1978 Chevrolet Trucks Service & Repair Manual

SECTION NAME 1979 LIGHT DUTY TRUCK (SERIES 10-35) CHASSIS SERVICE MANUAL CAUTION This vehicle contains some parts dimensioned in the metric system as well as in the customary system. Some fasteners are metric and are very dose in dimension to familiar customary fasteners in the inch system. It is important to note that, during any vehicle maintenance procedures, replacement fasteners must have the same measurements and strength as those removed, whether metric or customary. (Numbers on the heads of metric bolts and on surfaces of metric nuts indicate their strength. Customary bolts use ra- dial lines for this purpose, while most customary nuts do not have strength markings.) Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or possibly per- sonal injury. Therefore, fasteners removed from the vehicle should be saved for re-use in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. For information and assistance, see your au- thorized dealer. OA I GENERAL INFORMATION OB MAINTENANCE AND LUBRICATION 1A | HEATER, VENTILATION 1B AIR CONDITIONING 2A frame 2B BUMPERS 2C CHASSIS SHEET METAL 2D body 3A FRONT ALIGNMENT 3B STEERING 3C FRONT SUSPENSION 3D REAR SUSPENSION 3E WHEELS AND TIRES 4A PROPELLER SHAFT & UNIVERSAL JOINTS 4B REAR AXLE 4C FRONT WHEEL DRIVE BRAKES 6A ENGINE MECHANICAL 6B ENGINE COOLING 6C FUEL SYSTEM 6D ENGINE ELECTRICAL 6E 7A ENGINE EMISSION CONTROLS 6F ENGINE EXHAUST AUTOMATIC TRANSMISSION 7B MANUAL TRANSMISSION 7C CLUTCH 7D TRANSFER CASE 8 BODY AND CHASSIS ELECTRICAL ACCESSORIES © 1979 General Motors Corporation

T GENERAL INFORMATION OA-1 SECTION OA GENERAL INFORMATION CONTENTS OF THIS SECTION General............................................................................................. OA-1 Vehicle Identification Number........................................................ OA-1 Engine Code Number...................................................................... OA-1 Unit and Serial Number Locations................................................. OA-1 Service Parts Identification Sticker................................................. OA-3 Vehicle Loading................................................... ........................... OA-3 GENERAL 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 P10- 20-30 models, the plate is attached to the front of the dash and toe panel to the left of steering column (fig. 0A-2). The VIN also appears on the Vehicle Certificates of Title and Registration. 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 engineers 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. 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. o (CCL249F1532781 ° | ENGINE CODE| ------------------------- TYPICAL VIN ENGINE INDENTIFICATION MFD. BY GENERAL MOTORS CORPORATION LB/kg PSI /kPa GAWR FRT 08/78 4000/1814 GVWR 10.5 X 16.50 14000/6350 16.5 X 9.75 COLO DUAL 36/248 GAWR RR 10000/4536 10.5 X 16.50 16 6 X 9 75 42/290 THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT [ ON THE DATE MANUFACTURE SHOWN ABOVE 1 1 CZQI691100001 8US-N0T SCHOOL BUS I SEE OWNER S MANUAL FOR A0OITIONAL INFORMATION fZ L MFD BY GENERAL MOTORS CORPORATION O GVWRi^^ U GAWR FRONT^ S ^ ^ GAWR REAR VN INFLATION DATA FOR TIRES FURNISHED WITH VEHICLE SHOWN ON VEHICLE CERTIFICATION LABEL Q WARRANTY VOIDED IF LOADED IN EXCESS OF RATINGS Q . SEE OWNERS MANUAL FOR OTHER 10A0ING AND INFLATION DATA EXAMPLE ONLY Fig. OA-1--Vehicle Identification Number Location (CK and G) Fig. OA-2--Vehicle Rating Plate (P Model) LIGHT TRUCK SERVICE MANUAL

