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Discover everything Scribd has to offer, including books and audiobooks from major publishers. Report this Document Download Now Save Save 1988 g30 Chevy Van Repair Manual For Later 75% (4) 75% found this document useful (4 votes) 7K views 178 pages 1988 g30 Chevy Van Repair Manual Uploaded by wwwebcat Description: Full description Save Save 1988 g30 Chevy Van Repair Manual For Later 75% 75% found this document useful, Mark this document as useful 25% 25% found this document not useful, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 178 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. Chilton has the most accurate and up-to-date Chevrolet G30 Chevy Van repair manual online, available right now. Our Chevrolet G30 Chevy Van online content is updated monthly, ensuring you have the most up-to-date information for all your repairs, service, and maintenance. Now you can login at any time, day or night, and get the most accurate information available to guide your latest Do-It-Yourself project. We’ve checked the years that the manuals coverYou’ll then be shown the first 10 pages of this specific. Then you can clickSpam free: Maximum of 1 email per monthSpam free: Maximum of 1 email per month. That’s why Mr. Goodwrench wants to have a good stock of genuine GM Parts available. Everything from SHU GM QUALITY. OB-1 SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE General Information.OA- 1 Service Parts Identification Label.OA- 1 Vehicle Identification Number.OA- 2 Certification Label.OA- 2 Model Reference.OA- 3 Engine Identification Number.OA- 3 Vehicle Lifting Procedures.OA- 3 Metric Fasteners. O N G M C T ruck L o rd s to w n, OH. When lifting the G vehicle with a hoist, the rear hoist MODEL REFERENCE pads should be positioned under the rear spring forward hangers. Floor Jack C. Frame at toward body mount. D. Rear spring forward hanger. Hoist E.
Rear axle; between the spring and brake backing plate. F. Vehicle Jack Frame; at front body mount. Two Column Hoist Floor Jack Rear spring at front mount. B-07627 Figure 13 — Chassis Lift Points — G-Model. B-07628 Figure 15 —. Many fasteners are metric and are very close in dimension to well-known customary fasteners in the inch system. It is most important that replacement fasteners be of the correct nominal diameter, thread pitch and strength. This is most c. However, in some cases, if the correct tool is not NOTICE: When handling an electronic part that available, a hex socket head wrench may be used.Cloth Lamp — Roof Marker Trim Combination —. The information shown on pages OB-8 through OB-25 is the same as shown in the 1988 Light Duty Maintenance Schedule and Log. Brake Master Cylinder 4. Steering Gear Clutch Cross-Shaft - Automatic 11. Parking Brake Linkage L00523 Figure 9 — Lubrication Points for the G-Van. Replace if dirty or rusty. Refer to INSPECTIONS AND SERVICES Section 5 of your Owner’s Manual for further details. Windshield washer fluid level check —. Lock deicers which joints.Refer to Section 1 in your Owner’s Manual for adjustment instructions. Seatback latch and recliner operation on vehicles equipped with re- cliner seat —. Vehicle loading must be limited such that neither the wheel or tire inflation pressure or load limits are exceeded). Temperature of Heater Check and adjust. Heater hoses are routed from the thermostat housing or 4. Instrument panel compartment.Remove or Disconnect (Figure 12) NOTICE: Do not pinch the cable. 1. Battery ground cable. 4. Cable (51 or 52) from the heater case (24). 2. Instrument Panel Wiring Harness 56. Blower Switch B-09811 Figure 14 — Blower Switch. Screws. RESISTOR REPLACEMENT 3. Connector (4). Remove or Disconnect (Figures 5 and 15) 4. Battery ground cable. 1. Battery ground cable.If the heater hoses do not come off, cut the hoses forward of the core tubes. Left Outlet Assembly.134. Duct Assembly 135.
