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GMC C Series 1993, Repair Manual

The GMC C Series 1993 Repair Manual is a comprehensive guide that enables users to effortlessly maintain and repair their vehicles. This invaluable manual can be downloaded for free from manualshive.com, providing step-by-step instructions and detailed diagrams to guarantee a smooth and hassle-free repair experience.

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6A2-2  V8  ENGINES,  GASOLINE

CONTENTS  (cont’d)

SUBJECT

Oil  Pan  and  Rocker  Arm  Covers
Oil  Pump.................  ................
Valve  Train  Components

 

Pushrods,  Rocker  Arms,  Balls,  and  Bolts
Hydraulic  Lifters. . . . . . . .... .......... ........

Cylinder  Head.........  ............

Disassembly..................................  ......  ....
Cleaning  and  Inspection...............

Valve  Grinding 

..... .

Valve  Seat  Grinding .... 

.....

Reaming  Valve  Guides......

Assembly....... ......................................

Thermostat  and  Coolant  Outlet ....
Torsional  Dam per......  

.......

Crankshaft  and  Bearings...........   .....

Cleaning  and  Inspection.................. .........

Crankshaft  Grinding  ............   ................... .

Assembly  of  the  Engine.........

Prior  to  Assembly.

.......................

Crankshaft  and  Main  Bearing  Installation.*........:.,..:.................

Main  Bearing  Selection....... ............... ............ .............. .
Pinal  Assembly................. ............................ ....................................

Crankshaft  Rear  Oil  Seal  Installation.......
Camshaft,  Timing  Chain,  and  Sprocket  Installation

— ............

....... ..... .

' 

. 

!■:

.....

.......

Front  Cover  Installation................. .................. :L............................

Torsional  Damper  Installation........... ........................................ ..............

Piston  and  Connecting  Rod  Installation ......

Installation.... .........................................
Connecting  Rod  Bearing  Selection....
Final  Assembly.... .............................. j.^i.L....;......

Oil  Pump  Installation...,..... ...............................:..w.i*L...............
Oil  Pan  installation...... .........

Cylinder  Head  Installation........ 

.....

Valve  Train  Component  Installation

Intake  Manifold  Installation....................... .
Rocker Arm  Cover  Installation..............

Exhaust  Manifold  Installation........

Coolant  Pump  Installation...........   ............   ....
Flywheel  Installation..:,

Engine  Accessory  Installation■»».
Engine  Set-Up  and  Testing  ..........

Thread  Repair........... ................................................. .

Specifications..........  

.................

Engine  Specifications...................................................
Fastener  Tightening  Specifications..............  

.....

Special  Tools............  

....................

......

. . . . . . . . . .

i'll;.:

................*.....

... 

■

 

i j(i( .

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• • • • ■ • • • • • • • • ■ • a

GENERAL  DESCRIPTION

The  V8  engines  covered  in  this  section  are  90-degree

 

V8  type,  overhead  valve,  liquid  cooled,  with  cast  iron

 

block  and  cylinder  heads.

The  camshaft  is  supported  by  five  plain  type  bearings

 

and  is  chain  driven.  Motion  from  the  camshaft  is  trans­

mitted  to  the  valves  by  hydraulic  lifters,  pushrods,  and

 

ball-pivot  type  rocker  arms.  The  valve  guides  are

 

pressed  in  the  cylinder  head. 

;

The  crankshaft  is  supported  by  five  precision  insert

 

type  bearings,  with  crankshaft  thrust  taken  at  the  num­

ber  five;;(rear)  bearing.

The  connecting  rods  are  forged  steel,  with  precision

 

insert  type  brankpin  bearings.  The  piston  pins  are  a

 

press  fit, in  the  connecting  rods.

The  pistons  are  cast  aluminum  alloy.  The  piston  pins

 

are  a  floating  fit  in  the  pistons.

Summary of Contents for C Series 1993

Page 1: ......

Page 2: ...igned for the purpose Accordingly anyone who intends to use a replacement part service procedure or tool that is not recommended by the vehicle manufacturer must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the replacement part service procedure or tool selected It is important to note that this manual contains various Cautions and Notices th...

Page 3: ...missions Manual Wiring diagrams and electrical diagnosis for these models are published in the Electrical Diagrams and Diagnosis Manual This manual should be kept in a handy place for ready reference If properly used it will meet the needs of technicians and vehicle owners i GMC Truck Division service manuals are intended for use by professional qualified technicians Attempting repairs or service ...

Page 4: ...ual are based on the latest product information available at the time of publication approval The right is reserved to make changes at any time without notice GMC TRUCK DIVISION TRUCK BUS GROUP General Motors Corporation X 9338 Pontiac Michigan 1992 General Motors Corporation Printed in U S A April 1992 All rights reserved No part of this publication may be reproduced stored in any retrieval syste...

Page 5: ...COMPRESSOR ill COMPRESSOR 3 STEERING i 3B1A POWER STEERING GEAR 3B3 POWER STEERING 3B1B POWER STEERING PUMP COMPONENTS TRW ROSS 3B2 POWER STEERING 3B4 POWER STEERING c o m po n en ts Mid la nd c o m po n e n ts luk lf93 4 REAR AXLE 4B2 REAR AXLE CONTROLS 5 BRAKES 5A MASTER CYLINDER 5I AIR FOUNDATION BRAKE 5D2 HYDRAULIC BQdSTER 5J AIR COMPRESSOR AND 5H AIR BRAKE VALVES GOVERNOR 6 ENGINE 6A2 V8 ENGI...

Page 6: ...pt Only Sub Total Michigan Purchasers Add Sales Tax Rush Order Charge Please allow adequate time for postal service We also offer UPS Overnight Express Call for Rates PRICES SUBJECT TO CHANGE TO CHANGE WITHOUT NOTICE Overnight Delivery Grand Total Sold To Also Fill out Shipping Label Company Name Please Print Clearly 0 1 Name Street Address Apt No City State and Zip Code This is From Adistr Attn 1...

Page 7: ...tors dealer repair facilities can purchase TECH 1 scan tools and accessories from Kent Moore at the above address or Sun Electric Corporation One Sun Parkway Crystal Lake IL 60014 1 800 CALLSUN 225 5786 6 45 a m 7 00 p m CST SERVICE PARTS IDENTIFICATION LABEL The service parts identification label is provided on all vehicle models On the conventional cab models G6H and C7H the label is located on ...

Page 8: ...side of the driver s island figure 4 On B7 models it is located on the cowl panel above the engine compartment To find out the manufacturer 1 Typical yIN i F7557 Figure 3 VINi Location C6H and C7H Models Figure 4 VIN Location P6 Models model and chassis type engine type GVW range mod el year plant code and sequential number refer to figure VEHICLE CERTIFICATION LABEL The vehicle certification labe...

Page 9: ...icle Certification Label J F9825 Figure 7 Incomplete Vehicle Certification Label after it has left the factory This would include bodies winches booms etc the driver and all occupants and the load the vehicle is carrying The gross vehicle weight GVW must not exceed the gross vehicle weight rating GVWR Also the front and rear gross axle weights GAW must not exceed the front and rear GAWR Gross Axle...

Page 10: ...ad The engine serial numberis also located at the left rear corner of the engine block figure 9 r e a r AXLE IDEENTIFICATION NUMBER ROCKWELL All Rockwell axles are identified with two tags one tag is located on the right side of the differential carrier and the other tag is on the right rear leg of the axle housing On a tandem axle the rear rear axle tag is located on the axle housing cover figure...

Page 11: ...and strength Original equipment metric fasteners except beauty bolts such as exposed bumper bolts and cross recess head screws are identified by a number marking indi cating the strength of the material in the fastener as outlined later Metric cross recess screws are identified by a Posidriv or Type 1A Either a Phillips head or Type 1A cross recess screwdriver can be used in Posidriv recess screw ...

Page 12: ...OA 6 GENERAL INFORMATION Figure 11 Allison Transmission I D Location ...

Page 13: ...evel Nominal Torque Capacity F9377 Figure 12 Eaton Fuller Model FS transmission I D Location R T 11 6 09 A Roadranger 1 I J I Ratio Set Twin Countershaft I Forward Speeds Overdrive Design Level x 100 Nominal Torque Capacity F9376 Figure 13 Eaton Fuller Model RT Transmission I D Location ...

Page 14: ...available in the aftermarket parts channels were designed to metric standards of countries other than the United States and may be of a lower strength may not have the numbered head marking system and may be of a different thread pitch The metric fasteners used on GM products are designed to new international stan dards that may not yet be manufactured by some non domestic bolt and nut suppliers F...

Page 15: ...s and nuts that are rusty or damaged should be replaced with new parts of equal or greater strength METRIC ENGLISH CONVERSION For determining metric and english conversions refer to figure 19 DECIMAL AND METRIC EQUIVALENTS For determining decimal and metric equivalents refer to figure 20 J1930 WORD CONVERSION Starting with the 1993 model year General Motors will be complying with the Society of Au...

Page 16: ...ASTENERS 0 250 0 312 0 375 0 437 0 500 0 562 0 625 0 750 4 5 J l N m 0 4 0 6 1 4 1 8 2 4 3 2 4 2 6 2 In Lbs 4 0 5 0 12 15 20 27 v 35 51 1 2 3 6 8 9 N m 0 4 0 6 1 0 1 4 1 8 2 6 3 4 5 2 In Lbs 4 0 5 0 9 0 12 15 22 28 43 1 Top Lock Type 2 Center Lock 3 Dry Adhesive Coating 4 Out Of Round Thread 5 Deformed Thread Profile V F8432 Figure 18 Prevailing Torque Nuts and Bolts 6 Nylon Strip Or Patch 7 Nylon...

Page 17: ...PRESSURE OR STRESS Inches of water Pounds sq in 0 249 1 kilopascals kPa 6 895 f kilopascals ENERGY OR WORK Inch3 Quart 0 946 4 Gallon Yard3 16 387 16 387 0 016 4 liters 3 785 4 0 764 6 MASS mm3 cm3 liters 1 liters meters3 m3 BTU Foot pound Kilowatt hour 1055 1 355 8 3 600 000 or 3 6 x 106 LIGHT joules J joules joules J one W Pound 0 453 6 kilograms kg Foot candle 1 076 4 lumens meter2 lm m2 Ton 90...

Page 18: ... 0 703125 17 85937 7 32 0 21875 5 55625 23 32 0 71875 18 25625 15 64 0 234375 5 95312 47 64 0 734375 18 65312 1 4 0 250 6 3500 3 4 0 750 19 05000 17 64 0 265625 6 74687 49 64 0 765625 19 44687 9 32 0 28125 7 14375 25 32 0 78125 19 84375 19 64 0 296875 7 54062 51 64 0 796875 20 24062 5 16 0 3125 7 93750 13 16 0 8125 20 63750 21764 0 328125 8 33437 53 64 7 0 828125 21 03437 11 32 0 34375 8 73125 27 ...

Page 19: ...ol Module ECM Controlled Canister Purge CCP Evaporative Emission Canister Purge EVAP Canister Purge Coolant Temperature Switch CTS Engine Coolant Temperature Switch ECT Switch Coolant Temperature Sensor CTS Engine Coolant Temperature Sensor ECT Sensor Cooling Fan Control Cooling Fan Control Cooling FC Detonation Sensor Knock Sensor KS Diagnostic Circuit Check Onboard Diagnostic System Check OBD Sy...

Page 20: ...gen Oxides NO Nitrogen Oxides NOx Oxygen 0 Oxygen 02 t Oxygen Sensor 02 1 Heated Oxygen Sensor H02S 2 Oxygehi Sensor 02S Park Neutral Switch P N Switch Park Neutral ipostion Switch PNP Switch Port Fuel Injection PFI Multiport Ftielj Injection MFI Power Steering P S Power Steering PS Power Steering Switch Power Steering Pressure Switch PSP Switch Pulse Air Injection System PAIR Pulsed Secondary Air...

Page 21: ...ame Tor all vehicle applications there are differences in installations mounting brackets pulleys torque cushions and switches none of which will affect the following overhaul procedures There are two clutch driver designs for the HR6 HE compressor The clutch driver without a torque cushion and the clutch driver having a thin torque cushion Fig VV v 5 Service compressors are supplied with either t...

Page 22: ...ULLEY BEARING 4 PULLEY 5 CLUTCH COIL ASSEMBLY 6 SHAFT SEAL PARTS 7 PUMP ASSEMBLY 8 SWITCH O RING 9 10 SYSTEM CONTROL SWITCH HIGH PRESSURE RELIEF VALVE 11 RETAINER RING SWITCH 12 SUCTION DISCHARGE PORT SEALING WASHERS o 10 3 o o n O C3 1 121 Fig 2 HR6 HE Compressor Components disassembly ...

Page 23: ...the parts that preliminary diagnosis shows are in need of service Refer to Figures 2 and 5 for information relative to part names and location Removal and installation of external compressor parts and disassembly and assembly of internal parts must be performed on a clean workbench The work area tools and parts must be kept clean at all times COMPRESSOR CLUTCH PLATE AND HUB ASSEMBLY El Remove or D...

Page 24: ... assembly to its final position The air gap between frictional surfaces of the clutch plate and clutch rotor should be 0 50 0 76mm 020 030 i 1 _ NOTICE If the center screw is threaded fully onto the end of the compressor shaft or if the body of the installer is held and the center screw is rotated the key will wedge and will break the clutch hub 7 IT iJ 33013 B DRIVE 7 AIR GAP 0 20 plate Installer...

Page 25: ...se in the slots in the rotor Fig 8 4 Hold the J 33020 puller in place and tighten the puller screw against the puller guide to remove the pulley rotor and bearing assembly 5 To prevent damage to the pulley rotor during bearing removal the rotor hub must be properly supported Remove the forcing screw from J 33020 puller and with the puller tangs still engaged in the rotor slots invert the assembly ...

Page 26: ...ce is deformed while staking The stake metal should not contact the outer race Of the i i j bearing Stake three places 120 degrees apart as shown in Figure 12 T1 J 33019 1 BEARING STAKING GUIDE m Rubber band i n U 33019 2 BEARING STAKING PIN L j j i l ______ _________ G60150 1D2 EK R1 i l Staking Bearing In Rotor Hub Bore 5 With the cbmpresSor mounted to the J 33026 holding fixture position the ro...

Page 27: ...front head of compressor Fig 14 Also install J 8433 1 puller crossbar with J 33025 puller legs as shown in Figure 14 3 Tighten J 8433 3 forcing screw against the puller pilot to remove the clutch coil Install or Connect 1 Place the clutch coil assembly on the front head with the terminals positioned at the marked location 2 Piace the J 33024 clutch coil installer over the internal opening of the c...

