1983 Chevrolet Light Duty Truck 10 To 30 Service & Repair Manual

FOR CONTACT ORDERING SHOP MANUALS (CURRENT AND PAST MODELS) HELM, INC. P.O. BOX 07130 DETROIT, MICH. 48203 INQUIRIES ON YOUR VEHICLE, SUCH AS: • VEHICLE PERFORMANCE QUESTIONS • TECHNICAL ASSISTANCE/INFORMATION • COMPONENT IDENTIFICATION • DIAGNOSIS 1. LOCAL CHEVROLET DEALER 2. LOCAL CHEVROLET ZONE OFFICE (SEE LISTING IN YOUR OWNERS MANUAL) • SUGGESTED IMPROVEMENTS TO SHOP MANUAL • ERRORS/OMISSIONS IN SHOP MANUAL CHEVROLET MOTOR DIVISION GENERAL MOTORS CORPORATION SERVICE PUBLICATIONS .30007 VAN DYKE WARREN, MICH. 48090

CAUTION To reduce the chance of personal injury and/or property damage, the following instructions must be carefully observed: Proper service and repair are important to the safety of the service technician and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part. Do not use a replacement part of lesser quality. The service procedures recommended and described in this service manual are effective methods of performing service and repair. Some of these procedures require the use of tools specially designed for the purpose. Accordingly, anyone who intends to use a replacement part, service procedure or tool, which is not recommended by the vehicle manufacturer, must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part, service procedure or tool selected. It is important to note that this manual contains various "Cau- tions" and "Notices" that must be carefully observed in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that these 'Cautions' and 'Notices' are not exhaustive, because it is impos- sible to warn of all the possible hazardous consequences that might result from failure to follow these instructions.

1983 LIGHT DUTY TRUCK (Series 10-35) SHOP MANUAL FORWARD This manual includes procedures for diagnosis, maintenance and adjustments, minor service operations, removal and installa- tion of components and disassembly and assembly of major components of Chevrolet Light Duty Trucks. The Section Index on the contents page enables the user to quickly locate any desired section. At the beginning of each section containing more than one major subject is a Table of Contents, which gives the page number on which each major subject begins. An index is placed at the beginning of each major subject within the section. Summaries of Special Tools, when required, and specifications are found at end of major sections. When reference is made in this manual to a brand name, number, or specific tool an equivalent product may be used in place of the recommended item. This manual should be kept in a handy place for ready reference. If properly used, it will enable the technician to better serve the owners of Chevrolet built vehicles. All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice. CAUTION This vehicle contains many parts dimensioned in the metric system. Most fasteners are metric and many are very close in dimen- sion to familiar customary measurements in the inch system. However, it is important to note that, during any vehicle maintenance procedures, replacement fasteners must have the same measurements as those removed, whether metric or customary. Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly personal injury. Therefore, fasteners removed from the vehicle should be saved for re-use whenever pos - sible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. Additional information concerning this subject will be found following the specifications section at the end of this manual. CHEVROLET MOTOR DIVISION General Motors Corporation DETROIT, MICHIGAN TABLE OF CONTENTS SECTION GENERAL INFORMATION General Information 0A Maintenance and Lubrication OB HEATING AND AIR CONDITIONING Heating and Ventilation 1A Air Conditioning 1B A-6 Compressor 1D FRAME AND BUMPERS Frame and Body Mounts 2A Bumpers 2B Sheet Metal 2C Body 2D STEERING, SUSPENSION, WHEELS AND TIRES Front Alignment 3A Steering Linkage 3B1 Manual Steering 3B2 Power Steering 3B3 Steering Column 3B4 Front Suspension 3C Rear Suspension 3D Wheel and Tires 3E PROPELLER SHAFT AND AXLES 4 Propeller Shaft Rear Axles Front Axle BRAKES 5 ENGINE Engine Diagnosis 6 In-Line 6 (4.1 L/4.8U— > „ca-Small Rlnrk 01^71 ---------- - Mark IV (7.4L) / Diesel (6.2L) Engine Coding 6B Engine Fuel 6C E4ME Carburetor 6C1 E2SE Carburetor 6C3 1ME Carburetor 6C7 2SE Carburetor ___ . , 6C9 ( — 'fiMME CarBuretor _______— 6CTTT : Diesel Fuel Injection Engine Electrical 6D Emission Controls — Carburetor 6E1 Emission Controls — Diesel 6E3 Engine Exhaust 6F Vacuum Pump 6H TRANSMISSION 7 Automatic Service 350C-Unit Repair 400-Unit Repair (^700 R4-U n it^Repaip' Manual-Semce 3 Speed 76mm-Unit Repair 4 Speed 89mm-Unit Repair 4 Speed 117mm-Unit Repair Clutch Transfer Case-205 Transfer Case-208 ELECTRICAL — BODY AND CHASSIS Chassis Electrical 8B Instrument Panel and Gages 8C ACCESSORIES 9 ELECTRICAL WIRING DIAGRAMS REAR OF BOOK © 1982 General Motors Corporation

