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Manuals and User Guides for GMC P. We have
1
GMC P manual available for free PDF download: Service Manual
GMC P Service Manual (1576 pages)
Brand:
GMC
| Category:
Trucks
| Size: 70.77 MB
Table of Contents
Table of Contents
5
General Information
7
Oa-4 General Information
8
Manual
8
Manual
9
Manual
10
Manual
11
Metric Fasteners
19
Fastener Strength Identification
19
Prevailing Torque Fasteners
20
Six Lobed Socket Head Fasteners
20
Anticorrosion Treatment
21
Graphic Symbols
21
Electrostatic Discharge
21
Common Abbreviations
23
RPO Listing (Regular Production Option
26
Heating and Air Conditioning
57
Subject Page
58
1A-2 Heating
58
R/V and G Series Heaters - Description
58
Blower and Air Inlet Assembly
58
Heater Distributor Assembly
58
Insufficient Heat Diagnosis
59
Heater Circuit Diagnosis
62
Diagnosis of the Heater System
63
R/V Series Heater - On-Vehicle Service
64
Blower Motor Replacement
64
Heater Hose Routing
65
Heater Distributor Case and Core Replacement
65
Control Assembly Replacement
67
Control Cable Replacement
68
Cable Adjustment
68
Blower Switch Replacement
68
Resistor Replacement
69
Vent Replacement
69
R/V Series Auxiliary Heater
70
Description
70
R/V Series Auxiliary Heater - On-Vehicle Service
72
Blower Motor Replacement
72
Heater Core Replacement
72
Resistor Replacement
72
Auxiliary Blower Switch Replacement
72
Coolant-Control Valve Replacement
72
G-Van Heater - On-Vehicle Service
73
Blower Motor Replacement
73
Heater Hose Routing
73
Heater Distributor Case and Core Replacement
74
Distributor and Defroster Duct Replacement
75
Control Assembly And/Or Blower Switch Replacement
75
Control Cable Replacement
77
Cable Adjustment
77
Resistor Replacement
78
Vent Replacement
78
G>Van Auxiliary Heater
79
Description
79
G-Van Auxiliary Heater - On-Vehicle Service
82
Blower Motor Replacement
82
Heater Core Replacement
82
Coolant-Control Valve Replacement
82
Resistor Replacement
82
Specifications
83
Subject Page
86
Description
87
CCOT A/C System
87
Rear Interior Roof Mounted Systems (Suburban & G-Van)
87
System Components
87
Periodic Maintenance and Servicing
88
System Operation - R/V & G-Van
88
Functional Test - R/V & G-Van
88
Refrigerant-12 Operating Characteristics
92
System Components, Temperature and Pressure Relationships
92
Refrigerant and Oil Capacity
92
Handling Refrlgerant-12
93
Handling Refrigerant Lines and Fittings
93
Maintaining Chemical Stability
94
Refrigerant System Diagnosis
94
Insufficient Cooling "Quick-Check" Procedure
94
System Performance Test
94
Testing the Refrigerant System
95
Leak Testing the Refrigerant System
95
Pressure Sensing Switch
95
Compressor Cut-Out Switches
95
Electrical/Vacuum Trouble Diagnosis
102
Operational Test
102
Vacuum System Diagnosis
108
R/V and G-Van
108
Evacuating and Charging Procedures
108
Discharging, Evacuating, Adding Oil and Charging Procedures
108
Discharging the System
110
Refrigerant Oil Distribution
110
Evacuating and Charging
111
Gage Calibration
111
Vacuum System Check
111
Charging Station Method
111
Disposable Can or Multi-Can Method
111
Refrigerant Drum Method
111
Charging the System
111
Accumulator Assembly
112
Specific Component Diagnosis
112
Compressor
112
Condenser
112
Expansion Valve
112
Evaporator
113
Refrigerant Line Restrictions
113
On-Vehicle Service
113
Refrigerant-11 Flushing Procedure
113
Filter Installation
113
Compressor Replacement (R
114
Compressor Replacement (G-Van)
114
A/C System - - R/V Series
119
Condenser Replacement
119
Accumulator Replacement
120
Blower Assembly Replacement
121
Evaporator Core Replacement
122
Orifice (Expansion Tube) Replacement
122
Defroster Duct and Heater Core Replacement
122
Actuator - Plenum Side Vent Replacement
123
Plenum Valve Replacement
125
Control Assembly Replacement
126
Temperature Door Cable Adjustment
126
Blower Switch Replacement
126
Vacuum Tank Replacement
126
Blower Motor Resistor Replacement
127
Blower Motor Relay Replacement
127
Fuse Replacement
127
Vacuum Line Replacement - Engine Compartment
127
Vacuum Line Replacement - Dash
129
Refrigerant-12 Hose Replacement
129
Rear Interior Roof Mounted System - Suburban
131
Rear Duct Replacement
131
Blower Motor Resistor Replacement
131
Blower Motor Assembly Replacement
131
Expansion Valve Replacement
132
Evaporator Core Replacement