Page 28: ...e of proper clean service tools NOTICE Any attempt to use makeshift br inadequate service tools or equipment may result in damage and or improper compressor operation i All parts required for servicing the internal compressor are protected by a preservative process and packaged in a manner which will eliminate the necessity of cleaning washing or flushing of the parts The parts can be Used injthe ...

Page 29: ...efore installing new parts Clean Thoroughly clean O ring seal groove in front head NOTICE Seals should not be re used Always use a new specification service seal on rebuild Fig 18 Be sure that the seal to be installed is not scratched or damaged in anyway Make sure that the seal seat and seal are free of lint and dirt that could damage the seal surface or prevent sealing k 1 Install or Connect 1 D...

Page 30: ... excess oil resulting from installing the new seal parts from the shaft and inside the compressor neck 7 Install the clutch plate and hub assembly as described in minor repair procedures 8 Reinstall compressor belt and tighten bracket 9 Evacuate and charge the refrigerant system COMPRESSOR PRESSURE RELIEF VALVE 1 1 Remove or Disconnect 1 Recover the refrigerant Remove old pressure relief valve Fig...

Page 31: ...detector check for leaks at pressure relief valve rear head switch location compressor front and rear head seals center cylinder seal through bolt head gaskets and compressor shaft seal After checking shut off low pressure control and high pressure control on charging station v 10 Install a M9 x 1 25 threaded nut on the compressor crankshaft if the drive plate and clutch assembly are not installed...

Page 32: ...013 HUB DRIVE PLATE REMOVER INSTALLER 14 J 38100 C REFRIGERANT RECOVERY AND RECYCLING SYSTEM 15 J 33017 PULLEY BEARING ASSEMBLY INSTALLER 16 J 33019 BEARING STAKING TOOL 17 J 33020 PULLEY PULLER 18 J 34614 SHAFT SEAL PROTECTOR 19 J 33022 SHAFT NUT SOCKET 2 0 J 33023 PULLER PILOT 21 J 33024 CLUTCH COIL INSTALLER ADAPTER 22 J 33025 CLUTCH COIL PULLER LEGS r 23 J 34992 COMPRESSOR HOLDING FIXTURE I 1 ...

Page 33: ...e Plate Replacement Specifications General Specifications Fastener Tightening Specifications Special Tools 1D6 1 1D6 2 1D6 2 1D6 4 1D6 5 V 1D6 5 1D6 5 1D6 8 ii viiii D6 9 1D6 9 1D6 9 1D6 10 GENERAL DESCRIPTION The Sanden SD 510 HD is a belt driven five cylinder compressor with an integral clutch The clutch shaft seal cylinder head and valve plate assemblies are fully serviceable The compressor can...

Page 34: ...ith the socket wrench until the front plate is loosened 3 Shaft key 27 figure 4 Retain the shaft nut 13 if usable inspect All parts apd replace as necessary I install or Connect Figures 2 5 and 6 Tools Required J 37826 Clutch Face Installer 1 Shaft key 27 Allow the shaft key 27 to extend 4 5 mm 3 16 inch out of the bottom of the hub keyway The shaft key 27 is curbed to give an interference fit in ...

Page 35: ...embly until it has bottomed against the clutch shims NOTICE See Notice on page 1D6 1 3 Shaft nut 1 Tighten Shaft nut 1 to 39 N m 28 ft lbs Inspect Figure 6 Check the air gap with a feeler gage to 0 4064 to 0 7874 mm 0 016 to 0 031 inch The air gap is determined by the spacer shims When rein Figure A Removing lnstalling the Shaft Key Figure 5 Installing the Clutch Plate and Hub Assembly Figure 6 Me...

Page 36: ...35181 C Position J 37825 and 3 8 inch 16 x 1 1 4 inch cap screWs to hole J 37828 in place D Turn center bolt to the right with a socket wrench until the rotor pulley is loosened i 6 Bearing from the pulley figure 11 A Retaining ring using J 6435 B Drive the bearing from the pulley using J 29886 and J 37829 4 Install or Connect Figures 1 7 through 12 Tools Required J 4245 Internal Snap Ring Pliers ...

Page 37: ...ainer ring 7 using J 6435 3 Pulley and bearing assembly Refer to Pulley and Bearing Assembly Replacement 4 Clutch plate and hub assembly Refer to Clutch Plate and Hub Assembly Replacement MAJOR REPAIR TO THE COMPRESSOR SHAFT SEAL REPLACEMENT Remove or Disconnect Figures 1 14 through 19 Tools Required J 6435 External Snap Ring Pliers J 9393 A Seal Seat Remover and Installer J 9553 01 O Ring Remover...

Page 38: ...ainer F4529 Figure 14 Removing lnstalling the Felt Ring Metal Retainer Figure 16 Removing installing the Shaft Seal Seat Retainer Figure 17 Removing the Shaft Seal Seat Figure 18 Removing the Shaft Seal O Ring F7520 Figure 19 Removing lnstalling the Shaft Seal Assembly ...

Page 39: ... J 36048 Seal Remover and Installer J 29640 Seal Protector F9340 Figure 20 Installing Seal Protector Figure 21 Installing the Shaft Seal Cage Assembly Figure 23 Installing the Shaft Seal Seat Figure 24 Installing the Snap Ring Retainer Figure 25 Installing the Felt Ring Metal Retainer Dip the new O ring in clean 525 viscosity refriger ant oil 1i J 29640 onto the shaft figure 20 2 Shaft seal figure...

Page 40: ...late 18 figure 29 Position the gasket scraper between the outside edge of the valve plate and the cylinder block and lightly tap the valve plate loose 5 Valve plate gasket 17 figure 29 6 Cylinder gasket 19 figure 30 Inspect Valve plate for damage Remove old gasket materi a k j j i Cylinder head for damage Replace if necessary Install or Connect Figures 1 25 through 30 T Cylinder gasket 19 figure 3...

Page 41: ... or equivalent COMPRESSOR Type Rotation Oil SPECIFICATIONS GENERAL SPECIFICATIONS 5 Cylinder Axial v Clockwise 500 Viscosity Suniso 5GS or equivalent Capacity v i 0 142 kg 5 oz Clutch Hub Air Gap 0 4064 to 0 7874 mm 0 016 to 0 031 inch FASTENER TIGHTENING SPECIFICATIONS Clutch Retaining Nut 38 N m 28 ft lbs Cylinder Head Cap Screws 33 N m 24 ft lbs Service Port 14 N m 10 ft lbs Discharge Hose 1 2 ...

Page 42: ...J 29640 11 J 37828 1 Internal Snap Ring Pliers 2 External Snap Ring Pliers 3 Seal Seat Remover lnstaller 4 O Ring Seal Remover lnstaller 5 Seal Protector 6 Driver Handle 7 Seal Remover lnstaller 8 Puller Plate Assembly 9 Clutch Face Installer 10 Puller Pilot 11 Puller Fingers 12 Bearing Remover lnstaller 13 Spanner Wrench 12 J 37829 13 J 37872 F9373 ...

Page 43: ...emoved If a fastener needs to be replaced use the correct part number fastener for that application If the correct part number fastener is not available a fastener of equal size and strength or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above...

Page 44: ...3B1A 2 POWER STEERING GEAR UNIT REPAIR Figure 1 710 Power Steering Gear ...

Page 45: ...PIN 34 RACE THRUST BEARING WORM V 35 BEARING ASM ROLLER THRUST WORM 36 RACE THRUST BEARING WORM 37 SEAL O RING RELIEF VALVE 38 PLATE BYPASS 39 SEAL O RING RELIEF VALVE 40 VALVE ASM RELIEF 41 SEAL PITMAN SHAFT DUST 42 RING RETAINING PITMAN SHAFT SEAL 43 WASHER SEAL BACK UP PITMAN SHAFT 44 SEAL PITMAN SHAFT 45 BEARING ASM NEEDLE PITMAN SHAFT 46 GUIDE BALL RETURN 47 CLAMP BALL RETURN GUIDE 48 SCREW A...

Page 46: ...tub shaft 31 clockwise until rack piston 50 bottoms in housing 6 Align the end tooth of the pitman shaft 5 with the center groove of the rack piston 50 and 7 see Figure 7 Turn stub shaft 31 counterclockwise until the plug 12 separates from the housing 6 8 Secondary rack piston 7 see Figure 7 Important Do not remove the plug 8 from the rack piston 7 during this procedure Remove only for replacement...

Page 47: ...h races 34 and bearing 35 14 Worm shaft 33 from valve assembly 15 Races 34 and bearing 35 from worm shaft 33 Important Do not attempt to reuse damaged or worn parts by w elding or having them straightened Replace all bent broken or worn parts Clean All parts in a clean solvent and blow dry A HAMMER B DRIFT 14 NUTrADJUSTER PLUG LOCK Figure 8 Loosening Adjuster Plug Lock Nut Figure 7 Aligning Pitman...

Page 48: ...gear housing 1 Retainer ring 15 see Figure 10 2 Dust seal 16 3 Seal 17 Pry with a screwdriver from the bore of the adjuster plug 19 Do not scratch or score the seal bore see Figure 11 4 Retainer 25 Pry the retainer at the two raised areas see Figure 12 5 Spacer 24 6 Race 23 1 7 Bearing 22 8 Race 21 9 Seal 20 10 Needle bearing 18 if necessary Use J 8524 2 and J 7079 2 see Figure 13 Figure 12 Bearin...

Page 49: ...ed J 8524 1 Bearing Installer J 7079 2 Driver J 4245 Internal Snap Ring Pliers 1 New needle bearing 18 if required Place the new bearing over tools J 8524 1 and J 7079 2 with the manufacturer s ID against the tool Place a block of wood under the adjuster plug 19 then press the bearing into the adjuster plug until it bottoms see Figure 15 Lubricate seal 17 with power steering fluid 2 Seal 17 use to...

Page 50: ...r hub 7 Bearing 22 8 Small race 23 9 Spacer 24 with the grooves of the spacer away from small race 23 see Figure 18 10 New bearing retainer 25 Tap on the flat surface of the retainer see Figure 19 Important The retainer projections must not extend beyond the spacer when the retainer is seated The spacer must be free to rotate 22 BEARING ASM UPPER THRUST 23 RACE UPPER THRUST BEARING SMALL 24 SPACER...

Page 51: ...rn or broken replace the complete valve and shaft assembly Torsion bar and stub shaft 31 for leaking If there is leaking replace the valve assembly see Figure 23 Ground surface of the stub shaft 31 If a crocus cloth cannot clean the nicks or burrs replace the valve assembly Outside diameter of the valve spool and inside diameter of the valve body 28 If a crocus cloth cannot clean the nicks or burr...

Page 52: ...haft cap should be below the valve body notch see Figure 25 11 N Lubricate a new shaft cap to the seal 32 j New shaft cap and seal 32 into the valye body 28 assembly PITMAN SHAFT AND SIDE COVER Figure 1 l Inspect Bearing in side cover 3 Needles should rotate freely using finger pressure Replace bearing and side cover 3 if necessary j j Bearings surface in the side cover 3 for scoring Replace side ...

Page 53: ...aces 34 for scoring and excessive wear Rack piston 50 teeth and external ground surfaces for scoring or excessive wear If condition exists replace the rack piston 50 and worm 33 Assemble 1 New Seal 9 and ring 10 to rack piston 50 Lubricate new seal 9 and ring 10 with power steering fluid Figure 27 Placing Balls in the Ball Return Guide A INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING WORM COUNTE...

Page 54: ...actor may be used to remove the connectors 4 4 Install or Connect 1 New flare connectors 51 Drive connector seats in place using tool J 6217 see Figure 29 PITMAN SHAFT BEARING AND SEAL REPLACEMENT Figure 30 Tools Required J 4245 Internal Snap Ring Pliers J 24655 Bearing Installer and Remover J 8092 Handle NOTICE When removing seals be careful not to score the housing bore or leakage may result Dis...

Page 55: ...sing until it seats against the valve body 28 Adjust 1 Bearing preload Use tool J 7624 01 Turn the adjuster plug 19 clockwise until the plug and bearing 22 are firmly bottomed about 27 N m 29 lb ft Mark the housing in line with one of the holes in the adjuster plug Measure back counterclockwise 13 mm 1 2 inch and re mark the housing see Figure 35 Rotate the adjuster counterclockwise until hole in ...

Page 56: ...wed it will bis impossible to eliminate lash between the primary gear teeth i Install a new seal 3 on the side cover iirid lubrjicate with power steering fluid Push the side cover 3 into the housing 6 until the adjuster screw on pitman shaft 5 1 contacts the cover j Insert a hex wrench through the cover into the adjuster screw and turn it counterclockwise until the cover bottoms on the housing The...

Page 57: ... and bearing preload by turning the torque wrench through the center of travel and recording the highest reading 4 Tighten the adjusting screw on pitman shaft 5 until the torque wrench reading is 0 7 1 1 N m 6 19 lb in higher than the reading recorded in step 3 The total reading should not exceed 2 25 N m 20 lb in torque NOTICE See Notice on page 1 of this section 5 Tighten the nut 1 to 90 N m 66 ...

Page 58: ...ing torque wrench back to vertical Subtract this reading from reading taken in step 5 If the reading in step 5 is 0 23 N m 2 lb in then the gear is adjusted properly Go to step 7 If less than 0 23 N m 2 lb in proceed with the following adjustments If the reading in step 5 is at least 0 23 N m 2 lb in arid not more than 1 13 N m 10 lb in the gear is in proper adjustment Proceed with adjustment in s...

Page 59: ...ockN u t 108 N m 80 lb ft 19 Adjuster Plug and 22 Bearing 27 N m 29 lb ft 40 Relief Valve 47 N m 35 lb ft 48 Lockwasher Screws 8N m 6 lb ft ADJUSTMENT TIGHTENING SPECIFICATIONS 5 Pitman Shaft Over Center Preload New Gear 0 7 1 1 Nrnri 6 19 lb in Used Gear 0 5 0 6 N m 4 5 lb in 5 Pitman Shaft Final Over Center Reading Total Maximum New G ear 2 3 N m 201b in Used Gear 1 6 N m 141b in 35 Worm Shaft T...

Page 60: ... 1 14 J 8524 2 1 RACK PINION ARBOR 2 SEPARATOR PLATE 3 BEARING INSTALLER AND REMOVER 4 SEAL AND BEARING INSTALLER 5 SEAL AND BEARING REMOVER 6 INTERNAL SNAP RING PLIERS 7 VALVE CONNECTOR SEAT INSTALLER 8 SHAFT SEAL PROTECTOR 9 DRIVER 10 SPANNER WRENCH 11 0 2 8 N m 0 25 lb in TORQUE WRENCH 12 HANDLE 13 bearing SEAL INSTALLER 14 BEARING REMOVER ...

Page 61: ...or stronger may be used Fasteners that are not reused and those requiring thread locking compound will be called out The correct torque value must be used when installing fasteners that require it If the above conditions are riot followed parts or system damage could result CONTENTS V 3B1B 2 End Plate Rotating Group 0 Ring Seals Needle Bearing Assembly 3B1B 4 3B1B 3 Specifications 3B1B 6 3B1B 4 Fa...

Page 62: ......

Page 63: ...ools Required J 7728 Seal Installer Remove or Disconnect 1 Pump assembly from vehicle Reservoir cap assembly 25 from reservoir assembly 23 Drain oil from reservoir 23 2 Retaining ring internal 3 drive shaft 1 woodruffkey 2 and ball bearing assembly 4 and retaining ring external 5 as an assembly from pump housing assembly 9 Ring external 5 bearing 4 and key 2 from shaft 1 3 Drive shaft seal 6 using...

Page 64: ... 9 Clean AH parts in power steering fluid Dry parts 0 1 2 3 4 Install or Connect Magnet 29 to pump housing assembly 9 Lubricate new O ring seals 8 and 10 with power steering fluid Seals 8 and 10 to housing 9 Reservoir assembly 23 to housing 9 Lubricate two new Oaring seals 24 with power steering fluid Two seals 24 to two studs or bolts 26 I Two studs or bolts 26 and reservoir 23 to housing 9 Tight...

Page 65: ...plate 15 and rotor 16 to shaft assembly 1 Counterbore of thrust plate 15 and rotor 16 must face drive shaft end of housing 9 8 Pump vanes 17 to rotor 16 9 Ring 18 overpins 14 Identification arrow on top edge of ring 18 facing up 10 Lubricate pressure plate 19 with power steering fluid Plate 19 to housing 9 11 Lubricate end plate 21 with power steering fluid Spring 20 and plate 21 to housing 9 12 R...

Page 66: ...IONS FASTENER TIGHTENING SPECIFICATIONS 3B1B 6 MEDIUM DUTY TRUCK STEERING PUMP UNIT REPAIR P Series Heavy Duty 28 Connector Fitting Assembly 55 N m 401b ft 26 Reservoir Stud or Bolt 48 N m 35 lb ft SPECIAL TOOLS ...

Page 67: ... Ball Bearing Direct Drive Design Bushing Direct Drive Design Specifications Fastener Tightening Specifications 3B2 1 3B2 1 3B2 1 3B2 2 3B2 2 3B2 4 3B2 4 3B2 4 3B2 5 3B2 5 3B2 6 3B2 6 3B2 6 3B2 6 3B2 6 3B2 7 3B2 7 GENERAL DESCRIPTION The Midland BB Series power steering pump is a pump was tested after assembly is stamped on a hex hydraulically balanced roller vane assembly with a pres plug near th...

Page 68: ...assembly to a bench vise PULLEY TYPE PUMP1 2 3 Remove or Disconnect 1 Bolt 159 and washers 160 and 161 2 Pulley 162 with an appropriate puller If a puller is not available suspend the pump freely by sup porting the pulley rim only and carefully drive the shaft from the pulley hub Seat bolt in shaft and tap bolt head to loosen pulley and prevent damage to the shaft 3 Key 165 from the shaft 166 DIRE...

Page 69: ...th the cover figure d 7 Discharge fitting and seal from the bushing cover some models 8 Valve cap 193 9 Seal 192 10 Spring 191 and combination flow control and relief valve 190 from the bushing cover 188 Shake or gently strike the casting on wood or pad ded surface Do not use metal tools or any instru ment that may cause valve bore damage 11 Seals 185 and 187 figure 3 12 Roller vanes 184 from the ...

Page 70: ... and 179 by sliding the parts out of the pump body pocket 3 Seal 167 from the bushing body 169 Use a small punch placed against the Seal from the cam pocket side figure 6 CLEANING INSPECTION AND REPAIR Clean All parts with clean solvent and blow dry Inspect Figures 1 and 7 Shaft bushing for excessive burning scoring or oversize condition The bushing is NOT serviceable as a separate component Beari...

Page 71: ... 190 assembly It is difficult to visually determine if internal valve components are faulty Low pressure may be a sign for valve replacement The valve must move smoothly in the valve bore Minor polishing of the valve OD with the maximum material removal of 0 002 mm 0 000T inch is acceptable BEARING REPLACEMENT Disassemble Figure 1 Shaft 166 from the bearing 164 using an arbor press Assemble Figure...

Page 72: ...using caution not to damage the shaft seal lip C Install the snap ring 163 figure 8 2 New seals 178 and 179 A Install seal 178 into the bottom of each kidney shaped seal gland in the end plate 177 B Install the square cross section seal 179 into each gland on top of seal 178 All seals fit tightly to the gland wall 3 End plate 177 with seals 178 and 179 and locat ing pin 176 into the body as noted ...

Page 73: ...e gasket or seal at this time Clamp the pump mounting bracket or flange in a bench vise DO NOT distort the sealing sur face of the flange mounting Tighten Bracket mounting bolts to 48 Nm 35 ft lbs Valve cap to 65 N m 48 ft lbs Discharge fitting to 52 N m 38 ft lbs Inspect Figure 1 Shaft 166 should rotate freely and smoothly Maximum turning torque is 1 13 N m 10 in lbs 10 New seal 173 on the mounti...

Page 74: ...ing ball mechanism tries to move the rack piston axially through the gear housing cylinder bore The axial movement of the rack piston is resisted by its engagement to the sector shaft which is connected by linkage to the steered wheels Because of this resis tance the torsion bar is twisted by the input shaft thereby actuating the control valve Pressurized fluids directed by the control valve assis...

Page 75: ...3B3 2 POWER STEERING COMPONENTS TRW ROSS ...

Page 76: ...ns and bolt groove on the sec tor shaft with ONE LAYER of masking tape The tape should not extend onto the sector shaft bearing diameter 4 Six bolts 52 from the side cover 50 These bolts are equipped with a ring on the underside of the head If any bolt is replaced it should be replaced with the same special type and length as that which was removed 5 Side cover 50 and sector shaft 46 from the gear...

Page 77: ... 30 and seal 29 Notice Do not remove the input shaft valve worm assembly or balls from the rack piston until the ball return guides are removed or damage to the ball guides will occur 17 Ball return guide halves 28 Insert a small screwdriver between the rack pis ton and guides 18 32 steel balls 27 Rotate the the input shaft until the balls fall out The steel balls are a matched set If any are lost...

Page 78: ...ing roughness or unless worm preload adjustment is required Figure 7 Removing the Bearing Adjuster and Jam Nut 0 Remove or Disconnect Figures 1 2 and 7 Tools Required J 37070 Adjuster Tool J 37464 Adjuster Jam Nut Tool Place the valve housing and input shaft assembly in a vise with the worm shaft vertical figure 7 Unstake the valve housing where it was upset into the adjuster locknut slot using a ...

Page 79: ...or equivalent meeting GM Spec No 9985010 power steering fluid Failure to use the proper fluid will cause seal damage and fluid leaks Important Lubricate all seals and internal components with power steering fluid Before assembly VALVE HOUSING AND INPUT SHAFT ASSEMBLY M Install or Connect Figures 1 and 2 Tools Required J 37070 Adjuster Tool J 37464 Adjuster Jam Nut Tool 1 Valve housing in a vise so...

Page 80: ... cover end of the bearing bore 2 Roller bearing 35 if removed from the trunnion end of the bearing bore pressing bearing installa tion end of J 37071 against the lettered end of the bearing shell until the bearing is seated against the retaining ring i Lubricate the bearing bore I Make sure that the housing is square with the press base and that the bearing is not cocked 3 Washer 38 into the side ...

Page 81: ...k pistOri Line up the rack piston ball guide holes with the worm ball track grooves Rotate input shaft slightly if necessary Do not seat the guides with a hammer 13 32 balls into the ball return guides If a new rack piston or input shaft valve worm assembly is being used the balls removed from the unit must discarded and a service ball kit usedi The balls in a service ball kit are sized to functio...

Page 82: ...al 39 on J 37071 so the side with the spring is toward the tool 26 J 37071 into the side cover bushing Press the seal into the side cover housing with a force of 46 to 362 kg 100 to 800 lbs until it is seated against the bottom of the counterbore 27 Sector shaft into the side cover Lightly oil the short bearing area of the sector shaft Screw in the sector shaft adjusting screw coun ter clockwise u...

Page 83: ...at 1 1 2 revolu tions from the center position without the gear installed on the vehicle could make the auto matic pbppets inoperative when the gear is installed This would require disassembly of the a special service poppet adjusting screw kit and manual adjustment procedures Initial poppet contact will occur at less than one input shaft rotation in one direction from the Steering gear center pos...

Page 84: ... 54 Sector Shaft Adjust Screw Jam Nut 51 Special Side Cover Bolts 52 Special Side Cover Bolts 52 if Lubricated Valve Housing Bolts 1 Valve Housing Bolts 1 if Lubricated ln Lbs N m Ft Lbs 25 18 41 30 154 112 25 18 3 3 o CO 55 40 13 120 55 40 41 30 57 42 312 230 232 170 149 110 109 80 T2876 SPECIAL TOOLS J 37612 A J 36452 A POPPET DISASSEMBLY TOOL J 37070 SPANNER WRENCH J 37071 SEAL INSTALLER J 3707...

Page 85: ...g clean tools and equipm ent D irt o r g rit w ill damage the machined surfaces and result in leakage or damage to the pump The hydraulic system should be disassembled inspected cleaned and flushed before servicing is complete Important To ensure correct reassembly record or mark all information as specified in the procedure Place parts in an orderly manner on the kraft paper to avoid mixing the p...

Page 86: ...aft 4 Remove shaft by gently tapping end of shaft out though the flange 5 9 Shaft seal 2 10 Adjusting ring 3 7 4 Side plate 9 ring 10 dowel pins 8 rotor 11 with vanes 12 and pressure plate 13 CLEANING An d in s p e c t io n Clean Figure 1 All parts must be thoroughly cleaned and kept clean during inspection and assembly The close tolerancejs of the parts makes this requirement more stringent than ...

Page 87: ...haft seal is installed without damage Position shaft seal 2 with spring or open side of the seal facing the pump side of the flange Press the seal into place until it engages the shoulder within the flange This shoulder acts as a positive stop for the shaft seal NOTICE Do not overpress shaft seal as dam age to the shaft seal will result 4 Install the snap ring 1 into flange groove 5 Q rings 15 and...

Page 88: ...B2 4 Specifications 4B2 6 Fastener Tightening Specifications 4B2 6 GENERAL DESCRIPTION TWO SPEED AXLE ELECTRIC SHIFT UNIT The electric shift unit consists of a pre loading spring actuator that is driven by an electric motor When the axle range switch is moved into either HIGH or LOW position the electric motor compresses the spring actuator until a limit switch stops the motor When the driving loa...

Page 89: ...ems at low temperature conditions Use an RTV sealant GM P N 1052366 or equivalent on all sealing surfaces where noted 1 Cam pins 8 Apply a light coat of lubricant to each pin before assembly Lubricate the washer gear teeth and shaft 2 Washer 12 gear and shaft 11 3 Nut 13 Tighten Nut to 8 5 Nm 75 in lbs Hold the gear end of the shaft with pliers while tightening the nut Inspect Rotate the gear to b...

Page 90: ...10 Washer 5 11 Circuit board 3 A Connect the black motor lead to the male termi nal in the center of the circuit board B Install the circuit board on the gear shaft 12 Nut 4 Tighten Nut to 1 7 N m 15 in lbs Figure 4 Circuit Board Wire Connections 13 Cover 1 Connect the three circuit board wires as follows A Black Wire 18 to the terminal nearest the edge of the cover B Green Wire 20 to the center t...

Page 91: ...s 2 Cylinder bore for wedr or scoring 3 Pistpn 19 for wear or hardness 4 Felt rings 20 for wear or hardness 5 Sekl 21 for wear or hardness 6 Spring 3 for distortion or corrosion 7 Push rod 2 for out of round holes wear or dam age 8 Actuating lever 8 for wear or damage 9 Bushings 7 and 10 for wear or damage ASSEMBLY I I Install or Connect NOTICE For steps 7 13 and 16 see NO TICE on page 4B2 1 1 SAE...

Page 92: ...e spring 10 Clevis pin 9 at the push rod and actuator arm joint 11 Housing cover gasket 15 12 Housing cover 14 13 Cover screws 12 and washers 13 l Tighten Screws to 11 5 N m 100 in lbs 14 Cylinder cover seal 24 15 Cylinder cover 25 16 Cylinder cover bolts 5 and nuts 26 Tighten Nuts to 14 0 N m 120 in lbs 17 Filler plug 11 The oil will be put in after the shift unit is installed on the axle ...

Page 93: ...m In Lbs Gearshaft Nut 8 5 75 Housing Screw 12 105 Motor to Housing Screw V 6 50 Circuit Board Nut 1 7 15 Cover Screw 6 j50 t T2287 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Na m In Lbs Piston Nut 23 15 5 135 Cover Screws 12 11 5 100 Cylinder Cover Bolts 5 14 0 120 T2288 ...

Page 94: ...e it If the above conditions are not followed parts or system damage could result NOTICE Do not hone the master cylinder bore When the brake master cylinder is overhauled it is recommended that the cylinder body be replaced rather than cleaned up by honing the bore The master cylinder has a hard highly polished bearingized surface that is produced by diamond boring followed by ball or roller burni...

Page 95: ...ble force and cause L personal injury 17 Secondary piston 23 It may be necessary to plug the front outlet port and apply a small amount of air pressure to the front compensating valve port 18 O ring seal 21 19 Seal backup 22 20 O ring seal 25 21 Seal backup 24 22 Secondary actuator spring 12 23 Secondary actuator 11 24 Caging bolt 10 25 Secondary piston return spring 9 g Glean All riibber parts wi...

Page 96: ...g Bolt 11 Actuator Secondary 12 Actuator Spring Secondary 13 Snap Ring 14 Primary Piston 15 Seal Backup 16 O Ring Seal 17 Actuator Spring Primary 18 Actuator Primary 19 Retaining Ring 20 Piston Return Spring Primary 21 O Ring Seal 22 Seal Backup 23 Secondary Piston 24 Seal Backup 25 O Ring Seal 26 Bolts 27 Tube Seats 28 Stop Pin 29 O Ring F9361 Figure 1 Bendix Tandem Master Cylinder Components ...

Page 97: ...on the vehi cle fird j j y 1 Plugtthp outlet ports and mount the master cylinder in a ise with the front end tilted slightly down 2 Fiij tlie reservoir with clean brake fluid 3 Usd japsmooth round end tool and stroke the pri maryj piston about 25 mm 1 inch several times I Astdir is bled from the master cylinder resis aripe to primary piston travel will not allow the full 25 mm 1 inch stroke y 4 Re...

Page 98: ...ster head is controlled by brake pedal movement Fluid from the power steering pump enters the boost er at the inlet port flows through the control valve and seat leaves through the outlet port and flow switch and returns to the power steering pump The hydraulic booster cylinder rod attaches to a pis ton that contains the control valve seat This assembly moves when brake pedal pressure is applied A...

Page 99: ... o n a l i n j u r y f r o m t h e e n d c o v e r a n d s p r i n g r a p i d l y b e i n g r e l e a s e d f r o m t h e b o o s t e r b o d y insert a rod 13 InStail two 10 mm x 1 5 x 80 mm 3 inch bolts that are iftlilly threaded and have nuts installed on them in opposite corners of the master cylinder mounting hpjejsj jjfigure 2 14 Fingeri tighten the bolts in the mounting hojes 15 Fingef tig...

Page 100: ...witch 15 Flow Switch Q Ring 16 Relief Valve Stem 17 Relief Valve Spring 18 Power Piston Seal 19 Power Piston 20 Return Spring 21 Seal Expander 22 Cylinder Seal 23 Output Push Rod Piston Rod 24 Cover Screw 25 End Cover 26 Piston Rod Seal 27 Support Plate 28 Bracket Bolt and Washer 29 ID Tags 30 O Rings 31 Pump Mounting Bolt and Washer 32 Electro Hydraulic Pump 33 Pushrod 34 Retainer r 35 Mounting S...

Page 101: ...5P2 4 HYDRAULIC BOOSTER Figure 5 Removing the Seal Plug Figure 3 Removing the End Cover Assembly ...

Page 102: ...l damage Machined surfaces for scoring burrs or corrosion Replace any damaged parts I Install or Connect Figures 1 and 6 through 10 Tools required J 28681 Seal Installer J 8092 Handle NOTICE For steps 24 and 25 see Notice on page 5D2 1 1 Lubricate the seals and cylinder bores with clean power steering fluid only Figure 7 Installing the Control Valve Snubber ...

Page 103: ...ure 8 9 1 0 1 1 1 2 1 3 1 4 1 5 9 Valve return spring i 10 Seal 18 into the groove of the piston assembly 19 s 11 Piston assembly into the body bore Make sure the seat faces into the bore figure 9 12 Return spring 20 13 Seal expander 21 14 Xylinder seal 22 15 Cover support plate 27 26 Seal 25 End Plate B5739 Figure 10 Piston Rod Seal and End Cover 16 Seal 26 into the end cover 25 tiTfie seal lips ...

Page 104: ...ushrod Length 6 Press down firmly to make sure the rod is seated 7 After substitution recheck the piston rod extension using J 24866 8 Repeat the procedure as needed to bring the pis ton rod extension within limits SPECIFICATIONS HYDRAULIC BOOSTER Make Delco Moraine Bore v 76 2 mm 3 Pushrod Travel Minimum 60 35 mm 2 376 Pressure Relief 4 136 5 171 kPa 650 750 psi Mounting Studs Thread M10x1 5 End ...

Page 105: ...502 8 HYDRAULIC BOOSTER SPECIAL TOOLS r 1 C m i J 24866 V V 2 fl 4 J 26243 3 4 c S g i i J 28661 J 8092 1 Rod Height Gage 2 Seal Remover 3 Seal Installer Control Valve 4 3 4 Driver Handle F9146 _ v j ...

Page 106: ...rs CRBrakemaster Bendix AD 9 Air Supply Valves Bendix PP 1 Bendix PP 7 Bendix PP 8 Dual Application Valve Bendix E 6 Front Axle Limiting Ratio Valve Bendix LQ 4 Check Valves Bendix SC 2 Single Check Valve Bendix DC 4 Double Check Valve Moisture Ejector Valve Bendix DV 2 Pressure Protection Valve Bendix PR 2 Quick Release Valve Bendix QR N Relay Valves Bendix R 14 Bendix Proportioning Relay Valve B...

Page 107: ... 27 Gaskets 3 njj Clean All parts in mineral spirits or another suitable sol vent All gasket sealing surfaces Inspect Valve seats for scratches or burrs M Install or Connect Figure 1 NOTICE For steps 4 13 23 and 30 see No tice on page 5H 1 1 Gaskets 3 2 Deflector assembly 2 3 Bottom cap 4 to the body 1 4 Eight bolts 5 Tighten Bolts 5 to 20 Nrn 15 ft lbs 5 Packing ring gasket 14 in body 1 6 Filter ...

Page 108: ...metal parts for severe corrosion pitting and cracks Nut 13 to 81 N m 60 ft lbs 24 Remove the rod 25 Ball 24 26 Copper gasket 25 27 Check valve spindle 26 28 Spring 27 29 Copper gasket 28 30 Top nut 29 Tighten Nut 29 to 81 N m 60 ft lbs Minor corrosion and or pitting on the exterior of the upper and lower cases is allowed Bores of the end cover and purge valve housing for deep scuffing or gouges Re...

Page 109: ...NT V3020 Figure 2 Bendix AD 9 Air dryer Tighten Nut 18 to 8 N m 70 in lbs G O rings 7 8 and 9 3 Purge valve assembly 21 to end cover 4 Bolts 16 Tighten 4 10 O rihg 28 11 Housing 1 12 Bolts 6 and 24 washers 3 and nuts 2 Tighten Nuts 2 in sequence figure 3 to 38 N m 28 ft lbs Bolts 16 to 12 N m 100 in lbs 5 O ring 22 ori check valve 6 Check valve 23 Tighten Check valve 23 to 26 N m 19 ft lbs 7 O rin...

Page 110: ... 10 8 O ring 6 and cover 7 NOTICE See Notice on page 5H 1 9 Washers 9 and bolts 8 BENDIX PP 7 Remove or Disconnect Figure 5 1 Mark the upper and lower body halves to aid iri assembly 2 Bolts 53 and waShers 5 V 3 Separate the body halves 4 Seal ring 54 5 End plate 52 6 O ring 51 i 7 Control piston 49 8 O rings 50 and 48 9 Piston return spring 47 c 10 Snap ring 41 11 Sea retainer 42 12 O ring 43 1 1...

Page 111: ...t exhaust valve 45 9 Return spring 44 10 O ring 43 11 Seal retainer 42 12 Snap ring 41 13 Piston return spring 47 14 O ring 48 and 50 on control piston 49 15 Control piston 49 16 O ring 51 17 End plate 52 18 Seal ring 54 19 Piston valve bodies together NOTICE See Notice on page 5H 1 20 Washers and bolts 53 BENDIX PP 8 Remove or Disconnect Figure 6 1 Bolts 21 and washers 22 2 Cover1 23 and O ring 2...

Page 112: ...embly refer to Figure 10 and note that a nylon insert nut and stem are used to contain the No 1 piston return spring stem spring and relay piston spring The combined force of these springs is approximately 22 7 kg 50 pounds and care must be used when remov ing the nylon insert nut as the spring forces will be released Manually or mechanically restrain the relay piston and the No 1 piston while the...

Page 113: ...haust Valve Assembly iO O ring Retainer t 1 30 Adapter Spacer Some Models i 1 No 2 Inlet Exhaust 31 Adapter to Upper Body Bolt Washer Valve Spring 32 No 1 Primary Piston Retainer 12 No 2 Inlet Exhaust 33 Nylon Insert Nut Valve Retainer 1 34 Spring Guide 13 No 2 Inlet Exhaust 35 Stem Spring Valve Assembly V 36 Spring Seat Nut r 14 Cap Screw Washer 37 Spring Seat 15 Lower Body 38 Rubber Spring 16 Lo...

Page 114: ...taining ring 22 13 Relay piston 18 and O ring 19 AIR BRAKE VALVES SH 9 Figure 11 Installing the Rubber Washer CAUTION Before proceeding with the assem bly refer to Figure 10 and note that the nylon insert nut and stem are used to contain the No 1 piston return spring stem spring and the relay piston spring The combined force of these springs is approximately 22 7 kg 50 pounds and care must be take...

Page 115: ...ng 39 No 1 Piston 43 Upper Body B5761 Figure 12 Relay and No 1 Primary Pistons i j i Figurei3 Compressing the Valve FRONT AXLE LIMITING RATIO VALVE BENDIX LQ 4 Remove or Disconnect Figure 14 1 Mark the cover and body for assembly 2 Four screws 1 and washers 2 3 Separate body 14 and cover 3 4 Piston spring 13 5 Piston assemblies 5 and 11 6 Separate the two pistons 7 O ring 4 from upper piston 5 8 R...

Page 116: ...BENDIX SC 2 SINGLE CHECK VALVE Remove or Disconnect Figure 15 1 Screw cap 7 2 Identification washer 6 3 Spring 5 4 Disc valve 4 5 Valve seat 3 6 Washer 2 Clean All metal parts in mineral spirits or another suitable solvent Inspect The valve seat for evidence of deterioration or hardening Replace as needed The valve disc for smoothness and corrosion Replace as needed The valve cap and body for dama...

Page 117: ...ilicone Lube GM P N 18010909 or equivalent _ 2 Guide 16 3 Shuttle 15 4 O ring 14 5 Cap 13 N O TIC E See N o tice on p ag e 5H 1 6 Washers 12 and bolts 11 MOISTURE EJECTOR VALVE 4 4 BENDIX DV 2 Remove or Disconnect Figure 17 If the heater element has failed the entire cover must be replaced 1 Four bolts 1 and washers 2 2 Cover 3 3 O ring 4 4 Valve 6 and valve guide 5 5 Adapter 10 6 Filter 9 7 Filte...

Page 118: ...ts or another suitable sol vent I Inspect Springs for cracks and corrosion Replace as need ed Piston and piston bore for scoring and burrs Replace as needed Install or Connect Figure 18 1 1 Lubricate seals piston and body bore with Delco Silicone Lube GM P N 18010909 Or equivalent Use only new seals and valves from the repair kit 2 Valve stem 8 in piston 7 3 O ring 9 on piston plug 10 4 Piston plu...

Page 119: ...er to the body 2 Cap nut 13 3 Seal 14 4 Diaphragm 15 5 Four bolts 12 and washers 11 6 Cover 10 7 Piston 8 8 O ring 9 9 Snap ring 1 10 Exhaust valve body 2 11 Seal 3 12 Spring 4 13 Modulation tube 6 14 Seal retainer 5 All components in mineral spirits or another suit able solvent Inspect The valve seats for nicks and burrs Repair or replace as needed The spring for cracks and corrosion Replace as n...

Page 120: ...iston 63 and relay piston spring 65 The relay piston spring 65 is not used in all valves 10 O ring 64 from relay piston 63 11 Dust shield 67 and retaining ring 66 12 Exhaust piston 68 13 Exhaust piston O ring 69 and exhaust diaphragm 70 14 Service piston 71 15 Service piston O ring 72 from service piston 71 16 Spring 73 and spring cage 74 17 Blend back piston 75 18 O rings 76 and 77 from blend bac...

Page 121: ...5H 16 AIR BRAKE VALVES Figure 21 Bendix Proportioning Relay Valve Components ...

Page 122: ... 4 Small end of spring 85 over rubber on valve 84 Make sure the spring coils rest on the valve s four tabs 5 Spring 85 and valve 84 in valve seat 83 Make sure the four tabs are in the seat s bore 6 Valve 84 seat 83 and spring 85 assembly in proportioning piston 79 Large end of spring 85 first 7 Retaining ring 81 to secure seat 88 in propor tioning piston 79 8 O rings 78 and 80 on proportioning pis...

Page 123: ...gure 23 1 Body 4 from cage 2 2 Ball valve 3 i 3 Release pin 1 4 Spring 6 S 5 3 Clean All parts in mineral spirits or another suitable Sol vent Install or Connect Figure 23 1 Spring 6 in cage 2 2 Release pin 1 3 Ball valve 3 N O TIC E See N o tic e on page 5H 1 4 Body 4 Tighten Body 4 to 16 N m 12 ft lbs r 1 Release Pin 2 Cage 3 Ball Valve 4 Body 5 Exahust Port 6 Spring B6042 Figure 23 Bendix ST 3 ...

Page 124: ...0 Guide 11 Check Valve 12 Inlet Exhaust Valve 13 Valve Retainer 14 Spring 15 O Ring 16 0 Ring V 17 O Ring Retainer 18 Retainer Ring 19 Exhaust Cover 20 Screw 21 Diaphragm 22 Cap 23 O Ring 24 Stop 25 Spring 26 Valve Disc 27 Body 28 O Ring 29 O Rihg 30 Piston 31 Piston Spring 32 Inlet Exhaust Valve Assembly 21 B1559 Figure 24 Bendix SR 1 Spring Brake Control Valve ...

Page 125: ...etal moving surfaces with Delco Silicone Lube GM P N 18010909 or equivalent Use only new rubber seals from the repair kit 2 Piston 30 and O rings 29 and 28 3 Spring 31 4 Piston 5 and O rings 6 and 7 5 Inner piston spring 4 6 Outer piston spring 3 7 Cover 2 8 Four cover screws 1 and washers Q Tighten Screws 1 to 7 3 N m 65 in lbs 9 Valve disc 26 10 Springs 25 11 Stop 24 12 Cap 22 and O ring 23 Tigh...

Page 126: ...r suitable solvent r V inspect The shuttles and guides for wear scoring or burrs Install or Connect Figures 25 and 26 1 Lubricate seals plunger and valve bores with Del co Silicone Lube GM P N 18010909 or equiva lent Use only hew seals from the repair kit 1 TP Cap 2 O ring 3 O ing 4 Valve Plunger Piston 5 O ring 6 Valve Spring 7 TC Cap 8 O ring 9 Guide 10 Shuttle 11 Body 12 Valve Disc 13 Spring 14...

Page 127: ...3 O ring 43 4 Head 45 5 Seal 46 6 Lock ring 47 7 Screws 62 8 Cover 49 9 Gasket 50 10 Lever cam 51 11 Spring 52 12 Piston 53 13 O ring 54 14 Spring 55 15 Valve 56 16 Spring retainer 57 17 Spring 58 18 Stem 60 19 Valve 61 Clean Gasket material from the body and cover surfaces All parts in mineral spirits or another solvent Inspect Piston iapd piston bore for scoring and corrosion Install or Connect ...

Page 128: ...elivery pressure it can be adjusted 1 Remove the head 5 and lock ring 7 2 Rotate the adjusting ring to the right to raise the delivery pressure 3 If the delivery pressure is above the specified final delivery pressure rotate the adjusting ring to the left to lower the pressure TWO WAY CONTROL VALVE BENDIX TW 1 Kfl Clean Remove or Disconnect Figure 28 All metal parts in mineral spirits or another s...