GENERAL INFORMATION OA-1 SECTION OA GENERAL INFORMATION CONTENTS General Information ................................................... OA-1 Vehicle Identification Numbers .............................. OA-1 Service Parts Identification ....................................... OA-1 Vehicle Loading ....... , ................... ............. . OA-1 Engine Code Number ..................................................OA-2 GENERAL INFORMATION Information to identify the vehicle and vehicle components appears in this section. Detailed specifications on major units are given at the end of each respective section in this manual. VEHICLE IDENTIFICATION NUMBER (VIN) This is the legal identification of the vehicle. It appears on a plate which is attached to the left top of the instrument panel on CK and G truck and can be easily seen through the windshield from outside the vehicle (Fig. OA-1). On PI0-20-30 models, the plate is attached to the front of the dash and toe panel to the left of steering column (Fig. OA-2). The VIN (Fig. 0A-3) also appears on the Vehicle Certificates of Title and Registrations. SERVICE PARTS IDENTIFICATION STICKER The Service Parts Identification Sticker (Fig. OA-4) is provided on all Truck models. On C and K models, the identification sticker is located on the inside of the glove box door or on G model, the sticker will be located on an inner hood panel surface. On P models, the sticker is located on an inner body panel. The plate lists the vehicle identification number, wheelbase, and all Production options or Special Equipment on the vehicle when it was shipped from the factory including paint information. ALWAYS REFER TO THIS INFORMATION WHEN ORDERING PARTS. Unit and Serial Number Location ........................... OA-4 Capacities ................................................. .................... OA-6 Lubrication Points ...................................................... OA-7 Metric Information ...................................................... 0A-9 Common Abbrevations .......................................... OA-16 VEHICLE LOADING Vehicle loading must be controlled so weights do not exceed the numbers shown on the Vehicle Identification Number and/or Rating Plate for the vehicle. A typical example of a truck in a loaded condition is shown in Figure 0A-5. Note that the axle or GVW capa - bilities are not exceeded. ENGINE CODE NUMBER The engine code number indicates manufacturing plant, month and day of manufacture, and transmission type. A typical engine number would be F1210TTBB, which would breakdown thus: F - Manufacturing Plant (F-Flint, T-Tonawanda) 12 - Month of Manufacture (December) 10 - Day of Manufacture (tenth) T - Truck TBB - Transmission and engine type UNIT AND SERIAL NUMBER LOCATIONS For the convenience of service technicians and engines when writing up certain business papers such as Warranty Reports, Product Information Reports, or reporting product failures in any way, the location of the various unit numbers have been indicated. These unit numbers and their prefix or suffix are necessary on these papers for various reasons - such as accounting, follow-up on production, etc. O O MFD. BY GENERAL MOTORS CORPORATION GftWR F R O N T G » W H REAR INFLATION DATA FOR TIRES FURNISHED WITH VEHICLE SHOWN ON VEHICLE CERTIFICATION LABEL WARRANTY VOIDED IF LOADED IN EXCESS OF RATINGS SEE OWNERS MANUAL FOR OTHER LOADING AND INFLATION DATA EXAMPLE ONLY Fig. 0A-2 —V.I.N. Rating Plate (P Model)

