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1986 G-VAN
GMC 1986 G-VAN Manuals
Manuals and User Guides for GMC 1986 G-VAN. We have
1
GMC 1986 G-VAN manual available for free PDF download: Service Manual
GMC 1986 G-VAN Service Manual (1584 pages)
Brand:
GMC
| Category:
Trucks
| Size: 66.74 MB
Table of Contents
General Information
4
Maintenance and L U B Ric a Tio N
4
Table of Contents
6
Oa-2 General Information
6
Service Parts Identification Label
7
Vehicle Identification P la te
7
Certification Label
7
Model Reference
7
Engine Identification Number
7
Graphic Symbols
11
Metric Fasteners
13
Fastener Strength Identification
13
Prevailing Torque Fasteners
14
Six Lobed Socket Head Fasteners
14
RPO Listing (Regular Production O P Tio N
19
Maintenance and Lubrication
26
Heating and Air Conditioning
40
H E a Tin
41
C-K and G Series Heaters - General Description
41
Blower and Air Inlet Assembly
41
Heater Distributor Assembly
41
Insufficient Heat Diagnosis
42
Healer C Ircuit D Ia G N O S Is
43
Diagnosis of Heater System
44
C-K Series Heater - On-Vehicle Service
45
Blower Motor Replacement
45
Heater Hoses - Engine R O U Tin G
45
Heater Distributor and Core Assembly
46
Control Assembly Replacement
48
Control Cables Replacem Ent
48
Cable Adjustment
48
Blower Switch Replacement
50
Resistor R E P la Ce M E N
51
C-K Series Auxiliary Heater
51
General D E S C Rip Tio
51
Ccot System Components, Temperature and Pressure Relationships
68
Handling Refrigerant-12
68
Refrigerant-12 Operating Characteristics
68
Handling Refrigerant Lines and F Itt in G S
68
Maintaining Chemical Stability
71
Diagnosis
72
Testing the Refrigerant System
72
Leak Testing the Refrigerant System
72
Pressure Sensing Switch
72
Electrical/Vacuum Trouble D Ia G N O S
79
Operational T E S
79
Vacuum System Diagnosis
84
C-K and G S E R Ie
84
A/C Refrigerant System Diagnosis
84
Insufficient Cooling " Quick Check" P Ro C E D U
84
A/C Evacuating and Charging P Ro C E D U Re
85
Evacuation and Charging P Ro C E D U Re
85
Discharging, Evacuating, Adding Oil, and Charging Procedures Fo R CCOT A/C S y S te
85
Discharging the CCOT A/C S y S te
85
CCOT Refrigerant Oil D Is Trib U Tio
87
Evacuating and Charging the CCOT A/C S y S te
87
Gage C a Lib Ra Tio
87
Vacuum System C H E C
88
Charging Station M E Tho
88
Disposable Can or Multi-Can M E Th O
88
Refrigerant Drum M E Th O
88
Charging of the Ccot A/C System
88
Accum Ulator a S S E M B
89
Specific Component Diagnosis
89
Compressor
89
Condenser
89
Receiver-Dehydrator (Motor Home Chassis)
89
Expansion Valve
89
Evaporator
90
Refrigerant Line R E S Tric Tio N
90
Sight Glass Diagnosis (Motor Home Chassis Units)
90
On Vehicle Service
91
Compressor Replacement (C
91
Compressor Replacement (G and Motor Homes Chassis M O D E
91
Compressor Belt Tension Adjustm Ent (G and Motor Home Chassis M O D E
92
CCOT A/C System-C-K S E R Ie
95
Condenser R E P la Ce M E N
95
Accumulator Replacement
96
Blower Assembly Replacement
97
Evaporator Core R E P la C E M E N
97
O Rifice (Expansion Tube) R E P Lace M E N
98
Selector Duct and Heater Core R E P la Ce M E N
100
Actuator-Plenum Side Vent R E P Lace M E N
101
Plenum Valve Replacement
102
Control Assem Bly R E P la Ce M E N
