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DISASSEMBLY OF THE ENGINE
TOOLS AND SHOP EQUIPM ENT
A clean, well-lit, work area should be available. 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 help aid with the
work and help prevent personal injury or component
damage.
Special tools are listed and illustrated throughout this
section with a complete listing at the end of the section.
These tools (or their equivalents) are specially designed
to quickly and safely accomplish the operations for
which they are intended. The use of these special tools
will also minimize possible damage to engine compo
nents.
Some precision measuring tools are required for
in sp e ctio n of ce rta in c ritic a l com ponents. Torque
wrenches are necessary for the correct assembly of
various parts.
ACCESSORY REMOVAL
The various procedures in this manual assume that
the engine accessories have been removed. These
accessories may include one or more of the following:
• Power Steering Pump
• Drive Belt Tensioner
• Generator
• Air Conditioning Compressor
• Cooling Fan
• Distributor
It is beyond the scope of this section to cover in detail
the many different accessory installations. Refer to the
proper Light Duty Truck Service Manual for this infor
mation.
Diagrams of emissions and vacuum hose routings,
wiring harness routing, accessory drive belt layout, etc.
should be found or made before removing accessories.
CLEANING
Remove the engine accessories before cleaning to
provide better access to the engine’s exterior surfaces.
After removing the distributor, accessory brackets, etc.,
cover the openings with tape to prevent the entry of
contaminants.
Methods used to clean the engine will depend on the
means which are available. Steam cleaning, pressure
washing, or solvent cleaning are some of the accept
able methods. Allow the engine to dry thoroughly before
beginning any work.
It is important that the engine be as clean as possible
to prevent dirt, water, or any other contaminants from
entering critical areas during disassembly.
D RAINING TH E ENGINE
Remove or Disconnect
1. Oil pan plug and washer and allow the oil to drain
from the pan.
2. Oil filter.
3. Coolant drain plugs from the block and allow the
coolant to drain.
Install or Connect
NOTICE: For step s 1 and 3, refer to “Notice’
on page 6A4-1.
1. Coolant drain plugs into the block.
Tighten
&
• Coolant drain plugs to 30 N-m (22 lbs. ft.).
2. Oil filter.
3. Oil pan drain plug and washer.
• Oil pan drain plug to 25 N-m (18 lbs. ft.).
EXHAUST MANIFOLD REMOVAL
Remove or Disconnect
1. Exhaust manifold bolts, washers, and tab washers.
2. Heat shields.
3. Exhaust manifold.
COOLANT PUMP REMOVAL
4- +
Remove or Disconnect
1. Coolant pump bolts.
2. Coolant pump.
3. Gaskets.
ROCKER ARM COVER REMOVAL
Remove or Disconnect (Figure 7)
1. Rocker arm cover bolts (1).
2. Rocker arm cover (2).
3. Gasket (3).
Summary of Contents for S Series 1994
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...
Page 24: ...NOTES...
Page 26: ......
Page 69: ...NOTES...
Page 71: ...3 2 STEERING...
Page 73: ......
Page 84: ......
Page 102: ...40...
Page 130: ...NOTES...
Page 146: ...NOTES...
Page 162: ...NOTES...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...
Page 190: ...NOTES...
Page 202: ...NOTES...
Page 206: ...F5785...
Page 212: ...B Button Moved Out of Bearing Bore F5791...
Page 228: ...NOTES...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap...
Page 261: ...F7475...
Page 267: ...B Button Moved Out of Bearing Bore F5791...
Page 294: ...NOTES...
Page 300: ...NOTES...
Page 318: ...NOTES...
Page 322: ...SR207LN2 EDS...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...
Page 368: ...103 153 127 V1200...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...
Page 399: ...V2974...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...
Page 452: ......
Page 454: ...163 164 V1202...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...
Page 460: ......
Page 510: ......
Page 512: ...V2131...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751...
Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...
Page 566: ...NOTES...
Page 574: ...NOTES...
Page 618: ...SPECIAL TOOLS...
Page 620: ...NOTES...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E...
Page 697: ...SPECIAL TOOLS...
Page 698: ...SPECIAL TOOLS...
Page 758: ...RH0194 4L80 E...
Page 764: ......
Page 770: ...SPECIAL TOOLS...
Page 771: ...SPECIAL TOOLS CONT...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079...
Page 840: ......
Page 848: ...NOTES...
Page 852: ......
Page 860: ...F5435...
Page 866: ......
Page 878: ...F9167...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...
Page 890: ...F9168...
Page 908: ......
Page 919: ......