6A7-22 6.2 LITER DIESEL
i?
Tap the main bearing cap into place with a
brass or leather mallet. Then install the bolts.
Tig h ten
• Bolts to specifications, in the following
sequence:
• Inner bolts: 150 N-m (110 ft. lbs.).
• Outer bolts: 135 N-m (100 ft. lbs.).
• Re-tighten all bolts in the same
sequence.
6. Numbers 1, 2, and 4 main bearing caps and bolts.
• Bolts to specifications. Refer to step 5.
7. Number 3 (center) main bearing cap and bolts.
Tighten the bolts temporarily to 14 N-m (10 ft. lbs.).
M easure (Figure 33)
Crankshaft end play, as follows:
• Tap the end of the crankshaft first rearward
then forward with a lead hammer. This will line
up the main bearing and crankshaft thrust
surfaces.
• T ig h te n th e m ain b e a rin g ca p b o lts to
specifications. Refer to step 5.
• With the crankshaft forced forward, measure
at the front end of the number 3 main bearing
with a feeler gage (figure 33). The proper
clearance is 0.10-0.25 mm.
Inspect
Crankshaft for binding. Try turning the crankshaft to
check for binding. If the crankshaft does not turn
freely, loosen the main bearing cap bolts, one pair at
a time, until the tight bearing is located. Burrs on the
bearing cap, foreign matter between the insert and
the block or the bearing cap, or a faulty insert could
cause a lack of clearance at the bearing.
FLYWHEEL INSTALLATION
-►+ Install or C o nn ect (Figure 30)
1. Flywheel (140).
2. Bolts (141).
T ig h ten
• Bolts (141) to 90 N-m (65 ft. lbs.).
CONNECTING ROD AND
PISTON INSTALLATION
CONNECTING ROD BEARING SELECTION
Connecting rod bearings are of the precision insert type
and do not use shims for adjustment. DO NOT FILE
RODS OR ROD CAPS. If clearances are excessive install
a new bearing. Service bearings are available in standard
size and 0.026 mm (0.001-inch) undersizes.
Selective fitting of both rod and main bearing inserts is
necessary to obtain close tolerances. For this reason you
may use, for example, one half of a standard insert with
A.
Oil Control Ring Expander Gap
B. Second Compression Ring Gap
C. Centerline Of Piston Pin
D. Oil Control Ring Gap
E. Top Compression Ring Gap
B-08046
Figure 34— Ring Gap Location
one half of a 0.026 mm (0.001-inch) undersize insert which
will decrease the clearance 0.013 mm (0.0005-inch) from
using a full standard bearing.
Some VIN Code C (RPO LH6) (light duty emissions)
e n g in e s m ay h ave b o th s ta n d a rd a n d 0.08 mm
(0.003-inch) oversize co n n e c tin g rod b ea rin gs. The
oversize connecting rods are stamped “ O.S.” on the cap’s
lower end.
INSTALLATION
Install or C o nn ect (Figures 34, 35, and 36)
2
.
Tool Required:
J 8037 Ring Compressor
Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
Make sure the piston is installed in the matching
cylinder. Install new pistons in the cylinders for
which they were fitted. Install used pistons in the
cylinder from which they were removed.
Connecting rod bearings.
• Be certain that the bearings are the proper
size.
• Install the bearings in the connecting rod and
connecting rod cap.
Piston and connecting rod to the proper bore.
• With the connecting rod cap rmeoved, install
two short pieces of 10 mm (3/s-inch) hose onto
the connecting rod studs.
• Locate the piston ring end gaps as shown in
figure 34. Lubricate the piston and rings with
engine oil.
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...