Chevrolet BEAUVILLE SPORTVAN G10 SERIES Service Manual Download

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1 0 -3 0 SER IES

C H E V Y V A N -S P O R T V A N

SERVICE MANUAL

C H E V R O L E T ,

ST 140

Summary of Contents for BEAUVILLE SPORTVAN G10 SERIES

Page 1: ...10 30 SERIES CHEVY VAN SPO RTVAN SERVICE MANUAL C H E V R O L E T ST 140...

Page 2: ...pecifications covering vehicle com ponents are presented at the rear of the manual This manual should be kept in a handy place for ready refer ence If properly used it will enable the technician to be...

Page 3: ...78 83 Service Parts Identification Plate 0 2 Keys and Locks 0 3 Pushing to Start V ehicle 0 3 T ow ing 0 3 Engine Vehicle Availability 0 4 Load Capacity C h a rt 0 5 Fourth and Fifth Numbers Body and...

Page 4: ...in which the unit was manufactured and thereby permits proper follow up of the plant involved to get corrections made when necessary Always include the prefix in the number Starters Starter Serial Nu...

Page 5: ...y Do NOT permit vehicles to touch each other as this could establish a ground connection and counteract the benefits of this procedure 4 Attach one end of the remaining negative cable to the negative...

Page 6: ...r the Front and Rear Axle and Spring columns indicate that base equipment is satisfactory to qualify the vehicle for any given GVW rating When the letters RPO denoting Regular Production Option follow...

Page 7: ...972 CHEVROLET SERIES G10 G20 G30 SPORTVAN AND BEAUVILLE SPORTVAN 1972 MODELS W HEEL BASE GROSS VEHICLE WEIGHT RATING POUNDS MAXIMUM LOAD CAPACITY c MINIMUM MANDATORY EQUIPMENT FOR GVW RATING FRONT TIR...

Page 8: ...hevrolet light duty gasoline trucks regardless of model year and previous engine oil quality recommendations OIL CHANGE PERIOD Use only SE engine oil SE oils meet quality standard GM 6041 M Change oil...

Page 9: ...e system should be tested for proper function and serviced if necessary AIR INJECTION REACTOR SYSTEM A I R CONTROLLED COMBUSTION SYSTEM C C S The Air Injection Reactor system should have the drive bel...

Page 10: ...Gear Lubricant SAE 90 Gear Lubricant should be used only where ambient temperatures are continuously above 32 F TRANSMISSION SHIFT LINKAGE MANUAL AND AUTOMATIC Every 6 000 miles or 4 months lubricate...

Page 11: ...s Lube which meets GM Specification GM 6031M to lubricate the gear DO NOT O V E R F IL L the gear housing NOTE Lubricate intermediate steering shaft with water resistant EP chassis lubricant which mee...

Page 12: ...s Replace L 6 Rotate V 8 Replace V 8 at 24 000 miles 10 D istributor L 6 V 8 12 000 Miles Replace Cam Lubricator 11 Transmission Synchromesh Automatic 6 000 Miles 6 000 Miles GL 5 Dexron or Equivalent...

Page 13: ...oints on bodies which may occasionally require lubrication and which are difficult to service Window regulators and controls are confined in the space between the upholstery and the outside door panel...

Page 14: ...ower A ssem bly 1A 2 Control C ables 1A 5 Heater Core Case and Core Assembly 1A 2 Blower S w itc h 1A 6 Heater H o s e s 1A 3 R e sisto r 1A 6 Center Distributor D u c t 1A 3 GENERAL DESCRIPTION The h...

Page 15: ...f air to the defroster outlets until at the full down position all of the air is directed to the defroster outlets COMPONENT REPLACEMENT AND REPAIRS BLOWER MOTOR Fig 3 Replacement 1 Disconnect the bat...

Page 16: ...ged in the area of the core tube attachm ent seams whenever undue force is exerted on them Whenever the heater core hoses do not readily come off the tubes the hoses should be cut just forward of the...

Page 17: ...t It may be necessary to hold the cables down as the duct is being installed Be sure the left duct is fully installed over the center duct DEFROSTER OUTLETS AND HOSES Replacement Fig 7 1 Disconnect th...

Page 18: ...e control to I P lower mounting screw CONTROL CABLES Replacement Fig 9 1 Disconnect the battery ground cable 2 Unsnap the engine cover front latches Remove the two cover to floorpan screws and remove...

Page 19: ...nector 2 Remove the two resistor to dash mounting screws and remove the resistor 3 To install a new resistor reverse Steps 1 and 2 above AUXILIARY HEATER INDEX Page Page General D escrip tio n 1A 6 Co...

Page 20: ...T AND REPAIRS Since a detailed list of installation instructions is included with the auxiliary heater unit replacement procedures will not be repeated in this section CA U TIO N All Models When repla...

Page 21: ...HEATER 1A 8 Fig 12 Auxiliary Heater Water Valve 9 Auxiliary Heater Hose Routing 110 W B Models with Rear Seats Fig 13 Auxiliary Heater Control Switch C H E V Y V A N SHOP M A N U A L...

Page 22: ...of C om ponent Parts 1A 22 Foreign M aterial in the System 1A 22 R efrigerant Line Connections 1A 22 Repair of Refrigerant Leaks 1A 23 Refrigerant H ose F a ilu r e 1A 24 Com pressor 1A 24 Condenser...

Page 23: ...the outlet air temperature Fig 17 C 62 and C 63 Control Panel A self contained unit the factory installed C 62 or C 63 System operates on recirculated air only Recirculated inside air is drawn into th...

Page 24: ...tor expansion valve blower m otor resistors switches and relay assemblies are mounted underneath the cover The front distributor duct is located between the blower and evaporator assembly and the engi...

Page 25: ...am cleaning can result in a dangerous pressure buildup in the system Discharging large quantities of R 12 into a room can usually be done safely as the vapor would produce no ill effects however in th...

Page 26: ...r and moisture should be evacuated from the system before recharging J 8393 CHARGING STATION The J 8393 Charging Station is a portable assembly of a vacuum pump refrigerant supply gauges valves and mo...

Page 27: ...harging station provides two flexible lines for connect ing the gauge set to the system components VACUUM PUMP A vacuum pump should be used for evacuating air and moisture from the air conditioning sy...

Page 28: ...o not use lighted detector in any place where combustible or explosive gases dusts or vapors may be present Operating Detector 1 Determine if there is sufficient refrigerant in the system for leak tes...

Page 29: ...he complete system 6 If there is evidence o f an oil leak check the compressor to see that the oil charge is satisfactory NO TE A slight amount of oil leakage at the compressor front seal is considere...

Page 30: ...so that a component part can be safely removed 1 With engine stopped install high and low pressure lines of Charging Station gauge set to the proper high and low pressure gauge fittings See Installing...

Page 31: ...om container Therefore close observation of oil level in the container is necessary c Note level of oil in container Open valve on oil adding tool until oil level in container is reduced by an amount...

Page 32: ...ols set for Maximum cooling High blower speed NOTE When running a Performance Test on a C 62 and C 63 equipped vehicle both systems should be in operation 5 Gauge set installed 6 System settled out ru...

Page 33: ...ressor has the required am ount of oil To further check the compressor oil charge should the above test show insufficient oil it is necessary to remove the compressor from the vehicle drain and measur...

Page 34: ...switch wiring harness Remove the switch attaching screws and remove the switch 4 Remove the switch non metal end plate to gain access to the switch adjusting screw 5 If the outlet tem perature was les...

Page 35: ...rmed in the sequence shown 1 Purge the system by releasing the refrigerant to the atmosphere 2 Remove and replace the defective part 3 Evacuate charge and check the system W A R N IN G Always wear pro...

Page 36: ...hose REPAIR OF REFRIGERANT LEAKS Any refrigerant leaks found in the system should be repaired in the manner given below Leaks at O Ring Connection 1 Check the torque on the fitting and if too loose ti...

Page 37: ...gine cover and remove the cover 7 Remove the air cleaner to aid access to the compressor 8 Remove fitting and muffler assembly and cap or tape all open connections 9 Remove the nuts and bolts attachin...

Page 38: ...rom the vehicle 8 Remove the condenser mounting brackets from the condenser 9 To install reverse Steps 1 8 above Add 1 fluid ounce of clean refrigeration oil to a new condenser C A U TIO N Use new O r...

Page 39: ...at hold the duct to the engine cover 2 Lift upwards and rearward on the top of the distributor duct assembly and move it away from the evaporator and blower m otor assembly cover being careful not to...

Page 40: ...sembly removal procedure NOTE Add 3 fluid ounces of new refrigeration oil to a new core 3 Evacuate charge and check the system BLOWER M O TOR FRONT Removal 1 Disconnect the battery ground cable and co...

Page 41: ...g Diagrams at rear of this section SPORTVAN DUCT C 63 FRONT AND INTERMEDIATE Replacement Fig 37 1 Remove sealing strips at ends of ducts 2 Remove retaining screws 3 Squeeze the sides of the duct toget...

Page 42: ...shown in the Service Manual Fig 9 0 Blower Motor Installation 2 Install the blower m otor retaining strap and foam 3 Place the two blower m otor and wheel assemblies into the lower case Align the blo...

