![1-6 GENERAL INFORMATION AND MAINTENANCE
h-c —i
1 i
F ^^HI
i r
(. A —
' ] A - Length
k J B - Diameter (major diameter)
> y x ^ C - Threads per inch or mm
E - Size of the wrench required
r— E —«1 F - Root diameter (minor diameter)
TCCS1038
Fig. 20 Threaded retainer sizes are determined using these me
surements
-
^
r^=====^^$A=sf~—1
'! Z i DEFLECTING BEAM
—-S—-*~~—?^^r~~
& o , fe'JH--' '
(n ] o s'.1,1,1,' 't i 1
CLICK TYPE
TCCS1015
Fig. 21 Various styles of torque wrenches are usually available at
your local automotive supply store
same design, material and strength should be used. Markings on the he|ds of
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
safe operation of the vehicleafterwards.
Thread gauges are available to help measure a bolt or stud's thread. l|ost
automotive and hardware stores keep gauges available to help you selec the
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
finding another bolt which will thread in its place. If you find a nut which
threads properly onto the damaged bolt, then use that nut to help select he
replacement bolt.
••-••' WARNING
Be aware that when you find a bolt with damaged threads, you may
also find the nut or drilled hole it was threaded into has also teen
damaged. If this is the case, you may have to drill and tap thd hole,
replace the nut or otherwise repair the threads. NEVER try to I irce a
replacement bolt to fit into the damaged threads.
Torque
Torque is defined as the measurement of resistance to turning or rotat ig.
tends to twist a body about an axis of rotation. A common example of thi
would be tightening a threaded retainer such as a nut, bolt or screw. Mee ;uring
torque is one of the most common ways to help assure that a threaded retainer
has been properlyfastened.
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 ajoint together). This means that friction can account 'pr as
much as 90 percent of the applied torque on afastener.
TORQUE WRENCHES
I See Figure 21
In most applications, a torque wrench can be used to assure proper installa-
tion of a fastener.Torque wrenches come in various designs and most auDmo-
tive supply stores will carry a variety to suit your needs. A torque wrench should
be used any time we supply a specific torque value for a fastener. Again, the
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.
Beam Type
The beam type torque wrench is one of the most popular types. It cons sts of
a pointer attached to the head that runs the length of the flexible beam (srpft) to
a scale located near the handle. As the wrench is pulled, the beam bends fnd
the pointer indicates the torque using the scale.
Click (Breakaway) Type
Another popular design of torque wrench is the click type. To usethe click
type wrench you pre-adjust it to a torque setting. Once the torque is reached,
the wrench has a reflex signaling feature that causes a momentary breakaway of
the torque wrench body, sending an impulse to the operator's hand.
Pivot Head Type
I SeeFigure 22
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
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
comes in contact with the yoke extension during the process of pulling, there is
a very good chance the torque readings will be inaccurate because this could
alter the wrench loading point. The design of the handle is usually such as to
make it inconvenient to deliberately misuse the wrench.
••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
wrench you are using. For the most accurate readings, install the socket
directly on the wrench driver. If necessary, straight extensions (which
hold a socket directly under the wrench driver) will have the least effect
on the torque reading. Avoid any extension that alters the length of the
wrench from the handle to the head/driving point (such as a crow's
foot). U-joint or wobble extensions can greatly affect the readings; avoid
their use at all times.
PIVOTED HANDLE TORQUE WRENCH
TCCS1041
Fig. 22 Torque wrenches with pivoting heads must be grasped and
used properly to prevent an incorrect reading
Rigid Case (Direct Reading)
A rigid case or direct reading torque wrench is equipped with a dial indicator
to show torque values. One advantage of these wrenches is that they can be
held at any position on the wrench without affecting accuracy. These wrenches
are often preferred because they tend to be compact, easy to read and have a
great degree of accuracy.](https://image.slidesharecdn.com/1997chevroletckservicerepairmanual-231004011421-c3e07025/85/1997-Chevrolet-Ck-Service-Repair-Manual-pdf-10-320.jpg)
1997 Chevrolet Ck Service Repair Manual.pdf
- 1. 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 ABODE FGHI 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 Newbury Park California 91320 USA 3N3 Chilton is a registeredtrademark of W.G. Nichols, Inc., and has been licensedto Haynes North America,Inc.
