Sie sind auf Seite 1von 324

1975

CHEVROLET
LIGHT SERVICE
DUTY and
TRUCK I
IMPORTANT SAFETY NOTICE
Proper service and repair is important to the safe, reliable operation of all
motor vehicles. The service procedures recommended by Chevrolet and
described in this service manual are effective methods for performing service
operations. Some of these service operations require the use of tools
specially designed for the purpose. The special tools should be used when
and as recommended.
It is important to note that some warnings against the use of specific service
methods that can damage the vehicle or render it unsafe are stated in this
service manual. It is also important to understand these warnings are not
exhaustive. Chevrolet could not possibly know, evaluate and advise the
service trade of all conceivable ways in which service might be done or of the
possible hazardous consequences of each way. Consequently, Chevrolet has
not undertaken any such broad evaluation. Accordingly, anyone who uses a
service procedure or tool which is not recommended by Chevrolet must first
satisfy himself thoroughly that neither his safety nor vehicle safety will be
jeopardized by the service method he selects.
SECTION INDEX

SECTION NAME

1975 0 GENERAL INFORMATION


AND LUBRICATION

10-30 SERIES TRUCK 1A HEATER AND


AIR CONDITIONING

CHASSIS SERVICE 1B BODY

and 2 FRAME

O VERHAUL M A N U A L 4
REAR SUSPENSION
AND DRIVELINE
SU PPLEM EN T
5 BRAKES

FOREWORD
6 ENGINE

This manual has been prepared as a supplement to the 1974 Light 6M FUEL SYSTEM
Duty Truck Service and Overhaul Manuals. It covers, in sepa
rate sections, diagnosis, maintenance adjustments, service oper 6T
EMISSION CONTROL
ations, and overhaul procedures for the 1975 10-30 Series truck SYSTEMS
models.
Any reference to brand names in this manual is intended 6Y ENGINE ELECTRICAL
merely as an example of the types of lubricants, tools, materials,
etc., recommended for use. In all cases, an equivalent may be
used. 7A AUTOMATIC
All information, illustrations and specifications contained in TRANSMISSION
this literature are based on the latest product information availa
ble at the time of publication approval. The right is reserved to 7M CLUTCH AND
make changes at any time without notice. MANUAL TRANSMISSION
FUEL TANK AND
SERVICE SECTION 8 EXHAUST SYSTEM
The Service Section of this manual includes new or revised
procedures for maintenance and adjustments, minor service op 9 STEERING
erations and replacement of components.
10 WHEELS AND TIRES

11 CHASSIS SHEET METAL

ELECTRICALBODY
CHEVROLET MOTOR DIVISION 12 AND CHASSIS

General M otors Corporation


13 RADIATOR AND GRILLE

DETROIT, MICHIGAN
15 ACCESSORIES

SPECIFICATIONS AT REAR
OF MANUAL
1974 General M o to rs C orporation Printed in U.S.A.
SECTION 0

GENERAL INFORMATION AND LUBRICATION


C O N TE N TS OF THIS SECTION

General Information........................................................................ 0-1


Lubrication........................................................................................... 0-5
I
GENERAL INFORMATION

INDEX

Model Line U p ................................................................... 0-1 Unit and Serial Number Locations.............................. 0-1
Service Parts Identification Plate................................... 0-3
Truck Model Identification............................................... 0-1 Keys and Locks.................................................................... 0-3
Vehicle Identification Number and Rating Plate.... 0-1 Emergency Starting............................................................ 0-3
Engine N um ber.................................................................... 0-1 Towing.................................................................................... 0-5
MODEL LINE UP 10 - Day of Manufacture (tenth)
The 10 through 30 Series truck model line-up for 1975 T - Truck
consists of the models shown in the Charts in this
section. FA - Transmission and engine type
Truck Model Identification
U N IT AND SERIAL N U M B ER LOCATIONS
All 10-30 series models are identified by this model
system. Basically the designation consists of 7 characters, For the convenience of service technicians and engineers
2 letters followed by five numbers. The first letter when writing up certain business papers such as
indicates a Chevrolet model and the second identifies the Warranty Reports, Product Information Reports, or
chassis type. The first number designates the GVW reporting product failures in any way, the location of the
range, the second and third identify the cab-to-axle various unit numbers have been indicated. These unit
dimension or model type and the last two identify the numbers and their prefix or suffix are necessary on these
cab or body style.
papers for various reasons - such as accounting, follow-
VEHICLE ID ENTIFICATION NUM BER up on production, etc.
AND RATING PLATE The prefixes on certain units identify the plant in which
A combination vehicle identification number and rating the unit was manufactured and thereby permits proper
plate used on all models (fig. 1) is located on the left follow-up of the plant involved to get corrections made
door pillar of CK models. On Forward Control models when necessary.
(except P30 Motor Home Chassis) it is attached to the
dash and toe panel. Always include the prefix in the number.
The vehicle identification number stamped on the plate
decodes into the information shown in Figure 2. Axles
Series 10, 20 and P30 Code is stamped on Front of
ENGINE NUMBER Right Rear Axle Tube Inboard of Upper Control
The engine number indicates manufacturing plant, Arm Bracket.
month and day of manufacture, and transmission type.
A typical engine number would be F1210TFA, which Series CG30 (except dual wheel) code is stamped at
would breakdown thus: the Forward Upper Surface of Carrier.
F - Manufacturing Plant (F-Flint, T-Tonawanda) Dual Wheel Part Number and Production Code is
12 - Month of Manufacture (December) stamped on Front of Right Axle Tube.

TRUCK SUPP - SERVICE


0-2 GENERAL INFORMATION AND LUBRICATION

TRUCK MODEL IDENTIFICATION

1. CH EVRO LET C C 10703


2. CHASSIS TYPE
3. GVW RANGE -
4. CA D IM E N S IO N /M O D E L TYPE
5. CAB OR BODY S T Y L E ------------


CHASSIS TYPE CA D IM E N S IO N /M O D E L TYPE
C Conventional 4 x 2 0 5 -B L A Z E R
G Forward Control 4 x 2 07 42
(Body-Frame Integral) 08 FC or M otor Home Chassis
K Conventional 4 x 4 09 5 6 "
(Four Wheel Drive)
10 6 0 "/F C Chassis, Chevy
P Forward Control 4 x 2 Van, Sportvan
(Conventional)
11 M otor Home Chassis
13 Chevy Van, Sportvan,
(D Cutaway Van
GVW RANGE 14 8 4 "/F C or M otor Home
1 -4 5 0 0 to 7150 Chassis

2 -5 5 0 0 to 8200
3 -6 2 0 0 to 14,000
CAB OR BODY STY LE
03 Conventional Cab
(C-K models)
04 Cutaway Van (G models)
05 Chevy Van
06 Suburban/Sportvan w ith
Panel Rear Doors
14 Blazer
32 M otor Horne Chassis
42 Forward Control Chassis
63 Crew Cab

TRUCK SUPP SERVICE


GENERAL INFORMATION AND LUBRICATION 0-3

Engines
6-Cylinder Engine Unit Number Located on Pad at
GENERAL MOTORS CORPORATION Right Hand Side of Cylinder Block at Rear of
im u n t y u r i f m m v k k n i actus m y or unncs show n c io s s
Distributor.
n m c u v c u i t i u u d u k j s i i or u s nmciE. mascio e d u v m u i. 8-Cylinder Engine Unit Number Located on Pad at
nmcu.
Front, Right Hand Side of Cylinder Block.
w m iu n u u tti^ u c A u w m in L tA flu m T s uonto

RATINGS IN POUWPSAS MANIffjCTHED


tttS S K K U V DQ n m T K V QKU Delcotrons
4UDMVM FMMT EHO VDOTF AT Delcotron Unit Serial Number Located at Top of Rear
HAliWM tU I UN VDOn tT
Housing.
WKummncjimiiM. f Batteries
Battery Code Number Located on Cell Cover Top of
Battery.
Starters
Fig. 1 Vehicle Identification Number and Rating Starter Serial Number and Production Date Stamped on
Plate Information Outer Case, Toward Rear.
SERVICE PARTS ID E N T IF IC A T IO N PLATE
ENGINE The Service Parts Identification Plate (fig. 3) is provided
DESIGNATION on all Truck models. On most series it will be located on
Q = L 6 -2 5 0 -1
T= L6-292-1 the inside of the glove box door, or, on Forward Control
V= V 8-3 50-2 series, it will be located on an inner body panel. The
Y= V 8 -3 5 0 -4 SERIES plate lists the vehicle serial number, wheelbase, and all
M=
Z=
V 8-400-4
V 8 -4 5 4 -4
1 ' 2 TO N
2 -% Production options or Special Equipment on the vehicle
DIVISION L= V 8-454-4 when it was shipped from the factory including paint
C = CHEVROLET
T = GMT
31 MODEL YEAR
5 = 1975 fo r al information. ALW AYS REFER TO T H IS IN F O R M A T IO N
C C Q 1
Series. W H EN ORDERING PARTS.
CHASSIS TYPE
SEQUENTIAL NUMBER KEYS AND LOCKS
C - 2 WHEEL DRIVE
G =LIG H T DUTY Two keys are provided with each vehicle. Different lock
FORWARD CONTROL cylinders operated by a separate key are available as an
K 4 WHEEL DRIVE
L = LIGHT UTILITY
option for the sliding side load door and rear load doors.
P FORWARD CONTROL ASSEMBLY PLANT
Z =M O TO R HOME EMERGENCY STAR TIN G
A -L a k e w o o d V -G M Truck-P ontiac
BODY STYLE B -B altim ore S-St. Louis Engines in vehicles with automatic transmissions
2-Forw ard Control
chassis only
F-Flint
J- J an e s v ille
U -Lordstow n
Z -Frem ont
cannot be started by pushing or towing the vehicle.
3-Cab-chassis (Cutaway)
K- Leeds 1-O shaw a Never tow or push trucks equipped with light duty
4-C a b an d picku p box
5 -Van and Panel
3-G M A D D etroit
emission control systems to start engine.
6-S u b u rb a n bo dy
7 -M o to r Home
8 -U tility (Blazer)

Fig. 2 Vehicle Identification Number

Transmissions
3-Speed Transmission Unit Number Located on
Lower Left Side of Case Adjacent to Rear of Cover.
4-Speed Transmission Unit Number Stamped on
Rear of Case, Above Output.
Turbo Hydra-Matic 350 Transmission Unit Number
Located on Right Rear Vertical Surface of Oil Pan.
The Turbo Hydra-Matic Transmission 400 Serial
Number is Located on the Light Blue Plate on the Right IMPORTANT: RETAIN THIS PLATE AS A PERMANENT RECORD

Side of the Transmission. Fig. 3 Service Parts Identification Plate

TRUCK SUPP SERVICE


0-4 GENERAL INFORMATION AND LUBRICATION

A vehicle with a discharged battery may be started would cause personal injury. Batteries and
by transferring electrical power from a battery in battery acid should always be kept out o f reach
another car - called "jump starting". o f children.
Jump Starting TO J U M P START:
C A U TIO N : The following jum p start procedure 1. Position the two vehicles so they are NOT touching.
is for use only under the following conditions. Set parking brake firmly and place automatic
Departures from these conditions and proce transmission in "PARK" (neutral for manual
dures, could result in: (1) serious personal transmission) in each vehicle. Also turn off lights,
injury (particularly to eyes) or property damage heater and all other unnecessary electrical loads.
from such things as battery explosion, battery
acid or electrical burns, or (2) damage to 2. Remove the vent caps from the battery in the other
electronic components in either vehicle. I f all vehicle (unless it is also equipped with Delco flame
the conditions cannot be met, or if you are arrestor caps). Lay a cloth over the open vent wells.
uncertain about them, we strongly recommend These two actions help reduce the explosion hazard
fo r your safety and that o f your vehicle that always present in a battery when connecting "live"
you leave the starting to a competent mechanic. booster batteries to "dead" batteries. For safetys
sake, do not remove any of the flame arrestor vent
The battery in the other vehicle must be of the same caps from a Delco battery.
nominal voltage, 12 volts, and must be negatively
grounded. [All General Motors cars, light trucks 3. Attach one end of one jumper cable to the positive
(10,000 GVWR and under), and motor homes use terminal (identified by a red color, " + " or "P" on
12-volt, negatively grounded electrical systems and the battery case, post or clamp) of the battery in the
can be used to jump start one another.] The nominal other vehicle, and the other end of the same cable
voltage and grounding of the other vehicles battery to the positive terminal of your battery.
may be determined by checking the specifications in 4. Attach one end of the remaining jumper cable
its owners manual. Use of a booster battery of a FIRST to the negative terminal (black color, " " or
higher nominal voltage, or which is positively "N") of the battery in the other vehicle, and THEN
grounded may result in serious personal injury or the other end of the same cable to the negative
property damage. terminal of your battery in this vehicle. Take care
The battery in your vehicle must be a Delco battery that clamps from one cable do not inadvertently
(the original or a replacement) which is equipped touch the clamps on the other cable. Do not lean
with flame arrestor type filler/vent caps on all filler over the battery when making this connection.
openings, or a sealed-type battery which does not 5. Start the engine in the vehicle that is providing the
have filler openings or caps. Each flame arrestor cap jump start (if it was not running). Let run a few
contains a grey disc rather than a small hole. To minutes, then start the engine in the vehicle with
help avoid serious injury or property damage, this the discharged battery.
jump start procedure should not be used if one or 6. Reverse the above sequence exactly when removing
more of the flame arrestor caps is missing, or if they the jumper cables. Reinstall vent caps and dispose
are not present on a replacement battery. (If your in a safe manner of any cloths used to cover vent
vehicle contains a replacement battery other than a wells, as the cloths may have corrosive acid on
Delco, refer to jump starting instructions provided them.
by the manufacturer of the other battery.)
C A U TIO N : Never expose battery to open flame PUSH STARTING TRUC KS W ITH HEAVY
or electric sparkbattery action generates DUTY EMISSION C O N TR O L SYSTEMS
hydrogen gas which is flammable and explo
sive. Don't allow battery fluid to contact eyes, C A U TIO N : Trucks equipped with light duty
skin, fabrics, or painted surfacesfluid is a emission control systems must not be pushed or
corrosive sulfuric solution which could cause towed to start.
serious personal injury or property damage.
Flush any contacted area immediately with If your truck is equipped with a manual 3-speed or
water. Wear eye protection such as industrial 4-speed transmission, it can be started in an emergency
safety spectacles or goggles when working on or by pushing. When being pushed to start the engine, turn
near battery. Remove rings, metal watch bands off all unnecessary electrical loads, tufn ignition to
and other metal jewelry before jum p starting or "ON", depress the clutch pedal and place the shift lever
working around a battery. Be careful in using in high gear. Release the clutch pedal when speed
metal tools and equipment. I f such metal reaches 10 to 15 miles per hour. Bumpers and other parts
should contact the positive battery terminal (or contacted by the pushing vehicle should be protected
metal in contact with it) and any other metal from damage during pushing. Never tow the truck to
on the vehicle, a short circuit may occur which start.

TRUCK SUPP - SERVICE


GENERAL INFORMATION AND LUBRICATION 0-5

TO W IN G STEEL TU B IN G REPLACEM ENT


All Except Four Wheel Drive Trucks In the event that replacement of steel tubing is required
Normally your vehicle may be towed with all four wheels on brake line, fuel line, evaporative emission, and
on the ground for distances up to 50 miles at speeds of transmission cooling lines, only the recommended steel
less than 35 MPH. The engine should be off and the replacement tubing should be used.
transmission in neutral. Only special steel tubing should be used to replace brake
However, the rear wheels must be raised off the ground line. That is, a double wrapped and brazed steel tubing
or the drive shaft disconnected when the transmission is meeting G.M. Specification 123 M. Further, any other
not operating properly or when a speed of 35 MPH or steel tubing should be replaced only with the released
distance of 50 miles will be exceeded. steel tubing or its equivalent. Under no condition should
copper or aluminum tubing be used to replace steel
C A U T IO N : I f a truck is towed on its front tubing. Those materials do not have satisfactory fatigue
wheels only, the steering wheel must be secured durability to withstand normal vehicle vibrations.
with the wheels in a straight ahead position. All steel tubing should be flared using the upset (double
lap) flare method which is detailed in Section 5 of this
Four Wheel Drive Trucks Manual.
It is recommended that the truck be towed with the front
wheels off the ground. The truck can be towed, however, VEHICLE LOADING
with the rear wheels off the ground if there is damage in
the rear wheel area. In this event, the transmission Vehicle loading must be controlled so weights do not
selector lever should be placed in the "N " (neutral) exceed the numbers shown on the Vehicle Identification
position and with conventional four wheel drive the Number and Rating Plate for the vehicle.
front drive disengaged. With Full Time four wheel drive A typical example of a truck in a loaded condition is
the transfer case should be in high. Towing speeds shown in Figure 4. Note that the axle or GVW
should not exceed 35 MPH for distances up to 50 miles. capabilities are not exceeded.
If truck is towed on its front wheels, the steering wheel LOADED-MAXIMUM GVW : 6000-LBS-
should be secured to keep the front wheels in a straight
ahead position.
FRONT AXLE CAPACITY: 3 2 5 0 LBS. REAR AXLE CAPACITY: 3 5 8 2 LBS.

When towing the vehicle at slow speeds (approx. 20


MPH), for a very short distance only, the transmission
must be in NEUTRAL and with conventional four wheel
drive the transfer case MUST be in "TWO WHEEL
HIGH". With Full Time four wheel drive the transfer
case should be in high.
When towing the vehicle at faster speeds for greater
distances, the following steps MUST be taken:
If front wheels are on the road, disconnect the front Front Curb 2 1 0 0 lbs. Rear C urb 1 5 8 5 lbs.
drive shaft. Front C argo Rear C argo

If rear wheels are on the road, disconnect the rear


Load 4 0 0 lbs. Load 1915 lbs.
2 5 0 0 lbs. 3 5 0 0 lbs.
drive shaft. TOTAL W EIGHT AT G R O U N D : 6 0 0 0 lbs.
Fig. 4 Typical Vehicle Loaded Condition

LUBRICATION

INDEX

Maintenance Schedule........................................................ 0-6 Fuel Filter............................................................................ 0-8


Engine..................................................................................... 0-6 Governor.............................................................................. 0-8
Oil and Filter Recommendations................................ 0-6 Accelerator Linkage.......................................................... 0-8
Drive Belts........................................................................... 0-7 Automatic Transmission Fluid Recommendations... 0-8
Positive Crankcase Ventilation..................................... 0-7 Manual Transmission......................................................... 0-8
Air Injection Reactor System....................................... 0-7 Transmission Shift Linkage............................................. 0-8
Controlled Combustion System.................................... 0-7 Clutch....................................................................................... 0-8
GM Evaporation Control System................................ 0-7 Rear Axle............................................................................... 0-9
Manifold Heat Control Valve...................................... 0-7 Standard............................................................................... 0-9
Air Cleaner.......................................................................... 0-8 Propeller Shaft Slip Joints............................................... 0-9

TRUCK SUPP SERVICE


0-6 GENERAL INFORMATION AND LUBRICATION

Universal Joints................................................................... 0-9 Four Wheel Drive


Wheel Bearings Propeller Shaft Centering Ball................................... 0-10
Front...................................................................................... 0-9 Front Axle......................................................................... 0-10
R ear....................................................................................... 0-9 Air Vent Hose................................................................. 0-11
Brake Master Cylinder...................................................... 0-9 Transfer Case.................................................................... 0-11
Brake and Clutch Pedal Springs................................... 0-9 Control Lever and Linkage........................................ 0-11
Parking Brake....................................................................... 0-9 Speedometer Adapter...................................................... 0-11
Steering Complete Maintenance Schedule................................. 0-12
Lubrication Diagrams
Manual Steering G ear..................................................... 0-9 Conventional and Forward Control Models......... 0-19
Steering Linkage and Suspension................................ 0-9 Four Wheel Drive Models.......................................... 0-20
Hood Latch and Hood Hinge...................................... 0-10 1/2 ton G Models.......................................................... 0-21
Body Lubrication............................................................... 0-10
MAINTENANCE SCHEDULE ENGINE
A separate maintenance folder has been provided with Oil and Filter Recom m endations
each vehicle which contains a complete schedule and The letter designation "SE" has been established to
brief explanation of the safety, emission control, correspond with the requirements of GM 6136-M. "SE"
lubrication and general maintenance it requires. The engine oils will be better quality and perform better than
those identified with "SA" through "SD" designations
maintenance folder information is supplemented by this and are recommended for all light-duty gasoline trucks
section of this manual, as well as the separate vehicle regardless of model year and previous engine oil quality
and emissions warranty booklet also furnished with each recommendations.
vehicle. Read all three publications for a full Oil Change Period
understanding of vehicle maintenance requirements.
Use only SE engine oil.
The time or mileage intervals for lubrication and Change oil each 6 months or 7,500 miles. If more
maintenance services outlined in this section are than 7,500 miles are driven in a 6 month period,
intended as a general guide for establishing regular change oil each 7,500 miles.
maintenance and lubrication periods for trucks with light Change oil each 3 months or 3,000 miles, whichever
duty emission control systems (see chart). Sustained occurs first, under the following conditions:
heavy duty and high speed operation or operation under Driving in dusty conditions.
adverse conditions may require more frequent servicing. Trailer pulling or camper use.
For maintenance and iubrication information on trucks Frequent long runs at high speeds and high
designated with heavy duty emission control systems, ambient temperatures.
continue to refer to Section 0 of the 1974 Light Duty Motor Home use.
Truck Shop Manual. Stop and go type service such as delivery trucks,
etc.
CHEVRO LET LIG H T AN D H E A VY D UTY Extensive idling.
EMISSION CLASS VEH IC LES Short-trip operation at freezing temperatures
(engine not thoroughly warmed-up).
Light Duty: Operation in dust storms may require an immediate
C10 (exc. Suburban V-8 & 6200# GVW oil change.
L-6 or V-8) Replace the oil filter at the first oil change, and
K10 - L6 Only every second oil change thereafter. AC oil filters
G10 - All provide excellent engine protection.
The above recommendations apply to the first change as
Heavy Duty Vehicle: well as subsequent oil changes. The oil change interval
C10 - Suburban V-8 for the engine is based on the use of SE oils and quality
C10 - 6200# GVW L-6 or V-8 oil filters. Oil change intervals longer than those listed
K10 - V-8 Only above will seriously reduce engine life and may affect the
C20, 30 - All manufacturers obligation under the provisions of the
K20 - All New Vehicle Warranty.
P10, 20, 30 - All A high quality SE oil was installed in the engine at the
G20, 30 - All factory. It is not necessary to change this factory-
installed oil prior to the recommended normal change

TRUCK SUPP SERVICE


GENERAL INFORMATION AND LUBRICATION 0-7

period. However, check the oil level more frequently The oil level should be maintained in the safety margin,
during the break-in period since higher oil consumption neither going above the "FULL" line nor below "ADD
is normal until the piston rings become seated. OIL" line.
NOTE: Non-detergent and other low quality oils NOTE: The oil gauge rod is also marked "Use SE
are specifically not recommended. Engine Oil" as a reminder to use only SE oils.
Oil Filter Type and Capacity Supplemental Engine Oil Additives
Throwaway type, 1 quart U.S. measure, .75 quart The regular use of supplemental additives is specifically
Imperial measure. not recommended and will increase operating costs.
250 cu. in., 292 cu. in., AC Type PF-25. 350 cu. in. However, supplemental additives are available that can
454 cu. in., AC Type PF-35. effectively and economically solve certain specific
problems without causing other difficulties. For example,
Crankcase Capacity (Does N o t Include Filter) if higher detergency is required to reduce varnish and
2 9 2 L6 Engine; 5 quarts U.S. measure, 4 .2 5 sludge deposits resulting from some unusual operational
quarts difficulty, a thoroughly tested and approved additive -
Im perial measure. "Super Engine Oil Supplement" - is available.
Drive Belts
All other engines; 4 quarts U.S. measure, 3.25 Drive belts should be checked every 7,500 miles or 6
quarts months for proper tension. A loose belt will affect water
Imperial measure. pump and generator operation.

POSITIVE CRANKCASE V E N TIL A TIO N


Recomm ended Viscosity
VALVE
Select the proper oil viscosity from the following chart: Every 30,000 miles or 24 months the valve should be
replaced. Connecting hoses, fittings and flame arrestor
should be cleaned. At every oil change the system should
be tested for proper function and serviced, if necessary.
RECOMMENDED SAE VISCOSITY NUMBER (Also see maintenance schedule at end of this section.)

AIR INJECTIO N REACTOR SYSTEM (A.I.R.)


CONTROLLED C O M B U S T IO N SYSTEM
(C.C.S.)
-3 0 -2 0 0 20 40 60 80 100
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE, F.

The Air Injection Reactor system should have the drive


belt inspected for wear and tension every 24 months or
30,000 miles, whichever occurs first. In addition,
complete effectiveness of either system, as well as full
NOTE: SAE 5W-20 oils are not recommended for power and performance, depends upon idle speed,
sustained high-speed driving. SAE 30 oils may be ignition timing, and idle fuel mixture being set
used at temperatures above 40 F. SAE 5W-30 oils according to specification. A quality tune-up which
are recommended for all seasons in vehicles includes these adjustments should be performed
normally operated in Canada. periodically to assure normal engine efficiency, operation
The proper oil viscosity helps assure good cold and hot and performance.
starting.
Checking Oil Level GM EVAPO RATIO N C O N TR O L SYSTEM
The engine oil should be maintained at proper level. The Every 24 months or 30,000 miles (more often under
best time to check it is before operating the engine or as dusty conditions) the filter in the base of the canister
the last step in a fuel stop. This will allow the oil must be replaced and the canister inspected.
accumulation in the engine to drain back in the
crankcase. To check the level, remove the oil gauge rod MANIFO LD HEAT CO NTRO L VALVE
(dipstick), wipe it clean and reinsert it firmly for an
accurate reading. The oil gauge rod is marked "FULL" First 7,500 miles or 6 months check valve for freedom of
and "ADD OIL". If the oil is at or below the "ADD" operation. If valve shaft is sticking, free it up with GM
mark on the dipstick, oil should be added as necessary. Manifold Heat Control Solvent or its equivalent.

TRUCK SUPP SERVICE


0-8 GENERAL INFORMATION AND LUBRICATION

AIR CLEANER and stops, to bring transmission up to normal


operating temperature (approximately 180-190F).
C A U TIO N : Do not remove the engine air
2. Park vehicle on a level surface.
cleaner unless temporary removal is necessary 3. Place selector lever in "Park" and leave engine
during repair or maintenance o f the vehicle. running.
When the air cleaner is removed backfiring can 4. Remove dipstick and wipe clean.
cause fire in the engine compartment.
5. Reinsert dipstick until cap seats.
NOTE: Under prolonged dusty driving conditions, 6. Remove dipstick and note reading.
it is recommended that these operations be If oil level is at or below the ADD mark on the dipstick,
performed more often. oil should be added as necessary. One pint raises the
level from ADD to FULL. Do not overfill.
Under normal driving conditions, the transmission fluid
011 Wetted Paper Elem ent Type should be changed every 30,000 miles. If the vehicle is
L-6 engine, replace every 15,000 miles. V-8 engine, every driven extensively in heavy city traffic during hot
15,000 miles inspect inspect element for dust leaks, holes weather, or is used to pull a trailer, change fluid every
or other damage. Replace if necessary. If satisfactory, 15,000 miles. Likewise, operators of trucks in commercial
rotate element 180 from originally installed position. use where the engine idles for long periods, should
Replace at 30,000 miles. Element must not be washed, change fluid every 15,000 miles.
oiled, tapped or cleaned with an air hose. To Change Turbo H ydra-M atic 4 0 0 and Turbo Hydra-
M atic 3 5 0 fluid, remove fluid from the transmission
Crankcase Ventilation Filter sump, add approximately 7.5 pints U.S. measure (6.25
(Located W ithin Air Cleaner) pints Imperial measure) for the Turbo Hydra-Matic 400
If so equipped, inspect every oil change and replace if and 2 1/2 qts. U.S. measure (2 qts. Imperial measure) for
necessary. Replace at least every 30,000 miles; more the Turbo Hydra-Matic 350 of fresh fluid, to return level
often under dusty driving conditions. to proper mark on the dipstick.
Every 3 0 ,0 0 0 M ilesthe Turbo Hydra-Matic 400
FUEL FILTER transmission sump filter should be replaced.
Replace filter element located in carburetor inlet every
12 months or 15,000 miles whichever occurs first, or, if 3-AND 4-SPEED M A N U A L T R A N M IS S IO N
an in-line filter is also used, every 30,000 miles. Replace LUBRICANT
in-line filtc every 30,000 miles.
Every 6 months or 7,500 miles, whichever occurs first,
GOVERNOR
check lubricant level and add lubricant, if necessary, to
fill to lvel of filler plug hole with SAE 80W or SAE 80W-
The attaching bolts should be kept tight, the optionally 90 GL-5 Gear Lubricant. If temperatures below +32F
available governor should be kept clean externally and are expected, use SAE 80W GL-5 Gear Lubricant only.
the filter element should be replaced every 15,000 miles. For those vehicles normally operated in Canada, use
SAE 80W GL-5 Gear Lubricant only.
ACCELERATOR LINKAGE
Lubricate with engine oil every 30,000 miles as follows: TR A N SM IS SIO N SHIFT LINKAGE
1. On V8 engine, lubricate the ball stud at the (M A N U A L AND A U T O M A T IC )
carburetor lever. Every 7,500 miles or 6 months-lubricate shift linkage
2. On L6 engine, lubricate the two ball studs at the and, on Manual transmission floor control, lever
carburetor lever and lubricate the lever mounting contacting faces with water resistant EP chassis lubricant
stud. Do not lubricate the accelerator cable. which meets General Motors Specification GM6031-M.
Clutch
A U T O M A T IC T R A N S M IS S IO N
FLUID R E C O M M E N D A TIO N The clutch pedal free travel should be checked at regular
intervals.
Use only automatic transmission fluids identified with
the mark DEXRON II (or equivalent). Lubricate the clutch cross-shaft at fitting (on Series 10
Check the fluid level at each engine oil change period. Forward Control models also lubricate the clutch linkage
To make an accurate fluid level check: idler lever at fitting) every 7,500 miles or 6 months with
water resistant EP chassis lubricant which meets General
1. Drive vehicle several miles, making frequent starts Motors Specification GM 6031-M.

TRUCK SUPP - SERVICE


GENERAL INFORMATION AND LUBRICATION 0-9

REAR AXLES Rear

Standard The rear wheel bearings receive their lubrication from


the rear axle. When installing bearings which have been
Every 6 months or 7,500 miles, whichever occurs first, cleaned, prelube with wheel bearing grease.
check lubricant level and add lubricant, if necessary, to
fill to level of filler plug hole. Use SAE 80W or SAE BRAKE MASTER CYLINDER
80W-90 GL-5 Gear Lubricant. For those vehicles
normally operated in Canada, use SAE 80W GL-5 Gear Check master cylinder fluid level in both reservoirs every
Lubricant. 7,500 miles or 6 months. If the fluid is low in the
reservoir, it should be filled to a point about 1/4" from
the top rear of each reservoir with Delco Supreme No.
Positive Locking or Positraction 11 Hydraulic Brake Fluid or equivalent.
Every 6 months or 7,500 miles, whichever occurs first,
check lubricant level and add lubricant, if necessary, to BRAKE AND CLUTCH PEDAL SPRING S
fill to level of filler plug hole. Lubricate brake and clutch pedal springs every 7,500
Drain and refill at first 15,000 miles then maintain same miles or 6 months with engine oil for all models.
as standard axle but, use only the special positraction
differential lubricant available at your authorized PARKING BRAKE
Chevrolet dealer. Every 7,500 miles or 6 months clean and lubricate all
parking brake pivot points with water resistant EP
PROPELLER SHAFT SLIP JO IN TS chassis lubricant which meets General Motors Specifica
tion GM 6031-M.
Propeller shaft slip joints should be lubricated every
7,500 miles or 6 months with water resistant EP chassis STEERING
lubricant which meets General Motors Specification GM
6031-M. Manual Steering Gear
The steering gear is factory-filled with steering gear
UNIVERSAL JOINTS lubricant. Seasonal change of this lubricant should not
be performed and the housing should not be drained-no
All universal joints are the needle bearing type. lubrication is required for life of the steering gear.
Lubricate those universal joints (depending on truck
model) equipped with lube fittings every 7,500 miles or 6 Every 30,000 miles, the gear should be inspected for seal
months with water resistant EP chassis lubricant which leakage (actual solid grease-not just oily film). If a seal is
meets General Motors Specification GM 6031-M. More replaced or the gear is overhauled, the gear housing
frequent lubes may be required on heavy duty or "Off should be refilled with No. 1051052 (13 oz. container)
the Road" operations. Steering Gear Lubricant which meets GM Specification
GM4673-M or its equivalent.
WHEEL BEARINGS NOTE: Do not use EP Chassis Lube, which meets
GM Specification GM 6031-M, to lubricate the
Front gear. DO NOT OVER-FILL the gear housing.
NOTE: Use wheel bearing lubricant GM Part No. Power Steering System
1051344 or equivalent. This is a premium high Check the fluid level in the pump reservoir at each oil
melting point lubricant which meets all require change period. Add GM Power Steering Fluid or
ments of General Motors Specification GM 6031M. DEXRON II automatic Transmission Fluid) or
equivalent as necessary to bring level into proper range
Due to the weight of the tire and wheel assembly it is on filler cap indicator depending upon fluid temperature.
recommended that they be removed from hub before If at operating temperature (approximately 150Fhot to
lubricating bearings to prevent damage to oil seal. Then the touch), fluid should be between "HOT" and
remove the front wheel hub to lubricate the bearings. "COLD" marks.
The bearings should be thoroughly cleaned before
repacking with lubricant. If at room temperature (approximately 70 F), fluid
should be between "ADD" and "COLD" marks. Fluid
Front wheels are equipped with tapered roller bearings does not require periodic changing.
on all trucks. Wheel bearings should be lubricated every
30,000 miles. Do not mix wheel bearing lubricants. STEERING LINKAGE AND SUSPENSION
C A U TIO N : "Long fibre " type greases should Maintain correct front end alignment to provide easy
not be used on roller bearing front wheels. steering, longer tire life, and driving stability.

TRUCK SUPP - SERVICE


0-10 GENERAL INFORM ATION AND LUBRICATION

bolts, lock striker plates, dovetail bumper wedges, etc.


apply a thin film of light engine oil.
Where oil holes are provided in body parts a dripless oil
can be safely used, but any lubricant should be used
sparingly, and after application all excess should be
carefully wiped off.
The seat adjusters and seat track, ordinarily overlooked,
should be lubricated with water resistant EP chassis
lubricant which meets General Motors Specification GM
6031-M.
There are other points 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. Easy
access to the working parts may be made by removing
Check control arm bushings and ball joints for wear. the trim. Door weatherstrips and rubber hood bumpers
Lubricate tie rods, upper and lower control arms, and should be lightly coated with a rubber lubricant.
ball joints at fittings with water resistant EP chassis
lubricant which meets General Motors Specification GM UNDERBODY M A IN T E N A N C E
6031-M every 7,500 miles or 6 months. The effects of salt and other corrosive materials used for
Lubricate every 3,000 miles or 3 months whichever ice and snow removal and dust control can result in
occurs first under the following conditions: accelerated rusting and deterioration of underbody
Driving in dusty or muddy conditions. components such as brake or pan, exhaust system,
brackets, parking brake cables. These corrosive effects,
Extensive off-road use. however, can be reduced by periodic flushing of the
NOTE: Ball joints must be at +10F. or more underbody with plain water. In geographic areas having
before lubricating. a heavy concentration of such corrosive materials, it is
recommended that the complete underbody be inspected
Keep spring to axle U bolts and shackle bolts properly and flushed at least once a year, preferably after a
tightened (see Specifications Section for torque recom winters exposure. Particular attention should be given to
mendations). Check U bolt nuts after the first 1,000 miles cleaning out underbody members where dirt and other
of operation if the U bolt or U bolt nuts are changed in foreign materials may have collected.
service.
FOUR WHEEL DRIVE
HOOD LATCH AND HOOD HINGE
Every 7,500 miles or 6 months, whichever occurs first, Most lubrication recommendations and procedures for 4
lubricate hood latch assembly and hood hinge assembly wheel drive-equipped trucks are the same for corre
as follows: sponding components of conventional drive trucks.
1. Wipe off any accumulation of dirt or contaimina- In addition, the following items require lubrication at the
tion on latch parts. intervals mentioned.
2. Apply lubriplate or equivalent to latch pilot bolt Propeller S haft Centering Ball
and latch locking plate. A centering ball at the transfer case end of the front
3. Apply light engine oil to all pivot points in release propeller shaft on Four Wheel Drive Models should be
mechanism, as well as primary and secondary latch lubricated every 7,500 miles with water resistant EP
mechanisms. chassis lubricant which meets General Motors Specifica
4. Lubricate hood hinges. tion GM 6031-M. More frequent lubrication may be
required on heavy duty off the road operations.
5. Make hood hinge and latch mechanism functional
check to assure the assembly is working correctly. NOTE: A special needle nose grease gun adapter
for flush type grease fitting is required to lubricate
BODY LUBRICATIO N
the centering ball.
Normal use of a truck causes metal-to-metal movement Front Axle
at certain points in the cab or body. Noise, wear and The front axle should be checked every 7,500 miles or 6
improper operation at these points will result when a months and refilled with SAE 80W-90 GL-5 Gear
protective film of lubricant is not provided. Lubricant when necessary. With the differential at
For exposed surfaces, such as door checks, door lock operating temperature, fill to the level of filler plug hole.

