Sign In
Upload
Manuals
Brands
GMC Manuals
Automobile
1989 Light Duty Truck
GMC 1989 Light Duty Truck Manuals
Manuals and User Guides for GMC 1989 Light Duty Truck. We have
1
GMC 1989 Light Duty Truck manual available for free PDF download: Repair Manual
GMC 1989 Light Duty Truck Repair Manual (998 pages)
Unit Repair Manual
Brand:
GMC
| Category:
Automobile
| Size: 49.82 MB
Table of Contents
Table of Contents
7
Vehicle Identification
7
Engine Identification Number
8
Model Reference
8
Metric Fasteners
8
Fastener Strength Identification
9
Six Lobed Socket Head Fasteners
10
Prevailing Torque Fasteners
10
Decimal and Metric Equivalents
17
Air Conditioning
19
Air Conditioning C O M P Re S S O R
21
Air Conditioning Compressor
23
Clutch Coil and Housing Assembly Replacem Ent
24
Shaft Seal Replacement
25
Pressure Relief Valve Replacement
27
Compressor Disassembly
28
Gaging Operation
30
Gaging Procedure
32
Piston Ring Replacement
34
Compressor Assembly
36
Leak Testing
40
Specifications
41
Special Tools
42
Minor Repair to the Compressor
46
Clutch Plate and Hub Assembly Replacement
46
Pulley and Bearing Assembly Replacement
48
Clutch Coil R E P la C E M E N T
51
Pressure Relief Valve Replacement
51
High-Side Pressure and High-Side Low-Pressure Cutoff Switches Replacement
52
Control Valve Replacement
53
General Description
59
Air Conditioning C O M P Re S S O R
60
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
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 S H a Ft
87
Compressor Assem Bly- Internal Cylinder and S H a F T
88
Leak Testing
91
Specifications
92
Torque Specifications
92
Special Tools
93
Compressor Replacement
95
Special Tools
102
Power Steering
115
Description
116
Saginaw Integral Power Steering Gear- RV, G, P, ST, M
116
Disassembly
116
Cleaning and Inspection
119
Assembly
120
Saginaw Integral Power Steering Gear-CK (GMT 4 0 0 )
123
Saginaw Power Steering Pump- Model T C
123
Disassembly
123
Cleaning and Inspection
131
Assembly
131
Saginaw Power Steering Pump Model P
133
Disassembly
133
Cleaning and Inspection
133
Assembly
134
Specifications
135
Special Tools
136
Rear Axle
137
1 / 2 -Inch Ring Gear a X Le
138
AND 7 5 /S-INCH RING GEAR AXLES
140
Inspection
140
Assembly of the Rear Axle
141
Gear Tooth Pattern Check
146
Adjustments Affecting Tooth Contact
146
Specifications
147
Special Tools
148
Disassembly of the Rear Axle
178
Cleaning
178
Inspection
178
Assembly of the Rear Axle
181
Gear Tooth Pattern Check
185
Adjustments Affecting Tooth Contact
185
Specifications
187
Special Tools
188
Cleaning
190
Inspection
190
Assembly of the Rear Axle
195
Description
201
Disassembly of the Rear Axle
203
C Le a N in
206
Inspection
206
Assembly of the Rear Axle
207
Locking Differential
231
Front Axle
241
Cleaning and Inspection
245
Cleaning
245
Inspection
245
Assembly of Axle
246
Pinion Bearing Cup Installation
246
Pinion Depth Adjustment
246
Pinion Installation
247
Differential Case Assembly
247
Side Bearing Preload Adjustment
249
Backlash Adjustment
250
Gear Tooth Contact Pattern Check
251
Final Assembly
252
Disassembly of Axle
256
Inspection
256
Disassembly
256
Cleaning and Inspection
261
Cleaning
261
Inspection
261
Assembly of Axle
262
