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6A7-18 6.2 DIESEL
use, it can be assumed that the upper half is also
satisfactory. If the lower half shows evidence of wear or
damage, both upper and lower halves should be replaced.
Never replace one half without replacing the other half.
C h ec kin g C le a ra n c e
To obtain the most accurate results with "Plastigage"
(or its equivalent) a wax-like plastic material which will
compress evenly between the bearing and journal surfaces
without damaging either surface, certain precautions should
be observed.
If the engine is out of the vehicle and upside down, the
crankshaft will rest on the upper bearings and the total
clearance can be measured between the lower bearing and
journal. If the engine is to remain in the vehicle, the
crankshaft must be supported upward to remove the
clearance from the upper bearing. The total clearance can
then be measured between the lower bearing and journal.
To assure the proper seating of the crankshaft, all
bearing cap bolts should be at their specified torque. In
addition, preparatory to checking fit of bearings, the surface
of the crankshaft journal and bearing should be wiped clean
of oil.
1. With the oil pan and oil pump removed, and starting
with the rear main bearing, remove bearing cap and
wipe oil from journal and bearing cap.
2. Place a piece of gaging plastic the full width of the
bearing (parallel to the crankshaft) on the journal (fig.
6A7-33). Do not rotate the crankshaft while the gaging
plastic is between the bearing and journal.
3. Install the bearing cap and evenly torque the retaining
bolts to specifications. Bearing cap M UST be torqued
to specifications in order to assure proper reading.
Variations in torque affect the compression of the
plastic gage.
4. Remove bearing cap. The flattened gaging plastic will
be found adhering to either the bearing shell or journal.
5. On the edge of gaging plastic envelope there is a
graduated scale which is correlated in thousandths of
an inch. Without removing the gaging plastic, measure
its compressed width (at the widest point) with the
graduations on the gaging plastic envelope (fig. 6A7-
34). Normally main bearing journals wear evenly and
are not out-of-round. However, if a bearing is being
fitted to an out-of-round (.001 " max.), be sure to fit to
the maximum diameter of the journal. If the bearing is
fitted to the minimum diameter and the journal is out-
of-round .001 ", interference between the bearing and
journal will result in rapid bearing failure. If the
flattened gaging plastic tapers toward the middle or
ends, there is a difference in clearance indicating taper,
low spot or other irregularity of the bearing or journal.
Be sure to measure the journal with a micrometer if the
flattened gaging plastic indicates more than .001"
difference.
6. If the bearing clearance is within specifications # 1 , 2 ,
3, 4 (.0018" -.0032" ) and # 5 (.0022" - .0037"), the
bearing insert is satisfactory. If the clearance is not
within specifications, replace the insert. Always replace
both upper and lower inserts as a unit. If a new bearing
cap is being installed and clearances are less than
.001", inspect for burrs or nicks; if none required, then
install shims as required.
7. A standard, .001" or .002" undersize bearing may
produce the proper clearance. If not, it will be
necessary to regrind the crankshaft journal for use with
the next undersize bearing. After selecting new
bearing, recheck clearance.
8. Proceed to the next bearing. After all bearings have
been checked rotate the crankshaft to see that there is
no excessive drag. When checking # 1 main bearing,
loosen accessory drive belts so as to prevent tapered
reading with plastic gage.
9. Measure crankshaft end play (see specifications) by
forcing the crankshaft to the extreme front position.
Measure at the front end of the rear main bearing with
a feeler gage (fig. 6A 7-35).
10. Install a new rear main bearing oil seal in the cylinder
block and main bearing cap.
R e p la c e m e n t
Main bearings may be replaced with or without
removing the crankshaft.
With Crankshaft Rem oval
1. Remove and inspect the crankshaft.
2. Remove the main bearings from the cylinder block and
main bearing caps.
3. Coat
bearing
surfaces
of new,
correct
size,
mainbearings with oil and install in the cylinder block
and main bearing caps.
4. Install the crankshaft.
Without Crankshaft Rem oval
1. With oil pan, oil pump and glow plugs removed, remove
cap on main bearing requiring replacement and remove
bearing from cap.
2. Install a main bearing removing and installing tool in
oil hole in crankshaft journal. If such a tool is not
available, a cotter pin may be bent as required to do the
job.