TRUCK SUPP - SERVICE


GENERAL INFORMATION AND LUBRICATION 0-11

Fu ll Time Four Wheel Drive


If differential is cold, fill to level of 1/2" below the filler
plug hole. Add SAE 10W-30 or SAE 10W-40 engine oil to bring to
For vehicles normally operated in Canada use SAE 80W level 1/ 2" below filler plug hole.
GL-5 Gear Lubricant.
Control lever and Linkage
Air Vent Hoses
Check vent hose at front axle and at transfer case for Since no grease fitting is provided in the control ever it is
kinks and proper installation every 7,500 miles or 6 necessary to brush or spray engine oil on the lever pivot
months. point and on all exposed control linkage every 7,500
Transfer Case
miles 6 months.
Check the transfer case level every 7,500 miles or 6
months and, if necessary, add lubricant as follows: SPEEDOMETER ADAPTER
Conventional Four Wheel D rive On vehicles so equipped, lubricate adapter at fitting with
Add SAE 80W or SAE 80W-90 GL-5 Gear Lubricant to water resistant EP chassis grease which meets General
bring to level of filler plug hole. Motors Specification GM 6031-M every 7,500 miles.

TRUCK SUPP SERVICE


0-12 GENERAL INFORMATION AND LUBRICATION

COMPLETE VEHICLE MAINTENANCE SCHEDULE

When To Perform Services Item Services


(Months or Miles, Whichever Occurs First) No. (For Details, See Numbered Paragraphs)
Every 6 Months or 7,500 Miles 1 *Chassis Lubrication
2 *F luid Levels Check
3 *Engine Oil Change
At 1st Oil Chg. - Then Every 2nd 4 *Oil Filter Change
See Explanation 5 Tire Rotation (Steel Belted Radial)
6 Rear Axle Lube Change
Every 12 Months 7 A ir Conditioning Check
Every 12 M onths or 15,000 Miles 8 *Cooling System Check
Coolant Change & Hose Replacement
Every 30,000 Miles 9 Wheel Bearing Repack
10 *Auto. Trans. Fluid & Filter Change
11 Manual Steering Gear Check
12 Clutch Cross Shaft Lubrication
Every 6 M onths or 7,500 Miles 13 Owner Safety Checks
14 Tire and Wheel Inspection
15 *Exhaust System Check
16 *Drive Belt Check
* Belt Replacement
17 Suspension and Steering Check
18 Brake and Power Steering Check
Every 12 Months or 15,000 Miles 19 Drum Brake and Parking Brake Check
20 Throttle Linkage Check
21 Underbody Flush & Check
22 Bumper Check
At First 6 M onths or 7,500 23 Thermo. Controlled A ir Cleaner Check
Miles - Then at 18 Month/ 24 Carburetor Choke Check
22,500 Mile Intervals 25 Engine Idle Speed Adjustm ent
26 EFE Valve Check
27 Carburetor M ounting Torque
Every 12 Months or 15,000 Miles 28 Fuel Filter Replacement
29 Vacuum Advance System & Hoses Check
30 PCV System Check
PCV Valve & Filter Replacement
Every 18 M onths or 22,500 Miles 31 Idle Stop Solenoid Check
32 Spark Plug Wires Check
Every 22,500 Miles 33 Spark Plug Replacement
34 Engine Tim ing Adjustm ent & Dist. Check
Every 24 M onths or 30,000 Miles 35 ECS System Check & Filter Replacement
36 Fuel Cap, Tank and Lines Check
Every 30,000 Miles 37 A ir Cleaner Element Replacement

Also A Safety Service


* Also An Emission Control Service

TRUCK SUPP SERVICE


GENERAL INFORMATION AND LUBRICATION 0-13

EXPLANATION OF COMPLETE first 7,500 miles and then at every 15,000 miles
VEHICLE MAINTENANCE thereafter. Bias-belted tires should be rotated every
7,500 miles. To equalize wear, rotate tires as
SCHEDULE illustrated in Section 10 of this manual and adjust
Presented below is a brief explanation of each of the tire pressures as shown on Tire Inflation Table in
services listed in the preceding Complete Vehicle Section 10 of this manual.
Maintenance Schedule. 6. REAR AXLEChange lubricant at first 15,000 miles
Vehicle operation under conditions such as heavy dust, on positraction axles. Change lubricant every 7,500
continuous short trips, use of other than unleaded or low miles on all typo rear axles or final drives when
lead fuels or pulling trailers, is not considered normal using vehicle to pull a trailer.
use and therefore more frequent maintenance will be 7. AIR C O N D IT IO N IN G Check condition of air
required. Such additional maintenance requirements are conditioning system hoses and refrigerant charge at
included where applicable. Refer to the appropriate sight glass (if so equipped). Replace hoses and/or
section of this manual for additional details on specific refrigerant if need is indicated.
services. A listing of recommended lubricants and fluids 8. CO OLING S Y S T E M ** 12 month or 15,000-mile
is included at the end of this listing. intervals, wash radiator cap and filler neck with
LUBE AND GENERAL clean water, pressure test system and radiator cap
MAINTENANCE
for proper pressure holding capacity, (tighten hose
clamps and inspect condition of all cooling and
1. CHASSIS**-Lubricate all grease fittings in front heater hoses). Replace hoses every 24 months or
suspension and steering linkage. Also lubricate 30,000 miles, or earlier if checked, swollen or
transmission shift linkage, hood latch, hood hinges, otherwise deteriorated.
and parking brake cable guides and linkage, clutch Also each 12 months or 15,000 miles, clean exterior of
linkage, propeller shaft slip joint, universal joints radiator core and air conditioning condenser. Every 24
and brake and clutch pedal springs. Lubricate months or 30,000 miles, drain, flush, and refill the
suspension and steering linkage every 3 months or cooling system with a new coolant solution.
3,000 miles when operating under dusty or muddy 9. WHEEL BEARINGS-Clean and repack front wheel
conditions and in extensive off-road use. (See bearings with a lubricant as specified in the
elsewhere in this section for additional services Recommended Fluids and Lubricants" chart in this
required on four wheel drive models.) section.
2. FLUID LEVELS-Check level of fluid in brake
master cylinder*, power steering pump*, battery, 10. A U TO M A TIC TRANSMISSION F L U ID * *
Under normal driving conditions, change the trans
engine**, axle, transmission** and windshield mission fluid and service the sump filter every 30,000
washer*. Engine coolant should be checked for miles.
proper level and freeze protection to at least 20 F
or to the lowest temperature expected during the Under unusual conditions such as constant driving in
period of vehicle operation.** Proper engine heavy city traffic, trailer pulling, and commercial
coolant also provides corrosion protection. applications, services should be performed at 15,000 mile
Any significant fluid loss in any of these systems or intervals. See elsewhere in this manual for further details
on transmission care.
units could mean that a malfunction is developing and
corrective action should be taken immediately. A low 11. M A N U A L STEERING GEARCheck for seal leakage
fluid level in the brake master cylinder front reservoir around the pitman arm and housing. If leakage is
could also be an indicator that the disc brake pads need evident (solid grease oozing out-not just oily film),
replacing. it should be corrected immediately.
3. ENGINE OIL**Change each 6 months or 7,500 12. CLUTCH CROSS SHAFTLubricate clutch cross
miles, whichever occurs first under normal driving shaft lever.
conditions, or each 3 months or 3,000 miles when SAFETY MAINTENANCE
the vehicle is operated under the following NOTE: Items a thru u can be checked by the
conditions: (a) driving in dusty conditions, (b) owner, while Items 14 thru 22 should only be
trailer pulling, (c) extensive idling or (d) short-trip checked by a qualified mechanic. It is particularly
operation at freezing temperatures (with engine not important that any safety systems which may have
thoroughly warmed-up). See elsewhere in this been adversely affected in an accident be checked
section for additional details on engine oil. and repaired as necessary before the vehicle is
4. ENGINE O IL FITLER **-Replace at the first oil returned to use.
change and every other oil change thereafter. * Also a Safety Service
5. TIRES-Steel belted radial tires should be rotated at ** Also an Emission Control Service

TRUCK SUPP SERVICE


0-14 GENERAL INFORMATION AND LUBRICATION

13. SAFETY CHECKS TO BE PERFORMED BY indicated by a pull to the right or left when
OWNERThe following checks should be made driving on a straight and level road. The need
regularly during operation at no greater interval for wheel balancing is usually indicated by a
than 6 months or 7,500 miles, whichever occurs vibration he steering wheel or seat while
first, and more often when the need is indicated. driving at normal highway speeds.
Any deficiencies should be brought to the attention (h) BRAKES-Be alert to illumination of the brake
of your dealer or another service outlet, as soon as warning light or changes in braking action,
possible, so the advice of a qualified mechanic is such as repeated pulling to one side, unusual
available regarding the need for repairs or sounds either when braking or between brake
replacements. applications, or increased brake pedal travel.
(a) STEERING COLUMN LOCK-Check for proper Any of these could indicate the need for brake
operation by attempting to turn key to LOCK system inspection and/or service.
position in the various transmission gears with
car stationary. Key should turn to LOCK (i) EXHAUST SYSTEM^Be alert to any change in
position only when transmission control is in the sound of the exhaust system or a smell of
PARK on automatic transmission models or in fumes which may indicate a leak.
reverse on manual transmission models. Key (j) WINDSHIELD WIPERS AND WASHERS-Check
should be removable only in LOCK position. operation of wipers, as well as condition and
(b) PARKING BRAKE AND TRANSMISSION alignment of wiper blades. Check amount and
"PARK" MECHANISM-Check parking brake direction of fluid sprayed by washers during
holding ability by parking on a fairly steep hill use.
and restraining the vehicle with the parking (k) DEFROSTERS-Check performance by moving
brake only. On vehicles with automatic controls to "D EF" and noting amount of air
transmissions, check the holding ability of the directed against the windshield.
"PARK" mechanism by releasing all brakes
after the transmission selector lever has been (1) REARVIEW MIRRORS AND SUN VISORS-
placed in the "P" position. Check that friction joints are properly adjusted
so mirrors and sun visors stay in the selected
CAUTION: Before making the two checks position.
below, be sure to have a clear distance ahead
and behind the car, set the parking brake and (m) HORNBlow the horn occasionally to be sure
firmly apply the foot brake. Do not depress that it works. Check all button locations.
accelerator pedal. Be prepared to turn off (n) LAP AND SHOULDER BELTS-Check belts,
ignition switch immediately if engine should buckles, adjustable latch plates, retractors,
start. interlock and reminder systems, guide loops,
(c) STARTER SAFETY SWITCH (AUTOMATIC clips, and anchors for impaired operation or
TRANSMISSION VEHICLES>~Check starter damage. Check to make certain that anchor
safety switch by attempting to start the engine mounting bolts are tight.
with the transmission in each of the driving (o) HEAD RESTRAINTSCheck that head re
gears. The starter should operate only in the straints, if present, adjust properly in the up
Park ("P") or Neutral ("N") positions. detent positions, and that no components are
(d) STARTER, SAFETY SWITCH (MANUAL missing, damaged or loose.
TRANSMISSION VEHICLES)-To check, place (p) SEAT BACK LATCHES-Check to see that seat
the shift lever in neutral, depress the clutch back latches are holding by pulling forward on
halfway, and attempt to start. The starter the top of each folding seat back (with doors
should operate only when clutch is fully closed if equipped with automatic seat back
depressed. latches).
(e) TRANSMISSION SHIFT INDICATORCheck to (q) LIGHTS AND BUZZERS-Check all instrument
be sure automatic transmission shift indicator panel illuminating and warning lights, seat belt
accurately indicates the shift position selected. reminder light and buzzer, ignition key buzzer,
(f) STEERINGBe alert to any changes in steering interior lights, license plate lights, side marker
action. The need for inspection or servicing lights, headlamps, parking lamps, tail lamps,
may be indicated by "hard" steering, excessive brake lights, turn signals, backup lamps, and
free play or unusual sounds when turning or hazard warning flashers. Have headlamp aim
parking. checked every 12 months or 15,000 miles, or
(g) WHEEL ALIGNMENT AND BALANCEIn more often if light beams seem to be aimed
addition to uneven or abnormal tire wear, the improperly.
need for wheel alignment service may be (r) GLASS-Check for broken, scratched, dirty or

TRUCK SUPP - SERVICE


GENERAL INFORMATION AND LUBRICATION 0-15

damaged glass on vehicle that could obscure 19 DRUM BRAKES AND PARKING BRAKE- Check
vision or become an injury hazard. drum brake linings and other internal brake
(s) DOOR LATCHES-Check for positive closing, components at each wheel (drums, wheel cylinders,
latching and locking. etc.). Parking brake adjustment also should be
checked whenever drum brake linings are checked.
(t) HOOD LATCHES-Check to make sure hood NOTE: More frequent brake checks should be
closes firmly by lifting on the hood after each made if driving conditions and habits result
closing. Check also for broken, damaged or in frequent brake application.
missing parts which might prevent secure
latching. 20. THROTTLE LINKAGE- Check for damaged or
(u) FLUID LEAKS-Check for fuel, water, oil or missing parts, interference or binding. Any
other fluid leaks by observing the ground deficiencies should be corrected without delay by a
beneath the vehicle after it has been parked qualified mechanic.
for a while. (Water dripping from air 21. UNDERBODYIn geographic areas using a heavy
conditioning system after use is normal.) If concentration of road salt or other corrosive
gasoline fumes or fluid are noticed at any time, materials for snow removal or road dust control,
the cause should be determined and corrected flush and inspect the complete underside of the car
without delay because of the possibility of fire. at least once each year, preferably after a winters
14. TIRES AND WHEELS-To equalize wear, rotate tires exposure. Particular attention should be given to
as illustrated in Section 10 in this manual. Adjust cleaning out underbody members where dirt and
tire pressures as recommended on tire placard on other foreign materials may have collected.
left front door. Check disc brake pads and 22. BUMPERS-Check the front and rear bumper
conditions of rotors while wheels are removed. systems at 12-month/15.000 mile intervals to be
Check tires for excessive wear or damage. Make sure that impact protection and clearance originally
certain wheels are not bent or cracked and wheel designed into these systems remain in a state of full
nuts are tight. Check tire inflation pressure at least readiness. They also should be checked whenever
monthly, or more often if daily visual inspection there is obvious bumper misalignment, or whenever
indicates the need. the vehicle has been involved in a significant
15. EXHAUST SYSTEM**Check complete exhaust collision in which the bumpers were struck, even
system and nearby body areas and trunk lid for when slight or no damage to the bumper systems
broken, damaged, missing or mispositioned parts, can be seen.
open seams, holes, loose connections or other EMISSION CONTROL
deterioration which could permit exhaust fumes to MAINTENANCE
seep into the trunk or passenger compartment. Dust
or water in the trunk may be an indication of a NOTE: Additional recommended maintenance
problem in one of these areas. Any defects should instructions relating to vehicle use, evidence of
be corrected immediately. To help insure continued maintenance, and service replacement parts are
integrity, exhaust system pipes and resonators included in the New Vehicle Warranty Information
rearward of the muffler must be replaced whenever folder.
a new muffler is installed. 23 THERMOSTATICALLY CONTROLLED AIR
16. ENGINE DRIVE BELTS**Check belts driving fan, CLEANER-Inspect installation to make certain that
AIR pump, Delcotron, power steering pump and air all hoses and ducts are connected and correctly
conditioning compressor for cracks, fraying, wear installed. Also check valve for proper operation.
and tension. Adjust or replace as necessary. 24 CARBURETOR CHOKE AND HOSES^ Check choke
It is recommended that belts be replaced every 24 mechanism for proper operation. Any binding
months or 30,000 miles, whichever occurs first. condition which may have developed due to
17. SUSPENSION AND STEERING-Check for dam petroleum gum formation on the choke shaft or
aged, loose or missing parts, or parts showing from damage should be corrected. Check carburetor
visible signs of excessive wear or lack of lubrication choke hoses for proper connection, cracking,
in front and rear suspension and steering system. abrasion or deterioration and correct or replace as
Questionable parts noted should be replaced by a necessary.
qualified mechanic without delay. 25. ENGINE IDLE SPEED-Adj ust engine idle speed
18. BRAKES AND POWER STEERING-Check lines and accurately (following the specifications shown on
hoses for proper attachment, leaks, cracks, chafing, the label under the hood). Adjustments must be
deterioration, etc. Any questionable parts noted made with test equipment known to be accurate.
should be replaced or repaired immediately. When 26. EARLY FUEL EVAPORATION (EFE) VALVE-Check
abrasion or wear is evident on lines or hoses, the valve for proper operation. A binding condition
cause must be corrected. must be corrected. Check switch for proper

TRUCK SUPP - SERVICE


0-16 GENERAL INFORMATION AND LUBRICATION

operation. Check hoses for cracking, abrasion or 33. SPARK PLUGS-Replace plugs at 22,500 mile
deterioration. Replace parts as necessary. intervals with type specified in Section 6 in this
27. CARBURETOR MOUNTING At 7,500, 22,500, and manual.
45.000 miles, torque carburetor attaching bolts and/ 34. TIMING AND DISTRIBUTION CAP-Adjust ignition
or nuts to compensate for compression of the timing following the specifications shown on label
gasket. under hood. Also, carefully inspect the interior and
28. FUEL FILTERReplace filter (in carburetor) at exterior of the distributor cap and rotor for cracks,
15.000 mile intervals or more frequently if clogged. carbon tracking and terminal corrosion. Clean or
replace as necessary.
29. VACUUM ADVANCE SYSTEM AND HOSES-Check 35. EVAPORATION CONTROL SYSTEM (ECS)-Check
system for proper operation and hoses for proper all fuel and vapor lines and hoses for proper
connection, cracking, abrasion or deterioration. connections and correct routing as well as condition.
Replace parts as necessary. Remove canister and check for cracks or damage.
30. POSITIVE CRANKCASE VENTILATION SYSTEM Replace damaged or deteriorated parts as neces
(PCV)-Check the PCV system for satisfactory sary. Replace filter in lower section of canister.
operation at 15,000 mile intervals, and clean filter. 36. FUEL CAP, FUEL LINES AND FUEL TANK-Inspect
Replace the PCV valve at 30,000 mile intervals and the fuel tank, cap and lines for damage which could
blow out PCV valve hose with compressed air.
Replace deteriorated hoses. cause leakage. Inspect fuel cap for correct sealing
ability and indications of physical damage. Replace
The PCV filter (located in the air cleaner) should be any damaged or malfunctioning parts.
replaced whenever the air cleaner element is replaced. 37. AIR CLEANER ELEMENTReplace the engine air
31. IDLE STOP SOLENOID OR DASHPOTCheck for cleaner element under normal operating conditions
proper operation. An inoperative solenoid or every 30,000 miles on V-8 engines and L-6 engines.
dashpot must be replaced. Operation of vehicle in dusty areas will necessitate
32. SPARK PLUG WlRES-Clean exterior of wires; more frequent replacements.
remove any evidence of corrosion on end terminals. CAUTION: Do not operate the engine without
Inspect spark plug wires for evidence of checking, the air cleaner unless temporary removal
burning, or cracking of exterior insulation and tight is necessary during repair or maintenance
fit at distributor cap and spark plugs or other o f the vehicle. When the air cleaner is
deterioration. If corrosion cannot be removed or removed, backfiring can cause fire in the
other conditions above are noted, replace wire. engine compartment.

TRUCK SUPP SERVICE


GENERAL INFORMATION AND LUBRICATION 0-17

RECOMMENDED FLUIDS & LUBRICANTS

USAGE FLUID/LUBRICANT USAGE FLUID/LUBRICANT

Power steering system GM power steering fluid Hood hinges Engine oil
and pump reservoir Part No. 1050017 or equiv
alent if not available use Automatic transmission Engine oil
DEXRON-II automatic shift linkage
transmission fluid
Differential standard GL-5 gear lubricant Chassis lubrication Chassis grease meeting re
SAE-80W or SAE-80W-90 quirements of GM 6031-M
( 80W in Canada )
Differential Positraction Lubricant GM Part No. Automatic transmission DEXRON-II automatic
1051022 or equivalent transmission fluid
Manual steering gear Lubricant GM Part No. Parking brake cables Chassis grease
1051052 or equivalent
Manual transmission GL-5 gear lubricant Front wheel bearings Chassis grease meeting
SAE-80W or SAE-80W-90 requirements of GM 6031-M
v80W in Canada.)
Body door hinge pins, sta Engine Oil
Brake system and master Delco Supreme No. 11 fluid tion wagon tailgate hinge
cylinder or DOT-3 and linkage, station wagon
Clutch linkage folding seat, rear
(Man. trans. only) compartment lid hinges.
a. Pivot points Engine oil
b. Push rod to clutch fork Chassis grease meeting Windshield washer solvent GM Optikleen washer sol
joint, and cross shaft requirements of GM 6031-M vent Part No. 1050001 or
pressure fitting equivalent
Manual transmission shift Engine oil Energizer (Battery) Colorless, odorless drink
linkage, column shift ing water
Shift linkage, floor shift Engine oil Mixture of water and a high
Engine coolant
Hood Latch assembly quality Ethylene Glycol base
a. Pivots and spring Engine oil type anti-freeze conforming
anchor to GM Spec. 1899-M
b. Release pawl Chassis grease

TRUCK SUPP SERVICE


0-18 GENERAL INFORMATION AND LUBRICATION

DRIVE O N HOIST BUMPER JA C K LIFTING I I I FLOOR JA C K OR HOIST LIFT

Fig. 6 G Model Lifting Points

TRUCK SUPP SERVICE


GENERAL INFORMATION AND LUBRICATION 0-19

Lubrication Type of
No. Lubrication Points Period Lubrication Q uantity Remarks

1 Lower Control Arms 7,500 Miles Chassis Lubricant 4 places as required


2 Upper Control Arms 7,500 Miles Chassis Lubricant 4 places as required
3 Upper and Lower Control 7,500 Miles Chassis Lubricant 4 places as required
A rm Ball Joints
4 Intermediate Steering 7,500 Miles Chassis Lubricant 2 places as required
Shaft (PA10)
5 Tie Rod Ends 7,500 Miles Chassis Lubricant 4 places as required
6 Wheel Bearings 30.000 Miles Whl. Brg. Lubricant 2 places as required
7 Steering Gear 30,000 Miles Check fo r Grease Leak
Do not Lubricate
8 A ir Cleaner Element 15,000 Miles See Vehicle
Maintance Schedule
11 Master Cylinder 7,500 Miles Delco Supreme As required Check add fluid
No. 11 or DOT-3 fluids when necessary
12 Transmission Manual 7.500 Miles GL-5 As required Keep even w /fille r plug.
A utom atic 7.500 Miles Dexron -H or equivalent As required See Lubrication Section
13 T h ro ttle Bell Crank L-6 7,500 Miles Enqine Oil As required
14 Carburetor Linkage V-8 7,500 Miles Engine Oil As required
15 Brake and Clutch Pedal 7,500 Miles Engine Oil As required
Springs
16 Universal Joints 7,500 Miles Chassis Lubricant As required
17 Propeller Shaft Slip Joint 7,500 Miles Chassis Lubricant As required N ot shown
18 Rear Axle 7,500 Miles GL-5 As required Check
See Lubrication section

Fig. 7 Lubrication - C onventional and Forward Control Models

TRUCK SUPP - SERVICE


0-20 GENERAL INFORMATION AND LUBRICATION

Lubrication Type of
No. Lubrication Points Q uantity Remarks
Period Lubrication

1 A ir Cleaner 15,000 Miles See Vehicle


Maintenance
Schedule
4 Control Linkage Points 15,000 Miles Engine Oil As required Brush or Spray
to applv
7 Tie Rod Ends 7,500 Miles Chassis Lubricant 2 places as required
8 Wheel Bearings 30,000 Miles Wheel Bearing 2 places as required
Grease
9 Steering Gear 30,000 Miles Check fo r Grease Leak
Do not Lubricate
10 Master Cylinder 7,500 Miles Delco Supreme As required Check add fluid
N o.11 or DOT-3 fluids when necessary
11 Transmission Manual 7.500 Miles GL-5 As required Keep even w /fille r plug
Autom atic 7.500 Miles Dexron -II or equivalent As required See Lubrication Section
12 Carburetor Linkage V-8 7,500 Miles Engine Oil As required
13 Universal Joints 7,500 Miles Chassis Lubricant As required See Lubrication Section
14 Propeller Shaft Slip Joints 7,500 Miles Chassis Lubricant 3 places as required
15 Front and Rear Axle 7,500 Miles G L-5 As required Check
See Lubrication Section
17 Drag Link 7,500 Miles Chassis Lubricant 2 places as required
18 Brake and Clutch
Pedal Springs 7,500 Miles Enqine Oil As required
21 Transfer Case 7,500 Miles GL-5 As required Check
See Lubrication Section
22 T h ro ttle Bell Crank L-6 15,000 Miles Engine Oil As required

Fig. 8 Lubrication Four Wheel Drive Models

TRUCK SUPP SERVICE


GENERAL INFORM ATION AND LUBRICATION 0-21

Lubrication Type of
No. Lubrication Points Q uantity Remarks
Period Lubrication

1 Control Arm Bushings and


Ball Joints 7,500 Miles Chassis Lubricant 12 places as required
2 Tie Rod Ends 7,500 Miles Chassis Lubricant 4 places as required 2 fittin q s each side
3 Wheel Bearings 30,000 Miles Whl. Brq. Lubricant 2 places as required
4 Steering Gear 30,000 Miles
Clutch Cross-Shaft 7,500 Miles Chassis Lubricant As required
5 Trans. Control Shaft 7,500 Miles Chassis Lubricant As required
6 A ir Cleaner Element 15,000 Miles See Vehicle
Maintenance
Schedule
8 T ransmission Manual 7.500 Miles GL-5 As required See Lubrication Section
Autom atic 7.500 Miles Dexron-II or Equivalent As required See Lubrication Section
9 Rear Axle 7,500 Miles GL-5 As required See Lubrication Section
10 Oil F ilter Every Second
Oil Chanqe
11 Brake Master Cylinder 7,500 Miles Delco Supreme As required Check Add flu id when
No. 11 or DOT-3 fluids necessary
12 Parking Brake Linkage 7,500 Miles Chassis Lubricant Lubricate Linkage
and Cables

Fig. 9 L u b ric a tio n -l/2 T o n G Models

TRUCK SUPP - SERVICE


SECTION 1A

HEATER AND AIR CONDITIONING


C O N TE N TS OF THIS SECTION

General Inform ation..................................................................... 1A-1


Air Conditioning............................................................................. 1A-1

GENERAL INFORMATION
Refer to the 1974 Light Duty Truck Service Manual for
servicing the standard heater and auxiliary heater.

AIR CONDITIONING
Refer to the 1974 Light Duty Truck Service Manual for Refrigerant flows into the crankcase from the connector
servicing an air conditioning system with a V8 engine or block at the rear, is drawn through the reeds attached to
six cylinder engine with the following exception: the piston top during the suction stroke, and is
discharged outward through the discharge valve plate
RADIAL FOUR CYLINDER COMPRESSOR which is held in place at the top of the cylinder by a
snap ring. Discharge gas flows out of the compressor
A radial four cylinder compressor (Fig. 1) is used on a muffler cavity through the connector block at the rear.
vehicle with a six cylinder engine.
The compressor is mounted to the engine by mounting Clutch Coil
brackets (Fig. 2) and is belt driven by the engine when The clutch coil is moulded into the steel coil housing and
the electromagnetic clutch assembly on the compressor is must be replaced as a complete assembly. Three
energized by the air conditioning controls. protrusions on the rear of the housing fit into alignment
The purpose of the compressor is to pump low pressure, holes in the compressor front head. The coil is secured to
low temperature refrigerant vapor produced by the the front head by a pressed fit between the coil housing
evaporator and compress it into a high pressure, high and neck portion of the front head. The coil has 3.65
temperature vapor which can then be readily condensed ohms resistance at 80 F. ambient and will require no
back to a liquid state by the condensor. more than 3.2 amperes at 12 volts D.C. The clutch coil
The compressor has a displacement of 10.0 cu. in. The has two terminals for the power and ground leads.
compressor has variations in the pulley rim diameter
specified for the respective vehicle applications. Clutch-Pulley
The basic compressor mechanism is a modified scotch The movable part of the clutch drive plate is in front of
yoke with four cylinders located radially in the same and adjacent to the rotor and bearing assembly. The
plane. Opposed pistons are pressed into a yoke which armature plate, the movable member, is attached to the
rides upon a slider block located on the shaft eccentric. drive hub through driver springs riveted to both
Rotation of the shaft provides reciprocating piston members. The hub of the drive plate is pressed on the
motion with no "connecting rods". The mechanism is compressor shaft and keyed to the shaft by a square
completely balanced with counterweights. Needle bear drive key. A self-locking nut threads on the end of the
ings are used for the shaft journals and the shaft shaft and is tightened against the shaft. The rotor and
eccentric. Pistons and yokes, along with the main hub is a welded assembly and contains six threaded holes
cylinder housing and front cover, are made from for mounting the pulley rim. The pulley rim is secured to
aluminum to provide light weight. Teflon piston rings the rear portion of the rotor by six screws and six special
are used to provide both a gas compression seal and a lock washers.
piston-to-bore bearing surface. The outer shell is a A two-row ball bearing is pressed into the rotor hub and
simple steel band which encloses a large annular held in place by three punch stakes, 120 apart, into the
discharge muffler space. rotor hub near the hub bore. The entire clutch coil,
Two O-rings provide a seal between the compressor shell pulley rim, rotor and bearing assembly is pressed on the
and the compressor cylinder. A rubber seal ring seals the front head of the compressor and secured by a retainer
front head to the cylinder assembly and the shaft seal ring.
assembly provides a front head to shaft seal. When power is supplied to the clutch coil the armature

TRUCK SUPP SERVICE


1 A -2 HEATER AND AIR C O N D ITIO N IN G

1. Screw 13. S u p e rh e a t Switch 24. B e lle v ille W ashe r


2. Locking W ashe r 14. O -R ing 25. O -R ing
3. P ulley Rim 15. Pressure R elie f Valve 26. Shell Assy.
4. C oil a n d H ousing Assy. 16. O -R ing 27. Ring Seal
5. Rotor B e a rin g 17. Screw 28. M a in B e a rin g
6. Rotor an d B e a rin g Assy. 18. S h ip p in g P late 29. Front H e a d Assy.
7. R eta in ing Ring 19. O -R ing 30. Screw a n d W a sh e r Assy.
8. C lutch Drive Assy. 20. R eta in ing Ring 31. O -R ing
9. Clutch H ub Key 21. V alve P late Assy. 32. S h a ft Seal
10. S h a ft N u t 22. C y lin d e r an d S h a ft Assy. 33. Seal Seat
11. C ap 23. Thrust W asher 34. R e ta in ing Ring
12. R eta in ing Ring

Fig. 1 Radial Four Cylinder Compressor-Exploded View

plate of the drive plate and hub assembly electromagnet- seat is finished to a high polish and must be protected
ically engages the slotted portion of the rotor face which against nicks, scratches and even fingerprints. Any
then drives the crankshaft through the drive plate leaf surface damage will cause a poor seal. An "O" ring,
springs and hub. located in an internal groove in the neck of the front
Shaft Seal head provides a seal with the outer diameter of the seal
seat. A retainer ring, tapered side away from the seat,
The main shaft seal, located in the neck of the secures the seat in place. The hub and armature plate
compressor front head, consists of the seal assembly with
its ceramic seal face in a spring loaded cage. An "O" must be removed to gain access to the seal. A shaft seal
ring seal, located within the ceramic seal, provides a seal kit contains all necessary replacement parts for field
to the shaft surface. The contact surface of the shaft seal service.

TRUCK SUPP - SERVICE


HEATER AND AIR C O NDITIO NING 1A-3

9. Remove the condenser assembly by pulling it


forward and then lowering it from the vehicle.
10. To install a new condenser, reverse Steps 1-9 above.
Add one fluid ounce of clean refrigeration oil to a
new condenser.
NOTE: Use new "O" rings, coated with clean
refrigeration oil, when connecting all refrigerant
lines.
11. Evacuate, charge and check the system.
HEATER AIR D ISTR IB U TO R
AND EXTENSION DUCT G MODEL
Replacement
SPECIAL STUD 1. Disconnect battery ground cable.
FOR BATTERY
GROUND 2. Remove engine cover.
3. Remove evaporator-blower shield.
Fig. 2 Compressor Mounting - L6 Engine
4. Remove shield bracket.
Front Head 5. Remove left floor outlet deflector and bracket.
The front head contains the front main shaft bearing 6. Loosen steering column to instrument panel
pressed in place and a drilled oil hole for lubrication to reinforcement screws. Remove one screw. Torque
the shaft seal cavity. The front head is mounted to the both screws on installation.
cylinder assembly by four screw and washer assemblies. 7. Disconnect speedometer cable at meter.
8. Remove instrument panel to lower reinforcement
Thrust Washers attaching screws.
One thrust washer is used on the rear end of the 9. Move instrument panel assembly rearward.
crankshaft between the rear eccentric and the rear of the
cylinder. A belleville washer, sandwiched between two Disconnect radio antenna and electrical connector.
thrust washers at the front of the shaft between the front Support instrument panel at right visor.
eccentric and the front head controls the lateral thrust Disconnect electrical connector at brake switch.
tolerance of the shaft and cylinder assembly. The two 10. Remove blower-evaporator support bracket to door
thrust washers have tangs and are assembled with the
tangs facing inward to engage and cause the thrust and
belleville washer assembly to rotate as a unit and not
separately.

CONDENSER - CK MODEL
Replacem ent (Fig. 3)
1. Disconnect battery ground cable.
2. Purge the system of refrigerant.
3. Remove the grille assembly.
4. Remove the radiator grille center support.
5. Remove the left grille support to upper fender
support (2) screws.
6. Disconnect the condenser inlet and outlet lines and
the outlet tube line at the right end of the
condenser. Cap or plug all open connections at
once.
7. Remove the condenser to radiator support screws.
8. Bend the left grille support outboard to gain
clearance for condenser removal.

TRUCK SUPP SERVICE


1A-4 HEATER AND AIR CO N D ITIO N IN G

pillar and forward engine housing attaching screws. 17. To reassemble. Reverse Steps 1-16.
Move rearward to gain access.
11. Disconnect vacuum lines and electrical connectors. AIR INLET VALVE - G MODEL
Remove heater distributor duct assembly. Replacement
12. Transfer duct and relays. Follow Steps 1-10 of "Heater Air Distributor and
13. To reassemble. Reverse Steps 1-12. Extension Duct Extension Duct Replacement" procedure.
11. Remove duct assembly. Disconnect vacuum hose.
HEATER CORE CASE AND CORE - G 12. Remove vacuum valve.
MODEL 13. To reassemble, Reverse Steps 1-12.
Replacement
Follow Steps 1-10 of "Heater Air Distributor and TEM PE R A TU R E DOOR CABLE - G MODEL
Extension Duct Replacement" procedure. Replacement
11. Remove battery. Follow Steps 1-10 of "Heater Air Distributor and
12. Disconnect heater hoses at heater core (drain pan Extension Duct Replacement" procedure.
below hoses) refill radiator upon completion. 11. Disconnect temperature door control cable at heater
13. Remove air inlet valve assembly. case.
14. Remove temperature door control cable at heater 12. Disconnect temperature door control cable at
case. control.
15. Remove heater assembly. 13. Make up new cable.
16. Remove heater core. Reseal heater case. 14. To reassemble, Reverse Steps 1-13.

TRUCK SUPP - SERVICE


SECTION IB

BODY
NOTE: Except for the items listed below, all information found in
section IB of the 1974 Light Duty Truck Service Manual is applicable to
1975 Light Duty Trucks.

INDEX

C-K Models....................................................................................... IB-1


G Models............................................................................................ IB-3

C-K MODELS

Fig. 2 Glass Run Channel Adjustment

REAR SIDE DOOR (MODELS 0 6 AND 03)


Fig. 1 Cowl Vent Valves
Glass Run Channel Adjustment
COWL VENT VALVES Figure 2 illustrates the front run channel. At the lower
Two styles are shown in figure 1. Removing the attaching end, a slotted bracket provides for in-and-out adjust
screws allows removal of the valve from the side panels. ment. The screw and locknut at that bracket allow fore-
Refer to page IB-6 o f the 1974 manual. and-aft adjustment.
Together, this allows proper alignment of the glass to the
rear glass run channel for full up and down travel. Refer
to pages 1B-14 and IB-15 o f the 1974 manual.

TRUCK SUPP SERVICE


1 B -2 B O D Y

Fig. 4 Wedge and Striker Adjustments

REAR DOOR CHECK STRAP CAUTIO N A D D E D -


ENDGATE DISASSEMBLY
Model 06
Figure 3 shows the cloth check strap used for rear doors. Model 06
The door may be completely opened by removing the Refer to page IB-20 of the 1974 Light Duty Truck
strap pin from the bracket. The bracket attaches to the Service Manual.
pillar with three screws; the strap is fastened to the door Step 10 defines the proper method of removing the
panel with two screws and an attaching bar. Refer to regulator on an electric-powered window. The following
page IB -18 o f the 1974 manual. CAUTION emphasizes the need for following step 10
carefully:
REAR D O O R -
C A U TIO N : Step 10 must be performed if the
STRIKER AND WEDGE A D JU S TM E N TS window is removed or disengaged from the
Figure 4 illustrates the rear door latch strikers and door regulator lift arms. The lift arms are under
wedges. Be sure that adjustments are as shown to insure tension from the counter-balance spring, and
proper latching of the rear doors. Refer to page IB-18, can cause injury if the motor is removed
figure 48, o f the 1974 manual. without locking the sector gears in position.

TRUCK SUPP SERVICE


BODY IB - 3

G MODELS

Fig. 5 Remote Control and Latches

REAR DOOR ITEMS


Latches, Strikers and Wedges
Figures 5 and 6 illustrate the new latches, strikers,
wedges and adjustment dimensions for G-Model rear
doors. Refer to pages IB-44 and IB-45 o f the 1974 Light
Duty Truck Service Manual fo r replacement instructions.
Note the new dimensions for striker adjustments. Fig. 6 Rear Door Striker and Wedge Adjustments

TRUCK SUPP - SERVICE


SECTION 2

FRAME

Truck frames are essentially carryover with some models dimension changes. The 10-30 series frames and related
undergoing configuration and alignment reference dimensions are shown in figures 1 through 3.

