Page 1 1 0 -3 0 SER IES C H E V Y V A N -S P O R T V A N SERVICE MANUAL C H E V R O L E T , ST 140...
Page 2 AND CHASSIS • • • RADIATOR AND GRILLE CHEVROLET M O T O R D IV IS IO N BUMPERS G e n e ra l M o tors C o rp o ratio n DETROIT, M IC H IG A N...
Page 3 SECTION O GENERAL INFORMATION LUBRICATION CONTENTS OF THIS SECTION Page G eneral I n fo r m a tio n ...............0-1 L ubrication ..................0-6 GENERAL INFORM ATION INDEX Page Page Service Parts Identification Plate ..........0-2 Model Line U p ................. 0-1 Keys and Locks ................
Page 4 G EN ER A L IN F O R M A T IO N 0-2 Axles • Rear A xle Serial N um ber L ocated a t the B o tto m Flange CHEVROLET MOTOR DIVISION o f Carrier Housing. GENERAL MOTORS CORPORATION •...
Page 5 GEN ER A L IN F O R M A T IO N 0-3 KEYS A N D LOCKS “ PARK ” (n eu tral for m anual transm ission). T u rn off lights, h eater an d other electrical loads. Two keys are provided w ith each vehicle.
Page 6 G EN ER A L IN F O R M A T IO N 0-4 ENG INE—VEH IC LE A V A IL A B IL IT Y the drive shaft disconnected w hen the transm ission is n o t operating properly or w hen a speed o f 35 MPH or distance o f 50 miles will be exceeded.
Page 7 GEN ER A L IN F O R M A T IO N 0-5 LOAD CAPACITY CHART LOAD CAPA C ITY C H A R T FOR 1972 C H EV R O LET SERIES G10, G20, G30 C H E V Y VA N GROSS MINIMUM M AN D ATO RY EQUIPM ENT FOR GVW RATIN G V E H IC L E...
Page 8 The oil change interval for the recom m endations. Chevrolet engine is based on the use o f SE oils and quality oil filters. Oil change intervals longer than those listed above will O IL CHANGE PERIOD seriously reduce engine life and may affect C hevrolet’s obliga...
Page 9 LU B R IC A TIO N 0-7 Recommended Viscosity AIR INJECTION REACTOR SYSTEM (A.I.R.) CONTROLLED COMBUSTION SYSTEM (C.C.S.) Select the proper oil viscosity from the following chart: T he Air Injection R eactor system should have the drive belt inspected fo r wear and tension every 12 m o n th s or 12,000 miles, whichever occurs first.
Page 10 LUB RICA TIO N 0-8 TRANSMISSION SH IFT LINKAGE ACCELERATOR LINKAGE (M ANUAL AND A U TO M ATIC) Lubricate w ith engine oil every 12,000 miles as follows: Every 6 ,000 miles or 4 m onths—lubricate shift linkage and, 1.
Page 11 LU B R IC A TIO N 0-9 Due to th e w eight o f the tire and wheel assembly it is recom m ended th a t th ey be rem oved from h u b before lubricat ing bearings to prevent damage to oil seal.
Page 12 LU B R IC A TIO N 0-10 Lubrication T ype o f N o. Lubrication Points Period Lubrication Q uantity Rem arks C ontrol Arm Bushings and Ball Joints 6 ,0 0 0 Miles Chassis Lubricant 12 places as required Tie R od Ends 6 ,0 0 0 Miles Chassis Lubricant...
Page 13 LU B R IC A TIO N 0-11 BODY LUBRICATIO N w orking parts may be m ade b y removing th e trim . Door w eatherstrips and rubber h o o d bum pers should be lightly N orm al use of a truck causes m etal-to-m etal m ovem ent at coated w ith a rubber lubricant.
Page 14 SECTION 1A HEATER AND AIR CONDITIONING CONTENTS OF THIS SECTION Standard H e a t e r ................. 1A-1 A uxiliary H e a te r ................. 1A-6 Air Conditioning ............... 1A-9 STANDARD HEATER INDEX Page Page ....... General D escription ..............I A-! 1A-4 Left D istributor D uct ......
Page 15 HEATER 1A-2 CONTROLS The controls are located in the in stru m en t panel, ju st to the right o f the instrum ent cluster. In operation, three levers co n tro l all heater operations (figs. 1 and 2). HEAT Lever When this lever is fully up, all incom ing air is diverted around th e heater core.
Page 16 HEATER 1A-3 HEATER HOSES H eater hoses are ro u ted from the w ater p um p and th erm o stat housing to th e core inlet and o u tle t pipes as show n in Figure 5.
Page 17 H EATER 1A-4 Fig. 6 —D istributor Ducts Pull the center d istributor duct to the right and remove it D isconnect the defroster hose at b o th the center distribu from the vehicle. to r duct and instrum ent panel o u tlet and remove the T o install, reverse Steps 1-6 above.
Page 18 HEATER 1A-5 C A U T IO N : Care should be taken to prevent kink ing the bowden cables while lowering the control. D isconnect the three bow den cables, the control illum i natio n bulb, and remove the control from the vehicle. Remove th e blow er sw itch screws and rem ove th e blow er sw itch.
Page 19 HEATER 1 A-6 T o install, a ttac h th e new cable to the 4 ’ piece o f wire. 4. T o install a new sw itch, reverse Steps 1-3 above. T ape the m ounting tab and attach ed wire. Carefully pull th e new cable in to position.
Page 20 HEATER 1A-7 Fan Switch (Fig. 13) The tw o speed (HI-LOW) fan sw itch is located below the half-w ay places th e fan on “H I” ; at th e full o u t position, the fan is o n “ LOW” . left side o f the instrum ent cluster.
Page 21 HEATER 1A-8 Fig. 12—A u x iliary Heater W ater Valve ^'9- ^ A u xiliary Heater Hose Routing (1 1 0 " W .B. Models w ith Rear Seats) Fig. 13—A u xiliary Heater Control Switch C H E V Y V A N SH O P M A N U A L...
Page 22 A IR C O N D IT IO N IN G 1A-9 AIR CO N D ITIO N IN G INDEX P age P age G en e ra l D escrip tio n ..............1A- 9 M a in te n an ce an d A d ju s tm e n ts ..........1A-21 C h ev ro let S ystem C - 6 2 ............1A- 9 T h erm o static S w i t c h ............1A-21 R o o f-M o u n ted System C-63 ........1 A - 9...
Page 23 A IR C O N D IT IO N IN G 1A-10 CONTROLS (Fig. 17) The controls for the C-62 system consist o f a tem p eratu re knob and a blow er speed lever. The controls for the C-62 & C-63 system are the same as C-62 except for a separate blow er speed lever for the rear (C-63) unit.
Page 24 A IR C O N D ITIO N IN G 1A-11 C-62 or the C-62 and C-63 systems. The evaporator, expansion Move “ A IR ” lever (FR O N T) to “L ” “M” or “ H ” position. Turn “...
Page 25 A IR C O N D ITIO N I IMG 1A 12 GENERAL INFORMATION In any vocation or trade, th ere are established procedures • P rotection o f th e eyes is o f vital im portance! When and practices th a t have been developed after m any years of w orking around a refrigerating system , an accident m ay experience.
Page 26 A IR C O N D IT IO N IN G 1A-13 o f gauge readings. O pen very slowly, keeping face and leave the system open any longer th an is necessary. hands away so th a t no injury can occur if there happens •...
Page 27 A IR C O N D IT IO N IN G 1A-14 GAUGE SET The gauge set (fig. 21) is an integral p art o f the J-8393 Charging S tation. Is it used w hen purging, evacuating, charging or diagnosing trou ble in the system . T he gauge at the left is know n as the low pressure gauge.
Page 28 A IR C O N D IT IO N IN G 1A-15 • A five am pere tim e delay cartidge fuse has been installed CHIMNEY in the com m on line to p ro tec t the w indings o f the com pressor.
Page 29 AIR C O N D ITIO N IN G 1A-16 Norm ally, air conditioning system s are charged m aking use Due to the porosity o f the refrigerant hoses and connec o f the J-8393 Charging S tation w hich uses the 30 lb-container. tions, the system refrigerant level will show a definite drop Evacuating and Charging Procedures are n oted later in this after a period o f tim e.
Page 30 A IR C O N D IT IO N IN G 1A-17 EVACUATING AND CHARGING PROCEDURES AIR C O N D ITIO N IN G SYSTEM CAPACITY The purpose is to low er the pressure inside the system so th at a com ponent p art can be safely removed.
Page 31 A IR C O N D ITIO N IN G 1A-18 C A U T IO N : When removing the gauge lines from EVACUATING AND CHARGING THE SYSTEM the fittings, be sure to remove the adapters from the system fittings rather than the gauge lines from the G E N E R A L N O T E : In all evacuating procedures...
Page 32 A IR C O N D IT IO N IN G 1A-19 Charging the System Gauge set installed. System settled o u t (run-in approxim ately 10 m inutes). 1. O nly after evacuating as above, is system ready for A therm om eter placed in fro n t o f vehicle grille and charging.
Page 33 A IR C O N D IT IO N IN G 1A-20 charge, should the above test show insufficient oil, it is RE FRIG ERANT QUICK-CHECK PROCEDURE necessary to remove the com pressor from the vehicle, drain and measure the oil. The following procedure can be used to quickly determine whether or not an air conditioning system has a proper charge N O T E :...
Page 34 A IR C O N D IT IO N IN G 1A-21 MAINTENANCE AND ADJUSTMENTS THERM O STATIC SWITCH These system s make use o f a th erm o static sw itch w ith an air sensing capillary. This capillary controls the sw itch by sensing th e tem perature o f the air leaving the fins.
Page 35 A IR C O N D ITIO N IN G 1A-22 Check for Defective Valve The following procedure m ust be follow ed to determ ine if a m alfunction is due to a defective expansion valve. 1. Check to determ ine if the system will m eet the per form ance test as outlined previously.
Page 36 A IR C O N D IT IO N IN G 1A-23 Installation S teel A lum . Metal Thread and Tubing Tube F itting Tubing C oat tube an d hose w ith clean refrigeration oil. O .D. Size Torque* Torque* Carefully insert hose over the three beads on the fitting...
Page 37 A IR C O N D IT IO N IN G 1A-24 R E FR IG E R A N T HOSE FAILUR E brake equipped vehicles, if necessary, remove vacuum hose at m anifold end). Before beginning any com pressor disassembly, drain and A fter a leak or ru p tu re has occurred in a refrigerant hose, or measure oil in the com pressor.
Page 38 A IR C O N D IT IO N IN G 1A-25 D isconnect the condenser in let and o u tlet lines and cap outboard as required. Reinstall the idler as or tape th e open connections at once. sembly adjust belt...
Page 39 A IR C O N D IT IO N IN G 1A-26 Fig. 3 2 —Sight Glass Replacement SIGHT GLASS REPLACEMENT Remove the tem p eratu re co n tro l k n o b and place the blow er switch(es) on M . I f damage to the sight glass should occur, a new sight glass Remove the cover being careful n o t to damage the seal to kit should be installed.
Page 40 AIR C O N D IT IO N IN G 1A-27 FRONT BLOWER-EVAPORATOR ASSEMBLY Removal (Fig. 34) 1. D isconnect battery ground cable, and com pressor clutch lead from connector. 2. Purge system o f refrigerant. Rem ove from blow er-evaporator case described previously.
Page 41 A IR C O N D IT IO N IN G 1A-28 Replacement 1. D isconnect the b attery ground cable and com pressor clutch connector. R em ove blow er-evaporator cover described previously. Disconnect the electrical harness at the switch. Remove the attaching screws and remove the switch.
Page 42 A IR C O N D IT IO N IN G 1A-29 Fig. 9 0 —Blower M otor Installation Replacement Install th e blow er m o to r retaining strap and foam . Place th e tw o blow er m o to r and w heel assemblies into Remove th e sealing strip at the forw ard edge o f the duct.
Page 43 A IR C O N D IT IO N IN G 1A-30 Installation (Inner Valve) Remove caps or tape from system connections and install the new valve assembly using new “ O ” rings coated w ith clean refrigeration oil. Install the sensing bulb , m aking sure th a t the bulb makes good contact w ith the core o u tlet line.
Page 44 A IR C O N D IT IO N IN G 1A-31 SUPPORT EVAP & BLOWER ASM SUPPORT BLO W ER _________ BRACKET GRD WIRES Fig. 4 2 —Rear Blower-Evaporator Assembly C H E V Y V A N SH O P M A N U A L...
Page 45 14 B -------C E H * A -14 BRN ---------- COMPRESSOR B -14 BRN —f50B| - a © ' u : INSTRUMENT FRONT HEATER CONTROL PANEL WIRING i ( z m 1150 I 59 I BLOWER SWITCH CONNECTOR MOTOR & * / 1150 [ 59 I I6BLK-0RN - fsa*j | —...