3. Rotate the crankshaft clockwise as viewed from the
front of engine. This will roll upper bearing out of
block.
4. Oil new selected size upper bearing and insert plain
(unnotched) end between crankshaft and indented or
notched side of block. Rotate the bearing into place and
remove tool from oil hole in crankshaft journal.
5. Oil new lower bearing and install in bearing cap.
6. Install main bearing cap.
7. Torque all main bearing caps EXCEPT THE REAR
M A IN C A P to specifications. Torque rear main
bearing cap to 10-12 lb. ft. (14-16 N-m) then tap end of
crankshaft, first rearward then forward with a lead
hammer. This will line up rear main bearing and
crankshaft thrust surfaces. Retorque all main bearing
caps to specifications.
OIL SEAL-REAR M A IN
R ep air
1. Remove oil pan and oil pump as previously outlined.
2. Remove rear main bearing cap.
Summary of Contents for 1982 Light Duty Truck
Page 1: ......
Page 28: ...HEATER 1A 3 Fig lA 2 Heater Control C K Models Fig lA 3 Heater Control G Models...
Page 37: ...Fig 1A 11 T E E V A L V E A S M TEE AND VALVE C36...
Page 38: ...HEATER 1A 13 Fig 1A l2 Distributor Ducts G Models Fig 1A l5 Control Assembly G Models...
Page 39: ...1A 14 HEATER V IE W A V IE W B Fig 1A l7 Control Cable Routing G Models...
Page 42: ...HEATER 1A 19 Fig 1A 23 Auxiliary Heater Hose Routing...
Page 56: ...AIR CONDITIONING IB 13 Chart 1B 4 Pressure Cycling CCOT System Diagnosis...
Page 64: ...Fig 1B 17 C60 System Vacuum Diagram C K Series...
Page 65: ......
Page 66: ...Fig 1B 19 C60 Motor Home Chassis Wiring Diagram SWITCH AIR CONDITIONING IB 2 3...
Page 67: ...IB 24 AIR CONDITIONING Fig IB 20 1 P A C Harness Wiring...
Page 68: ...AIR CONDITIONING IB 25 VIE W A Fig IB 21 A C Compressor wiring...
Page 76: ...AIR CONDITIONING IB 33 Fig 1B 26 Compressor Mounting...
Page 91: ...IB 48 AIR CONDITIONING Fig 1B 59 C K Models Refrigerant Lines L6...
Page 150: ......
Page 162: ......
Page 164: ...2D 2 BODY Fig 2D 4 Typical Utility Vehicle Model...
Page 182: ...2D 20 BODY Fig 2D 51 Rear Door Controls Fig 2D 52 Rear Door Outside Handle and Lock Cylinder...
Page 193: ...BODY 2D 31 BELTS 3RD SEAT Fig 2D 82 Seat Belt Installation Suburban Driver Seat Suburban...
Page 194: ...2D 32 BODY Fig 2D 85 Passenger s Bucket Seat Chassis Cab...
Page 195: ...BODY 2D 33 Fig 2D 88 Rear Bench Seats Suburban...
Page 196: ...2D 34 BODY Fig 2D 89 CK Utility Seat Attachments...
Page 197: ...BODY 2D 35 Fig 2D 90 Seat Separator Compartment and Door CK Models...
Page 222: ......
Page 223: ...BODY 2D 61 Fig 2D 139 Front Seat Belt Installation...
Page 228: ......
Page 234: ......
Page 252: ...3B2 8 MANUAL STEERING GEAR Fig 3B2 11 Manual Steering Gear Exploded View...
Page 256: ......
Page 273: ...POWER STEERING SYSTEM 3B3 17 with LE3 Engine Exc HC4 LE4 LG9 LF4 LS9 LT9 and JB7 HC4 and JB8...
Page 342: ......
Page 389: ...REAR SUSPENSION 3D 7 Fig 3D 17 Rear Spring Installation C K Models...
Page 428: ...4 B 1 4 REAR AXLE Fig 4B 8 Gear Tooth Nomenclature Fig 4B 9 G ear Tooth Contact Pattern Check...
Page 444: ......
Page 454: ......
Page 468: ...4 B 5 2 REAR AXLE Fig 4B5 2 Rockwell Assembly...
Page 480: ...4 B 5 1 4 REAR AXLE...
Page 482: ...i...
Page 502: ......
Page 520: ......
Page 533: ...Fig 5 5 Front Brake Pipes and Hoses C K Models BRAKES 5 13...
Page 534: ...Fig 5 6 Front Brake Pipes and Hoses G M odels 5 14 B R A K E S...
Page 535: ...Fig 5 7 Front Brake Pipes and Hoses P Models BRAKES 5 15...
Page 536: ...5 16 BRAKES Fig 5 8 Rear Brake Hoses...
Page 538: ...5 18 BRAKES Fig 5 10 Parking Brake System Typical...
Page 539: ...BRAKES 5 19...
Page 570: ...5 50 BRAKES Fig 5 57 Power Steering Hose Routing C K Models...
Page 571: ...BRAKES 5 51 Fig 5 58 Power Steering Hose Routing G Models...
Page 572: ...Fig 5 59 Power Steering H ose Routing P Models 5 52 BRAKES...
Page 577: ...BRAKES 5 57 4 CONT A SECONDARY DIAPHRAGM B SECONDARY POWER 4 CONT C PRIMARY D Fig 5 5A Service...
Page 604: ......
Page 625: ...NOTES ENGINE 6 21...
Page 626: ......
Page 629: ...IN LINE 6 6A1 3 OIL PRESSURE SENDING UNIT Fig 6A1 1 In Line Engine Lubrication...
Page 630: ...6A1 4 IN LINE 6 Fig 6 A l 2 P Series Engine Front Mount...
Page 631: ...IN LINE 6 6A1 5 Fig 6Al 3 P Series Engine Rear Mount Fig 6 A l 4 C Series Engine Rear Mounts...
Page 634: ...6A1 8 IN LINE 6 Fig 6Al 7 K Series Engine Rear Mount...
Page 660: ......
Page 663: ...SMALL BLOCK 6A4 3 Fig 6A4 T Engine Lubrication...
Page 664: ...6A4 4 SMALL BLOCK Fig 6A4 2 Engine Lubrication...
Page 665: ...Fig 6A4 3 P Series Engine Mount Bracket...
Page 667: ...SMALL BLOCK 6A4 7 Fig 6A 4 5 P Series Engine Front Mount...
Page 668: ...6A4 8 SMALL BLOCK...
Page 669: ...SMALL BLOCK 6A4 9 Fig 6A 4 7 K Series Engine Mounts...
Page 670: ...6A4 10 SMALL BLOCK Fig 6A 4 8 C Series Engine Mounts...
Page 703: ...MARK IV 6A5 7 Fig 6A 5 6 P Series Engine Front Mount...
Page 704: ...6A5 8 MARK IV Fig 6 A 5 7 C Series Engine Mounts...
Page 731: ...6 2 DIESEL 6A7 3...
Page 760: ...6B 6 ENGINE COOLING Fig 6B 7 A C and A I R Adjustment...
Page 771: ...ENGINE COOLING 6B 17 Fig 6B 20 Engine O il C o o le r 6 2L Diesel...
Page 784: ......
Page 807: ...CARBURETOR MODEL 2SE 6C2 9 Fig 6C2 6 Typical 2SE Carburetor Assembly...
Page 820: ......
Page 830: ...6C4 10 CARBURETOR MODEL M4ME M4MC 101368 Fig 6C4 12 M 4M C M 4M E Carburetor Exploded View...
Page 848: ......
Page 876: ......
Page 888: ...6D 12 ENGINE ELECTRICAL Fig 6D 6C Generator Mounting Fig 6D 7C Generator Mounting...
Page 919: ...ENGINE ELECTRICAL 6D 43...
Page 934: ...Fig 6D 8E Starter M otor Mounting...
Page 974: ......
Page 1011: ...Figure 350C 25A Neutral Engine Running AUTOMATIC TRANSMISSION 350C 11...
Page 1054: ...Fig 7A 1C 400 Autom atic Transmission Side Cross Section Typical...
Page 1152: ...700 R4 40 AUTOMATIC TRANSMISSION Figure 700 R4 76 Transmission Assembly Exploded View...
Page 1162: ......
Page 1189: ...89MM MANUAL TRANSMISSION 7B3 5 Fig 7 3 4 4 Speed 89mm Exploded View...
