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FULL-SHE

1988-9 r^PAIR MANUAL

Covers all U.S. and Canadian models of


Chevrolet/GMC Pick-ups, Sierra, Blazer, Tahoe,
Yukon and Suburban; 2 and 4 wheel drive
gasoline and diesel engines

by Thomas A Mellon, A.S.E., SAE.

Automotive
Books
PUBLISHED BY HAYNES NORTH AMERICA. Inc.

AimDMCTIVIr
S)
ASSOCIATION

Manufactured in USA
1996 Haynes North America, Inc.
ISBN 0-8019-9102-1
Library of Congress Catalog Card No. 98-74837
5678901234 9876543210

Haynes Publishing Group


Sparkford Nr Yeovil
Somerset BA22 7JJ England
Haynes North America, Inc
861 Lawrence Drive
ABODE
FGHI
Newbury Park
California 91320 USA
3N3

Chilton is a registered trademark of W.G. Nichols, Inc., and has been licensed to Haynes North America, Inc.
Contents
1-2 HOW TO USE THIS BOOK 1-10 ROUTINE MAINTENANCE
GENERAL INFORMATION 1-2 TOOLS AND EQUIPMENT AND TUNE-UP
1-35 FLUIDS AND LUBRICANTS
AND MAINTENANCE 1-4 SERVICING YOUR VEHICLE
SAFELY 1-46 TRAILER TOWING
1 -5 FASTENERS, 1-47 JUMP STARTING A DEAD
MEASUREMENTS AND BATTERY
CONVERSIONS 1-48 JACKING
1-7 SERIAL NUMBER 1 -50 MAINTENANCE INTERVALS
IDENTIFICATION

2-2 HIGH ENERGY IGNITION 2-7 CHARGING SYSTEM


(HEI) SYSTEM 2-8 STARTING SYSTEM
ENGINE ELECTRICAL 2-2 DISTRIBUTOR IGNITION (Dl) o Q SENDING UNITS AND
SYSTEM SENSORS
2-6 FIRING ORDERS

3-2 ENGINE MECHANICAL 3-58 ENGINE RECONDITIONING


ENGINE AND ENGINE 3-56 EXHAUST SYSTEM
OVERHAUL

4-2 GASLINE ENGINE EMISSION 4-25 DIESEL ELECTRONIC


CONTROLS ENGINE CONTROLS
DRIVEABILITY
4-10 DIESEL ENGINE EMISSION 4-29 TROUBLE CODES
AND EMISSION CONTROLS CONTROLS 4-39 COMPONENT LOCATIONS
4-11 CARBURETED ELECTRONIC 4-55 VACUUM DIAGRAMS
ENGINE CONTROLS
4-17 FUEL INJECTED ELECTRONIC
ENGINE CONTROLS

5-2 BASIC FUEL SYSTEM 5-14 MULTI-PORT FUEL


DIAGNOSIS INJECTION (MFI)
FUEL SYSTEM 5-2 FUEL LINE FITTINGS 5-19 CENTRAL SEQUENTIAL FUEL
5-3 CARBURETED FUEL SYSTEM INJECTION (CSFI)

5-10 THROTTLE BODY INJEC- 5-22 DIESEL FUEL SYSTEM


TION (TBI) 5-26 FUEL TANK

6-2 UNDERSTANDING AND 6-13 ENTERTAINMENT SYSTEMS


TROUBLESHOOTING 6-17 WINDSHIELD WIPERS AND
CHASSIS ELECTRICAL ELECTRICAL SYSTEMS WASHERS
6-7 BATTERY CABLES 6-19 INSTRUMENTS AND
6-7 SUPPLEMENTAL INFLATABLE SWITCHES
RESTRAINT (SIR) SYSTEM 6-22 LIGHTING
6-8 HEATING AND AIR 6-26 TRAILER WIRING
CONDITIONING
6-26 CIRCUIT PROTECTION
6-12 CRUISE CONTROL
6-28 WIRING DIAGRAMS
Contents
7-2 MANUAL TRANSMISSION 7-9 DRIVELINE
7-4 CLUTCH 7-13 SOLID FRONT DRIVE AXLE
7-6 AUTOMATIC TRANSMISSION 7-16 INDEPENDENT FRONT
DRIVE AXLE
7-8 TRANSFER CASE
7-19 REAR AXLE

8-2 WHEELS 8-18 K-SERIES 4WD FRONT


. SUSPENSION
8-4 C AND R SERIES 2WD SUSPENSION
FRONT SUSPENSION 8-24 C3HD FRONT SUSPENSION
8-26 REAR SUSPENSION
AND STEERING
8-14 V-SERIES 4WD FRONT
SUSPENSION 8-30 STEERING

9-2 BRAKE OPERATING SYSTEM 9-20 FOUR WHEEL ANTI-LOCK


BRAKE SYSTEM
9-6 DISC BRAKES
9-12 DRUM BRAKES 9"25
REAR WHEEL ANTI-LOCK
(RWAL) BRAKE SYSTEM
9-18 PARKING BRAKE

10-2 EXTERIOR 10-5 INTERIOR

10-15 GLOSSARY

10-19 MASTER INDEX


SAFETY NOTICE

Proper service and repair procedures are vital to the safe, re iable operation of all motor vehicles, as well as the personal safety of those per-
forming repairs. This manual outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many
NOTES, CAUTIONS and WARNINGS which should be followed, along with standard procedures to eliminate the possibility of personal injury or
improper service which could damage the vehicle or compromise its safety.

It is important to note that repair procedures and techniquesM tools and parts for servicing motor vehicles, as well as the skill and experience of
the individual performing the work vary widely. It is not possibles to anticipate all of the conceivable ways or conditions under which vehicles may
be serviced, or to provide cautions as to all possible hazards ttit may result. Standard and accepted safety precautions and equipment should be
used when handling toxic or flammable fluids, and safety goggles or other protection should be used during cutting, grinding, chiseling, prying.
or any other process that can cause mate/ial removal or projectiles.

Some procedures require the use of tools specially designed for a specific purpose. Before substituting another tool or procedure, you must be
completely satisfied that neither your personal safety, nor the performance of the vehicle will be endangered.

Although information in this manual is based on industry sojurces and is complete as possible at the time of publication, the possibility exists
that some car manufacturers made later changes which could, inot be included here. While striving for total accuracy, the authors or publishers
cannot assume responsibility for any errors, changes or omissions that may occur in the compilation of this data.

PART NUMBERS

Part numbers listed in this reference are not recommendat ons by Haynes North America, Inc. for any product brand name. They are refer-
ences that can be used with interchange manuals and afterm rket supplier catalogs to locate each brand supplier's discrete part number.

SPECIAL TOOLS

Special tools are recommended by the vehicle manufacturer o perform their specific job. Use has been kept to a minimum, but where
absolutely necessary, they are referred to in the text by the part lumber of the tool manufacturer. These tools can be purchased, under the appro-
priate part number, from your local dealer or regional distributo , or an equivalent tool can be purchased locally from a tool supplier or parts out-
let. Before substituting any tool for the one recommended, readl the SAFETY NOTICE at the top of this page.

ACKNOWLEDGMENTS

Portions of materials contained herein have been reprints J with the permission of General Motors Corporation, Service Technology Group.

All rights reserved. No part of this book may be reproduce! or transmitted in any form or by any means, electronic or mechanical, includ-
ing photocopying, recording or by any information storage >r retrieval system, without permission in writing from the copyright holder.
While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or pub-
lishers for loss, damage or injury caused by any errors in, or omissions from, the information given.
HOW TO USE THIS BOOK 1-2 FLUIDS AND LUBRICANTS 1-35
WHERE TO BEGIN 1-2 FLUID DISPOSAL 1-35
AVOIDING TROUBLE 1-2 FUEL AND OIL RECOMMENDATIONS 1-35
MAINTENANCE OR REPAIR? 1-2 OIL 1-35
AVOIDING THE MOST COMMON MISTAKES 1-2 FUEL 1-36
TOOLS AND EQUIPMENT 1-2 ENGINE 1-37
SPECIAL TOOLS 1-4 OIL LEVEL CHECK 1-37
SERVICING YOUR VEHICLE SAFELY 1-4 OILS FILTER CHANGE 1-37
DO'S 1-4 MANUAL TRANSMISSION 1-38
DONTS 1-5 FLUID RECOMMENDATION 1-38
FASTENERS, MEASUREMENTS AND LEVEL CHECK 1-38
CONVERSIONS 1-5 DRAINS REFILL 1-39
BOLTS, NUTS AND OTHER THREADED RETAINERS 1-5 AUTOMATIC TRANSMISSION 1-39
TORQUE 1-6 FLUID RECOMMENDATIONS 1-39
TORQUE WRENCHES 1-6 LEVEL CHECK 1-39
TORQUE ANGLE METERS 1-7 DRAINS REFILL 1-39
STANDARD AND METRIC MEASUREMENTS 1-7 TRANSFER CASE 1-40
SERIAL NUMBER IDENTIFICATION 1-7 FLUID RECOMMENDATIONS 1-40
VEHICLE 1-7 LEVEL CHECK 1-40
ENGINE 1-7 DRAINS REFILL 1-40
TRANSMISSION 1-8 FRONT AND REAR DRIVE AXLES 1-40
DRIVE AXLE 1-8 FLUID RECOMMENDATIONS 1-40
TRANSFER CASE 1-8 LEVEL CHECK 1-40
SERVICE PARTS IDENTIFICATION LABEL 1-10 DRAINS REFILL 1-41
ROUTINE MAINTENANCE AND TUNE-UP 1-10 COOLING SYSTEM 1-41
AIR CLEANER 1-10 FLUID RECOMMENDATIONS 1-41
REMOVAL & INSTALLATION 1-13 LEVEL CHECK 1-42
FUEL FILTER 1-13 DRAINING S FLUSHING 1-42
REMOVAL & INSTALLATION 1-13 BRAKE MASTER CYLINDER 1-42
PCVVALVE 1-15 FLUID RECOMMENDATIONS 1-42
REMOVAL & INSTALLATION 1-15 LEVEL CHECK 1-42
CRANKCASE DEPRESSION REGULATOR AND FLOW CLUTCH MASTER CYLINDER 1-43
CONTROL VALVE 1-16 FLUID RECOMMENDATIONS 1-43
SERVICING 1-16 LEVEL CHECK 1-43
EVAPORATIVE CANISTER 1-16 POWER STEERING PUMP 1-43
SERVICING 1-16
BATTERY 1-16
PRECAUTIONS 1-16
GENERAL MAINTENANCE 1-16
FLUID RECOMMENDATION 1-43
LEVEL CHECK 1-43
STEERING GEAR 1-43
FLUID RECOMMENDATIONS 1-43
GENERAL
BATTERY FLUID 1-17 LEVEL CHECK 1-44
CABLES 1-17 CHASSIS GREASING 1-44
CHARGING 1-18 BODY LUBRICATION AND MAINTENANCE 1-45
REPLACEMENT 1-18 LOCK CYLINDERS 1-45
BELTS 1-18 HOOD LATCH S HINGES 1-45
INSPECTION 1-18 DOOR HINGES 1-45
ADJUSTMENT 1-18 BODY DRAIN HOLES 1-46
REMOVAL & INSTALLATION 1-19 FRONT WHEEL BEARINGS 1-46
BELT ROUTING 1-20 TRAILER TOWING 1-46
HOSES 1-23 GENERAL RECOMMENDATIONS 1-46
INSPECTION 1-23 TRAILER WEIGHT 1-46
REMOVAL & INSTALLATION 1-23 HITCH (TONGUE) WEIGHT 1-46
CV-BOOTS 1-24 ENGINE 1-47
INSPECTION 1-24 TRANSMISSION 1-47
SPARKPLUGS 1-25 HANDLING A TRAILER 1-47 HOW TO USE THIS BOOK 1-2
SPARK PLUG HEAT RANGE 1-25 JUMP STARTING A DEAD BATTERY 1-47 TOOLS AND EQUIPMENT 1-2
REMOVAL & INSTALLATION 1-25 JUMP STARTING PRECAUTIONS 1-47 SERVICING YOUR VEHICLE SAFELY 1-4
INSPECTION & GAPPING 1-26 JUMP STARTING PROCEDURE 1-47 FASTENERS, MEASUREMENTS
SPARK PLUG WIRES 1-27 SINGLE BATTERY GASOLINE AND DIESEL ENGINE AND CONVERSIONS 1-5
TESTING 1-27 MODELS 1-47
REMOVAL & INSTALLATION 1-27 DUAL BATTERY DIESEL MODELS 1-48 SERIAL NUMBER IDENTIFICATION 1-7
DISTRIBUTOR CAP AND ROTOR 1-27 JACKING 1-48
REMOVAL & INSTALLATION 1-27 JACKING PRECAUTIONS 1-49 AND TUNE-UP 1-10
INSPECTION 1-28 MAINTENANCE INTERVALS 1-50 FLUIDS AND LUBRICANTS 1-35
IGNITION TIMING 1-28 GENERAL RECOMMENDATIONS 1-50 TRAILER TOWING 1-46
GENERAL INFORMATION 1-28 BUT THE OWNER'S MANUAL IS DIFFERENT? 1-50
CHECKING & ADJUSTMENT 1-29
iTARTING A DEAD BATTERY 1-47
BUT THE REPLACEMENT PART IS
VALVE LASH 1-29 DIFFERENT? 1-50 JACKING 1-48
ADJUSTMENT 1-29 IS MY DRIVING "NORMAL" OR "SEVERE"? 1-50 MAINTENANCE INTERVALS 1-50
IDLE SPEED AND MIXTURE ADJUSTMENTS 1-30 COMPONENT LOCATIONS
CARBURETED ENGINES 1-30 UNDERHOOD MAINTENANCE COMPONENT
GASOLINE FUEL INJECTED ENGINES 1-30 LOCATIONSR-SERIES 1-11
DIESEL ENGINES 1-31 UNDERHOOD MAINTENANCE COMPONENT
AIR CONDITIONING SYSTEM 1-32 LOCATIONSC-SERIES 1-12
SYSTEM SERVICE S REPAIR 1-32 SPECIFICATIONS CHARTS
PREVENTIVE MAINTENANCE 1-32 VEHICLE IDENTIFICATION CHART 1-8
SYSTEM INSPECTION 1-32 GENERAL ENGINE SPECIFICATIONS 1-9
WINDSHIELD WIPERS 1-33 GASOLINE TUNE-UP SPECIFICATIONS 1-31
ELEMENT (REFILL) CARE & REPLACEMENT 1-33 RECOMMENDED LUBRICANTS 1-36
TIRES AND WHEELS 1-33 MAINTENANCE SCHEDULES 1-51
TIRE ROTATION 1-33 CAPACITIES 1-54
TIRE DESIGN 1-34
TIRE STORAGE 1-34
INFLATIONS INSPECTION 1-34
1-2 GENERAL INFORMATION AND MAINTENANCE
HOW TO USE THIS BOOK
This Chilton's Total Car Care manual for 1988-981/2, % and 1 ton Chevrolet Two basic mechanic's rules should be mentioned here. First, whenever the
and GMC Pick-ups, Blazers, Jimmys, Tahoes, Yukons and Suburbans is left side of the vehicle or engine is referred to, it means the driver's side. Con-
intended to help you learn more about the inner workings of your vehicle, while versely, the right side of the vehicle means the passenger's side. Second, screws
saving you money on its upkeep and operation. and bolts are removed by turning counterclockwise, and tightened by turning
The beginning of the book will likely be referred to the most, since that is clockwise unless specifically noted.
where you will find information for maintenance and tune-up. The other sections Safety is always the most important rule. Constantly be aware of the dangers
deal with the more complex systems of your vehicle. Systems (from engine involved in working on an automobile and take the proper precautions. Please
through brakes) are covered to the extent that the average do-it-yourselft r can refer to the information in this section regarding SERVICING YOUR VEHICLE
attempt. This book will not explain such things as rebuilding a different! I SAFELY and the SAFETY NOTICE on the acknowledgment page.
because the expertise required and the special tools necessary make thi; uneco-
nomical. It will, however, give you detailed instructions to help you chan je your
own brake pads and shoes, replace spark plugs, and perform many morj jobs
Avoiding the Most Common Mistakes
that can save you money and help avoid expensive problems. Pay attention to the instructions provided. There are 3 common mistakes in
A secondary purpose of this book is a reference for owners who want to mechanical work:
understand their vehicle and/or their mechanics better. 1. Incorrect order of assembly, disassembly or adjustment. When taking
something apart or putting it together, performing steps in the wrong order usu-
Where to Begin ally just costs you extra time; however, it CAN break something. Read the entire
procedure before beginning. Perform everything in the order in which the
Before removing any bolts, read through the entire procedure. This will give instructions say you should, even if you can't see a reason for it. When you're
you the overall view of what tools and supplies will be required. So read, ahead taking apart something that is very intricate, you might want to draw a picture of
and plan ahead. Each operation should be approached logically and all proce- how it looks when assembled in order to make sure you get everything back in
dures thoroughly understood before attempting any work. its proper position. When making adjustments, perform them in the proper
If repair of a component is not considered practical, we tell you how b order. One adjustment possibly will affect another.
remove the part and then how to install the new or rebuilt replacement. l(i this 2. Overtorquing (or undertorquing). While it is more common for over-
way, you at least save labor costs. tcrquing to cause damage, undertorquing may allow a fastener to vibrate loose
causing serious damage. Especially when dealing with aluminum parts, pay
attention to torque specifications and utilize a torque wrench in assembly. If a
Avoiding Trouble torque figure is not available, remember that if you are using the right tool to
Many procedures in this book require you to "label and d i s c o n n e c t . . . " a perform the job, you will probably not have to strain yourself to get a fastener
group of lines, hoses or wires. Don't be think you can remember where (very- tight enough. The pitch of most threads is so slight that the tension you put on
thing goesyou won't. If you hook up vacuum or fuel lines incorrectly,! he the wrench will be multiplied many times in actual force on what you are tight-
vehicle may run poorly, if at all. If you hook up electrical wiring incorrec ly, you ening.
may instantly learn a very expensive lesson. There are many commercial products available for ensuring that fasteners
You don't need to know the proper name for each hose or line. A pied j of won't come loose, even if they are not torqued just right (a very common brand
masking tape on the hose and a piece on its fitting will allow you to ass jn your is Loctite"). If you're worried about getting something together tight enough to
own label. As long as you remember your own code, the lines can be rel on- hold, but loose enough to avoid mechanical damage during assembly, one of
nected by matching your tags. Remember that tape will dissolve in gasaine or trese products might offer substantial insurance. Before choosing a threadlock-
solvents; if a part is to be washed or cleaned, use another method of idq itifica- irg compound, read the label on the package and make sure the product is
tion. A permanent felt-tipped marker or a metal scribe can be very hand; for compatible with the materials, fluids, etc. involved.
marking metal parts. Remove any tape or paper labels after assembly. 3. Crossthreading. This occurs when a part such as a bolt is screwed into a
nut or casting at the wrong angle and forced. Crossthreading is more likely to
occur if access is difficult. It helps to clean and lubricate fasteners, then to start
Maintenance or Repair: threading the bolt, spark plug, etc. with your fingers. I! you encounter resis-
Maintenance includes routine inspections, adjustments, and replacertent of tance, unscrew the part and start over again at a different angle until it can be
parts which show signs of normal wear. Maintenance compensates for wsar or irserted and turned several times without much effort. Keep in mind that many
deterioration. Repair implies that something has broken or is not workinji. A parts have tapered threads, so that gentle turning will automatically bring the
need for a repair is often caused by lack of maintenance, for example: dit lining part you're threading to the proper angle. Don't put a wrench on the part until it's
and refilling automatic transmission fluid is maintenance recommended it spe- been tightened a couple of turns by hand. If you suddenly encounter resistance,
cific intervals. Failure to do this can shorten the life of the transmission/ and the part has not seated fully, don't force it. Pull it back out to make sure it's
transaxle, requiring very expensive repairs. While no maintenance progm.m can clean and threading properly.
prevent items from eventually breaking or wearing out, a general rule is |rue: Be sure to take your time and be patient, and always plan ahead. Allow your-
MAINTENANCE IS CHEAPER THAN REPAIR. self ample time to perform repairs and maintenance.

