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Measure
• G low plug resistance. C onnect an ohm m eter
between the electrical connector blade and the
glow plug body. Replace any glow plug with a
resistance greater than 2 ohms.
THERM OSTAT AND COOLANT
CROSSOVER
There are two different types of thermostats used on
the 6.5L diesel engine. The C/K models use a “ blocking
bypass” type thermostat. The poppet at the bottom of
this thermostat closes off the coolant bypass hose when
the engine is at operating temperature and the thermo
stat is fully open. This causes all coolant to flow
through the radiator. Due to space restrictions, the P
truck and G-van models use a conventional “ balance
type” thermostat. Refer to SECTION 6B1 in the appro
priate application service manual.
*
Disassemble (Figure 19)
1. Bolts or studs (106).
2. Coolant outlet (107).
3. Thermostat (108).
4. Gasket (103).
L*
Inspect
• Coolant outlet and coolant crossover for cracks.
Thermostat Check
1. Suspend the therm ostat and a thermometer in
water with the thermometer located close to the
thermostat. The thermostat must be completely
submerged and the coolant thoroughly agitated
while heating. Apply heat to the coolant and record
both the tem perature at which the therm ostat
begins to open and the temperature at which the
thermostat is fully open. The thermostat should
begin to open at 1.6°C (4°F) above or below the
temperature stamped on the thermostat. It should
be fully open at approximately 13°C (24°F) above
the stamped temperature located on the thermo
stat.
2. Do not attempt to repair the thermostat. If the
thermostat does not function properly, replace it
with a new unit which has been checked as direct
ed previously.
Install or Connect (Figure 19)
1. Gasket (103).
2. Thermostat (108).
3. Coolant outlet (107).
N O T IC E : R e f e r to “N o t i c e ” o n p a g e 6 A 7 -1 .
4. Bolts or studs (106).
Tighten
IN JEC TIO N N O ZZLE TESTS
Tool Required:
J 29075-B Nozzle Tester
J 29079-125 Adapter Kit
J 29079-1 Line Assembly
J 29079-3 Adaptor Nut
J 29079-18 Adaptor
J 29079-13 Manifold Adaptor
J 7660-101 Washer
Nozzle testing is comprised of the following checks:
• Nozzle opening pressure
• Leakage
• Chatter
• Spray pattern
Each test should be considered independent of the
others. For example, when checking opening pressure,
do not check for leakage.
If all of the above checks are okay, the nozzle holder
assembly can be reused. If any one of the checks is
not okay, the complete nozzle holder assembly must be
replaced. The nozzle holder will then be checked and
repaired at a centralized location.
When performing the injection nozzle tests,
refer
to
the in s tru c tio n s provided w ith the nozzle te s te r
J 29075-B.
•Test Lines - 6x2x400-mm (1.5-mm bore).
•Test Fiuid - per ISO 4113 (Example: Shell V 1399,
Viscosity 1487C or equivalent).
• Kinetic Viscosity at 4°C (40°F) - per ISO 3104: 2.45
to 2.75 mm/second.
• Test oil temperature during test: 20 to 25° C (68° to
77°F).
1. Connect the nozzle holder assembly to the test
line.
2. Place clear plastic tubes on overflow connections
to prevent leakoff from being confused with actual
leak.
3. Close the shutoff valve to the pressure gage.
CAUTION: When testing nozzles, do not place
your hands or arms near the tip of the nozzle.
The high pressure atomized fuel spray from a
nozzle has sufficient penetrating power to
puncture flesh and destroy tissue and may
result in blood poisoning. The nozzle tip
should always be enclosed in a receptacle,
preferably transparent, to contain the spray.
4. Fill and flush the nozzle holder assembly with test
oil by activating the lever briskly and repeatedly.
This will apply test oil to all functionally important
areas of the nozzle and purge it of air.
OPENING PRESSURE TEST
I.O p e n the shutoff valve at the pressure gage
one-quarter turn.
CAUTION: When testing nozzles, do not place
your hands or arms near the top of the noz
zle. The high pressure atomized fuel spray
from a nozzle has sufficient penetrating pow
er to puncture flesh and destroy tissue and
may result in blood poisoning. The nozzle tip
should always be enclosed in a receptacle
preferably transparent, to contain the spray.
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: ......