102
Cable a D Ju Stm E N
103
Temperature Door Cable a Djustm E N
103
Blower Switch R E P Lace M E N
103
Vacuum Tank Replacement
103
Vacuum Lines-Engine C O M P a Rtm E N
103
Vacuum Harness-Dash
103
Blower Motor Resistor R E P la Ce M E N
105
Blower Motor Relay Replacement
108
Fuse R E P la Ce M E N
108
Rear Interior Roof Mounted System-Suburban
108
Rear Duct Replacement
108
Blower Motor Resistor R E P la Ce M E N
108
Blower Motor Assembly Replacement
108
Expansion Valve R E P la Ce M E N
109
Evaporator Core R E P la C E M E N
111
Blower Motor Switch Replacement
112
Fuse R E P la Ce M E N
112
CCOT A/C System-G S E Rie
112
Condenser R E P Lace M E N
112
Accumulator Replacement
112
Heater Core R E P la Ce M E N
113
O Rifice (Expansion Tube) R E P Lace M E N
117
Blower Motor Insulation (W/Diesel) Replacement
117
Evaporator Core (W/Diesel) R E P la C E M E N
118
Evaporator Core R E P la C E M E N
119
Blower Motor Replacement
120
Liter
120
Control Assembly R E P la Ce M E N
121
Temperature Door Cable a Djustm E N
121
Blower Switch R E P Lace M E N
121
Resistor R E P la C E M E N
121
Blower Motor Relay Replacement
122
A/C Ductwork Replacem Ent
122
Defroster Duct Replacement
122
Temperature Door Cable R E P la Ce M E N
122
Liter
122
Vacuum Tank Replacem Ent
123
Vacuum Line Engine C O M P a Rtm E N
123
Liter
123
Liter
124
Rear Interior Roof Mounted Systems-G S Eries
125
Liter
125
CCOT A/C System-P S E R Ie
127
Dash Mounted System-Motor Home C H a S S
127
Condensor R E P Lacem Ent
127
Liter
127
Receiver-Dehydrator Replacement
128
Sight Glass Replacement
128
Blower-Evaporator Assembly R E P la C E M E N
129
Blower Assembly Replacement
129
Expansion Valve, Evaporator And/Or Evaporator Case Replacement
130
Thermostatic And/Or Blower Switches Replacement
130
Blower Motor Resistor R E P la Ce M E N
130
Fuse R E P Lace M E N
130
S Pecifica Tio
131
Displacement
131
D Iagnosis
134
F Ra M
134
Frame
134
Minim Izing Frame S E Rv IC
135
Checking Frame a Lig N M E N
136
Straightening Fram
137
Repairing C Ra C K
137
W E Ld in
138
G Model Underbody
139
D E S C Rip Tio
139
Underbody a Lig N M E N
139
Rear Bumper Replacement (Utility Vehicle and Suburban)
143
Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew Cab)
145
Rear Step Bumper Replacement
146
Rear Bumper License Plate Bracket Replacement
146
Dead Weight Trailer Hitch Replacement (Utility Vehicle and Suburban)
147
Weight D Istribution Hitch Replacement (Suburban O N
148
Weight Distribution Hitch Replacement (Utility Vehicle Only)
149
P Model Bumpers
150
Front Bumper Replacement
150
Front Bumper Replacement (with RPO FS3 Front a X
150
Front Bumper Replacement
152
Rear Bumper Replacement
153
Rear License Plate Bracket R E P Lace M E N
154
Dead Weight Trailer Hitch R E P Lace M E N
154
Weight Distribution Hitch Replacement
155
C/K Models
158
Hood Replacement
158
Spring Assembly Replacement
158
Hood Hinge Replacement
158
Primary Hood Latch Replacement
159
Secondary Hood Latch and Spring Replacement
160
Hood Release Cable Replacement
160
Hood Ornament Replacement
160
Cowl Vent Grille Replacement
161
Grille and Molding Replacement
161
Front Fender Replacement
163
Wheelhouse Panel Replacement
164
Rear Fender Replacement
165
Radiator Support Replacement
167
Sheet Metal Unit R E P la Ce M E N
168
Sheet Metal a Djustm E N
170
G Models
170
Hood Replacement
170
Hood Hinge R E P la Ce M E N
170
Primary Hood Latch R E P la Ce M E N
171
Secondary Hood Latch and Spring Replacement
172
Hood Release Cable R E P Lace M E N
172
Cowl Vent Grille Replacement
172
Grille Replacement
174
Front End Sheet Metal Cross Panel R E P la C E M E N
174
Sheet Metal Vertical Support Replacement
175
Front End Panel Replacement
176
Diagnosis of Steering Linkage
186
On-Vehicle Service
186
Idler Arm Inspection
186
Idler Arm Adjustment (P30(32) Motorhome)
187
Idler Arm Replacement
187
Relay Rod Replacement
189
Pitman Arm Replacement
190
Steering Shock Absorber Inspection
191
Steering Shock Absorber Replacement
192
Tie Rod Replacement (C, G, P20 and 30(42) Models)
192
Tie Rod Replacement (K and P30(00)Fs3 Models)
193
Connecting Rod Replacement (K and P30(00)FS3 M O D E Ls)
195
Connecting Rod Replacement (P30(32) Motorhome)
196
Specifications
198
Special Tools
199
Description
200
Diagnosis of Manual Steering System
201
On-Vehicle Service
202
Maintenance
202
Steering Gear Replacement
202
Overhaul
202
Pitman Shaft Seal Replacement
203
Overhaul
203
Steering Gear Adjustments
204
Steering Gear High Point Centering
205
Specifications
206
Special Tools
206
Description
208
Integral Power Steering Gear
208
Hydraulic Pumps
208
Diagnosis of Power Steering System
211
Oil Leak Check
214
Power Steering System Test
214
Power Steering System On-Vehicle Service
218
Maintenance
218
Pump Belt Tension Adjustment
218
Fluid Level Adjustment
218
Bleeding the Power Steering System
219
Flushing the Power Steering System
219
Steering Gear High Point Centering
219
Power Steering Gear Replacement
220
Pitman Shaft Seal Replacement
222
Steering Gear Adjustments
222
Power Steering Pump Replacement
224
Liter
225
Liter
226
Liter
227
Liter
228
Power Steering Hoses
229
Liter
231
Liter
233
Liter
235
Specifications
237
Special Tools
239
Description
241
Diagnosis of the Steering Column
241
Steering Column Electrical Component Analyzer
249
Steering Column On-Vehicle Service (All M O D E Ls)
249
Inspection
249
Steering Wheel Replacement
250
Flexible Coupling Replacement
250
Intermediate Shaft Replacement
252
Steering Column On-Vehicle Service (C, K and G M Odels)
254
Ck Model Steering Column Replacement
254
G Model Steering Column Replacement
255
Turn Signal Switch Replacement
256
Lock Cylinder Replacement
257
Tone Alarm Switch Replacement
258
Ignition Switch Replacement
258
Standard Steering Column Unit Repair (C, K and G M O D E Ls )
259
Standard Steering Column Lower Bearing Adjustment
263
Tilt Steering Column Unit Repair (C, K and G M O D E Ls)
267
Steering Column On-Vehicle Service P(32) Models
273
Turn Signal Switch Replacement
273
Tilt Steering Column Replacement
274
Tilt Steering Column Bearing Housing Replacement
275
Tilt Steering Column Unit Repair P(32) Models
279
Steering Column On-Vehicle Service P(42) Models
280
Standard Steering Column Replacement
280
Upper Bearing Replacement
281
Lower Bearing Replacement
281
Steering Column Lower Bearing Adjustment
283
Shift Tube Adjustment
283
