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FOREWORD

This manual includes procedures for diagnosis, maintenance and adjustments, minor service operations, removal disassembly and installation for components of GMC Series 1500-3500 Light Duty Trucks. Procedures for S-15 and Caballero are contained in separate service manuals. The Section index on the contents page enables the user to quickly locate any desired section. At the beginning of each section containing more than one major subject is a Table of Contents, which gives the page number on which each major subject begins. An index is placed at the beginning of each major subject within the section. Summaries of Special Tools, when required, and specifications are found at the end of major sections. When reference is made in this manual to a brand name, number, or specific tool an equivalent product may be used in place of the recommended item. This manual should be kept in a handy place for ready reference, if properly used, it wil enable the technician to better serve the owners of GMC built vehicles. All information, illustrations and specifications contained in this literature are basec on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice.

GMC TRUCK & COACH OPERATION TRUCK & BUS GROUP General Motors Corporation Pontiac, Michigan

CAUTION
To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: ' Proper service and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part. Do not use a replacement part of lesser quality. The service procedures recommended and described in this ser vice manual are effective methods of performing service and re pair. Some of these procedures require the use of tools specially designed for the purpose. Accordingly, anyone who intends to use a replacement part, ser vice procedure or tool, which is not recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replace ment part, service procedure or tool selected. It is important to note that this manual contains various "Cau tions" and "Notices" that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these 'Cautions' and 'Notices' are not exhaustive, because it is impos sible to warn of all the possible hazardous consequences that might result from failure to follow these instructions.

1984 LIGHT DUTY TRUCK (Series 10-35) SHOP MANUAL


Any reference to brand names in this manual is intended mereiy as an example of the types of lubricants, tools, materials, etc., recommended for use. In all cases, an equivalent may be used. The Table of Contents on this page indicates the sections covered in this manual. At the beginning of each individual section is a Table of Contents which gives the page number on which each major subject begins.

TABLE OF CONTENTS GENERAL INFORMATION General Information Maintenance and Lubrication HEATING AND AIR CONDITIONING Heating and Ventilation Air Conditioning A-6 Compressor - Unit Repair R-4 Compressor - Unit Repair FRAME AND BUMPERS Frame and Body Mounts Bumpers Sheet Metal STEERING. SUSPENSION. WHEELS AND TIRES Diagnosis Front Alignment Steering Column Steering Linkage Power Steering Manual Steering Front Suspension Rear Suspension Wheel and Tires PROPELLER SHAFT AND AXLES Propeller Shaft Rear Axles Front Axle BRAKES ENGINE Engine Diagnosis In-Line 6 (4.1L/4.8L) Small Block (5.0L75.7L) Mark IV (7.4L) Diesel (6.2L) Engine Cooling Engine Fuel E4ME Carburetor E2SE Carburetor Diesel Fuel Injection 1ME Carburetor 2SE Carburetor M4ME Carburetor Engine Electrical Driveability & Emission - Carburetor Driveability & Emission - Diesel Engine Exhaust Vacuum Pump TRANSMISSION Automatic Service 350C-Unit Repair 400-Unit Repair 700R4-Unit Repair Manual-Service 3 Speed 76mm-Unit Repair 4 Speed 89mm-Unit Repair 4 Speed 117mm-Unit Repair Clutch Transfer Case 205 - Unit Repair 208 - Unit Repair ELECTRICAL Chassis Electrical Instrument Panel and Gages ACCESSORIES BODY SERVICE ELECTRICAL WIRING DIAGRAMS

SECTION

0A OB 1A 1B 1D 1D1 2A 2B 2C

3 3A 3B5 3B6 3B7 3B8 3C 3D 3E 4A 4B 4C 5 6 6A1 6A2 6A5 6A7 6B 6C 6C1 6C3 6C6 6C7 6C9 6C10 6D 6E8 6E9 6F 6H 7A

CAUTION
This vehicle contains many parts dimensioned in the metric sys tem. Most fasteners are metric and many are very close in dimen sion to familiar customary measurements in the inch system. However, it is important to note that, during any vehicle mainte nance procedures, replacement fasteners must have the same measurements as those removed, whether metric or customary. Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury. Therefore, fasteners re moved from the vehicle should be saved for re-use whenever pos sible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original.
A d dition al inform ation concerning this subject w ill be found fol low in g the specifications section a t the end o f this manual.

GMC TRUCK & COACH OPERATION TRUCK & BUS GROUP General Motors Corporation Pontiac, Michigan

7B

7C 7D

8B 8C 9 10 REAR OF BOOK

GENERAL IN F O R M A T IO N

OA-1

SECTION OA

GENERAL INFORMATION
CONTENTS
G eneral In fo rm a tio n ..................................................... OA-1 V ehicle Identification N u m b e r s ................................OA-1 Service Parts Id e n tific a tio n .........................................O A -1 V ehicle L o a d in g ............................................................ OA-1 Engine C ode N u m b e r................................................... OA-2 U nit and Serial N um ber L o c a tio n ............................ OA-4 C a p a c itie s ........................................................................ OA-6 L ubrication P o i n t s .........................................................OA-7 M etric In fo rm atio n .........................................................OA-9 C om m on A b b re v a tio n s............................................ OA-14 Production Option C o d e s ............................ ............... OA-15

VEHICLE LOADING
Vehicle loading m ust be controlled so weights do not exceed the num bers shown on the Vehicle Identification N um ber an d /o r R ating Plate for the vehicle. A typical ex am p le o f a truck in a loaded condition is show n in F igure O A -5. N ote that the axle or G V W ca p a bilities are not ex ceed ed .

ENGINE CODE NUMBER


T he engine code num ber indicates m an u factu rin g plant, month and day of m anufacture, and transm ission type. A typical engine num ber would be FI 210TTBB, which would breakdown thus: F - M anufacturing Plant (F -F lint, T-Tonaw anda) 12 - M onth of M anufacture (D ecem ber) 10 - Day of M anufacture (tenth) T - Truck TBB - Transm ission and engine type

UNIT AND SERIAL NUMBER LOCATIONS GENERAL INFORMATION


Inform ation to identify the vehicle and vehicle components appears in this section. Detailed specifications on m ajor units are given at the end of each respective section in this m anual. For the convenience of service technicians and engines when writing up certain business papers such as W arranty Reports, Product Inform ation Reports, or reporting product failures in any way, the location of the various unit num bers have been indicated. These unit num bers and their prefix or suffix are necessary on these papers for various reasons such as accounting, follow-up on production, etc.

VEHICLE IDENTIFICATION NUMBER (VIN)


T his is the legal identification o f the vehicle. It ap pears on a plate w hich is attached to the left top o f the instrum ent panel on C K and G truck and can be easily seen through the windshield from outside the vehicle (Fig. OA-1). O n P 1 0-2 0-3 0 m od els, the plate is attached to the front o f the dash and toe panel to the left o f steering col um n (Fig. OA-2). T he V IN (Fig. OA-3) also appears on the V ehicle C ertificates o f T itle and R egistrations.
M F D . BY G E N E R A L M O T O R S C O R P O R A T I O N

O
GAWR F R O N T ^ ^ ^

gvwr

^^^

GAWR REAR

VIN

SERVICE PARTS IDENTIFICATION STICKER


T he Service P arts Identification S ticker (Fig. OA-4) is provided on all T ru ck m odels. O n C and K m odels, the identification sticker is located on the inside o f the glove box door o r on G m od el, the sticker will be located on an inner hood panel surface. O n P m o dels, the sticker is located on an inner body panel. T he plate lists the vehicle identification num ber, wheelbase, and all Production options or Special Equipm ent on th e vehicle when it was shipped from the factory including paint information. ALWAYS REFER TO THIS INFORMATION WHEN ORDERING PARTS.
I N F L A T I O N D A T A FOR TI RES FURNISHED WITH VEHICLE

SHOWN ON V E H IC LE C E R T IF IC A T IO N LA B E L

W A R R A N T Y V O ID E D IF LO AD E D IN EXCESS OF RAT IN G S SEE OWNERS M A N U A L FOR OT HE R LO AD IN G AND I N F L A T I O N DA TA

EXAMPLE ONLY

Fig. OA-2 V.I.N. Rating Plate (P Model)

OA-2

GENERAL IN F O R M A T IO N

VEHICLE IDENTIFICATION NUMBER


GCEC14D9DF123456

J
NATION OF ORIGIN
1 2 USA CANADA CODE A B D F J K R

"| PLANT SEQUENTIAL NUMBER [ ASSEMBLY PLANT


ASSEM BLY PLAN T GM AD G M AD LAKEW OO D BA LT IM O R E F LIN T CODE S V GM AD AS SEM BLY PLAN T ST LOUIS PO NTtAC GMT & C

MANUFACTURER
3 G E N E R A L MOTORS

GM AD - D O R A V IL L E * C H EVR O LET G M AD G M AD JA N E S V IL LE LEEDS *

MAKE AND TYPE


BUS (V A N ) IN COM PLETE VE HICLE TRUCK M ULTIPURPOSE PASS VE HICLE

z l 3
4 7

GM AD F R E M O N T ' GM OF C A N A D A OSHAWA C H EVR O LET GM AD D ETR O IT SCARBOROUGH (iM Of- C A N A D A

G M AD A R L IN G T O N ' * EL C AM IN O PLAN TS

LORDSTOWN

GVWR/BRAKE SYSTEM
GVWR CODE B *C D E F * 'G H J <IN POUNDS) 3001 - 4000 4001 - 5000 5001 6001 7001 8001 9001 10001 6000 7000 8000 9000 10000 1/2 TON 3/4 TON 1 TON H Y D R A U L IC O N LY CODE C D .F H J L M P W Includes El Carnmo Includes G Van Bus 0 1 2 CHASSIS TYPE C O N V E N T IO N A L CAB C O N V E N T IO N A L CAB FO R W A R D CON TRO L CHASSIS V A N . SPORT V A N & C U TA W A Y VAN 3 4 5 6 7 8 9 MODELS BR AK E SYSTEM

CHECK DIGIT ENGINE TYPE AND MAKE


TYPE D ISP LA CE M E NT LITRE S 6 .2 L V 8 D IE S E L 4 1L 5 0L 5 0L 6 .2 L L62B B L V8 4BBL V8 4BBL V 8 D IE S E L MAKE (GM) PRODUCER C H EVR O LET CH EVR OLET C H EVR O LET C H EVR O LET CHEVROLET CH EVR OLET C H EVR O LET C H EVR O LET C H EVR O LET GM DE MEXICO M ODELS C -K G CKG CK G C -K CKG CKGP CK C K P C K P RPO L# |6 LE3 LF3 LE9 LL4 LS9 LT9 LF5 LE8 L25

TRUCK SERIES

11.000

5 7 L V8 4BBL 5 7L V 8 4 B B L 5 7L V8 2BBL 7 4L V 8 4 B B L 4 8L L6 1BBL

TRUCK BODY TYPE


SEDAN PICKUP HI C U BE/C U TAW AY VA N FO R W A R D C ON TRO L FOUR DOOR CAB TWO DOOR CAB VAN SUBURBAN MOTOR HOME BLAZER S T A K E /P LA T FO R M

LINE AND CHASSIS TYPE


LINE

4X2
4X4

4X2 4X2

104206

Fig. 0 A -3 -- Vehicle Identification Number Codes, CKGP, Truck


D a n a Built

On Front Axles, code is stam ped on Top R ear of Left Axle Tube. On R ear Axles, code is stam ped on R ear Surface of Right Axle Tube.

LOADEDMAXIMUM GVWR:
FRONT GAW R: 2944 LBS.

4900-LBS.

REAR GAW R: 2944 LBS.

Fig. OA-4 Service Parts Identification Plate

The prefixes on certain units identify the plant in which the unit was m anufactured and thereby perm its proper follow-up of the plant involved to get corrections made when necessary. Always include the prefix in the num ber.
'Front Curb 2219 lbs. Front Cargo & Pass. Load 284 lbs. 2503 lbs. *Rear Curb 1003 lbs. Rear Cargo & Pass. Load 1394 lbs. 2397 lbs.

Axles
C h evro let Built

On 10 Series, the Code is stam ped on Top of Right R ear Axle Tube. O n 20-30 Series, the Code is stam ped on Top of the R ight R ear Axle Tube.

TOTAL WEIGHT AT GROUND: 4900 lbs. *Curb weight equals the weight of the vehicle without driver, passenger or cargo, but including fuel and coolant. Fig. OA-5 - Typical Vehicle Loading Condition

GENERAL IN F O R M A T IO N

OA-3

Transmissions (Fig. OA-6)


O n 3-Speed Transm issions (except Trem ec), the U nit N u m b er is located on Lower Left Side of C ase Just Below Cover. On T rem ec Transm ission, U nit N um ber is located on U pper L eft A ttachm ent C ase (Top Side). O n M uncie 4-Speeds, U nit N um ber is located on R ear Face of Case below R etainer. On New Process 205 model 4-wheel drive transfer case, a build date is on tag attached to front face of transfer case. O n A u to m atic 350 T ransm ission, U n it N u m b er is located on R ight R ear V ertical Surface of Oil Pan. On the A utom atic 400 Transm ission, Serial N um ber is location on the L ight Blue Plate on the R ight Side of the Transm ission.

8-Cylinder Gasoline Engine Code is (305, 350, 400 C ID ) Located on Pad im m ediately forw ard of right hand cylinder head. 8-Cylinder Gasoline Engine (454 C ID ) Code is located on a pad of the front top center of the engine block im m ediately forward of the inlet manifold. 8-Cylinder Diesel Engine Code is on a label located on rear face of the left valve cover.

Generators
G enerator U nit Serial N um ber is located on the Drive End Fram e Below the P art N um ber.

Batteries
B attery Code N um ber is Located on Cell Cover Top of Battery.

Engines (Fig. OA-7)


6-Cylinder Engine U nit N um ber Located on Pad at R ig h t H and S ide o f C y lin d er Block a t R e ar of D istributor.

Starters
S ta rte r S erial N u m b er and P roduction D ate are Stam ped on O uter Case, Tow ard Rear.

OA-4

GENERAL IN F O R M A T IO N

T Y PI CA L T R AN SM IS S IO N - I D LO CAT IO NS H I. J T H M 350C STAMP ED I D L O CA TI O N T H M 350C V IN LO CA TI O N T H M 350C O P TI O NA L V I N LO CA TI O NS K L M N THM THM THM THM 400 400 700 700 I D TAG L O CA TI O N V IN LO CA TI O N R4 ST AMP ED I D LO CAT IO N R4 V IN LO CA TI O N H 7 A 1 6/81

TRANSMISSION NAMEPLATE YPSILANTI PLANT. MICHIGAN TRANSMISSION IDENTIFICATION THM 400 FOR: THM 350C-TOLEDO PLANT, OHIO

03

Y = SOURCE (Y = TOLEDO 3 = MODEL YEAR E = M O N TH (A= JAN 84 = DAY D = SHIFT <D = DAY SHIFT

B = PARMA)

B = FEB) 84 MODEL YEAR

N = NIGHT SHIFT)

PZ = MODEL 86992 = SERIAL NO.

H 7A-8-6/81

H 7 A - 1 2-6/81

TRANSMISSION NAMEPLATE BUICK FLINT PLANT. MICHIGAN THM 350C TRANSMISSION IDENTIFICATION THM 700R4 -TOLEDO PLANT, OHIO > 9 TA Y 83 M 12 D

L 1 D
9LD 001D 83 9LD = MODEL CODE (1982 LO) D = SHIFT <D = DAY SHIFT) 84 YEAR

9 = MODEL YEAR TA = MODEL Y = TOLEDO 84 = YEAR M = MONTH 12 = DAY D SHIFT (D = DAY N = NIGHT)

001 = PRODUCTION BUILD DATE

H 7A 9-6/81

H 7A 7-6/81

Fig. OA-6 -- Transmission V.I.N. Location

..... -

____ _........................................... ......- - - - m m i i - iMMMiiiniTnr--TTnTiiin r r r r m w i T ^ "

GENERAL IN F O R M A T IO N

OA-5

ENGINE V .I.N .

ENGINE V.I.N . (OPTIONAL) "N '

ENGINE V.I.N . (OPTIONAL)

ENGINE CASE PAD ENGINE V .I.N .

DISTRIBUTOR PAD

L6 ENGINE

V8 ENGINE

V8 ENGINE DIESEL

100820

Fig. OA-7 Engine V.I.N. Location

OA-6

GENERAL IN F O R M A T IO N

APPROXIMATE CAPACITIES - PICKUP MODELS


ITEMS Cooling System (approx.) All L -6 Without A/C With A/C Code F,H,L & M - V -8 Without A/C With A/C Code W - V -8 Without A/C With A/C Diesel Without A/C With A/C Crankcase Gasoline Engines Codes: D,F,H,L,M Without Filter With Filter Code: T Without Filter With Filter Code: W + Without Filter With Filter Diesel Engines Code: C,J t Fuel Tank (approx.) Short Bed Single Tank, Gas, Diesel *Dual Tanks, Gas. Diesel Long Bed Single Tank, Gas @*Dual Tanks, Gas Single Tank, Diesel *Dual Tanks, Diesel Front Axle Transfer Case 10-20 Series 30 Series Metric Measure U.S. Measure

14 Liters 14.7 Liters 16.6 Liters 17 Liters 22 Liters 23 Liters 22 Liters 23 Liters

15 Quarts 15.5 Quarts 17.5 Quarts 18 Quarts 23 Quarts 24.E ?Quarts 23 Quarts 24.5 Quarts

APPROXIMATE CAPACITIES - BLAZER, SUBURBAN


ITEMS Cooling System (approx.) Code: H, L ,M W ithout A/C W ith A/C Code: W W ithout A/C W ith A/C Diesel Engines Code: C, J W ithout A/C With A/C Crankcase Gasoline Engines Code: H, L and M W ithout Filter W ith Filter Code: W + W ithout Filter W ith Filter Diesel Engines t Code: C ,J With Filter Front Axle Transfer Case Fuel Tank Standard, A ll Gas Diesel NK7 O ption, A ll Gas Diesel NE2 O ption, Suburban Only Gas Diesel Metric Measure U.S. Measure

16.5 Liters 17 Liters 22 Liters 23 Liters

17.5 Quarts 18 Quarts 23 Quarts 24.5 Quarts

3.8 Liters 4.8 Liters 4.8 Liters 5.7 Liters 5.7 Liters 6.5 Liters 6.5 Liters

4 Quarts 5 Quarts 5 Quarts

23 Liters 23 Liters

24.5 Quarts 24.5 Quarts

6 Quarts 6 Quarts
7 Quarts 7 Quarts

3.8 Liters 4.8 Liters 5.7 Liters 6.5 Liters

4 Quarts 5 Quarts

6 Quarts
7 Quarts

61 Liters 61 Liters 76 Liters 61 Liters 76 Liters 76 Liters 2.4 Liters 4.8 Liters 2.4 Liters

16 Gallons 16 Gallons 20 Gallons 16 Gallons 20 Gallons 20 Gallons 2.5 Quarts 5 Quarts 2.5 Quarts

6.5 Liters 2.4 Liters 4.8 Liters 95 102 117 121 Liters Liters Liters Liters

7 Quarts 2.5 Quarts 5.0 Quarts 25 27 31 32 Gallons Gallons Gallons Gallons

151 Liters 155 Liters

40 Gallons 41 Gallons

A fte r re fill, flu id level must be checked. + K30 Models - 5 U.S. Quarts (4.8 Liters) t Qil F ilte r should be changed at E VE R Y oil change. Listed q u a n tity if fo r each tank. @ Above 8600 G V W R Both tanks 20 gallons (76 Liters)

A fte r re fill, flu id level must be checked. + K30 Models 5 U.S. Quarts (4.8 Liters), t Q il F ilte r should be changed at E V E R Y o il change

APPROXIMATE CAPACITIES - ALL MODELS


ITE M S Differential 81 /a" Ring Gear 8-7 /8 " Ring Gear 10 1 /4" Ring Gear (Chev.) 101 /a" Ring Gear (Dana) 9%" Ring Gear (Dana) 12%" Ring Gear (Dana) Transmission Autom atic 350 - Total Refill 400 - Total - Refill 700R4 - T otal - Refill Manual 4 Speed 117mm 3 Speed 76mm 3 Speed 77mm M e tric Measure U.S. Measure

1.9L 2.8L 3L 2.6L 11.7L

4% pts. 3% pts. 61 /2 pts. 7.2 pts. 6.0 pts. 26.8 pts.

9.5L 2.8L 10.4L 3.8L 10.9L 4.7L 3.8L 1.4L 1.4L

10 qts.
3 qts.

11 qts.
3.5 qts. 11.5 qts. 5 qts. 4 qts. 1.5 qts. 1.5 qts. 104254

Fig. 0A -8 Capacities Chart

' GENERAL IN F O R M A T IO N OA-7

CONVENTIONAL AND FORWARD CONTROL MODELS

LUBRICATION POINTS
1 2 3 4 5 Lower Control Arms Upper C ontrol Arms Upper and Lower Control Arm Ball Joints Intermediate Steering Shaft (PA10) Tie Rod Ends 6 7 8 9 10 Wheel Bearings Steering Gear A ir Cleaner - Element Master Cylinder Transmission - Manual - A utom atic 11 12 13 14 15 T h ro ttle Bell Crank - L-6 Carburetor Linkage - V-8 Brake and Clutch Pedal Springs Universal Joints Rear Axle

FOUR WHEEL DRIVE MODELS

LUBRICATION POINTS
1 2 3 4 5 A ir Cleaner Control Linkage Points Tie Rod Ends Wheel Bearings Steering Gear 6 7 8 9 10 Master Cylinder Transmission - Manual - A utom atic Carburetor Linkage - V-8 Universal Joints Propeller Shaft Slip Joints 11 12 13 14 15 Front and Rear Axle Drag Link Brake and Clutch Pedal Springs Transfer Case T h ro ttle Bell Crank - L-6

Fig. OA-9 Lubrication Points, CK

OA-8

GENERAL IN F O R M A T IO N

LUBRICATION POINTS
1 2 3 4 Control Arm Bushings and Ball Joints Tie Rod Ends Wheel Bearings Steering Gear Clutch Cross-Shaft 5 6 7 Trans. Control Shaft A ir Cleaner - Element Transmission - Manual - A utom atic 8 9 10 11 Rear A xle Oil Filter Brake Master Cylinder Parking Brake Linkage

Fig. 0A-10 Lubrication Points, G

GENERAL IN F O R M A T IO N

OA-9

USE OF METRIC AND CUSTOMARY NUTS, BOLTS AND SCREWS

Some vehicles present special service requ irem ents to the technician due to the use of both metric and c u s tomary (inch) type nuts, bolts and screws. Many are metric and some are very close in dim ension to c u s t o m ary nuts, bolts and screw s in the inch system. M ismatched o r incorrect nuts, bolts and screws can result in damage, m alfunction or possible personal injury. N u ts, bolts and screw s rem oved from the vehicle should be saved for re-use w h e n e v e r possible. If they are not re-usable, care should be ta ken to select a replacem ent that m atches the original.

G eneral M oto rs Engineering S tand ard s have adopted a portion of the standard metric fa sten er sizes defined by SI (System e International). This was done to reduce the n u m b er o f sizes used and yet retain the best strength ch aracteristics in each th read size. F or exam ple, the cu stom ary 1 4-20 and 1/4-28 screw s are replaced by the metric M6.3 x 1 screw which has nearly the same d iam eter and 25.4 thread s per inch. The thread pitch is in be tw een the c u sto m a ry coarse and fine thread pitches.

Metric and c u sto m a ry thread notation differ slightly. The difference is illustrated below.

CUSTOMARY

METRIC

1/4

M6.3

T hread Major D iam eter in In ches

T hread Major D iam eter in Millimeters

20

N u m b e r of T hreads per Inch

Distance B etw een T hread s in Millimeters

Care should be taken w hen servicing the vehicle to guard against cross threading or im pro per retention due to interchanged metric and inch nuts and bolts.

W hen obtaining metric o r c u sto m a ry nuts, bolts, and screws locally for servicing the vehicle, care must be exercised in selecting parts that are equivalent to the original parts in d im ensions, strength, and pitch of threads.

Fig. OA-11 Metric Information, Chart A

0A-10

GENERAL IN F O R M A T IO N

REUSE OF P R E V A IL IN G T O R Q U E N U T (S ) A N D BOLT(S)
PREVAILING TORQUE NUTS ARE THOSE NUTS WHICH INCORPORATE A SYSTEM TO DEVELOP AN INTERFERENCE BETWEEN NUT AND BOLT THREADS INTERFERENCE IS MOST COMMONLY ACHIEVED BY DISTORTING TOP OF ALL-METAL NUT, BUT ALSO MAY BE ACHIEVED BY DISTORTING AT MIDDLE OF HEX FLAT, BY NYLON PATCH ON THREADS, BY NYLON WASHER INSERT AT TOP OF NUT AND BY NYLON INSERT THROUGH NUT. PREVAILING TORQUE BOLTS ARE THOSE BOLTS WHICH INCORPORATE A SYSTEM TO DEVELOP AN INTERFERENCE BETWEEN BOLT AND NUT OR TAPPED HOLE THREADS. INTERFERENCE IS ACHIEVED BY DISTORTING SOME OF THE THREADS (SEVERAL METHODS EXIST), BY APPLYING A NYLON PATCH OR STRIP OR BY ADHESIVE COATING ON THREADS.

PREVAILING TORQUE NUTS


tl-T ) TOP LOCK MANY TYPES CENTER LOCK

PREVAILING TORQUE BOLTS

DRY ADHESIVE COATING NYLON INSERT


N YLO N

OUT OF ROUND THREAD AREA

PATCH

N YLO N

WASHER INSERT
RECOMMENDATIONS FOR REUSE
A. CLEAN. UNRUSTFD FOLLOWS 1. 2. PREV AILING TORQUE

NYLON STRIP OR PATCH

THREAD PROFILE DEFORMED

BOLTS

AND

NUTS

MAY

BE

REUSED

AS

3. 4

5. B.

C L E A N D I R T A N D O T H E R F O R E I G N M A T E R I A L O F F N U T A N D BO L T INSPECT BOLT A N D N U T T O A SSU RE T H E R E ARE NO C R A C K S . E L O N G A T IO N O R O T H E R SIGNS OF ABUSE O R O V E R T IG H T E N IN G LIGHTLY LU B R IC A TE T H R E A D S (IF A N Y D O U B T , R E P L A C E WI TH NE W P R E V A I L I N G T O R Q U E F A S T E N E R O F E Q U A L O R G R E A T E R STREN G TH .) ASSEM BLE P A RT S A ND ST A R T BOLT O R NUT O B S E R V E T H A T B E F O R E F A S T E N E R S E A T S . IT D E V L L O P S P R E V A I L I N G T O R Q U E P E R C H A R T B EL O W ( I F A N Y D O U B T . I N S T A L L NEW P R E V A I L I N G T O R Q l ' E F A S T E N E R O F EQUAL O R G R E A T E R STREN G TH ). T I G H T E N T O T O R Q U E S P E C I F I E D IN S E R V I C E M A N U A L .

B O L T S A N D N U T S W H IC H A R E R U S T Y O R D A M A G E D S H O U L D BE R E P L A C E D WI TH NE W PARTS O F EQUAL OR G R E A T E R STRENGTH

METRIC SIZES
6 & 6.3 8 10 12 14 16 20

NUTS AND A L L M E T A L BO L T S

N* m In. Lbs.

0.4

0. 8

1.4

* >

3.0

4. 2

7.0

4 .0

7. 0

12

18

25

35

57

N* m ADHESIVE OR NYLON C O A T E D BOLTS In. Lbs

0 .4

0.6

1.2

1.6

2.4

3.4

5.6

4 .0

5. 0

10

14

20

28

46

INCH SIZES
.2 50 N*m .312 .375 .437 .5 00 .562 .625 .750

NUTS AND ALL METAL BOLTS

0. 4

0. 6

1.4

1.8

2.4

3.2

4.2

6.2

In. Lbs.

4 .0

5.0

12

15

20

27

35

51

N*m A DHESIVE O R NYLON C O A T E D BO L T S In. Lbs.

0.4

0.6

1.0

1.4

1.8

2.6

3.4

5.2

4. 0

5. 0

9.0

12

15

T1

28

43

Fig. OA-12 - Metric Information, Chart B

GENERAL IN F O R M A T IO N

OA-11

METRIC BOLT AND NUT IDENTIFICATION

Common metric fastener strength property classes are 9.8 and 10.9 with the class identification embossed on the head of each bolt. Customary (inch) strength classes range from grade 2 to 8 with line identification embossed on each bolt head. Markings correspond to two lines less than the actual grade (i.e. grade 7 bolt will exhibit 5 embossed lines on the bolt head). Some metric nuts will be marked with single digit strength identification numbers on the nut face. The following figure illustrates the different strength markings.

GRADE 2 (GM 200-M )

GRADE 5 (GM 280-M )

GRADE 7 (GM 2 90-M )

G RADE 8 (GM 3 00-M )

Customary (inch) bolts - Id e n tifica tio n marks correspond to b o lt strength - Increasing numbers represent increasing strength.

Metric Bolts - Id e n tifica tio n class numbers correspond to bolt strength - Increasing numbers represent increasing strength.

M A N U FA C TU R E R S ID E N T IF IC A T IO N

N UT STRENGTH ID E N T IF IC A T IO N PO SID RIV SCREW H E A D

ID E N T IF IC A T IO N M A R K S (4)

Fig. OA-13 Metric Information, Chart C

r
OA-12 GENERAL IN F O R M A T IO N

SI

M ETRIC-CUSTO M ARY CO NVERSION T A B LE

by
LENGTH

to pet equivalent number of:

Multiply

by
AC C E LE R A TIO N

to get equivalent number o f:

Inch Foot
Yard

Mile

25.4 0.304 8 0914 4 1 609 AREA

m illim eters (m m ) meters (m ) meters kilometers (k m )

Foot/sec" Inch/sec^

0 304 8 0025 4 TORQUE

meter/sec2 (m /s2) meter/sec2

Inch'7

F oo t2 Y ard2

645.2 6.45 0.092 9 0836 1 VO LUM E

millim eters2 (m m 2) centimeters? (cm 2) meters2 (m 2 ) meters

Pound-inch Pound-toot

0 112 98 1 355 8

newton-meters (N *m ) newton-meters

POWER
Horsepower 0 746 PRESSURE OR STRESS kilo w a tts (kW )

Fig. OA-14 Metric Information, Chart D

Inch*

Quart Gallon Yard

16 387 16 387 0 016 0946 3.785 0 764 MASS

4 4 4 6

mnr* cm liters (1) liters liters meters3 (m 3 )

Inches o f mercury Pounds/sq in

3.377 6.895 ENERG Y OR WORK

kilopascals (kPa) k ilo pa seals

BTU Foot-pound K ilow att -hour

1 055 1.355 8 3 600 000 or 3 6x10*

joules (J) joules joules (J = one Ws)

Pound Ton Ton

0 453 6 907.18 0 907 FORCE

kilograms (kg) kilograms (kg) lonne (t) Fool candle

LIGHT
10.764 F U E L PERFORM ANCE lumens/meter2 (lm /m 2 )

Kilogram Ounce Pound

9 807 0.278 0 4.448 TEM PERATURE

newtons (N ) newtons newtons

Miles/gal Gal/m ile

0425 I 2 352 7 V E LO C ITY

kilom eters/liter (k m /1 ) lite rs/kilo m e te r (1 /k m )

Degree Fahrenheit f

(F -3 2)

18

degree Celsius (C)

Mile s/hour

f 609 3

kilom eters/hr. (k m /h )

-40 t- ^ -40
-C

0 y 20 ]i

32 140 0

98.6 80 t y - v 20 40 37 120 00 180

212 200 ,

t
80

i*

'1

100
*C

GENERAL IN F O R M A T IO N

OA-13

DECIMAL AND METRIC EQUIVALENTS Fractions Decimal In. 1/64 1/32 3/64 1/16 5/64 3/32 7/64 1/8 9/64 5/32 11/64 3/16 13/64 7/32 15/64 1/4 17/64 9/32 19/64 5/16 21/64 11/32 23/64 3/8 25/64 13/32 27/64 7/16 29/64 15/32 31/64 1/2 ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ------ . ____ . ____ . ____ . . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ____ . ------ . .015625 . . . .03125 .0625 .09375 .125 ... ____ .. . .......... ... ____ ... .......... ... ____ .. . .......... ... ____ . ... .046875 . . . .078125 . . . .109375 . . . .140625 . . . .15625 .1875 .21875 .250 .28125 .3125 .34375 .375 .40625 .4375 .46875 .500 .171875 . . . .203125 . . . .234375 . . . .265625 . . . .296875 . . . .328125 . . . .359375 . . . .390625 . . . .421875 . . . .453125 . . . . .484375 . . . .......... . Metric MM. .39688 .79375 1.19062 1.58750 1.98437 2.38125 2.77812 3.1750 3.57187 3.96875 4.36562 4.76250 5.15937 5.55625 5.95312 6.35000 6.74687 7.14375 7.54062 7.93750 8.33437 8.73125 9.12812 9.52500 9.92187 10.31875 10.71562 11.11250 <1.50937 11.90625 12.30312 12.70000 33/64 17/32 35/64 9/16 37/64 19/32 39/64 5/8 41/64 21/32 43/64 11/16 45/64 23/32 47/64 3/4 49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8 57/64 29/32 59/64 15/16 61/64 31/32 63/64 1 .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... Fractions Decimal In. .515625 . . .53125 . . . .546875 . . .5625 . . . .578125 . . .59375 . . . .609375 . . .625 ____ .640625 . . .65625 . . . .671875 . . .6875 . .. .703125 . . .71875 . . . .734375 . . .750 ____ .765625 . . .78125 . . . .796875 . . .8125 . .. .828125 . . .84375 . . . .859375 .875 . ____ Metric MM. 13.09687 13.49375 13.89062 14.28750 14.68437 15.08125 15.47812 15.87500 16.27187 16.66875 17.06562 17.46250 17.85937 18.25625 18.65312 19.05000 19.44687 19.84375 20.24062 20.63750 21.03437 21.43125 21.82812 22.22500 22.62187 23.01875 23.41562 23.81250 24.20937 24.60625 25.00312 25.40000

.890625 . . .90625 . . . .921875 . . .9375 . . . .953125 . . .96875 . . . .984375 . . 1.00 ..........

Fig. OA-15 Metric Information, Chart E

OA-14

GENERAL IN F O R M A T IO N

LIST OF AUTOMOTIVE ABBREVIATIONS WHICH MAY BE USED IN THIS MANUAL


A - A m p e re (s ) A - 6 - A x ia l 6 C y l. A /C C o m p re s s o r A /C - A ir C o n d itio n in g A C C - A u to m a tic C lim a te C o n tr o l A d j. - A d ju s t A /F - A ir /F u e l (As in A ir /F u e l R a tio ) A IR - A ir In je c tio n R e a c tio n System A LC - A u to m a tic Level C o n tr o l A LC L - A s s e m b ly L in e C o m m u n ic a tio n s Lin k A lt . - A l t it u d e AP T - A d ju s t a b le P a rt T h r o ttle A T - A u to m a tic T ra n s m is s io n A T C - A u to m a tic T e m p e r a tu r e C o n tro l A T D C - A f t e r T o p D e a d C e n te r FMVSS - F e d e ra l M o to r V e h ic le S a fe ty S ta n d a rd s Ft. Lb. - F o o t P o u n d s ( T o rq u e ) F W D - F ro n t W h e e l D riv e - F o u r W h e e l D riv e 4 x 4 - F o u r W h e e l D riv e H D - H e a v y D u ty H EI - H ig h E n e rg y Ig n it io n C a t. C o n v . - C a t a ly tic C o n v e rte r CC - C a t a ly tic C o n v e rte r - C u b ic C e n tim e te r - C o n v e rte r C lu tc h C C C - C o m p u te r C o m m a n d C o n tr o l C -4 - C o m p u te r C o n tr o lle d C a t a ly tic C o n v e rte r C B - C itiz e n s B a n d (R a d io ) C C O T - C y c lin g C lu tc h ( O r if ic e ) T u b e C C P - C o n tr o lle d C a n is te r P u rg e C .E . - C h e c k E n g in e C E A B - C o ld E n g in e A ir b le e d C EM F - C o u n te r E le c tro m o tiv e Force C ID - C u b ic In ch D is p la c e m e n t C LO O P - C lo s e d Loo p km - K ilo m e te rs k m /h r - K ilo m e te rs P e r H o u r KV - K ilo v o lts (T h o u s a n d s o f V o lts ) km /L - K ilo m e te r s /L ite r (m p g ) kP a - K ilo p a s c a ls L - L ite r L-4 - F o u r C y lin d e r In -L in e (E n g in e ) D BB - D u a l B e d B e a d D B M - D u a l B e d M o n o lith DEFI - D ig it a l E le c tro n ic F u e l In je c tio n DFI - D ig it a l F u e l In je c tio n D if f . - D if f e r e n t ia l D istr. - D is t r ib u to r M a n . V a c . - M a n if o ld V a c u u m M A P - M a n if o ld A b s o lu te P re ssure M /C - M ix tu r e C o n tr o l M P G - M ile s P er G a llo n M P H - M ile s P e r H o u r M T - M a n u a l T ra n s m is s io n N m - N e w to n M e tre s (T o rq u e ) O D - O u ts id e D ia m e te r X -V a lv e - E x p a n s io n V a lv e W / - W ith W /B - W h e e l Base W /O - W ith o u t W O T - W id e O p e n T h r o ttle L -6 - S ix C y lin d e r In -L in e (E n g in e ) LF - L e ft F ro n t LR - L e ft R e a r V - V o lt(s ) V - 6 - S ix C y lin d e r E n g in e - A r r a n g e d in a " V " V -8 - E ig h t C y lin d e r E n g in e - A r r a n g e d in a " V " V ac. - V acuum V A T S - V e h ic le A n ti- T h e ft S ystem V IN - V e h ic le I d e n t if ic a t io n N u m b e r VSS - V e h ic le S p e e d S e n s o r V M V - V a c u u m M o d u la t o r V a lv e C LC C - C lo s e d L o o p C a r b u r e to r C o n tr o l CLTBI - C lo s e d L o o p T h r o ttle B o d y In je c tio n C o n v . - C o n v e rte r CP - C a n is te r P u rg e C u . In . - C u b ic Inch C V - C o n s ta n t V e lo c ity C y l. - C y lin d e r(s ) U JT - U n iv e r s a l J o in t l/P IA C - Id le A ir C o n tr o l 1C - I n te g r a te d C ir c u it ID - I d e n t if ic a t io n - In s id e D ia m e te r ILC - Id le L o a d C o m p e n s a to r - In s tru m e n t P a n e l ISC - Id le S p e e d C o n tr o l TA C - T h e rm o s ta tic A i r C le a n e r T A C H - T a c h o m e te r TBI - T h r o ttle B o d y In je c tio n TC C - T ra n s m is s io n C o n v e r te r C lu tc h TCS - T ra n s m is s io n C o n tr o lle d S p a r k TD C - T o p d e a d C e n te r TPS - T h r o ttle P o s itio n S e n s o r TURB - T u rb o c h a rg e r T /V - T h r o ttle V a lv e T V B V - T u r b o c h a r g e r V a c u u m B le e d V a lv e TVRS - T e le v is io n & R a d io S u p p re s s io n TVS - T h e rm a l V a c u u m S w itc h H g . - M e rc u ry H i. A lt . - H ig h A lt it u d e H V A C - H e a te r - V e n t- A ir C o n d itio n in g H V A C M - H e a te r - V e n t- A ir C o n d itio n in g M o d u le H V M - H e a te r - V e n t- M o d u le SAE - S o c ie ty o f A u to m o tiv e E n g in e e rs SI - S ystem In t e r n a t io n a l S o l. - S o le n o id R - R e s is ta n c e R-4 - R a d ia l F o u r C y l. A /C C o m p re s s o r RF - R ig h t F ro n t RPM - R e v o lu tio n s P e r M in u te RR - R ig h t R e a r RTV - Room T e m p e r a tu r e V u lc a n iz in g (S e a le r ) RVR - R esponse V a c u u m R e d u c e r R W D - R e a r W h e e l D riv e EFE - E a rly F u e l E v a p o r a tio n EFI - E le c tro n ic F u e l In je c tio n EGR - E x h a u s t G a s R e c ir c u la tio n ELC - E le c tro n ic Level C o n tr o l EMF - E le c tro m o tiv e Force EMR - E le c tro n ic M o d u le R e ta rd EOS - E x h a u s t O x y g e n S e n s o r ESC - E le c tro n ic S p a rk C o n tr o l EST - E le c tro n ic S p a rk T im in g ETC - E le c tro n ic T e m p e r a tu r e C o n tr o l ETCC - E le c tro n ic T o u ch C o m fo r t C o n tr o l ETR - E le c t r o n ic a lly T u n e d R e c e iv e r E xh . - E x h a u s t PAIR - P ulse A ir In je c tio n R e a c tio n System P/B - P o w e r B ra k e s PCV - P o s itiv e C r a n k c a s e V e n t ila t io n PECV - P o w e r E n ric h m e n t C o n tr o l V a lv e P /N - P a rk , N e u tr a l P R O M - P r o g r a m m a b le , R e a d O n ly M e m o ry P/S - P o w e r S te e r in g PSI - P o u n d s P er S q u a r e In ch Pt. - P in t PTO - P o w e r T a k e o ff Q t. - Q u a r t O H C - O v e rh e a d C am O L - O p e n Loo p OXY - O xyg e n

B A R O - B a ro m e tric A b s o lu te P re ssure S e n sor B a t. - B a tte r y B a t. + - P o s itiv e T e r m in a l B b l. - B a r r e l B H P - B ra k e H o rs e p o w e r BP - B a c k P re ssure BTD C - B e fo re T o p D e a d C e n te r

M A T - M a n if o ld A ir T e m p e r a tu r e S e n sor VIR - V a lv e s in R e c e iv e r E AC - E le c tric A ir C o n tr o l V a lv e EAS - E le c tric A ir S w itc h in g V a lv e ECC - E le c tro n ic C o m fo rt C o n tro l E C M - E le c tro n ic C o n tr o l M o d u le ECS - E m issio n C o n trp l S ystem EC U - E n g in e C a lib r a t io n U n it EEC - E v a p o r a tiv e E m issio n C o n tro l EEVIR - E v a p o r a to r E q u a liz e d V a lv e s in R e c e iv e r

Fig. OA-16 Common Abbreviations

GENERAL INFORM ATIO N

OA-15

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O A -16

GENERAL INFORMATION

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GENERAL INFORMATION

OA-17

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O A -18

GENERAL INFORMATION

THIS PAGE LEFT BLANK INTENTIONALLY

GENERAL INFORM ATIO N

OA-19

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0A-2Q

GENERAL INFORMATION

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GENERAL INFORMATION

OA-21

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QA-22

GENERAL INFORMATION

GM PRODUCTION OPTIONS
. . . Glass D ee p T in t (Rr. W d o .) A B 3 . . . S e a tin g A r r a n g e m e n t , Six Passenger A B 5 . . . Lock S. Dr. Elec. (Key A c t iv a t e d ) . . W i n d o w Rr. In s e rt AB6 A B 7 . . . W i n d o w L o u v e re d Q u a rte r A B 8 . . W i n d o w Rear Q u a rt e r Form al S ty le AC1 . . . S eat Adj. 6 w a y Pw r. Pass. AC 2 . . . G la ss-Slid in g W i n d o w , R ig ht F ront D oor . S eat A dj-6 W a y P o w e r, AC 3 Bkt. Sea t T y pe D r iv e r A C 6 . . . St. A dj-6 W a y P o w e r, B u c k e t- P a s s e n g e r A D 2 . . P rop -H old Open, Rear C o m p a r t m e n t Flo or A D 3 . . G la ss-H inge d, R oo f W in d o w A D 5 . . G la ss-S ide, W i n d o w , Rear Slidin g A D 7 . . W i n d o w Rear Q u a rte r Te ar D rop Less Lo u v e rs A D 8 . . . D oo r Check Rear ADS . . . Seat Adj. 2 W a y P o w e r D riv e r AE1 . . . . Glass R oof Panel, R em ov able AE2 . . . Glass R oof Panel, R em ov able, w / M l d g . & Ma n. GIs. AF2 . . Glass, Fixed Sid e-LH ( U tility Bod y) AF3 . . . Glass, Fixed Side-RH ( U tility Body) AF4 . A d j u s t e r 6 W a y M a n. Dr. & Pass. AF5 . . . . Sea t A S M - Easy E n tr y Pass AF6 . . Seat Asm., Fron t B e n ch , 2 Pass. AF7 . . Seat Asm., Frt B e n c h , S p lit Back, w / C t r . A /R s t., 2 Pass. AF9 . . . S ea t Asm., R eclin in g B u c k e t, Pass & Dr. AG1 . Sea t Adj. - 6 W a y Pw r., Dr 0n ly /6 0 -4 0 AG2 . . Seat Adj. - 6 W a y Pw r., Pass.,'60-40 A G 3 . . Seat Adj. - 6 W a y P o w e r 2 Posn. M e m o r y . Sea t Adj. 2 W a y AG 6 M a n u a l Pass AG7 . . . S eat Ad) 6 W a y Pw r., D riv ers/50-5 0 AG8 . Seat Adj. 2 W a y M a n u a l D riv e r A H 4 . . . Sea t Asm . - - Easy E n try D riv e r A H 5 . . Seat A s m . - - Easy E n try Pass. AA3 Glass Bk. Dr. C o m m e rc ia l B o d y A H 7 . . . Glass Frt. W d o . C o m m e rc ia l B o d y A H 8 . . . Glass Si. A c c e s s LH Dr. C o m m e rc ia l B o d y A H 9 . . . Glass Si. A c c e s s RH Dr. C o m m e rc ia l B o d y AJ1 . . . . Glass One W a y AJ2 . . . . Seat Asm. Jum p A J 4 . . . . S ea t B e lt G u id e L o op (E xp o rt) A J 8 . . . . C e n te r Frt. St. A s m . T r a v e l Bed A J 9 . . . . C e n te r Rr. St. A s m . T ra v e l Bed AK1 . . . . B e lts F ro n t Ctr., R /S e a t & Frt. Shldr., Dlx. AL4 . . . . Rear B u c k e t S w iv e l S ea t A M 6 . . . S ea t A s m . Frt. St. S p lit 6 0 /40 w / C t r . A r m R es t A M 7 . . . Seat A s se m b ly Rear Fold ing A M 8 . . . S ea t A s s e m b l y Rear F o ld ing A u x il ia r y A M 9 . . . S e a t A s m . Rr. S e a t S p lit Bac k F o ld ing AN1 . . . S e a t A s s e m b l y B e n c h , F o ld ing Rear A N 5 . . . S e a t A s m . Frt. S p lit 4 0 /40 w / P a s s . Reel. A N 6 . . . S e a t Bk. A d j. Driv. S id e A N 7 . . . S e a t A s m . Frt. B k t. S w iv e l A 0 2 . . . T in t e d W i n d s h i e l d (E x p o rt) A P 7 . . . . P a r t it io n S lid in g /P lyw o o d /U n io n C ity B o d y AQ 3 . . . S e a t C e n te r R ear AQ4 . . . S e a t Rear AQ 9 . . . S e a t Frt. B k t. w / P a s s . Reel. AR3 . . . . A ir Cush. R e s t r a i n t AR4 . . . . R e s tr a i n t Sys. S e a t B e lt & S h ld r H a r n e s s AR5 . . . . S ea t Frt. B k t. w / R e c I AR6 . . . . F r o n t S ea t R e s t r a i n t (E x p o rt) AR7 . . . . S ea t A s m B u c k e t A R 9 . . . . Sea t Frt. B k t. w /R e c l. AS 1 . . . . S ea t A s m . H ig h Bac k B u c k e t D riv e r A S2 . . . . S e a t A s m . H ig h Back B u c k e t Pass. A S 3 . . . . S e a t Rear A S 5 . . . . Sea t A s m ., Frt. B u c k e t D e lu xe AS7 . . . . S e a t Frt. S p lit 45/45 A S8 . . . B e lts F /S e a t & Shldr. w /R e tra cto r AT5 . . . . S ea t A s m . Sub. Ctr. Fldg. AT6 . . . . S ea t Back R e c lin in g , Passenger M anual A T8 . . . . S e a t F /S p lit 50/5 0 w /R e c l. A U 2 . . . Lock C arg o D o o r AH6 .. . . . Lock S id e D o o r E le c tric AU 4 . . . Lock S id e Dr. A u t o E le c tric A U 5 . . . Lock Ele ct. F/S t Back & D o o r A U 6 . . . Lock T a ilg a t e / E le c tric A V 2 . . . . C a m p e r H o ld D o w n Packa ge A V 3 . . . . F a s te n e r, Carg o Tie D o w n A V 5 . . . . S ea t H ig h Back B u c k e t A V7 . . . . Sea t Frt. S p lit 50/50 A V 9 . . . . S e a tin g R e q u ir e m e n t s ( E x p o rt) (Ja pa n) A W 4 . . . Link Si R/D Ext A W 5 . . . S e a tin g R e q u ir e m e n t s E x p o rt R e lo c a tio n A W 9 . . . S e c u r i ty G ro u p Qtr. S t o w & Lug. C om pt. A X3 . . . . Key Less E n tr y S y s te m A X4 . . B e lts S e a t & Frt. Shldr. Harn. E x p o rt A X 5 . . . . P a r t itio n E xp a n d e d M e t a l D r iv e rs Side A X 6 . . . . P a r t itio n E x p a n d e d M e t a l w / R H Sldg. Dr. A X7 . . . . P a r t itio n E x p a n d e d M e t a l w / C t r . Sldg. Dr. AX 8 . . . . Sea t A m . Bkt. P e d e s ta l w / S t . B e l ts D r iv e r A X 9 . . . . La tch Rr Cargo Dr. AY9 . . . . Sea t A dj. 6 W a y Pw r. S p lit St. A01 . . . . T in te d G la ss All W i n d o w s A02 . . . . T in te d G la ss W / S S h a d e d U pr. A07 . . . . B o d y Glass A08 . . . . B o d y Glass R ig h t Sid e A12 . . . . Glass B a c k D o o r A 13 . . . . Glass S id e D o o r Fixed A17 . . . . Glass LH S w in g Out A18 . . . D o o r Glass S w in g O u t-R e a r A 19 . . . . Glass S w in g O ut s id e Rear D o o r A 20 . . . . W i n d o w S w in g Out Rear Q u a rt e r A26 . . . . U n it e d K in g d o m & E u ro p e a n Glazing A28 . . . . W i n d o w S lid in g Rr. A31 . . . . W i n d o w E le ctrica l C o n tro l A32 . . . . W i n d o w P o w e r O p e ra te d Frt. D o o r A33 . . . . W i n d o w T a ilg a te E le c tric a l C o n tro l A 40 . . . . W i n d o w P o w e r O p e ra te d Rr V e n t A42 . . . . S ea t A dj. 6 W a y P o w e r A44 . . . Seat A dj. 2 W a y M a n. B k t S eat A51 . . . . S e a t Frt. B k t. A52 . . . . S e a t Frt. B e n c h AU3

GENERAL INFORM ATIO N

OA-23

GM PRODUCTION OPTIONS
A57 . . S eat A s m . A u x . Pass. A58 . . . B e lts Frt. S e a t & S h o u l d e r w /R e tra cto r A 65 . . . Seat Back Frt. S ea t S p lit W i t h Ctr. A r m Rest A 7 0 . . . Rear Qtr. V e n t W d o . R e m o te C o n tr o l . . Cush. & Bk. Spr. Hvy. A75 D u ty Frt. St. A76 . . . Cush. & Bk. S p r Hvy. D u ty R /S e a t A77 . . . A u t o S ea t B e lt R es tr. S y s te m (3 P oint) A78 . . . . Sea t Back R ee l/P a ss . & D riv e r Man. A79 . . . . Seat B ack R e e l/D r iv e r M a n. A80 . . . S eat Back Reel. D riv e r/E le c. A81 . . . Sea t Back Reel. Pass/Elec. A 90 . . . . Lock RR C o m p t. Lid Rem. Cont. Elec. A91 . . . Pull D o w n Rr C o m p t Lid A93 . . Lock Q u a rte r S t o w C o m p t. A95 . . . Seat A S M Frt. B k tHi. Bk. Reel, Dr & Pass. A96 . . Lock Lu gg a g e & S pa re Tire Com pt. A 99 . . . . Lock In st. Pnl. C o m p t. . . . F ro n t Sea t S to r a g e C om pt. B B4 . . . In te r. Orna. D o o r T rim Panel M a p P o c k e t B B 5 . . . . In te r Orna. H e a d li n e r / T r u c k B B8 . . . In te r. Orna. D o o r Trim M ld g . B C l . . . . I n te rio r Orna. B r u s h e d A lu m BC2 . . . In te r. Orna. W o o d Grain Inst. C lu s te r I n s e r t BC3 . . . In te r io r Orna. I n s t r u m e n t P a n e l/D e lu x e I n te r io r Orna. Lo ad BC5 . . C om pt. Pnls. C a r p e te d M o ld in g , R o c k e r Pnl. (D e le te ) BD1 . Floor C o v e rin g BF2 . C arp et D e lu x e M a ts S t e p w e l l BF3 . . BF9 . . . In s u la to r & Pad, Fir M a t Filler Rr. Fir Pnl. BG3 . . C arpet W h e e l h o u s e BG7 M a t. R u b b e r Frt. & Rr. BG9 . Pkg. A c o u s tic a l BSl . . In su la tio n Package A c o u s t ic a l BS2 . . In s u la tio n /S p e c ia l BS4 . . In su la to r, Cab Bac k Panel BT1 . . . Police Car Side W i n d o w Rvl. M l d g BV1 . B rig h t & P a in te d BA8 BV2 . . . C o m p t Lid M ld g BV3 . . . I n t e r io r O rn a m e n ta t io n , l/P (Bla ck) BV6 . . . C ylin d er, P a in te d D o o r Lock BV7 . . . . A p p liq u e , Pillar (D e le te ) BV8 . . . . H a n d le Dr. D e lu x e BV9 . . . . M o ld in g Si. D e lu x e B W 1 . . . O r n a m e n t a t io n R ear End E x te r io r B W 2 . . . Exte r. Orna. B o d y S id e M l d g D e lu x e B W 5 . . . Ext. Orna. S im u l a te d Roll Bar M d g . R oo f B W 6 . . . Exte r. Orna. b o d y S id e D e c o r B W 7 . . . Exte r. Pillar A p p liq u e BX1 . . . . E x te rio r O r n a m e n t Frt. End S pe cial BX2 . . . . Exte r. Orna. B o d y S id e W i d e L o w e r M ld g . BX3 . . . . Exter. Orna. W o o d G rain BX4 . . . . Exte r. Orna. B o d y S id e M o ld in g BX 5 . . . . Exte r. Orna. R oof D rip M l d g P a in te d B X6 . . . Exter. Orna. M o ld in g & A p p liq u e M o ld in g B o d y S id e & BX8 . . T /G a t e B X9 . . . O r n a m e n t Frt End Panel & M ld g Hood BY1 . . . Exter. Orna. b o d y E m b le m BY3 . . . H e a d lin e r H a r d b o a r d Foam & P e r f o r a t e d V in yl BY8 . . . E x te r io r Orna M d lg . B 1Q . . Lock - T a i l g a t e / P o w e r B3D . . S c h o o l Bus E q u ip m e n t B 3J . . . D ie s e l E q u ip m e n t Pkg. B3M . D e lu x e S c h o o l Bus B4Q . . S te e r in g C olu m n , Tilt (D e le te ) B4T . . . Glass, E u ro p e a n (D e le te ) B 4 W . . W i n d o w , P o w e r O p e r a te d S p o r ts A p p e a r Pkg. B4X . . B5Q . . E m js s io n S y s t e m Calif. Bac k Up B5T . . . E m iss io n S y s t e m B ac k Up B5Y . . . . C lu s te r Elec. B a c k Up S y s te m B7K . . . . I n je c tio n Elec. Fu el 2 Port, w / o Convr. B7L . . . . In je c tio n Elec. Fuel 8 P o rt, w / o Convr. B 7 M . . . In je c tio n Elec. Fuel 8 P ort, w / o Convr. B02 . . . S pcl B o d y Taxi Cab A r m o r e d V e h ic le B05 M o d i f ic a t i o n s B07 . . . S pe cial B o d y P olic e Car B09 . . . Polic e G roup F r e e w a y E n fo r c e r B 18 . . . . Int. O r n a m e n t D e lu x e B19 . . . Int O r n a m e n t C u s to m In t O r n a m e n t L u x u ry B20 . . B2Z . . . A p p e a r a n c e Pac ka ge B22 . . . In te r. Orna. Dr. Inr. Pnl. E m b le m B23 . . . S po ile r, Rr. W hl. O p e n in g B24 . . . M o ld in g , Si W d o . Rvl. B25 . . . T rim L u g g a g e C o m p t. D e lu xe B26 . . . In te r. Orna. D o o r Pull H a n d le B28 . . . Fir. M a t s Frt. Rr. B29 . . . O r n a m e n t, I n t e r i o r Rr. D o o r H a n d le B30 . . . C a r p e tin g Flo or and W he elhou se B32 . . . M a t F lo o r/F rt. B33 . . . M a t Flo or /Rr. B34 . . . Frt. Fir. M a t s & C a rp e t Insert B35 . . . Rr. Fir. M a t s & C a rp e t I n s e rt B36 . . M a t L u g g a g e C o m p t. B37 . . . M a t F lo o r/F rt. & Rr. B39 . . . . Flo or C o v e rin g Load F lo or C a rp e t B42 . . . . M a t L u g g a g e C o m p t. Fir. Cvr. B44 . . . C a rp e t Load Flo or L o o s e / B46 . . . . Spl T rim B48 . . . T rim L u g g a g e C o m p t. D e lu x e B49 . . . . Flo or Cvgr. C a rp e t Frt. & Rr. D e lu x e B 51 . . . . Exter. Orna. Rkr. Pnl. M ld g . E xtra W id e B53 . . . M a t Frt. Fir. C a r p e te d I n s e r t D e lu x e B54 . . . . M a t Rr. Fir. C a r p e t I n s e rt D e lu x e B56 . . . . Ext Orna. Rkr Pnl. M ld g . Extra W id e (Bla ck) B57 . . . . E x te r io r T rim D e lu x e B65 . . . . Flo or & S id e W a ll C o v e r in g T r u n k C o m p t. B69 . . . I n s u la to r R oof B 71 . . . M ld g . W /O p g . C u s to m B72 . . . M ld g . Bit. Rvl. P a in te d B74 . E xte r. Orna. W h e e l O p e n in g W id e M ld g . (Bla ck) B75 . . . Linin g L u g g a g e C om partm ent B77 . . . M ld g . W / S h i e l d R eveal Exte r. Orna. Rr. End B79 . . B80 . . . M l d g R oo f Drip M o ld in g , B o d y Si ( D e le te ) B81 B82 . . . Em b le m , B o d y ( D e le te ) M l d g . - R k r Pnl. B83 . B84 . M ld g . B o d y S id e Bla ck B85 . . . M ld g B o d y S id e B r ig h t M l d g B o d y Rr B86 . B88 B o d y S id e M l d g C u s to m M ld g . B ac k W i n d o w B89 . . Reveal . M ldg S id e W d o Revl. B90 B91 . . . . M ld g D o o r Edge G uard

OA -24

GENERAL INFORMATION

GM PRODUCTION OPTIONS
B93 B 94 B95 B96 B97 B98 ... .... .... .... .... .. . G uard D o o r Edge E m b le m B o d y L o u v e r B o d y Sid e M ld g . W /O p g . S p o ile r Rr. F e n d e r M ld g . S id e T r im T ru c k M o ld in g , W h l. Opg. ( D e le te ) A lu m M a n ifo ld C25 . . . . W a s h e r & W i p e r RR W in d . C36 . . . . H e a te r A u x ilia r y C40 . . . . H e a te r, S ta n d a rd ( E le c tr o n ic ) C41 . . . . H e a te r & D e f r o s t e r C42 . . . . H e a te r & D e f r o s t e r H e a vy D u ty C43 . . . . S te e l T /G a te C44 . . . . P la stic T /G a te C46 . . . H e a te r H ig h C a p a c ity C47 . . . . Rear W i n d o w D e fo g g e r D e le te C49 . . . . D e fo g g e r Rr. W d o . E le c tric C50 . . . . D e fo g g e r Rr. W d o ., B lo w e r C51 . . . . D e f l e c t o r A ir C55 . . . V e n t il a t o r Roof C56 . . . . V e n tila to r , F o rc ed A ir R ig h t S id e C60 . . . A ir Cond. M a n u a l C o n tro l C61 . . . A ir Cond. A u t o m a t i c C o n tro l C62 . A ir Cond. Frt. In s ta l Fir. M td . C65 . . . A ir Cond. T e m p m a t ic C o n tro l C67 . . . . A ir C o n d itio n in g , A ll W e a t h e r ( E le c tro n ic ) C68 . . . . A ir Cond. E le c tr o n ic C lim ate C o n tro l C69 . . . . A ir C o n d itio n in g /O verhead S y ste m / C71 . . . . Lamp-Frt. Dr. Ctsy. C72 . . . . La mp-Rr. Dr. Ctsy. C73 . . . Lamp, M a n O p e ra te d Int. ( U tility B ody) C80 . . . S w it c h Frt. Dr. J a m b Rt. Side C81 . . . . S w it c h Rear D o o r Jamb C87 . . Lamp Rr. Qtr. C o u r t e s y C88 . . . . Lamp Rear C om pt. C o u r te s y C89 . . . Lamp Sail Panel R ea din g C90 . . . Lamp C om b C o u r t e s y & W a r n in g D oor C91 . . . . Lamp D om e C92 . . . . Lamp D o m e & Cargo C93 . . . . O pera Lamps Ext. Lk. Plr. or Sail Pnl. C94 . Lamp D ela ye d D o m e C95 . . . Lamp A s m D o m e & R eadin g C96 . . . . Q tr Rdg. Lamp C97 . . . D oo r Lock C o u r te s y Ligh t . . . M i r r o r Rem C o n t 0 / S RR V i e w Elec LT Side DD7 . . . M i r r o r Rem C on t 0 / S RR V i e w Elec w / T h e r m DD8 . . . M i r r o r , I/S Rr. V i e w D a y / N ig h t Auto. D D9 . . . M i r r o r 0 / S Rr. V i e w Elec. Rem. E x p o rt DEI . . . . L o u v e r S u n s h ie ld DE7 . . . . M i r r o r 0 / S Rr. V i e w Rem B r e a k w a y E x p o rt DE9 . . . . C o n so le N o n S h iftin g , N o n O p e ra tin g Type D Fl . . . . M i r r o r C a m p e r / P a in te d DF2 . . . . M i r r o r C a m p e r / S t a i n le s s / LH & Rr. Ld. DF3 . . . . M ir. Rem Cont. 0 / S Rr. V i e w Pass Sid e C hro m e DF4 . . . M ir. Rem . Cont. 0 / S Rr. V ie w Pass S id e S p o r t DF5 . . . . M ir. Rem. 0 / S Rr. V i e w Elec. Rt. & Lt. T h e rm . Ulus. DG1 . . . M i r r o r O u ts id e Rr. V i e w / Pass Sid e DG2 . . . M i r Rem . 0 / S Rr. V i e w Elec. Rt. & Lt. DG4 . . . M i r r o r W e s t Coast T y pe S mall DG5 . . M ir. S e n i o r / W e s t C o a s t/ D r iv e r s & Pass. Ld. DG6 . . . M ir. Rem. 0 / S Rr. V ie w Elec. Rt. & Lt. T h e rm . DG7 . . . M i r r o r Rem C ont 0 / S RR V i e w Elec S p o r t DG8 . . . M i r r o r B r e a k a w a y E x p o rt D H6 . . . M i r r o r - V is o r V a n ity -O r. & Pass. D J9 . . . . M i r r o r 0 / S Rr V i e w C u s to m Pass S id e DK2 . . . M i r r o r , 0 / S Rr. V i e w Elec. R e m o te DK4 . . C o n s o le F ro n t Floor C o m p a rtm e n t Non S h iftin g M in i DK7 . . . . Decal, W i n d o w ( D e le te ) DL1 . . . D ecals and S tr ip e s DL2 . . . . D ec als and S tr ip e s DL4 . . . . D ecals T w o T o n e Paint Scheme DL6 . . . D ecal & S tr ip e s DL8 . . . M i r r o r 0 / S Rr. V i e w Elec. Cont. H e a te d E le m e n t DL9 . . Decal, Frt. Fdr & Rr Qtr. B la c k o u t . D01 . . P aint L a cq u e r M a s t e r D02 . . . P aint Enamel M a s t e r D03 . . . Paint, W a t e r M a s t e r D05 . . H an dle , In s id e D06 . . . . R est Frt. Cnsl. A rm D07 . . . . C on so le , Frt Flo or (C u s to m ) D09 . . . R es t Frt. St A r m DT4 . . . . A s h R e c e p ta c le & C ig a r e tt e L ig h te r DX1 . . . Decal H o o d A p p liq u e DD5

B99 . . . B5R . . .

CA1 . . . . R oof S te e l S id in g Sun, E le ctric CA2 . . . . C o v e rin g Ext. S o ft T rim Rf. W /'P ad D e le te CA9 . . . . Cvr. Exter. S o ft T r im R oof W it h Pad Full Top CB4 . . Cvr. Exter. S oft T rim Rr. Half CB5 . . Cvr Exte r. S o ft T rim R oof W i t h Pad Full Top CB6 . . Cvr. E x te r S o ft T rim R oof Halo M ld g . Full Top CB7 . Cvr. Exter. S oft T rim Fron t Half CB8 . . . Top R e m o v a b le CC1 . Panels R e m o v a b le R oof H atc h CC2 . Cvr E x ter S o ft T rim W / P a d Rear Half CC3 . P anels R e m o v a b le H a tc h R oo f Pla stic CD2 . L o w W a s h e r Fluid I n d ic a to r CD4 . W ashe r & W ip e r Pulse W in d s h ie ld CE4 . . . . W a s h e r , H e a d la m p H ig h P r e s s u r e CF4 R oof Glass S li din g S un M a n u a l CF5 A s t r o R oof /S lid in g CF8 R oof Vin yl S im u la te d C o n v e rt ib le CGI . N a r r o w B o d y Lock Pillar CHI C o m p r e s s o r A x ia l 6 Cyl. CH2 . C o m p r e s s o r Radial 4 Cyl. C01 . Ext. O ma. Tu rb o Frt. End Pnl C 04 . . . Cvr. Exter. S o ft T rim vVith Fad Rear Half C 0 5 . . . Top C o n v e r t i b l e Fol di ng C 0 6 . . RF A s t r o V i e w & S i m u l a t e d Roll Bar RF M l d g C 0 9 . . Cvr. Exter. Sof t Tr i m Roof Full Top C10 Roof Vi nyl P ad de d Speci al Landau C18 . . . . W Shi el d W i p e r & Bl ade Black C21 . . . W Shi el d W i p e r & Bl ade Pai nt e d

DB2 DB3 DD3 DD4

. . A r m R est D e le te . . . S u n s h a d e , W / S , w E x te n s io n . . . M i r r o r O u ts id e R / V ie w C u s to m C hro m e . . M i r r o r Rem C on t 0 / S RR V ie w Elec RT Sid e

GENERAL INFORM ATIO N

0A -25

GM PRODUCTION OPTIONS
S tr ip e B o d y Si F r e e s p ir it S tr ip e , B o d y S id e / B u i c k S t r ip e - B o d y S id e / C h e v y S tr ip e B o d y S id e /3 M u lt i - T o n e DX9 . . . . T ape A c c e n t S tr ip DY1 . . . . D ecals an d S t r ip e s DY5 . . . . D ecals and S t r ip e s (D e c k Lid) D 12 . . . . S h e lf & Rr. C o m p t. W / H T r im Pkg. D20 . . . . S u n s h a d e Pass. Si. D24 . . . . C o n ta in e r L i t t e r D26 . . . . T ray S t o w a g e on Spare Tire 02 7 . . . . Rr. Com p. S t o w a g e Cvr. D28 . . . . M i r r o r s O u ts id e RR V i e w D e le te D29 . . . . M i r r o r B e l o w E y e lin e / J u n io r/P a in te d D31 . . . . M i r r o r I/S Rr. V i e w / Tit. D33 . . . . M i r r o r R e m o te C o n t O u ts id e Rr. V i e w LH D34 . . . . M i r r o r V is o r V a n it y D35 . . . . M i r r o r O u ts id e Rr. V i e w / C u s to m 0 3 6 . . . . M i r r o r In s id e R ear V i e w (1 0 " Tilt) ( E x p o rt) 041 . . . . A s h Tray R ea r Q u a rt e r D 4 2 ____Cover Rr. C o m p t S e c u r i t y D43 . . . . M i r r o r In s id e R ea r V i e w (1 2 " Tilt) (E x p o rt) 04 4 . . . . M i r r o r - B e l o w E y eline O u t s id e / P a in t e d D45 . . . . M i r r o r - B e l o w E y eline O u ts id e /S tn ls . Stl. D46 . . . . M i r r o r w / C le a r a n c e L ig h ts W e s t C oa st T y p e D49 . . . . M i r r o r - O u t s id e 05 0 . . . . C on so le Frt. C o m p t. ( D e le te ) D53 . . . . A p p liq u e - H o o d (B ir d ) D55 . . . . C o n s o le Frt. C o m p t. Fir. D57 . . . . P aint S pe cial T w o T o n e D58 . . . . C on so le Frt. C o m p t. Fir. E xtra Lo ng D64 . . . . M i r r o r V is o r V a n ity , Illu m in a te d Rt. S id e D65 . . . . M i r r o r O u ts id e Rr. V i e w / w i t h T h e rm . Lt. Si. 06 6 . . . . M i r r o r 0 / S R / V i e w / w i t h Ilium. T h e r m o . Lt. Si. D68 . . . . M i r r o r Rem. C on t. 0 / S Rr. V i e w D r iv e r s & Pass. (S p o rt) D69 . . . . M i r r o r O u ts id e Rr. V i e w R e m o te D r iv e r s S id e 0 7 3 . . . . Rail H a n d /P ic k - U p B o x 07 4 . . . . M i r r o r V is o r V a n ity , Illu m in a te d Lt. S id e 0 7 5 . . . . Front A ir D e f l e c t o r D78 . . . . M i r r o r 0 / S Rr. V i e w W i d e A n g le Dual S y s t e m D80 . . . . S po ile r D e c k Lid D84 . . . . Paint C u s to m T w o - T o n e DX4 D X5 D X5 DX6 .... .... .... .... 08 5 . . . . S t r ip e B o d y S id e Lw r. Accent D86 . . . . P a in t T w o T o n e D e s ig n e r s A c c e n t 08 8 . . . . D ec al S tr ip e H o o d and D e c k Lid D89 . . . . P a in t T w o T o n e S p e c ia l Decor D90 . . . . S tr ip e , Frt. End & B o d y S id e D91 . . . . P a in t S p e c ia l T w o - T o n e D92 . . . . T a p e D e c o r . / a t Frt. Dr. H a n d le D 9 3 ____ P a in t Dr. & W d o . Frm s D98 . . . . S t r ip e T ape D99 . . . . P a in t T w o - T o n e S p e cia l O rder E76 . . . . D o o r s Rr. 60 In ch E79 . . . . D o o r s Rr. S tra p H in g e s 74 in ch E81 . . . . F lo o r B o a r d E q u ip m e n t W ood E82 . . . . S te e l D e c k Lid E83 . . . . A l u m i n u m D e c k Lid E86 . . . . C o v e r T o n n e a u Carg o B o x /S n a p - O n E89 . . . . Pan el Cab D r iv e r Dr.

Opg
9 4 . . . . B e a u v ille Equip. (Chev.) or Rally Stx . Equip . (G M C )

E24 . . . . D o o r s , H in g e d Cargo S id e E26 . . . . D o o r, LH S id e A c c e s s ( U t il it y B o d y) E27 . . . . D o o r, RH S id e A c c e s s ( U t i l i t y B od y) E28 . . . . H a n d le A s s i s t E31 . . . . B o d y S t e e l/ 1 0 F t./H i-C u b e Van E32 . . . . B o d y S t e e l/ S q u a r e / F / C P an el E33 . . . . B o d y A lu m i n u m / S q u a r e / F/C Pan el E34 . . . . B o d y S t e e l/ 1 0 F t./H i-C u b e Van E35 . . . . B o d y S t e e l/ 1 2 F t./H i-C u b e Van E35 . . . . P ic k u p B ox, Less T a ilg a te ( F le e ts id e ) (1984) E36 . . . . B o d y A lu m i n u m / 1 0 Ft./ H i-C u b e Van E37 . . . . B o d y A lu m i n u m / 1 2 Ft./ H i- C u b e Van E38 . . . . B o d y - S te e l/ 1 2 F t./H i-C u b e Van E39 . . . . B o d y A lu m i n u m / 1 2 Ft./ H i-C u b e Van E46 . . . . D o o r w /G ls . Trk. B o d y O v e r h e a d Rr. 66 in ch E50 . . . . Bar Roll E52 . . . . D o o r s Rr. W r a p a r o u n d 83 in ch E53 . . . D o o r s Rr. W r a p a r o u n d 87 inch E55 . . . . End G ate S u b u rb a n E56 . . . . P la tfo r m & S k a te Rack E62 . . . . P ic k u p B o x S te p s id e E63 . . . . P ic k u p B o x F le e ts id e E65 . . . . B o d y H e ig h t, In c r e a s e d E67 . . . . B o d y L e n g th , 12 In. In c re a s e E70 . . . . H o u s in g W h l For Dual Rr W h l s . E71 . . . . F lo o r Cargo S m o o t h STL E72 . . . . B o d y L e n g th , 18 In. In c re a s e E73 . . . . B o d y W i d t h In c r e a s e d In t. (86 4 In.) E74 . . . . B o d y W i d t h I n c re a s e d In t. (90.5 In.)

FE1 . . . . Rally S u s p . Pkg. FE2 . . . Rally S u s p e n s io n Packa ge FE3 . . . . S u s p e n s io n S y s t e m S pe cial, Less Sta b. Shf. FE5 . . . . S u s p e n s io n , Spl. Perf. Frt. & Rr. ( D e le te ) FE7 . . . . S u s p e n s io n Frt. and Rr., H.D., Var. 3 FG2 . . . . S h o c k A b s . Frt. & Rr. Firm Ride FK2 . . . . A n c h o r T o r s io n B a r Rr. 57 D e g r e e FK3 . . . . A n c h o r T o r s io n B a r Rr. 63 D e g r e e FL2 . . . . A x le F r o n t Dana FL3 . . . . A x le F r o n t C h e v r o l e t F16 . . . . A x le F ro n t/2 .5 3 Ratio F W 2 . . . A x le F ro n t 3.06 Ratio F W 3 . . . A x le F r o n t/2 .3 3 Ratio F W 4 . . . A x le F r o n t/3 .3 6 Ratio F W 5 . . . A x le F r o n t/4 .1 0 Ratio F W 6 . . . A x le F ro n t/2 .1 4 Ratio F W 7 . . . A x le F ro n t/3 .8 3 R atio F W 8 . . . A x le F r o n t 1.99 Ratio F W 9 . . . A x le F r o n t 3.43 R atio FX2 . . . . A x le F r o n t 2.66 R atio F01 . . . . Fram e H.D. F16 . . . . A x le F r o n t 2.53 Ratio F17 . . . . A x le F ro n t/2 .8 4 Ratio F25 . . . . A x le F r o n t/3 .3 4 Ratio F29 . . . . A x le Frt./2.41 Ratio F36 . . . . A x le Frt./2.1 9 Ratio F40 . . . . S u s p e n s io n H e a v y D u ty F r o n t & Rear F41 . . . . S u s p e n s io n S p e cia l P e r f o r m a n c e Frt. & rr. F42 . . . . S u s p e n s io n H e a v y D u t y Frt. F44 . . . . C h a ss is E q u ip m e n t H e a vy D u ty F45 . . . . A x le F rt.2.93 Ratio F47 . . . . A x le F r o n t/2 .7 3 R a tio F51 . . . . A b s o r b e r H e a v y D u t y Shock F57 . . . . A x le F r o n t/3 .1 5 Ratio F58 . . . . S ta b iliz e r S h a ft F r o n t/ Heavy D uty F59 . . . . S ta b iliz e r Frt. F60 . . . . S p rin g H e a vy F r o n t on Var. 1

OA-26

GENERAL INFORMATION

GM PRODUCTION OPTIONS
F61 F62 F65 F66 . . . .... .... .... S h a ft Sta b. Rr. A x le F r o n t/2 .39 Ratio S u s p e n s io n Frt. A ir S u s p e n s io n (H.D. Frt. A ir Susp.) A x le F ro n t/3 .1 9 Ratio A x le F ro n t/3 .4 5 Ratio S p rin g w / S h k . A b s . H.D. Var. 1 S p rin g w / S h k . A bs . H.D. - Var. 2 A x le F ro n t 3.18 Ratio A xle F ro n t/3 .1 8 R atio A xle F ron t/2 .97 R atio S ta b iliz e r S h a ft F r o n t / H ea vy D u ty Panel Cab D r iv e r s D o o r O pe nin g A x le F ro n t/2 .7 3 Ratio G75 G80 G83 G87 G88 G89 G92 G95 . . . .. .. .. .. .. .. .. .. .. .. . .. .. A xle A x le Ring Ring Ring Ring A x le A x le -- Rea r/3.6 2 Ratio - - R e a r/L o c k in g T y pe Gear (8 3 /i) Gear (8 V 2") Gea r (87/ s ) C 5ear (71/ 2") - - R ea r/P erfo rm a nce - - R e a r /E c o n o m y JL1 JL2 JL5 JL6 JM 5 .... .. . . .. . . .. .. ... Pads Cus t. Ped. Trim B ra k e Sys. Frt. P w r. Disc B rake F ro n t Solid Disc B ra k e Sys. M a n . Disc P o w e r B ra k e B o o s t e r Tandem P o w e r Brk. B o o s. (Sin gle ) B ra k e R r./D is c B ra k e V a c u u m P o w e r D r u m s B ra k e C ast Iron D r u m s B ra k e A lu m in u m B rak e S y s t e m Vac. Pw r. Brake H e a vy D u ty Pw r. Brake, P w r . Dis c Frt. & Rr. B r a k e s Rr. D ru m Hvy. Dty.

F67 . . . . F68 . . . . F71 . . . . F72 . . . . F75 F77 F79 F85 . . .... .... ....

F89 . . . . F90 . . . .

H A3 HC2 HC4 HC7 HC8 HD1 HE3 HE4 HF7

... . .. . .. . .. . .. . .. . . .. , . .. . . .. . . . .

GH1 . . . A x le Rear/2.2 4 GH2 . . . A x le R e a r/2 .2 9 /R a tio GH4 . . . A x le Rear/2.2 8 R atio GL1 . . . . Diff. C a rrie r Rr. A x le / A lu m . G M 7 . . . A x le R ear/2.3 9 Ratio G M 8 . . . A x le Rear 2.56 Ratio GN1 . . . S ta b iliz e r S h a ft Rear G N 3 . . . D r iv e r C o n tro l L e v e lin g GQ1 . . . A x le Ratio S tu d Rr. GR4 . . . . A x le R ear/3 .7 3 Ratio GS4 . . . . A x le R ear/3.7 0 Ratio GT4 . . . . A x le R e a r/3 .7 3 /R a tio GT5 . . . . A x le Rr./4 10 Ratio GT8 . . . . A x le Rear 4.10 Ratio H eavy D u ty GUX . . . A x le Rear/3.0 8 R atio G U I . . . A x le Rear/2.41 Ratio GU2 . . . A x le Rear/2 .7 3 Ratio GU3 . . . A x le R ear/2.9 3 Ratio GU4 . . A x le R ear/3.0 8 Ratio G U5 . . . A x le Rear/3 .2 3 R atio GU6 . . . A x le Rea r/3.4 2 Ratio GV8 . . A x le R ear/2 72 Ratio GV4 . . . A x le R ear/3 36 R atio G W 4 . A x le Rear 3.31 Ratio G W 9 . . . A x le R ear/2 93 Ratio GX3 . . . A x le F r o n t/3 33 Ratio GX4 . . . . A x le Rear/3 .7 5 Ratio GX5 . . . . A x le R ear/4 09 R atio GX9 . . . . A xle Rear/2 92 Ratio GY5 . . . A x le F ro n t/3 .6 5 R atio G 50 . . S pring H evy Rr Var. 1 G51 . . S pring S pe cial H e a vy Rr. Var. 2 G52 . . . S pring Extra C a p a c ity Rr. G60 . . . S pring A u x ilia ry G66 . . . S h o c k Abs. A ir B o o s t e r Rr. G67 . . . . S h o c k Abs. A u t o Lvlg. Cont. Sys. (1977 & Prio r) G67 . . . S h o c k Abs. Elec Lvlg C o n t Sys (1978) G72 . . . Rear A xle (2.14:1)

HF8 . . . HK1 . . .. HK9 . . . H04 . . . H22 . . . H23 . . . .

A x le - A x le - A x le - A x le - A x le - A xle - A x le - A xle - A x le - Heavy A x le - A x le - A x le - A x le - A x le - A x le - -

Rear/5 .2 9 Rear/2.7 6 R ear/4.5 6 Rear/5 .1 3 Rear/3.21 Rea r/5.8 3 Rear/3.07 Rear/3 .4 0 Rea r/4.5 6 D u ty Rea r/4.8 8 Rea r/2.8 7 Rear 5 R e a r/4 .1 1 Rear/6.1 7 Rear/5.4 3

Ratio Ratio R atio Ratio Ratio Ratio R atio Ratio R a tio / R atio R atio 86 R atio Ratio R atio Ratio

JM 7 . . . JM 8 . . . J50 . . . . J41 . . . . J4 2 . . . . J5 0 .. . . J 55 . . . . J 65 . . . J 90 . . .

. . . B rake S y s t e m / D i s c / D r u m Lt. D u ty 11x 1 Frt. 9 ' / 2 x 2 Rr. J A 2 . . . . Brake S y s te m D is c / D r u m Heavy D u ty J A 3 . . . . Brake S y s te m D is c / D r u m 12x 1 Frt. 1 1x2 Rr. J A 4 . . . . B r a k e - D is c / D r u m J A 5 . . . . B r a k e - D is c / D r u m 12x1 Frt. 11x2 Rr. J A 6 . . . . 4 W h e e l Dis c J A 8 . . . . B rake S y s t e m D is c / D r u m M e d . D u ty J B 1 . . . B rake M a n. D is c / D r u m J B 2 . . . B r a k e - D is c / D r u m J B 3 . . . . B rake V a c u u m P o w e r D is c / D r u m / T y p e A J B 5 . . . Brake V a c u u m P o w e r D is c /D r u m T y pe B J B 6 . . . Brake V a c u u m P o w e r D is c / D r u m / T y p e C J B 7 . . . . Brake V a c u u m P o w e r D is c / D r u m / T y p e D J B 8 . . . Brake H y d ra u lic Pw r. D is c / D r u m / T y p e A JC4 . . . Brake F r o n t V e n t e d R o to r J D 3 . . . B rake V a c u u m P o w e r D is c /D r u m JD5 . . Brake S y s te m 11x 1 Pw r. Disc J D 6 . . Brake S y s te m 12x1 P w r Disc J D 7 . . . Brake S y s te m 12x1 P w r. D is c /H v y . D u ty J E 1 . . . Brake S y s te m (E u ro p e ) JF9 . . Brake H y d r a u lic P o w e r 4 W h e e l Disc

JA1

V a c u u m S y s t e m Cam D r iv e n V a c u u m S y s t e m Belt KA6 . . D r iv e n . Exhaust M a nifold Sheet KB1 . M e tal KB3 . . . W a t e r P u m p A lu m i n u m KB7 . . . Head C ast Iron K B 8 . . . Head A l u m i n u m KC4 . . . C o o le r E ng in e Oil KD2 . . . P u m p Fuel In je c tio n ( S ta n a d y n e ) P u m p Fuel In je c tio n KD3 . . (C.A.V.) K E 1 . . . E le c tr o n ic S park S e l e c tio n KF3 . . . . E le c tr o n ic Fuel In je c tio n K J 5 . . . . S ta rter M o to r Japanese E x p o rt KL7 . . . LP Gas P r e p a r a tio n K M 5 . . G lo w S y s t e m - S l o w S ta r t K M 6 . . . G lo w S y s te m - F a s t S ta r t K M 7 . . . Cast Ir o n In ta k e M a n ifo ld K M 9 . . Al. In ta k e M a n i fo l d K 0 2 . . . . Fan D riv e T h e r m o s t a t ic a l ly C o n t r o ll e d K 0 5 . . . . H e a te r E ng in e B lo c k / C an adian U se Only K 0 7 . . . . H e a te r D ie s e l Fuel K 15 . . . Line Fuel V a p o r R e tu rn K19 . . . A ir I n je c t io n S y s t e m K22 . . . D e lc o t r o n 94 A m p . K30 . . . C o n tro l S p e e d & C ruis e (A uto) K34 . . . C o n tr o l S p e e d & C ruis e w / R e s u m e E le c tro n ic ) K35 . . . C o n tro l S p e e d & C ruis e w /R e s u m e K43 . . . A ir C le a n e r - - H e a v y D u ty D ry T y p e K46 . . C le a n e r A ir Pre C ha m be K64 . D e lc o t r o n 78 A m p . K70 . . P ulsa ir A ir Inj. Eng K71 . . . E m is s io n C o n tr o l N o t C e r tifie d E x p o rt K73 . . G en e ra to r/7 0 Amp. K74 . . Early Fu el E v a p o r a tio n K76 . . G e n e r a t o r AC /6 1 A m p K A5 . .

GENERAL INFORMATION

OA-27

GM PRODUCTION OPTIONS
K77 K79 K80 K81 K85 K92 K97 K99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G enerator G e n e ra t o r D e lc o t ro n G enerator D e lc o t r o n G e n e ra t o r G e n e ra t o r G enerator A C /5 5 A m p. A C /4 2 A m p . 92 A m p . A C /6 3 A m p . 37 A m p . A C /1 0 5 A m p 80 A m p . A C /8 5 A m p . E ng in e L4 151 2 Bbl. E ngin e L4/151 2 Bbl. E ng in e V8/350 CID/4 Bbl. E ngin e P e r f o r m a n c e Pkg. H ig h Alt. LT6 . . . . E ng in e V6 4.3V Die sel LT7 . . . . E ngin e V6 4.3T Die sel LT8 . . . . E ng in e V8 4.1L LT9 . . . . E ng in e V8/350 4 Bbl./Trk. LU5 . . . . E ngin e V8 5.0-7 LV2 . . . . E ng in e V8/307 CID 4 Bbl. Carb. LV5 . . . . E ngin e L4/151 CID /2 Bbl. Carb. LV6 . . . . E ngin e V8/4.3 2 Bbl. LV8 . . . . E ngin e V8/260 CID/2 Bbl. Carb. L W 5 . . . E ngin e L4 1.6 1 Bbl. L W 9 . . . E ngin e L4/151 CID/2 Bbl. Carb. LX3 . . . . Engin e L4 1 4 Litre/1 Bbl. LX6 . . . . Eng. 151 2 Bbl. Carb. LX8 . . . . Engin e L4/151 2 Bbl. LY5 . . . . E n g in e /L 4 /1 6 Litre/1 Bbl. L02 . . . . D e lc o t r o n 100 A m p . L03 . . . . D e lc o t r o n 110 A m p . L04 . . . . D e lc o t r o n 145 Am p . L05 . . . . D e lc o t r o n 130 A m p. L07 . . . . Dele. 145 Am p ., D y n a m o t e P w r. I n v e rt e d LI 1 . . . . Engin e 140 CID L4 OHC 2 Bbl. Carb. L13 . . . . E ngin e 140 1 Bl. Carb. L17 . . . . E ngin e L4 1.6L L22 . . . . Engin e L6/250 Cl D /P ass. L25 . . . . E ngin e L6/292 CID L26 . . . . E ngin e V6 200 2 Bbl. L27 . . . . Engin e V8 301 2 Bbl. Carb. L32 . . . . Engin e V8 350 2 Bbl. L33 . . . Engin e V8/425 4 Bbl. L34 . . . . Engin e - V8 350 4 Bbl. Carb. L35 . . . . Engin e 8 Cyl., E.F.I 425 L37 . . . . Engin e V8 301 4 Bbl. L39 . . . . Engin e V8/267 2 Bbl. L46 . . . . Engin e L4 1.8G L48 . . . . E ngin e V 8 /3 5 0 C ID /4 Bbl. Carb. L49 . . . . Engin e 8 Cyl., E.F.I. 350 L61 . . . . Engin e V8 368-6 L62 . . . . E ngin e V8 368-9 L65 . . . . Engin e V8 350 2 Bbl. L69 . . . . Engin e V8 5.0L L76 . . . . Engin e 350 4 Bbl. Carb. I l l . . . . E ngin e V8 350 4 M L78 . . . . E ngin e 400 4 Bbl. Carb L80 . . . . Engin e V8 403 4 Bbl. Carb L82 . . . . Engin e V 8/350 C ID /S pe c. Hig h Perf. L83 . . . . E ngin e V8 5.7-8 L91 . . . . E x p o rt Engin e L92 . . . . E x p o rt Engin e L93 . . . . E x p o rt E n g in e /V e n e z u a la LS5 LS8 LS9 LT5 .... .... .... .... M B 4 . . . Trans. 5 Spd. M a n u a l 3.76:1 1st G ear R atio M B 6 . . . Trans. 5 Spd. M a n u a l M C I . . . T r a n s m is s io n H e a v y D uty/3 S p d ./M a n u a l/ Tra m a c M C 4 . . . T r a n s m is s io n S p o r t S h ift M D 2 . . . Trans. 3 Spd. A u t o m a t i c / S tr a s b o u r g M D 3 . . . Tran s. A u t o m a t i c / S tr a s b o u r g A T 180 M D 8 . . . Trans. 4 Spd. A u t o . 700 R4 M D 9 . . . Trans. 3 Spd. A u t o . TH 125C M E 9 . . . Trans. 4 Spd. A u t o 440 T4 MG1. . . . B lo c k Trans. L o w G ear M K 2 . . . Tran s. 4 Spd. M a n u a l 2.88:1 1st Gear M K 4 . . . Trans. 5 Spd. M a n u a l M K 5 . . . Tran s. 5 Spd, M a n u a l 3.50:1 1st Gea r M K 6 . . . Trans. 5 Spd. M a n u a l 2.90:1 1st G ear M K 7 . . . Tran s. 5 Spd. M a n u a l M M 3 . . . T ran s. 3 Spd. M a n u a l M e r c h a n d is in g O p tio n Only M M 4 . . . Tran s. 4 S p e e d M a n u a l M e r c h a n d is in g O p tio n Only M M 5 . . . Tran s. 5 Spd. M a n u a l M e r c h a n d is in g O p tio n Only M M 7 . . . Tran s. 4 Spd. M a n u a l M e r c h a n d is in g O p tio n Only M V 4 . . . Trans. 3 S p e e d A u t o m a t i c / C he vy B u i l t / T H M 350 M V 9 . . . Trans. 3 S p e e d A u t o m a t i c (T H M 200C) M W 9 . . Tran s. 4 Spd. A u t o . TH 200 4R M X 0 . . . Tran s. 4 Spd. A u t o . M e r c h a n d is in g O p tio n Only M X ! . . . Trans. 3 Spd. A u t o . M e r c h a n d is in g O p tio n Only M X 2 . . . Trans. 3 Spd. A u t o . M X 3 . . . Trans. 3 Spd. A u t o . TH 350 C M X 5 . . . Trans. A u t o . TH 350C MY1 . . . T ran s 4 S p e e d B ra z il/ Manual M Y 6 . . . Trans. 4 S p e e d M a n u a l O v e rd r iv e 3.09:1 1st Gear M Y 7 . . . Trans. 5 Spd. M a n u a l 3.92:1 1st Gea r M Y 8 . . . Trans. 4 Spd. M a n u a l 3.53:1 1st G ear M 0 8 . . . Trans. 4 Spd. M a n u a l 3.76:1 1st G ear M i l . . . Shift Flo or M 15 . . T r a n s m is s io n T h re e Speed M anual M 1 6 . . T ra n s m is s io n T h re e Speed Auto.

E ngin e L4 1.8L Engin e V6 2.8-1 Engin e V 6 229 CID Engine V6/4.1-4 4 Bbl. Engin e - V6 231 2 Bbl. Engine V6 231 2 Bbl. Engine V 6 231 4 Bbl. Engine V6 196 2 Bbl. Engine S ta n d a rd 6 Cyl. 250 CID T ru c k LD5 . . . . Engin e V6 231 2 Bbl. LD7 . . . . Engin e V6 231 2 Bbl. Carb. LE2 . . . . Engin e V6/2.8 Litre 2 Bbl. . . Engin e L6/250 2 Bbl. LE3 V ara je t LE4 . . . . Engine V8/400 CID /4 Bb C arb ./Truck LE8 . . . . Engine V8/454 CID /4 Bbl. C arb ./Truck LE9 . . . . Engin e V8 305 CID LF3 . . . . Engin e V8 305 CID LF4 . . . . Engin e V8/400 CID /4 Bbl. LF5 . . . . Engin e V8 350 CID LF7 . . . . Engin e V8/260 Die sel LF8 . . . . E ngin e V8/454 C ID /4 Bbl. Carb. M 4 /T r u c k LF9 . . . . Engin e V8 350 D ie sel LG3 . . . . Engin e V 8 /3 0 5 /2 Bbl. LG4 . . . . Engin e V8 305 4 Bbl. LG9 . . . . Engin e V8/305 CID /2 Bbl. LH6 . . . . Engin e V8/6.2 C D ie s el LH7 . . . . Engin e V6 2.8L LH8 . . . . Engine L4 1.8-0 LH9 . . . . Engin e V6 2.8L LJ5 . . . . Engin e L4 1.8D LJ9 . . . Engin e L4 1.8L LK6 . . . . Engin e V6 2.8L LK9 . . . . Engin e V6 3.0 LL1 . . . Engin e V6 2.8L LL4 . . . E ngin e V8/6.2 J Die sel LM1 . . . Engin e V8/350 4 Bbl. L M 9 . . Engine V6 3.8L LN 3 . . . . Engin e V6 3.8L L P 1 . . . . Engin e V6 3.2L LP9 . . . Engine V8 5.7L LQ2 . . Engine L4 2.0L LQ5 . . . Engine L4 2 0L LQ7 . . . . Engine 14 2.2L D ie sel LQ8 . . . Engine L4 2.5L LQ9 . . . . Engine L4 2.5L LR1 . . . . Engine L4 1.9-5 LR2 . . . Engine V6 2.8 LR8 . Engine L4 2 5L LR9 . . . Engine L4 2 01 LA5 LC1 LC3 LC4 LC5 LC6 LC8 LC9 LD4

.... .. .... .... ... . .... .... .... ....

O A-28

GENERAL INFORMATION

GM PRODUCTION OPTIONS
M17 M18 M19 M20 M 21 M24 M26 M27 M29 M31 M32 M33 M34 M38 . . . T ran s. 4 S p e e d M a n u a l 3.31:1 1st G ear . . . Tran s. 4 Spd. M a n u a l 2.88:1 1st G ear . . . T ran s. 4 S p e e d M a n u a l 3.53:1 1st G ear . . . Tran s. 4 S p e e d M a n u a l / S a g in a w . . . Tran s. 4 S p e e d M a n u a l / W arner . . Trans. 4 S p e e d M a n u a l 3.42:1 1st G ear . . . Tran s. 4 Spd. M a n u a l 3.50:1 1st G ea r . . . Tran s. 4 S p e e d M a n u a l . . . Tran s. 3 S p e e d A u t o . ( T H M 200) . . . Tran s. 3 S p e e d A u t o . / CBC 250C . . . Tran s. 3 S p e e d A u t o . ( T H M 325) . . . Tran s. 3 S p e e d A u t o . / B u ic k B u ilt (12.2 C o n v e rt e r ) . . . Tran s. 3 S p e e d A u t o . (T H M 1 25 ) . . . Tran s. 3 S p e e d A u t o . / Chev. B u ilt (11.75 C o n v e rt e r ) . . . Tran s. 3 S p e e d A u t o . ( T H M 400) . . . S trg . Sys. M a n u a l . . . Tran s. 4 Spd. A u t o . TH 325 . . . Tran s. 3 S p e e d M a n u a l 2.85:1 1st G ear . . . Tran s. 3 S p e e d M a n u a l . . . Trans. 3 S p e e d M a n u a l 3.50:1 1st G ear . . Trans. 4 S p e e d M a n u a l 2 85:1 1st G ear . . . Trans. 4 S p d M a n u a l . . . T r a n s m is s io n A s m . 5 Speed . . . Trans. 4 Spd. M a n u a l Fuel Tank 69 Litre Fuel T a n k 69 Litre Fuel Ta nk 76 Litre W h e e l S te e r in g Fo rm u la S trg . W h e e l S p o rt L e a th e r S trg. W h l. Std . Fuel Ta nk 83 L itre Fuel T a nk 31 Gallon Fuel T a n k 96 Litre Fuel T a nk A u x ilia r y Fuel Ta nk 33 Gallon Fuel T a n k 2K Gallon Rear M o un ted IMM4 . . . E m iss io n C o n tr o l N o n C lo sed Loop ( E x p o rt) N M 5 . . . E m iss io n C o n tr o l Non C lo s ed Lo op Canada IMM6 . . E m iss io n C o n tr o l Canada R e c a lib r a tio n N o n C los ed Loop N M 8 . . . U n le a d e d Gas C o n v e r s io n / E x p o rt N M 9 . . . D ies el E m iss io n S y s t e m / E xte rn a l EGR NN1 . . . E m iss io n S y s te m Dual Bed M o n a lit h e Conv. N N 2 . . . E m iss io n S in g le Bed M o n a lit h e Conv. N N 3 . . . E m iss io n S y s t e m S in g le Bed B ea d Conv. N N 4 . . . Fuel T a n k 60 Gallon N N 6 . . . EGR R e v e r s e F lo w N N 7 . . . Fuel Fille r D o o r D e le te Lock N N 9 . . . E m iss io n S y s te m L e a d e d Fuel E x p o r t NP1 . . . V6 E c o n o m y Equip N P 5 . . . L e a th e r W r a p p e d Str. W h l. NP7 . . . S te e rin g C olu m n N V5 . . . Shield, D iffe r e n tia l C a rrie r NY1 . . . . Shield & Skid Plate Fuel Tank NY6 . . . . T y p e 605/P.S. NY7 . . . . Shield T ra n s f e r Case NY8 . . . . T ype 80 0/P.S. NX1 . . . W h e e l 13 x 5 PA (H S L A Stl) N04 . . Lock Gas C a p /R e m o te C o n tro l N05 . . . Lo ck in g Gas Cap N08 . . . Rem C o n t Fuel Fille r Dr. Lk. N09 . . Lock-Fuel Filler Dr. N10 . . . . E x h a u s t S y s te m Dual N16 . . . . In te rn a l EGR w /E P R E m is s io n S ta n d a rd N18 . . . . Lo ck in g Kit S im u la te d W i r e W h l Cvr N20 . . . . Fuel Tank 50 Gallon N23 . . . . Fuel T a nk 83 Litre (22 Gal.) N24 . . . . W h e e l Cast A lu m . 1 5 x 7 N30 . . . . W h e e l S te e r in g D e lu x e N31 . . . W h e e l S te e r in g C u s to m N32 . . . . W h e e l - S t e e r in g C u s to m N33 . . . . W h e e l S t e e r in g / T i lt T y p e N34 . . W h e e l S te e rin g C u s to m S p o rt N36 . . . . W h e e l S te e r in g S p o r t NH8 . . . NK1 . . . NK2 . . . N K3 . . . NK4 . . . N K5 . . . N K6 . . . NK7 .. . N K8 . . . N L2 . . . . NL7 . . . . NL8 . . . . N37 . . . . W h e e l S tr g ./T il t & T e le s c o p ic N40 . . . . S te e r in g H y d r a u lic /N o n V ariab le N41 . . . . S t e e r in g H y d r a u lic / Varia b le Ratio N 46 . . . . W h e e l , S tr g (4 S p o k e ) ( V in \l) N49 . . . . W h e e l S tr g ./C a p O nly / S po rty N51 . . . . M a n u a l S te e r in g N60 . . . . W h e e l A lu m i n u m N 65 . . . . W h e e l & T ire S t o w a w a y Spare N 66 . . . . . W h e e l Equip. S ty le d S port N67 . . . . W h e e l s Rally N68 . . . Spa re T ire & W h l. C o n v e n tio n a l N69 . . . . W h e e l Gold S ty le d 13 x 6.00 N 70 . . . . W h e e l P a in te d 13 x 5.5 N71 . . . . W h e e l C ust. S p o r t N72 . . . . W h e e l C u s to m S p o r t 15 In ch N73 . . . . W h e e l E q u ip ./C u s to m S p o rt N 77 . . . . W h e e l s 13 x 6 /A lu m . Hub Caps & W h l. N u ts N78 . . . . W h e e l A l C ast w / D ie C ast 0 r n a . / l 4 x 6 N81 . . . . T ire S pa re Radial N82 . . . . W h e e l Equip. Cust. S p o r t / 1 5 x 6.00 N83 . . . . W h e e l Equ ip. Cust. S p o r t / 1 5 x 7 00 (Chr. S ty le d ) N84 . . . . S pa re T ire ( D e le te ) N85 . . . . W h e e l H.D. 14 x 6 N86 . . . . W h e e l P o ly c a s t 13 x 5.5 N89 . . . . W h e e l T u rb o A lu m . N90 . . . . W h e e l A lu m i n u m N91 . . . . C o v e r S im u la te d W ir e W he el w /L o ck s N 92 . . . . C o v e r S im u l a te d W ir e W h l/C o lo r Coded N94 . . . . S im u l a te d W ir e W h l disc (14 ) N95 . . . . C o v e r S im u l a te d W ir e Wheel N96 . . . . C o v e r S im u la te d C hro m e W h e e l 15 In. (1981) N 96 . . . . W h e e l , A lu m Cast 16x8 (1984) N97 . . . . W h e e l s Hvy. D ty. 15 x 7 N98 . . . . W h e e l A s m . Rally 11 Road (Chr.) N 99 . . . . W h e e l s Hvy. D u ty (15 x 6)

M40 M51 M57 M62 M63 M64 M67 M73 M75 M77

NA2 NA5 NA6 NA9 NB1 NB2 NB5 NC5 N C8 NDl NE2 NF1 NF2 . NG1 NH1 NH7

. . . E m is s io n Sys. Std . . . E m is s io n S y s t e m F e dera l . . . H ig h A l t i t u d e Perf. E m is s io n S y s te m . E m is s io n S y s t e m E v a p o ra tiv e . E m is s io n C o n tro l Clo sed Lo op . . C aliforn ia E m is s io n S y s t e m . E x h a u s t S y s t e m S in g le . . Exhaust S yste m S p o rty . . . D ie s e l E m iss io n S y s t e m / I n te r n a l EGR . . . Fuel Tank - - 86 Litre . . . Fuel Tank - - 40 G allon . . Fu el Tank - - 69 L itre . . . Fu el Tank - - 75 L itre . Fuel T ank - - 76 Litre . Fuel T ank - - 83 L itre . . Fuel T ank - - 103 L itre

C ov er W h e e l T r im / D e lu x e /1 5 In ./O ld s PA1 . . . . C over W h e e l T r i m / W i r e / 15 In ./B u i c k PA3 . . . C over D e lu x e W h e e l T rim /1 3 , 14 or 15 In.

PAl ...

GENERAL INFORM ATIO N

OA-29

GM PRODUCTION OPTIONS
PA4 . . . . H u b W h e e l Cover, P a in te d P A5 . . . . Cap H ub S p o r t PA6 . . . . S ty le d W h e e l PB1 . . . . D is c W h l . / l 5 In. PB2 . . . . C o v e r W h e e l T r im /A b s . P la s tic /1 5 In. PB4 . . . . Lock K it A l u m i n u m W h l PB5 . . . . W h e e l 13 x 5.5 M i ld Stl PB6 . . . . W h e e l I n c r e a s e d Size 14 in ch PB7 . . . . W h e e l, 14 x 6 ( P a in te d S ty le ) PCI . . . . W h e e l 14 x 6.00 Colo r Coded PC3 . . . . W h e e l 14 x 6 J J P o ly c a s t PC6 . . . . W h e e l 14 x 5.5 PD7 . . . . W h e e l, 14 x 6.5 (Cast A lu m i n u m ) PE1 . . . . W h e e l 14 x 7.00 P o ly c a s t/C o lo r C o d e d PE2 . . . . W h e e l 15 x 7.00 P o ly c a s t/C o lo r C o d e d PE3 . . . . W h e e l A s m . 14 x 7 P o ly c a s t/C o lo r PE4 . . . . W h e e l 1 4 x 7 P o l y c a s t/ T u rb in e DES PE5 . . . . W h e e l Rally V PG3 . . . . W h e e l 1 4 x 6 . 5 F o r g e d A l u m PG4 . . . . W h e e l 14 x 5.5 Cast A lu m PG5 . . . . W h e e l 1 5 x 6 Cast A lu m PG9 . . . . W h e e l Ligh t M e t a l A llo y P H I . . . . W h e e l 15 x 7 J J PH2 . . . . W h e e l 15 x 6 00 J J PH4 . . . . W h e e l 1 5 x 7 , S te e l S ty le d PH5 . . . . W h e e l , 1 4 x 6 (F o rg e d A lu m in u m ) PH6 . . . . W h e e l 15 x 6 PH7 . . . . W h e e l 1 5 x 7 F o rg e d A lu m i n u m PH8 . . . W ir e W hls. PX1 . . . . W h e e l, 13 x 5.5 (C ast A lu m in u m ) PX2 . . . . W h e e l Rear A lu m i n u m P01 . . . . C over W h e e l T r im / D elu xe /13 , 14 or 15 In. P02 . . . . C over W h e e l T r im / C u s to m /1 3 or 15 In. P03 . . . . Cap B r ig h t M e d a l H ub P05 . . . . W h e e ls C h r o m e / B u ic k P05 . . . . W h e e ls H o n e y c o m b / P on tia c P06 . . . . Ring W h e e l T rim P08 . . . . C o v e r W h e e l S u p e r D e lu xe P 10 . . . . C a rrie r W h e e l P 11 . . . . C arrie r Glide O ut Spa re Tire P12 . . . . W h e e l 1 4 x 6 C h ro m e P 13 . . . . C a rrie r W h e e l / S i d e M o un ted P 14 . . . Carrie r In s id e M o u n t e d , S pare T ire Lt Si. P 15 . . Carrie r In s id e M o u n t Spare Tire Rr. P17 . . . . C ov er S p a re W h e e l & Tire P20 . . . . Cap B r ig h t A lu m . H ub P41 . . . . Tire E x p o r t P42 . . . . Tire S e lf S ea lin g QE2 . . . . W h e e l 16 x 6.00 K /T ru c k Q E 6 ____W h e e l 16.5 x 6 / T r u c k QE7 . . . . W h e e l 16.5 x 6.75 QE8 . . . . W h e e l 16 x 6 .5 0 L /T ru ck Q18 . . . . W h e e l 16 x 5 K / T r u c k Q28 . . . . W h e e l 16 x 5 K / T r u c k Q34 . . . . W h e e l 19.5 x 6 .0 0 /T ru c k R04 . . . . W h e e l s S in g le Rear R05 . . . . C o n v e rs io n Dual Rear W heel S89 . . . . W h e e l 16.5 x 8 .2 5 /T ru c k TL1 TL4 TL6 TN 4 TP1 TP2 .... .... ,... ... .... .... G rille S p e cia l G rille C u s to m G rille B la ck Rod H o o d H old Open A s s is t H ig h C a p a c ity B a t t e r y B a t t e r y A u x il ia r y Camper Lamp G ro u p H e a d la m p s T u n g s t e n Q uartz H a lo g e n T u n g s t e n Q ua rt z H a lo g e n H dlp Lamp, RR M a r k e r Park & T u rn Lamp Le ns ( A m b e r) S h e e t M e ta l , Frt End S pe cial Lock I n t e r i o r O p e ra te d H oo d A lu m i n u m H o o d S te e l H o o d H oo d T u r b o A lu m Ram A ir H o o d S p o r t S te e l O r n a m e n t Frt. Fdr. S k irt Rr W h l. Opg. B uzzer H e a d la m p W a r n in g E x p o rt H e a d la m p s LHR R ou nd Export H e a d la m p s LHR 2 R e c ta n g u la r Lamps Rear Fog E x p o rt B eam C o n tr o l H e a d la m p A u to m a tic Lamp D e lu x e Tail & S to p T w il ig h t S e n tin e l H e a d la m p D o o r Spl. H e a d la m p s R ig ht Rule of Road E M a r k H e a d la m p L e h Rule of R o a d /E x p o r t Lamps C o rn e rin g Lamp Sig na l & M a r k i n g E x port Sig na lin g and M a r k in g Lam ps (E xp o rt) T93 . . . . Tail & S to p La m p S p e c ia l T96 . . . . Lamps Frt. Fog

TR9 . . . . TT4 . . . . TT5 . . . . TU2 . . . . T38 . . . . T41 . . . . T44 . . . . T45 T 46 T47 T48 T 52 T58 T63 .... .... .. . .... .... .... .. .

T70 . . . T72 . . T79 . . . T80 . . . . T81 T82 T83 T84 .... .... .... ....

T85 . . . . T87 . . . . T89 . . . T90 . .

U A 1 . . . H e a vy D u ty B a t t e r y U A2 . . . M ile s Per Gallon S e n t in e l D ig ital R e a d o u t U A6 . . . T h e ft D e t e r r e n t S y s t e m U A8 . . B a t t e r y S y s t e m Resv. Pw r. U B7 . . . C lu s te r A s m . T rip O dom eter U B8 . . . H orn Pac ka ge UD1 . . . C lu s te r I n s t r u m e n t Pnl. Oil & W ater UD8 . . . Clock Vac. F lo r e s e n t / D igital UE8 . . . . Clock E le c t r i c / D i g it a l UE9 . . . . S w it c h Rr. C o m p t. Lp. M e rcury UF2 . . . . Lamp Cargo UF3 . . . . Lamp M a p / O n S u n V is o r S upport UF7 . . . . Gauge I n s t r u m e n t Pnl./ Less T a c h o m e t e r UH1 . . . E le c tro n ic Lamp M c n i t o r i n g S y s te m U H9 . . . C lu s te r, l/P ( W a t . T e m p ., T rip Odo., T u r b o B oo s.) UJ1 . . . . In d ic a to r B ra k e W a r n in g S y s te m U J3 . . . . I n d ic a to r W a t e r and Fuel U J5 . . . . C lu s te r l/P ( W a t . T e m p ., Trip O d o m e t e r & V o l t m e t e r ) U J 9 . . . . C lu s te r, l/P (C ool T e m p ., Volt, Tach.) UK1 . . . . Radio F r e q u e n c y (J a p a n e s e ) UK2 . . . . L e ve r Dir Sig. (E x p o r t) UL1 . . . . Radio A M / F M S t e r e o W ith o u t S eek/Scan UL2 . . . . Radio F r e q u e n c y ( E u ro p e a n ) UL3 . . . . Radio w / D i g i t a l C lo c k A M / F M S te r e o UL5 . . . . Radio D e le te UL6 . . . . Radio w / C l o c k A M P ush B utto n UL7 . . . Radio A M / F M P u s h b u t t o n W i t h D ig ita l C lo ck UL8 . . . Radio w ' D i g i t a I C lo c k A M / F M S t e r e o T a pe UL9 . . . . Radio w / D i g i t a l C lo c k A M / F M S t e r e o C a s s e tte U M 1 . . . Radio A M P u s h b u t t o n & Tape Pla yer U M 2 . . . Radio A M - F M S t e r e o P u s h b u t t o n & T a p e Plyr. U M 3 . . . A M / F M C lo ck & C B / S t e r e o U M 4 . . . Radio A M / F M S t e r e o w / T a p e Sig. Skg. w /'Dig. Clk. U M 5 . . . A M / F M 8 T ra c k C lo c k R e m o te C B / S t e r e o U M 6 . . . A M / F M S t e r e o Sig. Skg C a s s e tte P la y e r

OA-30

GENERAL INFORMATION

GM PRODUCTION OPTIONS
U M 7 . . . A M / F M S te reo w /D ig ita l R eadout U M 8 . . . A M / F M S t e r e o Sig. Skg. R e m o te C o n tro l 8 Track U N I . . . A M / F M S t e r e o & T ape P la y e r / C a s s e t t e / C B UN2 . . . Radio A M / F M - S t e r e o S ig n a l S e e k in g U N 3 . . . R adio A M / F M S te r e o T a p e C a s s e tte U N 4 . . . T a p e C a r t r i d g e (D e le te ) ( E x p o r t) U N 5 . . . A M / F M S te r e o , Sig. S e e k in g , C a s s e tte , T / P l y r . f CB UN 8 . . . Radio C itize ns B and U N 9 . . . Radio S u p p r e s s io n Equip. U P 1 . . . . Radio A M / F M S te r e o T a p e & C.B. UP4 . . . . Radio A M / F M S te r e o and C .B ./23 B an d UP5 . . . . R adio C om bo. A M / F M M o n o . w /C .B . UP6 . . . . Radio A M / F M S te r e o an d C .B .'40 B an d UP7 . . . . In s ta lla tio n P ro v is io n s Radio M o n u a r a l UP8 . . . . I n s t a lla tio n P r o v is io n s R adio S te r e o UQ1 . . . H ig h Perf. Rr. S h e lf Spkrs. UQ2 . . . C o n c e r t S o u n d S te r e o UQ3 . . . A u d io Pw r. B o o s t e r UQ4 . . . S p e a k e r Sy te rn B os e 4-Spkr. w / A m p s . UQ5 . . . S p e a k e r, 4 Frt. D o o r Coax Rr. '/< E.R. UQ7 . . . S p e a k e r S y s te m , Sub W o o f e r UQ9 . . . S p e a k e r S y s t e m (D e le te ) UR1 . . . . Gage Fu el E c o n o m y UR3 . . . . Fuel Econ. In d ic a to r Lamp UR4 . . . . T u rb o . B o o s t G auge US6 . . . . A n t e n n a , Fixed M a s t (Black) US7 . . . . A n t e n n a , P o w e r (Black) U T 1 . . . . B u z ze r T o n e G e n e r a t o r W a r n in g UT2 . . . . Radio, A M / F M S t e r e o ETR ( R e m o te C o n tro l) UT3 . . . . Radio, A M / F M S t e r e o ETR C a s s e t t e (R e m o te C o n tro l) UT4 . . . . Radio, A M / F M S t e r e o ETR C a s s e tte w / E q (R e m o te C o n tro l) UU1 . . . R a d i o A M / F M S t e r e o Full F e a tu re /M tr. UU2 . . . R adio A M / F M S t e r e o Full F e a tu re /M tr/C a s se tte UU3 . . . R a d i o A M / F M S t e r e o Full F e a t u r e / M t r / 8 Track UU4 . . . S t e r e o w / D i g i t D is p la y UU5 . . . G ra p h ic E qualiz er UU6 . . . Radio A M / F M S t e r e o C a s s e t t e ETR w / C l o c k UU7 . . . R adio AM.^FM S te r e o C a s s e t t e ETR . . . Radio A M / F M S te r e o C a s s e tte Etr. D o lb y UU9 . . . Radio A M / F M S te re o , ETR, w i t h o u t S e e k /S c a n & Clock UV1 . . . . R e m in d e r, V o ic e S y n th e s is UW1 . . . S y s te m C lu s te r ( D ia g n o s tic ) U W 6 . . . Shelf, Dual Ext. Range Pkg. , U W 8 . . . R e ta in e r Garage Dr. T r a n s m it t e r U W 9 . . . O p e n e r G ara ge Dr. Rem. Cont. UX6 . . . . S p e a k e rs Dual Frt. UX7 . . . . S p e a k e r S y s te m Dual Frt. Dr & Dual E x te n d e d Range RR UX9 . . . . S p e a k e r F ro n t UY1 . . . . W ir i n g C a m p e r UY7 . . . . W ir i n g H a rn e s s H e a vy D uty/T ru ck UY8 . . . . Radio A M / F M S t e r e o w / D i g i t a l C lock UY9 . . . . S p e e d o K i l o / M i l e s M e c h a n ic a l D is pla y U01 . . . La m p R oof M a r k e r / T r u c k U 0 2 . . . S p e e d K i l o / M ile s D ig ita l U 0 3 . . . H o rn N o is e Reg. E x p o r t U 0 5 . . . H o r n Dual U09 . . . . H o rn Four N o te U11 . . . . C lu s te r Spl. C a lib ra te d U 14 . . . . Gauge I n s t r u m e n t Panel U 16 . . . . T a c h o m e t e r Ld. U17 . . . . C l u s t e r In s tr./O il, W a t e r , A m m ., Clock, Gas, Tach U18 . . . . I/P C lu s te r K ilo /T a c h U 19 . . . . I/P C lu s te r M . & Kilo O d o m ./C a n a d ia n U21 . . . . C lu s te r, In s tr. (O il- W a te r B a t te r y - T a c h ) U22 . . . . C lu s te r, In s tr. (O il-W a te rB a t te r y - C lo c k ) U23 . . . . S pe ed o., w / T r i p O d o m e t e r U25 . . . . Lamp L u g g a g e C om pt. U26 . . . . Lamp E ng in e C om partm ent U27 . . . Lamp I n s t r u m e n t Panel C om partm ent U28 . . . . Lamp A s h Tray U29 . . . . Lamp C o u r te s y U30 . . . . Gages Aux. In st. U32 . . . . C lu s te r S p e cia lly C a lib ra te d U35 . . . . C lo ck E le c tr ic ( N o n D ig ita l) U37 . . . . L i g h te r C ig a r e tt e U38 . . . . L o w C oo la n t W a r n in g Sys. U40 . . . . Trip M o n i t o r D ig ita l Readout U41 . . . . I n d ic a to r L o w Fuel U46 . . . . M o n i t o r E x te rn a l Lamp U52 . . . C lu s te r l/P (E le c tro n ic ) U57 . . . . P la ye r Tape U58 . . . Radio A M / F M S t e r e o U63 . . . . Radio Push B u t t o n U U8 U64 . . . . S p e a k e r S y s te m Dual Frt. D ash & Dual STD Range RR U65 . . . . S p e a k e r S y s te m Dual Frt. Dr. & Dual STD R an ge RR U66 . . . . S p e a k e r S y s te m Dual Frt. Dash & Dual E x te n d e d R an ge RR U67 . . . . Radio Rear C o n tr o l U69 . . . . Radio A M - F M w / M o n o U72 . . . . A u t o m a t i c P o w e r A ntenna U73 . . . . A n t e n n a S ta n d a rd (Fixed M ast) U74 . . . . A n t e n n a P o w e r Rdo. C itize n s Ban d U75 . . . . A n t e n n a P o w e r FDR U76 . . . . A n t e n n a W / S E m b e d d e d U79 . . . . S p e a k e r, 4 Dual Frt. Coax, Dual ETR Rr. U 80 . . . . Spkr. - Rr. A u x . All lo c a tio n s U81 . . . . S p e a k e r s Rear Dual U83 . . . . A n t e n n a P o w e r R adio and 40 Chnl. C.B. U88 . . . . Hole R oo f F la sh er W ir i n g H a rn e s s U89 . . . . W ir i n g Harn . Car T r a ile rs 5 W ire U90 . . . . W ir i n g Harn. Spl. Rf. F la sh er w/'Rf. Pnl. U92 . . . . S p e a k e r s F r o n t Dual & Rear Dual U93 . . . . A n t e n n a M a n A M / F M C.B. Tri. Ban d U 94 . . . . L ig h t Cable T ra ile r 7 - W ir e U95 . . . . S p e a k e r s D o o r U96 . . . . S p e a k e r S y s t e m / 6 S p e a k e r C on ce rt S ound

V A 2 . . . . M ile s Per Gal S e n tm a l E x p o r t Canada (1981) V A 2 . . . . S u p p o r t R a d ia to r S te e l (1982) V A 3 . . . . S u p p o r t R a d ia to r A lu m i n u m V B 2 . . . . B u m p e r w / l m p a c t S tr ip Rear S te p P a in te d V B 3 . . . B u m p e r w / l m p a c t S tr ip Rear S te p C h r o m e V B4 . . . . Saudi A r a b ia Pkg. E x p o r t VD1 . . . Radio P ro v is io n s (E x p o rt) (E uro pe ) V D2 . . . B u m p e r M ld g . V D4 . . . . R e in f o r c e m e n t Frt. Bpr. (S te e l) VD 5 . . . R e in f o r c e m e n t Rear B u m p e r S te e l VD6 . . R e in f o r c e m e n t F r o n t B u m p e r A lu m i n u m V D7 . . R e in f o r c e m e n t Rear B u m p e r A lu m i n u m

GENERAL INFORM ATIO N

OA-31

GM PRODUCTION OPTIONS
VE1 . . . . J a p a n e s e M o d i f i c a t i o n E x port VE5 . . . . S trip Frt. an d Rr. B u m p e r , Im p a c t VE6 . . . B u m p e r Frt. & Rr. P a in te d ( w / l m p a c t S tr ip s ) VF1 . . . . B u m p e r C h r o m e / R r . VF5 . . . B u m p e r Car C olo r VF6 . . . B u m p e r Rr. S te p VF9 . . . . B u m p e r Frt. an d Rr. Rbr. P r o t e c te d w / G r d s . VG3 . . . . Strip , Frt B u m p e d I m p a c t VG5 . . . Strip Rear B u m p e r Im p a c t VG7 . . . . B u m p e r R e in f o r c e m e n t , Fro nt VG8 . . . . B u m p e r R e in f o r c e m e n t Rr./Calif. & Flo rida VG9 . . . . Frt. B u m p e r G ua rd s VH6 . . . Black B u m p e r VH7 . . . . B u m p e r, C u s to m V lD . . .. A M /F M S te reo & Tape Player w / o Eject V J 5 . . . . M o u n t in g , L ic e n s e Pla te V J 6 . . . . P o c k e t Lie. Pit. R ear VJ7 . . . B r a c k e t w / L a m p R ear Lie Pit. V J 9 . . . . California E m is s io n C om plian ce I n f o r m a t i o n VK1 . . . . License Plate Frt. M o u n t in g Pkg. VK3 . . . . M o u n t in g L ic e n s e P la te / Front VL4 . . . . Plate, Frt. M t g . Lie. VN1 . . . M o d i f ic a t i o n s Calif. R eqm ts. VN 2 . . . M o d ific a tio n s G e o rg ia R eqm ts. V N 3 . . M o d i fic a ti o n s F lo rid a R eqm ts. VP 1 . . . . S po ile r L o w e r F r o n t VR2 . . . H itc h T r a i le r/ D e a d W eigh t VR4 H itch T r a i l e r / W e i g h t D is tr ib u tin g P la tfo r m VR5 . . Ball Tra ile r H it c h / 1 - 7 / 9 Inch VR6 . . . Ball Tra ile r H it c h / 2 Inch VT3 . . . D elu xe w / l m p a c t S tr ip s Frt. Bmpr. VT4 . . . D elu xe w / l m p a c t S tr ip s RR Bmpr. VT7 . . . Export U n r e g u l a t e d C o u n trie s V U 9 . . . Flashlite M t g . V1H . . Special P a in t- T w o T o n e V 1L . . . Special Trim V l T . . . Spare W h l C o n v e n tio n a l V01 . . . Radia tor H e a vy D u ty V02 . . . R adiator H.D w i t h HD .Trans. Oil C oo le r V03 . . . R adia tor Ex tra C a p a c ity Cooling V05 . . . . R adia tor H e a vy D u t y Truck C oo lin g S y s t e m , H ea vy D uty Cold C lim a te P ackage Cold C lim a te P ac ka ge D e le te Grille F ro n t B u m p e r / C hrom e V28 . . . . G ua rd s F r o n t B u m p e r / P a in te d V30 . . . . G u a rd s Frt. & Rr. Bumper V31 . . . . G u a rd Frt. B p r ./C h r V32 . . . . G u a rd Rr. B u m p e r V35 . . . . B u m p e r , Rr. w / R e c e s s e d L ig h ts V37 . . . . B u m p e r C h r o m e / F rt. & R r./T r u c k V38 . . . . B u m p e r R r . / P a in t e d / Truck V58 . . . . C a rrie r D ec k Lid Lu gg age V4S . . . . D e le g a n c e V4T . . . . D e le g a n c e V 4 W . . . W h e e l Disc V42 . . . . B u m p e r R ear S t e p / C hrom e/Truck V43 . . . . B u m p e r R ear S te p P ain te d Truck V46 . . . . B u m p e r C h r o m e / F r t . / Truck V50 . . . . Fram e Rear Lie. Pit. V51 . . . . Fram e F r o n t & Rear Lie. Pit. V54 . . . . C a rrie r L u g g a g e and R o o f Panel V55 . . . . C a rrie r R o o f Lu gg a g e V56 . . . . L u g g a g e C o m p t. Lock & T rim V62 . . . . J a c k A u t o V65 . . . . B u m p e r Lt. D u ty V69 . . . . T r a ile r P r o v is io n s V70 . . . . H o o k s T o w i n g Export V76 . . . . H o o k F ro n t T o w V78 . . . . Pla te Less C e r tific a te of C o m p lia n c e V81 . . . . T r a ile r P r o v is io n s V82 . . . . T r a ile r Prov. Class 2 2000-3500 V83 . . . . T r a ile r P r o v is io n s Class 3 3500-5000 V08 V 10 V13 V22 . . .... .... .... W F8 . . A p o llo XB-27 P ac ka g e W H 2 . . . F^ee S p i r it S k y h a w k D e s ig n 11 A p p e a r a n c e G ro u p WH3 . W H 4 . . T a c h o m e t e r & C lo ck W H 5 . . H a n d lin g Packa ge W H 6 . . N ig h t H a w k D e c o r. P a c ka g e W J4 . Firenza C ou pe, S p e c ia l E d itio n W J 5 . . Cie rra C ou pe, S p e cia l E d itio n W J 7 . . Trim , I n t e r io r L e a th e r W J8 S ta r fir e SX P a c ka ge W J 9 . . F85 D e lu x e Pac ka ge W K1 . . R oo f Panel S t o w a g e B r a c k e ts W K 2 . . . S p e c ia l T r im / D e l t a R oyale B r o u g h a m W K 9 . . . R egency Brou gh am Sedan O p tio n W 0 5 . . . Regal L i m i te d O p tio n W 0 6 . . . C e n tu r y E s ta te W a g o n (1984) W S 4 . . . T ran s. A m O p tio n W S 6 . . . S p e cia l P e r f o r m a n c e P ac ka ge W S 7 . . S p e c ia l H a n d lin g Pkg. W S 9 . . . P h o e n ix A p p e a r a n c e Pac ka ge W S 9 . . L e a d e r Fuel E c o n o m y (1982-83) WT1 . . S u s p e n s io n Bia s B e l t e d Tire W U 2 . . GT O p tio n WU7 WU9 WV6 WV7 WV8 WV9 WW1 WW2 WW3 WW7 WW8 WX3 WY5 W02 W 03 W 04 W06 W07 W08 W 09 W10 W 11 W 12 W13 W14 W15 W17 W18 W19 W20 W21 W22 W 24 C u s to m T h ird S te a W i n d o w Reveal M l d g s . G r a p h ic s P k g ./G o ld G ra p h ic s P k g ./C h a rc o a l G ra p h ic s P k g ./B lu e G ra p h ic s P k g ./R e d Less C o n so le . C u s to m Safari . Can A m O p tio n . A p lq . H o o d / F i r e b i r d . G ages Rally w i t h l/P Tach. and C lock . . Ram A ir S h a k e r H oo d . . . S u s p e n s io n Radial T u n e d . . W o o d G rain A p p liq u e . . . Regal L im ite d S edan . . . C e n tu r y L im ite d C ou pe . . . C u s to m T r im G roup . . C e n tu r y S p o r t C o u p e . . . C u s to m T r im G roup . . C e n t u r y L im ite d S ed an . Park A v e n u e O p tio n . . Regal S p o r t C ou pe . . . S k y h a w k Package . . . C e n t u r y T u rb o C ou pe . . L e S a b re S p o rt C o u p e C u s to m T r im G roup . I n t e r i o r T rim D e lu x e S p o r t O p tio n . C u s to m T rim G roup . . . C o n v e n ie n c e G roup . . C u s to m T rim G roup C u s to m T rim G roup . . . C u s t o m T rim G roup .. .. .. .. .. .. . . . . . . . . . . .

WA3 . . WA5 .

WB2 . . . WB5 . . . WB7 . . . WB9 . . . WC2 . . . WC3 . . . WC4 WD3 WD4 WF5 WF6 . . . . . . . . . . . . .

S ea t A dj. 6 W a y D riv e r & Pass. S p e a k e r Dual Frt. & Rear P r o m o ti o n a l P ac ka g e E s ta te W a g o n G roup Landau Top and Fo rm al W i n d o w G ro u p Palm B e a c h Opt. M o ld in g P a c ka ge M o ld in g s Rkr. Rr. Q tr & w / O p g . C o n v e n ie n c e G ro u p A p p e a r a n c e G roup A c c e s s o r y P ac ka g e C u s to m T rim G ro u p M o ld in g G roup

OA-32

GENERAL INFORMATION

GM PRODUCTION OPTIONS
W29 W30 W 40 W44 W 45 W47 W48 W 49 W50 W51 W52 W53 W55 W 56 W59 W60 W62 W63 W64 W65 W65 W66 W67 W68 W69 W70 W 71 W72 W73 W84 W85 442 A p p e a r a n c e Package H u r s t O lds Pkg. H u r s t O lds S p e c ia lt y Car S im u la te d C o n v e r t ib le Top E u ro p e a n S ed an Firenza " E S " E u r o p e a n S ty lin g C-4 C lo s e d Lo op (1980-81 M o d e l s Only) . . . A p p e a r a n c e G ro u p Spe cial . . . A p p e a r a n c e O p tio n , Bla ck Extr. .. . Japanese M o d ific a tio n / E x p o rt . . . S pe cia l A p p e a r a n c e - G r p . II Tw o-T one . . . E x h a u s t S y s t e m L ig h t W e ig h t . . . E x h a u s t S y s t e m S t a n d a rd . . . S pe cial A p p lic a t io n s G roup . . . E s prit S pe cia l A p p e a r a n c e . . . A e r o Package . . . Gauge & C lo c k Rally . . . S u n b ir d W a g o n , Spec. P a rts G roup . . . S t e r e o Spkr. w / M o n a u r a l Rdo. (1981) . . . Lock Pkg., S e c u r i t y (1984) . . . Fo rm ula O p tio n G roup . . . E s prit Lux. Opt. . . . E s prit S pe cial A p p e a r a n c e Red B ird . . . Fir e b ird S/E . . . L e M a n s S p o r t O p tio n . . . C u s to m S ea t G ro u p . . . P e r f o r m a n c e Opt. . . . E s p rit S pe cial Appearance . . . Gas A d d it i o n a l Fuel (Canada) . . . D ie s e l A d d it i o n a l Fuel (Can ada) ... ... .. . ... ... .. . .. . .. . B on an za Pkg. A /R o y a l Sie rra Pkg. A YG7 . . . . B on an za Pkg B /R o y a l S ie rra Pkg. B YG8 . . . . B on an za Pkg. C /R oyal S ie rra Pkg. C YG9 . . . . Spe cial C o m p o n e n ts , C e le b r ity Z YH9 . . . . In t e r io r D e lu x e YJ8 . . . . W h e e l C ast A lu m i n u m YK3 . . . . Pac ka ge Frt. & Rr. Shk. A bs . & Elim P itch YL1 . . . . U p h o ls t e r y L e a th e r V in yl YL2 . . . . P a in t F ir e m is t YL4 . . . . Rub S tr ip e I n s e r t ( W h i t e ) Y M 5 . . . S tr ip e A c c e n t D e le te Y M 6 . . . H e a d r e s t E x p o rt (Ja pa n) YP3 . . . . E ld o r a d o Cust., B ia rritz Opt. YP4 . . . . E le g a n te YP5 . . . . E ld o ra d o T o u r in g C ou pe O p tio n YP6 . . . . C im a rro n S pe cia l E ditio n YP7 . . . . C im a r ro n L im ite d E d itio n YR1 . . . . C u s to m F /S e a t YR2 . . . . D e lu x e F /S e a t YR3 . . . . L u x u r y F /S e a t YS1 . . . . C u s to m R /S e a t YS2 . . . . D e lu x e R /S e a t YS3 . . . . L u x u r y R /S e a t YT1 . . . . C u s to m B u ild -U p D r and Qtr. YT2 . . . . C u s t Dr and Q tr D e lu x e YT3 . . . . L u x u r y B uild Up D r & Qtr. YT6 . . . . S p e c ia l I n t e r i o r B u ild Up YT7 . . . . R e m in d e r G roup Y02 . . . . S ea t F r o n t C u s to m Y03 . . . . S ea t Rear C u s to m Y06 . . . . Panel C o w l Kic k C a r p e te d Y07 . . . . M ld g . S id e W d o . Rvl. P a in te d Y10 . . . . C u s to m B u ild -U p Dr. & Qtr. Y11 . . . . S eat F ro n t S pe cial D e s ig n Y12 . . . Seat Rear S pe cial D e s ig n Y13 . . . . T rim D o o r S p e c ia l D e s ig n Y17 . . . . Fdtn . C om pt. S h e lf C u s to m Y19 . . . . M ld g . B o d y Sid e Lw r. Y40 . . . . C oo lin g Hvy. D u ty Y41 . . . . Extra C ost T rim Y43 . . . . Road H a w k Package Y44 . . . . Regal S p o r t C ou pe D e c o r Y48 . . . . Regal Sr. Package (1981) Y48 . . . . E le ctra T y pe (1984) Y49 . . . D e s ig n e r C o n c e p t C ar/ S o m e r s e t II Y5A . . Body, M i li t a r y 5250 C om m S h e lte r (Type E) Y5B . . Body, M i lit a r y A m b u l a n c e (T y pe C) YG6 . . . Y5C . . . . B od y, M i l i t a r y Trp. & Cargo C a rrie r (T y pe B) Y5D . . . . Body, A m b u l a n c e ( C o m p le te Pkg.) Y5E . . . . G e n e r a to r , Dual D e lc o 66 Amp. Y5F . . . . G e n e r a to r , Dual D e lc o 100 Amp. Y5G . . . . G e n e r a to r , D ua l D e lc o 200 Amp. Y5J . . . . Radio P r o v is io n , S pe cial M i lit a r y Y5P . . . . M i lit a r y T r o o p S e a ts Pkg. Y5R . . . . C a b /C h a s sis, M i lit a r y (Type D) Y50 . . . . Riv eria S p o r t y " T " T y pe Y51 . . . . P r o t e c t iv e M o ld in g G roup Y52 . . . . Regal D e c o r Y54 . . . . C a rp e t S a v e rs M a t s Y55 . . . . R e m in d e r Pac ka ge G roup Y56 . . . . A c c e s s o r y G roup Y57 . . . . Lamp an d In d ic a t o r G roup Y59 . . . . V6 E c o n o m y Package Y60 . . . . A c c e s s o r y G ro u p Package Y61 . . . . O m e ga LS Y62 . . . . In st. C lu s te r Spl. F e a tu re s Y64 . . . . S ta r fir e GT Packa ge Y65 . . . . Firenz P ac ka g e Y66 . . . . O m e g a SX Pac ka ge Y67 . . . . R e m in d e r Pkg. Y68 . . . . C u s to m A p p e a r a n c e Package Y69 . . . . D ie s e l Econ. Packa ge (350 D ie s e l) Y70 . . . . S tr ip e - - B o d y Sid e Decal Y71 . . . L o w e r B o d y P a in t S c h e m e Y72 . . . . T ra ile r T o w i n g C ooling & Gen. Pkg. Y73 . . . . XS A p p e a r a n c e Opt. Y74 . . . . E x te r io r M o ld in g O p tio n Y75 . . . . C utlas s V a lu e Package Y76 . . . . M a r k e t i n g G roup O p tio n Y77 . . . . D ie s e l Econ. P ackage (260 D ie s e l) Y78 . . . . C u tla s s Calais Opt. (19781(1984) Y78 . . . . C u tla s s S alon O p tio n (1973-1977) Y78 . . . . 88 H o lid a y C ou pe Y78 . . . . S p o r t O m e ga Pkg. Y79 . . . . A p p e a r a n c e O p tio n Y80 . . . . C u s to m E x te r io r Y81 . . . . Spl. E d itio n T ran s. A M Less H a tc h e s Y81 . . . . C o n v e r t ib le C o n v e rs io n Pac ka g e (1982) Y82 . . . . S pe cia l E d itio n Tran s. A M Y83 . . . . A p p o i n t m e n t s O p ti o n LJ L u x u r y Y84 . . . S p e cia l E d itio n Tran s. A M Bla ck Y85 . . . . S pe cial E d itio n T ran s. A m Y87 . . . . B r o u g h a m O p tio n Y88 . . . . S p e c ia l E d itio n Tran s. A M Gold (1978) Y88 . . . . S ed an 6000 STE (1983-84)

YA1 . . . . D e c o r e Pkg. Luv T r u c k YB9 . . . In s u la to r Cab B ack Panel YC1 . . . . D u r a n g o Equ ip t. YC2 . . . T a h o e Equ ip t. YC3 . . . . S p o rt Equip t. YC6 . . . . C u s to m E s t a t e / W o o d g r a i n YD1 . . . . T ra ile r Pac ka ge H ea vy D u ty YE4 . . . . I n t e r io r & E x te r io r D e lu x e YE7 . . . Spec. S p o rt Equip. (G M C ) YE9 . . . S ilv e r a d o /S ie r r a Classic YG1 . . . . M o ld in g s Bdy. Si. Upr. & Lw r. W h l. O p g ./L e s s In s e rt YG2 . . . . W o o d g r a in , I n s e rt & N a m e Plate YG3 . . . M o ld in g B o d y S id e & W h l O p e n in g B r ig h t YG5 . . . . " S S " S p o r t P a c ka ge M o d i f ic a t i o n

GENERAL INFORM ATIO N

OA-33

GM PRODUCTION OPTIONS
Y89 . . . S ilv e r A n n iv e r s a r y T ra n s A M (1978) Y89 . . . La ndau B r o u g h a m (1982) Y90 . . . C u s to m T rim G roup (1980) Y90 . . . S pe cial S p o rt and H a n d lin g Pkg. (1984) Y91 . . . J 2 0 0 0 LE Y92 . . . Lamp G roup (1978) Y92 . . . J 200 0 SE Y94 . . . J 200 0 S Y95 . . . Rally O p tio n Y96 . . . Firm Ride O ption Y97 . . . SJ O p tio n (1982-83) Y97 . . . " S E " O p tio n (1984) Y98 . . . Ride C o n tro l S y s te m , E le c tr o n ic Y99 . . . H a n d lin g Package ZE1 . . . . S t r ip e - B o d y Si L w - A c a d ia n ZE7 . . . R e s tr a i n t ST B e l t & S hldr. Harn. Canadian ZE8 . . . . L e M a n s G.T. P a c ka ge ZE9 . . . . S t r ip e B od y Si. L w r. Canadian ZF2 . . . . C avalier S p o r ts Pkg. C anadian ZF3 . . . . S p o r t Package C anadian . . A c a d ia n ZF4 ZF5 . . . . A c a d ia n . . C u s to m In te r io r T w o ZJ1 Tone Z J 2 . . . . E x te r io r C u s to m M o ld in g Z J 3 . . . . I n t e r io r D ec or and C o n v e n ie n c e Package Z J 5 . . . . M o ld in g E x t e r i o r / L o w e r Z J 6 . . . . Fuel E cono m y Packa ge Z J 7 . . . W h e e l Special H ub Cap & T rim Ring Z J 9 . . . L ig h tin g Group A u x ilia r y ZK3 . . . . S pe cial I n te r io r P ac ka g e E x p o rt ZL9 . . . . I n t e r io r Lu xu ry Z M 1 . . . C aravan Pkg. Z M 2 . . . B o n a v e n tu r e T rim ZM4 . . N om ad/G ypsy . B e a u v ille T rim /R a lly S tx ZM8 ZN1 . . . . T r a ile rin g Package Z N 5 . . . . W h e e l R ally/P ain ted B o d y C olo r . O p e ra tin g C o n v e n ie n c e G roup ZQ2 . ZQ 8 . . . S p o r t Chassis Pkg. ZY7 . . . . P aint L o w e r A c c e n t ZY8 . . . . P a in t M id A c c e n t Z W 2 . . H e a vy D u ty E m issio n Eng. Z W 9 . . Base B o d y or C hassis ZX2 . . . C o n v e n ie n c e Package ZX4 . . Landau Roof Package ZX 5 . . Value A p p e a r a n c e Packa ge . H ea vy D u ty Chassis ZX6 . E q u ip m e n t M o n z a S py de r Z01 . . Monza Spyder Z02 . . A p p e a r a n c e Package Landau E q u ip m e n t Z03 . Z04 . M o n t e Carlo Classic Z05 . . . . S pe cia l 2-T o n e & S tr ip in g Z06 . . . . L u x u r y I n t e r i o r E q u ip m e n t Z07 . . . . E c o n o m y T r u c k Z08 . . . . C o n v e r t ib le E q u ip m e n t Pkg. Z11 . . . . Cadet Z 12 . . . . A p p e a r a n c e Pkg. Z13 . . . . O r n a m e n t a t io n S p o r t E x te rio r Z 14 . . . . T rim Cus t. In tr. Z 15 . . . . Spec. S p o r t Equ ip. SS 454 Z 16 . . . S p o r t D e c o r / B l a c k K n ig h t Z 18 . . . S p o r t D e c o r Z19 . . . S p o r t Pkg. XII Z20 . . . L im ite d E ditio n M o n t e Carlo Z21 . . . M o ld in g E x te r io r Z24 . . . Rally D e c o r G roup Z25 . . . La g u n a T y p e S3 Z26 . . . N ova Rally Z28 . . S pe cial P e r f o r m a n c e Packa ge Z29 . . . GT S p o r t Z29 . . . S p y d e r E q u ip m e n t Z32 . . . Canadian P a r is ie n n e P on tia c Z33 . . . C anadian P o n tia c , P a ris ie n n e Brougham Z36 . . . . P o n tia c C o n v e rs io n Packa ge Z44 . . . . A d d it i o n a l C o o la n t P r o t e c t io n Z46 . . . . P.J. P a c ka ge " X " Car M e r c h a n d is in g Z47 . . . . K.C. P ac ka g e " X " Car M e rc h a n d is in g Z48 . . . . F.X. P a c ka ge " X " Car M e r c h a n d is in g Z49 . . M a n d a t o r y C an adian Base Equ ip. M o d i f ic a t i o n s Z5B . . . SEO O v e rr id e of M V 4 fo r Polic e and Taxi Z5J . . . . SEO O v e r rid e o f RPO U25 Lu gg C o m p t. LP Z5 K . . . . C alifo rnia M e r c h a n d is in g Packa ge Z5S . . . C alifo rnia M e r c h a n d is in g P ackage Z5T . . SEO O v e r r id e of LM 1 fo r Police and Taxi Z50 . . . In d ia n a p o lis C o m m e m o r a t iv e Package Z52 . . . S ea t Full Foam Z53 . . . G auge V o l t m e t e r / O i l P ressure & Temp. Z54 . . . I n t e r io r D e c o r . / S i le n t S o u n d G roup, C ust. Tr. Z55 . . . Top R e m o v a b l e / L t Sla te T e xtu re d Z56 . . . Top R e m o v a b le /D k . B ro n z e T e xtu re d Z57 . . . Top R e m o v a b l e / D k Blu e T e xtu re d Z58 . . . Top R e m o v a b l e / W h i t e T e xtu red . Top R e m o v a b l e /B l a c k Z59 T e xtu re d Z6B . . . SEO O v e r r id e of RPO J A 2 H.D B ra k e . . Top R e m ov able/A lm o nd Z60 T e xtu red Z61 . . . C u s to m G roup Z62 . . . . S c o t t s d a le / S ie r r a G rand e Z64 . . . C u ta w a y Van Z65 . . . . S p o r t P a c k a g e M e r c h a n d is in g O p tio n (C o n s is ts of YG5) Z66 . . . . C o n v e rs io n Van C a m p e r Z71 . . Off Road C h a ss is Pkg. Z72 . . . . T ra ile rin g P a c k a g e L ig h t D u ty Z73 . . . . S pe cial I n t e r i o r T rim Z75 . . . . Frt. Quad. S h o c k s Z76 . . . . S p e cia l C o m m e ric a l C ha ss is Z77 .. . . C he vy S p o r t o r S t r e e t C oupe/G M C Z78 . . . . A p p e a r a n c e P ac ka g e Pace Car (L im it e d E d itio n ) Z79 . . . . S a n d p ip e r A p p e a r a n c e Pac ka ge Z80 . . . . T r im S pe cial Z81 . . . . C a m p e r S pe cial . . T r a ile rin g S pe cial Z82 . . C a m p e r P a c k a g e /D e lu x e Z83 Z84 . . . . C h e y e n n e / H ig h S ie rra Z85 . . . . S p o r t P ac ka g e Rally Z87 . . . . Fle xib le Facia F r o n t End Z88 . . . . C o n v e rs io n G M C Z94 . . . . C anadian O xidiz in g C o n v e r t e r S y s te m Z95 . . E m is s io n C o n tro l Equip. (D e le te ) Z98 . . . C anadian P o n tia c V e r s io n of 1TB08 A c a d ia n

M AINTENANCE AND LUBRICATION

OB-1

SECTION OB

MAINTENANCE AND LUBRICATION


CONTENTS
Gasoline Engine, L.D. Emissions, 49 S ta te s................. M aintenance S c h e d u le ................................................... Scheduled M aintenance S e rv ic e ................................. O w ner Inspections and Services.................................. Recom m ended Fluids and L u b ric a n ts....................... Gasoline Engine, L.D. Emissions, C a lifo rn ia ............... M aintenance S c h e d u le ................................................... Scheduled M aintenance S ervices................................ O wner Inspections and Services.................................. Recom m ended Fluids and L u b ric a n ts....................... OB-2 OB-2 OB-2 OB-4 OB-7 OB-8 OB-8 OB-8 OB-11 OB-15 Gasoline Engine, H .D .E m ission......................................OB-16 M aintenance S c h e d u le ................................................ .OB-16 Scheduled M aintenance S ervices...............................OB-16 Owner Inspections and Services................................. .O B -19 Recom m ended Fluids and L u b ric a n ts......................O B -23 Diesel E n g in e ...................................................................... .OB-24 M aintenance S c h e d u le ................................................ .O B -2^ Scheduled M aintenance S ervices.............................. .O B-25 Owner Inspections and Services................................ .OB-26 Recom m ended Fluids and L u b ric a n ts......................0B-.30

SECTION A Scheduled Maintenance Services For Your 1984 Gasoline-Fueled Vehicle


SCHEDULE I Follow Schedule I if you mainly operate your vehicle under one or more of the following conditions: Operating when outside temperatures remain below freezing and when most trips are less than 4 miles (6 km); or Idling for extended periods and/or low speed operation such as in door-to-door delivery; SCHEDULE I
TO BE SERVICED
ITEM NO. 1 2 3 4 Engine Oil and Oil Filter Change* Chassis Lubrication Carburetor Choke and Hoses* Carb. or Throttle Body Mounting*2 Enq. Idle Speed (See Explanation)* Vacuum or AIR Pump Drive Belts* Cooling System Refill* Wheel Bearing Repack Transmission Fluid Vacuum Advance System* Spark Plugs* PCV System Check and Service* EGR System* Air Cleaner and PCV Filter* Engine Timing* Spark Pluq Wires and Distributor* Fuel Tank, Cap and Lines* Early Fuel Evaporation System*2 Evaporative Control System* Idle Stop Solenoid* Fuel Filter* Valve Lash Adjustment*1 Thermostatically Controlled Air Cleaner

Also follow Schedule I when: Towing a trailer; Operating in dusty areas; or Using your vehicle in hard, police car, delivery or daily rental service.

WHEN TO PERFORM
Miles (Kilometers) or Months, Whichever Occurs First MILES (000) KILOMETERS (000) Every 3,000 mi. (5 000 km) o r 3 months. Every other oil change Check at 6,000 miles (10 000 km), then at 30,000 Miles (50 000 km). Also check item 3 at 45,000 Miles (75 000 km). Inspect every 12 Months or 15,000 Miles (25 000 km) Every 24 Months or 30,00 Miles (50 000 km) Every 15,000 Miles (25 000 km) See Explanation tor service intervals Check at 6,000 Miles (10 000 km), then at 30,000 Miles (50 000 km), and at 45,000 Miles (75 000 km) Replace every 30,000 Miles (50 000 km) See explanation for service intervals Service every 36 Months or 30,000 Miles (50 000 km) See Explanation for service intervals Adjust every 30,000 Miles (50 000 km) Inspect every 15,000 Miles (25 000 km) Inspect every 12 Months or 15,000 Miles (25 000 km) Check at 6,000 Miles (10 000 km) then at 30,000 Miles (50 000 km) Check at 30,000 miles (50 000 km) Service every 15,000 Miles (25 000 km) Every 30,000 Miles (50 000 km) 3 5 6 10 9

The services shown in this schedule up to 48,000 miles (60 000 km) are to be performed after 48,000 miles of the same intervals 12 20 15 25 18 30 21 35 24 40 27 45 30 50 33 55 36 60 39 65 42 70 45 75 48 80

15

5 6
7 8 9 10 1 1 12 13 14 15 16 17 18 19 20 21 22 23

Fig. O B -l-M aintenance Schedule I, Gasoline L.D. Emission, 49 States

OB-2

MAINTENANCE AND LUBRICATION

SCHEDULE II Follow Schedule II if, as a general rule, you drive your vehicle on a daily basis for several miles (km) and none of the above conditions apply. SCHEDULE II

TO BE SERVICED
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine Oil Change Filter Change Chassis Lubrication Carburetor Choke and Hoses* C arburetor or Throttle Body M ounting*2 Engine Idle Speed (See Explanation)* Vacuum or AIR Pump Drive Belts* Cooling System Refill* W heel Bearing Repack Transm ission Fluid Vacuum Advance System * Spark Plugs* PCV System Check and Service* EGR System* Air Cleaner and PCV Filter* Engine Tim ing* Spark Plug W ires and D istributor* Fuel Tank, Cap and Lines* Early Fuel Evaporation System *2 E vaporative C ontrol System Idle Stop Solenoid* Fuel Filter Valve Lash A djustm e nts*1 Therm ostatically C ontrolled Air C leaner*

WHEN TO PERFORM

Miles (kilom eters) or Months, W hichever O ccurs First M ILES (000) KILOMETERS (000)

The services shown in this schedule up to 45,000 miles (75 000 km) are to be perform ed after 45,000 m iles at the sam e intervals 7.5 12.5 15 25 22.5 37.5 30 50 37.5 62.5 45 75

Every 7,500 mi. (12 500 km) or 12 months At first and every other oil change Lubricate every 12 Months or 7,500 Miles (12 500 km) Check at 6 M onths or 7,500 Miles (12 500 km), then at 30,000 Miles (50 000 km). Also check Item 3 at 45,000 M iles (75 000 km). Inspect every 12 Months or 15,000 Miles (25 000 km) Every 24 M onths or 30,000 Miles (50 000 km) Every 30,000 M iles (50 000 km) See Explanation for service intervals Check at 6 M onths or 7,500 Miles (12 500 km) then at 30,000 Miles (50 000 km), and at 45,000 Miles (75 000 km) Replace every 30,000 M iles (50 000 km) See explanation for service intervals Service every 36 M onths or 30,000 Miles (50 000 km) See Explanation for service intervals Adjust every 30,000 M iles (50 000 km) Inspect every 15,000 Miles (25 000 km) Inspect every 12 Months or 15,000 Miles (25 000 km) Check at 7,500 Miles (12 500 km) then at 30,000 M iles (50 000 km) Check at 30,000 m iles (50 000 km) S ervice every 15,000 Miles (24 000 km) Every 30,000 Miles (50 000 km)

FOOTNOTES:
'O n ly app lica b le to 1 .9L eng ine, E n gine F am ily E1G 1.9T2H E C 9. 2AII engines EX CE PT 1.9L E n gine F am ily E1G1 9T2H EC 9. Also an E m ission C o ntrol S ervice

Fig. OB-2 Maintenance Schedule II, Gasoline, LD Emissions, 49 States

GASOLINE ENGINE, L.D. EMISSION, 49 STATES


NORMAL VEHICLE USE
The m aintenance instructions contained in this section are based on the assum ption th at your vehicle will be used as designed: to carry passengers and cargo within the lim itations indicated on the T ire Placard located on the edge of the drivers door. on reasonable road su rfaces w ithin legal operating limits. on a daily basis, as a general rule, for at least several miles (km ), and on unleaded gasoline. U nusu al o p eratin g conditions will require more frequent vehicle m aintenance as specified.

Item 1 Engine O il and O il Filter Change*


A lw a y s u se S F -Q U A L IT Y O IL S O F P R O P E R V ISC O SIT Y . A lso alw ays change oil and filter as soon as possible after driving in a dust storm . See O w n e rs M anual for fu rth er details.

Item 2 Chassis Lubrication


E very 12 m onths or 7 ,5 0 0 m iles (12 500 k m ), lubri cate transm ission shift linkage, hood latch and door hinges, parking brake cable guides, underbody contact points and linkage, clutch linkage, p ro p sh aft, tra n sfe r case shift le ver and clutch pedal springs. L u b ricate clutch cross-shaft ever 3 0 ,0 0 0 m iles (50 000 km ).

Item 3 Carburetor Choke and Hoses*


Verify th at choke and vacuum break work properly and are within specifications. Correct any binding caused by dam age or gum on the choke shaft. Inspect hoses for proper hookup, cracks, rubbing, or decay. C orrect as necessary.

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES

MAINTENANCE AND LUBRICATION

OB-3

Item 4 Carburetor Mounting Torque*


Check torque of m ounting bolts an d /o r nuts.

Item 5 Engine Idle Speed Adjustment*


A djust to the specifications shown on the underhood label. You m ust use calibrated test equipm ent.

Item 6 Vacuum or AIR Pump Drive Belts*


Inspect belts driving the vacuum or A IR pump. Look for cracks, fraying, wear and proper tension. A djust or replace as needed.

15.000 m iles (25 000 km ) if the vehicle is m ainly driven underone or m ore o f these hot conditions. In heavy city traffic where the outside tem perature regularly reaches 90F (32C). In hilly or m o u ntainous terrain. Frequent trailer pulling. Uses such as taxi, police or delivery service. If vehicle is not used under any of these conditions, change the fluid and filter (or service the screen) every 100.000 miles (160 000 km). See O w ners M anual for further details.

Item 7 Cooling System Refill *


D rain, flush and refill sy stem w ith new coolant.

Item 10 Vacuum Advance System and Hoses


Check system for proper operaion. Check hoses for proper hookup, cracks, rubbing or decay. Replace parts as needed.

Item 8 Wheel Bearing Repack


C lean and rep ack front w heel b earings at each brake relining or 15,000 m iles (25 0 0 0 k m ), w h ichever com es first, w hen vehicle is used in such service as p olice, taxi or d o o r-to -d o o r delivery. If you do not use your vehicle in such serv ice, clean and rep ack b earings at each brake relining o r 3 0 ,0 0 0 m iles (50 000 k m ), w h ichever com es first.

Item 11 Spark Plug Replacement


Replace with the type listed in your O w ners M anual.

Item 12 PCV Valve Inspection


Check th at system works properly each 15,000 miles (25 000 km ). Replace the valve and any worn, plugged or collapsed hoses at 3 0 ,0 0 0 m iles (50 000 km ).

Item 9 Transmission Fluid


Automatic Transmission - C hange the transm ission fluid and change the filter (or service the screen) every

Item 13 Exhaust Gas Recirculation System (EGR)


Conduct EGR operation system check as covered later in this m anual. Replace or clean parts as required.

Item 14 Air Cleaner and PCV Filter


R eplace every 3 0 ,0 0 0 m iles (50 000 km ). R eplace m ore often u n d e r dusty co n d itio n s. A sk your d ealer for th e p r o p e r r e p la c e m e n t in te r v a ls f o r y o u r d r iv in g conditions.

Item 15 Engine Timing Check


A djust tim ing to underhood label specifications.

Item 16 Spark Plug Wires and Distributor Inspection


Clean wires. Inspect for burns, cracks or other dam age. Check the boot fit at distributor cap and spark plugs. Inspect inside and outside of the cap and rotor for cracks, carbon tracking and corrosion. Replace as needed.

Item 17 Fuel Tank, Cap and Lines


Inspect the fuel tank, cap and lines for dam age or leaks. Remove cap, inspect gasket for an even filler neck im print, and any dam age. Replace parts as needed.

Item 18 Early Fuel Evaporation (EFE) System


Check th at valve works properly; correct any binding. Check th at therm al vacuum switch works properly. Check hoses for cracks, rubbing or decay. Replace parts as needed.
Fig. OB-3-Oil Viscosity Chart, Gasoline, LDX, 49 States

OB-4

MAINTENANCE AND LUBRICATION


before checking and adjusting valve clearance. Check and adjust valve clearance every 15,000 miles (24 000 km).

Item 19 Evaporative Control System (ECS)


Check all fuel and vapor lines and hoses for proper hookup, routing and condition. Check th at bowl vent and purge valves work properly, if equipped. Remove canister, check for cracks or dam age. Replace as needed.

Item 23 Thermostatically Controlled A ir Cleaner*


Inspect all hoses and ducts for proper hookup. M ake sure valve w orks properly.

Item 20 Idle Stop Solenoid, and/or Dashpot


C heck th a t p arts work properly. R eplace them as needed.

OWNER INSPECTIONS AND SERVICES


Listed in Figs. OB-4 through OB-6 are vehicle inspections and services which should be m ade by either you or a qualified tehcnician at the frequencies indicated to help ensure proper safety em ission perform ance and dependability of your vehicle. Take any problems prom ptly to your dealer or a qualified technician for service advice. W henever repairs are necessary, have them completed at once. For your safety and th at of others, any safety related components th at could have been dam aged in an accident should be inspected. All needed repairs should be performed before operating your vehicle.

Item 21 Fuel Filter


Replace carburetor fuel filter at mileage shown on M aintenance Schedule or sooner if clogged.

Item 22 Valve Lash Adjustment


Incorrect valve clearance will result in increased engine noise and lower engine output, thereby adversely affecting engine perform ance. Retorque rocker shaft bracket nuts

FREQUENCY BEFORE OPERATING YOUR VEHICLE

INSPECTION OR SERVICE
Warning light, buzzer tone and chime operation. Glass, light or reflector condition Seat adjuster operation Rearview mirror and sun visor operation Door and gate latch operation Automatic transmission shift indicator operation Windshield wiper and washer operation Defroster operation

WHATTO DO
Check operation of all warning lights, buzzers, tone generators and chimes also all interior lights. See your Owner's Manual for details. Look for broken, scratched, dirty or damaged glass that could reduce vi sion or visibility or cause injury. Replace, clean or repair promptly. When adjusting a manual seat, be sure seat adjusters latch by pushing seat forward and backward. Make sure friction joints hold mirrors and sun visors in place. Make sure that all doors and wagon or hatchback gates close, latch and lock tightly. Make sure the indicator points to the gear chosen. Note the operation and condition of the wiper blades and the flow and aim of the washer spray. Periodically check the air flow from the ducts at the inside base of the windshield. Do this with the heater control lever in defrost position and fan lever in high. Blow the horn occasionally to make sure it works. Check all button locations. Be alert to abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if the brake warning light goes on, some thing may be wrong. See your Owners Manual. Be alert to any changes in the sound of the system or any smell of fumes. These are signs the system may be leaking or overheating. Have it inspected and repaired at once. Also see Engine Exhaust Gas Caution (Carbon Monoxide) and Catalytic Converter" in your Owners Manual. Be alert to a vibration of the steering wheel or seat at normal highway speeds. This may mean a wheel balance is needed. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjust ment or wheel alignment. Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn, or has too much free play, or if unusual sounds are noted when turning or parking. Take note of light pattern occasionally. If beams seem improperly aimed, headlights should be adjusted. Check level and add if necessary. See Owner's Manual. Section 5. Check level in coolant reservoir tank and add if necessary. Inspect coolant and replace if dirty or rusty. See Owners Manual. Section 5. Check level in reservoir and add if necessary. When opening hood, note the operation of secondary latch. It should keep hood from opening all the way when primary latch is released. Make sure that hood closes firmly after services are performed.

Horn operation Brake system operation

WHILE OPERATING YOUR VEHICLE

Exhaust system operation

Tires, Wheels and Alignment

Steering system operation

Headlight aim Engine oil levelf

AT EACH FUEL FILL

Engine coolant level and conditionf Windshield washer fluid level Hood latch operation

Fig. OB-4--Owner Inspections and Services, Chart A

MAINTENANCE AND LUBRICATION

OB-5

FREQUENCY

INSPECTION OR SERVICE
Tire pressure check

WHATTO DO
Maintain pressures as shown on Tire Placard on the driver s door (include spare). Pressure should be checked when tires are "cold Check operation of license plate light, sidemarker lights, headlights, in cluding high beams, parking lights, taillights, brake lights, turn signals, backup lights and hazard warning flashers. Periodically, after the vehicle has been parked for a while, inspect the surface beneath the vehicle for water, oil, fuel or other fluids. Water drip ping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, the cause should be found and corrected at once Check level in accordance with Owner s Manual instructions (Section 5) and keep at proper level Check fluid level Note A low fluid level can indicate worn disc brake pads and should be checked. Note the clutch pedal free travel. It should be about 1". Adjust linkage whenever there is little or no free travel. Park on a fairly steep hill and hold the vehicle with the parking brake only This checks holding ability. For automatic transmission, check 'Park" by releasing all brakes after shifting the transmission to P" (Park). While parked, try to turn key to "Lock" in each gear range The key should turn to Lock'' only when gear is in Park" on automatic or Reverse" on manual transmission. Un vehicles with key release lever, try to turn key to "Lock" without depressing the lever The key should turn to "Lock" only with the key lever depressed. On all vehicles, the key should come out only in "Lock. Caution: Before performing the following safety switch check, be sure to have enough room around the vehicle Then, firmly apply both the parking brake (see Owner s Manual for procedure) and the regular brakes. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition promptly Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage On automatic transmission vehicles, try to start the engine in each gear. The starter should crank only in P (Park) or "N" (Neutral).

AT LEAST MONTHLY

Light operation

Fluid leak check

AT LEAST SEMI ANNUALLY (FOR EXAMPLE, EVERY SPRING AND FALL)

Power steering pump reservoir levelf Brake master cylinder reservoir levelf Clutch Pedal free travel Parking brake and transmission Park mechanism operation Steering column lock operation

Starter safety switch operation

AT LEAST ANNUALLY
Seatback latch operation Lap and shoulder belts condition and operation Movable head restraint operation Seatback recliner operation (if equipped) Spare tire and jack storage

On manual transmission vehicles place the shift lever in "Neutral push the clutch halfway and try to start The starter should crank only when the clutch is fully depressed. Be sure seatbacks latch on those vehicles with folding seats using mech anical latches. See Owners Manual for latch operating information. Inspect belt system, including: webbing, buckles, latch plates, retractors, guide loops and anchors. On vehicles with movable restraints, make sure restraints stay in the desired position. (See adjustment instructions in Owners Manual.) Make sure the recliner is holding by pushing and pulling on the top of the seatback while it is reclined. Be alert to rattles in rear of vehicle. Make sure the spare tire, all jacking equipment and any covers or doors are securely stowed at all times. Oil jack ratchet mechanism after each use. At least every spring, flush from the underbody with plain water any corrosive materials used for ice and snow removal and dust control Take care to thoroughly clean any areas where mud and other debris can collect. Sediment packed in closed areas of the vehicle should be loosened before being flushed. Inspect coolant and freeze protection. If dirty or rusty, drain, flush and refill with new coolant. Keep coolant at the proper mixture as specified in your Owners Manual. This provides proper freeze protection, corro sion inhibitor level and engine operating temperature. Inspect hoses and replace, if cracked, swollen or deteriorated. Tighten hose clamps. Clean outside of radiator and air conditioning condensor. Wash radiator filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and cap is also recommended.

Underbody flushing

Engine cooling system

Fig. OB-5--Owner Inspections and Services, Chart B


fN O TE: A large loss in these systems may indicate a problem. Have them inspected and repaired at once.

OB-6

MAINTENANCE AND LUBRICATION

FREQUENCY

INSPECTION OR SERVICE
M a nu a l. .

WHATTO DO
Maintain level within operating range on dipstick. Refer to Owner's Check tires for abnormal wear or damage. Also, check for damaged wheels. To equalize tire wear and obtain maximum tire life, it is sug gested that tires be rotated at about 7,500 miles (12 500 km) then each 15,000 miles (25 000 km) thereafter. See Tires in Owners Manual, for further information. Check fluid level and add as required. For convenience the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, binding, leaks, cracks, chafing etc. Inspect disc brake pads for wear and rotors for surface condition. Also inspect drum brake linings for wear and cracks. Inspect other brake parts, including drums, wheel cylinders, parking brake, etc. at the same time Check parking brake adjustment. INSPECT BRAKES MORE OFTEN IF HABIT OR CONDITIONS RESULT IN FREQUENT BRAKING.

Tire and wheel inspection and rotation

Manual transmission Brake systems inspection

Steering and suspension

EACH TIME OIL IS CHANGED (WHEN VEHICLE IS ON HOIST)

Exhaust system inspection

Inspect front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc (On vehicles equipped with manual steering gear, check for seal leakage.) Inspect final drive axle output shaft seals for leaking. Front Suspension and Steering Linkage (a) On C20 and G30, lubricate every 4 months or 6,000 miles (9 000 km). (b)On all other vehicles, lubricate every 12 months or 7,500 miles (12000 km). (c) Lubricate suspension and steering linkage every 3 months or 3,000 miles (4 800 km) when operating under dusty or muddy conditions and in extensive off-road use. Inspect complete system including catalytic converter. Jnspect body near the exhaust system. Look for broken, damaged, missing or out-ofposition parts as well as open seams, holes, loose connections or other conditions which could cause a heat build up in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment. Inspect for damaged or missing parts, interference or binding. Inspect all belts for cracks, fraying wear. Adjust or replace as needed. Check fluid level and add if needed. Locking Differential - In general service, drain fluid at 7,500 miles (12 000 km) and refill. Check fluid level and add as needed at subsequent 7,500 mile (12 000 km) intervals In severe operating conditions, or trailer towing applications, dram fluid every 7,500 miles, (12000km) and refill. Standard Differential - In general service, check fluid level and add as needed every 7,500 miles (12 000 km). In severe operating conditions, trailer towing applications, drain fluid every 7,500 miles (12 000 km) and refill. Four Wheel Drive - Every 12 months or 7,500 miles (12 000 km), check front axle and transfer case and add lubricant when necessary. Lubricate propeller shaft slip joint, constant velocity universal joint and steering linkage. Oil control lever pivot point and exposed control linkage. Check vent hose at front axle transfer case for kinks and proper installation More frequent lubrication may be required on heavy duty off-road operation See Owners and Drivers Manual for further information

Throttle linkage inspection Engine drive belts Rear axle/front axle/transfer case

Fig. OB-6--Owner Inspections and Services, Chart C

MAINTENANCE AND LUBRICATION

OB-7

USAGE
Engine Engine Coolant

FLUID/LUBRICANT
"SF or SF/CD or SF/CC Engine Oil conforming to GM spec. 6048-M Mixture of water and a high quality Ethylene Glycol base type antifreeze conforming to GM spec. 1825-M (GM Part No. 1052753) or equivalent Delco Supreme 11 fluid or DOT-3 Chassis grease meeting requirements of GM spec. 6031-M GM power steering fluid Part No. 1050017 or equivalent Lubricant GM Part No. 1051052 or equivalent DEXRON II Automatic Transmission Fluid

Brake System Parking Brake Cables Pdwer Steering System Manual Steering Gear Automatic T ransmission 4-Speed Manual Trans. w/O.D. S10 Truck with Manual Trans. Transfer Case DifferentialStandard Manual Transmission (Except: 4-Speed with O.D., and S10 Truck) DifferentialLocking Manual Transmission Shift Linkage, Column Shift, Propeller Shaft Slip Joint Key Lock Cylinders Clutch Linkage (Man. Trans, only) a. Pivot points b. Push rod to clutch fork joint, and cross shaft pressure fitting Chassis Lubrication Windshield Washer Solvent Hood Latch Assembly a. Pivots and spring anchor b. Release pawl Front Wheel Bearings Constant Velocity Universal Joint Automatic Transmission Shift Linkage, Floor Shift Linkage, Hood and Door hinges, body door hinge pins, tailgate hinge and linkage, folding seat, fuel door hinge

SAE-80W, GL-5 or SAE-80W-90 GL-5 gear lubricant (SAE-80WGL-5 in Canada) Lubricant GM Part No 1052271 Chassis grease meeting requirements of GM spec. 6031 -M (GM Part No. 1052276)* Light Oil or General Purpose Silicone Lubricant. a. Engine oil b. Chassis grease meeting require ments of GM spec. 6031 -M Chassis grease meeting requirements of GM spec. 6031-M GM Optikleen washer solvent Part No. 1051515 or equivalent a. Engine oil b. Chassis grease Lubricant GM Part No. 1051344 or equivalent* GM Lubricant Part No 1052497 or equivalent Engine Oil

Fluids and lubricants identified with GM part numbers or GM specification numbers may be obtained from your GM dealer

Fig. 0B-7--Recommended Fluids and Lubricants

OB-8

MAINTENANCE AND LUBRICATION

SECTION A Scheduled Maintenance Services For Your 1984 Gasoline-Fueled Vehicle


SCHEDULE I Follow Schedule I if you mainly operate your vehicle under one or more of the following conditions: Operating when outside temperatures remain below freezing and when most trips are less than 4 miles (6 km); or Idling for extended periods and/or low speed operation such as in door-to-door delivery; SCHEDULE
TO BE SERVICED
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Engine Oil and Oil Filter Change* Chassis Lubrication Carburetor Choke and Hoses* Carb. or Throttle Body Mounting*3 Engine Idle Speed (See Explanation)* AIR Pump Drive Belts* Cooling System Refill* Wheel Bearing Repack Transmission Fluid Vacuum Advance System* Spark Plugs* PCV System Check and Service* EGR System* Air Cleaner and PCV Filter* Engine Timing* Spark Plug Wires & Distributor* Fuel Tank, Cap & Lines* Early Fuel Evaporative System*3 Idle Stop Solenoid* Valve Lash Adjustment*2 Thermostatically Controlled Air Cleaner

Also follow Schedule I when: Towing a trailer; Operating in dusty areas; or Using your vehicle in hard, police car, delivery or rental service.

WHEN TO PERFORM
Miles (Kilometers) or Months, Whichever Occurs First MILES (000) KILOMETERS (000) Every 3,000 mi. (5 000 km) or 3 months. Every other oil change Check at 6,000 miles (10 000 km), then a t30,000 Miles (50 000 km). Also check item 3 at 45,000 Miles (75 000 km). Inspect every 12 Months or 15,000 Miles (25 000 km) Every 24 Months or 30,00 Miles (50 000 km) Every 15,000 Miles (25 000 km) See Explanation for service intervals Check every 30,000 Miles (50 000 km) Replace every 30,000 Miles (50 000 km) See explanation for service intervals Service every 36 Months or 30,000 Miles (50 000 km) See Explanation for service intervals Adjust every 30,000 Miles (50 000 km) Inspect every 30,000 Miles (50 000 km) Inspect every 12 Months or 15,000 Miles (25 000 km) Check at 6,000 Miles (10 000 km) then at 30,000 Miles (50 000 km) Check at 30,000 Miles (50 000 km) Adjust every 15,000 Miles (25 000 km) Every 30,000 Miles (50 000 km) 3 5 6 10 9

The services shown in this schedule up to 48,000 miles (60 000 km) are to be performed after 48,000 miles of the same intervals 12 20 15 25 18 30 21 35 24 40 27 45 30 50 33 55 36 60 39 65 42 70 45 75 48 80

15

Fig. OB- 8 -Maintenance Schedule I, Gasoline, LDX, California

MAINTENANCE AND LUBRICATION

OB-9

SCH ED U LE II Follow Schedule II if, as a general rule, you drive your vehicle on a daily basis for several miles (km) and none of the above conditions apply. SCHEDULE II

TO BE SERVICED
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Enqine Oil Chanqe Filter Change Chassis Lubrication C arburetor Choke and Hoses* Carburetor or T hrottle Body M ounting*3 Enqine Idle Speed (See E xplanation)* AIR Pump Drive Belts* Cooling System Refill* W heel Bearing Repack Transm ission Fluid Vacuum Advance System * Spark Pluqs* PCV System Check and Service* EGR System* Air C leaner and PCV Filter* Enqine Tim ing* Spark Pluq W ires and Distributor* Fuel Tank, Cap and Lines* Early Fuel Evaporative System *3 Idle Stop Solenoid* Valve Lash A djustm e nts*2 Therm ostatically C ontrolled Air C leaner

WHEN TO PERFORM
M iles (kilom eters) or Months, W hichever O ccurs First MILES (000) KILO METERS (000) Every 7,500 mi. (12 500 km) or 12 months At first and every other oil chanqe Lubricate every 12 M onths or 7,500 Miles (12 500 km) Check at 6 M onths or 7,500 Miles (12 500 km), then at 30,000 M iles (50 000 km). Also check Item 3 at 45,000 M iles (75 000 km). Inspect every 12 M onths or 15,000 Miles (25 000 km) Every 24 M onths or 30,000 Miles (50 000 km) Every 30,000 M iles (50 000 km) See Explanation for service intervals C heck every 30,000 Miles (50 000 km) Replace every 30,000 Miles (50 000 km) See explanation for service intervals Service every 36 Months or 30,000 Miles (50 000 km) See Explanation for service intervals Adjust every 30,000 M iles (50 000 km) Inspect every 30,000 M iles (50 000 km) Inspect every 12 M onths or 15,000 Miles (25 000 km) Check at 7,500 M iles (12 500 km) then at 30,000 M iles (50 000 km) Check at 30,000 m iles (50 000 km) Adjust every 15,000 Miles (25 000 km) Every 30,000 M iles (50 000 km)

The services shown in this schedule up to 45,000 miles (75 000 km) are to be perform ed after 45,000 miles at the sam e intervals 7.5 12.5 15 25 22.5 37.5 30 50 37.5 62.5 45 75

FOOTNOTES: *An Emission Control Service. *ln California these are the minimum Emission Control Maintenance Services an owner must perform according to the California Airl Resources Board General Motors, however, urges that all Emission Control Maintenance services shown above be performed. To maintain your other new car warranties, all services shown in this folder should be performed. I

Only these emissions control maintenance items are considered to be required maintenance as defined by the California Air Resources Board (ARB) regulations and are, according to such regulations, the minimum maintenance an owner in California must perform to fulfill the minimum requirements of

the emission warranty. All other emission maintenance items are recommended maintenance as defined by such regulations. General Motors urges that all emission control maintenance items be performed. 2Only applicable to 1,9L engine, Engine Family E1G1.9T2TBA8. 3Not applicable to 1,9L engine, Engine Family E1G1.9T2TBA8.

Fig. OB- 9 Maintenance Schedule II, Gasoline LDX California

OB-10 M AINTEN ANC E A N D LUBRICATION

GASOLINE ENGINE, L.D. EMISSION, CALIFORNIA


NORMAL VEHICLE USE
The m aintenance instructions contained in this section are based on the assum ption th a t your vehicle will be used as designed: to carry passengers and cargo within the lim itation indicated on the Tire Placard located on the edge of the drivers door, on reasonable road surfaces w ithin legal operating limits, on a daily basis, as a general rule, for a t least several miles (km ), and on unleaded gasoline. U nusu al o p eratin g conditons will req u ire frequent vehicle m aintenance as specified. more

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES Item 1 Engine O il and O il Filter Change*


A lw a y s u s e S F -Q U A L IT Y O IL S O F P R O P E R V ISC O SIT Y . A lso alw ays ch ange oil and filter as soon as possible after driv in g in a dust storm .

Item 2 Chassis Lubrication


E very 12 m o n th s o r 7 ,5 0 0 m iles (12 500 k m ), lu bri cate transm ission shift linkage, hood latch, hood and door h inges, parking brak e cab le g u id es, und erb o d y contact points and linkage, clutch linkage, propshaft, transfer case shift lever and clutch pedal springs. Lubricate clutch cross shaft every 3 0 ,0 0 0 m iles (50 0 0 0 km ).

Item 8 Wheel Bearing Repack


C lean and rep ack front w heel b earings at each brake relining or 15,000 m iles (25 0 0 0 k m ), w h ichever com es first, w hen vehicle is used in such service as po lice, taxi o r d o o r-to-door deliv ery . If you do not use your vehicle in such service, clean and rep ack bearings at each brake relining or 3 0 ,0 0 0 m iles (50 0 0 0 k m ), w h ichever com es first.

Item 3 Carburetor Choke and Hoses*


Verify th at choke and vacuum break work properly and are within specifications. C orrect any binding caused by dam age or gum on the choke shaft. Inspect hoses for proper hookup, cracks, rubbing or decay. C orrect as necessary.

Item 9 Transmission Fluid


A utom atic Transm ission C h ange the tran sm is sion fluid and change the filter (or service the screen) ev ery 15,000 m iles (25 000 km ) if the vehicle is m ainly driven u n d er one or m ore o f these hot conditions: In heavy city traffic w here the outside tem perature regularly reaches 90 (32C). In hilly or m o u ntainous terrain. F requent trailer p ulling. U ses such as tax i, p olice or deliv ery service. If vehicle is not used under any o f these conditions, change the fluid and filter (or service the screen) every 100,000 m iles (160 000 km ). M anual T ransm ission (S10 w ith 4-speed only) C hange tran sm issio n fluid at 7 ,5 0 0 m iles (12 500 km ), then every 3 0 ,0 0 0 m iles (50 000 km ).

Item 4 Carburetor Mounting Torque*


Check torque of m ounting bolts an d /o r nuts.

Item 5 Engine Idle Speed Adjustment*


A djust to the specifications shown on the underhood label. You m ust use calibrated test equipm ent.

Item 6 AIR Pump Drive Belts*


Inspect belts driving the A IR pump. Look for cracks, fraying, w ear and proper tension. A d ju st or replace as needed.

Item 7 Cooling System Refill


D rain, flush and refill system with new coolant.

M AINTENANCE A N D LUBRICATION

OB-11

Item 10 Vacuum Advance System and Hoses*


Check system for proper operation. Check hoses for proper hookup, cracks, rubbing or decay. R eplace parts as needed.

Item 18 Early Fuel Evaporation (EFE) System


Check th a t valve works properly; correct any binding. Check th a t therm al vacuum switch works, properly. Check hoses for crakcs, rubbing or decay. Replace parts as needed.

Item 11 Spark Plug Replacement*


R ep lace w ith the ty p e listed in y o u r O w n e rs and D riv ers M anual.

Item 19 Idle Stop Solenoid, a n d/o r Dashpot*


C heck th a t p a rts w ork properly. R eplace them as needed.

Item 12 PCV Valve Inspection*


C heck that system w orks properly each 15,000 miles (25 000 km ). F o r all en g in es ex c e p t 1 .9 L , rep lace the valve and any w o rn , p lu g g ed o r co llap sed hoses at 3 0 ,0 0 0 m iles (50 0 0 0 k m ). For 1.9L engine, clean the PC V orifice every 30,000 m iles (50 000 km ).

Item 20 Valve Lash Adjustment*


Incorect valve clearance will result in increased engine noise and lower engine output, thereby adversely affecting engine perform ance. R eplace rocker sh aft b ra ck e t nuts before checking and ad ju stin g valve clearan ce. C heck and adjust valve clearance every 15,000 m iles (25 000 km ).

Item 13 Exhaust Gas Recirculation System (EGR)*


C O N D U C T E G R O P E R A T IO N system check as covered in S erv ice M an u al. R ep lace o r clean parts as required.

Item 21 Thermostatic Controlled A ir Cleaner*


Inspect all hoses and ducts for proper hook-up. M ake sure valve w orks p roperly.

Item 14 Air Cleaner and PCV Filter*


R eplace ev ery 3 0 ,0 0 0 m iles (50 000 km ). R eplace m ore often u n d e r d usty co n d itio n s. A sk y o ur dealer for th e p r o p e r r e p l a c e m e n t in t e r v a l s f o r y o u r d r iv in g conditions.

OWNER INSPECTIONS AND SERVICES


Listed below are vehicle inspections and services which should be m ade by either you or a qualified technician at the frequencies indicated to help ensure proper safety, emission perform ance and dependability of your vehicle. Take any problems prom ptly to your dealer or a qualified technician for service advice. W henever repairs are necessary,have them com pleted at once. For your safety and th a t of others, any safety re lated com ponents th a t could have been dam aged in an accident should be inspected. All needed repairs should be perform ed before operating your vehicle.

Item 15 Engine Timing Check*


A djust tim ing to underhood label specifications.

Item 16 Spark Plug Wires and Distributor Inspection*


Clean wires. Inspect for burns, cracks or other dam age. Check the boot fit at distributor cap and spark plugs. Inspect inside and outside of the cap and rotor for cracks, carbon tracking and corrosion. Replace as needed.

Item 17 Fuel Tank, Cap and Lines*


Inspect the fuel tank, cap and lines for dam age or leaks. Remove fuel cap, inspect gasket for an even filler neck im print, and any dam age. R eplace p arts as needed.

OB-12 M AINTEN ANC E A N D LUBRICATION

FREQUENCY BEFORE OPERATING YOUR VEHICLE

INSPECTION OR SERVICE
Warning light, buzzer tone and chime operation. Glass, light and reflector condition

WHATTO DO
Check operation of all warning lights, buzzers, tone generators and chimes also all interior lights See your Owner s Manual for details. Look for broken, scratched, dirty or damaged glass, light or reflector that could reduce vision or visibility or cause injury. Replace, clean or repair promptly. When adjusting a manual seat, be sure seat adjusters latch by pushing seat forward and backward Make sure friction joints hold mirrors and sun visors in place Make sure that all doors and wagon or hatchback gates close, latch and lock tightly Make sure the indicator points to the gear chosen Note the operation and condition of the wiper blades and the flow and aim of the washer spray Periodically check the air flow from the ducts at the inside base of the windshield Do this with the heater control lever in defrost position and fan lever in "high" Blow the horn occasionally to make sure it works. Check all button locations. Be alert to abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if the brake warning light goes on, some thing may be wrong. Be alert to any changes in the sound of the system or any smell of fumes. These are signs the system may be leaking or overheating. Have it inspected and repaired at once. Also see Engine Exhaust Gas Caution (Carbon Monoxide) ' and Catalytic Converter in your Owner's Manual. Be alert to a vibration of the steering wheel or seat at normal highway speeds This may mean a wheel balance is needed Also, a pull right or left on a straight, level road may show the need for a tire pressure adjust ment or wheel alignment Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn, or has too much free play, or if unusual sounds are noted when turning or parking. Take note of light pattern occasionally If beams seem improperly aimed, headlights should be adjusted. Check level and add if necessary. See Owners Manual. Check level in coolant reservoir tank and add if necessary. Inspect coolant and replace if dirty or rusty. See Owner's Manual. Check level in reservoir and add if necessary. When opening hood, note the operation of secondary latch. It should keep hood from opening all the way when primary latch is released. Make sure that hood closes firmly after services are performed.

Seat adjuster operation Rearview mirror and sun visor operation Door and gate latch operation Automatic transmission shift indicator operation Wiper and washer operation Defroster operation

WHILE OPERATING YOUR VEHICLE

Horn operation Brake systum operation

Exhaust system operation

Tires, Wheels and Alignment

Steering system operation

Headlight aim Engine oil levelf

AT EACH FUEL FILL

Engine coolant level and conditionf Windshield washer fluid level Hood latch operation

Fig. OB-11 --Owner Inspections and Services, Chart A

M AINTENANCE A N D LUBRICATION

OB-13

FREQUENCY

INSPECTION OR SERVICE
Tire pressure check

WHATTO DO
Maintain pressures as shown on Tire Placard on the driver's door (include spare) Pressure should be checked when tires are cold Check operation of license plate light, sidemarker lights, headlights, including high beam, parking lights, taillights, brake lights, turn signals, backup lights and hazard warning flashers. Periodically, after the vehicle has been parked for a while, inspect the surface beneath the vehicle for water, oil, fuel or other fluids. Water drip ping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, the cause should be found and corrected at once. Check level in accordance with Owner s Manual instructions (Section 5) and keep at proper level Check fluid level. Note: A low fluid level can indicate worn disc brake pads and should be checked Note the clutch pedal free travel It should be about 1' Adjust linkage whenever there is little or no free travel. Park on a fairly steep hill and hold the vehicle with the parking brake only This checks holding ability For automatic transmission, check "Park by releasing all brakes after shifting the transmission to "P" (Park) While parked, try to turn key to "Lock"in each gear range. The key should turn to Lock'' only when gear is in Park' on automatic or Reverse" on manual transmission. Un vehicles with key release lever, try to turn key to Lock' without depressing the lever The key should turn to "Lock" only with the key lever depressed. On all vehicles, the key should come out only in Lock" Caution: Before performing the following safety switch check, be sure to have enough room around the vehicle. Then, firmly apply both the parking brake (see Owner's Manual for procedure) and the regular brakes. Do not use the accelerator pedal If the engine starts, be ready to turn off the ignition promptly Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage. On automatic transmission vehicles, try to start the engine in each gear. The starter should crank only in P (Park) or N" (Neutral) On manual transmission vehicles place the shift lever in Neutral" push the clutch halfway and try to start The starter should crank only when the clutch is fully depressed.

AT LEAST MONTHLY

Light operation

Fluid leak check

AT LEAST SEMI ANNUALLY (FOR EXAMPLE, EVERY SPRING AND FALL)

Power steering pump reservoir levelt Brake master cylinder reservoir level Clutch Pedal free travel Parking brake and transmission Park mechanism operation Steering column lock operation

Starter safety switch operation

Seatback latch operation

AT LEAST ANNUALLY

Be sure seatbacks latch on those vehicles with folding seats using mech anical latches. See Owners Manual for inertial latch operating information Inspect belt system, including: webbing, buckles, latch plates., retractors, guide loops and anchors. On vehicles with movable restraints, make sure restraints stay in the desired position (See adjustment instructions in Owner s Manual.) Make sure the recliner is holding by pushing and pulling on the top of the seatback while it is reclined. Be alert to rattles in rear of vehicle. Make sure the spare tire, all jacking equipment and any covers or doors are securely stowed at all times Oil jack ratchet mechanism after each use At least every spring, flush from the underbody with plain water any corrosive materials used for ice and snow removal and dust control Take care to thoroughly clean any areas where mud and other debris can collect Sediment packed in closed areas of the vehicle should be loosened before being flushed. Inspect coolant and freeze protection If dirty or rusty, drain, flush and refill with new coolant as shown in your Owner's Manual. Keep coolant at the proper mixture as specified in your Owners Manual. This provides proper freeze protection, corrosion inhibitor level and engine operating temperature. Inspect hoses and replace if cracked, swollen^leteriorated Tighten hose clamps. Clean outside of radiator and air conditioning condensor Wash radiator filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and cap is also recommended.

Lap and shoulder belts condition and operation Movable head restraint operation Seatback recliner operation (if equipped) Spare tire and jack storage

Underbody flushing

Engine cooling system*

Fig. OB-12-Owner Inspection and Services, Chart B

OB-14 M AINTEN ANC E A N D LUBRICATION

FREQUENCY

INSPECTION OR SERVICE
Automatic transmission fluid levelf Tire and wheel inspection and rotation

WHATTO DO
Maintain level within operating range on dipstick. Refer to Owner's Manual. Section 5. Check tires for uneven or abnormal wear. Check for damaged wheels. To equalize wear and obtain maximum tire life, it is suggested that tires be rotated at about 7,500 miles (12 500 km) then each 15,000 miles (25 000 km) thereafter See Tires" in owner's Manual. Section 5, for further information For convenience the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, binding, leaks, cracks, chafing etc Inspect disc brake pads for wear and rotors for surface condition. Also inspect drum brake linings for wear and cracks. Inspect other brake parts, including drums, wheel cylinders, parking brake, etc. at the same time. Check parking brake adjustment. INSPECT BRAKES MORE OFTEN IF HABIT OR CONDITIONS RESULT IN FREQUENT BRAKING.

Brake systems inspection

Steering and suspension

EACH TIME OIL IS CHANGED (WHEN VEHICLE IS ON HOIST)

Exhaust system inspection'

Inspect front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. (On vehicles equipped with manual steering gear, check for seal leakage ) Inspect final drive axle output shaft seals for leaking. Front Suspension and Steering Linkage (a) On C20 and G30, lubricate every 4 months or 6,000 milesflOOOO km). (b)On all other vehicles, lubricate every 12 months or 7,500 miles (12500 km). (c) Lubricate suspension and steering linkage every 3 months or 3,000 miles (5 000 km) when operating under dusty or muddy conditions and in extensive off-road use. Inspect complete system including catalytic converter, inspect body near the exhaust system Look for broken, damaged, missing or out-of position parts as well as open seams, holes, loose connections or other conditions which could cause a heat build up in the floor pan or could let exhaust fumes seep into the trunk or passenger compartment. Inspect for damaged or missing parts, interference or binding. Inspect all belts for cracks, fraying wear and proper tension. Adjust or replace as needed. Check fluid level and add if needed. Locking Differential - In general service, drain fluid at 7,500 miles (12 500 km) and re,il1 Check fluid level and add as needed at subsequent 7,500 mile (12 500 km) intervals. In severe operating conditions, or trailer towing applications, drain fluid every 7,500 miles, (12 500 km) and refill. Standard Differential - In general service, check fluid level and add as needed every 7,500 miles (12 600 km). In severe operating conditions, trailer towing applications, drain fluid every 7,500 miles (12 500 km) and refill. FourWheel Drive- Every 12 months or 7,500 miles (12 000 km), check front axle and transfer case and add lubricant when necessary. Lubricate propeller shaft slip joint, constant velocity universal joint and steering linkage. Oil control lever pivot point and exposed control linkage Check vent hose at front axle transfer case for kinks and proper installation. More frequent lubrication may be required on heavy duty off-road operation See Owner's and Driver's Manual for further information. Check fluid level and add as required.

Throttle linkage inspection Engine drive belts Rear axle/front axle/transfer case

Manual transmission

Fig. OB-13--Owner Inspections and Services, Chart C


*An emission service fN O T E: A large loss in these systems may indicate a problem. Have them inspected and repaired at once.

MAINTENANCE AND LUBRICATION

OB-15

USAGE
Engine Engine Coolant

FLUID/LUBRICANT
"SF' or "SFCD" or "SF/CC" Engine Oil conforming to GM spec. 6048-M Mixture of water and a high quality Ethylene Glycol base type antifreeze conforming to GM spec. 1825-M (GM Part No. 1052753) or equivalent Delco Supreme 11 fluid or DOT-3 Chassis grease meeting requirements of GM spec. 6031-M GM power steering fluid Part No. 1050017 or equivalent Lubricant GM Part No. 1051052 or equivalent DEXRON II Automatic Transmission Fluid

Brake System Parking Brake Cables Power Steering System Manual Steering Gear Automatic T ransmission 4-Speed Manual Trans. w/O.D S10 Truck with Manual Trans. Transfer Case DifferentialStandard Manual Transmission (Except: 4-Speed with O.D., and S10 Truck) DifferentialLocking Manual Transmission Shift Linkage, Column Shift, Propeller Shaft Slip Joint Key Lock Cylinders

SAE-80W, GL-5 or SAE-80W-90 GL-5 gear lubricant (SAE-80WGL-5 in Canada) Lubricant GM Part No. 1052271 Chassis grease meeting requirements of GM spec 6031-M Light Oil or General Purpose Silicone Lubricant (GM Part No. 1052276) a. Engine oil b. Chassis grease meeting require ments of GM spec. 6031 -M Chassis grease meeting requirements of GM spec. 6031-M GM Optikleen washer solvent Part No 1051515 or equivalent a. Engine oil b. Chassis grease Lubricant GM Part No 1051344 (one pound) or equivalent* GM Lubricant Part No 1052497 or equivalent Engine Oil

Clutch Linkage (Man. Trans, only) a Pivot points b. Push rod to clutch fork joint, and cross shaft pressure fitting Chassis Lubrication Windshield Washer Solvent Hood Latch Assembly a. Pivots and spring anchor b. Release pawl Front Wheel Bearings Constant Velocity Universal Joint Automatic Transmission Shift Linkage, Floor Shift Linkage, Hood and Door hinges, body door hinge pins, tailgate hinge and linkage, folding seat, fuel door hinge

Fluids and lubricants identified with GM part numbers or GM specification numbers may be obtained from your GM dealer.

Fig. OB-14 -Recommended Fluids and Lubricants

OB-16 M AINTEN ANC E A N D LUBRICATION

SECTION A Scheduled Maintenance Services For Your 1984 Gasoline-Fueled Vehicle


SCHEDULE I Follow Schedule I if vou mainly operate your vehicle under one or more of the following conditions: Operating when outside temperatures remain below freezing and when most trips are less than 4 miles (6 km); or
Idling for extended periods and/or low speed operation such as in door-to-door delivery;

Also follow Schedule I when: Towing a trailer; Operating in dusty areas; or Using your 'vehicle in'hard, police car, delivery or rental service.

SCHEDULE I
WHEN TO PERFORM TO BE SERVICED
ITEM NO. Miles (Kilometers) or Months, Whichever Occurs First MILES (000) KILOMETERS (000) Every 6,000 Miles (10 000 km) or 2 Months Every 4 Months or 6,000 Miles (10 000 km) Every 24 Months or 24,000 Miles (40 000 km) Every 12 Months or 12,000 Miles (20 000 k m l At 1st 4 Months or 6,000 Miles (10 000 km) then at 12 Month/ 12,000 Mile (20 000 km) intervals 3 5 6 10 9 15 The services shown in this schedule up to 48,000 miles (80 000 km) are to be performed after 48,000 miles of the same intervals 12 20 15 25 18 30 21 35 24 40 27 45 30 50 33 55 36 60 39 65 42 70 45 75 48 80

1 2
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Engine Oil and Filter* Intervals Chassis Lubrication Carburetor Choke Check* Carburetor Mounting Torque* Engine Idle Speed Adjustment* AIR Pump Drive Belts Cooling System Refill Wheel Bearing Repack Transmission Service Vacuum Advance System Check* Fuel Tank. Can and Lines* Idle Stop Solenoid Check* Spark Plug Wire Check & Plug Replacement* Engine Timing Adjust. & Distributor CheckA* Air Cleaner Element Replacements* Thermo. Controlled Air Cleaner CheckA* Manifold Heat Valve CheckA* Carburetor Fuel Filter Replacement* Throttle Return Control Check* PCV System Check* ECS System Check* Engine Idle Mixture Adjust (4.8L. L-6 only)* EFE System Check* Thermostatically Controlled Engine Cooling FanAf Shields and Underhood InsulationAf Air intake SystemAf GovernorAf EGR System

Every 12,000 Miles (20 000 km)

Every 24 Months or 24,000 Miles (40 000 km) At 1st 4 Months or 6,000 Miles (10 000 km) then at 12 Month/ 12,000 Mile (20 000 km) intervals Every 12,000 Miles (20 000 km) Every 12 Months or 12,000 Miles (20 000 km)

Every 24 Months or 24,000 Miles (40 000 km) Every 12 Months or 12,000 Miles (20 000 km) Every 12,000 Miles (20 000 km) Every 48 Months or 48,000 Miles (80 000 km) Every 36 Months or 36,000 Miles (60 000 km)

Fig. OB-15 -Maintenance Schedule I, Gasoline, H.D. Emission

M AINTEN ANC E A N D LUBRICATION

OB-17

SCHEDULE II Follow Schedule II if, as a general rule, you drive your vehicle on a daily basis for several miles (km) and none of the above conditions apply. SCHEDULE II WHEN TO PERFORM
ITEM NO.

TO BE SERVICED
Engine Oil Change* Filter Change Chassis Lubrication Carburetor C hoke Check* C arburetor M ounting Torgue* Engine Idle Speed Adjustm ent*

M iles (kilom eters) or Months, W hichever Occurs First

The services shown in this schedule up to 48,000 m iles (80 000 km) are to be perform ed after 45,000 m iles at the sam e interval 6 10 12 20 18 30 24 40 30 50 36 60 42 70 48 80

1 2 3 4 5

MILES (000) KILOMETERS (000) Every 6,000 mi. (10 000 km) or 4 months At first and every other oil change Every 4 M onths or 6,000 Miles (10 000 km) Every 24 M onths or 24,000 Miles (40 000 km) Every 12 M onths or 12,000 Miles (20 000 km) At 1st 4 M onths or 6,000 M iles (10 000 km) then at 12 M onth/12,000 Mile (20 000 km) intervals Every 12,000 M iles (20 000 km) Every 24,000 M iles (40 000 km) Every 24 M onths or 24,000 M iles (40 000 km) At 1 st 4 M onths or 6,000 Miles (10 000 km) then at 12 M onth/12,000 Mile (20 000 km) intervals Every 12,000 M iles (20 000 km)

6 7 8 9 10 11 12

AIR Pump Drive Belts Cooling System Refill W heel Bearing Repack Transm ission Service Vacuum Advance System Check* Fuel Tank, Cap and Lines* Idle Stop Solenoid Check*

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

Spark Plug Wire Check & Plug R eplacem ent* Engine Timing Adjust. & D istributor C heckA* Air C leaner Element R eplacem entA* Therm o. C ontrolled Air C leaner C heckA* M anifold Heat Valve CheckA* C arburetor Fuel Filter Replacem ent* Throttle Return C ontrol Check* PCV System Check* ECS System Check* Engine Idle M ixture Adjust (4.8L. L-6 o nly) EFE System Check* Therm ostatically C ontrolled Engine Cooling FanAt Shields and Underhood In s u la tio n A f A ir Intake S y s te m A t G o v e rn o rA t EGR System

Every 12 Months or 12,000 Miles (20 000 km)

Every 24 M onths or 24,000 Miles (40 000 km) Every 12 M onths or 12,000 Miles (20 000 km) Every 12,000 M iles (20 000 km) Every 48 M onths or 48,000 Miles (80 000km) Every 36 M onths or 36,000 Miles

"O OTNOTES: 'An Em ission C ontrol Service AA lso a Noise Emission Control Service tA p p lica b le only to vehicles sold only in the United States

Fig. O B -16-M aintenance Schedule II, Gasoline, H.D. Emission

GASOLINE ENGINE, H.D. EMISSION


NORMAL VEHICLE USE
The m aintenance instructions contained in this section are based on the assum ption th a t your vehicle will be used as designed: to carry passengers and cargo within the lim itations indicated on the Tire Placard. on reasonable road su rfaces w ithin legal operating limits, and on a daily basis, as a general rule, for at least several miles (km). on leaded gasoline. U nusual o perating conditions will require more frequent vehicle m aintenance as specified. V ISC O SIT Y . A lso alw ays change oil and filter as soon as possible after d riv in g in a dust storm .

Item 2 Chassis Lubrication


L ubricate all grease fittings in front suspension, steering lin k ag e, and co n stan t velocity universal jo in t. L ubricate transm ission and tran sfer case shift linkage, hood latch, hood and d o o r h in g es, parking brake cable guides, clutch lin k ag e, p ro p eller shaft slip jo in t, transfer case shift lever, u n iversal jo in ts, and brake and clutch pedal springs. L u b ricate suspension and steering linkage every 3 m onths or 3,000 miles (5 000 km ) w hen operating under dusty or m uddy co n d itions and in extensive offroad use. A lso, lubricate clutch cro ss-shaft lev er every 36,000 m iles (60 0 0 0 km ).

Item 1 Engine O il and O il Filter Change*


A lw a y s u se S F -Q U A L IT Y O IL S O F P R O P E R

OB-18

M AINTEN ANC E A N D LUBRICATION

Item 3 Carburetor Choke and Hoses*


Verify th at choke and vacuum break work properly. C orrect any binding caused by dam age or gum on the choke shaft. Inspect hoses for proper hookup, cracks, rubbing or decay. Correct as necessary.

Item 4 Carburetor Mounting*


Torque mounting bolts an d /o r nuts at mileage shown in M aintenance Schedule.

Item 5 Engine Idle Speed Adjustment*


A djust to the specifications shown on the underhood label. You m ust use calibrated test equipm ent.

Item 6 AIR Pump Drive Belts*


Inspect belts driving the A IR pum p. Look for cracks, fraying w ear, and proper tension. A djust or replace as needed.

Item 7 Cooling System Refill


Drain, flush and refill system with new coolant as shown in your O w ners M anual.

Item 8 Wheel Bearing Repack


C lean and rep ack front w heel b earings at each brake relining or 12,000 m iles (20 000 km ), w h ich ev er com es first. BE SU R E T O U S E L U B R IC A N T A S SP E C IF IE D IN T H E R E C O M M E N D E D FL U ID S & L U B R IC A N T S C H A R T IN FIG . 0B -21.

Item 9 Transmission Fluid


Automatic Transmission - C hange the transm ission fluid and change the filter (or service the screen) every 12.000 miles (19 200 km) if the vehicle is mainly driven under one or more of these hot conditions: In heavy city traffice where the outside tem perature regularly reaches 90F (32C). In hilly o r m o u n tain o u s terrain . Frequent trailer pulling. Uses such as taxi, police or delivery service. If vehicle is not used under any of these conditions, change the fluid and filter (or service the screen) every 2 4 .0 0 0 m iles (40 0 0 0 km ). See O w ners M anual for further details.

the boot fit at distributor cap and spark plugs. Replace wire if dam aged or if corrosion cannot be cleaned. Replace spark plugs as shown on Schedule. Use the type listed in your O w ners M anual.

Item 14 Timing and Distributor Cap*


A djust tim ing to underhood label specifications. Inspect the inside and outside of the cap and rotor for cracks, carbon tracking and corrosion. Clean or replace as needed.

Item 15 Air Cleaner Element*


Replace at mileage shown on Schedule. Replace more often under dusty conditions. Ask your dealer for the proper replacem ent tim es for your driving conditions.

Item 16 Thermostatically Controlled Air Cleaner*


Inspect all hoses and ducts for correct hookup. Be sure valve works properly.

Item 10 Vacuum Advance System and Hoses*


Check th at system works properly. Check hoses for proper hookup, cracks, rubbing or decay. Replace parts as needed.

Item 17 Manifold Heat Valve*


Some engines are equipped with a manifold heat valve which should be inspected and repaired as necessary to insure free operation.

Item 11 Fuel Tank, Cap and Lines*


Inspect for dam age or leaks. Remove fuel cap, and inspect gasket for an even filler neck im print, and any dam age. Replace as needed.

Item 18 Carburetor Fuel Filter*


Replace at mileage shown on M aintenance Schedule or sooner if clogged.

Item 12 Idle Stop Solenoid and/or Dashpot*


Check th a t p arts work properly. R eplace them as needed.

Item 19 Throttle Return Control (TRC) System*


C heck hoses for proper connections, cracking, abrasion, or deterioration and replace as necessary. Check for proper operation of system. Check for shorted or broken wires and ensure electrical connectors are fully engaged at distributor, speed switch and vacuum solenoid.

Item 13 Spark Plug Wires and Plug Replacement*


Clean wires. Remove corrosion on term inals. Inspect the wires for checks, burns, cracks or other dam age. Check

M AINTEN ANC E A N D LUBRICATION

OB-19

Item 20 Positive Crankcase Ventilation System*


Check th a t system works properly each 12,000 miles (19 200 km). Each 24,000 miles (38 400 km): replace the valve, replace any worn, plugged or collapsed hoses and replace filter.

Item 25 Shields and Underhood Insulation


(I f so equipped) Inspect shields and underhood insulation for dam age or looseness. A djust or replace as required.

Item 26 Air Intake System


Check the air intake system installation to see that gaskets are seated properly and all hose connections, fasteners, and other components are tight. For gasoline engines, also check to be sure air cleaner housing is properly seated on the carburetor, th at the cover fits tightly, and th at the wing nut is tight. Tighten connections and fasteners or replace dam aged parts as required.

Item 21 Evaporation Control System (ECS)*


Check all fuel and vapor lines and hoses for proper hookup, routing, and condition. Check th a t bowl vent and purge valves work properly if equipped. Remove canister, check for cracks or dam age. R eplace as needed.

Item 22 Engine Idle Mixture (4.8L; L6 Only)*


A t designated intervals or in case of a m ajor carburetor overhaul, or when poor idle quality exists, adjust m ixture by a m echanical m ethod (lean drop), following the specifications shown on the label under the hood.

Item 27 Governor
(If so equipped) Check the engine no-load governed speed and reset to specifications as required.

Item 28 Exhaust Gas Recirculation System (EGR)*


C onduct E G R op eratio n system check as covered in service m anual. R eplace or clean parts as required.

Item 23 Early Fuel Evaporation (EFE) System*


Check th a t valve works properly; correct any binding. Check th at therm al vacuum switch works properly. Check hoses for cracks, rubbing or decay. Replace part as needed.

OWNER INSPECTIONS AND SERVICES


L isted in Figs 0 B -18 th ro u g h 0B-2O are vehicle inspections and services which should be made by either you or a qualified technician at the frequencies indicated to help ensure proper safety, em ission perform ance and dependability of your vehicle. Take any problems promptly to your dealer or a qualified technician for service advice. W henever repairs are necessary, have them completed at once. For your safety and th at of others, any safety related components th a t could have been dam aged in an accident should be inspected. All needed repairs should be performed before operating your vehicle.

Item 24 Thermostatically Controlled Engine Cooling Fan


(If so equipped) W ith the engine off and below normal operating tem perature, check to sed th at the fan can be rotated by hand on fluid coupling, viscous, and air operated drives. Replace as necessary. For air-operated fan drives, the air pressure m ust be up to the norm al operating range to p erform the above c h e c k , as d esig n ated in this shop m anual.