135
Blower Motor Switch Replacement
135
Fuse Replacement
135
A/C System - G-Van
136
Condenser Replacement
136
Accumulator Replacement
136
Heater Core Replacement
136
Orifice (Expansion Tube) Replacement
136
Blower Motor Insulation (W/Diesel) Replacement
136
Evaporator Core (W/Diesel) Replacement
139
Evaporator Core Replacement (Except Diesel)
140
Blower Motor Replacement
140
Control Assembly Replacement
141
Temperature Door Cable Adjustment
141
Blower Switch Replacement
143
Selector Replacement
143
Resistor Replacement
143
Blower Motor Relay Replacement
143
A/C Right Duct Replacement
143
A/C Left Duct Replacement
144
Defroster Duct Replacement
144
Temperature Door Cable Replacement
145
Vacuum Tank Replacement
146
Vacuum Lines - Engine Compartment
147
Refrigerant-12 Hose Routing
147
Rear Duct Replacement
151
Rear Air Deflector Replacement
151
Blower Motor Resistor Replacement
151
Blower Motor Assembly Replacement
153
Expansion Valve Replacement
153
Evaporator Core Replacement
155
Blower Motor Switch Replacement
155
Fuse Replacement
155
A/C System - P-Truck
156
Specifications
157
Compressors
157
Torque Specifications
158
A/C Electrical
159
Refrigerant-12/Refrigerant Oil Capacities
159
Special Tools
160
2A-2 Frame and Bumpers
162
R/V and P-Model Frames
162
Description
162
Diagnosis of the Frame
162
Minimizing Frame Service
163
Checking Frame Alignment
164
Straightening Frames
164
Repairing Cracks
165
Welding
166
G-Model Underbody
166
Description
166
Underbody Alignment
166
R/V Model Bumpers
167
Front Bumper Replacement
167
Rear Bumper Replacement (Utility Vehicle and Suburban)
168
Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew Cab)
168
Rear Step Bumper Replacement
173
Rear Bumper License Plate Bracket Replacement
173
Dead Weight Trailer Hitch Replacement (Utility Vehicle and Suburban)
174
Weight Distribution Hitch Replacement (Suburban Only)
175
Weight Distribution Hitch Replacement (Utility Vehicle Only)
175
P-Model Bumpers
176
Front Bumper Replacement (with RPO FS3 Front Axle)
176
G-Model Bumpers
179
Front Bumper Replacement
179
Rear Bumper Replacement
180
Rear License Plate Bracket Replacement
180
Dead Weight Trailer Hitch Replacement
181
Weight Distribution Hitch Replacement
182
Specifications
183
R/V Models
186
Hood Replacement
186
Spring Assembly Replacement
186
Hood Hinge Replacement
186
Primary Hood Latch Replacement
187
Secondary Hood Latch and Spring Replacement
187
Hood Release Cable Replacement
188
Hood Ornament Replacement
189
Cowl Vent Grille Replacement
189
Grille and Molding Replacement
190
Front Fender Replacement
191
Wheelhouse Panel Replacement
192
Rear Fender Replacement
193
Radiator Support Replacement
194
Sheet Metal Unit Replacement
195
Sheet Metal Adjustments
196
Noise Shields
196
G-Models
200
Hood Replacement
200
Hood Hinge Replacement
200
Primary Hood Latch Replacement
200
Secondary Hood Latch and Spring Replacement
201
Hood Release Cable Replacement
201
Cowl Vent Grille Replacement
202
Grille Replacement
202
Front End Sheet Metal Cross Panel Replacement
204
Sheet Metal Vertical Support Replacement
204
Front End Panel Replacement
205
Noise Shields
205
Cab Mounts
209
Cab Mount Replacement
209
Anti-Corrosion Treatment
213
Sheet Metal Repair
213
Specifications
214
Special Tools
214
3A-2 Front End Alignment
216
Description
216
Definition of Terms
216
Diagnosis of Front End Alignment
217
On-Vehicle Service
217
Inspection
217
Front End Alignment Requirements
218
Alignment Adjustments
218
Specifications
220
On-Vehicle Service
224
Idler Arm Inspection
224
Idler Arm Adjustment - P30 Motorhome
226
Idler Arm Replacement
227
Relay Rod Replacement
228
Pitman Arm Replacement
228
Steering Shock Absorber Inspection
229
Steering Shock Absorber Replacement
230
Tie Rod Replacement - R, G, P20, and P30 Models Except Motorhome
231
Tie Rod Replacement - V and P30 FS3 Models
233
Connecting Rod Replacement - V and P30 FS3 Models
233
Connecting Rod Replacement - P30 Motorhome
235
Specifications
237
Special Tools
238
Description
240
Integral Power Steering Gear
240
Hydraulic Pumps
240
Diagnosis of Power Steering System
243
Fluid Leak Check
246
Power Steering System Test
246
On-Vehicle Service
249
Maintenance
249
Pump Belt Tension Adjustment
249
Fluid Level Adjustment
249
Bleeding the Power Steering System
250
Flushing the Power Steering System
250