- 2. Contents GENERAL INFORMATION AND MAINTENANCE 1-2 HOW TO USE THIS BOOK 1-2 TOOLS AND EQUIPMENT 1-4 SERVICING YOUR VEHICLE SAFELY 1 -5 FASTENERS, MEASUREMENTS AND CONVERSIONS 1-7 SERIAL NUMBER IDENTIFICATION 1-10 ROUTINE MAINTENANCE AND TUNE-UP 1-35 FLUIDS AND LUBRICANTS 1-46 TRAILER TOWING 1-47 JUMP STARTING A DEAD BATTERY 1-48 JACKING 1 -50 MAINTENANCE INTERVALS ENGINE ELECTRICAL 2-2 2-2 2-6 HIGH ENERGY IGNITION (HEI) SYSTEM 2-7 2-8 DISTRIBUTOR IGNITION (Dl) o Q SYSTEM FIRING ORDERS CHARGING SYSTEM STARTING SYSTEM SENDING UNITS AND SENSORS ENGINE AND ENGINE OVERHAUL 3-2 ENGINE MECHANICAL 3-56 EXHAUST SYSTEM 3-58 ENGINE RECONDITIONING 4-2 GASLINE ENGINE EMISSION 4-25 DIESEL ELECTRONIC DRIVEABILITY AND EMISSION CONTROLS CONTROLS 4-10 DIESEL ENGINE EMISSION CONTROLS 4-11 CARBURETED ELECTRONIC ENGINE CONTROLS 4-17 FUEL INJECTEDELECTRONIC ENGINE CONTROLS ENGINE CONTROLS 4-29 TROUBLE CODES 4-39 COMPONENT LOCATIONS 4-55 VACUUM DIAGRAMS FUEL SYSTEM 5-2 BASIC FUEL SYSTEM DIAGNOSIS 5-2 FUEL LINE FITTINGS 5-3 CARBURETEDFUEL SYSTEM 5-10 THROTTLE BODY INJEC- TION (TBI) 5-14 MULTI-PORT FUEL INJECTION (MFI) 5-19 CENTRALSEQUENTIAL FUEL INJECTION (CSFI) 5-22 DIESEL FUEL SYSTEM 5-26 FUEL TANK CHASSIS ELECTRICAL 6-2 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 6-7 BATTERY CABLES 6-7 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 6-8 HEATING AND AIR CONDITIONING 6-12 CRUISE CONTROL 6-13 ENTERTAINMENT SYSTEMS 6-17 WINDSHIELD WIPERS AND WASHERS 6-19 INSTRUMENTS AND SWITCHES 6-22 LIGHTING 6-26 TRAILER WIRING 6-26 CIRCUIT PROTECTION 6-28 WIRING DIAGRAMS
- 3. Contents 7-2 MANUAL TRANSMISSION 7-9 7-4 CLUTCH 7-13 7-6 AUTOMATIC TRANSMISSION 7-16 7-8 TRANSFER CASE 7-19 8-2 WHEELS 8-4 C AND RSERIES 2WD FRONT SUSPENSION 8-14 V-SERIES 4WDFRONT SUSPENSION DRIVELINE SOLID FRONT DRIVE AXLE INDEPENDENT FRONT DRIVE AXLE REAR AXLE 8-18 K-SERIES 4WDFRONT . SUSPENSION 8-24 C3HD FRONT SUSPENSION 8-26 REAR SUSPENSION 8-30 STEERING SUSPENSION AND STEERING 9-2 BRAKE OPERATING SYSTEM 9-20 9-6 DISC BRAKES 9-12 DRUM BRAKES 9"25 9-18 PARKING BRAKE FOUR WHEEL ANTI-LOCK BRAKE SYSTEM REAR WHEEL ANTI-LOCK (RWAL) BRAKE SYSTEM 10-2 EXTERIOR 10-5 INTERIOR 10-15 GLOSSARY 10-19 MASTER INDEX
- 4. SAFETY NOTICE Proper serviceand repair procedures are vital to the safe, re iable operation of all motor vehicles, as well as the personal safety of thoseper- forming repairs. This manual outlines proceduresfor servicingand repairingvehicles using safe, effective methods. The procedures contain many NOTES, CAUTIONS and WARNINGS which should be followed, along with standardprocedures to eliminate the possibility of personal injury or improper servicewhich could damage the vehicle or compromise its safety. It is important to note that repair procedures and techniquesM tools and parts for servicingmotor vehicles, as well as the skill and experience of the individual performing the work vary widely. It is not possibles to anticipateall of the conceivable ways or conditions under which vehicles may be serviced, or to provide cautions as to all possible hazards tti£t may result. Standard and accepted safety precautions and equipment should be used when handling toxic or flammable fluids, and safety goggles or other protectionshould 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 completely satisfied that neither your personal safety,nor the performance of thevehicle specific purpose. Before substituting anothertool or procedure, you must be will be endangered. Although information in this manual is based on industry sojurces and is completeas possibleat the time of publication,the possibility exists that some car manufacturersmade later changes which could,inot be includedhere. While strivingfor total accuracy, the authorsor publishers cannot assume responsibility for any errors, changes or omissions that may occur in the compilationof this data. PART NUMBERS Part numbers listed in this referenceare notrecommendat ences that can be used with interchange manuals and afterm ons by HaynesNorth America, Inc. for any product brand name.They are refer- rket supplier catalogsto locate each brand supplier's discrete partnumber. SPECIAL TOOLS Special tools are recommended by the vehicle manufacturer absolutely necessary, they are referredto in the text by thepart priate part number, from your local dealer or regional distributo let. Beforesubstituting any tool for the onerecommended, o perform their specificjob. Use has beenkept to a minimum, butwhere lumber of the tool manufacturer. Thesetools can be purchased, under theappro- , or an equivalenttool can be purchasedlocally from a tool supplier or parts out- readl the SAFETY NOTICE at the top of this page. ACKNOWLEDGMENTS Portions of materials contained herein have been reprints Jwiththe permissionof General MotorsCorporation,ServiceTechnology Group. All rights reserved. No part of this book may be reproduce! ing photocopying, recording or by any information storage or transmitted in any form or by any means, electronic or mechanical, includ- >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.