Page 129: ...olts Bendix AD 9 ChecK Valve Bendix AD 9 Housing Nuts Bendix QR 1C Cover to Body Bolts Bendix QR 1C Cap Nut Bendix PP 7 Bolts Bendix E 6 Nylon Insert Nut Bendix E 6 Lower Body to Upper Body Bolts Bendix LQ 4 Cover to Body Bolts Bendix R 14 Cover to Body Bolts Bendix R 14 Cap Nut Bendix BPR 1 Exhaust Cover Screw Bendix BPR 1 Cover to Body Screw Bendix ST 3 Body Bendix SR I Cover Screws Bendix Rt1 C...

Page 130: ... Fastener Tightening Specifications 51 8 AUTOMATIC SLACK ADJUSTER ROCKWELL 4 Remove or Disconnect Figure 1 1 Pressure relief cap screw 17 2 Gasket 18 3 Spring 19 4 Pawl 20 5 Clamp 1 6 Boot 2 7 Adjusting sleeve 7 from housing bore by pulling on actuator rod 3 8 Spiral ring 4 Push down on the side of the ring figure 2 9 Actuator rod 3 10 Piston pin 5 figure 3 11 Piston 6 12 Worm grease seal 14 figur...

Page 131: ...Retaining ring 11 5 Worm gear 12 It may be necessary to turn the gear counter clockwise 6 Snap ring 13 7 Worm grease seal 14 figures 5 and 6 The metal seal retainer must face inward i Use a sleeve or other suitable tool to install the seal until it bottoms in the bore 8 Piston 6 on actuator rod 3 9 Piston pin 5 10 Actuator rod 3 in adjusting sleeve 7 11 Spiral ring 4 12 Adjusting sleeve 7 in housi...

Page 132: ... pressure relief cap screw The Rockwell grease specification is 0 616 A and the following grease is suitable Texaco Termotex EP 1 Shell Darina 1 This grease is recommended for vehicles operating in temperatures to 29 C 20 F For vehicles operating in temperatures below 29 C 20 F contact Rockwell International for grease recommendations Figure 6 Installing the Grease Seal ...

Page 133: ...slack adjuster with a welded cover is not repairable 1 Rivets A Cut off the ends of the rivets 1 figure 9 B Drive put the rivets figure 10 2 Covers 3 3 Expansion plug 6 from the end of the worm bore 4 Worm shaft 10 Drive it but with a punch figure 1 1 5 Spring 12 6 Lock sleeve 11 7 Gear 4 8 Worm 5 9 Bushings 7 l Inspect Worm and gear for broken or worn teeth Body and locking sleeve for cracks Repl...

Page 134: ... Figure 11 Removing the Worm Shaft SERVICE BRAKE CHAMBERS ANCHORLOK Standard Remove or Disconnect Figure 12 1 Mark the pressure cap and housing assembly in relation to the clamp ring 2 Pull out the pushrod and clamp it using lock ing type pliers figure 13 3 Nuts 28 and bolts 27 4 Clamp assembly 24 5 Pressure cap 26 Release the locking pliers 6 Diaphragm 25 7 Pushrod assembly 21 8 Return spring 23 ...

Page 135: ...lok Gold Seal spring brake chamber uses a crimped safety seal and is not serviceable ANCHORLOK GOLD SEAL TYPE CAGING Figures 14 15 and 16 CAUTION Before attempting brake chamber removal block the vehicle s wheels securely since the parking brake will not be applied Do not remove the chamber from the vehicle before caging the power spring Do not remove the outer chamber clamp Failure to follow this...

Page 136: ...Release the locking pliers 6 Diaphragm 5 7 Pushrod assembly 4 8 Return spring 3 Inspect The diaphragm and return spring for wear The inside of the brake chamber for corrosion Replace if corroded The pushrod assembly for damaged threads Install or Connect Figures 17 and 18 1 Return spring 3 into the service housing assembly 2 Figure 15 Caging the Anchorlok Spring Brake Chamber 3 Diaphragm 5 4 Clamp...

Page 137: ...g and reassemble the release tool in the pocket of the adapter 8 Install the rubber cap in the release tool keyhole Figure 18 Anchorlok Gold Seal Spring Brake Chamber Components SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS ITEM N m Ft Lbs In Lbs Brake Chamber Clamp Nuts 34 25 T3023 ...

Page 138: ... Crankshaft Bendix Tu Flo 550 Cleaning Inspection and R Cleaning and Inspection Repair Discharge Valves Valve Stops and Seats Inlet Valves and Seats Bendix Tu Flo 550 Air Compressor Assembly Crankshaft Pistons and Connecting Rods Crankcase Base Plate or Adapter Cylinder Head Governor Bendix BX 2150 Air Compressor Disassembly Governor Cylinder Head Connecting Rod Crankshaft Bendix BX 2150 Cleaning ...

Page 139: ...Clean Gasket material from the cover plate cylinder head and crankcase 5 Unloaders 7 O rings 6 and springs 8 I Inspect Unloader piston bushings 9 for nicks wear corrosion and scoring If the unloader bushing is damaged or worn excessively replace the cylinder head or com pressor m Measure i Discharge valve travel before disassembling the discharge valve mechanism A Set up a dial indicator as shown ...

Page 140: ... COVER 10 GASKET 32 BEARING 11 SEAT INLET VALVE 33 CRANKSHAFT 12 VALVE INLET 34 BEARING CONNECTING ROD 13 SPRING 35 CAP CONNECTING ROD 14 STOP INLET VALVE 36 BOLT 15 GASKET 37 KEY CRANKSHAFT 16 SEAT DISCHARGE VALVE 38 WASHER THRUST 17 VALVE DISCHARGE 39 GASKET 18 SPRING 40 PLATE BASE 19 STOP DISCHARGE VALVE 41 BOLT 20 HEAD CYLINDER 42 BEARING SLEEVE 21 RINGS PISTON 43 CRANKCASE 22 RING OIL V2810 F...

Page 141: ...olts 36 2 Bearing caps 35 3 Pistons from the crankcase by pushing out the top Use care not to scratch the cylinder bores 4 Replace the bearing caps on their matched con necting rods 5 Piston rings figure 6 Figure 4 Measuring Discharge Valve Travel Figure 5 lnlet Valve Removal and Installation 6 Wrist pin button 24 wrist pin 25 and connecting rod 28 y Inspect Wrist pin wrist pin bore and connecting...

Page 142: ...in the crankshaft and end covers Use compressed air to remove dirt Inspect 1 Cylinder head body 43 Check for cracks and damage Apply compressed air to one coolant port with the others plugged Check for leakage by applying a soap solution to the exterior of the body If leakage is found replace the head 2 End cover 30 For cracks and external damage Crankshaft main bearing sleeve for wear and flat sp...

Page 143: ...linder bores to a smooth cross hatch surface Maintain a 0 002 to 0 004 inch clearance between the piston and cylinder bore figure 12 r V Figure 11 Measuring the Cylinder Bore Figure 12 Checking the Piston to Cylinder Fit 6 Connecting rod bearing 34 Replace used bearing inserts r Do not interchange connecting rod caps Position the locking slots of the connecting rod and cap next to each other Maint...

Page 144: ...cting rod bushing by rocking the piston If clearance is found replace the rod and bushing assembly Check the fit of the piston rings in the piston ring grooves Refer to Specifications Measure the gap and groove clearance with the rings installed on the piston figures 15 and 16 REPAIR DISCHARGE VALVES VALVE STOPS AND SEATS Lap slightly worn discharge valve seats with a lap ping stone grinding compo...

Page 145: ...er 24 5 Piston rings 21 expander ring 23 and oil rings 22 to the piston 11 pip marks up A Stagger the ring gaps 90 degrees B Coat the piston piston rings wrist pin and con necting rod bearings with clean motor oil 6 Connecting rod bearing inserts 34 in the connect ing rod and cap A Remove the bolts and bearing cap from one connecting rod B Turn the crankshaft to center one rod journal in the downw...

Page 146: ...e Cylinder head in relation to the crankcase Base plate or adapter in relation to the crankcase GOVERNOR Remove or Disconnect 1 Bolts 2 Washers 3 Governor 4 Gasket CYLINDER HEAD Remove or Disconnect Figures 18 and 19 1 Bolts 261 2 Cylinder head 263 Tap the head with a soft faced mallet to break the gasket seal 3 Discharge valve seat 268 valve 267 and spring 266 4 Unloader piston stop 260 and O rin...

Page 147: ...5J 10 AIR COMPRESSOR AND GOVERNOR 286 F9051 Figure 18 Bendix BX 2150 Compressor Components i ...

Page 148: ...crew and Springwasher r F9052 Figure 19 Bendix BX 2150 Compressor Components 4 Piston rings from the pistons figure 20 5 Piston pin plug 272 piston pin 273 and con necting rod 274 CRANKSHAFf Remove or Disconnect Figures 18 and 19 1 Crankshaft key 276 2 Four machine screws and spring washers 279 from the end cover 280 3 End cover assembly 280 thrust washer 281 and O ring 278 Use care not to damage ...

Page 149: ...d the main bearing crankshaft journals 1 Clean and oil passages 5 Cylinder bore 288 Grooved walls must be square and have a good finish Use an inside micrometer or caliper to check cylinder bores figure 21 Re bore or hone oversize cylinder bores scored Or out of round more than 0 0005 inch or tapered more than 0 002 inch Replace pistons with 0 010 0 020 and 0 030 inch oversize pistons and rings Fi...

Page 150: ...s to the pistons and connecting rod bushings Refer to Specifi cations for clearance If the fit is loose replace the piston and pin assembly Check the fit of the piston pin in the connecting rod bushing by rocking the piston If clearance is found replace the rod and bushing assembly Check the fit of the piston rings in the piston ring grooves figure 25 Refer to Specifica tions for clearances REPAIR...

Page 151: ...Important A When installing new piston pin bushings 273 line up the oil hole with the hole in the rod 2 Piston pin 273 3 Piston pin plug 272 7 4 Piston rings 270 to the piston 271 pip marks up t i _ Stagger the ring gaps 180 degrees Coat the piston piston rings piston pin and connecting rod bearings with clean motor oil 5 Crankshaft journal bearing inserts in the connecting rod 274 and connecting ...

Page 152: ...ston grommets 309 and 317 from the grooves in the piston 8 Valve spring 316 valve 315 exhaust stem 310 and exhaust stem spring 311 from the pis ton V 9 Exhaust stem grommet 313 and washer 312 from the bore Mount the adjusting screw and spring assembly in a vise with soft jaws 10 Jam nut 302 from the adjuster screw 308 then thread adjuster screw out of the upper spring seat 303 11 Adjuster screw sp...

Page 153: ...d 317 on the piston 314 7 Exhaust stem spring 311 exhaust stem 310 valve 315 and valve spring 316 The narrow end of the inlet valve spring is against the valve 8 Piston assembly 9 Rubber cover 300 10 Two pipe plugs e s t s a f t e r r e p a ir Make this test using shop equipment or with the unit installed in the vehicle Operating Test 1 Start the engine and build up air pressure 2 Observe the read...

Page 154: ... 0 030 Oversize Piston Pin To Connecting Rod Clearance Piston Ring Gap Compression Segment Piston to Cylinder Clearance Piston Ring Clearance In Groove Compression Segment Clearance Between Connecting Rod Inserts and Crankshaft Journal Crankshaft Connecting Rod Journal Diameter Front Bearing Journal Diameter Rear Bearing Journal Diameter 13 2 Cu Ft 2 78 1 50 2 77825 2 78825 2 79825 2 80825 2 7810 ...

Page 155: ...ce In Groove Wide Ring1 0 0015 0 0035 Narrow Ring 0 002 0 004 Clearance Bewreen Connecting Rod Inserts and Crankshaft J o u r n a l 0 001 0 0025 Crankshaft Connecting Rod Journal Diameter 1 249 1 250 Front Bearing Journal Diameter i 1 3779 i 3783 Rear Bearing Journal Diameter _________________ i 1 3779 1 3783 Length 9 2086 Crankshaft Journal Maximum Out Of Round 0 0003 Underloader Valve Spring Fre...

Page 156: ...Pa 105 psi Springs Free Length 21 mm 0 83 Solid Length 4 06 mm 0 16 Number Of Active Coils 3 1 2 Exhaust Stem Spring Free Length 14 98 mm 0 59 Solid Length 1 27 mm 0 05 Number of Active Coils 3 Adjuster Screw Spring Free Length L 43 68 mm 1 72 Solid Length 26 92 mm 1 06 Number of Active Coils 4 1 2 12301 SPECIAL TOOLS ...

Page 157: ...ntification 6A2 3 Disassembly of the Engine 6A2 3 Tools and Shop Eguipnflent 6A2 3 6A2 3 Cleaning 6A2 4 Draining the Engine 6A2 4 6A2 4 Coolant Pump Removal 6A2 4 Intake Manifold Removal 6A2 4 Rocker Arm Cover Removal 6A2 5 Valve Train Component Ren oval 6A2 5 Cylinder Head Removal 6A2 6 Torsional Damper Removal 6A2 6 6A2 7 Oil Pump Removal 6A2 8 Front Cover Removal 6A2 8 Timing Chain and Camshaft...

Page 158: ...ions Engine Specifications Fastener Tightening Specifications Special Tools i ll ij i PAGE 6 A 2 2 1 6 A 2 2 1 6 A 2 2 2 6 A 2 2 2 6 A 2 2 2 6 A 2 2 3 6 A 2 2 3 6 A 2 2 4 6 A 2 2 5 6 A 2 2 5 6 A 2 2 5 6 A 2 2 6 6 A 2 2 6 6 A 2 2 7 6 A 2 2 7 6 A 2 2 7 6 A 2 2 8 6 A 2 2 8 6 A 2 2 8 6 A 2 2 8 6 A 2 2 8 6 A 2 2 9 6 A 2 3 0 6 A 2 3 1 6 A 2 3 1 6 A 2 3 1 6 A 2 3 2 6 A 2 3 2 6 A 2 3 3 6 A 2 3 4 6 A 2 3 4...

Page 159: ...vailable Other necessary equipment includes a suitable parts cleaning tank compressed air supply trays to keep parts and fasteners organized and an adequate set of hand tools An approved engine repair stand will aid the techni cian and help prevent personal injury or damage to engine components Special tools are illustrated throughout this section and listed at its end These tools or their equival...

Page 160: ... to 12 N m 112 in lbs EXHAUST MANIFOLD REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e 2 R e m o v e o r D i s c o n n e c t 1 Oil pan drain plug Allow the oil pan to drain 2 Oil filter 3 Block drain plugs Allow the coolant to drain I n s t a l l o r C o n n e c t 1 Oil pan drain plug Tighten 1 Oil pan drain plug to 28 N m 20 ft lbs 2 Block drain plugs 1 Oil dipstick tube 2 Bolts and studs...

