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GMC 1990 Light Truck Manuals
Manuals and User Guides for GMC 1990 Light Truck. We have
1
GMC 1990 Light Truck manual available for free PDF download: Repair Manual
GMC 1990 Light Truck Repair Manual (1052 pages)
Unit Repair Manual
Brand:
GMC
| Category:
Trucks
| Size: 52.02 MB
Table of Contents
Table of Contents
7
General Information
7
Vehicle Identification
7
Vehicle Identification Number
8
Engine Identification Number
8
Transmission Identification Number
9
Model Reference
9
Metric Fasteners
9
Fastener Strength Identification
11
Six Lobed Socket Head Fasteners
11
Prevailing Torque Fasteners
11
Conversion Table
19
Decimal and Metric Equivalents
20
Air Conditioning Compressor
23
Air Conditioning Compessor
23
A-6 Air Conditioning Compressor
25
Clutch Coil and Housing Assembly Replacement
26
Major Repair to the Compressor
27
Shaft Seal Replacement
27
Pressure Relief \Falve Replacement
29
Compressor Disassembly
29
Gaging Operation
32
Gaging Procedure
34
Piston Ring Replacement
36
Compressor Assembly
37
Leak Testing
41
Specifications
42
Special Tools
43
Minor Repair to the Compressor
46
Clutch Plate and Hub Assembly Replacement
46
Pulley and Bearing Assembly Replacement
48
Pressure Relief Valve Replacement
51
High-Side Pressure and High-Side Low Pressure Cutoff Switches Replacement
52
Control Valve Replacement
53
Major Repair to the Compressor
53
Shaft Seal Replacement
53
Leak Testing
56
Specifications
57
Special Tools
58
Identification
60
Disassembly of the Drive Components
60
Clutch Drive Hub
60
Pole Clutch Rotor And/Or Bearing-V-Groove
60
Pole Clutch Rotor And/Or Bearing
61
Clutch Coil And/Or Pulley Rim
62
Disassembly of the Compressor
64
Pressure Relief Valve
64
High Side High Pressure Cutoff Switch
64
Front Head and Main Bearing
64
Compressor Shell
64
Discharge Valve Plate
65
Cleaning and Inspection
67
Cleaning
67
Inspection
67
Compressor Assembly
67
Discharge Valve Plate
67
Compressor Shell
67
Front Head and Main Bearing
67
High Side High Pressure Cutoff Switch
68
Pressure Relief Valve
68
Assembly of Drive Components
68
Shaft Seal
68
Clutch Coil And/Or Pulley Rim
68
Pole Clutch And/Or Bearing
69
Pole Clutch Rotor And/Or Bearing-V-Groove
70
Clutch Drive Hub
71
Leak Testing
72
Specifications
73
Air Conditioning Compressor
77
Minor Repair to the Compressor
78
Clutch Plate and Hub Assembly Replacement
78
Pulley and Bearing Assembly Replacement
81
Clutch Coil and Housing Assembly Replacement
83
Major Repair to the Compressor
84
Shaft Seal Replacement
85
High Pressure Relief Valve Replacement
85
Compressor Disassembly-Internal Cylinder and Shaft
87
Compressor Assembly-Internal Cylinder and S H a Ft
88
Leak Testing
91
Specifications
92
Special Tools
93
Assembly of the Clutch and Shaft Seal
98
Disassembly of the Cylinder Head and Valve Plate
100
Assembly of the Cylinder Head and Valve Plate
100
Specifications
101
Fasteners
101
Special Tools
102
Rear Axle
135
And 7 5 /S-Inch Ring Gear Axles
136
Checking the Axle before Disassembly
136
Disassembly of the Rear Axle
136
Cleaning
136
Inspection
138
Assembly of the Rear Axle
139
Gear Tooth Pattern Check
144
Adjustments Affecting Tooth Contact
144
Specifications
145
Special Tools
146
Disassembly of the Rear Axle
176
Cleaning
176
Inspection
176
Assembly of the Rear Axle
179
Gear Tooth Pattern Check
183
Adjustments Affecting Tooth Contact
183
Specifications
185
Special Tools
186
Cleaning
188
Inspection
188
Assembly of the Rear Axle
193
Description
199
Disassembly of the Rear Axle
201
Cleaning
204
Inspection
204
Assembly of the Rear Axle
222
Specifications
226
Outer Pinion Bearing Shim
226
Inner Pinion Bearing Shim
226
Special Tools
227
010 -Inch
232
Lubricant
237
Front Axle
239
Disassembly of Axle
240
Inspection
240
Disassembly
240
Cleaning and Inspection
243
Cleaning
243
Inspection
243
Assembly of Axle
244
Pinion Bearing Cup Installation
244
Pinion Depth Adjustment
244
Pinion Installation
245
Differential Case Assembly
245
Side Bearing Preload Adjustment