TOOLS AND EQUIPMENT


I See Figures 1 thru 15 Your monetary savings will be far outweighed by frustration and mangled
knuckles.
Without the proper tools and equipment it is impossible to properly service Begin accumulating those tools that are used most frequently: those associ-
your vehicle. It would be virtually impossible to catalog every tool that you ated with routine maintenance and tune-up. In addition to the normal assort-
would need to perform all of the operations in this book. It would be unwise for ment of screwdrivers and pliers, you should have the following tools:
the amateur to rush out and buy an expensive set of tools on the theory (hat Wrenches/sockets and combination open end/box end wrenches in sizes
he/she may need one or more of them at some time. 1/8-3/4 in. and/or 3mm-19mm 13/ie in. or % in. spark plug socket (depending
The best approach is to proceed slowly, gathering a good quality set of on plug type).
those tools that are used most frequently. Don't be misled by the low cost of
bargain tools. It is far better to spend a little more for better quality. Forged "If possible, buy various length socket drive extensions. Universal-
wrenches, 6 or 12-point sockets and fine tooth ratchets are by far preferable joint and wobble extensions can be extremely useful, but be careful
to their less expensive counterparts. As any good mechanic can tell yoM, there when using them, as they can change the amount of torque applied to
are few worse experiences than trying to work on a vehicle with bad torjls. the socket.
GENERAL INFORMATION AND MAINTENANCE 1-3
Jackstands (or support. ball of twine, electrical tape for wiring, small rolls of colored tape for tagging
Oil filter wrench. lines or hoses, markers and pens, a note pad, golf tees (for plugging vacuum
Spout or funnel for pouring fluids. lines), metal coat hangers or a roll of mechanic's wire (to hold things out of the
Grease gun for chassis lubrication (unless your vehicle is not equipped way), dental pick or similar long, pointed probe, a strong magnet, and a small
with any grease fittings) mirror (to see into recesses and under manifolds).
Hydrometer for checking the battery (unless equipped with a sealed, A more advanced set of tools, suitable for tune-up work, can be drawn up
maintenance-free battery). easily. While the tools are slightly more sophisticated, they need not be outra-
A container for draining oil and other fluids. geously expensive. There are several inexpensive tach/dwell meters on the mar-
Rags for wiping up the inevitable mess. ket that are every bit as good for the average mechanic as a professional model.
In addition to the above items there are several others that are not absolutely Just be sure that it goes to a least 1200-1500 rpm on the tach scale and-that it
necessary, but handy to have around. These include an equivalent oil absorbent works on 4, 6 and 8-cylinder engines. The key to these purchases is to make
gravel, like cat litter, and the usual supply of lubricants, antifreeze and fluids. them with an eye towards adaptability and wide range. A basic list of tune-up
This is a basic list for routine maintenance, but only your personal needs and tools could include:
desire can accurately determine your list of tools. Tach/dwell meter.
After performing a few projects on the vehicle, you'll be amazed at the other Spark plug wrench and gapping tool.
tools and non-tools on your workbench. Some useful household items are: a Feeler gauges for valve adjustment.
large turkey baster or siphon, empty coffee cans and ice trays (to store parts), a Timing light.

,SS*8i

Fig. 1 All but the most basic procedures Fig. 3 A hydraulic floor jack and a set of
will require an assortment of ratchets and Fig. 2 In addition to ratchets, a good set of jackstands are essential for lifting and
sockets wrenches and hex keys will be necessary supporting the vehicle

TCCS1205

Fig. 4 An assortment of pliers, grippers Fig. 6 Many repairs will require the use of
and cutters will be handy for old rusted Fig. 5 Various drivers, chisels and prybars a torque wrench to assure the components
parts and stripped bolt heads are great tools to have in your toolbox are properly fastened

fe"~ i .u '''"^Mlf

Fig. 7 Although not always necessary, Fig. 9 Various pullers, clamps and separa-
using specialized brake tools will save Fig. 8 A few inexpensive lubrication tools tor tools are needed for many larger, more
time will make maintenance easier complicated repairs
1-4 GENERAL INFORMATION AND MAINTENANCE
r /
vrr*>fes

Fig. 10 A variety of tools and gauges


^ Fig. 12 A screw-in type compression
TCCX1P02

should be used for spark plug gapping and gauge is recommended for compression
installation Fig. 11 ina ictive type timing light testing

TCCX1POG Fig. 15 Proper information is vital, so


Fig. 13 A vacuum/pressure tester is neces- Fig. 14 M( st modern automotive multi- always have a Chilton Total Car Care man-
sary for many testing procedures meters incorporate many helpful features ual handy

The choice of a timing light should be made carefully. A light which vorks newer click types (breakaway) are easier to use. The click type torque wrenches
on the DC current supplied by the vehicle's battery is the best choice; it mould tend to be more expensive. Also keep in mind that all types of torque wrenches
have a xenon tube for brightness. On any vehicle with an electronic ignit in sys- should be periodically checked and/or recalibrated. You will have to decide for
tem, a timing light with an inductive pickup that clamps around the No. | spark yourself which better fits your pocketbook, and purpose.
plug cable is preferred.
In addition to these basic tools, there are several other tools and gaut :syou
may find useful. These include:
Special Tools
Compression gauge. The screw-in type is slower to use, but e!imii(jates Normally, the use of special factory tools is avoided for repair procedures,
the possibility of a faulty reading due to escaping pressure. since these are not readily available for the do-it-yourself mechanic. When it is
Manifold vacuum gauge. possible to perform the job with more commonly available tools, it will be
12V test light. pointed out, but occasionally, a special tool was designed to perform a specific
A combination volt/ohmmeter function and should be used. Before substituting another tool, you should be
Induction Ammeter. This is used for determining whether or not thdre is convinced that neither your safety nor the performance of the vehicle will be
current in a wire. These are handy for use if a wire is broken somewhere! n a ccmpromised.
wiring harness. Special tools can usually be purchased from an automotive parts store or
As a final note, you will probably find a torque wrench necessary for; II but from your dealer. In some cases special tools may be available directly from the
the most basic work. The beam type models are perfectly adequate, althd jgh the tool manufacturer.

SERVICING YOUR VEHICLE SAFELY


See Figures 16,17 and 18 Do shield your eyes whenever you work around the battery. Batteries con-
tain sulfuric acid. In case of contact with, flush the area with water or a mixture
It is virtually impossible to anticipate all of the hazards involved with autt motive of water and baking soda, then seek immediate medical attention.
maintenance and service, but care and common sense will prevent most accidents. Do use safety stands (jackstands) for any undervehicle service. Jacks are
The rules of safety for mechanics range from "don't smoke around gaioline," for raising vehicles; jackstands are for making sure the vehicle stays raised until
to "use the proper tool(s) for the job." The trick to avoiding injuries is to you want it to come down.
develop safe work habits and to take every possible precaution. Do use adequate ventilation when working with any chemicals or haz-
ardous materials. Like carbon monoxide, the asbestos dust resulting from some
brake lining wear can be hazardous in sufficient quantities.
Do disconnect the negative battery cable when working on the electrical
Do keep a fire extinguisher and first aid kit handy. system. The secondary ignition system contains EXTREMELY HIGH VOLTAGE.
Do wear safety glasses or goggles when cutting, drilling, grinding or pry- In some cases it can even exceed 50,000 volts.
ing, even if you have 20-20 vision. If you wear glasses for the sake of v sion, Do follow manufacturer's-directions whenever working with potentially
wear safety goggles over your regular glasses. hazardous materials. Most chemicals and fluids are poisonous.
GENERAL INFORMATION AND MAINTENANCE 1-5

A f*1 ^

TCCS1020

Fig. 16 Screwdrivers should be kept in


good condition to prevent injury or dam- Fig. 17 Using the correct size wrench will Fig. 18 NEVER work under a vehicle
age which could result if the blade slips help prevent the possibility of rounding off unless it is supported using safety stands
from the screw a nut (jackstands)

Do properly maintain your tools. Loose hammerheads, mushroomed soles protect your toes and give a better grip on slippery surfaces. Watches and
punches and chisels, frayed or poorly grounded electrical cords, excessively jewelry is not safe working around a vehicle. Long hair should be tied back
worn screwdrivers, spread wrenches (open end), cracked sockets, slipping under a hat or cap.
ratchets, or faulty droplight sockets can cause accidents. Don't use pockets for toolboxes. A fall or bump can drive a screwdriver
Likewise, keep your tools clean; a greasy wrench can slip off a bolt head, deep into your body. Even a rag hanging from your back pocket can wrap
ruining the bolt and often harming your knuckles in the process. around a spinning shaft or fan.
Do use the proper size and type of tool for the job at hand. Do select a Don't smoke when working around gasoline, cleaning solvent or other
wrench or socket that fits the nut or bolt. The wrench or socket should sit flammable material.
straight, not cocked. Don't smoke when working around the battery. When the battery is being
Do, when possible, pull on a wrench handle rather than push on it, and charged, it gives off explosive hydrogen gas.
adjust your stance to prevent a fall. Don't use gasoline to wash your hands; there are excellent soaps avail-
Do be sure that adjustable wrenches are tightly closed on the nut or bolt able. Gasoline contains dangerous additives which can enter the body through a
and pulled so that the force is on the side of the fixed jaw. cut or through your pores. Gasoline also removes all the natural oils from the
Do strike squarely with a hammer; avoid glancing blows. skin so that bone dry hands will suck up oil and grease.
Do set the parking brake and block the drive wheels if the work requires a Don't service the air conditioning system unless you are equipped with
running engine. the necessary tools and training. When liquid or compressed gas refrigerant is
released to atmospheric pressure it will absorb heat from whatever it contacts.
This will chill or freeze anything it touches.
Don'ts Don't use screwdrivers for anything other than driving screws! A screw-
Don't run the engine in a garage or anywhere else without proper venti- driver used as an prying tool can snap when you least expect it, causing
lationEVER! Carbon monoxide is poisonous; it takes a long time to leave injuries. At the very least, you'll ruin a good screwdriver.
the human body and you can build up a deadly supply of it in your system by Don't use an emergency jack (that little ratchet, scissors, or pantograph
simply breathing in a little at a time. You may not realize you are slowly poi- jack supplied with the vehicle) for anything other than changing a flat! These
soning yourself. Always use power vents, windows, fans and/or open the jacks are only intended for emergency use out on the road; they are NOT
garage door. designed as a maintenance tool. If you are serious about maintaining your vehi-
Don't work around moving parts while wearing loose clothing. Short cle yourself, invest in a hydraulic floor jack of at least a 11/2 ton capacity, and at
sleeves are much safer than long, loose sleeves. Hard-toed shoes with neoprene least two sturdy jackstands.

FASTENERS, MEASUREMENTS AND CONVERSIONS

Bolts, Nuts and Other Threaded Retainers


See Figures 19 and 20

Although there are a great variety of fasteners found in the modern car or
truck, the most commonly used retainer is the threaded fastener (nuts, bolts,
screws, studs, etc.). Most threaded retainers may be reused, provided that they
are not damaged in use or during the repair. Some retainers (such as stretch
bolts or torque prevailing nuts) are designed to deform when tightened or in use
and should not be reinstalled.
Whenever possible, we will note any special retainers which should be
replaced during a procedure. But you should always inspect the condition of a
retainer when it is removed and replace any that show signs of damage. Check
all threads for rust or corrosion which can increase the torque necessary to LOCKWASHERS

achieve the desired clamp load for which that fastener was originally selected. CO)
Additionally, be sure that the driver surface of the fastener has not been com-
promised by rounding or other damage. In some cases a driver surface may
become only partially rounded, allowing the driver to catch in only one direc-
HI
tion. In many of these occurrences, a fastener may be installed and tightened,
TCCS1036
but the driver would not be able to grip and loosen the fastener again.
If you must replace a fastener, whether due to design or damage, you must Fig. 19 There are many different types of threaded retainers found
ALWAYS be sure to use the proper replacement. In all cases, a retainer of the on vehicles
1-6 GENERAL INFORMATION AND MAINTENANCE
h-c i
^
1 i r^=====^^$A=sf~ 1
F ^^HI
i r
'! Z i DEFLECTING BEAM

-S-*~~?^^r~~
(. A
& o , fe'JH--' '
' ] A - Length
k J B - Diameter (major diameter)
> y x ^ C - Threads per inch or mm (n ] o s'.1,1,1,' 't\ i 1
E - Size of the wrench required
r E 1 F - Root diameter (minor diameter) CLICK TYPE
TCCS1038 TCCS1015
Fig. 20 Threaded retainer sizes are determined using these me - Fig. 21 Various styles of torque wrenches are usually available at
surements your local automotive supply store

same design, material and strength should be used. Markings on the he|ds of Click (Breakaway) Type
most bolts will help determine the proper strength of the fastener. The saj ne
material, thread and pitch must be selected to assure proper installation nd Another popular design of torque wrench is the click type. To use the click
safe operation of the vehicle afterwards. type wrench you pre-adjust it to a torque setting. Once the torque is reached,
Thread gauges are available to help measure a bolt or stud's thread. l|ost the wrench has a reflex signaling feature that causes a momentary breakaway of
automotive and hardware stores keep gauges available to help you selec the the torque wrench body, sending an impulse to the operator's hand.
proper size. In a pinch, you can use another nut or bolt for a thread gauc;. If the
bolt you are replacing is not too badly damaged, you can select a match iy Pivot Head Type
finding another bolt which will thread in its place. If you find a nut which I See Figure 22
threads properly onto the damaged bolt, then use that nut to help select he
replacement bolt. Some torque wrenches (usually of the click type) may be equipped with a
pivot head which can allow it to be used in areas of limited access. BUT, it must
-' WARNING be used properly. To hold a pivot head wrench, grasp the handle lightly, and as
you pull on the handle, it should be floated on the pivot point. If the handle
Be aware that when you find a bolt with damaged threads, you may comes in contact with the yoke extension during the process of pulling, there is
also find the nut or drilled hole it was threaded into has also teen a very good chance the torque readings will be inaccurate because this could
damaged. If this is the case, you may have to drill and tap thd hole, alter the wrench loading point. The design of the handle is usually such as to
replace the nut or otherwise repair the threads. NEVER try to I irce a make it inconvenient to deliberately misuse the wrench.
replacement bolt to fit into the damaged threads.
It should be mentioned that the use of any U-joint, wobble or exten-
sion will have an effect on the torque readings, no matter what type of
Torque wrench you are using. For the most accurate readings, install the socket
directly on the wrench driver. If necessary, straight extensions (which
Torque is defined as the measurement of resistance to turning or rotat ig. hold a socket directly under the wrench driver) will have the least effect
tends to twist a body about an axis of rotation. A common example of thi on the torque reading. Avoid any extension that alters the length of the
would be tightening a threaded retainer such as a nut, bolt or screw. Mee ;uring wrench from the handle to the head/driving point (such as a crow's
torque is one of the most common ways to help assure that a threaded retainer foot). U-joint or wobble extensions can greatly affect the readings; avoid
has been properly fastened. their use at all times.
When tightening a threaded fastener, torque is applied in three distinc areas,
the head, the bearing surface and the clamp load. About 50 percent of thi mea-
sured torque is used in overcoming bearing friction. This is the friction b tween
the bearing surface of the bolt head, screw head or nut face and the base nater-
ial or washer (the surface on which the fastener is rotating). Approximate 140
percent of the applied torque is used in overcoming thread friction. This laves
only about 10 percent of the applied torque to develop a useful clamp IDE i (the
force which holds a joint together). This means that friction can account 'pr as
much as 90 percent of the applied torque on a fastener.

TORQUE WRENCHES

I See Figure 21
In most applications, a torque wrench can be used to assure proper installa- PIVOTED HANDLE TORQUE WRENCH
tion of a fastener. Torque wrenches come in various designs and most auDmo- TCCS1041
tive supply stores will carry a variety to suit your needs. A torque wrench should Fig. 22 Torque wrenches with pivoting heads must be grasped and
be used any time we supply a specific torque value for a fastener. Again, the used properly to prevent an incorrect reading
general rule of "if you are using the right tool for the job, you should not have
to strain to tighten a fastener" applies here.
Rigid Case (Direct Reading)
Beam Type
A rigid case or direct reading torque wrench is equipped with a dial indicator
The beam type torque wrench is one of the most popular types. It cons sts of to show torque values. One advantage of these wrenches is that they can be
a pointer attached to the head that runs the length of the flexible beam (srpft) to held at any position on the wrench without affecting accuracy. These wrenches
a scale located near the handle. As the wrench is pulled, the beam bends fnd are often preferred because they tend to be compact, easy to read and have a
the pointer indicates the torque using the scale. great degree of accuracy.
GENERAL INFORMATION AND MAINTENANCE 1-7
TORQUE ANGLE METERS
CONVERSION FACTORS

Because the frictional characteristics of each fastener or threaded hole will vary, LENGTH-DISTANCE
Inches (m ) x 25,4 = Millimeters (mm) x .0394
clamp loads which are based strictly on torque will vary as well. In most applica- Fee! (ft.) x 305 = Meters (m) x 3.281
= Inches
r--- Feet
tions, this variance is not significant enough to cause worry. But, in certain applica- Miles x ! 604 = Kilometers (km) x .0621 = Miles

tions, a manufacturer's engineers may determine that more precise clamp toads are VOLUME
necessary (such is the case with many aluminum cylinder heads). In these cases, a Cubic Inches (in3)
IMP Pints (IMP pt |
x 16.387
x .56S
= Cubic Centimeters
= Liters (t.)
x .061
x 1 76
= m3
= IMP pi.
torque angle method of installation would be specified. When installing fasteners IMP Quarts (IMPqt ) x 1.137 = Liters (L) x .88 = IMPqt

which are torque angle tightened, a predetermined seating torque and standard IMP Gallons (IMP gall
IMP Quails (IMP qt.)
x 4..S46
<t 1.201
- Liters (L)
= US Quarts (US qi.)
x .22
x .833
= IMPgai.
- IMP qt.
torque wrench are usually used first to remove any compliance from the joint. The IMP Gallons (IMP gal.) x 1.201 = US Gallons (US gal.) x 831 = IMP gal.
fastener is then tightened the specified additional portion of a turn measured in R Ounces x 29.573 -= Milliliters x 034 = Ounces
US Pints (US pi > x .473 = Liters (L) x 2.113 = Pints
degrees. A torque angle gauge (mechanical protractor) is used for these applications. US Quarts (US 4i ) x .946 - Liters (L) x 1.057 - Quarts
US Gallons (US g.,1.) x 3 7X5 - Liters (L) x 264 = Gallons
MASS-WEIGHT
Standard and Metric Measurements Ounces (oz I * 28.35 = Grams (g) x .035 Ounces
Pounds (Ib.) x 454 = Kilograms (kg) x 2 205 = Pounds

See Figure 23 PRESSURE


Pounds Pei Sq. In (psi) x 6.895 *= Kilopascals (kPa) x .145 = psi
Inches of Mercury (Hg) x 4912
Throughout this manual, specifications are given to help you determine the Inches of Mercury (Hg) x 3.377
-- psi
=-- Kilopascals (kPa)
x 2.036
x .2961
= Hg
= Hg
condition of various components on your vehicle, or to assist you in their Inches of Water (HjO) x .07355 - Inches of Mercury x 13783 = H,O
installation. Some of the most common measurements include length (in. or Inches of Water (H,O)
Inches of Water (H.O)
x .03613
x .248
=. psi x 27.684 - H.O
= Kilopascals (kPa) x4026 = H,0
cm/mm), torque (ft. Ibs., inch Ibs. or Nm) and pressure (psi, in. Hg, kPa or mm TORQUE
Hg). In most cases, we strive to provide the proper measurement as determined Pounds-Force Inches (in-lh) x . 1 13 = Newton Meters (N-m) x 8.85 = in-lb
by the manufacturer's engineers. Pounds-Force Feet (ft-lh) x 1 356 = Newton Meters (N-m) x .738 . ft-lb
VELOCITY
Though, in some cases, that value may not be conveniently measured with Miles Per Hour (MPH I x 1 .609 = Kilometers Per Hour (KPH) x .621 - MPH
what is available in your toolbox. Luckily, many of the measuring devices which POWER
are available today will have two scales so the Standard or Metric measure- Horsepower (Hp( * .745 =-- Kilowatts x 1 34 = Horsepower

ments may easily be taken. If any of the various measuring tools which are FUEL CONSUMPTION*
available to you do not contain the same scale as listed in the specifications, Miles Per Gallon IMP (MPG)
Kilometers Per Liter (Km/L)
x .154
x 2.352
- Kilometers Per Liter (Km/L)
- IMP MPG
use the accompanying conversion factors to determine the proper value.
The conversion factor chart is used by taking the given specification and Kilometers Per Liter {Km/1,) x 2.352 = US MPG
It is common to covert from miles per gallon (r ipg) to liters/100 kilometers (1/100 km), where upg (IMP) x 1/100 km
multiplying it by the necessary conversion factor. For instance, looking at the = 282 and mpg (US) x 1/10(1 km = 235

first line, if you have a measurement in inches such as "free-play should be 2 TEMPERATURE
in." but your ruler reads only in millimeters, multiply 2 in. by the conversion Degree Fahrenheit CF)
Degree CVUius f(') -
- f C x l . 8 ) t 32
(K - 32) \6
factor of 25.4 to get the metric equivalent of 50.8mm. Likewise, if the specifica-
tion was given only in a Metric measurement, for example in Newton Meters TCCS1044

(Nm), then look at the center column first. If the measurement is 100 Nm, multi- Fig. 23 Standard and metric conversion factors chart
ply it by the conversion factor of 0.738 to get 73.8 ft. Ibs.