- 5. HOW TO USE THIS BOOK 1-2 WHERE TO BEGIN 1-2 AVOIDING TROUBLE 1-2 MAINTENANCE OR REPAIR? 1-2 AVOIDING THE MOST COMMON MISTAKES 1-2 TOOLS AND EQUIPMENT 1-2 SPECIAL TOOLS 1-4 SERVICING YOUR VEHICLE SAFELY 1-4 DO'S 1-4 DONTS 1-5 FASTENERS, MEASUREMENTS AND CONVERSIONS 1-5 BOLTS, NUTS AND OTHER THREADED RETAINERS 1-5 TORQUE 1-6 TORQUE WRENCHES 1-6 TORQUE ANGLE METERS 1-7 STANDARD AND METRIC MEASUREMENTS 1-7 SERIAL NUMBER IDENTIFICATION 1-7 VEHICLE 1-7 ENGINE 1-7 TRANSMISSION 1-8 DRIVE AXLE 1-8 TRANSFER CASE 1-8 SERVICE PARTS IDENTIFICATION LABEL 1-10 ROUTINE MAINTENANCE AND TUNE-UP 1-10 AIR CLEANER1-10 REMOVAL & INSTALLATION 1-13 FUEL FILTER1-13 REMOVAL & INSTALLATION 1-13 PCVVALVE 1-15 REMOVAL & INSTALLATION 1-15 CRANKCASE DEPRESSION REGULATOR AND FLOW CONTROL VALVE 1-16 SERVICING1-16 EVAPORATIVE CANISTER 1-16 SERVICING 1-16 BATTERY 1-16 PRECAUTIONS 1-16 GENERAL MAINTENANCE 1-16 BATTERY FLUID 1-17 CABLES 1-17 CHARGING 1-18 REPLACEMENT 1-18 BELTS1-18 INSPECTION 1-18 ADJUSTMENT 1-18 REMOVAL & INSTALLATION 1-19 BELT ROUTING1-20 HOSES 1-23 INSPECTION 1-23 REMOVAL & INSTALLATION 1-23 CV-BOOTS1-24 INSPECTION 1-24 SPARKPLUGS1-25 SPARK PLUG HEAT RANGE 1-25 REMOVAL & INSTALLATION 1-25 INSPECTION & GAPPING1-26 SPARK PLUG WIRES 1-27 TESTING 1-27 REMOVAL & INSTALLATION1-27 DISTRIBUTOR CAP AND ROTOR1-27 REMOVAL & INSTALLATION 1-27 INSPECTION 1-28 IGNITION TIMING 1-28 GENERAL INFORMATION 1-28 CHECKING & ADJUSTMENT1-29 VALVE LASH 1-29 ADJUSTMENT 1-29 IDLE SPEED AND MIXTURE ADJUSTMENTS 1-30 CARBURETED ENGINES1-30 GASOLINE FUEL INJECTED ENGINES 1-30 DIESEL ENGINES 1-31 AIR CONDITIONING SYSTEM 1-32 SYSTEM SERVICE S REPAIR 1-32 PREVENTIVE MAINTENANCE 1-32 SYSTEM INSPECTION 1-32 WINDSHIELD WIPERS1-33 ELEMENT (REFILL) CARE & REPLACEMENT 1-33 TIRES AND WHEELS 1-33 TIRE ROTATION 1-33 TIRE DESIGN 1-34 TIRE STORAGE 1-34 INFLATIONS INSPECTION 1-34 FLUIDS AND LUBRICANTS 1-35 FLUID DISPOSAL 1-35 FUEL AND OIL RECOMMENDATIONS 1-35 OIL 1-35 FUEL1-36 ENGINE1-37 OIL LEVEL CHECK1-37 OILS FILTER CHANGE 1-37 MANUAL TRANSMISSION 1-38 FLUID RECOMMENDATION 1-38 LEVEL CHECK 1-38 DRAINS REFILL 1-39 AUTOMATIC TRANSMISSION 1-39 FLUID RECOMMENDATIONS1-39 LEVEL CHECK 1-39 DRAINS REFILL 1-39 TRANSFER CASE 1-40 FLUID RECOMMENDATIONS1-40 LEVEL CHECK1-40 DRAINS REFILL1-40 FRONT AND REAR DRIVE AXLES1-40 FLUID RECOMMENDATIONS 1-40 LEVEL CHECK1-40 DRAINS REFILL 1-41 COOLING SYSTEM1-41 FLUID RECOMMENDATIONS 1-41 LEVEL CHECK 1-42 DRAINING S FLUSHING1-42 BRAKE MASTER CYLINDER 1-42 FLUID RECOMMENDATIONS 1-42 LEVEL CHECK 1-42 CLUTCH MASTER CYLINDER1-43 FLUID RECOMMENDATIONS 1-43 LEVEL CHECK1-43 POWER STEERING PUMP1-43 FLUID RECOMMENDATION1-43 LEVEL CHECK1-43 STEERING GEAR 1-43 FLUID RECOMMENDATIONS 1-43 LEVEL CHECK1-44 CHASSIS GREASING 1-44 BODY LUBRICATION AND MAINTENANCE 1-45 LOCK CYLINDERS 1-45 HOOD LATCH S HINGES1-45 DOOR HINGES 1-45 BODY DRAIN HOLES1-46 FRONT WHEEL BEARINGS 1-46 TRAILER TOWING 1-46 GENERAL RECOMMENDATIONS 1-46 TRAILER WEIGHT1-46 HITCH (TONGUE) WEIGHT1-46 ENGINE 1-47 TRANSMISSION 1-47 HANDLING A TRAILER 1-47 JUMP STARTING A DEAD BATTERY 1-47 JUMP STARTING PRECAUTIONS 1-47 JUMP STARTING PROCEDURE 1-47 SINGLE BATTERYGASOLINE AND DIESEL ENGINE MODELS 1-47 DUAL BATTERYDIESEL MODELS 1-48 JACKING 1-48 JACKING PRECAUTIONS 1-49 MAINTENANCE INTERVALS 1-50 GENERAL RECOMMENDATIONS1-50 BUT THE OWNER'S MANUAL IS DIFFERENT? 1-50 BUT THE REPLACEMENT PART IS DIFFERENT?1-50 IS MY DRIVING "NORMAL" OR "SEVERE"? 1-50 COMPONENT LOCATIONS UNDERHOOD MAINTENANCE COMPONENT LOCATIONS—R-SERIES 1-11 UNDERHOOD MAINTENANCE COMPONENT LOCATIONS—C-SERIES 1-12 SPECIFICATIONS CHARTS VEHICLE IDENTIFICATION CHART 1-8 GENERAL ENGINE SPECIFICATIONS 1-9 GASOLINE TUNE-UP SPECIFICATIONS1-31 RECOMMENDED LUBRICANTS1-36 MAINTENANCE SCHEDULES 1-51 CAPACITIES1-54 GENERAL HOW TO USE THIS BOOK 1-2 TOOLS AND EQUIPMENT 1-2 SERVICING YOUR VEHICLE SAFELY 1-4 FASTENERS, MEASUREMENTS AND CONVERSIONS 1-5 SERIAL NUMBER IDENTIFICATION 1-7 AND TUNE-UP 1-10 FLUIDS AND LUBRICANTS 1-35 TRAILER TOWING 1-46 iTARTING A DEAD BATTERY 1-47 JACKING 1-48 MAINTENANCE INTERVALS 1-50
- 6. 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 and GMC Pick-ups, Blazers,Jimmys, Tahoes, Yukons and Suburbans is intended to help you learn more about the inner workings of your vehicle, while saving you money on its upkeep and operation. The beginning of the book will likely be referred to the most, since that is where you will find information for maintenance and tune-up. The other sections deal with the more complex systems of your vehicle. Systems (from engine through brakes) are covered to the extent that the average do-it-yourselft r can attempt. This book will not explain such things as rebuilding a different! I 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 that can save you money and help avoid expensive problems. A secondary purpose of this book is a reference for owners who want to understand their vehicle and/or their mechanics better. Where to Begin Before removing any bolts, read through the entire procedure. This will give you the overall view of what tools and supplies will be required. So read, ahead and plan ahead. Each operation should be approached logically and all proce- dures thoroughly understood before attempting any work. If repair of a component is not considered practical, we tell you howb remove the part and then how to install the new or rebuilt replacement. l(i this way, you at least save labor costs. Avoiding Trouble Many procedures in this book require you to "label and disconnect..." a group of lines, hoses or wires. Don't be think you can remember where (very- thing goes—you won't. If you hook up vacuum or fuel lines incorrectly,! he vehicle may run poorly, if at all. If you hook up electricalwiring incorrec ly, you may instantly learn a very expensive