Page 161: ... e o r D i s c o n n e c t F i g u r e s 6 t h r o u g h 1 0 Tools Required V j 3049 A Valve Lifter Remover Plier Type J 9290 01 Valve Lifter Remover Slide Hammer Type 1 Bolts 40 pushrod guides 260 balls 41 rocker arm 42 and pushrods 43 Note the exhaust valve pushrods are longer than the intake valve pushrods Every effort should be made to ensure these mating parts are installed in their original ...

Page 162: ...eposits These lifters can be removed using either J 3049 A figure 9 or J 9290 01 figure 10 S CYLINDER HEAD REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e s 6 a n d 7 1 Bolts 45 v 2 Cylinder heads 46 Use care when handling the cylinder heads to prevent damage to gasket seal ing surfaces 3 Gaskets 47 v TORSIONAL DAMPER REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e 1 1 tool Require...

Page 163: ...r e 9 R e m o v i n g t h e H y d r a u l i c L i f t e r OIL PAN REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e 1 2 1 Oil pan bolts 75 2 Oil pan 76 3 Gasket 74 Figure 8 Valve Train Component Organizer A 22 mm 7 s lnch B 55 mm 21 4 inch C 40 mm 11 2 inch D 10 mm 3 e inch drill 25 mm 1 inch deep E 22 mm 7 a inch drill 25 mm 1 Inch deep F Material 50 mm x 200 mm 2 x 8 inch lumber B5267 ...

Page 164: ... g u r e 1 1 R e m o v i n g t h e T o r s i o n a l D a m p e r OIL PUMP REMOVAL R e m o v e o r D i s c o n n e c t 1 Oil pump retaining bolt 2 Oil pump with drive shaft and connector FRONT COVER REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e 1 3 1 Bolts 93 2 Front cover 91 3 Gasket 90 i ...

Page 165: ...i g u r e s 1 6 a n d 1 7 Tool Required J 5239 Connecting Rod Guide Set 1 Ridge or deposits at the top of the cylinders as follows A Turn the crankshaft until one piston is at the bottom of its stroke Place a soft cloth on top of the piston B Using the manufacturer s directions install a ridge reamer into the top of the cylinder figure 16 Perform the cutting operation Figure 14 Timing Chain and Sp...

Page 166: ...hten D Repeat this procedure on the remaining piston and connecting rod assemblies FLYWHEEL REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e 1 8 1 Bolts 111 2 Retainer 113 automatic transmission only 3 Flywheel 11Q and flexplate 112 Flexplate 112 applies to automatic transmission only 4 Retainer 113 AT 545 transmission only CRANKSHAFT REMOVAL R e m o v e o r D i s c o n n e c t F i g u r e ...

Page 167: ... R G A U T O M A T I C T R A N S M I S S I O N 4 Ffiy M A N U A L T R A N S M I S S I O N 110A FLYWHEEL MANUAL TRANSMISSION 11OB FLYWHEEL AUTOMATIC TRANSMISSION 111 BOLT 112 PLATE FLYWHEEL FLEX 113 RETAINER 200 PIN ENGINE BALANCING GROOVE V3911 Figure 18 Flywheel and Components ...

Page 168: ...rk performed with proper methods and tools is most important The rebuilt engine cannot be expected to perform properly if parts worn beyond acceptable limits are reused BLOCK Clean 1 Block in solvent Block gasket surfaces 3 Cylinder bores v 4 5 Scale deposits from the coolant passages figure so L I n s p e c t 1 All expansion plugs for poor fit or leakage 2 Valve lifter bores for deep scratches an...

Page 169: ...main bearing cap is damaged and requires replacement replace it as outlined later in this section M e a s u r e F i g u r e 2 1 Head gasket surface distortion Use a straightedge and feeler gage to check for flatness of the milled surface at the top ot the cylinder block The surface must be flat within 0 10 trim 0 004 inch to ensure proper head gasket sealing C Y L I N D E R B O R E S I n s p e c t...

Page 170: ... the hbnp manufacturer s recommendations for the use of the hone and cleaning and lubrication during honing Use only clean sharp stones of the proper grade for amount of material to be removed Dull dirty stones cut unevenly and generate excessive heat 2 Occasionally during the honing operation the cylin der bore should be thoroughly cleaned and the pis ton selected for the individual cylinder chec...

Page 171: ... on the support fixture C Press out the piston pin C L E A N I N G A N D I N S P E C T I O N VSA C l e a n Piston Remove all varnish and carbon deposits DO NOT USE A WIRE BRUSH Remove the carbon from the ring grooves Use a ring groove cleaning tool Oil control ring groove holes I n s p e c t Piston pin bore in the piston and connecting rod Check for scuffing burrs etc Piston pin for scratches wear...

Page 172: ...ting rod with engine oil C Install the pin guide J 24086 3 item E figure 31 to hold the piston and connecting rod together 2 Piston pin A insert the piston pin into the piston pin hole B Place the assembly on the support fixture fig ure 31 C Adjust the piston pin installer J 24086 9 to the correct length using the letter number scale on the installer adjuster figure 31 This is neces sary to ensure...

Page 173: ...mbered to correspond with the new cylinder number Installing the Piston Rings Measure Figure 32 Ring end gap as follows 1 Select rings comparable in size to the piston being used 2 Slip the cOmpressioriring in the cylinder bore then press the ring down into the cylinder bore about 25 mm 1 inch Be sure the ring is square with the cylinder wall 3 Measure the space or gap between the ends of the ring...

Page 174: ...t file If binding is caused by a distorted ring try a new ring 7 Measure Figure 34 Ring clearance Use a feeler gage as shown in figure 34 Compare with Specifications i INTAKE AND EXHAUST MANIFOLDS Clean Old pieces of gasket from the gasket surfaces Excessive carbon build up in the exhaust passages of the intake manifold Scale and deposits from the coolant passages of the intake manifold EGR passag...

Page 175: ...heir bores Replace the camshaft bearings if nec essary Figure 36 Measuring Camshaft Run Out Figure 37 Checking the Camshaft Journals A BEARING TOOL C NUT B PILOT D PULLER SCREW Figure 38 Replacing the Inner Camshaft Bearings Figure 39 Replacing the Outer Camshaft Bearings Disassemble Figures 38 and 39 Tool Required J 6098 01 Camshaft Bearing Remover and Installer 1 Rear camshaft plug 2 Inner camsh...

Page 176: ...lange against the front face of the block B Slide the puller screw with nut and washer through the pilot C Place the new bearing on the bearing tool Hold the tearing tool and bearing against the bearing bore Align the bearing oil hole with the oil hole in the block D Thread the puller screw into the tearing tpdj enough to hold the tool and bearing in place E Hold the puller screw with a wrench Tur...

Page 177: ...nt pump If the shaft end play exceeds 0 381 mm 0 015 inch replace the coolant pump Coolant pump body at the drain weep hole Slight staining around the weep hole is normal Replace the coolant pump only if coolant is dripping from the weep hole while the engine is running or while the system is pressurized OIL RAN AND ROCKER ARM COVERS Clean Parts in solvent Remove allvsludge and varnish Old gaskets...

Page 178: ...s of cracking at the bolt shoulder Rocker arms and balls at their mating surfaces These surfaces should be smooth and free from scoring or other damage Rocker arm areas that contact the valve stems and the sockets that contact the pushrods These areas should be smooth and free of damage and wear Rocker arm bolts Inspect rocker arm bolts for signs of cracking at the bolt shoulder Replace if necessa...

Page 179: ...A Compress the springs 256 with J 8062 figure 46 B Remove the valve keepers C Remove J 8062 40 BOLT 41 BALL 42 ROCKER ARM 46 CYLINDER HEAD 47 GASKET 251 VALVE KEEPERS 253 CAP 254 ROTATOR 256 SPRING WITH DAMPER 257 SEAL 258 EXHAUST VALVE 259 INTAKE VALVE 260 PUSHROD GUIDE F9346 Figure 45 Cylinder Head and Components 46 Compressing the Valve Springs ...

Page 180: ...on from the combustion chambers using J 8Q59 or equivalent figure 47 1 B4519 Figure 47 Cleaning the Combustion Chambers Cylinder head for cracks in the exhaust ports com bustion chambers or external cracks to the coolant jackets Gasket surfaces should be free of damage Valves for burning pitting or warpage Grind or replace as needed as outlined later Check the valve stems for scoring or excessive ...

Page 181: ...ition due to heat localizing on this knife edge If the edge of the valve head is less than 0 80 mm 1 32 inch after grinding replace the valve figure 52 Several different types of equipment are available for refacing valves The recommendation of the manufac turer of the equipment being used should be carefully followed to attain proper results The correct valve face angle is 45 degrees V A L V E S ...

Page 182: ...e sure the valve keepers stay in place E Repeat this procedure on the remaining valves Measure Figures 54 and 55 Valve spring installed height of each valve spring A Use a narrow thin scale A cutaway scale may be helpful figure 54 A 1 r j r 1 A Grind out this portion B5248 Figure 54 Cutaway Scale Figure 55 Measuring Valve Spring Installed Height r 1 v B Measure from the spring seat to the top of t...

Page 183: ...gniflux method if available Crankpins main bearing journals and thrust sur faces for scoring nicks or damage caused by lack of lubrication Main bearing inserts for scoring or other damage In general the lower inserts except the 1 bearing show greater wear and the mbSt distress from fatigue If upon inspection the lower insert is suitable for use it can be assumed the upper insert is also satisfacto...

Page 184: ... 0 020 inch undersize Selective fitting of both rod and main bearing inserts is necessary in production to obtain close tolerances For this reason you may find one half of a standard insert with one half of a 0 001 inch undersize insert that will decrease the clearance 0 0005 inch from using a full standard bearing MAIN BEARING SELECTION The simplest most accurate way to rneasure main bearing clea...

Page 185: ...ly main bearing journals wear evenly and are not but of round However if a bearing is being fitted to an Out of round 6 001 inch maximum journal be sure to fit tp the maxiT mum diameter of the journal If the bearing is fitted to the minimum diameter and the journal is excessively out of round interference between the bearing and the journal will result in rapid bearing failure 5 If the bearing cle...

Page 186: ...ing cap bolts to 135 N m 100 ft lbs 2 With the crankshaft wedged forward measure at the front end of the rear main bearing with a feeler gage figure 63 The proper clearance is 0 006 0 010 inch Inspect Crarikshaft for binding Try turning the crankshaft to check for binding If the crankshaft does not turn freely loosen the bolts one pair at a time until the tight bearing is located Burrs on the bear...

Page 187: ...xceed 16mm 5 8 inch FRONT COVER INSTALLATION Install or Connect Figure 66 Lubricate the lips of the crankshaft front oil sea with engine oil 1 Gasket 90 2 Front cover 91 N O TIC E See N o tic e on p ag e 6A2 1 3 Bolts 93 Tighten Bolts 93 to 11 N m 100 in lbs TORSIONAL DAMPER INSTALLATION N O T IC E The in e rtia l w e ig h t s e c tio n o f the torsio nal d am p er is assem b led to the hub w ith ...

Page 188: ... OF ENGINE B7936 Figure 70 Pistons Installed ENGINE FRONT ENGINE LEFT ENGINE RIGHT B 3rd Compression Ring Gap C 2nd Compression Ring Gap D Top Compression Ring Gap v F9356 Figure 6fr Piston Ring End Gap Location PISTON AND CONNECTING ROD INSTALLATION INSTALLATION M Install or Connect Figures 68 69 and 70 Tools Required J 5329 Connecting Rod Guide Set J 8037 Ring Compressor Lubricate the cylinder w...

Page 189: ...ses evenly between the bearing and journal surfaces without dam aging them Proceed as follows It is assumed that the parts have been inspected as previously outlined Figure 71 Placing the Gaging Plastic on the Journal Clean Figure 71 Oil from crankshaft journal and the connecting rod bearing inserts 0 Install or Connect 1 Connecting rod with the upper connecting rod bear ing insert to the cranksha...

Page 190: ...ge The proper clearance is 0 013 0 023 inch OIL PUMP INSTALLATION Install or Connect 1 Oil pump wjth connector arid oil pump drive shaft A Sealing Compound 74 Gasket 75 Bolt 76 Oil Pan F9331 i Figure 74 Oil Pan N O TIC E See N o tice on p ag e 6 A2 1 2 Oil pump to main bearing cap bolt Figure 73 Measuring Connecting Rod Side Clearance T ig h te n Bolt to 90 N m 65 ft It OIL PAN INSTALLATION 0 Inst...

Page 191: ...d into place over the dowel pins and head gaskets N O TIC E S ee N o tic e on p ag e 6A2 1 3 Cylinder head bolts Coat the threads of the bolts with sealing compound Loctite 592 or equivalent and install finger tight Q Tighten Bolts in three steps using the sequence shown in figure 77 A The first sequence to 40 N m 30 ft lbs B The second sequence to 80 N m 60 ft lbs C The final torque sequence to 1...

Page 192: ...il Supplement GM P N 1051396 or equiv alent 1 Hydraulic lifters 44 to the block A Timing Marks 120 Torsional Damper 123v Timing Tab F9358 Figure 78 Timing Marks 2 Pushrods 43 Seat the pushrods into the socket in the hydraulic lifters v Note the exhaust valve pushrods are longer than the intake valve pushrods Coat the mating surfaces of the rocker arms 42 and balls 41 with Moly Kote or equivalent 3...

Page 193: ...TION 0 I n s t a l l o r C o n n e c t F i g u r e 8 1 Bolts 40 to 54 N m 40 ft lbs INTAKE MANIFOLD INSTALLATION E 3I n s t a l l o r C o n n e c t F i g u r e s 7 9 a n d 8 0 1 Gaskets 22 to the cylinder heads Apply a 5 mm 3 16 inch spot of RTV sealer GM P N 1052289 or equivalent on the front and rear of the block in four places as shown in figure 79 1 Gaskets 2 Rocker arm covers 32 NOTICE See N ...

Page 194: ...atic transmission only 3 Retainer 113 automatic transmission only I NOTICE See Notice on page 6A2 1 4 Flywheel bolts 111 Tighten 1 Gaskets 14 2 Coolant pump 15 NOTICE See Notice on page 6A2 1 3 Bolts 16 T i g h t e n Bolts 16 to 40 N m 30 ft lbs 4 Bypass hose and clamps Bolts 111 to 90 N m 65 ft lbs ENGINE ACCESSORY i f INSTALLATION J j I j i Install the engine accessories TBI unit distributor oil...

Page 195: ...ted crank the engine several times Listen for any unusual noises or evidence that any parts are binding 5 Start the engine and listen for unusual noises 6 Run the engine speed at about 1000 RPM until the engine is at operating temperature 7 Listen for improperly adjusted valves or sticking lift ers and other unusuaj noises 8 Check for oil and coolant leaks while the engine is running 9 Using the p...