Page 46 RESISTOR (FRONT) A -14 BRN - B - 14 BRN — Isoat 52> COMPRESSOR BLOWER HEATER CONTROL INSTRUMENT SWITCH CONNECTOR (REAR) PANEL WIRING I 5 0 | 5 9 14 B-----E g g ) - ^ GRD BLOWER (FRONT) £T 'I H ^ 14 G R A - g —...
Page 47 A IR C O N D IT IO N IN G 1A-34 i /* —i I— I I—I I—I t..U J I ! "-J n f ' 1 n> [ O D y 1. J-8393 Charging Station J-9481 Pulley and Bearing Installer 13.
Page 48 SECTION IB BODY INDEX Page Page Service I n f o r m a tio n ..............IB-1 Sliding Side D o o r ...............1 B-l 1 Body S e a lin g ..............IB-1 F ro n t L atch A sse m b ly ............IB -12 Locating Dust and Water L e a k s ........IB-1 Rear L atch an d/o r L atch A ctuating Rods ....IB-12 Body and Fram e ..............IB-1...
Page 49 BODY 1B-2 DASH PANEL FRONT INNER ROCKER PANEL FRONT WHEELHOU TEP PANEL FLOOR PANEL Fig. 1 —Body Sealing Areas C H E V Y V A N SH O P M A N U A L...
Page 50 BODY 1B-3 COMPONENT PART REPLACEMENT Windshield Wipers 2. A ttach end o f link rod to m o to r drive and arm . Secure rod w ith the tw o attaching nuts. Windshield wiper units on all m odels are o f the two-speed 3.
Page 51 BODY. 1B-4 Fig. 4 —Loosening Weatherstrip Fig. 6 —M odification of Tool J-22577 retention groove (fig. 3) after windshield removal from bo dy opening. Irregularities in body opening. 3. T o free w indshield rubber channel o f w eatherstrip loosen Irregularities in rubber channel w eatherstrip.
Page 52 BODY 1B-5 Fig. 9 —Pulling String to Seal Rubber Lip Cowl Side Ventilator Valve Assembly (Fig. 10) ■APPLY Removal SEALER 1. Remove screws retaining valve guide to panel. 2. Remove valve assembly by depressing pins at top and bottom o f valve. Fig.
Page 53 BODY 1B-6 Installation 1. Install insert into trim panel. 2. Install panel and insert in to the in strum ent panel and install retaining nuts. Instrument Panel Removal 1. Rem ove Steering C olum n, and all Instrum ents as outlined in Sections 9, 12, 15.
Page 54 BODY IB -7 Door Weatherstrip Success o f weatherstrip replacement depends entirely upon the quality o f the cem ent used and the care with which it is applied. All rust, road dirt and grease or oil must be com plete W IN D O W RUN ly removed as should all old cement and bits o f old weather...
Page 55 BODY 1B-8 slide freely into the channel. Push the glass w ith the filler around it into the channel until it is firmly seated. A fter the glass is firm ly in place, the oil softens the filler, causing it to swell, thereby making a perfect, w atertight seal.
Page 56 BODY IB -9 Front Door Lock Remote Control and Connecting The rem ote co n tro l is secured to the door inner panel by the three attaching bolts. Removal and Installation 1. Raise door w indow and remove door trim pad. 2.
Page 57 BODY 1B-10 2. In sert Tool J-23457 (Fig. 19) in to head o f striker b o lt, Reposition Door " F o re " or " A f t " th en tu rn b o lt counterclockw ise from plate in cab pillar. 3.
Page 58 BODY IB -1 1 on striker b o lt when door is closed. If bolt is positioned too high on pillar, rapid wear w ill occur to the lock cam; if too low , an extra load w ill be placed on door hinges as well as pull door downward and o u t of alignment.
Page 59 BODY 1B-12 Disassembly (Fig. 25) Installation 1. Remove rod connecting hinge and roller assembly. 1. Install latch assembly into do or by w orking latch assem 2. Remove roller. bly behind the lower hinge door catch. 3. Remove levers—noting position o f the springs. 2.
Page 60 BODY IB -13 Fig. 2 5 —Sliding D oor Upper L e ft Hinge Components Roller Bolt Screw Lockwashers Plate Guide Block Bushing N u t Upper lines Hinge (Body H alf) Hinge (D o or H alf) Spacer N u t Spring Washer Spring (Upper Lever)
Page 61 BODY 1B-14 Reposition Door "U p" or "Down" 1. Partially open door and loosen fro n t latch striker on pillar. 2. Remove upper left door hinge cover. 3. Loosen upper left hinge to d o o r bolts. Loosen rear lock striker and door wedge. 5.
Page 62 BODY 1B-15 . A djust fro n t upper roller so it travels in the center o f its channel. (Fig. 28) 7. A djust fro n t and rear strikers as outlined under “ F ro n t and Rear Striker A djustm ent” . .
Page 63 BODY 1B-16 SEATS Drivers Seat (Fig. 34) Seat Adjuster Removal 1. Remove seat by removing bolts securing seat to seat riser. 2. Remove seat belt from adjuster. 3. Remove adjuster from seat. Installation 1. Install seat adjuster to seat. T orque bolts to specifica tions.
Page 64 BODY 1B-17 Passenger Seat (Fig. 35). Mounting Brackets Removal 1. Remove seat and brackets from seat riser. 2. Remove brackets from seat. Installation 1. Install brackets to seat. T orque to specifications. 2. Install seat to seat riser. T orque to specifications. Seat Riser Removal 1.
Page 65 BODY 1B-18 2. From inside vehicle apply pressure w ith palm o f hand to b o tto m of glass and assist the lip o f the w eatherstrip over the flange w ith a flat bladed tool as show n in (Figure 38). With aid o f helper to hold w indow , continue moving w eatherstrip over flange until w indow is o u t o f opening.
Page 66 BODY 1B-19 Side Window Glass Latch (Swingout) Removal Swing o u t window . 2. Remove latch to body and latch to window screws and remove latch. Installation A ttach latch to w indow using escutcheon, spacer, washer. 2. A ttach latch to body. REAR DOORS Rear Door Hinge Strap (Fig.
Page 67 BODY 1B-20 Installation 1. Install lock cylinder and retainer. 2. Install rem ote control. T orque screws to specifications. 3. Install trim panel. Rear Door Glass and Weatherstrip Removal and installation procedures are the same as for the body side windows. Refer to those procedures for rear door glass and w eatherstrip replacem ent.
Page 68 BODY 1B-21 A djust striker by adding or deleting shims as necessary to o b ta in dim ension as show n in Fig. 44. This dim ension can be checked by applying grease to the latch and slow ly closing door until striker fully engages latch. Then open d o o r and m easure from grease im pression to b o tto m o f latch slot.
Page 69 SECTION 2 FRAME GENERAL DESCRIPTION The fram e side rails, cross sills and outriggers are part o f the and also influence th e suspension system , causing suspension u n d erbody assembly w hich is a w elded u n it o f the body misalignment.
Page 71 Inspection ............... 3-6 In s ta lla tio n ............... 3-6 GENERAL DESCRIPTION The Chevrolet Chevy Van and Sportvan line incorporates an independent coil fro n t suspension system. (Fig. 1). The unequal length control arm coil spring independent suspension is used on all 10, 20 and 30 series Vans. This...
Page 72 WHEEL BEARINGS—CHECK ADJUSTMENT whenever for other reasons th e alignm ent is being reset, Chevrolet recom m ends th a t th e specifications given in colum n 3 o f the aforesaid applicable chart be used. C A U T IO N :...
Page 73 FRO NT SUSPENSION 3-3 furnished w ith each particular m achine should be follow ed. In all cases, how ever, checks should be m ade on a level surface OF WHEEL - OF WHEEL w ith th e vehicle at curb weight. Before checking and adjusting alignm ent, such com ponents as wheel bearings, spring height, tie rods, steering gear, shock absorbers and tire inflation should be inspected and corrected...
Page 74 FR O N T SUSPENSION 3-4 CASTER A L IG N M E N T CASTER A L IG N M E N T R E A D IN G = + 2'/4° R E A D IN G = + 2 ° FRAME A NGLE = 1 V i0 D O W N FRAME A N G LE = 1 °...
Page 75 FRO NT SUSPENSION 3-5 Trucks w ithin these tolerances from th e m ean specification fram e angle m ust be "up in rear" subtracted from a caster reading. are safe and n o t hazardous w ith respect to alignm ent effects negative on o peration and handling.
Page 76 FRO NT SUSPENSION 3-6 N O T E : Be sure bearing parts have been thoroughly becomes necessary. Do not use replacement parts of cleaned and air-dried. lesser quality or substitute design. Torque values must be used as specified during reassembly to Wheel Stud Replacem ent (Fig.
Page 77 FRO NT SUSPENSION 3-7 Installation Remove spring. Installation 1. Install lower ball stud through steering knuckle and tighten nut. Properly position spring on the con tro l arm , and lift Install spring an d control arm as outlined u nder spring control arm .
Page 78 FRO NT SUSPENSION 3-8 N O T E : Tape shims and spacers together and tag Repairs fo r proper relocation when control arm is rein stalled. Bushings Installation Remove grease fittings from bushing o u ter ends and unscrew bushings from control arm an d shaft. 1.
Page 79 FRO NT SUSPENSION 3-9 N O T E : Position jack under the ball jo in t assembly N O T E : The shaft should rotate by hand after the or as near as possible and still have good support. nuts are torqued.
Page 80 FRO NT SUSPENSION 3-10 . Install tire and wheel an d low er vehicle to floor. E xtend b olt from to o l J-23742 to loosen ball stud in steering knuckle. When stud is loosened, remove tool and Upper-Removal ball stud nut.
Page 81 FRO NT SUSPENSION 3-11 loosen ball stud nuts. Free steering knuckle from ball separately as outlined in the preceding service operations. studs by installing Special Tool J-23742. Remove ball However, if extensive service is to be perform ed to cross stu d nuts and w ithdraw steering knuckle.
Page 82 FRO NT SUSPENSION 3-12 Ball Joint Installer 6. J-9519-9 Bearing Race Installer 1. J-8457 " C " Clamp Bearing Race Installer 7. J-9519-10 2. J-8458 Bearing Race Installer Ball Joint Remover 3. J-8849 8. J-9519-7 4. J-9276-2 Bearing Race Installer Spring Remover 9.
Page 83 SECTION 4 REAR SUSPENSION AND DRIVELINE CONTENTS OF THIS SECTION Page Rear S u s p e n s io n ................A x l e ....................4.15 Propeller S h a f t s ................REAR SUSPENSION INDEX Page Page C om ponent P arts R eplacem ent ..........
Page 84 REAR SUSPENSION A N D D R IV E L IN E 4-2 Fig. 2 —Spring Installation Spring Leaf N O T E : The shackle assembly must be attached to the rear spring eye before installing shackle to rear Replacement hanger.
Page 85: Rear Axle
REAR SUSPENSION A ND D R IV E L IN E 4-3 REAR AXLE INDEX Page Page Service I n f o r m a tio n ..............4-3 P ositraction D ifferential U nit ........4-9 Maintenance and A d ju s tm e n ts ..........4-3 Series 30 A x l e s ................4-10 L u b r i c a n t .................
Page 86 REAR SUSPENSION A N D D R IV E L IN E 4-4 Fig. 3 —Rear A xle Cross Section (Series 10-20) Differential Case Cover Thrust Washer Companion Flange Shim (A ) w ith Service Shim Pinion Shaft D ifferential Pinion D eflector Ring Gear Shim...
Page 87 REAR SUSPENSION A N D D R IV E L IN E 4-5 highw ay conditions, turning the steering w heel from left to 1. Pinion bearing noise resulting from a bearing failure can right defect wheel bearing noise, will aid even the beginner in be identified by a co n stan t rough sound.
Page 88 REAR SUSPENSION A N D D R IV E L IN E 4-6 Fig. 4 —Rear A xle V en t Fig. 5 —D ifferential Pinion Shaft Removal Axle Vent 3. L ubricate new bearing w ith wheel bearing lubricant, and Replacement install bearing so th a t it b o tto m s against shoulder in The axle vent system consists o f the vent connector, vent...
Page 89 REAR SUSPENSION AND D R IV E L IN E 4-7 Fig. 7 —Wheel Bearing Removal 5. Fill axle w ith lubricant to a level even w ith b o tto m o f filler hole. See Section O for proper lubricant. .
Page 90 REAR SUSPENSION A N D D R IV E L IN E 4-8 TOOL J-6627 or J- 5504 Fig. 9 —Pressing O u t Wheel Stud 3. Mark relationship o f propeller shaft to com panion flange. Fig. 1 1 —Drive Pinion N u t Removal Separate rear universal jo in t, taping trunnion bearings to jo in t.
Page 91 REAR SUSPENSION A N D D R IV E L IN E 4-9 Fig. 1 5 —Pinion Flange Installation It must be replaced w ith one o f the same part number or w ith an equivalent part if replacement becomes necessary.