Standard Steering Column Unit Repair P(42) Models
284
Intermediate Shaft Unit Repair P(42) Models
285
Specifications
286
Special Tools
286
Front Suspension
287
General Description
288
Diagnosis of Front Suspension
288
Diagnosis of Wheel Bearings
289
On-Vehicle Service: Two Wheel Drive Independent Front Suspension
294
Shock Absorber
294
Stabilizer Bar
294
Wheel Hub/Rotor Assembly
298
Upper Ball J O in
298
Lower Control Arm Pivot Shaft and Bushings
307
Upper Control Arm Pivot Shaft and Bushings
311
Lower Control a
313
On-Vehicle Service: Two Wheel Drive RPO FS3 (I-Beam) Front S U S P E N S Io
317
Shock a B S O Rb E
319
Wheel Hub/Rotor Assembly
321
Steering Arm, Knuckle and S P in D
323
Front Axle
323
Leaf S P Rin
325
Shock a B S O Rb E
326
Wheel Hub/Rotor Assembly
327
Spindle
334
Ball J O in
339
General Description
359
Certification Label
359
Tire Load Limits and Inflation Pressure
359
Diagnosis of Wheels and Tires
361
Checking Wheel and Tire R Unout
361
On-Vehicle Service
362
Measuring Wheel and Tire R U N Ou T
362
Excessively Tight Wheels
364
Separating the Tire from the Wheel
364
Mounting the Tire on the Wheel
364
Aluminum Wheel Refinishing
366
S P E C Ific a Tio N
369
Tire Load Lim Its and Inflation P Re S S U
370
Description
375
C Enter B E a R in G
377
Universal Joint
377
On-Vehicle Service
379
P Ro P E Lle R S Haft Balance C H E C K
379
Propeller Shaft Runout Check
379
Propeller Shaft Replacement (Rear Drive)
381
Propeller Shaft Replacement (Front Drive)
382
L U B R IC a Tio
384
S P E C Ific a Tio N
385
Ring Gear-
386
Description
387
Rear Axle Operation
387
Diagnosis of the Rear a X Le
388
On-Vehicle Service
395
Rear Axle Assem Bly R E P la Ce M E N
395
Axle Shaft, Oil Seal and Bearing Replacement
395
Pinion Flange, Dust Deflector/O Il Seal Replacement
399
Axle Shaft Replacement ( 93 / 4 - 1 0 1 / 2 -Lnch Ring Gear-Full Floating a X Le
401
Hub and Drum Assembly Replacement
402
Wheel Bearing/Cup Replacement
403
Non-Demountable Type Drum Replacement
404
Wheel Bolt Replacement
404
Pinion Oil Seal/Companion Flange Replacement
405
Axle Vent Replacement (12-Inch Ring Gear-Full Floating a X
406
Axle Shaft Replacement (12-Inch Ring Gear-Full Floating a X
406
Liter
409
Front Axle Assembly
414
Diagnosis of Brake System
424
Diagnosis of Hydro-Boost System
427
On Vehicle Service
428
Bleeding the Brake Hydraulic S y S te M
428
Flushing the Brake Hydraulic System
429
Brake Pipes and Hoses
429
Combination Valve
432
Height Sensing Brake Proportioning Valve
433
Brake Pedal Assembly
437
Checking Pedal Travel
437
Brake Pedal Replacement
437
Brake Pedal Rod Replacement
440
Stoplamp Switch
440
Parking Brake System
442
Parking Brake Pedal or Handle R E P la C E M E N T
442
Cable Replacement
443
Propeller Shaft Brake Replacement
447
Parking Brake Adjustment
447
Master Cylinders
450
Description
450
Master Cylinder R E P la Ce M E N T
450
Bench Bleeding
450
Vacuum Boosters
452
Description
452
Vacuum Booster Replacement
452
Hydraulic Brake Booster (Hydro-Boost)
453
Description
453
Bleeding the Hydro-Boost System
456
Disc Brakes
457
Description
457
Brake Lining Inspection
457
Brake Lining Replacement
458
Servicing the Rotor
461
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