Table Of Contents - Chevrolet CHEVY VAN G10 SERIES Service Manual

Table of Contents

Section Index2
General Information3
Series And Model Identification3
Vehicle Identification Number And Rating Plate3
Engine Number3
Table Of Contents3
Lubrication3
Service Parts Identification Plate4
Axles4
Transmissions4
Starters4
Keys And Locks5
Emergency Starting5
Jump Starting With Auxiliary5
Push Starting5
Towing5
Load Capacity Chart Interpretation6
Engine Vehicle A Vailability6
Load Capacity Chart7
Engine8
Oil And Filter Recommendations8
Oil Change Period8
Recommended Viscosity9
Supplemental Engine Oil Additives9
Drive B E Lts9
Positive Crankcase V E N Tila Tio N9
Air Injection R Eactor S Ystem9
C Ontrolled C Om Bustion S Y S Te M9
M Anifold H Eat C Ontrol V A Lv E9
Air Cleaner9
Fuel Filter9
Distributor9
Governor9
Accelerator Linkage10
Auto M Atic Transm Ission Flu Id Recommendations10
M Anual Transm Ission10
Transm Ission Shift Linkage10
Clutch10
Rear A X L E10
Standard10
Positraction10
Propeller Shaft Slip Joints10
Universal Joints10
Wheel Bearings10
Brake Master Cylinder11
Power Steering System11
Rear11
Brake And C Lutch Pedal Springs11
Parking Brake11
M An Ual Steering Gear11
Steering Linkage And Suspension11
Hood Latch And Hood Hinge11
Speedometer Adapter13
Vehicle Lifting Points13
Body Lubricatio N13
E Xtended Vehicle Storage13
Heater And Air Conditioning14
Standard Heater14
Heater Airflow Schematic14
Component Replacement And Repairs15
Blower Motor15
Heater Core Case And Core15
C O N Tro15
H Eater H O S E16
C Enter D Istributor D U C16
Left Distributor Duct17
Defroster Outlets And Hoses17
Control Assembly18
Control Cable Routings18
C Ontrol C A B Le18
Auxiliary Heater19
Water/Valve19
Blower S W I T C19
R E S Is To19
Fan Switch20
Auxiliary Heater Installations20
Auxiliary Heater Water Valve21
Auxiliary Heater Hose Routing21
Auxiliary Heater Control Switch21
Air Conditioning22
Interior Components22
Sportvan C-63 Interior Components22
Temperature Knob23
To Operate Front Air Conditioning Unit23
System Components24
To Operate Rear Air Conditioning Unit24
System Contaminants25
P Re Ca U Tio N S In H A N D Lin G R E F R Ig E R A N25
P Re Cau Tio N S In H A N D Lin G R E Frig E Ra N T L I N E25
M Ain Tain In G C Hem Ical S Tability In Th E R E Frig E Ra Tio N S Ystem26
J-8393 Charging Station26
Vacuum Pump27
Charging Station Gauge Set27
G Au G E S E27
Leak Testing The System28
Leak Detector28
Operation Detector28
A Vailability O F R Efrig Eran28
Periodic Service29
C O M Presso R O29
C Om P Resso R Serial N U M B E29
P Re-D Elivery In Sp Ectio29
6000 M Ile Insp Ectio29
Evacuating And Charging Procedures30
Air Conditioning System Capacity30
Installing Charging Station To Check System Operation30
Purging The System30
E V Acu Atin G An D C Harging P R O C E D U R E30
A Ir C O N D Itio N In G System C A P A C I T30
Evacuating And Charging The System31
Adding Oil31
E V Acu Ating An D C H A Rg In G The S Y S T E31
Performance Test32
Performance Data32
Charging The System32
Checking System Operation32
P Erfo Rm A N Ce D A32
Checking Oil33
Checking Compressor Oil Charge33
Refrigerant Quick Check Procedure33
Maintenance And Adjustments34
Checking For Proper Operation34
M A In Te N An Ce An D A D Ju S Tm E N34
T H Erm O Static S W I T C34
E X P An Sio N V Alv34
Check For Defective Valve35
Repairing System For Replacement Of Component Parts35
F O Re Ig N M Aterial In Th E System35
R E Frig E Ra N T L In E C O N N Ectio N35
Compressor Leaks36
Leaks At O Ring Connection36
Leaks At Hose Clamp Connection36
Repair Of R Efr Ig E R A N T Leaks36
R E Frig Eran T H O Se F A I L U R37
C O M P Resso37
Condenser38
R E Ce Iv Er-D Eh Y D Rato38
Front Air Distributor Duct Assembly39
Front Blower Evaporator Cover39
