chevrolet CHEVY VAN G20 SERIES Manuals

Manuals and User Guides for chevrolet CHEVY VAN G20 SERIES. We have 1 chevrolet CHEVY VAN G20 SERIES manual available for free PDF download: Service Manual

chevrolet CHEVY VAN G20 SERIES Service Manual

chevrolet CHEVY VAN G20 SERIES Service Manual (351 pages)

1972

Brand: chevrolet | Category: Trucks | Size: 14.95 MB

Table of Contents

Section Index
2
Table of Contents
3
Engine Number
3
General Information
3
- Vehicle Identification Number and Rating Plate
  3
- Series and Model Identification
  3
Lubrication
3
- Axles
  4
- Transmissions
  4
- Starters
  4
Service Parts Identification Plate
4
Keys and Locks
5
Towing
5
Load Capacity Chart Interpretation
6
Engine Vehicle a Vailability
6
Load Capacity Chart
7
- Engine
  8
- Lubrication
  8
- Oil and Filter Recommendations
  8
- Oil Change Period
  8
- Air Cleaner
  9
- Air Injection R Eactor S Ystem
  9
- C Ontrolled C Om Bustion S y S te M
  9
- Distributor
  9
- Drive B E Lts
  9
- Fuel Filter
  9
- M Anifold H Eat C Ontrol V a Lv E
  9
- Positive Crankcase V E N Tila Tio N
  9
  - Recommended Viscosity
    9
  - Supplemental Engine Oil Additives
    9
- Accelerator Linkage
  10
- Auto M Atic Transm Ission Flu ID Recommendations
  10
- Clutch
  10
- M Anual Transm Ission
  10
- Positraction
  10
- Propeller Shaft Slip Joints
  10
- Rear a X L E
  10
- Standard
  10
- Transm Ission Shift Linkage
  10
- Universal Joints
  10
- Brake and C Lutch Pedal Springs
  11
- Brake Master Cylinder
  11
- Hood Latch and Hood Hinge
  11
- M an Ual Steering Gear
  11
- Parking Brake
  11
- Power Steering System
  11
- Rear
  11
- Steering Linkage and Suspension
  11
- Body Lubricatio N
  13
- E Xtended Vehicle Storage
  13
- Speedometer Adapter
  13
  - Vehicle Lifting Points
    13
  - Heater Airflow Schematic
    14
  - Heater and Air Conditioning
    14
  - Standard Heater
    14
  - Blower Motor
    15
- C O N Tro
  15
  - Component Replacement and Repairs
    15
  - Heater Core Case and Core
    15
- C Enter D Istributor D U C
  16
- H Eater H O S E
  16
  - Defroster Outlets and Hoses
    17
  - Left Distributor Duct
    17
- C Ontrol C a B Le
  18
- Control Assembly
  18
  - Control Cable Routings
    18
  - Auxiliary Heater
    19
- Blower S W I T C
  19
- R E S Is to
  19
  - Water/Valve
    19
  - Auxiliary Heater Installations
    20
  - Fan Switch
    20
  - Auxiliary Heater Control Switch
    21
  - Auxiliary Heater Hose Routing
    21
  - Auxiliary Heater Water Valve
    21
  - Air Conditioning
    22
  - Interior Components
    22
  - Sportvan C-63 Interior Components
    22
  - Temperature Knob
    23
  - To Operate Front Air Conditioning Unit
    23
  - System Components
    24
  - To Operate Rear Air Conditioning Unit
    24
- General Information
  25
- P Re Ca U Tio N S in H a N D Lin G R E F R Ig E R a N
  25
- P Re Cau Tio N S in H a N D Lin G R E Frig E Ra N T L I N E
  25
- System Contaminants
  25
- J-8393 Charging Station
  26
- M Ain Tain in G C Hem Ical S Tability in Th E R E Frig E Ra Tio N S Ystem
  26
- Charging Station Gauge Set
  27
- G Au G E S E
  27
- Vacuum Pump
  27
- A Vailability O F R Efrig Eran
  28
- Leak Detector
  28
- Leak Testing the System
  28
- Operation Detector
  28
- 6000 M Ile Insp Ectio
  29
- C O M Presso R O
  29
- C Om P Resso R Serial N U M B E
  29
- P Re-D Elivery in Sp Ectio
  29
- Periodic Service
  29
- A Ir C O N D Itio N in G System C a P a C I T
  30
- Air Conditioning System Capacity
  30
- E V Acu Atin G an D C Harging P R O C E D U R E
  30
  - Evacuating and Charging Procedures
    30
  - Installing Charging Station to Check System Operation
    30
- Purging the System
  30
- Adding Oil
  31
- E V Acu Ating an D C H a Rg in G the S y S T E
  31
- P Erfo Rm a N Ce D a
  32
- Performance Data
  32
- Performance Test
  32
- E X P an Sio N V Alv
  34
- M a in te N an Ce an D a D Ju S Tm E N
  34
- Maintenance and Adjustments
  34
- T H Erm O Static S W I T C
  34
- Check for Defective Valve
  35
- F O Re Ig N M Aterial in Th E System
  35
- R E Frig E Ra N T L in E C O N N Ectio N
  35
- Repair of R Efr Ig E R a N T Leaks
  36
- C O M P Resso
  37
- R E Frig Eran T H O Se F a I L U R
  37
- Condenser
  38
- R E Ce IV Er-D Eh y D Rato
  38
  - Front Air Distributor Duct Assembly
    39
  - Front Blower Evaporator Cover
    39
- Sight G Lass R Eplacem en
  39
- B Low er M O to R- F Ro N
  40
- E Lectrical C O M P O N en
  40
- Front Blower Evaporator Assembly
  40
- Rear Blower Relay
  41
- Rear Duct C-63
  41
- B Low er M O to R a Ssem Blies
  42
- E X P an Sio N V Alves
  42
- Chevy Van Duct C-63
  41
- Sportvan Duct C-63
  41
E V Ap O Rato R C O Re
43
- Rear Blower-Evaporator Assembly
  44
- Air Conditioning Special Tools
  47
- Body
  48
- Body and Frame
  48
- Body Sealing
  48
- Locating Water Leaks
  48
- Body Sealing Areas
  49
- Arm Adjustment
  50
- Component Part Replacement
  50
- Windshield Glass
  50
- Windshield Wipers
  50
- Checking Windshield Opening
  51
- Checking Windshield Opening with J-2257 7
  51
- Loosening Weatherstrip
  51
- Modification of Tool J-22577
  51
- Cord Installation
  52
- Cowl Side Ventilator Valve Assembly
  52
- Instrument Panel Trim
  52
- Windshield Glass, Weatherstrip and Sealing
  52
- Cowl Ventilator Grille
  53
- Engine Access Cover
  53
- Inside Rear View Mirror
  53
- Instrument Panel
  53
- Door Ventilator Assembly
  54
- Door Weatherstrip
  54
- Front Side Door Weatherstrip
  54
- Trim Panel, Arm Rest and Handles
  54
- Adjusting Ventilator Operating Tension
  55
- Door Window Assembly
  55
- Ventilator Glass Replacement
  55
- Window Regulator Replacement
  55
- Door Adjustments
  56
- Door Lock
  56
- Front Door Lock Cylinder Assembly
  56
- Front Door Lock Remote Control and Connecting Rod
  56
- Door Striker
  57
- Striker Bolt Adjustment
  57
- Striker Bolt Replacement
  57
- To Reposition Door in or out
  57
- Front Latch Assembly
  58
- Sliding Door Front Latch
  58
- Sliding Side Door
  58
- Door Strikers
  59
- Front Latch Striker
  59
- Rear Latch And/Or Latch Actuating Rods
  59
- Upper Left Hinge
  59
- Fore and Aft
  60
- Front and Rear Striker
  60
- In and out
  60
- Up and down
  60
- Lower Catch
  61
- Reposition Door "Fore" or "Aft"
  61
- Reposition Door "Up" or "Down"
  61
- Upper Left Hinge Striker
  61
- Fore and Aft Adjustment
  62
- Front and Rear Striker Adjustment
  62
- Rear Striker
  62
- Up and down Adjustment
  62
- Drivers Seat
  63
- Lower Catch Adjustment
  63
- Seat Adjuster
  63
- Bench Seats
  64
- Mounting Brackets
  64
- Passenger Seat
  64
- Seat Riser
  64
- Body Windows
  65
- Cord Installation (Typical)
  65
- Side Window Glass and Hinge-Swingout
  65
- Rear Door Hinge Strap
  66
- Rear Doors
  66
- Side Window Glass Latch (Swingout)
  66
- Side Window Glass Weatherstrip (Swingout)
  66
- Rear Door Adjustments
  67
- Rear Door Glass and Weatherstrip
  67
- Rear Door Lock Cylinder
  67
- Rear Door Outside Handle
  67
- Door Wedge Adjustment
  68
- Excessive Body Damage
  69
- Frame
  69
- Measuring
  69
- Underbody Alignment
  69
- Front Suspension
  71
- Alignment Preliminary Steps
  72
- Front Alignment Description
  72
- Wheel Bearings—Check Adjustment
  72
- Caster and Camber
  73
- Front Alignment
  73
- How to Determine Caster
  73
- Caster Adjustment
  74
- Component Parts Replacement
  75
- Replacement of Bearing Cups
  75
- Toe-In
  75
- Wheel Hubs & Bearings
  75
- Coil Spring Suspension Assembly
  76
- Front Stabilizer Bar
  76
- Shock Absorbers
  76
- Wheel Stud Replacement
  76
- Loosening Ball Joint Stud-Typical
  77
- Lower Control Arm Assembly
  77
- Removing Inner Pivot Shaft
  77
- Upper Control Arm Assembly
  77
- Ball Joint Removal
  78
- Bushings
  78
- Upper an D Lower Control Arm Inner Pivot Shaft Replacement
  78
- Upper Removal
  78
- Ball Joint Replacement
  79
- Ball Joints
  79
- Ball Joint—Inspection
  79
- Steering Knuckle/Steering Arm
  80
- Crossmember and Suspension Unit
  81
- Leaf Spring And/Or Shackle
  83
- Rear Suspension and Driveline
  83
- Shock Absorber
  83
- Spring Leaf
  84
- Lubricant Leaks
  85
- Rear Axle
  85
- Rear Axle Noise Diagnosis
  85
- U-Bolts and Hub Nuts
  85
- Rear Axle Cross Section
  86
- Bearing Noise
  87
- Gear Noise
  87
- Series G10-G20 (Salisbury-Type) Axles
  87
- Axle Shaft
  88
- Axle Vent
  88
- Brake Flange Backing Plate
  88
- Oil Seal And/Or Bearing
  88
- Axle Shaft Installation
  89
- Pinion Flange, Dust Deflector And/Or Oil Seal
  89
- Wheel Bolt Replacement
  89
- Drive Pinion Nut Removal
  90
- Pressing out Wheel Stud
  90
- On the Vehicle Check
  91
- Positraction Differential Unit
  91
- Axle Assembly
  92
- Series 30 5200 Capacity Axle
  92
- Bearing Cup
  94
- Hub and Drum
  94
- Hub Stud
  95
- Removing Hub Inner Bearing Cup
  95
- Wheel Bolt
  95
- Wheel Hub Oil Seal
  95
- Drive Pinion Oil Seal
  96
- Installing Wheel Hub Oil Seal
  96
- Tightening Wheel Hub Bearing Adjustment Nut
  96
- No-Spin Differential Unit
  97
- Propeller Shaft and Universal Joints
  97
- Propeller Shaft Assembly
  97
- Aligning U-Joints
  99
- Special Tools
  100
  - Suspension and Driveline Tools
    100
  - Capacity Axle—Special Tools
    101
  - Brakes
    102
  - Hydraulic Brakes
    102
  - Disc Brakes Front
    103
  - Drum Brakes Rear
    103
  - Master Cylinder
    103
  - Valve
    103
- Brake Inspection
  104
- Maintenance and Adjustments
  104
  - Parking Brake
    104
  - Disc Brakes
    105
  - Drum Brake
    105
- H Ydraulic Brake F L U I
  105
  - Lining Inspection
    105
  - Manual Bleeding
    106
  - Brake Pipe Retainers
    107
  - Double Lap Flaring
    107
- Hydraulic Brake L I N E S
  107
- Tubing
  107
  - Brake Line Retainers
    108
  - Hydraulic Brake Tube Flaring Tool
    108
  - Single and Double Lap Flare
    108
  - Alternate Method of Adjustment
    109
  - Drum Brake Adjustment
    109
  - Recommended Method of Adjustment
    109
  - Service Brake
    109
  - Parking Brake Adjustment
    110
- Push Rod to Master Cylinder C Le a Ra N C E
  110
- Stop Lamp Switch Adjustment
  110
  - Drums, Shoes and Linings - Rear Drum Brakes
    111
  - Anchor Pin Replacement
    114
  - Relining Brake Shoes
    114
- Wheel C y Lin D E R
  114
  - Brake Drums
    115
  - Wheel Cylinder Repair
    115
  - Out-Of-Round or Tapered Drum
    116
- Shoes and Linings-Front Disc Brakes
  116
  - Caliper Removal and Installation
    118