M odel A B C D E F G H 1 J K L M N P R S T U V

C A107 13-3/8 15-1/4 16 19-7/8 12 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 6 9-5/8 76-1/2 110 16-7/8 16-7/8 14

CA 109 13-3/8 15-1/4 16 19-7/8 12 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 6 9 -5 /8 86-1/2 120 16-7/8 16-7/8 14

CA 209 13-3/8 15-1/4 17 19-7/8 12 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17 3 /4 6 9-5/8 86-1/2 120 16-7/8 16-7/8 14

C A 210 13-3/4 15-1/4 16 18-1/2 10 13 10 14-1/4 17-3/4 17-3/4 19-7/8 15-5/8 17-3/4 69-7/8 105 131 16-7/8 16-7/8 14
310

CA314 13-3/8 14-7/8 16 18-1/2 10 13 10 14-1/4 17-3/4 17-3/4 19-7/8 15-5/8 17-3/4 6 9-7/8 129 155-1/2 16-7/8 16 7 /8 14

KA107 13-3/8 15-1/4 17 19-7/8 12-1/2 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 69-5/8 76-1/2 110 16-7/8 16-7/8 14

k a 109
13-3/8 15-1/4 17 19-7/8 12-1/2 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 6 9-5/8 86-1/2 120 16-7/8 16-7/8 14
209

PA 100 7-5 /8 9-3/8 11 14-5/8 9 -1 /2 13 10 9-1/2 13 10-7/8 13 71-7/8 36 89 16-7/8 16-7/8 14

P A 208 7-5/8 9-3/8 11-5/8 14-5/8 9-1 /2 13 10 9-1/2 13 9 -1 /2 13 10-7/8 13 72-1/4 59 131 16-7/8 16-7/8 14
308

PA210 7-5/8 9-3/8 11-5/8 14-5/8 9-1/2 13 10 9-1/2 13 9-1 /2 13 10-7/8 10-7/8 13 7 1-7/8 67 153 16-7/8 16-7/8 14
310

PA314 7-5/8 9-3/8 11-5/8 14-5/8 9-1/2 13 10 9-1/2 13 9-1 /2 13 10-7/8 10-7/8 13 7 1-7/8 91 177 16-7/8 16-7/8 14

CA105 13-3/8 15-1/4 17 19-7/8 12 13 10 14-1/4 20 17-3/4 15-5/8 17-3/4 6 9-5/8 46 88 16-7/8 16-7/8 14

KA105 13-3/8 15-1/4 17 19-7/8 12-1/2 13 10 14-1/4 20 17 3 /4 15-5/8 17-3/4 6 9-5/8 46 88 16-7/8 16-7/8 14
PE
31132 9-1 /8 11-1/2 10-7/8 9-1/2 13 10 9-1 /2 13 9 -1 /2 13 10-7/8 10-7/8 13 68-1/2 71 157 16-7/8 16-7/8 14
(137)
PE
3 1432 9-1/8 11-1/2 10-7/8 9-1 /2 13 10 9-1 /2 13 9-1/2 13 9-7 /8 10-7/8 13 68-1/2 92-1/2 178-1/2 16-7/8 16-7/8 14
(157)

PE
9 -1 /8 11-1/2 10-7/8 9 -1 /2 13 10 9-1 /2 13 9 1/2 13 10-7/8 10-7/8 13 68-1/2 112 2 4 0 -3 /16 16-7/8 16-7/8 14
3 1832

Fig. 1 C-K-P Truck Reference Dimensions

TRUCK SUPP - SERVICE


2 -2 FR A M E

TRUCK SUPP - SERVICE


FRAM E 2 -3

TRUCK SUPP - SERVICE


m
SECTION 4

REAR SUSPENSION AND REAR AXLE


NOTE: Except for the following items, all information found in Section
4 of the 1974 Light Duty Truck Service Manual is applicable to the 1975
Light Duty Trucks.
INDEX

Bushing Replacement....................................................................... 4-1


Universal Joint Repair.................................................................... 4-1
Propshaft Phasing.............................................................................. 4-3
Axle Shaft Removal......................................................................... 4-3

SERVICE INFORMATION
BUSHING R E P L A C E M E N T - bearing cups, and press the lower bearing cup out
of the yoke ear as shown in figure 1. This will shear
Rear Spring, Front Eye the plastic retaining the lower bearing cup.
Heavy duty leaf springs on C20 and C30 trucks use a 2. If the bearing cup is not completely removed, lift
staked-in-place front eye bushing. Before this bushing is the cross and insert Spacer J-9522-5 between the
pressed out of the spring, the staked locations must be seal and bearing cup being removed, as shown in
straightened with a chisel or drift. After a new bushing figure 2.
is installed, it must be staked in three equally spaced Complete the removal of the bearing cup, by
locations. Refer to page 4-6 in the 1974 Light Duty Truck pressing it out of the yoke.
Service Manual.
3. Rotate the drive shaft, shear the opposite plastic
PROPSHAFT retainer, and press the opposite bearing cup out of
the yoke as before, using Spacer J-9522.
Universal JointRepair 4. Disengage cross from yoke and remove.
Two methods of retaining trunnions to universal joint NOTE: Production universal joints cannot be
yokes may be used. Each requires a different repair reassembled. There are no bearing retainer grooves
procedure.
The snap ring method is described on pages 4-9 through
4-10 o f the 1974 Light Duty Truck Service Manual.
An injection-molded plastic retainer ring is used on
other universal joints. For this type joint, the following
repair procedure should be used.
Disassembly
NOTE: Never clamp drive shaft tubing in a vise as
the tube may be dented. Always clamp on one of
the yokes, and support the shaft horizontally.
Avoid damaging the slip yoke sealing surface. lV i" SOCKET

Nicks may damage the bushing or cut the seal lip. TO SUPPORT
YOKE EAR
BUT MUST

1. Support the drive shaft in a horizontal position in CLEAR


BEARING

ine with the base plate of a press. Place the CUP

universal joint so that the lower ear of the shaft


yoke is supported on a 1-1/8" socket. Place the
cross press, J-9522-3, on the open horizontal Fig. 1 Pressing Out Bearing Cup

TRUCK SUPP - SERVICE


4 -2 REAR S U S P E N S IO N A N D REAR AXLE

TRUNNION

SPACER
J-9522-5

BEARING
CUP

Fig. 2 Using Spacer to Remove Bearing Cup


Fig. 4 Installing Trunnion into Yoke
in production bearing cups. Discard all universal
joint parts removed. bearing retainers from the grooves in the yokes.
5. Remove the remains of the sheared plastic bearing The sheared plastic may prevent the bearing cups
retainer from the ears of the yoke. This will aid in from being pressed into place, and this prevent the
reassembly of the service joint bearing cups. It bearing retainers from being properly seated.
usually is easier to remove plastic if a small pin or 2. Install one bearing cup part way into one side of
punch is first driven through the injection holes. the yoke, and turn this yoke ear to the bottom.
6. If the front universal joint is being serviced, remove 3. Insert cross into yoke so that the trunnion seats
the pair of bearing cups from the slip yoke in the freely into bearing cup as shown in figure 4.
same manner.
4. Install opposite bearing cup part way. Make sure
Reassembly that both trunnions are started straight and true
A universal joint service kit is used when reassembling into both bearing cups.
this joint. See figure 3. This kit includes one pregreased 5. Press against opposite bearing cups, working the
cross assembly, four service bearing cup assemblies with cross all of the time to check for free movement of
seals, needle rollers, washers, grease and four bearing the trunnions in the bearings. If there seems to be a
retainers. hang-up, stop pressing and recheck needle rollers,
Make sure that the seals are in place on the service to determine if one or more of them has been
bearing cups to hold the needle rollers in place for tipped under the end of the trunnion.
handling. 6. As soon as one bearing retainer groove clears the
1. Remove all of the remains of the sheared plastic inside of the yoke, stop pressing and snap the
bearing retainer into place as shown in figure 5.

ROLLER BEARINGS

u
Fig. 3 Repair Kit Fig. 5 Installing Snap Ring to Retain Trunnion

TRUCK SUPP - SERVICE


REAR SUSPENSION AND REAR AXLE 4-3

Fig. 7 Alignment Key

AXLE SHAFT
Fig. 6 Seating Snap Rings
Remove and Reinstall
7. Continue to press until the opposite bearing
retainer can be snapped into place. If difficulty is Axles equipped with 8-7/8" ring gears and Eaton
encountered, strike the yoke firmly with a hammer Locking differentials use a thrust block on the pinion
to aid in seating bearing retainers. This springs the shaft which affects the removal of axle shafts as noted
yoke ears slightly. See figure 6. below.
1. Raise the vehicle on a hoist. Remove both rear
8. Assemble the other half of the universal joint in the wheel and tire assemblies and both rear brake
same manner. drums.
9. Check the freedom of rotation of both sets of 2. Remove the rear cover and drain the lubricant.
trunnions of the cross. If too tight, again rap the 3. Rotate the case to the position shown in figure 9.
yoke ears as described above. This will loosen the Support the pinion shaft so that it cannot fall into
bearings and help seat the bearing retainers. the case, then remove the lock screw.
4. Carefully withdraw the pinion shaft part-way out,
as shown in figure 10. Rotate the case until the
PROPSHAFT IN S T A L L A T IO N - shaft touches the housing.
CORRECT PHASING 5. Reach into the case with a screwdriver or similar
When reinstalling propshafts, it is necessary to place the tool, and rotate the C-lock until its open end points
shafts into particular positions to assure proper directly inward, as shown in figure 11. The axle
operation. This is called phasing. Refer to procedures and shaft cannot be pushed inward until the C-lock is
illustrations on page 4-12 o f the 1974 Light Duty Truck properly positioned.
Service Manual. For 1975 trucks, three methods of Do not force or ham m er the axle shaft in an
phasing are used. attempt to gain clearance.
All models with 32 splines use an alignment key, as
6. When the C-lock is positioned to pass through the
shown in figure 7, to obtain proper phasing. The shafts end of the thrust block, push the axle shaft inward
can mate only in the correct position. as shown in figure 12, and remove the C-lock.
Remove the axle shaft and repeat steps 5 and 6 for
C and G models with 16 splines must be phased as the opposite axle shaft.
shown in figure 8. The rear shaft must be rotated four 7.When installing C-locks keep the pinion shaft
splines90 toward the left side of the vehicle after partially withdrawn. Place the C-lock in the same
aligning the trunnions vertically, as shown. position shown in figure 11. Carefully withdraw the axle
shaft until the C-lock is clear of the thrust block. When
K models with 16 splines must align the trunnions both locks are installed, install the pinion shaft and lock
vertically before installing. Do not rotate the shafts. screw.

TRUCK SUPP SERVICE


4-4 REAR SUSPENSION AND REAR AXLE

PLACE
FRONT YOKE OF
VERTICAL

REAR PROP SHAFT


IN VERTICAL POSITION
1 ) PLACE
TRANSMISSION
SLEEVE YOKE
IN VERTICAL REAR PROP
POSITION SHAFT

ROTATE REAR SHAFT


4 SPLINES (90)
TOWARD L.H. SIDE
INSTALL REAR SHAFT
TO FRONT SHAFT
Fig. 8 A lig n m e n t fo r Phasing C and G M odels O n ly

Fig. 9 Removing Lock Screw Fig. 10 Positioning Case For Best Clearance

TRUCK SUPP - SERVICE


REAR SUSPENSION AND REAR AXLE 4-5

Fig. 12 Push Axle Shaft Inward

Fig. 11 Correct C-Lock Position

TRUCK SUPP SERVICE


SECTION 5

BRAKES
The following caution applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at
appropriate locations by the terminology "See Caution on page 1 of this
section".
C A U T IO N : THIS FASTENER IS AN IMPORTANT ATTACHING
PART 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 IF REPLACEMENT BECOMES NECESSARY. DO NOT USE A
REPLACEMENT PART OF LESSER QUALITY OR SUBSTITUTE
DESIGN. TORQUE VALUES MUST BE USED AS SPECIFIED
DURING REASSEMBLY TO ASSURE PROPER RETENTION OF

I
THIS PART.

C O N TE N TS OF THIS SECTION

Standard Brakes................................................................................. 5-1


Vacuum Power Brakes...................................................................... 5-5
Hydro-boost Brakes............................................................................ 5-5

STANDARD BRAKES
The 1975 Light Duty Truck standard brake components are essentially
the same as those described in the 1974 Light Duty Truck Service
Manual. Design modifications to 1974 and 1975 models, differing from
the 1974 manual, are outlined on the following pages.
FRONT DISC BRAKE
1975 front disc brake rotors will not incorporate an anti
squeal groove in the disc pad contact surfaces (Fig. 1).
BRAKE PEDAL A D J U S T M E N T
All brake pedal push rods are non-adjustable on 1975
models except Motor Home Chassis Units see the
Hydro-boost section of the 1974 Service Manual.
STO PLAM P SW ITCH IN STALLATIO N (C-K
Models)
The stoplamp switch is mounted to a flange protruding
from brake pedal support bracket.
Installation (Fig. 2 )
1. Install the mounting clip in the brake pedal flange
from the pedal side of the flange.
2. Depress the brake pedal and push the switch into
the clip until the shoulder on the switch bottoms on
the clip.
Fig. 1-D isc Brake Rotor

TRUCK SUPP SERVICE


5 -2 BRAKES

Adjustm ent 5. Place parking brake lever in fully released position.


1. Allow the pedal to return to its normally released Take up slack in brake linkage by pulling back on
position. cable just enough to overcome spring tension.
Adjust clevis of pull rod or front cable to line up
2. Adjust the switch so that electrical contact is made with hole in relay levers.
when the brake pedal is depressed 3/8" to 5/8"
from its normally released position. a. Insert clevis pin and cotter pin, then tighten
clevis locknut.
PARKING BRAKE b. Install a new metal hole cover in drum to
prevent contamination of brake.
Parking brake and cable replacement procedures remain
the same as described in the 1974 Light Duty Truck c. Lower rear wheels. Remove jack and wheel
Service Manual; however, cable routings, clips or guides blocks.
incorporate minor changes as noted in Figures 3 and 4. C A U TIO N : See "Caution" on Page 1 o f this
section.
PARKING BRAKE (PROPELLER S H A F T ) -
INTERNAL EXPANDING Removal
Adjustm entDrum On 1. Remove the propeller shaft; see Section 4 of the
1. Jack up at least one rear wheel. Block wheels and 1974 Light Duty Truck Service Manual.
release hand brake. 2. Remove the brake drum.
2. Remove cotter pin and clevis pin connecting pull NOTE: It may be necessary to back off the shoe
rod and relay lever. This will assure freedom for adjustment before removing the drum.
full shoe release.
C A U TIO N : It may be necessary to knock out On automatic transmission models, the exhaust
lanced area in brake drum with punch and crossover pipe may be in the way. If so, loosen the
hammer to gain entry into adjusting screw transmission rear mounting bolts and jack the
through brake drum. Be sure all metal has been transmission sufficiently for brake drum to clear
removed from parking brake compartment. the pipe.
3. Rotate brake drum to bring one of access holes into 3. Remove the two pull back springs.
line with adjusting screw at bottom of shoes
(manual transmission), top of shoes (automatic 4. Remove the guide plate from anchor pin.
transmission). 5. Remove shoe hold down cups, springs, and washers
4. Expand shoes by rotating adjusting screws with from hold down pinsremove pins.
screwdriver inserted through hole in drum. Move 6. Pull brake shoe and lining assemblies away from
outer end of screwdriver away from drive shaft. anchor pin and remove the strut and spring.
Continue adjustment until shoes are tight against
drum and drum cannot be rotated by hand. Back 7. Lift the brake shoes and linings with the adjusting
off adjustment ten notches and check drum for free nut and bolt and connecting spring off the flange
rotation. plate.
8. Move the shoes toward each other until the
adjusting bolt and connecting spring drop off.
9. Remove the clip holding the brake lever to the
primary shoe (shoe with short lining).
10. Compress the spring on the brake cable and remove
the cable from the lever.
11. If necessary to remove the anchor pin, straighten
the washer from pin hex and reinforcement.
Remove reinforcement and washer with anchor pin.
12. If necessary to remove the cable, compress tangs on
cable and pull assembly out of the hole in the
flange plate.
13. If necessary to remove the flange plate, remove the
transmission flange nut and transmission output
flange. Remove bolts holding the flange plate to
bearing retainer and remove the flange plate.

TRUCK SUPP - SERVICE


BR AK ES 5 -3

G MODELS P300 (32) MODELS

Fig. 3--Parking Brake Assembly -Typical

Inspection tang of washer over reinforcement and side of


Replace any worn or broken parts. washer over hex of anchor pin.
CA U TIO N : See " Caution" on Page 1 o f this
Installation section.
1. Place the flange plate in position on the rear 5. Install lever on cable by compressing spring and
bearing retainer and fasten with four bolts. Torque inserting cable in channel of lever. Release spring.
bolts to 24 foot pounds.
C A U TIO N : See " Caution" on Page 1 o f this
6. Install primary shoe (short lining) to lever as
section. follows: Place pin in lever, place washer on pin and
push pin through hole in primary shoe. Fasten
2. Install transmission output flange on spline of parts together by installing the clip in groove of
mainshaft and fasten with flange nut. Torque nut to pin.
100 foot pounds.
C A U TIO N : See "Caution" on Page 1 o f this
C A U T IO N : See "Caution" on Page 1 o f this section.
section.
1. Fasten two brake shoes and linings together by
3. Install cable assembly from back of flange plate. installing connecting spring. Move the shoes toward
Push retainer through hole in flange plate until each other and install adjusting screw.
tangs securely grip the inner side of the plate.
4. Place washer and reinforcement over the threaded 8. Lubricate the flange plate contact surfaces with a
end of anchor pin. Hold anchor pin nut (flat side very light coat of Delco Brake Lube #5450032 (or
against flange on flange plate) in position behind equivalent).
flange plate and insert threaded end of anchor pin 9. Place shoe and linings in position on flange plate.
from front side. Thread the anchor pin into nut and NOTE: When facing the brake assembly, the shoe
tighten securely (140 foot pounds torque). Bend with the short lining should be to the left with the

TRUCK SUPP - SERVICE


5-4 BRAKES

Fig. 4 -Parking Brake System (Typical)

TRUCK SUPP SERVICE


BRAKES 5-5

lever assembled to it (automatic transmission), to 12. Place guide plate on anchor pin.
the right (manual transmission). 13. Install pull back springs.
10. Pull brake shoes apart and install strut lever and 14. Remove the "knock out" plug (if necessary) and
spring between them. The loop on the strut spring install a new metal plug in the brake drum
should be in the "up" position. adjusting hole.
11. Install hold down pins, washers, springs and cups 15. Install the brake drum.
from flange plate to shoes. 16. Install the propeller shaft.

VACUUM POWER BRAKES


POWER BOOSTER - REPAIR OR REPLACE
C A U TIO N : Any time the power brake vacuum
booster is removed fo r repair or replacement, be
sure to install a NEW check valve.

HYDRO-BOOST POWER BRAKES


All 1975 "C" model hydro-boost vehicles will incorporate The accumulator valve components are assembled in the
an accumulator which is integral with the booster (Fig. accumulator valve bore which is machined in the
5). "G " and "P" model trucks will incorporate boosters housing. This bore is connected by passages to the
and accumulators which are mounted separately (see accumulator and to the pressure port.
1974 Light Duty Truck Service Manual). The integral spring accumulator (Fig. 7) is used in
conjunction with the hydraulic brake booster. The
INTEGRAL A C C U M U LA TO R /B O O S TE R accumulator piston assembly and spring are assembled
in the accumulator bore which is machined in the
The booster power section includes three ports (Fig. 6): housing.
1. Pressure Port (11/16-18 thread)-the high pressure
line from the power steering pump is connected to
this port. W A R N IN G : Do not attem pt to disassemble
or cut into the accum ulator. The accum ulator
2. Gear Port (5/8-18 thread)-the high pressure line contains a spring compressed under high
leading to the power steering gear is connected to pressure.
this port.
3. Return Port (for 3/8 I.D. Hose)-the return line to
the power steering pump is connected to this port.
The pressure port and the gear port each contains an
aluminum tube seat insert.
PRESSURE PORT
RETURN PORT PEDAL ROD
ACCUMULATOR

MOUNTING BRACKET
OUTPUT PUSH ROD
BOOSTER POWER SECTION

Fig. 5--Hydro-Boost W ith Integral Accum ulator Fig. 6- Brake Booster Hydraulic Schem atic

TRUCK SUPP - SERVICE


5-6 BRAKES

4. Crank engine for 4 to 5 second intervals while


pouring fluid into the reservoir.
5. Fill reservoir and crank as in step 4 until system
will no longer accept fluid. It is normal that fluid
may spill when cranking stops (it is the result of air
in the system trying to escape). To prevent spilling,
crank engine.
6. Remove remote control starter switch. Reinstall
distributor primary lead.
7. Start engine and allow to run 2 seconds.
8. Check and refill fluid reservoir if necessary.
9. Start engine and depress the brake pedal several
times while rotating the steering wheel from stop to
stop.
10. Turn engine off and then pump brake pedal 4-5
times to deplete accumulator pressure.
BLEEDING HYDRO -BO O ST/PO W ER 11. Check and refill fluid reservoir if necessary.
STEERING HYDRAULIC SYSTEM 12. Repeat Steps 9, 10 and 11. Install pump reservoir
The following procedure should be used to bleed the cap.
power steering hydraulic system on hydro-boost vehicles. 13. Remove vehicle from hoist.
NOTE: If the power steering fluid has foamed due
to low fluid level, it will be necessary to park the BRAKE PEDAL A D J U S T M E N T
vehicle for approximately one hour (reservoir cap All hydro-boost equipped vehicles incorporate non-
loose) so that the foam can dissipate. adjustable brake pedal rods except P30(32) models.
1. Raise the front of the vehicle on a hoist so that the Refer to the 1974 Light Duty Truck Service Manual for
tires are clear of the floor. brake pedal adjustment on P30(32) models.
2. Check reservoir and fill with GM Power Steering
Fluid (or equivalent). BOOSTER INSTALLATIO N
NOTE: Leave the reservoir cap off during entire Refer to Figures 8 and 9 for booster installation.
bleed procedure.
ACCUM ULATO R
3. Install a remote control starter switch so that engine
can be cranked but not started. As noted earlier, "C " model boosters incorporate an
C A U TIO N : Whenever the engine is cranked
integral accumulator. Accumulator installation on " G "
and "P" models is shown in Figure 10.
remotely at the starter, with a special jumper or
other means, the distributor primary lead must
be disconnected from the negative post on the HYDRAULIC LINE R O U TIN G
coil. Refer to Figure 11 for typical hydraulic line routings.

TRUCK SUPP SERVICE


BRAKES 5-7

Fig. 8- Booster Installation-Except P30(32) Models

TRUCK SUPP - SERVICE


5-8 BRAKES

LIN K A G E BRACKET
PEDAL PUSH ROD
SUPPORT REAR

PEDAL ROD BOOSTER

LIN K A G E BRACKET
FRONT SUPPORT

PEDAL ROD
VIEW B LEVER

BOOSTER
REAR SUPPORT

VIEW
VIEW C

Fig. 9- Booster Installation-P30(32) Models

Fig. 10--Accumulator Installation

TRUCK SUPP SERVICE


BRAKES 5-9

C MODELS

M A N U A L STEERING P O W E R STEERING W IT H OIL C O O L E R

G MODELS

TO GEAR

FROM GEAR

M A N U A L STEERING P O W E R STEERING

P30 (42) MODELS P30 (32) MODELS


FROM POWER STEERING
PUMP ( PRESSURE)
TO POWER STEERING POWER BRAKE BOOSTER
PUMP (RETURN)

FROM POWER
STEERING GEAR
( RETURN)

TO POWER STEERING
GEAR ( PRESSURE)

M A N U A L STEERING P O W E R STEERING

Fig. 11 -H ydra u lic Line Routing

TRUCK SUPP - SERVICE


5-10 BRAKES

DIAGNOSIS - HYDRO - BOOST SYSTEM

NOTE: Before checking the hydraulic pow er booster for the source o f trouble, refer
to the trouble diagnosis procedures for Standard Brakes. A fter these possible causes have
been eliminated, check for the probable cause and remedy as outlined below:
N orm al O perating C haracteristics
Brake pedal application o f the Hydro-boost system
differs in some respects from a vacuum type power
brake system in the following manner:
1. On pedal application until booster run-out, 3. On the first full application of the brake pedal,
slight power steering pump noise may be a slight hissing sound may be heard. The hiss
heard. is the accumulator charging and the noise should
go away in a short period of time.
2. Pedal application through run-out will not
necessarily be smooth due to the internal 4. On a spike brake application, a slight pedal
ratio change. It is possible to push the pedal kick-back may be felt.
past run-out because of the higher pedal ratio.
At run-out o f the vacuum booster the pedal 5. If the vehicle is started with the pedal de
just becomes hard. pressed, the pedal will fall away slightly then
return back to approximately the original
position.

NO BOOST - HARD PEDAL


Prelim inary C heck
W ith the engine stopped, depress the brake pedal several tim es to e lim ina te all accum ulator reserve
fro m the system.
Hold the brake pedal depressed w ith m edium pressure (25 to 35 lbs.), start the engine. If the u n it is
operating co rre ctly, the brake pedal w ill fall s lig h tly and then push back against the driver's fo o t,
rem aining at about the same po sitio n . If the booster is n o t operating c o rre c tly , the tro u b le may be one
o f the fo llo w in g causes:

Probable Cause Remedy

1. Loose or broken power steering 1. Tighten or replace the b e lt .


pump be! t .
2. No f l u i d in power steering re s e rv o ir. 2. F i l l re se rvoir and check f o r
external leaks.
3. Leaks in power ste e rin g , booster or 3. Replace defective parts.
accumulator hoses.
4. Leaks a t tube f i t t i n g s , power steerin g, 4. Tighten f i t t i n g s or replace tube
booster or accumulator connections. seats, i f d e fec tive .
5. External leakage a t accumulator. 5. Replace accumulator (except C models
- replace booster on C models).
6. Faulty booster piston seal causing 6. Replace a l l booster seals.
leakage a t booster flange vent.
7. Faulty booster input rod seal with 7. Replace a l l booster seals.
leakage a t input rod end.
8. Faulty booster cover seal with leakage 8. Replace a l l booster seals.
between housing and cover.
9. Faulty booster spool plug seal. 9. Replace a l l booster seals.
10. Internal leakage in booster. 10. Replace booster.
11 . Contamination in power steering f l u i d . 11. Flush power steering system and
replace with new f l u i d .
12. Hydraulic line s routed in c o r r e c tly . 12. Re-route lin e s .

TRUCK SUPP SERVICE


BRAKES 5-11

DIAGNOSIS - HYDRO - BOOST SYSTEM

SLOW BRAKE PEDAL RETURN

Probable Cause Remedy

1. Excessive seal f r i c t i o n in booster. 1. Replace a l l booster seals.


2. Faulty spool a ctio n . 2. Clean spool and replace a l l booster seals.
3. Broken piston return spring. 3. Replace spring.
4. R e s tric tio n in re tu rn li n e from 4. Replace l i n e .
booster to pump re s e rv o ir.
5. Broken spool return spring. 5. Replace spring.
6. Excessive pedal p iv o t f r i c t i o n . 6. Lubricate p iv o t bushings with Delco Brake
Lube #5450032 (or equivalent) or replace
bushi ngs.

G RABBY BRAKES

Probable Cause Remedy

1. Broken spool re turn spring. 1. Replace spring.


2. Faulty spool action caused by 2. Inspect, clean and replace a l l
contamination in system. booster s e a ls .
3. No cargo body on chassis. 3. Normal con d itio n .

BOOSTER CHATTERS - PEDAL VIBRATES

Probable Cause Remedy

1. Power steering pump b e lt s li p s . 1. Tighten be! t .


2. Low f l u i d level in power steering 2. F i l l re s e rv o ir and check fo r
pump re s e rv o ir. external leaks.
3. Faulty spool operation caused by 3. Inspect, clean and replace a l l
contamination in system. booster s e a ls .
4. Excessive contamination in power 4. Flush power steering f l u i d from
steering f l u i d . system and replace with new
power steering f l u i d .
5. A ir in power steering f l u i d . 5. Allow vehicle to stand fo r
approximately one hour; then
bleed power steering hydraulic
system as described e a r l ie r in
t h is section.

TRUCK SUPP - SERVICE


5 12 BRAKES

DIAGNOSIS - HYDRO-BOOST SYSTEM

POWER STEERING PUMP NOISE ON BRAKE APPLY

Probable Cause Remedy

1. In s u f f i c ie n t f l u i d in pump 1. Fluid level decreases approximately


reservoi r . 1/2" on brake a p p l y - r e f i 11 to
proper le v e l. I f f l u i d is foamy,
l e t vehicle stand f o r approximately
one hour; then bleed power steering
hydraulic system as outlined e a r l i e r
in th is section.

BRAKE PEDAL PULLS DO W N SLIGHTLY ON ENGINE START

Probable Cause Remedy

1. R e stric tio n in gear or booster 1. Replace lin e s or re po sitio n


return lin e s . line s to eliminate r e s t r i c t i o n .

TRUCK SUPP - SERVICE


BRAKES 5-13

DIAGNOSIS - HYDRO - BOOST SYSTEM

ACCUMULATOR LEA KDO W N - SYSTEM DOES NOT HOLD CHARGE

Prelim inary C heck


S tart engine and tu rn the steering wheel u n til the wheels co ntact the wheel stops lig h tly . H old fo ra
m axim um o f five seconds. Then release the steering wheel and tu rn o ff the engine.
Depress and release the brake pedal. There should be a m in im u m o f three pow er assisted brake
ap plication s before a hard pedal is obtained.
Re-start the engine and tu rn the steering wheel u n til the wheels co ntact the wheel stops lig h tly . There
should be a lig h t hissing sound as the accum ulator is charged. H old steering wheel lig h tly against stop fo r
a m axim um o f five seconds. Then release the steering w heel, and tu rn o ff the engine.
W ait one h o u r and apply brake pedal (do n o t re-start the engine). There should s till be a m in im u m o f
three po w er assisted brake ap plications before o b ta ining a hard pedal.

If eith e r o f these p re lim in a ry checks shows th a t the a ccum ulator is no t h o ld in g its charge, the tro u b le
may be one o f the fo llo w in g causes.

Probable Cause Remedy

1. External leakage a t accumulator welds. 1. Replace accumulator, (e n tire booster


assembly on C models).
2. External leakage a t accumulator f i t t i n g s 2. Tighten or replace f i t t i n g s , as
(except C models). necessary.
3. Internal leakage in accumulator (past 3. Perform Accumulator Leakaae Test
piston seal or r e l i e f valve). as described below (except C models)
- replace booster (C models).
4. Internal leakage a t booster accumulator 4. Replace a l l booster seals and
valve ( i f accumulator is not leaking accumulator v a lv e s.
e x te rn a lly or i n t e r n a l l y ) .

A c c u m u l a t o r L e a k a g e T e st (P a n d G m o d e l vehicles)
S tart the engine and tu rn the steering wheel u n til the wheels co ntact the wheel stops lig h tly . H old fo r
a m axim u m of five seconds. Release the steering w heel, and tu rn o ff the engine.
CAUTION: Do not disconnect the fitting from the pressure side o f the accumulator
(this is the end connected to the booster) because the accumulator contains fluid under
pressure.
Remove the fittin g fro m the re tu rn end o f the accum ulator. This is the end connected to the pow er
steering pum p reservoir. Cap the line to the pum p reservoir.
A llo w excess flu id to drain fro m the accum ulator. Then re-start the engine, and ho ld the wheels
lig h tly against the wheel stops. There should be no co n tin u o u s flo w o f flu id out o f the accum ulator
return p o rt. If there is a co n tin u o u s flo w , eith e r the accum ulator piston seal or the re lie f valve is leaking,
and the accu m u la to r should be replaced.

TRUCK SUPP SERVICE


SECTION 6

ENGINE MECHANICAL
IN-LINE ENGINES
INDEX

Component Replacement and Adjustment................................ 6-3


Exhaust Manifold Assembly........................................................ 6-3
Removal............................................................................................ 6-3
Installation....................................................................................... 6-3

COMPONENT REPLACEMENT AND ADJUSTMENT


5. Disconnect exhaust pipe at manifold flange.

0 00
6. Remove manifold attaching bolts; then, remove
0 18/23
LBS FT 0 0 18/23
LBS FT manifold and discard gasket.
0 ^1
< > 30/35 - \^ 2 )
7. Check for cracks in manifold assembly.
25/30 25/30
LBS FT LBS FT ' '
LBS FT

<i>x Installation
1. Clean gasket surfaces on cylinder head and
mainfold.
Fig. 1A Exhaust Manifold to Cylinder Head Bolt
2. Position new gasket on exhaust manifold.
Tightening Sequence and Torque 3. Install manifold assembly bolts, while holding
manifold assembly in place.
EXHAUST M A N IFO LD ASSEMBLY
4. Clean, oil and torque all manifold to cylinder head
Removal bolts and nuts to specifications (fig. 1A).
1. Remove air cleaner. 5. Connect exhaust pipe to manifold.
2. Remove power steering pump and/or A.I.R. pump 6. Connect throttle controls and throttles return
brackets (if so equipped). spring.
3. Remove EFE valve bracket. 7. Install air cleaner, start engine and check for leaks.
4. Disconnect throttle controls and throttle return
spring.

TRUCK SUPP SERVICE


ENGINE MECHANICAL
V8 ENGINES
INDEX

General Inform ation...........................................;............................ 6-1


Component Replacement and Adjustment............................... 6-1
Intake M anifold......................................................................... ..... 6-1
Crankcase Front Cover................................................................. 6-1
Installation....................................................................................... 6-1
Diagnosis............................................................................................... 6-2

GENERAL INFORMATION
All light duty trucks will utilize a high energy ignition Except for the following changes, all information listed
system for 1975. Using this system, the conventional in Section 6 Engine of the 1974 Light Duty Truck
external ignition coil and other related components are Service Manual is applicable to 1975 light duty truck
eliminated. models.

COMPONENT REPLACEMENT AND ADJUSTMENT

IN TA K E M ANIFOLD 5. Loosely install cover-to-block.


The intake manifold removal and installation procedure NOTE: Insert the top four bolts loosely (approx
remains basically the same except that a new carburetor imately 3 turns). Install two 1/4-20 x 1/2" screws
heat choke tube assembly is used. Upon transfering one on each side at the low'er hole in the front
components on a manifold replacement operation the cover. Apply a bead of silicone sealer on the
choke tube assembly must be removed and (with a new bottom of the seal and install on cover (fig. 2R).
gasket) transfered to new manifold.
CRANKCASE FRONT COVER
The installation procedure for the small V8 crankcase
front cover has been revised. The removal procedure as
outlined on page 6-56 of the 1974 Light Duty Truck Service
Manual remains the same. The revised installation
procedure is as follows:
Installation
1. Clean gasket surface on block and crankcase front
cover.
2. Use a sharp knife or other suitable cutting tool to
remove any excess oil pan gasket material that may
be protruding at the oil pan to engine block
junction.
3. Apply a 1/8" bead of silicone rubber sealer, part
number 1051435 (or equivalent) to the joint formed
at the oil pan and cylinder block, as well as the
entire oil pan front lip (fig. 1R).
4. Coat the cover gasket with gasket sealer and place
in position on cover.
Fig. 1R Areas to Apply Front Cover Sealant

TRUCK SUPP SERVICE


6-2 ENGINE

M DOWEL PIN '-JH


(ONE AT EACH SIDE)

Fig. 2R Installing Front Cover and Seal Fig. 3R Aligning Cover to Dowel Pins

6. Tighten screws alternately and evenly while using used to draw up cover and install remaining cover
drift or other suitable tool to align dowel pins in screws.
block to corresponding holes in cover (fig. 3R). 8. Complete installation as outlined in the 1974
7. Remove the two 1/4-20 x 1/2" screws previously Passenger Car Service Manual.

DIAGNOSIS
EN G INE FAILS TO START
a. Clean and tighten loose battery terminal connec h. Inspect carburetor fuel filter for presence of water
tions. Using battery hydrometer, check specific and/or impurities. Correct as necessary.
gravity, if low, recharge battery. i. Check choke mechanism for proper operation. Any
b. Check for broken or loose ignition wires and/or binding condition which may have developed due to
ignition switch and repair or replace as necessary. petroleum gum formation on the choke shaft or
from damage should be corrected.
c. Remove moisture from spark plug wires and/or
distributor cap. j. Check fuel pump for leaks and proper operation.
Correct as necessary.
d. Inspect condition of distributor cap and rotor. k. Check operation of starter motor and solenoid.
Replace if damaged or cracked. Repair or replace as necessary.
e. Check inspect and regap spark plugs. Replace as 1. Inspect park or neutral safety switch. Adjust or
necessary. replace as necessary.
f. Check for weak or faulty H.E.I. System Coil as m. Check operation of EFE valve as outlined in
outlined in Section 6Y of this manual. Section 6T of this manual. Repair or replace as
g. Check carburetor float level, operation of secondary necessary.
vacuum break solenoid, air valve and enrichment n. Check for air or vacuum leaks. Correct as
system as outlined in Section 6M of' this manual. necessary.
EN G IN E LOPES WHILE IDLING
a. Check for vacuum leaks and correct as necessary. c. Inspect condition of camshaft, timing chain and/or
sprockets. Replace as necessary.
b. Check for blown head gasket and repair as
necessary.