Page 92 REAR SUSPENSION A N D D R IV E L IN E 4-10 Fig. 1 7 —Rear A xle Cross Section (Series 30, 5 2 0 0 lb.) D ifferential Bearing Differential Spider Universal Joint Y oke Drive Pinion D ifferential Bearing Adjusting N ut Differential Pinion (Spider) Gear 17.
Page 93 REAR SUSPENSION A N D D R IV E L IN E 4-11 N O T E : A ll axle attachments are im portant attach 4. C onnect hand brake cables and adjust parking brakes as ing parts in that they could affect the performance specified in Section 5.
Page 94 REAR SUSPENSION A N D D R IV E L IN E 4-12 N O T E : To remove inner and outer bearings and Hub and Drum (Fig. 20) cups see "Bearing Cup Replacem ent" for various Removal axles. 1.
Page 95 REAR SUSPENSION A N D D R IV E L IN E 4-13 Fig. 2 4 —Bearing Retainer Ring Removal 5. Press the bearing cup into positive co n tact w ith retainer ring. N O T E : bearing cup-to-retainer ring seating procedure is essential to assure th at an accurate wheel bearing adjustment w ill be obtained, and that adjustment...
Page 96 REAR SUSPENSION A N D D R IV E L IN E 4-14 internal com ponents. Install th ru st washer so th at tang on I.D. o f washer is in key w ay on axle housing. 4. Install adjusting n u t an d com plete th e installation as d irected u nder “...
Page 97 REAR SUSPENSION A N D D R IV E L IN E 4-15 2. Disconnect propeller shaft and remove pinion flange and part of lesser quality or substitute design. Torque deflector. values must be used as specified during reassembly 3. Remove bolts retaining the oil seal retainer to carrier, and to assure proper retention o f this part.
Page 98 REAR SUSPENSION A N D D R IV E L IN E 4-16 Fig. 2 8 -P ro p e lle r S haft, Universal Joint and Bearing Support Assembly S upport yoke in a bench vise. Using soft drift and ham m er, drive on one trunnion 1.
Page 99 REAR SUSPENSION A N D D R IV E L IN E 4-17 N O T E : In addition to packing the bearings, make N O T E : This propeller shaft pinion flange sure the lubricant reservoir at the end o f each fastener is an im portant attaching part in th at it trunnion is com pletely filled...
Page 100 REAR SUSPENSION A N D D R IV E L IN E 4-18 SPECIAL TOOLS • e # « = * Fig. 3 0 —Suspension and Driveline Tools (Series 10-20) J-8614 Companion Flange Rem over—Consisting o f J-8614-1 J-2619 Rear Wheel Bearing and Seal...
Page 101 REAR SUSPENSION A N D D R IV E L IN E 4-19 SPECIAL TOOLS Fig. 3 1 —5 2 0 0 lb. Capacity A x le —Special Tools J-22351 Wheel Oil Seal Installer J-22281 Pinion Flange Oil Seal Installer J-2223 Wheel Bearing Installer J-2222...
Page 102: Hydraulic Brakes
SECTION 5 BRAKES The following caution applies to one or m ore steps in the assembly procedure o f com ponents in this p o rtio n o f the m anual as indicated at appropriate locations by the term inology “ See C aution on page 1 of this S ection”...
Page 103 BRAKES 5-2 V A LV E All m odels have a com bination valve located below the m aster cylinder. The front and rear hydraulic lines are routed through this com bination “ m etering” and “ brake failure warn ing sw itch”...
Page 104 BRAKES 5-3 S EC O N D A R Y SHOE BRAKE MASTER PULL BACK CYLINDER OVERRIDE SPRING PIPE DISTRIBUTIO N A N D S W ITC H ASSEMBLY HO LD D O W N S PR IN G A N D PIN A C T U A T IN G LEVER STAR WHEEL Fig.
Page 105 BRAKES 5-4 LIN IN G INSPECTION Drum Brake Replace w henever the thickness o f any p art o f any lining is w orn to w ithin 1 /3 2 ” o f the shoe table or rivet head whichever is applicable.
Page 106 BRAKES 5-5 1. Clean all dirt from to p o f m aster cylinder and remove cylinder cover and rubber diaphragm . N O T E : Make sure brake flu id in bleeder equip m ent is at operating level and th at the equipment is capable o f exerting 20 to 30 lbs.
Page 107 BRAKES 5-6 N O T E : To assist the bleeding operation, a rawhide m allet may be used to tap the caliper while fluid is flowing. . Remove brake bleeder w rench and hose from the bleeder valve and repeat Steps 2 through on the remaining wheel cylinders.
Page 108 BRAKES 5-7 v i e w FUEL LINE A N D BRAKE PIPE CLIPS REAR BRAKE PIPE V IE W B U N IO N V IE W A Fig. 10—Brake Line R etainers Square o ff ends o f tu be and ream sharp edges w ith tubing in the block w ith approxim ately 1/4”...
Page 109 BRAKES 5-8 Fig. 1 3 —F la rin g O p e ra tio n —P o s itio n in g T u b in g punch is co u n terb o red or hollow ed out to gauge the am ount o f tubing necessary to form a double-lap flare.
Page 110 BRAKES 5-9 BRAKE RELEASE Fig. 17—C heckin g Brake Shoe L in in g Fig. 18—Brake Pedal Free M o vem en t Clearance w ith T o o l J -2 1177 C A U T IO N : "C a u tio n "...
Page 111 BRAKES 5-10 LEG D O W N SPEEDO CABLE LEG D O W N A D JU S TIN G Fig. 1 9 —P arking Brake S ystem . Release the parking brake and rotate rear wheels. No drag C A U T IO N : "C a u tio n "...
Page 112 BRAKES 5-11 Fig. 2 1 —B acking Plate Access H ole Fig. 2 3 —U n h o o k in g Pull Back S pring Removal disassembled fo r service purposes, unless they are broken. It is much easier to assemble and disas 1.
Page 113 BRAKES 5-12 C A U T IO N : Loose adjustment may occur from an adjusting screw that is not properly operating. If the lubrication in the adjusting screw of assembly is contam inated or destroyed, the adjusting screw should be thoroughly cleaned and lubricated. 5.
Page 114 BRAKES 5-13 Install actu ato r return spring. Use Chevrolet brake lining or equivalent and the rivets included in lining package which are o f the correct size. The rivets m ust fit the holes w ith the solid body o f rivet...
Page 115 BRAKES 5-14 Wheel Cylinder Repair Wash the cylinder and m etal parts in denatured alcohol. Remove excess cleaning fluid from the cylinder. Do n ot Wheel cylinders should not be disassembled unless they are use a rag to dry the cylinder as lint from the rag cannot be k ep t from the cylinder bore surfaces.
Page 116 BRAKES 5-15 S m ooth up any slight scores by polishing w ith fine em ery cloth. Heavy or extensive scoring will cause excessive brake lining w ear, and it will probably be necessary to refinish in order to true up the braking surface. If the brake linings are slightly worn and the drum is grooved, the drum should be tu rn ed ju st enough to remove grooves.
Page 117 The shoes should never be relined or C A U T IO N : M ark shoe positions if they are to be reconditioned fo r installation on Chevrolet vehicles. reinstalled. Removal Remove the shoe support spring from the piston.
Page 118 BRAKES 5-17 Installation C A U T IO N : If original shoes are being reinstalled, they must be installed in original positions (as marked at removal). L ubricate new sleeves, new rubber bushings, the bushing grooves an d the end o f the m ounting bolts using Delco M oraine Silicone Lube or its equivalent (Fig.
Page 119 The shoes should never be relined or pass u nder the retaining ears on the inboard shoe (Fig. reconditioned for installation on Chevrolet vehicles. 32). 13. Push the m ounting bolts through to engage the holes in the o u tb o ard shoe and the o u tb o ard caliper ears.
Page 120 BRAKES 5-19 C A U T IO N : Use just enough air pressure to ease CALIPER O VER H A U L the piston out o f the bore. Do not blow piston out of the bore. C A U T IO N : Always use denatured alcohol or brake N O T E : A nother method o f removing the piston is...
Page 121 BRAKES 5-20 w ith clean brake fluid. Position the seal in the caliper bore groove. Lubricate the piston w ith clean brake fluid and assemble a new boot in to the groove in the piston so th a t the fold faces the open end o f the piston as shown in Figure 38.
Page 122 BRAKES 5-21 Light Scoring Light scoring o f the disc surfaces n o t exceeding .015 inch in dep th , w hich m ay result from norm al use, is n o t detrim ental to brake operation. Checking Lateral Runout Tighten the wheel bearing adjusting nut until all o f the play is out o f the bearing.
Page 123 BRAKES 5-22 Each vehicle application o f these cylinders is designed to ham m er. With a box-end or socket w rench, thread a produce the correct displacem ent o f fluid from bo th the front - 32 x 5 /8 ” long self-tapping screw in to the and rear cham bers under norm al, failed and partially failed tube-fitting insert.
Page 124 BRAKES 5-23 B R A KE C O M B IN A TIO N V A L V E C A U T IO N : "C autio n" Page 1 o f this section. N O T E : brake com bination valve is a non- .
Page 125 BRAKES 5-24 T urn ignition key “ O N .” O pen bleed screw while helper applies heavy pressure to brake pedal. Warning lam p SW ITCH should light. Close bleed screw before helper releases TERMINAL pedal. FROM MASTER CYLINDER FROM MASTER N O T E : "reset"...
Page 126 BRAKES 5-25 Remove clutch pedal and shaft, if m anual transm ission, or shaft if autom atic transm ission and low er brake pedal from pedal bracket. SPACER Remove pedal retu rn spring. Installation IN S TR U M E N T PANEL 1.
Page 127 BRAKES 5-26 Remove the rear cable retainer at cross sill. . Install the fro n t cable to the cross sill spring. Pull the cable, left or right, o u t o f hole in cross sill. 9. Low er the vehicle to the floor. With brake shoes exposed remove secondary shoe re...
Page 128 BRAKES 5-27 Air Cleaner Service affect pow er brake response. A t any other tim e, if cleaning of the filter is felt necessary, it should be shaken free o f d irt or Servicing o f the air cleaner is recom m ended and the w ashed in soap and w ater and thoroughly dried, elem ent replaced w hen restriction becom es severe enough to COMPONENT PARTS REPLACEMENT...
Page 129 BRAKES 5-28 SPECIAL TOOLS 1. J-2185 Flaring Tool J-21472 Bleeder Wrench 2. J-8000 Tubing Cutter J-22904 Dust Boot Installer J-8049 Spring Remover 7. J-23518 Bleeder Adapter J-21177 Drum/Shoe Gage J-23709 Combination Valve Pin Retainer Fig. 4 5 —Special T o ols C H E V Y V A N SH O P M A N U A L...
Page 130 SECTION 6 ENGINE CONTENTS OF THIS SECTION Page Page Engine T u n e - U p ................6-1 Engine Mechanical (V ) ...............6-26 Engine Mechanical (In L in e ) ............6-13 Special Tools .................. 6-40 ENGINE TUNE-UP INDEX Page Page General D e s c rip tio n ...............
Page 131 ENG INE 6-2 C rank engine th rou gh at least four com pression strokes to ob tain highest possible reading. Check and record com pression o f each cylinder. I f one or m ore cylinders read low or uneven, inject about a tablespoon o f engine oil on top o f pistons in low reading cylinders (throu gh spark plug p o rt).
Page 132 ENG INE 6-3 • Installation o f plugs to corroded spark plug hole affect the ignition timing. C orrect any interference or binding condition noted. threads. . E xam ine distributor points and clean or replace if necessary. . C onnect spark plug wiring. •...
Page 133 ENGINE 6-4 W EIGHT ROTOR ASSEMBLY R.F.I. SHIELD C A M LUBRICATOR C O N T /.C T SET ATTAC H IN G CIRCUIT BREAKER SCREW PLATE ASSEMBLY PERMANENT LUBRICATION RESERVOIR VACUUM BUSHING ASSEMBLY PRIMARY ACCESS PASSAGE TERMINAL FOR ENGINE OIL QUICK FUMES DISCONNECT...
Page 134 ENG INE 6-5 HOLD D O N O T SUCK IN TO O MUCH VERTICAL ELECTROLYTE FLOAT MUST BE FREE TAKE READING AT EYE LEVEL Fig. 9 —M a n ifo ld Heat C o n tro l Valve (In Line ) Fig.
Page 135 ENG INE 6-6 Fig. 11—Crankcase V e n tila tio n Systems (In Line) Fig. 1 0 —M a n ifo ld H eat C o n tro l V alve (T y p ic a l V 8 ) In a “Closed Positive”...
Page 136 ENGINE 6-7 CRANKCASE VENTILATION FILTER Fig. 13—Crankcase V e n tila tio n Valve be burned. The “Closed Positive” ventilation system draws clean air from the carbureto r air cleaner and has a nonvented oil filter cap. V entilation valve should be replaced at intervals specified in Section O.