OA-2 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER GCEC14D9DF123456 J NATION OF ORIGIN 1 USA 2 CANADA MANUFACTURER 3 GENERAL MOTORS MAKE AND TYPE BUS (VAN) INCOMPLETE VEHICLE TRUCK MULTIPURPOSE PASS VEHICLE GVWR/BRAKE SYSTEM GVWR CODE (IN POUNDS) BRAKE SYSTEM B 3001 4000 *C 4001 - 5000 D 5001 - 6000 E 6001 7000 HYDRAULIC ONLY F 7001 8000 ’ ' G 8001 9000 H 9001 10000 J 10001 11.000 * Inc udes El Cd * ' Inc udes G Va Bus TRUCK SERIES 1/2 TON 3/4 TON 1 TON LINE AND CHASSIS TYPE LINE MODELS CONVENTIONAL CAB CONVENTIONAL CAB FORWARD CONTROL CHASSIS VAN. SPORT VAN & CUTAWAY VAN CHASSIS TYPE 4X2 4X4 4X2 4X2 PLANT SEQUENTIAL NUMBER ASSEMBLY PLANT CODE ASSEMBLY PLANT CODE ASSEMBLY PLANT A GMAD LAKEWOOD S GMAD ST LOUIS B GMAD BALTIMORE V GMT & C PONTIAC D GMAD DORAVILLE * z GMAD FREMONT * F CHEVROLET FLINT 1 GM OF CANADA OSHAWA J GMAD JANESVILLE 3 CHEVROLET DE TROIT K GMAD LEEDS ' 4 GM OF CANADA SCARBOROUGH R GMAD ARLINGTON’ • EL CAMINO PLANTS 7 GMAD LORDSTOWN CHECK DIGIT TRUCK BODY TYPE 0 SEDAN PICKUP 1 HI CUBE/CUTAWAY VAN 2 FORWARD CONTROL 3 FOUR DOOR CAB 4 TWO DOOR CAB 5 VAN 6 SUBURBAN 7 MOTOR HOME 8 BLAZER 9 STAKE/PLATFORM ENGINE TYPE AND MAKE TYPE MAKE (GM) CODE DISPLACEMENT LITRES PRODUCER MODELS RPO C 6.2L V8 DIESEL CHEVROLET CK L*6 D 4 1L L 6 2BBL CHEVROLET G LE3 F 5 OL V8.4BBL CHEVROLET C K G LF3 H 5 OL V84BBL CHEVROLET C K G LE9 J 6.2L V 8 DIESEL CHEVROLET C-K LL4 L 5 7L V8 4BBL CHEVROLET C K G LS9 M 5 7L V84BBL CHEVROLET CKGP LT9 P 5 7L V8 2BBL CHEVROLET C K LF5 W 7 4L V8 4BBL CHEVROLET C K P LE8 T 4 8L L6 1BBL GM DE MEXICO C K P L25 104206 Fig. 0A-3 -- Vehicle Identification Number Codes, CKGP, Truck Dana Built • On Front Axles, code is stamped on Top Rear of Left Axle Tube. • On Rear Axles, code is stamped on Rear Surface of Right Axle Tube. Fig. OA-4 —Service Parts Identification Plate The prefixes on certain units identify the plant in which the unit was manufactured and thereby permits proper follow-up of the plant involved to get corrections made when necessary. Always include the prefix in the number. Axles Chevrolet Built • On 10 Series, the Code is stamped on Top of Right Rear Axle Tube. • On 20-30 Series, the Code is stamped on Top of the Right Rear Axle Tube. LOADED—MAXIMUM GVWR: 4900-LBS. FRONT GAWR: 2944 LBS. REAR GAWR: 2944 LBS. * Front Curb Front Cargo & Pass. Load 2219 lbs. 284 lbs 2503 lbs. *Rear Curb Rear Cargo & Pass. Load 1003 lbs. 1394 lbs. 2397 lbs. TOTAL WEIGHT AT GROUND: 4900 lbs. Curb weight equals the weight of the vehicle without driver, passenger or cargo, but including fuel and coolant. Fig. 0A-5 - Typical Vehicle Loading Condition