Right Outlet Assembly 136. Engine Cover Assembly 137. Engine Cover Insulator 138. Defroster Plenum Outlet 139. Upper Instrument Panel ----- Q tB LO O 180. Cable (145 or 146) to the heater assembly (124). 1. Blower switch (56) to the control assembly (147). 2. Cable retaining tabs (150) and screws (149). 2. Protector 196. Harness 179. Hose 198. Wire Assembly Figure 28 — Auxiliary Heater Plumbing Component View — G-Van. Remove or Disconnect (Figure 27).G-Series 13.5 7.1 Max. 3250 Max. Fuses (Main Heater) — All Series — — Blower Motor (Auxiliary Heater) — All Series 13.5 9.6 Max. The switch responds to pressure changes to turn the compressor ON or OFF. L01051 Figure 7 — Functional Test — G-Van. This switch series systems. The switch also shuts off the compressor senses compressor outlet pressure. For electrical wiring and vacuum diagrams, refer to figures 19, 20, 21, 22 and 23. Fast Idle Solenoid (5.7L Carbureted Engine Only) 110. Head Pressure Cut-Out Switch (With 7.4L Engine) 111. Actuator L00256 Figure 23 — G-Van Vacuum Schematic. If vacuum was normal and even at all positions, Start the engine and allow it to idle. Move the selector the malfunction may be caused by improperly. Wear goggles and wrap a clean cloth around fittings and connections. Leak test the system with a J 29547 Leak Detector.Install the ferrule with the small end toward the nut sor and install a new compressor with an in-line filter (figure 27). Remove or Disconnect (Figures 33, 34, 35 and 36) 1. Belt B-07680 Figure 33 — G-Van Compressor Installation — 4.3L, 5.0L and 5.7L Engines (Serpentine Drive) Refer to “Temperature 1. Core (148). Door Cable Adjustment.” 2. Core mounting strap (149) and strap screws (150). 3. Vacuum and electrical harnesses. ACTUATOR —. Heater Air Outlet 181. Screw 198. Heater Case Assembly 182. Center Air Outlet Adapter 199. Remove or Disconnect (Figures 47, 48 and 3. Resistor (3). 1. Vacuum lines at the tank. Install or Connect (Figure 37) 2. Vacuum Hose 260.
Rear Heater Harness C36, C60 And K34 C36 Or C60 261. K34 Vacuum Harness 01041 Figure 49 —. Vacuum Hose 267. Recirc Air Valve (Actuator) E. Vacuum Line-G ray To Source 236. Cable 268. Heater Assembly F. Vacuum Line-Orange 244. Cam 269. Air Cond. Valve (Actuator) G. Refrigerant Hose 276.REPLACEMENT Install or Connect (Figure 55) This system incorporates an expansion valve which does not utilize an external equalizer line. 1. Valve Seat 473. REPLACEMENT 6. Instrument panel bezel. 7. Headlamp switch control knob. Remove or Disconnect (Figures 61, 62, 63 8. Battery ground cable. 1. Battery ground cable. 2. Headlamp switch control knob. 3. Control Assembly 495. Defroster Duct 501. Body Wiring Harness 502. Blower Motor Switch 504. Instrument Panel Harness 505. Ignition L00218 Figure 63 — Instrument Panel Wiring Harness Figure 64 —. Remove or Disconnect (Figure 67) 4. Quickly move the temperature lever from full HOT to 1. Electrical harness connector.Remove or Disconnect (Figure 62) 11. Vacuum Line C36 and C60 555. Vacuum Pump L01078 Figure 71 — Vacuum Pump Assembly — 6.2L Engine. REPLACEMENT 4. Drain hose screw (3) or clamp (74).Insulator 65. Insulator 66. O-Ring 67. Expansion Valve 68. Screw 69. Bulb Clamp 71. Insulation 72. Refrigerant Hoses 73. Drain Hose 74. Clamp Figure 78 — G-Van Rear Interior Roof Mounted Evaporator and Blower — Component View. They are removed and shipped 2. Compressor Installation — refer to figures 81 and 82.Mark the frame or when mounting a body or equipment on a points (figure 1). Install the washer REPLACEMENT (UTILITY VEHICLE and nut loosely.Remove or Disconnect (Figures 20 and 21) 3. Bumper to the vehicle. 4. Bumper to frame spacers (198) (where used), spring 1. Bumper Bar 54. GRILLE REPLACEMENT h 4! Install or Connect (Figure 19) 1. New cable to the vehicle. Remove or Disconnect (Figures 21 and 22) 2. When changing cab mounts, it is important to properly Install or Connect (Figures 29 through 31) support the frame while changing the mount.
