depth when the tool bottoms on the cylinder head. 2. Rocker arm, as outlined previously. 8. 9. 10. Adjust • Valves, as outlined previously. 3. Rocker arm cover, as outlined previously. 11. Battery negative cable. Engine cover (G models). Raise the vehicle. Support with suitable safety stands. Exhaust pipe at the manifold. Lower the vehicle. Oxygen sensor wire (if used) (left side manifold). Do not remove the oxygen sensor unless replacement is required. AIR hose at the check valve. Heat stove pipe (right side manifold). Components as follows on R and V models: • Air conditioning compressor rear bracket at the manifold (left side manifold). • Diverter valve and bracket (right side manifold). Components as follows on G models with TBI engines: • Power ste e rin g pum p rear bracket at the manifold (left side manifold). • Dipstick tube bracket (right side manifold). AIR pipe bracket at the manifold stud (carbureted engines — left side manifold). Exhaust manifold bolts, washers, tab washers and spark plug heat shields, as equipped. — Cast m anifolds are retained by bolts, tab washers, and plain washers. Remove the outside bolts first, then the center bolts. — Tubular (stainless steel) manifolds are retained by bolts and plain washers. Exhaust manifold. Clean — Mating surfaces on the manifold and head. — Threads on the exhaust manifold bolts. -►+ Install or Connect Exhaust manifold to the cylinder head. 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. Tighten • Bolts to 36 N m (26 ft. lbs.). 3. Components as follows on G models with TBI engines: • Power ste ering pum p rear bracket at the manifold (left side manifold). • Dipstick tube bracket (right side manifold). 4. Components as follows on R and V models: • Air conditioning compressor rear bracket at the manifold (left side manifold). • Diverter valve and bracket (right side manifold). 6A4-12 SMALL BLOCK 5. AIR bracket at the manifold (carbureted engines — left side manifold). 6. Heat stove pipe (right side manifold). 7. AIR hose at the check valve. 8. Oxygen sensor wire (if used). • Raise the vehicle. Support with suitable safety stands. 9. Exhaust pipe. • Lower the vehicle. 10. Engine cover. 11. Battery negative cable. 0 0 0 0 0 0 0 0 . CYLINDER HEAD REPLACEMENT ++ Figure 15—Cylinder Head Bolt Tightening Sequence Remove or Disconnect 1. Battery negative cable. 2. Engine cover (G models). 3. 4. 5. 6. 7. 8. 9. 10 11. 12. 13. 14. 15. B-09572 Drain the cooling system. Intake manifold, as outlined previously. Exhaust m anifold, as outlined previously. Ground strap at rear of cylinder head (right side cylinder head). Components as follows for right side cylinder head on R and V models: — AIR pipe at the rear of the cylinder head. — Spark plug wires from the support brackets. — Generator, and lay aside. Components as follows for left side cylinder head on R and V models: — Air conditioning compressor and front bracket (if equipped) and lay aside. — Power steering pump, and lay aside. — Coolant sensor wire. — Spark plug wires from the support brackets. — AIR pipe at the rear of the cylinder head. Components as follows for right side cylinder head on G models with TBI engines: — AIR pump bolt and spacer at the cylinder head. — N ut and s tu d a tta c h in g a ir c o n d itio n in g compressor to cylinder head. — Fuel pipe, plug wire and wiring harness brackets at the rear of the cylinder head. Components as follows for left side cylinder head on G models with TBI engines: — Nut and stud attaching main accessory bracket to the cylinder head. It may be necessary to loosen the remaining bolts and studs and move the bracket forward slightly for clearance to remove the cylinder head. — Coolant sensor wire. — Cruise control transducer and spark plug wire brackets at the rear of the cylinder head. Components as follows on carbureted engines: — Generator, and lay aside (right side cylinder head). — Air conditioning compressor and bracket, and lay aside (left side cylinder head). Rocker arm cover, as outlined previously. Spark plugs. Pushrods, as outlined previously. Cylinder head bolts. Cylinder head. 16. Head gasket. 13 1 Clean — Carbon deposits from com bustion chambers. — All traces of old head gasket from cylinder head and block. — C ylinder head bolt threads and threads in the block. L* Inspect Sealing surfaces of the block and cylinder head for nicks, heavy scratches, or other damage. Cylinder Head Repair • Refer to the proper Unit Repair Manual. Install or Connect (Figure 15) 1. Head gasket. • If a steel gasket is used, coat both sides of the gasket with sealer. Spread the sealer thin and even. • Do not use sealer on composition steel-asbestos gaskets. • Place the gasket over the block dowel pins with the bead up. 2. Cylinder head. Carefully guide the cylinder head ino place over the dowel pins and gasket. SMALL BLOCK 6A4-13 9. 10. 3. Cylinder head bolts. Coat threads of the cylinder head bolts with sealing com pound (GM part num ber 1052080 or equivalent) and install finger-tight. 11. Tighten • Cylinder head bolts, a little at a time, using the sequence shown in figure 15. Proper torque is 90 N m (65 ft. lbs.). 4. Pushrods, as outlined previously. Adjust • Valves, as outlined previously. 5. Rocker arm cover, as outlined previously. 6. Spark plugs. 7. Components as follows for right side cylinder head on R and V models: — AIR pipe at the rear of the cylinder head. — Spark plug wires to the support brackets. — Generator. 8. Components as follows for left side cylinder head on R and V models: 12. 13. 14. 15. 16. • — Air conditioning compressor and front bracket (if equipped). — Power steering pump. — Coolant sensor wire. — Spark plug wires to the support brackets. — AIR pipe at the rear of the cylinder head. Components as follows for right side cylinder head on G models with TBI engines: — AIR pump bolt and spacer at the cylinder head. — Nut and stud attaching the air conditioning compressor to the cylinder head. — Fuel pipe, plug wire and wiring harness brackets at the rear of the cylinder head. Components as follows for left side cylinder head on G models with TBI engines: — Nut and stud attaching main accessory bracket to the cylinder head. — Remaining main accessory bracket bolts and nuts, if necessary. — Coolant sensor wire. — Cruise control transducer and spark plug wire brackets at the rear of the cylinder head. Components as follows on carbureted engines: — Generator (right side cylinder head). — Air conditioning compressor and bracket (left side cylinder head). Ground strap at the rear of the cylinder head (right side cylinder head). Exhaust manifold, as outlined previously. Intake manifold, as outlined previously. Engine cover (G models). Battery negative cable. Fill the cooling system with the proper quantity and grade of coolant. TORSIONAL DAMPER AND FRONT CRANKSHAFT SEAL REPLACEMENT 0 1. 2. 3. 4. 5. 6. 7. Remove or Disconnect (Figure 16) Tool Required: J-23523-E Torsional Damper Puller and Installer Fan belts, fan, and pulley. Fan shroud assembly. Accessory drive pulley. Torsional damper bolt. Torsional damper. Use J-23523-E (figure 16). Front crankshaft seal. Pry out with a large screwdriver. Take care not to distort the timing cover. Crankshaft key, if necessary. Oil seal contact area on the torsional dam per shaft for grooving and roughness. Replace if necessary. Install or Connect (Figures 17 and 18) Tools Required: J-35468 Seal Installer J-23523-E Torsional Damper Puller and Installer 1. Crankshaft key, if removed. 6A4-14 SMALL BLOCK 2. Front crankshaft seal. Use J-35468 (figure 17). The open end of the seal faces inside the engine. Coat the seal lips with engine oil. NOTICE: The in e rtia w eig h t section o f the torsional dam per is assembled to the hub with a rubber type material. The correct installation procedures (w ith the p rop er tool) m ust be followed or m ovem ent o f 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 stud fully into the tapped hole in the crankshaft. 4. Torsional damper over the end of the stud. Align keyway in the torsional dam per shaft with crankshaft key. 5. Bearing, washer and nut (figure 18). • Turn the nut to pull the vibration damper place. • Remove the tool. • Use a small amount of RTV sealant to seal torsional damper key to crankshaft joint. 6. Torsional damper bolt and washer. $ the the the into Tighten the • Front cover to block bolts to 11.3 N m (100 in. lbs.). 4. Oil pan, as outlined later. 5. Water pump. Refer to ENGINE COOLING (SEC. 6B1). 6. Torsional damper, as outlined previously. Tighten • Bolt to 95 N m (70 ft. lbs.). 7. Accessory drive pulley. 8. Fan shroud assembly. 9. Fan pulley, fan, and fan belts. OIL PAN REPLACEMENT A one piece type oil pan gasket is used. FRONT COVER REPLACEMENT Remove or Disconnect □ 1. 2. 3. 4. 5. 6. 7. 131 Torsional damper, as outlined previously. Water pump. Oil pan, as outlined later. Front cover bolts. Front cover. Front cover to block gasket. 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. Inspect Front cover for distortion and damage. Replace if necessary. Install or Connect (Figure 19) Tools Required: J-35468 Seal Installer 1. Front crankshaft seal. Use J-35468 (figure 19). The open end of the seal faces inside the engine. Coat the seal lips with engine oil. 2. Front cover gasket to the front cover. Use gasket cement to hold it in place. 3. Front cover to the engine. Remove or Disconnect (Figure 20) □ 1. • • 2. 3. 4. Battery negative cable. Raise the vehicle. Support with suitable safety stands. Drain the engine oil. Exhaust crossover pipe. Flywheel/torque converter cover. Strut rods at the engine mountings (V models with automatic transmissions). 5. Oil pan bolts, nuts, and reinforcements. 6. Oil pan and gasket. jQ * Clean • Gasket surfaces on the engine and oil pan. y ] Inspect • Oil pan gasket for damage. Replace if necessary. + + I Install or Connect (Figure 20) • Apply sealant (GM part number 1052080 or equivalent) to the front cover to block joint and to the rear crankshaft seal to block joint. Apply the sealant for about 25 mm (1 inch) in both directions from each of the four corners. 1. Oil pan gasket to the oil pan. 2. Oil pan to the engine. 3. Oil pan bolts, nuts, and reinforcements. — Oil pan bolts to 11.3 N m (100 in. lbs.). — Oil pan nuts to 22.6 N m (200 in. lbs.). SMALL BLOCK 6A4-15 4. Strut rods at the engine mount (V m odels with automatic transmissions). 5. Flywheel/torque converter cover. 6. Exhaust crossover pipe. • Lower the vehicle. 7. Proper quantity and grade of engine oil. 8. Battery negative cable. OIL PUMP REPLACEMENT Remove or Disconnect (Figure 20) 1. Oil pan, as outlined previously. 2. Nuts (73) (if equipped). 3. Bolt (72). 4. Oil pump (70) and buffle (71) (if equipped). L* Inspect • Oil pump pickup tube for looseness. If the tube is loose in the oil pump body, replace it, as outlined in the proper unit repair manual. A loose pickup tube can result in an air leak and loss of oil pressure. Oil Pump Repair • Refer to the proper unit repair manual. 73 74 Install or Connect (Figure 20) 1. Oil pump to the engine. Align the slot in the oil pump shaft with the tang on the distributor shaft. The oil pump should slide easily into place. No 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). • Nuts (73) to 34 N-m (25 ft. lbs.). 4. O il pan, as o u tlin e d previously. REAR CRANKSHAFT OIL SEAL REPLACEMENT ++ Remove or Disconnect (Figure 21) 1. Transmission. 2. Clutch and flywheel or flexplate, as equipped. 70. 71. 72. 73. 74. 75. NOTICE: Care should be taken when removing the rear crankshaft oil seal so as not to nick the crankshaft sealing surface. Oil Pump Baffle (Some 5.7L Engines) Bolt Nut (Some 5.7L Engines) Gasket Reinforcement B-07916 3. Rear crankshaft oil seal. Insert a screwdriver into the notches provided in the seal retainer and pry the seal out (figure 21). Take care not to damage the crankshaft seal surface. Inspect Figure 20—Oil Pan Chamfer on crankshaft for grit, loose rust, and burrs. Correct as necessary. 6A4-16 SMALL BLOCK A. 80. 81. 82. 83. 84. Rear o f B lock Screw Nut R etainer Stud Gasket 83 F-02922 Figure 23—Rear Crankshaft Oil Seal Retainer Clean Seal running surface on the crankshaft with a non-abrasive cleaner. 0 Install or Connect (Figure 22) 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. • Tighten the screws securely with a screwdriver. This will ensure that the seal is installed squarely over the crankshaft. • Turn the handle until it bottoms. • Remove J-35621. 2. Clutch and flywheel or flexplate, as equipped. 3. Transmission. REAR CRANKSHAFT OIL SEAL RETAINER REPLACEMENT Remove or Disconnect (Figures 21 and 23). 1. Transmission. 2. Clutch and flywheel or flexplate, as equipped. 3. Oil pan, as outlined previously. 4. Screws (80) and nuts (81). 5. Seal retainer (82). 6. Gasket (84). 7. Rear crankshaft oil seal. Insert a screwdriver into the notches provided in the seal retainer and pry the seal out (figure 21). £] Clean • 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 (84) to the block. It is not necessary to use sealant to hold the gasket in place. 2. Seal retainer (82). 3. Screws (80) and nuts (81). Tighten • Screws (80) and nuts (81) to 15.3 N m (135 in. lbs.). 4. Oil pan, as outlined previously. 5. Rear crankshaft oil seal as outlined previously. 6. Clutch and flywheel or flexplate, as equipped. 7. Transmission. SMALL BLOCK 6A4-17 A. Align Marks as Shown B-05289 Figure 25—Timing Marks MEASURING CHAMSHAFT LOBE LIFT 1. 2. 3. 4. Tool Required: J-8520 Camshaft Lobe Lift Indicator Remove the rocker arm as outlined previously. Refer to figure 24. Position the dial indicator (part of J-8520) so the plunger rests on the pushrod end, as shown. Make sure the pushrod is in the lifter socket. Rotate the crankshaft slowly in the direction of normal rotation until the 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, or attach an auxiliary starter switch and “ bump” the engine dver, until the pushrod is in fully raised position. Important • Whenever the engine is cranked remotely at the starter, with a special jum per cable or other means, the distributor prim ary lead or coil primary leads should be disconnected. 5. Compare the total lift recorded from the dial indicator with specifications. 6. If c a m sh a ft rea d in g s fo r all lobes are w ith in specifications, remove dial indicator assembly. 7. Install the rocker arm and adjust the valves as previously outlined. CAMSHAFT REPLACEMENT ++ 1. 2. 3. 4. 5. Remove or Disconnect (Figures 25, 26, and 27) Tool Required: J-5825-A Crankshaft Sprocket Puller Battery negative cable. Engine cover (G models). Air cleaner. Grille (G models). Air conditioning condensor from its mounting and swing it forward (G models). Figure 26—Replacing the Crankshaft Sprocket 6A4-18 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 prevent damage to the camshaft bearings. Cleaning Inspection and Repair Clean, inspect and repair or replace the camshaft and related components, as outlined in the proper unit repair manual. The unit re p air m anual also d escrib e s ca m sh aft bearing replacement. Install or Connect (Figures 25 through 27 and 35 through 38) • 1. 2. • 3. Tool Required: J-5590 Crankshaft Sprocket Installer Coat the camshaft lobes and journals with a high q u a lity e ngine oil s u p p le m e n t (GM Engine Oil Supplement or equivalent). 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. Cam shaft to the engine (figure 27). Handle the camshaft carefully to prevent damage to the camshaft bearings. Lower the engine. Engine mount through-bolts. NOTICE: See section. 6. Fan, shroud, and radiator. Refer to ENGINE COOLING (SEC. 6B). 7. Rocker arm covers, as outlined previously. 8. Water pump. Refer to ENGINE COOLING (SEC. 6B). 9. Torsional damper, as outlined previously. 10. Front cover, as outlined previously. 11. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). Tighten $ • T h ro u g h -b o lts to s p e c ific a tio n s . R efer to figures 35 through 38. 4. Crankshaft sprocket (if removed). Use J-5590 (figure 26). Make sure the timing mark faces outside. 5. Camshaft sprocket and timing chain. Im portant 12. Intake manifold, as outlined previously. 13. Pushrods and hydraulic lifters, as outlined previously. 14. Fuel pump and pushrod (carbureted engines). • Align the timing marks (figure 25). • Line up the tim ing marks on the camshaft sprocket and crankshaft sprocket (figure 25). 6. Camshaft sprocket bolts. Tighten 15. Camshaft sprocket bolts. 16. Camshaft sprocket and timing chain. The sprocket is a light interference fit on the camshaft. Tap the sprocket on its lower edge to loosen it. • Bolts to 24 N m (18 ft. lbs.). Fuel pump and pushrod (carbureted engines). Hydraulic lifters and pushrods, as outlined previously. 17. Crankshaft sprocket (if required). Use J-5825 (figure 26). Im portant • R eplace all h y d ra u lic lifte rs, ch an ge the engine oil and filter, and add GM Engine Oil Supplem ent (or equivalent) to the engine oil whenever a new cam shaft is installed. 18. Front engine mounting through bolts. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pany may cause it to be bent against the pump screen, resulting in a dam aged oil pickup unit. • Raise the engine. 19. Camshaft ‘N o tice” on page 6A4-1 of this ft A djust • Valves, as outlined previously. 9. Intake manifold, as outlined previously. 10. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 11. Front cover, as outlined previously. 12. Torsional damper, as outlined previously. 13. Water pump. Refer to ENGINE COOLING (SEC. 6B). SMALL BLOCK 6A4-19 14. Rocker arm covers, as outlined previously. 15. Fan, shroud, and radiator. Refer to ENGINE COOLING (SEC. 6B). 16. Air conditioning condensor (G models). 17. Grille (G models). 18. Air cleaner. 19. Engine cover (G models). 20. Battery negative cable. • Fill the cooling system with the proper quantity and grade of coolant. CONNECTING ROD AND PISTON REPLACEMENT ++ 1. 2. 3. 4. 5. 6. 7. Remove or Disconnect (Figure 28) Tool Required: J-5239 Guide Set Cylinder head, as outlined previously. Oil pan, as outlined previously. Oil pump, as outlined previously (if necessary). Ridge or deposits from the upper end of the cylinder bores. • 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. • Turn the crankshaft until the piston is at TDC. • Remove the cloth and cuttings. 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. 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. Connecting rod bearing. C leaning, In sp e ctio n , and R epair Clean, inspect and repair or replace the components as necessary. Measure connecting rod bearing clearance, piston clearance, ring clearances, etc. Refer to the proper unit repair manual. The unit repair manual contains information on: — Connecting rod and piston. — Piston rings. — Connecting rod and crankpin. — Cylinder bores. • Install the bearings in the connecting rod and connecting rod cap. • Lubricate the bearings with engine oil. 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 29. Lubricate the piston and rings. • Without disturbing the ring end gap location, install J-8037 over the piston (figure 30). O ^ 2 ENGINE LEFT ENGINE FRONT ENGINE RIGHT c Install or Connect (Figures 28 through 31) Tools Required: J-5239 Connecting Rod Guide Set J-8037 Ring Compressor Make sure the cylinder walls are clean. Lubricate the cylinder wall lightly with engine oil. Make sure the piston is installed in the matching cylinder. Connecting rod bearings. • Be certain that the bearings are of the proper size. A. B. C D. Oil Ring Rail Gaps 2nd Compression Ring Gap Notch In Piston Oil Ring Spacer Gap (Tang In Hole Or Slot W ith Arc) E. Top Compression Ring Gap B-07895 Figure 29—Piston Ring End Gap Locations 6A4-20 SMALL BLOCK A. Valve Disc 93. O il F ilte r Bypass Valve 94. B olt B-05286 Figure 32—Oil Filter Bypass Valve m arked, begin nin g at the fro n t 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 num bered to correspond w ith the new cylinder number. • The piston must be installed so that the notch in the piston faces the front of the engine (figure 29). • Place the piston in its matching bore. The connecting rod bearing tang slots must be on the side opposite the camshaft. Using light blows with a hammer handle, tap the piston down into its bore (figure 30). At the same time, from beneath the vehicle guide the connecting rod to the crankpin with 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. Measure • Connecting rod bearing clearance. Refer to the proper unit repair manual. 3. Connecting rod cap and bearing. 4. Connecting rod cap nuts. Q • Connecting rod cap nuts to 60 N m (45 ft. lbs.). Measure • Connecting rod side clearance. Use a feeler gage between the connecting rods (figure 31). The correct clearance is 0.006-0.014-inch. Im portant • Each connecting rod and bearing cap should be Tighten 5. Oil pump (if removed), as outlined previously. 6. Oil pan and cylinder head, as outlined previously. OIL FILTER BYPASS VALVE ++ Rempve or Disconnect (Figure 32) 1. Oil filter. L* Inspect • Bypass valve spring and valve disc for proper operation, cracks, and dam age. If replacement is needed, the oil filter bypass valve (93) must be replaced, as follows: 2. Bolts (94). Figure 31—Measuring Connecting Rod Side Clearance 3. Oil filter bypass valve. SMALL BLOCK 6A4-21 Figure 33—Removing the Main Bearing Insert Main bearing cap replacement (shimming procedure). jjJJ| Clean • Valve cham ber in the block. "►+ Install or Connect (Figure 32) 1. Oil filter bypass valve (93). 2. Bolts (94). • Bolts (94) to 26 N-m (20 ft. lbs.). 3. Oil filter. 4. Engine oil, as needed. MAIN BEARING REPLACEMENT B i l l Remove or Disconnect (Figure 33) 1. 2. 3. 4. 5. 6. Tool Required: J-8080 Main Bearing Remover/Installer Spark plugs. Oil pan, as outlined previously. Oil pump, as outlined previously. 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. Lower main bearing inserts from the main bearing caps. Upper main bearing inserts. • Insert J-8080 into the crankshaft oil hole (figure 33). • Rotate the crankshaft to "turn” the bearing insert out of the block. Cleaning, Inspection, and Repair Clean, inspect, and repair or replace the components as required. Refer to the proper unit repair manual. The unit repair manual contains information on • Crankshaft. • Main and connecting rod bearings. -H" Install or Connect (Figures 33 and 34) Tool Required: J-8080 Main Bearing Remover/Installer 1. Upper main bearing inserts. • Insert tool J-8080 into a crankshaft main bearing oil hole (figure 33). • 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. • Remove the tool. 2. Lower main bearing inserts to the main bearing caps. • Make sure the inserts are of the proper size. • Apply engine oil to the inserts. Measure • Main bearing clearance. Refer to the proper unit repair manual. If the engine is in the vehicle, the crankshaft must be supported upward to remove any clearance from the upper bearing. The total clearance can then be measured between the lower bearing and journal. 3. Main bearing caps (except rear cap) and bolts to the 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. Rear main bearing cap bolts tem porarily to 14 N-m (10 ft. lbs.). 6A4-22 SMALL BLOCK Measure • Crankshaft end play, as follows: • Tap the end of the crankshaft first rearward then forward with a lead hammer. This will lin e up th e re a r m ain b e a rin g and crankshaft thrust surfaces. • Tighten the rear main bearing cap bolts to 110 N m (80 ft. lbs.). • W ith the c ra n k s h a ft fo rce d fo rw a rd , measure at the front end of the rear main bearing with a feeler gage (figure 34). The proper clearance 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. Production engines may have rear main bearings that are 0.008-inch wider across the thrust faces than standard. Refer to the proper unit repair manual for more information. 8 . Oil pump, as outlined previously. 9. Oil pan, as outlined previously. 10. Spark plugs. CRANKSHAFT REPLACEMENT 1. Remove the engine, as outlined later. 2. Refer to the proper unit repair manual for crankshaft replacement procedures. FLYWHEEL REPLACEMENT ♦a B Remove or Disconnect 1. Transmission, flywheel housing, and clutch. 2. Flywheel bolts. 3. Flywheel. Mating surfaces of crankshaft and flywheel. Remove any burrs. — Flywheel for burning, scoring, warping, and wear. Replace the flywheel if necessary. Do not machine the flywheel. — Flywheel ring gear for worn or broken teeth. Flywheel Ring Gear Replacement 1. Use a torch to heat the gear around the entire circumference, then drive the gear off the flywheel, using care not to damage the flywheel. NOTICE: Never heat starter gear to red heat as this will changemetal structure. 2. Uniformly heat the flywheel gear to temperature which will expand the gear to permit installation. Temperature must not exceed 204°C (400°F). 3. As soon as the gear has been heated, install on the flywheel. Install or Connect 1. Flywheel. 2. Flywheel bolts. Q T ig h te n • Flywheel bolts to 100 N m (75 ft. lbs.). 3. Clutch, flywheel housing, and transmission. ENGINE MOUNTINGS Broken or deterioratedmountings can cause misaligned and eventual destruction of certain drive train components. When a single mounting breakage occurs, the remaining mountings are subjected to abnormally high stresses. NOTICE: INSPECTING ENGINE MOUNTINGS F ro n t Engine M o u n tin g s Whenraisingor supporting theengine for anyreason, donot useajack under the oil pan, anysheet metal or crankshaft pulley. Due to thesmall clearance between theoil panand theoil pumpscreen, jackingagainst theoil pan may cause it to be bent against the pump screen, resulting in adamagedoil pickup unit. NOTICE: 1. Raise the engine to remove weight from the mountings and to place a slight tension on the rubber cushion. Observe both mountings while raising the engine. 2. Replace the mounting if the following conditions exist: — Hard rubber surface covered with heat check cracks. — Rubber cushion separated from the metal plate of the mounting. — Rubber cushion split through the center. 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 o u n tin g s 1. Push up and pull down on the transmission tailshaft. Observe the transmission mounting. 2. Replace the mounting if the following conditions exist: — Rubber cushion separated from the metal plate of the mounting. — Mounting bottomed out (tailshaft can be moved up but not down). 3. If there is relative movement between a metal plate of the mounting and its attaching point, tighten the bolts or nuts attaching the mounting to the transmission or crossmember. SMALL BLOCK 6A4-23 FRONT MOUNTING REPLACEMENT Remove or Disconnect (Figures 35 through 38) NOTICE: Whenraisingor supporting theengine for anyreason, do not useajack under the oil pan, anysheet metal or crankshaft pulley. Due to the small clearance between the oil panand theoil pumpscreen, jackingagainst theoil pan may cause it to be bent against the pump screen, resulting in adamagedoil pickup unit. • Support the engine with a suitable jack. Do not load the engine mounting. 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 housing damage. • Raise the engine only enough to permit removal of the engine mounting. 2. Mounting assembly bolts, nuts, and washers. 3. Mounting assembly. Install or Connect (Figures 35 through 38) 1. Mounting assembly. NOTICE: See “Notice” on page 6A4-1 of this section. 2. Mounting assembly bolts, nuts, and washers. Tighten • Fasteners to specifications. Refer to figures 35 through 38. 3. Engine mount through-bolt and nut lower the engine until the bolt can be inserted. Install the nut. -a B Install or Connect (Figures 39 through 42) 1. Mounting. • Lower the rear of the engine. 2. Mounting to transmission bolts and washers. NOTICE: See “Notice” on page 6A4-1 of this section. 3. Mounting to crossmember nut(s) and washer(s). • Fasteners to specifications. Refer to figures 39 through 42. REAR MOUNTING REPLACEMENT (P MODELS WITH FLYWHEEL HOUSING MOUNTING) Remove or Disconnect (Figure 43) 1. Bolt, cushion, and spacer. NOTICE: Whenraisingor supporting theengine for anyreason, do not useajack under the oil pan, anysheet metal or crankshaft pulley. Due to the small clearance between theoil panand theoil pumpscreen, jackingagainst theoil pan may cause it to be bent against the pump screen, resulting in adamagedoil pickup unit. • Raise the rear of the engine only enough to permit removal of the mounting. 2. Engine mounting. Install or Connect (Figure 43) 1. Engine mounting. Align the hole in the mounting with the hole in the crossmember. • Lower the engine. NOTICE: See “Notice” on page 6A4-1 of this section. 2. Spacer, cushion, and bolt. • Through-bolt nut to specifications. Refer to figures 35 through 38. REAR MOUNTING REPLACEMENT (EXCEPT P-MODELS WITH FLYWHEEL HOUSING MOUNTING) Remove or Disconnect (Figures 39 through 42) NOTICE: Whenraisingor supporting theengine for anyreason, do not useajack under the oil pan, anysheet metal or crankshaft pulley. Due to thesmall clearance between the oil panand theoil pumpscreen, jackingagainst theoil pan may cause it to be bent against the pump screen, resulting in adamagedoil pickup unit. • Support the rear of the engine to relieve the 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. 3. Mounting. a Tighten • Bolt to 90 N-m (65 ft. lbs.). ENGINE REPLACEMENT R AND V MODELS Remove or Disconnect 1. Battery negative cable. 2. Hood. • Drain the cooling system. 3. Air cleaner. 4. All accessory drive belts. 5. Fan and water pump pulley. 6 . Radiator and shroud. Refer to RADIATOR (SEC. 6B2). 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. 6A4-24 SMALL BLOCK A. Forward B. 40 N m (30 Ft. Lbs.) C. Torque B olt 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 B olt To 48 N-m (36 Ft. Lbs.) Or, Torque Nut To 40 N-m (30 Ft. Lbs.) B-07621 Figure 35—Front Engine Mounting (R Models) SMALL BLOCK 6A4-25 152 A. 40 N m (30 ft. lbs.) B. Torque bo lt to 115 N m (85 ft. lbs.) Or, Torque nut to 75 N m (55 ft. lbs.). C. 48 N-m (36 ft. lbs.). D. 65 N-m (48 ft. lbs.). E. Forward 152. Transm ission S truck Bracket (A utom atic Transm ission) O r S pacer (Manual Transm ission) Figure 36—Front Engine Mounting (V Models) B-07622 6A4-26 SMALL BLOCK B. Torque B olt To 100 N m (75 Ft. L b s .) Or, Torque N ut To 48 N m (36 C. 48 N m (36 Ft. Lbs.) D. Torque B olt To 52 N m (38 Ft. Lbs.) Or, Torque Nut To 40 N-m (30 Ft. Lbs.) E. Torque B olt O r N ut to 40 N-m (30 Ft. Lbs.) 150. Spacer OR Power Steering Pump Bracket (Left Side Only) B-07919 Figure 37—Front Engine Mounting (G Models) Tighten 12. Fuel lines. 13. Vacuum lines from the intake manifold. • Raise the vehicle. Support with suitable safety stands. • Fasteners to specifications. Refer to figures 35 and 36. 16. Flywheel or torque converter underpan. 3. Bell housing to engine bolts. Remove the transmission support. 4. Converter to flex plate bolts. 5. Fuel gage wiring. 6 . Starter. 7. Wiring along oil pan rail. 17. W iring along oil pan rail. 8 . Flywheel or torque converter underpan. 18. Starter. 9. Strut rods at the engine mountings (V models with automatic transmission). • Drain the crankcase oil. 14. Exhaust pipes from the manifolds. 15. Strut rods at the engine m ountings (V models with automatic transmission). 19. W iring for fuel gage. 20. Converter to flex plate bolts. • Lower the vehicle. 10. Exhaust pipes to the manifolds. • Lower the vehicle. • Support the transm ission. 11. Vacuum lines to the intake manifold. • Attach a suitable lifting fixture. 12. Fuel line. 21. Bell housing to engine bolts. 13. Engine wiring harness. 22. Front engine m ounting to frame bolts. 14. Power steering pump (if used). 23. Engine. 15. Air conditioning compressor (if used). Install or Connect (Figures 35 and 36) 16. Accelerator, cruise control, and detent linkages. 17. Heater hoses. 1 . Engine to the vehicle. 18. Radiator and shroud. Refer to RADIATOR (SEC. 6B2). • Raise the vehicle. Support with suitable safety stands. 20. Air cleaner. NOTICE: See “Notice” on page 6A4-1 of this section. 2. Front engine mounting to frame bolts. 19. Accessory drive belts. 21. Hood. 22. Proper quantity and grade of coolant and crankcase oil. 23. Battery negative cable. SMALL BLOCK 6A4-27 A. F ro n t B. 100 N m (75 Ft. Lbs.) C. 48 N m (36 Ft. Lbs.) D. 40 N m (30 Ft. Lbs.) MODELS WITHOUT I-BEAM AXLE MODELS WITH I-BEAM AXLE (RP0-FS3) B-07920 Figure 38—Front Engine Mounting (P Models) G MODELS Remove or Disconnect 1. • 2. 3. 4. 5. Battery negative cable. Drain the cooling system. Coolant reservoir bottle. Grille and lower grille valance. Upper radiator support. A ir c o n d itio n in g c o n d e n s o r. R e fe r to AIR CONDITIONING (SEC. 1 B). 6 . Radiator. Refer to RADIATOR (6B2). 7. Power steering pump, and lay aside. 8 . Engine cover. 9. Air cleaner. 10. Carburetor or TBI unit. 11. Engine wiring harness from the conductor on the dash panel. 12. Vacuum hoses and electrical wiring, as required. 13. Heater hoses at the engine. 14. Therm ostat housing. 15. Oil filler tube. 16. Cruise control servo, bracket, and transducer (if equipped). • Raise the vehicle. Support with suitable safety stands. 17. Exhaust pipes at the exhaust manifolds. 18. P ro p e lle r s h a ft at the tra n s m is s io n . P lug the transm ission end. 19. Transmission shift linkage and speedometer cable. 20. Fuel and vapor return hoses at the engine. • Drain the engine oil. 21. Rear engine m ounting bolts. NOTICE: Whenraisingor supporting theengine for anyreason, do not useajack under the oil pan, anysheet metal or crankshaft pulley. Due to thesmall clearancebetween the oil panand theoil pumpscreen, jackingagainst theoil pan may cause it to be bent against the pump screen, resulting in adamagedoil pickup unit. • Support the engine with a suitable jack. 22. Front engine mounting bracket to frame bolts and nuts. 6A4-28 SMALL BLOCK ALL MODELS EXCEPT WITH THM 400 TRANSMISSION (RPQ-M40) A MODELS WITH THM 400 TRANSMISSION (RPO-M4Q) A. Forward B. 48 N m (36 Ft. Lbs.) B-07921 Figure 39—Rear Engine Mounting (R Models) SMALL BLOCK 6A4-29 23. Front engine mounting through bolts. 24. Front engine mounting frame brackets. Raise the engine slightly to allow removal of the mounting bracket. Block the engine in place with wood blocks. • Lower the vehicle. • Install a suitable lifting fixture. 25. Engine and transmission from the vehicle. 0 Install or Connect (Figure 37) NOTICE: Whenraisingor supporting theengine for anyreason, do not useajack under the oil pan, any sheet metal or crankshaft pulley. Due to thesmall clearancebetween theoil panand theoil pumpscreen, jackingagainst theoil pan may cause it to be bent against the pump screen, resulting in adamagedoil pickup unit. • Support the engine with a suitable jack. NOTICE: See “Notice” on page 6A4-1 of this section. 2. Engine m ounting frame brackets. A. 54 N m (40 Ft. Lbs.) B. 48 N m (36 Ft. Lbs.) C. F orw ard • Raise the engine slightly and position the brackets against the engine mountings. • Install the through-bolts finger tight. • Lower the engine. • Install the mounting bracket to frame bolts and nuts. B B-07897 F igure 40— Rear Engine M o u n tin g (V M odels) • E n g in e m o u n tin g fa s te n e rs specifications. Refer to figure 37. • Remove the jack. 3. Rear engine mounting bolts. to Tighten 4. 5. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20 . 21 . 22. • Engine m ounting to transmission bolts to 48 N-m (36 ft. lbs.). Fuel and vapor return lines. Transmission shift linkage and speedometer cable. Propeller shaft. Exhaust pipes. Lower the vehicle. Cruise control servo, bracket, and transducer (if equipped). Oil filler tube. Thermostat housing. Heater hoses. Vacuum hoses and electrical wiring. Engine wiring harness connector. Carburetor or TBI unit. Air cleaner. Power steering pump. Radiator. Refer to RADIATOR (SEC. 6B2). Air conditioning condensor (if equipped). Refer to AIR CONDITIONING (SEC. 1 B). Upper radiator support. Grille and lower grille valance. Coolant reservoir bottle. Battery negative cable. 6A4-30 SMALL BLOCK Figure 42—Rear Engine Mounting (P Models with Transmission Tail Type Mounting) SMALL BLOCK 6A4-31 B-07899 Figure 43—Rear 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. Refer to AIR CONDITIONING (SEC. 1 B). 6A4-32 SMALL BLOCK SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: Type Displacement RPO (VIN Code) Bore Stroke Compression Ratio Firing Order Oil Pressure V6 5.0L (305 Cu. In.) L03 (H) L05 (K) 5.7L (350 Cu. In.) LS9 (L) LT9 (M) 4.00 3.736 3.480 ★ 19.3 8.3:1 1-8 -4 -3-6 -5 -7-2 10 psi @ 500 RPM; 30-55 psi @ 2000 RPM CYLINDER BORE: Diameter Out Of Round 3.7350-3.7385 3.9995-4.0025 0.001 (Maximum) 0.002 (Maximum) 0.0005 (Maximum) 0.001 (Maximum) 0.001 (Maximum) Production Service Thrust Side Relief Side Taper Service PISTON: Production Service Limit 0.0007-0.0017 0.0027 (Maximum) PISTON RING: C n M p R Groove Production Service Limit s o Production Gap N 0 I L Groove Clearance Gap 0.0012-0.0032 2 nd Clearance F S I Top Hi Limit Production +0.001 Top 0 .010 -0.020 2 nd 0.010-0.025 Service Limit Hi Limit Production + 0.010 Production Service Limit Production Service Limit 0.002-0.007 Hi Limit Production + 0.001 0.015-0.055 Hi Production +0.010 Production Service Limit 0.9269-0.9271 0.0002-0.0007 0.001 (Maximum) 0.0008-0.0016 Interference PISTON PIN: Diameter Clearance In Piston Fit In Rod *8.6:1 w ith RPO-NA4 9.3:1 w ith RPO-NA1 SMALL BLOCK 6A4-33 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. DISPLACEMENT CRANKSHAFT: 5.0L (305 Cu. In.) #1 Diameter Main Journal #2, #3, #4 #5 Production Service Limit Production Service Limit Taper Out Of Round #1 Production Main Bearing Clearance #2, #3, #4 #5 #1 #2, #3, #4 #5 Service Limit Crankshaft End Play Diameter Production Service Limit Production Service Limit Production Service Limit Taper Crankpin Out Round Rod Bearing Clearance Rod Side Clearance 5.7L (350 Cu. In.) 2.4484-2.4493 2.4481-2.4490 2.4479-2.4488 0.0002 (Maximum) 0.001 (Maximum) 0.0002 (Maximum) 0.001 (Maximum) 0.0008-0.0020 0.0011-0.0023 0.0017-0.0032 0.0010-0.0015 0.0010-0.0025 0.0025-0.0035 0.002-0.006 2.0988-2.0998 0.0005 (Maximum) 0.001 (Maximum) 0.0005 (Maximum) 0.001 (Maximum) 0.0013-0.0035 0.003 (Maximum) 0.006-0.014 CAMSHAFT: Intake Exhaust Lobe Lift + 0.002 Journal Diameter Camshaft End Play 0.2336 0.2565 0.2565 0.2690 1.8682-1.8692 0.004-0.012 VALVE SYSTEM: Hydraulic 1.50:1 Lifter Rocker Arm Ratio Stem Clearance Valve Spring (Outer) Valve Spring Damper Production Service Free Length Pressure lbs. @ in. a Face Angle (Intake & Exhaust) Seat Angle (Intake & Exhaust) Seat Runout (Intake & Exhaust Seat Width One Turn Down From Zero Lash CT) cn o o Intake Exhaust Valve Lash Intake Exhaust Intake Exhaust Intake Exhaust Closed Open Installed Height ± V32" Free Length Approx. # of Coils 0.002 (Maximum) V32-V16 1/l 6-3/32 0.0010-0.0027 0.0010-0.0027 High Limit Production +0.001 High Limit Production +0.002 2.03 76-84 lbs. @ 1.70" 194-206 lbs. @ 1.25" 123/32 1.86 4 6A4-34 SMALL BLOCK SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item N-m Rocker Arm Cover Nuts (Carbureted Engines)......................................................... ........ 7.3 Rocker Arm Cover Bolts (TBI Engines)............................................................................... 11.3 Intake Manifold B o lts .............................................................................................................. 48 Exhaust Manifold B o lts ................................................................................................. Cast Manifolds: Two Center B o lts:............................................................................... 36 All O thers:.................................................................................... ........ 28 Tubular (Stainless Steel) Manifolds (All B olts)........................................................... 36 C ylinder Head B o lts ........................................................................................................ ........ 90 Torsional Damper B o lt............................................................................................................ 95 Front Cover B o lts ............................................................................................................ ........ 11.3 Oil Pan Nuts at C orners................................................................................................. ........ 22.6 Oil Pan Bolts..................................................................................................................... ........ 11.3 Oil Pump B o lt................................................................................................................... ........ 90 Oil Pan Baffle Nuts (Some 5.7L Engines).................................................................. ........ 34 Rear Crankshaft Oil Seal Retainer Screws and N u t s ............................................ ........ 15.3 Camshaft Sprocket B o lts ............................................................................................... ........ 24 Connecting Rod Cap N uts..................................................................................................... 60 Oil Filter Bypass Valve B o lts ........................................................................................ ........ 26 Main Bearing Cap Bolts Outer Bolts on #2, #3, and #4 C a p s .................................................................. ........ 95 All O th e r s ......................................................................................................................... 110 Oil Pump Cover Bolts . ............................................................................................... ........ 9.0 Flywheel B o lts ......................................................................................................................... 100 Spark P lu g s ..................................................................................................................... ........ 30 Water Outlet B o lts .......................................................................................................... ........ 28 Water Pump B o lts .......................................................................................................... ........ 40 Flywheel Housing B o lts ................................................................................................. ........ 44 Rocker Arm Cover Studs to Head (Carbureted Engines)................................................ 1.7 Oil Pan Studs to Back or Rear Oil Seal R e ta in e r........................................................... 1.7 Ft. Lbs. — — 35 26 20 26 65 70 — — — 65 25 — 18 45 20 70 80 — 75 22 21 30 32 — — In. Lbs. 65 100 100 200 100 135 80 15 15 SMALL BLOCK 6A4-35 SPECIAL TOOLS 1. J-23523-E 2. J-5892-B 3. J-23590 4. 5. 6. 10. J-3049 11 J-5802-01 12. 13. J-5715 J-6036 14. J-6880 15. J-5825-A 16. J-5590 17. J-8520 18. J-35621 J-35468 J-8080 J-8037 7. J-5239 8. J-23738-A 9. 1. 2. 3. 4. 5. 6. 7. 8. 9. A \ o ^ J-9290-01 T orsion al D am pe r R em ove r and In s ta lle r Valve S p rin g C o m p re s s o r A ir A d a p te r C ra n k s h a ft Seal In s ta lle r and C e n te rin g Tool M ain B e aring R ep lace r P isto n R ing C o m p re s s o r G u id e Set V a cuu m Pum p H y d ra u lic L ifte r R em ove r (S lid e H a m m e r Type) 10. 11. 12. 13. 14. 15. 16. 17. 18. H y d ra u lic L ifte r R em over (P lie r Type) S tu d R em over R eam er (0.003-inch oversize) R eam er (0.013-inch oversize) S tu d In s ta lle r C ra n k s h a ft G ear P u lle r C ra n k s h a ft G ear In s ta lle r Dial In d ic a to r A d a p te r R ear C ra n k s h a ft Seal In s ta lle r F-02562 6A4-36 SMALL BLOCK 6A5-1 SECTION 6A5 7 .4 L IT E R V 8 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 term inology “ NOTICE: See ‘Notice’ on page 6A5-1 of this section.” NOTICE: All engine 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 replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part. CONTENTS SUBJECT PAGE D e s c rip tio n ....................................................................................................................................................................................6 A 5 - 1 E ngine L u b ric a tio n ..................................................................................................................................................................6 A 5 - 1 O n-V ehicle S e r v ic e .................................................................................................................................................................... 6 A 5 - 3 R ocker A rm C over R e p la c e m e n t...................................................................................................................................... 6 A 5 - 3 R ocker A rm and P ushrod R e p la ce m e n t........................................................................................................................... 6 A 5 - 3 Valve A d ju s tm e n t.................................................................................................................................................................... 6 A 5 - 4 Valve Stem Seal and Valve S p rin g R e p la c e m e n t.........................................................................................................6 A 5 - 4 Intake JManifold R e p la c e m e n t............................................................................................................................................. 6 A 5 - 5 H yd ra u lic L ifte r R e p la c e m e n t............................................................................................................................................. 6 A 5 - 6 R ocke r Arm S tud R e p la c e m e n t.........................................................................................................................................6 A 5 - 7 E xhaust M anifold R e p la c e m e n t........................................................................................................................................ 6 A 5 - 7 C ylin d e r Head R e p la c e m e n t................................................................................................................................................6 A 5 - 7 T o rsio n a l D am per and F ro n t C ra nksh a ft Seal R e p la c e m e n t.................................................................................... 6 A 5 - 8 F ront C over R e p la c e m e n t.................................................................................................................................................... 6 A 5 - 9 Oil Pan R e p la c e m e n t............................................................................................................................................................. 6 A 5 -1 0 Oil Pum p R e p la c e m e n t.........................................................................................................................................................6A5-11 Rear C rankshaft Oil Seal R e p la c e m e n t........................................................................................................................... 6A5-11 M easuring C am shaft Lobe L i f t ................................................................................................................ ....................... 6 A 5 -1 3 C am shaft R e p la c e m e n t.........................................................................................................................................................6 A 5 -1 3 C o n ne cting Rod and P isto n R e p la ce m e n t.......................................................................................................................6 A 5 -1 5 Oil F ilte r Bypass V a lv e .........................................................................................................................................................6 A 5 -1 7 Main Bearing R e p la c e m e n t..................................................................................................................................................6 A 5 -1 7 C rankshaft R e p la c e m e n t...................................................................................................................................................... 6 A 5 -1 8 Flyw heel R e p la c e m e n t.........................................................................................................................................................6 A 5 -1 8 E ngine M o u n tin g s ..................................................................................................................................................................6 A 5 -1 9 Engine R e p la c e m e n t............................................................................................................................................................. 6 A 5 -2 2 S p e c ific a tio n s ............................................................................................................................................................................. 6 A 5 -2 7 S pecial T o o ls ............................................................................................................................................................................... 6 A 5 -3 0 DESCRIPTION 7.4L engines are 90-degree V 8 type, overhead valve, ENGINE LUBRICATION water cooled with cast iron block and heads.. . The crankshaft is supported by five precision insert mam bearings, with crankshaft thrust taken at the number Lubrication schematics are shown in Figure 1. The gear Qj| drjven frQm th \ 1 t i A. 4 m m (11/64-inc h) B. 13 m m (1/ 2 -in ch C. 0.10 m m (0.004- in c h ) s h im s to c k Apply Sealant to Shaded Areas Only B-03498 B.0525Q Figure 20—Oil Seal Installation Tool Figure 22—Applying Sealer to the Block 7.4 LITER V8 6A5-13 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. 2 . Lower seal half. • Coat the seal lips lightly with engine oil. Keep the oil off of the seal mating ends. • Insert the seal half into the rear main bearing cap. Use the tool to protect the seal half from the sharp edge of the seal seat. Feed the seal half into the rear main bearing cap, using light finger pressure. Make sure the oil seal lip faces the front of the engine (figure 21). Rear main bearing cap with the lower main bearing. • Apply a brush-on type oil sealing compound to the mating surface of the block and cap (figure 22). Do not a llo w any s e a la n t on e ith e r crankshaft or rear oil seal. • Apply engine oil to the lower main bearing. • Position the cap to the block. Install the cap bolts. • Rear main bearing cap bolts tem porarily to 14 N m (10 ft. lbs.). Tap the end of the crankshaft first rearward then forward with a lead hammer. This will line up the rear main bearing and crankshaft thrust surfaces. Tighten • Rear main bearing cap bolts to 150 N-m 110 ft. lbs.). 4. Oil pan and oil pump, as outlined previously. 5. The proper quantity and grade of engine oil. MEASURING CAMSHAFT LOBE LIFT Tools Required: J-8520 Camshaft Lobe Lift Indicator 1. Remove the rocker arm as outlined previously. 2. Refer to figure 23. Position the dial indicator (part of J-8520) so the plunger rests on the pushrod end, as shown. Make sure the pushrod is in the lifter socket. 3. Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the cam lobe. At this point, the pushrod will be in its lowest position. 4. Set dial indicator on zero, then rotate the crankshaft slowly, or attach an auxiliary starter switch and “ bum p” 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 jum per cable or other means, the prim ary leads should be disconnected from the distributor or ignition coil. 5. C om pare the to ta l lift recorded from th e d ial indicator with specifications. 6. If c a m s h a ft re a d in g s fo r all lo b e s are w ith in specifications, remove dial indicator assembly. 7. Install the rocker arm and adjust the valves as previously outlined. CAMSHAFT REPLACEMENT Remove or Disconnect (Figures 24, 25, and 26) Tool Required: J-1619 Crankshaft Sprocket Puller 1. Battery negative cable. 6A5-14 7.4 LITER V8 17. Camshaft sprocket and tim ing chain. The sprocket is a light interference fit on the camshaft. Tap the sprocket on its lower edge to loosen it. Figure 25—Replacing the Crankshaft Sprocket 2. Air cleaner. 3. Grille. 4. Air conditioning condensor from its mounting and swing it forward. 5. Fan, sh ro ud , and radiator. R efer to EN G IN E COOLING (SEC. 6B1) and RADIATOR (SEC. 6B2). 6. Generator and bracket. 7. Rocker arm covers, as outlined previously. 8. Fuel line (carbureted engines). 9. Water pump. Refer to ENGINE COOLING (SEC. 6B1). 10. Torsional damper, as outlined previously. 11. Front cover, as outlined previously. 12. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 13. Intake manifold, as outlined previously. 14. P u s h ro d s a nd h y d ra u lic lifte rs , as o u tlin e d previously. 15. Fuel pump and pushrod (carbureted engines). • Align the tim ing marks (figure 24). 16. Camshaft sprocket bolts. 18. Crankshaft sprocket (if required). Use J-1619 (figure 25). 19. Camshaft. • Install two or three 5/ie -1 8 bolts 100-125 mm (4-5 inches) long into the cam shaft threaded holes. Use these bolts to handle the camshaft (figure 26). • Pull the cam shaft from the block. Use care to prevent damage to the cam shaft bearings. Cleaning Inspection and Repair Clean, inspect and repair or replace the cam shaft and related components, as outlined in the proper unit repair manual. T he u nit re p air m anual also d e s c rib e s ca m sh aft bearing replacement. Install or Connect (Figures 24, 25, and 26) Tool Required: J-22102 Crankshaft Sprocket Installer Coat the camshaft lobes and journals with a high q u a lity engine oil su pp le m en t (GM Engine Oil Supplem ent or equivalent). Two or three 5/ie -1 8 bolts 100-125 mm (4 -5 inches) long into the camshaft threaded holes. Use these bolts to handle the camshaft. 2 . Cam shaft to the engine (figure 26). Handle the c a m s h a ft c a re fu lly to p re ve n t d am ag e to the camshaft bearings. 7.4 LITER V8 6A5-15 C rankshaft sprocket (if removed). Use J-22102 (figure 25). Make sure the tim in g m ark faces outside. Camshaft sprocket and tim ing chain. Important • Line up the tim ing marks on the camshaft sprocket and crankshaft sprocket (figure 24). Camshaft sprocket bolts. Tighten • Bolts to 27 N m (20 ft. lbs.). Fuel pump and pushrod (carbureted engines). H y d ra u lic lifte rs and p u s h ro d s , as o u tlin e d previously. | j I Important • Replace all hydraulic lifters, crankcase oil and filter, and add GM Engine Oil Supplem ent (or equivalent) to the engine oil whenever a new camshaft is installed. jP Adjust • Valves, as outlined previously. 8. Intake manifold, as outlined previously. 9. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 10. Front cover, as outlined previously. 11. Torsional damper, as outlined previously. 12. Water pump. Refer to ENGINE COOLING (SEC. 6B1). 13. Fuel line (carbureted engines). 14. Rocker arm covers, as outlined previously. 15. Generator and bracket. 16. Fan, sh ro ud , and radiator. R efer to E N G IN E COOLING (SEC. 6B1) and RADIATOR (SEC. 6B2). 17. Air conditioning condensor. 18. Grille. 19. Air cleaner. 20. Battery negative cable. • Fill the cooling system with the proper quantity and grade of coolant. CONNECTING ROD AND PISTON REPLACEMENT E3 1. 2. 3. 4. Remove or Disconnect (Figure 27) Tool Required: J-5239 Guide Set C ylinder head, as outlined previously. Oil pan, as outlined previously. Oil pump, as outlined previously (if necessary). Ridge or deposits from the upper end of the cylinder bores. • 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. • Turn the crankshaft until the piston is at TDC. • Remove the cloth and cuttings. Figure 27—Replacing the Connecting Rod and Piston 5. Connecting rod cap. Check the connecting rod and cap for id e n tifica tio n marks. M ark 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 27). • Use the long guide rod of J-5239 to push the connecting rod and piston out of the bore. 7. Connecting rod bearing. Cleaning, Inspection, and Repair Clean, inspect and repair or replace the components as necessary. Measure connecting rod bearing clearance, piston clearance, ring clearances, etc. Refer to the proper unit repair manual. The unit repair manual contains information on: — Connecting rod and piston. — Piston rings. — Connecting rod and crankpin. — Cylinder bores. Install or Connect (Figures 27 through 31) Tools Required: J-5239 Connecting Rod Guide Set J-8037 Ring Compressor • Make sure the cylinder walls are clean. Lubricate the cylinder wall lightly with engine oil. • Make sure the piston is installed in the m atching cylinder for which it was fitted. Used pistons must be installed in the cylinder they were removed from. 1. Connecting rod bearings. 6A5-16 7.4 LITER V8 6 ENGINE LEFT ENGINE FRONT ENGINE RIGHT B. 2nd C o m p re s s io n R ing Gap C. O il R ing S p a c e r G ap (Tang In H o le O r S lo t W ith Arc) D. Top C o m p re s s io n R ing Gap B-07935 Figure 28—Ring End Gap Location • Be certain that the bearings are of the proper size. • Install the bearings in the connecting rod and connecting rod cap. • Lubricate the bearings with engine oil. 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. • W ithout disturbing the ring end gap location, install J-8037 over the piston (figure 29). • The piston must be installed so that the valve clearance notches are towards the center of the engine (figure 30). • Place the piston in its matching bore. Using light blows with a hammer handle, tap the piston down into its bore (figure 29). At the same time, from beneath the vehicle guide the connecting rod to the crankpin with J-5239 (figure 27). Hold the ring compressor against the block until all rings have entered the cylinder bore. • Remove J-5239 from the connecting rod bolts. Im portant • Each connecting rod and bearing cap should be m arked, 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 cylind er to another, new connecting rod and bearings should be fitted and the connecting rod should be num bered to correspond with the new cylinder number. tU Measure • Connecting rod bearing clearance. Refer to the proper unit repair manual. 3. Connecting rod cap and bearing. 4. Connecting rod cap nuts. Q Tighten • Connecting rod cap nuts to 66 N m (48 ft. lbs.), tjj Measure • Connecting rod side clearance. Use a feeler g a g e b e tw e e n th e c o n n e c tin g rod and crankshaft (figure 31). The correct clearance is 0.013-0.023-inch. 7.4 LITER V8 6A5-17 Figure 31—Measuring Connecting Rod Side Clearance 5. Oil pump (if removed), as outlined previously. 6. Oil pan and cylinder head, as outlined previously. OIL FILTER BYPASS VALVE • Bolts (94) to 26 N m (20 ft. lbs.). 3. Oil filter. 4. Engine oil, as needed. Remove or Disconnect (Figure 32) 1. Oil filter. ]? Tighten Inspect • Bypass valve spring and valve disc for proper operation, cracks, and damage. If replacement is needed, the oil filter bypass valve (93) must be replaced, as follows: MAIN BEARING REPLACEMENT ++ 2. Bolts (94). 1. 2. 3. 4. 3. Oil filter bypass valve. Clean • Valve chamber in the block. |-n-| Install or Connect (Figure 32) 1. Oil filter bypass valve (93). 5. 2. Bolts (94). 6. 8. Remove or Disconnect (Figure 33) Tool Required: J-8080 Main Bearing Remover/Installer Spark plugs. Oil pan, as outlined previously. Oil pump, as outlined previously. Main bearing caps. • Check the main bearing caps for location markings. Mark the caps if necessary. The ca ps m ust be retu rne d to th e ir o rig in a l locations during assembly. Lower main bearing inserts from the main bearing caps. Rear crankshaft oil seal, if necessary, as outlined previously. Upper main bearing inserts. • Insert J-8080 into the crankshaft oil hole (figure 33). • Rotate the crankshaft to “ turn” the bearing insert out of the block. Cleaning, Inspection, and Repair A. Valve D isc 93. O il F ilte r B yp ass Valve 94. B o lt Figure 32—Oil Filter Bypass Valve Clean, inspect, and repair or replace the components as required. Refer to the proper unit repair manual. The unit repair manual contains information on: • Crankshaft. • Main and connecting rod bearings. • Main bearing cap replacem ent (shim m ing procedure). Instair or Connect (Figures 22, 33, and 34) B-05286 Tool Required: J-8080 Main Bearing Remover/Installer 1. Upper main bearing inserts. 6A5-18 7.4 LITER V8 • Insert tool J-8080 into a crankshaft main bearing oil hole (figure 33). • 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. • Remove the tool. 2. Lower main bearing inserts to the main bearing caps. • Make sure the inserts are of the proper size. • Apply engine oil to the inserts. Measure • Main bearing clearance. Refer to the proper unit repair manual. If the engine is in the vehicle, the crankshaft must be s u p p o rte d u p w a rd to re m o ve a ny clearance from the upper bearing. The total clearance can then be measured between the lower bearing and journal. 3. Main bearing caps (except rear cap) and bolts to the block. $ Tighten • Main bearing cap bolts to 150 N m (110 ft. lbs.). 4. Rear crankshaft oil seal to the block and main bearing cap, as outlined previously. 5. Rear main bearing cap. • Apply a brush-on type oil sealing compound to the mating surface of the block and cap (figure 22). Do not allow any sealant on either crank­ shaft or rear oil seal. • Apply engine oil to the bearing insert. • Install the rear main bearing cap and bolts. Tighten the bolts temporarily to 14 N m (10 ft. lbs.). A. F orw ard B. F e e le r G age 100. R ear M ain B e aring C ap 101. C ra n k s h a ft B-07878 Figure 34—Measuring Crankshaft End Play FLYWHEEL REPLACEMENT «■+ Remove or Disconnect 1. Transmission, flywheel housing, and clutch. 2. Flywheel bolts. 3. Flywheel. Clean Mating surfaces of crankshaft and flywheel. Remove any burrs. Inspect — Flywheel for burning, scoring, warping, and wear. Replace the flywheel if necessary. Do not machine the flywheel. — Flywheel ring gear for worn or broken teeth. Measure • Crankshaft end play, as follows: • Tap th e end of the cra n ksh a ft firs t re a rw a rd th en fo rw a rd w ith a lead hammer. This will line up the rear main bearing and crankshaft thrust surfaces. • Tighten the rear main bearing cap bolts to 150 N m (110 ft. lbs.). • W ith the cran ksha ft forced forw ard, measure at the front end of the rear main bearing with a feeler gage (figure 34). The p ro p e r c le a ra n c e is 0.006-0.010-inch. 6. Oil pump, as outlined previously. 7. Oil pan, as outlined previously. 8. Spark plugs. CRANKSHAFT REPLACEMENT Flywheel Ring Gear Replacement 1. Use a torch to heat the gear around the entire circumference, then drive the gear off the flywheel, using care not to damage the flywheel. NOTICE: Never heat starter gear to red heat as this will change metal structure. 2. Uniformly heat the flywheel gear to temperature which will expand the gear to perm it installation. Temperature must not exceed 200°C (400°F). 3. As soon as the gear has been heated, install on the flywheel. -►4- Install or Connect 1. Flywheel. 2. Flywheel bolts. Tighten 1. Remove the engine, as outlined later. 2. Refer to the proper unit repair manual for crankshaft replacement procedures. • Flywheel bolts to 90 N m (65 ft. lbs.). 3. Clutch, flywheel housing, and transmission. 7.4 LITER V8 6A5-19 ENGINE MOUNTINGS NOTICE: Broken or deteriorated mountings can cause misaligned and eventual destruction of certain drive train components. When a single m o u n tin g breakag e o ccu rs, the re m ain in g mountings are subjected to abnormally high stresses. INSPECTING ENGINE MOUNTINGS Front Engine Mountings NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal or crankshaft pulley. Due to the small clearance betw een the oil pan and the oil pump screen, jacking against the oil pan may cause it to be b ent against the pum p screen, resulting in a dam aged oil pickup unit. 1. R aise the e n g in e to rem ove w e ig h t from the m ountings and to place a slight tension on the rubber cushion. Observe both m ountings while raising the engine. 2. Replace the m ounting if the following conditions exist: — Hard rubber surface covered with heat check cracks. — Rubber cushion separated from the metal plate of the m ounting. — Rubber cushion split through the center. 3. If there is movement between a metal plate of the m ounting and its attaching points, lower the engine and tighten the bolts or nuts attaching the mounting to the engine, frame, or bracket. Rear Mountings 1. Push up and pull down on the transmission tailshaft. Observe the transm ission m ounting. 2. Replace the mounting if the following conditions exist: — M ounting bottom ed o ut (ta ilsh a ft can be moved up but not down). 3. If there is relative movement between a metal plate of the m ounting and its attaching point, tighten the b o lts o r nuts a tta c h in g th e m o u n tin g to th e transm ission or crossmember. FRONT MOUNTING REPLACEMENT +-► Remove or Disconnect (Figures 35, 36, and 37) 1. Battery negative cable. NOTICE: When raising or supporting the 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 the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be bent against the pum p screen, resulting in a dam aged oil pickup unit. • Support the engine with a suitable jack. Do not load the engine mounting. 2. Engine m ounting through-bolt and nut. NOTICE: Raise the engine only enough for sufficient clearance. Check for interference between the rear o f the engine and the dash panel which could cause distributor damage. • Raise the engine only enough to perm it removal of the engine mounting. 3. Mounting assembly bolts, nuts, and washers. 4. M ounting assembly. Install or Connect (Figures 35, 36, and 37) 1. M ounting assembly. NOTICE: See “ N o tice” on page 6 A 5 - 1 o f this section. 2. Mounting assembly bolts, nuts, and washers. Tighten • Fasteners to specifications. Refer to figures 35, 36, and 37. 3. Engine m ount through-bolt and nut. Lower the engine until the bolt can be inserted. Install the nut. • Through-bolt nut to specifications. Refer to figures 35, 36, and 37. 4. Battery negative cable. REAR MOUNTING REPLACEMENT (EXCEPT P-MODELS WITH FLYWHEEL HOUSING MOUNTING) Remove or Disconnect (Figures 38, 39, and 40) 1. Battery negative cable. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be bent against the pum p screen, resulting in a damaged oil pickup unit. • Support the rear of the engine to relieve the weight on the rear mountings. 2. Mounting to crossm em ber nut(s) and washer(s). 3. Mounting to transm ission bolts and washers. • Raise the rear of the engine only enough to permit removal of the mounting. 4. Mounting. Install or Connect (Figures 38, 39, and 40) 1. Mounting. • Lower the rear of the engine. 2. Mounting to transm ission bolts and washers. NOTICE: See “ N o tice” on page 6 A 5 - 1 o f this section. 3. Mounting to crossm em ber nut(s) and washer(s). 6A5-20 7.4 LITER V8 A. F orw ard B. 40 N-m (30 Ft. Lbs.) C. Torque B o lt To 115 N-m (85 Ft. Lbs.) Or, Torque N ut To 75 N-m (55 Ft. Lbs.) D. 48 N-m (36 Ft. Lbs.) E. Torque B o lt To 48 N-m (36 Ft. Lbs.) Or, Torque N ut To 40 N-m (30 Ft. Lbs.) 151. H eat S h ie ld (E n gine s W ith Federal E m is s io n s — L e ft S id e O nly) B-07714 Figure 35—Front Engine Mounting (R Models) 7.4 LITER V8 6A5-21 A. B. C. D. E. 151. 152. 40 N m (30 Ft. Lbs.) Torque B o lt to 115 N-m (85 Ft. Lbs.) Or, Torque N ut to 75 N-m (55 Ft. Lbs.) 48 N-m (36 Ft. Lbs.) 65 N-m (48 Ft. Lbs.) Forw ard H eat S h ie ld (E n g in e s w ith Federal E m is s io n s -L e ft S ide O nly) T ra n s m is s io n S tru t B ra cke t (A u to m a tic T ra n s m is s io n ) o r S p a c e r (M anual T ra n s m is s io n s ). B-07715 Figure 36—Front Engine Mounting (V Models) 6A5-22 7.4 LITER V8 A. B. C. D. Front 100 N m (75 Ft. Lbs.) 48 N m (36 Ft. Lbs. 40 N m (30 Ft. Lbs. (3/a-inch Nut); 65 N m (48 Ft. Lbs.) (7/ie-inch Nut) 151. Heat Shield (Engines w ith Federal Em issions Side Only) MODELS WITHOUT I-BEAM AXLE MODELS WITH I-BEAM AXLE (RPO-FS3) B-07716 Figure 37—Front Engine Mounting (P Models) $ Tighten • Fasteners to specifications. Refer to figures 38, 39, and 40). 4. Battery negative cable. REAR MOUNTING REPLACEMENT (P-MODELS WITH FLYWHEEL HOUSING MOUNTING) Remove or Disconnect (Figure 41) 1. Battery negative cable. 2. Bolt, cushion, and spacer. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause it to be bent against the pum p screen, resulting in a damaged oil pickup unit. • Raise the rear of the engine only enough to permit removal of the m ounting. 3. Engine mounting. 0 Install or Connect (Figure 41) 1. Engine m ounting. Align the hole in the m ounting with the hole in the crossmember. • Lower the engine. NOTICE: See “ N otice” on page 6 A 5 - 1 of this section. 2. Spacer, cushion, and bolt. Tighten • Bolt to 90 N m (65 ft. lbs.). 3. Battery negative cable. ENGINE REPLACEMENT Remove or Disconnect 1. Hood. 2. Battery negative cable. 3. Air cleaner. 7.4 LITER V8 6A5-23 ALL MODELS EXCEPT WITH THM 400 TRANSMISSION (RPQ-M40) MODELS WITH THM 400 TRANSMISSION (RPO-M40) A. Forward B. 48 N m (36 Ft. Lbs.) B-07921 Figure 38—Rear Engine Mounting (R Models) 6A5-24 7.4 LITER V8 Install or Connect (Figures 36, 37, and 38) 1. Engine in the vehicle. NOTICE: See “Notice” on page 6A5-1 of this section. 2. Engine m ounting through bolts and nuts. Tighten 3. • • 4. A. 54 N m (40 Ft. Lbs.) B. 48 N-m (36 Ft. Lbs.) C. Forw ard 5. 6. 7. 8. 9. 10. 11. 12. B B-07897 Figure 39— Rear Engine Mounting (V Models) 4. R a d ia to r and fa n s h ro u d . R e fe r to E N G IN E COOLING (SEC. 6B). 5. Necessary engine wiring: — Starter and solenoid wires. — Generator wires. — Temperature sensor wire. — Oil pressure sender wire. — Distributor or coil wires. — Any other necessary wiring. 6. Accelerator, cruise control and TVS linkages, as equipped. 7. Fuel supply line. 8. Necessary vacuum hoses: — Evaporative emission hoses. — Vacuum booster hose (if used). — Cruise control hose (if used). — Any other necessary vacuum hoses. 9. Power steering pump, and lay aside. 10. Air conditioning compressor, and lay aside. • Raise the vehicle. Support with suitable safety stands. 11. Exhaust pipes at the manifolds. 12. Starter. 13. Flywheel or torque converter cover. 14. Flex plate to torque converter bolts (autom atic transmission). • Lower the vehicle. • Support the transm ission. • Attach a suitable lifting fixture. 15. Bell housing to engine bolts. 16. Front engine m ounting through bolts. 17. Engine. 13. 14. 15. 16. 17. 18. • Fasteners to specifications. Refer to figures 36, 37, and 38. Bell housing bolts. Remove the lifting fixture and transmission jack. Raise the vehicle. Support with suitable safety stands. Flex plate to torque co nve rte r bolts (autom atic transmission). Flywheel or torque converter cover. Starter. Exhaust pipes at the manifolds. Air conditioning compressor. Power steering pump. Vacuum hoses. Fuel supply line. Accelerator, cruise control, and TVS linkages, as equipped. Engine wiring. R a d ia to r and fa n s h ro u d : R e fe r to E N G IN E COOLING (SEC. 6B). Air cleaner. Hood. Battery negative cable. Proper quantity and grade of coolant. 7.4 LITER V8 6A5-25 Figure 40—Rear Engine Mounting (P Models with Transmission Tail Type Mounting) 6A5-26 7.4 LITER V8 Figure 41—Rear Engine Mounting (P Models with Flywheel Housing Type Mounting) 7.4 LITER V8 6A5-27 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherw ise noted. GENERAL DATA: Type Displacement RPO Bore Stroke Compression Ratio Firing Order Oil Pressure CYLINDER BORE: Diameter Production Out Of Service Round Production Taper V8 7.4L (454 Cu. In.) L19, LE8 4.25 4.00 7.9:1 1-8-4-3-6-5-7-2 10 psi @ 500 RPM Minimum; 40-60 psi @ 2000 RPM 4.2495-4.2525 0.001 (Maximum) 0.002 (Maximum) 0.0005 (Maximum) 0.001 (Maximum) 0.001 (Maximum) Thrust Side Relief Side Service PISTON: Production Service Limit PISTON RING: C 0 Production uiuu ve M 0.003-0.004 0.005 (Maximum) oiecucmoe p H lparanrp R 1 0 2nd 0.0017-0.0032 Hi Limit Production +0.001 Top 0.010-0.020 2nd 0.010-0.020 Production Gap N 0 1 L 0.0017-0.0032 Service Limit t S S Top Groove Clearance PISTON PIN: Diameter Clearance In Piston Fit In Rod Service Limit Hi Limit Production + 0.010 Production Service Limit Production Service Limit 0.0050-0.0065 Hi Limit Production + 0.001 0.015-0.055 Hi Production +0.010 Production Service Limit 0.9895-0.9898 0.00025-0.00035 0.001 (Maximum) 0.0013-0.0021 Interference 6A5-28 7.4 LITER V8 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. DISPLACEMENT CRANKSHAFT: 7.4 L Diameter Main Journal Taper Out Of Round Main Bearing Clearance Production Service Limit #1, #2, #3, #4 #5 Production Service Limit Production Service Limit #1,#2, #3, #4 #5 #1, #2, #3, #4 #5 Crankshaft End Play Crankpin Taper Out Round Rod Bearing Clearance Rod Side Clearance Diameter Production Service Limit Production Service Limit Production Service Limit 2.7481-2.7490 2.7476-2.7486 0.0002 (Maximum) 0.001 (Maximum) 0.0002 (Maximum) 0.001 (Maximum) 0.0013-0.0025 0.0024-0.0040 0.0010-0.0025 0.0025-0.0035 0.006-0.010 2.1990-2.200 0.0005 0.001 0.0005 0.001 0.0009-0.0025 0.003 (Maximum) 0.0013-0.023 CAMSHAFT: Lobe Lift ± 0.002 Journal Diameter Intake Exhaust 0.2343 0.2530 1.9482-1.9492 VALVE SYSTEM: Lifter Rocker Arm Ratio Valve Lash Hydraulic 1.70:1 Intake Exhaust Face Angle (Intake & Exhaust) Seat Angle (Intake & Exhaust) Seat Runout (Intake & Exhaust L _ Intake Seat Width Exhaust Intake Production Stem Exhaust Clearance Intake Service Exhaust Free Length Pressure Closed Valve lbs. @ in. Open Spring Installed Height ± V32" Valve Spring Fit In Damper 3U Turn Down From Zero Lash 45° 46° 0.002 (Maximum) 1/32-1/l6 1/l6-3/32 0.0010-0.0027 0.0012-0.0029 High Limit Production +0.001 High Limit Production +0.002 2.12 74-86 lbs. @ 1.80 in. 195-215 lbs. @ 1.40 in. 151/64 0.042-0.094 Interference 7.4 LITER V8 6A5-29 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Nm Ft. L bs. ............................ ............................ ............................ 13.0 40 54 — In. Lbs. 115 30 40 — — ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ 110 115 10.8 7.9 18.1 90 150 26 66 26 90 9.0 40 40 40 30 80 85 — Ite m Rocker Arm Cover N u t s ........................................................... Intake Manifold B o lts.................................................................. Rocker Arm S tu d s ...................................................................... Exhaust Manifold Bolts Cylinder Head Bolts.................................................................... Torsional Damper B o lts ............................................................. Front Cover to Block B o lt s ....................................................... Oil Pan to Front Cover B o lts .................................................... Oil Pan to Block B o lts ............................................................... Oil Pump Bolt............................................................................... Main Bearing C a p s .................................................................... Camshaft Sprocket B olts........................................................... Connecting Rod Cap N u t s ....................................................... Oil Filter Bypass Valve B olts.................................................... Flywheel B o lts ............................................................................ Oil Pump Cover B o lts ............................................................... Flywheel Housing B olts............................................................. Water Pump B o lts ...................................................................... Water Outlet B o lts ........................ ............................................. Spark P lu g s ................................................................................. — — — 65 110 20 48 20 65 — 30 30 30 22 — 96 70 160 — — — — — — 80 — — — — 6A5-30 7.4 LITER V8 SPECIAL TOOLS J-23523-E 2. J-5239 J-5892-B 8. J-23590 J-9290-01 J-3049 4. J-22102 10. J-1619 5. J-8080 11. J-8520 6. J-8037 1. T o rsio n a l D a m p e r R em ove r and In s ta lle r 2. Valve S p rin g C o m p re s s o r 3. A ir A d a p te r 7 . G u id e Set 4. C ra n k s h a ft Seal In s ta lle r and C e n te rin g Tool 5. M ain B e aring R e p la ce r 6 . P isto n R ing C o m p re s s o r 8 . H y d ra u lic L ifte r R em over (S lid e H a m m e r Type) 9 H y d ra u lic L ifte r R em over (F lie r Type) 1 0 . C ra n k s h a ft S p ro c k e t P u lle r 11 . Dial In d ic a to r A d a p te r B-07719 Special Tools \ 6A6-1 SECTION 6A6 6.2L D IESEL T he follow ing “ N otice” app lie s to one or m ore steps in the a ssem bly procedure of com p on en ts in th is portion of the m anual as indicated at appro priate locations by the te rm ino log y “ NOTICE: See ‘ N otice’ on page 6 A 6-1 of th is s e c tio n .” NOTICE: All enginefastenersareimportant attachingpartsin that theycouldaffect theperformanceof vital components and systems, and/or could result in major repair expense. Theymust be replaced with one of the samepart number or with an equivalent part if replacement becomes necessary. Donot use areplace­ ment part of lesser quality or substitute design. Torque values must beusedasspecified during reassembly to assureproper retention of this part. CONTENTS SUBJECT PAGE D e s c rip tio n ................................................................................................................................................................ 6A 6- 2 Engine L u b rica tio n ............................................................................................................................................... 6A6- 2 On-Vehicle S e r v ic e ................................................................................................................................................. 6A6- 3 Intake Manifold R e p lace m e n t............................................................................................................................6A6- 3 Exhaust Manifold R eplacem ent.........................................................................................................................6A 6- 3 Rocker Arm Cover R e p la c e m e n t..................................................................................................................... 6A 6- 4 Rocker Arm, Shaft, and Pushrod R e p la ce m e n t........................................................................................... 6A 6- 5 Hydraulic Lifter R e p la ce m e n t............................................................................................................................6A 6- 6 Valve Stem Seal and Valve Spring R e p la ce m e n t......................................................................................... 6A 6- 8 Cylinder Head R e p la ce m e n t..............................................................................................................................6A 6- 9 Oil Pump Drive R e p la c e m e n t............................................................................................................................6A6-12 Torsional Damper and Front Crankshaft Seal R e p la ce m e n t......................................................................6A6-12 Front Cover R e p lace m e n t.................................................................................................................................. 6A6-13 Tim ing Chain and Sprocket R eplacem ent...................................................................................................... 6A6-14 Camshaft R e p la ce m e n t.......................................................................................................................................6A6-14 Dipstick Tube Replacement................................................................................................................................ 6A6-16 Oil Pan Replacement (R and V M o d els).......................................................................................................... 6A6-17 Oil Pump Replacement (R and V M o d e ls )...................................................................................................... 6A6-18 Oil Pan and Oil Pump Replacement (G M o d e ls )........................................................................................... 6A6-18 Rear Crankshaft Oil Seal R e p la c e m e n t.......................................................................................................... 6A6-18 Connecting Rod and Piston R eplacem ent...................................................................................................... 6A6-21 Main Bearing R eplacem ent............. .................................................................................................................. 6A6-22 Crankshaft R eplacem ent.................................................................................................................................... 6A6-24 Oil Filter Bypass Valve R eplacem ent...............................................................................................................6A6-24 Engine M ountings................................................................................................................................................. 6A6-25 Engine R e p la ce m e n t......................................... ................................................................................................. 6A6-28 S pecifica tio ns............................................................................................................................................................ 6A6-33 Special T o o ls ............................................................................................................................................................ 6A6-36 6A6-2 6.2 L DIESEL DESCRIPTION 13 A. B. C. D. F orw ard To O il C o o le r F rom O il C o o le r F rom O il P um p 10. 11. 12. 13. 14. 15. 16. 17. 18. R o cke r A rm C a m s h a fl: B e a rin g s O il C o o le r B yp a ss Valve O il F ilte r B yp ass Valve O il F ilte r C up Plug Plug Valve L ifte rs P u shro d F-08022 Figure 1—Lubrication Diagram 6.2 L diesel engines are 90 degree V8 type, naturally aspirated, with indirect type combustion chambers. The crankshaft is supported by five precision insert main bearings, with crankshaft thrust taken at the number three (center) main bearing. The camshaft is supported by five plain type bearings and is chain driven. Motion from the camshaft is transm it­ ted to the overhead valves by roller type hydraulic lifters, pushrods, and spindle mounted rocker arms. The valve guides are integral in the cylinder head. The connecting rods are forged steel, with precision in­ sert type crankpin bearings. The piston pins are retained by snap rings. ENGINE LUBRICATION A lubrication schem atic is shown in figure 1. The gear type oil pum p is driven from either the vacuum pump shaft or from a drive gear, depending on engine application. The vacuum pump or drive gear is driven by the cam shaft. Oil is drawn into the pum p through a pickup screen and pipe. Pressurized oil is routed to the oil cooler, located in the radiator. A bypass valve is provided should the oil cooler become restricted. Oil flows from the cooler to a full flow oil filter. An oil filter bypass valve is provided should the oil filter become restricted. O il flo w s fro m th e o il f ilt e r to th e o il galleries, providing pressurized lubrication to various components. The hydraulic valve lifters receive oil from the oil galleries. Oil flows from the hydraulic lifters through hollow pushrods to the rocker arms. Oil from the overhead drains back to the crankcase through oil drain holes. The pistons, piston rings, cylinder walls, and connecting rod small end bearing are lubricated by oil splash. 6.2 L DIESEL 6A6-3 ON-VEHICLE SERVICE Figure 2—Intake Manifold INTAKE MANIFOLD REPLACEMENT 3. Intake manifold bolts and fuel line clips. Tighten <--► Remove or Disconnect 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Tool R equired: J-29664 Manifold Cover Set Battery cables. Engine cover (G models). Air cleaner. EGR/EPR solenoids with bracket from the intake manifold studs. CDR valve (G models). EGR and crankcase ventilation hoses. R ear a ir c o n d itio n in g c o m p re s s o r b ra cke t (if equipped). Fuel line bracket and ground strap. Fuel filter bracket at the intake manifold (G models). Intake manifold bolts and fuel line clips. On models w ith g e a r d riv e n va cu u m p u m p s, it m ay be necessary to loosen the vacuum pump clam p bolt and turn the pump to provide access to an intake manifold bolt. Intake manifold and gasket. Im portant If any further service work is to be done, cover the intake ports with J-29664-1. Gasket surfaces on intake manifold and cylinder heads. -►4- Install or Connect (Figure 2) 1. New gaskets. Be sure to use the correct gasket. The gaskets fo r ligh t d uty e m issio n s m odels have openings for the EGR ports, the gaskets for heavy duty emissions models do not. Intake manifold. • 4. 5. 6. 7. 8. 9. 10. 11. 12. • Intake m an ifold bolts to 42 N m (32 ft. lbs.). U se th e tig h te n in g s e q u e n c e s h o w n in fig ure 2. Rotate the vacuum pump to the proper position and tighten the clam p bolt (gear driven vacuum pumps). Fuel filter bracket (G models). Fuel line bracket and ground strap. R ear a ir c o n d itio n in g c o m p re s s o r b ra c k e t (if equipped). EGR and crankcase ventilation hoses. CDR valve (G models). EGR/EPR solenoids with bracket. Air cleaner. Engine cover (G models). Battery cables. EXHAUST MANIFOLD REPLACEMENT R AND V MODELS (RIGHT SIDE) ++ Remove or Disconnect 1. Battery cables. • Raise the vehicle. Support with suitable safety stands. 2. Exhaust pipe from the manifold. • Lower the vehicle. 3. Glow plug wires. 4. Air cleaner duct bracket. 5. Glow plugs. 6. Exhaust manifold bolts and exhaust manifold. Clean Sealing surfaces on exhaust manifold and cylinder head. 6A6-4 6.2 L DIESEL — Threads on manifold bolts. |-K-| Install or Connect 1. Exhaust manifold and bolts. \^X\ Tighten 2. 3. 4. • 5. • 6. • Bolts to 35 N-m (26 ft. lbs.). Glow plugs. Air cleaner duct bracket. Glow plug wires. Raise the vehicle. Support with suitable safety stands. Exhaust pipe to the manifold. Lower the vehicle. Battery cables. R AND V MODELS (LEFT SIDE) ++ 1. 2. 3. 4. 5. • 6. 7. Remove or Disconnect Battery cables. Dipstick tube. Glow plugs. A ir c o n d itio n in g c o m p re s s o r re a r b ra c k e t (if equipped). Exhaust manifold bolts. Raise the vehicle. Support with suitable safety stands. Exhaust pipe at the manifold. Exhaust manifold, from below the vehicle. — Sealing surfaces on the exhaust m anifold and cylinder head. — Threads on the exhaust manifold bolts. 0 Install or Connect 1. Exhaust manifold, from below the vehicle. Loosely install two or three bolts to hold the manifold in place. 2. Exhaust pipe to the manifold. • Lower the vehicle. 3. R e m a in in g e x h a u s t m a n ifo ld b o lts and a ir conditioning com pressor rear bracket (if used). Clean — Sealing surfaces on the exhaust m anifold and cylinder head. — Threads on the manifold bolts. Install or Connect Exhaust manifold. E x h a u s t m a n ifo ld b o lts and a ir c o n d itio n in g com pressor rear bracket (if equipped) (left side exhaust manifold). Tighten • Bolts to 35 N-m (26 ft. lbs.). 3. Glow plug wires. 4. Engine cover. • Raise the vehicle. Support with suitable safety stands. 5. Exhaust pipe to the manifold. 6. Lower the vehicle. 7. Battery cables. ROCKER ARM COVER REPLACEMENT R AND V MODELS (BOTH SIDES) G MODELS (RIGHT SIDE) Remove or Disconnect 1. Intake manifold, as outlined previously. 2. Fuel in je c tio n lin e s . R e fe r to D IE S E L F U E L INJECTION (SEC. 6C2). (Injection lines for #5 and #7 cylinders do not have to be removed for right side rocker arm cover replacement). 3. Glow plug wires (G models). 4. W iring harness from wiring harness clip. 5. W iring harness bracket (left rocker arm cover). 6. Rocker arm cover bolts. NOTICE: Do not pry on the rocker arm cover. Damage to sealing surfaces may result. 7. Rocker arm cover. jQV Clean • Bolts to 35 N-m (26 ft. lbs.). 4. Glow plugs. 5. Dipstick tube. 6. Battery cables. G MODELS (BOTH SIDES) |+ + | Remove or Disconnect 1. Battery cables. • Raise the vehicle. Support with suitable safety stands. 2. Exhaust pipe at the manifold. • Lower the vehicle. 3. Engine cover. 4. Glow plug wires. 5. A ir c o n d itio n in g c o m p re s s o r re a r b ra c k e t (if equipped) (left side exhaust manifold). 6. Exhaust manifold bolts and exhaust manifold. 1. RTV from the rocker arm cover and cylinder head. All loose RTV, or pieces that will cause installation interference, must be removed. 2. Oil and grease from the sealing surfaces on the rocker arm cover and cylinder head. Use a suitable solvent. Inspect Rocker arm cover sealing flanges for distortion. Replace as necessary. Install or Connect (Figure 3) NOTICE: Do not allow RTV sealant into the rocker arm cover bolt holes. This may cause a “ hydraulic lo ck” condition when the bolts are tightened, damaging the cylinder head casting. • Apply a 5 mm (3/ie-inch) bead of RTV sealant (GM 6.2 L DIESEL 6A6-5 Inspect • Rocker arm cover sealing flanges for distortion. Replace as necessary. Install or Connect (Figure 3) NOTICE: Do not allow RTV sealant into the rocker arm cover bolt holes. This may cause a “ hydraulic lo c k ” condition when the bolts are tightened, damaging the cylinder head casting. 1. Rocker arm cover. Figure 3—A pplying Sealant to the Rocker Arm Cover 2. Rocker arm cover bolts and fuel return bracket. part number 1052915 or equivalent) to the cylinder head, inboard of the bolt holes. Refer to figure 3. The sealer must be wet to the touch when the bolts are torqued. 1. Rocker arm cover. 2. Rocker arm cover bolts. $ Tighten • Bolts to 22 N-m (16 ft. lbs.). W iring harness bracket. W iring harness to the w iring harness clip. G low plug w ires (G m odels). Fuel in je c tio n lines. R efer to D IE S E L F U E L IN JEC TIO N (SEC. 6C2). Intake m anifold, as o utline d previously. G MODELS (LEFT SIDE) |<-+| Remove or Disconnect 1. Intake m anifold, as o u tlin e d previously. 2. Fuel in je c tio n line s. R efer to D IE S E L F U E L IN JEC TIO N (SEC. 6C2). 3. U pper fan shroud (vehicles w ith a ir cond itio nin g). 4. A ir co nd itio nin g co m p re ssor belt (if equipped). 5. L eft e xh a u st m a n ifo ld , as o u tlin e d p re v io u s ly (vehicles w ith air co nd itio nin g). 6. A ir co n d itio n in g co m p re ssor (if equipped). Refer to AIR C O N D ITIO N IN G (SEC. 1B). 7. D ipstick tu be fron t bracket from stud. 8. W iring harness brackets. 9. R ocker arm cover bolts and fuel return bracket. NOTICE: Do not pry on the rocker arm cover. Damage to the sealing surfaces may result. 10. Rocker arm cover. 1. RTV from the rocker arm cover and cylinder head. All loose RTV, or pieces that will cause installation interference, must be removed. 2. Oil and grease from the sealing surfaces on the rocker arm cover and cylinder head.'U se a suitable solvent. 7. 8. 9. 10. • Bolts to 22 N m (16 ft. lbs.). W iring harness brackets. Dipstick tube front bracket. Air conditioning compressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). Left exhaust m anifold, as outlined previously (if removed). Air conditioning compressor belt (if equipped). Upper fan shroud (if removed). Fuel in je c tio n lin e s . R efer to D IE S E L F U E L INJECTION (SEC. 6C2). Intake manifold, as outlined previously. ROCKER ARM, SHAFT, AND PUSHROD REPLACEMENT + + Remove or Disconnect (Figures 4 and 5) Rocker arm cover, as outlined previously. Rocker arm shaft nuts. R ocker arm s h a ft w ith rocker arm s. M ark the assem blies so they can be returned to the original location at assembly. Pushrods. Im portant • The pushrods must be installed in the original direction at assembly. This is because the pushrods have a different degree of hardness at each end. A paint stripe identifies the upper end of the pushrod. If the paint stripe is not visible, mark the pushrods on the upper end as they are removed. • The pushrods should be installed in the same location at assembly. 5. Rocker arms, if required. • Insert a screwdriver into the rocker arm shaft bore, and break off the end of the nylon rocker arm retainers. • Remove the rocker arm retainers with pliers (figure 5). • Slide the rocker arms from the shaft. Install or Connect (Figures 4 and 6) 1. Rocker arms to the rocker arm shaft. One type of rocker arm is used at all locations. 6A6-6 6.2 L DIESEL Figure 4—Valve Train Components Im portant • Lubricate the rocker arms with engine oil before installing. 2. Rocker arm retainers. • Center the rocker arms on the corresponding holes in the rocker arm shaft. • Install new retainers. Use a drift of at least 13 mm (1/2-inch) diameter. • Rotate the engine counterclockwise 88 mm ( 3 1/2 -in c h e s ), m e a s u re d at th e to rs io n a l damper. This measurem ent can be estimated by aligning the torsional dam per mark with the first lower water pump bolt (figure 6). This procedure will position the engine so no valves are close to a piston crown. • Install both bolts snug on the shaft. Tighten NOTICE: The pushrods must be installed with the marked or painted end up. Failure to do so may result in damage or premature wear. 3. Pushrods, with the painted or marked end up. 4. Rocker arm shaft assembly. Make sure the ball ends of the pushrods seat in the rocker arms. NOTICE: Im proper installation of the rocker arm s h a ft b o lts m ay c a u s e r o c k e r arm s h a ft breakage and/or piston to valve contact. 5. Rocker arm shaft bolts. • Rotate the e n g in e u n til the m ark on the torsional dam per aligns with the “ 0 ” mark on the tim ing tab. • Bolts alterna te ly to 55 N m (40 ft. lbs.). 6. Rocker arm cover, as outlined previously. HYDRAULIC LIFTER REPLACEMENT Remove or Disconnect (Figures 4 and 7) Tool Required: J-29834 Hydraulic Lifter Remover (R and V Models) 1. Rocker arm covers, as outlined previously. 2. Rocker arm shaft with rocker arms and pushrods, as outlined previously. • Rocker arm assem blies and pushrods must be m arked for p ro pe r assem bly, as o u tlin e d previously. 3. Cylinder head, as outlined later (G models). 4. Clamps (32). 5. G u ide plates (33). Use m ech an ical fin ge rs, if necessary. 6. Hydraulic lifters, through the access hole in the cylinder head. On R and V Models, use J-29834 (figure 7) and a magnet. Place the lifters in an organizer rack. The lifters must be installed in the same bore from which they were removed. 6.2 L DIESEL 6A6-7 B-08027 Figure 6—A ligning the Tim ing Mark 1* Inspect Im portant H ydraulic lifte r body for scu ffing and scoring. Replace the lifter if present. Prime new hydraulic lifters before installation by working the lifter plunger while submerged in clean kerosene or diesel fuel. Roller for looseness and excessive play. Check for m issing or broken needle bearings. R eplace if necessary. Roller surface for pits and roughness. If present, the mating camshaft lobe should also be checked. If the lobe is pitted or rough, replace both camshaft and lifter. Hydraulic Lifter Repair • Refer to the proper unit repair manual. Im portant • S o m e e n g in e s w ill have b o th s ta n d a rd 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. Install o r Connect (Figure 4) NOTICE: New hydraulic lifters must be prim ed before installation. Damage to the lifters may result if dry when the engine is started. 1. Hydraulic lifters to the engine. On R and V models, fabricate an installation tool from m echanic’s wire. C o a t th e lifte r ro lle r and b e a rin g s w ith lu b ric a n t (GM p a rt n u m b e r 1052365 or equivalent). Lifters MUST be installed in th eir original locations. 2. Guide plates (33). 3. Clam ps (32). Q Tighten • Clamp bolt to 26 N m (18 ft. lbs.). Im portant • A fte r a ll c la m p s are in s ta lle d , tu rn th e cran ksha ft by hand 720 degrees (two full turns), to insure free movement of the lifters in the guide plates. If the engine will not turn over by hand, one or more of the lifters may be binding in the guide plate. 4. Cylinder head, as outlined later (G models). 5. Rocker arm shaft with rocker arm s and pushrods, in th e ir o rigin al locations, as outline d previously. Hardened ends of the pushrods must face up. 6. Rocker arm covers, as outlined previously. 6A6-8 6.2 L DIESEL J-26513-A J-29666 F-02468 Figure 9—Compressing the Valve Spring 2. Rocker arm shaft with rocker arms, as outlined previously. Mark the assem blies so they can be returned to their original locations. 3. Glow plugs. 4. Valve keepers. • Rotate the engine until the piston for the cylinder being serviced is at TDC. F-02467 • Install J-29666 into the glow plug hole. Figure 7—Removing the Hydraulic L ifte r (R and V Models) • Apply compressed air to hold the valves in place. VALVE STEM SEAL AND VALVE SPRING REPLACEMENT • Use J-26513-A to compress the valve spring (figure 9). If the spring will not compress, tap on the tool lightly with a mallet to break the cap or rotator loose from the valve keepers. Remove or Disconnect (Figures 8 and 9) Tools Required: J-29666 Air Line Adapter J-26513-A Valve Spring Compressor 1. Rocker arm covers, as outlined previously. 40. 41. 42. 43. Valve K e ep e r C ap S h ie ld Valve Seal • Remove the valve keepers. • C arefully release sp ring tension. Remove J-26513-A. 5. Cap or rotator, shield, and valve spring with damper. 6. Valve seal. 0 Install or Connect (Figures 8 and 9) Tools Required: J-29666 Air Line Adaptor J-26513-A Valve Spring Compressor 1. New valve seal. 2. Valve spring with damper, shield and cap or rotator. 3. Valve keepers. • W ith air pressure applied to the cylinder with J-29666, co m p re ss the valve s p rin g w ith J-26513-A (figure 9). • Install the valve keepers. Use grease to hold them in place. 43 44. Valve S p rin g w ith D a m p e r 45. In ta ke Valve 46. R o ta to r 47. E xh a u s t Valve p-02411 • Carefully release spring pressure. Make sure the valve keepers stay in place. • Remove J-26513-A and J-29666. 5. Glow plugs. 6. Rocker arm shaft with rocker arms, as outlined previously. Figure 8—Valves and Components 7. Rocker arm covers, as outlined previously. 6.2 L DIESEL 6A6-9 Im portant CYLINDER HEAD REPLACEMENT REMOVAL (R AND V MODELS) (BOTH SIDES) Remove or Disconnect 1. Intake manifold, as outlined previously. 2. Injection lines. Refer to DIESEL FUEL INJECTION (SEC. 6C2). 3. Rocker arm covers, as outlined previously. • Drain the cooling system. 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. S upport with suitable safety stands. 7. Exhaust pipe from the manifold. Lower the vehicle. 8. Air conditioning com pressor (if equipped) and lay aside (left cylinder head). 9. Generator, and lay aside (right cylinder head). 10. Glow plug wires. 11. Glow plug temperature inhibit switch wire (right cylinder head). 12 Rocker arm assem blies and pushrods, as outlined previously. • 13. 14. 15. 16. 17. 18. 19. REMOVAL (G MODELS) (LEFT SIDE) Remove or Disconnect Important 13. 14. 15. 16. 17. • Rocker arm assem blies and pushrods must be m arked fo r p ro pe r assem bly, as o u tlin e d previously. Radiator, bypass and heater hoses. Ground strap. Water crossover pipe/therm ostat housing assembly. Cylinder head bolts. Rear bolt in left cylinder head may have to remain in the head during removal. Cylinder head. REMOVAL (G MODELS) (RIGHT SIDE) B Remove or Disconnect 1. Intake manifold, as outlined previously. 2. Injection lines. Refer to DIESEL FUEL INJECTION (SEC. 6C2). 3. Transducer (cruise control equipped vehicles). 4. Upper fan shroud and air conditioning compressor belt (vehicles with air conditioning). • Raise the vehicle. S upport with suitable safety stands. 5. Exhaust pipe at the manifold. 6. Rear air conditioning compressor bracket at the exhaust manifold (if equipped). 7. Glow plug wires. • Lower the vehicle. 8. Air conditioning compressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). 9. Dipstick tube front bracket from the stud. 10. Oil fill tube upper bracket. 11. Rocker arm cover, as outlined previously. 12. Rocker arm assemblies and pushrods, as outlined previously. • Rocker arm assemblies must be marked for proper assembly, as outlined previously. Drain the cooling system. Air cleaner resonator and bracket. Transmission dipstick tube. Heater, radiator and bypass hoses at the engine. Generator upper bracket. Water crossover pipe/therm ostat assembly. Cylinder head bolts. C ylinder head. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Intake m anifold, as outlined previously. Injection lines at the injection pump. Refer to DIESEL FUEL INJECTION (SEC. 6C2). Transducer (cruise control equipped vehicles). Upper fan shroud and air conditioning compressor belt (vehicles with air conditioning). Raise the vehicle. Support with suitable safety stands. Left exhaust m anifold, as outlined previously. Power steering pump lower adjusting bolts. Glow plug wires. Glow plug temperature inhibit switch. Injection lines. Refer to DIESEL FUEL INJECTION (SEC. 6C2). Lower the vehicle. Air conditioning com pressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). Upper power steering pum p brackets. Lay the pump aside. Dipstick tube front bracket from the stud. Transmission detent cable. Glow plug controller, bracket, and relay. W iring harness bracket. Vacuum line clip, at the cylinder head. Fuel return line bracket. Rocker arm cover, as outlined previously. Rocker arm assem blies and pushrods, as outlined previously. Im portant • 20. 21. 22. 23. 24. 25. • Rocker arm assemblies must be marked for proper assembly, as outlined previously. Drain the cooling system. Air cleaner resonator and bracket. Transmission dipstick tube at the front attaching stud and lay aside. Generator upper bracket. Water crossover pipe/therm ostat assembly. C ylinder head bolts. C ylinder head. CLEANING AND INSPECTION — Carbon deposits from combustion chambers. — All traces of old head gasket from cylinder head and b lo c k . Use o f a m oto rize d w ire b ru s h is not recommended. 6A6-10 6.2 L DIESEL A d d itio n a l s e a le r m ay ca u se leakage or m alfunction. In addition, some sealers may attack the sealant already on the head gasket. 2. Rear cylinder head bolt to the cylinder head (left c y lin d e r head). A p p ly s e a la n t to th e b o lt as described in step 4. Due to clearances, the bolt must be installed at this time. 3. C ylinder head. Make sure the gasket surfaces are clean. Guide the head carefully into place over the dowel pins. 4. Cylinder head bolts. • Make sure the bolt threads are clean. • Apply sealant (GM part num ber 1052080 or equivalent) to the bolt threads and under the bolt heads. Tighten — Cylinder head bolt threads using a wire brush. — Metal chips and dirt from the threads in the block. I? Inspect — Cylinder head for cracks between the intake and exhaust ports. Use the m agnaflux or dye method if available. — Sealing surfaces of the block and cylinder head for nicks, heavy scratches, or other damage. • Cylinder head bolts, as follows: • U sing the sequ en ce show n in fig u re 10, tighten all bolts to 25 N-m (20 ft. lbs.). • In sequence, tighten all bolts to 65 N-m (50 ft. lbs.). • In sequence, tighten all bolts an additional 90 degrees ( 1/4 turn). 5. Water crossover pipe/therm ostat assembly. Use new gaskets. — Block for missing or damaged dowel pins, or dowel pins in the wrong location. Measure — Cylinder head warpage. If warped more than 0.15 mm (0 .0 0 6 -in c h ) lo n g itu d in a lly o r 0.08 mm (0.003-inch) transversely, replace the cylinder head. Resurfacing is not recommended. — Pre-cham ber installed depth. The pre-cham ber s h o u ld be flu s h to a m a x im u m of 0.05 mm (0.002-inch) protrusion. • Make the measurement at two or more points on the pre-cham ber where the prechamber seats on the head gasket shield and sealing ring. • Measure the difference between the flat of the p re -ch a m b e r and the fla t surfa ce of the cylinder head. • The pre-cham ber must not protrude out of the cylinder head more than 0.05 mm (0.002-inch). • The pre-chamber must not be recessed into the cylinder head. CYLINDER HEAD REPAIR • Refer to the proper unit repair manual. INSTALLATION (R AND V MODELS) (BOTH SIDES) Install or Connect (Figure 10) 1. Head gasket to the block, over the dowel pins. Im portant The block gasket surfaces must be clean. DO NOT use a sealer on the head gasket. The head gasket is manufactured with the proper amount of sealant “ printed” on its surface. • Bolts to 42 N-m (31 ft. lbs.). 6. Ground strap. 7. Radiator, bypass, and heater hoses. 8. Pushrods and rocker arm assem blies, in th eir o rig in a l lo c a tio n s , as d e s c rib e d p re v io u s ly . Hardened ends of the pushrods must face up. 9. Glow plug temperature inhibit switch wire (right cylinder head). 10. Glow plug wires. 11. Generator (right cylinder head). 12. A ir co n d itio n in g com pressor (left side cylind er head). • Raise the vehicle. S upport with suitable safety stands. 13. Exhaust pipe to the manifold. • Lower the vehicle. 14. Glow plug relay (left cylinder head). 15. Ground wire at the cowl (right cylinder head). 16. Dipstick tube (left cylinder head). 17. Rocker arm covers, as outlined previously. 18. Injection lines. Refer to DIESEL FUEL INJECTION (SEC. 6C2). 19. Intake manifold, as outlined previously. • Fill the cooling system with the proper quantity and grade of coolant. INSTALLATION (G MODELS) (RIGHT SIDE) Install or Connect (Figure 10) 1. Head gasket to the block, over the dowel pins. | ^ I Im portant • The block gasket surfaces must be clean. • DO NOT use a sealer on the head gasket. The head gasket is m anufactured with the proper amount of sealant “ printed” on its surface. 6.2 L DIESEL 6A6-11 A d d itio n a l s e a le r m ay ca use lea kag e or m alfunction. In addition, some sealers may attack the sealant already on the head gasket. Cylinder head. Make sure the gasket surfaces are clean. Guide the head carefully into place over the dowel pins. 3. C ylinder head bolts. • Make sure the bolt threads are clean. • Apply sealant (GM part num ber 1052080 or equivalent) to the bolt threads and under the bolt heads. • Cylinder head bolts, as follows: • Using the sequence shown in figure 10, tighten all bolts to 25 N m (20 ft. lbs.). • In sequence, tighten all bolts to 65 N m (50 ft. lbs.). • In s e q u e n c e , tig h te n a ll b o lts an additional 90 degrees (1/4 turn). 4. Water crossover pipe/therm ostat assembly. Use new gaskets. 5. 6. 7. 8. 9. 10. 11. 12. 13. • 14. 15. 16. • 17. 18. 19. 20. • • Bolts to 42 N m (31 ft. lbs.). Generator upper bracket. Heater, radiator, and bypass hoses. Transmission dipstick tube. Air cleaner resonator and bracket. Pushrods and rocker arm assem blies, in th e ir o rig in a l lo c a tio n s , as d e s c rib e d p re v io u s ly . Hardened ends of the pushrods must face up. Rocker arm cover, as outlined previously. Oil fill tube upper bracket. Dipstick tube front bracket. Air conditioning com pressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). Raise the vehicle. S upport with suitable safety stands. Glow plug wires. R ear a ir c o n d itio n in g co m p re s s o r b ra c k e t (if equipped). Exhaust pipe. Lower the vehicle. Upper fan shroud and air conditioning compressor belt (vehicles with air conditioning). Transducer (if equipped). Injection lines. Refer to DIESEL FUEL INJECTION (SEC. 6C2). Intake manifold, as outlined previously. Fill the cooling system with the proper quantity and grade of coolant. A d d itio n a l s e a le r m ay ca u se leakage or m alfunction. In addition, some sealers may attack the sealant already on the head gasket. 2. Cylinder head. Make sure the gasket surfaces are clean. Guide the head carefully into place over the dowel pins. 3. Cylinder head bolts. • Make sure the bolt threads are clean. • Apply sealant (GM part number 1052080 or equivalent) to the bolt threads and under the bolt heads. & T ig h te n • C ylinder head bolts, as follows: • Using the sequence shown in figure 10, tighten all bolts to 25 N m (20 ft. lbs.). • In sequence, tighten all bolts to 65 N m (50 ft. lbs.). • In s e q u e n c e , tig h te n a ll b o lts additional 90 degrees (1/4 turn). an 4. Water crossover pipe/therm ostat assembly. Use new gaskets. T ig h te n • Bolts to 42 N m (31 ft. lbs.). 5. Generator upper bracket. 6. Transmission dipstick tube. 7. Air cleaner resonator and bracket. 8. Pushrods and rocker arm assem blies, in th e ir o rig in a l lo c a tio n s ; as d e s c rib e d p re v io u s ly . Hardened ends of the pushrods must face up. 9. Rocker arm cover, as outlined previously. 10. Fuel return line bracket. 11. Vacuum line clip. 12. W iring harness bracket. 13. Glow plug controller, bracket, and relay. 14. Transmission detent cable. 15. Dipstick tube front bracket. 16. Power steering pump and brackets. 17. Air conditioning compressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). • Raise the vehicle. Support with suitable safety stands. 18. Injection lines. Refer to DIESEL FUEL INJECTION (SEC. 6C2). 19. Glow plug temperature inhibit switch. 20. Glow plug wires. 21. Power steering pump lower adjusting bolts. 22. Left exhaust manifold, as outlined previously. INSTALLATION (G MODELS) (LEFT SIDE) ♦«" Install or Connect (Figure 10) 1. Head gasket to the block, over the dowel pins. Im p o rta n t The block gasket surfaces must be clean. DO NOT use a sealer on the head gasket. The head gasket is manufactured with the proper amount of sealant “ printed” on its surface. • Lower the vehicle. 23. Upper fan shroud and air conditioning compressor belt (vehicles with air conditioning). 24. Transducer (if equipped). 25. Intake manifold, as outlined previously. Fill the cooling system with the proper quantity and grade of coolant. Evacuate and charge the air conditioning system. Refer to AIR CONDITIONING (SEC. 1B). 6A6-12 6.2 L DIESEL F orw ard O il P um p Drive C lam p B o lt G a sket B-08031 Figure 11—Oil Pump Drive OIL PUMP DRIVE REPLACEMENT For gear driven vacuum pump replacement, refer to VACUUM PUMP (SEC. 6H). NOTICE: Do not run the engine without the gear driven vacuum pum p or oil pum p drive in place. This will cause extensive engine damage. Remove or Disconnect (Figure 11) -► * 1. • 2. Bolt and clamp. Oil pump drive. 3. Install or Connect (Figure 13) Tool Required: J-22102 Seal Installer New front crankshaft seal. Use J-22102 (figure 13). Lubricate the seal lips with engine oil. Apply engine oil to the crankshaft stub. Torsional damper. Tap into place with a mallet. Make sure the key is in place. Make sure the dam per is all the way on the crankshaft. Torsional dam per bolt and washer. Gasket. Install or Connect (Figure 11) 1. New gasket to the oil pump drive. 2. Oil pump drive to the engine. Index the drive with the camshaft gear and oil pump drive shaft. Make sure the drive seats fully. 3. Clamp and bolt. Tighten Bolt to 42 N-m (31 ft. lbs.). TORSIONAL DAMPER AND FRONT CRANKSHAFT SEAL REPLACEMENT ++ F-02472 Remove or Disconnect (Figure 12) Tools Required: Figure 13—Installing the Front Crankshaft Seal J-23523-E Torsional Damper Puller 1. Battery cables. 2. Upper fan shroud (G models). • Bolt to 270 N-m (200 ft. lbs.) 4. Crankshaft pulley and bolts. 3. Accessory drive belts. • Raise the vehicle (G models). Support with suitable safety stands. 4. Bolts and crankshaft pulley. 5. Torsional dam per bolt and washer. 6. Torsional damper. Use J-23523 (figure 12). 7. Front crankshaft seal. Pry out with a screwdriver. • Bolts to 40 N-m (30 ft. lbs.). Lower the vehicle, if necessary. A cce ssory drive belts. Tension as o u tlin e d ENGINE COOLING (SEC. 6B). Upper fan shroud (G models). Battey cables. in 6.2 L DIESEL 6A6-13 A. A p p ly A n a e ro b ic S e a le r B. M in im u m C le a ra n ce 1.0 m m (0.040-inch) 80. F ro n t C ove r 81. B a ffle 82. P robe H o ld e r 83. C a m s h a ft G ear B-08033 Figure 14—Front Cover and Components FRONT COVER REPLACEMENT 2. Front cover to the engine. Install the attaching bolts. Remove or Disconnect (Figures 14 and 15) □ • Drain the cooling system. 1. Water pump. Refer to ENGINE COOLING (SEC. 6B). • Rotate the engine until the tim ing marks on the pump gear and cam shaft gear are aligned (figure 15). • Scribe a mark aligning the injection pump flange and front cover. 2. Torsional damper, as outlined previously. 3. Four front cover to oil pan bolts. 4. Two fuel return line clips. 5. Injection pump gear. 6. Injection pump retaining nuts at the front cover. 7. Baffle. 8. Front cover bolts. 9. Front cover. 10. Front crankshaft seal. Pry out with a screwdriver. Tighten Front cover to block bolts to 45 N m (33 ft. lbs.). Oil pan to front cover bolts to 10.0 N m (84 in. lbs.). 3. Baffle. Q Tighten • Baffle bolts and nut to 45 N m (33 ft. lbs.). • Align the scribe marks on the front cover and injection pump. If a new front cover was installed, refer to “ M arking TDC on the Front Housing” in DIESEL FUEL INJECTION (SEC. 6C2). 4. Injection pump nuts. — RTV from oil pan sealing surface. — Sealing surfaces on front cover. L * Inspect 0 F ront co ver fo r cra cks or d am ag e to s e a lin g surfaces. Install or Connect (Figures 14 and 15) Tool Required: J-22102 Seal Installer 1. New front crankshaft seal to the front cover. Use J-22102. • Apply a 2 mm (3/32-inch) bead of anaerobic sealant (GM part num ber 1052357 or equivalent) to the front cover sealing area shown in Figure 14. Apply a 5 mm (3/ie-inch) bead of RTV sealant to the front cover sealing surface that mates against the oil pan. A. T im in g M arks 83. C a m s h a ft G ear 84. In je c tio n P um p G ear B-08034 Figure 15—Injection Pump Gear and Timing Marks 6A6-14 6.2 L DIESEL A. 83. 90. 91. T im in g M arks C a m s h a ft G ear C a m s h a ft S p ro c k e t C ra n k s h a ft S p ro c k e t B-08035 • Move the chain inward (parallel to the front face of the block) the maximum am o un t w ith fin g e r pressure on the outside of the chain. • The total indicator travel can be noted. With used parts, the deflection must not exceed 20.3 mm (0.800 inch). If the d e fle c tio n e x c e e d s th is lim it, th e sprockets and tim in g chain m ust be inspected fo r w ear and replaced as necessary. W ith new parts the maximum deflection m ust not exceed 12.7 mm (0.500 inch). Injection pump gear. Cam shaft gear. Align the tim ing marks (figure 16). Cam shaft sprocket with tim ing chain. Crankshaft sprocket. Install or Connect (Figures 14 and 16) Figure 16—Tim ing Chain and Sprockets Tighten Nuts to 42 N m (31 ft. lbs.). Injection pump gear and bolts. Align the tim ing marks (figure 15). 1. Crankshaft sprocket. 2. Camshaft sprocket with tim ing chain. Im portant • Align the tim ing marks (figure 16). Cam shaft gear, bolt, and washer. Tighten ^X Injection pump gear bolts to 23 N m (17 ft. lbs.). • Bolt to 100 N m (75 ft. lbs.) Injection pump gear and bolts. Im portant Measure • Clearance between injection pump gear and baffle (figure 14). It is necessary to maintain a minimum of 1.0 mm (0.040-inch) between the gear and baffle, or noise may result. 6. Fuel return line boits. 7. Torsional damper, as outlined previously. 8. Water pump. Refer to ENGINE COOLING (SEC. 6B). • Fill the cooling system with the proper quantity and grade of coolant. TIMING CHAIN AND SPROCKET REPLACEMENT Remove or Disconnect (Figure 16) 1. Front cover, as outlined previously. Measure Tim ing chain free play as follows: • Mount a dial indicator to the front of the block. • Position the dial indicator so that the p lu n g e r c o n ta c ts th e tim in g c h a in between the two gears. • Pull the chain outward (parallel to the front face of the block) the maximum am o un t w ith fin g e r p ressure on the inside of the chain. • Set the dial indicator to zero. Tighten Align the tim ing marks (figure 15). £ Tighten • Bolts to 23 N m (17 ft. lbs.). 5. Front cover, as outlined previously. Adjust • Injection pump tim ing, if new gears, sprockets, or tim ing chain were installed. Refer to DIESEL FUEL INJECTION (SEC. 6C2). CAMSHAFT REPLACEMENT R AND V MODELS Remove or Disconnect (Figure 17) 1. Battery cables. • Drain the cooling system. 2. R adiator, shrouds, and fan. R efer to ENG INE COOLING (SEC. 6B). 3. Vacuum pump. Refer to VACUUM PUMP (SEC. 6H). 4. P o w e r s te e rin g p u m p , g e n e ra to r, a nd a ir conditioning compressor and position aside. 5. Rocker arm covers, as outlined previously. 6. Rocker arm assemblies and pushrods, as outlined previously. Im portant Rocker arm assem blies and pushrods must be m arked for p ro pe r assem bly, as o u tlin e d previously. 6.2 L DIESEL 6A6-15 Tighten • Bolts to 23 N m (17 ft. lbs.). • Lower the engine. 100 NOTICE: See “ N o tic e ” on page 6A6-1 o f this section. 102 100. 101. 102. 103. 104. B o lt T h ru s t Plate Key S p a ce r C a m s h a ft B-08036 4. Engine m ounting through bolts and nuts. • Fasteners to specifications. Refer to figures 34 and 35. 5. Tim ing chain and sprockets, as outlined previously. Im portant Figure 17—Camshaft and Components 7. Hydraulic lifters, as outlined previously. Place the lifters in an organizer rack. The lifters must be installed in the same bore from which they were removed. 8. Front cover, as outlined previously. 9. Tim ing chain and cam shaft sprocket, as outlined previously. 10. Fuel pump (lift pump). 11. Front engine mounting through bolts. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance betw een the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be b en t against the pum p screen, resulting in a dam aged oil pickup unit. • Raise the engine and block in position. 12. A ir co n d itio n in g co n d e n so r m ou ntin g bolts (if equipped). Lift the condensor with the aid of an assistant. 13. Bolts and thrust plate. 14. Camshaft. Pull the cam shaft from the block carefully to avoid damage to the camshaft bearings. 15. Spacer (if necessary). Cleaning, Inspection and Repair Clean, inspect and repair or replace the camshaft and related components, as outlined in the proper unit repair manual. The u nit re p air m anual also d e scrib e s ca m sh aft bearing replacement. Install or Connect (Figures 16, 17, 34 and 35). • When a new camshaft is installed, replacement of all hydraulic lifters, engine oil, and oil filte r is recommended. 1. Spacer, with the ID cham fer towards the camshaft. 2. Camshaft. • Coat the camshaft lobes with “ Molykote” or equivalent. • Lubricate the cam shaft bearing journals with engine oil. • Insert the cam shaft carefully into the block to avoid damage to the camshaft-bearings. 3. Thrust plate and bolts. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. • • Align the tim ing marks (figure 16). Air conditioning condensor (if equipped). Fuel pump (lift pump). Front cover, as outlined previously. Hydraulic lifters, as outlined previously. Used lifters must be installed in the same bore from which they were removed. Rocker arm a ssem blies and pushrods, in th e ir original locations, as outlined previously. Hardened ends of the pushrods must face up. Rocker arm covers, as outlined previously. P o w e r s te e r in g p u m p , g e n e ra to r, a n d a ir conditioning compressor, as equipped. Vacuum pump. Refer to VACUUM PUMP (SEC. 6H). Fan, radiator, and ra d ia to r sh ro u d s. R efer to ENGINE COOLING (SEC. 6B). Battery cables. Fill the cooling system with the proper quantity and grade of coolant. G MODELS Remove or Disconnect (Figure 17) 1. 2. 3. 4. 5. 6. 7. • 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Battery cables. Headlight bezels. Grille, bumper, and lower valence panel. Hood latch. Coolant recovery bottle. Upper tie bar. A ir c o n d itio n in g c o m p re s s o r. R e fe r to A IR CONDITIONING (SEC. 1B). Drain the cooling system. R adiator and fan. Refer to ENG INE CO O LING (SEC. 6B). Oil pump drive, as outlined previously. Cylinder heads, as outlined previously. Generator lower bracket. Water pump. Refer to ENGINE COOLING (SEC. 6B). Torsional damper, as outlined previously. Front cover, as outlined previously. Fuel pum p (lift pump). Rocker arm covers, as outlined previously. Rocker arm assemblies and pushrods, as outlined previously. 6A6-16 6.2 L DIESEL ; 18. 19. 20. 21. 22. Important • Rocker arm assem blies and pushrods must be m arked fo r p ro pe r assem bly, as o u tlin e d previously. Hydraulic lifters, as outlined previously. Place the lifters in an organizer rack. The lifters must be installed in the same bore from which they were removed. Timing chain and camshaft sprocket, as outlined previously. Bolts and thrust plate. Camshaft. Pull the cam shaft from the block carefully to avoid damage to the camshaft bearings. Spacer, if necessary. Cleaning, Inspection and Repair Clean, inspect and repair or replace the camshaft and related components, as outlined in the proper unit repair manual. The u nit re p air m anual also d e scrib e s ca m sh aft bearing replacement. 0 Install or Connect (Figures 16 and 17). • When a new cam shaft is installed, replacement of all hydraulic lifters, engine oil, and oil filte r is recommended. 1. Spacer, with the ID cham fer towards the camshaft. 2. Camshaft. • Coat the cam shaft lobes with “ Molykote” or equivalent. • Lubricate the camshaft bearing journals with engine oil. • Insert the cam shaft carefully into the block to avoid dam age to the camshaft bearings. 3. Thrust plate and bolts. • Bolts to 23 N m (17 ft. lbs.). 4. Timing chain and camshaft sprocket, as outlined previously. • Align the tim ing marks (figure 16). 5. Hydraulic lifters, as outlined previously. Used lifters must be installed in the same bore from which they were removed. 6. Rocker arm a ssem blies and pushrods, in th eir original locations, as outlined previously. Hardened ends of the pushrods must face up. 7. Rocker arm covers, as outlined previously. 8. Fuel pump (lift pump). 9. Front cover, as outlined previously. 10. Torsional damper, as outlined previously. 11. Water pump. Refer to ENGINE COOLING (SEC. 6B). 12. Generator lower bracket. 13. Cylinder heads, as outlined previously. 14. Oil pump drive, as outlined previously. 15. R adiator and fan. R efer to ENGINE C OOLING (SEC. 6B). 16. A ir c o n d itio n in g c o m p re s s o r. R e fe r to A IR CONDITIONING (SEC. 1B). 17. Upper tie bar. 18. Coolant recovery bottle. 19. Hood latch. 20. 21. 22. • Grille, bumper, and lower valence panel. Headlight bezels. Battery cables. Fill the cooling system with the proper quantity and grade of coolant. • Evacuate and charge the air conditioning system (if equipped). Refer to AIR CONDITIONING (SEC. 1B). DIPSTICK TUBE REPLACEMENT R AND V MODELS Remove or Disconnect (Figure 18) 1. Battery cables. 2. D ipstick tu be bracket, nut and washer, at the exhaust manifold. 3. Dipstick tube. 4. O-ring from the dipstick tube. *►+ Install or Connect (Figure 18) 1. 2. 3. 4. New o-ring to the dipstick tube. Dipstick tube to the engine. Dipstick tube bracket nut and washer. Battery cables. G MODELS Remove or Disconnect (Figure 19) 1. 2. 3. 4. 5. • 6. 7. • 8. 9. Battery cables. Engine cover. Air cleaner. Dipstick tube bracket, at the therm ostat housing. D ipstick tube bracket, at the rocker arm cover bracket. Raise the vehicle. S upport with suitable safety stands. Left exhaust manifold, as outlined previously. Dipstick tube from the oil pan. Lower the vehicle. Dipstick tube from the vehicle. O-ring. 6.2 L DIESEL 6A6-17 Figure 20—Oil Pan and Oil Pump NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be bent against the pum p screen, resulting in a damaged oil pickup unit. Install or Connect (Figure 19) 1. New O-ring to the dipstick tube. 2. Dipstick tube to the vehicle. • Raise the vehicle. Support with suitable stands. 3. Dipstick tube to the oil pan. 4. Left exhaust manifold, as outlined previously. • 4. 5. 6. • Lower the vehicle. 5. Dipstick tube bracket at the rocker arm cover. 6. Dipstick tube bracket at the therm ostat housing. Clean 7. Air cleaner. 1. Old RTV from the oil pan and block. 2. All oil and grease from the gasket surfaces. 8. Engine cover. 9. Battery cables. OIL PAN REPLACEMENT (R AND V MODELS) Remove or Disconnect 1. Battery cables. • Raise the vehicle. Support with suitable safety stands. • Drain the engine oil. 2. Flywheel cover. 3. Left front engine m ounting through-bolt. Raise the engine. Oil pan bolts. Oil pan. Oil pan rear seal. □ Install or Connect (Figures 20, 34, and 35) • Apply a 5 mm (3/ie-inch) bead of RTV sealant (GM part num ber 1052915 or equivalent) to the oil pan sealing surface, inboard of the bolt holes (figure 20). The sealer must be wet to the touch when the oil pan is installed. 1. Oil pan rear seal. 2. Oil pan to the engine. Be sure to connect the oil dipstick. 3. Oil pan bolts. & Tighten — All except rear two bolts to 10.0 N-m (84 in. lbs.). — Rear two bolts to 23 N-m (17 ft. lbs.). 6A6-18 6.2 L DIESEL • Lower the engine. • Let the oil pump and extension shaft fall into the oil pan. • Remove the oil pan and oil pan rear seal. NOTICE: See “Notice” on page 6A6-1 of this section. 4. Engine mounting through-bolt and nut. Tighten 5. • 6. 7. • Fasteners to specifications. Refer to figures 34 and 35. Flywheel cover. Lower the vehicle. Proper quantity and grade of engine oil. Battery cables. 1. Old RTV from the oil pan and block. 2. All oil and grease from the gasket surfaces. I? Inspect — Oil pump pick up tube and screen for damage. — Oil pump extension shaft bushing for cracks. Oil Pump Repair • Refer to the proper unit repair manual, OIL PUMP REPLACEMENT (R AND V MODELS) Remove or Disconnect (Figure 20) 1. Oil pan, as outlined previously. 2. Oil pump to main bearing cap bolt. 3. Oil pump and extension shaft. I? Inspect — Oil pump pick up tube and screen for damage. — Oil pump extension shaft bushing for cracks. -►+ Install or Connect (Figure 20) • Apply a 5 mm (3/ie-inch) bead of RTV sealant (GM part num ber 1052915 or equivalent) to the oil pan sealing surface, inboard of the bolt holes (figure 18). The sealer must be wet to the touch when the oil pan is installed. 1. Oil pan rear seal to the oil pan. 2. Oil pan and oil pump to the engine. • Lay the oil pump and extension shaft in the oil pan. • Hold the oil pan and position the oil pump to the main bearing cap. Oil Pump Repair • Align the extension shaft hex with the drive hex on the oil pump drive or vacuum pump. The oil pump should push easily into place. Install the oil pump bolt and tighten. Refer to the proper unit repair manual. 0 Install or Connect (Figure 20) Oil pump and extension shaft to the engine. Align the extension shaft hex with the drive hex on the oil pump drive or vacuum pump. The oil pump should push easily into place. Oil pump bolt. & • Position the oil pan against the engine. Be sure to connect the dipstick tube. 3. Oil pan bolts. & Tighten • Oil pump bolt to 90 N m (65 ft. lbs. 3. Oil pan, as outlined previously. OIL PAN AND OIL PUMP REPLACEMENT (G MODELS) Remove or Disconnect 1. Battery cables. 2. 3. 4. • 5. • 6. 7. 8. 9. Engine cover. Engine oil dipstick. Engine oil dipstick tube at the rocker arm cover. Raise the vehicle. Support with suitable safety stands. Transmission. Refer to TRANSMISSION (SEC. 7). Drain the engine oil. Engine oil cooler lines at the block. Starter. Oil pan bolts. Oil pan and oil pump. • Lower the oil pan from the engine. • Rotate the crankshaft so that the forward c ra n k s h a ft th ro w and n u m b e rs 1 and 2 connecting rod journals are up. • Oil pump to main bearing cap bolt. 4. 5. 6. • 7. 8. 9. Tighten — 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.). Starter. Engine oil cooler lines. Transmission. Refer to TRANSMISSION (SEC. 7). Lower the vehicle. Engine oil dipstick tube at the rocker arm cover. Engine oil dipstick. Engine cover. 10. Proper quantity and grade of engine oil. 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 ch ecke d b efo re a new seal is in s ta lle d . R efer to DRIVEABILITY AND EMISSIONS— DIESEL (SEC. 6E9). 6.2 L DIESEL 6A6-19 A. C u t O ff S e c tio n O f O ld R ope Seal B. Use B e a rin g C ap A s H o ld in g F ix tu re B-08041 Figure 22—C utting the Rope Seal A. U pper Seal G roove B-08040 Figure 21—Packing the Upper Rear Crankshaft Rope Seal ROPE TYPE SEAL ++ Remove or Disconnect 1. Oil pan and oil pump, as outlined previously. 2. Rear main bearing cap. 3. Old rope seal from the main bearing cap. Do not discard. Use J-33154-2 to work the short pieces of seal cut previously onto the guide tool and into the seal groove in the block (figure 23). It may help to use engine oil on the seal pieces. The tools have been machined to provide a built-in stop. Use this procedure for both sides. New rope seal to the main bearing cap. Apply adhesive (GM part num ber 1052621 [Loctite 414] or equivalent) to the seal groove. Position the rope seal on the bearing cap. Use J-33153 to install the seal (figure 24). A fter co rrectly p ositioning the seal, rotate J-33153 slightly and cut the seal ends flush with the bearing cap surface. Use a sharp tool (figure 24). Measure Rear main bearing clearance, using plastic gaging material. Refer to the proper unit repair manual. If the clearance is out of specification, Clean — Main bearing cap and block mating surfaces. — Rope seal groove in the main bearing cap. 0 Install or Connect (Figures 21 through 24) 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 21. • Measure the amount the seal was driven up on one side. Add 1.5 mm (Vis-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 22). Use a sharp tool. Repeat this procedure for the other side. • Install J-33154-1 onto the cylinder block (figure 23). Figure 23—Installing the Rope Seal Pieces Rear Main Bearing Cap 6A6-20 6.2 L DIESEL & A. A p p ly A n a e ro b ic S e ale r B. A fte r C o rre c tly P o s itio n in g Seal, R o ta te Tool S lig h tly A nd C ut O ff Each End O f Seal F lu sh W ith Cap. Tighten Bolts to specifications, in the following sequence: • Inner bolts: 150 N m (110 ft. lbs.). • Outer bolts: 135 N m (100 ft. lbs.). • Re-tighten all bolts in the same sequence. 4. Oil pump and oil pan, as outlined previously. J-33153 TWO PIECE TYPE SEAL Remove or Disconnect Oil pan and oil pump, as outlined previously. Rear main bearing cap. Upper and lower rope seal. JH J| B-08043 Figure 24—Installing the Lower Rope Seal Piece 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 m ain 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 num ber 1052756 or equivalent) to the bearing cap as shown in figure 25. Keep the sealant off the seal and bearing. Do not put sealant in the bearing cap oil relief slot. • A p p ly a lig h t c o a t of e n g in e o il to th e crankshaft surface that will contact the seal. • Apply engine oil to the main bearing cap bolt threads. • Tap the main bearing cap into place with a brass or leather mallet. Then install the bolts. Clean 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 the clearance is outside specifications, correct as necessary. Install or Connect (Figures 25 and 26) 1. Seal halves to the block (figure 26). • Apply a light coat of engine oil to the seal lips where they contact the crankshaft. • “ R oll” one seal half into the block seal groove until 13 mm (1/2-inch) of the seal’s one end is extending out of the block. • Insert the other seal half into the opposite side of the seal groove in the block. Important The contact ends of the seal halves should now be at the four and ten o’clock positions, or at the eight and two o’clock positions. This is necessary to align the rear main bearing cap and seal lips. N O T IC E : To p re v e n t d a m a g e to th e m ain bearing caps, the caps are to be tapped into the block using a brass or leather hammer. The new seal is used as a guide. The cap must NOT be pulled into the block with the bolts. A. O il R e lie f S lo t B. A p p ly A n a e ro b ic S e a le r to S haded A rea F-02475 Figure 25—Applying Sealer to the Rear Main Bearing Cap 2. Main bearing cap to the block. • Lig htly coat the seal groove in the main bearing cap with adhesive (GM part num ber 1052621 [Loctite 414] or equivalent). • Apply a thin film of anaerobic sealant (GM part num ber 1052756 or equivalent) to the main bearing cap as shown in figure 25. Do not put sealant in the oil relief slot. • Apply engine oil to the main bearing cap bolt threads. • Tap the main bearing cap into place with a brass or leather mallet. Then install the bolts. 6.2 L DIESEL 6A6-21 A. Use s h o rt p ie c e s o f 10 m m (3/s-inch) h o se to p ro te c t th e c ra n k s h a ft jo u rn a l. B-08045 INSTALLING THE UPPER SEAL HALF Figure 27—Replacing the Connecting Rod and Piston INSTALLING THE LOWER SEAL HALF Figure 26—Installing the Two Piece Rear Crankshaft Seal • Place a cloth on top of the piston. • Perform the cutting operation with a ridge reamer. • Turn the crankshaft until the piston is at TDC. • Remove the cloth and cuttings. Connecting rod cap. Check the connecting rod and cap for id e n tifica tio n marks. M ark the parts if required. The connecting rod and cap must be kept together as mating parts. Connecting rod and piston. • Attach two short pieces of 10 mm (3/s-inch) hose to the connecting rod bolts (figure 27). This will protect the crankshaft journal during removal. • Push the connecting rod and piston out of the bore. Connecting rod bearings. Place the bearings in a rack if they are to be reused, so they can be returned to their original locations. Cleaning, Inspection and Repair • Main bearing cap bolts to specifications, in the following sequence: • Inner bolts: 150 N m (110 ft. lbs.). • Outer bolts: 135 N m (100 ft. lbs.). • Re-tighten all bolts using the same sequence. 3. Oil pump and oil pan, as outlined previously. CONNECTING ROD AND PISTON REPLACEMENT ++ 1. 2. 3. 4. Remove or Disconnect (Figure 27) C ylinder head, as outlined previously. Oil pan, as outlined previously. Oil pump, as outlined previously. Ridge or deposits from the upper end of the cylinder bores. • Turn the crankshaft until the piston is at BDC. Clean, inspect and repair or replace the components as necessary. Measure connecting rod bearing clearance, piston clearance, ring clearances, e tc Refer to the proper unit repair manual. The unit repair manual contains information on: — Connecting rod and piston. — Piston rings. — Connecting rod and crankpin. — Cylinder bores. Install or Connect (Figures 27 through 30) Tool Required: J-8037 Ring Compressor • Make sure the cylinder walls are clean. Lubricate the cylinder wall lightly with engine oil. • Make sure the piston is installed in the m atching cylinder. Install new pistons in the cylinders for which they were fitted. Install used pistons in the cylinder from which they were removed. 1. Connecting rod bearings. 6A6-22 6.2 L DIESEL Figure 28—Ring Gap Location Figure 29—Installing the Piston and Connecting Rod • Be certain that the bearings are the proper size. • Install the bearings in the connecting rod and connecting rod cap. • Lubricate the bearings with engine oil. • Connecting rod bearing clearance. Refer to the proper unit repair manual. 3. Connecting rod cap and bearing. 2. Piston and connecting rod to the proper bore. 4. Connecting rod cap nuts. • With the connecting rod cap removed, install two short pieces of 10 mm (3/e-inch) hose onto the connecting rod studs. • Locate the piston ring end gaps as shown in figure 28. Lubricate the piston and rings with engine oil. • W ithout disturbing the ring end gap location, install J-8037 over the piston (figure 29). • The piston m ust be installed so that depression in the piston crown is towards outside of the engine. The connecting b ea rin g ta ng slots m ust be o pp osite camshaft. Measure the the rod the Tighten Connecting rod cap nuts to 65 N m (48 ft. lbs. Measure • Connecting rod side clearance. Use a feeler g a g e b e tw e e n th e c o n n e c tin g rod and crankshaft (figure 30). The correct clearance is 0.17-0.63 mm. 5. Oil pump (if removed), as outlined previously. 6. Oil pan and cylinder head, as outlined previously. MAIN BEARING REPLACEMENT • Place the piston in its m atching bore. Using light blows with a hammer handle, tap the piston down into its bore (figure 29). At the same time, from beneath the vehicle guide the connecting rod to the crankpin with the pieces of hose (figure 27). Hold the ring compressor against the block until all rings have entered the cylinder bore. 2. Oil pan, as outlined previously. • Remove the hoses from the connecting rod bolts. 4. Main bearing caps. Remove or Disconnect (Figure 31) Tool Required: J-8080 Main Bearing Remover/Installer 1. Glow plugs. 3. Oil pump, as outlined previously. 6.2 L DIESEL 6A6-23 Q B-04580 Figure 30—Checking Connecting Rod Side Clearance • Check the main bearing caps for location markings. Mark the caps if necessary. The caps m ust be re tu rn e d to th e ir o rig in a l locations during assembly. 5. Lower main bearing inserts from the main bearing cafes. 6. Rear crankshaft oil seal, if necessary, as outlined previously. 7. Upper main bearing inserts. • Insert J-8080 into the crankshaft oil hole (figure 31). • Rotate the crankshaft to “ tu rn ” the bearing insert out of the block. -►«- Install or Connect (Figures 26, 31 and 32) Tool Required: Cleaning, Inspection and Repair Clean, inspect and repair or replace the components as required. Refer to the proper unit repair manual. The unit repair manual contains information on J-8080 Main Bearing Remover/Installer 1. Upper main bearing inserts. • Insert tool J-8080 into a crankshaft main bearing oil hole (figure 31). • Crankshaft. • Apply engine oil to inserts of the proper size. • Main and connecting rod bearings. • 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. • Remove the tool. 2. Lower main bearing inserts to the main bearing caps. • Make sure the inserts are of the proper size. • Apply engine oil to the inserts. Measure • Main bearing clearance. Refer to the proper unit repair manual. If the engine is in the vehicle, the crankshaft m ust be supported upward to remove any clearance from the upper bearing. The total clearance can then be measured between the lower bearing and journal. 3. Rear crankshaft oil seal (if necessary) as outlined previously. 6A6-24 6.2 L DIESEL 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. 4. Number 5 (rear) main bearing cap. • Apply a thin film of anaerobic sealant (GM part num ber 1052756 or equivalent) to the bearing cap as shown in figure 25. Keep the sealant off the seal and bearing. Do not put sealant in the bearing cap oil relief slot. • A p p ly a lig h t c o a t of e n g in e o il to th e crankshaft surface that will contact the seal. • Apply engine oil to the main bearing cap bolt threads. REMOVAL • Tap the main bearing cap into place with a brass or leather mallet. Then install the bolts. • Bolts to specifications, in the following sequence: • Inner bolts: 150 N m (110 ft. lbs.). • Outer bolts: 135 N m (100 ft. lbs.). • Re-tighten all bolts in the same sequence. 5. Numbers 1, 2, and 4 main bearing caps and bolts. Tighten • Bolts to specifications. Refer to step 46. Number 3 (center) main bearing cap and bolts. Tighten the bolts tem porarily to 14 N m (10 ft. lbs.). INSTALLATION Measure • Crankshaft end play, as follows: • Tap th e end of th e c ra n k s h a ft firs t re a rw a rd th e n fo rw a rd w ith a lead hammer. This will line up the rear main bearing and crankshaft tnrust surfaces. • Tighten the rear main bearing cap bolts to specifications. Refer to step 4. • W ith the cra n ksh a ft forced forw ard, measure at the front end of the num ber 3 main bearing with a feeler gage (figure 32). The proper clearance is 0.10-0.25 mm. 7. Oil pump, as outlined previously. F-02474 Figure 33—Replacing the Oil Filter Bypass Valve OIL FILTER BYPASS VALVE REPLACEMENT |<~+| Remove or Disconnect (Figure 33) 1. Oil filter. 2. Oil filter bypass valve. Pry out with a screwdriver. jiS Clean • Recess in the block. 8. Oil pan, as outlined previously. 9. Glow plugs. CRANKSHAFT REPLACEMENT |-K-| Install or Connect (Figure 33) 1. Oil filter bypass valve. Tap into place, using a 16 mm socket. 1. Remove the engine, as outlined later. 2. Oil filter. 2. Refer to the proper unit repair manual for crankshaft replacement procedures. 3. Engine oil, as required. 6.2 L DIESEL 6A6-25 ENGINE MOUNTINGS NOTICE: Broken or deteriorated mountings can cause misaligned and eventual destruction of certain drive train components. When a single m o u n tin g breakag e o ccu rs, the re m ain in g mountings are subjected to abnormally high stresses. INSPECTING ENGINE MOUNTINGS Front Engine Mountings NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cuase it to be bent against the pum p screen, resulting in a dam aged oil pickup unit. 1. R aise the e n g in e to rem ove w e ig h t from the m ountings and to place a slight tension on the rubber cushion. Observe both m ountings w hile raiding the engine. 2. Replace the m ounting if the following conditions exist: — Hard rubber surface covered with heat check cracks. — Rubber cushion separated from the metal plate of the mounting. — Rubber cushion split through the center. 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 Mountings 1. Push up and pull down on the transmission tailshaft. Observe the transm ission m ounting. 2. Replace the m ounting if the following conditions exist: — Rubber cushion separated from the metal plate of the mounting. — M ou ntin g bottom ed o ut (ta ilsh a ft can be moved up but not down). 3. If there is relative movement between a metal plate of the m ounting and its attaching point, tighten the b o lts or n u ts a tta c h in g th e m o u n tin g to th e transm ission or crossmember. FRONT MOUNTING REPLACEMENT Remove or Disconnect (Figures 34 through 37) NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be bent against the pum p screen, resulting in a dam aged oil pickup unit. • Support the engine with a suitable jack. Do not load the engine mounting. 1. Engine mounting through-bolt and nut. • Raise the engine only enough to perm it removal of the engine mounting. 2. Mounting assembly bolts, nuts, and washers. 3. Mounting assembly. -H - Install or Connect (Figures 34 through 37) 1. Engine m ounting assembly to the vehicle. • On V, G, and P models, the through-bolt must be inserted from the rear of the right side m ounting before the mounting is installed in the vehicle. NOTICE: See “ N o tice” on page 6A6-1 of this section. 2. Mounting assembly bolts, nuts, and washers. Tighten • Fasteners to specifications. Refer to figures 34 through 37. • On V, G, and P models (right side), make sure there is 25 mm (1 inch) clearance between the through bolt head and mounting assembly. • Lower the engine until the through bolts can be inserted. NOTICE: See “ N o tice” on page 6A6-1 of this section. 3. Through bolts and nuts. • Fasteners to specifications. Refer to figures 34 through 37. REAR MOUNTING REPLACEMENT (EXCEPT P MODEL FLYWHEEL HOUSING MOUNTING) Remove or Disconnect (Figures 38 through 41) NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, resulting in a dam aged oil pickup unit. • Support the rear of the engine to relieve the weight on the rear mountings. 1. Mounting to crossm em ber 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. 3. Mounting. Install or Connect (Figures 38 through 41) 1. Mounting. • Lower the rear of the engine. 2. Mounting to transmission bolts and washers. NOTICE: See “ N o tice” on page 6A6-1 of this section. 6A6-26 6.2 L DIESEL A. F orw ard B. 40 N m (30 Ft. Lbs.) C. T orque B o lt To 115 N m (85 Ft. Lbs.) Or, Torque N u t To 75 N m (55 Ft. Lbs.) D. 48 N m (36 Ft. Lbs.) E. T orque B o lt To 48 N m (36 Ft. Lbs.) Or, T orque N u t To 40 N m (30 Ft. Lbs.) B-08048 Figure 34—Front Engine Mountings (R Models) L 6.2 L DIESEL 6A6-27 A. Forw ard B. 40 N m (30 Ft. Lbs.) C. .Torque B o lt To 115 N m (85 Ft. Lbs.) Or, Torque N ut To 75 N m (55 Ft. Lbs.) D. 48 N m (36 Ft. Lbs.) 150. T ra n s m is s io n S tru t B ra cke t (A u to m a tic T ra n s m is s io n ) O r S p a c e r (M a nu al T ra n s m is s io n ) B-08049 Figure 35—Front Engine Mountings (V Models) B. Torque Torque C. 48 N m D. Torque Torque B o lt to 100 N m (75 ft. lbs.) o r N u t to 68 N m (50 ft. lbs.) (36 ft. lbs.) B o lt to 54 N m (40 ft. lbs.) o r N u t to 40 N m (30 ft. lbs.) s E. 40 N-m 150. S p a ce r Pum p B ra c k e t (L e ft S ide O nly) Figure 36—Front Engine Mountings (G Models) F-02410 6A6-28 6.2 L DIESEL A. F ro n t B. T ig h te n B o lt to 115 N-m (85 Ft. Lbs.) or, T ig h te n N u t to 75 N-m (55 Ft. Lbs.). C. 48 N-m (36 Ft. Lbs.). D. 40 N-m (30 Ft. Lbs.). MODELS WITHOUT I-BEAM AXLE MODELS WITH I-BEAM AXLE (RPO-FS3) B-08050 Figure 37—Front Engine Mountings (P Models) Tighten • Fasteners to specifications. Refer to figures 38 through 41. REAR MOUNTING REPLACEMENT (P MODELS FLYWHEEL HOUSING MOUNTING) |<~+| Remove or Disconnect (Figure 42) 1. Bolt, cushion, and spacer. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet m etal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pum p screen, jacking against the oil pan may cause it to be b ent against the pum p screen, resulting in a dam aged oil pickup unit. • Raise the rear of the engine only enough to permit removal of the mounting. 2. Engine mounting. Install or Connect (Figure 42) 1. Engine m ounting. Align the hole in the m ounting with the hole in the crossmember. • Lower the engine. NOTICE: See “ N o tice” on page 6A6-1 of this section. 2. Spacer, cushion, and bolt. $ Tighten • Bolt to 90 N-m (65 ft. lbs.). ENGINE REPLACEMENT R AND V MODELS ♦+ Remove or Disconnect 1. Battery cables. • Raise the vehicle. S upport with suitable safety stands. 6.2 L DIESEL 6A6-29 ALL MODELS EXCEPT WITH THM 400 TRANSMISSION (RPQ-M40) MODELS WITH THM 400 TRANSMISSION (RPO M40) A. Forw ard B. 48 N m (36 Ft. Lbs.) B-07921 Figure 38—Rear Engine Mountings (R Models) 6A6-30 6.2 L DIESEL A. 54 N-m (40 Ft. Lbs.) B. 48 N-m (36 Ft. Lbs.) C. Forw ard B B-07897 2. Flywheel cover. 3. Flyw heel to torque co n v e rte r bolts (autom atic transmission). 4. Exhaust pipes at the manifolds. 5. Starter. 6. Bell housing bolts. 7. Front engine mounting through-bolts. 8. Block heater. 9. W iring harness, transmission cooler lines, and front battery cable clamp at the oil pan. 10. Fuel return lines at the engine. 11. Oil cooler lines at the engine. 12. Lower fan shroud bolts. • Lower the vehicle. 13. Hood. • Drain the cooling system. 14. Air cleaner with resonator. 15. Fuel filter. 16. Ground cable at the generator bracket. 17. Generator wires and clips. 18. W iring at the injection pump. 19. W iring from rocker arm clips, including glow plug wires. 20. EGR-EPR solenoids, glow plug c o n tro lle r and temperature sensor. Move the harness aside. 21. Left side ground strap. 22. Fan. 23. Fan shroud. 24. Power steering pump and reservoir and lay aside. 25. Vacuum hose at the cruise control transducer (if equipped). 26. Accelerator, detent, and cruise control cables at the injection pump. 27. Heater hose at the engine. 28. Radiator. Refer to ENGINE COOLING (SEC. 6B). • Support the transmission with a suitable jack. 29. Engine. 0 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. • Figure 40—Rear Engine Mountings (G Models) 18. 19. 20. Install or Connect (Figures 34 and 35) Engine to the vehicle. Radiator. Refer to ENGINE COOLING (SEC. 6B). Heater hose. Accelerator, detent, and cruise control cables. Vacuum hose at the transducer. Power steering pump and reservoir. Fan shroud. Fan. Left side ground strap. EGR-EPR, glow plug controller, and temperature sensor. W iring at the rocker arm clips, including glow plug wires. Injection pump wiring. Generator wires and clips. Ground cable at the generator bracket. Fuel filter. Air cleaner and resonator. Hood. Raise the vehicle. Support with suitable safety stands. Lower fan shroud bolts. Oil cooler and fuel return lines. W iring harness, transm ission cooler lines, and front battery cable clamp at the oil pan. 6.2 L DIESEL 6A6-31 MODELS WITH PROPSHAFT PARKING BRAKE A. B. C. D. F orw ard 68 N m (50 ft. lbs.) 48 N m (36 ft. lbs.) 60 N m (44 ft. lbs.) MODELS WITHOUT PROPSHAFT PARKING BRAKE Figure 41— Rear Engine Mountings (P Models—Transmission Tail Type Mountings) B-07901 6A6-32 6.2 L DIESEL Figure 42—Rear Enging M ountings (P Models— Flywheel Housing Type Mounting) 21. Block heater. NOTICE: See “ N o tic e ” on page 6A6-1 of this section. 22. Engine m ounting through bolts. Tighten 23. 24. 25. 26. 27. • 28. • • Fasteners to specifications. Refer to figures 34 and 35. Bell housing bolts. Starter. Exhaust pipes. Flyw heel to to rq ue co nve rte r bolts (au tom a tic transmission). Flywheel cover. Lower the vehicle. Battery cables. Fill the cooling system with the proper quantity and grade of coolant. G MODELS B Remove or Disconnect 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. • Tool Required: J-33888 Lifting Fixture Battery cables. Headlight bezels, grille, bumper, and lower valence panel. Hood latch. Coolant recovery bottle. Upper fan shroud. Upper tie bar. Engine cover. Condenser (vehicles with air conditioning). Refer to AIR CONDITIONING (SEC. 1B). R adiator and fan. Refer to ENGINE COOLING (SEC. 6B). Injection pump. Refer to DIESEL FUEL INJECTION (SEC. 6C2). Raise the vehicle. Support with suitable safety stands. 11. Exhaust pipes at the manifolds. 12. Flywheel cover. 13. F lyw heel to torque co n v e rte r bolts (au tom a tic transmission). 14. Engine m ounting through bolts. 15. Block heater wires. 16. Bellhousing bolts. 17. Starter. • Lower the vehicle. 18. Cruise control transducer (if equipped). 19. Air conditioning compressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). 20. Power steering pump, and lay aside. 21. Oil fill tube upper bracket. 22. Glow plug relay. 23. Oil pressure sender harness. 24. Air cleaner resonator and bracket. 25. Transmission dipstick tube and move aside. 26. Heater hoses at the engine. 27. Generator upper bracket. 28. Water crossover/thermostat assembly. 29. Fuel lines at the fuel pump (lift pump). 30. Engine • Attach J-33888 to the center intake manifold bolt holes. The two pieces of the tool should extend down into the “ valley” between the cylinders. • Support the transmission. • Use a suitable lifting device to remove the engines. |-»<-| Install or Connect (Figure 36) 1. Engine to the vehicle. |+ + | Remove or Disconnect • J-33888, and lifting device. • Transmission support. 2. Fuel lines to the fuel pump (lift pump). 3. Water crossover/therm ostat assembly, Use new gaskets. Tighten 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. • 14. 15. 16. • Bolts to 42 N m (31 ft. lbs.). Generator upper bracket. Heater hoses. Transmission dipstick tube. Air cleaner resonator and bracket. Oil pressure sender harness. Glow plug relay. Oil fill tube upper bracket. Power steering pump. Air conditioning compressor (if equipped). Refer to AIR CONDITIONING (SEC. 1B). Cruise control transducer (if equipped). Raise the vehicle. Support with suitable safety stands. Starter. Bellhousing bolts. Block heater wires. NOTICE: See “ N o tice” on page 6A6-1 of this section. 17. Engine mounting through bolts. 6.2 L DIESEL 6A6-33 Tighten 18. 19. 20. • 21. 22. • Fasteners to specifications. (Refer to figure 36). F lyw heel to to rq ue co n ve rte r bolts (au tom a tic transmission). Flywheel cover. Exhaust pipes. Lower the vehicle. Injection pump. Refer to DIESEL FUEL INJECTION (SEC. 6C2). R adiator and fan. Refer to ENGINE COOLING (SEC. 6B). 23. C o n d e n s e r ( if e q u ip p e d ). R e fe r to A IR CONDITIONING (SEC. 1B). 26. Engine cover. 27. Upper tie bar. 28. Upper fan shroud. 29. Coolant recovery bottle. 30. Hood latch. 31; Lower valence panel, bumper, grille, and headlight bezels. 32. Battery cables. • Fill the cooling system with the proper quantity and grade of coolant. • Evacuate and charge the air conditioning system. Refer to AIR CONDITIONING (SEC. 1B). SPECIFICATIONS TORQUE SPECIFICATIONS Item N-m Intake M anifold Bolts E xh au st M anifold Bolts R ocker Arm Cover Bolts R ocker Arm S haft Bolts H ydrau lic Lifter G uide Plate C lam p Bolts C ylin d e r Head Bolts— R efer to Procedure Oil P um p Drive C lam p Bolt Torsional D am per Bolt C ra nksh a ft Pulley Bolts Front C over to B lock Bolts O il Pan Bolts (all except rear tw o bolts) (rear tw o bolts) Front C over Baffle Bolts and N ut Injection Pum p N uts Injection Pum p G ear Bolts C am sha ft G ear Bolt C am sha ft T hru st Plate O il P um p Bolt M ain B earing C ap Bolts— Inner O uter C on ne cting Rod C ap Nuts G low Plugs W ater C rossover/T herm ostat H ousing Bolts Fuel Pum p to Block Flyw heel Bolts B ell H ousing Bolts 42 35 22 55 26 — 42 270 40 45 10.0 23 45 42 23 100 23 90 150 135 65 14 42 34 90 40 Ft. Lbs. 31 26 16 40 18 — 31 200 30 33 — 17 33 31 17 75 17 65 110 100 48 10 31 25 65 30 In. Lbs. — — — — — — — — — — 84 — — — — — — — — — — — — — — — 6A6-34 6.2 L DIESEL SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS All S pecifications are in m illim eters (mm) unless otherwise noted. GENERAL DATA: Type 90-degree V8 Diesel D isplacem ent 6.2L RPO LH6 LL4 Bore 101 Stroke 97 C om pression Ratio 21.3:1 Firing O rder 1-8-7-2-6-5-4-3 Oil Pressure 10 psi at idle (hot); 4 0 -4 5 psi at 2000 RPM CYLINDER BORE: D iam eter 100.987-101.065 D iam eter 0.02 (M axim um ) Taper (Thrust Side) 0.02 (M axim um ) PISTON: Bohn Pistons C learance Z o lln e r P istons* Bores 1 through 6 0.089-0.115 Bores 7 and 8 0.102-0.128 Bores 1 th rough 6 0.112-0.138 Bores 7 and 8 0.125-0.151 PISTON RING: G roove C learance C om pression G ap Top 0.076-0.178 2nd 0.75-1.00 Top 0.30-0.55 2nd 0.75-1.00 G roove C learance Oil G ap 0.040-0.096 0.25-0.51 PISTON PIN: D iam eter 30.9961-31.0039 C learance 0.0081-0.0309 Fit in Rod 0.0081-0.0309 CRANKSHAFT Main Journal D iam eter #1, 2, 3, 4 74.917-74.941 #5 74.912-74.936 Taper 0.005 (M axim um ) O ut of Round 0.005 (M axim um ) Main Bearing #1, 2, 3, 4 0.045-0.083 C learance #5 0.055-0.093 C rankshaft End Play 0.10-0.25 D iam eter C rankpin 60.913-60.939 Taper 0.005 (M axim um ) O ut-of-R ound 0.005 (M axim um ) Rod Bearing C learance Rod Side C learance *N o t used in production — reference for service stock pistons only. 0.045-0.100 0.17-0.63 V 6.2 L DIESEL 6A6-35 SPECIFICATIONS (CONT.) ENGINE SPECIFICATIONS (CONT.) All S pecifications are in m illim eters (mm) unless otherw ise noted. DISPLACEMENT 6.2 L CAM SHAFT: Lobe LlTt ±0.05 Jo urna l D iam eter Intake 7.133 E xhaust 7.133 #1, 2, 3, 4 54.975-55.025 #5 50.975-51.025 Jo u rn a l C learance 0.026-0.101 C am sha ft End Play 0.051-0.305 VALVE SYSTEM: H ydraulic R oller Lifter 1.5 : 1 R ocker Arm Ratio Intake valve Lasn E xhaust N ot A d justa b le Face A n gle (Intake & Exhaust) 45° S eat A ngle (Intake & Exhaust) 46° S eat R unout (Intake & E xhaust 0.05 S eat W idth Stem C learance Valve Spring Pressure N ew tons @ mm Intake 0.89-1.53 E xhaust 1.57-2.36 Intake 0.026-0.069 E xhaust 0.026-0.069 C losed 356 N @ 46.0 mm O pen 1025 N @ 35.3 mm 46 Installed H eight Mining w iiam i iu c r lay New C hain Used C hain 12.7 mm (0.500-inch) 20.3 mm (0.800-inch) 6A6-36 6.2 L DIESEL SPECIAL TOOLS 1. J-8037 7. J-22102 2. J-33154 8. J-23523-E 3. J-33153 9. J-29664 4. J-26513-A 5. J-29666 10. J-8080 6. J-29834 11. J-33888 1. 2. 3. 4. 5. 6. R ing C o m p re s s o r R ear O il Seal P acker R ear O il Seal In s ta lle r Valve S p rin g C o m p re s s o r A ir L in e A d a p te r H y d ra u lic L ifte r R em over 7. 8. 9. 10. 11. Seal In s ta lle r T orsion al D a m p e r R em ove r M a n ifo ld C ove r Set M ain B e aring R e p la c e r E n g in e L iftin g F ix tu re (G M od els) F-02409 6A7-1 SECTION 6A7 4.8 LITER L6 The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of this m anual as indicated at appropriate locations by the term inology “ See NOTICE on page 6A7-1 of this section.” NOTICE: All engine fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in m ajor repair expense. They must be replaced with one of the same part number or with an equivalent part if replacem ent becomes necessary. Torque values must be used as specified during reassembly to assure proper retention of all parts. CONTENTS SUBJECT PAGE Description................................................................................................................................................................... 6A7- 2 Engine Lubrication...................................................................................................................................................6A7- 2 On-Vehicle S e rvice .....................................................................................................................................................6A7- 4 Rocker Arm Cover Replacem ent..........................................................................................................................6A7- 4 Rocker Arm and Pushrod Replacement............................................................................................................... 6A7- 4 Valve Adjustment.................................................................................................................................................... 6A7- 5 Valve Stem Seal And Valve Spring Replacement............................................................................................... 6A7- 5 Pushrod Cover R eplacem ent................................................................................................................................ 6A7- 6 Hydraulic Lifter Replacement................................................................................................................................ 6A7- 6 Intake And Exhaust Manifold Replacement......................................................................................................... 6A7- 7 Rocker Arm Stud R eplacem ent............................................................................................................................ 6A7- 8 Cylinder Head Replacement.................................................................................................................................. 6A7- 9 Torsional Damper And Front Crankshaft Seal Replacement............ ............................................................ 6A7-10 Timing Gear Cover Replacement..........................................................................................................................6A7-11 Oil Pan Replacement...............................................................................................................................................6A7-12 Oil Pump Replacement.......................................................................................................................................... 6A7-12 Rear Crankshaft Oil Seal Replacem ent................................................................................................................6A7-13 Checking Valve T im in g .......................................................................................................................................... 6A7-14 Measuring Camshaft Lobe L if t .............................................................................................................................. 6A7-14 Camshaft Replacement.......................................................................................................................................... 6A7-15 Connecting Rod And Piston R eplacem ent......................................................................................................... 6A7-16 Main Bearing Replacement.................................................................................................................................... 6A7-18 Crankshaft Gear Replacem ent.............................................................................................................................. 6A7-19 Oil Filter Bypass Valve Replacement....................................................................................................................6A7-20 Crankshaft Replacement........................................................................................................................................ 6A7-20 Flywheel R eplacem ent.......................................................................................................................................... 6A7-20 Engine M o u n tin g s.................................................................................................................................................. 6A7-21 Engine Replacement.............................................................................................................................................. 6A7-24 S p e cifica tio n s.............................................................................................................................................................6A7-25 Special T o o ls ...............................................................................................................................................................6A7-28 6A7-2 4.8 LITER L6 DESCRIPTION The connecting rods are forged steel, with precision in­ sert 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 B-05053 Figure 1—Lubrication Diagram (Side View) 4.8L engines are inline six cylinder type, overhead valve, water cooled, with cast iron block and head. The crankshaft is supported by seven precision insert main bearings, with crankshaft thrust taken at the number seven (rear) bearing. The camshaft is supported by four plain type bearings and is gear driven. Motion from the camshaft is transm it­ ted to the valves by hydraulic lifters, pushrods, and balltype rocker arms. The valve guides are integral in the cylinder head. 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 is provided. This valve will allow oil flow to the main oil gallery at the right side of the block. This gallery supplies oil to the camshaft bearings, hydraulic lifters, and main bearings. The connecting rods are supplied oil from the main bearings by means of drilled passages in the crankshaft. The valve train is supplied with oil by the hydraulic lifters. Oil is pumped from the lifters through the hollow pushrods to the rocker arms. Oil drains back to the crankcase through oil drain holes and the pushrod holes. The piston, piston pin, and tim ing gears are lubricated by oil splash. 4.8 LITER L6 6A7-3 A. B. C. D. E. O il P re ssu re S e n d in g U n it D is tr ib u to r S h a ft O ilin g S p la s h O ilin g F ilte r B yp a ss S y s te m F u ll F lo w O il F ilte r B-09222 Figure 2—Lubrication Diagram (Front View) 6A7-4 4.8 LITER L6 ON-VEHICLE SERVICE: 3. Bolts, clips, and reinforcem ents. Tighten • Bolts to 4.3 N-m (38 in. lbs.). 4. W iring, fuel and vacuum lines to the clips. 5. Air cleaner. 6. Crankcase ventilation hoses to the rocker arm cover. ROCKER ARM AND PUSHROD REPLACEMENT Remove or Disconnect 1. R ocker arm cover, as o utline d previously. 2. R ocker 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. 1. C lip 2. B o lt 3. R e in fo rc e m e n t 4. R o cke r A rm C over 5. G a ske t Im portant Figure 3—Rocker Arm Cover Installation ROCKER ARM COVER REPLACEMENT Remove or Disconnect (Figure 3) 1. C rankcase ve ntilatio n hoses at the rocker arm cover. 2. A ir cleaner. 3. W iring, fuel and vacuum lines from the clips. 4. Bolts, reinforcem ents, and clips. 5. Rocker arm cover. • If the rocker arm cover adheres to the cylinder head, try to shear the gasket by bumping the end of the cover with a rubber mallet. DO NOT DISTORT THE SEALING FLANGE. 6. Gasket. Clean All traces of old gasket from the rocker arm cover and cylind er head. 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. Store used com p on en ts in order so they can be reassem bled in the sam e location. B-07856 I* Inspect R ocker arm s and balls at th e ir m ating surfaces. T hese surfaces should be sm ooth and free from scoring or other dam age. R ocker arm areas w hich co nta ct the valve stem s and the sockets w h ich c o n ta c t th e pushrods. T h e s e a re as s h o u ld be s m o o th and free of dam age and wear. P ushrods for bending. Roll the pushrod on a flat s u rfa ce to d e te rm in e if it is bent. R ep lace if necessary. Ends of the pushrods fo r scoring or roughness. Install or Connect 1. Pushrod. M ake sure the pushrod seats properly in the hydraulic lifter. 2. R ocker arm w ith ball. Im portant W hen new rocker arm s a nd /or balls are installed, coat th e ir bearing surfaces w ith “ M olykote” or e quivalent. 3. Rocker arm nut. Adjust • Valves as outline d later. 4. Rocker arm cover, as outlined previously. 4.8 LITER L6 6A7-5 20. 21. 22. 23. Valve K e ep e r R o ta to r S h ie ld O -R ing Seal 24. 25. 26. 27. 28. Seal D am per S p rin g In ta ke Valve E x h a u s t Valve B-07859 Figure 4—Adjusting The Valves Figure 5—Valves And Components VALVE ADJUSTMENT VALVE STEM SEAL AND VALVE SPRING REPLACEMENT 1. Remove the rocker arm cover as outlined previously. 2. Adjust the valves when the lifter is on the base circle of the camshaft lobe as follows: a. Mark the distributor housing with chalk, at #1 and #6 plug w ire p osition s. Rem ove the distributor cap and lay aside. b. Crank the engine until the distributor rotor points to #1 cylinder position. The following valves can be adjusted with the engine in the #1 firing position: #1 cylinder-E xhaust and Intake #2 cylinder-lntake #3 cylinder-E xhaust #4 cylinder-lntake #5 cylinder-E xhaust c. Back out the adjusting nut until lash is felt at the pushrod, then turn in the adjusting nut u n til a ll la sh is re m o v e d . T h is can be determ ined by rotating the pushrod w hile 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 w ith the e ng in e in #6 firin g position: #2 cylinder-E xhaust #3 cylinder-lntake #4 cylinder-E xhaust #5 cylinder-lntake #6 cylinder-lntake and Exhaust 3. Install the distributor cap. 4. Install the rocker arm cover as outlined previously. Remove or Disconnect (Figures 5 and 6) Tools R equired: J-23590 Air Adapter. J-5892-B Spring Compressor. Rocker arm cover, as outlined previously. Rocker arms, as outlined previously. Spark plugs. Valve keepers (20). • Install J-23590 into the spark plug hole. • Apply compressed air to hold the valves in place. • Install a rocker arm nut (figure 6). • Use J-5892-B to compress the valve spring (figure 6). • Remove the valve keepers. • Carefully release the spring tension. Remove J-5892-B. 6A7-6 4.8 LITER L6 Figure 7—Testing The Valve Seals 5. Rotator (21), shield (22) and spring (26) with damper (25). 6. O-ring seal (23). 7. Seal (24) (intake valve only). |+<-| Install or Connect (Figures 5, 6, and 7) 1. 2. 3. 4. 5. Tools R equired: J-23590 Air Adapter. J-5892-B Spring Compressor. J-23738-A Vacuum Pump. New seal (24) (intake valve only). Install the seal over the valve stem and seat it against the head. Spring (26) with the dam per (25), shield (22) and rotator (21). 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-B (figure 6). • Lubricate the o-ring seal with engine oil. Install the seal on the valve stem. Make sure the seal is not twisted. • Install the valve keepers. Use grease to hold them in place. • Carefully release spring pressure. Make sure the valve keepers stay in place. • Remove J-5892-B and J-23590. • Check each o-ring seal for leakage (figure 7). • Place the suction cup furnished with J-23738-A over the shield. • Connect J-23738-A to the suction cup and apply a vacuum. Watch the vacuum pump gage. No air should be able to leak past the seal. If the seal will not hold a vacuum, it may have been damaged or improperly installed. Spark plugs. Rocker arms, as outlined previously. Adjust • Valves, as outline d previously. 6. Rocker arm cover, as outlined previously. PUSHROD COVER REPLACEMENT Remove or Disconnect 1. B attery negative cable. 2. D ipstick tube. 3. Distributor. Refer to E N G IN E E LE C TR IC A L (SEC. 6D). 4. Pushrod cover bolts. 5. Pushrod cover. 6. Gasket. |mj| Clean Old gasket from pushrod cover and block. 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. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 4. Dipstick tube (if removed). 5. Battery negative cable. HYDRAULIC LIFTER REPLACEMENT Remove or Disconnect (Figures 8 and 9) Tools R equired: J-3049 Hydraulic Lifter Remover (Plier Type) or J-9290-01 Hydraulic Lifter Remover (Slide Hammer Type) 1. Rocker arm cover, pushrod cover, and pushrod, as outlined previously. 2. Hydraulic lifters. 4.8 LITER L6 6A7-7 32. C la m p 33. N u t B-07861 Figure 10—Manifold Installation 2. Pushrod cover, as outlined previously. 3. Pushrod, as outlined previously. ft Adjust • Valves, as o utline d previously. 4. Rocker arm cover, as outlined previously. B-05064 INTAKE AND EXHAUST MANIFOLD REPLACEMENT Figure 9—Removing The Hydraulic Lifter — Remove the hydraulic lifters one at a tim e 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 8 or J-9290-01 (figure 9). — H ydraulic lifter body for scu ffing and scoring. If the lifte r body w all is w orn or dam ag ed , the m ating bore in the block should also be checked. — C heck the fit of each hydraulic lifte r in its m ating broe in the block. If the clearance is excessive, try a new lifter. — The hydraulic lifter foot m ust be sm ooth and slig h tly convex. If w orn, pitted, or dam aged, the m ating ca m sh aft lobe should also be checked. 4-+ Remove or Disconnect (Figures 10 and 11) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Disassemble (Figure 11) Bolt (35) and nuts (40). M anifolds (34 and 39). G asket (38). Hydraulic Lifter Repair • Refer to the proper unit repair manual. +4- Install or Connect H ydraulic lifters to the block. Lubricate the lifter foot and body w ith Engine Oil S u pp lem en t or equivalent. • W hen any new hydraulic lifters or a new c a m s h a ft is in s ta lle d , a ls o re p la c e th e c ra n k c a s e o il and filte r. E n g in e O il Supplement (or equivalent) should be added to the crankcase oil. • R eplace all h yd ra u lic lifte rs w hen a new camshaft is installed. B attery negative cable. A ir cleaner. T hrottle co ntrols at the bell crank. C arburetor (if necessary). Fuel and vacuum lines from the m anifold, EGR valve (if used) and EFE valve. AIR pum p and bracket. PCV hose. E xhaust pipe. M anifold heat stove. C lam ps (32), bolts (31), nuts (33) and w ashers. M anifold assem bly and gasket. ay Clean All m anifold bolts and studs. Then a pp ly e ngine oil to the threads. All traces of old gaskets from the c ylin d e r head and m anifolds. Inspect M a n ifo ld s fo r c ra c k s o r d a m a g e to g a s k e t surfaces. O peration of EFE or m anifold heat valve (if used). G askets, if n e c e ssa ry to d ia g n o se a leakage problem . 6A7-8 4.8 LITER L6 A. N u t B. F la t W a s h e r B-05245 Figure 12—Removing The Rocker Arm Stud 31. 32. 33. 34. 35. B o lt C la m p N ut E xh a u st M a n ifo ld B o lt Tighten 36. 37. 38. 39. 40. W a sh er S tu d G a sket In ta ke M a n ifo ld N ut B-07866 Figure 11—Manifolds And Components 5. 6. 7. 8. 9. Measure M anifold d istortion. Lay a straight edge along the full length of the m anifold exhaust port faces and m easure any gaps betw een the straig ht edge and the port faces. If at any point a gap of 0.80 mm (0.030-inch) or m ore exists, it is likely th at the m anifold has d istorted to a point w here it w ill not seal properly. If a good exhaust seal is to be e x p e c te d , th e e x h a u s t m a n ifo ld m u s t be replaced. * Assemble (Figure 11) 1. G asket (38) to the exhaust m anifold (34). 2. Intake m anifold (39) to the exhaust m anifold. 3. Both (35), w ashers (36) and nuts (40). LEAVE FING ER TIGHT. -►+ Install or Connect (Figures 10 and 11) 1. New gasket, over th e m an ifold stu d s on the cylin d e r head. 2. M anifold assem bly. 10. 11. 12. 13. • Bolts (31) and nuts (33) to 52 N-m (38 ft. lbs.). • Bolts (35) and nuts (40) to 60 N-m (44 ft. lbs.). Manifold heat stove. Exhaust pipe. PCV hose. AIR pump and bracket. Fuel and vacuum lines from the manifold, EGR valve (if used) and EFE valve (if used). Carburetor (if removed). Throttle controls. Air cleaner. Battery negative cable. Adjust Engine idle speed, if necessary. ROCKER ARM STUD REPLACEMENT Remove or Disconnect (Figure 12) Tool R equired: J-5802-01 Rocker Arm Stud Remover 1. Rocker arm cover and rocker arm, as outlined previously. 2. Rocker arm stud. • Place J-5802-01 over the rocker arm stud. • Install a nut and flat washer. • Turn the nut to remove the stud (figure 12). ■H" Install or Connect (Figures 13 and 14) 3. C lam ps (32). 4. Bolts (31), and nuts (33). Im portant Alw ays tig hte n the m anifold to cylind er head b o lts a n d n u ts (31 a n d 3 3 ) B E F O R E tig hte nin g the m anifold center bolt and nuts (35 and 40). Tools R equired: J-5715 Reamer (0.003-inch oversize) or J-6036 Reamer (0.013-inch oversize) J-6880 Rocker Arm Stud Installer NOTICE: Do not attem pt to install an oversize rocker arm stud without reaming stud hole as this could damage the cylinder head. 4.8 LITER L6 6A7-9 FRONT OF ENGINE B-05258 Figure 15—Cylinder Head Bolt Tightening Sequence Adjust • Valves, as outline d previously. 3. Rocker arm cover, as outlined previously. • R ea m th e h o le to th e p ro p e r s iz e fo r th e replacement oversize rocker arm stud. Use J-5715 for 0.003-inch oversize studs; J-6036 for 0.013-inch oversize stud (figure 13). CYLINDER HEAD REPLACEMENT Remove or Disconnect • Coat lower end (press-fit area) of the rocker arm stud with hypoid axle lubricant. 1. Rocker arm stud. Use J-6880 (figure 14). Stud is installed to proper depth when the tool bottoms on the cylinder head. 2. Rocker arm, as outlined previously. 8. 9. 10. 11. IJjl Battery ground cable. M anifold assem bly, as outlined previously. AIR ch eck valve. R ocker arm cover, as outlined previously. Pushrods. Back o ff th e rocker arm nuts. Turn the rocker arm s aside, then rem ove the pushrods. Place the push ro ds in a rack so th ey can be returned to th e ir o rigin al locations at assem bly. S park plug w ires at the spark plugs. Vacuum lines at the th erm al vacuum sw itch on the w ater outlet. Drain the radiator and block. U pp er ra d ia to r hose, h eater hose, and w ater pum p bypass hose. B attery ground strap at the cylind er head. C ylin de r head bolts. C ylin de r head and gasket. Clean C arbon deposits from co m b ustio n cham bers. All traces of old head gasket from cylin d e r head and block. C ylin de r head bolt th re ad s and th re ad s in the block. I? Inspect • S ealing su rfa ces of the block and c y lin d e r head for nicks, heavy scratches, or other dam age. Cylinder Head Repair • Refer to the proper Unit Repair Manual. Install or Connect (Figure 15) 1. Head gasket. • If a steel gasket is used, coat both sides of the gasket with sealer. Spread the sealer thin and even. 6A7-10 4.8 LITER L6 F-02325 Figure 17—Installing The Timing Gear Cover And Seal B-01325 Figure 16—Removing The Torsional Damper 1. Battery negative cable. 2. Radiator. Refer to ENGINE COOLING (SEC. 6B). 3. Drive belts from the crankshaft pulley. • Do n ot use s e a le r on c o m p o s itio n steel-asbestos gaskets. • Place the gasket over the block dowel pins with the bead up. 2. C ylinder head. Carefully guide the cylinder head into place over the dowel pins and gasket. 3. Cylinder head bolts. Coat threads of the cylinder head bolts with sealing compound and install finger tight. a Tighten • C ylin de r head bolts, a little at a tim e, using the sequ en ce show n in figure 15, until the specified to rq ue is reached. — Left hand front bolt: 115 N-m (85 ft. lbs.). — All other bolts: 130 N-m (95 ft. lbs.). Battery ground strap at the cylinder head. Upper radiator hose, heater hose, and water pump bypass hose. Fill the cooling system with the proper coolant. Vacuum lines at the thermal vacuum switch. Spark plug wires. Pushrods. Be sure to install them in their original locations. Rocker arms to the pushrods. 4. Torsional dam per bolt and washer. 5. Torsional damper. Use J-23523-E (figure 16). 6. F ro n t c ra n k s h a ft s e a l. P ry o u t w ith a la rg e screwdriver. Take care not to distort the tim ing gear cover. Inspect • Oil seal co nta ct area on the torsional d am pe r for grooving and roughness. R eplace if necessary. Install or Connect (Figures 17 and 18) Tools R equired: J -2 3 5 2 3 -E T o rsio n a l D a m p e r P u lle r and Installer J-35468 Centering Tool and Seal Installer 1. Front crankshaft seal. Use J-35468 (figure 17). Coat the seal lips with engine oil. The open end of the seal faces inside the engine. Adjust • Valves, as outline d previously. 10. Rocker arm cover, as outlined previously. 11. AIR check valve. 12. Manifold assembly, as outlined previously. 13. Battery ground cable. TORSIONAL DAMPER AND FRONT CRANKSHAFT SEAL REPLACEMENT Remove or Disconnect (Figure 16) Tool R equired: J -2 3 5 2 3 -E T orsion al D a m p e r P u lle r and Installer. A. Bearing B. W asher C. Stud D. N ut C B-05254 Figure 18—Installing The Torsional Damper 4.8 LITER L6 6A7-11 NOTICE: The in ertia w eig h t section o f the torsional dam per is assembled to the hub with a rubber type material. The correct installation procedures (w ith the p ro p er tool) m ust be follow ed or m ovem ent o f the inertia weight section of the hub will destroy the turning of the torsional damper. 2. Crankshaft key (if removed). 3. Stud (item C, figure 18) to the crankshaft. Thread the stud fully into the tapped end of the crankshaft. 4. Torsional damper over the end of the stud. Align the keyway in the torsional dam per shaft w ith the crankshaft key. 5. Bearing, washer, and nut (figure 18). • Turn the nut to pull the torsional dam per into place. • Remove the tool. 6. Torsional damper bolt and washer. • Torsional d am pe r bolt to 70 N m (50 ft. lbs.). Drive belts to the crankshaft pulley, and tension to specifications. Radiator. Refer to ENGINE COOLING (SEC. 6B). Battery negative cable. Fill the cooling system with the proper coolant. • 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 the retaining tips into the holes in the cover. 3. Timing gear cover to block gasket to the tim ing gear cover. Use gasket sealer to hold it in place. • Apply a 3 mm (Vs-inch) bead of RTV sealant to the joint formed at the oil pan and cylinder block. 4. Timing gear cover, with J-35468 in place, to the block (figure 17). Im portant TIMING GEAR COVER REPLACEMENT Remove or Disconnect 1. 2. 3. 4. 5. B attery negative cable. Torsional damper, as described previously. Oil pan to tim ing gear cover bolts. T im in g gear cover to block bolts. T im in g gear cover. • Pull the cover slightly forward only enough to permit cutting of the oil pan front seal. • Using a sharp knife or other suitable cutting tool, cut the oil pan front seal flush with the block at both sides of the oil pan. • Remove the cover and attached portion of the oil pan front seal. 6. Timing gear cover gasket. 