Chevrolet 1988 Light Duty Truck Manuals

Manuals and User Guides for Chevrolet 1988 Light Duty Truck. We have 1 Chevrolet 1988 Light Duty Truck manual available for free PDF download: Repair Manual

Chevrolet 1988 Light Duty Truck Repair Manual (981 pages)

Chevrolet 1988 Light Duty Truck Unit Repair manual

Brand: Chevrolet | Category: Trucks | Size: 46 MB

Table of Contents
5
Engine Identification Number
6
Model Reference
6
Metric Fasteners
6
Manual
6
Fastener Strength Identification
7
Six Lobed Socket Head Fasteners
8
Prevailing Torque Fasteners
8
Conversion T a B
14
Decimal and Metric Equivalents
15
A-6 Air Conditioning Compressor
17
Minor Repair to the Compressor
19
Clutch Plate and Hub Assembly Replacement
19
Pulley and Bearing Assembly Replacement
20
Clutch Coil and Housing Assembly R Eplacem Ent
22
Major Repair to the C O M P Re S S O R
23
Shaft Seal Replacement
23
Pressure Relief Valve Replacement
25
Compressor Disassembly
26
Gaging Operation
28
Gaging Procedure
30
Piston Ring Replacement
32
Compressor Assembly
34
Leak Testing
38
Specifications
39
Special Tools
40
Air Conditioning Compressor
44
Minor Repair to the Compressor
44
Clutch Plate and Hub Assembly Replacement
44
Pulley and Bearing Assembly Replacement
44
Clutch Coil and Housing a S S E M B Ly
48
Major Repair to the Compressor
50
Shaft Seal Replacement
50
Pressure Relief Valve Replacement
52
Com Pressor Disassembly- Internal Cylinder and S H a
52
Compressor Assembly -Internal Cylinder and Shaft
53
Leak Testing
56
Specifications
57
Special T O O
58
Air Conditioning Compressor
60
Minor Repair to the Compressor
60
Clutch Drive Hub Replacement
60
Clutch Rotor And/Or Bearing Replacement - V-Groove Type
62
Clutch Rotor And/Or Bearing Replacement - Poly-Groove Type
63
Clutch Coil And/Or Pulley Rim Replacement - Poly-Groove Type
65
Major Repair to the Compressor
66
Shaft Seal Replacement
66
Pressure Relief Valve R Eplacem en T
66
High-Side-High Pressure Cut off Switch Replacement
67
Front Head And/Or Seal Replacement
67
Main Bearing Replacement
67
Thrust and Belleville Washers Replacement
68
Shell And/Or Seal Replacement
68
Discharge Value Plate And/Or Retainer R Eplacem Ent
69
Cylinder and Shaft Assembly Replacement
70
Leak Testing
70
Specifications
71
Special Tools
72
Description
73
Minor Repair to the Compressor
76
Clutch Plate and Hub Assembly Replacement
76
Pulley and Bearing Assembly Replacement
77
Pressure Relief Valve Replacement
80
High-Side Pressure and High-Side Low-Pressure Cutoff Switches Replacement
81
Control Valve Replacement
81
Minor Repair to the Compressor
89
Clutch Plate and Hub Assembly Replacement
89
Pulley and Bearing Assembly Replacement
90
Clutch Coil and Housing Assembly Replacement
93
Major Repair to the Compressor
94
Shaft Seal Replacement
94
Pressure Relief Valve Replacement
96
Compressor Disassembly- Internal Cylinder and S H a
96
Compressor Assembly -Internal Cylinder and Shaft
97
Leak Testing
100
Specifications
101
Special Tools
102
Saginaw Integral Power Steering Gear Rv, G, P, St, M
117
Disassembly
117
Cleaning and Inspection
119
Assembly
120
Saginaw Integral Power Steering Gear- CK (GMT 4 0 0 )
123
D Isassem B
129
Cleaning and in S P E C Tio
129
A S S E M B
129
Saginaw Power Steering Pump Model
129
D Isassem B
133
Cleaning and in S P E C Tio
133
Saginaw Power Steering Pump Model C
133
Com Ponent R E P a
135
Hydraulic Pump a S S E M B
136
S P E C Ific a Tio N
138
Rear Axle
141
/S-INCH RING GEAR AXLES
142
Inspection
144
Assembly of the Rear Axle
145
Gear Tooth Pattern C H E C
150
Adjustm Ents Affecting Tooth C O N Ta C
150
Specifications
151
Description
153
Disassembly of the Rear Axle
182
Cleaning
182
Inspection
182
Assembly of the Rear Axle
185
Gear Tooth Pattern Check
189
Adjustments Affecting Tooth Contact