TRUCK SUPP SERVICE


ENGINE 6-3

d. Check engine operating temperature and correct as system as outlined in Section 6Y of this manual.
necessary. Correct as necessary.
e. Check the PCV system for satisfactory operation. i. Check carburetor for incorrect idle speed, defective
Correct as necessary. altitude compensator, sticking choke or enrichment
f. Check fuel pump for leaks and proper operation. system and adjust, repair or replace as necessary.
Correct as necessary. j. Check operation of EFE valve as outlined in Section
g. Check operation of Exhaust Gas Recirculation 6T of this manual. Repair or replace as necessary.
valve. Repair or replace as necessary. k. Check inspect and regap spark plugs. Replace if
h. Check ignition timing and operation of the H.E.I. necessary.
EN G IN E MISSES WHILE IDLING
a. Check, inspect and regap spark plugs. Replace as i. Check carburetor mounting gasket for air leaks.
necessary. Repair as necessary.
b. Remove moisture from spark plug wires and/or j. Check distributor spark advance mechanism for
distributor cap. proper operation. Repair or replace as necessary.
c. Check for broken or loose ignition wires. Repair or k. Inspect valve train components. Adjust, repair and/
replace as necessary. or replace as necessary.
d. Check condition of cylinders for uneven compres 1. Check engine for low compression. Repair as
sion. Repair as necessary. necessary.
e. Check for weak or faulty HEI system coil as m. Check operation of exhaust gas recirculation valve.
outlined in Section 6Y of this manual. Repair or replace as necessary.
f. Inspect condition of distributor cap and rotor.
Replace if damaged or cracked. n. Check ignition timing, and condition of ignition
g. Check carburetor for internal obstructions, incor system as outlined in Section 6Y of this manual.
Correct as necessary.
rect idle speed, faulty altitude, compensator sticking
choke or enrichment system and adjust, repair or 0. Check for vacuum leaks. Correct as necessary.
replace as necessary. p. Check operation of EFE valve as outlined in
h. Inspect carburetor fuel filter for presence of water Section 6T of this manual. Repair or replace as
and/or impurities and correct as necessary. necessary.
E N G IN E M ISSES AT VARIO US SPEEDS
a. Inspect carburetor fuel filter for presence of water h. Check for weak valve springs and condition of
and/or impurities. Correct as necessary. camshaft lobes. Repair or replace as necessary.
b. Check fuel system for leaks, plugged fuel lines 1. Check engine operating temperature. Correct as
incorrect fuel pump pressure and/or plugged necessary.
carburetor jets. Correct as necessary. j. Check operation of exhaust gas recirculation valve.
c. Check ignition timing. Correct as necessary. Repair or replace as necessary.
d. Check for excessive play in distributor shaft. k. Inspect distributor cap for evidence of carbon
Repair or replace as necessary. tracking. Replace if necessary.
e. Check for weak or faulty H.E.I. system coil as 1. Check for faulty altitude compensator and incorrect
outlined in Section 6Y of this manual. carburetor adjustments. Correct as necessary.
f. Check, inspect and regap spark plugs. Replace as m. Check for vacuum leaks. Correct as necessary.
necessary. n. Check operation of EFE valve as outlined in
g. Detonation and pre-ignition may be caused by Section 6T of this manual. Repair or replace as
using sub-standard fuel. Correct as necessary. necessary.
ENG INE STALLS
a. Check carburetor for incorrect and/or misadjusted b. Inspect carburetor fuel filter for presence of water
idle speed, float level, leaking needle and seat, air and/or impurities. Correct as necessary.
valve, sticking choke or enrichment system and c. Check H.E.I. system as outlined in Section 6Y of
secondary vacuum break operation. Adjust, repair this manual.
or replace as necessary.

TRUCK SUPP SERVICE


6 4 ENGINE

d. Check, inspect and regap spark plugs. Replace as k. Check engine operating temperature. Correct as
necessary. necessary.
e. Check distributor spark advance mechanism for Check for loose, corroded or leaking wiring
proper operation. Repair or replace as necessary. connections (bulk-head connectors etc.) Repair as
Inspect exhaust system for restrictions. Correct as necessary.
necessary. m. Check operation of exhaust gas recirculation
Check carburetor mounting gasket for air leaks. system. Repair or replace as necessary.
Repair as necessary. n. Check fuel system for leaks and/or obstructions.
h. Check and adjust valve lash. Repair as necessary.
Check for burned, warped or sticking valves. Repair o. Check for vacuum leaks. Correct as necessary.
or replace as necessary. Check operation of EFE valve as outlined in
Check engine for low compression. Repair as Section 6T of this manual. Repair or replace as
necessary. necessary.
EN G INE HAS LOW POWER
a. Check for weak or faulty H.E.I. system coil as J- Check condition of cylinders for uneven compres
outlined in Section 6Y of this manual. sion and/or blown head gasket. Repair as necessary.
b. Check ignition timing. Correct as necessary. k. Check power steering flow control valve operation.
c. Check for excessive play in distributor shaft. Repair Repair or replace as necessary.
or replace as necessary. Check for clutch slippage (vehicles with manual
transmissions) and adjust or replace as necessary.
d. Check, inspect and regap spark plugs. Replace as
necessary. m. Check hydraulic brake system for proper opera
tion. Correct as necessary.
e. Check carburetor for incorrect and/or misadjusted n. Check engine operating temperature. Correct as
idle speed, float level, leaking needle and seat, air necessary.
valve and sticking choke or enrichment system.
Adjust, repair or replace as necessary. o. Check pressure regulator valve (automatic transmis
Inspect carburetor fuel filter for presence of water sion) for proper operation. Repair as necessary.
and/or impurities. Correct as necessary. P- Check transmission fluid level. Correct as necessary.
Check fuel pump for leaks and proper operation. q- Loss of power may be caused by using sub-standard
Correct as necessary. fuel. Correct as necessary.
h. Check for sticking valves, weak valve springs, r- Check operation of EFE valve as outlined in Section
incorrect valve timing, lifter noise and worn 6T of this manual. Repair or replace as necessary.
camshaft lobes. Adjust, repair or replace as s. Check operation of diverter valve (A.I.R. system).
necessary. Repair or replace as necessary.
Check for insufficient piston to bore clearance. t. Check for engine vacuum leaks. Correct as
Correct as necessary. necessary.
EN G IN E DIESELING ON SHUT OFF
a. Check base idle speed for improper adjustment and d. Check accelerator and choke linkage operation and
correct as necessary. correct as necessary.
b. Check ignition timing and reset to specifications if e. Check engine operating temperature and correct as
necessary.
required.
f. Check thermae valve for sticking and correct as
c. Check idle mixture setting and correct as necessary. necessary.
EN G INE DETO N A TIO N
a. Check for overadvanced ignition timing and/or c. Check for the use of sub-standard fuel and correct
faulty ignition system and correct as necessary. as necessary.
b. Check for loose or improper application of spark d. Check for foreign material in fuel lines and/or
plugs, or spark plugs with cracked or broken carburetor and correct as necessary.
ceramic cores and replace as necessary.
e. Check for restricted fuel delivery to carburetor

TRUCK SUPP - SERVICE


ENGINE 6-5

(pinched lines, faulty fuel tank cap or pick-up) and j. Check P.C.V. system operation and correct as
correct as necessary. necessary.
f. Check fuel pump operation and replace if k. Check for vacuum leaks and repair or replace as
necessary. necessary.
g. Check EFH system operation and repair or replace 1. Check engine operating temperature and correct as
as necessary. necessary.
h. Check EGR system operation and correct as m. Check for excessive combustion chamber deposits
necessary. and correct as necessary.
i. Check thermostatically controlled air cleaner n. Check for leaking, sticking, or broken valves and
operation and correct as necessary. repair or replace as necessary.
EXTERNAL OIL LEAKAGE
a. Check for improperly seated or fuel pump gasket. h. Check for worn or improperly seated rear main
Replace as necessary. bearing oil seal. Replace if necessary.
b. Check for improperly seated or broken push rod i. Inspect for loose oil line plugs. Repair or replace if
cover gasket. Replace as necessary. necessary.
c. Check for improperly seated or broken oil filter j. Check for engine oil pan drain plug improperly
gasket. Replace as necessary. seated. Correct as necessary.
d. Check for broken or improperly seated oil pan k. Inspect camshaft rear bearing drain hole for
gasket. Replace as necessary. obstructions. Correct as necessary.
1. Check for loose rocker arm cover, broken, or cover
e. Inspect gasket surface of oil pan to be bent or distorted or bent. Correct as necessary.
distorted. Repair or replace as necessary.
m. Check EFE valve switch for leakage. Replace if
Check for improperly seated or broken timing chain necessary.
cover gasket. Replace as necessary. n. Check oil pressure switch for leakage. Replace if
Inspect timing cover oil seal. Replace if necessary. necessary.
EXCESSIVE OIL C O N S U M P TIO N DUE TO OIL ENTERING
C O M B U S TIO N C HAM B ER THRO UG H HEAD AREA
a. Check for intake valve seals to be damaged, c. Inspect for plugged oil drain back holes in head.
missing or loose. Repair or replace as necessaary. Correct as necessary.
b. Check for worn valve stems or guides. Repair as d. Inspect PCV system operation. Correct as necessary.
necessary.
EXCESSIVE OIL C O N S U M P TIO N DUE TO OIL ENTERIN G
C O M B U S TIO N C HAM B ER BY PASSING PISTO N RING S
a. Check engine oil level too high. Correct as h. Inspect rings sticking in ring grooves of piston and
necessary. correct as necessary.
b. Check for excessive main or connecting rod bearing i. Inspect ring grooves worn excessively in piston and
clearance and correct as necessary. correct as necessary.
c. Check for piston ring gaps not staggered and j. Inspect compression rings installed upside down and
correct as necessary. correct as necessary.
d. Check for incorrect size rings installed and correct k. Check for excessively worn or scored cylinder walls
as necessary. and correct as necessary.
e. Check for piston rings out of round, broken or
scored and replace as necessary. 1. Inspect oil too thin and replace if necessary.
f. Inspect insufficient piston ring tension due to engine m. Inspect mis-match of oil ring expander and rail
overheating and replace as necessary. and correct as necessary.
g. Check for ring grooves or oil return slots clogged
and corrected as necessary.

TRUCK SUPP SERVICE


6-6 ENGINE

NO OIL PRESSURE WHILE IDLING


a. Check faulty oil gauge sending unit, and correct as c. Inspect for excessive clearance at main and
necessary. connecting rod bearings and correct as necessary.
b. Check for oil pump not functioning properly. d. Inspect for loose camshaft bearings and correct as
(Regulator ball stuck in position by foreign necessary.
material) and correct as necessary. e. Inspect leakage at internal oil passages and correct
as necessary.

NO OIL PRESSURE W HILE ACCELERATING


a. Check low oil level in oil pan and correct as c. Check oil pump suction screen loose or fallen off
necessary. and correct as necessary.
b. Inspect leakage at internal oil passages and correct
as necessary.

BURNED, S TIC K IN G OR BROKEN VALVES


a. Check for weak valve springs and replace as formation on stems or guides and correct as
necessary. necessary.
b. Check for improper valve lifter clearance and f. Check for warped valves or faulty valve forgings
adjust as necessary. and correct as necessary.
c. Check for improper valve guide clearance and/or g. Check for exhaust back pressure and correct as
worn valve guides and correct as necessary. necessary.
d. Check for out-of-round valve seats or incorrect h. Check improper spark timing and correct as
valve seat width and correct as necessary. necessary.
e. Check for deposits on valve seats and/or gum i. Check excessive idling and correct as necessary.

NO ISY VALVES
a. Check and adjust valve lash if necessary. e. Check for worn camshaft lobes. Replace camshaft
if necessary.
b. Check for excessively worn, dirty or faulty valve
lifters. Replace if necessary. f. Inspect for pulled or loose rocker arm studs. Repair
or replace as necessary.
c. Check for worn valve guides. Repair as necessary. g. Check for bent push rods. Replace if necessary.
d. Check for excessive run-out of valve seat or valve h. Inspect for broken valve spring. Replace if
face. Repair as necessary. necessary.
NO ISY PISTO NS AND RINGS
a. Check for excessive piston to bore clearance. d. Check for connecting rods alignment. Correct as
Correct as necessary. necessary.
b. Inspect for improper fit of piston pin. Correct as e. Inspect for excessive clearance between rings and
necessary. grooves. Repair or replace as necessary.
c. Inspect for excessive accumulation of carbon in
combustion chamber or on piston tops. Clean and/ f. Check for broken piston rings. Replace as
or repair as necessary. necessary.

BROKEN PISTO NS A N D /O R RINGS


a. Check for undersize pistons. Replace if necessary. d. Check connecting rod alignment. Replace if
necessary.
b. Check for wrong type and/or size rings installed.
Replace if necessary. e. Check for excessively worn ring grooves. Replace if
necessary.
c. Check for tapered or eccentric cylinder bores.
Correct as necessary.

TRUCK SUPP - SERVICF


ENGINE 6-7

f. Check for improperly assembled piston pins. h. Inspect for engine overheating. Correct as
Replace as necessary. necessary.
g. Check for insufficient ring gap clearance. Correct as i. Check for sub-standard fuel. Correct as necessary,
necessary. j. Check ignition timing. Correct as necessary.

NO ISY C O N N E C TIN G RODS


a. Check connecting rods for improper alignment and d. Check for insufficient oil supply and correct as
correct as necessary. necessary.
b. Check for excessive bearing clearance and correct e. Check for low oil pressure and correct as necessary.
as necessary.
c. Check for eccentric or out-of-round crankshaft f. Check for connecting rod bolts not tightened
journals and correct as necessary. correctly and correct as necessary.

NO ISY M A IN BEARINGS
a. Check low oil pressure and/or insufficient oil supply e. Check for sprung crankshaft and replace if
and correct as necessary. necessary.
b. Check for excessive bearing clearance and correct f. Check for excessive belt tension and adjust as
as necessary. necessary.
c. Check for excessive crankshaft end play and correct g. Check for loose torsional damper and replace as
as necessary. necessary.
d. Check for eccentric or out-of-round crankshaft
journals and correct as necessary.

NO ISY VALVE LIFTERS


a. Check for broken valve springs and replace as g. Check for excessively worn camshaft lobes and
necessary. replace if necessary.
b. Check for worn or sticking rocker arms and repair h. Check valve lifter oil feed holes plugged causing
or replace as necessary.
c. Check for worn or bent push rods and replace as internal breakdown and correct as necessary.
necessary. i. Check faulty valve lifter check ball, (nicked, flat
d. Check for valve lifters incorrectly fitted to bore size spot, or out of round and replace as necessary.
and correct as necessary.
j. Check rocker arm retaining nut to be installed
e. Check faulty valve lifter plunger or push rod seat upside down and correct as necessary.
and replace lifters as necessary.
f. Check for plungers excessively worn causing fast k. Check for end of push rod excessively worn or
leakdown under pressure and replace as necessary. flaked and replace as necessary.

TRUCK SUPP - SERVICE


SECTION 6M

ENGINE FUEL
C O N TE N TS OF TH IS SECTION

1MV Carburetor............................................................................. 6M-1


2GC Carburetor.............................................................................. 6M-18
4MV Quadrajet Carburetor........................................................ 6M-31
M4MC/M4MCA Carburetor...................................................... 6M-31
Accelerator Control....................................................................... .6M-53
Air Cleaner...................................................................................... .6M-55
Fuel P u m p ....................................................................................... 6M-60

1MV MONOJET CARBURETOR


INDEX

General Description....................................................... 6M-1 Service Operations.......................................................... 6M-10


Theory of Operation...................................................... 6M-2 Diagnosis............................................................................ 6M-13
Maintenance and Adjustments................................... 6M-7

GENERAL DESCRIPTION
The Monojet carburetor is a single bore downdraft vent hole in the air horn, which leads from the float bowl
carburetor (fig. 1) using a triple venturi in conjunction into the bore beneath the air cleaner.
with a plain tube nozzle.
The main venturi is 1-5/16/r in diameter and the throttle The carburetor model identification is stamped on a
bore is 1-11/16". vertical portion of float bowl, adjacent to fuel inlet nut
Fuel flow through the main metering system is controlled CH OICE SHAFT A N D
PRIM ARY C H O K E
by a main well air bleed and a variable orifice jet. A LEVER A SSEM BLY
V A C U U M BREAK
power enrichment system is used to provide good AUXILIARY C H O K E D IAPHRAGM
performance during moderate to heavy accelerations and V A C U U M BREAK
at higher engine speeds.
The idle system incorporates a hot idle compensator
(A.T. only) to maintain smooth engine idle during
periods of extreme hot engine operation.
The model MV incorporates an automatic choke system.
The vacuum diaphragm units are mounted externally on CHOKE ROD
the air horn and connect to the thermostatic coil lever
through a connecting link.
The automatic choke coil is manifold mounted and
connects to the choke valve shaft by a rod.
An integral, pleated-paper fuel inlet filter is mounted in
the fuel bowl behind the fuel inlet nut to give maximum IDLE S T O P
SOLEN OID
filtration of incoming fuel.
THROTTLE
The Monojet carburetor has an aluminum throttle body LEVER
for decreased weight and improved heat distribution and
a thick throttle body to bowl insulator gasket to keep
excessive engine heat from the float bowl. The Fig. 1 1MV Monojet Carburetor
carburetor has internally balanced venting through a

TRUCK SUPP SERVICE


6M -2 ENGINE FUEL

(Figure 1). If replacing float bowl, follow manufacturers head screw installed in the lower hole of the bracket.
instructions contained in the service package so that the (Figure 2).
identification number can be transferred to the new float C A U TIO N : The throttle return spring bracket
bowl. screws must be installed in the proper locations.
An electrically operated idle stop solenoid is used on all The throttle lever has a spun-in plastic bushing, this is
1MV models. Dual throttle return springs are used on all used as the bearing surface for the dual throttle return
carburetors. springs. The spin-in plastic return spring bushing will
All carburetor models have an idle mixture-screw and withstand normal cleaning time in an approved cold
limiter. The plastic limit cap permits idle mixture screw immersion type carburetor cleaner. The bushing is not
to be adjusted leaner without breaking the cap. At serviced separately and should not be removed from the
carburetor overhaul, the mixture may be adjusted. carburetor throttle lever.
C A U TIO N : Do not bend the mixture screw
An Exhaust Gas Recirculation system (E.G.R.) is used on
when cutting the tang. some applications to control oxides of nitrogen depending
on truck model.
The vacuum supply port necessary to operate the
To get the best idle and keep emissions within standards recirculation valve is located in the throttle body and
set by law, always follow adjustment procedures and connects through a channel to a tube which is located at
specifications, see Idle Mixture Adjustment . the top of the air horn casting. See Idle System for port
A bracket for the 1MV dual throttle return springs is location and operation
added to the float bowl, secured by two tapered screws Six basic systems of operation are used: float, idle, main
installed in the upper holes of the bracket and by a flat metering, power enrichment, pump and choke.

THEORY OF OPERATION
INDEX

Float System...................................................................... 6M-2 Power Enrichment System............................................ 6M-5


Idle System........................................................................ 6M-3 Accelerating Pump System.......................................... 6M-5
Main Metering System.................................................. 6M-4 Choke System.................................................................... 6M-6

FLOAT SYSTEM (Fig. 2)


The float system controls the amount and level of the
fuel in the carburetor float bowl. Higher than specified INTERN AL VENT
fuel levels can cause flooding, hard, hot starting, rich PRESSURE
R E L IE F V A LV E
fuel mixtures causing poor economy, nozzle drip at idle
and stalling. Therefore, it is important that the float be
set to recommended specifications. VENT HOLE
The float system on the Monojet carburetor is located
adjacent to the main venturi. It is designed so that FLO A T
angular maneuvers such as steep hills and sharp turns FLO A T HINGE PIN
will not affect proper operation by keeping an adequate FLO A T
supply of fuel in the bowl at all times. The float system N EED LE
consists of the following: a fuel inlet filter and pressure N EED LE
relief spring, a solid single pontoon float made of special SEA T
lightweight plastic, a conventional needle and seat and a
float hinge pin. The float hinge pin fits in dual slots cast FU EL
in the float bowl and is held in place by compression of F IL T E R
IN LET
F|LT E R
the air horn gasket against the upper loop of the hinge R E L IE F
pin. SPRING
The float operates as follows: fuel from the engine fuel
pump is forced through the paper fuel inlet filter, located
behind the fuel inlet nut, passes from the filter chamber
up through the float needle seat and spills into the float
bowl; as the float bowl fills with fuel, it lifts the float Fig. 2 Float System
pontoon upward until the correct fuel level is reached in

TRUCK SUPP SERVICE


ENGINE FUEL 6M -3

the float bowl. At this point, the float arm forces the float
needle against the float needle seat, shutting off fuel TUBE TO
TOP AIR BLEED
* E.G.R (EXH AU ST GAS
flow. As fuel is used from the float bowl, the float drops E .G .R .'V A L V E RE CIRC ULATIO N)

downward, allowing the float needle to move off its seat


and more fuel to enter the float bowl. This cycle
continues throughout engine operation, constantly IDLE CH AN NEL
maintaining a positive fuel level in the float bowl. RESTRICTION

The fuel inlet filter has a pressure relief spring located at IDLE TUBE

the rear of the filter. It seats between the rear of the filter
and the inlet casting. Should the filter become clogged
.M A IN M ETERING JET
HOT IDLE
from improper servicing or excess dirt in the system, the COM PENSATOR TIMED VA C U U M

relief spring lets the filter move off its seat. This prevents
PORTS FOR E.G.R.*

complete stoppage of fuel flow to the carburetor until the


filter can be replaced.
The carburetor float chamber is internally vented THROTTLE VALVE

through a hole located in the air horn above the float IDLE M IX TU R E NEEDLE

chamber. The purpose of the internal vent is to balance


IDLE DISC HARG E HOLE

air pressure on the fuel in the float bowl with carburetor


inlet air. With this feature, a balanced air/fuel mixture
ratio can be maintained during part throttle and power Fig. 3 Idle System
operation because the air pressure acting on the fuel in air at the top of the idle channel through the idle air
the float bowl will be balanced with the air flowing bleed hole. The air/fuel mixture passes over through the
through the carburetor bore. cross channel and then downward through the calibrated
The carburetor float chamber is externally vented by a idle channel restriction where it is further metered. The
small plastic pressure relief valve located at the top of mixture continues down the idle passage past the lower
the air horn. Should excessive vapor pressure build up in idle air bleed hole and off-idle discharge port just above
the float bowl during periods of hot engine idle or hot the throttle valve, where it is again mixed with air. The
soak, the valve will be pushed off its seat, allowing the air/fuel mixture then moves downward past the idle
pressure to be relieved, there-by preventing fuel from mixture needle and out through the idle discharge hole
being forced from the float bowl into the engine. into the carburetor bore. Here it mixes with the air
passing around the slightly open throttle valve and then
IDLE SYSTEM (Fig. 3 ) continues through the intake manifold into the engine
The purpose of the idle system is to control fuel mixtures cylinders as a combustible mixture.
to the engine during idle and low speed operation. The
idle system is needed during this period because air OFF-IDLE O PER A TIO N
requirements of the engine are not great enough to
obtain efficient metering from the main discharge nozzle As the throttle valve is opened from curb idle to increase
and venturi system. engine speed, additional fuel is needed to combine with
The idle system consists of a removable idle tube, idle the extra air entering the engine. This is accomplished
passages, idle channel restriction, idle air bleeds, slotted by the slotted off-idle port. As the throttle valve is
off-idle port, vapor canister purge ports, exhaust gas opened, it passes the off-idle port, gradually exposing it
recirculation (E.G.R.) ports and passages, idle mixture to high vacuum below the throttle valve. The additional
adjusting needle and the idle mixture discharge hole. fuel from the off-idle port mixes with the increased air
flow past the opening throttle valve to meet increased
During curb idle, the throttle valve is held slightly open engine air and fuel demands.
by the idle stop solenoid. The small amount of air, which
passes between the throttle valve and bore, is regulated Further opening of the throttle valve causes increased air
by solenoid to provide the correct engine idle speed. flow through the carburetor bore, which causes sufficient
Since the engine requires very little air and fuel for idle pressure drop in the multiple venturi to start fuel
and low speed operation, fuel is mixed by direct delivery from the main discharge nozzle. The off-idle
application of engine manifold vacuum to the idle port fuel discharge does not cease at this transfer point
discharge hole just below the throttle valve. With the idle but rather diminishes as fuel flow from the main
discharge hole in a very low pressure area and the fuel discharge nozzle increases. In this way, the systems are
in the float bowl vented to atmosphere, fuel flows so designed that they combine to produce a smooth fuel
through the idle system as follows: flow at all engine speeds.
Atmospheric pressure forces fuel from the float bowl The lower idle air bleed is used strictly as an air bleed
down through the main metering jet into the main fuel during idle operation. It supplies additional air to the
well where it is picked up and metered at the lower tip of idle circuit for improved atomization and fuel control at
the idle tube. It passes up the idle tube and is mixed with low engine speeds.

TRUCK SUPP SERVICE


6M -4 ENGINE FUEL

The same air bleed is used as an additional fuel feed at dust cover over the valve chamber. A seal is used
higher engine speeds to supplement main discharge between the compensator valve and float bowl casting.
nozzle delivery during operation of the main metering In order to insure proper idle adjustment when the
system. engine is hot, the compensator valve must be closed. To
The timed spark port has one tube which supplies check this, plug the compensator inlet hole inside the air
vacuum during the off-idle and part throttle operation of horn bore (pencil can be used). If no drop in engine rpm
the carburetor. The tube leads to the purge valve on the is noted on a tachometer, the valve is closed; if the valve
vapor canister to provide a means of pulling fuel vapors is open, leave plug in hole when adjusting idle or cool
from the canister during periods of higher air flow engine down to a point where the valve automatically
through the carburetor bore. A limited amount of closes for proper idle adjustment.
canister purge is also provided by a separate tube which C A U TIO N : Always remove plug used in inlet
leads from the canister to the PCV valve hose hole after completing idle adjustment, other
connection. wise, the compensator will not operate.
An exhaust gas recirculation (E.C.R.) system is used on
all models to control oxides of nitrogen emissions. The M A IN M ETERIN G SYSTEM (Fig. 4 )
E.G.R. valve is operated by a vacuum signal taken from
the carburetor throttle body. The main metering system supplies fuel to the engine
A vacuum supply tube installed in the carburetor air from off-idle to wide open throttle operation. It feeds at
horn connects by a passage through the float bowl to the all times when air flow through the venturi is great
timed vertical port in the throttle body bore. This enough to maintain efficient fuel flow from the main
provides a vacuum signal to the E.G.R. valve in the off- discharge nozzle. The triple venturi stack-up used in the
idle and part throttle operation of the carburetor. The Monojet carburetor is very sensitive to air flow, which
purpose of the E.G.R. system is to supply a metered results in a finer and more stable metering control from
amount of exhaust gases to the combustion mixtures and light to heavy engine loads.
lower combustion temperatures, thereby reducing oxides The main metering system consists of a main metering
of nitrogen during these ranges of engine operation. jet, mechanical and vacuum operated metering rod, main
fuel well, main well air bleeds, fuel discharge nozzle and
Hot Idle Com pensator triple venturi.
The hot idle compensator (Figure 3), with automatic The main metering system operates in the following
transmission only, is located in a chamber on the float manner:
bowl casting, adjacent to the carburetor bore, on the As the throttle valve is opened beyond the off-idle range,
throttle lever side of the carburetor. Its purpose is to allowing more air to enter the engine manifold, air
offset enrichening effects caused by changes in air velocity increases in the carburetor venturi. This causes a
density and fuel vapors generated during hot engine drop in pressure in the main venturi which is increased
operation. many times in the double boost venturi. Since the lower
The compensator consists of a thermostatically controlled pressure (vacuum) is now in the smallest venturi, fuel
valve, a bi-metal strip which is heat sensitive, a valve flows from the main discharge nozzles in the following
holder and bracket. The valve closes off an air channel manner:
which leads from a hole inside the air horn to a point Fuel in the float bowl passes between the tapered
below the throttle valve where it exists into the throttle metering rod and the main metering jet where it is
body bore.
Normally, the compensator valve is held closed by
tension of the bi-metal strip and engine vacuum. During
extreme hot engine operation, excessive fuel vapors in
the carburetor can enter the engine manifold causing
richer than normally required mixtures. This can result
in rough engine idle and stalling. At a pre-determined
temperature, when extra air is needed to offset the
enrichening effects of fuel vapors, the bi-metal strip
bends and unseats the compensator valve, uncovering the
air channel leading from the compensator valve chamber
to the throttle body bore. This allows enough air to be
drawn into the engine manifold to offset the richer
mixtures and maintain a smooth engine idle. When the
engine cools and the extra air is not needed, the bi-metal
strip closes the valve and operation returns to normal.
Fig. 4 M ain M etering System
The compensator valve assembly is held in place by the

TRUCK SUPP SERVICE


ENGINE FUEL 6M -5

metered and flows on into the main fuel well. In the


main well the fuel is mixed with air from the air bleed at
the top of the well and another air bleed which leads
into the main well from the discharge nozzle cavity. M A IN
D IS C H A R G E
P O W E R P IS T O N

After the fuel in the main well is mixed with air from NO ZZLE D R IV E R O D

the air bleeds it then passes up the discharge nozzle BOOST VE N TU R U

where it sprays into the small boost venturi. At the boost


venturi, the fuel mixture then combines with air entering
M A IN V E N T U R U

the engine through the carburetor bore to provide the


correct air/fuel mixtures to the engine for efficient
combustion. M A IN
JE T
M E T E R IN G

Fuel flow to the main discharge nozzle is controlled by a


tapered metering rod which is actuated by linkage P O W E R P IS T O N

connected directly to the throttle shaft. As the throttle A C T U A T IN G L I N K A G E

valve is opened from idle position, the tapered metering


rod is gradually raised out of the main metering jet P O W E R P IS T O N V A C U U M

orifice. Fuel flow from the main discharge nozzle is


L O W E R ID L E A IR B L E E D

controlled by throttle opening and the depth of the


metering rod in the main metering jet orifice. With the Fig. 5 Power Enrichment System
fuel metering mechanically controlled by the throttle bottom side of the drive rod. This moves the tapered
valve angle, it is possible to maintain very accurate metering rod slightly upward and out of the main
mixture ratios throughout part throttle to wide open metering jet, allowing more fuel to flow through the jet,
throttle operation. An initial metering rod adjustment is enrichening the fuel mixture slightly.
required to set the depth of the rod in the main metering
jet.
C A U T IO N : It should be noted here that there is ACCELERATING P U M P SYSTEM (Fig. 6 )
a supplementary fu el feed passage in the Extra fuel for smooth, quick acceleration is supplied by a
bottom o f the float bowl adjacent to the main double spring loaded pump plunger. Rapid opening of
metering jet. Fuel is picked up from the float the throttle valve, when accelerating from low speed,
bowl and passes through a calibrated hole, past causes an immediate increase in air flow through the
a calibration screw and on into the same fuel carburetor bore. Since fuel is heavier than air, it requires
passage which leads from the main metering jet a short period of time for fuel flow through the main
to the main fuel well. The purpose o f the discharge nozzle to catch up with the air flow. To avoid
adjustable fu el feed is to allow the factory to leanness during this momentary lag in the fuel flow, the
refine part throttle calibration to meet very accelerator pump furnishes a metered quantity of fuel
accurate air/fuel mixture ratios. This adjust
ment is made using very sensitive instrumenta which is sprayed into the air stream. This mixes with the
tion and the screw should not be tampered with increased air flow to supply the extra fuel needed until
or it will require complete float bowl or unit the main discharge nozzles can feed the fuel required.
replacement. " T " DISCHARGE
SPRING RETAIN E R

POWER E N R IC H M E N T SYSTEM (Fig. 5)


The vacuum operated power enrichment system is used
to slightly enrichen mixture ratios during moderate to -PUMP LEVER

heavy loads during acceleration. The necessary enrich PUMP PLUNGER


'& D U R A TIO N
ment is obtained by movement of a spring loaded PUMP DISCHARGE SPRING

vacuum piston which senses changes in manifold


SPRING & B A LL

vacuum. The amount of enrichment is controlled by the


clearance between the groove in the power piston and
the diameter of the power piston drive rod. PUMP RETURN
SPRING

During part throttle and cruising ranges, manifold


vacuum is sufficient to hold the power piston down
against spring tension. The upper part of the groove in
the power piston is held down against the top side of the
drive rod. This places the main metering rod lower in the PUMP A C TU A TIN G L IN K

jet for maximum economy. On moderate to heavy PUMP CUP O PER ATIO N
accelerations, manifold vacuum drops and the power
piston spring pushes the power piston up so that the Fig. 6 Accelerating Pump System
ower edge of the slot in the power piston strikes the

TRUCK SUPP - SERVICE


6M -6 ENGINE FUEL

The accelerating pump is located at the side of the main


fuel bowl, adjacent to the venturi area. It consists of a
spring loaded pump plunger and pump return spring
operating in a fuel well. The pump plunger is connected
by linkage directly to a lever on the throttle shaft.
When the pump plunger moves upward in the pump
well, as happens during throttle closing, fuel from the
float bowl enters the pump well through a slot in the side
of the pump well and flows past the synthetic pump cup
seal into the bottom of the pump well. The pump cup is
a floating type (the cup moves up and down on the pump
plunger head). When the pump plunger is moved
upward, the flat on the top of the cup unseats from the
flat on the plunger head and allows free movement of
fuel through the inside of the cup into the bottom of the
pump well. This also vents any vapors which may be in
the bottom of the pump well so that a solid charge of
fuel can be maintained in the fuel well beneath the
plunger head.
When the throttle valve is opened, as happens during
acceleration, the connecting pump linkage forces the
pump plunger downward. The pump cup seats instantly
and fuel is forced through the pump discharge passage, Fig. 7 C hoke System
where it unseats the pump discharge check ball and
passes on through the passage to the pump jet located at valve and also rotates the fast idle cam so the high step
the top of the float bowl, where it sprays into the boost is in line with the fast idle cam follower on the throttle
venturi area. lever. As the throttle is released, the fast idle cam
follower comes to rest on the high step of the fast idle
The pump plunger is spring loaded; the upper duration cam, thus providing enough throttle valve opening to
spring is balanced with the bottom pump return spring keep the engine running after cold start. During
so that a smooth sustained charge of fuel is delivered cranking, engine vacuum below the choke valve pulls
during acceleration. fuel from the idle circuit and main discharge nozzle.
The pump discharge check ball prevents any pull over or This provides adequate enrichment for good cold starts.
discharge of fuel from the pump jet when the accelerator When the engine starts, manifold vacuum is transmitted
pump is not in operation. It also keeps the pump through a vacuum channel to the primary vacuum break
discharge passage filled with fuel to prevent pump diaphragm unit mounted on the air horn casting. This
discharge lag. moves the diaphragm plunger until it strikes the cover
The pump does not require adjustment in service as it is which, in turn, opens the choke valve to a point where
preset during manufacture. the engine will run without loading or stalling. This is
called the vacuum break position.
CHOKE SYSTEM (Fig. 7 ) The auxiliary vacuum break unit (Fig. 8) is used to open
The purpose of the choke system is to provide a richer the choke valve to a nearly wide open position during
mixture for cold engine starting and operation. Richer warmer temperatures above 80 F. This prevents too rich
than normal mixtures are required because vaporized a mixture when starting a cold engine during warm
fuel has a tendency to condense on cold engine parts. temperatures due to choke coil cooling, causing the choke
This occurs on the inside area of the intake manifold valve to be too far closed.
and cylinder heads, thereby, decreasing the amount of The auxiliary diaphragm unit is controlled by a vacuum
combustible mixture available in the engine cylinders. switch which is operated by engine coolant temperature.
The model MV carburetor is equipped with a fully When the engine is started at temperatures above 80 F.,
automatic choke control. The thermostatic coil is the vacuum switch opens and allows manifold vacuum to
mounted on the head and is connected by a link to the be applied to the auxiliary vacuum break diaphragm.
lever on the choke valve shaft. The vacuum break units The diaphragm unit pulls the choke valve to a nearly
are diaphragm operated and externally mounted on the open position overcoming choke coil tension. At the
same time the fast idle cam drops so that the fast idle
air horn casting. cam follower tang rests on the lowest step of the fast idle
The choke system operates as follows: when the engine is cam. This maintains some fast idle until the engine
cold, prior to starting, depressing the accelerator pedal to warms up. When the engine is warmed up the choke coil
the floor opens the carburetor throttle valve. This allows pulls the choke valve fully open and the fast idle cam
tension from the thermostatic coil to close the choke rotates so the fast idle cam follower tang drops off the

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -7

velocity through the air horn can continue to open the


choke valve. This continues until the engine is warm. At
this point the choke coil tension is completely relaxed
and the choke valve is wide open.
The fast idle cam has graduated steps so that fast idle
engine speed is lowered gradually during the engine
warm up period. The fast idle cam follows rotation of
the choke valve. When the choke valve is completely
open and the engine is warm, the fast idle tang on the
throttle lever will be off the steps of the fast idle cam. At
this point, the idle screw or idle stop solenoid controls
normal engine idle speed.
An unloader mechanism is provided should the engine
become flooded during the starting period. The unloader
partially opens the closed choke valve to allow increased
air flow through the carburetor to lean out the overly
rich mixtures. This is accomplished by depressing the
low step, at which point the engine will run at curb idle accelerator pedal to the floor so that wide open throttle is
speed. obtained. When this is done, a tag on the throttle lever
contacts an arm on the fast idle cam and forces the
As the engine warms up, the thermostatic coil is heated choke valve partially open. The extra air leans out the
and gradually relaxes its spring tension so that air fuel mixture enough so that the engine will start.

MAINTENANCE AND ADJUSTMENT


INDEX

Idle Speed.......................................................................... 6M-7 Fast Idle Adjustment......................................................6M -8


Fast Idle Cam Adjustment.......................................... 6M -8
Low Idle and Curb Idle Choke Unloader Adjustment....................................... 6M-9
Speed Adjustment....................................................... 6M-7 Choke Coil Rod Adjustment....................................... 6M-9
Idle Mixture....................................................................... 6M-7 Primary Vacuum Break Adjustment........................6M-9
Idle Mixture Adjustment............................................. 6M-8 Auxiliary Vacuum Break Adjustment...................... 6M-10
IDLE SPEED 5. Start engine, check timing and adjust as required.
Two idle speeds are required and are controlled and Reconnect vacuum advance hose.
adjustable by the idle stop solenoid. The purpose of two 6. Turn solenoid in or out to set curb idle speed to
idle speeds is to prevent dieseling when ignition is turned specified rpm on automatic transmission or manual
off. transmission.
One speed is Curb Idle Speed which is normal engine 7. Disconnect electrical connector at idle stop solenoid.
idle and solenoid is energized. The second speed is Low
Idle Speed and when solenoid is de-energized the 8. With automatic transmission in Drive or manual
carburetor throttle plate closes further than at normal transmission in Neutral, turn 1/8" hex screw
engine idle. located in end of solenoid body to set low idle
speed to specified rpm.
Low Idle and Curb Idle Speed Adjustm ent 9. Reconnect electrical connector to solenoid and crack
(Fig. 9) throttle slightly.
Refer to Vehicle Emission Control Information label on 10. Shut off engine and remove tachometer.
vehicle for latest certified specification information
which may differ from specifications in manual. 11. If vehicle is equipped with air-conditioning, reset idle
1. With engine at normal operating temperature, air speed to specification with air-conditioning ON. (All
cleaner on, choke open, and air conditioning OFF, except 250 manual transmission equipped with light
connect a tachometer to engine. duty emission control system.)
2. Set parking brake and block drive wheels. 12. Connect fuel tank hose to vapor canister.
3. Disconnect fuel tank hose from vapor canister. IDLE M IX TU R E
4. Disconnect vacuum advance hose at distributor and The idle mixture is factory preset and idle mixture screw
plug hose. is capped with a plastic limiter cap. The cap permits

TRUCK SUPP - SERVICE


6M -8 ENGINE FUEL

turning 1/ 8" hex screw in end of solenoid on


manual transmission.
8. Cut off tab on limiter cap. Do not remove cap from
screw. Turn idle mixture screw counterclockwise
until maximum idle speed is achieved. Reset idle
speed to specified rpm, if required.
9. Observe tachometer and turn idle mixture screw
clockwise until idle speed is at specified rpm.
10. Shut off engine and remove tachometer.
11. Connect fuel tank hose to vapor canister and on
manual transmission vehicle, connect electrical
connector to idle stop solenoid.
FAST IDLE A D JU S TM E N T (Fig. 10)
1. Check low and curb idle speed and adjust as
required.
2. With engine at normal operating temperature, air
cleaner on, choke open, EGR valve signal line
disconnected and plugged and air conditioning
OFF, connect tachometer to engine.
Fig. 9 Low and C urb Idle Speed A d ju s tm en t 3. Disconnect vacuum advance hose at distributor and
plug hose.
screw to be turned about one turn leaner (clockwise)
without breaking cap. The idle mixture is set to achieve 4. Start engine and with transmission in Neutral, set
the smoothest idle while maintaining emission levels fast idle cam follower so that tang is on high step
within standards prescribed by Federal Law. of cam.
At major carburetor overhaul the idle mixture may be 5. Bend tang in or out to obtain fast idle RPM.
adjusted. Before suspecting idle mixture as cause of poor
idle quality, check ignition system, distributor, timing, FAST IDLE CAM A D JU S TM E N T (Fig. 11)
air cleaner, PCV system, evaporation emission control 1. Check fast idle speed and adjust as required.
and compression pressures. Also check all vacuum hoses
and connections for leaks and check torques of 2. Set fast idle cam follower firmly on second stop of
carburetor attachment bolts. Adjustment is made using a cam.
tachometer. 3. Rotate and hold choke valve toward closed position
Refer to Vehicle Emission Control Information label on by applying force to choke coil rod.
vehicle for latest certified specification information 4. Insert specified gauge between lower edge of choke
which may differ from specifications in manual. valve and inside air horn wall.
5. Bend cam-to-choke rod as required to obtain
IDLE M IX T U R E A D JU S TM E N T clearance.
1. With engine at normal operating temperature, air
cleaner on, choke open, and air conditioning OFF,
connect a tachometer to engine.
2. Set parking brake and block drive wheels.
3. Disconnect fuel tank hose from vapor canister.
4. Disconnect vacuum advance hose at distributor and
plug hose.
5. Start engine, check timing and adjust as required.
Reconnect vacuum advance hose.
6. On automatic transmission, place selector in Drive.
On manual transmission, place selector in Neutral
and disconnect electrical connector at idle stop
solenoid.
7. Set idle speed to higher specified rpm by turning
solenoid in or out on automatic transmission or

TRUCK SUPP SERVICE


ENGINE FUEL 6M -9

'I
'S I G A U G E B E T W E E N L O W E R E D G E OF

1 ) W I T H F A S T ID L E A D J U S T M E N T
M A D E , C A M F O L L O W E R OR
F A S T ID L E S C R E W M U S T
BE H E L D F IR M L Y O N
S E C O N D STEP OF F A S T
\ ID L E C A M A G A IN S T
H IG H S T E P

Fig. 11 Fast Idle C am A d ju s tm en t

CHOKE UNLOADER A D JU S T M E N T (Fig. 12)


1. Hold down on choke valve by applying a light force Fig. 1 3 C hoke Coil Rod A d ju s tm e n t - 1M V
to choke coil lever.
PRIM A RY VA C U U M BREAK A D JU S TM E N T
2. Rotate throttle valve to wide open position. (Fig. 14)
3. Insert specified gauge between upper edge of choke 1. Using an outside vacuum source, apply vacuum to
valve and air horn wall. primary vacuum break diaphragm until plunger is
4. If adjustment is required, bend tang on throttle fully seated.
lever. 2. Insert specified gauge between lower edge of choke
valve and air horn wall.
CHOKE COIL ROD A D JU S TM E N T (Fig. 13) 3. If adjustment is required, bend vacuum break rod.
1. Pull up on rod to end of travel to completely close 4. After adjustment, make sure there is no interfer
choke valve. ence or binding.
2. Bottom of rod should be even with top of lever.
3. If adjustment is required, bend rod.

TRUCK SUPP SERVICE


6 M -10 ENGINE FUEL

AUXILIARY VA C U U M BREAK A D JU S TM E N T
(Fig. 15)
1. Using an outside vacuum source, apply vacuum to
auxiliary vacuum break diaphragm until plunger is
fully seated.
2. Position cam follower on highest step of fast idle
cam.
3. With vacuum break diaphragm in fully seated
position, insert specified gauge between upper edge
of choke valve and inner air horn wall.
4. If adjustment is required, bend link between
vacuum break and choke valve.

Fig. 1 5 A uxiliary V acuum B reak A d ju s tm en t

SERVICE OPERATIONS

INDEX

Carburetor Replacement................................................6M-10 Idle Stop Solenoid Replacement................................6M-I1


Choke Coil Replacement...............................................6M-11
Fuel Filter Replacement................................................6M-11 Air Horn Tightening Sequence..................................6M-11
CARBURETOR REPLACEM ENT (Fig. 16)

Removal
Flooding, stumble on acceleration and other perform
ance complaints are, in many instances, caused by
presence of dirt, water, or other foreign matter in
carburetor. To aid in diagnosing cause, carburetor
should be carefully removed from engine without
draining fuel from bowl. Contents of fuel bowl may then
be examined for contamination as carburetor is
disassembled. Check filter.
1. Remove air cleaner and gasket.
2. Disconnect fuel and vacuum lines from carburetor.
3. Disconnect choke coil rod.
4. Disconnect accelerator linkage.
5. Disconnect idle stop solenoid electrical connector.
6. If equipped with automatic transmission, disconnect
TV linkage.
7. Remove carburetor attaching nuts and remove
carburetor and solenoid assembly attachment.
8. Remove insulator gasket, air cleaner bracket and
flange gasket.
Installation
Fig. 16 Carburetor, Choke and Heat Stove It is good shop practice to fill carburetor bowl before
installing carburetor. This reduces strain on starting

TRUCK SUPP SERVICE


ENGINE FUEL 6M-11

2. Remove inlet fuel filter nut from carburetor.


3. Remove filter element and spring.
4. Install element spring and filter element in
carburetor.
5. Install new gasket on inlet fitting nut and install nut
SPRIN G in carburetor and tighten securely.
6. Install fuel line and tighten connector.
FILTER
IDLE STOP SO LENOID REPLACEM ENT
The idle stop solenoid should be checked to assure that it
GASKET
permits the throttle plate to close further when the
ignition switch is turned "off". An inoperative solenoid
should be replaced.
Removal
1. Remove carburetor air cleaner.
2. Disconnect electrical connector at solenoid.
3. Counting number of turns, unscrew and remove
idle stop solenoid from float bowl assembly.
Fig. 17Fuel Filter - M o nojet
Installation
motor and battery and reduces the possibility of 1. Hold choke valve wide open so that fast idle cam
backfiring while attempting to start engine. A small follower clears fast idle cam.
supply of fuel will enable carburetor to be filled and the 2. Install idle stop solenoid and turn in until it
operation of float and intake needle and seat to be contacts lever tang.
checked. Operate throttle lever several times and check
discharge from pump jets before installing carburetor. 3. Connect electrical connector.
1. Be certain throttle body and intake manifold 4. Install air cleaner.
sealing surfaces are clean. 5. Refer to Maintenance and Adjustment and adjust
2. Install carburetor insulator. low and curb idle speeds.
3. Install carburetor over manifold studs. CHOKE COIL REPLACEM ENT
4. Install vacuum and fuel lines at carburetor. Choke mechanism should be checked for free operation.
5. Install attaching nuts and tighten securely. A binding condition may have developed from
petroleum gum formation on the choke shaft or from
6. Tighten fuel and vacuum lines. damage. Choke shafts can usually be cleaned without
7. Connect accelerator linkage. disassembly by using Carbon X(X55) or equivalent.
8. Connect choke coil rod and idle stop solenoid 1. Remove air cleaner and disconnect choke rod upper
electrical connector. lever.
9. Guide vent tube into rocker cover and install air 2. Remove bolt attaching choke coil to head, and
cleaner. remove choke coil and choke rod as an assembly.
3. Disconnect choke rod from choke coil.
10. Refer to Maintenance and Adjustment and adjust
low and curb idle speeds. 4. Connect choke rod to new choke coil and install
assembly on manifold.
FUEL FILTER REPLACEM ENT (Fig. 17) 5. Install bolt and tighten securely.
6. Adjust and connect choke rod as outlined.
A plugged fuel filter will restrict fuel flow or by-pass 7. Start and warm-up engine, then check operation of
foreign material into carburetor and will result in a loss choke and install air cleaner.
of engine power or rough (pulsating) engine feel,
especially at high engine speeds. AIR HORN T IG H T E N IN G SEQUENCE
1. Disconnect fuel line connection at inlet fuel filter Refer to Figure 18 for proper air horn tightening
nut. sequence.

TRUCK SUPP SERVICE


6 M -1 2 ENGINE FUEL

Fig. 18Air Horn T ig h ten in g Sequence

TRUCK SUPP SERVICE


ENGINE FUEL 6M -13

DIAGNOSIS

G EN ER A L 5. Engine compression.
When carburetor troubles are encountered they can
usually be diagnosed and corrected with an adjustm ent as 6. Ignition system firing voltage.
outlined below and under M aintenance and Adjustm ents.
7. Ignition spark timing.
Before diagnosing the carburetor as the trouble area,
check and diagnose the following: 8. Spark plugs
1. Fuel Supply
9. Secure intake m anifold.
2. Fuel pum p pressure and volume.
10. Engine tem perature.
3. Plugged fuel filter or fuel lines.
Use the following tables to diagnose carburetor.
4. Linkage and emission control systems.

Problem: e n g in e id le s r o u g h a n d s t a l l s

Id le speed setting. Re-set low and curb idle speeds under m aintenance and
adjustm ents.

M a n ifo ld vacuum hoses disconnected o r im p ro p e rly in Check all vacuum hoses leading into th e m a n ifo ld or
stalled. ca rb u re to r base fo r leaks or being disconn ected. Install
o r replace as necessary.

C a rb u re to r loose on in ta k e m a n ifo ld . T o rq u e ca rb u re to r to m a n ifo ld bolts (1 0 -1 4 ft. lbs.).

In ta k e m a n ifo ld is loose or gaskets are d e fective. Using a pressure o il can, spray lig ht o il or kerosene arou nd
m a n ifo ld legs and c a rb u re to r base. If engine R P M changes,
tig h te n o r replace th e m a n ifo ld gaskets o r ca rb u re to r base
gaskets as necessary.

H o t idle co m pen sato r n o t o p e ratin g (w h ere used.) N o rm a lly th e h o t idle co m pen sato r should be closed w hen
engine is runnin g co ld and open w hen engine is h o t (ap p ro x.
1 4 0 F at co m p .) replace if d e fective.

C a rb u re to r flo o d in g . 1. R em ove air horn and check flo a t ad justm ent, as specified
N O T E : Also check carburetor flood ing w hen engine cranks in carburetor overhaul section.
(turn over) b ut w ill not start or starts hard w hen cold. 2. Check flo a t needle and seat fo r p ro p e r seal. If a needle
and seat tester is n o t available, m o u th su ction can be
ap plied to th e needle seat w ith needle installed. If th e
needle is d e fe c tiv e , replace w ith a fa c to ry m a tch e d set.
3. C heck flo a t fo r being loaded w ith fu e l, b ent flo a t hanger
o r binds in th e flo a t arm .
N O T E : A solid flo a t can be checked fo r fu el ab so rp tio n by
lig h tly squeezing b etw een fingers. If wetness appears on
surface o r flo a t feels heavy (check w ith k n o w n good flo a t),
replace th e flo a t assem bly.
4. If excessive d irt is fo u n d in th e c a rb u re to r, clean th e
fuel system and carb u reto r. R eplace fuel filte r as
necessary.

TRUCK SUPP SERVICE


6 M -1 4 ENGINE FUEL

Problem:
ENGINE CRANKS (TURNS OVER) BUT WILL NOT START OR STARTS HARD WHEN COLD.
PO SSIB LE CAUSE C O R R E C TIV E ACTION
Im p ro p e r starting p ro c ed u re used. Check proper starting, as o u tlin ed in the ow ner's m anual.

N o fuel in gas tan k A dd fuel. Check fuel gauge fo r proper o p e ratio n .

C h o ke valve n ot closing s u ffic ie n tly w hen cold. A djust the choke coil rod.
C h o ke valve or linkage bin d in g o r sticking. Realign th e ch oke valve or linkage as necessary. If caused
by d ir t and gum , clean w ith a u to m a tic ch oke cleaner.
D o n ot oil ch o ke linkage. If parts are replaced, check
ad justm ents.
N o fuel in carb u reto r. 1. R em ove fuel line at carb u reto r. C o n n e ct hose to fuel
line and run in to m etal co n tain e r. R em ove th e high
tension coil w ire fro m center to w e r on d is trib u to r cap
and ground. C rank over engine if th e re is no fuel
discharge fro m th e fuel line, check fo r kin ke d or bent
lines. D isconnect fuel line a t tan k and b lo w o u t w ith
air hose, reconnect line and check again fo r fuel dis
charge. If none, replace fuel pum p. C heck p um p for
ad equate flo w , as o u tlin e d in service m anual.
2. If fuel su pply is o .k ., check th e fo llo w in g :
a. Inspect fuel filte r. If plugged replace.
b. If filte r is o .k ., rem ove air horn and check fo r a bind in
the flo a t mechanism or a sticking flo a t needle.
If o .k ., adjust flo a t as specified in ca rburetor overhaul
section.
Engine F lo o d ed . Check proper ca rburetor unloading procedure. Depress th e
N O T E : T o check fo r flo o d in g , rem ove the air cleaner, accelerator to the flo o r and check th e carburetor to de
w ith the engine o ff, and look into the carburetor bore. term in e if the choke valve is opening. If n o t, adjust the
Fuel w ill be dripping o ff nozzle an d /o r the carburetor th ro ttle linkage and unlo ader, as specified.
w ill be very w et.
C arb u re to r flo o d in g N O T E : B efore rem oving the ca rb u reto r air h o rn , use th e
fo llo w in g procedure w h ich m ay e lim in a te th e flo o d in g .

1. R em ove th e fuel line at the c a rb u re to r and plug. C rank


and run th e engine u n til th e fuel b o w l runs d ry. T u rn
o ff th e engine and co nnect fuel line. T h e n re-start and
run engine. T h is w ill usually flush d irt past th e carbu
reto r flo a t needle and seat.
2. If d irt is in fuel system , clean th e system and replace
fuel filte r as necessary. If excessive d irt is fo u n d , re
m ove the ca rb u reto r u n it. Disassem ble and clean.
3. Check flo a t needle and seat fo r p ro p e r seal. If a needle
and seat tester is n o t available, a p p ly m o u th suction to
th e needle seat w ith needle installed. If th e needle is
d e fe ctiv e, replace w ith a fa c to ry m atched set.
4. Check flo a t fo r being loaded w ith fu e l, b ent flo a t hanger
or binds in th e flo a t arm .
N O T E : Check flo a t fo r fuel absorption by lig htly squeezing
betw een fingers. If wetness appears on surface or flo a t feels
heavy (Check w ith kn ow n good flo a t), replace th e flo a t
assembly.

5. A djust flo a t as specified in carburetor overhaul section.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -15

Problem: e n g in e s t a r t s a n d s t a l l s

Engine does not have enough fast idle speed when cold. Check and re-set th e fast idle setting and fast idle cam .

C h o ke vacuum break u n it is n o t adjusted to sp ecifica tio n 1. A d ju s t vacuum break to sp ecification.


or u n it is defective.
2. If adjusted O .K ., check th e vacuum break fo r pro p e r
o p e ratio n as follo w s:
O n th e e x te rn a lly m o u n ted vacuum break u n it, co nnect
a piece o f hose to th e nipp le on th e vacuum break u n it
and ap ply suction by m outh or use tool J -2 3 4 1 8 to
ap p ly vacuum . Plunger should m ove in w ard and hold
vacuum . If n o t, replace th e un it.

N O T E : A lw a y s check th e fast idle cam ad ju s tm e n t b e fo re


adjusting vacuum break u n it.
C h o k e coil rod o u t o f ad ju stm en t. A d ju s t ch oke coil rod.

C h o k e valve a n d /o r linkage sticking or binding. 1. Clean and align ch o ke valve and linkage. R eplace if
necessary.
2. R e-adjust if p a rt replacem ent is necessary.

Id le speed setting A djust low and curb idle speeds to specifications on label in
engine co m p artm en t.
N o t enough fuel in ca rb u reto r. 1. Check fuel p u m p pressure and vo lum e.
2. Check fo r p a rtia lly plugged fuel in let filte r. R eplace if
d irty .
3. R em ove air horn and check flo a t adjustm ents as specified
in ca rburetor overhaul section.

C a rb u re to r flo o d in g . 1. C heck flo a t needle and seat fo r p ro p e r seal. If a needle


N O T E : Also check carburetor flood ing w hen engine cranks and seat tester is n o t available, m o u th su ction can be
(turn over) but w ill not start or starts hard w hen cold. applied to th e needle seat w ith needle installed. If
needle is d e fe c tiv e , replace w ith a fa c to ry m atched set.
2. Check flo a t fo r being loaded w ith fu e l, b ent flo a t hanger
or binds in th e flo a t arm .

N O T E : Check flo a t fo r fuel absorption by lig htly squeezing


betw een fingers. If wetness appears on surface or flo a t feels
heavy (check w ith kn ow n good flo a t), replace the flo a t
assembly.

3. Check flo a t adjustm ents as specified in carburetor over


haul section.
4. If excessive d irt is fo u n d in the carb u reto r, clean the fuel
system and carburetor. R eplace fuel filte r as necessary.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -16

Problem: e n g in e r u n s u n e v e n o r s u r g e s

PO SSIB LE CAUSE C O R R E C T IV E ACTIO N

Fuel R es trictio n Check all hoses and fuel lines fo r bends, kin ks or leaks.
Straig hten and secure in position.
Check all fuel filte rs. If plugged or d ir ty - replace.
D ir t or w a te r in fuel system . Clean fuel tan k and lines. R em ove and clean carburetor.
Fuel level A djust flo a t as specified in carburetor overhaul section.
Check fo r free flo a t and flo a t needle valve o p eration.
M ain m etering jet d e fective, loose or incorrect part. Replace as necessary.

Power system in ca rburetor not functioning p roperly. Power F ree up or replace as necessary.
valve sticking in dow n position.
V ac u u m leakage It is ab so lu te ly necessary th a t all vacuum hoses and gaskets
are p ro p e rly installed, w ith no air leaks. T h e c a rb u reto r
and m a n ifo ld should be evenly tig h te n ed to specified
to rq u e .

Problem: p o o r f u e l econom y

Engine needs co m p le te tun e -u p . Check engine com pression. E x a m in e spark plugs, (if d irty
or im p ro p e rly gapped, clean and re-gap o r replace). C heck
ignition p o in t d w e ll, c o n d itio n , readjust ig n itio n points if
necessary and check and reset ignition tim in g . C lean or
replace air cleaner elem e n t if d irty . C heck fo r restricted
exhaust system and in ta ke m a n ifo ld fo r leakage, m ake sure
all vacuum hoses are co nnected c o rre c tly .

C hoke valve n o t fu lly opening. 1. Clean ch oke and free up linkage.


2. Check choke coil rod fo r proper ad justm ent. Reset to
specifications.

Fuel leaks. C heck fuel ta n k , fuel lines and fu el p u m p fo r any fuel


leakage.
Power system in carburetor not functioning properly. Power F ree up or replace as necessary.
valve sticking in up position.
H igh fuel level in ca rb u reto r o r ca rb u reto r flo o d in g . 1. C heck fo r d ir t in th e needle and seat. T est using suction
by m o u th o r needle seat tester. If d e fe c tiv e , replace
needle and seat assem bly w ith fa c to ry m atched set.
2. Check fo r loaded flo a t.

3. Re-set carburetor flo a t as specified in ca rburetor overhaul


section.
4 . If excessive d ir t is present in th e c a rb u re to r b o w l, th e
ca rb u reto r should be cleaned.

Fuel being pulled fro m accelerato r system in to venturi R un engine at R P M w h ere n o zzle is feeding fu e l. O bserve
through p um p jet. p um p je t. If fuel is feeding fro m je t, check p u m p discharge
ball fo r pro p e r seating b y fillin g ca vity above ball w ith
fuel to level o f casting. N o "le a k d o w n " should occur w ith
discharge ball in place. R e-stake or replace leaking check
b a ll, d e fe ctiv e spring, o r reta in er.
A ir bleeds or fuel passages in c a rb u re to r d ir ty or plugged. C lean ca rb u reto r o r overhaul as necessary.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -17

Problem: e n g in e h e s i t a t e s o n a c c e l e r a t i o n

D efe c tiv e accelerato r p um p system 1. R em ove air horn and check p u m p cup. If cracked,
scored or d is to rte d , replace th e p u m p plunger.
NOTE: A q u ick check o f th e p u m p system can be m ade as
fo llo w s . W ith th e engine o f f, rem ove air cleaner and look 2. C heck th e p um p discharge ball fo r p ro p e r seating at
in to th e ca rb u reto r bores and observe pum p stream , w h ile lo catio n . T h e p u m p discharge ball is located in a cavity
b ris kly opening th r o ttle valve. A fu ll stream o f fuel should n e xt to th e p u m p w e ll. T o check fo r pro p er seating,
e m it fro m pum p je t and strik e near th e ce n ter o f th e rem ove air horn and gasket and fill ca vity w ith fu e l. N o
ve n tu ri area. "leak d o w n " should occur. R estake and replace check
ball if leaking. M a k e sure discharge b a ll, spring, and re
tain er are p ro p e rly installed.

D ir t in p um p passages or p um p je t. Clean and B lo w o u t w ith compressed air.


Fuel level. Check fo r sticking flo a t needle or binding flo a t. Free up or
replace parts as necessary. C heck and reset flo a t level as
specified in carburetor overhaul section.
Leaking air horn to flo a t bo w l gasket. T o rq u e air horn to flo a t bo w l using proper tig h te n in g
procedure.
C a rb u re to r loose on m a n ifo ld . T o rq u e c a rb u re to r to m a n ifo ld bolts. (1 0 -1 4 ft. lbs.).

, # NO POWER ON HEAVY ACCELERATION


Problem: o r a t h ig h speed
C a rb u re to r th ro ttle valve n ot going w id e open. (C heck A d ju s t th r o ttle linkage to o b ta in w id e open th r o ttle in
by pushing accelerato r pedal to flo o r). carburetor.
D irty or plugged fuel filte r. R eplace w ith a new filte r elem ent.

Pow er system n o t operating. Check pow er valve fo r free up and dow n m ovem ent.

F lo a t level to o low . 1. Check and reset flo a t level as specified in carburetor over
haul section.
F lo a t n ot dro p p in g far enough in to flo a t bow l. C heck fo r bind ing flo a t hanger and fo r pro p e r flo a t align
m e n t in flo a t b o w l.

M a in m etering je t d ir ty , plugged or incorrect part. 1. If the main m etering je t is plugged or d irty and excessive
d irt is in fuel b o w l, ca rburetor should be co m p le tely dis
assembled and cleaned.

Problem: e n g in e s t a r t s h a r d w h e n h o t

C h o ke valve n ot opening c o m p le te ly . 1. Check fo r bin d in g ch o ke valve a n d /o r linkage. Clean


and free-u p or replace parts as necessary.
D o n o t oil ch oke linkage.
2. Check and adjust choke coil rod.

E ngine flo o d ed - C a rb u re to r flo o d in g . See procedure under "E n g in e cranks, w ill n o t s ta rt".
N o fu el in c a rb u reto r. 1. Check fuel pu m p . R un pressure and v o lu m e test.
2. Check flo a t needle fo r sticking in seat, or bin d in g flo a t.
Leaking flo a t b o w l. F ill bow l w ith fuel and look fo r leaks.

TRUCK SUPP SERVICE


6M -18 ENGINE FUEL

2GC CARBURETOR
IN D E X

General Description.......................................................6M-18 Service Operations........................................................... 6M-24


Theory of Operation ....................................................6M-18 Diagnosis............................................................................. 6M-26
Maintenance and Adjustment.....................................6M-21

GENERAL DESCRIPTION
CLEAN AIR TUBE
/
AIR H O R N

ACCELER ATO R
CHOKE CLOSING
PU M P ROD
FUEL INLET ASSIST. SPRING

THROTTLE
LEVER

CHOKE
BREAK DIAPHRAGM FULL
SPARK PORT

GAS
RECIRCULATION
THERMOSTATIC VACUUM PORT
C H O K E HE AT INLET
PURGE TUBE COIL

Fig. 192GC C arb u re to r Front Fig. 2 0 2GC C arb u re to r - 3 / 4 View

The Model 2GC (Figs. 19 and 20) is equipped with an pump cup to maintain good pump wall contact during
integral choke attached to the throttle body assembly. A pump operation.
large drilled hole in the air horn leads from inside the The end of the pump plunger stem is upset in
air horn bore to a vapor dome located in the air horn manufacturing to provide the "clipless" retaining
casting above the fuel in the float bowl. feature. The pump plunger assembly may be removed
Vapor canister purge ports are located in the throttle from the inner lever by twisting upset end with small
body casting. The ports connect by a channel to a tube pliers until it breaks. The service pump assembly has a
pressed into the throttle body casting which leads grooved end and is provided with a retaining clip.
directly to the vapor canister. This provides adequate Alphabetical code letters cast next to the vacuum and air
purge during engine operation to remove all fuel vapors tubes identify all hose connections. As mentioned, the
from the vapor collection canister. code letters are alphabetical and should be referred to
during carburetor installation on the engine.
The pump system has a raised cast in boss on the floor The carburetor part number is stamped on the flat
of the float bowl, which prevents entry of dirt into the section of the float bowl next to the fuel inlet nut. When
accelerator pump - power valve fuel inlet passage. The servicing the carburetor unit, refer to the Adjustment
pump plunger head has an expander spring beneath the section for proper procedures and specifications.

THEORY OF OPERATION
INDEX
Float System......................................................................6M-18 Main Metering System..................................................6M-19
Power Enrichment System............................................6M-20
Idle System........................................................................6M-19 Pump System.....................................................................6M-20
FLOAT SYSTEM (Fig. 21 ) must be maintained to give proper metering through all
operating ranges. As fuel is used from the carburetor
The float system controls the level of the fuel in the bowl, the plastic float drops, moving the float needle off
carburetor bowl. Fuel level is very important because it

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -19

its seat allowing more fuel to enter the bowl, thereby the off-idle discharge ports are exposed to manifold
keeping the fuel level constant. vacuum. These ports supply additional fuel mixture for
The fuel bowl is internally vented by a large drilled hole off-idle engine requirements.
which leads from inside the air horn bore to a vapor The fuel vapor collection canister is purged by ports
dome above the fuel in the float bowl. The internal vent located in the carburetor throttle body. Timed purge
provides a balance in air pressure to maintain constant ports are connected from the carburetor bore to a
air/fuel mixture ratios. Also, the large internal hole common tube pressed into the throttle body casting. The
vents fuel vapors that form during periods of hot engine tube connects directly to the vapor canister through a
operation for improved hot idle and restart. hose. Timed purge ports (one in each bore), located
above the throttle valve near the off-idle discharge ports,
purge the canister during off-idle and part throttle
IDLE (LOW SPEED) SYSTEM (Fig. 22) ranges of operation.
The idle system is used to provide the proper mixture An Exhaust Gas Recirculation system is used to control
ratios required during idle and low speed operation of oxides of nitrogen. A vacuum supply tube, located just
the engine. beneath the spark tube on the float bowl, connects by a
The idle system consists of the idle tubes, idle passages, channel to purge ports located just above the throttle
idle air bleeds, idle mixture needles, off-idle discharge valve in the throttle body bore.
ports and idle needle discharge holes. As the throttle valve is opened beyond the idle position,
The idle mixture needle discharge holes provide fuel for the E.G.R. ports are exposed to manifold vacuum which
curb engine idle. As the throttle valve is opened further, supplies a signal to the diaphragm in the E.G.R. valve.
The two ports located in the throttle body bore are timed
to provide just the right amount of vacuum to the E.G.R.
LA R G E IN T E R N A L
B O W L V E N T H O LE valve diaphragm to control exhaust gases introduced into
F U E L IN L E T
F IT T IN G
F IL T E R
the intake manifold air/fuel mixtures.
M A IN M E TE R IN G SYSTEM (Fig. 23)
As the throttle valves continue to open, the edge of the
valves are gradually moving away from the wall of the
carburetor bore, reducing the vacuum acting on the idle
needle and off-idle discharge ports which gradually
FLO A T NEEDLE decreases fuel flow from the idle system.
With the increased throttle opening, there is increased
air velocity in the venturi system. This causes a drop in
pressure in the large venturi which is increased many
times in the small venturi. Since the low pressure (high
vacuum) is now in the small venturi, fuel will flow in the
Fig. 2 1 Float System
following manner:
Fuel from the float bowl passes through the main
E . G .R . ( E X H A U S T G A S
metering jets into the main wells and rises in the main
well tubes. Plastic main well inserts are used in the main
R E C IR C U L A T IO N )

ID L E R E S T R IC T IO N P U L L -O V E R
E N R IC H M E N T
ID L E P A S S A G E
F U E L FEE D
ID L E T U B E

M A I N M E T E R IN G
JET -------------

P A R T THR O TTLE
A D J U S T M E N T SCREW

M A IN W E LL

Fig. 22 Idle (Low Speed) System Fig. 23 M ain M etering System

TRUCK SUPP - SERVICE


6M -20 ENGINE FUEL

wells to provide smooth fuel flow for efficient metering. restrictions into the main fuel wells for desired
This results in improved fuel control in the off-idle, enrichment at the main discharge nozzles. The power
transfer, and part throttle range of operation. Air valve, located at the bottom of the fuel bowl, provides
entering the main wells through the main well air bleeds the correct fuel enrichment for power requirements.
is mixed with fuel through calibrated holes in the main
well tube. The mixture moves up and out of the main
discharge nozzles into a mixture (high speed) passage PU M P SYSTEM (Fig. 2 5)
where more air is added. The mixture then travels down When the throttle valve is opened rapidly, air flow and
through the mixture passage to the small venturi where it manifold vacuum change almost instantly, while the
is delivered to the air stream and on into the engine heavier fuel tends to lag behind causing a momentary
intake manifold. leanness. The accelerator pump system provides the fuel
On some models, an additional fuel circuit, called "pull necessary for smooth operation on rapid acceleration.
over" enrichment (P.O.E.), has been provided which
supplements the main metering system of the carburetor Fuel for acceleration is supplied by a double spring
unit. In order to provide sufficient enrichment to the loaded pump plunger. The top and bottom springs
main metering system at higher air flows, two additional combine to move the plunger so that a smooth sustained
fuel feeds are located in the air horn just above the charge of fuel is delivered for acceleration.
choke valve. They connect directly to the fuel in the float Fuel is drawn into the pump well through the inlet check
bowl, through channels which lead directly into a tube ball on the upward stroke of the pump plunger.
that extends into the fuel just above the main metering
jets. At approximately 8 pounds of air per minute and Downward motion of the pump plunger, as on
above, the extra fuel enrichment is added to supplement acceleration, seats the aluminum inlet check ball and
the main metering system. forces the fuel through the pump discharge passage
With the addition of the pull-over enrichment system, where it unseats the pump discharge ball and passes on
leaner mixtures can be maintained during the part through to the pump jets, where it sprays into the venturi
throttle or cruising ranges and extra fuel supplied at area.
higher air flows to meet engine demands. An expander spring located beneath the pump cup
ensures good contact between the lip of the pump cup
POWER E N R IC H M E N T SYSTEM (Fig. 24) and the pump well at all times. When the pump is not in
The conventional vacuum sensitive power piston and operation, the pump cup unseats from the plunger head
power valve are used for power requirements. When and acts as a vent for the pump well. If vapors form in
manifold vacuum drops to a pre-determined point the pump well during hot operation, they are vented
(called power cut-in), the power piston moves downward between the head and pump cup out into the fuel bowl.
against spring tension to force the power valve plunger Without this pump vent, vapor pressure in the pump well
off its seat. might force fuel from the pump system into the engine
manifold, causing hard starting when the engine is hot.
Fuel then flows from the float bowl down past the valve
plunger through a small calibrated orifice in the valve The pump discharge ball in the accelerator pump
side and on into separate fuel channels leading to the passage prevents any pump pull-over or discharge of
power restrictions. The fuel passes through the power fuel from the pump nozzles when the accelerator is
inoperative.
M A N IF O L D V AC U U M
VAC U U M
R E LIE F PASSAGE
J

POWER
RESTR IC TIO N S
M A IN W ELL

Fig. 24 Power E nrichm ent System Fig. 2 5 Pump System

TRUCK SUPP SERVICE


ENGINE FUEL 6M-21

idle cam will drop from the high step to a lower step
when the throttle is opened. The vacuum break unit is
delayed in operation by an internal bleed check valve.
The delay check valve slows down further opening of the
valve a few seconds until the engine will run on slightly
leaner mixtures.
A choke closing assist spring is used on the vacuum
diaphragm plunger stem. The spring assists in closing
the choke valve, along with tension from the choke
thermostatic coil, for improved cold starting. The choke
closing assist spring only exerts pressure on the vacuum
break rod to assist in closing the choke valve during
engine starting. When the engine starts and the choke
vacuum diaphragm seats, the closing spring retainer hits
a stop on the plunger stem and no longer exerts pressure
on the vacuum break rod.
A clean air purge feature is used on the vacuum break
unit. The purpose of the clean air purge is to bleed air
into the vacuum break passage and purge the system of
O PERA TIO N OF CHOKE SYSTEM (Fig. 2 6) any fuel vapors or dirt which might contaminate and
plug the check valve located inside the diaphragm unit.
The model 2GC carburetor has an integral choke The purge system consists of a small bleed hole located
housing and thermostatic coil assembly mounted on the in the end cover of the vacuum break diaphragm.
carburetor throttle body. A ball check is encased in the vacuum inlet tube. The
The choke system operates as follows: ball seats when backfiring occurs to prevent contamina
tion of filter. Under normal engine operation the ball is
The thermostatic coil in the choke housing is calibrated pulled off its seat by manifold vacuum.
to hold the choke valve closed when the engine is cold. During engine operation, vacuum acting upon the
To close the choke valve, depress the accelerator pedal diaphragm unit pulls a small amount of filtered air
completely to allow the idle speed screw to clear the steps through the bleed hole to purge the system.
on the fast idle cam. At this point, tension of the Engine vacuum supplied through an orifice in the choke
thermostatic coil will rotate the choke valve to the closed housing pulls heat from the manifold heat stove into the
position and the idle speed screw will come to rest on the housing and gradually relaxes coil tension which allows
highest step of the fast idle cam. the choke valve to continue opening through inlet air
pressure pushing on the off-set choke valve.
During engine starting, the high vacuum beneath the
choke valve causes extra fuel to flow from the carburetor The choke system is equipped with an unloader feature
ports providing a rich mixture for quick engine starting. to partially open the choke valve should the engine
When the engine starts and is running, manifold vacuum become flooded or loaded.
is applied to the vacuum break diaphragm unit mounted To unload the engine, the accelerator pedal must be
on the carburetor air horn. The diaphragm unit, depressed so that the throttle valves are held wide open.
connected by linkage to the choke valve, opens the choke A tang on the throttle lever contacts the fast idle cam
valve a predetermined amount against coil tension so and through the choke rod forces the choke valve slightly
that the air/fuel mixture will be lean enough so the open. This allows extra air to enter the carburetor bores
engine will run without loading or stalling. When the and pass on into the engine manifold to lean out the fuel
choke valve moves to the vacuum break position, the fast mixtures so the engine will start.