Sight G Lass R Eplacem En39
Front Blower Evaporator Assembly40
B Low Er M O To R- F Ro N40
E Lectrical C O M P O N En40
Rear Blower Relay41
Sportvan Duct C-6341
Chevy Van Duct C-6341
Rear Duct C-6341
B Low Er M O To R A Ssem Blies42
E X P An Sio N V Alves42
E V Ap O Rato R C O Re43
Rear Blower-Evaporator Assembly44
Air Conditioning Special Tools47
Body48
Body Sealing48
Locating Water Leaks48
Body And Frame48
Body Sealing Areas49
Component Part Replacement50
Windshield Wipers50
Arm Adjustment50
Windshield Glass50
Checking Windshield Opening51
Loosening Weatherstrip51
Modification Of Tool J-2257751
Checking Windshield Opening With J-2257 751
Cowl Side Ventilator Valve Assembly52
Instrument Panel Trim52
Windshield Glass, Weatherstrip And Sealing52
Cord Installation52
Instrument Panel53
Cowl Ventilator Grille53
Inside Rear View Mirror53
Engine Access Cover53
Door Weatherstrip54
Trim Panel, Arm Rest And Handles54
Door Ventilator Assembly54
Front Side Door Weatherstrip54
Ventilator Glass Replacement55
Door Window Assembly55
Window Regulator Replacement55
Adjusting Ventilator Operating Tension55
Door Lock56
Front Door Lock Cylinder Assembly56
Front Door Lock Remote Control And Connecting Rod56
Door Adjustments56
To Reposition Door In Or Out57
Door Striker57
Striker Bolt Replacement57
Striker Bolt Adjustment57
Sliding Side Door58
Front Latch Assembly58
Sliding Door Front Latch58
Rear Latch And/Or Latch Actuating Rods59
Upper Left Hinge59
Door Strikers59
Front Latch Striker59
Up And Down60
Fore And Aft60
In And Out60
Front And Rear Striker60
Upper Left Hinge Striker61
Lower Catch61
Reposition Door "Up" Or "Down"61
Reposition Door "Fore" Or "Aft"61
Front And Rear Striker Adjustment62
Rear Striker62
Up And Down Adjustment62
Fore And Aft Adjustment62
Lower Catch Adjustment63
Drivers Seat63
Seat Adjuster63
Seat Riser64
Passenger Seat64
Mounting Brackets64
Bench Seats64
Body Windows65
Side Window Glass And Hinge-Swingout65
Cord Installation (Typical)65
Rear Doors66
Side Window Glass Weatherstrip (Swingout)66
Side Window Glass Latch (Swingout)66
Rear Door Hinge Strap66
Rear Door Outside Handle67
Rear Door Lock Cylinder67
Rear Door Glass And Weatherstrip67
Rear Door Adjustments67
Door Wedge Adjustment68
Frame69
Underbody Alignment69
Measuring69
Excessive Body Damage69
Front Suspension71
Wheel Bearings—Check Adjustment72
Front Alignment Description72
Alignment Preliminary Steps72
Front Alignment73
Caster And Camber73
How To Determine Caster73
Caster Adjustment74
Component Parts Replacement75
Toe-In75
Wheel Hubs & Bearings75
Replacement Of Bearing Cups75
Shock Absorbers76
Coil Spring Suspension Assembly76
Front Stabilizer Bar76
Wheel Stud Replacement76
Lower Control Arm Assembly77
Upper Control Arm Assembly77
Loosening Ball Joint Stud-Typical77
Removing Inner Pivot Shaft77
Upper An D Lower Control Arm Inner Pivot Shaft Replacement78
Bushings78
Upper Removal78
Ball Joint Removal78
Ball Joints79
Ball Joint—Inspection79
Ball Joint Replacement79
Steering Knuckle/Steering Arm80
Crossmember And Suspension Unit81
Rear Suspension And Driveline83
Shock Absorber83
Leaf Spring And/Or Shackle83
Spring Leaf84
Rear Axle85
Lubricant Leaks85
U-Bolts And Hub Nuts85
Rear Axle Noise Diagnosis85
Rear Axle Cross Section86
Series G10-G20 (Salisbury-Type) Axles87
Gear Noise87
Bearing Noise87
Axle Vent88
Axle Shaft88
Brake Flange Backing Plate88
Oil Seal And/Or Bearing88
Axle Shaft Installation89
Pinion Flange, Dust Deflector And/Or Oil Seal89
Wheel Bolt Replacement89
Pressing Out Wheel Stud90
Drive Pinion Nut Removal90
Positraction Differential Unit91
On The Vehicle Check91
Series 30 5200 Capacity Axle92
Axle Assembly92
Hub And Drum94
Bearing Cup94
Wheel Bolt95
Removing Hub Inner Bearing Cup95
Hub Stud95