SERIAL NUMBER IDENTIFICATION

Vehicle 1 4 N 4 J F 1 0 0 0 0 1

> See Figures 24 and 25


The Vehicle Identification Number (VIN) plate is mounted on the driver's side
of the instrument panel, and is visible through the windshield.
The models covered in this book are full size C/K trucks including the Tahoe,
Blazer, Jimmy, Yukon and Suburban. Starting in 1992 the Blazer was renamed
the Blazer/Tahoe and Jimmy the Jimmy/Yukon.
The 5th digit on the vehicle identification number is the vehicle line and
chassis type:
C and R are 2-wheel drive conventional cabs
V and K are 4-wheel drive conventional cabs

Fig. 25 Vehicle Identification Number decoding

Engine
See Figure 26
On the 4.8L, inline 6-cylinder engine, the engine identification number is
found on a machined pad on the left side of the block, just rear of center, below
the engine side cover.
On the 1988-92 4.3L V6 engine, the engine identification number is found
Fig. 24 The Vehicle Identification Number (VIN) is visible through on a machined pad on the block, at the front just below the right side cylinder
the windshield head.
1-8 GENERAL INFORMATION AND MAINTENANCE
VEHICLE IDENTIFICATION CHART
Engine Code Model Year
Engine
Engine Series Displacement Cubic No. of Fuel
(IO/VIN) Liters Inches Cylinders System Eng. Mfg. Code Year
Z 4.3 263 (4293) 6 TBI CPC J 1988
W 4.3 263 (4293) 6 CSFI CPC K 1989
T 4.8 292 (4785) 6 1BC CPC L 1990
H 5.0 305 (4999) 8 CPC M 1991
M 5.0 305 (4999) 8 CSFI CPC N 1992
K 5.7 350 (5735) 8 TBI CPC P 1993
R 5.7 350 (5735) 8 CSFI CPC R 1994
C 6.2 379(6210) 8 D DDA S 1995
J 6.2 379 (6210) 8 D DDA T 1996
F 6.5 395 (6473) 8 @ CPC V 1997
P 6.5 395 (6473) 8 D CPC W 1998
S 6.5 395 (6473) 8 TD CPC
N 7.4 454 (7440) 8 TBI CPC
W 7.4 454 (7440) 8 4BC CPC
J 7.4 454 (7440) 8 MFI CPC
The 10th digit of the Vehicle Identification Number (VIN) is the ; ear code and the 8th digit is the engine code.
4BCorTBI D-Diesel

D or TD/HO DDA-DetroitC sel Allison

1BC-1 Barrel Carburetor HO-High Oi put


4BC-4 Barrel Carburetor MFI-Multi-port uel Injection
CPC-Chevrolet/Pontiac ol Canada TBI-Throttle B^Jy Injection
CSFi-Central Sequential Fuel Injection TD-Turbo Dii

12Month of Manufacture (December)


10-Day of Manufacturer (Tenth)
TTruck engine
FATransmission and Engine Combination

Transmission
The Muncie 117mm 4-speed transmission is numbered on the rear of the
case, above the output shaft.
The 4-Speed 85mm and 5-Speed 85mm transmissions are numbered on the
right rear of the case.
The NVG 3500 5-speed transmissions are numbered on the top, left side of
the case, near the bellhousing.
The NVG 4500 5-speed transmissions are numbered on the top, left side of
Fig. 26 The engine identification number is usually located on < the case, near the bellhousing.
machined pad on the engine block The NVG 5LM60 5-speed transmissions are numbered on the lower left side,
about halfway back on the case.
The automatic transmissions are identified by a plate attached to the right
On the 1993-98 4.3L V6 engine, the engine identification number is f und side, which is stamped with the serial number.
on a machined pad on the rear of the cylinder block, below and behind t t ; left
cylinder head where the engine mates with the bellhousing. Drive Axle
On V8 gasoline engines, the engine identification number is usually f pnd on
a machined pad on the block, at the front just below the right side cylind The drive axle serial number is stamped on the axle shaft housing, where it
head. The engine identification number is sometimes also found on a mat hined connects to the differential housing.
pad on the left, rear upper side of the block, where the engine mates with he Front axles on four wheel drive models are marked on the front of the left
bellhousing. axle tube.
On V8 diesel engines, the engine identification number is found on a
machined pad on the front of the block, between the left cylinder head anf the Transfer Case
thermostat housing, and/or on a machined pad on the left rear of the bloc) t, just
behind the left cylinder head. In the following example, engine number All transfer cases have a build tag attached to the case.
F1210TFA is broken down as follows: On the NP205, it is attached to the bolt retaining the Power Take Off (PTO)
FManufacturing Plant. F-Flint and T-Tonawanda cover.
GENERAL INFORMATION AND MAINTENANCE 1-9

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1-10 GENERAL INFORMATION AND MAINTENANCE
On the NP231, NP233 and NP241, it is attached to the rear case half.
On the NV241 and NV243, it is attached to the rear case half.
On the Borg Warner 4401/4470, it is attached to an extension housing
bolt.

Service Parts Identification Label


I See Figure 27
The service parts identification label, commonly known as the optio i list,
is usually located on the inside of the glove compartment door. On sor IB 2 Wheel base
trucks, you may have to look for it on an inner fender panel. The label ists 3 Model designation
4 RPO and/Of SEO
5 Order numbef
6 E.lenoi colof
the vehicle serial number, wheelbase, all Regular Production Options (IPOs) 7 Paml lechnology

and all special equipment. Probably, the most valuable piece of inform tion
on this label is the paint code, a useful item when you have occasion tj need
paint. Fig. 27 Service parts identification label

ROUTINE MAINTENANCE AND TUNE-UP


Proper maintenance and tune-up is the key to long and trouble-free v :hicle and look through the filter at the light. If no glow of light can be seen through
life. Studies have shown (hat a properly tuned and maintained vehicle a \e better gas mileage than anmaterial,
the element out-of-tune vehicle.
replace As aIfconscientio
the filter. holes in thesfilter element are apparent
or signs of dirt seepage through the filter are evident, replace the filter.
owner and driver, set aside a Saturday morning, say once a month, to cf ick or
replace items which could cause major problems later. Keep your own p rsonal
log to jot down which services you performed, how much the parts cost m,
the date, and the exact odometer reading at the time. Keep all receipts fo such
items as engine oil and filters, so that they may be referred to in case of j elated
problems or to determine operating expenses. As a do-it-yourselfer, the:i
receipts are the only proof you have that the required maintenance was [ in-
formed. In the event of a warranty problem, these receipts will be invalua; )le.
The literature provided with your vehicle when it was originally delivered
includes the factory recommended maintenance schedule. If you no Ion; ;r have
this literature, replacement copies are usually available from the dealer.

Air Cleaner
1. Wing Nut
See Figures 28, 29 and 30 2.2 Hole Cover
3. Air Cleaner Assembly
4. Air Cleaner Extension
The element should be replaced at the recommended intervals shown in the 5. TBI Assembly
Maintenance Intervals chart later in this section. If your truck is operated under
severely dusty conditions or severe operating conditions, more frequent
changes will certainly be necessary. Inspect the element at least twice a \tear.
Early spring and early fall are always good times for inspection. Remove tie
element and check for any perforations or tears in the filter. Check the cli aner Fig. 29 Exploded view of the air cleaner housing1993 gasoline
housing tor signs of dirt or dust that may have leaked through the filter e ement engines
or in through the snorkel tube. Position a droplight on one side of the element

1 Air cleaner
2. Seal
3. Extension
4. Stud
5. Nut - 18 ini
\. Air Cleaner

3. EGR Valve

Fig. 28 Typical air cleaner housing assembly components198 -92 Fig. 30 Exploded view of the air cleaner housing6.2L diesel
gasoline engines engines
GENERAL INFORMATION AND MAINTENANCE 1-11

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UNDERHOOD MAINTENANCE COMPONENT LOCATIONSC/K-SERIES
1. Engine oil dipstick 5. Coolant recovery reservoir 10. Radiator hose (upper)
2. Automatic transmission 6. Air filter element (under
dipstick housing)
11. Windshield washer fluid
reservoir
ro
3. Battery 7. Brake master cylinder 12. Power steering reservoir
4. Distributor (under resonance 8. Oil filler cap 13. Underhood fuse panel CD
housing) 9. Serpentine belt 14. Radiator cap

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GENERAL INFORMATION AND MAINTENANCE 1-13
REMOVAL & INSTALLATION Fuel Filter
I See Figures 31. 32, 33. 34 and 35 REMOVAL & INSTALLATION
1. On older model vehicles, loosen the wingnut(s) and lift off the housing
cover. On newer model vehicles, unfasten the retaining clips and separate the
Carbureted Gasoline Engines
two case halves.
2. On the 6.5L diesel, position the cover with the air cleaner flexible hose FILTER IN CARBURETOR
off to the side.
3. Withdraw the element from the housing and discard it. I See Figure 36
4. With a clean rag, remove any dirt or dust from the front cover and also
The fuel filter should be serviced at the interval given on the Maintenance
from the element seating surface. Interval chart. Two types of fuel filters are used, a bronze type and a paper ele-
To install: ment type. Filter replacement should be attempted only when the engine is
5. Position and install the new filter element so that it seats properly in the
cold. Additionally, it is a good idea to place some absorbent rags under the
housing. fuel fittings to catch the gasoline which will spill out when the lines are loos-
6. On the 6.5L diesel, position the cover with the attached hose over the
ened.
element and snap the retaining clips into place,
1. Disengage the fuel line connection at the intake fuel filter nut. Plug the
7. On early model vehicles, install the housing lid and tighten the
opening to prevent loss of fuel.
wingnut(s) to about 18 inch Ibs. (2 Nm),
8. On late model vehicles, place the housing cover into position and engage 2. Remove the intake fuel filter nut from the carburetor with a 1 in open end
wrench (or adjustable wrench).
the retaining clip. 3. Remove the filter element and spring.
WARNING 4. Check the element for restrictions by blowing on the cone end. Air
should pass freely.
Do not drive the vehicle with air cleaner removed. Doing so will 5. Clean or replace the element, as necessary.
allow dirt and a variety of other foreign particles to enter the engine To install:
and cause damage and wear. Also, backfiring could cause a fire in 6. Install the element spring, then the filter element in the carburetor. Bronze
the engine compartment. filters should have the small section of the cone facing out.

Fig. 31 Loosen the wingnut and remove it Fig. 33 Remove the old air cleaner ele-
from the air cleaner cover Fig. 32 Removing the air cleaner cover ment

87981P05

Fig. 34 On newer vehicles, lift up the air Fig. 35 Remove the filter element1996
cleaner cover1996 truck shown truck shown Fig. 36 In-carburetor fuel filter
1-14 GENERAL INFORMATION AND MAINTENANCE
7. Install a new gasket on the intake fuel nut. Install the nut in the carburetor 3. Turn the filter housing counterclockwise and allow the fuel to drain into
body and tighten securely. a suitable container.
8. Install the fuel line and tighten the connector. 4. Remove the filter housing and gasket from the base.
5. Remove the fuel filter cartridge.
INLINE FILTER 6. Inspect the filter housing for signs of corrosion or damage, replace as
Some trucks may have an inline filter. This is a can-shaped device located in necessary.
the fuel line between the pump and the carburetor. It may be made of either To install:
plastic or metal. To replace the filter: 7. Appall a few drops of clean engine oil to the new housing gasket and
1. Place some absorbent rags under the filter. Remember, it will be Jill of install the gasket.
gasoline when removed. 8. Install a new filter cartridge and the place the filter housing into position.
2. Use a pair of pliers to expand the clamp on one end of the filter, I ji 9. Tighten the housing by turning it clockwise until the gasket seats, then
slide the clamp down past the point to which the filter pipe extends in tlpp rub- tighten the housing an additional % turn.
ber hose. Do the same with the other clamp. 10. Connect the negative battery cable.
3. Gently twist and pull the hoses free of the filter pipes. Remove arjjl dis- 11. Start the engine and check for fuel leaks.
card the old filter. 12. Repair as necessary.
Mcst replacement filters come with new hoses that should be Diesel Engines
installed with a new filter.
6.2L ENGINE
4. Install the new filter into the hoses, slide the clamps back into pla^e, and
check for leaks with the engine idling. > See Figures 40 and 41

Fuel Injected Gasoline Engines The fuel/water separator is usually located on the header assembly.
1. Drain the fuel from the fuel filter by opening both the air bleed and the
EXCEPT CARTRIDGE TYPE water drain valve allowing the fuel to drain out into an appropriate container.
2. Remove the fuel tank cap to release any pressure or vacuum in the tank.
See Figures 37 and 38
3. Unstrap both bail wires with a screwdriver and remove the filter.
The inline filter on the fuel injected models is found along the frame To install:
1. Properly relieve the fuel system pressure. 4. Before installing the new filter, insure that both filter mounting plate fit-
tings are clear of dirt.
CAUTION 5. Install the new filter, snap into place with the bail wires.
6. Close the water drain valve and open the air bleed valve. Connect a Ve
The 220 TBI unit used on the V6 and V8 engines contains a constant in. (3mm) I.D. hose to the air bleed port and place the other end into a suitable
bleed feature in the pressure regulator that relieves pressure any container.
time the engine is turned off. Therefore, no special relief procedure 7. Disconnect the fuel injection pump shut off solenoid wire.
is required, however, a small amount of fuel may be released when 8. Crank the engine for 10-15 seconds, then wait one minute for the starter
the fuel line is disconnected. To reduce the chance of personal motor to cool. Repeat until clear fuel is observed coming from the air bleed.
injury, cover the fuel line with cloth to collect the fuel and then
place the cloth in an approved container. If the engine is to be cranked, or starting attempted with the air
cleaner removed, care must be taken to prevent dirt from being pulled
2. Disconnect the fuel lines. into the air inlet manifold which could result in engine damage.
3. Remove the fuel filter from the retainer or mounting bolt. 9. Close the air bleed valve, reconnect the injection pump solenoid wire
To install: and replace the fuel tank cap.
4. Install the filter and tighten the bolt to 12 ft. Ibs. (16 Nm). Connecj the 10. Start the engine, allow it to idle for 5 minutes and check the fuel filter for
fuel lines and tighten the nuts to 20 ft. Ibs. (26 Nm). leaks.
5. Road test the truck and check for any leaks.
6.5L ENGINE
The filter has an arrow (fuel flow direction) on the side of the c; se, be
sure to install it correctly in the system, the with arrow facing aw; I See Figure 42
from the fuel tank.
1. Remove the fuel tank cap to release any pressure or vacuum in the tank.
CARTRIDGE TYPE 2. If equipped, remove the upper intake manifold cover.
> See Figure 39 3. Open the air bleed valve on top of the filter assembly.
4. Spin off the element nut at the top of the filterit looks like a large
1. Properly relieve the fuel system pressure. knurled knob.
2. Disconnect the negative battery cable. 5. Lift the filter element out of the header assembly.

87981P06

Fig. 37 The fuel filter is found along the Fig. 38 Using two flare nut wrenches, dis- Fig. 39 The cartridge type fuel filter is
frame rail connect thi fuel lines located along the frame rail
GENERAL INFORMATION AND MAINTENANCE 1-15
To install:
6. Clean the mating surfaces on the header assembly and the filter. Align
the widest key slot in the element cap with that in the header assembly, push the
element down until the two surfaces make contact, then tighten the nut by hand.
7. Open the air bleed valve on top of the filter assembly. Connect a hose to
the bleeder valve and insert the other end into a suitable glass container.
8. Disconnect the fuel injection pump shut-down solenoid wire or the
FUEL SOL relay center fuse (whichever applies to your vehicle, then crank the
engine in 10-15 second intervals until clear, clean fuel is coming out of the
hose.
Wait about one minute between cranking intervals!
9. Remove the hose and close the bleeder valve.
10. Connect the shut-down solenoid wire or fuse and install the fuel cap.
Start the engine and allow it to idle for a few minutes. Check for leaks.
1 Water drain valve
2. Bail wires 6 Air bleed port PCV Valve
3 Fuel filter element 7 Restriction switch
4 Air bleed 8 Fuel heater > See Figure 43
5 Filter adapter 9 Water sensor
84901031
"Diesel engines do not utilize a PCV system.
Fig. 40 Exploded view of the fuel filter6.2L engines The PCV valve, which is the heart of the positive crankcase ventilation sys-
tem, should be changed as noted in the Maintenance Intervals chart at the end
of this section. The main thing to keep in mind is that the valve should be free
FUEL FILTER/WATER SEPARATOR of dirt and residue and should be in working order. As long as the valve is not
showing signs of becoming damaged or gummed up, it should perform its
function properly. When the valve becomes sticky and will not operate freely, it
FILTER INLET HOSE should be replaced.
FUEL FILTE'R/WATER SEPARATOR ^ The PCV valve is used to control the rate at which crankcase vapors are
returned to the intake manifold. The action of the valve plunger is controlled
by intake manifold vacuum and the spring. During deceleration and idle, when
manifold vacuum is high, it overcomes the tension of the valve spring and the
plunger bottoms in the manifold end of the valve housing. Because of the
valve construction, it reduces, but does not stop, the passage of vapors to the
intake manifold. When the engine is lightly accelerated or operated at constant
speed, spring tension matches intake manifold vacuum pull and the plunger
takes a mid-position in the valve body, allowing more vapors to flow into the
manifold.
The valve is either mounted on the valve cover or in the line which runs from
Fig. 41 Fuel filter/water separator6.2L engines the intake manifold to the crankcase. Do not attempt to adjust or repair the
valve. If the valve is faulty, replace it.

7. NUT. ELEMENT
8. ASSEMBLY, ELEMENT
9. ASSEMBLY. HEADER
0. SEAL. WATER SENSOR
1 ASSEMBLY. WATER SENSOR
2 SCREW. SENSOR MOUNTING
4. SEAL. CAP
5. ASSEMBLY. HEATEfl
6. NUT. CAP
8. CAP, AIR BLEED

Fig. 43 PCV valve location-gasoline engines

REMOVAL & INSTALLATION

> See Figures 44 and 45


1. Remove the PCV valve from the cylinder head cover or trom the mani-
fold-to-crankcase hose.
2. Visually inspect all hose connections and hoses for cracks, clogs or
Fig. 42 Exploded view of the fuel filter6.5L engines deterioration and replace as necessary.
1-16 GENERAL INFORMATION AND MAINTENANCE

1 CDR V A L V E 3 HOSE

2 INTAKE MANIFOLD 1 RIGHT VALVE COVER


87981POB
84901038
Fig. 45 Disconnect the PCV valve from the
Fig. 44 Pull the PCV valve out of the cylin- hose and remove the valve from the vehi-
der head cle Fig. 46 COR valve6.2L engine

The evaporative emission canister is located on the left side of the engine
Crankcase Depression Regulator and Flow Control compartment, with a filter located in its bottom (if applicable).
Valve
For further information on the evaporative emission system, please
refer to Section 4.
SERVICING
To service the canister filter:
1. Note the installed positions of the hoses, tagging them as necessary, in
See Figures 46 and 47 case any have to be removed.
This system is found only on diesel engines. 2. Loosen the clamps and remove the canister.
3. Pull the filter out and throw it away.
The Crankcase Depression Regulator (CDR) is designed to scavenge 4. Install a new canister filter.
crankcase vapors in basically the same manner as the PCV valve on gas ine 5. Install the canister and tighten the clamps.
engines. The valve is located by the right cylinder head cover. On this sy! tern, 6. Check the hoses.
the valve and filter are replaced as an assembly.
The ventilation pipes and tubes should also be cleaned and replaced s wear
and tear dictates. Battery
Do not attempt to test the crankcase controls on these diesels.
Instead, clean the valve cover filter assembly and vent pipes and heck PRECAUTIONS
the vent pipes. Replace the breather cap assembly every 30,000 i illes
(48,000 km). Replace all rubber fittings as required every 15,000 miles Always use caution when working on or near the battery. Never allow a tool
(24.000 km). to bridge the gap between the negative and positive battery terminals. Also, be
careful not to allow a tool to provide a ground between the positive cable/termi-
nal and any metal component on the vehicle. Either of these conditions will
cause a short circuit, leading to sparks and possible personal injury.
Do not smoke or all open flames/sparks near a battery; the gases contained in
th.3 battery are very explosive and, if ignited, could cause severe injury or death.
All batteries, regardless of type, should be carefully secured by a battery
hold-down device. If not, the terminals or casing may crack from stress during
vehicle operation. A battery which is not secured may allow acid to leak, making
it discharge faster. The acid can also eat away at components under the hood.
Always inspect the battery case for cracks, leakage and corrosion. A white corro-
sive substance on the battery case or on nearby components would indicate a leak-
ing or cracked battery. If the battery is cracked, it should be replaced immediately.
1 HOSE 3 CDRVALVE GENERAL MAINTENANCE
2 HEATSHIELD 4 TURBO CHARGER