Steering Gear High-Point Centering
250
Power Steering Gear Replacement
250
Pitman Shaft Seal Replacement
252
Steering Gear Adjustments
255
Power Steering Pump Replacement
257
Power Steering Oil Coolers
264
Power Steering Hoses
265
Specifications
273
Special Tools
275
Description
278
Diagnosis of the Steering Column
279
On-Vehicle Service (All Models)
285
Inspection
285
Steering Wheel Replacement
286
Flexible Coupling Replacement
287
Intermediate Shaft Replacement
288
On-Vehicle Service (R/V and G-Models)
289
G-Model Steering Column Replacement
290
Turn Signal Switch Replacement
291
Lock Cylinder Replacement
293
Tone Alarm Switch Replacement
293
Ignition Switch Replacement
293
Standard Steering Column Unit Repair (R/V and G-Models)
295
Standard Steering Column Lower Bearing Adjustment
303
Tilt Steering Column Unit Repair (R/V and G-Models)
304
On-Vehicle Service (P30 Motorhome Models)
312
Turn Signal Switch Replacement
312
Tilt Steering Column Replacement
312
Tilt Steering Column Bearing Housing Replacement
315
Tilt Steering Column Unit Repair (P30 Motorhome Models)
318
On-Vehicle Service (P-Models; Except Motorhome)
319
Standard Steering Column Replacement
319
Upper Bearing Replacement
320
Lower Bearing Replacement
320
Lower Bearing Adjustment
320
Shift Tube Adjustment
320
Standard Steering Column Unit Repair (P-Models; Except Motorhome)
322
Intermediate Shaft Unit Repair (P-Models; Except Motorhome)
324
Special Tools
326
Description
328
Diagnosis of Front Suspension
329
Shock Absorber Bench Test
330
Diagnosis of Wheel Bearings
330
Shock Absorber
335
Stabilizer Bar
335
Wheel Hub/Rotor Assembly
335
Wheel Bearing Adjustment
343
Wheel Hub Bolt
343
Steering Knuckle
344
Coil Spring
346
Lower Ball Joint
346
Upper Ball Joint
348
Lower Control Arm Pivot Shaft and Bushings
349
Upper Control Arm Pivot Shaft and Bushings
353
Lower Control Arm
354
Upper Control Arm
355
Suspension Unit
356
Shock Absorber
359
Stabilizer Bar
362
Wheel Hub/Rotor Assembly
363
Wheel Bearing Adjustment
365
Wheel Hub Bolt
365
Steering Arm, Knuckle and Spindle
365
157. Front Axle
366
Leaf Springs
367
Shock Absorber
369
Stabilizer Bar
369
Wheel Hub/Rotor Assembly
369
Bearing Adjustment
377
Wheel Hub Bolt
377
Spindle
378
Steering Knuckle and Arm
379
Leaf Spring and Bushings
384
Special Tools
388
On-Vehicle Service
398
Shock Absorber Replacement
398
Stabilizer Bar Replacement
398
Leaf Spring Assembly Replacement
399
Bushing Replacement
400
General Description
404
Certification Label
404
Tire Load Limits and Inflation Pressure
404
Puncture-Sealing Tires
404
Diagnosis of Wheels and Tires
405
Checking Wheel and Tire Runout
405
On-Vehicle Service
407
Measuring Wheel and Tire Runout
407
Excessively Tight Wheels
409
Separating the Tire from the Wheel
409
Mounting the Tire on the Wheel
409
Installing the Wheel and Tire Assembly
411
Aluminum Wheel Refinishing
411
Wheel and Tire Balancing
412
Spare Tire Carriers
412
Specifications
418
Tire Load Limits and Inflation Pressure
418
Wheel Codes and Load Limits
418
Wheel Runout
418
Wheel Stud Nut Torque (Single Front and Rear Wheels)
418
Wheel Stud Nut Torque (Single Front and Dual Rear Wheels)
418
4A-2 Propeller Shaft
424
17. Universal Joint
424
Diagnosis of Driveline Vibration (Road Test)
425
Diagnosis of the Propeller Shaft and Universal Joint
426
On-Vehicle Service
427
Propeller Shaft Runout Check
427
Propeller Shaft Replacement (Rear Drive)
429
Propeller Shaft Replacement (Front Drive)
431
Lubrication
434
Rear Axle
437
Description
438
Rear Axle Operation
438
Diagnosis of the Rear Axle
439
Determining the Type of Noise
439
On-Vehicle Service
445
Rear Axle Assembly Replacement (All Axles)
445
Semi-Floating Axle (8 1/2- and 9 1/2-Inch Ring Gear)
445
Axle Shaft, Oil Seal and Bearing Replacement
445
Brake Backing Plate Replacement
448
Wheel Stud Replacement
449
Pinion Flange, Dust Deflector/Oil Seal Replacement
449
Axle Shaft Replacement
451
Hub and Drum Assembly Replacement
452
Wheel Bearing/Cup Replacement
453
Non-Demountable Type Drum Replacement
455
Wheel Stud Replacement
455
Wheel Bearing Adjustment
455
Pinion Oil Seal/Pinion Flange Replacement
456
Full-Floating Axle (12-Inch Ring Gear)
457
Axle Vent Replacement
457
Bearing Adjustment
458
Pinion Oil Seal/Pinion Flange Replacement
459
Specifications
460
Special Tools
461
Diagnosis of the Front Driving Axle
464
Road Test
464
Tire Noises
464
Test for Wheel Bearing Noise
464
Test for Differential Bearing Noise
464
Test for Pinion Bearing Noise
464
On-Vehicle Service
464
Axle Shaft Replacement
464
Front Driving Axle Assembly Replacement
466
Axle Joint Component Replacement
466
Automatic Locking Hub Service
467
Manual Locking Hub Replacement
468
Manual Locking Hub Rebuild Procedure
468
Specifications
471
Special Tools
471
Hydraulic Brakes
473
Brake System Diagnosis
474
Diagnosis of Brake System
475
On-Vehicle Service
477
Bleeding the Brake Hydraulic System
477
Flushing the Brake Hydraulic System
479
Brake Pipes and Hoses
479
Combination Valve
481
Height-Sensing Brake Proportioning Valve
482
Brake Pedal Assembly
486
Checking Pedal Travel
486
Brake Pedal Replacement
486
Brake Pedal Rod Replacement
488
Stoplamp Switch
489
Parking Brake System
492
Parking Brake Pedal or Handle Replacement
492
Cable Replacement
494
Propeller Shaft Brake Replacement
496
Parking Brake Adjustment
497
Master Cylinders
500
Bench Bleeding
500
Special Tools
504
Vacuum Boosters
507
Description
508
Hydraulic Brake Booster (Hydro-Boost)
508
Hydro-Boost Replacement
508
Bleeding the Hydro-Boost System
512
Rebuilding the Caliper
521
Drum Brakes
524
Description
524
Brake Lining Replacement
524
Servicing the Brake Drum
526
Brake Adjustment
526
Wheel Cylinder Replacement
526
Rebuilding the Wheel Cylinder
527
Special Tools
529
Engine, Driveability and Diagnosis
531
Radiator
532
Carburetors
532
Engine Electrical
532
Emissions
532
Diesel Emissions
532
Exhaust
532
Vacuum Pump
532
Tune-Up Information
534
Use of RTV Sealer and Anaerobic Gasket Eliminator
534
Replacing Engine Gaskets
534
Compression/Cranking Speed Checks
535
Gasoline Engine Compression Check
535
L Diesel Engine Compression Check
535
Cranking Speed Check (6.2L Diesel Engine)
536
Diagnosis Charts
536
Carbureted Gasoline Engine Diagnosis Chart
536
Diagnosis of Diesel Engine
538
Diagnosis of "Water in Fuel" Light
539
Diagnosis of Noises
540
Diagnosis of Power Problems
543
Diagnosis of Poor Fuel Economy/Smoke/Oil/Odors
553
Diagnosis of Spark Plugs
556
Special Tools
556
Description
558
Engine Lubrication
558
On-Vehicle Service
561
Rocker Arm Cover Replacement
561
Rocker Arm and Pushrod Replacement
562
Valve Adjustment
562
Valve Stem Seal and Valve Spring Replacement
563
Intake Manifold Replacement
564
Hydraulic Lifter Replacement
565
Rocker Arm Stud Replacement
567
Exhaust Manifold Replacement
568
Cylinder Head Replacement
568
Torsional Damper and Front Crankshaft Seal Replacement
570
Front Cover Replacement
571
Oil Pan Replacement
572
Oil Pump Replacement
573
Rear Crankshaft Oil Seal Replacement
573
Rear Crankshaft Oil Seal Retainer Replacement
574
Measuring Camshaft Lobe Lift
574
Connecting Rod and Piston Replacement
577
Main Bearing Replacement
579
Oil Filter Adapter and Oil Filter Bypass Valve Replacement (Models with Engine Oil Cooler)
580
Crankshaft Replacement
580
Flywheel Replacement
580
Engine Mountings
581
Engine Replacement
582
Specifications
584
Special Tools
587
Description
590
Engine Lubrication
590
On-Vehicle Service
593
Rocker Arm Cover Replacement
593
Rocker Arm and Pushrod Replacement
594
Valve Adjustment
595
Valve Stem Seal and Valve Spring Replacement
595
Intake Manifold Replacement
597
Hydraulic Lifter Replacement
598
Rocker Arm Stud Replacement
599
Exhaust Manifold Replacement
600
Cylinder Head Replacement
601
Torsional Damper and Front Crankshaft Seal Replacement
602
Front Cover Replacement
603
Oil Pan Replacement
604
Oil Pump Replacement
605
Rear Crankshaft Oil Seal Replacement
605
Rear Crankshaft Oil Seal Retainer Replacement
606
Measuring Camshaft Lobe Lift
606
Camshaft Replacement
607
Connecting Rod and Piston Replacement
609
Oil Filter Bypass Valve
611
Main Bearing Replacement
611
Crankshaft Replacement
612
Flywheel Replacement
612
Engine Mountings
613
Engine Replacement
621
Special Tools
627
Engine Lubrication
630
Rocker Arm Cover Nuts (Carbureted Engines)
632
On-Vehicle Service
632
Rocker Arm Cover Replacement
632
Rocker Arm and Pushrod Replacement
632
Valve Adjustment
633
Valve Stem Seal and Valve Spring Replacement
633
Intake Manifold Replacement
634
19. Intake Manifold Bolts
635
Hydraulic Lifter Replacement
635
Rocker Arm Stud Replacement
636
Exhaust Manifold Replacement
636
15. Cylinder Head Bolts
637
Cylinder Head Replacement
637
5. Torsional Damper Bolt
638
Torsional Damper and Front Crankshaft Seal Replacement
638
Front Cover Replacement
639
Oil Pan Replacement
640
Oil Pump Bolt
641
Oil Pump Replacement
641
Rear Crankshaft Oil Seal Replacement
641
Measuring Camshaft Lobe Lift
643
Camshaft Replacement
643
17. Camshaft Sprocket Bolts
644
4. Connecting Rod Cap Nuts
646
Oil Filter Bypass Valve Bolts
647
Spark Plugs
647
Oil Filter Bypass Valve
647
Main Bearing Replacement
647
Crankshaft Replacement
648
Flywheel Replacement
649
Engine Mountings
649
Bell Housing Bolts
659
Engine Replacement
659
Special Tools
664
Engine Lubrication
666
On-Vehicle Service
667
Intake Manifold Replacement
667
Exhaust Manifold Replacement
668
Rocker Arm Cover Replacement
669
Rocker Arm, Shaft, and Pushrod Replacement
670
Hydraulic Lifter Replacement
671
Valve Stem Seal and Valve Spring Replacement
673
Cylinder Head Replacement
674
Oil Pump Drive Replacement
677
Torsional Damper and Front Crankshaft Seal Replacement
678
Front Cover Replacement
679
Timing Chain and Sprocket Replacement
680
Camshaft Replacement
681
Dipstick Tube Replacement
683
Oil Pan Replacement (R/V Models)
684
Oil Pump Replacement (R/V Models)
684
Oil Pan and Oil Pump Replacement (G-Models)
685
Rear Crankshaft Oil Seal Replacement
686
Connecting Rod and Piston Replacement
687
Main Bearing Replacement
688
Crankshaft Replacement
690
Oil Filter Bypass Valve Replacement
690
Engine Mountings
690
Engine Replacement
698
Special Tools
705
Engine Lubrication
708
Valve Adjustment
711
Pushrod Cover Replacement
712
Hydraulic Lifter Replacement
713
Intake and Exhaust Manifold Replacement
714
Rocker Arm Stud Replacement
715
Cylinder Head Replacement
716
Torsional Damper and Front Crankshaft Seal Replacement
717
Timing Gear Cover Replacement
718
Oil Pan Replacement
719
Oil Pump Replacement
719
Checking Valve Timing
722
Measuring Camshaft Lobe Lift
722
Camshaft Replacement
722
Connecting Rod and Piston Replacement
724
Crankshaft Gear Replacement
728
Oil Filter Bypass Valve Replacement
728
Crankshaft Replacement
729
Flywheel Replacement
729
Engine Mountings
729
Engine Replacement
734
Special Tools
738
System Checks
740
Thermostat Diagnosis
741
Cooling System Diagnosis
742
Uncommon Cooling System Problems
744
On-Vehicle Service
745
Deaeration Tank Replacement
747
Thermostat Replacement
748
Fan and Fan Clutch Replacement
769
Auxiliary Cooling Fan Replacement
770
Special Tools
782
Diagnosis of the Radiator
787
Radiator Maintenance
788
On-Vehicle Service
789
Radiator Replacement
793
Pressure Cap
795
Coolant Recovery System
798
Surge Tank
798
Aluminum Radiator Repair
799
Aluminum Radiator Service
800
Tanks and Gaskets
803
Drain Cock
805
Special Tools
807
Accelerator Pedal
826
Carburetor Model 1MEF
830
Diagnosis of 1MEF and M4MEF Carburetor
834
On-Vehicle Service (1MEF)
846
Electric Choke
846
Idle Solenoid
847
Carburetor Replacement
847
Carburetor Adjustments
848
Carburetor Model M4MEF
852
On-Vehicle Service (M4MEF)
856
Fuel Filter Replacement
857
Carburetor Mounting Torque
857
Carburetor Replacement
857
Idle Mixture Adjustment (Heavy-Duty Emission Vehicles Only)
858
Float Adjustment
860
Pump Adjustment
860
Choke Stat Lever Adjustment
861
Choke Link and Fast Idle Cam Adjustment
861
Primary Side Vacuum Break Adjustment
862
Air Valve Link Adjustment
864
Unloader Adjustment
864
Secondary Throttle Lockout Adjustment
865
Special Tools
866
On-Vehicle Service
868
Housing Pressure Cold Advance
869
Injection Line Replacement
869
Injection Pump Replacement
871
Injection Timing Adjustment
874
Marking TDC on the Front Housing
874
Injection Nozzles
875
Injection Nozzle Replacement
876
Injection Nozzle Tests
876
Injection Pump On-Vehicle Service
878
Minimum-Maximum Governor Replacement
879
Throttle Shaft Seal Replacement
881
Shutdown And/Or Cold Advance Solenoid Replacement
883
Side Cover Gasket Replacement
883
Injection Pump Off-Vehicle Service
884
Special Tools
887
Subject Page
890
Battery
890
Electrical System
890
Visual Inspection
892
Hydrometer Test
892
Load Test
892
Current Drain Test
894
Battery Cables
894
Battery Replacement
894
Charging System
895
Noisy Generator
898
Electrical Tests
898
Cs-130 Charging System
901
Generator On-Vehicle Service
902
Generator Replacement
902
Circuit Check
905
Glow Plug On-Vehicle Service
908
Cranking System