If only one 1. Noisy Front End 1. Worn tie rod ends. Refer to FRONT SUSPENSION (SEC. 3C). Loose suspension bolts.This Satisfactory vehicle operation may occur over a wide will allow the proper upper control arm to drop down far range of front end alignment settings. Relay Arm 12. Washer 13. Grommet 14. Jam Nut 15. Adjuster Plug L00381 Figure 3 —. Use the proper tool to separate all ball joints. J 29193 Steering Linkage Installer (12mm). J 29194 Steering Linkage Installer (14mm). \ f \ Adjust 1. Tie Rod Jam Nut L00386 Figure 10 — Steering Linkage — V-Models STEERING SHOCK ABSORBER REPLACEMENT Remove or Disconnect (Figures 2, 3, 9 1. P20, AND P30 MODELS EXCEPT MOTORHOME There are two tie rod assemblies, one attached to each end of the relay rod. The number of 2. Shock absorber (7) from the tie rod assembly (3).But the gap next to the adjuster tube must be visible. B-07294 Figure 17 —. If the steering system becomes damaged and loses The hydraulic power steering system consists of a hydraulic pressure, the vehicle can be controlled manually.HYDRAULIC PUMPS INTEGRAL POWER The hydraulic pump is a vane-type design. Shaft Seal 50. Filter 13. Pump Housing 51. Pump Union 40. Dip Stick 52. Seals 41. Pump Ring 53. End Plate 42. Thrust Plate 54. Retaining Ring 43. Vanes 55. Rotor 44. Reservoir Hole 56. Poor Return Of 2. Loosen the pinch bolt and assemble 2. Lower coupling flange rubbing against the Steering properly.Refer to “Power Steering Pump Replacement” in this The hydraulic system should be kept clean.Side Cover 70. Mounting Bolt 73. Adjusting Screw 74. Pinch Bolt 75. Steering Shaft 76. Coupling Nut 77. Spring Washer 78. Coupling Flange 79. Coupling 80. Side Cover Bolt 81. Spacer F-02622 Figure 9 —. Side Cover 70. Mounting Bolt 71. Pinch Bolt 80. Side Cover Bolt 81. Spacer 83. Spring Washer 84. Pinch Bolt Nut F-02625 Figure 12 — Steering Gear installation — P30 with RPO FS3 I-Beam Front Axle 17.
Worm Bearing Preload \ S \ Adjust (Figures 1, 2, and 15 through 19) Tool Required: J 7624 Adjustable Spanner Wrench. 1. After pulley removal, return to this point in the procedure and continue. Hoses installed H O Tighten out of position may be subjected to chafing or other All fasteners. Refer to the appropriate figure and to abuses during sharp turns. Refer to “Power Steering “Specifications”. L00648 Figure 31 — Power Steering Pump Mounting — G-Model L00560 Figure 32 — Installing and Removing Pulley. Refer to “Bleeding the Power Steering System” in this section.Replace the bowl. The Bowl (Tilt Column) Steering Wheel Loose Loose fit between the lock shoe and pivot pin. Replace both. Flash Very Slowly 2. System charging voltage low. 2. Increase voltage to specifications. Refer to (SEC. Lower the steering gear far enough to remove the flexible coupling. 4. Remove or Disconnect (Figure 10) 1. Negative battery cable. 2. Nuts And Washers 9. It is not necessary to remove the steering wheel.Reinforcement 22. Lock Plate Cover 49. Actuator Rack 79. Retaining Clip 23. Retainer 50. Actuator Pivot Pin 80. Lower Bearing 24. Lock Plate 51. Dimmer Switch 21. Nut 40. Key Release Washer 66. Ignition Switch Screw 22. Lock Plate Cover 41. Housing Assembly 67. Ignition Switch 42. Bearing 23. Retainer 68. Dash Seal 24. Lock Plate 43. Gear Shift Shroud 40.Lock bolt spring (151). Remove the retaining screws spheres (169) and the anti-lash spring (170). (148) and move the spring clockwise to remove it from the bolt (figure 35). 19. Reinforcement 143. Actuator Pivot Pin 170. Spring 198. Adapter Clip 172. Lower Steering Shaft 144.Steering shaft assembly into the shift tube (194) from Column Replacement” in this section. HOUSING REPLACEMENT 8. Bearing housing (219). Pull up on the tilt release lever. This will disengage the shoes (224). Remove Remove or Disconnect (Figures 43 the housing. Shaft Assembly 218. Slide the housing over the upper 6. Washer (238) and retaining ring (237).
Pull up on the end of the column.Negative battery cable.Hazard Control Switch 289. Upper Bearing 290. Control Support Switch 291. Screw 292. Control Lever 304. Shift Tube 293. Housing 305. Refer to “Intermediate Shaft follows: Replacement” in this section. 1. Trunnion (326) into the yokes (331 and 330). Disassemble (Figure 53) 2. This suspension (RPO FS3), centered around a solid Model vehicles. This suspension features unequal length control arms (the lower control arm is the load carrying I-beam axle, includes leaf springs, shock absorbers and a stabilizer bar. Inflate tires to the recommended pressure. Incorrect front wheel alignment (manual Check and align the front suspension. Clean all parts and housings, check seals bearings and replace if leaking, rough or noisy. Slippage of parts with no lubrication.Clean related parts. Check overheating, overloads or handling damage.Clean related parts and replace bearing. Make sure races are properly seated. BRINELLING FATIGUE SPALLING Surface indentations in raceway caused by. WHEEL HUB BOLT Remove or Disconnect (Figure 19) Tool Required:. Steering Knuckle 102.Install or Connect (Figures 37 through 39, 41 and 43) 7. Washer (114) and nut (115). NOTICE: For steps 5, 7 and 9, see “ Notice” on HO Tighten page 3C-1 of this section. Bracket 224. Plate 238. Bolt C. With 6.2L 211. Spindle 250. Lock Nut 278. Bolt 266. Shaft Bearing 251. Ring 286. Bolt 267. Bearing Seal 252. Adjusting Nut 292. Nut 268. Spacer 253. Outer Wheel Bearing 293. Bracket 278. Bolt 291. Nut 250. Locking Nut 265. Spindle 279. King Pin 301. Retainer 251. Ring 266. Shaft Bearing 280. Seal 252. Adjusting Nut 267. Bearing Seal 281. Retainer 253. Outer Wheel Bearing 268. J 8849 Wheel Bearing Race Installer J 23445-A 19. J 29040 Outer Bearing Race Installer 20. J 23445-A Needle Bearing Installer 21. Rear Shock Absorber 26. Leaf Spring Eye 3. Washer 4. Rear Hanger 14. Bolt Bushing 27. Bolt 5. Nut 18. Front Hanger 28. Nut 6.
Stabilizer bar to the vehicle (if equipped).For jacking tire manufacturing plant. The sealant only covers the inside instructions, basic tire changing and rotation instructions, of the tire under the tread area. A dial indicator equipped with a roller contact point, mounted on a heavy, solid base is the measurement device. Cube Van models is shown in Figure 13.Vehicle loading must be limited such that neither the wheel or tire inflation pressure or load limits are exceeded). RADIAL TIRE SIZE AND LOAD LIMITS — kg (LBS.) Metric Radial Tires Used As Singles Inflation Pressure —. B-08076 Figure 23 — Wheel Codes and Load Limits (G) Essentially, the constant velocity joint Within the designed angle variations the universal joint will is made of two universal joints coupled by a yoke and phased for constant velocity. When a technician is road testing A technician should road test the vehicle to diagnose a vehicle for vibration he must remember the four major exactly what the complaint is. Lubricate joints and splines. Also check for worn or brinelled parts. Center bearing. Replace or lubricate. Whine Or Whistle Center support bearing. Place the vehicle on a hoist with rear wheels free to rotate and diagnose for source of noise, replace. One Piece Propeller Shaft 35.Refer to figure 7. yoke ears. These axles can When the vehicle turns a corner, the outer wheel must be identified by ring gear size in inches, by manufacturer turn faster than the inner wheel. The inner wheel turns (Corporate, Dana, or Rockwell) and by the type of axle slower than the outer wheel and slows its axle side gear, shaft used (Semi-Floating or Full-Floating). This is particularly true with low mechanical repair, is proper diagnosis of the problem. In tire pressure. axle work, one of the most difficult areas to diagnose is Tire Noise Test —. Slippage of parts with no lubrication.Clean related parts. Check overheating, overloads or handling damage.Make Replace bearing and correct bearing seats.
BRINELLING FATIGUE SPALLING Surface indentations in raceway caused by. Pull the shaft flange outward to seat the lock (G) in the differential side gear (F). Refer to PINION FLANGE, DUST HYDRAULIC FOUNDATION BRAKES (SEC. Refer to figure 3. 3. Front stabilizer bar. Refer to FRONT SUSPENSION AND AXLE (SEC. 3C). 4. Shock absorbers to the axle brackets. Refer to FRONT SUSPENSION AND AXLE (SEC. 3C). 5. To facilitate removal, loosely thread two screws 11. Inner Cage 61. Ring 50. Screw 73. Ring 62. Retainer Plate 51. O-Ring Seal 74. Brake Band 63. Retainer 52. Cover 75. Drag Sleeve 64. Return Spring 53. Hub Body 87. Inner Drive Gear 88. Spring 89. Clutch Ring 90. Axle Shaft Snap Ring 91. Screw 92. Hub Cap 93. Compression Spring 94. Clutch Cup 95. O-Ring Seal 96. Dial Screw 97. The tires must be The brakes should be tested on a dry, clean, reasonably equally inflated and the tread pattern of the right and smooth and level roadway. Uneven Brake Action 2. Front end out of alignment. 2. Check and align to specifications. (Brakes Pull) 3. Check for frozen or sluggish pistons and the lubrication of the retainer bolts. Caliper should slide. Contaminated or improper brake fluid. Repair as necessary. Improperly adjusted parking brakes. It is recommended that the entire hydraulic system be 1. Hose (32). thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. The metering or hold-off section of the valve limits the pressure to the front disc brakes until a predetermined front input pressure is reached, enough to overcome the rear shoe retractor springs. If a front wheel lock-up is experienced when the vehicle 5. See the list below for the correct travel specification. Install or Connect (Figures 15 and 16) R-V-G Manual.115mm (4.5-inches) R-V-G Power.90mm (3.5-inches) 1. Spacer (4). P (Except JF9). 90mm (3.5-inches) 2. Refer to “Stoplamp Switch” in this section. “Stoplamp Switch” in this section.
G-MODELS P30 MODELS; EXCEPT MOTORHOME Remove or Disconnect (Figure 17) Remove or Disconnect (Figure 18) 1. FRONT CABLE REPLACEMENT (G AND P-MODELS) 6. Parking brake pedal assembly. 7. Bend retaining fingers (34) and (35). Remove or Disconnect (Figures 22, 24 8. Anchor Pin Nut 65. Hold Down Clip 54. Hold Down Pin 66. Drum 55. Lever Strut 67. Lever Retaining Ring 56. Return Spring 68. Shoe 57. With the engine off, apply the brake pedal several times 3. Check and fill the power steering reservoir with power until the accumulator is completely depleted. Depress the steering fluid. The booster need not be removed from the vehicle for seal replacement. E. ACCUMULATOR SEAL. Damage to this seal will result in fluid leakage past the accumulator cap. Place the inboard and outboard lining surfaces together and check for a gap between the lining surfaces.If found, refer to “Rebuilding the Caliper” in this section. Do not move the vehicle until a firm pedal is obtained. Check the brake fluid level in the master cylinder after pumping the brakes. The drum brake assembly is a duo-servo design.Lever Pivot 16. Lever Return Spring 17. Adjusting Screw Assembly 18. Adjusting Screw Spring 19. Primary Shoe 1. Hold Down Pins 2. Backing Plate 3. Parking Brake Lever 4. Washer 5. Secondary Shoe 6. Whenever the brake drums are removed, they should be 1. Remove the lanced area in the brake backing plate.NOTICE: See “ Notice” on page 5A2-1 of this section. 1. Spring assembly (55). 2. Intermittent Light Drain water from the fuel filter. Light Stays On With Fuel filter is clogged or contains water. Drain the fuel filter. If no water is drained and Engine Running the light stays on, replace the filter element. Refer to During Cranking and flywheel. ENGINE ELECTRICAL (SEC. 6D). (Before Engine Fires) But Engine Cranks And Fires Normally High-Pitched Whine Distance too small between starter pinion. Becoming Louder As lifter malfunction.Check for valve lash by 2. Repair engine as needed.
Remove air horn and check pump cup. If During Normal cracked or hardened, replace the pump Make a quick check of the pump system: Acceleration plunger cup and spring. Check holder for damage. Replace if Acceleration Or At necessary. High Speed (Cont.) 16. Missing or damaged Check power piston operation: push piston Tail Pipe (Cont.) power piston spring, power piston rod, power down against piston rod and release;. Replace as necessary Low Oil Pressure 10. Excessive bearing clearance. 11. Repair or replace block. (Cont.) 11. Cracked, porous or plugged oil galleries. 12. Install plugs or repair as necessary. 12. Clean, regap, reinstall. Deposits And Slight Electrode Wear 1. Carburetion is too rich. Dry, Fluffy Black 1. Check the fuel mixture. Replace air cleaner Carbon Deposits element if clogged. Lubrication schematics are shown in figures 1 and 2. The gear-type oil pump is driven from the distributor shaft, The crankshaft is supported by four precision-insert main bearings, with crankshaft thrust taken at the number which is gear-driven from the camshaft. Showing Main Gallery, Oil Filter And Crankshaft Oil Feed. F-05526 Figure 2 — Engine Lubrication Diagram. REMOVAL — RIGHT SIDE 6. Crankcase ventilation pipe at the rocker arm cover. Remove or Disconnect (Figure 3) 7. This may be determined by placing fingers on the number Remove or Disconnect one valve as the mark on the damper comes near the. Rocker arms. The lifters must be installed in the same bore from which they INITIAL TIGHTENING SEQUENCE were removed. Refer to “Valve Adjustment” in this section. Remove or Disconnect (Figure 11) 3. Rocker arm cover. Refer to “Rocker Arm Cover Tool Required: Replacement” in this section. J 5802-01 Rocker Arm Stud Remover 1. Support with suitable safety stands. REPLACEMENT 7. Exhaust pipe to the manifold.Figure 16 — Removing the Torsional Damper Install or Connect (Figures 17 and 18) Tools Required: J 35468 Seal Installer J 23523-E Torsional Damper Puller and Installer.