Differential Case Assembly
262
Determining Total Differential Shim Pack Size
263
Pinion Depth Adjustment
263
Pinion Installation
265
Checking Backlash
268
Final Assembly
268
Specifications
269
Special Tools
270
Disassembly of Axle
272
Inspection
272
Disassembly
272
Cleaning and Inspection
277
Cleaning
277
Inspection
277
Assembly of Axle
278
Differential Case Assembly
278
Pinion Bearing Cup in S Ta Lla Tio N
278
Pinion Depth Adjustment
279
Pinion Installation
279
Differential Assembly Installation
279
Adjusting Backlash
279
Gear Tooth Contact Pattern C H E C
283
Final Assembly
283
Description
290
Disassembly of Axle
290
Inspection
290
Disassembly
290
Cleaning and Inspection
297
Cleaning
297
Inspection
297
Assembly of Axle
298
Pinion Bearing Cup Installation
298
Pinion Depth Adjustment
299
Pinion Installation
299
Differential Case Assembly
299
Adjusting Backlash
302
Gear Tooth Contact Pattern Check
304
Carrier Case Assembly
304
Axle Tube Assembly
305
Final Assembly
306
Drive Axle Assembly
309
Outer Deflecting Ring Replacement
309
Outer Joint Seal Replacement
309
Outer Joint Assembly Replacement
312
Inner Tri-Pot Seal Replacement
313
Specifications
315
Master Cylinders
322
Composite Master Cylinder
322
Cast Iron Master Cylinder
322
Bendix Master Cylinder
324
Vacuum Boosters
327
Single Diaphragm Vacuum Booster
327
Tandem Diaphragm Vacuum Booster
329
Specifications
332
Special Tools
333
General Engine Mechanical
335
General Information
336
Statement on Cleanliness and Care
336
Use of Rtv Sealer and Anaerobic Gasket Eliminator
336
Replacing Engine Gaskets
336
M Easuring C Ylinder Bore T Ap er and O Ut-Of-R Ound (All M O D E Ls )
337
Cylinder Bore Reconditioning (2.8 L Engines)
338
Cylinder Bore Reconditioning (All Except 2.5 L and 2.8 L Engines)
338
Boring
338
Honing
339
Piston and Connecting Rod a S S E M B Lie S
339
Piston Selection (2.5 L and 2.8 L Engines)
342
Piston Selection (All Except 2.5 L and 2.8 L E N G in E S )
342
Camshaft Bearings
346
C am Shaft Bearing Replacem Ent (2.5 L and 6.2 L E N G in E
346
C am Shaft Bearing Replacem Ent (All Except 2.5 L and 6.2 L E N G in E
346
Hydraulic Lifter O V Erh a U
347
Valve Lifter Leak-Down Rate Test (Flat Type Lifters O N
349
C Ylinder H E a
350
Cleaning and in S P E C Tio
350
Measuring Main Bearing C Le a Ra N C
353
M Easuring Connecting Rod Bearing C Le a R a N C
354
Subject Page
358
Description
358
Engine Lubrication
358
Disassembly of the Engine
360
Tools and Shop Equipment
360
Accessory Removal
360
Cleaning
360
Parts Identification
360
Draining the Engine
360
Intake Manifold Removal
362
Exhaust Manifold Removal
362
Thermostat Housing Removal
362
Water Pump Removal
362
Valve Train Component R Em Oval
365
Cylinder Head Removal
366
Crankshaft Pulley Hub R Em Oval
366
Oil Pan Removal
367
Oil Pump Driveshaft R Em Oval
367
Oil Pump Removal
367
Front Cover Removal
367
Piston and Connecting Rod Removal
367
Flywheel R E M O V a
368
Crankshaft Removal
368
Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft)
369
Camshaft Removal
369
Cleaning, Inspection, and Repair
370
Block
370
Cylinder Bores
371
Piston and Connecting Rod Assemblies
371
Piston Selection
371
Intake and Exhaust Manifold
372
Camshaft
372