7. Front crankshaft seal. Pry out with a screwdriver. Be careful not to distort the tim ing gear cover. • The tool is used to align the tim in g gear cover so th a t the front cran ksha ft seal is p roperly centered around the crankshaft. T h e s e a l m u s t be c e n te re d to p re v e n t dam age d u rin g hub installation. 5. Oil pan to tim ing gear cover bolts. Partially tighten the bolts. 6. Timing gear cover to block bolts. Tighten • T im in g gear cover to block bolts to 9.0 N m (80 in. lbs.). • Oil pan to tim in g gear cover bolts to 5.1 N m (45 in. lbs.). ++ Remove or Disconnect • J-35468 from the tim in g gear cover. 7. Torsional damper, as outlined previously. Clean • O ld gasket from the tim in g gear cover, block, and oil pan. -►+ Install or Connect (Figures 17, 19, and 20) Tool R equired: J-35468 Centering Tool and Seal Installer 1. Front crankshaft to the timing gear cover. • Lubricate the seal lips with engine oil. • Use J-35468 to press the seal into place (figure 19). • Leave the tool in position in the seal. 2. Timing gear cover to oil pan seal. A. C ut T h is P o rtio n F rom N ew Seal B-07870 Figure 20—Front Oil Pan Seal Modification 6A7-12 4.8 LITER L6 8. Battery negative cable. OIL PAN REPLACEMENT ++ Remove or Disconnect 1. Battery negative cable. • Drain the engine oil. 2. Starter. 3. Torque converter or flyw heel cover. 4. Front engine m ou nt through-bolts. • Raise the e ngine and block in position. 5. Oil pan bolts. 6. Oil pan. 7. Old gaskets and seals. • Old gasket and seals from the block and oil pan sealing surfaces. Install or Connect Oil Pump Repair • Refer to the proper unit repair manual. 1. New rear oil pan seal to the rear m ain bearing cap. Install or Connect 3. New oil pan to b lock gaskets to the block. Use gasket ce m e nt to hold them in place. 1. Oil pum p to the engine. A lign the slot in the oil pum p sh aft w ith the tang on th e d istrib u to r shaft. The oil pum p should slide easily into place. No gasket is used. 4. Oil pan bolts. 2. Oil pum p bolts. 2. New front oil pan seal to the tim in g gear cover. Press the retaining tip s into the holes in the cover. Tighten — 1/4-inch oil pan to block bolts to 9.0 N m (80 in. lbs.). — 5/ie -inch oil pan to block bolts to 18.6 N m (165 in. lbs.). — Oil pan to tim in g gear cover to 5.1 N m (45 in. lbs.). • Oil pum p bolts to 13.0 N m (115 in. lbs.). 3. Oil pump pickup tube bracket to main bearing cap nut. • N ut to 34 N m (25 ft. lbs.). 4. Oil pan, as outline d previously. • Lower the engine. 5. Front engine mount through-bolts. REAR CRANKSHAFT OIL SEAL REPLACEMENT 6. Torque converter or flywheel cover. 7. Starter. 8. Proper quantity and grade of engine oil. 9. Battery negative cable. OIL PUMP REPLACEMENT |+ + | Remove or Disconnect 1. Oil pan, as outline d previously. 2. Oil pum p p icku p tube bracket to m ain bearing cap nut. 3. Oil pum p bolts. 4. Oil pump. I* Inspect Oil pum p picku p tube for looseness. If the tube is loose in the oil pum p body, replace it, as outlined in the proper unit repair m anual. A loose pickup tube can result in an air leak and loss of oil pressure. The rear main bearing oil seal can be replaced (both halves) w ithout removal of the crankshaft. Always replace the upper and lower seal as a unit. Install the 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 outside diameter of the seal. An installation tool (figure 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). 4- + Remove or Disconnect (Figures 21 and 22) 1. Oil pan, as outlined previously. 2. R ear m ain bearing cap. 3. Lower seal half (figure 21). 4. U pper seal half (figure 22). • Tap on the upper seal half, using a small drift and hammer. • Remove the upper seal half, using pliers. 4.8 LITER L6 6A7-13 B-03487 Figure 22—Removing The Upper Seal Half Clean Sealing surfaces of the m ain bearing cap and block. Inspect C rankshaft, seal ch an ne l, and sealing surfaces fo r nicks, scratches, etc. +«- Install or Connect (Figures 23, 24, and 25) A. B. C. 80. 81. 82. 83. 84. F orw ard F a b ric a te d Tool O il Seal Lip U p p e r Seal H a lf C ra n k s h a ft B lo c k L o w e r Seal H a lf M ain B e a rin g Cap B-07871 Figure 24—Installing The Rear Crankshaft Oil Seal U pper seal half. Important An oil seal installation tool (figure 23) should be fabricated (if not provided in the seal kit) to prevent seal dam age \ 9 A. 4 m m (11/64-inch) B. 13 m m (1/ 2 -in ch) C. 0.10 m m (0.004-inch) s h im s to c k Apply Sealant to Shaded Areas Only 0 .9 3 4 9 8 B-05250 Figure 25—Applying Sealant To The Block Figure 23—Oil Seal Installation Tool 6A7-14 4.8 LITER L6 during installation. Extreme 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. • P osition th e tip of th e to ol betw een the crankshaft and the seal seat in the block (figure 24). • 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. 2. Lower seal half. • Coat the seal lips lightly with engine oil. Keep the oil off of the seal mating ends. • Insert the seal half into the rear main bearing cap. Use the tool to protect the seal half from the sharp edge of the seal seal. Feed the seal half into the rear main bearing cap, using light finger pressure. Make sure the oil seal lip faces the front of the engine (figure 24). 3. Rear main bearing cap with the lower main bearing. • Apply a brush-on type oil sealing compound to the mating surface of the block and cap (figure 25). Do not a llo w any se a la n t on e ith e r crankshaft or rear oil seal. • Apply engine oil to the lower main bearing. • Position the cap to the block. Install the cap bolts. Tighten • Rear main bearing cap bolts temporarily to 14 N m (10 ft. lbs.). Tap the end of the crankshaft first rearward then forward with a lead hammer. This will line up the rear main bearing and crankshaft thrust surfaces. J-8520 B-03714 Figure 26—Checking Valve Timing Or Camshaft Lobe Lift 2. Install a dial indicator, along with J-8520 (figure 26). Turn the crankshaft until the #2 exhaust valve opens and the notch on the dam per is aligned with the “ 0 ” mark on the tim ing tab. 3. P o s itio n th e d ia l in d ic a to r to m e a s u re lifte r m ovem ent and set ind ica to r at zero. Turn the crankshaft 360 degrees and read the indicator. On co rrectly tim ed engines the ind icato r w ill read 0.012-0.020-inch. 4. If the reading is not as shown, reset the indicator at zero and turn the crankshaft 360 degrees, then read the in d ic a to r again. If rea din g is now w ith in g specifications, the engine is tim ed properly. 5. The chart following shows indicator readings with gears properly indexed for 4.8L engines and the indicator readings resulting from im properly indexed gears. Engine Camshaft Valve Lift Dial Indicator Readings Part Number 4.8L 3848000 0.405” Gears Properly Indexed One Tooth Advanced One Tooth Retarded 0.012-0.020” 0.038” 0.007” Tighten • Rear main bearing cap bolts to 90 N-m (65 ft. lbs.). 4. Oil pan, as outlined previously. 5. The proper quantity and grade of engine oil. CHECKING VALVE TIMING Tool Required: J-8520-Dial Indicator Adaptor When it becomes necessary to make a check of valve tim ing, the procedure following may be used: 1. Loosen the nut at the #1 intake valve rocker arm, swing the rocker arm away from the pushrod, then remove the pushrod. MEASURING CAMSHAFT LOBE LIFT Tool Required: J-8520 Dial Indicator Adaptor To check for worn cam shaft lobes, use the following procedure: 1. Remove the rocker arm as outlined previously. 2. Install a dial indicator (part of J-8520) (figure 26). Position the dial indicator so the plunger rests on the pushrod end, as shown, Make sure the pushrod is in the lifter socket. 4.8 LITER L6 6A7-15 A. 90. 91. 92. 93. 94. Tinning M arks C a m s h a ft T h ru s t Plate C a m s h a ft G ear T h ru s t P late B o lts C ra n k s h a ft G ear uj-u /363 Figure 27—Camshaft And Components 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 the fully raised position. 4. C om pare the total lift recorded from the dial indicator with specifications. 5. Continue to rotate the crankshaft until the indicator reads zero. This will be a check on the accuracy of the original indicator reading. 6. Remove the dial indicator and adaptor. 7. Install the rocker arm and adjust the valves as previously outlined. CAMSHAFT REPLACEMENT To c h e c k fo r w o rn c a m s h a ft lo b e s w ith o u t disassem bling the engine, refer to “ Measuring Camshaft Lobe L ift” in this section. ++ Remove or Disconnect (Figures 27 and 28) 1. Front end sheet m etal as required, dep en din g on body builde r design. • Drain the cooling system . 2. Radiator, fan shroud, fan, and pulley. 3. A ir cleaner. 4. Fuel pum p. 5. R ocker arm cover, as o utline d previously. 6. D istributor. R efer to EN G IN E ELEC TR IC AL (SEC. 6D). 7. P ushrod covers, as outlined previously. 8. H ydraulic lifters, as outlined previously. 9. Torsional damper, as outline d previously. 10. T im in g gear cover, as outline d previously. • A lign the tim in g m arks (figure 27). 11. T h ru st plate bolts (39) (figure 28). 12. C a m s h a ft. S u p p o rt th e c a m s h a ft c a re fu lly to avoid dam ag e to the c a m sh a ft b earings. On som e vehicles, it m ay be necesary to d isco nn ect th e front engine m ounting and raise the engine to provide clearance. C a m s h a ft lo b e s a nd jo u rn a ls fo r s c ra tc h e s , pitting, and wear. T im in g g ear for dam aged teeth. ffj Measure (Figure 29) • T h ru st plate to cam shaft clea ra n ce. Use a fe e le r g a g e ( fig u r e 2 9 ). T h e p r o p e r c le a r a n c e is 0 .0 0 3 - 0 .0 0 8 - in c h . If th e clearance is excessive, replace the th ru s t plate. If th e clearance is insu fficien t, replace the sp ace r ring. R efer to th e proper unit repair m anual. Camshaft Gear And Thrust Plate Replacement • Refer to the proper unit repair manual. Camshaft Bearing Replacement • Refer to the proper unit repair manual. Install or Connect (Figure 27) C oat the ca m sh aft lobes and jo u rn a ls w ith a high qua lity e ngine oil su pp le m en t (GM Engine Oil S u pp lem en t or equivalent). Figure 28—Removing The Camshaft Thrust Plate Bolts 6A7-16 4.8 LITER L6 Figure 29—Measuring Camshaft To Thrust Plate Clearance A. G u id e Rod 1. C a m s h a ft (9 0 ) to th e e n g in e . H a n d le th e ca m sh a ft ca re fu lly to prevent dam ag e to the ca m sh aft bearings. • Line up the tim in g m arks on the crankshaft gear and ca m sh a ft gear (figure 27). Thrust plate bolts (94). Tighten T hru st plate bolts to 9.0 N m (80 in. lbs.). Measure B-05066 Figure 30—Replacing the Connecting Rod and Piston CONNECTING ROD AND PISTON REPLACEMENT Remove or Disconnect (Figure 30) Tool R equired: J-5239 Guide Set. 1. Cylinder head, as outlined previously. 2. Oil pan, as outlined previously. — C am shaft and crankshaft gear run-out. Use ai d ia l in d ica to r. C a m s h a ft g e a r ru n -o u t should not exceed 0.10 mm (0.004-inch), cran ksha ft g ea r run-out should not exceed 0.08 m m (0.003-inch). If g ear run o ut is excessive, the g ea r w ill have to be rem oved and any burrs cleaned from the sh aft or the gear w ill have to be replaced. — Tim in g gear backlash. Use a dial indicator. T h e c o rr e c t b a c k la s h is 0.10-0.15 m m (0.004-0.006-inch) w ith new parts, 0.20 mm (0.008-inch) m axim um w ith used parts. 4. Timing gear cover, as outlined previously. 5. Torsional damper, as outlined previously. 6. Hydraulic lifters, as outlined previously. Im portant • R eplace all h yd ra u lic lifters, ch a n g e the crankcase oil and filter, and add GM Engine Oil S u ple m e nt (or equivalent) to the engine oil if a new ca m sh aft w as installed. 7. Pushrod covers, as outlined previously. 8. Distributor. Refer to ENGINE ELECTRICAL (SEC. 6D). 9. Rocker arm cover, as outlined previously. 10. Fuel pump. 11. Air cleaner. 12. Radiator, fan, pulley, and shroud. • Fill the cooling system with the proper quantity and grade of coolant. 13. Front end sheet metal, as required. 3. Oil pump, as outlined previously (if necessary). 4. Ridge or deposits from the upper end of the cylinder bores. • 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. • Turn the crankshaft until the piston is at TDC. • Remove the cloth and cuttings. 5. Connecting rod cap. Check the connecting rod and cap for ide ntifica tion marks. M ark 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 30). • Use the long guide rod of J-5239 to push the connecting rod and piston out of the bore. 7. Connecting rod bearing. Cleaning, Inspection, And Repair Clean, inspect and repair or replace the components as necessary. Measure connecting rod bearing clearance, piston clearance, ring clearances, etc. Refer to the proper unit repair manual. The unit repair manual contains information on: — Connecting rod and piston. — Piston rings. — Connecting rod and crankpin. — Cylinder bores. 4.8 LITER L6 6A7-17 ____ ENGINE FRONT " A ” OIL RING SPAC ER GAP / B t - “C " \ / \ (TANG IN HOLE OR SLO T W ITH IN ARC ) “ B " O IL RING RAIL GAPS “ C" 2ND C O M PR ESSIO N RING GAP “ D" TOP CO M PRESSIO N RING GAP IN L IN E -A L L CYL. A-7809 Figure 31—Piston Ring Gap Location -►+ Install or Connect (Figures 30 through 34) • • 1. 2. Tools R equired: J-5239 Connecting Rod Guide Set J-8037 Ring Compressor Make sure the cylinder walls are clean. Lubricate the cylinder wall lightly with engine oil. Make sure the piston is installed in the m atching cylinder. Connecting rod bearings. • Be certain that the bearings are of the proper size. • Install the bearing inserts in the connecting rod and connecting rod cap. • Lubricate the bearings with engine oil. Piston and connecting rod to the proper bore. • With the connecting rod cap removed, install J-5239 onto the connecting rod studs (figure 30). • Locate the piston ring end gaps as shown in figure 31. Lubricate the piston and rings with engine oil. • W ithout disturbing the ring end gap location, install J-8037 over the piston (figure 32). • The piston must be installed so that the piston crown d epression’s fla t side faces to the engine’s left side (figure 33). • Place the piston in its m atching bore. Using light blows with a hammer handle, tap the piston down into its bore (figure 33). At the same time, from beneath the vehicle guide the connecting rod to the crankpin with J-5239 (figure 30). Hold the ring compressor against ■ the block until all rings have entered the cylinder bore. • Remove J-5239 from the connecting rod bolts. 2 , Measure • C onnecting rod b earing clearance. R efer to the proper unit repair m anual. 3. Connecting rod cap and bearing. 4. Connecting rod cap nuts. Q Tighten C on ne cting rod cap nuts to 60 N-m (44 ft. lbs.). Measure C on ne cting rod side clearance. Use a fe ele r g a g e b e tw e e n th e c o n n e c tin g rod a nd cran ksha ft (figure 34). The co rrect clea ra n ce is 0.006-0.017-inch. 5. Oil pump (if removed), as outlined previously. 6. Oil pan and cylinder head, as outlined previously. A. F ro n t o f E n g in e B. F ly w h e e l S id e o f E n g in e C. P is to n D e p re s s io n F la t S id e Figure 33—Pistons Installed B-05256 6A7-18 4.8 LITER L6 Figure 34—Measuring Connecting Rod Side Clearance MAIN BEARING REPLACEMENT Remove or Disconnect (Figures 35 and 36) Tool R equired: J-8080 Main Bearing Remover/Installer Spark plugs. Oil pan, as outlined previously. Oil pump, as outlined previously. Main bearing caps. • Check the main bearing caps for location markings. Mark the caps if necessary. The caps m ust be retu rne d to th e ir o rig in a l locations during assembly. 5. Lower main bearing inserts from the main bearing caps. 6. Rear crankshaft oil seal, if necessary, as outlined previously. 7. Upper rear main bearing insert. • Use a smali brass drift and hammer. Tap on the insert, on the side opposite the bearing tan, 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. 8. Upper main bearing inserts. • Insert J-8080 into the crankshaft oil hole (figure 36). • Rotate the crankshaft to “ turn” the bearing insert out of the block. Cleaning, Inspection, And Repair Clean, inspect, and repair or replace the components as required. Refer to the proper unit repair manual. The unit repair manual contains information on: • Crankshaft. • Main and connecting rod bearings. • M a in b e a rin g c a p re p la c e m e n t (s h im m in g procedure). Install or Connect (Figures 25, 35, 36, and 37) Tool R equired: J-8080-Main Bearing Remover/Installer Figure 35—Removing The Upper Rear Main Bearing Insert 4.8 LITER L6 6A7-19 • Rotate the crankshaft to “ roll” the insert into the block. • Remove the tool. 4. Lower main bearing inserts to the main bearing caps. • Make sure the inserts are of the proper size. • Apply engine oil to the inserts. Measure Figure 36—Removing The Upper Main Bearing Insert • M ain b earing clearance. R efer to the proper unit repair m anual. If the engine is in the vehicle, the crankshaft m ust be su pp orte d upw ard to rem ove any clearance from the upp er bearing. The total clerance can then be m easured betw een the lower bearing and jou rn a l. 5. Main bearing caps (except rear cap) and bolts to the block. Make sure the special bolt which retains the oil pump screen bracket is installed in the proper position. (#5 main bearing cap, camshaft side hole.) Tighten 1. Upper rear main bearing insert. • Apply engine oil to an insert of the proper size. • Insert the plain end (without the bearing tang) of the insert between the crankshaft journal and the notched side of the block. • Use p lie rs w ith ta pe d jaw s to clam p the bearing to the crankshaft as shown in figure 35. Rotate the crankshaft to “ roll” the insert into the block. Then seat the insert using a small drift and hammer. 2. Lower rear main bearing insert. • Apply engine oil to an insert of the proper size. • Press the insert into the rear main bearing cap. 3. Upper main bearing inserts. • Insert tool J-8080 into a crankshaft main bearing oil hole (figure 36). • 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. • M ain bearing cap bolts to 90 N m (65 ft. lbs.). 6. Rear crankshaft oil seal to the block and main bearing cap, as outlined previously. 7. Rear main bearing cap to the block. • Apply a brush-on type oil sealing com pound to the mating surface of the block and cap (figure 25). Do not a llow any s e a la n t on e ith e r crankshaft or rear oil seal. • Apply engine oil to the bearing insert. • Install the rear main bearing cap and bolts. Tighten the bolts tem porarily to 14 N m (10 ft. lbs.). Measure • C ra nksh a ft end play, as follow s: • Tap th e end of th e c ra n k s h a ft firs t re a rw a rd th e n fo rw a rd w ith a lead hammer. This will line up the rear main bearing and crankshaft thrust surfaces. • Tighten the rear main bearing cap bolts to 90 N m (65 ft. lbs.). • W ith the c ra n ksh a ft forced forw ard, measure at the front end of the rear main bearing with a feeler gage (figure 37). The proper clearance is 0.05-0.15 mm (0.002-0.006-inch). 8. Oil pump, as outlined previously. 9. Oil pan, as outlined previously. 10. Spark plugs. CRANKSHAFT GEAR REPLACEMENT A. B. 100. 101. F o rw ard F e e le r G age R ear M ain B e a rin g C ap C ra n k s h a ft Remove or Disconnect (Figure 38) B-07878 Figure 37—Measuring Crankshaft End Play Tool R equired: J-24420-A Puller. 1. 2. Crankshaft gear. Use J-24220-A (figure 38). 6A7-20 4.8 LITER L6 VALVE REMOVAL VALVE INSTALLATION B-03497 Figure 39—Replacing The Oil Filter Bypass Valve +«- Install or Connect (Figure 39) 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. CRANKSHAFT REPLACEMENT 1. Remove the engine. 2. Refer to the proper unit repair manual for crankshaft replacement procedure. FLYWHEEL REPLACEMENT Remove or Disconnect (Figure 40) ■H" Install or Connect (Figures 27 and 38) Tool R equired: J-5590 Crankshaft Gear Installer. 1. Crankshaft gear. Use J-5590 (figure 38). Make sure the tim ing mark faces out. Im portant • A lign the tim in g m arks (figure 27). 2. Timing gear cover, as outlined previously. 1. Transm ission, clutch housing, and clutch. 2. R e a r m a in b e a r in g c a p . R e fe r to “ R e a r C ra nksh a ft Oil Seal R e p la c e m e n t” in th is section. • M ark the flyw heel and cra n ksh a ft so the dowel pin holes can be aligned in th e ir o rigin al positions at assem bly (figure 40). • Loosen the flyw heel bolts a few turns. 3. Flyw heel dowel pins. • Turn the crankshaft so that a dowel pin is at the 6 o’clock position. • Drive the dowel pin out, using a hammer and drift. • Repeat the preceding steps to drive out the remaining dowel pins. The crankshaft must be turned each time so that the pin can be driven out w ithout contacting the block. 4. Flywheel bolts. 5. Flywheel. Clean OIL FILTER BYPASS VALVE REPLACEMENT Remove or Disconnect (Figure 39) 1. Oil filter. 2. Oil filte r relief valve. Pry it from the b lock w ith a screw driver (figure 39). • M a tin g s u rfa c e s o f c ra n k s h a ft and fly w h e e l. R em ove any burrs. Inspect Flyw heel R e p la c e m achine Flyw heel for burning, sco ring , w arping, and wear. th e fly w h e e l if n e c e s s a ry . Do n o t the flyw heel. ring gear for w orn or broken teeth. 4.8 LITER L6 6A7-21 5. Transmission, clutch housing, and clutch. ENGINE MOUNTINGS NOTICE: Broken or deteriorated mountings can cause misaligned and eventual destruction of certain drive train components. When a single m o u n tin g b re ak ag e o ccurs, the re m ain in g mountings are subjected to abnormally high stresses. INSPECTING ENGINE MOUNTINGS Front Engine Mountings Figure 40—Flywheel Dowel Pin Hole Locations Flywheel Ring Gear Replacement 1. Use a torch to heat the gear around the entire circumference, then drive the gear off the flywheel, using care not to damage the flywheel. NOTICE: Never heat starter gear to red heat as this will change m etal structure. 2. Uniformly heat the flywheel gear to temperature which will expand the gear to permit installation. Temperature must not exceed 2 0 4 °C (400°F). 3. As soon as the gear has been heated, install on the flywheel. 0 Install or Connect (Figure 40) 1. Flyw heel to the crankshaft. A lign the m arks m ade at disassem bly. M ake sure the dow el holes in the cran ksha ft and flyw heel are aligned. Flyw heel. • Bolts to 150 N m (110 ft. lbs.). 3. Dowel pins. • The in te rfe re n c e fit dow el pin s m ust 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 dowel pins into place, flush with the flywheel retaining bolt surface. Rear main bearing cap. Refer to “ Rear Crankshaft Oil Seal Replacem ent” in this section. 1. R aise th e e n g in e to rem ove w e ig h t from th e m ountings and to palce a slight tension on the rubber cushion. Observe both m ountings w hile raising the engine. 2. Replace the mounting if the following conditions exist: — Hard rubber surface covered with heat check cracks. — R ubber cushion separated from the metal plate of the mounting. — Rubber cushion split through the center. 3. If there is movement between a metal plate of the m ounting and its attaching points, lower the engine and tighten the bolts or nuts attaching the m ounting to the engine, frame, or bracket. Rear Mountings 1. Push up and pull down on the transm ission tailshaft. Observe the transm ission mounting. 2. Repalce the m ounting if the following conditions exist: — R ubber cushion separated from the metal plate of the mounting. — M ou ntin g bottom ed out (ta ils h a ft can be moved up but not down). 3. If there is relative movement between a metal plate of the m ounting and its attaching point, tighten the b o lts or n u ts a tta c h in g th e m o u n tin g to th e transm ission or crossmember. FRONT MOUNTING REPLACEMENT +-► Remove or Disconnect (Figures 41 and 42) • S upport the eng in e w ith a su itab le liftin g fixture. Do not load the e ngine m ounting. 1. Engine m ou ntin g thro ug h -b olt and nut. • Raise the eng in e only enough to p e rm it rem oval of the eng in e m ounting. 2. M ounting assem bly bolts, nuts, and w ashers. 3. M ounting assem bly. Install or Connect (Figures 41 and 42) NOTICE: See “ N o tice” on page 6A7-1 of this section for steps 2 and 3. 1. Mounting assembly. 2. Mounting assem bly bolts, nuts, and washers. 6A7-22 4.8 LITER L6 150 MODELS WITH I-BEAM AXLE (RPO-FS3) A. 48 N m (36 ft. lbs.) B. Torque N u t To 68 N m (50 ft. lbs.) Or, Torque B o lt To 100 N-m (75 ft. lbs.) C. Forw ard B-07883 Figure 41—Front Engine Mounting Brackets Tighten • Fasteners to sp ecifications. R efer to figures 41 and 42. 3. Engine m ount through-bolt and nut. Lower the engine until the bolt can be inserted. Install the nut. Tighten • T hro ug h-bo lt or nut to sp ecifications. Refer to fig ure 41. REAR MOUNTING REPLACEMENT (P-MODELS WITH TRANSMISSION TAIL MOUNTING) |+ + | Remove or Disconnect (Figure 43) • S u pp o rt the rear of the engine to relieve the w eig ht on the rear m ountings. 1. M ounting to crossm em be r nut(s) and washer(s). 2. M ounting to tran sm issio n bolts and washers. • Raise the rear of the e ngine only enough to p erm it rem oval of the m ounting. 3. M ounting. -►+ Install or Connect (Figure 43) 1. M ounting. • Lower the rear of the engine. 2. M ounting to tran sm issio n bolts and washers. MODELS WITHOUT I-BEAM AXLE A. 40 N-m B. F orw ard 150. M o u n tin g A s s e m b ly 152. Fram e B ra cket B-07894 NOTICE: See “ N o tice” on page 6A7-1 of this section. 3. Mounting to crossm em ber nut and washer. Figure 42—Front Engine Mountings (P Models) 4.8 LITER L6 6A7-23 MODELS WITH PROPSHAFT PARKING BRAKE A. B. C. D. F orw ard 68 N m (50 ft. lbs.) 48 N m (36 ft. lbs.) 60 N-m (44 ft. lbs.) MODELS WITHOUT PROPSHAFT PARKING BRAKE B-07901 Figure 43—Rear Engine Mounting (P Models With Transmission Tail Type Mounting) 6A7-24 4.8 LITER L6 10. 11. 12. 13. 14. 15. • 16. • 17. 18. Evaporate em ission and o the r vacuum hoses. Engine w iring. Starter. Exhaust pipe at the e xhaust m anifold. W ire the pipe out of the way. Flywheel cover. F lyw heel to to rq ue c o n v e rte r bolts (a u to m a tic transm ission). A ttach a su itab le lifting device to the engine. Rem ove the w eig ht from the engine m ountings. Front engine m ounting through-bolts. S u p p o rt th e tr a n s m is s io n w ith a c h a in o r transm ission jac. Bell housing to engine bolts. Engine. Move the eng in e forw ard to dise ng ag e the transm ission and rem ove. Install or Connect (Figure 41) Figure 44—Rear Engine Mounting (P Models With Flywheel Housing Type Mounting) Engine. Move the e ngine rearw ard to engage the transm ission. 2 . B e ll h o u s in g to e n g in e b o lts . R e m o v e th e tran sm issio n ja ck or su p p o rt chain. Front eng in e m ounting th ro ug h -b olts and nuts. Tighten • Fasteners to specifications. R efer to figure 43. REAR MOUNTING REPLACEMENT (P-MODELS WITH FLYWHEEL HOUSING MOUNTING 4. |+ + | Remove or Disconnect (Figure 44) 1. Bolt, cushion and spacer. • Raise the rear of the engine only enough to p erm it rem oval of the m ounting. 2. M ounting. |-n-| Install or Connect (Figure 44) 1. M ounting. A lign the hole in the m ounting w ith the hole in the crossm em ber. • Lower the rear of the engine. NOTICE: See “ N o tic e ” on page 6A7-1 of this section. 2. Spacer, cushion and bolt. Tighten • Bolt to 90 N m (65 ft. lbs.). ENGINE REPLACEMENT Additional steps may be necessary on “ P” models depending on body builder design. Remove or Disconnect 1. 2. 3. 4. 5. 6. 7. 8. 9. Battery negative cable. Hood and sheet m etal, as required. A ir cleaner. Radiator. H eater hoses from the engine. A ccelerator cable. Transm ission detent cable (if used). Fan and w ater pum p pulley. Fuel lines from the fuel pump. 5. 6. 7. 8. 9. 10. 11. 12 . 13. 14. 15. 16. 17. 18. 19. • Fasteners to specificatio ns. Refer to figure 41. Remove the lifting device. Torque c o n v e rte r to fly w h e e l b olts (a u to m a tic transmission). Flywheel cover. Exhaust pipe and new packing to the exhaust manifold. Starter. Engine wiring. Vacuum hoses. Fuel lines. Fan and water pump pulley. Transmission detent cable (if used). Accelerator cable. Heater hoses. Radiator. Air cleaner. Hood and sheet metal. Battery negative cable. Proper quantity and grade of coolant. 4.8 LITER L6 6A7-25 SPECIFICATIONS ENGINE SPECIFICATIONS All Specifications are in INCHES unless otherwise noted. GENERAL DATA: In L in e Type 4 .8 L ( 2 9 2 C u . In .) D is p la c e m e n t 6 N o . O f C y lin d e r s 3 .8 7 6 B o re S tro k e 4 .1 2 C o m p r e s s io n R a tio 8 .0 :1 1 - 5 - 3 - 6 - 2 - 4 F ir in g O r d e r 16 psi @ O il P r e s s u r e 7 0 0 R P M ; 3 0 -4 5 p si @ 1500 R PM CYLINDER BORE: 3 .8 7 5 0 -3 .8 7 8 0 D ia m e te r O ut O f P r o d u c tio n Round S e r v ic e P r o d u c tio n Taper 0 .0 0 0 5 (M a x im u m ) 0 .0 0 2 (M a x im u m ) T h r u s t S id e 0 .0 0 0 5 (M a x im u m ) R e lie f S id e 0 .0 0 0 5 (M a x im u m ) 0 .0 0 1 ( M a x im u m ) S e r v ic e PISTON: 0 .0 0 2 6 -0 .0 0 3 6 P r o d u c tio n 0 .0 0 4 5 (M a x im u m ) S e r v ic e L im it PISTON RING: C 0 M p Top G ro o v e P r o d u c tio n Ploaran np R t S S e r v ic e L im it s P r o d u c tio n G ap 1 0 N S e r v ic e L im it G ro o v e 0 C le a r a n c e 0 .0 0 2 0 -0 .0 0 4 0 2nd P r o d u c tio n S e r v ic e L im it 1 P r o d u c tio n L S e r v ic e L im it H i L im it P r o d u c tio n Top 0 .0 1 0 -0 .0 2 0 2nd 0 .0 1 0 -0 .0 2 0 H i L im it P r o d u c t io n ± 0 .0 0 1 + 0 .0 1 0 + 0 .0 0 1 0 .0 0 5 -0 .0 0 5 5 H i L im it P r o d u c tio n 0 .0 1 5 -0 .0 5 5 H i P r o d u c tio n + 0 .0 1 0 PISTON PIN: 0 .9 2 7 0 -0 .0 9 2 7 3 D ia m e te r C le a r a n c e P r o d u c tio n In P is t o n S e r v ic e L im it F it In R o d 0 .0 0 0 1 5 -0 .0 0 0 2 5 0 .0 0 1 ( M a x im u m ) 0 .0 0 0 8 -0 .0 0 1 6 In te r fe r e n c e B-07896 6A7-26 4.8 LITER L6 SPECIFICATIONS ENGINE SPECIFICATIONS (CONT.) All specifications are in INCHES unless otherwise noted. CRANKSHAFT: Diameter Main Journal Production Service Limit Production Service Limit Taper Out of Round Main Bearing Clearance Production Service Limit Crankshaft End Play Diameter Production Service Limit Production Service Limit Production Service Limit Taper Crankpin Out Round Rod Bearing Clearance Rod Side Clearance All 2.2979-2.2994 0.0002 (Maximum) 0.001 (Maximum) 0.0002 (Maximum) 0.001 (Maximum) #1-#6: 0.0010-0.0024 #7: 0.0016-0.0035 #1-#6: 0.0010-0.0025 #7: 0.0015-0.0035 0.002-0.006 2.099-2.100 0.0005 (Maximum) 0.001 (Maximum) 0.0005 (Maximum) 0.001 (Maximum) 0.0010-0.0026 0.0030 (Maximum) 0.006-0.017 CAMSHAFT: Lobe Lift ± 0.002 Journal Diameter Camshaft Runout Camshaft End Play Intake Exhaust 0.2315 0.2315 1.8677-1.8697 0.020 (Maximum) 0.003-0.008 VALVE SYSTEM: Lifter Rocker Arm Ratio Hydraulic 1.75:1 Intake Exhaust Valve Lash Seat Width Stem Clearance Valve Spring (Outer) Valve Spring Damper Production Service Free Length Pressure lbs. @ in. O CO Face Angle (Intake & Exhaust) Seat Angle (Intake & Exhaust) Seat Runout (Intake & Exhaust One Turn Down From Zero Lash Intake Exhaust Intake Exhaust Intake Exhaust Closed Open Installed Height ± V32" Free Length Approx. # of Coils 46° 0.002 (Maximum) 0.035-0.060 0.062-0.093 0.0010-0.0027 0.0015-0.0032 High Limit Production +0.001 High Limit Production +0.002 2.08 78-86 lbs. @ 1.66" 170-180 lbs. @ 1.26" 121/32 1.94 4 B-07898 4.8 LITER L6 6A7-27 SPECIFICATIONS (CONT.) TORQUE SPECIFICATIONS Item Nm Ft. Lbs. In. Lbs. Flywheel Bolts 150 110 — Flywheel Housing Bolts 40 30 — Main Bearing Cap Bolts 90 65 — Cam shaft 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 25 — Oil Pump Cover Bolts 7.9 — 70 Oil Pan Bolts (To Front Cover) (To Block [1/4-20]) (To Block [5/i 6-18]) 5.1 9.0 18.6 — — — 45 80 165 C ylinder Head Bolts (Left-Hand Front Bolt) (All Others) 115 130 85 95 — Rocker Arm Cover Bolts (Cork 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 — — 6A7-28 4.8 LITER L6 SPECIAL TOOLS 1. tV . o J-9290-01 J-23523-E eir <§> 2. J-5892-B 3. J-23590 4. J-35468 5. J-8080 10. J-3049 11. J-5802-01 12. 13. J-5715 J-6036 14. 0 15. 6. J-6880 J-24420-A J-8037 16. J-5590 J-5239 8. 1. 2. 3. 4. 5. 6. 7. 8. 9. 17. J-23738-A Torsional Dam per Remover and In staller Valve S pring C o m pressor A ir A dapter C rankshaft Seal In s ta lle r and C entering Tool Main Bearing R eplacer Piston Ring C o m pressor G uide Set Vacuum Pump H ydraulic L ifte r Rem over (Slide Ham m er Type) J-8520 S= 10. 11. 12. 13. 14. 15. 16. 17. H ydraulic L ifte r Remover (Plier Type) Stud Remover Reamer (0.003-inch oversize) Reamer (0.013-inch oversize) Stud In staller C rankshaft Gear Puller C rankshaft Gear In sta lle r Dial In d ica to r Adapter B-08357 6B-1 SECTION 6B1 ENGINE COOLING CONTENTS SUBJECT PAGE Description.................................................................................................................................................................. 6B1- 1 Diagnosis.................................................................................................................................................................... 6B1- 2 System Checks........................................................................................................................................................ 6B1- 2 Fan Clutch Diagnosis..............................................................................................................................................6B1- 2 Thermostat Diagnosis............................................................................................................................................6B1- 3 Coolant Level Indicator Diagnosis....................................................................................................................... 6B1- 3 Cooling System D iagnosis....................................................................................................................................6B1- 5 Uncommon Cooling System P ro b le m s............................................................................................................... 6B1- 5 On Vehicle S>ervice.................................................................................................................................................... 6B1- 6 Flushing The Cooling System................................................................................................................................6B1- 6 Coolant Recovery Tank Replacem ent................................................................................................................. 6B1- 6 Deaeration Tank Replacement..............................................................................................................................6B1- 6 Thermostat Replacem ent......................................................................................................................................6B1- 7 Thermostat Housing Crossover R em oval........................................................................................................... 6B1- 8 Drive Belt Replacement..........................................................................................................................................6B1-10 Fan And Fan Clutch Replacement....................................................................................................................... 6B1-13 Auxiliary Cooling Fan Replacement..................................................................................................................... 6B1-14 Water Pump Replacement......................................................................................................................................6B1-15 S pe cifica tio n s............................................................................................................................................................ 6B1-30 Special T o o ls .............................................................................................................................................................. 6B1-32 DESCRIPTION All R/V, G„ and P series vehicles have pressure type engine cooling systems with therm ostatic control of the coolant circulation. The cooling system is sealed by a pressure type radiator cap that causes the system to oper­ ate at higher than atmospheric pressure. This higher pressure operation raises the boiling point of the coolant, thereby increasing the cooling efficiency of the radiator. The 105 kPa (15 psi) pressure cap raises the boiling point of the coolant to approximately 125°C (258°F) at seal level. The pressure-vacuum valve radiator cap allows the coolant to expand through the pressure valve in the cen­ ter of the cap without building unnecessary pressure. This expanding coolant flows into the coolant reservoir. The vent valve closes due to expansion and coolant flow (the nominal 105 kPa (15 psi) pressure will not be reached until the system is working at maximum capacity). Any air or vapor in the cooling system will be forced into and out of the coolant reservoir through the vent tube at the top of the reservoir. As the system cools, the extra coolant in the reservoir will be drawn back to the radiator through the vent valve. In this manner, the radiator will keep itself full at all times. 6B1-2 ENGINE COOLING DIAGNOSIS SYSTEM CHECKS EXHAUST LEAKS To check for exhaust leaks into the cooling system, drain the system until the coolant level stands just above the top of the cylinder head(s), then disconnect the radiator upper hose and remove the therm ostat and fan belt(s). Start the engine and accelerate several times. At the same time note any appreciable coolant rise or the appearance of bubbles which may indicate that exhaust gases are leaking into the cooling system. NOTICE: A worn head gasket may allow exhaust gases to leak into the cooling system. This can d am age the c o o lin g system as the gases combine with the water to form acids which are harmful to the radiator and engine. WATER PUMP Check water pump operation by running the engine while squeezing the radiator upper hose. When the engine warms a pressure surge should be felt. Check for a plugged venthole in the pump. Diagnosis/Inspection 1. Isolate the area by probing the engine w ith a sounding bar (large screwdriver). 2. With the radiator cap removed, observe the water being circulated in the radiator. Feel the front area of the radiator for cold spots which indicate blockage. Blocked radiators generally occur on units that have accrued miles and not on new vehicles. CAUTION: The radiator cap should be removed from a cool engine only. If the radiator cap is removed from a hot cooling system, serious personal injury may result. 3. Inspect the therm ostat to see if it opens. 4. Inspect the therm ostat housing to make sure it is free of obstructions. 5. Remove the water pump from the vehicle and the back cover on the pump. Inspect internal passages using a flash light. 6. Inspect the cross over at the front of the inlet manifold. This entire passage can be seen with the therm ostat removed. 7. Remove the heads, and check the block. RADIATOR Test for restrictions in the radiator by warming the engine and then turning the engine off and feeling the radiator. The radiator should be hot along the left side and warm along the right side, with an even temperature rise from right to left. Cold spots in the radiator indicate clogged sections. THERMOSTAT Check the therm ostat by hanging the therm ostat on a hook in a 33% glycol solution, 25°C (4°F) above the temperature stamped on the therm ostat valve. Submerge the valve and agitate the solution. The valve should open. Remove the therm ostat and place it in a 33% glycol solution, -12°C (10°F) below the temperature indicated on the valve. With the valve submerged and coolant agitated, the valve should close. 8. With the water pump and heads removed, inspect the coolant passages by using a pen light flash light. Replace the block if a restriction can be seen. 9. If none of the above inspections reveal the problem area, inspect the heads. Heads with blocked coolant passages generally have more than one area that is blocked. Inspect the heads for signs of overheat discoloration (a dark blue or black area). If none are found, look in the coolant passages for blockage and probe all accessible passages. Use a substantial probe as a tag wire to go through or around a partially blocked area. If nothing is found by visual inspection and probing, inspect the passages for a rough, ragged appearance. The roughest internal passages are probably the ones that are blocked. Replace a blocked or suspect head and inspect the replacement head before installation. OVERHEAT AND/OR NOISE Restrictions in the cooling system can cause the engine to overheat and/or create cooling system noise. Components prone to this condition are the cylinder head, water pump, block, therm ostat housing and inlet manifold. Symptoms include: FAN CLUTCH DIAGNOSIS NOISE Fan noise is sometimes evident under the following normal conditions. • Engine may make snapping/cracking noises. • When the clutch is engaged for maximum cooling. • Heater core may gurgle or surge. • During the first few minutes after start-up until the clutch can re-distribute the silicone fluid back to its norm a l d is e n g a g e d o p e ra tin g c o n d itio n (a fte r overnight settling). • Radiator hoses may collapse and expand. • Heater hoses may vibrate and thump. • Overheat light may or may not come on. Symptoms are the result of coolant boiling at some localized area and may be noticed after extending idling and/or while driving. Determine which side of the engine is involved and whether it is more at the front or rear of the engine. Fan noise or an excessive roar will generally occur continuously under high engine speed conditions (2500 rpm and up) if the clutch assem bly is locked up due to an internal failure. If the fan cannot be rotated by hand or there is a rough grating feel as the fan is turned, replace the clutch. ENGINE COOLING 6B1-3 ‘ NOTE: 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 THERMOSTAT’S OPERATING TEMPERATURE BY RUBBING 86.6°C (188°F) AND 96.6°C (206°F) STICKS ON THE THERMOSTAT HOUSING. THE MARKS MADE BY THE STICKS SHOULD MELT WHEN COOLANT TEMPERATURES OF 86.6°C (188°F) AND 96.6°C (206°F) 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 -0 7 5 4 0 Figure 1—Thermostat Diagnosis Chart LOOSENESS Check a loose fan assembly for any wear and replace if necessary. Under various temperature conditions a visible lateral movement that can be observed at the tip of the fan blade. This is a normal condition due to the type of bearing used. Approxim ately 6.5 mm (1/4-inch) maximum lateral movement measured at the fan tip is allowable. This is not cause for replacement. THERMOSTAT DIAGNOSIS Refer to the therm ostat diagnostic chart for therm ostat diagnosis procedures (figure 1). COOLANT LEVEL INDICATOR DIAGNOSIS INDICATOR LAMP WILL NOT ILLUMINATE SILICONE FLUID LEAKS The fan clutch operation is generally not affected by small fluid leaks which may occur in the area around the bearing assembly. If leakage appears excessive, replace the fan clutch (see below). ENGINE OVERHEATING If the fan and clutch assembly free-wheel with no drag (revolves more than five tim es when spun by hand), replace the clutch. 1. Turn the ignition switch to the CRANK position. • If the lamp illuminates, the lamp is OK and the connector is properly installed on the module. Go to Step 2. • If the lamp does not illuminate, check the bulb, socket and wiring between the socket and the module connector and the connector on the module. Replace or repair as required. 2. Turn the ignition switch to the ON position and disconnect the electrical lead a t the coolant level sensor on the radiator. 6B1-4 ENGINE COOLING COOLING SYSTEM DIAGNOSIS— CHART A F-02619 Figure 2—Cooling System Diagnosis Chart ENGINE COOLING 6B1-5 • If the lamp fails to illuminate, check the wiring between the coolant level sensor connector and the module for a short circuit to ground. If the circuit is OK, replace the module. COOLING SYSTEM DIAGNOSIS - CHART B INDICATOR LAMP REMAINS ILLUMINATED 1. Turn the ignition switch to ON. • C he ck th e c o o la n t level. Add c o o la n t if necessary. • If the lamp remains illuminated, go to Step 2. 2. Disconnect the electrical lead at the coolant level sensor on the radiator (use a jum per wire and “ G ” type electrical connector). • If the lamp does not illuminate, replace the sensor. • IM he lamp remains illuminated, connect the electrical lead and go to Step 3. 3. Check for an open circuit between the sensor and the module. • If an open circuit is found, repair it. • If no open circuit is found, replace the module. COOLING SYSTEM DIAGNOSIS Refer to the cooling system diagnosis chart for detailed cooling system diagnostic procedures (figures 2 and 3). UNCOMMON COOLING SYSTEM PROBLEMS PROBLEMS NOT REQUIRING DISASSEMBLY OF THE COOLING SYSTEM 1. Locate and remove large obstructions blocking the radiator or the condenser. • Auxiliary oil cooler. • License plates. • Spare tires. • Ice, mud, or snow obstructing the grille. 2. Engine oil is overfilled. 3. Incorrect radiator for the application. • Check the part number. 4. Loose, damaged, or missing air seals. 5. Missing or damaged lower air baffle. 6. Incorrect ignition timing. PROBLEMS REQUIRING DISASSEMBLY OF THE COOLING SYSTEM F-02620 Figure 3—Cooling System Diagnosis Chart 1. Incorrect or damaged fan. 2. Worn or dam aged emission system components. • Could cause overheating at idle. • Damaged PCV valve, TVS or TCS. 3. P re ssu re c h e c k th e c o o lin g system w ith 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. • Worn or damaged bearing and/or seal-check for shaft or bearing play. 5. Plugged radiator tubes. • Perform a flow check. 6. Internal system leaks. • Head gasket. 6B1-6 ENGINE COOLING • Cracked block. • Timing chain cover. • Intake manifold gasket. 7. Plugged coolant passages in the cylinder heads. • Visual check. ON VEHICLE SERVICE 1. R ecovery Tank 2. B o lt/S c re w 3. Cap 4. R eturn H ose 5. R a d ia to r A s s e m b ly 6. N ut B-07542 Figure 4—R/V - Coolant Recovery System FLUSHING THE COOLING SYSTEM Various methods and equipm ent can be used to flush the cooling system. If special equipm ent is used, follow the equipm ent m anufacturer’s instructions. DEAERATION TANK REPLACEMENT Remove or Disconnect (Figures 7, 8 and 9) 1. Coolant from the deaeration tank (10). 2. Overflow hose from the filler neck. 3. Return hose (12) from the deaeration tank (10). • Remove the therm ostat before flushing the cooling system. 4. Deaeration tank (10) from the vehicle. • For R/V and P vehicles; bolts/screws (7), and the reta inin g strap s (8) from the su p p o rt brackets (9) (figures 6 and 8). COOLANT RECOVERY TANK REPLACEMENT • For the G series vehicle; bolts/screws (7) and nut (6) (figure 7). • The deaeration tank (10) is free of the vehicle. Remove or Disconnect (Figures 4, 5 and 6) 1. Coolant from the recovery tank (1). 2. Coolant overflow hose from the recovery tank (1). -►+ Install or Connect (Figures 7, 8 and 9) Deareation tank (10) to the vehicle. • For R/V and P vehicles; deaeration tank (10) onto the support brackets (9). A ttach the retaining straps with bolts/screws around the tank and the lip on the support brackets (9). 3. Coolant recovery tank (1) from the vehicle. • Bolt/screw (2). ♦«" Install or Connect (Figures 4, 5 and 6) • For the G vehicle; deaeration tank (10) into position and attach with bolts/screws (7) and the nut (6). 1. Coolant recovery tank (1), to the vehicle. • Bolt/screw (2). $ Tighten & Tighten • Bolt/screws (7) and nut (6) to “ Specifications.” • Bolt/screw (2) to 2.0 N m (1.5 ft. lbs.). 2. Return hose (12) to the deaeration tank (10). 2. Coolant overflow hose to the recovery tank (1). 3. Overflow hose to the filler neck. 3. Coolant to the recovery tank (1). 4. Coolant into the deaeration tank (10). ENGINE COOLING 6B1-7 A. B. 1. 2. 3. 4. 5. G S eries A rra n g e m e n t W ith o u t A ir C o n d itio n in g G S eries A rra n g e m e n t W ith A ir C o n d itio n in g (N o t 6.2L D iesel) R ecovery Tank B o lt/S cre w C ap R eturn H ose R a d ia to r A s s e m b ly B B-07543 Figure 5—G - Coolant Recovery System THERMOSTAT REPLACEMENT VEHICLES EXCEPT THOSE WITH 6.2L ENGINE Remove or Disconnect (Figures 10 through 13) 1. Drain the cooling system until the radiator coolant level is below the thermostat. 2. Thermostat (23) from the vehicle. • Bolts (20) and the water outlet (21). • Thermostat from its housing. Tighten • For bolts (20), refer to “ Specifications.” 4. Fill the cooling system. 5. Start the engine and run with the radiator cap re m o ve d u n til th e ra d ia to r u p p e r hose becomes hot (thermostat is open). 6. With the engine idling, add coolant to the radiator until the coolant level reaches the bottom of the filler neck. 7. Radiator cap to the radiator, making sure the arrows line up with the overflow tube. • Gasket. VEHICLES WITH THE 6.2L ENGINE Install or Connect (Figures 10, 11 and 12) • Make sure the thermostat housing and water outlet sealing surfaces are clean. 1. Thermostat (23) in its housing. 2. New gasket (22) into position. 3. Water outlet (21). • Bolts (20). Remove or Disconnect (Figures 14 and 15) 1. Upper fan shroud from the G vehicle. • Refer to RADIATOR (SEC. 6B2). 2. Drain the cooling system until the radiator coolant level is below the thermostat. 3. Engine oil dipstick tube brace and the oil fill brace on the G vehicle. 6B1-8 ENGINE COOLING Gasket (22) into position. Water outlet (21). • Studs (26) and the upper radiator inlet hose. • Studs (26) to 47 N m (35 ft. lbs.). 4. Engine oil dipstick tube brace and the oil fill brace on the G vehicle. • Refer to 6.2L DIESEL (SEC. 6A6). 5. Upper fan shroud on the G vehicle. • Refer to RADIATOR (SEC. 6B2). 6. Fill the cooling system. 7. Start the engine and run, with the radiator cap re m o ve d , u n til th e ra d ia to r u p p e r hose becomes hot (thermostat is open). 8. With the engine idling, add coolant to the radiator until the coolant level reaches the bottom of the filler neck. 9. Radiator cap to the radiator, making sure the arrows line up with the overflow tube. THERMOSTAT HOUSING CROSSOVER REPLACEMENT R/V VEHICLE WITH 6.2L ENGINE Remove or Disconnect (Figure 16) 1. Coolant from the radiator. 2. Crankcase depression regulator valve. • Refer to 6.2L DIESEL (SEC. 6A6). 4. Thermostat (23) from the vehicle. • Studs (26) and the water outlet (21). • Upper radiator inlet hose. • Thermostat from its housing. • Gasket (22). ♦«- Install or Connect (Figures 15 and 16) • Make sure the therm ostat housing and water outlet sealing surfaces are clean. 1. Thermostat (23) into its housing. 3. Generator upper bracket. 4. By pass hose, upper radiator hose, and heater hose 5. Crossover (32) from the vehicle. • Bolts (27) from the vehicle. • Therm ostat (23) and water outlet (21) are attached to the crossover along with the thermal bypass nipple. ♦«- Install or Connect (Figure 15) Make sure the crossover sealing surfaces are clean. New gasket (28) into position. Crossover (32) to the vehicle. 5. R a d ia to r A s s e m b ly 6. N ut 7. B o lt/S cre w 8 . R e ta in in g S tra p 9. S u p p o rt B ra cke t 10. D ea e ra tio n Tank Figure 7—R/V - Deaeration Tank Installation ENGINE COOLING 6B1-9 • Q 3. 4. 5. 6. 7. 5. 7. 8. 9. 10. 8. With the engine idling, add coolant to the radiator until the coolant level reaches the bottom of the filler neck. Bolts (27). Tighten • Bolts (27) to 47 N m (35 ft. lbs.). Heater hose, upper radiator hose, and bypass hose. Generator upper bracket. Crankcase depression regulator valve. Coolant to the radiator. Start the engine and run, with the radiator cap removed, until the radiator upper hose becomes hot (thermostat is open). R a d ia to r A s s e m b ly B o lt/S c re w R e ta in in g S trap S u p p o rt B ra cket D ea re a tion Tank 11. C la m p 12. R eturn H ose 14. R a d ia to r S u p p o rt Brace B-07547 Figure 9—P - Deaeration Tank Installation 9. Radiator cap to the radiator, making sure the arrows line up with the overflow tube. Figure 10—4.3L Engine Thermostat Replacement (R/V and P) 6B1-10 ENGINE COOLING 20. B o lt 21. W a te r O u tle t (G, P S eries) 21 A. W a te r O u tle t 20. 21. 22. 23. B o lt W a te r O u tle t G a ske t T h e rm o s ta t 25. 26. 27. 28. B o lt S tud T h e rm o s ta t H o u s in g G a sket B-08081 Figure 11—4.8L Engine Thermostat Replacement (R/V and P) G AND P VEHICLES WITH 6.2L ENGINES |<~+| Remove or Disconnect (Figure 16) 1. 2. 3. 4. 5. 6. 7. 8. Coolant from the radiator. Engine cover from the G vehicle. Air cleaner. Air cleaner resonator and its bracket. Upper fan shroud. Generator upper bracket. Bypass hose, upper radiator hose, and heater hose. Crossover (32) from the vehicle. • Bolts (27), studs (26) and the gasket (28). • Therm ostat (23) and the water outlet (21) are attached. -►+ Install or Connect (Figure 16) Make sure the crossover sealing surfaces are clean. New gaskets (28) into position. Crossover (32) to the vehicle. • Bolts (27) and studs (26). & 3. 4. 5. 6. 7. 8. Tighten • Bolts (27) to 47 N m (35 ft. lbs.). • Studs (26) to 47 N m (35 ft. lbs.). Heater hose, upper radiator hose, and the bypass hose. Generator upper bracket. Upper fan shroud. Air cleaner resonator and its bracket. Air cleaner. Engine cover on the G vehicle. 22. 23. 24. 26. (C-K S eries) G a ske t T h e rm o s ta t In le t M a n ifo ld S tud B-08082 Figure 12—5.0L and 5.7L Engine Thermostat Replacement (R/V, G and P) 9. Coolant to the radiator. 10. Start the engine and run, with the radiator cap removed, until the radiator upper hose becomes hot (thermostat is open). 11. W ith the engine idling, add coolant to the radiator until the coolant level reaches the bottom of the filler neck. 12. Radiator cap to the radiator, m aking sure the arrows line up with the overflow tube. DRIVE BELT REPLACEMENT PULLEY INSPECTION Examine the pulleys for chips, nicks, tool marks, cracks, bent sidewalls, corrosion or other damage. 1. Place a straightedge or position a cord across the two pulleys so they touch at all points (figure 17). 2. Turn each pulley one half revolution and recheck with a straightedge or cord. Full contact at all points must be made. If contact is not made at all points, the pulley may be warped or its shaft could be bent. Replace any damaged parts. DRIVE BELT INSPECTION Replace frayed or cracked belts and tension to the proper specification. Do not use drive belt dressings to extend the belt life. ENGINE COOLING 6B1-11 Figure 13—7.4L Engine Thermostat Replacement (R/V and P) CAUTION: Avoid over or under-tightening drive belts. Loose belts result in slippage which can cause belt and pulley “ glazing” and inefficient component operation. Once a belt has become “ glazed,” replace the belt. Loose belts can also place high im p a ct loads on d rive n component bearings due to the whipping action of a loose belt. Over tightening belts can lead to bearing damage and early belt failure. DRIVE BELT REPLACEMENT - V-BELT 1. Remove the old belt. • Loosen the com ponent driven by the belt (figures 18 through 22). NOTICE: Place the belts into the pulley grooves by hand. Do not force a belt into a pulley groove by prying with a screwdriver, crowbar, or other wedge type tool. Prying a belt into position can d am ag e b o th th e b e lt a n d th e b e lt d rive components. 2. Install the new belt. • Tension the new belt to “ Specifications” • Use J-23600-B to measure V-belt tension. • Place the gage at the center of the greatest span. Tighten Component to mounting bracket fasteners to the “ Specifications” at the end of this section. (R/V) 3. Run the engine at idle speed for a minimum of 15 minutes. • This allows the belt to seat itself in the pulleys, causing the belt fibers to relax, or stretch. 4. Allow the drive belt to cool until it is cool or at most, warm to the touch. Not hot. NOTICE: A used belt is one that has been rotated at least one com plete revolution on the engine pulleys. This begins the “ seating” of the belt and it must never be tensioned to new belt specifications. 5. Check the belt tension. • Use J-23600-B to measure V-belt tension. • Place the gage at the center of the greatest span. • The belt tension should be at the maximum used belt specifications from the chart in “ Specifications.” DRIVE BELT ADJUSTMENT - V-BELT Never tension a used belt to more than its specified tension limit. 1. Check the belt tension. • Belt should be cool or at least warm to the touch. Not hot. • Use J-23600-B to measure V-belt tension. • Place the gage at the center of the greatest span. • If the belt is below the minimum “ used b elt” tension specification, adjust the belt. 6B1-12 ENGINE COOLING 21. W a te r O u tle t 27. B o lt 28. G a ske t Figure 15—6.2L Engine Thermostat Replacement (G and P) 29. N ip p le 30. C la m p 31. H ose 32. C ro sso ve r H ose B-08086 Figure 16—6.2L Engine - Crossover Replacement - 2. Loosen the com ponent in its m ounting bracket (figures 18 through 2 2 ). 3. T ension th e b e lt to th e m axim u m used b e lt specification from the chart in “ Specifications.” T ig h te n • Component to mounting bracket fasteners to the specifications at the end of this section. 4. Run the engine at idle for a minimum of 15 minutes. • This allows the belt to reseat itself in the pulleys. 5. Allow the drive belt to cool. • Should be at most warm to the touch. Not hot. 6 . Check the belt tension. • Use J-23600-B to measure V-belt tension. • Place the gage at the center of the greatest span. • R e -a d ju s t if n ot w ith in th e s p e c ific a tio n s fro m th e “ Specifications.” u se d b e lt c h a rt in Figure 17—Checking the Pulley Alignment ENGINE COOLING 6B1-13 VIEW A A. B. C. 40. 41. 4.8L L 6 E n gin e 4.3L V 6 , 5.0/5.7L V 8 E n g in e s 7.4L V 8 E n gin e A d ju s tm e n t B o lt P ivot B o lt Figure 18—Generator Adjustment (R/V, G and P) DRIVE BELT ROUTING R efer to th e d rive b e lt ro u tin g d ia g ra m s if b elt replacement becomes necessary. Refer to figures 23 to 32. FAN AND FAN CLUTCH REPLACEMENT Remove or Disconnect (Figure 34) DRIVE BELT REPLACEMENT - SERPENTINE BELT 1. Remove the old belt (figure 33). • With a socket and breaker bar, release the te n s io n by tu rn in g th e te n s io n e r p u lle y assem bly. The te nsio ne r p ulley is sprung activitied and it can be turned to the left or right to apply or release the pulley tension. 2. Install a new belt. • Thread the belt around the pulleys. • W ith a breaker bar apply the tension by turning the tensioner pulley assembly. DRIVE BELT ROUTING - SERPENTINE BELT Refer to drive belt routing diagrams if belt replacement becomes necessary (figure 33). 1. Radiator fan shroud. • Refer to RADIATOR (SEC. 6B2). 2. Fan (73) and fan clutch (74) from the water pump pulley (70). • Nuts (75). 3. Fan (73) from the fan clutch (74). • Bolts (72). -►4- Install or Connect (Figure 34) Inspect the mating surfaces (the water pump hub and the fan clutch hub) for smoothness and rework as n ecessary to e lim in a te any burrs o r other imperfections. 6B1-14 ENGINE COOLING H A B. C. D. 40. 41. i 4 g L |_g E n gin e 4.3L V 6 , 5.0/5.7L V 8 E ngin es (N o t P o r G S eries) 4.3L V 6 5.0/5.7L V 8 Engine is (P and G Series) 7.4L V 8 E n gin e A d ju s tm e n t B o lt Pivot B o lt B-08089 Figure 19—Power Steering Pump Adjustment (R/V, G and P) CAUTION: Do not repair and reuse a fan with a bent or damaged blade. Replace the fan as an assembly. A damaged blade can change the balance of a fan. A fan out of balance could fly apart during use and create a dangerous condition to the owner and vehicle. 1. Fan (73) to the fan clutch (74). Q Tighten AUXILIARY COOLING FAN REPLACEMENT The Auxiliary Cooling Fan is available when a 7.4L engine (RPO LE 8 ) and Air C onditioning (C60, C69) are ordered. Its to provide additional cooling at low speed vehicle operations, extended idle, stop and go conditions, and when running the air conditioning system. «■+ Remove or Disconnect (Figure 35) • Bolts (72) to 25 N m (18 ft. lbs.). 2. Fan and clutch assembly to the water pump pulley (70). • Nuts (75). Align the yellow reference marks on the water pump hub and the fan clutch hub. Tighten • Nuts (75) to 25 N m (18 ft. lbs.). 3. Fan shroud. • Refer to RADIATOR (SEC. 6B2). 1 . Grille assembly. • Refer to SHEET METAL (SEC. 2B). 2. Fan harness connector (83). 3. Fan assembly (81) from the radiator support (80). • Bolts/screws (82). |~n~| Install or Connect (Figure 35) 1. Fan assembly (81) to the radiator support (80). • Bolts/screws (82). ENGINE COOLING 6B1-15 A. 4.8L L 6 E n g in e B. 4.3 V 6 , 5.0/5.7L V 8 E n g in e s (N o t G Van) C. 4.3 V 6 , 5.0/5.7 L -------------V 8 E n g in e s D. 7.4L V 8 E ngine 40. A d ju s tm e n t B o lt 41. Pivot B o lt 42. Brace 43. S u p p o rt B-08090 Figure 20—Air Conditioning Compressor Adjustment Tighten • Bolt/screw (82) to 6 N m (53 ft. lbs.). 2. Fan harness connector (83). 3. Grille assembly. • Refer to SHEET METAL (SEC. 2B). WATER PUMP REPLACEMENT 4.8L ENGINE Remove or Disconnect (Figure 36) • Coolant from the radiator. 1. Accessory drive belts. • Refer to “ Drive Belt Replacement.” 2. Fan (73) and fan clutch (74) (figure 36). • Nuts (75). 3. Water pump pulley (70). • Pulley off the water pump studs (71), but do not damage the threads. 4. Lower radiator hose and the heater hose from the water pump (91). 5. Water pump (91) from the engine block (figure 36). • Bolts (92, 93), and gasket (94). • Loosen the generator adjusting bolt to allow the brace to be moved away on vehicles where the brace will inhibit water pump removal. ++ Install or Connect (Figures 36) Clean the mating surfaces on the water pump and the engine block. Water pump (91) to the engine block (figure 36). • New gasket (94) onto the water pump (91). • Place the generator adjusting brace back into position if moved. • Bolts (92 and 93). Tighten • Bolts (92 and 93) to the “ Specifications” at the end of this section. 2. Lower radiator hose and the heater hose to the water pump (91). 6B1-16 ENGINE COOLING Figure 21—Air Conditioning and A.i.R. Pump Adjustment (R/V, G and P) ENGINE COOLING 6B1-17 DIESEL DIESEL B-08092 Figure 22—Drive Belt Adjustment - 6.2L Engine (R/V, G and P) 6B1-18 ENGINE COOLING A. B. C. 50. 51. 52. 53. 54. 1st Track 2nd Track 3rd Track W a te r P um p P ulley C ra n k s h a ft P ulley G e n e ra to r P ulley A.I.R. P um p P ulley Pow er S te e rin g P um p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P ulley 55 B-08093 Figure 23—Engine A cce sso ry D rive - R/V (4.8L Engine) 3. Water pump pulley (70), fan (73), and fan clutch (74) on the water pump hub. Q Tighten • Nuts (75) to 25 N m (18 ft. lbs.). 4. Drive belts and adjust. • Refer to “ Drive Belt Replacement.” 5. Coolant to the radiator. 6 . Start the engine and run, with the radiator cap removed, until the radiator upper hose ( 12 ) becomes hot (thermostat is open). 7. Add coolant to the radiator until the level reaches the bottom of the filler neck. • Engine must be running at idle speed. 8 . Radiator cap, making sure the arrows line up with the overflow tube. 4.3L, 5.0L 5.7L AND 7.4L ENGINES Remove or Disconnect (Figures 37, 38, and 39) • Coolant from the radiator. 1. Accessory drive belts. • Refer to “ Drive Belt R eplacem ent.” 2. Fan (73), the fan clutch (74), and the pulley (70) from the water pump (91). • Nuts (75). 3. Generator lower brace attaching bolts and swing the brace down and out of the way. 4. Generator upper brace attaching bolts. 5. Lower radiator hose and heater hose from the water pump (91). • On the 7.4L engine, remove the bypass hose. 6 . Water pump (91) from the engine block. • Bolts (92, 93) and studs (95). Install or Connect (Figures 36, 37, 38 and 39} Clean the mating surfaces on the water pump and the engine block. ENGINE COOLING 6B1-19 50 A. B. C. D. 50. 51. 52. 53. 54. 1st Track 2nd Track 3rd Track 4 th Track W a te r Pum p P ulley C ra n k s h a ft P u lle y G e n e ra to r P ulley A.I.R. P um p P u lle y P ow er S te e rin g P um p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P u lle y Figure 24—Engine Accessory Drive - 4.3L, 5.0L, 5.7L and 7.4L (R/V) 4------54 A. B. C. D. 50. 1st Track 2nd Track 3rd Track 4th Track W a te r P um p P ulley 51. 52. 53. 54. 55. C ra n k s h a ft P ulley G e n e ra to r P ulley A.I.R. P um p P ulley P ow er S te e rin g P u m p P ulley A ir C o n d itio n in g C o m p re s s o r P ulley Figure 25—Engine Accessory Drive - Heavy Duty Emissions - 5.7L Engine (R/V) B-08095 6B1-20 ENGINE COOLING A. B. C. 50. 51. 52. 53. 54. 1st Track 2nd Track 3rd Track W a te r P um p P u lle y C ra n k s h a ft P u lle y G e n e ra to r P ulley A.I.R. P um p P ulley Pow er S te e rin g Pum p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P u lle y B-08096 Figure 26—Engine Accessory Drive - Federal Emissions - 7.4L Engine (R/V) 1. Water pump (91) to the engine block. • New gaskets (94). • Place the pump against the block and retain it with bolts (92, 93 and 95). Tighten • Bolts (92 and 93) and studs (95) to the “ Specifications.” 2. Lower radiator hose and the heater hose to the water pump (91). • Bypass hose with 7.4L engine. 3. Generator upper and lower braces to the water pump (91). 4. Water pump pulley (70), fan (73) and fan clutch (74) to the water pump hub. • Nuts (75). Tighten • Nuts (75) to 25 N m (18 ft. lbs.). 5. Accessory belt drive and adjust. • Refer to “ Belt Drive Replacem ent.” 6. Coolant to the radiator. 7. Start the engine and run, with the radiator cap removed, until the radiator upper hose (12) becomes hot (thermostat is open). 8. Add coolant to the radiator until the level reaches the bottom of the filler neck. • Engine must be running at idle speed. 9. Radiator cap, making sure the arrows line up with the overflow tube. 6.2L ENGINE R e m o v e o r D is c o n n e c t (F ig u re 40) • Coolant from the radiator. 1. Fan. • Refer to “ Fan And Fan Clutch Replacem ent.” 2. Fan shroud. • Refer to RADIATOR (SEC. 6B2). 3. Air conditioning hose bracket nuts. 4. Oil fill tube. 5. Generator drive belt. 54 B. C. 50. 51. 2nd Track 3rd Track W a te r P um p P u lle y C ra n k s h a ft P u lle y 52. 53. 54. 55. G e n e ra to r P ulley A.I.R. P um p P ulley P ow er S te e rin g P um p P ulley A ir C o n d itio n in g C o m p re s s o r P u lle y Figure 27—Engine Accessory Drive - California Emissions - 7.4L Engine (R/V) B-08097 ENGINE COOLING 6B1-21 50 B .51 C 56 55 50 A. B. C. D. 50. 51. 52. 53. 54. 1st Tract 2nd Track 3rd Track 4 th Track W a te r P um p P u lle y C ra n k s h a ft P u lle y G e n e ra to r P ulley A.I.R. P um p P u lle y P ow er S te e rin g P um p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P u lle y 56. Id le r Pulley 54 B-09164 Figure 28—Engine Accessory Drive - 5.7L and 6.2L Engines - V-Belt (G) B. C. D. 50. 2nd Track 3rd Track 4th Track W a te r P um p P ulley 51. C ra n k s h a ft P u lle y 52. G e n e ra to r P u lle y 53. A.I.R. P um p P u lle y 54. 55. 56. A ir C o n d itio n in g C o m p re s s o r P ulley Id le r P u lle y Figure 29—Engine Accessory Drive - Heavy Duty Emission - 5.7L Engine - V-Belt (G) F-00911 6B1-22 ENGINE COOLING A. B. C. 50. 51. 52. 53. 54. 1st Track 2nd Track 3rd Track W a te r Pum p P u lle y C ra n k s h a ft P u lle y G e n e ra to r P u lle y A.I.R. P um p P ulley P ow er S te e rin g P u m p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P u lle y F-00912 Figure 30—Engine Accessory Drive - (P) 4.8L Engine 6. 7. 8. 9. 10. 11. 12. • Generator pivot bolt. • Refer to “ Drive Belt Replacement.” Generator lower bracket. Power steering belt. • Refer to “ Drive Belts Replacement.” Power steering pump. Air conditioning compressor belt, if equipped. • Refer to “ Drive Belts Replacement.” Bypass hose and the lower radiator hose. Water pump (91) (figure 44). • Bolts (96 and 97), water pump plate (99) and the water pump (91). Water pump plate (99) from the water pump (91). • Bolts (92 and 93) and the gasket (94). In s ta ll o r C o n n e c t (F ig u re 40) • Flanges must be free of oil. Clean the mating surfaces on the water pump, both sides of the water pump plate, and the engine block. 1. Water pump (91) to the water pump plate (99). • Gasket (94) and bolts (92 and 93). Tighten • Bolts (92 and 93) to “ Specifications.” 2. Water pump (91) to the engine block. • Apply anerobic sealer #1052357 or equivalent. • The sealer must be wet to the touch when the bolts are tightened. • Bolts (96 and 97). Tighten • Bolts (96 and 97) to “ Specifications.” 3. Bypass hose and lower radiator hose. 4. Power steering pump. 5. Generator in place. • Generator lower bracket. 6. Drive belts and adjust. • Refer to “ Drive Belts R eplacem ent.” 7. Oil fill tube. 8. Fan shroud. • Refer to RADIATOR (SEC. 6B2). 9. Fan (73) assembly. • Refer to “ Fan And Fan Clutch R eplacem ent.” 10. Coolant to the radiator. 11. Start the engine and operate with the radiator cap removed until the radiator upper hose (12) becomes hot (thermostat is open). 12 Add coolant to the radiator until the level reaches the bottom of the filler neck. • Engine must be running at idle speed. 13. Radiator cap, making sure the arrows line up with the overflow tube. ENGINE COOLING 6B1-23 C 56 55 A. B. C. D. 50. 51. 52. 53. 54. 1st Track 2nd Track 3rd Track 4th Track W a te r P um p P ulley C ra n k s h a ft P u lle y G e n e ra to r P u lle y A.I.R. P um p P u lle y P ow er S te e rin g P u m p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P u lle y 56. Id le r P ulley F-00913 Figure 31—Engine Accessory Drive - Heavy Duty Emissions - 5.7L Engine (P) 6B1-24 ENGINE COOLING 1st Track 2nd Track 3rd Track W a te r P um p C ra n k s h a ft P ulley G e n e ra to r P u lle y A.I.R. P um p P u lle y Pow er S te e rin g Pum p P ulley 55. A ir C o n d itio n in g C o m p re s s o r P u lle y A. B. C. 50. 51. 52. 53. 54. F-00914 Figure 32—Engine Accessory Drive - 7.4L Engine (P) ENGINE COOLING 6B1-25 G 4.3L, 5.0L and 5.7L Serpentine Accessory Drive F-02581 Figure 33—Engine Accessory Drive - Serpentine Drive, 4.3L, 5.0L and 5.7L Engine (G) 6B1-26 ENGINE COOLING 70. 71. 72. 73. 74. 75. 76. 77. W a te r P um p P u lle y S tud B o lt Fan Fan C lu tc h N ut C ra n k s h a ft P u lle y W a te r P um p A. Y ellow P aint M arks F o r P ro pe r A lig n m e n t O f T he Fan C lu tc h H ub To The W a te r P u m p H ub Figure 34—Fan and Fan Clutch Installation Figure 35—Auxiliary Cooling Fan Installation F-00921 ENGINE COOLING 6B1-27 90. E n g in e B lo c k 91. W a te r Pum p F-00924 Figure 37—Water Pump Replacement - 4.3L Engine 6B1-28 ENGINE COOLING Figure 39—Water Pump Replacement - 7.4L Engine ENGINE COOLING 6B1-29 Figure 40—Water Pump Installation - 6.2L Engine 6B1-30 ENGINE COOLING SPECIFICATIONS DRIVE BELT TENSION SPECIFICATIONS Generator Power Steering Pump Air Conditioning Compressor A.I.R. Pump Before Operating The Engine (New Belt) 750 N (169 lb.) 750 N (169 lb.) 750 N (169 lb.) 750 N (169 lb.) After 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.) After Operating The Engine (Old Belt) 400 N (90 lb.) 300 N (67 lb.) 400 N (90 lb.) 300 N (67 lb.) Before Operating The Engine (New Belt) 600 N (135 lb.) 650N (146 lb.) 750 N (169 lb.) 650 N (146 lb.) Tension Requirement Engine 4.8L L6 4.3L V6 5.0L V8 5.7L V8 7.4L V8 6.2L V8 (Diesel) After Operating The Engine (Old Belt) 400 N (90 lb.) 300 N (67 lb.) 400 N (90 lb.) 300 N (67 lb.) Before Operating The Engine (New Belt) 600 N (135 lb.) 650 N (146 lb.) 750 N (169 lb.) 650 N (146 lb.) After Operating The Engine (Old Belt) 400 N (90 lb.) 300 N (67 lb.) 400 N (90 lb.) 300 N (67 lb.) Before Operating The Engine (New Belt) 600 N (135 lb.) 650 N (146 lb.) 650 N (146 lb.) *650 N (146 lb.) After 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) 650 N (146 lb.) 650 N (146 lb.) 750 N (169 lb.) After Operating The Engine (Old Belt) 300 N (67 lb.) 300 N (67 lb.) 400 N (90 lb.) — — * When equipped with a right hand mounted pump and/or Federal Emissions (NAS) ONLY. DO NOT exceed the “ New Belt” tension specification when tensioning any belt, especially a used belt. 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 Adjustment Bolt 25 N m (18 ft. lbs.) 25 N-m (18 ft. lbs.) 25 N-m (18 ft. lbs.) 25 N-m (18 ft. lbs.) 27 N-m (20 ft. lbs.) *25 N-m (18 ft. lbs.) Generator Pivot Bolt 23 N m (17 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 43 N-m (32 ft. lbs.) 50 N-m (37 ft. lbs.) Power Steering Pump Adjustment Bolt 43 N-m (32 ft. lbs.) 33 N-m (24 ft. lbs.) 33 N-m (24 ft. lbs.) 33 N-m (24 ft. lbs.) 43 N-m (32 ft. lbs.) 88 N-m (65 ft. lbs.) Power Steering Pump Pivot Bolt 24 N m (17 ft. lbs.) 33 N m (24 ft. lbs.) 33 N-m (24 ft. lbs.) 33 N-m (24 ft. lbs.) 43 N-m (32 ft. lbs.) 50 N-m (37 ft. lbs.) Air Conditioning Condenser Adjustment Bolt 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) Air Conditioning Condenser Pivot Bolt 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N m (25 ft. lbs.) 34 N-m (25 ft. lbs.) 34 N m (25 ft. lbs.) Air Injection Reactor (A.I.R.) Pump Adjustment Bolt 25 N m (18 ft. lbs.) 25 N-m (18 ft. lbs.) 25 N-m (18 ft. lbs.) **2 5 N-m (18 ft. lbs.) - 33 N-m (24 ft. lbs.) Air Injection Reactor (A.I.R.) Pump Pivot Bolt 24 N-m (17 ft. lbs.) 24 N-m (17 ft. lbs.) 24 N-m (17 ft. lbs.) **2 4 N-m (17 ft. lbs.) - 33 N-m (24 ft. lbs.) * For P series vehicles, torque is 64 N m (47 ft. lbs.) with the K97 Generator. ** For the 5.7L V8 with Federal Emissions (RPO NA5), torque is 50 N m (37 ft. lbs.) ENGINE COOLING 6B1-31 SPECIFICATIONS (CONT.) THERMOSTAT AND RESERVOIR RELATED TORQUE SPECIFICATIONS Fastener Name R/V 10/1500 R/V 20/2500 R/V 30/3500 G 10/1500 G 20/2500 G 30/3500 Coolant Recovery Tank Bolt/Screw 2 Nm 2 Nm 2 Nm 2 N-m 2 Nm 2 Nm (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) (18 in. lbs.) Deaeration Tank Bolts/ Screws And Nuts 5 Nm 5 Nm 5 Nm (44 in. lbs.) (44 in. lbs.) (44 in. lbs.) Water Outlet To The Thermostat Housing Bolts *•2 7 N m (20 ft. lbs.) *•2 7 N m (20 ft. lbs.) Thermostat Crossover To The Engine Bolts (6.2L Diesel ONLY) 47 N m (35 ft. lbs.) Water Outlet To The Thermostat Housing Bolts (6.2L Diesel ONLY) 47 N m (35 ft. lbs.) P 20/2500 P 30/3500 — — — — - - 10 N m (88 in. lbs.) - 17 N-m (12 ft. lbs.) *•2 7 N m (20 ft. lbs.) *•2 7 N m (20 ft. lbs.) *•2 7 N m (20 ft. lbs.) *•2 7 N-m (20 ft. lbs.) *•2 7 N-m (20 ft. lbs.) *•2 7 N-m (20 ft. lbs.) 47 N m (35 ft. lbs.) 47 N m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N m (35 ft. lbs.) 47 N m (35 ft. lbs.) 47 N m (35 ft. lbs.) 47 N m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N-m (35 ft. lbs.) 47 N-m (35 ft. lbs.) * On vehicles with a 6.2L Diesel, torque to 47 N m (35 ft. lbs.) • On vehicles with a 7.4L V8, torque to 41 N m (30 ft. lbs.) 6B1-32 ENGINE COOLING SPECIAL TOOLS J-23600-B 1. U niversal V -B elt Tension G age F-02615 RADIATOR 6B2-1 SECTION 6B2 RADIATOR CONTENTS SUBJECT PAGE Description................................................................................................................................................................... 6B2- 1 Radiator Maintenance................................................................................................................................................ 6B2- 5 On-Vehicle S e rvice .................................................................................................................................................... 6B2- 6 Fan Shroud Replacement...................................................................................................................................... 6B2- 6 Radiator Replacement............................................................................................................................................ 6B2-10 Pressure C a p ...........................................................................................................................................................6B2-13 Coolant Recovery System...................................................................................................................................... 6B2-14 Surge T a nk...............................................................................................................................................................6B2-15 Aluminum Radiator R epair........................................................................................................................................ 6B2-15 Description...............................................................................................................................................................6B2-15 D ia g no sis................................................................................................................................................ ................ 6B2-15 Aluminum Radiator S e rv ic e ..................................................................................................................................6B2-17 S p e cifica tio n s.............................................................................................................................................................6B2-22 Special T o o ls ...............................................................................................................................................................6B2-23 DESCRIPTION The radiator in the R/V, G and P series vehicles is a crossflow tube and center type. Refer to figures 1 through 4. All radiators are fitted with a shroud designed to assist the fan in directing air flow through the radiator core and to also serve as a fan guard. Provision for coolant expan­ sion is achieved with a coolant recovery tank. This retards coolant overflow, and reduces frequent refills. Pressure is maintained in the radiator and system by a pressure cap. The pressure cap has two valves; one re­ lieves excessive pressure and the other compensates for coolant contraction when the engine is stopped. Radiator caps are provided in 105 kPa (15 psi) rating on all models. 6B2-2 RADIATOR 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. S u p p o rt R a d ia to r F ille r C ap U p p e r In s u la to r U p p e r Panel U -Shaped N u t S h ro u d B ra cke t S crew U p p e r S h ro u d L ow er S h rou d H ose R e se rvo ir C ap 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. R ese rvo ir W orm C la m p D rain C o c k L ow er In s u la to r B o lt W a sh er U p p e r C u s h io n S u p p o rt B ra cke t L ow er C u s h io n C u s h io n R e ta in e r N ut 24. 25. 26. 27. End Panel S u p p o rt R ig h t B a ffle N ut B-07687 Figure 1—R/V — Radiator Mounting and Related Parts (Typical) RADIATOR 6B2-3 39 2. 3. 4. 9. 10. 12. 13. 15. 31. 32. 33. 34. 37. 38. 39. 40. 41. 42. 43. 44. R a d ia to r F ille r C ap In s u la to r U p p e r S h rou d L ow er S h ro u d R e se rvo ir R e se rvo ir C ap D rain C o c k Panel U p p e r B ra cke t L o w e r Pad S cre w R e se rvo ir H ose In le t H ose C la m p O u tle t H ose B o lt “ J ” N ut S crew C lip 12 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 59. 60. 61. 62. 64. 65. 13 37 55 S cre w S crew In s u la to r M o u n tin g B ra c k e t C ro s s S ill R ig h t Panel S crew “ U ” N ut E x te n s io n B o lt S cre w Tank B ra cke t S u rge Tank H ose In le t H o se H o se N ip p le C la m p H ex B o lt H ex N u t B-07686 Figure 2—G — Radiator Mounting and Related Parts (Typical) 6B2-4 RADIATOR C lip L ow er Panel W a sh er L ow er In s u la to r E va po rato r H ose In le t H o se S u rge Tank P ressure C ap Tank B ra cke t Tank C la m p R a d ia to r F ille r C ap In s u la to r S crew U p p e r S h ro u d L ow er S h ro u d D rain C o c k L ow er In s u la to r N ut C la m p F ille r Tube F ille r H ose U p p e r Panel B o lt 3 71 86 B race W a sh e r 82 23 77 / 74 84 40 V J f e i e7 7 B-07685 Figure 3—P(32) — Radiator Mounting and Related Parts (Typical) RADIATOR 6B2-5 2. R adiator 3. F ille r Cap 9. Upper Shroud Lower Shroud Reservoir Cap Reservoir Drain C ock Insulator B olt C lam p Support Brace 93. 94. 95. 96. 97. 98. 99. 100. 102. 103. 105. Panel Upper Panel Hose Screw W asher N ut W asher Bracket Push N ut Bracket Retainer B-07684 Figure 4—P(42) — Radiator Mounting and Related Parts (Typical) RADIATOR MAINTENANCE Check the outside of the radiator for bent fins, or signs of leakage. Repair leaking radiator cores. Do not seal tem ­ porarily with a sealer type antifreeze or coolant additive. Remove any stones between the fins. Clean loose debris and road film from the radiator core with a quality grease solvent and compressed air. Direct the stream of solvent at the front of the core for more efficient cleaning. To insure a thorough cleaning, remove the grille, fan guard, and fan shroud. Remove the radiator cap and look for plugging and scale on the inside of the tank. Replace a badly plugged radiator. Test the radiator and system as described in EN­ GINE COOLING (SEC. 6B1). 1. Check the coolant level. If low, add recommended coolant as required. 2. Check the hose connections and tighten the clam ps if leakage is evident. Replace cracked, stripped, or corroded clamps. 3. Check the coolant hoses for spongy or checked ap­ pearance. Replace deteriorated hoses or bursting could occur which would result in coolant loss and extensive engine damage due to overheating. 4. Check the radiator core for leaks and for accum ula­ tion of dirt which may obstruct the air passages and reduce heat transfer. 5. Check the surge tank or recovery tank for leaks. Plastic bottles may develop cracks for being dam ­ aged by flying objects. Check metal tanks at the weld seams. 6. Inspect the radiator rubber m ountings and bum pers for deterioration and replace as necessary. Check the mounting bolts, supports, braces, tie rods, and stabilizer rods. Components should be securely fas­ tened in place if m ounting bolts are m issing, loose, or stripped. Also check for damage to the core, side flanges, and supporting components. 6B2-6 RADIATOR 7. Check for clearance between the fan blades, core, and shroud. Check the fan attaching bolts for tight­ ness and that none are missing. Replace the fan if any blade is bent. The distance between the blades and shroud should be equal around the perimeter of the shroud. Adjust as necessary after any adjust­ ment has been made to the fan or the fan mounting bracket and hub. 8. Inspect the filler cap seal for evidence of cracking, separation, or deterioration. Replace as required. 9. To assist in m aintaining efficient heat dissipation, an occasional external flushing with water will remove the majority of dirt accum ulation and foreign matter from between core fins. Direct water under moder­ ate pressure from behind the core to force debris out in the opposite direction of its entry. Direct the water stream in line with the fins to reduce the pos­ sibility of bending fins. RADIATOR INTERNAL DEPOSITS A radiator that has a dirty, obstructed core or is leaking will cause the engine to overheat. A scale deposit inside the radiator is a result of using hard, high mineral content water in the cooling system. The effect of heat on the minerals in the water causes the formation of scale, or hard coating, on m etal surfaces w ithin the radiator, thereby reducing the transfer of heat. Some hard water will produce a silt-like deposit which restricts the flow of water. This must be flushed out at least twice a year — more often if necessary. SCALE REMOVAL To remove the hardened scale, a direct chem ical action is necessary. A flushing compound at the specified rate of 30 grams per liter (4 oz. per gallon) of radiator capacity, should be added to the coolant water in the form of a dissolved solution while the engine is running. Operate the engine for 15 minutes, then drain and flush the system with clean water. T he re are v a rio u s typ e s of flu s h in g c o m p o u n d s comm ercially available and should be obtained from a reliable source. Most com pounds attack m etals and should not remain in the engine for more than a few minutes. Use a neutralizer after a descaling solvent is used. For extremely hard, stubborn coatings, such as lime scale, use a stronger solution. The corrosive action of a stronger solution will affect the thin metals of the radiator, thereby reducing its operating life. A complete flushing and rinsing is mandatory and must be accom plished skillfully. After using the solvent and neutralizer and flusing the cooling system, drain the system and fill it with clean, soft water plus a rust inhibitor or high boiling point type antifreeze. After filling the cooling system, check for radiator, hose, and engine coolant leaks. ON-VEHICLE SERVICE FAN SHROUD REPLACEMENT R/V VEHICLES □ Remove or Disconnect (Figures 1, 5 and 6) 1. Fan shroud to radiator retainer attaching bolts (60). 2. Fan clutch to water pump hub attachments. • Refer to ENGINE COOLING (SEC. 6B1). 3. Fan shroud assembly (61 and 64). • Pull up and out of the lower retaining clips. • The fan shroud and fan clutch assembly must be removed together. G AND P VEHICLES |+ + | R e m o v e o r D is c o n n e c t (F ig u re s 2, 3, 4, 7, 8, 9 a n d 10) 1. Vacuum reservoir, if equipped with air conditioning. 2. 3. 4. 5. 6. 7. 8. Install or Connect (Figures 5 and 6) Lower fan shroud (64) and the fan clutch. • Position along the back of the radiator (63). • Make sure the lower edge fits into the lower retaining clips. Fan clutch to water pump hub attachments. • Refer to ENGINE COOLING (SEC. 6B1). Shroud (61) to the radiator retainer attaching bolts (60). Tighten • Bolts (60) to 6 N m (53 in. lbs.) 9. • Refer to AIR CONDITIONING (SEC. 1B). Windshield washer jar and its bracket. Fan shroud retaining bolts (60). Radiator support bracket (67). Dipstick from the engine. D ipstick from the autom atic tra nsm ission, if equipped. Radiator hose strap from the fan shroud (61). Fan from the water pump. • Leave the pulley in place. • Refer to ENGINE COOLING (SEC. 6B1) in this section. Fan and the fan shroud together. Install or Connect (Figures 7 through 10) 1. Fan and the fan shroud together. 2. Fan to the water pump. • Refer to ENGINE COOLING (SEC. 6B1) in this section. 3. Radiator hose strap to the fan shroud. 4. D ipsticks into the engine, and tra n sm issio n if applicable. 5. Radiator support brace (67). RADIATOR 6B2-7 Figure 5—Fan Shroud — 4.3L, 5.0L and 5.7L Engines (R/V) A. B. 60. 63. 65. 66. 69. 100. 7.4L E n g in e Fan S h rou d 6.2L E n g in e Fan S h ro u d B o lt R a d ia to r C lip N u t R a d ia to r S u p p o rt Fan S h rou d R a d ia to r M o u n tin g Panel Figure 6—Fan Shroud — 6.2L and 7.4L Engines (R/V) F-02558 6B2-8 RADIATOR 60. 61. 62. 63. 64. 65. 67. B o lt 7 T U p p e r Fan S h ro u d In s u la to r _ R a d ia to r L ow er Fan S h rou d C lip N ut R a d ia to r M o u n tin g B ra cket U Figure 7—Fan Shroud — 4.3L Engine (G) • Bolts (60). Q Tighten • Bolts (60) to 17 N m (13 ft. lbs.). 6. Fan shroud retaining bolts (60). Tighten • Bolts (60) to 6 N-m (53 in. lbs.). • Bolts (60) for 4.3L engine to 27 N-m (20 ft. lbs.). 7. W indshield washer jar and its bracket. 8. Vacuum reservoir, if equipped with air conditioning. • Refer to AIR CONDITIONING (SEC. 1B). G AND P VEHICLES — 6.2L ENGINE Remove or Disconnect (Figures 2, 3, 4, 8 and 10) 1. Air cleaner intake. • Rotate the snorkel up. 60. 61. 63. 64. B o lt U p p e r Fan S h rou d R a d ia to r L ow er Fan S h rou d 65. C lip N ut 66. R a d ia to r S u p p o rt 67. R a d ia to r M o u n tin g 2. Fan shroud bolts (60). 3. Hood latch cable. 4. W indshield washer bottle. 5. Upper fan shroud (61). B ra cket F-00918 Figure 8—Fan Shroud — 5.0L, 5.7L and 6.2L Engines (G) Install or Connect (Figures 6 and 8) 1. Upper fan shroud (61). • Bolts (60). RADIATOR 6B2-9 A. Fan S h ro u d F o r 4.8L L6 O r 5.7L V8 (H eavy D u ty E m is s io n s ) E n gin e B. Fan S h ro u d fo r T he 5.7L V8 (H eavy D u ty E m is s io n s ) E n g in e W ith A ir C o n d itio n in g 60. 61. 63. 64. 65. 66. 67. 68 . 69. B o lt U p p e r Fan S h rou d R a d ia to r L o w e r Fan S h rou d C lip N u t R a d ia to r S u p p o rt R a d ia to r M o u n tin g B ra cke t C lip C o m p le te Fan S h ro u d B F-00919 Figure 9—Fan Shroud — 4.8L and 5.7L Engines — P(42) 60. 61. 63. 64. 65. B o lt U p p e r Fan S h rou d R a d ia to r L o w e r Fan S h rou d C lip N ut 66 . R a d ia to r S u p p o rt 68 . C lip A. P(32) S e rie s V e h ic le s Fan S h ro u d B. P(42) S e rie s V e h ic le s Fan S h rou d F-00920 Figure 10—Fan Shroud — 6.2L and 7.4L Engines — (P-32 and 42) 6B2-10 RADIATOR Tighten • Bolts (60) to 6 N m (53 in. lbs.). 2. W indshield washer bottle. 3. Hood latch cable. 4. Fan shroud bolts (60). Tighten • Bolts (60) to 6 N m (53 in. lbs.). 5. Air cleaner intake. RADIATOR REPLACEMENT The type of radiator core mounting varies according to model and engine type. Radiator assembly includes a shroud and may include an oil cooler in the core. Some m odels have a se pa ra te pow er ste ering oil co oler attached in front of the radiator core. On models so equipped it may be necessary to remove the oil cooler to facilitate removal of the radiator core. Refer to POWER STEERING (SEC. 3B3) in this m anual for oil cooler removal and installation. R/V, G, AND P VEHICLES (4.3L, 4.8L, 5.0L 5.7L AND 7.4L ENGINES) Remove or Disconnect (Figures 11,12 and 13) Coolant from the radiator. Radiator hoses from the radiator. • Radiator inlet hose and radiator outlet hose. Overflow hose from the radiator.' Fan shroud. • Refer to “ Fan Shroud Replacem ent.” 4. Transmission cooler lines. 5. Radiator from the vehicle. • Retainers from the radiator support. • Retainers from the upper mounting panel on R/V series vehicles. -►<- Install or Connect (Figures 1 1,1 2 and 13) 1. Radiator on the vehicle. • R ad iato r su p p o rt on the upper m ounting panel. Tighten • Fasteners to the “ Specifications.” 2. Transmission cooler lines. 3. Fan shroud. • Refer to “ Fan Shroud R eplacem ent.” 4. Overflow hose to the radiator. 5. Radiator hoses to the radiator. • Radiator inlet hose and radiator outlet hose. 6. Coolant to the radiator. • Refer to the vehicle O w ner’s Manual. 7. Remove the radiator pressure cap, start the engine, and let it run until the upper radiator hose becomes hot — therm ostat is open. 8. Add coolant, with the engine running at idle speed, until the coolant level reaches the bottom of the filler neck. 9. Install the radiator pressure cap, making sure the arrows line up with the overflow tube. R/V VEHICLES (6.2L ENGINE) Remove or Disconnect (Figures 11,12 and 13) • Drain the cooling system. 1. Fan shroud. • Refer to “ Fan Shroud R eplacem ent.” 2. Engine and transm ission oil cooler lines. 3. Upper radiator hose and lower radiator hose from the radiator. 4. Overflow hose from the radiator. 5. Upper radiator supports. 6. Radiator from the vehicle. Install or Connect (Figures 11, 12 and 13) Radiator to the vehicle. Radiator supports and/or m ounting panel. Tighten • Fasteners to the “ Specifications.” 3. Overflow hose to the radiator. 4. Upper radiator hose and lower radiator hose to the radiator. 5. Engine and transmission oil cooler lines. 6. Fan shroud. 7. Coolant to the radiator. 8. Remove the radiator pressure cap, start the engine, and let it run until the upper radiator hose becomes hot — therm ostat is open. 9. Add coolant, with the engine running at idle speed, until the coolant level reaches the bottom of the filler neck. 10. Install the radiator pressure cap, making sure the arrows line up with the overflow tube. G AND P VEHICLES (6.2L ENGINE) |<"+| Remove or Disconnect (Figures 11, 12 and 13) • 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Coolant from the radiator. Air intake snorkel. W indshield washer bottle. Hood release cable. Upper fan shroud. • Refer to “ Fan Shroud R eplacem ent.” Upper radiator hose from the radiator. Transmission cooler lines from the radiator. Low coolant sensor. Overflow hose from the radiator. Engine oil cooler lines from the radiator. Raise the vehicle. Lower radiator hose from the radiator. Lower the vehicle. Master cylinder from the booster. • Refer to BRAKES (SEC. 5A1). Radiator from the vehicle. -►+ Install or Connect (Figures 11, 12, and 13) 1. Radiator into the vehicle. Tighten • Fasteners to the “ Specifications.” 2. Master cylinder to the booster. • Refer to BRAKES (SEC. 5A1). 3. Raise the vehicle. RADIATOR 6B2-11 Figure 11—Radiator installation — R/V, G and P(42) 6B2-12 RADIATOR Figure 12—Radiator Installation — P(32) RADIATOR 6B2-13 A. R a d ia to r M o u n tin g F or C-K S e rie s W ith 4.8L L6 (Exc. C60), P(42) S e rie s W ith 4.8L L6 A n d 5.7L V8 B. R a d ia to r M o u n tin g F or C-K S e rie s W ith 4.8L L6 W ith C60 C. R a d ia to r M o u n tin g F or C-K A n d G S e rie s W ith 4.3L V6 D. R a d ia to r M o u n tin g F or C-K S e rie s W ith 5.0L, 5.7L; G S e rie s (Exc. 4.3L V6); P(42) S e rie s W ith 5.7L V8 E. R a d ia to r M o u n tin g F o r C-K S e rie s W ith 7.4L V8, 6.2L D iese l; P(42) S e rie s W ith 7.4L V8, 6.2L D iesel 60. 61. 62. 63. 64. B o lt U p p e r Fan S h rou d In s u la to r R a d ia to r L ow er Fan S hroud 65. C lip N ut 66. R a d ia to r S u p p o rt 67. R a d ia to r M o u n tin g B ra cke t 68. 69. 100. 101. 102. C lip C o m p le te Fan S h ro u d R a d ia to r M o u n tin g Panel R a d ia to r U p p e r M o u n tin g Panel R a d ia to r L ow er M o u n tin g Panel 103. 104. 105. 106. 107. 108. 109. W a sh e r N ut W a sh er N ut In s u la to r E x te n s io n A s s e m b ly R a d ia to r S u p p o rt B race F-00936 Figure 13—Radiator Installation Legend 4. Lower radiator hose to the radiator. 5. Lower the vehicle. 6. Engine oil cooler lines to the radiator. 7. Overflow hose to the radiator. 8. Low coolant sensor. 9. Transmission oil cooler lines to the radiator. 10. Upper radiator hose to the radiator. 11. Upper fan shroud. • Refer to “ Fan Shroud R eplacem ent.” 12. Hood release cable. 13. W indshield washer bottle. 14. Air intake snorkel. 15. Coolant to the radiator. 16. Remove the radiator pressure cap, start the engine and let it run until the upper radiator hose (12) becomes hot — therm ostat is open. 17. Add coolant, with the engine running at idle speed, until the coolant level reaches the bottom of the filler neck. 18. Install the radiator pressure cap, making sure the arrows line up with the overflow tube. PRESSURE CAP The pressure relief valve assembly, integral filler cap, incorporates a pressure valve and a valve (figure 14). When pressure in the system the valve setting, the pressure valve opens and allowed to escape. with the vacuum reaches vapor is 6B2-14 RADIATOR B-02682 Figure 15—Testing The Radiator Cap As liquid in the system cools it contracts; this allows the pressure valve to close and also creates a partial vacuum in the system. Atm ospheric pressure acting through the overflow tube unseats the vacuum valve and allows air to enter the system. The overflow pipe connects to the valve outside the valve seal; thus no liquid or air can escape from the system when both valves are in the closed position. 4. F ille r N e c k S a fe ty D e te n t T h e ra d ia to r f ille r c a p is c o n s tru c te d w ith a spring-loaded rubber seal which is pressed firm ly against the surface of the fille r neck seat when the cap is installed. The rubber seal must be in good condition and the top of the radiator filler neck must be clean and smooth to form an airtight seal. The seal of the filler cap and the operation of the pressure relief valve can be checked using a conventional cooling system testing kit (figure 15). When the engine is at normal operating temperature or above, the internal pressure buildup in the cooling system will blow out scalding fluid and vapors if the radiator cap is suddenly removed. To prevent loss of coolant and the danger of being burned check or add coolant when the engine is cool. If the cap must be removed when the engine is hot, place a cloth over the cap and rotate the cap slow ly counterclockw ise to first stop and allow pressure to escape. The cap and filler neck meet at right angles in a safety detent position. The cap locking tank is flat and the filler neck has a straight tab (figure 16). To turn the cap beyond this point and remove the cap, the cap must be pressed down to clear the safety detent and turned counterclockwise. B-02709 Figure 16—Radiator Cap and Filler Neck COOLANT RECOVERY SYSTEM The coolant recovery system consists of a reservoir, pressure cap, and interconnecting hose. Maintain the coolant level between the “ HOT LEVEL” and “ COLD LEVEL” markings on the tank. Refer to figures 1, 2, 3 and 4. The pressure cap is sim ilar to the radiator filler cap but has a gasket (figure 17). This gasket forms a seal at the radiator filler neck. A leak at this gasket will result in loss 2. 3. 4. 5. P re s s u re V alve S p rin g P re s s u re V alve V a c u u m V alve G asket B-03467 Figure 17—Coolant Recovery System Pressure Cap RADIATOR 6B2-15 of coolant during normal operation. Install the pressure cap so that the m arkings on top of the cap align with the overflow tube on the filler neck (figure 18). SURGE TANK The tank serves as a coolant reservoir for the radiator core. Hoses and pipes connect the tank to the radiator and water pump. The surge tank incorporates the cooling system filler cap. At regular intervals check the tank and connecting hoses for leaks. Keep the hose clam ps and mounting bolts tightened. Check the mounting brackets and supports for cracks and broken attaching parts. Check insulators and straps; if deteriorated or loose from wear, replace. ALUMINUM Rfi DESCRIPTION This radiator utilizes an aluminum core with plastic side ta n ks. T h e co re and sid e ta n k s can be re p la c e d separately and core repair is easily made with the hot melt adhesive method. A transm ission oil cooler is located in one of the side tanks. The oil coolers can be replaced. The drain cock is located on the lower part of one of the tanks. The drain cock is also serviceable. IATOR REPAIR TRANSMISSION OIL COOLER Replace the oil cooler by removing the tank from the core. A leaking oil cooler gasket can be replaced w ithout removing the tank from the core. DRAIN COCK The alum inum /plastic radiator utilizes a two piece plastic drain cock and a rubber seal. The drain cock is serviceable (figure 20). CORE The core is made of aluminum and is of the crossflow design. It utilizes large tubes that resist plugging, and repairs to the tubes and core are easily made using the hot melt adhesive method. The core is attached to the tanks by clinched tabs on the core that can be bent back if tank or core replacement is required. If the damage to a tube is too severe, a tube can be blocked or plugged as explained in “ Tube Blocking.” No more than two tubes should ever be blocked on a core. Also replace the core if more than three tabs are broken on one side or if two adjacent tabs are broken. TANKS The tanks are attached to the core by clinched tabs attached to the sides of the core. The clinched tabs can be bent back if the tanks need to be removed from the core. Bend the tabs back only enough to remove the tank. Overbending will weaken the tabs. A high temperature rubber gasket is used to seal the mating surface between the core and the tank (figure 19). The gasket must be replaced any tim e a tank is removed from the core. DIAGNOSIS LEAK TESTING Some core leaks can be detected by adding water to the radiator. Clean the core so that the damaged area can be found. 1. Remove d irt and insects from the fin s w ith a common water hose w ithout 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 alum inum -plastic radiator with J-24460-01 with J-23699 (figure 21). W ith 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 escaping coolant. Repair all hose and hose connections as required. Check the radiator cap to ensure that it will maintain the correct pressure. If the radiator leaks during the pressure test, mark the leak area. 6B2-16 RADIATOR 118 110. 111. 112. 113. 114. 115. 116. 117. 118. C ore O u tle t Tank In le t Tank S id e Tank G a ske t E n g in e O il C o o le r (D iesel O nly) T ra n s m is s io n O il C o o le r C o o le r G a ske t C o o le r R e ta in in g N u t D rain C o c k F-00937 Figure 19—Aluminum Radiator Assembly Off-Vehicle Leak Testing NOTICE: Do not use boil-out tanks or vats or other tanks that have been used for copper and brass radiators. The flux, acid, and caustic cleaners remaining in these tanks will attack the aluminum and cause radiator failure. A separate te s t ta n k c o n ta in in g c le a n w a te r is recom m ended for servicing alum inum/plastic radiators. 1. Install test fittings or rubber test caps in the inlet and outlet necks and seal the oil cooler fittings with metal plugs to protect the cooler and keep the fluid from running out (figure 22). Figure 21—Pressure Testing the Radiator RADIATOR 6B2-17 2. Attach the pressure tester and gradually apply air pressure until 138 kPa (20 psi) is attained. Do not exceed 138 kPa (20 psi). Check the pressure gage to see if there is a pressure loss. To ensure that there are no small leaks, run water over the repair area and look for bubbles. (A mild detergent is helpful). If a large water tank is available, submerge the radiator and a check for air bubbles. REPAIRABLE LEAKS There are two types of leaks that can be repaired on the alum inum -plastic radiator: core leaks and gasket leaks. Leaks in the plastic tanks cannot be repaired (figure 23). Core leaks can occur in a tube or in the joints between the tubes and headers. Gasket leaks can occur in the 113A 121 113B 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 is the most 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. Store the in a sealed container to keep them dry (figure 24). ALUMINUM RADIATOR SERVICE 113A. 121. 113B. 118B. 122. 123. The aluminum -plastic radiator can be repaired at the d e a le rs h ip . The fo llo w in g c o m p o n e n ts are e a s ily replaced: In le t Tank G a ske t C ore Tubes O u tle t Tank G a sket D rain C o c k G a sket O il C o o le r G a ske ts J o in t B e tw ee n Tube A n d H ea de r • Core • Tanks and gaskets • Oil coolers and gaskets • Drain cock and gasket F-00941 Figure 23—Possible Leak Areas The tanks cannot be repaired if broken or cracked. The radiator core can be replaced and the new core used with the original tanks and oil cooler. 6B2-18 RADIATOR PRECAUTIONS As with all cooling system service, take measures to prevent personal injury and damage to the system. uuiyuuuui/miuuuuui>uuL/uuuuuui/uL/uuuuuuuui/i;uuiiuuui;ui/uuviyuuiiiiuuuuuuiiyiiui CAUTION: To help avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Scalding flu id and steam can be blown out under pressure if the cap is taken off too soon. NOTICE: DO NOT USE “ BOIL O U T ’ TANKS OR VATS. Common service methods may destroy an aluminum radiator. Do not use caustic or lye cleaning solutions for aluminum radiators. USE CLEAN WATER WHEN SERVICING ALUMINUM RADIATORS. • Do not open the hood if you can see or hear steam or coolant escaping from the engine compartment. m u im m m iii m n n m w m im hi a m m m m M M m m m m i p lllIf f llilH l illiJ iJ M H B M m s E i u u m i i u im u m im ih m m r n m m m 'i MlRUmUL llL llll u m im m u m m ■ ii m i i i i im i iim m iiim iM m A. 6 m m (1/4-inch) Beyo n d M u iu i................ The D am aged Area M M M /I/I/M A , F-00946 Figure 25—Removing the Fins from a Damage Area • Do not remove the 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 chem icals on your skin. • P re v e n t d ir t a nd w a te r transm ission oil cooler. fro m e n te rin g th e • Do not use boil-out tanks or vats or other tanks that have been used for copper and brass radiators. The flux, acid, and caustic cleaners remaining in these tanks will attack the aluminum and cause radiator failure. A separate test tank containing clean water is recom m ended for servicing alum inum /plastic radiators. NOTICE: Never use shop air to pressure test radiators that is not regulated at 138 kPa (20 psi). Pressures o ver 138 kPa (20 psi) w ill damage the radiator. Figure 26—Tube Blocking HEADER REPAIR If the header or a tube near the header requires a repair, the side tank does not have to be removed. Place a damp cloth against the side tank where the repair has to be made (figure 27). The side tank can be submerged in a tank of water up to the header (figure 28). SPECIAL PREPARATION For damaged areas that are between the cooling fins, it may be necessary to remove some of the fins. Do not remove more fins than necessary. Usually 6 mm (1/4-inch) beyond the leak or dam age area is enough to make an effective repair (figure 25). TUBE BLOCKING If a tube is severely damaged, it can be blocked off (figure 26). 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 system. Cut the tube off 6 mm (1/4-inch) from the header and pinch shut before it is cleaned and sealed. Refer to “ General Core Sealing.” A. A p p ly W ith A W et C lo th Figure 27—Using A Wet Cloth to Cool the Side Tank RADIATOR 6B2-19 Figure 30—Scrubbing the Area with A Cotton Swab A. S u b m e rg e The T ank— K eep The H eader A bove The W ater Lin e B-00949 Figure 28—Submerging the Side Tank NOTICE: One of these procedures have to be used when repairs are made on or near the header to prevent damage to the tank or gasket. CAUTION: The primer contains trichlorethane. • It could be harmful or fatal if swallowed. If swallowed, get medical attention. • Use with adequate ventilation. • In case of eye contact, flush with water and get medical attention. • In case of body contact, wash with soap and water. • Do not mix the primer with water. GENERAL CORE REPAIR Preparation of the surface in the repair area cannot be overemphasized. If the leak area surface is not clean, none of the repair materials will stick to the surface. 6. Scrub the repair area with a cotton swab until a fresh swab stays clean. The clear, yellow-brown coating does not have to be removed (figure 30). 1. Position the core so the repair area is accessible. 7. Heat the repair area with a heat gun or by moving the torch in a circular pattern (figure 31). Use a soft, small blue flame (like a gas stove flame). 2. Apply a wet cloth if you are working near the plastic tanks or the joints between the core tubes and header (figure 27); or submerge the tank in water (figure 28). 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. 4. Brush the area to be repaired with the small steel brush that is supplied in the kit and blow dust away from the repair area (figure 29). 5. Open the tube of primer, using the spurred cap or a pin, and apply prim er to the repair area only. Use of the prim er produces a stronger repair. Do not heat the primer. Figure 29—Cleaning the Repair Area with A Steel Brush 8. W ithdraw the torch and rub the adhesive stick on the repair area (figure 32). The adhesive will flow at a temperature of approximately 260°C (500°F). If the stick doesn’t start to melt, remove it and reapply the heat. Do not heat the stick directly with a flame. High heat will burn and char the adhesive. 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 around the tube and header joint with the tank installed. Figure 31—Heating the Repair Area 6B2-20 RADIATOR A. Touch T he A d h e s iv e To The H o t M etal f -00954 Figure 32—Apply Hot Melt Adhesive to the Repair Area 10. H e a t th e re p a ir a re a u n til th e a d h e s iv e is bubble-free and smooth, with a light yellow color. Curing is not required. 11. Test the radiator when cool. If the repair area still leaks, reheat it gently to dry it. Heat and reflow the adhesive or apply more as necessary to repair the leak. TANK GASKET LEAK REPAIR Tank gasket leaks can be mistaken for tank or header leaks. If a plactic tank leaks from the header joint gasket, tighten the clinch tabs with locking-type pliers (figure 33). If this method doesn’t seal the leak, remove the tank for further inspection. 1. Pry open the clinch tabs, except those under the inlet, outlet, and filler necks, using J-33419-1 or a screwdriver (figure 34). Lift the tabs only enough to allow removal. N O T IC E : Do n o t o v e rb e n d th e tab s . Overbending could result in breakage. If there are more than 3 tabs broken on one side of the header, or more than 2 adjacent tabs together, replace the core. 2. L ift the ta nk and slide it out from under the remaining clinched tab. You may have to tap the tank with your hand to dislodge the gasket. Lift the remaining tab(s) with pliers. 3. Remove and discard the gasket. 4. Clean the header and gasket groove of all dirt and old rubber. 5. Clean the sealing edge of the plastic tank. 6. Examine the header gasket surface and tank flange for leakage, and clean or repair the surface to remove dirt, burrs, and bumps. 7. Remove the oil cooler, if equipped, and install it in the new tank, if used. 8. Dip or coat the new tank gasket in engine coolant and position it on the header surface. The coolant helps hold the gasket in place. 9. Position the tank and gasket to the header, clam p it in place and secure it by bending four clinch tabs as shown in figure 35. 10. Clamp remaining clinch tabs around the header using the clinching tool or pliers (figure 36). NOTICE: Tighten the clinch tabs by starting at the center and working out to the ends. 11. Replace the core if there are more than three tabs broken on one side or two adjacent tabs broken. 12. Install the drain cock, if removed. 13. Test the radiator for leaks. A Figure 33—Tightening the Clinch Tabs Figure 35—Sealing the Tank to the Radiator Core RADIATOR 6B2-21 OIL COOLER REPLACEMENT |<-+| Remove or Disconnect 1. Outlet tank. 2. Nuts from the oil cooler fittings. 3. Oil cooler and gaskets from the tank. Clean • Clean and dry the gasket area. Install or Connect 1. Gaskets to the oil cooler. 2. Oil cooler to the tank. 3. Nuts. a OIL COOLER GASKET REPLACEMENT Remove the outlet tank to replace the oil cooler. The oil cooler gaskets can be replaced without removing the tank. □ Remove or Disconnect (Figure 37) 1. Radiator and lay it on a flat surface. 2. Bottom oil cooler nut and loosen the top nut. 3. Press the oil cooler into the hole and remove the gasket using a small hook (figure 37). 4. Flow-dry all surfaces on the tank and oil cooler. ♦«- Install or Connect (Figure 37) 1. Gasket without lubrication. • Be sure it is seated properly inside the tip of the fitting. • Reach into the oil cooler and push it into position against the tank. 2. Oil cooler nuts. • Nuts to 20 N-m (15 ft. lbs. • Do not overtighten. 3. Leak test. 4. Radiator to the vehicle. Figure 37—Removing the Oil Cooler Gasket Tighten • Nuts to 20 N-m (15 ft. lbs.). 4. Outlet tank. 5. Test the radiator. 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. 6B-22 RADIATOR SPECIFICATIONS R/V Fan Shroud to the Radiator 4.3L 5.0L 5.7L 6.2L 7.4L 6 Nm (53 in. lbs.) 6 Nm (53 in. lbs.) 6 N-m (53 in. lbs.) 6 N-m (53 in. lbs.) 6 N-m (53 in. lbs.) Upper Fan Shroud to the Lower Fan Shroud 6 N-m (53 in. lbs.) 17 N-m (13 ft. lbs.) Upper Mounting Panel 17 N-m (13 ft. lbs.) Upper Mounting Brackets 17 N-m (13 ft. lbs.) Transmission Oil Cooler Lines Engine Oil Cooler Lines 17N m (13 ft. lbs.) 27 N-m (20 ft. lbs.) 24 N-m (18 ft. lbs.) 24 N-m (18 ft. lbs.) 24 N-m (18 ft. lbs.) G 4.3L 5.0L 5.7L 6.2L 7.4L Fan Shroud to the Radiator 27 N-m (20 ft. lbs.) 3 N-m (27 in. lbs.) 3 N-m (27 in. lbs.) 5 N-m (44 in. lbs.) 3 N-m (27 in. lbs.) Upper Fan Shroud to the Lower Fan Shroud 6 N-m (53 in. lbs.) Transmission Oil Cooler Lines 30 N-m (22 ft. lbs.) 30 N-m (22 ft. lbs.) 30 N-m (22 ft. lbs.) 22 N-m (16 ft. lbs.) 30 N-m (22 ft. lbs.) Engine Oil Cooler Lines 24 N-m (18 ft. lbs.) 24 N-m (18 ft. lbs.) 24 N-m (18 ft. lbs.) 24 N-m (18 ft. lbs.) 24 N m (18 ft. lbs.) 6.2L 7.4L Lower Mounting Panel 20 N-m (15 ft. lbs.) 20 N-m (15 ft. lbs.) Lower Mounting Panel 17 N-m (13 ft. lbs.) 17 N-m (13 ft. lbs.) Upper Mounting Brace 17 N-m (13 ft. lbs.) 17 N-m (13 ft. lbs.) Fan Shroud to the Radiator 10 N-m (89 in. lbs.) 10 N m (89 in. lbs.) Fan Shroud to the Radiator (Heavy Duty Radiator) 17 N-m (13 ft. lbs.) 17 N-m (13 ft. lbs.) Transmission Oil Cooler Lines 27 N-m (20 ft. lbs.) 27 N-m (20 ft. lbs.) P(32) RADIATOR 6B2-23 SPECIFICATIONS (CONT.) P(42) 4.8L Lower M ounting Panel 17 N m (13 ft. lbs.) Fan Shroud to the Radiator 6 Nm (53 in. lbs.) 5.7L 6 Nm (53 in. lbs.) 6.2L 7.4L 17 N m (13 ft. lbs.) 17 N m (13 ft. lbs.) 6 Nm (53 in. lbs.) 6 N-m (53 in. lbs.) 17 N m (13 ft. lbs.) 17 N m (13 ft. lbs.) Fan Shroud to the Radiator (Heavy Duty Radiator) 27 N m (20 ft. lbs.) Transmission Oil Cooler Lines 27 N m (20 ft. lbs.) 27 N m (20 ft. lbs.) 27 N m (20 ft. lbs.) SPECIAL TOOLS J-23699 J-24460-01 J-33419-A 1. O v e rflo w Tubge P re ssure A d a p te r 2. Q u ic k F ill A d a p te r C ap 3. R a d ia to r C ore R e m o v e r/In s ta lle r F-02614 6B2-24 RADIATOR 6C-1 SECTION 6C FUEL SYSTEM CONTENTS SUBJECT PAGE Description.....................................................................................................................................................................6C- 1 Air Cleaner.....................................................................................................................................................................6C- 2 Air Filter Element Replacem ent............................................................................................................................. 6C- 2 Carbureted Engine Fuel F ilte rs ..................................................................................................................................6C- 2 Fuel Filter Replacem ent..........................................................................................................................................6C- 2 Diagnosis Of “ WATER IN FUEL” Light (Diesel Engine O nly)................................................................................ 6C- 3 Diesel Engine Fuel Filters............................................................................................................................................ 6C- 3 Draining The Fuel Filter............................................................................................................................................ 6C- 3 Diesel Fuel Filter Replacement................................................................................................................................6C- 4 Diesel Fuel Filter Assembly Component Replacem ent...................................................................................... 6C- 5 Fuel P u m p .....................................................................................................................................................................6C- 5 Fuel Pump Tests (Carbureted Engine)................................................................................................................... 6C- 5 Fuel Pump Tests (Diesel Engine)........................................................................................................................... 6C- 5 Fuel Pump Replacement..........................................................................................................................................6C- 6 Fuel T a n k.......................................................................................................................................................................6C- 7 Draining The Fuel Tank............................................................................................................................................ 6C- 7 Fuel System Cleaning (Carbureted Engine)........................................................................................................... 6C- 8 Diesel Fuel System C ontam ination....................................................................................................................... 6C- 8 Fuel System Cleaning (Diesel Engine)................................................................................................................... 6C- 9 Fuel Tank P urging.................................................................................................................................................... 6C- 9 Fuel Tank Leak T e s t................................................................................................................................................ 6C-10 Fuel Tank Replacement............................................................................................................................................6C-10 Fuel Tank Filler Neck................................................................................................................... ............................ 6C-10 Fuel L in es.................................................................................................................................................................. 6C-10 Fuel Gage Sending U n it.............................................................................................................................................. 6C-13 Fuel Gage Sending Unit Replacement................................................................................................................... 6C-13 Fuel Tank Selector V a lv e ............................................................................................................................................ 6C-13 Diagnosis Of Selector V alve....................................................................................................................................6C-13 Fuel Tank Selector Valve Replacement................................................................................................................. 6C-13 Accelerator C ontrols....................................................................................................................................................6C-16 Accelerator Control Cable........................................................................................................................................6C-16 Accelerator Pedal...................................................................................................................................................... 6C-16 S pe cifica tio n s.............................................................................................................................................................. 6C-17 Special T o o ls ................................................................................................................................................................ 6C-18 All new GM vehicles are certified by the United States Environmental Protection Agency as conforming to the require­ ments 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 indiscrim inate or routine adjustm ent in the field. For this reason, the factory proce­ dure for tem porarily 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 supplement. DESCRIPTION This section covers information for carbureted and diesel engines only. For fuel system information on TBI equipped vehicles, refer to the “ Fuel And Emissions Service M anual.” 6C-2 FUEL SYSTEM AIR CLEANER CAUTION: The air cleaner also functions as a flame arrestor in the event of engine backfire. The air cleaner should be installed at all times unless its removal is necessary for repair or maintenance. To help reduce the risk of per­ sonal injury and property damage, be sure that no one is near the engine compartment before starting the engine with the air cleaner re­ moved. If engine backfire occurs with the air cleaner removed, there could be a burst of flame and possibly other fire in the engine com­ partment. On vehicles with diesel engines, do not use starting fluids—immediate engine damage can result. Also take care not to let objects fall into the engine if the air cleaner is removed. If the engine is running, suction can pull loose ob­ jects into the engine. Objects pulled or dropped into the engine can cause costly engine dam­ age. When replacement of the air cleaner filter element is necessary, an AC air filter element is recommended. Refer to “ MAINTENANCE AND LUBRICATION” (SEC. OB) for change intervals. Operation of the vehicle in dusty areas will necessitate more frequent replacement. AIR FILTER ELEMENT REPLACEMENT NOTICE: Extreme care should be taken when removing the filter element. Remove the filter elem ent slowly to prevent dirt from falling into the engine. Remove or Disconnect 1. 2. 3. 4. Wing nut. Air cleaner cover from the base. Air filter element. All accum ulated dirt from the base. i? Inspect • Filter element for dam age or excessive dirt accum ulation. Replace as necessary. • Seals or gaskets for damage. Install or Connect 1. Air filter element. 2. Air cleaner cover. 3. Wing nut. CARBURETED ENGINE FUEL FILTERS The fuel filter element should be replaced at the inter­ vals shown in MAINTENANCE AND LUBRICATION (SEC. OB). Fuel filter elements are of the throw away type and should be replaced, not cleaned. Internal fuel filters are located in the inlet fitting of the carburetor (Figure 1). The filter element (3) is placed in the inlet hole with the gasket (2) surface outward. 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 ++ Remove or Disconnect 1. Fuel line connection at the fuel inlet nut (1). 2. Fuel inlet nut (1). 3. Filter element (3), gasket (2), and spring (4). Install or Connect (Figure 1) 1. Spring (4). 2. Filter element (3). • The inlet check valve must be installed in the filter element to meet Motor Vehicle Safety Standards (M.V.S.S.) for roll-over. • The new filter element must include the check valve. • The check valve end of the filter element must face toward the fuel line. 3. Fuel inlet nut (1). 1. 2. 3. 4. Fuel In le t N ut G a sket F ilte r W ith C h e c k Valve S p rin g B-08098 Figure 1—Carburetor Fuel Filter Tighten • Fuel inlet nut to “ Specifications” at the end of this section. 4. Fuel line. • Start the engine and check for leaks. FUEL SYSTEM 6C-3 DIAGNOSIS OF “WATER IN FUEL” LIGHT (DIESEL ENGINE ONLY) PROBLEM CORRECTION POSSIBLE CAUSE Intermittent Light • Water in fuel filter. • Drain water from the fuel filter. Light Stays On With Engine Running (Temperature Above Freezing) • Fuel filter is clogged or contains water. • Drain the fuel filter. If no w ater is drained and the light stays on, replace the filter element. Light Stays On With Engine Running (Temperature Below Freezing) • Fuel filter is clogged with ice. • D rain the fuel filter. If no w ater is drained, open the air bleed and check for fuel pressure. Replace the filter ele­ ment if there is no pressure. Light Comes On At High Speed Or During Heavy Acceleration • Plugged fuel filter. • Replace the filter element. Light Stays On Continuously And Engine Stalls And Will Not Restart (After Initial Start-Up). • Fuel filter or lines plugged. • Replace the filter element or check the lines. Light Stays On Continuously And Engine Stalls And Will Not Restart (After Refueling). • Large amounts of water pumped into the tank. • Purge the fuel tank. DIESEL ENGINE FUEL FILTERS The diesel engine fuel filter is an inline type filter which com bines several different functions. It acts as a filter, water separator, water detector, water drain, and a fuel heater (Figure 2). The first stage of the filter element is a water coalesor. The coalesor element combines small droplets of water into larger drops. The water collects in the bottom of the filter element for draining. The fuel then passes through the second stage of the filter element which is a paper filter. The filter acts as a water detector by turning on the “ WATER IN FUEL” light on the instrum ent panel. The probe of the water detector will touch water when 65 ml. (2.2 fluid ounces) of water has collected in the filter. This completes a circuit through the water to the cover assem­ bly which turns on the “ WATER IN FUEL” light. NOTICE: If the “ WATER IN FUEL” light comes on and the fuel system is not purged of water, fuel injection system damage may result. When the light comes on, the filter should be drained as soon as practical, but within one to two hours of engine operation. A water drain is located in the bottom of the fuel filter assembly. By opening the water drain valve, water that has collected in the bottom of the filter element can be drained. A fuel heater is located in the fuel filter assembly to help prevent fuel waxing. The heater therm ostat turns the heater on at about 0°C (32°F) and off at about 30°C (80°F). The heater uses 7 to 13 amps depending on fuel temperature. DRAINING THE FUEL FILTER 1. Turn off the engine and apply the parking brake. 2. Remove the fuel filler cap to release any pressure or vacuum in the fuel tank. 3. Place a suitable container under the filter drain hose. 6C-4 FUEL SYSTEM 7. 8. 9. 10. 11. 12. 13. 14. 15. W a te r Drain Valve B a il W ire s F uel F ilte r E le m e n t A ir B leed F ilte r A d a p te r A ir B leed Port R e s tric tio n S w itc h F ue l H ea te r W a te r S e n s o r F-00796 Figure 2—Diesel Fuel Filter CAUTION: The water/diesel fuel mixture is flammable, and could be hot. To help avoid personal injury and/or property damage, do not touch the fuel coming from the drain hose, and do not expose the fuel to open flames or sparks. Be sure you do not overfill the container. Heat (such as from the engine) can cause the fuel to expand. If the container is too full, fuel could be forced out of the container. This could lead to a fire and the risk of personal injury and/or vehicle damage. 4. Open the drain valve (7) two to three turns (figure 2). 5. Start the engine and allow it to idle for one to two m inutes or until clear fuel is observed. 6. Stop the engine and close the drain valve (7). 7. Install the fuel filler cap. 8. Dispose of the drained m ixture in a proper manner. DIESEL FUEL FILTER REPLACEMENT Remove or Disconnect (Figure 2) 1 . Fuel filler cap to release any pressure or vacuum in the fuel tank. 2. Both bail wires (8). • Drain fuel from the filter by opening the air bleed (10) and the water drain valve (7). — Allow the fuel to drain into a suitable container. 3. Fuel filter element (9). SI Clean Any dirt from the fuel sealing surfaces of the filter element and the filter adapter (11). El Install or Connect (Figure 2) 1. 2. • 3. New filter element. Bail wires. Close the drain valve (7). A 3 mm (Vs-inch) inside diam eter hose to the air bleed port (12). 4. The other end of the hose into a suitable container. • Disconnect the fuel injection pum p shut-off solenoid wire. NOTICE: If the engine is to be cran ked or started with the air cleaner removed, take care not to let objects fall into the engine. If the eng in e is running, su ctio n can p u ll loose o b jects into the engine. O bjects p u lle d or d ro p p e d into the e n g in e can cause costly engine damage. • Crank the engine for 10 to 15 seconds and then wait one minute for the starter m otor to cool. Repeat until clear fuel is observed com ing from the air bleed. • Close the air bleed. 5. Injection pump solenoid wire. 6. Fuel filler cap. • Start the engine and allow it to idle for five minutes. • Check the fuel filter for leaks. FUEL SYSTEM 6C-5 DIESEL FUEL FILTER ASSEMBLY COMPONENT REPLACEMENT All component parts of the fuel filter assembly are serviceable. These components include the filter adapter, restriction switch, fuel heater, and the water sensor (figure Always replace any damaged or worn O-rings, gaskets, or seals. After replacing components, bleed air from the filter to save cranking time. Start the engine and check for leaks after replacing components. 2). FUEL PUMP All carbureted and diesel engines use a m echanical fuel pump located on the front right side of the engine. The pump is a diaphragm type pump and is actuated by a rocker arm through a link and pull rod. Some engines have a special fuel pump that has a me­ tering outlet for a vapor return system. Any vapor that form s is returned to the fuel tank along with hot fuel. This reduces the chance of vapor lock because cool fuel from the tank is always circulated through the fuel pump. The fuel pump rocker arm is moved back and forth by a rod which rides on an eccentric on the engine camshaft. The rocker arm pulls down on the pump diaphragm against spring pressure. This causes a vacuum in the pump cham ber which draws fuel from the tank through the inlet valve. The cam shaft rotates and releases pres­ sure on the rocker arm. This allows the spring to act on the diaphragm and force fuel out of the pump cham ber through the outlet valve and into the fuel line to the carbu­ retor or diesel fuel injection pump. When the carburetor float rises and closes the needle valve, fuel cannot leave the pum p chamber. The spring is held compressed by the fuel pressure in the pump cham ­ ber. The rocker arm idles on the cam eccentric and only moves enough to maintain pressure on the spring. A con­ stant pressure is maintained on the fuel in the line to the carburetor. This pressure is proportional to the force of the spring. W hen the immediate fuel needs of the diesel engine are satisfied, pressure builds in the fuel line and pump chamber. This pressure forces the diaphragm /piston to make shorter and shorter strokes, until more fuel is needed in the engine. FUEL PUMP TESTS (CARBURETED ENGINE) If the fuel system is suspected of not delivering enough fuel, it should be inspected as follows. Inspect Make certain that there is fuel in the tank. For leaks at all fuel connections from the fuel tank to the carburetor. FUEL PUMP FLOW TEST 1. Remove the fuel supply line from the carburetor or fuel injection pump and insert it into a suitable container. 2. Crank the engine. 3. The fuel pump should supply 237 ml (1/2-pint) or more in 15 seconds. 4. If the flow is insufficient, check for a restriction. 5. If there are no restrictions, check fuel pump vacuum and/or pressure. FUEL PUMP PRESSURE TEST 1. 2. 3. 4. Disconnect the fuel inlet line at the carburetor. Install a low pressure gage to the line. Start the engine. Fuel pump pressure should be 27.5 to 44.8 kPa (4 to 6 V2 psi). 5. If the pressure is low, check for restrictions in the fuel tank sender unit filter, lines, and hoses. NOTICE: Hold the carburetor fuel inlet nut while tig h te n in g the fu e l lin e fittin g to p re v e n t carburetor damage. 6 . Connect the fuel inlet line to the carburetor. FUEL PUMP VACUUM TEST 1. Disconnect the inlet hose at the fuel pump and connect a vacuum gage. 2. Crank or run the engine until the maximum vacuum is reached. 3. If the vacuum is less than 50.6 kPa (15-inches Hg), replace the fuel pump. 4. If the vacuum is 50.6 kPa (15-inches Hg), check the fuel line s and hoses fo r leaks, kinks, or s p lits by disconnecting each section of line and connecting a vacuum gage. Crank or run the engine until the maximum vacuum is reached. The vacuum should be at least 50.6 kPa (15-inches Hg). FUEL PUMP TESTS (DIESEL ENGINE) If the fuel system is suspected of not delivering enough fuel, it should be inspected as follows. — The engine should be running. Inspect — Tighten any loose connections. Make certain that there is fuel in the tank. For leaks at all fuel connections from the fuel tank to the injection pump. — The engine should be running. — Tighten any loose connections. All hoses for flattening or kinks that would restrict the flow of fuel. Air leaks or restrictions on the suction side of the fuel pump will seriously affect pump output. 6C-6 FUEL SYSTEM 25. Fuel P um p 26. B o lt 27. G a sket F-00797 Figure 3—Fuel Pump—Carbureted 4.8L Engine • All hoses for flattening or kinks that would restrict the flow of fuel. • Air leaks or restrictions on the suction side of the fuel pump will seriously affect pump output. FUEL PUMP FLOW TEST Remove or Disconnect 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). 26. B o lt 27. G asket 31. Push Rod F-00799 Figure 4—Fuel Pump—Carbureted 5.7L Engine 25. 26. 27. 28. 29. 30. Fuel P um p B o lt G asket B o lt M o u n tin g Plate G a sket P ush Rod FUEL PUMP VACUUM TEST 1. Disconnect the inlet line at the fuel pump. • Plug the hose or position it so fuel does not leak. 2. Connect a vacuum gage to the fuel pump inlet. 3. Start the engine. • The engine will use fuel from the filter 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 H Remove or Disconnect (Figures 3 through 5) 1. 2. 3. 4. Fuel pipes and hoses from the fuel pump (25). Bolts (26). Fuel pump (25). Gasket (27). F-00800 Figure 5—Fuel Pump—6.2L Engine FUEL SYSTEM 6C-7 f^l Tighten • Bolts to specification. 8. Fuel pipes and hoses to the fuel pump. • If it is difficult to start the outlet fitting, disconnect the line at the carburetor or the diesel fuel injection pump. • Start the engine and check for leaks. 7.4L ENGINE Remove or Disconnect (Figure 6) Fuel pipes and hoses from the fuel pump (35). Bolts (36). Fuel pump (35). Gasket (37). Plug (38). 6. The push rod (39). -►+ Install or Connect (Figure 6) 5. 6. 7. 8. Bolts (28). Mounting plate (29). Gasket (30). The push rod (31) (if necessary). -H - Install or Connect (Figures 3 through 5) 1. The push rod (39). • Apply some chassis grease to the rod and hold it up against the camshaft. Gasket sealer to the threads on the plug (38). Plug (38). Gasket (37). Fuel pump (35). Bolts (36). 1. The push rod (if removed). • Apply some chassis grease to the rod to hold it up against the camshaft. 2. New gasket (30). 3. Mounting plate (29). 4. Bolts (28). Tighten • Bolts alternately and evenly to 37 N m (27 ft. lbs.). Fuel pipes and hoses to the fuel pump. • If it is difficult to start the outlet fitting, disconnect the line at the carburetor. Start the engine and check for leaks. • Bolts to specification. 5. New gasket (27). 6. Fuel pump (25). 7. Bolts (26). FUEL TANK The fuel tank is located under the rear or the sides of the vehicle. The fuel tank is held in place by two metal straps that are attached to the underbody. Anti-squeak strips are used between the tank and the straps to reduce rattles and squeaks. The fuel tank, filler cap, and fuel lines should be checked for damage which could cause leakage. Replace any dam aged or worn parts. Before servicing the fuel tank or lines: • Disconnect the negative battery cable from the battery. • Place “ NO SMOKING” signs near work areas. • Have a C 0 2 fire extinguisher nearby. DRAINING THE FUEL TANK ++ Remove or Disconnect 1. Negative battery cable. • There are two batteries in diesel engine vehicles. • Have a dry chemical (Class B) fire extinguisher in the work area. 2. Fuel filler cap. CAUTION: Never drain or store gasoline or diesel fuel in an open container due to the possibility of fire or explosion. • Wear safety glasses. • Siphon or pump fuel into an explosion proof container. 3. Fuel through the filler tube using a hand operated pump. 6C-8 FUEL SYSTEM • If a hand operated pump cannot be used to complete the draining, use a siphon at the main (not return) fuel pipe at the fuel pump or the fuel gage sending unit. Install or Connect 1. Any lines or hoses. 2. Fuel filler cap. 3. Negative battery cable. 3. New fuel gage sending unit gasket. NOTICE: Take care not to fold or twist the strainer when installing the sending unit as this will restrict fuel flow. 4. Fuel gage sending unit using J-24187. 5. Fuel tank. 6. Fuel gage wire harness to the body harness. FUEL SYSTEM CLEANING (CARBURETED ENGINE) 7. All fuel lines. 8. A hose to the carburetor inlet line. • Disconnect the inlet line from the carburetor. CAUTION: This procedure will not remove all fuel vapor. Do not attempt any repair on the tank or fille r neck where heat or flame is required, as an explosion resulting in personal injury could occur. 9. The other end of the hose into a four liter (one gallon) fuel can. 10. Battery cable. 11. Six gallons of clean gasoline into the fuel tank. • Crank the engine until the fuel can is about one-half full. This will purge the fuel pump. Contaminated fuel or other foreign material in the tank can usually be removed by cleaning; however, if the fuel tank is rusted internally, it should be replaced. — Do not overheat the starter. ♦♦I Remove or Disconnect 12. Carburetor inlet line to the carburetor. Tool Required: J-24187 Fuel Gage Sending Unit Tool Negative battery cable. Engine harness connector at the distributor. Have a dry chem ical (Class B) fire extinguisher near the work area. Fuel from the fuel tank. • Refer to “ Draining the Fuel Tank.” Fuel tank. • Refer to “ Fuel Tank Removal.” Fuel filter. Replace the filter if it is plugged. Fuel gage sending unit using J-24187. • Locate th e ta n k aw ay from heat, flam e, or oth er sou rces o f ig n itio n . • If the strainer is contaminated or clogged, a new strainer should be installed upon reassembly. Remaining fuel from the tank by rocking the tank. Flush the fuel tank with hot running water for at least five minutes. Water from the fuel tank by rocking the tank. • Make sure that the water is completely removed. Fuel feed pipe at the fuel pump. Clean Fuel lines by applying air pressure in the opposite direction of fuel flow in the line. 0 Install or Connect Tool Required: J-24187 Fuel Gage Sending Unit Tool Lines and pipes. Tighten • Fittings to 30 N-m (22 ft. lbs.). 2. New strainer on the fuel gage sending unit (if necessary). • Use low air pressure to clean the pipes of the fuel gage sending unit. • Check all connections for leaks and tighten all hose clamps. 13. Engine harness connector to the distributor. DIESEL FUEL SYSTEM CONTAMINATION Fungi and other m icro-organism s can survive and m ultiply in diesel fuel if water is present. The fungi can be present in any part of the fuel handling system. These fungi grow into long strings and will form into large globules. The growths appear slim y and are usually black, green, or brown. The fungi may grow anywhere in the fuel but are most plentiful where diesel fuel and water meet. As the fuel is agitated (when service station tanks are being filled), fungi are distributed throughout the tank and may be pumped into a vehicle. Fungi use the fuel as their main energy supply and need only trace amounts of water and minerals. As they grow and multiply, they change fuel into water, sludge, acids, and products of metabolism. The most common symptom is fuel filter plugging; however, various metal components (fuel tank, lines, and injection pump) can corrode. CAUTION: To avoid personal injury, do not come into physical contact with biocides. If fungi have caused fuel system problems, use a diesel fuel biocide to sterilize the fuel system. Do not exceed the dosage recommended on the label. Discontinue the use of a biocide when towing a trailer. It is permissible to have biocide in the fuel when starting to tow, but do not add any biocide while towing. Steam cleaning may be necessary if most of the fungus growth cannot be removed with biocides. FUEL SYSTEM 6C-9 FUEL SYSTEM CLEANING (DIESEL ENGINE) CAUTION: Never drain or store diesel fuel in an open container due to the possibility of fire or explosion. • Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears from each nozzle. 11. HPCA lead to the injection pump. & WATER IN THE FUEL SYSTEM Remove or Disconnect Battery cables. Fuel from the tank. • Refer to “ Draining the Fuel Tank.” Fuel tank. Fuel gage sending unit, f c y l Clean 5. 6. • 7. 8. • Fuel tank. — The tank should be replaced if it is rusted internally. • The pick-up filter or replace if necessary. • The check valve assembly. Main fuel hose at the fuel pump. Fuel return line at the injection pump. Use low air pressure to blow out the lines toward the rear of the vehicle. — Replace the pipes if they are rusted internally. Fuel injection pump shut-off solenoid wire. Fuel filter. +«- Install or Connect 1. 2. 3. 4. 5. 6. 7. • 8. 9. • • 10. • • Fuel gage sending unit. Fuel tank. Fuel lines to the tank. Clean diesel fuel into the tank until it is 1/4 full. Fuel tank cap. Fuel hoses to the fuel pump. Battery cables. Crank the engine for 15 seconds with one minute cooling periods until clean fuel is pumped out. — Use a suitable container to catch the fuel. New fu e l filte r. R efer to “ D ie se l Fuel F ilte r Replacement.” A hose from the return line at the fuel injection pump to a closed metal container with a capacity of at least 8L (2-gallons). If the engine temperature is above 52°C (125°F), activate the HPCA (Housing Pressure Cold Advance) on the in je c tio n pum p. T h is can be done by disconnecting the two lead connectors at the Engine Temperature Switch and bridging the connector with a jumper wire. Crank the engine for 15 seconds with one minute cooling periods until clean fuel appears at the return line. Two lead connectors to the Engine Temperature Switch. • Remove the jumper wire. Disconnect the lead to the HPCA solenoid (on the injection pump). Crack open each injection line at the nozzle. Use two wrenches to prevent nozzle damage. 12. • • 13. Tighten • Injection line to nozzle fitting to 25 N m (20 ft. lbs.). — Use two w renches to prevent nozzle damage. Fuel injection pump shut-off solenoid wire. Start the engine and allow it to idle for 15 minutes. — Make sure the fuel return line is in the metal container and that the container does not overflow. Remove the hose from the metal container. Fuel return line to the injection pump. Check for leaks. GASOLINE IN THE FUEL SYSTEM Engine Will Run Or Start 1. Drain the fuel tank. 2. Fill the tank with diesel fuel. 3. Run the engine for 15 minutes. Engine Will Not Run 1. Drain the fuel tank. 2. Fill the tank with diesel fuel. 3. Remove the fuel injection pump shut-off solenoid wire. 4. Remove the fuel line between the fuel filter and the injection pump. 5. Connect a hose to the fuel filter outlet and run it to a closed metal container. 6. Crank the engine for 15 seconds with one minute cooling periods to purge gasoline from the system. 7. Install the fuel line between the fuel filter and the injection pump. 8. If the engine temperature is above 52°C (125°F), a c tiv a te th e H P C A (H o u s in g P re s s u re C o ld Advance) on the injection pump. This can be done by disconnecting the two lead connectors at the E n gin e T e m p eratu re S w itch and b rid g in g the connector with a jum per wire. 9. Install the fuel injection pump shut-off solenoid wire. 10. Start the engine and remove the jum per wire. 11. Connect the two lead connector. 12. Run the engine for 15 minutes. FUEL TANK PURGING The fuel tank should be purged before being repaired. ++ Remove or Disconnect 1. Fuel tank from the vehicle. 2. Fuel gage sending unit. 3. All remaining fuel from the tank. Inspect • Fuel tank for any rem aining fuel. 6C-10 FUEL SYSTEM -►+ Install or Connect 1. Tap water into the tank until it is full. • Move the tank to the flushing area (wash rack). • Agitate the water vigorously and then drain it. 2. Gasoline emulsifying agent into the tank. • Use an available emulsifying agent such as Product-Sol No. 913 or equivalent. 3. Water to the fuel tank. • Refer to the emulsifying agent specifications for the mixture ratio. • Agitate the mixture for ten minutes. • Drain the tank completely. • Fill the tank with water until it overflows. • Completely flush out any remaining mixture. • Drain the fuel tank. • Use an explosion meter (if available) to check for a negative reading. • Perform the required service work. FUEL TANK LEAK TEST If fuel is leaking from the tank, the tank should be replaced. Make sure that the fuel lines are not leaking onto the tank. 1. Remove the fuel tank. 2. Drain the tank. 3. Plug all of the outlets. 4. Apply 7 to 10 kPa (1 to 11/2 psi) air pressure through the vent tube. 5. Test for leaks with a soap solution or by submersion. 6. Replace the tank if a leak is found. FUEL TANK REPLACEMENT CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle at the opposite end from which com ponents are being removed. This w ill reduce the possibility of the vehicle falling off the hoist. E 3 Remove or Disconnect (Figures 7 through 9) 1. Fuel from the tank. 2. Fuel tank retaining straps. • Support the fuel tank. 3. Sending unit wire, hoses, and ground straps. • Lower the tank. 4. Fuel tank from the vehicle. -►+ Install or Connect (Figures 7 through 9) 1. Fuel tank into the vehicle. • Support the tank. 2. Sending unit wire, hoses, and ground straps. 3. Fuel tank retaining straps with the anti-squeak pieces. • Cement the anti-squeak material securely to the tank with 25 mm (1-inch) wide coverage for 10 cm (4-inches) on each end. Tighten Retaining strap bolts or nuts to specifications. FUEL TANK FILLER NECK A restrictor and deflector is built into the fuel filler neck on gasoline engine vehicles to help prevent refueling with leaded gasoline. The opening in the restrictor will only adm it the sm aller unleaded gas nozzle spout. The nozzle must be fully inserted to bypass the deflector (figures 10 through 12). FUEL FILLER CAP The fuel tank filler neck is equipped with a screw type cap. The cap requires several turns counterclockwise to remove. The long threaded area allows fuel tank pressure to escape while the cap is being removed. A torque limiting device prevents overtightening. To install, turn the cap clockwise until a clicking noise is heard. N O T IC E : If a fu e l f ille r c a p re q u ire s replacement, use only a cap with the same features. Failure to use the correct cap can result in a serious malfunction of the system. FUEL LINES NOTICE: Fuel and vapor hoses and pipes are specially manufactured. It is important to use re p la c e m e n t h o s e o r p ip e m e e tin g GM Specifications. Hoses and pipes not m eeting GM Specification could cause early failure or failure to m eet emission standards. When replacing fuel feed and return pipes, always use welded steel tubing meeting GM Specification 124 M or its equivalent. The replacement pipe must have the same type fittings as the original pipes to ensure integrity of the connection. — Never replace fuel pipe with copper or aluminum tubing. — Check and replace any damaged O-rings or washers. — Fuel pipes should be inspected occasionally for leaks, dents, or kinks. — Follow the same routing as the original pipe. — Pipes must be properly secured to the frame to prevent chafing. A minimum clearance of 6 mm (1/4-inch) must be maintained to prevent contact and chafing. FUEL AND VAPOR HOSES NOTICE: Fuel and vapor hoses are specially m a n u fa c tu r e d . It is im p o r ta n t to use replacem ent hoses that m eet GM Specification 6163-M. These hoses are identified by the word “ Fluoroelastomer” marked on them. Hoses not so marked could cause early failure or failure to m eet emission 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-11 Figure 7—Fuei Tank Mounting—R/V Pickup A. T ig h te n Thi N u t F irs t B. H o o k M u s t Face F orw ard B F-00803 Figure 8—Fuel Tank Mounting — Utility Vehicle and Suburban Figure 9—Fuel Tank Mounting — G Van 6C-12 FUEL SYSTEM Figure 10—R/V Filler Neck F-00806 Figure 12—G-Van Filler Neck FUEL SYSTEM 6C-13 FUEL GAGE SENDING UNIT 50. L o ckin g Cam 51. Fuel Gage S e n d in g U nit 52. G a sket 53. In-Tank Fuel F ilte r 53 Diesel engine vehicles have a check valve that will permit fuel to pass if the tank filter becomes plugged with paraffin during cold weather operation. When this plugging occurs, the last four gallons of fuel will not be used due to the location of the check valve. Therefore it is important to keep the fuel tank above the 1/4 mark at temperatures below -6°C (-20°F) when using number two diesel fuel. FUEL GAGE SENDING UNIT REPLACEMENT B-08104 Remove or Disconnect (Figure 13) Figure 13—Fuel Gage Sending Unit The fuel gage sending unit is mounted in the top of the fuel tank. It is held in place by a cam lock ring. A gasket is used between the tank and the sending unit. Sending units have either two or three nipples to attach hoses. These hoses are the fuel feed, fuel return, and vapor hoses. On some sending units a wire is attached to the unit; while on other sending units, connectors attach directly to the sender. IN TANK FUEL FILTER A woven plastic filter is located on the lower end of the fuel pickup tu b e jn the fuel tank (figure 13). This filter prevents dirt and water from entering into the fuel line unless it becomes completely submerged in water. The filt e r is s e lf c le a n in g a nd n o rm a lly re q u ire s no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water and should be thoroughly cleaned. Tool Required: J-24187 Fuel Gage Sending Unit Tool Fuel from the tank. Fuel tank from the vehicle. Locking cam (50) using J-24187. Fuel gage sending unit (51). Gasket (52). Install or Connect (Figure 13) Tool Required: J-24187 Fuel Gage Sending Unit Tool New gasket. Fuel gage sending unit. • Take care not to fold or twist the strainer or fuel flow will be restricted. Locking cam using J-24187. Fuel tank into the vehicle. FUEL TANK SELECTOR VALVE The fuel tank selector valve is operated by a switch on the instru m e nt panel. The sw itch controls fuel tank switching and fuel gage indication in a single operation. A simple check can be made to determine if the fuel tank selector valve is working by listening for selector valve motor operation when the switch is pressed. DIAGNOSIS OF SELECTOR VALVE CHECKING THE INSTRUMENT PANEL SIDE OF THE HARNESS R efer to fig u re s 14 th ro u g h 16 to d ia g n o s e the instrum ent panel side of the selector valve harness. CHECKING THE SELECTOR VALVE SIDE OF THE HARNESS 1. Make sure there is about 40 liters (10 gallons) of fuel in one tank and about 20 liters (5 gallons) in the other tank. 2. Remove the harness connector from the fuel tank 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. 5. The system is operating properly if a change is indicated between the tanks. Therefore, the original selector valve was the problem. 6. If a change is not indicated, there is an open in the harness between the connector on the cowl and the selector valve. 7. Refer to INSTRUMENT PANEL (SEC. 8C) if the fuel gage does not register accurately. FUEL TANK SELECTOR VALVE REPLACEMENT Remove or Disconnect (Figure 17) 1. Battery negative cable. 2. Hose shield (60) and brace (61). 3. Electrical connector from the selector valve (62). 60-14 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. T 1 TEST LIGHT LIGHTS. TEST LIGHT DOES NOT LIGHT. CHECK FOR PROPER GROUND CONNECTION (BLACK OR BLACK WITH PINK WIRE) AT THE BUSS BAR. ---- ------- I --------------------- CHECK FOR A PROPER CONNECTION TO THE IGNITION RECEPTACLE 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. „ 1 ] ----------------------------------------------------------------------------- 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. s TEST LIGHT LIGHTS. TEST LIGHT DOES NOT LIGHT. ..... . _______ 1 i 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. I ~ 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 14—Diagnosis of the Instrument Panel Side of the Selector Valve Harness FUEL SYSTEM 6C-15 > 917253 -.8 P N K - 3 0 - * - - T T 0 ] BULKHEAD CONNECTOR 691723? 30 — 30 [ T o } - - * - . 5 PN K-3 0- ' IN ST C LU STE R IN ST CONN (SEE (BASE) ’ ' 150 \© OH CLUSTER (B A S E ) ALSO GAGES) 1202001* «SM LEFT ---- ^ .8 LT GRN 5 3 ( HOT .8 OK GR 5 4 (HOT (A U X ILIA R Y) RIGH T TANK D PM /ALVE CO CO > ---- T z z O oLoc o FUEL TANK S E LE C T O R VALVE & METER SWITCH -...— tICMT , tIGM T-* •» LE F T ro ui in mm > — .8 FU EL TANK S E LE C T O R SWITCH PNK/BLK-830(SXL ) ■ M l 1220 (O) H t t t t C Juliet >4 i m u sj — .8 .8 BLK — I 5 0 ( HDT) IGN FUSED 20 AMP z z a OC CD CD P N K / W H T - 9 3 0 (H D T ) o ro I (PRODUCTION) L E F T TANK F USE BUS BAR GRO BLOCK B-08116 Figure 15—Auxiliary Fuel Tank Wiring 4. Fuel and vapor hoses. • Note the position of the hoses for installation. 5. Screws (63). 6. Valve (62). -►+ Install or Connect (Figure 17) 1. 2. 3. 4. 5. 6. To F uel Tank S e le c to r Valve 54. 55. 56. 57. 58. A n d S e n d in g U nit F use Panel S e le c to r Valve S w itc h In s tru m e n t Panel S ide O f H a rn e ss C o n n e c to r S e le c to r Valve S ide O f H a rn e ss F-08117 Figure 16—Auxiliary Fuel Tank Instrument Panel Wiring Valve (62). Screws (63). Fuel and vapor hoses in the correct position. Electrical connector. Brace (61) and hose shield (60). Battery negative cable. 6C-16 FUEL SYSTEM 62 V 00 % LU A Fuel R eturn R ig h t Feed (Orange) L e ft Feed (Yellow) R ig h t R eturn (Pink) L e ft R eturn (Blue) S h ie ld Brace S e le c to r Valve B o lt B-08119 Figure 17—Selector Valve ACCELERATOR CONTROLS The accelerator pedal controls the throttle through a ca­ ble. There are no linkage adjustments. The throttle cable must be replaced with an identical replacement part. 70 All linkages and cables must be checked to assure free movement with no rubbing, chafing, or binding. The throt­ tle must operate freely w ithout binding between 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 18). — 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 c o n ta c t w ith the fro n t of dash s e a le r d u rin g replacement. — 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 w ith A cce lerator Linkage Lubricant (1052541 or equivalent). 71. W a sh er B-08121 Figure 18—Control Cable Attachment ACCELERATOR PEDAL Observe the following when performing service on the accelerator pedal. — The m ounting surface between the support and the dash panel must be free of insulation. The carpet ana paaaing in the pedal and tunnel area must FUEL SYSTEM 6C-17 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 dam aged (figure 19). — The linkage must operate freely without binding between closed throttle and full throttle. — Wire, hoses, cable, and other flexible components must not be placed within 13 mm (0.52-inch) of the cable or rod at any point in their travel. 75. 76. 77. 78. R e ta in e r (M u st B ear A g a in s t Pedal Rib) S p rin g Rod R e in fo rc e m e n t B-08122 Figure 19—Accelerator Pedal Assembly SPECIFICATIONS FUEL PUMP BOLT TORQUE 4.8L 5.7L 5.7L 6.2L 6.2L 7.4L E n g in e .............................................................................................................. 23 N-m (17 Engines (Top B o lts ) ...................................................................................... 37 N-m (27 Engines (Bottom Bolts)...................................................................................... 4 N-m (3 Engine (Top B o lts ) ........................................................................................ 33 N-m (24 Engine (Bottom B o lts ) ...................................................................................... 8 N-m (6 E n g in e ............................................................................................................ (37 N-m (27 ft. ft. ft. ft. ft. ft. lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) R/V Model With Base Tank N u ts ............................................................................. 6 N-m (4 ft. R/V Model With RPO NL2 B o lts .........................................................................33 N-m (24 ft. Utility Vehicle And Suburban N u t s .................................................................... 16 N-m (12 ft. G-Van With Base Tank B o lts..................................................................................5 N-m (45 in. G-Van With RPO NL7 Bolts..................................................................................11 N-m (95 in. G-Van N u ts .............................................................................................................. 13 N m (10 ft. lbs.) lbs.) lbs.) lbs.) lbs.) lbs.) FUEL TANK MOUNTING STRAP FASTENERS FUEL INLET NUT TORQUE 1-Barrel — 1 M E F ...............................................................................................45 N-m (33 Ft. Lbs.) 4-Barrel — M 4 M E ...............................................................................................62 N-m (46 Ft. Lbs.) 6C-18 FUEL SYSTEM SPECIAL TOOLS Figure 20—Special Tools 6C1-1 SECTION 6C1 CARBURETORS CONTENTS SUBJECT PAGE Carburetor Model 1M EF...........................................................................................................................................6C1- 2 Description................................................. ............................................................................................................ 6C1- 2 Diagnosis of 1MEF Rochester Carburetor............................................................................................................... 6C1- 7 On-Vehicle Service (1MEF)........................................................................................................................................6C1-15 Electric C h o k e ........................................................................................................................................................ 6C1-15 Idle Solenoid............................................................................................................................................................ 6C1-16 Carburetor Replacement........................................................................................................................................6C1-17 Carburetor A djustm ents........................................................................................................................................6C1-17 Carburetor Models M4ME and M4MEF..................................................................................................................... 6C1-21 Description.............................................................................................................................................................. 6C1-21 Carburetor Identification........................................................................................................................................6C1-21 Diagnosis of M4ME and M4MEF Rochester Carburetors.......................................................................................6C1-28 On-Vehicle Service (M4ME and M4MEF)................................................................................................................. 6C1-37 Float Level - External C h e c k .................... ...........................................................................................................6C1-37 Choke Checking P ro ce d u re ..................................................................................................................................6C1-37 Checking idle Stop Solenoid (ISS)....................................................................................................................... 6C1-37 Checking Throttle Kicker........................................................................................................................................ 6C1 -38 Fuel Filter R eplacem ent........................................................................................................................................ 6C1-38 Carburetor Mounting T o rq u e ................................................................................................................................6C1-38 Carburetor Replacement........................................................................................................................................6C1 -38 Idle Mixture Adjustment (Heavy-Duty Emission Vehicles O n ly )...................................................................... 6C1-39 Idle Speed A d ju stm e n t.......................................................................................................................................... 6C1 -40 Throttle Kicker Adjustment....................................................................................................................................6C1 -40 Float A djustm ent.................................................................................................................................................... 6C1 -40 Pump A d ju s tm e n t.................................................................................................................................................. 6C1-41 Air Valve Return Spring A d ju stm e n t................................................................................................................... 6C1-41 Choke Stat Lever Adjustment................................................................................................................................6C1-42 Choke Link and Fast Idle Cam Adjustm ent......................................................................................................... 6C1 -42 Primary Side Vacuum Break Adjustment............................................................................................................. 6C1-42 Secondary Side Vacuum Break A djustm ent.......................................................................................................6C1-44 Air Valve Link A d ju s tm e n t....................................................................................................................................6C1-45 Unloader Adjustm ent..............................................................................................................................................6C1-45 Secondary Throttle Lockout Adjustment............................................................................................................. 6C1-46 S pe cifica tio ns............................................................................................................................................................ 6C1-47 Special T o o ls .............................................................................................................................................................. 6C1-48 All new GM vehicles are certified by the United States Environmental Protection Agency as conform ing to the require­ ments 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 in accessible to prevent indiscrim inate or routine adjustment in the field. For this reason the factory proce­ dure for temporarily removing plugs, cap, etc., for purpsoes 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 supplement. 6C1-2 CARBURETORS CARBURETOR MODEL 1MEF Figure 1—1 MEF Carburetor DESCRIPTION Model 1MEF carburetors are single bore downdraft carburetors using a triple venturi along with a discharge tube nozzle (figure 1 ). A power valve piston assem bly and m etering rod control the fuel flow in the main metering and power systems of the carburetor. The tapered metering rod is B M odel N um ber Day O f Year S o u rc e C o d e Year A s s e m b ly P la n t C o d e S h ift Id e n tific a tio n B-06647 Figure 2—Carburetor Identification 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 therm ostatic 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 in the fuel bowl behind the fuel inlet nut to give maximum filtration of incoming fuel. A check valve is used in the filter inlet to prevent fuel draining from the fuel system after rollover. To improve hot engine starting and meet evaporative emission requirements, fuel vapors from the carburetor bowl are vented to a vapor canister on some models. A tube (location F) is added to the air horn to connect the air horn and canister. Other features of the carburetors include an aluminum throttle body for decreased weight and improved heat distribution. A thick throttle body to bowl insulator gasket keeps excessive engine heat from the float bowl. All 1 MEF models have seals added in the float bowl to seal the power piston drive rod and the pum p lever. This prevents fuel vapors from escaping to atmosphere. During unit repair, the seals and retainer, where used, must be removed prior to immersion of the float bowl in carburetor cleaner. 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 m anufacturer’s 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. 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 • Main Metering • Choke CARBURETORS 6C1-3 226 215 215. 218. 226. 228. 231. 234. F uel In le t F ilte r F uel F ilte r S p rin g F loa t F loa t H in g e Pin F loa t N eedle F loa t N ee dle Seat A. In te rn a l V e n t B. V e n t Tube to C a n is te r C. C h e c k Valve Seat D. F uel In E. C h e c k Valve F. Valve C lo s in g S p rin g F-01479 Figure 3—Float System 240. 247. 248. 252. 256. 258. 260. 310. 317. A. B. C. D. Rod - P um p C up - P um p P lu n g e r S p rin g - P u m p P lu n g e r S p rin g - P u m p R eturn G u id e - P um p D isch a rg e S p rin g S p rin g - P um p D isch a rg e Ball Ball - P u m p D isch a rg e Lever - P um p and P ow er Rod L in k - P um p Pum p P lu n g e r Head Pum p D u ra tio n S p rin g P um p D isch a rg e C ha nn el P um p Jet 248 B-06645 Figure 4—Pump System 6C1-4 CARBURETORS 2:66. 274. 276. 279. 282. A. B. C. D. E. F. G. H. I. J. K. Rod - P ow er P isto n P ow er Valve P isto n A s s e m b ly S p rin g - P ow er P isto n M e te rin g Rod and S p rin g A s s e m b ly Je t - M ain M e te rin g T h ro ttle Valve V acuum C h a n n e l M ain V e n tu ri B o o s t V e n tu ri M ain D isc h a rg e N ozzle L ow er Id le A ir Bleed M ain W ell Fuel Feed O rific e Part T h ro ttle A d ju s tin g S crew Top M ain W e ll A ir Bleed M ain W ell to A s p ira to r Bleed K J A p F-01481 Figure 5—Main Metering System - 1 MEF 266. 274. 276. 279. 282. 310. 314. A. B. C. D. E. F. G. H. I. J. Rod - P ow er P isto n Pow er Valve P isto n A s s e m b ly S p rin g - P ow er P isto n M e te rin g Rod and S p rin g A s s e m b ly Je t - M ain M e te rin g Lever - P u m p and Pow er Rod L in k - P ow er Rod T h ro ttle Valve V acuum C h a n n e l M ain D isch a rg e N ozzle L ow er id le A ir B leed M ain W ell M e te rin g Rod A d ju s tin g S crew S e tscre w M e te rin g Rod A d ju s tin g S crew Plug Top M ain W ell A ir Bleed M ain W ell to A s p ira to r Bleed 266 276 B-06644 Figure 6—Power System - 1 MEF CARBURETORS 6C1-5 10. 15. 20. 40. 43. F a st Idle Cam F a st Idle Cam L in k C ho ke S h aft, Lever and L in k A s s e m b ly C h o ke S h a ft and Lever A s s e m b ly C ho ke S tat Lever B ow l S id e V a cuu m Break A s s e m b ly V a cuu m Break Lever and L in k A s s e m b ly C ho ke Valve T h e rm o s ta tic C oil P lu n g e r B u c k in g S p rin g (not used on all m o d e ls ) F-01482 Figure 7—Choke System 6C1-6 CARBURETORS 282. 286. 326. 333. A. B. C. D. E. F. G. J e t-M a in M e te rin g Id le Tube A s s e m b ly N e e d le -Id le M ix tu re P lu g -Id le M ix tu re N ee dle T h ro ttle Valve Id le C ha nn el R e s tric tio n Top Idle A ir Bleed L ow er Idle A ir B leed O ff-Id le Port Idle D isch a rg e O rific e T im e d V a cuu m Port B-06642 Figure 8—Idle 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 v e h icle syste m s can also cause problems and should be checked when listed on the chart. PROBLEM Engine Cranks Normally - Will Not Start or Starts Hard POSSIBLE CAUSE 1. Im proper starting procedure used. 2. Ignition system malfunction. 3. Choke not operating properly. 4. Engine loaded with fuel. (Improper start­ ing procedure used or choke unloader misadjusted.) 5. No fuel in carburetor. 6 . Engine flooded. To check for flooding, re­ move the air cleaner and look into the carburetor venturi for fuel dripping from nozzle. Engine Starts - Will Not Keep Running 1. Improper starting procedure used. 2 . Choke not operating properly. 3. Engine does not have correct fast idle speed when cold. 4. Vacuum break assembly malfunctioning or misadjusted. CORRECTION 1. Check with the customer to determine if proper starting procedure, outlined in the “ O w ner’s and Driver’s M anual” , is used. 2. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 3. Check for free movement, and com ­ plete opening and closing, of choke valve. See “ Choke Checking Proce­ dure” and “ Checking Electric Choke” later in this section. 4. Check with the custom er to determine if proper starting procedure, outlined in the “ O w ner’s and Driver’s M anual” , is used. Adjust choke unloader. 5. Inspect fuel filter(s) for being plugged. Replace as necessary. Check fuel pump pressure and vol­ ume. Replace pump if necessary. In­ s p e c t fu e l lin e s fo r le a k s a nd restrictions. Check the float level, and adjust if necessary. 6 . Remove the air horn. C heck float for restricted movement or being loaded. Inspect float needle and seat for wear and dirt or chips. If foreign material is found in the car­ buretor, clean the fuel system and car­ b u re to r. R e p la c e fu e l filte r ( s ) as necessary. Check float level, and adjust if neces­ sary. 1. Check with the custom er to determ ine if proper starting procedure, outlined in the O w ner’s and Driver’s M anual,” is used. 2. Check for free movement and complete opening and closing of choke valve. See “ Choke Checking Procedure” and “ Checking Electric Choke” later in this section. 3. Check for free movement of fast idle cam and linkage. See “ Choke Check­ ing Procedure” later in this section. Ad­ ju s t fast idle speed. See Em ission Control Information Label. 4. See “ Vacuum Break Checking Proce­ dure” later in this section. Adjust vac­ uum break assembly to specification. 6C1-8 CARBURETORS DIAGNOSIS OF 1MEF ROCHESTER CARBURETOR (CONT.) PROBLEM Engine Starts - Will Not Keep Running (Cont.) POSSIBLE CAUSE 5. Idle speed too low. 6 . Air leaks at carburetor flange/insulator gasket(s), or at intake manifold gasket. Vacuum hoses disconnected or installed improperly. 7. Not enough fuel in carburetor. 8 . Carburetor flooding. Engine Idles Abnormally (Too Fast or Too Slow) 1. Idle speed misadjusted. 2. Idle stop solenoid m alfunctioning. Faulty solenoid circuit wiring. 3. Choke not operating properly or fast idle cam sticking or binding. 4. Throttle linkage or throttle shaft sticking or binding. CORRECTION 5. Adjust idle speed. See Emission Con­ trol Information Label. 6 . Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head m ounting surfaces. If engine RPM changes, torque car­ buretor to manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange/in­ sulator gasket(s) and/or intake manifold gasket. Check condition and routing of vacuum hoses. Correct or replace as necessary. 7. Inspect fued filter(s) for being partially plugged. Replace as necessary. Check fuel pump pressure and vol­ ume. Replace pum p if necessary. In­ s p e c t fu e l lin e s fo r le a k s a nd restrictions. C heck the float level, and adjust if necessary. 8 . Remove the air horn. Check float for restricted movement or being loaded. Inspect flo at needle and seat for wear and dirt or chips. If foreign material is found in the car­ buretor, clean the fuel system and car­ b u re to r. R e p la c e fu e l filte r ( s ) as necessary. Check float level, and adjust if neces­ sary. 1. Adjust idle speeds. See Emission Con­ trol Information Label. 2. See “ Idle Stop Solenoid Checking Pro­ cedure” later in this section. 3., Check choke valve and fast idle cam for free movement. Check for complete opening and closing of choke valve. See “ Choke Checking Procedure” and “ Checking Electric Choke” later in this section. 4. Check throttle linkage and throttle shaft for smooth and free operation. Clean with suitable solvent. Replace throttle body if necesasry. CARBURETORS 6C1-9 DIAGNOSIS OF 1MEF ROCHESTER CARBURETOR (CONT.) PROBLEM Engine Idles Abnormally (Too Fast Or Tool Slow) (Cont.) POSSIBLE CAUSE CORRECTION 5. Air leaks at carburetor flange/insulator gasket(s), or at intake manifold gasket. Vacuum hoses disconnected or installed improperly. 5. Use a pressure oil can to spray light oil or kerosene around carbuertor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. If engine RPM changes, torque car­ buretor to manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange/in­ sulator gasket(s) and/or intake manifold gasket. Check condition and routing of vacuum hoses. Correct or replace as necessary. 6. Check PCV system. Clean or replace PCV valve and hoses as necessary. 7. Adjust timing. See Emission Control In­ formation Label. 8. Check operation. Refer to the “ Fuel and Emissions Service Manual.” 9. Clean carburetor if necesasry. Adjust idle mixture per specified procedure. 10. Replace if necessary. 11. Remove the air horn. Check float for restricted movement or being loaded. Inspect float needle and seat for wear, and for dirt or chips. If foreign material is found in the car­ buretor, clean the fuel system and car­ b ureto r. R e p la ce fu e l filte r(s ) as necessary. 6 . PCV system malfunctioning. 7. Ignition timing misadjusted. 8. Distributor vacuum or mechanical ad­ vance malfunctioning. 9. Idle system restricted or incorrect idle mixture adjustment. 10. Restricted air cleaner element. 11. Carburetor flooding. Check float level, and adjust if necessary. Engine Diesels (After Run) Upon Shut Off 1. Minimum idle speed misadjusted. 1. Adjust minimum idle speed. See Emis­ 2. Idle stop solenoid malfunctioning. Faulty solenoid circuit wiring. 3. Choke not operating proeprly or fast idle cam sticking or binding. 2 . See “ Idle Stop Solenoid Checking Pro­ sion Control Information Label. 4. Throttle linkage or throttle shaft sticking or binding. 5. Air leaks at carburetor flange/insulator gasket(s), or at intake manifold gasket. Vacuum hoses disconnected or installed improperly. cedure” later in this section. 3. Check choke valve and fast idle cam for free movement. Check for complete opening and closing of check valve. See “ Choke Checking Procedure” and “ Checking Electric Choke” later in this section. 4. Check throttle linkage and throttle shaft for smooth and free operation. Clean with suitable solvent. Replace throttle body if necessary. 5. Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. If engine RPM changes, torque car­ buretor to manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange/in­ sulator gasket(s) and/or intake manofld gasket. Check condition and routing of vacuum hoses. Correct or replace as necessary. 6C1-10 CARBURETORS DIAGNOSIS OF 1M E F RO CH ESTER CA RBU RETO R (CONT.) PROBLEM Engine diesels (After Run) Upon Shut Off (Cont.) Engine Hesitates On Acceleration * Hesitates During Cold Engine Operation. POSSIBLE CAUSE 6 . PCV system m alfunctioning. 7. Ignition tim ing retarded (causes throttle valve to be opened farther than normal to obtain correct idle speed). 8 . Lean idle mixture (causes throttle valve to be opened farther than normal to ob­ tain correct idle speed). CORRECTION 6 . Check PCV system. Clean or replace PCV valve and hoses as necessary. 7. Adjust timing. See Emission Control In­ form ation Label. 8 . Clean carburetor if necessary. Adjust idle mixture per specified procedure. 1. M alfunctioning pump system. Make a quick check of the pump sys­ tem: With the engine off, look into the carburetor bore and observe pump dis­ charge jet; actuate throttle lever. A full stream of fuel should emit from the jet. 1 . Remove air horn and check pum p cup. 2 . * Choke not operating properly. 2. 3. * Vacuum break assembly m alfunction­ ing or misadjusted. 3. 4. * Thermae system m alfunctioning. 4. 5. * Early Fuel Evaporation (EFE) system malfunction. 6 . Ignition tim ing misadjusted. 5. 7. Distributor vacuum or m echanical ad­ vance m alfunctioning. 8 . Float level too low. 7. 6. 8. 9. Power piston sticking. Missing or dam ­ aged power piston spring, power piston rod, power rod link, or pump and power rod lever. 9. 10. Metering rod hanger bent or metering rod misadjusted. 10. If cracked or hardened, replace the pump plunger cup and spring. Inspect pump well for scoring. Re­ place float bowl if necessary. Check for restricted pump passages. Clean and blow out passages w ith compressed air. Check the pump discharge ball for proper seating. Check for complete opening and clos­ ing of choke valve. See “ Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. See “ Vacuum Break Checking Proce­ dure” later in this section. Adjust vac­ uum break to specification. Check operation. Refer to the “ Fuel and Emissions Service M anual.” Check operation. Refer to the “ Fuel and Emissions Service M anual.” Adjust timing. See Emission Control In­ formation Label. C heck operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). Check float level, and adjust if neces­ sary. Check power piston operation: push piston down against piston rod and re­ lease; it should move freely in bore and return to its up position. Rotate throttle to wide open; piston should move up­ ward in bore. If piston does not move freely, clean power piston and bore. If piston does not return when de­ pressed, or does not move upward when th ro ttle is opened, check for missing or dam aged parts. Replace as necessary. Inspect metering rod hanger for dam ­ age. Replace power piston assembly if necessary. Adjust metering rod to spec­ ification. CARBURETORS 6C1-11 DIAGNOSIS OF 1M E F RO CH ESTER CA RBU RETO R (CONT.) PROBLEM Engine Hesitates On Acceleration (Cont.) POSSIBLE CAUSE 11. Restricted main metering jet or adjust­ able part throttle fuel feed orifice. Engine Has Less Than 1. Ignition system malfunction. Normal Power At 2. Ignition tim ing misadjusted. Normal Acceleration 3. Distributor vacuum or mechanical ad­ vance m alfunctioning. 4. Plugged air cleaner element. 5. Exhaust system restricted. 6 . Thermae system m alfunction. 7. Early Fuel Evaporation (EFE) system m alfunction. 8 . Transmission malfunction. 9. Choke not operating properly. 10. Fuel filter(s) partially plugged. 11. Faulty fuel pump, or leaking or restricted fuel lines. 12. Float level too low. 13. Power piston sticking. Missing or dam ­ aged power piston spring, power piston rod, power rod link, or pump and power rod lever. 14. Metering rod hanger bent or metering rod misadjusted. 15. Restricted main metering jet or adjust­ able part throttle fuel feed orifice. Loose main metering jet. CORRECTION 11. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ reto r. R e p la c e fu e l filte r ( s ) as necessary. 1. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 2. Adjust tim ing. See Emission Control In­ form ation Label. 3. C heck operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). 4. Replace element. 5. Check for restrictions. Correct as nec­ essary. 6 . Check operation. Refer to the “ Fuel and Emissions Service M anual.” 7. Check operation. Refer to the “ Fuel and Em issions Service M anual.” 8 . Refer to transmission diagnosis. 9. Check for complete opening and clos­ ing of choke valve. “ See Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. 10. Inspect fuel filter(s). Replace as neces­ sary. 11. Check fuel pump pressure and volume. Replace pump if necessary. Inspect fuel lines for leaks and restrictions. 12. Check the float level, and adjust if nec­ essary. 13. Check power piston operation: push piston down against piston rod and re­ lease; it should move freely in bore and return to its up position. Rotate throttle to wide open; piston should move up­ ward in bore. If piston does not move freely, clean power piston and bore. If piston does not return when de­ pressed, or does not move upward when th ro ttle is opened, check for missing or damaged parts. Replace as necessary. 14. Inspect metering rod hanger for dam ­ age. Replace power piston assem bly if necessary. Adjust metering rod. 15. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ reto r. R e p la c e fu e l filte r ( s ) as necessary. If m etering je t is loose, tighten. 6C1-12 CARBURETORS DIAGNOSIS OF 1M E F RO CH ESTER CARBU RETO R (CONT.) PROBLEM Less Than Normal Power On Heavy Acceleration Or At High Speed POSSIBLE CAUSE CORRECTION 1. Carburetor throttle valve not going wide open. 2. Ignition system malfunction. 1. Correct throttle linkage to obtain wide 3. Ignition timing misadjusted. 4. Distributor mechanical advance malfunc­ tioning. 5. Plugged air cleaner element. 6 . Exhaust system restricted. 7. Thermae system malfunction. 8 . Early fuel Evaporation (EFE) system mal­ function. 9. Transmission malfunction. 10. Choke no* operating properly. 11. Fuel filter(s) partially plugged. 12. Faulty fuel pump or leaking or restricted fuel lines. 13. Float level too low. 14. Power piston sticking. Missing or dam­ aged power piston spring, power piston rod, power rod link, or pump and power rod lever. 15. Metering rod hanger bent or metering rod misadjusted. 16. Restricted main metering jet or adjust­ able part throttle fuel feed orifice. Loose main metering jet. Engine Surges 1. Ignition system malfunction. 2. Distributor mechanical advance malfunc­ tioning. 3. Air leaks at carburetor flange/insulator gasket(s), or at intake manifold gasket. Vacuum hoses disconnected or installed improperly. open throttle in carburetor. 2. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 3. Adjust timing. See Emission Control In­ formation Label. 4. Check operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). 5. Replace element. 6 . Check for restrictions. Correct as nec­ essary. 7. Check operation. Refer to the “ Fuel and Emissions Service Manual.” 8 . Check operation. Refer to the “ Fuel and Emissions Service Manual.” 9. Refer to transmission diagnosis. 10. Check for complete opening and clos­ ing of choke valve. See “ Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. 11. Inspect fuel filter(s). Replace as neces­ sary. 12. Check fuel pump pressure and volume. Replace pump if necessary. Inspect fuel lines for leaks and restrictions. 13. Check the float level, and adjust if nec­ essary. 14. Check power piston operation: push piston down against piston rod and re­ lease; it should move freely in bore and return to its up position. Rotate throttle to wide open; piston should move up­ ward in bore. If piston does not move freely, clean power piston and bore. If piston does not return when de­ pressed or does not move upward when throttle is opened, check for missing or damaged parts. Replace as necessary. 15. Inspect metering rod hanger for dam­ age. Replace power piston assembly if necessary. Adjust metering rod. 16. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ retor. R e p la c e fu e l filte r(s ) as necessary. If metering jet is loose, tighten. 1. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 2. Check operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). 3. Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. CARBURETORS 6C1-13 DIAGNOSIS OF 1M E F RO CH ESTER CA RBU RETO R (CONT.) PROBLEM POSSIBLE CAUSE Engine Surges (Cont.) 4. PCV system m alfunctioning. 5. Exhaust system restricted. 6 . Thermae system malfunction. 7. Early Fuel Evaporation (EFE) system malfunction. 8 . Contaminated fuel. 9. Fuel filter(s) partially plugged. 10. Faulty fuel pump or leaking or restricted fuel lines. 11. Float level too low. 12. Float needle sticking in seat. 13. Power piston sticking. Missing or dam ­ aged power piston spring, power piston rod, power rod link, or pump and power rod lever. 14. Metering rod hanger bent or metering rod misadjusted. 15. Restricted main metering jet or adjust­ able part throttle fuel feed orifice. CORRECTION 3. Continued If engine RPM changes, torque car­ buretor to manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange/in­ sulator gasket(s) and/or intake manifold gasket. Check condition and routing of vacuum hoses. Correct or replace as necessary. 4. Check PCV system. Clean or replace PCV valve and hoses as necessary. 5. Check for restrictions. Correct as nec­ essary. 6 . Check operation. Refer to the “ Fuel and Emissions Service M anual.” 7. Check operation. Refer to the “ Fuel and Em issions Service M anual.” 8 . Check for water or excessive alcohol in fuel. 9. Inspect fuel filter(s). Replace as neces­ sary. 10. Check fuel pump pressure and volume. Replace pump if necessary. Inspect fuel lines for leaks and restrictions. 11. Check the float level, and adjust if nec­ essary. 12. Replace float needle and seat. 13. Check power piston operation: push piston down against piston rod and re­ lease; it should move freely in bore and return to its up position. Rotate throttle to wide open; piston should move up­ ward in bore. If piston does not move freely, clean power piston and bore. If piston does not return when de­ pressed or does not move upw ard when th ro ttle is opened, check for missing or damaged parts. Replace as necessary. 14. Inspect metering rod hanger for dam ­ age. Replace power piston assem bly if necessary. Adjust metering rod. 15. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ reto r. R e p la c e fu e l filte r ( s ) as necessary. 6C1-14 CARBURETORS DIAGNOSIS OF 1M E F RO CH ESTER CARBU RETO R (Cont.) PROBLEM Poor Gas Mileage * Black Smoke From Tail Pipe POSSIBLE CAUSE 1. Customer driving habits. 2. Wrong speedometer gear. 3. Low tire pressure or incorrect tire size. 4. Transmission malfunction or in wrong gear. 5. Fuel leaks. 6 . * Plugged air cleaner element. 7. * Choke not operating properly. 8 . * Vacuum break assembly malfunction­ ing or misadjusted. 9. Ignition system malfunction. 10. Ignition timing misadjusted. 11. Distributor vacuum or mechanical ad­ vance malfunctioning. 12. Air leaks at carburetor flange/insulator gasket(s), or at intake manifold gasket. Vacuum hoses disconnected or installed improperly. 13. Engine in need of service. 14. Restricted exhaust system. 15. * High fuel level in carburetor or flood­ ing. 16. Power piston sticking. Missing or dam­ aged power piston spring, power piston rod, power rod link, or pump and power rod lever. CORRECTION 1. Run mileage test, with customer driving if possible, make sure vehicle has 2000-3000 miles (3 200-4 800 km) for the “ break-in” period. 2 . Check odom eter against m easured mile. Replace speedometer gear if nec­ essary. 3. Inflate tires to specifications and use correct tire sizes. 4. Refer to transmission diagnosis. 5. Inspect fuel tank, fuel lines and fuel pump for any fuel leakage. 6 . Replace element. 7. Check for complete opening and clos­ ing of choke valve. See “ Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. 8 . See “ Vacuum Break Checking Proce­ dure” later in this section. Adjust vac­ uum break assembly to specification. 9. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 10. Adjust timing. See Emission Control In­ formation Label. 11. Check operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). 12. Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. If engine RPM changes, torque car­ buretor manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange/in­ sulator gasket(s) and/or intake manifold gasket. Check condition and routing of vacuum hoses. Correct or replace as necessary. 13. Check engine compression. 14. Check for restrictions. Correct as nec­ essary. 15. Inspect float for restricted movement or being loaded. Check float needle and seat for wear and dirt or chips. If foreign material is found in carbure­ tor, clean fuel system and carburetor. Replace fuel filter(s) as necessary. Check float level; and adjust if neces­ sary. 16. Check power piston operation: push piston down against piston rod and re­ lease; it should move freely in bore and return to its up position. Rotate throttle to wide open; piston should move up­ ward in bore. CARBURETORS 6C1-15 DIAGNOSIS OF 1M E F RO CH ESTER CA RBU RETO R (Cont.) PROBLEM CORRECTION POSSIBLE CAUSE Poor Gas Mileage (Cont.) 17. Metering rod hanger bent or metering rod misadjusted. 18. * Metering rod worn or damaged. 19. * Main metering jet worn or loose. Gasoline Odor 1 . Fuel feed or vapor return line leaking. 2. Leak in fuel tank. 3. Disconnected or leaking fuel tank vent lines or hoses to canister(s). 4. Purge lines not connected, .improperly routed, plugged or pinched. 5. Carbon canister(s) loaded. 6 . Faulty fill cap. Fuel Starvation 1. Fuel filter(s) plugged. 2. Fuel lines leaking, restricted, or misrouted. 3. Faulty fuel pump. 16. Continued If piston does not move freely, clean power piston and bore. If piston does not return when de­ pressed, or does not move upward when th ro ttle is opened, ch eck for missing or damaged parts. Replace as necessary. 17. Inspect metering rod hanger for dam ­ age. Replace power piston assembly if necessary. Adjust metering rod. 18. Inspect metering rod. Replace if neces­ sary. 19. Inspect metering jet. Replace if neces­ sary. If loose, tighten. 1. Repair/replace as required. 2. Purge tank and repair or replace tank as required. 3. Connect, repair/replace lines as re­ quired. 4. Connect, clean, or reroute lines as re­ quired. 5. Compare weight of canister with a new one. Replace if necessary. 6 . Install new cap. 1. Inspect fuel filter(s). Replace as neces­ sary. 2. Repair/replace, clean, or reroute as re­ quired. 3. Check fuel pump pressure and volume. Replace pump if necessary. ON-VEHICLE SE R V IC E (1M E F ) ELECTRIC CHOKE 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 disassem bly instructions 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, h ardn ess or o the r sign s of deterioration. Replace or correct as necessary. • The vacuum break diaphragm shaft should be fully extended when the engine is off. If the shaft is not fully extended, replace the vacuum break assembly. Start engine — the vacuum break diaphragm shaft should fully retract within 10 seconds. If the unit fails to retract, replace the vacuum break assembly. • Allow the choke to cool so that when the throttle is opened slightly, the choke blade fully closes. This c h e c k m u s t be p e rfo rm e d a t an a m b ie n t temperature of about 21 °C (70°F). • Start the engine and determine the tim e required for the choke blade to reach its’ full open position. (Start tim ing when the engine starts.) If the choke plate fails to open fully within five minutes, proceed with the rem aining steps. • Check voltage at the choke heater connection with the engine running. If the voltage is approxim ately 12-15 volts, replace the electric choke unit. If the v o lta g e is low o r zero, c h e c k a ll w ire s and 6C1-16 CARBURETORS Figure 10—Installing the Choke Coil Rivets connections. If the connections at the oil pressure switch are dirty or corroded, the oil warning lamp will be off with the ignition switch “ On” and the engine off. If the fuse is blown, the radio or turn signal indicator will be inoperative. Repair wires or replace fuses as necessary. □ IDLE SOLENOID L* Inspect Turn on the engine control switch, but do not start the engine. If all wiring and fuses are good, replace the oil pressure switch. Open the throttle to allow the solenoid plunger to extend. Remove or Disconnect Hold the throttle lever wide open, feel the end of the plunger and disconnect the wire at the solenoid. 1. Air cleaner. Plunger should move. Some spring tension should be felt. 2 . The choke electrical connector. 3. Rivet heads and retainers. If the plunger did not move, back out Ve hex screw (counter clockwise) one full turn and repeat step 3 and 4. • Align a #21 drill (0.156-inch) on the rivet head and drill only enough to remove the rivet head (figure 9). If the plunger moves in step 5, connect the wire to the solenoid and adjust the idle speed. • Use a drift and a small hammer to drive the re m a in d e r of th e riv e ts from th e ch oke housing. If the plunger did not move in step 5, insert test light (1893 bulb or smaller) between the solenoid feed wire and ground. • Use care in drilling to prevent damage to the choke cover or housing. 4. The choke cover assem bly from the housing. 5. The choke coil from the housing. +«- Install or Connect 1 . The choke cover and coil assembly in the choke housing. • Align the notch in the cover with the raised c a s tin g p ro je c tio n on th e h ou sin g co ver flange. • Make sure the coil pick-up tang engages the inside choke coil lever. 2. Retainers and rivets using a suitable blind rivet installing tool (figure 10 ). 3. Electrical connector. • Start the engine and check the operation of the choke. 4. Air cleaner. If the light lights, replace the solenoid. 0 If the light does not light, locate the cause of the open circuit in the solenoid feed wire. Remove or Disconnect Air cleaner. Electrical connector from the solenoid. Solenoid from the float bowl assembly. + 4- Install or Connect 1 . Solenoid. • Hold the choke valve wide open so the fast idle cam follower clears the fast idle cam. • Turn the solenoid until it contacts the lever tang. 2. Electrical connector. 3. Air cleaner. • Check and adjust the idle speed. CARBURETORS 6C1-17 Clean 450 • All traces of the old gasket from the carburetor flange and intake manifold. Install or Connect (Figure 11) 1. Heat shield and insulator gaskets to the intake manifold. CAUTION: Extinguish all open flames while filling and testing carburetor with gasoline to avoid personal injury. 2. Carburetor. • It is good shop practice to fill the carburetor float bowl before installing the carburetor. This reduces the strain on the starting motor and b a tte ry a n d re d u c e s th e p o s s ib ility o f backfiring while attempting to start the engine. Operate the throttle several tim es and check the discharge from pump jets before installing the carburetor. 3. Carburetor attaching nuts. & Tighten • Both nuts to 4.1 N-m (36 in. lbs.) and then both nuts to 22 N-m (16 ft. lbs.). 4. Accelerator linkage. 5. E le c tric a l c o n n e c to rs fo r the choke and solenoid. idle 6 . Fuel and vacuum 450. 451. 452. 453. N ut In s u la to r G a ske t H eat S h ie ld Intake M a n ifo ld lines. Refer to the Em ission Control Label, if necessary, for vacuum line routing information. 7. Air cleaner. Adjust B-09229 Figure 11—Carburetor installation CARBURETOR ADJUSTMENTS CARBURETOR REPLACEMENT F lo o d in g , s tu m b le on a c c e le r a tio n a n d o th e r performance complaints are, in many instances, caused by the presence of dirt, water or other foreign matter in the carburetor. To aid in dia gn osin g the cause, the carburetor should be removed carefully from the engine w ithout draining fuel from the bowl. Contents of the fuel bowl may then be examined for foreign materials as the carburetor is disassembled. Remove or Disconnect (Figure 11) 1. Air cleaner assembly. 2. Fuel and vacuum lines from the carburetor. • Make note of the vacuum hose routing. 3. E le c tric a l c o n n e cto rs fo r th e choke and solenoid. 4. Accelerator linkage. 5. Carburetor attaching nuts. 6 . Carburetor. 7. Insulator gaskets and heat shield. • Idle speed, as outlined later. idle A c a rb u re to r is d e s ig n e d to m eet th e p a rtic u la r requirements of the engine, transmission and vehicle and although they may look alike, they are not usually interchangeable. Refer to carburetor part number and/or specifications when making adjustments. Before suspecting the carburetor as the cause of poor engine perform ance or rough idle; check the ignition system including distributor, tim ing, spark plugs and w ires. C heck the a ir cleaner, e vaporative e m ission system, EFE System, PCV system, EGR valve and engine compression. Also inspect intake manifold, vacuum hoses and c o n n e c tio n s fo r le a k s and c h e c k to rq u e s of carburetor mounting bolts/nuts. Make all a d ju stm e n ts w ith the eng in e at norm al operating tem perature, choke full open, and the air cleaner installed. Except as noted, air conditioning should be “ o ff” and all vacuum lines and all electrical leads connected. Refer to “ Specifications” at the end of this section for carburetor adjustm ent specifications. Gages and tools for m aking adjustments are included in the Universal Gage J-9789D. 6C1-18 CARBURETORS A. H e x W re n c h B-09230 Figure 13^-Base Idle Adjustment 7. Start the engine and bring it to a normal operating te m p e ra tu re , ch o ke va lve o p e n , and th e a ir conditioning off. 8 . Connect an ACCURATE tachom eter to the engine. 9. Check the ignition tim ing, and adjust if necessary, by following the procedure described on the Vehicle Emission Control Information label. Figure 12—Removing the idle Mixture Needle Plug IDLE MIXTURE ADJUSTMENT In the case of a m ajor carburetor overhaul, throttle body re p la c e m e n t, or hig h id le CO as in d ica te d by an emissions inspection, the idle mixture may be adjusted. Adjusting the mixture by other than the following method may violate Federal and/or state laws. Tool Required: J-29030-B Idle Mixture Needle Socket 1. Set parking brake and block drive wheels. 2. Remove the carburetor from the engine. 3. Drain the fuel from the carburetor into a container. 4. Remove the idle m ixture needle plug (figure 12). — Invert carburetor, and support it to avoid dam aging external components. — Make two parallel hacksaw cuts in the throttle body, between the locator points near the idle mixture needle plug. The distance between the cuts depends on the size of the punch to be used. • Cut down to the plug, but not more than 1 / 8 -inch beyond the locator point. — Place a flat punch at a point near the ends of the saw marks. Hold the punch at a 4 5° angle, and drive it into the throttle body to break the casting away, to expose the plug. — Use a center punch to break the plug apart, to uncover idle m ixture needle. • Remove all loose pieces of plug. 5. Reinstall the carburetor on the engine. 6 . P la ce th e tra n s m is s io n in PARK (a u to m a tic transmission) or NEUTRAL (manual transmission). 10. Use J-29030-B to turn the mixture needle (1/8 turn at time), in or out, to obtain the highest RPM (Best Idle). 11. Adjust the idle speed solenoid to obtain the curb idle speed on the Emission Control Information label. 12. Again try to readjust the mixture needle to obtain the highest idle RPM. The adjustm ent is correct when the highest RPM (Best Idle) is reached with the m inimum number of mixture needle turns from the seated position. 13. If necessary, readjust the idle speed solenoid to obtain the specified curb idle speed. 14. Check and if necessary, adjust the base idle speed solenoid (solenoid deactivated) and the fast idle speed to the specification shown on the Emission Control Information label. 15. Turn off the engine, and remove the block from the drive 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. 4. Turn a 1/s” Hex screw to adjust the low idle speed to 450 RPM. • The solenoid should not be energized. CARBURETORS 6C1-19 CHOKE UNLOADER ADJUSTMENT (Figure 17) 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. 3. Gage between the lower edge of the choke valve and the inside of the air horn. 4. Bend the tang to adjust. FAST IDLE ADJUSTMENT (Figure 14) 1. Prepare the vehicle for adjustments according to the Emission Control Information label. • Ignition tim ing must be set per label 2. A d just the curb idle speed w ith 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 com pletely 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. W ith the fast idle adjustment made, the fast idle cam follower must be held firm ly on the second step of the fast idle cam and against the highest step. 2. Hold down on the choke valve so the rod is in the end of the slot. 3. Gage between the lower edge of the choke valve (at the center) and the inside air horn wall. • Refer to “ Specifications.” 4. Bend the rod at point A to adjust. 6C1-20 CARBURETORS 3. Push down on the choke valve (com press the plunger bucking spring and seat the plunger stem on models so equipped). 4. Gage between the lower edge of the choke valve 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) 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 a s k in g ta p e . R e m o ve th e ta p e a fte r adjustment. Figure 18—Vacuum Break Adjustment Tool Required: J-34817 Float Positioning Tool Kit 1 . Remove the air horn and gasket. 2. Attach J-34817-2 to the float bowl using an air horn attaching screw. 3. Place J-34817-3 in the base with the contact pin resting on the edge of the float lever. 4. Measure the distance from the top of the casting to the top of the index at the toe of the float. • Use J-9789-90. Figure 20—Metering Rod Adjustment CARBURETORS 6C1-21 5. If more than ± 2 /3 2 ” from specificatio n, use J-34817-30 to bend the lever up or down. Remove J-34817-30 and m easure, repeating until w ithin specification. 6 . Check float alignment. 7. Install the air horn and gasket. 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. • 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. • Use the specified plug gage. • Gage should have a slide fit. 5. Bend at point “ A” to adjust. CARBURETOR MODELS M4ME AND M4MEF the service package, and stamp or engrave the num ber on the new float bowl. METERING SYSTEMS B-09586 A single float cham ber supplies fuel to all carburetor bores. A float, float needle with pull clip, and a float needle seat, are used to control the level of fuel in the float chamber. A vacuum -operated power piston and metering rods control the air/fuel metering in the prim ary bores of the carburetor. Tapered m etering rods are attached to the power valve piston assembly, and move in fixed metering jets, to provide the fuel flow for varying engine demands. A factory-set adjustable part throttle screw, used on all models, precisely positions the tapered portion of the metering rods in the jets. (On M4MEF m odels, the factory-set rich stop adjusting bushing precisely positions the enrichm ent portion of the metering rods in the jets.) Figure 21—Carburetor Identification DESCRIPTION Models M4ME and M4MEF are four barrel, two stage carburetors with three major assemblies: the air horn, flo a t bowl, and th ro ttle body. T hey have six basic operating systems (figures 21 through 31). • Float • Power • Idle • Pump • Main Metering • Choke The first “ M” indicates this carburetor is of a Modified prim ary metering “ open loop” design. The “ 4M ” is the model designation, indicating it is a four barrel carburetor. The remaining letters designate specific features. E — Has an electric choke. F — has an adjustable wide open throttle mixture control. CARBURETOR IDENTIFICATION (Figure 21) The ca rb uretor id e n tific a tio n n um ber is stam ped vertically on the float bowl near the secondary throttle lever. Refer to this num ber before servicing the carburetor. If replacing the float bowl assembly, follow instructions in Air valves and tapered metering rods control the air/fuel mixture in the secondary bores during increased engine air flow at wide open throttle. On M4MEF models, the factory-set secondary well air bleed adjusting screw provides additional control of the air/fuel mixture during wide open throttle. PUMP SYSTEMS The pump system on all models uses a throttle actuated pump plunger, operating in the pump well. The pump provides extra fuel during quick throttle openings. CHOKE SYSTEMS A electrically heated choke coil provides the choke valve closing force for cold startup and for correct opening tim ing during warmup. A vacuum break assembly(s) controls initial choke valve opening at startup to provide sufficient air flow to the engine. An unloader tang on the throttle lever forces the choke valve open to purge a flooded engine when the accelerator is pressed to the floor. The fast idle cam, following choke valve movement, acts as a graduated throttle stop to provide increased idle speed during warmup. 6C1-22 CARBURETORS A. B. C. D. 236. 237. 238. 239. 240. 375. 377. In te rn a l B o w l V e n ts F lo a t C h a m b e r In le t C h e c k Valve V e n t Tube to C a n is te r F lo a t H in g e Pin F lo a t F lo a t N e e d le P u ll C lip F lo a t N e e d le F lo a t N e e d le Seat Fuel In le t F ilte r Fuel F ilte r S p rin g F-01883 Figure 22—Float System IDLE STOP SOLENOID (ISS) Federal (Non-California) V8 Engines With Manual Transmission. The e le c tric Idle S top S o le n o id (ISS), on th ese applications, provides the desired engine idle speed, and prevents “ dieseling” when the ignition is switched off. THROTTLE KICKER ASSEMBLY California V8 Engines A vacuum operated Throttle Kicker assembly, found on th e s e a p p lic a tio n s , re ta rd s th ro ttle clo sin g d u rin g deceleration, to improve emission control. Vacuum to the kicker is controller by the Throttle Return Control system, w hich is fu rth e r d e s c rib e d in D R IV E A B ILIT Y AND EMISSIONS - CARBURETED (SEC. 6 E8 ). CARBURETORS 6C1-23 A. B. C. D. E. F. G. H. J. K. F ixed Idle A ir By-Pass L ow er Idle A ir B leed T im e d V acuum P orts O ff-Id le O p e ra tio n P rim a ry T h ro ttle Valve Iflle D ischa rg e O rific e O ff-Id le Port Id le Tube Id le C hannel R e s tric tio n Idle A ir Bleed P rim ary M e te rin g Je t Idle M ix tu re N ee dle Idle M ix tu re N ee dle Plug F-01884 Figure 23—Idle System - M4ME A. B. C. D. E. F. G. H. J. Id le Tube Id le A ir B leed Idle C h a n n e l R e s tric tio n L ow er Id le A ir B leed O ff - Id le Port Idle D isc h a rg e O rific e F ixe d Id le A ir By-Pass P rim a ry T h ro ttle Valve T im e d V a cuu m Ports 420 248. P rim a ry M e te rin g J e t 420. Idle M ix tu re N e e d le 422. Idle M ix tu re N e e d le Plug F-01885 Figure 24—Idle System - M4MEF 6C1-24 CARBURETORS A. B. C. D. E. F. G. H. 212. 213. 218. 248. Part T h ro ttle A d ju s tin g S crew (Do N ot Turn o r Rem ove) M ain W ell A ir B le ed s M ain D isch a rg e N ozzle B o o st V e n tu ri M ain V e n tu ri M ain W ell P rim a ry T h ro ttle Valve V acuum C h a n n e l Pow er Valve P isto n A s s e m b ly P rim a ry M e te rin g Rod Pow er P isto n S p rin g P rim a ry M e te rin g Je t F-01886 Figure 25—Main Metering System - M4ME Part T h ro ttle A d ju s tin g S crew (Do N o t Turn o r Remove) R ich S to p A d ju s tin g B u sh in g (Do N o t Turn o r Rem ove) R ich S to p A d ju s t Plug V a cuu m C h a n n e l M ain W ell M ain W e ll A ir B le ed s M ain D is c h a rg e N ozzle B o o s t V e n tu ri M ain V e n tu ri P rim a ry T h ro ttle Valve 213. P rim a ry M e te rin g Rod 218. P ow er P is to n S p rin g 248. P rim a ry M e te rin g Je t Figure 26—Main Metering System - M4MEF F-02719 CARBURETORS 6C1-25 A. B. C. D. E. F. A ir Valve E c c e n tric C am B a ffle S e co n d a ry T h ro ttle Valve S e co n d a ry D ischa rg e N ozzle M e te rin g D isc 32. 50. 212. 213. 218. 248. S e c o n d a ry M e te rin g Rod A ir H orn B a ffle P ow er Valve P isto n A s s e m b ly P rim a ry M e te rin g Rod P ow er P isto n S p rin g P rim a ry M e te rin g Je t F-01888 Figure 27—Power System - M4ME A. B. C. D. E. 41. 67. 68. 203. 204. 206. 250. 251. P um p S u c tio n B reaker P um p Je t D isch a rg e Passage P um p P lu n g e r Head P um p D u ra tio n S p rin g P um p Lever P um p S tem Seal R e ta in e r P um p Stem Seal P um p P lu n g e r S p rin g P um p P lu n g e r C up P um p R eturn S p rin g P um p D isch a rg e P lug (R etainer) P um p D isch a rg e Ball 250 F-02717 Figure 28—Pump System 6C1-26 CARBURETORS A. B. C. D. E. F. G. H. J. K. L. M. Rich S top A d ju s tin g B u sh in g (Do n ot tu rn o r remove) Rich S top A d ju s tin g Plug Prim ary T h ro ttle Valve S econdary T h ro ttle Valve A ir Valve E cce n tric Cam M ete rin g D isc S econdary Fuel W ell A c ce le ra to r W ell In let O rific e A cce le ra to r W ell and Tube A cce le ra to r W ell D ischarge O rific e S econdary W ell Bleed Tube N. Clean A ir Inlet P. S econdary W ell Bleed A d ju s t Screw (Do not tu rn o r remove) Q- S econdary W ell Bleed A d ju s t S pring R- S econdary W ell Bleed A d ju s t Plug S. S econdary D ischarge Nozzle T. B a ffle 31. S econdary M ete rin g Rod H o ld e r 32. S econdary M ete rin g Rod 50. A ir H orn B a ffle 212. Power Valve P iston A s se m b ly 213. Prim ary M ete rin g Rod 218. Power P iston S pring 248. Prim ary M ete rin g Jet F-02718 Figure 29—Power System - M4MEF CARBURETORS 6C1-27 A. B. C. D. E. F. G. 55. 58. C ho ke Valve V acuum B reak A d ju s tin g S crew Leaf-Type B u c k in g S p rin g U n lo a d e r Tang F ast Id le C am F o llo w e r T h e rm o s ta tic C o il A ir Valve P rim a ry S id e V a cuu m B reak A s s e m b ly P rim a ry S id e V a cu u m B r e a k A ir Valve Lever L in k 356. C hoke L in k 360. S e co n d a ry T h ro ttle L o c k o u t Lever 425. F ast Idle A d ju s tin g S crew G 58 360 356 E 425 F-02716 Figure 30—Choke System - Electric - M4MEF (With Primary Side Vacuum Break Only) 360 A. B. C. D. E. C h o ke Valve T h e rm o s ta tic C o il U n lo a d e r Tang F ast Idle Cam F o llo w e r P lu n g e r B u c k in g S p rin g (N o t U sed On A ll M od els) F. A ir Valve D 55. P rim a ry S id e V a cuu m B reak A s s e m b ly 58. P rim a ry S id e V a cuu m B reak to A ir Valve Lever L in k 320. S e c o n d a ry S ide V a cuu m B reak A s s e m b ly 322. S e c o n d a ry S id e V a cu u m B reak To C hoke L in k 356. C h o ke L in k 360. S e c o n d a ry T h ro ttle L o c k o u t Lever 425. F ast Id le A d ju s tin g S cre w F-01894 Figure 31—Choke System - Electric - M4ME (With Primary Side and Secondary Side Vacuum Break) 6C1-28 CARBURETORS DIAGNOSIS OF M4ME AND M4MEF ROCHESTER CARBURETOR T h e fo llo w in g d ia g n o s tic p r o c e d u r e s a r e fo r c a r b u r e to r re la te d p r o b le m s a n d th e ir e ffe c ts o n v e h ic le p e r fo r m a n c e . O t h e r c a n a ls o c a u s e p r o b le m s a n d s h o u ld b e c h e c k e d w h e n lis te d o n th e c h a rt. vehicle systems PROBLEM Engine Cranks Normally - Will Not Start or Starts Hard POSSIBLE CAUSE 1. Improper starting procedure used. 2. Ignition system malfunction. 3. Choke not operating properly. 4. Engine loaded with fuel. (Improper start­ ing procedure used or choke unloader mi sad justed.) 5. No fuel in carburetor. 6 . Engine flooded. To check for flooding, re­ move the air cleaner and look into the carburetor venturi for fuel dripping from nozzles. Engine Starts - Will Not Keep Running 1. Improper starting procedure used. 2. Choke not operating properly. 3. Engine does not have correct fast idle speed when cold. CORRECTION 1. Check with the custom er to determine if proper starting procedure, outlined in the “ Ow ner’s and D river’s M anual” , is used. 2. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 3. Check for free movement, and com ­ plete opening and closing, of choke valve. See “ Choke Checking Proce­ dure” and “ Checking Electric Choke” later in this section. 4. Check with the custom er to determine if proper starting procedure, outlined in the “ Ow ner’s and D river’s M anual” , is used. Adjust choke unloader. 5. Inspect fuel filter(s) for being plugged. Replace as necessary. Check fuel pump pressure and vol­ ume. Replace pump if necessary. In­ s p e c t fu e l lin e s fo r le a k s a nd restrictions. Check the float level, and adjust if necessary. 6 . Remove the air horn. C heck float for restricted movement or being loaded. Check float needle pull clip location. Open end of clip should be installed over float lever cross bar, facing away from pontoon. Inspect flo at needle and seat for wear and for dirt or chips. If foreign material is found in the car­ buretor, clean the fuel system and car­ b u re to r. R e p la c e fu e l filte r ( s ) as necessary. Check float level, and adjust if neces­ sary. 1 . Check with the custom er to determ ine if proper starting procedure, outlined in the O w ner’s and Driver’s M anual,” is used. 2 . Check for free movement and complete opening and closing of choke valve. See “ Choke C hecking Procedure” and “ Checking Electric Choke” later in this section. 3. Check for free movement of fast idle cam and linkage. See “ Choke Check­ ing Procedure” later in this section. Ad­ ju s t fast idle speed. See Em ission Control Information Label. CARBURETORS 6C1-29 DIAGNOSIS OF M4ME AND M4MEF ROCHESTER CARBURETOR (CONT.) PROBLEM Engine Starts - Will Not Keep Running (Cont.) POSSIBLE CAUSE CORRECTION 4. Vacuum break assembly(s) malfunction­ ing or misadjusted. 4. See “ Vacuum Break Checking Proce­ dure” later in this section. Adjust vac­ uum break assembly to specification. 5. Adjust idle speed. See Emission Con­ trol Information Label. 6 . Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. If engine RPM changes, torque car­ buretor to manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange gas­ ket and/or intake manifold gaskets. Check condition and routing of vacuum hoses. Correct or replace as necessary. 7. Inspect fuel filter(s) for being partially plugged. Replace as necessary. Check fuel pump pressure and vol­ ume. Replace pump if necessary. In­ s p e c t fu e l lin e s fo r le a ks and restrictions. Check the float level, and adjust if necessary. 8 . Remove the air horn. Check float for restricted movement or being loaded. Check float needle pull clip location. Open end of clip should be installed over float lever cross bar, facing away from pontoon. Inspect float needle and seat for wear and for dirt or chips. If foreign material is found in the car­ buretor, clean the fuel system and car­ b ureto r. R e p la c e fu e l filte r(s ) as necessary. Check float level, and adjust if neces­ sary. 5. Idle speed too low. 6 . Air leaks at carburetor flange gasket, or at intake manifold gaskets. Vacuum hoses disconnected or installed improp­ erly. 7. Not enough fuel in carburetor. 8 . Carburetor flooding. Engine Idles Abnormally (Too Fast or Too Slow) 1. Idle speed misadjusted. 2. Idle stop solenoid or throttle kicker malfunctioning. Faulty solenoid circuit wiring. 3. Choke not operating properly or fast idle cam sticking or binding. 4. Throttle linkage or throttle shaft(s) stick­ ing or binding. 1. Adjust idle speeds. See Emission Con­ trol Information Label. 2. See “ Idle Stop Solenoid Checking Pro­ cedure” and “ Throttle Kicker Checking Procedure” later in this section. Refer to the “ Fuel and Emissions Service Manual.” 3., Check choke valve and fast idle cam for free movement. Check for complete opening and closing of choke valve. See “ Choke Checking Procedure” and “ Checking Electric Choke” later in this section. 4. Check throttle linkage and throttle shaft(s) for smooth and free operation. Clean with suitable solvent. Replace throttle body if necesasry. 6C-30 CARBURETORS DIAGNOSIS OF M4ME AND M4MEF ROCHESTER CARBURETOR (CONT.) Engine Idles Abnormally (Too Fast Or Tool Slow) (Cont.) 5. A ir le a k s a t c a r b u r e to r fla n g e g a s k e t, o r at in ta k e m a n ifo ld g a s k e ts . V a c u u m h o s e s d is c o n n e c te d o r in s ta lle d im p r o p ­ e rly . 5. 6. P C V s y s te m m a lfu n c tio n in g . 6. 7. Ig n itio n tim in g m is a d ju s te d . 7. 8. D is trib u to r v a c u u m o r m e c h a n ic a l a d ­ v a n c e m a lfu n c tio n in g . Id le s y s te m re s tric te d o r in c o rr e c t id le m ix tu re a d ju s tm e n t. R e s tric te d a ir c le a n e r e le m e n t. C a rb u re to r flo o d in g . 8. 9. 10. 11. Engine Diesels (After Run) Upon Shut Off CORRECTION POSSIBLE CAUSE PROBLEM 1. B a s e id le s p e e d m is a d ju s te d . 2. Id le s to p s o le n o id o r th ro ttle m a lfu n c tio n in g . F a u lty s o le n o id w irin g . 3. C h o k e n o t o p e r a tin g p ro e p rly o r fa s t id le c a m s tic k in g o r b in d in g . 4. T h r o ttle lin k a g e o r th ro ttle s h a ft s tic k in g o r b in d in g . 5. A ir le a k s a t c a r b u r e to r fla n g e /in s u la to r g a s k e t(s ), o r a t in ta k e m a n ifo ld g a s k e t. V a c u u m h o s e s d is c o n n e c te d o r in s ta lle d im p ro p e rly . k ic k e r c irc u it 9. 10. 11. U s e a p r e s s u r e o il c a n to s p r a y lig h t o il o r k e r o s e n e a r o u n d c a r b u e r to r th ro ttle b o d y (d o n o t s p r a y a t th ro ttle s h a ft e n d s ), a n d m a n ifo ld to h e a d m o u n tin g s u rfa c e s . If e n g i n e R P M c h a n g e s , t o r q u e c a r ­ b u re to r to m a n ifo ld b o lts a n d /o r in ta k e m a n i f o l d b o l t s t o s p e c i f i c a t i o n . If n e c e s ­ sary, re p la c e th e c a rb u re to r fla n g e g a s ­ ke t a n d /o r in ta k e m a n ifo ld g a s k e t. C h e c k c o n d itio n a n d ro u tin g o f v a c u u m h o ses . C o rre c t o r re p la c e a s n e c e s s a ry . C h e c k P C V s y s te m . C le a n o r re p la c e P C V v a lv e a n d h o s e s a s n e c e s s a ry . A d ju s t tim in g . S e e E m is s io n C o n tro l In ­ fo rm a tio n L a b e l. C h e c k o p e r a tio n . R e f e r to E N G IN E E L E C T R IC A L (S E C . 6 D ). C l e a n c a r b u r e t o r if n e c e s a s r y . A d j u s t id le m ix tu re p e r s p e c ifie d p r o c e d u r e . R e p l a c e if n e c e s s a r y . R e m o v e th e a ir h o rn . C h e c k flo a t fo r re s tric te d m o v e m e n t o r b e in g lo a d e d . C h e c k flo a t n e e d le p u ll c lip lo c a tio n . O p e n e n d o f c lip s h o u ld b e in s ta lle d o v e r flo a t le v e r c r o s s bar, fa c in g a w a y fro m p o n to o n . In s p e c t flo a t n e e d le a n d s e a t fo r w e a r , a n d fo r d irt o r c h ip s . If f o r e i g n m a t e r i a l is f o u n d in t h e c a r ­ b u re to r, c le a n th e fu e l s y s te m a n d c a r ­ b u re to r. R e p la c e fu e l filte r(s ) a s n ecessary. C h e c k f l o a t l e v e l , a n d a d j u s t if n e c e s ­ sary. 1. A d j u s t b a s e i d l e s p e e d . S e e E m i s s i o n C o n tro l In fo rm a tio n L a b e l. 2. S e e “ I d l e S t o p S o l e n o i d C h e c k i n g P r o ­ c e d u r e ” a n d “ T h ro ttle K ic k e r C h e c k in g P r o c e d u r e ” la t e r in t h is s e c t i o n . R e f e r to th e “ F u e l a n d E m is s io n s S e r v ic e M a n u a l.” 3. C h e c k c h o k e v a l v e a n d f a s t i d l e c a m fo r fre e m o v e m e n t. C h e c k fo r c o m p le te o p e n in g a n d c lo s in g o f c h o k e v a lv e . S e e “ C h o k e C h e c k in g P ro c e d u re ” a n d “ C h e c k i n g E l e c t r ic C h o k e ” l a t e r in th is s e c tio n . 4. C h e c k t h r o t t l e l i n k a g e a n d t h r o t t l e s h a f t fo r s m o o th a n d fr e e o p e r a tio n . C le a n w ith s u ita b le s o lv e n t. R e p l a c e th ro ttle b o d y if n e c e s s a r y . 5. U s e a p r e s s u r e o i l c a n t o s p r a y l i g h t o i l o r k e r o s e n e a r o u n d c a r b u r e to r th ro ttle b o d y (d o n o t s p r a y a t th ro ttle s h a ft e n d s ), a n d m a n ifo ld to h e a d m o u n tin g su rfa c e s . CARBURETORS 6C1-31 DIAGNOSIS OF M4ME AND M4MEF ROCHESTER CARBURETOR (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Engine Idles Abnormally (Too Fast Or Tool Slow) (Cont.) 5. 6. P C V s y s te m m a lfu n c tio n in g . 7. I g n i t i o n t i m i n g r e t a r d e d ( c a u s e s t h r o t t l e 8. Engine Hesitates During Normal Acceleration * Hesitates During Cold Engine Operation. 1. v a lv e to b e o p e n e d fa r th e r th a n n o r m a l to o b ta in c o rre c t id le s p e e d ). L e a n id le m ix tu r e (c a u s e s th ro ttle v a lv e to b e o p e n e d fa r th e r th a n n o r m a l to o b ­ ta in c o rr e c t id le s p e e d ). M a lfu n c tio n in g p u m p s y s te m o r m is a d ­ ju s te d p u m p . M a k e a q u ic k c h e c k of th e p u m p s y s ­ te m : W it h th e e n g in e o ff, lo o k in to th e c a rb u re to r b o re a n d o b s e r v e p u m p d is ­ c h a r g e je t s ; a c t u a t e t h r o t t le le v e r . A fu ll s t r e a m o f fu e l s h o u ld e m it fr o m th e je ts . 2. * C h o k e n o t o p e r a t i n g p r o p e r l y . 3. * V a c u u m b re a k a s s e m b ly (s ) tio n in g o r m is a d ju s te d . C o n tin u e d If e n g i n e R P M c h a n g e s , t o r q u e c a r ­ b u re to r to m a n ifo ld b o lts a n d /o r in ta k e m a n i f o l d b o l t s t o s p e c i f i c a t i o n . If n e c e s ­ sary, re p la c e th e c a rb u re to r fla n g e /in ­ s u la to r g a s k e t(s ) a n d /o r in ta k e m a n ifo ld g a s k e t. C h e c k c o n d itio n a n d ro u tin g o f v a c u u m h o s e s , co rrect o r re p la c e a s n ecessary. 6. C h e c k P C V s y s te m . C le a n r e p la c e P C V v a lv e a n d h o s e s a s n e c e s s a ry . 7. A d j u s t t i m i n g . S e e E m i s s i o n C o n t r o l I n ­ fo rm a tio n L a b e l. 8. C l e a n c a r b u r e t o r if n e c e s s a r y . A d j u s t id le m ix tu re p e r s p e c ifie d p r o c e d u r e . 1. R e m o v e a ir h o rn a n d c h e c k p u m p c u p . If c r a c k e d o r h a r d e n e d , r e p l a c e t h e p u m p p lu n g e r c u p a n d s p rin g . C h e c k fo r re s tric te d p u m p p a s s a g e s . C le a n a n d b lo w o u t p a s s a g e s w ith c o m p r e s s e d a ir. C h e c k th e p u m p d is c h a r g e b a ll fo r p ro p e r s e a tin g . A d ju s t p u m p to s p e c ific a tio n . C h e c k fo r c o m p le te o p e n in g a n d c lo s ­ i n g o f c h o k e v a l v e . S e e ‘ ‘C h o k e C h e c k ­ in g P r o c e d u r e ” a n d “ C h e c k in g E le c tric C h o k e ” l a t e r in t h is s e c t i o n . S e e ‘‘V a c u u m B r e a k C h e c k i n g P r o c e ­ d u r e ” la t e r in t h is s e c t i o n . A d j u s t v a c ­ u u m b re a k (s ) to s p e c ific a tio n . C h e c k o p e r a tio n . R e fe r to th e “ F u e l a n d E m is s io n s S e rv ic e M a n u a l.” C h e c k o p e r a tio n . R e fe r to th e “ F u e l a n d E m is s io n s S e rv ic e M a n u a l.” A d ju s t tim in g . S e e E m is s io n C o n tro l In ­ fo rm a tio n L a b e l. C h e c k o p e r a tio n . R e fe r to E N G IN E E L E C T R IC A L (S E C . 6 D ). C h e c k f l o a t l e v e l , a n d a d j u s t if n e c e s ­ sary. C h e c k p o w e r p is to n o p e r a tio n : p u s h p i s t o n d o w n a n d r e l e a s e ; it s h o u l d m o v e f r e e l y in b o r e a n d r e t u r n to its u p p o s itio n . If p i s t o n d o e s n o t m o v e f r e e l y , c l e a n p o w e r p is to n a n d b o re . If p i s t o n d o e s n o t r e t u r n w h e n r e ­ le a s e d , c h e c k fo r m is s in g o r d a m a g e d p o w e r p i s t o n s p r i n g . R e p l a c e if n e c e s ­ sary. In s p e c t m e te rin g rod h a n g e r fo r d a m ­ a g e . R e p l a c e p o w e r p i s t o n a s s e m b l y if necessary. 2. m a lfu n c ­ 3. 4. * T h e r m a e s y s t e m m a l f u n c t i o n i n g . 4. 5. * E a r l y F u e l E v a p o r a t i o n ( E F E ) s y s t e m 5. 6. m a lfu n c tio n . Ig n itio n tim in g m is a d ju s te d . 7. D i s t r i b u t o r v a c u u m 8. or v a n c e m a lfu n c tio n in g . F l o a t le v e l t o o lo w . m e c h a n ic a l 6. ad­ 9. P o w e r p i s t o n s t i c k i n g . M i s s i n g o r d a m ­ 7. 8. 9. a g e d p o w e r p is to n s p rin g . 10. P rim a ry m e te rin g rod h a n g e r b e n t. 10. 6C1-32 CARBURETORS DIAGNOSIS OF M4ME AND M 4M EF RO CH ESTER CARBU RETO R (CONT.) PROBLEM Engine Hesitates On Acceleration (Cont.) Engine Has Less Than Normal Power At Normal Acceleration POSSIBLE CAUSE 11. Restricted primary metering jets. 1. Ignition system malfunction. 2. Ignition tim ing misadjusted. 3. Distributor vacuum or mechanical ad­ vance m alfunctioning. 4. Plugged air cleaner element. 5. Exhaust system restricted. 6 . Thermae system malfunction. 7. Early Fuel Evaporation (EFE) system malfunction. 8 . Transmission malfunction. 9. Choke not operating properly. 10. Fuel filter(s) partially plugged. 11. Faulty fuel pump, or leaking or restricted fuel lines. 12. Float level too low. 13. Power piston sticking. Missing or dam­ aged power piston spring. 14. Primary metering rod hanger bent. 15. Primary metering jets restricted or loose. CORRECTION 11. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ re to r. R e p la c e fu e l filte r ( s ) as necessary. 1. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 2. Adjust tim ing. See Emission Control In­ formation Label. 3. C heck operation. Refer to ENG INE ELECTRICAL (SEC. 6 D). 4. Replace element. 5. C heck retrictions. Correct as neces­ sary. 6 . Check operation. Refer to the “ Fuel and Emissions Service M anual.” 7. Check operation. Refer to the “ Fuel and Emissions Service M anual.” 8 . Refer to transm ission diagnosis. 9. Check for complete opening and clos­ ing of choke valve. “ See Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. 10. Inspect fuel filter(s). Replace as neces­ sary. 11. Check fuel pump pressure and volume. Replace pump if necessary. Inspect fuel lines for leaks and restrictions. 12. Check the float level, and adjust if nec­ essary. 13. Check power piston operation: push piston down and release; it should move freely in bore and return to its up position. If piston does not move freely, clean power piston and bore. If piston does not return when re­ leased, check for missing or damaged power piston spring. Replace if neces­ sary. 14. Inspect metering rod hanger for dam ­ age. Replace power piston assembly if necessary. 15. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ re to r. R e p la c e fu e l filte r ( s ) as necessary. If m etering jets are loose, tighten. CARBURETORS 6C1-33 DIAGNOSIS OF M4ME AND M 4M EF RO CH ESTER CA RBU RETO R (CONT.) PROBLEM Less Than Normal Power On Heavy Acceleration Or At High Speed POSSIBLE CAUSE CORRECTION 1. Throttle valves not opening completely, or secondary throttle valves not opening. 1. Correct throttle linkage to obtain wide 2. Ignition system malfunction. 2. 3. Ignition timing misadjusted. 3. 4. Distributor mechanical advance malfunc­ tioning. 5. Plugged air cleaner element. 6 . Exhaust system restricted. 7. Thermae system malfunction. 4. 8 . Early fuel Evaporation (EFE) system mal­ 8. function. 9. Transmission malfunction. 10 . Choke not operating properly. 5. 6. 7. 9. 10. 11. Secondary air valve shaft, valves, or air valve link sticking or binding. 11. 12. Air valve link misadjusted. (May cause h e sita tio n when se con da ry th ro ttle valves are opened.) 13. Vacuum break assembly malfunctioning. (May cause hesitation when secondary throttle valves are opened.) 14. Air valve return spring broken or misad­ justed. 15. Secondary metering rod holder bent. 12. 16. Fuel filter(s) partially plugged. 17. Faulty fuel pump or leaking or restricted fuel lines. 18. Float level too low. Float needle pull clip missing or installed incorrectly. 19. Power piston sticking. Missing or dam­ aged power piston spring. 20. Primary metering rod hanger bent. open throttle. Check secondary throttle lockout lever for sticking or incorrect adjust­ ment. Clean or repair as necessary. Ad­ just lockout lever to specification. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). Adjust timing. See Emission Control In­ formation Label. Check operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). Replace element. Check for restrictions. Correct as necessary. Check operation. Refer to the “ Fuel and Emissions Service Manual.” Check operation. Refer to the “ Fuel and Emissions Service Manual.” Refer to transmission diagnosis. Check for complete opening and clos­ ing of choke valve. See “ Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. Check air valves for smooth operation. Clean, repair, or replace air horn and air valve link as necessary. Adjust air valve link to specification. 13. See “ Vacuum Break Checking Proce­ dure” later in this section. 14. Replace air valve return spring if nec­ essary. Adjust spring to specification. 15. Check holder for damage. Replace if necessary. 16. Inspect fuel filter(s). Replace as necessary. 17. Check fuel pump pressure and volume. Replace pump if necessary. Inspect fuel lines for leaks and restrictions. 18. Check the float level, and adjust if nec­ essary. Check for presence of float needle pull clip. Replace if necessary. Open end of clip should be installed over float lever cross bar, facing away from pon­ toon. 19. Check power piston operation: push piston down and release; it should move freely in bore and return to its up position. If piston does not move freely, clean power piston and bore. If piston does not return when released, check for missing or damaged power piston spring. Replace if necessary. 20. Inspect metering rod hanger for dam­ age. Replace power piston assembly if necessary. 6C1-34 CARBURETORS DIAGNOSIS OF M4ME AND M 4M EF RO CH ESTER CARBU RETO R (CONT.) PROBLEM Less Than Normal Power On Heavy Acceleration Or At High Speed (Cont.) Engine Surges POSSIBLE CAUSE 21. Primary metering jets restricted or loose. Secondary metering discs restricted or m issing. Secondary accelerator well tubes restricted. (Will cause hesitation when secondary th ro ttle valves are opened.) 1. Ignition system malfunction. 2. Distributor mechanical advance malfunc­ tioning. 3. Air leaks at carburetor flange gasket, or at intake m anifold gaskets. Vacuum hoses disconnected or installed improp­ erly. 4. PCV system malfunctioning. 5. Exhaust system restricted. 6 . Thermae system malfunction. 7. Early Fuel Evaporation (EFE) system malfunction. 8 . Contaminated fuel. 9. Fuel filter(s) partially plugged. 10. Faulty fuel pump or leaking or restricted fuel lines. 11. Float level too low. 12. Float needle sticking in seat. 13. Power piston sticking. Missing or dam­ aged power piston spring. 14. Primary metering rod hanger bent. 15. Restricted primary metering jets. CORRECTION 21. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ retor. R e p la ce fu e l filte r(s ) as necessary. If the primary metering jets are loose, tighten. If secondary metering discs are missing, replace float bowl. 1. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 2. Check operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). 3. Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. If engine RPM changes, torque car­ buretor to manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange gas­ ket and/or intake manifold gaskets. Check condition and routing of vacuum hoses. Correct or replace as necessary. 4. Check PCV system. Clean or replace PCV valve and hoses as necessary. 5. Check for restrictions. Correct as nec­ essary. 6 . Check operation. Refer to the “ Fuel and Emissions Service Manual.” 7. Check operation. Refer to the “ Fuel and Emissions Service Manual.” 8 . Check for water or excessive alcohol in fuel. 9. Inspect fuel filter(s). Replace as neces­ sary. 10. Check fuel pump pressure and volume. Replace pump if necessary. Inspect fuel lines for leaks and restrictions. 11. Check the float level, and adjust if nec­ essary. 12. Replace float needle and seat. 13. Check power piston operation: push piston down and release; it should move freely in bore and return to its up position. If piston does not move freely, clean power piston and bore. If piston does not return when re­ leased, check for missing or damaged power piston spring. Replace if neces­ sary. 14. Inspect metering rod hanger for dam­ age. Replace power piston assembly if necessary. 15. If foreign material is found in the carbu­ retor, clean the fuel system and carbu­ retor. R e p la ce fu e l filte r(s ) as necessary. CARBURETORS 6C-35 DIAGNOSIS OF M4ME AND M 4M EF RO CH ESTER CA RBU RETO R (Cont.) PROBLEM Poor Gas Mileage * Black Smoke From Tail Pipe POSSIBLE CAUSE 1. Customer driving habits. 2. Wrong speedometer gear. 3. Low tire pressure or incorrect tire size. 4. Transmission malfunction or in wrong gear. 5. Fuel leaks. 6 . * Plugged air cleaner element. 7. * Choke not operating properly. 8 . * Vacuum break assembly malfunction­ ing or misadjusted. 9. Ignition system malfunction. 10. Ignition timing misadjusted. 11. Distributor vacuum or mechanical ad­ vance malfunctioning. 12. Air leaks at carburetor flange gasket, or at intake m anifold gaskets. Vacuum hoses disconnected or installed improp­ erly. 13. Engine in need of service. 14. Restricted exhaust system. 15. * High fuel level in carburetor or flood­ ing. CORRECTION 1. Run mileage test, with customer driving if possible, make sure vehicle has 2000-3000 miles (3 200-4 800 km) for the “ break-in” period. 2. Check odom eter against measured mile. Replace speedometer gear if nec­ essary. 3. Inflate tires to specifications and use correct tire sizes. 4. Refer to transmission diagnosis. 5. Inspect fuel tank, fuel lines and fuel pump for any fuel leakage. 6 . Replace element. 7. Check for complete opening and clos­ ing of choke valve. See “ Choke Check­ ing Procedure” and “ Checking Electric Choke” later in this section. 8 . See “ Vacuum Break Checking Proce­ dure” later in this section. Adjust vac­ uum break assembly to specification. 9. Check ignition system. Refer to EN­ GINE ELECTRICAL (SEC. 6 D). 10. Adjust timing. See Emission Control In­ formation Label. 11. Check operation. Refer to ENGINE ELECTRICAL (SEC. 6 D). 12. Use a pressure oil can to spray light oil or kerosene around carburetor throttle body (do not spray at throttle shaft ends), and manifold to head mounting surfaces. If engine RPM changes, torque car­ buretor manifold bolts and/or intake manifold bolts to specification. If neces­ sary, replace the carburetor flange gas­ ket and/or intake manifold gaskets. Check condition and routing of vacuum hoses. Correct or replace as necessary. 13. Check engine compression. 14. Check for restrictions. Correct as nec­ essary. 15. Check float for restricted movement or being loaded. Check float needle pull clip location. Open end of clip should be installed over float lever cross bar, facing away from pontoon. Check float needle and seat for wear and dirt or chips. If foreign material is found in carbure­ tor, clean fuel system and carburetor. Replace fuel filter(s) as necessary. Check float level, and adjust if neces­ sary. 6C1-36 CARBURETORS DIAGNOSIS OF M4ME AND M 4M EF RO CH ESTER CA RBU RETO R (Cont.) PROBLEM Poor Gas Mileage (Cont.) 16. Power piston s tickin g . Power piston spring stretched. 17. Primary metering rod hanger bent. 18. * Worn or damaged prim ary metering rods. Worn or damaged secondary me­ tering rods (black smoke when second­ ary throttle valves are opened). 19. * Primary metering jets worn or loose. Secondary metering discs worn or miss­ ing (black smoke when secondary throt­ tle valves are opened). Gasoline Odor 16. Check power piston operation: push piston down and release; it should move freely in bore and return to its up position. If piston does not move freely, clean power piston and bore. Check power piston spring for dam ­ age. Replace if necessary. 17. Inspect metering rod hanger for dam ­ age. Replace power piston assem bly if necessary. 18. Inspect prim ary and secondary me­ tering rods. Replace as necessary. 19. Inspect metering jets. Replace if neces­ sary. If loose, tighten. If loose, tighten. Inspect secondary metering discs. If worn or missing, replace float bowl. 6 . Faulty fill cap. 1. Repair/replace as required. 2. Purge tank and repair or replace tank as required. 3. Connect, repair/replace lines as re­ quired. 4. Connect, clean, or reroute lines as re­ quired. 5. Compare weight of canister with a new one. Replace if necessary. 6 . Install new cap. 1. Fuel filter(s) plugged. 1 . Inspect fuel filter(s). Replace as neces­ 2. Fuel lines leaking, restricted, or misrouted. 3. Faulty fuel pump. 2 . Repair/replace, clean, or reroute as re­ 1. Fuel feed or vapor return line leaking. 2. Leak in fuel tank. 3. Disconnected or leaking fuel tank vent lines or hoses to canister(s). 4. Purge lines not connected, improperly routed, plugged or pinched. 5. Carbon canister(s) loaded. Fuel Starvation CORRECTION POSSIBLE CAUSE sary. quired. 3. Check fuel pump pressure and volume. Replace pump if necessary. CARBURETORS 6C1-37 ON-VEHICLE SE R V IC E (MODELS M4ME AND M 4M EF) A. Pump Cup or Valve Stem B. Tape Hole in Tube C. Tape End o f Cover B-06210 Figure 32— Float Level - External Check FLOAT LEVEL - EXTERNAL CHECK Tool Required: J-34935-1 External float Level Gage 1. W ith the engine idling and the choke valve wide open, insert J-34935-1 in the vent slot or vent hole (figure 32). • Allow the gage to float freely. NOTICE: Do not press dow n on the gage. Flooding or float damage could result. 2. Observe the mark on the gage that lines up with the top of the casting. The setting should be within 1.588mm (2/32-inch) of the specified float level setting. • Incorrect fuel pressure will adversely affect the fuel level. 3. If not within specification, remove the air horn and adjust the float. CHOKE CHECKING PROCEDURE (ENGINE OFF) 1. Remove the air cleaner assembly. 2. Hold the throttle half way down. 3. Open and close the choke several times. Be sure all links are connected, and are not damaged. Choke valve, linkage, and fast idle cam must operate freely. • If the choke valve, linkage, or fast idle cam is sticking due to varnish, clean with choke cleaner X-20-A or equvialent. • Do not lubricate linkage, as lub rica nt w ill collect dust and cause sticking. Figure 33— Plugging Vacuum Break Bleed Holes CHECKING ELECTRIC CHOKE - ON VEHICLE 1 . Allow the choke stat to stabilize at about 21 °C (70 °F). 2. Open the throttle, to allow the choke valve to close. 3. Start the engine, determ ine the length of tim e for the choke valve to reach full open position: • If longer than five minutes, check the voltage at the choke stat connector, with the engine running: • If voltage is between 12 and 15 volts: Check for proper ground between choke cover and choke housing. If correct, replace choke cover assembly. • If the voltage is low or zero: Check all wires and connections. Refer to ENGINE ELECTRICAL (SEC. 6 D). VACUUM BREAK CHECKING PROCEDURE Tool Required: J-23738-A, Hand Operated Vacuum Pump 1. If the vacuum break has an air bleed hole, plug it during this checking procedure (figure 33). 2. Apply -51 kPa (15 in. Hg.) vacuum to the vacuum break. • Apply finger pressure to see if the plunger has moved through full travel. If not, replace the vacuum break. • Observe the vacuum gage. Vacuum should hold vacuum for at least twenty seconds. If not, replace the vacuum break. 3. Replace vacuum break hoses that are cracked, cut or hardened. CHECKING IDLE STOP SOLENOID (ISS) A non-functioning idle stop solenoid (ISS) (if equipped) could cause stalling or rough idle. 1. Turn the igntion on but do not start the engine. 2. Open the throttle mom entarily to allow the solenoid plunger to extend. 6C1-38 CARBURETORS FUEL INLET / NUT GASKET FILTER (WITH CHECK VALVE) SPRING F-01899 Figure 35—Fuel Inlet Nut and Filter 3. Disconnect the wire at the solenoid. The plunger should drop back from the throttle lever. 4. Connect the solenoid wire. The plunger should move out and contact the throttle lever. 5. If the plunger does not move in and out as the wire is disconnected and connected, check voltage across the feed wire. • If the voltage is 12 to 15 volts, replace the solenoid. • If the voltage is low, locate the cause of the open circuit in the solenoid feed wire; repair as necessary. CHECKING THROTTLE KICKER Tool Required: J-23738-A, Hand Held Vacuum Pump 1. Hold the throttle half way open to allow the plunger to extend fully. 2. Apply - 6 8 (20" Hg) vaucum to the throttle kicker (figure 34). • Apply finger pressure to the plunger to see if it has extended fully. If not, replace the throttle kicker. • Observe the vacuum gage. Vacuum should hold for at least twenty seconds. If not, replace the throttle kicker. 3. Release the vacuum to the throttle kicker. • If the plunger does not retract to its starting position, replace kicker. • The filter must include an inlet check valve to m e e t M o to r V e h ic le S a fe ty S ta n d a rd s (M.V.S.S.) for roll-over. • The check valve end of the filter must face the fuel line. 4. Fuel inlet nut. Tighten • Inlet nut to 62 N-m (46 ft. lbs.). 5. Fuel line to inlet nut. • Start engine and check for leaks. CARBURETOR MOUNTING TORQUE After servicing, tighten m ounting bolts, in a clockwise direction, to 16 N m (144 in. lbs.). When retightening carburetor at recommended maintenance intervals, check in clockwise direction. If less than 7 N m (60 in. lbs.), retighten to 11 N-m (96 in. lbs.); but if greater than 7 N-m (60 in. lbs.), do not retighten. CARBURETOR REPLACEMENT F lo o d in g , s tu m b le on a c c e le r a tio n a nd o th e r performance complaints are, in many instances, caused by the presence of dirt, water or other foreign matter in carburetor. To aid in diagnosing the cause, the carburetor should be removed carefully from the engine without draining fuel from the bowl. Contents of the fuel bowl then may be examined for foreign m aterials as the carburetor is disassembled. Remove or Disconnect FUEL FILTER REPLACEMENT Remove or Disconnect (Figure 35) 1. Fuel line connection at the fuel inlet nut. 2. Fuel inlet nut. 3. Fuel inlet filter, gasket, and spring. [-►+[ Install or Connect (Figure 35) 1. Fuel filter spring in float bowl. 2. New gasketon inlet nut. 3. Fuel inlet filter in inlet nut. 1 . Negative battery terminal. 2. Air cleaner assembly and gasket. 3. Electrical connectors from the choke and idle stop solenoid. 4. Vacuum hoses. • Make note of the vacuum hose routing. 5. Accelerator linkage. 6 . Downshift cable (automatic transm ission only). 7. Cruise control linkage (if equipped). 8 . Fuel line connection at the fuel inlet nut. 9. Carburetor attaching bolts. 10. Carburetor and flange insulator. CARBURETORS 6C1-39 Clean • S e alin g su rfa c e s on th e intake m an ifo ld and carburetor. CAUTION: Extinguish all open flames while filling and testing carburetor with gasoline to avoid personal injury. + + Install or Connect 1. Carburetor with new flange gasket. • It is good shop practice to fill the carburetor float bowl before installing the carburetor. This reduces the strain on sta rtin g m otor and b a tte ry and re d u c e s th e p o s s ib ility o f backfiring while attempting to start the engine. Operate the throttle several tim es and check the discharge from pump jets before installing the carburetor. Carburetor attaching bolts. Figure 36—Removing idle Mixture Needle Plugs Tighten • Bolts to 16 N-m (144 in. lbs.) — Tighten in a criss-cross pattern. 3. Fuel line to the fuel inlet nut. 4. Cruise control cable (if equipped). 5. Downshift cable (automatic transm ission only). 6 . Accelerator linkage. 7. Vacuum hoses. • Refer to the Emission Control Inform ation Label for vacuum hose routing information. 8 . Electrical connectors to the choke and idle stop solenoid. 9. Air cleaner assembly with gasket. 10. Negative battery terminal. £ Adjust • Idle mixture and idle speeds. 5. 6. 7. IDLE MIXTURE ADJUSTMENT (HEAVY DUTY EMISSION VEHICLES ONLY) In case of a major carburetor overhaul, throttle body replacement, or high idle CO (when indicated by an emissions inspection), the idle m ixture may be adjusted. Adjusting the mixture by other than the following method may violate Federal and/or state laws (figures 36 through 38). 8. 9. 10. 11. Tool Required: J-29030-B Idle Mixture Needle Socket. 1. Set parking brake and block drive wheels. 12. 2. Remove the carburetor from the engine. 3. Drain fuel from the carburetor into a container. Dispose of the fuel in an approved container. 4. Remove idle m ixture needle plugs (figure 36): • Invert the carburetor and support it to avoid damaging external components. 13. • Make two parallel hacksaw cuts in the throttle body, between the locator points near one idle mixture needle plug. The distance between the cuts depends on the size of the punch to be used. — Cut down to the plug, but not more than 1 / 8 -inch beyond the locator point. • Place a flat punch at a point near the ends of the saw marks. Hold the punch at a 45 degree angle and drive it into the throttle body until the casting breaks away, exposing the steel plug. • Use a center punch to break the plug apart, uncover idle m ixture needle. — Remove all loose pieces of plug. • Repeat the previous steps for the other needle plug. Use J-29030-B to ligh tly seat the idle m ixture needles, then back out three turns. Reinstall carburetor on the engine. Place tra n sm issio n in “ P ” (PARK) (au tom a tic tr a n s m is s io n ) o r “ N ” (N E U T R A L ) (m a n u a l transmission). Start the engine and bring it to a normal operating temperature, choke valve open, and air conditioning off. C onnect a know n a ccurate ta ch o m e te r to the engine. Check ignition tim ing, and adjust if necessary, by following the procedure described on the Emission Control Information Label. Use J-29030-B to turn the mixture needles equally ( 1/8 turn at a time), in or out, to obtain the highest RPM (best idle). Adjust the idle speed screw (throttle stop) to obtain the base idle speed specified on the Emission Control Information label. Again try to readjust mixture needles to obtain the highest idle RPM. The adjustm ent is correct when the highest RPM (best idle) is reaches with the minimum num ber of mixture needle turns from the seated position. 6C1-40 CARBURETORS Figure 37—Fast Idle Adjustment 14. If necessary, readjust the idle speed screw (throttle stop) to obtain the specified base idle speed. 15. C heck, (and if necessary, adjust), idle speed solenoid activated speed, and fast idle speed. Refer to figures 38 and 39 and the Emission Control Emission Information label. 16. Check the throttle kicker (TRC RPM), and adjust if necessary. R efer to the “ Fuel and E m issions Service M a n u a l” and to the Em ission Control Information label. 17. Turn off the engine, and remove the block from the drive wheels. IDLE SPEED ADJUSTMENT Refer to figures 37 through 39 and the Emission Control Information label to adjust idle speed, idle speed solenoid activated speed, and fast idle speed. THROTTLE KICKER ADJUSTMENT Refer to the “ Fuel and Emissions Service M anual” to adjust the throttle kicker. FLOAT ADJUSTMENT Tools Required: J-9789-90, Float Level “ T ” Scale J-34817, Float Positioning Tool Kit 1. Remove the air horn, gasket, power piston and metering rod assembly, and the float bowl insert (figure 40). 2. Attach J-34817-1 to the float bowl. 3. Place J-34817-3 in J-34817-1 with the contact pin resting on the outer edge of the float lever. 4. Measure the distance from the top of the casting to the top of the float at a point 3/16-inch from the large end of the float. • Use J-9789-90. Figure 38—Idle Speed Adjustment - Without Idle Speed Solenoid CARBURETORS 6C1-41 0 Make sure Pump Link is in specified hole. (2) With Fast Idle Cam off Cam Follower Lever, turn Throttle Stop Screw out so it does not touch Throttle Lever. (3) Measure distance from top of Choke Valve wall to top of Pump Stem. (4) Adjust, if necessary, by supporting Pump Lever at (§) and bending at notch. PUMP ADJUSTMENT A. S o le n o id S crew B. Id le Speed S crew C. E le c tric a l C o n n e c tio n B-09284 F-02714 Figure 39—Fast Idle Adjustment J-34817-25 or BT-8427 J-9789-90 or BT-8037 Figure 41—Pump Adjustment J-34817-3 or BT-8227A J-34817-1 or BT-8227A-1 5. If more than ± 2/32-inch from specification, use J-34817-25 to bend the lever up or down. • Remove J-34817-25 and measure, repeating until within specification. 6 . Check the float alignment. 7. Reassemble the carburetor. PUMP ADJUSTMENT 1. 2. 3. 4. Tool Required: J-9789-90, Float Level “ T ” Scale The pump link (410) must be in the specified hole (figure 41). With the fast idle cam off the cam follower lever, turn the throttle stop screw (380) out so it does not touch the throttle lever. Measure the distance from the top of the choke valve wall to the top of the pump stem. Adjust, if necessary, by supporting the pump lever (41) with a screwdriver and bending it at the notch. AIR VALVE RETURN SPRING ADJUSTMENT F-02715 Figure 40—Float Adjustment 1. Loosen the setscrew (figure 42). 2. a. Turn spring flucrum pin counterclockwise until the air valves open, b. Turn the pin clockwise until the air valves close, then the additional turns specified. 3. Tighten the setscrew. 4. Apply lithium grease to the spring contact area. 6C1-42 CARBURETORS 0 Loosen set screw . (2a)Turn Spring Fulcrum Pin Q until Air Valves (§) open. (2^)Turn pin Q until Air Valves close, then additional turns specified. ( 3) Tighten set screw. (4) Apply Lithium grease to spring contact area. F-01927 Figure 42—Air Valve Return Spring Adjustment CHOKE STAT LEVER ADJUSTMENT 1. 2. 3. 4. 5. Tool Required: J-9789-111, Linkage Bending Tool Drill out and remove the choke cover attaching rivets. Remove choke cover and stat assem bly (figure 43). Place fast idle cam on high step against the cam follower lever. Push up on the choke stat lever to close the choke valve. C heck the stat lever for correct o rientation by inserting a 0 .120 -inch plug gage hole in the choke housing. • The gage should fit in the hole and touch the edge of the lever. Adjust, if necessary, by bending the choke link with J-9789-111. CHOKE LINK AND FAST IDLE CAM ADJUSTMENT Tool Required: J-26701-A, Choke Valve Angle Gage 1. Attach a rubber band to the vacuum break lever of the intermediate choke shaft (figure 44 and 45). 2. Open the throttle to allow the choke valve to close. 3. Set up J-26701-A and set the angle to specification. • Rotate the degree scale until zero is opposite the pointer. • Center the leveling bubble. • Rotate the scale to the specified angle. — Refer to “ Specifications.” 4. Place the fast idle cam on the second step against the cam follower lever, with the lever contacting the rise of the high step. If the lever does not contact the cam, turn the fast idle adjusting screw in additional turn s). J Im portant • Final Fast Idle Speed Adjustm ent must be performed according to the Emission Control Information label. 5. Adjust, if bubble is not recentered, by bending the fast idle cam kick lever with pliers. PRIMARY SIDE VACUUM BREAK ADJUSTMENT Tools Required: J-26701-A, Choke Valve Angle Gage J-23738-A, Hand Operated Vacuum Pump 1. Attach rubber band to the vacuum break lever of the intermediate choke saft (figures 44, 46 47). 2. Open the throttle to allow the choke valve to close. 3. Set up J-26701 and set angle to specifications. • Rotate the degree scale until zero is opposite the pointer. • Center the leveling bubble. • Rotate the scale to the specified angle. — Refer to “ Specifications.” CARBURETORS 6C1-43 ® If riveted, drill out and remove rivets. Remove Choke Cover and Stat Assembly. J-9789-111 or BT-3006M (2) Place Fast Idle Cam on high step against Cam Follower Lever. (3) Push up on Choke Stat Lever to close Choke Valve. (4) Check Stat Lever for correct orientation by inserting .120" plug gage in hole. Gage should fit in hole and touch edge of lever. (5) Adjust, if necessary, by bending Choke Link. F-01928 Figure 43—Choke Stat Lever Adjustment 0 Attach Angle Gage Magnet to closed Choke Valve. J-26701-A ' / y ' ° r BT-7704 (D Rotate degree scale until zero is opposite pointer. (3) Center the leveling bubble. (4) Rotate scale to specified angle. (5) Open Choke Valve as described. ©Adjust linkage if bubble is not recentered. F-01929 Figure 44—Choke Valve Angle Gage 6C1-44 CARBURETORS 4. • P lu g v a c u u m b re a k b le e d h o le s , if applicable. • Apply -51 kPa (15-inches Hg) vacuum to seat the vacuum break plunger. • Seat bucking spring, if applicable. • If necessary, bend the air valve link to permit full plunger travel, then reapply vacuum to fully retract plunger. 5. Adjust, if bubble is not recentered, by turning the vacuum break adjusting screw. SECONDARY SIDE VACUUM BREAK ADJUSTMENT Tools Required: J-26701-A, Choke Valve Angle Gage J-23738-A, Hand Operated Vacuum Pump J-9789-111, Linkage Bending Tool 1. Attach a rubber band to the vacuum break lever of the intermediate choke shaft. 2. Open the throttle to allow the choke valve to close. 3. Set up J-26701 and set angle to specification (figure 44). • Rotate the degree scale until zero is opposite the pointer. • Center the leveling bubble. • Rotate the scale to the specified angle. — Refer to “ Specifications.” Figure 45—Choke Link - Fast Idle Cam Adjustment P L U G G IN G A IR B L E E D H O L E S T APE HOLE IN TUBE PUMP CUP OR VALVE STEM S E A L T APE END OF COVER B U C K IN G S P R IN G S S p rin g S e a te d ( S p r in g C o m p r e s s e d ) PLUNGER B UC K IN G SPRING LEAF TYPE B U C K IN G SPR IN G F-01931 Figure 46—Vacuum Break Adjustment Information CARBURETORS 6C1-45 4. • P lu g applicable. vacuum b re a k b le e d h o le s , if • Apply - 51 kPa (15-inches Hg) vacuum to seat the vacuum break plunger. • C om press the p lu n g e r b ucking sp rin g , if applicable. • If necessary, bend the air valve link to permit full plunger travel, then reapply vacuum to fully retract the plunger (figures 46 and 47). 5. Adjust, if bubble is not recentered, by either: • Supporting the link where shown, and bending it with J-9789-111. Or • turning screw with a 1 / 8 -inch hex wrench. AIR VALVE LINK ADJUSTMENT Figure 48—Secondary Side Vacuum Break Adjust­ ment UNLOADER ADJUSTMENT Tools Required: J-26701-A, Choke Valve Angle Gage J-9789-111, Linkage Bending Tool 1. Attach a rubber band to the vacuum break lever of the intermediate choke shaft (figures 44 and 50). 2. Open the throttle to allow the choke valve to close. Tools Required: J-23738-A, Hand Operated Vacuum Pump J-9789-111, Linkage Bending Tool 1. Plug vacuum break bleed holes, if applicable. With the air valves closed, apply -51 kPa (15-inches Hg) vacuum to seat the vacuum break plunger (figure 46 and 49). 3. Set up J-26701-A and set angle to specifications. 2 . Gage the clearance between the air valve link and 4. Hold the secondary lockout lever away from the pin. the end of the slot in the air valve lever. Clearance should be 0.025-inch. 3. Adjust, if necessary, by bending link with J-9789-111. • Rotate the degree scale until zero is opposite the pointer. • Center the leveling bubble. • Rotate the scale to the specified angle. — Refer to “ Specifications.” 5. Hold the throttle lever in wide open position. 6 . Adjust, if bubble is not recentered, by bending fast idle lever with J-9789-111. 6C1-46 CARBURETORS Figure 49—Air Valve Link Adjustment SECONDARY THROTTLE LOCKOUT ADJUSTMENT 1. Place the fast idle cam on the high step against the cam follower lever (figure 51). 5. Push down on tail of fast idle cam to move lockout lever away from pin. 6 . Rotate the throttle lever to bring the lockout pin to the position of minimum clearance with the lockout lever. 2. Hold the throttle lever closed. 3. Gage the clearance between the lockout lever and pin. It must be 0.015-inch ± 0.005-inch. 4. Adjust, if necessary, by bending pin. 7. Gage the clearance between the lockout lever and pin. The minimum must be 0.015-inch. 8 . Adjust, if necessary, by filing the end of the pin. 0 Attach rubber band to Vacuum Break Lever of Intermediate Choke Shaft. (2) Open Throttle to allow Choke Valve to close. (3) Set up Angle Gage and set to specification. (4) On Quadrajet, hold Secondary Throttle Lockout Lever ® away from pin (g). (5) Hold Throttle Lever in wide open position. (6) Adjust, if bubble is not recentered, by bending Fast Idle Lever. F-01936 Figure 50—Unloader Adjustment CARBURETORS 6C1-47 SPECIFICATIONS MODEL 1ME AND 1MEF CARBURETORS Carburetor Part No. Float Level mm (Inches) Metering Rod mm (Inches) Choke Coil Lever mm (Inches) Choke Rod Cam Adj mm (Inches) Vacuum Break mm (Inches) Unloader mm (Inches) 17086101 17086102 8.7 (11/32) 8.7 (11/32) 2.3 (0.090) 2.3 (0.090) .120 .120 7.0 (0.275) 7.0 (0.275) 5.0 (0.200) 5.0 (0.200) 13.2 (0.520) 13.2 (0.520) MODEL M4MC/M4ME CARBURETORS Fast Air Choke Idle Cam Vacuum Vacuum Air retor Level Rod Rod Valve Coil Choke Break Break Valve Part mm (inches) Setting Location Spring Lever Rod Front Rear Rod No. ± 2/32" mm (Inches) ± 2.5° ± 2.5° ± 3.5° 17085000 9.5 (12/32) 7.0 (9/32) Inner 7/8 .120 O CO O CVJ 17085001 9.5 (12/32) 7.0 (9/32) Inner 1 .120 17085003 10.0 (13/32) 7.0 (9/32) Inner 7/8 17085004 10.0 (13/32) 7 .0 (9/32) Inner 7/8 17085212 10.0 (13/32) 7.0 (9/32) Inner 7/8 17085213 10.0 (13/32) 7 .0 (9/32) Inner 7/8 mm (Inches) ± 4° Speed 0 .6 (0.025) 0.6 (0.025) CO Enrich­ ment — 23° .120 46° 27 ° — 0.6 (0.025) 35° — .120 46° O CO CVJ — 0.6 (0.025) 35° — .120 46° 23° - 0.6 (0.025) 35° — .120 46° - 0.6 (0.025) 35° - -*>1 o 46 ° ro (Turns) Propane Unloader O O Pump o o Pump O O Float O O CO Carbu­ — 6C1-48 CARBURETORS SPECIAL TOOLS 1. J-29030-B 5. J-23738-A 6. J-9789-111 7. J-26701-A J-34817-A J-9789-90 J-34935-1 1. 2. 3. 4. 5. 6. 7. Id le M ix tu re N e e d le S o c k e t F lo a t P o s itio n in g Tool K it F lo a t Level “ T ” S ca le E xte rn a l F lo a t Level G age H and O p e ra te d V a cu u m P um p L in k a g e B e n d in g Tool C h o ke Valve A n g le G age F-02708 6C2-1 SECTION 6C2 DIESEL FUEL INJECTION CONTENTS SUBJECT PAGE Description.................................................................................................................................................................. 6C2- 1 On-Vehicle S e rvice .................................................................................................................................................... 6C2- 2 Fuel Filter R eplacem ent........................................................................................................................................6C2- 2 Idle Speed A d ju stm e n t..........................................................................................................................................6C2- 3 Throttle Position Switch Adjustment (LH6 Engine With 700 R4 Transm ission)........ .............................. 6C2- 3 Vacuum Regulator Valve Adjustment (LL4 Engine With Automatic Transmission) ................................. 6C2- 4 Housing Pressure Cold A d va n ce ......................................................................................................................... 6C2- 4 Injection Line R eplacem ent..................................................................................................................................6C2- 4 Injection Pump Replacem ent................................................................................................................................6C2- 5 Injection Timing Adjustment..................................................................................................................................6C2- 8 Marking TDC On The Front H o u sing ................................................................................................................... 6C2- 8 Injection Nozzles........................................................................................................................................................ 6C2-10 Injection Nozzle Replacement................................................................................................................................6C2-10 Injection Nozzle T e sts................................. ....................................................................................................... 6C2-10 Injection Pump On-Vehicle Service......................................................................................................................... 6C2-12 Pump Cover Seal and/or Guide Stud Seal Replacement.................................................................................. 6C2-12 Minimum-Maximum Governor Replacement....................................................................................................... 6C2-13 Throttle Shaft Seal Replacement......................................................................................................................... 6C2-14 Shutdown And/Or Cold Advance Solenoid Replacem ent................................................................................ 6C2-16 Side Cover Gasket Replacem ent......................................................................................................................... 6C2-17 Injection Pump Off-Vehicle Service......................................................................................................................... 6C2-17 Advance Pin Hole Plug Seal Replacem ent......................................................................................................... 6C2-17 Advance Piston Seals Replacement..................................................................................................................... 6C2-17 Advance Piston Replacement................................................................................................................................6C2-18 Hydraulic Head Seal Replacement................................................................................ .......................................6C2-18 Drive Shaft Seal Replacem ent..............................................................................................................................6C2-19 Pressure Testing The Injection P um p................................................................................................................. 6C2-19 S pecifications............................................................................................................................................................ 6C2-20 Special T o ols.............................................................................................................................................................. 6C2-21 \ ./ DESCRIPTION The 6.2 L diesel engine fuel system is composed of: • Fuel tank • Mechanical fuel pump • Fuel filter with water sensor and heater • Fuel filter restriction switch • Injection distributor pump • High pressure lines • Fuel injection nozzles Fuel is drawn from the fuel tank by the mechanical pump which is located on the right side of the engine. The pump is driven by an eccentric lobe on the camshaft through a push rod. Fuel is then pumped through the filter / water spearator. The filter / water separator is located on the engine side of the cowl (R-V models) or under the rear of the air cleaner (G-P models). The fuel is then trans­ ferred to the injection pump. The injection pump is mounted on top of the engine under the intake manifold. The pump is driven by the camshaft through two gears, one attached to the front of the camshaft and the other attached to the end of the injection pump shaft. These gears are the same size and have the same number of teeth; therefore, the injection pump shaft turns at the same speed as the camshaft. The pump turns in the opposite direction of the camshaft and crankshaft. The injection pump is a high pressure rotary type pump that meters, pressurizes, and distributes fuel to the eight injector nozzles. The eight high pressure lines are all the same length although their shape may be different. This prevents tim ing differences between cylinders. Injection lines should not be bent to ease removal. 6C2-2 DIESEL FUEL INJECTION ON-VEHICLE SERVICE FUEL FILTER REPLACEMENT The fuel filter on R-V models is located on the engine 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 accessible by removing the engine cover. Remove or Disconnect (Figures 1 and 2) 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. Any dirt from the fuel port sealing surface of the filter adapter and the new filter. ♦ 4- 1. 2. • 3. Install or Connect (Figures 1 and 2) New filter. The bail wires. Close the water drain valve and open the air bleed. A 3.18 mm (1/s inch) inside diameter hose to the air bleed port and the other end into a suitable container. • Disconnect the fuel injection pump shut off solenoid wire. NOTICE: If the engine is to be cranked, or start­ ing attem pted with the air cleaner removed, care must be taken to prevent material from be­ ing p ulled into the air inlet m anifold which could result in engine damage. • Crank the engine for 10-15 seconds and then wait one minute for the starter motor to cool. Repeat until clear fuel is observed coming from the air bleed. DIESEL FUEL INJECTION 6C2-3 A. B. C. D. E. F. G. Front C lo ckw ise R otation Power Test Light O r O hm m eter IGN (Pink Wire) EGR (Yellow Wire) O p tio n al Test Location EPR (Blue o r V io le t Wire) 6 . Open the throttle momentarily to energize and fully extend the fast idle solenoid plunger. 7. Adjust the extended plunger (3) by turning the 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 F-00008 Figure 4—Testing the TPS for Continuity • 4. 5. • Close the air bleed. Injection pump solenoid wire. Fuel tank cap. Start the engine and allow it to idle for five minutes. In s p e c t • Fuel filter for leaks. IDLE SPEED ADJUSTMENT CURB IDLE SPEED (Figure 3) Tool Required: J-26925, Tachometer 1. Set the parking brake and block the drive wheels. 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 m anufacturers 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) 1. 2. 3. 4. 5. Tool Required: J-26925, Tachometer Set the parking brake and block the drive wheels. Engine must be at normal operating temperature with the air cleaner on and all accessories turned off. Install J-26925 or equivalent per manufacturers instructions. Remove the connector from the fast idle solenoid. Connect an insulated jumper wire from the positive battery terminal to the solenoid terminal. This will energize the solenoid. the fast idle solenoid. THROTTLE POSITION SWITCH ADJUSTMENT (LH6 ENGINE WITH 700 R4 TRANSMISSION) Tool Required: J-33043-A, Gage Block 1. D is co n n e ct the th ro ttle p o s itio n sw itch (TPS) connector. 2. Loosen the mounting screws that hold the TPS. 3. Conect an ohmmeter or test light to the IGN (pink) and EGR (yellow) terminals of the TPS (figure 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 should be no continuity. If there is continuity, repeat steps 1 through 9. • Refer to the Emission Control Information label for correct gage block size. 10. Remove the gage block and ohmmeter. 11. Connect the TPS connector. 6C2-4 DIESEL FUEL INJECTION A. V a cuu m G age B. P ig ta il C o n n e c to r C. C lo c k w is e R o ta tio n D. To V a cuu m S o u rce E. W id e O pen S to p Pin F. J-36142 B-07635 Figure 6—VRV/Detent Switch Adjustment VACUUM REGULATOR VALVE ADJUSTMENT (LL4 ENGINE WITH AUTOMATIC TRANSMISSION) 1. 2. 3. 4. 5. Tool Required: J-33043-A, Gage Block J-36142, Switch Gage Tool Loosen the vacuum regulator valve (VRV) so it is free to rotate on the pump. Attach a vacuum source of 67 + 5 kPa (20 inches Hg ± 1.5 inch Hg) to the bottom vacuum port of the VRV. Attach a vacuum gage to the top vacuum port (figure 6). 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). • Refer to the Emission Control Information label for correct gage block size. 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 7. 8. 9. 10. regulator valve body clockwise (facing the valve) until the vacuum gage reads 38.8 ± 2 kPa (11.5 ± 0.6 inches Hg). Hold the valve body at this position and tighten the mounting screws to 6 N m (54 in. lbs.). 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 38.8 ± 2 kPa (11.5 ± 0.6 inches Hg). If vacuum is outside of limits, reset the valve. With the valve vacuum set, confirm the detent switch point by reading the resistance between the ignition terminal (pink with black stripe) and the detent terminal (orange). Insert J-36142 between the wide open stop pin and the wide open stop screw on the throttle lever. Rotate the throttle lever against the tool. There should be no continuity (infinite resistance). 11. Release the throttle lever and remove the switch gage tool. 12. Rotate the throttle lever to wide open throttle (the lever stop screw touching the pump stop pin). 13. Check the switch for continuity. The switch must have continuity (1 to 0 ohms) before the throttle reaches the wide open throttle position. If the switch does not meet these specifications, reset the assembly by returning to step 1 and repeating the entire procedure. HOUSING PRESSURE COLD ADVANCE The Housing Pressure Cold Advance feature advances the injection tim in g about fo u r degrees d urin g cold operation. This provides better cold starts, improved cold idle, and emission control. The circuit is actuated by a coolant temperature switch on the rear of the right cylinder head. The switch is calibrated to open the circuit at 35°C (95°F). Below the s w itc h in g p oint, tim in g is adva nce d by decrea sing housing pressure from 68.95 kPa (10 psi) to zero. Above the switching point, the housing pressure is returned to 68.95 kPa (10 psi). The fast idle solenoid is energized by the same switch. INJECTION LINE REPLACEMENT P y | Clean • All line fittings that will be loosened or removed. Remove or Disconnect (Figures 7 and 8) Tool Required: J-29664-1, Protective Covers 1. Battery negative cables. 2. Engine cover (G-Van only). 3. Air cleaner at the valve cover. 4. Crankcase ventilator bracket. 5. Intake manifold bolts. DIESEL FUEL INJECTION 6C2-5 A. L e ft B ank B. R ig h t B ank B B-08130 Figure 7—Fuel Injection Lines 6. 7. • 8. 9. • It may be necessary to loosen the vacuum pump hold down clamp and rotate the pump to gain access to all intake manifold bolts. Injection line clips. Intake manifold. Install J-29644-1 to the intake ports. Injection line clips at the loom brackets. Raise the vehicle (left bank of G-Van only). Injection lines at the nozzles. $ 7. 8. 9. 10. Tighten • Bolts to 40 N-m (30 ft. lbs.). Crankcase ventilator bracket. Air cleaner. Engine cover (G-Van only). Battery negative cables. INJECTION PUMP REPLACEMENT • Cap the lines and nozzles immediately. 10. • Do not bend injection lines. Injection lines at the pump. • Cap the lines and the pump fittings 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. • Fittings to 25 N m (20 ft. lbs.). Injection line clips at the loom brackets. Intake manifold. • Remove J-29664-1. Injection line clips. Intake manifold bolts. R-V TRUCK Remove or Disconnect Tool Required: J29664-1, Protective Covers 1. Battery negative cable. 2. Intake manifold. • Refer to 6.2 LITER DIESEL (SEC. 6 A 6 ). 3. Injection lines. 4. Accelerator cable at the injection pump (figure 9). 5. Detent cable (if equipped). 6. Fuel return line at the top of the injection pump. 7. Fuel inlet line from the injection pump. 8. All necessary wires and hoses from the injection pump. 9. Air conditioning hose retainer bracket (if equipped). 10. Oil fill tube (includes CDR valve vent hose). 11. Grommet. • Scribe or paint a mark on the front cover and the injection pump flange. • Rotate the engine to gain access to the bolts that hold the driven gear to the injection pump. 6C2-6 DIESEL FUEL INJECTION I <£) B E G H 12 . 13. 14. 15. — Access is gained through the oil filler neck hole (figure 10). Bolts (10). Nuts (11) (figure 11). Pump. • Cap all open lines and nozzles. Gasket (12). Install or Connect 1. New gasket (12). 2. Injection pump to the front cover. • Align the locating pin on the pump hub (14) with the slot in the injection pump driven gear (13) (figure 12). • Align the timing marks (figure 13). 3. Nuts (11) (figure 11). • Nuts to 40 N m (30 ft. lbs.). — Check the timing mark alignment before fully torquing the nuts. Drive gear to injection pump bolts ( 10) (figure 11). Tighten A. B. C. D. E. F. G. H. • Bolts to 25 N m (20 ft. lbs.). Grommet. C yl C yl C yl C yl C yl C yl C yl C yl nder nder nder nder nder nder nder nder N um ber N um ber N um ber N um ber N um ber N um ber N um ber N um ber 8 7 2 6 5 4 3 1 B-08131 10. B-08133 Figure 8—Injection Line Routing Figure 10—Pump Drive Gear Bolts DIESEL FUEL INJECTION 6C2-7 A. In je c tio n P um p G e ar B. A lig n m e n t M ark C. C am G ear 10. B o lt 11. N ut 12. G a sket 14. P um p H ub -j 2 B-08134 Figure 11—Injection Pump Installation 6 . Oil fill tube including the CDR valve vent hose. 7. Air conditioning hose retainer bracket (if equipped). 8 . Fuel feed line at the injection pump. Tighten • Fitting to 25 N m (20 ft. lbs.). Fuel return line to the top of the injection pump. Detent cable (if equipped). All necessary wires and hoses. Accelerator cable. Injection lines. Intake manifold. • Refer to 6.2 LITER DIESEL (SEC. 6 A 6 ). 15. Battery negative cable. 9. 10. 11. 12. 13. 14. G-VAN 0 Remove or Disconnect Tool Required: J-29664-1, Protective Covers 1. Battery negative cable. 2. Engine cover. 3. Intake manifold. • Refer to 6.2 LITER DIESEL (SEC. 6 A 6 ). 4. Air cleaner inlet hose. • Rotate the snorkel up. 5. Hood latch. 6 . Hood latch cable and move it aside. 7. Windshield washer bottle. 8 . Fan shroud bolts. 9. Upper fan shroud. 10. Rubber hose from the oil fill tube. 11. The oil fill tube nuts. 12. The oil fill tube. 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). 21. Accelerator cable. 22. Injection lines. 23. Fuel return line. • Scribe or paint a mark on the front cover and the injection pump flange. 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). • Align the timing marks (figure 13). 3. Nuts (11). 6C2-8 DIESEL FUEL INJECTION Tighten 26. Battery negative cable. • Nuts to 40 N m (30 ft. lbs.). — Check the timing mark alignment before fully torquing the nuts. 4. Drive gear to injection pump bolts (10). Tighten 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. • Bolts to 25 N-m (20 ft. lbs.). Fuel return line. Injection lines. Accelerator cable. Detent cable (if equipped). Electrical connections at the injection pump. The oil pan dipstick tube at the left cylinder head. Injection lines to the brackets. Wire looms to the injection lines. Fuel filter and bracket including the line to the injection pump. The oil fill tube grommet. The oil fill tube. The oil fill tube nuts. Rubber hose to the oil fill tube. Upper fan shroud. Fan shroud bolts. Windshield washer bottle. Hood latch cable. Hood latch. Air cleaner inlet hose. Intake manifold. • Refer to 6.2 LITER DIESEL (SEC. 6 A 6 ). Engine cover. INJECTION TIMING ADJUSTMENT For the engine to be properly tim ed, the marks on the top of the engine front cover must be aligned with the marks on the injection pum p flange (figure 13). The engine must be off when the tim ing is reset. On Federal models, align the scribe marks. On California models, align the half circles. Adjust Injection timing. • Loosen the three pump retaining nuts. • Align the mark on the injection pump with the mark on the front cover. Tighten • Pump retaining nuts to 40 N m (30 ft. lbs.). 2 . Throttle rod. MARKING TDC ON THE FRONT HOUSING Tool Required: J-33042, Timing Fixture 1. Set the engine so that number 1 cylinder is at TDC (firing). 2. Install J-33042 in the injection pump location. • Do not use the gasket. DIESEL FUEL INJECTION 6C2-9 — Align the timing mark on the injection pump flange with the mark on the front cover. 5. Remaining pump gear attaching bolts. • Rotate the engine to gain access to the bolts. Tighten • Bolts to 25 N m (20 ft. lbs.). 3. The slot in the injection pump gear should be in the vertical 6 o’clock 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 (figure 15). 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. 9. Strike the scriber with a mallet to mark TDC on the front housing. 10. Remove J-33042. "►«" Install or Connect Gasket. Injection pump. Nuts (finger tight). One 8 mm bolt to attach the gear to the pump hub. Bolt to 25 N m (20 ft. lbs.). Injection pump nuts to 40 N-m (30 ft. lbs.). B-07637 Figure 15—Marking TDC on the Front Housing 6C2-10 DIESEL FUEL INJECTION INJECTION NOZZLES Nozzles used in G m odels are shorter than nozzles used on R-V and P models. Attempts to use the incorrect nozzle will damage the cylinder heads. When replacing nozzles, reference should be made to the part number which is stamped on the side of the nozzle (figure 16). INJECTION NOZZLE REPLACEMENT Remove or Disconnect (Figure 17) 1. 2. 3. 4. Tool Required: J-29873, Nozzle Socket Negative battery cable. Fuel line clip. Fuel return hose. Fuel injection line. • Cap the nozzle and lines. NOTICE: When removing an injection nozzle, use J-29873. Remove the nozzle using the 30 mm hex portion (figure 16). Failure to do so will result in damage to the injection nozzle. 5. Injection nozzle using J-29873. |-n-| Install or Connect (Figure 17) 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 16). Failure to do so will result in damage to the injection nozzle. 1. Injection nozzle using J-29873. Tighten • Nozzle to 70 N-m (50 ft. lbs.). Fuel injection line. £ Tighten • Nut to 25 N-m (20 ft. lbs.). 3. F u e l re tu rn h o s e . 4. Fuel line clip. 5. Negative battery cable. INJECTION NOZZLE TESTS Nozzle testing is comprised of the following checks: • Nozzle opening pressure • Leakage • Chatter • Spray pattern Each test should be considered independent of the others (for example, when checking opening pressure, do not check for leakage). If all of the above tests are satisfied, the nozzle holder assembly can be re-used. If any one of the tests is not satisfied, the complete nozzle holder assem bly must be replaced. The nozzle holder will then be checked and repaired at a centralized location. • Test Lines - 6 x 2 x 400 mm (1.5 mm bore). • Test Fluid - per ISO 4113 (Example: Shell V 1399, Viscosity 1487C or equivalent). • Kinetic Viscosity at 40° - per ISO 3104: 2,45 - 2.75 mm 2/second. • Test oil temperature during test: 20 - 25°C (6 8 °F 77°F). DIESEL FUEL INJECTION 6C2-11 • Refer to the equipment manufacturers instructions for exact test procedures. 1. Connect the nozzle holder assembly to the test line. 2. Place clear plastic tubes on overflow connections to prevent leakoff from being confused with actual leak. 3. Close the shutoff valve to the pressure gage. CAUTION: When testing nozzles, do not place your hands or arms near the tip of the nozzle. The high pressure atomized fuel spray from a nozzle has sufficient penetrating power to puncture flesh and destroy tissue and may result in blood poisoning. The nozzle tip should always be enclosed in a receptacle, preferably transparent, to contain the spray. 4. Fill and flush the nozzle holder assembly with test oil by activating the lever briskly and repeatedly. This will apply test oil to all functionally important areas of the nozzle and purge it of air. OPENING PRESSURE TEST 1. O pen the s h u to ff valve at the p re ssure gage one-quarter turn. CAUTION: When testing nozzles, do not place your hands or arms near the top of the nozzle. The high pressure atomized fuel spray from a nozzle has sufficient penetrating power to puncture flesh and destroy tissue and may result in blood poisoning. The nozzle tip should always be enclosed in a receptacle preferably transparent, to contain the spray. 2. Depress the tester lever slowly. Note at what pressure the needle of the pressure gage stopped. The maximum observed pressure is the opening pressure. • Some nozzles may pop while other nozzles may drip down (this is not leakage). 3. The opening pressure should not fall below the lower limit of 105 bar (1500 psi) on used nozzles. 4. Replace nozzles which fall below the lower limit. LEAKAGE TEST 1. Further open the shutoff valve at the pressure gage V2 to 1 V2 turns). 2. Blow-dry the nozzle tip. CAUTION: When testing nozzles, do not place your hands or arms near the top of the nozzle. The high pressure atomized fuel spray from a nozzle has sufficient penetrating power to puncture flesh and destroy tissue and may result in blood poisoning. The nozzle tip should always be enclosed in a receptacle preferably transparent, to contain the spray. 3. Depress the lever of the manual test stand slowly until the gage reads a pressure of 95 bar (1400 psi). Observe the nozzle tip. A drop may form on the end of the nozzle but should not drop off within a period of 10 seconds. 4. Replace the nozzle assembly if a drop falls during the 10 seconds. CHATTER TEST When testing for chatter, it should be noted that the sound (chatter) for new and used nozzles may vary. This is due to carbonized fuel deposits on the pintle and nozzle tip of used nozzles. With some used nozzles, chatter is difficult to detect during slow actuation of the hand lever. Some nozzles may chatter louder than others. As long as there is chatter, the nozzle is acceptable. 1. Close the shutoff lever at the pressure gage. CAUTION: When testing nozzles, do not place your hands or arms near the top of the nozzle. The high pressure atomized fuel spray from a nozzle has su fficien t penetrating power to puncture flesh and destroy tissue and may result in blood poisoning. The nozzle tip should always be enclosed in a receptacle preferably transparent, to contain the spray. 2. Depress the lever of the test stand slowly and note whether chatter noise can be heard. 3. If no chattter is heard, move the lever faster until it chatters. At fast lever movement, the nozzle may make a “ hissing” or “ squealing” sound rather than the normal chatter. This is acceptable. 4. These sounds indicate that the nozzle needle moves freely and that the nozzle seat, guide, and pintle are OK. 5. Replace nozzles that do not chatter. SPRAY PATTERN This nozzle features a longer nozzle overlap, greater p in tle to b o d y c le a ra n c e , g re a te r n e e d le to b o d y clearance, and an internal wave washer between the nozzle nut and the nozzle. These features make objective spray pattern testing difficult. A pop tester will not deliver fuel fast enough for proper spray pattern analysis. Based on this, this type of nozzle should not be rejected for spray pattern. 6C2-12 DIESEL FUEL INJECTION INJECTION PUMP ON-VEHICLE SERVICE A. B. C. D. E. F. P um p C ove r H ead A n d R o to r A s s e m b ly Cam A d v a n c e S cre w T im in g L in e S id e C over G u id e S tu d A d va n ce S crew H o le Plug B-08139 Figure 18—Injection Pump Components Location Refer to figure 18 for injection pump components loca­ tion. PUMP COVER SEAL AND/OR GUIDE STUD SEAL REPLACEMENT 7. Injection pump cover screws. Clean • • • • Injection pump cover. Upper portion of the pump. The guide stud area. Place several rags in the engine valley to catch fuel. 4-+ Remove or Disconnect 1. 2. 3. 4. 5. 6. Tool Required: J-29664, Manifold Cover Set Negative battery cables. Air cleaner and intake manifold. • Install J-29664 in the cylinder heads. Injection pump fuel solenoid wire. Housing pressure cold advance wire. Fuel return line. Top attaching bolt and loosen the lower attaching bolt on the fast idle solenoid. Move the solenoid aside. NOTICE: Extreme care must be used to keep foreign m aterial out o f the pum p when the cover is off. If any objects are dropped into the pump, they must be removed before the engine is started or injection pum p and engine damage could occur. 8 . Injection pump cover. 9. The guide stud and washer. • Note location of parts prior to removal. DIESEL FUEL INJECTION 6C2-13 B-08142 Figure 19—Metering Valve Spring Position Figure 20—Installing the Injection Pump Cover » Observe the position of the metering valve spring over the top of the guide stud (figure 19). This position must be exactly duplicated during assembly. 10. Pump cover seal from the pump cover. 0 Install or Connect 1. The guide stud with a new washer. • Make sure that the upper extension of the metering valve spring rides on top of the guide studs. • The guide stud to 9.5 N m (85 in. lbs.). — Overtightening the guide stud may strip the aluminum threads in the housing. 2. New pump cover seal in the pump cover. 3. The pump cover. • The screws should not be in the pump cover. • Position the cover about 6 mm ( 1/4-inch) forward (toward the shaft end) and about 3 mm (Vs-inch) above the pump (figure 2 0 ). • Move the cover rearward and downward into position, being careful not to cut the seal. — Hold throttle in the idle position. 4. The cover screws. • Be careful not to drop or lose the flat washer and spring washer on each screw. • The flat washer must be against the pump cover. Tighten • Screws to 3.7 N m (33 in. lbs.). Battery negative cables. I* 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, 6. 7. 8. 9. • • 10. 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. Fuel return line, throttle cable, and the return springs. Fast idle solenoid. Housing pressure cold advance wire. Injection pump fuel solenoid wire. Start the engine and check for leaks. 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 m inutes to allow air bubbles to rise to the top of the pump. Intake manifold and air cleaner. • Remover J-29664. MINIMUM-MAXIMUM GOVERNOR REPLACEMENT Remove or Disconnect (Figure 21) Tool Required: J-29664, Manifold Cover Set Negative battery cables. Air cleaner and intake manifold. • Install J-29664 in the cylinder heads. Injection pump fuel solenoid wire. Housing pressure cold advance wire. Fuel Return line. Fast idle solenoid top attaching bolt. • Loosen the lower bolt, and move the solenoid aside. Injection pump cover screws. JQ* Clean Injection pump cover. Upper portion of the pump. The guide stud area. 6C2-14 DIESEL FUEL INJECTION Make sure that the upper extension of the metering valve spring rides on top of the guide stud. Tighten • The guide stud to 9.5 N-m (85 in. lbs.). — Overtightening the guide stud may strip the aluminum threads in the housing. 3. New pump cover seal in the pump cover. 4. The pump cover. • The screws should not be in the pump cover. • Position the cover about 6 mm (1/4-inch) forward (toward the shaft end) and about 3 mm (Vs-inch) above the pump (figure 2 0 ). • Move the cover rearward and downward into position, being careful not to cut the seal. — Hold throttle in the idle position. 5. The cover screws. • Be careful not to drop or lose the flat washer and spring washer on each screw. • The flat washer must be against the pump cover. A. B. C. D. M in - M ax G o ve rn o r A s s e m b ly M in - M ax G o ve rn o r Sleeve Seal T h ro ttle S h a ft • Screw s to 3.7 N-m (33 in. lbs.). 6 . Battery negative cables. I? B-08140 Figure 21—Injection Pump Cover Removed • Place several rags in the engine valley to catch the fuel. NOTICE: Extreme care must be used to keep foreign m aterial out o f the pum p when the cover is off. If any objects are dropped into the pump, they must be removed before the engine is started or injection pum p and engine damage could occur. 8 . Injection pump cover. 9. The guide stud and washer. • Note the location of parts prior to removal. • Observe the position of the metering valve spring over the top of the guide stud (figure 19). This position must be exactly duplicated during assembly. 10. Pump cover seal from the pump cover. 11. Minimum-Maximum governor assembly. • Rotate the throttle shaft and the governor assembly until the governor clears the housing. • Governor assembly from the throttle shaft. ♦ 4- Install or Connect (Figure 21) 1. Minimum-Maximum governor assembly. • Rotate throttle shaft to full throttle. • Place the slotted portion of the governor assembly onto the throttle shaft slot. • Rotate the throttle shaft with governor assembly into the housing. 2 . The guide stud with a new washer. 7. 8. 9. 10. 11. 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 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. Fuel return line, throttle cable, and the return springs. Fast idle solenoid. Housing pressure cold advance wire. Injection pump fuel solenoid wire. • Start the engine and check for leaks. • 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 m inutes to allow air bubbles to rise to the top of the pump. Intake manifold and air cleaner. • Remove J-29664. THROTTLE SHAFT SEAL REPLACEMENT Remove or Disconnect Tools Required: J-29601, Injection Pump Timing Adapter J-29664, Manifold Cover Set 1. Negative battery cables. DIESEL FUEL INJECTION 6C2-15 • Observe the position of the metering valve spring over the top of the guide stud (figure 19). This position must be exactly duplicated during assembly. 12. Min - max governor assembly (figure 21). • Rotate the assembly up to provide clearance. • If the idle governor spring becomes disengaged from the throttle block, it must be reinstalled with the tightly wound coils toward the throttle block. 13. The throttle shaft assembly. I* Inspect • Throttle shaft for unusual wear or damage. • Throttle shaft bushings for damage or unusual wear or leaks. — Remove the pump and send it to the local Stanadyne dealer if bushing replacement is necessary. 14. The throttle shaft seals. • Do not attempt to cut the seals, as nicks in the seal seat will cause leakage. 2. Air cleaner and intake manifold • Install J-29664 in the cylinder heads. 3. Injection pump fuel solenoid, housing pressure cold advance wires, and the fuel return line. 4. Throttle rod and the return springs. • Mark the position of the TPS switch or VRV for installation. 5. Top attaching bolt on the fast idle solenoid. Move the soleniod aside. 6 . Throttle cable bracket. 7. Throttle shaft advance cam and fiber washer. • Install J-29601 over the throttle shaft with the slots on the tool engaging the pin (figure 22). Put the spring clip over the throttle shaft advance cam and tighten the wing nut. Pull the tool off of the shaft without loosening the wingnut This provides proper advance cam alignm ent for assembly. • Loosen the face cam screw. • 1. 2. 3. 4. 5. D r iv e t h e p in f r o m t h e t h r o t t le s h a f t . 8 . Any burrs from the throttle shaft that may have resulted from pin removal. 9. Injection pump cover screws. Clean • • • • -►+ Install or Connect Injection pump cover. Upper portion of the pump. The guide stud area. Place several rags in the engine valley to catch fuel. NOTICE: Extreme care must be used to keep foreign m aterial out of the pum p when the cover is off. If any objects are dropped into the pump, they must be removed before the engine is started or injection pum p and engine damage could occur. 10. Injection pump cover. 11. The guide stud and washer. • Note location of parts prior to removal. 6. Tools Required: J-29601, Injection Pump Timing Adapter J-33198, Synkut Oil Seal Lubricant New throttle shaft seals. • Use care not to cut the seal on the sharp edges of the shaft. • Apply J-33198 or a light coating of clean chassis grease to the seals. The throttle shaft to the point where the min - max governor assembly will slide back onto the shaft. Throttle shaft and governor into position. • Rotate the min - max governor assem bly downward (figure 21 ). New mylar washer, the throttle shaft advance cam, and a new throttle shaft drive pin (figure 2 2 ). • Do not tighten the cam screw. J-29601 over the throttle shaft with the pin in the slots and the spring clip over the advance cam. A 0.005-inch feeler gage between the white washer on the throttle shaft and the pump housing (figure 23). Tighten • Cam screw to 3.1 N m (30 in. lbs.). — Squeeze the throttle shaft. — Secure the screw with Loctite 290 or equivalent. • Remove J-29601. 7. The guide stud with a new washer. • Make sure that the upper extension of the metering valve spring rides on top of the guide stud. Tighten • The guide stud to 9.5 N m (85 in. lbs.). — Overtightening the guide stud may strip the aluminum threads in the housing. 8 . New pump cover seal in the pump cover. 9. The pump cover. • The screws should not be in the pump cover. 6C2-16 DIESEL FUEL INJECTION Figure 23—Setting Advance Cam to Housing Clearance • Position the cover about 6 mm (1/4-inch) forward (toward the shaft end) and about 3 mm (Vs-inch) above the pump (figure 22 ). • Move the cover rearward and downward into position, being careful not to cut the seal. 10. The cover screws. • Be careful not to drop or lose the flat washer and spring washer on each screw. • The flat washer must be against the pump cover. Tighten • Screws to 3.7 N m (33 in. lbs.). 11. TPS switch or VRV. . Battery negative cables. 12 I? 13. 14. 15. 16. 17. 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. Fuel return line, throttle cable, and the return springs. Fast idle solenoid. Housing pressure cold advance wire. Injection pump fuel solenoid wire. Start the engine and check for leaks. 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. Intake manifold and air cleaner. • Remove J-29664. SHUTDOWN AND/OR COLD ADVANCE SOLENOID REPLACEMENT Remove or Disconnect (Figure 24) 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. Install or Connect (Figure 24) 1. Solenoid in the pump cover. • On the shutdown solenoid, make sure that the linkage is free. • On the cold advance solenoid, make sure that the plunger is centered so that it will contact the check ball in the fitting. 2. Insulating washers on the terminal studs (where used). 3. Terminal nuts. Tighten • Nuts to 1.2 N m (12 in. lbs.). 4. Pump cover. • Refer to “ Pump Cover Seal And/Or Guide Stud Seal Replacement.” I* Inspect Solenoid operation prior to installing the pump cover. Use a 12 V DC power source. DIESEL FUEL INJECTION 6C2-17 SIDE COVER GASKET REPLACEMENT Remove or Disconnect (Figure 25) 1. The two screws (40). 2. Cover (41). 3. Gasket (42). |+<-| Install or Connect (Figure 25) 1. Gasket. 2. Cover. 3. Screws. 40. S cre w s 41. C over 42. G a sket • Screws to 2 N m (18 in. lbs.) B-08147 Figure 25—Side Housing and Drive Group INJECTIO N PUMP OFF-VEHICLE SE R V IC E Refer to “ Injection Pump R eplacem ent.” Off-vehicle service operations require a leak test after the repair has been made. Refer to “ Pressure Testing The Injection Pump.” ADVANCE PIN HOLE PLUG SEAL REPLACEMENT Remove or Disconnect (Figure 26) 1. Injection pump. 2. Plug (50). • Tap the plug lightly with a hammer to loosen it. 3. Seal (51). ♦«- Install or Connect (Figure 26) 1. New seal. • Lubricate the seal. 2. Plug. Q Tighten • Plug to 10 N-m (90 in. lbs.). Injection pump. ADVANCE PISTON SEALS REPLACEMENT 0 49. 50. 51. 52. 53. 54. 55. 3. Seal (53). 4. Power side advance piston hold plug .(55). 5. Seal (54). Seal Seal P ow er S id e P lug Figure 26—Advance Piston Group Remove or Disconnect (Figure 26) 1. Injection pump. 2. Spring side advance piston hold plug (52). C am A d v a n c e Pin Plug Seal S p rin g S id e P lug Install or Connect (Figure 26) 1. New • 2. Plug 3. New seal (54). Lubricate the seal. (55). seal (53). B-08148 6C2-18 DIESEL FUEL INJECTION 4. Plug (52). 5. injection pump. ADVANCE PISTON REPLACEMENT Remove or Disconnect (Figure 26) 1. 2. 3. 4. 5. Injection pump. Advance piston hold plugs (52 and 55). Cam advance pin plug (50). Cam advance pin (49). Advance piston. +«- Install or Connect (Figure 26) 1. 2. 3. 4. Advance piston. Cam advance pin (49). Cam advance pin plug (50) using a new seal (51). Advance piston hold plugs (52 and 55) using new seals (54 and 53). 5. Injection pump. HYDRAULIC HEAD SEAL REPLACEMENT Remove or Disconnect 1. Injection pump. 2. Throttle shaft and seals. • Refer to “ Throttle Shaft Seal Replacement.” 3. Metering valve (figure 27) 4. Housing vent wire screw assembly (figure 28). 5. Cam advance pin hold plug (50) (figure 26). 6 . Seal from the plug. 7. Cam advance pin (49) (figure 26). 8 . Head locking screws (figure 29). • Locate the pump assembly so the rear of the pump is sloping down. 9. Head locating screw and seal (figure 30). 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 loosely (figure 29). • Lubricate the screws. 4. New seal on the head locating screw. 5. Head locating screw (figure 30). • Turn the pump upside down. Figure 28— V e nt W ire A s se m b ly Tighten • Screw to 23 N m (17 ft. lbs.). 6 . The advance pin (49) (figure 26). 7. New seal on the advance pin hole plug. • Lubricate the seal. 8 . The advance pin hold plug. Tighten • Plug to 10 N m (90 in lbs.). 9. Housing vent wire screw assembly (figure 28). DIESEL FUEL INJECTION 6C2-19 A. D rive S h a ft S e als B-08149 Figure 31—Drive Shaft Seals DRIVE SHAFT SEAL REPLACEMENT Figure 29—Head Locking Screws Remove or Disconnect (Figure 31) 10. Metering valve (figure 27). 11. Throttle shaft and seals. • Refer to “ Throttle Shaft Seal Replacement.” 12. Injection pump. Tool Required: J-29692-B, Holding Fixture Injection pump. Fast idle solenoid bracket. • Mount the pump in J-29692-B and tilt it. The drive shaft from the pump using a rotating motion (alignment pin at the top). • The shaft is retained by an o-ring. • Make sure that no pieces of the o-ring have broken off in the pump. 4. The drive shaft seals. ++ Install or Connect (Figure 31) Tools Required: J-29692-B, Holding Fixture J-29745-A, Shaft Seal Protector J-33198, Synkut Lubricating Oil 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. • Lubricate the seal protector with J-33198 or equivalent. 3. The other black seal using J-29745-A. • Lubricate the seal protector with J-33198 or equivalent. New o-ring retaining clip on the shaft. Drive shaft into the pump. • Make sure the drill points on the drive shaft end match up with the rotor. Fast idle solenoid bracket. Injection pump. PRESSURE TESTING THE INJECTION PUMP Drain all fuel from the pump. Connect an air line to the pump inlet connection. • Make sure the air supply is clean and dry. Completely immerse the pump in a bath of clean test oil. • Seal off the return line fitting. 6C2-20 DIESEL FUEL INJECTION 4. Raise the air pressure in the pump to 137.9 kPa (20 psi). Keep the pump immersed in the oil for 10 minutes to allow any trapped air to escape. 5. Watch for leaks after the ten minutes. If the pump is not leaking, reduce the air pressure to 13.8 kPa (2 psi) for 30 seconds. If there is still no leakage, increase the pressure to 137.9 kPa (20 psi). If there are no leaks, the pump is ready for use. SPECIFICATIO NS Fasteners Injection Line F ittin g s ................................................ Intake Manifold Bolts................................................... Injection Pump Mounting N u ts................................. Injection Pump Drive Gear B o lts ............................ Injection N ozzles......................................................... Injection Pump Cover S c r e w s ................................. Injection Pump Guide Stud ..................................... Solenoid Terminal N uts.............................................. Side Cover S c re w s ..................................................... Advance Pin Hole P lu g .............................................. Head Locating S c re w ................................................ Torque ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ ........................ 25 N m 40 N m 40 N m 25 N m 70 N m 3.7 N m 9.5 N m 1.2 N m 2 Nm 10 N m 23 N m 2 0 ft. lbs. 30 ft. lbs. 30 ft. lbs. 2 0 ft. lbs. 50 ft. lbs. 33 in. lbs. 85 in. lbs. 12 in. lbs. 18 in. lbs. 90 in. lbs. 17 ft. lbs. DIESEL FUEL INJECTION 6C2-21 SP E C IA L TOOLS J-26925 6 J-36142 J-29601 J-33198 -29664 J-33042 J-29692-B J-29745-A 1 . T a c h o m e te r 2 . In je c tio n P u m p T im in g A d a p te r 3. P ro te c tiv e C overs 4. H o ld in g F ix tu re 5. S h a ft Seal P ro te c to r 9 10 J-33043-A J-29873 6 . N ozzle S o c k e t 7. 8. 9. 10. T im in g F ix tu re G age B lo c k S y n k u t L u b ric a tin g O il S w itc h G age Tool B-07634 6C2-22 DIESEL FUEL INJECTION 6D-1 SECTION 6D EN G IN E ELECTRICAL CONTENTS S U B JE C T Electrical System............................................... B attery.............................................................. Description.................................................... General Information....................................... Diagnosis of Battery......................................... Visual Inspection........................................... Hydrometer T e s t........................................... Load T e s t...................................................... Battery On-Vehicle S e rvice............................. Battery Charging Procedures....................... Current Drain Test......................................... Battery Cables............................................... Battery Replacement..................................... Charging System............................................... Description...................................................... Diagnosis of Charging System......................... Noisy Generator............................................. Electrical Tests............................................... SI Charging System....................................... CS-130 Charging S ystem ............................. Generator On-Vehicle Service......................... Generator Replacement................................. Diesel Glow Plug Electrical System.................. Description..................................................... Diagnosis of Glow Plug Electrical System ----Circuit Check................................................. Glow Plug Inhibit Switch............................... Glow Plug System......................................... Glow Plug A fterstart..................................... Glow Plug On-Vehicle Service......................... Cranking System............................................... Diagnosis of Cranking System......................... Cranking Circuit............................................. Starter Motor Noise....................................... Diagnosis of Starter Motor Noise..................... Cranking System On-Vehicle Service.............. Maintenance................................................... Starter M o to r................................................. Starter Motor Replacement........................... Engine Block Heaters....................................... On-Vehicle S ervice....................................... Ignition System................................................. Description..................................................... Distributor...................................................... Engines with T B I........................................... Spark Plug W ires........................................... Spark P lu g s ................................................... Diagnosis of Ignition System........................... Distributor/Timing System for TBI-Equipped Engines.................................................................. Ingition System for Carbureted Engines___ Diagnosis of Spark Plugs................................. PAGE ................6D- 2 ................6D- 2 ................6D- 2 ................6D- 3 ................6D- 4 ................6D- 4 ................6D- 4 ................6D- 4 ................6D- 5 ................6D- 5 ................6D- 5 ................6D- 6 ................6D- 6 ................6D- 7 ................6D- 7 ................6D-10 ................6D-10 ................6D-10 ................ 6D-10 ............... 6D-12 ................6D-14 ................6D-14 ................6D-15 ................6D-15 ................6D-16 ................6D-16 ................6D-16 ................6D-19 ................6D-19 ................6D-19 ................6D-19 ................6D-19 ................6D-22 ................6D-22 ................6D-24 ................6D-27 ................6D-27 ................6D-27 ................6D-27 ................6D-27 ................6D-28 ................6D-28 ................6D-28 ................6D-33 ................6D-33 ................6D-33 .................. 6 D -3 3 ................6D-35 ................6D-35 ................6D-36 ................6D-36 ................6D-36 ................6D-39 6D-2 ENGINE ELECTRICAL t CONTENTS (Contd.) SUBJECT PAGE Ignition System On-Vehicle S ervice................................................................................................................... 6D-40 Service Precautions...........................................................................................................................................6D-40 Distributor Replacement...................................................................................................................................6D-41 Ignition Timing...................................................................................................................................................6D-41 Spark Plug W ires...............................................................................................................................................6D-42 Spark Plug Wire Replacement......................................................................................................................... 6D-42 Engine Wire Harness............................................................................................................................................ 6D-52 Specifications......................................................................................................................................................6D-77 Special T o o ls ......................................................................................................................................................6D-80 ELEC TRIC A L SY ST E M Engine electrical system diagnosis includes the battery, charging system (generator and related wiring), cranking system (starter and related wiring), ignition system (dis­ tributor, spark plugs and wiring) and the glow plug system (diesel electrical). Light duty emission vehicles are equipped with an elec­ tronic computer comm and control system. These vehicles have a “ Check Engine” or “ Service Engine Soon” lamp on the instrum ent panel. Refer to the Fuel and Emissions Service Manual for a detailed description of the lam p’s operation and use as a diagnostic indicator. Some vehicles sold in Canada may have variations in electrical components. Refer to the appropriate Canadian Service Manual Supplement. BA T T ER Y gasses that are produced in the battery to escape. The special chem ical composition inside the battery reduces gassing to a very small am ount at normal charging voltages. Besides reducing gassing, the special chem istry greatly reduces the possibility of overcharge damage. Keep the battery in an upright position to prevent electrolyte leakage. Tipping the battery beyond a 45 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 Figure 1—Sealed Battery with Side Terminals DESCRIPTION The battery has three m ajor functions in the electrical system: first, it provides a source of energy for cranking the engine; second, it acts as a voltage stabilizer for the electrical system; and third, it can, for a limited time, provide energy when the electrical load used exceeds the output of the generator. The sealed battery as shown in figure 1 is standard. Water never needs to be added. There are no filler caps in the cover. The battery is sealed, except for small vent holes in the cover. The vents allow what small amount of Batteries are rated according to their reserve capacity in minutes and their cold cranking power in amperes. Both methods involve m easuring the battery term inal voltage after a specified tim e period and discharge current. The “ reserve capacity” is defined as the maximum length of tim e it is possible to travel at night with m inimum electrical load and no generator output. Expressed in minutes, it is the tim e required for a fully charged 12 -volt battery, at a te m p e ra tu re of 2 7 ° C (8 0 ° F), being discharged at a constant current of 25 amperes, to reach a term inal 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. Refer to “ Specifications” at the end of this section for battery ratings. ENGINE ELECTRICAL 6D-3 battery, normal wearout, or overcharging because of a problem in the electrical system. C heck the system and replace the battery. o & <$> GENERAL INFORMATION COMMON CAUSES OF MALFUNCTION A 2. 3. 4. A. B. C. B Green Dot Dark C lear 65% o r Above S tate o f Charge B elow 65% S tate o f Charge Low Level E le ctro lyte B-06941 Figure 2—Built-In Hydrometer BUILT-IN HYDROMETER T he s e a le d b a tte ry has a s p e c ia l te m p e ra tu re compensated hydrometer built into the cover to show at a glance the battery’s state-of-charge. The hydrometer has a green ball within a cage which is attached to a clear plastic rod. The green ball will float at a predetermined specific gravity of the electrolyte. When the green ball floats, it rises within the cage and positions itself under the rod. Visually a green dot then shows in the center of the h ydrom eter (figure 2 ). The b uilt-in h ydrom eter provides a guide for battery testing and charging. When looking at the hydrometer, make sure that the battery has a clean top. A lamp may be needed in some poorly-lit areas. 1. GREEN DOT VISIBLE: The state of charge is 65 percent or more of the full charge. 2. DARK; GREEN DOT NOT VISIBLE: The state of charge is below 65 percent. Charge the battery until the green dot appears. (Shake the battery slightly to make the green dot appear after charging). 3. CLEAR OR LIGHT YELLOW: The fluid level has dropped below the bottom of the hydrometer. This can be caused by a broken case, tipping of the If testing shows the battery to be in good condition but the battery doesn’t perform satisfactorily, check for the following: 1 . Vehicle accessories left on overnight. 2. Extended slow-speed driving with many accessories turned on. 3. The v e h ic le e le c tric a l load is m ore th a n the generator output, particularly with the addition of aftermarket equipment. 4. Problems in the charging system such as shorts, slipping fan belt, or worn generator or regulator parts. 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 v e h ic le is p a rke d fo r a long p e rio d of tim e . Disconnect the negative cable if the vehicle will be stored for more than 30 days. Electrolyte Freezing The freezing point of electrolyte depends on its specific gravity. Since freezing may ruin a battery, protect it against freezing by keeping it in a charged condition. Carrier And Hold-Down The carrier and hold-down should be clean and free from corrosion before battery installation. The carrier should be in a sound mechanical condition so that it will support the battery securely and keep it level. Make certain there are no foreign objects in the carrier before installation. To prevent the battery from shaking in its carrier, tighten the hold-down bolts. However, do not tighten the bolts to where the battery case or cover is placed under a severe strain. 6D-4 ENGINE ELECTRICAL DIAGNOSIS OF BATTERY 7 7. C ase 8 . 3/8 -in ch 16 U N C N u t 9. 3/8 -in ch 16 U N C B o lt 10. E le c tric a l C o n ta c t B-09715 Figure 3—Testing and Charging Terminal Adapter In a diesel-equipped vehicle, check and test each bat­ tery separately. VISUAL INSPECTION Check for obvious damage such as a cracked or broken case or cover that could permit loss of electrolyte. If damaged, replace the battery. Determine the cause of the damage and correct. HYDROMETER TEST GREEN DOT VISIBLE: If the hydrometer has a GREEN DOT visible the battery is ready for testing. Proceed to “ Load Test” . DARK; GREEN DOT NOT VISIBLE: Charge the battery as o u tlin e d u n d e r the h e a d in g “ B a tte ry C h a rg in g Procedure” later in this section. LIGHT OR BRIGHT INDICATOR: Do not charge, test, or jump start the battery. Replace the battery. Figure 4—Testing and Charging Using Bolt and Nut Side Terminal Batteries: 3. If adapters are not available, use a 3/s-inch 16 UNC bolt and stainless steel nut (figure 4). Finger tighten. Contact must be made through the lead pads at the face of the terminals, not through the threads of the bolt. Top Terminal Batteries: 4. Attach term inal hex nuts, AC Delco # 7802, or equivalent (figure 5). 5. Attach the alligator clam ps of the tester or charger between the term inal nuts and the load pads of the term inal studs (figure 5). • If the te ste r c la m p s ca n n o t be atta che d between the nuts and the lead pads of the terminals, the ampere load for the load test may change. Refer to “ Specifications” at the end of this section. 6 . Install a voltmeter and battery load tester to the adapters. LOAD TEST If the battery is in the vehicle, make sure the engine control switch is off. If there is more than one battery, check each separately. 1 . Disconnect the battery cables from the terminals. 2 . Install adapter AC-Delco ST 1201 or equivalent (figure 3). 7. Remove the surface charge from recently charged batteries by applying a 300-ampere load across the adapters for 15 seconds. 8 . Do not remove the surface charge from batteries which have been in storage. 9. Turn the load off and wait 15 seconds for the battery to recover. ENGINE ELECTRICAL 6D-5 10. Apply the specified load selected from the chart in “ Specifications” . Observe the battery voltage after 15 seconds with the load connected, then turn off the load. 11. 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 m inim um voltage listed, replace the battery. Voltage And Temperature Chart MINIMUM VOLTAGE TEMPERATURE 21 ° C (70° F & A b o v e )....................................................... 9.6 10° C (50° F).........................................................................9.4 - 1 ° C (30° F ) ...................................................................... 9.1 -1 0 ° C (15° F )...................................................................... 8.8 -1 8 ° C (0° F).........................................................................8.5 Figure 5—Testing and Charging Using Top Terminal Adapter BATTERY ON-VEHICLE SERVICE BATTERY CHARGING PROCEDURES The following basic rules apply to any sealed battery charging situation: 1. Do not charge a battery if the hydrometer is clear or light yellow— replace the battery. 2. C harge rates betw een 3 and 50 am peres are satisfactory as long as spewing of electrolyte does not occur or the battery does not feel over 52° C, (125° F). If spewing occurs or temperature exceeds 5 2° C (125° F), the charging rate must be reduced or temporarily halted to permit cooling. Estimate battery temperature by touching or feeling the battery case. 3. The battery is sufficiently charged when the green dot in the built-in hydrometer is visible. No further charging is required. Shake or tilt the batter at h o u rly in te rv a ls d u rin g c h a rg in g to m ix th e electrolyte and see if the green dot appears. 4. Battery charging consists of a charge current in amperes for a period of time in hours. Thus a 25-ampere charging rate for 2 hours would be 50 ampere-hour charge to the battery. In most cases, batteries whose load test values are less than 2 0 0 amperes will have the green dot visible after at least a 50 ampere-hour charge. Most batteries whose load test values are greater than 2 0 0 amperes will have the green dot visible after at least a 75 ampere-hour charge. In the event that the green dot does not appear after this amount of charging, c o n tin u e c h a rg in g fo r a n o th e r 50 o r 75 ampere-hours. If the green dot still does not appear, replace the battery. 5. The time required for a charge will vary according to: a. Size of battery — Example: A discharged large heavy-duty battery requires more than twice the recharging as a discharged small passenger car battery. b. Temperature — Example: A longer time will be needed to charge any battery at -1 8 ° C (0° F) than at 27° C (80° F). When a fast charger is connected to a cold battery, the cu rre n t accepted by the battery will be very low at first; then, as the battery warms, it will accept a higher rate. c. State-of-charge — Example: A discharged battery requires more than twice as much c h a rg e as a o n e -h a lf-c h a rg e d b a tte ry . Because the electrolyte is nearly pure water and therefore a poor conductor, the current accepted is low at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current will likewise increase. d. C harger C apacity — Exam ple: A charger which can supply only 5 amperes will require a much longer period of charging than a charger that can supply 30 amperes or more. CURRENT DRAIN TEST If a battery needs recharging and no cause is evident, check the vehicle for excessive current drain. Remove or Disconnect Negative battery cable (both negative cables on diesels). 6D-6 ENGINE ELECTRICAL CAUTION: To prevent possible personal injury from a moving vehicle or operating engine do the following before performing the checks: 1. Engage the parking brakes and block the wheels. 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 transmission in park. 3. On gas engines disconnect the battery feed at the distributor. On diesel engines disconnect the battery feed at the engine shutoff (ESO) solenoid. 1 . Check the voltage drop between ground (negative 11 . Positive Battery Cable C onnected 12 . B a tte ry (D is c o n n e c t N e g a tiv e C ab le 13. 14. 15. 16. From O ther B attery On Diesel Vehicles) M u ltim e te r J-34029-A Equivalent Set On DC, MA and 2000 Scale M eter Test Leads End of Negative B attery Cable Jum per W ires B-07712 Figure 6—Battery Drain Test Circuit -►+ Install or Connect 2. 4. 6. 7. Tool Required: J-34029-A Multimeter. B attery side te rm in a l a dapter in the negative terminal or nut and bolt as described earlier in this section. A 3/s-inch 16 UNC nut on the negative battery cable terminal attaching screw. Clip of a jum per wire to the negative battery terminal adapter (figure 6 ). Clip at the other end of the jum per wire to digital multim eter J-34029-A or equivalent. Clip from the second jum per wire to the end of the negative battery cable. Clip at the other end of the wire to the multimeter. • Set the m ultim eter on the DC, MA and 2000 scale. • Take the reading w ith the engine control switch and all accessories off. If current draw is more than 50 milliamps, check the system for causes such as a shorted wire or a com partm ent lamp that does not shut off when it should. BATTERY CABLES E x c e s s iv e re s is ta n c e c a u s e d by p o o r te rm in a l connections and partial short circuits through worn cable insulation will result in an abnormal voltage drop in the starter cable. Low voltage at the starter will prevent normal starter operation and cause hard starting. battery terminal) and the vehicle frame. Place one prod of the test voltmeter on the grounded battery post (not on the cable clam p) and the other on the frame. Operate the starter and note the voltage reading. 2 . Check the voltage drop between the positive battery term inal and starter te rm ina l stud w ith 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 e lim in a te resistance, the c a b le s sh ou ld be disconnected and connections cleaned. If cables are frayed or the clam ps 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. B attery flu id is hig hly acidic. Avoid sp illin g on clothing or skin. Any spilled electrolyte should be flushed with large quantities of water and cleaned immediately. Remove or Disconnect 1. N e g a tiv e term inal. c a b le fro m th e n e g a tiv e b a tte r y 2. Positive cable from the positive battery term inal. 3. B attery hold-dow n clam p. 4. Battery. L * Inspect 1. B attery for dam age. 2. C ables and connectors. 3. C arrie r for dam age or fo re ign objects. 0 • If damage is noted, find and correct the cause. Install or Connect 1. B attery into cleaned carrier. 2. H old-dow n retainer or top bar, as e quipped. ENGINE ELECTRICAL 6D-7 Tighten Tighten 1. R etainer to 17 N m (13 ft. lbs.). 2. Top bar to 3.5 N-m (30 in. lbs.) on batteries w ith side term inals. 3. Top bar to 6.8 N-m (60 in. lbs.) on batteries w ith top term inals. 3. Battery terminals. • Top te rm in a ls to 17 N-m (13 ft. lbs.). • Side te rm in a ls to 15 N-m (11 ft. lbs. 4. Positive cable to the positive terminal. 5. Negative cable to the negative terminal. CHARGING SYSTEM 54 51. 52. 53. 54. BAT Term inal N o. 1 T erm inal N o. 2 Term inal F ie ld G ro u n d H o le F-00013 51. 52. 53. 54. “ BAT” T erm inal No. 1 T erm inal No. 2 T erm inal F ie ld G ro u n d H o le F-02518 Figure 7—12-SI Series 100 Generator Figure 8—17-SI Series 100 Generator DESCRIPTION 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 charging system consists of the battery, the g en erator, th e regulator, and th e ch a rg in g system indicator lamp circuitry. The generator supplies electrical power for charging the battery and operating accessories. Two types of generators are used on these vehicles, the SI generator with an external 2 -terminal connector on the re g ula tor, and the CS g e n e ra to r w ith an e x te rn a l 4-terminal connector on the regulator. The diagnostic tests for these generators are different. 12-SI 100 AND 17-SI 100 GENERATORS (Figures 7, 8 and 9) These generators are of the “ Systems Integral” series (generator with built-in regulator). The solid state regulator 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 stator w indings are assembled on the inside of a laminated core that forms part of the generator frame. T he 12-SI has a “ Y ” s ta to r and the 17-SI has a delta-wound stator. A rectifier bridge connected to the stator w indings contains six diodes, and electrically changes the stator AC voltages to a DC voltage which appears at the generator output (BAT) terminal. Generator field current is supplied thorugh a diode trio which also is c o n n e c te d to th e s ta to r w in d in g s . A c a p a c ito r or condenser, m ounted 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 is required on the entire generator assembly. 6D-8 ENGINE ELECTRICAL to the field coil, then through the wire at term inal number 1 to the charge indicator lamp. The lamp goes out since approximately the same voltage is present at both sides of the lamp. On vehicles with gages a voltmeter indicates voltage. CS-130 GENERATORS (Figures 10, 11 and 12) CIRCUIT OPERATION When the engine control switch is turned to “ Run” or “ S tart” , the switch closes and current from the battery flows through the charging system indicator lamp, the number 1 term inal, 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. W ith the generator o perating, direct cu rren t (DC) voltage is applied to the battery through the “ BAT” terminal. Some of the output flows through the diode trio 51. BAT T erm in al 55. T e rm in a ls P, L, I, S Figure 10—CS-130 Generator F-02516 These generators feature a high ampere output per pound of weight. The CS stands for charging system and 130 is the measurement in m illim eters of the outside diameter of the stator laminations. This generator with integral regulator does not have a diode trio. The delta stator, rectifier bridge, and rotor with slip rings and brushes are electrically sim ilar to other generators. A conventional fan and pulley are used, and an internal fan cools the slip rings, end frame, rectifier bridge and regulator. The charge indicator lights when the engine control switch is closed, and goes out when the engine is running. If the charge indicator is on with the engine running, a charging system problem is indicated. The indicator will glow at full brilliance, not half lit, if any charging problem occurs or if the system voltage is too high or too low. The regulator voltage setting varies with temperature, and limits system voltage by controlling rotor field current. It sw itches rotor field current on and off at a fixed frequency of about 400 cycles per second. By varying the on-off time, correct average field current for proper system voltage control is obtained. At high speeds, the on-time may be 10 percent and the off-time 90 percent. At low speeds, with high electrical loads, on-off tim e may be 90 percent and 10 percent respectively. The regulator has four terminals, “ P,” “ L,” “ I,” and “ S” (figure 12). The use of the “ P,” “ L ,” and “ S” term inals is optional. The “ P” term inal is connected to the stator, and may be wired to a tachometer or other device. The “ S” term inal may be wired to the battery to sense voltage to be controlled. The “ L” and “ I” term inals serve to turn on the regulator and allow field current to flow when the switch is closed. The “ I” term inal may be connected directly to the switch, or through a resistor. Both are illustrated. The “ I” circuit may be used with or w ithout the “ L” circuit; that is, with or w ithout anything connected to the “ L” circuit. Refer to the Light Duty Truck W iring Diagrams for specific application. The generator is not serviceable, and no periodic maintenance is required. ENGINE ELECTRICAL 6D-9 57. 58. 60. 64. 67. Rotor Stator R ectifie r Bridge R egulator Double Sealed Ball Bearing 68. Terminals 69. Internal Fan 60 69 F-01361 Figure 11—CS Series Generator -AAA,---------- -9- -i €? zA <> i i -w- i_______ \ [ ___________________j rh I________________________ _ F-02515 Figure 12—CS Generator Schematic 6D-10 ENGINE ELECTRICAL DIAGNOSIS OF CHARGING SYSTEM NOISY GENERATOR Noise from a generator may be caused by a loose drive pulley, loose mounting bolts, worn or dirty bearings, worn diode or stator. If the pulley and mounting bolts are snug and the noise continues, remove the generator for inspection and repair. Refer to “ Generator Replacem ent” later in this section. ELECTRICAL TESTS Before performing the diagnosis procedures on the vehicle, be certain that the system wiring is good and the generator belt is not slipping. Also, the battery must be fully charged for a valid test of the charging system. NO TICE: To a vo id dam age to the vehicle e le c tr ic a l s y s te m , o b s e rv e the fo llo w in g precautions: • Do not polarize the generator. • Do not short across or ground any o f the terminals in the charging circuit except as specifically instructed herein. • NEVER o p era te the g en e rato r with the output terminal open-circuited. • Make sure the generator and battery have the same ground polarity. • When c on nectin g a charger or booster battery to the vehicle battery, con nect n e g a tiv e to n e g a tiv e a n d p o s itiv e to positive. Trouble in the charging system will show up as one or more of the following conditions: 1. On vehicles w ithout gages, unusual operation of the charging indicator lamp. 2. An u n d e rc h a rg e d b a tte ry, in d ic a te d cranking or a dark battery hydrometer. by slow 3. An overcharged battery, indicated by spewing of electrolyte from the vents. SI CHARGING SYSTEM CHARGING SYSTEM INDICATOR LAMP OPERATION Check the indicator lamp for normal operation in the “ C ha rg ing System D ia g n o s is ,” (figure 13). If lam p operation is normal, proceed to “ Undercharged Battery” . UNDERCHARGED BATTERY Slow cranking or a dark battery hydrometer can be caused by one or more of the following conditions even though the indicator lamp may be operating normally. The following procedures also apply to vehicles equipped with a voltmeter. 1 . Check that the undercharged condition has not been caused by accessories having been left on for extended periods. 2. Check the drive belt for proper tension. Refer to E N G IN E C O O L IN G (SEC . 6 B) fo r b e lt specifications. 3. If you suspenct the battery is bad, do a load test. Refer to “ Battery” earlier in this section. 4. Inspect the wiring for cracks or breaks. Check all c irc u it co nn ectio ns, ca ble clam ps and b attery term inals for tightness and cleanliness. 5. With the engine control switch on and all wiring harness leads connected, use a voltmeter for the following checks: + 4- Install or Connect (Figures 7 and 8) 1. V o ltm e te r fro m th e g e n e r a to r b a tte r y te rm ina l to ground. • Should read 12 volts. 2. Voltm eter from the num ber 1 term inal to ground. • Should read one volt or more. 3. Voltm eter from the num ber 2 te rm ina l to ground. • Should read 12 volts. A zero reading on any of the above indicates an open between the voltmeter connection and the battery. If checks 1 through 5 are normal perform the generator output test. OVERCHARGED BATTERY If the battery feels hot, is spewing electrolyte, or lamps seem too b rig h t w hen tu rn e d on, an o v e rch a rg e d condition may exist. To check the voltage, install a voltmeter across the battery. Run the engine at m oderate speed with all accessories off. If the voltage reads 15.5 or more, remove the generator for repair. GENERATOR OUTPUT TEST (Figure 14) 1. Disconnect the battery ground cable. 2. Connect an ammeter in the circuit at the battery terminal of the generator. 3. Reconnect battery ground cable. 4. Turn on the radio, w indshield wipers, headlamps (high beam) and blower motor high speed. 5. Connect a carbon pile across the battery. 6 . Run the engine at moderate speed (about 2,000 rpm) and adjust the carbon pile to obtain maximum current output. 7. If the ampere output is within 10 amperes of the rated ouput as stamped on the generator frame, the generator is probably all right. 8 . If the vehicle is equipped with a charging system indicator lamp, and the lamp remains on while the engine runs, and ampere output is normal, remove the generator for repair. Check the diode trio and rectifier bridge. 9. If the ampere output is not within 10 percent of the rated ouput in amperes, see if the test hole is accessible (figure 15). If it is not accessible go to step 14. 10. Ground the field winding by inserting a screwdriver into the test hole. CHARGING SYSTEM INDICATOR LAMP OPERATION E ngine R unning E n g in e C o n tro l S w itc h ON TEST NO. 1 Lamp O ff NORMAL See Test 2 Lam p On NORM AL See Test 3 La m p O n C o n n e ct v o ltm e te r to BAT. te rm in a l on g e n e ra to r and c h a s s is gro un d. Turn ig n itio n key on. Figure 13—Charging System Battery voltage Engine S to p p e d E n g in e C o n tr o l S w itc h O N TEST NO. 2 C heck 10 amp. “ G AG ES” “ TR AN S.” fuse in fuse block C h eck drive b e lt and w irin g c o n n e c tio n s at g e n e ra to r and b a tte ry cables. D is c o n n e c t No. 1 and No. 2 c o n n e c to r at generator. C o n n e c t vo ltm e te r from No. 1 c o n n e c to r to ch a ssis ground. A p p ro x im a te ly 2 to 4 v o lts Zero volta ge ± R epair open c irc u it in No. 1 w ire fro m c o n n e c to r to e n g in e c o n tro l * lf b a tte ry is fu lly charged, use the s ta rte r to p a rtia lly d isch a rg e it before re co rd in g m a xim u m cu rre n t o u tp u t. |L a m p O f? D is c o n n e c t b a tte ry g ro u n d strap. D is c o n n e c t w ire fro m BAT. te rm in a l on generator. C o n n e c t a m m e te r b la ck lead to BAT. te rm in a l w ire s and red lead to BAT. te rm in a l. C o n n e ct b a tte ry gro u n d strap. T urn o n a ll a c c e s s o rie s , la m p s o n h igh beam , and b lo w e r on h igh speed. Run e n g in e as req uire d to o b ta in m a xim u m c u rre n t o u tp u t and record a m m e te r re a d in g .* If th e in d ic a to r la m p o p e ra tio n is norm al fo r all three te sts, refer to SI g e n e ra to r d ia g n o s is D is c o n n e c t No. 1 and 2 c o n n e c to r at ge ne rator. C h eck 10 amp. “ GAGES” “ T R A N S .” fu se in fu se b lo c k } {L a m p O ff I Lam p On Lam p On C h eck b a tte ry c o n n e c tio n s and battery c o n d itio n . 1. L a m p b u rn e d o u t. 2. O pen in No. 1 w ire from g e n e r a to r to e n g in e c o n tr o l s w itc h . 1. C o n n e c t No. 1 and No. 2 c o n n e c to r to generator. 2. In se rt s c re w d riv e r in to te s t h o le to gro u n d ro to r w in d in g . Lam p On | L a m p O fT I R e p la c e r e g u la to r R epair sh o rt betw een No. 1 and 2 w ire s in harness. R e p la c e r e c t if ie r b r id g e in g e n e r a to r SWITCH ENGINE LAM P OFF ON ON STOPPED STOPPED R U N N IN G O FF ON O FF N O R M A L LA M P O P E R A T IO N O u tp u t w ith in 10 am ps of rated o u t­ put s ta m p e d on g e ne rator fram e. o CO CO R eplace re g u la to r O u tp u t NOT w ith in 10 am ps o f rated o u tp u t sta m p e d on g e n e ra to r fram e. In s e rt s c re w d riv e r in to te st hole. End o f s c re w d riv e r m u st to u c h ta b and sid e o f s c re w d riv e r g ro un d a g a in st end fram e. Run e n g in e as be fore and re ch e ck o u tp u t. O u tp u t NOT w ith in 10 am ps o f rated o u tp u t s ta m p e d on g e n e ra to r fram e. Make sure No. 1 w ire c o n n e c to r is m aking good c o n ta c t on te rm in a l. D isa sse m b le g e n e ra to r and ch e c k brushes, s lip rin g s and ro to r w in d in g fo r open. Rem ove generator. R efer to g e n e r a to r d is a s s e m b ly . 6D-11 CD L a m p O ff] I X O u tp u t w ith in 10 am ps o f rated o u t­ p ut sta m p e d on ge n e ra to r fram e. NORMAL Lam p On ENGINE ELECTRICAL Diagnosis s w itc h . R e pa ir open c irc u it betw een BAT te rm in a l on g e n e ra to r and ju n c tio n b lo c k o r battery. Install No. 1 and 2 co n n e cto r. I L a m p O ff NORM AL D is c o n n e c t No. 1 and 2 c o n n e c to r at generator. G roun d No. 1 w ire. Do NOT gro u n d No. 2 w ire. Z e ro v o lta g e I Lam p On DIM E n g in e C o n tr o l S w itc h O F F TEST NO. 3 6D-12 ENGINE ELECTRICAL 6 6 . B a tte ry 54. F ie ld G ro u n d 73. Tab A. In s e rt screw driver, g ro u n d ta b to end fram e. 70. G e n e ra to r 71. C arbo n Pile 72. A m m e te r F-00010 Figure 14—Connections for Generator Output Test NOTICE: The tab is within 19 mm (3M inch) of th e c a s tin g s u r fa c e . Do n o t fo rc e th e screwdriver deeper than 25 mm (1 inch) into the end frame or the generator may be damaged. 11. Run the engine at moderate speed and adjust the carbon pile to get maximum current ouput. 12. If the output is within 10 amperes of the rated ouput, remove the generator for repair. Refer to the Light Duty Truck Unit Repair Manual to check the field winding and regulator. 13. If the output is not within 10 amperes of rated output, remove the generator and check the field winding, diode trio, rectifier bridge and stator. 14. If the test hole is not accessible, rem ove the generator for repair. GENERATOR DIAGNOSTIC TESTER INDICATIONS If a tester is available, check the generator following the tester m anufacturer’s instructions. It will indicate about 98 percent of the charging system problems. F-00011 Figure 15—Generator Field Ground Tab TRANSISTORIZED VOLTAGE REGULATOR TEST Connect a fast charger and a voltmeter to the battery as shown in figure 16. With the engine control switch on “ run” and the engine off, slowly increase the charge rate. The charging system indicator lamp (on vehicles without 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. CS-130 CHARGING SYSTEM CIRCUIT DIAGNOSIS Trouble in the charging system will show up as one or more of the following conditions: • Abnormal indicator lamp operation. • An undercharged battery as evidenced by slow cranking or dark hydrometer. • An overcharged battery as evidenced by excessive spewing of electrolyte from the vents. ENGINE ELECTRICAL 6D-13 A basic wiring diagram for the charging system is shown in fig ure 12. W hen the system is operating normally, the indicator lamp (on vehicles so equipped) will come on when the engine control switch is turned on and go out when the engine starts. If the lamp operates abnormally, or if an undercharged or overcharged battery condition occurs, the following procedure may be used to d ia gn ose the c h a rg in g system . R em em ber th a t an undercharged battery is often caused by accessories being left on overnight, or by a switch stuck closed which allows a lamp, such as a trunk or glove box lamp, to stay on. This generator does not have a test hole. DIAGNOSTIC TEST FOR CS-130 1. Check belt for wear and tension. Refer to ENGINE COOLING (SEC. 6 B) for belt tension. Check wiring. 2. Go to Step 5 for vehicles without a charge indicator lamp. 3. With the engine control switch on and the engine stopped, the lamp should be on. If not, detach the wiring harness at the generator and ground the “ L” terminal lead. • If the lamp lights, replace the generator. 74. Fast Charger 75. V oltm eter 66. Battery F-00012 Figure 16—On-Vehicie Regulator Test • If the lamp does not light, locate the open circuit between the grounding lead and the engine control switch. The lamp may be open. 4. W ith the switch on, and the engine running at moderate speed, the lamp should be off. If not, detach the wiring harness at the generator. • If the lamp goes out, replace the generator. • If the lamp stays on, check for a grounded “ L” term inal wire in the harness. 5. If the battery is undercharged or overcharged: • Detach the wiring harness connector from the generator. • With the switch on the engine not running, connect a voltmeter from ground to the “ L” terminal in the wiring harness, and to the “ I” term inal, if used. The wiring harness may connect to either “ I” or to both. • A zero reading ind icate s an open c irc u it between the term inal and the battery. Correct as required. • C o n n e c t th e h a rn e s s c o n n e c to r to th e generator and run the engine at moderate speed with accessories off. • Measure the voltage across the battery. If above 16 volts, replace the generator. 66. 70. 71. 72. 75. 77. A. Battery Generator Carbon Pile A m m eter V oltm eter R esistor C onnect R esistor to “ L” Terminal • Connect an ammeter at the generator output terminal, turn on the accessories and load the battery with a carbon pile to obtain maximum amperage. M aintain voltage at 13 volts or above. F-02514 Figure 17—Connections for Generator Output Test — If the output is within 15 amperes of the rated output, the generator is OK. (Refer to “ Specifications” at the end of this section.) — If the output is not within 15 amperes of the rated output, replace the generator. 6D-14 ENGINE ELECTRICAL GENEATOR BENCH CHECK 1 . Make connections as shown in figure 17, except leave the carbon pile disconnected. The ground polarity of the generator and battery must be the same. The battery must be fully charged. Use a 30 to 500 ohm resistor between the battery and the “ L” terminal. 2. Slowly increase generator speed and observe the voltage. 3. If the voltage is uncontrolled and increases above 16 volts, the rotor field is shorted, the regulator is not working properly, or both. A shorted rotor field coil can cause problems in the regulator. 4. If the voltage is below 16 volts, increase speed and adjust the carbon pile to obtain maximum amperage output. Maintain the voltage above 13 volts. 5. If the output is within 15 amperes of the rated output, the generator is good. 6 . If the output is not within 15 amperes of the rated output, replace the generator. GENERATOR ON-VEHICLE SERVICE GENERATOR REPLACEMENT The removal and installation instructions serve only as a guide. Additional operations may be required on some vehicles to remove other equipm ent to gain access to the generator, drive belts and brackets. CAUTION: Failure to observe Step 1 in this procedure may result in an injury from the hot battery lead at the generator. 0 +2 Remove or Disconnect 1. N egative battery cable at the battery. 2 . Term inal plug and battery lead from the back of the generator. • Loosen the upper m ou ntin g/ad ju stin g bolt on the generator m ounting. • Loosen the belt te nsio ne r (serpentine belt only). 3. Drive belt. 4. Lower m ounting bolt. 0 U pper m ounting bolt. Generator. Install or Connect G enerator to the top bracket w ith the bolt. • Do not tighten. Lower mounting bolt to the bracket. Generator drive belt. • Low er m o u n tin g b o lt. R e fe r to “ S p e c ific a tio n s ” at th e end of this section. • D rive b elt. R efer to E N G IN E C O O L IN G (SEC. 6 B) for belt specificatio ns. • U pper generator m ou ntin g bolt. R efer to “ S p e cifica tio n s” at th e end of th is section. 5. Terminal plug and battery lead to the back of the generator. 6 . Negative battery cable to the battery. Refer to the Light Duty Truck Unit Repair Manual for off-vehicle service. ENGINE ELECTRICAL 6D-15 DIESEL GLOW PLUG ELECTRICAL SYSTEM 630. 640. 641. 642. 643. G low Plug Fuel In je c to r C ylinder Head Pre C o m b u stio n C ham ber Heated Sheath F-00229 F-00228 Figure 18—Diesel Engine Glow Plug Location 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 18). T h e d ie s e l g lo w p lu g s y s te m c o n s is ts o f an intergral-electronic co ntrol/g low plug relay assem bly, 6 -volt glow plugs, a glow plug inhibit temperature switch and a “ GLOW PLUGS” lamp. Figure 19—Glow Plug Controller ELECTRONIC CONTROLLER/GLOW PLUG RELAY ASSEMBLY (Figures 19 and 20) The assembly contains the circuitry which monitors and controls glow plug relay operation. Information is received at pins B and C which is used by the controller to determ ine glow plug ope ra ting requirem ents. Pin B senses voltage at the starting 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. GLOW PLUG INHIBIT SWITCH 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 autom atically turn off. 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 on the P truck and G van, and in the water crossover near the front of the engine on the RV truck. INSTRUMENTATION CIRCUIT OPERATION V e h ic le s w ith th e d ie s e l e n g in e have s p e c ia l instrum entation indicators to p erm it the operator to properly apply the starting procedure. A “ GLOW PLUGS” lamp on the instrument panel provides this information on engine starting conditions. Vehicles equipped with diesel engines have a “ WATER IN FUEL” lamp and "LOW COOLANT” lamp. Refer to the engine fuel and engine cooling sections for information on these systems. A normal functioning system operates as follows: A. K ey on - E n g in e n o t ru n n in g a n d a t 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 ON/4.5 OFF, for a total duration (including the initial 4 to 6 seconds) of about 20 seconds. 6D-16 ENGINE ELECTRICAL 639 626. 627. 628. 629. 630. 631. 632. 633. 634. 635. 636. 637. B a tte ry Feed 5/ie -ln c h O u te r D ia m e te r S tu d s G lo w Plug C o n tro lle r G lo w P lug Feed G lo w P lu g s (6 Volt) G lo w P lu g s Lam p G lo w P lug In h ib it Tem perature S w itc h S ta rte r S o le n o id E n gin e C ra n k in g S ense In p u t (Purple) G lo w P lug V o lta g e S ense In p u t (Yellow o r Blue) E n gin e C o n tro l (Pink) G rou nd (B lack) 630 638. E n gin e C o n tro l S w itc h 639. B a tte ry F-02513 Figure 20—Electronic Glow Plug System 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 tim es shown above are approximate because they vary with initial engine temperature. The initial ON time and cycling ON/OFF tim es vary also with system voltage and/or temperature. Lower temperatures cause longer duration of cycling. DIAGNOSIS OF GLOW PLUG ELECTRICAL SYSTEM CIRCUIT CHECK If the system does not operate as described, check the following: I? 5. Temperature switch connector at top rear right cylinder head on the P and G truck, and in the water crossover near the front of the engine on the RV truck. 6 . “ GLOW PLUG” lamp on instrum ent panel for tight Inspect connection and operation. 1. All connectors. GLOW PLUG INHIBIT SWITCH 2. Engine harness ground connection to the engine. $ Tighten • N ut to 11 N m (8 ft. lbs.). 3. Four-wire connector at controller. It must be fully seated and latched. 4. Both controller copper stud upper nuts. Check the temperature-controlled switch to make sure it is c lo s e d at low te m p e ra tu re s and open at hig h temperatures. 1. Remove the connector from the inhibit switch when the engine temperature is below 38°C (100°F). 2 . Set th e Tighten • Nuts to 5 N-m (48 in. lbs.) • Do not tighten lower nuts. o h m m e te r on a low ran ge or use a self-powered test lamp. 3. Test across the terminals. 4. The switch should be closed (test lamp on or a reading of less than 0.1 ohm on the meter). ENGINE ELECTRICAL 6D-17 G-VAN 50 MIN. CONNECT AN AMMETER IN SERIES (INDUCTION TYPE METER MAY ALSO BE USED)* WITH RED OR ORANGE WIRE LEADING FROM THE TOP OF THE CONTROLLER TO THE LEFT BANK OF GLOW PLUGS. OPERATE THE SYSTEM AND NOTE THE AMMETER READ­ ING. REPEAT THE PROCEDURE FOR THE RED OR ORANGE WIRE LEADING FROM THE TOP OF THE CONTROLLER TO THE RIGHT BANK OF THE GLOW PLUGS. OPERATE THE SYSTEM AND NOTE THE READING. I VEHICLE MODEL NORMAL AMP READINGS R.V.P 55 MIN LEFT BANK AMMETER READING LESS THAN NORMAL ONE OR MORE GLOW PLUGS ON LEFT BANK NOT OPERATIVE. CHECK INDIVID­ UAL GLOW PLUG LEADS BY CONNECT­ ING AMMETER IN SERIES WITH GREEN WIRE THAT FEEDS GLOW PLUG. OPER­ ATE THE SYSTEM AND NOTE THE READING ON AMMETER. REPEAT PRO­ CEDURE FOR EACH GLOW PLUG. EACH INDIVIDUAL WIRE SHOULD HAVE A READING OF APPROXIMATELY: AMMETER READING NORMAL | GLOW PLUG SYSTEM OPERATING NOR­ MALLY. R, V, P = 14 am ps G VAN = 13 am ps READINGS NORMAL RIGHT BANK AMMETER READING LESS THAN NORMAL ONE OR MORE GLOW PLUGS ON RIGHT BANK NOT OPERATIVE. CHECK INDIVID­ UAL GLOW PLUG LEADS BY CONNECT­ ING AMMETER IN SERIES WITH GREEN WIRE THAT FEEDS GLOW PLUG. OPER­ ATE THE SYSTEM, NOTE THE READING ON AMMETER. REPEAT PROCEDURE FOR EACH GLOW PLUG. EACH INDIVID­ UAL WIRE SHOULD HAVE A READING OF APPROXIMATELY:__________________ READINGS LESS THAN NORMAL ON THOSE CYLINDERS WITH LESS THAN NORMAL READINGS, CHECK FOR CONTINUITY THROUGH THE HARNESS BY DISCONNECTING THE LEAD AND CONNECTING A 12-VOLT TEST LAMP FROM THE CONNECTOR TO GROUND. OPERATE THE GLOW PLUG SYSTEM. GLOW PLUGS AND HARNESS OK. | - TEST LAMP LIGHTS | HARNESS OK. REPLACE GLOW PLUG. TEST LAMP DOES NOT LIGHT WHEN GLOW PLUGS ARE OPERATING REPAIR OR REPLACE HARNESS. RE­ TEST GLOW PLUG FOR PROPER OPERA­ TION. IF USING AN IN LINE AMMETER READ BOTH BANKS AT ONCE. DO NOT CUT WIRE. SNAP-ON METER MT552, VAT-40, OR EQUIVALENT) F -0 25 1 2 Figure 21—Preliminary Diagnosis with an Ammeter 6D-18 ENGINE ELECTRICAL 6.2 LITER DIESEL ELECTRICAL SYSTEM DIAGNOSIS ENGINE DOES NOT START COLD - “ GLOW PLUGS” LAMP MAY OR MAY NOT COME ON. 1. FUEL SYSTEM CHECKED AND IS OK. 2. BATTERY VOLTAGE IS 12.4 VOLTS OR MORE WITH ENGINE CONTROL SWITCH OFF. 3. CRANKING SPEED OK (100 RPM OR MORE). 4. REFER TO ELECTRONIC GLOW PLUG SYSTEM FIGURE FOR WIRING HARNESS TERMINAL IDENTIFICATION. F-02511 Figure 22—Diesel Electrical System Diagnosis ENGINE ELECTRICAL 6D-19 5. Test term inals to ground with a test lamp or the ohmmeter on a high range. The lamp should be off or the meter show greater than 1.0 megohm. 6 . Replace the sw itch if it tests open across the term inals or if either term inal is closed to ground. 7. Disconnect the plug from the switch term inals when the engine is above 5 2° C (125° F). 8 . Set the ohmmeter on the highest scale or use a self-powered test lamp. 9. Test across the terminals. 10. Test from each teminal to ground. 11. Switch should be open (test lamp off or high ohm reading of greater than 1 megohm on the meter). 12. Replace the switch if it is closed. 13. When installing the switch, use a socket wrench. • S w itch to 23 N m (17 ft. lbs.). GLOW PLUG SYSTEM If all connections are intact, but the glow plug system does not operate as stated, do the system diagnosis shown in figure 21. It provides a fast way to find if the glow plug system is working properly. Use this procedure whenever there is doubt about correct system operation. Then refer to the diagnostic chart in figure 22 to pinpoint the condition. GLOW PLUG AFTERSTART The glow plug controller provides glow plug operation after starting a cold engine. This after-start operation is initiated when the engine control switch is returned to “ RUN” from the “ START” position. W hile loss of this function may not cause a cold start com plaint, it may result in excessive white sm oking and/or poor idle quality after start. To check for proper operation of this circuit proceed as follows: 1 . With the engine cold 2 7° C (80° F), turn the engine control switch to the RUN position and let the glow plugs cycle. 2. After 2 minutes crank the engine for 1 second. (It is not im portant that the engine starts.) Return the engine control switch to RUN. Glow plugs should cycle at least once after cranking. 3. If the plugs do not turn on, disconnect the controller connector, and c h e c k the c o n n e c to r h arne ss terminal B with a grounded 12-volt test lamp. The lamp should be off with the engine control switch in RUN, and on when the engine is cranked. 4. If the lamp does not operate as just described, repair a short or open in the engine harness purple wire. 5. If the lamp works right, but the afterstart glow plug feature does not, replace the controller. NOTICE: Do not manually bypass the relay in the glow plug controller. Do not jum p start with more than a 12-volt system. The glow plugs could be damaged. GLOW PLUG ON-VEHICLE SERVICE Check the system and its components on the vehicle. None of the components are serviceable. When install­ ing new co m p o n e n ts and m a kin g c o n n e c tio n s , be sure that connections are tight and torque values are used. Torque the glow plugs to 17 N m (12 ft. lbs.) when installed. CRANKING SYSTEM DESCRIPTION CRANKING CIRCUIT The basic cranking circuit consists of the battery, starter motor, engine control switch, neutral sensing or neutral start switch, and related electrical wiring (figure 23). STARTER MOTOR Two types of starter motors are used in the vehicles covered in this manual (figures 24 and 25). Both have the shift lever m echanism and the solenoid plunger enclosed in the drive housing to protect them from exposure to dirt, icing conditions and splash. In the basic circuit (figure 23), the solenoid w indings are energized when the switch is closed (in the “ S ta rt” position). The resulting plunger and shift lever 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 disengage. To prevent excessive overrun, open the engine control switch (release from the “ S tart” position) imm ediately when the engine starts. 6D-20 ENGINE ELECTRICAL 439 426. 427. 428. 429. 430. 431. 432. 433. 434. 440 442 B u lk h e a d C o n n e c to r To D is trib u to r “ BAT” T erm inal BAT. E n g in e C o n tro l S w itc h B a tte ry S ta rte r M o to r S h ift C o lla r P in io n C o m p re s s io n S p rin g C lu tc h 4 3 5 . F ly w h e e l 436. 437. 438. 439. 440. 441. 442. 470. P in io n S h ift Lever P lu n g e r H o ld In C o il Pull In C o il S o le n o id S o le n o id S w itc h C o n ta c ts N e u tra l S ta rt S w itc h F-02510 Figure 23—Cranking Circuit ENGINE ELECTRICAL GD-21 437. 438. 444. 446. 449. 451. — S hift Lever Plunger Bearing Grom met O verrunning C lutch Arm ature t 1 4* 444 444 449 F-00840 Figure 24—10MT Starting Motor 462 S h ift Lever O verrunning C lu tch Center Bearing Center Bearing R etaining Screw 452. C o n du cto r Banding 437. 449. 450. 451. 457. 458. 459. 460. 461. Bronze-Graphite B ushing Grease Reservoir Sealing G rom m et Sealing Washers C adm ium -C opper C ontact Disc 462. Gasket 458 457 458 452 Figure 25—27MT Starting Motor B-08267 6D-22 ENGINE ELECTRICAL DIAGNOSIS OF CRANKING SYSTEM 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 1 | : GREEN EYE SHOWING EYE DARK | jiz ix z z z CHARGE BATTERY, CHECK FOR DRAIN, AND CHECK GENERATOR. CHECK CRANKING VOLTAGE AT BATTERY POSTS. 9.6 VOLTS OR MORE LESS THAN 9.6 VOLTS TEST BATTERY; IF OK, REPAIR STARTER. CHECK VOLTAGE FROM ENGINE BLOCK TO BATTERY NEGATIVE POST, KEY IN START POSITION, VOLTMETER POSITIVE LEAD ON BLOCK. 0.5 VOLT OR MORE LESS THAN 0.5 VOLT CLEAN AND TIGHTEN GROUND CABLE CONNECTION AND/OR REPLACE CABLE. CHECK CRANKING VOLTAGE AT STARTER “ B” TERMINAL. X LESS THAN 9.0 VOLTS 9.0 VOLTS OR MORE CLEAN AND TIGHTEN POSITIVE BATTERY CABLE TERMINALS AND/OR REPLACE CABLE. REPAIR STARTER B-06799 Figure 26—Cranking System Diagnosis Refer to figures 26, 27 and 28 for a diagnosis of the cranking system. Before removing any unit in the system for repair, make the following checks. CRANKING CIRCUIT BATTERY D eterm ine the c o n d itio n of the battery. R efer to “ Battery” earlier in this section for battery diagnosis and testing. WIRING Inspect the circu it w iring for dam age. Inspect all connections to the starter motor, solenoid, engine control switch, and battery, including all ground connections. Clean and tighten all connections as required. SOLENOID AND CONTROL SWITCHES C heck all switches to determ ine th eir condition. A vehicle equipped with an automatic transm ission has a neutral start switch which allows the vehicle to be started in Park or Neutral. It is located on the steering column near the floor. A vehicle with a manual transm ission has a neutral start switch attached to the clutch. The P truck with a 7.4L engine has a m agnetic switch in the cranking circuit (figure 29). Magnetic Switch Check (Figure 30) To operate properly, the switch requires at least 11 volts. Connect a voltmeter across the winding. Close the engine control switch. If the voltmeter reads less then 11 volts, locate and repair the problem in the engine control switch, battery, or wiring. If the voltage reads 11 volts or above, yet the voltage does not seem to be reaching the starter, replace the magnetic switch. ENGINE ELECTRICAL 6D-23 Figure 27—Cranking System Diagnosis 6D-24 ENGINE ELECTRICAL SLOW CRANKING, SOLENOID CLICKS OR CHATTERS Figure 28—Cranking System Diagnosis STARTER MOTOR NOISE Refer to the starter noise diagnostic chart. Starter shims are shown in figure 31 and 32. the pinion teeth and flywheel teeth are meshed. If necessary, rotate the flywheel so that a pinion tooth is directly in the center of two flywheel teeth and on the centerline of the two gears (figure 34). 6 . Measure the clearance between the top of the PINION CLEARANCE 1. Remove the lower flywheel housing cover. 2. Inspect the flywheel for signs of unusual wear such as chipped or m issing gear teeth or the flywheel being bent. If the flywheel needs replacing, refer to “ Engine M echanical” earlier in 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 engine off and rotate the flywheel so that the marked teeth are in the area of the starter pinion gear. 4. Disconnect the negative battery cable to prevent accidental cranking of the engine. 5. Insert a screwdriver in the small hole in the bottom of the starter (shown by the arrow in figure 33) and move the starter pinion and clutch assembly so that pinion tooth and the bottom of the flywheel tooth using the width of the wire gage (figure 34). Normal clearance is 0.5 to 1.5 mm (0.02 to 0.06-inch). 7. If the clearance is less than 0.5 mm (0.02-inch) and the starter whines after firing, shim the starter away from the flywheel. • Diesel engine (figure 31): Add shims as required. Total shim stack must not exceed 4.0 mm (0.16-inch). If starter shims are not available, washers made of shim stock can be used. • Gas engines (figure 32): Add 1.0 mm (0.04-inch) shims, one at a time, to both long bolts between starter m ounting pads and engine until noise problem is corrected. Do not use more than 2 shims total. ENGINE ELECTRICAL 6D-25 476 475 8 . If the pinion clearance is more than 1.5 mm (0.06 inch) and the starter whines during cranking, shim the starter towards the flywheel. • Diesel engine (figure 31): Add a 1.0 mm (0.04-inch) shim between the starter motor mounting pad and the engine. If a starter shim is not available, a washer made of shim stock can be used. • Gas engines (figure 32): Add 0.38 mm (0.015 inch) shims between the outboard starter mounting pad and engine mount until the noise stops. Do not add more than 4 shims total. 9. When shimming is done, torque the mounting bolts. Figure 30—Magnetic Switch 466. 467. 475. 476. 477. S h im A = 1.0 m m (0.04-inch) S h im B = 2 .0 m m (0.08-inch) Long B o lt N ut B o lt F-02949 Figure 31—Shimming Diesel Engine Starter Motors Tighten 1 . Gas engine starter motor mounting bolts to 38 N-m (28 ft. lbs.) (figure 34). 2. Diesel engine starter motor (figure 31): • Through bolt to 38 N-m (28 ft. lbs.). • Nut to 10 N-m (90 in. lbs.). • Bolt to 32 N-m (24 ft. lbs.). 6D-26 ENGINE ELECTRICAL Figure 33—Meshing Starter and Flywheel Teeth 463 435. 436. 463. A. F ly w h e e l P in io n S u g g e s te d W ire G age 0.058 m m (0.020-inch) W ire G age 6.355*12.7mm (1/4"-1/2") ■“ 76.2mm APPROXIMATE X k~ ( T 463 436 436 B-08268 Figure 34—Flywheel to Pinion Clearance ENGINE ELECTRICAL 6D-27 DIAGNOSIS OF STARTER MOTOR NOISE PROBLEM POSSIBLE CAUSE CORRECTION High-pitched whine during cranking (before engine fires) but engine cranks and fires normally. Distance too great between starter pin­ ion and flywheel. Remove shims at the starter mount. Refer to “ Starter Motor Noise” . High-pitched whine after the engine fires as key is being released. The engine cranks and fires normally. This complaint is often diagnosed as “ starter hang-in” or “ solenoid weak” . Distance too small between starter pin­ ion and flywheel. Flywheel runout con­ tributes to the intermittent nature of the problem. Add shims at the starter mount. Refer to “ Starter Motor Noise” . A loud “ whoop” after the engine fires but while the starter is still held engaged. Sounds like a siren if the engine is revved while the starter is engaged. U sually due to a worn starter motor clutch. Remove the starter motor and check the clutch. Refer to the Light Duty Truck Unit Repair Manual. A “ rumble” “ growl” or (in severe cases) a “ knock” as the starter is coasting down to a stop after starting the engine. Usually due to a bent or unbalanced starter armature. Remove the starter motor and check the armature. Refer to the Light Duty Truck Unit Repair Manual. CRANKING SYSTEM ON-VEHICLE SERVICE MAINTENANCE Keep starter term inals and all other terminals in the electrical system clean and tight. A loose or corroded connection or terminal will cause excessive resistance in the system which will result in hard starting. At regular intervals, inspect the starting system to locate and correct potential causes of trouble before the system performance is affected. Starting motors do not require lubrication except during overhaul. STARTER MOTOR REPLACEMENT ++ Remove or Disconnect 1. N egative battery cable. 2. S tarter braces or shie lds if equipped. 3. W ires from the sta rter solenoid. • Raise the vehicle. 4. Two bolts, nuts, washers and shims holding the starter to the engine. 5. Starter from the engine. r*+ | Install or Connect STARTER MOTOR If the battery, wiring and switches are in satisfactory condition, and the engine is functioning properly, remove the motor and refer to the Light Duty Truck Unit Repair Manual. Never operate the starter motor more than 30 seconds at a tim e without pausing to allow it to cool for at least two minutes. Overheating, caused by excessive cranking, will damage the motor. 1 . Two bolts, nuts, w asher and shim s th ro ug h the starter to the engine. Tighten • Bolts to 38 N m (28 ft. lbs.). • Lower the vehicle. 2. Wires to the solenoid terminals. 3. Braces or shields, if equipped. 4. Negative battery terminal. 6D-28 ENGINE ELECTRICAL ENGINE BLOCK HEATERS 6 . B o lt/S c re w 2. O -ring 3. Yoke 4. T erm in al G ro u n d 5. G ro u n d T erm in al 7. S u p p o rt A. P o s itio n e d B. In s ta lle d F-02505 Figure 35— Engine Block Heater DESCRIPTION The optional engine block heater is used to preheat engine coolant for cold weather starting. The unit consists of a heating coil that fits into the engine block. It has an attached electrical cord with a plug. If the element fails to heat the coolant, check the cord and connections before replacing the element. ON-VEHICLE SERVICE REMOVAL B Remove or Disconnect 1. C oolant, R efer to E N G IN E C O O LIN G (SEC. 6 B). 2. Plug end from the heater. • Loosen the bolt/screw. 3. Heater from the engine block. INSTALLATION (Figures 35, 36 and 38) 1. Apply a coating of lubricant to the O-ring and to the cleaned surface of the plug opening in the block. 