OA-2 GENERAL INFORMATION 1979 LIGHT DUTY TRUCK V.I.N. SYSTEM IDENTIFICATION c \ © Example i ...... j — ;----------------- 1 100007 Serial No. Division Code Cab Engine Series C-Chevrolet Chassis Code G.V.W. Class T=GMC Truck Type Body Type or Model Designator Model Year 1979 Plant Code CHASSIS TYPE 3. ENGINE CODE 2 Wheel Drive Forward Control 4 Wheel Drive Forward Control INCLUDING BLAZER AND SUBURBAN Engine Engine Engine Carb. Code Displacement Type Type D 4.1 L (250) L/6 1-Bbl. L 5.7L (350) V/8 4-Bbl. M 5.7L (350) V/8 2-Bbl. R 6.6L (400) V/8 4-Bbl. S 7.4L (454) V/8 4-Bbl. T 4.8L (292) L/6 1-Bbl. U 5.0L (305) V/8 2-Bbl. z 5.7L (350) V/8 Dsl. 4. SERIES 1-1/2 Ton 2-3/4 Ton 3-1 Ton 4 -1 /2 Ton (HD SUSP) A-Lakewood GA. B-Baltimore MD. F—Flint (Chev) Ml. 7. PLANT CODE J— Janesville Wl. S— St. Louis MO. 7—Lordstown OH. BODY STYLE 2 Chassis Cowl, Forward Control Chassis & Cut-Away Van 3 Chassis Cab 4 Cab & Pick-up Box or Hi-Cube Van 5 Van & Panel 6 Sport Van & Suburban 7 Motor Home Chassis 8 Utility (Blazer, Jimmy) V— Pontiac (GMC) Ml. Z—Fremont CA. 1 —Oshawa Ont. 3—Detroit Ml. 4—Scarborough Ont. 5—London Ont. O-Pontiac, Mi. (Van only) Fig. 0A-3--Vehicle Identification Number LIGHT TRUCK SERVICE MANUAL

GENERAL INFORMATION OA-3 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. 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. Transmissions (Fig. 0A-4) • On 3-Speed Transmissions (except Tremec), the Unit Number is located on Lower Left Side of Case Just Below Cover. • On Tremec Transmissions, 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 203 and 205 model 4-wheel drive transfer case, a build date is on tag attached to front face of transfer case. • On Muncie Model 203 4-wheel drive transfer case, a build date is on front face of transfer case above output shaft. • On Automatic 350 Transmission, Unit Number is Located on Right Rear Vertical Surface of Oil Pan. • On the Automatic 400 Transmission, Serial Number is Located on the Light Blue Plate on the Right Side of the Transmission. Engines (Fig. 0A-5) • 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. 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. SERVICE PARTS IDENTIFICATION STICKER The Service Parts Identification Sticker (fig. OA-6) is provided on all Truck models. On C and K models, the identification sticker be 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 a 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. 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-7. Note that the axle or GVW capabilities are not exceeded. LIGHT TRUCK SERVICE MANUAL

OA-4 GENERAL INFORMATION PRIMARY V.I.N . LOCATION (M15) SECONDARY V.I.N. LOCATION [ NOTE | To be used only when suitable for stamping PRIMARY V .I.N . LOCATION (M38) PRIMARY V.I.N. LOCATION (MCI) SECONDARY V.I.N. LOCATION (M38) [ NOTE j To be used only when primary location is not suitable for stamping OPTIONAL V.I.N. LOCATION (M20) V.I.N. LOCATION (OPTIONAL) (M40) [ ww | a ] ^ VIEW V.I.N. LOCATION (OPTIONAL) (M40) V.I.N. LOCATION (M20) Fig. 0A-4--Transmission V.I.N. Location LIGHT TRUCK SERVICE MANUAL

ENGINE V.I.N (OPTIONAL) ENGINE V.I.N (OPTIONAL) ENGINE CASE PAD ENGINE V.I.N ENGINE V.I.N ENGINE V.I.N (OPTIONAL) DISTRIBUTOR PAD [ view I view ] A V8 ENGINE VIEW L6 ENGINE VIEW ENGINE V.I.N (OPTIONAL) ENGINE V.I.N V8 ENGINE — DIESEL GENERAL INFORMATION OA-5 Fig. OA-5-Engine V.I.N. Location LIGHT TRUCK SERVICE MANUAL

OA-6 GENERAL INFORMATION IMPORTANT: RETAIN THIS PLATE AS A PERMANENT RECORD Fig. OA-6-Service Parts Identification Plate LOADED-MAXIMUM GVWR: 5600 LBS FRONT GAWR: 2940 IBS. REAR GAWR: 2940 LBS. Front Cargo & Rear Cargo & Pass Load 30O lbs. Pass. Load 650 lbs. 2382 lbs. 2058 lbs. TOTAL WEIGHT AT GROUND: 4440 lbs. ’ Curb weight equals the weight of the vehicle without driver, passenger Or cargo, but including fuel and coolant. LOADED-MAXIMUM GVWR: 6200-LBS. FRONT GAWR: 3250 LBS. REAR GAWR: 3582 LBS. TOTAL WEIGHT AT GROUND: 6200 lbs. ’ Curb weight equals the weight of the vehicle without driver, passenger or cargo, but including fuel and coolant. ‘ Front Curb 2261 lbs. Front Cargo & Pass. Load 450 lbs. 2711 lbs- ’ Rear Curb 1549 lbs. Rear Cargo & Pass. Load 1940 lbs- 3489 lbs. Fig. 0A-7--Typical Vehicle Loading Condition LIGHT TRUCK SERVICE MANUAL

MAINTENANCE AND LUBRICATION OB-1 SECTION OB MAINTENANCE AND LUBRICATION M CONTENTS General........................................................................................ .OB-1 Maintenance Schedule................................................................ .OB-2 Lubricant and General Maintenance ............................... ....... .OB-4 Safety Maintenance................................................................... .OB-13 Emission Control....................................................................... .OB-14 Specifications......................... ................. ............................. ..... .OB-16 Recommended Fluids and Lubricants..................................... .OB-16 Fluid Capacities........ .................................................... ........... .OB-17 GENERAL The maintenance schedule for a gasoline engine follows two basic formats, Light Duty Emissions and Heavy Duty Emissions. The major difference between the two schedules is the intervals for service and Section "C", Emission Control Maintenance (fig. OB-1). A separate vehicle maintenance schedule is provided for those vehicles with a V-8 diesel engine (fig. OB-2). The maintenance schedule is provided in the glove box with the vehicle. LIGHT DUTY TRUCK SERVICE MANUAL

OB-2 MAINTENANCE AND LUBRICATION VEHICLE MAINTENANCE SCHEDULE GASOLINE ENGINE When To Perform Services (Months or Miles, Whichever Occurs First) Item No. Services Light Duty Emissions Heavy Duty Emissions Section A — Lubrication and General Maintenance Every 12 Months or 7,500 Miles (12 000 km) Every 4 months or 6,000 Miles (9 600 km) A-1 • Fluid Levels Check A-2 Clutch Pedal Free Travel Check A-3 * Engine Oil Change See Explanation A-4 • Chassis Lubrication © A-5 Four Wheel Drive See Explanation A-6 * Oil Filter Change A-7 Tire Rotation A-8 Rear Axle & Manual Trans. Lube Every 30,000 Miles (48 000 km) A-9 Wheel Bearing Repack Every 12 Months or 15,000 Miles (24 000 km) Every 12 Months or 12,000 Miles (19 200 km) A-10 ACooling System Check — See Explanation Every 30,000 Miles (48 000 km) Every 36 000 Miles (57 000 km) A-11 Manual Steering Gear Seals Check A-12 Clutch Cross Shaft Lubrication Every 100,000 Miles (160 000 km) Every 24,000 Miles (38 400 km) A-13 Auto. Trans. Fluid & Filter Change SECTION B — Safety Maintenance Every 12 Months or 7,500 Miles (12 000 km) Every 4 Months or 6,000 Miles (9 600 km) B-1 Owner Safety Checks B-2 Tire, Wheel and Disc Brake Check B-3 AExhaust System Check B-4 Suspension and Steering Check B-5 Brake and Power Steering Check Every 12 Months or 15,000 Miles (24 000 km) Every 12,000 Miles (19 000 km) B-6 * Drive Belt Check Every 12 Months or 12,000 Miles (19 200 km) B-7 Drum Brake and Parking Brake Check B-8 Throttle Linkage Check B-9 Bumper Check SECTION C — Emission Control Maintenance At First 6 Months or 7,500 Miles (12 000 km) - Then at 18 Month/ 22,500 Mile (36 000 km) Every 12 Months or 12,000 Miles (19 200 km) C-1 Thermo. Controlled Air Cleaner Check C-2 Carburetor Mounting Torque Every 24 months or 24,000 Miles (38 400 km) C-3 Carburetor Choke Check C-4 EFE System Check C-5 Vacuum Advance System & Hoses Check At 1st 4 Months or 6,000 Miles (9 600 km) Then at 12 Month/ 12,000 Miles (19 200 km) Intervals C-6 Engine Idle Speed Adjustment Every 22,500 Miles (36 000 km) C-7 Idle Stop Solenoid Check Every 12 Months or 15,000 Miles (24 000 km) Every 12 Months or 12,000 Miles (19 200 km) C-8 Fuel Filter Replacement C-9 PCV System Check — PCV Valve & Filter — See Explanation Every 22,500 Miles (36 000 km) Every 12,000 Miles (19 200 km) C-10 Spark Plug Wires Check C-11 Spark Plug Replacement C-12 Engine Timing Adjust. & Distrib. Check Not Applicable C-13 Carburetor Vacuum Break Check Every 30,000 Miles (48 000 km) Every 12,000 Miles (19 200 km) C-14 Air Cleaner Element Replacement Every 24 Months or 30,000 Miles (48 000 km) Every 24 Months or 24,000 Miles (38 400 km) C-15 ECS System Check & Filter Replacement C-16 Fuel Cap, Tank and Lines Check Not Applicable C-17 Engine Idle Mixture Adjust (4.8 L. L-6 only) Every 12 months or 12,000 Miles (19 200 km) C-18 Manifold Heat Valve Check C-19 Throttle Return Control Check • Also a Safety Service * Also an Emission Control Service ▲Also an Emission Control Service (Light Duty Emissions Only) © Refer to text for lube interval of front suspension and steering linkage. Fig. OB-1 -Vehicle Maintenance Schedule - Gasoline