Always keep the battery cables and terminals free of corrosion. Check and
clean these components about once a year.
Fig. 47 COR valve6.5L engine Keep the top of the battery clean, as a film of dirt can help discharge a bat-
tery that is not used for long periods. A solution of baking soda and water may
be used for cleaning, but be careful to flush this off with clear water. DO NOT let
Evaporative Canister any of the solution into the filler holes. Baking soda neutralizes battery acid and
will de-activate a battery eel I.
SERVICING Batteries in vehicles which are not operated on a regular basis can fall victim to
parasitic loads (small current drains which are constantly drawing current from the
battery). Normal parasitic loads may drain a battery on a vehicle that is in storage
The only regular maintenance that need be performed on the evaporatil/e and not used for 6-8 weeks. Vehicles that have additional accessories such as a
emission canister is to regularly change the filter (on those 1988-90 motlels phone or an alarm system may discharge a battery sooner. If the vehicle is to be
which utilize one; 1991-98 trucks do not have a canister filter) and check the stored for longer periods in a secure area and the alarm system is not necessary,
condition of the hoses. If any hoses need replacement, use only hoses wr ich the negative battery cable should be disconnected to protect the battery.
are marked EVAP. No other type should be used. Whenever the vapor ven hose Remember that constantly deep cycling a battery (completely discharging
is replaced, tne reslr/cfor adjacent to the canister should also be replaced and recharging it) will shorten battery lite.
GENERAL INFORMATION AND MAINTENANCE 1-17
BATTERY FLUID ** CAUTION
I See Figure 48 Battery electrolyte contains sulfuric acid. If you should splash any
on your skin or in your eyes, flush the affected area with plenty of
Check the battery electrolyte level at least once a month, or more often in hot clear water. If it lands in your eyes, get medical help immedi-
weather or during periods of extended vehicle operation. On non-sealed batter- ately.
ies, the level can be checked either through the case (if translucent) or by
removing the cell caps. The electrolyte level in each cell should be kept filled to The fluid (sulfuric acid solution) contained in the battery cells will tell you
the split ring inside each cell, or the line marked on the outside of the case. many things about the condition of the battery. Because the cell plates must be
If the level is low, add only distilled water through the opening until the level kept submerged below the fluid level in order to operate, the fluid level is
is correct. Each cell must be checked and filled individually. Distilled water extremely important. And, because the specific gravity of the acid is an indica-
should be used, because the chemicals and minerals found in most drinking tion of electrical charge, testing the fluid can be an aid in determining if the bat-
water are harmful to the battery and could significantly shorten its life. tery must be replaced. A battery in a vehicle with a properly operating charging
If water is added in freezing weather, the vehicle should be driven several system should require little maintenance, but careful, periodic inspection should
miles to allow the water to mix with the electrolyte. Otherwise, the battery could reveal problems before they leave you stranded.
freeze. At least once a year, check the specific gravity of the battery. It should be
Although some maintenance-free batteries have removable cell caps, the between 1.20 and 1.26 on the gravity scale. Most auto stores carry a variety of
electrolyte condition and level on all sealed maintenance-free batteries must be inexpensive battery hydrometers. These can be used on any non-sealed battery
checked using the built-in hydrometer "eye." The exact type of eye will vary. to test the specific gravity in each cell.
But, most battery manufacturers, apply a sticker to the battery itself explaining The battery testing hydrometer has a squeeze bulb at one end and a nozzle at
the readings. the other. Battery electrolyte is sucked into the hydrometer until the float is lifted
Although the readings trom built-in hydrometers will vary, a green eye from its seat. The specific gravity is then read by noting the position of the float.
usually indicates a properly charged battery with sufficient fluid level. A If gravity is low in one or more cells, the battery should be slowly charged and
dark eye is normally an indicator of a battery with sufficient fluid, but checked again to see if the gravity has come up. Generally, if after charging, the
which is low in charge. A light or yellow eye usually indicates that elec- specific gravity between any two cells varies more than 50 points (0.50), the
trolyte has dropped below the necessary level. In this last case, sealed battery should be replaced, as it can no longer produce sufficient voltage to
batteries with an insufficient electrolyte must usually be discarded. guarantee proper operation.
Checking the Specific Gravity CABLES
I See Figures 49, 50 and 51
I See Figures 52 thru 57
A hydrometer is required to check the specific gravity on all batteries that are
not maintenance-free. On batteries that are maintenance-free, the specific gravity Once a year (or as necessary), the battery terminals and the cable clamps
is checked by observing the built-in hydrometer "eye" on the top of the battery should be cleaned. Loosen the clamps and remove the cables, negative cable
case. first. On top post batteries, the use of a puller specially made for this purpose is
recommended. These are inexpensive and available in most parts stores. Side
terminal battery cables are secured with a small bolt.
Clean the cable clamps and the battery terminal with a wire brush, until all
corrosion, grease, etc., is removed and the metal is shiny. It is especially impor-
tant to clean the inside of the clamp thoroughly (an old knife is useful here),
since a small deposit of oxidation there will prevent a sound connection and
inhibit starting or charging. Special tools are available for cleaning these parts,
one type for conventional top post batteries and another type for side terminal
batteries. It is also a good idea to apply some dielectric grease to the terminal,
as this will aid in the prevention of corrosion.
After the clamps and terminals are clean, reinstall the cables, negative cable
last; DO NOT hammer the clamps onto battery posts. Tighten the clamps
securely, but do not distort them. Give the clamps and terminals a thin external
coating of grease after installation, to retard corrosion.
TCCA1G02
Check the cables at the same time that the terminals are cleaned. If the cable
insulation is cracked or broken, or if the ends are frayed, the cable should be
Fig. 48 Maintenance-free batteries usually contain a built-in replaced with a new cable of the same length and gauge.
hydrometer to check fluid level

Fig. 49 On non-sealed batteries, the fluid


level can be checked by removing the cell Fig. 50 If the fluid level is low, add only Fig. 51 Check the specific gravity of the
caps distilled water until the level is correct battery's electrolyte with a hydrometer
1-18 GENERAL INFORMATION AND MAINTENANCE

Fig. 54 A wire brush may be used to clean


Fig. 52 Loosen the battery cable retaining any corrosion or foreign material from the
nut. cable

TCCA1P05 TCCA1P06

Fig. 55 The wire brush can also be used to Fig. 56 Th battery terminal can also be Fig. 57 Before connecting the cables, it's
remove any corrosion or dirt from the bat- cleaned using a solution of baking soda a good idea to coat the terminals with a
tery terminal and water small amount of dielectric grease

CHARGING replace all drive belts at one time, as a preventive maintenance measure, during
this service operation.
** CAUTION ADJUSTMENT
The chemical reaction which takes place in all batteries gene ates
explosive hydrogen gas. A spark can cause the battery to expode V-Belts
and splash acid. To avoid personal injury, be sure there is pn ter > See Figures 63 and 64
ventilation and take appropriate fire safety precautions when vork-
ing with or near a battery. Belt tension should be checked with a gauge made for the purpose. If a ten-
sion gauge is not available, tension can be checked with moderate thumb pres-
A battery should be charged at a slow rate to keep the plates inside fr mget- sure applied to the belt at its longest span midway between pulleys. If the belt
ting too hot. However, if some maintenance-free batteries are allowed to is- has a free span less than 12 in. (305mm), it should deflect approximately Va-V*
charge until they are almost "dead," they may have to be charged at a hi h rate in. (3-6mm). If the span is longer than 12 in. (305mm), deflection can range
to bring them back to "life." Always follow the charger manufacturer's in: ruc- between Vs in. (3mm) and % in. (9.5mm).
tions on charging the battery. If a tension gauge is available use the following procedure:
1. Place a belt tension gauge at the center of the greatest span of a warm,
REPLACEMENT not hot, drive belt and measure the tension.
2. If the belt is not within the specification, loosen the component mounting
When it becomes necessary to replace the battery, select one with an mper- bracket and adjust to specification.
age rating equal to or greater than the battery originally installed. Deteric ation 3. Run the engine at idle for 15 minutes to allow the belt to reseat itself in
and just plain aging of the battery cables, starter motor, and associated v res the pulleys.
makes the battery's job harder in successive years. This makes it pruden to 4. Allow the drive belt to cool and re-measure the tension. Adjust as neces-
install a new battery with a greater capacity than the ofd. sary to meet the following specifications:
V6, V8 gasoline engines: used90 ft. Ibs. (122Nm); new135 ft. Ibs.
(183 Nm).
64.8L: used90 ft. Ibs. (122 Nm); new169 ft. Ibs. (229 Nm).
V86.2L76.5L diesel: used67 ft. Ibs. (90 Nm); new146 ft. Ibs. (197 Nm).
INSPECTION
A belt is considered "used" after 15 minutes of operation.
I See Figures 58, 59, 60, 61 and 62
Serpentine Belts
Inspect the belts for signs of glazing or cracking. A glazed belt will be per-
fectly smooth from slippage, while a good belt will have a slight texture t fabric The serpentine belt tension can be checked by simply observing the belt
visible. Cracks will usually start at the inner edge of (he belt and run out ard. acceptable belt wear range indicator located on the tensioner spindle. If the belt
All worn or damaged drive belts should be replaced immediately. It is be to does not meet the specified range, it must be replaced.
GENERAL INFORMATION AND MAINTENANCE 1-19

TCCS1215

Fig. 58 There are typically 3 types of Fig. 60 Deep cracks in this belt will cause
accessory drive belts found on vehicles flex, building up heat that will eventually
today Fig. 59 An example of a healthy drive belt lead to belt failure

Nippondenso
Borroughs

t TCCS1216

Fig. 61 The cover of this belt is worn, Fig. 62 Installing too wide a belt can
exposing the critical reinforcing cords to result in serious belt wear and/or break-
excessive wear age Fig. 63 Common belt tension gauges

REMOVAL & INSTALLATION


BELT
RULER DEFLECTION V-Belts
I See Figures 65, 66 and 67
STRAIGHT
EDGE
1. Loosen the driven accessory's pivot and mounting bolts. Remove the belt.
2. Install the belt. Move the accessory toward or away from the engine until
the tension is correct. You can use a wooden hammer handle, or broomstick, as
a lever, but do not use anything metallic, such as a prybar. Certain models may
utilize an adjusting bolt to do this work for you. Simply loosen the mounting
bolt and turn the adjuster.
MAKE SURE RULER IS
3. Tighten the bolts and recheck the tension. If new belts have been installed,
PERPENDICULAR TO STRAIGHT EDGE run the engine for a few minutes, then recheck and readjust as necessary.
It is better to have belts too loose than too tight, because overtight belts will
lead to bearing failure, particularly in the water pump and alternator. However,
Fig. 64 Measuring belt deflection
loose belts place an extremely high impact load on the driven component due to
the whipping action of the belt.

Fig. 67 Pull outward on the component


Fig. 65 Push the component toward the and tighten the adjusting and mounting
engine and slip off the belt Fig. 66 Slip the new belt over tlie pulley bolts
1-20 GENERAL INFORMATION AND MAINTENANCE
Serpentine Belts
See Figure 68
1. On all models except the 7.4L engine with an Air Injector P or
(AIR) pump (California emissions only), use a 1/2 in. breaker ba :.itl' a
socket placed on the tensioner pulley bolt, rotate the tensioner to reli ve belt
tension.
2. On all 7.4L engines with an AIR pump (California emissions only , use a
suitable wrench on the pulley axis bolt to rotate the tensioner clockwise
relieve belt tension.
3. Remove the serpentine belt.
To install:
4. Route the belt over all the pulleys except the tensioner.
5. On all models except the 7.4L engine with an AIR pump (Califorr a emis-
sions only), place the breaker bar and socket on the tensioner pulley bo! and
rotate the tensioner to the released position.
6. Install the belt and return the pulley to its original position.
7. On all 7.4L engines with an AIR pump (California emissions only use a
suitable wrench on the pulley axis bolt to rotate the tensioner clockwise o
relieve belt tension.
8. Install the belt and return the pulley to its original position.
9. Check that the belt is properly seated in each pulley. Fig. 70 Drive belt routing1988-90 5.7L and 6.2L engines

Fig. 68 Rotate the tensioner with a breaker bar to relieve belt t n-


sion
Fig. 71 Drive belt routing1988-90 4.3L, 5.0L and 7.4L engines

BELT ROUTING

I See Figures 69 thru 88

A. R/V3 5 7L (W/O A'C)


B. R.V35 7L (W A;C}
C. R/V1.2 5.7L (W AC)
D. R'Vl.a 5 7L (W/O A/C)
50 Coolanl Pump Pulley
51. Crankstial Pulley
52 Generator Pultey
54. Power Steering Pump Pulley
50 Waler pump pulle 55 Aif Conditioning Compressor Pulley
56 Idler Pulley
60. Tensioner

Fig. 69 Drive belt routing1988-90 5.7L HD engines Fig. 72 Drive belt routing1991 5.7L engines, R/V series
GENERAL INFORMATION AND MAINTENANCE 1-21

/ A.
B.
50.
R/V 6.2L <w A/C)
R/V 6.2L (w/o A/C)
Coolant Pump Pulley
51. Crankshaft Pulley
52. Generator Pulley
54. Power Steering Pump Pulley
55. Air Conditioning Compressor Pulley

Fig. 73 Drive belt routing1991 6.2L engines, R/V series

* 4.31, 5.0L, 5.7L Engines


A. With Power Steering Pump
B- With Power Steering Pump
and A/C Compressor
1. Belt C. With Power Steering Pump
2. Air Conditioning Compressor and AIR Pump
52 56 3- Tensioner D. With Power Steering Pump
4. Generator and AIR Pump and A/C Compressor
5. Power Steering Pump
6. Crankshaft * 6.2L Diesel Engines
A. P3 6.26 HD (W P/S, P/B Pump) 7. Coolant Pump E. With Air Conditioning
B. P3 4.3L, 5.7L (W P/S) 8. AIR Pump F. With Air Conditioning
C. P3 5.7L (W P.'S and A'C) 9. Idler Pulley or Vacuum Pump or Idler Pulley
50. Coolant Pump Pulley
5! Crankshaft Pulley
52 Generator Pulley
54 Power Steering Pump Pulley
55 Air Conditioning Compressor Pulley
56. Idler Pulley

Fig. 76 Drive belt routing1991 4.3L, 5,01, 5.7L and 6.2L engines,
Fig. 74 Drive belt routing1991 6.2L HD and 4.3L engines C/K series

1 (W A/C)
L (W/O A/C) A. 7.4L Engine without Air Conditioning 4 Generator
it Pump Pulley B. 7.4L Engine with Air Conditioning 5. Power Steering Pump
6. Crankshaft
ower Steering Pump P 7. Water Pump
2. Air Conditioning Compressor 8. AIR Pump
ir Conditioning Compre
Her Pulley
3. Tensioner 9. Idler Pulley

Fig. 75 Drive belt routing1991 7.4L engines, R/V series Fig. 77 Drive belt routing1991 7.4L engines, C/K series
1-22 GENERAL INFORMATION AND MAINTENANCE

A A/C compressor pulley


B Drive belttensioner pulley
C Generator pulley
D Power steering pump pulley
E Crankshaft pulley
F Coolanl pump pulley A PULLEY. A/C COMPRESSOR
H Idler pulley B- PULLEY. DRIVE BELT TENSIONEH
C PULLEY, GENERATOR
D PULLEY, POWER STEERING PUMP
E PULLEY, CRANKSHAFT
WITH A|I ; F. PULLEY. COOLANT PUMP
H. PULLEY, IDLER
E4901065

Fig. 78 Drive belt routing1992-93 4.3L, 5.0L and 5.7L engines Fig. 82 Drive belt routing1994-95 4.3L, 5.0L and 5.7L engines,
without AC C/K series (without AIR)

A A/C compressor pulley


B Drive belttensiorier pulley
C Generator pulley
D Power steering pump pull
E Crankshaft pulley A PULLEY, A/C COMPRESSOR
B PULLEY, DRIVE BELT TENSIONER
H Idler pulley C. PULLEY. GENERATOR
I A I R pump pulley D PULLEY, POWER STEERING
WITHOUT A/C
E PULLEY CRANKSHAFT
F PULLEY, COOLANT PUMP
H PULLEY. IDLER
I PULLEY. A I R. PUMP

Fig. 83 Drive belt routing1994-95 4.3L, 5.0L and 5.7L engines,


Fig. 79 Drive belt routing1992-93 4.3L and 5.7L engines with AC C/K series (with AIR)

C1 WITH A/C CK 2,3 WITHOUT A/C CK 2,3 WITH A/C


C1 WITH A/C CK 2,3 WITHOUT A/C CK 2,3 WITH
A PULLEY. A/C COMPRESSOR E PULLEY. CRANKSHAFT
A. PULLEY. AC COMPRESSOR E. PULLEY. CRANKSHAFT 8 PULLEY. DRIVE BELT TENSIONEH F PULLEY, COOLANT PUMP
B PULLEY, DRIVE 8ELT TENSONEH F PULLEY, COOLANT PUMP C PULLEY. GENERATOR M PULLEY, IDLER
C PULLEY. GENERATOR H. PULLEY. IDLER 0 PULLEY. POWER STEERING PUMP i PULLEY, A.I.R PUMP
0 PULLEY. POWER STEERING PUMP t. PULLEY, A.J.R. PUMP

Fig. 84 Drive belt routing1994-95 7.4L engines, C1. C/K 2, 3


Fig. 80 Drive belt routing1992-93 7.4L engines series

A PULLEY. A/C COMPRESSOR V. A/C COMPRESSOR


8. ULLEY, DRIVE BEIT TENSIONEH V DRIVE BELT TENSIONEH
C ULLEY. GENERATOR V, GENERATOR
O ULLEY, POWER STEERING PUMF Y, POWER STEERING PUMI
E ULLEY, CRANKSHAFT E. ULLEY. CRANKSHAFT
F PULLEY. COOLANT PUMP f PULLEY, COOLANT PUMP
G. ULLEY. VACUUM PUMP Y. VACUUM PUMP
H. ULLEY. IDLER ULLEY, IDLER

Fig. 81 Drive belt routing1992-93 6.2L and 6.5L engines Fig. 85 Drive belt routing1994-95 diesel engines
GENERAL INFORMATION AND MAINTENANCE 1-23
^GENERATOR PULLEY Hoses
GENERATOR PULLEY

IDLER PULLEY
INSPECTION
COMPRESSOR
PULLEY
See Figures 89, 90, 91 and 92
WATER PUMP
PULLEY
Upper and lower radiator hoses along with the heater hoses should be
checked for deterioration, leaks and loose hose clamps at least every 15,000
C/SHAFT PULLEY
miles (24,000 km). It is also wise to check the hoses periodically in early spring
and at the beginning of the fall or winter when you are performing other mainte-
nance. A quick visual inspection could discover a weakened hose which might
C/SHAFT PULLEY-' have left you stranded if it had remained unrepaired.
Whenever you are checking the hoses, make sure the engine and cooling sys-
tem are cold. Visually inspect for cracking, rotting or collapsed hoses, and replace
as necessary. Run your hand along the length of the hose. If a weak or swollen
Fig. 86 Drive belt routing1996-98 4.3L, 5.0L and 5.7L engines spot is noted when squeezing the hose wall, the hose should be replaced.

A/C COMPRESSOR
PULLEY

7.4 L ENGINE WITHOUT K19


. ,:, jj
IDLER
PULLEY

TCCS121S

Fig. 89 The cracks developing along this hose are a result of age-
related hardening

REMOVAL & INSTALLATION


TENSIONER
PULLEY
See Figures 93, 94, 95 and 96
1. Remove the radiator pressure cap.

A.I.R. PUMP ** CAUTION


PULLEY

Never remove the pressure cap while the engine is running, or per-
sonal injury from scalding hot coolant or steam may result. If possi-
WITHOUT A/C
ble, wait until the engine has cooled to remove the pressure cap. If
this is not possible, wrap a thick cloth around the pressure cap and
Fig. 87 Drive belt routing1996-98 7.4L engines C/K series turn it slowly to the stop. Step back while the pressure is released
from the cooling system. When you are sure all the pressure has
been released, use the cloth to turn and remove the cap.
- Av'C COMPRESSOR
2. Position a clean container under the radiator and/or engine draincock or
^ IDLER PULLEY
(IF NOT EQUIPPED WITH A/C) plug, then open the drain and allow the cooling system to drain to an appropri-
ate level. For some upper hoses, only a little coolant must be drained. To
remove hoses positioned lower on the engine, such as a lower radiator hose,
A/C COMPRESSOR
the entire cooling system must be emptied.
IDLER PULLEY

GENERATOR ** CAUTION
C'SHAFT ~f
When draining coolant, keep in mind that cats and dogs are
WITHOUT SECOND GENERATOR
attracted by ethylene glycol antifreeze, and are quite likely to drink
any that is left in an uncovered container or in puddles on the
ground. This will prove fatal in sufficient quantity. Always drain
coolant into a scalable container. Coolant may be reused unless it
is contaminated or several years old.
C/SHAFT -

WITH SECOND GENERATOR


3. Loosen the hose clamps at each end of the hose requiring replacement
Clamps are usually either of the spring tension type (which require pliers to
Fig. 88 Drive belt routing1996-98 diesel engines squeeze the tabs and loosen) or of the screw tension type (which require screw or
hex drivers to loosen). Pull the clamps back on the hose away from the connection.
1-24 GENERAL INFORMATION AND MAINTENANCE

Fig. 90 A hose clamp that is too tight can Fig. 91 A siift spongy hose (identifiable by Fig. 92 Hoses are likely to deteriorate
cause older hoses to separate and tear on the swollen section) will eventually burst from the inside if the cooling system is not
either side of the clamp and should be replaced periodically flushed

Approximately 1/4 inch

ose requiring replacement and Fig. 95 Position the hose clamp so that it
Fig. 93 Remove the radiator cap is about 1/4 in. from the end of the hose

To install:
6. Dip the ends of the new hose into clean engine coolant to ease installation.
7. Slide the clamps over the replacement hose, then slide the hose ends
over the connections into position.
Position and secure the clamps at least 1A in. (6.35mm) from the ends
of the hose. Make sure they are located beyond the raised bead of the connector.
9. Close the radiator or engine drains and properly refill the cooling sys-
tem with the clean drained engine coolant or a suitable mixture of ethylene gly-
col coolant and water.
10. If available, install a pressure tester and check for leaks. If a pres-sure
tester is not available, run the engine until normal operating temperature is
reached (allowing the system to naturally pressurize), then check for leaks.
** CAUTION
If you are checking for leaks with the system at normal operating
temperature, BE EXTREMELY CAREFUL not to touch any moving or
hot engine parts. Once temperature has been reached, shut the
Fig. 96 Properly refill the cooling system with a suitable mixture engine OFF, and check for leaks around the hose fittings and con-
ethylene glycol coolant and water nections which were removed earlier.