2. Install the hairpin end of the heating coil into the opening and push the support in as far as it will go. 3. Position the block heater as shown for the engine in figure 38. Tighten • B olt/screw to 1.8 N m (16 in. lbs.). 4. Route the heater cord so that it does not touch the engine, hot pipes, manifold, or any moving parts. Refer to figures 37, 39, 40 and 41. Coolant. Refer to ENGINE COOLING (SEC. 6 B). 9. H e a te r C ord 12. R a d ia to r S u p p o rt Figure 37—Heater Cord Wiring, 5.7 L, 7.4 L Engines, P Truck ENGINE ELECTRICAL 6D-29 F-02503 Figure 38—Heater Location 6D-30 ENGINE ELECTRICAL A. G-Van B. RV F-02502 Figure 39—Heater Cord Routing, 4.3L Engine ENGINE ELECTRICAL 6D-31 9. 10. A. B. C. H e a te r C ord C ap fo r C ord 5.0L (TBI), 5.7L (TBI) and 7.4L (TBI), RV 5.7L (Carb.), G 5.0L (TBI) and 5.7L (TBI), G Fz-02950 Figure 40—Heater Cord Routing, 5,0L, 5.7L, 7.4L Engines 6D-32 ENGINE ELECTRICAL Figure 41—Heater Cord Routing, 6.2L Engine ENGINE ELECTRICAL 6D-33 IGNITION SYSTEM DESCRIPTION All ignition systems include a battery, a distributor, an engine control switch, spark plugs, and the prim ary and secondary wiring. Information on the battery is located earlier in this section. Refer to CAB ELECTRICAL (SEC. 8 A) for information on the engine control switch. 158 There are two different igintion systems used on these vehicles. If the vehicle has a carbureted engine, spark is controlled by the module inside the distributor with an integral coil. If the vehicle engine is equipped with throttle body injection (TBI), the ignition system includes a knock sensor, an electronic spark control module, a computer (ECM), and a distributor with a separate coil. DISTRIBUTOR The distributor with an integral coil combines all ingition components in one unit (figures 42 and 43). The coii is in the cap and connects through a resistance brush to the rotor. On a d istribu to r w ith a separate coil the coil connects to the rotor through a high tension wire (figure 44). The d is trib u to r has an inte rn a l m agnetic pick-up assembly which contains a permanent magnet, a pole piece with internal teeth and a pick-up coil. When the teeth of the tim er core, rotating inside the pole piece, line up with the teeth of the pole piece, an induced voltage in the pick-up coil signals the electronic module to trigger the coil primary circuit. The prim ary current decreases and a high voltage of up to 35,000 volts is induced in the ignition coil secondary winding. This voltage is directed through the rotor and secondary leads to fire the spark plugs. The capacitor in the distributor is for radio noise suppression. The magnetic pick-up assembly is mounted over the main bearing on the distributor housing. On carbureted engines without computers, the assembly is made to rotate by the vacuum control unit, thus providing vacuum a dva nce . T he d is trib u to r sh a ft is m ounted on the camshaft at the rear of the engine, and rotates at one-half the rpm of the engine. The force of rotation moves the advance w eights against the springs, and provides cetrifugal advance to the tim er core. ENGINES WITH TBI On e ng in es w ith TBI, spark tim in g changes are determined electronically by the ECM (computer), which m onitors info rm a tio n from va riou s eng in e sensors, com putes the desired spark tim ing, and signals the distributor. The distributor does not contain centrifugal weights, springs, or a vacuum advance unit. Each TBI equipped engine also has a knock sensor mounted in the engine block and connected by a blue wire to a spark control module (called a “ half-function box” ) (figure 45). In response to engine knock, a signal is sent from the sensor to the module and then to the ECM, 152. B a tte ry T erm in al (C o n n e c te d to Ig n itio n S w tic h ) 153. V a cuu m U n it 156. Tach T erm in al 158. G ro u n d T erm inal B-09832 Figure 42—Distributor with Integral Coil which computes how much to retard spark tim ing to reduce knock. A retard command is then sent to the distributor. Information on TBI and the computer controlled ignition system, system com ponents and th eir locations, and diagnostic charts are located in the Light Duty Truck Fuel and Emissions Service Manual. IGNITION TIMING Timing specifications for each engine are listed on the V ehicle E m issions C ontrol Inform ation label on the radiator support. Always follow Vehicle Emissions Control Inform ation label procedures when adjusting tim ing. When using a tim ing light, connect an adapter between the number 1 spark plug and the num ber 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 jum p to the nearest ground, and the spark plug will not fire properly. 6D-34 ENGINE ELECTRICAL 153. 154. 159. 160. V a cuu m U n it C o n n e c to r C over C o il 151. 152. 155. 157. 158. 161. Cap 162. R o to r 163. G ear B-09833 Figure 43—Distributor Components Ig n itio n C o il C o n n e c to r T e rm in a ls B a tte ry T erm inal Tach and C o il T erm in al C o il Lead F o u r T erm inal C o n n e c to r F-02498 Figure 44—Distributor with Sealed Module Connectors and Separate Coil ENGINE ELECTRICAL 6D-35 R e s is to r 14 m m Thread H eat Range Taper Seat E x te n d e d T ip El-09847 Figure 46—Spark Plug Coding F-02497 Figure 45—Knock Sensor and Spark Control Module on P Truck Some engines incorporate a magnetic tim ing probe hole for use with special electronic tim ing equipment. C o n su lt m a n u fa ctu re r’s in s tru c tio n s fo r use of th is equipm ent. 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 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 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. Do not mistake corona discharge for flash-over or a shorted insulator. Corona is a steady blue light appearing SPARK PLUG WIRES The spark plug wiring is a carbon impregnated cord conductor encased in an 8 mm diameter rubber jacket. The silicone spark plug boots form a tight seal on the plugs. Refer to “ Spark Plug W ires” later in this section for service precautions. Numbers relate to thread size as follows: 1st number denotes THREAD SIZE 4 8 10 12 SPARK PLUGS Resistor type, tapered seat spark plugs are used on all engines. No gasket is used on these tapered seat plugs. Refer to figures 46 and 47 for an explanation of letter coding on spark plugs. Refer to the Vehicle Emissions C ontrol Inform ation label on the radiator support for correct gap information. 14 m m 18 m m 10 m m 12 m m 1/2 -in ch ta p e r 1/2-inch 3/4-inch 7/s-inch 2nd number denotes HEAT RANGE 0-1-2-3-4-5-6-7-8-9 C O L D -------------HOT F-02496 Figure 47—Spark Plug Coding Chart 6D-36 ENGINE ELECTRICAL around the insulator, just above the shell 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 repel dust particles, leaving a clear ring on the insulator just above the shell. This ring is som etim es m istakenly regarded as evidence that combustion gases have blown out between shell and insulator. TEST FOR SEPARATELY MOUNTED COIL 1. Disconnect the distributor lead and wiring from the coil. 2. Connect an ohm meter as shown in figure 48, step 1. Use the high scale. The reading should be infinite. If not, replace the coil. 3. Connect the ohm meter as shown in step 2. Use the low scale. The reading should be very low or zero. If not, replace the coil. 4. Connect the ohm meter as shown in step 3. Use the high scale. The meter should not read infinite. If it does, replace the coil. 5. Reconnect the distributor lead and wiring to the coil. A. S crape clea n m eta l g ro u n d . F-02117 Figure 48—Testing the Ignition Coil DIAGNOSIS OF THE IGNITION SYSTEM DISTRIBUTOR/TIMING SYSTEM FOR TBI-EQUIPPED VEHICLES IGNITION SYSTEM FOR CARBURETED ENGINE CAUTION: To prevent possible personal injury from a moving vehicle or operating engine do the following before performing the checks: 1 . Engage the parking brake and block the wheels. 2. Place the automatic transmission in park or the manual transmission in neutral. CAUTION: To prevent possible personal injury from a moving vehicle or operating engine do the following before performing the checks: 1. Engage the parking brake and block the wheels. 2. Place the automatic transmission in park or the manual transmission in neutral. 1. Refer to the Fuel and Emissions Service Manual for information on the computerized ignition system, including the diagnostic use of the “ Check Engine” or “ Service Engine Soon” lamp. 2. Refer to the Light Duty Truck Unit Repair Manual for distributor com ponent checks. 1. Refer to figure 49, 50 and 51 for system diagnosis. 2. Refer to the Light Duty Truck Unit Repair Manual for distributor component checks. ENGINE ELECTRICAL 6D-37 ENGINE CRANKS, BUT WILL NOT START (DISTRIBUTOR WITH INTEGRAL COIL) IF A TACHOMETER IS CONNECTED TO THE TACHOMETER TERMINAL, DISCONNECT IT BEFORE PROCEEDING WITH THE TEST. 2. CHECK VOLTAGE AT DISTRIBUTOR “ BAT” TERMINAL WHILE CRANKING. 7 VOLTS OR MORE UNDER 7 VOLTS 1 " 3. WITH ENGINE CONTROL SWITCH “ ON” , CHECK “ TACH" TERMINAL VOLTAGE. REPAIR PRIMARY CIRCUIT TO ENGINE CONTROL SWITCH. I UNDER 1 VOLT 1 TO 10 VOLTS 10 VOLTS OR MORE REPLACE MODULE AND CHECK FOR SPARK FROM COIL AS IN STEP 6. REPLACE IGNITION COIL SPARK INSPECT CAP FOR WATER, CRACKS, ETC. IF OK, RE­ PLACE ROTOR. | MH QPADk' NU orH n fV SPARK REMOVE PICKUP COIL LEADS FROM MODULE. CHECK TACH. TERMINAL VOLTAGE W/ENGINE CONTROL SWITCH "O N ” . WATCH VOLTMETER AS TEST LIGHT IS MOMENTARILY CON­ NECTED FROM BATTERY TO MODULE “ P " (VIEW D, FIGURE 44) NOT MORE THAN 5 SECONDS. NO DROP IN VOLTAGE ------- 1 I CHECK MODULE GROUND AND FOR OPEN IN WIRES FROM CAP TO DISTRIBUTOR. IF OK, REPLACE MODULE. NO SPARK SYSTEM OK VOLTAGE DROPS 6. CHECK FOR SPARK FROM COIL WITH ST-125 AS TEST LIGHT IS REMOVED FROM MODULE TERMINAL. F-02494 Figure 49—Ignition System Diagnosis 6D-38 ENGINE ELECTRICAL -------188 CUT BOOT HERE 11 mm (7/ie IN.) FROM TIP OF SPARK PLUG VIEW A 192 VIEW B 194 VIEW C VIEW D 168. S park P lug B o o t 189. D iscard 191. In se rt B o o t O ver P o rcelain End O f ST-125 192. 193. 194. 195. 196. 197. C o n n e c t To G ro u n d Leave H a rn e ss C o n n e c te d R em ove Leads To M o d u le To BAT + Test L ig h t C o n n e c t V o ltm e te r A n d Tach T erm inal To G ro u n d F-00251 Figure 50—Ignition System Diagnosis ENGINE ELECTRICAL 6D-39 INTERMITTENT OPERATION OR MISS F-02495 Figure 51—Ignition System Diagnosis DIAGNOSIS OF SPARK PLUGS PROBLEM Brown to grayish-tan deposits and slight electrode wear. Dry, fluffy black carbon deposits. POSSIBLE CAUSE Normal wear. 1. Carburation is too rich. 2. S ticking EFE valve or m anifold heat valve. 3. Sticking automatic choke. 4. Poor ignition output. Wet, oily deposits with very little electrode wear. Red, brown, yellow and white colored coatings on insulator. Engine misses intermittently under severe operating conditions. 1. “ Break-in” of new or recently overhauled engine. 2. Excessive valve stem guide clearances. 3. Worn intake valve seals. By-products of combustion. CORRECTION Clean, regap, reinstall. 1. Check the fuel mixture. Replace the air cleaner if clogged. 2. Replace if necessary. 3. Refer to CARUBRETORS (SEC. 6C1). 4. Check the distributor coil connections and cables (discussed in this section). Refer to the Fuel and Emission Service Manual. 1. Degrease, clean and reinstall the plugs. 2. Refer to ENGINE (SEC. 6 A). 3. Replace the seals. Clean, regap, and reinstall. If heavily coated, replace. 6D-40 ENGINE ELECTRICAL DIAGNOSIS OF SPARK PLUGS (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Colored coatings heavily deposited on portion of the plug projecting into the chamber and on the side facing the intake valve. Leaking seals if the condition is found in only one or two cylinders. Check the seals. Replace if necessary. Clean, regap, and reinstall the plugs. Shiny yellow glaze coating on the insulator. Melted by-products of combustion. Avoid sudden acceleration with wideopen throttle after long periods of low speed driving. Replace the plugs. Burned or blistered insulator tips and badly eroded electrodes. Overheating. Broken or cracked insulator tips. Heat shock from sudden rise in the tip temperature under severe operating conditons. Improper gapping of the plugs. 1 . Check the cooling system. 2. Check for sticking heat riser valves. Re­ fer to ENGINE (SEC. 6 A). 3. Check the air-fuel mixture. May be too lean. Refer to the Fuel and Emissions Service M anual for TBI engines or C ARBURETORS (SEC. 6C1) in this manual for carbureted engines. 4. Check the heat range of the plugs. May be too hot. 5. Check the ignition tim ing. May be over­ advanced. 6 . Check the torque value of the plugs to ensure good plug-engine seat contact. Replace the plugs. Gap correctly. IGNITION SYSTEM ON-VEHICLE SERVICE SERVICE PRECAUTIONS Some service tachometers and electronic diagnostic equipment may NOT be compatible with these ignition systems. Consult your representative of such equipment to update your equipm ent for com patibility with these systems. 1. When making compression checks, disconnect the engine control switch feed wire at the distributor. When disconnecting this connector release the locking tab while pulling downward on the connector body; do not use a screwdriver or tool to release the locking tab as it may break the tab. 2 . No p eriodic lub rica tion is required. Engine oil lu b rica te s the low er bush in g and an o il-fille d reservoir provides lubrication for the upper bushing. NOTICE: the tachom eter terminal must NEVER be allowed to touch ground, as damage to the module and/or ignition coil can result. 3. On integral coil distributors, the tachometer (TACH) terminal is next to the engine control switch (BAT) connector on the distributor cap. On distributors with separate coils, the TACH terminal is at the coil (figure 44). 4. There is no dwell adjustment since this is controlled by the module. 5. The material used to construct the spark plug wires is very pliable and soft. This wire will withstand more heat and carry a higher voltage. Due to the more pliable wire, scuffing and cutting become easier. Route the spark plug wires correctly to prevent chaffing or cutting. When removing a spark plug wire from a spark plug, twist the boot on the spark plug and pull on the boot to remove the wire. ENGINE ELECTRICAL 6D-41 DISTRIBUTOR REPLACEMENT Some components, such as the engine cover or air cleaner, may need to be removed to reach the distributor. DISTRIBUTOR WITH INTEGRAL COIL ++ Remove or Disconnect 1. Engine control sw itch battery feed w ire from the d istribu to r cap. 2. Tachom eter lead (if equ ip pe d ) from the cap. 3. Ignition coil co nn ecto r from the cap. • Do not use a screwdriver or tool to release the locking tabs. 4. D istrib u to r cap by pre ssin g down on the four spring-loaded screws and turning the latches to the left. 5. Vacuum hose from the vacuum advance unit (if equipped). 6 . Distributor clamp bolt and hold-down clamp from the engine. • Note the position of the rotor, then pull the distributor up until the rotor just stops turning to the left and again note the position of the rotor. 7. Distributor. “►+ Install or Connect To ensure correct tim ing of the distributor it must be installed with the rotor correctly positioned as noted in Step 7 of the removal procedure. If the engine was a c c id e n ta lly cranked a fte r the distributor was removed, the following procedure can be used for installation: • Remove the num ber 1 spark plug. • Place finger over the number 1 spark plug hole and c ra n k th e e n g in e s lo w ly u n til compression is felt. • Align the tim ing mark on the pulley to “ 0 ” on the engine tim ing indicator. • Turn the rotor to point between number 1 and number 8 spark plug towers on the distributor cap on V 8 engines and between number 1 and number 6 on 6 cylinder engines. 1. Distributor. • If the distributor shaft w on’t drop into the engine, first insert a screwdriver into the hole for the distributor and turn the oil pump drive shaft. 2. Distributor hold-down clam p and clamp bolt. 3. Vacuum hose to the vacuum unit (if equipped). DISTRIBUTOR WITH SEPARATE COIL |<-+| Remove or Disconnect 1. N egative battery cable. 2. W iring harness connectors at the side of the d istribu to r cap. 3. D istrib uto r cap and move it out of the way. • Scribe a mark on the engine in line with the rotor. • Note the position of the distributor housing in relation to the engine. 4. Distributor hold-down nut and clamp. 5. Distributor. Install or Connect • To ensure correct tim in g of the d is trib u to r it m ust be installed w ith the rotor correctly p ositioned as noted in step 3 of the rem oval procedure. • If the d is trib u to r sh aft w on ’t drop into the engine, in s e rt a s c r e w d r iv e r in to th e h o le fo r th e d istrib u to r and tu rn the oil pum p driveshaft. 1. Distributor. 2. H old-dow n nut and clam p. 3. D istrib uto r cap. 4. W iring harness co nn ecto r at the side of the cap. 5. Engine cover and console. 6 . N egative battery cable. COIL REPLACEMENT ++ Remove or Disconnect 1. N egative battery cable. 2. Engine control sw itch and ta cho m e te r te rm in a ls at the coil. 3. Coil to d is trib u to r lead at the coil. 4. Nuts holding the coil bracket and coil to the e ngine bracket. 5. Coil bracket and coil. • Drill and punch out the two rivets holding the coil to the bracket. 6 . Coil from bracket. Install or Connect Coil to the bracket w ith two screws. Coil bracket to the engine bracket w ith stu ds and nuts. Coil to the d is trib u to r lead at the coil. Engine control sw itch and ta cho m e te r connectors to the coil. N egative battery cable. IGNITION TIMING 4. Cap on the distributor. • The aligning tab on the cap should engage with the notch in the housing. 5. Four hold-down spring latches. 6 . Ignition coil connector to the cap. 7. Engine control switch battery feed wire. 8 . Tachometer lead (if equipped). • Set ignition tim ing as described later in this section. 1. Refer to the Vehicle Emissions Control Information label located on the radiator support. Follow all instructions on the label. 2. Refer to the Fuel and Emissions Service Manual for tim ing information for engines equipped with TBI. 3. With the engine control switch off, connect the pick-up lead of a tim ing light to the num ber 1 spark plug. Use a jum per lead between the wire and plug or an inductive type pick-up. DO NOT pierce the wire 6D-42 ENGINE ELECTRICAL SPARK PLUG WIRE REPLACEMENT 4. 5. 6. 7. or attempt to insert a wire between the boot and the w ire . C o n n e c t th e tim in g lig h t p o w e r le a d s according to the m anufacturer’s instructions. Disconnect the vacuum hose from the distributor if so equipped. Start the engine and aim the tim ing light at the tim ing mark (figure 52). The line on the balancer or pulley will line up at the tim ing mark. If a change is necessary, loosen the distributor hold-down clamp bolt at the base of the distributor. W hile observing the mark with the tim ing light, slowly rotate the distributor until the line indicates the correct timing. Tighten the hold-down bolt, and re-check the timing. Turn off the engine and remove the tim ing light. R e co n n e ct the n u m b e r 1 sp ark plu g w ire, if removed. Connect the vacuum hose to the distributor if so equipped. SPARK PLUG WIRES PRECAUTIONS 1. Twist boots 1/2 turn before removing. 2. When removing the boot, do not use pliers or other tools that could tear the boot. 3. Do not force anything between the wire and the boot, or through the silicone jacket of the wire. 4. Do not pull on the wires to remove the boot. Pull on the boot, or use a tool designed for this purpose. 5. Special care should be exercised when installing spark plug boots to assure that the metal terminal within the boot is fully seated on the spark plug terminal and that the boot has not moved on the wire. If boot to wire movement has occurred, the boot will give a false visual impression of being fully seated. A good check to assure that boots have been properly assembled is to push sideways on the installed boots. If they have been correctly installed, a stiff boot with only slight looseness will be noted. If the terminal has not been properly seated on the spark plug, only the resistance of the rubber boot will be felt when pushing sideways. Wire routings must be kept intact during service, and followed exactly when wires have been disconnected, or when replacement of the wires is necessary. Failure to route the wires properly can lead to radio ignition noise and crossfiring of the plugs, or shorting of the leads to ground. For the correct wiring routing for each engine, refer to figures 53 through 61. Some d is trib u to rs have s p a rk plug w ire retainer harness assemblies with the engine firing order marked on them. If the firing order is not indicated, install the plug wires according to the firing order as shown in figures 62, 63 and 64. When the wiring is 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 num ber 1 . The plug wire from cylinder number 6 (in 6 cylinder engines) or from cylinder num ber 8 (in V 8 engines) should lead to the distributor tower at the front of the engine next to the number 1 tower. Be sure to position all plug boots perpendicular to the centerline of the engine. On the LE 8 (7.4 L V 8 ) engine, the spark plug harness assembly and a dielectric paper insulator are fitted to a shield which is installed over the spark plug (figure 65). The insulator grounds the shield to the engine block. If the assembly is removed from the shield, make sure that th e in s u la to r is p re s e n t and u n d a m a g e d b e fo re reinstallation. ENGINE ELECTRICAL 6D-43 Figure 53—Spark Plug Wire Routing for the 7.4L (Carb.) Engine - P Truck (Federal) 6D-44 ENGINE ELECTRICAL Figure 54—Spark Plug Wire Routing for the 7.4L (Carb.) Engine - P Truck (California) ENGINE ELECTRICAL 6D-45 Figure 55—Spark Plug Wire Routing for the 7.4L (TBI) Engine 6D-46 ENGINE ELECTRICAL Figure 56—Spark Plug Wire Routing for the 5.7L (Carb.) Engine - P Truck (California) Figure 57—Spark Plug Wire Routing for the 5.7L (Carb.) Engine - G Van, P Truck (Federal) ENGINE ELECTRICAL 6D-47 #5 #7 175. C oil W ire F-02488 Figure 58—Spark Plug Wire Routing for the 5.7L (TBI) Engine - P Truck 6D-48 ENGINE ELECTRICAL Figure 59—Spark Plug Wire Routing for the 5.0L (TBI) and 5.7L (TBI) Engine - RV,G ENGINE ELECTRICAL 6D-49 Figure 60—Spark Plug Wire Routing for the 4.3L (TBI) Engine - G Van 6D-50 ENGINE ELECTRICAL Figure 61—Spark Plug Wire Routing for the 4.3L (TBI) Engine - RV ENGINE ELECTRICAL 6D-51 A (a j1 P — FIRING ORDER 1-6-5-4-3-2 \J I i) ( ) d> Jr 3 F-00262 Figure 63—Spark Plug Wire Schematic (V6 Engines) Figure 64—Spark Plug Wire Schematic (V8 Engines) 6D-52 ENGINE ELECTRICAL ENGINE WIRE HARNESS When it necessary to move any of the wiring, whether to lift wires away from their harnesses or move harnesses to reach some component, take care that all wiring is re­ placed in its original position and all harnesses routed correctly. If clips or retainers break, replace them. Electri­ cal problems can result from wiring or harnesses becom­ ing loose and moving from their original positions or from being rerouted. Refer to figures 66 through 94 for the cor­ rect routing of engine wiring. ENGINE ELECTRICAL 6D-53 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. J u n c tio n B lo c k W in d s h ie ld W ip e r M o to r H y d ra u lic C lu tc h R e se rvo ir H ose B u lkh e a d C o n n e c to r H eat S h ie ld K n o ck S e n so r W a te r Temp. S w itc h /S e n s o r D is trib u to r G rou nd O il P ressure S e n s o r O il P ressure S w itc h /S e n s o r 0 2 Sensor VIEW A F-02484 Figure 66—Engine Wiring for the 4.3L (TBI) - RV - Left Side 6D-54 ENGINE ELECTRICAL 1. 2. 3. 4. 8. 9. 10. 11. 12. 24. 28. J u n c tio n B lo c k W in d s h ie ld W ip e r M o to r H y d ra u lic C lu tc h R e se rvo ir H ose B u lkh e a d C o n n e c to r D is trib u to r G ro u n d O il P ressure S e n s o r O il P ressure S w itc h 0 2 Sensor C o il E n g in e Temp. S w itc h B-07749 Figure 67—Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - RV - Left Side ENGINE ELECTRICAL 6D-55 VIEW A 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. ECM M o d u le F uel P um p R elay S ta rte r M 40 D o w n s h ift Relay A.I.R. S w itc h Valve G e n e ra to r C o o la n t Temp. S e n s o r ESC H a lf F u n c tio n Box T h ro ttle P o s itio n S e n s o r I.A.C. A c tiv a to r M AP S e n s o r C oil EGR S o le n o id G ro u n d W ire G e n e ra to r M o u n tin g B racket B-07751 Figure 68—Engine Wiring for the 4.3L (TBI) - RV - Right Side 6D-56 ENGINE ELECTRICAL 6. 13. 14. 16. 17. 18. 19. 20. 21. 22. 23. 25. K nock S ensor ECM M o d u le Fuel P u m p R elay M 40 D o w n s h ift R elay A.I.R. Valve G e n e ra to r C o o la n t Temp. S e n s o r ESC H a lf F u n c tio n Box T h ro ttle P o s itio n S e n s o r I.A.C. A c tiv a to r M AP S ensor EGR S o le n o id B-07750 Figure 69—Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - RV - Right Side ENGINE ELECTRICAL 6D-57 1. 2. 4. 7. 9. 11. 9. 9. 0. J u n c tio n B ox W in d s h ie ld W ip e r M o to r B u lk h e a d C o n n e c to r W a te r Temp. S e n so r G ro u n d O il P re ssure S w itc h C o o la n t Temp. S e n s o r E n g in e E x h a u s t S e n d e r O il P re ssure S e nd e r B-07691 Figure 70—Engine Wiring for the 7.4L (TBI) - RV - Left Side 13. 14. 16. 18. 21. 23. 24. 31. 32. 33. 34. ECM M o d u le F uel P u m p Relay M 40 D o w n s h ift Relay G e n e ra to r T h ro ttle P o s itio n S e n s o r M A P S e n so r C o il B a tte ry C able A u x ilia ry C o o lin g Fan A.I.R. D ive rte r Valve In je c to r B-07692 Figure 71—Engine Wiring for the 7.4L (TBI) - RV - Right Side 6D-58 ENGINE ELECTRICAL VIEW A VIEW B 9. 15. 18. 28. 31. 35. 36. 37. 38. 39. 40. G ro u n d S ta rte r G e n e ra to r E n g in e Temp. S e n s o r B a tte ry C able S peed S e n s o r F uel F ilte r G lo w P lug In h ib it S w itc h F ast Id le S o le n o id G lo w P lug C o ld and F ast Id le S w itc h VIEW C B-07693 Figure 72—Engine Wiring for the 6.2L Diesel - RV - Right Side ENGINE ELECTRICAL 6D-59 VIEW 1. 2. 3. 7. 10. 11. 39. 41. 42. B J u n c tio n B lo c k W in d s h ie ld W ip e r M o to r H y d ra u lic C lu tc h R e se rvo ir H ose W a te r Temp. S w itc h /S e n s o r O il P ressure S e n s o r O il P ressure S w itc h G lo w P lug EGR/EPR S o le n o id G lo w P lug C o n tro lle r C o n n e c to r B-07694 Figure 73—Engine Wiring for the 6.2L Diesel - RV - Left Side 6D-60 ENGINE ELECTRICAL 4. 14. 15. 16. 17. 18. 21. 23. 24. B u lk h e a d C o n n e c to r Fuel P um p Relay S ta rte r M 40 D o w n s h ift Relay A.I.R. Valve S w itc h G e n e ra to r T h ro ttle P o s itio n S e n s o r MAP Sensor C o il 25. 31. 34. 47. 48. 49. 50. 51. EGR S o le n o id B a tte ry C able In je c to r W ip e r Pum p Fuel P um p P rim e r C o n n e c to r C o o la n t Temp. S w itc h Tach C o n n e c to r Id le A ir S w itc h B-07696 Figure 74—Engine Wiring for the 4.3L (TBI) - G Van - Left Side ENGINE ELECTRICAL 6D-61 6 . K n o c k S e n so r 8. 12. 30. 43. 44. 45. 46. D is trib u to r 0 2 S e n so r O il P ressure S e n d e r O il P re ssu re /F u e l P u m p S w itc h Temp. S e n s o r Fuel P um p W irin g H a rn e ss G rou nd S tra p T erm in al B-07695 Figure 75—Engine Wiring for the 4.3L (TBI) - G Van - Left Side 8. 12. 24. 30. 43. 44. 46. 50. 52. 53. D is trib u to r 0 2 Sensor C o il O il P ressure S e n d e r O il P re ssu re /F u e l P um p S w itc h Temp. S e n s o r G ro u n d S tra p Term inal Tach C o n n e c to r F uel L in e s Fuel P um p W irin g H a rn e ss B-07697 Figure 76—Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - G Van - Left Side 6D-62 ENGINE ELECTRICAL 34 16 4. 6. 14. 15. 16. 22. 23. 34. 48. 54. B u lk h e a d C o n n e c to r Knock S ensor F uel P u m p R elay S ta rte r M 40 D o w n s h ift R elay G e n e ra to r C o o la n t Temp. S e n s o r T h ro ttle P o s itio n S e n s o r I.A.C. A c tiv a to r M AP S e n s o r EGR S o le n o id B a tte ry C able A.I.R. D iv e rte r Valve In je c to r Fuel P um p P rim e r C o n n e c to r A/C C o n n e c to r B-07698 Figure 77—Engine Wiring for the 5.0L (TBI) and 5.7L (TBI) - G Van - Right Side ENGINE ELECTRICAL 6D-63 7. W a te r Temp. S w itc h 8. D is trib u to r 10. O il P ressure S e n so r 11. O il P ressure S w itc h 26. 45. 58. 72. 73. 74. 75. 78. 79. 80. G ro u n d W ire F uel P um p W irin g H a rn e ss E n g in e H a rn e ss G ro u n d S trap T ra n s m is s io n S w itc h V acuum Pipe H ig h F lo w A ir Valve T h ro ttle Valve (W ith o u t A/C) T h ro ttle Valve (A/C) S peed S w itc h R elay CALIFORNIA B-07699 Figure 78—Engine Wiring for the 5.7L (Carb.) - G Van - Left Side 6D-64 ENGINE ELECTRICAL VIEW A FEDERAL 15. 18. 25. 31. 58. 75. 76. 77. 81. S ta rte r G e n e ra to r EGR S o le n o id B a tte ry C able E n g in e H a rn e ss H ig h F lo w A ir Valve E le c tric C h o ke A.I.R. P um p C ho ke 77 CALIFORNIA B-07700 Figure 79—Engine Wiring for the 5.7L (Carb.) - G Van - Right Side ENGINE ELECTRICAL 6D-65 36 7. 30. 31. 36. 39. 42. 53. 55. 59. 60. 61. 62. 63. 64. 65. W a te r Tem p S w itc h O il P ressure S e n d e r B a tte ry C able F uel F ilte r G lo w Plug G lo w Plug C o n tro lle r C o n n e c to r F ue l P um p W irin g H a rn e ss EPR V a cuu m Pipe W a te r S e n s o r C o n n e c to r Temp. S w itc h F uel P ressure C o n n e c to r F uel H e a te r C o n n e c to r G lo w P lug C o n tro lle r EPR S o le n o id H y d ro -B o o s te r B ra cket VIEW B B-07701 Figure 80—Engine Wiring for the 6.2L Diesel - G Van - Left Side 6D-66 ENGINE ELECTRICAL 66 31 FtfT # 15. 18. 31. 39. 66. 67. 68. 69. S ta rte r G e n e ra to r B a tte ry C able G lo w P lug W in d s h ie ld W a sh e r Pum p C o ld A d van ce C o ld A d va n ce and Fast Idle F uel S h u to ff VIEW A 70. C o o la n t Probe 71. F ast Id le S o le n o id C o n n e c to r B-07702 Figure 81—Engine Wiring for the 6.2L Diesel - G Van - Right Side ENGINE ELECTRICAL 6D-67 CALIFORNIA 8. 80. 82. 83. 84. D is trib u to r Speed S w itc h Relay A n ti-D ie s e l S o le n o id M o d u la to r Pipe T h ro ttle R eturn Valve B-07647 Figure 82—Engine Wiring for the 5.7L (Carb.) - P Truck - Left Side 6D-68 ENGINE ELECTRICAL 31 58 VIEWC FEDERAL CALIFORNIA 15. 18. 31. 58. 81. 85. VIEW A S ta rte r G e n e ra to r B a tte ry C able E n g in e H a rn e ss C ho ke N e g a tive B a tte ry C able B-07648 Figure 83—Engine Wiring for the 5.7L (Carb.) - P Truck - Right Side ENGINE ELECTRICAL 6D-69 D is trib u to r O il P ressure S w itc h 0 2 S ensor M 40 D o w n s h ift Relay G e n e ra to r C o o la n t Temp. S e n s o r C o il G ro u n d W ire E n g in e Temp. S w itc h O il P ressure S e nd e r B-07649 Figure 84—Engine Wiring for the 5.7L (TBI) - P Truck - Left Side Knock S ensor ESC H a lf F u n c tio n Box T h ro ttle P o s itio n S e n s o r MAP S ensor EGR S o le n o id B a tte ry C ab le A.I.R. D iv e rte r Valve In je c to r E n g in e H a rn e s s Id le and A ir C o n tro l A c tiv a to r B-07650 Figure 85—Engine Wiring for the 5.7L (TBI) - P Truck - Right Side 6D-70 ENGINE ELECTRICAL CALIFORNIA 8. 11. 30. 60. 80. 87. 88. 89. D is trib u to r O il P re ssure S w itc h O il P re ssure S e nd e r Tem p S w itc h Speed S w itc h Relay T ra n s m is s io n S o le n o id E n g in e S peed S w itc h S o le n o id A ir C le a n e r S e n so r B-07652 Figure 86—Engine Wiring for the 7.4L (Carb.) - P32 Truck - Left Side ENGINE ELECTRICAL 6D-71 VIEW C CALIFORNIA VIEW B 15. 18. 31. 33. 58. S ta rte r G e n e ra to r B a tte ry C able A.I.R. D ive rte r Valve E n g in e H arne ss 81. C ho ke 90. S ta rte r M o to r M a g n e tic S w itc h 91. Fuel Pipe B-07651 Figure 87—Engine Wiring for the 7.4L (Carb.) - P32 Truck - Right Side 6D-72 ENGINE ELECTRICAL \ 8. 11. 24. 30. 60. 89. 92. D is trib u to r O il P re ssure S w itc h C o il O il P re ssure S e n d e r Temp. S w itc h A ir C le a n e r S e n s o r P ow er S te e rin g P um p B-07567 Figure 88—Engine Wiring for the 7.4L (Carb.) - P42 Truck - Left Side ENGINE ELECTRICAL 6D-73 15. 18. 31. 33. 58. 81. S ta rte r G e n e ra to r B a tte ry C able A.I.R. D iv e rte r Valve E n g in e H a rn e s s C ho ke B-07653 Figure 90—Engine Wiring for the 7.4L (Carb.) - P42 Truck - Right Side 6D-74 ENGINE ELECTRICAL 15. 18. 31. 39. 58. 71. 93. 94. 95. S ta rte r G e n e ra to r B a tte ry C able G lo w P lug E n g in e H a rn e ss F ast Id le S o le n o id C o n n e c to r H e a te r C o n n e c to r C o ld A d va n ce C o n n e c to r F ue l S h u to ff Valve C o n n e c to r B-07703 Figure 91—Engine Wiring for the 6.2L Diesel - P Truck - Right Side ENGINE ELECTRICAL 6D-75 28. 30. 58. 61. 63. 87. 96. 97. Temp. S w itc h O il P ressure S e n d e r E n g in e H arne ss F ue l P ressure C o n n e c to r G lo w P lug C o n tro lle r T ra n s m is s io n S o le n o id F uel H e a te r C o n n e c to r W a te r S e n s o r C o n n e c to r B-07704 Figure 92—Engine Wiring for the 6.2L Diesel - P32 Truck - Back of Engine E n g in e Temp. S w itc h O il P re ssure S e n d e r E n g in e H a rn e s s F uel P re ssure C o n n e c to r G lo w P lug C o n tro lle r W a te r S e n s o r C o n n e c to r B-07705 Figure 93—Engine Wiring for the 6.2L Diesel - P42 Truck - Back of Engine 6D-76 ENGINE ELECTRICAL P (32) 15. 31. 58. 93. S ta rte r B a tte ry C a b le E n g in e H a rn e ss H e a te r C o n n e c to r B-07706 Figure 94—Engine Wiring Starter Motor for the 6.2L Diesel - P32 and P42 Truck ENGINE ELECTRICAL 6D-77 SPECIFICATIONS BATTERY SPECIFICATIONS Volts Cold Cranking Amperes Rating @ -18 C (0° F) Reserve Capacity (Minutes at 25 Amps) Part No. Application Catalogue Replacement Number 1980337 P 1200 12 550 130 270 1980474 P 1110 12 625 160 310* 1981729 RV, G 729 12 430 90 210 1981730 RV,G,P 730 12 525 40 260 1981733 RV, G, P 733 12 540 115 270 1981734 RV, G, P 734 12 630 115 310 Load Test (Amperes) * Battery tester cable clamps should be between term inal nuts and lead pads of term inals. If not possible, load value should be 275 amperes. GENERATOR SPECIFICATIONS Part No. Series (Type 100) Rotation Viewing Dr. End Field Current @ 12 Volts 27°C (80°F) AMPS AMPS RPM AMPS RPM AMPS 1100207 12 SI CW 4 .5 -5 .0 23 1600 70 6500 66 1101205 17-SI cw 1.7-2.1 50 1600 120 6500 120 1101240 12 SI CW 4 .2 -5 .0 30 1600 94 6500 94 1101241 12 SI CW 4 .2 -5 .0 30 1600 94 6500 94 1101242 12 SI CW 4 .5 -5 .0 23 1600 66 6500 66 1101243 12 SI CW 4 .2 -5 .0 23 1600 66 6500 66 1101244 12 SI CW 4 .0 -5 .0 23 1600 66 6500 66 1101245 12 SI CW 4 .2 -5 .0 30 1600 94 6500 94 1105628 12 SI CW 4 .5 -5 .0 30 1600 81 6500 78 1105632 12 SI CW 4 .5 -5 .0 23 1600 70 6500 66 1105661 CS 130 CW 6 .0 -7 .5 42 1600 105 6500 105 1105688 CS 130 CW 6 .0 -7 .5 36 1600 100 6500 100 1105710 CS 130 CW 4 .8 -5 .7 30 1600 85 6500 85 1105711 CS 130 CW 6 .0 -7 .5 36 1600 100 6500 100 1105712 CS 130 CW 4 .8 -5 .7 30 1600 85 6500 85 1105718 CS 130 CW 6 .0 -7 .5 42 1600 105 6500 85 1105720 CS 130 CW 6 .0 -7 .5 42 1600 105 6500 105 Cold (lutput Hot Output 6D-78 ENGINE ELECTRICAL SPECIFICATIO NS (CONT.) GENERATOR APPLICATIONS Generator Part Number K22 1101241 25 18 47 35 K81 1101242 25 18 47 35 K22 1101240 25 18 47 35 K68 1105720 25 18 47 35 K81 1101243 25 18 47 35 K22 1101240 25 18 47 35 K68 1105720 25 18 47 35 K81 1101243 25 18 47 35 K64 1105628 27 20 43 32 K81 1105632 27 20 43 32 K68 1105661 25 18 50 37 K81 1101244 25 18 50 37 K22 1101245 25 18 50 37 K60 1105711 25 18 50 37 K99 1105710 25 18 50 37 K60 1105711 25 18 50 37 K99 1105710 25 18 50 37 K60 1105711 25 18 50 37 K99 1105710 25 18 50 37 5.7L (Carb.) K68 1105720 25 18 47 35 6.2L (Diesel) K81 1105632 27 20 43 32 5.7L (Carb. and (TBI) K68 1105720 25 18 47 35 K99 1105718 25 18 47 35 6.2L (Diesel) K09 1101215 27 20 43 32 K81 1105632 27 20 43 32 7.4L (Carb.) K68 1105661 25 18 50 37 4.8L (Carb.) K81 1100207 25 18 24 17 Engine RV 4.3L (TBI) 5.0L (TBI) 5.7L (TBI) 6.2L (Diesel) 7.4L (TBI) G Van 4.3L (TBI) 5.0L (TBI) 5.7L (TBI) P Truck Mounting Torque Bottom Bracket Bolt Top Bracket Bolt N-m Ft. Lbs. Nm Ft. Lbs. ENGINE ELECTRICAL 6D-79 SPECIFICATIO NS (CONT.) STARTER SPECIFICATIONS No Load Test @ 10 Volts Truck Model Engine Application Part No. Starter Series Type AM PS M inim um M axim um M inim um RPM M axim um R.V.G.P 6.2 L Diesel 1113589 27MT 136 120 210 9000 13400 V 6.2L Diesel 1113590 27MT 136 120 210 9000 13400 P 4.3 L (Carb.) 1998559 10MT 101 60 90 6500 10500 V 5.0L (TBI), 5.7L (TBI) 1998560 10MT 101 70 110 6500 10700 R,V,G 5.0L (TBI), 5.7L (TBI) 1998561 10MT 101 70 110 6500 10700 P 5.7L (TBI) 1998561 10MT 101 70 110 6500 10700 R,V 4.3L (TBI), 5.0L (TBI), 5.7L (TBI), 7.4L (TBI) 1998562 10MT 101 70 110 6500 11070 G 4.3L (TBI), 5.0L (TBI), 5.7L (TBI), 5.7L (Carb.) 1998562 * 10MT 101 70 110 6500 11070 P 7.4L (Carb.), 5.7L (Carb.), 5.7L (TBI) 1998562 10MT 101 70 110 6500 11070 V 4.3L (TBI), 5.0L (TBI), 7.4L (TBI), 5.7L (TBI), 1998565 10MT 101 70 110 6500 10700 P 5.7L (Carb.) 1998565 10MT 101 70 110 6500 10700 STARTER SHIMS Gas Engines Diesel Engines Shim Part No. Shim Part No. 0.38 m m (0.015-inch) 1246249 1.0 mm (0.04-inch) 23500396 1.0 mm 14036090 2 .0 mm (0.08-inch ) 23500397 (0.04-inch ) TORQUE VALUES Battery R etainer.......................................................................................................................................... Top Bar of Hold-Down: Side Terminal B a tte rie s ..................................................................................................................... Top Terminal B atteries....................................................................................................................... Battery Terminals: Top Term inals........................................................................................................................................ Side T e rm in a ls ..................................................................................................................................... Glow Plug Controller Upper N u ts ......................................................................................................... Glow Plug Temperature S w itch ............................................................................................................. Glow Plugs................................................................................................................................................... Diesel Engine Starter Mounts: Through B olt.......................................................................................................................................... N u t ........................................................................................................................................................... B o lt........................................................................................................................................................... Gas Engine Starter Mounting B olts...................................................................................................... Engine Block Heater S cre w ..................................................................................................................... N-m Ft. Lbs. 17 13 3.5 6.8 In. Lbs. 30 60 17 15 5.0 23 17 13 11 38 10 32 38 1.8 28 48 17 12 90 24 28 — 16 6D-80 ENGINE ELECTRICAL SPEC IA L TOOLS 6E-1 SECTION 6E EMISSIONS CONTENTS SUBJECT PAGE Drivability and Emissions - C a rb urete d ................................................................................................................. 6E8- 1 Orivability and Emissions - Diesel........................................................................................................................... 6E9- 1 For information on vehicles with Throttle Body Injection (TBI), refer to the Fuel and Emissions Service Manual. 6E8-1 SECTION 6E8 DRIVEABILITY AND EMISSIONS — CARBURETED This section applies to: 4.8 L L25 ENGINE CODE “T” 5.7 L LT9 ENGINE CODE “M” 7.4 L LE8 ENGINE CODE “W” CO NTENTS SUBJECT PAGE General In fo rm a tio n ................................................................................................................................................. 6E8- 2 D riv e a b ility ............................................................................................................................................................6E8- 2 E m is s io n s .................................................... ..........................................................................................................6E8- 2 Maintenance S chedule........................................................................................................................................ 6E8- 2 Vehicle Emission Control Inform ation L a b e l................................................................................................. 6E8- 2 Visual Underhood In s p e c tio n ........................................................................................................................... 6E8- 2 In tr o d u c tio n .............................................................................................................................................................. 6E8- 4 General D e s c rip tio n .............................................................................................................................................6E8- 4 Component L o c a tio n ...........................................................................................................................................6E8- 5 D riveability S ym ptom s.............................................................................................................................................6E8- 8 W on’t Start — Engine Cranks O K .....................................................................................................................6E8- 8 Hard Start — C old................................................................................................................................................. 6E8- 9 Hard Start — H o t .......................................................................................................... ...................................... 6E8- 9 Stall A fter Start — C o ld ...................................................................................................................................... 6E8-10 Stall A fter Start — H o t........................................................................................................................................ 6E8-10 Hesitation/Sag, S tu m b le .................................................................................................................................... 6E8-10 Surges and/or C h u g g le ...................................................................................................................................... 6E8-11 Lack of Power, Sluggish or S p o n g y.................................................................................................................6E8-11 B a c k fire .................................................................................................................................................................. 6E8-12 Misses/Cuts O u t ................................................................................................................................................... 6E8-12 Rough, Unstable or Incorrect Idle, S ta llin g ....................................................................................................6E8-13 W on’t I d l e ..............................................................................................................................................................6E8-13 Poor Fuel E c o n o m y .............................................................................................................................................6E8-13 Dieseling, Run O n................................................................................................................................................. 6E8-14 Detonation/Spark K n o c k .................................................................................................................................... 6E8-14 Excessive Exhaust Emissions (O d o rs )............................................................................................................ 6E8-14 Restricted Exhaust C h e c k ..................................................................................................................................6E8-15 Evaporative Emission Control System (E E C S )................................................................................................. 6E8-16 General D e s c rip tio n .............................................................................................................................................6E8-16 Diagnosis of E EC S...............................................................................................................................................6E8-17 On-Vehicle Service — E E C S ..............................................................................................................................6E8-18 A ir Injection Reaction (AIR) S ystem .....................................................................................................................6E8-19 General D e s c rip tio n .............................................................................................................................................6E8-19 Diagnosis of A IR ................................................................................................................................................... 6E8-20 On-Vehicle Service — A IR ..................................................................................................................................6E8-21 Exhaust Gas Recirculation (EGR) S y s te m ..........................................................................................................6E8-32 General D e s c rip tio n .............................................................................................................................................6E8-32 Diagnosis of E G R ................................................................................................................................................. 6E8-33 On-Vehicle Service — E G R ................................................................................................................................6E8-33 6E8-2 DRIVEABILITY AND EMISSIONS — CARBURETED CONTENTS (CONT.) SUBJECT PAGE Early Fuel Evaporation System (EFE)...................................................................................................................6E8-35 General D e s c rip tio n .............................................................................................................................................6E8-35 Diagnosis o f E F E ................................................................................................................................................. 6E8-35 On-Vehicle Service — EFE.................................................................................................................................. 6E8-36 Positive Crankcase V entilation (P C V ).................................................................................................................6E8-39 General D e s c rip tio n .............................................................................................................................................6E8-39 Diagnosis of P C V ................................................................................................................................................. 6E8-39 On-Vehicle Service — P C V ................................................................................................................................6E8-39 Therm ostatic A ir Cleaner (THERMAC).................................................................................................................6E8-40 General D e s c rip tio n .............................................................................................................................................6E8-40 Diagnosis o f THERM AC...................................................................................................................................... 6E8-41 On-Vehicle Service — THERM AC..................................................................................................................... 6E8-42 Throttle Return Control (TRC) S ystem .................................................................................................................6E8-43 General D e s c rip tio n .............................................................................................................................................6E8-43 Diagnosis of T R C ............. ................................................................................................................................... 6E8-43 On-Vehicle Service — T R C ................................................................................................................................6E8-44 G EN ERA L INFORMATION DRIVEABILITY The driveability diagnosis procedures apply to various systems in current GM vehicles. The procedures assume that the vehicle worked right at one time and the problem is due to time, wear, dirt or other causes. Start with the introduction that follows. This will describe a systematic diagnostic procedure. Any system disconnected during diagnosis should be reconnected. This includes wires, hoses, linkage, etc. When removing air cleaner, plug hose fittings that could cause an air leak. EMISSIONS The exhaust emission control systems used on General Motors engines perform a specific function to lower exhaust emissions while maintaining good fuel economy and driveability. MAINTENANCE SCHEDULE Refer to the General Motors Maintenance Schedule in Section OB of this Service Manual for the maintenance service that should be perform ed to retain emission control performance. VEHICLE EMISSION CONTROL INFORMATION LABEL The Vehicle Emissions Control Information label (Fig. 1) contains important emission specifications and setting procedures. In the upper left corner is exhaust emission information which identifies the year, the manufacturing division of the engine, the displacem ent in liters of the engine, the class of vehicle and type of fuel metering. Also there is an illustrated em ission com ponent and vacuum hose schematic. This label is located in the engine compartment of every General Motors Corporation vehicle. If the label has been removed, it can be ordered from the parts division. (WDDGM) VISUAL/PHYSICAL UNDERHOOD INSPECTION One of the most important checks that must be done as p a rt o f a n y d ia g n o s tic p ro c e d u re is a c a re fu l visual/physical underhood inspection. This can often lead to fixing a problem without further steps. Inspect all vacuum hoses for correct routing, pinches, cuts, or disconnects. Be sure to inspect hoses that are difficult to see beneath the air cleaner, compressor, generator, etc. Inspect all the wires in the engine com partm ent for correct and good connections, burned or chaffed spots, pinched wires, or contact with sharp edges or hot exhaust m a n ifo ld s . T h is v is u a l/p h y s ic a l in s p e c tio n is ve ry important. It must be done carefully and thoroughly. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-3 ADJUSTM ENT PROCEDURE ENGINE ADJUSTMENT SPECIFICATIONS LABEL CODE EMISSION COMPONENT AND VACUUM HOSE SCHEMATIC LABEL PART NUMBER AREA OF CERTIFICATION "ALW AYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS". E X H A U S T E M IS S IO N S Y S T E M HGM07.4 AG A 4 7S-3218 Figure 1—Vehicle Emission Control Information Label 6E8-4 DRIVEABILITY AND EMISSIONS — CARBURETED ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES ENVIRONMENTAL PROTEC­ TION 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 ADJUST­ MENT 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. INTRODUCTION GENERAL DESCRIPTION The engine has controls to reduce exhaust emissions while m aintaining good driveability and fuel economy. The following emission controls are on all engines: • Positive Crankcase Ventilation (PCV) • Exhaust Gas Recirculation (EGR) • Therm ostatic Air Cleaner (THERMAC) • Air Injection Reaction (AIR) • Early Fuel Evaporation (EFE) • Evaporative Emission Control (EECS) • Throttle Return Control (TRC) • Deceleration Control Positive Crankcase Ventilation (PCV) All engines have closed Positive Crankcase Ventilation S ystem to p ro v id e m ore co m p le te s c a v e n g in g of crankcase vapors. Ventilation air is drawn from the dirty air side of the air cleaner, through a hose, down into the crankcase, up through the ventilator valve, through a hose and into the intake manifold. Intake manifold vacuum draws any fumes from the crankcase to be burned in the engine. EXHAUST GAS RECIRCULATION (EGR) The Exhaust Gas Recirculation system is used on all engines. It meters exhaust gas into the induction system for recirculation through the combustion cycle to reduce oxides of nitrogen emissions. v The EGR valve rem ains closed during periods of engine idle and deceleration to prevent rough idle from excessive exhaust gas d ilu tio n in the idle a ir/fu e l mixtures. It also remains closed at wide open throttle to prevent power loss. Thermostatic Air Cleaner (THERMAC) The Therm ostatic Air Cleaner is designed to keep air entering the carburetor at approximately 100°F. Keeping the air at 100°F, or more, improves engine warm-up driveability, and will help m inimize carburetor icing. Air Injection Reaction (AIR) The Air Injection Reaction system provides additional oxygen to the exhaust gases to continue the combustion process. EARLY FUEL EVAPORATION (EFE) The EFE system is used to provide a source of rapid h eat to th e e n g in e in d u c tio n syste m d u rin g co ld driveaway. Rapid heating is desirable because it provides fo r q u ic k fu e l e v a p o ra tio n and m ore u n ifo rm fu el distribution to aid cold driveability. Evaporative Emission Control This system has a canister which stores fuel vapor from the fuel tank and the carburetor. The fuel vapor is removed from the canister and consumed in the normal combustion process when the engine is running. Throttle Return Control (TRC) The Throttle Return Control system helps to prevent an over-rich condition on deceleration. The vacuum operated Throttle Kicker will not allow the throttle to close fully until the engine speed falls below a specified RPM. By holding the throttle open slightly, more air is allowed to enter the engine to maintain a more efficient air/fuel ratio. Deceleration Control The deceleration control uses a deceleration valve to control emissions and back-fire on deceleration. When deceleration causes a sudden rise in manifold vacuum, the deceleration valve will open to adm it fresh air to the inlet manifold. After a calibrated tim e delay, the valve will c lo s e . T h e s y s te m is m a in ly u s e d w ith m a n u a l transmission equipped vehicles. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-5 'G'series rpo:LT9 v in c o d e :M 5.7L V8 4BBL Heavy Duty EM IS S IO N S D E V IC ES 1 Crankcase vent valve (PCV) 2 Air injection pump 2a Air injection divert valve 3 Deceleration valve 4 EFE valve 6 Fuse panel 17 Fuel vapor canister 17a Fuel vapor canister solenoid 19 Throttle return control 20 Throttle valve relay Exhaust Gas Recirculation valve 5S-2149 Figure 2—Component Locations — 5.7 L (G-Series) 6E8-6 DRIVEABILITY AND EMISSIONS — CARBURETED SERIES r p o :LT9 v in c o d e :M 5.7 L V 8 4BBL Heavy Duty ...I EMISSIONS DEVICES 1 2 Crankcase vent valve (PCV) Air injection pump 2a Air injection divert valve 3 Deceleration valve 4 EFE valve 6 Fuse panel 17 Fuel vapor canister solenoid 19 Throttle return control 20 Throttle valve relay 21 Engine speed relay Exhaust Gas Recirculation valve 5S-2150 Figure 3—Component Locations — 5.7 L (P-Series) DRIVEABILITY AND EMISSIONS - 'P' SERIES rpo :LE 8 v in c o d e CARBURETED 6E8-7 :W 7.4L V8 4BBL Heavy Duty «ii>: 19 *■ 2a — 2 IT f k_J 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 17 Fuel vapor canister 19 Throttle return control 20 Throttle valve relay Exhaust Gas Recirculation valve 5S-2152 Figure 4—Component Locations — 7.4 L (P-Series) 6E8-8 DRIVEABILITY AND EMISSIONS — CARBURETED DRIVEABILITY SYMPTOMS BEFORE STARTING VISUAL CHECK Verify the custom er com plaint, and locate the correct symptom below. Check the items indicated under that symptom. If the ENGINE CRANKS BUT WILL NOT RUN, see “ No Start — Engine Cranks O K ” below. Several of the symptom procedures below call for a careful visual check. This check should include: • V a cu u m h o s e s fo r s p lits , k in ks, and p ro p e r c o n n e c tio n s , as sh ow n on E m is s io n C o n tro l Information label. • A ir le a ks at c a rb u re to r m o u n tin g and in ta k e manifold. • Ignition wires for cracking, hardness, proper routing, and carbon tracking. • W iring for proper connections, pinches, and cuts. DISTRIBUTOR INFORMATION Refer to Section 6 D, Engine Electrical, for Ignition System including distributor information. CARBURETOR ADJUSTMENT Carburetor adjustment and specifications can be found in Section 6 C 1, Carburetors. Theimportanceof this step cannot bestressedtoo strongly—it canleadtocorrectingaproblemwithout furtherchecksandcansavevaluabletime. WON’T START — ENGINE CRANKS OK Definition: Engine cranks OK, but does not start. May fire a few times. • Make sure proper starting procedure is being used. See O w ner’s Manual. • Visual check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Ignition w ires fo r cracking, hardness and proper connections at both distributor cap and spark plugs. • Remove air cleaner: — C h e c k c a rb u re to r ch o ke v a lve , va c u u m break(s), linkage and unloader operation. See Section 6 C. Set to specifications. Choke valve should move sm oothly and be closed when cold, and open when hot. • Check for presence of fuel by noting carburetor ac­ celerator pum p operation. Look for gas squirt in car­ buretor bore while quickly opening throttle lever. — If no pump squirt: • Check for fuel in tank. • Check carburetor fuel inlet filter. Replace if dirty or plugged. • • • • • Check fuel pump capacity. • If fuel pump checks OK, check float nee­ dle for sticking in seat, or binding float. — If there is a pump squirt: • Crank engine and check for flooding. • If not flooding, see “ Ignition System Di­ agnosis,” Section 6 D. Remove spark plugs. Check for wet plugs, cracks, wear, im proper gap, burned electrodes, or heavy de­ posits. Repair or replace as necessary. Visually check distributor cap inside and out for moisture, dust, cracks, burns, and arcing to coil m ounting screws. Try to turn distributor shaft by hand. Drive pin may be broken. Very cold temperatures: — Check that the proper viscosity oil is being used, and crank case oil is not contaminated with gasoline. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-9 HARD START — COLD Definition: Engine cranks OK, but does not start for a long time. Does eventually run. If the engine starts but imm ediately dies (as soon as key is released from start position), see “ No Start, Engine Cranks O K” symptom. • Make sure driver is using correct starting procedure. See Ow ner’s Manual. • Visual check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Air leaks at carburetor m ounting and intake manifold. — Ignition wires for cracking, hardness, and proper connections, at both the distributor cap and spark plugs. — W iring for proper connections, pinches and cuts. • Check the choke valve, throttle and fast idle cam for s tic k in g . R eplace any m a lfu n ctio n in g parts. If caused by foreign material and gum, clean with suit­ able non-oil base solvent. See Section 6 C. • Check choke and vacuum break operation and ad­ justm ent. Choke should be closed cold. See Section 6 C. • Check EGR system for sticky operation that could cause valve to stick open. • Check float level using external float gage. Adjust float to specification if required. See Section 6 C. • Check carburetor fuel inlet filter. Replace if dirty or plugged. • Check ignition system — see Section 6 D. Check distributor for: — Worn shaft. — Bare and shorted wires. — Pick-up coil resistance and connections. — Loose ignition coil ground. — Moisture in distributor cap. • Remove spark plugs; check for wet plugs, wear, im­ proper gap, burned electrodes or heavy deposits. Repair or replace as necessary. • Check ignition tim ing per Vehicle Emission Control Information label. • Verify proper engine oil viscosity per recomm enda­ tions in M aintenance Schedule. • Check fuel pump volume, pressure and vacuum. HARD START — HOT Definition: Engine cranks OK, but does not start for a long time. Does eventually run. If the engine starts but imm ediately dies (as soon as key is released from start position), see Ignition System Diagnosis, Section 6 D. • Visual (physical) check: — Vacuum hoses for splits, kinks, and proper connections, as shown on Vehicle Emission Control Information label. — Ignition wires for cracking, hardness, and proper connections, at the distributor cap and s p a r k p lu g s . • • • • • • — W iring for proper connections, pinches and cuts. Make sure driver is using correct starting procedure. See O w ner’s Manual. Check choke valve, throttle linkage and fast idle cam for sticking. Check choke and vacuum break operation and ad­ justm ent. Choke should be open hot. See Section 6 C. Check for carburetor flooding. Check fuel inlet filter. If plugged replace. Check float level using external float gage. Adjust float to proper specification if required. See Section 6C. • Check fuel pump volume, pressure and vacuum. • Check fuel line routing. • Check EFE valve. EFE valve should be open. • Check EGR for sticky operation that could cause valve to stick open. • Check for obvious overheating problems: — Low coolant. — Loose water pump belt. — Restricted air flow to radiator, or restricted water flow through radiator. • Check ignition system, Section 6 D. Check distribu­ tor for: — Worn shaft. — Bare and shorted wires. — Interm ittent pickup coil or connections, mod­ ule, ignition coil ground and condenser. Repair or replace as necessary. • Remove spark plugs. Check for cracks, wear, im ­ proper gap, burned electrodes, heavy deposits. Re­ pair or replace as necessary. • Check ignition tim ing. See Vehicle Emission Control Information label. 6E8-10 DRIVEABILITY AND EMISSIONS — CARBURETED 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 “ O N ” or transmission engaged); or (3) Dies on initial driveaway. If symptom is present cold and hot, go to symptom “ Stall After Start — H ot.” • Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. • Make sure hot air tube is connected to air cleaner. • Check proper operation of THERMAC. • Check carburetor choke valve, throttle linkage and fast idle cam for sticking. • 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 vac­ uum is at hose, check for binding linkage. If linkage OK, replace vacuum break unit. • With engine “ OFF,” check all choke adjust­ ments, including vacuum breaks and TVS if used. See Section 6 C. • Check fast idle speed setting and curb idle speed. • Check carburetor accelerator pump operation. • Check EFE valve for proper operation. EFE valve should be closed cold. See Chart C-9C. • Check EGR valve for proper operation. See Chart C-7C. • Check engine tim ing. See Vehicle Emission Control Information label. • Poor or c o n ta m in a te d g a s o lin e . S u g g e st owner try different brand. 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 “ O N ” or transmission engaged); (3) dies on initial driveaway. Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. Make sure hot air tube is connected to air cleaner. Check proper operation of THERMAC. Check carburetor choke and vacuum breaks for proper operation. See Section 6 C for check proce­ dure. Check float level using external float gage. See Sec­ tion 6 C. Check carburetor accelerator pum p operation. Check EGR valve for proper operation — Chart C7C. Check for overcharged A/C System. Check for obvious overheating problems: — Low coolant. — Loose water pump belt. — Restricted air flow to radiator or restricted water flow through radiator. 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. • Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Ignition wires for cracking, hardness, and proper connections, at both distributor and spark plugs. — W iring for proper connections, pinches and cuts. • Make sure hot air tube is connected to air cleaner. • Check proper operation of THERMAC. See diagno­ sis of THERMAC. • Note: Cold engine only — check the following for sticking or faulty operation: — Carburetor choke, including vacuum breaks, throttle linkage and fast idle cam. — Check all choke adjustments, including vac­ uum breaks. • Check float level using external float gage. See Sec­ tion 6 C. • Check carburetor accelerator pump operation. • Check EGR valve operation — Chart C-7C. • Check canister purge system for proper operation. See Evaporative Emission Control System Diagno­ sis. • Check for open ignition coil ground and for interm it­ tent ECM ground. • Check engine tim ing. See Vehicle Emission Control Information label. • Poor or contaminated gasoline. Try a different brand of gasoline. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-11 SURGES AND/OR CHUGGLE Definition: Engine power variation under steady throttle or cruise. Feels like the car speeds up and slows down with no change in the accelerator pedal. • Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Ignition wires for cracking, hardness, and proper connections, at both distributor and spark plugs. — W iring for proper connections, pinches and cuts. • Have driver read explanation of transmission con­ verter clutch and A/C compressor operation in Own­ e r’s Manual. • Make sure hot air tube is connected to air cleaner. • Check proper operation of THERMAC. See diagno­ sis of THERMAC. • Check for intermittent open, or short to ground in TCC circuit. • Check for proper operation of EGR. See Chart C-7C. • Check carburetor fuel inlet filter, replace if dirty or plugged. • Check carburetor float level using external float gage. See Section 6 C. • Test fuel pump capacity. See Section 6 C. • Remove spark plugs, check for cracks, wear, im ­ proper gap, burned electrodes or heavy deposits. • Check condition of distributor cap, rotor and spark plug wires. • Check for arcing to coil attaching screws in distribu­ tor cap. • Check for interm ittent ground connection on integral ignition coil. • Poor or contam inated gasoline. Try a 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. • Visual check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Ig nitio n w ire s fo r cra ckin g , harness, and proper connections, at both the distributor cap and spark plugs. — W iring for proper connections, pinches and cuts. • Compare custom er’s vehicle to sim ilar unit. Make sure the custom er’s vehicle has an actual problem. Was the custom er’s old vehicle much more power­ ful? • Make sure hot air tube is connected to air cleaner. • Remove air cleaner and check air filter for dirt. • Check for proper operation of THERMAC. See diag­ nosis of THERMAC. • Check for full throttle valve opening in carburetor by depressing accelerator pedal to floor. • Check carburetor float level using external float gage. • Check for proper operation of carburetor air valve. See Section 6 C. • Check ignition tim ing. See Vehicle Emission Control Information label. • Check transmission for proper downshift and TCC operation. • Check EGR operation. See Chart C-7C. • Check EFE Valve. • Remove spark plugs. Check for cracks, wear, im­ proper gap, burned electrodes, heavy deposits. Re­ pair or replace as necessary. • Check for an exhaust system restriction: 1 . With engine at normal operating temperature, connect a vacuum gage to any convenient vacuum port on intake manifold. 2. Run engine at 1000 rpm and record vacuum reading. 3. Increase rpm slowly to 2500 rpm. Note vac­ uum reading at steady 2500 rpm. 4. If vacuum at steady 2500 rpm is more than 3 inches lower than 1000 rpm, exhaust system sh ou ld be insp ected fo r re s trictio n s. See Chart B-1 . • Check engine valve tim ing and compression. • Check engine for proper or worn camshaft, see Sec­ tion 6 A. • Poor or contaminated fuel. Try a different brand of gasoline. 6E8-12 DRIVEABILITY AND EMISSIONS — CARBURETED BACKFIRE Definition: Fuel ignites in intake manifold, or exhaust system, making a loud popping noise. • Visual check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Ignition wires for cracking or hardness proper connection, at both the distributor cap and spark plugs. — Chaffed wiring harness by pulleys or metal edges. • Make sure hot air tube is connected to air cleaner. • Check proper operation of THERMAC. See diagno­ sis of THERMAC. • Note: Cold engine only — check the following for sticking or faulty operation: — C arburetor choke, including vacuum break and throttle linkage. • Check EFE Valve. • Check carburetor accelerator pump operation. • Check for proper operation of EGR valve. • Perform a compression check — look for sticking or leaking valves. • Check for restricted exhaust system. See Chart B-1. • Check output voltage of ignition coil. See Ignition System Diagnosis, Section 6 D. • C h e c k o p e ra tio n of d e c e l (g u lp ) va lve if so equipped. • Check for crossfire between spark plugs, distributor cap, spark plug wires and proper routing of plug wires. W ires for cylinders which fire in sequence on the same side of the engine should not be routed next to each other; i.e., 8 and 4, and 5 and 7. See Section 6 D. • Check for intermittent condition in ignition system. — Pick-up coil. — Ignition coil ground on integral coil. — Ignition coil prim ary connections. • Check for proper valve tim ing. 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 rpm (48 km/h). Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections, as shown on Vehicle Emission Con­ trol Information label. — Ignition w ires for cracking, hardness and proper connections at both distributor cap and spark plugs. — W iring for proper connections, pinches and cuts. Check spark plug wire routing for correct firing or­ der. Check for m isfiring at spark plugs: 1. Disconnect and plug air cleaner and EGR vac­ uum hoses. 2. Check spark at all plug wires with J26792 (ST125). — If there is no spark on any cylinder, see “ Ignition System D iagnosis,” Section 6 D. — Spark at all cylinders. Visually check distributor cap inside and out for moisture, dust, cracks, burns and check for coil arcing to mounting screws. With engine running, spray cap and plug wires with fine water mist to check for shorts. Check for poor ground on integral ignition coil. Check EGR valve for sticking partially open. Remove spark plugs and check for cracks, wear, im­ proper cap, burned electrodes and heavy deposits. Check pickup coil in distributor with ohmmeter, and check for proper connections at module. Pickup coil should be 500-1500 ohms and not grounded. See Sec. 6 D. — If pickup coil checks OK, • Check for ignition dwell increase from low to high rpm by connecting dwell me­ ter to d istributor “ TACH” term inal. If dwell doesn’t increase, replace ECM. Remove rocker covers, check for bent pushrods, worn rocker arms, broken valve springs, worn cam ­ shaft lobes. Repair as necessary. See Section 6 A. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-13 ROUGH, UNSTABLE OR INCORRECT IDLE; STALLING Definition: The engine runs unevenly at idle. If bad enough, the car may shake. Also, the idle speed may vary (called “ hunting” ). Either condition may be bad enough to cause stalling. Engine idles at incorrect speed. • Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections as shown on Vehicle Emission Con­ trol Information label. — Ignition wires for cracking, hardness, or proper connections, at both distributor cap and spark plugs. • Check throttle linkage for sticking or binding. • Check carburetor for flooding. • Check float level using external float gage. See Sec­ tion 6 C. • Check engine idle speed. See Vehicle Emission Control Information label. • Check EGR System. See Chart C-7C. There should be no EGR at idle. • If rough idle occurs hot, perform these additional checks: — Check PCV valve for proper operation by plac­ ing finger over inlet hole in valve end several times. Valve should snap back. If not, replace valve. — Check canister purge and bowl vent control system. See Evaporative Emission C ontrol System Diagnosis. — Remove carbon with top engine cleaner. Fol­ low instructions on can. — Check for proper spark plug gap. — Run a cylinder compression check. See Sec­ tion 6 . • Check ignition tim ing. See Vehicle Emission Control Information label. • Check for exhaust system restriction. See Chart B-1 . WONT IDLE Definition: Engine starts OK, but dies at idle. Will run if accelerator pedal is held at part throttle. • Visual (physical) check: — Vacuum hoses for splits, kinks and proper con­ nections as shown on Vehicle Emission Con­ trol Information label. — Air leaks at carburetor m ounting and intake manifold. • Check carburetor float level using external float gage. See Section 6 C. • Check for carburetor flooding. See Section 6 C. • Check EGR system. See Chart C-7C. Check for a loose valve or sticking EGR plunger. If sticking oper­ ation is found, clean or replace valve. There should be no EGR at idle. It may be necessary to remove the valve to check for leaking. • Check engine idle speed. See Vehicle Emission Control Information label. • Check carburetor idle adjustment. If unable to ad­ just, check carburetor idle system. See Section 6 C. • Check spark plug condition and gap. • Check for exhaust system restriction. See Chart B1. 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 shown by an actual road test. Check owner’s driving habits. — Is A/C on full tim e (defroster mode on)? — Are tires at correct pressure? — Are excessively heavy loads being carried? — Is acceleration too much, too often? — Suggest driver read “ Im portant Facts on Fuel Econom y” in O w ner’s Manual. Check air cleaner dam per door operation (THERMAC). Check air cleaner element (filter) for dirt or being plugged. Check for proper calibration of speedometer. Visual check: — Vacuum hoses for splits, kinks and proper con­ nections as shown on Vehicle Emission Con­ trol Information label. — Ignition w ires for cracking, hardness and proper connections. Check ignition tim ing. See Vehicle Emission Control Information label. Remove spark plugs. Check for cracks, wear, im ­ proper gap, burned electrodes or heavy deposits. Repair or replace as necessary. Check compression. See Section 6 A. Check TCC for proper operation. Check for dragging brakes. Suggest owner fill fuel tank and recheck fuel econ­ omy. Check for exhaust system restriction. See Chart B-1 . 6E8-14 DRIVEABILITY AND EMISSIONS — CARBURETED DIESELING, RUN-ON Definition: Engine continues to run after key is turned “ OFF,” but runs very roughly. If engine runs smoothly, check ignition switch and adjustment. • Visual check: — Vacuum hoses for splits, kinks and proper con­ nections as shown on Vehicle Emission Con­ trol Information label. — Carburetor choke, throttle linkage and fast idle cam for sticking. • Check carburetor choke, vacuum break linkage, throttle linkage and fast idle cam for proper adjust­ ment. See Section 6 C. • Check cruise control for proper adjustment. • Check engine idle speed. • Check ignition timing. See Vehicle Emission Control Information label. • Remove carbon with top engine cleaner. Follow in­ structions on can. • Check for engine overheating. Normal coolant tem­ perature is 8 5 °C -1 0 0 °C (185°F-215°F). — Low coolant. — Loose vfater pump belt. — Restricted air flow to radiator, or restricted water flow through radiator. — Inoperative fan clutch. DETONATION/SPARK KNOCK Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp m etallic knocks that change with throttle opening. Sounds like popcorn popping. Check EGR System for proper operation. See Chart C-7C. Check ignition tim ing. See Vehicle Emission Control Information label. Check for obvious overheating problems. 8 5 °C 100°C (185°C -215°F) is normal. — Low coolant. — Loose water pump belt. — Restricted air flow to radiator, or restricted water flow through radiator. — Inoperative fan clutch. • Check for air leaks at carburetor mounting and in­ take manifold. • Check for poor fuel quality, proper octane rating. • Remove carbon with top engine cleaner. Follow in­ structions on can. • If excessive carbon in cylinders, check for leaking valve seals. • Check for improper operation of transmission (i.e., linkage adjustment) and TCC. • Check for incorrect basic engine parts, such as cam, heads, pistons, etc. EXCESSIVE EXHAUST EMISSIONS (ODORS) Definition: Car fails an emission test. May also have excessive “ rotten egg” smell (hydrogen sulfide). • If test shows excessive CO and HC (also has exces­ sive odors): • Remove air cleaner and check air filter for dirt or being plugged. Replace as necessary. • Check operation of air m anagem ent sys­ tem. See appropriate C-6 HD Chart in Air Injection Reaction section. • Check carburetor for flooding. • Check float level using external float gage. See Section 6 C. • Check canister for loading and check purge system for proper operation. See Evaporative Emission Control System Di­ agnosis. • Check for incorrect idle speed. • C heck for m isadjusted idle m ixture if plugs are removed. • Check for incorrect tim ing. See Vehicle Emission Control Information label. • Check choke valve and linkage for stick­ ing of faulty operation. • Check condition of spark plugs, plug wires and distributor cap. • If test shows excessive NOx: — Check items which cause car to run rich. • Make sure engine is at normal operating temperature. • Visually check hoses for splits, kinks and proper connections, as shown on Vehi­ cle Emission Control Information label. • Check choke, vacuum breaks and fast idle adjustments. • Check for stuck PCV valve or obstructed hose. • Check for lead contamination of catalytic converter. Check for absence of filler neck restrictor. — Check items which cause vehicle to run lean, or to run too hot. • Check EGR valve for not opening. See Chart C-7C in Section C. • Check for vacuum leaks. • Check for inoperative THERMAC. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-15 • Check ignition tim ing for excessive base advance. See Vehicle Emission Control Information label. Check coolant system and cooling fan for proper operation. Remove carbon with top engine cleaner. Follow instructions on can. 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 restricted catalytic converter should be suspected, and replaced using current recommended procedures. [ T ] fuel pump pr essur e g a u g e [ T ] hose a n d n ip p l e f r o m p r o p a n e e n r ic h ­ ment DEVICE (J-26911) 4S-1168 Chart B-1—Restricted Exhaust System Check 6E8-16 DRIVEABILITY AND EMISSIONS — CARBURETED EVAPORATIVE EMISSION CONTROL SYSTEM (EECS) Figure 5—Evaporative Emissions System GENERAL DESCRIPTION PURPOSE The Evaporative Em ission C ontrol System (EECS) (Figure 5) limits fuel vapor into the atmosphere. The system traps fuel vapor from the fuel tank and carburetor float bowl into a fuel vapor canister. The fuel tank has a non-vented fuel cap and a single vent pipe to the canister. The canister absorbs and stores the fuel vapor in a carbon element until it can be removed and burned during the normal com bustion process. When the engine is running, a therm ostatic vacuum switch determines when the fuel vapor is purged into the intake air flow. OPERATION (Figure 5) This system uses the following control valves: • Purge control valve mounted on the canister. • Vapor vent valve mounted on the canister. • A therm al bowl vent valve (some applications). • A therm ostatic vacuum switch (TVS) installed in the in ta k e m a n ifo ld to s e n s e e n g in e c o o la n t temperature. When the engine is shut off, manifold vacuum is lost at the vapor vent valve. The spring loaded valve in the vapor vent valve now connects the carburetor bowl vent to the canister. Carburetor float cham ber vapors now pass into the canister for storage. When the engine is restarted, manifold vacuum draws the vapor vent controlling valve against spring pressure, closing off the bowl vent. Ported vacuum from the carburetor is connected to the TVS. When the TVS opens, ported vacuum opens the purge control valve. When the valve opens, manifold vacuum draws vapors from the canister into the intake manifold. The therm al bowl vent valve (TBVV) is located in the section of hose that connects the carburetor bowl vent fitting to the canister control valve. The TBVV will close and prevent vapor movement at 3 2 °C (90°F) and below. The TBVV will open at 49°C (120°F) to permit vapor flow to the canister control valve. FUEL VAPOR CANISTER, PRIMARY (Figure 6) The basic large size, two cham ber closed bottom canister is used on all systems and operates as follows: Gasoline vapors from the fuel tank flow into the tube labeled “ Fuel Tank,” and vapors from the carburetor float bowl flow into the tube labeled “ CARB BO W L,” and are absorbed by the carbon. The canister is purged when the engine is running above idle speed. The closed bottom design keeps water from entering the bottom of the canister, freezing, and restricting purge air flow. During purge, air is drawn from the clean side of the air cleaner, to the tube on the canister labeled “ AIR C LN R ,” through the carbon and into the intake manifold to be burned. Some closed bottom canisters draw purge air directly from the atmosphere. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-17 m LARGE SIZE TWO CHAMBER CLOSED BOTTOM CANISTER l 2 j VAPOR VENT CONTROL VALVE H I PURGE CONTROL VALVE H H CLEAN AIR TUBE "A IR CLNR" m VAPOR FROM FUEL TANK [ 6 | VAPOR FROM BOWL VENT [ T ] TO MANIFOLD VACUUM SIGNAL [~8~! TO PORTED VACUUM [~9~i VAPOR TO PURGE LINE fTp"; FILTER j j j j CARBON f l T i BOTTOM COVER f l 3 ] DUST CAP O f ] AIR FLOW 5S-1659 Figure 6—Fuel Vapor Canister CANISTER PURGE CONTROL VALVE (Figure 6) The Canister Purge Control Valve is a spring-biased d ia p h ra g m valve, norm a lly close d, w hich allow s or prevents purging of the canister. When the engine is off or idling, the spring holds the valve closed, preventing canister purge. When the engine is off-idle, however, tim ed manifold vacuum pulls the diaphgram upward, opening the valve and allowing the canister to be purged. DIAGNOSIS OF EECS SYSTEM DIAGNOSIS • Poor idle, stalling and poor driveability can be caused by: • Inoperative vapor vent valve. • Inoperative purge control valve. • Damaged canister. • Hoses split, cracked and, or, not connected to the proper tubes. VAPOR VENT CONTROL VALVE (Figure 6) The vapor vent control valve prevents venting of the c a rb u re to r flo a t bow l d u rin g e n g in e o p e ra tio n . A spring-biased diaphragm valve, normally open, allows (or prevents) fuel vapors from the float bowl to enter the canister. When the engine is off, spring tension holds the valve open, allowing normal venting. W hen the engine is turned on, however, m anifold vacuum pulls the diaphragm up to close the valve. FUEL VAPOR CANISTER, AUXILIARY (Figure 7) An Auxiliary Fuel Vapor Canister is added to a primary closed bottom canister to increase capacity when a dual (aux.) fuel tank is used. On the bottom is a hose which connects to the primary canister’s purge air inlet. On top is a purge air inlet. Vapor overflowing from the primary canister is stored in the auxiliary canister. During purge, vapor flows through the auxiliary canister, the primary canister and into the intake manifold for burning during combustion. m A U X IL IA R Y CANISTER f~4~l AIR FLOW DURING PURGE | 2 j CARBON f 5 j DUST CAP m I S I VAPOR FROM PRIMARY CANISTER FILTERS 4S-1018 Figure 7—Auxiliary Vapor Canister 6E8--18 DRIVEABILITY AND EMISSIONS — CARBURETED • Evidence of fuel loss or fuel vapor odor can be caused by: • Liquid fuel leaking from fuel lines, fuel pump or carburetor. • Cracked or damaged canister. • Inoperative bowl vapor vent valve. • Inoperative purge control valve. • Disconnected, misrouted, kinked, deteriorated or damaged vapor hoses, or control hoses. • Bowl vent hose misrouted. • Air cleaner or air cleaner gasket inproperly seated. FUEL VAPOR CANISTER V is u a lly ch e ck c a n is te r and rep la ce if cracke d, damaged or saturated with fuel. Apply a short length of hose to the carburetor bowl vapor tube of the canister (lower tube), and blow into it, to determine that air will pass the vapor vent valve into the canister. If not possible to blow into the canister, it must be replaced. VAPOR VENT CONTROL VALVE Functional Test Apply a short length of hose to the carburetor bowl vapor tube of the canister (lower tube), and blow into it to determine that air will pass the vapor vent valve into the canister. If not possible to blow into the canister, it must be replaced. With a hand vacuum pump, apply vacuum 51 kPa (15" Hg) to the vacuum sign al tube on the d iaphragm assembly cover. The diaphragm should hold vacuum for at least 20 seconds. If it does not, diaphragm is leaking, and the canister must be replaced. With vacuum still applied to the vacuum signal tube, again attempt to blow into the carburetor bowl vapor tube of the canister. Now air should not pass the vapor vent valve into the canister, indicating that the valve is sealing properly. If air does enter the canister past the vapor vent valve, the valve is not functioning properly, and the canister must be replaced. PURGE CONTROL VALVE Functional Test Apply a short length of hose to the PCV tube of purge valve assembly (lower tube), and attempt to blow through it. Little or no air should pass into the canister. (A small amount of air will pass if the canister has a constant purge hole.) With a hand vacuum pump, apply vacuum 51 kPa (15" Hg) through the control vacuum signal tube to the purge valve diaphragm. If the diaphragm does not hold vacuum for at least 2 0 seconds, the diaphragm is leaking, and the canister must be replaced. If the diaphgram holds vacuum, again try to blow through the hose connected to the PCV tube while vacuum is still being applied. An increased flow of air should be observed. If not, the canister must be replaced. THERMOSTATIC VACUUM SWITCH (TVS) REPLACEMENT Thermal vacuum switches opens, closes, or switches vacuum source w hen the ca lib ra tion tem perature is reached. The following general checking procedures can be used for all therm al vacuum switches. Refer to number stam ped on base of valve or sw itch for calibration temperature. 1. Allow TVS to cool below calibration temperature. 2. Inspect switch to make sure it is in good condition. 3. Connect hand vacuum pump(s) to output port(s) of the TVS. (See vacuum hose schematic on Vehicle Control Emission Information label.) 4. Apply 51 kPa (15" Hg) vacuum. 5. Heat TVS to a temperature above the calibration temperature. Never apply a torch or open flame directly to the TVS. 6 . C om pare vacuum gage reading to the correct reading indicated on switch or valve base. NOTICE: Leakage of up to 7 kPa (2" Hg) vacuum in 2 minutes is allowable and does not mean a defective part. 7. If operation is satisfactory, reinstall valve or switch. If valve or switch is defective, replace with a new part. ON-VEHICLE SERVICE — EECS SYSTEM HOSES Refer to Vehicle Emission Control Information label for routing of system hoses. When replacing hoses, use hose identified with the word “ Fluoroelastromer.” VAPOR PIPE The vapor pipe is secured to the underbody with clamp and screw assemblies. Flexible hoses are connected at the fuel tank and the fuel vapor canister. The pipe should be inspected occasionally for leaks, kinks or dents and repaired as required. Repair Repair vapor pipe in sections using brazed seamless steel tu bin g m eeting GM S p ecifica tion 123M or its e q u iv a le n t o r h o s e id e n tifie d w ith th e w o rd “ Fluoroelastomer.” Hose not so marked could cause early failure or failure to meet emission standard. • Do not use copper or alum inum tubing to replace s te e l tu b in g . T h o s e m a te r ia ls do n o t have satisfactory durability to withstand normal vehicle vibrations. • Do not use rubber hose within 4 inches (100 mm) of any part of the exhaust system or within 10 inches (254 mm) of the catalytic converter. Hose inside diameter must match steel tubing outside diameter. 1. In repairable areas, cut a piece of fuel hose 4 inches (100 mm) longer than portion of the line removed. If more than a 6 -inch (152 mm) length of pipe is removed, use a com bination of steel tubing and hose so that hose lengths will not be more than 10 inches (254 mm). Follow the same routing as the original pipe. 2 . Cut ends of pipe rem aining on vehicle square with a tube cutter. Using the first step of a double flaring tool, form a bead on the end of both pipe sections. If pipe is too corroded to withstand bead operation DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-19 without damage, the pipe should be replaced. If a new section of pipe is used, form a bead on both ends of it also. 3. Use screw type hose clamp, Part Number 2494772, or equivalent. Slide clam ps onto pipe and push hose 2 inches (51 mm) onto each portion of fuel pipe. Tighten clamps on each side of repair. 4. Pipes must be properly secured to the frame to prevent chafing. FUEL CAP If a fuel tank filler cap requires replacement, use only a cap with the same features. Failure to use the correct cap can result in a malfunction of the system. CANISTER REPLACEMENT 1. Disconnect hoses from canister. Mark hoses for installation on new canister. Also refer to the Vehicle Emission Control Information label. 2. Remove screw from bracket and remove canister. 3. Install canister and bracket screw. 4. Connect hoses to canister. AUXILIARY VAPOR CANISTER Replacement 1. Disconnect hose from canister. 2. Remove screw from bracket and remove canister. 3. Install canister and connect hose. THERMOSTATIC VACUUM SWITCH 1. 2. 3. 4. Drain coolant below level of switch. Disconnect vacuum hoses. Remove switch. Apply a soft setting sealant to the threads of therm ostatic vacuum switch. Sealant should not be on the end of the switch. 5. Install switch, tighten to 14 N m (120 in. lbs.) and then turn clockwise as required to align with hoses. 6 . Connect hoses. 7. Add coolant as required. PARTS INFORMATION PART NAME..........................................................GROUP Canister, Fuel V a p o r.......................................................3,130 Solenoid, Fuel Vapor C a n is te r..................................... 3,140 AIR INJECTION REACTION (AIR) SYSTEM GENERAL DESCRIPTION The heavy duty emission engines with vehicle weight over 8500 GVW have an AIR System with increased air flow. The system is used to reduce carbon monoxide (CO), and hydrocarbon (HC) emissions. The air injection reaction (AIR) system provides a dditional oxygen to continue the combustion process after the exhaust gases leave the combustion chamber. The system diverts air from the exhaust manifold at increased engine speed or when an electrical malfunction is detected in the system. The system used on a 4.8 L engine consists of an air pump, air filter, air control valve, check valve, silencer, air tem perature sw itch, control m odule, and necessary plumbing. AIR CONTROL VALVE (HFEAC) (Figure 8) This valve is a high flow electric air control (HFEAC) valve that has an electric solenoid to combine electronic control with normal diverter valve function. With ignition “ O N ,” the solenoid is energized through the control m odule and the air control valve operates like a s ta n d a rd iz e d d iv e rte r va lve . W ith th e s o le n o id energized, air is directed to the exhaust manifold. During an engine decel, when there is a rise in the manifold vacuum signal, air is directed to the air cleaner or silencer even though the solenoid is energized. The solenoid is de-energized when there is high engine speed over a prolonged period or a m alfunction of the electrical circuit. “ SERVICE ENGINE SOON” LIGHT • The air pump(s) is belt driven on the front of the engine and supplies the air to the system. If there is a malfunction in the control module, wiring harness or solenoid(s), an amber “ SERVICE ENGINE SOON” light will illuminate on the instrument panel. The “ SERVICE ENGINE SO O N ” light is “ O N ” w ith the ignition key “ O N ” and the engine not running as a bulb check (except 7.4 L). When the engine is started, the light will remain on for three to six seconds and then turn off. On a 7.4 L system, with ignition “ O N ” and the engine not running, the “ SERVICE ENGINE SO ON” light will come “ O N ” and stay “ O N ” for 1 -2 seconds and then go “ O FF” as a bulb check. • Intake air passes through an external air filter to the air pump(s). DECELERATION CONTROL (Figure 9) The system used on a 5.7 L or 7.4 L engine consists of two AIR pumps, an air filter, two air control valves, two check valves, a control module and necessary plumbing. The 7.4 L engine also uses a control relay to operate the “ SERVICE ENGINE SOON” light. AIR OPERATION • Air flow from the pump(s) passes through a control valve(s) and an AIR pipe(s) and into the exhaust manifold. • The check valve prevents back flow of exhaust into the pump in the event of an exhaust backfire or pump drive belt failure. To help p re v e n t b a c k firin g d u rin g h ig h va cu u m conditions a deceleration (gulp) valve is used with these AIR systems. The high vacuum draws the deceleration valve diaphragm down and opens the valve allowing air from the air cleaner to flow into the intake manifold. This air enters the air/fuel mixture to lean the rich condition created by high vacuum when the throttle valve closes on deceleration. 6E8-20 DRIVEABILITY AND EMISSIONS — CARBURETED The vacuum draws the deceleration valve diaphragm down and opens the valve allowing air from the air cleaner to flow into the intake manifold. DIAGNOSIS OF AIR AIR SYSTEM NOTICE: If the e n g in e o r u n d e r hood compartment is to be cleaned with steam or high-pressure detergent, the intake air filter should be masked off to prevent liquids from entering the pump. [ 7 1 HIGH FLOW ELECTRIC ----- AIR CONTROL VALVE |~6~| DECEL TIM ING CHAMBER n riD E C E L TIMING ASSEMBLY [T~] DIVERT AIR TO AIR CLEANER OR SILENCER r y ] VERY HIGH VACUUM SIGNAL PORT f T I ELECTRICAL TERM INAL f T I SOLENOID 09 25 84 m AIR FROM PUMP ( T l AIR TO EXHAUST PORTS [To] PRESSURE RELIEF ASSEMBLY 5S-1934 Figure 8—Air Control Valve The AIR System is not completely noiseless. Under normal conditions, noise rises in pitch as engine speed increases. To determ ine if excessive noise is the fault of the Air Injection Reactor System, operate the engine with the pump drive belt removed. If excessive noise does not exist with the belt removed, check for the following: • A seized air pump. • Im proper m ounting and bolt torque of pump. • Im proper routing and connections of hoses. CAUTION: Do not oil air pump. • Replace pump if none of the above conditions exist. “ SERVICE ENGINE SOON” LIGHT If the “ SERVICE ENGINE SO O N ” light is on with the engine running, refer to the proper C- 6 HD Chart for diagnosis. AIR PUMP The air pum p is permanently lubricated and requires no periodic maintenance. Accelerate engine and observe air flow from hose(s). If air flow increases as engine is accelerated, pump is operating satisfactorily. If air flow does not increase or is not present, proceed as follows: L* Inspect 1. For proper drive belt tension. 2. For a leaky pressure relief valve. Air may be heard leaking with the pump running. AIR CONTROL VALVE f T ] AIR FLOW [Tl EXHAUST GAS f i~ 1 AIR CLEANER \j2 EXHAUST VA LV E [~9~] DECELERATION VALVE f~4~l INTAKE FLOW f T o l M ANIFOLD VACUUM l~5~l INTAKE VA LV E | 6 | COMBUSTION CHAMBER R l 1 DIAPHRAGM A ir pum p should be w orking properly. D isconnect solenoid connector at valve. W ith ignition “ O N ,” check for 12 volts at the connector. If there is no voltage, refer to the proper C- 6 HD Chart for diagnosis. Start engine. Air should go to the air cleaner or silencer. Connect the solenoid connector and air should go to the exhaust ports. Check for manifold vacuum signal at valve with engine idling. Vacuum should be 10" Hg (34 kPa). During decel and high vacuum signal, air should go to the air cleaner and silencer. Replace valve if any of the conditions are not correct. f i l l VALVE [ T l VACUUM BLEED VALVE Figure 9—Deceleration Control CHECK VALVE 4S -0507 Inspect A check valve should be inspected whenever the hose is d is c o n n e c te d from a c h e c k valve or whenever check valve failure is suspected. (A pump DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-21 th a t had becom e ino pe rative and had show n indications of having exhaust gases in the pump would indicate check valve failure). 2. Blow through the check valve (toward the cylinder head), then attempt to suck back through the check valve. Flow should only be in one direction (toward the exhaust manifold). Replace valve which does not operate properly. HOSE AND PIPES I? Inspect 1. 2. 3. 4. Hose or pipe for deterioration or holes. All hoses or pipe connections, and clam p tightness. Hose or pipe routing. Interference may cause wear. If a leak is suspected on the pressure side of the system or if a hose or pipe has been disconnected on the pressure side, the connections should be checked for leaks with a soapy water solution. With the pump running, bubbles will form if a leak exists. CONTROL MODULE Refer to the proper C-6 HD Chart for diagnosis of the control module. DECELERATION VALVE 1 . Remove air cleaner, plug air cleaner vacuum source and connect tachometer. With the engine running at specified idle speed, remove the small deceleration valve signal hose from the manifold vacuum source. Reconnect the signal hose and listen for air flow th ro u g h th e v e n tila tio n p ip e a nd in to th e d e c e le ra tio n v a lve . T h e re s h o u ld a lso be a noticeable speed drop when the signal hose is reconnected. If the air flow does not continue for at least one se co n d o r th e e n g in e sp e e d d oe s not d ro p noticeably, check the deceleration valve hoses for restrictions or leaks. If no restrictions or leaks are found, replace the deceleration valve. 2. 3. 4. 5. ON-VEHICLE SERVICE — AIR AIR WIRING DIAGRAM Refer to the proper C-6 HD Chart for the wiring diagram. DRIVE BELT Inspect the drive belt for wear, cracks or deterioration and replace if required. When installing new belt, it must be s e a te d a n d fu lly s e c u re d in g ro o v e s o f A /C compressor, AIR pump, generator, and crankshaft pulleys. AIR INJECTION PUMP (Figures 10 through 13) 0 Remove or Disconnect 1 . Hold pump pulley from turning by compressing drive belt, then loosen pump pulley bolts. 2. Loosen bolt, holding pump to m ounting brackets, release tension on drive belts. Remove belt from pulley. 3. Disconnect hoses at rear of pump. 4. Disconnect vacuum and electrical connections if control valve is attached to the pump. 5. Remove pump pulley. 6 . Remove pump. 7. Remove control valve if attached. ++ Install or Connect 1. Install pump with control valve if attached. 2 . C onnect vacuum and e le c tric a l co n n e c tio n s if control valve is attached to pump. 3. Connect hoses at rear of pump. 4. Install pump pulley bolts and tighten equally to 15 N m (10 ft. lbs.). Tighten again within 10 minutes to 15 N m (10 ft. lb s .) u s in g a c lic k w re n c h , port-a-t'orque or other equivalent tool. 6 . Install pump drive belt and adjust tension. AIR CONTROL VALVE (Figures 10 through 13) Remove or Disconnect 1. Electrical connector from solenoid. 2. Air outlet hoses from valve. 3. Manifold vacuum hose. 4. Air control valve, gaskets and adapter. |++| Install or Connect 1. Gaskets, adapter and air control valve. 2. Manifold vacuum hose. 3. Air outlet hoses to valve with clamps. 4. Electrical connector to solenoid. CHECK VALVE (Figures 10 through 13) Remove or Disconnect 1. Any parts required for access to valve. 2. Release clam p and disconnect air hoses from check valve. 3. Valve from bracket. 4. Unscrew check valve from air injection pipe. -►<- Install or Connect 1 . Screw check valve onto air injection pipe. 2. Valve to bracket. 3. Position air hose on check valve and secure with clamp. 4. Any parts removed for access. AIR INJECTION PIPE ASSEMBLY (Figures 10 through 13) |<” »| Remove or Disconnect 1. Hose from check valve. 2. Check valve. 3. Nuts attaching pipes-to-manifold. 4. Pipe assembly. -►«- Install or Connect 1. Nuts attaching pipes-to-manifold. 2. Check valve. 3. Hose to check valve with clamp. 6E8-22 DRIVEABILITY AND EMISSIONS — CARBURETED r n A.I.R. PUMP—TIGHTEN MOUNTING ----- SCREWS TO 25 N-m (18 FT. LBS.) m CHECK V A L V E —TIGHTEN NUT TO ----- 35 N-m (26 FT. LBS.) m HOSE—SILENCER TO A iR CONTROL V ALVE m HIGH FLOW ELECTRIC AIR CONTROL V A L V E TIGHTEN ATTACHING BOLTS TO 10 N-m (94 IN. LBS.) in SILENCER i n AIR INJECTION PIPE—TIGHTEN NUTS ----- TO 28 N-m (20 FT. LBS.) rn FILTER |~ 4l H O S E -A IR CONTROL VALVE TO CHECK V ALVE n DUCT (DRAIN HOLE MUST POINT DOWNWARD) R o l HOSE—FILTER TO PUMP 5S-1958 Figure 10—AIR System — 4.8 L Engine DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-23 m P U L L E Y —TIGHTEN SCREWS TO 15 N-m (10 FT. LBS.). TIGHTEN AGAIN WITHIN 10 MINUTES TO 15 N-m (10 FT. LBS.). m A.I.R. PUMP-TIGHTEN MOUNTING '---- ' SCREWS TO 25N-m (18FT.LBS). |~3~| ADAPTER—TIGHTEN SCREWS TO 25 N-m (18 FT. LBS.) m AIR CONTROL VALVE—TIGHTEN SCREWS TO ---- 25 N-m (18 FT. LBS.) [ 5 | HOSE-PUMP TO AIR CONTROL VALVE f~6~| ---m [~8~| CHECK VALVE—TIGHTEN NUT TO 35 N-n (26 FT. LBS.) HOSE-AIR CONTROL VALVE TO CHECK VALVE AIR INJECTION PIPE—TIGHTEN NUTS TO 28 N-m (20 FT. LBS.) [~9~] FILTER-DRAIN HOLE IN INLET HOSE MUST POINT DOWNWARD [Tol HOSE-FILTER TO PUMP 5S-1960 Figure 11—AIR System — 5.7 L (G) 6E8-24 DRIVEABILITY AND EMISSIONS — CARBURETED r n PULLEY—TIGHTEN SCREWS TO 15 N m (10 FT. LBS.) TIGHTEN AG AIN W ITHIN 10 MINUTES TO 15 N m (10 FT. LBS.) [ 6 j H O S E -A IR CONTROL V A LV E TO CHECK VALVE [ T 1 CHECK V A L V E —TIGHTEN NUT TO 35 N-m (26 FT. LBS.). p f ] A .I.R . PUMP—TIGHTEN MOUNTING SCREWS TO 50 N m (36 FT. LBS.) j 8 | A IR INJECTION PIPE—TIGHTEN NUTS TO 28 N-m (20 FT. LBS.) f T l AIR CONTROL V A L V E —TIGHTEN SCREWS — TO 25 N m (18 FT. LBS.) I 9 I F IL T E R -D R A IN HOLE ON INLET HOSE MUST POINT DOWNWARD fTl HOSE-PUMP TO AIR CONTROL VALVE fT o l HOSE—FILTER TO PUMP { 5 | H O SE-AIR CONTROL VALVES TO A IR CLEANER 5S-1971 Figure 12—AIR System — 5.7 L (P) DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-25 rr~ ] A.I.R. PUMP—TIGHTEN MOUNTING SCREWS 1----- 1 TO 25 N-m (18 FT. LBS.) m CHECK V A L V E -T IG H T E N TO 35 N-m (26 FT. LBS.) m H O SE-VALVE TO CHECK VALVE |~3~| AIR CONTROL V A L V E —TIGHTEN MOUNTING SCREWS TO 25 N-m (18 FT. LBS.) | 5 I H O SE-VALVE TO AIR CLEANER m AIR INJECTION PIPE (TIGHTEN NUTS TO 28 N-m/ 20 FT. LBS.) RIGHT SHOW N-LEFT SIMILAR 5S-1961 Figure 13— AIR S ystem — 7.4 L Engine m HO SE-M ANIFOLD m DECELERATION VALVE [ T ] HOSE-M ANIFOLD VACUUM m HO SE-AIR CLEANERTO-VALVE f~4~] HOSE—VALVE-TOINTAKE MANIFOLD [T jD E C E L E R A T IO N VALVE VACUUM [T lH O S E - A IR CLEANER-TO| 2 | HOSE—VALVE-TO -IN TAKE----- VALVE MANIFOLD 5S-1965 Figure 14—Deceleration Valve — 4.8 L Engine 5S-1962 Figure 15—Deceleration Valve — 7.4 L Engine 6E8-26 DRIVEABILITY AND EMISSIONS — CARBURETED [T 1 CONTROL MODULE [T ] [T 1 ELECTRICAL CONNECTOR [ T ] DASH AND TOE PANEL j j j ~ j CONTROL RELAY (7.4L) BRACKET _______________________________________5 S - 1969 Figure 18—Control Module — 5.7 L/7.4 L (P42) I T ] DECELERATION VALVE H H HOSE-VALVE-TO INTAKE MANIFOLD p T I H O SE-M ANIFO LD ----- VACUUM [ T ] HO SE-AIR CLEANERTO-VALVE 5S-1963 Figure 16—Deceleration Valve — 5.7 L Engine n ~ | CONTROL MODULE l~2~l ELECTRICAL CONNECTOR [ T ] CONTROL MODULE f~3 I BRACKET [ T lN U T (TIGHTEN TO 20 N-m/15 FT. LBS.) f 4 l PLENUM PANEL 5S-1967 Figure 17—Control Module — 5.7 L (G) 5S-1968 Figure 20—Control Module — 4.8 L Engine DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-27 : ILTER (Figures 10 through 13) Remove or Disconnect 1. Filter from bracket. 2. Hose from air intake and pump. |-n-| Install or Connect 1. Hose from air intake and pump. 2. Filter to bracket. SILENCER - 4.8 L ENGINE (Figure 10) ++ Remove or Disconnect 1. Hose from the silencer. 2. S ile n ce r from the bracket. Install or Connect 1. S ilen ce r to the bracket. 2. H ose to silencer. DECELERATION VALVE (Figures 15 and 16) Remove or Disconnect 1. Vacuum hoses from valve. 2. Screws securing valve to bracket. 3. Deceleration valve. -►+ Install or Connect 1. Deceleration valve. 2 . Screws securing valve to bracket. 3. Vacuum hoses to valve. CONTROL MODULE (Figures 17 through 20) |<“+| Remove or Disconnect 1. Electrical connector. 2 . Control module. -►4* Install or Connect 1 . Control module. 2. Electrical connector. CONTROL RELAY (7.4 L ONLY) Figures 18 and 19 4*+ Remove or Disconnect 1 . Electrical connector. 2. Control module. Install or Connect 1 . Control module. 2. Electrical connector. “SERVICE ENGINE SOON” LIGHT IS “ON” The illumination of the “ SERVICE ENGINE SO ON” light indicates that there is a m alfunction in the solenoid, control module, or wiring. Check solenoid and m odule connectors for proper connection. 1. D isconnect air tem perature switch and install a jum per wire across the terminals. 2. With ignition on, disconnect each solenoid connec­ tor and with a test light, check for a light from the pink/black wire to ground. • If light does not illuminate, check for an open in circuit 39 to the solenoid. • If light illuminates, check for a light across ter­ minals. Circuit is OK if there is a light. Check solenoid coil resistance and if less than 20 ohms, replace solenoid and valve. If there is no light, check for an open in circuit 900 to the air temperature switch, an open in circuit 436 or faulty control module. 3. Connect solenoid connectors and disconnect both connectors at control module. Check for a light be­ tween term inals “ A” and “ B” of the 5 pin connector. • If the test light does not illuminate, check for an open circuit to the module. • If the test light illuminates, check for a light between 5 pin connector harness term inals “ A” and “ D.” • If the test light illuminates, check for a short to ground in circuit 419. • If the test light does not illuminate, check for an open in circuit 900 between the solenoid term inal “ B” and the module 2 pin connector term inal “ A .” If circuit 900 is not open, replace the control module. 6E8-28 DRIVEABILITY AND EMISSIONS — CARBURETED Chart C-6HD-1 Air Management System 5.7 L Engine DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-29 “SERVICE ENGINE SOON” LIGHT IS “ON” The illumination of the “ SERVICE ENGINE SOON” light indicates that there is a malfunction in the solenoid, control module, control relay, or wiring. Before diagnosis, check solenoid and module connectors for proper connection. Chart C-6HD-2 Air Management System 7.4 L Engine 1 . This step is to determine if there is power to the air temperature switch. 2. This step will insure that there is power to the circuit by elim inating the air temperature switch. This step will also check the wiring between the air tempera­ ture switch and the solenoids. 3. This step will check the wiring between the sole­ noids and ground, including the circuit inside the control module. 4. This step will determ ine if the problem is a short to ground in the “ SERVICE ENGINE SOON” light cir­ cuit or a m alfunction in the air management system. 5. This step checks for Bat. ( + ) at “ A” and a ground at “ B,” to power up the control module. 6 . This step will determ ine if a ground signal is sent to the relay because CKT919 is grounded outside the module. 7. This step checks for a tach signal to the control module. 6E8-30 DRIVEABILITY AND EMISSIONS — CARBURETED © CHART C-6HD-2 • DISCONNECT AIR TEMPERATURE SWITCH • IGNITION "O N ." ENGINE STOPPED • WITH A TEST LIGHT, CHECK FOR A LIGHT FROM THE PINK/BLACK WIRE TO GROUND. LIGHT "OFF' LIGHT "O N ' © 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 FROM THE YELLOW WIRE TO GROUND. I REPAIR OPEN IN CKT 39 TO THE SWITCH LIGHT "O N " AT BOTH SERVICE ENGINE SOON" LIGHT "ON" AT ALL TIMES 7.4L ENGINE CARBURETED LIGHT "OFF" AT ONE OR BOTH ■ © CHECK FOR A LIGHT ACROSS THE TERMINALS (BOTH CONNECTORS) REPAIR OPEN IN CKT 900 TO THE SOLENOID LIGHT "O N " AT BOTH CONNECTORS LIGHT "OFF" AT ONE OR BOTH X X I USING AN O HM METER. CHECK THE RESISTANCE OF EACH SOLENOID COIL • CHECK FOR OPEN IN CKT 436 • IF OK. REPLACE CONTROL MODULE 20 OHMS OR GREATER © LESS THAN 20 OHMS I • RECONNECT BOTH SOLENOID CONNECTORS • START ENGINE AND DISCONNECT CONTROL RELAY • NOTE "SERVICE ENGINE SOON" LIGHT REPLACE THE VALVE ASSEMBLY LIGHT "OFF' m LIGHT "O N ' I ix USING AN O HM METER, CHECK FOR CONTINUITY BETWEEN TERMINALS "A " AND "D " OF THE HARNESS. REPAIR SHORT TO GROUND IN CKT 419 X CONTINUITY NO CONTINUITY © REPLACE CONTROL RELAY • DISCONNECT CONTROL MODULE CONNECTOR • USING A TEST LIGHT, CHECK FOR A LIGHT BETWEEN TERMINALS "A " AND "B" OF THE HARNESS ” 1 LIGHT "OFF" I LIGHT" ON" © CHECK FOR OPEN IN CKT 900 OR CKT 150 TO THE MODULE CHECK FOR A LIGHT BETWEEN TEMINALS "A " AND "D " OF THE HARNESS. X LIGHT "OFF" © LIGHT "O N ' I I • START ENGINE • USING A TEST LIGHT, CHECK FOR A FLICKERING LIGHT BETWEEN HARNESS TERMINAL "C" AND GROUND REPAIR SHORT TO GROUND IN CKT 919 X LIGHT DOES NOT"FLICKER" LIGHT "FLICKERS" zznzzn: I REPAIR OPEN IN CKT 121 REPLACE CONTROL MODULE 6S-2994 Chart C-6HD-2 DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-31 “ SE R V IC E ENGINE SOON” LIGHT IS “ ON” The illumination of the “ SERVICE ENGINE SO ON” light indicates that there is a malfunction in the solenoid, control module, or wiring. Check solenoid and m odule connectors for proper connection. A B C D E A B CONTROL MODULE 6S-2919 C hart C6HD-3 1. Disconnect the air temperature switch and install a jum per wire across the terminals. 2. With the ignition on, disconnect the solenoid con­ nector and with a test light, check for a light from the pink/black wire to ground. • If the light does not illuminate, check for an open in circuit 39 to the solenoid. • If the light illuminates, check for a light across the terminals. The circuit is OK if there is a light. Check the solenoid coil resistance and if less than 2 0 ohms, replace the solenoid and valve. If there is no light, check for an open in circuit 936 to the air temperature switch, an open in circuit 436 or a faulty control module. 3. Connect the solenoid connector and disconnect both connectors at the control module. Check for a light between term inals “ A” and “ B” of the 5 pin connector. • If the test light does not illuminate, check for an open circuit to the module. • If the test light illuminates, check for a light between the 5 pin connector harness term i­ nals “ A” and “ D.” • If the test light illuminates, check for a short to ground in circuit 419. • If the test light does not illuminate, check for an open in circuit 936 between the solenoid term inal “ B ” and the module 2 pin connector term inal “ A .” If circuit 936 is not open, replace the control module. 6E-32 DRIVEABILITY AND EMISSIONS — CARBURETED EXHAUST G A S RECIRCULATION (EGR) SY ST E M P H ASSEMBLY PLANT CODE [~2~l PART NUMBER H~j EGR VALVE m [ 5 | DIAPHRAGM [ 2 [ EXHAUST GAS m |~3~| INTAKE AIR I 7 1 VALVE CLOSED m \± ] VACUUM PORT VALVE OPEN s p r in g 4S-0536 4S 0538-6E F igu re 21— EGR Valve F igure 23— EGR V alve Id e n tific a tio n GENERAL DESCRIPTION source, the EGR pintle is closed and there is no exhaust gas recirculation. When the throttle valves are opened, vacuum is applied through the exposed vacuum signal port(s) to the vacuum diaphragm in the EGR valve through a connection tube. W hen the vacuum reaches a pre-determ ined level, the diaphragm moves upward against calibrated spring tension, pulling the pintle with it. The pintle rises off the seat, allowing exhaust gas to flow from the exhaust manifold to the intake manifold and into the engine cylinders. PURPOSE The EGR system is used to lower NOx (oxides of nitrogen) emission levels caused by high combustion temperatures. It does this by decreasing com bustion temperature. The EGR system has a ported EGR valve (figure 21), hose from a ported m anifold vacuum source and a method to control the vacuum source. A coolant tem perature TVS is used to control the vacuum source. OPERATION The therm ostatic vacuum switch (TVS) blocks vacuum to the EGR valve during cold engine operation (figure 22). When the engine is warm, the TVS opens, which opens the vacuum source to the EGR valve. At idle or wide-open throttle, there is little or no vacuum from the vacuum m DATE BUILT f~~4~~l LOOK HERE FOR LETTER P = POSITIVE BACK PRESSURE N = NEGATIVE BACK PRESSURE BLANK = PORTED V ALVE EGR VALVE E E EXHAUST GAS C H INTAKE FLOW VACUUM PORT m THROTTLE VALVE c m VACUUM CHAMBER H Q VALVE RETURN SPRING h o i THERMAL VACUUM SWITCH n n COOLANT [ u ] DIAPHRAGM 1— 4S -0002 Figure 22—EGR System with TVS Exhaust gas will be recirculated during periods of normal intake manifold vacuum, when the throttle is open beyond idle. Figure 24—TVS Location, 5.7 L-LT9 DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-33 4. C o m p a re v a c u u m g a g e re a d in g (s ) w ith th e procedures and in the TVS descriptions given under each valve name. 5. Heat TVS to a temperature above the calibration temperature. Never apply a torch or open flame directly to the TVS. 6 . C om pare vacuum gage reading to the correct reading indicated on switch or valve base. NOTICE: Leakage of up to 7 kPa (2" Hg) vacuum in 2 minutes is allowable and does not mean a defective part. f ~ n EGR VALVE 7. If operation is satisfactory, re-install valve or switch. If valve or switch is defective, replace with a new part. f~2~l TVS (EGR) ON-VEHICLE SERVICE — EGR 4S-1050 Figure 25—TVS Location, 7.4 L-LE8 DIAGNOSIS OF EGR EGR SYSTEM Too much EGR flow tends to weaken com bustion, causing the engine to run roughly or stop. With too much EGR flow at idle, cruise, or cold operation, any of the following conditions may happen: • Engine stops after cold start. • Engine stops at idle after deceleration. • Vehicle surges during cruise. • Rough idle. If the EGR valve should stay open all of the time, the engine may not idle. Too little o r no EGR flo w a llo w s c o m b u s tio n temperatures to get too high during acceleration and load conditions. This could cause: • Spark knock (detonation). • Engine overheating. • Emission test failure. CLEANING MANIFOLD PASSAGE I? Inspect If EGR p a s s a g e s in th e in le t m a n ifo ld in d ic a te excessive build-up of deposits, the passages should be cleaned. Care should be taken to insure that all loose particles are completely removed to prevent them from clogging the EGR valve or from being ingested into the engine. Do n ot w a s h EG R v a lv e in s o lv e n ts or degreaser — permanent damage to valve diaphragm may re s u lt. A ls o , s a n d b la s tin g o f th e v a lv e is n o t recommended since this can affect the operation of the valve. SYSTEM HOSES Refer to Vehicle Emission Control Information label for routing of system hoses. When replacing hoses, use hose identification with the word “ Fluoroelastromer.” EGR VALVE Refer to figure 23 to identify the EGR valve. S ystem C heck Diagnosis of the EGR system is covered in the chart at the end of this section. EGR VALVE Refer to EGR System Check at the end of this section for diagnosis of the EGR valve. The valve will open if vacuum is applied with the engine not running. THERMOSTATIC VACUUM SWITCH A therm al vacuum switch opens, closes, or switches vacuum source when the ca lib ra tion tem perature is reached. The following general checking procedures can be used for all thermal vacuum switches. Refer to number stam ped on base of valve or sw itch for calibration temperature. 1 . Allow TVS to cool below calibration temperature. 2. Inspect switch to make sure it is in good condition. 3. Connect vacuum gage(s) to output port(s) of the TVS. (See vacuum hose schem atic on Vehicle Control Emission Information label). Remove or Disconnect 1. 2. 3. 4. Air cleaner. EGR valve vacuum hose at valve. Bolts. EGR valve from manifold. Install or Connect 1. 2. 3. 4. EGR valve to manifold (use new gasket). Bolts. Vacuum hose to EGR valve. Air cleaner. THERMOSTATIC VACUUM SWITCH (Figures 24 and 25) Replacement 1. Drain coolant below level of therm ostatic vacuum switch (TVS). 2. Disconnect vacuum hoses. 3. Remove TVS. 6E8-34 DRIVEABILITY AND EMISSIONS — CARBURETED 4S-0611 Chart C-7C DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-35 4. Install replacement TVS with soft setting sealant applied to male threads. Sealant should not be on end of TVS. 5. Tighten TVS to 14 N m (120 in. lbs.), then turn clockwise as required to align with hoses. 6 . Connect vacuum hoses. 7. Add coolant as required. PARTS INFORMATION PARTS NAME GROUP V a lv e ..................................................................................3,670 Gasket, EGR Valve ( 1 5 ) .................................................3,680 EARLY FUEL EVAPORATION SYSTEM (EFE) ALL ENGINES EXCEPT 4.8 L -tn -m m — m — m --------------- 03 Pn VENT (FILTERED) | 2 1 TO EFE VALVE m , EE | I MANIFOLD VACUUM 4S -0550 Figure 27—Thermal Vacuum Switch therm al vacuum switch (TVS) (figure 27). When vacuum is applied to the actuator, the valve closes, causing the intake manifold to heat up. When coolant temperature increases, the TVS stops vacuum to the actuator. Results of Incorrect EFE Operation No EFE when cold: • Engine may stum ble and stall during warm-up. • E n g in e ta k e s lo n g e r tim e to w a r m up. • Choke may heat up and be off before engine is warm. GENERAL DESCRIPTION EFE stays on: • Poor performance. PURPOSE The EFE system used on all engines provides a source of rapid heat to the engine induction system during cold driveaway. Rapid heating is desirable because it provides quick fuel evaporation and more uniform fuel distribution to aid cold driveability. It also reduces the length of time carburetor choking is required, so it reduces exhaust emissions. • Lack of power when warm due to superheated gases. • Engine may overheat. DIAGNOSIS OF EFE GENERAL OPERATION The EFE system is a Vacuum Servo type that uses a valve and vacuum actuator which increases the exhaust gas flow under the intake manifold during cold engine operation. The valve is located in the exhaust and the vacuum actuator is vacuum operated (figure 26) by a The operation of the EFE system is to be checked at regular maintenance intervals. Refer to Section OB for maintenance interval information. VACUUM SERVO EFE DIAGNOSIS • TVS controlled. See Chart C-9C. 6E8-36 DRIVEABILITY AND EMISSIONS — CARBURETED m NUT—TIGHTEN TO 20 N-m (15 FT. LBS.) H I NUT—TIGHTEN TO N-m (15 FT. LBS.) [~2~| TENSION SPRING J T 1 TENSION SPRING ] 3 | RIGHT HAND EXHAUST PIPE [~3~| RIGHT HAND EXHAUST PIPE f T ] SEAL f T l SEAL f l T l VALVE AND ACTUATOR [ 5 | VALVE AND ACTUATOR |~6~l EXHAUST MANIFOLD 1 0 | STUD-EXHAUST MANIFOLD |T 1 M ANIFOLD VACUUM PIPE P H MANIFOLD VACUUM PIPE 4S-1028 Figure 28—Valve and Actuator — 7.4 L ON-VEHICLE SERVICE — EFE VALVE AND ACTUATOR (Figures 28 or 29) |+ + | Remove or Disconnect 1. Vacuum hose at EFE valve. 2. Exhaust pipe to manifold nuts, and tension springs. 3. Lower right hand exhaust (crossover) pipe and seal — com plete removal of pipe is not always necessary. 4S-1029 Figure 29—Valve and Actuator — 5.7 L ♦4- Install or Connect 1. A p p ly a s o ft s e ttin g s e a la n t u n ifo rm ly on replacement TVS male threads. No sealant should be applied to sensor end of TVS. 2. TVS. Tighten to 14 N-m (120 in. lbs.) and then hand to rq ue clockw ise as req uired to a lign TVS to accommodate hoses. 3. Hoses to TVS ports. 4. Coolant as required. 4. EFE valve and actuator. -►4- Install or Connect 1. EFE valve (replace seals and gaskets if used). 2. Exhaust (crossover) pipe and seal. 3. Exhaust pipe to manifold nuts and tension springs. Tighten nuts to 20 N m (15 ft. lbs.). 4. Vacuum hose at EFE valve. COOLANT THERMAL VACUUM SWITCH (TVS) (Figure 30) The TVS is located on the engine coolant outlet housing. 4- + Remove or Disconnect 1. Drain coolant below level of engine coolant outlet housing. 2 . Hoses at TVS ports. 3. TVS. Refer to num ber stamped on base of TVS for calibration temperature. l~H E FE-TVS SWITCH [~2~1 EG R-TVS SWITCH Figure 30—EFE Coolant TVS 4S-0549 DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-37 VAAAAAAAy VAAA/ ENGINE COOLANT TEMPERATURE 4S-0614 Chart C-9C 1 . Engine coolant temperature should be below 4 0 °C (105°F). 2. EFE valve should open above 40°C (105°F). 3. There should be at least 34 kPa (10" Hg) vacuum available to EFE actuator diaphragm. 4. Valve may be seized up. It may be freed up by using heat valve lubricant (part #1052627 or equivalent). If valve does not free up, it must be replaced. 6E8-38 DRIVEABILITY AND EMISSIONS — CARBURETED CHART C-9C VACUUM ACTUATED EFE SYSTEM CHECK 5.0L CARBURETED © © © 4S-0346 Chart C-9C DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-39 POSITIVE CRANKCASE VENTILATION (PCV) Figure 31—PCV Valve Cross Section GENERAL DESCRIPTION PURPOSE A Positive Crankcase Ventilation (PCV) system is used to provide more com plete scavenging of crankcase vapors. OPERATION Fresh air from the air clea ne r is supplied to the crankcase, mixed with blow-by gases and then passed through a positive crankcase ventilation (PCV) valve into the intake manifold (figure 32). The prim ary control is through the PCV valve (figure 31) which meters the flow at a rate depending on manifold vacuum. To maintain idle quality, the PCV valve restricts the flow w hen intake m anifold vacuum is h ig h. If abnorm al operating conditions arise, the system is designed to allow excessive amounts of blow-by gases to back flow through the crankcase vent tube into the air cleaner to be consumed by normal combustion. Results of Incorrect PCV Operation • A plugged valve or hose may cause: • Rough idle. • Stalling or slow idle speed. • Oil leaks. • Oil in air cleaner. • Sludge in engine. • A leaking valve or hose would cause: • Rough idle. • Stalling. DIAGNOSIS OF PCV If an engine is idling rough, check for a clogged PCV valve or plugged hose. Replace as required. Use the following procedure: 1. Remove PCV valve from rocker arm cover. 2. Run the engine at idle. 3. Place your thum b over end of valve to check for vacuum. If there is no vacuum at valve, check for plugged hoses or m anifold port, or PCV valve. Replace plugged or deteriorated hoses. Figure 32—PCV Flow 4. Turn off the engine and remove PCV valve. Shake valve and listen for the rattle of check needle inside the valve. If valve does not rattle, replace valve. With this system, any blow-by in excess of the system capacity (from a badly-worn engine, sustained heavy load, etc.) is exhausted into the air cleaner and is drawn into the engine. Proper operation of the PCV System (figure 33) is dependent upon a sealed engine. If oil sludging or dilution is noted, and the PCV System is functioning properly, check engine for possible cause and correct to insure that system will function as intended. ON-VEHICLE SERVICE — PCV See fig u re 33 fo r re p la c e m e n t o f PC V s y s te m components. An engine which is operated without any crankcase ventilation can be damaged. Therefore, it is im portant to 6E8-40 DRIVEABILITY AND EMISSIONS — CARBURETED replace the PCV valve and air clea ne r breather at intervals shown in Section OB. Periodically, inspect the hoses and clam ps and replace any showing signs of deterioration. PARTS INFORMATION PART NAME GROUP Air C le a n e r.......................................................................3,402 Tube, C/Case V e n t ......................................................... 1,762 Hose, C/Case Vent V lv ...................................................1,762 [~ T [ PCV VALVE [ 2 | AIR CLEANER I 3 j CRANKCASE VENT TUBE |~4~1 PCV VALVE HOSE | 5 | HOSE TO CANISTER VIEW A FIT] GROMMET 4S -0654 Figure 33—Positive Crankcase Ventilation System THERMOSTATIC AIR CLEANER (THERMAC) GENERAL DESCRIPTION PURPOSE A heated intake air system is used to give good driveability under varying clim atic conditions. By having a uniform inle t te m p era ture , the fuel system can be calibrated to reduce exhaust emissions and to eliminate throttle blade icing. OPERATION The THERMAC air cleaner operates by heated air and manifold vacuum (figure 34). Air can enter the air cleaner from outside the engine com partm ent or from a heat stove built around the exhaust manifold. A vacuum diaphragm motor, built into the air cleaner snorkel, moves a damper door, to adm it hot air from the exhaust manifold, outside air, or a combination of both. Inside the air cleaner is a temperature sensor that reacts to air intake temperature and controls the amount of vacuum going to the motor. • Hot Air Delivery Mode. When the temperature is below 8 6 °F (30°C), the sensor allows vacuum to the motor and the dam per door will be up, shuting off outside air and allowing only heated air from the exhaust manifold to enter the air cleaner. • Regulating Mode. Between 8 6 °F (30°C) and 131 °F (55°C) the dam per door allows both heated and outside air to enter the air cleaner. • Outside Air Delivery Mode. W hen the temperature is above 131 °F (55°C), the dam per door drops down and only outside air enters the air cleaner. THERMAC DELAY VALVE Some applications use a delay valve on the hose connecting the vacuum motor to the temperature sensor (figure 35). When vacuum in this hose drops for any reason, the check valve will bleed off the vacuum to the vacuum motor slowly. Results of Incorrect THERMAC Operation • Hesitation during warm-up can be caused by: • Heat stove tube disconnected. • Vacuum diaphragm motor inoperative (open to snorkel). • No manifold vacuum. • Damper door does not move. • Missing air cleaner to carburetor seal. • Missing air cleaner cover seal or loose cover. • Loose air cleaner. • Lack of power, sluggish or spongy, on a hot engine can be caused by: • Damper door does not open to outside air. • Temperature sensor doesn’t bleed off vacuum. DRIVEABILITY AND EMISSIONS — CARBURETED 6E8-41 Q D VACUUM DIAPHRAGM MOTOR a DIAPHRAGM SPRING TEMPERATURE SENSOR AIR BLEED VA LV E -C LO S E D 4B AIR BLEED V A L V E P A R TIA LLY OPEN [~4C~] AIR BLEED V A LV E -O P E N l~5~| VACUUM HOSES [~6 ~| DIAPHRAGM | T 1 HEAT STOVE pB~] HOT AIR (EXHAUST M AN IFO LD) f 9 l DAMPER DOOR f i o ] OUTSIDE INLET AIR Pm n n — - SNORKEL A - HOT AIR DELIVERY MODE B - REGULATING MODE C - OUTSIDE AIR DELIVERY MODE J?K • A. Oil Pan B. Case C. C ooler C onnecto rs & Plugs D. TV Cable Seal E. Servo Cover F. G. H. I. J. K. Oil F ill Tube Seal Oil Pump Seal A ssem bly Oil Pump To Case Seal Converter Vent E lectrical C onnector Seal L. M. N. 0. P. Manual Shaft Seal G overnor Cover Speedo Seal E xtension To Case Seal E xtension Oil Seal A ssem bly B-08659 Figure 6—Possible Leak Points AUTOMATIC TRANSMISSION 7A-11 LOAD CHECK GAGE INDICATOR 1. Install a modulator that is known to be good on either end of tool J-24466. 2. Install the moduator in question on the opposite end of the gage (figure 7). 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 gage line will be white. When m aking the c o m p a ris o n , make sure th a t both modulators are of the same type. The part numbers are stamped on the dome of the modulator. J-24466 SLEEVE ALIGNMENT CHECK Figure 7—Checking the Modulator ATMOSPHERIC LEAK CHECK 1. Apply a thick coating of soap bubble solution to the vacuum connector pipe seam and the crimped upper to lower housing seam. 2. Using a short piece of rubber hose, apply air pressure to the vacuum pipe by blowing into the tube. 3. If bubbles appear, replace the modulator. Do not use any method other than human lung power for applying air pressure, as pressures over v .i . , 41.37 kPa (6 psi) may damage the modulator. 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. Check freeness of modulator valve in transmission case. 2. Check the vacuum line from the manifold or vacuum pump to modulator for holes, cracks or dents. Check the rubber hose connection at the modulator and at the intake manifold or vacuum pump for leaks. DIAGNOSIS OF TORQUE CONVERTER Converter Shudder 1 . Torque converter assembly. 2 . Valve body. 1. Internal damage. 2 . Converter clutch shift valve stuck. 3. Oil pump assembly. 3. a. b. 4. a. b. c. 5. a. b. 6 . a. b. 4. Oil filter. 5. Miscellaneous. 6 . Input housing and shaft assembly. No Converter Clutch Release CORRECTION POSSIBLE CAUSE PROBLEM Converter clutch apply valve stuck. Restricted oil passage. Crack in filter body. Flash restricting filter neck. Seal cut or damaged. Low oil pressure. Engine not tuned properly. Turbine shaft seal cut or damaged. Turbine shaft retainer and ball as­ sembly damaged. 1 . Solenoid 2 . Converter. 1. External ground. 2 . Internal damage. 3. Oil pump assembly. 3. Converter clutch apply valve stuck. 7A-12 AUTOMATIC TRANSMISSIONS DIAGNOSIS OF TORQUE CONVERTER (CONT.) PROBLEM No C on verte r C lutch A p ply POSSIBLE CAUSE 1. Electrical. 2. Converter. 3. Oil pump assembly. 4. Valve body assembly. 5. Input housing and shaft. CORRECTION 1. a. 12 volts not supplied to transm is­ 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. In c o rre c t o r d a m a g e d p re s s u re switches. 2. Internal damage. 3. a. Converter clutch apply valve stuck or assembled backwards. b. Converter clutch apply valve retain­ ing ring mispositioned. c. Pump to case gasket mispositioned. d. Orifice cup plug plugged. e. Solenoid seal cut or damaged. f. Orifice cup plug omitted from cooler in passage. g. High or uneven bolt torque (pump body to cover). 4. Valves stuck. a. Converter clutch shift valve. b. Throttle valve. 5. a. Turbine shaft seal cut or damaged, b. Turbine shaft retainer and ball as­ sembly plugged. STATOR ASSEMBLY FREEWHEELS STATOR ASSEMBLY REMAINS LOCKED UP If the stator roller clutch becomes ineffective, the stator assembly freewheels at all times in both directions. With this condition, the vehicle tends to have poor acceleration from a standstill. At speeds above 48 to 56 km/h (30-35 mph), the vehicle may act normal. If poor acceleration problems are noted, it should first be determined that the exhaust system is not blocked, the engine is running properly and the transm ission 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. If the stator assembly remains locked up at all times, the engine rpm and vehicle speed will tend to be limited or restricted at high speeds. The vehicle performance when accelerating from a standstill will be normal. Engine overheating may be noted. Visual examination of the converter may reveal a blue color from the overheating that will result. DIAGNOSIS OF TORQUE CONVERTER CLUTCH (TCC) To properly diagnose the Torque Converter Clutch (TCC) system perform all electrical testing first and then the hydraulic testing. AUTOMATIC TRANSMISSION 7A-13 TORQUE CONVERTER CLUTCH (T.C.C.) ELECTRICAL DIAGNOSIS MECHANICAL CHECKS, SUCH AS LINKAGE, OIL LEVEL, ETC., SHOULD BE PERFORMED PRIOR TO USING THIS CHART. Figure 8—TCC Diagnosis 7A-14 AUTOMATIC TRANSMISSION THM 400 PRELIMINARY CHECKING CAUTION: TOTAL RUNNING TIME FOR THIS COMBINATION NOT TO EXCEED 2 MINUTES. CHECK ENGINE TIMING AND IDLE (See Section 6-C& 6-D.) INSTALL OIL PRESSURE GAGE (FIGURE 30) CONNECT TACHOMETER TO ENGINE C H E C K O iL P R E S S U R E S IN F O L L O W IN G M A N N E R 1 2 3 4 5 6 7 8 RANGE NORMAL kPa NORMAL P.S.I. NEUTRAL-BRAKES APPLIED ENGINE AT 1000 RPM 379 TO 483 55TO 70 DRIVE IDLE-SET ENGINE IDLE TO SPECIFICATIONS 414 TO 586 60 TO 85 DRIVE-BRAKES APPLIED ENGINE AT 1000 RPM 414 TO 621 60TO 90* 931 TO 1103 135to 160* 655 TO 1034 95 TO 150* 621 TO 758 90TO 110 INTERMEDIATE OR LO-BRAKES APPLIED ENGINE AT 1000 RPM REVERSE-BRAKES APPLIED ENGINE AT 1000 RPM DRIVE-BRAKES APPLIED ENGINE AT 1000 RPM DOWNSHIFT SWITCH ACTIVATED GOVERNOR CHECKFOR UPSHIFT iPROBLEM DRIVE-30 MPH-CLOSED THROTTLE ON ROAD, OR ON HOIST** OIL PRESSURE PATTERN LOW-NORMAL-HIGH DROP OF DROP OF 69 PSI OR MORE 10 PSI OR MORE 379 TO 483 55TO 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 9—Preliminary Checking Procedure AUTOMATIC TRANSMISSION 7A-15 7. Place the selector in “ Reverse” and check for reverse operation. Figure 10—THM 400 Pressure Tap Location ROAD TEST 1. Connect a portable tachometer to the engine. Engine rpm will identify the shift points. 2. Place the selector in “ Drive” position and accelerate 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 ve­ hicle speed decreases to 0 mph. Stop the vehi­ cle. 3. Place the selector in “ Intermediate” position and ac­ celerate the vehicle from a rest. A 1-2 shift should oc­ cur 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 ve­ hicle to 35 mph and move the selector to “ Intermedi­ ate” . A 3-2 downshift should occur, increasing the engine rpm and an engine braking effect should be noticed on deceleration. 6. With the selector in “ Intermediate” at approximately 25 mph, but not over 40 mph, at closed throttle, move the selector to “ Low.” A 2-1 downshift should occur, in­ creasing the engine rpm and an engine braking effect should be noticed on deceleration. Stop the vehicle. UPSHIFT MINIMUM 1-2 2-3 15 MPH 30 MPH UPSHIFT MAXIMUM 1-2 2-3 44-48 MPH 77-83 M PH DETENT DOWNSHIFT MINIMUM 3-2 2-1 68-73 MPH 28-32 MPH B-08325 Figure 11—THM 400 Shift Points CAUSES OF LOW LINE PRESSURE 1. Low transmission oil level. 2. Modulator Assembly. 3. Filter. • Blocked or restricted. (There is no approved service procedure for checking or cleaning the filter. If the filter is suspected or being plugged or restricted, it must be replaced). • Seal on intake pipe and/or grommet omitted or damaged. • Split or leaking intake pipe. • Wrong filter assembly. 4. Pump. • Pressure regulator or boost valve stuck. • Gear clearance, damaged, worn. (Pump will become damaged if drive gear is installed backwards, or if converter pilot does not enter crankshaft freely). • Pressure regulator spring, too week. • Not enough spacers in pressure regulator. • Pump to case gasket mispositioned. • Malfunctioning pump body and/or cover. • Mismatched pump cover/pump body. 5. Internal circuit leaks. • Forward clutch leak (pressure normal in neutral and reverse-pressure low in drive). — Check pump rings. — Check forward clutch seals. • Direct clutch leak (pressure normal in neutral, low, intermediate, and drive-pressure low in reverse). — Check center support oil seal rings. — Check direct clutch outer seal for damage. — Check rear servo and front accumulator pistons and rings for damage or missing. 6. Case assembly. • Porosity in intake bore area. • Check case for intermediate clutch plug leak or missing plug. • Lo-reverse check ball mispositioned or missing (this will cause no reverse and no overrun braking in Lo range). 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. • Detent sw itch actuated (plunger stuck) or shorted. • Detent wiring shorted. • Detent solenoid stuck open. • Detent feed orifice in the spacer plate blocked. • Detent solenoid loose. 7A-16 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 400 1 2 3 Drive Neutral Malfunction Brakes Drive Applied Idle Left — Brakes Applied 1000 rpm 1000 rpm 4 5 Drive-R Reverse Brakes Brakes Applied Applied 1000 rpm 1000 rpm 6 Drive Left — Brakes Applied 1000 rpm Downshift Switch Activated 7 8 Pressure Drop Drive Occurs while 30 mph Engine rpm Closed Possible Cause Increases from Throttle of Malfunction 1000 to 3000 rpm W heels Free Oil Oil Oil Oil Oil Oil Pressure Pressure Pressure Pressure Pressure Pressure Normal Normal Normal Normal Normal Normal to M ove* Oil Pressure 10 psi Drop or More M alfunction in Normal Control Valve Assembly M alfunction in Normal Normal Normal Normal Normal Normal Less than 10 psi Drop Normal Governor or Governor Feed System No 1-2 Upshift a n d /o r Delayed Upshift Normal High High Normal Normal High Normal Malfunction in Detent System M alfunction in M odulator or High High High Normal High - - - Vacuum Feed System to M odulator Oil Leak in Feed Slipping-Reverse Normal Normal Normal Normal Low Normal Normal System to the Direct Clutch Slipping-1 st Gear Normal Low to Low to Low to Normal Normal Normal High Normal Normal Normal Low to Low to Normal - Normal Downshift with Zero Throttle and No Engine Downshifts Forward Clutch Stator and Normal Normal - - High Detent Wires Switched Braking in Drive No Detent Oil Leak in Feed System to the Normal Normal Normal Normal Normal Low Normal M alfunction in 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 12—THM 400 Oil Pressure Check Chart AUTOMATIC TRANSMISSION 7A-17 DIAGNOSIS OF THM 400 Figure 13—No 1-2 Upshift and/or Delayed Upshift 7A-18 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 400 (CONT.) B-08737 Figure 1 4-1-2 Shift Feel Complaint — Firm Shift AUTOMATIC TRANSMISSION 7A-19 DIAGNOSIS OF THM 400 (CONT.) B-08735 Figure 1 5-1-2 Shift Feel Complaint — Firm Shift 7A-20 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 400 (CONT.) B-08336 Figure 1 6 -2 -3 Shift Complaint AUTOMATIC TRANSMISSION 7A-21 DIAGNOSIS OF THM 400 (CONT.) DIAGNOSIS OF THM 400 (CONT.) B-08333 B-08324 Figure 19—No Engine Braking — Lo Range — 1st Gear Figure 17—Drive In Neutral • Detent valve bore plug damaged. • Detent regulator valve pin short. 4. Pump. • Pressure regulator and/or boost valve stuck. • Incorrect pressure regulator spring. • Too many pressure regulator valve spacers. • Pump casting bad. • Pressure boost valve installed backwards or malfunctioning. CHECK O U TS ID E M A N U A L LINKAGE CONTROL VALVE ASSEMBLY—GOVERNOR LINE PRESSURE CHECK 1. 2. 3. 4. Install an oil pressure test gage. Install a tachometer. Disconnect the vacuum line to the modulator. With the vehicle on a hoist driving wheels off the ground, foot off the brake, in drive, check the line pressure at 1000 rpm. 5. Slowly increase the engine rpm to 3000 rpm and determine if a line pressure drop occurs (69 kPa [10 psi] or more). 6. If pressure drop of 69 kPa (10 psi) or more occurs, disassemble, clean and inspect the control valve assembly. & C O RRECT I - IN TE R N A L LINKAGE - 1. PAR K IN G BRAKE ROD A S S E M B L Y (CHECK A C TU A TO R FOR C H A M FE R ). 2. PAR K IN G P A W L BR O K EN , C H A M FE R O M IT T E D . 3. PAR K IN G BRAKE B R ACKET LOO SE, B U R R OR ROUGH EDGES OR IN C O R R E C TLY IN S T A L L E D 4. PAR K IN G P A W L R ETU R N S P R IN G M IS S IN G , BROKEN, IN C O R R E C LTY HOO KED. 5. BROKEN LU G S ON O U T P U T C A R R IE R . B-08329 Figure 18—Will Not Hold in Park or Will Not Release From Park Figure 20—No Engine Braking — Intermediate Range — 2nd Gear 7A-22 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 400 (CONT.) B-08629 Figure 21—No Reverse or Slips in Reverse 7. If the pressure drop is less than 69 kPa (10 psi): • Inspect the governor. — Stuck valve. — Weight freeness. — Restricted orifice in the governor valve. Figure 22—No 2-3 Upshift, 1st and 2nd Speeds Only — C heck the g ove rn or valve entry and exhaust (0.50 mm [0.20-in.] min.). • Governor feed system. — Check the screen in the control valve assembly or case. — Check for restrictions in the governor pipe. — Check for fit of the governor pipes in the case holes. AUTOMATIC TRANSMISSION 7A-23 DIAGNOSIS OF THM 400 (CONT.) B-08680 Figure 23—No Drive in Drive Range B-08675 Figure 24—No Detent Downshift 7A-24 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 400 (CONT.) NOTE: BEFORE C H E C K IN G T R A N S M IS S IO N FOR W H A T IS B E LIE V ED TO BE “ T R A N S M IS S IO N N O IS E ,” M A K E C E R TA IN TH E N O IS E IS N OT FROM TH E W A T E R P U M P , G E N E R A TO R , A IR C O N D IT IO N E R , P O W E R S T E E R IN G , ETC. TH E SE C O M P O N E N T S CAN BE IS O L A T E D BY R E M O V IN G TH E P R O P E R BELT A N D R U N N IN G TH E ENG IN E NO M O R E T H A N T W O M IN U T E S A T ONE T IM E . B-08669 Figure 25—Transmission Noisy TRANSMISSION 181. 182. 185. 187. 188. 189. 2-3 S h ift Valve G o v e rn o r M a n u a l Valve D e te n t P re ssu re R e g u la to r 1-2 A c c u m u la to r F ile r 190. 191. 192. 193. 194. 195. P re ssu re R e g u la to r F ro n t S ervo P re s s u re S w itc h R ear Servo 3-2 S h ift Valve D e te n t S o le n o id 7A-25 O il P u m p O il C o o le r S cre e n M o d u la to r Valve V a cu u m M o d u la to r 1-2 S h ift Valve AUTOMATIC TRANSMISSION • Figure 26—THM 400 Oil Circuits 110. 170. 171. 177. 178. 180. 7A-26 AUTOMATIC TRANSMISSION THM 400 CLUTCH PLATE APPLICATION CHART FORWARD CLUTCH NO. OF FLAT STEEL PLATES MODELS THICKNESS 2.32 MM (.0915") EV, FI, FS, HR, MA 5 FG, RC, RR, RT, RV, ZD, ZV 5 NO. OF WAVED STEEL PUTES NO. OF DISHED PUTES 1.54 MM (.0605") 1.37 MM (.054") 1.97 MM (.0775") NO. OF COMPOSITION PUTES 5 1 4 ALL OTHERS 5 1 5 THM 400 CLUTCH P U TE APPLICATION CHART DIRECT C LUTCH NO. OF F U T STEEL PUTES MODELS THICKNESS 2.32 MM (.0915") FA, FB, FC, FD, FF, FJ, FK, FM NO. OF WAVED STEEL PUTES NO. OF DISHED PUTES 1.54 MM (.0605") 1.37 MM (.054") 1.97 MM (.0775") NO. OF COMPOSITION PUTES 5 5 FN. FP, FR, FT, FV, FW, FX, FZ FG, ZD, ZV 2 EV, FT, FS, HR, MA, RV 6 FL, FQ, HZ, RC, RR 4 1 5 LR, LS 3 1 4 RT 5 1 6 3 1 5 6 THM 400 CLUTCH P U T E APPLICATION CHART INTERMEDIATE CLUTCH MODELS THICKNESS EV, FG, FI, FS, HR, MA NO. OF F U T STEEL PUTES NO. OF WAVED STEEL PUTES 2.51 MM (.099") 1.74 MM (.0685") 3 3 RV, ZD, ZV A LL OTHERS 2 NO. OF COMPOSITION PUTES 1 3 F-02663 Figure 27—THM 400 Clutch Usage Chart AUTOMATIC TRANSMISSION 7A-27 AL A A . Drive AB. M o d u la to r O r In te rm e d ia te AC. To C o o le r AD. From C o o le r AE. B re a th e r AF. L u b ric a tio n AG. V e n t AH AA AB AP AG A H . Lin e AJ. P ressure R e g u la to r Feed AK . C o n ve rte r AL. Intake A M . E xh au st AN . Reverse B-08635 Figure 28—THM 400 Pump Cover Oil Passages AA. AB. AC. AD. AG. AH. AK . AL. AN . AO. AN Drive M o d u la to r O r In te rm e d ia te To C o o le r From C o o le r V e nt Line C o n ve rte r Intake Reverse Seal Drain B ack H ole AA. Drive AB. M o d u la to r O r In te rm e d ia te AC. To C o o le r AD. From C o o le r AG. V e n t AH. AL. AN . AP Line Intake (Pum p) Reverse In te rm e d ia te C lu tc h C up Plug B-08630 Figure 30—THM 400 Case Oil Passages B-08641 Figure 29—THM 400 Pump Body Oil Passages Figure 31—THM 400 Center Support Oil Passages 7A-28 AUTOMATIC TRANSMISSION AA. AH . AM . AN. AQ. AR. AS. AT. AU. AV. AW. AX. AY. 185. Drive Line E xh a u st Reverse D ire ct C lu tc h In te rm e d ia te Servo D etent M o d u la to r G o ve rn o r Lo 1 -2 A c c u m u la to r Void M anual Valve B-08322 Figure 32—THM 400 Valve Body Oil Passages AUTOMATIC TRANSMISSION 7A-29 (TO F SERVO) AZ AA. AH . AM . AN . AR. AT. AU. AV. AW. AZ. BA. BB. (EXH D rive L in e E xh au st Reverse In te rm e d ia te D eten t M o d u la to r G o ve rn o r Lo Rnd 3rd C lu tc h 2nd C lu tc h 2-3 DR OIL TO F. SERVO (TO END OF MOD. VALVE) □ [) 0AN AA(2-3) OAU AA (2“ 3) (INT.)n n 00 AN CD AN O O AH AZ OAR □ A N □ am a t a a AUA „ n 0 AUT AT □ AW AW O (2ND CL FEED) ^ □ q OAN u O aaq an am AM 1 = 1 ^ AW ^ ( 2 - 3 DR TO 2 n d CL) L o nu n Uau n*„' d aa AA AT AA Q oJ K A % AH A AN (TO 3RD CL ' AW a \a OAH ah ■(TO DETENT) B-08320 Figure 33—THM 400 Valve Body Spacer Plate (Typical) 7A-30 AUTOMATIC TRANSMISSION AV (FEED) / AV (PRESSURE) AA. D rive AB. M o d u la to r o r In te rm e d ia te AH. AM . AN . AP. AQ. AR. Lin e E xh a u st R everse In te rm e d ia te C lu tc h D ire c t C lu tc h In te rm e d ia te AS. AT. AU. AV. AW. AX. BC. Servo D eten t M o d u la to r G o ve rn o r Lo 1-2 A c c u m u la to r Reverse o r Lo B-08323 Figure 34—THM 400 Case Oil Passages (Bottom View) AUTOMATIC TRANSMISSION 7A-31 THM 700-R4 PRELIM INARY CHECKING • • • • • • • CHECK TRANSMISSION OIL LEVEL CHECK AND ADJUST T V CABLE CHECK OUTSIDE MANUAL LINKAGE AND CORRECT CHECK ENGINE TUNE INSTALL OIL PRESSURE GAGE (FIGURE 57) CONNECT TACHOMETER TO ENGINE CHECK OIL PRESSURE AS FOLLOWS: * NOTICE Total running time for this combination not to exceed 2 minutes. CAUTION Brakes must be applied at all times. Minimum T V Line Pressure Check Set the T V cable to spe cifica tion; and w ith the brakes applied, take the line pressure readings in the ranges and at the engine r.p .m .'s indicated in the cha rt below . Full T V Line Pressure Check Full T V line pressure readings are obtained by ty in g or holding the T V cable to the fu ll e xte n t o f its travel; and w ith ,th e 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 Range PARK, NEUTRAL, OVERDRIVE & Normal Oil Pressure Normal Oil Pressure At M inim um T.V. At Full T.V. Model kPa PSI kPa PSI Y L M ,Y T M 38 5 - 444 5 6 - 64 818-1040 119-151 YMM 4 5 1 - 515 6 6 -7 5 1115-1430 162-207 YXM 451-515 6 5 -7 5 840-1053 122-153 MCM, MHM, PAM, TAM, YFM, MTM, PRM, TNM, TRM, PGM, TBM 451-515 65-7 5 844-1068 122-155 451 -51 5 65-7 5 851-1063 123-154 TJM, TKM, M WM, MZM, TUM, TXM, FAM, MOM, MPM, MAM, MSM, MMM, MRM, MXM, MKM, MUM MANUAL 3RD @ 1000 RPM YPM 3 84-444 56-64 876-1333 127-193 YKM 3 84-444 56-64 883-1129 128-164 TSM 3 84-444 56-64 962-1237 139-179 YAM, YCM, YWM, YZM, YDM 3 84-444 5 6 -6 4 1049-1359 152-197 YTM 6 32-729 92-106 * 1345-1710 195-248 YMM 7 42-846 108-123 *1834-2351 266-341 YLM 632 -72 9 92-106 *1380-1782 200-258 YXM 742-847 108-123 *1381-1731 200-251 REVERSE MCM, MHM, PAM, TAM, YFM, MTM, PRM, TNM,TRM, PBM, TBM 742-847 108-123 *1388-1755 201-254 @ 1000 RPM TJM, TKM, MWM, MZM, TUM, TXM. FAM, MDM, MPM, 742-847 108-123 *1399-1747 203-253 YPM 632 -73 0 92-106 *1441-2191 209-318 YKM 632-730 92-106 *1452-1856 211-269 TSM 632-730 92-106 *1581-2034 229-295 * @ 2000 RPM MANUAL 2ND & MANUAL L0 M AM, MSM, MMM, MRM, MXM, MKM, MUM YAM, YCM, YWM, YZM, YDM 632 -73 0 92-106 *1724-2234 250 -32 4 TSM, YAM, YCM, YKM, YLM, YPM, YTM, YWM, YZM, YDM 1120-1293 162-187 1120-1293 162-187 1127-1286 163-186 1127-1286 163-186 FAM, MCM, MDM, MHM, MPM, PAM, TAM, YFM, YMM, YXM, MAM, MSM, MMM, MRM, @ 1000 RPM MXM, MTM, PRM, MKM, MUM, TJM, TKM, TNM, TRM, MWM, MZM, TUM, TXM, PBM, TBM Line pressure is basically controlled by pump o u tp u t and the pressure regulator valve. In addition, line pressure is boosted in Reverse, Second and Lo by the reverse boost valve. A lso , in the Neutral, Drive, Interm ediate and Reverse positions o f the selector lever, the line pressure should increase w ith th ro ttle opening because of the T V system . The pressure is controlled by the T V cable, the th ro ttle lever and bracket assem bly and the T V link, as w ell as the control valve assem bly. The main line pressure tap plug is located on the le ft side of the transm ission above the outside manual lever. F-02664 Figure 35—Oil Pressure Check Procedure 7A-32 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 700-R4 9 o IMPORTANT A s a d ia g n o s is aid, you can c h e c k th e o il p re ssure d iffe re n tia l b etw e en lin e p re ssu re and th e 2nd, 3rd, and 4th c lu tc h p re ssure w h ile d riv in g th e v e h ic le . If th e p re ssure d iffe re n tia l b e ­ tw e e n lin e p re ssure and any o f th e c lu tc h c irc u its is m ore th a n 70 kPa (10 psi) (p ro vid e d y o u r g ag es are accurate), th e re is a p o s s ib le leak in th a t c lu tc h o il c irc u it. D A. B. C. D. C Line P ressure T h ird P ressure F o u rth P re ssure S e con d P ressure B-08331 Figure 36—THM 700-R4 Pressure Tap Locations AUTOMATIC TRANSMISSION 7A-33 ROAD TEST • Performthe road test following the sequence given. • KPH (MPH) shift points will vary with actual throttle position and driver habits. • Compare the results of the test with speed shift chart information. Use these results with the diagnosis information to evaluate the transmission (figure 37). • This test should only be performed when traffic and road conditions permit. • Observe all traffic safety regulations. GARAGE SHIFT CHECK 1. Start engine. 2. Depress brake pedal. 3. Move gear selector: — “Park” (P) to “Reverse” (R). — “Reverse” (R) to “Neutral” (N) to “Drive” (D). Gear selections should be immediate and not harsh. UPSHIFTS AND TORQUE CONVERTER CLUTCH (TCC) APPLY With gear selector in “Overdrive” (D). 1. Accelerate using a steady increasing throttle pressure. 2. Note the shift speed point gear engagements for: — 2nd gear. — 3rd gear. — Overdrive. 3. Note the speed shift point to TCC apply. This should occur while inthird gear or overdrive. If the apply is not noticed, refer to the Preliminary Torque Converter Clutch Diagnosis information contained in this section of the Service Manual. Im portant The torque converter clutch will not engage if engine coolant has not reached a minimum operating temperature of approximately 54°C (130°F). PART THROTTLE DETENT DOWNSHIFT At vehicle speeds of 40-55 MPH (64-88 KPH) quickly depress the accelerator to a half open position and observe: — TCC releases. — Transmission downshift to 3rd gear immediately. FULL THROTTLE DETENT DOWNSHIFT At vehicle speeds of 40-55 MPH (64-88 KPH) quickly depress the accelerator to a wide open position and observe: — TCC releases. — Transmission downshifts to 3rd gear immediately. MANUAL DOWNSHIFT 1. At vehicle speeds of 40-55MPH (64to88 KPH) release the accelerator pedal while moving the gear selector to “Third” gear (D) and observe: — TCC release. — Transmission downshift to 3rd gear should be immediate. — Engine should slow vehicle down. 2. Move gear selector to “ Overdrive (D) and accelerate to 40-45 MPH (64-72 KPH). Release the accelerator pedal while moving the gear selector to “ Second” gear (2) and observe. — TCC release. — Downshift to second gear should be immediate. — Engine should slow vehicle down. 3. Move gear selector to “ Overdrive” (D) and accelerate to 25 MPH (40 KPH). Release the accelerator pedal while moving the gear selector to “ First” gear (1) and observe: — TCC release. — Transmission downshift to 1st gear should be immediate. — Engine should slow vehicle down. COASTDOWN DOWNSHIFT 1. With the gear selector in “ Overdrive” (D) accelerate to 4th gear with TCC applied. 2. Release the accelerator pedal and lightly apply the brake to observe: — TCC release. — Shift points for downshifts. MANUAL GEAR RANGE SELECTION MANUAL THIRD (D) 1. With vehicle stopped, place gear selector in “ Third” (D) and accelerate to observe: — The first to second gear shift point. — The second to third gear shift point. MANUAL SECOND (2) 1. With vehicle stopped, place gear selector in “ Second” (2) and accelerate to observe: — The first to second gear shift point. 2. Accelerate to 25 MPH (40 KPH) and observe: — That a second to third gear shift does not occur. — That TCC does not engage. MANUAL FIRST (1) 1. With vehicle stopped, place gear selector in “ First” (1) and accelerate to 15 MPH (24 KPH) and observe: — T h a t no u p s h ift occurs. — That TCC does not engage. REVERSE 1. With vehicle stopped, place gear selector in “ Reverse” (R) and slowly accelerate to observe reverse gear operation. All possible throttle positions and corresponding MPH shift point information has not been provided. 7A-34 AUTOMATIC TRANSMISSION 1987 “ THM 700-4R” SPEED SHIFT CHART Model 1-2 Min Throt 2-3 Min Throt 3-4 Min Throt 4-3 Part Throt 3-2 IPart Throt FAM 12-15 20-30 33-55 + 55 + 38-55 + MDM 13-16 22-30 37-55 + 55 + MHM 9-11 17-24 28-47 55 + MPM 11-14 19-26 33-51 NTM 13-19 23-38 46-55 + 4-3 Coast Down 3-2 Coast Down 2-1 Coast Down 28-54 17-28 11-14 42-55 + 32-55 19-27 12-14 27-45 25-44 14-22 8-10 55 + 37-55 28-49 16-24 10-13 55 + 44-55 + 38-55 + 19-31 12-17 PAM 9-11 17-24 28-47 55 + 27-45 25-44 14-22 8-10 TAM 9-11 15-22 23-51 55 + 27-51 20-47 11-20 8 -10 TSM 8-10 16-22 25-53 55 + 26-55 23-48 13-20 7- 9 YMM 9-10 13-19 24-44 55 + 22-52 18-38 10-16 8- 9 YTM 12-14 19-25 36-55 55 + 38-55 + 31-53 15-23 11-13 YWM 8- 9 12-17 24-44 55 + 23-53 19-39 9 -14 7- 9 YXM 10-12 16-27 35-52 55 + 36-54 30-49 13-23 9-11 YZM 11-13 13-24 34-46 55 + 10-20 30-44 10-20 13-24 YLM 10-12 16-23 32-37 55 + 31-47 28-45 12-19 16-23 YKM 10-12 19-25 31-48 55 + 31-52 27-45 15-23 19-25 YFM 11-14 18-25 31-54 55 + 28-51 26-51 15-23 10-13 YCM 11-12 15-22 32-55 + 55 + 30-55 + 24-51 12-18 9-11 YAM 9 -10 13-18 27-48 55 + 25-55 + 21-43 10-16 8- 9 YPM 11-13 19-26 28-43 55 + 35-55 25-41 16-24 10-12 NOTES: 1. All speeds indicated are in miles per hour. Conversion to KPH = MPH x 1.609 2. Shift points will vary slightly due to engine loads and vehicle options 3. Speeds listed with + exceed 55 mph Figure 37—THM 700-R4 Speed Shift Charts F -0 2 6 6 5 AUTOMATIC TRANSMISSIONS7A-35 DIAGNOSIS OF THM 70O-R4 Oil Pressure High Or Low (Check With Gage Check Oil Level & Engine Tune) CORRECTION POSSIBLE CAUSE PROBLEM 1. Oil pump assembly. 2. Oil filter. 3. 4. 5. 6. TV exhaust ball. Throttle lever and bracket assembly. Throttle link. Valve body. 3. 4. 5. 6. 7. Case. High Or Low Shift Points 1. 2. 3. 4. TV cable. TV exhaust ball. Throttle lever and bracket assembly. Oil pump assembly. 5. Vaive body assembly. 1. 2. 3. 4. Pressure regulator valve stuck. P re ssure re g u la to r va lve s p rin g damaged. R o to r g u id e m is s in g or m isa ssembled. Rotor cracked or broken. TV valve, reverse boost valve or bushing stuck, damaged or incor­ rectly assembled. O rifice hole in pressure regulator valve plugged. S tickin g slide or excessive rotor clearance. Pressure relief ball not seated or damaged. Porosity in pump cover or body. Wrong pump cover. Pump faces not flat. Intake pipe restricted by casting flash. Cracks in filter body or intake pipe. Seal missing, cut or damaged. Stuck or damaged. Misassembled, binding or damaged. Misassembled, binding or damaged. a. Manual valve scored or damaged. b. Spacer plate or gaskets incorrect, misassembled or damaged. Face not flat. Throttle valve sticking. Throttle valve sleeve rotated in bore or retaining pin not seated. TV lim it valve sticking. Modulated downshift vaive stuck. Line bias valve stuck. 2-3 shift valve stuck. C h e c k b a lls m is s in g o r m is a s ­ sembled. Case to valve body face not flat. Binding or not correctly adjusted. Stuck or damaged. Misassembled, binding or damaged. a. Stuck pressure regulator valve or TV boost valve, b. Sticking pum p slide. 5. a. Sticking throttle valve or plunger. b. Modulated TV up or down valves sticking. c. TV limit valve sticking. d. S p ace r plate or gaskets m isas­ sembled, dam aged or incorrect. 7A-36 AUTOMATIC TRANSMISSIONS DIAGNOSIS OF THM 700-R4 (CONT.) PROBLEM 1st Gear Range Only POSSIBLE CAUSE 1. Governor assembly. — No Upshift 2. Valve body. 3. Case. 4. 2-4 servo assembly. 5. 2-4 band assembly. Slips In 1st Gear 1. Forward clutch assembly. 2. Input housing and shaft assembly. 3. Valve body. 4. TV cable. CORRECTION 1. a. Governor valve sticking. b. Governor driven gear loose or dam ­ aged. 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. a. 1-2 shift valve sticking. b. Spacer plate or gaskets mispositioned or damaged. 3. a. Case to valve body face not flat or damaged, b. Governor screen restricted or dam ­ aged. 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 dam aged piston or pin seals. d. 4th servo piston in backwards. 5. a. 2-4 band worn or damaged. b. Band anchor pin not engaged. 1. a. Clutch plates worn. b. Porosity or dam age in forward clutch piston. c. Forward clutch piston inner and outer seals m issing, cut or dam ­ aged. d. Input h ousing to forw ard clu tch housing seal missing, cut or dam ­ aged. e. Damaged forward clutch housing. f. Forward clutch housing retainer and ball assembly not sealing or dam ­ aged. 2. Turbine shaft seals m issing, cut or damaged. 3. a. Accum ulator valve stuck. b. Face not flat, dam aged lands or in­ terconnected passages. c. Spacer plate or gaskets incorrect, m ispositioned or damaged. 4. Binding or broken. AUTOMATIC TRANSMISSIONS 7A-37 DIAGNOSIS OF THM 700-R4 (CONT.) PROBLEM Slips In 1st Gear (Continued) 5. 1-2 accum ulator piston assembly. 6. Oil pressure. 7. 2-4 servo assembly. 1-2 Shift Speed — High Or Low 1. TV cable. 2. Governor assembly. 3. Throttle lever and bracket assembly. 4. Valve body. 5. Oil pump assembly or case. Slipping Or rough 1-2 Shift CORRECTION POSSIBLE CAUSE 1. Throttle lever and bracket assembly. 2. Valve body assembly. 5. a. Porosity in piston or 1-2 accum ulator 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 miss­ ing or damaged. e. Leak between piston and pin. f. Broken 1-2 accumulator spring. 6. Refer to Causes of High or Low Oil Pressure. 7. 4th servo piston in backwards. 1. a. Binding or broken. b. Not correctly adjusted. 2. Refer to 1st Gear Range Only — No Upshift. 3. a. M isa ssem b le d, b in din g or d am ­ aged. b. TV link missing, binding or dam ­ aged. 4. a. TV exhaust check ball stuck. b. TV plunger sticking. c. Face not flat. 5. Face not flat. 1. a. b. 2. a. b. c. d. 3. 2-4 service assembly. 3. 4. 2nd Accumulator. 4. 5. 2-4 band. 6. Oil pump assembly or case. 5. 6. Incorrectly installed or damaged, TV cable broken or binding. Throttle valve sticking. TV bushing turned in its bore. 1-2 shift valve train stuck. Gaskets or spacer plate incorrect, mispositioned or damaged. e. Line bias valve stuck. f. Accum ulator valve stuck. g. TV limit valve stuck. h. Face not flat. a. Apply pin too long or too short. b. Servo seals missing, cut or dam ­ aged. c. Restricted or missing oil passages. d. Servo bore in case damaged. a. Porosity in 1-2 accumulator housing or piston. b. Piston seal or groove damaged. c. Nicks or burrs in 1-2 accum ulator housing. d. Missing or restricted oil passage. Worn or mispositioned. Faces not flat. 7A-38 AUTOMATIC TRANSMISSIONS DIAGNOSIS OF THM 700-R4 (CONT.) PROBLEM No 2-3 Shift Or 2-3 Shift Slipping, Rough Or Hunting POSSIBLE CAUSE 1. Converter. 2. Governor assembly. 3. Oil pump. 4. Valve body. 5. Input housing assembly. 6. Case. 7. 2-4 servo assembly. No. 3-4 Shift/Slipping Or Rough 3-4 Shift 1. Governor. 2. Oil pump assembly. CORRECTION 1. Internal damage. 2. a. Valve stuck. 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. Stator shaft sleeve scored or off loca­ tion. 4. a. 2-3 valve train stuck. b. Accum ulator valve stuck. c. Spacer plate or gaskets incorrect, mispositioned or damaged. d. Throttle valve stuck. e. TV limit valve stuck. 5. a. Clutch plates worn (3-4 or forward). b. Excessive clutch plate travel. c. Cut or damaged piston seals (3-4 or forward). d. Porosity in 3-4 clutch housing or pis­ ton. e. 3-4 piston check ball stuck, dam ­ aged or not sealing. f. Restricted apply passages. g. Forward clutch piston retainer and ball assem bly not seating. h. Sealing balls loose or missing. 6. 3rd accum ulator retainer and ball as­ sembly not seating. 7. a. 2nd apply piston seals missing, cut or damaged. b. Servo pin seals missing, cut or dam ­ aged. 1. a. Governor weights binding. 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. a. Faces not flat. b. Pump cover retainer and ball as­ sembly m issing or damaged. AUTOMATIC TRANSMISSION 7A-39 DIAGNOSIS OF THM 700-R4 (CONT.) POSSIBLE CAUSE PROBLEM No 3-4 Shift/Slipping Or Rough 3-4 Shift (Continued) 3. Valve body assembly^ 4. 2-4 servo assembly. 5. Case. 6. Input housing assembly. 7. 2-4 band assembly. No Reverse Or Slips In Reverse 1. Input housing assembly. 2. Manual linkage. 3. Oil pump assembly. 4. Valve body assembly. CORRECTION 3. a. Valves stuck. -2 -3 shift valve train. -A ccum ulator valve. -T h rottle valve. -T V limit valve. -1-2 shift valve train. -3 -2 control valve. b. Manual valve link bent or damaged. c. Spacer plates or gaskets incorrect, m ispositioned or damaged. ,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. a. 3rd accum ulator retainer and ball assembly leaking. b. Porosity in 3-4 accumulator piston or bore. c. 3-4 accum ulator piston seal or seal grooves damaged. d. Plugged or missing orifice cup plug. e. Restricted oil passage. 6. Refer to Slipping 2-3 Shift. 7. Worn or misassembled. 1. a. 3-4 apply ring stuck in applied posi­ tion. b. Forward clutch not releasing. c. Turbine shaft seals missing, cut or damaged. 2. Not adjusted. 3. a. Retainer and ball assembly missing or damaged, b. S ta to r s h a ft seal rin g s o r rin g 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. a. 2-3 shift valve stuck. b. Manual linkage not adjusted. c. Spacer plate and gaskets incorrect, mispositioned or damaged. 7A-40 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 700-R4 (CONT.) PROBLEM No Reverse Or Slips In Reverse (Continued) POSSIBLE CAUSE 5. Reverse input clutch. 6. Lo and reverse clutch. 7. Case. No Part Throttle Or Delayed Downshifts 1. External linkage. 2. 2-4 servo assembly. 3. Governor assembly. 4. Valve body assembly. No Overrun Braking — Manual 3-2-1 1. External linkage. 2. Valve body assembly. CORRECTION 5. a. Clutch plates worn. b. Reverse input housing and drum as­ sembly cracked at weld. c. C lutch plate retaining ring out of groove. d. Return spring assem bly retaining ring out of groove. e. Piston deformed or dished. f. Seals cut or damaged. g. Retainer and ball assem bly not seal­ ing. h. Restricted apply passage. 6. a. Clutch plates worn. b. Clutch plate retaining ring mispositioned. c. Porosity in piston. d. Seals damaged. e. Return spring assem bly retaining ring m ispositioned. f. Restricted apply passage. 7. a. Cover plate gasket missing or dam ­ aged. b. Cover plate not torqued correctly. c. Porosity. 1. Not adjusted. 2. a. Apply pin seal cut or damaged. b. Servo cover retaining ring missing or misassembled. c. 4th apply piston dam aged or misas­ sembled. d. Servo inner housing damaged or misassembled. 3. a. Governor weights binding, b. Governor valve stuck. 4. a. Valves stuck. -T h rottle valve. -3 -2 control valve. -T V modulated downshift. b. TV sleeve turned in bore. c. 4-3 sequence valve body channel blocked. d. #5 check ball m issing from valve body. . 1. -Not adjusted properly. 2. a. Valves stuck. -4 -3 sequence valve. -T h rottle valve. b. Check ball #3 mispositioned. c. Spacer plate and gaskets incorrect, damaged or m ispositioned. AUTOMATIC TRANSMISSION 7A-41 DIAGNOSIS OF THM 700-R4 (CONT.) POSSIBLE CAUSE PROBLEM No Overrun Braking 3. Input clutch assembly. 3. a. Turbine shaft oil passages plugged or not drilled. b. Turbine shaft seal rings damaged. c. Turbine shaft sealing balls loose or missing. d. Porosity in forward or overrun clutch position. e. Overrun piston seals cut or dam ­ aged. f. Overrun piston check ball not seal­ ing. 1. Electrical. 1. a. 12 volts not supplied to transm is­ 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. In c o rre c t or d a m a g e d p re s s u re switches. 2. Internal damage. 3. a. Converter clutch apply valve stuck or assembled backwards. b. Converter clutch apply valve retain­ ing ring mispositioned. c. Pump to case gasket m ispositioned. d. Orifice cup plug plugged. e. Solenoid “ 0 ” ring seal cut or dam ­ aged. f. Orifice cup plug omitted from cooler in passage. g. High or uneven bolt torque (pump body to cover). 4. Valves stuck. -C onverter clutch shift valve. -T h rottle valve. 5. a. Turbine shaft “ 0 ” ring seal cut or damaged, b. Turbine shaft retainer and ball as­ sembly plugged. — Manual 3-2-1 (Continued) No Converter Clutch Apply 2. Converter. 3. Oil pump assembly. 4. Valve body assembly. 5. Input housing and shaft. Converter Shudder CORRECTION 1. Torque converter assembly. 2. Valve body. 3. Oil pump assembly. 4. Oil filter. 1. Internal damage. 2. Converter clutch shift valve stuck. 3. a. Converter clutch apply valve stuck, b. Restricted oil passage. 4. a. Crack in filter body. b. Flash restricting filter neck. c. Seal cut or damaged. 7A-42 AUTOMATIC TRANSMISSION DIAGNOSIS OF THM 700-R4 (CONT.) PROBLEM Converter Shudder (Continued) POSSIBLE CAUSE 5. Miscellaneous. 6. Input housing and shaft assembly. CORRECTION 5. a. b. 6. a. b. Low oil Engine Turbine Turbine sembly pressure. not tuned properly. shaft seal cut or damaged, shaft retainer and ball as­ damaged. No Converter Clutch Release 1. Solenoid. 2. Converter. 3. Oil pump assembly. 1. External ground. 2. Internal damage. 3. Converter clutch apply valve stuck. Drives In Neutral 1. Forward clutch. 2. Manual linkage. 1. Not releasing. 2. a. Incorrectly adjusted, b. Disconnected. 3. a. Face not flat. b. Internal leakage. 3. Case. 2nd Gear Start (Drive Range) 1. Governor assembly. 2. Forward sprag clutch. No Park Racheting Noise Oil Out The Vent 1. Parking linkage. Parking pawl. 1. Oil pump. 2. Valve body. Vibration In Reverse And Whining Noise In Park Oil pump. 1. a. Valve stuck. b. Governor support pin too long or missing. 2. Sprag assembly installed backwards. 1. a. Acutator rod assem bly bent or dam ­ aged. b. Actuator rod spring binding or im ­ properly crim ped. c. Actuator rod not attached to inside detent lever. d. Parking bracket dam aged or not torqued properly. e. Inside detent lever not torqued prop­ erly. f. Detent roller m ispositioned or not torqued properly. g. Parking pawl binding or damaged. Parking pawl return spring weak, dam ­ aged or misassembled. 1. Chamfer in pump body rotor pocket too large. 2. TV Imiit valve stuck. Broken vane rings. AUTOMATIC TRANSMISSION 7A-43 OIL AND WIRING CIRCUITS TRANSMISSION 110. 170. 172. 173. 174. 175. 176. 180. 181. 182. Oil Pump Oil C ooler TCC Solenoid TCC Apply Valve Line Pressure Tap 3rd A ccum ulator Pressure Tap 2nd C lutch Pressure Tap 1-2 Shift Valve Train 2-3 Shift Valve Train Governor 184. 3rd C lutch Pressure S w itch 185. Manual Valve 188. 1-2 A ccum ulator 189. Filter 190. Pressure Regulator 191. 2-4 Servo 192. 4-3 D ow nshift S w itch 194. 3-2 Control Valve Train 196. TCC Signal S w itch TRANSMISSION 197. TCC S hift Valve Train 198. MTV Up Valve Train 199. MTV Down Valve Train 200. 3-4 S hift Valve Train 201. 4th C lutch Pressure Sw itch 202. 3-4 Relay Valve 203, 4-3 Sequence Valve TV Plunger 204. 205. T hrottle Valve (TV) 206. TV Exhaust Lifter 207. A ccum ulator Valve Train 208. 3-4 A ccum ulator 209. TV Lim it Valve Train 210. Line Bias Valve Train 211. Pressure Relief Valve 212. 4th C lutch Pressure Tap • Check Balls B-08461 Figure 38—THM 700-R4 Oil Circuits 7A-44 AUTOMATIC TRANSMISSION AA. AB. AC. AD. AE. AF. AG. AH. AJ. AK. AL. AM . AN . AO. A P. AQ. V ent Lin e Dec. E xh au st Rev. C lu tc h D-2 MTV 3-4 C lu tc h O.R. C lu tc h Seal Drain Void Conv. C lu. Sig. To C o o le r Conv. C lu. Rel. Lube Conv. Feed AM AH AG B-08601 Figure 39—THM 700-R4 Pump Cover Oil Passages AQ. Conv. Feed AA. A P. AD. AO. AN. AM. AL. AK. AJ. AH. AG. AF. AE. AB. AC. Vent Lube E xh a u st Conv. C lu. Rel. To C o o le r Conv. C lu. Sig. Void Seal D rain O.R. C lu. 3-4 C lu tc h MTV D-2 Rev. C lu tc h Line Dec. Figure 40—THM 700-R4 Pump Body Oil Passages AUTOMATIC TRANSMISSION 7A-45 AR AD. AR. AS. AT. 220. 221. 222. 223. 224. 225. 226. 227. 228. AS 220 E xh au st 4th Oil 3rd A c c u m u la to r O il 2nd Oil Valve B ody Face O il Pan Flange Seal, “ 0 ” R ing (2-4 Servo Cover) Cover, 2-4 Servo P isto n , 4th S u p p ly R ing, O il Seal O u te r (4th A p p ly P iston) R ing, R e ta in e r (A p p ly Pin) W asher, Servo A p p ly Pin S p rin g, Servo A p p ly Pin AT 229. 230. 231. 232. 233. 234. 235. 236. 237. 238. 239. 240. 241. AD 221 Seal, “ O ” R ing H o u s in g , Servo P isto n In ne r R ing, O il Seal In n e r (2nd A p p ly P iston) R ing, O il Seal O u te r (2nd A p p ly P iston) P isto n, 2nd A p p ly S p rin g, Servo C u s h io n R etainer, Servo C u s h io n S p rin g R ing, R e ta in e r (2nd A p p ly P iston) Pin, 2nd A p p ly P isto n Seal, 2nd A p p ly P is to n Pin S p rin g, Servo R eturn R etaine r & Ball A sse m bly, 3rd A ccu m . Plug, C ase Servo B-08561 Figure 41—THM 700-R4 Servo Assembly 7A-46 AUTOMATIC TRANSMISSION AE. AF. AU. AV. AW. AX. AY. AS. AZ. AH. AG. AH. BA. AL. BB. AD. AB. BC. AT. BD. AR. AM. BE. BF. AJ. Reverse D-2 Lo Lo-1 D-4 G overnor Lo Reverse 3 A ccum ulator TV 3-4 C lutch MTV A ccum u la to r (4th) «#1 4th Signal Void 3-4 A ccu m u lato r TV-Ex Line Part Throttle-D rive 3 *#3 2nd (1-2) »#8 TVF 4th Conv. Clu. Sig. MTV Down MTV Up O.R. C lutch AF n . . BH BJ AT BK AE A FAll AV AW AX AR AZ B D ATBC ABADBB AL Detent Det./Lo ##9 3-4 C lutch (3-2 Ex.) »#10 AH BK. RND 4-3 • Check Balls B-08462 Figure 42—THM 700-R4 Case Oil Passages and Check Ball Locations BL. AG. AH . AE. AB. AF. BM . Fw d. C lu tc h M TV 3-4 C lu tc h Reverse Line D-2 P re ssure Tap AL. AA. BN. AN. AM . AJ. Void V e nt From C o o le r To C o o le r Conv. C lu. Sig. O.R. C lu tc h B-08465 Figure 43—THM 700-R4 Pump Case Oil Passages BP AD AD. BO. BP. BQ. 240. 241. Servo E x h a u s t H ole 3rd A c c u m u la to r P re ssu re Tap Passage 2-4 Servo Bore 2nd & 4 th Band A p p ly P assage R e ta in e r & Ball A s s e m b ly , 3rd A c c u m . P lug, C ase Servo y B-08464 Figure 44—THM 700-R4 Servo Oil Passages AUTOMATIC TRANSMISSION 7A-47 □ AE BK 6 ' O \> ° o AE o AZ BH (------- OAU V— ^ O □ CD AS AFO HAU °D# A B * A °u & C3 .w n AB AV AWO □ a o o ^ BG □ □ AH AZ AG # • □ □ BA AX BG ® a AG o AW BD D ag Y ^ o BB AB. AW. AE. AF. AU. AV. AX. AY. AS. AZ. AG. e m o BX be Oa q ax ax o »BoF S AE Q O Q □ • AB AJ □ Line D4 Reverse D2 Lo Lo-1 Governor Lo/Reverse 3rd A ccum ulator TV MTV • BR. BA. AT. BB. BD. AJ. AD. BC. BS. BT. Bolt Holes A ccum ulator 4th Signal 2nd C lutch 3-4 A ccum ulator TVF Overrun C lutch TV Ex. DC3/Part Throttle Part th ro ttle D3 BB r~\ / lJ BR( BA BU. AM. BF. BE. BG. AH. BH. BK. BX. By. 4th C lutch Conv. Clu. Sig. MTV Up MTV Down Detent 3-4 C lutch Detent/Lo Rnd. 4-3 3rd C lutch Id e n tifica tio n B-08831 Figure 45—THM 700-R4 Spacer Plate to Case Gasket 7A-48 AUTOMATIC TRANSMISSION BK □ AE A Q • A|J BG O ae AF O 0 _ 5 0 o a . b AF O AB® AY □ C D ' □ AW— * 0 AE AX O i a u o a c3 AU BH AV AZ AT BX AXr □ AX o ASD □ a QAE □AY 0 .AG AH A Z ^ f • BX ° BG □ ^ ^ a □ AW AX O BA □ BG op AS B0F BE □ Qa u D AG BB □ • AJ 0 X AW ’O ° i ' ) C? AB ^ BU C3 o o AT BS BT AB. AW. AF. AU. AE. AX. AV. AY. AS. AZ. AG. Line D4 D2 Lo Reverse G o ve rn o r Lo-1 Lo/R everse 3rd A c c u m u la to r TV MTV • BR. BA. AT. BB. BD. AJ. AD. BC. BS. BT. B o lt H o le s A c c u m u la to r 4th S ig na l 2nd C lu tc h 3-4 A c c u m u la to r TVF O verrun C lu tc h TV Ex. D3/Part T h ro ttle Part T h ro ttle D3 BU. AM . BF. BE. BG. AH . BH. BK. BX. BY. 4 th C lu tc h Conv. C lu. Sig MTV Up MTV D ow n D eten t 3-4 C lu tc h D e te n t/L o RND. 4-3 3rd C lu tc h Id e n tific a tio n B-08798 Figure 46—THM 700-R4 Spacer Plate to Valve Body Gasket AUTOMATIC TRANSMISSION 7A-49 GAS MODELS ONLY DIESEL MODELS AF o AE o AZ AU BG O C> i—, Q AS AU r\ AV u oa ° BH AB BX AW AX O 0 o BA □ AS b e n BG BB □ • AM □ O U n • AB ^ H -B Y gg 0 BU AB □ A_ ^ BS ATC3 O OBT o AM AB. AW. AF. AU. AE. AX. AV. AY. AS. AZ. AG. > \> B 0° u Line D4 D2 Lo Reverse G o ve rn o r Lo-1 Lo/R everse 3rd A c c u m u la to r TV MTV • BR. BA. AT. BB. BD. AJ. AD. BC. BS. BT. B o lt H o le s A c c u m u la to r 4 th S ig n a l 2nd C lu tc h 3-4 A c c u m u la to r TVF O verrun c lu tc h TV Ex. D 3/Part T h ro ttle Part T h ro ttle D3 BU. AM . BF. BE. BG. AH. BH . BK. BX. BY. 4 th C lu tc h Conv. C lu. S ig n . M TV Up M TV D ow n D e te n t 3-4 C lu tc h D e te n t/L o RND. 4-3 3rd C lu tc h Id e n tific a tio n F-00910 Figure 47—THM 700-R4 Spacer Plate (Typical) 7A-50 AUTOMATIC TRANSMISSION nan1 S AB. AW. AF. AU. AE. AX. AV. AY. AS. Line D4 D2 Lo Reverse G o verno r Lo-1 Lo/Reverse 3rd A c c u m u la to r AZ. AG. BR. BA. AT. BB. BD. AJ. AD. TV MTV A c c u m u la to r 4th S ignal 2nd C lu tc h 3-4 A c c u m u la to r TVF O verrun C lu tc h TV Ex. BC. BS. BT. BU. AM. BF. BE. BG. AH . D3/Part T h ro ttle Part T h ro ttle D3 4th C lu tc h Conv. C lu. Sig. MTV Up MTV Dow n D etent 3-4 C lu tc h BH. BK. BX. BY. AL. AD. BZ. CA. D e te n t/L o Rnd. 4-3 3rd c lu tc h Id e n tific a tio n Void E xh a u st SF 4-3 B-08520 Figure 48—THM 700-R4 Valve Body Oil Passages AUTOMATIC TRANSMISSION 7A-51 197 Or AandB H INDICATES VALVE BORE BUSHINGS ^ ------------------------P A 205. 204. 203. 202. 209. 207. 210. 194. 185. 180. T h ro ttle Valve (& B u sh in g ) T V P lu n g e r (& B u sh in g ) 4-3 S e qu e nce Valve 3-4 Relay Valve T V L im it Valve Train A c c u m u la to r Valve Train Line Bias Valve Train 3-2 C o n tro l Valve Train M anual Valve 1-2 S h ift Valve Train 181. 200. 197. 198. 199. A. 2-3 S h ift Valve Train 3-4 S h ift Valve Train TCC S h ift Valve Train M T V Up Valve Train M T V D ow n Valve Train C o n ve rte r C lu tc h T V B u s h in g Bore P lug (ECM C o n tro lle d V e h icle s) B. C o n v e rte r C lu tc h S h ift Valve Bore P lug (ECM C o n tro lle d V e h ic le s ) Figure 49—THM 700-R4 Valve Trains B-08521 7A-52 AUTOMATIC TRANSMISSION 4-3SHIFT (N.C.) 0.5 AMPS + 12V - » 0.5 AMPS ! B +12V 0.28 AMPSAD +12V TCC SOL (N.O. OIL PATH — r _ n 4TH CL (N.O.) I 3RD CL (N.O.) TCC SIG (N.O.) NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) TYPE 1 MODELS: MD, MK, TK Component 172. TCC S o le n o id 184. 3rd C lu tc h S w itc h T erm in als 192. 4-3 S h ift S w itc h T erm in als 196. TCC S ig n a l S w itc h Term inal 201. 4th C lu tc h S w itc h T erm in als 215. C o n n e c to r Color ID W h ite B lack/G reen D ot Lt. Green B la ck B ody Yellow B la ck Lt. Green B lack/G reen Dot B lue Wire A. C o n n e c to r A To 4-3 S h ift S w itc h B. C o n n e c to r B To 4th C lu tc h S w itc h D. C o n n e c to r D To 3rd C lu tc h S w itc h E. 4-3 S h ift S w itc h To 4th C lu tc h S w itc h F. TCC S ig n a l S w itc h To 3rd C lu tc h S w itc h G. TCC S o le n o id To 4-3 S h ift S w itc h Color ID Red W h ite W h ite W h ite W h ite Red B-08516 Figure 50—THM 700-R4 Wiring — Type 1 AUTOMATIC TRANSMISSION 7A-53 4-3SHIFT (N.C. TCC_SOL_____ (N.O. OIL PATH) 0.5 AMPS +12V 0.5 AMPS iB +12V i ^ ! 4TH CL D (N.O.) NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C. TYPE 2 MODELS: MF, MR, MX, TC, TD, TF, TR 201 Component Color ID 172. TCC S o le n o id 192. 4-3 S h ift S w itc h T erm inal 201. 4th C lu tc h S w itc h T erm in als 215. C o n n e c to r Y ellow B la ck Yellow B la ck/G ree n D ot B lue Wire A. C o n n e c to r A To 4-3 S h ift S w itc h B. C o n n e c to r B To 4th C lu tc h S w itc h E. 4-3 S h ift S w itc h To 4th C lu tc h S w itc h G. TCC S o le n o id To 4-3 S h ift S w itc h Color ID Red W h ite W h ite Red B-08517 Figure 51—THM 700-R4 Wiring — Type 2 7A-54 AUTOMATIC TRANSMISSION [T C C SOL 0 .5 A M P S I ( a ° ‘ 0 1 L P A T H ) I + 12 V — *— p ^ n - i i i4-3 SHIFT i(N.C.) NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) TYPE 3 MODELS: TS, YF, YL, MH, TN Component 172. TCC S o le n o id 192. 4-3 S h ift S w itc h T erm in a ls 215. C o n n e c to r Color ID B la ck B la ck B ody Yellow Wire A. C o n n e c to r A To 4-3 S h ift S w itc h G. TCC S o le n o id ( + ) To 4-3 S h ift S w itc h Color ID Red Red B-08513 Figure 52—THM 700-R4 Wiring — Type 3 AUTOMATIC TRANSMISSION 7A-55 4-3 PULSE (N.C.) \ T C C S0L (N.O. O IL PATH) 0.5 AMPS I + 12V a \ \ 0.010 AMPS I B + 12V ^ GROUNDS I I_____V______________ J 4TH DISCREET SW (N.C.) NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) 172 i TYPE 4 MODELS: FA, M A, M M , TJ, YK, YN, YP, YT Component 172. TCC S o le n o id 192. 4-3 S h ift S w itc h Term inal 201. 4th C lu tc h S w itc h * Term inal 215. C o n n e c to r * O p tio n a l Wire Color ID Red B la c k B ody Y ellow M e ta llic /W h ite B lue M e ta llic /B la c k A. C o n n e c to r A To 4-3 S h ift S w itc h B. C o n n e c to r B To 4th C lu tc h S w itc h D. C o n n e c to r D To TCC S o le n o id ( -) * * G. TCC S o le n o id ( + ) To 4-3 S h ift S w itc h ** Color ID Red W h ite B la c k Red CCC G ro u n d B-08512 Figure 53—THM 700-R4 Wiring — Type 4 7A-56 AUTOMATIC TRANSMISSION 4-3 S H IF T T C C SOL (N.O. OIL PATH) 0.5 AMPS i A + 12 V ->> 0.28 AMPS ,B + 12V E.C.M. GRD 3RD CL (N.O. (N.O.) 4TH CL NORMALLY OPEN (N.O.) 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 4.1L GAS 2 W.D. (C) TRUCK & (G) VAN WITH EMISSION SYSTEM FOR C ALIFO R N IA C om ponent 172. TCC S o le n o id 184. 3rd C lu tc h S w itc h T erm in als 192. 4-3 S h ift S w itc h T erm inals 196. TCC S ig na l S w itc h Term inal 201. 4th C lu tc h S w itc h T erm in als 215. C o n n e c to r C o lo r ID Blue B lack/G reen D ot Lt. Green B la ck B ody Yellow B la ck Lt. Green B la ck Blue W ire A. C o n n e c to r A To 4-3 S h ift S w itc h B. C o n n e c to r B To 3rd C lu tc h S w itc h D. C o n n e c to r D To 4th C lu tc h S w itc h F. TCC S ig n a l S w itc h To 3rd C lu tc h S w itc h G. TCC S o le n o id ( + ) To 4-3 S h ift S w itc h H. TCC S o le n o id (-) To 3rd C lu tc h S w itc h Figure 54—THM 700-R4 Wiring — Type 5 C o lo r ID Red W h ite B la ck W h ite Red B la c k AUTOMATIC TRANSMISSION 7A-57 T.C.C. SOL (N.O. O IL PATH) ---------- r 0.5 A M P S ^ + 12 V ->>— --------- >B G R O U N D ^ -----------------------i NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) TYPE 6 MODELS: MP, PL, TA, TB Component 172. TCC S o le n o id 215. C o n n e c to r Color ID Dk. Green Wire A. C o n n e c to r A To TCC S o le n o id ( + ) D. C o n n e c to r D To TCC S o le n o id (-) Color ID Red B la c k B-08510 Figure 55— THM 700-R4 W irin g — Type 6 7A-58 AUTOMATIC TRANSMISSION 4TH CL (NO.) T C C SOL (N O. OIL PATH) 0.5 AMPS + 12V 0.5 AMPS + 12V 0.28 AMPS + 12V (NO.) NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) TYPE-7 2.0L GAS 2 W.D. (S) TRUCK WITH EMISSION SYSTEM FOR HIGH ALTITUDE U.S.A. EXCEPT CALIFORNIA Component 172. TCC S o le n o id 196. TCC S ig n a l S w itc h Term inal 201. 4th C lu tc h S w itc h T erm in als 215. C o n n e c to r Color ID Gray B la ck Lt. Green B la ck/G ree n Dot B lue Wire A. C o n n e c to r A To 4th C lu tc h S w itc h B. C o n n e c to r B To 4th C lu tc h S w itc h D. C o n n e c to r D To TCC S ig n a l S w itc h J. TCC S o le n o id To 4th C lu tc h S w itc h Color ID Red Red W h ite Red B-08509 Figure 56—THM 700-R4 Wiring — Type 7 AUTOMATIC TRANSMISSION 7A-59 T C C SOL (N.O. OIL PATH) 0.5 A M P S' A 1 \ + 12 V 0.010 AMPS 'B +12 V “ ^ B GROUND^ i I ________ J 4TH DISCREET SW (N.C.) 201 172 NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) BC TYPE 9 MODELS: YC, YD, YW, YX, YZ, YA, YR, YS Component 172. TCC S o le n o id Term inal ( + ) 201. 4th C lu tc h S w itc h * Term inal ‘ O p tio n a l Color ID O range Red M e ta llic /W h ite Blue M e ta llic /B la c k Wire A. C o n n e c to r A To TCC S o le n o id ( + ) B. C o n n e c to r B To 4th C lu tc h S w itc h D. C o n n e c to r D To TCC S o le n o id ( - ) * * Color ID Red W h ite B la ck **C C C G rou nd F-02666 Figure 57—THM 700-R4 Wiring — Type 9 7A-60 AUTOMATIC TRANSMISSION T C C SOL (N.O. O IL PATH) 215 \ 0.5 AMPS I A + 12V 4 3 Sh ' f T (N.C.) E.C.M. G R D -y 1 *~ rh 4TH CL (N.O.) 192 NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C. 172 i TYPE 10 MODELS: MW, TW Component Color ID 172. TCC S o le n o id 192. 