GENERAL INFORMATION OA-3 Transmissions (Fig. OA-6) • On 3-Speed Transmissions (except Tremec), the Unit Number is located on Lower Left Side of Case Just Below Cover. • On Tremec Transmission, Unit Number is located on Upper Left Attachment Case (Top Side). • On Muncie 4-Speeds, Unit Number is located on Rear Face of Case below Retainer. • On New Process 205 model 4-wheel drive transfer case, a build date is on tag attached to front face of transfer case. • On Automatic 350 Transmission, Unit Number is located on Right Rear Vertical Surface of Oil Pan. • On the Automatic 400 Transmission, Serial Number is location on the Light Blue Plate on the Right Side of the Transmission. Engines (Fig. OA-7) • 6-Cylinder Engine Unit Number Located on Pad at Right Hand Side of Cylinder Block at Rear of Distributor. • 8-Cylinder Gasoline Engine Code is (305, 350, 400 CID) Located on Pad immediately forward of right hand cylinder head. • 8-Cylinder Gasoline Engine (454 CID) Code is located on a pad of the front top center of the engine block immediately forward of the inlet manifold. • 8-Cylinder Diesel Engine Code is on a label located on rear face of the left valve cover. : T' Generators Generator Unit Serial Number is located on the Drive End Frame Below the Part Number. Batteries Battery Code Number is Located on Cell Cover Top of Battery. Starters Starter Serial Number and Production Date are Stamped on Outer Case, Toward Rear.

OA-4 GENERAL INFORMATION TRANSMISSION IDENTIFICATION FOR: THM 3S0C - TOLEDO PLANT OHIO Y 3 E 03 D Y = SOURCE(Y = TOLEDO B = PARMA) 3 = MODEL YEAR E = MONTH (A = JAN B = FEB) 03 = DAY D = SHIFT (D = DAY SHIFT N = NIGHT SHIFT) H 7A-8-6/81 TRANSMISSION NAMEPLATE YPSILANTI PLANT. MICHIGAN THM 400 83 = MODEL YEAR PZ * MODEL 86992 = SERIAL NO. H 7A 12-6/81 TRANSMISSION NAMEPLATE BUICK-FLINT PLANT, MICHIGAN THM 3S0C 9LD = MOOEL CODE (1982 LD) 001 = PRODUCTION BUILD DATE D = SHIFT (D = DAY SHIFT) 83 = YEAR H 7A 9-6/81 TRANSMISSION IDENTIFICATION THM 700R4 -TOLEDO PLANT, OHIO 9 TA Y 83 M 12 O 9 * MODEL YEAR TA = MODEL Y =■ TOLEOO 83 * YEAR M * MONTH 12 = DAY D = SHIFT (O = DAY N = NIGHT) H 7A 7-6/81 Fig. OA-6 —Transmission V.I.N. Location