Page 43: ...th clean refrigeration oil 6 Connect the blower lead wires and ground straps 7 Install the rear duct as described previously 8 Connect the battery ground cable and the compressor clutch connector 9 Ev...

Page 44: ...AIR CONDITIONING 1A 31 BOW SUPPORT SUPPORT EVAP BLOWER ASM BLOW ER_________ GRD WIRES BRACKET Fig 4 2 Rear Blower Evaporator Assembly C H E V Y V A N SHOP M A N U A L...

Page 45: ...H GRD a z m I6BLK 0RN fsa j 1 vM3 14 BLU LT 14 Y EL s 14 O R N 172h C 5 I 1 B y A 2 RESISTOR 14 BRN 14 YEL m 14 GRN DK 16 BLK ORN V I4 ORN 14 YEL J BLOWER SWITCH POS CIRCUIT OFF BATT ONLY LO BATT LO M...

Page 46: ...I Q 1 9 0 4 152 1 I 72 V Q cr _ O LU 31 cd I g a 14 B E g g GRD I6BLK 0RN A K BLOWER MTR REAR BLOWER MTR FRONT ct 2 o oo 2 I BLOWER SWITCH T SL 4 ic g H J r e c p 9 0 2 9 0 l 63 19 0 3 1 FRONT FUSE P...

Page 47: ...e 25 15 J 9397 Compressing Fixture 16 J 9403 Clutch Hub Holding Tool 17 J 9399 9 16 Thin Wall Socket 27 18 J 9401 Hub and Drive Plate 28 Assembly Remover 19 J 9480 Hub and Drive Plate Assembly Install...

Page 48: ...17 Seat Riser Passenger Seat IB 17 Bench S e a ts IB 17 Seat and or Seat S u p p o rt IB 17 Body W indow s 1B l8 Side Stationary Window Glass Weatherstrip and Reveal M oldings IB 18 Side Window Glass...

Page 49: ...BODY 1B 2 DASH PANEL FLOOR PANEL FRONT INNER ROCKER PANEL FRONT WHEELHOU TEP PANEL Fig 1 Body Sealing Areas C H E V Y V A N SHOP M A N U A L...

Page 50: ...f link rod to m otor drive and arm Secure rod with the two attaching nuts 3 Install outside air cowl ventilator grille to top of cowl 4 Before installing wiper arms operate wiper m otor momentarily wh...

Page 51: ...d before installing a replacement windshield The replacement glass is used as a template 1 Check for the following conditions at the previous marked point of fracture a Chipped edges on glass Fig 5 Ch...

Page 52: ...upper corners d Seal windshield to weatherstrip and weatherstrip to body Fig 9 Pulling String to Seal Rubber Lip Cowl Side Ventilator Valve Assembly Fig 10 Removal 1 Remove screws retaining valve gui...

Page 53: ...nting bracket Torque screw to specifications Sunshade Removal 1 Remove sunshades to header panel screw Installation 1 Install sunshade to header panel screw and torque to specifications Engine Access...

Page 54: ...or Attachments Door Ventilator Assembly Removal NOTE The channel between the door window glass and door vent is removed as part of the vent assembly 1 Regulate the door window glass to the full down p...

Page 55: ...filler causing it to swell thereby making a perfect watertight seal Trim off the excess filler material around the channel and at the ends of the channel NOTE Glass should be installed so that rear e...

Page 56: ...nd remove door trim pad 2 Remove bolts securing remote to door inner panel 3 Pivot remote inboard slightly to disengage connecting rod and remove remote from door 4 To install reverse removal procedur...

Page 57: ...ir expense They must be replaced with parts of the same part numbers or with equivalent parts if replacement becomes necessary Do not use replace ment parts of lesser quality or substitute design Torq...

Page 58: ...is for purpose of aligning the rear surface of door flush with adjacent surfaces of cab If surfaces are not flush proceed as follows 1 Mark the horizontal line on cab pillar at top of striker bolt bas...

Page 59: ...embly Torque all parts to specifications 7 When holding hinge assembly as in Fig 26 the lower latch must engage cam Installation 1 Install hinge assembly to door Torque bolts to specifica tions 2 Chec...

Page 60: ...upper left hinge Fore and A ft Fore and aft adjustments are provided by loosening the upper left hinge striker body mounted In and Out Front in and out adjustments Fig 27 are provided by means of an...

Page 61: ...r up or down and tighten upper left hinge to door bolts Torque bolts to specifications 8 Position upper front roller in center of track and tighten roller bracket to door Fig 28 Torque bolts to specif...

Page 62: ...er must enter the lock freely Up and Down Adjustment 1 Loosen striker with Tool J 23457 Fig 19 2 Center striker vertically to door striker opening 3 Adjust laterally to match door outer panel and body...

Page 63: ...riker Fig 3 3 Adjusting tow er Catch SEATS Drivers Seat Fig 34 Seat Adjuster Removal 1 Remove seat by removing bolts securing seat to seat riser 2 Remove seat belt from adjuster 3 Remove adjuster from...

Page 64: ...ssengers Seat Seat Riser Removal 1 Remove seat and adjusters as an assembly by remov ing bolts securing seat to riser 2 Remove bolts securing seat riser to floor Installation 1 Install seat riser to f...

Page 65: ...chnician lightly pushing in on glass another technician inside should pull the cord as follows a Pull on loose ends Fig 40 until each is within 2 of respective corner b Finish seating corners by simul...

Page 66: ...that when hinge screws are removed door weight will be on support 2 Remove hinge strap release pin 3 Remove hinge to door bolts and remove door assembly 4 Remove hinge to body bolts and hinge Installa...

Page 67: ...l trim panel Rear Door Glass and Weatherstrip Removal and installation procedures are the same as for the body side windows Refer to those procedures for rear door glass and weatherstrip replacement R...

Page 68: ...ngages latch Then open door and measure from grease impression to bottom of latch slot Torque to specifications 2 Adjust door wedge by adding or deleting shims as necessary so that wedge contacts bump...

Page 69: ...ons are required 1 The horizontal dimension between the two points to be trammed 2 The vertical dimension from the datum line to the points to be trammed The tram bar should be on a parallel to that o...

Page 70: ......

Page 71: ...Steering Knuckle Steering A rm 3 10 Removal 3 10 In stallatio n 3 11 Crossmember and Suspension Unit 3 11 R em o v al 3 11 In stallatio n 3 11 Special Tools 3 12 GENERAL DESCRIPTION The Chevrolet Che...

Page 72: ...wheel disc 9 Lower car to ground 10 Repeat this procedure for the other wheel FRONT ALIGNMENT DESCRIPTION Satisfactory vehicle operation may occur over a wide range of front end wheel alignment settin...

Page 73: ...Therefore it will be necessary to know the angle of the frame whether up in rear or down in rear before a corrected caster reading can be determined Camber and toe can be read as is from the alignment...

Page 74: ...l A CASTER ALIGNM ENT READING A FRAME ANGLE V i D O W N FRAME ANGLE 1Vi UP ACTUAL CASTER ANGLE IS 1 ACTUAL CASTER ANGLE IS 1 CROSSMEMBER ANGLE B 1 BUMP STOP BRACKET BOTTOM OF FRAME LOWER CONTROL ARM P...

Page 75: ...usage COMPONENT PARTS REPLACEMENT C A U TIO N This hub to spindle fastener is an important attaching part in that it could affect the performance of vital components and systems and or could result i...

Page 76: ...ent parts if replacement becomes necessary Do not use replacement parts of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of t...

Page 77: ...er ball stud Extend bolt from Tool J 23742 to loosen lower ball stud in steering knuckle When stud is loosened remove tool and nut from lower stud 4 Remove control arm Fig 9 Loosening Ball Joint Stud...

Page 78: ...bolts 6 Lower jack just enough to get at shaft 7 Remove shaft end nuts and remove shaft Fig 11 Positioning Lower Control Arm Shaft Repairs Bushings 1 Remove grease fittings from bushing outer ends an...

Page 79: ...ue the shaft end nuts CUT TOOL ON DOTTED LINE J 9519 3 WATER PIPE 2 W HIGH W i Fig 13 A lteration to Tool J 9519 10 FIT PIPE ON TOOL NOTE The shaft should rotate by hand after the nuts are torqued 4 I...

Page 80: ...n in Figure 9 C A U TIO N Before proceeding with Step 4 be sure lower control arm is supported as pointed out in Step 1 4 Extend bolt from tool J 23742 to loosen ball stud in steering knuckle When stu...

Page 81: ...serviced separately as outlined in the preceding service operations However if extensive service is to be perform ed to cross member frame etc the unit can be removed and installed as follows Removal...

Page 82: ...r 2 J 8458 Bearing Race Installer 7 J 9519 10 C Clamp 3 J 8849 Bearing Race Installer 8 J 9519 7 Ball Joint Remover 4 J 9276 2 Bearing Race Installer 9 J 23028 Spring Remover 5 J 8092 Driver Handle 10...

Page 83: ...are important attaching parts in that they could affect the performance of vital components and systems and or could result in major repair expense They must be replaced with parts of the same part nu...

Page 84: ...er shell of bushing Spring Leaf Replacement 1 Place spring assembly in a bench m ounted vise and remove spring clips 2 Position spring in vise jaws compressing leaves at center and adjacent to center...

Page 85: ...ed to a one piece differential case which is supported by two preloaded tapered roller bearings 30 Series The 30 Series 5200 lb capacity rear axle fig 17 is of the full floating type with hypoid ring...

Page 86: ...nt establishes the need for a line between normal and abnormal or unacceptable axle noises Slight axle noise heard only at a certain speed or under remote conditions must be considered normal Axle noi...

Page 87: ...with the housing installed in the vehicle or with the housing installed in a holding fixture The following removal and installation procedure is necessary only when the housing requires replacement NO...

Page 88: ...tangs on tool engage bearing outer race Remove bearing using slide hammer as shown in Figure 7 Fig 5 Differential Pinion Shaft Removal 3 Lubricate new bearing with wheel bearing lubricant and install...

Page 89: ...rm draw on cover gasket Fig 7 Wheel Bearing Removal 5 Fill axle with lubricant to a level even with bottom of filler hole See Section O for proper lubricant 6 Install brake drum and wheel and tire ass...

Page 90: ...s damages ears and for smoothness of bearing contact surface Replace if necessary 9 If deflector requires replacement remove by tapping from flange clean up stake points install new deflector and stak...

Page 91: ...Pinion Oil Seal Installation Heavy Duty Fig 15 Pinion Flange Installation It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a...

Page 92: ...Case Left Half 19 Axle Shaft Differential Bearing Differential Bearing Adjusting Nut Adjusting Nut Lock Differential Case Right Half SERIES 30 5200 CAPACITY AXLE FIG 17 Axle Assembly Service operation...

Page 93: ...joint making sure that U bolts are drawn up tight and locked properly Torque to specifications 6 Install rear wheels remove stand jacks and lower vehicle 7 Test operation of brakes and rear axle Axle...

Page 94: ...d cups see Bearing Cup Replacement for various axles 2 Thoroughly clean all lubricant off axle housing tube and out of inside the hub wipe dry Make sure all particles of gasket are removed from outer...

Page 95: ...will not loosen during vehicle operation Drum IMondemountable Type Fig 20 Replacement Construction of the nondem ountable type hub and drum assembly is such that replacement cannot be accomplished wi...

Page 96: ...e flange plate will be barely noticeable and wheel will turn freely If movement is excessive adjust bearings as follows 1 Remove axle shaft and raise vehicle until wheel is free to rotate 2 Disengage...

Page 97: ...ant holding left wheel forward rotate the right wheel to the rear checking for free rotation 5 Rotate both wheels as far to the rear as possible 6 While holding the left wheel rearward rotate the righ...

Page 98: ...e bearing support as follows a Install inner deflector on propeller shaft if removed and prick punch deflector at two opposite points to make sure it is tight on shaft b Fill space between inner dust...

Page 99: ...rt in that it could affect the performance of vital components and systems and or could result in major repair expense It must be replaced with one of the same part number or with an equivalent part i...

Page 100: ...Installer Light Duty Axle Used 10 J 22804 Pinion Seal Gauge Plates 1 Heavy Duty 2 Light Duty with J 9458 11 J 8092 Drive Handle Threaded Type 4 J 5748 Positraction Torque Measuring Adapter 12 J 5853...

Page 101: ...Capacity Axle Special Tools 1 J 22351 Wheel Oil Seal Installer 2 J 22281 Pinion Flange Oil Seal Installer 3 J 2223 Wheel Bearing Installer 4 J 2222 Wheel Bearing Nut Wrench 5 J 8092 Driver Handle 6 J...

Page 102: ...s 5 10 Anchor P i n 5 13 Wheel C y lin d e r 5 13 Brake Drum Servicing 5 14 Shoes and Linings Front Disc Brakes 5 15 Caliper O verhaul 5 19 Disc Servicing 5 20 Master C ylinder 5 21 Brake Combination...

Page 103: ...r pull back springs then pressure is allowed to flow with the result being a good distribution of braking effort The brake failure warning switch portion of the combina tion valve senses a loss of hyd...

Page 104: ...very 12 months or 12 000 miles whichever occurs first Inspect drum brake linings or disc brake pads as well as the other internal brake com ponents at each wheel drums rotors wheel cylinders etc For c...

Page 105: ...m or if fluid has been used which contains the slightest trace of mineral oil Flushing is performed at each wheel cylinder in turn and in the same manner as the bleeding operation except that bleeder...

Page 106: ...cylinders 9 Disconnect bleeder equipment from brake bleeder adapter 10 Remove bleeder adapter Wipe all areas dry if fluid was spilled during adapter removal 11 Fill master cylinder reservoirs to withi...

Page 107: ...h on the hose fitting C A U TIO N See Caution on Page 1 of this section 5 Bleed all brakes as outlined in this section BRAKE PIPE RETAINERS Fig 10 Retainers are used to secure the brake pipes to the f...

Page 108: ...n results in better formation of the flare 3 Place one half of the die blocks in the tool body with the counterbored ends toward the ram guide Now lay the Line Retainers tubing in the block with appro...

Page 109: ...ver seating 7 Blow tubing out with compressed air to remove any foreign objects Recommended Method of Adjustment a Use Drum to Brake Shoe Clearance Gauge J 21177 to check the diameter of the brake dru...

Page 110: ...ck nut on push rod 2 Turn push rod as required to provide correct adjustment Movement of pedal pad before push rod contacts master cylinder pistons must be 1 16 to 1 4 3 Tighten check nut against clev...

Page 111: ...ing a chisel or similar tool Release the actuator from the star wheel with a small screwdriver on models with access hole in backing plate or with a wire hook on models with hole in drum Back off the...

Page 112: ...not recommended that they be Fig 22 Brake Drum Access Hole Fig 23 U nhooking Pull Back Spring disassembled for service purposes unless they are broken It is much easier to assemble and disas semble th...

Page 113: ...hly cleaned and lubricated 5 Connect brake shoes together with adjusting screw spring then place adjusting screw socket and nut in position C A U TIO N Make sure the proper adjusting screw is used lef...

Page 114: ...the solid body of rivet extending through the shoe rim but no farther C A U TIO N Keep hands clean while handling brake lining Do not permit oil or grease to come in contact with lining 3 Start rivet...

Page 115: ...Lubricate the cylinder bore with clean brake fluid and insert spring expander assembly 2 Install new cups with flat surface toward outer ends of cylinder Be sure cups are lint and dirt free before in...

Page 116: ...ter Method Fig 29 1 Place the brake drum on a smooth surface 2 Using micrometers place the tips at the center of the drum face 3 While sweeping horizontally and vertically slowly adjust the micrometer...

Page 117: ...piston is pushed back into its bore Discard the brake fluid removed Never reuse brake fluid 2 Raise the vehicle and remove the front wheels 3 Push the piston back into its bore This can be accom plis...

Page 118: ...s using Delco Moraine Silicone Lube or its equivalent Fig 33 NOTE It is essential that new sleeves and rubber bushings be used and that lubrication instructions be followed in order to ensure the prop...

Page 119: ...inboard shoe and insert the new inboard shoe 11 Position the caliper over the brake disc lining up the hole in the caliper ears with the holes in the mounting bracket C A U TIO N Make sure that the br...

Page 120: ...r and caution so as not to scratch the piston bore pry the dust boot out of the caliper piston bore 6 Using a small piece of wood or plastic remove the piston seal from its groove in the caliper pisto...

Page 121: ...ke hose to the brake line at the frame bracket C A U TIO N See Caution on Page 1 of this section 2 Bleed the calipers using the m ethod outlined in the beginning of this section DISC SERVICING Servici...

Page 122: ...r line Fig 40 Master Cylinder Typical ends with clean lint free material to prevent foreign m atter from entering the system 3 Disconnect the push rod from the brake pedal 4 Unbolt and remove the mast...

Page 123: ...he front and rear chambers under normal failed and partially failed conditions Cylinders are designed so that this variable dis placement requirement is controlled within each bore size by the seconda...

Page 124: ...e replaced Functions Metering Valve This section of the valve operates to hold off hydraulic flow to the front disc brakes until a predetermined pressure is reached This hold off action allows the rea...

Page 125: ...to close This can be accomplished by installing Tool J 23709 under the mounting bolt and de pressing the pin a slight amount Be sure to re torque the mounting bolt after removing Tool J 23709 Fig 6 C...

Page 126: ...e instrum ent panel screw NOTE Install the clevis pin so that the cotter pin hole is toward the center of the vehicle C A U TIO N See Caution on Page 1 of this section FRONT CABLE Removal 1 Remove bol...

Page 127: ...e Unit is a self contained hydraulic and pedal effort than is required with the conventional nonpower vacuum unit utilizing manifold vacuum and atmospheric hydraulic brake system The unit is m ounted...

Page 128: ...e front housing of the power head Plug vacuum hose to prevent dust and dirt from entering hose 3 Disconnect the power brake push rod from the brake pedal 4 Remove the four nuts inside vehicle from the...

Page 129: ...5 J 21472 Bleeder Wrench 2 J 8000 Tubing Cutter 6 J 22904 Dust Boot Installer 3 J 8049 Spring Remover 7 J 23518 Bleeder Adapter 4 J 21177 Drum Shoe Gage 8 J 23709 Combination Valve Pin Retainer Fig 4...

Page 130: ...nsumption It is seldom advisable to attem pt a tune up by correction of one or two items only Time will normally be saved and more lasting results assured if the technician will follow a definite and...

Page 131: ...this defect NOTE If a weak cylinder cannot be located with the compression check see Cylinder Balance test under Additional Ciiecks and Adjustments in this section SERVICE INSTALL SPARK PLUGS FIG 2 1...

Page 132: ...lor and only slight roughness or pitting need not be replaced Dirty points should be cleaned with a clean point file Use only a few strokes of a clean fine cut contact file The file should not be used...

Page 133: ...rge with a slow rate charger or if desired further check battery Fig 5 D istrib u to r V8 2 Connect a voltm eter across the battery terminals and measure the terminal voltage of the battery during cra...

Page 134: ...trol Valve In Line If the battery has been using too much water the voltage output is too high SERVICE DELCOTRON AND REGULATOR The Delcotron and regulator tests during tune up consist of the above bat...

Page 135: ...open position On vehicles equipped with Powerglide pull through detent 4 Adjust accelerator rod to freely enter hold in carburetor throttle lever NO TE Accelerator linkage is outlined in detail in Sec...

Page 136: ...ventilation system the carburetor and the carburetor air cleaner Carburetors and distributors for engines with the Air Injection Reactor System and Controlled Combustion System are designed particula...

Page 137: ...ne up chart in Specification section 3 Aim timing light at timing tab NOTE The markings on the tabs are in 2 increments the greatest number of markings on the Before side of the O The 0 marking is TDC...

Page 138: ...et engine idle or if the solenoid is adjusted out of limits as specified in Section 6M a decrease in engine braking may result Reconnect Fuel Tank line to vapor canister and reconnect distributor spar...

Page 139: ...il by passing resistance wire are in good condition b If below 9 volts check circuit until difficulty is located M eter reading below specification Weak battery defective cables connections switch or...

Page 140: ...th pressure testing equipment available commercially for this purpose This test provides an excellent means of detecting internal or external leaks within the cooling system 1 Remove radiator cap 2 Ap...

Page 141: ...en nut to just remove all push rod to rocker arm clearance This may be determined by rotating push rod with fingers as the nut is tightened Fig 23 When push rod does not readily move in relation to th...

Page 142: ...e assemblies the removal installation and adjustment of some sub assemblies and replacement of some components For service to all components and sub assemblies after removal and removal of some sub as...

Page 143: ...is time 20 Remove the six 3 on each side vertically driven front crossmember to frame attaching bolts Fig 2L 21 Remove the four 2 on each side frame to upper control arm inside attaching bolts Fig 3L...

Page 144: ...erter housing underpan and starter d Connect throttle linkage and vacuum modulator Connect detent cable on Turbo Hydra Matic 2 Raise engine and align m ounts on engine with brackets on crossmember ins...

Page 145: ...at the center of the manifold to finger tight 4 Position new gasket over manifold end studs on the cylinder head 5 Install manifold assembly bolts and clamps while holding manifold assembly in place b...

Page 146: ...ifter is not functioning properly a distinct shock will be felt when the valve returns to its seat The general types of valve lifter noise are as follows 1 Hard Rapping Noise Usually caused by the plu...

Page 147: ...the valve locks and release the compressor tool making sure the locks seat properly in the upper groove of the valve stem NO TE Grease may be used to hold the locks in place while releasing the compr...

Page 148: ...e oil pan bolts and withdraw oil pan from engine Installation 1 Discard old gaskets and seals thoroughly clean all gasket sealing surfaces 2 Install new rear seal in rear main bearing cap 3 Install ne...

Page 149: ...ing cap by prying from the bottom with a small screw driver Fig 10L 3 To remove the upper half of the seal use a small hammer Fig 13L Removing Torsional Damper to tap a brass pin punch on one end of s...

Page 150: ...tion of the tor sional damper is assembled to the hub with a rubber type material The installation procedures with proper tool must be followed or movement of the inertia weight section on the hub wil...

Page 151: ...mage the seal surface on the crankshaft 2 Install new seal so that open end of seal is toward the inside of cover and drive it into position with Tool J 23042 Fig 17L CAMSHAFT Measuring Lobe Lift NO T...

Page 152: ...he camshaft gear run out should not exceed 004 and the crankshaft gear run out should not exceed 003 4 If gear run out is excessive the gear will have to be removed and any burrs cleaned from the shaf...

Page 153: ...f the m ount or c Rubber split through center Replace the m ount If there is relative movement between a metal plate of the m ount and its attaching points lower the engine on the mounts and tighten t...

Page 154: ...ts b Connect clutch rod at outboard lever on clutch cross shaft 8 Lower vehicle on hoist and check operation o f clutch Rear Mount Replacement Fig 26L 1 Raise vehicle on hoist and support transmission...

Page 155: ...on covers the removal and installation of engine assemblies the removal installation and adjustment of some sub assemblies and replacement o f some components For service to all components and sub ass...

Page 156: ...o frame attaching bolts Fig 2V 19 Remove the four 2 on each side frame to upper control arm inside attaching bolts Fig 3V 20 Lower the vehicle on hoist so that weight of vehicle is on hoist but with w...

Page 157: ...transmission and clutch housing as out lined in Section 7 d Install clutch housing rear cover bolts and torque to specifications Install automatic transmission if so equipped a Position engine adjace...

Page 158: ...nsmission cooler lines and fill cooling system 23 Install engine cover 24 Connect battery ground cable at engine block and at battery 25 Bleed front and rear brakes as outlined in Section 5 26 Start e...

Page 159: ...connect crankcase ventilation hoses at rocker arm covers 3 Disconnect tem perature wire and plug wires from left rocker arm clips 4 Remove carburetor heater from right exhaust manifold 5 Remove rocker...

Page 160: ...extent that the return spring can no longer push the plunger back up to working position Probable causes are a E xcessive varnish or carbon deposit causing abnormal stickiness b Galling or pick up be...

Page 161: ...in the torque sequence chart until the specified torque is reached 6 Install exhaust manifolds as outlined 7 Install intake manifold as outlined 8 Install and adjust valve mechanism as outlined Oil Pa...

Page 162: ...cap by prying from the bottom with a small screwdriver Fig 12V 3 To remove the upper half of the seal use a small hammer to tap a brass pin punch on one end of seal until it protrudes far enough to b...

Page 163: ...ve accessory drive pulley then if so equipped remove damper retaining bolt 4 Install Tool J 23526 on damper then turning puller screw remove damper Fig 15V Installation Fig 15 V Removing Torsional Dam...

Page 164: ...ater pump as outlined in Section 6K 5 Install torsional damper as outlined 6 Install oil pan as outlined Oil Seal Front Cover Replacement With Cover Removed 1 With cover removed pry old seal out of co...

Page 165: ...Chain 6 Install timing chain on camshaft sprocket Hold the sprocket vertical with the chain hanging down and align marks on camshaft and crankshaft sprockets Fig 22V NOTE Do not attempt to drive spro...

Page 166: ...s then remove camshaft Fig 24V C A U TIO N All camshaft journals are the same diameter and care must be used in removing cam shaft to avoid damage to bearings Installation NOTE Whenever a new camshaft...

Page 167: ...ansmission mount If the rubber separates from the metal plate of the m ount or if the tailshaft moves up but not down m ount bottom ed out replace the m ount If there is relative movement between a me...

Page 168: ...pport from vehicle 4 Remove bolts securing m ount to transmission extension 5 Install new rear m ount and torque bolts to specifications 6 Position support crossmember to cross rail install bolts then...

Page 169: ...ocket Puller Crankshaft Gear Puller Crankshaft Sprocket or Gear Installer Crankcase Cover Centering Gauge Crankcase Cover and Seal Installer Engine L ift Kit 0 200 Ft Lb Torque Wrench 0 50 Ft Lb 0 100...

Page 170: ...ssure Cap pressure The higher pressure raises the boiling point o f the coolant which increases the efficiency of the radiator The radiator filler cap contains a pressure relief valve and a vacuum rel...

Page 171: ...th the area in which the vehicle will be operated Regardless of climate system protection should be maintained at least to 0 F to provide adequate corrosion protection When adding solution due to loss...

Page 172: ...inder Block and Cylinder Head 1 With the therm ostat removed attach a lead away hose to the water pump inlet and a length of new hose to the water outlet connection at the top of the engine N O T E Di...

Page 173: ...vement This represents the total radial run out Mark the point on the pulley at which the highest reading is obtained 4 If the total indicator reading is less than 006 inch the assembly is within spec...

Page 174: ...oper balance could fail and fly apart during subsequent use creating an extremely dangerous condition NOTE Thermostatic fan clutches must be kept in an in car position When removed from the car Fig 9...

Page 175: ...for free operation A binding condition may have developed from petroleum gum formation on the choke shaft or from damage Choke shafts can usually be cleaned w ithout disassembly by using United Delco...

Page 176: ...idle screw on Rochester 4MV Fig 2C b Bend fast idle lever as required on Rochester MV to specified speed Fig 1C Manual Choke 1 Use same procedure as above except in Step 1 rotate the fast idle cam cl...

Page 177: ...ve and air horn wall Adjust to specified dimension by bending tang on choke lever and collar assembly 4MV Fig 6C With the cam follower on second step of fast idle cam and against the high step rotate...

Page 178: ...ve in closed position by applying a light force to the choke operating lever 2 Rotate throttle lever to wide open throttle valve position 3 Bend unloader tang on throttle lever to obtain specified dim...

Page 179: ...With the therm ostatic coil rod disconnected with cover removed push downward on coil rod so that the rod contacts bracket surface 3 The coil rod must fit in choke lever notch as shown 4 Bend choke co...

Page 180: ...with air conditioning off distributor vacuum hose removed and plugged and fuel tank hose from vapor canister disconnected perform the following Fig 17C Accelerator Pump R od A djustm ent 2G V 1 Manua...

Page 181: ...atic transmission disconnect TV linkage 6 Remove C E C valve if so equipped vacuum hose and electrical connector 7 Remove idle stop electrical wiring from solenoid if so equipped 8 Remove carburetor...

Page 182: ...tional external settings and adjustments FUEL FILTER MAINTENANCE 1 Disconnect fuel line connection at inlet fuel filter nut 2 Remove inlet fuel filter nut from carburetor with a box wrench or socket 3...

Page 183: ...valve must be in full open positions Idle settings must follow procedure shown on decal ADDITIONAL EXTERNAL SETTINGS AND ADJUSTMENTS ALL VEHICLES EXCEPT VEGA After carburetor overhaul throttle body p...

Page 184: ...bly should be noted in 1972 as depicted by some of the following illustrations NOTE If any binding is present check for correct routing of cable or pedal interference with carpets THROTTLE ROD KICKDOW...

Page 185: ...ngines and 12 000 miles on L 6 engines Operation of vehicle in dusty areas will cause rapid clogging of element and enrichment of carburetor mixture Under these conditions the element must be replaced...

Page 186: ...ER V 8 Fig 3 A Air Cleaner and Heat Stove L 6 and V 8 INSPECTING PAPER ELEMENT 1 Remove air cleaner element as previously outlined 2 Inspect top and bottom seals for deformation or cracking These surf...

Page 187: ...diaphragm assembly through the hose This can be done by m outh Damper door should completely close snorkel passage when vacuum is applied If not check to see if linkage is hooked up correctly and for...

Page 188: ...sembly INSTALL REPLACEMENT RETAINING STRAP SENSOR ASSM IN SAME POSITION AS ORIGINAL ASSM Fig 9 A Vacuum Diaphragm Replacement Fig 8 A Checking Vacuum Diaphragm TEMPERATURE SENSOR REPLACEMENT Removal 1...

Page 189: ...vehicles covered in this manual is the diaphragm type The pump is actuated by an eccentric located on the engine camshaft On in line engine the eccentric actuates the rocker arm On V 8 engines a push...

Page 190: ...do this will result in a damaged grounding circuit in the ignition switch 3 If fuel flows from pump in good volume from pipe at carburetor check fuel delivery pressure to be certain that pump is opera...

Page 191: ...Choke Rod Bending 2 J 4 55 2 Choke Rod Bending 1 2 b bl 3 J 519 7 Unloader Bending 4 J 832 8 Carburetor Holding Tool J 8 3 2 8 5 J 9 78 9 Universal Carburetor Kit 6 J 1 0 1 7 6 Fast Idle Wrench 7 J 2...

Page 192: ...C H E V Y V A N SHOP M A N U A L...

Page 193: ...ng the six cylinder engine is accomplished by preventing ignition vacuum advance when the vehicle is operating in low forward gears Vacuum advance is controlled by a solenoid operated valve which is e...

Page 194: ...vides a path to ground for the CEC solenoid Fig 6T 2 With either one or both of the above circuits complete the CEC solenoid is energized permitting vacuum advance to distributor and additionally the...

Page 195: ...acket attached to the carburetor so that the plunger when extended contacts the throttle lever to maintain a predetermined engine RPM Time Relay The time relay is an electrically operated on off type...

Page 196: ...he spring to the electrical terminal The Powerglide transmission uses a pressure sensitive switch which is activated by transmission fluid pressure The Powerglide switch Fig 6T 9 is located externally...

Page 197: ...ergize or if it energizes far 3 Rem ove connector from ignition on Powerglide equipped vehi and retracts after 20 sec 00 3 With ignition off solenoid solenoid and apply 12 volts 3 Solenoid should ener...

Page 198: ...CEC PLUNGER IS EXTENDED VACUUM ADVANCE DIAGRAM FOR SIX CYLINDER T C S SYSTEM EMISSION CONTROL SYSTEM 6 T 6...

Page 199: ...r the retarded spark condition produced by the design of the emission reduction system To prevent engine dieseling at engine shut down an idle stop solenoid is pro vided The ignition activated idle st...

Page 200: ...distributor is perm itted by energizing the solenoid Subse quent interruption of the high gear position will result in a 23 second delay before the vacuum advance solenoid is energized again Fig 6T 1...

Page 201: ...ion is maintained at engine coolant temper atures above 82 degrees Fig 6T 18 Small V8 Time Delay Relay Fig 6T 19 Small V8 Temperature Switch Right Head Transmission Switch On manual shift synchromesh...

Page 202: ...ter minal with tan lead ground the relay terminal with the black lead if after 26 seconds the advance solenoid does not en ergize replace the relay Proceed to Step 3 if relay is not at fault Step 3 I...

Page 203: ...VACUUM ADVANCE DIAGRAM FOR SMALL V 8 T C S SYSTEM EMISSION CONTROL SYSTEM 6T 11...

Page 204: ...hoses and injection tubes into the exhaust system in the area of the exhaust valves Fig 6T 24 The fresh air helps burn the unburned portion of the exhaust gases in the exhaust system thus minimizing...

Page 205: ...CHEVY VAN SHOP M A N U A L Fig 6T 21 S ix C ylind er A I R System EMISSION CONTROL SYSTEM 6 T 1 3...

Page 206: ...Fig 6T 22 Eight Cylinder A I R System CHECK VALVE AIR PUMP CHECK VALVE DIVERTER VALVE EMISSION CONTROL SYSTEM 6T 14...

Page 207: ...spection Inspect drive belt for wear cracks or deterioration and replace if required Inspect belt tension and adjust if below 50 lbs using a strand tension gauge Adjustment Loosen pum p m ounting bolt...

Page 208: ...applicable then swing pump until drive belt may be removed Install a new drive belt and adjust as outlined above Fig 6T 27 Tightening Pump Pulley Bolts Fig 6T 28 Removing Centrifugal Filter PUMP PULL...

Page 209: ...C A U TIO N The 1 4 pipe threads at the cylinder head on L 6 or the exhaust manifolds on V 8 are a straight pipe thread Do not use a 1 4 tapered pipe tap The hoses of the A I R System are a special m...

Page 210: ...ecking for Vacuum Signal at Diverter Valve Fig 6T 34 Momentary Blast of Air Through Diverter Valve During Engine Over Run C A U TIO N Diverter valves although sometimes similar in appearance are desig...

Page 211: ...ses in pitch as engine speed increases To determine if excessive noise is the fault of the Air Injection Reactor System operate the engine with the pump drive belt removed If excessive noise does not...

Page 212: ...case partitions between cells The top is a one piece cover The cell connectors by passing through the cell partitions connect the elements along the shortest practical path Fig 2b With the length of t...

Page 213: ...b Internal View of Cells ratings For battery replacement a unit of at least equal power rating must be selected SERVICING The Indicator reveals at a glance if water is needed w ithout the necessity of...

Page 214: ...or around the Battery for several hours after it has been charged Sparks or flames can ignite this gas causing an internal explosion which may shatter the Battery The following precautions should be...

Page 215: ...however it may continue to provide additional Fig 7b Testing Specific Gravity Typical service if it has performed satisfactorily in the past An emergency boost charge consisting of a high charging ra...

Page 216: ...ng for at least 15 minutes at a rate high enough to cause vigorous gassing charging rate in amperes all cells are gassing freely and no change in specific gravity occurs For the most satisfactory char...

Page 217: ...n and return battery to service CHART NO 1 ENERGIZER LOAD TEST VALUES MODEL NO AMPLOAD Y86A 130 Y86 130 Y87 130 Y88 160 Y89 160 R88 180 R89 180 R 88ST 180 R 88WT 230 R 88W 230 R89W 230 CHART NO 2 VOLT...

Page 218: ...G IN E W IR IN G HARNESS V 8 ENGINES TO JU N C T IO N BLOCK STARTER M O T O R SO LEN O ID E N G IN E M O U N T IN G BRACKET A T T A C H IN G BOLT L 6 ENGINES V 8 E N G IN E R O U TIN G E N G IN E W I...

Page 219: ...gravity age of the battery etc Therefore an accurate test has more than one step Step 1 Visual inspection Step 2 Specific gravity check hydrometer Step 3 Programmed instrument test Step 4 Load test CA...

Page 220: ...r parts a stator and a rotor The stator is composed of a large number of windings assembled on the inside of a laminated core that is attached to the generator frame The rotor revolves within the stat...

Page 221: ...s that are not normally fused such as the ignition circuit The same size wire with a hypalon insulation must be used when replacing a fusible link The links are located in the engine com partment wiri...

Page 222: ...s and overhaul procedures of these components are also described in The Overhaul Manual and should be referred to as necessary STATIC CHECKS Before making any electrical checks perform the following s...

Page 223: ...ll a new regulator and repeat Step 6 Adjusting Regulator Voltage 7 Connect a 1 4 ohm 25 watt fixed resistor purchased commercially into the charging circuit at the junction block as shown in Figure 4c...

Page 224: ...meets the test specifications the prob lem is not in the generator 12 If the Delcotron fails to meet the test specifications remove it and perform bench tests and make repairs needed Indicator L a m...

Page 225: ...7c Testing Field Relay NOTE This test lamp procedure may be used on lamp type circuits and on ammeter circuits If Lamp Fails to Go Out or if Ammeter Shows Discharge the Possible Causes are 1 Loose dri...

Page 226: ...2 Turn resistor to open position 3 Turn ignition switch off 4 Slowly decrease resistance and note closing voltage of the relay Adjust by bending heel iron in the manner illus trated in Figure 9c Fig...

Page 227: ...revent damaging wiring harnesses 2 Disconnect wiring leads at Delcotron 3 Remove generator brace bolt and detach drive belt 4 Support generator and remove generator mount bolt and remove from vehicle...

Page 228: ...aning Dirty contact points should be dressed with a few strokes of a clean fine cut contact file The file should not be used for other metals and should not be allowed to become greasy or dirty Never...

Page 229: ...ate 5 Remove the primary and condenser leads from their nylon insulated connection Fig 2i in contact set 6 Reverse Steps 2 3 and 4 to install new contact set C A U TIO N Install the primary and conden...

Page 230: ...xceed 3 Excessive variation in this speed range indicates wear in the distributor NOTE Cam angle readings taken at speeds above 1750 engine rpm may prove unreliable on some cam angle meters Eight Cyli...

Page 231: ...ove the cap and place it clear of the work area NOTE If necessary remove secondary leads from the distributor cap after first marking the cap tower for the lead to No 1 cylinder This will aid in the r...

Page 232: ...late assembly for damage or wear and replace if necessary 3 Inspect the shaft for wear and check its fit in the bushings in the distributor body If the shaft or bushings are worn the parts should be r...

Page 233: ...tall the breaker plate in housing and the spring retainer on the upper bushing NO TE Spring should seat on the flat machined on one side of the mainshaft 2 Lubricate and slide weight cam over mainshaf...

Page 234: ...iming tab 2 Position distributor to opening block in normal installed attitude Figs lOi and H i noting position of vacuum control unit 3 Position rotor to point toward front of engine with distributor...

Page 235: ...and replace any terminals that are broken or distorted Replace any broken or deteriorated cable nipples or spark plug boots Spark Plug Cleaning Spark plugs which have carbon or oxide deposits should...

Page 236: ...ed with the armature The aluminum drive end housing is extended to enclose the entire shift lever and plunger mechanism protecting them from dirt splash and icing The flange m ounted solenoid switch o...

Page 237: ...s may be made if the specific gravity of the battery is 1 215 or higher 1 If the solenoid does not pull in measure the voltage between the switch S terminal of the solenoid and ground with the startin...

Page 238: ...SPECIAL TOOLS ENGINE ELECTRICAL 6Y 27 J 2150 PULLY ADAPTER Fig 2s Special Tool C H E V Y V A N SHOP M A N U A L...

Page 239: ...clutch efficiency and assure long life This adjustment is for the amount of free clutch pedal travel before the throwout bearing contacts the clutch fingers As clutch facings wear the amount of free p...

Page 240: ...lt at clutch pedal push rod lever then remove lever from pedal shaft 3 Hold pedal pad with one hand and slide pedal and shaft assembly outboard enough to clear pedal stop then allow return spring or o...

Page 241: ...iaphragm Clutch A djustm ent 7 4 Page C om ponent R eplacem ent 7 5 C lutch A ssem bly 7 5 R e m o v a l 7 5 Installation 7 5 MAINTENANCE AND ADJUSTMENTS PRELIMINARY INSPECTION There are many things w...

Page 242: ...ssed which may eventually cause loss of load and result in slippage If above measures fail to correct the trouble check driven disc with clutch pedal depressed it should spin freely with transmission...

Page 243: ...adjustments in this section Fig 6 Lubrication Points on Clutch Throwout Bearing COIL SPRING CLUTCH INDEX Page Page G eneral D escription 7 6 Rem oval from Vehicle 7 6 C om ponent R eplacem ent 7 6 Ins...

Page 244: ...t gearshift control lever is in neutral position 3 Connect control rods to tube levers making sure clamps are properly adjusted so that tube levers and transmission shifter levers remain in their neut...

Page 245: ...lines IM PO R TA NT Avoid springing the clutch when the transmission is being installed to the engine Do not force the transmission into the clutch disc hub Do not let the transmission hang unsupporte...

Page 246: ...ndicate the transmission case rear bore and record the indicator readings in the 12 3 6 and 9 o clock positions NOTE It is best to start the reading at the 3 6 9 or 12 o clock position closest to the...

Page 247: ...Install detent cam retaining C ring to pivot shaft and hook spring into detent cam notches 8 Install both shifter shaft assemblies in cover being careful not to damage seals Install both shift forks...

Page 248: ...n lift equipment to jack or other lifting device and attach on transmission 6 Disconnect engine rear mount on transmission extension then remove the transmission support crossmember 7 Remove converter...

Page 249: ...of normal transmission operation n particular knowing which units are involved in the various speeds or shifts so that the specific units or circuits involved in the problem can be isolated and invest...

Page 250: ...ler pipe 0 ring seal damaged or missing mis position of filler pipe bracket to engine loading one side of 0 ring b Modulator asssemby O ring seal damages or im properly installed c Governor cover and...

Page 251: ...nd V 8 LI or L2 Reverse 0 16 76 94 120 2000 16 79 96 124 4000 16 82 98 129 6000 16 85 100 133 8000 16 87 102 137 10000 16 90 103 141 12000 16 92 105 144 14000 16 94 107 148 VACUUM MODULATOR ASSEMBLY 1...

Page 252: ...essure until either modulator sleeve end just touches the line in the center of the gauge The gap between the opposite modulator sleeve end and the gauge line should then be 1 16 or less If the distan...

Page 253: ...250 4 11 Axle H78 15 Tire Throttle Position Closed Throttle Detent Touch Wide Open Throttle 1 2 up 5 8 26 34 26 35 2 1 dn 9 4 7 1 29 18 2 3 up 16 26 45 52 49 57 3 2 dn 24 14 40 31 56 48 1 2 up 5 8 27...

Page 254: ...CLUTCHES TRANSMISSIONS 7 18 SPECIAL TOOLS Fig 1ST C lutch and Manual Transm ission Special Tools C H E V Y V A N SHOP M A N U A L...

Page 255: ...sor 12 J 23062 2 Stator Shaft Rear Bushing Installer 13 J 23062 1 Case Bushing Installer 14 J 2 1424 9 Extension Housing Bushing Installer 1 15 J 2 1424 7 16 J 23062 5 17 J 5154 or J 21426 18 J 2 1359...

Page 256: ...M v m v y a v ilsrSf Meg jt C H E V Y V A N SHOP M A N U A L...

Page 257: ...h a self cleaning action Frame mounted tanks consist of an upper and lower half each with a wide flange The two tank sections are seam welded at the flange around the entire tank to assure leakproof c...

Page 258: ...hoses Fig 6 6 Support tank and remove support strap s 7 Lower tank until gauge unit wiring can be removed 8 Remove fuel tank 9 Install in the reverse order 10 Lower vehicle and remove from hoist GAUG...

Page 259: ...ank to assure complete removal of water IM PO R TA N T This procedure will not remove fuel vapor Do not attempt any repair on tank or filler neck where heat or flame is required Disconnect inlet fuel...

Page 260: ...NK FILLER NECK GAS CAP The fuel tank filler cap has a new two step removal and installation procedure plus a pressure vacuum relief valve It is equipped with a double set of locking tangs To remove Ro...

Page 261: ...r 5 If only replacing filter loosen clamps and remove from bottom of canister and pull out filter Inspection 1 Check hoses for cracks and hose connection openings Assure that they are open Check Restr...

Page 262: ...FUEL TANK AND EXHAUST 8 6 Fig 9 Fuel Tank Vent Pipes C H E V Y V A N SHOP M A N U A L...

Page 263: ...to the installation of the exhaust pipe and crossover pipe assembly on V 8 engine single exhaust systems Incorrectly assembled parts of the exhaust system are frequently the cause of annoying noises...

Page 264: ...FUEL TANK AND EXHAUST 8 8 C H E V Y V A N SHOP M A N U A L...

Page 265: ...FFLER AND TAIL PIPE ASSEMBLY HANGER ASSEMBLY VIEW B FUEL TANK ASSEMBLY 72 MIN VIEW A MUFFLER AND TAIL PIPE ASSEMBLY HANGER SUPPORT ASSEMBLY MUFFLER AND TAIL PIPE ASSEMBLY HANGER ASSEMBLY HANGER ASSEMB...

Page 266: ...FUEL TANK AND EXHAUST 8 10 1 Fig 13 Special Tools 1 J 23346 Fuel Tank Gauge Spanner C H E V Y V A N SHOP M A N U A L...

Page 267: ...to the new flexible coupling The 1972 Chevy Van incorporates Forward Steering whereas the steering linkage is located forward of the front crossmember Steering effort is transmitted to left and right...

Page 268: ...e steering wheel readjusting if necessary Tighten the locknut and recheck the torque NOTE If the gear feels lum py after adjusting the worm bearings there is probable bearing damage due to severe impa...

Page 269: ...s outlined in Section 3 if necessary Steering Wheel Alignment NOTE Check steering gear for high point center ing before checking steering wheel alignment 1 Set wheels in a straight ahead position by d...

Page 270: ...e replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used...

Page 271: ...art CAPTURING STRAP COUPLING TO STEERING SHAFT FLANGE BOLTS Fig 8 Flexible Type Steering Coupling 1 Install the new coupling onto the wormshaft aligning the flat on the shaft with the flat in the coup...

Page 272: ...of vital components and systems and or could result in major repair expense They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do n o t...

Page 273: ...pport 11 Remove the shift lever housing seat and bushing from the upper end of the column 12 Remove the bolt and screws from the adjusting ring clamp and remove the clamp adjusting ring and lower bear...

Page 274: ...pper bearing into the switch contact support 10 Install the directional signal switch housing contact support bearing and switch and torque the switch screws to 25 in lbs 11 Install the column wiring...

Page 275: ...round cable 2 Remove the steering wheel as outlined on Page 9 4 3 Remove the directional signal switch 4 Column Shift Models Using a suitable size punch drive out the shift lever pivot pin and remove...

Page 276: ...Fig 14 T ilt Steering Column Explode...

Page 277: ...sing in the full up position and then install tilt spring and retainer tapered end o f spring first Push into the housing approximately 3 16 and rotate counter clockwise 1 8 turn 7 Lubricate and insta...

Page 278: ...le the bearing housing proceed as follows a Press the upper and lower bearings out o f the housing b Using Puller J 5822 and Slide Hammer J 2619 pull the bearing races from the housing fig 18 Fig 18 R...

Page 279: ...tube Force the shift tube out of the housing by turning the nut onto the tool If the shift tube is not completely free when the nut is bottom ed on 18 the threads complete the removal by hand Fig 21 R...

Page 280: ...le the centering spheres and preload spring Fig 24 Installing Shift Pin Tube b Install the spheres into the upper short shaft and rotate 90 c Install the lower shaft 90 to the upper shaft and over the...

Page 281: ...a backing fig 15 4 Remove inner ball stud from relay rod using same procedure as described in Step 3 5 To remove tie rod ends from tie rod loosen clamp bolts and unscrew end assemblies Fig 26 Steerin...

Page 282: ...e the pitman arm using Tool J 6632 or J 5504 fig 10 Installation 1 Install the pitman arm on the pitman shaft lining up the marks made upon removal Install and torque the nut 2 Make sure that the thre...

Page 283: ...r Teeth engine Pressure is delivered from the pump through two hoses to the variable ratio steering gear MAINTENANCE AND ADJUSTMENTS ADJUSTMENTS Power Steering Gear The over center adjustment fig 29 i...

Page 284: ...Tension with J 23600 5 Raise front end of vehicle so that wheels are off the ground 6 Increase engine speed to approximately 1500 rpm 7 Turn the wheels off ground right and left lightly contacting the...

Page 285: ...icle to change tire to floor contact area c Hold steering wheel against a stop momentarily and read pressure gauge If the maximum pressure is below specifications a faulty hydraulic circuit is indicat...

Page 286: ...nut or pitman arm pinch bolt and torque to specifications 3 Remove the plugs and caps from the steering gear and hoses and connect the hoses to the gear Tighten the hose fittings to specified torque...

Page 287: ...STEERING 9 21 Fig 33 Power Steering Pump Mounting C H E V Y V A N SHOP M A N U A L...

Page 288: ...NG PUMP HOUSING V8 ENGINE L6 ENGINE V VIEW A PUMP ASM PUAAP ASM MIN J PARKING BRAKE PARKING BRAKE SPEEDOMETER LE SPEEDOMETER SPEEDO CABLE AND PARKING BRAKE CABLE TO BE ROUTED ABOVE POWER STEERING PIPE...

Page 289: ...1 Thermometer 9 J 7576 Rack Piston Seal Compressor 27 J 22407 Pitman Shaft Bearing Installer 10 J 21239 Pump Pulley Remover 28 J 22727 Terminal Remover 11 J 2927 Steering Wheel Puller 29 J 22708 Turn...

Page 290: ..._____________________________________ C H E V Y V A N SHOP M A N U A L...

Page 291: ...last 10 of tire life TREAD TREAD STILL GOOD WORN OUT Fig 1 Tire Tread Wear Indicator Puncture Inspection and Repair At each lubrication tires should be checked for foreign objects in the tread or brea...

Page 292: ...ater than specified 7 When towing trailers the additional load on the axle induced by the trailer tongue load must not cause the axle load to exceed the limits stamped on the GVW plate Tire inflation...

Page 293: ...turns will avoid grinding rubber off tires To offset normal cornering wear as much as possible tires should be interchanged at regular intervals Wheel and Tire Balancing It is desirable from the stan...

Page 294: ...m ounted on one piece full drop center rims are standard on some Chevrolet trucks These tires have a safety inner liner which if punctured tends to cling to the penetrating object forming a partial se...

Page 295: ...lows 1 Inspect rim to insure bead seats are clean and smooth Fig 7 Prying Second Bead from Rim Fig 8 Lubricating Tire Bead Then place rim on floor with wide side down and lubricate first bead of tire...

Page 296: ...If a tire mounting machine is being used lift the tire high in the rim forcing the top tire bead against the top rim flange seating the top bead The lower bead will be seated by the tire weight When a...

Page 297: ...olled by the position of the hood hinges and the height of the two bumpers located one at each side of the radiator support The adjustment at the hood lock must be made after the hinges and bumpers ar...

Page 298: ...A U TIO N Hood lock assembly to be adjusted fore and aft until hood lock bolt enters center of elongated guide Bending bolt to accomplish this adjustment may seriously effect lock operation and safety...

Page 299: ...usted fore and aft until nubbin part of Hood Lock Bolt Support Assembly enters center of elongated guide Socket Bending nubbin to accomplish this adjust ment may seriously effect lock operation and sa...

Page 300: ...ending bolt to accomplish this adjustment may seriously effect lock operation safety catch engagement is therefore not recommended NOTE Hood bumpers must be adjusted until hood fender line up to speci...

Page 301: ...casional check to see that all wiring connections are tight and clean that the lighting units are tightly m ounted to provide good ground and that the headlamps are properly adjusted Loose or corroded...

Page 302: ...e vehicle m ust be at normal weight that is with gas oil coolant and spare tire Tires must be inflated to the specified pressures Some states have special requirements for headlamp aim These requireme...

Page 303: ...ced by removing the lamp housing attaching nuts Fig 4 Rear Lighting MARKER LAMPS Front Bulb 1 Open hood 2 Grasp plug connector and rotate 1 4 turn counter clock wise to remove bulb inset in plug conne...

Page 304: ...to replacement switch and check operation 4 Position switch on floor pan and install retaining screws 5 Flip floor mat back in place NEUTRAL START SWITCH REPLACEMENT Fig 8 AUTOMATIC TRANSMISSION Swit...

Page 305: ...uge R eplacem ent 12 8 Oil P re ssu re 12 8 Sender Unit Replacement 12 8 Indicator Light 12 8 Guage R eplacem ent 12 8 Generator Indicator L ig h t 12 8 Ammeter Replacement 12 8 GENERAL DESCRIPTION Th...

Page 306: ...luster slip into instrument panel opening after bottom of cluster is installed INDICATOR AND ILLUM INATING BULB REPLACEMENT Fig 11 1 Reach up under instrum ent panel and turn bulb holder counter clock...

Page 307: ...rip on fuel gauge studs first then resistor then a nut on each stud next the laminated circuit then a plain washer on each of two studs holding laminated circuit and finally a nut on back of the studs...

Page 308: ...section NOTE Oil pressure line connection may leak oil when opened wrap w ith cloth 2 Remove bulb holders grounding screws and lift lami nated circuit aside as necessary 3 Remove instrument cluster c...

Page 309: ...ng facts should be kept in mind 1 The wiper dash switch is a grounding type switch and therefore must be securely mounted 2 When installed in a vehicle the wiper m otor is connected to the chassis thr...

Page 310: ...al No 1 to the dash switch to ground Turning the Wiper OFF Turning the wiper dash switch to the O FF position opens the wiper circuits to ground at the dash switch If however the wiper blades are in a...

Page 311: ...chassis 3 Dash switch is m ounted securely 4 Fuse 5 With ignition switch ON there is 12 volts at center terminal No 2 of wiper connector body Refer to Figure 18 for location of 2 terminal B To determ...

Page 312: ...TROUBLE Was POSSIBLE CAUSE 1 W iper n o voltage supply at wiper Blown fuse or open in wire that connects to N o 2 wiper terminal D efective Dash Switch W ire from Wiper Terminal N o 1 to dash switch o...

Page 313: ...the end of this section Park Switch Removal 1 Remove washer pump Figure 12 2 Remove screw retaining park switch Refer to Figure 20 3 Remove spacer Refer to Figure 20 4 Unsolder lead Terminal Board Rem...

Page 314: ...from circuit breaker Figure 26 5 Straighten out the 4 tabs that secure the brush plate to the field coil retainers Figure 26 C A U TIO N Be careful not to break any of the retainer tabs 6 Install U sh...

Page 315: ...Remove steel thrust plate and rubber disc from case bearing as required MOTOR RE ASSEMBLY 1 If new field and case assembly is being installed splice the black and black with pink stripe leads of the n...

Page 316: ...er the brush plate mounting holes over the mounting tabs and bend the tabs toward the brush holders as required to secure the brush plate in position STAMPED SHIELD NICKEL W ASHER SEAL NUT Fig 21 Cran...

Page 317: ...ush retainer clips and resolder black cotton covered lead to circuit breaker Refer to Figure 26 8 If new case and field assembly is used scribe a line on it in the same location as the one scribed on...

Page 318: ...using the scribed reference marks line up as near as possible the case and field assembly with the housing 10 Maintaining the armature in its assembled position in the case start the armature worm sh...

Page 319: ...ions from assembly 4 Remove 3 screws securing washer pump and cover to wiper assembly Remove pump from wiper gear box Valve Assembly 1 Remove the four 4 screws that attach the valve assem bly to the p...

Page 320: ...Light Blue L H Indicator and Front 65 Purple Blower Motor to Relay Direction Light 70 Red White Feed Relay Controlled 15 Dark Blue R H Indicator and Front Circuit Breaker Protected Direction Light 72...

Page 321: ...d Circuit Direct Single or Right Stereo 151 Black Ground Circuit Direct 201 Tan Front Speaker Feed from Radio 152 Black Ground Circuit Direct Left Stereo 153 Black Ground Circuit Direct 202 Black Comp...

Page 322: ...ELECTRICAL BODY AND CHASSIS 12 22 SD m r k lp SD MRK LP T l BRK PRESS J I HORN WRNG SW Fig 32 Engine Compartment C H E V Y V A N SHOP M A N U A L...

Page 323: ...18 B R N 18 B R N 16 GRN D K 14 BLU LT 18 W H T 18 BLK 2 0 BLU DK 2 0 GRN D K 2 0 B LK W H T STR 20 B L K 2 0 PNK 2 0 TAN 20 TAN 2 0 G R A 2 0 GRA 2 0 GRN L T 20 BLU LT 18 W HT 18 O R N 20 B R N 24 BR...

Page 324: ...33 BRAKE WARN IND 35 TEMP TELLTALE 39 IGN 150 GRD DIRECTION SIGNAL TRAFFIC HAZARD SWITCH REG PROD PR IN TED CIRC CONN HO CD00CO INSTR PNL LP RADIO PNL LTS CLSTR FEED IGNUNFUSEDl GL BOX4SPOT LP TAIL S...

Page 325: ...N B 18 W H T A n 18 W H T 18 O R N B 1 8 W H T B x 2 0 ORN 2 0 WHT 2 0 O RN 2 0 WHT 1 8 GRN D K 1 8 G RN LT 1 8 B R N 1 8 t a n s H I8 TAN co n r n r z r i rf K o 18 B R N 0 0 Q 18 BR N DOME LAMP DOM...

Page 326: ...ttached V 8 engines and rest fan shroud over engine fan 4 Lift radiator out of lower retainers Installation Install in reverse order of removal Be sure lower and upper retainers and mounting pads are...

Page 327: ......

Page 328: ...per 2 Remove the license plate support nuts and bolts 3 If necessary to remove the braces and brackets remove screws securing brackets and braces to sheet metal N O T E T h e b u m p e r m ay be rem o...

Page 329: ......

Page 330: ...t engine cover opening 4 Reverse steps 1 2 and 3 above for speaker replacement Fig 1 Radio and Speaker Mounting 1 Disconnect ground cable from battery 2 Remove engine cover 3 Remove air cleaner on car...

Page 331: ...4 5 I t t O j C H E V Y V A N SHOP M A N U A L iiilmn milm i i ii i I in m il in m i 1 1 n I i i i A...

Page 332: ...62 S ystem Deluxe Heater C62 C63 S y ste m 525 Viscosity Compressor Oil AIR CONDITIONING All S ystem s Compressor Make Frigidaire Torque Specifications T y p e Compressor Suction and Discharge D ispla...

Page 333: ...trol front latch to D o o r 90 in lb Rear Latch to Door 90 in lb Rear Plate to D o o r 90 in lb Lower Front Roller and Roller Support S upport to D oor 24 ft lb Support to Roller B racket 24 ft lb Rol...

Page 334: ...st not vary more than 1 fro m side to side s Caster and Camber m ust not vary more than 1 2 fro m side to side Toe setting must always be made after caster and camber t t See explanatory copy in fro n...

Page 335: ...Lock 20 ft lbs Side Bearing Adjuster Lock Bolt 15 ft lbs Drive Pinion Nut 220 ft lbs Differential Carrier to Axle Housing 45 ft lbs Pinion Bearing Cage to Carrier 95 ft lbs Thrust Pad Lock N u t 135...

Page 336: ...air drawn into the engine through the carburetor the air cleaner also acts as a flame arrestor in the event the engine backfires Because backfiring may cause fire in the engine compartment the air cl...

Page 337: ...1 Max Production 0002 Max Service 001 Max Type In Line V8 Displacement cu in 250 307 350 Horsepower 110 130 175 CRANKSHAFT Main Bearing Clearance Production All 0003 0029 1 0003 0015 2 3A 0006 0018 00...

Page 338: ...n Water Pump 15 lb in 3 8 16 Clutch Pressure Plate 35 lb ft Distributor Clamp 20 lb ft Flywheel Housing 30 lb ft Manifold Exhaust 20 lb ft Manifold Exhaust to Inlet 25 lb ft Manifold Inlet 30 lb ft Ma...

Page 339: ...Fast Idle Cam 2nd Step Air Valve D ashpot Choke Vacuum Break Choke U nloader MV 7 0 4 2 0 2 1 M 1 4 078 150 225 500 MV 7 0 4 2 0 2 2 A 1 4 0 7 9 125 1 9 0 500 MV 7 0 4 2 0 2 5 A M h D 1 4 0 7 0 180 2...

Page 340: ...FF EQUIPMENT See Note Above Column No 1 See Note Above Column No 2 See Note Above Column No 3 Transmission Engine Initial Curb Idle Speed R P M Final Curb Idle Speed R P M CEC Valve Engine Speed R P M...

Page 341: ...F Cold Output Rated Hot Output Amps Spec Volts Amps 2000 RPM Amps 5000 RPM 1102452 GS Models 3395 2 2 2 6 14 25 35 37 1102440 GE Models 3395 2 2 2 6 14 25 35 37 1102453 GS 10 30 w N40 or K19 3395 2 2...

Page 342: ...0 8 Hg 20 17 Hg 2 9 3 1 4 Manual AC R44T 307 Cu In V 8 20 30 Series 1112043 C 4824 0 800 RPM 2 1200 RPM 11 2100 RPM 20 4200 RPM C 3036 0 8 Hg 15 15 5 Hg 2 9 3 i 4 All AC R44T 350 Cu In V 8 RPOLS9 1112...

Page 343: ...20 ft lbs Lubrication Filler Plug 15 ft lbs Transmission Case to Clutch Housing B o lt s 55 ft lbs Crossmember to Frame N u t s 25 ft lbs Crossmember to Mount and Mount to Extension B o l t s 40 ft l...

Page 344: ...t Power Steering Hose Clamp Screws 15 lbs in Power Steering Gear Hose Fittings 25 lbs ft Power Steering Pump Hose Fittings 140 lbs in Flexible Coupling Bolt Studs 18 lbs in Lower Mast Jacket Bearing C...

Page 345: ...Locknut 80 ft lbs Over Center Preload 3 6 in lbs Over Center Adjusting Screw Locknut 25 ft lbs Total Steering Gear Preload 14 in lbs Max In excess o f ball drag In excess o f ball drag and thrust bear...

Page 346: ...rking and Direction Signal Tail Stop and Direction Signal 1157 4 3 2CP Turn Signal Indicator Upper Beam Indicator 168 3CP Radio Dial Lamp 1893 2CP Instrument Illumination 194 2CP Temperature Tell Tale...

Page 347: ...er to Tie B a r S 120 in lbs Drain C o c k Finger Guard to Tie B a r s Fan Shroud to Radiator Retainer 50 in lbs BUMPER SECTION 14 TORQUE SPECIFICATIONS Front Face Bar to Bracket 28 ft lbs Bracket to...

Page 348: ...0 1935 37 0 1040 64 0 0360 p 0 323 11 0 1910 38 0 1015 65 0 0350 0 0 316 12 0 1890 39 0 0995 66 0 0330 N 0 302 13 0 1850 40 0 0980 67 0 0320 M 0 295 14 0 1820 41 0 0960 68 0 0310 L 0 290 15 0 1800 42...

Page 349: ...875 f t 203125 5 A4 703125 2 21875 J 32 71875 f t 234375 7 Aa 734375 A 25 3 4 75 f t 265625 4 765625 Va 28125 J5 32 78125 296875 5 A 796875 Y u 3125 Vu 8125 328125 5 3 A 828125 A 34375 J7 32 84375 Jft...

Page 350: ...CHEVROLET SERVICE...

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Chevrolet BEAUVILLE SPORTVAN G10 SERIES, Service Manual

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