4-3 S h ift S w itc h T e rm in a ls 201. 4th C lu tc h S w itc h Term inal 215. C o n n e c to r B row n B la ck Yellow B la ck Blue Wire A. C o n n e c to r A to 4-3 S w itc h D. C o n n e c to r D To 4 th C lu tc h S w itc h G. TCC S o le n o id ( + ) To 4-3 S h ift Color ID Red B la ck F-02667 Figure 58—THM 700-R4 Wiring — Type 10 AUTOMATIC TRANSMISSION 7A-61 3RD CLU. (N.O.) 4-3 SHIFT (N.C.) '1 +12V 0.5 AMPS T C C SOL. ECM (N.O. O IL PATH) GROUND> fD NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C. 172 TYPE 14 MODELS: MC, MT, PR Component Color ID 172. TCC S o le n o id 184. 3rd C lu tc h S w itc h T erm inals 192. 4-3 S h ift S w itc h T erm inals 215. C o n n e c to r Pink B la ck/G ree n D ot Lt. Green B la ck B ody Y ellow Wire A. C o n n e c to r A To 3rd C lu tc h S w itc h D. C o n n e c to r D To TCC S o le n o id (-) G. TCC S o le n o id ( + ) To 4-3 S h ift S w itc h Color ID Red B la c k F-02668 Figure 59—THM 700-R4 Wiring — Type 14 7A-62 AUTOMATIC TRANSMISSION 215 4-3 PULSE (N.C.) \ T c c S0L (N.O. O IL PATH) \ | 0.5 AMPS + 12 V 0.010 AMPS I R + 12V G R O U N D -^ I____ v____________ J 4TH DISCREET SW (N.C.) NORMALLY OPEN (N.O.) NORMALLY CLOSED (N.C.) 172 TYPE 4 MODELS: FA, M A, M M , TJ, YK, YN, YP, YT Component 172. TCC S o le n o id 192. 4-3 S h ift S w itc h T erm inal 201. 4 th C lu tc h S w itc h * T erm inal 215. C o n n e c to r * O p tio n a l Color ID Red B la ck B ody Y ellow M e ta llic /W h ite B lue M e ta llic /B la c k Wire A. C o n n e c to r A To 4-3 S h ift S w itc h B. C o n n e c to r B To 4th C lu tc h S w itc h D. C o n n e c to r D To TCC S o le n o id ( -) * * G. TCC S o le n o id ( + ) To 4-3 S h ift S w itc h Color ID Red W h ite B la ck Red ** C C C G ro u n d F-02669 Figure 60— THM 700-R4 W irin g — T ype 15 ON VEHICLE SERVICE PARTS CLEANING, INSPECTION AND REPLACEMENT 1. Use appropriate safety equipment such as: • Safety glasses. • Safety shoes. • Gloves. 2. Keep work area and tools clean. 3. Clean the transmission exterior before removing parts. 4. Do not use wipe cloths or rags. 5. Do not use solvents on: • Rubber seals. • Plastic/Teflon® thrust washers. 6. Blow out all passages with compressed air. 7. Clean out small passages with fine wire. 8. Handle parts carefully to prevent damage. 9. Lubricate all internal parts with transmission fluid during assembly. 10. When installing screws, bolts or studs into aluminum always dip the threads in transmission fluid. 11. Always use a torque wrench for proper torque. 12. Recondition damaged or stripped aluminum threads with thread inserts. 13. Replace all gaskets and seals. • Do not use gasket cement or sealers. 14. Replace Teflon® and rubber lip seals only when necessary and install them using the appropriate seal protector. Inspect Manual linkage for: • Wear at pivoting points. • Bent or broken links and rods. AUTOMATIC TRANSMISSION 7A-63 2. All seals, gasket and mating surfaces for: • Nicks. • Cuts. • Damage. 3. Snap rings for: • Expansion or compression. • Distortion. • Nicks. • Proper ring to groove fit. 4. Bearings and thrust surfaces for: • Wear. • Scoring. • Pitting. OIL COOLER LINES If replacement of transm ission steel tubing cooler lines is required, use only double wrapped and brazed steel tubing meeting GM specification 123M or equivalent. Under no condition use copper or aluminum tubing to rep la ce steel tu b in g . Those m ate ria ls do not have satisfactory fatigue durability to withstand normal vehicle vibrations. Steel tubing should be flared using the double flare method. COOLER LINE FLUSHING In a major transmission failure, where particles of metal have been carried with the oil throughout the units of the transmission, it will be necessary to flush out the oil cooler and connecting lines. To flush the oil cooler and lines, use the following procedure: 1. Disconnect both cooler lines from the transmission. 2. Place a hose over the end of the cooler inlet line (from the bottom of the cooler) and insert the hose into an empty container. 3. Flush clean oleum solvent or equivalent through the return line (from the top of the cooler) using an oil suction gun until clean solvent comes out of the hose. This will “ back flush” the cooler. 4. Remove the hose from the inlet cooler line and place it on the return line. 5. Flush clean oleum solvent or equivalent through the inlet line until clean solvent comes out the return line. R em ove re m a in in g s o lv e n t from c o o le r w ith compressed air applied to the return line and flush with transmission fluid. 6. Reconnect oil cooler lines and torque nuts to 17 N m (12 ft. lbs.). CHECKING AND ADDING FLUID The automatic transmission is designed to operate at the "F U LL HOT” mark on the dipstick at normal operating temperatures of 8 8 °C -9 3 °C (190°F -200°F ), and should be checked under these conditions (figure 61). The normal operating temperature is obtained only after at least 24 km (15 miles) of highway type driving. If the vehicle has recently been operated for an extended period at high speed or in city traffic in hot weather or the vehicle is being used to pull a trailer, an accurate fluid level cannot be determined until the fluid has cooled down, usually about 30 minutes after the vehicle has been parked. %$&&&i A. O p e ra tin g Level F-02670 Figure 61—Transmission Dipstick Inspect 1. Park vehicle on level ground. 2. Apply parking brake and block wheels. 3. Start engine and operate vehicle for 15 minutes or until a normal operating temperature is reached. 4. Move gear selector through all gear positions. 5. Move gear selector to “ Park” (P). 6. Check fluid level, color and condition. Refer to “ Transmission Fluid Information” in this section. Important DO NOT OVERFILL. Overfilling can cause foaming and loss of fluid through the vent. Slippage and transm ission failure can result. Fluid level too low can cause slipping, particularly, when the transm ission is cold or the vehicle is on a hill. SHIFT LINKAGE Remove or Disconnect (Figure 62) Apply the parking brake. Retaining pin (226). Rod (240) from the column lever. • Note the position of any washers, spacers and insulators removed. 3. Rod (240) from the equalizer lever (238). — R, V and P Models. • Screw (242) and the washer. • Swivel (232). — G Models. • Nut (236), washers and the insulator. • Swivel (232). • Spacer and the retainer. 4. Retaining pin (227) and the equalizer lever (238). • Insulator, washer and the spring. Clean Metal parts using solvent. Wipe dry using a clean, dry rag. Rubber or nylon parts using soapy water. W ipe dry using a clean, dry rag. Install or Connect (Figure 62) Equalizer lever (238) and a new retaining pin (227). • Spring, washer and the insulator. 7A-64 AUTOMATIC TRANSMISSION 226 227. 228. 228. 230. 231. 232. 233. 234 235. 236. 237. 238. 239. R e ta in in g Pin R e ta in in g Pin N ut S p rin g W a sh e r In s u la to r S w ivel R eta in e r In s u la to r S p rin g W a sh er N ut W asher E q u a lize r Lever S p a ce r R V. P MODELS 229 240. 241. 242 243. 244. A. B. Rod W asher G MODELS Sc re vi S p a ce ' 240 In s u la to r S h ift Lever S te e rin g C o lu m n 239 /2 3 4 F-02671 Figure 62—Shift Linkage 2. Rod (240) to the equalizer iever (238 — R, V and P Models* • Swivel (232). • Washer and the screw (242) — G Models. • Retainer and the spacer • Swive! (232) • Insulator, washers anti the nut (236). 3. Rod (240) to the column lever • Insulators, spacers and washers i^ the positions they were removed from. 4. New retaining pin (226). A djust • Apply the parking brake. 1. Loosen the screw (242) or the nut (236), as used. 2. Put the column selector lever in the “ N ” (Neutral) position. • Put the lever into the neutral gate, do not use the indicator to find the neutral position. 3. Put the transmission in neutral. * tne shift ie^e- (A tc the rarwarc position, the DacK tc the seconc aeienv (Figure 63). Hold tne rod (240) tightly in the swivel (232) • Nut (236) o' the screw (242, tc 23 N m (17 ft. lb.). £ Put the column selector iever in the “ P” (Park) position 6. Check the adjustment • The column selector iever must go into all positions • The engine must start in the “ P” (Park) or “ N ” (Neutral) positions only. Adjust if needed, refer to “ Neutral Start Switch” in this section. CAUTION: With the selector lever in the “ Park” position, the parking pawl should freely engage within the rear (reaction) internal gear lugs or output ring gear lugs and prevent the vehicle from rolling, which could cause personal injury. AUTOMATIC TRANSMISSION 7A-65 |<-+| Remove or Disconnect (Figure 64) 1. Air cleaner. 2. Cable terminal (225) from the throttle lever (140). 3. C ab le h o u s in g (141) from compressing locking tangs (B). th e b ra c k e t w h ile 4. Routing clips or straps. 5. Screw (252) and the washer. 6. Cable (142) from the transmission link (144). • Pull up on cable cover at the transmission until the cable is visible. 7. Seal (254). Install or Connect (Figure 64) 1. New seal (254) into the transmission case hole. 2. Cable (142) to the transmission link. 3. Screw (252) and the washer. • Align the indicator, if needed. • Release the parking brake. £ Tighten • Screw (252) to 10 N m (7 ft. lbs.). 4. Cable routing clips or straps. TV CABLE The TV Cable used with the THM 700-R4 transmission should not be thought of as an automatic downshift cable. The TV cable used on the THM 700-R4 controls line pressure, shift points, shift feel, part throttle downshifts and detent downshifts. The function of the cable is sim ilar to the combined functions of a vacuum modulator and a detent cable. The TV cable operated the TV link (144) and bracket in the transmission (figure 64). The TV b ra cke t a s s e m b ly se rve s tw o (2) b a s ic functions: 1. The primary function of this assembly is to transfer the carburetor throttle plate movement to the TV plunger in the control valve assembly as related by the TV cable and linkage. This causes TV pressure and line pressure to increase according to engine throttle opening and also controls part throttle and detent downshifts. The proper adjustment of the TV cable is based on the TV plunger being fully depressed to flush with the TV bushing at engine wide open throttle. 2. The second function of the assembly involves a TV exhaust ball. The function of this system is to prevent the transmission from operating at low (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 ball to seat only if the cable if 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. 5. Cable (142) through the engine bracket and engage locking tangs (B) of the cable on the bracket. Im portant • Avoid damaging or kinking the cable. 6. Cable terminal (255) to the throttle lever (140). • Pull on upper end of cable. It should travel a short distance with light resistance caused by the small return spring on the TV lever. When releasing the upper end of the TV cable, it should return to the zero TV position. 7. Adjust the TV cable. Refer to “ TV Cable Adjustment” in this section. TV CABLE ADJUSTMENT Adjustm ent of the TV cable must be made by rotating the throttle lever at the carburetor or throttle body. Do not use the accelerator pedal to rotate the throttle lever. A djust (Figure 64) 1. Stop the engine. 2. Depress and hold down the metal re-adjust tab (250) at the engine end of the TV cable (142). 3. Move the slider (251) until it stops against the fitting. 4. Release the readjustment tab (250). 5. Rotate the throttle lever (140) to its “ full travel position.” 6. The slider (251) must move (ratchet) toward the lever when the lever is rotated to its “ full travel position.” • Check that cable moves freely. The cable may appear to function properly with the engine stopped and cold. Recheck after the engine is hot. 7. Road test the vehicle. 7A-66 AUTOMATIC TRANSMISSION 250 142 142 140 255 140. 141. 142. 144. 250. 251. 252. 253. 254. 255. A. B. T h ro ttle Lever C ab le H o u s in g C able L in k R e -A d ju st Tab S lid e r S crew W a sh er Seal T erm inal ID N u m b e r L o c k in g Tangs Figure 64—TV Cable (THM 700-R4) CHANGING THE FLUID AND FILTER Remove or Disconnect (Figure 65) • Raise the vehicle and support it using suitable safety stands. • Place a drain pan under transmission oil pan. 1. Oil pan screws (222) from the front and sides only. • Loosen the rear oil pan screws approximately 4 turns. NOTICE: Do not dam age the transmission case or oil pan sealing surfaces. 2. Lightly tap the oil pan (221) with a rubber mallet or pry down to allow the fluid to drain. • Inspect the fluid color, refer to “ Transmission Fluid Information” in this section. 3. Remaining oil pan screws (222), oil pan and the gasket (220 ). 4. Oil filter (189) and the seal (223). • The seal may be stuck in the case. Clean Transmission case and oil pan gasket surfaces with solvent and air dry. — All traces of old gasket m aterial must be removed. F-02702 AUTOMATIC TRANSMISSION 7A-67 3. Wire connector. A djust (Figure 66) 1. Press the plunger (A) as far forward as possible. 2. Press the accelerator pedal to the floor. VACUUM MODULATOR (THM 400) I*"*! Remove or Disconnect (Figure 67) • 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. l y l Clean - All parts using soapy water. Air dry. }^\ Inspect • Modulator and pipe for kinks, cracks and damage. • Hoses for cracks, wear and dry rot. +«- Install or Connect (Figure 67) -►+ Install or Connect (Figure 65) • Coat a new seal (223) with a small amount of petrolatum. 1. New seal (223) onto a new filter (189). 2. New filter (189) into the case. 3. Oil pan (221) and a new gasket (220). 4. Screws (222). Tighten • Screws (222) to 20 N m(15 ft. lbs.). 5. New transmission fluid. • Lower the vehicle. • Fill the transmission to the proper level with DEXRON® II fluid or equivalent. Refer to “Checking and Adding Fluid” in this section. Important • Do not overfill. 6. Check the oil pan gasket for leaks. DETENT SWITCH (THM 400) 1. Pipe (267) if removed. • Seat the pipe against the manifold fitting. • The pipe must be routed in the position it was removed from. 2. Vacuum modulator (178). • New seal. • Retainer and the screw. 3. Pipe (267) onto the modulator port. Im portant • The pipe must not be twisted or bent. 4. Transmission fluid if needed. Refer to “ Checking and Adding Fluid” in this section. SPEEDOMETER DRIVEN GEAR— VEHICLE SPEED SENSOR 0 • 1. 2. 3. 4. Remove or Disconnect (Figure 68) Apply the parking brake. Speedometer cable (277). Screw and the retainer. Sleeve and the seal. Driven gear or speed sensor (280), as used. U ] Inspect Remove or Disconnect (Figure 66) 1. Wire connector. 2. Screw. 3. Switch (260). Install or Connect (Figure 66) 1. Switch (260). 2. Screw. • Gear teeth for nicks and burrs. • All parts for wear and damage. Install or Connect (Figure 68) 1. 2. 3. 4. Driven gear or speed sensor (280) as used. New seal and the sleeve. Retainer and the screw. Speedometer cable (277). 7A-68 AUTOMATIC TRANSMISSION 178. 265. 266. 267. 268. 269. 270. 271. V a cuu m M o d u la to r M a n ifo ld F ittin g H ose P ipe C lip Seal R e ta in e r S cre w B-08653 F igure 67—Vacuum M o d u la to r (THM 400) • Release the parking brake. 5. Transmission fluid if needed. Refer to “ Checking and Adding Fluid” in this section. 1. Governor cover (287) and the seal or gasket as used. — THM 700-R4 • Tap around the cover flange with a punch. GOVERNOR — THM 400 Remove or Disconnect (Figure 69) • Raise the vehicle. • Lower the transm ission if needed for clearance, refer to “ Transmission Replacem ent" in this section. • R em ove th e screw s. Im portant Do not damage the governor cover. If the cover is damaged it must be replaced. O r S peed S e n s o r B-08637 Figure 68—Speedometer Driven Gear AUTOMATIC TRANSMISSION 7A-69 182. 285. 286. 287. G o v e rn o r Seal O r G a ske t (TH M 400 O nly) S cre w (TH M 400 O nly) G o v e rn o r C over B-08676 Figure 69—Governor 2 Governor (182). jyj Clean « Governor using solvent. Air dry and blow out all passages using dry compressed air. Inspect All parts for nicks, burrs, scoring and galling. Governor sleeve for binding. Governor valve for binding. Driven gear for loose fit. Weight springs for kinks or damage. Weights for binding. Valve entry opening. W ith the weights held all the way outward, the opening should be 5.1 mm (0.020 in.) (Figure 70). Valve exhaust opening. W ith the weights held all the way inward, the opening should be 5.1 mm (0.020 in.) (Figure 71). Figure 70—Measuring the Governor Valve Entry Opening if the weights, sleeve, or valve do not operate freely, disassem ble and clean the governor. If the driven gear must be repiaced, the governor must be disassembled. Im portant All the governor parts are a select fit. Except for the driven gear, the governor m ust be replaced as an assembly if repair is needed. MDisassemble (Figures 72 and 73) 1. R em ove the governor w eight 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 Vs in. drill. Figure 71—Measuring the Governor Valve Exhaust Opening 7A-70 AUTOMATIC TRANSMISSION Figure 72—Removing the Governor Weight Pins • Press the gear out of the sleeve using a punch, with the gear supported in a press with two 2.778 mm (7/64 in.) plates in the exhaust slots. 5. Clean the governor parts and inspect for damage. Assemble (Figures 73, 74 and 75) 1. New driven gear into the sleeve, if needed. • Press the gear in until it is almost seated using a socket with the governor supported 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. 312 310. 311. 312. 313. 314. 315. 316. 317. W e ig h t P in s Valve R e ta in in g Pin D riven G ear S p rin g P rim a ry W e ig h t S e co n d a ry W e ig h t T h ru s t C ap Figure 73—Governor Components • 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. Install or Connect (Figure 69) 1. Governor (182). 2. Governor cover (287) and a new seal or gasket as used. — THM 700-R4. • Put a thin coat of Loctite Cup Plug Sealant II, or equivalent, on the cover. • Tap the cover into place using a brass drift. — THM 400. • Screws. • Raise the transm ission if needed. Refer to “ Transmission Replacement” in this section. B-08523 Figure 75—Drilling the Driven Gear AUTOMATIC TRANSMISSION 7A-71 • Lower the vehicle. 3. Transmission fluid if needed. Refer to “ Checking and Adding Fluid” in this section. 2 -4 SERVO (THM 700-R4) Remove or Disconnect (Figures 76 and 77) • • 1. 2. 3. 4. 5. Tool Required: J-29714 Servo Cover Compressor. Raise the vehicle. Lower the transmission if needed for clearance. Refer to “ Transmission Replacement” in this section. Retaining ring and the cover (223) using J-29714. Seal from the cover. 4th apply piston (224). 2nd apply piston assembly (301). Spring (239). Disassemble (Figures 78 and 79) Tool Required: J-22269-01 Piston Compressor. Housing (230) from the piston (233). • Seal from the housing. 2. Retainer ring from the pin (237). • Washer and the spring. 3. Pin (237). • Seals from the pin. 4. Retainer ring from the piston (233) using J-22269-01. • Retainer and the spring. • Seals from the piston. Clean All parts using solvent. Air dry. Inspect Pistons for porosity and damage. Seal grooves for damage. Cover for porosity and damage. Seals for nicks and cuts and binding in the seal grooves. A. 222. 223. 224. 225. 229. 232. 238. 239. 300. 301. C ase Servo Bore Seal, “ O ” R ing (2-4 Servo Cover) Cover, 2-4 Servo P is to n , 4 th A p p ly R ing, O il Seal O u te r (4th A p p ly P isto n ) Seal, “ O ” R ing R ing, O il Seal O u te r (2nd A p p ly P is to n ) Seal, 2nd A p p ly P is to n R ing S p rin g , S ervo R eturn R ing, Servo C ove r R e ta in in g 2nd A p p ly P is to n A s s e m b ly B-08536 Figure 7 7 -2 -4 Servo (THM 700-R4) 7A-72 AUTOMATIC TRANSMISSION 236 A. J -22269-01 233. Piston, 2nd Apply 236. Ring, Retainer (2nd A pply Piston) B-08729 Figure 79—Removing the Retainer Pin (THM 700-R4) 233 — If damage is found, check for the cause of the damage. • Springs for kinks and bending. • Pin for wear and burrs. ---------234 9 o Im portant C h e c k th e c a s e s h a rp e d g e s . s e rv o b o re fo r d a m a g e and tp j Measure (Figures 80 and 81) T o o ls R e q u ir e d : J - 3 3 0 3 7 B a n d A p p ly P in T o o l V e r n ie r c a lip e r s o r m ic r o m e t e r 1 . S e r v o p in le n g t h ( F ig u r e 8 0 ) . • In s t a ll p in a n d J - 3 3 0 3 7 a s s h o w n . • A p p ly 1 1 .0 N m ( 1 1 0 in . lb s .) t o r q u e a n d c h e c k t h e g a g e s lo t (A ). • 226. 227. 228. 229. 230. 231. 232. 233. 234. 235. 236. 237. 238. Ring, Retainer (Apply Pin) Washer, Servo A pply Pin Spring, Servo A pply Pin Seal, “ O ” Ring Housing, Servo Piston Inner Ring, Oil Seal Inner (2nd Apply Piston) Ring, Oil Seal O uter (2nd Apply Piston) Piston, 2nd A pply Spring, Servo C ushion Retainer, Servo C ushion Spring Ring, Retainer (2nd A pply Piston) Pin, 2nd Apply Piston Seal, 2nd A pply Piston Pin B-08530 2. If t h e w h it e l in e is s e e n in t h e s lo t , t h e p in is c o r r e c t . — If t h e w h it e l in e is n o t s e e n in t h e r e p la c e t h e p in u s in g t h e c h a r t . R e m o v e t h e p in a n d J - 3 3 0 3 7 . P is to n a n d h o u s in g d im e n s io n (fig u r e 8 1 ). • * — M e a s u r e t h e p is to n d im e n s io n ( C ) . • M e a s u r e th e h o u s in g d im e n s io n (D ). • C h e c k th e c h a r t fo r th e p r o p e r d im e n s io n s . Assemble (Figures 78 and 79) Tool Required: Jr22269-01 Piston Compressor 1. Retainer and the spring in the piston (233). • New seals on the piston. • Retainer ring using J-22269-01. 2. Pin (237). • New seals on the pin. 3. Retainer ring on the pin. • Spring and the washer. Figure 78—2nd Apply Piston Assembly (THM 700-R4) 4. Housing (230) on the piston (233). • New seal on the housing. s lo t, AUTOMATIC TRANSMISSION 7A-73 2ND APPLY PISTON & HOUSING APPLICATION MODEL PISTON DIMENSION *A HOUSING DIMENSION **B YT, Y6, YK 63.10 mm (2.48") 64.00 mm (2.52") YC, YX 44.64 mm (1.78") 45.54 mm (1.79") ALL OTHERS 57.85 mm (2.28") 58.74 mm (2.31") A. Gage Slot B. J -33037 Pin Is Preset At Factory And M ust Not Be Re­ adjusted 2-4 SERVO PIN SEL ECTION PIN I.D. PIN LENGTH mm INCH 66.37-66.67 67.74-68.04 69.11-69.41 2.61-2.62 2.67-2.68 2.72-2.73 2 Rings 3 Rings W ide Band B -0 8 7 3 1 Figure 80—Measuring the Servo Pin Length (THM 700-R4) Important • B e s u re th e p r o p e r s e a ls a re in th e p ro p e r p o s itio n s (F ig u r e 7 7 ). 230. H ousing, Servo Piston (Inner) 233. Piston, 2nd A pply -►+ Install or Connect (Figures 76 and 77). B -0 8 7 3 0 T o o l R e q u ir e d : Figure 81—2nd Apply Piston and Housing Dimensions (THM 700-R4) J -2 9 7 1 4 S e rv o C o v e r C o m p re s s o r 1. S p rin g (2 3 9 ). 0 2 . 2 n d a p p ly p is to n a s s e m b ly ( 3 0 1 ) . 3 . 4 t h a p p ly p is to n ( 2 2 4 ) . T o o l R e q u ir e d : 4 . N e w s e a l o n th e c o v e r. J -2 1 4 2 6 E x te n s io n (T H M 7 0 0 -R 4 ) 5 . C o v e r ( 2 2 3 ) a n d t h e r e t a in in g r in g u s in g J - 2 9 7 1 4 . • R a i s e t h e t r a n s m is s io n if n e e d e d . R e f e r “ T r a n s m is s io n R e p l a c e m e n t ” in t h is s e c t io n . • L o w e r t h e v e h ic le . Install or Connect (Figure 82) H o u s in g O il Seal to 6 . T r a n s m i s s i o n f l u i d if n e e d e d . R e f e r t o “ C h e c k i n g a n d A d d in g F l u i d ” in t h is s e c t io n . REAR EXTENSION OIL SEAL 0 • Remove or Disconnect (Figure 82) R a is e th e v e h ic le . 1 . T r a n s m is s io n flu id . 2. P r o p e lle r s h a ft. R e fe r to P R O P E L L E R S H A F T (S E C . 4 A ). 3 . S e a l. Figure 82—Rear Extension Oil Seal In s ta lle r 7A-74 AUTOMATIC TRANSMISSION J-24057 Extension Housing and Pump Oil Seal Installer (THM 400) 1. New seal using J-21426 or J-24057 as needed. • Coat the outer edge of the seal case with a non hardening sealer. 2. Propeller shaft. Refer to PROPELLER SHAFT (SEC. 4A). • Lower the vehicle. 3. New transmission fluid. Refer to “Specifications” for the proper amount. TRANSMISSION REPLACEMENT 19. S c re w s (2 2 6 ). • N o te th e lo c a tio n o f a n y m o v e th e m a s id e . • S lid e th e tr a n s m is s io n b r a c k e t s o r c lip s a n d s tr a ig h t • T r a n s m is s io n c a s e u s in g a s o lv e n t d a m p e n e d c lo th , d o n o t a llo w s o lv e n t to e n t e r t h e t r a n s m is s io n . A ir d ry . • A ll h a r d w a r e a n d f ly w h e e l c o v e r u s in g s o lv e n t . A ir d ry . |<~+| Remove or Disconnect (Figure 83) A ll p a r t s f o r w e a r a n d d a m a g e . A ll s e a ls a n d f it t in g s f o r s ig n s o f le a k a g e . Tool Required: 6. 7. J-21366 Converter Holding Strap Negative battery cable. Air cleaner, and the TV cable fromthe throttle linkage, if the transmission is being removed. • Raise the vehicle. Transmission fluid. Shift linkage. Propeller shaft, refer to PROPELLER SHAFT (SEC. 4A). • Front propeller shaft, if used, from the transfer case. The support bracket at the catalytic converter. • Any other components as needed for clearance. • Support the transmission, and the transfer case, if used, with a transmission jack. Transmission crossmember. Im portant D o n o t s tr e tc h o r d a m a g e a n y c a b le s , w ir e s o r o th e r c o m p o n e n ts w h e n lo w e r in g th e tr a n s m is s io n . 8 . T r a n s m is s io n fa r e n o u g h fo r c le a r a n c e to r e a c h o th e r c o m p o n e n ts . 9 . D ip s t ic k t u b e ( 2 2 1 ) a n d t h e s e a l. 0 T o r q u e c o n v e r t e r fo r s tr ip p e d o r b r o k e n w e ld n u ts o r s c r e w h o le s . T r a n s m is s io n c a s e fo r p o r o s ity . Install or Connect (Figure 83) T o o l R e q u ir e d : J -2 1 3 6 6 C o n v e r te r H o ld in g S tr a p • If t h e t r a n s m is s io n w a s l o w e r e d f o r c l e a r a n c e o n ly , d o s te p s 1 3 -2 0 . 1. T ra n s m is s io n (2 2 5 ). • B e s u r e t h e t o r q u e c o n v e r t e r is s e a t e d p r o p e r ly a n d t h a t J - 2 1 3 6 6 is in p l a c e . • S u p p o r t th e tr a n s m is s io n , a n d t h e tr a n s f e r c a s e if u s e d , w it h a t r a n s m is s io n j a c k . • R a is e t h e tr a n s m is s io n J -2 1 3 6 6 . • S lid e t h e tr a n s m is s io n s tr a ig h t o n to t h e lo c a tin g p in s (A ) w h ile lin in g u p t h e m a r k s o n t h e f ly w h e e l a n d th e to rq u e c o n v e rte r. • • C o v e r t h e o p e n i n g in t h e t r a n s m is s io n . 1 0 . S p e e d o m e te r c a b le . 11. V a c u u m m o d u l a t o r l in e , if u s e d . 1 3 . C o o le r lin e s ( 2 2 3 ) . C a p a ll o p e n in g s lin e s . th e t r a n s m is s io n it a s i d e , and re fe r to N o te th e lo c a tio n o f th e ' b ra c e s , th e y m u s t b e i n s t a l l e d in t h e s a m e p o s it io n s . • th e fly w h e e l re m o v e T h e to r q u e c o n v e r te r m u s t b e flu s h fly w h e e l a n d r o ta te fr e e ly b y h a n d . o n to th e 2 . S c re w s (2 2 6 ). • A ll b r a c k e t s , c lip s a n d h a r n e s s e s m u s t b e in t h e p o s itio n s th e y w e r e r e m o v e d fr o m . • D o n o t in s ta ll th e d ip s tic k tu b e tr a n s m is s io n s u p p o r t b r a c e s c r e w s . or th e and • S c r e w s fin g e r tig h t to in s u r e p r o p e r c o n v e r te r s e a tin g . • S c r e w s to 6 5 N m ( 5 0 ft. lb s .). • R e m o v e th e e n g in e h o is t o r ja c k . 4 . C o n v e r te r h o u s in g c o v e r (2 2 8 ). • 17. C o n v e r te r h o u s in g c o v e r (2 2 8 ). M a rk and th e 1 5 . D a m p e n e r a n d t h e s u p p o r t , if u s e d . 1 6 . T r a n s m is s io n s u p p o r t b r a c e s (2 2 2 ). • p la c e 3. S c re w s (2 3 0 ). in 1 4 . T r a n s fe r c a s e s h ifte r a n d m o v e T R A N S F E R C A S E (S E C . 7 D ). • in to Im portant 1 2 . E le c tr ic a l c o n n e c to r s fr o m t h e tr a n s m is s io n . • th e Clean Inspect 3. 4. 5. o ff 2 0 . T r a n s m is s io n (2 2 5 ) fr o m th e v e h ic le . If the transmission is being lowered for clearance, do steps 1-8 only. 1. 2. back lo c a t in g p in s (A ) a n d in s t a ll J - 2 1 3 6 6 . th e to rq u e c o n v e rte r a lig n m e n t. 18. S c re w s (2 3 0 ). Im portant S u p p o r t t h e e n g in e w ith a ja c k o r h o is t b e fo r e d is c o n n e c t in g t h e tr a n s m is s io n . H o o k t h e c o v e r u n d e r t h e lip o f t h e e n g i n e o il pan. 5 . T h e s u p p o r t a n d d a m p e n e r , if u s e d . 6 . T r a n s m is s io n s u p p o r t b r a c e s (2 2 2 ). • T h e b r a c e s m u s t b e in s ta lle d th e y w e re re m o v e d fro m . in t h e p o s itio n s 7. T r a n s f e r c a s e s h if t e r , r e f e r to T R A N S F E R C A S E ( S E C . 7 D ). AUTOMATIC TRANSMISSION 7A-75 232 220. 221. 222. 223. 224. 225. 226. 227. 228. 229. 230. 231. 232. 233. Harness Dipstick Tube Support Brace Cooler Lines Seal Transmission Screws, Transmission To Engine Exhaust Bracket Converter Housing Cover Flywheel Screw, Flywheel To Torque Converter Dampener Insulator Support 228 227 B-08535 Figure 83—Transmission and Components (Typical) 7A-76 AUTOMATIC TRANSMISSION 8. Cooler lines (223). • Uncover the openings. • Do not twist or bend the lines. 9. Vacuum modulator line, if used. 10. Speedometer cable. 11. Electrical connectors to the transmission. 12. Dipstick tube (221) with a new seal. • Uncover the opening and install the seal first. • Screw (226). 13. Transmission into place. Im portant Do not pinch or damage any cables, wires or other com ponents when raising the transmission. 14. Transmission crossmember and the transmission mount. • Any components that were removed for clearance. • Remove the transmission jack. 15. The support bracket at the catalytic converter. 16. Propeller shaft, refer to PROPELLER SHAFT (SEC. 4A). • Front propeller shaft to the transfer case, if used. 17. Shift linkage. • Lower the vehicle. 18. New transmission fluid. 19. Air cleaner, and the TV cable, if removed. 20. Negative battery cable. SPECIFICATIONS FASTENER TORQUE Shift L in k a g e ............................................................................................................ TV Cable.................................................................................................................... Cooler Lines to Transm ission......................... ....................................................... Cooler Lines to R adiator......................................................................................... Dipstick Tube to Alternator Bracket (G models) —Except with LBI E n g in e ................................................................................... —With LBI E n g in e ............................................................................................... Transmission Support Braces —R and V M o d e ls ............................................................ ................................... —G Models (to E ngine)...... ............................ , . .................. ............................ (to Transmission)............................................................................ Dampener S upp ort........................................ .............................. .......................... Dampener to S u p p o rt................................... ...................... ................................... Converter Housing Cover —R and G Models Except with LBI Engine ................ . ................................. With LBI E n g in e ............................................................................................... —V Models Except 30/3500 with L25 Engine................................................................... 30/3500 with L25 E ngine......................... ....................................................... —P M odels...................................................... ..................................................... Transmission to E n g in e .................................................................. ........................ Converter to F lyw h e e l............................................................................................. Crossmember to Frame —R, G and P Models........................................................................................... —V M odels............................................................................................................ Note: LBI Engine - 4.3L (262 CID V6) Carbureted L25 Engine - 4.8L (292 CID L6) N-m 25 10 22 27 Ft. Lbs. 19 7 16 20 43 3.5 32 2.5 95 57 37 41 87 70 42 27 30 65 10 35 7 25 35 10 10 47 65 25 7 7 34.5 50 85 70 63 52 LUBRICATION Capacity —Pan Removal THM 400........................................................................ ........................ .. THM 700-R4................................................................................................ —Overhaul THM 400..................................................................................................... THM 700-R4................................................................................................ Type Recommended DEXRON® II or equivalent Note: DO NOT OVERFILL. Refer to “ Checking And Adding Fluid” in this section. 4 I. 4.7 I. 9 pts. 10 pts. 10 I. 10.9 I. 22 pts. 23 pts. AUTOMATIC TRANSMISSION 7A-77 SPECIAL TOOLS 1. J-21366 2. J-21426 5. J-29714 3. J-22269-01 6. J-33037 1. 2. 3. 4. 5. 6. J-24057 C onverter H olding Strap E xtension H ousing Oil Seal In staller (THM 700-R4) Piston C om pressor (THM 700-R4) E xtension H ousing Oil Seal In staller (THM 400) Servo Cover C om pressor (THM 700-R4) Band A pply Pin Tool (THM 700-R4) F-02673 7A-78 AUTOMATIC TRANSMISSIONS MANUAL TRANSMISSION 7B-1 SECTION 7B MANUAL TRANSMISSION CONTENTS SUBJECT PAGE Description.....................................................................................................................................................................7B- 1 Inspection.......................................................................................................................................................................7B- 1 Control Linkages.......................................................................................................................................................7B- 1 Transmission Shift E ffo r t........................................................................................................................................ 7B- 2 Diagnosis of Manual Transm ission............................................................................................................................7B- 2 On Vehicle S e rvice .......................................................................................................................................................7B- 3 Drian and F i l l .............................................................................................................................................................7B- 3 Rear Oil Seal...............................................................................................................................................................7B- 3 Speedometer Driven Gear........................................................................................................................................ 7B- 3 Shift L in k a g e .............................................................................................................................................................7B- 5 Shift Linkage A djustm ent.................................................................. ......................................................................7B- 6 Shift C ontrol...............................................................................................................................................................7B- 7 Side C o v e r.................................................................................................................................................................7B- 8 Transmission Replacement............... ....................................................................................................................7B-10 S pe cifica tio n s...............................................................................................................................................................7B-11 Fastener Torque.........................................................................................................................................................7B-11 L ub rication.................................................................................................................................................................7B-11 Special T o o ls .................................................................................................................................................................7B-12 DESCRIPTION M a n u a l t r a n s m is s io n s a r e id e n tifie d b y : (A ) t h e n u m b e r o f fo r w a r d g e a r s , a n d (B ) th e m e a s u r e d d is ta n c e b e tw e e n c e n te r lin e s o f th e m a in s h a ft a n d th e c o u n te r g e a r . T h e c o u n t e r s h a f t is n o t a p r e s s fit a n d is s e a l e d in t h e fr o n t o f t h e c a s e w ith a n e x p a n s io n p lu g . G e a r s h if t in g is d o n e w ith a f lo o r m o u n t e d s h if t c o n t r o l. 3-SPEED 76MM 4-SPEED 117MM T h e t h r e e s p e e d M u n c i e 7 6 m m t r a n s m i s s i o n s ( R P O ’s M 6 2 a n d M 6 4 ) a r e in c o n s t a n t m e s h a n d f u ll y uses s y n c h r o n iz e d in a ll f o r w a r d sp eed s s y n c h r o n iz e r s le e v e s . G e a r s h if t le v e r s a r e e it h e r a c o lu m n - t y p e s h ift le v e r . w ith flo o r -ty p e tw o or a s lid in g s te e r in g T h e fo u r s p e e d M u n c ie 1 1 7 m m t r a n s m is s io n ( R P O M 2 0 ) a c o n s ta n t m esh fir s t g ear and s y n c h r o n iz e d s e c o n d , th ir d a n d f o u r th g e a r s . G e a r s h if t in g is d o n e w it h a t r a n s m is s io n c o v e r m o u n t e d s h ift le v e r . T h e c o v e r h a s a b a ll p in t y p e in t e r lo c k w h ic h s to p s t h e t r a n s m is s io n fr o m b e in g s h ifte d in to tw o g e a r s a t o n e tim e . 4-SPEED O.D. 89MM T h e fo u r s p e e d N e w P r o c e s s 8 9 m m t r a n s m is s io n ( R P O M Y 6 ) is a n o v e r d r iv e u n it a n d is f u ll y s y n c h r o n i z e d in a ll fo rw a rd s p e e d s . INSPECTION • B e fo re r e p a ir in g th e tr a n s m is s io n , c h e c k th e a n d s h iftin g lin k a g e s to b e s u r e t h e p r o b le m tr a n s m is s io n . • c lu tc h is in t h e If a h y d r a u li c c lu t c h is u s e d , t h e r e a r e n o a d ju s t m e n t s fo r lin k a g e o r c lu tc h p e d a l. 3 . C h e c k t h e s h ift lin k a g e fo r w o r n s w iv e ls , b ra c k e ts o r d a m a g e d c o rd o n s h a ft. 4 . C h e c k th e n e c e s s a ry . s h ift lin k a g e a d ju s tm e n t a n d m o u n tin g a d ju s t a s STEERING COLUMN SHIFT CONTROL CONTROL LINKAGES 1. C h e c k th e c lu tc h and s h if t lin k a g e fo r d ir t, w e a r , o r dam age. 2 . C h e c k c lu tc h f r e e p e d a l tr a v e l a d ju s t m e n t a n d a d ju s t a s n e c e s s a r y . R e f e r to C L U T C H ( S E C .' 7 C ). 1. R e m o v e t h e s h ift c o n tr o l r o d s fr o m t h e c o lu m n le v e r s . 2 . C h e c k s h ift e f f o r t a t t h e s h ift c o n tr o l le v e r k n o b . 3 . If t h e e f f o r t is m o r e t h a n 9 N ( 2 lb .) , a d ju s t t h e s t e e r i n g c o lu m n lo w e r b e a r in g . R e f e r to S T E E R IN G ( S E C . 4 B ). 4. L u b r ic a t e a ll r o d a n d s w iv e l c o n n e c t io n s a n d r e c h e c k s h ift e ffo r t. 7B-2 MANUAL TRANSMISSION TRANSMISSION SHIFT EFFORT 5 . If s h if t lin k a g e is f r e e f r o m b in d i n g , c h e c k f o r 0 .1 3 m m ( 0 .0 0 5 in .) e n d p la y b e t w e e n t h e c o lu m n le v e r s a n d c o n tr o l le v e r . 6 . C o n n e c t th e c o n tr o l ro d s a n d c h e c k th e s te e r in g c o lu m n c o n t r o l le v e r s f o r a l ig n m e n t . In n e u t r a l, t h e c o lu m n c o n tr o l le v e r t a n g s s h o u ld lin e u p w ith t h e s lo t in t h e r e l a y le v e r . CLUTCH SPIN DOWN TIME 1 . R u n t h e e n g in e a t a n o r m a l id le w ith t h e t r a n s m is s io n in n e u t r a l a n d t h e c l u t c h e n g a g e d . 2 . D is e n g a g e t h e c lu t c h , w a it n in e s e c o n d s a n d s h ift t h e tr a n s m is s io n in to r e v e r s e . 3 . If a g r i n d i n g n o i s e is h e a r d , c h e c k t h e c l u t c h f o r t h e p ro b le m . R e fe r to C L U T C H (S E C . 7 C ). 1. R e m o v e t h e s h ift r o d s a t t h e t r a n s m is s io n . 2 . L in e u p t h e p r o b le m g e a r b y s h if t in g in to t h e g e a r a n d b a c k to n e u tr a l. 3 . C h e c k t h e e ffo r t n e e d e d to s h ift in to t h e p r o b le m g e a r u s in g a t o r q u e w r e n c h . 4 . If t h e s h if t e f f o r t is m o r e t h a n 5 N m ( 5 0 in . l b s . ) a n d t h e s h if t le v e r s h a f t is c l e a n a n d n o t d a m a g e d , a d d a n a n t i- c h a t t e r lu b r ic a n t, (p o s itr a c tio n a d d itiv e ) to th e tr a n s m is s io n . 5 . If t h e s h if t e f f o r t is s till h ig h , r e p a i r t h e t r a n s m is s io n a s needed. DIAGNOSIS OF MANUAL TRAN SM ISSIO N T h e fo llo w in g d ia g n o s is in f o r m a t io n 1. L u b r ic a n t le v e l to o h ig h . 2. M a in d r iv e b e a r in g r e ta in e r o r g a s k e t lo o s e o r d a m a g e d . S id e c o v e r o r g a s k e t lo o s e o r d a m a g e d . R e a r e x te n s io n s e a l d a m a g e d . C o u n t e r s h a f t lo o s e in c a s e . 3. 4. 5. Hard Shifting, Column Shift — Refer to “ Transmission Shift Effort” 7B-2 1. 2. Noisy Shifting 1. 2. 3. Noisy Neutral p r o b le m . CORRECTION POSSIBLE CAUSE PROBLEM Leaks Lubricant is t o b e u s e d o n ly a s a g u i d e t o lo c a t in g a t r a n s m is s io n 1. D r a in to c o r r e c t le v e l. 2 . T ig h te n o r r e p la c e . 3. T ig h te n o r r e p la c e . 4. 5. R e p la c e . R e p la c e c a s e . L e v e r s b in d in g — d ir ty o r d a m a g e d . L e v e r e n d p la y m o r e th a n 0 .1 3 m m (0 .0 0 5 in .). 1. 2. C le a n a n d lu b r ic a te o r r e p la c e . A d ju s t. R e fe r to S T E E R IN G C O L U M N (S E C . 3 B 4 ). S h ift lin k a g e o u t o f a d ju s t m e n t o r d a m ­ 1. A d ju s t o r r e p la c e . 2. A d ju s t o r r e p la c e . R e fe r (S E C . 7 C ). R e p a ir th e tr a n s m is s io n . aged. C lu tc h lin k a g e o u t o f a d ju s t m e n t o r d a m ­ aged. S y n c h r o n iz e r s o r g e a r s w o rn o r d a m ­ aged. 3. 1. S h ift lin k a g e o u t o f a d ju s t m e n t o r d a m ­ 1. A d ju s t o r r e p la c e . 2. 3. aged. P ilo t b e a r in g w o r n o r d a m a g e d . M a in d r iv e g e a r o r c o u n t e r g e a r b e a r in g s 2. 3. R e p la c e . R e fe r to C L U T C H R e p a ir th e tr a n s m is s io n . 1. 2. 3. 4. 5. F ill to c o r r e R e p la c e . R e p a ir th e R e p a ir th e R e p a ir th e 1. 2. R e p la c e . A d ju s t o r r e p la c e . to C LU TC H (S E C . 7 C ). w o rn o r d a m a g e d . Noisy Operation Slips Out Of Gear 1. L u b r i c a n t le v e l lo w . 2. 3. 4. 5. S S B G 1. 2. S h if t le v e r s e a l s tiff. S h ift lin k a g e o u t o f a d ju s t m e n t o r b in d ­ h ift lin k a g e d a m a g e d . y n c h r o n iz e rs w o rn o r d a m a g e d . e a r in g s w o rn o r d a m a g e d . e a rs w o rn o r d a m a g e d . 5. 6. in g . P ilo t b e a r in g D ir t b e tw e n tr a n s m is s io n . T ra n s m is s io n M a in d r iv e g 7. aged. T r a n s m is s io n n o t a lig n e d . 3. 4. lo o s e o r d a m a g e d . th e c lu tc h h o u s in g and lo o s e . e a r r e ta in e r lo o s e o r d a m ­ c t le v e l. tr a n s m is s io n . tr a n s m is s io n . tr a n s m is s io n . 3. R e p la c e . R e fe r to C L U T C H 4. C le a n th e m a tin g s u r fa c e s . 5. T ig h te n . 6. T ig h te n o r r e p la c e . 7. A lig n . (S E C . 7 C ). MANUAL TRANSMISSION 7B-3 ON VEHICLE SE R V IC E |-n-| Install o r Connect (Figure 1) T o o l R e q u ire d : J -2 1 4 2 6 , R e a r E x te n s io n S e a l In s ta lle r. 1. L o c k i n g c o m p o u n d o n t h e o u t s i d e o f a n e w s e a l ( 1 0 5 ) . 2 . N e w s e a l (1 0 5 ), j s e J -2 1 4 2 6 (fig u re 3 ). • F ill b e t w e e n t h e s e a l lip s w it h c h a s s i s g r e a s e . 3 . P r o p e l l e r s h a f t . R e f e r t o PROPELLER SHAFT (SEC. 100 102 101/103 4 A ). 4 . N e w t r a n s m is s io n o il. R e f e r t o “ D r a i n a n d F il l ” in t h is s e c tio n . • 105 L o w e r t h e v e h ic le . REAR RETAINER SEAL (4 SPEED) ++ Remove or Disconnect (Figure 2) • R a is e t h e v e h ic le . 1. T r a n s m i s s i o n o i l . 2 . P r o p e lle r s h a ft. R e f e r to P R O P E L L E R 100. 101. 102. 103. 104. 105. 106. 107. S p r in g W S c re w F ille r P lu D r a in R u T r a n s m is S eal R e ta in e r S c re w ash er g g s io n 108. 109. 110. 111. 112. 113. 114. G S S A C S P ear eal le e v e d a p te r a b le eal lu g 5. N u t (-*2 3 ) a n d th e fla n g e (1 2 2 ). 6. T r a n s m is s io n m o u n t. • S u p p o r t t h e tr a n s m is s io n w ith ja c k . 7. S c r e w s ( 1 2 5 ) a n d t h e r e t a i n e r th e c a s e . 9 . S e a l ( 105). Figure 1—Transmission and Components (3 Speed/ 4 Speed D.D. — Typical) install or Connect (Figure 2) T o o l R e q u ire d : j- 2 2 8 3 4 . R e a r R e ta in e r S e a i in s ta lle r DRAIN AND FILL L o c k in g c o m p o u n d o n th e o u ts id e o f a n e w s e a l \ e w s e a i (1 0 5 ), u s e J - 2 2 8 3 4 - 2 (fig u r e 4 ). «--► Remove or Disconnect (Figures 1 and 2) 1 . T h e f ille r p lu g 2 . T h e d ra in s lu g H G 3 ). 3 . T r a n s m is s io n o il. * C a t c h t h e o i l tin a o a n . install or Connect (Figures 1 and 2) 1 . T h e d r a in p lu g ( 1 0 3 ). 2 . M e w t r a n s m is s io n o il. » F ill to t h e e v e i o f t h e f i ll e r p lu g “ L u b r i c a t i o n '’ in t h is s e c t i o n . 3 . T h e fille r o fu g n o ie . R e f e r to 1102). S e a l (1 0 5 ). U s e J - 2 2 8 3 4 - 1 if a p a r k i n g b r a k e is u s e d . • F ill b e t w e e n t h e s e a l lip s w it h c h a s s i s g r e a s e . SPEEDOMETER DRIVEN GEAR REAR EXTENSION SEAL (3 SPEED AND 4 SPEED O.D.) 4A). • section. Lower the vehicle. ]+■») Remove or Disconnect (Figures 1 and 2)) Remove or Disconnect (Figure 1) SH A FT (S E C . (105). 3. N e w g a s k e t (1 2 0 ). 4. R e t a i n e r 1 2 1 ) a n d t h e s c r e w s ( 1 2 5 ) . 5. T r a n s m is s io n m o u n t. • R e m o v e th e ja c k . 5. F l a n g e 1 2 2 ) a n d t h e n u t ( 1 2 3 ) . 7. N e w s e a i ( 1 1 3 ) a n d t h e s p e e d o m e t e r c a b l e (112). 3. P a r k i n g b r a k e i f j s e d . R e f e r t o B R A K E S ( S E C . 5). 9. P r o p e l l e r s h a f t . R e f e r t o P R O P E L L E R S H A F T ( S E C . 4 A ). ^0. N l e w t r a n s m i s s i o n o il . R e f e r t o “ D r a i n a n d F i l l ” i n t h i s REAR OIL SEAL R a is e t h e ^ e h ic ie . T r a n s m i s s i o n o il. P r o p e lle r s h a ft. R e fe r to p R O P E L L £ R (121). 3. G a s k e t (1 2 0 ). • S c r a p e a ll g a s k e t m a t e r ia l fr o m t h e r e t a in e r a n d 8 -0 8 7 4 4 0 S H A F T (S E C . 4 A ). 3 . P a r k i n g b r a k e if u s e d . R e f e r t o B R A K E S ( S E C . 5 ) . 4 . S p e e d o m e t e r c a b l e ( 1 1 2 ) a n d t h e s e a l (113). • 1. 2. 3. 4. R S A R S a is e th e /e h ic le . p e e d o m e te r c a b le (1 1 2 ) a n d th e s e a i (1 1 3 ). d a p t e r (1 1 1 ) if u s e d . e ta in e r (1 0 6 ) a n d th e s c r e w (1 0 7 ) used. le e v e 1 1 0 ). f 7B-4 MANUAL TRANSMISSION ,124 100. 101. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115. 120. 121. 122. 123. 124. 125. 107 / 106 Spring W asher Screw F ille r Plug Drain Plug Transm ission Seal R etainer Screw Speedom eter Driver Gear Seal Sleeve A dapter S peedom eter Cable Seal Plug Harness Gasket Rear Bearing R etainer U-joint Flange Nut Screw Screw B-08639 Figure 2—Transmission and Components (4 Speed) 5 . S e a l (1 0 9 ). 6. G e a r (1 0 8 ). |-»<-| Install or Connect (Figures 1 and 2) • P u t a t h in c o a t o f t r a n s m is s io n o il o n t h e g e a r a n d s e a l. 1. G e a r (1 0 8 ). 2 . N e w s e a l (1 0 9 ) o n to th e s le e v e (1 1 0 ). 3 . S le e v e (1 1 0 ). 4 . R e t a in e r ( 1 0 6 ) a n d t h e s c r e w ( 1 0 7 ) if u s e d . Figure 3—Rear Extension Seal Installation (3 Speed/4 Speed O.D.) MANUAL TRANSMISSION 7B-5 137 133 147 146 130. 131. 132. 133. 134. 135. 136. 137. 138. 139. S h ift Rod, 1st/Rev. Spacer Spring Retainer S h ift Rod, 2nd/3rd C ross Lever S h ift Lever Retainer S h ift Lever Screw 140. 141. 142. 143. 144. W asher Swivel Spring W asher Insu lato r 140 145. 146. 147. 148. Bracket Nut Spring W asher Screw B-08644 Figure 5—Column Shift Linkage 5 . A d a p t e r ( 1 1 1 ) if u s e d . 6 . N e w s e a l (1 1 3 ) a n d th e s p e e d o m e te r c a b le (1 1 2 ). • 1 1. C r o s s le v e r (1 3 5 ). Install or Connect (Figure 5) L o w e r t h e v e h ic le . SHIFT LINKAGE • P u t a th in c o a t o f g r e a s e o n t h e in s u la to r . 1. C ro s s le v e r (1 3 5 ). STEERING COLUMN LINKAGE 0 Remove or Disconnect (Figures 5 and 6) • R a is e t h e v e h ic le . 1. R e ta in e r (1 3 3 ). 2 . S h if t ro d fr o m t h e c o lu m n . 3 . S p rin g (1 3 2 ) a n d th e s p a c e r (1 3 1 ). 4 . S c re w (1 3 9 ) a n d th e w a s h e r (1 4 0 ). 130. 134. 149. 150. 151. A. S h ift Rod, 1st/Rev. S h ift Rod, 2nd/3rd Lever Lever Relay Lever Gage Pin 150 5 . S h if t r o d a n d t h e s w iv e l (1 4 1 ) fr o m t h e s h ift le v e r ( 1 3 8 ) . 6 . S w iv e l (1 4 1 ). 7. R e ta in e r (1 3 7 ). 8 . N u ts (1 4 6 ), th e s p rin g w a s h e r s (1 4 7 ) a n d th e s c r e w s (1 4 8 ). 9 . B ra c k e t (1 4 5 ). 1 0 . In s u la to r ( 1 4 4 ), th e w a s h e r (1 4 3 ) a n d th e s p r in g (1 4 2 ). B-08483 Figure 6—Column Linkage Adjustment 7B-6 MANUAL TRANSMISSION 155. 156. 157. 158. 159. 160. 161. 162. 163. S h ift Rod, 1st/2nd S h ift Rod, 3rd/OD S h ift Rod, Rev. S h ift C ontrol Lever S h ift C ontrol R etainer W asher C ontrol Lever S h ift Rod, 1st/Rev. 164. 165. 166. 167. 168. 169. 170. A. B. S h ift Rod, 3rd/4th Nut Swivel Nut S h ift Lever W asher Retainer Gage Pin Gage Pin Hole B-08490 Figure 7—Floor Shift Linkage (3 Speed/4 Speed O.D.) T h e s p r in g ( 1 4 2 ) , t h e w a s h e r ( 1 4 3 ) a n d t h e in s u la to r 3. W a s h e r (1 6 9 ). (1 4 4 ). B ra c k e t (1 4 5 ). S c r e w s (1 4 8 ), n e w s p r in g w a s h e r s (1 4 7 ) a n d th e n u ts 4 . N e w r e ta in e r (1 7 0 ). (1 4 6 ). N e w r e ta in e r (1 3 7 ). S w iv e i (1 4 1 ) o n to t h e s h ift ro d . S h if t r o d a n d t h e s w iv e l (1 4 1 ) to t h e s h ift le v e r ( 1 3 8 ) . W a s h e r ( 1 4 0 ) a n d t h e s c r e w ( 1 3 9 ) lo o s e ly . 7. N e w r e ta in e r (1 6 0 ). 5 . S h ift ro d to t h e c o n tr o l le v e r (1 6 2 ). 6 . W a s h e r (1 6 1 ). • SHIFT LINKAGE ADJUSTMENT Im portant • 9. S p a c 10. S h i f t 11 . N e w • T h e w a s h e r m u s t s t a n d o ff t h e le v e r a s s h o w n . e r (1 3 1 ) a n d th e s p r in g (1 3 2 ). ro d to t h e c o lu m n . r e ta in e r (1 3 3 ). COLUMN SHIFT LINKAGE A djust (Figures 5 and 6) T h e fir s t a n d r e v e r s e s h ift r o d ( 1 3 0 ) m u s t b e a d ju s t e d b e f o r e t h e s e c o n d a n d th ir d s h ift r o d ( 1 3 4 ) . A d ju s t t h e s h ift lin k a g e . FLOOR SHIFT LINKAGE L o o s e n t h e s c r e w ( 1 3 9 ) if n e e d e d . P u t t h e t r a n s m is s io n l e v e r in p la c e . Remove or Disconnect (Figure 7) 1. R e ta in e r (1 6 0 ). 2 . W a s h e r (1 6 1 ). — F o r s h ift r o d ( 1 3 0 ) , m o v e t h e s h ift le v e r ( 1 2 8 ) to th e fro n t d e te n t (R e v e rs e ). — F o r s h ift r o d ( 1 3 4 ) , m o v e t h e s h ift le v e r to t h e fro n t d e te n t th e n b a c k o n e , (n e u tr a l). 3 . S h ift ro d fr o m t h e c o n tr o l le v e r (1 6 2 ). 4 . R e ta in e r (1 7 0 ). 3 . P u t t h e c o lu m n l e v e r in p la c e . — 5. W a s h e r (1 6 9 ). 6 . S h if t ro d fr o m t h e s h ift le v e r (1 6 8 ). 7 . N u ts (1 6 5 a n d 1 6 7 ) a n d th e s w iv e l (1 6 6 ). — 1. Nuts (165 and 167) and the swivel (166). • D o n o t tig h te n . F o r s h ift r o d ( 1 3 0 ) , m o v e t h e c o lu m n le v e r in to “ R e v e r s e ” a n d lo c k t h e s te e r in g c o lu m n . Install or Connect (Figure 7) 2 . S h if t r o d to t h e s h ift le v e r (1 6 8 ). A d ju s t t h e s h ift lin k a g e . 4. F o r s h ift r o d ( 1 3 4 ) , m o v e t h e c o lu m n le v e r in to “ N e u t r a l ” a n d p u t a 0 . 2 4 9 - 0 . 2 5 0 in . g a g e p in t h r o u g h th e le v e r s ( 1 4 9 a n d 1 5 0 ) a n d t h e r e la y le v e r (1 5 1 ) (fig u r e 6 ). H o ld t h e s h if t r o d ( 1 3 0 o r 1 3 4 ) d o w n t i g h t ly in t h e s w iv e l (1 4 1 ) a n d tig h te n th e s c r e w (1 3 9 ). MANUAL TRANSMISSION 7B-7 RV 4 Speed O.D. R-V 3 Speed G 4 Speed O.D. A. B. 158. 159. 175. 176. 178. 179. 180. Locating Hole F ittin g D irection S h ift Control Lever S h ift Control Knob Nut Boot Bracket Spring W asher 181. 182. 183. 184. 185. 186. 187. N uts Screw Screw F ittin g Gear Position Screw Plate B -0 8 4 9 7 Figure 8—Floor Shift Control (3 Speed/4 Speed O.D.) • SHIFT CONTROL U n l o c k t h e s t e e r i n g c o lu m n , o r t a k e t h e g a g e p in o u t. 5 . L u b r ic a t e a ll r o d a n d s w iv e l c o n n e c t io n s . R e f e r M A I N T E N A N C E A N D L U B R IC A T IO N ( S E C . O B ). to FLOOR SHIFT CONTROL El Remove or Disconnect (Figure 8) FLOOR SHIFT LINKAGE 1. K n o b (1 7 5 ) a n d th e n u t (1 7 6 ). ^ 2 . S c r e w s (1 8 6 ) a n d th e b o o t (1 7 8 ). A djust (Figure 7) • 1 . L o o s e n t h e n u t s ( 1 6 5 a n d 1 6 7 ) if n e e d e d . 2 . M o v e t h e s h ift c o n tr o l le v e r ( 1 5 8 ) in to “ N e u t r a l” . • 3 . M o v e t h e s h ift le v e r s ( 1 6 2 ) to t h e f r o n t d e t e n t t h e n b a c k o n e , (n e u tr a l). 4. Put a 0 .2 4 9 -0 .2 5 0 P l a t e ( 1 8 7 ) if u s e d . 3 . S h ift c o n tr o l le v e r (1 5 8 ). S lid e a p ie c e o f s h im s to c k b e tw e e n th e a n d t h e c o n tr o l to r e le a s e t h e le v e r . 4 . S h ift r o d s a t th e c o n tr o l (fig u r e 7 ). in . g a g e p in th ro u g h th e c o n tro l le v e r s (1 5 8 ). • G e a r p o s it io n s w it c h ( 1 8 5 ) if u s e d . 5 . S c r e w s ( 1 8 3 ) a n d t h e fittin g ( 1 8 4 ) . 5 . H o l d t h e s h if t r o d s f o r w a r d t i g h t ly in t h e s w iv e ls ( 1 6 6 ) a n d tig h te n th e n u ts (1 6 5 a n d 1 6 7 ). 6 . S h ift c o n tr o l (1 5 9 ). 7. S c r e w s (1 8 2 ) a n d th e s p rin g w a s h e r s (1 8 0 ). 6 . R e m o v e t h e g a g e p in a n d lu b r i c a t e t h e s h if t c o n t r o l. R e fe r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C . O B ). 8 . N u t s ( 1 8 1 ) a n d t h e s p r i n g w a s h e r s ( 1 8 0 ) , if u s e d . 9 . B ra c k e t (1 7 9 ). le v e r 7B-8 MANUAL TRANSMISSION 192 175. 176. 190. 191. 192. 193. 194. 195. A. B. Knob Nut S h ift Lever Boot Cap Screw R etainer Screw Remove Install B-08495 Figure 9—Shift Control Lever (4 Speed) -►+ Install or Connect (Figure 8) 1. B ra c k e t (1 7 9 ). 2. N e w s p r i n g w a s h e r s ( 1 8 0 ) a n d t h e n u t s ( 1 8 1 ) , if u s e d . SHIFT CONTROL LEVER (4 SPEED) |+ + | Remove or Disconnect (Figure 9) 3 . N e w s p r in g w a s h e r s (1 8 0 ) a n d th e s c r e w s (1 8 2 ). 1. T r a n s fe r c a s e s h ift le v e r b o o t T R A N S F E R C A S E (S E C . 7 D ). 4 . S h ift c o n tr o l (1 5 9 ). 2 . S c r e w s ( 1 9 3 ) a n d t h e r e t a in e r ( 1 9 4 ) if u s e d . 5 . F ittin g ( 1 8 4 ) a n d t h e s c r e w s ( 1 8 3 ) . Im portant • P u sh th e cap (1 9 2 ) c o u n te r -c lo c k w is e (A ). d ow n 2. • P u s h th e c a p (1 9 2 ) d o w n a n d tu r n c lo c k w is e (B ). 3 . S c r e w s ( 1 9 3 ) if u s e d . 4 . R e t a i n e r ( 1 9 4 ) a n d t h e s c r e w s ( 1 9 3 ) if u s e d . 5 . T r a n s fe r c a s e s h ift le v e r b o o t T R A N S F E R C A S E (S E C . 7 D ). • W ip e th e le v e r w ith a d a m p rag b e fo re s lid in g it in to p la c e . if used. SIDE COVER 8. B o o t (178) a n d th e s c re w s (186). • A d ju s t th e s h ift lin k a g e . tu rn B o o t (1 9 1 ). 7. S h ift c o n tro l le v e r (158). 10. L u b ric a te th e s h ift c o n tro l a n d th e s h ift lin k a g e . R e fe r to M A IN T E N A N C E A N D L U B R IC A T IO N (SEC. OB). an d Install or Connect (Figure 9) • T h e lu b ric a tio n fittin g m u s t p o in t in th e d ire c tio n s h o w n (B). 9. N u t (176) a n d th e k n o b (175). to B o o t (1 9 1 ). 1. L e v e r (1 9 0 ). • P la te (187), if u se d . re fe r 5. L e v e r (1 9 0 ). • T h e s c re w w ith th e lu b ric a tio n fittin g m u s t g o into th e to p h ole . • G e a r p o s itio n s w itc h (185), if u se d. used, 3 . S c r e w s ( 1 9 3 ) if u s e d . 4. • T h e s c re w w ith th e la rg e s h o u ld e r is a lo c a tin g s c re w a n d m u s t b e in s ta lle d in th e re a r-c e n te r h o le (A). 6. S h ift ro d s a t th e c o n tro l (fig u re 7). if Remove or Disconnect (Figure 10) • R a is e t h e v e h ic le . 1 . T r a n s m is s io n o il. 2. H a rn e s s e s (2 0 6 ) a s u s e d . 3 . S h ift r o d s (fig u r e 7 ). • M o v e t h e s h ift le v e r s in to n e u t r a l. R e fe r to MANUAL TRANSMISSION 7B-9 168. 200. 201. 202. 203. 204. S hift Lever 205. Side Cover S h ift Lever, Rev. 206. Harness W asher 207. Spring Nut 208. Detent Ball S h ift Fork 209. Seal Gasket 210. W asher 211. Nut 212. Screw 213. Spring W asher 214. Bracket A. Locating Hole 4 SPEED O.D. 200\ 207 202 208 210 B-08543 Figure 10—Side Cover (3 Speed/4 Speed O.D.) 4 . N u t ( 2 0 2 ) , t h e w a s h e r a n d t h e r e v e r s e s h ift le v e r ( 2 0 0 ) , (4 s p e e d O .D .). • S e a l (2 0 9 ). 5 . S c r e w s (2 1 2 ), s p r in g w a s h e r s (2 1 3 ) a n d th e b r a c k e ts (2 1 4 ). 6 . S id e c o v e r (2 0 5 ). • L ift t h e r e v e r s e in t e r lo c k le v e r to s e a t t h e c o v e r , (4 s p e e d O .D .). • T h e s h if t l e v e r s m u s t b e in n e u t r a l . 4 . B ra c k e ts (2 1 4 ), s c re w s (2 1 2 ). N o te th e r e m o v in g . 7. R e v e rs e d e te n t p o s itio n s o f th e b a ll ( 2 0 8 ) a n d th e s h ift fo rk s s p r in g w h ile (2 0 7 ), w a s h e rs (2 1 3 ) a n d th e T h e s c r e w w it h t h e l a r g e s h o u l d e r is a lo c a t in g s c r e w a n d m u s t b e i n s t a l l e d in t h e r e a r - c e n t e r h o le (A ). 5 . R e v e r s e s h ift le v e r ( 2 0 0 ) , t h e w a s h e r a n d t h e n u t ( 2 0 2 ) , (4 s p e e d O .D .). 8. G a s k e t (2 0 4 ). 0 • (4 s p e e d O .D .). • s p rin g Im portant Im portant • new S c r a p e a ll g a s k e t m a t e r ia l fr o m t h e c o v e r a n d t h e case. • N e w s e a l (2 0 9 ). 6 . S h ift r o d s ( fig u r e 7 ). Install or Connect (Figure 10) 7. H a r n e s s e s (2 0 6 ) a s u s e d . 1. N e w g a s k e t (2 0 4 ). 2. R e v e rs e d e te n t s p r in g s p e e d O .D .). 3 . S id e c o v e r (2 0 5 ). (2 0 7 ) and th e b a ll ( 2 0 8 ) , (4 8 . N e w t r a n s m is s io n o il. R e f e r to “ D r a in a n d F ill” in t h is s e c tio n . • Lower the vehicle and adjust the shift linkage. 7B-10 MANUAL TRANSMISSION TRANSMISSION REPLACEMENT ++ Remove or Disconnect (Figures 1 and 2) 1. N e w p lu g s (1 1 4 ) if n e e d e d . • P u t a t h in c o a t o f h ig h t e m p e r a t u r e g r e a s e o n t h e m a in d r iv e g e a r s p lin e s . 2 . T r a n s m is s io n (1 0 4 ). T o o l R e q u ire d : J -1 1 2 6 , T r a n s m is s io n G u id e P in (4 s p e e d ) • R a is e t h e v e h ic le . 1 . T r a n s m is s io n o il. 2. S h i f t c o n t r o l a n d r o d s i f u s e d , ( 3 s p e e d / 4 s p e e d O . D . ) . • S h if t le v e r , ( 4 s p e e d ) . P r o p e lle r s h a ft. R e fe r to P R O P E L L E R S H A F T (S E C . 4 A ). T r a n s f e r c a s e if u s e d . R e f e r t o T R A N S F E R C A S E (S E C . 7 D ). 5 . P a r k in g b r a k e a n d c o n t r o ls if u s e d . R e f e r t o B R A K E S (S E C . 5 ). 6. S p e e d o m e t e r c a b l e ( 1 1 2 ) a n d t h e s e a l ( 1 1 3 ) . 7. W ir in g h a r n e s s e s a s u s e d . 8. E x h a u s t p i p e s . R e f e r t o E X H A U S T ( S E C . 6 F ) . • S u p p o r t t h e t r a n s m is s io n w ith a ja c k . 9 . A n y p a r ts if n e e d e d f o r c le a r a n c e . 10. C r o s s m e m b e r . 11. S c r e w s ( 1 0 1 ) a n d t h e s p r i n g w a s h e r s ( 1 0 0 ) . • R e m o v e t h e t o p tw o fir s t a n d in s t a ll g u id e p in s J -1 1 2 6 , (4 s p e e d ). 12. T r a n s m i s s i o n ( 1 0 4 ) . im portant • D o n o t le t t h e tr a n s m is s io n h a n g fr o m t h e c lu tc h . » P u ll t h e tr a n s m is s io n s tr a ig h t b a c k o n t h e c lu tc h • h u b s p lin e s . S u p p o r t th e c lu tc h r e le a s e b e a r in g . 1 3 . P lu g s (1 1 4 ), if t h e y a r e lo o s e o r d a m a g e d . • N o t e t h e lo c a t io n o f th e p lu g s b e f o r e r e m o v in g . install o r Connect (Figures 1 and 2) T o o l R e q u ire d : j-1 1 2 6 , T r a n s m is s io n G u id e P in (4 s p e e d ) • S h ift th e tr a n s m is s io n in s ta llin g . • In s ta ll g u id e p in s J -1 1 2 6 in t h e t o p tw o h o le s (4 s p e e d ). R e m o v e th e c lu tc h r e le a s e b e a r in g s u p p o rt. • in to h ig h gear b e fo re Im portant • • 3. D o n o t fo r c e t h e tr a n s m is s io n in to th e c lu tc h . D o n o t le t t h e t r a n s m is s io n h a n g fr o m t h e c lu tc h , le a v e t h e ja c k u n d e r t h e tr a n s m is s io n to s u p p o r t it. N e w s p rin g w a s h e r s (100) a n d th e s c re w s • In s ta ll th e tw o b o tto m s c r e w s t h e g u id e p in s , ( 4 s p e e d ) . 4 . C ro s s m e m b e r. • (101). b e fo r e r e m o v in g R e m o v e th e ja c k . 5 . A n y p a rts th a t w e r e r e m o v e d fo r c le a r a n c e . 6 . E x h a u s t p ip e s . R e f e r to E X H A U S T ( S E C . 6 F ) . 7. W ir in g h a r n e s s e s a s u s e d . 8. N e w s e a l (113) a n d t h e s p e e d o m e t e r c a b l e (112). 9. P a r k i n g b r a k e l e v e r a n d c o n t r o l s i f u s e d . R e f e r t o B R A K E S (S E C . 5 ). 10. T r a n s f e r c a s e i f u s e d . R e f e r t o T R A N S F E R C A S E (S E C . 7 D ). 11. P r o p e l l e r s h a f t . R e f e r t o P R O P E L L E R S H A F T ( S E C . 4 A ). 12. S h if t c o n tr o l a n d r o d s if u s e d , • S h ift le v e r ( 4 s p e e d ) . 1a N e w t r a n s m is s io n o il. R e f e r t o “ D r a i n a n d F ill” in t h is s e c tio n . • • (3 s p e e d / 4 s p e e d O .D .). A d ju s t t h e s h ift lin k a g e . L o w e r t h e v e h ic le . MANUAL TRANSMISSION 7B-11 SPECIFICATIONS 3 SPEED TRANSMISSION M 62 R P O M 64 4 SPEED 4 SPEED O.D. M 20 M Y 6 M u n c ie M u n c ie M u n c ie N e w P ro c e s s C a s t Iro n C a s t Iro n C a s t Ir o n C a s t Ir o n /A lu m . 246 246 290 260 1st G ear 2 .8 5 3 .5 0 6 .5 5 3 .0 9 2nd G ear 1 .6 8 1 .8 9 3 .5 8 1 .6 7 3 rd G e a r 1 .0 0 1 .0 0 1 .7 0 1 .0 0 4 th G e a r — — 1 .0 0 0 .7 3 5 th G e a r — — — — M ake C a s e M a te r ia l T o r q u e R a tin g (F t. L b .) R a tio (:1 ) R e v e rs e S h a fts C e n te r D is ta n c e C lu tc h P la te D ia m e te r *3 0 2 m m 2 .9 5 3 .6 2 6 .0 9 3 .0 0 76 m m 76 m m 117 m m 89 m m (3 .0 in c h ) (3 .0 in c h ) (4 .5 in c h ) (3 .5 in c h ) 279 m m 279 m m 279 m m * 302 m m (1 1 .0 in c h ) (1 1 .0 in c h ) (1 1 .0 in c h ) (1 2 .0 in c h ) (1 2 .0 in c h ) w ith D ie s e l E n g in e FASTENER TORQUE Nm Ft. Lbs. l u g , D r a i n a n d F i l l .................................................................................................................... r o s s L e v e r B r a c k e t S c r e w ............................................................................................... h i f t R o d S w i v e l S c r e w ( C o l u m n S h i f t ) ................................................................... h if t R o d S w iv e l S c r e w (F lo o r S h ift) 23 25 14 17 18 10 3 S p e e d ................................................................................................................................... 4 S p e e d O . D .......................................................................................................................... C o n t r o l B r a c k e t S c r e w ........................................................................................................... 25 25 33 18 18 24 C o n tro l M o u n tin g S c r e w 3 S p e e d ................................................................................................................................... 32 23 45 P C S S 4 S p e e d ................................................................................................................................... C o n t r o l L u b r i c a t i o n S c r e w .................................................................................................. S i d e C o v e r S c r e w ....................................................................................................................... U - j o i n t F l a n g e N u t ....................................................................................................................... R e a r R e ta in e r S c r e w -4 S p e e d T o p ............................................................................................................................................... B o t t o m ...................................................................................................................................... T r a n s m i s s i o n t o C l u t c h H o u s i n g S c r e w ................................................................... T r a n s m is s io n to M o u n t S c r e w 3 S p e e d / 4 S p e e d .............................................................................................................. 4 S p e e d O . D .......................................................................................................................... C r o s s m e m b e r t o M o u n t S c r e w ......................................................................................... C r o s s m e m b e r t o F r a m e S c r e w ........................................................................................ 20 33 33 15 135 100 27 40 20 45 100 30 74 4 5 5 7 3 4 4 5 7 4 4 5 5 0 0 5 LUBRICATION C a p a c ity 3 S p e e d ................................................................................................................................... 4 S p e e d / 4 S p e e d O . D ................................................................................................... 1 .5 L 4 .0 L 1 .6 q u ts . 4 .2 q ts . Type R ecom m ended 3 S p e e d / 4 S p e e d ............................................................................................................................................ A P I G L 5 S A E 8 0 W 9 0 4 S p e e d O . D ..............................................................................................................D e x r o n I I A u t o m a t i c T r a n s m i s s i o n F l u i d 7B-12 MANUAL TRANSMISSION SPECIAL TOOLS J-22834 J-1126 J-21426 1. Rear Retainer Seal Insta lle r (4 speed) 2. Transm ission G uide Pins (4 speed) 3. Rear Extension Seal Installer (3 Speed/4Speed O.D.) B-08476 7C-1 SECTION 7C CLUTCH CONTENTS SUBJECT PAGE Description.................................................................................................................................................................... 7C- 2 C lu tc h ...................................................................................................... ................................................................. 7C- 2 Clutch C o n tro ls ........................................................................................................................................................ 7C- 2 Inspection...................................................................................................................................................................... 7C- 2 Linkage...................................................................................................................................................................... 7C- 2 Clutch Pedal.............................................................................................................................................................. 7C- 2 Release Bearing........................................................................................................................................................7C- 2 Hydraulic Clutch........................................................................................................................... ............................ 7C- 2 Diagnosis of C lutch......................................................................................................................................................7C- 3 On-Vehicle S ervice ...................................................................................................................................................... 7C- 4 Hydraulic Clutch P e d a l............................................................................................................................................7C- 4 Mechanical Clutch Pedal..........................................................................................................................................7C- 4 Master Cylinder and Reservoir............................................................................................................................... 7C- 5 Secondary (Slave) Cylinder and Hydraulic L in e ...................................................................................................7C- 6 Clutch Linkage..........................................................................................................................................................7C- 7 Cross L e v e r..............................................................................................................................................................7C- 8 Hydraulic Clutch Bleeding....................................................................................................................................... 7C- 9 Clutch Pedal Free Travel A d ju stm e n t................................................................................................................... 7C- 9 Clutch Assembly and Pilot B ea ring ....................................................................................................................... 7C-11 S pe cifica tio ns.............................................................................................................................................................. 7C-15 Fastener Torque........................................................................................................................................................7C-15 Clutch Pedal Free Travel......................................................................................................................................... 7C-15 L ub rication................................................................................................................................................................ 7C-15 Special T o o ls ................................................................................................................................................................ 7C-16 7C-2 CLUTCH DESCRIPTION CLUTCH CLUTCH CONTROLS T h e p r in c ip a l c o m p o n e n ts o n a c lu tc h p la te , p r e s s u r e p la te , d ia p h r a g m - t y p e r e le a s e b e a r in g . a r e th e d riv e n s p rin g a n d a T h e d r i v e n p la t e is s p li n e d o n t h e t r a n s m is s io n c l u t c h s h a f t s o t h a t it c a n m o v e b a c k a n d f o r t h w h e n t h e c l u t c h is d i s e n g a g e d , a n d c a n t u r n t h e s h a f t w h e n t h e c l u t c h is e n g a g e d . T h e d r iv e n p la t e h a s f r ic tio n p a d s r iv e t e d to b o t h s i d e s o f it, a n d a f l e x i b l e c e n t e r w i t h s p r i n g s t o a b s o r b v ib r a tio n . T h e p r e s s u r e p la t e h a s a m a c h in e d s u r f a c e t h a t fits a g a in s t th e d r iv e n p la te a n d a d ia p h r a g m -ty p e s p r in g m o u n te d in a cover on th e p re s s u re p la te . T h e s p r in g h o ld s th e p r e s s u r e p la te a n d d r iv e n p la te to g e t h e r a g a in s t t h e e n g i n e f ly w h e e l w h e n t h e c lu t c h is e n g a g e d . T h e r e le a s e b e a r in g is a b a ll- t h r u s t b e a r in g o n a s l e e v e t h a t p u s h e s in o n t h e c e n t e r o f t h e d i a p h r a g m s p r i n g , HYDRAULIC CONTROLS - R-V MODELS T h e h y d r a u lic c lu tc h h a s a m a s t e r c y lin d e r s e p a r a t e r e s e r v o ir. T h e c lu tc h p e d a l m o v e s t h e w ith a m a s te r c y lin d e r p u s h ro d a n d a s e c o n d a r y c y lin d e r a t th e c lu tc h h o u s in g m o v e s th e c lu tc h fo r k a n d th e r e le a s e b e a r in g . MECHANICAL CONTROLS - G AND P MODELS G m o d e ls h a v e a p u ll r o d f r o m t h e c lu tc h p e d a l t h a t m o v e s a c r o s s le v e r . T h e c r o s s le v e r m o v e s t h e c lu tc h fo r k a n d th e r e le a s e b e a r in g w ith a n a d ju s t a b le r o d . P m o d e ls h a v e a n u p p e r p u ll ro d fr o m t h e c lu tc h p e d a l to a b e ll c r a n k le v e r a n d a lo w e r p u ll r o d f r o m t h e b e ll c r a n k le v e r to a c r o s s le v e r . T h e c r o s s le v e r m o v e s t h e c lu tc h fo rk a n d th e r e le a s e b e a r in g w ith a n a d ju s ta b le ro d . r e le a s in g p r e s s u r e o n t h e p r e s s u r e p la te a n d d r iv e n p la te to d is e n g a g e th e c lu tc h . INSPECTION B e fo r e r e p a ir in g t h e c lu tc h , c h e c k th e t r a n s m is s io n a n d s h ift lin k a g e , a n d t h e e n g in e m o u n ts to b e s u r e t h e p r o b ­ le m LINKAGE 1. C h e c k th e c lu tc h ro d s fo r b e n d in g a n d d a m a g e . fo r w o rn s w iv e ls and lo o s e or re v e rs e RELEASE BEARING d am ag ed m o u n tin g b ra c k e ts . 3 . C h e c k th e c lu tc h le v e r fo r b e n d in g , w e a r a n d d a m a g e . • B e s u r e t h e r e is s o m e c l e a r a n c e b e t w e e n t h e c lu t c h le v e r a n d t h e m o u n t in g b r a c k e t s a n d b a ll s tu d s . 4 . L u b r ic a te t h e c lu tc h lin k a g e . CLUTCH PEDAL 1. C h e c k t h e b u s h in g s fo r d ir t, w e a r a n d d a m a g e . 2 . C h e c k t h e c lu tc h r e le a s e . • H o l d t h e c l u t c h p e d a l 1 2 . 7 m m (1/2 i n . ) a b o v e t h e flo o r m a t w ith th e e n g in e r u n n in g a n d th e p a r k in g b r a k e o n . M o v e t h e s h ift le v e r fr o m fir s t g e a r to g e a r a n d b a c k s e v e r a l tim e s . « If t h e s h if t is s m o o t h , t h e c lu t c h is d is e n g a g i n g fu lly . • A d j u s t t h e c lu t c h l in k a g e a n d r e p e a t , if n e e d e d . is in t h e c l u t c h . 2. C h eck « 1. C h e c k t h e c lu tc h fo r k fo r d ir t, w e a r a n d d a m a g e . 2 . C h e c k th e c lu tc h fo r k fo r p r o p e r in s ta lla tio n a n d lu b r ic a tio n . 3 . C h e c k th e r e le a s e b e a r in g a n d c le a r a n c e b e tw e e n th e s p r in g f in g e r s a n d t h e t r a n s m is s io n . HYDRAULIC CLUTCH 1. C h e c k th e h o s e s fo r c r a c k s a n d w e a r. 2 . C h e c k t h e c y lin d e r s fo r lo o s e m o u n tin g s c r e w s a n d s ig n s o f le a k a g e . 3 . C h e c k t h e c l u t c h p e d a l t r a v e l , it s h o u l d b e 2 1 0 . 8 m m (8 .3 in ). 4 . C h e c k th e s e c o n d a r y p u s h ro d tr a v e l a t th e c lu tc h fo rk , it s h o u l d b e a t l e a s t 2 5 . 4 m m ( 1 . 0 in ) . 5 . B le e d t h e c o n tr o ls a n d r e p e a t a s n e e d e d . CLUTCH 7C-3 DIAGNOSIS OF CLUTCH PROBLEM Will Not Disengage (Pedal to the floor and hard to shift into reverse). CORRECTION POSSIBLE CAUSE 1 . L in k a g e lo o s e o r o u t o f a d ju s tm e n t. 2 . A ir in t h e h y d r a u lic s y s t e m . 3 . M a s t e r o r s e c o n d a r y h y d r a u lic c y lin d e r s e a ls w o rn . 4 . N o t e n o u g h p e d a l tr a v e l. 1 . T ig h t e n o r a d ju s t. 2. 3. B le e d a n d c h e c k fo r d a m a g e . R e p a ir . 4. A d ju s t t h e b u m p e r. lin k a g e o r tr im th e pedal 5. R e le a s e b e a r in g w o rn o r d a m a g e d . 6. D r iv e n p la te w o rn o r d a m a g e d . C lu t c h f o r k o ff t h e b a ll s t u d . D r iv e n p la te b in d in g . 5. 6. 7. 8. R e p la c e . R e p la c e . In s ta ll c o r r e c tly a n d lu b r ic a te . R e p a ir o r r e p la c e th e p la te o r c lu tc h g ear D r iv e n p la te r u n -o u t m o r e th a n 5 .0 8 m m 9. R e p la c e . 7. 8. 9. ( 0 .2 0 in .). Slipping. Grabbing (Chattering). 1. 2. L in k a g e o u t o f a d ju s tm e n t. D r iv e n p la t e fr ic tio n p a d s 3. 4. 5. soaked. P r e s s u r e p la te o r fly w h e e l w a r p e d . D ia p h r a g m s p rin g w e a k . D r iv e n p la te o v e r h e a te d o r n o t s e a te d . or o il 1 . A d ju s t. 2 . R e p la c e . C h e c k fo r le a k s a s n e e d e d . 3. 4. 5. E n g in e m o u n ts io o s e o r d a m a g e d . 1 . T ig h t e n o r r e p la c e . D r iv e n p la t e f r ic t io n p a d s o il s o a k e d . P r e s s u r e p la te o r fly w h e e l w a r p e d . D r iv e n p la t e fr ic tio n p a d m a t e r ia l b u r n e d 2. 3. 4. R e p la c e a n d c h e c k fo r le a k s . R e p la c e a s n e c e s s a ry . C le a n o ff o r r e p la c e a s n e e d e d . 5. fly w h e e l. C lu tc h g e a r w o rn . 5. R e p a ir t h e tr a n s m is s io n . 1. 2. D ia p h r a g m s p rin g w e a k . C lu t c h fo r k io o s e o r o ff t h e b a ll s tu d . 1. 2. R e p la c e t h e p r e s s u r e p la te . R e p la c e t h e r e ta in in g s p r in g o r in s ta ll t h e fo r k c o rr e c tly . D r iv e n 3. p la te o n to th e s p r in g s o re s s u re w eak p la te or o r o il in t h e R e p la c e a n d c h e c k fo r le a k s as needed. d a m p e r. 1. 2. L in k a g e o u t o f a d ju s tm e n t. R e le a s e b e a r in g b in d in g . 3. 4. C lu t c h fo r k o ff t h e b a ll s tu d s p r in g te n s io n . L in k a g e 'e t u r n s p r in g s w e a k . 1. 2. R e le a s e b e a rin g w o rn o r d a m a g e d . C lu t c h fo r k o ff th e b a ll s tu d . 3. Pedal Stays On The Floor When Disengaged. Pedal Is Hard To Push. Noisy. n o rm a l 1. 3. Release Bearing Noisy With The Clutch Engaged R e p la c e a s n e e d e d . R e p la c e . A llo w to c o o l a n d m a k e 3 0 - 4 0 s ta rts - D O N O T O V E R H E A T . 2. 3. 4. o r s m e a re d Rattling (Transmission Click). w o rn or lo o s e 1. A d ju s t. 2 . C l e a n , o r r e p l a c e if d a m a g e d , a n d b r ic a te . 3 . In s ta ll, a n d lu b r ic a te . lu ­ 4. R e p la c e . P ilo t b e a r in g lo o s e 1. 2. 3. R e p la c e . In s ta ll c o r r e c tly a n d lu b r ic a te . R e p la c e . R e fe r to E N G IN E (S E C . 6 A ). 1. 2. 3. L in k a g e o r r e le a s e b e a r in g b in d in g . D ia p h r a g m s p r in g w e a k . R e tu r n s p r in g s b e in g o v e r tr a v e le d . 1. F r e e u p (o r r e p la c e ) a n d lu b r ic a te . 2. 3. R e p la c e t h e p r e s s u r e p la te . A d ju s t t h e lin k a g e o r r e p la c e t h e p e d a l b u m p e r if w o r n . 1. 2. 3. 4. L in k a g e b in d in g . H y d r a u lic in e b lo c k e d o r c r im p e d . M a s t e r o r s e c o n d a r y c y lin d e r s b in d in g . D r iv e n p la te w o rn . 1 . F r e e u p (o r r e p la c e ) a n d lu b r ic a te . 2 . C le a n o u t o r r e p la c e . 3 . R e p a ir o r r e p la c e a s n e e d e d . 4 . R e p la c e . 7C-4 CLUTCH ON-VEHICLE SERVICE 1++I Install or Connect (Figure 1) 1. N e w b u m p e r ( 1 1 1 ) i f n e e d e d . 2. N e w s p a c e r ( 1 1 0 ) a n d n e w b u s h i n g s ( 1 0 4 ) . • C o a t w ith g r e a s e b e fo r e in s ta llin g . 3 . S p rin g (1 0 3 ), th e p e d a l (1 0 9 ) a n d th e s tu d (1 0 1 ). • R e m o v e t h e lo n g s c r e w o r r o d w h ile in s ta llin g t h e s tu d . Im portant • T h e s tu d show n. m ust be in s ta lle d in th e d ir e c tio n 4 . B r a c e s (1 0 2 a n d 1 1 2 ). 5 . N u ts (1 0 0 ). 6 . N e w w a v e w a s h e r (1 0 8 ) a n d th e p u s h ro d (1 0 7 ). 7. 8. 9. 10. • T h e w a s h e r m u s t s ta n d o ff th e p e d a l a s s h o w n . W a s h e r (1 0 6 ) a n d th e r e ta in e r (1 0 5 ). N e u tr a l s ta r t s w itc h . T h e lo w e r le f t s id e a ir c o n d i t io n i n g d u c t , if u s e d . T h e lo w e r s t e e r in g c o lu m n c o v e r s . 1 1 . N e g a t iv e b a t t e r y c a b le . • L u b r ic a te th e c lu tc h p e d a l. R e fe r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C . 0 B ). MECHANICAL CLUTCH PEDAL 100. 101. 102. 103. 104. 105. 106. Nut Stud Outboard Brace Spring B ushing R etainer W asher □ 107. 108. 109. 110. 111. 112. Push Rod Wave W asher Pedal Spacer Bum per Inboard Brace Remove or Disconnect (Figure 2) 1. N e g a t i v e b a t t e r y c a b l e . 2. C o t t e r p i n ( 1 3 2 ) a n d t h e w a s h e r ( 1 3 1 ) . 3. 4. N e u t r a l s t a r t s w i t c h ( 1 2 5 ) . • N o t e t h e d ir e c t io n t h e s w it c h is m o u n t e d in . 5. N u t ( 1 2 0 ) a n d t h e s p r i n g w a s h e r ( 1 2 1 ) . 6. S c r e w ( 1 3 3 ) a n d t h e w a s h e r ( 1 3 6 ) . • • B-08845 Figure 1—Hydraulic Clutch Pedal Components HYDRAULIC CLUTCH PEDAL A P S 10. P N o t e t h e d ir e c t io n t h e s c r e w is m o u n t e d in . R e m o v e t h e w a s h e r ( 1 3 4 ) if u s e d . rm (1 3 5 ) a n d th e w a v e w a s h e r (1 2 2 ). e d a i ro d (1 2 8 ) a n d th e b u s h in g (1 2 9 ). p r in g (1 2 7 ). • P u s h t h e p e d a l d o w n , m o v e it t o t h e s i d e a n d le t it u p t o r e l e a s e t h e s p r i n g . e d a l (1 2 6 ). • |<-+| Remove or Disconnect (Figure 1) 1. N e g a t iv e b a tte r y c a b le . 2 . T h e lo w e r s t e e r in g c o lu m n c o v e r s . 3 . T h e lo w e r le f t s i d e a ir c o n d it io n in g d u c t if u s e d . 4 . N e u tr a l s ta r t s w itc h . 5 . R e ta in e r (1 0 5 ) a n d th e w a s h e r (1 0 6 ). 6 . P u s h ro d (1 0 7 ) a n d th e w a v e w a s h e r (1 0 8 ). 7. N u ts (1 0 0 ). 8 . B r a c e s (1 0 2 a n d 1 1 2 ). 9 . S tu d (1 0 1 ), th e p e d a l (1 0 9 ) a n d th e s p r in g (1 0 3 ). • S lid e a lo n g s c r e w o r r o d in to t h e b r a c k e t w h ile r e m o v in g t h e s tu d . 1 0 . B u s h in g s (1 0 4 ) a n d th e s p a c e r (1 1 0 ). 1 1 . B u m p e r ( 1 1 1 ) if it is w o r n o r d a m a g e d . S lid e a lo n g s c r e w o r ro d th r o u g h th e b r a c k e t w h ile r e m o v in g t h e p e d a l to k e e p t h e b r a k e p e d a l in p la c e . 11. B u s h i n g s ( 1 2 3 ) . 12. B u m p e r ( 1 2 4 ) i f i t i s w o r n o r d a m a g e d . &5J* Clean (Figure 2) M e t a l p a r ts w ith s o lv e n t. W ip e d ry . P la s tic a n d r u b b e r p a r ts w ith a d r y r a g . Inspect (Figure 2) P e d a l (1 2 6 ) fo r w e a r a n d b e n d in g . B u s h in g s (1 2 3 a n d 1 2 9 ) fo r c r a c k s a n d w e a r . Install or Connect (Figure 2) 1 . N e w b u m p e r ( 1 2 4 ) if n e e d e d . 2 . B u s h in g s (1 2 3 ). • C o a t t h e b u s h in g s w it h p e t r o le u m je lly . CLUTCH 7C-5 131 130 128 126 120. 121. 122. 123. 124. 125. 126. 127. 128. Nut Spring W asher Wave W asher Bushing Bum per Neutral Start S w itch Pedal Spring Pedal Rod 129. 130. 131. 132. 133. 134. 135. 136. Bushing Wave W asher W asher C otter Pin Screw W asher Arm W asher B-08846 Figure 2—Mechanical Clutch Pedal Components MASTER CYLINDER AND RESERVOIR 3. P e d a l (1 2 6 ). • S lid e th e s c r e w o r ro d o u t w h ile in s ta llin g th e p e d a l. 4 . S p r in g (1 2 7 ). • Remove or Disconnect (Figure 3) H o ld th e p e d a l u p , n e x t to th e p e d a l s to p to h o o k t h e s p r in g . • 1. N e g a t iv e b a tte r y c a b le . 2 . T h e lo w e r s te e r in g c o lu m n c o v e r s . P u s h t h e p e d a l d o w n , s l i d e i t t o t h e s i d e a n d l e t it u p a g a in s t t h e p e d a l s to p . 3 . T h e l o w e r l e f t s i d e a i r c o n d i t i o n i n g d u c t , if u s e d . 4 . R e ta in e r (1 0 5 ) a n d th e w a s h e r (1 0 6 ). 5 . B u s h in g (1 2 9 ) a n d th e p e d a l ro d (1 2 8 ). 5. P u s h ro d (1 0 7 ) a n d th e w a v e w a s h e r (1 0 8 ). 6 . N e w w a v e w a s h e r (1 2 2 ) a n d th e a rm (1 3 5 ). 6 . R e s e r v o ir h o s e (1 4 5 ). 7. W a s h e r (1 3 6 ) a n d th e s c re w (1 3 3 ). 7. S e c o n d a r y c y lin d e r h y d r a u lic m a s te r c y lin d e r (1 4 4 ). lin e (1 4 2 ) • I n s t a l l t h e w a s h e r ( 1 3 4 ) if u s e d . 8 . N u ts (1 4 3 ) a n d t h e m a s t e r c y lin d e r (1 4 4 ). • I n s t a l l t h e s c r e w in t h e d i r e c t i o n it w a s r e m o v e d fro m . 9 . G a s k e t (1 4 1 ). • 8 . N e w s p r in g w a s h e r (1 2 1 ) a n d th e n u t (1 2 0 ). fro m th e th e m a s te r 10 S c r e w s ( 1 4 6 ) a n d t h e r e s e r v o i r ( 1 4 0 ) . 9 . N e u tr a l s ta r t s w itc h (1 2 5 ). • S c r a p e a ll g a s k e t m a t e r ia l c y lin d e r a n d t h e c o w l. fro m Disassemble (Figure 4) I n s t a l l t h e s w i t c h in t h e p o s i t i o n it w a s r e m o v e d fro m . 1. R e m o v e th e a d a p te r (2 2 1 ) a n d th e s e a l (2 2 0 ). 10 . N e w w a v e w a s h e r (1 3 0 ). 2. 1 1 . W a s h e r ( 1 3 1 ) a n d a n e w c o t t e r p in ( 1 3 2 ) . P u ll t h e d u s t c o v e r ( 2 2 8 ) b a c k a n d r e m o v e t h e s n a p r in g ( 2 2 7 ) . 3 . S h a k e t h e p u s h ro d (1 0 7 ) a n d t h e p lu n g e r ( 2 2 4 ) o u t. 1 2 . N e g a t iv e b a tte r y c a b le . • A d ju s t th e c lu tc h lin k a g e . A d j u s t m e n t ” in t h is s e c t i o n . R e fe r to “ F re e T ra v e l • L u b r ic a te t h e c lu tc h p e d a l. R e f e r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C . 0 B ). 4 . R e m o v e t h e s e a l ( 2 2 6 ) . R e m o v e th e s p r in g ( 2 3 0 ) , th e s u p p o r t ( 2 2 2 ) , t h e s e a l ( 2 2 5 ) a n d t h e s h im ( 2 2 3 ) . jj ] Clean (Figure 4) • All parts with clean brake fluid. 7C-6 CLUTCH 105 105. 106. 107. 108. 140. 141. 142. 144 143. 144. 145. 146. 143 R etainer W asher Push Rod Wave W asher Reservoir Gasket H ydraulic Line, Secondary C ylinder Nut M aster C ylinder Reservoir Hose Screw B-08847 Figure 3—Master Cylinder and Reservoir Inspect (Figure 4) The c y lin d e r b o re • and th e p lu n g e r fo r s c ra tc h e s , r id g e s , a n d p it t in g . • Assemble (Figure 4) L u b r ic a t e a ll s e a ls w ith c le a n b r a k e flu id . In s ta ll t h e s h im ( 2 2 3 ) a n d a n e w s e a l ( 2 2 5 ) w ith t h e fla t a g a in s t t h e s h im ( 2 2 3 ) . In s ta ll t h e s u p p o r t ( 2 2 2 ) a n d th e s p r in g (2 3 0 ). B le e d t h e c lu tc h R e fe r to “ S p e c ific a tio n s ” s y s te m . R e fe r to in th is “ H y d r a u lic C lu tc h SECONDARY (SLAVE) CYLINDER AND HYDRAULIC LINE ++ Remove or Disconnect (Figure 5) In s ta ll a n e w s e a l ( 2 2 6 ) . 1. N e g a t iv e b a tte r y c a b le . C o a t t h e c y lin d e r b o r e w ith c le a n b r a k e flu id a n d s lid e t h e p lu n g e r ( 2 2 4 ) a n d t h e p u s h r o d ( 1 0 7 ) in . 2 . H y d r a u lic lin e ( 1 4 2 ) fr o m t h e s e c o n d a r y c y lin d e r ( 1 5 3 ) . P u s h t h e p u s h r o d ( 1 0 7 ) in a n d i n s t a l l t h e s n a p r in g (2 2 7 ). C o a t th e in s id e o f th e d u s t c o v e r ( 2 2 8 ) w ith 0 r e s e r v o ir. B l e e d i n g ” in t h is s e c t i o n . T h e d u s t c o v e r fo r w e a r a n d c r a c k in g . * F ill t h e s e c tio n . g r e a s e a n d s l i d e it i n t o p l a c e . • 3 . N u ts (1 5 1 ) a n d th e s e c o n d a r y c y lin d e r (1 5 3 ). 4. H y d r a u lic lin e ( 1 4 2 ) . • H y d r a u lic (1 4 4 ). • N u t (1 5 0 ) a n d t h e h y d r a u lic lin e (1 4 2 ). • In s ta ll t h e n u t (1 5 0 ) to c a b le ( B ) in p la c e . 5 . In s ta ll a n e w s e a l ( 2 2 0 ) a n d th e a d a p t e r (2 2 1 ). Install or Connect (Figure 3) 1. R e s e r v o i r ( 1 4 0 ) a n d t h e s c r e w s ( 1 4 6 ) . 2. N e w g a s k e t ( 1 4 1 ) . 3. M a s te r c y lin d e r (1 4 4 ) a n d th e n u ts (1 4 3 ). 4 . S e c o n d a r y c y lin d e r h y d r a u lic lin e ( 1 4 2 ) to t h e m a s t e r c y lin d e r (1 4 4 ). 5 . R e s e r v o ir h o s e (1 4 5 ). 6. N e w w a v e w a s h e r ( 1 0 8 ) a n d t h e p u s h r o d ( 1 0 7 ) . R a is e th e v e h ic le . lin e (1 4 2 ) fro m th e h o ld m a s te r th e c y lin d e r s p e e d o m e te r Im portant • C o v e r a ll h y d r a u lic lin e o p e n in g s to k e e p d ir t a n d m o is t u r e o u t o f t h e c o m p o n e n ts . Disassemble (Figure 6) 7. W a s h e r (1 0 6 ) a n d th e r e ta in e r (1 0 5 ). 1. R e m o v e th e p u s h ro d (2 4 1 ) a n d th e d u s t c o v e r (2 4 0 ). 8. T h e l o w e r l e f t s i d e a i r c o n d i t i o n i n g d u c t , i f u s e d . 2 . R e m o v e th e s n a p 9 . T h e lo w e r s t e e r in g c o lu m n c o v e r s . 10. N e g a t i v e b a t t e r y c a b l e . r in g (2 3 8 ) a n d s h a k e th e (2 3 9 ) o u t. 3 . R e m o v e th e s p r in g ( 2 4 2 ) a n d th e s e a l (2 3 7 ). p lu n g e r CLUTCH 7C-7 R e m o v e th e n u t (1 5 0 ). H y d r a u lic lin e (1 4 2 ) o n to th e m a s te r c y lin d e r (1 4 4 ). H y d r a u lic lin e ( 1 4 2 ) a n d t h e n u t (1 5 0 ). Im portant • T h e h y d r a u lic lin e m u s t b e u p r ig h t , a s s h o w n . 2 . S e c o n d a r y c y lin d e r (1 5 3 ) a n d th e n u ts (1 5 1 ). 3 . H y d r a u lic lin e ( 1 4 2 ) o n to t h e s e c o n d a r y c y lin d e r ( 1 5 3 ) . • L o w e r th e v e h ic le . 4 . N e g a t iv e b a tte r y c a b le . • B le e d t h e c lu tc h s y s te m . R e f e r to “ H y d r a u lic C lu t c h B l e e d i n g ” in t h is s e c t i o n . 223 225 222 CLUTCH LINKAGE 228 227 229 226 Remove or Disconnect (Figures 7 and 8) 1. N e g a t iv e b a tte r y c a b le . 2 . C o t t e r p in s ( 1 3 2 ) , t h e w a s h e r s (1 3 1 ) a n d th e w ave w a s h e rs (1 3 0 ). 3 . P e d a l ro d (1 2 8 ) a n d th e b u s h in g (1 2 9 ). • N o te t h e d ir e c tio n t h e ro d w a s r e m o v e d fr o m . 4 . S c r e w s (1 7 2 ) a n d th e b o o t (1 7 1 ). 144. 220. 221. 222. 223. 224. 225. 226. 227. 228. 229. 230. 5 . T h e lo w e r p e d a l r o d (1 6 3 ) , (P m o d e ls o n ly ). • C o t t e r p in s ( 1 6 0 ) , t h e w a s h e r s (1 6 1 ) a n d t h e w a v e M aster C ylind er Seal A dapter Support Shim P lunger Seal Seal Snap Ring Dust Cover Push Rod Spring w a s h e rs (1 6 2 ). 6 . T h e p u ll b a c k s p r in g ( 1 6 6 ) . • R e t a in i n g s p r i n g ( 1 6 4 ) if u s e d . 7 . C o t t e r p in ( 1 6 7 ) , t h e w a s h e r ( 1 6 8 ) a n d t h e w a v e w a s h e r (1 6 9 ). • T h e n u t ( 1 6 5 ) , if u s e d . 8 . A d ju s tin g ro d (1 7 0 ). • N o t e t h e d ir e c t io n t h e ro d w a s r e m o v e d fr o m . j j ] Clean (Figures 7 and 8) B -0 8 8 4 8 • • Inspect (Figures 7 and 8) Figure 4—Master Cylinder Components • • Clean (Figure 6) • I* A ll m e t a l p a r t s f o r w e a r , d a m a g e a n d b e n d i n g . A ll n y lo n a n d r u b b e r p a r t s f o r w e a r a n d c r a c k s . Install or Connect (Figures 7 and 8) A ll p a r t s w it h c l e a n b r a k e f lu id . Inspect (Figure 6) T h e c y lin d e r b o r e a n d t h e p lu n g e r fo r s c r a t c h e s r id g e s a n d p it t in g . T h e d u s t c o v e r fo r w e a r a n d c r a c k in g . * A ll m e t a l p a r t s w it h s o lv e n t . W i p e d r y . A ll n y lo n a n d r u b b e r p a r t s w it h a c l e a n , d r y r a g . 1. A d ju s tin g ro d (1 7 0 ). • In s t a ll t h e r o d in t h e d ir e c t io n it w a s r e m o v e d fro m . 2 . N e w w a v e w a s h e r (1 6 9 ), th e w a s h e r (1 6 8 ) a n d a n e w c o t t e r p in ( 1 6 7 ) . • Assemble (Figure 6) 1 . C o a t a n e w s e a l ( 2 3 7 ) w i t h c l e a n b r a k e f l u i d a n d s l i d e it in to p la c e a n d in s ta ll t h e s p r in g ( 2 4 2 ) . • t h e p lu n g e r ( 2 3 9 ) in . p l u n g e r ( 2 3 9 ) in a n d in s ta ll th e s n a p r in g (2 3 8 ). 4 . C o a t t h e in s id e o f t h e d u s t c o v e r ( 2 4 0 ) w ith g r e a s e a n d s l i d e it i n t o p l a c e . I n s t a l l t h e p u s h r o d ( 2 4 1 ) . Install or Connect (Figure 5) • U n c o v e r t h e h y d r a u lic lin e o p e n in g s . 1. H y d r a u lic lin e ( 1 4 2 ) . n u t ( 1 6 5 ) , if u s e d . 4 . T h e lo w e r p e d a l ro d (1 6 3 ) , (P m o d e ls o n ly ). 2 . C o a t t h e c y lin d e r b o r e w ith c le a n b r a k e flu id a n d s lid e 3. P u s h th e T h e ja m 3 . T h e p u ll b a c k s p r in g ( 1 6 6 ) . • T h e r e t a i n i n g s p r i n g ( 1 6 4 ) , if u s e d . N e w w a v e w a s h e rs (1 6 2 ), th e w a s h e rs (1 6 1 ) a n d n e w c o t t e r p in s ( 1 6 0 ) . 5 . T h e b o o t (1 7 1 ) a n d th e s c r e w s (1 7 2 ). • T h e d im p le m u s t f a c e t h e r e a r o f t h e v e h ic le , (P m o d e ls o n ly ). 6 . T h e b u s h in g (1 2 9 ) a n d th e p e d a l ro d (1 2 8 ). • In s ta ll th e fro m . ro d in t h e d ir e c t io n it w a s re m o v e d 7. N e w w a v e w a s h e rs (1 3 0 ), th e w a s h e rs (1 3 1 ) a n d n e w c o tte r p in s ( 1 3 2 ) . 7C-8 CLUTCH Figure 5—Secondary (Slave) Cylinder and Hydraulic Line Clean (Figure 9) N e g a t iv e b a tte r y c a b le . A d j u s t t h e c l u t c h , if n e e d e d . A d j u s t m e n t ” in t h is s e c t i o n . R e fe r to “ F re e T ra v e l L u b r ic a te t h e c lu tc h lin k a g e . R e f e r to M A IN T E N A N C E A N D L U B R IC A T IO N ( S E C . O B ). CROSS LEVER Remove or Disconnect (Figure 9) 1. N e g a t iv e b a tte r y c a b le . 2 . S p r in g s a n d t h e a d ju s tin g ro d (1 7 0 ), ( F ig u r e s 7 a n d 8 ). 3 . P e d a l ro d (1 2 8 ) o r th e lo w e r p e d a l ro d (1 6 3 ), (fig u re s 7 a n d 8 ). 4 . S c r e w s (1 8 5 ) a n d th e s p r in g w a s h e r s (1 8 9 ). • N u ts ( 1 9 0 ), (P m o d e ls o n ly ). 5 . B r a c k e t (1 8 6 ) a n d th e c r o s s le v e r (1 9 1 ). 6 . B a ll s t u d ( 1 8 1 ) , t h e n u t ( 1 8 8 ) a n d t h e s t a r w a s h e r ( 1 8 7 ) fro m th e b ra c k e t (1 8 6 ). 7 . E n g i n e s i d e b a ll s t u d ( 1 8 1 ) if it is w o r n o r d a m a g e d . A ll m e t a l p a r t s w it h s o lv e n t . W i p e d r y . A ll n y lo n a n d p la s t ic p a r t s w it h a c l e a n , d r y r a g . I? 0 Inspect (Figure 9) A ll m e t a l p a r t s f o r w e a r , d a m a g e a n d b e n d in g . A ll n y lo n a n d p la s t ic p a r t s f o r w e a r a n d c r a c k s . Install or Connect (Figure 9) E n g i n e s i d e b a ll s t u d ( 1 8 1 ) if n e e d e d . N e w s t a r w a s h e r ( 1 8 7 ) , t h e n u t ( 1 8 8 ) a n d t h e b a ll s tu d (1 8 1 ) o n to th e b ra c k e t (1 8 6 ). C r o s s le v e r (1 9 1 ) a n d th e b r a c k e t (1 8 6 ). N e w s p r in g w a s h e r s (1 8 9 ) a n d th e s c r e w s (1 8 5 ). • N u ts (1 9 0 ), (P m o d e ls o n ly ). P e d a l ro d (1 2 8 ) o r th e lo w e r p e d a l ro d (1 6 3 ), (fig u r e s 7 a n d 8 ). CLUTCH 7C-9 5 . In s ta ll th e s e c o n d a ry c y lin d e r (1 5 3 ) and r e fill t h e r e s e r v o ir ( 1 4 0 ) if n e e d e d . CLUTCH PEDAL FREE TRAVEL ADJUSTMENT P MODELS 6JP \ 240 152. 153. 236. 237. 238. A djust (Figures 7 and 10) 1 . R e m o v e t h e p u ll b a c k s p r in g (1 6 6 ). 2. 237 L o o s e n th e n u t (2 0 1 ) a t t h e s w iv e l (2 0 2 ). • 239 238 T a k e th e s w iv e l ( 2 0 2 ) o u t o f th e c r o s s le v e r (1 9 1 ), (m o d e ls w ith o u t J F 9 ). 3 . M o v e t h e c lu t c h fo r k ( 2 0 0 ) b a c k u n til t h e c lu t c h s p r in g p r e s s u r e is f e lt , a n d a d ju s t t h e r o d l e n g t h . Bleeder Screw Secondary Cylinder Cap Seal Snap Ring Models without JF9. • • H o ld th e c lu tc h p e d a l a g a in s t th e b u m p e r . T u r n t h e n u t (2 0 1 ) u n til t h e s w iv e l ( 2 0 2 ) fits in to t h e g a g e h o le (A ), t h e n r e m o v e a ll la s h . 239. Plunger 240. Dust Cover 241. Pushrod 242. Spring • In s ta ll th e s w iv e l ( 2 0 2 ) w ith a n e w w a v e w a s h e r ( 1 6 9 ) a n d c o t t e r p in ( 1 6 7 ) . Models with JF9. B -0 8 8 5 0 Figure 6—Secondary (Slave) Cylinder Components 6 . A d ju s tin g r o d (1 7 0 ) a n d t h e s p r in g s , (fig u r e s 7 a n d 8 ). • A d ju s t th e c lu tc h lin k a g e . A d ju s t m e n t ” in t h is s e c t io n . R e fe r to “ F re e T ra v e l • L u b r ic a te th e c lu tc h lin k a g e . R e fe r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C . O B ). HYDRAULIC CLUTCH BLEEDING R-V MODELS Bleed (Figures 3 and 5) 2 . R e m o v e t h e s e c o n d a r y ( s l a v e ) c y l i n d e r ( 1 5 3 ) a n d t i p it s o t h e b l e e d e r s c r e w ( 1 5 2 ) is u p . 3 . H o ld th e c lu tc h p e d a l d o w n , o p e n th e b le e d e r s c r e w (1 5 2 ) to le t a ir a n d flu id e s c a p e , a n d c lo s e t h e b le e d e r s c r e w (1 5 2 ). L e t th e c lu tc h p e d a l u p . 4. H o ld th e c lu tc h p e d a l a g a in s t th e b u m p e r . • L o o s e n t h e n u t (1 6 5 ) a n d tu r n t h e n u t ( 2 0 3 ) u n til it is 7 . 3 7 m m ( 0 . 2 9 - i n . ) f r o m t h e r o d s h o u l d e r ( B ) . • T ig h t e n t h e n u t ( 1 6 5 ) a n d tu r n t h e n u t ( 2 0 1 ) to r e m o v e a ll la s h . 4. In s ta ll t h e p u ll b a c k s p r in g (1 6 6 ). 5 . C h e c k t h e c l u t c h p e d a l f r e e t r a v e l a n d r e - a d j u s t if n e e d e d . R e f e r to “ C lu t c h P e d a l F r e e T r a v e l” in t h is s e c tio n . 6 . L u b r ic a te th e c lu tc h lin k a g e . R e f e r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C . 0 B ). G MODELS 1 . F ill t h e r e s e r v o i r ( 1 4 0 ) w it h n e w D O T 3 b r a k e f lu id t o t h e le v e l o f t h e d ia p h r a g m . NOTICE: Never, under any circumstances, use fluid which has been bled fromasystemto fill the reservoir, as it may be aerated, have too much moisture content and possibly be contaminated. • A djust (Figures 8 and 10) 1 . R e m o v e t h e p u ll b a c k s p r in g ( 1 6 6 ) . 2 . L o o s e n th e n u t (2 0 3 ). 3 . M o v e t h e c lu tc h fo r k ( 2 0 0 ) b a c k u n til t h e c lu t c h s p r in g p r e s s u r e is f e lt . 4. H o ld th e c lu tc h p e d a l a g a in s t th e b u m p e r a n d tu r n th e n u t ( 2 0 1 ) u n t i l i t i s 7 .1 1 m m ( 0 . 2 8 - i n . ) f r o m t h e c r o s s le v e r (1 9 1 ). 5 . T ig h t e n th e n u t ( 2 0 3 ) a g a in s t th e c r o s s le v e r (1 9 1 ). 6 . In s ta ll t h e p u ll b a c k s p r in g ( 1 6 6 ) . Important 7 . C h e c k t h e c l u t c h p e d a l f r e e t r a v e l a n d r e - a d j u s t if n e e d e d . R e f e r t o “ C lu t c h P e d a l F r e e T r a v e l” in t h is s e c tio n . C h e c k a n d r e fill t h e r e s e r v o ir a s n e e d e d w h ile b le e d i n g s o t h a t a i r is n o t d r a w n in t o t h e s y s t e m . 8 . L u b r ic a te th e c lu tc h lin k a g e . R e fe r to M A IN T E N A N C E A N D L U B R IC A T IO N (S E C . 0 B ). R e p e a t s t e p 3 u n t i a ll a ir is o u t o f t h e s y s t e m . 7C-10 CLUTCH 128. 129. 130. 132. 160. 161. 162. 163. 164. 165. 166. 167. 168. 169. 170. Pedal Rod B ushing Wave W asher C o tte r Pin C o tte r Pin W asher Wave W asher Lower Pedal Rod R etaining Spring (Except JF9) Nut Pull Back Spring C otter Pin W asher Wave W asher A d ju s tin g Rod 171. Boot 172. Screw A. Dim ple B-08840 Figure 7—Clutch Linkage — P Models CLUTCH 7C-11 CLUTCH ASSEMBLY AND PILOT BEARING CAUTION: When servicing clutch parts, do not create dust by grinding or sanding clutch disc or by cleaning parts with a dry brush or with co m p re sse d a ir. (A w a te r dam pened cloth—NOT SOAKED—should be used). The clutch disc contains asbestos fibers which can become airborne if dust is created during servicing. Breathing dust containing asbestos fibers may cause serious bodily harm. 131 Remove or Disconnect (Figure 11) T o o l R e q u ir e d : J - 5 8 2 4 - 0 1 C lu tc h A lig n m e n t T o o l J - 1 4 4 8 P ilo t B e a r in g P u lle r ( G a s E n g in e O n ly ) J - 2 3 9 0 7 P ilo t B e a r in g P u lle r ( 6 .2 L D ie s e l O n ly ) 1. T r a n s m is s io n . R e f e r to T R A N S M IS S IO N (S E C . 7 B ). 2 . A d ju s tin g ro d (1 7 0 ) o r th e s e c o n d a r y c y lin d e r (1 5 3 ), (fig u re s 5 , 7 o r 8 ). • P u l l b a c k s p r i n g ( 1 6 6 ) if u s e d . • R e t a i n i n g s p r i n g ( 1 6 4 ) if u s e d . 3. S c r e w s (2 1 6 ) a n d th e c o v e r (2 1 5 ). 4 . S c r e w s ( 2 0 8 ) a n d th e fly w h e e l h o u s in g (2 0 7 ). 5. B o o t (2 1 0 ), th e b e a r in g (2 1 2 ). • • c lu tc h fo rk (2 0 0 ) and th e r e le a s e P r y t h e c lu t c h fo r k ( 2 0 0 ) o ff t h e b a ll s t u d ( 2 0 9 ) . P r y th e r e ta in e r (2 1 1 ) o u t o f th e c lu tc h fo r k (2 0 0 ) if it is w o r n o r d a m a g e d . 6 . B a ll s t u d ( 2 0 9 ) . 7. S c r e w s ( 2 0 6 ) a n d th e s p r in g w a s h e r s (2 0 5 ). Im portant 128. 129. 130. 131. 132. 164. 166. 167. 168. 169. 170. 171. 172. Pedal Rod B ushing Wave W asher W asher C otte r Pin R etaining Spring Pull Back Spring C otte r Pin W asher Wave W asher A d ju s tin g Rod Boot (Two Piece) Screw • In s ta ll J - 5 8 2 4 - 0 1 c lu tc h a lig n m e n t to o l o r a u s e d c lu tc h d r iv e g e a r to s u p p o r t th e c lu tc h . • M a r k th e fly w h e e l, c lu tc h c o v e r a n d a p r e s s u r e p la t e lu g fo r a lig n m e n t w h e n in s ta llin g . • L o o s e n e a c h s c r e w o n e tu r n a t a t im e to a v o id w a r p in g th e c lu tc h c o v e r. 8 . C o v e r a s s e m b ly (2 1 3 ) a n d t h e d r iv e n p la t e (2 1 4 ). • R e m o v e t h e c lu tc h a lig n m e n t to o l. 9 . P i lo t b e a r i n g ( 2 1 7 ) if it is w o r n o r d a m a g e d . U s e J -1 4 4 8 o r J - 2 3 9 0 7 a s n e e d e d (fig u r e 1 2 ). Disassemble (Figure 11) 1. R e m o v e th e s c r e w s (2 1 8 ) a n d s tra p s (2 1 9 ). • 2. N o t e t h e lo c a tio n o f t h e r e tr a c tin g s p r in g s . R e m o v e t h e p r e s s u r e p la te ( 2 2 0 ) . Clean (Figure 11) • A ll p a r t s w it h a c l e a n , w a t e r d a m p e n e d c lo t h t o r e m o v e a n y a s b e s to s fib e r s . • C lu t c h fo r k ( 2 0 0 ) , t h e f ly w h e e l h o u s in g ( 2 0 7 ) a n d t h e b a ll s tu d ( 2 0 9 ) w it h s o lv e n t . W ip e d ry . B -0 8 8 3 9 Figure 8—Clutch Linkage — G Models NOTICE: The release bearing is permanently packedwithlubricant andshouldnot besoaked in cleaning solvent as this will dissolve the lubricant. 7C-12 CLUTCH 180 180 183 1811182 185 187 184/186 / l 88 170. 180. 181. 182. 183. 184. 185. 186. 187. 188. 189. 190. 191. A. A d ju s tin g Rod Seat Ball Stud Seal Spring Retainer Screw Bracket Star W asher Nut Spring W asher Nut Cross Lever Pedal Rod (G M odels) Lower Pedal Rod (P M odels) 185189 B -0 8 8 4 1 Figure 9—Cross Lever ]? Inspect (Figure 11) 1. N e w A ll p a r t s f o r w e a r a n d d a m a g e . C o n ta c t s u r f a c e s fo r s c o r in g , a n d fla tn e s s w ith a s tr a ig h t e d g e . D r iv e n p la t e r u n -o u t m u s t n o t b e m o r e th a n 5 .0 8 m m (0 .2 0 -in .). F r ic tio n p a d s fo r s c o r in g , g o u g e s , a n d C h e c k t o s e e if t h e y a r e o il s o a k e d . lo o s e r iv e ts . A ll s p li n e s f o r n ic k s , b u r r s a n d s lid in g fit. A ll s p r in g s f o r b e n d i n g a n d b r e a k s . p ilo t J -1 5 2 2 or L u b r i c a t e t h e b e a r i n g w it h a f e w d r o p s o f m a c h i n e o il. — 6.2 L Diesel Engine T h e b e a r in g lu b ric a tio n . is s e a le d and does not need any • In s ta ll J - 5 8 2 4 - 0 1 c lu tc h a lig n m e n t to o l o r a u s e d c lu tc h d r iv e g e a r to s u p p o r t th e c lu tc h . • A lig n th e m a r k s m a d e d u r in g r e m o v a l. h o u s in g fo r ru n Assemble (Figure 11) 3 . N e w s p r in g w a s h e r s ( 2 0 5 ) a n d th e s c r e w s (2 0 6 ). • | 2 | Im portant T ig h t e n e a c h s c r e w o n e t u r n a t a t im e to a v o id w a r p in g th e c lu tc h c o v e r. L in e u p t h e m a r k s m a d e d u r in g r e m o v a l. 2 . S tr a p s (2 1 9 ) a n d th e s c r e w s (2 1 8 ). In s t a ll t h e r e t r a c t in g s p r i n g s in t h e p o s it io n s t h e y w e re re m o v e d fro m . Install or Connect (Figure 11) T o o l R e q u ire d : J - 5 8 2 4 - 0 1 C lu tc h A lig n m e n t T o o l J - 1 5 2 2 P ilo t B e a r in g D r iv e r ( G a s E n g in e O n ly ) J - 3 4 1 4 0 P ilo t B e a r in g D r iv e r ( 6 .2 L D ie s e l O n ly ) R e m o v e t h e c lu tc h a lig n m e n t to o l. Important 1. In s ta ll th e p r e s s u r e p la te (2 2 0 ) . • U se Important o u t u s in g a d ia l in d ic a to r . R u n o u t s h o u ld n o t b e m o r e th a n 0 .3 8 0 m m (0 .0 1 5 -in .). • if n e e d e d . 2 . D r iv e n p la te (2 1 4 ) a n d t h e c o v e r a s s e m b ly (2 1 3 ). Measure (Figure 11) T r a n s m i s s i o n p il o t h o l e in t h e c l u t c h (2 1 7 ) — Gas Engine B o o t fo r te a r s a n d b r ittle n e s s . — b e a r in g J - 3 4 1 4 0 a s n e e d e d t o d r i v e t h e b e a r i n g in u n t il t h e t o o l b o tto m s o u t. NOTICE: Be careful not to use too much lubricant Excessivelubricant mayget onclutch fingers and cause slippage or damage may result to theclutch. 4 . B a ll s t u d ( 2 0 9 ) . • P a c k t h e s e a t w ith h ig h t e m p e r a t u r e g r e a s e . 5 . C o a t t h e r o u n d e d e n d o f t h e b a ll s t u d ( 2 0 9 ) w ith h ig h te m p e ra tu re g re a s e . CLUTCH 7C-13 • P a c k t h e b a ll s t u d s e a t fr o m t h e lu b r ic a t io n f ittin g (A ) o n th e fly w h e e l h o u s in g ( 2 0 7 ) (R - V m o d e ls o n ly ). 6 . N e w r e t a in e r ( 2 1 1 ) if n e e d e d . • T h e r e ta in e r m u s t b e in s ta lle d s o th e fin g e r s a n d t a b s fit in to t h e r e le a s e b e a r in g g r o o v e a n d t h e r e t a in e r w r a p s a r o u n d t h e fla t s id e o f t h e b a ll s tu d h e a d . 7. R e le a s e b e a r in g (2 1 2 ), th e c lu tc h fo rk (2 0 0 ) a n d th e b o o t (2 1 0 ). • P a c k th e in s id e r e c e s s (A ) a n d th e o u ts id e g r o o v e (B ) o f t h e r e le a s e b e a r in g ( 2 1 2 ) w it h h ig h t e m p e r a t u r e g r e a s e a s s h o w n , (fig u r e 1 3 ). 8 . F ly w h e e l h o u s in g ( 2 0 7 ) a n d t h e s c r e w s (2 1 6 ). 9 . C o v e r (2 1 5 ) a n d th e s c re w s (2 1 6 ). 1 0 . A d ju s tin g ro d (1 7 0 ) o r t h e s e c o n d a r y c y lin d e r (1 5 3 ) a s n e e d e d . (F ig u r e s 5 , 7 o r 8 ). • R e t a i n i n g s p r i n g ( 1 6 4 ) if u s e d . • P u ll b a c k s p r i n g ( 1 6 6 ) if u s e d . 1 1 . T r a n s m is s io n . R e fe r to T R A N S M IS S IO N (S E C . 7 B ). 1 2 . A d ju s t t h e c lu tc h lin k a g e a s n e e d e d . 165. 170. 191. 200. 201. 202. 203. A. B. Nut A d ju s tin g Rod Cross Lever C lutch Fork Nut Swivel Nut Gage Hole Rod S houlder B -0 8 8 4 2 Figure 10—Clutch Linkage Adjustment 7C-14 CLUTCH 200. 205. 206. 207. 208. 209. 210. 211. 212. 213. 214. C lutch Fork Spring W asher Screw Flyw heel H ousing Screw Ball Stud Boot Retainer Release Bearing Cover A ssem bly Driven Plate Cover Screw Pilot Bearing Screw Strap Pressure Plate L ubrication F ittin g (CK M odels Only) B-08833 Figure 11—Clutch Assembly and Pilot Bearing A. Recess B. Groove Figure 12—Removing the Pilot Bearing B-08844 Figure 13—Release Bearing CLUTCH 7C-15 SPECIFICATIONS FASTENER TORQUE Flywheel Housing to E ngine................................... .............................................................. Clutch Pedal Stud ..................................................................................... ............................ Master C ylin d e r........................................................................................... .. Secondary (Slave) Cylinder....................................... ........................................................... Cross Lever Ball Stud Bracket Side . . . ........ ........................................................................... ............................ Engine Side (6 Models)............................................... ........................ ........................ .... (P Models).................................................................................... .. Adjusting Rod Swivel (G M odels)................................................................ (P M o d e ls )....................................... ............................................. N-m 54 39 18 18 Ft. Lbs. 40 29 13 13 27 54 46 43 27 20 40 34 32 20 CLUTCH PEDAL FREE TRAVEL G M o d e ls.................................................................... ............ ............................................... P Models (Without JF9)......................................................................................................... P Models (With J F 9 ) ............................................................................................................. mm 34 34 38 in. 1.375 1.375 1.500 LUBRICATION Hydraulic Clutch C apacity................. Type recommended Fill to level of diaphragm. Brake fluid meeting DOT 3. 7C-16 CLUTCH SPECIAL TOOLS Figure 14—Special Tools 7D1-1 SECTION 7D1 205 TRANSFER CASE CONTENTS SUBJECT PAGE D e s c rip tio n ...................................................................................................................................................................7D1-1 Maintenance and A d ju s tm e n t.................................................................................................................................. 7D1-2 Diagnosis o f the Transfer C a s e ..............................................................................................................................7D1-2 On-Vehicle S e r v ic e ....................................................................................................................................................7D1-3 Transfer Case R e p la c e m e n t................................................................................................................................ 7D1-3 S pe cifica tio ns.............................................................................................................................................................. 7D1 -5 DESCRIPTION A . B. C. D. E. S h if t R a il L in k P o p p e t N u ts F r o n t In p u t S h a ft A s s e m b ly Id le r a n d R e a r O u tp u t S h a ft N u t F. G . H . F r o n t O u tp u t S h a ft A s s e m b ly R e a r O u tp u t A s s e m b ly F ill P lu g Id le r S h a ft C o v e r I. F ro n t O u tp u t S h a ft R e a r B e a rin g J. D r a in P lu g F -0 0 0 4 4 f e r c a s e m o u n ts b e h in d t h e tr a n s m is s io n t o r q u e t o b e t r a n s m it t e d in a p r o p o r t io n a l f r o n t a x l e a n d t h e r e a r a x l e , r e s u l t i n g in (fig u r e s 1 a n d 2 ). T h e s h ift c o n tr o l le v e r fo r t h e t r a n s f e r c a s e m o u n t e d in t h e p a s s e n g e r c o m p a r t m e n t . F -0 0 0 4 5 Figure 2—Rear View Figure 1—Front View T h e 2 0 5 tra n s a n d a llo w s d r iv e s p lit to b o th t h e fo u r -w h e e l d riv e R e ta in e r is f l o o r - T h e m o d e l 2 0 5 is a t w o - s p e e d u n it , w h ic h o f f e r s t w o w h e e l o r f o u r - w h e e l d i r e c t d r i v e ( 1 ; 1 r a t i o ) , is a v a i l a b l e in t w o m o d e s : 2 H f o r t w o - w h e e l d r i v e o r 4 H f o r f o u r - w h e e l d r iv e . G e a r r e d u c t i o n ( 1 .9 6 : 1 r a t io ) is u s e d in t h e 4 L p o s itio n . T h is u n it u s e s c o n s t a n t m e s h h e lic a l g e a r s to c o n n e c t th e in p u t s h a ft, id le r g e a r a n d tw o o u tp u t g e a r s , th u s a llo w in g g e a r s e le c t io n to m a tc h d r iv in g c o n d i­ tio n s . W h e n d r iv in g in a f o u r - w h e e l m o d e ( 4 L o r 4 H I) , t u r n t h e h u b s o n th e fr o n t w h e e ls to t h e “ L o c k e d ” p o s itio n . 7D1-2 205 TRANSFER CASE MAINTENANCE AND ADJUSTMENT 1. K n o b 2. N u t 3. S c re w 4. P la te 5. L ever 6. R e ta in e r 7. B o o t 8. P in 9. W ash er 10. W a s h e r 1 1 . L in k 12. R od 13. G ro m m e t 1 4 . F ittin g 1 5 . B o lt F -0 0 0 3 5 Figure 3—Shift Control Component View LUBRICATION INFORMATION R e fe r to S e c tio n ty p e s o f lu b ric a n t. OB fo r in fo r m a tio n LINKAGE ADJUSTMENT AND INSPECTION on in te r v a ls and P e r io d ic a lly in s p e c t th e lin k a g e s y s te m fo r f r e e d o m o f o p e r a t io n , p r o p e r e n g a g e m e n t , lo o s e a t t a c h in g b o lts , fo r e ig n m a te r ia l, e tc . A d ju s t, c le a n a n d tig h te n a s n e c e s s a r y (fig u r e 3 ). DIAGNOSIS OF THE TRANSFER CASE B e fo r e s e r v ic in g a m a lfu n c tio n , c h e c k th e fr o n t h u b s , a x le s , p r o p e lle r s h a fts , w h e e ls a n d tir e s , tr a n s m is s io n o r c lu tc h . PROBLEM Excessive Noise POSSIBLE CAUSE CORRECTION 1. 2. 3. L u b r ic a n t le v e l lo w . W o r n o r d a m a g e d b e a r in g s . M is a lig n m e n t o f p r o p e lle r s h a fts o r u n i­ 1. 2. 3. F ill a s r e q u ir e d . R e p la c e . A lig n . 4. 5. v e r s a l jo in ts . F la n g e b o lts lo o s e . L o o s e a d a p t e r b o lts . 4. 5. R e fe r to S p e c ific a tio n s . R e fe r to S p e c ific a tio n s . Shift Lever Difficult To Move B in d in g in s id e t h e tr a n s f e r c a s e . R e p a ir a s r e q u ir e d . Shifter Lever Disengages From Position 1. 2. 3. G e a rs w o rn o r d a m a g e d . S h ift r o d b e n t. M is s in g d e t e n t b a ll o r s p r in g . 1. 2. 3. Lubricant Leaking 1. 2. 3. 4. E L L S 1. A d ju s t le v e l. 2 . R e p la c e . 3 . T ig h te n x c e s s iv e l u b r ic a n t in c a s e . e a k in g s e a ls o r g a s k e ts . o o s e b o lts . c o r e d f l a n g e in s e a l c o n t a c t a r e a . 4. R e p la c e . R e p la c e . R e p la c e . R e fin is h o r r e p la c e . 205 TRANSFER CASE 7D1-3 ON-VEHICLE SERVICE B -0 6 9 1 8 Figure 5—Strut Rod Support (Automatic Transmissions) 2. C o n n e c t i n g r o d t o t h e s h i f t r a i l l i n k o r c o n n e c t t h e s h ift le v e r to t r a n s f e r c a s e a s r e q u ir e d ( f ig u r e 3 ). $ Tighten • N u t s to 1 7 N m ( 1 2 ft. lb s .). F ro n t p r o p s h a ft to fla n g e o r y o k e . th e tra n s fe r c a s e fro n t o u tp u t Tighten TRANSFER CASE REPLACEMENT ++ R a is e a n d s u p p o r t t h e v e h ic le o n a s u ita b le h o is t. D ra in th e tr a n s fe r c a s e . S p e e d o m e t e r c a b le . S k id p la te s a n d c r o s s m e m b e r s (fig u r e 4 ). S tr u t ro d (a u to m a tic tr a n s m is s io n s ) (fig u r e 5 ). R e a r p ro p s h a ft fro m th e c a s e . • M a r k p ro p s h a ft fo r a s s e m b ly re fe re n c e . • T i e it u p a n d m o v e it a w a y f r o m t h e w o r k a r e a . S h if t le v e r r o d f r o m t h e s h if t r a il lin k . B o lts a tt a c h in g t h e t r a n s f e r c a s e to t h e t r a n s m is s io n a d a p t e r (fig u r e 6 ). • S u p p o r t th e tr a n s f e r c a s e w ith a s u ita b le s ta n d . T ra n s fe r c a s e . M o v e th e tr a n s fe r c a s e to th e in p u t s h a ft c le a r s th e a d a p te r. • B o lts to 1 0 2 N m ( 7 5 ft. lb s .). R e a r p ro p s h a ft to th e tr a n s fe r c a s e r e a r o u tp u t y o k e . $ Remove or Disconnect • 4. r e a r u n til t h e Tighten • B o lts to 2 0 N m (1 5 ft. lb s .). 5 . C r o s s m e m b e r s u p p o r t a n d s k id p la te , fig u re 4 ). Tighten • B o lts to 6 3 N m ( 4 6 ft. lb s .). S tr u t ro d (a u to m a tic tr a n s m is s io n ) (fig u r e 5 ). • • T r a n s m is s io n e n d b o lts to 4 7 N m ( 3 5 ft. lb s .). T r a n s fe r c a s e e n d b o lts to 1 7 5 N m ( 1 2 9 ft. lb s .). S p e e d o m e t e r c a b le . F ill t h e t r a n s f e r c a s e to t h e lu b r ic a n t. R e f e r to S e c tio n O B . F ille r p lu g . p ro p e r “►+ Install or Connect S u p p o r t t h e t r a n s f e r c a s e in a s u it a b l e s t a n d a n d p o s itio n th e c a s e to th e t r a n s m is s io n a d a p te r . B o lts a tta c h in g t h e c a s e to t h e a d a p t e r (fig u r e 6 ). Tighten B o lts to 6 1 N m ( 4 5 ft. lb s .). R e m o v e th e s ta n d . if r e m o v e d • P lu g to 4 4 N m ( 3 2 ft. lb s .). L o w e r a n d r e m o v e th e v e h ic le fr o m h o is t. le v e l w ith 7D1-4 205 TRANSFER CASE MANUAL TRANSMISSION F-00037 Figure 6—Transmission Adapters 205 TRANSFER CASE 7D1-5 SPECIFICATIONS N-m Ft. Lbs. 23 17 Nut, Shift Lever-To-Shifter Assembly 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 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 31 Bolt, Support Strut Rod —Transmission End 47 35 —Transfer Case End 175 129 —Transfer Case (Front) 75 55 —Transfer Case (Rear) 15 11 Propeller Shaft MODEL NO. AVAILABILITY RATIOS: Hi Range Lo Range 205 (PART TIME) All K30 Series 1.00 To 1 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® *To Be Filled W ithin One Inch Of Fill Plug. II In. Lbs. 7D1-6 205 TRANSFER CASE 7D2-1 SECTION 7D2 208 TRANSFER CASE CONTENTS SUBJECT PAGE Description..................................................... ...............................................................................................................7D2-1 Diagnosis of the Transfer C ase..................................................................................................................................7D2-3 On-Vehicle S ervice ...................................................................................................................................................... 7D2-4 Maintenance and A djustm ent..................................................................................................................................7D2-4 Transfer Case Replacement....................................................................................................................................7D2-5 S pe cifica tio ns...............................................................................................................................................................7D2-8 DESCRIPTION a n n u lu s g e a r , p r o v id e s t h e fo u r -w h e e l d r iv e lo w r a n g e w h e n e n g a g e d . R e d u c t i o n r a t io n is 2 .6 1 : 1 in t h is r a n g e . SHIFT CONSOLE AND LEVER CONTROLS A f lo o r m o u n t e d s h if t le v e r is u s e d t o s e l e c t o p e r a t in g r a n g e ( f ig u r e 2 ) . T h e s h if t le v e r is lo c a t e d o n f lo o r p a n tr a n s m is s io n tu n n e l a d ja c e n t to t h e tr a n s m is s g e a r s h if t le v e r . T h e s h if t p a t t e r n is n o t in a s t r a ig h t lin e th e th e io n fo r 2 0 8 m o d e ls (fig u r e 3 ). FOUR-WHEEL DRIVE INDICATOR LAMP A n i n d ic a t o r l a m p m o u n t e d in t h e i n s t r u m e n t p a n e l , a l e r t s t h e d r i v e r w h e n e v e r t h e v e h i c l e is b e in g o p e r a t e d in f o u r - w h e e l r a n g e . A n in d ic a t o r s w it c h in t h e t r a n s f e r c a s e c o n tr o ls t h e lig h t ( F ig u r e 2 ). T h e s w it c h is a b a ll a n d p lu n g e r u n it a c t iv a t e d b y t h e r a n g e s e le c t o r w h e n f o u r - w h e e l r a n g e is s e le c t e d . IDENTIFICATION F o r s e r v ic in g , a n id e n tific a tio n ta g a t t a c h e d to t h e r e a r h a lf o f t h e t r a n s f e r c a s e p r o v id e s th e t r a n s f e r c a s e m o d e l A. B. C. D. n u m b e r , lo w r a n g e r e d u c tio n r a tio a n d a s s e m b ly n u m b e r . If t h e t a g is r e m o v e d o r b e c o m e s d is l o d g e d d u r i n g s e r v i c e o p e r a t io n s , r e a t t a c h u s in g a n a d h e s iv e s e a la n t s u c h a s L o c tite 3 1 2 o r e q u iv a le n t (fig u r e 1 ). Id e n tifica tio n Tag Drain Plug F ill Plug In d ica to r S w itch LUBRICATION B -0 7 6 8 3 Figure 1—Indicator Switch, Identification, Tag and Drain and Fill Plug Location T h e M o d e l 2 0 8 tra n s fe r c a s e is a n a lu m in u m c h a in d r iv e n , fo u r p o s itio n u n it p r o v id in g fo u r -w h e e l h ig h a n d lo w r a n g e s , a t w o - w h e e l h ig h r a n g e a n d a t r a l p o s it io n . T h e m o d e l 2 0 8 is a p a r t - t i m e f o u r - w h e e l u n it . T o r q u e in p u t in f o u r - w h e e l h ig h a n d lo w r a n g e s s a m e (fig u r e 1 ). case, d riv e neu­ d riv e is t h e A tw o -p ie c e a lu m in u m c a s e c o n ta in s fr o n t a n d r e a r o u t­ p u t s h a fts , tw o d r iv e s p r o c k e ts , a s h ift m e c h a n is m a n d a p la n e t a r y g e a r a s s e m b ly . T h e d r iv e s p r o c k e ts a r e c o n ­ n e c te d a n d o p e r a te d b y th e d r iv e c h a in . T h e p la n e ta r y a s s e m b ly , w h ic h c o n s is ts o f a fo u r p in io n c a r r ie r a n d a n C h a n g e th e lu b r ic a n t a t th e in te r v a ls s p M a in te n a n c e S c h e d u le . W h e n a d d in g lu b r ic th e tr a n s f e r c a s e a f t e r s e r v ic in g , u s e D e x r o n th e m a in t e n a n c e a n d a d ju s tm e n ts s e c tio n c h a n g e p r o c e d u r e s a n d fill l e v e l . e c i f ie d in t h e a n t o r r e fillin g ® II. R e f e r to fo r lu b ric a n t 7D2-2 208 TRANSFER CASE 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Knob Rod G rom m et Lever W asher Pin Lever Nut Plate Screw 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. Bezel Boot Seal Nut W asher Bushing H ousing Fork W asher Spring \s \ 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. G uide Lever Pin Swivel Bolt Nut W asher Bolt Nut Nut Figure 2—Console and Shift Control Component View B-08867 208 TRANSFER CASE 7D2-3 B -0 8 8 9 3 Figure 3—Shift Lever DIAGNOSIS OF THE TRANSFER CASE B e fo r e r e p a ir in g a s u s p e c t e d t r a n s f e r c a s e p r o b le m c h e c k t h e d r iv e lin e c o m p o n e n ts . T h e p r o b le m fr o n t h u b s , a x le s , p r o p e lle r s h a fts , w h e e ls a n d tir e s , t r a n s m is s io n o r c lu tc h . PROBLEM Transfer Case Difficult To Shift Or Will Not Shift Into Desired Range POSSIBLE CAUSE 1. 2. CORRECTION V e h i c l e s p e e d is t o o g r e a t t o p e r m i t s h if t ­ in g . 1. If t h e v e h ic le w a s o p e r a t e d f o r e x t e n d e d p e r io d in t h e 4 H m o d e o n d r y p a v e d s u r ­ 2. S to p th e v to n e u tr a l, m ode and d ry p a v e d 3. L u b r ic a te , r e p a ir o r r e p la c e lin k a g e , o r tig h te n lo o s e c o m p o n e n ts a s n e c e s ­ s a ry . 4. D r a i n a n d r e f ill t o t h e e d g e o f t h e fill h o le w ith D E X R O N ® II. D is a s s e m b le t h e u n it a n d r e p la c e w o r n o r d a m a g e d c o m p o n e n ts a s n e c e s s a ry . 3. T ra n s fe r b in d in g . 4. In s u ffic ie n t o r in c o r r e c t lu b r ic a n t. 5. In te r n a l c o m p o n e n ts dam ag ed. 1. In s u ffic ie n t o r in c o r r e c t lu b r ic a n t. case e x te rn a l s h ift lin k a g e b in d in g , w o rn is or S to p t h e v e h ic le a n d s h ift in to t h e d e ­ s ir e d r a n g e . O r r e d u c e th e s p e e d to 2 -3 m p h (3 -4 k m /h ) b e fo r e a tte m p tin g to s h ift . f a c e , d r iv e lin e to r q u e lo a d m a y c a u s e d if­ f ic u lt s h iftin g . Transfer Case Noisy In All Drive Modes m a y b e r e la te d to th e 5. 1. e h ic le , s h ift t h e t r a n s m is s io n s h ift t h e t r a n s f e r c a s e to 2 H o p e r a t e t h e v e h ic le in 2 H o n s u rfa c e s . D r a i n a n d r e f ill t o t h e e d g e o f t h e fill h o le w ith D E X R O N ® II. C h e c k fo r l e a k s a n d r e p a i r if n e c e s s a r y . If u n i t is s till n o is y a fte r d r a in in g and r e fillin g , d is a s s e m b le a n d in s p e c t to lo c a te th e s o u r c e o f t h e n o is e . Noisy In — Or Jumps Out Of Four Wheel Drive Low Range 1. T r a n s f e r c a s e is n o t c o m p l e t e l y e n g a g e d in 4 L p o s it io n . 1. S to p t h e v e h ic le , s h ift t h e t r a n s f e r c a s e in to N e u t r a l, t h e n s h ift b a c k in to t h e 4 L p o s itio n . 2. S h if t l in k a g e is lo o s e o r b in d in g . 2. T ig h te n , lu b r ic a te o r r e p a ir lin k a g e a s n e c e s s a ry . 3. R an fo rk A nn dam or 3. D is a s s e m b le n e c e s s a ry . th e u n it and r e p a ir as or 4. D is a s s e m b le n e c e s s a ry . th e u n it and r e p a ir as 4. g e F o r k c r a c k e d , in s e r ts w o rn , is b in d in g o n s h if t r a il. u lu s g e a r o r lo c k p la t e is w o r n ag ed. 7D2-4 GENERAL DESCRIPTION DIAGNOSIS OF THE TRANSFER CASE (CONT.) CORRECTION POSSIBLE CAUSE PROBLEM Lubricant Leaking From Output Shaft Seals Or From Vent 1. 2. 3. 1. 2. 3. T r a n s fe r c a s e o v e r fille d . V e n t c lo s e d o r r e s tr ic te d . O u tp u t s h a ft s e a ls d a m a g e d o r in s ta lle d in c o r r e c tly . D r a in to th e c o r r e c t le v e l. C l e a r o r r e p l a c e t h e v e n t if n e R e p la c e s e a ls . B e s u r e s e a l in te r io r o f c a s e w h e n in s ta lle d s u re fla n g e s e a l s u rfa c e s c e s s a ry . lip f a c e s . A ls o b e a re n ot s c o r e d o r n ic k e d . R e m o v e s c o r e s , n ic k s w ith fin e s a n d p a p e r o r r e p la c e th e f l a n g e if n e c e s s a r y . Abnormal Tire Wear 1. 1. E x te n d e d o p e r a tio n o n d ry h a rd s u r fa c e ( p a v e d ) r o a d s in 4 H O p e r a t e in 2 H o n h a rd s u rfa c e (p a v e d ) ro a d s . ra n g e . ON-VEHICLE SERVICE MAINTENANCE AND ADJUSTMENT M CASE-OIL CHANGE Remove or Disconnect • R a is e th e v e h ic le . • P o s itio n a d r a in p a n u n d e r t h e t r a n s f e r c a s e . • D r a i n a n d fill p lu g s . • D r a in th e lu b r ic a n t. I+ H Install or Connect 1 . D r a in p lu g . Tighten 24 N m (18 • P lu g to • R e m o v e th e d r a in p a n . ft. lb .). • 2. F ill t h e t r a n s f e r c a s e to t h e e d g e o p e n in g w ith D E X R O N ® II. F ill p lu g . o f fill p lu g Tighten • P lu g to 2 4 N m ( 1 8 ft. lb .). • L o w e r th e v e h ic le . INSPECTION P e r io d ic a lly in s p e c t t h e lin k a g e s y s te m fo r fr e e d o m o f o p e r a tio n , p r o p e r e n g a g e m e n t , lo o s e a tta c h in g b o lts a n d fo r e ig n m a te r ia l. LINKAGE ADJUSTMENTS Gage 129 mm (0.200”) Rod Grom met Lever Lever Nut Nut B-08895 Figure 4—Linkage Adjustment 4 . H a n g a 1 2 9 m m ( 0 .2 0 0 ) g a g e (F ) w ith a 6 m m in c h ) r a d iu s o v e r t h e r o d b e h in d t h e s w iv e l. Adjust (Figures 1 and 4) 1. P u t t h e t r a n s f e r c a s e le v e r in to t h e 4 H 4 ). F. 21. 22. 23. 26. 27. 49. d e te n t (F ig u r e 2 . P u s h t h e lo w e r s h if t e r le v e r ( 2 6 ) fo r w a r d in to t h e 4 H d e te n t. 3 . In s ta ll t h e r o d s w iv e l (2 1 ) in to t h e s h ift le v e r h o ld . (0 .2 5 5 . R u n t h e r e a r ro d n u t ( 2 7 ) a g a in s t t h e g a g e w ith th e s h ifte r a g a in s t t h e 4 H d e t e n t . 6. R e m o v e th e g a g e a n d a g a in s t th e n u t (2 7 ). 7. R u n th e tig h te n . fro n t ro d push n u t (4 9 ) th e s w iv e l a g a in s t th e re a rw a rd s w iv e l a n d 208 TRANSFER CASE 7D2-5 • R o ta te th e tra n s fe r case o u tp u t s h a ft (tu rn f la n g e ) u n til t h e o u p u t s h a f t g e a r e n g a g e s t h e tr a n s fe r c a s e in p u t s h a ft. • M o v e th e tra n s fe r c a s e fo rw a rd s e a t s a g a in s t t h e tr a n s m is s io n . u n til t h e case NOTICE: Place the transfer case flush against the transmission. The case can be damaged if theattachingboltsaretightenedwhenthecase is cockedor in abind. 3 . A t t a c h in g b o lts . • B o lts to 4 1 N m ( 3 0 ft. lb s .) 4 . S p e e d o m e te r c a b le . 5 . F r o n t a n d r e a r p r o p e lle r s h a fts . | ^ \ | Tighten • F r o n t f la n g e b o lts to 1 0 0 N m ( 7 5 ft. lb s .). | 9 | Im portant • L in e u p t h e r e f e r e n c e r e m o v a l. 6 . S k id p la t e (fig u r e 7 ). m a rk s m ade d u r in g Tighten B o lts to 6 3 N m ( 4 6 ft. lb s .). • Figure 5—Strut Rod Support—-Automatic Transmission P l a c e t h e t r a n s f e r c a s e in 4 H d e t e n t . R a is e th e v e h ic le . • D r a in th e lu b r ic a n t fr o m th e tr a n s f e r c a s e . 1. C o t t e r p in fr o m t h e s h if t le v e r s w iv e l ( f ig u r e 2 ). 2 . S p e e d o m e te r c a b le . 3 . In d ic a to r s w itc h w ir e . 4 . F r o n t a n d r e a r p r o p e lle r s h a fts . fla n g e fo r a s s e m b ly 5 . P a r k in g b r a k e c a b le g u id e f r o m t h e p iv o t lo c a t e d o n t h e r ig h t f r a m e r a il. 6 . E n g in e s tru t ro d (fig u re 5 ). on a u to m a tic tr a n s m is s io n m o d e ls 7 . T r a n s fe r c a s e -to -tr a n s m is s io n a d a p t e r b o lts (fig u r e 6 ). • S u p p o r t th e tr a n s fe r c a s e w ith a s u ita b le s ta n d . 8 . S k id p la te (fig u r e 7 ). 9. C a s e . • M o v e t h e t r a n s f e r c a s e r e a r w a r d u n t i l it i s f r e e o f t h e t r a n s m is s io n o u tp u t s h a ft. 1 0 . G a s k e t m a te r ia l. Install or Connect (Figures 5, 6 and 7) • P l a c e t h e t r a n s f e r c a s e in 4 H d e t e n t . • P l a c e t h e t r a n s f e r c a s e in a s u p p o r t s t a n d . 1. G a s k e t to t h e tr a n s m is s io n (fig u r e 6 ). 2 . O u tp u t s h a ft. under T r a n s m is s io n b o lts to 4 7 N m ( 3 5 ft. lb s .). T r a n s fe r c a s e b o lts to 1 7 5 N m ( 1 2 9 ft. lb s .). . F ill t h e t r a n s f e r c a s e w it h D E X R O N ® II. • L o w e r th e v e h ic le . 10 • M a rk th e s h a fts a n d a lig n m e n t r e fe r e n c e . fro m th e P a r k i n g b r a k e c a b l e if d is c o n n e c t e d . Remove or Disconnect (Figures 2, 5, 6 and 7) • s ta n d C o t t e r p in to t h e s h if t le v e r s w iv e l ( f ig u r e s 2 a n d 4 ) . S tr u t ro d s u p p o r t to th e tr a n s f e r c a s e o n a u to m a tic tr a n s m is s io n s (fig u r e 5 ). TRANSFER CASE REPLACEMENT • R e m o v e th e s u p p o rt tra n s fe r c a s e . 7D2-6 208 TRANSFER CASE B-08899 Figure 6—Transmission Adapters 208 TRANSFER CASE 7D2-7 Figure 7—Skid Plate Installation 7D2-8 208 TRANSFER CASE SPECIFICATIONS Nm Ft. Lbs. N u t, S h ift L e v e r -T o -S h ifte r A s s e m b ly 23 17 N u t, K n o b A s s e m b ly -T o -S h ift L e v e r 33 24 B o lt, S h ifte r A s s e m b ly -T o -T r a n s fe r C a s e 130 96 17 13 S c r e w , S h ift L e v e r B o o t R e t a in e r 2 .7 24* B o lt, D e t e n t R e t a in e r 31 23 S w itc h , In d ic a to r 149 111 B o lt, A d a p te r -T o -T r a n s m is s io n 33 24 B o lt, A d a p te r -T o -T r a n s m is s io n C a s e 33 24 F ille r P lu g 47 35 N u t, S k id P la te -T o -C r o s s m e m b e r 63 47 47 35 175 129 N u t, S h ift A r m s -T o -C a s e B o lt, S u p p o r t S tr u t R o d * — T ra n s m is s io n E n d — T ra n s fe r C a s e E n d B o lts , F r o n t P r o p e lle r S h a f t F la n g e 100 74 T ra n s fe r C a s e , F ro n t 75 55 T ra n s fe r C a s e , R e a r 15 11 In c h P o u n d s Model No. Ratios: 208 (Part Time) Hi R ang e Lo R ang e Lever Positions 2 .6 1 to 1 4 - L o ( A ll W h e e l U n d e r d r iv e ) 2 -H i (R e a r W h e e l D r iv e ) 4 - H i ( A ll W h e e l D r iv e ) Lever Location R e a r o f T ra n s . S h ift L e v e r Lubricant: O il C a p a c it y T ype, G ra d e * F ill T o T h e E d g e O f T h e P l u g H o l e . 1 0 P in ts * D E X R O N ® II 8A-1 SECTION 8 ELECTRICAL CONTENTS SUBJECT PAGE Cab E le c tric a l.............................................................................................................................................................. 8 A - 1 Chassis E lectrical........................................................................................................................................................ 8 B - 1 Instrum ent P a n e l........................................................................................................................................................ 8C - 1 SECTION 8A CAB ELECTRICAL CONTENTS SUBJECT PAGE Basic E lectrical............................................................................................................................................................ 8 A - 2 C ircuits ..................................................................................................................................................................... 8 A - 2 Wire Size Conversion T a b le ................................................................................................................................ 8 A - 4 C ircuit M alfu nctio n s................................................................................................................................................8 A - 4 C ircuit D ia g n o s is ....................................................................................................................................................8 A - 4 Diagnostic Tools...................................................................................................................................................... 8A - 4 C ircuit Maintenance and R e p a ir..........................................................................................................................8 A - 6 Cab Electrical S y s te m s ........................................................................................... ................................................. 8 A - 9 RV Cab Harness R o u tin g s .....................................................................................................................................8 A - 9 RV Fuse B lo c k ........................................................................................................................................................ 8A -14 G Van Cab Harness R o u tin g s .............................................................................................................................. 8A -15 G Van Fuse B lo ck.................................................................................................... ............................................... 8A -17 Power Door Lock S y s te m .....................................................................................................................................8A - 17 Diagnosis o f Power Door Lock S yste m ................................................................................................................. 8A -23 On-Vehicle S ervice..................................................................................................................................................8A -24 Power W indow S y s te m ......................................................................................................................................... 8A -24 Diagnosis o f Power W indow S yste m ..................................................................................................................... 8A-24 On-Vehicle S ervice..................................................................................................................................................8A -26 W indshield W iper—RV and G M o d e ls ................................................................................................................. .8A-26 D e s c rip tio n ...............................................................................................................................................................8A-26 Diagnosis o f W indshield W ip e r .............................................................................................................................. 8A -28 On-Vehicle S ervice..................................................................................................................................................8A -26 W indshield W asher—RV and G M o d els................................................................................................................. 8A-34 D e s c rip tio n ...............................................................................................................................................................8A-34 W indshield Washer D ia g n o s is ................................................................................................................................ 8A -35 On-Vehicle S ervice..................................................................................................................................................8A -36 W iper M otor Unit R e p a ir........................................................................................................................................... 8A -36 Replacement o f C o m p o n e n ts .............................................................................................................................. 8A -36 W indshield W iper Delay C ir c u it.............................................................................................................................. 8A -38 D e s c rip tio n .............................................................................................................................................................. 8A -38 Diagnosis o f the Wiper Delay C ir c u it................................................................................................................. 8A -38 On-Vehicle S ervice..................................................................................................................................................8A -38 W indshield Wiper and Washer—P M o d e ls .......................................................................................................... 8A -40 D e s c rip tio n ...............................................................................................................................................................8A-40 D iagnosis...................................................................................................................................................................8A-41 8A-2 CAB ELECTRICAL C O N T E N T S (C O N T .) SUBJECT PAGE Diagnosis of the W iper—O n -V e h icle ..................................................................................................................... 8A-43 Diagnosis of the W iper—O ff-V e h icle ..................................................................................................................... 8A-43 Diagnosis of the W asher S y s te m ............................................................................................................................8A-44 On-Vehicle S ervice ................................................................................................................................................. 8A-45 Unit R e p a ir................................................................................................................................................................... 8A-45 Wiper Motor D is a sse m b ly.................................................................................................................................... 8A-45 In s p e c tio n .................................................................................................................................................................8A-45 Wiper Motor A ssem bly........................................................................................................................................... 8A-46 W indshield Washer D isa sse m b ly.......................................................................... ..........................................8A-47 W indshield Washer A ssem bly.............................................................................................................................. 8A-48 Heater System C ircuits ............................................................................................................................................. 8A-48 D e s c rip tio n .............................................................................................................................................................. 8A-48 D iagnosis...................................................................................................................................................................8A-48 On-Vehicle S e rvice ......................................................................................... ........................................................ 8A-48 A ir C onditioning Electrical S y s te m ....................................................................................................................... 8A-48 D e s c rip tio n ...............................................................................................................................................................8A-48 Diagnosis................................................................................................................................................................... 8A-48 On-Vehicle S ervice ..................................................................................................................................................8A-48 Special T o o ls ...............................................................................................................................................................8A-49 BASIC ELECTRICAL CIRCUITS A n e le c t r ic a l c ir c u it s t a r t s fr o m a s u p p ly o f e le c tr ic ity , c o n d u c t s t h e e le c t r ic it y b a c k to t h e s u p p ly o f e le c tr ic ity . T h e r e s h o u ld b e a d e v ic e to o p e n a n d c lo s e t h e c ir c u it, a n d a p r o t e c t iv e d e v ic e to o p e n t h e c ir c u it in c a s e t o o m u c h c u r r e n t f l o w s in t h e c ir c u it . E le c tr ic a l c ir c u its c a n b e s e t u p a s s e r ie s c ir c u its o r p a r a l l e l c ir c u it s . T h e c i r c u i t s in t r u c k s a r e u s u a l l y p a r a l l e l c irc u its . SERIES CIRCUITS (Figure 1) In s e r i e s c i r c u i t s , e a c h e l e c t r i c a l d e v i c e is c o n n e c t e d in th e c irc u it s o th a t th e c u r r e n t c a n o n ly g o a lo n g o n e p a th a s it f l o w s f r o m t h e p o w e r s u p p l y , a r o u n d t h e c i r c u i t a n d b a c k to th e p o w e r s u p p ly . PARALLEL CIRCUITS (Figure 1) In p a r a lle l c ir c u it s , t h e e le c t r ic a l d e v ic e s a r e c o n n e c t e d b y p a r a lle l w ir e s th a t a r e jo in e d a t th e s ta r t o f th e c irc u it. T h e c u r r e n t d iv i d e s : p a r t o f it f l o w s in t o o n e d e v ic e , p a r t in to a n o th e r . W it h c ir c u it s in p a r a l l e l, e a c h c ir c u it c a n b e s w it c h e d o n a n d o ff b y its e lf s in c e e a c h c ir c u it r e c e iv e s e le c t r ic it y d ir e c tly fr o m t h e p o w e r s u p p ly . CIRCUIT COMPONENTS (Figure 2) T h e u s u a l c ir c u it p a th s ta r ts a t t h e p o w e r s u p p ly w h ic h is t h e b a t t e r y /g e n e r a t o r s y s t e m . N e x t in t h e c ir c u it is t h e c ir c u it p r o te c tio n c o m p o n e n t w h ic h c a n b e a fu s ib le lin k , a fu s e , o r a c ir c u it b r e a k e r . T h e n th e c ir c u it g o e s to th e c ir c u it c o n t r o lle r w h ic h c a n b e a s w it c h o r a r e la y . F r o m CAB ELECTRICAL 8A-3 closes the contacts. So the circuit breaker opens 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 Figure 2—C ircuit Components the circuit controller the circuit goes into the circuit load. The circuit load can be one light or many lights in parallel, an electric motor or a solenoid. After the electricity has passed through the load it must return to the power supply via the ground path. The ground path can be a wire in the harness or it could be through the load housing into the body or frame, thus returning the electricity to the power supply. The body and frame are connected by flexible ground straps. FUSIBLE LINK A fusible link is a section of wire that is usually four gage sizes smaller than the circuit it protects. A special insulation is used that swells when heated by the wire. Fusible links are usually found in the engine compartment harnesses. The function of the fusible link is to melt open when an overload occurs, thus preventing any damage to the circuit. FUSES The most common protector in the vehicle circuit is a fuse. A fuse consists of a fine wire or strip of metal inside a glass tube or plastic housing. The strip melts and interrupts the flow of current in the circuit when there is an overload caused by an unwanted short or ground. The fuse is designed to melt before the wiring or electrical components in a circuit can be damaged. Naturally, the cause must be located and corrected before the fuse is replaced or the new fuse will also blow. Since different circuits handle different amounts of current, fuses of various ratings are used. Fuses are rated in amperes. Be sure to replace a blown fuse with a fuse of the connecting rating. CIRCUIT BREAKERS Circuit breakers are another form of circuit protector. There are two types of circuit breakers; automatic reset and remote reset. The automatic reset breaker opens when excess current heats a bimetallic strip, causing the strip to bend and open a set of contacts. Then the strip cools and C ircuit 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 ground path. For example, the switch controlling the headlights is at the power end of the circuit while the door switch controlling the domelight completes the ground path. Relays are remotely controlled switches. They are used in high current circuits and in circuits controlled by sensors. Relays are designed so that a small current circuit will be able to control a large current circuit. WIRING HARNESS AND WIRES Every wire is a specific size with colored or striped insulation that is indicated on the wiring diagrams. Insulation colors help to trace circuits and to make proper connections. A bbreviations and sym bols used for indicating wire insulation colors and patterns are as follows: B L K ............... .................. B l a c k B R N ............... .................. B r o w n C H K ............... ............... C h e c k P P L ............... ............... P u r p l e T R .................. .................. T r a c e r Y E L ............... ............... . Y e l l o w C R ............... .................. C r o s s G R N ............... .................. G r e e n / / .................. ............ P a r a l l e l W H T ............ .................. W h i t e B L U ............ ...................... B l u e S T R ............... .................. S t r i p e P N K ............ ...................... P i n k D K .................. ..................... D a r k N A T ............ ............... N a t u r a l S G L ............... .................. S i n g l e O R N ............ ............... O r a n g e G R ............... ......................G r a y Some wires are grouped and taped together or encased in a split plastic casing. This grouping of wires is called a harness. For some purposes, it is more practical to use a single wire protected by a braided tubing called a loom. Wiring harnesses are joined by using a multiple plug and receptacle connector block, or a terminal post chassis junction block. In the instrument panel area plastic insulated blade-type connectors and screw-type terminals are used. Each harness or wire must be held securely in place by clips or other holding devices to prevent chafing of the insulation. 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. 8A-4 CAB ELECTRICAL B -0 0 7 2 4 Figure 3—Open Circuit Figure 4—Short C ircuit WIRE SIZE CONVERSION TABLE a ls o b e c a u s e d b y d e p o s its o f o il, d ir t a n d m o is t u r e a r o u n d c o n n e c t io n s o r te r m in a ls , w h ic h p r o v id e a g o o d p a th to g r o u n d .- METRIC SIZE (mm)2 AWG SIZE 0 .2 2 24 0 .5 0 .8 20 18 1 .0 2 .0 3 .0 16 14 12 5 .0 8 .0 1 3 .0 1 9 .0 3 2 .0 4 0 .0 5 0 .0 10 8 6 2 .0 00 CIRCUIT DIAGNOSIS A c le a r u n d e r s ta n d in g o f th e c ir c u it a n d a w ir in g d ia g r a m a r e n e e d e d fo r e f f e c t iv e d ia g n o s is . U s e a lo g ic a l s e q u e n c e o f te s tin g to fin d t h e t r o u b le . U s e t h e d ia g n o s tic to o ls . A fte r t h e w o rk s c o rr e c tly . 6 4 2 1 OPEN CIRCUIT (Figure 3) A n o p e n c i r c u i t o c c u r s w h e n e v e r t h e r e is a b r e a k in t h e c ir c u it. T h e b r e a k c a n b e c o r r o s io n a t th e c o n n e c to r , a w ir e b r o k e n o f f in a d e v ic e , o r a w ir e t h a t b u r n e d fro m to o m u c h c u rre n t. open SHORT CIRCUIT (Figure 4) h e n th e c u rre n t b y p a s s e s p a rt y p a s s in g is u s u a lly c a u s e d b y in o r o n a d e v ic e s u c h a s a s o ld e r m e ltin g a n d b r id g in g c o n d u c t o r s in a d e v ic e . GROUNDED CIRCUIT (Figure 5) s h o r t c irc u it c ir c u it t h a t is e caused by S o m e tim e s a s u re th e c irc u it T h is to o l c o n s is ts o f a 1 2 v o lt la m p w ith le a d s . T h e e n d s o f t h e le a d s u s u a lly h a v e a llig a t o r c la m p s , b u t v a r io u s k in d s o f p r o b e s , te r m in a l s p a d e s , a n d s p e c ia l c o n n e c to r s a r e u s e d a ls o . 0 A g r o u n d c ir c u it is lik e a flo w s d ir e c tly in to a g r o u n d o rig in a l c ir c u it. T h is m a y b a g a in s t th e f r a m e o r b o d y . m ake UNPOWERED TEST LAMP T h e r e a r e t h r e e e le c t r ic a l c o n d itio n s t h a t c a n c a u s e a n o n w o r k in g c ir c u it; a n “ O p e n C ir c u it ,” a “ S h o r t C ir c u it ,” a n d a “ G r o u n d C ir c u it.” u it h a p p e n s w c ir c u it. T h is b g , s a lt w a te r c o n n e c to r o r is f ix e d , DIAGNOSTIC TOOLS CIRCUIT MALFUNCTIONS A s h o r t c irc o f th e n o rm a l w ir e s to u c h in s w itc h o r a tr o u b le b u t th e c u rre n t n o t p a rt o f th e a w ir e r u b b in g w ir e w ill b r e a k a n d fa ll a g a in s t m e t a l t h a t is c o n n e c t e d e le c t r ic a lly to t h e g r o u n d s id e o f t h e p o w e r s u p p ly . A g r o u n d c ir c u it m a y T h e u n p o w e r e d t e s t la m p is u s e d o n O n e le a d o f t h e t e s t la m p is g r o u n d e d a n is m o v e d a r o u n d t h e c ir c u it t o f in d t h e o o n th e p h y s ic a l la y o u t o f th e c ir c u it, s o m e a s ie r to s ta r t a t th e p o w e r s u p p ly a n d e a s ie r to s ta r t a t th e c ir c u it lo a d o r g r o u n an open d th e o th pen. D ep e t i m e s it o th e r tim d c ir c u it. c irc u it. e r le a d e n d in g w ill b e e s it is POWER TEST LAMP T h is la m p is a p e n c il s h a p e d u n it w it h a s e lf c o n t a in e d b a tt e r y , a 1 .5 v o l la m p b u lb , a s h a r p p r o b e a n d a g r o u n d le a d f it t e d w it h a n a llig a t o r c lip . CAB ELECTRICAL 8A-5 33 30. 31. 32. 33. 34. P C S A L o w e r S o u rc e ir c u it B re a k e r w it c h (C lo s e d ) m m e te r oad 41. 42. 43. 44. B-06086 m a in ly fo r te s tin g c o m p o n e n ts th a t a r e d is c o n n e c te d fr o m t h e v e h ic le p o w e r s u p p ly . T h e p o w e r t e s t la m p is a ls o u s e f u l f o r t e s t in g s u s p e c t e d h ig h r e s i s t a n c e p o i n t s in a c i r c u i t s u c h a s c o n n e c t o r s a n d g r o u n d c ir c u its t h a t a r e c o r r o d e d o r lo o s e . JUMPER T h e j u m p e r is A v e r s io n o f th e A m p fu s e . T h is j u m p e r is c o n n e T end th e la m usu ju m w ill c te d a lly a lo n g w ir e w ith a llig a to r c la m p s . p e r h a s a f u s e h o l d e r in it w i t h a 1 0 p r e v e n t d a m a g i n g t h e c i r c u i t if t h e in t h e w r o n g w a y . h e j u m p e r is u s e d t o l o c a t e o p e n s in a c ir c u it . O n o f t h e j u m p e r is a t t a c h e d t o a p o w e r s o u r c e a n d t h e o t h e r e n d is a t t a c h e d t o t h e l o a d in t h e c ir c u it , i .e p , m o to r . If t h e lo a d w o r k s , t r y “ j u m p i n g ” to c ir c u B-07497 Figure 7—Ohmmeter C ircuit Figure 6—Am m eter Circuit T h i s t e s t la m p is u s e d Circuit Breaker Switch (Open) Ohmmeter Load e n .; it p o in ts t h a t a r e p r o g r e s s iv e ly c lo s e r to t h e p o w e r s u p p ly . W h e n th e c ir c u it lo a d s to p s w o r k in g , th e o p e n h a s b e e n lo c a te d . T h e j u m p e r is a ls o u s e d t o t e s t c o m p o n e n t s in t h e c ir c u it s u c h a s c o n n e c t o r s , s w it c h e s , a n d s u s p e c t e d h ig h r e s is t a n c e p o in ts . NOTICE: The following instruments: Ammeter, Voltmeter, and Ohmmeter, each have a particular application for trouble shooting electrical circuits. Whenusinganammeteror voltmeter, andthe value being tested is unknown, always use the highest scale first and work downward to a midscale reading whenever possible. This will avoiddamageto theinstrument. Never useanohmmeter in apower circuit, or as asubstitute for a voltmeter or ammeter, as damageto theinstrument will result. AMMETER (Figure 6) D is c o n n e c t th e c ir c u it fr o m th e p o w e r s o u r c e b e fo r e c o n n e c tin g th e a m m e te r. T h e a m m e te r m e a s u r e s th e a m o u n t o f e le c tr ic a l c u r r e n t, a m p e r e s , m o v in g th r o u g h a c o n d u c to r . T h e a m m e t e r m u s t b e p la c e d in .s e r ie s w ith th e c i r c u i t b e i n g t e s t e d . B e s u r e t h a t t h e a m m e t e r ’s p o s i t i v e t e r m in a l is c o n n e c t e d to t h e p o s it iv e ( b a t t e r y ) s id e o f t h e c i r c u i t a n d t h e a m m e t e r ’s n e g a t i v e t e r m i n a l i s c o n n e c t e d to th e n e g a t iv e (g r o u n d ) s id e o f th e c irc u it. OHMMETER (Figure 7) T h e o h m m e t e r is a n in s t r u m e n t d e s ig n e d t o in d ic a t e r e s i s t a n c e in o h m s . It is u s e d t o t e s t t h e c o n d i t i o n o f a u n i t d is c o n n e c te d fr o m th e c ir c u it. Ohmmeter Calibration W h e n th e o h m m e te r p ro b e s a r e c o n n e c te d to g e th e r, a c ir c u it is c o m p le t e d c a u s in g t h e m e t e r n e e d l e to d e f le c t . T h e n e e d l e s h o u l d r e a d Z E R O o h m s , if it d o e s n o t , r o t a t e th e C A L o r A D J k n o b to Z E R O th e n e e d le . W h e n t h e p r o b e s a r e h e ld a p a r t , t h e n e e d le m o v e s to t h e m a x im u m (in fin ite ) r e s is ta n c e s id e o f th e s c a le . T h e m e t e r is n o w r e a d y fo r u s e . VOLTMETER (Figure 8) T h e v o lt m e t e r ( p r o p e r ly o b s e r v e d ) w ill g iv e t h e t e c h n ic ia n m o r e in fo r m a tio n th a n t h e a m m e te r , o h m m e t e r an d te s t la m p c o m b in e d . Its a p p lic a tio n fo r 8A-6 CAB ELECTRICAL 60. Connector 61. Terminal B -0 6 1 5 6 Figure 9—Removing Terminal t r o u b le s h o o t in g h e r e is to m e a s u r e t h e e le c t r ic a l p r e s s u r e ( v o lt a g e ) d r o p in a r e s is t a n c e c ir c u it . T o u s e a v o lt m e t e r fo r t r o u b le s h o o tin g a n e le c tr ic a l p r o b l e m , c o n n e c t it in p a r a l l e l w i t h t h e e x i s t i n g c i r c u i t . If t h e v o lt m e t e r is c o n n e c t e d in s e r i e s w i t h t h e c i r c u i t b e in g te s te d , th e n a tu r e o f th e c ir c u it w o u ld b e c h a n g e d a n d th e r e a d in g w o u ld h a v e n o p a r tic u la r v a lu e o r u s e . C o n n e c t th e m e te r t e r m in a ls a c c o r d in g to p o la r ity a s s h o w n . T h e d a s h m o u n t e d v o lt m e t e r (in t h e v e h ic le ) s h o u ld a ls o b e o b s e r v e d fo r m o n ito r in g p r o p e r o p e r a tio n o f th e g e n e r a t o r b a t t e r y c r a n k in g m o t o r , a n d c r a n k in g c ir c u it . In th is a p p lic a tio n , b a t t e r y v o lt a g e d r o p c a n b e m o n ito r e d w h il e t h e e n g i n e is c r a n k i n g ; a n d a f t e r t h e e n g i n e is r u n n in g , g e n e r a t o r o u tp u t v o lta g e c a n b e m o n ito r e d . T h is c a n b e a v a lu a b le firs t s te p p r io r to d ia g n o s in g o th e r e le c tr ic a l p r o b le m s . A ll e le c t r ic a l c o n n e c t io n s m u s t b e k e p t c l e a n a n d t ig h t . L o o s e o r c o r r o d e d c o n n e c tio n s m a y c a u s e a d is c h a r g e d b a tte r y , d iffic u lt s t a r t in g , d im la m p s , a n d p o s s ib le d a m a g e t o t h e g e n e r a t o r a n d r e g u l a t o r . W i r e s m u s t b e r e p l a c e d if in s u la tio n b e c o m e s b u r n e d , c r a c k e d , o r d e t e r io r a t e d . T o s p lic e a w ir e o r r e p a ir o n e t h a t is f r a y e d o r b r o k e n , a lw a y s u s e r o s in flu x s o ld e r to b o n d t h e s p lic e a n d s iz e s or l y in due to v ib r a tio n . Never replace a wire with one of a smaller size or replace a fusible link with a wire of a larger size. WIRING CONNECTOR TERMINAL REPLACEMENT (BLADE TYPE) |<"»| Remove or Disconnect (Figure 9) 1. T e r m in a l lo c k ta n g . 2 . T e rm in a l (6 1 ). Install or Connect (Figure 10) 1. P ry u p o n th e ta n g (7 0 ). 2 . T e r m in a l in to t h e c o n n e c to r . Figure 10—Resetting the Lock Tang WIRING CONNECTOR TERMINAL REPLACEMENT (TWIN LOCK TYPE) Remove or Disconnect (Figure 11) T o o l R e q u ir e d : J -2 2 7 2 7 T e r m in a l R e m o v e r 1. C o n n e c to r lo c k ta n g s . 2 . T e r m in a l lo c k s u s in g J - 2 2 7 2 7 . 3 . T e r m in a l. Install or Connect METRI-PACK CONNECTOR REPLACEMENT MAINTENANCE AND REPAIR in s u la tin g t a p e to c o v e r a ll s p lic e s o r b a r e w ir e s . W h e n r e p l a c i n g w i r e , it is i m p o r t a n t t h a t t h e c o r r e c t w ir e b e u s e d a s s h o w n o n a p p lic a b le w ir in g d ia g r a m p a r ts b o o k . E a c h h a r n e s s o r w ir e m u s t b e h e ld s e c u r e p la c e to p r e v e n t c h a f in g o r d a m a g e to th e in s u la tio n B -0 6 2 2 7 1. P ry o u t th e ta n g s . 2 . T e r m in a l in to th e c o n n e c to r. CIRCUIT MAINTENANCE AND REPAIR 71 70. Term inal Lock Tang 71. Term inal |<-+| Remove or Disconnect (Figure 12) T o o l R e q u ir e d : J -3 5 6 8 9 -A T e r m in a l R e m o v e r 1 . P r im a r y lo c k ( 1 2 1 ) b y liftin g . CAB ELECTRICAL 8A-7 190 121 122 VIEW B 120. 121. 122. 123. 124. 125. 126. 127. 128. 129. C onnecto r Seal Prim ary Lock Secondary Lock Staple Secondary Lock Terminal Barrel Secondary Lock Lock Opened Lock Opened J-28742 Terminal Remover Wire 130. 131. 132. 133. 134. 136. 137. 138. 139. 5 mm (0.2 inch) Terminal Roll C rim p Roll C rim p Terminal Insulator Metri-Pack Series 150 Fem ale Terminal C onnecto r Body Locking Tang J-35689 Terminal Remover F-02349 Figure 12—Weather-Pack and Metri-Pack Connectors 8A-8 CAB ELECTRICAL 90 91 101 100 \ 92 \ \ nn //(Lr/ 90. 91. 92. 93. 94. 95. Jacket Twisted W ires S plice C lip C rim p and S older E lectrical Tape W rap O uter E lectrical Tape Wrap. 106 AXW W \ V Figure 13—Twisted Lead Repair 2 . C o n n e c to r b o d y (1 3 7 ). 3 . C o n n e c t o r s e a l ( 1 2 0 ) b y p u llin g t h e s e a l b a c k o n to th e w ir e s a w a y fr o m th e c o n n e c to r b o d y (1 3 7 ). 4 . T e r m in a l (1 3 6 ) b y in s e r tin g J - 3 5 6 8 9 (1 3 9 ) in to th e c o n n e c to r b o d y (1 3 7 ) to d e p r e s s th e lo c k in g ta n g (1 3 8 ), th e n p u s h th e w ir e a n d te r m in a l th r o u g h th e c o n n e c to r b o d y (F ig u r e 1 2 ). • S n ip o f f t h e o ld t e r m in a l u n le s s t h e t e r m in a l is t o b e r e u s e d , r e s h a p e th e lo c k in g ta n g . 5 . 5 m m (0 .2 - in c h ) o f t h e w ir e in s u la tio n (1 3 0 ). IJI • 107 B -0 6 2 3 0 Clean T e r m in a l c a v ity o f th e c o n n e c to r b o d y . Install or Connect (Figure 12) 1 . T e r m in a l (1 3 6 ) o n t h e w ir e . • C r im p a n d s o ld e r t h e te r m in a l. 2 . T e r m in a l ( 1 3 6 ) in to t h e c o n n e c t o r c a v ity b y p u llin g t h e w ir e o n t h e s e a l s id e o f t h e c o n n e c to r u n til th e lo c k in g t a n g ( 1 3 8 ) is f u lly s e a t e d . 3 . S e a l ( 1 2 0 ) b y p r e s s in g t h e s e a l in to t h e c o n n e c t o r b o d y ( 1 3 7 ) u n t il it is f u ll y s e a t e d . 4 . C o n n e c t o r u n til t h e p r im a r y lo c k (1 2 1 ) e n g a g e s . WEATHER-PACK CONNECTORS (Figure 100. 101. 102. 103. 104. 105. 106. Jack et A lu m in u m /M y la r T a p e D ra in W ir e S p lic e C lip C r im p a n d S o ld e r E le c tr ic a l T a p e W r a p D r a in W ir e S p lic e C lip , C r im p e d d e re d . 1 0 7 . O u t e r E le c tr ic a l T a p e W r a p . A nd S o l­ B -0 6 2 3 1 Figure 14—Twisted/Shielded Lead Repair M a k e s u re th a t th e c o n n e c to r s a r e p ro p e r ly s e a te d a n d a ll o f t h e s e a l i n g r in g s a r e in p l a c e w h e n c o n n e c t i n g t h e le a d s . T h e h in g e -ty p e fla p p r o v id e s a b a c k -u p , o r s e c o n d a r y lo c k in g fe a t u r e fo r t h e te r m in a ls . T h e y a r e u s e d to im p r o v e t h e c o n n e c to r r e lia b ility b y r e ta in in g th e t e r m in a l s if t h e s m a ll t e r m in a l lo c k t a n g s a r e n o t p o s itio n e d p ro p e rly . M o ld e d -o n -c o n n e c to r s r e q u ir e c o m p le te r e p la c e m e n t o f t h e c o n n e c tio n . T h is m e a n s s p lic in g a n e w c o n n e c to r a s s e m b ly c a n n o t b In s tr u c tio c o n n e c to r in to e r n s and th e e p la a re te rm h a r n e s s . E n v ir o n m e n ta l c o n n e c tio n s c e d w ith s t a n d a r d c o n n e c tio n s . p r o v id e d w ith th e W e a t h e r - P a c k in a l p a c k a g e s . 12) S p e c ia l c o n n e c to r s k n o w n a s W e a th e r -P a c k c o n n e c to rs r e q u ir e a s p e c ia l to o l J - 2 8 7 4 2 fo r s e r v ic in g . T h is s p e c ia l W it h t h e lo w c u r r e n t a n d v o lt a g e le v e ls f o u n d in s o m e c i r c u i t s , it is i m p o r t a n t t h a t t h e b e s t p o s s i b l e b o n d a t a ll w ir e s p lic e s b e m a d e b y s o ld e r in g t h e s p lic e s . t o o l is r e q u ir e d t o r e m o v e t h e p in a n d s l e e v e t e r m in a l s . If r e m o v a l is a t t e m p t e d w it h a n o r d in a r y p ic k , t h e r e is a g o o d c h a n c e t h a t t h e t e r m in a l w ill b e b e n t o r d e f o r m e d . U n lik e s ta n d a r d b la d e - t y p e te r m in a ls , t h e s e te r m in a ls c a n n o t b e s tr a ig h te n e d o n c e th e y a r e b e n t. U s e c a r e w h e n p ro b in g th e c o n n e c tio n s o r r e p la c in g t e r m i n a l s in t h e m , it is p o s s i b le t o s h o r t b e t w e e n o p p o s it e t e r m i n a l s . If t h i s h a p p e n s t o t h e w r o n g t e r m i n a l p a r t , it is p o s s ib le th a t d a m a g e m a y b e d o n e to c e r t a in CAB ELECTRICAL 8A-9 c o m p o n e n ts . A lw a y s u se ju m p e r w ir e s b e tw e e n c o n n e c to r s fo r c irc u it c h e c k in g . N e v e r p r o b e th r o u g h th e W e a t h e r - P a c k s e a ls . W h e n d i a g n o s i n g f o r p o s s i b le o p e n c i r c u it s , it is o f t e n d iffic u lt to t e r m in a l M e re ly w h a rn e s s s h o u ld a in d ic a te d lo c a te th e m by s ig h t because o x id a tio n Remove or Disconnect (Figure 12) T o o l R e q u ir e d : J -2 8 7 4 2 T e r m in a l R e m o v e r P r im a r y lo c k (1 2 1 ) b y liftin g . o n n e c to r s e c tio n s . e c o n d a r y lo c k (1 2 5 ) b y s p r e a d in g th e s id e s o f th e a s p , th u s c le a r in g th e s ta p le s a n d r o ta tin g th e a s p (1 2 7 ). T e r m in a l (1 3 1 ) b y u s in g J - 2 8 7 4 2 (1 2 8 ) . • S n ip o ff t h e o ld t e r m in a l a s s e m b ly . 5. 5 m m T h e w ire r e p a ir is v e ry im p o r ta n t fo r th e c o n tin u e d r e lia b le o p e r a tio n o f th e v e h ic le . T h is r e p a ir m u s t b e d o n e a s d e s c r ib e d in t h e f o llo w in g p r o c e d u r e s . or m is a lig n m e n t a r e h id d e n b y t h e c o n n e c to r s . i g g l in g a c o n n e c t o r o n a s e n s o r o r in t h e w i r i n g m a y c o r r e c t t h e o p e n c ir c u it c o n d itio n . T h is l w a y s b e c o n s i d e r e d w h e n a n o p e n c i r c u i t is w h ile t r o u b le s h o o tin g . In te r m itte n p r o b le m s m a y a ls o b e c a u s e d b y o x id iz e d o r lo o s e c o n n e c tio n s . C S h h WIRING REPAIR o f th e w ir e in s u la tio n (1 3 0 ). Clean T e r m in a l B a rr e l (1 2 4 ). ♦«- Install or Connect (Figure 12) T e r m in a l in s u la to r ( 1 3 4 ) o n th e w ir e . S lid e th e in s u la to r b a c k o n t h e w ir e a b o u t 8 c m (3 in c h e s ). T e r m in a l (1 3 1 ) o n th e w ir e . • R o ll c r im p (1 3 2 ) a n d s o ld e r t h e te r m in a l. T e r m in a l in s u la t o r ( 1 3 4 ) a n d r o ll c r im p ( 1 3 3 ) . T e r m in a l in to t h e c o n n e c t o r . S e c o n d a r y lo c k (1 2 5 ). C o n n e c t o r s e c t io n s u n til t h e p r im a r y lo c i (1 2 1 ) Twisted Leads (Figure 13) Remove or Disconnect 1. J a c k e t (9 0 ). 0 2 . T w is te d w ir e s ( 9 1 ) . 3 . In s u la tio n fr o m t h e w ir e . Install or Connect 1 . S p lic e c lip ( 9 3 ) . • C r im p . • S o ld e r . 2 . E le c tr ic a l t a p e w r a p ( 9 4 ) o n w ir e s . 3 . O u t e r e le c tr ic a l t a p e w r a p (9 5 ). Twisted Leads/Shielded Cable (Figure 14) [+ “►[ Remove or Disconnect 1. J a c k e t (1 0 0 ). 2 . U n w r a p a lu m in u m /m y la r ta p e (1 0 1 ). 3 . D r a in w ir e (1 0 2 ). 0 4. Leads. 5 . In s u la tio n o n t h e le a d s . Remove or Disconnect 1. 2. 3. 4. 5. S p lic e c lip s (1 0 3 ). C r im p a n d s o ld e r t h e s p lic e c lip s ( 1 0 4 ). E le c t r ic a l t a p e ( 1 0 5 ) o n t h e s p lic e s . A lu m in u m /m y la r t a p e b y w r a p p in g a n d t a p in g . D r a in w ir e w ith a s p lic e c lip (1 0 6 ). C r im p a n d s o ld e r t h e s p lic e c lip . 6 . O u t e r ja c k e t e le c tr ic a l t a p e w r a p (1 0 7 ). engages. CAB ELECTRICAL SYSTEMS RV CAB HARNESS ROUTINGS T h e r e a r e s e v e r a l w irin g h a r n e s s e s r o u te d th r o u g h o u t t h e c a b w h ic h p r o v id e c o n tin u ity b e t w e e n t h e e le c tr ic a l c o m p o n e n ts . T h e s e h a r n e s s e s c o n s is t o f: th e in s tr u m e n t p a n e l h a r n e s s , th e p o w e r d o o r lo c k s a n d p o w e r w in d o w h a r n e s s , th e r a d io h a r n e s s , th e h e a t e r h a r n e s s e s , th e a ir c o n d itio n in g h a r n e s s e s a n d th e in te r io r lig h tin g h a rn e s s e s . INSTRUMENT PANEL HARNESS (Figure 15) T h i s h a r n e s s is l o c a t e d a l o n g t h e u p p e r b a c k e d g e o f t h e i n s t r u m e n t p a n e l . It s t a r t s f r o m t h e f u s e p a n e l w h ic h is lo c a te d a t t h e le ft s id e o f t h e d a s h p a n e l, a n d g o e s u p to th e le ft s id e o f th e in s tr u m e n t p a n e l a n d a c r o s s th e in s t r u m e n t p a n e l to t h e r ig h t s id e o f t h e c a b . A s t h e in s t r u m e n t p a n e l h a r n e s s is r o u t e d a c r o s s t h e in s t r u m e n t p a n e l, v a r io u s c ir c u its b r a n c h o ff to th e s w it c h e s , in d ic a to r s , a n d t h e in s t r u m e n t p a n e l. T h e h a r n e s s is h e ld in p la c e w it h b e n d a b l e c lip s . O th e th e con t h e r h a r n e s s e s a r e c a r r i e d in t h e s a m e s u p p o r t s a s in s tr u m e n t p a n e l h a r n e s s . T h e s e h a r n e s s e s c o n s is t o f p o w e r d o o r lo c k s , p o w e r w in d o w , r a d io , h e a t e r a n d a ir d itio n in g . POWER DOOR LOCKS AND POWER WINDOWS HARNESS (Figures 16 and 17) T h is h a r n e s s s ta r ts a t t h e fu s e b lo c k a n d r o u te s to th e le ft a n d r ig h t a lo n g t h e in s t r u m e n t p a n e l. A t t h e m id d le o f th e in s tr u m e n t p a n e l, th e h a r n e s s b r a n c h e s o ff to th e r e la y a s s e m b ly . T h e r e la y a s s e m b l y is lo c a t e d o n t h e in s id e o f th e d a s h p a n e l, ju s t a b o v e th e s te e r in g c o lu m n . T h e h a r n e s s th e n g o e s to a s e t o f c o n n e c to rs o n th e in n e r w h e e l h o u s in g . F ro m th e c o n n e c to r s th e h a r n e s s p a s s e s t h r o u g h a g r o m m e t in t h e f r o n t d o o r o p e n i n g t r im p a n e l a n d th e n th r o u g h a f le x ib le c o u p lin g to t h e d o o r. In s id e th e d o o r th e d o o r h a rn e s s w ith r e ta th e h a r n e s s b r a n c h e s o ff to th e c o n tr o l s w itc h e s , lo c k m o to r s , a n d th e p o w e r w in d o w m o to r s . T h e c o n n e c to r s a r e fa s te n e d to th e c o n tr o l s w itc h e s in in g n u ts . 8A-10 CAB ELECTRICAL 1. H eater C ontrol Lamp Bulb 2 . H eater C onnector 3. In strum e n t Panel C lu ste r C onnector 4. In strum e n t Panel G round C onnector 5. G round C onnecto r 6. Ground C irc u it W ire 7. Main Lam p S w itch C onnector 8. Engine F un ction D iagnosis C onnector 9. D oor Jam b & Dome Lamp C onnector . Parking Brake S w itch C onnecto r 11. Dash Panel C onnector 12. Horn Relay 13. Dome Lam p And D oor Jam b Harness C onnector 14. C onvenience C enter 15. Radio C o nn e cto r 16. C igarette Ligh ter C onnector 17. C ourtesy Lamp 10 F-00728 Figure 15—RV Instrument Panel Harness CAB ELECTRICAL 8A -11 20. 21. 22. 23. 24. 25. 26. In stru m en t Panel Harness Power Lock And W in do w Harness Door H arness C o n ne cto r Power W indow C o n ne cto r Ground Fuse B lock Power Lock C on ne cto r 27. 28. 29. 30. 31. 32. 33. Power W indow C o nnecto r Dash Panel C o nnecto r Power Door Lock Relay Brake Pedal Bracket Side Front Door Harness Rear Panel Door H arness C onnector Rear Panel D oor Power Lock C onnector F-00729 Figure 16—RV Power Door Locks and Window Harnesses 8A-12 CAB ELECTRICAL 39. 40. 41. 42. 43. 44. 45. 46. 47. N ut P ow er W in d o w S w itc h C o n n e c to r R e ta in e r Bezel P ow er W in d o w S w itc h P ow er D o o r L ock S w itc h C o n n e c to r R e ta in e r Bezel P ow er D o o r L ock S w itc h P ow er D o o r L ock M o to r P ow er W in d o w M o to r 48. F ro n t D o o r H a rn e ss Figure 117— RV Door W iring F-00730 CAB ELECTRICAL 8A-13 60. 61. 62. 63. F use B lo ck P ow er D oo r L ock S w itc h L ock M o to r Pop R ivet F-00731 Figure 18—RV Rear Door Lock Harness 8A-14 CAB ELECTRICAL Figure 19—Cargo Lamp Harness REAR DOOR POWER LOCK HARNESS (Figure 18) The rear doors power lock harness starts at a connector in the fuse block. The harness is routed along the instrument panel harness, with a branch going to the power door lock switch assem bly in the instrument panel. The harness then drops down the right front door hinge frame and routes back alon the right door sill to the right front door latch frame. The harness then travels up the right front door latch fram e to its m idpoint where a connector is located. The harness then goes to the roof halo panel and back to the rear door frame. At the rear door frame, the harness is connected to a contact assembly on the right rear door frame. This contact assembly is aligned with a contact assembly m ounted on the rig h t rear door. From the co n ta ct assembly on the door, the harness then goes to the lock motor. CARGO LAMP HARNESS (Figure 19) The harness starts from the instrum ent panel harness and routes under the left front door sill. The harness then goes up the left front door latch fram e, through a connector, and into a control switch. From the control switch, the harness goes down the frame, back along the rear door sill and then up the rear door latch frame. From the top of the frame the harness goes to the cargo lamp. RV FUSE BLOCK The fuse block holds the fuses and circuit breakers that protect the circuits. The fuse block is located on the left side of the dash panel and is fastened to the dash panel connector block with two screws. The fuse panel connects to the engine com partm ent harness. Power leads from the various circuits plug into the fuse block. The fuses are encased in plastic and have twin blade connectors. The fuses are printed and color coded with the amperage rating. Refer to Figure 20. CAB ELECTRICAL 8A-15 ® (3 0 jg A U X HEAT 0 A /C / 0 E I] REAR DOOR POWER LOCK CIRCUIT (Figure 25) 0 E 0 0 ) d ACC B ATT LPS PWR 30 C IR /B R K ECM !* [XI CRANK* C=3 front door latch frame, where it connects to the door frame contact assembly. The door fram e contact assem bly aligns with the door contact assembly so that electrical contact is made when the door is closed. In this way, electricity is conducted to the side door power lock motor. o \ C ° * N o t on D iesel E n g in e e q u i p p e d ve h icle s. B-07656 The rear power door lock harness is routed from the connector on the left front door hinge frame. The harness goes up the frame to the roof, rearward along the roof halo panel and then crosses over to the right 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 passes through grommets and into the right rear door. Inside the door the harness connects to the power lock motor. POWER WINDOW SYSTEM (Figures 22, 23, 24 and 25) This harness starts at the fuse block and routes to the left and right along the instrument panel. The harness then routes into the left and right front doors. At the left door hinge pillar, the harness routes up to the left roof halo panel, back to the first roof frame, branches to the right side of the van and rearward to the rear door. The branch that went to the right side routed down the side door hinge pillar and into the side door. Figure 20—RV Fuse Block INTERIOR LIGHTING SYSTEM (Figures 26 and 27) G VAN CAB HARNESS ROUTINGS INSTRUMENT PANEL HARNESS (Figure 21) The instrum ent panel harness in the G van includes the circuits for the instrument panel gages, indicators, main ligh t sw itch, w indshield w iper and washer, and the steering column controls. The harness is held in place with clips that plug into brackets which are mounted on the instrum ent panel. FRONT DOOR POWER LOCK SYSTEM (Figure 22 and 23) The harness starts from the fuse block, which is located under the far left side of the instrum ent panel. The left branch of the harness has a connector at the left door hinge frame. Then the harness passes into the frame and routes down to a flexible conduit to the door. Inside the door, the harness branches; one branch going down to the door lock motor, and the other branch going up to the door lock switch. The right branch of the harness routes across the top of the instrum ent panel to the right door hinge frame. The harness passes through a connector and continues into the door frame. The harness routes down to a flexible conduit. The harness passes through the flexible conduit into the door. Inside the door, the harness branches; one branch going up to the door lock switch, and the other branch going to the door lock. SIDE DOOR POWER LOCK CIRCUIT (Figure 24) The side door power lock circuit branches off from the left roof halo harness just behind the front door latch frame. It goes across the roof frame and down the right This circuit starts at the fuse block and routes to the body harness connector. The standard harness is then routed up the left front door hinge frame and back along the left roof halo panel. The harness branches at the first and third roof frames, with connectors located next to the left roof halo panel. The harnesses then go to the roof lamps and term inate in bulb clips. The standard harness also branches off to the door switches. The optional harness is routed from the body harness connector to a control switch on the 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. When the harness reaches the first roof frame, it goes into a connector. There are two branches coming 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 to the right side of the roof, where it goes into a connector. From this connector, one lead goes to the side door grounding switch. The other leads are routed down the right front door lock frame to the stepwell lamp assembly. The o the r b ranch, co m ing out of the roof fram e connector, goes back along the left roof halo panel, across the rear halo panel and terminates at the rear door ground switch. Also coming from this connector is a branch that goes down the left front door lock frame to the left stepwell lamp assembly. 8A-16 CAB ELECTRICAL 71 70. 71. 72. 73. 74. 75. 76. 77. H e a te r L am p C o n n e c to r H e a te r C o n tro ls A s s e m b ly In s tru m e n t C lu s te r C o n n e c to r (Telltale) In s tru m e n t C lu s te r C o n n e c to r (Gages) N e u tra l S w itc h (M a nu al T ra n sm issio n ) L ig h t S w itc h C o n n e c to r B o d y W irin g H a rn e ss C o n n e c to r H orn Relay 78. Park Brake S w itc h C o n n e c to r 79. Test C o n n e c to r 80. G ro u n d Bus 81. 82. 83. 84. 85. 86. 87. 88. 