189
Specifications
191
Front Axle
245
Disassembly
246
Cleaning and Inspection
249
Cleaning
249
Inspection
249
Assembly of Axle
250
Pinion Bearing Cup Installation
250
Pinion Depth Adjustment
250
Pinion Installation
251
Differential Case Assembly
251
Side Bearing Preload Adjustment
253
Backlash Adjustment
254
Gear Tooth Contact Pattern Check
255
Final Assembly
256
Specifications
257
Disassembly of Axle
260
Inspection
260
Disassembly
260
Cleaning and Inspection
265
Cleaning
265
Inspection
265
Assembly of Axle
266
Differential Case Assembly
266
Determining Total Differential Shim Pack Size
267
Pinion Depth Adjustment
267
Pinion Installation
269
Checking Backlash
272
Final Assembly
272
Disassembly of Axle
276
Inspection
276
Disassembly
276
Cleaning and Inspection
281
Cleaning
281
Inspection
281
Assembly of Axle
282
Differential Case Assembly
282
Pinion Bearing Cup Installation
282
Figure
282
Pinion Depth Adjustment
283
Pinion Installation
283
Differential Assembly Installation
283
Adjusting Backlash
283
Gear Tooth Contact Pattern Check
287
Final Assembly
287
Specifications
290
Special Tools
291
Inspection
300
Cleaning and Inspection
300
Cleaning
300
Assembly of Axle
301
Pinion Bearing Cup Installation
301
Gear Tooth Contact Pattern C H E C
306
Final Assembly
309
Special Tools
313
Master Cylinders
318
Composite Master Cylinder
318
Cast Iron Master Cylinder
318
Bendix Master Cylinder
320
Vacuum Boosters
323
Single Diaphragm Vacuum Booster
323
Tandem Diaphragm Vacuum Booster
325
Specifications
328
Special Tools
329
6A-2 General Engine Mechanical
332
Statement on Cleanliness and Care
332
Use of Rtv Sealer and Anaerobic Gasket Eliminator
332
Replacing Engine Gaskets
332
Cylinder Bores, Pistons, Rings, and Connecting Rods
333
M Easu Ring C y Lin D E R Bore T a P E R and O U T-O F-R O U N D (All M O D E Ls )
333
Cylinder Bore Reconditioning (2.5 L Engines)
333
Cylinder Bore Reconditioning (2.8 L Engines)
334
Cylinder Bore Reconditioning (All Except 2.5 L and 2.8 L Engines)
334
Boring
334
Honing
335
Piston and Connecting Rod Assemblies
335
Piston Selection (2.5 L and 2.8 L Engines)
338
Piston Selection (All Except 2.5 Land 2.8 L Engines)
338
Camshaft Bearing
342
In Sp Ection B Efore D Is a S S E M B
343
Special Tools
352
Subject Page
390
Description
390
Engine Lubrication
390
Disassembly
394
Tools and Shop Equipment
394
Accessory Removal
394
Cleaning
395
Draining the Engine
395
Air Injection Tube Removal
395
Egr Valve Removal
395
Exhaust Manifold Removal
395
Rocker Arm Cover Removal
395
Intake Manifold Removal
395
Valve Train Component Removal
396
Cylinder Head Removal
396
Torsional Damper Removal
396
Front Cover and Water Pump Removal
397
Oil Pan Removal
397
Oil Pump Removal
397
Timing Chain and Camshaft Sprocket Removal
397
Camshaft Removal
398
Piston and Connecting Rod R E M O V a
398
Flywheel Removal
399
Crankshaft Removal
399
Main Bearing Removal (Without Removing Crankshaft)
399
Cleaning, Inspection, and Repair
400
Piston and Connecting Rod a S S E M B Lie
401
Intake and Exhaust Manifolds
401
Camshaft
402
Camshaft Bearings
402
Timing Chain and Sprockets
402
Front Cover
402
W Ater P U M
403
Oil Pan and Rocker Arm Covers
403
Oil Pump
403
Valve Train Components
404
Hydraulic Lifters
404
Cylinder H E a
404
Therm Ostat and W Ater O U Tle
406
Crankshaft and Bearings
406
Rear Crankshaft Oil Seal in S Ta Lla Tio
408
Camshaft, Timing Chain and Sprocket Installation
409
Torsional Damper Installation
409
Piston and Connecting Rod in S Ta Lla Tio
410
Oil Pan Installation
411
Valve Train Com Ponent in Stallatio
412
Valve Adjustment
413
Intake Manifold in Stallatio
413
Rocker Arm Cover in S Ta Lla Tio
413
Exhaust Manifold in S Ta Lla Tio
414
Air Injection Tube Installation
415