Page 137 ENG INE 6-8 IN LIN E ENGINES • Remove distrib u to r cap and recheck poin t setting. If dwell is still n o t w ithin specifications check the distributo r as ou tlined in Section CHECK DWELL V A R IA T IO N Slowly accelerate engine to 1750 rpm and no te dwell reading.
Page 138 ENG INE 6-9 ADJUST IDLE SPEED (FIG. 17) With engine running at operating tem perature, choke TRANSMISSION VEHICLE EMISSION CONTROL INFORMATION AIR EXHAUST valve in fully open position, parking brake on and drive MANUAL EMISSION CONTROL AUTOMATIC GEN ERAL M OTORS CORPORATION [ f t ] DWELL 33°...
Page 139 ENGINE 6-10 C ra n k in g speed below normal—Excessive resistance in cables or starting m o to r; excessive m echanical drag in engine. Uneven cranking speed— Uneven com pression, defective starter to starter drive. IG N ITIO N SWITCH With voltm eter connected as described for the Cranking Voltage T est, turn ignition switch to ON.
Page 140 ENG INE 6-11 SECONDARY RESISTANCE FUEL PUMP Use eq uipm ent as directed by m anufacturer. If the ow ner has com plained o f poor high speed per form ance, th e fuel pum p may be at fault. Too low a pum p •...
Page 141 ENGINE 6-12 The following valves can be adjusted w ith engine in determ ined by ro tatin g push rod w ith fingers as the num ber six firing position: n ut is tightened (Fig. 23). When push rod does n ot Engine —...
Page 142 ENG INE 6-13 ENGINE M ECHANICAL IN-LINE ENGINE INDEX Page Page G eneral D e sc rip tio n ..............6-13 Oil Pum p .................6-19 R e m o v a l................6-19 C om ponent R eplacem ent and A djustm ent ......6-13 I n s ta lla tio n .................
Page 143 ENGINE 6-14 Fig. 3 L —Suspension-to-Frame Attaching Bolts Disconnect shock absorbers at frame or at low er control D isconnect accelerator linkage at dash panel m ounted arm attach m en t and position shocks up and rearw ard. bell crank. Remove propeller shaft as outlined in Section 4—install D isconnect pow er brake vacuum line at inlet m anifold.
Page 144 ENGINE 6-15 Install clutch housing rear cover and starter. Install the transm ission and clutch housing as o u t lined in Section 7. Install clutch housing bolts and to rq u e to specifica tions. • Install autom atic transm ission (if so equipped). Position engine adjacent to the transm ission and align th e converter w ith th e flyw heel.
Page 145 EN G IN E 6-16 C onnect TCS system electrical leads at carburetor C om plete torquing th e inlet to exhaust m anifold b o lt m ounted CEC valve and at tem perature sw itch—position and tw o nuts at th e center o f the m anifold to specifica harness in rocker arm cover clips.
Page 146 ENGINE 6-17 Locating Noisy Lifters and rem ove d istribu to r cap and plug wire assembly (if n o t previously done). C rank engine until distributor ro to r points to Locate a noisy valve lifter b y using a piece o f garden hose num ber one cylinder position an d breaker points approxim ately four feet in length.
Page 147 ENGINE 6-18 N O T E : Grease may be used to hold the locks in place while releasing the compressor tool. . Install spark plug and torque to specifications. Install and adjust valve mechanism as outlined. C Y LINDER HEAD ASSEMBLY Removal 1.
Page 148 ENG INE 6-19 Install new fro n t seal on crankcase front cover, pressing tips in to holes provided in cover. Install new side gaskets on cylinder block (Fig. N O T E : Do not use sealer. Position oil pan to block, making sure th at seals and gaskets rem ain in place, install and torque pan screws to specifications.
Page 149 ENGINE 6-20 Fig. 11 L — Removing Oil Seal (Upper Half) Typical Fig. 1 3 L —Removing Torsional Damper N O T E : Oil pum p should slide easily into place, if not, remove and reposition slot to align w ith dis to tap a brass pin punch on one end o f seal until it trib u to r tang.
Page 150 ENG INE 6-21 to pro tect seal bead from sharp corner o f seal seat surface in cylinder case. - C A U T IO N : Installation tool must remain in posi tion until seal is properly positioned w ith both ends flush with block.
Page 151 ENGINE 6-22 W ithout Cover Removed With crankshaft pulley and dam per rem oved, pry old seal o u t o f cover from the fro n t w ith a large screwdriver, being careful n ot to damage the seal surface on the crankshaft.
Page 152 ENGINE 6-23 Fig. 2 0 L —Checking Camshaft Gear R unout Removal Fig. 21 L—Checking Tim ing Gear Backlash Remove valve lifters as outlined. T IM IN G GEARS Remove crankcase front cover as outlined. Remove grille as outlined in Section 13. Replacement Remove fuel pum p as o utlined in Section Align tim ing gear m arks th en remove the tw o cam shaft...
Page 153 ENGINE 6-24 Fig. 2 3 L —Installing Crankshaft Gear 2. Install flyw heel on crankshaft and position to align dowel hole o f crankshaft flange and flywheel (Fig. 24L). I n s t a l l f ly w h e e l re ta in in g bolts an d...
Page 154 ENGINE 6-25 Rem ove th e tw o bolts securing clutch cross shaft Rear Mount Replacement (Fig. 26L) b rack et to fram e side rail, and position clutch linkage away from engine m o unt. 1. Raise vehicle on hoist and support transm ission so as n o t Rem ove m ount-to-bracket through-bolt.
Page 155 ENGINE 6-26 ENGINE M ECHANICAL V-8 ENGINES INDEX Page Page General D e s c r ip tio n ..............6-26 R e m o v a l................6-32 I n s ta lla tio n ................6-32 C om ponent R eplacem ent and A djustm ent (V ) ....6-26 Oil P u m p ...................
Page 156 ENGINE 6-27 11. D isconnect E vaporation C ontrol System lines a t rocker arm cover and at carburetor—position lines to one side. D isconnect pow er brake vacuum hose at rocker arm tube-to-hose junction. Raise vehicle on a hoist and disconnect: •...
Page 157 ENG INE 6-28 Remove auto m atic transm ission (if so equipped). Lower engine secured b y the hoist, and support engine o n blocks. Remove starter and converter housing underpan. Remove flyw heel-to-converter attaching bolts. S upport transm ission on blocks. D isconnect th ro ttle linkage and vacuum m odulator o n Powerglide.
Page 158 ENG INE 6-29 connect fro n t brake pipe at equalizer tee and connect INTAKE M A N IFO LD rear brake pipe at left fram e rail connector. Removal Install cross shaft and connect clutch linkage and/or transm ission linkage as outlined in Section 7. Drain radiator and remove air cleaner.
Page 159 ENG INE 6-30 Installation Install (if rem oved) oil filler bracket, air cleaner bracket, coil, accelerator retu rn spring and bracket and accelerator Clean gasket surfaces on cylinder head an d rocker arm bellcrank. cover w ith degreaser th e n , using a new gasket, install Install d istributor, positioning ro to r at chalk m ark, then rocker arm cover and to rq u e to specifications.
Page 160 ENG INE 6-31 M oderate Rapping Noise— Probable causes are: C rank engine until m ark on torsional dam per lines up w ith center or “ O ” m ark on the tim ing tab Excessively high leakdow n rate. fastened to th e crankcase fro n t cover an d the engine Leaky check valve seat.
Page 161 ENG INE 6-32 C A U T IO N : Use no sealer on engines using a com N O T E : Grease may be used to hold the locks in position S T E E L ASBESTOS gasket. place w hile releasing the compressor tool.
Page 162 ENG INE 6-33 Fig. 1 1 V —Oil Seal Installation Tool . Coat seal lips an d seal bead w ith light engine oil — keep oil off seal m ating ends. SIDE Position tip o f to o l betw een crankshaft and seal seat in GASKETSj cylinder case.
Page 163 ENG INE 6-34 APPLY S E A L A N T T O S H A D E D A R EA S O N L Y Fig. 1 4 V —Sealing Bearing Cap Roll seal around crankshaft using tool as a “shoehorn” to Fig.
Page 164 ENG INE 6-35 Install fan belt and adjust to specifications using strand tension gauge. . Fill cooling system , start engine and check for leaks. Crankcase Front Cover Removal Remove oil pan as outlined. Rem ove torsional dam per as outlined. Remove w ater pum p as outlined in Section Remove crankcase fro n t cover attaching screws and remove fro n t cover and gasket, th en discard gasket.
Page 165 ENG INE 6-36 J-5825 Fig. 2 0 V —Removing Crankshaft Sprocket Timing Chain and/or Sprockets Replacement Remove torsional dam per and crankcase fro n t cover as outlined. 2. C rank engine u ntil m arks on cam shaft and crankshaft sprockets are in alignm ent (Fig.
Page 166 ENG INE 6-37 If cam shaft readings for all lobes are w ithin specifi cations, remove dial indicator assembly. . Install an d adjust valve m echanism as outlined. Removal Remove valve lifters as outlined. Remove crankcase fro n t cover as outlined. Remove grille as outlined in Section 13.
Page 167 ENG INE 6-38 CONVERTER BOLT AREA GEAR DEPRESSED TRANS. > SYNCHROMESH AUTOMATIC Fig. 2 5 V —Flywheel Installation (Typical) C oat thread end o f bolts w ith sealer th e n install b olts and torque to specifications. Engine Mounts Engine m ounts are th e non-adjustable typ e and seldom require service.
Page 168 ENG INE 6-39 Rear Mount Replacement (Fig. 27V) CYLINDER HEAD TORQUE SEQUENCE Raise vehicle on hoist and support transm ission so as n o t to interfere w ith support crossm em ber removal. Remove bolts securing rear m o u n t to sup p o rt cross m em ber.
Page 169 ENG INE 6-40 SPECIAL TO O LS (.003") Rocker Arm Stud J-5715 Engine L ift K it J-4536 Reamer J-1264 (0-200 Ft. Lb.) Torque Wrench (.013” ) J-6036 J-8058 (0-50 Ft. Lb.) Rocker Arm Stud Installer J-6880 J-5853 (0-100 in lb.) J-5802 Rocker Arm Stud Remover Indicator Set (Cylinder Bore)
Page 170 Installation ................6K -5 GENERAL DESCRIPTION All Chevrolet trucks have pressure ty p e engine cooling pressure. The higher pressure raises th e boiling po in t o f the system s w ith therm ostatic control o f coolant circulation. The coolant w hich increases the efficiency o f th e radiator.
Page 171 ENG INE COOLING 6K-2 procedures are covered in this section. For rad iato r service Water pum p com ponents are n o t serviced separately; th e re refer to Section 13 o f this m anual. R adiator fan shroud fore, in th e event o f w ater p um p failure, it will be necessary to replacem ent is covered in Section 11 o f this m anual.
Page 172 ENG INE C O OLING 6K-3 Add the liquid p o rtio n (No. 1) o f the cooling system cleaner. Fill the cooling system w ith w ater to a level o f ab o u t 3 inches below the to p o f the overflow pipe. Cover the radiator and run th e engine at m oderate speed until engine coolant tem p eratu re reaches 180 degrees.
Page 173 ENG INE C O O LING 6K-4 Submerge th e valve com pletely and agitate th e water thoroughly. U nder this condition the valve should open fully. . Remove the th erm o stat and place in a 33% glycol solution °...
Page 174 ENG INE C O OLING 6K-5 Vi6 DIA. ■ „ ------------- .010 SHIM = - 0 - R U N OUT TOTAL RUN-OUT + 2 = SHIM THICKNESS Fig. 8 —Shim Fabrication Dimensions TO OBTAIN ZERO ( - 0 - ) RUN-OUT Fig.
Page 175 SECTION 6M ENGINE FUEL N O T E : Also refer "Emission Control Systems" Booklet fo r required' maintenance and warranty inform ation. CONTENTS OF THIS SECTION P ag e P ag e C arburetors ........6M -1 Fuel Pumps ................6 M -1 5 A ccelerators and Choke C ontrols 6M -9 Special Tools ................
Page 176 ENGINE FUEL 6M-2 PRELIMINARY CHECKS (ALL CARBURETORS) 1. Thoroughly w arm -up engine. If th e engine is cold, allow Check and adjust choke as required, using procedures to run for at least 15 m inutes. specified in this section. 2.
Page 177 ENG INE FUEL 6M-3 ROD IN END OF SLOT HOLD DOWN ON CHOKE VALVE GAUGE BETW EEN CHOKE VALVE AND A IR HORN W ALL BEND ROD TO ADJU ST CAM FO LLO W ER MUST BE HELD FIRM LY ON SECOND S TE P OF FAST ID LE CAM AGAIN ST HIGH STEP position by turning the external choke lever counterclockw ise.
Page 178 E NG INE FUEL 6M-4 ( T ) PLACE GAUGE BETWEEN UPPER EDGE OF CHOKE V A L V E AND AIR DIAPHRAGM HORN W ALL PLUNGER MUST BE SEATED. USE OUTSIDE VACUUM V A C U U M BREAK ADJUSTMENT Fig.