908
Diagnosis of Cranking System
910
Cranking Circuit
910
Starter Motor Noise
913
Diagnosis of Starter Motor Noise
915
Cranking System On-Vehicle Service
916
Starter Motor
916
Engine Block Heaters
917
Description
922
Ignition System
922
Distributor
922
Spark Plug Wires
924
Spark Plugs
924
Diagnosis of the Ignition System
926
Diagnosis of Spark Plugs
930
Service Precautions
931
Distributor Replacement
931
Ignition Timing
932
Spark Plug Wires
933
Spark Plug Wire Replacement
933
Engine Wire Harness
941
Maintenance Schedule
972
Driveability Symptoms
978
Won't Start - Engine Cranks OK
978
Hard Start - Cold
979
Hard Start - Hot
979
Stall after Start - Cold
980
Stall after Start - Hot
980
Hesitation/Sag, Stumble
981
Surges And/Or Chuggle
981
Lack of Power, Sluggish or Spongy
982
Backfire
984
Misses/Cuts out
984
Won't Idle
985
Poor Fuel Economy
986
Dieseling, Run on
986
Detonation/Spark Knock
987
Excessive Exhaust Emissions (Odors)
987
Description
1022
Crankcase Ventilation System
1024
Description
1024
Diagnosis
1025
On-Vehicle Service
1025
Diesel Electronic Control System
1026
Description
1026
Diagnosis
1028
Diesel Diagnostic Circuit Check
1032
Service Engine Soon" Lamp Inoperative
1034
EPR Solenoid Electrical Circuit Check
1038
EPR Vacuum Circuit Check
1040
On-Vehicle Service
1064
Exhaust Gas Recirculation (EGR) System
1072
Description
1072
Diagnosis
1072
On-Vehicle Service
1073
Transmission Converter Clutch (TCC)
1074
Description
1074
Diagnosis
1074
On-Vehicle Service
1074
Glow Plug Control System
1078
Description
1078
Diagnosis
1079
On-Vehicle Service
1079
Cold Advance Control System
1082
Description
1082
Diagnosis
1082
Description
1087
On-Vehicle Service
1088
Diagnosis of Exhaust System
1088
Installing Exhaust Parts
1088
Catalytic Converter Replacement
1090
General Description
1097
Belt Driven Vacuum Pump
1097
Gear Driven Vacuum Pump
1097
Diagnosis of Vacuum Pump
1097
On-Vehicle Service
1100
Belt Driven Pump Replacement
1100
Specifications
1100
On Vehicle Service
1167
Parts Cleaning, Inspection and Replacement
1167
Oil Cooler Lines
1168
Checking and Adding Fluid
1168
TV Cable Adjustment
1171
Changing the Fluid and Filter
1171
Detent Switch (THM 400)
1172
Vacuum Modulator (THM 400)
1172
Speedometer Driven Gear/Vehicle Speed Sensor
1173
Servo (THM 700-R4)
1178
Rear Extension Oil Seal
1178
7B-2 Manual Transmission
1186
Inspection
1186
Control Linkages
1186
Transmission Shift Effort
1186
Diagnosis of Manual Transmission
1186
On Vehicle Service
1187
Drain and Fill
1187
Rear Oil Seal
1187
Speedometer Driven Gear
1189
Shift Linkage
1189
Shift Linkage Adjustment
1189
Shift Control
1189
Side Cover
1192
Transmission Replacement
1192
Specifications
1194
Lubrication
1194
Special Tools
1195
Description
1198
Hydraulic Clutch
1198
On-Vehicle Service
1200
Hydraulic Clutch Pedal
1200
Mechanical Clutch Pedal
1201
Master Cylinder and Reservoir
1202
Master Cylinder Unit Repair
1203
Secondary (Slave) Cylinder and Hydraulic Line Replacement
1203
Secondary (Slave) Cylinder Unit Repair
1204
Hydraulic Clutch Bleeding
1207
Clutch Pedal Free Travel Adjustment
1208
Clutch Assembly and Pilot Bearing
1209
Specifications
1212
Diagnosis of the Transfer Case
1222
On-Vehicle Service
1222
Maintenance and Adjustment
1222
Transfer Case Replacement
1223
Specifications
1227
8A-2 Cab Electrical
1230
Basic Electrical
1230
Circuits
1230
Wire Size Conversion Table
1231
Circuit Malfunctions
1231
Circuit Diagnosis
1232
Diagnostic Tools
1232
Circuit Maintenance and Repair
1233
Cab Electrical Systems
1238
R/V Cab Harness Routings
1238
R/V Fuse Block
1244
G-Van Cab Harness Routings
1244
G-Van Fuse Block
1252
Power Door Lock System
1252
Power Window System
1252
Windshield Wiper - R/V and G-Van Models
1252
Windshield Washer - R/V and G-Van Models
1253
Windshield Wiper and Washer - P-Models
1253
Windshield Wiper Delay Circuits
1254
Heater System Circuits
1254
Air Conditioning Electrical System
1254
Diagnosis of Power Door Lock System
1256
Diagnosis of Power Window System
1257
Diagnosis of Windshield Wiper - R/V and G-Van
1258
Diagnosis of Windshield Wiper - P-Models
1262
Wiper System Checks
1262
Diagnosis of Wiper (P-Models) - on Vehicle
1263
Diagnosis of Wiper (P-Models) - off Vehicle
1264
Diagnosis of Windshield Washer - R/V and G-Van
1264
Diagnosis of Washer System - P-Models
1265
Diagnosis of Wiper Delay Circuit