Engine Accessory in S Ta Lla Tio
415
Special Tools
419
Subject Page
422
Description
422
Engine Lubrication
422
Disassembly
425
Tools and Shop Equipment
425
Accessory Removal
425
Cleaning
425
Draining the Engine
425
Egr Valve Removal
425
Exhaust Manifold Removal
425
Rocker Arm Cover Removal
426
Intake Manifold Removal
426
Valve Train Component Removal
426
Cylinder Head Removal
427
Torsional Damper Removal
427
Oil Pan Removal
427
Oil Pump Removal
427
Front Cover Removal
427
Camshaft Removal
427
Piston and Connecting Rod Removal
428
Flywheel Removal
429
Rear Crankshaft Oil Seal Removal
429
Rear Crankshaft Oil Seal Retainer Removal
429
Crankshaft Removal
429
Main Bearing Removal (W Ithout Removing C Ra N K S H a
430
Cleaning, Inspection, and Repair
430
Intake and Exhaust Manifolds
431
Camshaft
431
Camshaft Bearings
431
Timing Chain and Sprockets
431
Front Cover
432
W Ater P U M
432
Oil Pan and Rocker Arm Covers
432
Oil P U M
432
Valve Train Components
433
Hydraulic Lifters
433
Cylinder H E a
433
Therm Ostat and W Ater O U Tle
436
Crankshaft and Bearings
436
Rear Crankshaft Oil Seal Retainer in S Ta Lla Tio
437
Rear Crankshaft Oil Seal in S Ta Lla Tio
438
Camshaft, Timing Chain and Sprocket in S Ta Lla Tio
438
Front Cover Installation
438
Torsional Damper Installation
438
Piston and Connecting Rod in S Ta Lla Tio
440
Oil Pump Installation
441
Oil Pan Installation
441
Cylinder Head Installation
441
Valve Train Com Ponent in Stallatio
443
Valve Adjustment
443
Intake Manifold in Stallatio
443
Rocker Arm Cover in S Ta Lla Tio
443
Exhaust Manifold in S Ta Lla Tio
443
EGR Valve in Stallatio
444
Flywheel in S Ta Lla Tio
444
Engine Accessory in S Ta Lla Tio
444
Engine Set-Up and T E S Tin
445
Liter L6
453
Disassembly
454
Tools and Shop Equipment
454
Accessory Removal
454
Cleaning
454
Parts Identification
454
Draining the Engine
458
Air Manifold and Injection Tube Removal
458
Manifold Removal
458
Thermostat Housing Removal
459
Water Pump Removal
459
Valve Train Component Removal
459
Cylinder Head Removal
460
Torsional Damper Removal
460
Oil Pan Removal
460
Oil Pump R E M O V a
460
Timing Gear Cover Removal
461
Piston and Connecting Rod Removal
461
Flywheel Removal
461
Crankshaft Removal
462
Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft)
462
Main Bearing Removal (W Ithout Removing C Ra N K S H a
462
Camshaft Removal
463
Cleaning, Inspection, and Repair
464
Main Bearing Cap R E P la C E M E N
464
Cylinder B O R E
465
Piston and Connecting Rod a S S E M B Lie
465
Intake and Exhaust Manifolds
465
Camshaft
466
Camshaft Bearings
467
Timing Gear Cover
467
W Ater P U M
467
Oil Pan and Rocker Arm Cover
468
Oil P U M
468
Valve Train Components
469
Cylinder H E a
469
Thermostat and Housing
471
Torsional Damper
472
Crankshaft and Bearings
472
Oil Filter Relief Valve R E P la C E M E N
473
Assembly of E N G in
473
Prior to a S S E M B
473
Crankshaft Rear Oil Seal in S Ta Lla Tio
473
Main Bearing Installation (with Crankshaft in S Ta Lle
475
Crankshaft and Main Bearing in S Ta Lla Tio
475
Cam Shaft in Stallatio
476
Timing Gear Cover Installation
476
Torsional Damper Installation
477
Piston and Connecting Rod in S Ta Lla Tio
477
Oil Pump in Stallatio
478
Oil Pan Installation
478
Cylinder Head in S Ta Lla Tio
479
Valve Train Com Ponent in Stallatio
479
Valve Adjustment
479
Checking Valve T IM in
480
W Ater Pump in S Ta Lla Tio
480
Therm Ostat Housing in S Ta Lla Tio
480
Intake and Exhaust Manifold Installation
481
Air Manifold Installation
481
Flywheel Installation
481
Engine Accessory Installation
481
Engine Set-Up and Testing
481
S P E C Ific a Tio N
482

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Chevrolet 1988 Light Duty Truck Repair Manual (981 pages)

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