4. Twist, pull and slide the hose off the fitting, taking care not to darjjage
the neck of the component from which the hose is being removed. CV-Boots
lt the hose is stuck at the connection, do not try to insert a screw triver
or other sharp tool under the hose end in an effort to free it, as the con- INSPECTION
nection and/or hose may become damaged. Heater connections espe-
cially may be easily damaged by such a procedure. If the hose is ti: be I See Figures 97 and 98
replaced, use a single-edged razor blade to make a slice along the por-
tion of the hose which is stuck on the connection, perpendicular to he The CV (Constant Velocity) boots should be checked for damage each time
end of the hose. Do not cut deep so as to prevent damaging the coi nec- the oil is changed and any other time the vehicle is raised for service. These
tion. The hose can then be peeled from the connection and discarded. boots keep water, grime, dirt and other damaging matter from entering the
CV-joints. Any of these could cause early CV-joint failure which can be
5. Clean both hose mounting connections. Inspect the condition of I IB expensive to repair. Heavy grease thrown around the inside of the front
hose clamps and replace (hem, if necessary. wheel(s) and on the brake caliper/drum can be an indication of a torn boot.
GENERAL INFORMATION AND MAINTENANCE 1-25
Thoroughly check the boots for missing clamps and tears. If the boot is dam- km). As the gap increases, the plug's voltage requirement also increases. It
aged, it should be replaced immediately. Please refer to Section 7 for proce- requires a greater voltage to jump the wider gap and about two to three times as
dures. much voltage to fire the plug at high speeds than at idle. The improved air/fuel
ratio control of modern fuel injection combined with the higher voltage output of
modern ignition systems will often allow an engine to run significantly longer
Spark Plugs on a set of standard spark plugs, but keep in mind that efficiency will drop as
I See Figure 99 the gap widens (along with fuel economy and power).
When you're removing spark plugs, work on one at a time. Don't start by remov-
A typical spark plug consists of a metal shell surrounding a ceramic insu- ing the plug wires all at once, because, unless you number them, they may become
lator. A metal electrode extends downward through the center of the insulator mixed up. Take a minute before you begin and number the wires with tape.
and protrudes a small distance. Located at the end of the plug and attached to 1. Disconnect the negative battery cable, and if the vehicle has been run
the side of the outer metal shell is the side electrode. The side electrode recently, allow the engine to thoroughly cool.
bends in at a 90 angle so that its tip is just past and parallel to the tip of the 2. Carefully twist the spark plug wire boot to loosen it, then pull upward and
center electrode. The distance between these two electrodes (measured in remove the boot from the plug. Be sure to pull on the boot and not on the wire,
thousandths of an inch or hundredths of a millimeter) is called the spark plug otherwise the connector located inside the boot may become separated.
gap. 3. Using compressed air, blow any water or debris from the spark plug well
The spark plug does not produce a spark but instead provides a gap across to assure that no harmful contaminants are allowed to enter the combustion
which the current can arc. The coil produces anywhere from 20,000 to 50,000 chamber when the spark plug is removed. If compressed air is not available, use
volts (depending on the type and application) which travels through the wires to a rag or a brush to clean the area.
the spark plugs. The current passes along the center electrode and jumps the
gap to the side electrode, and in doing so, ignites the air/fuel mixture in the -Remove the spark plugs when the engine is cold, if possible, to pre-
vent damage to the threads. If removal of the plugs is difficult, apply a
combustion chamber.
few drops of penetrating oil or silicone spray to the area around the
SPARK PLUG HEAT RANGE base of the plug, and allow it a few minutes to work.
4. Using a spark plug socket that is equipped with a rubber insert to prop-
I See Figure 100 erly hold the plug, turn the spark plug counterclockwise to loosen and remove
the spark plug from the bore.
Spark plug heat range is the ability of the plug to dissipate heat. The longer
the insulator (or the farther it extends into the engine), the hotter the plug will ** WARNING
operate; the shorter the insulator (the closer the electrode is to the block's cool-
ing passages) the cooler it will operate. A plug that absorbs little heat and Be sure not to use a flexible extension on the socket. Use of a flexi-
remains too cool will quickly accumulate deposits of oil and carbon since it is ble extension may allow a shear force to be applied to the plug. A
not hot enough to burn them off. This leads to plug fouling and consequently to shear force could break the plug off in the cylinder head, leading to
misfiring. A plug that absorbs too much heat will have no deposits but, due to costly and frustrating repairs.
the excessive heat, the electrodes will burn away quickly and might possibly

PORCELAIN
INSULATOR
INSULATOR CRACKS
OFTEN OCCUR HERE

ADJUST FOR
PROPER GAP

SIDE ELECTRODE CENTER ELECTRODE:


(BEND TO ADJUST GAP) FILE FLAT WHEN
ADJUSTING GAP,
DO NOT BEND
TCCS1010
TCCS1045
Fig. 97 CV-boots must be inspected peri- Fig. 98 A torn boot should be replaced
odically for damage immediately Fig. 99 Cross-section of a spark plug

lead to preignition or other ignition problems. Preignition takes place when plug
tips get so hot that they glow sufficiently to ignite the air/fuel mixture before the THE SHORTER
THE PATH THE
THE LONGER
THE PATH. THE
actual spark occurs. This early ignition will usually cause a pinging during low FASTER THE SLOWER THE
HEAT IS DIS- HEAT is DIS-
speeds and heavy loads. SIPATED AND SIPATED AND
The general rule of thumb for choosing the correct heat range when picking a THE COOLER
HE PLUG
THE HOTTER
H PLUG
spark plug is: if most of your driving is long distance, high speed travel, use a
colder plug; if most of your driving is stop and go, use a hotter plug. Original
equipment plugs are generally a good compromise between the 2 styles and
most people never have the need to change their plugs from the factory-recom-
mended heat range. HEAVY LOADS. SHORT TRIP
HIGH SPEEDS STOP-AND-GO

REMOVAL & INSTALLATION SHORT Insulator T,p LONG Insulalor Tip


f a s t Heat Tianster Slow Heat Transfer
L O W E R Heat Range HIGHER Heal Range
COLD PLUG HOT PL'UG
A set of spark plugs usually requires replacement after about 20,000-30,000
miles (32,000-48,000 km), depending on your style of driving. In normal oper-
ation plug gap increases about 0.001 in. (0.025mm) for every 2500 miles (4000 Fig. 100 Spark plug heat range
1-26 GENERAL INFORMATION AND MAINTENANCE
To install: 8. Carefully tighten the spark plug. If the plug you are installing is equipped
5. Inspect the spark plug boot for tears or damage. If a damaged boct is with a crush washer, seat the plug, then tighten about Vi turn to crush the
found, the spark plug wire must be replaced. washer. If you are installing a tapered seat plug, tighten the plug to specifica-
6. Using a wire feeler gauge, check and adjust the spark plug gap. When jsing a tions provided by the vehicle or plug manufacturer.
gauge, the proper size should pass between the electrodes with a slight drag. The next 9. Apply a small amount of silicone dielectric compound to the end of the
larger size should not be able to pass while the next smaller size should pass freely. spark plug lead or inside the spark plug boot to prevent sticking, then install the
7. Carefully thread the plug into the bore by hand. If resistance is felt before the boot to the spark plug and push until it clicks into place. The click may be felt
plug is almost completely threaded, back the plug out and begin threading again. In or heard, then gently pull back on the boot to assure proper contact.
small, hard to reach areas, an old spark plug wire and boot could be used a|s a
threading tool. The boot will hold the plug while you twist the end of the wife and INSPECTION & GAPPING
the wire is supple enough to twist before it would allow the plug to crossthread.
See Figures 101,102,103,104 and 105
> WARNING
Check the plugs for deposits and wear. If they are not going to be replaced,
Do not use the spark plug socket to thread the plugs. Always care- clean the plugs thoroughly. Remember that any kind of deposit will decrease the
fully thread the plug by hand or using an old plug wire to prevf nt the efficiency of the plug. Plugs can be cleaned on a spark plug cleaning machine,
possibility of crossthreading and damaging the cylinder head ore. which can sometimes be found in service stations, or you can do an acceptable

A n o r m a l l y orn A carbon fouled


s p a r k p l u g s ou Id plug, identified by
h a v e l i g h t t a or sort, sooty, black
g r a y d e p o s i t on the deposits, may indi-
firing tip. cate an improperly
tuned vehicle. Check
the air cleaner, igni-
tion components and
engine control sys-
tem .

This spark p ug has An oil fouled spark


been left in he plug i n d i c a t e s an
e n g i n e too I ng, as engine with worn
e v i d e n c e d by the poston rings and/or
extreme gap- Plugs bad valve seals
with such an extreme allowing excessive
gap can caus m is- oil to enter the
f i r i n g and st mbl ing chamber.
accompanied by a
n o t i c e a b l e la k of
power.

A p h y s i c a l l y dam- A b r i d g e d or a l m o s t
aged s p a r k lug may bridged spark plug,
b e e v i d e n c e if i d e n t i f i e d by a b u i l d -
s e v e r e d e t o n ati o n in up between the elec-
that cylinder Watch trodes caused by
that cylindei ca re- excessive carbon or
fully betwee ser- oil build-up on the
v i c e s , as a c o n t i n - plug.
u e d d e t o n a t i n wi.ll
not o n l y darr age t h e
plug, but co Id a l s o
d a m a g e t h e ng i n e .

Fig. 101 Inspect the spark plug to determine engine running co ditions
GENERAL INFORMATION AND MAINTENANCE 1-27

&
:

Fig. 102 A variety of tools and gauges are Fig. 103 Checking the spark plug gap with
needed for spark plug service a feeler gauge Fig. 104 Adjusting the spark plug gap

job of cleaning with a stiff brush. If the plugs are cleaned, the electrodes must To check resistance:
be filed flat. Use an ignition points file, not an emery board or the like, which 1. Remove the distributor cap, leaving the wires in place.
will leave deposits. The electrodes must be filed perfectly flat with sharp edges; 2. Connect one lead of an ohmmeter to an electrode within the cap.
rounded edges reduce the spark plug voltage by as much as 50%. 3. Connect the other lead to the corresponding spark plug terminal (remove
Check spark plug gap before installation. The ground electrode (the L- it from the spark plug for this test).
shaped one connected to the body of the plug) must be parallel to the center 4. Replace any wire which shows a resistance over 30,000 ohms. Generally
electrode and the specified size wire gauge (please refer to the Tune-Up Specifi- speaking, however, resistance should not be over 25,000 ohms, and 30,000
cations chart for details) must pass between the electrodes with a slight drag. ohms must be considered the outer limit of acceptability.
It should be remembered that resistance is also a function of length. The longer
NEVER adjust the gap on a used platinum type spark plug. the wire, the greater the resistance. Thus, if the wires on your truck are longer than
Always check the gap on new plugs as they are not always set correctly at the the factory originals, the resistance will be higher, possibly outside these limits.
factory. Do not use a flat feeler gauge when measuring the gap on a used plug,
because the reading may be inaccurate. A round-wire type gapping tool is the REMOVAL & INSTALLATION
best way to check the gap. The correct gauge should pass through the electrode
gap with a slight drag. If you're in doubt, try one size smaller and one larger. When installing new wires, replace them one at a time to avoid mixups. Start
The smaller gauge should go through easily, while the larger one shouldn't go by replacing the longest one first.
through at all. Wire gapping tools usually have a bending tool attached. Use that 1. Remove the spark plug wire by gripping the boot firmly and disengaging
to adjust the side electrode until the proper distance is obtained. Absolutely the wire from the spark plug and the distributor.
never attempt to bend the center electrode. Also, be careful not to bend the side 2. Install the boot of the new wire firmly over the spark plug. Route the wire
electrode too far or too often as it may weaken and break off within the engine, over the same path as the original.
requiring removal of the cylinder head to retrieve it.
Distributor Cap and Rotor
Spark Plug Wires
REMOVAL & INSTALLATION
TESTING

> See Figures 106 and 107 Carbureted Engines


> See Figures 108,109,110 and 111
At every tune-up/inspection, visually check the spark plug cables for burns
cuts, or breaks in the insulation. Check the boots and the nipples on the distrib- 1. Remove the feed and module wire terminal connectors from the distribu-
utor cap and/or coil. Replace any damaged wiring. tor cap.
Every 50,000 miles (80,000 Km) or 60 months, the resistance ot the wires 2. Remove the retainer and spark plug wires from the cap.
should be checked with an ohmmeter. Wires with excessive resistance will 3. Depress and release the 4 distributor cap-to-housing retainers and lift off
cause misfiring, and may make the engine difficult to start in damp weather. the cap assembly.

o.on

Fig. 105 If the standard plug is in good Fig. 106 Checking plug wire resistance TCCS1009

condition, the electrode may be filed through the distributor cap with an ohm- Fig. 107 Checking individual plug wire
flatWARNING: do not file platinum plugs meter resistance with a digital ohmmeter
1-28 GENERAL INFORMATION AND MAINTENANCE

Fig. 108 Loosen the distributor hold-down Fig. 109 II necessary, label and remove the 8/981P14

fasteners spark plug wires from the distributor cap Fig. 110 Remove the distributor cap . . .

Ideally, the air/fuel mixture in the cylinder will be ignited by the spark plug
just as the piston passes TDC of the compression stroke. If this happens, this
piston will be beginning the power stroke just as the compressed and ignited
air/fuel mixture starts to expand. The expansion of the air/fuel mixture then
forces the piston down on the power stroke and turns the crankshaft.
Because it takes a fraction of a second for the spark plug to ignite the gases
in the cylinder, the spark plug must fire a little before the piston reaches TDC.
Otherwise, the mixture will not be completely ignited as the piston passes TDC
and the full benefit of the explosion will not be used by the engine. The timing
measurement is given in degrees of crankshaft rotation before the piston
reaches TDC (BTDC). If the setting for the ignition timing is 5 degrees BTDC,
the spark plug must fire 5 degrees before that piston reaches TDC. This only
holds true, however, when the engine is at idle speed.
As the engine speed increases, the pistons go faster. The spark plugs have to
ignite the fuel even sooner if it is to be completely ignited when the piston
reaches TDC. To do this, the distributor has a means to advance the timing of
Fig. 111 . . . then the rotor from the distributor the spark as the engine speed increases.
If the ignition is set too far advanced (BTDC), the ignition and expansion of
4. Remove the 4 coil cover screws and cover. the fuel in the cylinder will occur too soon and tend to force the piston down
5. Using a finger or a blunt drift, push the spade terminals up out o the dis- while it is stili traveling up. This causes engine ping. If the engine is too far
tributor cap. retarded after TDC (ATDC), the piston will have already passed TDC and started
6 Remove all 4 coil screws and lift the coil, coil spring and rubber ,eal on its way down when the fuel is ignited. This will cause the piston to be forced
washer out of the cap coil cavity. down for only a portion of its travel. This will result in poor engine performance
7. Remove the two rotor attaching screws (if equipped) and rotor. and lack of power.
8. Using a new distributor cap and rotor, reverse the above procedu esto Timing should be checked at each tune-up and any time the points are
assemble, being sure to clean and lubricate the rubber seal washer with dielec- adjusted or replaced. It isn't likely to change much with HEI. The timing marks
trie lubricant. consist of a notch on the rim of the crankshaft pulley or vibration damper and a
graduated scale attached to the engine front (timing) cover. A stroboscopic flash
Fuel Injected Engines (dynamic) timing light must be used, as a static light is too inaccurate for emis-
sion controlled engines.
1. Tag and remove the spark plug wires. There are three basic types of timing lights available. The first is a simple
2. Loosen the cap retaining fasteners and remove the cap. neon bulb with two wire connections. One wire connects to the spark plug ter-
3. Remove the rotor from the distributor shaft. minal and the other plugs into the end of the spark plug wire for the No. 1 cylin-
4. Installation is the reverse of removal. der, thus connecting the light in series with the spark plug. This type of light is
pretty dim and must be held very closely to the timing marks to be seen. Some-
INSPECTION times a dark corner has to be sought out to see the flash at all. This type of light
is very inexpensive. The second type operates from the vehicle batterytwo
1. Remove the distributor cap and rotor as described in this sectior alligator clips connect to the battery terminals, while an adapter enables a third
2. Check the cap for wear, electrode cracks or damage. Replace if di fective. clip to be connected between No. 1 spark plug and wire. This type is a bit more
3. Check the rotor for cracks and wear. Replace if defective. expensive, but it provides a nice bright flash that you can see even in bright
sunlight. It is the type most often seen in professional shops. The third type
replaces the battery power source with 115 volt current.
Ignition Timing Some timing lights have other features built into them, such as dwell meters,
or tachometers. These are convenient, in that they reduce the tangle of wires
GENERAL INFORMATION under the hood when you're working, but may duplicate the functions of tools
you already have. One worthwhile feature, which is becoming more of a neces-
sity with higher voltage ignition systems, is an inductive pickup. The inductive
This procedure does not apply to diesel engines. pickup clamps around the No. 1 spark plug wire, sensing the surges of high
Ignition timing is the measurement, in degrees of crankshaft rotation of the voltage electricity as they are sent to the plug. The advantage is that no mechan-
point at which the spark plugs fire in each of the cylinders. It is measured in ical connection is inserted between the wire and the plug, which eliminates false
degrees before or after Top Dead Center (TDC) of the compression strok Igni- signals to the timing light. A timing light with an inductive pickup should be
tion timing is controlled by turning the distributor in the engine. used on HEI systems.
GENERAL INFORMATION AND MAINTENANCE 1-29
CHECKINGS ADJUSTMENT 7. Turn the ignition OFF, remove the timing light and engage the "set tim-
ing" connector.
HEI Systems 1996-98 MODELS

1. Start the engine and allow it to reach operating temperature. Stop the The distributor on the 4.3L engine is non-adjustable and any attempt
engine and connect the timing light to the No. 1 (left front) spark plug wire, at to adjust the distributor could cause cross firing. This procedure applies
the plug or at the distributor cap. You can also use the No. 6 wire, if it is more to the 5.0L, 5.7L and 7.4L engines.
convenient. Numbering is illustrated in this section. The ignition timing is preset and cannot be adjusted. If the distributor posi-
Do not pierce the plug wire insulation with HEI; it will cause a miss. tion is moved, crossfiring may be induced. To check distributor position the fol-
The best method is an inductive pickup timing light. lowing:
2. Clean off the timing marks and mark the pulley or damper notch and An OBD-II compliant scan tool is required for this procedure
timing scale with white chalk. 1. With the ignition OFF install scan tool to the Data Link Connector
3. Disconnect and plug the vacuum line at the distributor on models with a (DLC).
carburetor. This is done to prevent any distributor vacuum advance. On fuel 2. Start the engine and bring the vehicle to operating temperature.
injected models, disengage the timing connector which comes out of the har- 3. Monitor cam retard on the scan tool.
ness conduit next to the distributor, this will put the system in the bypass mode. 4. If cam retard is between -2 and +2, the distributor is properly adjusted.
Check the underhood emission sticker for any other hoses or wires which may 5. If cam retard is not between -2 and +2, the distributor must adjusted.
need to be disconnected. 6. With the engine OFF loosen the distributor hold-down bolt.
4. Start the engine and adjust the idle speed to that specified on the Under- 7. Start the engine and check the cam retard reading. Rotate the distributor
hood Emissions label. With automatic transmission, set the specified idle speed counterclockwise to compensate for a negative reading and clockwise to com-
in Park. It will be too high, since it is normally (in most cases) adjusted in pensate for a positive reading.
Drive. You can disconnect the idle solenoid, if any, to get the speed down. Oth- 8. Momentarily raise the engine speed to over 1000 RPM and check the
erwise, adjust the idle speed screw. cam retard reading.
The tachometer connects to the TACH terminal on the distributor and to a 9. If the proper reading is not achieved repeat Steps 7 and 8.
ground on models with a carburetor. On models with fuel injection, the 10. When the proper reading has been achieved, tighten the distributor
tachometer connects to the TACH terminal on the ignition coil. Some tachome- hold-down bolt and disconnect the scan tool.
ters must connect to the TACH terminal and to the positive battery terminal.
Some tachometers won't work with HEI.
Valve Lash
WARNING All engines described in this book use hydraulic lifters, which reguire no
Never ground the HEI TACH terminal; serious system damage will periodic adjustment. In the event of cylinder head removal or any operation that
result. requires disturbing the rocker arms, the rocker arms will have to be adjusted.