It is not necessary to use sealant to hold the gasket in place. Valve Keeper J 23590, compress the spring using J 5892-B 21.ROCKER ARM STUD REPLACEMENT Remove or Disconnect (Figure 12) Tool Required: J 5802-01 Rocker Arm Stud Remover 1. Rocker arm cover. Refer to “Rocker Arm Cover Replacement”. Battery negative cable.OIL PAN REPLACEMENT A one piece type of oil pan gasket is used. Remove or Disconnect (Figure 19) Correct as necessary. 1. Oil pan. Refer to “Oil Pan Replacement” in this Clean section. 2. Refer to “Rear Crankshaft Oil Seal” in this section. RETAINER REPLACEMENT 6. Clutch and flywheel or flexplate, as equipped. Refer to TRANSMISSION AND CLUTCH (SEC. Refer to AIR CONDITIONING (SEC. 1B). 6. Fan, shroud, and radiator.Refer to figures 34 through 37. 4. Crankshaft sprocket (if removed). Use J 5590 (figure 25). Make sure the timing mark faces outside. L00711 5. Camshaft sprocket and timing chain. Figure 25 —. Refer to AIR CONDITIONING (SEC. 1B). 18. Grille (G-models). 19. Air cleaner. Refer to figures 38 through 41. Remove or Disconnect NOTICE: When raising or supporting the engine 1. GENERAL DATA: Type Displacement 5.0L (305 Cu. In.) 5.7L (350 Cu. In.) RPO (VIN Code) L03 (H) L05 (K) LS9 (L) LT9 (M) Bore 3.736 4.00 Stroke 3.480 Compression Ratio. Lubrication schematics are shown in Figure 1. The gear The crankshaft is supported by five precision insert main type oil pump is driven from the distributor shaft, which is bearings, with crankshaft thrust taken at the number five gear driven from the camshaft. CYLINDER WALL AND CAMSHAFT LOBE OILING OIL FILTER AND FUEL PUMP PUSH DISTRIBUTOR OILING ROD OILING CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILING B-09187 Figure 1 —. Battery negative cable. 2. Engine cover (G-Van). Upper radiator hose and water pump bypass hose. Heater hose and pipe (TBI engines) or heater hose (carbureted engines). G e n e ra to r re a r b ra c k e t and p o w e r s te e rin g 16. Cylinder head.
Thread the stud fully into the tapped hole in the crankshaft. FRONT CRANKSHAFT SEAL 4. Torsional damper over the end of the stud.Use J 22102 (figure 14). The open end of the seal faces inside the engine. Coat the seal lips with engine oil. Remove or Disconnect (Figure 13) 2. Front oil pan seal. 1. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause it to be bent against the pump screen, resulting in a damaged oil pickup unit. REAR CRANKSHAFT OIL SEAL REPLACEMENT The rear main bearing oil seal can be replaced (both halves) without removal of the crankshaft. Use care to 19. Air cleaner. prevent damage to the camshaft bearings. 20. Engine cover (G-Van). Cleaning, Inspection and Repair 21.Using light cap for identification marks. Mark the parts if required.Mark the caps if necessary. The caps 2. When a single mounting breakage occurs, the remaining mountings are subjected to abnormally high stresses. INSPECTING ENGINE MOUNTINGS Front Engine Mountings NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil. NOTICE: See “ Notice” on page 6A5-1 of this section. 2. Mounting assembly bolts, nuts, and washers. Check for interference between H O Tighten the rear of the engine and the dash panel which could cause distributor damage. Heat Shield (Engines With Federal Emissions - Left Side Only) MODELS WITH I-BEAM AXLE (RPO-FS3) MODELS WITHOUT I-BEAM AXLE. Remove or Disconnect (Figures 38 and 42) 9. Power steering pump, and lay aside. Install or Connect (Figures 38 and 42) 6. Radiator and fan shroud. NOTICE: When raising or supporting the engine 7. Power steering pump and lay aside.The vacuum pump or drive gear is driven by the ration and indirect type combustion chambers. camshaft. Oil is drawn into the pump through a pickup The crankshaft is supported by five precision insert main screen and pipe. Intake manifold bolts and fuel line clips. On models. Support with suitable safety 6.