Page 196: ...I S S I O N A T 5 4 5 A U T O M A T I C T R A N S M I S S I O N M A N U A L T R A N S M I S S I O N 110A FLYWHEEL MANUAL TRANSMISSION 11OB flyw heel automatic transm issio n 111 BOLT 112 PLATE FLYWHEEL FLEX 113 RETAINER 200 PIN ENGINE BALANCING GROOVE V3911 Figure 84 Flywheel arid Components ...

Page 197: ...f necessary adjust stop collars on cutting tool and tap to required depth 3 Tap hole Lubricate tap with light engine oil Clean the thread I m p o r t a n t Avoid build up of chips Back out the tap every few turns and remove chips 4 Thread the thread insert onto the mandrel of the installer figure 85 Engage the tang of the insert onto the end of the mandrel 5 Lubricate the insert with light engine ...

Page 198: ...r Relief Side 0 001 Maximum Service 0 001 Maximum PISTON Production 0 0030 0 0042 0 0040 0 0054 Service Limit 0 0046 Maximum 0 0058 Maximum PISTON RING C A Production Top 0 0012 0 0029 o M Groove Clearance 2nd 3rd 0 0012 0 0029 P R Service Limit Hi Limit Production 0 001 E S S Production Top 0 010 0 018 2nd 3rd 0 016 0 024 1 0 N u a p Service Limit Hi Limit Production 0 010 Groove Production 0 005...

Page 199: ...rvice Limit 0 001 Out Of Production 0 0004 0 0005 Round Service Limit 0 001 Rod Bearing Production 0 0011 0 0029 Clearance Service Limit 0 003 Maximum Rod Side Clearance 0 0013 0 023 CAMSHAFT Lobe Intake 0 2343 Lift 0 002 Exhaust 0 2343 0 2530 Journal Diameter 1 9482 1 9492 VALVE SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 70 1 Valve Lash Intake Net Lash Exhaust Face Angle Intake Exhaust 45 Seat An...

Page 200: ...Lbi 26 20 66 48 40 30 37 27 110 80 54 40 90 65 44 32 ___ 40 30 10 96 54 40 135 100 18 y 160 90 65 9 80 54 40 8 70 30 22 115 85 T2294 1 Torsional Damper Remover and Installer 2 Valve Spring Compressor 3 Crankshaft Seal and Sprocket Installer 4 Piston Ring Compressor 5 Guide Set 6 Vacuum Pump 7 Hydraulic Lifter Remover Slide Hammer Type 8 Hydraulic Lifter Remover Plier Type 9 Reamer 0 003 inch overs...

Page 201: ...V8 ENGINES GASOLINE 6A2 45 1 2 3 4 5 J 39046 SPECIAL TOOLS 12 J 8062 J 22102 J 8037 J 5239 13 14 15 16 17 18 J 8001M J 7872 J 38841 J 7049 J 8087 J 8101 S8089 F9526 ...

Page 202: ...AC Valve Throttle Position Sensor TP Sensor Fuel Meter Cover Fuel Injectors Pressure Regulator Fuel Meter Body Cleaning Governor Throttle Drive Assembly Governor Drive Motor Governor Lubrication and Cleaning Throttle Body Reassembly Fuel Meter Body Fuel Injectors Fuel Meter Cover Pressure Regulator Throttle Position Sensor TP Sensor Idle Air Control IAC Valve Governor Throttle Drive Assembly Gover...

Page 203: ...r Body Cover 300 Throttle Drive Assembly 40 Injector 301 Screw Assembly Motor Plate 42 Upper Fuel Injector O ring 310 Shock Absorber 43 Lower Fuel Injector O ring 311 Shock Absorber Ring Retainer 50 Fuel Va or Block 330 Drive Motor 60 Pressure Regulator Cover 331 Screw Assembly Drive Motor 61 Screw Assembly Regulator Cover 34p Stud 65 Pressure Regulator Spring Seat 341 Stud Washer 66 Pressure Regu...

Page 204: ...MODEL 295 TBI UNIT 6C1 3 F7973 Figure 3 Model 295 TBL Unit ...

Page 205: ...Figures 2 and 3 1 IAC valve Remove IAC valve screw assemblies 2 Fuel meter body cover I Inspect Fuel meter body cover and seal for damage Replace cover if seal is damaged Do not try to remove the seal from the fuel meter body cover FUEL INJECTORS Each fuel injector is serviced as a complete assembly only figure 5 2 IAC valve O ring arid discard THROTTLE POSITION SENSOR TP SENSOR N O TIC E The TP s...

Page 206: ... and gaskets from the fuel meter body assembly Discard gaskets A Screwdriver Blade B Fulcrum 20 Fuel Meter Body Assembly 40 TBI Injector v F9236 Figure 4 Removing Fuel Injector 20 Fuel Meter Body Assembly 40 TBI Injector 42 Upper Fuel Injector O Ring 43i Lower Fuel Injector O Ring F9237 Important Note locations of nuts for proper reassembly later Inlet nut has a larger passage than outlet nuL t 2 ...

Page 207: ...e TO for lubrication points A Refer to Governor Cleaning and Lubrication if any of the above conditions apply 300 Throttle Drive Assembly 301 Motor Plate Attaching Screw Assembly F9239 Figure 7 rGovernor Thrpttle Drive Assembly GOVERNOR DRIVE MOTOR I Remove or Disconnect Figures 8 and 9 1 Governor throttle drive assembly Important Throttle lever cam spring is under tension Move throttle lever cam ...

Page 208: ...ecessary Disassemble Governor throttle drive assembly following previous component replacement procedure Important Before cleaning the throttle body assembly remove parts listed below from the assembly L Inspect Remove or Disconnect Check for worn or damaged parts and parts in need of lubrication no apparent sign of grease See figure 10 for lubrication points A Throttle to governor motor link tor ...

Page 209: ...to 3 N m 28 in lbs PRESSURE REGULATOR Inspect Figure 6 M Pressure regulator valve seat in fuel meter body for pitting or nicks If seat is damaged replace the fuel meter body Install or Connect 1 New pressure regulator diaphragm assembly Be sure it is seated in groove in fuel meter body 2 Regulator spring seat and spring into cover assem bly v 7 v 3 Cover assembly over diaphragm lining up mount ing...

Page 210: ... position Proper idle regulation should result Install or Connect Figures 2 and 3 N O TIC E See N o tice on page 6C1 1 IAC valve into throttle body Important New IAC valves have been reset at the factory and should be installed in the throttle body in an as is condition Without any adjustment Q Tighten Attaching screw assemblies to 3 N m 28 in lbs GOVERNOR THROTTLE DRIVE ASSEMBLY 0 Install or Conn...

Page 211: ...ld figure 9 2 Align motor lever with governor throttle drive assembly casting so the motor lever will clear the assembly when the drive motor is installed Position straight end of motor lever spring on cutout area of plate and position motor drive lever against shock absorber support figure 8 N O TIC E See N o tice on p ag e 6C1 1 3 Four drive motor attaching screw assemblies coat ed Iwjth Loctite...

Page 212: ...eners that are no t reused an d those requiring thread locking C om pound w ill be called out The correct torque value m u st be used when installing fasteners th at require it If the abo ve conditions are n o t follow ed p arts o r system dam age could result CONTENTS SUBJECT PAGE Delco Remy 21 SI 200 Generator 6D1 2 General Description 6D1 2 Generator Output Test v w 6D1 2 Disassembly 6D1 3 Slip...

Page 213: ...dge connected to the stator windings contain six diodes and electrically changes the stator AC volt ages to DC voltage that appears at the generator output BAT terminal Generator field current is supplied through a diode trio connected to the stator windings A capacitor mounted to the end frame protects the rectifi er bridge and diode trio from high voltages and sup presses radio noise The generat...

Page 214: ... and Electrical Tests DISASSEMBLY SLIP RING END FRAME Disassemble Figures 5 through 7 Hold the generator in a vise clamping to one mounting lug lengthwise Scribe a mark to help locate the frame end parts in the same position during assembly 1 Four through bolts 44 2 Slip ring end frame 5 from the drive end frame 26 and rotor assembly Prying with a screwdriver at the stator slots will aid disassemb...

Page 215: ...LIP RING END 25 BEARING FRONT 6 REGULATOR 26 FRAME DRIVE END 10 BRUSH HOLDER AND BRUSHES 29 FAN P 13 STATOR 30 PULLEY 17 TRIO DIODE 32 NUT PULLEY 18 CAPACITOR 38 TERMINAL I 19 WASHER 44 BOLT THROUGH 2b BRIDGE RECTIFIER 45 CONNECTING STRAP T TERMINAL 21 ROTOR F9216 Figure 5 21 SI Series 200 Components ...

Page 216: ...y larger inside diame ter than the outside diameter of the bearing B Press the bearing from the drive end frame with a metal tube against the bearing s inner race INSPECTION AND REPAIR CLEANING AND INSPECTION 3 Clean All metal parts except the voltage regulator rectifier bridge stator rotor and bearing assemblies in a suitable solvent Wipe or blow the parts dry Inspect 1 Brush holder 2 Insulating ...

Page 217: ...y with a 110 volt test lamp or an ohmmeter figure 8 Open Circuit To check for opens connect the test lamp or ohmme ter to each slip ring If the lamp fails to light or if the ohmmeter reading is high infinite the winding is open Short Circuit or Resistance Check The winding is checked for Short circuits or excessive resistance by connecting a 12 volt battery and ammeter in series with the edges of ...

Page 218: ... between the insulated heat sink and each of the three connectors This makes a total of six checks with two readings taken for each check The ohmmeter check of the rectifier bridge and of the diode trio as previously covered is a valid and accurate check Do not replace either unit unless at least one pair of readings is the same STATOR CHECKS The stator windings may be checked with a 110 volt test...

Page 219: ...est Lamp F9224 Figure 12 Testing the Voltage Regulator ASSEMBLY Assemble Figure 5 N O TIC E F o r steps 3 8 9 11 13 16 18 an d 20 refer to N o tic e on p ag e 6D1 1 1 Bearing 4 in the slip ring end frame 5 Support the inside of the frame Use a thin wall tube in the space between the grease cup and the housing to push the bearing in flush with the housing figure 13 2 Bearing 25 in the drive end fra...

Page 220: ... the brush holder assembly and use a retainer such as a toothpick to retain them figure 15 V The longer end of the retainer should extend through the end frame for removal after the rotor and and the drive end frame are installed 21 l 200 GENERATOR 6D1 9 53 10 Brush Holder 53 Brush Retainer F9228 Figure 15 Brush Retainer Installed 15 Regulator brush holder assembly and diode trio to the end frame ...

Page 221: ... 1600 too 5000 100 1117928 21 SI 200 Either 1 7 1 8 6 7 7 1 12 50 1600 130 5000 130 FASTENER TIGHTENING SPECIFICATIONS N m Ft Lbs In Lbs BAT Terminal Nut 5 5 50 50 Pulley Nut 100 75 Rectifier Bridge Ground S c r e w s 3 25 Rectifier Bridge Insulated Screw 22 Regulator Nut 2 5 22 Relay terminal Nuts 2 5 22 S R E Retainer S c r e w s 26 Stator Lead to Rectifier Bridge Nuts 2 5 22 LUBRICATION For gen...

Page 222: ...2 8 6D2 8 6D2 8 6D2 9 6D2 9 602 10 i 6D2 10 6D2 10 6D2 10 GENERAL DESCRIPTION DELCO REMY CS 144 GENERATOR The generator with integral regulator shown in figure 1 features a high ampere output per pound of weight It does not use a diode trio The delta stator rectifier bridge and rotor with slip rings and brushes are electri cally similar to other generators The CS stands for Charging System and 144...

Page 223: ...matic DIAGNOSIS GENERATOR OUTPUT TEST 1 Put the generator in a test stand and make con nections as shown in figure 3 except leave the carbon pile disconnected The ground polarity of the generator and battery must be the same The battery must be fully charged Use a 30 to 500 ohm resistor between the battery and the L termi nal 2 Slowly Increase the generator speed and observe the voltage 3 If the v...

Page 224: ...p ly to roller type slip ring en d fram e bearings Place the rotor in a vise and tighten only enough to permit removal of the pulley nut N O TIC E The ro to r m ay be distorted if the vise is overtightened 3 Nut 28 and the washer 27 from the shaft 4 Pulley 26 collar 25 fan 24 and outside collar 23 from the shaft 5 Drive end frame 22 and the inside collar 20 from the rotor shaft 6 Three screws 29 a...

Page 225: ...ULATOR VOLTAGE 17 BOLT THROUGH 18 STATOR 19 PLATE RETAINER SOME MODELS 20 COLLAR BEARING INSIDE 21 BEARING DRIVE END 22 FRAME DRIVE END 23 COLLAR BEARING OUTSIDE 24 FAN 25 COLLAR FAN AND PULLEY 26 PULLEY 27 WASHER 28 NUT SHAFT DRIVE END 29 SCREW RETAINER PLATE V3044 Figure 4 CS 144 Components 11 ROTOR 1 19 PLATE RETAINER SOME MODELS 20 COLLAR BEARING INSIDE 21 BEARING DRIVE END 22 FRAME DRIVE END ...

Page 226: ...G 16 REGULATOR VOLTAGE V3047 Figure 7 Slip Ring End Frame with Stator Removed 7 Capacitor 14 and rectifier bridge 5 from the frame 8 BAT terminal from the outside of the frame LATER MODELS 9 Two insulated screws 38 from the heat sink fig ured V 10 Two grounded bolts 6 and washers from the grounded heat sink 11 Capacitor 12 Rectifier bridge and BAT terminal Figure 8 Rectifier Bridge in End Frame Ea...

Page 227: ...must be replaced any time the two halves of the generator are separated 5 Drive end bearing for roughness looseness or wear iff the condition of the bearing is doubtful replace it 6 Windings for burned insulation Replace the rotor or stator if either looks burned Burned insulation appears as very dark or blackened wiring A strong acid odor will be apparent 7 Terminal connectors for corrosion or br...

Page 228: ...rt ed The specified resistance value can be determined by dividing the Voltage by the current A CHECK FOR GROUNDS B CHECK FOR OPENS 22 FRAME DRIVE END 4 1 OHMMETER V3051 F i g u r e 1 2 C h e c k i n g t h e R o t o r F i e l d W i n d i n g s Remember that the winding resistance and ammeter readings will vary slightly with winding temperature changes If the rotor is not defective but the generato...

Page 229: ...t A design change in the brush holder and slip ring 0ncl frame prevents early design brush holders from being installed in later design slip ring end frames unless the brush holder assembly is modified figure 15 5 BAT terminal nut 36 with the flat side down to the insulated heat sink LATER MODELS 6 Terminal insulator 40 to the outside of the slip ring end frame 7 BAT terminal to the rectifier brid...