lesson. You don't need to know the proper name for each hose or line. A pied j of masking tape on the hose and a piece on its fitting will allow you to ass jn your own label. As long as you remember your own code, the lines can be rel on- nected by matching your tags. Remember that tape will dissolve in gasaine or solvents; if a part is to be washed or cleaned, use another method of idq itifica- tion. A permanent felt-tipped marker or a metal scribe can be very hand; for marking metal parts. Remove any tape or paper labels after assembly. Maintenance or Repair: Maintenance includes routine inspections, adjustments, and replacertent of parts which show signs of normal wear. Maintenance compensates for wsar or deterioration. Repair implies that something has broken or is not workinji. A need for a repair is often caused by lack of maintenance, for example: dit lining and refilling automatic transmission fluid is maintenance recommended it spe- cific intervals. Failure to do this can shorten the life of the transmission/ transaxle, requiring very expensive repairs. While no maintenance progm.m can prevent items from eventually breaking or wearing out, a general rule is |rue: MAINTENANCE IS CHEAPER THAN REPAIR. TOOLS AND EQUIPMENT I SeeFigures 1thru 15 Without the proper tools and equipment it is impossible to properly service your vehicle. It would be virtually impossible to catalog every tool that you would need to perform all of the operations in this book. It would be unwise for the amateur to rush out and buy an expensive set of tools on the theory (hat he/she may need one or more of them at some time. The best approach is to proceed slowly, gathering a good quality set of 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 wrenches, 6 or 12-point sockets and fine tooth ratchets are by far preferable to their less expensive counterparts. As any good mechanic can tell yoM, there are few worse experiences than trying to work on a vehicle with bad torjls. Two basic mechanic's rules should be mentioned here. First, whenever the left side of the vehicle or engine is referred to, it means the driver's side. Con- versely, the right side of the vehicle means the passenger's side. Second, screws and bolts are removed by turning counterclockwise, and tightened by turning clockwise unless specifically noted. Safety is always the most important rule. Constantly be aware of the dangers involved in working on an automobile and take the proper precautions. Please refer to the information in this section regarding SERVICING YOURVEHICLE SAFELY and the SAFETYNOTICE on the acknowledgment page. Avoiding the Most Common Mistakes Pay attention to the instructions provided. There are 3 common mistakes in mechanical work: 1. Incorrect order of assembly, disassembly or adjustment. When taking something apart or putting it together, performing steps in the wrong order usu- 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 instructions say you should, even if you can't see a reason for it. Whenyou're taking apart something that is very intricate, you might want to draw a picture of how it looks when assembled in order to make sure you get everything back in its proper position. When making adjustments, perform them in the proper order. One adjustment possibly will affect another. 2. Overtorquing (or undertorquing). While it is more common for over- 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 specificationsand utilize a torque wrench in assembly. If a torque figure is not available, remember that if you are using the right tool to perform the job, you will probably not have to strain yourself to get a fastener tight enough. The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times in actual force on what you aretight- ening. There are many commercial products availablefor ensuring thatfasteners won't come loose, even if they are not torqued just right (a very common brand is Loctite"). If you're worried about getting something together tight enough to hold, but loose enough to avoid mechanical damage during assembly, one of trese products might offer substantial insurance. Before choosing a threadlock- irg compound, read the label on the package and make sure the product is compatible with the materials, fluids, etc. involved. 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 lubricatefasteners, then to start threading the bolt, spark plug, etc. with your fingers. I! you encounter resis- tance, unscrew the part and start over again at a differentangle until it can be irserted and turned several times without much effort. Keep in mind that many parts have tapered threads, so that gentle turning will automatically bring the part you're threading to the proper angle. Don't put a wrench on the part until it's been tightened a couple of turns by hand. If you suddenly encounter resistance, and the part has not seated fully, don't force it. Pull it back out to make sure it's clean and threading properly. Be sure to take your time and be patient, and always plan ahead. Allow your- self ample time to perform repairs and maintenance. Your monetary savings will be far outweighed by frustration and mangled knuckles. Begin accumulating those tools that are used most frequently: those associ- ated with routine maintenance and tune-up. In addition to the normal assort- ment of screwdrivers and pliers, you should have the following tools: • Wrenches/sockets andcombination open end/box end wrenches in sizes 1/8-3/4 in. and/or 3mm-19mm 13/ie in. or % in. spark plug socket (depending on plug type). •"If possible, buy various length socket drive extensions. Universal- joint and wobble extensions can be extremely useful, but be careful when using them, as they can change the amount of torque applied to the socket.