Wiring harness bracket (left rocker arm cover). Install or Connect (Figure 4) 5. Glow plug wires (G-models). 6. CDR valve. NOTICE: Do not allow RTV sealant Into the 7. Fuel injection lines.Make sure the ball ends previously.Refer to “Cylinder Head NOTICE: Improper installation of the rocker arm Replacement” in this section.Place the lifters in an organizer rack. The lifters must be installed in the same bore from which they were removed. Refer to “Cylinder Head Replacement” in this section. 5. Rocker arm shaft with rocker arms and pushrods, in their original locations. Glow plug temperature inhibit switch connector at the Tool Required: water crossover pipe. J 26513-A Valve Spring Compressor 15.REMOVAL (G-MODELS) (RIGHT SIDE) 3. Cylinder head. Make sure the gasket surfaces are clean. Guide the head carefully into place over the Remove or Disconnect dowel pins. Support with suitable safety stands. 19. Injection lines at the nozzles. Refer to DIESEL FUEL INSTALLATION (G-MODELS) (LEFT SIDE) INJECTION (SEC. 6C2). 20. Glow plug wires. Install or Connect (Figure 11) 21. Power steering pump lower adjusting bolts. Refer to 1. Support with suitable safety stands. 4. Bolts and crankshaft pulley. 5. Torsional damper bolt and washer.Install the attaching bolts.Remove or Disconnect (Figure 18) 1. Figure 20 — Oil Dipstick (Typical — P Non-Motorhomes and G-Models) PCH Clean 3. Be sure OIL PAN AND OIL PUMP to connect the dipstick tube.Refer to MAINTENANCE AND LUBRICATION (SEC. OB). 11. Battery cables. REAR CRANKSHAFT OIL SEAL REPLACEMENT Before a new seal is installed, the CDR and crankcase ventilation system should be thoroughly inspected and crankcase pressure should be checked. Then install the bolts.Refer to the 1988 Light Duty Trucks Unit Repair Manual. 3. Connecting rod cap and bearing. 4. Connecting rod cap nuts.Do not use the required. Refer to step 4. 6. Number 3 (center) main bearing cap and bolts.
L b s ) B-08048 Figure 32 Front Engine Mountings (R-Models) Tighten Fasteners to specifications. Refer to figures 36 NOTICE: See “. Remove or Disconnect (Figure 40) 4. Exhaust pipes at the manifolds. 1. Bolt, cushion, and spacer. 5. Starter. NOTICE: When raising or supporting the engine 6. Tool Required:. GENERAL DATA: 90-degree V8 Diesel Type 6.2L Displacement LH6, LL4 Bore Stroke 21.3: 1 Compression Ratio 1-8-7-2-6-5-4-3 Firing Order 10 psi at idle (hot); 40-45 psi at 2000 RPM Oil Pressure CYLINDER BORE: 100.987-101.065. The valve, water-cooled engines, with a cast iron block and valve train is supplied with oil by the hydraulic lifters. Oil is head. Refer to “Valve Adjustment” in this section. 4. Rocker arm cover. Refer to “Rocker Arm Cover Replacement” in this section. VALVE ADJUSTMENT 1. Remove the rocker arm cover. Refer to “Rocker Arm Cover Replacement” in this section. 2. After cleaning, apply 1. Hydraulic lifters in the block. Lubricate the lifter foot engine oil to the threads.Refer to MAINTENANCE AND LUBRICATION (SEC. OB). 6. Vacuum lines at the thermal vacuum switch. 7. Spark plug wires. 8. Refer to ENGINE COOLING (SEC.Both halves of the rear main bearing oil seal can be Important replaced without removal of the crankshaft. Always replace An oil seal installation tool (figure 23) the upper and lower seal as a unit. Refer to “Rocker Arm and Pushrod Replacement” in this section. J 8520 Dial Indicator Adapter 2. Install a dial indicator with J 8520 (figure 26). Position When it becomes necessary to make a check of valve the dial indicator so the plunger rests on the pushrod timing, the following procedure may be used:. Crankshaft Gear B-07863 Figure 27 — Camshaft And Components Figure 28 — Removing The Camshaft Thrust Figure 29 — Measuring Camshaft To Thrust Plate Bolts Plate Clearance 1. Tap on the Remove or Disconnect (Figures 35 and 36) insert, on the side opposite the bearing tang, until the insert rotates out of position (figure 35).