GENERAL INFORMATION OA-5 Fig. OA-7 -- Engine V.I.N. Location

OA-6 GENERAL INFORMATION APPROXIMATE CAPACITIES - PICKUP MODELS ITEMS Metric Measure U.S. Measure Cooling System (approx.) All L-6 Without A/C 14 Liters 15 Quarts With A/C 14.7 Liters 15.5 Quarts Code F,H,L & M - V-8 Without A/C 16.6 Liters 17.5 Quarts With A/C 17 Liters 18 Quarts Code W - V-8 Without A/C 22 Liters 23 Quarts With A/C 23 Liters 24.5 Quarts Diesel Without A/C 22 Liters 23 Quarts With A/C 23 Liters 24.5 Quarts Crankcase ♦ Gasoline Engines Codes: D,F,H,L,M Without Filter 3.8 Liters 4 Quarts With Filter 4.8 Liters 5 Quarts Code:T Without Filter 4.8 Liters 5 Quarts With Filter 5.7 Liters 6 Quarts Code: W + Without Filter 5.7 Liters 6 Quarts With Filter 6.5 Liters 7 Quarts Diesel Engines Code: C,J t 6.5 Liters 7 Quarts Fuel Tank (approx.) Short Bed — Single Tank, Gas, Diesel 61 Liters 16 Gallons *Dual Tanks, Gas. Diesel 61 Liters 16 Gallons Long Bed - Single Tank, Gas 76 Liters 20 Gallons @*Dual Tanks, Gas 61 Liters 16 Gallons Single Tank, Diesel 76 Liters 20 Gallons *Dual Tanks, Diesel 76 Liters 20 Gallons Front Axle 2.4 Liters 2.5 Quarts Transfer Case 10-20 Series 4.8 Liters 5 Quarts 30 Series 2.4 Liters 2.5 Quarts APPROXIMATE CAPACITIES - BLAZER, SUBURBAN Metric U.S. ITEMS Measure Measure Cooling System (approx.) Code: H, L,M Without A/C 16.5 Liters 17.5 Quarts With A/C 17 Liters 18 Quarts Code: W Without A/C 22 Liters 23 Quarts With A/C 23 Liters 24.5 Quarts Diesel Engines Code: C, J Without A/C 23 Liters 24.5 Quarts With A/C 23 Liters 24.5 Quarts Crankcase ♦ Gasoline Engines Code: H, L and M Without Filter 3.8 Liters 4 Quarts With Filter 4.8 Liters 5 Quarts Code: W + Without Filter 5.7 Liters 6 Quarts With Filter 6.5 Liters 7 Quarts Diesel Engines t Code: C, J With Filter 6.5 Liters 7 Quarts Front Axle 2.4 Liters 2.5 Quarts Transfer Case 4.8 Liters 5.0 Quarts Fuel Tank Standard, All — Gas 95 Liters 25 Gallons — Diesel 102 Liters 27 Gallons NK7 Option, All — Gas 117 Liters 31 Gallons — Diesel 121 Liters 32 Gallons NE2 Option, Suburban Only — Gas 151 Liters 40 Gallons — Diesel 155 Liters 41 Gallons ♦ After refill, fluid level must be checked. + K30 Models — 5 U.S. Quarts (4.8 Liters) t Qil Filter should be changed at EVERY oil change. Listed quantity if for each tank. @ Above 8600 GVWR—Both tanks 20 gallons (76 Liters) ♦ After refill, fluid level must be checked. + K30 Models — 5 U.S. Quarts (4.8 Liters), t Oil Filter should be changed at EVERY oil change APPROXIMATE CAPACITIES - ALL MODELS Metric U.S. ITEMS Measure Measure Differential 8Vi" Ring Gear 1.9L 4!4 pts. 8-7/8" Ring Gear 3% pts. 10’/s" Ring Gear (Chev.) 2.8L 6 Vi pts. 101 /a" Ring Gear (Dana) 3L 7.2 pts. 9%" Ring Gear (Dana) 2.6L 6.0 pts. 12V*" Ring Gear (Dana) 11.7L 26.8 pts. Transmission Automatic 350 - Total 9.5L 10 qts. — Refill 2.8L 3 qts. 400 — Total 10.4L 11 qts. - Refill 3.8L 3.5 qts. 700R4 — T otal 10.9L 11.5 qts. - Refill 4.7L 5 qts. Manual 4 Speed 117mm 3.8L 4 qts. 3 Speed 76mm 1.4L 1.5 qts. 3 Speed 77mm 1.4L 1.5 qts. 104254 Fig. 0A-8 - Capacities Chart

1983 Chevrolet Light Duty Truck 10 To 30 Service & Repair Manual

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