247
Backlash Adjustment
248
Gear Tooth Contact Pattern Check
249
Final Assembly
250
FASTENER N-M FT. LBS
251
Ring Gear Bolts
251
Bearing Cap Bolts
251
Axle Cover Bolts
251
Specifications
251
Special Tools
252
Disassembly of Axle
254
Inspection
254
Disassembly
254
Cleaning and Inspection
259
Cleaning
259
Inspection
259
Lubricant
260
Assembly of Axle
260
Differential Case Assembly
260
Determining Total Differential Shim Pack Size
261
Pinion Depth Adjustment
261
Pinion Installation
263
Checking Backlash
266
Final Assembly
266
Differential Bearing Adjusting S H IM
267
Outer Pinion Bearing Shim
267
Inner Pinion Bearing Shim
267
Specifications
267
Special Tools
268
Disassembly of Axle
270
Inspection
270
Disassembly
270
Cleaning and Inspection
275
Cleaning
275
Inspection
275
Assembly of Axle
276
Differential Case Assembly
276
Pinion Bearing Cup Installation
276
Pinion Depth Adjustment
277
Pinion Installation
277
Differential Assembly Installation
277
Adjusting Backlash
277
Gear Tooth Contact Pattern Check
281
Final Assembly
281
Specifications
284
Special Tools
285
Description
288
Disassembly of Axle
288
Inspection
288
Disassembly
288
Cleaning and Inspection
295
Cleaning
295
Inspection
295
Assembly of Axle
296
Pinion Bearing Cup Installation
296
Pinion Installation
297
Differential Case Assembly
297
Adjusting Backlash
300
Gear Tooth Contact Pattern Check
302
Carrier Case Assembly
302
Axle Tube Assembly
303
Final Assembly
304
Drive Axle Assembly
307
Outer Deflecting Ring Replacement
307
Outer Joint Seal Replacement
307
Outer Joint Assembly Replacement
310
Inner Tripot Seal Replacement
311
Specifications
313
Special Tools
336
General Engine Mechanical
353
Use of RTV Sealer and Anaerobic Gasket Eliminator
354
Replacing Engine Gaskets
354
Measuring Cylinder Bore Taper and Out-Of-Round (All M Odels)
355
Cylinder Bore Reconditioning (2.8 L Engines)
356
Cylinder Bore Reconditioning (All Except 2.5 L and 2.8 L Engines)
356
Boring
356
Honing
357
Piston and Connecting Rod Assemblies
357
Piston Selection (2.5 L and 2.8 L Engines)
360
Piston Selection (All Except 2.5 Land 2.8 L Engines)
360
Camshaft Bearings
364
Camshaft Bearing Replacement (2.5 L and 6.2 L Engines)
364
Camshaft Bearing Replacement (All Except 2.5 L and 6.2 L Engines)
364
Hydraulic Lifters
365
Inspection before Disassembly
365
Hydraulic Lifter Overhaul
365
Valve Lifter Leak-Down Rate Test (Flat Type Lifters O N
367
Cylinder Head
368
Disassembly
368
Cleaning and in Sp Ectio
368
Assembly
370
Measuring Main Bearing Clearance
371
Measuring Connecting Rod Bearing C Le a Ra N C
372
Subject Page
376
Description
376
Engine Lubrication
376
Disassembly of the Engine
378
Tools and Shop Equipment
378
Accessory Removal
378
Cleaning
378
Parts Identification
378
Draining the Engine
378
Intake Manifold Removal
380
Exhaust Manifold Removal
380
Thermostat Housing Removal
380
Water Pump Removal
380
Valve Train Component Removal
383
Cylinder Head Removal
384
Crankshaft Pulley Hub Removal
384
Oil Pan Removal
385
Oil Pump Driveshaft Removal
385
Oil Pump Removal
385
Front Cover Removal
385
Piston and Connecting Rod Removal
385
Flywheel Removal
386
Crankshaft Removal
386
Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft)
387
Main Bearing Removal (Without Removing the Crankshaft)
387
Camshaft Removal
387
Cleaning, Inspection, and Repair
388
Block
388
Cylinder Bores
389
Piston and Connecting Rod Assemblies
389
Piston Selection
389
Intake and Exhaust Manifold
390
Camshaft
390
Camshaft Bearings
391
Front Cover
391
Water Pump
392
Oil Pan and Rocker Arm Covers
392
Oil Pump
392
Valve Train Components
393
Cylinder Head
393
Thermostat and Housing
395
Crankshaft and Bearings
395
Assembly of Engine
396
Prior to Assembly
396
Crankshaft and Main Bearing Installation
396
Main Bearing Installation (Without Removing the Crankshaft)
398
Camshaft Installation
398
Front Cover Installation
398
Crankshaft Pulley Hub Installation
399
Piston and Connecting Rod Installation
399
Oil Pump Installation
400
Oil Pan Installation
401