Wheel Hub Oil Seal95
Drive Pinion Oil Seal96
Installing Wheel Hub Oil Seal96
Tightening Wheel Hub Bearing Adjustment Nut96
Propeller Shaft And Universal Joints97
Propeller Shaft Assembly97
No-Spin Differential Unit97
Aligning U-Joints99
Suspension And Driveline Tools100
Special Tools100
Capacity Axle—Special Tools101
Brakes102
Hydraulic Brakes102
Master Cylinder103
Valve103
Disc Brakes Front103
Drum Brakes Rear103
Brake Inspection104
Lining Inspection105
Drum Brake105
Disc Brakes105
H Ydraulic Brake F L U I105
Manual Bleeding106
Brake Pipe Retainers107
Double Lap Flaring107
Hydraulic Brake L I N E S107
Tubing107
Brake Line Retainers108
Hydraulic Brake Tube Flaring Tool108
Single And Double Lap Flare108
Drum Brake Adjustment109
Service Brake109
Recommended Method Of Adjustment109
Alternate Method Of Adjustment109
Stop Lamp Switch Adjustment110
Parking Brake Adjustment110
Push Rod To Master Cylinder C Le A Ra N C E110
Drums, Shoes And Linings - Rear Drum Brakes111
Anchor Pin Replacement114
Relining Brake Shoes114
Wheel C Y Lin D E R114
Brake Drums115
Wheel Cylinder Repair115
Out-Of-Round Or Tapered Drum116
Shoes And Linings-Front Disc Brakes116
Caliper Removal And Installation118
Lubrication Points118
Installing Support Spring119
Fitting Shoe To Caliper119
Installing Shoe To Caliper119
Caliper O Ver H A U L120
Disc Servicing121
Installing Boot To Caliper121
Installing Boot To Piston121
Minimum Requirements121
Light Scoring122
Checking Lateral Runout122
Checking Parallelism122
Master Cylinder - Typical122
Rubber Parts123
Master C Y Lin D E R123
Bench Bleeding124
Metering Valve124
Proportioning Valve124
Brake C Om Bination V A L V E124
Brake Pedal125
Brake Warning Light Checking125
Testing Warning Switch125
Front Cable126
Parking Brakes126
Power Brakes127
Center Cable127
Rear Cable127
Bleeding Inspections127
Pedal127
Power Brake Unit128
Engine Tune-Up130
Spark Plug Removal130
Test Compression131
Service & Install Spark Plugs131
Checking Compression131
Spark Plug Detail131
Service Ignition System132
Cleaning And Inspecting Distributor Cap, Rotor And Coil132
Service Battery And Battery Cables133
Distributor (In Line)133
Distributor (V8)133
Point Alignment133
Service Delcotron And Regulator134
Service Belts134
Tighten Manifold134
Service Fuel Lines And Fuel Filter134
Service Cooling System135
Check And Adjust Accelerator Linkage135
Service Crankcase Ventilation135
Instrument Check-Out136
Service Air Injection Reactor System136
Check And Adjust Dwell136
Choke Adjustment136
Check Dwell Variation137
Check And Adjust Ignition Timing137
Idle Speed And Mixture Screws137
Additional Checks And Adjustments138
Adjust Idle Speed138
Cylinder Balance Test138
Battery139
Ignition139
Cranking Voltage139
Distributor Resistance139
Secondary Resistance140
Ignition Output And Secondary Leakage140
Carburetor140
Fuel Pump140
Engine Mechanical142
In-Line Engine142
Engine Assembly142
Manifold Disassembly145
Rocker Arm Cover145
Valve Mechanism145
Valve Lifters146
Locating Noisy Lifters146
Valve Stem Oil Seal And/Or Valve Spring147
Cylinder Head Assembly147
Oil Pan148
Oil Pump148
Oil Pan Gasket And Seal Location148
Oil Seal (Rear Main)149
Torsional Damper150
Crankcase Front Cover150
Oil Seal151
Camshaft151
Measuring Lobe Lift151
Timing Gears152
Flywheel152
Engine Mounts153
Checking Engine Mounts153
Front Mount153
Rear Mount153
Rear Mount Replacement154
V-8 Engines155
Intake Manifold158
Exhaust Manifold159
H Eadlam P A D Ju S Tm E N T302
Service Operations302
Rear L I G H Ti N G303
Marker Lamps303
Wiper-Washer Switch Replacement303
Light Sw Itch R Eplacem Ent304
Stop Lamp Switch Replacement304
D Im M Er Switch Replacement304
N E Utra L Start Switch Replacement304
Backing Lamp Switch Replacement304