- 7. GENERAL INFORMATION AND MAINTENANCE 1-3 • Jackstands (or support. • Oilfilter wrench. • Spout or funnel for pouring fluids. • Grease gun for chassis lubrication (unless your vehicle is not equipped with any grease fittings) • Hydrometer for checking the battery (unless equipped with a sealed, maintenance-free battery). • A container for draining oil and other fluids. • Rags for wiping up the inevitable mess. In addition to the above items there are several others that are not absolutely necessary, but handy to have around. These include an equivalent oil absorbent gravel, like cat litter, and the usual supply of lubricants, antifreeze and fluids. This is a basic list for routine maintenance, but only your personal needs and desire can accurately determine your list of tools. After performing a few projects on the vehicle, you'll be amazed at the other tools and non-tools on your workbench. Some useful household items are:a large turkey baster or siphon, empty coffee cans and ice trays (to store parts), a ball of twine, electrical tape for wiring, small rolls of colored tape for tagging lines or hoses, markers and pens, a note pad, golf tees (for plugging vacuum lines), metal coat hangers or a roll of mechanic's wire (to hold things out of the way), dental pick or similar long, pointed probe, a strong magnet, and a small mirror (to see into recesses and under manifolds). A more advanced set of tools, suitable for tune-up work, can be drawn up easily. While the tools are slightly more sophisticated, they need not be outra- geously expensive. There are several inexpensivetach/dwell meters on the mar- ket that are every bit as good for the average mechanic as a professional model. Just be sure that it goes to a least 1200-1500 rpm on the tach scale and-that it works on 4, 6 and 8-cylinder engines. The key to these purchases is to make them with an eye towards adaptability and wide range. A basic list of tune-up tools could include: • Tach/dwell meter. • Spark plug wrench and gapping tool. • Feeler gauges for valve adjustment. • Timing light. ,SS«*»8i Fig. 1 All but the most basic procedures will require an assortment of ratchets and sockets Fig. 4 An assortment of pliers, grippers and cutters will be handy for old rusted parts and stripped bolt heads fe"~ i .u '''"^Mlf Fig. 7 Although not always necessary, using specialized brake tools will save time Fig. 2 In addition to ratchets, a good set of wrenches and hex keys will be necessary Fig. 3 A hydraulic floor jack and a set of jackstands are essential for lifting and supporting the vehicle Fig. 5 Various drivers, chisels and prybars are great tools to have in your toolbox TCCS1205 Fig. 6 Many repairs will require the use of a torque wrench to assure the components are properly fastened * Fig. 8 A few inexpensive lubrication tools will make maintenance easier Fig. 9 Various pullers, clamps and separa- tor tools are needed for many larger, more complicated repairs
- 8. 1-4 GENERAL INFORMATION AND MAINTENANCE Fig. 10 A variety of tools and gauges should be used for spark plug gapping and installation vrr*>fes» ^ Fig. 11 ina ictive type timing light Fig. 13 A vacuum/pressure tester is neces- sary for many testing procedures r / TCCX1P02 Fig. 12 A screw-in type compression gauge is recommended for compression testing TCCX1POG Fig. 14 M( st modern automotive multi- meters incorporate many helpful features The choice of a timing light should be made carefully. A light which vorks on the DC current supplied by the vehicle's battery is the best choice; it mould have a xenon tube for brightness. On any vehicle with an electronic ignit in sys- tem, atiming light with aninductive pickup that clamps around theNo.| spark plug cable is preferred. In addition to these basic tools, there are several other tools and gaut Fig. 15 Proper information is vital, so always have a Chilton Total Car Care man- ual handy :syou may find useful. These include: • Compression gauge. The screw-in type is slower to use, but e!imii(jates the possibility of a faulty reading due to escaping pressure. • Manifold vacuum gauge. • 12V test light. • A combination volt/ohmmeter • Induction Ammeter. This is used for determining whether or not thdre is current in a wire. These are handy for use if a wire is broken somewhere! n a wiring harness. As a final note, you will probably find a torque wrench necessary for; II but the most basic work. The beam type models are perfectly adequate, althd jgh the SERVICING YOUR VEHICLE SAFELY » See Figures 16,17 and 18 It is virtually impossible to anticipate all of the hazards involved with autt motive maintenance and service, but care and common sense will prevent most accidents. The rules of safety for mechanics range from "don't smoke around gaioline," to "use the proper tool(s) for the job." The trick to avoiding injuries is to develop safe work habits and to take every possible precaution. • Do keep a fire extinguisher and first aid kit handy. • Do wear safety glasses or goggles when cutting, drilling, grinding ing, even if you have 20-20 vision. If you wear glasses for the sake of v wear safety goggles over your regular glasses. or pry- sion, newer click types (breakaway) are easier to use. The click type torque wrenches tend to be more expensive. Also keep in mind that all types of torque wrenches should be periodically checked and/or recalibrated. You will have to decide for yourself which better fits your pocketbook, and purpose. Special Tools Normally, the use of special factory tools is avoided for repair procedures, since these are not readily available for the do-it-yourself mechanic. When it is possible to perform the job with more commonly available tools, it will be pointed out,but occasionally, a special tool was designed to perform a specific function and should be used. Before substituting another tool, you should be convinced that neither your safety nor the performance of the vehicle will be ccmpromised. Special tools can usually be purchased from an automotive parts store or from your dealer. In some cases special tools may be available directly from the tool manufacturer. • Do shield your eyes whenever you work around the battery. Batteriescon- tain sulfuric acid. In case of contact with, flush the area with water or a mixture of water and baking soda, then seek immediate medical attention. • Do use safety stands (jackstands) for any undervehicle service. Jacksare for raising vehicles; jackstands are for making sure the vehicle stays raised until you want it to come down. • 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 system. The secondary ignition system contains EXTREMELY HIGH VOLTAGE. In some cases it can even exceed 50,000 volts. • Do follow manufacturer's-directions whenever working with potentially hazardous materials. Most chemicals and fluids are poisonous.