MAINTENANCE AND LUBRICATION OB-3 VEHICLE MAINTENANCE SCHEDULE DIESEL ENGINE When To Perform Services (Months or Miles, Whichever Occurs First) Item No. Services (For Details, See Numbered Paragraphs) SECTION A — Lubrication and General Maintenance Every 3,000 Miles (4 800 km) A-3 * Engine Oil Change A-6 * Oil Filter Change Every 6,000 Miles (9 600 km) A-4 • Chassis Lubrication A-2 Clutch Pedal Free Travel Check A-1 • Fluid Levels Check See Explanation A-8 Rear Axle Lubricant Check A-18 Tire Rotation Every 12 Months or 12,000 Miles (19 200 km) A-10 * Cooling System Check Every 15,000 Miles (24 000 km) A-9 Wheel Bearings Repack Every 30,000 Miles (48 000 km) A-11 Manual Steering Gear Check Every 100,000 Miles (160 000 km) A-13 Auto Trans. Fluid and Filter Change SECTION B — Safety Maintenance Every 12 Months or 6,000 Miles (9 600 km) B-1 Owner Safety Checks B-2 Tire, Wheels and Disc Brake Check B-3 Exhaust System Check B-4 Suspension and Steering Check B-5 Brakes and Power Steering Check B-6 * Drive Belt Check Every 12 Months or 15,000 Miles (24 000 km) B-7 Drum Brakes and Parking Brake Check B-8 Throttle Linkage Check B-9 Bumper Check SECTION C — Emissions Control Maintenance Every 15,000 Miles (24 000 km) C-8 Fuel Filter Replacement Every 6,000 Miles (9 600 km) C-20 Crankcase Ventilation System At First 3,000 Miles (4 800 km) Then at 30,000 Mile (48 000 km) Intervals C-6 Engine Idle Speeds Adjust Every 30,000 Miles (48 000 km) C-14 Air Cleaner Element Replacement • Also a Safety Service * Also an Emission Control Service Fig. 0B-2--Vehicle Maintenance Schedule - Diesel LIGHT DUTY TRUCK SERVICE MANUAL

1978 Chevrolet Trucks Service & Repair Manual

You're Reading a Preview

Recently Viewed