Page 179 ENGINE FUEL 6M-5 Fig. 1 3 C —C hoke C oil R od A d ju s tm e n t (2 G V ) To adjust, bend lever at point shown w ith screwdriver end. 4M V (Fig. 14C) Fig.
Page 180 ENGINE FUEL 6M-6 Fig. 15C —C .E .C . V alve A d ju s tm e n t C.E.C. V A L V E ADJUSTMENT (L-6 ENGINES) (EXCEPT 30 SERIES, CARGO VANS) IM P O R T A N T : Do not set CEC Valve adjustment to idle R.P.M .
Page 181 ENG INE FUEL 6M-7 ALL CARBURETORS m o to r and b attery and reduces the possibility o f backfiring while attem p tin g to start the engine. A fuel pum p clam ped to REM O VAL (Figs. K1, K2 and K3) the bench, a small supply o f fuel and the necessary fittings enable the carburetor to be filled and the operation o f the Flooding, stum ble on acceleration and o th e r perform ance...
Page 182 E NG INE FUEL 6M-8 IN S TA LLA TIO N . C onnect C.E.C. Valve (L- ) electrical wiring and attach vacuum lines. 1. Be certain th ro ttle body and intake m anifold sealing C onnect idle stop wiring connector to solenoid. surface are clean.
Page 183 ENG IN E FUEL 6M-9 AU TO M A TIC CHOKE COIL ASSEMBLIES A D D IT IO N A L EXTERN AL SETTINGS A N D ADJUSTMENTS Refer to “ E xternal A djustm ents” for choke coil adjustm ent ALL VEHICLES - EXCEPT VEGA procedures and typical installed views.
Page 184 ENG INE FUEL 6M-10 Fig. K 6—Accelerator Linkage— L 6 Engine Set dw ell a n d tim in g an d rec h eck low idle speed. H old carburetor thro ttle in wide open position, push th ro ttle rod rearw ard (to position accelerator pedal at the R e c o n n e c t electrical c o n n e c to r to th e solenoid.
Page 185: Maintenance And Service
ENGINE FUEL 6M-11 AIR CLEANERS P ag e P age G eneral D escription ..............6 M -11 Elem ent R eplacem ent ..............6M -11 M aintenance P ro c e d u re s ............6 M -1 1 Inspecting Paper E le m e n t............6 M -1 2 GENERAL DESCRIPTION Air cleaners on all models operate prim arily to remove dust paper elem ent air cleaner and the oil bath air cleaner.
Page 186 ENG INE FUEL 6M-12 17 IN . LBS. TO RQ UE TO AIR T~TK CLEANER 4 .8 8 CHAMFER END ? T U D C (1 7 IN . LBS.) E XTENSIO N ■ ^ S U P P O R T OIL LEVEL AIR CLEANER G A G E TUBE...
Page 187 ENG INE FUEL 6M-13 S tart and idle engine. With air tem p eratu re below 8 5 °F, T H E R M O S TA TIC A LLY CO NTROLLED snorkel passage should be closed, View B. When dam per A IR CLEANER door begins to open snorkel passage, remove air cleaner cover and observe therm om eter reading.
Page 188 ENG INE FUEL 6M-14 Fig. 8 A —Checking Vacuum Diaphragm Fig. 7 A —Tem perature Gauge Installation TEMPERATURE SENSOR REPLACEMENT Removal VACUUM MOTOR REPLACEMENT Remove air cleaner from engine and disconnect vacuum Removal hoses at sensor. 2. Pry up tabs o f sensor retaining clip (Fig. 11 A). Rem ove air cleaner from engine.
Page 189 I n s p e c tio n ................. 6 M -1 6 Installation ................. 6 M -1 6 GENERAL DESCRIPTION The fuel pum p (Fig. IP and 2P) used on all Chevrolet arm. On V engines, a push rod (located betw een the vehicles covered in this m anual is the diaphragm type.
Page 190: Service Procedures
ENGINE FUEL 6M-16 SERVICE PROCEDURES INSPECTION If fuel flows from pum p in good volum e from pipe at carb ureto r, check fuel delivery pressure to be certain th at pum p is operating w ithin specified limits as follows: The fuel pum p (Fig.
Page 191 ENGINE FUEL 6M-17 SPECIAL TOOLS 2 2 9 7 3 0 1 7 6 J - 1 1 3 7 J— 4 5 5 2 J - 8 3 2 8 BENDING TOOLS J-1 137 Choke Rod J -9 7 8 9 Universal Bending C arb ureto r Kit...
Page 192 C H E V Y V A N S H O P M A N U A L...
Page 193 SECTION 6T EMISSION CONTROL SYSTEMS INDEX Page Page Positive Crankcase V e n tila tio n ..........6T-1 Transmission C ontrolled Spark System ......6T -1 C ontrolled C om bustion S y s t e m ..........6T -1 Air Injection R eactor S y s te m ..........6 T -1 2 Evaporation Emission C o n t r o l ..........6T-1 POSITIVE CRANKCASE VENTILATION This system removes engine crankcase vapors w hich result...
Page 194 EMISSION C O N TR O L SYSTEM 6T-2 dieseling tendencies by allowing th e th ro ttle valve to close relay coil and to ground, also as long as the relay points are beyond th e norm al idle position w hen the ignition is turned closed it provides a path to ground for the CEC solenoid (Fig.
Page 195 EMISSION CO N TR O L SYSTEM 6T-3 COMPONENT DESCRIPTION Idle Stop Solenoid The idle stop solenoid is a tw o position electrically oper ated con trol, used to provide a predeterm ined th ro ttle setting (Fig. 6T-5). In the energized position (plunger extended) the plunger contacts th e carburetor th ro ttle lever and prevents full closing o f th e carb uretor th ro ttle plates.
Page 196 EMISSION C O N TR O L SYSTEM 6T-4 Fig. 6 T -9 —Powerglide Transmission Switch Location Fig. 6 T -8 —Manual Transmission Switch (Sectional V iew ) minal and the sw itch housing (Fig. ). The m olded top and the plunger are non-conductors and therefore insulate the cup contact and sw itch term inal when th e plunger is depressed.
Page 197 TROUBLE SH O O TIN G GUIDE SIX CYLINDER ENGINE C O M P L A IN T C O M P L A IN T Poor High Gear Perform ance Excessive Creep at Idle S tum ble— S tall— Cold or H ot S tart High Hole Speeds Excessive Fuel C onsum ption Dieseling...
Page 198 (CEC PLUNGER IS EXTENDED) VACUUM ADVANCE DIAGRAM FOR SIX CYLINDER T.C.S. SYSTEM...
Page 199 EMISSION C O N TR O L SYSTEM 6T-7 TRA N SM ISSIO N CO N TRO LLED SPA R K SYSTEM SMALL V -8 ENGINE GENERAL DESCRIPTION C ontrol o f exhaust emissions em itted by vehicles using the small block V engine, is accom plished by elim inating ignition vacuum advance w hen the vehicle is operating in low forw ard...
Page 200 EMISSION CON TR O L SYSTEM 6T-8 Fig. 6 T -1 4 -S m a ll V 8 TCS System Fig. 6 T -1 6 —Small V 8 Idle Stop Solenoid (High Gear Delay Relay) COMPONENT DESCRIPTION In low gear o peratio n, w ith engine tem perature above 82 degrees, the tem perature sw itch cold override p oin ts open Idle Stop Solenoid (Fig.
Page 201 EMISSION CONTROL SYSTEM 6T-9 Vacuum Advance Solenoid The vacuum advance solenoid is located on the right rear portion o f the inlet m anifold (Fig. 6T-17). This electrically operated tw o-position plunger controlled valve serves to supply or deny vacuum to the d istribu tor vacuum advance unit.
Page 202 TROUBLE SH O O TIN G GUIDE SMALL V-8 ENGINE C O M P L A IN T C O M P L A IN T C O M P L A IN T Engine Stalls a t Idle P oor High Gear Perform ance V acuum at all Times Excessive Creep at Idle S tu m b le—...
Page 203 VACUUM ADVANCE DIAGRAM FOR SMALL V-8 T.C.S. SYSTEM...
Page 204 The Air Injection R eactor (A .I.R .) System (Fig. 21 & 22), backfiring during this richer period. used on Chevrolet passenger car engines consists of: the air A t high engine speeds excess air is dum ped through the injection pum p (w ith necessary brackets and drive attach ...
Page 205 Fig. 6 T -2 1 -S ix -C y lin d e r A .I.R . System...
Page 206 CHECK VALVE DIVERTER VALVE CHECK VALVE AIR PUMP Fig. 6 T -2 2 —Eight-C ylinder A .I.R . System...
Page 207 EMISSION CO N TR O L SYSTEM 6T-15 VENT HOLE (DO NO T OIL) HOUSING FILTER FAN DRIVE HUB ROTOR SHAFT Fig. 6 T -2 4 —Schematic of A .I.R . System OUTLETS' PRESSURE RELIEF VALVE INLET- DIVERTED AIR OUTLET SIG N AL' LINE C O NN ECTIO N...
Page 208 EMISSION C O N TR O L SYSTEM 6T-16 Fig. 6 T -2 6 —Checking A .I.R . Pump Belt Tension C A U T IO N : not pry on the pump housing. Fig. 6 T -2 8 —Removing Centrifugal Filter Distortion o f the housing will result in extensive damage to the A ir Injection Pump.
Page 209 EMISSION CON TR O L SYSTEM 6T-17 • Install and adjust drive belt as outlined above. • If leak is suspected on the pressure side o f the system or • Hold pum p pulley from turning by com pressing drive any tubes and/or hoses have been disconnected on the belt then torque pum p pulley bolts to 25 ft.
Page 210 EMISSION CO N TR O L SYSTEM 6T-18 Fig. 6 T -3 2 —Rem oving Check Valve Replacement Fig. 6 T -3 4 —M om entary Blast o f A ir Through Diverter Valve During Engine Over-Run • D isconnect pum p o u tlet hose a t check valve. Remove check valve from air m anifold, being careful not to bend C A U T IO N : Diverter...
Page 211 EMISSION CONTROL SYSTEM 6T-19 • Rem ove any carbon build up w ith a wire brush. removed. If excessive noise does not exist with the • Warped or b u rn ed tubes m ust be replaced. belt removed proceed as follows: Replacement •...
Page 212 SECTION 6Y ENGINE ELECTRICAL CONTENTS OF THIS SECTION P age P age B a tte r y ...., ..............6Y -1 S tarting System .................6Y -25 Charging S y s te m ............... 6 Y -9 Special Tools ................6 Y -2 7 Ignition System ...............
Page 213 ENGINE ELECTRICAL 6Y-2 ratings. F o r battery replacem ent, a unit o f at least equal pow er confused w ith th e am pere hour rating since tw o batteries w ith rating m ust be selected. the same am pere hour rating can have quite different w att SERVICING PERIODIC COMMON CAUSES OF FAILUR E...
Page 214 ENG INE E LEC TR IC A L 6Y-3 the vent plugs and may form an explosive atm osphere around the B attery itself if ventilation is poor. This explosive gas m ay rem ain in or around the B attery for several hours after it has been charged.
Page 215 E NG INE ELEC TR IC A L 6Y-4 Fig. 7b —Testing Specific Gravity (Typical) service if it has perform ed satisfactorily in the past. An “ em ergency b oo st charge,” consisting of a high charging rate for a short period o f tim e, m ay be applied as a tem porary Fig.
Page 216 ENG INE E LEC TR IC A L 6Y-5 CHARGING GUIDE R ecom m ended R ate* and Tim e for Fully Discharged C ondition W att R ating 5 A m peres 10 Amperes 20 Amperes 30 Amperes 40 Amperes 50 Amperes Below 2450 10 Hours...
Page 217 ENGINE ELEC TR IC A L 6Y-6 CHART NO. 2 INSTRUMENT TEST VO LTAG E AND TEM PERATURE CHART A num ber o f suppliers have approved testing equipm ent available. These testers have a program m ed test procedure consisting o f a series.
Page 218 ENGINE ELEC TR IC A L 6Y-7 R A D IA T O R UPPER TIE BAR STARTER M O T O R S O L E N O ID ( ^ V R A D IA T O R ' BAFFLE R.H E N G IN E W IR IN G...
Page 219 ENG INE ELEC TR IC A L 6Y-8 EN ER G IZER /B A TTER Y TEST PROCEDURE Step 3: Program m ed instrum ent test Step 4: Load test* To determ ine th e ability o f an Energizer or b attery to function properly requires testing.
Page 220 ENGINE ELEC TR IC A L 6Y-9 CH ARG IN G SYSTEMS INDEX P age P age F ield C irc u it R esistan c e W ire T ests 6 Y -1 4 G en e ra l D escrip tio n 6Y -9 F ie ld R e la y C h eck an d A d ju stm e n t 6 Y -1 5...