1266
On-Vehicle Service
1266
Power Door Lock Motor Replacement
1266
Power Door Lock Switch Replacement
1266
Power Window Motor Replacement
1267
Power Window Switch Replacement
1267
Wiper Motor Replacement
1268
Washer Motor Replacement
1269
Replacement of the Wiper Delay Module
1270
Replacement of the Wiper Delay Switch
1270
Unit Repair
1270
Replacement of Wiper Motor Components - R/V and G-Van
1270
Wiper Motor Disassembly and Assembly - P-Models
1271
Windshield Washer Disassembly and Assembly - P-Models
1274
Special Tools
1275
Diagnosis of Headlamps
1278
Diagnosis of Front Parking Lamps
1279
Diagnosis of Front Side Marker Lamps
1279
Diagnosis of Rear Side Marker Lamps
1280
Diagnosis of Running, Park and License Lamps
1280
Diagnosis of the Turn Signal and Hazard Systems
1281
Diagnosis of the Stoplamp System
1282
Diagnosis of the Backup Lamp System
1282
Front Lighting Systems
1283
Headlamp System
1283
Front Parking Lamps System
1283
Front Side Marker Lamp System
1283
Headlamp Unit Replacement
1290
Headlamp Adjustment
1290
Lamp Switch Replacement
1291
Dimmer Switch Replacement
1292
Front Parking Lamp Replacement
1293
Front Side Marker Lamp Replacement
1293
Rear Running Lamps and Marker Lamps
1295
Rear Park Lamps
1295
Rear Turn, Stop and Hazard Systems
1295
Backup Lamp System
1295
Rear Lamp Harness Layouts
1297
Trailer Wiring
1298
Rear Lamp Bulb Replacement
1305
Rear Lamp Housing and Seal Replacement
1305
License Plate Lamp Replacement
1306
Rear Marker Lamp Bulb Replacement
1308
Backup Switch Replacement
1309
Fuses/Circuit Breakers Specifications
1311
R/V Model Fuses
1311
P-Model Fuses
1312
G-Model Fuses
1313
Circuit Breakers
1313
Lamp Specifications
1314
Special Tools
1315
Description
1318
Speedometer
1318
Fuel Gage
1318
Oil Pressure Gage
1318
Temperature Gage
1318
Engine Control/Ignition Switch
1318
Lamp Switch
1318
Diagnosis of Speedometer System
1319
Diagnosis of the Fuel Gage
1320
Diagnosis of the Oil Pressure Gage
1321
Diagnosis of the Temperature Gage
1322
On Vehicle Service
1323
Speedometer Replacement
1323
Speedometer Cable Core Replacement
1325
Fuel Gage Replacement
1326
Fuel Sender Unit Replacement
1329
Temperature Gage Replacement
1329
Temperature Gage Sensor Replacement
1330
Oil Pressure Gage Replacement
1330
Oil Pressure Gage Sensor Replacement
1331
Voltmeter Replacement
1331
Instrument Cluster Replacement
1332
Laminated (Printed) Circuit Replacement
1333
Ignition Switch Replacement
1333
Lamp Switch Replacement
1333
Special Tools
1333
Cruise Control
1335
Diagnosis of Cruise Control System
1338
On-Vehicle Service
1342
Vacuum Release Valve Replacement
1342
Clutch Release Switch Replacement
1342
Cruise Control Module Replacement
1343
Multi-Function Switch Replacement
1344
Servo Replacement
1344
Radio
1349
Diagnosis
1349
Accessory Noise
1360
Diagnostic RF Sniffer
1362
Radio On-Vehicle Service
1363
Radio Receiver Replacement
1363
Antenna Replacement
1363
Speaker Replacement
1365
Doors
1373
Subject Page
1375
Door and Hinge Replacement
1376
Door Adjustment
1376
Door Trim Panel Replacement
1378
Door Vent/Window Run Channel Assembly Replacement
1379
Vent Glass Replacement
1379
Vent Window Adjustment
1380
Door Window Replacement
1380
Inner Window Weatherstrip Replacement
1381
Outer Window Weatherstrip Replacement
1381
Rear Glass Run Channel Replacement
1382
Window Regulator Replacement
1382
Door Lock Replacement
1384
Power Door Lock Motor Replacement
1384
Door Outside Handle Replacement
1385
Door Lock Cylinder Replacement
1385
Door Inside Handle Replacement
1386
Door Weatherstrip Replacement
1386
Outside Rear View Mirror Replacement
1387
Below Eyeline Outside Rear View Mirror Replacement
1387
West Coast Outside Rear View Mirror Replacement
1387
Door Air Valve Replacement
1388
R/V Model Side Rear Doors
1388
Door and Hinge Replacement
1388
R/V Model Side Rear Doors (Continued)
1388
Door Adjustment
1389
Door Trim Panel Replacement
1390
Stationary Glass/Window Run Channel Assembly Replacement
1391
Door Window Replacement
1392
Inner Window Weatherstrip Replacement
1392
Outer Window Weatherstrip Replacement
1393
Front Glass Run Channel Replacement
1394
Window Regulator Replacement
1394
Door Lock Replacement
1395
Power Door Lock Motor Replacement
1395
Door Outside Handle Replacement
1395
Door Inside Handle Replacement
1396
Remote Control Replacement