Camshaft Bearings
373
Front Cover
373
Water P U M
374
Oil Pan and Rocker Arm Covers
374
Oil P U M
374
Valve Train Components
375
Cylinder Head
375
Thermostat and Housing
377
Crankshaft and Bearings
377
Assembly of Engine
378
Prior to Assembly
378
Crankshaft and Main Bearing in Stallatio N
378
Main Bearing Installation (Without Removing the Crankshaft)
380
Camshaft Installation
380
Front Cover Installation
380
Crankshaft Pulley Hub Installation
381
Piston and Connecting Rod Installation
381
Oil Pump Installation
382
Oil Pan Installation
383
Oil Pump Driveshaft Installation
383
Cylinder Head Installation
383
Valve Train Component Installation
385
W Ater Pump in S Ta Lla Tio
385
Thermostat Housing Installation
386
Intake Manifold Installation
386
Exhaust Manifold in S Ta Lla Tio
386
Flywheel in S Ta Lla Tio
386
Engine Accessory in S Ta Lla Tio
386
Engine Setup and Testing
386
Engine Specifications
389
Disassembly
398
Tools and Shop Equipment
398
Accessory Removal
398
Cleaning
399
Draining the Engine
399
Air Injection Tube Removal
399
Egr Valve Removal
399
Exhaust Manifold Removal
399
Rocker Arm Cover Removal
399
Intake Manifold Removal
399
Valve Train Component Removal
400
Cylinder Head Removal
400
Torsional Damper Removal
400
Front Cover and W Ater Pump R Em O Val
401
Oil Pan Removal
401
Oil Pump Removal
401
Timing Chain and Camshaft Sprocket Removal
401
Camshaft Removal
402
Piston and Connecting Rod R E M O V a
402
Crankshaft Removal
403
Main Bearing Removal (Without Removing Crankshaft)
403
Cleaning, Inspection, and Repair
404
Block
404
Piston and Connecting Rod Assemblies
405
Intake and Exhaust Manifolds
405
Camshaft
406
Camshaft Bearings
406
Timing Chain and Sprockets
406
Front Cover
406
Water P U M
407
Oil Pan and Rocker Arm Covers
407
Oil P U M
407
Valve Train Components
408
Hydraulic Lifters
408
Cylinder Head
408
Thermostat and Water O U Tle
410
Crankshaft and Bearings
410
Rear Crankshaft Oil Seal Installation
412
Camshaft, Timing Chain and Sprocket Installation
413
Front Cover and Water Pump Installation
413
Torsional Damper Installation
413
Piston and Connecting Rod Installation
414
Oil Pump Installation
415
Oil Pan Installation
415
Cylinder Head Installation
415
Valve Train Component Installation
416
Valve Adjustment
417
Intake Manifold Installation
417
Rocker Arm Cover Installation
417
Exhaust Manifold Installation
418
EGR Valve Installation
418
Air Injection Tube Installation
419
Special Tools
423
Disassembly
429
Tools and Shop Equipment
429
Accessory Removal
429
Cleaning
429
Draining the Engine
429
Egr Valve Removal
429
Exhaust Manifold Removal
429
Rocker Arm Cover Removal
430
Intake Manifold Removal
430
Valve Train Component Removal
430
Cylinder Head Removal
431
Torsional Damper Removal
431
Oil Pan Removal
431
Oil Pump Removal
431
Front Cover Removal
431
Camshaft Removal
431
Piston and Connecting Rod Removal
432
Flywheel Removal
433
Rear Crankshaft Oil Seal R Em O Val
433
Rear Crankshaft Oil Seal Retainer R E M O V a L
433
Crankshaft Removal
433
Main Bearing Removal (Without Removing C Ra N K S H a
434
Cleaning, Inspection, and Repair
434
Piston and Connecting Rod a S S E M B Ly
434
Intake and Exhaust Manifolds
435
Camshaft
435