- 9. GENERAL INFORMATION AND MAINTENANCE 1-5 A f*1 ^ TCCS1020 Fig. 16 Screwdrivers should be kept in good condition to prevent injury or dam- age which could result if the blade slips from the screw Fig. 17 Using the correct size wrench will help prevent the possibility of rounding off a nut Fig. 18 NEVER work under a vehicle unless it is supported using safety stands (jackstands) • Do properly maintain your tools. Loose hammerheads, mushroomed punches and chisels, frayed or poorly grounded electrical cords,excessively worn screwdrivers, spread wrenches (open end), cracked sockets, slipping ratchets, or faulty droplight sockets can causeaccidents. • Likewise, keep your tools clean; a greasy wrench can slip off a bolt head, ruining the bolt and often harming your knuckles in the process. • Do use the proper size and type of tool for the job at hand. Do select a wrench or socket that fits the nut or bolt. The wrench or socket should sit straight, not cocked. • Do, when possible, pull on a wrench handle rather than push on it, and adjust your stance to prevent a fall. • Do be sure that adjustable wrenches aretightly closed on the nut or bolt and pulled so that the force is on the side of the fixedjaw. • Do strike squarely with a hammer; avoid glancing blows. • Do set the parking brake and block the drive wheels if the work requires a running engine. Don'ts • Don't run the engine in a garage or anywhere else without proper venti- lation—EVER! Carbon monoxide is poisonous; it takes a long time to leave the human body and you can build up a deadly supply of it in your system by simply breathing in a little at a time. You may not realize you are slowly poi- soning yourself. Always use power vents, windows, fans and/or open the garage door. • Don't work around moving parts while wearing loose clothing. Short sleeves are much safer than long, loose sleeves. Hard-toed shoes with neoprene soles protect your toes and give a better grip on slippery surfaces. Watches and jewelry is not safe working around a vehicle. Long hair should be tied back under a hat or cap. • Don't use pockets for toolboxes.A fall or bump can drive ascrewdriver deep into your body. Even a rag hanging from your back pocket can wrap around a spinning shaft or fan. • Don't smoke when working around gasoline, cleaning solvent or other flammable material. • Don't smoke when working around the battery. When the battery is being charged, it gives off explosive hydrogengas. • Don't use gasoline to wash your hands; there are excellent soaps avail- able. Gasoline contains dangerous additives which can enter the body through a cut or through your pores. Gasoline also removes all the natural oils from the skin so that bone dry hands will suck up oil and grease. • Don't service theair conditioning system unless you are equipped with 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 ittouches. • Don't use screwdriversfor anything other than driving screws! A screw- driver used as an prying tool can snap when you least expect it, causing injuries. At the very least, you'll ruin a good screwdriver. • Don't use an emergency jack (that little ratchet, scissors, or pantograph jack supplied with the vehicle) for anything other than changing a flat! These jacks are only intended for emergency use out on the road; they are NOT designed as a maintenance tool. If you are serious about maintaining your vehi- cle yourself, invest in a hydraulic floor jack of at least a 11/2ton capacity, and at 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 threadedfastener (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 achieve the desired clamp load for which that fastener was originally selected. 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- tion. In many of these occurrences, a fastener may be installed and tightened, 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 ALWAYS be sure to use the proper replacement. In all cases,a retainer of the LOCKWASHERS CO) •HI • TCCS1036 Fig. 19 There are many different types of threaded retainers found on vehicles
- 10. 1-6 GENERAL INFORMATION AND MAINTENANCE h-c —i 1 i F ^^HI i r (. A — ' ] A - Length k J B - Diameter (major diameter) > y x ^ C - Threads per inch or mm E - Size of the wrench required r— E —«1 F - Root diameter (minor diameter) TCCS1038 Fig. 20 Threaded retainer sizes are determined using these me surements - ^ r^=====^^$A=sf~—1 '! Z i DEFLECTING BEAM —-S—-*~~—?^^r~~ & o , fe'JH--' ' (n ] o s'.1,1,1,' 't i 1 CLICK TYPE TCCS1015 Fig. 21 Various styles of torque wrenches are usually available at your local automotive supply store same design, material and strength should be used. Markings on the he|ds of 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 safe operation of the vehicleafterwards. Thread gauges are available to help measure a bolt or stud's thread. l|ost automotive and hardware stores keep gauges available to help you selec the 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 finding another bolt which will thread in its place. If you find a nut which threads properly onto the damaged bolt, then use that nut to help select he replacement bolt. ••-••' WARNING Be aware that when you find a bolt with damaged threads, you may also find the nut or drilled hole it was threaded into has also teen damaged. If this is the case, you may have to drill and tap thd hole, replace the nut or otherwise repair the threads. NEVER try to I irce a replacement bolt to fit into the damaged threads. Torque Torque is defined as the measurement of resistance to turning or rotat ig. tends to twist a body about an axis of rotation. A common example of thi would be tightening a threaded retainer such as a nut, bolt or screw. Mee ;uring torque is one of the most common ways to help assure that a threaded retainer has been properlyfastened. 