6A7-1
SECTION 6A7
6.2 LITER DIESEL
CONTENTS
SUBJECT
PAGE
D escription.................................................................................................................................................................................... 6 A 7 - 2
Engine Lubrication.................................................................................................................................................................. 6 A 7 - 2
Disassem bly..................................................................................................................................................................................6 A 7 - 3
Tools and Shop Equipm ent.................................................................................................................................................. 6 A 7 - 3
Accessory R em o v al................................................................................................................................................................6 A 7 - 3
C le a n in g .................................................................................................................................................................................... 6 A 7 - 4
Draining the E n g in e................................................................................................................................................................6 A 7 - 4
Vacuum Pump/Oil Pump Drive R em o v al....................................................................... ..............................................6 A 7 - 5
Intake Manifold R em oval.......................................................................................................................................................6 A 7 - 5
Injection Line R e m o v a l......................................................................................................................................................... 6 A 7 - 5
Injection Nozzle R e m o v a l.................................................................................................................................................... 6 A 7 - 5
Glow Plug R e m o v a l............................................................................................................................................................... 6 A 7 - 5
Exhaust Manifold R e m o v a l.................................................................................................................................................. 6 A 7 - 5
Dipstick Tube R e m o v a l.........................................................................................................................................................6 A 7 - 6
Water Crossover Rem oval........................................................................................................................................... ..
.6 A 7- 6
Rocker Arm Cover R e m o v a l................................................................................................................................................6 A 7 - 6
Rocker Arm and Pushrod R e m o v a l.................................................................................................................................. 6 A 7 - 6
Cylinder Head R em o val.........................................................................................................................................................6 A 7 - 7
Hydraulic Lifter R em oval...................................................................................................................................................... 6 A 7 - 7
W ater Pump R e m o v a l........................................................................................................................................................... 6 A 7 - 8
Torsional Damper R em oval.................................................................................................................................................. 6 A 7 - 8
Injection Pump R e m o v a l.......................................................................................................................................................6 A 7 - 8
Front Cover R em oval............................................................................................................................................................. 6 A 7 - 8
Timing Chain and Sprocket Rem oval................................................................................................................................6 A 7 - 8
Camshaft R em oval.................................................................................................................................................................. 6 A 7 - 9
Oil Pan Rem oval.......................................................................................................................................................................6 A 7 - 9
Oil Pump R em o v al.................................................................................................................................................................. 6 A 7 - 9
Piston and Connecting Rod R e m o v a l..............................................................................................................................6 A 7 - 9
Flywheel R e m o v a l.................................................................................................................................................................. 6 A 7 - 9
Crankshaft Rem oval................................................................................................................................................................6 A 7 - 9
Cleaning, Inspection, and R epair........................................................................................................................................... 6A 7-11
B lo c k ........................................................................................................................................................................................... 6A7-11
Cylinder B o re s .........................................................................................................................................................................6 A 7 -1 2
Piston and Connecting Rod A ss em b lies ......................................................................................................................... 6 A 7 -1 2
Intake and Exhaust M anifolds............................................................................................................................................. 6 A 7 -1 2
C am shaft.................................................................................................................................................................................... 6 A 7 -1 2
Camshaft Bearings.................................................................................................................................................................. 6 A 7 -1 2
Timing Chain, Sprockets, and Timing G e a r s ................................................................................................................6 A 7 -1 4
Front Cover................................................................................................................. ............................................................. 6A 7 -1 4
W ater P u m p ............................................................................................................................................................................. 6A 7-14
Oil Pan and Rocker Arm C overs.........................................................................................................................................6A 7 -1 4
Oil P u m p .................................................................................................................................................................................... 6 A 7 -1 4
Valve Train Com ponents...................................................................................................................................................... 6A 7 -1 5
Cylinder H ead ...........................................................................................................................................................................6A 7 -1 5
Glow P lu g s ............................................................................................................................................................................... 6 A 7 -1 7
Thermostat and W ater C ro s s o v e r.................................................................................................................................... 6 A 7 -1 8
Injection N o z z le s .................................................................................................................................................................... 6 A 7 -1 8
Injection L in e s .........................................................................................................................................................................6 A 7 -1 8
Injection P u m p ............................................................................................................................................................... ..
.6 A 7 -1 8
Crankshaft and Bearings...................................................................................................................................................... 6 A 7 -1 8
F ly w h e e l............................................................................................................................................................................. L. .6 A 7 -1 9
Torsional Dam per.................................................................................................................................................................... 6 A 7 -2 0
Oil Filter Bypass Valve R eplacem ent................................................................................................................................6 A 7 -2 0
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...