Page 1219: ...CLUTCH 7C 5 Fig 7C 6 C K Truck Clutch Controls...
Page 1220: ...Fig 7C 7 G Truck Clutch Controls...
Page 1221: ...CLUTCH 7C 7 Fig 7C 8 P Truck Clutch Controls...
Page 1234: ...7E 2 TRANSFER CASE Fig 7E 1 Model 208 Transfer Case Cross Section...
Page 1252: ...7E 20 TRANSFER CASE Fig 7E 39 Transfer Case Attachment Typical...
Page 1278: ...8A 16 ELECTRICAL BODY AND CHASSIS Fig 8A 11 License Plate Lamps C K Series...
Page 1280: ...8A 18 ELECTRICAL BODY AND CHASSIS VIEW A VIEW B Fig 8A 15 CK Series Rear Lamp W iring...
Page 1281: ...ELECTRICAL BODY AND CHASSIS 8A 19 Fig 8A 16 CK Series Auxiliary W iring...
Page 1290: ...8B 8 ELECTRICAL AND WIRING Fig 8B 13 Seat Belt Reminder System Schematic...
Page 1292: ......
Page 1346: ...8C 54 INSTRUMENT PANEL AND GAGES Fig 8C 46 CK Series W iring 3 of 29...
Page 1351: ...INSTRUMENT PANEL AND GAGES 8C 59 SUBURBAN Fig 8C 51 CK Series W iring 8 of 29...
Page 1364: ...8C 72 INSTRUMENT PANEL AND GAGES Fig 8C 64 CK Series W iring 21 of 29...
Page 1365: ...INSTRUMENT PANEL AND GAGES 8C 73 CAB CRFW CAB CHASSIS Fig 8C 65 CK Series W iring 22 of 29...
Page 1366: ...8C 74 INSTRUMENT PANEL AND GAGES Fig 8C 66 CK Series W iring 23 of 29...
Page 1374: ...8C 82 INSTRUMENT PANEL AND GAGES Fig 8C 74 G Series W iring 2 of 19...
Page 1375: ...INSTRUMENT PANEL AND GAGES 8C 83 Fig 8C 75 G Series W iring 3 of 19...
Page 1376: ...8C 84 INSTRUMENT PANEL AND GAGES Fig 8C 76 G Series W iring 4 of 19...
Page 1379: ...INSTRUMENT PANEL AND GAGES 8C 87 Fig 8C 79 G Series W iring 7 of 19...
Page 1383: ...INSTRUMENT PANEL AND GAGES 8C 91 Fig 8C 83 G Series W iring 11 o f 19...
Page 1384: ...8C 92 INSTRUMENT PANEL AND GAGES BUS BARGWO Fig 8C 84 G Series W iring 12 of 19...
Page 1390: ...8C 98 INSTRUMENT PANEL AND GAGES Fig 8C 90 G Series W iring 18 of 19...
Page 1391: ...INSTRUMENT PANEL AND GAGES 8C 99 Fig 8C 91 G Series W iring 19 of 19...
Page 1392: ...8C 100 INSTRUMENT PANEL AND GAGES Fig 8C 92 P Series W iring 1 of 11...
Page 1393: ...INSTRUMENT PANEL AND GAGES 8C 101 Fig 8C 93 P Series W iring 2 of 11...
Page 1396: ...8C 104 INSTRUMENT PANEL AND GAGES Fig 8C 96 P Series W iring 5 of 11...
Page 1399: ...INSTRUMENT PANEL AND GAGES 8C 107 Fig 8C 99 P Series W iring 8 of 11...
Page 1401: ...INSTRUMENT PANEL AND GAGES 8C 109 START RUN OF LOCK ACC Fig 8C 101 P Series W iring 10 of 11...
Page 1415: ...ACCESSORIES 9 13 RADIO NOISE BLOWER MOTOR Fig 9 6R Radio Diagnosis Chart B...
Page 1416: ...9 14 ACCESSORIES D E A D R A D IO A M R A D IO I Fig 9 7R Radio Diagnosis Chart C...
Page 1417: ...ACCESSORIES 9 15 DEAD RADIO AM FM RADIO Fig 9 8R Radio Diagnosis Chart D...
Page 1435: ...t f l i t 1...