Page 221 ENGINE ELEC TR IC A L 6Y-10 Fig. 1c—10 DN Series 100B Type Delcotron The double-contact regulator assembly (Fig. 2c) consists o f w ith a h y palon insulation m ust be used w hen replacing a a double-contact voltage regulator unit and a field relay unit. fusible link.
Page 222 ENG INE E LEC TR IC A L 6Y-11 MAINTENANCE AND ADJUSTMENTS A t regular intervals, inspect the term inals for corrosion and SYSTEM C O N D ITIO N TEST loose connections, an d the wiring for frayed insulation. Check m ounting bolts for tightness.
Page 223 ENG INE E LEC TR IC A L 6Y-12 Fig. 4 c —Voltage Setting Test Connection nect the connector. Then repeat S tep . T urn on high-beam headlights and heater blow er m o to r tu rn voltage adjusting screw (Fig. 3c) to raise to high speed, run engine at or above 1500 rpm (for a few m inutes, if necessary) an d read the voltage on m eter.
Page 224 ENG INE E LE C TR IC A L 6Y-13 SYSTEM COMPONENT TESTS I f the D elcotron fails to m eet the test specifications, remove it and perform bench tests and m ake repairs D elcotron O u tp u t Test— A m m e te r M e th o d (Fig. 5c) needed.
Page 225 ENGINE ELEC TR IC A L 6Y-14 Test as Follows: N O T E : This test lamp procedure may be used on lamp type circuits and on am meter circuits. D isconnect conn ector from regulator and tu rn ignition If Lamp Fails to Go O ut, or if A m m eter Shows Discharge switch to “...
Page 226 ENGINE ELEC TR IC A L 6Y-15 Field Relay Checks and Adjustment To check for a faulty relay proceed as follows: 1. C onnect a voltm eter into the system at the regulator No. 2 term inal to ground (Fig. 7c). O perate th e engine at fast idle (1500 to 2000 rpm ) and observe voltm eter reading.
Page 227 ENG INE ELEC TR IC A L 6Y-16 FWD. VIEW A Fig. 12c—Delcotron Installation Double Groove Pulley S upport generator an d remove generator m o u n t b o lt and remove from vehicle. 1. Place a 1 5 /16” socket (w ith w rench flats on th e drive end Reverse removal procedure to install, then adjust drive or use A dapter J-21501 and a box w rench) on retaining belt as described under tune-up section.
Page 228 ENGINE E LEC TR IC A L 6Y-17 IGNITION SYSTEMS INDEX P age M a i n t e n a n c e ........6 Y -1 7 Page P eriod ic M a i n t e n a n c e ........... 6Y -1 7 P erfo rm an ce D iagnosis 6 Y -2 0 S p ark Plugs...
Page 229 ENGINE ELEC TR IC A L 6Y-18 PRIMARY LEAD CAM LUBRICATOR CONTACT SET ATTACHING SCREW QUICK Fig. 2 i—D istributor Lead Arrangements DISCONNECT TERMINAL Setting Dwell Angle Six Cylinder Engine Distributor BREAKER PLATE The p o in t opening o f new points can be checked w ith a ATTACHING SCREWS feeler gauge, b u t the use o f a feeler gauge on rough or uncleaned used points is n o t recom m ended since accurate...
Page 230 ENGINE ELEC TR IC A L 6Y -19 readings betw een idle speed and 1750 engine rpm should n o t exceed 3°. Excessive variation in this speed range indicates wear in the distributor. N O T E : Cam angle readings taken at speeds above 1750 engine rpm may prove unreliable on some cam angle meters.
Page 231 ENG INE E LEC TR IC A L 6Y-20 T urn th e adjusting screw clockwise (Fig. i) until N O T E : If necessary, remove secondary leads from th e lam p lights, th en give the w rench tu rn in the the distributor cap after first marking the cap tower opposite direction (counterclockw ise) to obtain the...
Page 232 ENG INE E LEC TR IC A L 6Y-21 Remove th e spring retainer, remove th e breaker plate assembly from the d istrib u to r housing. Remove the contact p o in t and condenser from th e breaker plate. Remove th e felt washer and plastic seal located beneath th e breaker plate.
Page 233 ENGINE ELECTRICAL 6Y-22 Condenser Breaker Plate Housing Drive Gear Ma inshaft Contact Point Felt Washer 7a. Tanged Washer Advance Weights Assembly 5a. Plastic Seal Shim Washer Rotor Cam Weight Retaining Ring Vacuum Advance Drive Gear Pin Weight Springs Base Assembly Unit Fig.
Page 234 ENG INE ELEC TR IC A L 6Y-23 N O T E : I t may be necessary to move rotor slightly to start gear into mesh w ith camshaft gear, but rotor should line up w ith the m ark when distributor is down in place.
Page 235 ENG INE ELEC TR IC A L 6Y-24 SPARK PLUG AND WIRE SERVICE Removal and Inspection 1. To disconnect wires, pull only on the b o o t. Pulling on the wire might cause separation o f th e core o f the wire. Rem ove spark plugs and gaskets using a 5 /8 ”...
Page 236 ENGINE E LEC TR IC A L 6Y-25 STARTING SYSTEM INDEX Page Page G eneral D e s c rip tio n ..............6 Y -2 5 S tarting M otor and Solenoid C h e c k s ......6 Y -2 6 M aintenance and A d ju s tm e n ts ...........
Page 237 ENGINE ELECTRICAL 6Y-26 If the solenoid does n o t feel w arm , it should pull in points in the cranking circuit as outlined below and observe the reading w ith the starting sw itch closed and th e m o to r whenever th e voltage available at the SWITCH term inal is 7.7 volts or m ore.
Page 238 ENG INE E LEC TR IC A L 6Y-27 SPECIAL TOOLS J -2 1 5 0 ) PULLY ADAPTER Fig. 2s—Special Tool C H E V Y V A N SH O P M A N U A L...
Page 239 SECTION 7 CLUTCHES TRANSMISSIONS CONTENTS OF THIS SECTION P ag e P age C lutch C ontrols ................7-1 T urbo Hydra-M atic 350 ............7 -9 C lu tc h e s ...................7-3 Special Tools ................7 -1 8 Manual T ransm issions..............7-6 CLUTCH CONTROLS INDEX P ag e...
Page 240 CLUTCHES & TRANSM ISSIONS 7-2 BRAKE PEDAL CLUTCH LEVER BRKT. ASM CLUTCH PEDAL ASSEMBLY GA 10 GS 20-30 CLUTCH PEDAL ASSEMBLY GE 20-30 CLUTCH CONTROL RODS CLUTCH SHAFT & BRACKET Fig. 1—Clutch Pedal and Linkage Assemblies Installation and not the usable stroke, the lash m ust be reduced to specifications in order to gain the additional stroke benefit.
Page 241 CLUTCHES & TRANSMISSIONS 7-3 1. Slide one pedal shaft bushing over shaft, install shaft in support enough to still clear pedal bum per stop, hook pedal retu rn (or overcenter) spring to pedal, th en rotate pedal forw ard o f bum per stop; slide shaft into position in support and release pedal against bum per stop.
Page 242 CLUTCHES & TRANSM ISSIONS 7-4 Fig. 5 —Gauging Shim R equirem ent ing springs per step 2. If trouble still exists, loosen clutch-to-flyw heel m ounting b o lt at position o f lowest reading (leave oth er bolts tight), pry cover, Fig.
Page 243 CLUTCHES & TRANSMISSIONS 7-5 5. T urn C lutch assembly until “ X” m ark on clutch cover flange lines up w ith “ X” m ark on flywheel. COAT THIS GROOVE . Install attaching bolts and tighten each one a turn at a tim e to prevent distorting the cover as the spring pressure is taken up.
Page 244 CLUTCHES & TRANSM ISSIONS 7-6 COMPONENT REPLACEMENT as the holding screws are removed or when clutch is CLUTCH ASSEMBLY removed from engine. Removal From Vehicle Installation To Vehicle Before removing clutch from flyw heel, m ark w ith a punch 1.
Page 245 CLUTCHES & TRANSMISSIONS 7-7 2ND & 3RD LEVER 1ST & REV LEVER 2ND & 3RD LEVER 1 ST-REVERSE CONTROL ROD 1ST & REV LEVER 2ND-3RD CONTROL ROD Fig. 8 —3-Speed Column Gearshift Controls not force the transmission into the clutch disc hub. Installation Do not let the transmission hang unsupported in the 1.
Page 246 CLUTCHES & TRANSM ISSIONS 7-8 12. Refill transm ission w ith lubricant recom m ended in L ubri cation, Section “0 ” o f this m anual. 13. Check and if necessary, adjust clutch or transm ission control linkage to achieve proper operation. TRANSM ISSION A LIG N M E N T In some instances where “...
Page 247 CLUTCHES & TRANSMISSIONS 7-9 SPEEDOMETER D R IV E N GEAR REPLACEMENT DETENT CAM DETENT SPRING D isconnect speedom eter cable, remove lock plate to housing b o lt and lock washer and remove lock plate. Insert screw driver in lock plate slot in fitting and pry fitting, gear and shaft from housing.
Page 248 CLUTCHES & TRANSM ISSIONS 7-12 DETENT CABLE ADJUSTMENT Holding lever and cable in above position, push snap lock on cable dow nw ard un til to p is flush w ith cable. Refer to Figure 2 N O T E : Do not lubricate cable.
Page 249 CLUTCHES & TRANSMISSIONS 7-13 7. Reinstall transmission support crossm ember to trans 2. Remove oil pan , governor cover, governor and all park mission and frame. lock pawl attaching parts. . Remove transm ission lift equipm ent. 3. Slide pawl tow ards front o f case and cock on shaft. 9.
Page 250 CLUTCHES & TRANSM ISSIO NS 7-14 C o n v erter-leak in weld. With the selector lever in the Park position, the parking Pum p “ 0 ” ring seal— dam aged. (Also check pum p paw l should freely engage and prevent the vehicle from rolling. The p o inter on the ind icator q u adrant should line up properly groove and case bore.) w ith the range indicators in all ranges.
Page 251 CLUTCHES & TRANSMISSIONS 7-15 . Allow epoxy cem ent to dry for three hours and retest for Approxim ate Drive L-6 and leaks, as outlined in Steps l and 2. A ltitude o f Check Neutral Reverse (F t. A bove Park O IL PRESSURE CHECK Sea Level)
Page 252 CLUTCHES & TRANSM ISSIONS 7-16 The gap betw een the opposite m odulator sleeve end and 3. Bellows Comparison Check the gauge line should then be 1 /1 6 " or less. If the Using a com parison gauge, as shown in Fig. 5. com pare the distance is greater than this am o u n t, the m odulator in load o f a know n good T urbo Hvdra-M alic 350 m odulator w ith question should be replaced.
Page 253 CLUTCHES & TRANSMISSIONS 7-17 TURBO HYDR A -M A TIC 350 SHIFT POINTS G 100-150 L-6 (250) L-6 (25 0) Engine 3 .4 0 A xle F 78-1 4 Tire 3.7 3 Axle F 7 8 -1 4 T ire T h ro ttle Position 1-2 up 2-1 dn...
Page 254 CLUTCHES & TRANSMISSIONS 7-18 SPECIAL TOOLS Fig. 1S T—C lu tc h and M anual T ransm issio n—Special Tools C H E V Y V A N SH O P M A N U A L...
Page 255 CLUTCHES AND TRANSMISSIONS 7-19 J -8 7 6 3 Transmission Holding Fixture J - 2 1424-7 Stator Shaft Front Bushing (M odified for TH M 350) Installer J -3 2 8 9 -1 4 Transmission Holding Fixture J -2 3 0 6 2 -5 Input Ring Gear Bushing Base Installer...
Page 256 ■ M ; v - % : ; \ v.. •' ■ ■ ■ -. ■ y ■ a ■ ) ■ * ;: :-v - ‘ ilsrSf; •'M eg -jt- - ■ C H E V Y V A N SH O P M A N U A L...
Page 257 SECTION 8 FUEL TANK AND EXHAUST CONTENTS OF THIS SECTION P ag e P age Fuel T anks and A ttachm ents ..........Exhaust System s ................ 8-7 Fuel Lines ................... Special T ools ................8 -1 0 Evaporation C ontrol System (ECS) C o m p o n e n ts .... FUEL TAN KS AND ATTACHMENTS INDEX P ag e...
Page 258 FUEL T A N K A N D EXH A UST 8-2 C A U T IO N : Before draining be sure th at the fuel tank gauge unit wire or battery negative cable is disconnected. Always drain gasoline fro m complete fuel system including carburetor, fuel pump, all fuel lines and fuel tank if the vehicle is to be stored fo r any appreciable length o f tim e.
Page 259 FUEL T A N K A N D EXH A UST 8-3 Locate tan k away from heat, flame or o th e r source of ignition. Remove fuel gauge tank unit and inspect condition o f filter. If filter is contam inated, a new filter should be installed upon reassembly.