Page 230: ...nuts 7 Tighten the nuts securely m DRIVE END FRAME Assemble Figures 4 and 5 Figure 16 Installing the Slip Ring End Bearing Slip ring end bearing into the slip ring end frame some models l To install a roller bearing in the end frame press the bearing in from the outside of the frame until if is flush with the outer edge of the frame 4 Rotor shaft through the inside collar 20 and through the end fr...

Page 231: ...NS GENERATOR SPECIFICATIONS Series Rotor Field Ohms Field Current 12 Ampere r ari no Type 100 27 Q 80 F Volts 27 C 80 F AMPS Rating 10480022 CS 144 2 1 2 4 5 0 5 7 124 10480023 CS 144 2 1 2 4 5 0 5 7 145 FASTENER TIGHTENING SPECIFICATIONS ...

Page 232: ... i s a s s e m b l y D i s a s s e m b l y o f t h e S D r 3 0 0 S t a r t e r M o t o r F i e l d F r a m e D r i v e E n d B r u s h e s S o l e n o i d D i s a s s e m b l y o f t h e S D 2 6 0 S t a r t e r M o t o r S o l e n o i d F r a m e a n d F i e l d A s s e m b l y D r i v e E n d F r a m e A s s e m b l y R e p a i r a n d T e s t i n g I n s p e c t i o n a n d R e p a i r A s s e m...

Page 233: ... one of the pole shoe screws has a grounding stud on it The starter motor has the drive end housing extended to enclose the shift lever and solenoid plunger The starter motor bearings are lubricated during motor assembly and do riot require service except dur ing motor repair The part number can be found either stamped on the outside of the frame or on an identification tag attached by a through b...

Page 234: ...is slightly higher the rpm will be slightly higher with the current remaining basically unchanged However if the exact voltage is desired a carbon pile connected across the battery can be used to reduce the voltage to the specified value Compare the test results as follows 1 Rated current draw and no load speed indicates normal condition of the starter motor 2 Low free speed and high current draw ...

Page 235: ...1 Armature from the drive housing by tilting the armature to disengage the shift lever fingers 1 from the drive collar figure 6 2 Drive assembly 32 from the armature shaft 9 as follows A Remove the thrust collar 17 from the armature shaft B Drive the stop collar 39 away from the pinion stop retainer ring 37 by sliding a metal cylin deronto the armature shaft and with d hammer striking the metal cy...

Page 236: ...lder pivot pins 63 2 Brush springs 64 3 Brushes 33 from the brush holders Figure 7 Retaining Ring on Armature Retaining Ring SOLENOID First perform the electrical tests on the solenoid described under Inspection and Repair later in this section Then disassemble the solenoid to inspect the contact disc and terminals l Remove or Disconnect Figure 10 1 Nuts from the S terminal 23 and the motor ter mi...

Page 237: ...ary to make repair or replacement of parts As a precaution it is suggested that safety glasses be worn When disassembling of assembling the starter motor Before disassembly perform the electrical tests oh the solenoid described under Inspection and Repair later in this section SOLENOID Disassemble Figure 11 Clean the outside of the starter housing removing grease oil mud etc Scribe marks to show t...

Page 238: ...ENOID ATTACHMENT 54 SCREWS SOLENOID ATTACHMENT 55 TUBE DRAIN 57 ASSEMBLY FRAME AND FIELD INCLUDING BRUSHES 58 BOLTS THROUGH F9324 6 Drive assembly 32 from the armature shaft 9 as follows A Remove the thrust collar 17 from the armature shaft B Drive the pinion stop collar 39 away from the pinion stop retainer ring by sliding a metal cylin der onto the armature shaft and with a hammer striking the m...

Page 239: ...mutator Do not undercut the insulation Clean the commutator with No 240 grit emery cloth Blow away any copper dust present If the commutator cannot be cleaned replace the armature 4 Armature for short circuits figure 13 i Rotate the armature in a growler with a steel strip such as a hacksaw blade held on the armature parallel to the shaft The steel strip will vibrate on the area of the short circu...

Page 240: ...0 a pole shoe spreader and pole shoe screwdriver should be used Care should be exercised in replacing the field coils to pre vent grounding or shorting them as they are tightened into place 14 Drive assembly clutch by turning the drive pinion in the cranking direction If the drive pinion turns roughly or slips in the cranking direction replace the complete over running clutch assembly 15 Solenoid ...

Page 241: ...noid 22 Battery 23 S Terminal 24 M Terminal 25 BAT Terminal 26 Voltmeter 27 Ammeter 29 Switch 30 Carbon Pile A Checking Solenoid Pull in Winding B Checking Solenoid Hold in Winding Q B 24 22 F4222 Figure 17 Solenoid Test Connections ...

Page 242: ...ubricate lightly the end frame bushings Avoid excessive lubrication Use Delco Remy lubri cant No 1960954 Lightly lubricate the shaft underneath the drive assembly with a silicone grease such as Del co Remy lubricant No 1960954 The drive assembly does not require lubrication 3 Drive assembly 32 on the armature shaft Slide the drive assembly on the shaft with the pinion gear toward the shaft end 4 S...

Page 243: ... armature shaft 9 clean and lubricate the area that will be under the drive assembly Use Delco Remy lubricant No 1960954 Wipe the drive assembly 32 clean 1 Drive assembly onto the armature shaft 2 Pinion stop collar 39 with the flat side of the collar toward the drive pinion figure 20 3 New retaining ring 37 onto the armature shaft Slide the ring down the shaft until it seats in the shaft groove 4...

Page 244: ... onto the commutator making sure all four brushes move freely and contact the commutator 2 Brake washer onto the armature assembly 3 End frame 41 to the field frame If the end frame bearing shows no lubrication or looks damaged replace it Recess the new bearing 2 mm 0 08 inch into the housing The bearing is pre lubricated so do not add lubricant 4 Identification tag over the hole in the end frame ...

Page 245: ...10 70 110 6500 10700 3563 Pinion Clearance 0 25 to 4 06 mm 0 01 to 0 16 inch SOLENOID SWITCH Starter Solenoid I Pull In Hold In Volts AMPS I Volts AMPS Volts All SD 300 1114489 12 11 18 5 13 18 10 10455013 10469039 12 30 36 5 12 15 10 FASTENER TIGHTENING SPECIFICATIONS N m Ft Lbs In Lbs SD 260 Starter Motor Field Lead Attaching Nut 11 95 Shield Attaching Nuts 8 70 Solenoid Clamp Retaining Screws 1...

Page 246: ...tor Solenoid Switch Fastener Tightening 6 D 4 1 6 D 4 1 6 D 4 2 6 D 4 3 6 D 4 3 6 D 4 3 6 D 4 4 6 D 4 4 6 D 4 4 6 D 4 4 6 D 4 5 6 D 4 5 6 D 4 5 6 D 4 5 6 D 4 5 6 D 4 9 6 D 4 1 1 6 D 4 1 1 6 D 4 1 1 6 D 4 1 1 6 D 4 1 1 6 D 4 1 3 6 D 4 1 4 6 D 4 1 4 6 D 4 1 4 6 D 4 1 4 DELCO REMY 37 MT STARTER MOTORS GENERAL DESCRIPTION The 37 MT 300 and 37 MT 350 heavy duty starter motors covered in this section ha...

Page 247: ...he cranking cycjeji After the motor cools usually in one to 6 minutes thO thermostat closes and the motor can again be cranked Internally the thermostat is attached to the commutator end ground terminal lead figure 2 i Type 300 starter motors have a grounding terminal installed in the commutator end frame Type 350 starter motors have this terminal plus a grounding stud installed in the field frame...

Page 248: ...ha form A 83 is January 1983 Therefore 3 K 18 is 1983 November 18 DIAGNOSIS OF THE STARTER MOTOR STARTER MOTOR TESTS t Before disassembling the starter motor for repair the fol owing tests should be made Figure 6 Solenoid Identification J N O T IC E N e v e r o p e ra te th e s ta rte r m o to r m o re th an 3 0 s e c o n d s a t a tim e w ith o u t p au sin g to a llo w it to co o l fo r a t le a...

Page 249: ...rmature of fields Check further after disassembly 3 Failure to operate with high current draw indicates A direct ground in the terminal or fields Seized bearings This should have been noted by turning the armature by hand 4 Failure to operate with no current draw indicates Open field circuit This can be checked after disassembly by inspecting internal connections and tracing the circuit with a tes...

Page 250: ...ng 48 2 Drive assembly 42 from the lever housing 3 Shaft retainer ring 46 from the lever housing at the end of the shift lever shaft 35 J Important The retainer will be bent during removal Do not attempt to reuse the same onesduring reassem bly y 4 Shift lever shaft 35 5 Shift lever 34 FIELD COIL Disassemble Figures 8 and 9 Important Check the field coil for grounds as described under Inspection a...

Page 251: ...6D4 6 37 MT STARTER MOTORS V3022 Figure 8 37 MT Components ...

Page 252: ... SHIFT LEVER SHAFT 60 NUT 13 INSULATOR FIELD COIL 37 BUSHING 61 SCREW 14 SCREW POLE SHOE 38 SCREW MOUNTING 62 SOLENOID 15 SHOE POLE 39 HOUSING DRIVE 63 PLUNGER SOLENOID SWITCH 16 SPACER ARMATURE AND 40 RING PINION STOP RETAINER 64 NUT LEVER HOUSING 41 STOP PINION 65 RING THERMOSTAT RETAINING 17 COIL 42 ASSEMBLY DRIVE 66 TERMINAL 18 ARMATURE 43 O RING 67 TERMINAL AND LEAD 19 PIN BRUSH PLATE LOCATIN...

Page 253: ...uc tors join the commutator bars Poor connections cause arcing and burning of the commutator If the bars are not badly burned the leads can be resoldered using rosin flux and the commutator turned down in a lathe to remove the burned material 6 Armature for grounds by using a test lamp figure 15 If the test lamp lights when one test prod is placed on the commutator and the other test prod is place...

Page 254: ...in figure 16 to check the pull in winding NOTICE To prevent overheating the pull in winding do not leave the winding energized more than 15 seconds The current draw will decrease as the w inding tem perature increases Compare the reading to the pull in winding specification at the end of this section A high reading indicates a shorted pull in winding A low reading indicates excessive resistance 17...

Page 255: ... A CHECKING HOLD IN WINDING TYPE 300 B CHECKING HOLD IN WINDING TYPE 350 C CHECKING PULL IN WINDING BOTH 115 TERMINAL BAT 116 TERMINAL M 117 TERMINAL S 118 VOLTMETER 119 AMMETER 120 SWITCH 121 BATTERY 122 PILE CARBON 117 119 V3035 Figure 18 Checking Windings ...

Page 256: ...nsulator 13 to the field frame figure 17 NO TICE R e fe r to N o tic e on pag e 6D 4 1 Q Tighten Pole shoe screws and frame ground terminal if used to 45 N m 33 ft lbs 5 Outer field coil terminal insulator 67 to the field frame MAIN ASSEMBLIES 0 Install or Connect Figures 8 and 9 N O T IC E F o r step s 10 16 19 2 1 a n d 2 5 through 29 re fe r to N o tic e on p ag e 6D 4 1 1 Shift lever 34 in the...

Page 257: ...e pliers to pull the free end of ihe brush spring past the holder and place the spring against the side of the brush This will hold the brush in a retracted position for further motor assembly 19 Terminal assembly 10 with the thermostat 12 if present to the negative grounded brush holders and brush leads with the brush attaching screws 23 Place the terminal leads between the brush holders and brus...

Page 258: ...hermostat connector if present and commutator terminal mounting nut 64 to the commutator end ground terminal T i g h t e n Mounting nut to 30 N m 22 ft lbs Ground lead from the commutator end terminal to the solenoid type 350 if used outer nut 64 Hold the mounting nut next to the end frame to keep it from turning while tightening the outer terminal nut a T i g h t e n Terminal nut to 30 N m 22 ft ...

Page 259: ...r t e r S o l e n o i d V o l t s P u l l n H o l d I n A M P S V o l t s A M P S V o l t s 1993947 1115618 12 24 29 5 16 20 10 1993963 1115609 12 24 29 5 16 20 10 1993964 1115609 12 24 29 5 16 20 10 FASTENER TIGHTENING 37 MT Starter Motors N m Ft Lbs In Lbs Lever Housing to Field Frame Bolts 20 15 Drive Housing to Lever Housing Screws 24 18 End Frame Bolts 5 6 50 Field Connector to Solenoid Screw...

Page 260: ...on control module to trig ger the primary ignition circuit Current flow in the pri mary circuit is interrupted and a high voltage of up to 35 0CI0 volts is induced in the ignition coil secondary winding This high voltage is directed through the sec ondary ignition circuit to fire the spark plugs The magnetic pickup assembly is mounted over the main bearing on the distributor housing The electronic...

Page 261: ...o v i n g s p r i n g s t e e l r e t a i n e r c j i p s a s d e s c r i b e d i n t h i s p r o c e d u r e I f y o u r e y e s a r e n o t p r o t e c t e d f l y i n g m e t a l p i e c e s m a y c a u s e i n j u r y Round Retainer A Wear safety goggles B Wedge a screwdriver under the edge of the retainer and use a lift and twist motion to pry the edge up just far enough to get the metal I sn...

Page 262: ...ewdriver 10 Pickup coil 11 11 Two screws holding the ignition control module to the housing 12 Module 14 INSPECTION AND ELECTRICAL TESTS Inspect 1 Cap for cracks or tiny holes Replace the cap if it is damaged at ail 2 Metal terminals in the cap for corrosion Scrape them clean with a knife or replace the cap 3 Rotor for wear or burning at the outer terminal The presence of carbon on the terminal in...

Page 263: ... the low scale The reading should be very loW 0 35 0 45 ohms If not replace the coil Jj Connect the ohmmeter as shown jn step 3 Use the high scale The meter should read 7 000 to 10 000 ohms If not replace the coil F2116 Figure 5 Testing the Pickup Coil 4 ASSEMBLY I r i s t a i l o r C o n n e c t F i g u r e 3 N O TIC E B e su re to tho ro u g h ly c o a t the b o t tom o f the Ig n itio n m odule...

Page 264: ...o the bottom of the shaft Align the marks on the driven gear housing and shaft assembly 8 Roil pin 27 into the gear Spin the shaft and make sure the teeth on the shaft assembly do not touch the pole piece 9 Rotor 10 onto the shaft Fit the tab in the rotor into the slot on the shaft 10 Cap 23 to the housing with screws 25 A Hammer B 15 mm 5 8 inch Socket C Round Retainer D Square Retainer E Distrib...

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