5. Aim the timing light at the pointer marks. Be careful not to touch the fan, ADJUSTMENT
because it may appear to be standing still. If the pulley or damper notch isn't
aligned with the proper timing mark (see the Underhood Emissions label), the 4.8L Engines
timing will have to be adjusted.
TDC or Top Dead Center corresponds to OB, or BTDC, or Before Top 1. Remove the rocker arm cover.
Dead Center may be shown as BEFORE. A, or ATDC, or After Top Dead 2. Mark the distributor housing at the No. 1 and No. 6 wire positions and
remove the cap.
Center may be shown as AFTER.
3. Turn the crankshaft until the rotor points to the No. 1 position. The fol-
6. Loosen the distributor base clamp locknut. You can buy trick wrenches lowing valves can be adjusted:
which make this task a lot easier. No. 1 exhaust and intake
7. Turn the distributor slowly to adjust the timing, holding it by the body No. 2 intake
and not the cap. Turn the distributor in the direction of rotor rotation to retard, No. 3 exhaust
and against the direction of rotation to advance. No. 4 intake
8. Tighten the locknut. Check the timing again, in case the distributor No. 5 exhaust
moved slightly as you tightened it. To adjust a valve, back off the adjusting nut until lash (play) is felt at the
9. Reinstall the distributor vacuum line or the timing connector. Correct the pushrod. Tighten the nut just until all lash is removed. This can be determined
idle speed. by rotating the pushrod with your fingers. When all lash is removed, the
10. Stop the engine and disconnect the timing light. pushrod wil! stop rotating. When all play is removed, tighten the nut 1 full turn
(360).
Distributor ignition (Dl) Systems 4. Rotate the crankshaft until the rotor points to the No. 6 position. The fol-
lowing valves can be adjusted:
1995 MODELS No. 2 exhaust
"Refer to the underhood label for the proper timing setting. No. 3 intake
No. 4 exhaust
1. Engage the parking brake, block the wheels and set the transmission in P. No. 5 intake
2. Disconnect the Ignition Control (1C) system by disengaging the "set tim- No. 6 intake and exhaust
ing connector". This is a single wire sealed connector that has a tan with black 5. Install the distributor cap,
stripe lead. This wire comes out of the wiring harness below the heater case. 6. Install the rocker cover.
3. With the ignition switch OFF, connect the timing light pickup lead to the
No. 1 spark plug wire. V6 and V8 Engines
4. Start the engine and point the timing light at the timing mark on the bal-
ancer or pulley and check the timing. See Figure 112
5. If the timing is not within specifications refer to the underhood emission
sticker, loosen the distributor hold-down bolt. Slowly rotate the distributor until Valve adjustment on 1991-98 7.4L engines and 1995-98 models equipped
the proper timing setting is achieved. with V6 engines is not required. These models use a positive stop shoulder. On
6. Tighten the hold-down bolt and recheck the timing. models with a positive stop shoulder, simply tighten the rocker arm retainers to
the torque listed in the torque specifications chart in this section.
1-30 GENERAL INFORMATION AND MAINTENANCE
On models not equipped with positive stop shoulders, perform the sleps out-
lined in this procedure. Idle Speed and Mixture Adjustments
1. Remove the rocker covers and gaskets.
2. Crank the engine until the mark on the damper aligns with the TDC or CARBURETED ENGINES
0 mark on the timing tab and the engine is in No. 1 firing position. Tils can
be determined by placing your finger on the No. 1 cylinder valves as the Mixture screws are concealed under staked-in plugs. Idle mixture is
marks align. If the valves do not move, it is in No. 1 firing position. If the adjustable only during carburetor overhaul, and requires the addition of
valves move, it is in No. 6 firing position (No. 4 on the V6) and the crank- propane as an artificial mixture enricher. For these reasons, mixture adjust-
shaft should be rotated 1 more revolution to the No. 1 firing positions To ments are not considered part of routine maintenance. Refer to Section 5 for
adjust a valve, back off the adjusting nut until lash (play) is felt at thti these procedures.
pushrod. Tighten the nut just until all lash is removed. This can be dieter-
mined by rotating the pushrod with your fingers. When all lash is removed, 4.8L Engines
the pushrod will stop rotating. When all play is removed, tighten the iuM
CURB IDLE SPEED
With the engine in No. 1 firing position, the following valves can
I See Figure 113
adjusted:
V6 Engines With the idle speed solenoid energized, turn the solenoid body to establish
Exhaust1,5, the curb idle speed shown on your underhood sticker.
Intake1,2, 3
V8 Engines BASE IDLE SPEED
Exhaust1,3,4,8 With the solenoid wire disconnected, turn the V& in. hex head solenoid
Intake1,2,5,7 plunger adjusting screw to establish the base idle speed shown on your under-
Crank the engine 1 full revolution until the marks are again in ah nment. hood sticker.
This is No. 6 firing position (No. 4 on the V6). The following valves cannow be
adjusted: 5.7L Engines
V6 Engines
Exhaust2, 3, 4 I See Figures 114 and 115
Intake4,5, 6 1. All adjustments should be made with the engine at normal operating tem-
V8 Engines perature, air cleaner on, choke open, and air conditioning off, unless otherwise
Exhaust2,5,6,7
noted. Set the parking brake and block the rear wheels. Automatic transmissions
Intake3,4, 6. should be set in Drive, manuals in Neutral, unless otherwise noted in the proce-
5. Reinstall the rocker arm covers using new gaskets. dures or on the emission control label.
6. Install the distributor cap and wire assembly.

1 PREPARE VEHICLE FOR


ADJUSTMENTS - SEE
EMISSION LABEL ON VEHICLE
NOTE IGNITION TIMING SET_
PER LABEL

84903157

Fig. 112 Adjusting the valvegasoline Fig. 1131 le speed adjustment4.81 Fig. 114 Idle speed adjustment5.7L
engines engines engines without solenoid

I. PREPARE VEHICLE FOR 2. Refer to the underhood emission sticker and prepare the vehicle for
ADJUSTMENTS - SEE
EMISSION LABEL ON VEHICL
adjustment as specified on the sticker. On models without a solenoid, turn
NOTE IGNITION TIMING SET
PER LABEL
the idle speed screw to obtain the idle speed listed in the underhood emis-
3 SOLENOID ENERGIZED -
A / C COMPRESSOR LEAD sion control label. On models with a solenoid, turn the solenoid screw to
DISCONNECTED AT A7C
COMPRESSOR, A7C ON, A/T
obtain the idle speed listed in the underhood emission control label.
TRANSMISSION IN DRIVE
Disconnect the wire at the air conditioning compressor and turn the ait con-
5. TURN SCREW TO ADJUST ditioning on. Rev the engine momentarily to fully extend the solenoid
TO SPECIFIED PRM.
(RECONNECT A/C plunger. Turn the solenoid screw to obtain the solenoid idle speed listed on
COMPRESSOR LEAD AFTER
ADJUSTMENT)
the underhood emission sticker. Reconnect the air conditioning wire at the
ELECTRICAL
compressor.
CONNECTION

4 OPEN THROTTLE SLIGHTLY


2 TURN IDLE SPEED SCRE
TO SET CURB IDLE SPEED
GASOLINE FUEL INJECTED ENGINES
TO ALLOW SOLENOID SPECIFICATIONS - AyC OF
PLUNGER TO FULLY EXTEND (SEE EMISSION LABEL)

The fuel injected vehicles are controlled by a computer which supplies the
correct amount of fuel during all engine operating conditions and controls idle
Fig. 115 Idle speed adjustment5.7L engines with solenoid speed; no adjustment is necessary or possible.
GENERAL INFORMATION AND MAINTENANCE 1-31
DIESEL ENGINES
SOLENOID - FAST IDLE

Idle Speed
> See Figure 116
A special tachometer suitable for diesel engines must be used. A
gasoline engine type tach will not work with the diesel engine.
1. Set the parking brake and block the drive wheels.
2. Run the engine up to normal operating temperature. The air cleaner must SCREW - LOW IDLE
be mounted and all accessories turned off.
3. Install the diesel tachometer as per the manufacturer's instructions.
4. Adjust the low idle speed screw on the fuel injection pump to the specifi-
cation listed on the underhood label in Neutral or P for both manual and auto- Fig. 116 Idle speed adjustmentdiesel engines
matic transmissions.

GASOLINE TUNE-UP SPECIFICATIONS*


Ignition Idle
Engine Spark Plugs Timing Fuel Speed Valve
Engine Displacement Gap (deg.) Pump (rpm) Clearance
Year ID/VIN Liters (cc) (in.) MT AT (PSl) MT AT In. Ex.
1988 Z 4.3 (4293) 0.040 9-13 700 700 HYD HYD
T 4.8(4785) 0.035 88 8B 5.0 700 700 HYD HYD
H 5.0 (4999) 0.045 4B 4B h4.0-6.5 1 700 700 HYD HYD
K 5.7 (5735) 0.045 4B 4B 4.0-6.5 700 700 HYD HYD
N 7.4 (7440) 0.045 4B 48 9-13 700 700 HYD HYD
W 7.4 (7440) 0.045 4B 4B 4.0-6.5 700 700 HYD HYD
1989 Z 4.3 (4293) 0.040 9-13 700_j 700 HYD HYD
T" 4.8 (4785) 0.035 88 8B 5.0 700 700 HYD HYD
H 5.0 (4999) 0.035 4B 48 4.0-6.5 700 700 HYD HYD
K 5.7 (5735) 0.035 4B 4B 4.0-6.5 700 700 HYD HYD
N 7.4 (7440) 0.035 4B 4B 9-13 700 700 HYD HYD
W 7.4 (7440) 0.035 4B 4B 4.0-6.5 700 700 HYD HYD
1990 Z 4.3 (4293) 0.040 9-13 HYD JHYD
T 4.8 (4785) 0.035 9-13 HYD HYD
H 5.0 (4999) 0.035 9-13 HYD HYD
K 5.7(5735) 0.035 9-13 HYD HYD
N 7.4 (7440) 0.035 9-13 HYD HYD
W 7.4 (7440) 0.035 5.0 HYD ^HYD
1991 Z 4.3(4293) 0.040 9-13 HYD HYD
H 5.0(4999) 0.035 9-13 HYD HYD
K 5.7 (5735) 0.035 9-13 HYD HYD
N 7.4 (7440) 0.035 9-13 HYD HYD
1992 Z 4.3(4293) 0.035 9-13 HYD HYD
H 5.0(4999) 0.035 9-13 HYD HYD
K 5.7 (5735) 0.035 9-13 HYD HYD
N 7.4 (7440) 0.035 9-13 HYD HYD
1993 Z 4.3 (4293) 0.035 9-13 HYD HYD
H 5.0 (4999) 0.035 9-13 HYD HYD
K 5.7(5735) 0.035 9-13 HYD HYD
N 7.4 (7440) 0.035 J 9-13 HYD HYD
1994 Z 4.3(4293) 0.035 9-13 HYD HYD
H 5.0 (4999) 0.035 9-13 HYD HYD
K 5.7 (5735) 0.035 9-13 HYD HYD
N 7.4 (7440) 0.035 9-13 HYD HYD
1995 Z 4.3 (4293) 0.045 9-13 HYD HYD
H 5.0 (4999) 0.035 9-13 HYD HYD
K 5.7 (5735) 0.035 9-13 HYD HYD
N 7.4 (7440) 0.035 9-13 HYD HYD
1996 W 4.3 (4293) 0.060 6CV66 HYD HYD
M 5.0 (4999) 0.060 60-66 HYD HYD
R 5.7 (5735) 0.060 6066 HYD HYD
J 7.4 (7440) 0.060 60-66 HYD HYD

*Refer to the Vehicle Emissions Control Information label in the engine compartment; use the information
there if it differs from that listed here.
1-32 GENERAL INFORMATION AND MAINTENANCE
GASOLINE TUNE-UP SPECIFICATIONS
Ign tion Idle
Engine Spark Plugs Tim ing Fuel Speed Valve
Engine Displacement Gap (de g.) Pump (rpm) Clearance
Year IDA/IN Liters (cc) (in.) MT AT (psi) MT AT In. Ex.
1997 W 4.3 (4293) 0.035 60-66 HYD HYD
M 5.0 (4999) 0.045 60-66 HYD HYD
R 5.7 (5735) 0.045 60-66 HYD HYD
J 7.4 (7440) 0.045 60-66 HYD HYD
1998 W 4.3 (4293) 0.035 60-66 HYD HYD
M 5.0 (4999) 0.045 60-66 HYD HYD
R 5.7 (5735) 0.045 60-66 CD HYD HYD
J 7.4 (7440) 0.045 60-66 HYD HYD
NOTE: The Vehicle Emission Control Information label often rellei s specification changes made during production.
The label figures must be used if they differ from those in this cha
HYDHydraulic (D Refer to the underhood label
NANot Available

"All idle speeds are to be set within 25 rpm of the specified va ies. R-12 Refrigerant Conversion
5. Adjust the fast idle speed as follows: If your vehicle still uses R-12 refrigerant, one way to save A/C system costs
a. Remove the connector from the fast idle solenoid. Use an insi ated down the road is to investigate the possibility of having your system converted
jumper wire from the battery positive terminal to the solenoid termin to to R-134a. The older R-12 systems can be easily converted to R-134a refriger-
energize the solenoid. ant by a certified automotive technician by installing a few new components and
b. Open the throttle momentarily to ensure that the fast idle solei old changing the system oil.
plunger is energized and fully extended. The cost of R-12 is steadily rising and will continue to increase, because it is
c. Adjust the extended plunger by turning the hex-head screw to an no longer imported or manufactured in the United States. Therefore, it is often
engine speed of 800 rpm (check the underhood label) in Neutral. possible to have an R-12 system converted to R-134a and recharged for less
d. Remove the jumper wire and reinstall the connector to the fast idle solenoid. than it would cost to just charge the system with R-12.
6. Disconnect and remove the tachometer. If you are interested in having your system converted, contact local automo-
tive service stations for more details and information.
Air Conditioning System PREVENTIVE MAINTENANCE
SYSTEM SERVICE & REPAIR
Although the A/C system should not be serviced by the do-it-yourselfer, pre-
ventive maintenance should be practiced to help maintain the efficiency of the
It is recommended that the A/C system be serviced by an EPA (lection vehicle's A/C system. Be sure to perform the following:
609 certified automotive technician utilizing a refrigerant recovel y/recy- The easiest and most important preventive maintenance for your A/C sys-
cling machine. tem is to be sure that it is used on a regular basis. Running the system for five
The do-it-yourselfer should not service his/her own vehicle's A/C sy tern for minutes each month (no matter what the season) will help ensure that the seals
many reasons, including legal concerns, personal injury, environmenta damage and all internal components remain lubricated.
and cost. Some vehicles automatically operate the A/C system compressor
According to the U.S. Clean Air Act, it is a federal crime to service o 1 repair whenever the windshield defroster is activated. Therefore, the A/C sys-
(involving the refrigerant) a Motor Vehicle Air Conditioning (MVAC) sy: lem for tem would not need to be operated each month if the defroster was
money without being EPA certified. It is also illegal to vent R-12 and RJ 34a used.
refrigerants into the atmosphere. State and/or local laws may be more s rict than
the federal regulations, so be sure to check with your state and/or local luthori- In order to prevent heater core freeze-up during A/C operation, it is neces-
ties for further information. sary to maintain proper antifreeze protection. Be sure to properly maintain the
engine cooling system.
Federal law dictates that a fine of up to $25,000 may be leviei on Any obstruction of or damage to the condenser configuration will restrict
people convicted of venting refrigerant into the atmosphere. air flow which is essential to its efficient operation. Keep this unit clean and in
When servicing an A/C system you run the risk of handling or comii g in proper physical shape.
contact with refrigerant, which may result in skin or eye irritation or fro$ bite. Buq screens which are mounted in front of the condenser (unless they
Although low in toxicity (due to chemical stability), inhalation of concentrated are original equipment) are regarded as obstructions.
refrigerant fumes is dangerous and can result in death; cases of fatal caidiac
arrhythmia have been reported in people accidentally subjected to high evels of The condensation drain tube expels any water which accumulates on the
refrigerant. Some early symptoms include loss of concentration and drowsiness. bottom of the evaporator housing into the engine compartment. If this tube is
obstructed, the air conditioning performance can be restricted and condensation
'Generally, the limit for exposure is lower for R-134a than it is or R- buildup can spill over onto the vehicle's floor.
12. Exceptional care must be practiced when handling R-134a.

Also, some refrigerants can decompose at high temperatures (near gas SYSTEM INSPECTION
heaters or open flame), which may result in hydrofluoric acid, hydrochli: ric acid
and phosgene (a fatal nerve gas). Although the A/C system should not be serviced by the do-it-yourselfer, sys-
It is usually more economically feasible to have a certified MVAC automotive tem inspections should be performed to help maintain the efficiency of the vehi-
technician perform A/C system service on your vehicle. cle's A/C system. Be sure to perform the following:
GENERAL INFORMATION AND MAINTENANCE 1-33
The easiest and often most important check for the air conditioning system streaking, smearing and blade deterioration if left on the glass. It is advisable to
consists of a visual inspection of the system components. Visualiy inspect the wash the windshield carefully with a commercial glass cleaner at least once a
system for refrigerant leaks, damaged compressor clutch, abnormal compressor month. Wipe off the rubber blades with the wet rag afterwards. Do not attempt to
drive belt tension and/or condition, plugged evaporator drain tube, blocked con- move wipers across the windshield by hand; damage to the motor and drive
denser fins, disconnected or broken wires, blown fuses, corroded connections mechanism will result.
and poor insulation. To inspect and/or replace the wiper blade elements, place the wiper switch in
A refrigerant leak will usually appear as an oily residue at the leakage point the LOW speed position and the ignition switch in the ACC position. When the
in the system. The oily residue soon picks up dust or dirt particles from the sur- wiper blades are approximately vertical on the windshield, turn the ignition
rounding air and appears greasy. Through time, this will build up and appear to switch to OFF.
be a heavy dirt impregnated grease. Examine the wiper blade elements. If they are found to be cracked, broken or
For a thorough visual and operational inspection, check the following: torn, they should be replaced immediately. Replacement intervals will vary with
Check the surface of the radiator and condenser for dirt, leaves or other usage, although ozone deterioration usually limits element life to about one
material which might block air flow. year. If the wiper pattern is smeared or streaked, or if the blade chatters across
Check for kinks in hoses and lines. Check the system for leaks. the glass, the elements should be replaced. It is easiest and most sensible to
Make sure the drive belt is properly tensioned. During operation, make replace the elements in pairs.
sure the belt is free of noise or slippage. If your vehicle is equipped with aftermarket blades, there are several different
Make sure the blower motor operates at all appropriate positions, then types of refills and your vehicle might have any kind. Aftermarket blades and
check for distribution of the air from all outlets. arms rarely use the exact same type blade or refill as the original equipment.
Regardless of the type of refill used, be sure to follow the part manufacturer's
Remember that in high humidity, air discharged from the vents may instructions closely. Make sure that all of the frame jaws are engaged as the
not feel as cold as expected, even if the system is working properly. refill is pushed into place and locked. If the metal blade holder and frame are
This is because moisture in humid air retains heat more effectively than allowed to touch the glass during wiper operation, the glass will be scratched.
dry air, thereby making humid air more difficult to cool.

Windshield Wipers Tires and Wheels


Common sense and good driving habits will afford maximum tire life. Make
ELEMENT (REFILL) CARE & REPLACEMENT sure that you don't overload the vehicle or run with incorrect pressure in the
tires. Either of these will increase tread wear. Fast starts, sudden stops and
sharp cornering are hard on tires and will shorten their useful life span.
See Figures 117,118 and 119
For optimum tire life, keep the tires properly inflated, rotate them
For maximum effectiveness and longest element life, the windshield and often and have the wheel alignment checked periodically.
wiper blades should be kept clean. Dirt, tree sap, road tar and so on will cause
Inspect your tires frequently. Be especially careful to watch for bubbles in the
tread or sidewall, deep cuts or underinfiation. Replace any tires with bubbles in
the sidewall. If cuts are so deep that they penetrate to the cords, discard the tire.
Any cut in the sidewall of a radial tire renders it unsafe. Also look for uneven
tread wear patterns that may indicate the front end is out of alignment or that the
tires are out of balance.

TIRE ROTATION

See Figure 120


Tires must be rotated periodically to equalize wear patterns that vary with a
tire's position on the vehicle. Tires will also wear in an uneven way as the front
steering/suspension system wears to the point where the alignment should be
reset.
Rotating the tires will ensure maximum life for the tires as a set, so you will
not have to discard a tire early due to wear on only part of the tread. Regular
ADAPTERS rotation is required to equalize wear.
Fig. 117 Most aftermarket blades are available with multiple When rotating "unidirectional tires," make sure that they always roll in the
same direction. This means that a tire used on the left side of the vehicle must
adapters to fit different vehicles not be switched to the right side and vice-versa. Such tires should only be