MAINTENANCE AND ADJUSTMENT

INDEX

Idle Speed Adjustment..................................................6M-22 Fast Idle Cam Adjustment.......................................... 6M-22


Choke Unloader Adjustment....................................... 6M-22
Idle Mixture.......................................................................6M-22 Intermediate Choke Rod Adjustment...................... 6M-23
Idle Mixture Adjustment.............................................6M-22 Automatic Choke Coil Adjustment...........................6M-23
Pump Rod Adjustment..................................................6M-22 Vacuum Break Adjustment.......................................... 6M-23

TRUCK SUPP SERVICE


6M -2 2 ENGINE FUEL

IDLE SPEED 8. Adjust idle rpm to the higher of the two idle speeds
1. With engine at normal operating temperature, air specified. (Example 650/600).
cleaner on, choke open, and air conditioning OFF, 9. Equally enrich (turn out) mixture screws until
connect a tachometer to engine. maximum idle speed is achieved. Reset speed if
2. Set parking brake and block drive wheels. necessary to the higher specified idle speed.
3. Disconnect fuel tank hose from vapor canister. 10. Equally lean (turn in) mixture screws until the lower
specified idle speed is achieved (Example 650/600).
4. Disconnect vacuum advance hose at distributor and Connect fuel tank vent hose.
plug hose.
5. Start engine, check timing and adjust as required. P U M P ROD A D JU S TM E N T (Fig. 27)
Reconnect vacuum advance hose. 1. Back out idle speed adjusting screw.
6. With automatic transmission in Drive or manual 2. Hold throttle valve completely closed.
transmission in Neutral, turn idle speed screw to
specified rpm. 3. Gauge from top of air horn ring to top of pump
rod.
7. Shut off engine and remove tachometer.
4. If adjustment is required, bend rod.
8. Connect fuel tank hose to vapor canister.
9. Remove blocks from drive wheels. FAST IDLE CAM A D JU S T M E N T (Fig. 28)
1. Turn idle speed screw in until it just contacts low
IDLE M IXTU R E step of fast idle cam. Then, turn screw in one full
The idle mixture is factory preset and idle mixture turn.
screws are capped with plastic limiter caps. The cap 2. Place idle speed screw on second step of fast idle
permits screw to be turned about one turn leaner cam against highest step.
(clockwise) without breaking cap. The idle mixture is set 3. Place gauge between upper edge of choke valve and
to achieve the smoothest idle while maintaining emission wall of air horn.
levels within standards prescribed by Federal Law. 4. If adjustment is required, bend choke lever tang.
At major carburetor overhaul the idle mixture may be
adjusted. Before suspecting idle mixture as cause of poor CHOKE UNLOADER A D JU S TM E N T (Fig. 29)
idle quality, check ignition system, distributor, timing,
air cleaner, PCV system, evaporation emission control 1. With throttle valves held in wide open position,
and compression pressures. Also check all vacuum hoses place choke valve toward closed position.
and connections for leaks and check torques of 2. Place specified gauge between upper edge of choke
carburetor attachment bolts. Adjustment is made using a valve and air horn casting to check clearance.
tachometer. 3. If adjustment is required, bend tang on throttle
Refer to Vehicle Emission Control Information label on lever.
vehicle for latest certified specification information
which may differ from specifications in manual.

Idle M ixture Adjustm ent


1. With engine at normal operating temperature, air
cleaner on, choke open, and air conditioning OFF,
connect a tachometer to engine.
2. Set parking brake and block drive wheels.
3. Disconnect fuel tank hose from vapor canister.
4. Disconnect vacuum advance hose at distributor and
plug hose.
5. Start engine, check timing and adjust as required.
Reconnect vacuum advances hose.
6. With engine at normal operating temperature (not
hot), air conditioning off, and air cleaner installed,
position transmission selector in drive (automatic
transmission) or neutral (manual transmission).
7. Break off tab on mixture cap using needle nose Fig- 2 7 Pum p Rod A d ju s tm en t
pliers.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -23

5. Bend intermediate choke rod at point shown to


adjust.

A U TO M A TIC CHOKE COIL A D JU S TM E N T


(Fig. 31)
1. Place idle speed screw on the highest step of fast
idle cam.
2. Loosen thermostatic shoke coil cover retaining
screws.
3. Rotate choke cover against coil tension until choke
valve begins to close. Continue rotating until index
mark lines up with specified point on choke
housing.
4. Tighten choke cover retaining screws.

VACUUM BREAK A D JU S TM E N T
Fig. 2 8 Fast Idle C am A d ju s tm en t
1. Seat the vacuum break diaphragm using an outside
vacuum source.
2. Cover vacuum break bleed hole as shown using a
small piece of tape, so that diaphragm unit will
hold inward and not bleed down.
3. Place idle speed screw on high step of fast idle cam.

Fig. 2 9 C hoke U n lo a d er A d ju s tm en t Fig. 3 0 In te rm e d ia te Choke Rod A d ju s tm en t

IN TE R M E D IA TE CHOKE ROD A D JU S TM E N T
(Fig. 3 0 ) ^ SET M A R K O N C O VE R TO
S P E C IF IE D P O IN T O N C H O K E

1. Remove thermostatic cover coil, gasket, and inside H O U S IN G

baffle plate assembly by removing three attaching


screws and retainers.
2. Place idle speed screw on the highest step of fast
idle cam. LO O S EN TH REE

3. Close choke valve by pushing up on intermediate R E T A IN IN G S C R E W S


SET ID LE SP EED S C R E W

choke lever. O N H IG H E S T STEP OF C A M

4. Edge of coil lever inside choke housing must line up


with edge of plug gauge. Fig. 3 1 A u to m a tic C hoke Coil A d ju s tm en t

TRUCK SUPP - SERVICE


6 M -2 4 ENGINE FUEL

4. Hold choke coil lever inside choke housing towards


G A U G E BETWEEN
the closed choke position.
UPPER EDGE OF 5. Gauge between upper edge of choke valve and air
CHOKE VALVE A N D
AIR HORN W ALL. horn wall.
SEAT DIAPHRAGM 6. Bend vacuum break rod at point shown to adjust.
PLUNGER USING 7. After adjustment, remove piece of tape covering
OUTSIDE VAC U U M
small bleed hole at rear of vacuum break
diaphragm unit. Reconnect vacuum hose.
SOURCE
/
NOTE:
PLUG PURGE BLEED'
HOLE W ITH A PIECE
OF M ASKING TAPE

NOTE: PLACE IDLE SPEED H O L D TOWARDS


SCREW ON HIGH STEP OF CLOSED CHOKE
FAST IDLE CAM

Fig. 3 2 Vacuum B reak A d justm en t

SERVICE OPERATIONS

INDEX

Carburetor Replacement................................................6M-24 Fuel Filter Replacement................................................6M-25


Air Horn Tightening Sequence..................................6M-25
CARBURETOR REPLACEM ENT (Fig. 3 3 ) operation of float and intake needle and seat to be
Removal
checked. Operate throttle lever several times and check
discharge from pump jets before installing carburetor.
Flooding, stumble on acceleration and other perform
ance complaints are, in many instances, caused by 1. Clean throttle body and intake manifold sealing
presence of dirt, water, or other foreign matter in surfaces.
carburetor. To aid in diagnosis, carburetor should be
carefully removed from engine without draining fuel
from bowl. Contents of fuel bowl may then be examined
for contamination as carburetor is disassembled. Check
filter.
1. Remove air cleaner and gasket.
2. Disconnect fuel and vacuum lines from carburetor.
3. Disconnect fresh air hose and choke hose from
choke system.
4. Disconnect accelerator linkage.
5. If equipped with automatic transmission, disconnect
downshift cable.
6. Remove carburetor attaching bolts and remove
carburetor.
7. Remove insulator.
Installation
It is good shop practice to fill carburetor bowl before
installing carburetor. This reduces strain on starting
motor and battery and reduces the possibility of
backfiring while attempting to start engine. A small
supply of fuel will enable carburetor to be filled and the

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -25

Fig. 3 4 Fuel Filter R eplacem ent Fig. 3 5 A ir H orn Tig h ten in g Sequence

2. Install new insulator. of engine power or rough (pulsating) engine feel,


3. Position carburetor over intake manifold and install especially at high engine speeds.
bolts. Tighten bolts simultaneously to 145 in. lbs. 1. Disconnect fuel line connection at inlet fuel filter
4. Connect downshift cable and adjust as required. nut.
5. Connect accelerator linkage. 2. Remove inlet fuel filter nut from carburetor.
6. Connect fresh air hose and choke hose to choke 3. Remove filter element and spring.
system. 4. Install element spring and filter element in
7. Connect fuel and vacuum lines. carburetor.
8. Install air cleaner. 5. Install new gasket on inlet fitting nut and install nut
9. Refer to Maintenance and Adjustment and check in carburetor and tighten securely.
idle speed. 6. Install fuel line and tighten connector.
FUEL FILTER REPLACEM ENT (Fig. 3 4 ) AIR HORN TIG H T E N IN G SEQUENCE
A plugged fuel filter will restrict fuel flow or by-pass Refer to figure 35 for proper air horn tightening
foreign material into carburetor and will result in a loss sequence.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -2 6

DIAGNOSIS

G EN ER A L 5. Engine compression.
When carburetor troubles are encountered they can
usually be diagnosed and corrected with an adjustm ent as 6. Ignition system firing voltage.
outlined below and under M aintenance and Adjustm ents.
7. Ignition spark timing.
Before diagnosing the carburetor as the trouble area,
check and diagnose the following: 8. Spark plugs
1. Fuel Supply
9. Secure intake m anifold.
2. Fuel pum p pressure and volume.
10. Engine tem perature.
3. Plugged fuel filter or fuel lines.
Use the following tables to diagnose carburetor.
4. Linkage and emission control systems.

Problem: e n g in e id le s r o u g h a n d s t a l l s

Idle speed setting. Re-set low and curb idle speeds under m aintenance and
adjustm ents.

M a n ifo ld vacuum hoses disconnected or im p ro p e rly in Check all vacuum hoses leading in to th e m a n ifo ld or
stalled. ca rb u re to r base fo r leaks or being disconn ected. Install
or replace as necessary.
C a rb u re to r loose on in ta ke m a n ifo ld . T o rq u e c a rb u re to r to m a n ifo ld b olts (1 0 -1 4 ft. lbs.).
In ta k e m a n ifo ld is loose or gaskets are defective. Using a pressure o il can, spray lig ht o il or kerosene arou nd
m a n ifo ld legs and c a rb u re to r base. If engine R P M changes,
tig h te n o r replace th e m a n ifo ld gaskets o r c a rb u re to r base
gaskets as necessary.
H o t idle co m pen sato r n o t op eratin g (w h ere used.) N o rm a lly th e h o t idle co m pen sato r should be closed w hen
engine is runnin g cold and open w hen engine is h o t (ap p ro x.
1 4 0 F at co m p .) replace if d e fective.

C a rb u re to r flo o d in g . 1. Rem ove air horn and check flo a t ad ju stm en t, as specified
N O T E : Also check carburetor flood ing w hen engine cranks in carburetor overhaul section.
(turn over) but w ill not start or starts hard w hen cold. 2. Check flo a t needle and seat fo r p ro p e r seal. If a needle
and seat tester is n o t available, m o u th su ctio n can be
ap plied to th e needle seat w ith needle installed. If th e
needle is d e fe ctiv e, replace w ith a fa c to ry m atched set.
3 . Check flo a t fo r being loaded w ith fu e l, b e n t flo a t hanger
or binds in th e flo a t arm .
N O T E : A solid flo a t can be checked fo r fu el a b so rp tio n by
lig h tly squeezing betw een fingers. If w etness appears on
surface o r flo a t feels heavy (check w ith k n o w n good flo a t),
replace th e flo a t assem bly.
4 . If excessive d irt is fo u n d in th e c a rb u re to r, clean th e
fuel system and ca rb u reto r. R ep lace fuel filte r as
necessary.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -27

Problem:
ENGINE CRANKS (TURNS OVER) BUT WILL NOT START OR STARTS HARD WHEN COLD.
PO SSIB LE CAUSE C O R R E C T IV E ACTION

Im p ro p e r starting p rocedure used. Check proper starting, as o u tlin ed in the ow ner's m anual.

N o fuel in gas tan k A dd fuel. C heck fuel gauge fo r proper op eratio n .

C h o ke valve n o t closing s u ffic ie n tly w hen cold. A djust the choke coil rod.

C h o ke valve or linkage bin d in g o r sticking. R ealign th e ch o ke valve or linkage as necessary. If caused


by d ir t and gum , clean w ith a u to m a tic ch o ke cleaner.
D o n o t oil ch oke linkage. If parts are replaced, check
ad justm ents.
Inoperative choke or vacuum break. 1. Inspect choke and vacuum break fo r w o rn or missing
parts. Replace and adjust as required.
2 . Inspect choke therm o sta tic coil fo r proper op eratio n .
Replace and adjust as required.
N o fuel in carb u reto r. 1. R em ove fuel line at ca rb u reto r. C o n n ect hose to fuel
line and run in to m etal container. R em o ve th e high
tension coil w ire fro m center to w e r on d is trib u to r cap
and ground . C rank over engine if th e re is no fuel
discharge fro m th e fuel line, check fo r k in k e d or bent
lines. D isconnect fuel line at ta n k and b lo w o u t w ith
air hose, reconnect line and check again fo r fuel dis
charge. If none, replace fuel pum p. C heck p um p fo r
ad equate flo w , as o u tlin e d in service m anual.
2. If fuel su p p ly is o .k ., check th e fo llo w in g :
a. Inspect fuel filte r. If plugged replace.
b. If filte r is o .k ., rem ove air horn and check fo r a bind in
the flo a t mechanism or a sticking flo a t needle.
If o .k ., adjust flo a t as specified in ca rburetor overhaul
section.

Engine F lo o d ed . Check proper c a rb u reto r unloading procedure. Depress the


N O T E : T o check fo r flo o d in g , rem ove air cleaner, w ith accelerator to th e flo o r and check the ca rb u reto r to de
engine o ff and look into ca rburetor bore. Fuel w ill be term in e if th e choke valve is opening. If n o t, adjust the
dripping o ff nozzle a n d /o r carburetor w ill be very w e t. th ro ttle linkage and unlo ader, as specified.

C arb u re to r flo o d in g N O T E : B efo re rem oving th e ca rb u reto r air h o rn , use the


fo llo w in g p ro c ed u re w h ich m ay e lim in a te th e flo o d in g .
1. R em ove th e fuel line at th e c a rb u re to r and plug. C rank
and run th e engine u n til th e fuel b o w l runs d ry . T u rn
o ff th e engine and co nnect fuel line. T h e n re-start and
run engine. T h is w ill usually flush d irt past th e carbu
reto r flo a t needle and seat.
2. If d irt is in fuel system , clean th e system and replace
fuel filte r as necessary. If excessive d irt is fo u n d , re
m ove th e ca rb u reto r u n it. Disassem ble and clean.
3. Check flo a t needle and seat fo r p ro p e r seal. If a needle
and seat tester is n o t available, a p p ly m o u th su ction to
th e needle seat w ith needle installed. If th e needle is
de fe ctiv e, replace w ith a fa c to ry m atched set.
4. Check flo a t fo r being loaded w ith fu e l, bent flo a t hanger
or binds in th e flo a t arm .
N O T E : Check flo a t fo r fuel absorption by lig htly squeezing
betw een fingers. If wetness appears on surface or flo a t feels
heavy (Check w ith kn ow n good flo a t), replace the flo a t
assembly.
5. A djust flo a t as specified in carburetor overhaul section.

TRUCK SUPP - SERVICE


6M -2 8 ENGINE FUEL

Problem: e n g in e s t a r t s a n d s t a l l s

Engine does not have enough fast idle speed when cold. C heck and re-set th e fast idle setting and fast idle cam.

C hoke vacuum break u n it is n o t ad justed to sp ecification 1. A d ju s t vacuum break to sp ecification.


or u n it is defective.
2. If adjusted O .K ., check th e vacuum break fo r proper
o p e ratio n as follo w s:
O n th e e x te rn a lly m o u n ted vacuum break u n it, connect
a piece o f hose to th e n ip p le on th e vacuum break u n it
and apply suction by m ou th or use tool J -2 3 4 1 8 to
ap p ly vacuum . Plunger should m ove inw ard and hold
vacuum . If n o t, replace th e u n it.

N O T E : A lw a y s check th e fast idle cam a d ju s tm e n t befo re


adjusting vacuum break u n it.
C h o ke coil rod o u t o f ad ju stm en t. A d ju s t ch oke coil rod.

C h o ke valve a n d /o r linkage sticking or binding. 1. Clean and align ch oke valve and linkage. R eplace if
necessary.
2. Re-adjust if pa rt replacem ent is necessary.

Idle speed setting A djust low and curb idle speeds to specifications on label in
engine co m p artm en t.
N o t enough fuel in ca rb u reto r. 1. Check fuel p u m p pressure and vo lu m e.
2. Check fo r p a rtia lly plugged fuel in let filte r. R eplace if
d irty .
3. R em ove air horn and check flo a t adjustm ents as specified
in ca rburetor overhaul section.
C a rb u re to r flo o d in g . 1. C heck flo a t needle and seat fo r pro p e r seal. If a needle
N O T E : Also check ca rburetor flood ing w hen engine cranks and seat tester is n ot available, m o u th su ction can be
(turn over) but w ill not start or starts hard w hen cold. applied to th e needle seat w ith needle installed. If
needle is d e fe ctiv e, replace w ith a fa c to ry m atched set.
2. Check flo a t fo r being loaded w ith fu e l, b ent flo a t hanger
or binds in th e flo a t arm .

N O T E : Check flo a t fo r fuel ab sorption by lig htly squeezing


betw een fingers. If wetness appears on surface or flo a t feels
heavy (check w ith kn ow n good flo a t), replace the flo a t
assembly.

3. Check flo a t adjustm ents as specified in carburetor over


haul section.
4. If excessive d irt is found in the ca rb u reto r, clean the fuel
system and carburetor. Replace fuel filte r as necessary.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -29

Problem: e n g in e r u n s u n e v e n o r s u r g e s

PO SSIB LE CAUSE C O R R E C T IV E A CTIO N

Fuel R es trictio n Check all hoses and fuel lines fo r bends, kin ks or leaks.
S traig hten and secure in position.
C heck all fuel filte rs. If plugged or d ir ty - replace.
D ir t o r w a te r in fuel system. C lean fuel ta n k and lines. R em ove and clean c a rb u reto r.
Fuel level Adjust flo a t as specified in carburetor overhaul section.
Check fo r free flo a t and flo a t needle valve operation.
M ain m etering jet defective, loose or incorrect part. Replace as necessary.

Pow er system in carburetor not fu n c tioning p ro p e rly. Pow er F ree up o r replace as necessary.
valve sticking in dow n position.
V ac u u m leakage It is a b so lu te ly necessary th a t all vacuum hoses and gaskets
are p ro p e rly installed, w ith no air leaks. T h e c a rb u reto r
and m a n ifo ld should be evenly tightened to specified
to rq u e.

Problem: poor fu el ec o n o m y

E ngine needs co m p le te tu ne-up. C heck engine com pression. E x a m in e spark plugs, (if d irty
o r im p ro p e rly gapped, clean and re-gap o r replace). Check
ignition p o in t d w e ll, c o n d itio n , readjust ig n itio n poin ts if
necessary and check and reset ignition tim in g . C lean or
replace air cleaner e lem e n t if d irty . Check fo r restricted
exhaust system and in ta k e m a n ifo ld fo r leakage, m ake sure
all vacuum hoses are co nnected c o rre ctly .

C h o ke valve n o t fu lly opening. 1. Clean ch oke and free up linkage.


2. Check choke coil rod fo r proper ad justm ent. Reset to
specifications.

Fuel leaks. Check fuel ta n k , fuel lines and fuel p um p fo r an y fuel


leakage.
Power system in ca rburetor not fu n ctioning properly. Power F ree up or replace as necessary.
valve sticking in up position.
H igh fuel level in c a rb u re to r or ca rb u reto r flo o d in g . 1. Check fo r d irt in th e needle and seat. T est using suction
by m o u th or needle seat tester. If d e fe ctiv e, replace
needle and seat assem bly w ith fa c to ry m atched set.
2. Check fo r loaded flo a t.

3. Re-set carburetor flo a t as specified in ca rburetor overhaul


section.
4. If excessive d irt is present in th e c a rb u re to r b o w l, th e
c a rb u re to r should be cleaned.

Fuel being pulled fro m accelerato r system in to venturi R un engine at R P M w h ere n o zzle is feeding fu el. Observe
th ro u g h p um p je t. p um p je t. If fuel is feeding fro m je t, check p um p discharge
ball fo r p ro p e r seating b y fillin g ca vity above ball w ith
fuel to level o f casting. N o "leak d o w n should occur w ith
discharge ball in place. R e-stake or replace leaking check
b a ll, d e fe c tiv e spring, or retainer.
A ir bleeds or fuel passages in c a rb u re to r d ir ty or plugged. C lean c a rb u re to r o r overhaul as necessary.

TRUCK SUPr
6M -3 0 ENGINE FUEL

Problem: e n g in e h e s it a t e s o n a c c e l e r a t io n

D efe ctive accelerator p u m p system 1. R em ove air horn and check p u m p cup. If cracked,
scored or d is to rte d , replace th e p u m p plunger.
N O T E : A quick check o f th e p u m p system can be m ade as
fo llo w s. W ith th e engine o ff, rem ove air cleaner and look 2. C heck th e p u m p discharge ball fo r pro p e r seating an
in to th e c a rb u reto r bores and observe pum p stream , w h ile lo catio n . T h e p u m p discharge ball is located in a cavity
briskly opening th r o ttle valve. A fu ll stream o f fuel should n e xt to th e p u m p w e ll. T o check fo r pro p e r seating,
em it fro m pum p je t and strik e near th e cen ter o f th e rem ove air horn and gasket and fill ca vity w ith fu el. N o
venturi area. "le a k d o w n should occur. R estake and replace check
ball if leaking. M a k e sure discharge b a ll, spring, and re
tain er are p ro p e rly installed.

D ir t in pum p passages or p um p jet. Clean and B lo w o u t w ith compressed air.


Fuel level. Check fo r sticking flo a t needle or binding flo a t. Free up or
replace parts as necessary. Check and reset flo a t level as
specified in carburetor overhaul section.
Leaking air horn to flo a t b o w l gasket. T o rq u e air horn to flo a t bow l using p ro p e r tig h ten in g
procedure.
C arb u re to r loose on m a n ifo ld . T o rq u e c a rb u re to r to m a n ifo ld bolts. (1 0 -1 4 ft. lbs.).

D | # NO POW ER ON H E A V Y A C C E L E R A T IO N
Problem: o r a t h ig h s p e e d

C arb u re to r th r o ttle valve n ot going w id e open. (C heck A d ju s t th r o ttle linkage to o b ta in w id e open th r o ttle in
by pushing accelerato r pedal to flo o r). carburetor.
D irty or plugged fuel filte r. R eplace w ith a new filte r elem ent.
Pow er system no t operating. Check pow er valve fo r free up and d ow n m ovem ent.

F lo a t level to o low . 1. Check and reset flo a t level as specified in carburetor over
haul section.
F lo a t not dro p p in g fa r enough in to flo a t bow l. Check fo r bind ing flo a t hanger and fo r pro p e r flo a t align
m e n t in flo a t b o w l.
M ain m etering je t d ir ty , plugged or incorrect part. 1. If the main m etering jet is plugged or d irty and excessive
d irt is in fuel b o w l, carburetor should be com pletely dis
assembled and cleaned.

Problem: e n g in e s t a r t s h a r d w h e n h o t

C h o ke valve n o t opening co m p le te ly . 1. C heck fo r bind ing ch oke valve a n d /o r linkage. Clean


and free-up or replace parts as necessary.
D o n o t oil ch o ke linkage.
2. Check and adjust choke coil rod.

Engine flo o d ed - C a rb u re to r flo o d in g . See p rocedure under "E n g in e cranks, w ill n o t s ta rt .


N o fuel in carb u reto r. 1. Check fuel pum p. R un pressure and v o lu m e test.
2. Check flo a t needle fo r sticking in seat, o r bin d in g flo a t.
Leaking flo a t b o w l. F ill bow l w ith fuel and look fo r leaks.

TRUCK SUPP SERVICE


ENGINE FUEL 6M-31

4MV QUADRAJET CARBURETOR


The 1975 Non-California and California 350/400 V8 Refer to specifications section for 1975 4MV carburetor
vehicle of 6200 pounds gross vehicle weight (G.V.W.) adjustment specifications. Refer to 1974 Light Duty
and above will continue to use the basic 1974 4MV Truck Service Manual for service procedures,
carburetor.

M4MC/M4MCA QUADRAJET CARBURETOR


INDEX

General Description.......................................................6M-31 Service Operations............................................................6M-45


Theory of Operation......................................................6M-32 Diagnosis............................................................................. 6M-47
Maintenance and Adjustment.....................................6M-39

GENERAL DESCRIPTION
The M4MC-M4MCA model Quadrajet carburetors (fig. The 1975 M4MC/M4MCA Quadrajet carburetors have
36) are two stage carburetors of downdraft design. The the following features:
revised carburetors include the proven design features of 1. All models are calibrated to meet performance and
previous models. The triple venturi system (with l-7/32" emission requirements for the 1975 engines.
venturi) is used on the primary side of the Quadrajet
carburetor, with small l-3/8" throttle valve bores. The 2. The choke system has a choke housing and
triple venturi stack-up, plus small primary throttle valve thermostatic coil mounted on the carburetor float
bores, results in good fuel control during idle and part bowl. In addition, a dual vacuum break system is
incorporated to improve choke operation during the
throttle operation. warm-up period.
The secondary side has two large bores (2-1/4"). Using A two step fast idle cam is used on all models. A
the air valve principle in the secondary side, fuel is separate tang is added to the fast idle cam on models
metered in direct proportion to the air passing through for the 454" V-8 engine to provide a fast idle cam
the secondary bores. The carburetor part number is "pull-off" feature.
stamped on a vertical section of the float bowl, near the 3. For ease of field serviceability, alphabetical code
secondary throttle lever. Refer to the part number on the letters are included in the air horn, float bowl, and
bowl when servicing the carburetor. When replacing the throttle body at external tube locations to identify
float bowl assembly, follow the manufacturers instruc air, vacuum, and fuel hose routings under the hood.
tions contained in the service package so that the part 4. A 2" pleated paper fuel inlet filter is used for more
number can be transferred to the new float bowl. fuel filtering capacity. A longer fuel inlet nut is
mounted in the side inlet location to accommodate
AIR HO R N the 2" filter.
ASSEMBLY C H O KE VALVE
5. The float bowl casting is designed to use a new
ACCELERATOR plastic filler block above the float chamber, and a
metal baffle added to the pump well fill slot, to
reduce fuel slosh in the float chamber during severe
vehicle manuevers. A new float assembly is used
with revisions to the float chamber.
REAR V AC U
BREAK 6. M4MC and M4MCA models for 350 and 400 V-8
engine applications use a "windowless" type needle
seat for better fuel handling in the float bowl.
CHO KE
7. The Adjustable Part Throttle (A.P.T.) feature is
COVER
changed in that an adjustable metering rod
assembly, operating in a fixed jet, has been added
FRONT V A C U U M FUEL INLET to the float bowl on the choke housing side of all
BREAK models. The threaded metering rod is adjusted at
the factory to provide close tolerance control of fuel
Fig. 36 M 4M C /M 4M C A Q uadrajet C arburetor flow to the main metering system, thereby better

TRUCK SUPP SERVICE


6 M -3 2 ENGINE FUEL

controlling air/fuel ratios during the part throttle throttle lever, to open the primary throttle valves
range. slightly to lean out the rich air/fuel mixture in the
intake manifold. The deceleration throttle stop
On models designated M4MCA, a barometric pressure- vacuum unit requires new adjustment procedures.
sensitive aneroid (sometimes called a "bellows") is
included as an integral part of the threaded A.P.T. 10. On some models, an integral baffle has been added
metering rod assembly. The aneroid, being sensitive to to the bottom side of the secondary air valve. The
air pressure change (such as altitude), responds to a baffle provides improved mixture distribution from
change in air pressure to maintain control of part the secondary side at higher air flows.
throttle air/fuel ratios. 11. Some models have a milled slot added at the larger
diameter of the secondary metering rod tip. The
8. An expander (garter) spring has been added milled slot allows enough fuel to by-pass the orifice
beneath the plunger cup on the accelerator pump plate to keep the secondary main wells full of fuel
assembly for improved pump fuel delivery. when the air valve is in the closed position. This
9. A deceleration throttle step vacuum unit with insures adequate fuel supply in the main wells at all
bracket, is used on M4MCA models for California times to give immediate fuel delivery from the
Heavy Duty Trucks with the 454 V-8 engine. The secondary discharge nozzles.
vacuum unit and bracket assembly is mounted on The primary side of the carburetor has six systems of
the float bowl (similar to the Idle Stop Solenoid operation. They are float, idle, main metering, power,
location on some models). When manifold vacuum pump, and choke. The secondary side has one metering
is high, such as on deceleration, the vacuum system which supplements the primary main metering
diaphragm plunger moves outward, contacting the system and receives fuel from a common float chamber.

THEORY OF OPERATION

INDEX

Float System......................................................................6M-32 Main Metering System..................................................6M-34


Power System....................................................................6M-35
Idle System........................................................................6M-33 Air Valve Dashpot.......................................................... 6M-36
Exhaust Gas Recirculation........................................... 6M-34 Accelerating Pump System.......................................... 6M-36
Canister Purge................................................................. 6M-34 Choke System....................................................................6M-37
FLOAT SYSTEM (Fig. 3 7 ) On some models, no side windows are used in the float
The float system operates in the following manner: valve seat so that all fuel will be discharged over the top
of the float valve seat to control fuel turbulence in the
Fuel from the engine fuel pump enters the carburetor float bowl.
fuel inlet passage. It passes through the pleated paper
filter element, fuel inlet valve, and on into the float bowl The carburetor float chamber is internally vented by a
chamber. As the incoming fuel fills the float bowl to the vertical slot, cast in the air horn, located at the rear of
prescribed level, the float pontoon rises and forces the the primary venturis, and by a pressed-in vent tube
fuel inlet valve closed, shutting off fuel flow. As fuel is
used from the float bowl, the float drops allowing the
float valve to open, when more fuel again fills the bowl.
This cycle continues, maintaining a constant fuel level in
the float bowl. A new float assembly is used for
improved fuel handling in the float bowl.
The float pontoon is solid and is made of a light weight
closed cell plastic material. This feature gives added
buoyancy to allow the use of a single float to maintain
constant fuel levels. A float pull clip, fastened to the float
valve, hooks over the edge of the float arm at the center
rear. Its purpose is to assist in lifting the float valve off
its seat whenever fuel level in the float bowl is low.
CA U TIO N : Do not place pull clip through
small holes in top o f float arm. Severe flooding
will result.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -33

located in the air horn. The purpose of the vertical vent low pressure area and the fuel in the float bowl vented to
slot and vent tube is to balance air pressure acting on the atmosphere (high pressure), the idle system operates as
fuel in the float bowl with air flow through the follows:
carburetor bores. In this way, balanced air/fuel ratios Fuel flows from the float bowl down through the main
are maintained throughout all ranges of carburetor metering jets into the main fuel wells. It is picked up in
operation. Also, during periods of hot engine operation, the main wells by the two idle tubes (one for each bore)
the vents are used to relieve vapor pressures that build which extend into the wells. The fuel is metered at the
up in the float bowl, thereby preventing the pushing of lower tip of each idle tube and passes up through the
raw fuel through the discharge nozzles into the engine to tube. The fuel is mixed with air at the top of each idle
cause hard hot restarts. tube through an idle air bleed.
The float bowl casting is revised to accommodate the Then the fuel mixture crosses over to the idle down
addition of a new A.P.T. metering rod assembly. As a channels where it is mixed with air at the side idle bleed
result, a new air horn gasket and new plastic filler block located just above the idle channel restriction. The
are used. The new plastic filler block, located in the top mixture continues down through the calibrated idle
of the float chamber over the float valve, is used to channel restrictions, past the lower idle air bleeds and
prevent fuel slosh in the float bowl. In addition, a metal off-idle discharge ports where it is further mixed with
baffle is added to the pump well fill slot to further reduce air. The air/fuel mixture moves down to the idle mixture
fuel slosh in the float chamber. needle discharge holes where it enters the carburetor
New float bowl disassembly and assembly procedures are bores and blends with the air passing the slightly open
required with the addition of the A.P.T. metering rod throttle valves. The combustible air/fuel mixture then
assembly, new plastic filler block, and pump well baffle. passes through the intake manifold to the engine
cylinders.
IDLE SYSTEM The idle mixture needles are adjusted at the factory to
Each bore of the Quadrajet carburetor has a separate blend the correct amount of fuel mixture from the idle
and independent idle system to supply the correct air/ system with the air entering the engine at idle. Turning
fuel mixture ratios during idle and off-idle operation. the idle mixture needles inward (clockwise) decreases the
The idle system is used during this period because air idle fuel discharge and turning the mixture needles
flow through the carburetor venturi is not great enough outward (counter- clockwise) enriches the engine idle
to obtain efficient metering from the main discharge mixture. Idle mixture needles are adjusted at the factory
nozzles. and then limiter caps are installed to discourage idle
mixture needle readjustment in the field.
The idle system operates as follows:
M4MC-M4MCA carburetor models have a fixed idle air
During curb idle, the throttle valves are held slightly bypass system. This consists of air channels which lead
open by the idle speed screw or idle stop solenoid from the top of each carburetor bore in the air horn to a
plunger. The small amount of air passing between the point below each throttle valve. At normal idle, extra air
throttle valves and bores is regulated by this screw or passes through these channels supplementing the air
plunger to give the engine the desired idle speed. Since passing by the slightly opened throttle valves. The
the engine requires very little air for idle and low speeds, purpose of the idle air bypass system is to allow
fuel is added to the air to produce a combustible mixture reduction in the amount of air going past the throttle
by the direct application of vacuum (low pressure) from valves so they can be nearly closed at idle. This reduces
the engine manifold to the idle discharge holes below the the amount of air flowing through the carburetor venturi
throttle valves. With the idle discharge holes in a very to prevent the main fuel nozzles from feeding during
idle operation. The venturi system is very sensitive to air
flow and where larger amounts of idle air are needed to
maintain idle speed, the fixed idle air bypass system is
used.
As the primary throttle valves are opened from curb idle
to increase engine speed, additional fuel is needed to
combine with the extra air entering the engine. This is
accomplished by the slotted off-idle discharge ports. As
the primary throttle valves open they pass by the off-idle
ports, gradually exposing them to high engine vacuum
below the throttle valves. The additional fuel added from
the off-idle ports mixes with the increasing air flow past
the opening throttle valves to meet increased engine air
and fuel demands.
Further opening of the throttle valves increases the air
velocity through the carburetor venturi sufficiently to

TRUCK SUPP - SERVICE


6 M -3 4 ENGINE FUEL

cause low pressure at the lower idle air bleeds. As a Timed Bleed Purge
result, fuel begins to discharge from the lower idle air The timed bleed purge port is located in each bore next
bleed holes and continues to do so throughout operation to the off-idle discharge ports. The timed purge operates
of the part throttle to wide open throttle ranges, during off-idle, part throttle, and wide open throttle
supplementing the main discharge nozzle delivery. operation. This provides a larger purge capacity for the
vapor canister and prevents over-rich mixtures from
EXHAUST GAS R EC IR C U LA TIO N (E.G.R.) being added to the carburetor metering at any time.
(Fig. 3 8)
An Exhaust Gas Recirculation (E.G.R.) system is used on M A IN M ETER IN G SYSTEM (Fig. 3 9)
all models to control oxides of nitrogen (NOx) emissions. The main metering system supplies fuel to the engine
The E.G.R. valve is operated by a vacuum signal taken from off-idle to wide open throttle. The primary bores
from the carburetor. Two punched ports, one located just (two smaller bores) supply air and fuel during this range.
above the throttle valve and the other near the upper As the primary throttle valves are opened beyond the
edge of the throttle body casting, provide a timed off-idle range allowing more air to enter the engine
vacuum signal port for E.G.R. valve operation in the off- intake manifold, air velocity increases in the carburetor
idle and part throttle ranges of the carburetor. venturi to cause the main metering system to operate as
The purpose of the E.G.R. system is to supply a metered follows:
amount of exhaust gases to the combustion mixtures and Fuel from the float bowl flows between the main
lower combustion temperatures, thereby reducing oxides metering rods and jets into the main fuel wells. It passes
of nitrogen during these ranges of engine operation. upward in the main well and is bled with air by an air
The port system operates as follows: bleed located at the top of the well. The fuel is further
bled air through calibrated air bleeds located near the
As the throttle valve is opened beyond the idle position, top of the well in the carburetor bores. The fuel mixture
the first vacuum port for the E.G.R. system is exposed to then passes from the main well through the main
manifold vacuum to supply a vacuum signal to the discharge nozzles into the boost venturi. At the boost
E.G.R. valve. To control the vacuum signal at the lower venturi, the fuel mixture then combines with the air
port, the upper port bleeds air into the vacuum channel entering the engine through the carburetor bores. It then
and modulates the amount of vacuum signal supplied by passes as a combustible mixture through the intake
the lower E.G.R. port. In this manner, the E.G.R. valve manifold and on into the engine cylinders.
can be timed for precise metering of exhaust gases to the
intake manifold, dependent upon location of the ports in The main metering system is calibrated by tapered and
the carburetor bore and degree of throttle valve opening. stepped metering rods operating in metering jets and
also through the main well air bleeds.
As the throttle valves are opened further in the part During cruising speeds and light engine loads, manifold
throttle range, the upper port ceases to function as an air vacuum is high. In this period, the engine will run on
bleed and is gradually exposed to manifold vacuum to leaner mixtures than required during heavy loads.
supplement the vacuum signal at the lower port and
maintain correct E.G.R. valve position. The primary main metering rods are connected to a
The upper and lower vacuum ports connect to a cavity in vacuum responsive piston which operates against spring
the throttle body which, in turn, through a passage, tension. Engine manifold vacuum is supplied to a power
supply the vacuum signal to an E.G.R. tube pressed into piston through a vacuum channel. When the vacuum is
the front corner of the throttle body casting. The tube in high, the piston is held downward against spring tension
the throttle body is connected by a hose to the E.G.R.
valve located on the intake manifold.
The E.G.R. valve remains closed during periods of
engine idle and deceleration to prevent rough idle, which
could be caused from excessive exhaust gas contamina
tion in the idle air/fuel mixtures.