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 ajoint together). This means that friction can account 'pr as much as 90 percent of the applied torque on afastener. TORQUE WRENCHES I See Figure 21 In most applications, a torque wrench can be used to assure proper installa- tion of a fastener.Torque wrenches come in various designs and most auDmo- tive supply stores will carry a variety to suit your needs. A torque wrench should be used any time we supply a specific torque value for a fastener. Again, the 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. Beam Type The beam type torque wrench is one of the most popular types. It cons sts of a pointer attached to the head that runs the length of the flexible beam (srpft) to a scale located near the handle. As the wrench is pulled, the beam bends fnd the pointer indicates the torque using the scale. Click (Breakaway) Type Another popular design of torque wrench is the click type. To usethe click type wrench you pre-adjust it to a torque setting. Once the torque is reached, the wrench has a reflex signaling feature that causes a momentary breakaway of the torque wrench body, sending an impulse to the operator's hand. Pivot Head Type I SeeFigure 22 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 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 comes in contact with the yoke extension during the process of pulling, there is a very good chance the torque readings will be inaccurate because this could alter the wrench loading point. The design of the handle is usually such as to make it inconvenient to deliberately misuse the wrench. ••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 wrench you are using. For the most accurate readings, install the socket directly on the wrench driver. If necessary, straight extensions (which hold a socket directly under the wrench driver) will have the least effect on the torque reading. Avoid any extension that alters the length of the wrench from the handle to the head/driving point (such as a crow's foot). U-joint or wobble extensions can greatly affect the readings; avoid their use at all times. PIVOTED HANDLE TORQUE WRENCH TCCS1041 Fig. 22 Torque wrenches with pivoting heads must be grasped and used properly to prevent an incorrect reading Rigid Case (Direct Reading) A rigid case or direct reading torque wrench is equipped with a dial indicator to show torque values. One advantage of these wrenches is that they can be held at any position on the wrench without affecting accuracy. These wrenches are often preferred because they tend to be compact, easy to read and have a great degree of accuracy.
- 11. GENERAL INFORMATION AND MAINTENANCE 1-7 TORQUE ANGLE METERS Because the frictional characteristics of eachfastener or threaded hole will vary, clamp loads which are based strictly on torque will vary as well. In most applica- tions, this variance is not significant enough to causeworry. But, in certain applica- tions, a manufacturer's engineers may determinethat more preciseclamp toads are necessary (such is the case with many aluminum cylinder heads). In these cases,a torque angle method of installation would be specified.When installing fasteners which are torque angle tightened, a predetermined seating torque and standard torque wrench are usually used firstto removeany compliance from the joint. The fastener is then tightened the specified additional portion of a turn measured in degrees. A torque angle gauge (mechanical protractor) is used for these applications. Standard and Metric Measurements » See Figure 23 Throughout this manual, specificationsare given to help you determine the condition of various components on your vehicle, or to assist you in their installation. Some of the most common measurements include length (in. or cm/mm), torque (ft. Ibs., inch Ibs. or Nm) and pressure (psi, in. Hg, kPa or mm Hg). In most cases, we strive to provide the proper measurement as determined by the manufacturer's engineers. Though, in some cases, that value may not be conveniently measured with what is available in your toolbox. Luckily, many of the measuring devices which are available today will have two scales so the Standard or Metric measure- ments may easily be taken. If any of the various measuring tools which are available to you do not contain the same scale as listed in the specifications, use the accompanying conversion factors to determine the proper value. The conversion factor chart is used by taking the given specificationand multiplying it by the necessary conversion factor. For instance, looking at the first line, if you have a measurement in inches such as "free-play should be 2 in." but your ruler reads only in millimeters, multiply 2 in. by the conversion 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 (Nm), then look at the center column first. If the measurement is 100 Nm, multi- ply it by the conversion factor of 0.738 to get 73.8 ft. Ibs. CONVERSIONFACTORS LENGTH-DISTANCE Inches (m ) x 25,4 Fee! (ft.) x 305 Miles x ! 604 VOLUME Cubic Inches (in3) x 16.387 IMP Pints (IMP pt | x .56S IMP Quarts (IMPqt ) x 1.137 IMP Gallons (IMP gall x 4..S46 IMP Quails (IMP qt.) <t 1.201 IMP Gallons (IMP gal.) x 1.201 R Ounces x 29.573 US Pints (US pi > x .473 US Quarts (US 4i ) x .946 US Gallons (US g.,1.) x 3 7X5 MASS-WEIGHT Ounces (oz I * 28.35 Pounds (Ib.) x 454 PRESSURE Pounds Pei Sq. In (psi) x 6.895 Inches of Mercury (Hg) x 4912 Inches of Mercury (Hg) x 3.377 Inches of Water (HjO) x .07355 Inches of Water (H,O) x .03613 Inches of Water (H.O) x.248 TORQUE Pounds-Force Inches (in-lh) x .1 13 Pounds-Force Feet (ft-lh) x 1 356 VELOCITY Miles Per Hour (MPH I x 1.609 POWER Horsepower (Hp( *.745 FUEL CONSUMPTION* Miles Per Gallon IMP (MPG) x .154 Kilometers Per Liter (Km/L) x 2.352 Kilometers Per Liter {Km/1,) x 2.352 •It is common to covert from miles per gallon (r = 282 and mpg (US) x 1/10(1 km = 235 TEMPERATURE Degree Fahrenheit CF) - f C x l . 8 ) t 32 Degree CVUius f(') - (°K - 32) 6 = Millimeters (mm) x .0394 = Meters (m) x 3.281 = Kilometers (km) x .0621 = Cubic Centimeters x .061 = Liters (t.) x 1 76 = Liters (L) x .88 - Liters (L) x .22 = US Quarts (US qi.) x .833 = US Gallons (US gal.) x 831 -= Milliliters x 034 = Liters (L) x 2.113 - Liters (L) x 1.057 - Liters (L) x 264 = Grams (g) x .035 = Kilograms (kg) x 2205 *= Kilopascals (kPa) x .145 -- psi x 2.036 =-- Kilopascals (kPa) x .2961 - Inches of Mercury x 13783 =. psi x 27.684 = Kilopascals (kPa) x 4 0 2 6 = Newton Meters (N-m) x 8.85 = Newton Meters (N-m) x .738 = Kilometers Per Hour (KPH) x .621 =-- Kilowatts x 1 34 - Kilometers PerLiter (Km/L) - IMP MPG = US MPG ipg) to liters/100 kilometers (1/100 km), where = Inches r--- Feet = Miles = m3 = IMP pi. = IMPqt = IMPgai. - IMP qt. = IMP gal. = Ounces = Pints - Quarts = Gallons « Ounces = Pounds = psi = Hg = Hg = H,O - H.O = H,0 = in-lb .ft-lb -MPH = Horsepower upg (IMP)x 1/100 km TCCS1044 Fig. 23 Standard and metric conversion factors chart SERIAL NUMBER IDENTIFICATION Vehicle > 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 theTahoe, 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 Rare2-wheel drive conventional cabs • V and K are 4-wheel drive conventional cabs Fig. 24 The Vehicle Identification Number (VIN) is visible through the windshield 1 4 N 4 J F 1 0 0 0 0 1 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 on a machined pad on the block, at the front just below the right side cylinder head.