89. B ack Up S w itc h C o n n e c to r In s tru m e n t Panel H a rn e ss G ro u n d C o n n e c to r S te e rin g C o lu m n C o n n e c to r W in d s h ie ld W ip e r C o n n e c to r S to p Lam p C o n n e c to r S to p Lam p S w itc h T orque C o n v e rte r C lu tc h C o n n e c to r B lo w e r M o to r C o n n e c to r W in d s h ie ld W ip e r A n d W a sh e r H a rn e ss C o n n e c to r Figure 21—Van Instrum ent Panel Harness F-00734 CAB ELECTRICAL 8A-17 104 100. P ow er Lock Relay 103. Pow er D o o r L ock C o n n e c to r 101. R ig h t D oor H a rne ss 104. G ro u n d C o n n e c to r 102. P ow er W in d o w C o n n e c to r 105. Power D o o r L ock C irc u it 106. P ow er W in d o w C irc u it B reaker 107. L e ft D o o r H arne ss F-00735 Figure 22—Van Power Door Lock and W indow Harness G VAN FUSE BLOCK The fuse block holds the fuses and circuit breakers that protect the circuits. The fuse block is located on the left side of the dash panel and is fastened to the dash panel connector block with two screws. The fuse block connects to the engine compartm ent harness. Power leads from the various circuits plug into the fuse block. The fuses are encased in plastic and have twin blade connectors. The fuses are printed and color coded with the amperage rating. Refer to Figure 28. POWER DOOR LOCK SYSTEM DESCRIPTION Individual motors operate each door lock. The direction the motor turns depends on the polarity of the supply voltage. The door lock switches control the supply voltage polarity. Each switch will lock all the doors. Each motor has a self-resetting circuit breaker built in. Voltage is present at the door lock switches at all times. Voltage is also present on the open contacts of the door lock relay at all times. When a door switch is moved to “ Lock,” current flows through the switch and lock relay coil to ground. The relay closes, causing current to flow through the lock relay contacts, door lock motor, the unlock relay contacts, and then to ground. When a door lock switch is moved to “ U nlock,” current flows through the switch, the unlock relay contacts, the door lock motor, the lock relay contacts, and to ground. This causes the lock motor to unlock the door. For RV models, the door lock relay is located on, the dash panel, above the steering column. For G van models the door lock relay is located on front left door hinge pillar. 8A-18 CAB ELECTRICAL Figure 23—Van Front Door Harness CAB ELECTRICAL 8A-19 P ow er W in d o w M o to r C o n n e c to r P ow er W in d o w M o to r C o n ta c ts A s s e m b ly Pow er W in d o w s H arne ss C o n n e c to r P ow er L o ck M o to r C o n n e c to r P ow er L o ck M o to r 135 134 F-00737 Figure 24—Van Side Door Harness Figure 25~ V a n Rear Door Harness CAB ELECTRICAL 8A-21 Figure 26—Van Door Jamb Switch and Dome Lamp 8A-22 CAB ELECTRICAL Figure 27—Van Interior Lighting Harness CAB ELECTRICAL 8A-23 □ □ □ □ □ □ □ □ BATT □ □ □ □ □ □ □ "V □ □ □ ° WDO □ IGN ACC LPS INST LPS HO RN/DM TAIL LPS AUX HEAT □ K ] [M l □ Q □ 30A PW R ACC D °3 K ] GAUGES K ] AUX HTR A/C TURN/BU HTR A/C ECM 1 PW R WDO r^ n ~ jc M B o 30A 0§] FUSPLR B-07570 Figure 28—Van Fuse Block DIAGNOSIS OF POWER DOOR LOCK SYSTEM PROBLEM One Door Lock Will Not Work. POSSIBLE CAUSE 1. No power at lock motor. 2. Open ground circuit between the motor and the relay. None of the Door Locks Function; All Switches Tried. 1. No power. 2. Relay not working. CORRECTION 1. Check for voltage at the lock motor. If no voltage at lock motor, check for volt­ age at the connector which is located at the front door hinge pillar. If there is no voltage at the connector, check for an open between the connector and the door lock relay. 2. Move a door switch to “ Lock.” Backprobe the TAN wire at the motor. If there is voltage, find the open between the motor and the relay. 1. C heck for power at the fuse block (ORN/BLK). Check for power at the door lock relay (ORN/BLK). If power is p re s e n t at the fu s e b lo c k b u t not present at the relay, find the open in the harness. 2. Hold a switch to “ Lock.” Backprobe the LT BLU wire at the relay. If there is no voltage, find the open in the harness. If there is voltage, check the relay case to ground path. If the ground is OK, check the relay coil for conduction. 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 harness. 8A-24 CAB ELECTRICAL DIAGNOSIS OF POWER DOOR LOCK SYSTEM (CONT.) PROBLEM One Switch Won’t Lock the Doors. POSSIBLE CAUSE CORRECTION 1. No power to the switch. 1. Check for voltage on the ORN wire at the switch. If there is no voltage, find the open between the switch and the fuse block. 2. Move the switch to “ Lock.” Check for voltage on the LT BLU w ire at the switch. If there is no voltage, replace the switch. 2. Switch has internal open. ON-VEHICLE SERVICE |-n-| Install or Connect 1. 2. 3. 4. 5. POWER DOOR LOCK MOTOR REPLACEMENT «"► Remove or Disconnect 1. Battery ground cable from the battery. 2. Door trim panel. 3. Motor. Refer to DOORS (SEC. 10A1). POWER WINDOW SYSTEM |-K-| Install or Connect 1. Motor. Refer to D O O R S (SEC. 10A1) 2. Door trim panel. 3. Battery ground cable. SWITCH REPLACEMENT Remove or Disconnect 1. Battery ground cable from the battery. 2. Door trim panel. 3. Switch connector. The connector is secured with a retaining nut. 4. Switch. Press in both retaining tabs at the same time. Switch. Switch connector. Retaining nut. Door trim panel. Battery ground cable. DESCRIPTION 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. Switches for controlling all the power windows are located at the driver’s door. Each passenger’s window switch controls only the w indow at that passenger’s position. The motors have a self resetting circuit breaker built in. The circuit breaker allows the motor to be stalled without damage. There are no travel-limit switches. When a window switch is moved to “ UP,” current 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 the BLK wire which goes to ground. DIAGNOSIS OF POWER WINDOW SYSTEM PROBLEM Passenger Window Will Not Work, Using Either Passenger Switch or Driver Switch. POSSIBLE CAUSE 1. No power at the passenger switch. 2. Passenger switch is not working. CORRECTION 1. Ignition switch at RUN or ACC. Check for voltage at the PNK wire on the pas­ senger switch. If there is no voltage, find the open between the switch and the fuse block. 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. CAB ELECTRICAL 8A-25 DIAGNOSIS OF POWER WINDOW SYSTEM (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Passenger Window Will Not Work, Using Either Passenger Switch or Driver Switch (Continued) 3. Motor has an internal open. 3. With the window switch moved to the “ U P” position, check for voltage on the DK BLU wire at the motor. If there is no voltage, find the open betw een the switch and the motor. If there is voltage on the DK BLU wire, backprobe a jum per ground at the BRN wire at the motor. If the motor does not run, re­ place the motor. If the motor does run, find the open in the ground circuit. Note: the ground circuit does run back through the passenger window “ DN” contacts and the driver window switch “ DN” contacts before reaching ground. Passenger Window Will Not Work Using the Passenger Switch. The Window Will Work Using the Driver Switch 1. No power at the passenger switch. 1. Check for voltage on the PNK wire at the passenger switch. If voltage is not present, find the open in the circuit be­ tween the switch and the I.P. harness connector. 2. If voltage is present, replace the switch. Passenger Window Won’t Work Using the Driver Switch. 2. Switch has internal open. 1. No power. 2. Open in driver switch. 3. Open in harness. Driver Window Won’t Work. Passenger Window Works. 1. Switch won’t work. 2. Motor has internal open. 3. Motor ground circuit is open. 1. Check driver window action. If the dri­ ver w indow works, power is at the switch. 2. With the driver switch moved to “ UP,” check for voltage on the DK BLU wire at the driver switch. If voltage is not present, replace the switch. 3. W ith voltage present on the DK BLU wire at the driver switch, find the open between the driver switch and the pas­ senger switch. 1. Switch moved to “ UP.” Check for volt­ age at the DK BLU wire at the switch. If voltage is not present, replace the switch. 2. Switch moved to “ UP.” Check for volt­ age on the DK BLU wire at the motor. If voltage is present, backprobe a jum per ground at the BRN wire at the motor. If the motor won’t run, replace the motor. 3. B ackprobe a ju m p e r ground at the BRN wire at the motor. Move the driver switch to “ UP.” If the motor runs, find the open in the ground circuit. 8A-26 CAB ELECTRICAL ON-VEHICLE SERVICE SWITCH REPLACEMENT Remove or Disconnect POWER WINDOW MOTOR REPLACEMENT ++ Remove or Disconnect 1. Battery ground cable from the battery. 2. Door trim panel. 3. Motor. Refer to DOORS (SEC. 10A1). Install or Connect 1. Motor. R efer to D O O R S (SEC. 10A1). 2. D oor trim panel. 3. B attery ground cable. 1. Battery ground cable from the battery. 2. Door trim panel. 3. Switch connector. The connector is secured with a retaining nut. 4. Switch. Press in both retaining tabs at the same time. ♦«- Install or Connect 1. 2. 3. 4. 5. Switch. Switch connector. Retaining nut. Door trim panel. Battery ground cable. WINDSHIELD WIPER—RV AND G MODELS DESCRIPTION A permanent magnet type wiper is used on RV and 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 halves are referred to as u pp er and low er housings. The two housings are attached to each other by ten extrusions which are staked over. ' The wiper motor is protected by an automatic reset type c irc u it breaker located on the m otor brush holder assembly. A fuse located in the fuse block protects the vehicle wiring. The wiper motor can be operated only when the ignition switch is in the “ run” or “ accessory” position. The wiper motor has three brushes; the “ com m on,” the low speed, and the high speed. When the ignition switch is “ O N ,” power is applied to the common brush. The low speed and high speed brushes are connected to their respective ground via the control switch. When the control switch is positioned at “ HI” or “ LO” speed, a ground path is connected to the high or low speed brush in the motor. The motor runs at the switch selected speed. In order to have the wiper blades stop in their normal park position and the w iper motor shut off properly, the motor must run in LO speed. When the control switch is moved to the OFF position, the low speed brush circuit goes through a park switch located in the gear housing and then to ground at the control switch. The park switch is normally closed and this allows the wiper to keep running. When the wiper blades reach their park position, cam on the gear opens the normally closed park switch, which turns off the wiper. Refer to Figures 29 and 30. DIAGNOSIS OF WINDSHIELD WIPER Refer to Figures 31 through 35. ON-VEHICLE SERVICE WIPER MOTOR REPLACEMENT RV Truck 4-+ Remove or Disconnect (Figure 36) • 1. 2. 3. W iper motor must be in the Park position. Ground cable from the battery. Electrical harness (38) from the w iper motor. Drive rod (34) from the w iper motor crank arm (36). • Reach down through the access hole (32) in the plenum and loosen the wiper drive rod attaching nuts (33) before removing the drive rod (34). 4. W iper motor to dash panel attaching screws (40). 5. W iper motor. Install or Connect (Figure 36) 1. W iper motor. 2. W iper motor to dash panel attaching screws (40). 3. Drive rod (34) the wiper motor crank arm (36). • Lubricate wiper motor crank arm pivot ball (35) prior to installing the drive rod (34). 4. Electrical harness (38) to the wiper motor. 5. Ground cable to the battery. G Van |+ + | Remove or Disconnect (Figure 37) • W iper motor must be in Park position. Ground cable from the battery. W iper arms. Cowl panel cover. Drive arm (34) to the wiper motor crank arm (36). Loosen nuts (33) holding the drive bar (34) to the wiper motor crank arm (36) removing the drive bar (34). Electrical harness (38) from the w iper motor. Left dash defroster outlet from the flex hose. CAB ELECTRICAL 8A-27 1. G e ar Cam 2. Park S w itc h (N o rm a lly C lose d) 3. T erm inal No. 5 4. T erm in al No. 4 5. B L K w /d b l LT BLU Tracer 6. 7. 8. 9. 10. 11. B LK LT BLU BLK M ovable C o n ta c t O F F P o s itio n LOW P o s itio n 12. H IG H P o s itio n 13. Pow er 14. Ig n itio n S w itc h 15. Fuse 16. B L K w /d b l Y E L Tracer 17. T erm inal No. 3 Term inal No. 2 Term inal N o. 1 C irc u it B re ake r C o m m o n B ru sh 22. H igh Speed B ru sh 23. Low Speed B ru sh F-00668 Figure 29—RV Windshield Wiper Diagram 7. Screw securing the left hand heater duct to the engine cover shroud. 8. Heater duct down and out. 9. Three screws (30) securing the wiper motor to the cowl. W iper motor. Install or Connect (Figure 37) 1. W iper motor. 2. Three screws (30) securing the w iper motor to the cowl. 3. Heater duct in and up. 4. Screw securing the left hand heater duct to the engine cover shroud. 5. Left dash defroster outlet to the flex hose. 6. Electrical harness (38) to the wiper motor. 7. Drive bar (34) to the wiper motor crank arm (36). • Lubricate the wiper motor crank arm pivot ball (35). 8. Cowl panel cover. 9. W iper arms. 10. Ground cable to the battery. 8A-28 CAB ELECTRICAL G 17 3. 4. 17. 18. 19. F. G. H. G ro u n d — Park J u m p e r— Park G ro u n d — H igh Speed G ro u n d — Low Speed P o w e r— M o to r H ig h Speed O p e ra tio n Low Speed O p e ra tio n Park O p e ra tio n F-00792 Figure 30—Diagnosis Connection CAB ELECTRICAL 8A-29 DIAGNOSIS CHART PROCEDURE NO. SYMPTOM 1) WIPER INOPERATIVE—BOTH LOW AND HIGH SPEED 1 2) LOW SPEED ONLY-INOPERATIVE IN HIGH SPEED 2 3) HIGH SPEED ONLY-INOPERATIVE IN LOW SPEED 3 4) ONE SPEED-SAME IN BOTH LOW AND HIGH SPEED 4 5) BLADES STOP AT RANDOM POSITIONS WHEN WIPER IS TURNED OFF. (DO NOT RETURN TO PARK POSITION.) 5 6) WIPER WILL NOT SHUT OFF 6 7) INTERMITTENT OPERATION 7 8) WIPER MOTOR RUNS BUT BLADES DON’T MOVE 8 PROCEDURE 1 (W IPER INOPERATIVE) IGNITION SWITCH “ ON.' ’ USING A TEST LIGHT CHECK FOR VOLTAGE AT WIPER TERMINAL NO. 19 NO VOLTAGE GO TO STEP 5 | STEP 2 | GO TO STEP 2 CHECK FUSE FUSE BLOWN ...... ... .................... GO TO STEP 3 I FUSE OK LOCATE AND REPAIR OPEN IN WIRE FROM FUSE BLOCK TO WIPER. F-00715 Figure 31—W iper Diagnosis 8A-30 CAB ELECTRICAL PROCEDURE 1 (CONT.) GO TO STEP 4 REPLACE FUSE AND RECHECK SYSTEM LOCATE AND REPAIR SHORTED OR GROUNDED CONDITION IN WIRING. PROBLEM IS IN THE MOTOR. REFER TO “ WIPER REPAIR” CHECK THE WIPER SWITCH GROUND WIRE CONNECTION. IF OK, PROBLEM IS IN THE MOTOR. REFER TO “ WIPER REPAIR". REPLACE THE W IP E R S W IT C H . PROCEDURE 2 (LO SPEED ONLY) (INOP IN HI) PROBLEM IS AN OPEN WIRE FROM TERMINAL NO. 17 TO THE DASH SWITCH. REPAIR THE WIPER MOTOR. (LOOK FOR A HIGH SPEED HUNG BRUSH.) F-00742 Figure 32—Wiper Diagnosis CAB ELECTRICAL 8A-31 PROCEDURE 3 ( “ H I” SPEED ONLY) (INOP IN LO) PROBLEM IS ON OPEN WIRE FROM WIPER TERMINAL NO. 2 TO THE WIPER SWITCH. REPAIR THE WIPER MOTOR (LOOK FOR LO SPEED HUNG BRUSH). PROCEDURE 4 (ONE S P E E D -S A M E IN BOTH LO AND HI). PROBLEM IS IN THE WIRING BETWEEN THE WIPER SWITCH AND WIPER OR A FAULTY WIPER SWITCH. REPAIR THE WIPER MOTOR. CHECK FOR LO AND HI SPEED BRUSH LEADS SHORTING TOGETHER INTERNALLY. PROCEDURE 5 (W IPER SHUTS OFF BUT BLADES DON’T RETURN TO PARK POSITION) REPLACE THE WIPER PARK SWITCH ASSY. WIRE FROM THE WIPER TERMINAL NO. 3 TO THE WIPER SWITCH IS OPEN OR THE SWITCH IS FAULTY. F-00743 Figure 33—W iper Diagnosis 8A-32 CAB ELECTRICAL PROCEDURE 6 (W IPER W ILL NOT SHUT OFF) GO TO STEP 2 REPAIR THE WIPER MOTOR (REPLACE THE PARK SWITCH ASSY.) REPAIR THE WIPER MOTOR (LOOK FOR INTERNAL GRD. CONDITION IN “ LO” OR “ HI” BRUSHES) LOCATE AND REPAIR THE GROUND CONDITION IN THE WIRES FROM THE WIPER TERMINALS 18 OR 17 TO THE WIPER SWITCH. PROCEDURE 7 (INTERM ITTENT OPERATION) (W IPER HAS BOTH SPEEDS) A WEAK CIRCUIT BREAKER IS INDICATED. REPLACE MOTOR END CAP ASSY. GO TO STEP 2 REPLACE BLADE ELEMENTS CHECK WIPER LINKAGE FOR A BINDING CONDITION AND REPAIR OR REPLACE AS REQ’D. Figure 34—Wiper Diagnosis GO TO STEP 3 PROBLEM IS IN THE WIPER MOTOR. CHECK FOR ARMATURE END PLAY, SHORTED OR GROUNDED ARMATURE. F-00744 CAB ELECTRICAL 8A-33 PROCEDURE 8 (W IPER RUNS BUT BLADES DON’T MOVE) STEP 1 CHECK THE WIPER LINKAGE CONNECTION TO THE WIPER CRANK ARM LINKAGE CONNECTED WIPER GEAR IS STRIPPED. REPLACE THE WIPER MOTOR. LINKAGE DISCONNECTED CHECK THE LINKAGE AND CHECK THE SYSTEM. F-00745 Figure 35—W iper Diagnosis Figure 36—RV W iper Motor Mounting 8A-34 CAB ELECTRICAL Figure 37—Van Wiper Motor Mounting WINDSHIELD W ASH ER—RV AND G MODELS DESCRIPTION The washer motor is located in the bottom of the w in d s h ie ld w a sh e r flu id re se rvo ir. The w a sh e r is controlled by a washer switch, which is located on the turn signal and m ulti-function lever. Two wires go to the washer. The white wire is power coming from the fuse box. The same fuse that protects the washer motor also protects the wiper motor. The pink wire is the ground circuit that goes through the washer switch to ground. Refer to figures 38 and 39. CAB ELECTRICAL 8A-35 54 51. 52. 53. 54. W in d s h ie ld W a sh e r M o to r C o n n e c to r R e se rvo ir R e ta in in g S cre w W a sh e r F lu id R e se rvo ir W in d s h ie ld W a sh e r M o to r F-00748 Figure 38—RV W indshield Washer 50. 51. 52. 53. 54. Dash Panel W in d s h ie ld W a s h e r M o to r C o n n e c to r R e s e rv o ir R e ta in in g S crew W a sh e r F lu id R e s e rv o ir W in d s h ie ld W a s h e r M o to r F-00749 Figure 39—Van W indshield Washer WINDSHIELD WASHER DIAGNOSIS PROBLEM Washer Fluid Does Not Spray on the Windshield POSSIBLE CAUSE 1. No fluid. 2. Clogged jets. 3. Clogged filter in the reservoir. 4. Washer motor is not running. CORRECTION 1. Check the fluid reservoir. Refill, if nec­ essary. 2. Using a fine pin, carefully clear the jets. 3. Remove the filter and back flush it. Also clean the reservoir. 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. 8A-36 CAB ELECTRICAL ON-VEHICLE SERVICE WASHER MOTOR REPLACEMENT 4. Reservoir. 5. Two reservoir retaining screws. 6. Battery ground cable to the battery. G Van RV Models Remove or Disconnect Remove or Disconnect (Figure 39) Battery ground cable from the battery. Two reservoir retaining screws. Reservoir. Electrical connector at the motor. Fluid tube at the motor. Motor from the reservoir. Battery ground cable from the battery. Electrical connector at the motor. Fluid tubes from the motor. Motor from the bracket. -►+ Install or Connect (Figure 38) Motor to the reservoir. Fluid tube at the motor. Electrical connector at the motor. Install or Connect (Figure 39) Motor onto the bracket. Fluid tubes to the motor. Electrical connector to the motor. Battery ground cable to the battery. WIPER MOTOR UNIT REPAIR REPLACEMENT OF COMPONENTS PARK SWITCH |+ + | Remove or Disconnect (Figure 40) 1. Cover 2. Park switch. • Depress tang (61). I++I Install or Connect (Figure 40) 1. Park switch. 2. Cover. END CAP-BRUSH HOLDER, ARMATURE ASSEMBLY Remove or Disconnect 1. Retainer tabs. 2. End cap assembly. • Rotate crank arm clockwise. 3. Armature. B Install or Connect (Figure 41 and 42) 1. Armature in the end cap assembly. • Release the brush spring tension (65). • Slide the brushes back in the brush holders. • Put the armature in the end cap assembly. • Reposition the brush spring legs behind their respective notches (66). • Tie the armature to the end cap assembly with small wire. 2. Armature in the w iper housing. 3. End cap into the slot area of the wiper housing. • Remove the wire. 4. End cap assembly into the housing until it bottoms. 5. Retainer tabs. 60. 61. 62. 63. C o n n e c to r Tang C am F o llo w e r P o in ts F-00753 Figure 40—Park Switch CRANK ARM, SPACER, SEAL Remove or Disconnect (Figure 43) 1. Crank arm retaining nut (71). • Have the crank arm clamped in a vise. 2. Crank arm (70). 3. Shaft seal (72). 4. Spacer (73). Install or Connect (Figure 43, 44 and 45) Spacer (73). Shaftseal (72). Crank arm (70). • Be sure the wiper motor is in “ Park.” • Install the crank arm according to figure 44 or 45, depending on the vehicle model. Crank arm retaining nut (71). CAB ELECTRICAL 8A-37 70. C ra nk A rm 71. N ut 72. S h a ft Seal (R ubber) 73. S p a c e r (P la s tic ) 74. A rm a tu re End Play A d ju s tin g S c re w 65. B ru sh S p rin g Leg R eleased fro m R eta in e r N o tc h 66. R otate B rush S p rin g in D ire c tio n o f A rro w to R e p o s itio n it B e h in d R e ta in e r N o tc h 67. R e ta in e r N o tc h F-00754 Figure 41—Brush Spring Release Position F-00755 Figure 43—Crank Arm, Spacer and Seal 80. C rank A rm Park P o s itio n — C K M o d e ls 81. Id e n tific a tio n C ode F-00758 Figure 42—End Cap Assembly Figure 44—Crank Arm Position — RV Models 8A-38 CAB ELECTRICAL 81. Id e n tific a tio n C od e 82. C rank A rm Park P o s itio n G Van M o d e ls F-00759 Figure 45—Crank Arm Position — Van WINDSHIELD WIPER DELAY CIRCUIT DESCRIPTION The wiper pulse control circuit is an option on RV and G models. This option allows the wiper to operate at a slower rate than the low speed setting on the standard control. The optional module is inserted into the harness under the steering column. Refer to figure 46. DIAGNOSIS OF WIPER DELAY CIRCUIT Refer to Figure 47. ON-VEHICLE SERVICE REPLACEMENT OF THE MODULE Remove or Disconnect (Figure 46) 1. Harness connectors. 2. Module (91) by sliding it off the bracket. Remove or Disconnect 1. Module (91). 2. Harness connectors. REPLACEMENT OF THE SWITCH. Refer to STEERING COLUMN (SEC. 3B4). CAB ELECTRICAL 8A-39 90. S te e rin g C o lu m n 91. W in d s h ie ld W ip e r D elay M o d u le 92. In s tru m e n t Panel H a rn e ss Figure 46—W iper Pulse Module F-00818 8A-40 CAB ELECTRICAL DIAGNOSIS OF THE WIPER DELAY CIRCUIT Figure 47—Diagnosis of the W iper Delay Module WINDSHIELD WIPER AND WASHER P MODELS DESCRIPTION T h e s y s te m c o n s is ts o f a c o m p o u n d w o u n d re c ta n g u la r-sh a p e d m oto r a tta ch e d to a g e a r box containing a parking switch in addition to the gear train. The gear train consists of a motor arm ature helical gearshaft which drives an intermediate gear and pinion assembly. The pinion gear of the intermediate gear and pinion drives an output gear and shaft assembly. Turning the wiper switch to the LO speed position completes the circuits from the wiper term inals 1 and 3 to ground (Figure 48). Current then flows from the battery via wiper terminal No. 2 through the series field and divides; (1) part passes through the armature to ground via wiper terminal No. 1 to the wiper switch and (2) the second part passes through the shunt field to ground through wiper terminal No. 3 to the wiper switch. The wiper switch must be securely grounded to body metal. Moving the wiper switch to the HI speed position opens the shunt field circuit to ground at the switch. However, the shunt field is connected to a 20 ohm resistor which is connected across wiper term inals 1 and 3. The shunt field current then flows via terminal No. 3 through the resistor to terminal No. 1 to the switch, to ground. T he p a rk in g c irc u it co vers th a t p o rtio n of w ip e r operation when the wiper switch is turned “ o ff” and the wiper blades have not reached the park position. When the wiper blades are not in the normal park position, the parking switch contacts are still closed. The wiper will continue to operate until the wiper output gear CAB ELECTRICAL 8A-41 1. 2. 3. 4. 5. 6. 7. 8. M o to r S h u n t R e s is to r S e rie s R e s is to r G R A W ire Term inal No. 3 Term inal No. 1 Term inal No. 2 In s tru m e n t Panel S w itc h 9. 10. 11. 12. 13. 14. 15. 16. M o vin g C o n ta c t R achet W a sh er T erm inal #1 T erm inal #2 S o le n o id Pawl O F F P o s itio n 17. 18. 19. 20. 21. 22. 23. 24. LOW P o s itio n H IG H P o s itio n P ow er RED W ire PARK S w itc h R e s is to r A rm a tu re B rush Figure 48—P-Model Wiper Diagram is turned to a position where its cam opens the park switch. The wiper motor circuits are completed to ground through the parking switch. The wiper motor must be securely grounded to body metal. The shunt field circuit is completed from terminal No. 3 via the switch to terminal No. 1 through the parking switch to ground. The series field and armature circuit is also completed from terminal No. 1 through the parking switch to ground. T he s h u n t fie ld is c o n n e c te d d ire c t to g ro u n d , by-passing the resistor. This results in LO speed operation during the parking operation. When the output gear cam opens the park switch contacts, the wiper is OFF. 2. 3. 4. 5. DIAGNOSIS WIPER SYSTEM CHECKS 1. Inspect for the following items: a. W iring harness is securely connected to wiper and switch. 6. b. W iper motor is securely grounded to body. c. W ip e r s w itc h is s e c u re ly m o u n te d and grounded. d. Check fuse. If items in Step 1 check out, try operating w iper in both “ LO” and “ HI” speeds, then turn w iper off (blades should return to park position). If wiper fails to operate correctly, proceed to Step 3. D isconnect w iring harness from w ipe r and try operating w iper as shown in Figures 49, 50, and 51. If wiper operates correctly independently of switch and vehicle w iring, refer to “ DIAGNOSIS — WIPER ON VEH IC LE.” If wiper still fails to operate correctly in Step 3, disconnect wiper linkage from motor crank arm and try operating w iper again. If wiper operates correctly independently of linkage, check linkage for cause of wiper m alfunction. If wiper fails to operate correctly independently of linkage, remove wiper motor from vehicle and refer to “ DIAGNOSIS — WIPER OFF VEHICLE.” 8A-42 CAB ELECTRICAL 30. 31. 32. 33. 34. 35. Term inal No. 2 T erm inal No. 1 T erm in al No. 3 A m m e te r; 0-30 A m p e re Range G ear S h a ft In T he Park P o s itio n W ip e r G ro u n d S tra p F-00808 Figure 49—Jum per Connections — Low Speed 30. 31. 32. 33. 34. 35. T erm in al N o. 2 Term in al N o. 1 Term in al N o. 3 A m m e te r; 0-30 A m p e re R ange G ear S h a ft In T he Park P o s itio n W ip e r G ro u n d S tra p F-00809 Figure 50—Jum per Connections — High Speed 30. 31. 32. 33. 34. 35. T erm in al No. 2 T erm in al No. 1 T erm in al No. 3 A m m e te r; 0-30 A m p e re R ange G e ar S h a ft In T he Park P o s itio n W ip e r G ro u n d S tra p F-00810 Figure 51—Jum per Connections — Off CAB ELECTRICAL 8A-43 DIAGNOSIS OF THE WIPER—ON VEHICLE PROBLEM Wiper Not Working or Intermittent POSSIBLE CAUSE 1. Blown fuse 2. Open circuit in feed wire (No. 2 terminal on wiper motor) 3. Loose mounting of wiper switch. 4. Faulty wiper switch. 5. Open circuit in wire to w iper switch (No. 1 term inal on wiper motor) CORRECTION 1. Locate short circuit and repair. Replace fuse. 2. Locate broken wire and repair. 3. Tighten switch mounting. 4. Replace switch. 5. Locate broken wire and repair. Wiper Will Not Shut Off. Wiper has Both “ Lo” and “ Hi” Speeds Grounded wire (No. 1 term inal on wiper motor) to wiper switch. Locate short circuit and repair. Wiper Will Not Shut Off. Wiper Has “ Lo” Speed Only. 1. Defective wiper switch. 2. Grounded wire (No. 3 terminal on wiper motor) to w iper switch. 1. Replace wiper switch. 2. Locate and repair short circuit. Wiper Will Not Shut Off. Wiper has “ Hi” Speed Only 1. Defective wiper switch. 2. Open circuit in wire (No. 3 term inal on wiper motor) to wiper switch. 1. Replace wiper switch. 2. Locate and repair broken wire. Wiper Has “ Hi” Speed Only Open circuit in wire (No. 3 term inal on w iper motor) to wiper switch. Locate broken wire and repair. Wiper Has “ Lo” Speed Only 1. Grounded wire (No. 3 term inal on wiper motor) to wiper switch. 2. Defective wiper switch. 1. Locate short circuit and repair. Blades Do Not Return To Full Park Position Loose wiper ground strap connection. 2. Replace wiper switch. Tighten strap connection. DIAGNOSIS OF THE WIPER — OFF VEHICLE PROBLEM POSSIBLE CAUSE Wiper Not Working or Intermittent 1. Broken or damaged gear train (only if not working). 2. Poor so ld e r co n n e c tio n s at te rm ina l board. 3. Loose splice joints at brush plate. 4. Brushes binding in brush holder. Wiper Will Not Shut-Off. Wiper Has Normal “ Hi” and “ Lo” Speed CORRECTION 1. Replace gears as required. 2. Resolder wires at terminals. 5. Open circuit in armature. 3. Recrimp or solder splice joints. 4. Clean holder or replace brush, spring or brush plate assembly. 5. Replace armature. 1. Faulty part switch. 2. Grounded red lead wire. 1. Replace term inal board assembly. 2. Repair short circuit in red wire. 8A-44 CAB ELECTRICAL DIAGNOSIS OF THE WIPER — OFF VEHICLE (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Wiper Will Not Shut Off. Wiper Has “ Lo” Speed Only 1. Grounded shunt field coil. 2. Grounded black wire. 1. Replace frame and field assembly. 2. Repair short circuit in black wire. Wiper Will Not Shut Off. Wiper Has “ Hi” Speed Only 1. Open circuit in shunt field coil. 2. Open circuit in black wire. 1. Replace frame and field assembly. 2. Repair broken wire or poor solder con­ nection. Wiper Shuts Off—But Not In Park Position Park switch defective or contacts dirty. Replace term inal board assembly or clean contacts. “ Hi” Speed Too Fast Resistor defective. Replace term inal board assembly. DIAGNOSIS OF THE WASHER SYSTEM PROBLEM Washers Inoperative POSSIBLE CAUSE 1 Inadequate quantity of washer solution. 2. Hoses damaged or loose. 3. Plugged screen at end of jar cover hose. 4. Loose electrical connection to washer pump or wiper switch. 5. Open circuit in feed wire to ratchet relay coil. 6. W iper switch faulty. 7. Ratchet relay coil defective. 8. Washer nozzles plugged. 9. Ratchet wheel tooth missing. 10. Ratchet pawl spring missing. 11. Faulty pump valve assembly. Washer Pumps Continuously When Wipers Are Operating 1. G rounded wire from ratchet relay to switch. 2. W iper switch faulty. 3. Ratchet wheel tooth missing. 4. Ratchet wheel dog broken or not con­ tacting ratchet wheel teeth. 5. Lock-out tang broken or bent on piston actuating plate. CORRECTION 1. Add washer solution. 2. Cut short length off end of hose to in­ sure air tig ht connection or replace hose. 3. Clean screen. 4. Check electrical connections and repair if necessary. 5. Locate open circuit and repair. 6. 7. 8. 9. 10. 11. Replace wiper switch. Replace ratchet relay. Clean washer nozzles. Replace ratchet wheel. Replace ratchet pawl spring. Replace pump valve assembly. 1. Locate grounded wire and repair. 2. Replace wiper switch. 3. Replace ratchet wheel. 4. Replace of repair ratchet wheel dog. 5. Replace piston actuating plate. CAB ELECTRICAL 8A-45 ON-VEHICLE SERVICE WIPER MOTOR W iper motor replacement procedures are not included here since installation is performed by the individual body manufacturers; however, disassem bly of the unit will be covered in “ Unit Repair.” UNIT REPAIR WIPER MOTOR DISASSEMBLY GEAR BOX AND MOTOR Remove or Disconnect (Figure 52, 53, and 54) 1. Two washer pump mounting screws (72). 2. Pump (71) from the gear box cover. 3. Washer pump drive cam (75). • Wedge off the cam and the plate using two screwdrivers. 4. Crank arm retaining nut (58). • Clamp the crank arm (57) in a vise before removing the nut (58). 5. Crank arm (57). 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. O utput gear and shaft assembly (52). 12. Intermediate gear and pinion assembly off the shaft (51). 13. T erm inal board and p a rk sw itch assem bly, if necessary. • Unsolder the motor leads from the terminals. • Label the motor leads. • Drill out the rivets securing the terminal board and the park sw itch ground strap to the m ounting plate. 14. Motor through bolts (42). 15. Motor from the mounting plate. • Tap motor frame lightly. 16. Brush spring tension (61). 17. Armature (46) and end plate (43) from the motor frame (44). 18. End plate (43) from the armature (46). • There is a th ru s t plug (45) betw een the armature shaft and the end plate. 19. End play adjusting washers (47 and 41) from the armature. • Note the washers positions. INSPECTION Inspect all the parts for wear or damage. All the parts 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. 8A-46 CAB ELECTRICAL 40. 41. 42. 43. 44. 45. 46. 47. B ru s h e s Wave W a sh e rs M o to r T h ro u g h B o lt End P late F ram e A n d F ie ld T h ru s t P lug A rm a tu re F la t W a sh e rs 47. 48. 49. 50. 51. F lat W ashers B rush P late A s s e m b ly A n d M o u n tin g B ra cke ts G ear B ox H o u s in g W ave W a sh e r In te rm e d ia te G ear O u tp u t G ear A n d S h a ft A s s e m b ly G ear B ox C over S p a ce r R e ta in in g R ing Seal Cap 57. 58. 59. 60. 61. C ra nk A rm N ut B ru s h H o ld e r S lo t G roo ve F o r B ru sh S p rin g F-00811 Figure 54—M otor Assem bly 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). 5. Motor to the m ounting plate (49). 6. Motor through bolts (42). 7. Term inal board and p ark sw itch assem bly, if removed. • Secure the term inal 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). 80 57. C ra nk A rm 80. G ear C ase A lig n m e n t M a rks 81. C ra nk A rm A lig n m e n t M arks Figure 55—Park Alignm ent F-00834 CAB ELECTRICAL 8A-47 ftfi 85. 86. 87. 88. 89. 90. 91. 92. on Valve A s s e m b ly M o u n tin g S crew Valve A s s e m b ly Pum p R achet D og R achet D og R e ta in in g S crew S o le n o id C oil S o le n o id P lu n g e r R achet W h e el 93. 94. 95. 96. 97. 98. 99. 100. R achet Pawl S p rin g Cam F o llo w e r U p p e r Pin “ E” R ing Cam F o llo w e r Fram e R achet Pawl R achet W h e el S p rin g R e ta in in g G roove F-00835 Figure 56—Washer Pump Assembly 14. Seal cap (56). 15. Crank arm (57). • Place the w iper in the park position. • Install the crank arm on the output shaft. • Rotate the crank so that the alignm ent marks line up with those on the cover (80 and 81). 16. Crank arm retaining nut (58). • C la m p th e c ra n k arm in a v is e b e fo re tightening the retaining nut. 17. Washer pump drive cam (75). • Press the cam on the shaft. 18. Pump on the gear box cover. 19. Two pump mounting screws (72). WINDSHIELD WASHER DISASSEMBLY Remove or Disconnect (Figure 56) 1. Washer pump cover 2. Ratchet dog retaining screw (89). 3. Solenoid assem bly (90) and ratchet dog (88) off the pump frame (97). • Hold the spring loaded solenoid plunger (91) in position while lifting the solenoid assembly. 4. Ratchet pawl spring (93). 5. Ratchet pawl retaining ring (94). 6. Ratchet pawl (98) from the cam follower Upper Pin. 7. Ratchet wheel spring (99) out of the shaft groove. 8. Ratchet wheel (92) from the shaft. 9. Pump and actuator plate assembly. • Pull the pump housing away from the drive cam until the housing grooves (100) clear the frame. • Lift the cam follower (96) from the ratchet wheel and cam follower shafts. 10. Four valve assem bly screws (85). 11. Valve assembly (86) from the pump housing. 8A-48 CAB ELECTRICAL WINDSHIELD WASHER ASSEMBLY |~n~| Install or Connect (Figure 56) 1. Valve assembly (86). To the pump housing (87). • Be sure th a t the seal between the pum p h o u sin g and th e valve p la te is p ro p e rly positioned in the pump housing and valve plate grooves. • Be sure that the triple seal is properly installed b e tw e e n th e v a lv e b o d y a nd th e p ip e assembly. 2. Four valve assem bly screws (85). 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 (94). 7. Ratchet pawl retaining “ E ” ring (95). 8. Ratchet pawl spring (93). 9. Solenoid assembly (90) and ratchet dog (88) on the pump fram e (97). • Hold the spring loaded solenoid plunger (91) in p o s itio n w h ile in s ta llin g th e so le n o id assembly. 10. Ratchet dog retaining screw (89). 11. Washer pump cover. HEATER SYSTEM CIRCUITS DESCRIPTION The heater blower motor is controlled by the blower 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 into the motor circuit, thereby dropping the voltage available to the motor. The blower switch is located on the control assembly. The harness from the switch goes to the dash panel connector and into the engine compartment. The harness is then routed to the resistor block, which is located on the blower housing. From the resistor block, the harness then g o e s to th e b lo w e r m otor. T h e w ire c o lo rs can be found in the wiring diagrams which are at the back of this manual. DIAGNOSIS For diagnosis of the heater blower circuit, refer to HEATING AND VENTILATION (SEC. 1A). ON-VEHICLE SERVICE For on-vehicle service of the heater blower circuit, refer to HEATING AND VENTILATION (SEC. 1A). AIR CONDITIONING ELECTRICAL SYSTEM DESCRIPTION DIAGNOSIS The compressor electro-magnetic clutch is turned on and off by the pressure sensing switch. When refrigerant pressure drops below a certain predetermined level, the switch opens the compressor clutch circuit, which causes the refrigeration system to stop working. The pressure sensing switch is located near the top of the accumulator. For diagnosis of the A/C electrical system, refer to AIR CONDITIONING (SEC. 1B). ON-VEHICLE SERVICE For on-vehicle service of the air conditioning, refer to AIR CONDITIONING (SEC. 1B). CAB ELECTRICAL 8A-49 SPECIAL TOOLS 8A-50 CAB ELECTRICAL CHASSIS ELECTRICAL 8B-1 SECTION 8B CHASSIS ELECTRICAL CONTENTS SUBJECT PAGE Front Lighting S y s te m ................................................................................................................................................ 8B- 1 Headlamp S y s te m .................................................................................................................................................... 8B- 1 Diagnosis Of Headlamp................................................................................................................................................ 8B- 6 On-Vehicle S e rv ic e .................................................................................................................................................. 8B- 7 Front Parking Lamps S ystem ..................................................................................................................................8B- 8 Diagnosis Of The Front Parking L a m p s ...... .............................................................................................................8B- 8 On-Vehicle S e rv ic e .................................................................................................................................................. 8B- 9 Front Side Marker Lamp S y s te m ............................................................................................................................8B-10 Diagnosis Of The Front Side Marker Lamps............................................................................................................. 8B-10 On-Vehicle S e rv ic e .................................................................................................................................................. 8B-11 Rear Lighting S ystem s................................................................................................................................................ 8B-11 Rear Running Lamps And Marker L a m p s ............................................................................................................. 8B-11 Rear Park L am ps.......................................................................................................................................................8B-11 Rear Turn, Stop And Hazard System s................................................................................................................... 8B-11 Back-Up Lamp S y s te m ............................................................................................................................................ 8B-12 Rear Lamp Harness Layouts....................................................................................................................................8B-12 Diagnosis Of The Rear Side Marker L a m p s ............................................................................................................. 8B-17 Diagnosis Of The Running, Park And License Lamps.............................................................................................8B-18 Diagnosis Of The Turn Signal And Hazard S ystem s............................................................................................... 8B-19 Diagnosis Of The Stoplamp S y s te m ..........................................................................................................................8B-20 Diagnosis Of The Back Up Lamp S ystem ................................................................................................................. 8B-20 On-Vehicle S e rv ic e .................................................................................................................................................. 8B-21 Fuses, Circuit Breakers S pecifications..................................................................................................................... 8B-27 Lamp S pecifications.................................................................................................................................................... 8B-29 FRONT LIGHT SYSTEMS The front lighting system includes the headlamps, the front parking lamps, and the front side marker lamps. The circuit starts at the fuse block and goes to the light switch in the instrum ent panel. From the light switch the circuit goes to the dash panel connector and then to the front lamps. HEADLAMP SYSTEM The headlamp system has two options. One option is two headlamps, each headlamp having a parking lamp located under it. The other option is four headlamps, with the parking lam ps located in the g rill. On the four headlamp option, when the low beam 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. 8B-2 CHASSIS ELECTRICAL Figure 1—RV Two Headlamp Wiring Harness CHASSIS ELECTRICAL 8B-3 Figure 2—RV Four Headlamp Wiring Harness 8B-4 CHASSIS ELECTRICAL 41. 42. 43. 45. 46. H e a d la m p G ro u n d Two H e a d la m p H a rn e ss Dash Panel C o n n e c to r F o u r H e a d la m p H a rn e s s 47. L ow er H e a d la m p Figure 3—G Van Front Lighting Harness F-00862 CHASSIS ELECTRICAL 8B-5 Figure 4—Two Headlamp Assembly 8B-6 CHASSIS ELECTRICAL DIAGNOSIS OF HEADLAMP PROBLEM One Headlamp Inoperative Or Intermittent. POSSIBLE CAUSE 1. Loose connection. 2. Defective sealed beam unit. One Or More Headlamps Are Dim. One Or More Headlamps Short Life. All Headlamps Inoperative Or Intermittent. 1. O p e n g ro u n d c o n n e c tio n at th e headlamp. 2. Black ground w ire m islocated in the headlam p connector (three-wire, hi-lo, connector only). Charge circuit problem. 1. Loosen connection. 2. Defective dim m er switch. 3. Open wiring— lamp switch to the dim m er switch. 4. Open w iring— lamp switch to the battery. 5. Shorted ground circuit. 6. Defective switch. Upper Or Lower Beam Will Not Light Or Intermittent. 1. Open connection or defective dim m er switch. 2. Short circuit to ground. CORRECTION 1. S e c u re th e c o n n e c tio n s to th e headlamp including the ground (black wire). 2. Replace the headlamp. 1. Repair the black wire connection be­ tween headlamp and the body ground. 2. Relocate the black wire in the connec­ tor. Refer to ENGINE ELECTRICAL (SEC. 6D), charging system diagnosis. 1. Check and secure the connections at the dim m er switch and the lamp switch. 2. Check the voltage at the dim m er switch with a test lamp. Refer to CAB ELEC­ TRICAL (SEC. 8A) for the test points. 3. Check the yellow wire with a test lamp. If the bulb lamps at the lamp switch yel­ low wire terminal but not at the dim m er switch, repair the open wire. 4. Check the red wire term inal at the lamp switch with a test lamp. If the bulb does not lamp, repair the open red wire cir­ cuit to the battery (possible open fusi­ ble link). 5. If, after a few minutes operation, the headlamps flicker “ O N ” and “ OFF” and/or a thum ping noise can be heard from the lamp switch (circuit breaker opening and closing), repair the short to ground in the circuit between the lamp switch and the headlamps. After repairing the short, check for headlamp flickering after one minute operation. If flickering occurs, the circu it breaker has been d a m a g e d and the lam p switch must be replaced. 6. Check the red and yellow wire term i­ nals at the lamp switch with test. If the bulb lamps at the red wire terminal but not at the yellow term inal, replace the lamp switch. 1. Check the dim m er switch term inals with a test lamp. If the bulb lights at the light green or tan wire terminals, repair the open wiring between the dim m er switch and the headlamps. If the bulb will not light at either of these term i­ nals, depending upon switch position, replace the dim m er switch. 2. F o llo w th e d ia g n o s is a b o v e (a ll headlamps inoperative or intermittent). CHASSIS ELECTRICAL 8B-7 F-00751 Figure 5—Four Headlamp Assembly ON-VEHICLE SERVICE HEADLAMP UNIT REPLACEMENT Remove or Disconnect (Figure 4 and 5) 1. 2. 3. 4. 5. 6. 7. 8. Battery ground cable from the battery. Headlamp bezel retaining screws. Bezel. Retaining ring screws. Be careful not to move the adjustm ent screws. Retaining ring spring, using a hooked tool. Retaining ring from the m ounting ring. Headlamp unit. Headlamp electrical connector. |++-| Install or Connect (Figure 4 and 5) 1. Headlamp electrical connector. • On the dual headlamp option, the 2A1 headlamp is the upper unit and the 1A1 headlamp is the lower unit. 2. Headlamp. 3. Retaining ring. 4. Retaining ring screws. Make sure that the headlamp is properly seated. 5. 6. 7. 8. Retaining ring spring. Bezel. Bezel retaining screws. Battery ground cable to the battery. HEADLAMP ADJUSTMENT (Figure 6) Horizontal and vertical aiming of each headlam p is done by two (2) a d ju s tin g screw s w hich m ove the mounting ring against the tension of the coil spring. S om e s ta te and lo c a l a u th o ritie s have s p e c ific re q u ire m e n ts fo r a im in g h e a d la m p s a nd th e s e requirements should be followed. Replacement of a headlamp will normally not require aiming adjustment. However, do check the aim. U se th e s a fe ty a im e r J-6878-01 or e q u iv a le n t. Instructions for using the safety aimer are supplied by the instrument manufacturer. DIMMER SWITCH REPLACEMENT Refer to STEERING COLUM NS (SEC. 3B4). 8B-8 CHASSIS ELECTRICAL LAMP SWITCH REPLACEMENT Refer to “ Rear Lighting Systems.” _ FRONT PARKING LAMPS SYSTEM — ^ d ° — N> The front parking lamps circuit is in the headlamp harness. The circuit starts from the fuse block, goes to the lamp switch, and then forward to the front parking lamps. The circuit also includes the rear parking lamps, which are covered later in this section. The parking lamp system is turned on when the lamp switch is pulled out to the first detent. y r DESCRIPTION 20. V e rtic a l A d ju s tin g S cre w 21. H o riz o n ta l A d ju s tin g S cre w F-00821 Figure 6—Headlamp Aiming Screws DIAGNOSIS OF THE FRONT PARKING LAMPS PROBLEM POSSIBLE CAUSE CORRECTION One Side Not Working. 1. Bulb burnt out. 2. Open connection at the bulb socket or the ground wire terminal. 1. Replace the bulb. 2. Jum per the bulb base socket connec­ tion to ground. If the bulb lamps, repair the open ground circuit. Both Sides Not Working. 1. Fuse blown. 1. R eplace the fu se. If the new fuse blows, repair the short to ground in the brown wire circuit between the fuse panel through the lamp switch to the lamps. 2. Secure the c o n n e cto r at the lam p switch. 3. Using a test lamp, check the circuit on both sides of the fuse. If the test bulb does not lamp on either side, repair 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 term inal, repair the open wiring between the lamp switch and the lamps. 4. If the test bulb lam ps at the lamp socket brown wire term inal, replace the bulb(s). 5. If the test bulb lam ps at the lamp switch orange wire but not at the brown wire, replace the defective lamp switch. 2. Loose connection. 3. Open wiring. 4. M ultiple bulb burnout. 5. Defective lamp switch. CHASSIS ELECTRICAL 8B-9 25. Park Lam p 26. N u t 27. R a d ia to r G rille B-00824 Figure 7—Parking Lamp Assembly ON-VEHICLE SERVICE REPLACEMENT OF THE LAMP SWITCH Refer to INSTRUMENT PANEL (SEC. 8C). REPLACEMENT OF THE FRONT PARKING LAMP RV and G Models—Two Headlamp Option |<-+| Remove or Disconnect (Figures 3 and 4) 1. 2. 3. 4. 5. 6. Battery ground cable from the battery. Four bezel retaining screws. Bezel. Three park lamp retaining screws. Parking lamp. Electrical connector from the parking lamp. 5. Four bezel retaining screws. 6. Battery ground cable to the battery. RV and G Models—Four Headlamp Option ++ Remove or Disconnect (Figure 7) 1. Radiator grille (27). Refer to SHEET METAL (SEC. 2B). 2. Electrical connector from the parking lamp. 3. Two nuts (26) at the top of the housing (25). 4. Housing by lifting it up from the radiator grille. Install or Connect (Figure 7) 1. Park lamp housing (25) on the radiator grille (27). Install or Connect (Figures 3 and 4) 1. 2. 3. 4. Electrical connector to the parking lamp. Parking lamp. Three parking lamp retaining screws. Bezel. 2. Two nuts (26) at the top of the housing (25). 3. Electrical connector into the parking lamp. 4. Radiator grille (27). Refer to SHEET METAL (SEC. 2B). 8B-10 CHASSIS ELECTRICAL FRONT SIDE MARKER LAMP SYSTEM DESCRIPTION The front side marker lamp circuit is included in the 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 PROBLEM One Lamp Won’t Work POSSIBLE CAUSE 1. Turn signal bulb burnt out (front lamp). 2. Side marker bulb burnt out. 3. Loose connection or open in wiring. Front or Rear Lamps Won’t Work 1. Loose connection or open ground circuit. 2. Multiple bulbs burnt out. All Lamps Won’t Work 1. Blown fuse. 2. Loose connection. 3. Open in wiring. 4. Defective lamp switch. CORRECTION 1. Switch turn signals on. If the signal bulb does not light, replace the bulb. (Bulb filam ent provides ground path for marker lamp bulb hrough the dark blue or brown wires.) 2. Replace the bulb. 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. 1. If the associated tail or park lamps do not operate, check all the connectors in the brown wire circuit. If the park and turn lamps are not working, repair the open ground connections. 2. Replace the burnt out bulbs. 1. If the park and tail lamps do not oper­ ate, replace the blown fuse. If the new fuse blows, check for a short to ground between the fuse panel and the lamps. 2. Secure the c o n n e c to r to the lam p switch. 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 w ir­ ing between the fuse and the battery. (Possible open fusible link.) 4. Check the lamp switch with a test light. If the test bulb lights at the orange wire but not at the brown wire, replace the lamp switch. CHASSIS ELECTRICAL 8B-11 30. 31. 32. 34. F ro n t F e n d e r S id e M arker Lam p S crew N ut F-00871 Figure 9—G Van Front Side Marker Lamp ON-VEHICLE SERVICE REPLACEMENT OF THE FRONT SIDE MARKER LAMP -►+ Install or Connect (Figures 8 and 9) 1. Bulb (33) the lamp (31). 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). REAR LIGHTING SYSTEMS The rear lighting systems contain the circuits for the running, park, turn, stop and license lamps. One bulb may function for more than one circuit. The harness for the rear lighting systems starts at the fuse block, goes to the various switches and then back along the left frame to the various lamps. REAR RUNNING LAMPS AND MARKER LAMPS This circuit starts at the lamp switch. The lamps will be on when the lamp switch is in the first and second detents. The front park lamps and front marker lamps will also be on when the lamp switch is in the first detent. REAR PARK LAMPS These lamps will be on when the lamp switch is in the first detent. The front park lamps will also be on. The side marker lamps will also be on. REAR TURN, STOP, AND HAZARD SYSTEMS These three systems use the same bulb in the rear 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 the turn system. The stop lamp system is turned on by a brake switch closing. The two rear bright lamps are then turned on. The hazard system is turned on by the hazard switch. The hazard system therm al oscillator is then turned on 8B-12 CHASSIS ELECTRICAL 1. 2. 3. 4. Ig n itio n S w itc h C o n n e c to r N e u tra l S w itc h C o n n e c to r D im m e r S w itc h C o n n e c to r B ack Up S w itc h C o n n e c to r 5. 6. 7. 8. S te e rin g C o lu m n Turn S ig n a l In d ic a to r C o n n e c to r S to p Lam p S w itc h C o n n e c to r— W ith C ru is e C o n tro l S to p Lam p S w itc h C o n n e c to r— W ith o u t C ru is e C o n tro l Figure 10—Steering Column Connectors — RV Models which causes the front park lamps and the rear bright lamps to flash. BACKUP LAMP SYSTEM This shifted turning located circuit is turned on when the transm ission is into reverse. The backup switch is closed, thus on the backup lamps. The backup lamps are in the rear lamp assemblies. REAR LAMP HARNESS LAYOUTS Refer to Figures 10, 11, 12, 13, 14, 15,16, 17, 18 and 19. F-00837 CHASSIS ELECTRICAL 8B-13 10. 11. 12. 13. 14. 15. 16. M arker Lam p (Cream ) R u n n in g , Turn, S to p Lam p (Gray) G rou nd L e ft H a rn e ss C o n n e c to r R ig h t H a rn e s s C o n n e c to r L ic e n s e Lam p B ack Up Lam p F-00838 Figure 12—Rear Lamp Harness — Suburban 8B-14 CHASSIS ELECTRICAL 10. 11. 12. 15. 16. M arker L am p (Cream ) R u n n in g , Turn, S to p Lam p (Gray) G ro u n d L ic e n s e Lam p B ack Up Lam p F-00841 Figure 13—Rear Lamp Harness — Fleetside 13. L e ft H a rn e ss C o n n e c to r 15. L ic e n s e Lam p F-00842 Figure 14—Rear Lamp Harness — Stepside CHASSIS ELECTRICAL 8B-15 Figure 15—Rear Lamp Harness — Utility Vehicle 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. R ear L ig h tin g H a rn e ss C o n n e c to r R ear Lam p A s s e m b lie s R un, S top, Turn Lam p C o n n e c to r B a ck Up Lam p C o n n e c to r L ic e n s e Lam p C o n n e c to r F uel Tank S e nd e r C o n n e c to r S id e M arker Lam p C o n n e c to r G ro u n d Run, Stop, Turn, B a ck Up L a m p s C o n n e c to r LT GRN W ire G R N W ire BRN W ire L ic e n s e Lamp, F uel Tank S e n d e r C o n n e c to r 63. W H W ire 64. ORG W ire 65. P N K W ire 66. BRN W ire 67. R ear Lam p H arne ss 68 . Y E L W ire 69. DK G RN W ire 70. LT GRN W ire 71. In s tru m e n t Panel H a rne ss F-00872 Figure 16—Rear Lamp Harness — Van 8B-16 CHASSIS ELECTRICAL Figure 18—Tailgate Lamp Wiring Harness CHASSIS ELECTRICAL 8B-17 30. In s tru m e n t Panel H a rn e ss C o n n e c to r 31. C o n n e c to r — 4 S peed M an ua l T ra n s m is s io n 32. A u to m a tic T ra n s m is s io n 33. Back Up S w itc h 34. M anual T ra n s m is s io n Figure 19—RV Model Backup Lamp Switch and Wiring DIAGNOSIS OF THE REAR SIDE MARKER LAMPS PROBLEM One Lamp Won’t Work POSSIBLE CAUSE 1. Turn signal bulb burnt out (front lamp). 2. Side marker bulb burnt out. 3. Loose connection or open in wiring. Front Or Rear Lamps Won’t Work 1. Loose connection or open ground circuit. 2. Multiple bulbs burnt out. CORRECTION 1. Switch turn signals on. If the signal bulb does not light, replace the bulb. (Bulb filam ent provides ground path for m arker lamp bulb through the dark blue or brown wires.) 2. Replace the bulb. 3. Using a test lamp, check the brown wire term inal 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. 1. If the associated tail or park lamps do not operate, check all the connectors in the brown wire circuit. If the park and turn lamps are not working, repair the open ground connections. 2. Replace the burnt out bulbs. 8B-18 CHASSIS ELECTRICAL DIAGNOSIS OF THE REAR SIDE MARKER LAMPS (CONT.) PROBLEM POSSIBLE CAUSE All Lamps Won’t Work 1. Blown fuse. 2. Loose connection. 3. Open in wiring. 4. Defective lamp switch. CORRECTION 1. If the park and tail lamps do not oper­ ate, replace the blown fuse. If the new fuse blows, check for a short to ground between the fuse panel and the lamps. 2. Secure the c o n n e c to r to th e lam p switch. 3. C heck the tailla m p 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 w ir­ ing between the fuse and the battery. (Possible open fusible link.) 4. Check the lamp switch with a test lamp. If the test bulb lights at the orange wire but not at the brown wire, replace the light switch. DIAGNOSIS OF THE RUNNING, PARK AND LICENSE LAMPS PROBLEM POSSIBLE CAUSE CORRECTION One Side Not Working 1. Bulb burnt out. 2. Open connection at the bulb socket or the ground wire terminal. 1. Replace the bulb. 2. Jum per the bulb base socket connec­ tion to ground. If the bulb lights, repair the open ground circuit. Both Sides Not Working 1. Tail lamp fuse blown. 1. R eplace the fu se. If the new fuse blows, repair the short to ground in the brown wire circuit between the fuse panel through the lamp switch to the lamp. 2. Secure the c o n n e c to r at the lam p switch. 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 term inal, repair the open wiring between the lamp switch and the lamps. 4. If the test bulb lights at the lamp socket b ro w n w ire te rm in a l, re p la c e th e bulb(s).' 5. If the test bulb lights at the lamp switch orange wire but not at the brown wire, replace the defective lamp switch. 2. Loose connection. 3. Open wiring. 4. M ultiple bulb burnout. 5. Defective lamp switch. CHASSIS ELECTRICAL 8B-19 DIAGNOSIS OF THE TURN SIGNAL AND HAZARD SYSTEMS PROBLEM POSSIBLE CAUSE CORRECTION Turn Signals Not Working On One Side 1. Bulb(s) burnt out (flasher cannot be heard). 1. Turn the hazard warning system “ O N .” If one or more bulbs are inoperative, re­ place the bulbs as necessary. 2. Turn the hazard warning system on. If one or more bulbs are inoperative, use the test lamp and check the circuit at the bulb socket. If the test bulb lights, repair the open ground connection. If not, repair the open wiring between the bulb socket and the turn signal switch. 3. Turn the hazard warning system on. If all the front lamps and rear lamps oper­ ate, check for an improper bulb (see bulb chart). If the bulbs are OK, replace the defective turn signal switch. 4. Locate and repair the short to ground by disconnecting the front and rear cir­ cuits separately. 2. Open wiring or loose ground connector. 3. Improper bulb or defective turn signal switch. 4. Short to ground. (Flasher can be heard, no bulbs operate). Turn Signals Not Working 1. Blown turn signal fuse. 2. Defective flasher (located in conven­ ience center near steering column). 3. Loose connection. Hazard Warning Not Working 1. Blown stop-hazard fuse. 2. Faulty hazard warning flasher. (Located in the convenience center). 3. Open in the wiring or a defective turn signal switch. 1. Turn the hazard warning system on. If all the lam ps operate, replace the blown fuse. If the new fuse blows, re­ pair the short to ground between the fuse and the lamps. 2. If the turn signal fuse is OK and the hazard warning system will operate the lamps, replace the defective turn signal flasher. 3. Secure the steering column connector. 1. Switch the turn signals “ O N .” If the lights operate, replace the stop-hazard fuse if blown. If the new fuse blows, re­ pair the short to ground. (Could be in stop lamp circuit). 2. If the stop-hazard fuse is OK, switch the turn signals on. If the lamps oper­ ate, re p la c e th e d e fe c tiv e h aza rd flasher. 3. Using the test lamp, check the brown wire in the turn signal steering column connector. If the test bulb does not light, repair the open circuit between 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 term inals (It. blue, blue, ye llo w and d a rk green wires). 8B-20 CHASSIS ELECTRICAL DIAGNOSIS OF THE STOPLAMP SYSTEM PROBLEM One Bulb Not Working One Side Not Working (Multi-Bulb Design) POSSIBLE CAUSE Bulb burnt out. 1. Loose connection, open wiring or faulty bulbs. 2. Faulty directional signal switch or can­ celling cam. All Stoplamps Inoperative 1. Stop-hazard fuse is blown. 2. Open in the wire from the fuse to the stop-switch. 3. Stop-switch misadjusted or faulty. Will Not Turn Off Stop switch misadjusted or faulty. CORRECTION Replace the bulb. 1. Turn on the directional signal. If lamp does not operate, check the bulbs. If the bulbs are OK, check all connec­ tions. If the lam p still does not operate, use the test lamp and check for open wiring. 2. If the lamp will operate by turning the directional signal on, the switch is not centering properly during the cancel­ ling operation. Replace faulty cancel­ ling cam or directional signal switch. 1. R eplace the fu se. If the new fuse blows, repair the short to ground in the circuit between the fuse and the lamps. 2. Check for power at the brown wire at 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. 3. With the brake pedal pressed, check the white wire term inal in the steering column connector with a test lamp. If the bulb does not light, check the stop switch for proper adjustment. If the ad­ justm ent is OK, jum per the stop switch. If the stop lamps operate, replace the stop switch. Readjust the switch. If the switch still malfunctions, replace the switch. DIAGNOSIS OF THE BACKUP LAMP SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION One Lamp Not Working Or Intermittent 1. Loose or burnt out bulb. 2. Loose connection. 3. Open ground connections. 1. Secure or replace the bulb. 2. Tighten the connectors. 3. Repair the bulb ground circuit. Both Lamps Not Working Or Intermittent 1. G ear se le cto r sw itch is m isadjusted (open when shifter lever is in reverse po­ sition). 2. Loose connection or open circuit. 1. Readjust the gear selector switch. 3. Blown fuse. 2. Check all connectors. If OK, check the continuity of the circu it from the fuse to the lamp on either side of the fuse. Cor­ rect the open circuit from the battery to the fuse. 3. R eplace the fu se. If the new fuse blows, repair the short to ground in the circuit from the fuse through the gear selector or from the fuse through the g ea r s e le c to r o r the b a cku p lam p switch to the backup lamps. CHASSIS ELECTRICAL 8B-21 DIAGNOSIS OF THE BACKUP LAMP SYSTEM (CONT.) PROBLEM Both Lamps Not Working Or Intermittent (Continued) POSSIBLE CAUSE CORRECTION 4. Faulty gear selector or backup lamp switch. 4. W ith the ignition “ O N ,” check the switch term inals in the backup position with the test lamp. If the test bulb lights at the dark blue wire terminal but not at the light green wire terminal, replace the switch. 5. If the test bulb lights at the ignition switch battery terminal, but not at the output term inal, replace the ignition switch. 5. Faulty ignition switch. Lamp Will Not Turn Off Gear selector switch misadjusted (closed when the shift lever is not in the reverse position). Readjust the gear selector switch. Figure 20—RV Model Rear Lamp Assembly ON-VEHICLE SERVICE REAR LAMP BULB REPLACEMENT—RV MODELS |<~~»[ Remove or Disconnect (Figure 20) 1. Battery ground cable from the battery. 2. Lens retaining screws (86). 3. Lens (80). 4. Bulb (10, 11 or 16). -►+ Install or Connect (Figure 20) 1. Bulb (10, 11 or 16). 2. Lens (80). 3. Lens retaining screws (86). 4. Battery ground cable to the battery. 8B-22 CHASSIS ELECTRICAL REAR LAMP HOUSING AND SEAL REPLACEMENT-RV MODELS B 3 . H o u s in g (1 1 2 ). 4 . B u lb s o c k e t (5 6 ). Remove or Disconnect (Figures 20) B a tte r y g r o u n d c a b le fr o m 5 . B u lb . Install or Connect th e b a tte ry . L e n s r e ta in in g s c r e w s (8 6 ). 1 . B u lb . L e n s (8 0 ). H o u s in g r e ta in in g s c r e w s (8 1 ). H o u s in g (8 2 ). L a m p s (1 0 , 11 a n d 1 6 ). S e a l (8 4 ). Install or Connect (Figure 20) 2. B u lb s o c k e t ( 5 6 ) in to t h e h o u s in g (1 1 2 ). 3. H o u s in g (1 1 2 ). 4. H o u s in g r e ta in in g s c r e w s (1 1 3 ). 5. B a tte r y g r o u n d c a b le fr o m th e b a tte ry . LIGHT SWITCH REPLACEMENT 1. S e a l ( 8 4 ) . • In s ta ll t h e s e a l w ith t h e ta b s (8 3 ) p o in te d fo r w a r d . • A p p l y a d h e s i v e a t t h e f o u r c o r n e r s o f t h e s e a l in o r d e r t o h o ld t h e s e a l in p la c e . L a m p s (1 0 , 11 a n d 1 6 ). RV Models K-M Remove or Disconnect (Figures 24 and 25) 1. B a tte r y g r o u n d c a b le fr o m 2. H o u s in g (8 2 ). th e b a tte ry . K n o b a s s e m b ly (1 3 1 ). H o u s in g s c r e w s (8 1 ). L e n s (8 0 ). • P u s h in r e t a in e r p in o n t h e s w it c h b o d y . » P u ll o u t t h e k n o b a s s e m b ly . L e n s s c re w s (8 6 ). 3 . T rim p a n e l s c r e w s ( 1 2 1 ). B a tte r y g ro u n d c a b le to th e b a tte ry . 4 . T rim p a n e l (1 2 0 ). 5 . B e z e l (1 3 2 ). LICENSE LAMP REPLACEMENTRV MODELS 6 . L ig h t s w itc h h a r n e s s ( 1 3 0 ) . 7. L ig h t s w itc h (1 3 3 ). + + Remove or Disconnect (Figure 21) 1. B a tte r y g r o u n d c a b le fr o m th e b a tte r y . 2. H o u s in g r e ta in in g s c r e w s (9 2 ) o r b o lts (9 7 ). + 4* 1 . L ig h t s w itc h (1 3 3 ) . 2. 3. L en s. 4. Install or Connect (Figures 24 and 25) L ig h t s w itc h h a r n e s s (1 3 0 ). 3. B e z e l (1 3 2 ). B u lb . 4 . T rim p a n e l (1 2 0 ). Install or Connect (Figure 21) 5 . T rim p a n e l s c r e w s (1 2 1 ). 1 . B u lb . 6 . K n o b a s s e m b ly (1 3 1 ). 2. Lens. 3 . H o u s in g r e ta in in g s c r e w s ( 9 2 ) o r b o lts (9 7 ). 7. B a tte r y g r o u n d c a b le to th e b a tte r y . 4 . B a tte r y g r o u n d c a b le fr o m th e b a tte ry . REAR LAMP BULB REPLACEMENT—G VAN Remove or Disconnect (Figures 22 and 16) G-Van B Remove or Disconnect (Figures 26 and 27) 1. B a tte r y g r o u n d c a b le fr o m 2. B a tte r y g r o u n d c a b le fr o m th e b a tte ry . L e n s h o u s in g r e ta in in g s c r e w s (1 0 1 ). L a m p h o u s in g (1 0 0 ). B u lb s o c k e t ( 5 2 a n d 5 3 ) b y s q u e e z in g t h e r e te n t io n lo c k a n d r o ta tin g t h e s o c k e t c o u n te r c lo c k w is e . B u lb fr o m ♦ 4- th e b u lb s o c k e t (5 2 a n d 5 3 ). • P re s s th e s w itc h . knob a s s e m b ly • P u ll o u t t h e k n o b a s s e m b ly . r e ta in in g p in o n th e lig h t s w itc h 3 . T r im p la t e r e t a in in g s c r e w s ( 1 4 2 ) . 4 . T r im p la t e ( 1 4 0 ) . 5. B e z e l (1 4 3 ). Install or Connect 6 . L ig h t s w itc h ( 1 4 4 ) . 7. L ig h t s w itc h h a r n e s s ( 1 4 5 ) B u lb in to t h e b u lb s o c k e t. B u lb s o c k e t ( 5 2 a n d 5 3 ) in to th e h o u s in g . Install or Connect L a m p h o u s in g (1 0 0 ). L e n s h o u s in g r e ta in in g s c r e w s (1 0 1 ). B a tte r y g ro u n d c a b le to th e b a tte ry . 1 . L ig h t s w itc h (1 4 4 ). h a rn e s s (1 4 5 ) fro m th e 2 . L ig h t s w itc h (1 4 4 ). REAR MARKER LAMP BULB REPLACEMENT—G VAN |<-+| Remove or Disconnect (Figure th e b a tte ry . K n o b a s s e m b ly (1 4 1 ). 3. 2 3 ) B e z e l (1 4 3 ). 4 . T rim p la te (1 4 0 ). 5 . T r im p la te r e ta in in g s c r e w s (1 4 2 ). 1. B a tte r y g r o u n d c a b le fr o m th e b a tte r y . 6 . K n o b a s s e m b ly (1 4 1 ) in to t h e s w itc h (1 4 4 ). 2. 7. B a tte r y g r o u n d c a b le to th e b a tte r y . H o u s in g r e ta in in g s c r e w s (1 1 3 ). CHASSIS ELECTRICAL 8B-23 90. C o n n e c to r 91. R ear L am p 92. S c re w H a rn e s s 93. L a m p A s s e m b ly 94. T o o th e d W a s h e r 95. B o lt 96. N u t F -0 0 8 7 5 Figure 21—RV Model License Lamp 8B-24 CHASSIS ELECTRICAL BARK UP SWITCH REPLACEMENT Automatic Transmission Manual Trnsmission |++| Remove or Disconnect (Figure 28) Remove or Disconnect (Figure 28) 1. B a tte ry g ro u n d c a b le fr o m 2. th e b a tte ry . B a c k u p s w itc h h a r n e s s (1 6 4 ). 1 . B a tte r y g ro u n d c a b le fr o m t h e b a tte r y . 2 . S w itc h a s s e m b ly h a r n e s s . 3 . S w itc h a s s e m b ly . • P l a c e g e a r s e l e c t o r in n e u t r a l . • • 3 . B a c k u p s w itc h (1 6 3 ). 4 . S e a l (1 6 2 ). Install or Connect (Figure 28) 1. S e a l (1 6 2 ). 2. B a c k u p s w itc h (1 6 3 ). 3. B a c k u p s w itc h h a r n e s s (1 6 4 ). 4 . B a tte r y g ro u n d c a b le to th e b a tte ry . S q u e e z e th e s w itc h ta n g s (1 5 1 ) to g e th e r . L ift o u t t h e s w it c h a s s e m b l y ( 1 5 2 ) . ++• Install or Connect 1. S w itc h a s s e m b ly . • P l a c e g e a r s e l e c t o r in n e u t r a l . « A l i g n t h e a c t u a t o r ( 1 5 7 ) w i t h t h e c u t o u t ( 1 5 9 ) in t h e s te e r in g c o lu m n ja c k e t (1 5 8 ). • In s e r t th e ta n g s (1 5 1 ) in to th e r e c ta n g u la r h o le s (1 5 0 ). • P u s h d o w n o n th e s w itc h a s s e m b ly (1 5 2 ). Adjust tP • S w itc h b y m o v in g t h e g e a r s e le c to r to p a r k . T h e a c t u a t o r w ill r a c h e t , p r o v id in g p r o p e r s w itc h a d ju s tm e n t. 2. S w it c h a s s e m b l y h a r n e s s . Figure 23—Van Rear Marker Lamp CHASSIS ELECTRICAL 8B-25 Figure 24—RV Model Instrument Panel Trim Plate 131. L ig h t S w it c h 132. B ezel 133. K n o b A s s e m b ly Figure 25—RV Model Light Switch B -0 6 9 1 0 8B-26 CHASSIS ELECTRICAL Figure 27—Van Light Switch CHASSIS ELECTRICAL 8B-27 150. R e c ta n g u la r H o le 151. Tang 152. S w itc h 153. B a c k U p S w itc h T e r m in a l 154. B a c k U p S w itc h T e r m in a l 155. P a rk , N e u tr a l S w itc h T e r m in a l A s s e m b ly (A u to T r a n s .) 156. P a rk , N e u tr a l S w itc h 157. A c tu a to r 158. S te e r in g 159. C u to u t 160. S h ift T u b e C o lu m n T e r m in a l Jack et 161. M a n u a l T r a n s m is s io n 162. S eal 163. S w itc h 164. H a rn e s s F -0 0 8 8 1 Figure 28—Van Backup Lamp Switch FUSES—CIRCUIT BREAKERS SPECIFICATIONS T h e w ir in g c o m b in a tio n lin k s in t h e w e le c tr ic a lly c c irc u its a r e p r o te c te d fr o m s h o r t c irc u its b y a o f fu s e s , c ir c u it b r e a k e r s , a n d fu s ib le t h e r m a l ir in g its e lf. T h is g r e a t ly r e d u c e s t h e h a z a r d o f a u s e d f ir e s in t h e v e h ic le s . T h e h e a d la m p c irc u its a r e p r o te c te d b y a c ir c u it b r e a k e r in t h e lig h t s w i t c h . A n e l e c t r ic a l o v e r l o a d o n t h e b r e a k e r w ill c a u s e t h e l a m p s t o g o o n a n d o f f , o r in s o m e c a s e s t o r e m a in o ff. In a d d i t i o n t o a f u s e , t h e w i n d s h i e l d w i p e r m o t o r is a l s o p r o t e c t e d b y a c i r c u i t b r e a k e r . If t h e m o t o r o v e r h e a t s , d u e to o v e r lo a d in g c a u s e d b y h e a v y s n o w , e t c ., t h e w ip e r s w ill r e m a in s t o p p e d u n til t h e m o to r c o o ls . F u s e s lo c a t e d in t h e J u n c t io n o n th e d r iv e r s s id e a r e : B lo c k b e n e a t h th e d a s h RV TRUCK H e a te r , F r o n t A /C , G e n e r a t o r W a r n in g L a m p ..................................................................................................... 2 0 A m p Id le S to p S o le n o id , A u x . B a tte r y , R a d io , T im e D e la y R e la y , E m is s io n C o n tr o l S o le n o id , T r a n s m is s io n D o w n s h ift ( M 4 0 ) ..................................................................................................... 1 5 A m p C ig a r e t t e L ig h t e r , C lo c k , D o m e L a m p , C a r g o L a m p ...................................................................................... 2 0 A m p F u e l G a g e , B ra k e W a r n in g L a m p , T e m p e r a t u r e W a r n in g L a m p , O il P r e s s u r e W a r n i n g L a m p .......................................................... 4 A m p C o u rte s y L a m p , R o o f M a rk e r L a m p , L ic e n s e P la te L a m p , P a r k in g L a m p , S i d e M a r k e r L a m p , T a il L a m p , C l e a r a n c e L a m p ......................................................................... 2 0 A m p D ir e c tio n a l S ig n a l In d ic a t o r L a m p , S to p L a m p , T r a f f i c H a z a r d ................................................................ 1 5 A m p In s t r u m e n t C lu s t e r L a m p , H e a t e r D ia l L a m p , R a d io D ia l L a m p , C r u is e C o n tr o l L a m p , W i n d s h i e l d W i p e r S w i t c h L a m p ..................... 4 A m p 8B-28 CHASSIS ELECTRICAL C i g a r e t t e L i g h t e r , D o m e L a m p , S p o t L a m p ................1 5 A m p W i n d s h i e l d W i p e r / W a s h e r ....................................................... 2 5 A m p C r u is e C o n tr o l, R e a r W in d o w A u x ., F u e l T a n k , T a c h o m e te r, B a c k -u p L a m p , D ir e c tio n a l S ig n a l In d ic a to r L a m p , D ir e c tio n a l S ig n a l L a m p , H e a d la m p B u z z e r ................................................................................................. 1 5 A m p F u e l G a g e , B ra k e W a rn in g L a m p , T e m p e r a tu r e W a rn in g L a m p , G e n e r a to r W a r n in g L a m p , O il P r e s s u r e W a r n in g L a m p . . . .3 A m p S t o p L a m p , T r a f f i c H a z a r d ....................................................... 1 5 A m p A u x ilia r y B a tte r y , B a c k in g L a m p , P TRUCK H e a t e r * , A i r C o n d i t i o n i n g * ....................................................... 2 5 A m p In s tr u m e n t C lu s te r L a m p , W in d s h ie ld W i p e r S w i t c h L a m p ...................................................................... 3 A m p D ir e c tio n a l S ig n a l In d ic a to r L a m p , S to p L a m p , T r a f f i c H a z a r d ................................................................ 1 5 A m p F u e l G a g e , B r a k e W a r n i n g L a m p ...........................................3 A m p L ic e n s e P la te L a m p , P a r k in g L a m p , S i d e M a r k e r L a m p , T a il L a m p , C l e a r a n c e L a m p , I d e n t i f i c a t i o n L a m p ........................ 1 5 A m p W i n d s h i e l d W a s h e r / W i p e r ....................................................... 2 5 A m p C ig a r e tte L ig h t e r * , C lo c k * , C o u r t e s y * , D o m e L a m p * .................................................................................. 1 5 A m p A u x ilia r y B a t t e r y * , B a c k -u p L a m p , R a d i o ..................................................................................................... 1 5 A m p Id le S to p S o le n o id , C r u is e C o n t r o l* , D ir e c tio n a l S ig n a l L a m p , T im e D e la y R e la y , E m is s io n C o n t r o l S o le n o id , T r a n s m i s s i o n D o w n s h i f t ( M 4 0 ) ....................................... 1 0 A m p I n - l in e f u s e s a r e l o c a t e d in t h e a u x il i a r y h e a t e r c ir c u it s (C -K -P m o d e ls ) a n d u n d e r h o o d la m p , fr o n t a n d r e a r A /C c ir c u its (C -K m o d e ls ). * W h e n in c o r p o r a t e d b y b o d y b u ild e r . D o n o t u s e f u s e s o f h ig h e r a m p e r a g e re c o m m e n d e d a b o v e . T h e fo llo w in g w ir in g h a rn e s s e s a re th a n th o s e p ro te c te d by a “ f u s ib l e l i n k ” w h ic h is a s p e c i a l w i r e i n c o r p o r a t e d in t h e c ir c u it h e a d la m p h i- b e a m in d ic a to r , h o r n , a ir c o n d it io n in g h ig h b lo w e r , ig n it io n c ir c u it s ( R V - P m o d e ls ) s t a r t e r s o le n o id (p u ll-in a n d h o ld ) c ir c u it ( R V m o d e ls ). S h o u ld a n e le c t r ic a l o v e r lo a d o c c u r , th is w ir e d a m a g e to th e m a jo r h a rn e s s . w ill fa il a n d p re v e n t G TRUCK H e a t e r , A / C ........................................................................................... 2 5 A m p Id le S to p S o le n o id , C r u is e C o n tr o l, D ir e c t io n a l S ig n a l L a m p , D ir e c tio n a l S ig n a l In d ic a to r L a m p , T r a n s m is s io n D o w n s h i f t ( M - 4 0 ) ......................................................................... 1 0 A m p R a d i o D i a l L a m p , R a d i o ....................................................... 1 5 A m p In s tr u m e n t C lu s t e r L a m p , H e a t e r D ia l L a m p , T ra n s m is s io n C o n tr o l L a m p w ith T ilt W h e e l, C r u is e C o n tr o l L a m p , W /S W ip e r S w itc h L a m p , H e a d l a m p B u z z e r ..........................................................................3 A m p L ic e n s e L a m p , P a r k in g L a m p , S id e M a r k e r L a m p , T a i l L a m p ....................................................... 1 5 A m p W i n d s h i e l d W i p e r .............................................................................2 5 A m p A n in - l in e f u s e is l o c a t e d in t h e A m m e t e r a n d t h e a u x ilia r y h e a t e r c irc u its . D o n o t u s e fu s e s o f h ig h e r a m p e r a g e r a tin g t h a n t h o s e re c o m m e n d e d a b o v e . T h e f o llo w in g w ir in g h a r n e s s e s a r e p r o te c te d b y a “ f u s ib l e l in k ” w h ic h is a s p e c i a l w i r e i n c o r p o r a t e d in t h e c ir c u it, ig n itio n , h o r n a n d h e a d la m p h i- b e a m in d ic a to r c ir c u it s , a ir c o n d it io n in g h ig h b lo w e r . S h o u ld a n e le c t r ic a l o v e r lo a d o c c u r , t h is w ir e w ill f a il a n d p r e v e n t d a m a g e to th e m a jo r h a r n e s s . CIRCUIT BREAKERS DEVICE OR CIRCUIT PROTECTED MODELS AMPS. R V -P -G 15 R V 30 G 35 H e a d la m p a n d p a r k in g la m p c ir c u it T a ilg a te w in d o w m o to r R e a r A /C (C 6 9 o v e rh e a d ) LOCATION L am p s w itc h D ash (fo r w a r d s id e ) D ash (fo r w a r d s id e ) CHASSIS ELECTRICAL 8B-29 LAMP SPECIFICATIONS LAMP BULB DATA RV-P TRUCK Q U A N .T R A D E # U S E D IN LAMP BULB DATA G TRUCK POW ER U S E D IN Q U A N .T R A D E # 2 O il p r e s s u r e in d ic a to r la m p 1 161 1 C P G e n e r a t o r in d ic a to r la m p 1 194 2 C P I n s t r u m e n t c l u s t e r l a m p s 11 1 161 1 C P 3 C P H e a d la m p b e a m la m p 1 161 1 C P 168 3 C P P a r k , d ir e c tio n a l s ig n a l la m p s 2 1157 3 -3 2 C P T a il, s t o p la m p s 2 1157 3 -3 2 C P 2 1157 3 -3 2 C P L ic e n s e L a m p 4 1 67 4 C P D ir e c tio n a l s ig n a l (fr o n t p a r k la m p s )6 2 1157 3 -3 2 C P 1 1 1004 2 1 1 -2 15 C P 12 C P O il P r e s s u r e in d ic a to r la m p 1 1 168 3 C P G e n e r a t o r in d ic a to r la m p 1 1 168 3 C P In s tr u m e n t c lu s te r la m p s 2 5 168 H e a d la m p b e a m la m p 1 L a m p a s s e m b ly — ta il & s to p la m p in d ic a to r H ead Lam ps 2 6014 5 0 -6 0 W T e m p e r a t u r e in d ic a to r la m p 1 168 3 C P D ir e c t io n a l s ig n a l in d ic a to r la m p 2 168 3 C P C le a r a n c e a n d m a r k e r la m p s 4 3 C P R o o f m a r k e r la m p s 5 5 168 194 B r a k e w a r n in g in d ic a to r la m p 1 168 T r a n s m is s io n c o n tr o l (a u to ) B a c k in g la m p (e x c . m o to r h o m e ) 1 2 1445 1156 2 1 1 -2 POW ER D o m e la m p s D om e Lam ps: C ab U tility & S u r b u r b a n 12 C P in d ic a to r L ic e n s e la m p 1 67 4 C P H e a d l a m p s 12 2 6014 5 0 -6 0 W T e m p e r a t u r e in d ic a to r la m p 1 194 2 C P D ir e c tio n a l s ig n a l in d ic a to r la m p 2 194 2 C P M a r k e r la m p s 4 168 3 C P B r a k e w a r n in g in d ic a to r la m p 1 194 2 C P B a c k -u p la m p 2 1156 32 C P R a d io d ia l la m p 1 1893 2 C P 3 C P H e a t e r o r A /C Iliu m , la m p 1 194 2 C P 0 .7 C P T r a n s m is s io n c o n tr o l w /tilt w h e e l Iliu m , la m p 1 1445 0 .7 C P 2 C P 32 C P W /S w ip e r s w itc h la m p 1 161 1 C P T r a n s m is s io n c o n tr o l Iliu m , la m p 1 73 .3 C P C h o k e h e a t e r in d ic a to r la m p 1 1893 2 C P S e a t b e lt w a r n in g la m p 1 194 2 C P B a c k in g la m p (m o to r h o m e ) 2 1295 50 C P H e a t e r o r A /C Iliu m , la m p 1 161 1 C P C o r n e r m a r k e r la m p s 7 67 4 C P In s tr u m e n t c lu s te r la m p s 9 5 194 2 C P C a r g o la m p (R V c a b ) 1 1142 21 C P I n s t r u m e n t c l u s t e r l a m p s 10 1 168 3 C P R a d io d ia l la m p — A M — A M /F M 1 1 216 216 1 C P 1 C P C o u r te s y la m p 1 1003 15 C P W in d s h ie ld w ip e r s w itc h la m p 1 161 1 C P (p la tfo r m ) C lo c k la m p 1 168 3 C P R e a r id e n t ific a t io n 7 la m p 10 1895 2 C P U n d e r h o o d la m p 1 93 15 C P S e a t b e lt w a r n in g la m p 1 168 3 C P C a r g o /d o m e la m p 2 2 1 1 -2 12 C P F o u r w h e e l d r iv e in d ic a to r la m p 1 161 1 C P C h o k e h e a t e r in d ic a to r la m p 1 168 3 C P 1O n R V i n s t r u m e n t c l u s t e r s o n l y . 23 l a m p s u s e d o n i n s t r u m e n t c l u s t e r o n P m o d e l s o r R V w / o gages. 3D o u b l e f i l a m e n t s e a l e d b e a m 6 0 W h i g h b e a m , 5 0 W l o w beam . "2 la m p s u s e d w ith s te p b u m p e r a n d P m o d e ls . 54 r e q u i r e d o n P m o d e l s . 61 1 5 7 N A , 2 . 2 - 2 4 C P o n R V m o d e ls . 7W i d e s i d e P i c k u p . 8‘ P ’ t r u c k o n ly . 9‘G ’ m o d e l w /o g a g e s ; 1 l a m p w it h g a g e s . 10‘ G ’ m o d e l w / o g a g e s ; 3 l a m p s w i t h g a g e s . ” ‘G ’ m o d e l w ith g a g e s o n ly . 12D o u b l e f i l a m e n t s e a l e d b e a m 6 0 W h i g h b e a m , 5 0 W beam . lo w 8B-30 CHASSIS ELECTRICAL 8C-1 SECTION 8C INSTRUMENT PANEL CONTENTS SUBJECT PAGE Description........................................................................................................................................................... 8C- 2 Speedometer....................................................................................................................................................8C- 2 Fuel Gage......................................................................................................................................................... 8C- 2 Oil Pressure G age............................................................................................................................................ 8C- 2 Temperature Gage............................................................................................................................................ 8C- 2 Ignition Switch..................................................................................................................................................8C- 2 Lamp Switch......................................................................................................................................................8C- 2 Diagnosis Of Speedometer System.....................................................................................................................8C- 3 Diagnosis Of The Fuel Gage................................................................................................................................ 8C- 4 Diagnosis Of The Oil Pressure Gage...................................................................................................................8C- 5 Diagnosis Of The Temperature G age.................................................................................................................8C- 6 On Vehicle Service.............................................................................................................................................. 8C- 7 Speedometer Replacement.............................................................................................................................. 8C- 7 Speedometer Cable Core Replacement........................................................................................................... 8C- 7 Fuel Gage Replacement.................................................................................................................................. 8C- 9 Fuel Sender Unit Replacement.........................................................................................................................8C-11 Temperature Gage Replacement.....................................................................................................................8C-11 Temperature Gage Sensor Replacement......................................................................................................... 8C-13 Oil Pressure Gage Replacement.......................................................................................................................8C-13 Oil Pressure Gage Sensor Replacement......................................................................................................... 8C-14 Voltmeter Replacement.................................................................................................................................... 8C-14 Instrument Cluster Replacement.....................................................................................................................8C-15 Laminated (Printed) Circuit Replacement....................................................................................................... 8C-16 Ignition Switch Replacement...........................................................................................................................8C-16 Lamp Switch Replacement...............................................................................................................................8C-16 Special Tools........................................................................................................................................................8C-16 X-8732, Sec. 8C, Service Manual 8C-2 INSTRUMENT PANEL DESCRIPTION SPEEDOMETER T h e s p e e d o m e te r on th e in s tr u m e n t p an el is a m e c h a n ic a l t y p e t h a t is d r iv e n b y a c a s e d c a b le w h ic h is c o n n e c t e d to t h e t r a n s m is s io n . T h e s p e e d o m e t e r is lo c a t e d in t h e c e n t e r o f t h e i n s t r u m e n t p a n e l . R e f e r to fig u r e 1 fo r d ia g n o s is . FUEL GAGE T h e f u e l g a g e is a n e le c t r ic a l, c u r r e n t s e n s in g t y p e o f in d ic a t o r . It h a s t w o c o ils in it. O n e c o il s e t s u p a c o n s t a n t m a g n e t ic f ie ld . T h e o t h e r c o il h a s a v a r y in g m a g n e t ic f ie ld w h ic h is v a r ie d b y t h e r e o s t a t a t t a c h e d to a f lo a t in t h e f u e l t a n k . A m a g n e t , a t t a c h e d to a p o in t e r , is lo c a t e d b e t w e e n t h e t w o c o ils . T h e m a g n e t w ill e s t a b l is h a p o s it io n w h ic h is c o n t r o lle d b y t h e m a g n e t ic f ie ld s o f t h e t w o c o ils . R e f e r to fig u r e 2 fo r d ia g n o s is . OIL PRESSURE GAGE T h e o il p r e s s T h e g a g e is e l e w h ic h c o n tr o ls R e fe r to fig u re u r e g a g e d is p la y s t h e e n g i n e o il p r e s s u r e . c t r ic a l. T h e s e n d e r is a v a r ia b le r e s is t a n c e th e c u r r e n t p a s s in g th ro u g h th e g a g e . 3 fo r d ia g n o s is . ENGINE CONTROL IGNITION SWITCH O n t h e R V a n d G m o d e ls , t h e ig n it io n s w it c h is lo c a t e d in t h e s t e e r i n g c o lu m n o n t h e r ig h t h a n d s i d e j u s t b e lo w t h e s t e e r in g w h e e l. T h e e le c t r ic a l s w it c h in g p o r tio n o f t h e a s s e m b ly is s e p a r a t e f r o m t h e k e y a n d lo c k c y lin d e r . H o w e v e r , b o t h a r e s y n c h r o n iz e d a n d w o r k in c o n ju n c t io n w ith e a c h o th e r th r o u g h t h e a c tio n o f t h e a c tu a to r ro d a s s e m b ly . F o r a c o m p le t e e x p la n a t io n o f t h e k e y a n d lo c k c y lin d e r , a n d th e a c tu a to r ro d a s s e m b ly , r e fe r to S T E E R IN G C O L U M N , (S e c . 3 B 4 ). T h e ig n it io n a n d s t a r t in g s w it c h is k e y o p e r a t e d t h r o u g h t h e a c t u a t o r r o d a s s e m b ly to c lo s e t h e ig n itio n p r im a r y c ir c u it a n d to e n e r g iz e t h e s ta r tin g m o to r s o le n o id fo r c r a n k in g . O n t h e P m o d e ls t h e ig n it io n s w it c h is lo c a t e d o n t h e in s tr u m e n t p a n e l. T h e s w itc h c o n tr o ls t h e e n g in e s ta r t fu n c tio n s , a n d th e a c c e s s o r ie s . T h e c o n n e c t io n s to t h e ig n itio n s w itc h a r e s h o w W ir in g D ia g r a m s B o o k le t. T h e c h a r ts in c lu d e d d ia g r a m s s h o w h o w th e s w it c h e s a r e in te r n a lly c o in e a c h s w it c h p o s it io n . ru n a n d n in t h e o n th e n n e c te d LAMP SWITCH TEMPERATURE GAGE T h is g a g e d is p la y s t h e t e m p e r a t u r e o f t h e e n g in e c o o l a n t . I t i s a n e l e c t r i c a l g a g e . T h e g a g e ’s s e n d e r i s a v a r ia b le r e s is t a n c e t h a t c o n tr o ls t h e c u r r e n t p a s s in g th r o u g h th e g a g e . R e f e r to fig u r e 4 fo r d ia g n o s is . T h e la m p s w itc h c o n tr o ls th e h e a d la m p s , m a r k e r la m p s , r u n n in g la m p s a n d p a r k in g la m p s . T h e s w itc h a ls o c o n tr o ls th e d o m e la m p s a n d in s t r u m e n t illu m in a tio n la m p s . th e lig h t le v e l o f th e INSTRUMENT PANEL 8C-3 DIAGNOSIS—SPEEDOMETER SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Noisy Kinked, pinched or burned casings. Replace both the cable and casing. Recheck for noise. Bent cable tips. Replace both the cable and casing. Recheck for noise. Improper or insufficient lubrication of cable. Lubricate cable core with P/N 6478535 or equivalent. Pack ferrule with grease. Faulty driven gear or rough drive gear. Remove driven gear assembly 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. Whine Oversize driven gear stem in transmission binds with adapter. Replace driven gear and stem. Buzzing sound with manual transmission. Shift linkage vibration. Adjust transmission shift linkage. Tick or ringing sound with jumpy pointer between 0 and 30 MPH. Faulty cable. Replace cable. Sticky speedometer pointer. Speedometer pointer is bent and rubs. Remove speedometer cluster or lens and straighten pointer. Recheck speedometer operation. Incorrect calibration. Wrong transmission adapter, drive gear or sleeve. Check speedometer gear reference for correct application and replace if necessary. n Oversize or undersize tires. Check calibration using correct tire size. ii Faulty speedometer head. Remove speedometer for repair. 11 it 11 F -0 0 9 3 0 Figure 1—Diagnosis of the Speedometer 8C-4 INSTRUMENT PANEL DIAGNOSIS OF THE FUEL GAGE DISCONNECT FUEL GAGE SENDER WIRE IN REAR COMPARTMENT J-24538-A TESTER TO SENDER WIRE & TO GROUND TURN IGNITION ON GO TO STEP 2 GAGE RESPONDS TO TESTER ACCURATELY GO TO STEP 3 GAGE RESPONDS BUT NOT ACCURATELY GO TO STEP 6 GAGE DOES NOT RESPOND GO TO STEP 4 REPLACE SENDER CHECK REAR COMPARTMENT CONNECTOR & WIRES TO SENDER OK REPAIR WIRE OR CONNECTOR DISCONNECT FRONT BODY CONNECTOR. CONNECT J-24538-A TESTER TO LEAD THAT GOES TO THE GAGE. REMOVE GAGE CHECK FOR BAD CONNECTIONS AT GAGE TERMINALS OR INST CLUSTER CONNECTOR GAGE READS BETWEEN 1/4 & 1/2 WITH 90 OHMS FROM J-24538-A GAGE RESPONDS TO TESTER ACCURATELY CHECK WIRING BETWEEN REAR COMPARTMENTS FRONT BODY CONNECTOR GAGE DOES NOT RESPOND GOOD CONNECTIONS BAD CONNECTIONS GO TO STEP 5 REPLACE GAGE REPAIR CONNECTIONS & REINSTALL GAGE NUTS LOOSE REMOVE GAGE AND CHECK FOR LOOSE NUTS AT GAGE TERMINALS TIGHTEN NUTS & REINSTALL GAGE NUTS TIGHT GAGE IS INACCURATE IN OTHER WAYS REPLACE GAGE F-00885 Figure 2—Diagnosis of the Fuel Gage INSTRUMENT PANEL 8C-5 Figure 3—Diagnosis of the Oil Pressure Gage 8C-6 INSTRUMENT PANEL DIAGNOSIS OF THE TEMPERATURE GAGE DISCONNECT TEMP GAGE SENDER WIRE TURN IGNITION ON GO TO STEP 2 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 "H O T” END OF SCALE GO TO STEP 5 DISCONNECT TEMP. GAGE LEAD AT ENGINE HARNESS CONNECTOR. CONNECT J-24538-A TESTER TO LEAD THAT GOES TO THE GAGE REMOVE GAGE REMOVE GAGE GAGE RESPONDS TO TESTER ACCURATELY GAGE DOES NOT RESPOND GOOD CONNECTIONS CHECK FOR BAD CONNECTIONS AT GAGE TERMINALS OR INST. CLUSTER CONNECTOR OR LOOSE NUTS AT GAGE TERMINALS BAD CONNECTIONS CHECK FOR LOOSE NUTS AT GAGE TERMINALS OR LACK OF GROUND CONNECTION TO GAGE GOOD CONNECTIONS BAD CONNECTIONS CHECK WIRING BETWEEN SENDER CONNECTOR & ENGINE HARNESS CONNECTOR GO TO STEP 4 REPLACE GAGE REPAIR CONNECTIONS & REINSTALL GAGE REPLACE GAGE REPAIR CONNECTIONS & REINSTALL GAGE F-00937 Figure 4—Diagnosis of the Temperature Gage INSTRUMENT PANEL 8C-7 ON VEHICLE SERVICE SPEEDOMETER REPLACEMENT El ♦ i l Install or Connect 1. S p e e d o m e te r (8 0 ). S e r v ic in g o f th e s p e e d o m e t e r a s s e m b ly s h o u ld o n ly b e p e r f o r m e d b y t r a in e d t e c h n ic ia n s h a v in g t h e p r o p e r te s t e q u ip m e n t. W h e n r e p la c in g a s p e e d o m e te r o r o d o m e te r a s s e m b ly , t h e la w r e q u ir e s t h e o d o m e t e r r e a d in g o f t h e r e p la c e m e n t u n it to b e s e t to r e g is te r th e s a m e m ile a g e a s th e p r io r o d o m e t e r . If t h e s a m e m i le a g e c a n n o t b e s e t , t h e la w r e q u ir e s th e r e p la c e m e n t o d o m e t e r b e s e t to z e r o a n d a l a b e l b e i n s t a l l e d o n t h e d r i v e r ’s d o o r f r a m e t o s h o w t h e p r e v io u s o d o m e te r r e a d in g a n d th e d a te o f r e p la c e m e n t. 2 . S p e e d o m e te r c a b le a s s e m b ly . 3 . T w o h e x h e a d s c r e w s a n d r u b b e r g r o m m e ts t h a t h o ld th e s p e e d o m e te r a s s e m b ly to th e c lu s te r c o v e r. 4 . S p e e d o m e t e r d ia l r e ta in in g s c r e w s . 5 . In s tr u m e n t c lu s te r . R e fe r to R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t C lu s te r 6 . B a tte r y g ro u n d c a b le to th e b a tte ry . P MODELS Remove or Disconnect RV MODELS 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . |++| Remove or Disconnect (Figures 5 and 6) 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . 2 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). 2 . In s tr u m e n t c lu s te r . R e fe r to R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t C lu s te r 3 . L a m p s o c k e t a s s e m b lie s . 4 . L a m in a t e d c ir c u it r e ta in in g n u ts . 5 . L a m in a te d c ir c u it. 3 . R a d io c o n tro l k n o b s . 6 . C lu s t e r c a s e r e ta in in g s c r e w s . 4 . C lo c k a d ju s te r s te m . 7. C lu s te r c a s e fr o m th e b e z e l. 5 . In s tr u m e n t c lu s te r b e z e l (4 3 ). 8 . S p e e d o m e t e r r e t a in in g b o lts . 6 . S t e e r in g c o lu m n c o v e r. 9 . S p e e d o m e te r fro m th e c lu s te r c a s e . 7. In s tr u m e n t c lu s te r le n s (4 2 ). Install or Connect 8 . T r a n s m is s io n s h ift in d ic a t o r ( 4 1 ) . 9 . R e ta in e r (4 4 ). 1. S p e e d o m e te r to th e c lu s te r c a s e . 1 0 . S p e e d o m e t e r c a b le . 2 . S p e e d o m e t e r r e ta in in g b o lts . • D e p r e s s s p r in g c lip ( 3 0 ). • R e m o v e c a b le a n d c a s e fr o m th e s p e e d o m e te r (3 6 ). 3. C lu s te r c a s e to th e b e z e l. 4 . C lu s t e r c a s e r e ta in in g s c r e w s . 5 . L a m in a te d c ir c u it. 6 . L a m in a t e d c ir c u it r e ta in in g n u ts . -►+ Install or Connect (Figures 5 and 6) 7. L a m p s o c k e t a s s e m b lie s . 1. S p e e d o m e te r (3 6 ). 8 . In s tr u m e n t c lu s te r . R e fe r to R e p l a c e m e n t ” in t h is s e c t io n . 2 . S p e e d o m e te r c a b le a s s e m b ly . • P u s h t h e c a b le a s s e m b ly in to t h e s p e e d o m e t e r h e a d , r o ta tin g t h e c a b le a s s e m b ly , u n til th e s p r in g c lip e n g a g e s . “ In s tr u m e n t C lu s te r 9 . B a tte ry g ro u n d c a b le fro m th e b a tte ry . SPEEDOMETER CABLE CORE REPLACEMENT 3 . R e ta in e r (4 4 ). 4 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ). 5 . In s tr u m e n t c lu s te r le n s (4 2 ). 6 . S t e e r in g c o lu m n c o v e r. ALL VEHICLES 7. In s tr u m e n t c lu s te r b e z e l (4 3 ). |++| Remove or Disconnect (Figures 5, 8 „ 9, and 10) 8 . C lo c k a d ju s te r s te m . 9 . R a d io c o n tro l k n o b s . 1 0 . H e a d la m p s w itc h k n o b a s s e m b ly . 1. B a tte ry g r o u n d c a b le fr o m th e b a tte ry . 1 1. B a tte r y g r o u n d c a b le to th e b a tte r y . 2 . S p e e d o m e te r c a b le a s s e m b ly fr o m th e s p e e d o m e te r. G MODELS 3. Remove or Disconnect (Figure 7) C o m p r e s s t h e s p r in g c lip • P u ll t h e c a b le a s s e m b ly f r o m t h e s p e e d o m e t e r . C a b le c o re . • 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . 2 . In s t r u m e n t c lu s te r. R e f e r to R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t C lu s te r 3 . S p e e d o m e t e r d ia l r e t a in in g s c r e w s . 4 . T w o h e x h e a d s c r e w s a n d r u b b e r g r o m m e t s s e c u r in g th e s p e e d o m e te r a s s e m b ly to th e c lu s te r c o v e r. 5 . S p e e d o m e te r c a b le a s s e m b ly fr o m th e s p e e d o m e te r. 6 . S p e e d o m e te r (8 0 ). + « - (30). • P u ll t h e c o r e o u t o f t h e s p e e d o m e t e r e n d o f t h e c a s in g . If t h e c a b le c o r e is b r o k e n , r e m o v e t h e lo w e r p ie c e o f t h e c o r e fr o m t h e tr a n s m is s io n e n d o f th e c a s in g . Install or Connect (Figures 5, 8, 9, and 10) L u b r i c a n t in t h e c a s i n g a n d o n t h e c o r e . C o r e in to th e s p e e d o m e te r e n d o f th e c a s in g . T u rn th e c o r e t o e n g a g e t h e d r i v e g e a r in t h e t r a n s m is s io n . 8C-8 INSTRUMENT PANEL 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. S peedom eter Cable Spring Clip Lamp B ulb Socket Lam inated C ircu it C luster Case In d ica to r Lamp F ilte r (Turn Signal) Fuel Gage S peedom eter Tem perature Gage Brake W arning Lamp F ilter A m m eter Oil Pressure Gage Transm ission S h ift In dica to r In strum en t C lu ster Lens Instru m en t C luster Bezel R etainer F -0 0 9 4 5 Figure 5—RV Model Instrument Panel INSTRUMENT PANEL 8C-9 ^ "-< ^ --6 0 32. 33. 50. 51. 52. 53. 54. 55. 56. Lam inated C ircu it C luster Case Fuel Gage C lip Lamp Socket Hole Speedom eter Hole High Beam In d ica to r Lamp O il Pressure In d ic a to r Lamp Engine Temperature W arning Lamp Brake W arning Lamp 57. 58. 59. 60. 61. 62. 63. 64. Charging System Lamp Instrum ent C lu ste r C onnecto r A m m eter C lip Brake W arning Lam p/C lock Temperature Gage C lip Fuel Gage C lip Turn Signal In d ica to r Lamp Brake W arning Lamp F -0 0 9 5 3 Figure 6—RV Model Laminated C ircuit 3 . S p e e d o m e t e r c a b le a s s e m b ly in to t h e h e a d u n til t h e s p r in g c lip ( 3 0 ) e n g a g e s . s p e e d o m e te r 4 . B a tte r y g r o u n d c a b le to t h e b a tte r y . a Install or Connect (Figures 5 and 6) 1. F u e l g a g e (3 5 ). 2 . F u e l g a g e a tta c h in g s c re w s . 3 . C a s e fro n t c o v e r (4 4 ). FUEL GAGE REPLACEMENT 4 . T r a n s m is s io n s h ift in d ic a to r (4 1 ). 5 . In s tr u m e n t c lu s te r le n s (4 2 ). Remove or Disconnect (Figures 5 and 6) 6 . S te e r in g c o lu m n c o v e r. 7. In s tr u m e n t c lu s te r b e z e l (4 3 ). 1. B a tte r y g r o u n d c a b le fr o m th e b a tte r y . 2 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). 8 . C lo c k a d ju s te r s te m . 9 . R a d io c o n tro l k n o b s . 3 . R a d io c o n tro l k n o b s . 1 0 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). 4 . C lo c k a d ju s te r s te m . 1 1. B a tte r y g r o u n d c a b le to th e b a tte r y . 5 . In s tr u m e n t c lu s te r b e z e l (4 3 ). 6 . S t e e r in g c o lu m n c o v e r. 7. In s tr u m e n t c lu s te r le n s (4 2 ). 8 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ). 9 . C a s e fro n t c o v e r (4 4 ). G MODELS Remove or Disconnect (Figure 7) 1. B a tte r y g r o u n d c a b le fr o m th e b a tte ry . 1 0 . F u e l g a g e a tta c h in g s c re w s . 2 . In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . 11. F u e l g a g e (3 5 ). 3. L e n s (8 3 ). ‘‘In s tr u m e n t 8C-10 INSTRUMENT PANEL 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. B olt (#8-32 x 7/ie") S peedom eter M ounting B ushing Nut Flat W asher Lam inated C ircu it Screw (#8-18 x 7/ie") Engine C oolant Temperature Gage V oltm eter Screw (#8-16 x 7/ie") R etainer 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. Speedom eter Gage Mask Lens Retainer Lens Bezel Fuel Gage Lamp Engine Oil Pressure Gage Instrum ent C luster W ith Gages Instrum ent C luster W ith o u t Gages F -0 0 9 6 0 Figure 7—Van Instrum ent Panel P MODELS 4 . L e n s r e ta in e r (8 2 ). 5 . L a m in a t e d c ir c u it r e ta in in g n u ts . Remove or Disconnect 6 . L a m in a te d c ir c u it (7 4 ) fr o m t h e r e ta in e r (7 9 ). B a tte r y g r o u n d c a b le fr o m th e b a tte r y . In s tr u m e n t 7. F u e l g a g e r e ta in in g n u ts (7 2 ). c lu s te r. R e fe r to R e p l a c e m e n t ” in t h is s e c t i o n . 8. F u e l g a g e . L a m p s o c k e t a s s e m b lie s . L a m in a te d c ir c u it r e ta in in g n u ts . ■H" Install or Connect (Figure 7) L a m in a te d c irc u it. C lu s t e r c a s e r e ta in in g s c r e w s . 1. F u e l g a g e to th e la m in a te d c ir c u it. C lu s te r c a s e fr o m th e b e z e l. 2 . F u e l g a g e r e ta in in g n u ts (7 2 ). 0 3 . L a m in a te d c ir c u it (7 4 ) to th e r e ta in e r (7 9 ). 4 . L a m in a t e d c ir c u it r e ta in in g n u ts . 5 . L e n s r e ta in e r (8 2 ). F u e l g a g e r e t a in in g b o lts . F u e l g a g e fro m th e c lu s te r c a s e . Install or Connect 1. F u e l g a g e to th e c lu s te r c a s e . 2 . F u e l g a g e r e t a in in g b o lts . 6. L e n s (8 3 ). 3 . C lu s te r c a s e to th e b e z e l. 7. In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . 8 . B a tte r y g ro u n d c a b le to th e b a tte ry . “ In s tru m e n t 4 . C lu s t e r c a s e r e ta in in g s c r e w s . 5 . L a m in a te d c irc u it. 6 . L a m in a t e d c ir c u it r e ta in in g n u ts . “ In s tr u m e n t C lu s te r INSTRUMENT PANEL 8C-11 2. Speedom eter Cable C o nnecto r 4. Transfer Case F -0 0 8 8 3 Figure 9—Speedom eter Cable—Four Wheel Drive 7. L a m p s o c k e t a s s e m b lie s . 8 . In s tr u m e n t c lu s te r . R e fe r to “ In s tr u m e n t R e p l a c e m e n t ” in t h is s e c t io n . 9 . B a tte ry g ro u n d c a b le fr o m th e b a tte ry . C lu s te r FUEL SENDER UNIT REPLACEMENT ALL MODELS R e fe r to F U E L S Y S T E M S (S E C . 6 C ) o r th e F U E L A N D E M IS S IO N S M a n u a l ( T B I v e h ic le s ) . TEMPERATURE GAGE REPLACEMENT 1. Speedom eter 2. Speedom eter Cable C onnecto r 3. Seal RV MODELS F -0 0 8 8 2 Remove or Disconnect (Figure 5) 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . Figure 8—Speedometer Cable—Two Wheel Drive 2 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). 8C-12 INSTRUMENT PANEL 2. Speedom eter Cable C onnecto r 4. Transfer Case 5. 6. 7. 8. 9. 10. 11. 12. Sleeve Gear Transm ission Retainer Seal Retainer Sleeve A ssem b ly Bolt 13. 14. 15. 16. 17. 18. 19. 20. A dapter A sse m b ly— P osition for All Transm issions Except SM465 A dapter A sse m b ly— P osition For SM465 Transm ission O utput Key A dapter A sse m b ly— Right A ngle A dapter A ssem bly In-Line A dapter A ssem bly (W ith SM465 Transm ission) Parallel A dapter A ssem bly (Except SM465 Transm ission) In-Line A dapter F 00884 Figure 10—Speedometer Adapter Assemblies INSTRUMENT PANEL 8C-13 E 3 . R a d io c o n tro l k n o b s . 4 . C lo c k a d ju s t e r s te m . 1. 5 . In s tr u m e n t c lu s te r b e z e l (4 3 ). 2. 6 . S t e e r in g c o lu m n c o v e r . 3. 7. In s tr u m e n t c lu s te r le n s (4 2 ). 0 Install or Connect 4. 8 . T r a n s m is s io n s h ift in d ic a t o r ( 4 1 ). 5. 9 . R e ta in e r (4 4 ). 6. 1 0 . T e m p e ra tu r e g a g e a tta c h in g s c re w s . 7. 11. T e m p e ra tu re g a g e (3 7 ). 8. Install or Connect (Figure 5) 9. Temperature gage to the cluster case. Temperature gage retaining bolts. Cluster case to the bezel. Cluster case retaining screws. Laminated circuit. Laminated circuit retaining nuts. Lamp socket assemblies. Instrument cluster. Refer to “ Instrument Cluster Replacement” in this section. Battery ground cable from the battery. 1. T e m p e ra tu re g a g e (3 7 ). 2 . T e m p e ra tu r e g a g e a tta c h in g s c re w s . TEMPERATURE GAGE SENSOR REPLACEMENT 3 . R e ta in e r (4 4 ). 4 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ). 5 . In s tr u m e n t c lu s te r le n d s (4 2 ). 6 . S t e e r in g c o lu m n c o v e r . A L L MODELS 7. In s tr u m e n t c lu s te r b e z e l (4 3 ). CAUTION: Do n o t rem ove cap w ith th e e n g in e h o t. A llo w th e v e h ic le to c o o l o ff firs t. 8 . C lo c k a d ju s te r s te m . 9 . R a d io c o n tro l k n o b s . 1 0 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). 1 1. B a tte r y g r o u n d c a b le to t h e b a tte r y . Remove or Disconnect 1. R a d i a t o r c a p . • G MODELS Remove or Disconnect (Figure 7) • 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . 2 . In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . L o o s e n t h e c a p to t h e fir s t s to p . T h is w ill r e lie v e t h e c o o lin g s y s te m p r e s s u r e . “ In s tr u m e n t T ig h t e n t h e c a p . T h is w ill m in im iz e t h e lo s s o f c o o la n t w h e n r e p la c in g th e te m p e r a tu r e s e n d e r. S e n s o r h a rn e s s c o n n e c to r. S e n s o r. • 3 . L e n s (8 3 ). 4 . L e n s r e ta in e r ( 8 2 ). 5 . L a m in a t e d c ir c u it r e ta in in g n u ts . H a v e t h e n e w s e n d e r r e a d y to in s ta ll o r c lo s e th e s e n d e r h o l e w it h a c o r k in o r d e r t o m i n i m i z e c o o la n t lo s s . Install or Connect 6 . L a m in a t e d c ir c u it (7 4 ) fr o m t h e r e t a in e r (7 9 ). 7 . T e m p e r a t u r e g a g e r e ta in in g n u ts (7 2 ). S e n s o r. 8 . T e m p e ra tu re g a g e (7 6 ). S e n s o r h a rn e s s c o n n e c to r. C o o la n t to r e tu r n t h e c o o la n t le v e l to t h e p r o p e r le v e l. Install or Connect (Figure 7) 1. T e m p e r a t u r e g a g e (7 6 ) to t h e la m in a t e d c ir c u it. OIL PRESSURE GAGE REPLACEMENT 2 . T e m p e r a t u r e g a g e r e ta in in g n u ts (7 2 ). 3 . L a m in a te d c irc u it (7 4 ) to th e r e ta in e r (7 9 ). 4 . L a m in a te d c ir c u it r e ta in in g n u ts . 5 . L e n s r e ta in e r (8 2 ). RV MODELS 6. L e n s (8 3 ). 7. In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t Remove or Disconnect (Figure 5) 1. B a tte r y g r o u n d c a b le fr o m th e b a tte ry . 8 . B a tte r y g ro u n d c a b le to th e b a tte ry . 2 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). P MODELS 3 . R a d io c o n tro l k n o b s . 4 . C lo c k a d ju s te r s te m . |++| Remove or Disconnect 5 . In s tr u m e n t c lu s te r b e z e l (4 3 ). 1. B a tte ry g r o u n d c a b le fr o m th e b a tte ry . 2 . In s t r u m e n t c lu s te r . R e f e r to R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t 3 . L a m p s o c k e t a s s e m b lie s . 6 . S t e e r in g c o lu m n c o v e r . C lu s te r 7. In s tr u m e n t c lu s te r le n s (4 2 ). 8 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ). 9 . R e ta in e r (4 4 ). 4 . L a m in a t e d c ir c u it r e ta in in g n u ts . 1 0 . O il p re s s u r e g a g e a tta c h in g s c re w s . 5 . L a m in a te d c irc u it. 11. O il p r e s s u r e g a g e (4 0 ). 6 . C lu s t e r c a s e r e ta in in g s c r e w s . 7. C lu s te r c a s e fr o m th e b e z e l. r+ J Install or Connect 8 . T e m p e r a t u r e g a g e r e t a in in g b o lts . 1. O il p r e s s u r e g a g e (4 0 ). 9 . T e m p e r a tu r e g a g e fr o m th e c lu s te r c a s e . 2 . O il p r e s s u r e g a g e a tta c h in g s c r e w s . 8C-14 INSTRUMENT PANEL OIL PRESSURE GAGE SENSOR REPLACEMENT 3 . R e ta in e r . 4 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ). 5 . In s tr u m e n t c lu s te r le n s (4 2 ). 6 . S t e e r in g c o lu m n c o v e r . ALL MODELS 7. In s tr u m e n t c lu s te r b e z e l (4 3 ). 8 . C lo c k a d ju s te r s te m . + + Remove or Disconnect 9 . R a d io c o n tro l k n o b s . 1 0 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . 2 . W ir in g h a r n e s s c o n n e c to r fr o m th e s e n s o r. E L E C T R IC A L (S E C . 8 B ). 1 1. B a tte r y g r o u n d c a b le to th e b a tte ry . G MODELS • L - 6 e n g i n e s — t h e s e n s o r is lo c a t e d in t h e b lo c k a b o v e th e s ta rte r. • V - 6 a n d V - 8 e n g i n e s — t h e s e n s o r is lo c a t e d a t t h e le f t f r o n t s id e o f t h e d is tr ib u to r . • V -8 (4 5 4 ) e n g in e s — Remove or Disconnect (Figure 7) 1 . B a tte ry g ro u n d c a b le fr o m th e b a tte ry . 2 . In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . t h e s e n s o r is lo c a t e d a t t h e r e a r le ft s id e o f t h e b lo c k . “ In s tr u m e n t 3 . L e n s (8 3 ). • D ie s e l e n g in e s — h o u s in g . L e ft s id e , a b o v e th e fly w h e e l 3. S e n s o r. 4 . L e n s r e ta in e r (8 2 ). • 5 . L a m in a t e d c ir c u it r e ta in in g n u ts . 6 . L a m in a te d c ir c u it (7 4 ) fr o m th e r e ta in e r (7 9 ). U s e T o o l J -2 1 7 5 7 . Install or Connect 7. O il p r e s s u r e g a g e r e ta in in g n u ts (7 2 ). 1. S e n s o r. 8 . O il p r e s s u r e g a g e (8 7 ). • Install or Connect (Figure 7) U s e T o o l J -2 1 7 5 7 . 2 . W ir in g h a r n e s s c o n n e c to r to th e s e n d e r . 3 . B a tte r y g r o u n d c a b le to t h e b a tte r y . 1. F u e l g a g e (8 7 ) to th e la m in a te d c irc u it. 2 . F u e l g a g e r e ta in in g n u ts (7 2 ). 3 . L a m in a te d c ir c u it (7 4 ) to th e r e ta in e r (7 9 ). VOLTMETER REPLACEMENT 4 . L a m in a t e d c ir c u it r e ta in in g n u ts . 5 . L e n s r e ta in e r (8 2 ). RV MODELS 6 . L e n s (8 3 ). 7. In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . ‘In s tr u m e n t + « - Install or Connect (Figure 5) 1. B a tte r y g ro u n d c a b le fr o m th e b a tte r y . 8 . B a tte ry g ro u n d c a b le to th e b a tte ry . 2 . H e a d la m p s w itc h k n o b a s s e m b ly . R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). P MODELS 3 . R a d io c o n tro l k n o b s . Remove or Disconnect 4 . C lo c k a d ju s te r s te m . B a tte ry g ro u n d c a b le fr o m th e b a tte ry . In s tr u m e n t c lu s te r . R e fe r to R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t 5 . In s tr u m e n t c lu s te r b e z e l (4 3 ). C lu s te r 6 . S t e e r in g c o lu m n c o v e r . 7. In s tr u m e n t c lu s te r le n s (4 2 ). L a m p s o c k e t a s s e m b lie s . 8 . T r a n s m is s io n s h ift in d ic a t o r (4 1 ). L a m in a t e d c ir c u it r e ta in in g n u ts . 9 . R e ta in e r (4 4 ). L a m in a te d c ir c u it. C lu s t e r c a s e r e ta in in g s c r e w s . 1 0 . V o ltm e te r a tta c h in g s c r e w s . C lu s te r c a s e fr o m th e b e z e l. 1 1 . V o ltm e te r . O il p r e s s u r e g a g e r e t a in in g b o lts . Install or Connect (Figure 5) O il p r e s s u r e g a g e fr o m th e c lu s te r c a s e . 1 . V o ltm e te r . Install or Connect 2 . V o ltm e te r a t ta c h in g s c r e w s . O il p r e s s u r e g a g e to th e c lu s te r c a s e . 3 . R e ta in e r (4 4 ). O il p r e s s u r e g a g e r e t a in in g b o lts . 4 . T r a n s m is s io n s h ift in d ic a t o r ( 4 1 ). C lu s te r c a s e to th e b e z e l. 5 . In s tr u m e n t c lu s te r le n s (4 2 ). C lu s t e r c a s e r e ta in in g s c r e w s . 6 . S t e e r in g c o lu m n c o v e r. L a m in a te d c ir c u it. 7. In s tr u m e n t c lu s te r b e z e l (4 3 ). L a m in a te d c ir c u it r e ta in in g n u ts . 8 . C lo c k a d ju s te r s te m . L a m p s o c k e t a s s e m b lie s . In s tr u m e n t c lu s te r . R e fe r to “ In s tr u m e n t C lu s te r 9 . R a d io c o n tro l k n o b s . R e p l a c e m e n t ” in t h is s e c t io n . 1 0 . H e a d la m p s w itc h k n o b a s s e m b ly . B a tte r y g ro u n d c a b le fr o m th e b a tte ry . 1 1. B a tte r y g ro u n d c a b le to th e b a tte r y . INSTRUMENT PANEL 8C-15 G MODELS In s tr u m e n t b e z e l (4 3 ). S p e e d o m e te r d r iv e c a b le . Remove or Disconnect (Figure 7) • B a tte r y g ro u n d c a b le fr o m th e b a tte r y . In s tr u m e n t c lu s te r a s s e m b ly . R e f e r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . “ In s tr u m e n t L a m in a t e d c ir c u it r e ta in in g n u ts . L a m in a t e d c ir c u it (7 4 ) fr o m t h e r e t a in e r (7 9 ). V o lt m e t e r r e ta in in g n u ts (7 2 ) . V o ltm e te r . + + Install or Connect (Figure 5) 1. C l u s t e r . 2. C lu s t e r h a r n e s s c o n n e c t o r . 3 . F o u r c lu s te r r e ta in in g s c r e w s . 4 . S p e e d o m e te r d r iv e c a b le . 4- Install or Connect (Figure 7) 5 . In s tr u m e n t b e z e l (4 3 ). 6. E i g h t i n s t r u m e n t b e z e l r e t a i n i n g s c r e w s . 7. S t e e r in g c o lu m n c o v e r . 8. F o u r s t e e r i n g c o l u m n c o v e r r e t a i n i n g s c r e w s . 1. V o ltm e te r to t h e la m in a t e d c ir c u it. 2 . V o lt m e t e r r e ta in in t n u ts (7 2 ) . 3 . L a m in a te d c irc u it (7 4 ) to th e r e ta in e r (7 9 ). 4 . L a m in a t e d c ir c u it r e ta in in g n u ts . 5 . L e n s r e ta in e r (8 2 ). 6 . L e n s (8 3 ). 7. In s tr u m e n t c lu s te r a s s e m b ly . R e f e r to C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . 9 . R a d io c o n tro l k n o b s . H e a d la m p s w itc h k n o b a s s e m b ly . 11. B a t t e r y g r o u n d c a b l e t o t h e b a t t e r y . 10. “ In s tr u m e n t 0 G MODELS 8 . B a tte ry g ro u n d c a b le to th e b a tte ry . P MODELS 0 Remove or Disconnect “ In s tr u m e n t 5 . L a m in a t e d c irc u it. 6 . C lu s t e r c a s e r e ta in in g s c r e w s . • P u ll t h e to p o f t h e c lu s t e r a w a y in s tr u m e n t p a n e l. • L ift o u t t h e b o t t o m o f t h e c lu s te r . In s tr u m e n t c lu s te r h a r n e s s c o n n n e c to r. 7. C lu s te r c a s e fr o m th e b e z e l. 8 . V o lt m e t e r r e ta in in g b o lts . 9 . V o ltm e te r fr o m t h e c lu s te r c a s e . Install or Connect V o ltm e te r to t h e c lu s t e r c a s e . V o lt m e t e r r e ta in in g b o lts . C lu s te r c a s e to th e b e z e l. C lu s t e r c a s e r e ta in in g s c r e w s . L a m in a t e d c ir c u it. L a m in a t e d c ir c u it r e ta in in g n u ts . L a m p s o c k e t a s s e m b lie s . In s t r u m e n t c lu s te r . R e f e r to “ In s t r u m e n t R e p l a c e m e n t ” in t h is s e c t i o n . 9 . B a tte r y g r o u n d c a b le fr o m th e b a tte r y . INSTRUMENT CLUSTER REPLACEMENT B a tte ry g r o u n d c a b le fr o m th e b a tte ry . • P u ll o u t t h e d r iv e c a b le . C lo c k s e t s te m k n o b . In s t r u m e n t c lu s te r b e z e l r e ta in in g s c r e w s . In s tr u m e n t b e z e l (8 4 ). T w o lo w e r c lu s t e r r e ta in in g s c r e w s . C lu s te r . C lu s te r 4 . L a m in a t e d c ir c u it r e ta in in g n u ts . 1. 2. 3. 4. 5. 6. 7. 8. Remove or Disconnect (Figure 7) S p e e d o m e te r d r iv e c a b le . • P r e s s in t h e t a n g o n t h e s p e e d o m e t e r h e a d . 1. B a tte r y g r o u n d c a b le fr o m th e b a tte r y . 2 . In s t r u m e n t c lu s te r . R e f e r to R e p l a c e m e n t ” in t h is s e c t i o n . 3 . L a m p s o c k e t a s s e m b lie s . -► 4 - C lu s te r 1. 2. 3. 4. 5. 6. 7. 8. | + j Remove or Disconnect (Figure 5) 1. B a tte r y g ro u n d c a b le fr o m th e b a tte ry . 2 . H e a d la m p s w itc h k n o b a s s e m b ly . 3 . R a d io c o n tro l k n o b s . 4 . F o u r s te e r in g c o lu m n c o v e r r e ta in in g s c r e w s . 5 . S te e r in g c o lu m n c o v e r . fro m Install or Connect (Figure 7) C lu s t e r h a r n e s s c o n n e c t o r in to t h e c lu s te r. C lu s te r . T w o lo w e r c lu s t e r r e ta in in g s c r e w s . In s tr u m e n t b e z e l (8 4 ). In s t r u m e n t c lu s te r b e z e l r e ta in in g s c r e w s . C lo c k s e t s te m k n o b . S p e e d o m e te r d r iv e c a b le . B a tte ry g ro u n d c a b le to th e b a tte ry . P MODELS Remove or Disconnect B a tte ry g ro u n d c a b le fr o m th e b a tte ry . S p e e d o m e te r d r iv e c a b le . • RV MODELS 6 . E ig h t in s tr u m e n t b e z e l r e ta in in g s c e r w s . c lip ( 3 0 ) a t t h e s p e e d o m e t e r 10 L e n s (8 3 ). L e n s r e ta in e r (8 2 ). ♦ P r e s s th e s p r in g (3 6 ). • P u ll t h e c a b le fr o m t h e s p e e d o m e t e r h e a d . 9 . F o u r c lu s te r r e ta in in g s c r e w s . . C lu s te r h a r n e s s c o n n e c to r. 1 1 . C lu s te r . P r e s s in t h e t a n g o n t h e s p e e d o m e t e r h e a d . • P u ll o u t o f t h e d r iv e c a b le . In s tr u m e n t c lu s te r h a rn e s s c o n n e c to r. In s tr u m e n t c lu s te r b e z e l s c re w s . In s tr u m e n t c lu s te r fr o m th e d a s h p a n e l. Install or Connect In s tr u m e n t c lu s te r to t h e d a s h p a n e l. In s tr u m e n t c lu s te r b e z e l s c re w s . In s tr u m e n t c lu s te r h a r n e s s c o n n e c to r. th e 8C-16 INSTRUMENT PANEL Install or Connect (Figures 5, 6, and 7) 4 . S p e e d o m e t e r d r iv e c a b le . 5 . B a tte r y g r o u n d c a b le fr o m t h e b a tte r y . 1. L a m in a te d c ir c u it (5 1 ) to th e c lu s te r c a s e (3 3 ). LAMINATED (PRINTED) CIRCUIT REPLACEMENT ALL MODELS Remove or Disconnect (Figures 5, 6, and 7) 2 . L a m in a t e d c ir c u it r e ta in in g s c e r w s . 3 . G a n d P m o d e ls . • F u e l g a g e te r m in a l n u ts . • A m m e te r te r m in a l n u ts . 4 . In s tr u m e n t c lu s te r la m p b u lb a s s e m b lie s (5 7 ). 5 . In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to “ In s tr u m e n t C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . IGNITION SWITCH REPLACEMENT 1. In s tr u m e n t c lu s te r a s s e m b ly . R e fe r to “ In s tr u m e n t C lu s t e r R e p l a c e m e n t ” in t h is s e c t io n . 2 . In s tr u m e n t c lu s te r la m p b u lb a s s e m b lie s (5 7 ). 3 . L a m in a t e d c ir c u it r e ta in in g s c r e w s . 4 . G a n d P m o d e ls . • F u e l g a g e te r m in a l n u ts . • T e m p e r a tu r e g a g e te r m in a l n u ts . • A m m e te r te r m in a l n u ts . 5 . L a m in a te d c ir c u it fr o m th e c lu s te r c a s e (3 3 ). R e fe r to S T E E R IN G C O L U M N (S E C . 3 B 4 ). LAMP SWITCH REPLACEMENT R e fe r to C H A S S IS E L E C T R IC A L (S E C . 8 B ). SPECIAL TOOLS [ill III) V#-------- f — J-21757-03 O il P r e s s u r e S e n d in g U n it S o c k e t W re n c h B -0 7 6 6 7 Figure 11—Special Tool 9-1 SECTION 9 ACCESSORIES CONTENTS SUBJECT PAGE Cruise C o n tro l........................................................................................................................................................ 9- 1 Description..........................................................................................................................................................9- 1 Diagnosis................................................................................................................................................................9- 3 On-Vehicle S ervice................................................................................................................................................ 9- 6 Vacuum Release Valve Replacement................................................................................................................. 9- 6 Clutch Release Switch Replacement................................................................................................................. 9- 6 Cruise Control Modual Replacement................................................................................................................. 9- 8 Multi-Function Switch Replacement................................................................................................................... 9-10 Servo Replacement............................................................................................................................................ 9-11 Radio................................................................................................... ....................................................................9-16 Description..........................................................................................................................................................9-16 Diagnosis................................................................................................................................................................9-16 Accessory Noise................................. ................................................................................................................ 9-16 Chart 1 — System Diagnosis and Analysis........................................................................................................... 9-17 Chart 2 — Noisy Part 1 .......................................................................................................................................... 9-18 Chart 3 — Noisy Part 2 .......................................................................................................................................... 9-19 Chart 4 — ECM or Digital Dash N oise................................................................................................................... 9-20 Chart 5 — Ignition Noise........................................................................................................................................ 9-21 Chart 6 — Antenna Noise Part 1 .............................................................. ............................................................9-22 Chart 7 — Antenna Noise Part 2 ...........................................................................................................................9-23 Chart 8 — Weak...................................................................................................................................................... 9-24 Chart 9 — Alternator W hine...................................................................................................................................9-25 Chart 10 — Dead.................................................................................................................................................... 9-26 Chart 11 — T ap e.................................................................................................................................................... 9-27 Diagnostic RF Sniffer...........................................................................................................................................9-30 Radio Receiver Replacement.................................................................................................................................9-30 RV Models............................................................................................................................................................9-30 G Van....................................................................................................................................................................9-30 Antenna Replacement.............................................................................................................................................9-32 RV Models............................................................................................................................................................9-32 G Van....................................................................................................................................................................9-32 Speaker Replacement............................................................................................................................................ 9-32 RV Models............................................................................................................................................................9-32 G Van....................................................................................................................................................................9-35 CRUISE CONTROL DESCRIPTION C r u is e c o n tro l is a sp eed c o n tro l s y s te m w h ic h m a in t a in s a d e s ir e d v e h ic le s p e e d u n d e r n o r m a l d r iv in g c o n d itio n s . H o w e v e r, s t e e p g r a d e s u p o r d o w n m a y c a u s e v a r ia t io n s in t h e s e l e c t e d s p e e d s . T h e e l e c t r o n ic c r u i s e c o n tr o l s y s te m h a s th e c a p a b ility to c r u is e c o a s t, r e s u m e s p e e d , a c c e le r a te , a n d “ t a p - u p ” a n d “ t a p -d o w n ” (fig u r e 1 )T h e m a in p a rts o f th e c r u is e c o n tr o l s y s te m a r e th e m o d e c o n tr o l s w itc h e s , c o n tr o lle r (m o d u le ), s e r v o u n it, s p e e d s e n s o r, v a c u u m s u p p ly , e le c tr ic a l a n d v a c u u m 2' 1. Set/Coast Switch 2. O ff/O n /R e s u m e /A c c e l S w itc h 3. D ir e c tio n a l S ig n a l L e v e r r e le a s e s w itc h e s , a n d e le c tr ic a l h a r n e s s . T h e c r u is e c o n tr o l s y s te m u s e s v a c u u m to o p e r a te a th r o ttle s e r v o u n it. T h e s e r v o u n it m a in t a in s a d e s ir e d F ig u r e 1 — M u lti-F u n c tio n L e v e r F -0 2 4 2 5 9-2 ACCESSORIES F -0 2 4 2 6 Figure 2—Controller Module v e h i c l e s p e e d b y t r a p p i n g v a c u u m in t h e s e r v o u n it a t t h e p r o p e r s e r v o p o s itio n . T h e c o n tr o lle r m o n ito r s v e h ic le s p e e d a n d s e r v o p o s itio n a n d o p e r a te s th e v a c u u m a n d v e n t v a l v e s in t h e s e r v o t o m a i n t a in d e s ir e d s p e e d . T h e c o n t r o lle r c o n t a in s a lo w s p e e d lim it w h ic h w ill p r e v e n t s y s te m e n g a g e m e n t b e lo w a m in im u m s p e e d , a b o u t 2 5 m p h . T h e o p e r a t i o n o f t h e c o n t r o ll e r is c o n t r o ll e d b y m o d e c o n t r o l s w i t c h e s l o c a t e d in t h e e n d o f t h e d ir e c t i o n a l s ig n a l le v e r . T o d is e n g a g e t h e s y s te m , tw o r e le a s e s w itc h e s a r e p r o v id e d . A n e le c tr ic a l r e le a s e s w itc h m o u n te d o n th e b r a k e p e d a l b r a c k e t (a n d c lu tc h p e d a l b r a c k e t o n v e h ic le s e q u ip p e d w ith m a n u a l tr a n s m is s io n ) d is e n g a g e s th e s y s te m e le c tr ic a lly w h e n th e b r a k e p e d a l ( o r c lu t c h p e d a l) is d e p r e s s e d . A v a c u u m r e le a s e v a lv e , m o u n te d o n th e b ra k e p e d a l b ra c k e t, v e n ts th e tra p p e d v a c u u m in t h e s e r v o t o a t m o s p h e r e w h e n t h e b r a k e p e d a l is d e p r e s s e d , a l lo w i n g t h e s e r v o u n it to q u i c k l y r e t u r n t h e t h r o ttle to id le p o s itio n . T h e c o n tr o lle r in te r p r e ts t h e p o s itio n o f th e s e r v o , p o s itio n o f th e m o d e c o n tr o l s w itc h e s a n d th e o u tp u t h e s p e e d s e n s o r . In r e s p o n s e to t h e s e in p u t s , c o n tr o lle r e le c tr ic a lly s ig n a ls t h e o p e n in g o r c lo s in g o f v e n t a n d v a c u u m s o le n o id v a l v e s in t h e s e r v o ( f i g u r e c o n t r o ll e r is u s u a l l y m o u n te d on th e p e d a l b r a c k e t. F o r m o u n tin g lo c a tio n , O n - V e h ic le S e r v ic e p o r tio n o f th is s e c tio n . th e t of th e th e 2 ). a c c e le r a to r re fe r to th e SERVO UNIT (Figure 3) T h e s e r v o c o n s is ts o f a v a c u u m o p e r a te d d ia p h r a g m , a n o r m a lly o p e n s o le n o id v a lv e to v e n t th e d ia p h r a g m c h a m b e r to a t m o s p h e r e , a n o r m a lly c lo s e d s o le n o id v a lv e to c o n n e c t th e d ia p h g r a m c h a m b e r to th e v a c u u m s o u r c e , a n d a v a r ia b le in d u c ta n c e p o s itio n s e n s o r. T h e s e r v o o p e r a t e s t h e t h r o t t le in r e s p o n s e t o s i g n a l s f r o m t h e e le c t r o n ic c o n t r o lle r a s f o llo w s : • Steady Cruise State B o th (s y s te m e n g a g e d an d vacuum a n d v e n t v a lv e s a r e c lo s e d o r s e a le d . o n th e d ia p h r a g m o n th e v a c u u m d ia p h g r a m c h a m b T h e s e rv o h a s a c o n s ta n t v a c u u m a n d p la c e s n o -flo w r e q u ir e m e n ts s o u rc e . V a c u u m is t r a p p e d in e r. o p e r a tin g ) — 51. 52. 53. 54. 55. Servo Valve (To Vacuum Supply) Valve (To Vacuum Brake Release Valve) Vacuum Solenoid and Valve (N orm ally Closed) T h ro ttle A ttachm ent Variable Inductance P osition Sensor Vent Solenoid and Valve (N orm ally Opened) Coil Steel Core F -0 2 4 2 7 Figure 3—Servo Unit ELECTRONIC CONTROLLER (MODULE) T h e 35. 40. 41. 50. ACCESSORIES 9-3 • Vehicle Losing Speed (d u e to s te e p g ra d e s or • • c o n tro l s w itc h e s ) — T he c o n tr o lle r vacuum s o le n o id to o p e n t h e v a c u u m A n o p e n v a r i a b l e i n d u c t a n c e p o s i t i o n s e n s o r c o il in th e s e rv o . d r iv e r w is h e s to in c r e a s e s p e e d b y o p e r a tin g m o d e th e • A lo s s o f e le c tr ic a l p o w e r to th e s y s te m . v a lv e to th e • T h e ig n it io n is t u r n e d o ff. e n e rg iz e s v a c u u m s o u r c e . T h i s i n c r e a s e s t h e v a c u u m l e v e l in th e s e r v o to in c r e a s e t h e th r o ttle o p e n in g . T h e v e n t r e m a in s c lo s e d . Vehicle Gaining Speed ( d u e t o s t e e p g r a d e s o r d r iv e r w is h e s to d e c r e a s e s p e e d b y o p e r a tin g m c o n tr o l s w itc h e s ) — T h e c o n tr o lle r d e - e n e r g iz e s v e n t s o le n o id to o p e n th e v e n t v a lv e to a t m o s p h e r e w h ic h r e d u c e s v a c u u m in t h e s e r v o a llo w s t h e th r o ttle r e tu r n s p r in g to d e c r e a s e ode th e th e and th e th r o ttle o p e n in g . T h e v a c u u m v a lv e r e m a in s c lo s e d . W h e n t h e c r u is e s y s t e m is e n g a g e d a n d o p e r a t in g (w ith o u t a n y in te r fe r e n c e fr o m th e d r iv e r v ia th e m o d e c o n t r o l s w it c h e s ) , n o s p e e d c o r r e c t io n w ill b e m a d e u n til t h e v e h i c l e e x c e e d s a p p r o x i m a t e l y ± AU m p h o f s e t speed. W h e n th e c o n tr o lle r s e n s e s a n o v e r o r u n d e r s p e e d c o n d i t i o n it w ill p u l s e t h e o p e n i n g o f t h e v e n t o r v a c u u m v a lv e . T h e a v e r a g e d u r a t io n o f o n e p u ls e w ill b e 1 0 m illis e c o n d s . T h e p u ls e w ill b e r e p e a t e d , a s r e q u ir e d , u n til t h e s p e e d c o r r e c tio n r e q u ir e d b r in g s t h e v e h ic le to th e s e t s p e e d . F ro m a n y s e t s p e e d , u n d e r n o rm a l ro a d lo a d c o n d i t io n s , t h e v a c u u m v a l v e w ill r e m a i n in a c o m p le te ly o p e n p o s itio n w h e n v e h ic le s p e e d h a s d r o p p e d 5 m p h b e lo w s e t s p e e d . L ik e w is e , w h e n v e h ic le s p e e d h a s e x c e e d e d 3 m p h o v e r th e s e t s p e e d , s u c h a s d o w n a s t e e p g r a d e , t h e v e n t w ill g o in t o c o n s t a n t o p e n SPEED SENSORS VSS Buffer Amplifier (Figure 4) T h is is t h e d e v ic e t h a t w ill s u p p ly t h e v e h ic le s p e e d in p u t to t h e c o n tr o lle r . T h e o p tic h e a d p o r tio n o f t h e v e h i c l e s p e e d s e n s o r ( V S S ) is l o c a t e d in t h e s p e e d o m e t e r f r a m e . A r e f le c t iv e b l a d e is a t t a c h e d t o t h e s p e e d o m e t e r c a b le /h e a d a s s e m b ly . T h e r e f le c t iv e b la d e s p in s lik e a p r o p e lle r , w it h its b la d e s p a s s in g t h r o u g h a lig h t b e a m f r o m a L .E . D . in t h e o p t ic h e a d . A s e a c h b la d e e n t e r s t h e L . E . D . l ig h t b e a m , l ig h t is r e f l e c t e d b a c k t o a p h o t o c e l l in th e o p tic h e a d c a u s in g a lo w p o w e r s p e e d s ig n a l to b e s e n t to a b u ffe r fo r a m p lific a tio n a n d s ig n a l c o n d itio n in g . T h is a m p lif ie d s ig n a l is t h e n s e n t to t h e c o n t r o lle r . VACUUM SUPPLY T h e v a c u u m s u p p ly to o p e r a te th e c r u is e c o n tr o l s y s te m is r o u t e d to t h e s e r v o . T h is c a n b e d o n e b y r o u t in g m a n if o ld v a c u u m s tr a ig h t to t h e s e r v o o r fr o m m a n if o ld th ro u g h a v a c u u m s to ra g e ta n k . ELECTRICAL AND VACUUM RELEASE SWITCHES p o s itio n . T h e s e r v o in c o r p o r a te s a s te e l c o r e w h ic h m o v e s w ith in a c o il. Its r e s u lt in g v a r ia b le in d u c t a n c e p r o v id e s a c o n t in u o u s ( v o lt a g e ) s e r v o p o s it io n s ig n a l to t h e c o n t r o lle r . T h i s v o lt a g e s i g n a l is c o n s t a n t l y c o m p a r e d to t h e v e h ic le s p e e d s i g n a l . T h i s c o m p a r i s o n d e t e r m i n e s if t h e p u l s e s i s s u e d h a v e c o r r e c t e d t h e s p e e d e r r o r o r if a d d i t i o n a l p u l s e s a r e r e q u ir e d . T h i s c o m p a r i s o n is a ls o u s e d to l e n g t h e n t h e a v e r a g e p u l s e w h e n it is n o t e n o u g h t o T h e s e s w itc h e s a r e u s e d to d is e n g a g e th e c r u is e c o n tr o l s y s te m . A n e le c tr ic a l r e le a s e s w itc h m o u n te d o n th e b r a k e p e d a l b r a c k e t (a n d c lu tc h p e d a l b r a c k e t o n v e h ic le s e q u ip p e d w ith m a n u a l tr a n s m is s io n ) d is e n g a g e s t h e s y s t e m e l e c t r i c a l l y w h e n t h e b r a k e ( o r c l u t c h ) p e d a l is d e p r e s s e d . T h i s is d o n e b y in t e r r u p t in g t h e f lo w o f c u r r e n t to t h e c o n tr o lle r . A v a c u u m r e le a s e v a lv e , m o u n t e d o n t h e b r a k e p e d a l b r a c k e t v e n t s t h e t r a p p e d v a c u u m in t h e s e r v o to a t m o s p h e r e w h e n t h e b r a k e p e d a l is d e p r e s s e d , a llo w in g t h e s e r v o u n it to m o r e q u ic k ly r e ta in t h e th r o ttle to id le p o s it io n . T h is is d o n e b y r o u t in g a s e p a r a t e h o s e d ir e c tly to t h e s e r v o fr o m t h e n o r m a lly c lo s e d v a c u u m c o m p e n s a te fo r th e s p e e d e rro r, s u c h a s a s te e p g ra d e . T h e s e r v o w ill g o in to a n o p e n v e n t - v a lv e p o s it io n u n d e r t h e f o llo w in g c o n d itio n s : • W h e n t h e b r a k e ( o r c lu t c h ) p e d a l is d e p r e s s e d . s w itc h . T h e s e tw o ty p e s o f b e c o m b in e d w ith s to p C o n v e r te r C lu tc h ) s w itc h T ra n s m is s io n (S e c . 7 A ) O n -V s w it c h e s w ill a lig h t s w itc h , , e tc . R e fe r e h ic le S e r v ic e ls o s o m e tim e s T C C (T o rq u e to A u to m a tic in t h is s e c t io n . DIAGNOSIS OF CRUISE CONTROL SYSTEM Inoperative System (Electrical) CORRECTION POSSIBLE CAUSE PROBLEM 1. N o p o w e r to m o d u le t e r m in a ls “ G ” a n d “ A ” (fig u re 5 ). 1. C h e c k , r e p a ir , a d ju s t o r r e p la c e th e fu s e , b r a k e a n d c lu tc h s w itc h e s , tu r n s i g n a l l e v e r , w i r e s in t h e s t e e r i n g c o l ­ um n. 9-4 ACCESSORIES DIAGNOSIS OF CRUISE CONTROL SYSTEM (CONT.) PROBLEM Inoperative System (Electrical) (Cont.) POSSIBLE CAUSE 2. 3. 4. 5. 6. Inoperative System (Mechanical) n o o n a g r o u n d c ir c u its to th e m o d u le , o r b u ffe r. M o d u le te r m in a l J , H a n d te r m in a l C . le a d s to o r a t th e s e r v o te r m in a ls n d “ D ” (s e r v o p o s itio n s e n s o r ). O p e n le a d s to a n d “ E ” (v e n t N o h ig h a n d m o d u le s p e e d o r a t s e rv o te rm a n d v a c u u m c ir c lo w v o lt a g e s ig n s e n d e r te r m in a l in a ls “ A ” u its ). a l a t th e “ D .” 7. In c o r r e c t in p u t s ig n a ls to th e m o d u le , S e t/C o a s t o r R e s u m e /A c c e le r a te te r m i­ n a ls (fig u r e 8 ). P o o r c o n n e c tio n s a t th e m o d u le . 8. C r u is e c o n tr o l m o d u le . 1. N o vacuum s e rv o . 2. Vehicle Surges (Electrical) O p e s e rv s e rv O pe “ B ” CORRECTION at th e s m a ll hose to th e C o c k e d s e r v o p o s itio n ro d a n d s p r in g . L e a k y s e r v o , b r o k e n f it tin g s , a n d /o r in o p ­ 3. 4. e r a tiv e v a lv e s . D is c o n n e c t e d s e r v o lin k a g e . M is a d ju s te d o r le a k y v a c u u m v a lv e o r h o s e . 1. 2. 2. 3. 4. C h e c k th e g r o u n d c ir c u its fo r lo o s e o r b ro k e n c o n n e c tio n s . C le a n a n d r e p a ir as needed. R e p a ir th e le a d s o r r e p la c e th e s e rv o (fig u r e s 6 a n d 7 ). R e p a ir th e le a d s o r r e p la c e th e s e rv o . 5. C h e c k , r e p a ir , r e p la c e : o p e n le a d s , b a d p r i n t e d c i r c u i t fo il a t t h e c lu s t e r , b a d b u f f e r a m p lifie r , t e r m in a l “ B ” o f s e r v o to “ B ” o f b u ffe r, g ro u n d fo r b u ffe r, fo r­ e ig n m a t e r i a l o r g r e a s e in s p e e d o m e t e r head. 6 . C h e c k , r e p a ir , r e p la c e : o p e n le a d s , o p e n c o n n e c to r , b a d tu r n s ig n a l le v e r a n d t e r m i n a l in t h e p r o p e r c a v it y . 7. C le a n , r e p a ir th e m o d u le c o n n e c to r a s needed. 8 . R e p la c e th e m o d u le . 1. C heck 2. n e c te d v a c u u m h o s e s , in c o r r e c tly p o s i­ tio n e d 3 -p o r t o r 2 -p o r t c h e c k v a lv e , r e s t r ic t e d e n g in e v a c u u m f ittin g . R e p la c e th e s e rv o . R e p la c e th e s e rv o . fo r p lu g g e d , p in c h e d , d is c o n ­ 3. 4. R e c o n n e c t. C h e c k f o r l e a k in v a c u u m r e le a s e h o s e o r v a lv e o r m is a d ju s te d v a c u u m d u m p s w itc h . In te r m itte n t g r o u n d . 1. I n t e r m i t t e n t o p e n in t h e v a c u u m , v e n t , S P S ( S e r v o P o s itio n S e n s o r ) le a d s o r c o n n e c to r s o r te r m in a ls o r s e r v o . S p ik e s o n t h e p o s itiv e b a t t e r y lin e (T r a n ­ s ie n t). 2. C h e c k fo r p o o r g r o u n d in g to th e s e r v o m o d u le , V S S ( V e h ic le S p e e d S e n s o r ) b u f f e r . If c h a s s i s g r o u n d is s u s p e c t , a t ­ ta c h a n e w g ro u n d s tra p b e tw e e n th e c o w l a n d e n g in e b lo c k . R e t o r q u e a ll g ro u n d c o n n e c tio n s . D o a p h y s ic a l a n d a n e le c tr ic a l in s p e c ­ t io n a s s h o w n in t h e t e s t c h a r t s . 4. T u rn s ig n a l, r a d io o r o th e r e le c tr ic a l d e ­ v ic e in te r fe r e n c e . 4. 5. W r o n g m o d u le p a r t n u m b e r . 5. n o d e f e c t is f o u n d , r e p l a c e t h e m o d u le . R e p la c e th e m o d u le w ith a c o r r e c t p a r t n u m b e r. 6. C r o s s e d v a c u u m a n d v e n t e le c tr ic a l le a d s b e tw e e n th e m o d u le a n d s e rv o . 6. R e w ir e . 3. r e le a s e 3. C h e c k fo r a n y h o t w ir e s in te r m itte n tly m a k in g c o n ta c t w ith c h a s s is g ro u n d . R e p a ir a s r e q u ir e d . R e p o s itio n e le c tr ic l le a d s a w a y fr o m c r u is e o r V S S (V e h ic le S p e e d S e n s o r ) b u f f e r l e a d s . C h e c k f o r p o o r g r o u n d s . If ACCESSORIES 9-5 DIAGNOSIS OF CRUISE CONTROL SYSTEM (CONT.) Vehicle Surges (Mechanical) CORRECTION POSSIBLE CAUSE PROBLEM 1. E x c e s s s l a c k in s e r v o l in k a g e . 1. 2. 3. S e r v o v a lv e s tic k in g . M is a d ju s te d o r le a k y v a lv e o r h o s e . 2. 3. tio n . R e p la c e th e s e rv o . C h e c k f o r l e a k in v a c u u m r e l e a s e h o s e , o r v a lv e , o r m is a d ju s te d v a c u u m d u m p 4. 5. — D r y o r o v e r lu b e d s p e e d o c a b le . S p e e d o m e te r p o in te r s h a k e : D u e to m is r o u te d s p e e d o m e te r c a b le a n d c a s in g a s s e m b ly . T ra n s m is s io n s p e e d o m e te r d r iv e o r 4. 5. v a lv e . L u b r ic a t e to s p e c ific a tio n s . R e r o u te o r r e p la c e th e c a b le s e m b ly . — R e p la c e c o m p o n e n t. 6. In s p e c t h o s e s a n d q u ire d . R e p a ir o r r e p la c e . — vacuum r e le a s e 7. d r iv e n g e a r. R e s tr ic te d (k in k e d o r le a k in g ) v a c u u m s u p p ly h o s e to a c c u m u la to r o r s e r v o . B in d in g s e r v o lin k a g e d u e to in te r fe r ­ 8. e n c e , ru s t, e tc . M is a d ju s te d o r 6. le a k y vacuum 7. r e le a s e 8. speedo 9. v a lv e o r h o s e . 9. 10. 11. 12. G re a s e or fo r e ig n m a te r ia l in head. T o r q u e c o n v e r te r c lu tc h c u ttin g o u t, o r t r a n s m is s io n s h iftin g . A d ju s t to r e q u ir e m e n t s o u t lin e d in t h e O n - V e h ic l e S e r v ic e p o r t io n in t h is s e c ­ C h d C r e p o s itio n and as­ as re ­ h e c k f o r l e a k in t h e v a c u u m r e l e a s e o s e o r v a lv e , o r m is a d ju s te d v a c u u m u m p s w itc h . le a n o r r e p la c e . and 10. E n g i n e c u t s in a n d o u t d u e t o m i x t u r e ig n itio n p r o b le m . In c o r r e c tly p o s itio n e d 3 p o r t o r 2 p o rt 11. (N o t a c r u is e p r o b le m .) C h e c k T V c a b le a d ju s t m e n t o n th e tr a n s m is s io n . R e fe r to s e c tio n 7 A . R e p a ir a n d /o r a d ju s t a s r e q u ir e d . 12. M a k e c o r r e c tio n . in c h e c k v a lv e . Cruise Set Speed No Resume Function 1. E x c e s s s l a c k in s e r v o l in k a g e . 2. In c o rr e c t m o d u le p a rt n u m b e r u s a g e . 1. 2. 3. 4. No “ Tap Down” Function 1. I n c o r r e c t o p e r a t o r t e c h n i q u e . ( I f R / A is h e ld d o w n fo r m o r e t h a n 1 s e c o n d , t h e s y s te m r e v e r ts to th e a c c e le r a to r m o d e . T h e s p e e d a t t h e t i m e o f r e le a s e is t h e n e w c r u is e s p e e d ). O p e n c o n n e c tio n a t te r m in a l “ A ” o f th e m o d u l e o r t h e t e r m in a l is in t h e w r o n g c a v ity . C r u is e c o n tr o l m o d u le . In te r m itte n t O n /O ff S w itc h . In c o r r e c t o p e r a to r te c h n iq u e . (S e t/C o a s t s w i t c h h e ld d o w n in e x c e s s o f .4 s e c o n d s r e s e t s s p e e d w h e n t h e S e t / C o a s t is r e ­ le a s e d ). 1 . A d j u s t t o r e q u ir e m e n t s o u t l in e d in t h e O n - V e h i c l e S e r v i c e p o r t io n in t h is s e c ­ tio n . 2 . In s ta ll a m o d u a l w ith th e c o r r e c t p a r t n u m b e r. 3. R e p la c e . 1. A d v is e th e o p e ra to r. 2. R e p a ir . 3. 4. R e p la c e . R e p la c e 1. A d v is e o p e ra to r. 9-6 ACCESSORIES DIAGNOSIS OF CRUISE CONTROL SYSTEM (CONT.) P R O B L E M U n w a n te d C r u is e o r A c c e le ra tio n P O S S IB L E C A U S E 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. C O R R E C T IO N C r o s s e d v a c u u m a n d v e n t w ire s . D e fe c tiv e o r in te r m itte n t tu rn s ig n a l m o d e c o n tr o l s w itc h e s . S t i c k i n g v a l v e s in t h e s e r v o . B in d in g th r o ttle lin k a g e d u e to in te r fe r ­ e n c e , r u s t o r o th e r c o n ta m in a n ts . G r e a s e in t h e s p e e d o m e t e r h e a d . F lo o r m a t in te r fe r e n c e . L o o s e r e t a in e r o n t h e b a il o f t h e s e r v o . G r o u n d c ir c u it. S p e e d s e n s o r b u ffe r. In c o r r e c t m o d u le . 1. 2. R e w ir e . R e p la c e th e le v e r. 3. 4. R e p la c e s e rv o . C o r r e c t a s r e q u ir e d . 5. 6. 7. 8. 9. 10. S R R C R R e r v ic e s p e e d o m e te r. e p o s itio n a s r e q u ir e d . e p la c e s e rv o . le a n a n d r e p a ir a s r e q u ir e d . e p la c e . e p la c e . Cruise Disengages While Tapping Down C r u is e c o n tr o l m o d u le . R e p la c e m o d u le . Occasional Missed Cruise “ Sets” C r u is e c o n tr o l m o d u le . R e p la c e m o d u le . ON-VEHICLE SERVICE VACUUM RELEASE VALVE REPLACEMENT CLUTCH RELEASE SWITCH REPLACEMENT Remove or Disconnect (Figure 9) In s tr u m e n t p a n e l h a r n e s s c o n n e c to r (8 ). 1. C o n n e c to r (9 8 ). V acuum 2. lin e s (1 0 ). R e t a in e r (1 2 ). T u r n t h e r e t a in e r c o u n t e r c lo c k w is e to u n s e a t it. 0 4. V acu u m Install or Connect (Figure 9) 2 . V a c u u m r e l e a s e v a l v e ( 9 o r 1 1 ) u n t il it is s e a t e d o n t h e r e t a in e r , w it h t h e b r a k e p e d a l in t h e d e p r e s s e d p o s itio n . 3 . C lu tc h r e le a s e s w itc h (9 9 ). N o te t h a t a u d ib le “ c lic k s ” c a n b e h e a r d a s th e t h r e a d e d p o r t io n o f t h e v a lv e is p u s h e d t h r o u g h t h e -►+ Install or Connect (Figure 10) 1 . R e t a in e r (1 0 2 ) . L in e u p t h e n o t c h e s o n p e d a l b r a c k e t (1 0 1 ) to t h e r e ta in e r . P u ll t h e b r a k e p e d a l f u lly r e a r w a r d a g a in s t t h e p e d a l s to p , u n til t h e a u d ib le “ c lic k ” s o u n d s c a n n o lo n g e r R e le a s e th e b r a k e p e d a l a n d r e p e a t s te p 2 to a s s u r e th a t n o a u d ib le “ c lic k ” s o u n d s r e m a in . 3. V a c u u m lin e s (1 0 ). 4. Instrument panel harness connector (8). c lu tc h • N o te th a t a u d ib le “ c lic k s ” c a n b e h e a r d a s th e t h r e a d e d p o r t io n o f t h e v a lv e is p u s h e d t h r o u g h t h e r e ta in e r to w a r d th e b r a k e p e d a l. • P u ll t h e b r a k e p e d a l fu lly r e a r w a r d a g a in s t t h e p e d a l s to p , u n til th e a u d ib le “ c lic k ” s o u n d s c a n n o lo n g e r b e h e a rd . • R e le a s e th e b ra k e p e d a l a n d r e p e a t s te p 2 to a s s u r e th a t n o a u d ib le “ c lic k ” s o u n d s r e m a in . b e h e a rd . • th e 2 . C l u t c h r e l e a s e s w i t c h ( 9 9 ) u n t i l it is s e a t e d o n t h e r e t a in e r , w it h t h e b r a k e p e d a l in t h e d e p r e s s e d p o s itio n . r e ta in e r to w a r d th e b r a k e p e d a l. • R e t a in e r (1 0 2 ). T u rn th e r e ta in e r c o u n te r c lo c k w is e to u n s e a t it. r e le a s e v a lv e . 1 . R e t a i n e r ( 1 2 ) . T u r n t h e r e t a i n e r c l o c k w i s e t o s e a t it. • Remove or Disconnect (Figure 10) 3. Connector (98). ACCESSORIES 9-7 VOLTAGE CHECK - MODULE CONNECTED TEST TERMINAL v, G v2 A V3 M V, V5 L B Vs D SPECIFIED VOLTAGE TO GROUND FUNCTION Brake Input Cruise On-Off Input Resume/Accel Input Set/Coast Input Cruise Lamp Speed Signal 12V OV 12V OV 12V OV OV .......................... .......................... .......................... .......................... .......................... .......................... .......................... 12V .......................... OV .......................... 12V .......................... Greater than 4V High, Near OV Low CONDITIONS Brake/Clutch Not Applied Brake/Clutch Applied Slider Switch On Slider Switch Off, Set/Coast Depressed or Normal Slider Switch in Ft/A Position Slide Switch On, Set/Coast Depressed or Normal Slider Switch Off, Set/Coast Depressed or Normal Slider Switch On, Set/Coast Depressed Slider Switch Off, Set/Coast Normal Cruise Engaged Drive Wheels Rotating on Applications Listed RESISTANCE CHECK - MODULE DISCONNECTED TEST Re r, R3 R< TERMINAL C to Ground F to H Fto Ground H to Ground Kto Ground J to Ground SPECIFIED RESISTANCE FUNCTION CONDITIONS Vent Valve Control SPS High, 30-55 .................... Open Circuit ............ 15-25 .................... Measured to Ground, Servo Connected Measured to Ground, Servo Disconnected Measured F to H, Servo Connected SPS Low Open Circuit ............ Measured F and H to Ground, Servo Disconnected Vacuum Valve Control 30-55 .................... Open Circuit ............ Measured to Ground, Servo Connected Measured to Ground, Servo Disconnected Ground 0 ......................... Measured to Vehicle Ground F-02424 Figure 5—Control Module Validation Test 9-8 ACCESSORIES • S E R V O C O N N E C T O R D IS C O N N E C T E D • M E A S U R E AT S E R V O P IN S PIN FUNCTION RESISTANCE CONDITIONS D to B SPS 15 -2 5 n M E A S U R E D B E T W E E N P IN S D A N D B (IF M E A S U R E D R E S IS T A N C E IS N O T S T A T E D V A L U E , R E P L A C E S E R V O ) A to C V E N T VA LV E 3 0 -5 5 n M E A S U R E D B E T W E E N P IN S A A N D C (IF M E A S U R E D R E S IS T A N C E IS N O T S T A T E D V A L U E , R E P L A C E S E R V O ) E to C V A C U U M V A LV E 3 0 -5 5 n M E A S U R E D B E T W E E N P IN S E A N D C (IF M E A S U R E D R E S IS T A N C E IS N O T S T A T E D V A L U E , R E P L A C E S E R V O ) 4. M u lti-m e te r 5. S e rv o 6. S e rv o C o n n e c to r B -0 7 6 4 4 Figure 6~Servo Resistance Measurement -► + CRUISE CONTROL MODULE REPLACEMENT Install or Connect (Figure 11) 1. M o d u le a s s e m b ly (1 1 6 ). 2. Remove or Disconnect (Figure 11) H a r n e s s c o n n e c to r (1 2 1 ). 1. H a rn e s s c o n n e c to r (1 2 1 ). 2. M o d u le a s s e m b ly (1 1 6 ) b y p r y in g b a c k t h e r e ta in in g c lip o n t h e b r a c k e t a n d s lid in g t h e m o d u le o u t. Test 1 Action A p p ly C (A -C 2 1 2 v o lts to A an d Reaction E , th e n g ro u n d c lo s e s t h e n o r m a lly o p e n v e n t v a lv e — E -C o p e n s th e n o r m a lly c lo s e d va c u u m v a lv e ). R e m o v e v o lta g e fr o m E S e r v o s h o u ld u u m fu ll s tr o k e . If n o t, c h e c k v a c ­ h o s e s to th e v a c u u m T h e s e r v o s h o u ld h o ld s u p p ly . a fu ll s t r o k e . If n o t, g o to th e n e x t s te p . If s e r v o h o ld s , g o to s te p 4 . 3 D is c o n n e c t th e v a c u u m th e s e rv o a n d b r a k e r e le a s e a t p lu g t h e s e r v o . M o m e n t a r ­ ily a p p ly 1 2 v o lt s t o E to a llo w th e s e rv o If t h e s e r v o h o ld s its p o s it io n , a d ju s t t h e b ra k e v a c u u m r e le a s e v a lv e o r r e p la c e th e v a lv e . S e e O n - V e h ic le S e n /ic e in t h is s e c t io n . to fu ll s tr o k e . 4 • T u rn Ig n itio n “O N ” • V acu u m • T u rn Ig n itio n “ O F F ” a n d d is c o n n e c t • W ith vacu u m T u rn v a lv e c o n n e c t o r a t t h e v a lv e . Ig n itio n “O N .” r e le a s e v a lv e s h o u ld a p r o p e r ly a d ju s te d b a tte r y v o lta g e s h o u ld e n g a g e . b ra k e s w itc h , b e p re s e n t a c ro s s t h e (2 ) c o n n e c t o r t e r m in a ls . N o v o lta g e in d ic a te s a n o p e n b a tte ry c ir c u it. F -0 2 4 3 6 Figure 7—Vacuum Servo Test ACCESSORIES 9-9 SET/COAST (S/C) SW POSITION SLIDER 1-2 C-B 1-3 C-D 1-4 C-A 2-3 B-D 2-4 B-A 3-4 D-A Normal Normal Normal Depressed Depressed Depressed Off On R/A Off On R/A 0 0 0 0 0 0 0 0 0 0 0 0 0 c 0 0 0 0 0 c c c c c c c 0 0 c 0 0 c c c c c C — Closed 0 — Open B A . B lu e B. G re e n C. Y e llo w D. R ed C F -0 2 4 3 7 Figure 8—Mode Control Test 11. V a c u u m 12. R e ta in e r 13. S to p 14. B ra k e R e le a s e V a lv e A s s e m b ly (M a n u a l T r a n s m is s io n ) L a m p S w itc h P ed al Figure 9—Vacuum Release Valve F -0 2 4 3 5 9-10 ACCESSORIES 116. M odule 117. Nut (2.8-4.0 N-m) 118 Bolt/Screw 120. Convenience Pack Bracket 121. Cruise C ontrol Harness 122. Park Brake ASM F -0 2 2 6 0 Figure 10—Clutch Release Switch MULTI-FUNCTION SWITCH REPLACEMENT Remove or Disconnect (Figure 12) 1. P ro te c to r c o v e r (2 6 ). 2. + « - Install or Connect (Figure 12) 1. C r u is e c o n tr o l w ir e (2 7 ) w ith t h e u s e o f a p ia n o w ir e . 2. M u lti-fu n c tio n s w itc h (2 4 ). 3. P ro te c to r c o v e r (2 6 ). M u lti-fu n c tio n s w itc h (2 4 ). 3 . C r u is e c o n tr o l w ir e (2 7 ). G TRU CK 99. 100. 101. 102. C lutch Release S w itch C lutch Brake Pedal Bracket R etainer 102 100 R V -T R U C K F -0 2 2 6 1 Figure 11—Controller Module Mounting ACCESSORIES 9-11 Figure 12—Multi-Function Lever Replacement Install or Connect (Figures 13 through 16) SERVO REPLACEMENT 1. S e rv o (3 5 ). Remove or Disconnect (Figures 13 through 16) 1. V a c u u m h o s e s (3 9 ) a n d h o s e a s s e m b ly (4 9 ). 2 . R e ta in e r (3 4 ). 3. R o d (3 3 ). 4 . C r u is e c a b le a s s e m b ly (5 0 ) (fig u r e 1 6 ). 5. 2. • B o lts (3 6 ) . Ig n itio n a n d f a s t id le c a m s h o u ld b e t h r o ttle s h o u ld b e fu lly c lo s e d b e f o r e th e th e a d ju s tm e n t p r o c e d u r e . 3 . C r u is e c a b le a s s e m b ly (5 0 ). 4 . R o d (3 3 ). B o lts ( 3 6 ) a n d s e r v o (3 5 ) . NOTICE: Flexible components (hoses, wires, con du its, e tc .) m ust not be ro u te d w ithin 50 m m (2 in c h e s ) o f m o ving parts o f the a c c e le ra to r lin k a g e fo rw a rd o f the servo a s s e m b ly u n le s s ro u tin g is p o s itiv e ly controlled. o ff a n d s ta r tin g Adjust • R o d ( 3 3 ) s o t h a t it a s s e m b l e s o v e r s t u d ( 3 2 ) (fig u r e 1 4 ). • C r u is e c a b le a s s e m b ly ( 5 0 ) to t h e th ir d b a ll o n t h e s e r v o c h a in (fig u r e 1 6 ). • J a m n u t ( 5 3 ) u n til t h e c a b le s le e v e a t t h e t h r o t t le le v e r is t ig h t b u t n o t h o ld in g t h e t h r o t t le o p e n (fig u r e 1 6 ). R e ta in e r (3 4 ). V a c u u m h o s e s (3 9 ) a n d h o s e a s s e m b ly (4 9 ). R e fe r to fig u r e s 1 7 th r o u g h 2 0 fo r h o s e r o u tin g s . 9-12 ACCESSORIES A. 1.0-0.5 mm VIEW A G VAN VIEW A B. 0.2-.04 mm 30. VIEW A C-K TRUCK N u t 31. L ever 32. S tu d 33. R od 34. R e ta in e r 35. S e rv o 36. B o lt 3 7 . B ra c k e t 56. Tab A . 0 .5 -i.0 m m (0 .1 9 -0 .3 9 -in c h e s ) B. 0 .2 -0 .4 m m ( .0 0 7 8 7 - .0 1 5 7 5 -in c h e s ) VIEW F -0 2 2 5 8 F ig u r e 1 3 — S e r v o M o u n tin g ( V 6 G a s ) 30. N u t 31. L ever 32. S tu d 33. R od 34. R e ta in e r 35. S e rv o 36. B o lt 37. B ra c k e t F -0 2 2 5 9 Figure 14—Servo Mounting (V8 Gas) ACCESSORIES 9-13 F ig u r e 1 5 — S e r v o M o u n tin g (R V D ie s e l) 34. 35. 37. 48. 49. 50. 51. 52. 53. Retainer Servo Bracket A ccelerator Cable Hose A ssem bly Cruise Cable A ssem bly Radiator S upport C lips Jam N uts VIEW B Figure 16—Servo Mounting (G-Van Diesel) 9-14 ACCESSORIES 55 4? VIEW A 35. S e rv o 39. V acu u m 42. F ittin g 44. V acu u m 45. A /C 49. S e rv o 52. S tra p 55. C h e c k V a lv e H o s e T ank V acu u m H o se H o s e A s s e m b ly F -0 2 2 5 5 Figure 17—Vacuum Hose Routing (RV-Truck V6) 35. S e rv o 39. V acu u m H o se 44. V acu u m T ank 45. A /C 46. C ap V acu u m H o se 49. S e rv o 52. S tra p 53. O il F ill T u b e 54. V a c u u m VIEW B H o s e A s s e m b ly F ittin g ^ F -0 2 2 5 4 Figure 18—Vacuum Hose Routing (G-Van V6) ACCESSORIES 9-15 35. 39. 44. 45. 46. 52. 54. 55. S e rv o Vacuum Hose Vacuum Tank A/C Vacuum Hose Cap Strap Vacuum F itting Check Valve 39 F -0 2 4 0 0 F ig u r e 1 9 — V a c u u m H o s e R o u tin g R V - T r u c k (V 8 G a s ) Figure 20—Vacuum Hose Routing G-Van (V8 Gas) 9-16 ACCESSORIES RADIO DESCRIPTION F o r o p e r a tio n o f th e fa c to r y in s ta lle d s ta n d a r d a n d o p t i o n a l r a d i o s a v a i l a b l e , r e f e r t o t h e O w n e r ’s M a n u a l o r r a d io s u p p le m e n t s u p p lie d w ith th e v e h ic le . T h e r e c e i v e r is m o u n t e d u s in g t h e f r o n t s u p p o r t t u b e s s u rr o u n d in g th e c o n tro l s h a fts , a n d a r e a r s u p p o rt b r a c k e t. T h e fr o n t s u p p o r t t u b e s a r e s e c u r e d w ith n u ts . T h e r e a r s u p p o r t b r a c k e t is s e c u r e d w it h a s c r e w . T h e p o w e r , a n t e n n a , a n d s p e a k e r h a r n e s s e s c o n n e c t to th e r e a r o f t h e r e c e iv e r. D e p e n d in g o n th e m o u n te d a t th e c e n te r p a n e l s o r in t h e r e a r c o T h e a n te n n a m a y b e t h e r ig h t f r o n t c o r n e r o f s y s te m , th e s p e a k e rs c a n b e o r e n d o f t h e d a s h , in t h e s id e rn e rs o f th e c a b . m o u n t e d in t h e w in d s h ie ld , o r o n th e v e h ic le . DIAGNOSIS ACCESSORY NOISE S in c e r a d io p r o b le m s a r e m o s t o fte n r e p a ir e d a t a u th o r ­ iz e d w a r r a n t y r e p a ir s t a t io n s , t h e t e n d e n c y is to r e m o v e t h e s e t w h e n a p r o b le m is r e p o r t e d , w it h o u t a n y p r e lim i­ n a r y d ia g n o s i s . T h i s r e s u lt s in a l a r g e n u m b e r o f r a d io s s h o w in g u p a s “ N O T R O U B L E F O U N D ” u n its w h e n r e ­ c e iv e d b y th e w a r r a n ty r e p a ir s ta tio n s . M a n y tim e s , w h e n t h is is t h e c a s e , t h e t r o u b le u s u a lly c o u ld h a v e b e e n c o r ­ o n e e n d to t h e b lo w e r m o to r a n d t h e o th e r e n d to t h e h o t le a d f r o m t h e b lo w e r m o t o r s w it c h . A ls o , g r o u n d t h e r e c te d w ith o u t r e m o v a l o f th e r a d io , s u c h a s n o is e c o m ­ c a p a c ito r g ro u n d ta b . BLOWER MOTOR NOISE (Figure 32) In s ta ll a b lo w e r m o to r fe e d th ro u g h c a p a c ito r . A tta c h p la in t s . T h e in c o n v e n ie n c e o f d r iv in g w ith o u t a r a d io , w h ile th e s e t is b e in g s e r v ic e d a t a w a r r a n t y r e p a ir s t a t io n , c a n f r e ­ q u e n t l y b e a v o id e d if t h e f o ll o w in g q u i c k c h e c k s a r e u s e d to e lim in a te e x te r n a l r a d io s y s te m p r o b le m s b e fo r e r e m o v ­ in g th e r a d io fo r r e p a ir : BLOWER SWITCH POP (HIGH SETTING TO OFF) In s ta ll a d io d e ( d io d e n u m b e r IN 4 0 0 1 , o r t h e e q u iv a le n t d io d e to w ith s ta n d a 5 0 V in v e r s e p e a k v o lta g e ) fr o m th e h ig h s p e e d s w it c h w ir e ( o r a n g e ) to g r o u n d o n t h e h ig h s p e e d b lo w e r r e la y u n d e r t h e h o o d . • T e s t th e r a d io s o u ts id e , w ith th e h o o d d o w n . BRAKE SWITCH POP • M o s t n o is e c a n In s ta ll a 0 .5 M F D c a p a c it o r b e t w e e n th e tw o w ir e s g o in g to t h e b r a k e s w it c h a t t h e b r a k e p e d a l. A ls o , in s t a ll a 0 .5 M F D c a p a c ito r fr o m th e 1 4 V le a d to g r o u n d a t th e b r a k e b e fo u n d on w eak “ A M ’’ s ta tio n s n e a r t h e lo w f r e q u e n c y a n d e n d o f t h e b a n d • Ig n itio n n o is e o n F M s y s te m . in d ic a te s a p o s s ib le f a u lty H E I • If a t e s t a n t e n n a is u s e d , g r o u n d t h e b a s e t o t h e c a r body and D O N O T H O LD T H E M A ST. • 9 0 % o f th e n o is e s e n te r v ia th e a n te n n a . • A s m a ll a m o u n t o f ig n itio n n o is e m a y b e n o r m a l w h e n t h e H E I is lo c a t e d n e a r t h e c o w l ( w in d s h ie ld a n t e n n a s o n ly ). • • C o a te d s c r e w s o r b o lts C A N W in d s h ie ld a c t a s a p o o r g ro u n d . a n te n n a s a r e m o r e p r o n e to n o is e a n d s t a t io n d ir e c tiv ity . • • CLICKING OR POPPING NOISE (DIESEL ENGINE) 1 ) T h e p r o b le m w ill s o u n d s im ila r to ig n it io n n o is e . H o w e v e r , i t w o n ’t v a r y w i t h e n g i n e s p e e d . A l s o t h e n o i s e w ill m o s t lik e ly b e n o t i c e a b le o n l y in t h e id le c o n d itio n . 2 ) T h e n o is e is b e in g g e n e r a t e d b y t h e h ig h v a c u u m s w it c h in t h e E G R a s s e m b l y ( f i g u r e 3 4 ) . 3 ) C h e c k th e s y s te m 4 ) If t h e fo r a n y v a c u u m le a k s a n d r e p a ir . n o i s e s till r e m a i n s , c h a n g e t h e E G R c o n tro l a s s e m b ly . M o s t h o s e s a r e c o n d u c t iv e u n le s s t h e y h a v e a w h ite CRUISE CONTROL POP (TRANSDUCER TYPE) s tr ip e . F o r c r u is e c o n tr o l e n g a g e a n d d is e n g a g e p o p s , in s ta ll a 0 .5 M F D c a p a c it o r fr o m t h e h o ld lin e a t t h e t r a n s d u c e r to W h e n s h ie l d in g t h e d a s h , w ir e , h o s e , e t c ., u s e fo il o r s c r e e n a n d g r o u n d it. • s w itc h . W e a k o r f a d in g “ A M ” is o f t e n c a u s e d b y i m p r o p e r ly a d ju s te d a n t e n n a t r im m e r (w h e n p r e s e n t). A lw a y s a s a n a id in te r m itte o r r u n n in d e te r m in e th e e x a c t n a to d ia g n o s is . K n o w in g n t o r c o n s ta n t, w h e th e r g , a n d w h e t h e r it o c c u tu r e o f th e r a d io p r o b le m w h e t h e r t h e c o n d i t i o n is it o c c u r s w i t h e n g i n e o f f r s w ith c a r s ta tio n a r y o r m o v in g , w ill h e lp to p in p o in t t h e p r o b le m . U s e C h a r t 1 to is o la te r a d io p r o b le m s , t h e n p r o c e e d to th e d ia g n o s tic c h a rts . g r o u n d . If d is e n g a g e p o p s a r e s till p r e s e n t , s p lic e a 0 .5 M F D c a p a c ito r a c r o s s th e c o n ta c ts o f th e d is e n g a g e s w itc h a t th e b r a k e p e d a l. HORN BLOW-THRU NOISE OR HASH (STATIC IN RADIO SPEAKERS WHEN USING HORN) S p lic e b lo w e r m o to r c a p a c it o r s in to th e c a p a c ito r s a s c lo s e to th e h o r n a s th e c a s e o f th e c a p a c ito r to c h a s s is m e ta l g r o u n d ta b o n th e c a p a c ito r . T h e s o ld e r a ll c o n n e c t io n s in s t e a d o f u s in g e a c h le a d . In s ta ll p o s s ib le . G r o u n d g r o u n d u s in g t h e t e c h n ic ia n s h o u ld q u ic k c o n n e c ts . ACCESSORIES 9-17 B-06920 Figure 21—Chart 1 (System Diagnosis & Analysis) 9-18 ACCESSORIES B-06921 Figure 22—Chart 2 (Noisy Part 1) ACCESSORIES 9-19 B-06922 Figure 23—Chart 3 (Noisy Part 2) 9-20 ACCESSORIES Try the fo llo w in g fix e s in the given o rd e r 1. Install 1224205 filte r p a ck a g e s on BOTH th e battery and ig n i­ tio n pow er leads to th e d ig it a l d a s h . These should be tried w ith and w ith o u t the 1224205’s black lead a tta c h e d to ground, to determ ine best re­ sults. Also, the black w ire o f th e filte r pack­ age m ust face away from the dash. 2. Install one-piece an­ tenna lead-in and run a b r a id e d g r o u n d strap from the base o f the antenna to the negative battery te r­ m inal. Try the fo llo w in g fixe s in the given order. 1. Install a 1224205 filte r package to the ig n i­ tio n pow er line (pink and black wire) o f the ECM. The black w ire o f the filte r package s h o u ld fa c e a w a y fro m th e ECM. The filte r should be tried w ith the filte r’s black le a d g ro u n d e d and ungrounded to de te r­ m in e b e s t re s u lts . The black w ire o f the filte r m ust face away from the ECM. 2. Install a 1224205 filte r package to the m em ­ ory lead (orange wire, te r m in a l R) o f th e ECM. Again, face the b la c k w ir e o f th e 1224205 aw ay fro m the ECM. B-06923 Figure 24—Chart 4 (ECM or Digital Dash Noise) ACCESSORIES 9-21 CHART 5 IGNITION NOISE D eterm ine the source of the ig n itio n noise. 1 o r 2 cylinders. A ll cylinders. - Try th e fo llo w in g fixe s in the given order: 1. C h e ck fo r lo o s e o r defective spark plug wire. 2. R eroute s p a rk plu g w ires laying a gainst a n y th in g th a t c o u ld p o s s ib ly tr a n s m it n o is e to th e ra d io ( w ir in g o r s e n s o r leads th a t travel into the passenger c o m ­ partm ent). 3. C heck fo r f a u lt y spark plug. 4. R e pla ce d is tr ib u to r cap and rotor. ' n Try the fo llo w in g fixes in the given order: 1. C h e c k th e g ro u n d from engine to bulk­ head; in s t a ll a braided ground strap if necessary. 2. I n s t a ll a b ra id e d ground strap on the hood. 3. C h e c k h e a te r c o re ground; clean or in ­ stall braided ground strap if necessary. 4. C heck air co n d itio n e r accu m u la to r ground; c le a n o r in s t a ll a braided ground strap if necessary. 5. Move all w irin g away from HEI and spark plug wires. 6. In s p e c t HEI fo r the fo llo w in g and replace if necessary: • D is t r ib u t o r c a p c a rb o n b a ll eroded away, o r cracked or loose cap. • A r o to r w ith b u rn e d b la c k spot on w ip e r o r p its in w ip e r sur­ face. • A fa u lty coil. • A n o ily film on som e of the lead te rm in a ls o r in ­ side the cap. • Faulty HEI m od­ ule; can cause ig­ n itio n n o is e on FM only. B-06924 Figure 25—Chart 5 (Ignition Noise) 9-22 ACCESSORIES CHART 6 ANTENNA NOISE - PART 1 W in dsh ie d antenna Noise elim inated. Plua antenna back into the radio. r Place alum inum fo il over the entire dash to p and g ro u n d it w ith c lip le ads to each d o o r and jam s w itc h . Noise remains Use a s n iffe r to lo ­ c a te fro m w h ic h part o f the dash the n o is e is b e in g generated. A fte r lo c a tin g th e a re a o f th e d a s h where the noise is b e in g g e n e r a te d , th e fo llo w in g fix e s are possible. U np lug a n ten n a at the cow l. N oise elim inated. C heck the m o unting (g ro u n d ) c o n n e c ­ tio n s o f th e c o w l s h ie ld . It m u s t be grounded. G ro u n d th e h o o d w ith a short ground strap from the cow l. (Scrape the surface around th e m o u n t­ ing holes fo r good contact). N oise rem ains Suppress the noise at the source using th e a p p r o p r ia te c h a r t: IG N IT IO N NO ISE, A LT E R N A ­ TOR W H IN E , A C ­ CESSORY NOISE. Line the underside o f the dash w ith alum in u m ta p e , th e ta p e M UST BE GROUNDED. N oise remains. If a “ n o isy” w ire or c a b le c a n be lo ­ cated w it the sniffer, re-route it o r ground th e s h ie ld o f any “ n o isy” cable. M e a s u re g ro u n d from lead-in shield (at radio end o f leadGood ground. in) to good ground, Less than usin g low est scale on a d ig ita l ohm m e- 0.2 Ohm s ter. G re a te r th a n 0.2 O hm s C heck antenna leadin screw s at cow l. Scrape area and in ­ stall “ sh in y” screw s to in s u re a g o o d ground. »-------- ----------- A g a in m e a s u re ground from the an­ tenna lead-in shield to a good ground. iG r e a te r R e p la c e th e antenna lead-in. If all else fails, in ­ s ta llin g an o u ts id e a n te n n a w ill o fte n e lim in a te th e c u s ­ to m e r’s com plaint. Less than 0.2 O hm s han 0 .2 O hm s N oise rem ains. S uppress the noise at the source using th e a p p r o p r ia te c h a r t: IG N IT IO N N O IS E , A LT E R N A ­ TOR W H IN E , A C ­ CESSORY NOISE. B-06925 Figure 26—Chart 6 (Antenna Noise Part 1) ACCESSORIES 9-23 B-06926 Figure 27—Chart 7 (Antenna Noise Part 2) 9-24 ACCESSORIES CHART 8 WEAK [only AM and FM weak or o n ly AM is weak. Com pare the FM re­ c e p tio n to a n o th e r car w ith an FM ra­ d io . T u n e in t o a weak station. Trim the A n te n n a 1 See P rocedure Be­ low W on’t trim 1 weak. Check the antenna system w ith a test antenna. Radio W orks STOP FM is weak o r s till C u s to m e r ’s ra d io h a s c o n s id e r a b ly weaker reception. Both radios have rel­ a tiv e ly s im ila r re ­ ce p tio n capabilities. S till Weak Return to Norm al Remove t ie Radio Remove the Radio. Repair the antenna system . Retrim . Explain to the cu s ­ to m e r that the radio is norm al. *ETR and 2000 series radios do not have an an­ tenna trim m er. Try a s u b s titu te antenna. ANTENNA TRIMMER ADJUSTMENT The antenna trim m e r adju stm e nt m atches the antenna c o il in the radio to the antenna. Only AM radios, o r the AM part o f AM /FM radios, need th is a d justm e n t. (ETR m odels and all 2000 series radios use “ se lf a d ju s tin g ” circu its, and do not have an antenna trim m er). 1. Tune the radio to a weak AM sta tio n o r noise near 1400 kHz. Turn the volum e all the way up. You sho u ld barely hear the station. 2. Remove the rig ht inner and oute r knobs. 3. Use a sm all screw driver to ad just the trim ­ m er screw. A d ju s t the screw fo r the loudest volum e. 4. R einstall th e c o n tro l knobs. B-06927 Figure 28—Chart 8 (Weak) ACCESSORIES 9-25 Try th e f o llo w in g fixes in the given o r­ der: 1. I n s t a ll a 250 MFD, 100V capa­ c ito r on the al­ te rn a to r o u tp u t lead and/or th e brown fie ld w ire o f the a lterna tor to ground. 2. Exchange radio w it h a k n o w n g o o d ra d io . If th is e lim in a te s the noise, send the fa u lty radio to an authorized repair shop. 3. D e d i c a t e d g ro u n d fo r th e ra d io re c e iv e r. C u t th e b la c k w ire o f the black plug in back of the radio. A ttach a b ra id e d g ro u n d s tr a p from the case o f th e ra d io to a g o o d c h a s s is . Try th e f o llo w in g fixe s in the given or­ der: 1. I n s t a ll a 250 MFD, 100V capa­ c ito r on the al­ te rn a to r o u tp u t lead and/or the brown fie ld w ire at the alternator. 2. Install a 1224205 filte r p a cka g e on the e x is tin g ground w ire fo r the radio. 3. E x c h a n g e th e ra d io w ith a know n good ra­ dio. If th is e lim i­ nates the noise, send the fa u lty ra d io to an a u th o r iz e d re ­ pair shop. 4. Replace the a l­ ternator. 4. Run a w ire d i­ re c tly fro m the p o sitive ba ttery te rm in a l to the alternator. 5. Replace the a l­ ternator. B-06928 Figure 29—Chart 9 (Alternator Whine) 9-26 ACCESSORIES CHART 10 DEAD I 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. { A ll m odes are dead. U sing an ohmmeter, m easure from all 8 speaker term inals of b lu e and w h ite p lugs at the back of radio, to ground. O n e o r m o re A ll open shorted 1 Check the radio 14V at ca vity F on the black plug of the ra­ dio. Also, check for 14V on the orange wire o f the m em ory c o n n e c to r on th e back of radio. Also, c h e ck the speaker co n n e ctio n s at the w h ite an d b lu e plugs on the back of the radio. Refer to diagram below). i M e a s u re a c ro s s each speaker (A-C, B-D, etc.) ot open or Shorted R e p a ir o r re p la c e h a rn e s s . R e c h e c k radio. I Open o r Shorted Replace speaker or repair co n ne ctio n. Remove radio. Not O K I Remove radio. OK STOP Bad .r AM and FM dead or AM only dead. X C heck antenna and lead-in w ith a sub ­ s titu te a n te n n a . I Bad Repair the connection. I C o rre c t th e p ro b lem. Radio W orks Radio W orks No Reception Remove the rad io.’ S top. R e p la c e th e m a lfu n c tio n in g antenna or lead-in. Retrim . *W hen radio has been determ ined to be defective, be sure to describe the sym p tom s to aid th e radio te c h ­ nician. Remove radio Check all the acces­ sories on the fuse fo r the problem . Re­ fe r to S e rv ic e Manual. Test drive if necessary). C heck the antenna co n ne ctio n. U n p lu g th e ra d io pow er lead. Replace the fuse. G o o d Repair G ood Check the fuse. I F u s e Blown Fuse Fuse Blows A gain Fuse Doesn’t Blow P lu g th e ra d io pow er lead back in. F use B lo w s Remove the radio. FM only is dead. I Remove the unit. Front and rear speaker harnesses, and p o w e r p lu g c o n n e c to r pin ____________ ________| views. + 14V ANT. F BLACK G trt FDIMMER R.F. WHITE Figure 30—Chart 10 (Dead) BLUE L.R. B-06929 ACCESSORIES 9-27 *NOTE: Jam m ed tape cannot be removed from th e search and repeat tape deck. Send the radio to authorized repair shop. CAPSTAN CLEANING PARTS OF TAPE PLAYER TO REDUCE TAPE NOISE There are tw o parts th a t you clean on a tape player; the head and the capstan. S ince 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 co tto n swab dipped in ordinary rubbing alcohol. W ipe the head and capstan as show n. B-06930 Figure 31—Chart 11 (Tape) 9-28 ACCESSORIES HORN SWITCH POPS (Figure 36 and 37) 1 ) In s ta ll a 0 .5 M F D c a p a c it o r b e t w e e n t h e s w itc h e d 1 4 v o lt le a d a n d h o r n le a d a t t h e h o r n d e la y . 2 ) If p o p p e r s i s t s , i n s t a ll a 0 .5 M F D c a p a c i t o r f r o m t h e s w it c h e d 1 4 v o lt le a d o f t h e h o r n r e la y to g r o u n d a n d a 0 .5 M F D c a p a c it o r fr o m th e h o r n le a d to g r o u n d . e n g in e s p e e d . A ls o th is n o is e s h o u ld b e n o t ic e a b le w ith t h e i g n i t i o n “ o n ” , a n d e n g i n e “ o f f ” , b u t n o t in “ a c c e s s o r y ” p o s itio n . P r o b le m : N o is e is b e in g r a d i a t e d f r o m t h e m ix t u r e s o le n o id d u ty c y c le le a d to t h e A L D L c o n n e c to r . c o n tro l MIXTURE CONTROL SOLENOID POPPING F ix : C o m p la in t: A p o p p in g n o is e w h ic h s o u n d s lik e ig n it io n n o is e o c c u r i n g o n t h e A M b a n d . T h i s n o is e w ill N O T v a r y w it h 1 ) L o c a t e d th e b r e a k o u t h a r n e s s e x te n d in g fr o m th e m a in h a r n e s s , a b o u t s ix in c h e s fr o m t h e E C M h a rn e s s c o n n e c to r. 2 ) L o c a t e d t h e lig h t b lu e w ir e . It s h o u ld c o n n e c t to P in D o n t h e 1 5 p in b r e a k o u t c o n n e c t o r . 3 ) C u t t h e lig h t b lu e w ir e o n t h e v e h ic le c o n n e c to r a t th e c o n n e c to r. 15 i Low Vacuum S w itch S olenoid EGR A ssem bly High Vacuum S w itch B -0 6 9 9 0 Figure 34—Diesel EGR High Vacuum Switch 15. 16. 17. 18. 19. 16 17 \ V 18 s id e o f th e 19 \ Lead from the Horn S w itch .5 MFD Feed through C apacitor Horn No. 1 .5 MFD Feed through C apacitor Horn No. 2 Figure 36—Horn Capacitor * B -0 6 9 9 4 ACCESSORIES 9-29 30 \ 20. 21. 22. 23. 24. To the horn s w itch (steering colum n) Horn relay. Power (fused 14 volts) .5 MFD ca pa citor To the horns. B-06995 Figure 37—Horn Switch Capacitor REAR DEFOGGER NOISE OR HASH A b r o k e n g r i d in t h e d e f o g g e r in t h e r e a r g la s s m a y c a u s e a “ h a s h ” in t h e r a d i o . R e p a i r i n g t h is b r e a k w ill e lim i n a t e t h e n o is e . A b r e a k in t h e r e a r d e f o g g e r g r id c a n b e fo u n d b y to u c h in g e a c h “ lin e ” o f t h e g r id w h ile t h e r e a r d e f o g g e r is o n . T h e c o ld g r id is t h e o n e b r o k e n . TACHOMETER NOISE L o c a te th e w ir e fr o m th e d is tr ib u to r c a p to th e t a c h o m e t e r a n d s h i e l d t h e w i r e b y w r a p p i n g it w i t h a lu m in u m ta p e . T h e ta p e m u s t a ls o b e c o n n e c te d to a g o o d g ro u n d . TORQUE CONVERTER LOCK-UP NOISE M o d e l: D ie s e l E n g in e s 31. 32. 33. 34. 35. 36. 37. To a Test Terminal To th e Brake S w itch and Fuse B lock F ilte r Package. 1224205 4-3 S h ift (M om entary open) TCC S olenoid 4th Gear S w itch (Closed when engaged) F ilte r G round W ire D nQiQo Figure 38—Torque Converter Lock Up Noise WIPER SWISH WINDSHIELD ANTENNA T h e s w is h s o u n d e n c o u n te r e d w h o v e r t h e w i n d s h i e l d a n t e n n a is d u e b e tw e e n t h e w in d s h ie ld a n d t h e w ip w in d s h ie ld w ith O p tic le a n o r a d d a s o a p to th e w a s h e r b o ttle . e n th e w ip e r s p a s s to a s ta tic b u ild u p e r. T ry c le a n in g th e t a b le s p o o n o f d is h C o m p la in t: H ash o r p o p p in g n o is e on “A M ” band a fte r to rq u e c o n v e r te r “ lo c k -u p ” ( 3 5 - 4 5 m p h ). F ix : 1 ) In s ta le a d pack le a d ll a 1 2 2 4 2 0 5 f i lt e r p a c k a g e in s e r ie s w it h g r e e n o n t h e V R V s w it c h ( s e e t h e i n s t r u c t io n s in f ilt e r a g e ) . F o r th is a p p lic a t io n , c o n n e c t t h e g r o u n d in t h e f ilt e r p a c k a g e to t h e b lu e le a d o n t h e V R V s w itc h , in s te a d o f to g r o u n d . In s ta ll a c a p a c it o r (0 .5 M F D ) fr o m th e b lu e le a d o n V R V s w itc h to g r o u n d . F ix : 2 ) In s ta ll a 2 2 0 M F D c a p a c ito r r a te d a t 5 0 V D C a c r o s s t h e V R V s w itc h b e t w e e n t h e g r e e n a n d b lu e w ir e s . OTHER ELECTRIC MOTOR NOISES WINDOWS, BLOWER MOTORS) (POWER In s ta ll a 0 .5 M F D c a p a c it o r r a te d a t 5 0 V D C a c r o s s e a c h m o to r. OTHER SWITCH POPS (BLOWER SWITCHES, POWER LOCKS, POWER MIRROS, PARK - NEUTRAL SWITCH, POWER WINDOWS, WIPERS, REAR WINDOW DEFOGGER) In s ta ll a 0 .5 M F D c a p a c it o r r a te d a t 5 0 V D C c o n ta c ts o f th e s w itc h , fr o m g ro u n d o r b o th . a c ro s s th e th e h o t s id e o f th e s w itc h to 9-30 ACCESSORIES 40 42 / 41 / _ fn j Ii/ ------ /1-------- _ b p lu g g used P ro 1. e d i n t o t h e r a d i o ’s a n t e n n a s o c k e t . I t c a n t h e n b e to p ro b e a n d s e a r c h o u t “ H o t S p o ts ” . c e d u re : W h ile lis te n in g to t h e c o m p la in t n o is e , d is c o n n e c t th e a n t e n n a a n d p lu g t h e s n if f e r in to t h e a n t e n n a s o c k e t. 2 . T u rn th e r a d io v o lu m e u p . 3 . W h e n s e a r c h in g fo r th e n o is e s o u r c e , k e e p fin g e r s o f f o f t h e p r o b e , o t h e r w is e e r r o n e o u s r e s u lt s w ill b e r e c e iv e d . \ 43 40. 41. A n te n n a L e a d C e n t e r W ir e 42. W h ite 43. 50 m m P la s tic In In s u la to r (2 in .) o f C o a x S h ie ld R em o ved B -0 9 1 9 7 Figure 39—RF Sniffer DIAGNOSTIC RF SNIFFER T h e a n t e n n a s n iffe r c a n b e r a d io to lo c a te “ H o t S p o t s ” w n o is e in te r fe r e n c e . T h e s e “ H o t h a r n e s s e s , in t h e u p p e r p a r t o f u s e d a lo h ic h a r e S p o ts ” w th e d a s h T h e s n i f f e r i s m a d e from an o l d p i e c e o f a n t e n n a l e a d - i n fr o m a m a s t o r p o w e r a n te n n a . T h e lo n g e r th e le a d -in th e b e t t e r , s i n c e it w ill m a k e t h e s n i f f e r m o r e f l e x i b l e a s a d ia g n o s tic to o l. M a k e t h e s n if f e r a s s h o w n in f i g u r e 3 9 . T h e 5 0 m m ( 2 in c h ) s e c tio n w ith t h e b la c k c o a t in g a n d b r a id e d s h ie ld s t r ip p e d b a c k b e c o m e s t h e a n t e n n a w h e n t h e s n if f e r is n g w i t h t h e c a r ’s g e n e r a tin g r a d io ill b e f o u n d in t h e o r e v e n b e tw e e n th e h o o d a n d w in d s h ie ld . W h e n c h e c k in g b e a c h ie v e d w h e n T h e s n iffe r c a n a re a o f th e d a s h w in d s h ie ld a n t e n n fo r n o is e o n a t h e s n if f e r is p a ls o b e u s e d t h e n o i s e is a. w ir e , t h e b e s t r e s u lt s w ill la c e d p a r a lle l to th e w ir e . to d e te r m in e fr o m w h a t b e in g g e n e r a te d o n to a T h e s n iffe r c a n a ls o b e u s e d to lo c a te “ H o t S p o t s ” b e tw e e n th e w in d s h ie ld a n d th e h o o d t h a t m a y b e d ir e c tin g n o is e o n to th e w in d s h ie ld a n t e n n a . It m u s t b e n o t e d t h a t t h e s n if f e r w ill a l s o lo c a t e “ n o r m a l” h o t s p o ts . H o w e v e r , th e te c h n ic ia n w h o b e c o m e s f a m i l i a r w i t h t h e s n i f f e r s c a p a b i l i t i e s w i l l f i n d it t h e m o s t u s e f u l d ia g n o s t ic t o o l in n o is e s u p p r e s s io n w o r k . RADIO RECEIVER REPLACEMENT RV MODELS 2. 3. 4. 5. 6. *■+ Remove or Disconnect (Figure 40) 1. B a t t e r y g r o u n d c a b l e S N K C B u u n o a p p o rt b ra c k e t s c re w s (5 5 ) ts (5 2 ) o n th e s u p p o rt tu b e s (5 1 ) o b b e z e ls (5 3 ) n tro l k n o b s (5 4 ) tte r y g r o u n d c a b le 2. C o n t r o l k n o b s ( 5 4 ) G VAN 3 . K n o b b e z e ls (5 3 ) 4 . N u ts (5 2 ) fro m th e s u p p o rt tu b e s (5 1 ) 5 . S u p p o r t b r a c k e t r e ta in e r s c r e w s (5 5 ) 6. H a r n e s s e s Remove or Disconnect (Figure 40) • L ift u p t h e r e a r e d g e o f t h e r e c e iv e r . • P u s h t h e r e c e iv e r fo r w a r d u n til t h e s h a fts c le a r th e in s tr u m e n t p a n e l. L o w e r th e c o n tro l s h a fts . • c o n tro l • R e m o v e th e p o w e r fe e d , s p e a k e r a n d a n te n n a c o n n e c to rs . R e c e iv e r (5 0 ) 0 R e c e iv e r (5 0 ) • P o s itio n p a n e l. • C o n n e c t th e p o w e r, s p e a k e r a n d a n te n n a le a d s . L ift t h e r e a r o f t h e r e c e iv e r in to p la c e . • • r e c e iv e r under th e in s tr u m e n t M o v e th e r e c e iv e r r e a rw a rd s o th a t th e c o n tro l s h a f t s s l id e t h r o u g h t h e c o n t r o l s h a f t h o l e s in th e in s tr u m e n t p a n e l. 3 . A ir c le a n e r c o v e r 4 . A ir c le a n e r e le m e n t 5. C o n tro l k n o b s (5 4 ) 6. K n o b b e z e l s ( 5 3 ) 7. R e ta in in g n u ts (5 2 ) 8. R e a r m o u n t i n g b r a c k e t s c r e w s ( 5 5 ) Install or Connect (Figure 40) th e 1. B a t t e r y g r o u n d c a b l e 2. E n g i n e c o v e r 9 . P o w e r, s p e a k e r a n d a n te n n a le a d s • P u s h r e c e iv e r fo rw a rd . • L o w e r r e c e iv e r. • D is c o n n e c t le a d s . 