CANISTER PURGE (Fig. 3 8 )


In that the fuel tank is not vented to atmosphere and
fuel vapors are collected in the vapor canister, a purge
port is provided in the carburetor throttle body. The
purge port leads through passages to a common chamber
in the throttle body to a purge tube which connects by a
hose to the vapor canister. The purge port consists of a
separate timed canister purge.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M 35

and the larger diameter of the metering rod is in the the high speed fuel feeds, supplementing fuel flow from
main metering jet orifice. This results in leaner fuel the main metering system. The pull-over enrichment
mixtures for economy operation. As engine load system begins to feed fuel at approximately eight pounds
increases and engine manifold vacuum drops, spring of air per minute and continues to feed at higher engine
pressure acting on the power piston overcomes the speeds to provide the extra fuel necessary for good
vacuum pull and gradually lifts the metering rods engine performance.
partially out of the main metering jets. This enrichens
the fuel mixture enough to give the desired power to POWER SYSTEM (Fig. 4 0 )
overcome the added load.
The power system provides extra mixture enrichment for
Adjustable Part Throttle heavy acceleration or high speed operation. The richer
An adjustable part throttle (A.P.T.) feature is used in mixture is supplied through the main metering system in
production to maintain very close tolerance of air/fuel the primary and secondary sides of the carburetor.
mixtures during part throttle operation. The power system located in the primary side consists of
An adjustable metering rod assembly with filler spool, or a vacuum piston and spring located in a cylinder
combination aneroid-metering rod assembly, has been connected by a passage to intake manifold vacuum. The
added to the float bowl on the choke housing side of all spring located beneath the vacuum operated power
models. (For an explanation of aneroid, see Altitude piston tends to push the piston upward against manifold
Compensation below). The adjustable metering rod, with vacuum.
or without aneroid, provides close tolerance control of In part throttle and cruising ranges, manifold vacuums
fuel flow to the main metering system during the part are sufficient to hold the power piston down against
throttle range. spring tension so that the larger diameter of the
The A.P.T. adjustment is performed at the factory by metering rod is held in the main metering jet orifice.
turning the threaded metering rod, or the aneroid- Mixture enrichment is not necessary at this point.
metering rod assembly, up or down to position the However, as engine load is increased to a point where
metering rod in a fixed metering jet located at the extra fuel enrichment is required, the spring tension
bottom of the fuel reservoir in the float bowl. This sets overcomes the vacuum pull on the power piston and the
the part throttle air/fuel mixture to the desired flow tapered primary metering rod moves upward in the main
band. metering jet orifice. The smaller diameter of the
metering rod allows more fuel to pass through the main
Altitude Compensation metering jet and enrich the mixture flowing into the
primary main wells and out the main discharge nozzles.
On M4MCA models, a barometric pressure-sensitive
aneroid (sometimes called a "bellows") is included as an As the engine speed increases, the primary side of the
integral part of the threaded A.P.T. metering rod carburetor can no longer meet the engine air and fuel
assembly. The aneroid, being sensitive to air pressure requirements. To meet these demands, the secondary
change (such as altitude), automatically either expands side of the carburetor is used.
or contracts to lower or raise the metering rod in the As the secondary throttle valves are opened, engine
fixed metering jet. In this way, the aneroid responds to a manifold vacuum (low pressure) is applied directly
change in air pressure to maintain control of part beneath the air valves. Atmospheric pressure on top of
throttle air/fuel ratios. the air valves forces the air valves to open against spring
NOTE: The position of the A.P.T. metering rod in tension and allows metered air to pass through the
the fixed jet is extremely critical. Adjustment secondary bores of the carburetor.
should NEVER be attempted unless a replacement When the secondary throttle valves begin to open, the
is required. The threaded A.P.T. metering rod accelerating well ports are exposed to manifold vacuum.
should be readjusted carefully following adjust
ment procedures provided.
Pull-Over Enrichm ent (P.O.E.)
A fuel pull-over enrichment (P.O.E.) circuit is used to
supply extra fuel at higher engine speeds. The purpose
of the supplementary fuel feeds is to allow the use of
lean fuel mixtures during part throttle operation and still
provide the extra fuel needed at higher engine speeds for
good performance.
Two calibrated holes, one in each primary bore, are
located just above the choke valve and are supplied fuel
from the float bowl. During high carburetor air flows,
low pressure created in the air horn bore pulls fuel from

TRUCK SUPP SERVICE


6 M -3 6 ENGINE FUEL

The ports immediately start to feed fuel from the point, the vacuum break rod is in the forward end of the
accelerating wells and continue to feed fuel until the fuel slot in the air valve lever and the air valves are closed.
in the well is gone. This prevents a momentary leanness During acceleration or heavy engine loads, when the
as the air valve opens and before the secondary nozzles secondary throttle valves are open, the manifold vacuum
begin to feed fuel. drops. The spring located in the vacuum break
As the air valves open, a plastic eccentric cam attached diaphragm overcomes the vacuum pull and forces the
to the center of the air valve shaft rotates and, through plunger and link outward which, in turn, allows the air
the metering rod lever, lifts the secondary metering rods valves to open. The opening rate of the air valves is
out of the secondary orifice plates. The fuel mixture controlled by the calibrated restriction in the vacuum
travels from the main wells through the secondary inlet nipple in the diaphragm cover. This gives the
discharge nozzles where it sprays into the secondary dashpot action required to delay air valve opening
bores supplementing the air/fuel mixture delivered from enough for efficient fuel flow from the secondary
the primary bores. In this way, correct air/fuel mixtures discharge nozzles.
through the secondary bores are controlled by the
position of the metering rods in the orifice plates. ACCELERATING P U M P SYSTEM (Fig. 4 2 )
There are other features incorporated in the secondary During quick acceleration when the throttle is opened
metering system as follows: rapidly, the air flow and manifold vacuum change
1. The main well bleed tubes textend below the fuel almost instantaneously. The fuel, which is heavier, tends
level in the main well. These bleed air into the fuel to lag behind causing a momentary leanness. The
in the well to quickly emulsify the fuel with air for accelerator pump is used to provide the extra fuel
good atomization as it leaves the secondary necessary for smooth operation during this time.
discharge nozzles. The accelerating pump system consists of a spring loaded
2. Two baffle plates are used, one in each secondary pump plunger and pump return spring, operating in a
bore. They extend up and around the secondary fuel well. The pump plunger is operated by a pump lever
fuel discharge nozzles. Their purpose is to provide on the air horn which is connected directly to the throttle
good fuel distribution at lower air flows by lever by a pump rod.
preventing too much fuel from going to the front of When the pump plunger moves upward in the pump
the engine. As mentioned earlier, a baffle is added well, as happens during throttle closing, fuel from the
on the underneath side of the air valve on some float bowl enters the pump well through a slot in the
applications to aid in good mixture distribution well. It flows past the synthetic pump cup seal into the
from the secondary side of the carburetor. bottom of the pump well. The pump cup is the floating
type. (The cup moves up and down on the pump plunger
AIR VALVE DASHPO T (Fig. 4 1 ) head - see inset). When the pump plunger is moved
The air valve dashpot operates off of the front choke upward, the flat on the top of the cup unseats from the
vacuum break diaphragm unit. The secondary air valve flat on the plunger head and allows free movement of
is connected to the vacuum break unit by a rod, to fuel through the inside of the cup into the bottom of the
control the opening rate of the air valve. This delays the pump well. This also vents any vapors which may be in
air valve opening rate to prevent secondary discharge the bottom of the pump well so that a solid charge of
nozzle "lag". fuel can be maintained in the fuel well beneath the
Whenever manifold vacuum is above approximately 5" plunger head.
to 6" Hg., the vacuum break diaphragm is seated
(plunger is fully inward) against spring tension. At this

Fig. 41 A ir Valve Dashpot Fig. 42 Accelerating Pum p System

TRUCK SUPP SERVICE


ENGINE FUEL 6M -37

When the throttle valves are opened, the connecting lever comes to rest on the high step of the fast idle cam.
linkage forces the pump plunger downward. The pump During engine cranking, the closed choke valve restricts
cup seats instantly and fuel is forced through the pump air flow through the carburetor bores to provide a richer
discharge passage where it unseats the pump discharge starting mixture. When the engine starts, manifold
check ball and passes on through the passage to the vacuum applied to the front vacuum break diaphragm
pump jets, located in the air horn, where the fuel sprays opens the choke valve to a point where the engine will
into the venturi of each bore. run without loading or stalling lean. When the choke
An expander (garter) spring, located beneath the pump valve moves to the vacuum break position, the fast idle
plunger cup, is used to assist in maintaining constant cam follower will drop from the high step on the fast
pump cup to pump well contact for good pump fuel idle cam to the next lower step (second step) when the
delivery. throttle is opened.
A metal baffle is installed in the slot in the pump well to Engine vacuum supplied through an orifice in the choke
prevent fuel slosh into the pump well during severe housing pulls heat from the manifold heat stove into the
vehicle maneuvers. housing and heat gradually relaxes choke coil tension
which allows the choke valve to continue opening
The pump plunger is spring loaded - the upper duration through inlet air pressure pushing on the off-set choke
spring is balanced with the bottom pump return spring valve. As the thermostatic coil warms up, the choke coil
so that a smooth sustained charge of fuel is delivered lever in the housing moves the choke rod up in the slot
during acceleration. in the upper choke lever to open the choke valve further
The pump discharge check ball seats in the pump to the near wide open position, while still keeping the
discharge passage during upward motion of the pump cam follower lever on the low step of the fast idle cam.
plunger so that air will not be drawn into the passage; In this way, the fast idle speed is maintained long
otherwise, a momentary lag in acceleration could result. enough to keep the engine from stalling, yet allows use
of a choke coil which lets the choke valve open quickly.
During high speed operation, a vacuum exists at the As the thermostatic coil warms up to the fully hot
pump jets. A cavity just beyond the pump jets is vented position, the choke coil lever allows the fast idle cam to
to the top of the air horn, outside the carburetor bores. drop down so that the cam follower is completely off the
This acts as a suction breaker so that when the pump is steps of the fast idle cam.
not in operation, fuel will not be pulled out of the pump On all models (except 454 V-8), the rear vacuum break
jets into the venturi area. This insures a full pump diaphragm unit includes a choke closing assist spring.
stream when needed and prevents any fuel "pull-over" The spring assists in closing the choke valve, along with
from the pump discharge passage. tension from the thermostatic coil, for improved engine
starting. The choke closing assist spring exerts pressure
CHOKE SYSTEM (Fig. 4 3 ) on the vacuum break rod to assist in closing the choke
The M4MC-M4MCA models have an integral choke valve during engine starting. When the engine starts and
housing and thermostatic coil assembly mounted on the the vacuum break diaphragm seats, the closing spring
carburetor float bowl. Dual vacuum units are used on hits a stop on the plunger stem and no longer exerts
these models with a special screw adjustment added to pressure on the vacuum break rod.
front vacuum break unit. In addition, a 2-step fast idle A clean air purge feature is used in the rear vacuum
cam is used. break unit. A filter element is installed internally, with a
The choke system operates as follows: small bleed hole located in the end cover of the
diaphragm unit. During engine operation, vacuum
acting upon the diaphragm unit pulls a small amount of
The thermostatic coil in the choke housing is calibrated filtered air through the bleed hole to purge the system of
to hold the choke valve closed when the engine is cold. any fuel vapors or dirt contaimination which might be
To close the choke valve, depress the accelerator pedal pulled into the bleed check valve located inside the
completely to allow the fast idle cam follower lever to diaphragm unit. During adjustment of the rear vacuum
clear the steps of the fast idle cam. At this point, tension break unit, it will be necessary to plug the bleed hole
of the thermostatic coil will rotate the choke valve to the with a piece of tape.
closed position and through rotation of the upper choke M4MC-M4MCA models for the 454 V-8 engine use the
lever and movement of the choke rod, the cam follower fast idle cam "pull-off" feature.

TRUCK SUPP SERVICE


6M -3 8 ENGINE FUEL

FRONT VA C UU M
BREAK A D J U S T IN G
SCREW
CHOKE VALVE
FRONT V A C U U M
CHOKE
BREAK
ROD D IA P H R A G M
REAR
VACUUM
BREAK
D IA P H R A G M
(SEE IN S E T )

D IA P H R A G M SECONDARY / IN S ID E ^ ^ .
F IL T E R
LOCKOUT / CUP TANG
B U C K IN G LEVER F A S T BAFFLE ' DLE
/S P R IN G ID L E D H rrL C A D J U S T IN G
CAM SCREW
PURGE
FOLLOW ER
F IL T E R

DELAY

S P R IN G
CHECK
VALVE
(350/400 ENGINE)
CAM PULL-OFF FEATURE
FRONT V A C U U M
PU LL OFF BREAK A D J U S T IN G
TANG SCREW

FRONT V A C U U M
BREAK
D IA P H R A G M
L IN K TO R EA R
V A C U U M U N IT

REAR
VACUUM
BREAK
D IA P H R A G M

SECONDARY IN S ID E \ AQX ^ UNLOADER


LOCKOUT / ri)P FAST TANG
LEVER FAST BAFFLE ' DLE
ID L E B M rrLC A D J U S T IN G
CAM SCREW
FOLLOWER

(454 ENGINE)
Fig. 43 Choke System

TRUCK SUPP SERVICE


ENGINE FUEL 6M -39

Manifold vacuum to the rear vacuum break diaphragm valve lock-out pin. This allows the secondary throttle
is controlled by a water temperature switch mounted in valves to open for hot engine power requirements.
the engine cooling jacket near the front of the engine. The choke system is equipped with an unloader feature
During cold operation when manifold vacuum is applied which is designed to open the choke valve partially,
to rear vacuum break diaphragm, vacuum break rod should the engine become flooded or loaded. To unload
rotates the vacuum break lever to "pull-off" the fast idle the engine, the accelerator pedal must be depressed so
cam from the high step to the lower step setting. Thus, that the throttle valves are held wide open. A tang on the
the cam "pull-off" feature prevents prolonged high idle lever on the choke side of the throttle shaft contacts the
speeds during the engine warm-up period. fast idle cam and through the intermediate choke shaft
On all models, the secondary throttle valves are locked forces the choke valve slightly open. This allows extra air
out during choke operation and the engine warm-up to enter the carburetor bores and pass on into the engine
period. As the thermostatic coil warms up to the fully hot manifold to lean out the fuel mixture so that the engine
position, the choke coil lever allows the fast idle cam to will start.
drop down so that the cam follower is completely off the As mentioned, an adjustment screw has been added to
steps of the fast idle cam. As the fast idle cam drops the front vacuum break diaphragm plunger stem and a
down, it strikes the secondary throttle valve lock-out change in vacuum break adjustment procedure is
lever and pushes it away from the secondary throttle required on all models.

MAINTENANCE AND ADJUSTMENT


INDEX

Idle Speed Ajustment................................................... 6M-39 Front Vacuum Break Adjustment............................ 6M-41


Idle Mixture..................................................................... 6M-39 Rear Vacuum Break Adjustment............................. 6M-42
Idle Mixture Adjustment.......................................... 6M-40 Automatic Choke Coil Adjustment........................ 6M-42
Pump Rod Adjustment................................................ 6M-40 Unloader Adjustment................................................... 6M-42
Fast Idle Adjustment................................................... 6M-40 Secondary Throttle Valve Lock-Out Adjustment 6M-42
Secondary Closing Adjustment................................. 6M-44
Choke Coil Lever Adjustment.................................. 6M-40 Secondary Opening Adjustment............................... 6M-44
Fast Idle Cam (Choke Rod) Adjustment............. 6M-41 Air Valve Spring Wind-Up Adjustment............... 6M-45
Air Valve Dashpot Adjustment................................ 6M-41 Deceleration Throttle Stop Adjustment................. 6M-45
IDLE SPEED 5. Start engine, check timing and adjust as required.
Two idle speeds are required and are controlled and Connect vacuum advance hose.
adjustable by the idle stop solenoid. The purpose of two 6. Disconnect electrical connector at idle stop solenoid.
idle speeds is to prevent dieseling when ignition is turned
off. 7. With automatic transmission in Drive or manual
transmission in Neutral, turn low idle screw to
One speed is Curb Idle Speed which is normal engine obtain low idle speed at specified rpm.
idle and solenoid is energized. Where solenoid is used,
the second speed is Low Idle Speed and when solenoid is 8. Reconnect electrical connector to solenoid and crack
de-energized the carburetor throttle plate closes further throttle slightly, to extend solenoid plunger.
than at normal engine idle. 9. Turn solenoid plunger screw in or out to set curb
LOW IDLE AND CURB IDLE SPEED idle speed to specified rpm.
A D JU STM EN T 10. Shut off engine and remove tachometer.
Refer to Vehicle Emission Control Information label on 11. If vehicle is equipped with air-conditioning, reset idle
vehicle for latest certified specification information speed to specification with air-conditioning ON. (350
which may differ from specifications in manual. and 400 cubic inch with heavy duty emission systems
only).
1. With engine at normal operating temperature, air
cleaner on, choke open, and air conditioning OFF, 12. Connect fuel tank hose to vapor canister.
connect a tachometer to engine.
2. Set parking brake and block drive wheels. IDLE M IX T U R E
3. Disconnect fuel tank hose from vapor canister. The idle mixture is factory preset and idle mixture
screws are capped with plastic limiter caps. The cap
4. Disconnect vacuum advance hose at distributor and permits screw to be turned about one turn leaner
plug hose. (clockwise) without breaking cap. The idle mixture is set

TRUCK SUPP - SERVICE


6M -40 ENGINE FUEL

to achieve the smoothest idle while maintaining emission


levels within standards prescribed by Federal Law.
At major carburetor overhaul the idle mixture may be
adjusted. Before suspecting idle mixture as cause of poor
idle quality, check ignition system, distributor, dwell and
timing, air cleaner, PCV system, evaporation emission
control and compression pressures. Also check all
vacuum hoses and connections for leaks and check
torques of carburetor attachment bolts. Adjustment is
made using a tachometer.
Refer to Vehicle Emission Control Information label on
vehicle for latest certified specification information
which may differ from specifications in manual.
Idle M ixture Adjustm ent
1. With engine at normal operating temperature, air
cleaner on, choke open, and air conditioning OFF,
connect a tachometer to engine. Fig. 4 4 Pum p Rod A d ju s tm en t

2. Set parking brake and block drive wheels. 4. To adjust, support pump lever with screwdriver and
bend pump lever.
3. Disconnect fuel tank hose from vapor canister. 5. Adjust idle speed.
4. Disconnect vacuum advance hose at distributor and
plug hose. FAST IDLE A D JU S TM E N T (Fig. 4 5 )(B e n c h )
5. Start engine, check timing and adjust as required. 1. Hold cam follower lever on highest step of fast idle
Connect vacuum advance hose. cam.
6. With engine at normal operating temperature (not 2. Turn fast idle screw out until primary throttle
hot), air conditioning off, and air cleaner installed, valves are closed.
position transmission selector in drive (automatic 3. Turn fast idle screw in to contact lever, then turn
transmission) or neutral (manual transmission). screw in specified number of turns to adjust.
7. Break off tab on mixture cap using needle nose 4. Recheck fast idle speed on the car setting to
pliers. specifications listed on the underhood tune-up label.
8. Adjust idle rpm to the higher of the two idle speeds
specified. (Example 650/600). CHOKE COIL LEVER A D JU S T M E N T (Fig. 4 6 )
9. Equally enrich (turn out) mixture screws until 1. Loosen three retaining screws and remove the
maximum idle speed is achieved. Reset speed if thermostatic cover and coil assembly from choke
necessary to the higher specified idle speed. housing.
10. Equally lean (turn in) mixture screws until the lower 2. Push up on thermostatic coil tang (counterclock
specified idle speed is achieved (Example 650/600). wise) until choke valve is closed.
11. Connect fuel tank vent hose.
PU M P ROD A D JU S TM E N T (Fig. 4 4 )
1. With fast idle cam follower off steps of fast idle
cam, back out carburetor idle speed screw until the
throttle valves are completely closed in bore.
NOTE: Be sure secondary actuating rod is not
keeping the primary throttle valves from closing. If
the primary throttle valves do not completely close,
bend the secondary closing tang out of position
closing tang out of position and then readjust after
pump adjustment.
2. Place pump rod in specified hose in lever.
3. Gauge from top of choke valve wall, next to vent
stack, to top of pump stem.
Fig. 4 5 Fast Idle A d ju s tm e n t

TRUCK SUPP SERVICE


ENGINE FUEL 6M-41

AIR VALVE DASHPO T A D JU S T M E N T (Fig.


48)
1. Seat front vacuum break diaphragm using outside
vacuum source.
2. Air valves must be closed completely.
3. Place specified gauge between air valve dashpot and
end of slot in air valve lever.
4. Bend air valve dashpot rod at point shown if
necessary to adjust.
FRO NT VA C U U M BREAK A D JU S TM E N T
(Fig. 49 )
1. Loosen three retaining screws and remove thermo
static cover and coil assembly from choke housing.
Fig. 4 6 Choke Coil Lever A d ju s tm en t
2. Place cam follower lever on highest step of fast idle
3. Insert specified plug gauge in hole in choke cam.
housing. 3. Seat the front vacuum diaphragm using an outside
4. Lower ege of choke coil lever should just contact vacuum source.
side of plug gauge. 4. Push up on inside choke coil lever until tang on
5. Bend choke rod at point shown to adjust (see inset). vacuum break lever contacts tang on vacuum break
plunger.
FAST IDLE CAM (CHOKE ROD)
A D JU S TM E N T (Fig. 4 7 )
1. Make fast idle adjustments.
2. Place can follower lever on second step of fast idle
cam held firmly against rise of high step.
3. Close choke valve by pushing upward on choke coil
lever inside choke housing.
4. Gauge between upper edge of choke valve and
inside air horn wall.
5. Bend tang on fast idle cam to adjust. Make sure
tang lays against cam after bending.
6. Recheck fast idle adjustment on the car, setting to
specifications listed on the underhood tune-up label.

Fig. 4 9 Front Vacuum Break A d ju stm en t

TRUCK SUPP - SERVICE


6M -4 2 ENGINE FUEL

5. Place gauge between upper edge of choke valve and 5. Tighten retaining screws.
inside air horn wall. Dimension should be as
specified.
6. To obtain correct specification, turn the adjustment
screw on the vacuum break plunger lever. UNLOADER A D JU S TM E N T (Fig. 52)
7. After adjustment, install vacuum hose to vacuum 1. Install choke thermostatic coil and cover assembly
break unit. with gasket in choke housing and align index mark
on cover with specified point on housing (see
REAR VACUUM BREAK A D JU S TM E N T (Fig.
Automatic Choke Coil Adjustment, Figure 51).
5 0) 2. With choke valve completely closed, hold throttle
1. Loosen three retaining screws and remove thermo valves wide open.
static cover and coil assembly from choke housing. NOTE: On warm engine, close choke valve by
2. Place cam follower lever on highest step of fast idle pushing up on tang of intermediate choke lever
cam. that contacts fast idle cam. A rubber band may be
3. Plug the bleed hose in the end cover of the vacuum used for this purpose.
break unit using a small piece of tape. 3. Gauge between upper edge of choke valve and air
4. Seat the rear vacuum diaphragm using an outside horn wall.
vacuum source. 4. Bend tang on fast idle lever as shown to adjust.
5. Push up on the choke coil lever inside choke
housing toward closed choke. C A UTION : Check to be sure tang on fast idle
6. With choke rod in bottom of slot in choke lever, lever is contacting center point o f fa st idle cam
gauge between upper edge of choke valve and air after adjustment.
horn wall. Dimension should be as specified.
7. Bend vacuum break rod at point shown if necessary SECONDARY THRO TTLE VALVE LOCK-OUT
to adjust.
A D JU S TM E N T (Fig. 53)
8. After adjustment, remove tape from end cover of
vacuum break unit. Install vacuum hose to vacuum
break unit. Secondary Lock-Out Lever Clearance
1. Hold choke valve and secondary throttle valves
A U TO M A T IC CHOKE CO IL A D JU S TM E N T closed.
(Fig. 5 1) 2. Using specified plug gauge, measure clearance
1. Install choke thermostatic coil and cover assembly between lock-out pin and lock-out lever as shown.
with gasket between choke cover and choke 3. If necessary, bend lock-out pin at point shown to
housing. obtain specified clearance.
NOTE: On all models, except 454 V-8, tang on Opening Clearance
thermostatic coil must be installed in slot in inside 4. Hold choke valve wide open by pushing down on
choke coil lever pick-up arm. tail of fast idle cam.
2. Place fast idle cam follower on the highest step of 5. Hold secondary throttle valves slightly open.
the fast idle cam.
6. Using specified plug gauge, measure clearance
3. Rotate cover and coil assembly counterclockwise between end of lock-out pin and toe of lock-out
until choke valve just closes. lever as shov/n.
4. Align index point on cover with specified index 7. If necessary, file off end of lock-out pin to obtain
point on choke housing. specified clearance.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -43

@ G A U G E B ETW EEN A IR
NOTE: HOLD H ORN W ALL & UPPER EDGE
GAUGE OF C H O K E V A L V E
VER TIC A LLY
C LO SIN G
A S S IS T R O D IN B O T T O M
S P R IN G OF SLOT

NOTE: PLUG PURGE


BLEED HOLE W IT H A
PIECE OF M A S K IN G
TAPE

(6) BEND ROD


P U S H UP ON C H O K E COIL LEVER T O W A R D S
(2) TO A D J U S T CLOSED CHOKE
SEAT REAR V A C U U M
BREAK D IA P H R A G M U S IN G ( 7 ) PLACE C A M FO LLO W ER LEVER ON H I G H E S T
O U T S ID E V A C U U M SO U RC E S TEP OF F A S T IDLE C A M

(ALL EXCEPT 45 4 ENGINE)

CHOKE VALVE
S H O U L D BE


W ID E OPEN
(VER TIC A L)

R O D IN B O T T O M
OF SLO T

/T n P U SH UP ON C H O K E COIL LEVER T O W A R D S
^ CLOSED CHOKE

SEAT REAR V A C U U M PLACE C A M FOLLO W ER LEVER O N H IG H E S T
BREAK D IA P H R A G M U S IN G S TEP OF F A S T IDLE C A M
O U T S ID E V A C U U M SO U RC E

(454 ENGINE)
Fig. 50 Rear Vacuum Break A d ju stm en t

TRUCK SUPP - SERVICE


6 M -4 4 ENGINE FUEL

SECONDARY CLOSING A D JU S T M E N T (Fig.


54 )

cOJ__IL r'i
1. Pre-set carburetor speed screw to specifications.
2. Hold choke valve wide open with cam follower lever
off steps of fast idle cam.
3. Using specified gauge, measure clearance between
slot in secondary throttle valve pick up lever and
secondary actuating rod.
4. Bend secondary closing tang on primary throttle
lever as shown to adjust.
Fig. 5 1 A u to m a tic Choke Coil A d ju stm en t

( 3 ) O N W A R M EN G IN E , C L O S E C H O K E
V A L V E BY P U S H IN G U P O N TA N G
O N V A C U U M B R E A K L EV ER
(H O LD IN P O S IT IO N W ITH R U B B E R

Fig. 5 2 U n lo a d er A d ju s tm en t
SECONDARY O PENING A D JU S T M E N T (Fig.
55)

1. Lightly open primary throttle lever until link just


CHOKE VA LV E
contacts tang on secondary lever.
2. With link against tang, the link should be in center
of slot in the secondary lever.
(S T E P 2) 3. Bend tang on secondary lever, as shown, if
necessary to adjust.

H O L D C H O K E V A L V E W ID E
O P E N B Y P U S H IN G D O W N O N
T A I L O F F A S T ID L E C A M

F IL E E N D O F PIN/ ------
B E N D P IN FO R C L E A R A N C E
TO A D J U S T .0 1 5 M A X ( C H E C K FO R N O
C LE AR AN C E B U R R S AFTER
F IL IN G )


SE CO ND A RY LO CKO UT
O P E N IN G C L E A R A N C E

Fig. 5 3 Secondary T h ro ttle Valve Lock-Out


A d ju s tm e n t

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -45

AIR VALVE SPRING W IN D -U P


A D JU S TM E N T (Fig. 56)

1. Remove front vacuum break diaphragm unit and


air valve dashpot rod.
2. Loosen lock screw using special hex wrench.
3. Turn tension adjusting screw counterclockwise until
air valve opens part way.
4. Turn tension adjusting screw clockwise while
tapping lightly on casting with handle of a
screwdriver.
5. When air valve just closes, turn tension adjusting
screw clockwise specified number of turns after
spring contacts pin.
6. Tighten lockscrew and replace air valve dashpot rod
and front vacuum break diaphragm unit and Fig. 5 6 Air Valve Spring W in d -U p A d ju stm en t

bracket.
D E C E L E R A T IO N T H R O T T L E S T O P
A D J U S T M E N T (F ig . 5 7 )

1. Adjust carburetor idle speed screw to specifications.


2. Push hex end of throttle stop plunger in (toward
throttle lever) until plunger stem hits stop inside
diaphragm unit.
3. With plunger held inward against stop, turn
plunger adjusting screw in or out to obtain specified
decel R.P.M.

Fig. 5 7 D eceleration T h ro ttle Stop A d ju s tm en t

SERVICE OPERATIONS
INDEX
Carburetor Replacement.............................................. 6M-45 Air Horn Tightening Sequence................................ 6M-46
Fuel Filter Replacement............................................. 6M-46
CARBURETOR REPLACEM ENT (Fig. 58) 5. If equipped with automatic downshift cable,
Removal
disconnect cable.
Flooding, stumble on acceleration and other perform 6. Remove carburetor attaching bolts and remove
ance complaints are. in many instances, caused by carburetor.
presence of dirt, water, or other foreign matter in 7. Remove insulator.
carburetor. To aid in diagnosis, carburetor should be
carefully removed from engine without draining fuel Installation
from bowl. Contents of fuel bowl may then be examined It is good shop practice to fill carburetor bowl with a
for contamination as carburetor is disassembled. Check small amount of unleaded fuel before installing
filter. carburetor. This reduces strain of starting motor and
1. Remove air cleaner and gasket. battery and reduce the possibility of backfiring while
attempting to start engine. The carburetor float and
2. Disconnect fuel and vacuum lines from carburetor. intake needle and seat can also be checked. Operate
3. Disconnect fresh air hose and choke hose from throttle lever several times and check discharge from
choke system. pump jets before installing carburetor.
4. Disconnect accelerator linkage. 1. Clean throttle body and intake manifold sealing
surfaces.
TRUCK SUPP - SERVICE
ENGINE FUEL 6M -46

4. Connect downshift cable and adjust as required.


5. Connect accelerator linkage.
6. Connect fresh air hose and choke hose to choke
system.
7. Connect fuel and vacuum lines.
8. Install air cleaner.
9. Refer to Maintenance and Adjustment and check
idle speed.
FUEL FILTER REPLACEM ENT
A plugged fuel filter will restrict fuel flow or bypass
foreign material into carburetor and will result in a loss
of engine power or rough (pulsating) engine feel,
especially at high engine speeds.
1. Disconnect fuel line-connection at inlet fuel filter
nut.
2. Remove inlet fuel filter nut from carburetor.
3. Remove filter element and spring.
4. Install element spring and filter element in
Fig.59 - A ir Horn T ig h ten in g Sequence
carburetor.
5. Install new gasket on inlet fitting nut and install nut
in carburetor and tighten securely.
6. Install fuel line and tighten connector.
2. Install new insulator.
3. Position carburetor over intake manifold and install AIR HORN T IG H T E N IN G SEQUENCE
bolts. Tighten long bolts to 144 in. lbs. and then Refer to figure 59 for proper air horn tightening
tighten short bolts to 144 in. lbs. sequence.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -47

DIAGNOSIS

GENERAL 5. Engine compression.


When carburetor troubles are encountered they can
usually be diagnosed and corrected with an adjustment as 6. Ignition system firing voltage
outlined below and under Maintenance and Adjustments.
Before diagnosing the carburetor as the trouble area, /. Ignition spark timing.
check and diagnose the following: 8. Spark plugs
1. Fuel Supply
9. Secure intake manifold.
2. Fuel pump pressure and volume.
10. Engine temperature.
3. Plugged fuel filter or fuel lines.
Use the following tables to diagnose carburetor.
4. Linkage and emission control systems.

Problem: e n g in e i d l e s r o u g h a n d s t a l l s

Idle speed setting. Re-set idle speed under maintenance and adjustment.

M anifold vacuum hoses disconnected or im p ro p erly in Check all vacuum hoses leading into the m anifold or
stalled. carburetor base fo r leaks or being disconnected. Install
or replace as necessary.
C arburetor loose on intake m anifold . Torque carburetor to manifold bolts.

Intake m anifold is loose or gaskets are defective. Using a pressure o il can, spray light oil or kerosene around
m anifold legs and carburetor base. If engine R PM changes,
tighten or replace th e m anifold gaskets or carburetor base
gaskets as necessary.
Carburetor flooding. 1. Remove air horn and check float adjustments as specified
N O T E : Also check carburetor flooding when engine cranks in carburetor overhaul section.
(turn over) but w ill not start or starts hard when cold. 2. If excessive d irt is found in the carburetor, clean the fuel
system and carburetor.
3. Replace fuel filters as necessary.

4. Check float needle and seat for proper seal. If a needle


and seat tester is not available, mouth suction can be
applied to the needle seat w ith needle installed. If the
needle is defective, replace w ith a factory matched set.
5. Check float fo r being loaded w ith fuei, bent float hanger
or binds in the float arm.
NOTE: A solid float can be checked fo r fuel absorption by
lightly squeezing between fingers. If wetness appears on
surface or float feels heavy (check w ith known good float,
replace the float assembly.

6. Check metal float for leakage by shaking.

D irt in idle channels. If excessive d irt is found in carburetor or idle channels,


clean fuel system and carburetor. Replace fuel filters as
necessary.
Poor secondary th ro ttle valve alignment. If mis-aligned, loosen screws, align valves, tighten screws
and re-stake as necessary.

TRUCK SUPP SERVICE


6M -48 ENGINE FUEL

Problem:
ENGINE CRANKS (TURNS OVER) BUT WILL NOT START OR STARTS HARD WHEN COLD.
POSSIBLE CAUSE CO RRECTIVE ACTION
Im proper starting procedure used. Check proper starting procedure, as outlined in the owner's
manual.

N o fuel in gas tank Add fuel. Check fuel gauge for proper operation.

C hoke valve not closing su fficiently when cold. Adjust the choke thermostatic coil.

C hoke valve or linkage binding or sticking. Realign the choke valve or linkage as necessary. If caused
by d irt and gum , clean w ith au to m atic choke cleaner.
Do not oil choke linkage. If parts are replaced, check
adjustm ents.
N o fuel in carburetor. 1. R em ove fuel line at carburetor. C onnect hose to fuel
line and run into metal container. R em ove the high
tension coil w ire from center to w er on dis trib u to r cap
and ground. Crank over engine if there is no fuel
discharge from the fuel line, check fo r kinked or bent
lines. Disconnect fuel line at tank and blo w out w ith
air hose, reconnect line and check again fo r fuel dis
charge. If none, replace fuel pum p. C heck pum p for
adequate flo w , as outlined in service m anual.
2. If fuel supply is o .k ., check the follow ing:
a. Inspect fuel filter. If plugged replace.
b. If filte r is o .k ., remove air horn and check for a bind in
the float mechanism or a sticking float needle.
If o .k ., adjust float as specified in carburetor overhaul
section.
Engine Flooded. C heck carburetor unloading procedure. Depress the
N O T E : To check for flooding, remove the air cleaner, accelerator to the floor and check the carburetor to
w ith the engine o ff, and look into the carburetor bore. determine if the choke valve is opening. If not, adjust
Fuel w ill be dripping off nozzle and/or the carburetor unloader, as specified.

w ill be very wet.


C arburetor flooding N O T E : Before rem oving the carburetor air horn, use the
follo w ing procedure w hich may elim inate the flooding.

1. Rem ove the fuel line at the carburetor and plug. Crank
and run the engine until the fuel bow l runs dry. Turn
o ff the engine and connect fuel line. Then re-start and
run engine. This w ill usually flush d irt past the carbu
retor flo a t needle and seat.
2. If d irt is in fuel system, clean the system and replace
fuel filte r as necessary. If excessive d irt is found, re
move the carburetor unit. Disassemble and clean.
3. Check flo a t needle and seat fo r proper seal. If a needle
and seat tester is not available, ap ply m outh suction to
the needle seat w ith needle installed. If th e needle is
defective, replace w ith a fac to ry matched set.
4. Check flo a t fo r being loaded w ith fu el, bent float hanger
or binds in the float arm .
N O T E : Check float for fuel absorption by lightly squeezing
between fingers. If wetness appears on surface or float feels
heavy (Check w ith known good flo a t), replace the float
assembly.

5. Adjust float as specified in carburetor overhaul section.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -49

Problem: e n g in e s t a r t s a n d s t a l l s

Engine does not have enough fast idle speed when cold. Check and re-set fast idle cam.

Choke vacuum break u n it is not adjusted to specification 1. Adjust vacuum break to specification.
or unit is defective.
2. If adjusted O .K ., check the vacuum break fo r proper
operation as follows:
On the ex tern a lly m ounted vacuum break u n it, connect
a piece o f hose to the nipple on the vacuum break unit
and apply suction by m outh or use tool J -2 34 18 to
apply vacuum. Plunger should move inw ard and hold
vacuum. If not, replace the unit.
N O T E : A lw ays check the fast idle cam ad justm ent before
adjusting vacuum break unit.
Choke coil out of adjustment. Adjust choke coil rod.

Choke valve an d /o r linkage sticking or binding. 1. Clean and align choke valve and linkage. Replace if
necessary.
2. Re-adjust if part replacement is necessary.

Idle speed setting Adjust idle speed to specifications on label in engine


compartment.
N ot enough fuel in carburetor. 1. Check fuel pum p pressure and volum e.
2. Check fo r p a rtially plugged fuel inlet filte r. R eplace if
d irty .
3. Remove air horn and check float adjustm ents as specified
in carburetor overhaul section.

