V-
6A1-1
SECTION 6A1
2.5 LITER L4 ENGINE
CONTENTS
SUBJECT
PAGE
D escription.................................................................................................................................................................................... 6 A 1 - 2
Engine Lubrication.................................................................................................................................................................. 6 A 1 - 2
Disassembly of the E n g in e...................................................................................................................................................... 6 A 1 - 4
Tools and Shop Equipm ent.................................................................................................................................................. 6 A 1 - 4
Accessory R em o v al................................................................................................................................................................6 A 1 - 4
C le a n in g .................................................................................................................................................................................... 6 A 1 - 4
Parts Identification.................................................................................................................................................................. 6 A 1 - 4
Draining the E n g in e................................................................................................................................................................6 A 1 - 4
Intake Manifold R em oval...................................................................................................................................................... 6 A 1 - 6
Exhaust Manifold R e m o v a l.................................................................................................................................................. 6 A 1 - 6
Therm ostat Housing R e m o v a l........................................................................................................................................... 6 A 1 - 6
W ater Pump R e m o v a l........................................................................................................................................................... 6 A 1 - 6
Valve Train Component R em o val...................................................................................................................................... 6 A 1 - 9
Cylinder Head R em o val.........................................................................................................................................................6 A 1 -1 0
Crankshaft Pulley Hub R em o val.........................................................................................................................................6 A 1 -1 0
Oil Pan Rem oval...................................................................................................................................................................... 6A 1-11
Oil Pump Driveshaft R em oval............................................................................................................................................. 6A1-11
Oil Pump R em o val.................................................................................................................................................................. 6A 1-11
Front Cover Rem oval............................................................................................................................................................. 6A1-11
Piston and Connecting Rod R e m o v a l............................................................................................................................. 6A 1-11
Flywheel R e m o v a l.................................................................................................................................................................. 6 A 1 -1 2
Crankshaft Rem oval................................................................................................................................................................6 A 1 -1 2
Crankshaft Rear Oil Seal Removal (Without Removing C rankshaft).......................................................................6 A 1 -1 2
Main Bearing Removal (Without Removing the C ra n k s h a ft).................................................................................... 6A 1 -1 3
Camshaft Rem oval.................................................................................................................................................................. 6A 1 -1 3
Cleaning, Inspection, and R epair........................................................................................................................................... 6A 1 -1 4
B lo c k ........................................................................................................................................................................................... 6 A 1 -1 4
Cylinder B o re s .........................................................................................................................................................................6A 1 -1 4
Piston and Connecting Rod A ssem blies......................................................................................................................... 6 A 1 -1 5
Piston S election.......................................................................................................................................................................6 A 1 -1 5
Intake and Exhaust Manifold................................................................................................................................................6A 1 -1 5
Cam shaft.................................................................................................................................................................................... 6A1 -1 6
Camshaft Bearings.................................................................................................................................................................. 6 A 1 -1 7
Front C over................................................................................................................................................................................6A 1 -1 7
W ater P u m p ............................................................................................................................................................................. 6 A 1 -1 8
Oil Pan and Rocker Arm Covers............................................................................................. ...........................................6 A 1 -1 8
Oil P u m p .................................................................................................................................................................................... 6 A 1 -1 8
Valve Train Com ponents...................................................................................................................................................... 6 A 1 -1 9
Cylinder H ead ........................................................................................................................................................................... 6 A 1 -1 9
Thermostat and H ousing...................................................................................................................................................... 6A1-21
Crankshaft and B earings...................................................................................................................................................... 6A1-21
Assembly of E n g in e .................................................................................................................................................................. 6A 1 -2 2
Prior to A s s e m b ly ..................................................................................................................................................................6A 1 -2 2
Crankshaft and Main Bearing In s ta lla tio n .......................................................................................................................6 A 1 -2 2
Crankshaft Rear Oil Seal and Retainer In s ta lla tio n .................................................................................................... 6 A 1 -2 3
Main Bearing Installation (Without Removing the C ran ksh aft)................................................................................6 A 1 -2 4
Camshaft Installation............................................................................................................................................................. 6 A 1 -2 4
Front Cover Installation.........................................................................................................................................................6 A 1 -2 4
Crankshaft Pulley Hub Installation.................................................................................................................................... 6A 1 -2 5
Piston and Connecting Rod In s ta lla tio n .........................................................................................................................6 A 1 -2 5
Oil Pump Installation............................................................................................................................................................. 6A 1 -2 6
Summary of Contents for 1989 Light Duty Truck
Page 1: ...vr V Light Duty Truck Unit Repair Manual...
Page 2: ......
Page 11: ...GENERAL INFORMATION OA 5 Figure 8 RV Models...
Page 13: ...GENERAL INFORMATION OA 7 Figure 11 ST Models...
