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2.5 LITER L4 ENGINE 6A1-17
A. A rb o r Press
B. Press Tool
104. C a m s h a ft G e ar
105. T h ru s t Plate
108. C a m s h a ft
104
108
F-02027
Figure 29— Installing the Camshaft Gear
NOTICE: The thrust p la te m u st b e p o s itio n e d
so th at the w o o d ru ff key (1 0 7 ) does n o t dam age
it during the rem oval operatio n .
• Press the cam shaft (108) out of the camshaft
gear.
2. Thrust plate (105).
3. Spacer (106).
*
A ssem ble (Figure 29)
• Support the cam shaft on the back of the front
journal in an arbor press using press plate adapters.
• Lubricate the thrust plate with engine oil.
1. W oodruff key (107).
2. Spacer (106).
3. Thrust plate (105).
4. Camshaft gear (104).
• Make sure that the tim ing mark is to the
outside.
• Press the cam shaft gear onto the cam shaft
until it bottoms on the spacer (106).
• Remove the cam shaft from the press.
m
M easure (Figure 27)
Cam shaft to thrust plate clearance using a feeler
gage.The correct clearance is 0.0015-inch to 0.0050-
inch.
CAMSHAFT BEARINGS
0
* ± i R em ove or D isconnect (Figure 30)
Tool Required:
J 33049 Universal Cam shaft Bearing
Remover and Installer
1. Expansion plug.
• Drive out the plug from inside the block at the
rear camshaft bearing.
2. Front and rear bearings (109) using J 33049.
• Drive the bearings towards the center of the
block.
3. Center bearing using J 33049.
• Drive the bearing towards the rear of the
engine.
-►+ Install or C o nn ect (Figure 30)
Tool Required:
J 33049 Universal Cam shaft Bearing
Remover and Installer
1. Center bearing using J 33049.
• Install the bearing from the front of the engine.
• Make sure that the oil holes in the bearing are
aligned with the oil holes in the block.
2. Rear bearing (109) and expansion plug.
• Drive the bearing in from the rear of the
engine.
• Make sure that the oil holes in the bearing are
aligned with the oil holes in the block.
• Drive the expansion plug into the block from
the rear of the engine.
3. Front bearing (109).
• D riv e th e b e a rin g in to th e b lo c k , and
approximately 3.18 mm (Vs-inch) past the front
surface of the block. This uncovers the timing
gear oil nozzle hole.
FRONT COVER
*
*
Clean
Old RTV sealant from the sealing flange.
Inspect
Front cover for cracks, large dents, etc.
Sealing flange for straightness.
D isassem ble (Figure 5)
Seal (101). Pry the seal out with a screwdriver.
A ssem ble (Figure 31)
Tool Required:
J 34995 Crankshaft Front Cover
Oil Seal Installer
New seal (101) using tool J 34995.
— Support the inside of the front cover around
the seal bore area.
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...