Camshaft Bearings
435
Front Cover
436
Water Pump
436
Oil Pan and Rocker Arm Covers
436
Oil Pump
436
Valve Train Components
437
Hydraulic Lifters
437
Cylinder Head
437
Thermostat and Water Outlet
440
Crankshaft and Bearings
440
Rear Crankshaft Oil Seal Retainer in S Ta Lla Tio
441
Rear Crankshaft Oil Seal Installation
442
Camshaft, Timing Chain and Sprocket in S Ta Lla Tio
442
Front Cover Installation
442
Torsional Damper Installation
442
Piston and Connecting Rod in S Ta Lla Tio
444
Oil Pump Installation
445
Oil Pan Installation
445
Cylinder Head Installation
445
Valve Train Component Installation
447
Valve Adjustment
447
Intake Manifold Installation
447
Rocker Arm Cover Installation
447
Exhaust Manifold in S Ta Lla Tio
447
EGR Valve Installation
448
Flywheel Installation
448
Engine Accessory Installation
448
Description
456
Disassembly
458
Tools and Shop Equipment
458
Accessory Removal
458
Cleaning
458
Parts Identification
458
Draining the Engine
462
Manifold Removal
462
Thermostat Housing Removal
463
Water Pump Removal
463
Valve Train Component Removal
463
Cylinder Head Removal
464
Torsional Damper Removal
464
Oil Pan Removal
464
Oil Pump Removal
464
Piston and Connecting Rod Removal
465
Flywheel Removal
465
Crankshaft Removal
466
Crankshaft Rear Oil Seal Removal (Without Removing Crankshaft)
466
Main Bearing Removal (Without Removing Crankshaft)
466
Camshaft Removal
467
Cleaning, Inspection, and Repair
468
Main Bearing Cap R Eplacem Ent
468
Cylinder Bores
469
Piston and Connecting Rod Assemblies
469
Intake and Exhaust Manifolds
469
Camshaft
470
Camshaft Bearings
471
Timing Gear Cover
471
Oil Pan and Rocker Arm Cover
472
Oil Pump
472
Valve Train Components
473
Cylinder Head
473
Thermostat and Housing
475
Torsional Damper
476
Crankshaft and Bearings
476
Prior to Assembly
477
Crankshaft Rear Oil Seal Installation
477
Crankshaft and Main Bearing Installation
479
Camshaft Installation
480
Timing Gear Cover Installation
480
Torsional Damper Installation
481
Piston and Connecting Rod Installation
481
Oil Pump Installation
482
Oil Pan Installation
482
Cylinder Head Installation
483
Valve Train Component Installation
483
Valve Adjustment
483
Thermostat Housing in S Ta Lla Tio
484
Intake and Exhaust Manifold Installation
485
Flywheel Installation
485
Engine Accessory Installation
485
Engine Set-Up and Testing
485
Specifications
486
Description
492
Disassembly
496
Tools and Shop Equipment
496
Accessory Removal
496
Cleaning
496
Draining the Engine
496
Exhaust Manifold Removal
496
Water Pump Removal
496
Intake Manifold Removal
496
Rocker Arm Cover Removal
497
Valve Train Component Removal
497
Cylinder Head Removal
498
Torsional Damper Removal
498
Oil Pan Removal
498
Oil Pump Removal
498
Front Cover Removal
498
Timing Chain and Camshaft Sprocket Removal
499
Camshaft Removal
499
Piston and Connecting Rod Removal
499
Advertisement
Advertisement
Related Products
GMC 1997 Safari
GMC 1998 Envoy
GMC 1996 Suburban
GMC 1997 Savana Van
GMC 1998 Jimmy
GMC 1998 Safari
GMC 1998 Sonoma
GMC 1999 Sonoma
GMC 1999 Yukon Denali
GMC 1993 Yukon
GMC Categories
Automobile
Saw
Drill
Sander
Automobile Accessories
More GMC Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL