1986 Chevrolet Light Duty Trucks Service & Repair Manual

1987 LIGHT DUTY TRUCK SERVICE MANUAL R-V, P-TRUCK AND G-VAN MODELS The Table of Contents on this page in- dicates the sections covered in this manual. At the beginning of each individual section is a Table of Contents which gives the page number on which each major subject begins. 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. All information, illustrations, and specifications contained in this Manual are based on the latest product information available at the time of publication ap- proval. The right is reserved to make changes at any time without notice. Printed in U.S.A. © 1986 General Motors Corporation July, 1986 iii SEC NAME 0 GENERAL INFORMATION 0A General Information OB Maintenance and Lubrication 1 HEATING AND AIR CONDITIONING 1A Heating 1B Air Conditioning 2 FRAME AND CAB 2A Frame and Bumpers 2B Sheet Metal 3 STEERING, SUSPENSION, WHEELS AND TIRES 3A Front End Alignment 3B1 Steering Linkage 3B2 Manual Steering 3B3 Power Steering 3B4 Steering Column 3C Front Suspension and Axle 3D Rear Suspension 3E Wheels and Tires 4 PROPELLER SHAFT AND AXLES 4A Propeller Shaft 4B Rear Axle 4C Front Driving Axle 5 BRAKES 6 ENGINE 6A Engine 6A3 4.3 Liter V6 6A4 Small Block 6A5 7.4 Liter V8 6A6 6.2 Liter Diesel 6A7 4.8 Liter L6 6B1 Engine Cooling 6B2 Radiator 6C Fuel System 6C1 Carburetors 6C2 Diesel Fuel Injection 6D Engine Electrical 6E Drivability And Emissions 6E8 Drivability And Emissions - Carburetor 6E9 Drivability And Emissions - Diesel 6F Exhaust 6H Vacuum Pump 7 TRANSMISSION AND CLUTCH 7A Automatic Transmission 7B Manual Transmission 7C Clutch 7D1 205 Transfer Case 7D2 208 Transfer Case 8 ELECTRICAL 8A Cab Electrical 8B Chassis Electrical 8C Intrument Panel 9 ACCESSORIES 10 BODY 10A1 Doors 10A2 Seats 10A3 Glass 10A4 Interior Trim 10A5 Endgate INDEX

He knows quality parts make a difference even on simplejobs. Mr. Goodwrench wants you to have the right parts for your truck—whether you see him for service or whether you do the work yourself. That’s why Mr. Goodwrench wants to have a good stock of genuine GM Parts available. Everything from exclusive GM Goodwrench replacement engines and transmissions to GM Goodwrench Motor Oil that meets or exceeds all specifications for General Motors cars or light trucks. And Mr. Goodwrench has a complete line of GM chemicals for fine care of your GM vehicle. Plus accessories to add convenience— or just a little extra style. So keep that great GM feeling with genuine GM parts at participating independent Mr. Goodwrench dealers selling Chevrolets, Pontiacs, Oldsmobiles, Buicks, Cadillacs, GMC and Chevy Trucks. OiNERAl MOTORS CORPORATION )VA(joodxtrijMC^ B-05884 iv

FOREWORD This service manual contains diagnosis, “On-Vehicle” maintenance, and light repair for Light Duty Truck Models (“ R-V, P-Truck, and G-Van”). Fuel and emissions related compo - nents for throttle body injection vehicles are covered in a separate manual. Procedures involving disassembly and assembly of major components for these vehicles are published in a separate “Truck Unit Repair Manual.” Wiring diagrams for these models are also published in a separate “Truck Wiring Diagram” booklet. This manual should be kept in a handy place for ready reference. If properly used, it will meet the needs of technicians and vehicle owners. ^ L *-/ - vp 'sEtyg. Ho Ipl CAUTION: These vehicles contain some parts dimensioned in the metric system as well as in the customary system. Some fasteners are metric and are very close 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 radial lines for this purpose, while most customary nuts do not have strength markings.) Mis- matched 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 in the same location 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 authorized dealer. CHEVROLET MOTOR DIVISION General Motors Corporation Detroit, Michigan

CAUTION To reduce the chance of personal injury and/or property damage, the fol- lowing instructions must be carefully observed. Proper service and repair are important to the safety of the service techni- cian 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 Cautions and No- tices 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 impossible to warn of all the possible hazardous consequences that might result from failure to follow these instructions.

OA-1 SECTION 0 GENERAL INFORMATION CONTENTS SUBJECT PAGE General Inform ation ........... .. .................................................................... .. ........................... .. ........... .. .................................. „0A- 1 Maintenance and Lubrication ....................................... .. .................... ............................................... .. ........... .. .................... ,08- 1 SECTION 0A GENERAL INFORMATION CONTENTS SUBJECT PAGE Service Parts Identification Label .............. .................... ...................................................................................... .. .......... 0A- 1 Vehicle Identification Plate .................................................. .. ............................................. ............................... .. .QA- 1 Certification Label .................................................................. .. ........... .. ...................... .. ...................... .. ............................. .0A- 2 Model Reference ....................................... ................................................................................. .. ........................................... 0A- 2 Engine identification Number ........................................... .. ...................................... .. ...................... .... ............................. 0A- 2 Vehicle Lifting Procedures ........................................... .. ............................................................................. .. ...................... 0A- 3 Emergency Starting Due to a Discharged Battery ................................................................................................ .. ,0A- 8 Graphic Symbols ..................................................................................................................................................................... 0A- 8 Metric Fasteners ................................................................ .. ........................................................................................................ 0A-1Q Fastener Strength Identification ............................................................................................. .. ......................................... 0A-10 Prevailing Torque Fasteners ........................................ ............. .......................................... .. ............................................. 0A-11 Six Lobed Socket Head Fasteners .............. ............................................... ............. .. ............. .. .................... .. .................. OA-12 RPO Listing (Regular Production Option) .................................................................... .......................................... .. .0A-15 SERVICE PARTS IDENTIFICATION LABEL The Truck Service Parts Identification Labei is provided on all models (figure 1). It is located on the inside of the gloye box door (or on an inner body panel for Forward Control models). The Label lists the ViN (Vehicle Identification Number), wheelbase, paint information and all Production options or Special Equipment on the vehicle when it was shipped from the factory. ALWAYS REFER TO THIS INFORMATION WHEN ORDERING PARTS. Printed in U.S.A 15516776 SERVICE PARTS IDENTIFICATION THE OPTIONAL EQUIPMENT LISTED 3ELOW HAS BEEN VEHICLE FOR PROPER IDENTIFICATION OF REPLACEMENT PARTS. $URE TO SPECIFY THE APPLICABLE OPTION NUMBERS. NOTICE: THIS INFORMATION IS SUPPLIED AS AN AID IN '.DENTIFYING PARTS FOR SERVICE. SERVICE PARTS REQUIREMENTS FOR THIS VEHICLE MAY VARY FROM THOSE LISTED. BEFORE ORDERING ANY OF THE ABOVE PARTS, ALWAYS HAVE YOUR GENERAL MOTORS TRUCK DEALER CHECK THIS VEHICLE'S BROADCAST SUPPLEMENT FOR POSSIBLE PART CHANGES. IMPORTANT: RETAIN THIS PLATE AS A PERMANE * 8-05559 VEHICLE IDENTIFICATION NUMBER The VIN is the legal identifier of the vehicle, On all models except Forward Controi, it is located on a plate which is attached to the left top of the instrument panel and can be seen through the windshield from the outside of the vehicle (figure 2). On Forward Control models, the plate is on the dash and toe panel. To find out the Figure 1—Service Parts Identification Label manufacturer, model and chasis type, engine type, GVW range, model year, plant code, and sequential number, refer to figure 3.

OA-2 GENERAL INFORMATION 1GCDC14N4GF100001 o 1. Typical VIN F-00687 Figure 2—VIN Location CERTIFICATION LABEL The Certification Label shows the GVWR, and the front and rear GAWRs, and the Payload Rating for your vehicle (figure 4). Gross Vehicle Weight (GVW) is the weight of the orginally equipped vehicle and all items added to it after it has left the factory. This would include bodies, winches, booms, etc.; the driver and all occupants; and the load the vehicle is carrying. The GVW must not exceed the GVWR. Also, the front and rear gross axle weights must not exceed the front and rear GAWRs. The Payload Rating shown on the label is the maximum allowable cargo load (including the weight of the driver and all occupants) that the vehicle can carry based on all factory installed equipment on the vehicle. The Payload Rating is reduced if any accessories or other equipment is added to the vehicle after final date of manufacture. The weight of these items should be determined and deducted from the Payload Rating. The vehicle may also have a GCWR (Gross Combination Weight Rating). The GCW (Gross Combination Weight) is the total weight of the loaded tow vehicle (including passengers) and a loaded trailer. The tires on the vehicle must be the proper size and properly inflated for the load which you are carrying. The vehicle Certification Label shows the originally equipped tire size and recommended inflation pressures. For more information on tires, refer to WHEELS AND TIRES (Sec.3E). MODEL REFERENCE Refer to figures 5 and 6 to determine the vehicle model. For R/V models, a “ R” is a two-wheel drive vehicle and a “V” is a four-wheel drive vehicle. ENGINE IDENTIFICATION NUMBER Refer to figure 7 to determine the location of the engine I.D. number. Nation of Origin 1 = U.S. Built 2 = Canadian Built 3 = Mexican Built Manufacturers G = General Motors Code Make A Chevrolet Bus * B Chevrolet Incomplete c Chevrolet Truck D GMC Incomplete E Cadillac Incomplete H GM of Canada Bus T GMC Truck IGJ GMC Van/Bus IGK GMC MPV IGN Chevrolet MPV *Van with 4th Seat GVWR/BRAKE SYSTEM Code GVWR Range Brake System B 3001-4000 Hydraulic C 4001-5000 Hydraulic D 5001-6000 Hydraulic E 6001-7000 Hydraulic F 7001-8000 Hydraulic G* 8001-9000 Hydraulic H 9001-10,000 Hydraulic J 10,001-14,000 Hydraulic K 14,001-16,000 Hydraulic ' Includes G-Van Bus Code Series 1 V2 Ton 2 Jon 3 1 Ton Ti Production Sequence Number J Code Body Type 0 Pickup/Panel Delivery 1 Hi-Cube/Cutaway Van 2 Forward Control 3 Four-Door Cab 4 Two-Door Cab 5 Van 6 Suburban 7 Motor Home Chassis 8 Utility (Jimmy/Blazer) 9 Stake Code Year H 1987 Line and Chassis Type Chassis Code Line Type R Conventional Cab 4x2 D Military Truck 4x4 V Conventional Cab 4x4 G Van 4x2 P Forward Control 4x2 S Sm Conventional Cab 4x2 T Sm Conventional Cab 4x4 M Sm Van 4x2 Assembly Plant Baltimore, MD Flint, Ml Janesville, Wl St. Louis, MO Pontiac East, Ml Pontiac, Ml Fort Wayne, IN Oshawa, ON Moraine, OH Detroit, Ml Scarborough, ON Lordstown, OH Shreveport, LA Pontiac, Ml______ Engine Type and Make Code Producer Type RPO C DDAD 6.2L V8 Diesel LH6 E Pontiac 2.5L L4 TBI LN8 H Chevrolet 5.0L V8 TBI L03 J DDAD 6.2L V8 Diesel LL4 K Chevrolet 5.7L V8 TBI LOS N Chevrolet 7.4L V8 TBI L19 R Chevrolet 2.8L V6 TBI LL2 Z Chevrolet 4.3L V6 TBI LB4 M Chevrolet 5.7L V8 4BBL LT9 W Chevrolet 7.4L V8 4BBL LE8 ✓ F-02139 Figure 3—Vehicle Identification Number (VIN)

GENERAL INFORMATION OA-3 ' MFD. BY GENERAL MOTORS CORPORATION GVWR g AWR PRT gawr rr SEE OWNER'S MANUAL FOR ADDITIONAL INFORMATION F-01407 When lifting the R vehicle with a hoist, the rear hoist pads should be positioned under the rear spring front hangers. When lifting the V vehicle with a hoist, the front hoist pads should be positioned under the frame, at the front body mount. The rear hoist pads should be positioned under the rear spring front hangers. When lifting the front of the V vehicle with a floor jack, position the jack pad at the center of the axle, not under the front differential. Figure 4—Certification Label VEHICLE LIFTING PROCEDURES For lifting a vehicle, various lift points are recommended. Refer to figures 8, 9, 10, and 11. When lifting the P vehicle with a hoist, the rear hoist pads should be positioned under the frame and inboard of the rear spring front hangers. When lifting the G vehicle with a hoist, the rear hoist pads should be positioned under the rear spring forward hangers. Chassis - Cab, Bonus/Crew Cab Pickup, Bonus/Crew Cab Utility Vehicle Jimmy (Blazer) F-02281 Pickup, Regular Cab R V MODELS Chassis - Cab, Regular Cab Suburban Figure 5—RV Models

OA-4 GENERAL INFORMATION G VAN MODELS BALLY (SPORTVAN) VANDURA (CHEVY VAN) VALUE VAN (STEP VAN) (ALUMINUM) MAGNAVAN (HI-CUBE VAN) VALUE VAN (STEP VAN) (STEEL) FORWARD CONTROL CHASSIS B-09178 CUTAWAY VAN MODELS___________ MOTOR HOME CHASSIS Figure 6—G Van and P Models

GENERAL INFORMATION OA-5 Figure 7—Engine I.D. Number Location

1986 Chevrolet Light Duty Trucks Service & Repair Manual

You're Reading a Preview

Recently Viewed