Front Front

(FORNON (FOR
DIRECTIONAL TIRES DIRECTIONAL TIRES
AND WHEELS) AND WHEELS)
i
Fig. 118 Choose a blade which will fit your FCCS1231

vehicle, and that will be readily available Fig. 119 When installed, be certain the Fig. 120 Compact spare tires must NEVER
next time you need blades blade is fully inserted into the backing be used in the rotation pattern
1-34 GENERAL INFORMATION AND MAINTENANCE
rotated front-to-rear or rear-to-front, while always remaining on the sam|j side of ing and braking characteristics of the vehicle. Once the snow tires are installed,
the vehicle. These tires are marked on the sidewall as to the direction of rota- you must re-learn the behavior of the vehicle and drive accordingly.
tion; observe the marks when reinstalling the tire(s).
Some styled or "mag" wheels may have different offsets front to rear :|n these Consider buying extra wheels on which to mount the snow tires. Once
cases, the rear wheels must not be used up front and vice-versa. Further done, the "snow wheels" can be installed and removed as needed. This
these wheels are equipped with unidirectional tires, they cannot be rotatf j eliminates the potential damage to tires or wheels from seasonal
unless the tire is remounted for the proper direction of rotation, removal and installation. Even if your vehicle has styled wheels, see if
inexpensive steel wheels are available. Although the look of the vehicle
The compact or space-saver spare is strictly for emergency use It will change, the expensive wheels will be protected from salt, curb hits
must never be included in the tire rotation or placed on the vehicl jfor and pothole damage.
everyday use.
TIRE STORAGE
TIRE DESIGN
If they are mounted on wheels, store the tires at proper inflation pressure.
I See Figure 121 All tires should be kept in a cool, dry place. If they are stored in the garage or
For maximum satisfaction, tires should be used in sets of four, basement, do not let them stand on a concrete floor; set them on strips of
ferent brands or types (radial, bias-belted, fiberglass belted) should be a wood, a mat or a large stack of newspaper. Keeping them away from direct
In most cases, the vehicle manufacturer has designated a type of tire on moisture is of paramount importance. Tires should not be stored upright, but
the vehicle will perform best. Your first choice when replacing tires shoi in aflat position.
use the same type of tire that the manufacturer recommends.
When radial tires are used, tire sizes and wheel diameters should be: ilected INFLATION & INSPECTION
to maintain ground clearance and tire load capacity equivalent to the ork nal
specified tire. Radial tires should always be used in sets of four. I See Figures 122 thru 127
The importance of proper tire inflation cannot be overemphasized. A tire
CAUTION employs air as part of its structure. It is designed around the supporting
Radial tires should never be used on only the front axle. strength of the air at a specified pressure. For this reason, improper inflation
drastically reduces the tire's ability to perform as intended. A tire will lose some
When selecting tires, pay attention to the original size as marked on t e tire. air in day-to-day use; having to add a few pounds of air periodically is not nec-
Most tires are described using an industry size code sometimes referred o as essarily a sign of a leaking tire.
P-Metric. This allows the exact identification of the tire specifications, regard- Two items should be a permanent fixture in every glove compartment: an
less of the manufacturer. If selecting a different tire size or brand, rememher to accurate tire pressure gauge and a tread depth gauge. Check the tire pres-
check the installed tire for any sign of interference with the body or susp nsion sure (including the spare) regularly with a pocket type gauge. Too often, the
while the vehicle is stopping, turning sharply or heavily loaded. gauge on the end of the air hose at your corner garage is not accurate
because it suffers too much abuse. Always check tire pressure when the tires
Snow Tires are cold, as pressure increases with temperature. If you must move the vehi-
cle to check the tire inflation, do not drive more than a mile before checking,
Good radial tires can produce a big advantage in slippery weather, bu in A cold tire is generally one that has not been driven for more than three
snow, a street radial tire does not have sufficient tread to provide tractior and hours.
control. The small grooves of a street tire quickly pack with snow and thi tire A plate or sticker is normally provided somewhere in the vehicle (door post,
behaves like a billiard ball on a marble floor. The more open, chunky tre; d of a hood, tailgate or trunk lid) which shows the proper pressure for the tires. Never
snow tire will self-clean as the tire turns, providing much better grip on: nowy counteract excessive pressure buiid-up by bleeding off air pressure (letting
surfaces seme air out). This will cause the tire to run hotter and wear quicker.
To satisfy municipalities requiring snow tires during weather erherger ies,
most snow tires carry either an M + S designation after the tire size starr ied on #* CAUTION
the sidewall, or the designation "all-season." In general, no change in tin; size
is necessary when buying snow tires Never exceed the maximum tire pressure embossed on the tire!
Most manufacturers strongly recommend the use of 4 snow tires on t jeir This is the pressure to be used when the tire is at maximum load-
vehicles for reasons of stability. If snow tires are fitted only to the drive v leels, ing, but it is rarely the correct pressure for everyday driving. Con-
the opposite end of the vehicle may become very unstable when braking ir sult the owner's manual or the tire pressure sticker for the correct
turning on slippery surfaces. This instability can lead to unpleasant endi gs i tire pressure.
the driver can't counteract the slide in time.
Note that snow tires, whether 2 or 4, will affect vehicle handling in all pon- Once you've maintained the correct tire pressures for several weeks, you'll
snow situations. The stiffer, heavier snow tires will noticeably change the|turn- be familiar with the vehicle's braking and handling personality. Slight adjust-
ments in tire pressures can fine-tune these characteristics, but never change
the cold pressure specification by more than 2 psi. A slightly softer tire pres-
METRIC TIRE SIZES
sure will give a softer ride but also yield lower fuel mileage. A slightly harder
tire will give crisper dry road handling but can cause skidding on wet surfaces.
Unless you're fully attuned to the vehicle, stick to the recommended inflation
pressures.
All automotive tires have built-in tread wear indicator bars that show up as
1/2 in. (13mm) wide smooth bands across the tire when Vie in. (1,5mm) of tread
remains. The appearance of tread wear indicators means that the tires should be
replaced. In fact, many states have laws prohibiting the use of tires with less
than this amount of tread.
You can check your own tread depth with an inexpensive gauge or by using a
Lincoln head penny. Slip the Lincoln penny (with Lincoln's head upside-down)
into several tread grooves. If you can see the top of Lincoln's head in 2 adjacent
grooves, the tire has less than Vie in. (1.5mm) tread left and should be
replaced. You can measure snow tires in the same manner by using the "tails"
side of the Lincoln penny. If you can see the top of the Lincoln memorial, it's
Fig. 121 P-Metric tire coding time to replace the snow tire(s).
GENERAL INFORMATION AND MAINTENANCE 1-35

HAVE TIRF INSPECTED FOR FURTHFR USE

Fig. 122 Common tire wear patterns and causes

PROPERLY IMPROPERLY
INFLATFD INFLATED

Fig. 124 Radial tires have a characteristic


Fig. 123 Tires with deep cuts, or cuts sidewall bulge; don't try to measure pres-
which bulge, should be replaced immedi- sure by looking at the tire. Use a quality Fig. 125 Tread wear indicators will appear
ately air pressure gauge when the tire is worn

Fig. 126 Accurate tread depth indicators are inexpensive and handy Fig. 127 A penny works well for a quick check of tread depth

FLUIDS AND LUBRICANTS


the SAE grade number, the lighter the oil. For example, the mono-grade oils
Fluid Disposal begin with SAE 5 weight, which is a thin light oil, and continue in viscosity up
Used fluids such as engine oil, transmission fluid, antifreeze and brake fluid to SAE 80 or 90 weight, which are heavy gear lubricants. These oils are also
are hazardous wastes and must be disposed of properly. Before draining any known as "straight weight", meaning they are of a single viscosity, and do not
fluids, consult with your local authorities; in many areas, waste oil, antifreeze, vary with engine temperature.
etc. is being accepted as a part of recycling programs. A number of service sta- Multi-viscosity oils offer the important advantage of being adaptable to temper-
tions and auto parts stores are also accepting waste fluids for recycling. ature extremes. These oils have designations such as 10W-40,20W-50, etc. The
Be sure of the recycling center's policies before draining any fluids, as many 10W-40 means that in winter (the "W" in the designation) the oil acts like a thin
will not accept different fluids that have been mixed together. 10 weight oil, allowing the engine to spin easily when cold and offering rapid
lubrication. Once the engine has warmed up, however, the oil acts like a straight
40 weight, maintaining good lubrication and protection for the engine's internal
Fuel and Oil Recommendations components. A 20W-50 oil would therefore be slightly heavier than and not as
ideal in cold weather as the 10W-40, but would offer better protection at higher
OIL rpm and temperatures because when warm it acts like a 50 weight oil. Whichever
011 viscosity you choose when changing the oil, make sure you are anticipating the
I See Figures 128,129 and 130 temperatures your engine will be operating in until the oil is changed again Refer
to the oil viscosity chart for oil recommendations according to temperature.
The Society of Automotive Engineers (SAE) grade number indicates the vis- The American Petroleum Institute (API) designation indicates the classification of
cosity of the engine oil; its resistance to flow at a given temperature. The lower engine oil used under certain given operating conditions. Only oils designated for
1-36 GENERAL INFORMATION AND MAINTENANCE
HOT WEATHER
HOT WEATHER

SAE 10W-30
JEfl
SAE 15W-40
SAE 5W-30 IF NEIER SAE 5W-30 PREFERRED
PREFERRED NQR SA ,,_,

OQN'TPQLL T, CONSERVE RESOURCES, SAE 10W-30


COLD WEATHER GRADE OILS ARE AVAILABLE,
SAE 30 GRADE MAY BE USED AT TURN USI 3 OIL TO COLLECTION CENTERS Do Not Use SAE 10W-40 Grade
TEMPERATURES ABOVE 40'F (4C) COLD WEATHER Oil or any Other Grade
Not Recommended.

TCCS1235 84901

Fig. 128 Gasoline engine oil viscosity Fig. 129 Lcok for the API oil identification
chart label whe choosing your engine oil Fig. 130 Diesel engine oil viscosity chart

RECOMMENDED LUBRICANTS
Component Lubricant
Engine Oil API SG/CE
Coolant EthyleneGlycol Anti-Freeze
Manual Transmission
Muncie 117mm API GL5, SAE 80W-90
Getrag 85mm Synchromesh Transmission Fluid
NVG 4500 Castrol Syntorq GL-4
NVG5LM60 Synchromesh Transmission Fluid
Automatic Transmission AFT Dexron I
Transfer Case
Differential APIGL-5, SAE80W-90
Master Cylinder DOT 3 Brake Fluid
Power Steering GM Power Steering Fluid
Manual Steering Gear GM Lubricant
Multi-Purpose Grease NLGI#2

use "Service SG, SH" or greater should be used. Oils of the SG, SH or its SL lersed- determines the speed at which the gas will burn. The lower the octane rating,
ing oil type perform a variety of functions inside the engine in addition to the basic the faster it burns. The higher the octane, the slower the fuel will burn and a
function as a lubricant. Through a balanced system of metallic detergents an I poly- greater percentage of compounds in the fuel prevent spark ping (knock), detona-
meric dispersants, the oil prevents the formation of high and low temperatur tion and preignition (dieseling).
deposits and also keeps sludge and particles of dirt in suspension. Acids, p;i licu- As the temperature of the engine increases, the air/fuel mixture exhibits a
larly sulfuric acid, as well as other by-products of combustion, are neutralize i. Both tendency to ignite before the spark plug is fired. If fuel of an octane rating too
the SAE grade number and the APE designation can be found on top of the i il can lew for the engine is used, this will allow combustion to occur before the piston
Diesel engines also require SG, SH or greater engine oil. In addition, the >il must has completed its compression stroke, thereby creating a very high pressure
qualify for a CC or greater rating. The API has a number of different diesel er gine very rapidly.
ratings, including CB, CC, and CD. Any of these other oils are fine as long a:; the Fuel of the proper octane rating, for the compression ratio and ignition timing
designation CC appears on the container label along with them. Do not use ol your truck, will slow the combustion process sufficiently to allow the spark
labeled only SG, SH or only CC. Both designations must always appear togf he; plug enough time to ignite the mixture completely and smoothly. Many non-cata-
For recommended oil viscosities, refer to the chart. Note that 10W-3C and lyst models are designed to run on regular fuel. The use of some super-premium
10W-40 grade oils are not recommended for sustained high speed driving when fuel is no substitution for a properly tuned and maintained engine. Chances are
the temperature rises above the indicated limit. that if your engine exhibits any signs of spark ping, detonation or pre-ignition
when using regular fuel, the ignition timing should be checked against specifica-
Synthetic Oil tions or the cylinder head should be removed for decarbonizing.
Vehicles equipped with catalytic converters must use UNLEADED GASOLINE
There are many excellent synthetic and fuel-efficient oils currently av; liable ONLY. Use of unleaded fuel shortened the life of spark plugs, exhaust systems
that can provide better gas mileage, longer service life, and in some cas s better and EGR valves and can damage the catalytic converter. Most converter
engine protection. These benefits do not come without a few hitches, ho (ever; equipped models are designed to operate using unleaded gasoline with a mini-
the main one being the price of synthetic oils, which in most cases is mi: re mum rating of 87 octane. Use of unleaded gas with octane ratings lower than 87
expensive per quart of conventional oil. can cause persistent spark knock which could lead to engine damage.
Synthetic oil is not for every truck and every type of driving, so you s ould Light spark knock may be noticed when accelerating or driving up hills. The
consider your engine's condition and your type of driving. Also, check yi: ur slight knocking may be considered normal (with 87 octane) because the maxi-
truck's warranty conditions regarding the use of synthetic oils. mum fuel economy is obtained under condition of occasional light spark knock.
FUEL Gasoline with an octane rating higher than 87 may be used, but it is not neces-
sary (in most cases) for proper operation.
If spark knock is constant, when using 87 octane, at cruising speeds on level
Gasoline Engines ground, ignition timing adjustment may be required.
It is important to use fuel of the proper octane rating in your truck. Oc
.ane 'Your engine's fuel requirement can change with time, mainly due to
rating is based on the quantity of anti-knock compounds added to the fuel and carbon buildup, which changes the compression ratio. If your engine
GENERAL INFORMATION AND MAINTENANCE 1-37
pings, knocks or runs on, switch to a higher grade of fuel. Sometimes Remove oil from skin by washing thoroughly with soap and water or
just changing brands will cure the problem. If it becomes necessary to waterless hand cleaner. Do not use gasoline, thinners or other solvents.
retard the timing from specifications, don't change it more than a few Avoid prolonged skin contact with oil-soaked clothing.
degrees. Retarded timing will reduce power output and fuel mileage
and will increase the engine temperature. OIL LEVEL CHECK
Diesel Engines I See Figures 131,132 and 133
Diesel engines require the use of diesel fuel. At no time should gasoline be Every time you stop for fuel, check the engine oil as follows:
substituted. Two grades of diesel fuel are manufactured, No. 1 and No. 2, 1. Park the truck on level ground.
although No. 2 grade is generally more available. Better fuel economy results 2. When checking the oil level it is best for the engine to be at operating
from the use of No. 2 grade fuel. In some northern parts of the U.S. and in most temperature, although checking the oil immediately after a stopping will lead to
parts of Canada, No. 1 grade fuel is available in the winter or a winterized blend a false reading. Wait a few minutes after turning off the engine to allow the oil to
of No. 2 grade is supplied in winter months. When the temperature falls below drain back into the crankcase.
20F (-7C), No. 1 grade or winterized No. 2 grade fuel are the only fuels that can 3. Open the hood and locate the dipstick which is on the left side of the
be used. Cold temperatures cause unwinterized No. 2 to thicken (it actually engine. Pull the dipstick from its tube, wipe it clean and reinsert it.
gels), blocking the fuel lines and preventing the engine from running. 4. Pull the dipstick out again and, holding it horizontally, read the oil level.
Do not use home heating oil in your truck. The oil should be between the FULL or OPERATING RANGE and ADD or
Do not use ether or starting assist fluids in your truck. ADD OIL marks on the dipstick.
Do not use any fuel additives recommended for use in gasoline engines. 5. If "he oil is below the ADD mark, add oil of the proper viscosity through
It is normal that the engine noise level is louder during the warm-up period the capped opening on the top of the cylinder head cover. See the "Oil and Fuel
in winter. It is also normal that whitish/blue smoke may be emitted from the Recommendations" chart in this section for the proper viscosity and rating of
exhaust after starting and during warm-up. The amount of smoke depends upon acceptable oils.
the outside temperature. 6. Reinsert the dipstick and check the oil level again after adding any oil. Be
careful not to overfill the crankcase. Approximately one quart of oil will raise the
Engine level from the ADD to the FULL. Excess oil will generally be consumed at an
accelerated rate.
** CAUTION OIL & FILTER CHANGE
Prolonged and repeated skin contact with used engine oil, with no
effort to remove the oil, may be harmful. Always follow these sim- See Figures 134,135,136 and 137
ple precautions when handling used motor oil: The oil should be changed every 7500 miles (12,000 km). General Motors
recommends changing the oil filter with every other oil change; we suggest that
Avoid prolonged skin contact with used motor oil. the filter be changed with every oil change. There is approximately 1 quart of

Fig. 131 Remove the oil dipstick and Fig. 133 Using a funnel, add the proper
check the oil level Fig. 132 Remove the oil filler cap grade and viscosity of oil

Fig. 135 Remove the drain plug while


Fig. 134 With the proper size socket, maintaining a slight upward force, to keep Fig. 136 With a filter wrench, loosen the
loosen the drain plug the oil from running out prematurely oil filter counterclockwise
1-38 GENERAL INFORMATION AND MAINTENANCE
12. Open a container of new oil and smear some of this oil onto the rubber
gasket of the new oil filter. Get a feel for where the filter post is and start the fil-
ter by hand until the gasket contacts the seat. Turn the filter an additional %
turn with your hand.
13. Install the drain plug and metal gasket. Be sure that the plug is tight
enough that the oil does not leak out, but not tight enough to strip the
threads. Over time you will develop a sense of what the proper tightness of
the drain plug is. If a torque wrench is available, tighten the plug to 18 ft. Ibs.
(25 Nm).
Replace the drain plug gasket at every third or fourth oil change.
14. Through a suitable plastic or metal funnel, add clean new oil of the
proper grade and viscosity through the oil filler on the top of the valve cover. Be
sure that the oil level registers near the (full) mark on the dipstick.
Fig. 137 Before installing a new oil filter, coat the rubber gaskei 15. Install and tighten the oil filler cap.
with clean oil 16. Start the engine and allow it to run for several minutes. Check for leaks
at the filter and drain plug. Sometimes leaks will not be revealed until the
engine reaches normal operating temperature.
dirty oil left remaining in the old oil filter if it is not changed! A few doll; more 17. Stop the engine and recheckthe oil level. Add oil as necessary.
every year seems a small price to pay for extended engine lifeso chan ethe When you have finished this job, you will notice that you now possess
filter every time you change the oil! several quarts of dirty oil. The best thing to do with it is to pour it into
The oil drain plug is located on the bottom, rear of the oil pan (botton of the plastic jugs, such as milk or anti-freeze containers. Then, find a gas station
engine, underneath the truck). or service garage which accepts waste oil for recycling and dispose of it
The mileage figures given are the recommended intervals assuming n rmal there.
driving and conditions. If your truck is being used under dusty, polluted r off-
road conditions, change the oil and filter more frequently than specified he
same goes for trucks driven in stop-and-go traffic or only for short dista es. Manual Transmission
Always drain the oil after the engine has been running long enough to b ig it to
normal operating temperature. Hot oil will flow easier and more contami nts FLUID RECOMMENDATION
will be removed along with the oil than if it were drained cold. To chang he oil
and filter: Muncie 117mm: API GL-5, SAE80W-90
If the engine is equipped with an oil cooler, this will also have be Getrag 85mm: Syncromesh Transmission Fluid
drained, using the drain plug. Be sure to add enough oil to fill tin NVG 4500: Castrol Syntorq GL-4
cooler in addition to the engine. NVG 5LM60: Syncromesh Transmission Fluid
NVG 3500: Syncromesh Transmission Fluid
1. Warm the oil by running the engine for a short period of time or least
until the needle on the temperature gauge rises above the C mark. This v LEVEL CHECK
make the oil flow more freely from the oil pan.
2. Park on a level surface, apply the parking brake and block the wi els.
See Figure 138
3. Stop the engine. Raise the hood and remove the oil filler cap fro the
top of the valve cover. This allows the air to enter the engine as the oil d ins. Check the lubricant level at least twice a year, even more frequently if driven
Remove the dipstick, wipe it off and set it aside. in deep water.
4. Position a suitable oil drain pan under the drain plug. 1. With the truck parked on a level surface, remove the filler plug from the
All diesel and gasoline engines hold approximately 5-8 quarts oil side of the transmission case. Be careful not to take out the drain plug at the
(give or take), so choose a drain pan that exceeds this amount to How bottom.
for movement of the oil when the pan is pulled from under the ve cle. 2. If lubricant begins to trickle out of the hole, there is enough. If not, care-
This will prevent time lost to the cleaning up of messy oil spills. fully insert a finger (watch out for sharp threads) and check that the level is up
to the edge of the hole.
5. With the proper size socket or wrench (DO NOT use pliers or vis grips), 3. If not, add sufficient lubricant with a funnel and tube, or a squeeze bulb
loosen the drain plug. Back out the drain plug while maintaining a sligh pward to bring it to the proper level. You can also use a common kitchen baster.
force on it to keep the oil from running out around it (and your hand). A wthe 4. Install the plug and tighten to 17 ft. Ibs. (23 Nm) on the Muncie and
oil to drain into the drain pan. Getrag; 30 ft. Ibs. (40 Nm) on NVG 4500; and 44 ft. Ibs. (60 Nm) on the NVG
5LM60. Road test the truck and check for any leaks.
CAUTION
The engine oil will be hot. Keep your arms, face and hands away
from the oil as it is draining.

6. Remove the drain pan and wipe any excess oil from the area arou d the
hole using a clean rag.
7. Clean the threads of the drain plug and the drain plug gasket to re nove
any sludge deposits that may have accumulated.
8. Place the drain pan under the oil filter location to prevent spilling any oil
from the filter on to the ground.
9. With a filter wrench, loosen the oil filter counterclockwise and back the
filter off the filter post the rest of the way by hand. Keep the filter end up so that
the oil does not spill out. Tilt the filter into the drain pan to drain the oil.
10. Remove the drain pan from under the vehicle and position it off to the
side. 84901096
11. With a clean rag, wipe off the filter seating surface to ensure a proi: er Fig. 138 Use your finger to check the oil level in the manual trans-
seal. Make sure that the old gasket is not stuck to the seating surface. If it s, mission
remove it and thoroughly clean the seating surface of the old gasket mater al.
GENERAL INFORMATIONAND MAINTENANCE 1-39
DRAIN & REFILL has been running at high speed for a long period, in city traffic on a hot day or
pulling a trailer, let it cool down for about thirty minutes before checking the level.
1. Park the truck on a level surface with the engine idling. Shift the trans-
No intervals are specified for changing the transmission lubricant, but it is a
mission into P and set the parking brake.
good idea on a used vehicle, one that has been worked hard, or one driven in
2. Remove the dipstick (on newer models, you may have to flip up the handle
deep water. The vehicle should be on a level surface and the lubricant should be first), wipe it clean and reinsert it firmly. Be sure that it has been pushed all the way in.
at operating temperature. 3. Remove the dipstick and check the fluid level while holding it horizon-
1. Position the truck on a level surface. tally. All models have a HOT and a COLD side to the dipstick.
2. Place a pan of sufficient capacity under the transmission drain plug.
COLD: the fluid level should fall in this range when the engine has been
3. Remove the upper (fill) plug to provide a vent opening. running tor only a short time.
4. Remove the lower (drain) plug and let the lubricant drain out.
HOT: the fluid level should fall in this range when the engine has reached
** CAUTION normal running temperatures.
4 Early models have two dimples below the ADD mark, the level should be
The oil will be hot! Be careful when you remove the plug or you'll between these when the engine is cold.
be taking a bath in hot gear oil. 5. If the fluid level is not within the proper area on either side of the dipstick,
pour ATF into the dipstick tube. This is easily done with the aid of a funnel.
5. Install the drain plug and tighten to 17 ft. Ibs. (23 Nm) on the Muncie Check the level often as you are filling the transmission. Be extremely careful not
and Getrag; 30 ft. Ibs. (40 Nm) on NVG 4500; and 44 ft. Ibs. (60 Nm) on the to overfill it. Overfilling will cause slippage, seal damage and overheating.
NVG 5LM60. Approximately one pint of ATF will raise the level from one notch to the other.
6. Add lubricant with a suction gun or squeeze bulb.
7. Reinstall the filler plug. Run the engine and check for leaks ** WARNING
The fluid on the dipstick should always be a bright red color. It if is
Automatic Transmission discolored (brown or black), or smells burnt, serious transmission
troubles, probably due to overheating, should be suspected. The
FLUID RECOMMENDATIONS transmission should be inspected by a qualified service technician
to locale the cause of the burnt fluid.
Use Dexron III' or its superseding fluid type.
DRAIN 8, REFILL
LEVEL CHECK
> See Figures 142,143,144 and 145
See Figures 139,140 and 141 1. The fluid should be drained with the transmission warm. It is easier to
Check the level of the fluid at least once a month. The fluid level should be change the fluid if the truck is raised somewhat from the ground, but this is not
checked with the engine at normal operating temperature and running. If the truck always easy without a lift. The transmission must be level for it to drain properly.