OB-20

M AINTEN ANC E A N D LUBRICATION

FREQUENCY BEFORE OPERATING YOUR VEHICLE

INSPECTION OR SERVICE
Warning light, buzzer tone and chime operation. Glass, light and reflector condition

WHAT TO DO
Check operation of all warning lights, buzzers, tone generators and chimes also all interior lights. See your Owner's Manual for details. Look for broken, scratched, dirty or damaged glass, light or reflector that could reduce vision/visibility or cause injury. Replace, clean or repair promptly. When adjusting a manual seat, be sure seat adjusters latch by pushing seat forward and backward. Make sure friction joints hold mirrors and sun visors in place. Make sure that all doors and wagon or hatchback gates close, latch and lock tightly. Make sure the indicator points to the gear chosen. Note the operation and condition of the wiper blades and the flow and aim of the washer spray. Periodically check the air flow from the ducts at the inside base of the windshield. Do this with the heater control lever in defrost position and fan lever in high". Blow horn occasionally to make sure it works. Check all button locations. Be alert to abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if the brake warning light goes on, something may be wrong. See your O w ners Manual. Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn, or has too much free play, or if unusual sounds are noted when turning or parking. Be alert to a vibration of the steering wheel or seat at normal highway speeds. This may mean a wheel balance is needed. Also, a pull right or left on a straight, level road may show the need for a tire pressure adjust ment or wheel alignment. Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn, or has too much free play, or if unusual sounds are noted when turning or parking. Take note of light pattern occasionally. If beams seem improperly aimed, headlights should be adjusted. Check level and add if necessary. See O wner's Manual. Check level in coolant reservoir tank and add if necessary. Inspect coolant and replace if dirty or rusty. See O wner's Manual. Check level in reservoir and add if necessary. When opening hood, note the operation of secondary latch. It should keep hood from opening all the way when primary latch is released. Make sure that hood closes firmly after services are performed.

Seat adjuster operation Rearview mirror and sun visor operation Door and gate latch operation Automatic transmission shift indicator operation Wiper and washer operation Defroster operation

WHILE OPERATING YOUR VEHICLE

Horn operation Brake system operation

Exhaust system operation

Tires, Wheels and Alignment

Steering system operation

Headlight aim Engine oil levelf Engine coolant level and conditiont Windshield washer fluid level Hood latch operation

AT EACH FUEL FILL

Fig. OB-18 -Owner Inspections and Services, Chart A

M AINTEN ANC E A N D LUBRICATION

OB-21

FREQUENCY

INSPECTION OR SERVICE
Tire pressure check

WHATTO DO
Maintain pressures as shown on Tire Placard on the drivers door (include spare). Pressure should be checked when tires are cold. Check operation of license plate light, sidem arker lights, headlights including high beams, parking lights, taillights, brake lights, turn signals, backup lights and hazard warning flashers. Periodically, after the vehicle has been parked for a while, inspect the surface beneath the vehicle for water, oil, fuel or other fluids. Water drip ping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, the cause should be found and corrected at once. Check level in accordance with Owners Manual instructions (Section 5) and keep at proper level. Check fluid level. Note: A low fluid level can indicate worn disc brake pads and should be checked. Note the clutch pedal free travel. It should be about 1. Adjust linkage whenever there is little or no free travel. Park on a fairly steep hill and hold the vehicle with the parking brake only. This checks holding ability. For automatic transmission, check Park" by releasing all brakes after shifting the transmission to P (Park). While parked, try to turn key to Lock in each gear range. The key should turn to Lock only when gear is in Park on automatic or Reverse on manual transmission. On vehicles with key release lever, try to turn key to Lock without depressing the lever. The key should turn to Lock" only with the key lever depressed. On all vehicles, the key should come out only in Lock. Inspect all hoses and ducts for proper hookup. Be sure valve works properly.

AT LEAST MONTHLY

Light operation

Fluid leak check

AT LEAST SEMI ANNUALLY (FOR EXAMPLE, EVERY SPRING AND FALL)

Power steering pump reservoir le v e lf Brake m aster cylinder reservoir le v e lf Clutch Pedal free travel Parking brake and transmission Park" mechanism operation Steering column lock operation

Thermostatically controlled air cleaner* Starter safety switch operation

Seatback latch operation

Caution: Before performing the following safety switch check, be sure to have enough room around the vehicle. Then, firmly apply both the parking brake (see Owners Manual for procedure) and the regular brakes. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition promptly. Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage. On automatic transmission vehicles, try to start the engine in each gear. The starter should crank only in P" (Park) or N (Neutral). On manual transmission vehicles place the shift lever in Neutral push the clutch halfway and try to start. The starter should crank only when the clutch is fully depressed. Be sure seatbacks latch on those vehicles with folding seats using mech anical latches. See O wners Manual for latch operating inform ation.
Inspect belt system, including: webbing, buckles, latch plates, retractors, guide loops and anchors. On vehicles with movable restraints, make sure restraints stay in the desired position. (See adjustment instructions in Owners Manual.) Make sure the recliner is holding by pushing and pulling on the top of the seatback while it is reclined. Be alert to rattles in rear of vehicle. Make sure the spare tire, all jacking equipment, and any covers or doors are securely stowed at all times. Oil jack ratchet mechanism after each use. At least every spring, flush from the underbody with plain water any corrosive materials used for ice and snow removal and dust control. Take care to thoroughly clean any areas where mud and other debris can collect. Sediment packed in closed areas of the vehicle should be loosened before being flushed.

AT LEAST ANNUALLY

Lap and shoulder belts condition and operation Movable head restraint operation Seatback recliner operation (if equipped) Spare tire and jack storage

Underbody flushing

Fig. OB-19 -Owner Inspection and Services, Chart B


*An emission control service tN O T E : A large loss in these systems may indicate a problem. Have them inspected and repaired at once.

OB-22

M AINTEN ANC E A N D LUBRICATION

FREQUENCY AT
LE AS T

INSPECTION OR SERVICE
Engine cooling system

WHATTO DO
Inspect coolant and freeze protection. If dirty or rusty, drain, flush and refill with new coolant. Keep coolant at the proper mixture as specified in yo u r O w n e rs M anual. T his p ro vid e s p ro p e r fre e ze p ro te c tio n , corrosion inhibitor level and engine operating temperature. Inspect hoses and replace if cracked, swollen or deteriorated. Tighten hose clamps. Clean outside of radiator and air conditioning condensor. Wash radiator filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and cap is also recommended. M aintain level within operating range on dipstick. Refer to O wners Manual. Check tires for abnormal wear or damage. Check for damaged wheels. To equalize wear and obtain maximum tire life, it is suggested that tires be rotated at about 7,500 miles (12 500 km). then each 15,000 miles (24 000 km) thereafter. See T ires in O wners Manual, Section 5, for further inform ation. For dual wheels, whenever the truck, or wheel or fasteners are new, also have the wheel fastener torque set at the first 100,1,000 and 6,000 miles (16 0 ,1 6 0 0 and 10 000 km). For convenience the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, binding, leaks, cracks, chafing etc. Inspect disc brake pads for wear and rotors for surface condition Also inspect drum brake linings for wear and cracks. Inspect other brake par^s, including drums, wheel cylinders, parking brake, etc. at the same time. Check parking brake adjustment. INSPECT BRAKES MORE OFTEN IF HABIT OR CONDITIONS RESULT IN FREQUENT BRAKING Inspect front an<4 rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. (On vehicles equipped with manual steering gear, check for seal leakage.) Inspect final drive axle output shaft seals for leaking. Front Suspension and Steering Linkage (a) On C20 and G30, lubricate every 4 months or 6,000 miles (10 000 km). (b)O n all other vehicles, lubricate every 12 months or 7,500 miles (12 500 km). (c) Lubricate suspension and steering linkage every 3 months or 3,000 miles (5 000 km) when operating under dusty or muddy conditions and in extensive off-road use. Inspect complete system. Inspect body near the exhaust system. Look for broken, damaged, missing or out-of- position parts as well as open seams, holes, loose connections or other conditions which could let exhaust fumes seep into the trunk or passenger compartment. Inspect for damaged or missing parts, interference or binding. Inspect all belts for cracks, fraying wear and proper tension. Adjust or replace as needed. Check fluid level and add if needed. Lockina Differential - In general service, drain fluid at 6000 miles (10 000 km) and refill. Change fluid at 12, ''00 mile intervals, and check tiuid and add as needed at 6000 mile intervals thereafter. In severe operating conditions, or trailer towing applications, drain fluid every 6000 miles(10 000<m) and refill. Standard Differential - In general service, drain fluid level every 24,000 miles (40 000 km) and refill. Check fluid level and add as needed at 6000 m ile(|0 000 km) intervals. In severe operating conditions, or trailer towing applications, drain fluid every 12,500 miles i(20 000km) and refill. Check fluid level and add as needed at 6000 mile (lUixJOkm) intervals. Four Wheel Drive - Every 4 months or 6,000 miles (10 000 km), check front axle and transfer case and add lubricant when necessary. Lubricate propeller shaft slip joint and constant velocity universal joint. Oil control lever pivot points and exposed control linkage. Check vent hose at front axle and transfer case for !<inks and proper installation. More frequent lubrication may be required on heavy duty off-road operations. See O wner's and Drivers Manual for further information. Check fluid level and add as required.

ANNUALLY
Automatic transm ission fluid le v e lt Tire and wheel inspection and rotation

Brake systems inspection

Steering and suspension

EACH TIME OIL IS CHANGED (WHEN VEHICLE ISON HOIST


Exhaust system inspection*

Throttle linkage inspection Engine drive belts Rear a x le /fro n t a x le /tra n s fe r case

Manual transmission

Fig. OB-2C-Owner Inspections and Services, Chart C


*An emission control service tNOTE: A large loss in these systems may indicate a problem. Have them inspected and repaired at once.

M AIN TEN A N C E A N D LUBRICATION

OB-23

USAGE
Engine Engine Coolant

FLUID/LUBRICANT
"SF" or "SF/CD or "SF/CC" Engine Oil conforming to GM spec 6048-M Mixture of water and a high quality Ethylene Glycol base type antifreeze conforming to GM spec 1825-M (GM Part No 1052753) or equivalent Delco Supreme 11 fluid or DOT-3 Chassis grease meeting requirements of GM spec. 6031-M GM power steering fluid Part No. 1050017 or equivalent Lubricant GM Part No. 1051052 or equivalent DEXRON*ll Automatic Transmission Fluid SAE-80W, GL-5 or SAE-80W-90 GL-5 gear lubricant (SAE-80WGL-5 in Canada) Lubricant GM Part No. 1052271 Chassis grease meeting requirements of GM spec 6031-M Light oil or general purpose silicone lubricant (GM Part No. 1052276) a. Engine oil b. Chassis grease meeting require ments of GM spec. 6031 -M Chassis grease meeting requirements of GM spec. 6031-M GM Optikleen washer solvent Part No. 1051515 or equivalent a Engine oil b. Chassis grease Lubricant GM Part No. 1051344 (one pound) or equivalent GM Lubricant Part No 1052497 or equivalent Engine Oil

Brake System Parking Brake Cables Power Steering System Manual Steering Gear Automatic T ransmission Transfer Case DifferentialStandard Manual Transmission DifferentialLocking Manual Transmission Shift Linkage, Column Shift, Propeller Shaft Slip Joint Key Lock Cylinders Clutch Linkage (Man Trans only) a. Pivot points b Push rod to clutch fork joint, and cross shaft pressure fitting Chassis Lubrication Windshield Washer Solvent Hood Latch Assembly a. Pivots and spring anchor b Release pawl Front Wheel Bearings Constant Velocity Universal Joint Automatic Transmission Shift Linkage, Floor Shift Linkage, Hood and Door hinges, body door hinge pins, tailgate hinge and linkage, folding seat, fuel door hinge

* Fluids and lubricants identified with GM part numbers or GM specification numbers may be obtained from your GM dealer

Fig. OB-21-Recommended Fluids and Lubricants

OB-24

M AINTEN ANC E A N D LUBRICATION

SECTION A Scheduled Maintenance Services For Your 1984 6.2L Diesel-Fueled Vehicle
SCHEDULE 1Follow Schedule I if you mainly operate your vehicle under one or more of the following conditions: Operating when outside temperatures remain below freezing and when most trips are less than 4 miles (6 km); or Idling for extended periods and/or low speed operation such as in door-to-door delivery;
SCHEDULE I
TO BE SER VIC ED
ITEM NO.

Also follow Schedule I when: Towing a trailer; Operating in dusty areas; or Using your vehicle in hard, police car, delivery or daily rental service.

W H EN TO PERFORM
Miles (kilom eters) or Months. W hichever O ccurs First MILES (000) KILOMETERS (000) C hange Oil and Oil Filter every 2,500 m iles (4 000 km), or 3 m onths Lub rica te every other oil change Inspect at 5,000 M iles (8 000 km) then every 15,000 Miles (48 000 km) C heck at 5,000 M iles (8 000 km), then at 30,000 M iles (48 000 km) Service every 12 M onths or 15,000 Miles (24 000 km) Every 24 M onths or 30,000 Miles (48 000 km) Every 30,000 M iles (48 000 km) Every 15,000 Miles (24 000 km) R eplace every 30,000 Miles (48 000 km)<') Every 12 M onths or 10,000 Miles (16 000 km) Every 10,00 Miles (16 000 km) 2 5 4 5 8 75 12

The service show n in this s chedule up to 47,500 m iles (76000 km) are to be perfo rm e d after 47,500 m iles of the sam e intervals 10 16 125 20 15 24 175 28 20 32 22.5 36 25 40 275 44 30 48 32 5 52 35 56 37.5 60 40 64 42.5 68 45 72 47 5 76

1 2 3 4 5 6 7 8 9 10 11 12

E ngine Oil & O il Filter* Chassis Lub rica tion Exhaust Pressure R egulator Valve* Engine Idle S peed Cheek* C rankcase V entilation System * C ooling System Refill* Front W heel B ea rin qs R epack Transm ission Service Air C leaner* Th erm ostatica lly C ontrolled Engine C ooling FanA S hields and U nde rhood InsulationA Air Intake System A


**

Fig. OB-22 -- Maintenance Schedule, Diesel -- Schedule I


*Also An Emission Control Service AAlso a Noise Emission Control Service (A pplicab le only to vehicles with Engine Family EGM06.2DAB17 and sold only in the United States) (1)For engines with Engine Family EGM06.2DAB17, replace element every 15,000 miles (24 000 km). (2)Only these em issions control m aintenance items are considered to be required m aintenance as defined by the C alifornia Air Resources Board (ARB) regulations and are, according to such regulations, the minimum m aintenance an owner in C alifornia must perform to fulfill the minimum requirem ents of the emission warranty. All other em ission m aintenance items are recommended m aintenance as defined by such regulations. General Motors urges that all emission control m aintenance items be perform ed. (Only a pp lica ble to Engine Family E166.2K7ZZ74.)

SCHEDULE II Follow Schedule II if, as a general rule, you drive your vehicle on a daily basis for several miles (km) and none of the above conditions apply. SCHEDULE II TO BE SERVICED
ITEM NO. 1 2 3 4 5 6 7 8 9 10 11 12 Engine Oil & Filter* Chassis Lubrication Exhaust Pressure R egulator Valve* Engine Idle Speed Check* Crankcase Ventilation System * Cooling System Refill* Front Wheel Bearings Repack Transmission Service Air Cleaner* Therm ostatically C ontrolled Engine Cooling FanA Shields and Underhood InsulationA Air Intake System A

WHEN TO PERFORM
Miles (kilom eters) or Months, W hichever Occurs First MILES (000) KILOMETERS (000) C hange Oil and Oil Filter every 5,000 Miles (8 000 km) or 12 M onths Lubricate every 12 Months or 5,000 Miles (8 000 km) Inspect at 5,000 Miles (8 000 km), then every 15,000 mi. (24 000 km) Check at 5,000 M iles (8 000 km), then at 30,000 Miles (48 000 km) Service every 12 M onths or 15,000 Miles (24 000 km) Every 24 M onths or 30,000 Miles (48 000 km) Every 30,000 M iles (48 000 km) Every 100,000 M iles (160 000 km) Replace every 30,000 Miles (48 000 km)<1) Every 12 M onths or 10,000 Miles (16 000 km) Every 10,000 M iles (16 000 km) 5 8 ** 10 16

The services shown in this schedule up to 45,000 m iles (72 000 km) are to be perform ed after 45,000 m iles at the sam e interval 15 24 20 32 25 40 30 48 ** 35 56 40 64 45 72

FOOTNOTES: *An Em ission C ontrol Service **ln C alifornia, these are the m inim um Em ission C ontrol M aintenance Services an ow ner m ust perform according to the C a lifo rn ia A ir R esources Board. G eneral M otors, however, urges th at all Em ission C ontrol M aintenance Services shown above be perform ed. To m aintain your other new vehicle w arranties, all services shown in this fo lde r should be perform ed.

Fig. 0B- 23--Maintenance Schedule, DieselSchedule II

M AINTEN ANC E A N D LUBRICATION OB-25

6.2L DIESEL ENGINE


NORMAL VEHICLE USE
T he o w ners or d riv e rs m ain ten an ce instructions contained in this section are based on the assum ption th at your vehicle will be used as designed: to carry passengers and cargo within the lim itations indicated on the Tire Placard. on reasonable road surfaces w ithin legal o perating limits. on a daily basis, as a general rule, for at lease several miles (km ) and on N o. 1 blend o r N o. 2 grad e diesel fuel. U n u su al o perating conditions will require m ore frequent vehicle m aintenance as specified. or door-to-door d eliv ery . If you do not use your vehicle in such service, clean and repack bearings at each brake relining or 3 0 ,0 0 0 m iles (48 000 k m ), w h ich ev er com es first. Be sure to use p ro p er lubricant as show n in the R ecom m ended F luids and L u b ric a n ts chart in this section.

Item 8 Automatic Transmission Fluid


C hange the transm ission fluid and filter (or service the screen) every 15,000 miles (24 000 km) if the vehicle is mainly driven under one of more of these hot conditions: In heavy city traffic where the outside tem perature regularly reaches 90F (32C). In hilly or m o u n tain o u s terrain. Frequent trailer pulling. Uses such as taxi, police or delivery service. If vehicle is not used m ainly u nder any of these conditions, change the fluid and filter (or serice the screen) every 100,000 miles (160 000 km). See S ection 7 o f this M anual fo r fu rth er details.

EXPLANATION OF SCHEDULED MAINTENANCE SERVICES Item 1 Engine O il and Filter


A L W A Y S U S E S F -C D O R S F /C C O IL O F T H E PR O PER V ISC O SITY . A lso alw ays change oil and filter as soon as p o ssible after driv in g in a dust storm . See O w n e rs M anual for fu rth er details.

Item 9 A ir Cleaner Element*


R eplace at 30,000 miles (48 000 km ). Replace more often under dusty conditons. Ask your delaer for the proper replacem ent tim es for your driving conditions.

Item 2 Chassis Lubrication


L u b ricate all g rease fittings in front suspension, steering linkage. L ubricate transm ission shift linkage, hood latch, hood and door hinges, parking brake cable guides, clutch linkage, propeller shaft slip joint, universal joints, brake pedal springs, underbody contact points and linkage. L u b ric a te suspension and steerin g linkage every 2 m onths or 2,500 miles (4 000 km ) when operating under dusty or m uddy conditions and extensive off-road use.

Item 10 Thermostatically Controlled Engine Cooling Fan


If so equipped) W ith the engine off and below normal operating tem perature, check to see th a t the fan can be rotated by hand on fluid coupling, viscous and air operated

Item 3 Exhaust Pressure Regulator Valve*


S E LE C T T H E S A E G R A D E O IL B A S E D O N

Check th at valve works properly. C orrect any binding. Check hoses for cracks, rubbing or decay. Replace parts as needed.

TH E E X P E C T E D T E M P E R A T U R E R A N G E BEFO R E N E X T O IL C H A N G E

HOT W EATHER

Item 4 Engine Idle Speed*


A djust to the specifications shown on the underhood label. You m ust use calibrated test equipm ent.

Item 5 Crankcase Ventilation System*


Inspect ru b b er fittings, hoses a n a reguiaiui c v u ; 30,000 miles (48 000 km). Replace as required.

Item 6 Cooling System Refill*


D rain , flush and refill system w ith new coolant.
W EATHER
OTHER GRADE NOT RECOMMENDED

Item 7 Wheel Bearings


C lean and repack front w h eel bearin g s at each brake relining o r 15,000 m iles (24 000 k m ), w h ichever com es first, w hen vehicle is u sed in such service as police, taxi
Fig. OB- 24 O il Viscosity Chart

OB-26

M AINTEN ANC E A N D LUBRICATION

drives. Replace as necessary. For air-operated fan drives, the air pressure must be up to the normal operating range to perform the above check.

OWNER INSPECTIONS AND SERVICES


L isted in Figs. O B - 2 5 through O B - 2 7 are vehicle inspections and services which should be made by either you or a qualified technician at the frequencies indicated to help ensure proper safety, em ission perform ance and dependability of your vehicle. Take any problems promptly to your dealer or a qualified technician for service advice. W henever repairs are necessary, have them completed at once. For your safety and th at of others, any safety related components th at could have been dam aged in an accident should be inspected. All needed repairs should be perform ed before operating your vehicle.

Item 11 Shields and Underhood Insulation


(If so equipped) Inspect shields and underhood insulation for dam age or looseness. A djust replace as required.

Item 12 Air Intake System


Check the air intake system installation to see th at gaskets are seated properly and all hose connections, fasteners, and oth er com ponents are tig h t. T ighten connections and fasteners or replace dam aged p arts as required.

FREQUENCY

INSPECTION OR SERVICE
Warning light, buzzer tone and chime operation Glass, lights, and reflector condition

WHAT TO DO
Check operation of all warning lights, buzzers, tone generators and chimes also all interior lights. See your Owners Manual for details. Look for broken, scratched, dirty or damaged glass, lights, or reflectors that could reduce vision or visibility or cause injury Replace, clean or repair promptly When adjusting a manual seat, be sure seat adjusters latch by pushing seat forward and backward Make sure friction joints hold mirrors and sun visors in place Make sure that all doors, trunk lid and wagon or hatchback gates close, latch and lock tightly Make sure the indicator points to the gear chosen. Note the operation and condition of the wiper blades and the flow and aim of the washer spray Periodically check the air flow from the ducts at the inside base of the windshield. Do this with the heater control lever in "defrost" position and fan lever in "high." Blow the horn occasionally to make sure it works. Check all button locations. Be alert to abnormal sounds, increased brake pedal travel or repeated pulling to one side when braking. Also, if the brake warning light goes on, something may be wrong See your Owner's Manual. Be alert to any changes in the sound of the system or any smell of fumes. These are signs the system may be leaking. Have it inspected and repaired at once. Also see Engine Exhaust Gas Caution (Carbon Monoxide) in your Owners Manual. Be alert to a vibration of the steering wheel or seat at normal highway speeds. This may mean a wheel balance is needed Also, a pull right or left on a straight, level road may show the need for a tire pressure adjustment or wheel alignment. Be alert to changes in steering action. An inspection is needed when the steering wheel is harder to turn or has too much free play or if abnormal sounds are noted when turning or parking. Take note of light pattern occasionally. If beams seem improperly aimed, headlights should be adjusted Check level and add if necessary. See Owners Manual. Check level in coolant recovery tank and add if necessary Inspect coolant and replace if dirty or rusty. See Owners Manual. Check level in reservoir and add if necessary. When opening hood, note the operation of secondary latch. It should keep hood from open ing all the way when prim ary latch is released Make sure that hood closes firmly after services are performed.

BEFORE OPERATING YOUR VEHICLE

Seat adjuster operation Rearview mirror and sun visor operation Door, trunk and gate latch operation Automatic transmission shift indicator operation Wiper and washer operation Defroster operation Horn operation Brake system operation

WHILE OPERATING YOUR VEHICLE

Exhaust system operation

Tires, Wheels and Alignment

Steering system operation Headlight aim Engine oil levelt Engine coolant level and condition! Windshield washer fluid level Hood latch operation

AT EACH FUEL FILL

Fig. OB-25 O w ner Inspection and Services Chart A t NOTE: A large loss in these systems may indicate a problem. Have them inspected and repaired at once.

M AINTENANCE A N D LUBRICATION

OB-27

FREQUENCY

INSPECTION OR SERVICE
Tire pressure check

WHAT TO DO
Maintain pressures as shown on Tire Placard on the drivers door (include spare). Pressure should be checked when tires are "cold." Check operation of license plate light, sidemarker lights, headlights including high beams, parking lights, taillights, brake lights, turn signals, backup lights and hazard warning flashers. Periodically, after the vehicle has been parked for a while, inspect the surface beneath the vehicle for water, oil, fuel or other fluids. Water dripping from the air conditioning system after use is normal. If you notice fuel leaks or fumes, the cause should be found and corrected at once. Check level in accordance with Owners Manual instructions and keep at proper level. Check fluid level. Note: A low fluid level can indicate worn disc brake pads and should be checked. Note the clutch pedal free travel. It should be about 1. Adjust linkage whenever there is little or no free travel. Park on a fairly steep hil! and hold the vehicle with the parking brake only. This checks holding ability. For automatic transmission, check Park" by releasing all brakes after shifting the transmission to "P" (Park). While parked, try to turn key to "Lock" in each gear range. The key should turn to "Lock" only when gear is in "Park" on automatic or "Reverse" on manual transmission. On vehicles with key release lever, try to turn key to "Lock" without depressing the lever. The key should turn to Lock" only with the key lever depressed. On all vehicles, the key should come out oniy in "Lock." Caution: Before performing the following safety switch check, be sure to have enough room around the vehicle. Then, firmly apply both the parking brake (see Owners Manual for pro cedure) and the regular brakes. Do not use the accelerator pedal. If the engine starts, be ready to turn off the ignition promptly Take these precautions because the vehicle could move without warning and possibly cause personal injury or property damage On automatic transmission vehicles, try to start the engine in each gear. The starter should crank only in P" (Park) or "N' (Neutral). On manual transmission vehicles, place the shift lever in Neutral," push the clutch halfway and try to start. The starter should crank only when the clutch is fully depressed

AT LEAST MONTHLY

Light operation Fluid leak check

AT LEAST SEMI ANNUALLY (FOR EXAMPLE, EVERY SPRING AND FALL)

Power steering pump reservoir level t Brake master cylinder reservoir level t Clutch Pedal free travel Parking brake and transmission Park" mechanism operation Steering column lock operation

Starter safety switch operation

Seatback latch operation

AT LEAST ANNUALLY

Be sure seatbacks latch on those vehicles with folding seats using mechanical latches See Owners Manual for latch operating information. Inspect belt system, including, webbing, buckles, latch piates. retractors, guide loops and anchors. On vehicles with movable restraints, make sure restraints stay in the desired position (See adjustment instructions in Owners Manual.) Make sure the reclmer is holding by pushing and pulling on the top of the seatback while it is reclined. Be alert to rattles in rear of vehicie. Make sure the spare tire, all jacking equipment, and any covers or doors are securely stowed at all times. Oil jack mechans n after each use. At least every spring, flush from the underbody with piain water any corrosive materials used for ice and snow removal and dust control. Take care to thoroughly clean any areas where mud and other debris can collect. Sediment packed in closed areas of the vehicle should be loosened before being flushed. Inspect coolant and freeze protection. If dirty or rusty, dram, flush and refill with new coolant. Keep coolant at the proper mixture as specified in your Owners Manual. This provides proper freeze protection, corrosion inhibitor level and engine operating temperature. Inspect hoses and replace if cracked, swollen or deteriorated Tighten hose clamps. Clean outside of radiator and air conditioning condensor. Wash radiator filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and cap is also recommended.

Lap and shoulder belts condition and operation Movable head restraint operation Seatback reclmer operation (if equipped) Spare tire and jack storage Underbody flushing

Engine cooling system*

Fig. OB-26 Owner's Inspection and Services Chart B


* An Emission Control Service TNOTE: A large loss in these systems may indicate a problem. Have them inspected and repaired at once.

OB-28 M A IN TEN A N C E A N D LUBRICATION

FREQUENCY

INSPECTION OR SERVICE
Tire and wheel inspection and rotation

WHAT TO DO
Check tires for abnormal wear or damage. Check for damaged wheels. To equalize tire wear and obtain maximum tire life, it is suggested that tires be rotated at about 5,000 miles (8 000 km), then each 15.000 miles (24 000 km) thereafter. See "Tires" in Owner's Manual for further information. For dual wheels, whenever the truck, or wheels or fasteners are new, also have the wheel fastener torque set at the first 100.1.000 and 5,000 miles (160.1 600 and 8 000 km).

Brake systems inspection

For convenience the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. Inspect disc brake pads for wear and rotors for surface condition. Also inspect drum brake linings for wear and cracks. Inspect other brake parts, including drums, wheel cylinders, parking brake, etc. at the same time. Check parking brake adjustment. INSPECT BRAKES MORE OFTEN IF HABIT OR CONDITIONS RESULT IN FREQUENT BRAKING.

Steering and suspension inspection

Inspect front and rear suspension and steering system for damaged, loose or missing parts, signs of wear or lack of lubrication. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc. On vehicles equipped with manual steering gear, check for seal leakage. Inspect final drive axle output shaft seals for leaking. Inspect complete system. Inspect body near the exhaust system. Look for broken, damaged, missing or out-of-position parts as well as open seams, holes, loose connections or other conditions which could cause a heat build up in the floor pan or could let exhaust fumes seep into the passenger compartment. Inspect for damaged or missing parts, interference or binding. Inspect all belts for cracks, fraying and wear Adjust or replace as needed. Check fluid level and add if needed. Locking Differential in vehicles less than 8600# GVW In general service, drain fluid at 5.000 miles (8 000 km) and refill. Check fluid level and add as needed at subsequent 5.000 mile (8 000 km) intervals. In severe operating conditions, or trailer towing applica tions. drain fluid every 5.000 miles (8 000 km) and refill. Locking Differential in vehicles of 8600# GVW and above In general service, drain fluid at 5.000 miles !8 000 km) and refill. Change fluid at 10.000 mile (16 000 km) intervals and check fluid and add as needed at 5.000 mile (8 000 km) intervals thereafter. In severe operating conditions, or trailer towing applications, dram fluid every 5.000 miles (8 000 km) and refill as specified. Standard Differential in vehicles less than 8600# GVW In general service, check fluid level and add as needed every 5.000 miles (8 000 km). In severe operating conditions, or trailer towing applications, drain fluid every 5.000 miles (8 000 km) and refill as specified. Standard Differential in vehicles of 8600# GVW and above In general service, dram fluid every 25.000 miles (40 000 km) and refill. Check fluid level and add as needed at 5.000 mile (8 000 km) intervals. In severe operating conditions, or trailer towing applica tions. drain fluid every 10.000 miles (16 000 km) and refill. Four Wheel Drive Every 12 months or 5.000 miles (8 000 km), check front axle and transfer case and add lubricant when necessary. Lubricate propeller shaft slip joint, con stant velocity universal joint and steering linkage. Oil control lever pivot point and exposed control linkage Check vent hose at front axle transfer case for kinks and proper installa tion. More frequent lubrication may be required on heavy duly off-road operation See Owners and Drivers Manual for further information. Maintain level within operating range on dipstick. Refer to Owners Manual Check fluid level and add as required.

Exhaust system inspection

Throttle linkage inspection

EACH TIME OIL IS CHANGED (WHEN VEHICLE IS ON HOIST)

Engine drive belts Rear axle front axle transfer case

Automatic transmission fluid level r Manual transmission

Fig. OB-27 Owner's Inspection and Services Chart C


*An Emission Control Service f NOTE: A large loss m these systems may indicate a problem. Have them inspected and repaired at once.

M AINTENANCE A N D LUBRICATION

OB-29

.............................................. .................. .. USAGE E ngine O il E ng in e C o o la n t

FLUID LUBRICANT S F C D ' or "S F C C ' E n g in e O il M ixtu re of w ate r an d a high q u a lity E th yle n e G ly co l base type a n tifre e z e c o n fo rm in g to G M spec. 1825-M (G M Part No. 1 0 52 753 ) or e q u iva le n t D e lc o S u p re m e 11 flu id or DOT-3 C h a ss is g re ase m e e tin g re q u ire m e n ts of G M spec. 6 0 3 1 -M G M Pow er S te e rin g Fluid Part No. 1 0 5 0 0 1 7 or e q u iva le n t L u b ric a n t G M Part No. 10 51 052 or e q u iva le n t D E X R O N * II A u to m a tic T ra n sm is sio n Fluid

B rake S yste m P arking B rake C a b le s P ow er S te e rin g S yste m M anu al S te erin g G ea r A u to m a tic T ra n sm issio n 4 -S p e e d M a nu al Trans, w O .D. S10 Truck w ith M a n u a l Trans. Transfer C ase D iffe ren tia l S ta n d a rd or M anu al T ra n sm issio n (E xce p t: 4 -S p e e d w ith O .D .. a nd S 10 Truck) D iffe ren tia l Lo ckin g M anu al T ran sm ission S h ift Linkage . C o lu m n S hift, P rop eller S ha ft S lip J o in t Key Lock C ylin d e rs

S A E -80 W . G L-5 or S A E -8 0 W -9 0 G L-5 g e a r lu b ric a n t (S A E -8 0 W G L-5 in C a n a d a ) L u b ric a n t G M Part No. 1052271 C h a ss is g re ase m e eting re q u ire m e n ts of G M spec. 6 0 3 1 -M Ligh t oil or g e n e ra l p u rp o se s ilic o n e lu b rica n t (G M Part No. 10 52 276 )

C lutch L inkage (M a nu al T ra n sm is sio n O nly) a. Pivot points b. Push rod to c lu tc h fork jo in t and cro ss sh a ft p re ssure fittin g C h a ssis Lu b rica tio n W in d s h ie ld W ashe r S o lve n t H ood Latch A s se m b ly a. P ivots and s p rin g a n ch o r b. R ele ase paw l Front W he el B e a rin g s

a. E n g in e O il b. C h a ss is G rease m e e tin g re q u ire m e n ts of G M spec. 6 0 3 1 -M C h a ss is g re ase m e e tin g re q u ire m e n ts of G M spec. 6 0 3 1 -M G M O p tikle e n w ashe r s o lv e n t Part No. 10 51 5 1 5 or e q u iva le n t a. E n g in e Oii b. C h a ssis G rease L u b ric a n t G M Part No. 1 0 5 1 3 4 4 (on e p o un d) o r e q u iva le n t* G M L u b ric a n t Part No. 1 0 5 2 4 9 7 o r e q u iva le n t E n g in e O il

C o n sta n t V elocity U n ive rsa l J oin t A u to m a tic T ra n sm is sio n S h ift Linkage , F loor S h ift L inkage , H oo d and D oo r H ing es. B od y D oo r H ing e P ins, Ta ilg ate H ing e and Linkage . Folding S eat, Fuel D oo r H ing e F luids and L u b ric a n ts id e n tifie d w ith G M pa rt n u m b e rs or G M s p e c ific a tion n u m b e rs m ay be o b ta in e d fro m yo u r G M dealer.

Fig. OB-28 Recommended Fluids and Lubricants

HEATER

1A-1

SECTION 1A

HEATER
CONTENTS
S tan d ard H e a te r................................................................................................ 1A -1 A uxiliary H e a te r ............................................................................................. 1A-15 Specifications.................................................................................................... 1A-20

STANDARD HEATER
INDEX
G eneral D escription..............................................................1A-1 System C om ponents........................................................ ..1A -1 System C o n tro ls............................................................... ..1A -1 Diagnosis............................................................................... ..1A-4 On Vehicle Service Blower M otor.......................................................................1A-8 H eater D istributor and Core A ssem bly........................1A-8 H eater H o ses..................................................................... 1A-9 C enter D istributor D u c t ................................................. 1A-9 Defroster D u c t................................................................... 1A-9 Control A ssem bly............................................................. 1A-9 Control C ables................................................................ 1A-11 Blower S w itch................................................................. 1A -11 Resistor U n i t ................................................................... 1A-11

GENERAL DESCRIPTION
H eating components are attached to the dash panel on th e rig h t side of the vehicle. T he blower and air inlet assembly and water hoses are located on the forward side of the dash panel while the heater core and distributor duct are on the passenger side. T he heater system is an air mix type system in which outride air is heated and then mixed in varying am ounts with cooler outside air to attain the desired air tem perature. The system consists basically of three parts: (1) the blower and air inlet assembly, (2) the heater distributor assembly and (3) the heater control assembly. the air. Since the unit has no w ater valve, w ater circulation keeps the core hot at all times. T hat portion of the air passing through the core receives m axim um heat from the core. A ir entering the distributor assembly is channeled as follows:

C-K Models
Air entering the distributor can be directed out the purge door opening, on the right end of the distributor assembly, by the purge door. If the purge door is closed, then air is directed thrdugh an d /o r around the heater core by the tem perature door. A ir is then directed into the passenger com partm ent through the heater (floor) outlets an d/or the defroster (dash) outlets by th e defro ster door. The tem perature of the outlet air is dependent on the ratio of heated to unheated air (controlled by the tem perature door).

HEATER AIR FLOW SCHEMATIC


C-K Series heater airflow is shown in Fig. 1A - l .

BLOWER AND AIR INLET ASSEMBLY


The blower and air inlet assembly draws outside air through the outside air inlet grille located forward of the windshield reveal molding and channels the air into the heater distributor assembly. The operation of the blower m otor is controlled by the FA N switch on the heater control. T he m otor is connected in series with the FA N switch and also the blower resistor assembly.

G Models
A ir flow is controlled by doors in the d istrib u to r assembly. The air door can be adjusted to vary airflow. If air is allowed to en ter the d istrib u to r assem bly, it is then directed through an d/or around the heater core by the tem p eratu re door. A ir is directed into the passenger com partm ent through the heater (floor) and /o r defroster (dash) outlets by the defroster door. The tem perature of the outlet air is dependent of the ratio of heated to unheated air (controlled by the tem perature door).

HEATER DISTRIBUTOR ASSEMBLY


T he heater distributor assembly houses the heater core and the doors necessary to control mixing and channeling of

CONTROLS
H eater controls for C-K and G Models are shown in Fig. 1A-2.

1A-2

HEATER

HEATER A DEFROSTER ASM HEATER A DEFROSTER ASM

AIR OUTLET

VI EW

AIR F L O W LEG EN D

[TJ TEMPERATURE VALVE [____ ] OUTSIDE AIR


[ 2] DASH P ANEl DEFROSTER VALVE PURGE VALVE M I X E D AIR W/M/M HEATED AIR

C-K MODELS

Fig. 1A-1--Heater A ir Flow Schematic--C-K Models

HEATER

1A-3

Fig. lA-2--Heater Control-C-K Models

1A-4

HEATER

DIAGNOSIS
TROUBLE CAUSE AND CORRECTION

Temperature of heater a i r a t o u t l e t s too low to heat up pas senger compartment.

1.

See " I n s u f f i c i e n t Heat Diagn ostic Ch art".

Temperature of heater a i r a t o u t l e t s adequate but the v e h i c l e w i l l not build up s u f f i c i e n t heat.

Check fo r body lea k s such a s:

1. 2.
3.

Floor side kick pad v e n t i l a t o r s p a r t i a l l y open. Leaking grommets in dash. Leaking welded seams along rocker panel and w indsh ield . Leaks through acces s holes and screw ho les. Leaking rubber molding around door and windows. Leaks between se alin g edge of blower and a i r i n l e t assembly and dash, and between se alin g edge of heater d i s t r i b u t o r assembly and dash.

4. 5. 6.

Inadequate de fro st in g a c t io n .

1. 2.
3.

Check that DEFROST le v e r completely opens d e f ro st e r door in DEF p osi tion - Adjust i f ne ce ss ary. Insure that temperature and a i r doors open f u l l y - Adjus t. Look f or o b struc ti o ns in d e f r o s t e r ducts - Remove any obstructions. Check for a i r leak in ducting between d e f r o s t e r o u t l e t on heater assembly and d e f ro s t e r duct under instrument panel Seal area as nece ssary. Check p o sit io n of bottom of nozzle to heater loc ating tab A djust. Check p osition of d e f r o s t e r nozzle openings r e l a t i v e to i n s t r u ment panel openings. Mounting tabs provide p o s i t i v e p osi tion i f prope rly i n s t a l l e d .

4.

5. 6.

Inadequate c i r c u l a t i o n of heated a i r through v e h i c l e .

1. 2.

Check heater a i r o u t l e t for c o r r e c t i n s t a l l a t i o n - R e i n s t a l l . Inspect f l o o r ca rp et to in su re that car p et l i e s f l a t under f r o n t se at and does not o b st ruct a i r flow under se a t , and a ls o in sp ect around o u t le t ducts to i n sure th at carpet i s well fastened to f l o o r to prevent cupping of a i r flow - Correct as nece ssary.

E r r a t i c heater operation.

1. 2.
3.

Check coolant le v e l - F i l l

to proper l e v e l .

Check for kinked heater hoses - r e l i e v e kinks or re p lace hoses. Check operation of a l l necessa ry . bowden cables and doors - Adjus t as

4.

Sediment in heater l i n e s and r a d ia t o r causing engine thermo s t a t to s t i c k open - fl u s h system and cle a n or r ep lace thermo s t a t as necessa ry .

5.

P a r t i a l l y plugged heater core -

backflu sh core as necessa ry .

Hard operating or broken c o n t r o l s .

1.

Check f or loose bowden cable tab screws or mis-adjusted bowden cab les - Co rr ec t as req uired . Check f or s t i c k i n g heater system door(s) - Lu b ri c a te as required using a s i l i c o n e spray.

2.

HEATER

1A-5

INSUFFICIENT HEAT D IA GN O SIS


P osition the c o n tro ls so th a t the: Tem perature lever is o n fu ll heat. Selector o r heater lever is on Heater. Fan sw itch is on Hi.

CHECK DUMP DOOR OUTLET FOR AIR FLOW

NO AIR FLOW

AIR FLOW

I
CHECK DEFROSTER OUTLETS FOR AIR FLOW
( If in d o u b t as to High or L o w a ir flo w set selector on DEF w h ich is High and compare. Reset selector on Heater) [

X
A djust dum p doo r fo r no air flo w .

NO OR LOW AIR FLOW CHECK HEATER OUTLET AIR FLOW


( If in d ou bt, switch fan switch fro m Hi to Lo>

HIGH AIR FLOW


| A djust defro ster d oo r fo r lo w a ir flo w . ]

------------------ c " ..............;


I CHANGE IN AIR FLOW | NORMAL AIR FLOW 1 LITTLE OR NO CHANGE IN AIR FLOW LOW OR NO AIR FLOW
**C h e ck s h u to ff doo r p o sitio n fo r fu ll system air flo w . A d ju st if necessary.

i
Check heater o u tle t tem perature w ith 220 F range therm om eter. (ap pro xim ate o u tle t air tem peratures) O utle t A ir A m b ien t A ir r !4 5 0 1 r 1 5 0 "^ r 25

1 55
40

165 75

[ LOW AIR FLOW | NORMAL TEMPERATURE


Check heater o u tle t fo r o b s tru c tio n - re move. Remove all obstru ctio ns under fro n t seat. Check m o to r voltage a t closest m o to r line co nnection w ith a vo ltm e te r.

NO AIR FLOW CHECK FUSE

FUSE B LO W N - replace fuse.

Car does n ot b u ild up heat - operate vent c o n tro ls and see th a t the air vent doors close co m p lete ly, if n ot, adjust.

.......-rsystem ' okay. '= ; ~ A IR ~ FLOW

LOW TEMPERATURE

X
(Check the system tem perature a fte r re pairing the item checked to co m p lete th e diagnosis.) Check co o la n t level; if low , fill. L o o k fo r or feel all ra d iato r and heater hoses and connections fo r leaks. Repair or replace. Check th e ra d ia to r cap fo r damage and re place if required.

UNDER 10 VOLTS.

OVER 10 VOLTS |

BLOWS FUSE
Remove p ositive lead fro m m o to r and replace fuse.

Check b a tte ry vo lts - under 10 volts, recharge the n recheck m o to r voltage. Check w irin g and connections fo r under 10 vo lts fro m m o to r to fan sw itch. Repair o r replace last p o in t o f under 10 v o lt reading.

FUSE R E M A IN S O K - remove m o to r and check fo r o b s tru c tio n in system opening, if none, REPLACE M O TO R . If o b s tru c tio n , remove material and re -in sta ll m o to r.

.....'

~
BLOWS FUSE - check fo r shorted w ire in b low er electric c irc u it See Heater C irc u it Diagnostic Chart. A p p ly external ground, (jum per w ire) to m o to r case. IN C R E A S E D A IR FLO W repair ground.

Check heater and radiator hoses fo r kin ks straighten and replace as necessary. Check tem perature d o o r fo r max heat po sitio n. A d ju s t if necessary.

HEATER CORE FUSE OK


[ Feel tem peratures o f heater in le t and o u tle t hoseT~| SAM E A l R FLO W - remove m o to r and check fo r o b s tru c tio n in system open ing. If none, REPLACE M O TO R . If o b stru ctio n , remove m aterial and re install m o tor. FUSE O K - See Heater C ircu it Diagnostic Chart.

WARM INLET AND OUTLET HOSES

....................... I------- .--------Check engine therm ostat.

HOT INLET AND WARM OUTLET HOSES

_______________ i
----

CHECK FOR CK MODELS ONLY CHECK FOR G MODELS ONLY

Check pulleys, b e lt tension, etc., fo r p ro per operation. Replace o r service as neces sary.

Remove hoses fro m heater core. Reverse flush w ith tap w ater. I f plugged, repair o r replace.

HEATER C IR C U IT DIAGN OSIS*


BLOW ER M O TO R IN O P E R A TIV E (A N Y SPEED)

1 z
Check fuse in fuse panel.

T
FUSE BLOWN

...;t :'~
With Ignition switch in " R U N " position and blower speed switch " O N " use meter to locate short in one of the following wires: 1. From fuse panel to blower speed switch. 2. From blower speed switch to heater resistor. 3. From heater resistor to blower. Note: Short circuit may be interm ittent. If meter does not indicate a short circuit, move harness around as much as possible to re-create short circuit. Watch and listen for arcing. The following tests should be made with the ignition switch in " R U N " position the blower speed switch " O N " and the lever on heat position.

X
Check blower motor ground

POOR OR NO GRO UND G R O U N D OK

I
Repair ground

I
Check m otor connector with 12 volt test light.

I
LAM P LIG H TS Replace Motor I LAMP DOES N O T L IG H T I

............

1 I

'

Check blower feed wire in connector on resistor with 12 volt test light.

LA M P DOES N O T L IG H T

| LAM PLIGHTS | Repair open in feed wire from resistor to blower motor.

~
* See heater circuit diagrams

Use 12 volt test light and check feed terminal (brown) on blower speed switch.

LA M P DOES N O T L IG H T Repair open in brown wire from blower speed switch to fuse panel.

LAM P L IG H TS

r
Replace switch

HEATER

1A-7

!fv w w -7 |
CIRCUIT OFF LO MED HI B A T -O N L Y B AT -LO BAT-M ED B A T -H I LO HEATER OPERATI ON B AT - BL O SW-RES Rl R2BLO MTR- GRD BLOWER RESISTOR

BAT - BLO SW-RES RlMED BLO MTR- GRD HI BAT - BLO SWBLO MTR- GRD 16 LBL-

| B L O M ED|

fm if
f i

HI
MED

i f f i
16 YEL

LO
BAT BLOWER SWITCH

<co C S C N iruo G

T orn
50
! 52 J

16 ORN

*>"1 15 2 BI DASH 14 ORN

INST. PANEL HARN CIRCUIT#4 (ACC) 2 5 A M P IN FUSE PANEL FUSE PANEL

p p
' i

j/
(IN ENG H A R N )

L; I I r* l J | !52 1 '52!

L.J
BULKHEAD C O N N JUN CT IO N BLOCK

co Q t/>

28

BLOWER M O TO R

Fig. lA-4--Heater W iring Diagrams

1A -8

HEATER

ON VEHICLE SERVICE

BLOWER MOTOR
Rem oval (Fig. 1A-5)

1. Disconnect battery ground cable. G Models - Remove the coolant recovery tank, and power antenna as outlined in Sections 6 and 9. 2. Disconnect the blower m otor lead wire. 3. Remove the five blower m otor m ounting screws and remove the motor and wheel assembly. Pry gently on the blower flange if the sealer acts as an adhesive. 4. Rem ove th e blow er wheel to m otor sh aft n u t and separate the wheel and motor assemblies. 5. To install a new m otor, reverse Steps 1-4 above. The following steps should be taken to assure proper installation: a. Assemble the blower wheel to the motor with the open end of the wheel aw ay from the blower motor. b. If the motor m ounting flange sealer has hardened, or is not intact, remove the old sealer and apply a new bead of sealer to the entire circum ference of the mounting flange. c. Check blower operations: blower wheel should rotate freely with no interference.

3. Rem ove the nuts from the d istrib u to r duct studs projecting into the engine com partm ent. 4. Remove the glove box and door assembly. 5. D isconnect the A ir-D efrost and T em p eratu re door cables. 6. Remove the floor outlet and remove the defroster duct to heater distributor duct screw. 7. Remove the heater distributor to dash panel screws. Pull the assembly rearw ard to gain access to wiring harness and disconnect all harnesses attached to the unit. 8. Remove the heater-distributor from the vehicle. 9. Remove the core retaining straps and remove the core. 10. To install, reverse Steps 1-9 above. Be sure core to case and case to dash panel sealer is in tact before assembling unit.

G Models
R ep lacem en t (Fig. 1A-7)

1. Disconnect the battery ground cable. 2. Remove coolant recovery tank and lay aside.

HEATER DISTRIBUTOR AND CORE ASSEMBLY C-K Models


R ep lace m en t (Fig. 1A-6)

1. Disconnect the b attery ground cable. 2. Disconnect the heater hoses at the core tubes and drain engine coolant into a clean pan. Plug the core tubes to prevent coolant spillage a t removal.

HEATER

1A-9

Fig. 1A -7-H eater Distributor - G Models

3. Place a clean pan under the vehicle and then disconnect th e h e a te r core inlet and o u tlet hoses a t th e core connections (see "H e a te r H oses-R eplacem ent" later in this section). Quickly plug th e h eater hoses and support them in a raised position. Allow the coolant in the h eater core to drain into the pan on the floor. 4. R em ove h eater d istrib u to r d u c t to d istrib u to r case attaching screws and distributor duct to engine cover screw and remove duct. 5. Remove engine housing cover. 6. Remove instrum ent panel attaching screws: above, at w indshield, all lower screw s and rig h t lower I.P. support bracket a t door pillar and engine housing. 7. Lower steering colum n, and raise and support right side o fl.P . 8. Remove defroster duct to distributor case attaching screw, and 2 screws attaching distributor to heater case. 9. Disconnect tem perature door cable and fold cable back for access (R efer to Fig. 1A-17). 10. Remove three (3) nuts a t engine com partm ent side of distributor case and one (1) screw on passenger side. 11. Remove the heater case and core as an assembly. T ilt th e case assembly rearw ard a t the top while lifting up until the core tubes clear th e dash openings. 12. Remove the core retaining strap screws and remove the core. 13. To install a new core, reverse Steps 1-10 above. Be sure core to case and case to dash panel sealer is intact before assembling unit.

Replacement T he heater core can be easily dam aged in the area of the core tube attachm ent seams whenever undue force is exerted on them . W henever the heater core hoses do not readily come off the tubes, the hoses should be cut just forward of the core tubes. The portion of the hose rem aining on the core tube should then be split longitudinally. Once the hoses have been split, they can be removed from the tubes w ithout dam aging to the core.

m , DISTRIBUTOR DUCTS - G Models

> i 1

Replacement (Fig. 1A-12) 1. Disconnect the b attery ground cable. 2. R aise I.P. a t rig h t side as outlined under h eater distributor removal. 3. U nsnap the engine cover front latches. Remove the two cover to floorpan screws and remove the cover. 4. Remove the heater distributor duct to case attaching screws as shown in Fig. 1A -12. 5. Remove one (1) screw at left center of distributor duct. 6. Pull the center distributor duct to the right and remove it from the vehicle. 7. To install, reverse Steps 1 thru 5. Check cable and door operation; cables should be free from kinks or binding and doors should close properly. If cable adjustm ent is . necessary, refer to " Bowden C able-A d justm ent."

DEFROSTER DUCT
D efroster assemblies attachm ent are shown in Fig. 1A13.

CONTROL ASSEMBLY C>K Models


Replacement (Fig. 1A-14) 1. Disconnect the battery ground cable. 2. Remove the instrum ent panel bezel. 3. Disconnect the bowden cables and the blower switch

HEATER HOSES
H eater hoses are routed from the therm ostat housing or inlet m anifold and w ater pum p (ra d ia to r on some autom atic transmission vehicles) to the core inlet and outlet pipes as shown in Figures 1A-8 th ru 1A-11. Hoses are attach ed a t each end with screw type clamps.

1A-10

HEATER

Fig. lA-8--Heater Hose Routings

wiring harness. Be careful not to kink the bowden cables. 4. Remove the control through the opening above the control. 5. If a new unit is being installed, transfer the blower switch to the new unit. 6. To reinstall, reverse Steps 1 th ru 4.

G Models
R ep lace m en t (Fig. 1A-15)

1. Disconnect the b attery ground cable.

2. Remove I.P. bezel as outlined in Section 8C of this m anual. 3. Rem ove the control to in stru m en t panel m ounting screws (3) and carefully pull the control rearw ard far enough to gain access to the bowden cable attachm ents. C are should be taken to prevent kinking the bowden cables while lowering the control. 4. Disconnect the bowden cables, the control illum ination bulb, the blow er sw itch connector and rem ove the control from the vehicle. 5. Rem ove the blower sw itch screws and rem ove the blower switch. 6. To install, reverse Steps 1 thru 4.

HEATER

1A-11

Fig. lA-9--Heater Hose Routing-Diesel

Fig. 1 A-10--Heater Hose Routing V8

CONTROL CABLES (Fig. 1A-16, 1A-17) C-K Models


R ep lace m en t

A d ju s tm e n t - G V a n
1. A ttach inner cable and sheath to I.P. Control.
2. W ith I.P. installed, move tem perature cable to cold and

1. Disconnect the b attery ground cable. 2. Remove the instrum ent panel bezel. 3. Remove the control to instrum ent panel screws. 4. R aise or lower control as necessary to remove cable push nuts and tab a ttaching screws. 5. Remove glove box and door as an assembly. 6. Remove cable push nut and tab attaching screw at door end of cable. 7. Remove cable from retaining clip and remove cable assembly. 8. To install, reverse Steps 1 th ru 7. Be careful not to kink the cable during installation. Be sure to route the cable as when removed. Check cable adjustm ent.

attach loop on inner cable to tem perature door on heater case. 3. A ttach cable sheath to heater case. 4. Move tem perature lever to full heat. This will require some effort due to force required to slide inner cable clip to its proper position.

BLOWER SWITCH C-K M o d els


R ep lace m en t (Fig.

1A-14)

1. Disconnect the battery ground cable.


2. Remove the instrum ent panel bezel. 3. Remove the control to instrum ent panel screws and

lower the control onto the radio.


4. Disconnect the switch electrical harness.

G Models
R ep lace m en t (Fig. 1A-17)

H eater and defroster cable routing and attachm ent to control and to distributor case is shown in Fig. 1A - 17. If cable adjustm ent is required, refer to A djustm ent, C -K Series.

5. Remove the switch attaching screws and remove the switch. 6. To install, reverse Steps 1-5 above.

G M o d els
R ep lacem en t (Fig.

1A-15)

Adjustment - C-K Series


1. Disconnect the b attery ground cable. 2. Remove glove box and door as an assembly. 3. Pry off the appropriate cable eyelet clip and disconnect the cable from the door. 4. Remove the cable retaining screw. 5. W hile holding th e cab le w ith pliers, ro ta te the m ounting tab on the cable to lengthen or shorten the cable, whichever is required. Do not pinch the cable too tightly or dam age to the cable could result.
N O TIC E:

1. Disconnect the b attery ground cable.


2. Disconnect the blower switch wiring harness connector

at the switch.
3. Remove the two switch attaching screws and remove

the switch assembly.


4. To install a new switch, reverse Steps 1 thru 3.

RESISTOR
R ep lacem en t (Figs.

1A-5

and

1A-18)

1. Disconnect the wiring harness at the resistor connector.


2. Remove the two resistor m ounting screws and remove

the resistor.
3. To install a new resistor, reverse Steps 1 and 2 above.

6. Install the cable, reversing Steps 1-4 above.

1A-12

HEATER

Fig. 1A -11--Heater Hose Routing G Series

HEATER

1A-13

Fig. 1A -l 2--Distributor Ducts--G Models

Fig. 1A-15--Control Assembly, G Models

1A-14

HEATER

V IE W A

VIEW B

Fig. 1A-17--Control Cable Routing, G Models

HEATER

1A-15

AUXILIARY HEATER
INDEX
G eneral D escrip tio n ............................................................................................1A-15 C o n tro l............................................................................................................... ..1A-15 Diagnosis........................................................................................................ ..... 1A-17 On Vehicle S erv ice..............................................................................................1A-18 Specifications...................................................................................................... ..1A-20

GENERAL DESCRIPTION
An auxiliary heater is available accessory to provide additional heating capacity for the rearm ost extrem ities of the certain modles. This unit operates entirely independent of the standard heater and is regulated through its own controls at the instrum ent panel. This system consists of a separate core and fan unit m ounted as shown in Fig. 1A -19. H eater hoses extend from the unit to the front of the vehicle where they are connected to the standard heater hoses with "te e s " . An "on-off" vacuum operated w ater valve is installed in the heater core inlet line in the engine com partm ent. The purpose of the valve is to cut off coolant flow to the au x iliary core d u rin g w arm w eather and elim inate the radiant heat th a t would result.

CONTROLS
Two methods of control are employed with this system:

Water Valve (Refer Fig. 1A -11)


W hen heat is desired, and the fan switch is any position except off, a vacuum operated w ater valve controlled by the switch, opens the w ater line to perm it hot w ater circulation through the heater core. In the O F F position the valve is closed to prevent unw anted heat during w arm w eather.

Fan Switch (Fig. 1A-20)


T he th ree speed fan sw itch (L O W -M E D -H I) is located in the instrum ent panel, to the right of the steering column.

1A-16

HEATER

Fig. 1A-19-Auxiliary Heater Installation

HEATER

1A-17

DIAGNOSIS
R efer to the "S tan d ard H e ate r" section of this m anual for diagnostic inform ation; R efer to Electrical D iagram Fig. 1A-21.

1A-18

HEATER

n r ir r .f- a w

r TnrTT ~ym

"TT?H 'T f'T T l m m

29737818905026 3 3 298092 i3 W HT-952 BRN/WHT-5' YEL-51-----LT BLU-728905426 8905426 LT BLU-72 1 2 YEL-51 H -2 L-2 2984092 2989576 GROMMETBRN/W HT-50| W H T-952A 3 BRN/W HT-50--------3 WHT-952A 2 WHT-952B

2984092

L fJ
LT BLU-72* WHT-952BiiS n l 2977940rEL-51-2

G Series

FUSE PANEL

Fig. 1A -21 Electrical Diagram

ON VEHICLE SERVICE
Since a d etailed list of in stallatio n instructions is included w ith the auxiliary h eater unit, replacem ent procedures will not be repeated in this section. On G M odels W hen replacing heater hoses, m aintain a 1/2 in. m inimum clearance between hose clip and upper control arm , a 1-1/2 in. minimum clearance between hoses and propshaft and a 1-1/4 in. minim um clearance between the auxiliary heater core lines and the exhaust pipe as shown in Fig. 1A-24. All M odels-D raw hoses tight to prevent sag or rub against other components. Be sure to route hoses through all clamps as originally installed.

Fig. 1A-22--Control Mounting

HEATER

1A-19

Fig. 1A-23--Auxiliary Heater Hose Routing

1A-20

HEATER

SPECIFICATIONS
SECTION 1A HEATER
V o lt s
Blower Motor

A m p s. (C o ld )

RPM (Cold)

C-K M odels G M odels . . . .

13.5 13.5

6 .2 5 Max. 7.1 Max.

2550 2950 2850 3250

Min. Max. Min. Max.

Fuses

C-K Models G M odels . . . .

AUXILIARY HEATER
V olts Blower M otor . . . . 13.5 Amps. (Cold) 9 .6 Max. RPM (Cold) 2 7 0 0 Min.

AIR C O ND ITIO NIN G

IB-1

SECTION IB

AIR CONDITIONING
NOTICE: W hen perform ing air conditioning diagnosis on vehicles equipped with a catalytic converter, it will be necessary to warm the engine to a norm al operating tem perature before attem pting to idle the engine for periods greater than five (5) minutes. Once the choke is open and fast idle speed reduced to a norm al idle, diagnosis and adjustm ents can be made.

CONTENTS
G eneral D escription..............................................................IB-1 C60 System (C -K & G M odels)............,..................... ..IB-1 Air D istribution O u tle ts................................................. ..IB-1 Overhead System s (C -K & G Series)......................... ..IB-1 M otor Home Chassis S y stem ........................................ ..IB-1 System C om ponents......................................................... ..IB-1 System C on tro ls.................................................................. ..IB-5 C60 System (C -K & G S e rie s).......................................IB-5 Overhead System (C -K S eries)....................................... ..IB-5 Overhead System (G M odels)......................................... ..IB-5 Dash M ounted U nit (M otor Hom e C hassis).................IB-5 C C O T System C om ponents...............................................IB-5 H andling R efrig eran t-1 2 .....................................................IB-5 H andling R efrigerant Lines and F ittin g s.......................IB-8 M aintaining Chem ical Stability In the Refrigeration S y stem ......................................................................................IB-10 D iagnosis............................................................................... ..IB -11 Testing The R efrigerant S y stem .................................. ..IB -1 1 Leak Testing The R efrigerant S y s te m .........................IB -1 1 Pressure Cycling C C O T System , C60 (C -K & G M o d els)............................................................................... ..IB -11 E lectrical/V acuum Trouble D iagnosis.......................... ..IB -12 O perational T e s t............................................................... ..IB-12 Vacuum System D iagnosis............................................... ..IB -12 C-K and G, C60 S y s te m ................................................ ..IB-12 A /C R efrigerant System D iagnosis............................... ..IB -12 Insufficient Cooling "Q uick C heck" P rocedure.........IB-12 Evacuating and Charging Procedures..............................IB-21 P recautionary Service M easu res.................................. ..IB-21 Discharging, Evacuating, A dding Oil and C harging Discharging the C C O T A /C S y stem .......................... ..IB-21 Procedures for C C O T A /C System s..............................IB-21 C C O T R efrigerant Oil D istrib u tio n ..............................IB-21 Evacuating and C harging the C C O T A /C System.. IB- 23 Vacuum System C h e c k .................................................. ..IB-23 Charging Station M ethod............................................... ..IB-23 Disposable C an or R efrigerant M eth o d........................IB-23 C harging of the C C O T A /C S y stem .......................... ..IB-25 A ccum ulator A ssem b ly .....................................................IB-25 A ccum ulator R eplacem ent...............................................IB-25 Expansion Tube (O rifice)............................................... ..IB-25 Specific Com ponent D iagnosis........................................ ..IB-25 C om p resso r........................................................................ ..IB-25 C ondenser..............................................................................IB-26 Receiver-D ehydrator (M otor Hom e Chassis) ........ .. IB-26 Expansion V a lv e ............................................................... .. IB-26 E vaporator.......................................................................... .. IB-26 R efrigerant Line R estrictions........................................ .. IB-26 Sight Glass D iagnosis (M otor H om e C hassis units) 1B-26 On Vehicle S e rv ic e ............................................................... IB-27 C o m p resso r........................................................................ .. IB-27 C om pressor Belt Tension A d ju stm e n t........................ ..IB-27 C60 System (C-K Series)................................................. ..IB-27 C ondenser............................................................................ A c cu m u la to r...................................................................... Blower A ssem b ly.............................................................. Evaporator C ore................................................................. Expansion T u b e ................................................................ Selector Duct and H eater Core Assem bly................. Kick Pad V alve.................................................................. Plenum V alve..................................................................... Control A ssem b ly ............................................................. Tem perature Door C able A d ju stm e n t........................ M aster Switch a n d /o r Blower S w itch......................... Vacuum T a n k .................................................................... Blower M otor R e sisto r.................................................... Blower M otor R elay-A ll.................................................. F u se ............;......................................................................... Overhead System (C -K M odels)..................................... R ear D u c t........................................................................... Blower M otor R e sisto r.................................................... Blower M otor A ssem bly.................................................. Expansion V a lv e ............................................................... Evaporator C ore................................................................. Blower M otor Sw itch........................................................ F u se ....................................................................................... C60 System (G S eries)...................................................... Condenser............................................................................ H eater C o r e ........................................................................ Blower M otor Insulation (w /D iesel)............................ Evaporator Core (w /D iesel)........................................... Blower M o to r..................................................................... Evaporator C ore................................................................. Control A ssem bly............................................................. Blower S w itc h .................................................................... R esistors............................................................................... Blower M otor R e la y ......................................................... C enter A /C O u tle t........................................................... A /C D uctw ork................................................................... Defroster D u c t................................................................... T em perature Door C able................................................ Vacuum T a n k .................................................................... Overhead System (G S e rie s)............................................ Dash M ounted System (M otor Home C h a ssis)......... C ondenser............................................................................ R eceiver-D ehydrator....................................................... Sight Glass R ep la c e m e n t............................................... Blower-Evaporator A ssem bly........................................ Blower A ssem b ly .............................................................. Expansion Valve, Evaporator an d/o r Evaporator C a s e ..................................................................................... Therm ostatic an d /o r Blower Sw itches........................ R e sisto r................................................................................ F u se ...................................................................................... Specifications..................................................................... Special T ools...................................................................... IB -30 IB-30 IB-30 IB-30 1B-30 IB -30 IB-31 IB-32 IB-32 IB-32 IB-32 IB-32 IB-32 IB-33 IB-33 IB-33 IB-33 IB-34 IB-34 IB-35 IB-36 IB-36 IB-36 IB-36 IB-36 IB-36 IB-37 IB-37 IB-38 IB-38 IB-38 IB-40 IB-40 IB-40 IB-40 IB-40 IB -40 IB-40 IB-41 IB-41 IB -44 IB -44 IB-45 IB-45 IB-45 IB-45 IB -46 IB -47 IB-47 IB-47 IB-48 IB-49

EVA PO RA TO R SH RO U D

CORE BLO W ER & EV A PO R A TO R ASM

R .H . CON TROL

O U TLET

0
R .H . O U T L E T

VIEW A
Fig. 1B-1--Airflow
A IR PLEN U M V A LV E H EATER BLO W ER EVAPO RATO R CORE & ASM IN L E T V A LV E

CEN TER O U TLET

AIR CONDITIONING OVERHEAD SYSTEM

L .H .

O U TLET

Chart - C -K Models

L .H . O U T L E T

SELECTO R DUCT EVAPO RA TO R CORE ASM

FO O T

D EFLECTO R

(CK) MODELS

AIR CO NDITIO NING

IB -3

GENERAL DESCRIPTION
C60 A /C SYSTEM
Both the heating and cooling functions are perform ed by this system. A ir entering the vehicle m ust pass through the cooling unit (evaporator) and through (or around) the heating unit, in th at order, and the system is referred to as a "re h e a t" system. The evaporator provides m axim um cooling of the air passing through the core when the air conditioning system is calling for cooling. On C -K and G S eries, com pressor operation is controlled by a pressure sensing switch, located near the top of the accum ulator. The switch responds to pressure changes to turn the compressor O N or O F F , as required. System operation is as follows: A ir, either outside air or recirculated air, enters the system and is forced through the system by the blower. As the air passes thro u g h th e evap o rato r core, it receives m axim um cooling if the air conditioning controls are calling for cooling. A fter leaving the evaporator, the air enters the heater and air conditioner selector duct assembly where, by means of diverter doors, it is caused to pass through or to bypass th e h eater core in th e proportions necessary to provide the desired outlet tem perature. Then conditioned air enters the vehicle through either the floor distributor duct or the dash outlets. D uring cooling operations, the air is cooled by the evaporator to below com fort level, it is then warm ed by the heater to the desired tem perature. D uring "heating only" operations, the evaporator will not be in operation and am bient air will be warm ed to the desired level in the same m anner. These units are self contained, operating on inside (recirculated) air only. Air is draw n into the unit, passed through the evaporator core and then directed into the passenger com partm ent through the air distributor duct. System control is through the front system. The only control on the overhead system is a three speed blower switch.

MOTOR HOME CHASSIS SYSTEM


This system perform s the cooling functions only. W hen heating (above am bient tem peratures) is desired, the vehicle heater m ust be used. W hen air conditioning is desired, the heater should be completely shut O FF. This self-contained unit is bracket m ounted to the dash by the body m a n u fa c tu rer. It operates on inside (recirculated) air only. A ir is drawn into the unit, passed through the evaporator core (receiving m axim um cooling) and then d irected into the vehicle through ad ju stab le outlets. A therm ostatic switch, located on the face plate is used to control compressor operation by sensing air tem perature as it leaves the evaporator core.

SYSTEM COMPONENTS Receiver-Dehydrator (Motor Home Chassis Models)


T he receiv er-d eh y d rato r, serving as a reservoir for storage of high pressure liquid produced in the condenser, incorporates a screen sack filled with the dehydrating agent. The receiver-dehydrator, used prim arily as a liquid storage tank, also functions to trap m inute quantities of m oisture and foreign m aterial which may have rem ained in the system a fte r in stallatio n or service operations. A refrigerant sight glass is built into the receiver-dehydrator to be used as a quick check of the state and condition of charge of the entire system. The receiver-dehydrator is m ounted near the condenser.

AIR DISTRIBUTION OUTLETS C-K Series


The dash outlets are rectangular in design. The outlets can be rotated horizontally or vertically to direct air as desired. U nder the left distributor duct is located a floor cooler which can be rotated to provide cooling air or shut off completely.

Sight Glass (Motor Home Chassis Models Only)


W hile having no real function to perform in the system, the sight glass is a valuable aid in determ ining w hether or not the refrigerant charge is sufficient and for elim inating some guess work in diagnosing difficulties. The sight glass, is built into the receiver-dehydrator outlet connection and is designed and located so th a t a shortage of refrigerant at this point will be indicated by the appearance of bubbles beneath the glass. The dust cap provided should be kept in place when the sight glass is not in use.

G-Van
The dash outlets are rectangular in design and can be rotated horizontally or vertically to direct air as desired. Foot coolers are provided on both driver and passenger side. In the h eater-d efro st m odes, th e air conditioning outside air door is closed. The heater air door is open and outside air is allowed to pass th ro u g h th e h e ater core (receiving maxim um heating) and is then directed into the passenger com partm ent through the h eater an d /o r defroster outlets.

Thermostatic Expansion Valve (Fig. IB-2)


C-K and G overhead, and m otor home chassis systems use a therm ostatic expansion valve in place of a float system. The valve consists prim arily of the power element, body, actuating pins, seat and orifice. A t the high pressure liquid inlet, is a fine mesh screen which prevents dirt, filings or other foreign m atter from entering the valve orifice. W hen the valve is connected in the system , high pressure liquid refrigerant enters the valve through the screen from the receiver-dehydrator or condenser and passes

OVERHEAD SYSTEMS (C-K & G SERIES)


These systems (C69 on C-K & G Series) operate in conjunction with the C 60 S y s te m -th e y do not o perate independently. However, control of rear blower motor speed is possible even when the front system is O FF, thus, rear air circulation without the refrigerant function m ay be had by operating the rear blower control switch.

IB -4

AIR CO NDITIO NING

Accumulator C-K, & G Series (Fig. 1B-3)


The accumulator is located at the evaporator outlet. Its most important function is not to "accumulate" although this too is important. Its primary function is to separate liquid retained from vapor, retain the liquid and release the vapor to the compressor. Thus, in an ideal accumulator with no oil bleed hole, and in a correctly designed system, no liquid can get to the compressor. In an actual accumulator, there is some entrained liquid in the vapor stream to the compressor. Flow out of the accumulator to the compressor consists mostly of vapor with the addition of entrained liquid, and liquid flow through the oil bleed hole. A bag of desiccant (dehydrating agent) is located in the accumulator as a moisture collecting device. There is no sight glass in the accumulator-clutch cycle system.

Expansion Tube--C-K, & G Series


on to the seat and orifice. Upon passing through the orifice the high pressure liquid becomes low pressure liquid. The low pressure liquid leaves the valve and flows into the evaporator core where it absorbs heat from the evaporator core and changes to a low pressure vapor, and leaves the evaporator core as such. The power element bulb is clamped to the low pressure vapor line just beyond the outlet of the evaporator (Fig. IB-2). Expansion tube flow rate depends on pressure difference and on subcooling; however, the flow rate is more sensitive to subcooling. The expansion tube is located in the evaporator inlet line (Fig. IB-4).

Thermostatic Switch - Motor Home Chassis Units Only


System temperature is controlled by running the compressor intermittently, automatically turning it on and off as necessary to maintain proper temperatures. The compressor is started and stopped through the use of an electro-m agnetic clutch and a thermostat affected by variations in temperature. The thermostatic switch incorporates a metallic tube which contains a highly expansive gas. This tube is located in the air stream as it leaves the evaporator. The tube leads to a bellows operated switch. As air temperature rises, the gas inside the tube expands, travels through the tube to the bellows and closes the electrical switch which

Fig. 1B-4--Expansion Tube

AIR C O ND ITIO NIN G


engages the compressor clutch. As soon as th e com pressor sta rts running, the tem perature begins to go down. As the air being cooled gets colder, the gas in the therm ostatic tube begins to reduce the pressure on th e sw itch bellows. T his allows th e sw itch contact to open and the com pressor clutch disengages.

IB -5

an A IR knob and T E M P knob located in the center of the unit face plate (Fig. 1B -11).

Air Knob
Turning the A IR knob clockwise operates a three speed (L O W -M E D -H I) blower motor.

Pressure Cycling Switch - Low Refrigerant Charge Protection System - C-K&G Series
Low refrigerant charge protection is afforded by the pressure cycling switch as a secondary function. W hen refrigerant pressure drops below a certain predeterm ined level, th e sw itch opens th e com pressor clutch circuit, shutting the system O FF.

Temp Knob
This knob is used to control the degree of cooling desired. Fully clockw ise at C IT Y provides m axim um cooling, w hile tu rn in g the knob to H IW A Y provides adequate cooling for highway operation. Reduced cooling could be encountered when operating at highway speeds with the controls at the C IT Y setting. The heater m ust be fully off to obtain m axim um cooling.

SYSTEM CONTROLS
C60 SYSTEM (C-K & G SERIES) - FIG. IB-5 System Operation - C-K Truck
System operation is shown in Fig. 1B-6.

CCOT SYSTEM COMPONENTS


CCOT R efrig e ra n t System com ponents and refrigerant flow are shown in Fig. IB -12. Fig. IB -13 shows pressure tem perature relationships of R -12.

Refrigerant Capacities
R efrigerant charge is shown in Fig. 1B-14.

Vacuum Schematic - C-K Truck


The C-K T ruck air conditioning vacuum schem atic is shown in Fig. IB-7.

HANDLING REFRIGERANT-12
A ir conditioning systems contain R efrig eran t-12. This is a chem ical m ix tu re w hich requires special handling procedures to avoid personal injury. Always wear goggles and w rap a clean cloth around fittings, valves and connections when perform ing work that involved opening the refrigerant system. Always work in a well ventilated area and do not weld or steam clean on or near any car installed air conditioning lines or components. If R efrig e ra n t-12 should come in contact with any part of the body, flush the exposed area with cold w ater and im m ediately seek m edical help. All R e frig eran t-12 drum s are shipped with a heavy m etal screw cap. The purpose of the cap is to protect the valve and safety plug from dam age. It is good practice to replace the cap after each use of the drum for this same reason. If it is necessary to transport or carry any container of R efrig eran t-12 in a vehicle, do not carry it in the passenger com partm ent. If the occasion arises to fill a small R efrig eran t-12 drum from a large one, never fill the drum completely. S pace should alw ays be allowed above the liquid for expansion. 1. Do not leave drum of R efrig eran t-12 uncapped. 2. Do not c a rry any co n tain e r of R e frig e ra n t-12 in passenger com partm ent of car. 3. Do not subject any container of R efrig eran t-12 to high tem perature. 4. Do not weld or steam clean on or near system. 5. Do not fill drum of R efrig e ra n t-12 completely. 6. Do not discharge vapor into a re a w here flam e is exposed. 7. Avoid breathing smoke and fumes produced by the burning of the R efrig eran t-12. Such fumes may be hazardous. 8. One of the most im portant cautions concerns the eyes. A ny liquid R e frig e ra n t-12 w hich may

System Operation - G Models


System operation is shown in Fig. 1B-8.

OVERHEAD SYSTEM (C-K SERIES)


T his system operates in conjunction w ith th e C 60 vsystem. Since refrigerant flow is controlled by the front system, the only control provided for on the overhead system is a three-speed fan switch (L O W , M E D , H I). The fan switch is m ounted in the instrum ent panel, to the right of the steering column (Fig. IB-9). In th e O F F position, th e blow er is inoperative; however, refrigerant is circulating in the system if the C60 System is O N . In any of the three blower positions (LO W , M ED , H I), the blower will be operative regardless if the Four-Season system is O N . To obtain m axim um cooling, the Four-Season System should be on A /C , tem perature lever on C O L D , blower switch on H I and the overhead unit blower switch should be on H I.

OVERHEAD SYSTEM (G MODELS)


T his system o perates in co njunction w ith th e C 60 system. Since refrigerant is controlled by the C60 system, the only control provided on the rear overhead system is a three speed blower switch (Fig. IB -10). In th e O F F position, th e blow er is inoperative; however, refrigerant is circulating in the system if the front system is O N . To operate the rear overhead system, simply select the desired blower speed (L O W , M E D , H I). W hen air circulation only is desired, the rear A /C blower motor m ay be operated independent of the front A /C blower motor and w ithout the cooling function.

DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS)


This system is self contained and is m ounted below the dash by the body m anufacturer. System controls consist of

p ~ l CONDITIONED AIR IS DIRECTED THROUGH W/SHLD. I.R & FLOOR DISTRIBUTOR OUTLETS. CONDITIONED AIR IS DIRECTED THROUGH I.R OUTLETS. [~2~] IN THIS MODE LEVER POSITION, M AXIM U M COOLING IS OFFERED WITH THE CONDITIONED AIR DISTRIBUTED THROUGH I.R OUTLETS AT ANY BLOWER SPEED. 1 3 | A NON-COMPRESSOR OPERATING POSITION, WITH OUTSIDE AIR DELIVERED THROUGH I.R OUTLETS. [~ ~ 4 ~ ~ 1 A NON-COMPRESSOR OPERATING POSITION, WITH OUTSIDE AIR DISTRIBUTED ABOUT 80% TO FLOOR & 20% TO W/SHLD. | 5 | CONDITIONED AIR DISTRIBUTED ABOUT 80% TO W/SHLD. & 20% TO FLOOR. | 6 1VACUUM OPERATED SYSTEM SELECTOR (MODE) LEVER. [~ T ] TEMPERATURE LEVER POSITION REGULATES TEMPERATURE OF THE AIR ENTERING THE PASSENGER COMPARTMENT BY CABLE OPERATION OF THE HEATER CORE TEMPERATURE DOOR. | 8 14-SPEED FAN CONTROL LEVER.

Fig. 1B-5--C60 System Controls (C -K & G Series)

104214

AIR CO ND ITIO NIN G

IB -7

SELECTOR LEVER POSITION OFF MAX A/C NORM A/C BI-LEVEL VENT HTR

COMPRESSOR OFF
ON ON ON O FF O FF

BLOWER SPEEDS AVAIL


LO W HI ALL ALL ALL ALL

AIR SOURCE
O U T S ID E IN S I D E % O U T S ID E O U T S ID E O U T S ID E O U T S ID E

AIR ENTERS VEHICLE


FLOOR O U TLETS DASH O U TLETS DASH O U TLETS FLOOR AND DASH O U TLETS DASH O U TLETS FLOOR O UTLETS

HEATER A/C DOOROPEN TO:


HEATER A /C A /C A /C & HEATER A /C HEATER HEATER

HEATER DEFROSTER DOOR-OPEN TO:


HEATER HEATER HEATER HEATER HEATER HEATER DEFROST

DEF ON O U T S ID E DEFRO ST O U TLETS ALL NOTE % 1 0 0 % In s id e a ir is n o t a v a ila b le , som e b le e d th ro u g h o f o u ts id e a ir is a llo w e d .

Fig. lB-6--System Operation - C-K Truck

accid en tally escape is ap p ro x im ately 21F (-6C ) below zero. If liquid R efrig eran t-12 should touch the eyes, serious dam age could result. Always wear goggles to p ro tect the eyes w hen opening re frig e ran t connections. If R efrig eran t-12 liquid should strike the eye: a. C all a doctor or eye specialist im m ediately and obtain treatm ent as soon as possible. b. DO N O T R U B T H E E Y E. Splash the affected area with quantities of cold w ater to gradually get the tem perature above the freezing point. c. The use of an antiseptic oil is helpful in providing a protective film over th e eyeball to reduce the possibility of infection. Should liquid R efrig eran t-12 come into contact with the skin, the injury should be

treated the sam e as skin which has been frostbitten or frozen. All R efrig eran t-12 drum s are shipped with a heavy m etal screw cap. The purpose of the cap is to protect the valve and safety plug from dam age. It is good practice to replace the cap after each use of the drum for the same reason. If it is necessary to transport or carry any container of R efrig eran t-12 in a car, keep it in the luggage com partm ent. If the drum is exposed to the radiant heat of the sun, the resultant increase in pressure m ay cause the safety plug to release or the drum to burst. W elding or steam cleaning near any of the refrigerant lines or com ponents of the air conditioning system could build up dangerous and dam aging pressures in the system. If the occasion arises to fill a small R efrig eran t-12

Fig. lB-7--Air Conditioning Vacuum Schematic - C-K Truck

IB -8

AIR CONDITIO NING

COMPRESSOR

BLOWER SPEEDS A V A IL
NONE

AIR SOURCE OUTSIDE

AIR ENTERS VEHICLE FLOOR OUTLETS

HEATER DEFROSTER DOOR OPEN TO

HEATER A/C DOOR OPEN TO HEATER-DEF A/C

OFF

O FF

HEATER
ON

MAX

ALL

INSIDE %

DASH OUTLETS

HEATER

NORM

ON

ALL

OUTSIDE

DASH OUTLETS

HEATER

A/C

Bl LEV

ON

ALL

OUTSIDE

DASH OUTLETS FLOOR OUTLETS DASH OUTLETS

HEATER

A/C & HEATER A/C

VENT

Of F

ALL

OUTSIDE

HEATER

HEATER

OFF

ALL

OUTSIDE

BLEED TO DEFROST & FLOOR OUTLETS

HEATER

HEATER

DEFR

ON*

A LL

OUTSIDE

DEFROST OUTLETS

DEFROST

HEATER

PRO VIDED COMPRESSOR PRESSURE SWITCH CLOSED

Fig. lB-8--System Operation - G Models

SINGLE SWITCH LOCATION ONLY

INSTRUMENT PANEL

W/RR A/C AND AUX HTR


Fig. 1B-lQ--Overhead Unit Control (G Models)

C69 0R C36

r3> ^
Fig. 1B-9--Overhead Unit Control (C-K Series)

102035

drum from a large one, never fill the drum completely. Space should alw ays be allow ed above th e liquid for expansion. If the R efrig eran t-12 drum were completely full and the tem perature was increased, trem endous hydraulic force could be developed.

HANDLING OF REFRIGERANT LINES AND FITTINGS


Tighten all tubing connections as shown in torque chart IB -15. Insufficient or excessive torque when tightening can

AIR C O ND ITIO NIN G

IB -9

PRESSURE CYCLING SYSTEM


"HPV" "HPL" "LPL" "LPV"
lp|

HIGH PRESSURE VAPOR LEAVING COMPRESSOR. VAPOR IS COOLED DOWN BY CONDENSER AIR FLOW AND LEAVES AS HIGH PRESSURE LIQUID. ORIFICE METERS THE LIQUID R-12, INTO EVAPORATOR, REDUCING ITS PRESSURE, AND WARM BLOWER AIR ACROSS EVAPORATOR CORE CAUSES BOILING OFF OF LIQUID INTO VAPOR. LEAVES EVAPORATOR AS LOW PRESSURE VAPOR AND RETURNS WITH THE SMALL AMOUNT OF . . . . . . LOW PRESSURE LIQUID THAT D ID N T BOIL OFF COMPLETELY BACK TO THE COMPRESSOR TO BE COMPRESSED AGAIN.

Fig. 1B-12--CCOT System Components

resu lt in loose joints or deform ed jo in t p arts. E ith er condition can result in refrigerant leakage. All m etal tubing lines should be free of dents or kinks to prevent loss of system capacity due to line restriction. The flexible hose lines should never be bent to a radius of less than 4 times the diam eter of the hose. The flexible hose lines should never be allowed to come within a distance of 63.5m m (2-1/2 in.) of the exhaust manifold.

Flexible hose lines should be inspected regularly for leaks or brittlen ess and replaced w ith new lines if deterioration or leaking is found. W hen disconnecting any fitting in the refrigeration system , the system m ust first be discharged of all re frig e ra n t-12. H ow ever, proceed very cautiously regardless of gage readings. Open very slowly, keeping face and hands away so th a t no injury can occur if there happens to be liquid R e frig eran t-12 in the line. If pressure is noticed

REFRIGERANT 12 PRESSURE TEMPERATURE RELATIONSHIP


The table below indicates the pressure of Refri gerant 12 at various temperatures. For in stance, a drum of Refrigerant at a temperature of 80>F (26.(PC) will have a pressure of 84.1 PSI (579.9 kPa). If it is heated to 129sF (S l.ffC ), the pressure will increase to 167.5 PSI (1154.9 kPa). It also can be used conversely to deter mine the temperature at which Refrigerant 12 boils under various pressures. For example, at a pressure of 30.1 PSI (207.5 kPa), Refriger ant 12 boils at 32F (0C).

fF)('C)

(PSIG)(kPa)

CW C) 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 140 12.7C 15.5C 18.3C 21.1C 23.8C 26.6C 29.4C 32.2C 35.0C 37.7C 40.5C 43.3C 46.1C 48.8C 51.6C 54.4C 60.OC

(PSIGXkPa) 52.0 57.7 63.7 70.1 76.9 84.1 91.7 99.6 108.1 116.9 126.2 136.0 146.5 157.1 167.5 179.0 204.5 358.5 397.8 439.2 482.7 530.2 579.9 632.3 686.7 745.3 806.0 870.2 937.7 1010.1 1083.2 1154.9 1234.2 1410.0

21.7 -2 9 .8 C 0(ATM0SPHERIC O(kPa) PRESSURE) 2.4 16.5 20 -2 8 .8 C 4.5 31.0 10 -2 3 .3 C 6.8 46.9 5 -2 0 .5 C 63.4 9.2 0 -1 7 .7 C 81.4 11.8 5 - 15.0C 101.4 14.7 10 -1 2 .2 C 122.0 17.7 15 - 9.4C 145.5 21.1 20 - 6.6C 169.6 24.6 25 - 3.8C 196.5 28.5 30 - 1.1C 207.5 30.1 32 OC 224.8 32.6 35 1.6C 255.1 37.0 40 4.4C 287.5 41.7 45 7.2C 322.0 46.7 50 10. OC

Fig. 1B-13--Pressure Temperature Relationships of R-12

IB -10

AIR CONDITIO NING

Refrigerant

Charge C60 System

METAL TUBE THREAD AND OUTSIDE FITTING SIZE DIAMETER

C-K M o d e Is G M o d e Is

3 lbs. 3 lbs . Overhead System 4 oz. 8 oz.

m w w

1/4

X L U w m u s rs ir COPPER NOMINAL TUBING TORQUE WRENCH SPAN TORQUE LB. FT. N m 8/8 8-7 7-8 7/18 ' " 'WW ~1TW THJ f lit i .... v r i 8/1 i -id "WfT JO-38 414* 7/8 .......Wi r - T ji - im ' i e i r t .... w . ....... ' w z w 3 5 3*48 H /i _ j tu t... ! ! j STEEL TUBING TORQUE LB. FT. Nm 10-18 14-20

C-K M o d e l s G Models

5 lbs. 4 lbs.

Fig. 1B-15 Pipe and Hose Connection-Torque Chart

Fig. 1B-14--A/C System Refrigerant Capacities

when fitting is loosened, allow it to bleed off as described under D IS C H A R G IN G , A D D IN G O IL , E V A C U A T IN G AND C H A R G IN G PR O C E D U R E S FO R C.C .O .T. A /C SY ST E M S . In the event any line is opened to atm osphere, it should be im m ediately capped or taped to prevent entrance of m oisture and dirt, which can cause internal compressor wear or plugged lines, condenser and evaporator core, expansion tubes (orifice) or compressor inlet screens. T he use of the proper w renches when m aking connections on " O " ring fittings is im portant. The use of im proper wrenches m ay dam age the connection. The opposing fitting should always be backed up with a wrench to prevent distortion of connecting lines or com ponents. W hen connecting th e flexible hose connections it is im portant th a t the swaged fitting and the flare nut, as well as the coupling to which it is attached, be held at the sam e tim e using three different wrenches to prevent turning the fitting and dam aging the ground seat. " O " rings and seats m ust be in perfect condition. A burr or piece of dirt m ay cause a refrigerant leak. Always replace the " O " ring when a connection has been broken. W hen replacing the " O " ring, first dip it in clean 525 viscosity refrigeration oil. W here steel to alum inum connections are being made, use torque for alum inum tubing (R efer to Fig. 1B -15).

MAINTAINING CHEMICAL STABILITY IN THE REFRIGERATION SYSTEM


T he efficient operation of th e air conditioning refrig eratio n system is dependent upon the chem ical

stability of the refrigeration system. W hen foreign m aterials, such as dirt, air or m oisture contam inate the system, they will change the stability of R efrig eran t-12. They will also affect pressure-tem perature relationships, reduce efficient o p eration, possibly cause interior corrosion and abnorm al w ear of moving parts. The following general practices should be observed to ensure chem ical stability in the system: 1. Before disconnecting a refrigerant connection, wipe away any dirt or oil at and near the connection to reduce the possibility of dirt entering the system. Both sides of the connection should be capped, plugged or taped as soon as possible to prevent the entrance of dirt, foreign m aterial and moisture. 2. Keep tools clean and dry. This includes the manifold gage set and replacem ent parts. 3. W hen adding 525 viscosity refrigerant oil (R efer to A D D IN G O IL in th e D ischarging, A dding O il, E vacuating and C harging Procedures for C C O T A /C System s), the transfer device and container should be clean and dry to assure th a t refrigeration oil rem ains as m oisture free as possible. 4. W hen it is necessary to "open" an A /C system, have everything needed ready and handy so th at as little tim e as possible will be req u ired to perform the operation. Do not leave the A /C system open any longer than is necessary. 5. Any tim e the A /C system has been "o p en ed ," it should be properly E vacuated before recharging with R e frig e ra n t-12 according to the D IS C H A R G IN G A D D IN G O IL , E V A C U A T IN G & C H A R G IN G P R O C E D U R E S FO R C C O T A /C SY ST E M S. All service parts are dehydrated and sealed prior to shipping. They should rem ain sealed until ju st prior to m aking connections. All p a rts should be a t room tem perature before uncapping (this prevents condensation of m oisture from the air entering the system). If, for any reason, caps are removed, but the connections are not made, parts should be resealed as soon as possible.

AIR C O ND ITIO NIN G

IB -11

DIAGNOSIS
TESTING THE REFRIGERANT SYSTEM
If a m alfunction in the refrigerant system is suspected due to abnorm al system pressures, check the following: 1. Check outer surfaces of radiator and condenser cores to be sure they are not plugged with dirt, leaves or other foreign m aterial. Be sure to check betw een the condenser and radiator as well as the outer surfaces. 2. R estrictions or kinks in evaporator core or condenser core, hoses, tubes, etc. 3. R efrigerant leaks. 4. C heck all air ducts for leaks or restrictions. A ir restrictio n m ay indicate a plugged (or p a rtially plugged) evaporator core. 5. Com pressor clutch slippage. 6. Im proper drive belt tension. 7. Plugged accu m u lato r, expansion tu b e (orifice) or plugged suction inlet screen (A6 Com pressor). 8. Excessive moisture in refrigerant system. in. above reactor plate. The reaction plate will quickly heat to a cherry red. 4. Explore for leaks by moving the end of the sam pling hose around possible leak points in the system. Do not pinch or kink hose. Since R e frig eran t-12 is heavier than air, it is good practice to place open end of sam pling tube im m ediately below point being tested, particularly in cases of small leaks.
C A U T IO N : Do not b rea th e th e fu m e s th a t a re produced by th e b u rn in g of R e frig e ra n t-12 g a s in the detector fla m e , since such fu m es ca n be toxic in larg e concentrations.

LEAK TESTING THE REFRIGERANT SYSTEM Liquid Leak Detectors


There are a num ber of locations (fittings, valves, etc.) on the air conditioning system where a liquid leak detector solution m ay be used to pinpoint refrigerant leaks. By applying test solution to the area in question with the swab th a t is attached to the bottle cap, bubbles will form within seconds if there is a leak. For restricted access areas, such as sections of the evaporator and condenser, a Leak D etector such as J-6084 or equivalent is more practical for determ ining and locating leaks.

5. W atch for color changes. T he color of the flame which passes through the reaction plate will change to green or yellow-green when sam pling hose draw s in very sm all leaks of R e frig e ra n t-12. L arg e leaks will be indicated by a change in color to a brilliant blue or purple; when the sam pling hose passes the leaks, the flame will clear to an alm ost colorless pale-blue again. Observations are best m ade in a sem i-darkened area. If the flame rem ains yellow when unit is removed from leak, insufficient air is being draw n in or the reaction plate is dirty. A refrigerant leak in the high pressure side of the system m ay be m ore easily detected if the system is operated for a few m inutes, then shut off and checked im m ediately (before system pressures equalize). A leak on the low pressure side m ay be more easily detected after the engine has been shut off for several m inutes (system pressures equalized); this applies particularly to the front seal.

J-6084 Leak Detector


Tool J-6084 is a propane gas-burning torch which is used to locate a leak in any p art of the system. R efrigerant gas draw n into the sam pling tube attach ed to the torch will cause the torch flame to change color in proportion to the size of the leak. Propane gas fuel cylinders used with the torch are readily available com m ercially throughout the country.
C A U T IO N : Do not use a lig hted detector in a n y place w h e re com bustible or explosive g a ses, d usts or vapors m a y be present. O p eratin g Detector

PRESSURE CYCLING CCOT SYSTEM C60, C-K and G MODELS


C om pressor clu tch cycling on C -K & G S eries C60 C C O T A /C System s is accom plished through the use of a pressure sensing sw itch, located n ea r th e top of the accum ulator. T he switch perform s two functions in the system. In addition to cycling the com pressor on and off to control refrigerant flow, the switch shuts off the compressor clu tch when pressure falls to a p red eterm in ed level, indicating low refrigerant charge in the system. W hen diagnosis (R efer to Fig. IB -16 & IB -17) indicates replacem ent of the switch is necessary, it should be noted th a t it will not norm ally be necessary to discharge the A /C system , as th e pressure sw itch fitting on the accum ulator is equipped with a schrader type valve. W hen replacing the pressure cycling switch, a new oiled " O " ring m ust be installed and the switch m ust be torqued to 10 N-m (7.5 ft lb). Do not exceed this torque, as the threads in the accum ulator m ay be stripped.

1. D eterm ine if there is sufficient refrigerant in the system for leak testing. 2. Open control valve only until a low hiss of gas is heard, then light gas at opening in chimney. 3. A djust flame until desired volume is obtained. This is most satisfactory when blue flame is approxim ately 3/8

IB -12

AIR CONDITIO NING

ELECTRICAL /V A C U U M TROUBLE DIAGNOSIS


W hen diagnosing problem s in the electrical and vacuum systems of the air conditioning system, consult electrical wiring diagram s and vacuum diagram s. Ports on rotary vacuum valves are illustrated in a m anner to provide sim plicity in following vacuum schem atic lines but are num bered in consecutive order on the actual valve. are operating properly and efficiently, proceed with the following steps. 1. O peration of the air conditioning blower at all four speeds and engagem ent of the compressor clutch would indicate th a t electrical circu its are functioning properly. 2. The sam e hand-felt tem perature of the evaporator inlet pipe and the accum ulator can surface of an operating system would indicate a properly charged R -12 system. 3. O peration of the A /C control selector (mode) lever to d istrib u te a ir from designed o u tlets would indicate proper vacuum and diaphragm function.

OPERATIONAL TEST
To aid in d eterm in in g w hether or not th e air conditioning electrical, vacuum and refrigeration systems

V A C U U M SYSTEM DIAGNOSIS
C-K and G, C60 SYSTEM
S ta rt the engine and allow it to idle - move the selector lever to each position and refer to the vacuum diagram s and operational charts for proper airflow, air door functioning and vacuum circuits. If air flow is not out of the proper outlets at each selector lever position, then proceed as follows: 1. C heck for good hose c o n n e c tio n s -a t th e vacuum actuators, control head valve, reservoir, tees, etc. 2. Check the vacuum source circuit as follows: Install vacuum tee and gage (w ith restrictor) at the vacuum ta n k outlet. Idle the engine and read the vacuum (a normal vacuum is equivalent to m anifold vacuum ) at all selector lever positions. a. Vacuum Less Than N orm al A t All Positions Remove the tee and connect the vacuum gage line directly to the tank - read the vacuum. If still low, then the problem lies in the feed circuit, the feed circuit to the tank or in the tank itself. If vacuum is now norm al, then the problem lies dow nstream . b. Vacuum Less T han N orm al at Some Positions. If vacuum was low at one or several of the selector lever positions, a leak is indicated in these circuits. c. Vacuum N orm al a t All Positions; If vacuum was norm al and even at all positions, then the m alfunction is probably caused by im properly connected or plugged lines or a defective vacuum valve or valves. 3. Specific Vacuum C ircuit Check Place the selector lever in the m alfunctioning position and check for vacuum a t th e p ertin en t vacuum actuators. If vacuum exists at the actuator but the door does not move, then the actu ato r is defective or the door is m echanically bound. If low or no vacuum exists at the actuator, then the next step is to determ ine w hether the cause is the vacuum harness or the vacuum valve. Check the vacuum harness first. 4. Vacuum H arness C ircuit Check a. Disconnect the vacuum harness at the control head. b. The black line ( # 1 ) should show engine vacuum - if not, trace back through connector to vacuum tank. c. To check any individual circuit place the selector lever at the involved circuit position and check for vacuum presence.

A /C REFRIGERANT SYSTEM DIAGNOSIS


INSUFFICIENT COOLING 'QUICK-CHECK ' PROCEDURE
The following C C O T "H a n d -F e el" procedure can be used to quickly determ ine w hether or not the A /C system has the proper charge of R efrig eran t-12 (providing am bient tem perature is above 21C (70F) This check can be m ade in a m atter of m inutes, sim plifying system diagnosis by pinpointing the problem to the am ount of R efrig eran t-12 charge in the system or by elim inating this possibility from the over-all checkout. 1. Engine m ust be w arm (C H O K E O P E N and O F F FA ST ID L E S PE E D C A M ) and at norm al idle speed. 2. Hood and body doors open. 3. Selector (mode) lever set a t N O R M . 4. T em perature lever at C O LD . 5. Blower on H I. 6. " H a n d -F e e l" te m p e ra tu re of ev ap orator inlet pipe afte r orifice and a c cu m u la to r can surface w ith com pressor engaged. a. B O TH S A M E T E M P E R A T U R E AND S O M E D E G R E E C O O L E R T H A N A M B IE N T -P ro p e r condition: check for other problem s (R efer to A /C System Diagnostic Procedure). b. IN L E T P IP E C O O L E R th an accum ulator surface low refrigerant charge. A dd slight am ounts 120 ml (1 /4 lb.) of refrigerant U N T IL BO TH feel the sam e tem perature. Allow stabilization tim e between additions. Then add 420 ml (.88 lbs.) one can additional refrigerant. (The 420 m l/14 oz. disposable can of R efrig eran t-12 is the equivalent to .88 lbs.) c. IN L E T P IP E H A S F R O S T A C C U M U L A T IO N A ccum ulator surface w arm er; proceed as in Step b above.

AIR C O ND ITIO NIN G

IB - 13

INSUFFICIENT COOLING

A/C SYSTEMS WITH CYCLING CLUTCH (PRESSURE SENSING)


M O V E T E M P LEVER R A P ID L Y BA C K ANC? FORTH FR O M MOT T O COLO LIS T E N FOR DO O R H IT T IN G A T EACH EN D

EXPANSION TUBE

E N G A G E D OR C YC LIN G

This S y s te m D o e s N o t H a v e a S ig h t G la ss U n d e r N o
C irc u m s ta n c e s S h o u ld a S ig h t G la ss Be In s ta lle d Feel L iq u id L in e B e fo re E x p a n s io n T u b e W ARM

Restriction in High Side o f System V isually Check fo r Froet Spot to Locate Restriction. Repair as Necessary Evacuate & Charge System (O K.)

Feel E v a p o ra to r In le t a n d O u tle t P ip es IN LE T PIPE A N D O U T LE T PIPE S A M E T E M P E R A T URE OR O U T LE T C O LD E R T H A N IN LE T

In s ta ll G a g e Set an d C h e c k C o m p re s s o r C y c lin g Press

ON at 28 2 6-351 6 kPa (41 51 PSD


OFF a t 13 8-1 93 kPa (20-28 PSI)

RUNS CONTINUOUSLY WITHIN LIMITS Disconnect Blow er W ire and Check F or Cycling Of* *1 138 193 kPa (20-28 PSD

[ CYCLES W IT H IN L IM IT S

C YC LES H IG H OR LO W (O N A B O V E 51 PSI OR OFF B E LO W 20 PSII D e fe c tiv e P re ssu re S w itc h

PRESSURE FALLS BELOW 20 PSI Detective Pressure Switch Replace 'D o N ot D ischarge System There is Schrader Valve in the F ining System (OK)

C YC LES OFF A T 138 193 k P a (20 -2 8 PSI) O R D O ES N O T PU LL D O W N TO PRESS

R ep la ce *D o N o t D is c h a rg e

In s ta ll T h e rm o m e te r in A/C O u tle t an d C he ck P e rfo rm a n c e S yste m 1 2 3 4 5. 6 SET T E M P LEVER TO F U LL COLD SET SELECTOR LEVER T O MAX A/C SET BLO W ER S W IT C H O N HI CLOSE D O O R S A N D W IN D O W S R U N E N G IN E A T 20 00 R P M U SE A U X F A N IN FR O N T OF GRILL

(O K)

A M B IE N T TEM P A /C O U T LE T TEMP.