Page 18: ......
Page 44: ......
Page 76: ...1B3 18 R 4 AIR CONDITIONING COMPRESSOR N...
Page 114: ......
Page 162: ......
Page 176: ...4B3 14 91 2 INCH RING GEAR...
Page 192: ...4B5 4 DANA REAR AXLES Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...
Page 218: ......
Page 220: ...4B6 2 12 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components...
Page 229: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools...
Page 230: ...4B6 12 12 INCH RING...
Page 240: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 260: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing...
Page 273: ...T TRUCK FRONT AXLE 4C3 3 F 05785 Figure 1 Axle Components...
Page 291: ...K TRUCK FRONT AXLE 4C4 3 Figure 1 Front Axle Com ponents K 15 25 Models...
Page 293: ...K TRUCK FRONT AXLE 4C4 5 Figure 3 Front Axle Com ponents K35 Models...
Page 318: ...C4 30 K TRUCK FBOHT AXLE...
Page 334: ......
Page 361: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components...
Page 363: ...2 5 LITER L4 ENGINE 6A1 7 F 05715 Figure 5 Block and Components...
Page 395: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram...
Page 396: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram...
Page 424: ...6A2 32 2 8 LITER V 6...
Page 427: ...I 4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857...
Page 451: ...4 3 LITER V 6 6A3 27 SPECIFICATIONS ENGINE SPECIFICATIONS F 6344...
Page 457: ...4 8 LITER L6 6A4 3 Figure 2 Lubrication Diagram Front View...
Page 460: ...6A4 6 4 8 LITER L6 C 1 107 112 fK 108 3 109 165 129 B 05056 Figure 5 Block and Components...
Page 490: ...Ml...
Page 493: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines...
Page 494: ...6A5 4 V8 ENGINE Figure 2 Lubrication Diagram 5 0L and 5 7L Engines...
Page 530: ...6A5 40 V8 ENGINE Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components...
Page 571: ...6 2 LITER DIESEL 6A7 35 Figure 58 Vacuum Pump Installed...
Page 576: ......
Page 582: ...6C1 6 MODEL 1MEF CARBURETOR Figure 9 Monojet Model 1MEF...
Page 604: ...6C2 6 MODEL M4MEF CARBURETOR Figure 9 Model M4MEF...
Page 640: ...6C4 8 MODEL 700 THROTTLE BODY...
Page 652: ...nmm...
Page 672: ......
Page 693: ...DISTRIBUTORS 6D5 13 Figure 27 Testing the Pickup Coil Figure 28 Testing the Ignition Coil...
Page 696: ......
Page 698: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts J H 0 0 5 3 7 0 0 R 4 R 2...
Page 745: ...700 R4 AUTOMATIC TRANSMISSION 7A1 49...
Page 762: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts H H 0021 400 R 3...
Page 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0 0 4 3 4 0 0 R 2...
Page 797: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assem bly...
Page 803: ...400 475 AUTOMATIC TRANSMISSION 7A2 43 Figure 104 Bushing Replacement Procedure...
Page 808: ...J c I i sal...
Page 838: ......
Page 840: ......
Page 842: ......
Page 850: ...7B1 12 HM 290 MANUAL TRANSMISSION J i t i a x V L...
Page 856: ...7B1 18 HM 290 MANUAL TRANSMISSION...
Page 892: ...7B1 54 HM 290 MANUAL TRANSMISSION Figure 93 Special Tools...
Page 897: ...HM 117 TRANSMISSION 7B2 5...
Page 901: ...HM 117 TRANSMISSION 7B2 9 B 05180 Figure 17 Installing the 1st and 2nd Synchronizer...
Page 912: ...20 HM...
Page 924: ...7B3 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS...
Page 927: ...BORG WARNER TRANSMISSIONS 7B4 3 Figure 2 77 mm Transmission and Components...
Page 940: ...i ii iii m i in m i...
Page 944: ...7D1 4 TRANSFER CASE FO 5688 Figure 3 NP205 Transfer Case...
Page 952: ...7D1 12 TRANSFER CASE...
Page 963: ...NEW PROCESS 241 TRANSFER CASE 7D2 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes...
Page 964: ...7D2 12 NEW PROCESS 241 TRANSFER CASE Figure 18 NP 241 Transfer Case Cut Away...
Page 978: ......
Page 981: ...BORG WARNER 1370 TRANSFER CASE 7D4 3 J...
Page 992: ...7D4 14 BORG WARNER 1370 TRANSFER CASE Figure 26 Installing the Rear Output Yoke...
Page 993: ...BORG WARNER 1370 TRANSFER CASE 7D4 15 Figure 27 BW 1370 Transfer Case...
Page 997: ......
Page 998: ...X 8937...