10. R e c e i v e r ( 5 0 ) ♦ «- Install or Connect (Figure 40) 1 . P o w e r , s p e a k e r a n d a n t e n n a le a d s . 2 . R e c e iv e r (5 0 ) • R a is e r e c e iv e r in to p la c e . ACCESSORIES 9-31 A. B. 50. 51. 52. 53. 54. 55. G Van CK Truck Receiver Support Tube Nut Knob Bezel Knob Support Bracket Screw B-06949 Figure 40—Receiver Installation 9-32 ACCESSORIES • M o v e r e c e iv e r r e a r w a r d s o th a t s h a f t s a r e in t h e m o u n t i n g h o le s . th e c o n tro l 3 . R e a r m o u n tin g b r a c k e t s c r e w s (5 5 ). 4 . R e ta in in g n u ts (5 2 ) o n th e s u p p o r tin g tu b e s (5 1 ). 8 . A ir c le a n e r c o v e r. 9 . E n g in e c o v e r. 1 0 . B a tte r y g ro u n d c a b le . NOTICE: Always connect the speaker wiring harness to the receiver before applying power to the receiver in order to prevent receiver damage. 5. K n o b b e z e l (5 3 ). 6. C o n tro l k n o b s (5 4 ). 7. A ir c le a n e r e le m e n t . ANTENNA REPLACEMENT + « - Install or Connect (Figure 41) 1. W in d o w . R e fe r to S e c . 10 “ W in d s h ie ld R e p la c e m e n t” . 2 . A n te n n a c a b le c o n n e c to r 3 . B a tte r y g r o u n d c a b le G VAN Remove or Disconnect (Figure 42) 1. 2. 3. 4. 5. 6. 7. B a tte r y g r o u n d c a b le M a s t r e t a i n i n g n u t (56) M a s t (57) N u t (55) S e a l (54) a n d b e z e l S e a l (52) (53) B o d y a n d c a b le a s s e m b ly 8. W a s h e r (50) (51) |+<-| Install or Connect RV MODELS Remove or Disconnect (Figure 41) 1. B a tte r y g r o u n d c a b le 2 . A n te n n a c a b le c o n n e c to r 3. W in d o w . R e fe r to S e c . R e p la c e m e n t” . 10 “ W in d s h ie ld 1. 2. 3. 4. 5. 6. 7. W a s h e r (51) B o d y a n d c a b le a s s e m b ly S e a l (52) S e a l (54) a n d b e z e l (53) N u t (55) M a s t (57) M a s t r e t a i n i n g n u t (56) 8 . B a tte r y g r o u n d c a b le (50) SPEAKER REPLACEMENT Install or Connect (Figures 43 and 44) RV MODELS 1. S p e a k e r h a r n e s s to s p e a k e r (7 1 ) FRONT SPEAKER 2 . S p e a k e r (7 1 ) Remove or Disconnect (Figures 43 and 44) 1. B a tte r y g r o u n d c a b le 2 . In s tr u m e n t c lu s te r b e z e l u p p e r fo u r s c r e w s 3 . In s tr u m e n t p a n e l p a d s c r e w s 4. P a d ( 7 0 ) 3 . S p e a k e r to d a s h p a n e l s c r e w s (7 2 ) 4. P a d (7 0 ) 5 . In s tr u m e n t p a n e l p a d s c r e w s 5 . S p e a k e r to d a s h p a n e l s c r e w s (7 2 ) 6. S p e a k e r h a rn e s s • 6 . In s tr u m e n t c lu s te r b e z e l u p p e r fo u r s c r e w s L ift u p s p e a k e r ( 7 1 ) 7. S p e a k e r (7 1 ) 7. B a tte r y g r o u n d c a b le ACCESSORIES 9-33 Body and Cable A sse m b ly W asher Seal Bezel Seal Nut M ast R etaining Nut M ast ? B-09198 Figure 42—Antenna System G-Van Figure 43—Front Speakers RV ACCESSORIES 9-35 A. B. C. 80. 81. 82. 83. CK Pickup U tility Suburban G rille Speaker Speaker M o u n tin g Screw C lip Nut 84. In su la to r 85. In su la to r 86. Bracket 87. Bracket R etaining Screw 88. Speaker R etaining Screw 89. Trim Panel 90. G rille R etaining Screw Figure 45—Rear Speakers RV REAR SPEAKER G VAN Remove or Disconnect (Figure 45) 1 . B a tte r y g r o u n d c a b le FRONT SPEAKER Remove or Disconnect (Figure 46) 2 . G r ill r e ta in in g s c r e w s ( 9 0 ) 3 . G r ill ( 8 0 ) 1. B a tte r y g r o u n d c a b le 4 . S p e a k e r r e ta in in g s c r e w s ( 8 2 ) 2. In s tr u m e n t p a n e l b e z e l 3. In s tr u m e n t c lu s te r 5. S p e a k e r h a rn e s s fro m th e s p e a k e r (8 1 ) 4 . S p e a k e r s c re w s (1 0 2 ) 6 . S p e a k e r (8 1 ) 0 Install or Connect (Figure 45) 1 . S p e a k e r h a r n e s s to th e s p e a k e r 2 . S p e a k e r (8 1 ) 3 . S p e a k e r r e ta in in g s c r e w s (8 2 ) 5 . S p e a k e r c o n n e c to r (1 0 1 ) 6 . S p e a k e r (1 0 0 ) “►+ Install or Connect (Figure 46) 1. S p e a k e r c o n n e c to r (1 0 1 ) to th e s p e a k e r (1 0 0 ) 2. S p e a k e r (1 0 0 ) 3. S p e a k e r s c re w s (1 0 2 ) 4 . G r ill ( 8 0 ) 4. In s tr u m e n t c lu s te r 5 . G r ill r e ta in in g s c r e w s ( 8 2 ) 5 . In s tr u m e n t p a n e l b e z e l 6. 6. B a tte r y g ro u n d c a b le B a tte r y g r o u n d c a b le 9-36 ACCESSORIES REAR CORNER SPEAKER Remove or Disconnect (Figure 47) 1. B a t t e r y g r o u n d c a b l e . 2. L o w e r c o r n e r t r i m p a n e l ( 1 1 4 ) . 3. L o w e r e d g e s c r e w s o f t h e u p p e r c o r n e r tr im panel ( 110). 4 . T r im s tr ip (1 1 5 ) s c r e w s . 5 . R e a r d o o r u p p e r m o ld in g (1 1 3 ) s c r e w s . 6. U p p e r c o r n e r t r i m p a n e l ( 1 1 0 ) u p p e r s c r e w s . 7. U p p e r c o r n e r tr im p a n e l a s s e m b ly (1 1 0 ). 8. H o r n e s s c o n n e c t o r f r o m t h e s p e a k e r . 9 . In s u la tio n r e ta in in g s c r e w s . 10. I n s u l a t i o n ( 1 1 2 ) . 11 . S p e a k e r r e t a i n i n g s c r e w s . 12. S p e a k e r ( 1 1 1 ) f r o m t h e u p p e r c o r n e r t r i m p a n e l ( 1 1 0 ) . El Install or Connect (Figure 47) 1. S p e a k e r ( 1 1 1 ) t o t h e u p p e r c o r n e r t r i m p a n e l ( 1 1 0 ) . 2. S p e a k e r r e t a in in g s c r e w s . 3 . In s u la tio n (1 1 2 ). 4 . In s lu la tio n r e ta in in g s c r e w s . 5 . H a r n e s s c o n n e c to r to th e s p e a k e r . 6. U p p e r c o r n e r t r i m p a n e l a s s e m b l y ( 1 1 0 ) . 7. U p p e r c o r n e r tr im p a n e l s c r e w s . 8. R e a r d o o r u p p e r m o l d i n g ( 1 1 3 ) s c r e w s . 9 . T r im s tr ip (1 1 5 ). 10. T r i m s t r i p ( 1 1 5 ) s c r e w s . 11 . L o w e r c o r n e r t r i m p a n e l ( 1 1 4 ) . 12. B a t t e r y g r o u n d c a b l e . REAR SIDE SPEAKER Remove or Disconnect (Figure 48 and 49) 1. B a tte r y g r o u n d c a b le . 2 . F o u r f o r w a r d lo w e r s c r e w s r e t a in in g t h e r e a r t r im p a n e l. • P u ll t h e t r im p a n e l o u t to r e a c h t h e s p e a k e r . 110. 111. 112. 113. 114. 115. Upper Corner Trim Panel Speaker Speaker Insulation Rear Door Upper M olding Lower C orner Trim Panel Trim S trip B.og219 Figure 47—Rear Corner Speakers G-Van 3 . H a rn e s s c o n n e c to r fro m 4 . S p e a k e r r e ta in in g n u ts . 5. S p e a k e r. th e s p e a k e r. Install or Connect (Figure 48 and 49) 1. S p e a k e r. 2 . S p e a k e r r e ta in in g n u ts . 3 . H a r n e s s c o n n e c to r to th e s p e a k e r . 4 . R e a r tr im p a n e l s c r e w s . 5 . B a tte r y g ro u n d c a b le . ACCESSORIES 9-37 120. Speaker 121. N ut 122. Harness C o n n e cto r B -0 9 2 4 7 Figure 48—Rear Side Speakers 9-38 ACCESSORIES Figure 49—Speaker Harness G-Van 10A1-1 SECTION 10 BODY CONTENTS SUBJECT PAGE D o o rs..................................................................................................................................................................10A1-1 Seats................................................................................................................................................................... 10A2-1 Glass................................................................................................................................................................... 10A3-1 Interior Trim ........................................................................................................................................................10A4-1 End Gate..............................................................................................................................................................10A5-1 SECTION 10A1 DOORS NOTICE: Door lock striker system fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or coulr result in major repair expense. They must be replaced with one o f the same part num ber or with an equivalent part if replacem ent becom es necessary. Do not use a replacem ent part o f lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of these parts. CONTENTS SUBJECT PAGE RV Model Side Front D o or...............................................................................................................................10A1- 4 Door And Hinge Replacement.....................................................................................................................10A1- 4 Door Adjustment.......................................................................................................................................... 10A1- 4 Door Trim Panel Replacement.....................................................................................................................10A1- 4 Door Vent/Window Run Channel Assembly Replacement.......................................................................... 10A1- 5 Vent Glass Replacement...............................................................................................................................10A1- 6 Vent Window Adjustment.............................................................................................................................10A1- 7 Door Window Replacement...........................................................................................................................10A1- 7 Inner Window Weatherstrip Replacement..................... ............................................................................ 10A1- 8 Outer Window Weatherstrip Replacement................................................................................................. 10A1- 8 Rear Glass Run Channel Replacement....................................................................................................... 10A1- 8 Window Regulator Replacement................................................................................................................. 10A1- 9 Door Lock Replacement.............................................................................................................................. 10A1-10 Power Door Lock Motor Replacement......................................................................................................... 10A1-10 Door Outside Handle Replacement............................................................................................................. 10A1-11 Door Lock Cylinder Replacement................................................................................................................. 10A1-11 Door Inside Handle Replacement................................................................................................................. 10A1-12 Door Weatherstrip Replacement................................................................................................................. 10A1-12 Outside Rear View Mirror Replacement....................................................................................................... 10A1-13 Below Eyeline Outside Rear View Mirror Replacement.............................................................................. 10A1-13 West Coast Outside Rear View Mirror Replacement..................................................................................10A1-13 Door Air Valve Replacement.........................................................................................................................10A1-13 RV Model Side Rear Doors..............................................................................................................................10A1-14 Door And Hinge Replacement.....................................................................................................................10A1-14 Door Adjustment.......................................................................................................................................... 10A1-15 Door Trim Panel Replacement.....................................................................................................................10A1-16 10A1-2 DOORS CONTENTS (CONTINUED) SUBJECT PAGE RV Model Side Rear Doors (Continued) Stationary Glass/Window Run Channel Assembly Replacement.............................................................. 10A1-16 Door Window Replacement...........................................................................................................................10A1-17 Inner Window Weatherstrip Replacement...................................................................................... ............ 10A1-17 Outer Window Weatherstrip Replacement................................................................................................. 10A1-18 Front Glass Run Channel Replacement....................................................................................................... 10A1-19 Window Regulator Replacement................................................................................................................. 10A1-19 Door Lock Replacement...............................................................................................................................10A1-20 Power Door Lock Motor Replacement......................................................................................................... 10A1-20 Door Outside Handle Replacement............................................................................................................. 10A1-21 Door Inside Handle Replacement................................................................................................................. 10A1-21 Remote Control Replacement....................................................................................................................... 10A1-21 Door Weatherstrip Replacement................................................................................................................. 10A1-22 Door Air Valve Replacement.........................................................................................................................10A1-22 RV Model Rear D oors...................................................................................................................................... 10A1-23 Door And Hinge Replacement..................................................................................................................... 10A1-23 Door Adjustm ent.......................................................................................................................................... 10A1-23 Striker Replacement.....................................................................................................................................10A1-23 Bumper Wedge Replacement...................................................................................................................... 10A1-25 Door Trim Panel Replacement..................................................................................................................... 10A1-25 Window Replacement...................................................................................................................................10A1-25 Right Door Lower Latch Replacement........................................................................................................ 10A1-26 Right Door Upper Latch Replacement......................................................................................................... 10A1-27 Right Door Control Assembly Replacement................................................................................................10A1-28 Door Outside Handle Replacement............................................................................................................. 10A1-28 Left Door Lower Latch Replacement........................................................................................................... 10A1-28 Check Strap Replacement.............................................................................................................................10A1-29 Right Door Weatherstrip Replacement....................................................................................................... 10A1-29 Left Door Weatherstrip Replacement........................................................................................................... 10A1-29 Secondary Weatherstrip Replacement......................................................................................................... 10A1-30 G Model Side Front D o o r.................................................................................................................................10A1-32 Door And Hinge Replacement..................................................................................................................... 10A1-32 Door Adjustment.......................................................................................................................................... 10A1-32 Door Trim Panel Replacement..................................................................................................................... 10A1-33 Door Vent/Window Run Channel Assembly Replacement.......................................................................... 10A1-34 Vent Glass Replacement...............................................................................................................................10A1-35 Vent Window Adjustment.............................................................................................................................10A1-36 Door Window Replacement...........................................................................................................................10A1-36 Window Stop Assembly Adjustment........................................................................................................... 10A1-37 Inner Window Weatherstrip Replacement....................................................................................................10A1-37 Outer Window Weatherstrip Replacement..................................................................................................10A1-37 Rear Glass Run Channel Replacement....................................................................................................... 10A1-37 Window Regulator Replacement................................................................................................................. 10A1-38 Door Lock Replacement...............................................................................................................................10A1-39 Power Door Lock Motor Replacement......................................................................................................... 10A1-40 Door Outside Handle Replacement............................................................................................................. 10A1-40 Door Lock Cylinder Replacement................................................................................................................. 10A1-40 Door Lock Control Assembly Replacement....................................... .......................................................... 10A1-41 Door Weatherstrip Replacement................................................................................................................. 10A1-41 Below Eyeline Outside Rear View Mirror Replacement.............................................................................. 10A1-41 G Model Intermediate Doors.............................................................................................................................10A1-42 Door And Hinge Replacement..................................................................................................................... 10A1-42 Door Adjustment.......................................................................................................................................... 10A1-42 DOORS 10A1-3 CONTENTS (CONTINUED) SUBJECT PAGE G Model Intermediate Doors (Continued) Bumper Wedge Replacement.......................................................................................................................10A1-44 Door Trim Panel Replacement.....................................................................................................................10A1-44 Window Replacement.................................................................................................................................. 10A1-45 Intermediate Front Door Lock Replacement............................................................................................... 1QA1-46 Intermediate Front Door Lock Control Replacement..................................................................................10A1-47 Door Lock Cylinder Replacement................................................................................................................. 10A1-47 Door Outside Handle Replacement............................................................................................................. 10A1-47 Intermediate Rear Door Lower Latch Replacement....................................................................................10A1-49 Intermediate Rear Door Upper Latch Replacement....................................................................................10A1-49 Intermediate Rear Door Control Assembly Replacement.......................................................................... 10A1-50 Power Door Lock Motor Replacement......................................................................................................... 10A1-50 Intermediate Front Door Weatherstrip Replacement..................................................................................10A1-50 Intermediate Rear Door Weatherstrip Replacement....................................................................................10A1-51 G Model Sliding Side Door.............................................................................................................................. 10A1-53 Door Replacement........................................................................................................................................ 10A1-53 Hinge Assembly Replacement.....................................................................................................................10A1-53 Lower Roller Assembly Replacement.........................................................................................................10A1-54 Upper Front Roller Replacement.................................................................................................................10A1-54 Door Adjustment.......................................................................................................................................... 10A1-54 Door Trim Panel Replacement....................................................................................................................10A1-58 Window Replacement...................................................................................................................................10A1-58 Front Lock Replacement...............................................................................................................................10A1-59 Rear Lock Replacement...............................................................................................................................10A1-61 Lock Cylinder Replacement.........................................................................................................................10A1-61 Sliding Side Door Weatherstrip Replacement............................................................................................. 10A1-61 G Model Rear D oors........................................................................................................................................ 10A1-63 Door And Hinge Replacement.....................................................................................................................10A1-63 Door Adjustment....................................................................................................... ..................................10A1-64 Striker Replacement.................................................................................................................................... 10A1-64 Door Trim Panel Replacement.....................................................................................................................10A1-64 Bumper Wedge Replacement.......................................................................................................................10A1-66 Window Replacement...................................................................................................................................10A1-66 Swing Out W indow ...................................................................................................................................... 10A1-67 Left Door Lower Latch Replacement........................................................................................................... 10A1-67 Right Door Lower Latch Replacement......................................................................................................... 10A1-67 Right Door Upper Latch Replacement......................................................................................................... 10A1-69 Right Door Control Assembly Replacement............................................................................................... 10A1-69 Door Outside Handle Replacement............................................................................................................10A1-70 Door Lock Cylinder Replacement................................................................................................................. 10A1-70 Check Strap Replacement.............................................................................................................................10A1-70 Check Assembly Replacement............................................................................................................... . .10A1-71 Left Door Weatherstrip Replacement........................................................................................................... 10A1-71 Right Door Weatherstrip Replacement....................................................................................................... 10A1-72 Power Door Lock Motor Replacement......................................................................................................... 10A1-72 Special Tools....................................................................................................................................................10A1-74 10A1-4 DOORS RV MODEL SIDE FRONT DOOR Adjust f t • T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d , a n d in o r o u t, a t t h e d o o r h in g e s . 1. A d ju s t th e d o o r to o b ta in a g a p o f 6 m m ± (0 .2 4 -in c h ± 0 .0 9 -in c h ) b e tw e e n th e r o c k e r p a n e l a n d th e d o o r. 1. Cowl 2. Door 3. Lower H inge 4. B olt 5. Upper H inge 6. B olt 7. B olt 2 . T h e g a p b e tw e e n th e d o o r a n d t h e r o o f p a n e l s h o u ld b e 5 m m ± 2 m m (0 .1 9 -in c h ± 0 .0 9 -in c h ). 3 . A d ju s t th e d o o r to o b ta in a g a p o f 5 m m ± 2 m m (0 .1 9 -in c h ± 0 .0 9 -in c h ) b e tw e e n th e d o o r s r e a r e d g e a n d t h e r e a r d o o r p illa r . 4. T h e gap b e tw e e n th e d o o r a n d th e w in d s h ie ld s h o u ld b e 2 m m ± 1 .5 m m ( 0 . 0 8 - i n c h ± 5 . T h e d o o r s u r fa c e s h o u ld b e flu s h w ith th e o th e r p a n e ls w ith in ± 1 .5 m m ( ± 0 .0 6 - in c h ) e x c e p t fo r t h e d o o r to r o o f p a n e l s u r fa c e w h ic h s h o u ld b e flu s h w ith in m m ( + 0 .0 6 -in c h ). 2 p illa r 0 .0 6 -in c h ). F-00444 + 1 .5 6 . T ig h t e n t h e h in g e b o lts . Install or Connect (Figures 2 and 3) Figure 1—Door Hinge Components NOTICE: Refer to “ N otice” on page 10A1-1 of this section. DOOR AND HINGE REPLACEMENT 1 . D o o r s t r ik e r b o lt. Remove or Disconnect (Figure 1) O p e n th e d o o r. • E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t ,” a c c e s s to th e w ir in g h a rn e s s . Adjust f t fo r M a r k t h e p o s itio n o f t h e h in g e s o n t h e d o o r. a Tighten • 2. D o o r h i n g e t o d o o r b o l t s ( 4 ) . 3. D o o r fr o m th e v e h ic le . • M a r k t h e p o s it io n o f t h e h in g e s o n t h e b o d y s i d e p illa r . 4 . H in g e to d o o r p illa r b o lts (6 ). 5 . D o o r p illa r to h in g e b o lt (7 ). 6. H i n g e s f r o m t h e v e h i c l e . + 4 - B o lt to p r o p e r ly e n g a g e t h e d o o r lo c k . 2 . T ig h t e n t h e s tr ik e r b o lt. S t r ik e r b o lt to 6 3 N m ( 4 6 ft. lb s .). DOOR TRIM PANEL REPLACEMENT Remove or Disconnect (Figures 4 and 5) T o o is R e q u ir e d : J -9 7 7 6 -0 1 D o o r H a n d le C lip R e m o v e r . Install or Connect (Figure 1) H in g e s to th e v e h ic le . A lig n t h e h in g e s to t h e m a r k s o n t h e b o d y s id e p illa r s . H in g e to d o o r p illa r b o lts (6 ). D o o r p illa r to h in g e b o lt (7 ). 1 . W in d o w r e g u la t o r h a n d le u s in g J - 9 8 8 6 - 0 1 . 2. L o c k k n o b . 3. A rm re s t to a r m re s t b ra c k e t s c re w s (7 7 ). D o o r to th e v e h ic le . 4 . A rm re s t fro m th e d o o r. A lig n t h e m a r k s o n t h e d o o r to t h e h in g e s . 5 . S t r a p a s s e m b ly c o v e r s (if e q u ip p e d ) . D o o r h in g e to d o o r b o lts (4 ). 6. S t r a p a s s e m b l y s c r e w s ( 2 4 ) ( i f e q u i p p e d ) . E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e fe r to “ D o o r T rim P a n e l R e p la c e m e n t,” J - 2 4 5 9 5 - B D o o r T rim P a d C lip R e m o v e r . 7. S t r a p a s s e m b ly (if e q u ip p e d ) . fo r a c c e s s to th e w ir in g h a rn e s s . 8. D o o r t r i m p a n e l t o d o o r s c r e w s ( 2 2 ) . 9 . D o o r tr im p a n e l to d o o r r e t a in e r s u s in g J - 2 4 5 9 5 - B . 10. D o o r t r i m p a n e l f r o m t h e d o o r . DOOR ADJUSTMENT Remove or Disconnect (Figures 2 and 3) T o o ls R e q u ir e d : J -2 2 5 8 5 -0 1 • P r y th e to p o f th e p a n e l a w a y fr o m th e d o o r s id e w in d o w s e a l c lip s . Install or Connect (Figures 4 and 5) D o o r H in g e B o lt W r e n c h . J -2 3 4 5 7 -A W re n c h . D o o r s tr ik e r b o lt u s in g J - 2 3 4 5 7 - A . C h e c k t h a t a ll t h e t r im r e t a in e r s a r e s e c u r e ly f a s t e n e d , an d a re not fa s te n e rs . d am ag ed . R e p la c e any d am ag ed U s e to o l J - 2 2 5 8 5 - 0 1 w h e n lo o s e n in g t h e d o o r h in g e to b o d y s id e p illa r b o lts . T h e r e a r f e n d e r b o lts m a y n e e d D o o r t r im p a n e l o n to t h e d o o r s id e w in d o w s e a l c lip s . to b e lo o s e n e d fo r a c c e s s to t h e s e b o lts . D o o r tr im p a n e l to d o o r s c r e w s ( 2 2 ) . D o o r t r im r e t a in e r s in to t h e d o o r p a n e l. DOORS 10A1-5 A. B. C. D. 2 5 5 6 mm mm mm mm ± ± ± ± 1.5 mm (0.08-inch ± 0.06-inch) 2 mm (0.19-inch ± 0.09-inch) 2 mm (0.19-inch ± 0.09-inch) 2 mm (0.24-inch ± 0.09-inch) W indshield P illar Door A ssem bly Roof Panel Rocker Panel Front D oor Rear P illar F -0 0 4 4 5 Figure 2—Door Adjustments 4 . S t r a p a s s e m b ly o n t o t h e d o o r (if e q u ip p e d ) . 5 . S t r a p a s s e m b ly s c r e w s (if e q u ip p e d ) . 6 . S t r a p a s s e m b ly c o v e r s (if e q u ip p e d ) . 7. A rm re s t to th e d o o r. 8 . A rm re s t to a rm re s t b ra c k e t s c re w s (7 7 ). 9. L o ck kn ob . 1 0 . W in d o w r e g u la to r h a n d le . DOOR VENT/WINDOW RUN CHANNEL ASSEMBLY REPLACEMENT T h e d o o r v e n t a n d th e fr o n t w in d o w ru n c h a n n e l a r e o n e a s s e m b ly . T h i s a s s e m b ly is fit in to t h e f r o n t o f t h e d o o r fra m e . 16. J-986-01 17. Spring C lip 18. Inside Handle A Push The Tool In The D irection Of The Arrow F -0 1 2 2 7 Figure 3—Door Striker Figure 4—Handle Clip Remover 10A1-6 DOORS •20 19. 20. 21. 22. 23. 24. 25. 77. 21 22 ^25 R etainer D oor Trim Panel Arm Rest Screw Cover Screw Strap Screw F-00446 Figure 5—Trim Panel Components Remove or Disconnect (Figure 6) • 5 . D o o r v e n t/w in d o w P l a c e t h e w i n d o w in t h e lo w e r e d p o s it io n . 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” 2 . R u n c h a n n e l m o ld in g . • ru n channel a s s e m b ly fro m th e v e h ic le . • P u ll t h e to p o f t h e v e n t b a c k w a r d s a w a y f r o m t h e d o o r fra m e . • L if t a n d r o t a t e t h e a s s e m b l y o u t o f t h e d o o r . -►<- Install or Connect (Figure 6) P u ll t h e m o ld in g o u t o f t h e v e n t a s s e m b ly o n ly . 3 . D o o r p a n e l to r u n c h a n n e l b o lt (3 1 ). 4 . D o o r to v e n tila to r s c r e w s ( 2 6 ) a n d s p a c e r s ( 2 7 ). 1. D o o r v e n t/w in d o w ru n c h a n n e l a s s e m b ly to th e v e h ic le . • R o ta te th e v e n t a s s e m b ly in to th e d o o r. • F it t h e a s s e m b ly in to t h e d o o r f r a m e . 2 . D o o r to v e n tila to r s c r e w s ( 2 6 ) a n d s p a c e r s (2 7 ) . • S t a r t w ith t h e s c r e w a t t h e to p o f t h e d o o r, a n d w o rk d o w n w a rd . 3 . D o o r p a n e l to r u n c h a n n e l b o lts (3 1 ). 4 . R u n c h a n n e l m o ld in g . • S e a t t h e c lip in to t h e v e n t , t h e n p u s h th e r e m a in d e r o f t h e m o ld in g in to t h e r u n c h a n n e l. 5. D o o r tr im p a n e l. R e f e r to “ D o o r T r im P an el R e p la c e m e n t.” VENT GLASS REPLACEMENT CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. REMOVAL (Figure 6) 1. O p e n t h e v e n t w in d o w . 2 . S q u ir t s o lv e n t o n t h e t a r - p a p e r - lik e fille r a ll a r o u n d t h e g la s s c h a n n e l, o n b o th s id e s o f t h e g la s s . 3 . W h e n t h e fille r a n d s e a le r s o f t e n , p u ll t h e g la s s a n d t h e o ld f ille r f r o m t h e c h a n n e l. Screw Spacer D oor V ent/W indow G lass Run A ssem bly Run C hannel M old ing B olt F-00447 Figure 6—Door Vent/Window Run Channel Components INSTALLATION (Figure 6) 1. T h o r o u g h ly c le a n th e in s id e o f t h e g la s s c h a n n e l w ith s a n d p a p e r to r e m o v e a ll r u s t a n d f o r e ig n m a tte r . 2 . C u t t h e n e w p ie c e o f g la s s c h a n n e l fille r ( 2 - in c h e s ) lo n g e r th a n r e q u ir e d . 3 . P o s itio n th e f ille r ( s o a p s to n e d s id e aw ay 51 m m fro m th e g la s s ) e v e n ly a r o u n d a n d o v e r t h e e d g e o f t h e g la s s t h a t w ill b e in s e r t e d in t h e c h a n n e l . P r e s s t h e f ille r fir m ly o n to th e e d g e o f t h e g la s s to e n s u r e a g o o d DOORS 10A1-7 b o n d . ( U s u a ll y t h is is d o n e w it h a m e c h a n ic a l w in d o w p r e s s .) S q u e e z e t o g e t h e r t h e d o u b le d e n d s o f t h e f ille r w h ic h p r o je c t b e y o n d t h e e d g e o f t h e g la s s . 4 . B r u s h t h e in n e r c h a n n e l w ith s o a p s o lu tio n . D O U S E G R E A S E O R O IL 5 . P r e s s th e g la s s a n d fir m ly s e a te d . 32. 33. 34. 35. 36. N O T t h e f ille r in to t h e c h a n n e l u n til G lass W indow Sash R egulator A ssem bly R egulator Rail N otch F-00449 6 . T rim o ff e x c e s s fille r m a t e r ia l a r o u n d , a n d a t t h e e n d o f th e c h a n n e l. Figure 8—Window Assembly Components VENT WINDOW ADJUSTMENT • S l i d e t h e g l a s s f o r w a r d u n t i l t h e f r o n t r o l le r is in lin e w it h t h e n o t c h in t h e s a s h c h a n n e l . D is e n g a g e t h e r o lle r fr o m t h e c h a n n e l. • P u s h t h e w i n d o w f o r w a r d , t h e n t i lt it u p u n t i l t h e r e a r r o lle r is d is e n g a g e d . • P l a c e t h e i w n d o w in a l e v e l p o s i t i o n , a n d r a i s e it s tr a ig h t u p a n d o u t o f t h e d o o r. Adjust (Figure 7) 1 . R e m o v e t h e d o o r tr im p a n e l. R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t.” 2 . B e n d th e ta b s o n th e a d ju s tm e n t n u t a w a y fr o m th e n u t. 3 . A d ju s t t h e v e n t b y p la c in g a w r e n c h o n t h e a d ju s tin g n u t, a n d t h e n t u r n in g t h e v e n t w in d o w to t h e p r o p e r te n s io n . 4 . B e n d th e ta b s o v e r th e a d ju s tm e n t n u t. 5 . In s t a ll t h e d o o r tr im R e p la c e m e n t.” p a n e l. R e f e r to “ D o o r T rim Panel Install or Connect (Figure 8) ++ 1. D o o r w in d o w g la s s . DOOR WINDOW REPLACEMENT Remove or Disconnect (Figure 8) • L o w e r th e w in d o w in to th e d o o r fr a m e . • P u s h t h e w i n d o w f o r w a r d , t h e n t ilt it u p , a n d s l id e t h e r e a r r o lle r in to t h e s a s h c h a n n e l. • S l i d e t h e g l a s s b a c k w a r d u n t i l t h e f r o n t r o l l e r is in lin e w it h t h e n o t c h in t h e s a s h c h a n n e l . E n g a g e t h e r o lle r to t h e s a s h c h a n n e l. • S lid e th e c h a n n e l. CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. • L o w e r t h e g la s s to t h e b o tto m o f t h e d o o r. 1. D o o r tr im p a n e l. R e p la c e m e n t.” 2. R e fe r D o o r v e n t/w in d o w r u n “ D o o r V e n t/W in d o w to “ D o o r T r im • c h a n n e l a s s e m b ly . R e fe r to R u n C h a n n e l A s s e m b ly M a s k o r c o v e r a n y s h a r p e d g e s th a t c o u ld s c r a tc h th e g la s s . 3 . D o o r w in d o w g la s s . re a rw a rd in to th e g la s s ru n P an el R e p la c e m e n t.” • g la s s R e m o v e a n y m a s k in g o r c o v e r in g . 2 . D o o r v e n t/w in d o w r u n “ D o o r V e n t/W in d o w R e p la c e m e n t.” 3. D o o r tr im p a n e l. R e p la c e m e n t.” c h a n n e l a s s e m b ly . R e fe r to R u n C h a n n e l A s s e m b ly R e fe r to “ D o o r T r im P an el 10A1-8 DOORS 39. O uter Door Panel F -0 0 4 5 1 Figure 10—Outer Window Weatherstrip REAR GLASS RUN CHANNEL REPLACEMENT Remove or Disconnect (Figure 11) 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” • L o w e r t h e w in d o w c o m p le te ly . 2 . In n e r a n d o u te r w in d o w w e a t h e r s tr ip s . 3 . D o o r to r u n c h a n n e l b o lts (4 1 ). 4 . R u n c h a n n e l fr o m t h e v e h ic le . • P u ll t h e r u n c h a n n e l u p w a r d s w h ile t w is t in g to c le a r th e lo w e r b r a c k e t. Figure 9—Inner Window Weatherstrip Install or Connect (Figure 11) INNER WINDOW WEATHERSTRIP REPLACEMENT 1. R u n c h a n n e l to t h e v e h ic le . • W o rk th e r u n c h a n n e l in to t h e d o o r fr a m e . B e c e r t a i n t h a t t h e g la s s is in t h e c h a n n e l . |<-+| Remove or Disconnect (Figure 9) 2 . L o w e r d o o r to ru n c h a n n e l b o lt (4 1 ). 1. D o o r t r im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el P r y t h e c lip s o n t h e w e a t h e r s t r ip fr o m p a n e l s h o u ld e r . t h e tr im Install or Connect (Figure 9) 1 . W e a t h e r s t r ip ( 3 7 ) to t h e t r im p a n e l. • P u s h t h e w e a t h e r s t r ip c lip s o n to t h e t r im s h o u ld e r . 2. D o o r tr im p a n e l. R e fe r to “ D oo r T r im panel P an el R e p la c e m e n t.” OUTER WINDOW WEATHERSTRIP REPLACEMENT |<"»| Remove or Disconnect (Figure 10) • L o w e r t h e w in d o w . • W e a th e rs tr ip (3 8 ) fro m th e d o o r. • P r y t h e w e a t h e r s t r ip c lip s fr o m t h e d o o r p a n e l. Install or Connect (Figure 10) W e a th e r s tr ip (3 8 ) to th e d o o r. • R a is e t h e w in d o w c o m p le te ly . 3 . U p p e r d o o r to r u n c h a n n e l b o lt (4 1 ). 2 . W e a t h e r s t r ip ( 3 7 ) f r o m t h e tr im p a n e l. • • P u s h t h e w e a t h e r s t r ip c lip s o n to t h e d o o r p a n e l. 4 . In n e r a n d o u te r w in d o w w e a t h e r s tr ip s . 5 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el DOORS 10A1-9 33. 34. 35. 42. W ind ow Sash R egulator A ssem bly R egulator Rail Bolt 28. 43. 44. 45. 46. Bolt R egulator A ssem bly Nut Bolt W iring Harness F -0 0 4 5 4 F -0 0 4 5 3 F igure 13— P o w er W in do w R eg ula tor Figure 12— M anual W in do w R eg ula tor WINDOW REGULATOR REPLACEMENT M ANUAL REGULATOR R e m o ve o r D is c o n n e c t (F ig u re 12) • R a is e th e w in d o w and t a p e t h e g la s s in t h e f u ll u p p o s itio n u s in g c lo th b o d y t a p e . 1. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to T r im • S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n , a n d in s e r t t h e r e g u la to r d r iv e t h r o u g h t h e d o o r p a n e l. P an el R e m o v e t h e t a p e fr o m th e w in d o w . P O W E R R E G U L A T O R F o r th e d ia g n o s is o f p o w e r w in d o w c irc u its , r e fe r to C A B E L E C T R IC A L (S E C . 8 A ). 3 . W in d o w r e g u la to r . S lid e th e r e g u la to r r e a r w a r d to d is e n g a g e t h e r e a r r o lle r fr o m th e s a s h c h a n n e l. A ls o d is e n g a g e t h e lo w e r r o lle r f r o m t h e r e g u la t o r r a il. • D is e n g a g e t h e f o r w a r d r o lle r fr o m th e c h a n n e l a t th e n o tc h in th e s a s h c h a n n e l. sash • C o l l a p s e t h e r e g u la t o r , a n d r e m o v e it t h r o u g h t h e a c c e s s h o le in t h e d o o r . R e m o v e o r D is c o n n e c t (F ig u re s 12 a n d 13) • R a i s e t h e w i n d o w a n d t a p e t h e g l a s s in t h e f u ll u p p o s itio n u s in g c lo th b o d y t a p e . 1. B a tte r y g r o u n d c a b le . 2 . D o o r tr im p a n e l. R e f e r to “ D o o r T r im P an el R e p la c e m e n t.” 3 . R e m o v e c o n tr o l to d o o r tr im p a n e l b o lts . • |~n-| In s ta ll o r C o n n e c t (F ig u re 12) • T r im P an el 2 . D o o r p a n e l to r e g u la to r b o lts ( 4 2 ) . • S lid e th e r e g u la to r r e a r w a r d to e n g a g e th e r e a r r o lle r to t h e s a s h c h a n n e l. A ls o e n g a g e t h e lo w e r r o lle r t o t h e r e g u la t o r r a il. 2 . D o o r p a n e l to r e g u la t o r b o lts (4 2 ). 3. D o o r tr im p a n e l. R e f e r to “ D o o r R e p la c e m e n t.” • “ D o o r • L u b r ic a t e t h e r e g u la t o r a n d t h e s a s h a n d r e g u la t o r r a ils w ith lu b r ip la te o r e q u iv a le n t. 1. W in d o w r e g u la to r . • C o l l a p s e t h e r e g u la t o r , a n d i n s e r t it t h r o u g h t h e a c c e s s h o le in t h e d o o r . • U n f o ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d r o lle r to t h e s a s h c h a n n e l a t t h e s a s h c h a n n e l n o tc h . 4. L a y th e c o n tr o l a s id e . R e g u la t o r to d o o r p a n e l b o lts ( 4 5 ) a n d n u ts ( 4 4 ). 5 . W ir in g h a r n e s s f r o m t h e r e g u la to r . 6 . W in d o w r e g u la to r . • S lid e th e r e g u la to r r e a r w a r d to d is e n g a g e th e r e a r r o lle r fr o m t h e s a s h c h a n n e l. A ls o d is e n g a g e t h e lo w e r r o lle r fr o m t h e r e g u la t o r r a il. • D is e n g a g e t h e fo r w a r d r o lle r fr o m t h e c h a n n e l a t t h e n o t c h in t h e s a s h c h a n n e l . sash • C o l l a p s e t h e r e g u l a t o r , a n d r e m o v e it t h r o u g h t h e a c c e s s h o l e in t h e d o o r . 10A1-10 DOORS CAUTION: The n e xt ste p m u st be p erform ed w he n th e re g u la to r is rem oved fro m th e d oo r. The re g u la to r lift arm s are u n d e r te n sio n fro m th e c o u n te rb a la n c e s p rin g and ca n c a u se se rio u s in ju ry if th e m o to r is rem oved w ith o u t lo c k in g th e s e c to r g ea r in p o sitio n . • D r ill a h o le t h r o u g h t h e r e g u la t o r s e c t o r g e a r a n d b a c k p l a t e . D r i l l t h e h o l e a t l e a s t 1 2 . 7 m m ( 1/ 2- i n c h ) a w a y fr o m t h e e d g e o f t h e s e c to r g e a r o r b a c k p la te . In s ta ll a p a n h e a d s h e e t m e ta l ta p p in g s c r e w a t le a s t 1 9 m m ( 3/4 - in c h ) l o n g in t o t h e d r i ll e d h o l e t o l o c k t h e s e c t o r g e a r in p la c e . 7. M o to r to r e g u la to r a t t a c h in g b o lts (2 8 ). 8 . M o t o r f r o m t h e r e g u la to r . 0 In s ta ll o r C o n n e c t (F ig u re s 12 a n d 13) L u b ric a te th e te e th . m o to r d r iv e g e a r a n d r e g u la to r s e c to r R e g u la t o r m o t o r to r e g u la to r . • T h e m o to r p in io n g e a r te e th m u s t m e s h p r o p e r ly w ith t h e s e c t o r g e a r t e e t h b e f o r e in s ta llin g t h e m o to r to r e g u la to r s c r e w s . 47. 48. 49. 50. 51. 52. R e g u la t o r m o to r to r e g u la to r b o lts (2 8 ) . R e m o v e t h e s h e e t m e ta l s c r e w fr o m th e b a c k p la te a n d s e c to r g e a r. W in d o w r e g u la to r to t h e d o o r. • C o l l a p s e t h e r e g u l a t o r , a n d i n s e r t it t h r o u g h t h e a c c e s s h o le in t h e d o o r . • U n fo ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d r o lle r to t h e s a s h c h a n n e l a t t h e s a s h c h a n n e l n o tc h . • S lid e th e r e g u la to r r e a r w a r d to e n g a g e th e r e a r r o lle r to t h e s a s h c h a n n e l. A ls o e n g a g e t h e r o lle r to t h e r e g u la t o r r a il. • S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n . W ir in g h a r n e s s to t h e r e g u la to r . R e g u la t o r to d o o r p a n e l b o lts ( 4 5 ) a n d n u ts ( 4 4 ). R e m o t e c o n tr o l to d o o r t r im p a n e l b o lts . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el B a tte r y g r o u n d c a b le . Lock Knob Inside Door Lock Rod C lip Lock A ssem bly Inside Door Handle Rod Screw F -0 0 4 5 5 F igure 14— D oor L o c k C om p o n e n ts • + 4 - T ilt th e lo c k a s s e m b ly a w a y fr o m th e o u ts id e lo c k c y lin d e r . P u ll t h e lo c k a s s e m b ly d o w n w a r d to m a k e c le a r a n c e fo r th e in s id e lo c k ro d . In s ta ll o r C o n n e c t (F ig u re 14) L o c k a s s e m b ly to th e d o o r. • A lig n t h e in s id e lo c k r o d t o t h e h o le in t h e d o o r p a n e l. T ilt t h e lo c k a s s e m b ly o n to t h e o u t s id e lo c k c y lin d e r . D o o r to lo c k a s s e m b ly s c r e w s (5 2 ). In s id e d o o r lo c k k n o b . O u ts id e d o o r a s s e m b ly . R e m o v e th e t a p e fr o m th e w in d o w . DOOR LOCK REPLACEMENT h a n d le to lo c k ro d o n to th e lo c k C lip o n to t h e lo c k ro d . • P iv o t t h e c lip u p a n d o n t o t h e lo c k r o d . In s id e d o o r h a n d le to lo c k ro d o n to th e lo c k a s s e m b ly . |<"»| R e m o ve o r D is c o n n e c t (F ig u re 14) C lip o n to t h e lo c k r o d . • R a is e t h e w in d o w c o m p le te ly . 1. D o o r t r im p a n e l. R e p la c e m e n t.” R e fe r • to “ D oo r T r im P an el P iv o t t h e c lip u p a n d o n t o t h e lo c k r o d . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 2 . In s id e d o o r h a n d le to lo c k r o d c lip s (4 9 ) . • U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c lip w h e r e it is c o n n e c t e d t o t h e r o d . P iv o t t h e c lip a w a y fr o m t h e ro d . 3 . In s id e d o o r h a n d le to lo c k ro d fr o m th e lo c k . 4 . O u t s i d e d o o r h a n d l e t o lo c k r o d c lip . • POWER DOOR LOCK MOTOR REPLACEMENT R e fe r to C A B E L E C T R IC A L (S E C . d ia g n o s is o f th e d o o r lo c k m o to r. 8 A ) fo r e le c tr ic a l U s e t h e p r o c e d u r e g iv e n u n d e r s te p 2 . 5 . O u t s id e d o o r h a n d le to lo c k ro d fr o m t h e lo c k . R e m o v e o r D is c o n n e c t (F ig u re 15) 6 . In s id e d o o r lo c k k n o b . 1 . B a tte r y g r o u n d c a b le . 7. D o o r to lo c k a s s e m b ly s c r e w s (5 2 ). 2 . D o o r tr im p a n e l. R e p la c e m e n t.” 8 . L o c k a s s e m b ly fro m th e d o o r. R e fe r to “ D o o r T r im P an el DOORS 10A1-11 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. Bolt O utside Handle Rod Sm all Gasket Handle A ssem bly Key Lock C ylinder Gasket Large Gasket Retainer C lip F -0 0 4 5 7 Figure 16—Outside Handle and Lock Cylinder Components 48. 49. 50. 53. 78. Inside D oor Lock Rod C lip Lock A ssem bly M otor A ssem bly Screw 5 . H a n d le w ith t h e c o n tr o l ro d fr o m t h e d o o r. 6 . G a s k e ts fro m th e d o o r. Install or Connect (Figure 16) 1. L a r g e g a s k e t o v e r t h e l o c k r o d a n d o n t o t h e h a n d l e . F -0 0 4 5 6 2 . H a n d le w ith th e lo c k ro d o n to th e d o o r. 3 . D o o r to o u ts id e h a n d le s c r e w (5 4 ) to th e p u s h b u tto n Figure 15—Power Door Lock Motor s id e o f th e h a n d le . • E le c tr ic a l c o n n e c to r fr o m t h e m o to r. D o o r to m o to r s c r e w s (7 8 ). M o to r fr o m th e lo c k r o d . • S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o ff 5 . D o o r to o u ts id e h a n d le s c r e w (5 4 ) to th e o th e r s id e o f th e h a n d le . • o f th e d o o r lo c k ro d . + D o n o t tig h te n . 4 . S m a ll g a s k e t b e tw e e n th e d o o r a n d th e h a n d le . T ig h te n b o th s c r e w s . 6. M o t o r f r o m t h e d o o r . 6 . O u ts id e d o o r h a n d le to lo c k ro d to th e lo c k a s s e m b ly . 4- 7. C lip o n to t h e lo c k ro d . Install or Connect (Figure 15) • 1. M o t o r i n t o t h e d o o r . 2. M o t o r t o t h e lo c k r o d . • 3. 4. 5. 6. S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o n to th e d o o r lo c k ro d . D o o r to m o to r s c r e w s (7 8 ). E le c tr ic a l c o n n e c t o r to t h e m o to r. D o o r t r im p a n e l. R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t.” B a tte r y g r o u n d c a b le . DOOR OUTSIDE HANDLE REPLACEMENT Remove or Disconnect (Figure 16) P iv o t t h e c lip u p a n d o n to t h e lo c k r o d . 8. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el DOOR LOCK CYLINDER REPLACEMENT Remove or Disconnect (Figure 16) • R a is e t h e w in d o w c o m p le te ly . 1. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 2 . L o c k c y lin d e r r e t a in in g c lip ( 6 2 ) fr o m t h e c y lin d e r . • S lid e t h e c lip o ff t h e c y lin d e r w ith a s c r e w d r iv e r . 3 . L o c k c y lin d e r a n d g a s k e t fr o m th e d o o r. R D R O a is e t h e w in d o w c o m p le te ly . o o r tr im p a n e l. R e f e r to “ D o o r T r im P an el e p la c e m e n t.” u t s i d e d o o r h a n d l e t o lo c k r o d c lip . • U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l ip w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y f r o m t h e r o d . O u t s id e d o o r h a n d le to lo c k r o d fr o m t h e lo c k . D o o r to o u ts id e h a n d le s c r e w s (5 4 ). Install or Connect (Figure 16) 1. L o c k c y l i n d e r w i t h g a s k e t t o t h e d o o r . • T h e c y lin d e r ro d m u s t e n g a g e th e lo c k a s s e m b ly le v e r . 2 . L o c k c y lin d e r ( 6 2 ) r e t a in in g c lip o n to t h e c y lin d e r . 3. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 10A1-12 DOORS Figure 17—Door Inside Handle DOOR INSIDE HANDLE REPLACEMENT DOOR WEATHERSTRIP REPLACEMENT 4-4 Remove or Disconnect (Figure 18) Remove or Disconnect (Figure 17) 1. D o o r t r im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el • O p e n th e d o o r. 1 . S ill p la t e fr o m t h e v e h ic le . 2 . D o o r h a n d le s e a l. 2 . W e a t h e r s t r ip fr o m t h e p in c h w e ld f la n g e . 3 . H a n d le to d o o r s c r e w s (6 5 ). • 4 . C o n tro l ro d fr o m th e in s id e h a n d le . • S l i d e t h e c l i p s o t h a t t h e l a r g e d i a m e t e r s l o t i s in lin e w it h t h e lo c k r o d . T h e n , p u ll t h e r o d f r o m t h e h a n d le . 5 . In s id e h a n d le fr o m th e d o o r. Install or Connect (Figure 17) 1. C o n tro l ro d to th e in s id e h a n d le . • P la c e t h e r o d in to t h e c lip a n d t h e le v e r. S lid e t h e c l ip s o t h a t t h e s m a l l d i a m e t e r s lo t is in l in e w i t h th e lo c k ro d . 2. H a n d le to d o o r s c r e w s (6 5 ). 3 . D o o r h a n d le s e a l. 4. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el P u ll t h e w e a t h e r s t r ip a w a y fr o m t h e f la n g e . DOORS 10A1-13 68. Screw 69. M irror 70. Bolt 71. Bracket 72. G asket F -0 0 4 6 0 Figure 19—Outside Rear View Mirror Components 73. Below Eyeline 74. W est Coast Install or Connect (Figure 18) 1 . W e a t h e r s t r ip to t h e p in c h w e ld f la n g e . • • S ta r t a t th e b o tto m c e n te r o f th e d o o r o p e n in g . T rim t h e w e a t h e r s t r ip , a n d b u tt t h e e n d s to g e th e r . 2 . S ill p la t e to t h e v e h ic le . OUTSIDE REAR VIEW MIRROR REPLACEMENT F -0 0 4 6 1 Remove or Disconnect (Figure 19) 1 . M ir r o r to b r a c k e t s c r e w . Figure 20—Below Eyeline and West Coast Style Mirrors 2 . M ir r o r fr o m t h e d o o r. 3 . B r a c k e t to d o o r b o lts . WEST COAST OUTSIDE REAR VIEW MIRROR REPLACEMENT 4 . B r a c k e t a n d g a s k e t fr o m t h e v e h ic le . Install or Connect (Figure 19) 1 . B r a c k e t a n d g a s k e t to th e v e h ic le . 2 . B r a c k e t to d o o r b o lts . «»► 1. M ir r o r 3 . M ir r o r to t h e b r a c k e t. 4 . M ir r o r to b r a c k e t s c r e w . Remove or Disconnect (Figure 20) b ra c k e t to door b ra c k e t n u ts , b o lts , and n u ts , b o lts , and b u s h in g s . 2 . M ir r o r b r a c k e t fr o m t h e v e h ic le , 3 . D o o r b r a c k e t n u ts a n d b o lts . BELOW EYELINE OUTSIDE REAR VIEW MIRROR REPLACEMENT B Remove or Disconnect (Figure 20) 4. B ra c k e ts fro m th e d o o r. Install or Connect (Figure 20) 1. D o o r b ra c k e ts to th e d o o r. 2 . D o o r b r a c k e t n u ts a n d b o lts . 1. M ir r o r c o v e r s c r e w . 3 . M ir r o r b r a c k e t to t h e d o o r b r a c k e ts . • 4. L if t t h e c o v e r , a n d p iv o t t h e m ir r o r t o w a r d s t h e w in d o w . M ir r o r b ra c k e t to door b ra c k e t b u s h in g s . 2 . M ir r o r to d o o r b o lts . 3 . M ir r o r a n d s e a l fr o m t h e d o o r. |-n-| Install or Connect (Figure 20) 1 . M ir r o r a n d s e a l to th e d o o r. 2 . M ir r o r to d o o r b o lts . • DOOR AIR VALVE REPLACEMENT Remove or Disconnect (Figure 21) P iv o t th e m ir r o r a w a y fr o m th e w in d o w , a n d lo w e r th e 1. D o o r tr im p a n e l. R e p la c e m e n t.” m ir r o r c o v e r. 2 . D o o r to a ir v a lv e s c r e w s . 3 . M ir r o r c o v e r s c r e w . R e fe r 3 . A ir v a lv e f r o m t h e d o o r. to “ D oo r T r im P an el 10A1-14 DOORS |++| Install or Connect (Figure 21) 1. A ir v a lv e to t h e d o o r. 2 . D o o r to a ir v a lv e s c r e w s . 3. D o o r tr im p a n e l. R e fe r to “ D oo r T r im P an el R e p la c e m e n t.” Figure 21—Door Air Valve RV MODEL SIDE REAR DOORS Figure 22—Door Hinge Components DOOR AND HINGE REPLACEMENT • 3 . H in g e to d o o r p illa r b o lts ( 8 0 ) . Remove or Disconnect (Figure 22) • M a r k th e p o s itio n o f th e h in g e s o n th e d o o r a n d o n th e d o o r p illa r . 4 . D o o r fr o m t h e v e h ic le . 5 . H in g e to d o o r b o lts (8 0 ). O p e n th e d o o r. 6 . H in g e s fr o m th e d o o r. 1. E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • 2. R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t ” a c c e s s to th e w ir in g h a r n e s s . In n e r h in g e p illa r c o v e r s c r e w s (7 8 ) a n d c o v e r s (7 9 ). fo r Install or Connect (Figure 22) 1. H in g e s to th e d o o r. • A lig n t h e h in g e s w ith t h e p r e v io u s ly m a d e m a r k s . DOORS 10A1-15 2. 1. A d ju s t th e d o o r to o b ta in a g a p o f 6 m m ± 2 m m (0 .2 4 -in c h ± 0 .0 9 -in c h ) b e tw e e n th e r o c k e r p a n e l a n d th e d o o r. H in g e to d o o r b o lts (8 0 ). 3 . D o o r to t h e v e h ic le . • A lig n t h e h in g e s w ith t h e p r e v io u s ly m a d e m a r k s . 2 . T h e g a p b e tw e e n th e d o o r a n d th e ro o f p a n e l s h o u ld b e 5 m m ± 2 m m (0 .1 9 -in c h ± 0 .0 9 -in c h ). 4 . H in g e to d o o r p illa r b o lts ( 8 0 ) . 5 . In n e r h in g e p illa r c o v e r s (7 9 ) a n d s c r e w s (7 8 ). 3 . A d ju s t th e d o o r to o b ta in a g a p o f 5 m m ± 2 m m (0 .1 9 -in c h + 0 .0 9 -in c h ) b e tw e e n th e d o o r s r e a r e d g e a n d t h e r e a r d o o r p illa r . 6 . E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t ” a c c e s s to th e w ir in g h a r n e s s . fo r 4 . T h e g a p b e tw e e n t h e d o o r a n d t h e c e n t e r p illa r s h o u ld b e 5 m m DOOR ADJUSTMENT E Remove or Disconnect T o o l R e q u ire d : J -2 3 4 5 7 -A W re n c h . • D o o r s tr ik e r b o lt u s in g J - 2 3 4 5 7 - A . Adjust (Figure 23) T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d , a n d in o r o u t, a t t h e d o o r h in g e s . 0 ± 2 m m (0 .1 9 -in c h ± 0 .0 9 -in c h ). 5 . T h e d o o r s u r f a c e s h o u ld b e flu s h w ith t h e o t h e r p a n e ls w it h in ± 1 .5 m m ( ± 0 .0 6 - in c h ) e x c e p t fo r t h e d o o r to r o o f p a n e l s u r fa c e w h ic h s h o u ld b e f lu s h w it h in + 1 .5 m m ( + 0 .0 6 - in c h ) . Install or Connect NOTICE: Refer to “ N o tice” on page 10A1-1 of this section. • Door striker bolt. 10A1-16 DOORS 87. C ontrol A ssem bly 88. Retainer 89. 90. 91. 92. 93. 94. 95. Bezel Door Trim Panel Screw Arm Rest Screw Plate Handle F-00468 Figure 24—Door Trim Panel Components Adjust • B o lt to p r o p e r ly e n g a g e t h e d o o r lo c k . Tighten • S t r ik e r b o lt to 6 3 N m ( 4 6 ft. lb s .). DOOR TRIM PANEL REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Door Door Door S tra p S S A A L W t r im t r im t r im ass p a n e l o n t o t h e d o o r s i d e w in d o w s e a l c lip s . r e ta in e r s in to t h e d o o r p a n e l. p a n e l to d o o r s c r e w s (9 3 ). e m b ly o n to t h e d o o r (if e q u ip p e d ) . tr a p a s s e m b ly s c r e w s (if e q u ip p e d ) . t r a p a s s e m b ly c o v e r s (if e q u ip p e d ) . rm r e s t to th e d o o r. r m r e s t to a r m r e s t b r a c k e t s c r e w s (9 1 ). ock knob. in d o w r e g u la to r h a n d le . Remove or Disconnect (Figure 24) T o o ls R e q u i r e d : J -9 8 8 6 -0 1 D o o r H a n d le C lip R e m o v e r . J - 2 4 5 9 5 - B D o o r T rim P a d C lip R e m o v e r . 1. W in d o w r e g u la t o r h a n d le u s in g J - 9 8 8 6 - 0 1 . 2. Lock knob. 3. A rm re s t to a r m re s t b ra c k e t s c re w s (9 1 ). 4 . A rm re s t fro m th e d o o r. 5 . S t r a p a s s e m b ly c o v e r s (if e q u ip p e d ) . STATIONARY GLASS/WINDOW RUN CHANNEL ASSEMBLY REPLACEMENT T h e s t a t io n a r y g la s s a n d t h e r e a r w in d o w r u n c h a n n e l a r e o n e a s s e m b ly . T h is a s s e m b ly fits in to t h e r e a r o f t h e d o o r fra m e . 6 . S t r a p a s s e m b ly s c r e w s (if e q u ip p e d ) . Remove or Disconnect (Figure 25) 7 . S t r a p a s s e m b ly (if e q u ip p e d ) . P l a c e t h e w in d o w in t h e lo w e r e d p o s it io n . 8 . D o o r t r im p a n e l to d o o r s c r e w s ( 9 3 ) . D o o r tr im p a n e l. R e p la c e m e n t.” 9 . D o o r t r im p a n e l to d o o r r e t a in e r s u s in g J - 2 4 5 9 5 - B . 10. D o o r t r im p a n e l fr o m t h e d o o r. • P r y th e to p o f th e p a n e l a w a y fro m th e d o o r s id e w in d o w s e a l c lip s . Install or Connect (Figure 24) C h e c k t h a t a ll t h e t r im r e t a in e r s a r e s e c u r e ly f a s t e n e d , a n d a r e n o t d a m a g e d . R e p la c e a n y d a m a g e d fa s te n e rs . R e fe r to “ D o o r T r im P an el R u n c h a n n e l m o ld in g (9 6 ) . • P u ll t h e m o ld in g o u t o f t h e r u n c h a n n e l o n ly . D o o r p a n e l to r u n c h a n n e l b o lt (9 9 ). D o o r fr a m e to ru n c h a n n e l s c r e w (9 7 ). S ta tio n a r y g la s s /w in d o w th e d o o r. • ru n c h a n n e l a s s e m b ly fro m P u ll t h e t o p o f t h e c h a n n e l b a c k w a r d s a w a y fr o m th e d o o r fra m e . DOORS 10A1-17 DOOR WINDOW REPLACEMENT Remove or Disconnect (Figure 26) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. • L o w e r th e w in d o w to th e b o tto m o f th e d o o r. 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” 2 . S ta tio n a r y g la s s /w in d o w ru n c h a n n e l a s s e m b ly . R e fe r to “ S ta t io n a r y G la s s /W in d o w R u n C h a n n e l A s s e m b ly R e p la c e m e n t.” • M a s k o r c o v e r a n y s h a r p e d g e s th a t c o u ld s c r a tc h th e g la s s . 3 . D o o r w in d o w g la s s (1 0 0 ). • S l i d e t h e g l a s s r e a r w a r d u n t i l t h e r e a r r o l l e r is in l in e w it h t h e n o t c h in t h e s a s h c h a n n e l . D is e n g a g e t h e r o lle r fr o m t h e c h a n n e l. • • P u s h t h e w i n d o w r e a r w a r d , t h e n t ilt it u p u n t il t h e f r o n t r o lle r is d is e n g a g e d . P l a c e t h e w i n d o w i n a l e v e l p o s i t i o n , a n d r a i s e it s tr a ig h t u p a n d o u t o f t h e d o o r. -►«- Install or Connect (Figure 26) 1. D o o r w in d o w g la s s ( 1 0 0 ). 96. 97. 98. 99. 107. 108. 109. Run Channel M o ld ing Screw S tationary G lass/W indow Run Channel B olt B olt Front Glass Run Channel N ut F-00469 Figure 25—Stationary Glass/Window Run Channel Components L ift a n d r o t a t e t h e a s s e m b l y o u t o f t h e d o o r . □ • L o w e r th e w in d o w in to th e d o o r fr a m e . • P u s h t h e w i n d o w r e a r w a r d , t h e n t ilt it u p , a n d s lid e t h e fr o n t r o lle r in to t h e s a s h c h a n n e l. • S l i d e t h e g l a s s f o r w a r d u n t i l t h e r e a r r o l l e r is in l in e w it h t h e n o t c h in t h e s a s h c h a n n e l . E n g a g e t h e r o lle r to t h e s a s h c h a n n e l. • S lid e th e g la s s fo rw a rd in to th e g la s s ru n c h a n n e l. • R e m o v e a n y m a s k in g o r c o v e r in g . 2 . S ta tio n a r y g la s s /w in d o w r u n c h a n n e l a s s e m b ly . R e fe r to “ S t a t io n a r y G la s s A /V in d o w R u n C h a n n e l A s s e m b ly R e p la c e m e n t.” 3. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el Install or Connect (Figure 25) 1 . S ta tio n a r y g la s s /w in d o w ru n c h a n n e l a s s e m b ly to th e d o o r. 2. • R o t a t e t h e v e n t a s s e m b ly in to t h e d o o r. • F it t h e a s s e m b ly in to t h e d o o r f r a m e . |++| Remove or Disconnect (Figure 27) 1. D o o r P u s h t h e m o ld in g in to t h e r u n c h a n n e l. T h e s lo t a t t h e to p o f t h e m o ld in g m u s t b e o n to p o f t h e m u s t p a s s th ro u g h th e ru n c h a n n e l • tr im p a n e l. R e p la c e m e n t.” “ D o o r T r im P an el P r y t h e c lip s o n t h e w e a t h e r s t r ip fr o m t h e tr im 1 . W e a t h e r s t r ip to t h e tr im p a n e l. • D o o r p a n e l to ru n c h a n n e l b o lt ( 9 9 ). 5. D o o r to "►+ Install or Connect (Figure 27) m o ld in g s lo t. 4. R e fe r p a n e l s h o u ld e r . 3 . D o o r fr a m e to ru n c h a n n e l s c r e w (9 7 ). T h e s c re w p a n e l. 2 . W e a th e r s t r ip fr o m t h e tr im p a n e l. ru n c h a n n e l. • tr im R e p la c e m e n t.” R u n c h a n n e l m o ld in g . • INNER WINDOW WEATHERSTRIP REPLACEMENT R e fe r to “ D op r T r im P an el P u s h t h e w e a t h e r s t r ip c lip s o n to t h e t r im s h o u ld e r . 2 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im panel Panel 10A1-18 DOORS 100. 101. 102. 103. 104. A. Glass F ille r Sash Channel R egulator Bolt N otch Figure 26—Window Assembly Components OUTER WINDOW WEATHERSTRIP REPLACEMENT |++| Remove or Disconnect (Figure 28) • L o w e r th e w in d o w . 1. W e a th e r s tr ip fro m th e d o o r. • P r y t h e w e a t h e r s t r ip c lip s fr o m t h e d o o r p a n e l. Install or Connect (Figure 28) 1. W e a th e r s tr ip to t h e d o o r. • P u s h t h e w e a t h e r s t r ip c lip s o n to t h e d o o r p a n e l. 105. Inner W ind ow W eatherstrip F -0 0 7 2 7 106. O uter W indow W eatherstrip F -0 0 9 6 3 Figure 27—Inner Window Weatherstrip Figure 28—Outer Window Weatherstrip DOORS 10A1-19 FRONT GLASS RUN CHANNEL REPLACEMENT 0 110. 111. 112. 113. Remove or Disconnect (Figure 25) • L o w e r t h e w in d o w c o m p le te ly . Bolt W iring Harness Nut R egulator A ssem bly 1. O u t e r w in d o w w e a t h e r s tr ip . 2 . D o o r to r u n c h a n n e l b o lt (1 0 7 ) a n d n u t (1 0 9 ). 3 . R u n c h a n n e l fr o m t h e v e h ic le . • P u ll t h e r u n c h a n n e l u p w a r d s w h ile tw is tin g to c le a r t h e lo w e r b r a c k e t. Install or Connect (Figure 25) 1. R u n c h a n n e l to th e v e h ic le . • 2. W o r k th e ru n c h a n n e l in to th e d o o r fr a m e . B e c e r t a i n t h a t t h e g la s s is in t h e c h a n n e l . D o o r to r u n c h a n n e l b o lt (1 0 7 ) a n d n u t (1 0 9 ). 3 . O u t e r w in d o w w e a t h e r s tr ip . WINDOW REGULATOR REPLACEMENT MANUAL REGULATOR 110 Remove or Disconnect (Figure 26) 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el F -0 0 4 7 5 R e p la c e m e n t.” 2. D o o r w in d o w . R e f e r to “ D o o r W in d o w R e p la c e m e n t .” Figure 29—Power Regulator 3 . D o o r p a n e l to r e g u la to r b o lts (1 0 4 ). 4 . W in d o w r e g u la to r . • C o l l a p s e t h e r e g u l a t o r , a n d r e m o v e it t h r o u g h t h e a c c e s s h o le in t h e d o o r . Install or Connect (Figure 26) • L u b r ic a t e t h e r e g u la t o r a n d t h e s a s h a n d r e g u la t o r r a ils w ith lu b r ip la te o r e q u iv a le n t . • 1. W in d o w r e g u la to r . • 2. C o l l a p s e t h e r e g u l a t o r , a n d i n s e r t it t h r o u g h t h e a c c e s s h o l e in t h e d o o r . D o o r p a n e l to r e g u la to r b o lts (1 0 4 ). 3 . D o o r w in d o w s . R e fe r to “ D o o r W in d o w R e p la c e m e n t .” 4. D o o r tr im p a n e l. R e fe r CAUTION: The next step must be performed when the regulator is removed from the door. The regulator lift arms are under tension from the counterbalance spring and can cause serious injury if the motor is removed without locking the sector gear in position. to “ D o o r T r im P an el Install or Connect (Figure 29) P O W E R R E G U L A T O R F o r th e d ia g n o s is o f p o w e r w in d o w c irc u its , r e fe r to C A B L u b ric a te th e 1. E L E C T R IC A L (S E C . 8 A ). 1. B a t te r y g r o u n d c a b le . tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” 3 . D o o r w in d o w . R e fe r to “ D o o r W in d o w R e p la c e m e n t .” 4. R e g u la t o r to d o o r p a n e l b o lts (1 1 0 ) a n d n u ts (1 1 2 ). 5 . W ir in g h a r n e s s fr o m t h e r e g u la to r . 6 . W in d o w r e g u la to r . • 1. m o to r d riv e gear and r e g u la to r s e c to r te e th . R e g u la t o r m o t o r to r e g u la to r . • [<"►[ Remove or Disconnect (Figure 29) D o o r ( 1/ 2- i n c h ) a w a y k p la te . In s ta ll a a t le a t 1 9 m m lo c k t h e s e c to r 8 . M o t o r f r o m t h e r e g u la to r . R e p la c e m e n t.” 2. D r ill a h o le t h r o u g h t h e r e g u la t o r s e c t o r g e a r a n d b a c k p la t e . D r ill t h e h o le a t le a s t 1 2 .7 m m fro m th e e d g e o f th e s e c to r g e a r o r b a c p a n h e a d s h e e t m e ta l ta p p in g s c re w ( 3/ 4 - in c h ) l o n g i n t o t h e d r i l l e d h o l e t o g e a r in p la c e . 7. M o to r to r e g u la to r a tta c h in g s c r e w s . T h e m o t o r p in io n g e a r t e e t h m u s t m e s h p r o p e r ly w ith t h e s e c to r g e a r t e e th b e fo r e in s ta llin g t h e m o to r to r e g u la to r s c r e w s . R e g u la t o r m o to r to r e g u la to r s c r e w s . R e m o v e th e s h e e t m e ta l s c r e w fr o m th e b a c k p la te a n d s e c to r g e a r. 3 . W in d o w r e g u la to r to th e d o o r. • C o l l a p s e t h e r e g u la t o r , a n d i n s e r t it t h r o u g h t h e a c c e s s h o le in t h e d o o r . 4 . W ir in g h a r n e s s to t h e r e g u la to r . C o l l a p s e t h e r e g u l a t o r , a n d r e m o v e it t h r o u g h t h e 5 . R e g u la t o r to d o o r p a n e l b o lts (1 1 0 ) a n d n u ts (1 1 2 ). a c c e s s h o l e in t h e d o o r . 6 . D o o r w in d o w . R e fe r to “ D o o r W in d o w R e p la c e m e n t .” 10A1-20 DOORS 117. Remote C ontrol To Lock Rod 118. Inside Door Handle To Lock Rod 119. Power Door Lock M otor F -0 0 4 7 6 Figure 30—Door Lock Components 7. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el 8 . B a tte r y g r o u n d c a b le . 4. O u ts id e d o o r a s s e m b ly . DOOR LOCK REPLACEMENT “ D o o r • T r im P an el 3 . In s id e d o o r h a n d le to lo c k r o d fr o m t h e lo c k . 4 . O u t s i d e d o o r h a n d l e to lo c k r o d c lip . 8 . L o c k a s s e m b ly fro m th e d o o r. T ilt t h e lo c k a s s e m b ly a w a y fr o m t h e o u ts id e lo c k c y lin d e r . P u ll t h e lo c k a s s e m b ly d o w n w a r d to m a k e c le a r a n c e fo r t h e in s id e lo c k ro d . P iv o t t h e c lip u p a n d o n t o t h e lo c k r o d . 8. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r R e fe r to C A B E L E C T R IC A L (S E C . d ia g n o s is o f th e d o o r lo c k m o to r. R e fe r to th e o u ts id e P an el 8 A ) fo r e le c tr ic a l “ D o o r lo c k T rim P an el 3 . E le c tr ic a l c o n n e c to r fr o m t h e m o to r. 4 . D o o r to m o to r s c r e w s . 5 . M o to r fr o m t h e lo c k ro d . S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o ff o f t h e d o o r lo c k ro d . 6 . M o to r fro m th e d o o r. 1. L o c k a s s e m b ly to th e d o o r. o n to T rim POWER DOOR LOCK MOTOR REPLACEMENT • Install or Connect (Figure 30) a s s e m b ly lo c k P iv o t t h e c lip u p a n d o n t o t h e lo c k r o d . 2 . D o o r tr im p a n e l. R e p la c e m e n t.” 7. D o o r to lo c k a s s e m b ly s c r e w s (1 1 6 ). T ilt t h e lo c k c y lin d e r . th e 1. B a tte r y g r o u n d c a b le . 6 . R e m o v e c o n tr o l to lo c k a s s e m b ly c lip a n d r o d . • o n to Remove or Disconnect (Figure 30) U s e t h e p r o c e d u r e g iv e n u n d e r s te p 2 . 5 . O u t s id e d o o r h a n d le to lo c k ro d fr o m t h e lo c k . • ro d 7. C lip o n to t h e lo c k ro d . In s id e d o o r h a n d le to lo c k r o d c lip (1 1 5 ). • U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y f r o m t h e r o d . • lo c k 6 . In s id e d o o r h a n d le to lo c k r o d o n to t h e lo c k a s s e m b ly . Remove or Disconnect (Figure 30) 2. to 5 . C lip o n to t h e lo c k ro d . • • R a is e t h e w in d o w c o m p le te ly . 1. D o o r t r im p a n e l. R e f e r to R e p la c e m e n t.” h a n d le Install or Connect (Figure 30) 2 . D o o r to lo c k a s s e m b ly s c r e w s (1 1 6 ). 1. M o to r in to th e d o o r. 3 . R e m o t e c o n t r o l t o lo c k a s s e m b l y r o d a n d c lip . 2 . M o to r to t h e lo c k r o d . DOORS 10A1-21 Screw Sm all Gasket Key F -0 0 4 7 7 5 . D o o r to o u ts id e h a n d le s c r e w (1 2 0 ) to th e o th e r s id e o f th e h a n d le . Figure 31—Door Outside Handle Components • T ig h te n b o th s c r e w s . 6 . O u ts id e d o o r h a n d le to lo c k ro d to th e lo c k a s s e m b ly . • S lid e th e r u b b e r m o u n t a t t h e to p o f th e m o to r o n to th e d o o r lo c k r o d . . D o o r to m o to r s c re w s . . E le c tr ic a l c o n n e c to r to t h e m o to r. . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 7. C lip o n to t h e lo c k ro d . • p a n e l. to “ D o o r T r im P an el Remove or Disconnect (Figure 32) 1. D o o r t r im p a n e l. R e p la c e m e n t.” Remove or Disconnect (Figure 31) R D R 2. O R e fe r DOOR INSIDE HANDLE REPLACEMENT DOOR OUTSIDE HANDLE REPLACEMENT R e fe r to “ D o o r T r im P an el 2 . D o o r h a n d le s e a l. T r im P an el 3 . H a n d le a s s e m b ly to d o o r s c r e w s (1 3 1 ). 4 . C o n tro l ro d fr o m th e in s id e h a n d le . s h o n th e to p t h e r o d . P iv o t • S l id e t h e c l ip s o t h a t t h e l a r g e d i a m e t e r s lo t is in lin e w ith t h e lo c k r o d . T h e n , p u ll t h e r o d fr o m t h e h a n d le . lo c k . D o o r to o u ts id e h a n d le s c r e w s (1 2 0 ). 0 tr im R e p la c e m e n t.” . B a tte r y g r o u n d c a b le . a is e t h e w in d o w c o m p le te ly . o o r tr im p a n e l. R e f e r to “ D o o r e p la c e m e n t.” u t s i d e d o o r h a n d l e to lo c k r o d c lip . • U s in g a fla t b la d e d s c r e w d r iv e r , p u o f t h e c l ip w h e r e it is c o n n e c t e d t o t h e c lip a w a y fr o m t h e ro d . O u ts id e d o o r h a n d le to lo c k ro d fr o m th e P iv o t t h e c lip u p a n d o n to t h e lo c k r o d . 8. D o o r H a n d le w ith th e c o n tr o l ro d fr o m t h e d o o r. G a s k e ts fro m th e d o o r. Install or Connect (Figure 31) 1. L a r g e g a s k e t o v e r t h e l o c k r o d a n d o n t o t h e h a n d l e . 2. H a n d l e w it h t h e lo c k r o d o n t o t h e d o o r . 3 . D o o r to o u ts id e h a n d le s c r e w (1 2 0 ) to th e p u s h b u tto n s id e o f th e h a n d le . • D o n o t tig h te n . 4. S m a l l g a s k e t b e t w e e n t h e d o o r a n d t h e h a n d l e . 5 . In s id e h a n d le fr o m th e d o o r. Install or Connect (Figure 32) 1. C o n tro l ro d to th e in s id e h a n d le . • P l a c e t h e r o d in to t h e c lip a n d t h e le v e r . S lid e t h e c lip s o t h a t t h e s m a l l d ia m e t e r s lo t is in lin e w it h th e lo c k ro d . 2 . H a n d le a s s e m b ly to d o o r s c r e w s (1 3 1 ). 3 . D o o r h a n d le s e a l. 4 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oor T rim Panel 10A1-22 DOORS Figure 32—Door Inside Handle Components REMOTE CONTROL REPLACEMENT Remove or Disconnect (Figure 32) 1. D o o r t r im p a n e l. R e p la c e m e n t.” 2. R e fe r to “ D o o r 134. W eatherstrip T r im 134 P an el R e m o te c o n tr o l to lo c k a s s e m b ly ro d . • U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l ip w h e r e it is c o n n e c t e d t o t h e r o d . P iv o t t h e c lip a w a y fr o m t h e ro d . • P u ll t h e r o d f r o m t h e r e m o t e c o n tr o l. 3 . D o o r p a n e l to r e m o t e c o n tr o l b o lts (1 2 9 ). 4 . R e m o te h o le . c o n tr o l le v e r s a n d ro d s th ro u g h th e access th e access [-►<-[ Install or Connect (Figure 32) 1. R e m o te h o le . c o n tr o l le v e r s a n d ro d s th ro u g h 2 . D o o r p a n e l to r e m o t e c o n tr o l b o lts (1 2 9 ). 3 . R e m o te c o n tr o l to lo c k a s s e m b ly ro d . • P iv o t t h e c lip u p a n d o n to t h e lo c k ro d . 4 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T rim P an el DOOR WEATHERSTRIP REPLACEMENT F-00965 + + Remove or Disconnect (Figure 33) • O p e n th e d o o r. 1 . S ill p la t e f r o m t h e v e h ic le . 2 . W e a t h e r s t r ip fr o m t h e p in c h w e ld f la n g e . Figure 33—Door Weatherstrip DOORS 10A1-23 Install or Connect (Figure 33) 1. W e a t h e r s t r ip to t h e p in c h w e ld f la n g e . • • S ta r t a t th e b o tto m c e n te r o f th e d o o r o p e n in g . T r im t h e w e a t h e r s t r ip , a n d b u tt t h e e n d s to g e th e r . 2 . S ill p la t e to t h e v e h ic le . DOOR AIR VALVE REPLACEMENT «-+l Remove or Disconnect (Figure 34) 1. D o o r tr im p an el R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el T r im P an el 2 . D o o r to a ir v a lv e s c r e w s . 3 . A ir v a lv e fr o m t h e d o o r. Install or Connect (Figure 34) 1. A ir v a lv e to t h e d o o r. Figure 34—Door Air Valve 2 . D o o r to a ir v a lv e s c r e w s . 3. D o o r tr im p a n e l. R e fe r to “ D oor R e p la c e m e n t.” RV MODEL REAR DOORS DOOR ADJUSTMENT DOOR AND HINGE REPLACEMENT E a c h o f t h e t w o d o o r s m u s t f ir s t b e a d ju s t e d in t h e d o o r o p e n in g b e fo r e a d ju s tin g t h e d o o r to d o o r c le a r a n c e . |«"»| Remove or Disconnect (Figure 35) • M a r k t h e p o s itio n o f t h e d o o r a n d t h e d o o r o p e n in g o n t h e h in g e s . T h e d o o r h e i g h t s o t h a t t h e r e is a g a p o f 5 m m ± 2 . 3 m m (0 .1 9 0 -in c h ± 0 .0 9 -in c h ) b e tw e e n th e ro o f p a n e l 1 . S t r a p p in . a n d th e r e a r d o o r p a n e l. 2 . E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e fe r to “ D o o r T rim Panel R e p la c e m e n t” fo r a c c e s s to th e w ir in g h a r n e s s . 3 . R e a r d o o r h in g e a c c e s s p lu g s c r e w , a n d t h e a c c e s s p lu g (if e q u ip p e d ) . 2 . T h e g a p b e tw e e n th e b o tto m o f th e d o o r p a n e l (n o t th e b o tto m o f t h e o u t e r p a n e l) a n d t h e p la tfo r m p a n e l s h o u ld b e 7 m m (0 .2 8 0 -in c h ). T h is m e a s u r e m e n t s h o u ld b e ta k e n on each d o o r in d iv id u a lly fr o m 5 . D o o r fr o m t h e v e h ic le . 6 . D o o r o p e n in g to h in g e b o lts (1 3 7 ). 3 . T h e r e a r d o o r o u te r p a n e l to th e b o d y s id e o u te r p a n e l g a p to 5 m m ± 2 .3 m m (0 .1 9 0 -in c h ± 0 .0 9 -in c h ). 7. H in g e s fr o m th e d o o r o p e n in g . 4 . T h e d o o r to d o o r c le a r a n c e b e t w e e n t h e le ft a n d r ig h t o u te r d o o r p a n e ls s h o u ld b e 5 m m ± 2 .3 m m (0 .1 9 0 -in c h ± 0 .0 9 -in c h ). Install or Connect (Figure 35) 1. H in g e s to th e d o o r o p e n in g . A lig n t h e h in g e w ith t h e p r e v io u s ly m a d e m a r k . STRIKER REPLACEMENT 2 . D o o r o p e n in g to t h e h in g e b o lts (1 3 7 ). «-► Remove or Disconnect (Figure 37) 3 . D o o r to t h e v e h ic le . • A lig n t h e h in g e w ith t h e p r e v io u s ly m a d e m a r k . 1. S tr ik e r to d o o r f r a m e b o lts (1 5 0 ). 2 . S tr ik e r fr o m th e d o o r fr a m e . 4 . D o o r to h in g e b o lts (1 3 9 ). 3 . S p a c e r (if e q u ip p e d ) . 5 . R e a r d o o r h in g e a c c e s s p lu g a n d s c r e w (if e q u ip p e d ) . 6 . E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e fe r to “ D o o r T rim w ir in g h a rn e s s . 7 . S t r a p p in . th e s i d e o f t h e d o o r . T h e d o o r s h o u ld b e in its n o r m a l c l o s e d p o s i t i o n . ( T h e o u t e r r e a r d o o r p a n e l is 1 4 m m ± 1 .5 m m ( 0 . 5 6 0 - i n c h ± 0 .0 6 - in c h ) a w a y f r o m t h e r e a r p la tfo r m p a n e l w h e n n o r m a lly c lo s e d ). 4 . D o o r to h in g e b o lts (1 3 9 ). • Adjust (Figure 36) P a n e i” fo r a c c e s s to th e -►* Install or Connect (Figure 37) 1. S p a c e r (a s r e q u ir e d ). 2 . S tr ik e r to t h e d o o r fr a m e . 3 . S tr ik e r to d o o r f r a m e b o lts (1 5 0 ). 10A1-24 DOORS 137. 138. 139. 140. 141. Bolt Hinge Bolt Screw Cover F -0 0 4 6 4 Figure 35—Hinge Components 14 mm ± 1.5 mm (0.560-inch ± 0.06-inch) Figure 36—Door Adjustments F -0 0 9 6 2 DOORS 10A1-25 152 147. 148. 149. 150. 151. 152. Spacer B um per Screw Bolt S triker Spacer 150. Bolt 151. S triker 152. Spacer F -0 0 4 7 1 F -0 0 4 7 0 Figure 38—Striker Adjustment Figure 37—Striker Components Adjust (Figure 38) DOOR TRIM PANEL REPLACEMENT T h e s tr ik e r to d o o r la tc h c le a r a n c e s o th a t t h e r e a r e 4 .4 m m (0 .1 7 2 -in c h ) b e t w e e n t h e s tr ik e r a n d t h e d o o r la tc h w hen t h e d o o r is in t h e s e c o n d a r y l a t c h e d Remove or Disconnect (Figure 39) p o s itio n . ( T h e d o o r is l a t c h e d b u t n o t f u ll y c l o s e d . ) A n 11/e 4 - in c h 1. L o w e r g a r n is h m o ld in g to d o o r s c r e w s (1 5 8 ). d ia m e t e r d r ill b it m a y b e u s e d to g a g e th is c l e a r a n c e . 2 . L o w e r g a r n is h m o ld in g . 3 . C h e c k s tra p fro m th e d o o r. 4 . D o o r tr im p a n e l to d o o r s c r e w s (1 5 6 ). BUMPER WEDGE REPLACEMENT IE! Remove or Disconnect (Figure 37) 1. B u m p e r to u p p e r d o o r fr a m e s c r e w s (1 4 9 ). 2 . B u m p e r a n d s p a c e r. 5 . D o o r tr im p a n e l. 6 . U p p e r g a r n is h m o ld in g to d o o r s c r e w s (1 5 3 ). 7. U p p e r g a r n is h m o ld in g . + « - Install or Connect (Figure 39) 1. U p p e r g a r n is h m o ld in g . 2 . U p p e r g a r n is h m o ld in g to d o o r s c r e w s ( 1 5 3 ). 3 . D o o r tr im p a n e l. ■n- Install or Connect (Figure 37) 4 . D o o r tr im p a n e l to d o o r s c r e w s (1 5 6 ). 5 . C h e c k s tr a p to t h e d o o r. 1. S p a c e r (a s r e q u ir e d ). 6 . L o w e r g a r n is h m o ld in g . 7. L o w e r g a r n is h m o ld in g to d o o r s c r e w s (1 5 8 ). 2 . B u m p e r. 3 . B u m p e r to u p p e r d o o r fr a m e s c r e w s (1 4 9 ). Adjust T h e b u m p e r to d o o r c l e a r a n c e s o t h a t t h e r e is 1 m m (0 .0 4 -in c h ) b e tw e e n th e b u m p e r a n d th e d o o r w h e n th e d o o r is in t h e s e c o n d a r y p o s i t i o n . ( T h e d o o r is l a t c h e d b u t n o t fu lly c lo s e d ). WINDOW REPLACEMENT If a g l a s s is c r a c k e d b u t s t ill i n t a c t , it s h o u l d b e c r is s c r o s s e d w it h m a s k in g t a p e to r e d u c e t h e r is k o f in ju r y a n d / o r d a m a g e to t h e v e h ic le . If a c r a c k e x t e n d s t o t h e e d g e o f t h e g la s s , m a r k t h e d o o r w ith a p ie c e o f c h a lk a t th e p o in t w h e r e th e c r a c k m e e ts th e w e a t h e r s tr ip . L a te r, w h e n e x a m in in g th e fla n g e o f th e o p e n in g fo r a c a u s e o f th e c r a c k , s ta r t a t th e p o in t m a r k e d . 10A1-26 DOORS Screw G arnish M old ing D oor Trim Panel Screw Lower G arnish M olding 158. Screw 153. 154. 155. 156. 157. 153 --- 155 ' n \\ \Jr ®ssr~\ 158' ¥ i 157 F -0 2 7 4 0 Figure 39—Door Trim Panel Components It is i m p o r t a n t t h a t t h e c a u s e o f t h e c r a c k b e d e t e r m in e d a n d t h e c o n d itio n c o r r e c te d , b e fo r e t h e n e w g la s s is in s ta lle d . T h e cau se o f th e c ra c k m ay be • an o b s tr u c tio n o r h ig h s p o t s o m e w h e r e a r o u n d t h e f la n g e o f t h e o p e n in g ; c r a c k in g m a y n o t o c c u r u n til p r e s s u r e fr o m t h e h ig h s p o t o r o b s t r u c t io n b e c o m e s p a r t ic u la r ly h ig h d u e to w in d s , e x t r e m e s o f t e m p e r a tu r e , o r r o u g h te r r a in . RIGHT DOOR LOWER LATCH REPLACEMENT Remove or Disconnect (Figure 41) Remove or Disconnect (Figure 40) 1. D o o r t r im p a n e l. R e p la c e m e n t.” CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. • th e 3 . W in d o w fr o m t h e w e a t h e r s tr ip . 4. th e c o n tro l L o w e r la tc h to d o o r s c r e w s (1 6 5 ). 5 . L o w e r la tc h w ith th e ro d fr o m th e d o o r. 1. L o w e r la tc h w ith t h e ro d to t h e d o o r. 2 . L o w e r la tc h to d o o r s c r e w s (1 6 5 ). 2 . A s i x m m ( 1/ 4 - i n c h ) c o r d i n t h e w e a t h e r s t r i p g r o o v e . T h e 3 . L o w e r la tc h to c o n tr o l a s s e m b ly a s s e m b ly . 3 . W in d o w P an el U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p 1. W e a t h e r s t r ip to t h e g la s s . about 5 T r im |++| Install or Connect ++■ Install or Connect (Figure 40) e n d s s h o u ld o v e r la p w in d o w b o tto m . “ D o o r o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y fr o m t h e r o d . H a v e a n a s s is ta n t o u ts id e th e c a b b y th e w in d o w . F o r c e th e w e a t h e r s tr ip fr o m th e fla n g e fr o m in s id e w ith a p u t t y k n ife . to 3 . L o w e r la tc h to c o n tr o l a s s e m b ly ro d fr o m a s s e m b ly . 2 . W e a th e r s tr ip a n d g la s s fr o m t h e f la n g e . • R e fe r 2 . D o o r lo c k a c c e s s c o v e r. 1. W e a t h e r s t r ip s e a l b y r u n n in g a p u tty k n ife b e t w e e n t h e f la n g e a n d th e w e a t h e r s tr ip (in s id e a n d o u ts id e th e d o o r). • H a v e a n a s s is t a n t p u ll t h e c o r d fr o m in s id e t h e c a b to s e a t t h e lip o f t h e w e a t h e r s t r ip o n t h e fla n g e . cm (6 -in c h e s ) a n d w e a t h e r s tr ip o n th e fla n g e fr o m th e c a b . • Brush soapy water on the flange. a t th e • o u ts id e ro d in to t h e c o n tr o l P iv o t t h e c lip o n to t h e r o d . 4 . D o o r lo c k a c c e s s c o v e r. 5 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el DOORS 10A1-27 RIGHT DOOR UPPER LATCH REPLACEMENT Remove or Disconnect (Figure 42) 1. D o o r t r im p a n e l. R e p la c e m e n t.” R e fe r to “ D oo r T r im P an el 2 . D o o r lo c k a c c e s s c o v e r . 3 . U p p e r la tc h to c o n tr o l a s s e m b ly ro d fr o m a s s e m b ly . th e c o n tro l Figure 42—Right Door Upper Latch 10A1-28 DOORS |++| Install or Connect (Figure 43) 1. C o n tr o l a s s e m b ly th r o u g h th e a c c e s s h o le . 2. D o o r to c o n tr o l a s s e m b ly b o lts (1 7 3 ). 3 . E le c t r ic a l d o o r a c t u a t o r (if e q u ip p e d ) . 4. U p p e r and lo w e r door la tc h ro d s to th e c o n tro l T r im P an el a s s e m b ly . • P iv o t t h e c lip s o n to t h e r o d s . 5 . D o o r lo c k a c c e s s c o v e r. 6. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r DOOR OUTSIDE HANDLE REPLACEMENT I+-+I Remove or Disconnect (Figure 44) 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” 2 . D o o r lo c k a c c e s s c o v e r. 3 . O u t s i d e d o o r h a n d l e to lo c k r o d c lip . • U s in g a fla t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c lip w h e r e it is c o n n e c t e d to t h e r o d . P iv o t t h e c lip a w a y fr o m t h e ro d . 4 . O u t s id e d o o r h a n d le to lo c k ro d fr o m t h e lo c k . 5 . D o o r to o u ts id e h a n d le s c r e w s (1 7 4 ). 6 . H a n d le w ith th e c o n tr o l ro d fr o m th e d o o r. 7. G a s k e ts fro m th e d o o r. Figure 43—Right Door Control Assembly Install or Connect • 4. U s in g a fla t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t 1. L a r g e g a s k e t o v e r th e lo c k ro d a n d o n to th e h a n d le . t h e c lip a w a y fr o m t h e ro d . 2. U p p e r la tc h to d o o r b o lts (1 6 8 ). 3 . D o o r to o u ts id e h a n d le s c r e w (1 7 4 ) to th e p u s h b u tto n s id e o f th e h a n d le . 5 . U p p e r la tc h w ith t h e ro d fr o m t h e d o o r. □ • Install or Connect 1. U p p e r la tc h w ith t h e ro d to t h e d o o r. 2 . U p p e r la tc h to d o o r b o lts (1 6 8 ). 3 . U p p e r la tc h to c o n tr o l a s s e m b ly ro d in to th e c o n tr o l a s s e m b ly . • P iv o t t h e c lip o n to t h e ro d . 4 . D o o r lo c k a c c e s s c o v e r . 5. D o o r tr im p a n e l. R e f e r to “ D o o r T r im P an el R e p la c e m e n t.” p a n e l. 5 . D o o r to o u ts id e h a n d le s c r e w (1 7 4 ) to th e o th e r s id e o f th e h a n d le . • T ig h te n b o th s c r e w s . 6 . O u ts id e d o o r h a n d le to lo c k ro d to th e lo c k a s s e m b ly . 7. C lip o n to t h e lo c k ro d . • P iv o t t h e c lip u p a n d o n t o t h e lo c k r o d . 9. D o o r tr im p a n e l. R e p la c e m e n t.” Remove or Disconnect (Figure 43) tr im D o n o t tig h te n . 4 . S m a ll g a s k e t b e tw e e n th e d o o r a n d th e h a n d le . 8 . D o o r lo c k a c c e s s c o v e r. RIGHT DOOR CONTROL ASSEMBLY REPLACEMENT 1. D o o r H a n d le w ith t h e lo c k ro d o n to t h e d o o r. R e fe r to “ D oo r T r im P an el R e p la c e m e n t.” 2 . D o o r lo c k a c c e s s c o v e r. 3 . U p p e r a n d lo w e r d o o r R e fe r to “ D o o r LEFT DOOR LOWER LATCH REPLACEMENT Remove or Disconnect (Figure 45) la tc h ro d s fro m th e c o n tro l a s s e m b ly . • U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y fr o m t h e ro d . T rim O p e n th e d o o r. 1. L a tc h to d o o r s c r e w s (1 8 2 ). 2 . L a tc h fro m th e d o o r. Install or Connect (Figure 45) 4 . E le c tr ic d o o r a c t u a t o r (if e q u ip p e d ) . 5 . D o o r to c o n tr o l a s s e m b ly b o lts (1 7 3 ). 1. L a tc h to th e d o o r. 6 . C o n tr o l a s s e m b ly t h r o u g h t h e a c c e s s h o le . 2 . L a tc h to d o o r s c r e w s (1 8 2 ). P an el DOORS 10A1-29 174. 175. 176. 177. 178. 179. 180. 181. Screw Sm all Gasket O utside Handle Large Gasket Key Door Lock C ylinder Seal Retainer F -0 0 8 2 9 Figure 44—Door Outside Handle Components Install or Connect (Figure 46) CHECK STRAP REPLACEMENT ++ Remove or Disconnect (Figure 46) 1. B ra c k e t. 2 . B r a c k e t to in n e r p a n e l b o lts (1 8 7 ). 1. P in . 3 . S tr a p to th e d o o r. 2 . S t r a p to d o o r b o lts (1 8 4 ). 3. S tra p . 4 . S tr a p to d o o r b o lts (1 8 4 ). 5 . P in . 4 . B r a c k e t to in n e r p a n e l b o lts (1 8 7 ). RIGHT DOOR WEATHERSTRIP REPLACEMENT 5 . B ra c k e t. Remove or Disconnect (Figure 47) 1. W e a th e rs tr ip fro m (o r e q u iv a le n t). t h e d o o r u s in g 3 M R e le a s e A g e n t jQ [ Clean • 182 T h e d o o r a n d w e a t h e r s t r ip o f a ll t h e o ld c e m e n t . “►+ Install or Connect (Figure 47) 1. W e a th e r s tr ip to th e d o o r A d h e s iv e (o r e q u iv a le n t). 162. 163. 164. 182. 183. Screw B um per Spacer Screw Latch A ssem bly u s in g 3M W e a th e rs tr ip LEFT DOOR WEATHERSTRIP REPLACEMENT Remove or Disconnect (Figure 48) T o o l R e q u ire d : J - 2 4 5 9 5 - B D o o r T rim P a d C lip R e m o v e r . Figure 45—Left Door Lower Latch 1. W e a t h e r s t r ip to d o o r f a s t e n e r s u s in g J - 2 4 5 9 5 - B . 10A1-30 DOORS 184. 185. 186. 187. 188. F -0 0 4 7 9 Figure 46—Check Strap Components 2 . W e a t h e r s t r ip fr o m t h e d o o r u s in g 3 M R e le a s e a g e n t (o r e q u iv a le n t). ijji • Clean T h e d o o r a n d w e a t h e r s t r ip o f a ll t h e o ld c e m e n t . Install or Connect (Figure 48) 1. W e a t h e r s t r ip to t h e d o o r u s in g A d h e s iv e (o r e q u iv a le n t). 2 . W e a th e r s tr ip to d o o r fa s te n e r s . 3M W e a th e r s tr ip SECONDARY WEATHERSTRIP REPLACEMENT Remove or Disconnect (Figure 49) 1. W e a th e r s tr ip fro m (o r e q u iv a le n t). t h e d o o r u s in g 3 M R e le a s e A g e n t Clean T h e d o o r a n d w e a t h e r s t r ip o f a ll t h e o ld c e m e n t . -► 4 - Install or Connect (Figure 49) 1. W e a th e r s tr ip to th e d o o r A d h e s iv e (o r e q u iv a le n t). Figure 47—Right Door Weatherstrip u s in g 3M W e a th e r s tr ip DOORS 10A1-31 189. W eatherstrip 190. P lastic Nails 191. Fastener 191 F -0 0 4 8 1 Figure 48—Left Door Weatherstrip Figure 49—Door Secondary Weatherstrip 10A1-32 DOORS G MODEL SIDE FRONT DOORS 191. 192. 193. 194. 195. U pper H inge B olt Screw Cover Lower H inge 193 F -0 0 4 8 3 Figure 50—Door Hinge Components DOOR AND HINGE REPLACEMENT ++ Remove or Disconnect (Figure 50) 1. E le c t r ic a l w ir in g h a r n e s s fr o m t h e d o o r (if e q u ip p e d ) . • R e f e r to “ D o o r T r im P a d R e p l a c e m e n t ” a c c e s s to th e w ir in g h a rn e s s . fo r 2 . K ic k p a n e l (if e q u ip p e d ) . 3 . H in g e b o lt c o v e r s c r e w (1 9 3 ). 4 . H in g e b o lt c o v e r. • M a r k t h e p o s itio n o f t h e h in g e s o n t h e d o o r a n d d o o r p illa r . • S u p p o rt th e d o o r. 5 . D o o r f r a m e to h in g e b o lts (1 9 2 ). 6 . D o o r fr o m th e v e h ic le . 7. H in g e to d o o r b o lts . 8 . H in g e s fr o m th e d o o r. DOOR ADJUSTMENT Install or Connect (Figure 50) |<-+| Remove or Disconnect (Figure 51) 1. H in g e s to th e d o o r. T o o l R e q u ire d : J -2 3 4 5 7 -A # 5 0 T o rx W re n c h . 2 . H in g e to d o o r b o lts . • A lig n t h e h in g e s to t h e p r e v io u s ly m a d e m a r k . 1. L o c k s t r i k e r p r o t e c t o r s c r e w ( 1 9 6 ) . 2. L o c k s t r i k e r p r o t e c t e r . 3 . D o o r to t h e v e h ic le . • • A lig n t h e h in g e s w ith t h e p r e v io u s ly m a d e m a r k . S u p p o rt th e d o o r. 4 . D o o r f r a m e to h in g e b o lts (1 9 2 ). 6 . K ic k p a n e l (if e q u ip p e d ) . 5 . H in g e b o lt c o v e r . • 7. H in g e b o lt c o v e r s c r e w (1 9 3 ) . 8 . H in g e b o lt c o v e r. P la c e th e t a b o n t h e c o v e r in to th e s lo t. • 6 . H in g e b o lt c o v e r s c r e w s (1 9 3 ). 7 . K ic k p a n e l (if e q u ip p e d ) . R e fe r to “Door T r im Panel a c c e s s to th e w ir in g h a rn e s s . R e p la c e m e n t” L o o s e n t h e d o o r h in g e b o lts a s n e e d e d to a d ju s t t h e d o o r. Adjust (Figure 52) 8 . E le c t r ic a l w ir in g h a r n e s s to t h e d o o r (if e q u ip p e d ) . • 3. S p rin g . 4 . D o o r s tr ik e r u s in g J - 2 3 4 5 7 - A . 5. S p a c e r. fo r T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d a n d in o r o u t, a t t h e d o o r h in g e s . DOORS 10A1-33 Figure 52—Door Adjustments 1. A d ju s t th e d o o r to o b ta in a g a p o f 4 .5 m m ± 0 .5 m m (0 .1 8 -in c h ± 0 .0 2 -in c h ) b e tw e e n th e fr o n t d o o r a n d th e ro o f p a n e l. 2 . T h e g a p b e tw e e n th e ro c k e r p a n e l a n d th e fro n t d o o r a t its b a s e s h o u ld b e 6 m m ± 0 .5 m m ( 0 .2 5 - in c h ± 0 .0 2 -in c h ). 3 . A d ju s t t h e d o o r to o b ta in a g a p o f 4 .5 m m ± 0 .5 m m (0 .1 8 -in c h ± 0 .0 2 -in c h ) b e tw e e n th e d o o rs r e a r e d g e a n d t h e r e a r d o o r p illa r . 4 . T h e g a p b e tw e e n th e d o o rs fro n t e d g e a n d th e re a r e d g e o f th e fe n d e r s h o u ld b e 4 .5 m m ± 0 .5 m m (0 .1 8 -in c h ± 0 .0 2 -in c h ). • T ig h te n t h e d o o r h in g e b o lts th a t w e r e lo o s e n e d . + + Install or Connect (Figure 51) 1 . H in g e b o lt c o v e r . • P la c e t h e t a b o n t h e c o v e r in to t h e s lo t. 2 . H in g e b o lt c o v e r s c r e w (1 9 3 ). NOTICE: Refer to “ N o tice” on page 10A1-1 of this section. 5 . D o o r s tr ik e r . 6 . S p rin g . 7. L o c k s tr ik e r p r o te c te r . 8 . L o c k s tr ik e r p r o t e c t e r s c r e w ( 1 9 6 ) . DOOR TRIM PANEL REPLACEMENT Remove or Disconnect (Figures 53 and 54) T o o l R e q u ir e d : J - 9 8 8 6 -0 1 D o o r H a n d le C lip R e m o v e r . 1. W in d o w r e g u la t o r h a n d le u s in g J - 9 8 8 6 - 0 1 . 2 . W in d o w r e g u la to r h a n d le b e z e l. 3 . D o o r lo c k c o n t r o l a s s e m b ly h a n d le u s in g J - 9 8 8 6 - 0 1 . 4 . C o n tr o l a s s e m b ly h a n d le b e z e l. 5 . A s s is t h a n d le (if e q u ip p e d ) . 3 . K ic k p a n e l (if e q u ip p e d ) . 6 . A r m r e s t (if e q u ip p e d ) ( f ig u r e 5 5 ) . 4 . S p a c e r to t h e d o o r s tr ik e r . 7 . D o o r tr im o u t e r p a n e l s c r e w s (if e q u ip p e d ) . 10A1-34 DOORS Inner Panel Seal Screw Bezel Door Handle W indow H andle F-00486 Figure 53—Door Trim Inner Panel ++ 8 . D o o r t r im o u t e r p a n e l (if e q u ip p e d ) . • P u ll t h e p a n e l a w a y fr o m t h e r e ta in e r s . 9 . D o o r tr im in n e r p a n e l s c r e w s . P l a c e t h e w in d o w in t h e lo w e r e d p o s it io n . 1. D o o r t r im p a n e l. R e p la c e m e n t.” 1 0 . D o o r tr im in n e r p a n e l. 0 • Remove or Disconnect (Figure 56) Install or Connect (Figures 5 3 and 5 4 ) R e fe r to “ D o o r • 1 . D o o r t r im in n e r p a n e l. P u ll t h e m o ld in g o u t o f t h e v e n t a s s e m b l y o n ly . 3 . D o o r p a n e l to r u n c h a n n e l b o lt ( 2 2 8 ) . 3 . D o o r tr im o u t e r p a n e l (if e q u ip p e d ) . 4 . D o o r to v e n tila to r s c r e w s ( 2 2 3 ) . P u s h t h e p a n e l in to t h e r e ta in e r . 4 . D o o r t r im o u t e r p a n e l s c r e w s (if e q u ip p e d ) . 5. A rm P an el 2 . R u n c h a n n e l m o ld in g . 2 . D o o r t r im in n e r p a n e l s c r e w s . • T r im 5 . D o o r v e n t/w in d o w v e h ic le . r e s t (if e q u ip p e d ) ( f ig u r e 5 5 ) . c h a n n e l a s s e m b ly fro m th e • P u ll t h e to p o f t h e v e n t b a c k w a r d s a w a y fr o m t h e d o o r fra m e . • L ift a n d r o t a t e t h e a s s e m b ly o u t o f t h e d o o r . 6 . A s s is t h a n d le (if e q u ip p e d ) . 7. C o n tr o l a s s e m b ly h a n d le b e z e l. ru n 8 . W in d o w r e g u la to r h a n d le b e z e l. Install or Connect (Figure 56) 9 . T h e c lip s to t h e w in d o w r e g u la t o r h a n d le a n d t h e d o o r lo c k c o n tr o l a s s e m b ly h a n d le . 1. D o o r v e n t /w in d o w r u n c h a n n e l a s s e m b ly to t h e v e h ic le . 1 0 . W in d o w r e g u la to r h a n d le . • P u s h th e h a n d le o n to th e s h a ft. 1 1 . D o o r lo c k c o n tr o l a s s e m b ly h a n d le . • • R o t a t e t h e v e n t a s s e m b ly in to t h e d o o r. • F it t h e a s s e m b ly in to t h e d o o r f r a m e . 2 . D o o r to v e n tila to r s c r e w s ( 2 2 3 ) . P u s h th e h a n d le o n to th e s h a ft. • DOOR VENT/WINDOW RUN CHANNEL ASSEMBLY REPLACEMENT T he door vent and th e fr o n t w in d o w ru n S t a r t w ith t h e s c r e w a t t h e to p o f t h e d o o r, a n d w o rk d o w n w a rd . 3 . D o o r p a n e l to r u n c h a n n e l b o lt ( 2 2 8 ) . 4. R u n c h a n n e l m o ld in g . • c h a n n e l a re P u s h th e c h a n n e l. o n e a s s e m b ly . T h is a s s e m b l y is f it in to t h e f r o n t o f t h e D o o r d o o r fra m e . R e p la c e m e n t.” tr im c o rn e r o f th e p a n e l. m o ld in g in to th e ru n R efer to “ D oor Trim Panel DOORS 10A1-35 218. A ssist Strap 219. Screw 220. Bezel F-00487 Figure 54—Door Trim Outer Panel VENT GLASS REPLACEMENT CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. REMOVAL (Figure 57) 1. O p e n th e v e n t w in d o w . 2 . S q u ir t s o lv e n t o n t h e t a r - p a p e r - lik e f ille r a ll a r o u n d t h e g la s s c h a n n e l, o n b o th s id e s o f t h e g la s s . 3 . W h e n t h e fille r a n d s e a le r s o fte n , p u ll t h e g la s s a n d th e o ld f ille r f r o m t h e c h a n n e l. INSTALLATION 1 . T h o r o u g h ly c le a n t h e in s id e o f t h e g la s s c h a n n e l w ith s a n d p a p e r to r e m o v e a ll r u s t a n d f o r e ig n m a tte r . 2 . C u t th e n e w p ie c e o f g la s s c h a n n e l fille r 5 1 ( 2 - in c h e s ) lo n g e r th a n r e q u ir e d . m m 3 . P o s itio n th e th e fille r (s o a p s to n e d s id e aw ay fro m g la s s ) e v e n ly a r o u n d a n d o v e r t h e e d g e o f t h e g la s s t h a t w ill b e in s e r t e d in t h e c h a n n e l . P r e s s t h e f ille r 10A1-36 DOORS 26. 27. 29. 30. 31. 223. 224. 225. 226. 227. 228. 229. Figure 57—Door/Vent Window Run Channel Components Screw Run Channel M olding Bolt Rear Run Channel A ssem bly Bolt Bolt Door Vent/Run Channel A ssem bly • In s ta ll t h e d o o r t r im R e p la c e m e n t.” p a n e l. R e f e r to “ D o o r T rim P a n e l DOOR WINDOW REPLACEMENT Remove or Disconnect (Figure 59) F -0 0 4 9 1 Figure 56—Door Run Channel Assemblies f ir m ly o n to t h e e d g e o f t h e g la s s to e n s u r e a g o o d b o n d . ( U s u a ll y t h is is d o n e w it h a m e c h a n ic a l w in d o w p r e s s .) S q u e e z e t o g e t h e r t h e d o u b le d e n d s o f t h e f ille r w h ic h p r o je c t b e y o n d t h e e d g e o f t h e g la s s . 4 . B r u s h t h e in n e r c h a n n e l w ith s o a p s o lu tio n . D O N O T U S E G R E A S E O R O IL . 5 . P r e s s t h e g la s s a n d fir m ly s e a te d . Screw Spacer D oor Vent/W indow G lass Run A ssem bly Run Channel M olding B olt F-00447 CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. • L o w e r t h e g la s s to t h e b o tto m o f t h e d o o r. t h e fille r in to t h e c h a n n e l u n til 6 . T rim o ff e x c e s s f ille r m a t e r ia l a r o u n d , a n d a t t h e e n d o f th e c h a n n e l. VENT WINDOW ADJUSTMENT Adjust (Figure 58) • • • • R e m o v e t h e d o o r t r im p a n e l. R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t.” B e n d th e ta b s o n th e a d ju s tm e n t n u t a w a y fr o m th e n u t. A d ju s t t h e v e n t b y p la c in g a w r e n c h o n t h e a d ju s tin g n u t, a n d th e n t u r n in g t h e v e n t w in d o w to t h e p r o p e r te n s io n . B e n d th e ta b s o v e r th e a d ju s tm e n t n u t. F-00448 Figure 58—Vent Window Adjustment DOORS 10A1-37 230. 231. 232. 233. 234. 235. 236. 237. 238. 239. WINDOW STOP ASSEMBLY ADJUSTMENT G lass Sash A ssem bly O uter W indow W eatherstrip Inner W indow W eatherstrip R egulator Rail B olt W asher B olt R egulator Stop 1. R e m o v e t h e d o o r t r im p a n e l. R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t.” 2. L o w e r t h e w i n d o w u n t i l it is f l u s h w i t h t h e w i n d o w s i ll . 3 . L o o s e n t h e g la s s s to p b o lt, a n d a d ju s t t h e s to p u n til t h e g la s s is c o m p le t e l y f lu s h w it h t h e w i n d o w s ill ( f i g u r e 5 9 ). 4 . T ig h t e n t h e b o lt. 5 . In s ta ll th e tr im R e p la c e m e n t.” pad. R e fe r to “ D oor T rim Panel INNER WINDOW WEATHERSTRIP REPLACEMENT |++| Remove or Disconnect (Figure 59) • L o w e r t h e w in d o w . 1. W e a th e rs tr ip fro m th e d o o r. • + 4 - P r y t h e w e a t h e r s t r ip c lip s fr o m t h e d o o r p a n e l. Install or Connect (Figure 59) 1. W e a th e r s tr ip to th e d o o r. • F -0 0 4 9 2 Figure 59—Door Window Components 1. D o o r tr im p a n e l. R e fe r R e p la c e m e n t.” 2 . D o o r v e n t/w in d o w ru n “ D o o r V e n t/W in d o w • to “ D o o r T r im P an el • L o w e r th e w in d o w . 1. W e a th e rs tr ip fro m th e d o o r. c h a n n e l a s s e m b ly . R e fe r to R u n C h a n n e l A s s e m b ly g la s s . 3 . D o o r w in d o w g la s s (2 3 0 ) . • S l id e t h e g la s s f o r w a r d u n t il t h e f r o n t r o lle r is in l in e w it h t h e n o t c h in t h e s a s h c h a n n e l . D is e n g a g e t h e r o lle r fr o m t h e c h a n n e l. • P u s h t h e w i n d o w f o r w a r d , t h e n t i lt it u p u n t i l t h e r e a r r o lle r is d is e n g a g e d . • P l a c e t h e w i n d o w i n a l e v e l p o s i t i o n , a n d r a i s e it s tr a ig h t u p a n d o u t o f t h e d o o r. Install or Connect (Figure 59) 1. D o o r w in d o w g la s s (2 3 0 ) . • R 2. D “ R 3. D R OUTER WINDOW WEATHERSTRIP REPLACEMENT |++| Remove or Disconnect (Figure 59) R e p la c e m e n t.” M a s k o r c o v e r a n y s h a r p e d g e s th a t c o u ld s c r a tc h th e • • P u s h t h e w e a t h e r s t r ip c lip s o n to t h e d o o r p a n e l. L o w e r t h e w in d o w in to t h e d o o r f r a m e . P u s h t h e w i n d o w f o r w a r d , t h e n t i lt it u p , a n d s l i d e t h e r e a r r o lle r in to t h e s a s h c h a n n e l. • S l i d e t h e g l a s s b a c k w a r d u n t i l t h e f r o n t r o l l e r is in l in e w it h t h e n o t c h in t h e s a s h c h a n n e l . E n g a g e t h e r o lle r to t h e s a s h c h a n n e l. • S lid e t h e g la s s r e a r w a r d in to t h e g la s s r u n c h a n n e l. e m o v e a n y m a s k in g o r c o v e r in g . o o r v e n t/w in d o w ru n c h a n n e l a s s e m b ly . R e fe r to D o o r V e n t/W in d o w R u n C h a n n e l A s s e m b ly e p la c e m e n t.” o o r tr im p a n e l. R e f e r to “ D o o r T r im P an el e p la c e m e n t.” • + 4- P r y t h e w e a t h e r s t r ip c lip s fr o m t h e d o o r p a n e l. Install or Connect (Figure 59) 1. W e a th e rs tr ip to th e d o o r. • P u s h t h e w e a t h e r s t r ip c lip s o n to t h e d o o r p a n e l. REAR GLASS RUN CHANNEL REPLACEMENT Remove or Disconnect (Figure 56) 1. D o o r t r im p a n e l. R e f e r to “ D o o r T r im R e p la c e m e n t.” • L o w e r t h e w in d o w c o m p le te ly . 2 . In n e r a n d o u te r w in d o w w e a t h e r s tr ip s . 3 . D o o r to r u n c h a n n e l b o lts ( 2 2 5 a n d 2 2 7 ) . P an el 4 . R u n c h a n n e l fr o m t h e v e h ic le . • P u ll t h e r u n c h a n n e l u p w a r d s w h ile t w is t in g to c le a r th e lo w e r b r a c k e t. Install or Connect (Figure 56) 1. R u n c h a n n e l to t h e v e h ic le . • W o r k t h e r u n c h a n n e l in to t h e d o o r f r a m e Be c e r t a i n t h a t t h e g la s s is in t h e c h a n n e l . L o w e r d o o r to r u n c h a n n e l b o lt ( 2 2 7 ) . R a is e t h e w in d o w c o m p le te ly . U p p e r d o o r to r u n c h a n n e l b o lt (2 2 5 ) . In n e r a n d o u t e r w in d o w w e a t h e r s tr ip s . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 10A1-38 DOORS WINDOW REGULATOR REPLACEMENT MANUAL REGULATOR Remove or Disconnect (Figure 59) • R a is e th e w in d o w a n d t a p e th e g la s s p o s itio n u s in g c lo th b o d y t a p e . 1. D o o r tr im p a n e l. R e fe r to in t h e f u ll u p “ D oo r T r im P an el R e p la c e m e n t.” 2 . D o o r p a n e l to r e g u la t o r b o lts (2 3 7 ) . 3 . W in d o w r e g u la to r ( 2 3 8 ) . • S lid e t h e r e g u la to r r e a r w a r d to d is e n g a g e t h e r e a r r o lle r fr o m th e s a s h c h a n n e l. A ls o d is e n g a g e t h e lo w e r r o lle r f r o m t h e r e g u la t o r r a il. • D is e n g a g e t h e fo r w a r d r o lle r fr o m t h e c h a n n e l a t t h e n o t c h in t h e s a s h c h a n n e l . • C o l l a p s e t h e r e g u l a t o r , a n d r e m o v e it t h r o u g h t h e a c c e s s h o l e in t h e d o o r . sash Install or Connect • L u b r ic a t e t h e r e g u la t o r a n d t h e s a s h a n d r e g u la t o r r a ils w ith lu b r ip la te o r e q u iv a le n t . 1. W in d o w r e g u la to r (2 3 8 ). • C o l l a p s e t h e r e g u l a t o r , a n d i n s e r t it t h r o u g h t h e a c c e s s h o l e in t h e d o o r . • U n f o ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d r o lle r to t h e s a s h c h a n n e l a t t h e s a s h c h a n n e l n o tc h . • S lid e t h e r e g u la to r r e a r w a r d to e n g a g e t h e r e a r r o lle r to t h e s a s h c h a n n e l. A ls o e n g a g e t h e lo w e r r o lle r t o t h e r e g u la t o r r a il. • S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n , a n d 231. 240. 241. 242. 243. 244. 245. 246. in s e r t t h e r e g u la to r d r iv e th r o u g h t h e d o o r p a n e l. Sash Channel Bum per Stop Bolt W asher Bolt Nut Power R egulator 2 . D o o r p a n e l to r e g u la to r b o lts (2 3 7 ) . 3. D o o r tr im p a n e l. R e p la c e m e n t.” • R e fe r to “ D oo r T r im P an el F -0 0 4 9 3 R e m o v e th e t a p e fr o m t h e w in d o w . Figure 60—Power Window Regulator POWER REGULATOR F o r t h e d ia g n o s is o f p o w e r w in d o w c irc u its , r e fe r to C A B E L E C T R IC A L (S E C . 8 A ). Remove or Disconnect (Figure 60) • R a is e t h e w i n d o w a n d t a p e t h e g la s s in t h e f u ll u p p o s itio n u s in g c lo th b o d y t a p e . 1. B a tte r y g r o u n d c a b le . 2 . D o o r tr im p a n e l. R e p la c e m e n t.” CAUTION: The next step must be performed when the regulator is removed from the door. The regulator lift arms are under tension from the counterbalance spring and can cause serious injury if the motor is removed without locking the sector gear in position. • R e fe r to “ D oo r T r im P an el 3 . R e m o t e c o n tr o l to d o o r tr im p a n e l b o lts . • L a y th e c o n tr o l a s id e . 4 . R e g u la t o r to d o o r p a n e l b o lts ( 2 4 4 ) a n d n u ts (2 4 5 ) . 5 . W ir in g h a r n e s s f r o m t h e r e g u la to r . 7 . M o to r to r e g u la to r a t t a c h in g s c r e w s . 6 . W in d o w r e g u la to r ( 2 4 6 ) . • S lid e th e r e g u la to r r e a r w a r d to d is e n g a g e th e r e a r r o lle r fr o m t h e s a s h c h a n n e l. A ls o d is e n g a g e t h e lo w e r r o lle r f r o m t h e r e g u la t o r r a il. • D is e n g a g e t h e fo r w a r d r o lle r fr o m t h e c h a n n e l a t t h e n o t c h in t h e s a s h c h a n n e l . • C o l la p s e t h e r e g u la t o r , a n d r e m o v e it t h r o u g h t h e a c c e s s h o l e in t h e d o o r . D r ill a h o le t h r o u g h t h e r e g u la t o r s e c t o r g e a r a n d b a c k p l a t e . D r i l l t h e h o l e a t l e a s t 1 2 . 7 m m ( 1/ 2- i n c h ) a w a y fr o m t h e e d g e o f t h e s e c to r g e a r o r b a c k p la te . In s ta ll a p a n h e a d s h e e t m e ta l ta p p in g s c r e w a t le a s t 1 9 m m ( 3/ 4 - in c h ) l o n g i n t o t h e d r i ll e d h o l e t o l o c k t h e s e c t o r g e a r in p l a c e . sash 8 . M o t o r fr o m t h e r e g u la to r . ♦ t l Install or Connect (Figure 60) E3 • L u b ric a te th e te e th . m o to r d riv e g e a r a n d 1. Regulator motor to regulator. r e g u la to r s e c to r DOORS 10A1-39 247 Lock A ssem bly C lip Inside Handle Rod Inside Lock Rod C lip Power Lock Rod 249 268. B olt ZDD F -0 0 4 9 4 F -0 0 4 9 5 Figure 61—Door Lock With Lock Rods • 2. • Figure 62—Door Lock Attachments T h e m o to r p in io n g e a r t e e t h m u s t m e s h p r o p e r ly w ith t h e s e c t o r g e a r t e e t h b e f o r e in s ta llin g t h e m o to r to r e g u la r s c r e w s . R e g u la to r m o to r to r e g u la to r s c r e w s . 3 . R e m o v e c o n tr o l a s s e m b ly . R e fe r to “ R e m o te C o n tr o l R e p la c e m e n t.” 4. R e m o v e t h e s h e e t m e t a l s c r e w fr o m t h e b a c k p la te a n d s e c to r g e a r. • Run C o l l a p s e t h e r e g u l a t o r , a n d i n s e r t it t h r o u g h t h e 6 . L o c k fro m th e d o o r. a c c e s s h o le in t h e d o o r . • “ R e a r G la s s 5 . D o o r to lo c k s c r e w s ( 2 6 7 ) . 3 . W in d o w r e g u la to r to t h e d o o r. • R e a r g la s s r u n c h a n n e l. R e f e r to C h a n n e l R e p la c e m e n t.” U n fo ld t h e r e g u la to r , a n d e n g a g e t h e f o r w a r d r o lle r to t h e s a s h c h a n n e l a t t h e s a s h c h a n n e l n o tc h . S lid e t h e r e g u la to r r e a r w a r d to e n g a g e t h e r e a r r o lle r to t h e s a s h c h a n n e l. A ls o e n g a g e t h e lo w e r r o lle r to t h e r e g u la t o r r a il. 5 . R e g u la t o r to d o o r p a n e l b o lts ( 2 4 4 ) a n d n u ts (2 4 5 ). 6 . R e m o t e c o n tr o l to d o o r tr im p a n e l b o lts . R e fe r to “ D oo r T r im -► + L o w e r t h e lo c k in t h e d o o r f a r e n o u g h t o p r o v id e c le a r a n c e fo r th e in s id e lo c k ro d . Install or Connect (Figures 61 and 62) 1. L o c k to th e d o o r. • S l id e t h e r e g u la t o r in t o its p r o p e r p o s it io n . 4 . W ir in g h a r n e s s to t h e r e g u la to r . 7. D o o r t r im p a n e l. R e p la c e m e n t.” • • A lig n t h e lo c k r o d w it h t h e h o le in t h e t o p o f t h e d o o r p a n e l. P an el 2 . D o o r to lo c k s c r e w s (2 6 7 ) . 8 . B a t t e r y g r o u n d c a b le . • 3 . R e a r g la s s r u n c h a n n e l. R e f e r to “ R e a r G la s s C h a n n e l R e p la c e m e n t.” R e m o v e th e ta p e fr o m th e w in d o w . DOOR LOCK REPLACEMENT Remove or Disconnect (Figures 61 and 62) • R a is e t h e w in d o w c o m p le te ly . 1. D o o r t r im p a n e l. R e p la c e m e n t.” 2 . D o o r lo c k k n o b . R e fe r Run 4 . R e m o te c o n tr o l a s s e m b ly . R e f e r to “ R e m o t e C o n tr o l A s s e m b ly .” 5 . D o o r lo c k k n o b . to “ D o o r T r im P an el 6. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T rim P an el 10A1-40 DOORS POWER DOOR LOCK MOTOR REPLACEMENT Refer to CAB ELECTRICAL (SEC. 8A) for electrical diagnosis of the door lock motor. 0 Remove or Disconnect (Figure 62) 1. B 2. D R 3. E 4. D a tte r y g r o u n d c a b le . o o r tr im p a n e l. R e fe r to “ D oo r T r im P an el e p la c e m e n t.” le c tr ic a l c o n n e c t o r fr o m t h e m o to r. o o r to m o to r s c r e w s (2 6 8 ). 5 . M o to r fr o m th e lo c k ro d . • S lid e t h e r u b b e r m o u n t a t t h e to p o f t h e m o to r o ff o f th e d o o r lo c k ro d . 6. M o to r fro m th e d o o r. Install or Connect (Figure 62) -► « - 1. M o to r in to t h e d o o r. 2 . M o to r to th e lo c k ro d . • S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o n to th e d o o r lo c k ro d . 3 . D o o r to m o to r s c r e w s (2 6 8 ). 4 . E le c tr ic a l c o n n e c t o r to th e m o to r. p a n e l. R e fe r to “ D o o r 5. D o o r tr im T r im P an el R e p la c e m e n t.” 6 . B a tte r y g r o u n d c a b le . DOOR OUTSIDE HANDLE REPLACEMENT 253. 254. 255. 256. Bolt Small Gasket Door Handle Large Gasket 257. 258. 259. 260. Retainer Key Lock C ylinder Gasket F-00496 Figure 63—Outside Handle and Lock Cylinder Components Remove or Disconnect (Figure 63) R a is e t h e w in d o w c o m p le te ly . D oo r R 2. D 3. H 4. G tr im p a n e l. R e fe r to “ D oo r T r im P an el e p la c e m e n t.” o o r to o u ts id e h a n d le s c r e w s (2 5 3 ). a n d le fro m th e d o o r. a s k e ts fro m th e d o o r. -►+ Install or Connect (Figure 63) 1. L a rg e g a s k e t o n to th e h a n d le . 2 . D o o r to o u ts id e h a n d le s c r e w (2 5 3 ) to th e p u s h b u tto n s id e o f th e h a n d le . • D o n o t tig h te n . 3 . S m a ll g a s k e t b e tw e e n th e d o o r a n d th e h a n d le . 4 . D o o r to o u ts id e h a n d le s c r e w (2 5 3 ) to th e o th e r s id e o f th e h a n d le . • T ig h t e n b o th s c r e w s . 5 . D o o r tr im p a n e l. R e fe r to “ D oo r T r im P an el R e p la c e m e n t.” DOOR LOCK CYLINDER REPLACEMENT 248. 261. 262. 263. Inside Handle Rod C ontrol A ssem bly Screw C lip 248 261 Remove or Disconnect (Figure 63) • R a is e t h e w in d o w c o m p le te ly . 1. D o o r tr im p a n e l. R e fe r to “ D oo r T r im P an el R e p la c e m e n t.” 2 . L o c k c y lin d e r r e t a in in g c lip fr o m t h e c y lin d e r . • S lid e t h e c lip o ff t h e c y lin d e r w ith a s c r e w d r iv e r . 3 . L o c k c y lin d e r a n d g a s k e t fr o m t h e d o o r. F-00497 Figure 64—Door Lock Control DOORS 10A1-41 El Install or Connect (Figure 64) 1. C o n tr o l to th e v e h ic le . 2 . C o n tr o l a s s e m b ly to th e lo c k a s s e m b ly ro d . • T w is t t h e c o n t r o l a s s e m b l y (w it h c lip ) o n to t h e ro d . • P iv o t t h e c lip o n t o t h e r o d . 3 . D o o r p a n e l to c o n tr o l a s s e m b ly s c r e w s (2 6 2 ). 4 . D o o r tr im p a n e l. R e f e r to “ D o o r T r im R e p la c e m e n t.” P an el DOOR WEATHERSTRIP REPLACEMENT |++| Remove or Disconnect (Figure 65) 1 . W e a t h e r s t r ip f r o m t h e d o o r u s in g 3 M (o r e q u iv a le n t). 2 . P la s tic n a ils fr o m t h e d o o r. R e le a s e A g e n t JQB Clean • T h e d o o r o f a ll t h e o ld c e m e n t . “►+ Install or Connect (Figure 65) 1. W e a t h e r s t r ip a d h e s iv e to t h e d o o r . U s e 3 M W e a th e r s tr ip A d h e s iv e (o r e q u iv a le n t). 2 . W e a th e r s tr ip to th e d o o r. • L o c a t e t h e w e a t h e r s t r i p p a r t n u m b e r , a n d p l a c e it a t t h e to p o f t h e v e n t w in d o w . • P r e s s t h e p la s t ic n a ils in to t h e d o o r. 264. Weatherstrip 265. Plastic Nail B BELOW EYELINE OUTSIDE REAR VIEW MIRROR REPLACEMENT ♦♦I Remove or Disconnect (Figure 20) F-00498 0 Figure 65—Door Weatherstrip Install or Connect (Figure 20) 1. L o c k c y lin d e r w ith g a s k e t to t h e d o o r. T h e c y lin d e r ro d m u s t e n g a g e t h e lo c k a s s e m b ly le v e r . 2 . L o c k c y lin d e r r e t a in in g c lip o n t o t h e c y lin d e r . 3. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el DOOR LOCK CONTROL ASSEMBLY REPLACEMENT |<” >| Remove or Disconnect (Figure 64) 1. D o o r t r im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 2 . D o o r p a n e l to c o n tr o l a s s e m b ly s c r e w s (2 6 2 ). 3 . C o n tr o l a s s e m b ly fr o m th e lo c k a s s e m b ly ro d . • P iv o t t h e c lip a w a y f r o m th e ro d a t th e c o n tro l a s s e m b ly . • T w is t t h e c o n t r o l a s s e m b l y o f f t h e r o d . 4 . C o n tr o l fr o m t h e v e h ic le . • L ift t h e c o v e r , a n d p iv o t t h e m ir r o r t o w a r d s t h e w in d o w . 2 . M ir r o r to d o o r b o lts a n d n u t. 3 . M ir r o r a n d s e a l fr o m t h e d o o r. Install or Connect (Figure 63) • 1. M ir r o r c o v e r s c r e w . 1. M ir r o 2 . M ir r o • P iv o t m ir r o 3 . M ir r o r a n d s e a l to th e d o o r. r to d o o r b o lts a n d n u t. th e m ir r o r a w a y fr o m th e w in d o w , a n d lo w e r th e r c o v e r. r c o v e r s c re w . 10A1-42 DOORS G MODEL INTERMEDIATE DOORS 0 DOOR AND HINGE REPLACEMENT 7. H in g e s fr o m th e d o o r. 8 . R e ta in e r s (2 7 4 ), s e a ls (2 7 3 ), a n d g r o m m e ts (2 7 2 ) fr o m t h e d o o r o r t h e h in g e s . Remove or Disconnect (Figures 66 and 67) • O p e n th e d o o r. 1. E le c t r ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e f e r to “ D o o r T r im P a n e l R e p l a c e m e n t ” a c c e s s to th e w ir in g h a r n e s s . Install or Connect (Figures 66 and 67) 1. G r o m m e t to th e d o o r. fo r M a rk w ax p 2 . H in g e 3. S tra p • t h e p o s itio n o f t h e d o o r o n t h e h in g e s u s in g a e n c il. h o le p lu g s o n t h e b o d y s i d e p illa r . p in ( 2 7 5 ) f r o m t h e b r a c k e t . R e m o v e t h e s n a p r in g f r o m t h e p in , a n d p u ll t h e p in . • S u p p o rt th e d o o r. 4 . H in g e to t h e b o d y p illa r b o lts ( 2 7 0 ). 5 . D o o r fr o m t h e v e h ic le . 6 . H in g e to d o o r b o lts ( 2 7 0 ). 2 . H in g e to th e d o o r. 3 . H in g e to d o o r b o lts (2 7 0 ). • • A lig n t h e h in g e to t h e p r e v io u s ly m a d e m a r k . 4 . T h e s e a ls a n d r e ta in e r s to t h e b o d y h a lf o f t h e h in g e . 5 . D o o r to t h e v e h ic le . • S u p p o rt th e d o o r. 6 . H in g e to b o d y p illa r b o lts (2 7 0 ) . • A lig n t h e h in g e to t h e p r e v io u s ly m a d e m a r k . 7 . S t r a p p in ( 2 7 5 ) to t h e b r a c k e t . 8. S n a p r i n g t o t h e p i n . 9 . H in g e h o l e p lu g s o n t h e b o d y s i d e p illa r . 10. E le c tr ic a l w ir in g h a r n e s s (if e q u ip p e d ) . • R e f e r to “ D o o r T rim P a n e l R e p la c e m e n t ” a c c e s s to t h e w ir in g h a r n e s s . fo r DOOR ADJUSTMENT Remove or Disconnect (Figure 68) 277 T o o l R e q u ir e d : J -2 3 4 5 7 -A W re n c h . 1 . D o o r lo c k s t r ik e r f r o m t h e r e a r in t e r m e d ia t e d o o r u s in g J -2 3 4 5 7 -A . 275. 276. 277. 278. 279. 280. Pin Bracket Bolt Ring Strap Pin 2 . U p p e r a n d lo w e r r e a r i n t e r m e d ia t e d o o r s tr ik e r s . • Loosen d o o rs . th e h in g e b o lts as n e c e s s a ry to a d ju s t th e Adjust 279 278 F -0 0 5 0 0 Figure 67—Check Strap Components E a c h o f t h e t w o d o o r s m u s t f ir s t b e a d ju s t e d in t h e d o o r o p e n in g b e fo r e a d ju s tin g t h e d o o r to d o o r c le a r a n c e . T h e d o o r u p o r d o w n , f o r w a r d o r r e a r w a r d , a n d in o r o u t, a t t h e d o o r h in g e s . DOORS 10A1-43 4 mm ± 0.5 mm (0.16-inch ± 0.020-inch) 282 F -0 0 5 0 1 Figure 68—Door Adjustments T h e d o o r h e ig h t s o t h a t t h e r e is a g a p o f 4 . 5 m m ± 0 .5 m m (0 .1 8 -in c h ± 0 .0 2 0 -in c h ) b e tw e e n th e d o o r s a n d th e ro o f p a n e l. U 2. T h e g a p b e t w e e n t h e d o o r a n d t h e r o c k e r p a n e l t o 6 m m ± 0 .5 m m (0 .2 4 -in c h + 0 .0 2 0 -in c h ). 287 T h e g a p b e t w e e n t h e d o o r s a n d t h e b o d y a t t h e h in g e p illa r s to 4 m m ± 0 .5 m m ( 0 .1 6 -in c h ± 0 .0 2 0 - in c h ) . T h e g a p b e tw e e n th e fr o n t a n d r e a r in te r m e d ia te d o o rs to 6 m m ± 0 .5 m m (0 .2 5 -in c h ± 0 .0 2 0 -in c h ). T ig h t e n t h e h in g e b o lts th a t w e r e lo o s e n e d . Install or Connect 1. 287. S triker 288. Latch A. 4.4 mm (0.172-inch) 287 U p p e r a n d lo w e r r e a r in t e r m e d ia t e d o o r s t r ik e r s to t h e body. D o o r lo c k s tr ik e r to t h e r e a r in t e r m e d ia t e d o o r u s in g J -2 3 4 5 7 -A . F -0 0 5 0 3 Adjust (Figure 69) T h e u p p e r a n d lo w e r r e a r in t e r m e d ia t e d o o r s tr ik e r to d o o r c l e a r a n c e s o t h a t t h e r e is 4 . 4 m m ( 0 .1 7 2 - in c h ) b e t w e e n t h e s t r ik e r a n d t h e d o o r l a t c h w h e n t h e d o o r is Figure 69—Striker Adjustments 10A1-44 DOORS Adjust T h e b u m p e r t o d o o r c l e a r a n c e s o t h a t t h e r e is 1 m m (0 .0 4 -in c h ) b e tw e e n th e b u m p e r a n d th e d o o r w h e n th e d o o r is in t h e s e c o n d a r y p o s it io n . ( T h e d o o r is l a t c h e d b u t n o t fu lly c lo s e d ) . DOOR TRIM PANEL REPLACEMENT INTERMEDIATE FRONT DOOR Remove or Disconnect (Figure 71) D o o r s tra p . P r y t h e l o c k k n o b o f f o f t h e l o c k r o d , w h e n t h e k n o b is in t h e u n lo c k e d p o s it io n . D o o r h a n d le b e z e l s c re w s . B e z e l a n d lo c k k n o b fr o m t h e v e h ic le . D o o r tr im p a n e l to d o o r s c r e w s ( 2 9 5 ) . D o o r t r im p a n e l. • P u ll t h e p a n e l fr o m t h e r e t a in e r s . R e ta in e r to d o o r s c r e w s (2 9 3 ). R e ta in e r s fr o m th e d o o r. 312 D o o r g a r n is h m o ld in g s c r e w s ( 2 8 9 ) . D o o r g a r n is h m o ld in g fr o m t h e d o o rs . 310 313 307. 308. 309. 310. 311. 312. 313. 314. Bolt Screws B um per Spacer Upper Latch Lower Latch Screw Drain Hole Plug “►+ Install or Connect (Figure 71) D o o r g a r n is h m o ld in g to t h e d o o r. D o o r g a r n is h m o ld in g s c r e w s ( 2 8 9 ) . 309 R e ta in e r s to th e d o o r. R e ta in e r to d o o r s c r e w s (2 9 3 ). D o o r tr im p a n e l. • 308 314 P u s h t h e e d g e o f t h e p a n e l in to t h e r e ta in e r s . D o o r tr im p a n e l to d o o r s c r e w s ( 2 9 5 ) . D o o r h a n d le b e z e l a n d lo c k k n o b to t h e v e h ic le . F -0 0 5 0 6 • P la c e th e lo c k k n o b o n to th e lo c k ro d . D o o r h a n d le b e z e l s c re w s . D o o r s tra p . Figure 70—Bumper Wedge Components in t h e s e c o n d a r y l a t c h e d p o s i t i o n . ( T h e d o o r is l a t c h e d b u t n o t f u lly c l o s e d . ) A n 11/e 4 - in c h d ia m e t e r d r ill b it m a y b e u s e d to g a g e th is c le a r a n c e . T h e f r o n t i n t e r m e d i a t e s t r i k e r o n t h e r e a r d o o r . A d j u s t it s o th a t th e fr o n t d o o r lo c k p r o p e r ly e n g a g e s th e r e a r d o o r , a n d s o t h e f r o n t d o o r is f lu s h w it h t h e r e a r d o o r . INTERMEDIATE REAR DOORS Remove or Disconnect (Figure 72) D o o r tr im p a n e l to d o o r s c r e w s ( 3 0 5 ) . D o o r tr im p a n e l. • P u ll t h e p a n e l f r o m t h e r e ta in e r s . S id e d o o r g a r n is h m o ld in g s c r e w s ( 3 0 4 ) a n d b o lt (3 0 2 ) . S id e d o o r g a r n is h m o ld in g fr o m t h e d o o r. R e ta in e r to d o o r s c r e w s (3 0 1 ). BUMPER WEDGE REPLACEMENT Remove or Disconnect (Figure 70) 1. B u m p e r to u p p e r a n d lo w e r d o o r fr a m e s c r e w s (3 0 8 ). 2 . B u m p e r a n d s p a c e r. ♦«" Install or Connect (Figure 70) 1. S p a c e r (a s r e q u ir e d ). 2 . B u m p e r. 3 . B u m p e r to u p p e r a n d lo w e r d o o r fr a m e s c r e w s (3 0 8 ). R e ta in e r fr o m th e d o o r. U p p e r d o o r g a r n is h m o ld in g s c r e w s ( 2 9 8 ) . U p p e r d o o r g a r n is h m o ld in g fr o m t h e d o o r. -►4- Install or Connect (Figure 72) U p p e r d o o r g a r n is h m o ld in g to t h e d o o r. U p p e r d o o r g a r n is h m o ld in g s c r e w s ( 2 9 8 ) . R e ta in e r to th e d o o r. R e ta in e r to d o o r s c r e w s (3 0 1 ). S id e d o o r g a r n is h m o ld in g to t h e d o o r. S id e d o o r g a r n is h m o ld in g s c r e w s ( 3 0 4 ) a n d b o lt ( 3 0 2 ) . D o o r tr im p a n e l. • P u s h t h e e d g e o f t h e p a n e l in to t h e r e ta in e r . D o o r tr im p a n e l to d o o r s c r e w s ( 3 0 5 ) . DOORS 10A1-45 Figure 71—Intermediate Front Door Trim Panel WINDOW REPLACEMENT If a g l a s s is c r a c k e d b u t s t ill i n t a c t , it s h o u l d b e c r is s c r o s s e d w it h m a s k in g t a p e to r e d u c e t h e r is k o f in ju r y a n d / o r d a m a g e to t h e v e h ic le . If a c r a c k e x t e n d s to t h e e d g e o f t h e g la s s , m a r k t h e d o o r w ith a p ie c e o f c h a lk a t t h e p o in t w h e r e t h e c r a c k m e e ts t h e w e a t h e r s tr ip . L a te r , w h e n e x a m in in g th e fla n g e o f th e o p e n in g fo r a c a u s e o f th e c r a c k , s ta r t a t th e p o in t m a r k e d . It is im p o r t a n t t h a t t h e c a u s e o f t h e c r a c k b e d e t e r m in e d a n d t h e c o n d itio n c o r r e c te d , b e fo r e th e n e w g la s s is in s t a lle d . T h e c a u s e o f t h e c r a c k m a y b e a n o b s t r u c t io n o r h ig h s p o t s o m e w h e r e a r o u n d t h e f la n g e o f t h e o p e n in g ; c r a c k in g m a y n o t o c c u r u n til p r e s s u r e fr o m t h e h ig h s p o t o r o b s t r u c t io n b e c o m e s p a r t ic u la r ly h ig h d u e to w in d s , e x tr e m e s o f te m p e r a tu r e , o r r o u g h te r r a in . STATIONARY GLASS Remove or Disconnect (Figure 73) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. 1. W e a t h e r s t r ip s e a l b y r u n n in g a p u tty k n ife b e t w e e n t h e fla n g e a n d th e w e a t h e r s tr ip (in s id e a n d o u ts id e th e d o o r). • H a v e a n a s s is ta n t o u ts id e th e c a b b y th e w in d o w . 2 . W e a t h e r s t r ip a n d g la s s fr o m th e fla n g e . • F o r c e th e w e a t h e r s tr ip fr o m th e fla n g e fr o m th e in s id e w ith a p u t t y k n ife . 3 . W in d o w fr o m t h e w e a t h e r s tr ip . Install or Connect (Figure 73) 1 . W e a t h e r s t r ip to t h e g la s s . • T h e s e a m o f th e w e a t h e r s tr ip m u s t b e lo c a te d a t t h e b o tto m c e n t e r lin e o f t h e g la s s . 2 . A s i x m m ( 1/ 4 - i n c h ) c o r d i n t h e w e a t h e r s t r i p g r o o v e . T h e e n d s s h o u ld o v e r la p a b o u t 5 c m (6 -in c h e s ) a t th e w in d o w b o tto m . 3 . W in d o w a n d w e a t h e r s tr ip o n th e fla n g e fr o m th e c a b . o u ts id e • B ru s h s o a p y w a te r o n th e fla n g e . • H a v e a n a s s is ta n t p u ll t h e c o r d fr o m in s id e t h e c a b to s e a t t h e lip o f t h e w e a t h e r s t r ip o n t h e fla n g e . 10A1-46 DOORS Nut Screw G arnish M olding R etainer Screw Bolt Side G arnish M olding Screw Screw D oor Trim Panel F -0 0 5 0 5 Figure 72—Intermediate Rear Door Trim Panel SWING OUT WINDOW Remove or Disconnect (Figures 74 and 75) • T w i s t t h e l a t c h o n t o t h e c o v e r w i t h 1A o f a t u r n . 4 . W in d o w la tc h to d o o r s c r e w s ( 3 2 7 ) . INTERMEDIATE FRONT DOOR LOCK REPLACEMENT CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. Remove or Disconnect (Figure 76) 1. W in d o w la tc h to d o o r s c r e w s (3 2 7 ) . 2 . W in d o w la tc h fr o m t h e w in d o w . • • T w i s t t h e l a t c h 1/ 4 o f a t u r n t o r e l e a s e t h e l a t c h c o m p o n e n t s fr o m t h e w in d o w . L ift t h e w i n d o w f o r a c c e s s to t h e h in g e s c r e w s . 3 . H in g e to d o o r s c r e w s (3 2 0 ). 1. D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r 2 . D o o r lo c k c o n tr o l. R e p la c e m e n t.” R e fe r Install or Connect (Figures 74 and 75) 1 . H in g e a n d h in g e s e a l to t h e d o o r. 2 . H in g e to d o o r s c r e w s (3 2 0 ). 3 . W in d o w la tc h to t h e w in d o w . to “ D o o r “ D oor T r im Lock P an el C o n tro l 3 . P o w e r d o o r lo c k m o to r (if e q u ip p e d ) . R e f e r to “ P o w e r 4 . H in g e fr o m th e d o o r. 5 . H in g e s e a l fr o m th e d o o r. to D o o r L o c k M o to r R e p la c e m e n t.” 4 . D o o r to r e m o te c o n tr o l s c r e w s (3 3 0 ). 5 . D o o r to lo c k s c r e w s ( 3 3 1 ). 6 . L o c k a n d r e m o te c o n tr o l w ith r o d s fr o m th e d o o r. + 4 - Install or Connect (Figure 76) 1. L o c k a n d r e m o te c o n tr o l w ith r o d s to th e d o o r. • P la c e t h e c o v e r a n d s p a c e r th r o u g h t h e w in d o w . 2 . D o o r to lo c k s c r e w s (3 3 1 ). • P la c e th e w a s h e r a n d s p r in g o n to th e c o v e r. 3 . D o o r to r e m o te c o n tr o l s c r e w s (3 3 0 ). DOORS 10A1-47 INTERMEDIATE FRONT DOOR LOCK CONTROL REPLACEMENT Remove or Disconnect (Figure 77) 1. D o o r t r im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el 2 . L o c k c o n tro l to d o o r s c r e w (3 3 7 ). 3 . L o c k c o n tro l fro m th e d o o r. • S lid e th e c o n tr o l to w a r d s th e fr o n t o f th e d o o r. 4 . L o c k r o d f r o m t h e lo c k c o n tr o l. • S l i d e t h e c l i p s o t h a t t h e l a r g e d i a m e t e r s l o t is in lin e w ith t h e lo c k r o d . T h e n , p u ll t h e r o d f r o m t h e c o n tr o l. -►+ Install or Connect (Figure 77) 1. L o c k r o d to t h e lo c k c o n tr o l. • P la c e t h e r o d in to t h e c lip a n d t h e le v e r . S lid e t h e c l ip s o t h a t t h e s m a l l d ia m e t e r s lo t is in l in e w it h t h e lo c k ro d . 2 . L o c k c o n tro l to th e d o o r. • S lid e th e c o n tr o l to w a r d s th e r e a r o f th e d o o r. 3 . L o c k c o n tr o l to d o o r s c r e w s (3 3 7 ). 4 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T rim P an el DOOR LOCK CYLINDER REPLACEMENT Remove or Disconnect (Figure 78) 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” 2. L o c k c y lin d e r r e t a in in g c lip fr o m t h e c y lin d e r . • S lid e t h e c lip o ff t h e c y lin d e r w ith a s c r e w d r iv e r . 3 . L o c k c y lin d e r a n d g a s k e t fr o m th e d o o r. Install or Connect (Figure 78) 1. L o c k c y lin d e r w ith g a s k e t to th e d o o r. • 4. P D 5. D R 6. D R o w e r d o o r lo c k m o to r o o r L o c k M o to r R e p la o o r lo c k c o n tr o l. R e p la c e m e n t.” o o r tr im p a n e l. R e p la c e m e n t.” (if e q u ip p e d ) . R e f e r to “ P o w e r c e m e n t.” e fe r to “ D o o r L o c k C o n tro l e fe r to “ D o o r T r im T h e c y lin d e r r o d m u s t e n g a g e t h e lo c k a s s e m b ly le v e r. 2 . L o c k c y lin d e r r e t a in in g c lip o n to t h e c y lin d e r . 3 . D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r T r im P an el P an el DOOR OUTSIDE HANDLE REPLACEMENT Remove or Disconnect (Figure 78) • R a is e t h e w in d o w c o m p le te ly . 1. D o o r t r im p a n e l. R e p la c e m e n t.” 2. R e fe r to “ D oo r T r im P an el D o o r to o u ts id e h a n d le s c r e w s (3 4 1 ). 3 . H a n d le fro m th e d o o r. 4 . G a s k e ts fro m th e d o o r. 322. Cover 323. Spacer 325. W asher 326. Spring 327. Screw 328. Latch________________ F-00508 Figure 74—Swing Out Latch Components Install or Connect (Figure 78) 1. L a r g e g a s k e t o n to th e h a n d le . 2 . D o o r to o u ts id e h a n d le s c r e w (3 4 1 ) to th e p u s h b u tto n s id e o f th e h a n d le . • D o n o t tig h te n . 10A1-48 DOORS F-00509 Figure 75—Swing Out Window Attachment 329. 330. 331. 332. 333. 334. 335. 336. Rem ote C ontrol B olt B olt Lock A sse m b ly C lip Rem ote C on trol Rod Inside H andle Rod Inside Lock Rod Figure 76—Intermediate Front Door Lock Components DOORS 10A1-49 Figure 77—Intermediate Front Door Lock Control ++ 3 . S m a ll g a s k e t b e tw e e n th e d o o r a n d th e h a n d le . 4 . D o o r to o u ts id e h a n d le s c r e w (3 4 1 ) to th e o th e r s id e o f th e h a n d le . • T ig h te n b o th s c r e w s . 3 . L o w e r la tc h to c o n tr o l a s s e m b ly ro d a s s e m b ly . • P iv o t t h e c lip o n to t h e r o d . INTERMEDIATE REAR DOOR LOWER LATCH REPLACEMENT Remove or Disconnect (Figure 79) 1. D o o r tr im p a n e l. R e fe r to “ D o o r T r im P an el R e p la c e m e n t.” 2. th e c o n tro l U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y f r o m t h e r o d . 3 . L o w e r la tc h to d o o r s c r e w s ( 3 4 9 ) . 4 . L o w e r la tc h w ith t h e ro d fr o m t h e d o o r. 339. 340. 341. 342. 343. 344. 345. 346. 4. D o o r tr im p a n e l. R e fe r to in to th e c o n tr o l “ D o o r T r im P an el R e p la c e m e n t.” INTERMEDIATE REAR DOOR UPPER LATCH REPLACEMENT Remove or Disconnect (Figure 80) L o w e r la tc h to c o n tr o l a s s e m b ly ro d fr o m a s s e m b ly . • 1. L o w e r la tc h w ith th e ro d to th e d o o r. 2 . L o w e r la tc h to d o o r s c r e w s (3 4 9 ). 5 . D o o r tr im p a n e l. R e f e r to “ D o o r T rim P a n e l.” B Install or Connect (Figure 79) D o o r tr im p a n e l. R e p la c e m e n t.” R e fe r to “ D o o r U p p e r la tc h to c o n tr o l a s s e m b ly ro d fr o m T r im P an el th e c o n tro l a s s e m b ly . • U s in g a f la t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y fr o m t h e r o d . O utside Handle Large Gasket B olt R etainer Key Lock C ylinder Gasket Sm all Gasket Figure 78—Outside Handle And Lock Cylinder Components 10A1-50 DOORS 8 . C o n tr o l a s s e m b ly w ith 347. Lower Latch Rod 348. Lower Latch 349. Bolt ------ 347 1 -3 4 5 F-00513 Figure 79—Intermediate Rear Door Lower Latch 3 . U p p e r la tc h to d o o r b o lts ( 3 5 0 ) . 4 . U p p e r la tc h w ith t h e ro d fr o m th e d o o r. 4. 5. 6. 7. l+il 1. U p p e r l a t c h w i t h t h e r o d t o t h e d o o r . 3 . U p p e r la tc h to c o n tr o l a s s e m b ly ro d in to t h e c o n tr o l a s s e m b ly . • P iv o t t h e c lip o n to t h e ro d . p a n e l. R e f e r to “ D o o r T r im P an el 4 . D o o r tr im R e p la c e m e n t.” INTERMEDIATE REAR DOOR CONTROL ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 81) R e fe r to “ D oo r 7. th e access T r im P an el R e fe r to C A B E L E C T R IC A L (S E C . d ia g n o s is o f t h e d o o r lo c k m o to r. 8 A ) fo r e le c tr ic a l Remove or Disconnect (Figure 82) 4 -+ 1. B a tt e r y g r o u n d c a b le . 2 . D o o r tr im p a n e l. R e fe r to “ D o o r R e p la c e m e n t.” 3 . E le c tr ic a l c o n n e c t o r fr o m t h e m o to r. T r im P an el 4 . D o o r to m o to r s c r e w s (3 7 0 ). 5 . M o to r fr o m th e lo c k ro d . • S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o ff o f th e d o o r lo c k ro d . 6 . M o to r fro m th e d o o r. T r im P an el R e p la c e m e n t.” lo w e r d o o r la tc h r o d s fr o m t h e c o n tr o l a s s e m b ly . • U s in g a fla t b la d e d s c r e w d r iv e r , p u s h o n t h e to p o f t h e c l i p w h e r e it is c o n n e c t e d t o t h e r o d . P i v o t t h e c lip a w a y f r o m t h e r o d . E le c tr ic d o o r a c t u a t o r (if e q u ip p e d ) . L o c k k n o b (3 5 6 ). R e a r d o o r in s id e h a n d le s c r e w ( 3 6 4 ) a n d h a n d le (3 6 5 ). R e a r d o o r lo c k ro d c lip a t t h e d o o r p a n e l. • P iv o t t h e c lip a w a y fr o m t h e r o d . D o o r to c o n tr o l a s s e m b ly b o lts (3 6 3 ) . 2. U p p e r a n d 3. 4. 5. 6. access POWER DOOR LOCK MOTOR REPLACEMENT 2. U p p e r l a t c h t o d o o r b o l t s ( 3 5 0 ) . p a n e l. th e • P iv o t t h e c lip o n to t h e r o d . R e a r d o o r in s id e h a n d le (3 6 5 ) a n d s c r e w (3 6 4 ). L o c k k n o b (3 5 6 ). E le c t r ic d o o r a c t u a t o r (if e q u ip p e d ) . U p p e r a n d lo w e r d o o r la tc h r o d s to th e c o n tr o l a s s e m b ly . • P iv o t t h e c lip o n to t h e r o d . 8. D o o r tr im p a n e l. R e fe r to “ D o o r R e p la c e m e n t.” |~n-| Install or Connect (Figure 80) tr im th ro u g h 1. C o n tr o l a s s e m b ly w ith lo c k r o d th r o u g h h o le . 2 . D o o r to c o n tr o l a s s e m b ly b o lts (3 6 3 ). 3 . R e a r d o o r lo c k r o d c lip a t t h e d o o r p a n e l. j o D o o r ro d "►+ Install or Connect (Figure 81) -------348 1. lo c k h o le . 350 Install or Connect (Figure 82) 1. M o to r in to t h e d o o r. 2 . M o to r to t h e lo c k ro d . • S lid e th e r u b b e r m o u n t a t th e to p o f th e m o to r o n to th e d o o r lo c k ro d . 3 . D o o r to m o to r s c re w s (3 7 0 ). 4 . E le c tr ic a l c o n n e c to r to th e m o to r. 5 . D o o r tr im p a n e l. R e f e r to “ D o o r T r im P an el R e p la c e m e n t.” 6 . B a tte r y g r o u n d c a b le . INTERMEDIATE FRONT DOOR WEATHERSTRIP REPLACEMENT I++I Remove or Disconnect (Figure 83) 1. W e a th e rs tr ip fro m (o r e q u iv a le n t). 2. t h e d o o r u s in g 3 M R e le a s e A g e n t P la s tic n a ils fr o m t h e d o o r. jQjj Clean 350. Bolt 351. Upper Latch 352. Upper Latch Rod • T h e d o o r o f a ll t h e o ld c e m e n t . Install or Connect (Figure 83) F -0 0 5 1 4 Figure 80—Intermediate Rear Door Upper Latch 1. W e a t h e r s t r ip a d h e s iv e to t h e d o o r . W e a th e r s tr ip A d h e s iv e (o r e q u iv a le n t). 2 . N e w w e a t h e r s tr ip to th e d o o r. • P r e s s t h e p la s tic n a ils in to t h e d o o r. U se 3M DOORS 10A1-51 .353 356 357 / 355 353. 354. 355. 356. 357. 358. 359. 360. 361. 362. 363. 364. 365. Control A ssem bly C lip Lock Rod Lock Knob Ferrule Screw Protector Spring S triker W asher Bolt Screw Handle F-00515 Figure 81—Intermediate Rear Door Control Assembly INTERMEDIATE REAR DOOR WEATHERSTRIP REPLACEMENT B 1 . W e a th e r s tr ip to d o o r p a n e l s c r e w s (3 7 5 ). t h e d o o r u s in g 3 M R e le a s e A g e n t 1. W e a t h e r s t r i p a d h e s iv e to t h e d o o r . W e a th e r s tr ip a d h e s iv e (o r e q u iv a le n t). 2 . N e w w e a t h e r s tr ip to th e d o o r. • P r e s s t h e p la s t ic n a ils in to t h e d o o r. 3 . W e a th e rs tr ip to d o o r p a n e l s c r e w s (3 7 5 ). 3 . P la s t ic n a ils fr o m t h e d o o r. 367 368 T h e d o o r o f a ll t h e o ld c e m e n t . Install or Connect (Figure 84) Remove or Disconnect (Figure 84) 2 . W e a th e rs tr ip fro m (o r e q u iv a le n t). Clean 332. 367. 368. 369. 370. Lock A ssem bly C lip Lock M otor Rod Lock M otor Screws 370 Figure 82—Power Door Lock Motor Attachments U se 3M 10A1-52 DOORS 371. W eatherstrip 372. P lastic Nail 371 F-00518 Figure 83—Intermediate Front Door Weatherstrip 373. W eatherstrip 374. P lastic Nail 375. Screw 373 373 374 F-00519 Figure 84—Intermediate Rear Door Weatherstrip DOORS 10A1-53 G MODEL SLIDING SIDE DOOR DOOR REPLACEMENT 381. 415. 416. 417. 418. A. Remove or Disconnect (Figures 85 through 89) U p p e r r e a r tr a c k c o v e r a n d h in g e c o v e r. O p e n t h e d o o r c o m p le te ly . 2. U p p e r f r o n t r o l l e r a s s e m b l y ( 3 8 1 ) f r o m t h e d o o r . • M a r k t h e p o s it io n o f t h e r o lle r a s s e m b ly o n t h e d o o r. U p p e r re a r U p p e r re a r • L ift t h L o w e r fro n t 0--c=y r I h in g e r e t a in e r ( 3 9 3 ) f r o m t h e h in g e . h in g e ( 3 9 4 ) fr o m t h e u p p e r r e a r tr a c k . e h in g e o ff o f t h e tr a c k . r o lle r ( 3 9 8 ) fr o m t h e t r a c k . • P iv o t th e d o o r a w a y d is e n g a g e t h e r o lle r s . 6. D o o r f r o m t h e v e h i c l e . -► 4 - Front R oller Bracket Upper R oller Spacer Spring W asher Nut C enter The R oller In The Track fro m th e v e h ic le F -0 0 5 2 2 to Figure 87—Upper Front Roller Components Install or Connect (Figures 85 through 89) • L if t t h e h in g e r o lle r o n t o t h e t r a c k . U p p e r r e a r h in g e r e t a in e r ( 3 9 3 ) to t h e h in g e . D o o r to t h e v e h ic le . U p p e r fr o n t r o lle r a s s e m b ly ( 3 8 1 ) to t h e d o o r. L o w e r f r o n t r o lle r ( 3 9 8 ) to t h e t r a c k . P iv o t th e d o o r a w a y fr o m th e v e h ic le to e n g a g e t h e r o lle r s to t h e t r a c k . T h e n p iv o t t h e d o o r to w a r d s t h e v e h ic le . 3. U p p e r rear hinge (394) to th e u p p e r rear track. • • A lig n t h e r o lle r a s s e m b ly to t h e p r e v io u s ly m a d e m a rk . 6. U p p e r r e a r t r a c k c o v e r a n d h i n g e c o v e r . HINGE ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 88) C lo s e t h e d o o r c o m p le te ly . 1. H i n g e c o v e r ( f i g u r e 8 5 ) . 2 . T ra c k c o v e r (fig u re 8 6 ). 3 . H in g e r e ta in e r p la te ( 3 9 3 ) . • M a r k th e p o s itio n o f th e h in g e o n th e d o o r. N u t ( 3 9 0 ) , w a s h e r ( 3 8 9 ) , a n d r e ta in e r (3 8 0 ) . H in g e to d o o r s c r e w (3 9 1 ). H in g e to d o o r b o lt (3 8 8 ) . H in g e fr o m t h e v e h ic le . Install or Connect (Figure 88) H in g e to t h e v e h ic le . • P la c e t h e r o lle r o n t h e t r a c k . A lig n t h e h in g e to t h e p r e v io u s ly m a d e m a r k . H in g e to d o o r b o lt (3 8 8 ) . H in g e to d o o r s c r e w (3 9 1 ). R e ta in e r (3 8 0 ), w a s h e r ( 3 8 9 ) a n d n u t (3 9 0 ). 10A1-54 DOORS 387 395 380. 387. 388. 389. 390. 391. 392. 393. 394. 395. A. Cover R etainer Spring Bolt W asher Nut Screw Bolt R etainer H inge A ssem bly S triker L u b rica tion P oints 392 380 393 A 394 A 389 390 F -0 0 5 2 3 Figure 88—Upper Rear Hinge Components UPPER FRONT ROLLER REPLACEMENT 5 . H in g e r e ta in e r p la te (3 9 3 ). 6 . T ra c k c o v e r (fig u r e 8 6 ). 7. H in g e c o v e r (fig u r e 8 5 ). Remove or Disconnect (Figure 87) • LOWER ROLLER ASSEMBLY REPLACEMENT 2. Remove or Disconnect (Figure 89) 3 . B r a c k e t to d o o r b o lts ( 3 8 6 ) . M a r k th e p o s itio n o f th e a s s e m b ly to th e b r a c k e t o n th e r o lle r a s s e m b ly . 4. 1. R o lle r a s s e m b ly to d o o r b r a c k e t b o lts (4 0 1 ). 1. R o lle r m o ld in g (if e q u ip p e d ) . P la s tic c a p (if e q u ip p e d ) . R o lle r fr o m th e tr a c k . |++| Install or Connect (Figure 87) 2 . C a t c h c lip ( 4 0 0 ) a n d r o d f r o m t h e c a t c h . 1. R o lle r in to t h e tr a c k . 3 . P iv o t t h e r o lle r a s s e m b ly o u t o f t h e lo w e r d o o r tr a c k . 2. ♦ «- Install or Connect (Figure 89) 1. P iv o t t h e r o lle r a s s e m b ly in to t h e lo w e r d o o r tr a c k . 2. B r a c k e t to d o o r b o lts (3 8 6 ) . 3 . P la s t ic c a p (if e q u ip p e d ) . 4. R o lle r m o ld in g (if e q u ip p e d ) . R o lle r a s s e m b ly to d o o r b r a c k e t b o lts (4 0 1 ). • DOOR ADJUSTMENT A lig n t h e r o lle r a s s e m b ly to t h e p r e v io u s ly m a d e m a rk . 3 . C a t c h c lip ( 4 0 0 ) a n d r o d to t h e c a t c h . UP AND DOWN ADJUSTMENT Remove or Disconnect (Figure 90) T o o l R e q u ir e d : J -2 3 4 5 7 # 5 0 T o rx W re n c h . 1. U p p e r r e a r h in g e c o v e r. 2. F r o n t lo c k s tr ik e r ( 4 0 4 ) . 3 . R e a r lo c k s tr ik e r ( 4 0 5 ) u s in g J - 2 3 4 5 7 . 4. R e a r d o o r w e d g e a s s e m b ly (4 0 7 ). Adjust (Figure 91) Figure 89—Lower Front Roller Assembly 1. T h e r e a r e d g e o f th e d o o r to o b ta in a g a p o f 4 .5 m m ± 0 .5 m m (0 .1 8 -in c h ± 0 .0 2 - in c h ) b e t w e e n t h e to p o f th e d o o r a n d t h e r o o f s id e r a il. T h is a d ju s t m e n t s h o u ld p r o v id e a g a p o f 6 m m ± 0 .5 m m ( 0 .2 5 - in c h ± 0 .0 2 -in c h ) b e tw e e n th e b o tto m o f th e d o o r a n d th e r o c k e r p a n e l. T o a c c o m p lis h th is a d ju s t m e n t , lo o s e n t h e u p p e r r e a r h in g e to d o o r b o lts ( f ig u r e 8 8 ) , a n d a lig n th e r e a r e d g e o fth e d o o r u p o r d o w n . N e x t, tig h te n th e u p p e r r e a r h in g e to d o o r b o lts (fig u r e 8 8 ) . DOORS 10A1-55 2 . T h e fr o n t e d g e o f t h e d o o r b y lo o s e n in g t h e u p p e r fr o n t r o lle r b r a c k e t to d o o r b o lts ( f ig u r e 8 7 ) a n d t h e lo w e r h in g e to d o o r b o lts ( f ig u r e 8 9 ) . A lig n t h e d o o r to o b t a in t h e s a m e g a p a s in s t e p 1 , t h e n t i g h t e n t h e l o w e r h i n g e to d o o r b o lts (fig u r e 8 9 ) . 3 . T h e u p p e r fr o n t r o lle r b r a c k e t u p o r d o w n s o t h a t t h e r o lle r is c e n t e r e d in t h e t r a c k . T h e r o lle r m u s t n o t t o u c h t h e to p o r b o tto m o f th e tr a c k . T ig h t e n t h e u p p e r fr o n t r o lle r b r a c k e t to d o o r b o lts ( f ig u r e 9 2 ) . 1. R e a r d o o r w e d g e a s s e m b ly (4 0 7 ). 2 . R e a r lo c k s tr ik e r ( 4 0 5 ) u s in g J - 2 3 4 5 7 . 1. R e m o v e t h e fr o n t lo c k s tr ik e r ( 4 0 4 ) . 6. 7. 8. 9. 3 . T h e g u id e o n t h e d o o r m u s t fit s n u g ly in to t h e r u b b e r lin e d o p e n i n g in t h e s t r ik e r a s s e m b l y . REAR STRIKER ADJUSTMENT (Figure 90) IN AND OUT ADJUSTMENT (Figures 90 through 92) 4. 5. 1. L o o s e n t h e fr o n t la tc h s tr ik e r b o lts (4 0 3 ) . 2 . S l id e t h e d o o r t o w a r d s t h e s tr ik e r . 5 . T ig h t e n t h e s tr ik e r b o lts ( 4 0 3 ) . 3 . F r o n t lo c k s tr ik e r ( 4 0 4 ) . 4 . U p p e r r e a r h in g e c o v e r. 3. FRONT STRIKER ADJUSTMENT (Figure 90) 4 . C h e c k t h a t t h e la t c h f u lly e n g a g e s t h e s t r ik e r . A d d o r d e le t e s h im s b e h in d t h e s tr ik e r to a c c o m p lis h th is a d ju s tm e n t. Install or Connect (Figure 90) 2 . L o o s e n th e n u t (4 1 8 ) r e ta in in g 7. In s ta ll th e u p p e r fr o n t tr a c k c o v e r. 8 . In s ta ll t h e fr o n t ( 4 0 4 ) a n d r e a r ( 4 0 5 ) lo c k s t r ik e r s a t t h e p o s itio n p r e v io u s ly m a r k e d (fig u r e 9 0 ). th e T o o l R e q u ir e d : J -2 3 4 5 7 W re n c h . 1 . L o o s e n t h e s tr ik e r u s in g J - 2 3 4 5 7 . u p p e r f r o n t r o lle r ( 4 1 5 ) to t h e u p p e r r o lle r b r a c k e t ( 3 8 1 ) . L o o s e n th e lo w e r fr o n t r o lle r a s s e m a s s e m b ly b r a c k e t b o lts (fig u r e 8 9 ) . L o o s e n t h e r e a r d o o r lo c k s tr ik e r . A d ju s t t h e d o o r in o r o u t u n til t h e s u r f a c e flu s h w ith th e s u r fa c e o f th e b o d y . T ig h t e n t h e r e a r d o o r lo c k s tr ik e r . T ig h t e n t h e lo w e r fr o n t r o lle r a s s e m a s s e m b ly b r a c k e t b o lts (fig u r e 8 9 ). T ig h t e n t h e n u t (4 1 8 ) r e ta in in g t h e u p p (4 1 5 ) to t h e u p p e r r o lle r b r a c k e t ( 3 8 1 ) . In s t a ll t h e f r o n t lo c k s tr ik e r . b ly to r o lle r o f t h e d o o r is b ly to r o lle r 2 . L o o s e n th e r e a r w e d g e a s s e m b ly . 3 . C e n t e r t h e s tr ik e r v e r t ic a lly s o t h a t t h e s tr ik e r p r o p e r ly e n g a g e s t h e d o o r lo c k . M a r k t h e v e r tic a l p o s itio n o f t h e s tr ik e r . 4 . A d j u s t t h e s t r ik e r in o r o u t t o a l ig n t h e s u r f a c e o f t h e d o o r flu s h w ith th e b o d y s u r fa c e . M a r k t h e p o s itio n o f t h e s tr ik e r . 5 . T ig h t e n t h e s tr ik e r u s in g J - 2 3 4 5 7 . 6 . O p e n t h e d o o r , a n d a p p ly g r e a s e to t h e s tr ik e r . e r f r o n t r o lle r FORWARD AND REARWARD ADJUSTMENT 1 . M a r k t h e p o s itio n o f t h e fr o n t a n d r e a r la tc h s tr ik e r s o n t h e b o d y p illa r s . 2 . R e m o v e t h e fr o n t ( 4 0 4 ) a n d r e a r ( 4 0 5 ) lo c k s tr ik e r s (fig u re 9 0 ). 3 . R e m o v e th e u p p e r fro n t tr a c k o v e r. 4 . L o o s e n t h e u p p e r r e a r h in g e s tr ik e r (fig u r e 8 8 ). 5 . A d ju s t th e d o o r fo rw a rd o r r e a r w a r d to o b ta in a g a p o f 4 .5 m m ± 0 .5 m m (0 .1 8 -in c h ± 0 .0 2 -in c h ) b e t w e e n t h e le ft a n d r ig h t d o o r e d g e a n d t h e d o o r p illa r s ( f ig u r e 9 1 ). 6 . T ig h t e n t h e u p p e r r e a r h in g e s tr ik e r (fig u r e 8 8 ). 7. C lo s e th e d o o r to m a k e a n im p r e s s io n o f th e lo c k o n t h e s tr ik e r . 8 . O p e n th e d o o r a n d m e a s u r e th e d is ta n c e fr o m th e r e a r o f t h e s tr ik e r h e a d to t h e im p r e s s io n . T h e d is t a n c e s h o u ld b e b e tw e e n 5 m m a n d 8 m m (0 .2 0 -in c h a n d 0 .3 0 -in c h ). 9 . A d ju s t t h e s tr ik e r b y a d d in g o r d e le t in g s h im s . A lig n t h e s tr ik e r to t h e p r e v io u s ly m a d e m a r k s . 1 0 . T ig h t e n t h e s t r ik e r u s in g J - 2 3 4 5 7 . UPPER REAR HINGE ADJUSTMENT (Figure 93) 1. T h e lo w e r h in g e le v e r (4 1 9 ) s h o u ld h a v e a g a p o f 2 .5 m m to 4 m m (0 .1 0 -in c h to 0 .1 6 -in c h ) b e tw e e n th e o u te r e d g e o f t h e lo w e r le v e r a n d t h e s tr ik e r la tc h e d g e . T h is a d j u s t m e n t is m a d e b y a d d in g an equal am ount of 10A1-56 DOORS Figure 91—Door Adjustments DOORS 10A1-57 381. Front R oller Assem bly 382. M olding 383. Screw 384. Screw 385. Cap 386. Bolt F-01401 Figure 92—Upper Front Roller Adjustment s h im s b e t w e e n a s s e m b ly , a s s e m b ly . and th e g u id e b e tw e e n b lo c k ( 4 2 0 ) a n d th e r o lle r and th e th e h in g e h in g e 2 . A d ju s t t h e s t r ik e r u p o r d o w n to o b t a in a g a p o f 1 .5 m m ( 0 .0 6 -in c h ) b e t w e e n t h e lo w e r e d g e o f th e s tr ik e r p la t e ( 3 9 5 ) a n d t h e lo w e r e d g e o f t h e lo w e r h in g e le v e r (4 1 9 ). 3 . A d ju s t th e g u id e u p o r d o w n to o b ta in a g a p o f 0 .5 m m (0 .0 2 -in c h ) b e tw e e n th e tr a c k a n d th e g u id e . DOOR HOLD OPEN CATCH ADJUSTMENT (Figure 89) 1. M a r k t h e p o s it io n o f t h e lo w e r r o lle r a s s e m b ly to t h e b ra c k e t. 2 . L o o s e n t h e lo w e r r o lle r a s s e m b ly b o lts ( 4 0 1 ) . 3 . P iv o t t h e lo w e r r o lle r a s s e m b ly to p r o p e r ly e n g a g e t h e la t c h s tr ik e r . 4 . T ig h t e n t h e lo w e r r o lle r a s s e m b ly b o lts ( 4 0 1 ) . REAR WEDGE ASSEMBLY ADJUSTMENT (Figure 94) 1. L o o s e n th e r e a r w e d g e a s s e m b ly s c re w s (4 0 8 ). 2 . C o m p le te ly c lo s e th e d o o r. 3 . F r o m in s id e t h e v e h ic le , c e n t e r t h e w e d g e a s s e m b ly (4 0 7 ) o n to th e d o o r w e d g e . 4 . M a r k th e p o s itio n o f th e w e d g e a s s e m b ly . 5 . O p e n th e d o o r, a n d m o v e th e w e d g e a s s e m b ly fo rw a rd 4 . 7 m m ( 3/ i e - i n c h ) . 6 . T ig h t e n t h e r e a r w e d g e a s s e m b ly s c r e w s ( 4 0 8 ) . 394. 395. 419. 420. 421. A. B. C. H inge A ssem bly S trike r Lower H inge Lever G uide Block Track 2.5 mm to 4 mm (0.10- inch to 0.16-inch) 1.5 mm (0.06-inch) 0.5 mm (0.02-inch) F-00539 Figure 93—Upper Rear Hinge Adjustments 10A1-58 DOORS 430 422. 423. 424. 425. 426. 427. 428. 429. 430. 422 423 Inside Handle A s s is t Strap Door Trim Panel Screw Cover Screw Lock Knob Screw Cover 424 -425 426 427 429 428 F-00541 Figure 95—Door Trim Panel Components DOOR TRIM PANEL REPLACEMENT 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. 5. Door assist strap screws (425), and assist strap (423). 6. Trim panel to door screws (427). 7. Trim panel from the door. *►+ Install or Connect (Figure 95) 1. Trim panel to the door. 2. Trim panel to door screws (427). 3. Door assist strap (423) and assist strap screws (425). 4. Lock knob (428). 5. Inside door handle cover (430). 6. Inside door handle (422). 7. Inside door handle screw (429). WINDOW REPLACEMENT If a glass is cracked but still intact, it should be crisscrossed with masking tape to reduce the risk of injury and/or damage to the vehicle. If a crack extends to the edge of the glass, mark the door with a piece of chalk at the point where the crack meets the 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 ofthe crack be determined and the condition corrected, before the 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 winds, extremes of temperature, or rough terrain. STATIONARY GLASS Remove or Disconnect (Figure 96) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. 1. Weatherstrip seal by running a putty knife between the flange and the weatherstrip (inside and outside the door). • Have an assistant outside the cab by the window. 2. Weatherstrip and glass from the flange. • Force the weatherstrip from the flange from the inside with a putty knife. 3. Window from the weatherstrip. Install or Connect 1. Weatherstrip to the glass. • The seam of the weatherstrip must be located at the bottom of the glass. 2. Asix mm (1/4-inch) cord in the weatherstrip groove. The ends should overlap about 5 cm (6-inches) at the window bottom. 3. Window and weatherstrip on the flange from outside the cab. • Brush soapy water on the flange. • Have an assistant pull the cord from inside the cab to seat the lip of the weatherstrip on the flange. SWING OUT WINDOW Remove or Disconnect (Figure 97) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. 1. Window latch to door screws (441). 2. Window latch from the window. • Twist the latch 1At of a turn to release the latch components from the window. • Lift the window for access to the hinge screws. 3. Hinge to door screws (435). DOORS 10A1-59 FRONT LOCK REPLACEMENT 4. Hinge from the door. 5. Hinge seal from the door. |+ + | Remove or Disconnect (Figures 98 and 99) -►+ Install or Connect (Figure 97) 1. Hinge and hinge seal to the door. 2. Hinge to the door screws (435). 3. Window latch to the window. • Place the cover and spacer through the window. • Place the washer and spring onto the cover. • Twist the latch onto the cover with 1/4 of a turn. 4. Window latch to door screws (441). 434. 435. 436. 437. 438. G lass Screw H inge W eatherstrip Cover 439. 440. 441. 442. 443. Spacer W asher Screw Latch Spring 1. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” 2. Lock access panel screws (445) and the panel (444). • Pull the panel upwards to disengage the clips. 3. Outside door handle (422). 4. Lock to door screws (449 and 451). 5. Rear door lock rods from the front lock. • Pivot the clips from the rods, and pull the rods from the lock. 6. Lower latch rod from the lock. • Pivot the clip from the rod and pull the rod from the lock. 437 435 436 434 438 439 440 441 442 F-00543 Figure 97—Swing Out Window Components 10A1-60 DOORS Figure 98—Door Lock Access Panel Figure 99—Door Lock Attachment DOORS 10A1-61 447. 448. 454. 455. 456. 457. 458. 459. Upper Lock Rod Lower Lock Rod Latch Rod R etainer C lip Rear Lock A sse m b ly Screw Bum per Screw 448 F-00546 Figure 100—Rear Lock Attachment 7. Lock cylinder rod clips. • Slide the clip to release the rod. 8 Lock assembly from the door. Install or Connect (Figures 98 and 99) 1. Lock assembly to the door. 2. Lock cylinder rod clip. 3. Lower latch rod to the lock. • Pivot the clip onto the rod: 4. Rear door lock rods to the front lock. • Pivot the clip onto the rod. 5. Lock to door screws (449 and 451). 6. Outside door handle (422). 7. Lock access panel (444) and panel screws (445). 8. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” REAR LOCK REPLACEMENT Remove or Disconnect (Figure 100) 1. Lock rods from the lock. • Pivot the clip from the rod, and pull the rod from the lock. 2. Lock to door screws (457). 3. Lock from the door through the access hole. |+<-| Install or Connect (Figure 100) 1. Lock to the door through the access hole. 2. Lock to door screws (457). 3. Lock rods to the lock. • Pivot the clip onto the rod. LOCK CYLINDER REPLACEMENT Remove or Disconnect (Figure 101) 1. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” 2. Door lock cylinder rod (450). 3. Cylinder retainer (462). • Pry the retainer from the lock. 4. Cylinder (464) and seal (463) from the door. -►«- Install or Connect (Figure 101) 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). 4. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” SLIDING SIDE DOOR WEATHERSTRIP REPLACEMENT Remove or Disconnect (Figure 102) 1. Weatherstrip from the door using 3M Release Agent (or equivalent). 2. Plastic nails from the door. • The door of all the old cement. 10A1-62 DOORS 460 450. 460. 461. 462. 463. 464. 465. Lock C ylin d e r Rod O utsid e H andle W asher Retainer G asket C ylind e r Key F-00547 Figure 101—Outside Handle and Lock Cylinder Attachments -►+ Install or Connect (Figure 102) 1. W e a th e rs trip a d h e s iv e to the door. Weatherstrip Adhesive (or equivalent). 2. New weatherstrip to the door. • Press the plastic nails into the door. Use 3M DOORS 10A1-63 466. W e a th e rs trip 467. P la s tic N a ils F-00548 Figure 102—Sliding Side Door Weatherstrip G MODEL REAR DOORS DOOR AND HINGE REPLACEMENT □ Remove or Disconnect (Figure 103) Open the doors. 1. Electrical wiring harness (if equipped). Refer to “ Door Trim Panel Replacement” for access to the wiring harness. • Mark the position of the door on the hinges using a wax pencil. 2. Strap pin (469). • Support the door. 3. Hinge to body pillar bolts (475). 4. Door from the vehicle. 5. Hinge to door bolts (470). 6. Hinges from the door. 7. Retainers (478), seals (477), and grommets (479) from the door or the hinges. Install or Connect (Figure 103) 1. Grommet to the door. 2. Hinge to the door. 3. Hinge to door bolts (470). • 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 (475). • Align the hinge to the previously made mark. 7. Strap pin (469). 8. Electrical wiring harness. • Refer to “ Door Trim Panel Replacement” for access to the wiring harness. 10A1-64 DOORS Figure 103—Hinge Components DOOR ADJUSTMENT Each of the two doors must first be adjusted in the door opening before adjusting the door to door clearance. Adjust (Figure 104) 1. The door height so that there is a gap of 6 mm ± 0.5 mm (0.25-inch ± 0.02-inch) between the roof panel and the rear door panel. 2. The gap between the bottom of the door panel (not the bottom of the outer panel) and the 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 the side of the door. Thedoor should be in its normal closed position. (The outer rear door panel is 15.25 mm ± 0.5 mm (0.60-inch ± 0.02-inch) away from the rear platform panel when normally closed). 3. The rear door outer panel to the body side outer panel gap to 4 mm ± 0.5 mm (0.16-inch ± 0.02-inch). 4. The door to door clearance between the left and right outer door panels should be 6 mm ± 0.5 mm (0.25-inch ± 0.02-inch). ++ Install or Connect (Figure 105) 1. Spacer (as required). 2. Striker to the door frame. 3. Striker to door frame bolts (486). ft A djust (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 closed.) An 11/e4-inch diameter drill bit may be used to gage this clearance. DOOR TRIM PANEL REPLACEMENT |+"*| Remove or Disconnect (Figure 107) 1. Door trim panel to door screws (489). 2. Door trim panel from the vehicle. • Slide the panel out of the retainers. STRIKER REPLACEMENT Remove or Disconnect (Figure 105) 1. Striker to door frame bolts (486). 2. Striker from the door frame. 3. Spacer (if equipped). "►+ Install or Connect (Figure 107) 1. Door trim panel to the vehicle. • Slide the panel into the retainers. 2. Door trim panel to door screws (489). DOORS 10A1-65 485 Roof Panel Roof Side Rail Left Door Right Door Body Side Panel Floor E xtension Panel 6 mm ± 0.5 mm (0.25-inch ± 0.02-inch) 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 104—Door Adjustments 10A1-66 DOORS 3. Bumper to upper door frame screws (495). Adjust The bumper to door clearance so that there is 1 mm (0.04-inch) between the bumper and the door when the door is in the secondary position. (The door is latched but not fully closed). WINDOW REPLACEMENT If a glass is cracked but still intact, it should be crisscrossed with masking tape to reduce the risk of injury and/or damage to the vehicle. If a crack extends to the edge of the glass, mark the door with a piece of chalk at the point where the crack meets the weatherstrip. Later, when examining the flange of the opening for a cause of the crack, start at the point marked. It is im p o rta n t th a t th e c a u s e of th e c ra c k be determined and the condition corrected, before the 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 winds, extremes of temperature, or rough terrain. Remove or Disconnect (Figure 109) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. BUMPER WEDGE REPLACEMENT 1. Using a 3/ie-inch drill bit, drill the rivets from the weatherstrip (if equipped). |<*+| Remove or Disconnect (Figure 108) 2. Weatherstrip seal by running a putty knife between the flange and the weatherstrip (inside and outisde the door). 1. Bumper to upper door frame screws (495). 2. Bumper and spacer. El • Have an assistant outside the cab by the window. Install or Connect (Figure 108) 3. Weatherstrip and glass from the flange. 1. Spacer (as required). 2. Bumper. • Force the weatherstrip from the flange from the inside with a putty knife. 488. 4. Window from the weatherstrip. |+ + | Install or Connect (Figure 109) 487486. 487. 488. A. "S ' 1. Weatherstrip to the glass. 2. A six mm (1/4-inch) cord in the weatherstrip groove. The ends should overlap about 5 cm (6-inches) at the window bottom. B olt \ S trike r 486 Spacer 4.4 mm (0.172-inch) 3. Window and weatherstrip on the flange from outside the cab. 486 • Brush soapy water on the flange. • Have an assistant pull the cord from inside the cab to seat the lip of the weatherstrip on the flange. ... Figure 106—Striker Components F-00552 4. Rivets (if equipped) to the weatherstrip with a rivet gun. • Use 3/ie-inch blind rivets. DOORS 10A1-67 489. 490. 491. 492. 493. 494. Screw D oor Trim Panel Side R etainer Screw Side R etainer Top Retainer F-00553 Figure 107—Door Trim Panel Components SWING OUT WINDOW |+<-| Install or Connect (Figure 110) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. 1. Window latch to door screws (509). 2. Window latch from the window. • Twist the latch 1/4 of a turn to release the latch components from the window. • Lift the window for acess to the hinge screws. 3. Hinge to door screws (502). 4. Hinge from the door. 5. Hinge seal from the door. 496 Install or Connect (Figure 110) 1. Hinge and hinge seal to the door. 2. Hinge to door screws (502). 3. Window latch to the window. • Place the cover and spacer through the window. • Place the washer and spring onto the cover. • Twist the latch onto the cover with 1/4 of a turn. 4. Window latch to door screws (509). LEFT DOOR LOWER LATCH REPLACEMENT Remove or Disconnect (Figure 111) • Open the door. 1. Latch to door screws (511). 2. Latch from the door. ■H" Install or Connect (Figure 111) 1. Latch to the door. 2. Latch to door screws (511). RIGHT DOOR LOWER LATCH REPLACEMENT Remove or Disconnect (Figure 112) Figure 108—Bumper Wedge Components 1. D oor trim p a n e l. R e fe r to “ D oor Trim Panel Replacement.” 2. Lower latch to control assembly rod from the control assembly. 10A1-68 DOORS 510 510 509 507 508 501 i 504 501. 502. 503. 504. 505. 506. 507. 508. 509. 510. W eatherstrip Screw Latch A ssem bly Cover W indow Spacer W asher S pring Screw H inge 506 502 510 505 503 505 F-00556 Figure 110—Swing Out Window Components DOORS 10A1-69 • Using a flat bladed screwdriver, push on the top of the clip where it is connected to the rod. Pivot the clip away from the rod. 3. Lower latch to door screws (513). 4. Lower latch with the rod from the door. Figure 113—Right Door Upper Latch 3. Upper latch to door bolts (517). Install or Connect (Figure 112) Lower latch with the rod to the door. 2. Lower latch to door screws (513). 3. Lower latch to control assembly rod into the control assembly. • Pivot the clip onto the rod. 4. D oor trim p a n e l. R e fe r to “ D oor Trim Panel Replacement.” 4. Upper latch with the rod from the door. |-n-| Install or Connect (Figure 113) 1. Upper latch with the rod to the door. 2. Upper latch to door bolts (517). 3. Upper latch to control assembly rod into the control assembly. • Pivot the clip onto the rod. RIGHT DOOR UPPER LATCH REPLACEMENT 4. D oor trim p a n e l. R e fe r to “ D oor Trim Panel Replacement.” Remove or Disconnect (Figure 113) D oor trim p a n e l. R e fe r to “ D oor Trim Panel Replacement.” Upper latch to control assembly rod from the control assembly. • Using a flat bladed screwdriver, push on the top of the clip where it is connected to the rod. Pivot the clip away from the rod. 513. 514. 515. 516. S cre w L o w e r Latch L o w e r L ock Rod D rain H ole C lip RIGHT DOOR CONTROL ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 114) 1. D oor trim p a n e l. R e fe r to “ D oor Trim Panel Replacement.” 2. Upper and lower door latch rods from the control assembly. • Using a flat bladed screwdriver, push on the top of the clip where it is connected to the rod. Pivot the clip away from the rod. 3. Electric door actuator (if equipped). 4. Door to control assembly bolts (520). 5. Control assembly through the access hole. 514 "►+ Install or Connect (Figure 114) 1. Control assembly through the access hole. 513 2. Door to control assembly bolts (520). 3. Electrical door actuator (if equipped). 4. Upper and lower door latch rods to the control assembly. F-00558 Figure 112—Right Door Lower Latch • Pivot the clips onto the rods. 5. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” 10A1-70 DOORS 0 111 Install or Connect (Figure 115) 1. Large gasket onto the handle. 2. Door to outside handle screw (502) to the push button side of the handle. • Do not tighten. 3. Small gasket between the door and the handle. 4. Door to outside handle screw (522) to the other side of the handle. • Tighten both screws. 5. Door trim panel. Refer to “ Door Trim Panel.” DOOR LOCK CYLINDER REPLACEMENT I++I Remove or Disconnect (Figure 115) 1. D oor trim p a n e l. R efer to “ D oor Trim Replacement.” Panel 2. Lock cylinder retaining clip from the cylinder. • Slide the clip off the cylinder with a screwdriver. 3. Lock cylinder and gasket from the door. Install or Connect (Figure 115) 1. Lock cylinder with gasket to the door. • The cylinder rod must engage the lock assembly lever. Figure 114—Right Door Control Assembly Attachment DOOR OUTSIDE HANDLE REPLACEMENT M Remove or D isconnect (Figure 115) 1. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” 2. Door to outside handle screws (502). 3. Handle from the door. 4. Gaskets from the door. 2. Lock cylinder retaining clip onto the cylinder. 3. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” CHECK STRAP REPLACEMENT Remove or Disconnect (Figure 103) 1. Pin (469). 2. Strap to door bolts (474). 3. Strap (472). 4. Bracket to inner panel bolts (471). 5. Bracket (473). 523 522 522. 523. 524. 525. 526. 527. 528. 529. 524 Screw Sm all G asket O utsid e Handle Key Lock C ylin d e r Large G asket Retainer G asket 525 F-00561 Figure 115—Outside Handle and Lock Cylinder Attachments DOORS 10A1-71 530. 531. 532. 533. 534. Pin C h e ck A s s e m b ly B o lt B o lt B ra cke t 530 534 533 532 535. F a ste n e r 536. W e a th e rs trip 537. P la s tic N ail F-00562 Figure 116—Check Assembly Components Install or Connect (Figure 103) 1. Bracket (473). 2. Bracket to inner panel bolts (471). 3. Strap to the door. F-00563 4. Strap to door bolts (474). Figure 117—Left Door Weatherstrip 5. Pin (469). LEFT DOOR WEATHERSTRIP REPLACEMENT CHECK ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 116) 1. Pin (530). 2. Check assembly to door bolts (532). 3. Check assembly (531). 4. Bracket to inner panel bolts (533). 5. Bracket (534). □ Remove or Disconnect (Figure 117) 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). 3. Plastic nails from the door frame. jQ|[ Clean |-K-| Install or Connect (Figure 116) • The door and weatherstrip of all the old cement. 1. Bracket (534). 2. Bracket to inner panel bolts (533). 3. Check assembly (531). 4. Check assembly to door bolts (532). 5. Pin (530). Install or Connect (Figure 117) 1. New weatherstrip to the door using 3M Weatherstrip Adhesive (or equivalent). • Push the plastic nails into the door frame. 2. Weatherstrip to door fasteners. 10A1-72 DOORS POWER DOOR LOCK MOTOR REPLACEMENT Remove or Disconnect (Figure 119) 1. Battery ground cable. 2. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” 3. Electrical connector from the motor. 4. Door to motor screws (540). 5. Motor from the lock rod. • Slide the rubber mount at the top of the motor off of the door lock rod. 6. Motor from the door. 0 1. Motor into the door. 2. Motor to the lock rod. • Slide the rubber mount at the top of the motor onto the door lock rod. 3. Door to motor screws (540). 4. Electrical connector to the motor. 5. D oor trim p a n e l. R efer to “ D oor Trim Panel Replacement.” 6. Battery ground cable. 538. W e a th e rs trip 539. P la s tic N ail F-00564 Figure 118—Right Door Weatherstrip RIGHT DOOR WEATHERSTRIP REPLACEMENT Remove or Disconnect (Figure 118) 1. Weatherstrip from the door using 3M Release Agent (or equivalent). 2. Plastic nails from the door frame. Clean The door and weatherstrip of all the old cement. + Install or Connect (Figure 119) 4- Install or Connect (Figure 118) 1. New weatherstrip to the door using 3M Weatherstrip Adhesive (or equivalent). Push the plastic nails into the door frame. DOORS 10A1-73 Figure 119—Power Door Lock Motor Attachment 10A1-74 DOORS SPECIAL TOOLS 1. 2. ____________ J-22585-01 jm rr r7 Z S J-23457-A 3. f*>)------------------------------ ---- 4./i r------- --------- —* 1. D o o r H in g e B o lt W re n ch 3. D o o r H a n d le C lip R em ove r 2. D o o r S trik e r W re n ch 4. D o o r Trim Pad C lip R em ove r Figure 120—Special Tools J-9886-01 J-24595-B F-02460 10A2-1 SECTION 10A2 SEATS 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 term inology “ NOTICE: See ‘Notice’ on page 10A2-1 of this 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 replacem ent becomes necessary. Do not use a replacem ent 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 Diagnosis Of Manual Seat A djuster....................................................................................................................... 10A2- 2 Seat Adjuster Adjustm ent................................................................................................................................... 10A2- 3 RV Model Front Seat................................................................................................................................................10A2- 3 Front Seat And Seat Adjuster Replacement.....................................................................................................10A2- 3 Utility Vehicle Passenger Front Bucket Seat Replacement............................................................................ 10A2- 3 Front Pivot Bracket Disassembly....................................................................................................................... 10A2- 3 Bench Seatback And Catch Replacement.........................................................................................................10A2- 5 Seat Belt Replacement........................................................................................................................................10A2- 6 High Back Bucket Seat Belt Replacement.........................................................................................................10A2- 7 RV Model Suburban Center S eat........................................................................................................................... 10A2- 8 Center Seatback Replacement........................................................................................................................... 10A2- 8 Center Seat Bottom Replacem ent............................................................................................... ...................10A2- 8 Center Seat Bottom Support Bracket Replacement........................................................................................ 10A2- 8 Center Seatback Bumper And Striker Replacement........................................................................................ 10A2- 9 Center Seat Bottom Striker Replacement.........................................................................................................10A2- 9 Center Seatback Latch Replacement................................................................................................................. 10A2- 9 Center Seat Bottom Latch Replacement...........................................................................................................10A2- 9 Center Seat Belt Replacement........................................................................................................................... 10A2-11 RV Model Rear S e a ts ..............................................................................................................................................10A2-13 Crew Cab Rear Seat Replacement..................................................................................................................... 10A2-13 Crew Cab Rear Seatback And Catch R eplacem ent........................................................................................ 10A2-13 Crew Cab Rear Seat Belt Replacement.............................................................................................................10A2-13 Utility Vehicle Rear Seat Replacem ent................................................... ......................................................10A2-14 Utility Vehicle Rear Seat Cover Rod Replacement.......................................................................................... 10A2-14 Utility Vehicle Rear Seat Storage Strut Replacem ent.................................................................................... 10A2-14 Utility Vehicle Rear Seat Belt R eplacem ent.....................................................................................................10A2-14 Utility Vehicle And Suburban Seatback And Hinge Replacement..................................................................10A2-16 Utility Vehicle And Suburban Latch And Support Assembly Replacement................................................. 10A2-16 Suburban Rear Seat Replacement..................................................................................................................... 10A2-17 Suburban Rear Seat Belt Replacement............................................................................................................. 10A2-18 RV Model Top Strap Belt Anchor Installation.......................................................................................................10A2-19 Pickup And Crew Cab M o d e ls ........................................................................................................................... 10A2-19 Utility Vehicle Rear S e a t......................................................................................................................................10A2-19 Suburban Front S eat............................................................................................................................................10A2-19 Suburban Second S e a t........................................................................................................................................10A2-21 Suburban Third S e a t............................................................................................................................................10A2-21 G Model Front S eat..................................................................................................................................................10A2-23 Front Seat Replacement......................................................................................................................................10A2-23 Front Seat D isassem bly......................................................................................................................................10A2-23 Front Seat Belt Replacement............................................................................................................................. 10A2-23 10A2-2 SEATS CONTENTS (CONTINUED) SUBJECT PAGE G Model Center And Rear S e a ts ............................................................................................................................10A2-26 Center And Rear Seat R eplacem ent................................................................................................................. 10A2-26 Center And Rear Seat Disassembly....................................................................................................................10A2-26 Center And Rear Seat Armrest Replacement................................................................................................... 10A2-27 Center And Rear Seat Belt Replacement.................................................................. .........................................10A2-27 G Model Top Strap Belt Anchor Installation......................................................................................................... 10A2-30 Vehicles With A 125-Inch W heelbase............................................................................................................... 10A2-30 Vehicles With A 110-Inch W heelbase............................................................................................................... 10A2-31 S pe cifica tio ns...........................................................................................................................................................10A2-34 DIAGNOSIS OF MANUAL SEAT ADJUSTER PROBLEM Adjuster Will Not Lock POSSIBLE CAUSE 1. Locking wire too tight. 2. Adjuster lock bar spring disconnected or broken. 3. Adjuster lock bar sticking or binding. Adjuster Will Not Unlock 1. Locking wire too loose or disconnected. 2. Adjuster lock bar sticking or binding. CORRECTION 1. L o o s e n th e lo c k in g w ire te n s io n enough to provide full engagem ent of the lock bar in the locking slots of the adjuster lower channel. Refer to “ Seat Adjuster A djustm ent.” 2. Connect the spring or install a new spring. 3. Lubricate the lock bar pivot. If the bar is binding, elim inate the cause of binding or replace the adjuster. 