Oil Pump Driveshaft Installation
401
Cylinder Head Installation
401
Valve Train Component Installation
403
Water Pump Installation
403
Thermostat Housing Installation
404
Intake Manifold Installation
404
Exhaust Manifold Installation
404
Flywheel Installation
404
Engine Accessory Installation
404
Engine Setup and Testing
404
Specifications
407
Special Tools
410
Subject Page
412
Description
412
Engine Lubrication
412
Disassembly
416
Tools and Shop Equipment
416
Accessory Removal
416
Cleaning
417
Draining the Engine
417
Air Injection Tube Removal
417
EGR Valve Removal
417
Exhaust Manifold Removal
417
Rocker Arm Cover Removal
417
Intake Manifold Removal
417
Valve Train Component Removal
418
Cylinder Head Removal
418
Torsional Damper Removal
418
Front Cover and Water Pump Removal
419
Oil Pan Removal
419
Oil Pump Removal
419
Timing Chain and Camshaft Sprocket Removal
419
Camshaft Removal
420
Piston and Connecting Rod Removal
420
Flywheel Removal
421
Crankshaft Removal
421
Main Bearing Removal (Without Removing Crankshaft)
421
Cleaning, Inspection, and Repair
422
Block
422
Piston and Connecting Rod Assemblies
423
Intake and Exhaust Manifolds
423
Camshaft
424
Camshaft Bearings
424
Timing Chain and Sprockets
424
Front Cover
424
Water Pump
425
Oil Pan and Rocker Arm Covers
425
Oil Pump
425
Valve Train Components
426
Hydraulic Lifters
426
Cylinder Head
426
Thermostat and Water Outlet
428
Crankshaft and Bearings
428
Assembly of Engine
429
Prior to Assembly
429
Crankshaft and Main Bearing Installation
429
Rear Crankshaft Oil Seal Installation
430
Camshaft, Timing Chain and Sprocket Installation
431
Front Cover and Water Pump Installation
431
Torsional Damper Installation
431
Piston and Connecting Rod Installation
432
Oil Pump Installation
433
Oil Pan Installation
433
Cylinder Head Installation
433
Valve Train Component Installation
434
Valve Adjustment
435
Intake Manifold Installation
435
Rocker Arm Cover Installation
435
Exhaust Manifold Installation
436
EGR Valve Installation
436
Air Injection Tube Installation
437
Flywheel Installation
437
Engine Accessory Installation
437
Engine Set-Up and Testing
437
Specifications
438
Special Tools
441
Subject Page
444
Description
444
Engine Lubrication
444
Disassembly
447
Tools and Shop Equipment
447
Accessory Removal
447
Cleaning
447
Draining the Engine
447
EGR Valve Removal
447
Exhaust Manifold Removal
447
Rocker Arm Cover Removal
448
Intake Manifold Removal
448
Valve Train Component Removal
448
Cylinder Head Removal
449
Torsional Damper Removal
449
Oil Pan Removal
449
Oil Pump Removal
449
Front Cover Removal
449
Camshaft Removal
449
Piston and Connecting Rod Removal
450
Flywheel Removal
451
Rear Crankshaft Oil Seal Removal
451
Rear Crankshaft Oil Seal Retainer Removal
451
Crankshaft Removal
451
Main Bearing Removal (Without Removing Crankshaft)
452
Cleaning, Inspection, and Repair
452
Block
452
Piston and Connecting Rod a Ssem Bly
452
Intake and Exhaust Manifolds
453
Camshaft
453
Camshaft Bearings
453
Timing Chain and Sprockets
453
Front Cover
454
Water Pump
454
Oil Pan and Rocker Arm Covers
454
Oil Pump
454
Valve Train Components
455
Hydraulic Lifters
455
Cylinder Head
455
Thermostat and Water Outlet
458
Crankshaft and Bearings
458
Assembly of Engine
459
Prior to Assembly
459
Crankshaft and Main Bearing Installation
459
Rear Crankshaft Oil Seal Retainer Installation
459
Rear Crankshaft Oil Seal Installation
460
Camshaft, Timing Chain and Sprocket Installation
460
Front Cover Installation
460
Torsional Damper Installation
460
Piston and Connecting Rod Installation
462
Oil Pump Installation
463
Oil Pan Installation
463
Cylinder Head Installation
463
Valve Train Component Installation
465
Valve Adjustment
465
Intake Manifold Installation
465
Rocker Arm Cover Installation
465
Exhaust Manifold Installation
465
EGR Valve Installation
466
Flywheel Installation
466
Engine Accessory Installation
466
Engine Set-Up and Testing
467
Specifications
469
Special Tools
472
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