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Contents

1-2 HOW TO USE THIS BOOK 1-10 ROUTINE MAINTENANCE


GENERAL INFORMATION 1-2 TOOLS AND EQUIPMENT AND TUNE-UP
1-35 FLUIDS AND LUBRICANTS
AND MAINTENANCE 1-4 SERVICING YOUR VEHICLE
SAFELY 1-46 TRAILER TOWING
1 -5 FASTENERS, 1-47 JUMP STARTING A DEAD
MEASUREMENTS AND BATTERY
CONVERSIONS 1-48 JACKING
1-7 SERIAL NUMBER 1 -50 MAINTENANCE INTERVALS
IDENTIFICATION

2-2 HIGH ENERGY IGNITION 2-7 CHARGING SYSTEM


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

3-2 ENGINE MECHANICAL 3-58 ENGINE RECONDITIONING


ENGINE AND ENGINE 3-56 EXHAUST SYSTEM
OVERHAUL

4-2 GASLINE ENGINE EMISSION 4-25 DIESEL ELECTRONIC


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

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


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

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


TION (TBI) 5-26 FUEL TANK

6-2 UNDERSTANDING AND 6-13 ENTERTAINMENT SYSTEMS


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

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


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

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


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

10-2 EXTERIOR 10-5 INTERIOR

10-15 GLOSSARY

10-19 MASTER INDEX


SAFETY NOTICE

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

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

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

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

PART NUMBERS

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

SPECIAL TOOLS

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

ACKNOWLEDGMENTS

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

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

TOOLS AND EQUIPMENT


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

,SS*8i

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

TCCS1205

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

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

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

Fig. 10 A variety of tools and gauges


^ Fig. 12 A screw-in type compression
TCCX1P02

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

TCCX1POG Fig. 15 Proper information is vital, so


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

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

SERVICING YOUR VEHICLE SAFELY


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

A f*1 ^

TCCS1020

Fig. 16 Screwdrivers should be kept in


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

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

FASTENERS, MEASUREMENTS AND CONVERSIONS

Bolts, Nuts and Other Threaded Retainers


See Figures 19 and 20

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

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

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

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

TORQUE WRENCHES

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

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

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

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

See Figure 23 PRESSURE


Pounds Pei Sq. In (psi) x 6.895 *= Kilopascals (kPa) x .145 = psi
Inches of Mercury (Hg) x 4912
Throughout this manual, specifications are given to help you determine the Inches of Mercury (Hg) x 3.377
-- psi
=-- Kilopascals (kPa)
x 2.036
x .2961
= Hg
= Hg
condition of various components on your vehicle, or to assist you in their Inches of Water (HjO) x .07355 - Inches of Mercury x 13783 = H,O
installation. Some of the most common measurements include length (in. or Inches of Water (H,O)
Inches of Water (H.O)
x .03613
x .248
=. psi x 27.684 - H.O
= Kilopascals (kPa) x4026 = H,0
cm/mm), torque (ft. Ibs., inch Ibs. or Nm) and pressure (psi, in. Hg, kPa or mm TORQUE
Hg). In most cases, we strive to provide the proper measurement as determined Pounds-Force Inches (in-lh) x . 1 13 = Newton Meters (N-m) x 8.85 = in-lb

by the manufacturer's engineers. Pounds-Force Feet (ft-lh) x 1 356 = Newton Meters (N-m) x .738 . ft-lb
VELOCITY
Though, in some cases, that value may not be conveniently measured with Miles Per Hour (MPH I x 1 .609 = Kilometers Per Hour (KPH) x .621 - MPH
what is available in your toolbox. Luckily, many of the measuring devices which POWER
are available today will have two scales so the Standard or Metric measure- Horsepower (Hp( * .745 =-- Kilowatts x 1 34 = Horsepower

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

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

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

SERIAL NUMBER IDENTIFICATION

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

> See Figures 24 and 25


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

Fig. 25 Vehicle Identification Number decoding

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

D or TD/HO DDA-DetroitC sel Allison

1BC-1 Barrel Carburetor HO-High Oi put


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

12Month of Manufacture (December)


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

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

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

Service Parts Identification Label


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

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

ROUTINE MAINTENANCE AND TUNE-UP


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

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

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

3. EGR Valve

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

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

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

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

87981P05

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

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

87981P06

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

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

Fig. 43 PCV valve location-gasoline engines

REMOVAL & INSTALLATION

> See Figures 44 and 45


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