  - Lubrication Points
    118
  - Fitting Shoe to Caliper
    119
  - Installing Shoe to Caliper
    119
  - Installing Support Spring
    119
- Caliper O Ver H a U L
  120
- Disc Servicing
  121
  - Installing Boot to Caliper
    121
  - Installing Boot to Piston
    121
  - Minimum Requirements
    121
  - Checking Lateral Runout
    122
  - Checking Parallelism
    122
  - Light Scoring
    122
  - Master Cylinder - Typical
    122
- Master C y Lin D E R
  123
  - Rubber Parts
    123
  - Bench Bleeding
    124
- Brake C Om Bination V a L V E
  124
  - Metering Valve
    124
  - Proportioning Valve
    124
- Brake Pedal
  125
  - Brake Warning Light Checking
    125
  - Testing Warning Switch
    125
  - Front Cable
    126
- Parking Brakes
  126
  - Bleeding Inspections
    127
  - Center Cable
    127
- Pedal
  127
  - Power Brakes
    127
  - Rear Cable
    127
  - Power Brake Unit
    128
  - Engine Tune-Up
    130
  - Spark Plug Removal
    130
  - Checking Compression
    131
  - Service & Install Spark Plugs
    131
  - Spark Plug Detail
    131
  - Test Compression
    131
  - Cleaning and Inspecting Distributor Cap, Rotor and Coil
    132
  - Service Ignition System
    132
  - Distributor (in Line)
    133
  - Distributor (V8)
    133
  - Point Alignment
    133
  - Service Battery and Battery Cables
    133
  - Service Belts
    134
  - Service Delcotron and Regulator
    134
  - Service Fuel Lines and Fuel Filter
    134
  - Tighten Manifold
    134
  - Check and Adjust Accelerator Linkage
    135
  - Service Cooling System
    135
  - Service Crankcase Ventilation
    135
  - Check and Adjust Dwell
    136
  - Choke Adjustment
    136
  - Instrument Check-Out
    136
  - Service Air Injection Reactor System
    136
  - Check and Adjust Ignition Timing
    137
  - Check Dwell Variation
    137
  - Idle Speed and Mixture Screws
    137
  - Additional Checks and Adjustments
    138
  - Adjust Idle Speed
    138
  - Cylinder Balance Test
    138
  - Battery
    139
  - Cranking Voltage
    139
  - Distributor Resistance
    139
  - Ignition
    139
  - Carburetor
    140
  - Fuel Pump
    140
  - Ignition Output and Secondary Leakage
    140
  - Secondary Resistance
    140
  - Engine Assembly
    142
  - Engine Mechanical
    142
  - In-Line Engine
    142
  - Manifold Disassembly
    145
  - Rocker Arm Cover
    145
  - Valve Mechanism
    145
  - Locating Noisy Lifters
    146
  - Valve Lifters
    146
  - Cylinder Head Assembly
    147
  - Valve Stem Oil Seal And/Or Valve Spring
    147
  - Oil Pan
    148
  - Oil Pan Gasket and Seal Location
    148
  - Oil Pump
    148
  - Oil Seal (Rear Main)
    149
  - Crankcase Front Cover
    150
  - Torsional Damper
    150
  - Camshaft
    151
  - Measuring Lobe Lift
    151
  - Oil Seal
    151
  - Flywheel
    152
  - Timing Gears
    152
  - Checking Engine Mounts
    153
  - Engine Mounts
    153
  - Front Mount
    153
  - Rear Mount
    153
  - Rear Mount Replacement
    154
  - V-8 Engines
    155
  - Intake Manifold
    158
  - Exhaust Manifold
    159
- H Eadlam P a D Ju S Tm E N T
  302
- Service Operations
  302
- Marker Lamps
  303
- Rear L I G H Ti N G
  303
- Wiper-Washer Switch Replacement
  303
- Backing Lamp Switch Replacement
  304
- D IM M er Switch Replacement
  304
- Light Sw Itch R Eplacem Ent
  304
- N E Utra L Start Switch Replacement
  304
- Stop Lamp Switch Replacement
  304

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