1396
Door Weatherstrip Replacement
1398
R/V Model Rear Doors
1399
Door Adjustment
1399
Striker Replacement
1400
Bumper Wedge Replacement
1401
Window Replacement
1401
Right Door Lower Latch Replacement
1402
Right Door Upper Latch Replacement
1403
Right Door Control Assembly Replacement
1404
Door Outside Handle Replacement
1404
Left Door Lower Latch Replacement
1405
Check Strap Replacement
1406
Right Door Weatherstrip Replacement
1406
Left Door Weatherstrip Replacement
1407
Secondary Weatherstrip Replacement
1408
G-Model Side Front Doors
1408
Door Adjustment
1409
Door Vent/Window Run Channel Assembly Replacement
1413
Vent Glass Replacement
1413
Vent Window Adjustment
1414
Door Window Replacement
1414
Window Stop Assembly Adjustment
1414
Inner Window Weatherstrip Replacement
1414
Outer Window Weatherstrip Replacement
1414
Rear Glass Run Channel Replacement
1415
Window Regulator Replacement
1415
Door Lock Replacement
1416
Power Door Lock Motor Replacement
1417
Door Outside Handle Replacement
1417
Door Lock Cylinder Replacement
1418
Door Lock Control Assembly Replacement
1418
Door Weatherstrip Replacement
1419
Below Eyeline Outside Rear View Mirror Replacement
1419
G-Model Intermediate Doors
1420
Door Adjustment
1421
Bumper Wedge Replacement
1422
Window Replacement
1424
Intermediate Front Door Lock Replacement
1426
Intermediate Front Door Lock Control Replacement
1427
Door Lock Cylinder Replacement
1427
Intermediate Rear Door Lower Latch Replacement
1428
Intermediate Rear Door Upper Latch Replacement
1429
Intermediate Rear Door Control Assembly Replacement
1429
Power Door Lock Motor Replacement
1430
Intermediate Front Door Weatherstrip Replacement
1430
Intermediate Rear Door Weatherstrip Replacement
1431
G-Model Sliding Side Door
1432
Door Replacement
1432
Hinge Assembly Replacement
1433
Lower Roller Assembly Replacement
1434
Upper Front Roller Replacement
1434
Door Adjustment
1434
Door Trim Panel Replacement
1438
Window Replacement
1438
Front Lock Replacement
1439
Rear Lock Replacement
1441
Lock Cylinder Replacement
1441
Sliding Side Door Weatherstrip Replacement
1441
G-Model Rear Doors
1444
Door and Hinge Replacement
1444
Door Adjustment
1444
Striker Replacement
1446
Door Trim Panel Replacement
1446
Bumper Wedge Replacement
1446
Window Replacement
1447
Swing out Window
1448
Left Door Lower Latch Replacement
1449
Right Door Lower Latch Replacement
1450
Right Door Upper Latch Replacement
1450
Right Door Control Assembly Replacement
1450
Door Outside Handle Replacement
1451
Door Lock Cylinder Replacement
1451
Check Strap Replacement
1451
Check Assembly Replacement
1452
Left Door Weatherstrip Replacement
1452
Right Door Weatherstrip Replacement
1453
Power Door Lock Motor Replacement
1453
Special Tools
1454
Subject
1456
Diagnosis of Manual Seat Adjuster
1456
Seat Adjuster Adjustment
1456
R/V Model Front Seats
1457
Front Seat and Seat Adjuster Replacement
1457
Utility Vehicle Passenger Front Bucket Seat Replacement
1458
Front Pivot Bracket Disassembly
1458
Bench Seatback and Catch Replacement
1459
Seat Belt Replacement
1460
High Back Bucket Seat Belt Replacement
1460
R/V Model - Suburban Center Seat
1463
Center Seatback Replacement
1463
Center Seat Bottom Replacement
1463
Center Seat Bottom Support Bracket Replacement
1463
Center Seatback Bumper and Striker Replacement
1464
Center Seat Bottom Striker Replacement
1464
Center Seatback Latch Replacement
1464
Center Seat Bottom Latch Replacement
1467
Center Seat Belt Replacement
1467
R/V Model Rear Seats
1468
Crew Cab Rear Seat Replacement
1468
Crew Cab Rear Seatback and Catch Replacement
1469
Crew Cab Rear Seat Belt Replacement
1469
Utility Vehicle Rear Seat Replacement
1470
Utility Vehicle Rear Seat Cover Rod Replacement
1470
Utility Vehicle Rear Seat Storage Strut Replacement
1471
Utility Vehicle Rear Seat Belt Replacement
1472
Utility Vehicle and Suburban Seatback and Hinge Replacement
1472
Utility Vehicle and Suburban Latch and Support Assembly Replacement
1473
Suburban Rear Seat Replacement
1474
Suburban Rear Seat Belt Replacement
1474
Pickup and Crew Cab Models
1475
Suburban Front Seat
1475
Suburban Second Seat
1477
Suburban Third Seat
1477
G-Model Front Seat
1479
Front Seat Replacement
1479
Front Seat Disassembly
1479
Front Seat Belt Replacement
1480
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