21C (70 F) 5-8*C (41-47) 6-9 C (42-48)

27 C (80F) 5-8C (41-47) 6-9 C (42-48)

32 C (90F) 6-10C (42-50) 10-14C (50 58)

38 C (1 0 0 F ) 6 1 1C (43-57) 12-1 7C (54 6 2)

43 C (11 0 F) 6-1 r c (43 51) 14 19C (57 67)

PICK UP S U BU R BA N

R e p a ir o r R e p la ce S cre e n E va c u a te & C h a rg e

S y s te m O ve r C h a rg e d E v a c u a te & C h a rg e S ystem (O .K .|

System

(O K )

Fig. 1B-16--Pressure Cycling CCOT System Diagnosis

IB -14

AIR CONDITIO NING

OFF ALL THE TIME A ttach Fused Jum per W ire fro m C om pressor Hot Lead to P ositive ( + ) B attery Post and Check C om pressor O peration

NOT ENGAGED A p p ly External G round to C om pressor, if C lutch is S till N ot Engaged Rem ove C lutch & Repair as per Service M anual System (O.K.) R em ove J u m p e r and Check R efrigerant Pressure at A c c u m u la to r Fitting

INLET PIPE COLDER THAN OUTLET PIPE

-------1 -------Leak Check System


NO LEAK FOUND A d d 1 Lb. o f R e frige ra nt 12 T hen Check C lutch Cycle Rate LEAK FOUND R epair as Necessary

| BELOW 345 kPa (50 PSD |

------ 1 -----I Evacuate & Charge


System (O.K.)

1
Check H igh S ide R efrigerant Pressure

I ABOVE 345 kPa (50 PSD I Ju m p Pressure S w itch. Does C om pressor Run

--------i------- '

ABOVE 8 CYCLES PER MINUTE 'D is c h a rg e S ystem and Check For P lugged O rifice Evacuate & Charge System
( O K .)

8 CYCLES PER M IN OR LESS Feel Inlet & O utlet Pipes Again

ABOVE 345 kPa (50 PSD --------------------- ,---------------------

1
O pen C ircuit, Broken W ire, etc. Repair as N ecessary System (O.K.) Pressure S w itch Replace * Do N ot D ischarge S ystem . T here is a Schrader V a lve in the Fitting System (O.K.)

Discharge S ystem and Check fo r Plugged O rifice or H igh Side R estriction Repair or Replace Evacuate & Charge System

(O K )

| INLET A N D OUTLET SAM E TEMP., OR O U T LET COLDER THAN INLET


i i

BELOW 345 kPa (50 PSD


|

INLET PIPE COLDER THAN OUTLET PIPE A d d 1 Lb R efrigerant 12 and Feel Inlet & O utlet Pipes A gain

Lost Charge Leak Test & Repair Evacuate & Charge System (O K .)

A d d O ne M o re Pound of R efrig era nt 12 System (O.K.)

INLET AND OUTLET SAME TEMP . OR O U T LET COLDER THAN INLET A dd One M o re Pound of R efrig e ra n t 12 System (O.K.)

INLET PIPE COLDER TH AN OUTLET PIPE T "D ischarge S ystem and Check fo r Plugged O rifice Evacuate & Charge System (O.K.|

Fig. 1B-17--Pressure Cycling CCOT System Diagnosis (Cont.)

INSUFFICIENT COOLING DIAGNOSIS CHART


DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS)
The following procedures should be applied before performance testing *n A/C System. 1. Check for proper belt installation and tension with J-23600. 2. Check for proper dutch coil terminal connector installation. 3. Check for clutch air Gap (.022 - .057). 4. Check for broken, burst, or cut hoses. Also check for loose fittings on all components.
NORMAL AIR FLOW

5. 6. 7. 8. 9.

Check for condenser air blockage due to foreign material. Check for proper air ducting hose connections. Check heeler temperature door adjustment, adjust if incorrect. Check evaporator sealing for air leak, repair if leaking. Install pressure gages and thermometer and make performance test.
|N 0 OR LOW AIR FLOW CHECK BLOWER OPERATION

CHECK AIR FLOW

[ CHECK OISCHARGE AIR TEMPERATURE (SEE PERFORMANCE DATA) j

BLOWER NOT OPERATING CHECK FOR BLOWN FUSE, OEFECTIVE BLOWER SWITCH. BROKEN WIRE, LOOSE CONNECTIONS. LOOSE BLOWER MOTOR GROUND WIRE OR INOPERATIVE BLOWER MOTOR.

IQRMAL BLOWER OPERATION |

DISCHARGE TEMPERATURE AT OUTLET COLD CHECK FOR AIR LEAKS THROUGH OASH PANEL. DOORS, WINDOWS, OR FROM HEATER.
|
f o a m in g H

HIGH OUTLET AIR TEMPERATURE


CHECK SIGHT GLASS

Check for loose or disconnected air distribution ducts, restricted or leaking air ducts, partially closed air out let valve or clogged evaporator core, if above check is OK, check for ice blocking evaporator. ICE BLOCKING EVAPORATOR

NO FOAMING 1. SYSTEM MAY BE EITHER FULLY CHARGED OR EMPTY. FEEL HIGH ANO LOW PRESSURE PIPES AT COMPRESSOR. HIGH PRESSURE PIPE SHOULD BE WARM. LOW PRESSURE PIPES SHOULD BE COLD. 2. IF PIPES ARE NOT INDICATING PROPER TEMPERATURES, RECHARGE SYSTEM AS RECOMMENDED. IF NOZZLE AIR TEMPERATURE IS STILL HIGH. CHECK EVAPORATOR PRESSURE. CHECK FOR LOW EVAPORATOR PRESSURE 1. ALLOW SYSTEM TO WARM UP. 2. STOP ANO RESTART ENGINE. 3. CHECK EVAPORATOR PRESSURE IMMEDIATELY AFTER RESTART AND PULL DOWN OF EVAPORATOR PRESSURE. NORMAL EVAPORATOR PRESSURE

Fig. 1B-18--System Diagnosis (Dash Mounted Unit)

SYSTEM IS PROBABLY LOW ON REFRIGERANT. CHECK FOR LEAKS, REPAIR, AND ADO REFRIGERANT. IF FOAMING STILL OCCURS, CHECK FOR RESTRICTION IN REFRIGERANT SYSTEM BETWEEN CONDENSER AND SIGHT GLASS.

u l,

T T

LOW EVAPORATOR * PRESSURE

LOW EVAPORATOR PRESSURE

I 'CHECK EVAPORATOR PRESSURE I

I
SYSTEM HAS EXCESS MOISTURE. REPLACE RECEIVER DEHYDRATOR AND EVACUATE THOROUGHLY. RECHARGE SYSTEM. Check for malfunctioning expansion valve-See Component Diagnosis.

X
CHECK EVAPORATOR OUTLET LINE

, 1
HIGH EVAPORATOR * PRESSURE

'

X
EVAPORATOR OUTLET LINE WARM

X
CHECK COMPRESSOR DISCHARGE PFIESSURE

NORMAL EVAPORATOR PRESSURE Check Compressor Discharge Pressure. |

I
1. CHECK FOR LIQUID LINE RESTRICTION (FROST SPOT ON LINE). IF NOT, 2. CHECK FOR PLUGGED INLET SCREEN IN EXPANSION VALVE. IF NOT, 3. CHECK FOR OEFECTIVE EXPANSION VALVE BY REMOVING VALVE ANO BLOWING THROUGH VALVE. IF UNABLE TO BLOW THROUGH VALVE, BULB IS DISCHARGED. REPLACE EXPANSION VALVE.

X
| HIGH DISCHARGE PRESSURE

LOW DISCHARGE PRESSURE Check for restriction in liquid line, partially plugged inlet screen at expansion valve, or defective expansion valve, replace valve if defective.

NORMAL DISCHARGE PRESSURE!

U'"

I
Refrigeration System is ok 1. Check for proper function of heater TEMPERATURE door. 2 Check for proper sealing of evaporator case. 3. Check for proper operation and seal around temperature door. 4. Non-Foaming sight glass does not always indicate a fully charged system. Add 1/2 lb. refrigerant and observe performance. 5. Check for excess oil in system. A symptom of excess oil is a slipping clutch or belt or broken belt. To remove excess oil in system set "CHECKING COMPRESSOR OIL CHARGE"

r
LOW DISCHARGE * PRESSURE Check for malfunctioning expansion valve-See Component Diagnosis.

1. Check engine cooling system, fan clutch and check for restricted air flow thru condenser. 2. Check expansion valve bulb contact. Correct if necessary. 3. Check for refrigerant restriction in condenser. Return bends at equal elevation should be approximately same temperature. II temperature of bends is appreciably different, the cooler bend indicates a restricted circuit, replace con denser if restriction is found. If condenser is OK, check for air in system. To check observe outlet air temperature and compressor discharge pressure while slowly discharging system at receiver inlet connection.

Dash M o u n te d U n it (M o to r H o rn * Chassis)

AIR CONDITIONING

(R e frig e ra n t C ha rge 3 lb s.-4 ox.) T e m p e ra tu re of A ir E n te rin g C o n d e n se r

7 0

80

9 0

100

110*

120

OUTLET AIR TEMPERATURE DROPS AS COMPRESSOR DISCHARGE PRESSURE DROPS REFER TO PERFORMANCE CHART FOR CORRECT PRESSURES

OUTLET AIR TEMPERATURE INCREASES AS COMPt ~ ? R OISCHARGE PRESSURE DROPS

E" * ,n * C o m p re sso r H ead Pressure* 11 0 120 135MS 160 170

20 0 0 190200 220230 260 270

~ ~

......^

LEAK TEST SYSTEM. REPAIR AS NECESSARY. DISCHARGE. EVACUATE. ANO RECHARGE.

X
REPLACE EXPANSION VALVE

P ressure psi* D ischarge Air T e m p e ra tu re *

4045

4146

4146

4247

4449

4449

I B - 15

* J u s i p rio r t o c o m p re sso r c lu tc h dise n g ag e m e n t

COMPRESSOR DIAGNOSIS

CLUTCH SLIPPING. COMPRESSOR ENGAGED BUT NOT O PER A TIO N A L. BELT SLIPPING

Check for proper air gap. Correct if necessary.

( 022.057)
Check and correct belt tension. R E FR IG ER A TIO N CHARGE IS DEPLETED. SYSTEM HAS SOME REFR IG ER A N T.

If previous step does not correct clutch slippage, repair compressor.

Add one pound refrigerant.

Leak test complete system before removing compressor.

Repair compressor. Operate and leak test system.

LEAKS REFRIGERANT. COMPRESSOR THROW S O IL. Blow out seal cavity with air hose and leak test.

Repair compressor.

L _ | 1
DOES NOT LEAK REFRIGERANT. Wipe off oil - O.K.

IB -1 6

AIR C O N D IT IO N IN G

Fig. lB-19--Compressor Diagnosis

HIGH TORQUE COMPRESSOR. (SEIZED)

ELECTRICAL SYSTEM DIAGNOSTIC CHART


BLOWER MOTOR INOPERATIVE (ANY SPEED) Check for proper fuse |FUSE BLOWN] With ign. switch in "Run" position and heater or A/C on, locate short in one of the following wires: (see note) | fuse o k | The following tests should be made with the ignition switch in "Run" position, heater or A/C on and blower switch on high. Check blower motor ground 1. From fuse panel to master switch on control. 2. From master switch to compressor clutch. 3. Master switch to blower switch. 4. From blower speed switch to resistor. 5. From resistor to blower motor. BLOW ER M O TO R IN O P E R A T IV E (C E R T A IN SPEED S-EXC EPT H IG H ON C-K FO U R -S E A S O N )

Disconnect resistor connectors, connect one lead of a self powered test light to any one terminal and uss the other lead to probe each of the other terminals.

I
|POOR OR NO GROUND^ | Repair ground | I g RQUND 0I<1 Check motor connector witl 12 volt test light.
r ... ' ~

TEST LIGHT DOES NOT LIGHT ON ALL TERMINALS Replace resistor

TEST LIGHT LIGHTS ON ALL TERMINALS

JL
With ignition switch in "R un" position and heater or A /C on, use 12 volt test lamp to check for voltage at resistor connector with blower speed switch in each position.

Fig. 1B-20--Electrical Diagnosis

I la m p l ig h t s ] Replace motor

{ l a m p DOES NOT LIGHT! Check wire connector on blower relay with 12 volt test light. |LAMP LIGHTS IN ALL POSITIONS!

I
| LAMP POES NOT LIGHT IN ALL POSITIONsj

NO TE: Short circuit may be inter m ittent. If tester does not indicate a short circuit, move heater harness around as much as possible to re create short circuit. Watch and listen for arcing.

I la m p lig h t s ] Repair open in wire from blower motor to blower relay.

I l a m p d o es n o t l ig h t ! Check wire connector on blower relay with 12 volt test light.

Connect 12 volt test light at wire terminal on blower relay (wire from resistor to blower relay).

| lam p

li g h t s I

[ l a m p d o e s * n q t l ig h t | Repair O p e n in wire from resistor to blower relay.

Turn ignition key off and put Heater or A /C Control in o ff position. With blower resistor wire connector disconnected, connect a jum per lead from battery positive terminal to the wire terminal in connector. Use 12 volt test light to check for voltage at wire at blower speed switch connector. Repeat same test on the other wires.

I LAMP DOES NOT LIGHT^ Use 12 volt test light and check wire terminals at resistor. Replace relay

Replace blower relay

LA M P LIG H TS ON A L L W IRES Replace blower speed switch.

LAM P DOES N O T L IG H T ON A L L W IRES Repair open in affected wire.

LAMP OFF

LAMP LIGHTS

AIR CONDITIONING

Check FEED wire from resistor to blower speed switch.

Replace resistor

Ila m p o n |

jlLAMP 0 F F | Repair open in wire from blower speed switch.

I
Replace blower speed switch.

I B - 17

IB -18

AIR CO NDITIO NING

Fig. 1B-21--C60 System W iring Diagram (C-K Series)

MEUL CRD

$ ' \ 3 B L * ' 15

M O T E I , W H E N E A S T I DL E S O L E N O I D IS M O T U S E D - E K TE M 3 1 O N n IRE M I L L N O T BE I N S T A L L E D A ND M I R E 6 6 8 M I L L BE C UT OF F AT MIRE H A R N B R EAKOUT

JUNCTION BLOCK

Fig. 1B-22--C60 System W iring Diagram (G Series)

AIR C O ND ITIO NIN G

IB -19

Fig. 1B-23--Overhead W iring Diagram

J T O FUSE P A N E L

| l GROUND

GRN

RESISTOR

BLOWER SWITCH SET AT OFF LOW MED HIGH CONNECTION N TO NONE N TO 1 & 2 N TO 1 A 4 N TO 1, 3 A 4

AIR C O N D IT IO N IN G

THERMOSTATIC SWITCH

BLOWER SWITCH

IB-20

Fig. 1B-24--C60 Motor Home Chassis Wiring

59

1 6

D K

Diagram

COMPRESSOR

AIR CO ND ITIO NIN G

IB -21

EVACUATING AND CHARGING PROCEDURES


PRECAUTIONARY SERVICE MEASURES
Before any service is attem pted which requires opening of refrigerant lines or com ponents, the person doing the work should be thoroughly fam iliar with the inform ation under P R E C A U T IO N S IN H A N D L IN G R efrig eran t-12, P R E C A U T IO N S IN H A N D L IN G R E F R IG E R A N T L IN E S A N D F IT T IN G S M A IN T A IN IN G C H E M IC A L S T A B IL IT Y IN T H E R E F R IG E R A T IO N S Y S T E M , A N D R E F R IG E R A N T C H A R G IN G P R E C A U T IO N S and should follow very carefu lly the D IS C H A R G IN G , E V A C U A T IN G , O IL A D D IT IO N A N D C H A R G IN G T H E R E F R IG E R A N T S Y S T E M instructions given on the following pages for the unit being serviced. Sealing caps should be removed from subassemblies just prior to making connections for final assembly. Use a sm all am ount of clean 525 viscosity refrigerant oil on all tube and hose joints. Always use new " O " rings dipped in the clean 525 viscosity refrigerant oil when assembling joints. The oil will aid in assem bly and help provide a leakproof joint. W hen tightening joints, use a second wrench to hold stationary part of connection so th a t a solid feel can be attained. This will indicate proper assembly. Tighten all tubing connections, as shown in torque chart, see Fig. IB -15. Insufficient or excessive torque when tightening can result in loose joints or deform ed joint parts. E ither condition can result in refrigerant leakage.
c h a rg in g ho se a t g a g e set w h ile a tta c h e d to service low -sid e fitting . This w ill result in com plete d isch arg e of system d u e to th e d ep ressed schrad er v a lv e in service low -sid e fitting a n d m a y ca u se personal inju ry d u e to esca p in g R e frig e ra n t-12.

DISCHARGING THE CCOT A /C SYSTEM


In replacing any of the air conditioning refrigeration components the system m ust be completely discharged of R efrig eran t-12. Always discharge system at low side service fitting. 1. W ith ignition turned O FF, remove protective cap from L O W -S ID E service fitting and connect C h arging S tation J-23500-01 G age Set as indicated in Figure IB-25. If charging statio n J-23500-01 is not being used, discharge system by slowly connecting a gage hose to low-side service fitting on A ccu m u lato r and discharging into oil bottle (Fig. IB -26). As hose is S L O W L Y tig h ten ed dow n onto sch rad er valve, R efrig e ra n t-12 will be in to discharge from the system into the container. If no discharge occurs, check for missing or defective schrader depressor in hose fitting. 2. W ith the low-side of system fully discharged, check high-side system fitting (on liquid line or muffler) for rem aining pressure. 3. If pressure is found, attem p t to discharge high-side using sam e procedure as used for low-side. (T his condition indicates a restriction on the high-side and the cause m ust be diagnosed and co rrected before evacuating and charging the system ). 4. W hen the system is completely discharged (no vapor escaping with hose fully-tightened down), m easure, record am ount and discard the collected refrigerant oil. If this quantity is 15 ml (1 /2 oz.) or more, this am ount of new 525 viscosity refrigerant oil m ust be added to system , plus any q u a n tity in rem oved p a rts before evacuation and charging with R e frig eran t-12 (R efer to C C O T R e frig e ra n t O il D istrib u tio n for specific quantity of oil norm ally retained in removed parts). 5. If adding oil is necessary, remove the suction hose at the accum ulator outlet pipe connection and pour the correct quantity of refrigerant oil into the hose or pipe and then properly reconnect hose or pipe. (See D ischarging Step No. 4 and C .C .O .T . R efrigerant Oil D istribution for specific q uantity instructions).

DISCHARGING EVACUATING ADDING OIL AND CHARGING PROCEDURES FOR CCOT A /C SYSTEMS
The refrigerant system m ay be D ischarged, Evacuated and C h arg ed using J-23500-01 air conditioning service C harging Station or the J-5725-04 M anifold and G age Set, and 420 m l-14 oz. disposable cans of R efrig eran t-12. C harging lines from the C harging Station or M anifold and G age Set require the use of gage adapters to connect to the system service fittings. A straight gage A dapter J-5420 and a 90 angle gage A dapter J-9459 is available. Always wear goggles and w rap a clean cloth around fittings and connections w hen doing w ork th a t involves opening the refrigeration system. If liquid refrigerant comes into contact with the skin or eyes injury can result. B efore rem oving and replacing any of th e air conditioning refrig eratio n lines or com ponents, the system m ust be completely discharged of R egrigerant12 .

Always use service valve and pressure gage sets during evacuation and charging procedures. Do not charge while com pressor system is hot. Always discharge system at low-side service fitting and perform the entire evacuate and charging procedure through the low-side service fitting. Do not connect high pressure line or any line to the high-side service fitting d u rin g d ischarging and charging procedures.
C A U T IO N : N ever rem ove a g a g e line from its a d a p te r w h e n line is connected to A / C system . A lw a y s rem ove the line a d a p te r from the service fittin g to d isco n n ect a lin e . Do not rem o ve

CCOT REFRIGERANT OIL DISTRIBUTION


A-6 C O M P R E S S O R requires 300 ml (10 oz.) of 525 viscosity refrigerant oil. R-4 C O M P R E S S O R -- requires 6 oz. (180 ml) of 525 viscosity refrigerant oil. New oil quantities m ust be added to the system during Service com ponent replacem ent and conditions stated as follows: A. W H E N T H E R E A R E N O S IG N S of excessive oil leakage, for: Com pressor - Remove, drain oil, m easure, replace sam e am ount of new oil plus 1 oz. (30 ml). On A-6 compressor, if am ount of oil drained is 240 ml (8

IB -22

AIR CONDITIO NING

CLOSE ALL CONTROLS ON GAUGE SET

J-23500-01 SERVICE CHARGING STATION

SLOWLY OPEN LOW-SIDE VALVE ON GAUGE SET TO DISCHARGE REFRIGERANT-12 FULLY OPEN GAUGE SET VACUUM VALVE

CONNECT LOW-SIDE GAUGE HOSE TO LOW-SIDE PRESSURE SERVICE FITTING ON VEHICLES ACCUMULATOR ASSEMBLY. USING J-5420 ADAPTER RE-CONNECTVACUUM HOSE TO PUMP AFTER DISCHARGE DO NOT CONNECT HIGH-SIDE HOSE TO A/C SYSTEM

DISCONNECT VACUUM HOSE AT VACUUM PUMP AND PLACE INTO CAN (SEE NOTE BELOW)

VACUUM PUMP

NOTE: AN EMPTY 3 LB. COFFEE CAN WITH A PLASTIC LID CROSS-SLIT (Xed) TO ALLOW HOSE ENTRY IS RECOMMENDED.
Fig. 1 B-25--Discharging The CCOT System With J-23500-01 Charging Station

AIR C O ND ITIO NIN G

IB -23

If more than 90ml (3 fl. oz), add sam e am ount of new oil as drained. If a new A ccum ulator m ust be added to R-4 system, add 60ml (2 fl. oz) additional oil, to com pensate for th a t h e ld /a b so rb ed by the original A ccu m u lato r dessicant.

EVACUATING AND CHARGING THE CCOT A /C SYSTEM


If the system has been opened for any repair, or the R efrig eran t-12 charge lost, the system m ust be evacuated prior to charging. Evacuation and C harging is a combined procedure, and all gage lines m ust be purged with R e frig eran t-12 prior to charging. T here are three standard R e frig eran t-12 evacuate and charge procedures: J-23500-01 C harging Station M ethod Disposable Can M ethod D rum M ethod
Charging Station J-23500-01

oz.) or more, an oil overcharge should be suspected. Evaporator - Add 90 ml (3 oz.). Condenser - Add 30 ml (1 oz.). A ccum ulator - Remove, drain oil, m easure, replace sam e am ount of new oil plus 60 ml (2 oz.) to com pensate for th a t retain ed by the original accum ulator dessicant. B. W IT H S IG N S O F E X C E S S IV E O IL L E A K A G E , for:
A -6 Com pressor System s

NOTICE: U nder no circum stances should alcohol be used in the system in an attem p t to remove moisture. D am age to the system com ponents could occur.

GAGE CALIBRATION
Prior to Evacuation, check the low pressure gage for proper c a lib ra tio n and d eterm in e if vacuum system is operating properly. W ith the gage disconnected from the refrigeration system, be sure th at the pointer indicates to the center of " O " . Lightly tap gage a few tim es to be sure pointer is not sticking. If necessary, calibrate as follows: a. Remove cover from gage. b. Holding gage pointer adjusting screw firmly with one hand, carefully force pointer in the proper direction to position pointer at the " O " position. T ap gage a few times to be sure pointer is not sticking. Replace gage cover.

Rem ove C om pressor A N D A ccu m u lator. D rain, m easure and record T O T A L oil from both components. Discard old oil. If less than 180 ml (6 oz.), add 180 ml (6 oz.) of new oil to system. If more than 180 ml (6 oz.), add sam e am ount of new oil as drained. If a new A ccum ulator m ust be added to A-6 system, add 2 additional ounces (60 m l) of oil to com pensate for th at held/absorbed by the original accum ulator dessicant.
R-4 Com pressor System s

VACUUM SYSTEM CHECK


Before connecting vacuum pum p to the A /C system, run pum p connected to the low pressure gage to determ ine the vacuum pum p cap ab ility . If th e vacuum system is unable to reach 7 1 1 .2-736.6m m ( 2 8 " - 2 9 " ) or more vacuum , the system should be checked for leaks. If no leaks are found, the vacuum pum p may require repair.

A. W ith no signs of excessive oil leakage, add: Com pressor - Remove, drain oil, m easure, replace same am ount of new oil plus 30ml (1 fl. oz). Evaporator - Add 90ml (3 fl. oz). Condenser - Add 30 ml (1 fl. oz). A ccum ulator - Remove, drain oil, m easure, replace sam e am ount of new oil plus 60ml (2 fl. oz) to com pensate for th a t retain ed by the original accum ulator dessicant. B. W ith signs of excessive oil leakage: Remove only the A ccum ulator. D rain, m easure and record q u a n tity of oil in A ccu m u lato r. It is not necessary to remove and drain the R-4 Compressor because the Com pressor only retains a m inim um quantity of oil. If less than 90ml (3 fl. oz), add 90ml (3 fl. oz) of new oil to system.

J-23500-01 CHARGING STATION METHOD


Follow C h arg in g instru ctio n s provided w ith the J-23500-01 C h arg in g S ta tio n in use w ith the following exceptions: 1. Do not connect the high pressure line to the air conditioning system. 2. Keep the high pressure valve on the charging station closed at all times. 3. Perform th e entire evacuate and ch arg e procedure through th e accu m u lato r low-side pressure service fitting. 4. Follow ing these procedures will prevent accidental high-side vehicles system pressure being subjected to the C harging Station in the event an error is m ade in valve sequence during compressor operation to pull in the R efrig eran t-12 charge.

IB -24

AIR CO NDITIO NING

J5725-04 MANIFOLD GAUGE SET / USING J-5420 ADAPTER OPEN DURING EVACUATION AND CHARGING / / TH|S H jq H PRESSURE VALVE IS OPEN A N D VACUUM PUMP LINE DISCONNECTED ONLY DURING EVACUATION THIS HIGH PRESSURE VALVE IS CLOSED AND LINE DISCONNECTED DURING DISCHARGING AND CHARGING

HIGH SIDE

VALVE

VALVE

VACUUM PUMP ACCUMULATOR CAUTION: Make sure outlet valve on opener is closed (clockwise) before installing opener to R-12 container. 14 OZ. CANS

30 LB. DRUM HAS OWN OPENER-VALVE DECREASE OF WEIGHT ON SCALE INDICATES CHARGE ADDED

MULTI-CAN DISPENSING UNIT USING J6271-01 SINGLE CAN OR J6272-02 MULTI CAN OPENER-VALVE

CLOSED D U R IN G / EVACUATION X OPEN AND INVERTED DURING CHARGING

USING J23390 OPENER-VALVE FOR 12 LB. CAN

Fig. 1 B-27--Charging the CCOT A /C System with Disposable Can or Refrigerant Drum.

DISPOSABLE CAN OR REFRIGERANT DRUM METHOD


If the R efrig eran t-12 drum is used, place it on a scale and note the total weight before Charging. W atch the scale during C harging to determ ine the am ount of R efrig eran t-12 used. If disposable 420 ml (14 oz.) R efrig eran t-12 cans are used, close the tapping valve and then attach can(s) following instructions included with the tapping valve or tapping m anifold adapter. 1. Connect M anifold G age Set J-5725-04 as follows. Also see Fig. IB-27. Low pressure gage set valve to A ccum ulator fitting G age set center hose to R efrig eran t-12 source

High pressure gage to vacuum pump 2. To begin evacuation of the A /C system, with M anifold G age Set and V acuum Pum p as illustrated in Fig. 1B27, S L O W L Y open high and low-side gage valves and begin vacuum pum p operation. Pum p the system until the low-side gage reaches 711.2 - 736.6m m (28 to 29 in.) m ercury (vacuum ) or more. N o te th a t in all E vacuation procedures, the specification of 711.2 - 736.6m m (28 to 29 in.) of m ercury vacuum is used. This specification can only be reached at or near sea level. For each 304.8m (1,000 feet) above Liea level, specification should be lowered by one inch of vacuum. A t 1524m (5,000) feet elevation only 584.2 - 609.6m m (23 to 24 in.) of m ercury (vacuum )

AIR C O ND ITIO NIN G


is required. If prescribed m ercury (vacuum ) cannot be reached, close vacuum control valve, shut off pum p and look for a leak at connections or pump. 3. W hen the gage reaches prescribed vacuum , the system is fully evacuated. Close the high-side gage set valve and turn O F F the vacuum pump. 4. W atch low-side gage to be sure vacuum holds for five (5) m inutes. If vacuum is held, disconnect vacuum hose a t gage set and then proceed to charging. 5. If vacuum does not hold for five (5) m inutes, charge system with 420 ml (1 /2 lb.) R efrig eran t-12 and and leak check. Discharge system again then repair leak as necessary. R epeat Evacuation procedure.

IB -25

CHARGING OF THE CCOT A /C SYSTEM


1. S ta rt engine, run with choke open and fast idle speed reduced to normal idle, set A /C control lever on O FF. 2. W ith the R efrig eran t-12 drum or 420 ml (14 oz.) can(s) inverted, open R efrig eran t-12 source valve(s) and allow 480 ml (one (1) pound) or one 420 ml (14 oz.) can of liquid R efrig eran t-12 to flow into system through low-side Service fitting on A ccum ulator (R efer to Fig. IB-27). 3. As soon as 480 ml (1 lb.) or one 420 ml (14 oz.) can of liquid R e frig e ra n t-12 has been added to system , im m ediately engage the com pressor, by setting the A /C control lever to N O R M and blower speed on H I, to draw in the rem ainder of the R efrig eran t-12 charge. The C harging operation can be speeded up by using a large volume fan to pass air over the condenser. If condenser tem perature is m aintained below charging cylinder tem perature, R efrig eran t-12 will enter system more rapidly. 4. S hut off R efrig eran t-12 source valve and run engine for 30 seconds to clear lines and gages. 5. W ith the engine running, remove the charging low-side hose adapter from the A ccum ulator Service fitting. Unscrew rapidly to avoid excess R efrig eran t-12 escape from system.
C A U T IO N : N ever rem ove a g a g e line from its a d a p te r w h e n line is connected to A / C system . A lw a y s rem ove the l:ne a d a p te r from th e service fittin g to d isco n n ect a lin e . Do not rem o ve c h a rg in g ho se a t g a g e set w h ile a tta c h e d to a ccum u lato r. This w ill result in com plete d isch a rg e of system d u e to the d ep ressed schrad er v a lv e in service low -sid e fitting, a n d m a y ca u se personal inju ry d u e to escap in g R e frig e ran t-12.

inlet and outlet connections). T he desicant within the shell is N O T serviced sep arately - it is p a rt of the sealed accu m u lato r assem bly. See C C O T R efrig eran t Oil and D istribution for presence of re frig e ra n t oil and service conditions when the accum ulator m ust be removed from the vehicle to m easure the am ount of oil present inside the accum ulator. The accum ulator assembly should O N L Y be replaced when: 1. A physical perforation to the accum ulator is found resulting in a leak. 2. T he expansion (orifice) tu b e screen experiences continued or repeated plugging. 3. T he com pressor inlet screen is plugged (A 6 com pressor). 4. An evaporator fails because of inside-out in ternal corrosion. DO N O T R E P L A C E the ac cu m u la to r assem bly where: 1. M erely a den t is found in the o u ter shell of the accum ulator. 2. A vehicle is involved in a collision and no physical perfo ratio n to the accu m u lato r is found. A n open refrigerant line should be capped or have a plastic bag tightly taped around it.

ACCUMULATOR REPLACEMENT
1. Disconnect battery ground cable. 2. Discharge system of refrigerant. 3. Disconnect accum ulator inlet and outlet connections. C ap or plug open lines im m ediately. 4. Rem ove ac cu m u la to r a tta c h in g screw s and check am ount of oil in accum ulator and install this am ount of fresh 525 viscosity refrigerant oil into new accum ulator plus 60 ml (2 oz.) 5. In stall new a c cu m u la to r, using clean 525 viscosity refrigerant oil on " O " rings. 6. Evacuate and recharge system.

EXPANSION TUBE (ORIFICE)


Rem oval a n d In stallatio n

1. D ischarge the refrigerant from the system. 2. Disconnect liquid line at evaporator inlet and remove expansion tube (orifice) from the inlet pipe. 3. To in stall, reverse th e above procedure. W hen installing th e expansion tube (orifice) inside the evaporator inlet pipe, it M U S T be in stalled w ith "shorter screen end" inserted first.

6. 7. 8. 9. 8.

R eplace protective cap on A ccum ulator fitting. T urn engine off. Leak check system with J-6084 Leak D etector. S ta rt engine. W ith system fully C harged and leak-checked, continue to operate system and test for proper system pressures as outlined under P E R F O R M A N C E C O N D IT IO N S AND PERFORM AN CE PRESSU RET E M P E R A T U R E D A TA in Figs. 1 B -I6 an d IB-17.

SPECIFIC COMPONENT DIAGNOSIS


The following is a description of the type of symptom each refrigerant com ponent will evidence if a defect occurs:

COMPRESSOR
A com pressor defect will appear in one of four ways: Noise, seizure, leakage, or low discharge pressure.
N O T IC E : Resonant compressor noises are not cause for alarm ; however, irregular noise or rattles m ay indicate

ACCUMULATOR ASSEMBLY
T he accum ulator assembly for the C C O T system has a service replacem ent which includes two "O " rings (for the

IB -26

AIR CONDITIO NING

broken parts or excessive clearances due to wear. To check seizure, de-energize the m agnetic clutch and check to see if drive plate can be rotated. If rotation is impossible, com pressor is seized. To check for a leak, refer to leak testing. Low discharge pressure m ay be due to a faulty internal seal of the compressor, or a restrictio n in the com pressor. F u rth e rm o re , low d ischarge pressure m ay be due to an insufficient refrigerant charge or a restriction elsewhere in the system. These possibilities should be checked prior to servicing the com pressor. If th e com pressor is inoperative, but is not seized, check to see if current is being supplied to the m agnetic clutch coil term inals.

b. Poor Cooling.

Diagnosis for Defective Valve


The following procedure m ust be followed to determ ine if a m alfunction is due to a defective expansion valve. 1. C heck to determ ine if the system will m eet the perform ance test as o utlined previously. If the expansion valve is defective, the low pressure readings (evaporator pressure) will be above specifications. 2. The loss of system perform ance is not as evident when the compressor head pressure is below 1379 kPa (200 psi). Therefore, it may be necessary to increase the system head pressure by p artia lly blocking the condenser. Disconnect the blower lead wire and repeat the "p erfo rm an ce ch eck" to determ ine if the evaporator pressure can be obtained. 3. The system will also indicate a low refrigerant charge by bubbles occurring in the sight glass (M otor Home Chassis System s).

CONDENSER
A condenser may be defective in two ways: it m ay leak, or it may be restricted. A condenser restriction will result in excessive com pressor d ischarge pressure. If a p a rtial restriction is present, som etim es ice or frost will form im m ediately after the restriction as the refrigerant expands after passing through the restriction. If air flow through the condenser or radiator is blocked, high discharge pressures will result. D uring norm al condenser operation, the outlet pipe will be slightly cooler than the inlet pipe.

EVAPORATOR
W hen the evaporator is defective, the trouble will show up as an inadequate supply of cool air. A partially plugged core due to dirt, a cracked case, or a leaking seal will generally be the cause.

RECEIVER-DEHYDRATOR - MOTOR HOME CHASSIS


A defective receiv er-d eh y d rato r m ay be due to a restriction inside the body of the unit. A restriction a t the inlet to th e receiv er-d eh y d rato r will cause high head pressures. O utlet tube restrictions will be indicated by low head pressures and little or no cooling. An excessively cold receiver-dehydrator outlet m ay be indicative of a restriction.

REFRIGERANT LINE RESTRICTIONS


Restrictions in the refrigerant lines will be indicated as follows: 1. Suction Line - A restricted suction line will cause low suction pressure a t the com pressor, low discharge pressure and little or no cooling. 2. Discharge Line - A restriction in the discharge line generally will cause the pressure relief valve to open. 3. Liquid Line - A liquid line restriction will be evidenced by low discharge and suction pressure, and insufficient cooling.

EXPANSION VALVE
A m alfunction of the expansion valve will be caused by one of the following conditions: valve stuck open, valve stuck closed, broken power elem ent, a restricted screen or an improperly located or installed power elem ent bulb. The first three conditions require valve replacem ent. The last two may be corrected by replacing the valve inlet screen and by properly installing the power elem ent bulb. A ttach m en t of the expansion valve bulb to the evaporator outlet line is very critical. The bulb m ust be attached tightly to the line and m ust m ake good contact with the line along the entire length of the bulb. A loose bulb will result in high low side pressures and poor cooling. Indications of expansion valve trouble are provided by perform ance tests; consult diagnostic charts. 1. VALVE S T U C K O P E N a. Noisy Com pressor b. N o Cooling - Freeze Up. 2. Valve stuck closed, broken power elem ent or plugged screen a. Very Low Suction Pressure. b. N o Cooling. 3. PO O R L Y LO C A T E D P O W E R E L E M E N T BULB a. N orm al Pressure.

SIGHT GLASS DIAGNOSIS (MOTOR HOME CHASSIS UNITS)


At tem peratures higher than 70F (21C ), the sight glass m ay in d icate w heter th e re frig e ra n t charg e is sufficient. A shortage of liquid refrigerant is indicated after above five m inutes of com pressor operation by the appearance of slow-moving bubbles (vapor) or a broken column of refrigerant under the glass. Continuous bubbles may appear in a properly charged system on a cool day. This is a norm al situation. If the sight glass is generally clear and perform ance is satisfacto ry , occasional bubbles do not indicate refrigerant shortage. If the sight glass consistently shows foam ing or a broken liquid column, it should be observed after partially blocking the air to the condenser. If under this condition the sight glass clears and the perfo rm an ce is otherw ise satisfactory, the charge shall be considered adequate. In all instances where the indications of refrigerant shortage continues, additional refrigerant should be added in 120 ml (1 /4 lb.) increm ents until the sight glass is clear. An additional charge of 240 ml (1 /2 lb.) should be added as a reserve after the glass clears. In no case should the system be overcharged.

AIR C O ND ITIO NIN G

IB -27

ON VEHICLE SERVICE
COMPRESSOR C-K Series
Rem oval (Fig. IB -2 8 )

Installatio n

1. Discharge the system. 2. Remove connector attaching bolt and connector. C ap or plug open connections at once. 3. Disconnect electrical lead to clutch actuating coil. 4. Loosen brace and pivot bolts and detach belt. 5. Remove the nuts and bolts attaching the compressor b rackets to th e m ounting b rack et. Rem ove the compressor. 6. Before beginning any compressor disassembly, drain and m easure oil in the compressor. Check for evidence of contam ination to determ ine if rem ainder of system requires servicing.
Installation

1. If the oil d rain e d from the com pressor showed no evidence of contam ination replace the sam e am ount of fresh re frig eratio n oil into the com pressor before reinstallation. If it is necessary to service the entire system because of excessive contam ination in the oil removed, install a full charge of fresh refrigeration oil in the compressor. 2. Position com pressor on the m ounting b ra ck e t and install the nuts, bolts, lock washers, and ground wire. 3. Install the connector assem bly to the compressor rear head, using new " O " ring coated w ith clean refrigeration oil. 4. Connect the electrical lead to the coil and install and adjust com pressor belt, using idler pulley. R efer to "C om pressor Belt Tension A djustm ent." 5. Evacuate, charge and check the system. 6. Replace air cleaner. On G series, replace the engine cover. 7. Connect the battery ground cable.

1. If oil previously drained from the com pressor upon removal shows no evidence of contam ination, replace the same am ount of fresh refrigeration oil into the compressor before reinstallation. If it was necessary to service th e entire system because of excessive contam ination in the oil removed, install a full charge of fresh refrigeration oil into the compressor. 2. Position com pressor on th e m ounting b rack et and install all nuts, bolts and lock washers. 3. Install the connector assembly to the compressor rear head, using new " O " rings coated w ith clean refrigeration oil. 4. Connect the electrical lead to the coil and install and adjust compressor belt. 5. Evacuate, charge and check the system.

COMPRESSOR BELT TENSION ADJUSTMENT


A djust the com pressor belt to the specifications shown in the Engine section of the Service M anual. On some G and M otor Hom e Chassis units it may be necessary to increase idler pulley slack adjustm ent. This m ay be accom plished by (1) Remove and discard the idler adjustm ent bolt. (2) Remove the idler backing plate and elongate all 3 adjusting slots 1/2 in. inboard or outboard as required. (3) R einstall the idler assem bly and adjust belt tension using a lever (screwdriver, etc.) to move the pulley outboard until proper belt tension is reached. If the belt is being replaced it may be necessary to remove and replace the throttle cable during the belt replacem ent. If so check throttle cable adjustm ent upon completion. It may also be necessary to remove the crankshaft pulley to install a new compressor belt.

G and Motor Home Chassis Models


Rem oval (Fig. IB -2 8)

C60 SYSTEM--C-K SERIES


CONDENSER - C-K SERIES
R ep lace m en t (Fig. IB -2 9 )

Disconnect battery ground cable. Disconnect compressor clutch connector. Purge the system of refrigerant. Release the belt tension at the idler pulley and remove the belt from the com pressor pulley. On some vehicles it m ay be necessary to remove the crankshaft pulley in order to remove the belt. 5. G Series--Remove the two bolts and two clamps th at hold the engine cover and remove the cover. 6. Remove the air cleaner to aid access to the compressor. 7. Remove fitting and muffler assem bly and cap or plug all open connections. 8. Remove the nuts and bolts attaching the compressor to the bracket. 9. Remove the engine oil tube support bracket bolt and nut from the compressor, and the com pressor clutch ground lead. Before beginning any com pressor disassembly, drain and m easure oil in the compressor. Check for evidence of contam ination to determ ine if rem ainder of system requires servicing.

1. 2. 3. 4.

1. 2. 3. 4. 5.

Disconnect b attery ground cable. D ischarge system. Remove the grille assembly. Remove the radiator grille center support. Remove the left grille support to upper fender support (2) screws.

6. D isconnect the condenser inlet and outlet lines and the outlet tube line at the right end of the condenser. C ap or plug all open connections at once. 7. Remove the condenser to radiator support screws. 8. Bend the left grille support outboard to gain clearance for condenser removal. 9. Remove the condenser assembly by pulling it forward and then lowering it from the vehicle. 10. To install a new condenser, reverse Steps 1 thru 9 above. A dd one fluid ounce of clean refrigeration oil to a new condenser.

IB -28

AIR CO NDITIO NING

Fig. 1B-28A--Compressor Mounting

AIR C O ND ITIO NIN G

IB -29

L-6 C-K MODELS

6.2L C-K MODELS

6.2LG MODELS
Fig. 1B-28B--Compressor Mounting (Cont.)

IB -30

AIR CONDITIO NING


2. Discharge system.

Fig. 1B-29--Condenser Installation (C-K Series)

Use new "O " rings, coated with clean refrigeration oil, when connecting all refrigerant lines. 11. Evacuate, charge and check the system.

3. Rem ove the nuts from the selector duct studs projecting through the dash panel. 4. Remove the cover to dash and cover to case screws and remove the evaporator case cover. 5. Disconnect the evaporator core inlet and outlet lines and cap or plug all open connections at once. 6. Rem ove the expansion tu b e as outlined under expansion tube replacem ent. 7. Remove the evaporator core assembly. 8. To install, reverse Steps 1 th ru 7 above. Add 90 ml (3 oz.) of clean refrigeration oil to a new evaporator core. Use new " O " rings, coated with clean regrigeration oil, when connecting refrigerant lines. Be sure cover to case and dash panel sealer is intact before reinstalling cover. 9. Evacuate, charge and check the system.

EXPANSION TUBE-C-K,& G
The expansion tube is located in the evaporator core inlet line.
R ep lacem en t

ACCUMULATOR - ALL
R ep lacem en t

1. D isconnect th e b a tte ry ground cable and the compressor clutch connector. 2. Discharge system. 3. Disconnect the accum ulator inlet and outlet lines and cap or plug the open connections at once. 4. Remove the accum ulator bracket screws and remove the accum ulator from the vehicle. 5. D rain any excess refrigerant oil from the accum ulator into a clean container. M easure and discard the oil. 6. If a new accum ulator is being installed, add one ounce of clean refrigeration oil to the new accum ulator PL U S an am ount equal to th a t drained in Step 5 above. 7. To install the new accum ulator, reverse Steps 1 thru 4 above. Connect all lines using new "O " rings, coated with clean refrigeration oil. Do not uncap the new unit until ready to fasten the inlet and outlet line to the unit. 8. Evacuate charge and check the system.

1. Discharge system. 2. Disconnect the condenser to evaporator line at the evaporator inlet. C ap the open line at once. 3. Using needle-nose pliers, remove the expansion tube from the evaporator core inlet line. 4. Remove the expansion tube " O " ring from the core inlet line. 5. To install, reverse Steps 1 thru 4 above. Install the expansion tube using a new "O " ring coated w ith clean regrig eratio n oil, by inserting the short screen end of the tube into the evaporator inlet line. 6. Evacuate, charge and check the system.

SELECTOR DUCT AND HEATER CORE ASSEMBLYC-K


R ep lace m en t (Fig. IB -3 1 )

1. Disconnect the battery ground cable.


2. D rain the radiator and remove the heater hoses from

BLOWER ASSEMBLY - C-K SERIES


R ep lacem en t

the core tubes. Plug the core tubes to prevent coolant spillage during removal.

1. 2. 3. 4.

Disconnect the b attery ground cable. Disconnect the blower motor lead and ground wires. Disconnect the blower m otor cooling tube. Remove the blow er to case a tta c h in g screws and remove the blower assembly. Pry the blower flange away from the case carefully if the sealer acts as an adhesive. 5. Remove the nut attaching the blower wheel to the m otor shaft and separate the assemblies. 6. To install, reverse Steps 1 thru 5 above; replace sealer as necessary.

EVAPORATOR CORE
R ep lacem en t (Fig. IB -3 0 )

1. Disconnect the battery ground cable.

AIR C O ND ITIO NIN G

IB-31

Fig. 1B-31 A ir Selector and Ducts (C-K Series)

3. Remove the glove box and door as an assembly. 4. Remove the center duct to selector duct and instrum ent panel screws and remove the center lower and center upper ducts. 5. Disconnect the bowden cable at the tem perature door. 6. Remove the nuts from the three selector duct studs projecting through the dash panel. 7. Remove the selector duct to dash panel screw (inside vehicle). 8. Pull the selector duct assembly rearw ard until the core tubes clear the dash panel. Lower the selector assembly far enough to gain access to all vacuum and electrical harnesses.

9. D isconnect th e vacuum and electrical harness and remove the selector duct assembly. 10. Remove the core m ounting strap screws and remove the core. 11. To install, reverse Steps 1 thru 10 above. 12. Refill coolant system and connect the battery ground strap. Check tem perature door cable adjustm ent.

KICK PAD VALVE - C-K SERIES


R ep lace m en t (Fig. IB -3 2 )

1. 2. 3. 4.

Disconnect the vacuum hose at the actuator. U nhook the valve return spring a t the actuator end. Remove the actu ato r bracket m ounting screws. Remove the cam to actuator arm screw and separate

IB -32

AIR CONDITIO NING


5. Disconnect the bowden cable, vacuum harness and electrical harness at the control. 6. Remove the control. 7. If a new unit is being installed, transfer the m aster blower switches to the new control. 8. To reinstall, reverse Steps 1 th ru 6 above. C heck control operation.

TEMPERATURE DOOR CABLE ADJUSTMENT - C-K MODELS


1. Remove glove box and door assembly. 2. Loosen the cable attaching screw at the selector duct assembly. 3. M ake sure the cable is installed in the bracket on the selector duct assembly. 4. Place tem perature lever in full C O L D position and hold while tightening cable attaching screw.

MASTER SWITCH AND/OR BLOWER SWITCH C-K SERIES


The m aster switch is located on rear of the control assembly.
R ep lacem en t

Fig. 1B-32--Air Inlet Valves (C-K Models)

the actuator and bracket from the cam. 5. Remove the actuator to bracket nuts and separate the actuator and bracket. 6. To install reverse Steps 1 thru 5 above.

1. Disconnect the battery ground cable. 2. Remove the instrum ent panel bezel. 3. Remove the control to instrum ent panel screws and allow control to rest on top of the radio. 4. Remove the switch to control screws, disconnect the electrical harness (and vacuum harness on m aster switch) at the switch and remove the switch assembly. 5. To install a new switch, reverse Steps 1 thru 4 above.

VACUUM TANK
The vacuum tank is m ounted to the engine side of the dash panel above the blower assem bly (Fig. 1B-34).
R ep lacem en t

PLENUM VALVE - C-K SERIES


R ep lacem en t (Fig. IB -3 2 )

1. Raise the hood. 2. Remove the cowl plastic grille. 3. Remove the three cowl to valve assembly screws and remove the valve assembly from the vehicle. 4. Remove the actuator arm pushnut. 5. Remove the actuator to valve nuts and separate the valve and actuator. 6. To install, reverse Steps 1 th ru 5 above.

1. Disconnect the vacuum lines at the tank. 2. Remove the tank to dash panel screws and remove the tank. 3. To install, reverse Steps 1 and 2 above.

BLOWER MOTOR RESISTOR


The blower motor resistor is located in the blower side of the blow er-evaporator case (Fig. 1B-36).

CONTROL ASSEMBLY - C-K SERIES


Rem oval (Fig. IB -3 3 )

1. Disconnect the battery ground cable. 2. Remove the radio as outlined in Section 8 of this manual. 3. Remove the instrum ent panel bezel. 4. Remove the control to instrum ent panel screws and lower the control far enough to gain access to the control assembly. Be careful not to kink the bowden cable.

AIR CO ND ITIO NIN G

IB -33

GRAY-TO
^ / V A C U U M TA N K /

/P LE N U M VALVE

r/'

_ O R AN G E

V IE W

Fig. 1B-35--Vacuum Line Routing - C-K Models


R ep lacem en t

remove the relay. 3. Place the new relay in position and drive the m ounting screws. 4. Connect the relay wiring harness.

1. Disconnect the wiring harness at the resistor. 2. Rem ove the resistor to case a tta c h in g screws and remove the resistor. 3. Place th e new resistor in position and install the attaching screws. 4. Connect the resistor wiring harness.

FUSE
A 25 am p fuse, located in the junction block protects the entire air conditioning system except for the blower circuit, the fuse for the blower circuit is located in the electrical wiring between the junction block and the blower relay.

BLOWER MOTOR RELAY - ALL


The blower motor relay is located on the blower side of the blower-evaporator case (Fig. 36).
R eplacem en t

1. Disconnect the wiring harness at the relay. 2. Rem ove the relay to case a tta c h in g screws and

OVERHEAD SYSTEM-C-K MODELS


The O verhead System is used in conjunction with the C60 System . Since replacem ent of C60 System com ponents has been covered previously, only those com ponents peculiar to the O verhead System will be covered in this section.

REAR DUCT
This duct covers the blow er-evaporator assembly, at the rear of the vehicle, and incorporates four adjustable air outlets (Fig. IB-37).
R ep lace m en t

1. Disconnect the battery ground cable. 2. Disconnect the drain tube from the rear duct. 3. Remove the screws securing the duct to the roof panel and rear header brackets. 4. Remove the duct.

Fig. 1B-34--Vacuum Tank C-K Models

IB -3 4

AIR CO NDITIO NING

Fig. 1B-36--Engine Compartment W iring Harness (C-K Models)

5. To install, reverse Steps 1 thru 4 above.

BLOWER MOTOR ASSEMBLY


R em oval (Fig. IB -3 9 )

BLOWER MOTOR RESISTOR


The blower motor resistor is located on the cover side of the C60 System blow er-evaporator as shown in Fig. 1B-38.
R ep lacem en t

1. 2. 3. 4. 5.

1. Disconnect battery ground cable. 2. Disconnect the electrical harness at the resistor. 3. Remove the resistor attaching screws and remove the resistor. 4. To install a new resistor, reverse Steps 1 thru 3 above.

Disconnect the battery ground cable. Remove the rear duct as outlined previously. Disconnect the blower motor ground strap. Disconnect the blower m otor lead wire. Remove the lower to upper blow er-evaporator case screws and lower the lower case and m otor assembly.

N O T IC E : Before removing the case screws, support the lower case to prevent dam age to the case or motor assemblies. 6. Rem ove the m otor re tain in g stra p and rem ove the m otor and wheels. Remove the wheels from the motor shaft. Installatio n

1 . Place the blower wheels onto the m otor shaft m aking


sure the wheel tension springs are installed on hub of wheels. Be sure th a t the blower wheels are installed as shown in Fig. IB-40. 2. Install the blower motor retaining strap and foam. 3. Place the blower m otor and wheel assembly into the lower case. Align the blower wheels so th at they do not contact the case. 4. Place the lower case and blower motor assembly in position in the vehicle and install the lower to upper case screws.
N O TIC E:

R otate the blower wheels to m ake sure th a t

AIR C O ND ITIO NIN G

IB -35

Fig. 1B-38--Overhead System Front W iring (C-K Models)

4. Disconnect the blower m otor lead and ground wires. 5. Remove the lower to upper blow er-evaporator case screws and lower the lower case and m otor assembly.
N O T IC E : Before removing the case screws, support the lower case and m otor assemblies to prevent dam age to the case or m otor assemblies. 6. Remove the expansion valve sensing bulb clam ps. 7. Disconnect the valve inlet and outlet lines and remove the expansion valve assembly. C ap or plug the open connections at once. Installatio n

1. Remove caps or plugs from system connections and install the new valve assem bly using new " O " rings coated with clean refrigeration oil. they do not rub on the case. 5. Install the center ground wire and connect the blower lead wire.

6. Install the rear duct assembly as described previously.


7. Connect the battery ground cable.

EXPANSION VALVE
This sytem incorporates an expansion valve which does not utilize and external equalizer line (Fig. 1B-41).
Rem oval

1. Disconnect battery ground cable. 2. Purge the system of refrigerant. 3. Remove the rear duct as outlined previously.

IB -3 6

AIR CONDITIO NING


5. Install the blow er-evaporator assembly to the roof and install the support to roof rail screws. 6. Connect the refrigerant lines to the blower-evaporator unit using new " O " rings coated w ith clean refrigeration oil. 7. Connect the blower lead and ground wires. 8. Install the rear duct as outlined previously. 9. Connect the battery ground cable. 10. Evacuate, charge and check the system.

BLOWER MOTOR SWITCH


The three-speed (L O -M E D -H I) blower motor switch is located in the instrum ent panel, ju st to the left of the ash tray.
Fig. 1B-41 --Expansion Valve C69 System
R ep lacem en t

2. Install the sensing bulb, making sure th at the bulb

makes good contact with the core outlet line. 3. Install the lower case and blower m otor assemblies. Connect the blower motor lead and ground wires. 4. Install the rear duct as outlined previously. 5. Connect the b attery ground cable.

1. Disconnect the battery ground cable. 2. Remove the switch retaining screws. 3. Disconnect the wiring harness at the switch and remove the switch. 4. To install, reverse Steps 1 thru 3 above.

6. Evacuate, charge and check the system.

FUSE
The Four Season portion of this system is protected by a 25 am p fuse in the junction block. The rear blower high speed circuit is protected by a 20 am p in-line fuse, located between the junction block and the rear blower motor switch.

EVAPORATOR CORE
Rem oval

1. Disconnect the b attery ground cable.


2. Purge the system of refrigerant.

3. Remove the rear duct as outlined previously. 4. Disconnect the blower motor lead and ground wire connections. 5. D isconnect th e re frig e ran t lines at th e re a r of the blow er-evaporator assem bly. C ap or plug th e open connections at once.

C60 SYSTEM -G SERIES


CONDENSER - G Series
R ep lace m en t (Fig. IB -4 2 )

6. Rem ove the b low er-evaporator support to roof rail


screw s, lower the blow er-evaporator assem bly and place it on a work bench upside down. 7. Remove the lower to upper case screws and remove the lower case assembly. Remove the support to upper case screws and remove the upper case from the evaporator core. 8. Remove the expansion valve inlet and outlet lines and cap or plug the open connections at once. Remove the expansion valve capillary bulb from the evaporator outlet line and remove the valve. 9. Remove the plastic pins holding the screen to the core and remove the screen.
Installation

1. Disconnect battery ground cable. 2. Purge the system of refrigerant. 3. Remove grille, hood lock, and center hood lock support as an assembly. 4. D isconnect condenser inlet and o utlet lines at condenser. 5. Remove screws attaching left side condenser bracket to radiator. 6. Remove screws attaching right side condenser bracket to condenser. 7. Remove condenser from vehicle. 8. Remove left hand bracket from condenser. 9. To install new condenser, reverse steps 3 thru 8 above. A dd 30 ml (1 oz.) of clean refrigeration oil to a new condenser. 10. Evacuate charge and test the system.

1. Install the wire screen to the front of the core and insert the plastic pins.
2. Install the expansion valve inlet and outlet lines using

HEATER CORE - G SERIES


R ep lace m en t

new " O " rings coated with clean refrigeration oil. Install the sensing bulb to the evaporator outlet line as shown in Fig. IB-41; m ake sure the bulb has good contact with the line. Add 3 oz. clean refrigeration oil when installing a new core. 3. Install the upper case and supports to the core. 4. Install the lower core case and blower assembly.

1. Disconnect battery ground cable. 2. Remove engine cover. 3. Remove steering column to instrum ent panel attaching bolts and lower column. 4. Remove upper and lower instrum ent panel attaching screws and radio support bracket attaching screw. 5. Raise and support right side of instrum ent panel. 6. Rem ove rig h t lower in stru m e n t panel support

AIR C O ND ITIO NIN G

IB -3 7

VIEW [A ] &LH6/LL4

CONDENSER ASH 4 L H 6 /L L 4 BO LT/SCR EW NUT

[T1
E l [T ]

Fig. 1 B-42--Condenser-G Series

bracket. 7. Remove recirculating air door vacuum actuator. Refer to Fig. IB-43. 8. Disconnect tem perature cable and vacuum hoses at distributor case. 9. Remove heater distributor duct, refer to Fig. 1B-44. 10. Remove 2 defroster duct to dash panel attaching screws (below windshield). 11. W orking from the engine co m p artm en t, disconnect

12. Remove three (3) nuts from bolts attaching heater core case to dash panel and one ( 1 ) screw at lower right corner (inside). 13. Remove d istributor assem bly from vehicle. 14. Remove gasket to expose screws attaching case sections together as shown in Fig. 1B-45. 15. Remove tem perature cable support bracket. 16. Remove case attaching screws and separate case. 17. Remove heater core. 18. To install new heater core, reverse Steps 2 thru 17 above.

BLOWER MOTOR INSULATION (W/DIESEL)


T he 6.2 L ite r D iesel E ngine has ex tra insulation around the blow er m otor on vehicles w ithout C 60 and around the blower m otor and evaporator core with C60 option.
Rem oval

1. 2. 3. 4. 5. 6.

Remove parking lam p assembly. Remove the radiator overflow tank. See Fig. 1 B-46 for location of the screws. Remove insulation through the hood opening. Proceed with norm al blower m otor removal. To install, reverse the above procedure.

EVAPORATOR CORE (W/DIESEL)


1. Remove cold air intake. 2. Disconnect hood latch assembly and cable retainer and place it out of the way.

heater hoses and plug to prevent w ater spillage.

IB -38

AIR CO NDITIO NING


The following steps should be taken to assure proper installation: a. Assemble the blower wheel to the motor with the open end of the wheel away from the blower motor. b. If the m otor mounting flange sealer has hardened, or is not intact, remove the old sealer and apply a new bead of sealer to the entire circum ference of the m ounting flange. c. Check blower operations: blower wheel should rotate freely with no interference.

EVAPORATOR CORE
R ep lace m en t (Fig. IB -5 1 )

Fig. 1B-44--Heater Distributor Duct

3. Remove windshield solevent tank. 4. Discharge the A /C system.


N O T IC E: W hen removing any A /C com ponents, make sure th a t th e com ponent is capped to prevent contam ination.

5. Disconnect the low pressure vapor line and move it out of the way.

6. Remove accum ulator.


7. Disconnect and remove high pressure line inlet to the evaporator and the connecting bracket.

8. Remove the wiring harnesses going to the blower motor


relay and resistors. 9. Remove the blower m otor relay and resistors. 10. Remove the fan shroud upper half. 11. Remove the radiator. 12. Disconnect the heater valve assembly bracket and move it out of the way. 13. Remove the upper screws of the lower section, see Fig. 1B-46, and push it down and out of the way. 14. See Fig. IB -46 for th e location of th e insulation m ounting screws. 15. Remove insulation through the hood opening. 16. Proceed with the A /C evaporator procedure. 17. Reverse the above procedure for installation.

1. Disconnect battery ground cable. 2. Purge system of refrigerant. 3. Remove coolant recovery tank and bracket as outlined earlier. 4. D isconnect all electrical connectors from core case assembly. 5. Remove bracket at evaporator case. 6 . Remove right hand m arker lam p for access. 7. Disconnect accum ulator inlet and outlet lines and 2 brackets attaching accum ulator to case. 8. Disconnect evaporator inlet line. 9. Remove three (3) nuts and one (1) screw attaching module to dash panel. 10. Remove core case assembly from vehicle. 11. Remove screws and separate case sections. 12. Remove evaporator core. 13. To install new core, reverse Steps 3 thru 14 above. 14. A dd 90 ml (3 oz.) 525 viscosity refrigeration oil to a new condenser. 15. Evacuate charge and check the system.

CONTROL ASSEMBLY - G SERIES


R ep lace m en t

1. Disconnect the battery ground cable. 2. Remove the headlam p switch control knob. 3. Remove the instrum ent panel bezel.

BLOWER MOTOR - G SERIES


Rep lacem en t

1. Disconnect battery ground cable.


G S eries - Remove the coolant recovery tank, and

power antenna. 2. Disconnect the blower motor lead wire. 3. Remove the five blower motor m ounting screws and remove the motor and wheel assembly. Pry gently on the blower flange if the sealer acts as an adhesive. 4. Rem ove th e blower wheel to m otor sh aft nut and separate the wheel and motor assemblies. 5. To install a new m otor, reverse Steps 1 thru 4 above.

AIR C O ND ITIO NIN G

IB -39

[~T~| BLOWER MOTOR INSULATION


[~2~1 BLOWER MOTOR MODULE 1 3 | EVAPORATOR CORE INSULATION [~~4~1 EVAPORATOR CORE MODULE
104 208

Fig. 1B-46--G Van Blower Motor (Diesel Only)

Fig. 1B-47--Air Deflector Outlets (G Series-C60 System)

IB -40

AIR CO NDITIO NING

RESISTORS
Replacement (Fig. IB -48)

1. Disconnect electrical harness at the resistor. 2. Remove the resistor m ounting screws and remove the resistor. 3. To install, reverse Steps 1 thru 3 above.

BLOWER MOTOR RELAY - G SERIES


Replacement (Fig. IB -48)

1. Disconnect electrical harness at the relay. 2. Remove the relay m ounting screw and remove the relay. 3. To install, reverse Steps 1 thru 3 above. 4. Remove the control to in stru m en t panel a tta c h in g screws. 5. Remove the te m p e ra tu re cable eyelet clip and mounting tab screw. 6. Pull the control through the instrum ent panel opening as follows: First pull the lower right m ounting tab through the opening, then the upper tab and finally the lower right tab. 7. D isconnect electrical and vacuum connections and remove the control assembly. 8. To install, reverse Steps 1 th ru 7 above. C heck tem perature door operation; adjust if necessary.

CENTER A /C OUTLET - G SERIES


Replacement

1. 2. 3. 4. 5. 6. 7. 8. 9.

Disconnect negative battery cable. Remove engine cover. Remove steering column to I.P. attaching screw. Remove radio support bracket screw. Remove I.P. attaching screws. Pull right side of 1.P. rearw ard. Remove duct (distributor) attaching screws. Remove center deflector. To replace, reverse Steps 1 thru 8 above.

BLOWER SWITCH
Rep lacem en t

A /C DUCTWORK
A ir Conditioning duct attachm ent is shown in Fig. 1B57.

1. Disconnect the battery ground cable. 2. Remove the left foot cooler outlet assembly at the instrum ent panel attachm ent. 3. Disconnect the switch electrical harness. 4. Remove the switch m ounting screws and remove the switch. 5. To install, reverse Steps 1 thru 4 above.

DEFROSTER DUCT
D efroster duct mounting is shown in Fig. 1B-58.

TEMPERATURE DOOR CABLE


T em perature cable attachm ent and routing is shown in Fig. IB-59.

Fig. lB-49~Center A /C Outlet Assembly-G Series

Fig. 1B-50--Heater Defroster Assembly-G Series

AIR C O ND ITIO NIN G

IB-41

VACUUM TANK - G SERIES


Replacement

1. Raise the hood. 2. Disconnect the vacuum harness at the tank. 3. Remove the tank attaching screws and remove the tank. 4. To install, reverse Steps 1 th ru 3 above.

OVERHEAD SYSTEM--G SERIES


This system is used in conjunction with the C60 system. T he G Van C69 system is alm ost identical to the C-K M odels overhead system R efer to C K Series overhead system service procedures.

Fig. 1B-51--Evaporator Blower Assembly-G Series

IB -42

AIR CONDITIO NING

Fig. 1 B-52--Refrigerant Lines - G Series

AIR C O ND ITIO NIN G

IB -43

Fig. 1B-56--Vacuum Tank C-K Series-Diesel Engine

IB -44

AIR CO NDITIO NING

Fig. 1B-57--A/C Ducts-G Series

A/C HEATER ASM (TYPICAL)


|v i i w [a !

SNAPINTi CONTROL ASM

DUCT ASSEMBLY

"CONTROL ASM

Fig. 1B-58--Defroster Duct-G Series

Fig. 1 B-59--Temperature Cable-G Series

DASH MOUNTED SYSTEM-MOTOR HOME CHASSIS


This system is installed on the vehicle and checked at assembly. The blower-evaporator is then disconnected and shipped with the chassis unit to the body supplier. For this reason, it will only be possible to give basic replacem ent procedures on some components.

CONDENSER
Replacement (Fig. IB -6 0 )

1. Disconnect the battery ground cable. 2. Purge the system of refrigerant. 3. D isconnect the condenser inlet and outlet lines and cap or plug all open connections at once.

AIR C O ND ITIO NIN G

IB -45

BLOWER-EVAPORATOR ASSEMBLY
Removal (Fig. IB -6 3 )

1. Disconnect battery ground cable. 2. Purge system of refrigerant. 3. Disconnect inlet and outlet refrigerant lines from the back of unit. C ap or plug all open connections at once. 4. Disconnect drain tubes from evaporator case. 5. D isconnect e lectrical connector from com pressor. Remove the term inal (R efer to Fig. IB -64) and allow connector to hang on ground wire. 6. Rem ove screws securing grom m et re ta in e r to dash panel. Remove wire from grom m et through slit. 7. Disconnect electrical lead at connector. 8. Rem ove unit m ounting bolts. Rem ove u n it from vehicle, carefully pulling com pressor electrical lead through dash panel. Once the unit has been removed from the vehicle, continue with com ponent replacem ent as follows:
Fig. 1B-60--Condenser (Motor Home Chasis Unit) 4 . Remove the condenser to radiator support screws and

BLOWER ASSEMBLY
Removal (Fig. IB -6 5 )

remove the condenser. 5. To install a new condenser, reverse Steps 1 thru 4 above. Add one fluid ounce of clean refrigeration oil to a new condenser.
N O T IC E : Use new " O " rings, coated w ith clean refrigeration oil, when connecting all refrigerant lines.

1. Remove the cover plate and separate the upper and lower case halves. Remove blower m otor m ounting strap screw and remove strap. 2. Remove blower assembly. Remove the wheels from the m otor shaft.
Installation

6. Evacuate, charge and check the system. RECEIVER-DEHYDRATOR


R ep lace m en t (Fig. IB -6 1 )

1. Disconnect the b attery ground cable. 2. Purge the system of refrigerant. 3. Disconnect the inlet and outlet lines at the receiverdehydrator and cap or plug the open lines at once. 4 . Rem ove the receiv er-d eh y d rato r b rack et atta c h in g screws and rem ove th e b rack et and receiverdehydrator. 5. To install a new receiver-dehydrator, reverse Steps 1 thru 4 above. Add one fluid ounce of clean refrigeration oil to a new receiver-dehydrator.
N O T IC E : U se new " O " rings, coated w ith clean refrigeration oil, when connecting all refrigerant lines. 6. Evacuate, charge and check the system.

1. Install the blower wheels on the m otor so th a t the lower blades curve tow ard the dash panel side of the unit when the m otor is placed in the case as shown in Fig. IB-65. 2. Place th e m otor in th e b rac k et w ith the electrical connector side of the m otor to the right side of the b rack et. A tta c h the m ounting strap . A lign blower wheels so th at they do not contact case. 3. A ssem ble the case halves and a tta c h th e cover

SIGHT GLASS REPLACEMENT


If dam age to the sight glass should occur, a new sight glass kit should be intalled. The kit contains the sight glass, seal and retainer. (R efer to Fig. IB-62). 1. Purge system. 2. Remove the sight glass retainer nut using a screwdriver and remove old glass and " O " ring seal. 3. Install the new glass and seal and retainer nut, being careful not to turn the nut past the face of the housing. To do so may dam age the " O " ring seal. 4 . E vacuate, charge and check the system.

Fig. 1B-61--Receiver-Dehydrator (M otor Home Chassis Unit)

IB -4 6

AIR CONDITIO NING

Fig. 1B-62--Sight Glass Replacement


TERMINAL

A. kiMft k t * w driver in groove & pr*i tang toward terminal to rtleoso. I . Pry tang bock out to mturc locking whon rainstaUod into conncctor.

Fig. 1B-63--Blower-Evaporator (Motor Home Chassis Units)

Fig. 1 B-64--Terminal Removal

plate. 4. Reverse S teps 1-8 on the Assembly " removal procedure. "B lo w er-E v ap o rator

5. Evacuate, charge and check the system.

EXPANSION VALVE, EVAPORATOR AND/OR EVAPORATOR CASE


Removal (Fig. IB -65)

1. Remove the cover plate and separate upper and lower case halves. 2. Remove inlet and outlet lines from the expansion valve. Rem ove sensing bulb from th e evap o rato r outlet manifold. Remove expansion valve. C ap or plug open connections a t once.

CORRECT BLOWER BLADE ANGLE


Fig. 1B-65--Blower Assembly (M otor Home Chassis Unit)

AIR C O ND ITIO NIN G

IB -4 7

THERMOSTATIC SWITCH CAPILLARY TUBE

SCREEN MESH

BUMPER

BLOWER SWITCH
Fig. 1B-67-Thermostatic and Blower Switches

Fig. 1B-66--Expansion Valve (Motor Home Chassis Unit)

3. Remove evaporator core retaining screws and remove core. 4. Remove blower motor and harness assembly from case.
Installation

cover plate and remove appropriate switch (Fig. 1B67). 3. Install replacem ent switch, reinstall cover plate and reverse steps 1-8 of th e "B lo w er-E v ap o rato r A ssem bly" removal precedure. W hen installing therm ostatic switch, be sure to position sensing capillary as when unit was removed.

1. Reverse applicable steps in the removal procedure.


NOTICE: U se new " O " rings coated w ith clean refrigeration oil when connecting lines. Add 3 oz. of new refrigeration oil to a new core. 2. Reverse steps 1 thru 8 of the "Blower Evaporator A ssem bly" removal procedure. 3. Evacuate, charge and check the system.

RESISTOR
The blower m otor resistor is located on the top of the unit. The entire unit m ust be removed to replace the resistor.

THERMOSTATIC AND/OR BLOWER SWITCHES


Replacement

FUSE
This U nit does not incorporate an in-line fuse. T he lead wire is connected to th e H e a te r W iring H arn ess and operates off the 20 am p H eater Fuse.

1. Remove the cover plate assem bly from the evaporator case.

IB -48

AIR CO NDITIO NING

AIR CONDITIONING
Compressor Type . . . . 4 Cylinder Radial Displacement 6 Cylinder Axial 4 Cylinder Radial Rotation . . Volts Blower Motor C -K Fo u r Season . . 12.0 C-K-G Overhead, G Floo r and Motor Home' 12.0 Units 12.8 Max. 3400 Min. ........................12 .6C u . In. ........................1 0 .0 C u .ln . Amp*. (Cold) RPM (Cold) Torque Specifications Compressor Suction and Discharge Connector B o l t ................................... Rear Head to Shell Stud Nuts ( 6 C yl.) Shaft Mounting Nut (6 C y l . ) ............... Shaft Mounting Nut (4 Cyl.) High Pressure Relief Valve (6 Cyl.) Oil Charge Screw (6 C yl.) . . . . Air Gap on Clutch (6 C yl.) . . . Compressor Mounting Bracket . . . Compressor to Front Bracket Bolts Belt Tension ................................... Fuse B lo c k C -K S y s t e m s ............................................ Motor Hojne Chassis U nit..................... In -L in e C-K Systems ............................................ Motor Home Chassis U n it ..................... Circuit Breaker G Model System s...................................... ............25 f t Iba. ............23 f t Iba. ............20 f t Iba. . . . . . 1 2 ft.lb s. 1 4 ft.lb s.

13.7 Max.

3400 Min.

Compressor Clutch Coil Ohms (at 8 0 F ) . . Amps, (at 8 0 F ) . ...................................... 3.70 ..................3.33 @ 12 volts

. . . 25 ft. lbs See Tune-Up Chart

Fig. 1B-68--Specifications

AIR C O ND ITIO NIN G

IB -49

f t
m m m m

CD

##

DE

( j

O il

a
a
9/ i e " THIN WALL SOCKET
HUB AND DRIVE PLATE ASSEMBLY REMOVER DRIVER HANDLE SNAP RING PLIERS ( * 2 1 INTERNAL) SHAFT SEAL PROTECTOR SEAL SEAT REMOVER AND INSTALLER SHAFT SEAL REMOVER AND INSTALLER SEAL SEAT O-RING INSTALLER PRESSURE TEST CONNECTOR CLUTCH HUB HOLDING TOOL

hd

j 939t

|~2~| J >480-01 HUB AND DRIVE PLATE ASSEMBLY INSTALLER [~3~] J 9401

ElJ18553-01 QTJjI 8398 [ m]JI 25008 I 24092 @ J


8433 [je] -1 QD.19393 D EI-*I8083 G)jI24898 [ )JI 28271

O-RING REMOVER ROTOR 8EARING REMOVER COMPRESSOR HOLDING FIXTURE PULLEY HUB ADAPTER SET (USED WITH J 84331 COMPRESSOR PULLEY PULLER SEAL SEAT REMOVER & INSTALLER SNAP RING PLIERS ( * 2 4 EXTERNAL) BEARING REMOVER (FRONT HEAD) ROTOR AND BEARING INSTALLER (WITHOUT HANDLE) BEARING INSTALLER (FRONT HEAD)

jm m

[~5~] J S403 ( T ] J 22974 | 7 ~ ~ | J 23128

[T)J392

f~5~l J 21808 n n j 9626


rm J 2S030

(JTjj124896

[ m ] j125031-2 ROTOR AND BEARING PULLER WITH GUIDE

Fig. 1B-69--Air Conditioning Special Tools

IB -5 0

AIR CO NDITIO NING

1. 2. 3. 4. 5.

J-8393 J-24095 J-5453 J-9459

6. 7. 8. 9. 10.

CHARGING STATION OIL INDUCER GOGGLES 7/16"-20 90 GAUGE LINE J-25499 3/8"-24 ADAPTER 7/16"-20 J-5420 STRAIGHT GAUGE LINE J-25498 3/8" ADAPTER J-6084 LEAK DETECTOR J-8433 PULLER PULLER PILOT J-9395 J-23595 REFRIGERANT CAN VALVE (SIDE-TAP) J-6271-01 REFRIGERANT CAN VALVE (TOP-TAP)

11. J-5421-02 POCKET THERMOMETERS (2) 12. J-5403 NO. 21 SNAP RING PLIERS NO. 26 SNAP RING 13. J-6435 PLIERS COMPRESSOR 14. J-9396 HOLDING FIXTURE 15. J-25030 COMPRESSING FIXTURE CLUTCH HUB HOLDING 16. J-9403 TOOL 17. J-9399 9/16" THIN WALL SOCKET HUB AND DRIVE 18. J-9401 PLATE ASSEMBLY REMOVER 19. J-9480-01 HUB AND DRIVE PLATE ASSEMBLY REMOVER SEAL REMOVER 20. J-9392 21. J-23128 SEAL SEAT REMOVER

22. J-9398

PULLEY BEARING REMOVER 23. J-9481 PULLEY AND BEARING INSTALLER 24. J-8092 HANDLE 25. J-21352 INTERNAL ASSEMBLY SUPPORT BLOCK 26. J-5139 OIL PICKUP TUBE REMOVER 27. J-9432 NEEDLE BEARING INSTALLER 28. J-9553-01 SEAL SEAT 0 RING REMOVER 29. J-21508 SEAL SEAT 0 RING INSTALLER 30. J-22974 SHAFT SEAL PROTECTOR 31. J-9625 PRESSURE TEST CONNECTOR 32. J-9402 PARTS TRAY

Fig. 1B-70--Air Conditioning Special Tools

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -1

S E C T IO N 1 D

AIR CONDITIONING COMPRESSOR OVERHAUL


F or C om pressor R E M O V A L A N D IN ST A L L A T IO N , see A ir Conditioning Section. For D IS C H A R G IN G , A D D IN G O IL, E V A C U A T IN G A N D C H A R G IN G PR O C E D U R E S FO R C.C.O.T. A /C SYSTEMS, see A ir Conditioning Section.

CONTENTS OF THIS SECTION


M inor Repair Procedures for the A -6 C om pressor......................................................................................... A -6 Compressor C lutch Plate and H ub A ssem bly...................................................................................... A -6 Com pressor Pulley and Bearing Assy..................................................................................................... A -6 Com pressor Pulley B earin g ....................................................................................................................... A -6 Com pressor C lutch Coil and Housing A ssem bly................................................................................ M ajor A -6 Com pressor R epair Procedures........................................................................................................ A -6 Com pressor Shaft S e a l................................................................................................................................ Seal Leak D etection......................................................................................................................................... A -6 Com pressor Pressure Relief Valve............................................................................................................ A -6 Com pressor Cylinder and Shaft A ssem bly ........................................................................................... Removal............................................................................................................................................................... Disassembly........................................................................................................................................................ Gaging O peration.............................................................................................................................................. A -6 Teflon Piston Ring Replacem ent......................................................................................................... A ssem bly............................................................................................................................................................. R e-Install............................................................................................................................................................. A -6 Comp. Leak Testing (External and In te rn a l)...................................................................................... For all practical purposes, all vehicles make use of the same air conditioning 4 and 6-cylinder compressors. A ctual differences between compressors are found in their mounting brackets, pulleys, connector assemblies and compressor capacities, none of which will affect the following Overhaul Procedures. W hen servicing the compressor, it is essential that steps be taken to prevent dirt or foreign m aterial from getting on or into the compressor parts and system during disassembly ID-2 ID-2 ID-5 1D -6 ID-7 ID -8 ID -8 ID -10 ID -11 ID -13 ID -13 ID -13 ID -14 ID -18 ID -18 ID-21 ID-25

or reassembly of the compressor. Clean tools and clean work area are very im portant for proper service. The compressor connection areas and the exterior of the com pressor should be cleaned off as m uch as possible prior to any on car repairs or removal of the compressor for workbench service, The parts must be kept clean at all times and any parts to be reassembled should be cleaned with naphtha, Stoddard solvent, kerosene or equivalent solvent

1 D -2 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
and dried off with dry air. W hen necessary to use a cloth on any part, it should be of a non-lint producing type. A lthough certain service operations can be performed w ithout completely removing the compressor from the vehicle, the operations described herein are based on bench over-haul with the com pressor removed from the vehicle. They have been prepared in sequence in order of accessibility of the components. Pad fender/skirt and secure com pressor near top of fender skirt with wire, rope, etc. when perform ing on-car service. W hen an A -6 or R-4 com pressor is removed from the vehicle for servicing, the am ount of oil remaining in the com pressor should be drained and measured. This oil should then be discarded and new 525 viscosity refrigerant oil added to the com pressor (See Fig. ID-1, and C.C.O.T. Refrigerant Oil D istribution in the A ir Conditioning section). Should an A -6 compressor, its com pressor shaft seal or any other com ponent ever be removed for servicing because it was determ ined to be the cause of excessive signs of oil leakage in the A /C system, then the oil in the A -6 com pressor m ust be drained, m easured and replaced according to C.C.O.T. Refrigerant Oil D istribution in the A ir Conditioning section to determ ine oil loss. The accum ulator in this A -6 system then m ust also be removed - oil drained - measured, etc. according to same section. NOTICE: To avoid possible damage do not kink or place excessive tension on refrigerant lines or hoses.

M I N O R R E P A IR P R O C E D U R E S FOR T H E A - 6 COMPRESSOR
THE FOLLOWING OPERATIONS TO THE A-6 COMPRESSOR CLUTCH PLATE AND HUB, PULLEY AND BEARING, AND COIL AND HOUSING ARE COVERED AS "MINOR" BECAUSE THEY M AY BE PERFORMED WITHOUT FIRST PURGING THE SYSTEM OR REMOVING THE COMPRESSOR from the vehicle. The Com pressor Shaft Seal assembly and Pressure Relief Valve may also be serviced without removing the com pressor from the vehicle but these operations are covered later in this section as M ajor R epair Procedures because the system m ust first be purged of R efrigerant-12. Illustrations used in describing these operations show the com pressor removed from the vehicle only to more clearly illustrate the various operations.
H IPRESSURE R E LIE F V A L V E PROVIDES COMPRESSOR PROTECTION

are in need of service. Refer to the A IR C O N D IT IO N IN G section and Fig. ID-2 and Fig. ID-3 for inform ation relative to parts nom enclature and location. Removal and installation of external compressor com ponents and disassembly and assembly of internal com ponents m ust be performed on a clean workbench. The work area, tools, and parts must be kept clean at all times. P arts Tray J 9402 (Fig. ID -33) should be used for all A -6 internal compressor parts being removed, as well as for replacem ent parts.

A-6 C O M P R E SS O R CLUTCH PLATE A N D HUB A S S E M B L Y


Remove
1. Place Holding Fixture J 9396 in a vise and clamp the com pressor in the Holding Fixture. 2. Keep clutch hub from turning with C lutch H ub H older J 25030 or J 9403, and remove locknut from end of shaft using Thin Wall Socket J 9399 (Fig. ID-3). NOTICE: To avoid internal damage to the compressor, DO N O T D R IV E O R PO U N D on the C lutch Plate and H ub assembly O R on the end of the shaft. If proper tools to remove and replace clutch parts are not used, it is possible to disturb the position of the axial plate (keyed to the main shaft), resulting in compressor dam age and seal leakage due to shifting of the crankshaft.

O IL D R A IN PLUG (TORQUE TO 15 LB.FT.)

Fig. 1D-1 A-6 Compressor

3. Thread 9401 into hub. tighten center assembly (Fig. hub.

C lutch Plate and H ub assembly Remover J H old body of Rem over with a wrench and screw to remove Clutch Plate and H ub ID-4).

4. Remove square drive key from shaft or drive plate W hen servicing the compressor, remove only the necessary com ponents that prelim inary diagnosis indicates 5. Inspect driven plate for cracks or stresses in the drive surface. Do not replace driven plate for a scoring condition (Fig. ID-5).

O-RING
FRONT HEAD S H A F T SEAL ASSEMBLY / O-RINGS PRESSURE RELIE F VALVE O-RING O-RING SUCTION SCREEN INNER OIL PUMP G EAR O IL D R A IN PLUG

j S E A L SE AT
S E A L SE AT R E T A IN E R RING

ABSO RB ENT SLEEVE SLEEVE R E T A IN E R

C LUT CH C O IL R E T A IN E R RING COMPRESSOR S H E L L CL UTCH C O IL A N D HOUSING AS SEMBLY PULLEY I JBE ARING BE A R IN G R E T A IN E R P U L L E Y R E T A IN E R RING CLUTCH P L A T E A N D HUB A S SE M B LY

Fig. 1D-2 Exploded View of A -6 Compressor

LOCK N U T R EA R HEAD

O IL PICK-UP TUBE

OUTER O IL PUMP COVER

f
A X I A L PLATE SUCTION \ CROSSOVER COVER

AIR

REA R DISC HAR GE V A L V E PLATE ASSEMBLY REAR SUCTION REED' BUSHING* / NEEDLE BE ARfN G

CONDITIONING

SHAFT LO CK N U T

REAR C Y L IN D E R H A L F TEFLO N PISTON RING-

T H R U ST BEARING F RO NT C Y L IN D E R H A L F BALL

/
NEEDLE BE ARING

COMPRESSOR

SHOE DISC T E F L O N RING TYPE PISTON T E F L O N PISTON RING S H A FT / DISCHARGE CROSSOVER TUBE T H R U S T RACES DISCHARGE CROSSOVER TUBE O-RING OR BUSHING

DO WE L PINS,

OVERHAUL

BUSHING F RO NT SUCTION REED F RO NT DISCHARGE V A L V E PLATE AS SE M B LY

1D-3

1 D -4 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
SCORING OF D RIVE A ND D RIVE N PLATES IS N O R M A L DO NOT REPLACE FOR THIS CONDITION

Fig. 1D-5 A-6 Clutch Driven Plate and Drive Plate

If the frictional surface shows signs of damage due to excessive heat, the C lutch Plate and H ub and Pulley and Bearing should be replaced. Check further for the underlying cause of the damage (i.e. low coil voltage, coil should draw 3.2 am ps at 12 volts) binding of the com pressor internal m echanism (cylinder and shaft assembly), clutch air gap too wide (see Fig. 1D - 8), broken drive plate to hub asm. springs, etc.

Replace
1. Insert the square drive key into the hub of driven plate; allow it to project approxim ately 4.8mm (3 /1 6 ") out of the keyway. The key has a slight curve for interference fit into hub keyway. 2. Line up the key in the hub with keyway in the shaft (Fig. ID - 6). 3. Install the Drive Plate Installer J 9480-1 as illustrated. This Installer has a left hand thread on the body (Fig. ID-7). 4. Press the driven plate onto the shaft until there is approxim ately 2.4mm (3 /3 2 ") space between the frictional faces of the C lutch D rive Plate and Pulley. M ake certain key remains in place when pressing hub on shaft. A zero thrust race is approxim ately 2.4mm (3/32") thick and may be used to roughly gage this operation. Use C lutch H ub H older J 25030 or J 9403 to hold Clutch Plate and H ub if necessary. 6. Using Thin-W all Socket J 9399 and C lutch H ub H older J 25030 or J 9403 to install a new shaft locknut. Tighten the nut to 19 to 35 N -m (14-26 lb.ft.) torque. A ir gap between the frictional faces should now be .6 to 1.4mm (.022" to .057") (Fig. ID - 8). If not, check for mispositioned key or shaft.

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

ID -5

N O T IC E : It is im portant that Puller Pilot J 9395 be used to prevent internal dam age to com pressor when removing pulley. U nder no circum stances should puller be used directly against threaded end of shaft.

5. Remove Pulley and Bearing Assembly, using Pulley Puller J 8433 (Fig. ID-10).

7. The pulley should now rotate freely. 8. O perate the refrigeration system in the M A X A /C control selector (mode) lever position and warm engine (off fast idle) speed at 2000 R PM . Rapidly cycle the com pressor clutch by turning the A /C control selector (mode) lever from O FF-to-M A X at least 15 times at approxim ately one second intervals to burnish the m ating parts of the clutch.

A-6 C O M P R E SS O R PULLEY A N D BEARING A S SE M B L Y


Remove
1. Remove Clutch Plate and H ub assembly as described in A -6 Com pressor Clutch Plate and H ub A sm . Removal procedure. 2. Remove pulley retainer ring, using Snap-Ring Pliers J 6435, Fig. ID-9. 3. Pry out absorbent sleeve retainer, and remove absorbent sleeve from com pressor neck. 4. Place Puller Pilot J 9395 over end of com pressor shaft.

Inspection
Check the appearance of the Pulley and Bearing assembly (see Fig. ID -5). The frictional surfaces of the Pulley and Bearing assembly should be cleaned with trichloroethane, naphtha, Stoddard solvent, kerosene or equivalent solvent before reinstallation.

Replace
1. If original Pulley and Bearing assembly is to be reinstalled, wipe frictional surface of pulley clean. If frictional surface of pulley shows any indication of damage due to overheating, the Pulley and Bearing assembly should be replaced.

1 D -6 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
2. Check bearing for brinelling, excessive looseness, noise, and lubricant leakage. If any of these conditions exist, bearing should be replaced. See A -6 Com pressor Pulley Bearing Replacem ent procedure. 3. Press or tap Pulley and Bearing assembly on neck of compressor until it seats, using Pulley and Bearing Installer J 9481 with Universal H andle J 8092 (Fig. I D - 11). The Installer will apply force to inner race of bearing and prevent damage to bearing if tool is installed on handle as shown. 3. Remove pulley bearing retainer ring with a small screwdriver or pointed tool (Fig. ID - 12).
BEARING R E T A IN E R RING

BEARING

Fig. 1D-12 Removing A-6 Pulley and Bearing Retainer Ring

4. Place Pulley and Bearing assembly on inverted Support Block J 21352 and, using Pulley Bearing Remover J 9398 with Universal H andle J 8092, drive Bearing assembly out of pulley (Fig. ID - 13).

4. Check pulley for binding or roughness. Pulley should rotate freely. 5. Install retainer ring, using Snap Ring Pliers J 6435.

Replace
1. Install new bearing in pulley using Pulley and Bearing Installer J 9481 with Universal H andle J 8092 (Fig. ID -14). The Installer will apply the force to the outer race of the bearing when tool is used as shown.

6. Install absorbent sleeve retainer in neck of


compressor. Using sleeve from Seal Seat Rem over-Installer J 9393, install retainer so that outer edge is recessed . 8mm (1/32") from com pressor neck face. 7. Install C lutch Plate and H ub assembly as described in A -6 C om pressor C lutch Plate and H ub A sm . Replacem ent procedure.

A-6 C OM P R E SS O R PULLEY BEARING


Remove
1. Remove Clutch Plate and H ub assembly as described in A -6 Com pressor C lutch Plate and H ub A sm . Removal procedure. 2. Remove Pulley and Bearing assembly as described in A -6 Com pressor Pulley and Bearing A sm . Removal procedure.

N O T I C E : D o not clean new bearing assembly with any type of solvent. Bearing is supplied with correct lubricant when assembled and requires no other lubricant at any time.

2. Install bearing retainer ring, making certain that it is properly seated in ring groove. 3. Install Pulley and Bearing assembly as described in A -6 Com pressor Pulley and Bearing A sm . Replacem ent procedure.

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1D -7

Fig. 1D-14 Installing Bearing on A-6 Pulley

4. Install Clutch Plate and H ub assembly as described in A -6 Compressor Clutch Plate and H ub A sm . Replacem ent procedure.

A-6 C O M P R E SS O R CLUTCH COIL A N D H O U S IN G A S SE M B L Y


Rem ove 1. Remove Clutch Plate and H ub assembly as described in Com pressor C lutch Plate and H ub A sm . Removal procedure. 2. Remove Pulley and Bearing assembly as described in A -6 Com pressor P rlley and Bearing A sm . Removal procedure. N ote position of term inals on coil housing and scribe location on com pressor front head casting. 3. Remove coil housing retaining ring, using Snap-Ring Pliers J 6435 (Fig. ID -15). 4. Lift Coil and Housing assembly off com pressor front head. Replace 1. Position coil and housing assembly on com pressor 5. Install Clutch Plate and H ub assembly as described front head casting so that electrical term inals line up with in A -6 Com pressor Clutch Plate and H ub A sm . m arks previously scribed on com pressor (Fig. ID - 16). Replacem ent procedure.

2. Align locating extrusions on coil housing with holes in front head casting. 3. Install coil housing retainer ring with flat side of ring facing coil, using Snap-Ring Pliers J 6435. 4. Install Pulley and Bearing assembly as described in A -6 Com pressor Pulley and Bearing A sm . Replacement procedure.

1 D -8 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

M A J O R A - 6 C O M P R E S S O R R E P A IR P R O C E D U R E S
Service repair procedures to the Compressor Shaft Seal, Pressure Relief Valve, or disassembly of the Internal Compressor Cylinder and Shaft Assembly are considered "MAJOR" SINCE THE REFRIGERATION SYSTEM MUST BE COMPLETELY PURGED OF REFRIGERANT before proceeding and/or because major internal operating and sealing components of the compressor are being disassembled and serviced. Should an A -6 compressor, its com pressor shaft seal, or any other com ponent ever be removed for servicing because it was determ ined to be the cause of excessive signs of oil leakage in the A -6 A /C system, then the oil in the compressor m ust be drained, measured and replaced according to C.C.O.T. Refrigerant Oil D istribution in the A ir Conditioning section to determ ine oil loss. The accum ulator in this A -6 system must then also be removed - oil drained - measured, etc. according to same section. W hen replacing the shaft seal assembly (Fig. ID -17), pressure relief valve (Fig. ID-23), even if the com pressor remains on the vehicle during the operation, it will be necessary to purge the system of refrigerant as outlined in the A ir Conditioning section (see Discharging, Adding Oil, Evacuating and Charging Procedures for C.C.O.T. A /C Systems). The same holds true for any disassembly of the internal A -6 compressor cylinder and shaft assembly. If the A -6 Com pressor Internal Cylinder and Shaft Assembly is to be serviced or replaced, then the oil in the compressor m ust be drained, m easured and replaced according to C.C.O.T. Refrigerant Oil D istribution in the A ir Conditioning section to determ ine addition of proper oil quantity to new assembly. A clean workbench, preferably covered with a sheet of clean paper, orderliness in the work area and a place for all parts being removed and replaced is of great im portance, as is the use of the proper, clean service tools. Any attem pt to use make-shift or inadequate equipm ent may result in damage a n d /o r im proper com pressor operation. These procedures are based on the use of the proper service tools and the condition that an adequate stock of service parts is available. All parts required for servicing the internal com pressor are protected by a preservation process and packaged in a m anner which will eliminate the necessity of cleaning, washing or flushing of the parts. The parts can be used in the internal assembly just as they are removed from the service package. Piston shoe discs and shaft thrust races will be identified by num ber on the parts themselves for reference to determ ine their size and dimension (see Fig. ID-41). SH O U LD A N A -6 C O M PRESSO R SH A FT SEAL EV ER H A V E TO BE R E PL A C E D BECAUSE IT WAS D E T E R M IN E D TO BE THE CAUSE OF EXCESSIVE SIGNS OF OIL LEAKAGE IN T H E A /C SYSTEM, T H E N T H E O IL IN T H E A -6 C O M PRESSO R M UST BE D R A IN E D , m easured and replaced according to C.C.O.T. Refrigerant Oil D istribution in the A IR C O N D IT IO N IN G section to determ ine oil loss. T H E A C C U M U L A T O R IN TH IS A -6 SYSTEM MUST T H E N ALSO be removed - oil drained - measured, etc. according to same section.

SPECIFICATIO N PARTS SEAL CARBON M A T E R IA L LARGE CHAMFER ON INSIDE D IA M E T E R . CERAM IC M A T E R IA L WITH POLISHED FACE. N EO PRENE,THUS CAPABLE OF G IV IN G HEAT RESISTANCE AN D LIF E EXPECTANCY.

SEAT

O-RINGS

Fig. 1D-17 Specification A-6 and R-4 Compressor Shaft Seal Kit

Remove
1. D ischarge the Refrigerant System according to the discharging, adding oil, evacuating and charging procedures for C.C.O.T. A /C systems in the A ir Conditioning section. 2. Remove the clutch plate and hub assembly and shaft key as described in A -6 Com pressor Clutch Plate and H ub A sm . removal procedure. 3. Pry out the sleeve retainer and remove the absorbent sleeve. Remove the shaft seal seat retaining ring, using SnapRing Pliers J 5403. See Fig. ID -18. 4. Thoroughly clean inside of com pressor neck area surrounding the shaft, the exposed portion of the seal seat and the shaft itself. This is absolutely necessary to prevent any dirt or foreign material from getting into compressor. 5. Place Seal Protector J 22974 over the end of the shaft to prevent chipping the ceramic seat. Fully engage the knurled tangs of Seal Seat Rem over-Installer J 23128 into the recessed portion of the seal seat by turning the handle clockwise. Remove the Seal Seat from the compressor with a rotary-pulling motion (Fig. ID -19). D iscard the Seat. Do not tighten the handle with a wrench or pliers; however, the handle must be hand-tightened securely to remove the Seat.

A-6 C OM P R E SS O R SH A FT SEAL
SEAL LEAK D E TE C TIO N A SHAFT SEAL SHOULD NOT BE CHANGED BECAUSE OF AN OIL-LINE ON THE HOOD INSULATOR. The Seal is designed to seep some oil for lubrication purposes. Only change a Shaft Seal when a leak is detected by evidence of oil sprayed in LARGE AMOUNTS and then only after actual refrigerant leakage is determined by testing with a Leak Detector J 23400.

6. W ith Seal Protector J 22974 still over the end of the shaft, set Seal Rem over-Installer J 9392 down over shaft

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -9

O -R IN G IN S T A L L E R J -2 1 5 0 8

Retaining Ring

Fig. 1D-20 Replacing A-6 Seal and O-Ring

Inspection
Seals should not be reused. Always use a new seal kit on rebuild (see Fig. ID - 17). Be extremely careful that the face of the Seal to be installed is not scratched or damaged in any way. M ake sure th at the Seal Seat and Seal are free of lint and dirt that could damage the seal surface or prevent sealing.

Replace
1. Coat the new seal seat O-ring in clean 525 viscosity refrigerant oil and assemble onto O-Ring Installer J 21508 (see Fig. IB-20). 2. Insert the O-Ring Installer J 21508 completely down into the com pressor neck until the Installer bottom s. Lower the movable slide of the O-Ring Installer to release the O-ring into the seal seat O-ring lower groove. (The com pressor neck top groove is for the shaft seal seal retainer ring.) R otate the Installer to seat the O-ring and remove Installer (See Fig. ID-21). 3. D ip the O-ring and seal face of the new Seal assembly into clean 525 viscosity refrigerant oil. Carefully m ount the Seal assembly to Seal Installer J 9392 by engaging the tabs of the Seal with the tangs of the Installer (Fig. ID-20). 4. Place Seal Protector J 22974 (Fig. ID-20) over end of com pressor shaft and carefully slide the new Seal assembly down onto the shaft. G ently twist the Installer J 9392 C LO CK -W ISE, while pushing the seal assembly down the shaft until the Seal assembly engages the flats on the shaft and is seated in place. Disengage the Installer by pressing dow nw ard and twisting counter-clockwise.

end, turning clockwise, while pressing down, to engage Rem over tangs with the tabs on the Seal assembly. Then lift the Shaft Seal assembly out (see Fig. ID-20). Discard the Seal. 7. Remove and discard the seal seat O-ring from the com pressor neck, using O-Ring Rem over J 9533 (see Fig. I D -19).

8. Recheck the shaft and inside o f the com pressor neck for dirt or foreign m aterial and be sure these areas are perfectly clean before installing new parts.

ID -1 0

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

'/^(APPROX.)
S T R A IG H T E D G E W IR E GAUG E . 0 2 6 SH O U LD "GO" . 0 7 5 S H O U L D "N O T GO* OR SH O U LD '*JUST GO4 ABSORBENT S L E E V E S L E E V E R E TA IN E R S E A L SEAT R E T A IN E R R IN G SEAT R IN G

S E A L A SSEM B LY

or sim ilar instrum ent, carefully spread the sleeve until the ends of the sleeve butt at the top vertical centerline. 10. Position the new metal sleeve retainer so th at its flange face will be against the front end of the sleeve. The sleeve from seal seat remove installer tool J 9393 may be used to install the retainer. Press and tap with a mallet, setting the retainer and sleeve into place (retainer should be recessed approxim ately . 8mm (1 /3 2 ") from the face of the com pressor neck). (See Fig. ID-21.) 11. Reinstall the Clutch Plate and H ub assembly as described in A -6 Com pressor C lutch Plate and H ub A sm . Replacem ent procedure. Some com pressor shaft seal leaks may be the result of m ispositioning of the axial plate on the compressor shaft. The mispositioning of the axial plate may be caused by im proper procedures used during pulley and driven plate removal, pounding, collisions or dropping the compressor. If the axial plate is mispositioned, the carbon face of the shaft seal assembly may not contact the seal seat and the rear thrust races and bearing may be damaged. To check for proper positioning of the axial plate on the shaft, remove the clutch driven plate and measure the distance between the front head extension and the flat shoulder on the shaft as shown in Fig. ID-21. To measure this distance, use a wire gage (the clearance should be between .7 and 1.9mm (.026" and .075")). If the shaft has been pushed back in the axial plate (measurem ent greater than 1.9mm (.075")), disassemble the com pressor and replace the shaft and axial plate assembly rear thrust races and thrust bearing. If there also appears to be too m uch or insufficient air gap between the drive and driven plates, dislocation of the shaft should be suspected. If the carbon seal is not seating against the seal seat, it will not be possible to completely Evacuate the System as outlined under discharging, adding oil, evacuating and charging procedures for C.C.O.T. A /C systems in the A ir Conditioning section. 12. A dd Oil, Evacuate and Charge System (see discharging, adding oil, evacuating and charging procedures for C.C.O.T. A /C systems in the air conditioning section).

204983

Fig. 1D-21 A-6 Compressor Shaft and Seal

5. A ttach the ceramic Seal Seat to the Seal Seat Rem over and Installer J 23128 and dip the ceramic Seat in clean 525 viscosity refrigerant oil to coat the seal face and outer surface. Carefully install the Seat over the com pressor shaft end and Seal Protector J 22974 and push the Seat into place with a rotary motion. Take care not to dislodge the seat O-ring. However, be sure Seal Seat makes a good seal with O-ring. Remove Installer J 23128 and Seal P rotector J 22974 (Fig. I D - 19).

6. Install the new seal seat retainer ring with its flat side against the Seal Seat, using Snap-Ring Pliers J 5403. See Fig. ID -18. Use the sleeve from Seal Seat Rem over-Installer J 9393 to press in on the seal seat retainer ring so th at it snaps into its groove.
7. Install Com pressor Leak Test Fixture J 9625 (Fig. ID-22) on rear head of com pressor and connect gage charging lines or pressurize suction side (low-pressure side) of com pressor on vehicle with R efrigerant-12 vapor to equalize pressure to the drum pressure. Tem porarily install the shaft nut and, with com pressor in horizontal position and oil sum p down, rotate the com pressor shaft in norm al direction of rotation several times by hand then leak test the Seal. Correct any leak found. Remove, discard and later replace the shaft nut.

8. Remove any excess oil, resulting from installing the new seal parts, from the shaft and inside the com pressor neck.
9. Install the new absorbent sleeve by rolling the m aterial into a cylinder, overlapping the ends, and then slipping the sleeve into the com pressor neck with the overlap tow ards the top of the compressor. W ith a small screwdriver

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -1 1

A-6 C OM P R E SS O R PRESSURE RELIEF VALVE


W hen necessary to replace the Pressure Relief Valve located in the com pressor rear head casting (Fig. ID-23), the valve assembly should be removed after purging the system o f refrigerant. A new valve and O-ring coated with 525 viscosity refrigerant oil should be installed (see discharging, adding oil, evacuating and charging procedures for C.C.O.T. A /C systems in the air conditioning section).

oil drain plug down. Record the am ount of oil drained from the com pressor (See C.C.O.T. Refrigerant Oil D istribution in the A ir Conditioning section). 3. Invert com pressor and Holding Fixture J 9396, with front end of com pressor shaft up, suction - discharge ports now facing downw ard (Fig. ID-24).

A-6 C O M PR ESSO R INTER N A L M E C H A N IS M (CYLINDER A N D S H A F T A S M .)


Service operations to the A -6 com pressor R ear Head or Internal M echanism (Cylinder and Shaft) of the com pressor should be perform ed with the system purged of refrigerant according to the discharging, adding oil, evacuating and charging procedures for C.C.O.T. A /C systems in the A ir Conditioning section. The com pressor m ust also be removed from the vehicle to insure that the necessary degree of cleanliness may be maintained. Additionally, Com pressor C lutch Plate and Hub, Pulley and Bearing, Clutch Coil and Housing and Shaft Seal Removal procedures, as described earlier in the O V E R H A U L section, all are to have been followed. Clean hands, clean tools and a clean bench, preferably covered with clean paper, are of extrem e im portance. An inspection should be made of the Internal M echanism (Cylinder and Shaft) assembly to determ ine if any service operations should be performed. A detailed inspection of parts should be m ade to determ ine if it is necessary to replace them.

A dditional oil may drain from the com pressor at this time. All oil must be drained into a container so that total am ount can be measured. (SEE STEP 2 ABOVE.) A liquid measuring cup may be used for this purpose. D rained oil should then be discarded. 4. Remove four locknuts from threaded studs on com pressor shell and remove rear head. Tap uniformly around rear head if head is binding (Fig. ID-24). 5. Wipe excess oil from all sealing surfaces on rear head casting webs, and examine sealing surfaces (Fig. ID-25). If any damage is observed, the R ear Head should be replaced.

SUCTION SCEEN

SE ALIN G SURFACES REAR HEAD y S H E LL TO ------ " O RING HEAD

O IL PUMP ROTORS

Removal
Fig. 1D-25 A-6 Rear Head Removal

1. Before proceeding with disassembly, wipe exterior surface of compressor clean. 2. All oil in com pressor should be drained and measured. Assist draining by positioning com pressor with

6. Remove Suction Screen and examine for any damage or contam ination. Clean or replace if necessary.

1 D -1 2 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
7. M ake an identifying m ark on exposed face of inner and outer Oil Pum p G ears and then remove gears. Identifying m arks are to assure that gears, if re-used, will be installed in identical position. 8. Remove and discard rear head to shell O-ring. 9. Carefully remove R ear Discharge Valve Plate assembly. Use two small screwdrivers under reed retainers to pry up on assembly (Fig. ID-26). Do not position screwdrivers between reeds and reed seats.
O IL PICK-UP TUBE REMOVER J-5139 O IL PICK-UP TUBE

Fig. 1D-28 Removing A-6 Oil Pick-Up Tube

15. Lift F ront Head and Com pressor Shell Assembly up, leaving Internal Cylinder and Shaft Assembly resting on Internal Assembly Support Block.
N O T IC E : To prevent damage to shaft, DO N O T T A P O N E N D O F C O M PRESSO R SH A FT to remove Internal Cylinder and Shaft Assembly. If Internal Assembly will not slide out of com pressor shell, tap on F ront H ead with a plastic ham m er.

Fig. 1D-26 Removing A-6 Rear Discharge Valve Plate

10. Exam ine Valve Reeds and Seats. Replace entire assembly if any reeds or seats are damaged. 11. Using two small screwdrivers, carefully remove R ear Suction Reed (Fig. ID-27). Do not pry up on horseshoe-shaped reed valves.

16. Rest com pressor shell on its side and push Front H ead assembly through Com pressor Shell, being careful not to damage sealing areas on inner side of front head. Discard O-ring. It may be necessary to tap on outside of front head, using a plastic ham m er, to overcome friction of O-ring seal between front head and compressor shell. 17. W ipe excess oil from sealing surfaces on front head casting webs and examine sealing surface. If any surface damage is observed, the head should be replaced. 18. Remove F ront Discharge Valve Plate assembly and F ront Suction Reed Plate. Examine reeds and seats. Replace necessary parts. 19. Remove Suction Cross-Over Cover by prying with screw driver between cylinder casting and cover (Fig. 1D29).

12. Examine reeds for damage, and replace if necessary. 13. Using Oil Pick-Up Tube Rem over J 5139 (Fig. 1D28), remove Oil Pick-U p Tube. Remove O-ring from oil inlet. 14. Loosen com pressor from Holding Fixture J 9396, place Internal Cylinder and Shaft Assembly Support Block J 21352 over oil pum p end of shaft and, while holding Support Block in position with one hand, lift com pressor from Holding Fixture with other hand. Invert com pressor (shaft will now be facing upw ard) and position on bench with Internal Assembly Support Block resting on bench.

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
20. Examine Internal Cylinder and Shaft Assembly for any obvious damage. If Internal Assembly has sustained m ajor damage, due to loss of refrigerant or oil, it may be necessary to use the Service Internal Cylinder and Shaft Assembly rather than replace individual parts.

1 D -1 3

A-6 CO M PR ESSO R INTERNAL CYLINDER A N D SH A FT A S M Disassembly


Use Parts Tray J 9402 (Fig. ID-33) to retain com pressor parts during disassembly. 1. Remove Internal Cylinder and Shaft Assembly from com pressor as described in A -6 Com pressor Internal M echanism (Cylinder and Shaft A sm .) Removal procedure. 2. Identify by pencil m ark, or some other suitable means, each piston num bering them as 1, 2 and 3 (Fig. 1D30).

Fig. 1D-31 Separating A-6 Cylinder Halves

. Inspect the Teflon piston rings for nicks, cuts or metal particles imbedded in exposed ring surface and replace the piston rings as required if either condition exists. See A -6 Teflon Piston R ing Replacement procedure. . Remove and discard the piston shoe discs. 7. Remove and examine piston balls, and if satisfactory for re-use, place balls in No. 1 com partm ent of Parts Tray J 9402 (Fig. ID-33). 8. Place piston in No. 1 com partm ent of Parts Tray J 9402, with notch in casting web at front end of piston (Fig. ID -32) into the dimpled groove of Parts Tray com partm ent.

N um ber the piston bores in the front cylinder half in like m anner, so that pistons can be replaced in their original locations. 3. Separate cylinder halves, using a wood block and m allet (Fig. ID-31). M ake certain th at discharge cross-over tube does not contact axial plate when separating cylinder halves (a new Service Discharge Cross-Over Tube will be installed later - see Step 5 of Internal Cylinder and Shaft Assembly procedure).
N O T IC E : UNDER NO C IR C U M STA N C ES SH O U LD SH A FT BE ST R U C K A T E IT H E R EN D in an effort to separate upper and lower cylinder halves because the shaft and the axial plate could be damaged.

9. Repeat Steps 5 through 9 for Pistons No. 2 and No. 3. 10. Remove rear com bination of thrust races and thrust bearing from shaft. D iscard races and bearing. 11. Remove shaft assembly from front cylinder half. If the Discharge Cross-Over Tube remained in the front cylinder half, it may be necessary to bend discharge cross over tube slightly in order to remove shaft.

4. Carefully remove the R ear H alf of the cylinder from the pistons and set the F ront Cylinder Haif, with the piston, shaft and axial plate in Com pressing Fixture J 9397. 5. Pull up on com pressor shaft and remove piston previously identified as No. 1, with balls and shoe discs, from axial plate.

1 D -1 4 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
with bearing identification m arks up. Use Needle Bearing Installer J 9432 and drive bearing into cylinder head (Fig. ID-35 until Installer bottom s on the cylinder face. Two different width needle bearings are used in Production compressors - a 13mm (1 /2 ") size and a 16mm (5 /8 ") size. The bearings are interchangeable. Service replacement bearings are all 12.7mm (1/2").

12. Remove front com bination of thrust races and bearing from shaft. D iscard races and bearing (Fig. ID-34).

13. Exam ine surface of Axial Plate and Shaft. Replace as an assembly, if necessary. A certain am ount of shoe disc wear on axial plate is norm al, as well as some markings indicating load of needle bearings on shaft. 14. Remove Discharge Cross-Over Tube from cylinder half, using self-clamping pliers. This is necessary only on original factory equipment, as ends of the tube are swedged into cylinder halves. The discharge cross-over tube in Internal C ylinder and Shaft Assemblies that have been previously serviced have an Oring and bushing at each end of the tube, and can be easily removed by hand (see Fig. ID-53). 15. Exam ine piston bores and needle bearings in front and rear cylinder halves. Replace front and rear cylinders if any cylinder bore is deeply scored or damaged. 16. Needle bearings may be removed if necessary by driving them out with special Thin-W all Socket J 9399. Insert socket in hub end (inner side) of cylinder head and drive bearing out. To install needle bearing, place cylinder half on Support Block J 21352, and insert bearing in end o f cylinder head

17. W ash all parts to be re-used with trichloroethane, naphtha, Stoddard solvent, kerosene, or a similar solvent. A ir-dry parts using a source of clean, dry air. A -6 com pressor internal com ponents may be identified by referring to Fig. ID-2.

A-6 C O M R E S SO R IN TER N A L C YLINDER A N D SH A FT A S M Gaging Operation


1. Install Compressing Fixture J 9397 on Holding Fixture J 9396 in vise. Place front cylinder half in Compressing Fixture, flat side down. F ront cylinder half has long slot extending out from shaft hole. Legs of front cylinder half will be pointed upward. 2. Secure from Service parts stock four zero thrust races, two thrust bearings and three zero shoe discs. 3. Now install a zero thrust race, then one thrust bearing, and a second zero thrust race onto front end of com pressor shaft. 4. Insert threaded end of axial shaft through needle bearing in front cylinder half, and allow thrust race and bearing assembly (race-bearing-race) to rest on hub of cylinder.

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -1 5

5. Now install a zero thru st race on rear end of 8. R otate shaft and axial plate until high point of axial com pressor axial shaft (Fig. ID-36), so that it rests on hub plate is over the No. 1 Piston cylinder bore. of axial plate. Then add one thrust bearing and a second zero 9. Lift the axial shaft assembly up a little out of front thru st race onto shaft. cylinder half and hold front thrust race and bearing A t this point, both front end and rear end of axial shaft assembly ( zero race-bearing- zero race) against axial will have a stack-up of one zero race-one bearing-one zero plate hub. race. 10. Position No. 1 Piston over No. 1 cylinder bore (notched end of piston being on bottom and piston straddling axial plate) and lower the shaft to allow No. 1 Piston to drop into its bore (Fig. ID-38). If ball and shoe THRUST BEARING will not remain in front socket of piston during assembly use a light sm ear of petrolatum on the piston and shoe ball socket surfaces.
THR UST RACE COMPRESSING F IX TU R E J-9397 HO LD IN G F IX T U R E J-9396 REAR NEEDLE THRUST BEARING AND "Z E R O "T H R U S T RACES PISTON D R IV E B A L L O N LY A T REAR

FRONT C Y LIN D E R H A LF

Fig. 1D-36 Installing A-6 Rear Thrust Races and Bearings

6. Lubricate ball pockets of the No. 1 Piston with 525 viscosity refrigerant oil and place a ball in each socket. Use balls previously removed if they were considered acceptable for re-use. 7. Lubricate cavity of a zero shoe disc with 525 viscosity refrigerant oil and place shoe disc over ball in front end of piston (Fig. ID-37). F ront end of piston has an identifying notch in casting web (Fig. ID-32).

FRONT C Y LIN D E R

B A L L AN D "Z E R O "S H O E DISC A T FRO NT

Fig. 1D-38 Installing A-6 Piston During Gaging Operation

NOTICE: Exercise care in handling the Piston and Ring Assembly, particularly during assembly into and removal from the cylinder bores to prevent damage to the Teflon piston rings.
Shoe discs should not be installed on rear of piston during following G aging operation.

11. Repeat Steps 6 through 10 for Pistons No. 2 and No. 3. 12. Now install rear cylinder half onto pistons, aligning cylinder with discharge cross-over tube hole in front cylinder half. Tap into place using a plastic m allet or piece of clean wood and ham m er (Fig. ID-39). 13. Position discharge cross-over tube opening between a pair of Compressing Fixture J 9397 bolts to perm it access for feeler gage. 14. Install top plate on Compressing Fixture J 9397. Tighten nuts to 20 N m (15 lb. ft.) torque using a 0-60 N m (0-25 lb.ft.) torque wrench.

Gaging Procedure (Steps 15 thru 18)


The gaging operations which follow have been worked out on a simple basis to establish and provide necessary running tolerances. Two gaging procedures are necessary. The first is made to choose the proper size shoe discs to provide, at each piston, a .04 to .06mm (.0016" to .0024") total preload between the seats and the axial plate at the tightest place through the 360-degree rotation of the axial plate. The bronze shoe discs are provided in .01mm (.0005") variations, including a basic Z E R O shoe. The second, perform ed at the rear shaft thrust race and bearing stack-up, is designed to obtain .06 to .08mm (.0025" to .0030") preload between the hub surfaces of the axial plate and the front and rear hubs of the cylinder. A total

1 D -1 6 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

of 14 steel thrust races, including a basic Z E R O race, are provided in increm ents of .01mm (.0005") thickness to provide the required fit. Feeler and Tension Gage Set J 9564-01 or J 9661-01 may be used for gaging proper shoe disc size. Feeler Gage Set J 9564-01 or D ial Indicator Set J 8001 may be used to determ ine proper thrust race size. P roper selection of thru st races and ball seats is of extreme importance. 15. M easure clearance between rear ball of No. 1 Piston and axial plate, in following manner: a. Select a suitable combination of well-oiled Feeler Gage leaves to fit snugly between ball and axial plate. b. A ttach Tension Gage J 9661-3 to the feeler gage. A distributor point checking scale or Spring Scale J 544 may be used. c. Pull on Spring Scale to slide Feeler Gage stock out from between ball and axial plate, and note reading on Spring Scale as Feeler Gage is removed (Fig. ID-40). Reading should be between 4 and 8 ounces. d. If reading in Step c above is under 4 O R over 8 ounces, reduce or increase thickness of Feeler Gage leaves and repeat Steps a. through c. above until a reading of 4 to 8 ounces is obtained. Record the clearance between ball and axial plate that results in the desired 4 to 8 ounce pull on Spring Scale. 16. Now rotate shaft 120 and repeat Step 15 between this same No. 1 Piston R ear Ball and axial plate. Record this measurem ent. If shaft is hard to rotate, install shaft nut onto shaft and turn shaft with wrench.

17. R otate shaft an o th e r 12(P and again rep e at Step 15 betw een th ese sam e p arts and rec o rd m easurem ents. 18. Select a num bered shoe disc corresponding to m inim um feeler gage reading recorded in the three checks just made above. (See example in Fig. ID-42). Place the selected shoe discs in Parts Tray J 9402 com partm ent corresponding to Piston No. 1 and Rear Ball pocket position. Shoe discs are provided in .01mm (.0005") (one-half thousandths) variations. There are a total of 11 sizes available for field servicing. All shoe discs are marked with the shoe size, which corresponds to the last three digits of the piece part number. (See Shoe Disc Size C hart in Fig. ID-41.) Once a proper selection of the shoe has been made, the m atched com bination of shoe disc to rear ball and spherical cavity in piston m ust be kept in proper relationship during disassembly after Gaging operation, and during final assembly into the Internal Cylinder and Shaft Assembly. 19. Repeat in detail the same Gaging Procedure outlined in Steps 15 through 18 for Piston No. 2 and No. 3. 20A. M ount Dial Indicator J 8001 on edge of Compressing Fixture J 9397 with Clam p J 8001-1 and Sleeve J 8001-2 (Fig. ID-43). Position Dial Indicator on rear end of axial shaft and adjust to zero. From bottom , apply full hand-force at end of shaft a few times before reading clearance. This will help squeeze the oil out from /betw een m ating parts. Now push upw ard again and record measurement. Dial Indicator increments are .03mm (.001"); therefore, reading m ust be estimated to nearest .01mm (.0005".).

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -1 7

SHOE DISC PART NO. ENDING IN 000 175 180 185 190 195 200 205 210 215 220 ID E N T IF IC A T IO N STAMP 0 17-1/2 18 18-1/2 19 19-1/2 20 20-1/2 21 21-1/2 22 M IN .F E E L E R GAGE READING .0000 .0175 .0180 .0185 .0190 .0195 .0200 .0205 .0210 .0215 .0220 PART NO. ENDING IN 000 050 055 060 065 070 075 080 085 090 095 100 105 110 115 120

THRUST BEARING RACE ID E N TIFIC A TIO N STAMP 0 5 5-1/2 6 6-1/2 7 7-1/2 8 8-1/2 9 9-1/2 10 10-1/2 11 11-1/2 12 D IA L INDICATOR READING .0000 .0050 .0055 .0060 .0065 .0070 .0075 .0080 .0085 .0090 .0095 .0100 .0105 .0110 .0115 .0120
200913

Fig. 1D-41 Available A-6 Service Shoes and Thrust Races

P O S IT IO N 1 P IS T O N N O . 1 P IS T O N N O . 2 P IS T O N N O . 3 .0 1 9 " .0 2 0 " .0 2 1 "

P O S IT IO N 2 .0 1 9 5 " .0 2 0 " .0 2 1 "

P O S IT IO N 3 .0 1 9 " .0 2 0 " .0 2 2 "

SELECT A N D U SE SHOE N O . 19 20 21

200914

Fig. 1D-42 Selection of Proper A-6 Shoe Disc

20B. An alternate m ethod of selecting a proper race is to use Gage Set J 9661-01 selecting a suitable feeler gage leaf until the result is a 4 to 8 ounce pull on the scale between the rear thrust bearing and upper (which also happens to be the outer rear) thrust race (Fig. ID-44). If the pull is just less than 4 ounces, add .01mm (.0005") to the thickness of the feeler stock used to m easure the clearance. If the pull on the scale reads just over 8 ounces, then subtract .01 mm (.0005") from the thickness of the feeler stock. 21. F o r either m ethod used, select a thrust race with a num ber corresponding to two ( 2) full sizes larger than D ial Indicator or Feeler Gage m easurem ent of the am ount of end play shown. (If m easurem ent is .17mm (.007"), select a N o.9 or 090 race.) Place thru st race in right-hand slot at bottom center of parts tray J 9402.

Fig. 1D-43 Gaging A-6 Rear Thrust Race

ID -1 8

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
4. Install a Teflon ring on the Ring Installer G uide J 24605-2 as shown in Fig. ID-47, with the dished or dull-side down and glossy-side up. 5. Push the Ring Installer J 24608-5 down over the Installer G uide J 24608-2 to install the Teflon ring in the piston ring groove (Fig. ID-47). If the Teflon ring is slightly off position in the ring groove, it can be positioned into place by fingernail or blunt-edged tool th at will not damage the piston. The Ring Installer J 24608-5 will retain the Installer Guide J 24608-2 internally when the Teflon ring is installed on the piston. Remove the Installer G uide from the Ring Installer and do not store the installer guide in the ring installer, as the Ring Installer Segment Retainer O-Ring J 24608-3 will be stretched and possibly weakened during storage. This could result in the O-Ring J 24608-3 not holding the Ring Installer segments tight enough to the Installer G uide J 24608-2 to properly install the Teflon ring on the piston. 6. Lubricate the piston ring area with 525 viscosity refrigerant oil and rotate the Piston and Ring Assembly into the Ring Sizer J 24608-6 at a slight angle (Fig. ID-48). R otate the piston, while pushing inward, until the piston is inserted against the center stop of the Ring Sizer J 23608-6.
N O T IC E : DO N O T push the Piston and Ring Assembly into the Ring Sizer J 24608-6 w ithout proper positioning and rotating as described above, as the ends of the needle bearings of the Ring Sizer may damage the end of the piston.

CHECKING FOR REAR D TH RUST ^ AND RACE THICKNESS

FR O N T T H R U S T GIVES PROPER HEAD C LEAR AN C E

ru-i CHECKING FOR SHOE THICKNESS X

204980 Fig. 1D-44 Checking A-6 Piston and Shaft End Play

Fifteen (15) thrust races are provided in increm ents of .01 mm (.0005") (one-half thousandths) thickness and one ZER O gage thickness, providing a total of 16 sizes available for field service. The thrust race num ber also corresponds to the last three digits of the piece part number. See T hrust Race Size C hart in Fig. ID-41. 22. Remove nuts from top plate of Compressing Fixture J 9397, and remove top plate. 23. Separate cylinder halves while unit is in Fixture. It may be necessary to use a wooden block and mallet. 24. Remove R ear Cylinder H alf and carefully remove one piston at a tim e from axial plate and front cylinder half. D o not lose the relationship of the front ball and shoe disc and rear ball. Transfer each piston, ball and shoe disc to its proper place in Parts Tray J 9402. 25. Now remove rear outer zero thrust race (it will be on top) from shaft and install the thrust race just selected in Steps 20 and 21 that is presently setting in the right-hand slot at bottom center of Parts Tray J 9402. The removed zero thrust race may be put aside for re use in additional Gaging or rebuilding operations.

7. R otate the Piston and Ring Assembly in the Ring Sizer J 24608-6 several complete turns, until the Assembly rotates relatively free in the Ring Sizer (Fig. ID-48). 8. Remove the Piston and Ring Assembly, wipe the end of the piston and ring area with a clean cloth and then push the Piston and Ring Assembly into the Ring Gage J 24608-1 (Fig. ID-49). The piston should go through the Ring Gage with a 2 to 8 lb. force or less w ithout lubrication. If not, repeat Steps 6 and 7. 9. Repeat the procedure for the opposite end of the piston (Fig. ID-50).
N O T IC E : DO N O T lay the piston down on a dirty surface where dirt or metal chips might come into contact and become imbedded in the Teflon ring surface.

A-6 C O M P R E SS O R CYLINDER A N D S H AFT A SSE M B LY


A-6 Teflon Piston Ring Replacement
The Teflon piston ring installing, sizing and gaging tools are shown in Fig. ID-45. 1. Remove the old piston rings by carefully slicing through the ring with a knife or sharp instrum ent, holding the blade almost flat with the piston surface. Be careful not to damage the alum inum piston or piston groove in cutting to remove the ring. Exercise personal care in cutting the piston ring for removal to prevent injury. 2. Clean the piston and piston rin g grooves w ith trichloroe thane , naphtha, Stoddard solvent, kerosene o r equivalent solvent and b lo w the piston d ry w ith D R Y air. 3. Set the piston on-end on a clean, flat surface and install the Ring Installer G uide J 24608-2 on the end of the piston (Fig. ID-46).

10. Lubricate both ends of the piston with 525 viscosity refrigerant oil before inserting the piston into the cylinder bore.
N O T IC E : Reasonable care should be exercised in installing the piston into the cylinder bore to prevent damage to the Teflon ring.

A-6 C O M P R E SS O R IN TE R N A L CYLINDER A N D SH A FT A S M .
Assembly
A fter properly performing the Gaging Procedure, choosing the correct shoe discs and thrust races, and

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1D -19

J-24608-2
RING IN S T A L L E R G UIDE

J-24608-1 PISTON RING GAGE

Fig. 1D-45 A-6 Teflon Piston Ring Installing, Sizing and Gaging Tools
TEFLO N PISTON RING

IN S T A LLE R GUIDE

Fig. 1D-46 A-6 Teflon Piston Ring Positioned on Ring Installer Guide

Fig. 1D-47 Installing A-6 Teflon Piston Ring

installing any needed Teflon piston rings, the cylinder 2. A pply a light sm ear of petroleum jelly to the shoe assembly may now be reassembled. Be sure to install all new discs and piston ball sockets and install all balls and shoe seals and O-rings. All are included in the com pressor Odiscs in their proper place in the piston assembly. Ring Service Kit. 3. R otate the axial plate so that the high point is above Assembly procedure is as follows: cylinder bore No. 1. 1. Support the front half o f the cylinder assembly on a. Carefully assemble Piston No. 1, complete with ball Com pressing Fixture J 9397. Install the shaft and axial and zero shoe disc on the front and ball and num bered plate, threaded end down, with its front bearing race pack shoe disc on the rear, over the axial plate. (Z E R O race-bearing-ZERO race), if this was not already done at the end of the G aging Procedure. Install rear b. H old front thrust bearing pack tightly against axial bearing race pack (Z E R O race-bearing-N U M B ER ED plate hub while lifting shaft and axial plate to install piston race). asm.

ID -2 0

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

"S E L E C T E D " REAR SHOE DISC

"S E L E C T E D " REAR THRUST RACE

THR U ST BEARING "Z E R O " THRUST RACES L IF T SHAFT UPWARD AND HO LD THE T HRUST RACES AN D BEARING AG A IN S T HUB OF A X IA L PLATE.

Tool

"Z E R O "F R O N T SHOE DISC

THRUST BE AR IN G

Fig. 1D-51 Installing 1st A-6 Piston Assembly Into Front Cylinder Half

c. Insert the Piston Assembly into the Front Cylinder H alf (Fig. ID-51). 4. Repeat this operation for Pistons No. 2 and No. 3 (Fig. ID-52). 5. W ithout installing any O-rings or bushings, assemble one end of the new Service Discharge Cross-Over Tube into the hole in the front cylinder half (Figs. ID-53 and ID-54). Be sure the flattened portion of this tube faces the inside of the com pressor to allow for axial plate clearance (Fig. ID-54). 7. W hen all three Piston a rd Ring assemblies are in their respective cylinders, align the end of the discharge cross-over tube with the hole in the rear half of the cylinder.

6. Now rotate the shaft to position the pistons in a stair-step arrangem ent; then carefully place the R ear Cylinder H alf over the shaft and start the pistons into the cylinder bore (Fig. ID-55).

8. W hen all parts are in proper alignment, tap with a clean wooden block and mallet to seat the rear half of the cylinder over the locating dowel pins. If necessary, clamp the cylinder in Compressing Fixture J 9397, to complete drawing the cylinder halves together.
9. Generously lubricate all moving parts with clean 525 viscosity refrigerant oil and check for free rotation of the parts.

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1D -21

10. Replace the Suction Cross-Over Cover (Fig. 1D56). Com press the cover as shown to start it into the slot, and then press or carefully tap it in until flush on both ends.

A-6 C OM P R E SS O R IN TER N A L CYLINDER A N D S H A F T A S M


Re-Install
1. Place Internal Cylinder and Shaft Assembly on Internal Assembly Support Block J 21352,with rear-end of shaft in Support Block hole. 2. Now install new O-ring and bushing in front-end of discharge cross-over tube (Fig. ID-57). The O-ring and bushing are Service parts only for Internal Cylinder and Shaft Assemblies that have been disassembled in the field (Also see Fig. ID-53). 3. Install new dowel pins in front cylinder half, if previously removed. 4. Install F ront Suction Reed Plate on front cylinder half. Align with dowel pins, suction ports, oil return slot, and discharge cross-over tube (Fig. ID-58). 5. Install F ront Discharge Valve Plate assembly (it has a large diam eter hole in the center), aligning holes with dowel pins and proper openings in front suction reed plate (Fig. ID -59 and Fig. ID-60.)

6. Coat sealing surfaces on webs of com pressor front head casting with clean 525 viscosity refrigerant oil. 7. D eterm ine exact position of Front Head casting in relation to dowel pins on Internal Cylinder and Shaft Assembly. M ark position of dowel pins on sides of F ront Head assembly and on sides of Internal Cylinder and Shaft Assembly with a grease pencil. Carefully lower F ront Head casting into position (Fig. ID-61), making certain that sealing area around center bore of head assembly does not contact shaft as head assembly is lowered. D o not rotate head assembly to line up with dowel pins, as the sealing areas would then contact the reed retainers.

1 D -2 2 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

Fig. 1D-57 Installing O-Ring On A-6 Discharge Cross-Over Tube

Fig. 1D-58 Installing A-6 Front Suction Reed

Fig. 1D-59 Installing A-6 Front Discharge Valve Plate

8. Generously lubricate new O-ring and angled groove at lower edge of front head casting with 525 viscosity refrigerant oil and install new O-ring into groove (Fig. 1D62). 9. Coat inside machined surfaces of com pressor shell with 525 viscosity refrigerant oil and position shell on Internal Cylinder and Shaft Assembly, resting on J21352 support block. 10. Using flat-side of a small screwdriver, gently position O-ring in around circum ference of Internal Cylinder and Shaft Assembly until Com pressor Shell slides down over Internal Cylinder and Shaft Assembly. As shell

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -2 3

Fig. 1D-63 Installing A-6 Compressor Shell

slides down, line up oil sum p with oil intake tube hole (Fig. ID-63). 11. Holding Support Block J 21352 with one hand, invert Internal Cylinder and Shaft Assembly and place back into Holding Fixture J9396 with front end of shaft now facing downward. Remove Support Block. 12. Install new dowel pins in rear cylinder half, if previously removed. 13. Install new O-ring in oil pick-up tube cavity. 14. Lubricate Oil Pick-U p Tube with 525 viscosity refrigerant oil and install into cavity, rotating com pressor m echanism to align tube with hole in shell baffle (Fig. 1D64). 15. Now install new O-ring and bushing on rear-end of discharge cross-over tube (See Fig. ID-53). 16. Install R ear Suction Reed over dowel pins, with slot tow ards sump. 17. Install R ear Discharge Valve Plate assembly over dowel pins, with reed retainers UP. 18. Position Inner Oil Pum p G ear over shaft with previously applied identification m ark UP. 19. Position O uter Oil Pum p G ear over inner gear with previously applied identification m ark up and, when standing facing oil sump, position outer gear so that it meshes with inner gear at the 9-oclock position. The resulting cavity between gear teeth is then at 3-oclock position (Fig. ID-65). 20. Generously oil R ear D ischarge Valve Plate assembly with 525 viscosity refrigerant oil around outer edge where large diam eter O-ring will be placed. Oil the valve reeds, pum p gears, and area where sealing surface will contact R ear Discharge Valve Plate.

21. Using the 525 oil, lubricate new head to-shell O-ring and install on rear discharge valve plate, in contact with shell (Fig. ID - 66). 22. Install Suction Screen in rear head casting, using care not to damage screen. 23. Coat sealing surface on webs of com pressor rear head casting with 525 viscosity refrigerant oil. 24. Install R ear H ead assembly over studs on com pressor shell. The two lower threaded compressor m ounting holes should be in alignm ent with the compressor sump. M ake certain that suction screen does not drop out of place when lowering rear head into position (Fig. ID-67).

1 D -2 4 A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L
C A V IT Y BETWEEN

Fig. 1D-65 Positioning A-6 Oil Pump Gears

If R ear Head assembly will not slide down over dowels in Internal Cylinder and Shaft Assembly, twist Front Head assembly back-and-forth very slightly by-hand until R ear Head drops over dowel pins (Fig. ID-67). 25. Install nuts on threaded shell studs and tighten evenly to 34 N*m (25 lb. ft.) torque using a 0-60 N -m (0-50 lb. ft.) torque wrench. 26. Invert com pressor in Holding Fixture and install com pressor Shaft Seal as described in A -6 Com pressor Shaft Seal Replacem ent procedure. 27. Install com pressor C lutch Coil and Housing assembly as described in A -6 Com pressor C lutch Coil and Housing A sm . Replacement procedure. 28. Install com pressor Pulley and Bearing assembly as described in A -6 Com pressor Pulley and Bearing Replacem ent procedure. 29. Install com pressor C lutch Plate and H ub assembly as described in A -6 Com pressor Clutch Plate and H ub A sm . Replacem ent procedure. 30. A dd required am ount of 525 viscosity refrigerant oil (see C.C.O.T. Refrigerant Oil D istribution in the A ir Conditioning section). 31. Check for external and internal leaks as described in the following A -6 Com pressor Leak Testing procedure found at the end of this over-haul section. 32. Evacuate and charge the refrigerant system according to the Discharging, Adding Oil, Evacuating and Charging Prcoedures for C.C.O.T. A /C Systems in the A ir Conditioning section.

Fig. 1D-67 Installing A-6 Rear Head

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 D -2 5

12. Connect the Charging Station high pressure line or a high pressure gage and Gage Adapter J 5420 to the Test Plate J 9625 high side connector. B e n c h -C h e c k P ro c e d u re 13. Attach an Adapter J 5420 to the suction or low pressure port of the Test Plate J 9625 to open the schrader1. Install Test Plate J 9625 on Rear Head of type valve. compressor. Oil will drain out of the compressor suction port 2. Attach center hose of Manifold Gage Set on adapter if the compressor is positioned with the suction port Charging Station to a refrigerant drum standing in an downward. upright position and open valve on drum. 14. Attach the compressor to the J 9396 Holding 3. Connect Charging Station high and low pressure Fixture. Clamp the compressor Holding Fixture in a lines to corresponding fittings on Test Plate J 9625, using vise so that the compressor can be manually turned with a J 5420 Gage Adapters if hoses are not equipped with valve wrench. depressors. 15. Using a wrench, rotate the compressor crankshaft Suction port (low-side) o f compressor has large or drive plate hub 10-complete revolutions at a speed of internal opening. Discharge port (hi-side) has smaller approximately one-revolution per second. internal opening into compressor. Turning the compressor at less than one-revolution per 4. Open low pressure control, high pressure control and second can result in a lower pump-up pressure and refrigerant control on Charging Station to allow refrigerant disqualify a good pumping compressor. vapor to flow into compressor. 16. Observe the reading on HIGH pressure gage at the 5. Using a Leak Detector, check for leaks at Pressure completion of the tenth revolution of the compressor. The Relief Valve, compressor Shell to cylinder, compressor front pressure reading for a good pumping compressor should be head seal, and compressor Shaft Seal. After checking, shut off low pressure control and high pressure control on 413.7 kPa (60 P.S.I.) or above for the A-6 Charging Station. compressor. A pressure reading of less than 344.75 kPa (50 p.s.i.) for the A-6 would indicate one or more 6. If an external leak is present, perform the necessary suction and/or discharge valves leaking, an internal leak, corrective measures and recheck for leaks to make certain or an inoperative valve and the compressor should be the leak has been corrected. disassembled and checked for cause of leak. Repair as 7. Loosen the Manifold Gage hose connections to the needed, reassemble and repeat the pump-up test. Externally Gage Adapters J 5420 connected to the low and high sides leak test. and allow the vapor pressure to release from the compressor. 17. When the pressure pump-up test is completed, 8. Disconnect both Gage Adapters J 5420 from the Test release the air pressure from the HIGH side and remove the Plate J 9625. Gage Adapters J 5420 and Test Plate J 9625. 9. Rotate the complete compressor assembly (not the 18. Remove oil charge screw and drain the oil sump. crankshaft or drive plate hub) slowly several turns to distribute oil to all cylinder and piston areas. 19. Allow the compressor to drain for 10 minutes, then 10. Install a shaft nut on the compressor crankshaft if charge with the proper amount of oil. The oil may be poured the drive plate and clutch assembly are not installed. into the suction port. 11. Using a box-end wrench or socket and handle, If further assembly or processing is required, a shipping rotate the compressor crankshaft or clutch drive plate on plate or Test Plate J 9625 should be installed to keep out the crankshaft several turns to ensure piston assembly to air, dirt and moisture until the compressor is installed. cylinder wall lubrication.

A-6 C O M P R E SS O R LEAK TESTING (EXTERNAL A N D INTERNAL)

1 D -2 6

A IR C O N D IT IO N IN G C O M P R E S S O R O V E R H A U L

1 s
7 8

>

f .
10 11

I
12
17 15

o
19

d
25 26 27

l^ r l_J Uj iI Lli l J u g (i u q q y y o c y
G u

20

28

29
1

2. 3. 4. 5.

9.
10.

J 23500 J 24095 J 5453 J 8433 J 9395 J 9393-1 'J 9393-2 9 4 5 9 -----7/16' "J 25499 3 /8 "-J 5 4 2 0 ---- 7/16' "J 25498 3 /8 "J 23595 J 6271-01 J 5421-02

11.

Charqmg Station Oil Inducer Goqgles Puller Puller Pilot Seal Seat Remover + Installer 20 9 0 Gauge Line 24 Adapter - 2 0 Straight Gauge Line 24 Adapter Refrigerant Can Valve (Side-T ap) Refrigerant Can Valve (Top-Tap) Pocket Thermometers (2)

12. 13. 14. 15. 16. 17. 18. 19 20. 21. 22.

J 5403 J 6435 J 9396 J 9397 J 25030 J 9399 J 9401 J 9398 J 8092 J 21352 J5 1 3 9

No. 21 Snap Ring Pliers No. 26 Snap Ring Pliers Compressor Holding Fixture Compressing F ixture Clutch Hub Holding Too 9 /1 6 " Thin Wall Socket Hub and Drive Plate
A s s e m b ly In s ta lle r

23. 24. 25. 26. 27 28. 29.


30. 31. 32.

J 9432 Needle Bearing Installer J 9553-01 Seal Seat O " Ring Remover J 21508 Seal Seat " O " Ring Installer J 22974 Shaft Seal Protector J 9625 Pressure Test Connector J 9402 Parts Tray J 9480-01 Hub and Drive Plate
A sse m b ly R e m ove r J 9392 J 23128 J9481 Se al R e m o v e r i n s t a l l e r Se al S e a t R e m o v e r I n s ta lle r

Pulley Bearing Remover Handle Internal Assembly Support Block Oil Pickup Tube Remover

Pulley Bearing and Pulley Installer

200957

Fig. 1D-105 Special Tools, A/C Refrigerant System and A-6 Compressor

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1 D M

SECTION 1D1

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


F o r C o m p re s s o r R E M O V A L AND IN S T A L L A T IO N , see A ir C o n d itio n in g S ectio n . For D I S C H A R G I N G , A D D I N G O IL , E V A C U A T IN G A N D C H A R G I N G P R O C E D U R E S F O R C .C .O .T . A / C S Y S T E M S , see A ir C o n d itio n in g S ection.

CONTENTS
GENERAL DESCRIPTION ..................... SERVICE PROCEDURES
M in o r R -4 C o m p re sso r R e p a ir P ro c e d u re s .............................................................. R -4 C o m p re sso r C lu tc h R o to r a n d / o r B earin g - V -G ro o v e T yp e ............................................ R -4 C o m p re sso r C lu tc h R o to r a n d / o r B earin g - P o ly -G ro o v e T y p e ....................................... R -4 C o m p re s s o r C lu tc h C o il a n d / o r P u lle y R im ......................................................... R -4 C o m p re s s o r I n e rtia R in g I n s ta lla tio n ......................................................... ID I-i R e p la c e m e n t (O n C a r) ............................. C o m p re sso r S haft Seal R e p la c e m e n t (O ff C a r) ............................. C o m p re sso r P re ssu re R e lie f V a l v e ............... H i-S ide H ig h P re ssu re C u t-O ff S w itch ( I f U sed ) .............................................................. C o m p re sso r F ro n t H e a d a n d / o r O -R in g .................................................................. C o m p re sso r T h ru s t a n d B elleville W a sh e rs ................................................................ C o m p re sso r M a in B earin g ............................... C o m p re sso r Shell a n d / o r O -R in g s .............. C o m p re sso r D isc h a rg e V alve P la te a n d / o r R e ta in e r ............................................... C o m p re sso r C y lin d e r a n d S haft A sse m b ly ............................................................. C o m p . L eak T e stin g (E x te rn a l an d In te rn a l) ................................................................ C o m p re sso r O v e rh a u l S pecial T o o ls Illu s tra te d ............................................................ ID 1-13 ID I - 16 1D1-17 1D1-I7 1D1-18 ID 1-19 ID 1-19 ID I - 19 ID 1-21 ID 1-21 ID 1-22 1D1-23

I D l -1

ID 1-5

ID 1-8 ID 1-8 1D1-I0

M a jo r R-4 Com pressor Repair Procedures ......................................................... 1 D 1-12


C o m p re sso r Shaft Seal ...................................... Seal L eak D e te c tio n ...................................... C o m p re sso r Shaft Seal ID 1-13 1D1-I3

GENERAL DESCRIPTION
F o r all p ra c tic a l p u rp o ses, all vehicles m a k e use o f th e sam e 4 -cy lin d er a ir c o n d itio n in g co m p re sso r. A c tu a l differences b etw een c o m p re sso r in sta lla tio n s are in th e ir m o u n tin g b ra c k e ts, d riv e system , p ulleys, c o n n e c to r assem blies a n d system c ap acities, n o n e o f w h ich w ill affect th e fo llow ing O v e rh a u l P ro c e d u re s. W h en servicing th e c o m p re sso r, it is essential th a t step s be tak en to p re v e n t d irt o r fo reig n m a te ria l from g e ttin g on o r in to th e c o m p re sso r p a rts a n d sy stem d u rin g d isassem bly o r reassem b ly. C lean to o ls an d clean w o rk a re a a re very im p o rta n t fo r p ro p e r service. T h e c o m p re sso r c o n n e c tio n a re a s a n d th e e x te rio r o f th e c o m p re sso r sh o u ld be c le a n e d o ff as m u c h as p ossible p rio r to an y on c a r re p a irs o r rem o val o f th e c o m p re sso r fo r w o rk b e n c h service. T h e p a rts m u st be k e p t clean a t all tim es a n d an y p a rts to be reassem b led sh o u ld be clean ed w ith tric h lo ro e th a n e , n a p h th a , S to d d a rd solvent, k e ro se n e o r e q u iv a le n t solvent an d b lo w n d ry w ith d ry air. W h e n n ecessary to use a clo th on an y p a rt, it sh o u ld be o f a n o n lin t p ro d u c in g type. A lth o u g h c e rta in service o p e ra tio n s can be p e rfo rm e d w ith o u t co m p le te ly rem o v in g th e c o m p re sso r from th e vehicle, th e o p e ra tio n s d escrib ed a re b ased on ben ch o v e r-h a u l w ith th e c o m p re sso r rem o v ed fro m th e vehicle. T h e y h av e been p re p a re d in seq uence in o rd e r o f accessib ility o f th e c o m p o n e n ts. If c o m p re sso r is rem o ved fro m b ra c k e ts b u t not

d isc o n n e c te d fro m lines a n d hoses, th e sy stem is not d isc h a rg e d . P a d fe n d e r sk irt a n d se c u re c o m p re s s o r n e a r to p o f fe n d e r sk irt w ith w ire, ro pe, etc. w hen p e rfo rm in g o n -c a r service. W h en th e R -4 c o m p re s s o r is rem o v ed fro m th e vehicle fo r serv icin g, th e a m o u n t o f oil re m a in in g in th e c o m p re sso r sh o u ld be d ra in e d a n d m e a su re d . T h is oil sh o u ld th e n be d isc a rd e d a n d new 525 viscosity re frig e ra n t oil a d d e d to th e c o m p re s s o r (See R e frig e ra n t O il D is trib u tio n in th e A ir C o n d itio n in g Section 1B1).

SERVICE PROCEDURES
MINOR REPAIR PROCEDURES, R-4 COMPRESSOR

THE FOLLOW ING OPERATIONS TO THE R-4 COMPRESSOR CLUTCH PLATE A N D HUB, ROTOR A N D BEARING, A N D COIL & PULLEY RIM ARE COVERED AS "M IN O R " BECAUSE THEY M A Y BE PERFORMED W ITH O U T FIRST PURGING THE SYSTEM OR REM OVING THE COMPRESSOR FROM THE VEHICLE.
T w o ty p es o f d riv e sy ste m s a re used on th e R -4 C o m p re sso r: V -groo v e ty p e a n d p o ly -g ro o v e ty p e. T h e d riv e sy stem affects o n ly m in o r re p a ir p ro c e d u re s an d is so n o te d w h e re re q u ire d . M a jo r re p a ir p ro c e d u re s are n o t affected by th e ty p e o f d riv e system .

1D1-2 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


T h e C o m p re sso r S h aft Seal assem b ly , a n d P re ssu re R e lie f V alve m ay also be serv iced W I T H O U T R E M O V I N G T H E C O M P R E S S O R from th e veh icle b u t th ese o p e ra tio n s a re co v e re d la te r in th is sectio n as M A J O R R E P A I R P R O C E D U R E S b ec a u se th e sy stem m u st be d isc h a rg e d , e v a c u a te d a n d re c h a rg e d to c o m p le te service. Illu s tra tio n s used in d e sc rib in g th ese o p e ra tio n s show th e c o m p re s s o r re m o v e d fro m th e vehicle o n ly to m o re clea rly illu s tra te th e v a rio u s o p e ra tio n s.

R-4 COMPRESSOR CLUTCH PLATE AND HUB ASM.


Remove 1. I f c o m p re sso r is on th e c a r, loosen c o m p re sso r m o u n tin g b ra c k e ts, d isc o n n e c t th e c o m p re sso r d riv e belt a n d re p o sitio n th e c o m p re s s o r for access, if necessary . If c o m p re sso r h a s been rem o v e d fro m th e c ar, a tta c h th e c o m p re sso r to H o ld in g F ix tu re J-2 5 0 0 8 -A a n d c la m p th e H o ld in g F ix tu re in a vise (F ig. 1D 1-7). C o m p re sso r m o u n tin g h o les are m e tric . U se p ro p e r m e tric b o lts w ith h o ld in g fix tu re J-2 5 0 0 8 -A .

2.

K e e p th e c lu tc h h u b fro m tu rn in g w ith th e C lu tc h H u b H o ld in g T o o l J-25030, rem o v e, a n d d isc a rd th e sh a ft n u t, u sin g T h in W all S o ck et J-9 3 9 9 , F ig. 1D 1-8. T h re a d th e C lu tc h P la te a n d H u b A sse m b ly R e m o v e r J-9 4 0 1 -A , in to th e h u b . H o ld th e b o d y o f th e R e m o v e r w ith a w re n c h a n d tu rn th e c e n te r screw in to th e R e m o v e r b o d y to rem o v e th e C lu tc h P la te an d H u b assem b ly (F ig. 1D 1-9). R em o v e th e sh a ft key.

3.

4.
[ j j PO LY GROOVE PULLEY RO TO R

Replace 1. In sta ll th e sh a ft key in to th e h u b key g ro o v e (F ig. 1D 1-10). A llo w th e key to p ro je c t a p p ro x im a te ly 4 .8 m m ( 3 /1 6 " ) o u t o f th e keyw ay. T h e sh a ft key is c u rv e d slig h tly to p ro v id e an in te rfe re n c e fit in th e sh a ft key g ro o v e o f th e h u b . 2. Be su re th e fric tio n a l su rfa c e o f th e c lu tc h p la te a n d th e c lu tc h r o to r a re c le a n b e fo re in sta llin g th e C lu tc h P la te a n d H u b assem b ly . A lig n th e sh a ft key w ith th e sh a ft k eyw ay a n d p la ce th e C lu tc h P la te a n d H u b assem b ly o n to th e c o m p re sso r shaft. N O T IC E : T o av o id in te rn a l d a m a g e to th e co m p re sso r, do n o t d riv e o r p o u n d on th e c lu tc h h u b o r sh aft. 4. In s ta ll th e C lu tc h P la te a n d H u b J-9 4 8 0 -B as illu s tra te d in F ig. 1D 1-11. In s ta lle r

[~ 2 ] H IG H PRESSURE C U T O FF SW ITCH (IF U SE D ) f~3~l H IG H PRESSURE R E L IE F VALVE

3.

420002-1D1

Fig. 1D1-2 R-4 C o m pre sso r, Poly-G roove P ulley Type

W h e n serv icin g th e c o m p re sso r, rem o v e o n ly th e n e cessary c o m p o n e n ts th a t p re lim in a ry d ia g n o sis in d ic a te s a re in need o f service. R e fe r to th e A I R C O N D I T I O N I N G se c tio n a n d Fig. 1D 1-3 a n d Fig. 1D 1-4 fo r in fo rm a tio n re la tiv e to p a rts n o m e n c la tu re a n d lo c atio n .

5.

H o ld th e hex p o rtio n o f th e In s ta lle r B ody J-9 4 8 0 -B w ith a w re n c h a n d tig h te n th e c e n te r screw to p ress th e h u b o n to th e sh a ft u n til th e re is a .5 m m - 1.0m m (.0 2 0 " -.0 4 0 " ) in c h a ir g ap b etw een th e fric tio n a l su rfa c e s o f th e c lu tc h p la te a n d c lu tc h ro to r. In s ta ll a new sh aft n u t w ith th e sm all d ia m e te r boss o f th e n u t a g a in st th e c ra n k s h a ft sh o u ld e r, u sin g T h in W all S ocket J-9 3 9 9 . H o ld th e C lu tc h P la te a n d H u b assem b ly w ith C lu tc h H u b H o ld in g T o o l J-25030, a n d tig h te n to 14 N * m (10 lb. ft.) to rq u e , u sin g a 0-60 N * m (0-25 lb .ft.) to rq u e w re n ch . I f o p e ra tio n is p e rfo rm e d w ith c o m p re s s o r on c ar, c o n n e c t d riv e belt, tig h te n m o u n tin g b ra c k e ts a n d a d ju st b elt ten sio n .

6.

R e m o v a l a n d in s ta lla tio n o f e x te rn a l c o m p re sso r c o m p o n e n ts a n d d isassem b ly a n d assem b ly o f in te rn a l c o m p o n e n ts m u st be p e rfo rm e d on a clean w o rk b e n c h . T h e w o rk a re a , to o ls a n d p a rts m u st be k e p t clean at all tim es.

7.

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-3

1-R E T A IN E R RING 2 -S E A L SEAT 3 -S H A F T SEAL 4 - 0 RING, SEAL SEAT 5 -S H A F T SEAL K IT 6-SCREW AND WASHER ASSEMBLY FRONT HEAD MOUNTING 7 -F R O N T HEAD 8 -M A IN BEARING 9 -R IN G SEAL, FRONT HEAD TO CYLINDER 1 0-S H E L L 1 1 -0 -R IN G , CYLINDER TO SHELL 12-T H R U S T WASHER 13 B E LLE V ILLE WASHER 14-T H R U S T WASHER KIT 15-C Y LIN D E R AND SHAFT ASSEMBLY 16 -R E T A IN E R RING 1 7 -V A L V E PLATE 18-SHIPPING PLATE 19-SCREW 2 0 - O-RING SUCTIONDISCHARGE PORTS 21-PRESSURE RELIEF V A LV E 22-O -R IN G , PRESSURE RELIEF V ALVE 23 -S H A F T NUT 24-C LU T C H HUB KEY 25-C LU T C H DRIVE ASSEMBLY 2 6 -R E T A IN E R RING 27-R O T O R 28-R O T O R BEARING 29-R O T O R AND BEARING ASSEMBLY 3 0 -C O IL AND HOUSING ASSEMBLY 3 1 -P U L L E Y RIM M OUNT ING SCREW 32-S P E C IA L WASHERPULLEY RIM MOUNTING SCREW LOCKING 3 3 -P U L L E Y RIM
420003-1D1
One Piece Design

Fig. 1D1-3 E xploded V ie w o f R-4 C o m p re sso r

1D1-4 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL

f T ] COMPRESSOR SHELL |~~2~1 T H R U S T A N D B E L L E V IL L E WASHER

[7 T ]S H A F T S E A L [7 7 ] SEAL SEAT [7 5 ] CLUTCH DRIVE ASSEMBLY n~6~l ROTOR AND HUB ASSEMBLY []7 ]C L U T C H c o |L AND HOUSING ASSEMBLY
S E A L S E A T O -R IN G fT 9 ] FRONT HEAD [2 0 ] V A L V E PLATE ASSEMBLY [2 1 ] V A L V E PLATE R E T A IN E R R IN G S H E L L R E T A IN E R PIS TO N A S S E M B L Y [~24~| M A I N B E A R I N G REAR [ 2 5 ] SU C TIO N PORT 26l D IS C H AR G E PORT
4 2 0 0 0 4 -1D1

\~3~] M A I N B E A R I N G FRONT

|T 1 C L U T C H C O IL
T E R M IN A L S H H P U L L E Y R IM P H P U L L E Y R IM M T G .S C R E W

\~7~] P U L L E Y R I M
M T G .S C R E W LOCKW ASHER f T ] RO TOR B E A R IN G f T ] RO TO R B E A R IN G R E T A IN E R fT o l SEAL SEAT R E T A IN E R

[7 7 ] S H A F T K E Y [W \ S H A F T N UT

Fig. 1D1-4 R-4 C o m p re s s o r Cross S e ctio n - Early D esign

1-COMPRESSOR SHELL 2 -R O L L PINS 3-T H R U S T AND B ELLE V ILLE WASHER 4 -M A IN BEARING - FRONT 5-C LU T C H COIL TERM INALS 6 -P U L L E Y RIM 7 -P U L L E Y RIM MOUNTING SCREW AND LOCKWASHER 8-R O T O R BERAING 9-R O T O R BEARING RETAINER 1 0-S E A L SEAT RETAINER 11 -S H A F T KEY 12 -S H A F T NUT 13 -S H A F T SEAL 14-C LU TC H DRIVE ASSEMBLY 15-R O TO R AND HUB ASSEMBLY 16-C LU TC H O IL AND HOUSING ASSEMBLY 1 7-S E A L SEAT O-RING 18 -F R O N T HEAD 1 9 -V A L V E PLATE ASSEMBLY 2 0 -V A L V E PLATE RETAINING RING 2 1 -S H E L L RETAINER 22-P IS TO N ASSEMBLY 2 3 -M A IN BEARING - REAR 24-S U C TIO N PORT 25-D IS C H A R G E PORT
4 2 0 0 0 5 -1 D1

Fig. 1D1-5 R-4 C o m p re s s o r Cross S e ctio n - Late Design

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-5

r n

CLUTCH COIL

[ 2 ] PULLEY BEARING [~3 ~ ] POLY GROOVE


PULLEY ROTOR [~4~] RETAINER l~ 5 ] CLUTCH DRIVE AND HUB ASSEMBLY [~6~l SHAFT KEY
(~

7~1 SHAFT NUT

42 0 0 0 6 - 1D1

Fig. 1D 1-6 E xploded V ie w o f Poly G roove P ulley D rive

SUCTION PORT O-RING DISCHARGE PORT HIGH PRESSURE RELIEF VALVE J-25008-A HOLDING FIXTURE
420007 1D1

[ 1 1J-9401-A HUB AND CLUTCH DRIVE PLATE ASSEMBLY REMOVER | 2 | CLUTCH PLATE AND HUB ASSEMBLY

Fig. 1D1-7 C o m p re sso r In H o ld in g F ixture

p r y 25030
CLUTCH HUB HOLDING TOOL

420009-1D 1

Fig. 1D1-9 C lu tch Plate & Hub Asm . Rem oval

J-9399 SHAFT NUT SOCKET

| 3 [CLUTCH ASSEMBLY H P J-25008-A HOLDING FIXTURE

| 1 | CLUTCH PLATE AND HUB ASSEMBLY | 2 | CLUTCH ROTOR |~3 | SHAFT

4 2 0 0 0 8 -1 D1

Fig. 1D1-8 R em oving S h a ft N ut

R-4 COMPRESSOR CLUTCH ROTOR AND/OR BEARING-V-GROOVE TYPE


Remove 1. R e m o v e th e C lu tc h P la te a n d H u b assem b ly as d e sc rib e d in R -4 C O M P R E S S O R C L U T C H P L A T E & H U B A S M . re m o v a l p ro c e d u re .
Fig. 1 D 1-1 0 In s ta llin g S h a ft Key

4 2 0 0 1 0 -1 D1

1D1-6 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL

] 1 j DRIVE PLATE INSTALLER J-9480-B 1 2 | DRIVE PLATE INSTALLER BEARING | 3~| AIR GAP (.020"-.040") [ 4~[ CLUTCH PLATE AND HUB ASM.

C1 H| J 25031

c n
[

ROTOR AND BEARING PULLER GUIDE PULLEY ARM

3 JP U LLE Y RIM i ] SCREW AND LOCKWASHER (6) LOCATIONS

4 2 0 0 1 1-1D1

420013 1D1

Fig. 1D1-1 1 In s ta llin g C lu tch Plate & Hub Asm .

Fig. 1 D 1 -1 3 In s ta llin g R otor & B e a rin g P uller G uide

2. R e m o v e R o to r a n d B e a rin g asse m b ly re ta in in g rin g , u sin g S n ap R in g P lie rs J-6 0 8 3 , Fig. 1D 1-12. M a rk th e lo c a tio n o f th e c lu tc h coil te rm in a ls.

J-25031 ROTOR AND BEARING PULLER J-25031 GUIDE

[~T~l J 6083
PLIERS |~2~| CLUTCH ROTOR | 3 [ RETAINER RING

42 0 0 1 4 -1 D1

Fig. 1 D 1 -1 4 R em oving C lu tc h R otor Asm .


420012-1D1

Fig. 1D 1-1 2 R em oving R otor & B e a rin g Asm . R etainer Ring

I f o n ly th e C lu tc h R o to r a n d / o r R o to r B e a rin g a re to be re p la c e d , b e n d th e lo c k w a sh e rs aw ay fro m th e p u lley rim m o u n tin g screw s (see F ig. I D 1-13), a n d re m o v e th e six ( 6) m o u n tin g screw s a n d sp ecial lo ck w a sh e rs b e fo re p ro c e e d in g w ith S tep 3. D is c a rd th e lo ck w ash ers. 3. In s ta ll R o to r a n d B e a rin g P u lle r J-25031 d o w n in to th e ro to r u n til th e P u lle r a rm s e n g ag e th e recessed edge o f th e r o to r h u b . H o ld th e P u lle r a n d a rm s in p la c e a n d tig h te n th e P u lle r screw a g a in st th e P u lle r G u id e to re m o v e th e C lu tc h R o to r a n d B e a rin g a ssem b ly (F ig . I D 1-13 a n d I D 1-14), b ein g c a re fu l n o t to d ro p th e P u lle r G u id e . I f th e p u lley rim m o u n tin g sc rew s a n d w a sh ers w ere re m o v e d in S tep 2, o n ly th e C lu tc h R o to r a n d B e a rin g assem b ly w ill be re m o v e d fo r re p la c e m e n t. T h e C lu tc h C o il a n d H o u sin g assem b ly is p re sse d o n to th e F r o n t H e a d o f th e

c o m p re sso r w ith a p re ss fit a n d w ill n o t be re m o v e d u n less th e p u lle y rim m o u n tin g screw s a re left se cu rely in p la c e a n d th e p u lley rim p u lls th e C o il a n d H o u sin g a ssem b ly o ff w ith th e to ta l C lu tc h R o to r a n d P u lle y R im A ssem bly. 5. P la c e th e R o to r a n d B e a rin g assem b ly on b lo ck s as sh o w n in Fig. I D 1-15. D riv e th e b e a rin g o u t o f th e r o to r h u b w ith R o to r B e arin g R e m o v e r J-9398. It is n o t n ece ssa ry to re m o v e th e sta k in g at th e re a r o f th e ro to r h u b to re m o v e th e bearin g . H o w ev er, it w ill be n ec essary to file aw a y th e o ld sta k e m e ta l for p ro p e r c le a ra n c e fo r th e new b e a rin g to be in sta lle d in to th e r o to r b o re , o r th e b e a rin g m a y be d a m a g e d (see Fig. 1D 1-16). Replace 1. 2. P la c e th e R o to r a n d H u b asse m b ly face d o w n on a cle an , flat a n d firm su rfac e. A lig n th e new b e a rin g sq u a re ly w ith th e h u b b o re a n d u sin g P u lley a n d B e a rin g In s ta lle r J-9 4 8 1 -A w ith U n iv e rsa l H a n d le J-8 0 9 2 , d riv e th e b e a rin g fully in to th e h u b (F ig . 1D 1-17). T h e In s ta lle r

4.

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-7


4. h h J -8092
DRIVER HANDLE [~~2~~l J-9398-A ROTOR BEARING REMOVER

R e p la ce ro to r a n d b e a rin g assem bly.

On Car
A. B. P o sitio n th e R o to r a n d B e arin g assem b ly on th e fro n t head. W ith R o to r & B earin g In s ta lle r J-2 6 2 7 1 -A (w ith o u t d riv e r h a n d le ) in p o sitio n a n d R o to r a n d B earin g asse m b ly alig n ed w ith th e F r o n t H e a d as sh o w n in (F ig. 1D 1-18), d riv e th e a sse m b ly p a rt w ay o n to th e head .

420015-1D1

Fig. 1D 1-15 C lutch R otor B e aring R em oval

I 1 [ b e a r in g STAKE LOCATION

C. D.

P lu g c lu tc h coil c o n n e c to r o n to C lu tc h C oil. P o sitio n th e C lu tc h C o il so th e th re e (3) lo c a tin g ta b s w ill alig n w ith th e h o les in th e h e a d a n d c o n tin u e to d riv e th e R o to r a n d B ea rin g assem b ly o n to th e fro n t head . In s ta ll th e re ta in e r rin g (F ig . 1D 1-12). R e a sse m b le th e C lu tc h P la te a n d H u b w ith th e sh a ft key o n to th e sh a ft w ith In s ta lle r J-9 4 8 0 -B u n til .5 to 1.0m m (.020" to .0 4 0 ") a ir g ap is o b ta in e d . In s ta ll sh a ft lock n u t. T o rq u e to 14 N * m (10 lb. ft.).

E.
470016-1D1

F.
Fig. 1D 1-16 R otor & B earing Asm .

w ill a p p ly force to th e o u te r race o f th e b e a rin g if u sed as sh o w n .

G.

On Bench

r n j-8092
DRIVER HANDLE I 2 j J-9481-A PULLEY BEARING AND PULLEY INSTALLER

R ea sse m b le th e R o to r a n d B ea rin g assem b ly to th e fro n t h e a d o f th e c o m p re sso r usin g R o to r & B e arin g In s ta lle r J-2 6 2 7 1 -A . W ith In s ta lle r a ssem b le d to th e U n iv e rsa l H a n d le J-8 0 9 2 , as sh o w n in F ig. I D 1-19, fo rce w ill be a p p lie d to th e in n e r ra c e o f th e b e a rin g a n d th e face o f th e ro to r w h en in sta llin g th e a sse m b ly o n to th e fro n t h e a d o f th e c o m p re sso r. 5. In sta ll r o to r a n d b e a rin g assem b ly re ta in e r ring, usin g S n a p R in g P lie rs J-6083 (see Fig. I D 1-12). A p p ly se a le r (L o c tite R C -7 5 , L o c tite 601 o r eq u iv a le n t) to th re a d s o f p u lley rim m o u n tin g screw s. In s ta ll sc rew s a n d new special lock w a sh e rs b u t d o n o t to rq u e th e screw s. R o ta te th e p u lley rim a n d r o to r to in su re th a t p u lley rim is ro ta tin g in -lin e . I f p u lley rim is d is to rte d (d o es n o t ro ta te in-line), a d ju s t o r re p la c e p u lley rim . T ig h te n p u lley rim m o u n tin g sc rew s to 11 N * m

[~3~]

ROTOR BEARING ROTOR AND HUB ASM.


420 017-101

6.

[~4~l

7.

Fig. 1D 1-17 In s ta llin g C lu tch R otor B earing

3.

U sin g a c e n te r p u n c h w ith a 45 an g le p o in t, sta k e 1.1 - 1.4m m (.0 4 5 "-.0 5 5 " d e e p ) th e b e a rin g in th re e p laces 120 a p a r t as sh o w n in Fig. I D 1-16, b u t d o n o t sta k e to o d eep ly to a v o id d isto rtin g th e o u te r ra c e o f th e b e a rin g .

8.

(100 in c h -p o u n d s) to rq u e a n d lo ck sc re w h ea d s in
p lac e by b e n d in g sp ecial lo ck w a sh e rs (F ig. 1D 1-19), sim ila r to o rig in a l c rim p a n d lock b e n d s o n w ash ers.

1D1-8 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL

r n j 25031
GUIDE j 2 1 J-25031 ----- ROTOR & BEARING PULLER f3 ~ j POLY GROOVE PULLEY ROTOR

| T | CLUTCH PLATE AND HUB ASSEMBLY | 2 | CLUTCH ROTOR [~3~~| S H A F T KEY

4 2 0 0 2 0 -1D1

Fig. 1 D 1-20 R em oving C lu tch R otor Asm . - Poly-G roove D rive

Replace
4 2 0 0 1 0-1D1

1. 2.

Fig. 1D 1-19 In s ta llin g R otor & B earing Asm . V-Groove Type

3. 9. R e in sta ll C lu tc h P la te a n d H u b asse m b ly as d esc rib e d in R -4 C o m p re s so r C lu tc h P la te a n d H u b R e p la c e m e n t p ro c e d u re s. 4.

R-4 COMPRESSOR CLUTCH ROTOR AND/OR BEARING - POLY GROOVE TYPE


Remove 1. 2. R em o v e th e c lu tc h p la te a n d h u b assem b ly as d esc rib e d p rev io u sly . R em o v e th e p u lle y -ro to r a n d b e a rin g assem b ly re ta in in g rin g , u sin g S n ap R in g P lie rs J-6083 (F ig . 1D 1-12). In sta ll R o to r a n d B e a rin g P u lle r G u id e J-25031 to th e fro n t h e a d a n d in sta ll R o to r a n d B e a rin g P u lle r J-25031 d o w n in to th e r o to r u n til th e p u lle r a rm s e n g ag e th e re c e sse d edge o f th e ro to r h u b . H o ld th e P u lle r a n d a rm s in p lace a n d tig h te n th e P u lle r screw a g a in st th e P u lle r G u id e to re m o v e th e c lu tc h p u lle y -ro to r a n d b e a rin g assem b ly (F ig s. I D 1-13 a n d I D 1-20), being ca re fu l n o t to d ro p th e P u lle r G u id e . P la c e th e p u lle y -ro to r a n d b e a rin g a ssem b ly on b lo c k s sim ila r to th a t sh o w n in Fig. 1D 1-15. D riv e th e b e a rin g o u t o f th e r o to r h u b w ith R o to r B e a rin g R e m o v e J-9398. It is n o t n e c e ssa ry to re m o v e th e sta k in g a t th e re a r o f th e r o to r h u b to rem o v e th e b ea rin g . H o w e v e r, it w ill be n e c e ssa ry to file aw ay th e old s ta k e d m e ta l fo r p ro p e r c le a ra n c e fo r th e new b e a rin g to be in sta lle d in to th e r o to r bore, o r th e b e a rin g m ay be d a m a g e d (see F ig. I D 1-16).

5.

P lac e th e p u lley ro to r a n d h u b assem b ly face d o w n on a clean , flat, firm su rface. A lig n th e new b e a rin g s q u a re ly w ith th e h u b b o re sim ila r to th a t sh o w n in F ig. ID 1-17, a n d usin g P u lley a n d B earin g In s ta lle d J-9 4 8 1 -A w ith U n iv e rsa l H a n d le J-8 0 9 2 , d riv e th e b e a rin g fully in to th e h u b . T h e in sta lle r w ill ap p ly fo rce to th e o u te r rac e o f th e b e a rin g if used as sh o w n . U sin g a c e n te r p u n c h w ith a 45 angle p o in t, sta k e 1.1 - 1.4m m (0 .45" - 0 .5 5 " d ee p ) th e b e a rin g in th re e p laces 120 a p a rt s im ila r to th a t sh o w n in Fig. 1D 1-16. Do N ot sta k e to o deeply to av o id d is to rtin g th e o u te r ra c e o f th e bearin g . P o sitio n th e p u lley ro to r a n d b e a rin g assem b ly on th e fro n t h e ad . W ith R o to r a n d B earin g in sta lle r J-2 6 2 7 1 -A a n d U n iv e rsa l D riv e H a n d le J-8092 alig n e d in p o sitio n w ith th e p u lley ro to r a n d b e a rin g assem b ly , F ig. 1D 1-21, d riv e th e asse m b ly o n to th e fro n t h ead . In sta ll th e re ta in e r rin g (F ig . 1D 1-12). B ench)

3.

R-4 COMPRESSOR CLUTCH COIL AND/OR PULLEY RIM


I f o rig in a l p u lley rim w as eq u ip p e d w ith an in e rtia rin g , e ith e r b o lte d o r w eld ed on, o r if a rin g is to be a d d e d , refe r to I N E R T I A R I N G IN S T A L L A T IO N .

Remove - V-Groove Drive 1. P e rfo rm S teps 1 th r o u g h 4 of R -4 C O M P R E S S O R C L U T C H R O T O R A N D /O R B E A R I N G re m o v a l p ro c e d u re b u t do n o t lo o sen o r rem o v e th e p u lley rim m o u n tin g screw s u n til th e C lu tc h R o to r, C o il a n d P u lle y R im assem b ly h av e been rem o v e d fro m th e F ro n t H e ad . Be c a re fu l n o t to d ro p th e P u lle r G u id e J-25031 w h en re m o v in g th e assem b ly . R em o v e th e p u lley rim m o u n tin g screw s a n d special lo ck w ash ers. D is c a rd th e lock w a sh e rs a n d screw s.

4.

2.

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-9


by using ro to r a n d b e a rin g p u lle r g u id e J-25031 (F ig. 1D 1-13) w ith p u lle r to o l J-2 5 2 8 7 (F ig. 1D 1-24).

rn j -8 0 9 2 HANDLE
I T ] J-26271-A ROTOR & BEARING ASSEMBLY INSTALLER [~3~] POLY GROOVE PULLEY ROTOR

FT]

J-24092 PULLER LEGS

H f ] J-25031 GUIDE [ T ] CLUTCH COIL

[ T ] J-8433 PULLER

42 0 0 2 1 -1 D1

Fig. 1D 1-21 In s ta llin g R otor & B e aring A sse m b ly, Poly-G roove Type (On
1D1

3.

S lide th e p u lley rim o ff th e R o to r a n d H u b assem b ly . T h e P u lle y R im a n d th e C lu tc h C oil (F ig . I D 1-22) a re re p la c e a b le a t th is p o in t.

Fig. 1 D 1 -2 3 R em oving Poly-G roove C lu tch Coil

Replace V-Groove Drive 1. A ssem b le th e C lu tc h C oil, P u lley R im a n d th e C lu tc h R o to r a n d B ea rin g a sse m b ly as sh o w n in F ig. I D 1-25. U se new sc re w s a n d special lock w a sh e rs a n d ap p ly se a le r (L o c tite R C -7 5 , L o c tite 601, o r e q u iv a le n t) to screw th re a d s b u t d o n o t lock th e screw s in place. P lace th e assem b ly on th e n eck o f th e F r o n t H e a d a n d seat in to p lac e u sin g R o to r & B earin g In s ta lle r J-2 6 2 7 1 -A (F ig . 1D 1-19). B efore fu lly se a tin g th e asse m b ly on th e F r o n t H e a d , be su re th e c lu tc h coil te rm in a ls a re in th e p ro p e r lo c a tio n in re la tio n to th e c o m p re s s o r a n d th a t th e th re e p ro tru s io n s on th e re a r o f th e c lu tc h coil alig n w ith th e lo c a to r h o le s in th e F ro n t H ea d . In s ta ll th e r o to r a n d b e a rin g assem b ly re ta in in g rin g a n d rea sse m b le th e C lu tc h P la te a n d H u b asse m b ly as d e sc rib e d in R -4 C o m p re s s o r C lu tc h P la te a n d H u b A s m . R e p la c e m e n t p ro c e d u re . C h e c k to see th a t th e c lu tc h p la te to c lu tc h ro to r a ir g ap is .5 to 1.0m m (.0 2 0 to .040 in ch es). R o ta te th e P u lle y R im a n d R o to r to be su re th e P u lle y R im is ro ta tin g in -lin e a n d a d ju s t o r re p la c e as re q u ire d . T ig h te n th e p u lley rim m o u n tin g sc rew s to 11 N * m (100 in c h -p o u n d s ) to rq u e a n d lock th e screw h e a d s in p lac e by b e n d in g lock w ash ers

2.

Remove Poly-Groove Drive 3. 1. R e m o v e th e c lu tc h p la te a n d h u b asse m b ly as d e sc rib e d p rev io u sly . R e m o v e th e p u lley r o to r a n d b e a rin g assem b ly as d e sc rib e d p rev io u sly . M a rk th e lo c a tio n o f th e c lu tc h coil te rm in a ls o n th e c o m p re sso r. In s ta ll R o to r a n d B e a rin g P u lle r G u id e J-25031 (F ig . 1D 1-13) to th e fro n t h e a d a n d in sta ll P u lle r J-8 4 3 3 w ith P o ly -V -B elt P u lle r L eg Set J-2 4 0 9 2 a n d rem o v e th e c lu tc h coil fro m th e fro n t h e ad (F ig . I D 1-23). C lu tc h coil m a y also be rem o v ed

2.

3.

4.

1D1-10 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


3.
n ~ | J-25287 CLUTCH COIL PULLER | 2 | J-25031 GUIDE [~~3~~| J-25008-A HOLDING FIXTURE [ T ] CLUTCH COIL "

4.

In s ta ll th e p u lle y -ro to r a n d b e a rin g assem b ly re ta in in g rin g a n d rea sse m b le th e c lu tc h p la te a n d h u b asse m b ly as d e sc rib e d in C lu tc h P la te a n d H u b A sse m b ly - R e p la c e . C h e c k to see th a t th e c lu tc h p la te to c lu tc h ro to r a ir gap is 0.5 - 1.0m m (0 .0 2 0 " - 0 .0 4 0 ").

R-4 COMPRESSOR INERTIA RING INSTALLATION


R -4 c o m p re sso rs w ill be b u ilt w ith o ne o f th re e co n d itio n s: 1. N o In e rtia R in g In s ta lle d - N o in sta lla tio n is re q u ire d u n less d ire c te d by a d ia g n o stic p ro c e d u re . I f a rin g is to be a d d e d , use P ro c e d u re I. 2. B o lte d -O n In e rtia R in g Is In s ta lle d - R ep lac e usin g P ro c e d u re I. A ll new screw s, w ash ers, a n d L o c tite 601 (o r e q u iv a le n t) m u s t be used. 3. W e ld e d -O n In e rtia R in g Is In s ta lle d - R e p la c e u sin g P ro c e d u re II. Procedure I

BOLTED-ON IN ER TIA IN S TA LLA TIO N OR REPLACEM ENT


1.
420024- 1D1

RING:

Fig. 1D 1-24 R em oving Poly-G roove C lu tch Coil (O p tio n a l M e th o d )

2.

Fig. 1D 1-25 A s s e m b lin g C lu tch C oil, P ulley Rim, R otor & B earing

3.

(F ig. I D 1-19), sim ila r to o rig in a l c rim p a n d lock b e n d s o n w ash ers. Replace Poly-Groove Drive 1. P lac e th e c lu tc h coil asse m b ly o n th e n eck o f th e fro n t h e a d w ith c lu tc h coil te rm in a ls in lin e w ith m a rk sc rib e d in S tep 2 o f th e re m o v a l p ro c e d u re . P lac e th e p u lley ro to r a n d b e a rin g a ssem b ly on th e n e c k o f th e fro n t h e a d a n d seat th e c lu tc h coil a n d p u lle y r o to r in p lace u sin g R o to r a n d B e a rin g In s ta lle r J-26271 (F ig . 1D 1-19). B efo re fu lly se a tin g th e assem b ly o n th e fro n t h ead , be su re th e c lu tc h coil te rm in a ls a re in p ro p e r lo c a tio n in re la tio n to th e c o m p re s s o r a n d th a t th e th re e p ro tru s io n s o n th e re a r o f th e c lu tc h coil h o u sin g alig n w ith th e lo c a to r h o les in th e fro n t head .

4.

2.

5.

L o o sen th e c o m p re sso r d riv e belt a n d ro ta te th e c o m p re sso r p u lley as re q u ire d to lo c a te o n e ( 1 ) screw a n d lock w a sh e r m o u n te d th ro u g h a m o u n tin g h o le o f th e P u lle y R im , F ig u re 1D 1-26, ra th e r th a n a m o u n tin g n o tc h screw lo c a tio n . D o n o t rem o v e th e d riv e belt u n less n ecessary . F o r id e n tific a tio n p u rp o se s, w a sh e rs lo ck e d o v e r th e edge o f th e P u lle y R im at th e m o u n tin g h o le lo c a tio n s w ill n o t u su a lly d im p le d o w n in th e c e n te r like th e in d e n ta tio n o f th e lo c k o v e r at a m o u n tin g n o tc h screw lo c atio n . R e m o v e th e th re e (3) m o u n tin g screw s a n d lo c k w a sh e rs a t th e p u lley rim m o u n tin g h o le lo c a tio n s. (T h e p u lley rim m o u n tin g h o le s a re lo c a te d 120 a p a r t ra d ia lly a ro u n d th e rim o r every o th e r m o u n tin g scre w lo c a tio n .) D o n o t re m o v e th e screw s in th e m o u n tin g n o tc h e s . T e m p o ra rily m a k e a tria l fit o f th e In e rtia R in g to th e P u lle y R im . I f a n y p o rtio n o f th e sh e e r edge o f th e P u lley R im p re v e n ts th e in sta lla tio n o f th e In e r tia R in g , th e ra ise d ed g e m ay be filed o ff to re m o v e th e excess m e ta l a n d 4fa c ilita te in sta lla tio n . D o n o t use u n d u e fo rce o r c o c k th e rin g in a sse m b lin g th e I n e rtia R in g in p lace o v e r th e P u lle y R im th a t c o u ld c a u se rin g d is to rtio n o r stress. A sse m b le th e In e rtia R in g o n to th e P u lle y R im , b ein g c a re fu l to alig n th e in e rtia rin g m o u n tin g h o les w ith th e m o u n tin g h o le s in th e p u lley rim . I f th e In e rtia R in g m u s t be r o ta te d on th e P u lley R im fo r c e n te rin g th e m o u n tin g holes a n d c a n n o t be sh ifte d by h a n d , u se a d rift p u n c h o r b lu n t to o l a n d a h a m m e r to c a re fu lly ta p th e I n e r tia R in g a t a c le a ra n c e n o tc h , F ig u re I D 1-28, to m o v e th e rin g in to p o sitio n . D esig n In sta ll L o c k w asher:

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-11

n n MOUNTING NOTCHES (3) | 2 I MOUNTING HOLES (3)

1 j CLEARANCE NOTCH

~2 ~ ] LOCK WASHER TO SIDES OF SCREW ------ HEAD AND DOWN OVER NOTCH IN RING. (3 "MOUNTING HOLE LOCATIONS)
I 3 I "L O C K WASHER TO SIDES OF SCREW ----- HEAD AND DOWN OVER EDGE OF PULLEY RIM. (3 "MO UNTING NOTCH" LOCATIONS) 1 4 1 PULLEY RIM

Fig. 1D 1-2 6 P ulley Rim M o u n tin g L o ca tio n D etail

Fig. 1 D 1-28 P ulley Rim and In e rtia Ring M o u n tin g D etail

Fig. 1D 1-27 P ulley Rim M o u n tin g L o ca tio n D etail O p tio n a l D esgin

6.

7.

8.

W ith se p a ra te w a s h e r d esig n : In s ta ll a sp ecial lo c k w a sh e r o n to e a c h 6 .4 m m -2 8 x 13.5m m ( l / 4 " - 2 8 X 1 7 /3 2 " ) m o u n tin g screw . W ith in te g ra l b o lt/w a s h e r : P ro c e e d to S tep 6 . A p p ly L o c tite 601 (o r e q u iv a le n t se aler) to th e screw th re a d s o f e a c h m o u n tin g screw a n d th re a d s o f th e m o u n tin g h o les in th e C lu tc h R o to r. W et th e th r e a d s th o ro u g h ly to e n su re c o m p le te th re a d co v erag e. In s ta ll th e screw s in to th e m o u n tin g h o les a n d tig h te n fin g e r-tig h t. T o rq u e each sc re w to 11 N * m (1 0 0 in. lbs.) to rq u e . In s ta ll S crew s: W ith se p a ra te w a sh e r desig n : L o c k th e th re e (3) screw s in p lace by fla tte n in g th e sp ecial w a sh e r a g a in st tw o sides o f th e h ex h e a d screw u sin g vise g rip p lie rs a n d o n e p o rtio n o f th e lo c k w a sh e r b e n t d o w n o v e r th e ed g e o f th e in e rtia rin g slot, Fig. I D 1-28. D o n o t m o v e th e screw h e a d s fro m th e to rq u e d p o sitio n . L o c k in g o f th e screw s m u st be sim ila r to th e p ro d u c tio n fo rm in g o f th e lo c k w a s h e r in o r d e r to effectively re ta in th e screw .

1 -C L E A R A N C E NOTCH 2 " L O C K " W A S H E R D O W N O V E R N O T C H IN R IN G . (TH R E E " M O U N T IN G H O L E " L O C A T IO N S )


4 2 0 029 I D 1

Fig. 1 D 1-29 P ulley Rim and In e rtia Ring M o u n tin g D etail - O p tio n a l

1D1-12 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


W ith o p tio n a l in e rtia rin g design a n d in te g ra l b o lt/w a s h e r : L o ck th e th re e (3) screw s in p lace usin g vice g rip p liers a n d b e n d in g a p o rtio n o f th e lo c k w a sh e r d o w n o v e r th e edge o f th e in e rtia ring slot (F ig . 1D 1-29). R e tig h te n th e c o m p re s s o r d riv e belt to p ro p e r belt ten sio n . C h e c k c o m p re s s o r a n d sy stem o p e ra tio n . I f m o u n tin g n o tc h screw s m u st be re p la c e d fo r a n y re a so n , th e screw s s h o u ld be to rq u e d in to p lace 11 N - m (100 in. lbs.) to rq u e u sin g L o c tite 601 (o r e q u iv a le n t se a le r) o n th e th re a d s a n d lo ck ed in to p lace s im ila r to th e o rig in a l lo ck in g m e th o d . th e rim is p o sitio n e d p ro p e rly , tig h te n th e th re e (3) m o u n tin g screw s to 11 N - m (100 in. lbs.) to rq u e . T e m p o ra rily m a k e a tria l fit o f th e In e rtia R in g to th e P u lley R im . If an y p o rtio n o f th e sh e e r edge o f th e P u lley R im p re v e n ts th e in sta lla tio n o f th e In e rtia R in g , th e ra ised ed g e m ay be filed o ff to re m o v e th e excess m e ta l and fa c ilita te in sta lla tio n . D o n o t use u n d u e fo rce o r co ck th e rin g in a ssem b lin g th e In e rtia R in g in place o v er th e P u lle y R im th a t c o u ld cau se rin g d is to rtio n o r stress. A sse m b le th e In e rtia R in g o n to th e P u lle y R im b eing c a re fu l to align th e In e rtia R in g m o u n tin g holes w ith th e m o u n tin g h o les in th e P u lle y R im . I f th e I n e r tia R in g c a n n o t be m o v ed by h a n d a n d m u st be ro ta te d fo r c e n te rin g th e m o u n tin g holes, use a d rift p u n c h o r b lu n t to o l a n d a h a m m e r to ca re fu lly ta p at o n e o f th e la rg e c le a ra n c e n o tc h e s in th e in e rtia rin g to ro ta te th e rin g in to p o sitio n , Fig. 1D 1-28. In sta ll th e special lock w a sh e rs o n to th e 13m m -28 x 13.5m m (1 /4 -2 8 X 1 7 /3 2 " ) m o u n tin g sc rew s a n d a p p ly L o c tite 601 (o r e q u iv a le n t sea ler) to th e to ta l screw th re a d a n d th e th re a d s o f th e m o u n tin g h o les in th e ro to r. In sta ll th e screw a n d w a sh e rs in to th e ro to r m o u n tin g h o les a n d tig h te n fin g er tig h t. W h e n all screw s a re in p lace, to rq u e e a c h screw to 11 N - m (100 in. lbs.) to rq u e . U sin g R o to r a n d B e arin g assem b ly In s ta lle r J-2 6 2 7 1 -A a n d U n iv e rsa l H a n d le J-8 0 9 2 , in sta ll th e P u lley , C lu tc h C oil, R o to r a n d B ea rin g asse m b ly o n to th e F ro n t H e a d o f th e c o m p re sso r. Be su re to lo c a te th e c lu tc h coil te rm in a ls in th e p ro p e r p o sitio n . Spin th e R o to r a n d P u lley assem b ly to a ssu re th a t th e p u lley ru n s in lin e . I f n o t, th e m o u n tin g screw s w ill h av e to be lo o se n ed an d th e p a rts alig n ed . W h e n all screw s a re to rq u e d in place, lock all m o u n tin g screw s in p o sitio n by fla tte n in g th e special w a sh e r a g a in st tw o o p p o site sides o f th e hex h e a d screw , usin g v ise-g rip pliers. F o rm a p o rtio n o f th e lock w a sh e r d o w n o v e r th e p u lley rim o r o v e r th e In e rtia R in g slot to se c u re th e screw s in place. D o n o t m o v e th e screw h e a d s fro m th e to rq u e d p o sitio n . See F ig. 1D 1-28. In sta ll th e C lu tc h H u b a n d D riv e P la te as d e sc rib e d in R -4 C O M P R E S S O R C L U T C H PLA TE AND HUB ASM . R e p la c e m e n t p ro c e d u re s. In sta ll th e c o m p re sso r d riv e belt a n d a d ju st for p ro p e r te n sio n . O p e ra te th e a ir c o n d itio n in g sy ste m to c h e c k fo r p ro p e r o p e ra tio n .

10.

9. 10.

11.

Procedure II

INERTIA RING A N D PULLEY RIM W ELDED ASSEM BLY; REPLACEM ENT (NEW PULLEY RIM AN D INERTIA RING KIT REQUIRED)
1. 2. L o o sen th e c o m p re s s o r m o u n tin g b ra c k e t a n d rem o v e th e c o m p re s s o r d riv e belt. R em o v e th e C lu tc h H u b a n d D riv e P la te assem b ly as d e sc rib e d in R -4 C O M P R E S S O R C L U T C H PL A T E A N D H U B ASSEM BLY rem o v a l p ro c e d u re . T o re m o v e as a n assem b ly , p e rfo rm S tep s 1 th ro u g h 4 o f R -4 C O M P R E S S O R C L U T C H ROTOR A N D /O R B E A R IN G re m o v a l p ro c e d u re s, b u t d o n o t loosen o r re m o v e th e p u lley rim m o u n tin g screw s so as to re m o v e th e C lu tc h R o to r a n d B earin g , C lu tc h C oil, P u lley R im a n d I n e rtia R in g as a to ta l assem b ly . Be ca re fu l n o t to d ro p th e P u lle r G u id e J-25031 w h en re m o v in g th e assem b ly . R em o v e all six ( 6) p u lley rim m o u n tin g screw s a n d lo c k w a sh e rs fro m th e assem b ly a n d d isc a rd . S e p a ra te th e P u lle y R im a n d In e rtia R in g assem b ly aw ay fro m th e R o to r a n d B e a rin g assem b ly . In sp e c t th e d riv e su rfa c e s o f th e R o to r a n d D riv e P la te to be su re th e y a re still in g o o d c o n d itio n . R e p la c e as re q u ire d . A sse m b le a new P u lle y R im o v e r th e C lu tc h C oil a n d m o u n t th e P u lle y R im to th e R o to r a n d B ea rin g assem b ly , u sin g th e s h o rt n o tc h m o u n tin g lo c a tio n s, F ig u re I D 1-26. The m o u n tin g n o tc h e s a re lo c a te d 120 a p a r t ra d ia lly a ro u n d th e P u lle y R im . A sse m b le th re e (3) new lo c k w a sh e rs o n th e th re e (3) new 6 .4 m m -2 8 x 13.5m m (1 /4 -2 8 X 5 /1 6 " ) m o u n tin g screw s a n d a p p ly L o c tite 601 (o r e q u iv a le n t se a le r) to th e e n tire th re a d su rfa c e o f th e m o u n tin g screw s a n d th e m o u n tin g h o le th re a d s in th e R o to r. A sse m b le th e th re e (3) screw s in to th e s h o rt n o tc h m o u n tin g hole lo c a tio n s a n d tig h te n fin g e r tig h t. A lig n th e P u lle y R im so th a t th e b o tto m o f th e rim n o tc h e s to u c h th e m o u n tin g screw s a t all th re e (3) m o u n tin g lo catio n s. A lso c e n te r th e d rille d h o les in th e P u lley R im w ith th e re m a in in g m o u n tin g h o les in th e R o to r. W h en 12.

13.

3.

14.

4. 5.

15.

16.

6.

7.

17.

8.

18. 19.

9.

MAJOR REPAIR PROCEDURES, R-4 COMPRESSOR


S ervice repair procedures to th e C om pressor S h a ft Seal, Pressure R elief V alve or disassem bly o f th e In te rn a l C om pressor C ylin d er and S h a ft A sse m b ly are considered

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-13

"M A J O R " SINCE THE REFRIGERATION SYSTEM MUST BE DISCHARGED, EVACUATED A N D RECHARGED to co m plete service a n d /o r because m a jo r in te rn a l o p e ra tin g and sealing com p on e n ts o f th e com pressor are being disassem bled and serviced.
W h e n re p la c in g th e sh a ft seal assem b ly (see Fig. 1D 1-35) o r p re ssu re re lie f v alve (see Fig. 1D 1-3), even if th e c o m p re s s o r re m a in s o n th e veh icle d u rin g th e o p e ra tio n , it w ill be n e cessary to p u rg e th e sy stem o f re frig e ra n t (see S ectio n 1B1). O th e r th a n c lu tc h re p a ir p ro c e d u re s , th e sam e h o ld s tru e fo r an y d isa ssem b ly o f th e c o m p re sso r. I f th e c o m p re ss o r sh ell, fro n t h ead o r c y lin d e r a n d sh a ft assem b ly a re to be serv iced o r re p lac ed , th e oil in th e c o m p re s s o r m u st be d ra in e d , m e a su re d a n d re p la c e d (see Sectio n 1B 1) to d e te rm in e a d d itio n o f p ro p e r oil q u a n tity to new assem b ly . A clean w o rk b e n c h , p re fe ra b ly co v e red w ith a sh eet o f cle a n p a p e r, o rd e rlin e ss in th e w o rk a re a a n d a p la c e fo r all p a rts bein g re m o v e d a n d re p la c e d is o f g re a t im p o rta n c e , as is th e use o f th e p ro p e r, clean serv ice tools.

re p lac ed a c c o rd in g to th e d ire c tio n s in S ection 1B1 to d e te rm in e oil loss. Remove (On Car) 1. 2. 3. 4. 5. D isc h a rg e th e R e frig e ra n t S y ste m a c c o rd in g to th e d ire c tio n in S ectio n 1B1. L o o sen a n d rep o sitio n c o m p re s s o r in m o u n tin g b ra c k e ts, if n ecessary . R em o v e C lu tc h P la te a n d H u b assem b ly from c o m p re sso r as d e sc rib e d in M in o r R ep airs. R e m o v e th e sh a ft seal seat re ta in e r ring, using S n ap R in g P lie rs J-5 4 0 3 -A . T h o ro u g h ly cle an in sid e o f c o m p re s s o r n eck a re a su rro u n d in g th e sh a ft, th e ex p o sed p o rtio n o f th e seal seat a n d th e sh a ft itself. A n y d irt o r fo reig n m a te ria l g e ttin g in to c o m p re s s o r m ay c au se d am a g e. R em o v e T w o P iece Seal Seat o r L ip Seal: O n e P iece Seal: F u lly e n g ag e th e k n u rle d ta n g s o f Seal R e m o v e r-In s ta lle r J2 3 1 2 8 -A in to th e recessed p o rtio n o f th e Seal by tu rn in g th e h a n d le clockw ise. R e m o v e th e Seal fro m th e c o m p re s s o r w ith a ro ta ry -p u llin g m o tio n . D is c a rd th e Seal. T h e h a n d le m u st be h a n d -tig h te n e d secu rely . D o n o t use a w re n c h o r p rier. T w o P iece Seal: P la c e Seal P ro te c to r J-2 2 9 7 4 -A o r J-3 4 6 1 4 o v er th e e n d o f th e sh a ft to p re v e n t c h ip p in g th e c e ra m ic seat. F u lly en g a g e th e k n u rle d ta n g s o f Seal Seat R e m o v e r-In s ta lle r J-2 3 1 2 8 -A in to th e rec essed p o rtio n o f th e seal seat by tu rn in g th e h a n d le clo ck w ise. R e m o v e th e Seal S eat fro m th e c o m p re s s o r w ith a ro ta ry -p u llin g m o tio n (F ig . 1D 1-31). D is c a rd th e Seat. T h e h a n d le m u st be h a n d -tig h te n e d secu rely . D o n o t use a w re n c h o r plier. R e m o v e T w o P iece Seal: O n e P iece Seal: P ro c e e d to S tep 8. T w o P iece Seal: W ith Seal P ro te c to r J-2 2 9 7 4 -A o r J-3 4 6 1 4 still o v e r th e e n d o f th e sh a ft, set Seal R e m o v e r-In s ta lle r J-9392-01 d o w n o n to sh a ft en d , tu r n in g c lo ck w ise, w h ile p re ssin g d o w n to en g ag e R e m o v e r ta n g s w ith th e ta b s on th e Seal assem b ly . T h e n lift th e S haft Seal assem b ly o u t (see F ig. 1D 1-33). D is c a rd th e Seal. R e m o v e a n d d is c a rd th e seal seat O -rin g fro m th e c o m p re sso r, n eck u sin g O -R in g R em over J-9553-01 (F ig . 1D 1-31). R e c h e c k th e sh a ft a n d in sid e o f th e c o m p re s s o r neck and O ring g ro o v e for dirt or foreign m ate rial and be sure these areas are p erfectly clean b e fore installing new parts.

6.

NOTICE: A n y a tte m p t to use m a k e-sh ift o r in a d e q u a te e q u ip m e n t m ay re su lt in d a m a g e a n d / o r im p ro p e r c o m p re s s o r o p e ra tio n .


A ll p a rts re q u ire d fo r se rv ic in g th e in te rn a l c o m p re s s o r a re p ro te c te d by a p re s e rv a tio n p ro ce ss a n d p a c k a g e d in a m a n n e r w h ic h w ill e lim in a te th e n ecessity o f clean in g , w a sh in g o r flu sh in g o f th e p a rts. T h e p a rts can be used in th e in te rn a l asse m b ly ju s t as th e y a re re m o v e d fro m th e serv ice p ack ag e. Seals and

protective packaging should be left intact until ju st prior to installation .

7.

R-4 COMPRESSOR SHAFT SEAL Shaft Seal Design


S h a ft seal design m a y be o n e o r tw o piece. W h e n re p la c in g sh a ft seals, it is im p o rta n t th a t a tw o piece (face) seal be serv iced o n ly w ith a tw o piece seal. W h e n a o n e piece (lip ) seal is re p la c e d e ith e r o ne o r tw o piece seals m ay be u sed. D a m a g e to th e o n e piece seal m a y o c c u r a n d re s u lt in a seal leak, if th is p ro c e d u re is n o t follow ed.

8.

9.

Seal Leak Detection


A sh a ft seal s h o u ld n o t be c h a n g e d b ecau se o f an oil-lin e o n th e h o o d in s u la to r. T h e Seal is d e sig n e d to seep so m e oil fo r lu b ric a tio n p u rp o se s. O n ly c h a n g e a S h a ft Seal w h en a leak is d e te c te d by e v id en ce o f oil sp ra y e d in larg e a m o u n ts a n d th e n o n ly a fte r a c tu a l re frig e ra n t leak ag e is fo u n d b y u sin g a n a p p ro v e d leak D e te c to r su c h as J-2 9 5 4 7 o r e q u iv a le n t. S h o u ld an R -4 c o m p re s s o r sh a ft seal ev er h av e to be re p la c e d , th e a c c u m u la to r in th is R -4 sy stem m u st also be re m o v e d fro m th e vehicle. T h e oil in th e a c c u m u la to r th e n m u s t be d ra in e d , m e a su re d a n d

Inspection Seals s h o u ld n o t be re u se d . A lw a y s use a new sp e c ific a tio n serv ice seal kit on re b u ild (see Fig. I D 1-35). B e e x tre m e ly ca re fu l th a t th e face o f th e tw o piece Seal to be in sta lle d is n o t s c ra tc h e d o r d a m a g e d in an y w ay. S im ila r c a re s h o u ld be ta k e n to p re v e n t d a m a g e to th e lip o f th e o n e piece seal. M a k e su re th a t th e Seal S eat a n d Seal L ip a re free o f lin t a n d d irt th a t co u ld d a m a g e th e seal su rfa c e o r p re v e n t sealing.

1D1-14 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL

Fig. 1 D 1-30 R em oving and In s ta llin g Seal(One Piece)

Fig. 1 D 1-31 R em oving and In s ta llin g C e ra m ic Seal S eat (Tw o Piece Seal)

Replace (On Car) 1. D ip th e new seal seat O -rin g in clean 525 v iscosity re frig e ra n t oil a n d assem b le o n to O -R in g In s ta lle r J-2 1 5 0 8 -A (F ig . 1D 1-33). In s e rt th e O -R in g In s ta lle r J - 2 1508-A c o m p le te ly d o w n in to th e c o m p re s s o r n eck u n til th e In s ta lle r b o tto m s . L o w e r th e m o v eab le slid e o f th e O -R in g In s ta lle r to release th e O -R in g in to th e seal seat O -rin g lo w e r gro o v e. (T h e c o m p re sso r n eck to p g ro o v e is fo r th e sh a ft seal re ta in e r rin g .) R o ta te th e In s ta lle r to seat th e O -rin g a n d re m o v e th e In sta lle r. P re p a re Seal: O n e P iece Seal: A ssem b le seal to Seal In s ta lle r J - 2 3 12 8-A , by tu rn in g h a n d le clo ck w ise, a n d th e n p u s h Seal P r o te c to r J-3 4 6 1 4 , in to seal lip. 5. 4.

o f th e seal w ith th e ta n g s o f th e In s ta lle r (F ig . 1D 1-28). In s ta ll Seal: O n e P iece Seal: P la c e seal p ro te c to r J-34614 o v er en d o f c o m p re sso r sh a ft a n d slid e new seal o n to th e sh a ft u n til it sto p s. D ise n g a g e in sta lle r fro m seal. T w o P iece Seal: P lac e Seal P ro te c to r J-2 2 9 7 4 -A o r J-3 4 6 1 4 o v e r e n d o f c o m p re s s o r sh a ft a n d slide th e n ew Seal assem b ly o n to th e sh aft. T w ist th e In s ta lle r J-9392-01 clo ck w ise, w h ile p u sh in g th e Seal assem b ly d o w n th e sh a ft u n til th e Seal asse m b ly en g ag es th e fla ts o n th e sh a ft a n d is se a te d in place. D ise n g a g e th e In s ta lle r by p ressin g d o w n w a rd and tw istin g co u n te rc lo c k w ise . In sta ll T w o P iece Seal S eat: O n e P iece Seal: P ro c e e d to S tep 6 T w o P iece Seal:: A tta c h th e c e ra m ic Seal S eat to th e Seal Seat R e m o v e r a n d In s ta lle r J - 2 3 128 a n d d ip th e c e ra m ic Seat in c le a n 525 v iscosity re frig e ra n t oil to c o a t th e seal face a n d o u te r su rface. In s ta ll th e S eat o v e r th e c o m p re s s o r sh a ft a n d J-2 2 9 7 4 -A o r J-3 4 6 1 4 Seal P ro te c to r a n d p u sh th e S eat in to p lac e w ith a ro ta ry m o tio n (F ig. 1D 1-31). T a k e c a re n o t to d islo d g e th e seat O -rin g . Be su re Seal S eat m a k e s a g o o d seal w ith

2.

3.

NO TICE: H A N D L I N G A N D C A R E O F S E A L P R O T E C T O R IS I M P O R T A N T . I F S E A L P R O T E C T O R IS N I C K E D O R T H E B O T T O M FLARED, THE NEW SEAL MAY BE D A M A G E D D U R IN G IN S T A L L A T IO N .


T w o P iece Seal: D ip th e O -R in g a n d seal face o f th e new Seal assem b ly in to clean 525 viscosity re frig e ra n t oil. C a re fu lly m o u n t th e Seal assem bly to Seal In s ta lle r J-9392-01 by en g a g in g th e tab s

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-15

|~n SE A L
f~2~| J-9392-01

[J]
[jJ

J-9553-01 " O " RING

[T] j-21508
[ T ] J 9392

1 -S E A L 2J-23185-A

3 J-9553-01 4 -O -R IN G

5J-21508

4 2 0 0 3 2 -1 D 1

Fig. 1 D 1-32 R em oving and In s ta llin g Seal and O-Ring (One Piece Seal)

Fig. 1 D 1-3 3 R em oving and In s ta llin g Seal and O-Ring (Tw o Piece Seal)

1D1-16 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


an d , w ith c o m p re sso r in h o riz o n ta l p o sitio n , ro ta te th e c o m p re sso r sh a ft in n o rm a l d ire c tio n o f ro ta tio n sev eral tim e s by h a n d . L e ak te st th e Seal a n d c o rre c t an y leak fo u n d . R em o v e , d is c a rd a n d la te r re p la c e th e sh a ft n u t. R e m o v e an y excess oil, re su ltin g fro m in sta llin g th e new seal p a rts, fro m th e sh aft a n d in sid e th e c o m p re s s o r neck. In sta ll th e C lu tc h P la te a n d H u b assem b ly as d e sc rib e d in m in o r re p a ir p ro c e d u re s. R e in sta ll c o m p re sso r b elt a n d tig h te n b ra c k e try . E v a c u a te a n d C h a rg e th e R e frig e ra n t S ystem a c c o rd in g to d ire c tio n s in S e ctio n 1B1.

9. 10. 11.

Replace (Off Car) 1. 2. F o llo w a p p lic a b le o n -c a r p ro c e d u re s. T o L ea k T e st, in sta ll leak T e st F ix tu re J-9625 (F ig . I D 1-41) on re a r h e a d o f c o m p re sso r a n d c o n n e c t gage c h a rg in g lines, o r p re ssu riz e su c tio n side (low p re ssu re side) o f c o m p re sso r on c a r w ith R e f rig e r a n t- 12 v a p o r to e q u a liz e p re ssu re to th e d ru m p re ssu re . T e m p o ra rily in sta ll th e sh a ft n u t a n d , w ith c o m p re sso r in h o riz o n ta l p o sitio n a n d u sin g a w re n c h , ro ta te th e c o m p re sso r sh a ft in n o rm a l d ire c tio n o f ro ta tio n several tim es by h a n d . L ea k test th e seal a n d c o rre c t a n y leak fo u n d . R em o v e, d isc a rd a n d la te r re p la c e w ith a new sh a ft n u t. See F igs. 1D 1-38, 1D 1-39 a n d 1D 1-40.

SPECIF- 1C A T I O N P A R T S SEAL CARTON M A T E R IA L 1 L A R G E C H A M F E R ON I N S I D E D I A M E T ER SEAT C ER AM IC M A T E R IA L W IT H P O L IS H E D FACE 0 R IN G S , N E O PR EN E . TH US C A P A B L E OF G IV IN G HEAT RESISTANCE A N D LI FE E X P E C T A N C Y

420035-1D1

Fig. 1D 1-35 T w o Piece C o m p re s s o r S h a ft Seal and 0-R in g s

3.

O -rin g . R e m o v e In s ta lle r J-2 3 1 2 8 P ro te c to r J-2 2 9 7 4 -A o r J-34614.

and

Seal

1-J-23128 A Fig. 1 D 1-36 R em oving and In s ta llin g S h a ft Seal S eat R e ta in in g Ring 2-ONE-PIECE SEAL 3 - J-34614 - SHAFT SEAL PROTECTOR
420037-1D 1

6.

7.

In sta ll th e new seal se a t re ta in e r rin g w ith its flat side a g a in st th e Seal Seat, u sin g S n a p -R in g P liers J-5403. See Fig. 1D 1-36. U se th e sleeve fro m Seal Seat R e m o v e r-In s ta lle r J-9 3 9 3 -A to p ress in on th e seal seat re ta in e r rin g so th a t it sn a p s in to its groove. For L eak T est, p re ssu riz e s u c tio n side (lo w -p re ssu re side) o f c o m p re s s o r on v eh icle w ith R e f r ig e r a n t- 12 v a p o r to e q u alize p re s s u re to th e d ru m p re ssu re . T e m p o ra rily in sta ll th e sh a ft n u t

Fig. 1D 1-37 R em oving & In s ta llin g One Piece Seal (O ff Car)

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-17

R-4 COMPRESSOR PRESSURE RELIEF VALVE


1 J-22974-A OR J-34614 SHAFT SEAL PROTEC TOR 2 CERAMIC SEAL SEAT 3 J-23128-A SEAL SEAT REMOVER AND INSTALLER

T h e P re s s u re R e lie f V alve, lo c a te d in th e c o m p re s s o r re a r h e a d c a stin g (F ig . I D 1-3), s h o u ld on ly be re p la c e d a fte r p u rg in g th e sy stem o f re frig e ra n t. A new valve a n d O -rin g c o a te d w ith 525 v isco sity re frig e ra n t oil s h o u ld be in sta lle d .

| T 1 L E A K TEST ADAPTER J 9625

[~2~| H I G H
PRE SS URE CUT OFF S W IT C H 420038- 1D1 N O T IC E : H IG H

Fig. 1 D 1 -3 8 R em o vin g & In stallin g T w o P ie c e S e a l S e a t (Off Car)

PR ESS URE C U T OFF SW IT C H IN S U L A T O R S ARE COLORED RED


4 2 0 0 4 1 -1 D1

1 J-22974-A OR J-34614 SHAFT SEAL PROTEC TOR 2SHAFT SEAL 3 J-9392-01 SHAFT SEAL REMOVER AND INSTALLER

Fig. 1D1- 41 C o m p re s s o r Leak T e s tin g F ixture

HI-SIDE HIGH PRESSURE CUT-OFF SW ITC H (IF USED)


Remove and Replace 1. D isc h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e D IS C H A R G IN G , A D D IN G O IL , E V A C U A T IN G AND C H A R G IN G P R O C E D U R E S F O R C .C .O .T . A / C S Y S T E M S in th e A ir C o n d itio n in g S ectio n 1B1. D isc o n n e c t th e e le c tric a l c o n n e c to r fro m th e H i P re ssu re c u t-o ff sw itc h in th e re a r h e a d o f th e c o m p re s s o r (F ig . I D 1-42). R e m o v e th e h ig h p re ssu re c u t-o ff sw itc h re ta in in g rin g (F ig . I D 1-42) u sin g J-5 4 0 3 -A in te rn a l sn a p rin g p liers. R e m o v e h ig h p re s s u re c u t-o ff sw itc h fro m c o m p re s s o r by p u llin g o n te rm in a l h o u sin g . R e m o v e o ld O -rin g seal fro m sw itc h c a v ity u sin g J-9 5 5 3 O -rin g re m o v al to o l o r eq u iv a le n t. I f h ig h p re s s u re c u t-o ff sw itc h w ill be re in sta lle d in c o m p re sso r, a new O -rin g seal m u s t be u sed a n d p re fe ra b ly a new re ta in e r rin g s h o u ld a lso be used . A new sw itc h k it h a s th e O -rin g a n d re ta in e r rin g in c lu d e d . C h e c k sw itc h c a v ity a n d O -rin g g ro o v e in th e re a r h e a d fo r d irt o r fo re ig n m a te ria l a n d cle a n as n ec essary . In s ta ll new O -rin g c o a te d w ith clea n 525 v isco sity re frig e ra n t oil in to g ro o v e in sw itc h cav ity . L u b ric a te th e h ig h p re s s u re c u t-o ff sw itc h h o u sin g w ith cle an 525 v isc o sity re frig e ra n t oil a n d c a re fu lly in se rt sw itc h in to sw itc h ca v ity u n til sw itc h b o tto m s in c av ity . U sin g J-5 4 0 3 -A sn a p rin g p liers, in sta ll sw itc h re ta in in g rin g w ith h ig h p o in t o f c u rv e d sides a d ja c e n t to th e sw itc h h o u sin g . Be su re re ta in in g

420039-1D1

2.

Fig. 1 D 1 -3 9 R em o vin g & In sta llin g T w o P ie c e S e a l (Off C ar)

3.

D p J21508 O RING INSTALLER [ T ] SEAL SEAT O RING

4.

5.

6.

420040-1D1

7.

Fig. 1D1-40 Installing Seal Seat O-Ring (Off Car)

8.

1D1-18 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


rin g is p ro p e rly se a te d re ta in e r rin g groove. in th e sw itc h cav ity

fT ]

OIL HOLE TO SHAFT AREA

f~2~l FRONT HEAD SEALING RING

fT !
iT 1

MAIN BEARING THRUST WASHERS AND BELLEVILLE WASHER


4 2 0 0 4 4 -1D1

Fig. 1D 1-42 H igh Pressure C ut-O ff S w itc h and R etainer

R-4 COMPRESSOR FRONT HEAD A N D/O R O-RING


Remove 1. 2. D isc h a rg e th e R e frig e ra n t System a c c o rd in g to th e d ire c tio n s in S ectio n IB 1. P e rfo rm ste p s 1 th r o u g h 4 of R -4 C O M P R E S S O R C L U T C H R O T O R A N D /O R B E A R I N G re m o v a l p ro c e d u re , b u t d o n o t lo osen o r re m o v e th e p u lley rim m o u n tin g screw s so as to re m o v e th e C lu tc h R o to r a n d B earin g , C lu tc h C oil a n d P u lle y R im as a to ta l assem b ly . Be ca re fu l n o t to d ro p th e P u lle r G u id e J-25031 w h en re m o v in g th e assem b ly . R e m o v e a n d d isc a rd th e S h aft Seal p a rts as d e sc rib e d in R -4 C O M P R E S S O R S H A F T S E A L rem o v a l p ro c e d u re . R em o v e th e fo u r fro n t h e a d m o u n tin g screw s (F ig . 1D 1-43) a n d rem o v e th e F r o n t H e a d assem b ly (F ig . I D 1-44). 1.

Fig. 1 D 1-44 R em oving F ro n t Head A sse m b ly

Replace C h e c k th e F r o n t H e a d a n d c o m p re sso r c y lin d e r a re a fo r a n y d irt, lin t, etc. a n d clea n if n ecessary . In s ta ll a new S ervice th r u s t w a sh e r kit, if re q u ire d , as d e sc rib e d in R -4 C O M P R E S S O R T H R U S T A N D B E L L E V IL L E W A S H E R S REM OVAL AND REPLACEM ENT p ro c e d u re s. D ip th e new fro n t h e ad O -rin g in clea n 525 v isco sity re frig e ra n t oil a n d in sta ll in th e seal g ro o v e on th e fro n t h e a d (F ig . ID 1-44). P o sitio n th e oil h o le in th e F ro n t H e a d to be U P w h en assem b led to th e c o m p re sso r c y lin d e r to c o rre sp o n d w ith th e U P p o sitio n o f th e c o m p re sso r. In sta ll th e F ro n t H e a d a n d tig h te n th e fro n t h e ad m o u n tin g screw s to 27 N * m (20 lb. ft.) to rq u e . In sta ll new sp ec ifica tio n S erv ice S haft Seal kit (F ig . ID 1-35) as d e sc rib e d in R -4 COM PRESSOR SH A FT SEAL R EPLA C EM EN T PRO CED U RE. In sta ll th e C lu tc h R o to r a n d B e arin g assem b ly , C lu tc h C oil a n d P u lley R im assem b ly to th e F ro n t H e a d , u sin g R o to r a n d B earin g In s ta lle r J-2 6 2 7 1 -A (F ig . 1D 1-19). B efore fully se a tin g th e assem b ly o n to th e F ro n t H e a d , be su re th e c lu tc h coil te rm in a ls a re in th e p ro p e r lo c a tio n in re la tio n to th e c o m p re sso r a n d th a t th e th re e p ro tru s io n s on th e re a r o f th e c lu tc h coil align w ith th e lo c a to r holes in th e F r o n t H e ad . In s ta ll th e ro to r a n d b e a rin g assem b ly re ta in e r rin g a n d re assem b le th e C lu tc h P la te a n d H u b a ssem b ly as d esc rib e d in R -4 C O M P R E S S O R C L U T C H P L A T E A N D H U B re p la c e m e n t p ro c e d u re . C h ec k to see th a t th e c lu tc h p la te to c lu tc h ro to r g a p is .5 - 1 .Omm (.0 2 0 - .040 in ch es). E v a c u a te a n d c h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ection 1B1.

2.

3.

3.

4.

|~ 1 | FRONT HEAD

| 2 | MOUNTING SCREWS (4)

Fig. 1 D 1-43 R em oving F ront Head M o u n tin g S cre w s

5.

R em o v e a n d d is c a rd th e fro n t h e a d O -rin g .

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-19 R-4 COMPRESSOR THRUST AND BELLEVILLE WASHERS
Remove and Replace
1. 2. D is c h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1. R e m o v e th e F r o n t H e a d a ssem b ly as d e sc rib e d in F r o n t H e a d R e m o v a l P ro c e d u r e . R em o v e an d d is c a rd th e fro n t h e a d O -rin g seal. R e m o v e th e tw o th r u s t w a sh e rs a n d o ne belleville w a sh e r fro m th e c o m p re s s o r sh aft. N o te th e a sse m b le d p o sitio n o f th e w ash ers. In s ta ll a new th r u s t w a s h e r on th e c o m p re sso r sh a ft w ith th e th r u s t w a s h e r ta n g p o in tin g U P " (F ig . 1D 1-45).

3.

4.

2.

A lig n th e new M a in B e arin g a n d th e B e arin g In s ta lle r J-24895 sq u a re ly w ith th e b e a rin g b o re o f th e F r o n t H e a d a n d d riv e th e b e a rin g in to th e F r o n t H e a d . T h e In s ta lle r J-2 4 8 9 5 m u st seat a g a in st th e F r o n t H e a d to in se rt th e b e a rin g to th e p ro p e r c le a ra n c e d e p th (see Fig. I D 1-47).

5. 6. 7.

In s ta ll th e new bellev ille w a sh e r o n th e sh a ft w ith th e h ig h c e n te r o f th e w a s h e r U P . In s ta ll th e re m a in in g th r u s t w a sh e r on th e sh aft w ith th e ta n g p o in tin g D O W N (F ig. I D 1-45). L u b ric a te th e th re e w a sh e rs w ith clean 525 v isco sity re frig e ra n t oil a n d assem b le th e F ro n t H e a d a n d new O -rin g o n to th e c o m p re sso r as d e sc rib e d in R -4 C O M P R E S S O R F R O N T H E A D re p la c e m e n t p ro c e d u re .

3.

R-4 COMPRESSOR MAIN BEARING


Remove
1. 2. D is c h a rg e th e re frig e ra n t sy ste m a c c o rd in g to th e d ire c tio n in S ectio n 1B1. R e m o v e th e F r o n t H e a d asse m b ly as d e sc rib e d in FRO N T H EA D REM OVAL PRO CED U RE. D is c a rd fro n t h e a d O -rin g . P la c e th e F r o n t H e a d asse m b ly on tw o b lo ck s, as sh o w n in Fig. I D 1-46, a n d use M a in B e arin g R e m o v e r J-2 4 8 9 6 to d riv e th e M a in B ea rin g o u t o f th e F r o n t H e a d .

4.

A sse m b le th e F r o n t H e a d to th e c y lin d e r, using a new O -rin g as d e sc rib e d in R -4 C O M P R E S S O R F R O N T H E A D re p la c e m e n t p ro c e d u re . E v a c u a te a n d c h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1.

R-4 COMPRESSOR SHELL AND/OR O-RINGS


Remove
1. 2. D isc h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1. T h o ro u g h ly clean e x te rio r o f c o m p re s s o r to p re v e n t d irt fro m g e ttin g in to c o m p re s s o r d u rin g shell rem o v a l. R e m o v e th e C lu tc h P la te a n d H u b asse m b ly as d e sc rib e d in C O M P R E S S O R C L U T C H P L A T E A N D H U B rem o v a l p ro c e d u re s. P e rfo rm S tep s 1 th ro u g h 4 of R -4 C O M P R E S S O R C L U T C H R O T O R A N D /O R B E A R I N G rem o v a l p ro c e d u re b u t d o n o t loosen

3.

3.

Replace
1. P la c e th e F ro n t H e a d w ith n e c k -e n d d o w n on a flat, solid su rface.

4.

1D1-20 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


o r rem o v e th e p u lley rim m o u n tin g screw s so as to rem o v e th e C lu tc h R o to r a n d B earin g , C lu tc h C oil a n d P u lley R im as a to ta l assem b ly . Be ca refu l n o t to d ro p th e P u lle r G u id e J-25031 w hen re m o v in g th e assem b ly . P ry th e sh ell re ta in in g s tra p aw ay fro m th e c y lin d e r a n d p o sitio n th e s tra p h ig h e n o u g h to c le a r th e c y lin d e r as th e Shell is re m o v e d (F ig. 1D 1-48). 7. A lte rn a te ly tig h te n each b o lt a p p ro x im a te ly 1 /4 tu rn to p u sh th e Shell free o f th e O -rin g s on th e c y lin d e r (F ig . 1D 1-49). I f o n e (1) screw a p p e a rs to re q u ire m o re fo rce to tu rn th a n th e o th e r, im m e d ia te ly tu rn th e o th e r screw to b rin g th e screw th re a d in g se q u en c e in -ste p o r th e Shell w ill be c o c k e d a n d m a d e m o re d iffic u lt to rem ove. N o rm a l rem o v al d o es n ot re q u ire m u c h fo rce on th e w re n c h if th e screw s a re k ep t in -ste p w hile tu rn in g . T h e Shell can be rem o v ed by h a n d as so o n as th e Shell is free o f th e shell to c y lin d e r O -rin g s. D o n o t tu r n th e screw s an y f u r th e r th a n n ecessary to release th e Shell. 8. R em o v e th e c o m p re sso r S hell a n d re m o v e th e H o ld in g F ix tu re J-2 5 0 0 8 -A fro m th e c o m p re sso r. R ev e rse th e H o ld in g F ix tu r e to ag ain h o ld th e c o m p re sso r by th e o p p o site side, using th e sh o rt-le n g th screw s w ith m e tric th re a d s. R em ove O -rin g s. and d isc a rd b o th c y lin d e r to Shell

5.

9.

Replace
1. C h e c k th e c o m p re sso r c y lin d e r assem b ly an d in te rio r o f th e c o m p re sso r S hell to be su re th ey a re free o f lin t, d irt, etc. D ip a new c y lin d e r-to -sh e ll O -rin g in clean 525 v iscosity re frig e ra n t oil a n d in stall in th e re a r O -rin g g ro o v e o f th e c y lin d e r. Be c a re fu l in m o v in g th e O -rin g a c ro ss th e c y lin d e r su rfa c e to p re v e n t d a m a g in g th e O -rin g . D ip th e re m a in in g c y lin d e r-to -sh e ll O -rin g in th e 525 oil a n d in sta ll it in th e fro n t O -rin g g ro o v e o f th e c y lin d e r. A lso c o a t in n e r O -rin g su rfa c e o f c o m p re sso r S hell w ith oil. P la ce th e c o m p re s s o r Shell on th e c y lin d e r a n d ro ta te th e re ta in in g s tra p to its o rig in a l lo c a tio n . A tta c h th e Shell In sta llin g F ix tu re J-2 5 0 0 8 -A to th e H o ld in g F ix tu re J-2 5 0 0 8 -A , using th e lo n g -b o lts a n d p la te w a sh e rs o f th e set. A lig n th e ste p p ro je c tio n s o f th e In s ta llin g F ix tu re J-2 5 0 0 8 -A , to c o n ta c t th e c o m p re s s o r Shell evenly on b o th sides. P u sh th e c o m p re sso r shell as close to th e O -rin g , F ig. ID 1-50, as p ossible by h a n d a n d c h ec k for eq u al a lig n m e n t o f th e sh ell a ro u n d th e c y lin d e r. T ig h te n th e F ix tu re screw s fin g e r tig h t. A lte rn a te ly tig h te n ea ch b o lt a p p ro x im a te ly 1 /4 tu r n to p u sh th e c o m p re s s o r Shell o v e r th e O -rin g s a n d b ack a g a in st th e sh ell s to p flan g e at th e re a r o f th e c o m p re s s o r c y lin d e r. I f o n e (1) screw a p p e a rs to re q u ire m o re fo rce to tu r n th a n th e o th e r, im m e d ia te ly tu r n th e o th e r screw to b rin g th e sc rew th re a d in g seq u e n ce in -ste p o r th e shell w ill be c o c k e d a n d m a d e m o re d iffic u lt to in stall. N o rm a l in sta lla tio n do es n ot re q u ire m u c h fo rce on th e w re n c h if th e screw s a re k e p t in -ste p w h ile tu rn in g . 8.
Fig. 1D 1-49 R em oving Shell

2.

6.

R e m o v e C o m p re s s o r H o ld in g F ix tu re J-2 5 0 0 8 -A , a n d rev erse H o ld in g F ix tu re w ith ste p b lo ck p ro tru s io n s e n g ag in g th e c o m p re s s o r Shell. In sta ll th e m e d iu m -le n g th m e tric th re a d m o u n tin g b o lts th ro u g h th e H o ld in g F ix tu re a n d th re a d th e m fin g e r-tig h t o n b o th sides in to th e c o m p re s s o r c y lin d e r u n til th e ste p o f th e fix tu re p ro tru s io n s c o n ta c t th e c o m p re s s o r Shell (F ig. I D 1-48). C h e c k to be su re th e ste p p ro tru s io n s d o n o t o v e rla p th e c y lin d e r b u t w ill p ass b o th sides. A llo w c o m p re s s o r to co o l to ro o m te m p e ra tu re b efo re re m o v in g c o m p re s so r shell.

3.

4.

5.

rn

J-25008-A HOLDING FIXTURE

6.

H H SHELL TO
CYLINDER O-RING

7.

f T ! ALTER NATELY
TIGHTEN SCREWS APPROX. 1/4 TURN f T ] STEP CONTACTS COMPRESSOR SHELL

4 2 0 0 4 9 -1 D1

W h e n th e shell is se a te d a g a in st th e sto p s, b en d th e shell re ta in in g s tr a p d o w n in to p lac e by ta p p in g g en tly w ith a h a m m e r. R e m o v e th e Shell In sta llin g F ix tu re J-2 5 0 0 8 -A .

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-21

r r ij -2 5 0 0 8 - A
------'COMPRESSOR 1 SHELL INSTALLER

rT ]j-2 5 0 0 8 -A
------HOLDING FIXTURE

[ T I a LT. ------ TIGHTEN SCREWS APPROX. V* TURN

Fig. 1 D 1 -5 0 In s ta llin g S hell

9.

R e in s ta ll C lu tc h R o to r a n d B e a rin g A sm ., C lu tc h C o il a n d P u lley R im as a n asse m b ly w ith In s ta lle r J-2 6 2 7 1 -A (F ig. 1D 1-12), a n d th e C lu tc h P la te a n d H u b A sse m b ly w ith I n s ta lle r J-9480-B (F ig. 1 D 1 -1 1). E v a c u a te a n d C h a rg e th e R e frig e ra n t S y ste m a c c o rd in g to th e d ire c tio n s in S ectio n IB .

I 1 ] VALVE PLATE | 2 [PISTON AND REED ASSY.

10.

R-4 COMPRESSOR DISCHARGE VALVE PLATE AND/OR RETAINER


Remove and Replace
1. D is c h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1. P e rfo rm S tep s 1 th ro u g h 9 of R -4 C O M P R E S S O R S H E L L A N D / O R O -R I N G S re m o v a l p ro c e d u re . R e m o v e valve p la te re ta in e r rin g , u sing I n te rn a l S n ap R in g P lie rs J-4 2 4 5 , F ig . 1D 1-51. R em o v e C o m p re sso r D is c h a rg e V alve P la te (F ig. I D 1-52) fo r valve p la te re p la c e m e n t a n d / o r p isto n in sp e c tio n . R e p e a t th is o p e ra tio n fo r a d d itio n a l valve p lates a n d re ta in e r rin g s. I f all fo u r v alve p la te s a n d re ta in e rs a re to be re m o v e d , re m o v e tw o sets an d th e n ro ta te c o m p re s s o r a n d H o ld in g F ix tu re J-2 5 0 0 8 -A in vise fo r access to th e re m a in in g tw o v alv e p la te s a n d re ta in e rs. 4. In s ta ll D isc h a rg e V alve P la te s a n d / o r R e ta in e rs as sh o w n in Figs. 1D 1-51 a n d 1D 1-52. R e p o sitio n c o m p re s s o r a n d H o ld in g F ix tu re in vise as n e c e ssa ry fo r access. R e in s ta ll c o m p re s so r S hell as d e sc rib e d in R -4 C O M P R E S S O R S H E L L A N D / O R O -R IN G S re p la c e m e n t p ro c e d u re s. E v a c u a te a n d c h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1.

/MIL

^
4 2 0 0 5 2 -1 D1

2.

Fig. 1 D 1 -5 2 R e p la cin g D isch a rg e V alve Plate

3.

R-4 COMPRESSOR CYLINDER AND SHAFT ASM.


Remove
1. 2. D isc h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1. R e m o v e th e C lu tc h P la te a n d H u b a sse m b ly as d e sc rib e d in C O M P R E S S O R C L U T C H P L A T E A N D H U B re m o v a l p ro c e d u re . P e rfo rm S teps 1 th ro u g h 4 of R -4 C O M P R E S S O R C L U T C H R O T O R A N D /O R B E A R I N G rem o v a l p ro c e d u re b u t d o n o t loosen o r rem o v e th e p u lley rim m o u n tin g screw s. R e m o v e th e C lu tc h R o to r a n d B earin g , C lu tc h C oil a n d P u lle y R im as an assem b ly . Be ca refu l n o t to d ro p th e P u lle r G u id e J-2 5 0 3 1 , w h en re m o v in g th e assem b ly . 4. 5. R e m o v e th e sh a ft seal as d e sc rib e d in S H A F T S E A L re m o v a l p ro c e d u re . R em o v e th e fro n t h e ad as d e sc rib e d in F R O N T H E A D R E M O V A L p ro c e d u re .

5.

6.

1D1-22 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL


6. R em o v e th e th r u s t a n d belleville w a sh e rs as d e sc rib e d in T H R U S T A N D B E L L E V IL L E W A S H E R S re m o v a l p ro c e d u re s. R em o v e th e c o m p re ss o r shell as d e sc rib e d in S H E L L re m o v a l p ro c e d u re . R em o v e th e d isc h a rg e valve p la te a n d re ta in e r as d e sc rib e d in D I S C H A R G E V A L V E P L A T E A N D / O R R E T A I N E R re m o v a l p ro c e d u re . R em o v e th e h ig h p re ssu re re lie f valve as d e sc rib e d in H I G H P R E S S U R E R E L IE F VALVE REM O V A L PR O CED U RE. 10. In sta ll a sh a ft n u t on th e c o m p re sso r c ra n k s h a ft if th e d riv e p la te an d c lu tc h assem b ly a re n ot in sta lled . 11. U sin g a box -en d w re n c h o r so c k et a n d h a n d le , ro ta te th e c o m p re sso r c ra n k s h a ft o r c lu tc h d riv e p la te on th e c ra n k s h a ft several tu rn s to e n su re p isto n a ssem b ly to c y lin d e r w all lu b ric a tio n . C o n n e c t th e C h a rg in g S ta tio n h igh p re ssu re line o r a h ig h p re ssu re gage a n d G a g e A d a p te r J-5420 to th e T e st P la te J-9625 h ig h side c o n n e c to r. A tta c h an A d a p te r J-5 4 2 0 to th e su c tio n o r low p re ssu re p o rt o f th e T est P la te J-9625 to o p en th e S c h ra d e r-ty p e valve. O il w ill d ra in o u t o f th e c o m p re s s o r su c tio n p o rt a d a p te r if th e c o m p re sso r is p o sitio n e d w ith th e su c tio n p o rt d o w n w a rd . 14. A tta c h th e c o m p re sso r to th e H o ld in g F ix tu re J-2 5 0 0 8 -A usin g m e tric m o u n tin g screw s. C la m p th e c o m p re s s o r H o ld in g F ix tu r e in a vise so th a t th e c o m p re s s o r c an be m a n u a lly tu rn e d w ith a w ren c h . U sin g a w re n c h , ro ta te th e c o m p re sso r c ra n k s h a ft o r d riv e p la te h u b ten (10) c o m p le te re v o lu tio n s a t a sp eed o f a p p ro x im a te ly o n e -re v o lu tio n p e r seco n d . T u rn in g th e c o m p re sso r at less th a n o n e -re v o lu tio n p e r sec o n d c a n re su lt in a lo w e r p u m p -u p p re ssu re a n d d isq u a lify a good p u m p in g c o m p re sso r. 16. O b serv e th e re a d in g on H I G H p re ssu re gage at th e c o m p le tio n o f th e te n th (1 0 th ) re v o lu tio n o f th e c o m p re sso r. T h e p re ssu re re a d in g fo r a g o o d p u m p in g c o m p re s s o r s h o u ld be 344.75 k P a (50 p. s.i.) o r above. A p re ssu re re a d in g o f less th a n 310. 275 k P a (45 p .s.i.) w o u ld in d ic a te o ne o r m o re su c tio n a n d / o r d isc h a rg e valves leaking, an in te rn a l leak o r an in o p e ra tiv e valve, a n d th e c o m p re s s o r sh o u ld be d isa sse m b le d a n d ch e c k e d fo r ca u se o f leak. R e p a ir as n e ed e d , rea ssem b le a n d re p e a t th e p u m p -u p test. E x te rn a lly leak test. W h e n th e p re ssu re p u m p -u p te st is c o m p le te d , release th e a ir p re ssu re fro m th e H I G H side an d re m o v e th e G a g e A d a p te rs J-5 4 2 0 a n d T est P la te J-9625. O n th e R -4 c o m p re sso r, tilt th e c o m p re sso r so th a t th e c o m p re sso r s u c tio n a n d d isc h a rg e p o rts a re d o w n . D ra in th e oil fro m th e c o m p re sso r. A llo w th e c o m p re sso r to d ra in fo r 10 m in u te s, th e n c h a rg e w ith th e p ro p e r a m o u n t o f oil. T h e oil m ay be p o u re d in to th e su c tio n p o rt. I f f u rth e r assem b ly o r p ro c e ssin g is re q u ire d , a sh ip p in g p la te o r T e st P la te J-9 6 2 5 s h o u ld be in sta lle d to keep o u t air, d ir t a n d m o is tu re u n til th e c o m p re sso r is in sta lle d .

7. 8.

12.

9.

13.

Replace
1. 2. R ep la c e ab o v e p a rts in o p p o site o rd e r. E v a c u a te a n d c h a rg e th e re frig e ra n t sy stem a c c o rd in g to th e d ire c tio n s in S ectio n 1B1.

R-4 COMPRESSOR LEAK TESTING (EXTERNAL AND INTERNAL)


Bench-Check Procedure
1. 2. In sta ll T e st P la te J-9625 on R e a r H e a d o f c o m p re sso r. A tta c h c e n te r h o se o f M a n ifo ld G a g e Set on C h a rg in g S ta tio n to a re frig e ra n t d ru m s ta n d in g in an u p rig h t p o sitio n a n d o p en v alve o n d ru m . C o n n e c t C h a rg in g S ta tio n h ig h a n d low p re ssu re lines to c o rre s p o n d in g fittin g s o n T e st P la te J-96 2 5 , u sin g J-5 4 2 0 G a g e A d a p te rs if h o ses a re n o t e q u ip p e d w ith valve d e p re sso rs. S u c tio n p o rt (lo w -sid e) o f c o m p re s s o r h as la rg e in te rn a l o p en in g . D is c h a rg e p o rt (h i-sid e) h as s m a lle r in te rn a l o p e n in g in to c o m p re sso r. O p e n lo w -p re ssu re c o n tro l, h ig h -p re ssu re c o n tro l a n d re frig e ra n t c o n tro l on C h a rg in g S ta tio n to allo w re frig e ra n t v a p o r to flow in to c o m p re sso r. U sin g a L e a k D e te c to r, c h e c k fo r leak s at P re s s u re R e lie f V alve, c o m p re s s o r sh ell to c y lin d e r, c o m p re s s o r fro n t h e a d seal, a n d c o m p re s s o r S h aft Seal. A fte r ch e c k in g , s h u t o ff low p re ssu re c o n tro l a n d h ig h p re ssu re c o n tro l on C h a rg in g S ta tio n . I f a n e x te rn a l leak is p re se n t, p e rfo rm th e n ec e ssa ry c o rre c tiv e m e a su re s a n d re c h e c k fo r leak s to m a k e c e rta in th e leak h a s been c o rre c te d . L o o sen th e M a n ifo ld G a g e h o se c o n n e c tio n s to th e G a g e A d a p te rs J-5 4 2 0 c o n n e c te d to th e low a n d h ig h sides a n d allo w th e v a p o r p re ssu re to release fro m th e c o m p re sso r. D is c o n n e c t b o th G a g e A d a p te rs J-5 4 2 0 fro m th e T e st P la te J-9625. R o ta te th e c o m p le te c o m p re ss o r assem b ly (n o t th e c ra n k s h a ft o r d riv e p la te h u b ) slow ly several tu rn s to d is trib u te oil to all c y lin d e r a n d p isto n areas.

15.

3.

4.

5.

17.

6.

7.

18.

19.

8. 9.

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-23

DU

D3

DU

18

(Qi
m
19
1J-9399 2 J-9480-B 3 J-9401 A 4 J-8092 5J-5403-A 5 J-4245 5 J-6083

f2 0 |
9/1 6 " THIN W A LL SOCKET HUB AND DRIVE PLATE ASSEMBLY IN STALLER HUB AND DRIVE PLATE ASSEMBLY REMOVER DRIVER HANDLE SNAP RING PLIERS (#21 IN TER N AL) SNAP RING PLIERS (#23 IN T ER N AL ) SNAP RING PLIERS (^24 IN TER N AL)

22
12 J-25030 13 J 9553-01 14J-9398-A 1 5 - J 25008 A 1 6 - J 24092 17 -J-8433 18J-9393 A 19 J-25287 20 J 24896 21J-9481 A 22J 26271 A 23 J-24895 24J-25031

23 CLUTCH HUB HOLDIN G TOOL O-RING REMOVER ROTOR BEARING REMOVER COMPRESSOR H OLD IN G FIXTURE PULLEY HUB ADAPTER SET (USED WITH J-8433) COMPRESSOR P ULLE Y PULLER SEAL SEAT REMOVER AND INSTALLER CLUTCH COIL PULLER BEARING REMOVER (FRONT HEAD) PULLEY BEARIN G AND PULLEY INSTALLER ROTOR AND BEARING IN S TA LLE R (WITHOUT HANDLE) BEARING IN STALLER (FRONT END) ROTOR AND BEARING PULLER WITH GUIDE

6 J-22974-A SHAFT SEAL PROTECTOR (FACE SEAL ONLY) 7J-34614 8 J-23128-A 9 J-9292-01 10J-25108 11 J 9625 SHAFT SEAL PROTECTOR (FACE SEAL AND LIP SEAL) SEAL SEAT REMOVER AND INSTALLER SHAFT SEAL REMOVER AND INSTALLER SEAL SEAT O RING IN STALLER PRESSURE TEST CONNECTOR

4 2 0 0 5 3 -1 D 1

Fig. 1 D 1-53 S p e cia l T ools, R-4 A /C C o m p re s s o r O verhaul

FRAME

2A-1

SECTION 2A

FRAME
CONTENTS
G eneral D escrip tio n ......................................................................................... On Vehicle S ervice........................................................................................... M aintenance and Inspection........................................................................ U nderbody Inspection................................................................................. F ram e Inspection.......................................................................................... Fram e A lig n m en t........................................................................................... U nderbody A lignm ent................................................................................... Excessive Body D am age................................................................................ 2 A -1 2A-1 2A-1 2A-1 2A-1 2A-1 2A-4 2A-4

GENERAL DESCRIPTION
L ight duty 10-30 Series fram es are of the ladder channel section riveted type. Figure 2A-1 thru 2A-4 illustrates typical light duty truck frames with crossmembers, body mounts and suspen sion attaching brackets. This section also includes general instructions for checking fram e alignm ent and recommen dations on frame repair. The G-Van fram e side rails, cross sills and outriggers are part of the underbody assembly which is a welded unit. M isalignm ent of the underbody can affect door opening fits and also influence the suspension system , causing suspension m isalignm ent. It is essential, therefore, th a t underbody alignm ent be exact to within - 1/16 in. (1 .9mm) of the specified dimensions.

ON VEHICLE SERVICE
MAINTENANCE AND INSPECTION
UNDERBODY INSPECTION
Raise the vehicle on a hoist (preferably a twin-post type). Check for obvious floor pan deterioration. Check for loose dirt and rust around the inside of the floor pan reinforcement member access holes. This is the first indication that corrosion may exist in hidden areas, and that repairs might be required before the final cleaning and protective treatm ent is performed. Using a chisel, ensure th at the drain provisions in the floor pan reinforcement members are open. There are drain holes in the body side panels also. These holes can be opened by using a punch or drift. The side panel drain holes are in the rear section of the rocker panels, and in the lower rear quarter panels.

FRAME ALIGNMENT
Horizontal fram e checking can be made with tram ming gages applied directly to the frame or by transferring selected points of m easurem ent from the fram e to the floor by means of a plum bob and using the floor layout for measuring. Fig. 2A-2 or 2A-4 may be used as a general guide in the selection of checking points; however, selection of these points is arbitrary depending on accessibility and convenience. An im portant point to rem em ber is that for each point selected on one side of the frame, a corresponding point on the opposite side of the fram e must be used for vertical checks, opposite and alternate sides for horizontal checks.

Vehicle Preparation
Points to rem em ber when preparing vehicle for fram e checking: 1. Place vehicle on a level surface. 2. Inspect dam aged areas for obvious frame misalignment to elim inate unnecessary measuring. 3. Support vehicle so th at fram e sidemembers are parallel to the ground.

FRAME INSPECTION
Raise the vehicle on a hoist (preferably a twin-post type). Check for obvious floor pan deterioration. Check for loose dirt and rust around the inside of the fram e rails, on top and at the ends where corrosion may exist in hidden areas. Check especially in the fram e box sections for accum ulation of debris.

Tramming Sequence (Fig. 2A-1)


1. Dimensions to bolts an d/or holes in frame extend to dead center of the hole or bolt. 2. Dimensions must be within 3/16 in. (4.7 mm). 3. If a tram bar is used, for horizontal alignm ent " X " check from opposite and alternate reference points AA, BB and CC, as illustrated by the lines in Fig. 2A-1.

2A-2

FRAME

Error will result if a tram bar is not level and centered at the reference points. 4. O btain vertical dimensions and com pare the differences betw een these dim ensions w ith the dim ensions as shown in Fig. 2A-3 or 2A-4.

Vertical Check
Vertical dimensions are checked with a tram m ing bar from indicated points on the fram e (Figs. 2A-2 and 2A-4). For example, if the tram bar is set at point B with a vertical pointer length of 8-1/4 in. (206 m m ), and at point E with a vertical pointer length of 5-1/4 in. (131 mm) (a height difference of 3 in. (75 mm), the tram bar should be parallel with the frame. If the area is twisted or misaligned in any way, tram bar will not be parallel. Placing the tram bar vertical pointers on opposite sides of the fram e side rail is preferable in th a t fram e twist will show up during this vertical check. Fig. 2A-2 and 2A-4 show typical checking points, with dimensions for various fram es shown in Fig. 2A3.

Horizontal Check
1. M easure fram e width at front and rear. If widths correspond to specifications, draw centerline full length of vehicle halfway between lines indicating front and rear widths. If fram e widths are not correct, layout centerline as shown in Step 4. 2. M easure distan ce from centerline to corresponding points on each side of fram e layout over entire length. Opposite side m easurem ent should correspond within 3/16 in. (4.7 m m). 3. M easure diagonals m arked A, B and C. If the lengths of intersecting diagonals are equal and these diagonals intersect the centerline, fram e area included between these points of m easurem ent may be considered in alignm ent. 4. If front or rear end of fram e is dam aged and width is no longer within limits, fram e centerline may be drawn through the intersection of any two previously drawn pairs of equal, intersecting diagonals.

Frame Repair
Welding

Before welding up a crack in fram e, a hole should be drilled at the starting point of the crack to prevent spread ing. W iden V groove crack to allow com plete weld penetration.
NOTICE: Do not weld into corners of fram e or along edges of side rail flanges. W elding at these points will tend to weaken the frame and encourage new cracks.

Fig. 2A-1-Frame Horizontal Checkina-Tvpical

FRAME

2A-3

[OJ

I f

DIMENSIONS TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT GAUGE HOLES ARE 5 /8 " DIAMETER INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR INSIDE OF THE FRAME OUTER SURFACE

NOTE:

FRAME ILLUSTRATED IS TYPICAL. FRAME DESIGN VARIES ACCORDING TO TRUCK MODEL

Fig. 2A-2--C-K-P Series Truck Frame

M odel CA107 CA109 CA209 CA210 310 CA314 KA107 KA 109 209 PA 100 PA208 308 PA210 310 PA314 CA105 KA105 PE 31132 (137) PE 31432 (157) PE 31832

A 13-3/8 13-3/8 13-3/8 13-3/4 13-3/8 13-3/8 13-3/8 7-5/8 7-5/8

B 15-1/4 15-1/4 15-1/4 15-1/4 14 7/8 15-1/4 15-1/4 9-3/8 9-3/8

C 16 16 17 16 16 17 17 11 11-5/8

D 19-7/8 19-7/8 19-7/8 18-1/2 18-1/2 19-7/8 19-7/8 14-5/8 14-5/8 12 12 12 10 10

F 13 13 13 13 13 13 13 13 13

G 10 10 10 10 10 10 10 10 10

H 14-7/8 14-7/8 14-7/8 14-1/4 14-1/4 14-7/8 14-7/8

1 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4

J 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 9-1/2

K 19-7/8 19-7/8 19-7/8 19-7/8 19-7/8 19-7/8 19-7/8 13 13

L 16-3/4 16-3/4 16-3/4

M 15-5/8 15-5/8 15-5/8 15-5/8 15-5/8

N 17 3/4 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 17-3/4 13 13

P 68-1/2 69-5/8 69-5/8 68-3 /4 69-7/8 68-1/2 68-1/2 71-7/8 72-1/4

R 76-1/2 86-1/2 86-1/2 105 129 76-1/2 86-1/2 36 59 110 120 120 131

T 16-7/8 16-7/8 16-7/8 16-7/8 16-7/8 16-7/8 16-7/8 16-7/8 16-7/8

U 16-7/8 16-7/8 16-7/8 16-7/8 16 7/8 16-7/8 16-7/8 16-7/8 16-7/8

V 14 14 14 14 14 14 14 14 14

155-1/2 110 120 89 131

12-1/2 12-1/2 9-1/2 9-1/2

16-3/4 16-3/4

15-5/8 15-5/8 10-7/8 10-7/8

9-1/2

13

9-1/2

7-5/8 7-5/8 13-3/8 13-3/8 9-1/8

9-3/8 9-3/8 15 1/4 15-1/4 11-1/2

11-5/8 11-5/8 17 17 10-7/8

14-5/8 14-5/8 19-7/8 19-7/8

9-1/2 9-1/2 12 12-1/2 9-1/2

13 13 13 13 13

10 10 10 10 10

9-1/2 9-1/2

13 13

9-1/2 9-1/2 14 1/4 14-1/4

13 13 20 20 13

10-7/8 10-7/8 17-3/4 17 3/4 10-7/8

10-7/8 10-7/8 15-5/8 15-5/8 10-7/8

13 13 17-3/4 17 3/4 13

71-7/8 71-7/8 69-5/8 69-5/8 68-1/2

67 91 46 46 71

153 177 88 88 157

16-7/8 16-7/8 16-7/8 16-7/8 16-7/8

16-7/8 16-7/8 16-7/8 16-7/8 16-7/8

14 14 14 14 14

9-1/2

13

9-1/2

9-1/8

11-1/2

10-7/8

9-1/2

13

10

9-1/2

13

9-1/2

13

9-7/8

10-7/8

13

68-1/2

92-1/2

178-1/2

16-7/8

16-7/8

14

9-1/8

11-1/2

10-7/8

9-1/2

13

10

9-1/2

13

9 1/2

13

10-7/8

10-7/8

13

68-1/2

112

240-3/16

16-7/8

16-7/8

14

Fig. 2A-3--C-K-P Series Frame Reference Dimensions

2A-4

FRAME

Fig. 2A-4--G Van Truck Reference Dimensions Bolting

W herever rivets or failed bolts are replaced, bolt hole must be as near the O.D. of the bolt as possible to prevent bolt from working and wearing. Drill out and line ream hole (or holes) to the bolt O.D.

2. The vertical dimension from the datum line to the points to be tram m ed. The tram bar should be on a parallel to that of the body plane. The exception to this would be when one of the reference locations is included in the misaligned area; then the parallel plane between the body and the tram bar may not prevail. A fter completion of the repairs, the tram gage should be set at the specified dim ension to check the accuracy of the repair operation.

UNDERBODY ALIGNMENT
One m ethod of determ in in g the alignm ent of the underbody is with a tram gage which should be sufficiently flexible to obtain all necessary m easurem ents up to three quarters the length of the vehicle. A good tram m ing tool is essential for analyzing and d eterm ining the extent of collision misalignm ent present in underbody construction.

EXCESSIVE BODY DAMAGE


If dam age is so extensive th at key locations are not suitable as reference points, repair operations should always begin with the underbody area. All other components should be aligned progressively from this area. Unlike the conven tional type of fram e design, the unitized type of body construction seldom develops the two conditions of "tw ist" and "diam ond" in the underbody area as a result of front or rear end collisions, therefore, there usually is an undam aged area suitable as a beginning reference point.

MEASURING
To m easure the distance accurately between any two reference points on the underbody, two specifications are required. 1. The horizontal dimension between the two points to be tram m ed.

BUMPER

2B-1

SECTION 2B

BUMPERS
NOTICE: Fasteners are im portant attaching parts in

th a t they could affect th e perfo rm ance o f vital com ponents and systems, a n d /o r could result in m ajor repair expense. They m ust be replaced with one of the sam e p a rt nu m b er or w ith an equivalent p a rt if rep lacem en t becom es necessary. Do not use a

replacem ent part of lesser quality or substitute design. T orque values m ust be used as specified during reassembly to assure proper retention of these parts. For prevailing torque nut(s) and bolt(s), refer to the "R eu se of P revailing T orque N u t(s) and B o lt(s)" chart in Section 10.

CONTENTS
G eneral D escription........................................................... Service Procedures - 10 th ru 30 series.......................... Front Bum per - C, K and P M o d els............................ R ear Bum per - C and K M odels.................................. 2B-1 2B-1 2B-1 2B-2 R ear Step Bum per - C and K M o d els......................... Front Bum per G S e rie s .................................................... R ear Bumper G S e rie s ..................................................... R ear Bum per G S e rie s ..................................................... 2B-2 2B-2 2B-3 2B-3

GENERAL DESCRIPTION
All truck front and rear bum pers are of a single piece design. Bumper attachm ents are the standard bracket and brace to fram e mountings. This section contains procedures for the removal and installation of face bar, brackets, braces and license plate brackets.

SERVICE PROCEDURES-10 THRU 30 SERIES


Installation

A ssem ble and install fro n t bum per following the removal procedure in reverse order.

REAR BUMPER-C AND K MODELS (FIG 2B- 3)


Removal

1. Remove bolts attaching bum per face bar to left and right bum per brace. Disconnect license lam p wiring on suburban, panel and pickup models. 2. Remove bolts attaching bum per face bar to left and

FRONT BUMPER-C, K AND P MODELS


Removal Fig. 2B-1, 2B-2

1. Remove bolts securing bum per face bar to left and right bum per brackets. 2. Remove bolts securing bum per face bar to left and right bum per braces and remove bum per from vehicle. 3. If necessary, remove the brackets and braces from fram e by removing the bolt attachm ents. 4. I f equipped w ith bum per guards, the bum per is removed in same m anner as above.

2B-2

BUMPER

Fig. 2B-3--Rear Bumper - C, K Models

Fig. 2B-5--Front Bumper - G Models Installation

right bum per bracket. 3. Remove bum per from vehicle. 4. If necessary, remove the rear stone shields and the bum per brackets and braces from fram e by removing bolt attachm ents.
Installation

In stall re a r step bum per by reversing rem oval procedure. Connect license lam p wiring.

FRONT BUMPER - G MODELS


Removal Fig. 2B-5, 2B-6

Install rear bum per following removal procedure in reverse order. Connect license lamp wiring on suburban, panel, and pickup models.

REAR STEP BUMPER C AND K MODELS


Removal (Fig. 2B-4)

1. Remove nuts securing bum pers to brackets and braces from left and right side. Remove bum per. 2. If necessary to remove the braces and brackets, remove screws securing brackets and braces to sheet metal. 3. If equipped with bum per guards (Fig. 2B-6) they may be removed from the face bar at this time.
Installation

1. 2. 3. 4. 5.

Disconnect license lam p wiring. Remove bolts connecting bum per to braces. Remove bolts retaining bum per to brackets. Remove bum per assembly. Remove bolts securing bum per brace to fram e and bum per b rack ets and reinforcem ents to fram e if necessary.

Reverse removal steps to install bum pers.

.160/.180 Ref (CLEARANCE)

Fig. 2B-4--Rear Step Bumper C and K Models

Fig. 2B-6--G-Models Front Bumper Guards

BUMPER

2B-3

REAR BUMPER-G MODELS


Removal Fig. 2B-7

1. Remove nuts securing bum per to left hand and right hand brackets and braces and remove the bum per. 2. Remove the license plate support nut and bolts. 3. Rem ove bolts securing left hand and rig h t hand brackets and braces to body. The bum per may be removed with brackets and braces attached if necessary.
Installation

Install in reverse order of removal.

Fig. 2B-7--Rear Bumper-G Models

SPECIFICATIONS
TORQUE SPECIFICATIONS C, P AND K Front Bumper ............................................................... 35 Front Bumper Bracket and Brace ........................... 70 Rear Bumper to O uter Bracket ................................35 Rear Bumper O uter Bracket and Brace ................50 License Plate B ra c k e t..................................................18 Gravel Deflector ........................................................ 85 Rear Step Bumper to Bracket or Frame ................40 ft.-lb s . ft.-lb s . ft.-lb s . ft.-lb s . ft.-lb s . in.-lbs. ft.-lb s .

TORQUE SPECIFICATIONS G Front Face Bar to Bracket .........................................24 ft.-lb s . Bracket to Cross S i l l ....................................................24 ft.-lb s . License Plate Bracket to Face Bar .......................100 in .-lb s. Rear Face Bar to B ra c k e ts .........................................55 ft.-lb s . Bracket to Floor ...........................................................55 ft.-lb s .

Fig. 2B-ST--Specifications

'- ;\ f

SHEET METAL 2C-1

SECTION 2C

SHEET METAL
N O TIC E Fasteners are im portant attaching parts in th a t they could affect the perform ance of vital components and systems, an d /o r could result in m ajor repair expense. They m ust be replaced with one of the sam e part num ber or with an equivalent part if replacem ent becomes necessary. Do not use a replacem ent part of lesser quality or substitute design. Torque values m ust be used as specified during reassembly to assure proper retention of these parts. For prevailing torque nut(s) and bolt(s), refer to the "R euse of Prevailing Torque N u t(s) and B olt(s)" ch art in Section 10.

CONTENTS
G eneral D e sc rip tio n ................................. ...................... O n Vehicle S e r v ic e ................................... ...................... H ood - C K M o d e ls ................................. ...................... Cow l Top Vent Panel .......................... ...................... H o o d H inge .......................................... ...................... H ood Lock M e c h a n ism ...................... ...................... H ood A s s e m b ly ................................... ...................... H o o d ......................................................... ...................... H o o d H inge .......................................... ...................... H ood L o c k ............................................ ...................... H o o d B u m p e r.................................................................. 2C-1 2C-1 2C-1 2C-1 2C-2 2C-2 2C-2 2C-3 2C-3 2C-3 2C-5 F ront S heet M etal ................................................... R adiator S upport ................................................... F ront F e n d e r ............................................................ F ront F en d er and Skirt ........................................ Running B o a r d ....................................................... F en d er Skirt - P S e r ie s ............................................ A dhesive B odyside M olding (All V eh ic les)___ Wood G rain A pplique ............................................ D ecal A pplique Procedure (All Vehicles) ......... S p e c ific a tio n s.............................................................. ... ... ... ... ... ... ... ... ... ... 2C-6 2C-7 2C-8 2C-8 2C-8 2C-8 2C-8 2C-9 2C-10 2C-11

GENERAL DESCRIPTION
CK MODELS
The chassis sheet m etal assem bly is attached to the fram e and body a t adjustm ent points. The front of the assem bly is supported by two m ounts located at the fram e side rails. Fore and aft and side adjustm ent is allowed by oversize holes a t the fender rear attaching point and chassis sheet m etal mounts. Special shims at the rear locations allow adjustm ent of the rear of the assembly. The lower rear edge of the assembly is attached to the body a t the rocker panel by bolts on each side. Shim s are used a t this location to provide in and out adjustm ent at the rear of the fender. The bolts th a t retain the sheet m etal braces m ust be torqued to the required torques. If these bolts are loose, the braces will not provide additional support for the sheet m etal assembly. these items are welded together as an integral p a rt of the Front end sheet m etal includes the hood assembly, hood hinges, hood lock catch and support, a hood rod assembly which supports the hood, a bolted radiator-upper ^ a ran^ series designation plates and hoods emblems. A . ,

Anti-Corrosion Information
A nti-corrosion m aterials have been applied to the interior surfaces of som e m etal panels to provide rust resistance. W hen servicing these panels, areas on which this m aterial has been disturbed should be properly recoated service-type anti-corrosion m aterial."

G MODELS
T he front end sheet m etal design does not include the rad iato r support and fenders as loose item s inasm uch th at

ON VEHICLE SERVICE
HOOD - CK MODELS Cowl Top Vent Panel (Fig. 2C-1)
Replacement

2. Open hood and remove two screws a t each wiper nozzle attachm ent. 3. Remove four screws a t front of cowl panel. 4. Pry the five plastic fasteners loose from windshield fram e. Remove the panel. 5. Reverse the above listed procedure to replace.

1. Remove wiper arm s.

2C-2

SHEET METAL

PLASTIC RETAINER ----------- H IN G E A S M

5. Remove two bolts hinge to rear reinforcem ent at the body and remove hinge. 6. Replace by reversing the above procedure.

Hood Lock Mechanism


[v i e w [a 1
TYPICAL 5 PLACES

The hood latch assembly and bracket are m ounted to the R adiator Support. Elongated holes in the bracket are provided for alignm ent purposes. A sep arate secondary latch is m ounted to the striker plate in the hood. See Fig. 2C-3 and 2C-4.
Replacement

VENT SCREEN

1. Open hood and remove the two bolts holding the hood latch to the bracket. If original hood lock assembly is to be replaced, scribe a line around lock for alignm ent on installation. 2. Replace hood latch assembly and bolts loosely. 3. Align within scribe m arks and tighten bolts.

rviswfBl

BRACKET

Hood Bumper Adjustment


Hood Bumpers m ust be adjusted until hood and fender line up flush at front corner.

TYPICAL 2 PLACES

Fig. 2C-l--Cowl Top Vent Panel

Hood
Removal

Hood Hinge (Fig. 2C-2)


Replacement

1. Prop the hood in the extrem e open position and place protective covering over the cowl and fenders. Scribe position of hinge attachm ent to hood. 2. Remove two bolts link assembly to hood and two bolts at hinge to the hood. 3. Rem ove two bolts link assem bly to fender inner, remove link. 4. Remove wiper arm s and at the cowl cover panel remove four screws and lift up w ithout removing for access.

1. Open hood and prop in full open position. If hood is to be reinstalled and present alignm ent is satisfactory, m ark each hinge in relation to hood, to assure original alignm ent. 2. Remove two (2) cap screws which attach each hinge

Fig. 2C-2--Hood Hinge -CK Models

Fig. 2C-3--Primary Hood Latch -CK Models

SHEET METAL

2C-3

m ovem ent of th e hood while the vehicle is in m otion. In te g ra l w ith th e strik er plate is the com bination lock release lever and safety catch. 1. S cribe a line around the en tire hinge p late to be repositioned. 2. Loosen the appropriate screws and shift the position of the hood into correct alignm ent using the scribe m arks to check am ount of movement. Check alignm ent by tightening screws and closing the hood.
Replacement

1. O pen hood and rem ove th e four bolts holding the com bination lock catch and lock bolt. If original hood lock assembly is to be replaced, scribe a line around lock for alignm ent on installation. 2. Place hood lock assembly in position. 3. A djust as outlined under A djustm ents.
Adjustment

and link to hood; then with a helper remove hood from vehicle.
Installation

Hood lock assembly to be adjusted fore and aft until hood lock bolt enters center of elongated guide. Bending bolt to accomplish this adjustm ent may seriously effect lock operation and safety catch engagem ent and is, therefore not recommended. 1. A djust lock bolt as shown in Fig. 2C-7. 2. Open hood and adjust tightness of catch assembly so th a t it is ju st "snug" enough to hold lock bolt in position. 3. Close hood in a norm al m anner. 4. Raise hood again; lock bolt assem bly will have shifted to o perating position. T ighten bolts fully. F u rth e r a d ju stm e n t m ay be m ade a t lock bolt support, if necessary. 5. A djust lock bolt to obtain a secure hood closure and reasonable lock release effort.

1. If original hood is to be installed, position hood to hinges and links and install four cap screws snug which a tta c h hinges and links to hood. If a new hood is to be installed, perform procedures as outlined under A lignm ent, directly below. 2. Shift hood on hinges to location m arks m ade before removal of hood, then tighten attaching cap screws at hinges firmly. Close hood and check fit. If necessary to align hood p erform p rocedure as o u tlined under "A lignm ent" which follows.
Alignm ent

1. Loosen hood hinge bolts. N ote th a t the rear most bolt holes in hinge are slotted to allow hood to move back and forth. 2. A djust bracket at hood latch, as necessary. Slotted hole in the bracket allow m ovem ent up or down a t the latch, and right or left at the rad iato r support. 3. A djust hood bum per as necessary in proportion to the latch.

Hood - G Model
The alignm ent of the hood is controlled by the position of the hood hinges and the height of the two bum pers located one a t each side of the radiator support. The adjustm ent at the hood lock must be m ade after the hinges and bum pers are properly adjusted (R efer to Hood Lock A djustm ent Fig. 2C-7). To align the hood and lock proceed as follows:
Hood Hinge (Fig. 2C-5) Hood Lock

A bolt-type hood lock is used as shown in Fig. 2C-7. T he lock bolt, located on th e hood, dovetails w ith the m ounted strik e r plate, preventing upw ard or dow nw ard

Fig. 2C-5--Hood Hinge-G Model

2C-4

SHEET METAL

HOOD CABLE RELEASE - CK MODELS (FIG. 2C-8)


Replacement

1. Release the hood from below, using a suitable rod, by pressing on the hood release tab at the right side of the lock assembly. 2. Remove the cable at the lock assembly. 3. R em ove hood release handle to kickpad attaching screw s.

Fig. 2C-6--Hood Lock Catch Assembly-G Model

Fig. 2C-7--Hood, Bumpers and Latch-G Model

Fig. 2C-8--Hood Release Cable - CK Models

SHEET METAL

2C-5

Alignm ent

1. Loosen hood hinge bolts. N ote th a t the rear bolt holes in hinge is slotted to allow hood trailing edge to move up and down. 2. A djust hood bum pers so th a t hood and a d jac en t surfaces are flush. 3. P erform hood lock a d ju stm e n t as outlined in this section if necessary. Hood Lock Assembly to be adjusted fore and aft until nubble (p art of Hood Lock Bolt Support Assembly) enters center of elongated guide (Socket). Bending nubble to accomplish this adjustm ent may seriously effect lock operation and safety catch engagem ent and is, therefore, N O T R E C O M M E N D E D .

Hood Support Rod - G Model


R efer to Fig. 2C-10 for rem oval and installation of hood support rod.

CARBURETOR OUTSIDE AIR INLET SNORKELS (Fig. 2C-11)


Removal

4. Remove hood release cable. 5. To install, reverse Steps 2 through 4.

HOOD EMBLEM - CK MODELS (FIG. 2C-9) Hood Bumper


A djust hood bum pers so th a t hood top surface is flush with the fender and grille top surfaces.

1. Raise hood and remove carburetor air duct from air snorkel by sliding duct rearw ard. 2. Disconnect the attachm ent incorporated in the duct attaching the air snorkel to radiator support turn and remove from vehicle.

LOWER RADIATOR GRILLE (FIG. 2C-12) RADIATOR GRILLE PANEL OR BRACKETS (FIG. 2C-13)

Hood - G Model (Fig. 2C-7)


Removal

GRILLE MOLDING (FIG. 2C-14)

1. Lay a fender cover along cowl top to prevent hood from scratching painted surfaces. 2. O pen hood and prop in full open position. If hood is to be reinstalled and present alignm ent is satisfactory, m ark each hinge in relation to hood, to assure original alignm ent. 3. Remove two cap screws which attach each hinge to hood; (Fig. 2C-5) then with a helper remove hood from vehicle.
Installation

1. If original hood is to be installed, position hood to hinges w ith helper and install four cap screws snug which attach hinges to hood. 2. Install rod assembly. If a new hood is to be installed, perform procedures as outlined under A lignm ent, directly below. 3. Shift hood on hinges to location m arks m ade before rem oval of hood, then tighten attaching cap screws at hinges firmly. Close hood and check fit. If necessary to align hood perform proced u re as o u tlined under "A lignm ent" which follows.

2C-6

SHEET METAL

Fig. 2C-12--Lower Radiator Grille - G Models

Fig. 2C-11--Typical Carburetor A ir Inlet Snorkel - CK Model

FRONT SHEET METAL - CK MODEL


Shim s which are found at various locations should be recorded to ease installation of sheet m etal assembly.
Removal

1. Remove bolts at hood hinge and link. Remove hood assembly.

Fig. 2C-14-- Grille Moldings - CK, G Models

Fig. 2C-13--Grille Panel or Brackets

SHEET METAL

2C-7

11. Connect upper and lower radiator hoses. Connect oil cooler lines to the radiator on models so equipped. 12. Connect battery and fill radiator. S ta rt engine and check for leaks. 13. Install Hood.

Radiator Support
Removal

2. D rain rad iato r and remove radiato r hoses. Disconnect oil cooler lines if so equipped. 3. D isconnect wire connectors at the dash and toe panel and wire connector to horn and voltage regulator. 4. Disconnect battery and generator wires. 5. Remove front bum per bolts and remove bum per. 6. Remove bolts attaching fender upper edge to cowl door fram e. 7. Remove fan shroud. 8. W orking from u n d e rn e a th re a r of fender, rem ove a ttach m en t from each fender a t the hinge pillar. 9. Remove bolt from each radiator support m ounting. 10. Remove bolts a t each fender skirt to cab underbody (Fig. 2C-15). 11. W ith a helper, remove front sheet m etal assembly, with radiator, battery, horn and voltage regulator attached.
Installation

1. D rain radiator, saving coolant, loosen attachm ents and remove radiator and coolant recovery tank. 2. Disconnect and remove battery. 3. Remove wiring from radiator support. 4. Disconnect fan shroud and lay back on engine. 5. Remove both head lam p assemblies. 6. Remove grille assembly. 7. Remove lower radiator grille panel. (Fig. 2C-13). 8. Rem ove screw s securing front fenders to ra d ia to r support. 9. Rem ove screws securing fender skirts to ra d iato r support bottom. (Fig. 2C -15). 10. Rem ove bolt securing center support to ra d ia to r support. 11. Remove bolts securing hood latch assembly to radiator support. 12. Remove radiator support bolts secured to frame. 13. T ilt radiator support rearw ard and lift up and off.
Installation

1. R otate radiator support into position and loosely install attachm ents to fram e. 2. Connect center support to radiator support. 3. Connect hood latch plate. 4. Connect radiator support brackets to fenders.

1. W ith a helper place sheet m etal assem bly in position. In stall all bolts loosely to fa c ilita te aligning a fte r com plete installation. 2. Install fender bolts a t cowl. 3. Install com bination bolt and flat w asher assembly into each fender rein fo rcem en t w hile inserting shim s req u ired betw een fender rein fo rcem en t and body (R efer to Fig. 2 C -16). 4. Install two bolts and shims required at each fender rear lower edge to hinge pillar. 5. Install bolt in each fender skirt to underbody. 6. Install bolts at steering column skirt reinforcem ent, final torque 25 ft. lb. (33 N-m ). 7. Tighten each radiator support m ounting bolt 33 ft. lb. (44 N -m ). 8. T orque bolts a t fender to cowl 25 ft. lb. (33 N-m) 9. Install front bumper. 10. Connect wire connectors at dash and toe panel. A ttach generator and regulator wires.

2C-8

SHEET METAL

Installation

To install, reverse the removal procedure using sealing tape between filler panel and fender. Check sheet m etal alignm ent.

FRONT FENDER AND SKIRT (FIGS. 2C-15 AND 2016)


Removal

CREW CAB

Fig. 2C-17~Running Boards-CK Models

1. Remove hood and hood hinge assembly. 2. Disconnect and remove battery (right side or auxiliary leftside). 3. Remove head lam p bezel, wiring and attachm ents from fender. 4. Remove screws attaching lower radiator grille panel. 5. Remove screws attaching skirt to radiator support. 6. Remove two (2) top rear fender bolts and shims. 7. Remove bolt and shims at bottom of fender. 8. Remove bolts attaching skirt to underbody. 9. Remove two (2) screw attaching support bracket to fender. 10. Remove five (5) screws attaching radiator support to front fender. 11. Lift fender and skirt from truck.
Installation

5. Connect support to fenders. 6. C onnect screws from underside o f fender skirts to support bottom. 7. A ttach grille lower panel to fenders. 8. T ighten radiator support bolts. 9. Install radiato r coolant recovery tank hoses and shroud. 10. Connect removed wiring to radiator support. 11. Install both head lam p assemblies. 12. T ighten all previously installed bolts and screws. 13. Install b attery and connect leads and wires. 14. Install grille assembly. 15. Fill rad iato r w ith coolant as specified in S ection 6B. Install front fender and skirt assembly in reverse order of removal.

RUNNING BOARDS
R efer to Fig. 2C-17 for removal and installation of running boards.

Fender Skirt - P Model


R efer to figure 2C-18 for removal and installation of fender skirt, brackets, rear supports and hangers.

ADHESIVE BODY SIDE MOLDING


Body side moldings are attached to body panels with butyl adhesive tape. To insure a good molding replacem ent (new or old moldings), the panel surface should be w arm (21 to 32C or 70 to 90F), clean and free of any wax or oily film residue. Two methods are listed for attaching loose molding ends and completely removed moldings.
Molding End Loose

FRONT FENDER (FIG. 2C-16)


Removal

1. Remove hood and hinge assembly. 2. Remove head lam p bezel, wiring and attachm ents from fender. 3. Remove screws attaching lower radiator grille panel. 4. Remove screws attaching fender wheel opening flange to skirt. 5. Rem ove sk irt to fender bolts, located inboard on underside of skirt. 6. Rem ove two (2) screws a tta c h in g b a tte ry support bracket to fender. 7. Remove five (5) screws attaching radiator support to front fender. 8. Remove bolt and shim attaching trailing edge of fender to hinge pillar. 9. Remove two bolts and shims a t top rear of fender attaching to cowl.

1. W ash affected area with detergent and w ater and wipe dry. W ipe panel and adhesive side of molding with clean naphtha or alcohol. If molding has separated from adhesive backing (tape rem ains on body panel), do not remove tape from body. Clean back of molding and tape on body with naphta or alcohol and proceed with step 3. 2. If needed, apply a length of m asking tape as a molding guideline. A suitable straightedge m ay also be used in most cases. 3. Apply adhesive to back of molding and press in place. a. If L octite 414 adhesive (p a rt no. 1052283) or equivalent is used, apply co n stan t pressure to molding for 30 seconds or until a firm bond has been established.

SHEET METAL

2C-9

Fig. 2C-18-Fender Skirt, Dash and Toe Pan-P Series

b. If 3M Super W eath erstrip Adhesive (or equivalent) is used, tape m olding in place for 15 m inutes. Use naphtha for clean-up. c. I f 3M Plastic and Em blem Adhesive (or equivalent) is used, follow pack ag e in stru ctio n s for apply adhesive and tape m olding in place for 30 m inutes. Molding Completely Removed 1. W ash affected panel a rea w ith soap and w ater and wipe dry. Remove all traces o f adhesive from body panel and back o f molding using oil-free n aphtha or alcohol. 2. M ark proper alignm ent position o f molding w ith a length o f masking tape. U se adjacent moldings as a guide, if applicable (view A, Fig. 2C-19.) 3. I f body is below 70F (21C ) due to shop tem perature or prior outside tem perature, w arm body panel with h eat lam p or heat gun while proceeding with step 4. 4. Apply 3M N eoprene Fam e T ape, P a rt No. 06377 or 06378 or equivalent to molding. 5. Align molding to previously installed tape guideline and firmly press in place.

The surface m ust be free of any im perfections th a t m ight high-light through the film. Remove d irt nibs and other foreign m aterial in the paint by light sanding with 600 grit sandpaper. The tem perature of the body m ust be m aintained at a m oderate level between approxim ately 70 and 90F (21 and 32C). Too w arm a body will cause the wood grain film to stick prem aturely while too cool a body will reduce the adhesion of the wood grain film. Cool the body panel with cool w ater when too w arm and heat the body panel with a heat gun or a heat lam p when too cold. T ransfers should not be replaced in tem peratures below 65 F (18C). The transfer should not be subjected to tem perature greater than 175F (79C) and should not be left a t or near this tem perature for extended periods of time. Shelf life of the transfer m aterial is 90 days a t a tem perature not to exceed 105F (40C).
Removal

WOOD GRAIN APPLIQUE


General T he wood grain applique (tran sfer film) is a vinyl m aterial with a pressure sensitive adhesive backing. The transfers are serviced in precut panels. T he transfers are designed w ith an appealing wood grain p attern and a 50 degree or semigloss finish. P reparation of the surface to which th e transfer will be applied is very im portant. In cases w here body m etal repair has been m ade it is necessary to prim e and color coat these areas to blend with the undam aged surface. A pply the transfer film to color coated panels only, never to bare m etal or prim er.

Remove the moldings from the affected panel. The transfer film m ay then be removed by lifting an edge and peeling the m aterial from the painted surface. Exercise care so as not to dam age the paint. A pplication of heat to the transfer and the panel by m eans of a heat gun or heat lam p will aid in the removal.
Installation

1. W ith a solvent dam pened sponge, clean entire surface to be covered w ith applique. 2. W ipe area dry with a clean cloth. 3. Prior to application of transfer, wet down the com plete transfer surface of the fender with a solution of 1/4 oz. of neutral detergent cleaner (m ust not contain oils, perfum es, or bleaches) per gallon of clear w ater. It is essential th a t no substitute for this solution be used and th a t the specified proportions be m aintained. 4. W hile entire area is still wet with solution, remove pap er backing from tra n sfe r and align upper

2C-10

SHEET METAL

transfer area. Allow the adhesive to set for one m inute then press transfer to fender for adhesion. 9. Inspect transfer installation from critical angle using adequate light reflection to detect any irregularities th at may have developed during installation. Remove all air or m oisture bubbles by piercing each at an acute angle with a fine pin or needle and by pressing the bubble down. 10. Install previously removed parts and clean up vehicle as required.

DECAL APPLICATION PROCEDURE (ALL VEHICLES)


1. W ipe clean the entire fender surface, body surface, door jam flanges, door facings, fender flanges, etce, to be covered with the transfer with a sponge dam pened with N ap th a or equivalent. 2. W ipe cleaned surface dry with clean cloth. 3. S tarting with front fender, cut stripe to length. Allow excess at ends if necessary to avoid handling ends of strip e w ith fingers. T rim excess before w rapping around or tucking ends. 4. Remove about 6.00 in. (1 52.4m m ) of the paper backing from stripe and align stripe on vehicle. Fender stripe should bridge the gap at the fender extension, be tucked in with the edge of the squeegee and then trim m ed with a razor blade. 5. Pressurize stripe with a soft squeegee or a felt pad. Do not use thum bs or fingers as adequate pressure cannot be applied. 6. Remove the decal backing about 12.00 in. (304.8m m ) at a tim e careful not to touch adhesive with fingers and repeat step no. 5. 7. A fter com plete pressurization, remove the protective prem ask from the stripes at 180 angle. 8. R epeat above steps no. 4 thru 7 for the doors, q u arter panels, and end caps. 9. Fold m aterial around wrap areas, pressurize, heat to approxim ately 90F (32C ) w ith h eat gun, and repressurize. 10. H eat all areas at ends of stripes (end caps, front of fender, rear of quarter panel, etc.) 11. Reinspect entire stripe, especially ends and wraps and re- pressurize and heat where necessary to insure entire stripe is down. 12. Best results are obtained when m etal tem perature is 7090F (2132C). Use heat gun or allow cooling tim e when m etal is outside approxim ate tem perature range. 13. The m axim um tem perature th a t the tape should be subjected to is 175F (79C ) (p ain t rep air oven tem perature). N o tape stripe job should be left in a paint repair oven as dam age to the tape m ay occur. 14. The tape will not be affected by any of the cleaning solvents, waxes or detergents now being used at the assembly plants. Acrylic lacquer solvents will affect the clear coating over the vinyl. 15. This tape stripe highlights m etal im perfections so that all dings and rough m etal m ust be repaired before applying the tape. 16. If a fte r application of stripes, th e re ap p ears to be bubbles in the surface of the tape stripes,

Fig. 2C-19--Molding Application

edge with pierced holes in fender and press on lightly. 5. S ta rt at center of transfer and squeeze outboard from middle to edges removing all air bubbles and wetting solution to assu re a satisfacto ry bond. U se teflonbacked plastic squeegee only. 6. N otch applique at fender rear contour bend areas with scissors. Also notch out front m arker lamp. 7. Fold ends of applique over fender flanges using squeegee. H eat the w rap-around area of applique with a heat lam p or gun to approxim ately 90F (32C) and press w ith squeegee to secure entire edge surface. 8. If the w rap-around of the transfer has trouble sticking to fender edges, brush vinyl adhesive onto the fender or

SHEET METAL

2C-11

piercing them with an ordinary safety pin will relieve the en- trapped air so th a t the bubble can be smoothed out. 17. Shelf life of the vinyl tape is 90 days at a m axim um tem perature of 105F (40C).
REPAIR

REMOVAL

Removal of decal should cause it to be perm anently dam aged. Test to be conducted at an am bient tem perature not to exceed 90F (32C) and after a m inim um of 72 hours aging.

1. 2.

1.

2.

R epair is required when: If the tape is dam aged. The paint is dam aged as the tape is pulled back for realignm ent or releasing traped air. The following repair procedure is recom mended: If th e tape is ruined w ith no paint being removed, the surface should be wiped w ith a prep-sol to insure a smooth and clean surface. A nother section of tape would then be applied according to the application procedure. If a section of paint is removed when the tape is pulled away, the area m ust be repainted and feathered into the adjoining surfaces. A nother section of tape should be applied according to the application procedure.

For Large Decals


1. Prior to application of transer, wet down the complete transfer surface with a solution of 0.25 oz. of neutral detergent cleaner (m ust not contain oils, perfum es, or bleaches) per gallon of clear w ater. It is essential th at no substitute for this solution be used and th a t the specified proportions be m aintained. 2. W hile entire area is still wet with solution, remove paper backing from tra n sfe r, locate and press on lightly. 3. S tart at center of transfer and squeegee outboard from middle to edges, removing all air bubbles and wetting solution to assure a satisfac to ry bond. U se teflonbacked plastic squeegee only.

TORQUE SPECIFICATIONS CK
Lock to Bracket & Rad. Support Lock Support to Hood Lock Bolt Nut Bumper Bolt Nut Hood Hinge Hood Lock Catch Lock Support to Rad. Support Rad. Support to Frame Rad. Support to Fender Fender Skirt to Fender Fender to Cowl Rad. G rille Panel Lower 27 N- m ( 20 ft. lb s.) 17 54 17 24 24 24 N- m (150 in. lb s .) N- m ( 40 ft. lb s.) N- m (150 in. lb s .) N* m ( 18 ft. lb s . ) N- m ( 18 ft. lb s .) N- m ( 18 ft. lb s.)

24 27 17 48 17 17 48

N- m N- m N. m N- m N- m N- m N- m

( 18 ( 20 (150 ( 35 (150 (150 ( 35

ft. lb s.) ft. lb s.) in. lb s .) ft. lb s.) in . lb s .) in .lb s .) ft. lb s .)

17 N- m (150 in. lb s .)

.'M

V l '?

' j I;* b.M v>

! 'r '

ec; '

DIAGNOSIS

3-1

SECTION 3

STEERING, SUSPENSION, WHEELS AND TIRES


DIAGNOSIS............................................................................................... 3-1 FRONT END ALIGNM ENT................................................................ 3A-1 STEERING LINKAGE.......................................................................... 3B1-1 MANUAL STEERING G EA R ............................................................ 3B2-1 POWER STEERING SY ST E M ......................................................... 3B3-1 STEERING COLUM N.......................................................................... 3B4-1 FRONT SU SP E N SIO N .......................................................................... 3C-1 REAR SU SPE N SIO N ............................................................................. 3D-1 WHEELS AND T IR E S........................................................................... 3E-1

CONTENTS
Steering L inkage.................................................................... 3-2 Manual Steering G ear.......................................................... 3-4 Power Steering S y ste m ................................................... 3-6 System N o ise........................................................................ 3-6 System Operation................................................................ 3-7 Steering Colum ns................................................................ 3-11 Auto. Transmission Cols.................................................. 3-11 Man. Trans. C olum ns...................................................... 3-15 Tilt Columns........................................................................ 3-16 From Suspension.................................................................. 3.21 Shock Absorbers................................................................. 3-23 Ball Joints............................................................................ 3-26 Bearings and R aces........................................................... 3-27

3-2

DIAGNOSIS

C O NDITIO N

POSSIBLE CA U SE

CORRECTION

Excessive Play or Looseness in Steering System.

Front wheel bearings loosely adjusted.

Adjust bearings to obtain proper end play.

Worn steering shaft couplings.

Replace part.

Worn upper ball joints.

Check and replace if necessary.

Steering wheel loose on shaft, loose pitman arm, tie rods, steering arms or steering linkage ball studs.

Tighten to specified torque, or replace if necessary.

Steering gear thrust bearings loosely adjusted.

Adjust preload to specification.

Excessive over-center lash in steering gear.

Adjust preload to specification.

Worn intermediate rod or tie rod sockets.

Replace worn part.

Excessive looseness in tie rod or intermediate rod pivots, or excessive vertical lash in idler support.

Seal damage and leakage resulting in loss of lubricant, corrosion and excessive wear.

Replace damaged parts as necessary. Properly position upon reassembly.

Excessive vertical lash in idler arm (P Series Motorhome)

Excessive end play in support assembly.

Adjust end play.

Fig. 3-1--Steering Linkage Diagnosis A

DIAGNOSIS

3-3

CONDITIO N

POSSIBLE C A U SE

CORRECTIO N

Hard Steering - Excessive Effort Required at Steering Wheel.

Low or uneven tire pressure.

Inflate to specified pressures.

Steering linkage or bolt joints need lubrication.

Lube with specified lubricant.

Tight or frozen intermediate rod, tie rod or idler socket.

Lube replace or reposition as necessary.

Steering gear to column misalignment.

Align column.

Steering gear adjusted too tightly.

Adjust over-center and thrust bearing preload to specification.

Front wheel alignment incorrect, (manual gear)

Check alignment and correct as necessary.

Poor Returnability.

Steering linkage or ball joints need lubrication.

Lube with specified lubricant.

Steering gear adjusted too tightly.

Adjust over-center and thrust bearing preload to specifications. Align column.

Steering gear to column misalignment.

Front wheel alignment incorrect. (Caster)

Check alignment and correct as necessary.

Fig. 3-2--Steering Linkage Diagnosis B

3-4

DIAGNOSIS

CONDITIO N

PO SSIBLE C A U SE

CORRECTION

Rattle or Chuck in Steering Gear.

Insufficient or improper lubricant in steering gear.

Add lube specified.

Pitman arm loose on shaft or steering gear mounting bolt loose.

Tighten to specified torque.

Loose or worn steering shaft bearing.

Replace steering shaft bearing.

Excessive over-center lash or worm thrust bearings adjusted too loose. NOTE: On turns a slight rattle may occur, due to the increased lash between ball nut and pitman shaft as gear moves off the center of high point position. This is normal and lash must not be reduced to eliminate this slight rattle.

Adjust steering gear to specified preloads.

Poor Returnability

Steering column misaligned.

Align column.

Insufficient or improper lubricant in steering gear or front suspension.

Lubricate as specified.

Steering gear adjusted too tight.

Adjust over-center and thrust bearing preload to specifications.

Front wheel alignment incorrect (Caster)

Adjust to specifications.

Fig. 3-3--Manual Steering Gear Diagnosis A

DIAGNOSIS

3-5

CONDITION

POSSIBLE CAUSE

CORRECTIO N

Excessive Play or Looseness in Steering System.

Front wheel bearings loosely adjusted.

Adjust to obtain proper end play.

Worn upper ball joints.

Check and replace ball joints if necessary.

Steering wheel loose on shaft, loose pitman arm, tie rods, steering arms or steering linkage ball nuts.

Tighten to specification, replace if worn or damaged.

Excessive over-center lash.

Adjust over-center preload to specifications.

Worm thrust bearings loosely adjusted.

Adjust worm thrust bearing preload to specifications.

Hard Steering Excessive Effort Required at Steering Wheel

Low or uneven tire pressure.

Inflate to specified pressures.

Insufficient or improper lubricant in steering gear or front suspension.

Lubricate as specified. Relubricate at specified intervals.

Steering shaft flexible coupling misaligned.

Align column and coupling.

Steering gear adjusted too tight.

Adjust over-center and thrust bearing preload to specifications.

Front wheel alignment incorrect. (Manual Gear)

Adjust to specifications.

Fig. 3-4-Manual Steering Gear Diagnosis B

3-6

DIAGNOSIS

C O N D IT IO N

PO S S IB L E C A U S E

C O R R E C T IO N

S Y S T E M N O IS E
T h e re is som e noise in all p ow er steering system s. C o m m o n c o m p la in ts are listed as follows: P u m p no ise- c h i r p . Belt squeal. G ear noise ( hissing s o u n d ) Loose belt. Loose belt. T h ere is som e noise in all p ow er steer ing systems. O ne o f the m ost c o m m o n is a hissing so u n d m ost evident at standstill parking. T h ere is no re la tio n ship b e tw e e n this noise and p e rf o r m an ce o f the steering. Hiss m ay be e x p e c te d w hen steerin g wheel is at e n d o f travel or w hen slowly tu r n in g at standstill. A djust belt te nsio n to specification. A djust belt ten sio n to specification. Do n o t replace valve unless hiss is e x tr e m e ly ob jectio nab le.. Slight hiss is no rm al an d in no way affects ste e r ing. A re p la c e m e n t valve will also e x h i bit slight noise and is not alw ays a cure for the o b je c tio n . Investigate clearance a ro u n d flexible cou p lin g rivets. Be sure steering shaft arid gear are aligned so flexible c o u p lin g ro tates in a flat plane and is n o t d is to rte d as shaft r o tates. A ny m etal-to-m etal c o n ta c ts th ro u g h flexible c o u p lin g will tran sm it hiss in to passenger c o m p a r tm e n t. Also, check for proper sealing betw een steering column and toe pan. A djust hose p ositio n.

R attle .

Pressure hose to u c h in g o th e r parts o f car. Loose p u m p pulley n u t P u m p vanes n ot installed p roperly. P u m p vanes sticking in ro to r slots.

R eplace n u t, to r q u e to specs. Install p ro pe rly . Free up by rem ov ing burrs, varnish or dirt. A djust to specifications.

Gear noise (r a ttl e or chu ck le ).

Im p ro p e r o ver-cen ter a d ju s tm e n t N O T E : A slight rattle m ay o c c u r on tu rn s because o f increased cle arance o f f the high p o i n t . This is norm al a n d cle arance m ust n o t be re d u c e d b elo w specified limits to elim in a te this slight rattle. Loose p itm a n arm . Gear loose on fram e.

T igh ten to sp ecific atio ns C heck gear-to-fram e m o u n t in g bolts. T ig h ten b o lts to 7 0 f o o t-p o u n d s . C heck linkage pivot p o in ts for wear. R eplace if necessary. Fill reservoir to p ro p e r level.

R a tt le o r c hu ckle .

S teering linkage looseness.

Groan. Groan.

L o w oil level. Air in the c o n n e c tio n . oil. Po or pressure hose

Bleed sy s te m by o p e ra tin g steerin g fro m right to left - full turn. C heck c o n n e c t io n s , t o r q u e to specs. L o cate re s tric tio n an d c o rre c t. R eplace pari if necessary.

Growl.

Excessive back pressure caused hoses or steering gear, ( r e s tr ic tio n )

by

Fig. 3-5--Power Steering System Diagnosis A

DIAGNOSIS

3-7

CON DITION P u m p growl Note: Most noticeable at full wheel travel and stand still parking

POSSIB LE CAUSE S cored p u m p pressure plates, thrust plate or ro tor. E x trem e wear o f p u m p cam ring.

C O R R E C T IO N Replace affected p a rts, flush system.

Replace affected parts. Replace valve Replace housing and shaft, flush system Replace 0 ring.

Swish in p u m p Whine in p u m p Sq uaw k in gear (n o t belt)

Defective p u m p flow con tro l valve P u m p shaft bearing scored. D a m p e r 0 rin g o n v a lv e s p o o l c u t

SY ST E M O P E R A T IO N
Excessive wheel kick-back steering. or loose Backlash in steering linkage. Adjust parts affected or replace worn parts. Add oil to p u m p reservoir and bleed by operating steering. Check all connections. A djust to specification. Adjust to specification.

Air in system.

Excessive over-cen ter lash. Loose th ru st bearing preload adju st ment. Worn p o p p e t valve (G ear) Steering gear loose on frame.

Replace p o p p et valve. Tighten attach ing bolts to 70 f o o t pounds. Tighten flange pinch bolts to 30 f o o t pou nd s, if serrations are not damaged. Tig hten u p p er flange to coupling n uts to 20 foot-pounds. Replace loose co m p o n en ts.

Steering gear flexible coupling to o loose on shaft or rubber disc m o u n tin g screws loose.

Steering linkage ball studs w orn enough to be loose. F ro n t wheel bearings incorrectly ad j u s t e d or worn.

Adjust bearings or replace w ith new parts as necessary.

P o o r re tu rn o f steering.

Tires under-inflated. L ower c oupling flange rubbing against steering gear adjuster plug. Steering wheel ru bbing against direc tional signal housing. Tight or frozen steering shaft bearings. Steering linkage or ball jo in ts binding. Steering gear to colu m n misalignment. Tie rod pivots n o t centralized.

Inflate to specified pressure. Loosen pinch bolt and assemble p ro p erly. Adjust steering jacket.

Replace bearings. Replace affected parts. Align steering colum n. A djust tie rod ends as required to cen te r pivots. Lubricate and relubricate at proper intervals

Lack o f lubricant in suspension ball jo in ts and steering linkage

Fig. 3-6--Power Steering System Diagnosis B

3-8

DIAGNOSIS

CONDITION Poor return of steering. (Contd.)

POSSIBLE CAUSE Steering gear adjustments over specifications. Sticky or plugged valve spool. Rubber spacer binding in shift tube.

CORRECTION Check adjustment with pitman arm disconnected. Readjust if necessary. Remove and clean or replace valve. Make certain spacer is properly seated. Lubricate inside diameter with sili cone lubricant. Check and adjust to specifications. Replace bearings.

Improper front suspension alignment. Tight steering shaft bearings.

Car leads to one side or the other. (Keep in mind road condition and wind. Test car on flat road going in both directions)

Front suspension misaligned Steering shaft rubbing ID of shift tube. Unbalanced or badly worn steering gear valve. NOTE: If this is cause, steering effort will be very light in direction of lead and heavy in opposite direction. Steering linkage not level.

Adjust to specifications. Align column. Replace valve.

Adjust as required.

Low oil level in pump. Steering wheel surges or jerks when turning with engine running especially during parking. Loose pump belt. Sticky flow control valve.

Check oil level, add as necessary. Adjust tension to specification. Inspect for varnish or damage, replace if necessary. Check pump pressure. (See pump pressure test). Replace relief valve if defective. Correct clearance.

Insufficient pump pressure.

Steering linkage hitting engine oil pan at full turn. Pump belt slipping. Momentary increase in effort when turning wheel fast to right or left. Low oil level in pump. High internal leakage. Hard steering or lack of assist. High internal leakage. (Gear or pump) Loose pump belt. Low oil level in reservoir.

Tighten or replace belt. Check oil level, add as necessary. Check pump pressure (Test) Check pump pressure test). pressure. (See pump

Adjust belt tension to specification. Fill to proper level. If excessively low, check all lines and joints for evidence of external leakage, torque to specs.

Fig. 3-7--Power Steering System Diagnosis C

DIAGNOSIS

3-9

CONDITION

POSSIBLE CAUSE

CORRECTION

Hard Steering or lack of assist (Continued)

Lack of lubricant in suspension or ball joints. Tires not properly inflated. Steering gear to column misalignment. Steering gear adjusted too tight.

Lubricate, relubricate at proper intervals. Inflate to recommended pressure. Align steering column. Test steering system for binding with front wheels off floor. Adjust as neces sary. Check tie rod pivot points for exces sive friction. Replace the affected pivot. Loosen pinch bolt and assemble properly. Replace or clean valve. Check frame for proper alignment or cracking. Repair or replace as neces sary. Check standing height. Weak or sag ging springs should be replaced with new ones. If above checks do not reveal cause of hard steering, diagnose hydraulic system to determine problem.

Excessive friction in steering linkage.

Lower coupling flange rubbing against steering gear adjuster plug. Sticky flow control valve. Frame bent.

Front springs weak and sagging.

Insufficient oil pressure.

Low oil pressure due to restriction in hoses:

Check for kinks in hoses. Foreign object stuck in hose.

Remove kink. Remove hoses and remove restricting object or replace hose.

Low oil pressure due to steering gear:

Pressure loss in cylinder due to worn piston ring or scored housing bore. Leakage at valve rings, valve body to worm seal. Loose fit of spool in valve body or leaky valve body. Damaged poppet valve.

Remove gear from car for disassembly and inspection of ring and housing bore. Replace affected parts. Remove gear from car for disassembly and replace seals. Replace valve. Replace valve.

(See pump pressure test)

Fig. 3-8~Power Steering System Diagnosis D

3-10

DIAGNOSIS

CONDITION

P O S S IB L E C A U S E

C O R R EC TIO N

L o w oil pump:

pressure

due

to

steering

L o ose belt. L o w oil level.

A djust ten s io n to specific atio n Fill reservoir to p r o p e r level. L o c a te so urce Bleed system . o f leak a n d c o rre ct.

(See p u m p pressure te s t.) Air in th e oil.

D efective hoses or steering gear. F lo w c o n tr o l valve stu c k or in o p e r a tive. L oose screw in end o f flow c o n tr o l valve. C ra c k e d or b ro k e n th r u s t or pressure plate. Pressure ring. N o te : Steering s y s te m e x te rn a l leakage , E x tre m e w ear o f cam ring. S c o red pressure plate, th ru st p late or ro to r. V anes n o t installed p ro pe rly. V an es stick ing in ro to r slots. plate not flat against cam

C o rre ct as necessary. R e m o v e b u rrs or dirt or replace.

T ig h ten.

R eplace part.

R eplace pressure plate.

R eplace p arts, flush sy stem R ep lace parts. ( I f r o t o r , replace w ith ro ta tin g g ro u p k it), flush system Install p ro pe rly . R ad iu s edge to o u ts id e . Free-up by re m o vin g b u rrs, varnish or dirt. C heck for leak a n d c o rrect. Bleed system . E x tre m e ly cold t e m p e r a t u r e s will cause sy s te m aeriatio n sh o uld the oil level be low . If oil level is c o rre ct an d p u m p still foam s, rem ove p u m p fro m vehicle and sep arate reservoir fro m housing. C heck welsh plug and ho usin g for cracks. If plug is loose or hou sing is cra c k e d , rep lace housing.

F o a m in g m ilk y p o w e r steering fluid, low level an d possible low pressure.

Air in the fluid, a n d loss o f fluid d ue to internal p u m p leakage causing overflow .

Fig. 3-9--Power Steering System Diagnosis E

DIAGNOSIS

3-11

Instrument Panel Bracket Capsule Damage NOTE: The bolt head must not contact surface A . If contact is made, the capsule shear load will be increased. If this condition exists replace the bracket. _____ I ~ 1

SU RFA CE A

ZD

AUTOMATIC TRANSMISSION COLUMNS


LOCK S Y S T E M - W I L L Cause A. Lock bolt damaged. B. Defective lock cylinder. C. Damaged housing. D. Damaged or collapsed sector. E. Damaged rack. F. Shear Flange on sector shaft collapsed. LOCK S YSTEM Cause A. Lock bolt spring broken or defective. B. Damaged sector tooth, or sector installed incorrectly. C. Defective lock cylinder. D. Burr or lock bolt or housing. E. Damaged housing. F. Transmission linkage adjustment incorrect. G. Damaged rack. H. Interference betw een bowl and coupling (tilt). I. J. Ignition switch stuck. Actuator rod restricted or bent. EFFO RT Solution A. Replace lock cylinder. B. Replace switch. C. Replace spring. D. Remove Burr. E. F. Replace shaft. Replace rack W IL L N O T LOCK Solution A. Replace spring. B. Replace, or install correctly. C. Replace lock cylinder D Remove Burr. NOT UNLOCK Solution A. Replace lock bolt. B. C. Replace or repair lock cylinder. Replace housing.

D. Replace sector. E. F. Replace rack. Replace.

E. Replace housing. F. Readjust (see Sec. 7).

G. Replace rack. H. Adjust or replace as necessary. I. J. Readjust or replace. Readjust or replace.

LOCK S YSTEM - H IG H Cause A. Lock cylinder defective. B. Ignition switch defective.

C. Rack preload spring broken or deformed. D. Burrs on sector, rack, housing, support, tang of shift gate or actuator rod coupling. E. Bent sector shaft. F. Distorted rack. G. Misalignment o f housing to cover (tilt only).

G. Replace either or both.

Fig. 3-10--Auto Transmission Column Diagnosis A

3-12

DIAGNOSIS

LOCK SYSTEM Cause

HIGH EFFORT (CONT'D.) Solution H. Replace rack. I. Straighten remove restriction or replace.
J. Straighten or replace.

H. Distorted coupling slot in rack (tilt). I. J. Bent or restricted actuator rod. Ignition switch mounting bracket bent.

HIGH EFFORT LOCK CYLINDER - BETWEEN "OFF" AND "OFF-LOCK" POSITIONS Cause
A. Burr on tang of shift gate. B. Distorted rack.

Solution
A. Remove burr. B. Replace rack.

STICKS IN "START" POSITION Cause


A. Actuator rod deformed. B. Any high effort condition.

Solution
A. Straighten or replace. B. Check items under high effort section.

KEY CAN NOT BE REMOVED IN "OFF-LOCK" POSITION Cause


A. Ignition switch is not set correctly. B. Defective lock cylinder.

Solution
A. Readjust ignition switch. B. Replace lock cylinder.

LOCK CYLINDER CAN BE REMOVED WITHOUT DEPRESSING RETAINER Cause


A. Lock cylinder with defective retainer. B. Lock cylinder without retainer. C. Burr over retainer slot in housing cover.

Solution
A. Replace lock cylinder. B. Replace lock cylinder. C. Remove burr.

LOCK BOLT HITS SHAFT LOCK IN "OFF" AND "PARK" POSITIONS Cause
A. Ignition switch is not set correctly.

Solution
A. Readjust ignition switch.

IGNITION SYSTEM - ELECTRICAL SYSTEM WILL NOT FUNCTION Cause


A. Defective fuse in accessory circuit. B. Connector body loose or defective. C. Defective wiring.

Solution
A. Replace fuse. B. Tighten or replace. C. Repair or replace.

Fig. 3-11-Auto Transmission Column Diagnosis B

DIAGNOSIS

3-13

IGNITION SYSTEM - ELECTRICAL SYSTEM WILL NOT FUNCTION (CONT'D.)


Cause
D. Defective ignition switch. E. Ignition switch not adjusted properly.

Solution
D. Replace ignition switch. E. Readjust ignition switch.

SWITCH WILL NOT ACTUATE MECHANICALLY Cause


A. Defective ignition switch.

Solution
A. Replace igntion switch.

SWITCH CAN NOT BE SET CORRECTLY Cause


A. Switch actuator rod deformed. B. Sector to rack engaged in w rong to o th (tilt).

Solution
A. Repair or replace switch actuator rod. B. Engage sector to rack correctly.

NOISE IN COLUMN Cause


A. Coupling bolts loose. B. Column not correctly aligned. C. Coupling pulled apart. D. Sheared intermediate shaft plastic joint: E. Horn contact ring not lubricated.

Solution
A. Tighten pinch bolts to specified torque. B. Realign column. C. Replace coupling and realign column. D. Replace or repair steering shaft and realign column. E. Lubricate with lubriplate.

F. Lick of grease on bearings or bearing surfaces.


G. Lower shaft bearing tight or frozen.

F. Lubricate bearings.
G. Replace bearing. Check shaft and replace if scored.

H. Upper shaft tight or frozen.


I. Shaft lock plate cover loose.

H. Replace housing assembly. I. Tighten three screws or, if missing, replace.


J. CAUTION: Use specified screws. (15 in. lbs.) Replace snap ring. Check for proper seating in groove.

J. Lock plate snap ring not seated.


K. Defective buzzer dog cam on lock cylinder.

K. Replace lock cylinder. L. Normal condition - lock bolt is seating.

L. One click when in off-lock position and the steering


wheel is moved.

Fig. 3-12-Auto Transmission Column Diagnosis C

3-14

DIAGNOSIS

H IG H S T E E R IN G S H A F T E F F O R T Cause A. Column assembly misaligned in vehicle. B. Improperly installed or deformed dust seal. C. Tight or frozen upper or lower bearing. D. Flash on I.D. of shift tube from plastic joint. Solution A. Realign. B. Remove and replace. C. Replace affected bearing or bearings. D. Replace shift tube.

H IG H S H IF T E F F O R T Cause A. Column not aligned correctly in car. B. Improperly installed dust seal. C. Lack of grease on seal or bearing areas. D. Burr on upper or lower end of shift tube. E. Lower bowl bearing n o t assembled properly (tilt). F. Wave washer w ith burrs (tilt only). Solution A. Realign. B. Remove and replace. C. Lubricate bearings and seals. D. Remove burr. E. Reassemble properly. F. Replace wave washer.

IM PROPER T R A N S M IS S IO N S H IF T IN G Cause A. Sheared shift tube joint. B. Improper transmission linkage adjustment. C. Loose lower shift lever. D. Improper gate plate. E. Sheared lower shift lever weld. LASH IN M O U N T E D C O L U M N A SS E M B LY Cause A. Instrument panel mounting bolts loose. B. Broken weld nuts on jacket. C. Instrument panel bracket capsule sheared. D. Instrument panel to jacket mounting bolts loose. E. Loose shoes in housing (tilt only). F. Loose tilt head pivot pins (tilt only). G. Loose shoe lock pin in s u p p o rt (tilt only). M IS C E L L A N E O U S Cause A. Housing loose on jacket - will be noticed with ignition in Off-Lock and a torque applied to the steering wheel. B. Shroud loose on shift bowl. Solution A. Tighten four mounting screws (60 in. lbs.) B. Bend tabs on shroud over lugs on bowl. Solution A. Tighten to specifications. (20 ft. lbs.) B. Replace jacket assembly. C. Replace bracket assembly. D. Tighten to specifications. (15 ft. Ibs.) E. Replace. F. Replace. G. Replace. Solution A. Replace shift tube assembly. B. Readjust linkage. C. Replace shift tube assembly. D. Replace with correct part. E. Replace tube assembly.

Fig. 3-13--Auto Transmission Column Diagnosis D

DIAGNOSIS

3-15

MANUAL TRANSMISSION COLUMNS


GENERAL INFORMATION All ot the preceding diagnosis information for automatic transmission will apply to the manual transmission. The following information is supplied in addition to and specifically for manual transmission columns.

DRIVER CAN LOCK STEERING IN SECOND GEAR Cause


A. Defective upper shift lever. B. C.

Solution
A. B. C.

Replace shift lever. Replace shift lever gate. Replace shift tube assembly.

Defective shift lever gate. Loose relay lever on shift tube.

HIGH SHIFT EFFORT Cause


A. Column not aligned correctly in car. B. C.

Solution
A. Realign column. B. C.

Lower bowl bearing not assembled correctly. Improperly installed seal.

Reassemble correctly. Remove and replace.

D. Wave washer in lower bowl bearing defective. E. Improper adjustm ent o f lower shift levers.
F.

D. Replace wave washer. E. Readjust (see Sec. 7).


F.

Lack o f grease on seal, bearing areas or levers.

Lubricate seal, levers and bearings.

G. Damaged shift tube in bearing areas.

G. Replace shift tube assembly.

IMPROPER TRANSMISSION SHIFTING Cause


A. Loose relay lever on shift tube.

Solution
A. Replace shift tube assembly.

Fig. 3-14--Manual Transmission Column Diagnosis

3-16

DIAGNOSIS

TILT COLUMNS
GENERAL INFORMATION All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in addition to and specifically for tilt columns.

HOUSING SCRAPING ON BOWL Cause


A. Bowl bent or not concentric with hub.

Solution
A. Replace bowl.

STEERING WHEEL LOOSE


Cause
A. Excessive clearance between holes in support or housing and pivot pin diameters. B. Defective or missing anti-lash spring in spheres. C. Upper bearing seat not seating in bearing. D. Upper bearing inner race seat missing. F. Loose support screws. G. Bearing preload spring missing or broken.

Solution
A. Replace either or both.
B. Add spring or replace both.

C. Replace both. D. install seat. F. Tighten to 60 in. lbs. G. Replace preload spring.

STEERING WHEEL LOOSE EVERY OTHER TILT POSITION Cause


A. Loose fit between shoe and shoe pivot pin.

Solution
A. Replace both.

NOISE WHEN TILTIN G COLUMNCause


A. Upper tilt bumper worn. B. Tilt spring rubbing in housing.

Solution
A. Replace tilt bumper.
B. Lubricate.

STEERING COLUMN NOT LOCKING IN ANY TILT POSITION Cause


A. Shoe seized on its pivot pin. ivot pin. B. Shoe grooves may have burrs or dirt. C. Shoe lock spring weak or broken.

Solution
A. Replace shoe and-pivot pin. B. Replace shoe. C. Replace lock spring.

STEERING WHEEL FAILS TO RETURN TO TOP T IL T POSITION Cause


A. Pivot pins are bound up.
B. Wheel tilt spring is defective.

Solution
A. Replace pivot pins.
B. Replace tilt spring.

C. Turn signal switch wires too tight.

C. Reposition wires.

Fig. 3-15--Tilt Column Diagnosis

DIAGNOSIS

3-17

* SIGNAL SWITCH DIAGNOSIS CONDITION Turn signal will not cancel A. B. C. D. POSSIBLE CAUSE Loose switch mounting screws Switch or anchor bosses broken Broken, missing or out of position detent, return or cancelling spring Uneven or incorrect cancelling cam to cancelling spring interference. (.120)/side A. B. C. D. CORRECTION Tighten to specified torque (25 in-lbs) Replace switch Reposition or replace springs as required Adjust switch position 1. If interference is correct and switch will still not cancel, replace switch. 2. If interference cannot be corrected by switch adjustment, replace cancelling cam. Tighten mounting screw (12 in-lb) Replace switch Reposition or replace springs Remove foreign parts and/or material Tighten mounting screws (25 in-lbs) Replace switch Replace or reposition as required Loosen mounting screws, reposition base or wires and retighten screws(25 in-lbs) Remove material and/or parts Replace spring Replace switch Remove foreign material 1. No foreign material impeding function of hazard switch replace turn signal switch

Turn signal difficult to operate

A. B. C. D. E.

Actuator rod loose Yoke broken or distorted Loose or misplaced springs Foreign parts and/or materials Switch mounted loosely Broken lane change pressure pad or spring hanger Broken, missing or misplaced lane change spring Jammed base or wires

A. B. C. D. E.

Turn signal will not indicate lane change

A. B. C.

A. B. C.

Turn signal will not stay in turn position

A. B. C.

Foreign material or loose parts impeding movement of yoke Broken or missing detent or cancelling springs None of the above Foreign material between hazard support cancelling leg and yoke

A. B. C. A.

Hazard switch cannot be turned off

A.

Fig. 3-16--Turn Signal Switch Diagnosis A

3-18

DIAGNOSIS

SIGNAL SWITCH DIAGNOSIS CONDITION Hazard switch will not stay on or difficult to turn off A. B. C. D. No turn signal lights A. B. C. D. POSSIBLE CAUSE Loose switch mounting screws Interference with other components Foreign material None of the above Defective or blown fuse Inoperative turn signal flasher Loose chassis to column connector Disconnect column to chassis connector. Connect new switch to chassis and operate switch by hand. If vehicle lights now operate normally, signal switch is inoperative If vehicle lights do not operate check chassis wiring for opens, grounds, etc. Inoperative turn , flasher Loose chassis to column connection Inoperative turn signal switch To determine if turn signal switch is defective, substitute new switch into circuit and operate switch by hand. If the vehicle's lights operate normally, signal switch is inoperative If the vehicle's lights do not operate, check light sockets for high resistance connections, the chassis wiring for opens, grounds, etc. A. B. C. D. A. B. C. D. CORRECTION Tighten mounting screws (25 in-lbs) Remove interference Remove foreign material Replace switch Replace fuse and check operation Replace turn signal flasher Connect securely, check operation Replace signal switch

E.

E.

Repair chassis wiring as required using manual as guide

Turn indicator lights on, but not flashing

A.

A.

B. C. D.

B. C. D.

Replace turn flasher Note: There are two flashers in the system. Consult manual for location. Connect securely and check operation Replace turn signal switch Replace signal switch

E.

E.

Repair chassis wiring as required using manual as guide

Fig. 3-17--Turn Signal Switch Diagnosis B

DIAGNOSIS

3-19

SIGNAL SWITCH DIAGNOSIS CONDITION Front or rear turn signal lights not flashing A. B. C. D. E. POSSIBLE CAUSE Burned out fuse Burned out or damaged turn signal bulb High resistance connection to ground at bulb socket Loose chassis to column connector Disconnect column to chassis connector. Connect new switch into system and operate switch by hand. If turn signal lights are now on and flash, turn signal switch is inoperative. If vehicle lights do not operate, check chassis wiring harness to light sockets for opens, grounds, etc. Burned out fuse Loose column to chassis connection Disconnect column to chassis connector. Connect new switch into system without removing old. Operate switch by hand. If brake lights work with switch in the turn position, signal switch is defective If brake lights do not work check connector to stop light sockets for grounds, opens, etc. P ned out bulbs High resistance to ground at bulb socket Opens, grounds in wiring harness from front turn signal bulb socket to indicator lights A. B. C. D. E. CORRECTION Replace fuse and check operation Replace bulb Remove or repair defective connection and check operation Connect securely and check operation Replace turn signal switch.

F .

F .

Repair chassis wiring as required using manual as guide

Stop light not on when turn indicated

A. B. C.

A. B. C.

Replace fuse and check operation Connect securely and check operation Replace signal switch

D.

D.

Repair connector to stop light circuits using manual as guide.

Turn indicator panel lights not flashing

A. B. C.

A. B. C.

Replace bulbs Replace socket Locate and repair as required. Use shop manual as guide.

Fig. 3-18--Turn Signal Switch Diagnosis C

3 -20

DIAGNOSIS

SIGNAL SWITCH DIAGNOSIS CONDITION Turn signal lights flash very slowly A. B. C. D. E. POSSIBLE CAUSE Inoperative turn signal flasher System charging voltage low High resistance ground at light sockets Loose chassis to column connection Disconnect column to chassis connector. Connect new switch into system without removing old. Operate switch by hand. If flashing occurs at normal rate, the signal switch is defective. If the flashing rate is still extremely slow, check chassis wiring harness from the connector to light sockets for grounds, high resistance points, etc. Blown fuse Inoperative hazard warning flasher Loose chassis to column connection Disconnect column to chassis connector. Connect new switch into system without removing old. Depress the hazard warning button and observe the hazard warning lights. If they now work normally, the turn signal switch is defective. If the lights do not flash, check wiring harness " K " lead (brown) for open between hazard flasher and harmonica connector. If open, fuse block is defective. A. B. C. D. E. CORRECTION Replace turn signal flasher 1ncrease voltage to specified. See Sec. 6Y Repair high resistance grounds at light sockets Connect securely and check operation Replace signal switch

F.

F.

Locate and repair as required. Use manual as guide. See Section 12

Hazard signal lights w ill not flash - turn signal functions normally

A. B. C. D.

A. B. C. D.

Replace fuse and check operation Replace hazard warning flasher Connect securely and check operation Replace the turn signal switch

E.

E.

Replace fuse block (See Sec. 12)

Fig. 3-19--Turn Signal Switch Diagnosis D

DIAGNOSIS

3-21

FRONT SUSPENSION DIAGNOSIS


HARD STEERING
Probable Cause a. b. c. d. e. Ball joints and steering linkage need lubrication Low or uneven fro n t tire pressure Power steering partially or n o t operative Steering gear n o t properly adjusted Incorrect fro n t wheel alignment (manual steering) a. b. c. d. e. Probable Remedy Lubricate ball joints and linkage Inflate tires to the proper recommended pressure Check power steering components fo r proper operation A djust steering gear Check and align fro n t suspension

POOR DIRECTIONAL STABILITY


a. b. c. d. e. f. Ball joints and steering linkage need lubrication Low or uneven fro n t or rear tire pressure Loose wheel bearings Steering Gear not on high p o in t Incorrect fro n t wheel alignm ent (caster) Broken springs M alfunctioning shock absorber. Broken stabilizer bar, or missing lin k a. b. c. d. e. f. Lubricate at proper intervals Inflate tires to the proper recommended pressure A djust wheel bearings A djust steering gear Check and align fro n t suspension Replace springs Diagnose shock absorbers. Replace stabilizer or lin k

gh.

gh.

FRONT WHEEL SHIMMY (SMOOTH ROAD SHAKE)


a. b. c. d. e. T ire and wheel o u t o f balance, or o u t o f round Worn or loose wheel bearings Worn tie rod ends Worn ball joints M alfunctioning shock absorber a. b. c. d. e. Balance tires, check run-out A djust wheel bearings Replace tie rod end Replace ball joints Diagnose shock absorbers

VEHICLE PULLS TO ONE SIDE (NO BRAKING ACTION)


a. b. c. d. Low or uneven tire pressure F ront or rear brake dragging Broken or sagging fro n t spring Incorrect fro n t wheel alignment (camber) a. b. c. d. Inflate tires to the proper recommended pressure A djust brakes Replace spring Check and align fro n t suspension

EXCESSIVE PLAY IN STEERING


a. b. Incorrect steering gear adjustment Worn steering gear parts a. b. A d ju st steering gear Overhaul gear

103401 Fig. 3-20--Front Suspension Diagnosis A

3-22

DIAGNOSIS

N O IS E IN F R O N T E N D Probable Cause
a.

Probable Remedy a. b. c. d. e. f. Lubricate at recommended intervals Tighten bolts and/or replace bushings Replace bushings Replace tie rod ends A djust or replace wheel bearings Tighten all stabilizer bar attachments Tighten the wheel nuts to proper torque Reposition Torque to specifications or replace

Ball joints and steering linkage need lubrication Shock absorber loose or bushings worn Worn control arm bushings Worn tie rod ends Worn or loose wheel bearings Loose stabilizer bar Loose wheel nuts Spring im properly positioned Loose suspension bolts

b.
c. d. e. f.

g.
h. i.

g.
h. i.

W HEEL TRAM P
a. b. c. d. Tire and wheel o u t o f balance Tire and wheel out o f round Blister or bump on tire Im proper shock absorber action a. b. c. d. Balance wheels Replace tire Replace tire Replace shock absorber

E X C E S S IV E O R U N E V E N T IR E W E A R
a. b. c. d. e. U nderinflated or overinflated tires Im proper toe-in Wheels o ut o f balance Hard Driving Overloaded vehicle a. b. c. d. e. Inflate tire to proper recommended pressure A djust toe-in Balance wheels Instruct driver Instruct driver

S C U F F E D T IR E S
a. b. c. d. Toe-in incorrect Excessive speed on turns Tires im properly inflated Suspension arm bent or twisted a. b. c. d. A d ju st toe-in to specifications Advise driver Inflate tires to proper recommended pressure Replace arm

C U P P E D T IR E S
a. b. c. d. e. F ron t shock absorbers defective Worn ball joints Wheel bearings incorrectly adjusted or w orn Wheel and tire o u t o f balance Excessive tire or wheel runout a. b. c. d. e. Replace shock absorbers Replace ball joints A d ju st or replace wheel bearings Balance wheel and tire Compensate fo r runout

Fig. 3-21--Front Suspension Diagnosis B

DIAGNOSIS

3-23

SHOCK ABSORBER DIAGNOSIS


ON VEHICLE CHECKS
(F o llo w the Procedures O utlined Below in the Order Indicated.)

Preliminary Inspection and Ride Test:


Tire Pressure Check tire pressure, compare to vehicle specifications and adjust as required. Poor vehicle control and ride com plaints are caused in many cases by im proper tire inflation. Special Suspension Equipm ent Check Service Parts Id e n tifica tio n S ticker fo r any special suspension equipm ent; such as, a heavy d u ty suspen sion. Vehicles equipped w ith this type o f o ption have a somewhat s tiffe r or harsh ride, and this should be kept in m ind during the follow ing tests. If com plaint about s tiff ness should occur while vehicle is still new (under 5,000 miles) (8 000 km ), owner should be advised to have ride re checked after 7,000 to 8,000 miles (11 200 to 12 800 km ). Vehicle Load Conditions

Test each fro n t and rear shock by bouncing each corner o f the vehicle. This can usually be done by liftin g up and pushing down on the end o f the bumper near each corner o f the vehicle u n til m axim um movement up and down is reached. Then let go o f bumper and observe if the up and down m o tio n stops very q u ickly. If up and down m o tion continues longer at one corner when compared to opposite com er (example, both fro n t shocks), the one having the longer up and down m o tio n may be suspect. Do N o t compare fro n t to rear. If com plaint is noise, this test should help to locate the suspected area. Inspecting Shock Mountings If noisy and/or loose shock mountings are suspected, place vehicle on hoist th a t supports wheels and check all mountings fo r the fo llo w in g conditions: (1) Worn or defective grommets (2) Loose m ounting nuts (3) Possible interference co n d ition (4) Bump stops missing If no apparent defects are noted in this step but noise co n d ition still exists when vehicle is bounced up and down, proceed. Inspecting Shocks fo r Leaks and

Note any exceptional load conditions under w hich the owner norm ally operates the vehicle; such as, large tool boxes fu ll o f tools, pick up bed fu ll etc. If exceptional loading is apparent, check the d is trib u tio n o f this weight. Note if it is all tow ard one side o f the vehicle or at the extreme rear o f the vehicle. Reposition load as required to obtain a more un ifo rm w eight d istrib u tio n . Check Vehicle Ride and Handling A fte r com pleting previous checks, ride vehicle w ith ow ner to determine if problem has been corrected or to d e fin ite ly establish type o f problem th a t still exists. If problem still exists (poor handling, bottom ing, noise, ride sway, etc.), proceed. Inspecting and Testing the Shocks Three procedures are included in this step. They are (a) Bounce Test, (b) Inspecting Shock Mountings fo r Noise (Looseness) and (c) Manually Operating Shocks to Deter mine if Shocks are Weak, Leaking H ydraulic F luid, and/or if Shocks have an Internal Noise C ondition. Test procedures (b) and (c) require vehicle to be on a hoist th a t supports wheels or rear axle housing and fro n t low er control arms. Bounce Test This is only a comparison type test to help locate the suspected shock or noise co n d itio n before proceeding.

Manually Operating Shocks This procedure is subdivided in to tw o general areas, (1) Inspecting Shocks fo r Loss o f H ydraulic Fluid and (2) Manually Operating Shock. It should aid the technician to localize defective shocks caused by internal noise in the shock, weakness, leaking etc. 1. Inspecting Shocks fo r Possible Loss o f H ydraulic Fluid. (a) Disconnect each shock lower m ounting as required and pull dow n on the shock u n til it is fu lly extended.

(b) Inspect shocks fo r leaks in seal cover area. Shock flu id is a very th in hydraulic flu id and has a char acteristic odor and dark brown t in t . Certain precautions should specting shocks fo r leaks: be observed when in

shocks may have glossy paint on them . Do n o t confuse this paint w ith a leak co n d ition . a slight trace o f shock flu id around the seal cover area is n o t cause fo r replacement. The shock seal is engineered to pe rm it a slight seepage to lubricate the rod. The shock absorber has reserve flu id to compen sate fo r the slight seepage. shocks are sometimes in co rre ctly diagnosed as leakers due to oil spray originating fro m some other source. If in doubt, wipe the w et area fro m and man ually operate shock as described in Step (2). F luid w ill reappear if shock is leaking.

Fig. 3-22--Shock Absorber Diagnosis

3-24

DIAGNOSIS

C-K-G-P TRUCK

2. Manually operating shocks.


It may be necessary w ith certain types o f shock m ount ings to fabricate a bracket th a t can be installed on a shock to enable a technician to securely grip the shock when manually operating the shock. See Figure 3C-9 fo r suggested methods o f providing tem porary grip. This test should help the mechanic to isolate the fo llow ing shock defects: binding co ndition internally verify leaking shock im proper or defective valving (a) If suspected problem is in fro n t shocks, disconnect both fro n t shock low er mountings and stroke each shock as follow s: G rip the lower end o f the shock securely and pull down (rebound stroke) then push up (compression stroke). The control arms w ill lim it the movement o f the fro n t shocks during the compression stroke. Compare the rebound resistance between both fro n t shocks, then com pare the compression resistance. If a noticeable difference can be fe lt during either stroke, usually the shock having the least resistance is at fa u lt. If shock has an internal noise co n d itio n , extend shock fu lly , then exert an extra pull. If noisy, shock should be replaced. O ther noise conditions th a t require shock replace m ent are: a grunt or squeal after one fu ll stroke in both directions a clicking noise on fast reverse a skip or lag at reversal near mid-stroke When air adjustable shocks are being manually oper ated, the air line must be disconnected at the shock absorber. E XIS TIN G HOLE

Gripping Methods

(b)

103405

Fig. 3-22A~Shock Absorber Diagnosis

DIAGNOSIS

3-25

BENCH CHECKS
The bench checks are recommended if the proper type hoist is n o t available to perform the "o n vehicle" tests, or if there is still some d o u b t as to whether the shocks are defective. In addition, the bench test allows a more th o r ough visual inspection. Bench check procedures are discussed fo r three general types o f shocks.

3. Manually pump each shock by hand at various rates o f speed and compare resistance o f suspected shock w ith the new one. Rebound resistance (extending the shock) is norm ally stronger than the compression resistance (approxi mately 2 :1). However, resistance should be smooth and constant fo r each stroking rate. 4. Observe or listen fo r the fo llo w in g conditions th a t w ill indicate a defective shock: a skip or lag when reversing stroke at mid travel. seizing or binding co n d itio n except at extreme end o f either stroke. a noise, such as a grunt or squeal, after com pleting one fu ll stroke in both directions. a clicking type noise at fast reversal. flu id leakage. 5. To check fo r a loose piston, com pletely extend shock to fu ll rebound; then exert an extra hard pull. If a give is fe lt, a loose piston is indicated and shock should be replaced.

S P IR A L G R O O V E R E S E R V O IR
If this type o f shock has been stored or allowed to lay in a horizontal position fo r any length o f tim e, an air void w ill develop in the pressure chamber o f the shock absorber. This air void if n o t purged, can cause a technician to diag nose the shock as defective. To purge the air fro m the pressure chamber, proceed as fo llo w s: (a) H olding the shock in its normal vertical position (top end up), fu lly extend shock.

(b) H old the to p end o f the shock dow n and fu lly collapse the shock. (c) Repeat Steps (a) and (b) at least five (5) times to assure air is purged. T Y P IC A L REAR SHOCK BOTTOM M O UNT SHOCK " COLLAPSED ROD EXTEND ED (REBO UND): - r BOTTOM M O UN T BOTTOM M O UN T

P L IA C E L L O R G E N E T R O N
Pliacell and Genetron are some o f the trade names used to indicate a gas-filled cell in the shock reservoir. The reservoirs o f Pliacell and Genetron shocks are smooth, compared to the spiral groove type. The cell takes the place o f air in the reservoir. Thus, aeration or foam ing o f the flu id is elim inated, as air and flu id cannot m ix. Due to this feature, these shocks should be bench checked in an inverted position (top end dow n). If, when stroked, a lag is noticed, it means the gas-filled cell has been ruptured, and the shock should be replaced. I f no lag is noticed, the remainder o f the bench check is the same as given in the Spiral Groove Reservoir, Section 1, Bench Check Procedure.

T Y P IC A L FRO NT SHOCK ROD EXTEND ED (REBO UND) BOTTOM M O UN T

w
DUST ' TUBE TOP END DOWN N

SHOCK C OLLAPSED.

TOP END DOWN IN V E R T THEN COLLAPSE POSITION FOR PURGING A IR FROM SHOCK ABSORBER

A IR A D J U S T A B L E S H O C K S
This type o f shock contains an air chamber like the spiral groove reservoir typ e , and must have the air purged fro m the w orking chamber. See Section 1, Spiral Groove Reservoir. A fte r air has been purged from shock, proceed as fo llo w s: (a) Clamp lower shock m ounting ring in vise in vertical position w ith larger diameter tube at the top. (b) Pump u n it by hand at d iffe re n t rates o f speed. Smooth resistance should be fe lt through the length o f the stroke. Since the units are norm ally pressurized, the sound o f air bubbles or a gurgling noise is normal. (c) The remainder o f the bench check is the same as given in the Spiral Groove Reservoir, Section 1, Bench Check Procedure. 103406

IN V E R T THEN COLLAPSE

Position fo r Purging A ir From Shocks Bench Test Procedure 1. This is a comparison type test. If possible, obtain a new or know n good shock w ith same part number as shock under test. 2. W ith shocks in vertical position (to p end up), clamp b o tto m mounts in vise. Do n o t clamp on reservoir tube or m ounting threads.

Fig. 3-22BShock Absorber Diagnosis

3 -2 6

DIAGNOSIS

BALL JOINT DIAGNOSTIC PROCEDURE

Fig. 3-23 Ball Joint Diagnosis

DIAGNOSIS

3-27

BEARINGS AND RACES BENCH DIAGNOSTIC PROCEDURE


. . . . . , . This section describes common types o f bearing dis tress and th e ir causes. Illustrations are included to help diagnose the cause o f distress and comments are provided * u ! i to help make effective repairs. Consider The Follow ing Factors When Diagnosing Bearing Distress: M * r* i r> -j *t ii . i . . . 1. Note General C ondition o f all parts during teardown and examinations.

Common Causes For Bearing Distress Include The Follow ing: 1. Im proper adjustment or preloading.

2. M ounting or teardown abuse,


. 3. mproper m ounting methods, 4. Inadequate or wrong lubricants. 5 - Entrance o f d irt or w ater6. Wear from d irt or metal chips. 7. Corrosion or rusting. 8. Overload. ^ 9. Overheating causing tempering. x. '0 . Frettage o f bearing seats, 11. B rinelling fro m im pact loads and shipping.

2. Classify the failure w ith the aid o f these illustrations


where possible. 3. Determine the cause. Recognizing the cause w ill perm it . r .. correction o f the problem and prevent a repeat failure o f the same type. 4. Make all repairs follow ing recommended procedures.

12. Manufacturing defects.

FRO NT W H EEL, P IN IO N , D IF F E R E N T IA L SIDE A N D REAR W HEEL R O LLE R BEARINGS

DIAGNOSIS
EXCESS NOISE C O M P LA IN T DIAG N O STIC PROCEDURE 1. Check tires fo r irregular wear Check tire pressure Check lubricant level Drive to warm-up rear axle Test at various speeds in drive, flo a t, coast and cornering Change tire pressure to m inim ize noises Drive over d iffe re n t road surfaces Smooth black-top minimizes tire noise Cross switch tires, if necessary Snow tire treads and studs caused added noises Drive slightly above speed where noise occurs, place transmission in neutral Let engine speed drop to idle Stop car Run engine at various speeds Drive car at low speed on a smooth road T urn car to develop le ft and right m otions, tra ffic perm itting Noise should change due to cornering loads Jack-up wheels to verify roughness at wheels Drive car at low speed on a smooth road Constant low pitch bearing noise may be heard Noise should not change in reversing turns Noise pattern should vary w ith wheel speed Roughness or w hine noise should increase w ith speed Noise pitch should be higher than differentials Test on smooth road to m inim ize tire noises Test at various speeds in drive, flo a t, and coast Rear pinion bearing noise may be louder on acceleration F ro n t pinion bearing noise may be louder on deceleration Gear noises tend to peak in a narrow speed range Fig. 3-24--Bearing Diagnosis Chart A

2.
Road Test 3. 4. 5. 1.

2.
Tire Noises 3. 4. 5. 1.

Engine or Exhaust Noises

2.
3. 4. 1.

Test fo r Wheel Bearing Noise

2.
3. 4.

Test fo r D ifferential Bearing Noise

1. 2.
3. 4. 1.

2.
Test fo r Pinion Bearing Noise 3. 4. 5. 6. 7.

103407

3-28

DIAGNOSIS

FRONT WHEEL BEARING DIAGNOSIS


CONSIDER THE FOLLOW ING FAC TO R SW H E N DIAG NO SING BE AR IN G CO N D ITIO N : 1. G E N E R A L CO N D ITIO N OF A L L PARTS D URING DISASSEM BLY A N D INSPECTION. 2. CLASSIFY THE F A IL U R E W ITH THE A ID OF THE ILLU S T R A T IO N S . 3. D ETERM INE THE CAUSE. 4. M AKE A L L REPAIRS FOLLO W ING RECOM M ENDED PROCEDURES.

GOOD BEARING BENT CAGE


CAGE D AM AG E DUE TO H A N D LIN G OR TO O L USAGE. REPLACE B E AR IN G . IMPROPER

BENT CAGE
CAGE DAM AG E DUE TO H A N D LIN G OR TO O L USAGE. REPLACE B E AR IN G . IMPROPER

GALLING
M E T A L SMEARS ON R O LLER ENDS DUE TO O V E R H E A T , LU B R IC A N T F A IL U R E OR O V E R LO A D . REPLACE BE AR IN G - CHECK SEALS AND CHECK FOR PROPER LU B R IC A TIO N .

ABRASIVE STEP WEAR


PATTERN ON R O LLER ENDS CAUSED BY FIN E ABRAS IVES .

ETCHING

BEARING SURFACES APPEAR G R AY OR G R A Y IS H B LA C K IN COLOR W ITH R E LA TE D ETCHING A W AY OF M A T E R IA L CLEAN A L L PARTS A N D HOUSINGS, U S U A LLY A T R O LLER SPACING. CHECK SEALS A N D BEARING S AN D R EP LAC E IF L E A K IN G , ROUGH OR REPLACE BEARINGS CHECK SEALS NOISY. AN D CHECK FOR PROPER LU B R IC A TIO N .

MISALIGNMENT
OUTER RACE M IS A LIG N M E N T DUE TO FOR EIGN OBJECT. C LEAN R E L A T E D PARTS A N D REPLACE BE A R IN G . M AKE SURE RACES ARE PROPERLY SEATED.

INDENTATIONS

FATIGUE SPALLING
METAL

SURFACE DEPRESSIONS ON RACE AND F L A K I N G OF SURFACE RO LLERS CAUSED BY H AR D PARTICLES R ESULTING FROM F A TIG U E . OF FOREIGN M A T E R IA L . REPLACE BEARING CLEAN A L L PARTS A N D HOUSINGS, R E LA TE D PARTS. CHECK SEALS A N D REPLACE BEARING S IF ROUGH OR NOISY. -

CLEAN

ALL

Fig. 3-25--Bearing Diagnosis Chart B

DIAGNOSIS

3 -29

FRONT WHEEL BEARING DIAGNOSIS (CONTD)


2 l~

BRINELLING
SURFACE IN D E N TA T IO N S IN RACEW AY CAUSED BY ROLLERS EITHER U NDER IMPACT LO A D IN G OR V IB R A T IO N W H ILE THE BE AR IN G IS NOT R O T A TIN G . REPLACE BEARING IF ROUGH OR NOISY.

CAGE WEAR
WEAR AR O U N D OUTSIDE D IAM ETER OF CAGE A N D RO LLER POCKETS CAUSED BY ABRASIVE MATERIAL AND INEFFICIENT L U B R IC A T IO N . CHECK SEALS A N D REPLACE BEARINGS.

ABRASIVE ROLLER WEAR


PATTERN ON RACES AN D CAUSED BY FIN E ABRASIVES. R O LLERS

CLEAN A L L PARTS A N D HOUSINGS, CHECK SEALS A N D BEARING S AND R EP LAC E IF L E A K IN G , ROUGH OR NOISY.

CRACKED INNER RACE


RACE C RACKED DUE TO IMPROPER FIT, COCKING , OR POOR BEARING SEATS. SM EARING OF M E T A L DUE TO SLIPPAGE, C O R R O S I O N SET UP BY SMALL SLIPPAGE CAN BE CAUSED BY POOR R E L A T IV E M O VEM EN T OF PARTS WITH FITS, L U B R IC A T IO N , O V E R H E A TIN G , NO LU B R IC A T IO N . O VE R LO AD S OR H A N D LIN G DAM AG E. REPLACE BE A R IN G . CLEAN R E LA TE D REPLACE BEARING S, CLEAN R E LA TE D PARTS. CHECK SEALS A N D CHECK FOR PARTS AN D CHECK FOR PROPER F IT PROPER L U B R IC A T IO N . AND LU B R IC A T IO N . REPLACE SH A FT IF DAM AG E D .

HEAT DISCOLORATION
HEAT D ISC O LO RATIO N CAN RANGE FROM F A IN T YELLO W TO D A R K BLUE RESULTI NG FRO M O V E R LO A D OR INCORRECT LU B R IC A N T. EXCESSIVE HEAT CAN CAUSE SOFTENING OF RACES OR RO LLERS. TO CHECK FOR LOSS OF TEMPER ON RACES OR ROLLERS A SIMPLE F 'L E TEST M AY BE M AD E. A F ILE DRAWN OVER A TEMPERED PART W IL L GRAB A N D CUT M ETA, WHEREAS, A F IL E DRAW N OVER A H AR D PART W IL L G LID E R E A D IL Y WITH NO M E T A L C UTTING . REPLACE BEARINGS IF OVER H E A TIN G DAM AG E IS IN D IC A T E D . CHECK SEALS A N D OTHER PARTS.

STAIN DISCOLORATION
DISC O LO R A TIO N CAN RANGE FROM LIG H T BROWN TO BLA C K CAUSED BY INCORRECT L U B R IC A N T OR MOISTURE. RE-USE BEARING S IF STAINS CAN BE REM OVED BY L IG H T POLISHING OR IF NO EVIDENCE OF O V E R H E A TIN G IS OBSERVED. CHECK SEALS AN D R E LA TE D PARTS FOR DAM AG E.

Fig. 3-26--Bearing Diagnosis Chart C

- - H

LAS'

:! . V

FRONT ALIGNMENT

3A-1

SECTION 3A

FRONT ALIGNMENT
CONTENTS
G eneral D escrip tio n .................. M aintenance and A djustm ents S pecifications............................... 3A-1 3A-2 3A-5

GENERAL DESCRIPTION
FRONT ALIGNMENT
T he term "fro n t alig n m en t" refers to the ang ular relationships between the front wheels, the front suspension attaching parts and the ground. The pointing in or "toe-in" of the front wheels, the tilt of the front wheels from vertical (when viewed from the front of the vehicle) and the tilt of the suspension members from vertical (when viewed from the side of the vehicle), all these are involved in front alignm ent. The various factors that enter into front alignm ent are covered here each one under its own heading. viewed from a side elevation. C aster is designed into the front axle assembly on all K series vehicles (four-wheel drive), and is non-adjustable. See caster copy under A D JU S T M E N T S .

CAMBER
C am ber is the tilting of the front wheels from the vertical when viewed from the front of the vehicle. W hen the wheels tilt outw ard at the top, the cam ber is said to be positive ( + ). W hen the wheels tilt inward at the top, the cam ber is said to be negative (-). The am ount of tilt is m easured in degrees from the vertical and this m easurem ent is called the cam ber angle. C am ber is designed into the front axle assembly of all K series vehicles and is non-adjustable. See cam ber copy under A D JU S T M E N T S .

CASTER
C aster is the tilting of the front steering axis either forward or backward from the vertical (when viewed from the side of the vehicle). A backw ard tilt is said to be positive ( + ) and a forward tilt is said to be negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrum ent, but you can understand th at if you look straight down from the top of the upper control arm to the ground you would find th at the ball joints do not line up (fore and aft) when a caster angle other than 0 is present. If you had a positive caster angle the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. In short then, caster is the forward or backw ard tilt of the steering axis as

TOE-IN
Toe-in is the turning in of the front wheels. The actual am ount of toe-in is norm ally only a fraction of an inch. The purpose of a toe specification is to ensure parallel rolling of the front wheels. (Excessive toe-in or toe-out will cause tire wear). Toe-in also serves to offset the small deflections of the wheel support system which occurs when the vehicle is rolling forward. In other words, even when the wheels are set to toe-in slightly when the vehicle is standing still, they tend to roll parallel on the road when the vehicle is moving. See toe-in copy under A D JU S T M E N T S .

3A-2

FRONT ALIGNMENT

<L OF WHEEL

DIRECTION

CAMBER ANGLE
FRONT V IE W

CASTER ANGLE
SIDE V IE W

Fig. 3A-1--Caster - Camber - Toe-In

MAINTENANCE AND ADJUSTMENTS


PRELIMINARY CHECKS PRIOR TO ADJUSTING FRONT ALIGNMENT
Before m aking any adjustm ent affecting caster, cam ber or toe-in, the following checks and inspections should be m ade to insure correctness o f alignm ent readings and alignm ent adjustm ents. 1. C heck all tires for proper inflation pressures and approxim ately the same tread wear. 2. Check front wheel bearings for looseness (.001-.008 end play is correct) and adjust if necessary. 3. Check for looseness of ball joints, tie rod ends and steering relay rods; if excessive looseness is noted, it must be corrected before adjusting. 4. Check for run-out of wheels and tires. 5. Check dimension A in Fig. 3A-4; if out of specifications and a correction is to be m ade, the correction m ust be made before adjusting caster. 6. Check for steering gear looseness a t fram e. 7. Check for im properly operating shock absorbers. 8. Check for loose control arms. 9. Check for loose or missing stabilizer bar attachm ents. 10. Consideration m ust be given to excess loads, such as tool boxes. If this excess load is normally carried in the vehicle, it should rem ain in the vehicle during align ment checks. 11. Consider the condition of the equipm ent being used to check alignm ent and follow the m a n u fa c tu rers instructions. 12. Regardless of equipm ent used to check alignm ent, the vehicle m ust be on a level surface both fore and aft and transversely. 13. Steering and vibration com plaints are not always the result of im proper alignm ent. An additional item to be checked is the possibility of tire lead due to worn or im properly m anufactured tires. "L e a d " is the devia tion of the vehicle from a straight path on a level road w ithout hand pressure on the steering wheel. Section 3E of this m anual, "W heels and T ire s", contains a procedure for determ ining the presence of a tire lead problem.

FRONT ALIGNMENT REQUIREMENTS


Satisfactory vehicle operation m ay occur over a wide range of front end wheel alignm ent settings. N evertheless, should settings vary beyond certain tolerances, readjust ments of alignm ent is advisable. The specifications stated in column 1 of the chart in the specifications section of this m anual should be used by owners, dealers and repairm en as guidelines in vehicle diagnosis either for repairs under the new vehicle w arranty or for m aintenance service a t custom ers request. These specifications provide an acceptable allaround operating range in th at they prevent abnorm al tire wear caused by wheel alignm ent.

FRONT ALIGNMENT G overnm ental Periodic M otor V ehicle Inspection program s usually include wheel alignm ent among items that are inspected. To provide useful inform ation for such inspections, the specifications stated in column 2 of the wheel alignm ent ch art are given and these are well within the range of safe vehicle operation. In the event the actual settings are beyond the specifi cations set forth in column 1 or 2 (whichever is applicable), or whenever for other reasons the alignm ent is being reset, the specifications given in column 3 of the wheel alignm ent chart should be used. It is good p ractice to set front end alignm ent to specifications while the vehicle is in its normally loaded condition. T rucks which are consistently operated with heavy loads should have toe-in adjusted with the truck under heavy load. This procedure should result in longer tire life.

3A-3

Caster
All caster specifications are given assuming a fram e angle of zero. Therefore, it will be necessary to know the angle of the fram e (w hether "u p " in rear or "dow n" in rear) before a corrected caster reading can be determ ined. C am ber and toe can be read "as is" from the alignm ent equipment.
How to Determine Caster (Fig. 3A-4)

ALIGNMENT ADJUSTMENTS
A norm al shim pack will leave at least two (2) threads of the bolt exposed beyond the nut. If two (2) threads cannot be obtained, check for dam aged control arm s and related parts. T he difference between front and rear shim packs must not exceed 7.62mm (.30 inches). Front shim pack must be at least 2.54mm (.10 inches).

Access to Shim Packs


G10-20 Models, CIO Models with 3/4" Nut: W ith vehicle on front end rack, jack at fram e and raise the wheel off the ground. This will allow the upper control arm to pivot down far enough to use a socket on the nuts and perm it shim removal. G30 Models, C20 and 30 Models with 7 /8 " Nut: Remove the upper control arm bum per; then follow the sam e procedure as above. R einstall the upper control arm bum per when alignm ent is completed.

All caster specifications are given assuming vehicle fram e angle is zero. Therefore, it is necessary to adjust specifications when applying them to vehicles w ith any fram e angle other than zero. 1. W ith vehicle on a level surface, determ ine fram e angle (w hether up or down in rear) with the use of a bubble protractor or inclinometer. Record this m easurem ent (See Figure 4). 2. M easure dimension " A " (See Figure 4). 3. Check and record specifications for caster under that column related to dimension "A " as m easured in step 2. 4. Using one of the following rules, add or subtract fram e angle found in step 1 to or from specification found in step 3. a. A dow n-in-rear fram e angle m ust be added to a positive caster specification. b. An up-in-rear fram e angle must be subtracted from a positive caster specification. c. A dow n-in-rear fram e angle must be subtracted from a negative caster specification. d. An up-in -rear fram e angle m ust be added to a negative caster specification. V ehicle caster specification should be adjusted to answer arrived at in step 4.

Camber
1. D eterm ine the cam ber angle from the alignm ent equipm ent. 2. Add or subtract shims from both the front and rear bolts to affect a change.

PIVOT SHAFT OUTBOARD OF FRAME


CASTER CAMBER

FORWARD

Fig. 3A-2--Caster - Camber Adjustment

3A-4

FRONT ALIGNMENT

Toe-In
1. D eterm ine the wheel toe-in from the alignm ent equipment. 2. Change the length of both tie rod sleeves to affect a toe change. Toe-in can be increased or decreased by changing the length of the tie rods. A threaded sleeve is provided for this purpose. W hen the tie rods are mounted ahead of the steering knuckle they m ust be decreased in length in order to increase toe-in. W hen the tie rods are mounted behind the steering knuckle they m ust be lengthened in o rder to increase toe-in. See Section 3B for proper tie rod clam p orientation and positioning.

" B IS LESS TH AN A " W H EN WHEELS TOE-IN

Fig. 3A-3--Toe-ln Adjustment

Fig. 3A-4--Determining Caster

FRONT ALIGNMENT

3A-5

SPECIFICATIONS
W H E E L A L IG N M E N T S P E C IF IC A T IO N S C ASTER
D IM E N S IO N " A '

MODELS (mm) CIO C20, 30 K10,20,30

21 / 2" 63.5 3 .6 1.5

2% " 69.8 3 .4 1.2

3" 76.2 3 .1 0.9

3% " 82.5 2 .8 0.6

3 Vi" 89.0 2 .6 0.3

33 /a" 95.2 2.4 0.1

4"

4 % " 5 414" 4 /2" 102.0 107.9 114.3 121.6 127.0 2 .0 0 1.8 -0.1 1.5 -0.7 1 .2 -1.0 1.0 -1.2

(8)

(NO AD JU S TM E N T PR O V ISIO N )

V /"
(mm) G10, 20 G30 (mm) P10 38.0 3.5C 2.8C 2%" 63.5 2.3 2" (mm) *P20, 30 51.0 2.9

VA"
44.4 3.3C 2.5C 2%" 69.8 2.0

2" 51.0 3.1' 2.2' 3" 76.2 1.7 2%" 63.5 2.3

TA"
57.1 2.9 1.9' 3% " 82.5 1.5 2%" 69.8 2.0

T /"
63.5 2.7' 1.6' 3% " 89.6 1.2 3" 76.2 1.7

2%" 69.8

3" 76.2 2.4' 1.0'

31 /4" 82.5 2.2 .7

3 Vi" 89.0 2.1 .5

33 /a" 95.2 1.9 .2

4 / 4"

102.0 107.9 1.8 0 16 -0 .2

3 %"

5" 41 /4" 4%" 4% " 4" 95.2 102.0 107.9 114.3 120 6 127.0 0.6 3 %" 89.0 1.2 0.4 0.1 -0 .1 4%" -0 .3 " 41 //' 43 /4"

0.9 3% " 82.5 1.4

2'A"
57.1 2.6

3% " 4

95.2 102.0 107.9 114.3 120.6 0.9 0.6 0.4 0.2 o .r

* A D D .3 W ITH JB 8 OR JF9 SU B TR A C T .4 W ITH R05 MOTOR HOME (32) (mm)


2 %" 63.5 23 /4 ''

3" 76.2 5.0

69.8 5.3

3% " 82.5 4.7

3% " 89.0 4.4

3% " 95.2 4.1

/2" 4 3 /4 4 Vi" 4 1 5" 102.0 107.9 114.3 120.6 127.0 3.8 3.6 3.3 3.1 2.9

5.5

CAM BER M O D EL C10 C20.30 K10, 20 K30 G10, 20 G30 P10, 20, 30 M O TO R HOME (32) .7 .2 1.0 (NO ADJU STM EN T PR O V ISIO N ) .5 (NO AD JU STM EN T PR O V IS IO N ) 5 .2 .2 .2

A L IG N M E N T T O LE R AN C E S Periodic M oto r Vehicle Inspection CIO, C20, C30 K10, K20, K30 G10, G20, G30 P10, P20, P30 M OTOR HOME P30 (32)

TO E-IN 3 /1 6 " 3 /1 6 " 3 /1 6 " 3 /1 6 " 5 /1 6 " (4.7 mm) (4.7 mm) (4.7 mm) (4.7 mm) (7.9 mm)

W arranty Repair Checking Caster Camber Toe-In

Resetting Target

2 0.5 + 1 1.5 0.5 0.7 + . 1 /C "(3 .2 mm) 1 /1 6 "(1 .6 mm) 3 /8 "(9 .5 mm)

100823

Specifications

STEERING C O LU M N S

3B5-1

SECTION 3B5

STEERING COLUMNS
The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section". NOTICE: This fastener is an important attaching part in that it could affect the performance of vital components and systems, a nd/or could result in major repair expense. It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part.

CONTENTS
General Description........................................................................................ .3B5-1 Maintenance and A d ju stm e n ts.....................................................................3B5-3 On-Vehicle Service......................................................................................... .3B5-4 C-Series, K-Series....................................................................................... .3B5-4 G-Series, P-Series....................................................................................... .3B5-20 Specifications.....................................................................................................3B5-35 Special Tools..................................................................................................... .3B5-36

GENERAL DESCRIPTION
FUNCTION LOCKING COLUMNS
The function locking energy absorbing steering column includes three important features in addition to the steering function: 1. The column is energy absorbing, designed to compress in a front-end collision to minimize the possibility of injury to the driver of the vehicle. 2. The ignition switch and lock are mounted conveniently on the column. 3. With the column mounted lock, the ignition, steering and gearshifting operation can be locked to inhibit theft of the vehicle. The function locking energy abosrbing column may be easily disassembled and reassembled. It is important that only the specified screws, bolts and nuts be used as designated and that they are tightened to their specified torque. This precaution will insure the energy absorbing action of the assembly. Over-length bolts should not be used, as they may prevent a portion of the assembly from compressing under impact. Equally as important is correct torque of bolts and nuts. Care should be taken to assure that the bolts or nuts securing the column mounting bracket to the instrument panel are torqueti to the proper specification in order that the bracket will break away under impact. When the function locking energy absorbing column assembly is installed in a vehicle, it is no more susceptible to damage through usage than an ordinary column; however, when the column is removed, special care must be taken in handling this assembly. Only the specified wheel puller should be used. When the column is removed from the vehicle, such actions as a sharp blow on the end of the steering shaft or shift lever, leaning on the column assembly, or dropping of the assembly could shear or loosen the plastic fasteners that maintain column rigidity. It is, therefore, im portant th a t the removal and installation and the disassembly and reassembly procedures be carefully followed when servicing the assembly.

Fig. 3B5-1-Steering Column

3B5-2

STEERING CO LUM NS

GENERAL INFORMATION
This section contains diagnostic information to help locate the cause of the problem in the column. Reference should be made to the correct method of column disassembly, repair, adjustment and reassembly. Damaged, broken or deformed parts must be replaced with the correct replacement. To perform diagnostic procedures on the steering column upper end components, it is not necessary to remove the column from the vehicle. The steering wheel, horn components, directional signal switch, ignition switch and lock cylinder may be removed with the column remaining in the vehicle as described in the Service Manual under "Component Part Replacement".

To use the tool just unfasten the harmonica connector on the column and plug the harness from J-23980 into the vehicle chassis harness. The " A " , " B " , a n d " C " terminals on the tester will overhang the chassis connector. This does not affect the test results. These terminals are for vehicles with cornering lights. Connect the single black jum per to a good ground. The tester is now ready for use.

COLLISION DIAGNOSIS
To determine if the energy absorbing steering column components are functioning as designed, or if repairs are required, a close inspection should be made. An inspection is called for in all cases where dam age is evident or whenever the vehicle is being repaired due to a front end collision. Whenever a force has been exerted on the steering wheel or steering column, or its components, inspection should also be made. If damage is evident, the affected parts must be replaced. See Section 3 for Diagnosis. The inspection procedure for the various steering column components on C and K trucks is as follows:

CAUTION: The outer mast jacket shift tube, steering shaft and instrument panel mounting bracket are designed as energy absorbing units. Because of the design of these components, it is absolutely necessary to handle the column w ith care w h en perform ing any service operation. Avoid hammering, jarring, dropping or leaning on any portion of the column. When reassembling the column components, use only the specified screws, nuts and bolts and tighten to specified torque. Care should be exercised not to use over length screws or bolts as they may prevent a portion of the column from compressing under impact. Personal injury could result from lack of care w hen servicing the steering column.

Column Support Bracket


Damage in this area will be indicated by separation of the mounting capsules from the bracket. The bracket will have moved forward toward the engine compartment and will usually result in collapsing of the jacket section of the steering column.

COLUMN JACKET
Inspect jacket section of column for looseness, and/or bends.

SHIFTER SHAFT
Separation of the shifter shaft sections will be internal and cannot be visually identified. Hold lower end of the "shifter shaft" and move "shift lever" on column through its ranges and up and down. If there is little or no movement of the "shifter sh a ft", the plastic joints are sheared.

STEERING COLUMN ELECTRICAL ANALYZER J-23980 For C-Series and K-Series


Tool J-23980 will help the technician analyze the steering column wiring harness for electrical problems. The tool in actuality eliminates the steering column, related wiring and components; and replaces them with the tool itself. In this way disassembly of the column is not performed until the problem has been determined to be in the column. By moving the tester switch, (with the key in the "on" position), the various functions may be checked. The switch positions are " O F F " , " H O R N " , "L E F T T U R N " , " R I G H T T U R N " , "K E Y B U Z Z E R " , and " H A Z A R D " . (Trucks do not incorporate a Key Buzzer Switch) if the systems function properly while using the tester, then the malfunction has been narrowed to the column wiring or components. W hen this has been determined then the column may be serviced to correct the malfunction.

Steering Shaft
If the steering shaft plastic pins have been sheared, the shaft will rattle when struck lightly from the side and some lash may be felt when rotating the steering wheel while holding the rag joint. It should be noted that if the steering shaft pins are sheared due to minor collision with no appreciable damage to other components, that the vehicle can be safely steered; however, steering shaft replacement is recommended. Because of the differences in the steering column types, be sure to refer to the set of instructions below which apply to the column being serviced.

METHOD TO DETERMINE COLUMN COLLAPSE


Measure distance between top of neutral-start switch window opening and the bottom of the upper jacket. The correct value is shown below: a. C -T ru ck 5 11/16" t o 5 1/2". b. K-Truck 5 11/16" to 5 1 /2 ".

STEERING CO LU M N S

3B5-3

MAINTENANCE AND ADJUSTMENTS


STEERING WHEEL ALIGNMENT
On all series vehicles, check steering gear for high point centering as shown in Sections 3B8 and 3B7 before checking steering wheel alignment. 1. Set wheels in straight ahead position by driving vehicle a short distance. 2. Note steering wheel position. If off more than 1 inch from center (Fig. 3 B 5-2), remove steering wheel as outlined under "Steering Wheel - Removal", center high point on gear, reposition and reinstall the wheel.

1. Loosen clamp on steering shaft. 2. Applying 50 lb. force to the steering wheel end of the steering shaft, adjust clam p to obtain clearances indicated in Figure 3B 5-3. 3. Tighten clamp bolt to specified torque.

SHIFTER TUBE ADJUSTMENT G and P Series Only


3-Speed Transmission

1. Loosen adjusting ring attaching screws and clamp bolt. .2. Rotate adjusting ring to give .005" end play between adjusting ring and first and reverse shifter lever (Fig. 3B5-4). 3. Tighten attaching screws and clamp bolt.
Automatic Transmission

STEERING COLUMN LOWER BEARING ADJUSTMENT

1. Place the shift tube lever in " N e u t r a l " or " Drive". 2. Loosen adjusting ring clamp screws and rotate the shift tube adjusting ring to obtain .33" to .36" clearance between the shift tube lever and adjusting ring (Fig. 3B5-5). 3. Tighten the adjusting ring clamp screws to 70 in. lbs.

Fig. 3B5-3--Steering Column Lower Bearing Adjustment

Fig. 3B5-5 Shift Tube Adjustment-Automatic Transmission

3B5-4

STEERING CO LUM NS

ON-VEHICLE SERVICE
INDEX
C-Series and K -S eries.................................................... 3B5-4 Steering W h e e l............................................................... 3B5-4 Flexible Coupling........................................................... .. 3B5-4 Intermediate S h a ft......................................................... 3B5-5 Directional Signal Switch............................................ .. 3B5-6 Lock C y lin d e r................................................................. .. 3B5-7 Ignition Switch.................................................................. 3B5-7 Steering C o lu m n ............................................................ .. 3B5-8 R e m o v a l......................................................................... .. 3B5-9 Disassembly, Standard C o lu m n ................................. 3B5-10 Disassembly, Tilt C o lu m n ......................................... .. 3B5-10 Installation, Mandatory Sequ ence.......................... .. 3B5-20 G-Series and P-Series........................... Steering W h e e l .................................... Flexible Coupling................................. Intermediate S h a ft.............................. Column Upper B e a rin g ..................... Column Lower B e a rin g ..................... Tilt Column Bearing Housing......... Directional Signal Sw itch................. Steering C o lu m n ................................. R em o val.............................................. Disassembly, Standard C o lu m n .... Disassembly, Tilt C o lu m n .............. Installation, Mandatory Sequence 3B 5-20 3B 5-20 3B5-21 3B5-21 3B5-23 3B5-23 3B5-24 3B5-25 3B5-27 3B5-27 3B5-27 3B5-29 3B5-33

STEERING WHEEL
Removal

1. With turn signal in neutral position, align marks and set wheel onto steering shaft. Torque steering shaft nut to specifications and install snap ring.
NOTICE: Do not over torque shaft nut or steering wheel

1. Disconnect battery ground cable. 2. Remove horn button cap. 3. Remove snap ring and steering wheel nut. 4. Using tool J - 1859-03, thread puller anchor screws into holes provided on steering wheel. See Fig. 3B5-6. Turn center bolt of tool clockwise to remove wheel.
NOTICE: Do not hammer on puller, or damage could

rub may result. 2. Place steering wheel horn button on wheel and snap into proper position. 3. Connect battery ground cable.

STEERING COUPLING (FLEXIBLE TYPE)


Removal

occur to the components. The tool centering adapters need not be used.
Installation NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in step 1.

1. Remove the coupling to steering shaft flange bolt nuts. 2. Remove the coupling clamp bolt. This is a special bolt and will require a 12 pt. socket or box wrench. 3. Remove the steering gear to frame bolts and lower the steering gear far enough to remove the flexible coupling. It is not necessary to disconnect the pitman arm from the pitman shaft. 4. Tap lightly on the flexible coupling with a soft mallet to remove the coupling from the steering gear wormshaft.

Fig. 3B5-6--Steering Wheel Removal

Fig. 3B5-7--Flexible Type Steering Coupling

STEERING C O LU M N S

3B5-5

4. Supporting shaft assembly securely, with chamfer up, press pin out of shaft with arbor press.
NOTICE: Do not drive pin out with hammer. This could cause sticky or binding bearings when reassembled. 5. Remove seal clamp and slide seal off end of shaft. Assembly

1. Be sure all parts are free of dirt. Slide seal onto steering shaft. With lip of seal against step in shaft clamp seal. 2. Press pin back into shaft from chamfered side. Locate pin in shaft using scribe mark as reference.
NOTICE: Pin must be centered within .012 in. or binding in the coupling could result. C heck centering o f pin (Fig. 3B5-9). a. Place just enough 3/8 " flat washers on pin to prevent bearing block from bottoming when installed. b. Measure distance from end of pin to top of bearing with micrometer. c. Remove bearing and washers and place same bearing and washers on other end of pin. Measure distance from end of pin to top of bearing. If micrometer readings in Steps b and c differ more than .012, repeat last part of Step 2 and recheck. Apply a liberal amount of wheel bearing grease to inside and outside of bearing blocks and inside of cover. Position tension spring and bearing blocks on pin. Slide cover over bearing blocks aligning reference mark on cover with mark on shaft. Install seal into end of cover and secure with snap ring retainer.

3.

Installation NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in steps 2 ,4 and 5.

1. Install the flexible coupling onto the steering gear wormshaft, aligning the flat on the shaft with the flat in the coupling. Push the coupling onto the wormshaft until the coupling reinforcement bottoms against the end of the worm. 2. Install the special bolt into the split clamp and torque to specifications.
NOTICE: The bolt m ust pass through the shaft undercut, or damage could occur to the components.

4. 5. 6.

3. Place the steering gear into position, guiding the flexible coupling bolts into the proper holes in the steering shaft flange. 4. Install and tighten the steering gear to frame bolts. 5. Install the coupling to flange bolt nuts and washers and torque to specifications. Be sure to maintain a coupling to flange dimension of .250" to .375". The coupling alignment pins should be centered in the flange slots.

Installation NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in steps 1, 3 and 4. 1. Install the interm ediate shaft assembly onto the

INTERMEDIATE STEERING SHAFTS WITH POT JOINT COUPLINGS


Removal

1. Remove the lower shaft flange to flexible coupling bolts. 2. Remove upper shaft to intermediate coupling bolt. 3. If necessary, remove the steering gear to frame bolts and lower the steering gear far enough to remove the intermediate shaft assembly. It is not necessary to remove the pitman arm from the pitman shaft.
Disassembly

1. M ark cover to shaft relationship. Pry off snap ring and slide cover from shaft. 2. Remove bearing blocks and tension spring from pivot pin. 3. Clean grease off pin and end of shaft. Scribe location mark on pin on same side as chamfer in shaft.

3B5-6

STEERING CO LUM N S

Removal (Fig. 3B5-10)

steering shaft, aligning the flat on the shaft with the flat in the coupling. Install the pot joint clamp bolt and torque to specifications. 2. Lift the steering gear into position, guiding the flexible coupling bolts into the shaft flange holes. 3. Install the steering gear to frame bolts and torque to specifications. 4. Install the flexible coupling to steering shaft flange bolt lockwashers and nuts. Check th at the coupling alignment pins are centered in the flange slots and then torque the coupling bolts to specifications.

1. Remove the steering wheel as outlined under "Steering Wheel - Removal". 2. Remove the column to instrument panel trim cover. 3. Position screwdriver blade into cover slot. Pry up and out to free cover from lock plate. 4. Screw the center post of Lock Plate Compressing Tool J-23653 onto the steering shaft as far as it will go. Compress the lock plate by turning the center post nut clockwise (Fig. 3B5-11). Pry the round wire snap ring out of the shaft groove and discard the ring. Remove Tool J-23653 and lift the lock plate off the end of the shaft.
NOTICE: If the column is being disassembled on the

DIRECTIONAL SIGNAL SWITCH


The directional signal switch can be removed with the steering column in the vehicle and without disturbing any of the column mountings.

bench, with the snap ring removed the shaft could slide out of the lower end of the mast jacket, damaging the shaft assembly. 5. Slide the directional signal cancelling cam, upper bearing preload spring and thrust washer off the end of the shaft.

Fig. 3B5-11Removing Lock Plate Retaining Ring

Fig. 3B5-13-Removing Directional Signal Switch Assembly

STEERING C O LU M N S

3B5-7

5. Make certain that the switch is in " N e u tr a l" and the hazard warning knob is'out. Slide the thrust washer, upper bearing preload spring and cancelling cam onto the upper end of the shaft. 6. Place the lock plate onto the end of the shaft. Screw the center post of Lock Plate Compressing Tool J-23653 onto the steering shaft as far as it will go. Place a N E W snap ring over the center post. Place the " C " bar over the center post and then compress the lock plate by turning the nut clockwise. Slide the new snap ring down the tapered center post and into the shaft groove (Fig. 3B5-15). Rem ove Tool J-23653. Always use a new snap ring when reassembling. 7. Place cover on the lock plate and snap into position. 8. Install the steering wheel as outlined under "Steering Wheel-Installation".

LOCK CYLINDER
Fig. 3B5-14Installing Switch Connector Onto Jacket Clips

The lock cylinder is located on the upper right hand side of the column. The lock cylinder should be removed in the " R U N " position only.
Replacement

6. Remove the directional signal lever screw and remove the lever. 7. Push the hazard warning knob in and unscrew the knob. 8. Remove the three switch mounting screws. 9. All Columns - Pull the switch connector out of the bracket on the jacket and feed switch connector through column support bracket and pull switch straight up, guiding the wiring harness through the column housing and protector. 10. Remove wire protector by pulling downward out of colum n with pliers using tab provided (Fig. 3B5-12). Tilt Column - Position the direction signal and shifter housing in the "low" position. Remove the harness cover by pulling toward the lower end of the column, be careful not to damage the wires. 11. Remove the three switch mounting screws and pull the switch straight up, guiding the wiring harness and cover through the colu m n housing (Fig. 3B5-13).
Installation CAUTION: It is extremely im portant that only the specified screws, bolts and nuts be used at assembly, or personal injury could result. Use of overlength screws could prevent a portion of the assembly from compressing under impact.

1. Remove the steering wheel as outlined under "Steering Wheel - Removal". 2. Remove the directional signal switch as outlined under " Directional Signal Switch - Removal". It is not necessary to completely remove the directional signal switch from the column. Pull the switch rearward far enough to slip it over the end of the shaft do not pull the harness out of the column. 3. Refer to Fig. 3B5-16 for details on replacement of lock cylinder.

IGNITION SWITCH
The ignition switch is mounted on top of the column jacket near the front of the dash. For anti-theft reasons, the switch is located inside the channel section of the brake pedal support and is completely inaccessible without first lowering the steering column (see steering column removal). The switch is actuated by a rod and rack assembly. A portion of the rack is toothed and engages a gear on the end

1. All except Tilt - Be sure that the wiring harness is in the protector. Feed the connector and cover down through the housing and under the mounting bracket (column in vehicle). Tilt - Feed the connector down through the housing and under the mounting bracket. Then install the cover on the harness. 2. Install the three m ounting screws and clip the connector to the bracket on the jack et (Fig. 3B5-14). 3. Install the column to instrument panel trim plate. 4. Install the hazard warning knob and directional signal lever.

3B5-8

STEERING CO LUM N S

LOCK CYLINDER INSTALLATION


DISASSEMBLE 1. Place lock in "run" Remove lock plate, turn signal switch and buzzer switch (see service manual.) Remove screw & lock cylinder. CAUTION: If s c re w is d ro p p e d o n re m o v a l, it c o u ld fa ll in to th e c o lu m n , re q u irin g c o m p le te d is a s s e m b ly to re trie v e th e sc re w . LOCK CYLINDER SET 1 2. 3. ASSEMBLE Rotate as shown, align cylinder key with keyway in housing. Push lock all the way in. Install screw Tighten to 4.5 N-m for regular colum ns 2.5 N-m for adjustable columns.

To assemble Rotate to stop while holding cylinder

HOUSING

CYLINDER KEY

LOCK RETAINING SCREW

Fig. 3B5-16-Lock Cylinder Removal

of the lock cylinder, thus enabling the rod and rack to be moved axially (with respect to the column) to actuate the switch when the lock cylinder is rotated.
Removal

2. The switch should be positioned in "Lock" position before removing. If the lock cylinder has already been removed, the actuating rod to the switch should be pulled up until there is a definite stop, then moved down one detent, which is the " Lock" position. 3. Remove the two switch screws and remove the switch assembly.
Installation

1. Lower the steering column as outlined under "Steering Column Removal" later in this section. It is not necessary to remove the steering wheel. If the steering column is not removed from the vehicle, be sure that it is properly supported, before proceeding.

1. Before replacing the switch, be sure that the lock is in the L o c k position (Fig. 3B5-17); if it is not, a screwdriver (placed in the locking rod slot) can be used to move the switch to " L o c k " . 2. Install the activating rod into the switch and assemble the switch on the column; tighten the mounting screws.
CAUTION: Use only the specified screws since over-length screws could prevent a portion of the assembly from compressing under impact, which could result in personal injury.

3. Reinstall the steering column assembly following the "M an datory Installation Sequence" outlined later in this section.

STEERING COLUMN
To perform service procedures on the steering column upper end components, it is not necessary to remove the column from the vehicle. The steering wheel, horn components, directional signal switch, and ignition lock cylinder may be removed with the column remaining in the vehicle as described earlier in this section.

STEERING C O LU M N S
Shifter Shaft

3B5-9

Separation of the shifter shaft sections will be internal and cannot be visually identified. Hold lower end of the "shifter shaft" and move "shift lever" on column through its ranges and up and down. If there is little or no movement of the "shifter sh a ft", the plastic joints are sheared.
Steering Shaft

If the steering shaft plastic pins have been sheared, the shaft will rattle when struck lightly from the side and some lash may be felt when rotating the steering wheel while holding the rag joint. It should be noted that if the steering shaft pins are sheared due to minor collision the vehicle can be safely steered; however, steering shaft replacement is recommended. Because of the differences in the steering column types, be sure to refer to the set of instructions below which apply to the column being serviced.
Removal

Typical

CAUTION: The outer mast jacket shift tube, steering shaft and instrument panel mounting bracket are designed as energy absorbing units. Because of the design of these components, it is absolutely necessary to handle the column w ith care w h en perform ing an y service operation. Avoid hammering, jarring, dropping or leaning on any portion of the column. When reassembling the column components, use only the specified screws, nuts and bolts and tighten to specified torque. Care should be exercised in using over length screws or bolts as they may prevent a portion of the column from compressing under impact. Inspection

To determine if the energy absorbing steering column components are functioning as designed, or if repairs are required, a close inspection should be made. Inspection is called for in all cases where damage is evident or whenever the vehicle is being repaired due to a front end collision. Whenever a force has been exerted on the steering wheel or steering column, or its components, inspection should also be made. If damage is evident, the affected parts must be replaced. The inspection procedure for the various steering column components on all C and K Series Trucks is as follows:
Column Support Bracket

Front of dash mounting plates must be loosened whenever the steering column is to be lowered from the instrument panel. 1. Disconnect the battery ground cable. 2. Remove the steering wheel as outlined under "Steering Wheel Removal". 3. Remove the nuts and washers securing the flanged end of the steering shaft to the flexible coupling. 4. Disconnect the transmission control linkage from the column shift tube levers. 5. Disconnect the steering column harness at the connector. Disconnect the n eu tral-start switch and back-up lamp switch connectors if so equipped. 6. Remove the floor pan trim cover screws and remove the cover. 7. Remove the transmission indicator cable, if so equipped (Fig. 3B5-18). 8. Remove the screws securing the two halves of the floor pan cover; then remove the screws securing the halves and seal to the floor pan and remove the covers (Fig. 3B5-19). 9. Move the front seat as far back as possible to provide maximum clearance. 10. Remove the two column bracket-to-instrument panel

Damage in this area will be indicated by separation of the mounting capsules from the bracket. The bracket will have moved forward toward the engine compartment and will usually result in collapsing of the jacket section of the steering column.
Column Jacket

Inspect jacket section of column for looseness, and/or bends.

3B5-10

STEERING CO LUM NS
adapter by light pressure on the bearing outer race. Remove the three screws from bearing at the lower end and slide out the shift tube assembly. Remove the gearshift housing lower bearing from the upper end of the mast jacket.
Assembly of Standard Columns

nuts and carefull remove from vehicle. Additional help should be obtained to guide the lower shift levers through the firewall opening.

C and K Series, Standard Column - (Fig. 3B5-21)


Disassembly

1. Remove the four dash panel bracket-to-column screws and lay the bracket in a safe place to prevent damage to the mounting capsules. 2. Place the column in a vise using both weld nuts of either Set A or B as shown in Figure 3B5-22. The vise jaws must clamp onto the sides of the weld nuts indicated by arrows shown on Set B.
NOTICE: Do not place the column in a vise by clamping onto one weld nut of both sets A and B or by clamping onto the sides not indicated by arrows, since damage to the column could result. Remove the Directional Signal Switch, Lock Cylinder, and Ignition Switch as outlined previously in this section. Column Shift Models - Drive out the upper shift lever pivot pin and remove the shift lever. Remove the upper bearing thrust washer. Remove the four screws attaching the turn signal and ignition lock housing to the jacket and remove the housing assembly (Fig. 3B5-23). Remove the thrust cap from the lower side of the housing. Lift the ignition switch a c tuating rod and rack assembly, the rack preload spring and the shaft lock bolt and spring assembly out o f the housing (Fig. 3B524). Remove the shift lever detent plate (shift gate). Remove the ignition switch actuator sector through the lock cylinder hole by pushing firmly on the block tooth of the sector with a blunt punch or screwdriver (Fig. 3B5-25). Remove the gearshift lever housing and shroud from the jacket assembly (transmission control lock tube housing and shroud on floor shift models). Remove the shift lever spring from the gearshift lever housing (lock tube spring on floor shift models). Pull the steering shaft from lower end of the jacket assembly. Remove the two screws holding the back-up switch or neutral-safety switch to the column and remove the switch. Remove the lower bearing retainer clip (Fig. 3B5-26).

3.

4. 5.

6.
7.

8. 9.

10.

11. 12. 13.

14.

15. Automatic and Floorshift Columns - Remove the lower bearing retainer, bearing adapter assembly, shift tube thrust spring and washer. The lower bearing may be removed from the adapter by light pressure on the bearing outer race. Slide out the shift tube assembly. Manual Transmission - Column Shift - Remove the lower bearing adapter, bearing and the first reverse shift lever. The lower bearing may be removed from the

Apply a thin coat of lithium soap grease to all friction surfaces. 1. Install the sector into the turn signal and lock cylinder housing. Install the sector in the lock cylinder hole over the sector shaft with the tang end to the outside of the hole. Press the sector over the shaft with a blunt tool. 2. Install the shift lever detent plate onto the housing. 3. Insert the rack preload spring into the housing from the bottom side. The long section should be toward the handwheel and hook onto the edge of the housing (Fig. 3B5-27). 4. Assemble the locking bolt onto the crossover arm on the rack and insert the rack and lock bolt assembly into the housing from the bottom with the teeth up (toward hand-wheel) and toward the ccnterline of the column (Fig. 3B5-24). Align the 1st tooth on the sector with the 1st tooth on the rack; if aligned properly, the block teeth will line up when the rack assembly is pushed all the way in. 5. Install the thrust cup on the bottom hub of the housing. 6. Install the gearshift housing lower bearing. Insert the bearing from the very end of the jacket. Aligning the indentations in the bearing with the projections on the jacket (Fig. 3B 5-28). If the bearing is not installed correctly, it will not rest on all of the stops provided. 7. Install the shift lever spring into the gearshift lever (or lock tube) housing. Install the housing and shroud assemblies onto the upper end of the mast jacket. Rotate the housing to be sure it is seated in the bearing. 8. With the shift lever housing in place, install the turn signal and lock cylinder housing onto the jacket. The gearshift housing should be in " P a r k " position and the rack pulled downward. Be sure the turn signal housing is seated on the jacket and drive the four screws. 9. Press the lower bearing into the adapter assembly. 10. Insert the shift tube assembly into the lower end of the jacket and rotate until the upper shift tube key slides into the housing keyway. 1 1. Automatic and Floor shift Columns - Assemble the spring and lower bearing and adapter assembly into the bottom of the jacket. Holding the adapter in place, install the lower bearing reinforcement and retainer clip. Be sure the clip snaps into the jacket and reinforcement slots. 12. Manual Transmission - Column Shift - Loosely attach the three screws in the jacket and shift tube bearing. Assemble the 1st-Reverse lever and lower bearing and ad a p te r assembly into the bottom of the jacket. Holding the ad a p te r in place, install the bearing reinforcement and retaining clip. Be sure the retaining clip snaps into the jacket and reinforcement slots. Refer to Fig. 3B 5-29 for adju stm ent procedure.

STEERING C O LU M N S

3B5-11

GROOVE IN STEERINC---SHAFT SPLINES INDICATES METRIC THREADS ---------

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

STEERING COLUMN R E T A IN E R NUT, Hexagon Jam COVER, Shaft Lock RIN G , Retaining LOCK, Steering Shaft CAM ASM, Turn Signal Cancelling SPRING, Upper Bearing SCREW, Pan Head Cross Recess SWITCH ASM, Turn Signal PROTECTOR, W iring SCREW, Hex Washer Head Tapping W ASHER, Thrust B E A R IN G ASM HOUSING, Steering Column S H A FT, Sector SECTOR, Switch A ctu a to r SPRING, Rack Preload CUP, Thrust RACK ASM, Rod & SCREW, Dim m er Switch M ounting SWITCH ASM, Dim m er SCREW, Flat Head Cross Recess GATE, S h ift Lever W ASHER, Spring Thrust BO LT ASM, Spring & SPRING, Upper S h ift Lever

30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 61. 62. 67.

BOWL, Gearshift Lever SHROUD, S h ift Bowl B EA R IN G , Bowl Lower JA C K E T ASM, Steering Column SCREW, Washer Head SWITCH ASM, Ignition SEAL, Dash TUBE ASM, S h ift W ASHER, Spring Thrust SPRING, S h ift Tube Return A D A P TE R , Lower Bearing R E T A IN E R , Bearing Adapter CLIP, Lower Bearing Adapter B EA R IN G ASM SCREW ASM, Lockwasher & SPACER, Lower S h ift Lever LE VE R , Lower S h ift BUSHING ASM, Steering Shaft RING, Retaining S H A FT ASM, Steering SCREW, Flat Head ROD, Dimmer Switch A ctu a to r WASHER, Wave PLATE, Support & A lignm ent LOCK C Y LIN D E R SET, Strg Column 68. SCREW, Lock Retaining

Fig. 3B5-20--Std. Column; Auto. Trans, o r 3-Speed

3B5-12

STEERING CO LUM N S

1. 2. 3. 4. 5. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

ROD, Switch A ctuator RACK, Switch A ctuator SPRING, Rack Preload SECTOR, Switch A ctuator HOUSING, Steering Column WASHER, Thrust SCREW, Hex Washer Head Tapping SWITCH ASSEMBLY, Turn Signal SCREW, Pan Head Cross Recess SPRING, Upper Bearing CAM ASM, Turn Signal Cancelling LOCK, STEERING SHAFT RING, Retaining COVER, Shaft Lock NUT, Hexagon Jam R ETAIN ER SCREW, Pan Head Cross Recess SHROUD, Steering Column WASHER, Spring Thrust BOLT ASSEMBLY, Spring

23. 24. 25. 26. 27. 30. 32. 33. 34. 49. 50. 51. 58. 59. 62. 63. 64. 65.

SPRING, Key Release LE VE R , Key Release W ASHER, Wave S H A FT ASSEMBLY, Steering RING, Retaining SEAL, Jacket & Dash Bracket JA C K E T ASSEMBLY, Sleeve SWITCH ASSEMBLY, Ignition SCREW, Washer Head B EA R IN G ASM R E T A IN E R , Upper Bearing SCREW, Flat Head BOWL. Floor S hift PROTECTOR, W iring A D A P TE R , Lower Bearing B EA R IN G ASM CLIP, Lower Bearing Adapter R E T A IN E R , Bearing Adapter 66. LOCK C Y LIN D E R SET, Strg Column 67. SCREW, Lock Retaining

Fig. 3B5-21 Std. Column, 4-Speed Trans.

STEERING C O LU M N S

3B5-13

Fig. 3B5-26--Removing Lower Bearing Retainer

Fig. 3B5-24~Tum Signal Housing Assembly

Fig. 3B 5-27Installing Rack Preload Spring

3B5-14

STEERING CO LUM N S

.M A S T JACKET
A. TO REDUCE CLEARANCE SLIDE THE CLAMPING SCREWS AROUND THE MAST JACKET IN THE DIRECTION OF ARROW A B. TO INCREASE CLEARANCE SLIDE THE CLAMPING SCREWS AROUND THE M AST JACKET IN THE DIRECTION OF ARROW B . M A S T JA C K E T . 2 - 3 SHIFT LEVER .P IC K UP LEVER 1ST REV. S HIFT LEVER A. TO REDUCE CLEARANCE SLIDE THE CLAMPING SCREWS AROUND THE M AST JACKET IN THE DIRECTION OF ARROW A

.2 -3 SHIFT LEVER .PICK UP LEVER

B TO INCREASE CLEARANCE SLIDE^THE CLAMPING SCREWS AROUND THE M AST JACKET IN THE DIRECTION OF ARROW B

ALIGNMENT LEVER

UPPER STRG. S H A FT SPACER LOW ER BEARING RETAINER LOW ER M A S T JA C K E T BEARING

.0 0 5 IN. SHIM SPACER \ U LO W ERM AST LOWER BEARING JACKET BEARING RETAINER

ADJUSTMENT PROCEDURE
1. W IT H T H E T R A N S M IS S IO N IN N E U T R A L D ISC O N N E C T T H E T R A N S M IS S IO N R O DS. 2. T E S T FO R R O T A T IO N A L D R A G B Y T U R N IN G T H E S H IF T L E V E R (IN S ID E T R U C K ) T H R O U G H T H E 2 3 S H IF T A R C . D R A G M E A S U R E D A T TH E S H IF T K N O B M U S T BE N O M O R E T H A N 2 .0 LBS. IF D R A G IS M O R E T H A N 2.0 LBS. C O R R E C T IO N S M U S T BE M A D E B E F O R E P R O C E E D IN G W IT H T H IS ADM USTM ENT. 3. LO O S E N TH E T H R E E C L A M P IN G SCREW S. 4 . IN S T A L L A .005 IN . T H IC K S H IM B E T W E E N TH E SPACE A N D E IT H E R O F T H E S H IF T L E V E R S . TH E A B O V E IL L U S T R A T IO N SHOW S T H E S H IM B E T W E E N T H E SPAC ER A N D T H E 2-3 S H IF T L E V E R . 5. S L ID E T H E C L A M P IN G SCREW S IN D IR E C T IO N O F A R R O W B U N T IL T H E S Y S T E M IS LO O S E . T H E N S L ID E T H E SCREW S IN O PP O S ITE D IR E C T IO N U N T IL A D E F IN IT E D R A G -IS F E L T A T T H E 1ST R E V . S H IF T L E V E R . 6. T IG H T E N T H E C L A M P IN G SCREW S. 7. R E M O V E T H E S H IM . 8. R E IN S T A L L T H E T R A N S M IS S IO N R O D S . N O T E : IF T H E R E IS N O P R O B L E M W IT H S T E E R IN G C O L U M N D R A G . T H IS A D J U S T M E N T C A N BE M A D E B Y D IS C O N N E C T IN G O N L Y T H E 1ST. REV. T R A N S M IS S IO N RO D AND O M IT T IN G STEP. 2.

ADJUSTMENT PROCEDURE
1. W IT H T H E T R A N S M IS S IO N IN N E U T R A L D IS C O N N E C T T H E T R A N S M IS S IO N RO D S. 2. T E S T FO R R O T A T IO N A L D R A G B Y T U R N IN G T H E S H IF T L E V E R (IN S ID E T R U C K ) T H R O U G H T H E 2 -3 S H IF T A R C . D R A G , M E A S U R E D A T T H E S H IF T K N O B . M U S T BE N O M O R E T H A N 2 .0 LBS. IF D R A G IS M O R E T H A N 2 .0 LBS. C O R R E C T IO N S M U S T BE M A D E B E F O R E P R O C E E D IN G W IT H T H E A D JU S TM E N T. LO O S E N T H E T H R E E C L A M P IN G SCREW S. IN C R E A S E C L E A R A N C E B Y S L ID IN G T H E C L A M P IN G SC R EW S IN D IR E C T IO N O F A R R O W " B " A B O V E U N T IL T H E 1 S T -R E V . S H IF T L E V E R C O M P L E T E L Y FREE OF D R AG . 5. D E C R E A S E C L E A R A N C E B Y S L ID IN G T H E C L A M P IN G SCREW S IN D IR E C T IO N O F A R R O W " A " A B O V E U N T IL A S L IG H T D R A G IS F E L T A T T H E 1ST R E V . S H IF T L E V E R . 6 . T IG H T E N T H E T H R E E C L A M P IN G SCREW S. 7. R E C O N N E C T T H E T R A N S M IS S IO N RODS N O T E : IF N O P R O B L E M W IT H S T E E R IN G C O L U M N D R A G IS I N V O L V E D , T H IS A D J U S T M E N T C A N BE M A D E B Y D IS C O N N E C T IN G O N L Y TH E 1ST. R E V . T R A N S M IS S IO N R O D A N D O M IT T IN G S TEP 2. 3. 4.

Fig. 3B5-29 Adjusting Lower Bearing-Typical

13. Install the neutral-safety or back-up switch as outlined in Section 8 of this manual. 14. Slide the steering shaft into the column and install the upper bearing thrust washer. 15. Install the turn signal switch, lock cylinder assembly and ignition switch as previously outlined in this section. 16. Install the shift lever and shift lever pivot pin. 17. Remove the column from the vise. 18. Install the dash bracket to the column; torque the screws to specifications.

Disassembly-Tiit Columns

Steps 3-14 may be performed with the steering column in the vehicle. 1. Remove the four screws retaining the dash mounting bracket to the column and set the bracket aside to protect the breakaway capsules.

Fig. 3B5-28Installing Gearshift Housing Lower Bearing

STEERING C O LU M N S

3B5-15

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

STEERING COLUMN B EA R IN G ASM PIN, Release Lever SPRING, Release Lever SPRING, Shoe PIN, Pivot PIN, Dowel S H A FT, Drive SHOE, Steering Wheel Lock SHOE, Steering Wheel Lock SPRING, Lock B o lt BO LT, Lock B EA R IN G ASM SCREW, Oval Head Cross Recess RACE, Inner SEAT, Upper Bearing Inner Race SWITCH ASM, Turn Signal SCREW, Binding HD. Cross Recess CAM ASM, Turn Sig. Cancelling LOCK, Shaft COVER, Shaft Lock NUT, Hexagon Jam RIN G , Retaining

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 38. 39. 40. 41. 43. 44. 45. 46. 47. 48. 49. 50.

SPRING, Upper Bearing PROTECTOR, W iring COVER, Lock Housing (Painted) SH IELD , T ilt Lever Opening R E T A IN E R , Spring SPRING, Wheel T ilt G U ID E, Spring SCREW, Hex. Washer Head RING, Retaining SECTOR, Switch A ctu a to r HOUSING, Steering Column SPRING, Rack Preload RACK, Switch A ctuator LEVER , Shoe Release A C TU A TO R ASM, Ignition Switch SPRING, S h ift Lever W ASHER, Wave PLATE, Lock W ASHER, Thrust RING, S h ift Tube Retaining SCREW, Oval Head Cross Recess GATE, S h ift Lever SUPPORT, Strg. Column Housing

51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65.
66.

77. 84. 85.


86.

87.

SCREW, Support PIN, Dowel S H AFT ASM, Lower Steering SPHERE, Centering SPRING, J o in t Preload S H A FT ASM, Race & Upper SCREW, Wash. Hd. SWITCH ASM, Ignition JA C K E T ASM, Steering Column CLIP, Lower Bearing Adapter SEAL, Dash TUBE ASM, S h ift R E T A IN E R , Bearing Adapter B EA R IN G ASM A D A P TE R , Lower Bearing R ETA IN ER SCREW, Flat Head SHROUD, Gearshift Bowl BOWL, Gearshift Lever LOCK C Y LIN D E R SET, Strg C olum r SCREW, Lock Retaining

Fig. 3B 5-30 Tilt Column W ith Auto. Trans.

3B5-16

STEERING CO LUM NS

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 17. 18. 19. 20. 21. 22. 23. 24. 25.

BEAR IN G ASM PIN, Release Lever SPRING, Release Lever SPRING, Shoe PIN, Pivot PIN, Dowel SHAFT, Drive SHOE, Steering Wheel Lock SHOE, Steering Wheel Lock SPRING, Lock B olt BOLT, Lock BEAR IN G ASM SH IELD , T ilt Lever Opening COVER, Lock Housing SCREW, Oval Head Cross Recess RACE, Inner SEAT, Upper Bearing Inner Race SWITCH ASM, Turn Signal SCREW, Binding HD Cross Recess CAM ASM, Turn Signal Cancelling LOCK, Shaft COVER, Shaft Lock NUT, Hexagon Jam (9/16-18)

26. 27. 28. 29. 30. 31. 32. 33. 35. 36. 37. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.

R ETA IN ER RING, Retainer SPRING, Upper Bearing PROTECTOR, W iring R E T A IN E R , Spring SPRING, Wheel T ilt GUIDE, Spring SCREW, Hex. Washer Head SECTOR, Switch A ctu a to r PIN, Pivot HOUSING, Steering Column SPRING, Rack Preload RACK, Switch A ctuator LEVER, Shoe Release A C TU ATO R ASM, Switch SHROUD, Column Housing SPRING, Key Release LEVER, Key Release PLATE, Lock SUPPORT, Steering Column Housing SCREW, Support SCREW, Oval Head Cross Recess PLATE, Shroud Retaining

51. 52. 53. 54. 55. 56. 57. 61. 62. 63. 64. 65.
66.

76. 77. 81. 82. 83. 84. 85.


86.

PIN, Dowel S H AFT ASM, Lower Steering SPHERE, Centering SPRING, J o in t Preload SPHERE, Centering S H A FT ASM, Race 8i Upper SWITCH ASM, Ig n itio n JA C K E T ASM, Sleeve & BE a XRING ASM, A dapter & B EA R IN G ASM SPACER, Steering Shaft SEAL, Jacket & Dash Bracket BR A C KE T ASM, Column Dash SCREW, Washer Head (#10-24 x .25) SCREW, Flat Head (#10-24 x .31) CLIP, Lower Bearing Adapter A D A P TE R , Lower Bearing B EA R IN G ASM R E T A IN E R , Bearing Adapter LOCK C Y L IN D E R SET, Strg Column SCREW, Lock Retaining

Fig. 3B5-31 Tilt Column With 4-Speed

STEERING C O LU M N S

3B5-17

2. Mount the column in a vise using both weld nuts of either Set A or B as shown in Figure 3B5-22. The vise jaws must clam p onto the sides of the weld nuts indicated by arrows shown on Set B.
NOTICE: Do not place the column in a vise by clamping onto only one weld nut, by clamping onto one weld nut of both Sets A and B or by clamping onto the sides not indicated by arrows, since damage to the column could result.

3. Remove the directional signal switch, lock cylinder and ignition switch as outlined previously in this section. 4. Remove the tilt release lever. Drive out the shift lever pivot pin and remove the shift lever from the housing. 5. Remove the three turn signal housing screws and remove the housing.

6. Install the tilt release lever and place the column in the
full up position. Remove the tilt lever spring retainer using a # 3 phillips screwdriver that just fits into the slot opening. Insert the phillips screwdriver in the slot,

Fig. 3B5-33--Removing Bearing Housing Pivots Pins

Fig. 3B5-34~Removing Shift Tube

Fig. 3B 5-36-R em oving Sector Drive Shaft

3B5-18

STEERING CO LUM N S
mast jacket. If the tube is allowed to interfere with the jacket in any way, damage to the tube and jacket could result. 16. Remove the bearing housing support lock plate by sliding it out of the jacket notches, tipping it down toward the housing hub at the 12 oclock position and sliding it under the jacket opening. Remove the wave washer. 17. All Columns - Remove the shift lever housing from the mast jacket (transmission control lock tube housing on floor shift models). Remove the shift lever spring by winding the spring up with pliers and pulling it out. On floor shift models, remove the spring plunger. 18. Disassemble the bearing housing as follows: a. Remove the tilt lever opening shield. b. Remove the lock bolt spring by removing the retaining screw and moving the spring clockwise to remove it from the bolt (Fig. 3B 5-35). c. Remove the snap ring from the sector drive shaft. With a small punch, lightly tap the drive shaft from the sector (Fig. 3B 5-36). Rem ove the drive shaft, sector and lock bolt. Remove the rack and rack spring. d. Remove the tilt release lever pin with a punch and hammer. Remove the lever and release lever spring. To relieve the load on the release lever, hold the shoes inward and wedge a block between the top of the shoes (over slots) and bearing housing. e. Remove the lock shoe retaining pin with a punch and ham m er. Remove the lock shoes and lock shoe springs. With the tilt lever opening on the left side and shoes facing up, the four slot shoe is on the left. f. Remove the bearings from the bearing housing only if they are to be replaced. Remove the separator and balls from the bearings. Place the housing on work bench and with a pointed punch against the back surface of the race, carefully ham m er the race out of the housing until a bearing puller can be used. Repeat for the other race.

7.

8.
9.

10. 11. 12. 13.

14. 15.

press in approximately 3/16", turn approximately 1/8 turn counterclockwise until the ears align with the grooves in the housing and remove the retainer, spring and guide (Fig. 3B5-32). Remove the pot joint to steering shaft clamp bolt and remove the intermediate shaft and pot joint assembly. Push the upper steering shaft in sufficiently to remove the steering shaft upper bearing inner race and seat. Pry off the lower bearing retainer clip and remove the bearing reinforcement, bearing and bearing adapter assembly from the lower end of the mast jacket. Remove the upper bearing housing pivot pins using Tool J-21854-1 (Fig. 3B5-33). Install the tilt release lever and disengage the lock shoes. Remove the bearing housing by pulling upward to extend the rack full down, and then moving the housing to the left to disengage the ignition switch rack from the actuator rod. Remove the steering shaft assembly from the upper end of the column. Disassemble the steering shaft by removing the centering spheres and the anti-lash spring. Remove the transmission indicator wire, if so equipped. Remove the four steering shaft bearing housing support to gearshift housing screws and remove the bearing housing support. Remove the ignition switch actuator rod. Remove the shift tube retaining ring with a screwdriver and then remove the thrust washer. Install Tool J-23072 into the lock plate, making sure that the tool screws have good thread engagement in the lock plate. Then, turning the center screw clockwise, force the shift tube from the housing (Fig. 3B5-34). Remove the shift tube (transmission control lock tube on floor shift models) from the lower end of the mast jacket. Remove Tool J-23072.
NOTICE: W hen removing the shift tube, be sure to guide the lower end through the slotted opening in the

STEERING C O LU M N S

3B5-19

jacket opening. Slide the lock plate into the notches in the jacket. Carefully install the shift tube into the lower end of the mast jacket. Align keyway in the tube with the key in the shift lever housing. Install the wobble plate end of Tool J-23073 into the upper end of the shift tube far enough to reach the enlarged portion of the tube. Then install the adapter over the end of the tool, seating it against the lock plate. Place the nut on the threaded end of the tool and pull the shift tube into the housing (Fig. 3B 5-39). Remove Tool J-23073.
NOTICE: Do not push or tap on the end of the shift tube.

Assem bly-Tilt Columns

Apply a thin coat of lithium grease to all friction surfaces. 1. If the bearing housing was disassembled, repeat the following steps: a. Press the bearings into the housing, if removed, using a suitable size socket. Be careful not to damage the housing or bearing during installation. b. Install the lock shoe springs, lock shoes and shoe pin in the housing. Use an approximate .180" rod to line up the shoes for pin installation. c. Install the shoe release lever, spring and pin. To relieve the load on the release lever, hold the shoes inward and wedge a block between the top of the shoes (over slots) and bearing housing. d. Install the sector drive shaft into the housing. Lightly tap the sector onto the shaft far enough to install the snap ring. Install the snap ring. e. Install the lock bolt and engage it with the sector cam surface. Then install the rack and spring. The block tooth on the rack should engage the block tooth on the sector (Fig. 3B5-37). Install the external tilt release lever. f. Install the lock bolt spring and retaining screw (Fig. 3B5-32). Tighten the screw to 35 in. lbs. 2. Install the shift lever spring into the housing by windng it up with pliers and pushing it into the housing. On floor shift models, install the plunger, slide the gearshift lever housing onto the mast jacket. 3. Install the bearing support lock plate wave washer. 4. Install the bearing support lock plate. Work it into the notches in the jacket by tipping it toward the housing hub at the 12 oclock position and sliding it under the

13

14.
j5

1 6.
17. j

19. 20.

Be sure that the shift tube lever is aligned with the slotted opening at the lower end of the mast jacket or damage to the shift tube and mast jacket could result. Install the bearing support thrust washer and retaining ring by pulling the shift lever housing up far enough to compress the wave washer. Install the bearing support by aligning the " V " in the support with the " V " in the jacket. Insert the screws through the support and into the lock plate and torque to 60 lbs. in. Align the lower bearing adapter with the notches in the jacket and push the adapter into the lower end of the mast jacket. Install lower bearing, bearing reinforcement and retaining clip, being sure that the clip is aligned with the slots in the reinforcement, jacket and adapter. Install the centering spheres and anti-lash spring in the upper shaft. Install the lower shaft from the same side of the spheres that the spring ends protrude. Install the steering shaft assembly into the shift tube from the upper end. Carefully guide the shaft through the shift tube and bearing. Install the ignition switch actuator rod through the shift lever housing and insert in the slot in the bearing support. Extend the rack downward from the bearing housing. Assemble the bearing housing over the steering shaft and engage the rack over the end of the actuator rod (Fig. 3B5-38). With the external release lever installed, hold the lock shoes in the disengaged position and assemble the bearing housing over the steering shaft until the pivot pin holes line up. Install the pivot pins. Place the bearing housing in the full " u p " position and install the tilt lever spring guide, spring and spring retainer. With a suitable screwdriver, push the retainer in and turn clockwise to engage in the housing. Install the upper bearing inner race and race seat. Install the tilt lever opening shield. Remove the tilt release lever,install the turn signal housing and torque the three retaining screws to 45 lbs. in. Install the tilt release lever and shift lever. Drive the shift lever pin in. Install the lock cylinder, turn signal switch and ignition switch as outlined previously in this section.

3B5-20

STEERING CO LUM N S

2. Attach bracket (D) to jacket and tighten four bolts (E) to specified torque.

Mandatory Installation Sequence


1. Position column in body and position flange to rag joint and install lock washers and nuts (F) (M a y be tightened to specified torque at this time). Coupling (G) on manual steering must be installed prior to column installation. 2. Loosely assemble (2) capsules nuts (H ) at the instrument panel bracket (D). 3. Position lower clamp (J) and tighten attaching nuts (K) to specified torque. 4. Tighten two nuts ( H) at capsules to specified torque. 5. Install seal (C) and covers (A and B) to dash. 6. Install attaching screws (L) and tighten to specified torque. 7. Tighten two nuts (F) at capsules to specified torque if not already done. 8. Remove plastic spacers from flexible coupling pins. 9. Install transmission indicator cable on column automatics. 10. Install the instrument panel trim cover. 1 1. Connect the transmission control linkage at the shift tube levers. 12. Install the steering wheel as outlined previously in this section. 13. Connect the battery ground cable.

Mandatory System Requirements 1 . Pot joint operating angle must be 1 1 / 2 4 .


2. Flexible coupling must not be distorted greater than .06 due to pot joint bottoming, in either direction.

STEERING COLUMN SERVICE FOR G AND P SERIES


STEERING WHEEL
Removal Fig. 3B 5-40 Steering Column Installation-CK

21. Align the groove across the upper end of the pot joint with the flat on the steering shaft. Assemble the intermediate shaft assembly to the upper shaft. Install the clamp and bolt and torque the nut to specifications.
NOTICE: The clamp bolt must pass through the shaft

1. Disconnect battery ground cable. 2. Remove horn button or shroud, receiving cup, belleville spring and bushing and mark steering wheel to steering shaft relationship. 3. Remove snap ring, and steering shaft nut. 4. Use Tool J-1859-03 to remove w heel (Fig. 3B5-41).
In sta lla tio n NOTICE: See N O T I C E on page 1 of this section regarding the fastener referred to in step 2 . NOTICE: Directional signal control assembly must be in

undercut, or damage may occur to the components. 22. Install the neutral-safety switch or back-up switch as outlined in Section 12 of this manual. 23. Install the four dash panel bracket to column screws and torque to specifications.
CAUTION: Be sure that the slotted openings in the bracket (for the mounting capsules) face the upper end of the steering column.

1. 2. 3. 4.

COLUMN INSTALLATION-MANDATORY SEQUENCE Mandatory Preliminary Instructions


1. Assemble lower dash cover (A) and upper dash cover (B) to seal (C) with "C arrots" (part of seal).

neutral position when assembling steering wheel to prevent d am age to cancelling cam and control assembly. Place the steering wheel onto the steering shaft, aligning the marks made at removal. Position into place and secure to proper torque with nut. Install snap ring. Install horn button assembly. Connect battery ground cable.

STEERING C O LU M N S
Installation

3B5-21

NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in steps 2, 4 and 5. 1. Install the flexible coupling onto the steering gear wormshaft, aligning the flat on the shaft with the flat in the coupling. Push the coupling onto the wormshaft until the coupling reinforcement bottoms against the end of the worm. 2. Install the special bolt into the split clamp and torque to specifications. NOTICE: The bolt m ust pass through the shaft undercut,or damage may occur to the components. 3. Place the steering gear into position, guiding the flexible coupling bolts into the proper holes in the steering shaft flange. 4. Install and tighten the steering gear to frame bolts. 5. Install the coupling to flange bolt nuts and washers and torque to specifications. Be sure to maintain a coupling to flange dimension of .250" to .375". The coupling alignment pins should be centered in the flange slots.

INTERMEDIATE STEERING SHAFTS WITH POT JOINT COUPLINGS


Removal (Fig. 3B5-43)

STEERING COUPLING (FLEXIBLE TYPE)


Removal (Fig. 3B5-42)

1. Remove the coupling to steering shaft flange bolt nuts. 2. Remove the coupling clamp bolt. This is a special bolt and will require a 12 pt. socket or box wrench. 3. Remove the steering gear to frame bolts and lower the steering gear far enough to remove the flexible coupling. It is not necessary to disconnect the pitman arm from the pitman shaft. 4. Tap lightly on the flexible coupling with a soft mallet to remove the coupling from the steering gear wormshaft.

1. Remove the lower shaft flange to flexible coupling bolts. 2. Remove upper shaft to intermediate coupling bolt 3. If necessary, remove the steering gear to frame bolts and lower the steering gear far enough to remove the intermediate shaft assembly. It is not necessary to remove the pitman arm from the pitman shaft.
Disassembly

1. Mark cover to shaft relationship. Pry off snap ring and slide cover from shaft. 2. Remove bearing blocks and tension spring from pivot pin. 3. Clean grease off pin and end of shaft. Scribe location mark on pin on same side as chamfer in shaft. 4. Supporting shaft assembly securely, with chamfer up, press pin out of shaft with arbor press.

CAPTURING STRAP

FLA N G E BOLTS

SPRING

NUT

Fig. 3B5-42--Flexible Type Steering Coupling

Fig. 3B 5-43-S teering Shaft Intermediate Coupling

3B5-22

STEERING CO LUM N S
Installation NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in steps 1, 3 and 4. Install the in term ediate shaft assembly onto the steering shaft, aligning the flat on the shaft with the flat in the coupling. Install the pot joint clamp bolt and torque to specifications. Lift the steering gear into position, guiding the flexible coupling bolts into the shaft flange holes. Install the steering gear to frame bolts and torque to specifications. Install the flexible coupling to steering shaft flange bolt lockwashers and nuts. Check th a t the coupling alignment pins are centered in the flange slots and then torque the coupling bolts to specifications.

1.

2. 3. 4.

INTERMEDIATE STEERING SHAFT WITH UNIVERSAL JOINT COUPLINGS


Removal (Fig. 365-43)

Fig. 3B5-44~Checking Coupling Pin Centering NOTICE: Do not drive pin out with hammer. This may cause sticky or binding bearings when reassembled. 5. Remove seal clamp and slide seal off end of shaft. Assembly

1. Set front wheels in straight ahead position. This can be done by driving the vehicle a short distance on a flat surface. 2. M ark upper universal joint yoke to steering shaft relationship and lower yoke to steering gear wormshaft relationship. 3. Remove both upper and lower universal yoke pinch bolts. 4. Remove steering gear to frame bolts and lower the gear. It is not necessary to disconnect the pitman arm from the steering gear pitman shaft. 5. Remove the intermediate steering shaft and universal joint assembly.
Disassembly

1. Be sure all parts are free of dirt. Slide seal onto steering shaft. With lip of seal against step in shaft clamp seal. 2. Press pin back into shaft from chamfered side. Locate pin in shaft using scribe mark as reference.
NOTICE: Pin must be centered within .012 in. or binding in the coupling could result.

1. If the upper or lower half of the intermediate steering shaft is to be replaced, proceed as follows: a. With the shaft assembly on a bench, straighten the tangs on the dust cap. S e p a ra te the upper and

3. C heck centering o f pin (Fig. 3B5-44). a. Place just enough 3 /8 " flat washers on pin to prevent bearing block from bottoming when installed. b. Measure distance from end of pin to top of bearing with micrometer. c. Remove bearing and washers and place same bearing and washers on other end of pin. Measure distance from end of pin to top of bearing. If micrometer readings in Steps b and c differ more than .012, repeat last part of Step 2 and recheck. 4. Apply a liberal amount of wheel bearing grease to inside and outside of bearing blocks and inside of cover. 5. Position tension spring and bearing blocks on pin. 6. Slide cover over bearing blocks aligning reference mark on cover with mark on shaft. Install seal into end of cover and secure with snap ring retainer.

STEERING C O LU M N S

3B5-23

a. Place the dust cap, plastic washer and a new felt seal over the shaft on the lower yoke assembly. b. Align the arrow on the lower yoke assembly shaft with the arrow on the upper yoke assembly tube and push the two assemblies together. c. Push the dust cap, plastic washer and felt washer into position on the lower end of the upper yoke assembly and bend the tangs of the dust cap down against the yoke tube.
Installation NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in steps 1, 3 and 4. Align the marks made at removal and assemble the intermediate shaft lower yoke onto the steering gear wormshaft. Install the pinch bolt and torque to specifications. The pinch bolt must pass through the shaft undercut. If a new yoke was installed, the slit in the yoke should be in the 12 oclock position. Raise the steering gear into position while guiding the upper yoke assembly onto the steering shaft. The marks on the coupling and steering shaft must align. If a new yoke was installed, assemble the upper yoke to the steering shaft with the steering wheel in straight ahead position (gear must be on high point). Install the steering gear to frame bolts and torque to specifications. Install the upper yoke to steering shaft pinch bolt and torque to specifications. NOTICE: The pinch bolt must pass through the shaft

1.

2.

3. 4.

Fig. 3B5-46--Steering Column Upper Bearing

undercut, or dam age may occur to the components.

lower portions of the shaft assembly. b. Remove the felt washer, plastic washer and dust cap. Discard the felt washer. 2 . If the trunnion assemblies are to be replaced, proceed as follows: a. Remove the snap rings retaining the trunnion bushings in one of the yokes. b. Support the yoke on a bench vise and drive out one bushing by tapping on the opposite bushing using a soft drift and hammer. c. Support the other side of the yoke and drive out the remaining bushing as in Step b above. d. Move the yoke on the trunnion as necessary to separate the upper and lower yokes. e. Remove the trunnion from the lower yoke as outlined in Steps a through d above. Remove and discard the seals.
Assembly

STEERING COLUMN UPPER BEARING-G AND P SERIES Standard Column


Removal

1. Remove steering wheel as outlined in this section. 2. Remove directional signal cancelling cam. 3. Pry out upper bearing.
Installation NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in step 1 . 1. Replace all component parts in reverse order of removal making sure th a t directional switch is in neutral position before installing steering wheel. Torque steering wheel nut to specifications.

Tilt Column
The upper bearings on the tilt column are spun into the bearing housing assembly. If the bearings indicate need of replacement, the entire bearing housing must be replaced. See "Tilt Steering Column - Disassembly and Assembly" for the correct replacement procedure.

1 . If the yoke trunnions were removed, reassemble as


follows: a. Place the new trunnion into the lower yoke. b. Place new seals onto the trunnion and then press the new bushings into the yoke and over the trunnion hubs far enough to install the snap rings. c. Install the snap rings. d. Repeat Steps a through c to attach the upper yoke to the trunnion. 2. Reassemble the intermediate shaft assembly as follows:

STEERING COLUMN LOWER BEARING P SERIES


Removal

1. Remove the intermediate steering shaft and universal joint assembly as outlined earlier in this section. Remove the preload spring clam p and spring

3B5-24

STEERING CO LUM N S
retainer using a screwdriver that just fits into the slot opening. Insert the screwdriver into the slot, push in approximately 3 /1 6 ", rotate clockwise approximately 1/8 turn until the retainer ears align with the grooves in the housing and remove the retainer and spring.

6. Remove the steering shaft bearing locknut using Socket


J-22599. Remove the upper bearing race seat and race. 7. Remove the two bearing housing pivot pins using Tool J-21854.

8. Pull up on the tilt release lever (to disengage the lock


shoes) and remove the bearing housing. If the bearing housing is being replaced or it is necessary to disassemble the bearing housing, proceed as follows: a. Press the upper and lower bearings out of the housing. b. Using Puller J-5822 and Slide Ham m er J-2619, pull the bearing races from the housing. c. Remove the tilt release lever. d. Drive out the shoe release pivot pin using Tool J-22635 or a suitable punch. Remove the lever spring and remove the wedge. e. Using a suitable size punch, drive out the lock shoe retaining pin. Remove the shoes and shoe springs. If the upper steering shaft, lower steering shaft, or centering spheres are being removed, proceed as follows: 9. To remove the steering shaft assembly through the upper end of the column. If it is necessary to
Fig. 3B 5-47 Steering Column Lower Bearing

from the end of the steering shaft. 2. Pry out the lower bearing assembly.
Installation NOTICE: See N O T IC E not on page 1 of this section

regarding fasteners referred to in step 2 . 1. Place the new bearing over the end of the steering shaft and press into position in the column. 2. Install the preload spring and clamp and torque the clamp bolt nut to specifications. Refer to "Bearing A d ju stm e n t" in " M ain te n a n c e and A djustm ent Section. Reinstall the intermediate shaft and universal joint assembly as outlined under "In te rm ed iate Steering Sh aft with Universal Joint Couplings Installation".

TILT COLUMN BEARING HOUSING ASSEMBLY G AND P SERIES


Removal (Column in Vehicle)

1. Disconnect the battery ground cable. 2. Remove the steering wheel as outlined under "Steering Wheel - Removal". 3. Remove the directional signal switch as outlined under " Directional Signal Switch - Rem oval". 4. Column Shift Models - Using a suitable size punch, drive out the shift lever pivot pin and remove the shift lever. 5. Install the tilt release lever and place the column in the full "u p " position. Remove the tilt lever spring and

Fig. 3B5-48 Tilt Column Bearing Housing

STEERING C O LU M N S

3B5-25

5.

6.

Fig. 3B5-49--Directional Signal Switch

7.

disassemble the shaft, proceed as follows: a. To remove the lower steering shaft first disconnect the shaft at the pot joint coupling clamp. b. Turn the upper shaft 90 to the lower shaft and slide the upper shaft and centering spheres from the lower shaft. c. Rotate the centering spheres 90 and remove the centering spheres and preload spring from the upper shaft. If the bearing housing support is being replaced, proceed as follows: 10. Remove the four bearing housing support screws and remove the support.
Assembly NOTICE: See N O T I C E on page 1 of this section

8. 9.
10. 11. 12.

c. Place the lock shoe springs in position in the housing. Install each shoe in place and compress the spring until a suitable size straight punch can be used to hold the shoe in position (it may be necessary to acquire assistance to install the shoes). Once the shoes are in place, drive in the shoe retaining pin. d. Install the shoe release lever and drive in the pivot pin. e. Install the tilt release lever. f. Lubricate the shoes and release lever. Install the bearing housing assembly to the support. Hold the tilt release lever in the " u p " position until the shoes have fully engaged the support. Lubricate and install the bearing housing pivot pins. Press the pins in flush with the housing. Place the housing in the full " u p " position and then install tilt spring and retainer (tapered end of spring first). Push into the housing approximately 3 /1 6 " and rotate counterclockwise 1 /8 turn. Lubricate and install the upper bearing race, race seat and locknut. T ighten the locknut (using Socket J-22599) to remove the lash and then carefully further tighten 1/16 to 1/8 of a turn (column must be in straight ahead position). Remove the tilt release lever. Install the directional signal switch as outlined under "Directional Signal Switch - Installation". Column Shift Models - Install the shift lever and pivot pin. Install the steering wheel as outlined under "Steering Wheel - Installation". Check electrical and mechanical functioning of column.

DIRECTIONAL SIGNAL SWITCH


If the directional signal switch must be replaced, the steering column does not have to be removed from the vehicle.

regarding the fasteners referred to in steps 3 ,9 and 11. 1. Assemble the steering shaft as follows: a. Lubricate and assemble the centering spheres and preload spring. b. Install the spheres into the upper (short) shaft and rotate 90. c. Install the lower shaft 90 to the upper shaft and over the centering spheres. Slowly straighten the shafts while compressing the preload spring. 2. Install the shaft assembly into the housing from the upper end. 3. Install the lower shaft to the pot joint coupling clamp. Install the coupling clam p bolt and torque to specifications.
NOTICE: The coupling bolt must pass through the shaft

undercut, or damage may occur to the components. 4. Assemble the bearing housing as follows: a. Press the new upper and lower bearing races into the bearing housing. b. Lubricate and install the bearings into the bearing races.

3B5-26

STEERING CO LUM NS

8. Push in on the hazard warning light knob and then


unscrew and remove the knob. 9. Tilt Columns Only a. A utom atic Transmission Models - Remove the P R N D L dial screws and remove the dial and indicator needle. Remove the cap and dial illumination bulb from the housing cover. b. Unscrew and remove the tilt release lever. c. Assemble Tool J-22708 inside the directional signal housing cover; push in until the tangs lock inside the cover flange (Fig. 3B5-52). Turn the tool center screw clockwise to pull the cover from the housing. 10. Remove the three directional signal switch mounting screws and then carefully remove the switch assembly from the column while guiding the wiring harness through the opening in the shift lever housing.
Installation

1.
Removal

1. Remove the steering wheel as outlined under "Steering Wheel - Removal". 2. Remove the directional signal switch cancelling cam and spring. 3. Remove the column to instrument panel trim plate (if so equipped). 4. Disconnect the directional signal switch wiring harness at the half-moon connector. 5. Pry the wiring harness protector out of the column retaining slots as shown in Figure 3B5-50. 6. M ark the location of each wire in the half-moon connector and then remove each individual wire from the connector using Tool J-22727 (Fig. 3B5-51). Insert the tool into the lower end of the connector and push in until the tool bottoms on the connector. Remove the tool and then pull the wire from the connector. 7. Remove the directional signal lever screw and remove the lever.

2.

3.

4. 5.

1 of this section regarding the fasteners referred to in step 9. W rap the ends of the directional signal switch wires with tape and then guide them through the opening at the lower left hand side of the bearing housing (tilt columns), out the lower end of the shift lever housing and under the dash seal. Place the directional signal switch in position and install the three mounting screws; torque to 25 lbs. in. after screw head has been firmly seated. Tilt Columns Onlya. Align the openings in the directional signal switch cover with the proper lever positions and tap the cover into place using a plastic hammer. b. Install the tilt release lever. c. A utom atic Transmission Model - Install the P R N D L dial, pointer, dial illumination bulb and cap. Install the directional signal switch lever and hazard warning knob. Bend the wire retaining tabs slightly outward on each wire in the wiring harness as shown in Figure

NOTICE: See N O T I C E on page

Fig. 3B5-52--Removing Directional Signal Housing Cover

Fig. 3B 5-53-P reparing W ire Retaining Tabs fo r Installation

STEERING C O LU M N S

3B5-27

STEERING SYSTEM MANDATORY REQUIREMENTS

1.

Using a 50 lb. force a p p lie d to the steering w heel end o f Shaft a ] , Lower Clam p Nut must be

tightened to the specified torque to give a compressed spring dimension | C | o f .50 . 0 4 a fte r assembly.

2 . Flexible Coupling
.2 5 0 /.3 7 5 . NOTICE

setup dimension f~ E ~ | must be This dimension must be held

to prevent distortion of Flexible Coupling w ith resultant bind and 3. harshness.

All M ast Jacket attachm ents (cf) & [TT] must be tightened to recommended torque.

4.

Threaded portion of Steering Shaft Q J must be com pletely free of lubricant a fte r M ast Jacket | K | assembly to m ain tain steering w heel clam ping load and hub clearance.

Fig. 3B 5-54 Steering Column Attachment-G Series

STEERING SYSTEM MANDATORY REQUIREMENTS

1.

Using a 50 lb. force a pp lied to the steering w heel end o f Shaft | A | f lo w e r Clam p Nut | B | must be tightened to the specified torque to give a compressed spring dimension | C | of 1.26 . 0 2 a fte r assembly.

2 . All M ast Jacket attachments | p [ & | E | must


be tightened to recommended torque. 3. Threaded portion of Steering Shaft | F [ must be com pletely free of lubricant a fte r M ast Jacket ( g ] assembly to m ain tain steering w heel clam ping load and hub clearance.

Fig. 3B5-55--Steering Column Attachment-P Series

3B5-28

STEERING CO LUM N S

1. 2. 3. 4. 6. 7. 8. 9. 10. 11. 12.

U pper S te e rin g SKoft S h ift H ousing Bushing Bushing Seat M ast J o c k e t B a c k -U p Lamp S w itc h Screw B a c k -U p Lam p S w itc h Toe Pan Seol R e ta ine r Toe Pan Seol A d ju s tin g Ring C lo m p Screws N u t and Lockw osher A d ju s tin g Ring C la m p Bolt

13. 14.

S h ift Tube F e lt W asher S h ift Tube Assem bly

25. 26 . 27. 28 . 29. 30. 31 . 32 . 33. 34. 35. 36

Turn S ig n o l S w itc h Screw Turn S ig n a l S w itc h S te e rin g Shoft U pper Bearing S w itc h C o n ta c t S upport Turn S ig n o l H ousing Turn S ig n a l S w itc h Le ver Screw Turn S ig n a l S w itc h Le ver Rubber Ring P la stic Thrust W osher S h ift Le ver H ousing S h ift Le ver Pin S h ift Le ver

15. S h ift Lever Spacer 16. 1st-R ever* S h ift Lever 17. A d ju s tin g Ring 18. 19. 20 . 21 . 22 . S h aft Low er Bearing Low er B e aring P relood S p rin g P relo od S p rin g C lo m p N u t and Lockw osher S te e rin g Shaft N u t

5. C o lu m n C ove r

23 . Lockw osher 24 . | Turn S ig na l C a n c e llin g Cam

Fig. 3B5-56~Standard Column-Typical G & P

6.

7.

8. 9.
10.

3B5-53; this will provide proper retention o f the wire in the half-moon connector. Install each wire in its marked location in the half moon connector. Push in until square part of clip is flush with the bottom side of the connector. Connect the directional signal switch wiring harness. Snap the wiring harness protector into the column retaining slots. Install the directional signal cancelling cam and spring. Install the steering wheel as outlined under "Steering Wheel - Installation". Install the column to instrument panel trim plate (if so equipped).

3. G Models - Remove the intermediate steering shaft flange to flexible coupling bolts. P Models - Remove the intermediate steering shaft upper universal yoke to steering shaft pinch bolt. Mark the coupling to shaft relationship. 4. Remove column clam p screw(s) on engine side of firewall, if equipped, and remove or slide the clamp down the column. 5. From inside the vehicle, remove the screws from the toe pan cover and slide the cover and seal up the column.

6. Remove the steering wheel as outlined under "Steering


W h e el-R e m o val", and reinstall the shaft nut and washer. 7. All Columns - Disconnect the directional signal wiring harness. S ta n d a rd Colum n with A utom atic Transmission - Disconnect the conductor tube (for transmission indicator) at the instrument panel. Tilt Column with A utom atic Transmission Disconnect the single wire at the fuse block and unclip it from the parking brake bracket.

STEERING COLUMN G AND P SERIES


Removal

1 . Disconnect the battery ground cable. 2. Column Shift Models - Disconnect transmission shifter rods at the lower end of the column.

STEERING C O LU M N S

3B5-29

8. Remove the cap screws from the column support


bracket at the dash panel. 9. C arefully lower and then w ithdraw the column assembly, rotating so that the shift levers clear the toe pan opening.
Disassembly of Standard Column (Fig. 3B5-56)

Assembly

In the following assembly sequence use any general purpose lithium soap grease for lubricating those components so indicated. 1. Install the dash panel seal, toe panel and firewall clamps over the end of the jacket. 2. Lubricate all bearing surfaces on the shift tube. 3. Place the felt seal onto the shift tube (next to spring) and then place the shift tube in the jacket. 4. 3-Speed Columns - Temporarily install spacer, 1streverse shift lever and lower adjusting ring. Place a block of wood on top of the adjusting ring and tap until the shift tube bottoms. Remove adjusting ring, shift lever and spacer. Automatic Columns - Align the three holes in the selector plate with the three holes in the jacket, position the clamping ring and install the three screws. The shift tube spring retainer must be bottomed against the jacket stops. 5. 3-Speed Columns-Lubricate and install the spacer and 1 st-reverse shift lever (tang of lever towards top of column). 6. Install lower bearing in the adjusting ring and then install the adjusting ring, clamp and screws. 7. Install the shift lever housing (or extension housing) seat and bushing to upper end of housing. 8. T h read directional signal switch wiring harness through the switch and lever (or extension) housings, lubricate the inner diameter of the shift housing, and then place the shift lever (or extension) housing onto the upper end of the column. 9. Install the switch housing plastic washer assembly. Press the upper bearing into the switch contact support. 10. Install the directional signal switch housing, contact support, bearing and switch and torque the switch screws to 25 lbs. in. 11. Install the column wiring harness cover and back-up lamp switch. 12. Install the directional signal and gearshift levers. 13. Adjust the shift tube as outlined under "Shifter Tube Adjustment." 14. Loosely install the lower bearing preload spring and clamp. 15. Slide the steering shaft assembly up through the column assembly. Install the directional signal cancelling cam, steering shaft nut and lock washer.
Disassembly O f Tilt Column (Fig. 3B5-57)

For floor shift transmission models, omit Steps 4, 14, 15 and 16. 1. Remove the steering wheel nut and lock washer and then slide the steering shaft assembly from the lower end of the column. 2. G Models - Remove the lower bearing preload spring and clamp from the steering shaft. P Models - Remove the lower bearing preload spring and clamp. 3. Remove the back-up lamp switch. 4. Drive out the shift lever pivot pin and remove the shift lever. 5. Remove the directional signal cancelling cam. Remove the directional signal switch lever. 6. Remove the column wiring harness cover. 7. Remove the directional signal switch screws. 8. Rotate the directional signal switch housing counterclockwise and remove the housing from the column. The housing and switch cannot be fully removed from the column until the shift lever housing is removed. 9. Remove the plastic thrust washer assembly and then remove the shift lever housing (or extension housing) from the column. 10. Separate the directional signal switch, switch control support assembly, directional signal housing and shift lever housing (or housing extension) assemblies. 11. Press the steering shaft upper bearing out of the switch contact support. 12. Remove the shift lever housing (or extension housing) seat and bushing from the upper end of the column. 13. Remove the bolt and screws from the adjusting ring clamp and remove the clamp, adjusting ring and lower bearing. Press the lower bearing out of the adjusting ring. 14. 3-Speed Columns - Remove 1st-reverse shift lever and lever spacer. A uto m atic Columns - Remove the selector plate clamping ring screws (3). 15. Place the column upright on the floor, supporting it with two pieces of wood. Place a block of wood on the upper end of the shift tube. Press down on the shift lever with foot while tapping on the wood block to withdraw the tube from the column jacket.
NOTICE: In some tolerance stack-up cases it may be

1. If the column is removed from the vehicle, place the column in a bench vise using Holding Fixtures J-22573 (Fig. 3B5-58).
NOTICE: Clamping the column directly in a vise, could

necessary to use a press. Be careful not to damage the tube or jacket. 16. Remove the felt seal from the shift tube. 17. Remove firewall clamp, toe pan seal and dash panel seals from the jacket.

result in a damaged column. 2. Remove the directional signal switch as outlined under " Directional Signal Switch-Removal".

3B5-30

STEERING CO LUM NS

3. Remove the lower steering shaft and pot joint assembly and lower bearing and adapter assembly as outlined under " Lower Bearing and A dapter-Removal". 4. Column Shift Models - Using a suitable size punch, drive out the shift lever pivot pin and remove the shift lever. 5. Install the tilt release lever and place the column in the full " u p " position. Remove the tilt lever spring and retainer using a screwdriver that just fits into the slot o p e n i n g ( F i g . 3 B 5 - 5 9 ) . I n s e r t th e s c r e w d r i v e r clockwise approximately 1/8 turn until the retainer ears align with the grooves in the housing and remove the retainer and spring.

64). This allows the shift tube to be pushed further out of the housing and will not affect the use of the tool on other columns. 14. Remove the shift tube assembly using Tool J-22551 (Fig. 3B5-65). Insert the hooked end of the tool into the notch in the shift tube just below the shift lever housing key. Pilot the sleeve over the threaded end of the tool and into the upper end of the shift tube. Force the shift tube out of the housing by turning the nut onto the tool. If the shift tube is not completely free when the nut is bottomed on the threads, complete the removal by hand.
NOTICE: Do not hammer or pull on the shift tube during removal. On column shift models, guide the lower shift lever through the slotted opening in the column to prevent damage to the tube or column.

6. Remove the steering shaft bearing locknut using socket


J-22599. Remove the upper bearing race seat and race. 7. Remove the two bearing housing pivot pins using Tool J-21854 (Fig. 3B5-60).

8. Pull up on the tilt release lever (to disengage the lock


shoes) and remove the bearing housing. If it is necessary to disassemble the bearing housing, proceed as follows: a. Press the upper and lower bearings out of the housing. b. Using Puller J-5822 and Slide Hammer J-2619 pull the bearing races from the housing (Fig. 3B5-61). c. Remove the tilt release lever. d. Drive out the shoe release lever pivot pin using Tool J-22635 or a suitable punch (Fig. 3B5-62). Remove the lever spring and remove the wedge. e. Using a suitable size punch, drive out the lock shoe retaining pin. Remove the shoes and shoe springs. 9. Remove the steering shaft assembly through the upper end of the column. If it is necessary to disassemble the shaft proceed as follows: a. Turn the upper shaft 90 to the lower shaft and slide the upper shaft and centering spheres from the lower shaft. b. Rotate the centering spheres 90 and remove the center spheres and preload spring from the upper shaft. 10. Remove the four bearing housing support screws and remove the support. Column Shift Models - If the shift tube index plate must be removed, remove the two retaining screws and remove the plate.

15. Remove the lock plate by sliding out of the column notches, tipping the plate downward toward the housing (to compress the wave washer) and then removing as shown in Figure 3B5-66. Remove the wave washer. 16. Remove the shift lever housing. 17. Column Shift Models - Remove the shift lever spring by winding the spring up with pliers. 18. If necessary, remove the dash panel seal, mounting plate and the instrument panel seal from the column jacket.
Assembly of Tilt Column

W hen lubricating components during the following installation sequence, use any general purpose lithium soap grease. 1. Install the dash panel seal, mounting plate and the instrument panel seal on the column. 2. Column Shift Models - Press a new shift lever spring into the shift lever housing. 3. Slide the shift lever housing over the upper end of the column. 4. Place the wave washer and lock plate in position. Work the lock plate into the notches by tipping the plate toward the housing (compressing the wave washer) at the open side of the column. Lubricate the lock plate and upper end of the shift tube. 5. Carefully install the shift tube into the lower end of the column (make sure the foam seal is at lower end of the shift tube). Align the keyway in the tube with the key in the shift lever housing and complete installation of the shift tube using Tool J-22549 (Fig. 3B5-67). The shift lever housing key must bottom in the shift tube slot to be fully installed. Remove Tool J-22549 from the column. Lubricate and push foam seal in flush with column housing.
NOTICE: Do Not h am m er or force the tube when

1 1 . Remove the shift tube retaining ring with a screwdriver


(Fig. 3B5-63). Remove the thrust washer. 12. Remove the neutral-safety or back-up lamp switch screws and remove the switch. 13. Rework Shift T ube Removing Tool J-22551 by removing 1/2" from the pilot end of the tool (Fig. 3B5-

INSTRU. PANEL O PEN ING COVER

Fig. 3B 5-57 Tilt Steering Column-G &P

H O U SIN G ASSY.

SHOE HO USING BEARING BUMPER (3) SPRING (2)

PROTECTOR WIRE

SPRING RELEASE PIN RELEASE *-0 SHOE RELEASE-----BEARING ASS Y. ^ - CLIP JACKET DASH SEAL RETAINER

DASH SEAL

STEERING

LEVER ADAPTER RETAINER BEARING

COLUMNS 3B5-31

3B5-32

STEERING CO LUM NS

Fig. 3B5-62--Removing Release Lever Pivot Pin

Fig. 3B5-60--Removing Bearing Housing Pivot Pin

Fig. 3B5-63--Removing Shift Tube Retaining Ring

STEERING C O LU M N S

3B5-33

Fig. 3B5-66~Removing Lock Plate Assembly

The alignment pin plastic spacers must be removed before the vehicle can be driven. installing in the column, or damage could occur to the components. 6. Pull up on the shift lever housing (to compress the wave washer) and install the thrust washer and retaining ring. Be sure the ring is seated in both slots of the shift tube. 7. Lubricate the l.D. of the bearing housing support and install the support, aligning the bolt holes in the support with the bolt holes in the lock plate. Install the four support screws and torque to 45 in. lbs. 8. Assemble the steering shaft as follows: a. Lubricate and assemble the centering spheres and preload spring. b. Install the spheres into the upper (short) shaft and rotate 90.

c. Install the lower shaft 90 to the upper shaft and over the centering spheres. Slowly straighten the shafts while compressing the preload spring.
9. Install the shaft assembly into the housing from the

upper end. 10. Install the lower bearing and adapter, bearing reinforcement, wire clip, pot joint coupling and lower shaft as described under "Low er Bearing Installation". 11. Assemble the bearing housing as follows: a. Press the new upper and lower bearing races into the bearing housing. b. Lubricate and install the bearings into the bearing races. c. Place the lock shoe springs in position in the housing. Install each shoe in place and compress the spring until a suitable size straight punch can be used to hold the shoes in position (it may be necessary to acquire assistance to install the shoes). Once the shoes are in place, drive in the shoe retaining pin.

Fig. 3B5-65--Removing Shift Tube Assembly

Fig. 3B 5-67Installing Shift Pin Tube

3B5-34

STEERING CO LUM NS

STEERING SYSTEM MANDATORY REQUIREMENTS


Using a 50 lb. force applied to the steering w heel end o f Shaft | A | , Lower Clam p Nut | B | must be tightened to the specified torque to give a compressed spring dimension [ c ] of .50 .0 4 a fte r assembly.

Flexible Coupling | D | setup dimension | E | must be .2 5 0 /.3 7 5 . NOTICE This dimension must be held

to prevent distortion of Flexible Coupling with resultant bind and 3. harshness.

All M ast Jacket attachments | g J & [ h ] must be tightened to recommended torque.

4.

Threaded portion o f Steering Shaft Q ] must be com pletely free of lubricant a fte r M ast Jacket J~ K ~ ) assembly to m aintain steering w heel clam ping load and hub clearance.

Fig. 3 B 5 -6 8 -M a n d a to ry Sequence For Installation Of G Series Column d. Install the shoe release lever and drive in the pivot

12.

13.

14.

15. 16. 17. 18. 19.

pin. e. Install the tilt release lever. f. Lubricate the shoes and release lever. Install the bearing housing assembly to the support. Hold the tilt release lever in the " u p " position until the shoes have fully engaged the support. Lubricate and install the bearing housing pivot pins. Press the pins in flush with the housing. Place the housing in the full " u p " position and then install tilt spring and retainer (tapered end of spring first). Push into the housing approximately 3 /1 6" and rotate counter clockwise 1 /8 turn. Lubricate and install the upper bearing upper race, race seat and locknut. Tighten the locknut (using Socket J-22549) to remove the lash and then further tighten 1/16 to 1/8 of a turn (column must be in straight ahead position). Remove the tilt release lever. Install the directional signal switch as outlined under " Directional Signal Switch-Installation". Column Shift Models - Install the shift lever and pivot pin. Install the neutral-safety or back-up lamp switch. Remove the column from the bench vise.

COLUMN INSTALLATION Mandatory Installation Sequence G Series


NOTICE: See N O T I C E on page 1 of this section regarding the fasteners referred to in steps 3 and 10. 1. Adjust the column lower bearing preload by applying a force on the steering wheel end of the steering shaft (A). Position the spring and clamp to maintain the dimension as detailed under "M ain te n a n c e and Adjustments.

2. Install the plastic spacers onto the flexible coupling alignment pins. 3. From inside the vehicle, carefully insert the lower end of the column through the toe pan opening guiding the steering shaft flange onto the flexible coupling. Install and torque the glange to coupling bolts. 4. Locate the index slot in the column jacket with the protrusion on the clutch and brake pedal support. 5. Loosely install the column dash bracket and screws. 6. Push the column down until the steering shaft flange bottoms on the plastic spacers on the flexible coupling and then torque the dash bracket screws. 7. Remove the plastic spacer from the alignment pins using a wire hook. C heck the flexible coupling to steering shaft flange clearance (.25" to .325"), if not within specifications, the dash bracket screws must be loosened and the column raised or lowered as required. Retorque the bracket screws. 8. Push the toe pan seal to the toe pan, install and torque the mounting screws. 9. All Colum ns-Connect the directional signal switch wiring harness. Automatic Columns-Connect the conductor tube (for transmission indicator) to the instrument panel. See Fig. 3B5-69. 10. Install the steering wheel as outlined under "Steering Wheel Installation". 1 1. Connect the transmission linkage. 1 2. Connect the battery ground cable.

Mandatory Sequence P Series


NOTICE: See N O T IC E note on page 1 of this section

regarding the fasteners referred to in steps 1, 2, 3 and 10. 1. Applying 50 lbs. force on the steering wheel end of the steering shaft, adjust the lower bearing preload to allow

STEERING C O LU M N S

3B5-35

up the marks made at removal. Install the yoke pinch bolt and torque to specifications. The pinch bolt must pass through the shaft undercut. 3. Position and attach the lower clamp mounting bracket to the firewall. Locate the steering column protrussions against the toe pan bracket while at the same time, aligning protrusion in brake and clutch pedal support with index slot in the steering column, as shown in Figure 3B5-69. Install the colum n to bracket clam p and torque the clamp bolt to specifications. The toe pan bracket must not override the protrusions on the steering column. 4. Position the steering column to dash panel bracket, install the attaching bolts and torque to specifications. 5. If plastic spacers were used on the flexible coupling alignment pins, remove the spacers after all bolts have been properly torqued. 6. Install the seal at the toe pan and then install the toe pan bracket screws; torque to specifications. 7. Install the dash panel trim plate (if so equipped). 8. Connect the transmission shift linkage on column shift models. 9. All Columns - Connect the directional signal wiring harness. S ta n d a rd Column with A uto m atic Transmission Connect the conductor tube (for transmission indicator) at the instru m ent panel (Fig. 3B 5-70). 10. Install steering wheel as outlined under "S teering Wheel-Installation". 1 1 . Connect battery ground cable.

Indicator

steering shaft end play as indicated in "M aintenance and Adjustments". Tighten the shaft clamp on pot joint bolt to specifications. 2. From the passenger side of the dash panel, carefully insert the lower end of the steering column through the toe panel opening. Guide the steering shaft into the universal yoke, lining

STEERING SYSTEM MANDATORY REQUIREMENTS 1. Using a 50 lb. force applied to the steering wheel end of Shaft [ a ], Lower Clamp Nut [~ B ~ | must be tightened to the specified torque to give a compressed spring dimension [ c ] of 1.26 .02 after assembly. 2. All Mast Jacket attachments [D ] & \ e \ must be tightened to recommended torque. 3. Threaded portion of Steering Shaft [F] must be completely free of lubricant after Mast Jacket [G ] assembly to maintain steering wheel clamping load and hub clearance.

Fig. 3 B 5 -7 0 -M a n d a to ry Sequence For Installation o f P Series Column

3B5-36

STEERING CO LUM N S

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

J-6632 J-5504 J-23073 J-23072 J-5176 J-5822 J-8433 J-21854 J-23653 J 5421 J-5860 J-21239 J-2927 J-1614 J-7539 J-7624 J-4245 J-22670

Pitman Arm Puller Pitman Arm Puller . S hift Tube Installer S hift Tube Remover Oil Pressure Gauge Wormshaft Bearing Cup Remover Pump Pulley Remover (Cast Pulley) Column Pivot Pin Remover Lock Plate Compressor Thermometer Torque Wrench Adapter Pump Pulley Remover (Stamper Pulley) Steering Wheel Puller Sector Shaft Bushing Remover Ball Retainer Spanner Wrench #23 Internal Pliers Pump Shaft Seal Installer

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

J-6222 J-23600 J-8947 J-5755 J-2619 J-8092 J-6278 J-6278-2 J-7079-2 J-8524-1 J-8524-2 J-6219 J-22407 J-8937 J-6217 J-23980

Shaft Seal Protector Belt Tension Gauge Rack-Piston Seal Compressor Wormshaft Bearing Race Installer Slide Hammer Handle Pitman Shaft Bearing Remover Pitman Shaft Bearing Installer Handle Adjuster Plug Bearing Installer Adjuster Plug Bearing Remover Pitman Shaft Seal Installer Pitman Shaft Bearing Installer Ball Seal Remover Connector Seat Installer Steering Column Electrical Analyzer Torque Wrenches

Fig. 3B5-1ST--Special Tools C and K Models

STEERING C O LU M N S

3B5-37

12

13
ft

17

tf
18

22 25 19

26

TT
20
21

23

27

29

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

J-6632 J-5504 J-5176 J-5822 J-5860 J-22670 J-6222 J-9226 J-7576 J-21239 J-2927 J-1614 J-7539 J-7624 J-4245 J-23600 J-5755 J-2619

Pitman A rm Puller Pitman A rm Puller Pressure Gauge Wormshaft Bearing Cup Puller Torque Wrench A dapter Pump S haft Seal Installer Shaft Seal Protector Pitman Shaft Bushing Replacer Rack-Piston Seal Compressor Pump Pulley Remover Steering Wheel Puller Sector Shaft Bushing Remover Ball Retainer Spanner Wrench #23 Internal Pliers Belt Tension Gauge W ormshaft Bearing Cup Installer Slide Hammer

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

J-6278 J-6278-2 J-7079-2 J-8524-1 J-8524-2 J-6219 J-6217 J-5421 J-22407 J-22727 J-22708 J-22573 J-22599 J-21854 J-22551 J-22549

Pitman Shaft Bearing Remover Pitman Shaft Bearing Installer Drive Handle A djuster Plug Bearing Installer A djuster Plug Bearing Remover Pitman Shaft Seal Installer Connector Seat Installer Thermom eter Pitman Shaft Bearing Installer Term inal Remover Turn Signal Cover Remover Steering Colum n Holding Fixture Lock N ut Socket Pivot Pin Remover S h ift Tube Remover S h ift Tube Installer Torque Wrenches

Fig. 3B5-2ST Special Tools G and P Models

STEERING LINKAGE

3B6-1

SECTION 3B6

STEERING LINKAGE
The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section". NOTICE: These fasteners are important attaching parts in that they could affect the performance of vital components and systems, a nd/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of these parts. For prevailing torque nut(s) and bolt(s), refer to the " Reuse of Prevailing Torque Nut(s) and Bolt(s)" chart in Section 10.

CONTENTS
General Description...................................................................................... .3B6-1 Maintenance and A d ju stm e n ts...................................................................3B6-2 On-Vehicle Service....................................................................................... .3B6-2 Tie R ods................. .................................................................................... .3B6-2 Relay R o d ....................................................................................................3B6-5 Idler A r m ............................... .................................................................... .3B6-6 Pitman A r m ............................................................................................... .3B6-6 Steering Connecting R o d ....................................................................... ..3B6-7

GENERAL DESCRIPTION
The steering linkage is located forward of the front crossmember. Refer to Fig. 3B 6-1, for a typical system. Steering effort is tra n sm itte d to left and right hand adjustable tie rods through a relay rod. The relay rod is connected to an idler arm on the right and to the pitman arm on the left.

DIAGNOSIS
Reference should be made to the correct method of disassembly, repair, adjustment and reassembly. Damaged, broken or deformed parts must be replaced with the correct replacement. See Section 3.

Fig. 3B6-1 Typical Steering Linkage

3B6-2

STEERING LINKAGE

MAINTENANCE AND ADJUSTMENTS


LUBRICATION LUBRICATION OF STEERING LINKAGE
The steering linkage under normal conditions should be lubricated with any w ater resistant EP type chassis lubricant every 7,500 miles (12 000 km) or six months, whichever occurs first. Lubricate every 3,000 miles (4 800 km) or two months whichever occurs first when operating in dusty or muddy conditions or if the vehicle is used "offroad ". Lubrication points and additional information on the chassis lubricant recommended can be found in Section 0-General Information and Lubrication.

STEERING DAMPER CHECK (Fig. 3B6-2)


This type of steering dam per is nonadjustable, nonrefillable and is not repairable. At each lubrication interval make check # 1 and # 2 on the steering damper system. 1. Inspecting Damper Mountings: Check the dam per attachments to be sure they are properly and securely installed. (Tighten, if loose). Replace the dam per assembly if the rubber bushings are badly worn. 2. Inspecting Damper For Leaks: Inspect the damper for evidence of fluid leakage. A light film of fluid is permissible on the body of the dam per near the shaft seal. A dripping damper should be replaced. If a Funtional or Noise Complaint is Reported, Make the Following Inspections: 3. Inspecting Damper For Noise: Disconnect the frame or axle end of the damper. Extend and compress the damper using as much travel as possible. The damper action should be smooth throughout each stroke. 4. Inspecting Damper For Functioning: While checking the dam per in step (3) above, observe the operation of the damper for fluid leakage, effort and lag. Items from this check that require damper replacement are: a. Any fluid leakage during this check. b. Seizing or binding condition during travel of damper. c. A skip or lag at reversal near mid-stroke of damper. 5. Reinstall Disconnected End of Damper Using Proper Torque.

ON-VEHICLE SERVICE
NOTICE: See N O T I C E on page 1 of this section regarding all fasteners referred to in servicing steering linkage components.

TIE RODS
Removal

1. Raise vehicle on hoist. 2. Remove nuts from ball studs. The inner tie rod ends use crimp nuts, while the outer ends use castellated nuts and cotter pins. 3. To remove outer ball stud, tap on steering arm at tie rod end with a hammer while using a heavy hammer or similar tool as a backing. 4. Remove inner ball stud from relay rod using same procedure as described in Step 3. 5. To remove tie rod ends from tie rod, loosen clamp bolts and unscrew end assemblies.
Installation NOTICE: See the N O T IC E on page 1 of this section regarding the fasteners referred to in steps 4 and 6.

Tie rod adjuster components often become rusted in service. In such cases, it is recommended that if the torque required to remove the nut from the bolt after breakaway exceed 7 pounds, discard the nuts and bolts. Apply penetrating oil between the clamp and tube and rotate the clamps until they move freely. Install new bolts and nuts having the same part number to assure proper clamping at the specified nut torque. As a guide to correct orientation of the inner tie rod end relative to the outer tie rod end, rotate both ends to the extremes of travel in the same direction before clamping. The position of each tie rod end must be maintained as the clamps are tightened to ensure free movement of each joint. Return the rod assembly to midposition of its travel. This should result in the inner and outer ball studs being retained in a parallel relationship with the intermediate (relay) rod and steering knuckle (a rm ) respectively. T he following procedure should be used when installing tie rods. 1. If the tie rod ends were removed, lubricate the tie rod threads with EP Chassis lube and install ends on tie rod making sure both ends are threaded an equal distance from the tie rod.

STEERING LINKAGE

3B6-3

RELAY ROD

IDLER ARM ASSEMBLY

TIE ROD ASSEMBLY KNUCKLE

[A] tCAUIlQMJ All clamps must be between &


clear of dimples before torquing nut.

STEERING GEAR PITMAN AR M 1

|~ B ~ | Exposed socket thread length must be


equal within .0 6 at each end of ad justing sleeve on L.H. & R.H. tie rod asm.

C-SERIES

[~C~| All bolts must be installed in directions


shown ADJUSTABLE CONNECTING ROD

IDLER ARM ASSEMBLY RELAY ROD TIE ROD ASSEMBLY TIE ROD STEERING GEAR ASSEMBLY

STEERING ARM

PITMAN ARM

STEERING ARM

STEERING GEAR KNUCKLE PITMAN ARM

G-SERIES
CONNECTIN ROD

K-SERIES

SUPPORT ASSEMBLY SUPPORT PITMAN ARM LEFT IDLER ARM

/ GEAR MOUNTING BRACKET

IDLER ARM ASSEMBLY STEERING GEAR PITMAN ARM

P-SERIES

Fig. 3B6-3--Steering Linkage

3B6-4

STEERING LINKAGE

IMPORTANT
WHENEVER ANY OF THE CRIMP NUTS OR STUDS AT THE (5) LOCATIONS SHOWN ARE LOOSENED OR REMOVED, THE FOLLOWING STEPS MUST BE TAKEN: A. WHEN RE-ATTACHING ANYTWO COMPONENTS BY MEANS OF A BALL STUD, CAREFULLY POSITION THE TWO PARTS. THEN IN STALL A FREE-SPINNING NUT, AND DRAW THE ITEMS TOGETHER TO SEAT THE TAPER, TORQUE NUT TO 54 N m (40 FT-LBS), THEN REMOVE NUT. B. THEN USE A TORQUE PRE VA ILIN G SERVICE REPLACEMENT NUT (#351249) AND TORQUE TO 90 N-m (66 FT-LBS),

Fig. 3B6-4 Typical Crimp Nut Locations

NOTE Slot in adjuster sleeve must not be w itn in this area o f clamp jaws.

CAUTION Clamps must be between


& clear o f dim ples before to rq u in g nut.

E ROD - OUTER ADJUSTER SLEEVE SLOT R EARW AR DR O TATIO N NOTE Locate clamps w itn in tolerance shown. S TEE R IN G K N U C K LE

VIEW A

NOTE Equal w ith in three threads, must be visible at inner and outer ends o f adjuster sleeve when assembled to steering knuckle. NOTE Locate clamps w itn in tolerance shown.
H O R IZ O N T A L LIN E TIGHT

NOTE Slot in adjuster


sleeve must not be w ith in this area o f clam p jaws. .005 M IN . GAP

T IG H T

.005 M IN . GAP

CAUTION Clamp ends may


touch when nuts are torqued to specifications, but gap adjacent to adjuster sleeve must not be less than m inim um dimension shown.

VIEW B

REARW AR D R O TATIO N

AD JU STE R SLEEVE SLOT

CAUTION Clamp ends may touch when nuts are torqued to specifications, b u t gap adjacent to adjuster sleeve must n o t be less than m inim um dim ension shown. VIEW B

C,K & P

VIEW A

Fig. 3B6-5~Tie Rod Clamp Relationship

STEERING LINKAGE
2. Make sure that threads on ball studs and in ball stud nuts are clean and smooth. If threads are not clean and smooth, ball studs may turn in tie rod ends when attempting to tighten nut. Check condition of ball stud seals; replace if necessary. Tool J-24434 may be used to install ball stud seals. 3. Install ball studs in steering arms and relay rod. For the inner tie rod ends, use J-29193 or J-29194 to seat the tapers, as shown in Fig. 3B 6-4 .A torque of 20 N-m is required. With the tapers seated, remove the tool. 4. For the inner tie rod ends, install a torque prevailing ball stud nut, and tighten to 54 N-m (40 ft. lbs.). At the outer tie rod ends, install a ball stud nut, tighten to 70 N-m (50 lb. ft.), and install new cotter pins. Lubricate tie rod ends. 5. Adjust toe-in as described in Section 3A. Before tightening the tie rod adjusting sleeve clamp bolts, be sure that the following conditions have been met: a. The sleeve clamps must be positioned between the locating dimples at either end of the sleeve. b. The clamps must be positioned within the angular travel indicated in Figure 3B6-5. c. The relationship of the clamp slot with the slit in the sleeve should be maintained as shown in Figure 3B14. d. Rotate both inner and outer tie rod housing rearward to the limit of ball joint travel before tightening clamps. Tighten clamps to 22 N-m, 16 ft. lbs. Return tie rod assembly to the center of travel. e. All procedures for alignment, adjustm en t and assembly of tie rods applies to each side. f. Check each assembly to be sure that a total travel of at least 35 can be obtained using a bubble protractor and a pair of vise grips.
Inspection

3B6-5

If rotating checks, outlined above, reveal a rough or lumpy feel, the inner or outer tie rod end assembly may have excessive wear and should be replaced. If all of the above mentioned conditions are met, proper tie rod installation is assured.

Fig. 3B6-6 Checking Idler Movement, Typical

RELAY ROD
Removal

1. Raise vehicle on hoist. 2. Remove inner ends of the tie rods from relay rod as described under "Tie Rod-Removal". 3. Remove the nuts from the pitman and idler arm ball studs at the relay rod. 4. Remove the relay rod from the pitman and idler arms by tapping on the relay rod ball stud bosses with a hammer, while using a heavy ham m er as a backing (Fig. 3B6-4). 5. Remove the relay rod from the vehicle.
Installation NOTICE: See the N O T IC E on page 1 of this section

To ensure proper installation, it is necessary to perform the following inspection after any change of toe setting or removal of any ball stud: 1. Check the total rotation of the tie rod assembly using the following procedure: a. Lubricate inner and outer tie rod ends. b. Attach vise grip pliers to the outer tie rod end. c. Rotate outer tie rod end counterclockwise (up) to maximum position. Attach bevel protractor. Center protractor bubble indicator and record reading. d. Rotate tie rod end clockwise (down) to maximum position. Center pro tractor bubble indicator and record reading. e. Compare protractor readings obtained in Steps c and d. Total rotation of tie rod assembly should measure at least 35. f. If rotation is less than 35, loosen one tie rod sleeve clamp and rotate both tie rod ends to their maximum limit both ends must be rotated in the same direction. g. Tighten tie rod clamp and again rotate both ends to their maximum limits, repeating Steps c and d. This recheck of total rotation will result in a minimum of 35 travel. h. After obtaining the correct amount of rotation (35 or greater), position the outer tie rod end approximately midway in this travel.

regarding the fasteners referred to in steps 2 and 3. 1. Make sure that threads on the ball studs and in the ball stud nuts are clean and smooth. If threads are not clean and smooth, ball studs may turn in sockets when attempting to tighten nut. Check condition of ball stud seals; replace if necessary. 2. Install the relay rod to the idler arm and pitman arm ball studs, making certain the seals are in place. Use a free-spinning nut to seat the tapers, as shown in Fig. 3B6-4. 3. Install the tie rods to the relay rod as previously de scribed under Tie Rod- Installation . Lubricate the tie rod ends. 4. Lower the vehicle to the floor. 5. Adjust toe-in (see Section 3A) and align steering wheel as described previously in Section 3B4 under "Steering Wheel Alignment and High Point Centering".

3B6-6

STEERING LINKAGE

IDLER ARM (EXCEPT P SERIES MOTORHOME)


Use of the proper diagnosis and checking procedure is essential to prevent needless replacement of good idler arms. 1. Raise the vehicle in such a manner as to allow the front wheels to rotate freely and the steering mechanism freedom to turn. Position the wheels in a straight ahead position. 2. Using a spring scale located as near the relay rod end of the idler arm as possible, exert a 25 lb. force upward and then downward while noticing the total distance the end of the arm moves. This distance should not exceed 1 / 1 6 inch for a total acceptable movement of 1/8 inch (Figure 3B6-6). It is necessary to ensure that the correct load is applied to the arm since it will move more when higher loads are applied. It is also necessary that a scale or ruler be rested against the frame and used to determ ine the am ount of movement since observers tend to over-estimate the actual movement when a scale is not used. The idler arm should always be replaced if it fails this test. Jerking the right front wheel and tire assembly back and forth, thus causing an up and down movement in the idler arm is not an acceptable method of checking since there is no control on the amount of force being applied. Caution should be used in assuming shimmy complaints are caused by loose idler arms. Before suspecting suspension or steering components, technicians should eliminate shimmy excitation factors, such as dynamic imbalance, run-out or force variation of wheel and tire assemblies and road surface irregularities.
Removal

IDLER ARM-P SERIES MOTORHOME


The frame mounted idler support assembly is adjustable for support shaft end play. Check for idler arm movement at the relay rod end as indicated above. If the movement at the end of the arm exceeds 1/16 inch ( 1/8 inch total movement), readjust the support shaft end-play as follows: 1. Loosen the support assembly jam nut. 2. Tighten the adjusting plug to metal-to-metal contact. 3. Back off the adjusting plug 1/8 of a turn (1/2 of a flat on the square nut, or 45 ). 4. Retorque the jam nut to 25-35 ft. lbs., while taking care that the adjusting plug does not rotate.

PITMAN ARM
Removal

1. Raise vehicle on hoist. 2. Remove nut from pitman arm ball stud. 3. Remove pitman arm or relay rod from ball stud by tapping on side of rod or arm (in which the stud mounts) with a hammer while using a heavy hammer or similar tool as a backing. Pull on linkage to remove from stud. 4. Remove pitman arm nut from pitman shaft or clamp bolt from pitm an arm, and m ark relation of arm position to shaft. 5. Remove pitman arm, using Tool J-6632 or J-5504.
Installation NOTICE: See the N O T IC E on page 1 of this section

1. Raise vehicle on a hoist. 2. Remove the nut from ball stud at the relay rod. Remove the ball stud from the relay rod by tapping on the relay rod boss with a hammer, while using a heavy hammer as a backing. 3. Remove the idler arm to frame bolt and remove the idler arm assembly.
Installation NOTICE: See the N O T IC E on page 1 of this section regarding the fasteners referred to in steps 1 and 3.

regarding the fasteners referred to in steps 3 and 4. 1. Install pitman arm on pitman shaft, lining up the marks made upon removal.
NOTICE: If a clamp type pitman arm is used, spread the

pitman arm just enough, with a wedge, to slip arm onto pitman shaft. Do not spread pitman arm more than required to slip over pitman shaft with hand pressure. Do not hammer or damage to steering gear may result. Be sure to install the hardened steel washer before installing the nut. 2. Make sure that threads on ball studs and in ball stud nuts are clean and smooth. If threads are not clean and smooth, ball studs may turn in sockets when attempting to tighten nut. Check condition of ball stud seals; replace if necessary. 3. Install pitman shaft nut or pitman arm clamp bolt and torque to specifications; (C, G Series - 260 N-m (192 ft. lbs.), K Series - 125 N-m (92 ft. lbs.), P Series - 180 N-m (132 ft. lbs.). 4. Position ball stud onto pitman arm or relay rod. Use a 5/8-18 free spinning nut to seat the tapers, as shown in Fig. 3B6-4. 5. Lubricate ball studs.

1. Position the idler arm on the frame and install the mounting bolts (special plain washers under bolt heads); torque the nuts to 40 N-m, 30 ft. lbs. 2. Make sure that the threads on the ball stud and in the ball stud nut are clean and smooth. If threads are not clean and smooth, ball stud may turn in the socket when attempting to tighten nut. Check condition of ball stud seal; replace if necessary. 3. Install the idler arm ball stud in the relay rod, making certain the seal is positioned properly. Use a 5/8-18 free-spinning nut to seat the tapers, as shown in Fig. 3B6-4. 4. Lower the vehicle to the floor.

6. Lower the vehicle to the floor.

STEERING LINKAGE

3B6-7

CAUTION: ENDS OF ADJUSTABLE T IE ROD MUST BE HELD IN CORRECT RELATIONSHIP TO EACH OTHER AFTER ADJUSTMENT WITHIN + 2 .

CAUTION: CLAMPS MUST BE BETWEEN AND CLEAR OF DIMPLES BEFORE TORQUING NUT. NOTE: STEERING CONNECTING ROD MUST BE INSTALLED WITH SHORT END FORWARD.

STEE R IN G G E A R ASSEMBLY

.10 C LA M P

VIEW

NOTE: SLOT OF ADJUSTER TUBE MAY BE IN ANY POSITION ON ARC SHOWN BUT NOT CLOSER THAN .10 TO THE EDGE OF CLAMP JAWS OR BETWEEN THEM

ADJUSTER TUBE

Fig. 3B6-7--Adjustable Connecting Rod Assembly - K Series

STEERING CONNECTING ROD (K MODELS ONLY)


Removal

1. Remove cotter pins from ball studs, and then remove the castellated nuts. 2. Remove ball studs from steering arm and pitman arm boss with a heavy ham m er and striking other side of boss with lighter h a m m e r .
Installation NOTICE: See the N O T IC E on page 1 of this section

smooth, ball studs may turn in connecting rod when attem ptin g to tighten nut. Check condition of ball stud seals-replace if necessary. 2. Install ball studs and torque to 120 N m, 89 ft. lbs. Never back off nut to install cotter pin, always tighten nut to next slot that lines up with hole in stud. 3. Install ball stud nuts and to 95 N m (70 ft. lbs.) 4. Install cotter pins and lubricate ball studs. For proper alignment and orientation of connecting rod clamps see Figure 3B6-7.

regarding the fasteners referred to in step 3. 1. Make sure that threads on ball studs and in ball stud nuts are clean and smooth. If threads are not clean and

SPECIFICATIONS AND SPECIAL TOOLS


Refer to Specifications and Special Tools at end of Section 3B4.

POWER STEERING SYSTEMS 3B7-1

POWER STEERING SYSTEM


The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology. "See Notice on Page 1 of this section ". N O T ICE This fastener is an important attaching part in that it could affect the performance of vital components and systems, an d/or could result in major repair expense. It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part.

CONTENTS
General Description........................................................................................ 3B7-1 Maintenance and A d ju stm e n ts.................................................................... 3B7-1 On-Vehicle Service......................................................................................... .3B7-3 Power Steering G e a r .....................................................................................3B7-3 Power Steering P u m p ....................................................................................3B7-4 Specifications.....................................................................................................3B7-17 Special Tools......................................................................................................3B7-16 Unit R e p a ir ....................................................................................................... .3B7-7

GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This gear provides for ease of handling by transmitting forces

fr m

wormshaft to the pitman shaft through the use of

^ear^n 8s-

MAINTENANCE AND ADJUSTMENTS


LUBRICATION OF POWER STEERING PUMP
Check the fluid level in the pump reservoir according to the intervals listed in Section OB. Use only an approved power steering lubricant in the pump. NOTICE: Never use brake fluid in the power steering pump, or damage may occur. front end alignment, shock absorbers, wheel balance and tire pressure for possible steering system problems. See Diagnosis steps listed earlier in Section 3. Once it is determined to make adjustments, refer to Section 3B of the Overhaul M anual for specific instructions.

STEERING GEAR HIGH POINT CENTERING


1. Set front wheels in straight ahead position. This can be checked by driving vehicle a short distance on a flat surface to determine steering wheel position at which vehicle follows a straight path. 2. With front wheels set straight ahead, check position of m ark on w orm shaft designating steering gear high point. This m ark should be at the top side of the shaft at 12 oclock position and lined up with the m ark in the coupling lower clamp. 3. On C, G and P series, if gear has been moved off high point when setting wheel in straight ahead position, loosen the adjusting sleeve clamps on both left and right hand tie rods. Then turn both sleeves an equal number of turns in the same direction to bring gear back on high point. Turning the sleeves an unequal number of turns or in different directions will disturb the toe-in setting of the wheels. 4. On K series, if the gear has been moved off high point when setting wheels in straight ahead position, loosen the adjusting sleeve clamps on the connecting rod. Then turn sleeve to bring gear back on high point.

ADJUSTMENTS Power Steering Gear Adjustment Procedure


Adjustment of the steering gear in the vehicle is not recomm ended because of the difficulty encountered in adjusting the worm th ru s t bearing preload and the confusing effects of the hydraulic fluid in the gear. Since a gear adjustment is made only as a correction and not as a periodic adjustment, it is better to take the extra time and make the adjustment correctly the first time. Since a handling stability complaint can be caused by improperly adjusted worm bearings as well as an improper gear over-center adjustment, it is necessary that the steering gear assembly be removed from the vehicle and both thrust bearing and over-center preload be checked and corrected as necessary. An in-vehicle check of the steering gear will not pin-point a thrust bearing looseness. Before any adjustments are made to the steering gear attem pt to correct complaints of loose or hard steering, or other wheel disturbances, a careful check should be made of

3B7-2

POWER STEERING SYSTEMS

AD J U S TM EN T

C- .

SL0T

^
>*

S.
""V 1

^ . s n .

PIVOT BO LT S

Fig. 3B7-1-Adjusting Pump Position

5. R eadjust toe-in as outlined necessary).

in Section

3A

(if

6. Be sure to properly orient sleeves and clamps, as shown


in Section 3B1, when fastening and torquing clamps to proper specifications.

7. Turn the wheels (off ground) right and left, lightly contacting the wheel stops. 8. Add oil if necessary. 9. Lower the vehicle and turn wheels right and left on the ground. 10. Check oil level and refill as required. 11. If oil is extremely foamy, allow vehicle to stand a few minutes with engine off and repeat above procedure. a. Check belt tightness and check for a bent or loose pulley. (Pulley should not wobble with engine running.) b. Check to make sure hoses are not touching any other parts of the truck, particularly sheet metal except where design calls for a clamp. c. Check oil level, filling to proper level if necessary, following operations 1 through 10. This step and Step " d " are extremely important as low oil level a nd/or air in the oil are the most frequent causes of objectional pump noise. d. Check the presence of air in the oil. If air is present, attempt to bleed system as described in operations 1 through 10. If it becomes obvious that the pump will not bleed after a few trials, proceed as outlined under Hydraulic System Checks.

HYDRAULIC SYSTEM CHECKS


The following procedure outlines methods to identify and isolate power steering hydraulic circuit difficulties. The test provides means of determining whether power steering system hydraulic parts are actually faulty. This test will result in readings indicating faulty hydraulic operation, and will help to identify the faulty component. Before perform ing hydraulic circuit test, carefully check belt tension, fluid level and condition of driving pulley.

PUMP BELT TENSION ADJUSTMENT


1. Loosen pivot bolt and pump brace adjusting nuts. See Fig. 3B7-1.
NOTICE: Do not move pump by prying against reservoir or by pulling on filler neck, or damage to the pump could occur.

2. Move pump, with belt in place until belt is tensioned to specifications as indicated by Tool J-23600 (Fig. 3B72). See Figure 3B7-3. 3. Tighten pump brace adjusting nut. Then tighten pivot bolt nut.

Power Steering System Test


Engine m ust be at normal operating tem perature. Inflate front tires to correct pressure. All tests are made with engine idling. C heck idle a d ju stm en t and, if necessary, adjust engine idle speed to correct specifications listed in Section 6C and proceed as follows:

FLUID LEVEL ADJUSTMENT


1. Check oil level in the reservoir by checking the dipstick when oil is at operating tem perature. On models equipped with remote reservoir, the oil level should be maintained approximately 1/2 to 1 inch from top with wheels in full left turn position. 2. Fill, if necessary, to proper level with G M Power Steering Fluid or equivalent.
NOTICE: Never use brake fluid in the power steering pump, or damage may occur.

BLEEDING HYDRAULIC SYSTEM


1. Fill oil reservoir to proper level and let oil remain undisturbed for at least two minutes. 2. S tart engine and run only for about two seconds. 3. Add oil if necessary. 4. Repeat above procedure until oil level remains constant after running engine. 5. Raise front end of vehicle so that wheels are off the ground. 6. Increase engine speed to approximately 1500 rpm.

POWER STEERING SYSTEMS 3B7-3

NOTICE: Do not leave valve fully closed for more than

BELT TENSION

5/16" WIDE NEW BELT USED BELT USED COGGED BELT 350 N Max. 80 Lbs. Max. 200 N Min. 50 Lbs. Min.

3/8" WIDE 620 N Max. 140 Lbs. Max. 300 N Min. 70 Lbs. Min. 250 N Min. 60 Lbs. Min.

15/32 WIDE 750 N Max. 165 Lbs. Max. 400 N Min. 90 Lbs. Min.

Fig. 3B7-3--Belt Tension Chart

1. With engine NOT running disconnect pressure hose from pum p and install Tool J-5176 using a spare pressure hose between gage and pump. Gage must be between shut-off valve and pump (Fig. 3B7-4). Open shut-off valve. 2. Remove filler cap from pump reservoir and check fluid level. Fill pump reservoir to full m ark on dipstick. Start engine and, m om entarily holding steering wheel against stop, check connections at Tool J-5176 for leakage. 3. Bleed system as outlined under M a inten a nc e and Adjustments. 4. Insert thermometer (Tool J-5421) in reservoir filler opening. Move steering wheel from stop to stop several times until thermometer indicates that hydraulic fluid in reservoir has reached tem perature of 150 to 170F.
NOTICE: To prevent scrubbing flat spots on tires, do not turn steering wheel more than five times without rolling vehicle to change tire-to-floor contact area.

5. Start engine and check fluid level adding any fluid if required. W hen engine is at normal operating tem perature, the initial pressure read on the gage (valve open) should be in the 80-125 PSI range. Should this pressure be in excess of 200 PSI, check the hoses for restrictions and the poppet valve for proper assembly. 6. Close gate valve fully 3 times. Record the highest pressure attained each time.

5 seconds as the pump could be damaged internally. a. If the pressures recorded are within the listed specs and the range of readings are within 50 PSI, the pump is functioning within specs. (Ex. Spec. 12501350 PSI - readings - 1270-1275-1280). b. If the pressures recorded are high, but do not repeat with 50 PSI, the flow controlling valve is sticking. Remove the valve, clean it and remove any burrs using crocus cloth or fine hone. If the system contains some dirt, flush it. If it is exceptionally dirty, both the pump and the gear must be completely disassembled, cleaned, flushed and reassembled before furth er usage. c. If the pressures recorded are constant, but more than 100 PSI, below the low listed spec., replace the flow control valve and recheck. If the pressures are still low, replace the rotating group in the pump. 7. If the pump checks within specifications, leave the valve open and turn (or have turned) the steering wheel into both corners. Record the highest pressures and compare with the maximum pump pressures recorded. If this pressure cannot be built in either (or one) side of the gear, the gear is leaking internally and must be disassembled and repaired. See the current Overhaul Manual. 8. S h u t off engine, remove testing gage, spare hose, reconnect pressure hose, check fluid level an d/or make needed repairs.

ON-VEHICLE SERVICE
POWER STEERING GEAR Removal
1. Disconnect hoses at gear. W hen hoses are disconnected, secure ends in raised position to prevent drainage of oil. Cap or tape the ends of the hoses to prevent entrance of dirt. 2. Install two plugs in gear fittings to prevent entrance of dirt. 3. Remove the flexible coupling to steering shaft flange bolts (G, C and K models) or the lower universal joint pinch bolt (P models). M ark the relationship of the universal yoke to the stub shaft. 4. M a rk the relationship of the pitm an a rm to the

3B7-4

POWER STEERING SYSTEMS

2. Place the steering gear in position, guiding the coupling bolt into the steering shaft flange. 3. Install the steering gear to frame bolts and torque to specifications. 4. If flexible coupling alignment pin plastic spacers were used, make sure they are buttomed on the pins, tighten the flange bolt nuts to specifications and then remove the plastic spacers. 5. If flexible coupling alignment pin plastic spacers were not used, center the pins in the slots in the steering shaft flange and then install and torque the flange bolt nuts to specifications.
P Models

Fig. 3B7-5--Removing Pitman Arm

pitman shaft. Remove the pitman shaft nut or pitman arm pinch bolt and then remove the pitman arm from the pitman shaft using Puller J-6632 (Fig. 3B7-5). 5. Remove the steering gear to frame bolts and remove the gear assembly.

a. Place the steering gear in position, guiding the stud shaft into the universal joint assembly and lining up the marks made at removal. If a new gear was installed, line up the mark on the stub shaft with the mark on the universal yoke. b. Install the steering gear to frame bolts and torque to specifications. c. Install the universal joint pinch bolt and torque to specification. The pinch bolt must pass through the shaft undercut.
A ll Models

6. Install the pitman arm onto the pitman shaft, lining up


the marks made at removal. Install the pitman shaft nut or pitm an arm pinch bolt and torque to specifications. 7. Remove the plugs and caps from the steering gear and hoses and connect the hoses to the gear. Tighten the hose fittings to specified torque.

6. G, C and K Models - Remove the flexible coupling


pinch bolt and remove the coupling from the steering gear stub shaft.

Installation (Fig. 3B7-6)


NOTICE: See N O T I C E on Page 1 of this section regarding the fasteners referred to in Steps 1, 3 ,4 and 5. 1. Install the flexible coupling onto the steering gear stub shaft, aligning the flat in the coupling with the flat on the shaft. Push the coupling onto the shaft until the stub shaft bottoms on the coupling reinforcement. Install the pinch bolt and torque to specifications. NOTICE: The coupling bolt must pass through the shaft

POWER STEERING PUMP (3B7-7 THROUGH 3B717)

Removal
1. Disconnect hoses at pump. W hen hoses are disconnected, secure ends in raised position to prevent d rainage of oil. C ap or tape the ends of the

Fig. 3B7-6--Power Steering Gear Mounting-Typical

undercut, or damage to the components could occur.

Fig. 3B7-7-P/S Pump Mounting, CK10,20,30 w/LE9/LF3/LS9 Exc. C 60/C 69

POWER STEERING SYSTEMS 3B7-5

Fig. 3B7-8-P/S Pump Mounting, CK10,20,30 w/LE9/LS9/LT9 and C69

Fig. 3B7-10--P/S Pump Mounting, CK10,20,30 w/LE8

2. 3. 4. 5.

hoses to prevent entrance of dirt. On Models with remote reservoir, disconnect reservoir hose at pump and secure in raised position. Cap hose pump fittings. Install two caps at pump fittings to prevent drainage of oil from pump. Loosen bracket-to-pump mounting nuts. Remove pump belt. Remove pump from attaching parts and remove pump from vehicle.

Installation
1. Position pum p assembly on vehicle and install attaching parts loosely. 2. Connect and tighten hose fittings. 3. Fill reservoir. Bleed pump by turning pulley backward (counter-clockwise as viewed from front) until air bubbles cease to appear. 4. Install pump belt over pulley. 5. Tension belt as outlined u nd er " P u m p Belt

NB2

Tension-Adjustment" in this section.

6. Bleed as outlined under "B leeding Power Steering


System ".

POWER STEERING HOSES


W hen servicing the power steering hoses be sure to align the hoses in their correct position as shown in the following figures. It is im p orta n t th a t the power steering hoses be installed correctly. Hoses installed out of position may be subjected to chafing or other abuses during sharp turns. Do not twist hoses unnecessarily during installation. NOTICE: Do not start engine with any power steering hose disconnected, or damage to the components could occur.

SPECIFICATIONS SPECIAL TOOLS


Fig. 3B7-9--P/S Pump Mounting, CK10,20,30 w /LE 9/LF9/LS 9/ LT9 and C60

Refer to Specifications and Special Tools at end of Section 3B5.

3B7-6

POWER STEERING SYSTEMS

Fig. 3B7-13--P/S Pump Mounting, G 1 0,20,30 w/LE3 Fig. 3B7-15--P/S Pump Mounting, P10,20,30 w /L 25 and JB7

POWER STEERING SYSTEMS 3B7-7

Fig. 3B7-16--P/S Pump Mounting, P10,20,30 w/LT9

Fig. 3B7-17--P/S Pump Mounting, P30 w/LE8

3B7-8

POWER STEERING SYSTEMS

REMOVE AND INSTALL DRIVE SHAFT SEAL WITHOUT DISASSEMBLING THE PUMP.
REMOVE 1. PROTECT DRIVE SHAFT WITH SHIM STOCK. 2. USE CHISEL TO CUT SEAL AND REMOVE. : h is e l rDRlVE SHAFT SHIM STOCK -HYDRAULIC PUMP ASSEMBLY INSTALL

4. REMOVE AND INSTALL ROTATING GROUP.


REMOVE INSTALL

I. COAT DRIVE SHAFT SEAL WITH HYDRAULIC PUMP FLUID. REFER TO INSET FOR DRIVE SHAFT SEAL INSTALLATION.

J. USING A RUBBER MALLET. TAP LIGHTLY ON DRIVE SHAFT UNTIL PRESSURE PLATE IS FREE. 2. REMOVE RETAINING RING FROM DRIVE SHAFT AND DISCARD. REMOVE PARTS AS SHOWN.

1. - INSTALL parts AS shown ON DRIVE SHAFT. INSTALL NEW RETAINING RING ON DRIVE SHAFT AND INSTALL IN PUMP HOUSING. 2. REFER TO INSET FOR POSITIONING OF PUMP RING IN HOUSING.

VANES
NOTICE: INSTALL WITH

PRESSURE PLATE

ROUNDED EDGE OF VANES OUTWARD.

ARROW -DRIVE SHAFT SEAL

PUMP RING

INSTALL PUMP RING.

INSTALL DRIVE SHAFT SEAL.

SHAFT, ROTOR AND THRUST PLATE ASSEMBLY HOUSING ASSEMBLY

2. REMOVE AND IN S T A L L PUMP RESERVOIR ASSEMBLY


REMOVE INSTALL

t. DRAIN OIL FROM RESERVOIR ASSEMBLY BEFORE REMOVAL. 2. REMOVE PARTS AS SHOWN

USE ALL NEW SEALS AND LUBRICATE WITH POWER STEERING FLUID BEFORE INSTALLATION INSTALL PARTS AS SHOWN.

^
RESERVOIR CAP ASSEMBLY* WELCH PLUG
DO NOT REMOVE. IF DEFORMED OR DISLOOGED. REPLACE HOUSING ASSEMBLY,

SHAFT RETAINING RING F L THRUST PLATE not' SHAFT -DRIVE

RETAINING RING REMOVAL

,STUD OR BOLT* /^ T O R Q U E TO 35 N m w fii 1 -ITTING ASSEMBLY ]<5r TORQUE TO 50 N m NO-RING SEAL v_PUMP RESERVOIR ASSEMBLY*

MAGNET *

5. REMOVE AND IN S T A L L DRIVE SH AFT AND O -R IN G SEALS.


REMOVE INSTALL

I. REMOVE PARTS AS SHOWN.

O-RING SEALS* HOUSING ASSEMBLY

NO T USED ON 125-N SE RIES

REFER TO THE INSET ^OR DRIVE SHAFT SEAL INSTALLATION. USE ALL NEW SEALS AND LUBRICATE SEALS WITH POWER STEERING FLUID BEFORE INSTALLATION. NSTALL PARTS AS SHOWN.

3. REMOVE AND IN S T A L L END PLATE.


REMOVE INSTALL

t. REFER TO INSET FOR RETAINING RING REMOVAL.

r SCREWDRIVER rPUNCH

!. LUBRICATE END PLATE AND RETAINING RING. INSTALL PARTS AS SHOWN. REFER TO INSET FOR POSITIONING OF RETAINING RING IN HOUSING,

DOWEL PINS

0 RING SEALS HOUSING ASSEMBLY

REMOVE RETAINING RING

l-RETAINING RING LOCATE RING GAP AT POSITION SHOWN

DRIVE SHAFT SEAL

END PLATE PRESSURE PLATE SPRING POSITIONING


of r e t a in in g

.J
r in g .

END PLATE RETAINING RING -CONTROL VALVE ASSEMBLY -FLOW CONTROL SPRING -HOUSING ASSEMBLY
-NOTICE

BEFORE PROCEEDING. EXAMINE THIS PART OF THE DRIVE SHAFT. IF IT IS CORRODED, CLEAN WITH CROCUS CLOTH 8EFORE REMOVING. THIS WILL PREVENT DAMAGE TO THE SHAFT BUSHING WHICH MIGHT REQUIRE REPLACEMENT OF THE ENTIRE HOUSING.

Fig. 3B7-18--P/S Pump Overhaul

POWER STEERING SYSTEMS 3B7-9

POWER STEERING GEAR (800 MODEL)


GENERAL DESCRIPTION

These Integral Power Steering Gears have a control valve which directs oil to either side of the rack piston. The rack piston converts hydraulic power into mechanical force. This force is transmitted to the mating pitman shaft teeth, through the pitman shaft to the steering linkage. The model 800 incorporates a recirculating ball system in which steel balls act as a rolling thread between a steering worm-shaft and the rack-piston.

W henever a part which forms a sealing surface for an O ring is removed, the 0 ring seal should also be removed and replaced with a new seal. W hen ever one of the Pitman shaft or stub shaft seals are removed all adjacent seals should be removed and replaced with new seals. Lubricate all new seals with power steering fluid to ease assembly

* |r

Mam*

Kty lit.

Mtmt

Her No

Nam e

1 -H O U S IN G . STEERING GEAR 2 RACE. THRUST BEAPING (WORM) 3 -B E A R IN G ASSY , ROLLER THRUST (WORM) 4 -R A C E . THRUST BEARING (WORM) 5 - W O R M , STEERING 6 -S E A L , "O " RING (STUB SHAFT) 7 - SHAFT, STUB 8 -S P O O L , VALVE 9 -S E A L , "O " RING (SPOOL) 1 0 -B O D Y , VALVE 11 - RING, VALVE BODY (3) 1 2 -S E A L , "O " RING (VALVE BODY) (3) 1 3 -RETA IN ER, BEARING (ADJUSTER) 1 4 -SPA C E R . THRUST BEARING 1 5 - R A C E , UPPER THRUST BEARING (SMALL) 1 6 -B E A R IN G . UPPER THRUST 1 7 -R A C E . UPPER THRUST BEARING (LARGE) 1 8 -S E A L , "O " RING (ADJUSTER)

1 9 - P L U G ADJUSTER 70 - BEARING. NEEDLE 21 SEAL, STUB SHAFT 22 - SEAL, STUB SHAFT DUST 23 - RING, RETAINING 24 NUT, ADJUSTER PLUG LOCK 25 BEARING ASSY NEEDLE (PITMAN SHAFT) 26 SEAL, PITMAN SHAFT (SINGLE LIP) 2 7 -W A S H E R , SEAL BACK-UP (PITMAN SHAFT) 2 8 -SE A L , PITMAN SHAFT (DOUBLE LIP) 2 9 -W A S H E R SEAL BACK-UP (PITMAN SHAFT) 3 0 -R IN G , RETAINING (PITMAN SHAFT SEAL) 31 -W A S H E R , PITMAN SHAFT LOCK 32 - NUT, PITMAN SHAFT 33 - NUT, RACK PISTON 34 - BALL 35 - GUIDE, BALL RETURN (2) 36 CLAMP, BALL RETURN GUIDE

37 38 39 40 41 42 43 44 45 46 4/ 48 49

50
51 52

SCREW ASSY LOCKWASHER & (2) PLUG RACK PISTON SEAL O RING (RACK PISTON) RING, RACK PISTON SEAL O RING (HOUSING END PLUG) PLUG HOUSING END RING RETAINING (HOUSING END PLUG) GEAR ASSY PITMAN SHAFT SEAL ASSY GASKET COVER ASSY , HOUSING SIDE BOLT HEX HEAD {SIDE COVER) (4) NUT. LASH ADJUSTER SPRING. CHECK VALVE POPPET CHECK VALVE CONNECTOR INVERTED FLARE CONNECTOR INVERTED FLARE

!* t

:M L A

:^T LU ^
(5)
(31 > -------

(!])
S

POWER STEERING GEAR EXPLODED VIEW (Model 800)

383051072

Fig. 3B7-19--Overhaul 800 /8 0 8 Gear, Chart A

3B7-10 POWER STEERING

P f Nm m

K ty No.

P e rf M onti

Key No.

P o rt Nome

1 -HOUSING, STEERING GEAR 2 -RACE, THRUST BEARING (WORM) 3 -BEARING ASSY., ROLLER THRUST (WORM) 4 -RACE, THRUST BEARING (WORM) 5 -W O R M , STEERING 6 -SEAL, "O " RING (STUB SHAFT) 7 -SHAFT, STUB 8 -SPO O L, VALVE 9 -SEAL, "O " RING (SPOOL) 1 0 -B O D Y , VALVE 11 - RING, VALVE BODY (3) 1 2 -SEAL, "O " RING (VALVE BODY) (3) 1 3 -RETAINER, BEARING (ADJUSTER) 1 4 - SPACER, THRUST BEARING 1 5 -R A C E, UPPER THRUST BEARING (SMALL) 1 6 -BEARING, UPPER THRUST 1 7 - RACE, UPPER THRUST BEARING (LARGE) 1 8 - SEAL, "O" RING (ADJUSTER)

1 9 - PLUG, ADJUSTER 2 0 -BEARING. NEEDLE 2 1 -SEAL, STUB SHAFT 2 2 -SEAL, STUB SHAFT DUST 2 3 -R IN G , RETAINING 24 - NUT, ADJUSTER PLUG LOCK 2 5 -BEARING ASSY., NEEDLE (PITMAN SHAFT) 2 6 -SEAL. PITMAN SHAFT (SINGLE LIP) 2 7 -WASHER, SEAL BACKUP (PITMAN SHAFT) 2 8 -SEAL, PITMAN SHAFT (DOUBLE LIP) 2 9 -WASHER, SEAL BACK-UP (PITMAN SHAFT) 3 0 -RIN G , RETAINING (PITMAN SHAFT SEAL) 3 1 -WASHER, PITMAN SHAFT LOCK 3 2 -N U T , PITMAN SHAFT 3 3 -N U T , RACK PISTON 34 - BALL 3 5 -GUIDE, BALL RETURN (2) 3 6 -CLAMP, BALL RETURN GUIDE

3 7 -SCREW ASSY., LOCKWASHER & (2) 3 8 -PLU G , RACK PISTON 3 9 -SEAL, "O" RING (RACK PISTON) 4 0 -R IN G , RACK PISTON 41 -SEAL, "O" RING (HOUSING END PLUG) 4 2 -PLUG, HOUSING END 4 3 -R IN G , RETAINING (HOUSING END PLUG) 4 4 -G EA R ASSY., PITMAN SHAFT 4 5 -SEA L ASSY., GASKET 4 6 -CO V ER ASSY., HOUSING SIDE 4 / -BOLT, HEX. HEAD (SIDE COVER) (4) 4 8 - NUT, LASH ADJUSTER 49 - SPRING, CHECK VALVE 5 0 -POPPET, CHECK VALVE 5 1 -CONNECTOR, INVERTED FLARE 5 2 -CONNECTOR, INVERTED FLARE 5 3 -BOLT, COUPLING PINCH 5 4 -COUPLING, STEERING SHAFT

SYSTEMS

Fig. 3B7-20-Overhaul 800/808 Gear, Chart B

I
U S E D O N S O M E M O D E LS

A s s e m b lie s a n d S e rv ic e K its

GEAR ASSY , STEERING VALVE ASSY., STEERING GEAR PLUG SERV. ASSY., ADJUSTER SEAL SERV. KIT, ADJUSTER PLUG SEAL SERV. KIT, VALVE RING & NUT SERV. KIT, RACK-PISTON HOUSING SERV. KIT, STRG. GEAR COVER SERV. KIT, HSG. SIDE GEAR SERV KIT, PITMAN SHAFT THIS NUMBER NOT USED SEAL SERV. KIT, END PLUG SEAL SERV. KIT, HSG. SIDE COVER SEAL SERV. KIT, MASTER SEAL SERV. KIT, RACK-PISTON VALVE SERV. KIT, 'CHECK SEAL SERV. KIT, PITMAN SHAFT BALL SERV. KIT, RECIRCULATING BEARING ASSY. SERV. KIT, UPR. THR. BEARING ASSY. SERV. KIT, LWR. THR.

POWER STEERING GEAR EXPLODED VIEW

POWER STEERING SYSTEMS

3B7-11

1. REMOVE AND INSTALL PITMAN SHAFT SEALS IN CAR


REMOVE
1. Clean exposed end o f pitm an shaft and end of housing after rem oving pitm an arm 2. Remove retaining ring w ith snap ring pliers J-4245 3. S ta rt engine and turn w heels fully to the left to fo rce seals and w asher out. 4. Turn o ff engine. 5. Inspect housing and shaft. PITMAN SHAFT Inspect seal surface fo r roughness and p ittin g

3. REMOVE AND INSTALL HOUSING END PLUG


REMOVE
1. Remove parts as shown.

INSTALL
1. Install parts as shown.

INSTALL
1. Install parts as shown. Open end o f retaining ring to be approx. 25 mm (1 inch) from access hole.

HOUSING ASSEMBLY Inspect fo r burrs

jr - iT
SEAL (SINGLE LIP) WASHER SEAL (DOUBLE LIP) WASHER RETAINING RING .------PITMAN ARM LOCK WASHER NUT-Torque

Retaining ring access hole

250 Newton Meters (185 Ft. Lbs.)

Remove Pitman Arm

Install Seals

2 . REMOVE AND INSTALL PITMAN SHAFT

4. REMOVE AND INSTALL RACK PISTON


REMOVE
1. Remove p a rts as show n.

AND SIDE COVER


REMOVE
If pitm an shaft and side cover are to be separated, remove preload adjuster nut Rotate stub shaft to center gear, then rem ove parts as shown

INSTALL
1. If removed, install gasket seal by bending tabs around cover edges 2. Install parts as shown. SIDE COVER BOLTS
T o rq u e t o 6 0 N e w to n M eters (4 0 F t. L bs.)

INSTALL
1. Install parts as shown.

When installing rack, care should be taken not to cut teflon seal, rack piston seal compressor J-7576 or J-8947 may be used to compress seal.

shaft and gasket seal from side cover if required

RACK PISTON PLUG M ust be rem oved before rem oving rack.

Insert ball retainer J-21552. Hold to o l tig h tly against w orm w h ile tu rn in g stub shaft co u n te r-clo ckw ise . The rack-piston w ill be forced o nto the tool. Remove the rack-piston and ball retainer from the gear housing together.

Fig. 3B7-21 -Overhaul 800 /8 0 8 Gear, Chart C

3B7-12

POWER STEERING SYSTEMS

5. REMOVE AND INSTALL ADJUSTER PLUG ASSEMBLY


REMOVE
Loosen lock nut. Use punch against edge of slots. 2 Remove adjuster plug using spanner w rench J-7624

7. REMOVE AND INSTALL BEARING, WORM, AND VALVE ASSEMBLY


REMOVE
1 Grasp stub shaft and rem ove valve and worm assembly as a unit.

INSTALL
1. Install parts as shown.

INSTALL
1. Install parts as shown.

LOCK NUT

Separate the valve from the worm Note how the pin in the worm fits the slot in the valve.-------"" THRUST BEARING AND R A C E S - tk ^

ADJUSTER P L U G ------\

When installing adjuster plug care should be taken not to cut seals.

VALVE ASSEMBLY WORM ASSEMBLY When reassembling gear make sure angle of thrust races are as shown.

6. DISASSEMBLE AND ASSEMBLE ADJUSTER PLUG ASSEMBLY


DISASSEMBLE
1. Disassem ble p a rts as shown.

ASSEMBLE
1. Assem ble parts as shown. ~

8. DISASSEMBLE AND ASSEMBLE VALVE


DISASSEMBLE
1. Disassem ble parts as shown. / / / / / /

ASSEMBLE

Assem ble parts as shown.

RETAINING RING STUB SHAFT DUST SEAL

VALVE BODY "O ' RING VALVE BODY VALVE SPOOL STUB SHAFT 7 \

L f STUB SHAFT SEAL * NEEDLE BEARING L ADJUSTER PLUG 'O ' RING SEAL UPPER BEARING RACE (LARGE) UPPER THRUST BEARING UPPER BEARING RACE (SMALL) J-29810 THRUST BEARING SPACER BEARING RETAINER RETAINER * Use stub shaft seal protector J-29810 on stub shaft when installing stub shaft seal. A

1
Shaft cap Loosen shaft cap

VALVE BODY RING (teflon) *

SPOOL TO BODY "O " RING * To ease assembly, soak - , teflon rings in warm water. B. Remove and install stub shaft.

Pull cap out approx. 6 mm('/<')

Screwdriver Pry bearing retainer at raised area. Remove bearing retainer. Tap lig h tly on w ood block Pin on shaft and hole in spool (Disengage to remove)

Use suitable size a rb o r to press bearing in place

C. Remove and install spool Bearing to be pressed 16 mm (%m ch) into adjuster w ith stam ped I D. end up and from d irectio n of arrow . Rotate w h ile rem oving or in sta llin g

Lub rica te spool and body w ith pow er steering fluid. Install bearing

Notch must fully engage pin and cap must seat against shoulder.

Fig. 3B7-22--Overhaul 80 0 /8 0 8 Gear, Chart D

POWER STEERING SYSTEMS 3B7-13

9.

DISASSEMBLE AND ASSEMBLE RACK PISTON


DISASSEM BLE 1. Disassemble parts as shown. Clean and inspect all parts for excessive wear. ASSEM BLE 1. Assemble parts as shown.

10. REMOVE AND INSTALL PITMAN SHAFT SEALS AND BEARING


REMOVE Clean end of housing thoroughly to prevent dirt from entering and be extremely careful not to score the housing bore. Remove retaining ring with snap ring pliers J-4245. Using screw driver, pry seals and washers from bore. PITMAN SHAFT SEAL (SINGLE LIP) PITMAN SHAFT SEAL (DOUBLE LIP) RETAINING RING INSTALL 1. Coat seal lip and washer face with anhydrous calcium grease. 2. Install parts as shown.

The black balls are smaller than the silver balls. The black and silver balls must be installed alternately into the rack-piston and return guide to maintain rack piston to worm gear preload.

HOUSING ASSEMBLY Inspect for burrs-------

TEFLON SEAL AND "O ' RING If replaced lubricate new seal and "O ring with power steering fluid.

Turn worm until worm groove is aligned with the lower ball return guide hole.

SEAL BACK UP WASHER

NEEDLE BEARING Remove only if it needs replacing.

WORM Slide all the way into the rack-piston.

Bearing remover J-6278

Removing bearing

Before assembling rack in housing, ball retainer J-21552 must be inserted into rack to allow removal of worm.

Lubricate balls with power steering fluid. Install balls, through ball return guide hole, while rotating worm counterclockwise.

Installer J-8092

Installer J-6219

GUIDEAlternately install remainder of balls and retain with grease at each end of guide.

Installer J-22407

CLAMP When tool bottom s on housing bearing is fully in sta lle d.-----------

SCREW-Tighten to 5 Newton Metres (4 Ft. Lbs.)

Install Pitman shaft bearing.

Install Pitman shaft seals.

Fig. 3B7-23~Overhaul 8 0 0 /8 0 8 Gear, Chart E

3B7-14

POWER STEERING SYSTEMS

11. REMOVE AND INSTALL CHECK VALVE


REMOVE
1. Remove parts as shown

13. PITMAN SHAFT OVER-CENTER SECTOR ADJUSTMENT

INSTALL
1. Install parts as shown

With small screwdriver, pry check valve from housing. Care should be taken not to damage threads when prying on edge of housing.

When gear is on center flat on stub shaft is normally on same side as, and parallel with, side cover.

Remove check valve

Using a piece of 3/8 tubing, 4 inches long, carefully drive the check valve into the housing.

Install check valve.

12. ADJUST THRUST BEARING PRELOAD


A. Using spanner wrench J-7624, tighten adjuster plug until thrust bearing is firmly bottomed, 27 Newton Metres (20 Ft. Lbs.) The block tooth on the Pitman shaft is in line with the over-center preload adjuster. -

B. Back off preload adjuster until it stops, then turn it in one full tu rn .-i

C. Turn adjuster in until torque to turn stub shaft is 0.6 to 1.2 Newton Metres (6 to 10 in. Lbs.) more than reading # 1 . ------

Mark housing and face of adjuster p lu g .------------------

Measure back counterclockwise 13 mm (V2") and place a second mark on housing

Turn adjuster counterclockwise until mark on face of adjuster lines up with second mark on h o u sin g .---------

Using punch in notch tighten lock nut securely. Hold adjuster plug to maintain alignment of the marks.

With gear at center of travel, check torque to turn stub shaft (reading #1).

Torque adjuster lock nut to 27 Newton Metres (20 Ft. Lbs.) ------------Prevent adjuster screw from turning while torqueing lock nut.

Fig. 3B7-24--Overhaul 800 /8 0 8 Gear, Chart F

POWER STEERING SYSTEMS 3B7-15

GENERAL SPECIFICATIONS LUBRICATION L u b rica n t.....................................................................................................................Power Steering Fluid No. 1050017 or equivalent ADJUSTMENTS Valve Assembly and Seal D rag............................................................. .....................................................0.1 to 0.4 N*m (1 to 4 in. lbs.) Thrust Bearing P re-lo a d ............................................... 0.3 to 0.4 N*m (3 to 4 in. lbs.) in excess o f valve assembly and seal drag. Overcenter A d ju stm en t.................0.6 to 1.2 N*m (6 to 10 in. lbs.) (new gear) 0.4 to 0.5 Nm (or 4 to 5 in. lbs.) (used gear) in excess o f combined thrust bearing pre-load. Adjustment o f the steering gear in the car is not recommended because o f the difficulty encountered in adjusting the worm thrust bearing preload and the confusing effects o f the hydraulic fluid in the gear. Since a gear adjustment is made only as a correction and not as a periodic adjustment, it is better to take the extra time arid make the adjustment correctly the first time. Since a handling stability complaint can be caused by improperly adjusted worm thrust bearings as well as an improper gear over-center adjustment, it is necessary that the steering gear assembly be removed from the car and both thrust bearing and over-center preload be checked and corrected as necessary. An in-car check o f the steering gear will not show a thrust bearing adjustment error.

TORQUE SPECIFICATIONS POWER STEERING PUMP N*m FT. LBS.

Reservoir Bolt........... Flow Control Fitting Pressure H o s e ...........

48 48 27

35 35 20

GENERAL SPECIFICATIONS POWER STEERING LUBRICATION L u b r ic a n t.............................................................................................................Power Steering Fluid No. 1050017 or equivalent Capacity (Exc. Diesel) - Complete S y s t e m .............................................................................. 1-1/4 Liters 1-1/4 Qts. Capacity (Diesel) - Complete System ....................................................................................... 1-3/4 Liters 1-3/4 Qts. Capacity - Pump O n l y ................................................................................. ..........................................1/2 Liter 1/2 Qt.

STEERING GEAR RECOM M ENDED TORQUE SPECIFICATIONS


N E W T O N M E T E R S F O O T -P O U N D S
Gear to Frame B o l t s ................................................... High Pressure Line Fitting (At Gear) ...................... Oil Return Line Fitting (At G e a r ) ........................... Adjusting Screw L ocknut........................................... Side Cover B o lts........................................................... Adjuster Plug Locknut................................................ Coupling Flange Nuts ................................................ Return Guide Clamp Screws . . . ............................. Rack-Piston Plug ........................................................ Pitman Shaft N u t ........................................................ Coupling Flange B o lt...................................................
110 27 27 27 60 110 27 5 100 240 40 ......................................... ......................................... ......................................... ......................................... ......................................... 80 20 20 20 45 ........................................... 80 ........................................... 20 ................................................. 4 ........................................... 75 ........................................... 185 ......................................... 30

Fig. 3B7-25-Overhual 800/808 Gear, Chart G

3B7-16

POWER STEERING SYSTEMS

POWER STEERING PUM P

J-25033 BT-7002-3 J-23600

J-25034 BT-7515

<=r-3
J 22616 J-7132-2

POWER STEERING GEAR

J-6221 J-7576 J-8947 J-29810 J-21552

J-6222 J-6217 J-5188

J-6278 J-7624

A
J-22407

J-29107 OR J-24319-01

J-5176-01 J-5188 J-6217 J-6221 J-6222 J-6278 J-6278-2 BT-7002-3 J-7132-2 BT-7515

Pressure Testing Manifold End Cover Seal and Needle Bearing Installer Hose Connector Installer Bearing Installer End Cover Seal Protector (Used for Installing Adjuster Plug) Pitman Shaft Bearing Remover and Installer Adapter (Used with J-6278 for Installing Pitman Shaft Seals and Bearing) Belt Tension Gage Seal Installer Pulley Remover and Installer

J-7576 J-7624 J-8947 J-21552 J-24319-01 J-22407 J-22616 J-23600 J-25033 J-25034 J-29107 J-29810

Rack-Piston Teflon Ring Compressor Spanner Wrench Rack-Piston Teflon Ring Compressor Ball Retainer Puller Pitman Bearing Installer Seal Protector Belt Tension Gage Power Steering Pump Pulley Installer Power Steering Pump Pulley Remover Pitman Arm Puller Stub Shaft Seal Protector

Fig. 3B7-26--Special Tools

3B7-17

POWER STEERING SYSTEM

STEERING GEAR RATIOS


Manual Vehicle Gear Ratio Overall Ratio Gear Ratio Overall Ratio Power

G 10-20

24:1

29.4:1 to 36.7:1 29.4:1 to 36.4:1

14:1

21.4:1 to 26.7:1 21.4:1 to 26.5:1 21.2:1 to 25.7:1 16.0:1 to 21.9:1 16.9:1 to 20.2:1 17.2:1 to 20.6:1 13.2:1 to 17.2:1

G30

24:1

14:1

P20-30

17.5:1

M otor Home

14:1 16:1 to 13:1 16:1 to 13:1 16:1 to 13:1

C10

24:1

29.1:1 to 37.0:1 29.4:1 to 36.3:1

C20-30

24:1

K 10-20

MANUAL STEERING GEAR


Components Thrust Bearing Preload Adjuster Plug Lock Nut Over Center Preload Over Center Lock Nut Total Steering Gear Preload A ll C-G 5 to 8 lbs. in. 85 lbs. ft. 4 to 10 lbs. in .* 25 lbs. ft. 18 lbs. in. Max.

POWER STEERING PUMP PRESSURES


Vehicle Pressure

C 10-30 G 10-20-30 G30 P10-30 M otor Home & K w /o H ydroboost w ith H ydroboost

1200 - 1300 psi 900 - 1000 psi 1350 - 1450 psi 1200- 1300 psi 1350- 1450 psi

* ln excess o f thrust bearing preload.

Fig. 3B7--Specs

.ih 'r - -

Q - ; b H

MANUAL STEERING GEAR 3B8-1

SECTION 3B8

MANUAL STEERING GEAR


The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See N otice on page 1 of this Section ". N O T IC E : This fastener is an important attaching part in that it could affect the performance of vital components and systems, and/or could result in major repair expense. It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part.

CONTENTS
General Description....................................................................................... 3B8-1 Maintenance and Adjustm ents...................................................................3B8-2 On-Vehicle Service........................................................................................ 3B8-3 Manual Gear...............................................................................................3B8-3 Pitman Shaft Seal...................................................................................... 3B8-4 Unit Repair...................................................................................................... 3B8-6

GENERAL DESCRIPTION
WORMSHAFT BALLS AND GUIDES

The steering gear is of the recirculating ball type. This gear provides for ease of handling by transmitting forces from the wormshaft to the pitman shaft through the use of ball bearings.

WORM BEARING (UPPER) BALL NUT

BEARING (LOWER) PITMAN SHAFT SECTOR

Fig. 3B8-1 Manual Steering Gear

3B8-2 MANUAL STEERING GEAR

MAINTENANCE AND ADJUSTMENTS


LUBRICATION OF MANUAL STEERING GEAR
The manual steering gear is factory-filled with steering gear lubricant. Seasonal change of this lubricant should not be performed and the housing should not be drained-no lubrication is required for the life of the steering gear. According to the intervals listed in Section OB, the manual gear should be inspected for seal leakage (actual solid grease - not just oily film). If a seal is replaced or the gear is overhauled, the gear housing should be refilled with 1051052 (13 oz. container) Steering Gear Lubricant which meets GM Specification GM 4673M , or its equivalent. NOTICE: Do not use EP Chassis Lube, which meets GM Specification GM 6 0 3 1M, to lubricate the gear DO NOT OVER-FILL the gear housing, or damage may occur to the gear. 6. Turn the steering wheel gently in one direction until stopped by the gear; then turn back one-half turn. NOTICE: Do not turn the steering wheel hard against the stops when the steering linkage is disconnected from the gear as damage to the ball guides could result. 7. Measure and record "bearing drag" by applying a torque wrench with a socket on the steering wheel nut and rotating through a 90 arc (Fig. 3B8-6). D o not use a torque wrench having a maximum torque reading of more than 50 inch pounds. 8. Adjust "thrust bearing preload" by tightening the adjuster plug until the proper "thrust loading preload" is obtained (See specifications section). When the proper preload has been obtained, tighten the adjuster plug locknut to specifications and recheck torque. If the gear feels "lumpy" after adjustment, there is probably damage in the bearings due to severe impact or

ADJUSTMENT OF MANUAL STEERING GEAR


NOTICE: See N otice on page one of this section regarding the fasteners referred to in steps 9d and 10. Before any adjustments are made to the steering gear attempt to correct complaints of loose or hard steering, or other wheel disturbances, a careful check should be made of front end alignment, shock absorbers, wheel balance and tire pressure for possible steering system problems. See Diagnosis earlier in this section. Correct adjustment of steering gear is very important. W hile there are but two adjustments to be made, the following procedure must be followed step-by-step in the order given. 1. Disconnect the battery ground cable. 2. Raise the vehicle. 3. Remove the pitman arm nut. Mark the relationship of the pitman arm to the pitman shaft. Remove the pitman arm with Tool J-6632 or J-5504 as shown in Figure 3B8-4. 4. Loosen the steering gear adjuster plug locknut and back the adjuster plug o ff 1/4 turn (Fig. 3B 8-5). 5. Remove the horn shroud or button cap.

Fig. 3B8-4-Removing Pitman Arm

MANUAL STEERING GEAR 3B8-3 improper adjustment; the gear must be disassembled and inspected for replacement of damaged parts. 9. Adjust "over-center preload" as follows: a. Turn the steering wheel gently from one stop all the way to the other carefully counting the total number of turns. Turn the wheel back exactly half-way, to center position. b. Turn the lash adjuster screw clockwise to take out all lash between the ball nut and pitman shaft sector teeth and then tighten the locknut. c. Check the torque at the steering wheel, taking the highest reading as the wheel is turned through center position. See Specifications for proper over-center preload. d. If necessary, loosen locknut and readjust lash ad juster screw to obtain proper torque. Tighten the locknut to specifications and again check torque reading through center of travel. If maximum speci fication is exceeded, turn lash adjuster screw coun terclockwise, then come up on adjustment by turning the adjuster in a clockwise motion. 10. Reassemble the pitman arm to the pitman shaft, lining up the marks made during disassembly. Torque the pitman shaft nut to specifications. If a clamp type pitman arm is used, spread the pitman arm just enough, with a wedge, to slip the arm onto the pitman shaft. Do not spread the clamp more than required to slip over pitman shaft with hand pressure. Do not hammer the pitman arm onto the pitman shaft. Be sure to install the hardened steel washer before installing the nut.

11. Install the horn button cap or shroud and connect the battery ground cable. 12. Lower the vehicle to the floor.

STEERING GEAR HIGH POINT CENTERING


1. Set front wheels in straight ahead position. This can be checked by driving vehicle a short distance on a flat surface to determine steering wheel position at which vehicle follows a straight path. 2. With front wheels set straight ahead, check position of mark on wormshaft designating steering gear high point. This mark should be at the top side of the shaft at 12 oclock position and lined up with the mark in the coupling lower clamp. 3. On C, G and P series, if the gear has been moved off high point when setting wheel in straight ahead position, loosen adjusting sleeve clamps on both left and right hand tie rods. Then turn both sleeves an equal number of turns in the same direction to bring gear back on high point. Turning the sleeves an unequal number of turns or in different directions will disturb the toe-in setting of the wheels. 4. On K series, if the gear has been moved off high point when setting wheels in straight ahead position, loosen adjusting sleeve clamps on the connecting rod. Then turn sleeve to bring gear back on high point. 5. Readjust toe-in as outlined in Section 3A (if necessary). 6. Be sure to properly orient sleeves and clamps when fastening and torqueing clamps to proper specifications.

ON-VEHICLE SERVICE
STEERING GEAR
Removal 1. Set the front wheels in straight ahead position by driving vehicle a short distance on a flat surface. 2. Remove the flexible coupling to steering shaft flange bolts (C-K models) or the lower universal joint pinch bolt (P models). Mark the relationship of the universal yoke to the wormshaft. 3. Mark the relationship of the pitman arm to the pitman shaft. Remove the pitman shaft nut or pitman arm pinch bolt and then remove the pitman arm from the pitman shaft using Puller J-6632 (Fig. 3B 8-9).

Fig. 3B8-7-Steering G ear Attachment, C-K Models

Fig. 3B8-8--Steering G ear Attachment, G-P Models

3B8-4

MANUAL STEERING GEAR 3. Install the pitman arm onto the pitman shaft, lining up the marks made at removal. Install the pitman shaft nut or pitman arm pinch bolt and torque to specifications. If a clamp type pitman arm is used, spread the pitman arm just enough, with a wedge, to slip the arm onto the pitman shaft. Do not spread the clamp more than required to slip over pitman arm onto the pitman shaft. Be sure to install the hardened steel washer before installing the nut.

4. Remove the steering gear to frame bolts and remove the gear assembly. 5. C-K Models - Remove the flexible coupling pinch bolt and remove the coupling from the steering gear wormshaft. Installation NOTICE: See N O T IC E on page 1 o f this section regarding the fasteners referred to in steps la, lc, Id, le, 2b, 2c and 3. 1. C-K Models a. Install the flexible coupling onto the steering gear wormshaft, aligning the flat in the coupling with the flat on the shaft. Push the coupling onto the shaft until the wormshaft bottoms on the coupling rein forcement. Install the pinch bolt and torque to specifications. The coupling bolt must pass through the shaft undercut. b. Place the steering gear in position, guiding the coupling bolt into the steering shaft flange. c. Install the steering gear to frame bolts and torque to specifications. d. If flexible coupling alignment pin plastic spacers were used, make sure they are bottomed on the pins, torque the flange bolt nuts to specifications and then remove the plastic spacers. e. If flexible coupling alignment pin plastic spacers were not used, center the pins in the slots in the steering shaft flange and then install and torque the flange bolt nuts to specifications. 2. P Models a. Place the steering gear in position, guiding the wormshaft into the universal joint assembly and lining up the marks made at removal. If a new gear was installed, line up the mark on the wormshaft with the slit in the universal joint yoke. b. Install the steering gear to frame bolts and torque to specifications. c. Install the universal joint pinch bolt and torque to specification. The pinch bolt must pass through the shaft undercut.

PITMAN SHAFT SEAL REPLACEMENT


A faulty seal may be replaced without removal of steering gear from C, G and P trucks by removing pitman arm as outlined under Maintenance and Adjustments Steering Gear Adjustments and proceed as follows: On K series vehicles remove the gear from the vehicle first. 1. Rotate the steering wheel from stop to stop, counting the total number of turns. Then turn back exactly half way, placing the gear on center (the wormshaft flat should be at the 12 oclock position). 2. Remove the three self-locking bolts attaching side cover to the housing and lift the pitman shaft and side cover assembly from the housing. 3. Pry the pitman shaft seal from the gear housing using a screwdriver and being careful not to damage the housing bore. See Fig. 3B 8-10. NOTICE: Inspect the lubricant in the gear for contami nation If the lubricant is contaminated in any way, the gear must be removed from the vehicle and completely overhauled as outlined in the Unit Repair Manual, or damage to the gear could result. 4. Coat the new pitman shaft seal with Steering Gear Lubricant meeting GM Specification GM 4673M (or equivalent). Position the seal in the pitman shaft bore and tap into position using a suitable size socket. 5. Remove the lash adjuster lock nut. Remove the side cover from the pitman shaft assembly by turning the lash adjuster screw clockwise.

Fig. 3B8-9--Removing Pitman Arm-Typical

MANUAL STEERING GEAR 3B8-5 6. Place the pitman shaft in the steering gear such that the center tooth of the pitman shaft sector enters the center tooth space of the ball nut. 7. Fill the steering gear housing with Steering Gear Lubricant meeting GM Specification GM 4673M (or equivalent). 8. Install a new side cover gasket onto the gear housing. 9. Install the side cover onto the lash adjuster screw by reaching through the threaded hole in the side cover with a small screwdriver and turning the lash adjuster screw counter- clockwise until it bottoms and turns back in 1/4 turn. 10. Install the side cover bolts and torque to specifications. 11. Install the lash adjuster screw locknut, perform steerin gear adjustment and install the pitman arm as outllined under " Maintenance and Adjustm ents". On K series install the gear into the vehicle using previously outlined procedure.

SPECIFICATIONS AND SPECIAL TOOLS


Refer to Specifications and Special Tools at end of Section 3B4i

3B8-6

MANUAL STEERING GEAR

PRELOAD ADJUSTER NUT SIDE COVER BOLTS WORM BEARING ADJUSTER LOCKNUT

SIDE COVER PRELOAD ADJUSTER SHIM PRELOAD ADJUSTER

I
/ / /

WORM BEARING ADJUSTER / / LOWER WORM BEARING CUP LOWER WORM BEARING / LOWER BEARING RETAINER BALL NUT WORMSHAFT UPPER WORM BEARING

PITMAN SHAFT

SIDE COVER GASKET

HOUSING STONE SHIELD ADAPTER

BALL GUIDES BALLS BALL GUIDE CLAMP SCREWS BALL GUIDE CLAMP UPPER WORM BEARING CUP PITMAN SHAFT SEAL

COUPLING PINCH BOLT

WORM SHAFT SEAL

STEERING SHAFT COUPLING

Fig. 3B8-ll--Manual Steering Gear, Exploded View

MANUAL STEERING GEAR 3B8-7

1.
REMOVE Wrap 0.1 mm to 0 2 mm (.005" to .008") shim stock around shaft and insert between shaft and seal Pry seal out WORM SHAFT SHIM STOCK WORM SHAFT SEAL

R E M O V E A N D IN S T A L L W O R M S H A F T S E A L 'G E A R A S S E M B LE D
INSTALL

Install parts as shown

J-21421-01 SCREWDRIVER WORM SHAFT SEAL

HOUSING HOUSING

Install seal NOTICE: Do not turn steering wheel hard against "stops" when linkage is disconnected, as damaged to the ends of ball guides may occur.

R E M O V E A N D IN S T A L L P IT M A N S H A F T A N D S ID E C O VE R
REMOVE 1. Center steering gear. 2. Remove parts as shown. INSTALL 1. Before installing turn preload adjuster screw counter-clockwise until it bottoms, then back screw off one half turn. 2. Install parts as shown.

Checking end clearance

1 J

| If clearance is greater than 05 mm ( 002 ") a steering gear lash adjuster kit is available

PRELOAD ADJUSTER SHIM


FEELER GAUGE (Select to get proper clearance

P R ELO AD A D JU S T ER N U T

(If replacing gasket only, do not remove.) SIDE COVER BOLTS

/ .f

^SIDE COVER PRELOAD .ADJUSTER SHIM

SIDE COVER GASKET

PITMAN SHAFT

A '*

{^ P R E L O A D i ADJUSTEF

HOUSING

PITMAN SHAFT

V
PITMAN SHAFT SEAL

PITMAN SHAFT SEAL

Install seal

L U B R IC A T IO N
The steering gear requires 3118 kg (11 oz.) of lubricant GM4673M or equivalent

Fig. 3B8-12~Manual G ear Overhaul, Chart A

3B8-8

MANUAL STEERING GEAR

R E M O VE A N D IN S T A LL W O R M S H A F T A N D BALL N U T
REMOVE
1. 2 Loosen lock nut. Use punch against edge of slot. Remove parts as shown. 1

4.

D IS A S S E M B LE A N D A S SEM B LE W O R M B E A R IN G A D JU S TE R
DISASSEMBLE
Pry lower bearing re tainer out with screw driver R em ove cu p u s in g 1.

INSTALL
Install parts as shown.

ASSEMBLE
Press cup into adjuster using J-5755. Install parts as shown.

2.

NOTICE: Use care that the ball nut does not run down to either end of the worm. Damage may be done to the ends of the ball guides if the ball nut is allowed to rotate until stopped at the end of the worm

J-5822 puller and slide hammer. WORM BEARING ADJUSTER LOWER WORM BEARING CUP LOWER WORM BEARING LOWER BEARING RETAINER

WORM BEARING ADJUSTER LOCKNUT

5.

D IS A S S E M B LE A N D A S S E M B LE W O R M S H A F T A N D BALL N U T
DISASSEMBLE ASSEMBLE
as 1 2. A s s e m b le shown p a rts as Disassemble shown parts

1 2

Clean and inspect all p a rts fo r e xce ssive wear

Refer to Fig A for number of balls used

BALL NUT

I r*

J-5755

Assemble wormshaft Remove bearing cup from housing only if necessary.

Dimension A-Measure land I between ball grooves

Dim A Balls mm in per circuit 0 04 25 1.0 2.5 5.0

Remove Cup

Install Cup

0 10 0.20

27 27

Fig A

Fig. 3B8-13-Manual Gear Overhaul, Chart B

MANUAL STEERING GEAR 3B8-9

6.
1. 2 3. 4.

A D J U S T W O R M B E A R IN G PR E LO A D
Tighten worm bearing adjuster until it bottoms then loosen one-quarter turn. Carefully turn the wormshaft all the way to end of travel then turn back one-half turn Tighten adjuster plug until torque wrench reads 0 6 to 1.0 N.m (5 to 8 in. lbs ) Tighten locknut using punch against edge of slot.

7.

A D J U S T O VER C E N T E R PR ELO A D

A B a c k o f f p r e lo a d adjuster until it stops, then turn it in one full turn

B. Turn adjuster in torque to turn stub is 0.5 to 1.2 N m 10 in. lbs.) more reading #1

until shaft (4 to than

With gear at center of travel, check torque to turn stub shaft (reading # 1 )

Torque adjuster lock nut to 34 N m (25 ft. lbs.) Prevent adjuster screw fro m tu rn in g w h ile torqueing lock nut.

A D JU STM E N T S PE C IFIC A TIO N S - M A N U A L STE E R IN G T O R Q U E TO TU R N W ORM SHAFT ...............................................5-8 In. Lbs. .............................................4-10 In. Lbs. in excess of Worm Bearing Preload. .......................... 16 in. Lbs. Maximum

A D JU STM EN T Worm B earin g ................................................................... 0.6-1.0 N-m

Over Center Preload................................................0.5-1.2 N-m


Total Steering Gear Preload .............................................. 1.8 N-m

R EC O M M E N D ED TO R Q U E S PE C IFIC A TIO N S M A NU AL STEERING GEAR Gear to Frame Bolts Pitman Shaft Nut N-m FT. LB. . . . . 70

................................................................. 95

...................................................................................251 Side Cover Bolts ......................................................................... 40 Pitman Shaft Adjusting Screw Locknut .............................. 34 Coupling Flange To Gear Pinch B o l t .................................. 40 Coupling Clamp N u t (S ta rfire )............................................... 70 Clamp To Ball Nut S crew ...... .................................................... 5.5

. . . 185 . . . . 30 . . . . 25 . . . . 30 . . . . 50 .... 4

TOOLS
J-21421-01 Seal Installer J-5755 Worm Bearing Cup Installer J-5822 Worm Bearing Adjuster Cup Puller

J-21421-01

J-5755 J-5822

Fig. 3B8-14-Manual Gear Overhaul, Chart C

3B8-10 MANUAL STEERING GEAR

STEERING GEAR RATIOS


Manual Vehicle Gear Ratio Overall Ratio Gear Ratio Overall Ratio Power

G 10-20

24:1

29.4:1 to 36.7:1 29.4:1 to 36.4:1

14:1

21.4:1 to 26.7:1 21.4:1 to 26.5:1 21.2:1 to 25.7:1 16.0:1 to 21.9:1 16.9:1 to 20.2:1 17.2:1 to 20.6:1 13.2:1 to 17.2:1

G30

24:1

14:1

P20-30

17.5:1

M otor Home

14:1 16:1 to 13:1 16:1 to 13:1 16:1 to 13:1

C10

24:1

29.1:1 to 37.0:1 29.4:1 to 36.3:1

C20-30

24:1

K 10-20

MANUAL STEERING GEAR


Components Thrust Bearing Preload Adjuster Plug Lock Nut Over Center Preload Over Center Lock Nut Total Steering Gear Preload A ll C-G 5 to 8 lbs. in. 85 lbs. ft. 4 to 10 lbs. in.* 25 lbs. ft. 18 lbs. in. Max.

POWER STEERING PUMP PRESSURES


Vehicle Pressure

C10-30 G 10-20-30 G30 P10-30 M otor Home & K w /o Hydroboost w ith Hydroboost

1200 - 1300 psi 900 - 1000 psi 1350 - 1450 psi 1 2 0 0 - 1300 psi 1 3 5 0 - 1450 psi

* In excess o f thrust bearing preload.

Fig. 3B8-Specs

FRONT SUSPENSION

3C-1

SECTION 3C

FRONT SUSPENSION
The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See N otice on page 1 of this section ". NOTICE This fastener is an important attaching part in that it could affect the performance of vital components and systems, and/or could result in major repair expense. It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of this part.

CONTENTS OF THIS SECTION


Front Suspension (C -G -P-Series).................................................................. 3C-1 Front Suspension (K -Series)........................................................................... 3 C -18

FRONT SUSPENSION, TWO-WHEEL DRIVE


INDEX
General Description............................................... ............ Maintenance and Adjustm ents....................................... Diagnosis............................................................................... Component Parts Replacement....................................... Wheel Hubs, Bearings................................................... Shock Absorber.............................................................. Stabilizer.......................................................................... Coil Spring....................................................................... Upper Control Arm Shaft........................................... 3C-1 3C-7 3C-7 3C-7 3C-7 3C-8 3C-8 3C-9 3C-9 Lower Control Arm Sh aft............................................ Upper Control A rm ....................................................... Lower Control Arm ........................................................ Ha|| Joim ........................................................................... _ Steering K nuckle............................................................ Suspension U n it.............................................................. Specifications........................................................................ Special Tools......................................................................... 3C -10 3 C -1 1 3C-12 3C -I.' _ _ 3 C -15 3C-16 3C-48 3C -49

GENERAL DESCRIPTION C-G-P Ser