8/981P27

Fig. 139 Remove the dipstick to check the Fig. 140 Hold the dipstick horizontally and Fig. 141 Use a funnel to add transmission
transmission fluid level check the fluid level fluid

1 Fig. 143 Pull one corner of the pan down


to drain most of the fluid and remove the Fig. 144 Remove the old pan gasket and
Fig. 142 Loosen all the pan bolts pan clean both gasket mating surfaces
1-40 GENERAL INFORMATION AND MAINTENANCE

87981P31 84901106

Fig. 145 Remove the filter from the trans- Fig. 146 C eck the transfer case fluid Fig. 147 The rear differential filler plug
mission level with our finger may be in either of these locations

2. Place a shallow pan underneath to catch the transmission fluid (t bout 5 DRAIN & REFILL
pints). Loosen all the pan bolts, then pull one corner down to drain mos of the
fluid. If it sticks, VERY CAREFULLY pry the pan loose. You can buy after arket
1. With the transfer case warmed up, park on a level surface.
drain plug kits that makes this operation a bit less messy, once installed 2. Slide a pan of a least 6 pts. capacity under the case drain plug.
*ll the fluid removed smells burnt, serious transmission trouble: 3. Remove the filler plug from the rear of the transfer case (behind the
probably due to overheating, should be suspected. transmission). Remove the drain plug from the bottom.
4. Wipe the area clean and install the drain plug.
3. Remove the pan bolts and empty out the pan. On some models, ere 5. Add lubricant with a suction gun or squeeze bulb.
may not be much room to get at the screws at the front of the pan. 6. When the lubricant level is up to the bottom of the filler hole, install the
4. Clean the pan with solvent and allow it to air dry. If you use a rag| to plug and tighten it to specifications.
wipe it out, you risk leaving bits of lint and threads in the transmission . 4401 and 4470 models: 18 ft. Ibs. (25 Nm).
5. Remove the filter or strainer retaining bolts. On the Turbo Hydra-H/latic NV241 and NV243 models: 35 ft. Ibs. (47 Nm),
400, there are two screws securing the filter or screen to the valve body,
reusable strainer may be found on some models. The strainer may be cle| ned in
solvent and air dried thoroughly. The filter and gasket must be replaced. Front and Rear Drive Axles
To install:
6. Install a new gasket and filter. FLUID RECOMMENDATIONS
7. Install a new gasket on the pan, and tighten the bolts evenly to 1 ft. Ibs.
(25 Nm) in a crisscross pattern.
8. Add DEXRON111 or its superseding type of transmission fluid thr ugh Front axles use SAE 80W-90, GL-5 Gear Lubricant. Rear axles use SAE 80W-
the dipstick tube. The correct amount is in the Capacities Chart. Do not t rfill. 90 gear oil. Posi-traction axles must use special lubricant available from dealers
9. With the gearshift lever in Park, start the engine and let it idle. D not and most auto parts stores. If the special fluid is not used, noise, uneven opera-
race the engine. tion, and damage will result. There is also a Posi-traction additive used to cure
10. Move the gearshift lever through each position, holding the braki noise and slippage. Posi-traction axles have an identifying tag, as well as a
Return the lever to Park, and check the fluid level with the engine idling. The warning sticker near the jack or on the rear wheel well.
level should be between the two dimples on the dipstick, about 1/< in. (6r m)
below the ADD mark. Add fluid, if necessary. LEVEL CHECK
11. Check the fluid level after the truck has been driven enough to th
oughly warm up the transmission. If the transmission is overfilled, the excess See Figures 147 and 148
must be drained off. Overfilling causes aerated fluid, resulting in transm Hsion The oil level in the front and/or rear differentials should be checked at least
slippage and probable damage. twice a year. If driven in deep water it shoujd be checked immediately after-
ward. The fluid level in the front axle should be 1/2 in, (13mm) below the filler
Transfer Case plug opening. The fluid level in the rear axle should be up to the bottom of the
filler plug opening. Lubricant may be added with a suction gun or squeeze
bulb.
FLUID RECOMMENDATIONS

Use Dexron II5 or its superseding fluid type on models through 1994. pn
1995-98 models, use Dexron III" or its superseding fluid.

LEVEL CHECK

See Figure 146


Check the four wheel drive transfer case lubricant at least twice a year.
1. With the truck parked on a level surface, remove the filler plug fronf the
rear of the transfer case (behind the transmission). Be careful not to take (ut the
drain plug at the bottom.
2. If lubricant trickles out, there is enough. If not, carefully insert a fin ier
and check that the level is up to the edge of the hole, EXCEPT in full time our
wheel drive cases which should be 1/2 in. (13mm) below the hole.
3. Lubricant may be added, if necessary, with a funnel and tube, or a
squeeze bulb, Fig. 148 If necessary, fill with the proper fluid
4. Tighten the plug to 18 ft. Ibs. (25 Nm).
GENERAL INFORMATION AND MAINTENANCE 1-41
1. Park on level ground. 7. Refill the differential with the proper lubricantdo not overfill!
2. Remove the filler plug from the differential housing cover. 8. Install the filler plug and tighten both plugs to:
3. If lubricant trickles out there is enough. If not, carefully insert a finger REAR:
and check that the level is up to the bottom of the hole. Locking front hubs 8 1 /2in 25ft. Ibs. (34 Nm)
should be run in the LOCK position for at least 10 miles (6 km) each month to 91/2 and 10V2 in19 ft. Ibs. (24 Nm)
assure proper lubrication to the front axle. 9%-101/2in.10ft. Ibs. (14 Nm)
4. Fill with the proper fluid, install the plug and tighten to: 12 in35ft. Ibs. (47 Nm)
REAR: FRONT:
81/2 in.25 ft. Ibs. (34 Nm) All: 80 ft. Ibs. (110 Nm)
91/2 and 10'/2 in19 ft. Ibs. (24 Nm) 9. Road test the truck and check for any leaks.
93/4-101/2in 10ft. Ibs. (14 Nm)
12 in35ft. Ibs. (47 Nm) Cooling System
FRONT:
. All80ft. Ibs. (110 Nm) See Figures 152,153,154,155 and 156
DRAIN & REFILL The cooling system was filled at the factory with a high quality coolant solu-
tion that is good for year around operation and protects the system from freez-
I See Figures 149,150 and 151 ing down to -20F (-29C) (-32F/36C in Canada). It is good for two full calendar
years or 24,000 miles (38,500 km), whichever occurs first, provided that the
No intervals are specified for changing axle lubricant, but it is a good idea proper concentration of coolant is maintained.
every year or so. If you have driven in water over the axle vents, change the fluid The hot coolant level should be at the FULL HOT mark on the expansion tank
immediately. and the cold coolant level should be at the FULL COLD mark on the tank. Do
1. Park the vehicle on the level with the axles at normal operating tempera- not remove the radiator cap to check the coolant level.
ture.
2. Place a pan of at least 6 pints capacity under the differential housing. FLUID RECOMMENDATIONS
3. Remove the filler plug.
4. If you have a drain plug, remove it. If not, unbolt and remove the differen-
tial cover. On 1988-95 models, the coolant mixture in Chevy/GMC trucks is 50/50 eth-
5. Install the drain plug, or differential cover. Use a new gasket if the differ- ylene glycol and water for year round use. Use a good quality anti-freeze with
ential cover has been removed. water pump lubricants, rust inhibitors and other corrosion inhibitors along with
6. Install the drain plug and tighten it so it will not leak. Do not over- acid neutralizers.
tighten. On 1996-98 models, Use a 50/50 mixture of DEX-COOL' coolant and water.
Do not mix any other type of coolant with the DEX-COOL as they are incom-
Hi is usually a good idea to replace the gasket at this time. patible and may cause damage to the cooling system.

Fig. 150 After removing the bolts, care-


Fig. 149 Using a wire brush, clean the fully pry the bottom of the cover off and Fig. 151 After the oil has drained, remove
bolts and edges of the differential cover drain the fluid the differential cover

\. 153 Remove any debris from the radi-

Fig. 152 The system should be pressure- Fig. 154 Coolant condition can be checked
tested once a year ator's cooling fins with an inexpensive tester
1-42 GENERAL INFORMATION AND MAINTENANCE

Fig. 155 Check the condition of the radia-


tor cap gasket and seal Fig. 156 I sped coolant for contamination Fig. 157 Master cylinder fluid level

LEVEL CHECK any that is left in an uncovered container or in puddles on the


ground. This will prove fatal in sufficient quantity. Always drain the
1. Check the level on the see-through expansion tank. coolant Into a scalable container. Coolant should be reused unless
it is contaminated or several years old.
CAUTION
1. Drain the existing anti-freeze and coolant. Open the radiator and engine
The radiator coolant is under pressure when hot. To avoid the i anger drain petcocks (located near the bottom of the radiator and engine block,
of physical harm, coolant level should be checked or replenish id respectively), or disconnect the bottom radiator hose at the radiator outlet.
only when the engine is cold. To remove the radiator cap when the 2. Close the petcock or reconnect the lower hose and fill the system with
engine is hot, first cover the cap with a thick rag, or wear a hef vy waterhot water if the system has just been run.
glove for protection. Press down on the cap slightly and slowly turn it 3. Add a can of quality radiator flush to the radiator or recovery tank, fol-
counterclockwise until it reaches the first stop. Allow all the pr ssure lowing any special instructions on the can.
to vent (indicated when the hissing sound stops). When the prt ssure 4. Idle the engine as long as specified on the can of flush, or until the
is released, press down on the cap and continue to rotate it co) nter- upper radiator hose gets hot.
clockwise. Some radiator caps have a lever for venting the pre sure 5. Drain the system again. There should be quite a bit of scale and rust in
but you should still exercise extreme caution when removing tie cap. the drained water.
6. Repeat this process until the drained water is mostly clear.
2. Check the level and, if necessary, add coolant through the expans on tank 7. Close all petcocks and connect all hoses.
to the proper level. Use a 50/50 mix of ethylene glycol anti-freeze and w ter. 8. Flush the coolant recovery reservoir with water and leave empty.
Alcohol or methanol base coolants are not recommended. Anti-freeze scj utions 9. Determine the capacity of your truck's cooling system (see Capacities
should be used, even in summer, to prevent rust and to take advantage t the specifications in this guide). Add a 50/50 mix of ethylene glycol anti-freeze and
solution's higher boiling point compared to plain water. This is imperathp on air water to provide the desired protection.
conditioned trucks; the heater core can freeze if it isn't protected. Cooian 10. Run the engine to operating temperature, then stop the engine and check
should be added through the coolant recovery tank, not the radiator fille neck. for leaks. Check the coolant level and top up if necessary.
11. Check the protection level of your anti-freeze mix with an anti-freeze
WARNING tester (a small, inexpensive syringe type device available at any auto parts
store). The tester has five or six small colored balls inside, each of which sig-
Never add large quantities of cold coolant to a hot engine! A nify a certain temperature rating. Insert the tester in the recovery tank and suck
cracked engine block may result! just enough coolant into the syringe to float as many individual balls as you can
(without sucking in too much coolant and floating all the balls at once). A table
Each year the cooling system should be serviced as follows supplied with the tester will explain how many floating balls equal protection
Wash the radiator cap and filler neck with clean water. down to a certain temperature (three floating balls might mean the coolant will
Check the coolant for proper level and freeze protection. protect your engine down to +5F (-15C), for example.
Have the system pressure tested 15 psi. (103 kPa), If a replacemer) cap is
installed, be sure that it conforms to the original specifications.
Tighten the hose clamps and inspect all hoses. Replace hoses that|are Brake Master Cylinder
swollen, cracked or otherwise deteriorated.
Clean the frontal area of the radiator core and the air conditioning Con- FLUID RECOMMENDATIONS
denser, if so equipped.
DRAINING & FLUSHING I See Figure 157
Use only Heavy Duty Brake fluid meeting or exceeding DOT 3 standards.
The cooling system in you truck accumulates some internal rust and coirosion
in its normal operation. A simple method of keeping the system clean is kn jwn as LEVEL CHECK
flushing the system. It is performed by circulating a can of radiator flush thiough
the system, and then draining and refilling the system with the normal cool.int. > See Figures 158 and 159
Radiator flush is marketed by several different manufacturers, and is availal: le in Chevrolet and GMC trucks are equipped with a dual braking system, allow-
cans at auto departments, parts stores, and many hardware stores. This operation ing a vehicle to be brought to a safe stop in the event of failure in either front or
should be performed every 30,000 miles (48,000 kmjor once a year. rear brakes. The dual master cylinder has 2 entirely separate reservoirs, one
CAUTION connected to the front brakes and the other connected to the rear brakes. In the
event of failure in either portion, the remaining part is not affected. Fluid level in
When draining the coolant, keep in mind that cats and dogs are the master cylinder should be checked on a regular basis.
attracted by ethylene glycol anti-freeze, and are quite likely to drink The master cylinder is mounted to the left side of the firewall.
GENERAL INFORMATION AND MAINTENANCE 1-43
1. Clean all of the dirt from around the cover of the master cylinder. 1. Clean all of the dirt from around the cover of the master cylinder.
2. Be sure that the vehicle is resting on a level surface. 2. Be sure that the vehicle is resting on a level surface.
3. Carefully pry the clip from the top of the master cylinder to release the 3. Carefully remove the cover from the master cylinder.
cover. On some later models, just pull up on the tabs. 4. The fluid level should be approximately V* in. (6mm) from the top of the
4. The fluid level should be approximately V* in. (6mm) from the top of the master cylinder or at least above the MIN mark. If not, add fluid until the level is
master cylinder or at least above the WIN mark. If not, add fluid until the level is correct. Replacement fluid should be Delco Supreme No. 11, DOT 3, or its
correct. Replacement fluid should be Delco Supreme No. 11, DOT 3, or its eguivalent.
equivalent. It is normal for the fluid level to fall as the disc brake pads wear. If 5. Install the cover of the master cylinder.
the fluid level in the master cylinder is excessively low, check the brake system
for leaks and wear. Power Steering Pump
:-!: WARNING
FLUID RECOMMENDATION
Brake fluid dissolves paint! It also absorbs moisture from the air.
Never leave a container or the master cylinder uncovered any Use GM Power Steering fluid, or its equivalent.
longer than necessary!
LEVEL CHECK
5. Install the cover of the master cylinder. On most models there is a rubber
gasket under the cover, which fits into two slots on the cover. Be sure that this is
seated properly. > See Figures 160,161 and 162
6. Push the clip back into place and be sure that it seats in the groove on Check the dipstick in the pump reservoir when the fluid is at operating tem-
the top of the cover. perature. The fluid should be between the HOT and COLD marks. If the fluid is
at room temperature, the fluid should be between the ADD and COLD marks.
Clutch Master Cylinder The fluid does not require periodic changing.
On systems with a remote reservoir, the level should be maintained approxi-
mately 1/2-1 in. (13-25mm) from the top with the wheels in the full left turn
FLUID RECOMMENDATIONS position.
Use hydraulic clutch fluid or heavy duty brake fluid meeting DOT 3 stan-
dards. Steering Gear
LEVEL CHECK FLUID RECOMMENDATIONS

The clutch master cylinder is located on the firewall in the engine compart- Use GM Lubricant (part No. 1051052).
ment.

87981P39 87961P40

Fig. 158 Remove the master cylinder Fig. 159 Add brake fluid until the level is Fig. 160 Remove the power steering pump
cover correct dipstick

Fig. 161 Hold the dipstick horizontally and check the power steering Fig. 162 Add power steering fluid to the pump and fill it to the
fluid level proper level
1-44 GENERAL INFORMATION AND MAINTENANCE
LEVEL CHECK 2. if the truck has been parked in temperatures below 20F (-7C) for any
length of time, park it in a heated garage for an hour or so until the bail joints
No lubrication is needed for the life of the gear, except in the event oflpeal loosen up enough to accept the grease.
replacement or overhaul, when the gear should be refilled with a 13 oz. con- 3. Depending on which front wheel you work on first, turn the wheel and tire
tainer of Steering Gear Lubricant (Part No. 1051052) which meets GM Specifi- outward, either full-lock right or full-lock left. You now have the ends of the
cation GM 4673M, or its equivalent. upper and lower suspension control arms in front of you; the grease nipples are
visible pointing up (top ball joint) and down (lower ball joint) through the end of
each control arm.
Chassis Greasing 4. If the nipples are not accessible enough, remove the wheel and tire.
5. Wipe all dirt and crud from the nipples or from around the plugs (if
I See Figures 163,164,165,166 and 167 installed). If plugs are on the truck, remove them and install grease nipples in the
Refer to the diagrams for chassis points to be lubricated. Not all vehicles have holes (nipples are available in various thread sizes at most auto parts stores).
all the fittings illustrated. Water resistant EP chassis lubricant (grease) conform- 6. Using a hand operated, low pressure grease gun loaded with a quality chas-
ing to GM specification 6031-M should be used for all chassis grease pants. sis grease, grease the ball joint only until the rubber joint boot begins to swell out.
Every year or 7500 miles (12,067 km) the front suspension ball joints;! both The steering linkage should be greased at the same interval as the ball joints.
upper and lower on each side of the truck, must be greased. Most trucks cov- Grease nipples are installed on the steering tie rod ends on most models.
ered in this guide should be equipped with grease nipples on the ball jo (its, 7. Wipe all dirt and crud from around the nipples at each tie rod end.
although some may have plugs which must be removed and nipples fittaf 8. Using a hand operated, low pressure grease gun loaded with a suitable
chassis grease, grease the linkage until the old grease begins to squeeze out
-' WARNING around the tie rod ends.
9. Wipe off the nipples and any excess grease. Also grease the nipples on
Do not pump so much grease into the ball joint that excess gr ase the steering idler arms.
squeezes out of the rubber boot. This destroys the watertight s al. Use chassis grease on the parking brake cable where it contacts the cable
guides, levers and linkage.
1. Raise up the front end of the truck and safely support it with jacks ids. Apply a small amount of clean engine oil to the kickdown and shift linkage
Block the rear wheels and firmly apply the parking brake. points at 7500 mile (12,000 km) intervals.

15 13 9 8 1 11 6 3 5 2 4 12
1. Air cleaner
2. Control linkage
3. Tie rod ends
4. Wheel bearings
5- Steering gear
6. Master cylinder
7. Transmission
8. Carburetor linkage
9. U-joints
10. Driveshaft slip joints
11. Drive axle
12. Drag link
13. Brake and clutch pedal
springs
14. Transfer case
15. Throttle bell crank, 6-
48L
10 i 6 3 5 2 1

Fig. 163 Lubrication points for the R-series

1. Air cleaner
2. Control linkage
3 4 3 Tie rod ends
4. Wheel bearings
5. Steering gear
6. Master cylinder
7. Transmission

8. Carburetor linkage
9. U-joints
10. Driveshaft slip joints
11. Drive axle

12. Drag link


13. Brake and clutch pedal
springs
14. Transfer case
15. Throttle bellcrank, 6-
8 1 5 12 3 4 15 4.8L
84901119

Fig. 164 Lubrication points for the V-series


GENERAL INFORMATION AND MAINTENANCE 1-45

1. Steering linkage
2. Wheel bearings
3. Air cleaner
Transmission
Dnveshaft slip joint
Drive axle
Clutch actuator
Master cylinder
Oil filter
Steering gear
11. Engine

Fig. 165 Lubrication points for the C-series

1 Steering linkage
2 Wheel bearings
3. Air cleaner
4 Transmission
5. Rear Drive axle
6. Transfer case
7. Clutch actuator
8 Master cylinder
9 Front driveshaft
10. Oil filter
11. Engine
12. Front drive axle

Fig. 166 Lubrication points for the K-series

Body Lubrication and Maintenance


LOCK CYLINDERS

Apply graphite lubricant sparingly through the key slot. Insert the key and operate
the lock several times to be sure that the lubricant is worked into the lock cylinder.
HOOD LATCH & HINGES

Clean the latch surfaces and apply clean engine oil to the latch pilot bolts
and the spring anchor. Also lubricate the hood hinges with engine oil. Use a
chassis grease to lubricate all the pivot points in the latch release mecha-
nism.
DOOR HINGES

The gas tank filler door and truck doors should be wiped clean and lubri-
cated with clean engine oil once a year. The door lock cylinders and latch mech-
anisms should be lubricated periodically with a few drops of graphite lock
Fig. 167 Front lubrication fittingsC/K series lubricant or a few shots of silicone spray.
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