- 12. 1-8 GENERAL INFORMATION AND MAINTENANCE VEHICLE IDENTIFICATION CHART Engine Code Engine Series (IO/VIN) Z W T H M K R C J F P Engine Displacement Liters 4.3 4.3 4.8 5.0 5.0 5.7 5.7 6.2 6.2 6.5 6.5 Cubic No.of Fuel Inches Cylinders System 263 (4293) 6 263 (4293) 6 292 (4785) 6 305 (4999) 8 305 (4999) 8 350 (5735) 8 350 (5735) 8 379(6210) 8 379 (6210) 8 395 (6473) 8 395 (6473) 8 TBI CSFI 1BC ® CSFI TBI CSFI D D @ D Eng. Mfg. CPC CPC CPC CPC CPC CPC CPC DDA DDA CPC CPC Model Year Code J K L M N P R S T V W Year 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 P S N W J 6.5 6.5 7.4 7.4 7.4 395 (6473) 395 (6473) 454 (7440) 454 (7440) 454 (7440) 8 8 8 8 8 The 10th digit of the Vehicle Identification Number (VIN) is the ; D TD TBI 4BC MFI CPC CPC CPC CPC CPC ear code and the 8th digit is the engine code. ®4BCorTBI ® D or TD/HO 1BC-1 Barrel Carburetor 4BC-4 Barrel Carburetor CPC-Chevrolet/Pontiac ol Canada CSFi-Central Sequential Fuel Injection D-Diesel DDA-DetroitC HO-High Oi MFI-Multi-port TBI-Throttle B^Jy Injection TD-Turbo Dii sel Allison put uel Injection Fig. 26 The engine identification number is usually located on < machined pad on the engine block On the 1993-98 4.3L V6 engine, the engine identification number is f und on a machined padon the rear of the cylinder block, below and behind tt; left cylinder head where the engine mates with the bellhousing. 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 head. The engine identification number is sometimes also found on a mat hined pad on the left, rear upper side of the block, where the engine mates with he bellhousing. 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 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 F1210TFA is broken down as follows: • F—Manufacturing Plant. F-Flint andT-Tonawanda 12—Month of Manufacture (December) 10-Day of Manufacturer (Tenth) T—Truck engine FA—Transmission and Engine Combination Transmission The Muncie 117mm 4-speed transmission is numbered on the rear of the case, abovethe 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 the case, near the bellhousing. 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 attachedto the right side, which is stamped with the serial number. Drive Axle The drive axle serial number is stamped on the axle shaft housing, where it connects to the differential housing. Front axles on four wheel drive models are marked on the front of the left axle tube. Transfer Case All transfercases have a build tag attached to the case. On the NP205, it is attachedto the bolt retaining the Power Take Off (PTO) cover.
- 13. GENERAL INFORMATION AND MAINTENANCE 1-9 l i i l l u- S,f s s » e 8 _ 3 3 q> * E 1 1 1 Silll s 3 , e -h T— O O o i o _, o i l l
- 14. 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 trucks, you may have to look for it on an inner fender panel. The label ists the vehicle serial number, wheelbase, all Regular Production Options (IPOs) 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. ROUTINE MAINTENANCE AND TUNE-UP Proper maintenance and tune-up is the key to long and trouble-free v :hicle life. Studies have shown (hat a properly tuned and maintained vehicle a e better gas mileage than an out-of-tune vehicle. As a conscientio s 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 arethe 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 » See Figures 28, 29 and 30 The element should be replaced at the recommended intervalsshown in the 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 housing tor signs of dirt or dust that may have leaked through the filter e ement or in through the snorkel tube. Position a droplight on one side of the element 2 Wheel base 3 Model designation 4 RPO and/Of SEO 5 Order numbef 6 E.lenoi colof 7 Paml lechnology Fig. 27 Service parts identification label and look through the filter at the light. If no glow of light can be seen through the element material, replace the filter. If holes in the filter element are apparent or signs of dirt seepage through the filter are evident, replace the filter. 1 Air cleaner 2. Seal 3. Extension 4. Stud 5. Nut - 18 ini Fig. 28 Typical air cleaner housing assembly components—198 gasoline engines 1. Wing Nut 2.2 Hole Cover 3. Air Cleaner Assembly 4. Air Cleaner Extension 5.TBI Assembly Fig. 29 Exploded view of the air cleaner housing—1993 gasoline engines -92 . Air Cleaner 3. EGR Valve Fig. 30 Exploded view of the air cleaner housing—6.2L diesel engines
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