1. Tighten the locking wire enough to al­ low the lock bar to disengage from the locking slots in the adjuster lower chan­ nel when the lock control lever is ac­ tiv a te d . R e fe r to “ S e a t A d ju s te r Adjustm ent.” 2. Lubricate the lock bar pivot. If the bar is binding, elim inate the cause of binding or replace the adjuster. When The Left Adjuster Locks, The Right Adjuster Is Between Lock Positions 1. Right adjuster either rearward or forward of the left adjuster. 1. Loosen the adjuster to floor pan bolts or nuts — move one adjuster forward or rearward as far as possible and the other adjuster in the opposite direction. Refer to “ Seat Adjuster Adjustm ents.” Seat Hard To Move Forward Or Rearward 1. Adjusters new, not broken in. 1. Operate the seat to the full forward and full rearward positions several tim es to work the new tightness out of the chan­ nels. 2. Lubricate the adjuster channels with Lubriplate or equivalent. 3. Replace the adjuster. 2. Adjuster(s) improperly lubricated. 3. Adjuster(s) binding due to bent or dam ­ aged channels. 4. Adjusters not in parallel alignm ent with each other. 4. Loosen the floor pan attaching bolts or nuts, align the adjusters parallel on the floor pan and tighten nuts. Refer to “ Seat Adjuster Adjustm ents.” SEATS 10A2-3 SEAT ADJUSTER ADJUSTMENT Adjust • Remove the seat. Refer to “ Front Seat and Seat Adjuster Replacement.” • 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. Wire assembly tension. Three holes on the secondary adjuster rail allow for tension adjustment of the wire assembly (figure 1). • Slide the spring off of the hook. • Open the hook, and remove it from the hole. • Move the hook to a forward hole to loosen the wire, move the hook to a rearward hole to tighten it. • Close the hook, and slide the spring over the hook. • Install the seat. Refer to “ Front Seat and Seat Adjuster Replacement.” RV MODEL FRONT SEATS FRONT SEAT AND SEAT ADJUSTER REPLACEMENT This procedure applies to all RV Model front seats, w hether bench or bucket type with the exception of the utility vehicle passenger front bucket seat. Refer to “ U tilit y V e h ic le P a s s e n g e r F ro n t B u c k e t S e a t Replacem ent” for information on this type of seat. Remove or Disconnect (Figures 2 and 3) 1. 2. 3. 4. 5. Bolt cover (5) (if equipped). Seat adjuster to floor panel bolts (7). Seat (10) with adjuster (2) from the vehicle. Adjuster to seat bolts (8). Adjuster (2) from the seat (10). E 1. 2. 3. 4. 5. 7. Latch assembly to seat bolts. 8. Latch assembly from the seat. Install or Connect (Figure 4) 1. 2. 3. 4. 5. 6. 7. Latch assembly to the seat. Latch assembly to seat bolts. Seat brackets (14) to the seat. Upper seat bracket bolts (15). Seat to the vehicle. Lower seat bracket (22) to the floor panel bolts (20). Spring retaining bracket (13) onto the springs (21), and the spring retaining bracket bolts (12). 8. Restraint cable (19) to the floor panel bolts (22). FRONT PIVOT BRACKET DISASSEMBLY Install or Connect (Figures 2 and 3) Adjuster (2) to the seat (10). Adjuster to seat bolts (8). Seat (10) with adjuster (2) to the vehicle. Seat adjuster to floor panel bolts (7). Bolt cover (5) (if equipped). UTILITY VEHICLE PASSENGER FRONT BUCKET SEAT REPLACEMENT Remove or Disconnect (Figure 4) • Place the seat in its forward position. 1. Restraint cable (19) to the floor panel bolt (22). • Allow the seat to tip forward. 2. Spring retaining bracket bolts (12) and the bracket (13). 3. Lower seat bracket (23) to the floor panel bolts (20). 4. Seat from the vehicle. 5. Upper seat bracket bolts (15). 6. Seat brackets (14) from the seat. This procedure applies only to Utility Vehicle passenger front bucket seats. Remove or Disconnect (Figure 4) 1. Seat. Refer to “ Utility Vehicle Passenger Front Bucket Seat Replacement.” 2. Nut (18). 3. Washer (17). 4. Pivot stud (25). 5. Sleeve (24). 6. Springs (21). 7. Upper bracket (14) from the lower bracket (23). Install or Connect (Figure 4) 1. 2. 3. 4. 5. 6. Upper bracket (14) to the lower bracket (23). Springs (21) onto the sleeve (24). Brackets (14 and 16) to the sleeve. Pivot stud (25). Washer (17). Nut (18). • Tighten each nut until it bottoms out. 10A2-4 SEATS Figure 3—Bucket Seat Components SEATS 10A2-5 14 11. Seat 12. B o lt 13. S p rin g R e ta in in g B ra cket 14. U p p e r B ra cke t 15. B o lt 16. B o lt 17. W a sh er 18. 19. 20. 21. 22. 23. 24. 25. N ut C able B o lt S p rin g B o lt “ L ow er B ra cket Sleeve P ivot S tud F-00589 Figure 4—Utility Vehicle Passenger Seat Components 7. Seat. Refer to “ Utility Vehicle Passenger Front Bucket Seat Replacement.” BENCH SEATBACK AND CATCH REPLACEMENT |+ + | Remove or Disconnect (Figure 5) 1. Seat back trim cover (32). 2. Striker (27). 3. Catch (28) with bushing (29). 4. Washer (30). 5. Seatback to seat base bolt (26). 6. Washer (30). 7. Seatback from the vehicle. |-n-| Install or Connect (Figure 5) 1. Seatback to the vehicle. 2. Washer (30) between the seat base and the seatback frame. 3. Seatback to seat base bolt (26). Figure 5—Seat Back Catch Components 10A2-6 SEATS 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. R e tra c to r B u c k le A n c h o r P late B o lt Plug B o lt Plug B o lt W ire A s s e m b ly C over Figure 6—Bucket Seat Belt Components 4. 5. 6. 7. 9. Buckle (34) to floor bolt (38). 10. Buckle from the floor. Washer (30). Catch (28) with bushing (29). Striker (27). Seat back trim cover (32). NOTICE: For steps 2, 6, and 9 see “ N otice” on page 10A2-1 o f this section. SEAT BELT REPLACEMENT This procedure covers belts for all seats except high back bucket seats. El Install or Connect 1. Buckle (38) to the floor. 2. Buckle to floor bolt (38). Remove or Disconnect (Figures 6 and 7) 1. Upper seat belt anchor plate cover (42). • Pry the top of the cover away from the anchor plate. 2. Anchor plate bolt (36). 3. Anchor plate (35). 4. Plug (39) (except regular cab). 5. Retractor (33) to floor bolt (40). 6. Seat belt wire (left side only). 7. Retractor from the vehicle. 8. Plug (37). Tighten 3. 4. 5. 6. • Bolt to 50 N m (37 ft. lbs.). Plug (37). Retractor to the vehicle. Seat belt wire (left side only). Retractor to floor bolt (40). & Tighten • Bolt to 50 N m (37 ft. lbs.). Plug (39) (except regular cab). Figure 7—Bench Seat Belt Components SEATS 10A2-7 45 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. B u c k le R e tra c to r A n c h o r Plate L ow er A n c h o r B o lt B o lt C over B o lt Plug W ire A s s e m b ly B o lt F lap F-00595 Figure 8—High Back Bucket Seat Belt Components 8. Anchor plate (35) to the door pillar. 9. Anchor plate bolt (36). a Tighten • Bolt to 50 N m (37 ft. lbs.). 10. Upper seat belt anchor plate cover (42). • Pivot the cover upwards, and press it into place. HIGH BACK BUCKET SEAT BELT REPLACEMENT Install or Connect Buckle to the floor. Seat belt wire (left side only). Buckle (43) to floor bolt (50). £ Tighten • Bolt to 50 N m (37 ft. lbs.). Plug (51). Retractor to the vehicle. Lower anchor (46) to the pillar. Lower anchor bolt (53). Remove or Disconnect (Figure 8) 1. Upper seat belt anchor plate cover (49). • Pry the top of the cover away from the anchor plate. 2. Anchor plate bolt (48). 3. Anchor plate (45). 4. Retractor lower flap (54). 5. Retractor (44) to pillar bolt (47). 6. Lower anchor bolt (53). 7. Lower anchor (46). 8. Retractor from the vehicle. 9. Plug (51). 10. Buckle (43) to floor bolt (50). 11. Seat belt wire (left side only). 12. Buckle from the floor. NOTICE: For steps 3, 7, 8 and 11see “Notice” onpage 10A2-1of this section. • Bolt to 50 N m (37 ft. lbs.). Retractor (44) to pillar bolt (47). Tighten • Bolt to 50 N m (37 ft. lbs.). 9. Retractor lower flap. 10. Anchor plate (45). 11. Anchor plate bolt (48). • Bolt to 50 N m (37 ft. lbs.). 12. Upper seat belt anchor plate cover (49). 10A2-8 SEATS RV MODEL — SUBURBAN CENTER SEAT 0 • 1. 2. 3. 4. 5. CENTER SEATBACK REPLACEMENT Remove or Disconnect (Figure 9) Fold the seatback forward. Hinge (57) to floor panel bolts (58). Seatback (55 or 56) from the vehicle. Seal (59). Hinge (57) to seatback bolts (60). Hinge (57) from the seatback (55 or 56). |-»+| Install o r Connect (Figure 9) 1. Hinge (57) to the seatback (55 or 56). 2. Hinge (57) to seatback bolts (60). 3. Seal (59). 4. Seatback (55 or 56) to the vehicle. 5. Hinge (57) to floor panel bolts (58). CENTER SEAT BOTTOM REPLACEMENT Remove or Disconnect (Figure 10) • 1. 2. 3. 4. Fold the seat bottom forward. Bracket (105) to floor panel bolts (61). Seat bottom (55 or 56) from the vehicle. Center stop bracket bolts (103) and bracket (64). Side stop bracket bolts (104) and brackets (63). Install or Connect 1. Side stop bracket (63) and bolts (104). 2. Center stop bracket (64) and bolts (103). 3. Seat bottom (55 or 56) to the vehicle. 4. Bracket (105) to floor panel bolts (61). CENTER SEAT BOTTOM SUPPORT BRACKET REPLACEMENT Remove or Disconnect (Figure 11) • Fold the seat bottom forward. 1. Trim panel bolts (69) and the panel (68). 2. Bracket to seat bolts (67). 3. Bracket to floor panel bolts. 4. Bracket (105) from the vehicle. Install or Connect (Figure 11) 1. Bracket (105) to the vehicle. 2. Bracket to floor panel bolts. 3. Bracket to seat bolts (67). 4. Trim panel (68) and bolts (69) to the seat. SEATS 10A2-9 61. 62. 63. 64. 103. B o lt B ra cket Large Seat B o tto m S m a ll Seat B o tto m B o lt C over B ra cket S to p B o lt Figure 10—Center Seat Body Mounting CENTER SEATBACK BUMPER AND STRIKER REPLACEMENT Remove or Disconnect (Figure 12) • 1. 2. 3. 4. 5. 6. 7. Fold the seatback forward. Bumper covers (73). Bumper (75) to seat bolts (74). Bumpers (75). Striker bolts (76). Striker (77). Spacer (78). Plate (79). Install or Connect (Figure 12) 1. 2. 3. 4. 5. 6. 7. Plate (79). Spacer (78) as required. Striker (77). Striker bolts (76). Bumpers (75). Bumper (75) to seat bolts (74). Bumper covers (73). CENTER SEAT BOTTOM STRIKER REPLACEMENT ♦«" Install or Connect (Figure 11) 1. Striker (65) to the seat. 2. Striker (65) to seat bolts (66). CENTER SEATBACK LATCH REPLACEMENT Remove or Disconnect (Figure 13) • Fold the seatback forward. 1. Latch bolts (83). 2. Latch from the vehicle. -►4- Install or Connect (Figure 13) 1. Latch to the vehicle. 2. Latch bolts (83). CENTER SEAT BOTTOM LATCH REPLACEMENT Remove or Disconnect (Figure 14) Fold the seat bottom forward. 1. Latch to floor panel bolts (89). 2. Latch (88) from the vehicle. Remove or Disconnect (Figure 11) • Fold the seat bottom forward. 1. Striker (65) to seat bolts (66). 2. Striker (65) from the seat. Install or Connect 1. Latch (88) to the vehicle. 2. Latch to floor panel bolts (89). SEATS 10A2-11 76 72. 73. 74. 75. 76. 77. 78. 79. 77 S crew C over B o lt Bum per B o lt S trik e r S pacer Plate B-07257 Figure 12—Center Seatback Bumper and Striker Components CENTER SEAT BELT REPLACEMENT Remove or Disconnect (Figure 15) • Fold the seat bottoms forward. • Note the position of the belts. Tighten • Bolts to 50 N m (37 ft. lbs.). Guide assemblies (96) and guide bolts (97). Retractor (92) to the vehicle. Retractor bolts (93). Tighten 1. Retractor flaps (94). • Retractor bolts to 50 N m (37 ft. lbs.). 6. Retractor flaps (94). 2. Retractor bolts (93). 3. Retractor (92) from the vehicle. 4. Guide assembly bolts (97) and the guides (96). 5. Buckle (95) and latch plate (99) assembly bolts (98). 6. Buckle and latch plate assemblies from the vehicle. Install or Connect (Figure 15) NOTICE: For steps 2 and 5 see page 10A2-1 of this section. a ‘N o tice” on 1. Buckle and latch plate assemblies to the vehicle. 2. Buckle and latch plate assembly bolts (98). 10A2-12 SEATS 82. 83. 84. 85. B ra cket A s s e m b ly B o lt Bum per S crew B-07258 Figure 13—Center Seatback Latch 92. 93. 94. 95. 96. 97. 98. 99. R e tra c to r B o lt F lap B u c k le G u id e B o lt B o lt L atch Plate B-07260 Figure 15—Center Seat Belt Components SEATS 10A2-13 RV MODEL REAR SEATS CREW CAB REAR SEATBACK AND CATCH REPLACEMENT Remove or Disconnect (Figure 5) 1. 2. 3. 4. 5. 6. 7. Seat back trim cover (32). Striker (27). Catch (28) with bushing (29). Washer (30). Seatback to seat base bolt (26). Washer (30). Seatback from the vehicle. Install or Connect (Figure 5) 1. Seatback to the vehicle. 2. Washer (30) between the seat base and the seatback frame. 3. Seatback to seat base bolt (26). 4. Washer (30). 5. Catch (28) with bushing (29). 6. Striker (27). 7. Seat back trim cover (32). CREW CAB REAR SEAT BELT REPLACEMENT RETRACTOR REPLACEMENT Remove or Disconnect (Figure 17) 1. Retractor to floor panel bolts (115). 2. Retractor (112). ♦4- Install or Connect (Figure 17) 1. Retractor (112) to the floor panel. NOTICE: See “ N o tice” on page section. 10A2-1 o f this 2. Retractor to floor panel bolts (115). Tighten CREW CAB REAR SEAT REPLACEMENT Remove or Disconnect (Figure 16) 1. Rear bracket (107) to floor bolts (106). • Bolts to 50 N m (37 ft. lbs.). CENTER BUCKLE AND LATCH PLATE REPLACEMENT Remove or Disconnect (Figure 17) 2. Front bracket (109) to floor bolts (110). 3. Seat from the vehicle. 4. Front and rear bracket to seat bolts (108). 5. Rear bracket (107). 6. Front bracket (109). Install or Connect (Figure 16) 1. Front bracket (109) and bolts (108). 2. Rear bracket (107) and bolts (108). 3. Seat to the vehicle. 4. Front bracket (109) to floor bolts (110). 5. Rear bracket (107) to floor bolts (106). 1. • 2. 3. +4" Seat. Refer to “ Crew Cab Rear Seat Replacement.” Note the position of the belts. Belt to floor panel bolts (114). Left belt (113) and right belt (113) from the vehicle. Install or Connect (Figure 17) 1. Left belt (113) and right belt (113) to the vehicle. NOTICE: See “ N o tice” on page section. 2. Belt to floor panel bolts (114). 10A2-1 of this 10A2-14 SEATS Tighten UTILITY VEHICLE REAR SEAT STORAGE STRUT REPLACEMENT • Bolts to 50 N m (37 ft. lbs.). 3. Seat. Refer to “ Crew Cab Rear Seat Replacement.” UTILITY VEHICLE REAR SEAT REPLACEMENT Remove or Disconnect (Figure 18) • Fold the seat forward. 1. Hinge to floor bolt (116) and spring washer (117). 2. Seat from the vehicle. |+<-| Install or Connect (Figure 18) Remove or Disconnect (Figure 20) • 1. 2. 3. Tilt the seat forward. Strut (125) to floor bolts (126). Strut (125) to seat bolts (127). Strut from the vehicle. Install or Connect (Figure 20) 1. Strut (125) to the vehicle. 2. Strut (125) to seat bolts (127). 3. Strut (125) to floor bolts (126). 1. Seat to the vehicle. 2. Spring washer (117) and bolt (116). UTILITY VEHICLE REAR SEAT COVER ROD REPLACEMENT Remove or Disconnect (Figure 19) 1. Actuator rod clip (123). 2. Actuator rod (124). |-»<-| Install or Connect (Figure 19) UTILITY VEHICLE REAR SEAT BELT REPLACEMENT Remove or Disconnect (Figure 21) • Fold the seat forward. 1. Side latch plate (128) to floor panel bolts (129). 2. Side latch plate (128) from the vehicle. 3. Rear seat cover rod. 4. Latch and support assembly from the seat. Refer to “ Utility Vehicle and Suburban Latch and Support Assembly Replacement.” 1. Actuator rod (124). 5. Seat belt (130) to latch bolts (131). 2. Actuator rod clip (123). 6. Seat belts from the latch. SEATS 10A2-15 NOTICE: For steps 2 and 6 see “ N otice” on page 10A2-1 of this section. 0 Install or Connect (Figure 21) 3. Latch and support assembly to the seat. Refer to “ Utility Vehicle and Suburban Latch and Support Assembly Replacement.” 4. Rear seat cover rod. 1. Seat belts (130) to the latch. 5. Side latch plate (128) to the vehicle. 2. Seat belts (130) to latch bolts (131). 6. Side latch plate (128) to floor panel bolts (129). Q Tighten • Bolts to 50 Nm(37 ft. lbs.). Figure 19—Utility Vehicle Cover Rod Tighten • Bolts to 50 N m(37 ft. lbs.). Figure 20—Utility Vehicle Storage Strut 10A2-16 SEATS UTILITY VEHICLE AND SUBURBAN SEATBACK AND HINGE REPLACEMENT 132. 133. 134. 135. 136. 137. 138. 139. 153. 154. Remove or Disconnect (Figures 22 and 23) 1. 2. 3. 4. 5. 6. Seatback to hinge bolts (139). Seatback (154) from the vehicle. Hinge (153) to seat bottom bolts (137). Hinge from the vehicle. Armrest to hinge bolt (136). Armrest support (138) from the hinge. 132 A sh Tray A rm re s t S p rin g W a sh er B o lt B o lt B o lt S u p p o rt B o lt H in g e S e atba ck Install or Connect 1. 2. 3. 4. 5. 6. Armrest (133) to the hinge. Armrest to hinge bolt (136). Hinge to the vehicle. Hinge (153) to seat bottom bolts (137). Seatback (154) to the vehicle. Seatback to hinge bolts (139). 154 UTILITY VEHICLE AND SUBURBAN LATCH AND SUPPORT ASSEMBLY REPLACEMENT Remove or Disconnect (Figures 24 and 25) • Fold the seat forward (Utility vehicle only). 1. The seat (Suburban only). Refer to “ Suburban Seat Replacement.” 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. 6. Latch cover (143) (Utility vehicle only). 137 B-07267 Install or Connect 1. Latch cover (141) to the seat (Utility vehicle only). 2. Latch (144) to the seat. 3. Latch to seat bolts (145). Figure 22—Left Seatback Hinge SEATS 10A2-17 4. Latch cover (Suburban only). 5. Latch cover rod (Utility vehicle only). 6. The seat (Suburban only). Referr to “ Suburban Seat Replacement.” SUBURBAN REAR SEAT REPLACEMENT REMOVAL 139 136. 137. 138. 139. 140. 1. Unlatch the seat, and pull towards the rear of the vehicle. 2. Remove the seat from the vehicle. —*-e f S crew S crew S u p p o rt B o lt H in g e A nd Latch INSTALLATION 1. Place the seat in the vehicle. 2. Place the hooked retainers onto the anchor pins. B-07268 Figure 23—Right Seatback Hinge 141. C ove r 142. B o lt 141 B-09074 Figure 24—Suburban Rear Seat Latch Cover 10A2-18 SEATS 4. Side buckle (148) to floor panel bolts (149). 5. Buckle (148) from the vehicle. NOTICE: For steps 2 and 4 see “ N o tice” on page 10A2-1 of this section. 0 Install or Connect 1. Buckle (148) to the vehicle. 2. Buckle (148) to floor panel bolts (149). • Bolts to 50 N m (37 ft. lbs.). 3. Seat belts (151 and 152) to the seat. 4. Seat belt to latch bolts (150). £ Tighten • Bolts to 50 N m (37 ft. lbs.). 5. Rear seat latch cover (figure 24). Figure 25—Rear Seat Latch Components 3. Latch the seat. 4. Push back and forth on the seat to be sure it is latched. SUBURBAN REAR SEAT BELT REPLACEMENT Remove or Disconnect (Figure 26) 1. Rear seat latch cover (figure 24). 2. Seat belts (151 and 152) to latch bolts (150). 3. Seat belts from the seat. 148. 149. 150. 151. B u c k le B o lt B o lt B u c k le A s s e m b ly 152. L a tch Plate B-09076 Figure 26—Suburban Rear Seat Belts SEATS 10A2-19 RV MODEL TOP STRAP BELT ANCHOR INSTALLATION NOTICE: See “ N o tice” on page 10A2-1 o f this section. 5. Install the bolt (161), anchor bracket (160), anchor plate (158), and lock nut (159) to the hole with an appropriate sealant. 6. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the seating position for which the anchor bracket has been installed, latching the Child Seat top strap hook to the anchor bracket as shown. CAUTION: In the event that the Child Seat anchorage assembly is removed, the 8 mm (5/ie-inch) diam eter hole must be properly resealed to prevent toxic exhaust fumes from entering the cab. 156. 157. 158. 159. 160. 161. W in d o w S e ale r A n c h o r Plate N ut A n c h o r B ra cket B o lt B-09152 Figure 27—Pickup Top Strap Belt Components 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 ad­ ditional requirem ents provided by its manufacturer, or with any recomm endations in the Child Restraint section of the O w ner’s Manual. The child seat may be used only in a forward facing seating location. PICKUP AND CREW CAB MODELS 1. Place the Child Seat in the front seating position (rear seating position on crew cab models) (figure 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. Select a suitable anchor bracket mounting location on the cab back panel. The location must be: — Located near the rear window reinforcement. The angle between the Child Seat top strap and horizontal should not exceed 45°. — As close to the center line of the Child Seat as possible, but in no case more than 50 mm (2-inches) towards the passenger side of the cab, and 150 mm (6-inches) towards 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. UTILITY VEHICLE REAR SEAT 1. Determine the location for the anchor by measuring 140 mm (51/2-inches) forward from the rear edge of the floor pan (figure 28). Make this measurement in the center of one of the depressed floor pan ribs. Next, measure 1330 mm (52.25-inches) inboard of the right quarter inner panel. Mark the position where these measurements meet. 2. Drill an 8 mm (5/ie-inch) hole at the mark. 3. To insure proper sealing of the hole, remove any dirt or foreign matter from around the hole on the underside of the floor pan where the sealer is to be applied. NOTICE: See “ N o tice” on page 10A2-1 o f this section. 4. Place sealer on the hole from the underside of the vehicle and assembly the bolt (162), anchor 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 Child Seat only in the seating position for which the anchor bracket has been installed. NOTICE: In the event the Child Seat anchorage assembly is removed, the 8 mm (s/i6 — inch) diam eter hole must be properly resealed. SUBURBAN FRONT SEAT This procedure applies to vehicles not equipped with a second seat or vehicles with the second seat in the down position. 1. Determine the location for the anchor by measuring 51 mm (2-inches) rearward from the rear edge of the kick up molding. Make this measurement in the center of one of the depressed floor pan ribs (figure 29). A. Measure 360 mm (14.6-inches) inboard of the right quarter inner panel for the right seating position. 10A2-20 SEATS . /c cn"\ 1 4 0 m m (5 .5 0 ) j i ; y s 162. 163. 164. 165. 166. B o lt A n c h o r Plate S ealer W a sh er N ut F-02685 Figure 28—Utility Vehicle Second Seat Top Strap Belt Components Figure 29—Suburban Front Seat Top Strap Belt Components SEATS 10A2-21 172. 173. 174. 175. 176. B o lt A n c h o r Plate S ealer W a sh er N ut (55mm) 2 . 12" 55mm (2.12") 174 175 176 B-09129 F igure 30—S uburban S econd Seat T op S trap B e lt C om po n en ts B. Measure 895 mm (35.25-inches) inboard of the right quarter inner panel for the center seating position. Mark the position where the measurements meet. 2. Drill an 8 mm (5/ie-inch) hole at the mark. 3. To insure proper sealing of the hole, remove any dirt or foreign matter from around the hole on the underside of the floor pan where the sealer is to be applied. NOTICE: See “ N otice” on page 10A2-1 of this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (167), anchor plate (168), washer (170), and lock nut (171) to the floor pan. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the seating position for which the anchor bracket has been installed. NOTICE: In the event the child seat anchorage assem bly is rem oved, the 8 mm (5/ie-in ch ) diam eter hole must be properly resealed. SUBURBAN SECOND SEAT 1. Determine the location for the anchor by measuring 650 mm (251/2-inches) rearward from the rear edge of the kick-up molding (figure 30). Next: A. Measure 55 mm (2.12-inches) inboard of the right wheelhouse for the right seating position. B. Measure 590 mm (23.25-inches) inboard of the right wheelhouse for the center seating position. C. Measure 55 mm (2.12-inches) inboard of the left wheelhouse for the left seating position. Mark the position where the measurements for the desired seating position meet. 2. Drill an 8 mm (5/ie-inch) hole at mark. 3. To insure proper sealing of the hole, remove any dirt or foreign matter from around the hole on the underside of the floor pan where the sealer is to be applied. NOTICE: See “ N o tice” on page 10A2-1 o f this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (172), anchor plate (173), washer (175), and lock nut (176) to the floor pan. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the second seat seating position for which the anchor bracket has been installed. NOTICE: In the event the child seat anchorage assem bly is rem oved, the 8 mm (5/ie -in c h ) diam eter hole must be properly resealed. SUBURBAN THIRD SEAT 1. Determine the location for the anchor by measuring 127 mm (5-inches) forward from the rear edge of the floor pan. Make this measurement in the center of one of the depressed floor pan ribs (figure 31). 10A2-22 SEATS 1,160mm (45.75") 181 177. 178. 179. 180. 181. B o lt A n c h o r Plate S ealer W a sh er N ut B-09029 Figure 31—Suburban Third Seat Top Strap Belt Components Next: A. Measure 535 mm (21-inches) inboard of the right quarter inner panel for the right seating position. B. Measure 805 mm (31.75-inches) inboard of the right quarter inner panel for the center seating position. C. Measure 1,160 (45.75-inches) inboard of the right quarter inner panel for the left seating position. 2. Drill an 8 mm (5/ie-inch) hole at the mark. 3. To insure proper sealing of the hole, remove anydirt or foreign matter from around the hole on the underside of the floor pan where the sealer is to be applied. NOTICE: See “ N o tice” on page 10A2-1 of this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (177), anchor plate (178), washer (180), and lock nut (181) to the floor pan. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the third seat seating position for which the anchor bracket has been installed. NOTICE: In the event the Child Seat anchorage assem bly is rem oved, the 8 mm (s/i6 -in ch ) diam eter hole must be properly resealed. NOTICE: If the hole penetrates to the exterior of the vehicle, apply a sealant between the anchor bolt washer and the sheet m etal to prevent carbon monoxide from entering the vehicle. S uitable sealers in c lu d e silico n e, b u tyl or acrylic type caulking. In the event that the child seat anchorage assembly is removed, all bolt holes penetrating to the exterior of the vehicle must be resealed to prevent exhaust fumes from entering the vehicle. SEATS 10A2-23 G MODEL FRONT SEAT B-09027 Figure 32—Front Bucket Seat Components FRONT SEAT REPLACEMENT 4. Seat riser to adjuster nuts (184). 5. Seat. Refer to “ Seat Replacement.” Remove or Disconnect (Figure 32) 1. Seat belts. Refer to “ Seat Belt Replacement.” • Raise and support the vehicle. 2. Seat riser (183) to floor panel nuts (185), washers (186), and reinforcements (187) from underneath the vehicle. 3. Seat from the vehicle. Install or Connect (Figure 32) 1. Seat (182) to floor panel nuts (185), washers (186), and reinforcements (187) to the underside of the vehicle. • Lower the vehicle. 3. Seat belts. Refer to “ Seat Belt Replacement.” FRONT SEAT DISASSEMBLY + + Remove or Disconnect (Figures 32 and 33) 1. 2. 3. 4. 5. Seat. Refer to “ Front Seat Replacement.” Seat riser to adjuster nuts (184). Seat (182) and adjuster (190) from the riser (183). Adjuster to seat bolts (193) and spacers (191). Adjuster (190) from the seat (182). FRONT SEAT BELT REPLACEMENT Remove or Disconnect (Figure 34) 1. 2. 3. 4. 5. 6. 7. 8. Anchor plate (194) to the roof side rail bolt (198). Anchor plate (194). Seat belt warning wire (left side only). Retractor (195) to seat riser bolt (199). Retractor (195) and anchor plate (194) from the vehicle. Plug (200). Buckle (196) to seat riser bolt (201) and washer (202). Buckle (196) from the vehicle. NOTICE: For steps 2, 5, and 7see “Notice” on page 10A2-1of this section. Install or Connect (Figure 34) 1. Buckle (196) to the vehicle. 2. Buckle (196) to seat riser washer (202) and bolt (201). -► * Install or Connect (Figures 32 and 33) 1. Adjuster (190) to the seat (182). 2. Adjuster to seat spacers (191) and bolts (193). 3. Seat (182) and adjuster (190) to the riser (183). • Bolt to 60 N m (44 ft. lbs.). 3. Plug (200). 4. Retractor (195) and anchor plate (194) to the vehicle. 10A2-24 SEATS B-09028 Figure 33—Bucket Seat Adjusters 5. Retractor (195) to seat riser bolt (199). Tighten Bolt to 60 N m (44 ft. lbs.). 6. Seat belt warning wire (left side only). 7. Anchor plate (194) to the roof side rail. 8‘ Anchor P|ate bolt (198)^ Tighten • Bolt to 60 N m (44 ft. lbs.). SEATS 10A2-25 Figure 34—Bucket Seat Belt Components 10A2-26 SEATS G MODEL CENTER AND REAR SEATS CENTER AND REAR SEAT DISASSEMBLY CENTER AND REAR SEAT REPLACEMENT |+ + | Remove or Disconnect (Figures 36 and 37) REMOVAL (Figure 35) 1. Unlatch the seat, and pull towards the rear of the vehicle. 1. Seat from the vehicle. Refer to “ Center and Rear Seat Replacement.” 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), bolts (206) and spring washers (205). INSTALLATION (Figure 35) 1. Place the seat in the vehicle. 4. Support assembly (210) from the legs (209). 2. Place the hooked retainers onto the anchor pins. 0 Install or Connect (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 latched. 2. Support assembly (210) to leg assembly (209), springs washers (205) and bolts (206). 205. 206. 207. 208. 209. 210. W a sh er B o lt B o lt B o lt Leg A s s e m b ly S u p p o rt A s s e m b ly 210 B-09030 Figure 36—Center Seat Components SEATS 10A2-27 205. 206. 207. 208. 209. 210. W asher Bolt Bolt Bolt Leg A ssem bly S upport A ssem bly B-09110 Figure 37—Rear Seat Components $ Tighten • Bolts to 155 N m (114 ft. lbs.). 3. Support (210) and leg assembly (209) to seat bolts (207 and 208). 4. Seat to the vehicle. Refer to “ Center and Rear Seat Replacement.” CENTER AND REAR SEAT ARMREST REPLACEMENT Remove or Disconnect (Figures 38 and 39) 1. 2. 3. 4. Armrest bracket (217) to seat bolts (216). Armrest to seatback bolts (213). Armrest cover (218) (if equipped). Arm rest bracket (217) to arm rest nuts (215) and washers (214). 5. Armrest bracket (217) from the armrest (212). B Install or Connect 1. Armrest bracket (217) to the armrest (212). 2. Armrest bracket (217) to armrest washers (214) and nuts (215). 3. Armrest cover (218) (if equipped). 4. Armrest to seatback bolts (213). 5. Armrest bracket (217) to seat bolts (216). CENTER AND REAR SEAT BELT REPLACEMENT Remove or Disconnect (Figures 40, 41, and 42) 1. Retractor to support assembly bolts (221). 2. Retractor (220) from the seat. 3. Buckle (219) and latch plate (225) (if equipped) to support assembly bolts (222). 4. Buckle (219) and latch plate (225) (if equipped) from the seat. NOTICE: For steps 2 and 4 see “ N otice” on page 10A2-1 of this section. 1. Buckle (219) and latch plate (225) (if equipped) to the seat. 2. Buckle (219) and latch plate (225) (if equipped) bolts (222). • The shoulder of the bolt must bottom on the weld nut. • Bolts to 50 N m (37 ft. lbs.). 3. Retractor (220) to the seat. 4. Retractor to support assembly bolts (221). $ Tighten Bolts to 50 N m (37 ft. lbs.). 10A2-28 SEATS 211. 212. 213. 214. 215. 216. 217. 212 A sh Tray A rm R est B o lt W a sh er N ut B o lt S u p p o rt A s s e m b ly B-09108 Figure 39—Rear Seat Armrest 211. 212. 213. 214. 215. 216. 217. 218. A sh Tray A rm R est B o lt W a sh e r N ut B o lt S u p p o rt A s s e m b ly C over B-08586 Figure 38—Center Seat Armrest SEATS 10A2-29 219. 220. 221. 222. B u c k le R e tra c to r B o lt B o lt B-09134 Figure 40—Center Seat Belt Components 219. 220. 221. 222. 225. B u c k le R e tra c to r B o lt B o lt L atch Plate B-09132 Figure 41—Rear Seat Belt Components 10A2-30 SEATS S crew C over B-09106 Figure 42—Seat Leg Cover G 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 ad­ ditional requirements provided by its manufacturer, or with any recomm endations in the Child Restraint section of the Ow ner’s manual. The child seat may be used only in a forward facing seating location. Installation of top strap belts is not recommended in the front passenger seat of “ G ” Vans. The second seat offset which allows passenger entry does not position a second seat lap belt within the recommended zone for attach­ ment to the top strap hook. Also, a floor anchorage is impractical since the top strap length is insufficient to di­ rectly connect the restraint to the floor with high back bucket seats. VEHICLES WITH A 125-INCH WHEELBASE SECOND SEAT LEFT SEATING POSITION This procedure is for vehicles not having a third seat. 1. Determine the location for the anchor by measuring 76 mm (3-inches) rearward from the front edge of the left wheelhouse. Measure 60 mm (2 3/s-inches) inboard from the left wheelhouse. Mark the position on top of the rib where these measurements meet (figure 43). 2. Drill an 8 mm (5/ie-inch) hole at the mark. 3. To insure proper sealing of the hole, remove any dirt or foreign matter from around the hole on the underside of the floor pan where sealer is to be applied. NOTICE: See “ N o tice” on page 10A2-1 of this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (227), anchor bracket 226. 227. 228. 229. 230. 231. 232. 233. R ig h t W h e e lh o u s e B o lt A n c h o r B ra cket S e ale r S p a c e r W a sh ers A n c h o r Plate L ock N u t F ro n t E dge O f The L e ft W h e e lh o u s e B-09127 Figure 43—Second Seat Top Strap Components— Left Position (228), two 35 mm (13/s-inch) outside diameter spacer washers (230), anchor plate (231) and lock nut (232) to the floor pan. SEATS 10A2-31 233. 234. 235. 236. 237. 238. 239. 240. R ig h t W h e e lh o u s e B o lt A n c h o r B ra cke t S e ale r A n c h o r Plate L ock N ut F ro n t Edge O f The R ig h t W h e e lh o u s e S p a ce r W ashers A. R ig h t S e a tin g P o s itio n B. C e n te r S e a tin g P o s itio n B-09128 Figure 44—Second Seat Top Strap Components—Center and Right Position 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the seating position for which the anchor bracket has been installed. NOTICE: In the event the Child Seat anchorage assem bly is rem oved, the 8 mm (s/i6 -in ch ) diam eter hole must be properly resealed. SECOND SEAT—CENTER OR RIGHT SEATING POSITIONS This procedure is for vehicles not having a third seat. 1. Determine the location for the anchor by measuring 35 mm ( 13/8-inch) rearward from the front edge of the left wheelhouse (figure 44). Next: A. Measure 580 mm (227/a-inches) inboard from the right wheelhouse for the center seating position. B. Measure 395 mm (151/2-inches) inboard of the right wheelhouse for the right seating position. Mark the position where the measurements for 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 dirt or foreign matter from around the hole on the underside of the floor pan where sealer is to be applied. NOTICE: See “ N otice” on page 10A2-1 of this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (234), anchor bracket (237), two 35 mm (13/e-inch) outside diameter spacer washers (240), anchor plate (237) and lock nut (238) to the floor pan. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the seating position for which the anchor bracket has been installed. NOTICE: In the event the Child Seat anchorage assem bly is rem oved, the 8 mm (5/ie -in ch ) diam eter hole must be properly resealed. THIRD SEAT It is recommended that only the left seating position be used for the third seat. 1. Determine the location for the anchor by measuring 76 mm (3-inches) rearward from the left wheelhouse. M easure 10 mm ( 3/s-inch) inboard from the left w h e e lh o u s e . M ark th e p o s itio n w he re th o s e measurements meet (figure 45). 2. Drill an 8 mm (5/ie-inch) hole at the mark. 3. To insure proper sealing of the hole, remove any dirt or foreign matter from around the hole on the underside of the floor pan where sealer is to be applied. NOTICE: See “ N o tice” on page 10A2-1 o f this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (241), anchor bracket (242), anchor plate (244) and lock nut (245) to the floor pan. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the seating position for which the anchor bracket has been installed. NOTICE: In the event the Child Seat anchorage assem bly is rem oved, the 8 mm (5/ie -in c h ) diam eter hole must be properly resealed. VEHICLES WITH A 110-INCH WHEELBASE SECOND SEAT This procedure is for vehicles without a third seat (figures 46 and 47). 1. Determine the location of the anchor by: A. Measuring 457 mm (18-inches) rearward from the front edge of the left wheelhouse. Measure 50 mm (2-inches) inboard of the left wheelhouse for the left seating position. B. Measuring 546 mm (211/2-inches) rearward from the front edge of the left wheelhouse. Make this m easurem ent in the center of one of the 10A2-32 SEATS 241. 242. 243. 244. 245. 246. 247. B o lt A n c h o r B ra cke t S e ale r A n c h o r Plate N ut R ig h t W h e e lh o u s e L e ft W h e e lh o u s e Figure 45—Third Seat Top Strap Components—Left Position depressed floor pan ribs. Next, measure 580 mm (2 2 7/a-inches) inboard of the left wheelhouse for the center seating position. C. Measure 546 mm (211/2-inches) rearward from the front edge of the right wheelhouse. Next, measure 395 mm (151/2-inches) inboard from the right wheelhouse for the right seating position. Mark the position where the measurements for the desired seatings positions meet. 2. Drill an 8 mm (5/ie-inch) hole at the mark. 3. To insure proper sealing of the hole, remove any dirt or foreign matter from around the hole on the underside of the floor pan where sealer is to be applied. NOTICE: See “ N otice” on page 10A2-1 o f this section. 4. Place sealer on the hole from the underside of the vehicle and assemble the bolt (248), anchor bracket (249), anchor plate (251) and lock nut (252) to the floor pan. 5. Tighten the nut to 31 N m (23 ft. lbs.). Use the Child Seat only in the second seat seating position for which the anchor bracket has been installed. NOTICE: In the event the Child Seat anchorage assem bly is rem oved, the 8 mm (5/ie -in c h ) diam eter hole must be properly resealed. SECOND SEAT — VEHICLES EQUIPPED WITH A THIRD SEAT Use the Child Seat as directed 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 253 - + / 250 251 248. 249. 250. 251. 252. 253. 7 :50mm (2 ") B o lt Anchor S ealer A n c h o r Plate L ock N ut F ro n t Edge O f T he L e ft W h e e lh o u s e B-09131 Figure 46—Second Seat Top Strap Components— Left Position The Child Seat is not recommended for use in the third seat of a 110-inch wheelbase model. SEATS 10A2-33 248. 249. 250. 251. 252. 253. A. B. Bolt A n cho r Bracket Sealer A nch or Plate Lock Nut Front Edge Of The Left R ight Seating P osition C enter Seating P osition B-09037 Figure 47—Second Seat Top Strap Components—Center and Right Position 10A2-34 SEATS SPECIFICATIONS ITEM RV Models All Seat Belt Fasteners — Except Top S tra p ................................................................................. N m TORQUE FT. LBS. 50 37 G Models Front Seat Belt Fasteners.................................................................................................................. Center And Rear Seat Belt Fasteners — Except Top S tra p ....................................................... 60 50 44 37 Top Strap Fasteners All M o d e ls ............................................................................................................................................. 31 23 GLASS 10A3-1 SECTION 10A3 GLASS NOTICE: If a glass is cracked but still intact, it should be crisscrossed with masking tape to reduce the risk of damage to the vehicle. If a crack extends to the edge o f the glass, mark the cab with a piece of chalk at the point where the crack meets the cab. CONTENTS SUBJECT PAGE RV M o d e ls .................................................................................................................................................................10A3- 1 Windshield Replacement...................................................................................................................................... 10A3- 1 Stationary Glass Replacement............................................................................................................................10A3- 3 G M o d e ls ...................................................................................................................................................................10A3- 6 Windshield Replacement...................................................................................................................................... 10A3- 6 Stationary Glass Replacement............................................................................................................................10A3-10 All Models.................................................................................................................................................................. 10A3-11 Glass P o lis h in g .................................................................................................................................................... 10A3-11 Special T o o ls.............................................................................................................................................................10A3-12 RV MODELS WINDSHIELD REPLACEMENT When replacing a cracked windshield, it is important that the cause of the crack be determ ined 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 p articularly high due to winds, extremes of temperature, or rough terrain. Suggestions of what to look for are described later in this section under “ Inspection” . If a crack extends to the edge of the glass, mark the point where the crack meets the weatherstrip. (Use a piece of chalk and mark the point on the cab, next to the weatherstrip.) Later, when examining the flange of the opening for a cause of the crack start at the point marked. The higher the temperature of the work area, the more pliable the weatherstrip will be. The more pliable the weatherstrip, the more easily the w indshield can be removed. Remove or Disconnect (Figures 1 and 2) CAUTION: Always wear heavy gloves when handling glass to avoid the risk of injury. Tool Required: J-24402-A, Glass Sealant Removal Knife • Place protective coverings around the glass removal area. 1. Reveal molding cap. 2. Reveal molding. 1. W e a th e rs trip 2 . C ap 3. G la ss "T 4. W in d s h ie ld Reveal M o ld in g B-09049 Figure 1—Windshield Components • From inside the cab, apply a firm controlled pressure to the edge of the glass while forcing the weatherstrip from the flange with a flat-blade tool. NOTICE: See “ N o tice” on page 10A3-1 of this section. 3. Windshield glass. • With the aid of a helper from outside the vehicle, remove windshield from opening. 4. Excess urethane and remaining weatherstrip from the pinchweld flange. 10A3-2 GLASS 4. 5. 6. 7. 8. Figure 2—Forcing the Weatherstrip Over the Flange IQ* Clean • Pinchweld with a dry cloth. INSPECTION An inspection of the flange of the windshield opening, the weatherstrip, and the glass may reveal the cause of a broken windshield. This can help prevent future breakage. If th e re is no a p p a re n t c a u s e o f b re a k a g e , th e weatherstrip should be removed from the flange of the opening and the flange inspected. Look for high weld or solder spots, hardened spot weld sealer, or any other o bstruction or irre g u la rity in the flange. C heck the weatherstrip for irregularities or obstructions in it. Check a windshield that is to be installed to make sure it does not have any chipped edges. Chipped edges can be ground off, restoring a smooth edge to the glass, and m in im iz in g c o n c e n tra tio n s of p re ssu re th a t ca use breakage. Remove no more than necessary, in an effort to maintain the original shape of the glass and the proper clearance between it and the flange of the opening. See “ G lass-To-O pening C lea ra nce C h e c k ” later in th is section. GLASS-TO-OPENING CLEARANCE CHECK Before installing a windshield, the clearance between the edge of the glass and the flange of the opening should be checked. On RV Models the glass and flange overlap by 5 mm (0.2-inch). If the windshield is too big, rework the metal flange or grind off the edge of the glass. If the glass is to be ground off, place a strip of tape on the glass and use the edge of the tape as a guide. If there is too much clearance between the glass and the flange of the opening, the flange can be built up. Braze a piece of 3 mm (Ve-inch) diameter wire to the edge of the flange. Usually, building up one side and half way around one corner will be enough. Taper off the ends of the wire to avoid an abrupt change in contour which could result, later, in a broken windshield. Rubber cleaner. Rubber primer. Pinchweld primer. Blackout primer. Filler strip (for use on windshield installations for v e h ic le s e q u ip pe d w ith e m b edded w in d s h ie ld antenna). 9. Primer applicators. Other materials are required for windshield 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 standard household cartridge type 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 (for cutting along the edge of the glass). 6 . Weatherstrip Tool J-2189-02. W indshield installation requires a num ber of timed steps because of the cure tim es involved with the primers, solvents, and adhesives used in this procedure. This tim ing is important and must be followed. Install or Connect (Figures 3 and 4) Tools Required: J-24811 Adhesive Dispensing Gun J-2189-02 Weatherstrip Tool 1. Pinchweld primer. • Primer must be thoroughly stirred and agitated. • Allow to cure for 30 minutes. 2. R u b b e r c le a n e r to both c h a n n e ls of ru b b e r weatherstrip. • Wait 5 minutes before wiping the channels with a clean dry cloth. 3. Rubber primer to both channels of the weatherstrip. • Wait 30 minutes for curing. XJJK Clean 4. 5. SERVICE KIT To rep la ce a u re th a n e a d h e re d w in d s h ie ld , GM adhesive service kit No. 9636067 contains some the m aterials needed, and must be used to insure the original integrity of the w indshield design. Materials in the kit include: 1. One tube of adhesive material. 2 . One dispensing nozzle. 3. Steel music wire. 6. 7. 8. 9. « Inner surface of glass with a clean alcohol dampened cloth. Allow the glass to air dry. Blackout primer to the inside face of the glass. • Start 10 mm (.40-inch) from the edge and work the primer outward to the edge. • Allow the primer to dry. Urethane adhesive bead with a diameter of 6 mm (.25-inch) to the center of the pinchweld flange around the entire windshield opening. » Glass must be installed within 20 minutes of performing this step. • Spray a mist of water to the urethane bead, wetting it fully. Rubber weatherstrip to the pinchweld flange. Urethane adhesive bead with a 4.5 mm (.18-inch) diameter to the rubber weatherstrip glass channel (figure 3). Glass to the window opening. Rubber lubricant to the lockstrip channel. • Glass must be seated before the lubricant is applied. GLASS 10A3-3 5. 6. 7. 8. 9. 10. 11. P rim e r L o ca tio n R u b b e r C lea ne r A n d P rim e r L o c a tio n C le a n e r L o ca tio n B la c k o u t P rim e r L o c a tio n 10 m m (0.40-inch) U re th an e L o ca tio n R u b b e r L u b ric a n t L o c a tio n Figure 3—Primer and Adhesive Application Locations 10. Reveal molding to the weatherstrip using J-2189-02 (figure 4). STATIONARY GLASS REPLACEMENT 11. Reveal molding cap at the joint. Remove or Disconnect (Figures 5 through 9) CAUTION: Always wear heavy gloves when handling glass to avoid the risk of injury. 1. Reveal molding. • Push the clip to one side to free the ends. NOTICE: Refer to “ N o tice” on page 10A3-1 of this section. 2. Window glass. • Insert a putty knife between the glass and the weatherstrip and run the knife around the entire edge of the window. NOTICE: Refer to “ N o tice” on page 10A3-1 of this section. • With a helper standing outside the vehicle, push the glass from the weatherstrip from inside the cab while the helper removes the glass. install or Connect (Figures 5 through 9) Tool Required: J-2189-02 Weatherstrip Tool 10A3-4 GLASS CAUTION: Always wear heavy gloves when handling glass to avoid risk of injury. 1. Sealing tape on the outside upper corners of the opening, 120 mm (Ve-inch) wide. 2. Weatherstrip at the center of the bottom edge of the opening and work around the entire opening of the flange. • Brush the weatherstrip with soapy water. Inspect • Glass for cracks or chips on the edge. If the glass is chipped, it should be ground smooth. 3. Glass in place on the weatherstrip. • Insert the hook end of tool J-2189-02 between the weatherstrip and the edge of the glass. • Pull the tool around the glass to slip the edge of the glass into the groove of the weatherstrip. 4. Reveal molding. 17. S lid in g B a ck W in d o w A s s e m b ly B-09084 Figure 6—Sliding Back Window Components GLASS 10A3-5 Thread the end of the molding through the handle of tool J-2189-02. Push the end of the molding into the groove of the weatherstrip at the center of the bottom edge (figure 4). 5. Retaining clip over one end of the molding. • Butt the ends of the molding together and secure them with the clip. 6 . Ends of the molding, with the clip in place, into the groove of the weatherstrip. Move the tool around the window while feeding the molding. Use a hitching motion to avoid stretching the molding. Cut any excess molding leaving the ends to overlap by 25 mm (1-inch). 22. 23. 24. 25. S lid in g W in d o w A s s e m b ly W e a th e rs trip Reveal M o ld in g C ap B-09089 Figure 8—Sliding Body Side Window Components 10A3-6 GLASS 26. 27. 28. 29. G la ss Reveal M o ld in g W e a th e rs trip C ap B-09091 Figure 9—Suburban Rear Stationary Window Components G MODELS WINDSHIELD REPLACEMENT When replacing a cracked windshield, it is important that the cause of the crack be determ ined 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 p articularly high due to winds, extremes of temperature, or rough terrain. Suggestions of what to look for are described later in this section under “ Inspection” . If a crack extends to the edge of the glass, mark the point where the crack meets the weatherstrip. (Use a piece of chalk and mark the point on the cab, next to the weatherstrip.) Later, when examining the flange of the opening for a cause of the crack start at the point marked. The higher the temperature of the work area, the more pliable the weatherstrip will be. The more pliable the weatherstrip, the more easily the w indshield can be removed. NOTICE: When cleaning windshield glass, avoid contacting the edge o f the plastic laminate material (on the edge o f the glass) with volatile cleaner. Contact may cause discoloration and deterioration o f the plastic laminate by wicking action. Do not use a petroleum based solvent such as kerosene or gasoline. The presence of oil will prevent adhesion o f new material. Remove or Disconnect (Figures 10 and 11) CAUTION: Always wear heavy gloves when handling glass to minimize the risk of injury. • 1. 2. 3. 4. 5. Tool Required: J-24402-A, Glass Sealant Removal Knife Place protective coverings around the glass removal area. Windshield wiper arms. Interior garnish moldings. Reveal molding cap. Reveal molding. Interior support molding. NOTICE: Refer to “ N o tice” on page 10A3-1 of this section. 6 . Windshield from the flange. • Use J-24709-1 or J-24402-A to cut the glass from the urethane adhesive. Keep the cutting edge of the knife against the glass, and cut the sealant from the windshield. • W ith the aid of an a ssistan t, remove the windshield. Two methods of glass replacement may be used. The first of these methods is called the short method. This method can be used when the original adhesive is left on the window opening pinchweld flange after the glass has been removed. The old adhesive serves as a base for the new glass. The second method, is the extended method. This is used when the original adhesive cannot be used as a base for the new glass. The original adhesive is removed and replace with new adhesive. When repair to the sheet m etal or w indow opening is required, the extended method must be used. INSPECTION An inspection of the flange of the windshield opening, the weatherstrip, and the glass may reveal the cause of a broken windshield. This can help prevent future breakage. If th e re is no a p p a re n t c a u s e o f b re a k a g e , th e GLASS 10A3-7 G la s s C ap Reveal M o ld in g S p a c e r B lo c k S u p p o rt M o ld in g B-09092 Figure 10—Windshield Components weatherstrip should be removed from the flange of the opening and the flange inspected. Look for high weld or solder spots, hardened spot weld sealer, or any other o bstructio n or irre gu la rity in the flange. C heck the weatherstrip for irregularities or obstructions in it. Check a windshield that is to be installed to make sure it does not have any chipped edges. Chipped edges can be ground off, restoring a smooth edge to the glass, and m in im iz in g c o n c e n tra tio n s o f p re ssu re th a t ca use breakage. Remove no more than necessary, in an effort to maintain the original shape of the glass and the proper clearance between it and the flange of the opening. 8 . Filler strip (for use on windshield installations for v e h ic le s e q u ip p e d w ith em bedded w in d s h ie ld antenna). 9. Primer applicators. Other m aterials are required for windshield 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 standard household cartridge type gun reworked as follows: SERVICE KIT (Figures 12 through 16) To re p la ce a u re tha n e a d h e re d w in d s h ie ld , GM adhesive service kit No. 9636067 contains some of the m aterials 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. 4. Rubber cleaner. 5. Rubber primer. 6 . Pinchweld primer. 7. Blackout primer. Figure 11—Cutting the Glass from the Adhesive Figure 12—Primer Applications Locations 10A3-8 GLASS Figure 14—Urethane Application 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 (for cutting along the edge of the glass). 6 . Weatherstrip Tool J-2189-02. W indshield installation requires a num ber of timed steps because of the cure tim es involved with the primers, solvents, and adhesives used in this procedure. This tim ing is important and must be followed. SHORT METHOD Clean 1. Loose material from the glass frame opening. 2. Edge of the glass with alcohol or equivalent. Install or Connect (Figures 12 through 16) 1. Support molding onto the pinchweld flange from inside the vehicle. • Locate the joint of the molding at the bottom center of the molding. 2. Clear glass primer to the inner edge of the windshield from the edge of the glass inward 10 mm (.40-inch), and around the entire perimeter of the glass. • Allow 30 minutes to cure. 3. Blackout primer to the glass in the same area as the clear primer. • Allow to dry to the touch. 4. Windshield. » 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. • With the aid of a helper, left the glass into the opening. Center the glass in the opening, on top of the support molding. • Check the fit of the reveal molding. If necessary, remove the glass and cut away additional urethane to give the proper windshield height. Place the glass in the window opening. GLASS 10A3-9 34 32 34. S u p p o rt M o ld in g 36. U re th an e A d h e s iv e 30 B-09105 Figure 16—Windshield Support M o ld in g Short Method • C ut th e tip of the a d h e s iv e c a rtrid g e approximately 5 mm (3/ie-inch) from the end of the tip. • Apply the adhesive first in and around the spacer blocks. Apply a smooth 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 method) or solidified urethane base (short method). • Spray a mist of water onto the urethane. Water will assist int he curing process. Dry the area where the reveal molding will contact the body or glass. 31 5. New reveal moldings. • Remove the protective tape covering the butyl adhesive on the underside of the molding. • Push the molding caps onto each end of one of the reveal moldings. • Press the lip of the molding into the urethane adhesive while holding it against the edge of the windshield. Take care to seat the molding in the corners. The lip must fully contact the adhesive and the gap must be entirely covered by the crown of the molding. 30. 31. 32. 34. 36. G la ss C ap Reveal M o ld in g S u p p o rt M o ld in g U rethane A d h e sive • Slide the m olding caps onto the adjacent moldings. • Use tape to hold the molding in position until the adhesive cures. B-09104 6 . Wiper arms. 7. Interior garnish moldings. Figure 15—Reveal Molding • Allow the vehicle to sit for sixe hours before driving. 10A3-10 GLASS EXTENDED METHOD STATIONARY GLASS REPLACEMENT Clean • The old adhesive from the pinchweld flange using a sharp scraper or chisel. H Remove or Disconnect (Figures 17, 18 and 19) CAUTION: Always wear heavy gloves when handling glass to avoid the risk of injury. |-»+-| Install or Connect (Figure 12) 1. Rivets (if equipped) using a 5 mm (3/ie-inch) drill bit. • Pinchweld primer to the pinchweld area. • Do not allow primer to touch exposed paint. • Allow 30 minutes to dry. • Follow the steps as listed under “ Short Method” in this section for the rest of this procedure. NOTICE: Refer to “ N o tice” on page 10A3-1 of this section. 2. Window glass and weatherstrip. • Run a putty knife around the edge of the window, between the weatherstrip and the cab panels (inside and outside the cab). 39. W e a th e rs trip 40. G la ss 40 B-09118 Figure 18—Body Side Rear Window GLASS 10A3-11 41. W e a th e rs trip 42. R ivet B-09119 Figure 19—Body Side Rear Window — Riveted Have a helper stand outside the cab next to the window. Use a putty knife, or other blunt tool, to force the edge of the weatherstrip off the flange of the opening inside the cab, while pushing out on the glass. C ontinue around the window, fo rcin g the weatherstrip off the flange, until the glass and weatherstrip are free of the opening. Have the h e lp e r rem ove th e g la s s and weatherstrip from the outside of the vehicle. L* Inspect • Flange. • Weatherstrip. • New glass. Install or Connect (Figures 17, 18 and 19) • To ease installation, the weatherstrip can be heated with a non-flame source. Do not heat above 52°C (125°F), or for more than than 11/2 hours. 1. Weatherstrip around the edge of the replacement glass. • Place a length of cord about 6 mm (1/4-inch) thick in the groove of the weatherstrip where the flange of the opening will fit. • Overlap the ends of the cord about 152 mm (6 inches) and locate at the bottom of the window. • Brush a soapy solution of water around the outside edge of the cab opening. 2. Glass and weatherstrip to flange. • Have a helper hold the glass and weatherstrip (with the cord around it) up to the window opening from the outside of the cab; with the ends of the cord placed through the opening and hang loosely inside the cab. • While the helper holds the glass firmly in place, pull one end of the cord, forcing the lip of the weatherstrip up and over the flange. • Pull the cord out from around the weatherstrip. 3. Rivets (if equipped) to the weatherstrip and the side panel with a rivet installing gun. ALL MODELS GLASS POLISHING MINOR SCRATCH AND ABRASION REMOVAL M inor scratches and abrasions can be removed or reduced by follow ing the procedure outlined below. P re c a u tio n s m u st be ta k e n , how ever, to p re v e n t 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 driver’s line of vision; in such cases, the glass should be replaced. The procedure that follows was developed using a cerium oxide compound. Follow m anufacturer’s directions if other materials are used. Recommended Equipment 1. A low speed (600-1300 rpm) rotary polisher. 2. A wool, felt, rotary polishing pad 76 mm (three-inches) in diameter and 51 mm (two-inches) thick. 3. Powdered cerium oxide mixed with water. This is the abrasive compound. 4. A w ide m outh c o n ta in e r to hold the a b rasive compound. Polishing Procedure (Figure 20) 1. Mix at least 44 ml (1.5 oz.) of cerium oxide with enough water to obtain a creamy consistency. (If the mixture is too thick it will cake on the felt pad more quickly. If it is too runny, more polishing time will be needed.) 2. Draw a circle around the scratches on the opposite side of the glass with a marking crayon, or equivalent. 3. Draw a line directly behind the scratch(es) to serve as a guide for locating the scratch while polishing. 4. Cover the surrounding area with masking paper to catch the drippings or spattered polish. 10A3-12 GLASS 5. Dip the felt pad attached to the polisher into the mixture. Do not submerge the pad or allow the pad to stay in the mixture as it may loosen the bond between the pad and the metal plate. NOTICE: Never hold the tool in one spot or operate the tool on the glass any longer than 30 to 45 seconds. If the glass becomes hot to touch, let it air cool before proceding further. Cooling with c o ld w ater may crack heated glass. Avoid excessive pressure. It may cause overheating of the glass. 6. Polish the scratched area, but note the following: a. Agitate the m ixture as often as needed to m a in ta in th e cre a m y c o n s is te n c y o f the compound. b. Use moderate but steady pressure. c. Hold the pad flat against the glass. d. Use a feathering-out motion. e. Dip the pad into the mixture 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. SPECIAL TOOLS J-24811 3. J-2189-02 1. A d h e s iv e D is p e n s in g G un 2. W e a th e rs trip Tool 3. S e a la n t R em over F-02461 Figure 21—Special Tools INTERIOR TRIM 10A4-1 SECTION 10A4 INTERIOR TRIM CONTENTS SUBJECT PAGE RV Model Interior T rim .................................................................................................................................... 10A4- 1 Front Trim Replacement.............................................................................................................................. 10A4- 1 Pick Up Models................................................................................................................................................10A4- 3 Carpet Replacement.................................................................................................................................... 10A4- 3 Headliner And Trim Replacement...................................................... .....................................................10A4- 3 Bonus Cab M odels..........................................................................................................................................10A4- 5 Carpet Replacement.................................................................................................................................... 10A4- 5 Headliner And Trim Replacement...............................................................................................................10A4- 6 Utility Vehicle Models...................................................................................................................................... 10A4- 8 Carpet Replacement.................................................................................................................................... 10A4- 8 Headliner And Trim Replacement...............................................................................................................10A4- 8 Front Floor Compartment Replacement..................................................................................................... 10A4- 8 Suburban Models..............................................................................................................................................10A4-13 Carpet Replacement.................................................................................................................................... 10A4-13 Headliner And Trim Replacement...............................................................................................................10A4-13 Roof Rear Header Trim Panel Replacement............................................................................................... 10A4-14 G Model Interior T rim ...................................................................................................................................... 10A4-18 Carpet Replacement.................................................................................................................................... 10A4-18 Headliner Replacement................................................................................................................................ 10A4-18 Interior Trim Replacement.......................................................................................................................... 10A4-19 Engine Cover Replacement.......................................................................................................................... 10A4-21 RV MODEL INTERIOR TRIM The following procedure covers the trim located at the front of the cab, and applies to all RV models. FRONT TRIM REPLACEMENT ++ 1. Remove or Disconnect (Figures 1 through 4) Sill plate screws (1). 2 . Sill plate (2). 3. 4. 5. 6. 7. Kick panel screws (3). Kick panel (4). Instrument panel outer filler screws (5). Instrument panel outer filler (6). Upper garnish molding screws (7). 8 . Upper garnish molding (8). 9. Windshield side garnish molding screws (9). 10. Windshield side garnish molding (10). Install or Connect (Figures 1 through 4) Windshield side garnish molding (10). Windshield side garnish molding screws (9). Upper garnish molding (8). Upper garnish molding screws (7). Instrument panel outer filler (6). Instrument panel outer filler screws (5). 7. 8. 9. 10. Kick panel (4). Kick panel screws (3). Sill plate (2). Sill plate screws (1). 10A4-2 INTERIOR TRIM Figure 3—Instrument Panel Outer Filler Figure 4—Sill Plate INTERIOR TRIM 10A4-3 PICK UP MODEL HEADLINER AND TRIM REPLACEMENT CARPET REPLACEMENT ++ Remove or Disconnect (Figures 5 through 8) 1. Seats and seat belts. Refer to SEATS (SEC. 10A2). 2. Kick panel. 3. Front door scuff plate (12). 4. Rear panel nails (13). • Pull the nails from the panel. 5. Rear panel (14). 6. Dash panel retainers (15). 7. Carpet (16) from the vehicle. -►<- Install or Connect (Figures 5 through 8) 1. Carpet (16) to the vehicle. 2. Dash panel retainers (15). 3. Rear panel (14). 4. New rear panel nails (13). • Push the nails through the panel and into the body panels. 5. Front door scuff plate (12). 6. Kick panel. 7. Seats and seat belts. Refer to SEATS (10A2). «"► Remove or Disconnect (Figure 9) 1. 2. 3. 4. 5. 6. 7. 8. 9. Windshield upper garnish molding screws (23). Windshield upper garnish molding (17). Side window garnish molding screws (21). Side window garnish molding (22). Windshield garnish molding screws. Windshield garnish molding (24). Back window garnish molding screws. Back window garnish molding (25). Headliner (20). ♦4- Install or Connect (Figure 9) 1. 2. 3. 4. 5. 6. 7. 8. 9. Headliner (20). Back window garnish molding (25). Back window garnish molding screws. Windshield garnish molding (24). Windshield garnish molding screws. Side window garnish molding (22). Side window garnish molding screws (21). Windshield upper garnish molding (17). Windshield upper garnish molding screws (23). 10A4-4 INTERIOR TRIM Figure 7—Carpet Retainers INTERIOR TRIM 10A4-5 17. 18. 19. 20. 21. 22. 23. 24. W in d s h ie ld U pper G a rn ish M o ld in g S cre w B a ck W in d o w U p p e r G a rn ish M o ld in g H e a d lin e r S crew S id e W in d o w G a rn ish M o ld in g S crew W in d s h ie ld G a rn ish M o ld in g 25. B ack W in d o w G a rn ish M o ld in g B-09067 Figure 9—Headliner and Interior Trim BONUS CAB MODELS CARPET REPLACEMENT -►«- Install or Connect (Figures 10 through 12) 1. Carpet (29) to the vehicle. ++ Remove or Disconnect (Figures 10 through 12) 1. Seats and seat belts. Refer to SEATS (Sec. 10A1). 2. Carpet to floor panel bolts (28) (if equipped). 3. Lock pillar garnish molding (42) and the screws (41). 2. Kick panel. 3. Front and rear door scuff plates (27). 4. Rear panel nails (figure 6). • Pull the nails from ther panel. 5. Rear panel (figure 6). 6. Dash panel retainers (figure 7). 4. Dash panel retainers (figure 7). 5. Rear panel (figure 6). 6. Rear panel nails (figure 6). • Push the nails through the panel and into the body panels. 7. Lock pillar garnish molding screws (41) and the molding (42). 7. Front and rear door scuff plates (27). 8. Carpet to floor panel bolts (28) (if equipped). 8. Kick panel. 9. Carpet (29) from the vehicle. 9. Seats and seat belts. Refer to SEATS (SEC. 10A1). 10A4-6 INTERIOR TRIM Figure 10—Front Door Sili Plate HEADLINER AND TRIM REPLACEMENT +-► Remove or Disconnect (Figures 13 and 14) 1. Windshield upper garnish molding screws (39) and the molding (31). 2. Side window garnish molding screws (40) and the molding (38). 3. Windshield garnish molding screws and the molding (30). 4. Back window garnish molding screws and the molding (35). 5. Lock pillar garnish molding screws and the molding. 6. Sunshade screws (44) and sunshade (43). 7. Headliner (32) from the vehicle. Install or Connect (Figures 13 and 14) 1. 2. 3. 4. 5. 6. 7. Figure 11—Lock Pillar Garnish Molding Headliner (32) to the vehicle. Sunshade (43) and screws (44). Lock pillar garnish molding and screws. Back window garnish molding (35) and screws. Windshield garnish molding (30) and screws. Side window garnish molding (38) and screws (40). Windshield upper garnish molding (31) and screws (39). INTERIOR TRIM 10A4-7 B-09156 Figure 12—Carpet 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. W in d s h ie ld G a rn ish M o ld in g W in d s h ie ld U pp er G a rn ish M o ld in g H e a d lin e r S crew B a ck W in d o w U p p e r G a rn ish M o ld in g B a ck W in d o w G a rn ish M o ld in g S crew Cap S id e H ea de r M o ld in g S crew S crew B-09135 Figure 13—Headliner and Interior Trim 10A4-8 INTERIOR TRIM UTILITY VEHICLE MODELS CARPET REPLACEMENT ++ Remove or Disconnect (Figures 15 through 19) Seats and seat belts. Refer to SEATS (SEC. 10A2). Kick panel. Front door scuff plate. Side trim carpet panel screws (45) and the panel (46). Side trim panel screws (47) and the panel (48). Floor panel trim plate screws (49) and the trim plate (50). Rear scuff plate screws (51) and the plate (52). Dash panel retainers (figure 7). Carpet (53) from the vehicle. 4. Roof rear header molding screws (60) and the molding (53). 5. Lock pillar garnish molding screws and the molding (61). 6. Sunshade screws and sunshade (figure 14). 7. Headliner (54) from the vehicle. Install or Connect (Figure 20) 1. 2. 3. 4. 5. 6. 7. Install or Connect (Figures 15 through 19) Carpet (53) to the vehicle. Dash panel retainers (figure 7). Rear scuff plate (52) and screws (51). Floor panel trim plate (50) and screws (49). Side trim panel (48) and screws (47). Side trim carpet panel (46) and screws (45). Front door scuff plate. Kick panel. Seats and seat belts. Refer to SEATS (Sec. 10A2). HEADLINER AND TRIM REPLACEMENT Remove or Disconnect (Figure 20) 1. Windshield upper garnish molding screws (56) and the molding (55). 2. Side window garnish molding screws (58) and the molding (59). 3. Windshield garnish molding screws and the molding (57). Headliner (54) to the vehicle. Sunshade and screws (figure 14). Lock pillar garnish molding(61) and screws. Roof rear header molding (53) and screws (60). Windshield garnish molding (57) and screws. Side window garnish molding (59) and screws (58). Windshield upper garnish molding (55) and screws (56). FRONT FLOOR COMPARTMENT REPLACEMENT Remove or Disconnect (Figure 21) Open the compartment door. Compartment to floor bolts (74). 2. Compartment from the vehicle. 1. +«- Install or Connect (Figure 21) 1. Compartment to the vehicle. 2. Compartment to the floor bolts (74). 10A4-10 INTERIOR TRIM Figure 17—Floor Panel Trim Panel Figure 18—Rear Scuff Plate INTERIOR TRIM 10A4-11 53. 54. 55. 56. 57. 58. 59. 60. 61. Rear H e a d e r M o ld in g H e a d lin e r W in d s h ie ld U p p e r G a rn ish M o ld in g S cre w W in d s h ie ld G a rn is h M o ld in g S cre w S id e W in d o w G a rn is h M o ld in g S crew L ock P illa r G a rn is h M o ld in g B-09071 Figure 20—Headliner and Interior Trim 10A4-12 INTERIOR TRIM 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. Lock C y lin d e r Bezel C ase A s s e m b ly D o o r A s s e m b ly D o o r S to p S crew H in g e S trik e r N ut B o lt Bum per C o m p a rtm e n t A s s e m b ly B o lt B o lt S u p p o rt B-09072 Figure 21—Floor Compartment INTERIOR TRIM 10A4-13 SUBURBAN MODEL Figure 22—Corner Garnish Molding CARPET REPLACEMENT Remove or Disconnect (Figures 22 through 27) 8. 9. 10. 11. 1. Seats and seat belts. Refer to SEATS (SEC. 10A1). 2 . Front and rear door scuff plates (figure 5). 3. Kick panel. HEADLINER AND TRIM REPLACEMENT 4. Rear corner garnish molding screws (77) and the molding (78). 5. Rear lock pillar garnish molding screws (79) and the 6. 7. 8. 9. 10. 11. molding (80). Front lock pillar garnish molding screws (81) and the molding (82). Body side trim panel screws (83) and the panel (84). Front scuff plate screws (85) and the plate (86). Rear scuff plate screws (87) and the plate (88). Dash panel retainers (figure 7). Carpet (89) from the vehicle. Install or Connect (Figures 22 through 27) Carpet (89) to the vehicle. Dash panel retainers (figure 7). Rear scuff plate (88) and the screws (87). Front scuff plate (86) and the screws (85). Body side trim panel (84) and the screws. Front lock pillar garnish molding (82) and the screws (81). Rear lock pillar garnish molding (80) and the screws (79). Rear corner garnish molding (78) and the screws (77). Kick panel. Front and rear door scuff plates (figure 5). Seats and seat belts. Refer to SEATS (SEC. 10A1). Remove or Disconnect (Figures 28 and 29) 1. Windshield upper garnish molding screws (90) and the molding (91). 2. Side header garnish molding screws (92) and the molding (93). 3. Windshield garnish molding screws and the molding (94). 4. Rear roof header molding screws (95) and the molding (96). 5. Side header rear garnish molding screws (97) and the molding (98) (if equipped). 6. Upper side garnish molding screws (99) and the molding (100) (if equipped). 7. Roof inner trim pane! screws (101) and the panel (102). 8. Headliner (103) from the vehicle. -► 4- Install or Connect (Figures 28 and 29) 1. Headliner (103) to the vehicle. 2. Roof inner trim panel (102) and screws (101). 10A4-14 INTERIOR TRIM ROOF REAR HEADER TRIM PANEL Remove or Disconnect (Figures 30 and 31) 1. Lower trim panel screws (104) and the lower panel (105). 2. Upper trim panel screws (106) and the upper panel (107). Install or Connect (Figures 30 and 31) 1. Upper trim panel (107) and the screws (106). 2. Lower trim panel (105) and the screws (104). Figure 24—Front Lock Pillar Molding 3. Upper side garnish molding (100) and screws (99) (if equipped). 4. Side header rear garnish molding (98) and screws (97) (if equipped). 5. Rear roof header molding (96) and screws (95). 6. Windshield garnish molding (94) and screws. 7. Side header garnish molding (93) and screws (92). 8. Windshield upper garnish molding (91) and screws (90). Figure 25—Side Trim Panel INTERIOR TRIM 10A4-15 Figure 27—Carpet 10A4-16 INTERIOR TRIM 90. S crew 91. W in d s h ie ld U p p e r G a rn ish M o ld in g 92. S crew 93. S ide H e a d e r G a rn is h M o ld in g 94. W in d s h ie ld G a rn is h M o ld in g 95. S crew 96. 97. 98. 101. 102. 103. Rear R oof H ea d e r M o ld in g S crew S ide H ea de r Rear G a rn ish M o ld in g S crew R oo f In n e r Trim Panel H e a d lin e r Figure 28—Headliner and Interior Trim Figure 29—Side Garnish Molding B-09039 INTERIOR TRIM 10A4-17 Figure 30—Rear Header Lower Trim Panel B-09040 Figure 31—Rear Header Upper Trim Panel 10A4-18 INTERIOR TRIM G MODEL INTERIOR TRIM CARPET REPLACEMENT Remove or Disconnect (Figures 32 through 41) □ 1. Seats. Refer to SEATS (SEC. 10A2). 2. Front carpet retainer (110). Front door scuff plate (112). Front step panel mat (if equipped) (114). Carpet from the dash retainers (108). • Bend the retainers away from the dash. Front carpet (115) from the vehicle. 7. Side door scuff plate (116). 8. Side door mat (if equipped) (118). 9. Carpet to side door screws (119). 10. Rear door scuff plate (121). 11. Front trim panel (123). 12. Rear trim panel (125). 13. Rear corner panel (127). 14. Rear carpet from the vehicle. 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 Remove or Disconnect (Figure 42) 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). 4. Headliner (131) from the vehicle. • Shift the headliner from side to side to disengage the headliner from the clips. ♦«- Install or Connect (Figures 32 through 41) 1. 2. 3. 4. 5. 6. 7. Rear carpet to the vehicle. Rear corner panel (127). Rear trim panel (125). Front trim panel (123). Rear door scuff plate (121). Carpet to side door screws (119). Side door mat (if equipped) (118). □ Install or Connect (Figure 42) 1. Headliner (131) to the vehicle. • Place the headliner into the roof clips. 2. Retainers (130) to the headliner, and the retainer bolts (129). 3. Headliner retainer bow (if equipped). INTERIOR TRIM 10A4419 • Push the bow (128) onto the retainer. 4. Upper window trim that supports the headliner. Refer to “ Interior Trim Replacement.” INTERIOR TRIM REPLACEMENT ++ Remove or Disconnect 1. Lock pillar garnish molding screws and the lock pillar garnish molding (figure 43). 2. Front door hinge pillar molding screws and the front door hinge pillar molding (figure 44). 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. 48) For vehicles with the sliding side door only. Lower lock pillar garnish molding sc and the molding (figure 49). Body side front garnish molding sc and the molding (figure 49). Roof rear header garnish molding sc anc the molding (figure 50). and the Body rear corner garnish molding sc molding (figure 51). and the molding (figure 52). 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). • Pull the panel from the retainers. 14. Body side trim rear corner panel screws and the panel (figure 41). • Pull the panel from the retainers. -►+ Install or Connect 1. Body side trim rear panel and screws (figure 41). 2. Body side rear trim panel and screws (figure 40). 10A4-20 INTERIOR TRIM 3. Body side front trim panel and screws (figure 39). 4. Body side rear garnish molding and screws (figure 52). 5. Body rear corner garnish molding and screws (figure 51). 6. Roof rear head garnish molding and screws (figure 50). 7. Body side front garnish molding and screws (figure 49). 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. 11. Front header garnish molding and screws (figure 46). 12. Sunshade and screws (figure 45). Figure 38—Rear Door Scuff Plates 13. Front door hinge pillar molding and screws (figure 44). 14. Lock pillar garnish molding and screws (figure 43). INTERIOR TRIM 10A4-21 ENGINE COVER REPLACEMENT |++| Remove or Disconnect (Figures 53 and 54) 1. Instrum ent 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. Install or Connect (Figures 53 and 54) 1. 2. 3. 4. 5. Engine cover (158) to the vehicle. Clamp (157) to the pin (155). Engine cover (158) to floor panel bolts (156). Instrument panel lower extension (153). Instrum ent panel lower extension screws (150), washers (151) and shims (152). 122. Screw 123. F ront Trim Panel B-09123 Figure 39—Front Trim Panel 124. Screw 125. Rear Trim Panel B-09137 Figure 40—Rear Trim Panel 10A4-22 INTERIOR TRIM Figure 41—Rear Corner Panel 128. 129. 130. 131. B ow B o lt R e ta in e r H e a d lin e r 128 Figure 42—Headliner Retainer B-09151 INTERIOR TRIM 10A4-23 Figure 44—Hinge Pillar Molding 10A4-24 INTERIOR TRIM Figure 46—Front Header Garnish Molding Figure 47—Roof Rear Rail Garnish Molding INTERIOR TRIM 10A4-25 146 144 144. S crew 145. L ow er Lock P illa r G a rn ish M o ld in g 146. S cre w | 147. F ro n t S ide G a rn ish M o ld in g * 145 B-09070 Figure 49—Front Garnish Moldings Figure 51—Rear Corner Garnish Molding Figure 50—Rear Header Garnish Molding 10A4-26 INTERIOR TRIM 151 151 150. 151. 152. 153. Screw _____ W asher Shim s Instrum ent Panel Lower Extension Figure 53—Instrument Panel Lower Extension 150 150 B-09054 INTERIOR TRIM 10A4-27 Figure 54—Engine Cover — ---------------------------------------, 10A5-1 SECTION 10A5 END GATE CONTENTS S U BJE C T Fender Side M odels............................................................................................. End Gate Replacement..................................................................................... Fleet Side M odels............................................................................................... End Gate Replacement.................................................................................... Handle And Latch Replacement...................................................................... Utility Vehicle Models......................................................................................... End Gate Replacement.................................................................................... Torque Rod Replacement................................................................................ Hinge Replacement......................................................................................... End Gate Cover Replacement.......................................................................... Handle And Control Assembly Replacement................................................. Latch Replacement......................................................................................... Regulator Replacement.................................................................................... Window Motor And Blockout Switch Replacement....................................... Sash Assembly Replacement.......................................................................... Run Channel Replacement.............................................................................. End Gate Outside Crank Replacement.......................................................... Window Glass Seal Replacement.................................................................... Weatherstrip Replacement.............................................................................. Utility Vehicle Removable Top............................................................................ Removable Top Replacement................................................................ . Suburban Models................................................................................................. End Gate Replacement.................................................................................... Torque Rod Replacement................... .......................................................... Hinge Replacement......................................................................................... End Gate Trim And Cover Panel Replacement............................................... Handle And Control Assembly Replacement................................................. Latch Replacement......................................................................................... Regulator Replacement................................................................................... Blockout Switch Replacement....................................................................... Sash Assembly Replacement.......................................................................... Run Channel Replacement................................. ............................................ End Gate Outside Crank Replacement.......................................................... Window Glass Seal Replacement.................................................................... Weatherstrip Replacement.............................................................................. PA G E .........................................10A, >- 2 .........................................10A, 5- 2 .........................................10A j- 2 .........................................10A >- 2 .........................................10A >- 2 .........................................10A >- 4 .........................................10A >- 4 .........................................10A 5- 5 .........................................10A j- 6 .........................................10A 5- 6 .........................................10A 5- 6 .........................................10A 5- 7 .........................................10A 5- 8 .........................................10A 5- 9 .........................................10A 5-10 .........................................10A 5-11 .........................................10A 5-11 .........................................10A 5-11 .........................................10A 5-11 .........................................10A 5-12 .........................................10A 5-12 ..................................... . .10A 5-13 .........................................10A 5-13 .........................................10A 5-13 ........................................10A 5-13 .........................................10A 5-15 .........................................10A 5-15 .........................................10A 5-16 .........................................10A 5-16 .........................................10A 5-17 .........................................10A 5-17 ......................... .............. 10A 5-17 .........................................10A 5-17 .........................................10A 5-17 .........................................10A 5-18 10A5-2 END GATE FENDER SIDE MODELS END GATE REPLACEMENT Remove or Disconnect (Figure 1) Open the end gate and support it with a table or other suitable support. Fender to end gate bolt (6) and washer (7). End gate (4), and bushing (5) from the vehicle. Chain (3) to fender nut (1), washer (2), and eye bolt. Install or Connect (Figure 1) 1. 2. 3. 4. Chain (3) with eye bolt to the fender. Washer (2) and nut (1) to the eye bolt. End gate (4) and bushing (5) to the vehicle. Fender to end gate washer (7), and bolt (6). • Anti-rattle bumper must seat fully against vertical surface of tab (159). 1. 2. 3. 4. N ut S p rin g W a sh er C h a in A s s e m b ly End G ate 5. 6. 7. 159. 5 B u s h in g B o lt W asher A n ti-R a ttle B u m p e r F-02459 Figure 1—Fender Side End Gate Components FLEET SIDE MODELS END GATE REPLACEMENT 4- + Remove or Disconnect (Figure 2) Open the end gate and support it with a table or other suitable support. Link and striker plate (8) to fender bolts (17). Link and striker (8) from the end gate. • Rotate the link until it aligns with the tab (9) on the end gate, and pull it from the end gate. Hinge (14) to end gate bolts (13). End gate (12) from the vehicle. Inner hinge half (A). Hinge (14) to fender bolts (16). 7. Outer hinge half (B). 8. Bumper (10) to fender screws (11). 9. Bumpers (10) from the vehicle. Install or Connect (Figure 2) Bumpers (10) to the vehicle. Bumper (10) to fastener screws (11). Outer hinge half (B). Hinge (14) to fender bolts (16). Inner hinge half (A). End gate (12) to the vehicle. Hinge (14) to end gate bolts (13). 8 . Link and striker (8) to the end gate. • Place the slot on the link in line with the tab (9) on the end gate, and place the link onto the end gate. Pivot the link into its proper position. 9. Link and striker to the fender. 10. Link and striker to fender bolts (17). HANDLE AND LATCH REPLACEMENT Remove or Disconnect (Figure 3) Lower and support the end gate with a table or other suitable support. Latch rods (19) from the clips (20). End gate to handle bolts (22). Handle (21) from the end gate. Link from the end gate. • Refer to “ End Gate Replacement.” Latch (18) to end gate bolts (23). Latch (18) from the vehicle. Install or Connect (Figure 3) Latch (18) to the vehicle. Latch (18) to end gate bolts (23). END GATE 10A5-3 8. L in k A nd S trik e r Plate A s s e m b ly 9. Tab 10. B u m p e r 11. S crew 12. End G ate 13. B o lt 14. H in g e 16. B o lt 17. B o lt A. In n e r H in g e H a lf B. O u te r H ing e H a lf B-09023 Figure 2—Fleet Side End Gate Components 3. Link to the end gate. • Refer to “ End Gate Replacement.” 4. Handle (21) to the end gate. 5. End gate to handle bolts (22). 6. Latch rods (19) to the clips (20). 10A5-4 END GATE UTILITY VEHICLE MODELS 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. B o lt O u te r B ra cke t Torque Rod B o lt S ile n c e r In n e r B ra cke t S tu d Fram e N ut S ile n c e r B-09034 Figure 4—Utility Vehicle — Torque Rod END GATE REPLACEMENT |++| Remove or Disconnect (Figures 4, 5, and 6) • The end gate must be in the closed position. 1. Torque rod to frame stud (30) and nut (32). • Allow the torque rod to swing down. • Open the end gate, and support it with a table or other suitable support. 2. Electrical wiring harness (if equipped). Refer to “ End Gate Cover Replacement” for access to the harness. 3. Cable (34) to end gate opening bolts (37), spacers (36), and washers (35). END GATE 10A5-5 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. Cable W asher Spacer Bolt W asher Spring W asher Bolt Screw Guide B-09035 Figure 5—Cable Assembly Components Torque rod bracket bolts (24) and brackets (25). Hinge (49) to floor panel bolts (48) from the under side of the vehicle. End gate from the vehicle. • Lift the end gate from the body. • Guide the torque rods over the gravel deflectors to prevent damage. Install or Connect (Figures 4, 5, and 6) End gate to the vehicle. • Guide the torque rods over the gravel deflectors to prevent damage. • Insert the hinges into the floor panel slots. Hinge (49) to floor pan bolts (48) to the under side of the vehicle. Torque rod brackets (25) and bolts (24). Cable (34) to the end gate opening with bolts (37), spacers (36), and washers (35). Electrical wiring harness (if equipped). Refer to “ End Gate Cover Replacement” for access to the harness. Close the end gate. Torque rod to frame stud (30) and nut (32). Torque rods onto the studs. TORQUE ROD REPLACEMENT Remove or Disconnect (Figure 4) 1. 2. 3. 4. End gate. Refer to “ End Gate Replacement.” End gate cover. End gate to torque rod inner bracket bolts (27). Torque rod (26) with silencers (28) from the end gate. 10A5-6 END GATE Inner bracket (29) from the end gate. 1. 2. 3. 4. 5. |-n-| Install or Connect (Figure 7) Install or Connect (Figure 4) 1. End gate cover (50). Torque rod (26) with silencers (28) to the end gate. Inner bracket (29) to the torque rod. End gate to torque rod inner bracket bolts (27). End gate cover. End gate. Refer to “ End Gate Replacement.” 2. End gate cover screws (51). HANDLE AND CONTROL ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 8) HINGE REPLACEMENT Remove or Disconnect (Figure 6) • Lower the end gate. 1. Hinge to body bolts (48) for the hinge to be removed only. • Loosen the hinge to body bolts (48) on the opposite hinge. 2. Hinge to end gate bolts (47) 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 6) • Lift the end gate slightly and install the hinge to the ond gate. • Pull the end gate away from the body several inches, and insert the hinge into the body. 1. Hinge to end gate bolts (47). 2. Hinge to body bolts (48). • Tighten the hinge to body bolts on the opposite hinge. END GATE COVER REPLACEMENT Remove or Disconnect (Figure 7) 1. End gate cover screws (51). 2. End gate cover (50). 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). 9. Lockout rod (53) to end gate bolts (52). 0 10. Lockout rod (53) from the end gate. Install or Connect (Figure 8) Lockout rod (53) to the end gate. • The bottom of the rod must fit into the clip at the base of the end gate. 2. Lockout rod (53) to end gate bolts (52). 3. Window lockout rod spring (54). 4. Control assembly (55) to the end gate. 5. Control assembly to end gate bolts (60). 6 . R ight and left latch rods (65) from the control assembly. 7. Handle (61) to the end gate. 8 . Handle to end gate screws (62). 9. Control rod (64) to the handle (61). 10. End gate cover. END GATE 10A5-7 Figure 8—Handle and Control Assembly LATCH REPLACEMENT |-K-| Install or Connect (Figure 9) 1. Latch (66) with rod to the end gate. Remove or Disconnect (Figure 9) 1. End gate cover. 2. Latch (66) to end gate screws (67). 2. Right or left latch rod (65) from the control assembly. 3. Right or left latch rod (65) to the control assembly. 3. Latch (66) to end gate screws (6.7). 4. End gate cover. 4. Latch (66) from the end gate. Figure 9—Latch Components 10A5-8 END GATE 69. 70. 71. 72. 73. 74. 75. R e g u la to r B o lt Sash Rail B o lt Sash A s s e m b ly F ille r G la ss 75 B-09142 Figure 10—Regular and Sash Components REGULATOR REPLACEMENT MANUAL REGULATOR l+ +| Remove or Disconnect (Figure 10) 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 injury if the gear box is removed without locking the sector gears in place. 1. End gate cover. 2. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 3. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 4. Regulator (69) to end gate bolts (70). 4. Drill a 3.1 mm (Vs-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. 5. Regulator (69) from the end gate. 6. Regulator (76) to end gate bolts (78). I++J Install or Connect (Figure 10) 1. Regulator (69) to the end gate. 2. Regulator (69) to end gate bolts (70). 3. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 5. Drive cable (77) at regulator (76). 7. Regulator (76) from the end gate. 8. Gear assembly (80) to regulator bolts. 9. Gear assembly (80) from the regulator (76). Install or Connect (Figures 10 and 11) 1. Gear box (80) to the regulator (76). 4. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 2. Gear box (80) to regulator bolts. 5. End gate cover. 3. Regulator (76) to the end gate. POWER REGULATOR |++| Remove or Disconnect (Figures 10 and 11) 1. End gate cover. 2. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 3. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 4. Regulator (76) to end gate bolts (78). 5. Drive cable (77) to the regulator (76). • Remove the sheet metal screw. 6. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 7. Control assembly. Refer to “ Handle and Control Assembly Replacement.” 8. End gate cover. END GATE 10A5-9 76. 77. 78. 79. 80. R e g u la to r C a b le A s s e m b ly B o lt M o to r A s s e m b ly G e ar A s s e m b ly B-09143 Figure 11—Power Regulator Components WINDOW MOTOR AND BLOCKOUT SWITCH REPLACEMENT |<-+| Remove or Disconnect (Figure 12) 1. End gate panel. 2. Wiring harness from the motor and switch. 3. Cable from the motor. 4. End gate to motor bolts (103). 5. Motor (104) from the end gate. 6. Latch containing the blockout switch from the end gate. Refer to “ Latch Replacement.” 7. Blockout switch (106) to latch bolts (105). 8. Blockout switch (106) from the latch. + + Install or Connect (Figure 12) 1. Blockout switch (106) to the latch. 2. Blockout switch (106) to latch bolts (105). 3. Latch to the end gate. Refer to “ Latch Replacement.” 4. Motor (104) to the end gate. 5. End gate to motor bolts (103). 6. Cable to the motor. 7. Wiring harness to the motor and the switch. 8. End gate panel. 10A5-10 END GATE SASH ASSEMBLY REPLACEMENT Remove or Disconnect (Figure 10) 1. Window run channel caps (figure 13). 2. Inner and outer window glass seals. Refer to “ Window Glass Seal Replacement.” 3. End gate cover. • Regulate the window so that the sash channel bolts (72) are accessable. 4. Sash (73) to sash channel bolts (72). 85. 86. 87. 88. 89. 90. 91. Nut Bezel G asket H andle A ssem bly C lip Bezel Gasket 92. 93. 94. 95. 96. 97. 98. 5. Sash (73) with glass (75) from the end gate. 6. Sash rails (71) from the regulator (69). |“K “| Install or Connect (Figure 10) 1. Sash rails (71) to the regulator (69). 2. Sash (73) with glass (75) to the end gate. 3. Sash (73) to sash channel bolts (72). 4. End gate cover. Cover G asket Lock C ylinder Retainer C lutch Pawl Spring B-09058 Figure 14—Window Control Components END GATE 10A5-11 5. Inner and outer window glass seals. Refer to “ Window Glass Seal Replacement.” 6. Window run channel caps (figure 13). RUN CHANNEL REPLACEMENT -►«* Install or Connect (Figure 14) 1. Crank (88) and bezel (86) to the end gate. 2. Crank to end gate nuts (85). 3. Handle and control assembly. Refer to “ Handle And Control Assembly Replacement.” |++| Remove or Disconnect (Figure 13) 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. Install or Connect (Figure 13) 1. Run-channel (81) to the end gate. • Twist the channel into the window opening. 2. Run-channel (81) to end gate bolts (82). 3. Window run-channel caps (83). END GATE OUTSIDE CRANK REPLACEMENT Remove or Disconnect (Figure 14) 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. WINDOW GLASS SEAL REPLACEMENT Remove or Disconnect (Figure 15) • Lower the window. • Inner or outer seal by prying the clips from the end gate. Install or Connect (Figure 15) Inner or outer seal by pressing the clips into the holes in the end gate. WEATHERSTRIP REPLACEMENT |<-+| Remove or Disconnect (Figure 16) • Weatherstrip from the end gate using 3M Release Agent (or equivalent). Install or Connect (Figure 16) Weatherstrip to the end gate using 3M Weatherstrip Adhesive (or equivalent). 10A5-12 END GATE UTILITY VEHICLE REMOVABLE TOP 5. Side trim panel rear attaching screws. • Remove twelve screws on the left side. • Remove eleven screws on the right side. • Pull the panel away only far enough to gain access to the hidden top bolt. 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. 0 Figure 17—Removable Top—Access Plate Components REMOVABLE TOP REPLACEMENT B Remove or Disconnect (Figures 17 and 18) 1. • 2. 3. 4. Access plate (108) and dome lamp wiring harness. Lower the end gate. Top (111) to roof mounting bolts (110) and (114). Top (111) to side panel mounting bolts (113) and (112). Upper tire brace bolt and the upper brace. • Reinstall the brace after the top is removed. Install or Connect (Figures 17 and 18) To prevent damage to the top and to ensure proper weatherstrip sealing, the following procedure must be fol­ lowed. • 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). • Start with the bolts nearest the end gate, and work towards the cab. • Do not install the second bolt from the rear on the right side at this time. • Do not install the bolts (113) nearest the cab. • Loosen the top (111) to roof mounting bolts (114). 4. Top to side panel mounting bolts (113). 5. Top to roof mounting bolts (110) and (114). 6. Hidden bolts (115). 7. Trim panel screws to the right and left trim panels. 8. The upper spare tire brace with the remaining bolt. 9. Dome lamp wiring harness, and access plate (108). END GATE 10A5-13 Figure 18—Removable Top Components SUBURBAN MODELS END GATE REPLACEMENT |++| Remove or Disconnect (Figures 19, 20, and 21) • Lower the end gate. 1. Torque rod bracket (119). 2. Wiring harness (if equipped). Refer to “ End Gate Trim And Cover Panel Replacement” for access to the wiring harness. 3. Hinge access cover (131) and seal (132). 4. End gate to hinge bolts (133). • Lift the end gate to the almost closed position. 5. Support cable (136) to end gate bolt (142) and washer (143). 6. End gate with torque rod from the vehicle. -►+ Install or Connect (Figures 19, 20 and 21) 1. End gate with torque rod (117) to the vehicle. 2. Support cable (136) to end gate washer (143) and bolt (142). 3. End gate to hinge bolts (133). 4. Hinge cover seal (132) and access cover (131). 5. Wiring harness (if equipped). Refer to “ End Gate Trim And Cover Panel Replacement” for access to the wiring harness. 6. Torque rod bracket (119). TORQUE ROD REPLACEMENT |++| Remove or Disconnect (Figure 19) 1. 2. 3. 4. 5. 6. End gate. Refer to “ End Gate Replacement.” Trim panel (if equipped) and the cover panel. End gate to torque rod inner bracket bolts (126). End gate to torque rod outer bracket bolts (122). Inner (118) and outer (119) brackets from the end gate. Torque rod (117) from the end gate. Install or Connect (Figure 19) 1. 2. 3. 4. 5. 6. 7. Torque rod (117) to the end gate. Outer brackets (117) to the end gate. Outer bracket bolts (122). Inner bracket (118) to the end gate. Inner bracket bolts (126). The cover panel and trim panel (if equipped). End gate. Refer to “ End Gate Replacement.” HINGE REPLACEMENT Remove or Disconnect (Figure 20) • Lower the end gate. 1. Hinge to body bolts (134) for the hinge to be removed. • Loosen the hinge to body bolts (134) on the opposite hinge. 10A5-14 END GATE B-09077 Figure 19—Suburban—Torque Rod Components 128. 129. 130. 131. 132. 133. 134. 135. S trik e r W a sh er S crew C over Seal B o lt B o lt H in g e B-09078 Figure 20—Hinge Components Hinge cover screws (130) and covers (131). 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. ♦ 4- Install or Connect (Figure 20) Lift the end gate slightly and install the hinge to the end gate. Pull the end gate away from the body several inches, and insert the hinge into the body. 1. Hinge to end gate bolts (133). 2. Hinge to body bolts (134). • Tighten the hinge to body bolts on the opposite hinge. 3. Hinge covers (131) and cover screws (130). END GATE 10A5-15 136. 137. 138. 139. 140. 141. 142. 143. C able B o lt W a sh er S p rin g Plug W a sh er B o lt W a sh e r 142 B-09079 Figure 21—Cable Assembly Components Figure 22—Trim Panel Components 10A5-16 END GATE 146. 147. 148. 149. 150. 151. S crew C over B o lt C o n tro l A s s e m b ly L a tc h Rod Lever A s s e m b ly B-09081 Figure 23—End Gate Cover and Control Assembly Components END GATE TRIM AND COVER PANEL REPLACEMENT |++| Remove or Disconnect (Figures 22 and 23) 1. Trim panel screws (145). 2. Trim panel (144). • Slide the panel away from the glass opening. • Note the position of the cover panel screws. Five of the holes in the cover panel are also holes for the trim panel. 3. Cover panel screws (146). 4. Cover panel (147). Install or Connect (Figures 22 and 23) 1. 2. 3. 4. Cover panel (147). Cover panel screws (146). Trim panel (144). Trim panel screws (145). HANDLE AND CONTROL ASSEMBLY REPLACEMENT + + Remove or Disconnect (Figures 23 and 24) 1. Trim panel (if equipped) and the cover panel. 2. Control rod (154) from the handle (159). 3. Handle to end gate screws (161). 4. Handle (159) from the end gate. 5. Right and left latch rods (150) from the control assembly. 6. Control assembly to end gate bolts (148). 7. Control assembly (149) from the end gate. Install or Connect (Figures 23 and 24) 1. Control assembly (149) to the end gate. 2. Control assembly to end gate bolts (148). 3. Right and left latch rods (150) from the control assembly. 4. Handle (159) to the end gate. 5. Handle to end gate screws (161). 6. Control rod (154) to the handle (159). 7. End gate cover and trim panel (if equipped). LATCH REPLACEMENT [<"»| Remove or Disconnect (Figure 24) 1. Trim panel (if equipped) and the cover panel. 2. Right or left latch rods (150) from the control assembly. 3. Latch (153) to end gate screws (152). 4. Latch (153) from the end gate. END GATE 10A5-17 Figure 24—Handle and Latch Components |+<-| Install or Connect (Figure 24) 1. Latch (153) with rod to the end gate. 2. Latch (153) to end gate screws (152). 3. Right or left latch rod (150) to the control assembly. 4. Cover panel and trim panel (if equipped). REGULATOR REPLACEMENT MANUAL REGULATOR Remove or Disconnect (Figure 10) 1. Trim panel (if equipped) and cover panel. 2. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 3. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 4. Regulator (69) to end gate bolts (70). 5. Regulator (69) from the end gate. Install or Connect (Figure 10) 1. Regulator (69) to the end gate. 2. Regulator (69) to end gate bolts (70). 3. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 4. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 5. End gate cover and trim panel (if equipped). POWER REGULATOR Remove or Disconnect (Figures 10 and 11) 1. Trim panel (if equipped) and end gate cover. 2. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 3. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 4. Wiring harness from the motor. 5. Regulator (76) to end gate bolts (78). 6. Regulator (76) from the end gate. CAUTION: Step 7 must be performed if the gear box is removed or disengaged from the regulator lift arms. The lift arms are under tension from the counterbalance spring, and can cause injury if the gear box is removed without locking the sector gear in place. 7. Drill a 3.1 mm (Vs-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. 8. Motor to regulator bolts. 9. Motor from the regulator. Install or Connect (Figures 10 and 11) 1. Motor to the regulator. 2. Motor to regulator bolts. • Remove the sheet metal screw. 3. Regulator (76) to the end gate. 4. Regulator (76) to end gate bolts (78). 5. Wiring harness to the motor. 6. Sash assem bly (73). Refer to “ Sash Assem bly Replacement.” 7. Control assembly. Refer to “ Handle And Control Assembly Replacement.” 8. Trim panel (if equipped) and end gate cover. 10A5-18 END GATE RUN CHANNEL REPLACEMENT BLOCKOUT SWITCH REPLACEMENT |<-+| Remove or Disconnect (Figure 25) Remove or Disconnect • Completely lower the window. 1. Run-channel (156) to end gate bolts (155). 2. Run-channel (156) from the end gate. • Pull the channel from the end gate. Twist the channel to clear the window opening. 1. Trim panel (if equipped) and the end gate cover. 2. The rig h t la tch Replacement.” assem bly. R efer to “ Latch 3. Wiring harness from the switch. Install or Connect (Figure 25) 4. Switch from the latch. 1. Run-channel (156) to the end gate. • Twist the channel into the window opening. 2. Run-channel (156) to end gate bolts (155). -►+ Install or Connect 1. Switch to the latch. 2. Wiring harness to the switch. END GATE OUTSIDE CRANK REPLACEMENT 3. The right latch assembly to the end gate. Refer to “ Latch Replacement.” 4. End gate cover and trim panel (if equipped). |<“+| Remove or Disconnect (Figure 14) 1. Handle and control assembly. Refer to “ Handle And Control Assembly Replacement.” 2. Crank to end gate nuts (85). 3. Crank (88) and gasket (87) from the end gate. SASH ASSEMBLY REPLACEMENT 0 Remove or Disconnect (Figure 10) 1. Inner and outer window glass seals. Refer to “ Window Glass Seal Replacement.” 2. Trim panel (if equipped) and cover panel. • Regulate the window so that the sash channel bolts (72) are accessable. 3. Sash (73) to sash channel bolts (72). 4. Sash (73) with glass (75) from the end gate. 5. Sash rails (71) from the regulator (69). 0 M 1. 2. 3. 4. 5. Install or Connect (Figure 10) Sash rails (71) to the regulator (69). Sash (73) with glass (75) to the end gate. Sash (73) to sash channel bolts (72). End gate cover and trim panel. Inner and outer window glass seals. Refer to “ Window Glass Seal Replacement.” 0 Install or Connect (Figure 14) 1. Crank (88) and gasket (87) to the end gate. 2. Crank to end gate nuts (85). 3. Handle and control assembly. Refer to “ Handle And Control Assembly Replacement.” END GATE 10A5-19 WINDOW GLASS SEAL REPLACEMENT |++| Remove or Disconnect (Figure 15) • Lower the window. 1. Trim panel (if equipped). • The inner seal is attached to the trim panel, w hen e qu ip pe d , and re p la ce m e n t is not recommended. 2. Inner or outer seals by prying the clips from the end gate. rs Install or Connect (Figure 15) 1. Inner or outer seal by pressing the clips into the holes in the end gate. 2. Trim panel (if equipped). WEATHERSTRIP REPLACEMENT |<~+| Remove or Disconnect (Figure 26) 1. Weatherstrip screws (158). 2. Weatherstrip from the end gate using 3M Release Agent (or equivalent). Install or Connect (Figure 26) 1. Weatherstrip to the end gate using 3M Weatherstrip Adhesive (or equivalent). 2. Weatherstrip screws (158). Figure 26—Weatherstrip Components 10A5-20 END GATE SECTION PAGE A A/C Com ponents—G Series Accum ulator R eplacem ent........................................1B-50 Blower Motor R ep lace m e nt................................... ,.1B-54 Blower Switch R e p la ce m e n t................................... 1B-57 Condenser R eplacem ent..........................................1B-50 Control Assem bly R e p la c e m e n t............................ 1B-55 Defroster Duct R eplace m e nt................................... 1B-57 Ductwork R e p la ce m e n t............................................ 1B-57 Evaporator Core (Diesel) R eplacem ent................. 1B-53 Evaporator Core R eplacem ent.................................1B-53 Heater Core R ep lace m e nt....................................... 1B-51 Orifice Replacem ent...................................................1B-53 Refrigerant-12 Hose R o u tin g ................................... 1B-58 Relay R e p la ce m e n t...................................................1B-57 Resistor R e p la ce m e n t.............................................. 1B-57 Temperature Door Cable A d ju s tm e n t....................1B-55 Temperature Door Cable R eplacem ent................. 1B-57 Vacuum Lines— E n g in e ............................................ 1B-57 Vacuum Tank R eplacem ent..................................... 1B-57 A/C Components— R/V Series Accumulator Replacem ent........................................1B-35 Actuator-Plenum Side Vent Replacem ent............. 1B-37 Blower Assembly R eplacem ent...............................1B-35 Blower Switch R e p la ce m e n t................................... 1B-40 Condenser R eplacem ent..........................................1B-34 Control Assembly R e p la c e m e n t.............................1B-39 Evaporator Core R eplacem ent.................................1B-36 Fuse R eplacem ent.....................................................1B-43 Heater Core R eplacem ent........................................1B-36 Orifice Replacement...................................................1B-36 Plenum Valve Replacem ent..................................... 1B-37 Refrigerant-12 Hose R o u tin g ................................... 1B-43 Relay R e p la c e m e n t...................................................1B-41 Resistor R e p la c e m e n t.............................................. 1B-41 Selector Duct R eplacem ent..................................... 1B-36 Temperature Door Cable A d ju s tm e n t....................1B-40 Vacuum Line Replacement — D a s h ......................1B-43 Vacuum Line Replacement— E ngine......................1B-43 Vacuum Tank R eplacem ent..................................... 1B-41 A/C Charging Station M e th o d ..................................... 1B-26 A/C Compressor D iag no sis..........................................1B-27 A/C Compressor Replacement ( G ) ............................ 1B-30 A/C Compressor Replacement ( R / V ) ........................ 1B-29 A/C Condenser D iag no sis............................................1B-27 A/C Electrical/Vacuum Trouble D iag no sis..................1B-18 A/C Evacuation and Charging Procedures............... 1B-23 A/C Evaporator D ia g n o sis............................................1B-27 A/C Expansion Valve D ia g n o s is ................................. 1B-27 A/C Functional Test — R/V & G ................................... 1B-4 A/C Gage C alibration.....................................................1B-26 A/C Handling R efrigerant-12..........................................1B-9 A/C Handling Refrigerant Lines and F ittin g s ............. 1B-9 A/C M aintaining Chemical Stability...............................1B-9 A/C Periodic Maintenance and S e rvicin g ....................1B-4 A/C Pressure Sensing S w itc h ..................................... 1B-13 A/C “ Quick-Check” P ro c e d u re ................................... 1B-11 A/C Rear Interior Roof Mounted Systems (Suburban & G Series) D escription.......................... 1B-3 A/C Rear Roof Mounted System— G S eries............. 1B-63 A/C Refrigerant and Oil C a p a c ity ................................. 1B-9 A/C Refrigerant Drum M ethod..................................... 1B-26 SECTION PAGE A/C Refrigerant-11 Flushing Procedure......................1B-29 A/C Refrigerant-12 Operating C haracteristics............. 1B-9 A/C Refrigerant System D ia g n o s is .............................1 B -11 A/C Special Tools........................................................... 1B-67 A/C S p e cifica tio n s......................................................... 1B-65 A/C System Com ponents................................................ 1B-4 A/C System Description.................................................. 1B-3 A/C System— P Series A/C System Performance T e s t..................................... 1B-11 A/C System Operation — R/V & G ...............................1B-4 A/C Temperature and Pressure R ela tion ship s........... 1B-9 A/C Testing the Refrigerant System ............................ 1B-11 A/C Vacuum System C h e c k ....................................... 1B-26 A/C Vacuum System D iagnosis................................... 1B-23 Accelerator C ontrols.......................................................6C-16 Accelerator Control C a b le ............................................6C-16 Accelerator P e d a l........................................................... 6C-16 A/C Electrical C irc u its .................................................. 8A-48 Advance Pin Hole Plug Seal Replacement (D ie se l).............................................. 6C2-17 Advance Piston Replacement (D ie s e l)....................6C2-18 Advance Piston Seals Replacement (D ie s e l).........6C2-17 Air C le a n e r.........................................................................6C-2 AIR D iagnosis................................................................6E8-21 Air Filter Element R e p la c e m e n t................................... 6C-2 Air Injection Reaction (A IR ) ....................................... 6E8-19 Air Valve Link Adjustm ent (M4ME and M4MEF M od els).................................6C1-45 Air Valve Return Spring Adjustm ent (M4ME and M4MEF M o d e ls ).................................6C1-41 Aluminum R adiator.......................................................6B2-15 Anaerobic Gasket Eliminator, U s in g ............................ 6A-2 Auxiliary Cooling Fan R eplacem ent.......................... 6B1-14 Auxiliary Heater Components — G Blower Motor Replacement ......................................1A-25 Coolant-Control Valve R ep la ce m e n t......................1A-26 Heater Core R eplacem ent....................................... 1A-26 Resistor R e p la c e m e n t.............................................. 1A-26 Auxiliary Heater Components — R/V Blower Motor R e p la c e m e n t..................................... 1A-17 Blower Switch R eplacem ent..................................... 1A-17 Coolant-Control Valve Replacem ent........................ 1A-17 Heater Core R e p la c e m e n t....................................... 1A-17 Resistor R eplacem ent................................................ 1A-17 Axle Joint Component R e p la c e m e n t.......................... 4C-4 Axle Shaft Replacement, F ro n t......... .................. .4C-2 Axle Shaft, Oil Seal and Bearing Replacement (8 V2 and 9 1/2-inch Ring G e a r ) .................................4B1-9 Axle Shaft Replacement Full Floating Axle (9 3/4 and 101/2-inch Ring G ear)...............................4B1-14 Axle Shaft Replacement (12-inch Ring G e a r).........4B1-18 Axle Vent Replacement (12-inch Ring G e a r ) .........4B1-18 B Ball Joint, Lower, I.F.S.....................................................3C-17 Ball Joint, Upper, I.F.S.................................................... 3C-19 Ball Joints (V10/1500 and 20/2500 Models O n ly ).. .3C-48 Battery C a b le s .................................................................. 6 D-6 Battery Charging P ro ce d u re s........................................6D-5 Battery Description........................................................... 6D-2 Battery-General In fo rm a tio n ............... ..........................6D-3 Battery R eplacem ent.......................................... ......... 6 D -6 SECTION PAGE Bearing Adjustm ent Full Floating Axle (9 3/4 and 101/2-inch Ring G ear)...............................4B1-16 Bearing Adjustment (12-inch Ring G ear)................. 4B1-18 Bleeding, Hydraulic C lu tc h ............................................ 7C-9 Bleeding the Brake Hydraulic S y s te m ........................ 5A-5 Bleeding the Hydro-Boost System ...............................5A1-7 Blower and Air Inlet A s s e m b ly ..................................... 1A-2 Brake A d ju stm e n t......................................................... 5A2-10 Brake Backing Plate Replacement (8 V2 and 9 1/2-inch Ring G e a r ) ................................................ 4B1-11 Brake Caliper R ebuilding.............................................. 5A2-6 Brake Drum S e rvice .....................................................5A2-10 Brake Lining Replacement (Drum B rakes)............... 5A2-9 Brake Pedal A s s e m b ly ...................................................5A-13 Brake Pedal R e p la ce m e n t............................................ 5A-13 Brake Pedal Rod R e p la ce m e n t................................... 5A-15 Brake Pedal Travel C h e c k ............................................ 5A-13 Brake Pipes and H o s e s ...................................................5A-6 Brake System D ia g n o s is ................................................ 5A-2 Bumpers, G M o d e l......................................................... 2A-18 Bumpers, P M o d e l......................................................... 2A-15 Bumpers, R/V M o d e l....................................................... 2A-7 c Cab Mount R eplacem ent.............................................. 2B-18 Camshaft Lobe Lift, Measuring (4 .3 L )...........................................................................6A3-17 (Small B lo ck )..............................................................6A4-17 (7 .4 L )...........................................................................6A5-13 ( 4 .8 L )...........................................................................6A7-14 Camshaft Replacement (4 .3 L )...........................................................................6A3-17 (Small B lo ck)..............................................................6A4-17 (7.4 L ) ...........................................................................6A5-13 (6 .2 L ) ........................................................................... 6A6-14 ( 4 .8 L )........................................................................... 6A7-15 Carburetor Adjustm ent ( 1 M E F ) ................................. 6C1-17 Carburetor, 1 B B L ......................................................... 6C1-15 Carburetor Diagnosis, 1 B B L ........................................6C1-7 Carburetor, 4 B B L ....................................................... 6C1-37 Carburetor Diagnosis, 4 B B L..................................... 6C1-28 Carburetor Identification (M4ME and M4MEF M o d e ls)................................. 6C1-21 Carburetor Model 1 M E F .............................................. 6C1-2 Carburetor Models M4ME and M 4 M E F ..................6C1-21 Carburetor Mounting Torque (M4ME and M4MEF M odels)................................. 6C1-38 Carburetor Replacement (1 M E F ).............................6C1-17 Carburetor Replacement (M4ME and M4MEF) . . .6C1-38 Carburetor Special T o o ls ............................................ 6C1-48 Carburetor S p e c ific a tio n s ..........................................6C1-47 Carbureted Engine Fuel F ilte rs ..................................... 6C-2 Catalytic Converter R e p la ce m e n t................................. 6F-4 CDR Valve C heck........................................................... 6E9-4 CDR Valve R eplacem ent.............................................. 6E9-5 Charging System — C S -1 3 0 ........................................6D-12 Charging System — S I...................................................6D-10 Chassis E lectrical..............................................................8 B-1 Choke Checking Procedure (M4ME and M4MEF M odels).................................6C1-37 Choke Link and Fast Idle Cam Adjustment (M4ME and M4MEF M odels).................................6C1-42 SECTION PAGE Choke Stat Lever Adjustm ent (M3ME and M3MEF M od els)................................. 6C1-42 Circuit Check — Glow Plug S y s te m ...........................6D-16 Circuit D ia g n o s is ..............................................................8A-4 Circuit R e p a ir.................................................................... 8A-6 Clutch Assembly and Pilot B e a rin g .............................7C-11 Clutch D ia g n o s is ..............................................................7C-3 Clutch Inspe ction ..............................................................7C-2 Clutch L in k a g e .................................................................. 7C-7 Clutch Pedal Free Travel A d ju s tm e n t.......................... 7C-9 Clutch Pedal, M a n u a l.....................................................7C-4 Clutch Pedal, H ydraulic...................................................7C-4 Clutch S p e c ific a tio n s ..................................................... 7C-15 Coil Springs, I.F.S.............................................................3C-17 Combination V a lv e ........................................................... 5A-7 Compression Check Diesel E n g in e ..............................................................6A-10 Gasoline E n g in e ............................................................6A-5 Connecting Rod and Piston Replacement (4.3 L)........................................................................... 6A3-20 (Small B lo ck).............................................................. 6A4-19 (7.4 L ) ........................................................................... 6A5-15 (6 .2 L )........................................................................... 6A6-21 (4 .8 L ) ........................................................................... 6A7-16 Control Arm, Lower, I.F.S............................ ................3C-24 Control Arm, Upper, I.F .S ............................................. 3C-25 Control Arm Pivot Shaft and Bushings, Lower, I.F.S.3C-20 Control Arm Pivot Shaft and Bushings, Upper, I.F.S.3C-23 Coolant Level Indicator D iagnosis............................... 6B1-3 Coolant Recovery S y s te m ...................... ................6B2-14 Coolant Recovery Tank R eplace m e nt........................ 6B1-6 Cooling System Capacities— Blazer/Jimmy, S u b u rb a n ............................................ OB-2 Cooling System Capacities— Forward C o n tr o l............................................................0B-3 Cooling System Capacities — G V a n ...........................OB-5 Cooling System Capacities — Pickup M o d e ls ........... OB-4 Cooling System D iagnosis............................................ 6B1-5 Cowl Vent Grille Replacement (G M o d e l)..................2B-15 Cowl Vent Grille Replacement (R/V M o d e l)................2B-4 Crankcase Ventilation System (6.2L D iesel)............. 6E9-4 Cranking C irc u it.............................................................. 6D-22 Cranking Speed Check (6 .2 L )......................................6A-10 Cranking System D escription........................................6D-19 Cranking System M ainten an ce ................................... 6D-27 Crankshaft Gear Replacement (4.8L)........................ 6A7-19 Crankshaft Replacement (4.3 L)........................................................................... 6A3-23 (Small Block).............................................................. 6A4-22 (7.4 L ) ........................................................................... 6A5-18 (6.2L)........................................................................... 6A6-24 (4.8 L ) ........................................................................... 6A7-20 Cross Lever, C lu tc h ..........................................................7C-8 Current Drain T e s t............................................................6D-5 Cylinder Head Replacement (4 .3 L )........................................................................... 6A3-12 (Small B lo c k )..............................................................6A4-12 (7.4 L ) ............................................................................. 6A5-7 (6.2 L)............................................................................. 6A6-9 (4 .8 L )............................................................................. 6A7-9 SECTION PAGE D Deaeration Tank Replacem ent..................................... 6B1-6 Detent Switch (THM 400).............................................. 7A-67 Diagnosis , AIR ...............................................................................6E8-21 Battery.............................................................................6D-4 Carburetor, 1 B B L .......................................................6C1-7 Carburetor, 4 B B L.....................................................6C1-28 C irc u it.............................................................................8A-4 C lu tc h .............................................................................7C-3 C o o lin g ........................................................................ 6B1-2 Diesel E n g in e ................................................................6A-8 Door L o c k .................................................................... 8A-23 D riv e lin e ........................................................................ 4A-3 E E C S .......................................................................... 6E8-17 E F E .............................................................................6E8-35 EGR.............................................................................6E8-33 Front A x le ...................................................................... 4C-2 Front Side M arker.......................................................8B-10 Front S uspension......................................................... 3C-2 Fuel G a g e ...................................................................... 8C-4 Fuel Tank Selector V a lv e ..........................................6C-13 Gas E n gin e ....................................................................6A-2 Glow Plug Electrical S y s te m ................................... 6D-16 H e a d la m p ...................................................................... 8B-6 Heater Circuit D ia g n o s is ............................................1A-8 Heater S y s te m ............................................................. 1A-9 Hydraulic L ifte rs ........................................................... 6A-6 Ignition System ........................................................... 6D-36 Insufficient Heat D ia g n o s is ....................................... 1A-5 Marker L a m p ............................................................... 8B-10 Manual S tee rin g ......................................................... 3B2-2 Oil Pressure G a g e .......................................................8C-5 Parking L a m p s ............................................................. 8B-8 P C V .............................................................................6E8-39 Power S tee rin g ........................................................... 3B3-5 Power W in d o w ........................................................... 8A-24 Rear A x le ....................................................................4B1-2 Rear Lighting S ystem s.............................................. 8B-17 Spark P lu g s ............................................................... 6D-39 S p e e d o m e te r................................................................8C-3 Steering C olum n......................................................... 3B4-2 Steering Linkage......................................................... 3B1-2 Temperature G a g e .......................................................8C-6 THERMAC..................................................................6E8-41 T h e rm o s ta t..................................................................6B1-3 Torque C o n ve rte r........................................................ 4C-11 Torque Converter C lutch ............................................7A-12 Transmission, Automatic.............................................. 7A-6 Transmission, M anual.................................................. 7B-2 Transmission, THM 400 ............................................7A-16 Transmission, THM 700 R -4..................................... 7A-35 T R C .............................................................................6E8-43 Vacuum P u m p ............................................................. 6H-1 “ Water In Fuel” Light.................................................. 6C-3 Wheels and T ire s ......................................................... 3E-3 Wheel B e a rin g s ........................................................... 3C-3 Windshield Washer.....................................................8A-35 Windshield W ip e r................................... ................... 8A-26 W iper D e la y ............................................................... 8A-38 Diesel Engine D ia g n o sis................................................ 6A-8 Diesel Fuel F ilte rs ........................................................... 6C-3 SECTION PAGE Diesel Fuel Filter Assembly Component Replacement..................................................................6C-5 Diesel Fuel Filter R eplacem ent..................................... 6C-4 Diesel Fuel Injection Special T oo ls.......................... 6C2-21 Diesel Fuel Injection S p e c ific a tio n s ........................ 6C2-20 Diesel Fuel System C ontam ination...............................6C-8 Diesel Glow Plug Electrical System D e s c rip tio n ..................................................................6D-15 Diesel Idle Speed A djustm ent..................................... 6C2-2 Diesel Throttle Position Switch Adjustment (LH6 Engine With 700 R4 T ra n sm ission )............. 6C2-3 Differential C a p a c itie s .....................................................0B-1 Dipstick Tube Replacement (6.2L)............................ 6A6-16 Disc Brakes...................................................................... 5A2-1 Disc Brake Lining In spection....................................... 5A2-1 Disc Brake Lining R e p la c e m e n t.................................5A2-2 D istributor........................................................................ 6D-33 Distributor R e p la c e m e n t.............................................. 6D-41 Distributor/Timing System for TBI-Equipped V e h ic le s ...................................................................... 6D-36 Doors (G Model Front) Door and Hinge R ep lace m e nt............................ 10A1-32 Outside Handle R e p la c e m e n t............................ 10A1-40 Lock R e p la c e m e n t................................................ 10A1-39 Power Lock R eplacem ent..................................... 10A1-40 Trim Panel R eplacem ent........................................10A1-33 Vent R e p la c e m e n t................................................ 10A1-35 Window Regulator R e p la ce m e n t........................ 10A1-38 Window R eplacem ent............................................10A1-36 Doors (G Model Intermediate) Door and Hinge R ep la ce m e n t............................ 10A1-42 Lock R e p la c e m e n t................................................ 10A1-46 Power Lock R eplacem ent..................................... 10A1-50 Trim P a n e l................................................................10A1-44 Window R eplacem ent............................................10A1-45 Doors (G Model Rear) Door and Hinge R e p la ce m e n t............................ 10A1-63 Lock R eplacem ent...................................................10A1-70 Outside Handle R eplacem ent...............................10A1-70 Power Lock R eplacem ent..................................... 10A1-72 Trim Panel R eplacem ent........................................10A1-64 Window R eplacem ent............................................10A1-66 Doors (G Model Sliding) Door and Hinge R ep la ce m e n t............................ 10A1-53 Lock R e p la c e m e n t................................................ 10A1-59 Trim Panel R eplacem ent....................................... 10A1-58 Window R eplacem ent...........................................'10A1-58 Doors (RV Model F ro n t).............................................. 10A1-4 Door and Hinge R eplacem ent...............................10A1-4 Trim Panel Replacement..........................................10A1-4 Vent/Window R e p la c e m e n t................................... 10A1-5 Lock Replacement.................................................. 10A1-10 Outside Rear View Mirror Replacement............. 10A1-13 Power Lock Motor R eplacem ent.......................... 10A1-10 Window Regulator R ep lace m e nt.......................... 10A1-9 Doors (RV Model Side Rear) Door and Hinge R e p la c e m e n t.............................10A1-14 Lock R e p la c e m e n t................................................ 10A1-20 Power Lock R eplacem ent..................................... 10A1-20 Trim Panel R eplacem ent....................................... 10A1-16 Window Regulator R e p la c e m e n t........................ 10A1-19 Window R ep lace m e nt............................................10A1-17 Doors (RV Model Rear) Door and Hinge R e p la ce m e n t........................ .. .10A1-23 SECTION PAGE Trim Panel Replacem ent....................................... 10A1-25 W indow R eplacem ent............................................10A1-25 Draining the Diesel Engine Fuel F ilte r........................ 6C-3 Draining the Fuel Tank.....................................................6C-7 Drivability S ym p to m s.....................................................6E8-8 Drive Belt R e p la ce m e n t.............................................. 6B1-10 Drive Pinion Oil Seal Replacement (12-Inch Ring G ear).................................................. 4B1-19 Drive Shaft Seal Replacement (Diesel)....................6C2-19 Drum Brakes.................................................................... 5A2-9 E Early Fuel Evaporation (E F E )................................... 6E8-35 EECS D ia g n o sis........................................................... 6E8-17 EFE D ioa gn osis........................................................... 6E8-35 EGR D iagnosis..............................................................6E8-33 EGR System Check (6.2L D ie s e l)...............................6E9-6 EGR Valve Replacement (6.2L D ie s e l)...................... 6E9-7 Electric Choke (1 M E F ) .............................................. 6C1-15 Electrical C irc u its ..............................................................8A-2 Electrical Systems, C a b ................................................... 8A-9 Electrical Tests — G e ne ra to r....................................... 6D-10 Emissions, Carb...............................................................6E8-2 Emissions Components, Carb...................................... 6E8-5 End Gate Fender Side M o d e ls ........... .....................................10A5-2 Fleet Side M odels.....................................................10A5-2 Suburban M o d e ls ............. .....................................10A5-13 Utility Vehicle M odels.............................................. 10A5-4 Engine Block H e a te rs ...................................................8D-28 Engine Code Identification.............................................. OB-1 Engine Crankcase Capacities— Blazer/Jimmy, S u b u rb a n ....................................... .. .0B-2 Engine Crankcase Capacities — Forward C o n tr o l........................................................... OB-3 Engine Crankcase Capacities — G V a n ............................................................................. OB-5 Engine Crankcase Capacities — Pickup M o d e ls ..............................................................OB-4 Engine Electrical System ................................................ 6D-2 Engine Electrical System Specifications....................6D-77 Engine Emission Classification VIN C o d e ..................OB-8 Engine Gaskets, R e p la cin g ............................................6A-2 Engine Lubrication (4.3L)............................................................................. 6A3-2 (Small Block)................................................................6A4-2 (7.4 L ) ............................................................................. 6A5-3 (6.2 L)............................................................................. 6A6-2 (4 .8 L )............................................................................. 6A7-2 Engine Replacement (4.3 L)............................................ .............................. 6A3-24 (Small Block)..............................................................6A4-23 (7.4 L ) ...........................................................................6A5-22 (6.2 L)...........................................................................6A6-28 (4 .8 L )...........................................................................6A7-21 Engine Mountings (4 .3 L )...........................................................................6A3-23 (Small Block)............................................................. 6A4-22 (7.4 L ) ...........................................................................6A5-19 (6.2 L)...........................................................................6A6-25 (4 .8 L )...........................................................................6A7-21 Engine Wire Harness.....................................................6D-52 SECTION PAGE Engines with T B I ............................................................6D-33 EPR Vacuum Actuator R eplacem ent.......................... 6E9-7 EPR/EGR Solenoid R eplacem ent............................... 6E9-7 Evaporator Emissions Control System (EEC S).........................................................................6E8-16 Exhaust Gas Recirculation (EGR).............................6E8-32 Exhaust Gas Recirculation System (6.2L D ie s e l)................................................................ 6E9-5 Exhaust Inspection........................................................... 6F-2 Exhaust Manifold Replacement (4 .3 L )........................................................................... 6A3-11 (Small B lo ck)..............................................................6A4-10 (6.2 L)............................................................................. 6A6-3 (7 .4 L )............................................................................. 6A5-7 Exhaust Parts, Installing...................................................6F-2 Exhaust S pecifications...................................................6F-10 Exhaust System D ia g n o s is ............................................ 6F-2 F Fan and Fan Clutch R eplacem ent.............................6B1-13 Fan Clutch D iagnosis..................................................... 6B1-2 Fan Shroud R e p lace m e nt............................................ 6B2-6 Float Adjustment (M4ME and M4MEF M o d e ls ). . .6C1-40 Float Level-External Check (M4ME and M4MEF M odels)................................. 6C1-37 Fluids and L u b ric a n ts ...................................................OB-24 Flushing the Brake Hydraulic S ystem .......................... 5A-6 Flushing the Cooling System ........................................6B1-6 Flywheel Replacement (4.3 L)........................................................................... 6A3-23 (Small Block)..............................................................6A4-22 (7.4 L ) ...........................................................................6A5-18 (4 .8 L )........................................................................... 6A7-20 Frame A lig n m e n t..............................................................2A-4 Frame D ia g n o s is ..............................................................2A-2 Frame Straightening......................................................... 2A-5 Front Axle Assembly Replacem ent............................... 4C-3 Front Axle Capacities — Blazer/Jimmy, S u b u rb a n ............................................ OB-2 Front Axle Capacities — Pickup M o d e ls ....................OB-4 Front Axle D ia g n o sis....................................................... 4C-2 Front Axle, I-B eam ......................................................... 3C-34 Front Axle Specifications.................................................4C-8 Front Cover Replacement (4 .3 L )........................................................................... 6A3-14 (Small B lo ck)..............................................................6A4-14 (7 .4 L )........................................................................... 6A4-14 (6 .2 L )........................................................................... 6A6-13 (4.8L)............................................................................. 6A7-11 Front End A lig n m e n t....................................................... 3A-2 Front End Alignment R e q u ire m e n ts.............................3A-3 Front End Alignment S p e c ific a tio n s .............................3A-6 Front End Panel Replacement (G M o d e l)..................2B-17 Front End Sheet Metal Cross Panel Replacement (G M odel).......................................................................2B-17 Front Fender Replacement (R/V M odel)...................... 2B-6 Front Suspension, D ia g n o s is ........................................3C-2 Front Suspension, S p e c ific a tio n s............................... 3C-51 Fuel Filter R e p la c e m e n t.................................................6C-2 Fuel Filter Replacement (M4ME and M4MEF M od els)................................. 6C1-38 Fuel Gage D iagnosis....................................................... 8C-4 SECTION PAGE Fuel Gage R ep lace m e nt................................................ 8C-9 Fuel Gage Sending U n i t .............................................. 6C-13 Fuel Gage Sending Unit R eplacem ent...................... 6C-13 Fuel L in e s .........................................................................6C-10 Fuel Pump Replacem ent................................................ 6C-6 Fuel Pump Tests (Carbureted E n g in e )........................ 6C-5 Fuel Pump Tests (Diesel E n g in e )................................. 6C-5 Fuel System Cleaning (Carbureted E ngine)............... 6C-8 Fuel System Cleaning (Diesel E n g in e )........................ 6C-9 Fuel System S p e c ific a tio n s ..........................................6C-17 Fuel T a n k ...........................................................................6C-7 Fuel Tank Capacities — Blazer/Jimmy, S u b u rb a n ............................................ OB-2 Fuel Tank Capacities — Forward C o n tro l....................0B-3 Fuel Tank Capacities — G V a n ........................ .............0B-5 Fuel Tank Capacities — Pickup M o d e ls ...................... 0B-4 Fuel Tank Filler N e c k .....................................................6C-10 Fuel Tank Leak T e s t....................................................... 6C-10 Fuel Tank P u rg in g ........................................................... 6C-9 Fuel Tank R eplacem ent................................................ 6C-10 Fuel Tank Selector V a lv e .............................................. 6C-13 Fuel Tank Selector Valve Replacem ent...................... 6C-13 Full Floating Axle (93/4 and 101/2-inch Ring G e a r).............................................. 4B1-14 Full Floating Axle (12-inch Ring A x le )...................... 4B1-18 Fuse Block R V ................................................................................. 8A-14 V an................................................................................. 8A-17 G G a ge s................................................................................. 8C-9 Gasoline Engine Mechanical D ia g n o sis...................... 6A-2 Generator R eplacem ent................................................ 6D-14 Glow Plug A fte rsta rt.......................................................6D-19 Glow Plug Inhibit S w itc h .............................................. 6D-16 Glow Plug S y s te m ..................................... ................... 6D-19 Governor, Automatic T ra n sm issio n .............................7A-68 Grille and Molding Replacement (R/V M o d e l)........... 2B-5 Grille Replacement (G M o d e l)..................................... 2B-15 H H e a d la m p ...........................................................................8B-7 Headlamp D ia g n o s is .......................................................8B-6 Heater Electrical C ircu its.............................................. 8A-48 Heating Components — G Cable A djustm ent.......................................................1A-22 Control Assembly R e p la c e m e n t............................ 1A-22 Control Cable R eplacem ent..................................... 1A-22 Blower Motor R e p la ce m e n t..................................... 1A-18 Blower Switch R e p la ce m e n t................................... 1A-22 Distributor and Defroster Duct R eplacem ent................................................................1A-21 Heater Core R e p la ce m e n t........................................1A-19 Heater Distributor Case R eplacem ent....................1A-21 Heater Hose R o u tin g ................................................ 1A-18 Resistor R ep la ce m e n t.............................................. 1A-22 Vent R ep lace m e nt.....................................................1A-22 Heating Components — R/V Blower Motor R e p la ce m e n t..................................... 1A-10 Blower Switch R eplacem ent..................................... 1A-14 Cable A d ju stm e n t.......................................................1A-14 SECTION PAGE Control Assembly R eplacem ent...............................1A-11 Control Cable R eplacem ent..................................... 1A-12 Heater Distributor Case and Core R e p la c e m e n t.....................................................1A-10 Heater Hose R o u tin g ................................................ 1A-10 Resistor R eplacem ent................................................ 1A-14 Vent R e p la c e m e n t.....................................................1A-14 Height Sensing Brake Proportioning Valve..................5A-9 Hood Hinge Replacement (R/V M odel)........................ 2B-2 Hood Hinge Replacement (G M o d e l) ........................ 2B-13 Hood Ornament Replacement (R/V M o d e l)............... 2B-4 Hood Release Cable Replacement (R/V M odel).................................................................... 2B-3 Hood Release Cable Replacement (G Model)...................................................................... 2B-15 Hood Replacement (G M o d e l)..................................... 2B-13 Hood Replacement (R/V M o d e l)................................... 2B-2 Housing Pressure Cold Advance (Diesel)................. 6C2-4 Hub and Drum Assembly Replacement Full Floating Axle (93/4 and 101/2~inch Ring G e a r ) ....................4B1-14 Hydraulic Brake B o o s te r.............................................. 5A1-4 Hydraulic Head Seal Replacement (D ie s e l)........... 6C2-18 Hydraulic Lifters D ia g n o s is ............................................ 6A-6 Hydraulic Lifter Replacement (4.3L)............................................................................. 6A3-9 (Small Block)................................................................6A4-9 (7.4 L ) ............................................................................. 6A5-6 (6.2L)................................. ........................................... 6A6-6 (4 .8 L )............................................................................. 6A7-6 Hydro-Boost R eplacem ent............................................ 5A1-4 Hydro-Boost System D ia g n o s is ................................... 5A1-1 Hydro-Boost System Tests............................................ 5A1-2 Hydrometer Test................................................................ 6D-4 I Idle Mixture Adjustment (Heavy-Duty Emissions Vehicle Only) M4ME and M4MEF M o d e ls .........6C1-39 Idle Speed Adjustm ent (M4ME and M4MEF M od els)................................. 6C1-40 Idle Solenoid (1 M EF)...................................................6C1-16 Idle Stop S o le n o id ....................................................... 6C1-37 Idler Arm Adjustment (P30(32) M otorhom e)............. 3B1-2 Idler Arm Inspection....................................................... 3B1-2 Idler Arm R e p la c e m e n t................................................ 3B1-3 Ignition System for Carbureted E ngine......................6D-36 Ignition System Service P re c a u tio n s ........................ 6D-40 Ignition S w itc h ................................................................8C-16 Ignition Switch Replacement (R, V, G M o d e ls ).. . .3B4-18 Ignition T im in g ................................................................6D-41 Injection Line Replacement (D iesel).......................... 6C2-4 Injection Nozzles (Diesel)............................................ 6C2-10 Injection Nozzle Replacement (D ie s e l)....................6C2-10 Injection Nozzle Tests (D iesel)................................... 6C2-10 Injection Pump Off-Vehicle Service (D ie sel)........... 6C2-17 Injection Pump On-Vehicle Service (D ie sel)........... 6C2-10 Injection Pump Replacement (Diesel)........................ 6C2-5 Injection Timing Adjustm ent (D ie s e l)........................ 6C2-8 Instrument C lu s te r......................................................... 8C-15 Intake and Exhaust Manifold Replacement (4.8L) . .6A7-7 Intake Manifold Replacement (4 .3 L ).............................................................................6A3-7 (Small Block)................................................................6A4-8 SECTION PAGE (6.2L).............................................................................6A6-3 (7.4 L).............................................................................6A5-5 Interior Trim G M odels..................................................................10A4-18 R/V M o d e ls ............................................................... 10A4-1 Suburban M o d e l.....................................................10A4-13 L Lamp S w itch ....................................................................8C-16 Leaf Spring and Bushings, 4 W.D............................... 3C-49 Leaf Spring Assembly R eplacem ent............................ 3D-9 Leaf Spring Eye Bushing R e p la ce m e n t....................3D-10 Leaf Springs, I-Beam .....................................................3C-34 License Plate Bracket R ep la ce m e n t.......................... 2A-13 Load Test — B a tte ry .......................................................6D-4 Locking Hub Rebuild Procedure, M anual....................4C-8 Locking Hub Component R ep la ce m e n t......................4C-4 Locking Hub Replacement, M a n u a l............................ 4C-7 Locking Hub to the Wheel Adjustment, A u to m a tic.. .4C-7 Lubrication Points— Conventional, Forward Control M o d e ls ............................................................. OB-6 Lubrication Points— Four Wheel Drive M odels...........0B-6 Lubrication Points— G Van..............................................0B-7 M Main Bearing Replacement (4.3L).......................................................................... 6A3-22 (Small Block)............................................................. 6A4-21 (7.4 L ) .......................................................................... 6A5-17 (6.2L).......................................................................... 6A6-22 (4 .8 L ).......................................................................... 6A7-18 Maintenance Schedules.................................................. 0B-7 Manual Steering Gear M aintenance.......................... 3B2-3 Manual Steering Gear S p ecifica tion s........................ 3B2-7 Manual Steering System D ia g n o s is .......................... 3B2-2 Marker Lam p.................................................................... 8B-11 Marker Lamp D iagnosis................................................ 8B-10 Marking TDC on the Front Housing (D ie s e l)...........6C2-8 Master Cylinder and Reservoir, C lu tc h ........................ 7C-5 Master C y lin d e rs ........................................................... 5A-24 Master Cylinder Bench Bleeding.................................5A-26 Master Cylinder R eplacem ent..................................... 5A-24 Minimum-Maximum Governor Replacement (Diesel Fuel Injection)..............................................6C2-13 o Oil Filter Bypass Valve Replacement (4.3 L).......................................................................... 6A3-23 (Small Block)............................................................. 6A4-20 (7.4 L ) .......................................................................... 6A5-18 (6.2L).......................................................................... 6A6-24 (4 .8 L ).......................................................................... 6A7-20 Oil Pan Replacement (4 .3 L ).......................................................................... 6A3-15 (Small B lock)............................................................. 6A4-14 (7.4 L ) .......................................................................... 6A5-10 (6 .2 L ).......................................................................... 6A6-17 (4 .8 L ).......................................................................... 6A7-12 Oil Pressure Gage D ia g n o s is ....................................... 8C-5 Oil Pressure Gage R eplacem ent.................................8C-13 SECTION PAGE Oil Pressure Gage S ensor............................................ 8C-14 Oil Pump Drive Replacement (6 .2 L )........................ 6A6-12 Oil Pump Replacement (4 .3 L )...........................................................................6A3-16 (Small B lo c k )............................................................. 6A4-15 (7.4 L).............................................................................6A5-11 (6 .2 L )...........................................................................6A6-18 ( 4 .8 L )...........................................................................6A7-12 P Parking Brake A d justm e nt............................................ 5A-22 Parking Brake Cable R e p la ce m e n t............................ 5A-18 Parking Brake Pedal or Handle R eplacem ent........... 5A-17 Parking Brake S y s te m ...................................................5A-17 Parking L a m p .................................................................... 8B-9 Parking Lamp D ia g n o s is................................................ 8 B -8 PCV D iagnosis............................................................. 6E8-39 Pinion Flange, Dust Deflector/Oil Seal Replacement (8 V2 and 9 1/2-inch Ring Gear).................................4B1-12 Pinion Oil Seal/Companion Flange Replacement Full Floating Axle (9 3/4 and 101/2-inch Ring G e a r ) .............................................. 4B1-17 Pitman Arm R ep lace m e nt............................................3B1-5 Pitman Shaft Seal R eplacem ent.................................3B2-5 Positive Crankcase Ventilation (P C V )......................6E8-39 Power Door L o c k ........................................................... 8A-24 Power Lock D ia g n o sis.................................................. 8A-23 Power Steering D iag no sis............................................3B3-5 Power Steering F lu s h .................................................. 3B3-12 Power Steering G e a r .................................................. 3B3-13 Power Steering Gear Adjustm ents............................ 3B3-17 Power Steering Pum p.................................................. 3B3-19 Power Steering System B le e d in g .............................3B3-12 Power Steering System T e s t........................................3B3-8 Power W in d o w ................................................................8A-26 Power Window D ia g n o s is ............................................ 8A-24 Pressure Testing the Injection Pump ( D ie s e l)...................................................................... 6C2-19 Primary Hood Latch Replacement (G M odel)...........2B-13 Primary Hood Latch Replacement (R/V M od el).........2B-2 Primary Side Vacuum Break Adjustm ent (M4ME and M4MEF M odels)................................. 6C1-42 Propeller S h a ft.................................................................. 4A-1 Propeller Shaft Balance C h e c k ..................................... 4A-5 Propeller Shaft Brake R e p la ce m e n t.......................... 5A-22 Propeller Shaft Replacement (Front D rive)..................4A-7 Propeller Shaft Replacement (Rear D riv e )..................4A-6 Propeller Shaft Runout C heck....................................... 4A-5 Pump Adjustm ent (M4ME and M4MEF Models) . .6C1-41 Pump Cover Seal and/or Guide Stud Seal Replacement (Diesel Fuel In je c tio n )....................6C2-12 Pushrod Cover Replacement (4.8L).............................6A7-6 R Radiator Support Replacement (R/V M odel)............. 2B-10 Rear Axle Assembly Replacement (All A x le s ) .........4B1-8 Rear Axle Diagnosis....................................................... 4B1-2 Rear Axle S p e cifica tio n s............................................ 4B1-20 Rear Crankshaft Seal Retainer Replacement (4 .3 L )........................................................................ 76A3-16 (Small B lo ck)............................................................. 6A4-16 SECTION PAGE Rear Crankshaft Oil Seal Replacement (4.3L) . . . .................................................................... 6A3-16 (Small B lo ck)..............................................................6A4-15 (7.4 L)............................................................................. 6A5-11 (6 .2 L )...........................................................................6A6-18 (4 .8 L )...........................................................................6A7-13 Rear Extension Oil Seal, Automatic Transm ission................................................................7A-73 Rear Fender Replacement (R/V M o d e l)...................... 2B-8 Rear Lighting S e rv ic e ...................................................8B-21 Rear Lighting D iagnosis................................................ 8B-17 Rear Lighting System s...................................................8B-11 Rear Oil Seal, Manual Transm ission.............................7B-3 Rear Suspension S p e cifica tio n s................................. 3D-12 Relay Rod R ep la ce m e n t.............................................. 3B1-4 Road Testing the B ra k e s.................................................5A-2 Rocker Arm and Pushrod Replacement (4.3 L)............................................................................. 6A3-5 (Small Block)................................................................6A4-5 (7.4 L ) ............................................................................. 6A5-3 (4 .8 L )............................................................................. 6A7-4 Rocker Arm Cover Replacement (4.3L)............................................................................. 6A3-5 (Small Block)................................................................6A4-5 (7.4 L ) ............................................................................. 6A5-3 (6.2L)............................................................................. 6A6-4 (4 .8 L )............................................................................. 6A7-4 Rocker Arm, Shaft, and Pushrod Replacement (6 .2 L )...................................................6A6-4 Rocker Arm Stud Replacement (4 .3 L )...........................................................................6A3-10 (Small B lko ck)........................................................... 6A4-10 (7.4 L ) ............................................................................. 6A5-7 (4 .8 L )............................................................................. 6A7-8 Rotor Servicing................................................................5A2-6 RTV Sealer, U s in g ........................................................... 6A-2 s Seat Adjuster Diagnosis.............................................. 10A2-2 Seat B e lts ...................................................................... 10A2-7 Seats G Model Center and R e a r................................... 10A2-26 G Model F ront......................................................... 10A2-23 RV Model Front......................................................... 10A2-3 RV Model R e a r....................................................... 10A2-13 Suburban Model C enter..........................................10A2-8 Secondary Hood Latch and Spring Replacement (G Model)...................................................................... 2B-14 Secondary Hood Latch and Spring Replacement (RV M o d e l).................................................................... 2B-3 Secondary (Slave) Cylinder and Hydraulic Line, C lutch.................................................................... 7C-6 Secondary Side Vacuum Break Adjustment (M4ME and M4MEF M odels)................................. 6C1-44 Secondary Throttle Lockout Adjustment (M4ME and M4MEF M odels)................................. 6C1-46 Selector Valve D ia g n o sis.............................................. 6C-13 Servo, 2-4 (THM 7 00-R 4).............................................. 7A-71 Semi Floating Rear Axle (8 V2 and 9 1/a Ring G e a r)........................................................... 4B1-9 Sheet Metal Adjustments (R/V M odel)........................ 2B-11 Sheet Metal Unit Replacement (R/V M o d e l)............. 2B-11 SECTION PAGE Sheet Metal Vertical Support Replacement (G M o d e l)............................................ 2B-17 Shift Control, Manual Transmission...............................7B-7 Shift Linkage Adjustment, Manual T ransm ission...................................................7B-6 Shift Linkage, Automatic T ransm ission...................... 7A-63 Shift Linkage, Manual T ransm ission.............................7B-5 Shock Absorber Bench T e s t..........................................3C-3 Shock Absorber, I-B e a m .............................................. 3C-28 Shock Absorber, I.F.S....................................................... 3C-8 Shock Absorber, 4 W.D.................................................. 3C-36 Shock Absorber R e p la c e m e n t..................................... 3D-8 Shutdown and/or Cold Advance Solenoid Replacement (D ie se l).............................................. 6C2-16 Side Cover Gasket Replacement (D iesel)............... 6C2-17 Side Cover, Manual Transm ission.................................7B-8 Spark P lu g s .................................................................... 6D-35 Spark Plug W ire s........................................................... 6D-35 Spark Plug Wires — Service........................................6D-42 Spark Plug Wire R ep la ce m e n t................................... 6D-42 Specifications (Engine) (4.3L)........................................................................... 6A3-28 (Small Block)..............................................................6A4-32 (7.4L)...........................................................................6A5-27 (6.2L)...........................................................................6A6-33 (4 .8 L )...........................................................................6A7-25 Speedometer Cable Core R eplacem ent...................... 8C-7 Speedometer Diagnosis...................................................8C-3 Speedometer Drive Gear, Manual Transmission.................................................................. 7B-3 Speedometer Drive Gear/Vehicle Speed S ensor..............................................................7A-67 Speedometer R eplacem ent............................................ 8C-7 Spindle, 4 W.D..................................................................3C-41 Spring Assembly Replacement (R/V M o d e l)............. 2B-2 Stabilizer Bar R eplacem ent............................................ 3D-8 Stabilizer Bar, I-B e a m ...................................................3C-30 Stabilizer Bar, I.F.S............................................................ 3C-8 Stabilizer Bar, 4 W.D.......................................................3C-36 Starter Motor N o is e ....................................................... 6D-24 Starter Motor R eplacem ent..........................................6D-27 Starter Motor Service.....................................................6D-27 Steering Arm, Knuckle and Spindle, I-B e a m ........... 3C-33 Steering Column D iagnosis..........................................3B4-2 Steering Column (G Model) R e p la c e m e n t............. 3B4-16 Steering Column Lock C ylinder Replacement (R, V, G M o d e ls )....................................................... 3B4-17 Steering Column Lower Bearing Adjustment -P(42) M odels........................................................... 3B4-42 Steering Column Lower Bearing Replacement -P (42 M o d e ls ........................................................... 3B4-42 Steering Column Lower Bearing Adjustment (Standard).................................................................. 3B4-23 Steering Column Replacement (Standard)P(42) M odels............................... .............................. 3B4-38 Steering Column (RV Model) R e p la c e m e n t........... 3B4-15 Steering Column Shift Tube A djustm entP(42) M odels..............................................................3B4-41 Steering Column Special T ools................................. 3B4-45 Steering Column S p e c ific a tio n s ...............................3B4-44 Steering Column (Standard) Unit R epairP(42) M odels..............................................................3B4-42 Steering Column Unit R epairStandard (R, V, G M o d e ls )............................., . . .3B4-19 SECTION PAGE Steering Column Unit R epairTilt (R, V, G M odels)................................................ 3B4-26 Steering Column Upper Bearing ReplacementP(42) Models............................................................. 3B4-39 Steering Connecting Rod Replacement (P30(32) Motorhome)................................................ 3B1-11 Steering Connecting Rod Replacement (V and P30(00) FS3 M o d e ls )............................................................. 3B1-10 Steering Flexible Coupling R e p lace m e nt............... 3B4-14 Steering Gear Adjustments, M anual.......................... 3B2-6 Steering Gear High Point Centering, M a n u a l........................................................................ 3B2-7 Steering Gear Replacement, M a n u a l........................ 3B2-3 Steering Intermediate Shaft R e p la ce m e n t............. 3B4-13 Steering Intermediate Shaft Unit R epairP(42) M odels............................................................. 3B4-43 Steering Knuckle and Arm, 4 W.D...............................3C-45 Steering Knuckle, I.F.S................................................... 3C-15 Steering Linkage D iagnosis..........................................3B1-2 Steering Linkage Specifications.................................3B1-13 Steering Shock Absorber Inspection.......................... 3B1-6 Steering Shock Absorber R e p la ce m e n t....................3B1-7 Steering Wheel Inspection......................................... 3B4-12 Stoplamp S w itch............................................................. 5A-16 Suspension Unit, I.F.S....................................................3C-26 T Temperature Gage D ia g n o s is ....................................... 8C-6 Temperature Gage R eplacem ent.................................8C-11 THERMAC D iagnosis.................................................. 6E8-41 Thermostat D ia g n o s is .................................................. 6B1-3 Thermostat Housing Crossover R e m o va l................. 6B1-8 Thermostatic Air Cleaner (TH E R M AC )....................6E8-40 Thermostat R eplacem ent.............................................. 6B1-7 Throttle K ic k e r ............................................................. 6C1-38 Throttle Kicker Adjustm ent (M4ME and M4MEF M odels).................................6C1-40 Throttle Position Switch Adjustment (6.2L D ie s e l)................................................................6E9-8 Throttle Return Control (TR C )...................................6E8-43 Throttle Shaft Seal Replacement (Diesel Fuel Injection).............................................. 6C2-14 Tie Rod Replacement (R, G P20 and 30(42) Models)............................................................. 3B1-7 Tie Rod Replacement (V and P30(00) FS3 M o d e ls )................................................................3B1-8 Tilt Steering Column Unit R epairP(32) M odels............................................................. 3B4-38 Tilt Steering Column Replacem entP(32) M odels............................................................. 3B4-33 Tilt Steering Column Bearing Housing ReplacementP(32) M odels............................................................. 3B4-35 Timing Gear Cover Replacement (4.8L)....................6A7-11 Tire Load Limits and Inflation P re s s u re ......................3E-1 Tone Alarm Switch (Steering Column) Replacement (R, V, G M o d e ls ).......................................................3B4-18 Torque Converter Clutch D iagnosis............................ 7A-12 Torque Converter D iagnosis..........................................7A-11 T o rs io n a l D a m p e r and F ro n t C ra n k s h a ft S e al Replacement (4 .3 L )...........................................................................6A3-13 (Small B lo ck)............................................................. 6A4-13 SECTION PAGE (7.4 L)............................................................................. 6A5-8 (6 .2 L )...........................................................................6A6-12 (4 .8 L )...........................................................................6A7-10 Trailer Hitch R eplacem ent............................................ 2A-20 Trailer Hitch Replacement (Utility Vehicle and S u b u rb a n )........................................................... 2A-13 Transfer Case Capacities — Blazer/Jimmy, S u b u rb a n ...................................................................... OB-2 Transfer Case Capacities — Pickup M o d e ls ............. OB-4 Transfer Case Diagnosis (205)......................................7D1-3 Transfer Case Maintenance and Adjustm ent (205)......................................................... 7D1-2 Transfer Case Replacement (205)...............................7D1-3 Transmission Capacities...................................................OB-1 Transmission Diagnosis, A utom atic............................... 7A-6 Transmission Diagnosis, M anual................................... 7B-2 Transmission Diagnosis, THM 400............................... 7A-16 Transmission Diagnosis, THM 700 R -4 ...................... 7A-35 Transmission Fluid Checking and Adding, A u to m a tic .................................................................... 7A-63 Transmission Fluid and Filter Changing, A u to m a tic .................................................................... 7A-66 Transmission Inspection, M anual................................... 7B-1 Transmission Oil Circuits, THM 400 ...........................7A-25 Transmission Oil Cooler and Lines, A u to m a tic .................................................................... 7A-63 Transmission Oil Drain and Fill, M a n u a l......................7B-3 Transmission Oil and Wiring Circuits, THM 700 R - 4 ..............................................................7A-43 Transmission Preliminary Checking, THM 4 0 0 .........7A-14 Transmission Preliminary Checking, THM 700 R-4 .7A-31 Transmission Replacement, A u to m a tic ...................... 7A-74 Transmission Replacement, M a n u a l.......................... 7B-10 Transmission Specifications, A utom atic......................7A-74 Transmission Specifications, M a n u a l.......................... 7B-11 TRC D iagnosis..............................................................6E8-43 Turn Signal Switch R eplacem entP(32) M odels..............................................................3B4-33 Turn Signal Switch Replacement (R, V, G M o d e ls )....................................................... 3B4-16 TV C able........................................................................... 7A-65 TV Cable A djustm ent..................................................... 7A-65 Tune-Up Inform ation......................................................... 6A-2 u Underbody A lig n m e n t..................................................... 2A-6 Underbody, G M o d e l....................................................... 2A-6 Universal J o in t .................................................................. 4A-1 Unloader Adjustment (M4ME and M4MEF M od els)....................................................... 6C1-45 V Vacuum B oosters........................................................... 5A1-3 Vacuum Booster R e p la ce m e n t................................... 5A2-3 Vacuum Modulator (THM 400)......................................7A-67 Vacuum P u m p s ................................................................6H-1 Vacuum Pump Diagnosis.................................................6H-1 Vacuum Pump Replacem ent..........................................6H-4 Vacuum Regulator Valve Adjustm ent (LL4 Engine with Automatic Transm ission)...........6C2-4 Vacuum Regulator V a lv e .............................................. 6E9-9 PAGE SECTION Valve Adjustm ent (4.3 L). . . .......................................................................6A3-6 (Small Block)................................................................ 6A4-6 (7.4 L)............................................................................. 6A5-4 (4 .8 L )............................................................................. 6A7-5 Valve Stem Seal and Valve Spring Replacement (4.3 L)............................................................................. 6A3-6 (Small B lo ck)................................................................6A4-7 (7.4 L ) ............................................................................. 6A5-4 (6.2 L)............................................................................. 6 A 6 -8 (4 .8 L )............................................................................. 6A7-5 Valve Timing, Checking (4 .8 L )................................... 6A7-14 Vehicle Em issions C lassification................................... OB-8 Voltmeter R e p la c e m e n t.................................................8C-14 w “ WATER IN FUEL” Light D ia g n o s is .............................6C-3 Water Pump R eplacem ent.......................................... 6B1-15 W elding............................................................................... 2A-6 Weight Distribution Hitch R e p la ce m e n t....................2A-20 Weight Distribution Hitch Replacement (Suburban O n ly )......................................................... 2A-14 Weight Distribution Hitch Replacement (Utility Vehicle O n ly )...................................................2A-15 Wheel and Tire B alancing.............................................. 3E-8 Wheel and Tire Installing.................................................3E-7 Wheel and Tire R u n o u t...................................................3E-4 Wheel Bearing Adjustment, I-B e a m .......................... 3C-32 Wheel Bearing Adjustment, I.F.S..................................3C-13 W heel Bearing Adjustment, 4 W.D.............................. 3C-37 Wheel Bearing/Cup Replacement Full Floating Axle (9 3/4 and 101/2-inch Ring G ear)...............................4B1-15 Wheel Bearings, D iag no sis............................................ 3C-3 Wheel Bolt Replacement Full Floating Axle (9 3/4 and 101/2-inch Ring G ear)...............................4B1-16 Wheel Cylinder R ebuilding................................... . .5A2-11 Wheel Cylinder R eplacem ent..................................... 5A2-11 W heelhouse Panel Replacement (R/V M o d e l)........... 2B-7 Wheel Hub feolt, I-B e a m .............................................. 3C-33 Wheel Hub Bolt, I.F.S......................................................3C-15 Wheel Hub Bolt, 4 W.D.................................................. 3C-41 Wheel Hub/Rotor Assembly, I-Beam .......................... 3C-31 Wheel Hub/Rotor Assembly, I.F.S.................................. 3C-8 Wheel Hub/Rotor Assembly, 4 W.D............................. 3C-36 Wheel Stud Replacement (8 V2 and 9 1/ 2-inch Ring G e a r ) ................................................ 4B1-11 Window Replacement (G M o d e l).............................10A3-10 Window Replacement (RV M odel).............................10A3-3 Windshield Replacement (G M o d e l)........................ 10A3-6 W indshield Replacement (RV M o d e l)...................... 10A3-1 Windshield W a s h e r....................................................... 8A-36 W indshield Washer D iagnosis..................................... 8A-35 W indshield W ip e r........................................................... 8A-26 W indshield W iper D ia g n o sis........................................8A-26 W iper D e la y .................................................................... 8A-38 Wiper Delay D ia g n o s is ................................................ 8A-38 W iper Motor R e p a ir....................................................... 8A-36 SECTION 1 » M