Page 260 Correct replacement When replacing any evaporative emission hose, use only caps may be obtained fro m your Chevrolet dealer. replacem ent hose m arked “ EVAP.” No o th er ty p e o f hose is to be used.
Page 261 FUEL TA N K A N D EXH A UST 8-5 COMPONENT PART REPLACEMENT (Fig. 6-10) (Refer to Illustrations) CANISTER A ND /O R CANISTER FILTER Removal Raise vehicle on hoist. 2. N ote installed position o f hoses on canister. 3.
Page 262 FUEL T A N K A N D EXH A UST 8-6 Fig. 9 —Fuel Tank V ent Pipes C H E V Y V A N SH O P M A N U A L...
Page 263: Exhaust System
FUEL TA N K A N D EXH A UST 8-7 Reinstall separator access cover and spare tire (if V E N T LINES AND/O R SEPARATOR (TYPICAL) rem oved). Removal Low er vehicle and remove from hoist. Raise vehicle on hoist. CANISTER PURGE V A LV E (FIG .
Page 264 FUEL T A N K A N D EXHAUST 8-8 C H E V Y V A N SH O P M A N U A L...
Page 265 FUEL T A N K A N D EXHAUST 8-9 FUEL TANK ASSEMBLY FUEL TANK ASSEMBLY MUFFLER AND BODY SIDE TAIL PIPE HANGER ASSEMBLY ASSEMBLY ASSEMBLY .72 MIN. MUFFLER AND TAIL PIPE 1.38 MIN. ASSEMBLY VIEW A MUFFLER AND HANGER SUPPORT TAIL PIPE ASSEMBLY ASSEMBLY...
Page 266 FUEL T A N K A N D EXH A UST 8-10 « Fig. 1 3 —Special Tools 1. J-2334 6 Fuel Ta n k Gauge Spanner C H E V Y V A N SH O P M A N U A L...
Page 267 SECTION 9 STEERING CONTENTS OF THIS SECTION Page S tandard Steering ..............9- 1 Pow er Steering ...............9-17 Special Tools ................9-24 STANDARD STEERING INDEX Page Page G eneral D escription ..............9-1 Steering C olum n U pper B e a r in g ........9 - 4 M aintenance A nd A djustm ents ..........
Page 268 STEERING 9-2 A fter proper adjustm ent o f w orm bearing preload has front end alignm ent, shock absorbers, w heel balance and tire been obtained, sector lash adjustm ent m ust be m ade. pressure for possible cause. Check th a t all steering gear and side cover bolts are C orrect adjustm ent o f steering gear is very im p o rtan t.
Page 269 STEERING 9-3 Steering Gear High Point Centering 1. Set fro n t wheels in straight ahead position. This can be checked by driving vehicle a short distance on a flat surface to determ ine steering wheel position at which vehicle follows a straight path. 2.
Page 270 STEERING 9-4 Fig. 5 - S hift Tube A djustm ent - 3 Speed Manual Fig. 6 — S h ift Tube A djustm ent - A utom atic Transmission COMPONENT REPLACEMENT AND REPAIRS STEERING WHEEL STEERING COLUMN UPPER BEARING Removal Removal 1.
Page 271 STEERING 9-5 FLEXIBLE COUPLING (Fig. 8) 1. Install the new coupling onto the w orm shaft, aligning the flat on the shaft w ith the flat in the coupling. Push the coupling o n to the shaft until the coupling reinforcem ent Removal b o tto m s on the shaft.
Page 272 STEERING 9-6 2. D isconnect the transm ission shifter rods at the colum n 7. Reassemble the p itm an arm to the pitm an shaft, lining up shift levers. the m arks m ade at disassembly; torque th e n u t to 3.
Page 273 STEERING 9-7 10. Press the steering shaft upper bearing o u t o f the switch co n tact support. PEDAL INSTRUMENT PANEL HARNESS 11. Remove the shift lever housing seat and bushing from the SUPPORT BRKT upper end o f the colum n. 12.
Page 274 STEERING 9-8 CLUTCH AN D BRAKE PEDAL SUPPORT PROTRUSION SLOT V IE W A Fig. 13 — Steering C olum n Mounting 1. Install the toe pan seal o n to the colum n jacket. 11. Install the colum n wiring harness cover. 2.
Page 275 STEERING 9-9 4. L ocate th e index slot in the colum n jacket w ith the Remove th e steering w heel as outlined o n Page 9-4. protrusion on the clutch and brake pedal support (fig. Remove th e directional signal switch. 13).
Page 276 Fig. 14—T ilt Steering C olum n - E xplode...
Page 277 STEERING 9-11 first). Push in to the housing approxim ately 3 /1 6 ” and Install the shaft assembly in to the housing from the ro tate cou n ter clockwise turn. u p p er end. Install th e lower shaft to the p o t jo in t coupling clamp. L ubricate and install th e upper bearing race, race seat and I n s t a l l th e...
Page 278 STEERING 9-12 S T E E R IN G S H A F T B E A R IN G L O C K N U T J - 5 8 2 2 TILT LEVER S P R IN G R ETA IN ER Fig.
Page 279 STEERING 9-13 1 / 1 6 ” 4 5 ° C H A M F E R R E M O V E D O T T E D P O R T IO N Fig. 2 0 —Removing S h ift Tube Retaining Ring Fig.
Page 280 STEERING 9 -1 4 L O C K PLATE Fig. 2 3 —Rem oving Lock Plate Assembly Fig. 2 4 —Installing S hift Pin Tube Assembly—T ilt Columns Install the spheres into th e upper (sho rt) shaft and 90°. ro tate N O T E : When lubricating components during the...
Page 281 STEERING 9-15 thread length must be equal within ± .06 at each end Qdiust'n9 sleeve. V IE W A TIE R O D A S S E M B L Y Slit in sleeve and slit in clomps must align. IDLER ARM S T E E R IN G ASSEMBLY...
Page 282 STEERING 9-16 Pitman Arm Removal 1. Place vehicle on a hoist. 2. Remove the co tter pin and castellated n u t from ball stud at the relay rod. Remove the ball stud from the relay rod by tapping on the relay rod boss w ith a ham m er, while using a heavy ham m er as a backing (fig.
Page 283 STEERING 9-17 POWER STEERING P ag e P ag e B leeding H y d ra u lic S ystem ..........9 -1 8 G en e ra l D e s c r i p t i o n ..............9 -1 7 H y d ra u lic System C heck s ..........
Page 284 STEERING 9-18 Fig. 2 9 —Over-Center Adjustm ent Fig. 3 0 —Checking Belt Tension w ith J-2360 0 number or w ith an equivalent part if replacement Raise fro n t end o f vehicle so th at wheels are o ff the becomes necessary.
Page 285 STEERING 9-19 leakage. Bleed system as outlined under M ainte nance and A djustm ents. Insert therm om eter (Tool J-5421) in reservoir filler opening. Move steering w heel from stop to stop several times until ther m om eter indicates th a t hydraulic fluid in reservoir PRESSURE has reached tem perature o f 150°...
Page 286 STEERING 9-20 Install the pitm an arm o n to the pitm an shaft, lining up the m arks made at removal. Install the pitm an shaft n u t o r pitm an arm pinch b o lt and torque to specifications. Remove the plugs and caps from the steering gear and hoses and connect the hoses to the gear.
Page 287 STEERING 9-21 Fig. 3 3 —Power Steering Pump M ounting C H E V Y V A N SH O P M A N U A L...
Page 288 STEERING 9-22 PUAAP ASM PUMP ASM PARKING M IN . [J ] BRAKE PARKING BRAKE SPEEDOMETER SPEEDOMETER V V IE W A ® TO ORIENTATE PRESSURE HOSE WHEN INSTALLING, ROTATE PIPE ENDS TO REST AGAINST STEERING PUMP HOUSING. SPEEDO CABLE AN D PARKING BRAKE CABLE TO BE ROUTED ABOVE POWER STEERING PIPES...
Page 289 STEERING 9-23 J-6632 Pitman A rm Puller J-6278 Pitman Shaft Bearing Remover J-5504 Pitman A rm Puller J-6278-2 Pitman Shaft Bearing Installer J-5176 Pressure Gauge J-7079-2 Drive Handle J-5822 W ormshaft Bearing Cup Puller J-8524-1 Adjuster Plug Bearing Installer J-5860 Torque Wrench Adapter J-8524-2 Adjuster Plug Bearing Remover J-22670...
Page 290 C H E V Y V A N SH O P M A N U A L _____________________________________...
Page 291 SECTION 10 WHEELS AND TIRES INDEX Page Page G eneral D e s c r ip tio n ..............10-1 Wheel N ut Torques (Also See Specifications) ..10-2 Tire Tread Wear I n d i c a t o r ..........10-1 C orrecting Irregular Tire W e a r ........
Page 292 WHEELS A N D TIR ES 10-2 TIRE LOAD AND IN FLA TIO N PRESSURE TIRES FOR LIG H T TRUCKS USED IN HIGHW AY SERVICE W ID E BASE T U B E L E S S T IR E S U S E D A S S IN G L E S T ire Load Lim its at Various In flation Pressures Load Tire...
Page 293 WHEELS A N D TIRES 10-3 Side Wear—This m ay be caused by incorrect wheel camber, equipm ent should be accurately balanced. This may be underinflation, high cam bered roads or by taking corners at accom plished by either o f th e tw o types o f balancing systems too high a rate o f speed.
Page 294 Lubricate tire beads, rim flanges, and bead ledge areas w ith a liberal am ount o f th in vegetable oil soap solution, All tubeless tires used on Chevrolet trucks should be or approved rubber lubricant. dem ounted and m oun ted as described in this section. Sizes...
Page 295 WHEELS AND TIR ES 10-5 Fig. 6 —Inserting T ire Iron in Second Bead D em ounting Fig. 8 —Lubricating T ire Bead Then place rim on floor w ith wide side dow n and Remove valve core to com pletely deflate tire. With tire lubricate first bead o f tire and u pper bead seat o f rim lying flat on floor, loosen beads from rim seats by (fig.
Page 296 WHEELS A N D TIRES 10-6 th e same procedure used in m ounting tube ty pe tires, however, extrem e care m ust be exercised to prevent injury to the sealing bead w hen forcing tire over th e rim . A slight application o f rubber lubricant on the last 1/2 o f each bead circle to be m oun ted will ease m ounting.
Page 297 SECTION 11 FRONT END SHEET METAL INDEX P age Page G eneral D escription H ood L ock A ssem b ly ..........11-1 M aintenance and A djustm ents . . H ood A lignm ent ............11-3 H o o d A ssem b ly and A djustm ents Front End Sheet M etal A s s e m b ly .......
Page 298 FRO NT END SHEET M E T A L 11-2 Adjustm ent C A U T IO N : Hood lock assembly to be adjusted fore striker plate, preventing upward or downward movement o f and a ft until hood lock bolt enters center of the hood while the vehicle is in m otion.
Page 299 FRO NT END SHEET M E T A L 11-3 NAME PLATES AND EMBLEMS Hood Assembly Removal Designation plates attach ed to the front end sheet m etal are . Lay a fender cover along cowl to p to prevent hood from easily attach ed and accessible w ith spring nuts.
Page 300 FRO NT END SHEET M E T A L 11-4 NOTE Hood lock assembly to be adjusted fore & a ft until hood lock bolt enters center of elongated guide. See Section A-A. Bending bolt to accomplish this adjustment may seriously effect lock operation &...
Page 301: Lighting System
Chevrolet wiring are four gauge sizes smaller than tight and clean, th a t the lighting units are tightly m o u n ted to th e cable it is designed to p ro tect.
Page 302 E L E C T R I C A L - BODY A N D CHASSIS 12-2 CONNECTOR GROMMET CONNECTOR FUEL TANK CONNECTOR CUP (UNDER FLR PNL SIDE EXT) DOME LAMP Fig. 1— Body Wiring and Harness Routing SERVICE OPERATIONS HEADLAMP ADJUSTMENT (Fig.
Page 303 ELE C TR IC A L - BODY A N D CHASSIS 12-3 PARKING LAMP HOUSING REPLACEMENT (Fig. 3) N O T E : T h e lam p housing and lens are not inter changeable left to right side. Left Side 1.
Page 304 ELE C TR IC A L - BODY AND CHASSIS 12-4 GROUND WIRES Fig. 5— Wiper-Washer Switch Fig. 7 -S to p Lamp Switch LIG HT SWITCH REPLACEMENT (Fig. 6) D IM M ER SWITCH REPLACEMENT 1. F old back left side o f floor m at and disconnect wiring 1.
Page 305 E L E C T R IC A L -B O D Y A N D CHASSIS 12-5 Fig. 8 —N e u tra l S ta rt S w itc h Fig. 9 —B ackin g L a m p S w itc h INSTRUMENTS AND GAUGES INDEX Page...
Page 306 E L E C T R IC A L -B O D Y A N D CHASSIS 12-6 SERVICE OPERATIONS Ignition Switch Replacement . Install cluster in reverse order o f removal, noting th a t clips at top o f cluster slip in to instrum ent panel opening (Fig.
Page 307 E LE C TR IC A L - BODY A N D CHASSIS 12-7 N O T E : If old cable is broken it w ill be necessary N O T E : M o un t insulator strip on fuel gauge studs to remove lower piece fro m transmission end of first, then resistor, then a nut on each stud, next the casing.
Page 308 E L E C T R IC A L -B O D Y A N D CHASSIS 12-8 TEM PERATURE IN D IC A TO R LIG HT N O T E : O il pressure line connection may leak oil when opened;...
Page 309 E L E C T R IC A L -B O D Y A N D CHASSIS 12-9 WINDSHIELD WIPER AND WASHER INDEX Page Page G eneral D e s c rip tio n ..............12-9 Inspection ..............12-11 Principal o f O peration ............
Page 310 E L E C T R IC A L -B O D Y A N D CHASSIS 12-10 Turning the Wiper "O F F " pleted to ground at th e dash sw itch as follows: (R efer to Figure 14). C urrent flows from the battery thru the ignition T urning the wiper dash sw itch to the “...
Page 311 E L E C T R IC A L -B O D Y AND CHASSIS 12-11 12 VOLTS BATTERY DASH SWITCH BLACK WITH PINK STRIPE IGNITION SWITCH FUSE WIPER TERMINAL BOARD RESISTOR 20 OHMS BLACK LEGEND SPLICE POWER CIRCUIT TO SERIES FIELD MOTOR SERIES FIELD SERIES FIELD AND ARMATURE CIRCUIT...
Page 312 E L E C T R IC A L -B O D Y A N D CHASSIS 12-12 12 VOLTS BATTERY DASH SWITCH BLACK WITH PINK STRIPE IGNITION SWITCH PARK (closed S W I T C H during park-Vj. WIPER TERMINAL ing cycle) f \ X BOARD CIRCUIT...
Page 313 E LE C TR IC A L - BODY A N D CHASSIS 12-13 DASH BATTERY SWITCH BLACK WITH PINK STRIPE IGNITION SWITCH WIPER TERMINAL BOARD S P L I C E RCUIT RESISTOR 20 OHMS BLACK LEGEND POWER CIRCUIT TO SERIES FIELD SERIES FIELD MOTOR SERIES FIELD AND ARMATURE CIRCUIT...
Page 314 E L E C T R IC A L -B O D Y A N D CHASSIS 12-14 Crank Arm Reassembly N O T E : It may be necessary to remove the arm ature end play adjusting screw and insert a rod thru 1.
Page 315 ELEC TR IC A L - BODY A N D CHASSIS 12-15 Fig. 1 9 —Wiper M o tor Assembly Installation Armature Removal MOTOR RE-ASSEMBLY 1. Follow Steps 1 thru 8 under brush plate removal. 1. If new field and case assembly is being installed, splice 2.
Page 316 E L E C T R IC A L -B O D Y A N D CHASSIS 12-16 AR M A TU R E EN D PLAY A D J U S T IN G SCREW A N D LO C K N U T Fig.
Page 317 E L E C T R IC A L -B O D Y A N D CHASSIS 12-17 DRIVE PLATE A N D SHAFT ASSEMBLY DRIVE PLATE SUPPORTS PARTIALLY DISASSEMBLED FR O M W H E N ASSEMBLED G E A R A N D TUBE ASSEMBLY PROPERLY , DRIVE PLATE S H O U L D FIT TIGHTLY BETW EEN...
Page 318 - BODY CHASSIS 12-18 E L E C T R IC A L A N D C A U T IO N : It may be necessary at this point to rotate armature slightly before the arm ature worm w ill engage w ith worm gear teeth. 11.
Page 319 E L E C T R IC A L -B O D Y A N D CHASSIS 12-19 SPRING PISTON INTAKE V A LV E OPEN DIRECTION OF T R A V E L / / I ^ / / / / \ - ACTUATOR P LA T E EXHAUST I N T A K E...
Page 320 ELEC TR IC A L - BODY A N D CHASSIS 12-20 ELECTRICAL C IR C U IT ID E N TIFIC A TIO N Circuit Circuit Circuit Circuit Circuit Nam e Color Num ber Circuit Nam e Num ber C olor Dark Blue Flasher, F use Feed...
Page 321 E L E C T R IC A L - B O D Y A N D CHASSIS 12-21 ELECTRICAL C IR C U IT ID E N T IF IC A T IO N (Cant'd.) Circuit Circuit Circuit Circuit Num ber C olor Circuit Name...
Page 322 ELECTRICAL - BODY A N D CHASSIS 12-22 m r k l p T l ” BRK PRESS WRNG SW I H O R N SD MRK LP Fig. 3 2 —Engine Com partm ent C H E V Y V A N SH O P M A N U A L...
Page 323 E LE C TR IC A L - BODY A N D CHASSIS 12-23 H T R RESISTOR 2 9 7 7 9 4 0 626 8 70 2 H T R CONT LP 2 9 7 7 6 4 6 WSHH WSW WASHER o o o o * o...
Page 324 E LE C TR IC A L - BODY A N D CHASSIS 12-24 1550 - A - DASH P N L G R D B L K - '8 RING TERM ■18 B L K --------A OFF IDCKED s t a r t WSW SW GRD ■...
Page 325 ELECTRICAL - BODY CHASSIS 12-25 DOME LAMP DOME LAMP Fig. 3 5 —Body and Rear L ig h tin g...
Page 326 SECTION 13 RADIATOR AND GRILLE CONTENTS OF THIS SECTION Page Radiator Service P r o c e d u r e s.............13-1 Grille Service P r o c e d u r e s............13-1 RADIATOR SERVICE PROCEDURES Removal (Figs. 1 and 2) NOTE: When draining the radiator use a short piece of 3 /8 inch I.D.
Page 328 SECTION 14 BUMPER GENERAL DESCRIPTION All Chevy V an fro n t and rear bum pers are o f a single piece This section includes procedures for the removal and installa design. Bum per attachm ents are b racket and brace to frame. tio n o f face bars, brackets, braces and license plate support.
Page 330 SECTION 15 ACCESSORIES RADIO REPLACEMENT (Fig. 1) gently tilt radio dow n and slide radio out far enough to disconnect electrical connectors and aerial. 1. D isconnect ground cable from battery. Reverse removal procedure for installation o f radio. 2. Remove engine cover. 3.
Page 331 ■ 5 I t t O . j C H E V Y V A N SH O P M A N U A L iiilmn.milm i i ii i ....I ......in— m il..in ..m i »...
Page 332 SPECIFICATIONS HEATING AND AIR CO N DITIO N IN G SEC TIO N 1A HEATER Compressor Clutch Coil Ohms (a t 80° F) ............... 3.70 Amps Amps (a t 80° F) ........... 3.22 @ 12 volts V olts (Cold) (Cold) Blower M otor...
Page 333 S PEC IFIC ATIO N S 2 BODY S EC TIO N IB TORQUE SPECIFICATIONS M IRRO RS A N D SUNSHADE S LID IN G SIDE DOOR Rem ote C ontrol (fro n t latch) to D o o r ......90 in. lb. Inside Rear View Mirror to Bracket ......
Page 334 SPECIFICATIONS 3 FRONT SUSPENSION SECTION 3 VEH IC LE A LIG N M E N T TOLERANCES t t Field Usage Colum n 1 Column 3 *Service Checking @Service Reset Camber ......................± ° Caster ......................± ° ± ° $ Toe-in ......................
Page 335 SPECIFICATIO NS 4 REAR SUSPENSION AND DRIVE LINE SEC TIO N 4 AXLE SPRING TORQUE Ring Gear to Pinion Gear Backlash (.0 0 5 ” -.008” Preferred) 10-20 s e rie s ..............0 0 3 ” -.010” R etainer Plate-to-“ U ” Bolts ( G 10-20 Models) ..120 ft.
Page 336 SPECIFICATIONS 5 ENGINE SECTION 6 TUNE UP CHART Type In Line ENGINE D isplacem ent H orsepower COMPRESSION 130 psi 150 psi Standard AC-R46T AC-R44T Make & Num ber Cold AC-R45T AC-R43T .035" P oint D w ell 3 1 - 3 4 ° 29 °-31 •...
Page 337 SPEC IFIC ATIO N S 6 In Line T yp e ENGINE: D isplacem ent (cu. in.) 2 5 0 H orsepower CRANK SH AFT: GENER AL D A T A : In Line Type .0 0 0 3 -.0 0 1 5 2 5 0 D isplacem ent (cu.
Page 338 SPECIFICATIO NS 7 ENGINE TORQUES In Line Size Usage 2 5 0 1/4 -20 Cam shaft Thrust Plate 80 lb. in. Crankcase F ron t Cover 8 0 lb. in. F lyw heel H ousing Pans 8 0 lb. in. O il Filler Bypass Valve | 8 0 lb.
Page 339 SPECIFICATIO NS 8 CARBURETORS SECTION 6M ID E N TIFIC A TIO N Also refer to Rochester Carburetor Identification Illustration in the Overhaul Shop Manual. VEHICLES ENGINES TRUCK CARBURETORS California Type D isplacem ent BBL. (E xcept Calif.) and Type Manual A uto.
Page 340 ADJUSTMENTS (CONT'D.) S P E C IF IC A T IO N S 9 Fast Idle (Running) RPM Adjustment C a rb u reto rs — R o c h e ste r 4 Q J 2G V Vehicles Auto. Man.
Page 341 SPECIFICATIONS 10 ENGINE ELECTRICAL SECTION 6Y BATTERY Cranking Capacity @ 20 N o. o f Power @ Hour Rate Plates A pplication M odel No. (A m p. Hr.) 0 ° F (W atts) Per Cell 2 3 0 0 1 9 8 0 1 4 1 (Y -86) 2 5 0 L -6E n gin es 2 9 0 0...
Page 342 SPECIFICATIO NS 11 DISTRIBUTORS Engine Ignition Centrifugal Vacuum Point Ignition Original D escription Advance D istributor Advance Dwell Timing E quipm ent Transmission (Product (Crank Degrees <s (In Crank Setting BTDC at Spark A pplication Part No.) Engine RPM) Degrees) Plug Engine Id le’* C-4797...
Page 343 SPECIFICATIONS 12 TRANSMISSION AND CLUTCH SECTION 7 THREE SPEED SAGINAW Clutch Gear R etainer to Case B olts ...................................... 15 ft. lbs. Side Cover to Case B olts ........................................... 15 ft. lbs. E x ten sio n to Case B o l t s ..........................................45 ft.
Page 344 SPECIFICATIONS 13 STEERING SECTION 9 TORQUE CHART 10-50 20-30 Power Steering Hose Tie Rod Ball Join t Nut 4^*** 15 lbs. in. T£T** Clamp Screws O uter and Inner lbs. ft. lbs. ft. Power Steering 25 lbs. ft. Gear Hose Fittings Tie Rod Clamp Bolt lbs.
Page 345 SPEC IFIC ATIO N S 14 SECTION 9 (CONT'D.) POWER STEERING GEAR 3 in. lbs. Max. Steering Gear Ball Drag to 2 in. lbs.* T hrust Bearing Preload 80 ft. lbs. A djuster Plug L ocknut 3 - 6 in. lbs. ** Over-Center Preload Over-Center A djusting Screw 25 ft.
Page 346 SPECIFICATIONS 15 WHEELS AND TIRES SECTION 10 WHEELS Wheel N ut Torques SERIES DESCRIPTION TORQUE G 10 7 /1 6 ” B olts (6 ) 55-75 F t. Lbs. G 20 1 /2 ” B olts (5) 6 5-90 F t. Lbs. G 30 9 / 1 6 ”...
Page 347 SPECIFICATIONS 16 RADIATOR AND GRILLE SECTION 13 TORQUE SPECIFICATIONS Grille to U pper T ie B a r ............................................20 ft. lbs. Grille to Sill ....................................................,, . r .„ ......... 4 0 m lbs. Em blem to Grille ............................................
Page 348 DRILL SIZES Drill Wire Drill Wire Drill W ire Drill Letter Diam. Gage Diam. Gage Diam . G age Diam. Sizes Inches Sizes Inches Sizes Inches Sizes Inches 0.413 0.2280 0.1405 0.0520 0.404 0.2210 0.1360 0.0465 0.397 0.2130 0.1285 0.0430 0.386 0.2090 0.1200...
Page 349 D E C IM A L E Q U IV A L E N T S ........ .015625 3 ft ........515625 ........03125 ........53125 '7 / » ........046875 3 X* ........546875 .....
Page 350 CHEVROLET SERVICE...

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Chevrolet CHEVY VAN G10 SERIES Service Manual

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Summary of Contents for Chevrolet CHEVY VAN G10 SERIES

Page 85: Rear Axle

Page 102: Hydraulic Brakes

Page 185: Maintenance And Service

Page 190: Service Procedures

Page 263: Exhaust System

Page 301: Lighting System

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