C arburetor flooding. 1. Check flo a t needle and seat fo r proper seal. If a needle
N O T E : Also check carburetor flooding when engine cranks and seat tester is not available, m outh suction can be
(turn over) but w ill not start or starts hard when cold. applied to the needle seat w ith needle installed. If
needle is defective, replace w ith a fac to ry m atched set.
2. Check flo a t fo r being loaded w ith fu el, bent flo a t hanger
or binds in the flo a t arm .

N O T E : Check float for fuel absorption by lightly squeezing


between fingers. If wetness appears on surface or float feels
heavy (check w ith known good flo a t), replace the float
assembly.

3. Check float adjustm ents as specified in carburetor over


haul section.
4. If excessive d irt is found in the carburetor, clean the fuel
system and carburetor. Replace fuel filte r as necessary.

TRUCK SUPP SERVICE


6 M -5 0 ENGINE FUEL

Problem: e n g in e r u n s u n e v e n o r s u r g e s

POSSIBLE CAUSE C O R REC TIV E ACTION

Fuel Restriction Check all hoses and fuel lines fo r bends, kinks or leaks.
Straighten and secure in position.
Check fuel filter. If plugged or d irty - replace.
D irt or w ater in fuel system. Clean fuel tank and lines. R em ove and clean carburetor.
Fuel level Adjust float as specified in carburetor overhaul section.
Check for free float and float needle valve operation.
Main metering rod not adjusted to specification. Remove carburetor air horn and gasket. Adjust metering rod
as specified in carburetor overhaul section.

Metering rod bent or incorrect part. Main metering jet Replace as necessary as specified in carburetor overhaul
defective, loose or incorrect part. section.

Power system in carburetor not functioning properly. Power Free up or replace as necessary.
valve sticking in down position.
Vacuum leakage It is absolutely necessary th a t all vacuum hoses and gaskets
are properly installed, w ith no air leaks. T h e carburetor
and m anifold should be evenly tightened to specified
torque.

Secondary th ro ttle valves sticking open or not seating Loosen secondary th ro ttle valve screws. A lign valves in
properly. carburetor bores and tighten securely.

Problem: e n g in e h e s i t a t e s o n a c c e l e r a t i o n

D efective accelerator pum p system 1. Rem ove air horn and check pum p cup. If cracked,
N O T E : A quick check o f th e pum p system can be made as scored or distorted, replace th e pum p plunger.
follow s. W ith the engine o ff, rem ove air cleaner and look 2. Check the pum p discharge ball fo r proper seating an
into the carburetor bores and observe pum p stream , w hile location. T h e pum p discharge ball is located in a cavity
briskly opening th ro ttle valve. A fu ll stream o f fuel should next to th e pum p w ell. T o check fo r proper seating,
em it from pum p je t and strike near th e center o f the rem ove air horn and gasket and fill cavity w ith fuel. No
venturi area. "leak d o w n should occur. Restake and replace check
ball if leaking. M ake sure discharge ball, spring, and re
tainer are properly installed.

D irt in pum p passages or pum p jet. Clean and B low o u t w ith compressed air.
Fuel level. Check for sticking float needle or binding float. Free up or
replace parts as necessary. Check and reset float level to
specification per carburetor overhaul section.
Leaking air horn to flo a t bow l gasket. T o rq u e air horn to flo a t bow l using proper tightening
procedure.
C arburetor loose on m anifold . T o rq u e carburetor to m anifold bolts.

Air valve binding (sticks open)


1. Torque air horn screws evenly using proper tightening
sequence.

2. Free-up air valve shaft and align air valves.

3. Check air valve spring for closing tension. If defective,


replace w ith spring kit.
Secondary th ro ttle valve lockout. 1. Free-up and check for proper operation.

2. Adjust secondary th ro ttle valve lockout.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -51

NO POWER ON H E A V Y A C C E LE R A TIO N
OR A T H IG H SPEED
POSSIBLE CAUSE CO RRECTIVE ACTION

C arburetor th ro ttle valve not going w ide open. (Check Lubricate thro ttle linkage to obtain wide open th ro ttle in
b y pushing accelerator pedal to flo o r). carburetor.

D irty or plugged fuel filter. Replace w ith a new filte r elem ent.

Power system not operating. Check power piston for free up and down movement. If
power piston is sticking check power piston and cavity for
d irt, or scores. Check power piston spring for distortion.
Clean or replace as necessary.

Metering rod not adjusted to specification. Adjust metering rod per carburetor overhaul section.

Float level to o low. 1. Check and reset flo a t level to specification per carburetor
overhal section.
Float not dropping far enough into flo a t bow l. Check fo r binding flo a t hanger and fo r proper float align
m ent in flo a t bow l.
Main metering jet or metering rod d irty , plugged or incorrect 1. If the main metering jets are plugged or d irty and exces
part. sive d irt is in the fuel bowl, Carburetor should be com
pletely disassembled and cleaned.

2. Check the jet or rod for being the correct part. Consult
the parts list for proper usage. The last tw o digits stamped
on the jet face are the same as the last two digits of the
part number.

Air valves binding, stuck closed or wide open. 1. Free-up air valve shaft and align air valves.
2. Torque air horn screws evenly using proper tightening
sequence.
3. Check air valve spring for closing tension. If defective,
replace w ith spring kit.

Problem: e n g in e s t a r t s h a r d w h e n h o t

C hoke valve no t opening com pletely. 1. Check fo r binding choke valve a n d /o r linkage. Clean
and free-up or replace parts as necessary.
Do n ot oil choke linkage.
2. Check and adjust choke intermediate rod (fig. 29).

Engine flooded - C arbureto r flooding. See procedure under "E n gine cranks, w ill not start".
N o fuel in carburetor. 1. Check fuel pum p. Run pressure and volum e test.
2. Check flo a t needle fo r sticking in seat, or bind ina float.
Leaking flo a t bow l. Fill bow l w ith fuel and look fo r leaks.

TRUCK SUPP SERVICE


6M -52 ENGINE FUEL

Problem: p o o r fu e l econom y

POSSIBLE CAUSE CO RRECTIVE ACTION

Engine needs com plete tune-up. Check engine compression. Exam ine spark plugs, (if d irty
or im properly gapped, clean and re-gap or replace). Check
ignition poin t dw ell, co ndition, readjust ignition points if
necessary and check and reset ignition tim ing. Clean or
replace air cleaner elem ent if d irty . Check fo r restricted
exhaust system and intake m anifold fo r leakage, m ake sure
all vacuum hoses are connected correctly.

Choke valve not fu lly opening. 1. Clean choke and free up linkage.
2. Check intermediate choke rod fo r proper adjustment.
Reset to specifications (fig. 29).

Fuel leaks. Check fuel tank, fuel lines and fuel pum p fo r any fuel
leakage.

Main metering rod not adjusted to specification. Remove carburetor air horn and gasket. Adjust metering rod
as specified in carburetor overhaul section.
Metering rod bent or incorrect part. Main metering jet Replace as necessary as specified in carburetor overhaul
defective, loose or incorrect part. section.
Power system in carburetor not functioning properly. Power Free up or replace as necessary in carburetor overhaul
valve sticking in up position. section.
High fuel level in carburetor or carburetor flooding. 1. Check fo r d irt in the needle and seat. Test using suction
by m outh or needle seat tester. If defective, replace
needle and seat assembly w ith fac to ry matched set.
2. Check fo r loaded float.

3. Re-set carburetor float as specified in carburetor overhaul


section.
4. If excessive d irt is present in the carburetor bow l, the
carburetor should be cleaned.

Fuel being pulled fro m accelerator system into venturi Run engine at R PM w here nozzle is feeding fuel. Observe
through pum p jet. pum p jet. If fuel is feeding from je t, check pum p discharge
ball fo r proper seating by fillin g cavity above ball w ith
fuel to level o f casting. N o "leak d o w n " should occur w ith
discharge ball in place. Re-stake or replace leaking check
ball, defective spring, or retainer.
A ir bleeds or fuel passages in carburetor d irty or plugged. Clean carburetor or overhaul as necessary.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M -53

ACCELERATOR CONTROL
GENERAL H AND THRO TTLE CO N TR O L
The accelerator control system is cable type. There are Refer to figure 63 for hand throttle controls for CK
no linkage adjustments. A reference between the bottom vehicles.
of accelerator pedal and floor pan should be used only as
a check for bent bracket assembly. Check torque ACCELERATOR PEDAL
references. Check for correct opening and closing
positions by operating accelerator pedal and if any Refer to figures 64 through 67 for removal and
binding is present, check routing of cable. installation of accelerator pedal.
ACCELERATOR C O N TRO L CABLE
Refer to figures 60, 61 and 62 for removal and
installation of accelerator control cable.
NOTE: With Inner Spring inside
OUTER Outer Spring, anchor both Springs
INNER SPRING thru nylon bushing in Carb Lever
SPRING and hole in Carb Bracket.
RETAINER
CAUTION: Cable is not
to be kinked or damaged in
any way during assembly

SUPPOR CABLE

FASTENER
STUD

LEVER RETAINER

Fig. 6 0 A ccelerator C ontrols L 6-1 B b l. Fig. 6 2 A ccelerator C ontrols V 8-4B bl

CA U TIO N : F le x ib le c o m p o n e n ts (hoses
w ires, c o n d u its , e tc .) m ust n o t be ro u te d
w ith in 2 inches o f m o v in g parts o f
ac ce lerato r lin kag e fo rw a rd o f S u p p o rt,
unless ro u tin g is p o s itiv e ly c o n tro lle d .

E N G IN E S U P P O R T

CABLE A SSEM B LY
NO TE: C able is n o t to be
k in k e d or dam aged in an y
w ay d u rin g assem bly.
CARBURETO R STUD

CARBURETOR S P R IN G O U T E R

FASTENER NO TE: W ith In n e r S pring inside O u te r S pring ,


a n c h o r b o th Springs th ru h o le in C a rb u re to r
Lever and holes in S u p p o rt and B ra c k e t.

Fig. 61 Accelerator Controls V8-2Bbl

TRUCK SUPP SERVICE


6 M -5 4 ENGINE FUEL

1 NOTE [ S l i p a c c e l e r a t o r c o n t r o l c a b l e
RADIO BRACKET
t h r u s l o t in Rod. I n s t a l l r e t a i n e r ,
INSTRUMENT PANEL be in g s u r e i t is s e a t e d .
I CAUTtQW~|C are must be used in p r e s s in g
t h e r e t a i n e r i n t o h o le in Rod to a s s u r e
c a b l e is not k in k e d o r damaged i n any
way.
REINFORCEM ENT
ACCELERATO R
C O N T R O L C ABLE
R O D ASSEM BLY

S U P P O R T,

S P R IN G

TORQUE AT
R E IN F O R C E M E N T 3 0 IN . LBS.

I NOTE 1 Havinq se cure d a l l components o f th e


a c c e l e r a t o r l i n k a g e as s p e c i f i e d , l i n k a g e
must o p e r a t e f r e e l y w i t h o u t bind between f u l l
c lo s e d t h r o t t l e and f u l l w id e open t h r o t t l e .
In s ta l1
TO RQUE AT
f l u s h w i t h pedal
20 IN. LBS.
rib . PEDAL
C A U T I O N - ] . 030 Min cl e ara nce between
I Lever and a c c e le r a t o r pedal rod at
cl ose d t h r o t t l e , (hot i d l e p o s i t i o n
with choke o f f ) , to al lo w engine to
re t u r n to i d l e when Knob i s a g a i n s t
B u sh in g . I f cl e ara nce i s not
adequate, loose n Adj Screw, move R O D ASSEM BLY
Lever to provide req uire d clearance,
S P R IN G
and torque Screw to 20 IN. LBS.
CABLE WIRE MUST NOT BE KINKED OR VIEW A
VIEW B BENT. (Ref: M in .cle arance with
co ld engine & choke on i s .140).
ASSEMBLED

Fig. 6 4 A ccelerator Pedal CK

Fig. 6 3 Fland T h ro ttle C ontrols-CK

TRUCK SUPP SERVICE


ENGINE FUEL 6M -55

NOTE: Slip acce lera tor control


cable thru slot in rod. Install
retainer, being sure it is seated.
CABLE RETAINER
CAUTION: Care must be used
in pressing the retainer into
hole in rod to assure cable is
not kinked or dam aged in any
w a Y- ^ REINFORCEMENT

ACCELERATOR
CONTROL CABLE
TIGHTEN TO
PEDAL 42 IN. LBS.

Fig. 66 Accelerator Pedal-P42

Fig. 67 Accelerator Pedal P32

AIR CLEANER
GENERAL The air cleaner has an automatic air inlet temperature
Air cleaner operates primarily to remove dust and dirt control device. Air temperature is automatically
form the air that is taken into the carburetor and engine. controlled by a thermostatic valve which selects warmed
The air cleaner is also effective in reducing engine air air from the heat stove and/or cooler air from the
inlet noise. engine compartment or outside air inlet on some vehicles
(Fig. 68).
Two types of air cleaner elements are used on trucks, an This system is designed to improve carburetor operation
oil wetted paper element and a polywrap element. and engine warm-up characteristics. It achieves this by
The oil wetted paper element consists of an accordian keeping the air entering the carburetor at a temperature
pleated oiled paper filter supported by wire mesh with a of at least 100 F or more except at wide open throttle.
plastisol seat on both top and bottom. The thermostatic air cleaner system includes a,
The polywrap element consists of the oil wetted paper temperature sensor, a vacuum motor and control damper
element with an additional polyurethane band around it. assembly mounted in the air cleaner, vacuum control

TRUCK SUPP - SERVICE


6M -56 ENGINE FUEL

AIR BLEED VALVE


VIEW AENGINE OFF VIEW BUNDERHOOD TEMPERATURE , CLOSED
BELOW 85F
DIAPHRAGM SPRING TEMP. SENSING
DIAPHRAGM SPRING SPRING
SNORKEL TUBE VACUUM CHAMBER
VACUUM CHAMBER SNORKEL TUBE

LINKAGE DIAPHRAGM
cO| DIAPHRAGM

r~ CONTROL DAMPER ASSM. ' f f HOT AIR PIPE


CONTROL DAMPER ASSM. HOT AIR PIPE

VIEW C-UNDERHOOD TEMPERATURE VIEW D - UNDERHOOD TEMPERATURE AIR BLEED VALVE


ABOVE 128F BETWEEN 85F AND 128F
AIR BLEED VALVE OPEN
DIAPHRAGM SPRING TEMP. SENSING
DIAPHRAGM SPRING
SNORKEL TUBE VACUUM CHAMBER SPRING
VACUUM CHAMBER
SNORKEL TUBE
XN ..
LINKAGE DIAPHRAGM AIR INLET
AIR INLET
r
CONTROL DAMPER ASSM. HOT
HOT AIR PIPE
r
CONTROL DAMPER ASSM

Fig. 68 Air Cleaner Operation

hoses, manifold heat stove and connecting pipes. The


vacuum motor is controlled by the temperature sensor.
---------- W IN G NUT -
TORQUE AT 2 0 LBS. IN.

The vacuum motor operates the air control damper


assembly to regulate the flow of hot air and under hood
air to carburetor. The hot air is obtained from the heat
stove on the exhaust manifold. I NOTE 1 P olyurethiiane
POLYWRAP AIR
CLEANER E LE M E N r
Band must w ra p ( B AN D S H O W N ) ^
o v e r b oth end seals o f p a p e r e lem ent as AIR C L E A N E R ^ . .
shown. /
AIR CLEANER ELEM ENT REPLACEM ENT ELEMENT
(PAPER FILTER
P O R T IO N ),---- -
Paper Elem ent
1. Remove air cleaner cover.
2. Remove and discard air cleaner element. f NOTE 1 P olyu re th a ne Band must

3. Clean bottom section of air cleaner and inspect POLYWRAP ^ = J = ____


c o m p le te ly c o v e r the oute r screen

cover seal for tears or cracks. Replace seal if


surface o f p a p e r ele m e n t as shown.
AIR CLEANER ELEMENT
:( BAN D S H O W N ) ___ ___
damaged. PAPER FILTER PORTION
4. Install new element in bottom section of air cleaner OF POLYWRAP AIR

with either end up.


CLEANER ELEMENT

5. Install air cleaner cover. Do not over-torque wing


nut(s).
Polywrap Elem ent
1. Remove air cleaner cover. Fig. 69 Polywrap Air Cleaner Element

2. Remove element. NOTE: Never use a hot degreaser or any solvent


3. Remove polywrap band from paper element and containing acetone or similar solvent; also, never
discard element (fig. 69). shake, swing or wring the element to remove excess
solvent as this may tear the polyurethane material.
4. Clean bottom section of air cleaner and inspect Instead, "squeeze" the excess solvent from the
cover seal for tears or cracks. Replace seal if element.
damaged. 7. Dip band into light engine oil and squeeze out
5. Inspect band for tears and replace if damaged. excess oil.
6. If band is serviceable, wash in kerosene or mineral 8. Install band around outer surface of new paper
spirts and squeeze out excess solvent (fig. 70). element.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -57

Fig. 70 Cleaning Polywrap Band

9. Install element in bottom section of air cleaner with


either end up.
10. Install air cleaner cover. Do not over-torque wing
nut(s).
AIR CLEANER
Refer to figure 71 for air cleaner used with in line L6
engine.
Refer to figure 72 for air cleaner used on CK truck with
350/400 V8 engine.
Refer to figure 73 for air cleaner used on G truck with
350/400 V8 engine.
Refer to figure 74 for air cleaner used with 454 V8
engine.
Refer to figure 75 for air cleaner used of P20(42),
P30(42) and P30(32) truck with 350 V8 engine and 4MV
carburetor.
Inspection
Visual
1. Check for proper, secure connections of heat pipe
and hoses.
2. Check for kinked or deteriorated hoses. Repair or
replace as required.
Operational
1. Remove air cleaner cover and install temperature
gauge (Tool J-22973) as close as possible to sensor
(fig. 76).
Reinstall cover without wing nut. (Temperature must
be below 85 F before proceeding.)
2. With the engine "Off", observe damper door
position through snorkel opening. Snorkel passage
should be open. (fig. 68 view A) If not, check for
binds in linkage.
3. Start and idle engine. With air temperature below Fig. 72 Air C leaner-350/400 V8-CK

TRUCK SUPP - SERVICE


6 M - 5 8 E N G IN E FUEL

W IN G NUT

GASKET
(P O S ITIO N RED
X / SURFACE D O W N )

EXTENSION
G 1 0 - 3 5 0 V 8 2Bbl.
G A S K E T ------ --------
(P O S IT IO N RED
SURFACE D O W N )

Fig. 73 Air Cleaner 350/400 V8-G

WING NUT.
LOWER STOVE

NOTE: Inboard flange


of lower stove must be
installed on top of rib
of exhaust manifold.

GASKET (POSITION
RED SURFACE
DOWN)

EXTENSION

GASKET (POSITION
RED SURFACE DOWN)

UPPER STOVE

LOWER STOVE

Fig. 7 5 - A ir Cleaner-P20(42), P30(42), P30(32)

TRUCK SUPP SERVICE


ENGINE FUEL 6 M -59

door should remain in position (closed snorkel


passage). If it does not, there is a vacuum leak in
diaphragm assembly. Replace diaphragm
assembly.
TOOL J-22973 5. If vacuum motor check is found satisfactory,
replace sensor unit.
Vacuum M otor Replacem ent
Removal
1. Remove air cleaner from engine.
2. Drill out spot welds fastening vacuum motor
retaining strap to snorkel tube.
3. Remove vacuum motor by lifting and unhooking
linkrod from damper door.
Replacement
Fig. 76 Damper Door Thermometer Reading
85 F, snorkel passage should be closed, (fig. 68 view 1. Drill 7/64" hole in snorkel tube at center of
B) When damper door begins to open snorkel vacuum motor retaining strap (fig. 77).
passage, remove air cleaner cover and observe 2. Connect vacuum motor linkage to damper door.
thermometer reading. It should be between 85 F Fasten retaining strap to air cleaner with sheet
and 115 F. metal screw.
4. If damper door does not close completely or does 3. Replace air cleaner on engine and check operation
not open at correct temperature continue with the of vacuum motor and control damper assembly.
following vacuum motor check:
Tem perature Sensor Replacem ent
a. Turn off engine. Disconnect diaphragm assem
bly vacuum hose at sensor unit. Removal
b. Apply at least 9 in. Hg. of vacuum to diaphragm 1. Remove air cleaner from engine and disconnect
assembly through the hose. This can be done by vacuum hoses at sensor.
mouth. Damper door should completely close 2. Pry up tabs of sensor retaining clip (fig. 78).
snorkel passage when vacuum is applied. If not, Observe position of sensor, new sensor must be
check to see if linkage is hooked up correctly. installed in this same position.
Also check for a vacuum leak. 3. Remove clip and sensor from air cleaner.
c. With vacuum applied, bend or clamp hose to
trap vacuum in diaphragm assembly. Damper Replacement
1. Install sensor and gasket assembly in air cleaner in
DRILL 7 / 6 4 " HOLE position as noted above.
IN CENTER POSITION
OF STRAP

VACUUM

INSTALL REPLACEMENT
RETAINING SENSOR ASSM. IN SAME
STRAP POSITION AS ORIGINAL ASSM.

Fig. 77 Vacuum D iaphragm Replacem ent Fig. 78 Removing Sensor U n it

TRUCK SUPP SERVICE


ENGINE FUEL 6M -60

2. Press retaining clip on sensor. Support the sensor CARBURETOR AIR IN TA K E


on ,its sides . to prevent
* damage to the control Refer >to figure
a m r u * . i j w
mechanism at the center. ttrucks. 79 for carburetor air intake used on CK
3. Install air cleaner on engine and connect vacuum
hoses.

FUEL PUMP
GENERAL
The fuel pump is a diaphragm type. The pump is
actuated by an eccentric located on engine camshaft. On
in-line engine, the eccentric actuates the rocker arm. On
V-8 engines, a push rod (located between camshaft
eccentric and fuel pump) actuates the pump rocker arm.
Because of design, this pump is serviced as an assembly
only.
IN SPECTIO N
The fuel pump (figs. 80 through 82) should be checked to
make sure mounting bolts and inlet and outlet
connections are tight.
TEST
Always test pump while it is mounted on engine and be
sure there is gasoline in tank.
The line from the tank to the pump is the suction side of
system and the line from pump to carburetor is the
pressure side of system. A leak on pressure side,
therefore, would be made apparent by dripping fuel, but
a leak on the suction would not be apparent except for
its effect of reducing volume of fuel on pressure side.
1. Tighten any loose line connections and look for
bends or kinks in lines.
2. Disconnect fuel pipe at carburetor. Disconnect
distributor to coil primary wire so that engine can
be cranked without firing. Place suitable container
at end of pipe and crank engine a few revolutions.

TRUCK SUPP - SERVICE


ENGINE FUEL 6M-61

4 BBL. C A R B U R E T O R BBL. C A R B U R E T O R

PUSH ROD
GASKET
PLATE
GASKET
TIGHTEN TO
27 FT. LBS.

TIG HTEN TO
36 IN. LBS. T IG H T E N T O
T IG H T E N
22 FT. LBS.
TIG HTEN TO V IE W A TO 27 FT. LBS.
22 FT. LBS.

Fig. 82 Fuel Pump 454 V8


Fig. 81 Fuel Pump - 350/400 V8
If little or no gasoline flows from open end of pipe, 1. Disconnect fuel inlet and outlet pipes at fuel pump.
then fuel pipe is clogged or pump is inoperative. 2. Remove fuel pump mounting bolts and remove
Before removing pump, disconnect fuel pipe at gas pump and gasket.
tank and outlet pipe and blow through them with 3. On V8 engines if push rod is to be removed,
an air hose to make sure they are clear. Reconnect remove pipe plug and push rod (454 cu. in.
pipes and retest while cranking engine. engines), and fuel pump adapter and gasket and
3. If fuel flows from pump in good volume from pipe push rod (350 and 400 cu. in. engines).
at carburetor, check fuel delivery pressure to be
certain that pump is operating within specified
limits as follows:
IN STALLATIO N
a. Attach a fuel pump pressure test gauge to
disconnected end of pipe. 1. On V8 engines, if fuel pump push rod has been
b. Run engine at approximately 450-1,000 rpm removed, install push rod and pipe fitting or fuel
(using gasoline in carburetor bowl) and note pump adapter using gasket sealer on gasket or pipe
reading on pressure gauge. fitting.
c. If pump is operating properly, the pressure will 2. Install fuel pump using a new gasket and tighten
be within specifications and will remain constant securely. Use sealer on fuel pump mounting bolt
at speeds between 450-1,000 rpm. If pressure is threads.
too low, too high, or varies significantly at
different speeds, the pump should be replaced. NOTE: On V8 engines, a pair of mechanical
fingers or heavy grease may be used to hold fuel
REMOVAL pump push rod up while installing fuel pump.
NOTE: Whenever disconnecting or connecting fuel 3. Connect fuel pipes to pump.
pump outlet pipe fitting, always double wrench to
avoid damaging fuel pump. 4. Start engine and check for leaks.

TRUCK SUPP SERVICE


ENGINE FUEL 6M -62

FUEL PUMP DIAGNOSIS

CAMSHAFT DRIVEN FUEL PUMP 3. With engine idling (using fuel in the carburetor float
Complete diagnosis of all possible causes of the trouble bowl), the vacuum should be at least 12 Hg.
prior to replacement of the fuel pump will save time, expense 4. If the vacuum is less than 12" Hg., replace pump. If
and possibly prevent a repeat complaint. the vacuum is okay, proceed to the next test.
When a fuel pump is suspected of not performing properly, NOTE: Do not be concerned if vacuum drops off after the
the following tests must be made: engine is stopped. Many pumps have valves with a bleed
NOTE: Do not remove the pump for any of these inspec hole that allows vapors to bleed back to the gasoline tank.
tions or tests. Be certain sufficient gasoline is in the tank.
PRESSURE TEST:
IN IT IA L INSPECTION This will determine if the pump can deliver fuel at the
1. Be certain all fittings and connections are tight and proper pressure to the carburetor:
cannot leak fuel between the pump and the carburetor 1. Reconnect the inlet fuel line to the pump.
or air between the gas tank and the pump.
2. Reconnect the fuel line at the carburetor. Idle engine
2. Look for kinks in the fuel lines. for two minutes so the carburetor float bowl can be
3. With engine idling, look for leaks: refilled. (This step may be omitted if enough fuel
remains in the carburetor after vacuum test.)
a. In the line between the pump and the carburetor.
3. Disconnect fuel line at the carburetor and install a
b. At the diaphragm flange on the pump. pressure gage into the end of this fuel line. If the pump
c. At the breather holes in the pump casting. has a vapor return line, pinch the line closed.
d. At the sheet metal cover (pump) and its fittings. 4. With the engine idling (using fuel in the carburetor
If leaks are evident in the lines or fittings, tighten or float bowl), the pressure gage when held at the level of
replace as necessary. If the fuel pump leaks (diaphragm the pump outlet should read at least VA psi.
flange, sheet metal cover, or pump casting breather 5. If the pressure is less than this value, determine if the
holes), replace the pump. line from the pump to the carburetor is restricted. If
If the above steps do not cure the problem, proceed to the this line is restricted, replace or clean it. If the line is
next test. not restricted, remove the pump and install a new one.
6. If the pressure is okay, determine if fuel can be pulled
VAC UU M TEST: up to the pump. Disconnect the fuel line at both the
This will determine if the pump has the ability to pump fuel pump inlet and the gas tank outlet. Blow air into
fuel: the fuel pump end of the line to determine if fuel can
1. Disconnect the fuel line at the carburetor. Install a flow through this line.
rubber hose on to the fuel line and run it back into the NOTE: Failure to disconnect the fuel line at the gasoline
gas tank. tank prior to blowing air, can damage the tank strainer. If
2. Disconnect the inlet fuel line at the pump. Fasten the the line is restricted, replace or clean it. If the line was not
inlet line in an up position so fuel will not run out. restricted, proceed to other areas such as gas tank or car
Install a vacuum gage on to the inlet of the pump. buretor. The fuel pump is not at fault.

TRUCK SUPP SERVICE


SECTION 6T

EMISSION CONTROL SYSTEMS


C O N TE N TS OF THIS SECTION

NOTE: Except for the following changes, all information listed in


Section 6T of the 1974 Truck Service Manual is applicable to 1975 light
duty trucks. Refer to 1974 Truck Service Manual for any service
procedures not contained herein.

AIR INJECTION REACTOR SYSTEM


The A.I.R. system remains basically the same in injected into the exhaust manifold forward of
theory and operation with the following modifi- the catalytic converter. Refer to 1974 Service
cation on trucks equipped with light duty emission Manual when performing service on the A.I.R.
controls. system.
Addition of converter A.I.R., whereby air is
EARLY FUEL EVAPORATION SYSTEM
An early fuel evaporation E.F.E. valve is used on all the coolant outlet housing and directly controls vacuum.
engines with light duty emission systems. This system With coolant temperatures below 180F., manifold
provides improved driveability while reducing exhaust vacuum is applied to the actuator which in turn closes
emissions. (Fig. 1 ). the EFE valve. This routes the hot exhaust gases to the

I
base of the carburetor. When temperatures reach 180F.,
L-6 and M ark IV
vacuum to the actuator is denied. This allows an internal
spring to return the actuator to its "at rest" position,
L-6 and Mark IV EFE systems consist of an EFE valve at opening the EFE valve.
the flange of the exhaust manifold, an actuator, a
thermal vacuum switch (TVS) and a vacuum solenoid.
The Thermal Vacuum Switch (TVS) is located on the
right hand side of the case forward of the oil pressure
switch on L-6 engines and directly above the oil filter on
Mark IV. The TVS is a normally closed switch which is
sensitive to oil temperature. With a cold engine, below
150F. on L-6 and 100 F. on Mark IV, the TVS is closed
which energizes the vacuum solenoid and allows
manifold vacuum to the actuator valve. The vacuum
pulls the diaphragm bellows in the actuator, closing the
EFE valve. This causes the hot exhaust gases to be routed
up to the base of the carburetor. When oil temperature
reaches 150F. on L-6 or 100 F. on Mark IV the thermal
vacuum switch opens. This de-energizes the vacuum
solenoid, denying vacuum to the actuator. Without
vacuum, an internal spring in the actuator pushes the
diaphragm bellows back to its "at rest" position, opening
the EFE valve.
Sm all Block V8
Small block V8 EFE systems consist of an EFE valve at
the flange of the exhaust manifold, an actuator and a
thermal vacuum switch (TVS). The TVS is mounted in

Fig. 1 T y p ica l E FE Valve

TRUCK SUPP - SERVICE


EMISSION CONTROL SYSTEMS 6T-2

THROTTLE RETURN CONTROL SYSTEM


A throttle return control system (TRC) is also vacuum to operate the throttle lever actuator. The
used on some California Truck engines. throttle lever actuator then pushes the throttle lever
slightly open, thus reducing the hydro-carbon
O P E R A T IO N emission during coast down. When manifold vacuum
drops below a pre-determined level the control valve
When the vehicle is coasting against the engine, closes, the throttle actuator retracts and the throttle
the control valve (Fig. 2) will be open to allow lever closes to idle position.

Fig. 2 T h ro ttle R eturn C ontrol


Valve Typical

THROTTLE RETURN CONTROL (TRC)


SYSTEM DIAGNOSIS
HOW TO CHECK AND ADJUST
THE TRC SYSTEM

C O N T R O L V A L V E - C H E C K IN G P R O C E D U R E : TH R O TTLE LEVER AC TU ATO R -


C H E C K IN G P R O C E D U R E :
1. Disconnect valve to carburetor hose at the 1. Disconnect valve to actuator hose at valve and
carburetor and connect to an external vacuum connect to an external vacuum source equipped
source equipped with a vacuum gauge. with a vacuum gauge.
2. Disconnect the valve to actuator hose at the 2. Apply 20 in. Hg. vacuum to the actuator and seal
actuator and connect to a vacuum gauge. off the vacuum source. If the vacuum gauge
3. Place finger firmly over the end of the bleed reading drops, then the actuator is leaking and
fitting (the foam air filter need not be removed). must be replaced.
4. Apply a minimum of 23 in. Hg. vacuum to the 3. To check the actuator for proper operation:
control valve and seal off the vacuum source. The a. Check the throttle lever, shaft, and linkage to
gauge on the actuator side should read the same be sure that they operate freely without
as the source gauge. If not, then the valve needs binding or sticking.
adjustment. If the vacuum drops off on either
gauge (finger still on the bleed fitting), the valve is b. Start engine and run until warmed up and idle
leaking and must be replaced. is stable with transmission in neutral or park.
5. With a minimum 23 in. Hg. vacuum level in the Note idle RPM.
valve, remove finger from bleed fitting. The c. Apply 20 in. Hg. vacuum to the actuator.
vacuum reading on the actuator side will drop to Manually open the throttle slightly and allow
zero and the reading on the source gauge will to close against the extended actuator plunger.
drop to a value which will be designated as the Note the engine RPM.
valve set point. If this value is not within .50 in.
Hg. of the specified valve set point, then the valve d. Release and reapply 20 in. Hg. vacuum to the
must be adjusted per the Control Valve Adjusting actuator and note the RPM to which the engine
Procedure. speed increases (do not assist the actuator).

TRUCK SUPP SERVICE


EMISSION CONTROL SYSTEMS 6T-3

e. If the RPM obtained in step 3 d is not within c. Recheck the valve set point per steps No. 3 and
150 RPM of that obtained in step 3c, then the 4.
actuator plunger may be binding due to dirt,
corro sio n , varnish, etc. or the actuator d. Repeat steps 5b and c as necessary to obtain
diaphragm may be too weak. If binding is not the specified value within .50 in. Hg.
indicated or cannot be corrected then the e. Reinstall plastic cover.
actuator must be replaced.
6. If the valve cannot be adjusted it must be
f. Release the vacuum from the actuator and the replaced.
engine speed should return to within 50 RPM
of the idle speed noted in step 3b. If it does V A L V E S E T P O IN T S
not, the plunger may be binding due to dirt,
corrosion, varnish, etc. If the problem cannot Engine Set Point - in. Hg.
be corrected, the actuator must be replaced. 350 -4V 21.5
4. If the engine RPM noted in 3c is not within the 4 0 0 -4V 21.5
specified TRC speed range, the TRC actuator 4 5 4 -4V 21.0
must be adjusted per the throttle lever actuator
adjusting procedure. THRO TTLE LEVER ACTUATOR -
A D J U S T IN G P R O C E D U R E :
C O N T R O L V A L V E - A D J U S T IN G P R O C E D U R E : 1. Disconnect valve to actuator hose at valve and
1. Disconnect valve to carburetor hose at the connect to an external vacuum source equipped
carburetor and connect to an external vacuum with a vacuum gauge.
source equipped with a vacuum gauge. 2. Check the throttle lever, shaft, and linkage to be
2. Disconnect the valve to actuator hose at the sure that they operate freely without binding or
actuator and connect to a vacuum gauge. sticking.
3. Place finger firmly over the end of the bleed 3. Start engine and run until warmed up and idle is
stable. Place transmission in neutral or park.
fitting (the foam air filter need not be removed).
4. Apply 20 in. Hg. vacuum to the actuator.
4. Apply a minimum 23 in. Hg. vacuum to the Manually open the throttle slightly and allow to
control valve and seal off the vacuum source. close against the extended actuator plunger. Note
Remove finger from bleed fitting. The vacuum the engine RPM.
reading on the actuator side will drop to zero and
the reading on the source gauge will drop to a 5. If the RPM noted above is not within the
value which will be designated as the valve set specified TRC speed range, then turn the screw
point. If this value is not within .50 in. Hg. of the on the actuator plunger in the appropriate
specified valve set point, then the valve must be direction and repeat step No. 4 until the specified
adjusted. TRC speed range is obtained.
5. To adjust the valve set point:
a. Gently pry off the conical plastic cover. TR C SPEED

b. Turn the adjusting screw in (clockwise) to raise Engine Setting RPM


the set point or out (counter-clockwise) to 350/400 Cl D 1475-1525
lower the set point value. 454 CID 1375-1425

TRUCK SUPP SERVICE


SECTION 6Y

ENGINE ELECTRICAL
NOTE: Except for the following changes, all information listed in
Section 6Y of the 1974 Truck Service Manual is applicable to 1975 light
duty trucks. Refer to 1974 Truck Service Manual for any service
procedure not contained herein.

10-SI SERIES GENERATOR


The 1975 10-SI generator is mostly carryover from 1974. The only
difference being that a 40-ohm resistor has been added to the warning
indicator circuit (figs. lc and 2c). The purpose of this resistor is to
provide a definite warning indicator light in the case of an open field
circuit in the generator. Refer to Section 6Y of the 1974 Truck Service
Manual for all service procedures.

BRUSH
HOLDER 40-O H M
RESISTOR

REGULATOR
INSULATED
HEAT SINK INSULATING
WASHER
GROUNDED
HEAT SINK

Fig. 2C Resistor Location

Fig. 1C Integral Charging System Circuitry

TRUCK SUPP SERVICE


6Y-2 ENGINE ELECTRICAL

STARTER SYSTEM
The 1975 starter is mostly carryover from 1974. The only difference
being that the "R " terminal of the starter solenoid has been removed.
This terminal was removed because with the High Energy Ignition
System there is no longer any requirement for the electrical lead from
the starter solenoid to the ignition coil. Refer to Section 6Y of the 1974
Truck Service Manual for all service procedures.

HIGH ENERGY IGNITION SYSTEM


INDEX

General Description........................................................ 6Y-2 Removal........................................................................... 6Y-5


Theory of Operation....................................................... 6Y-3 Installation...................................................................... 6Y-5
Service Operations........................................................... 6Y-4 Disassembly.................................................................... 6Y-5
Routine Maintenance.................................................... 6Y-4 Assembly......................................................................... 6Y-5
Electronic Module.......................................................... 6Y-4 Ignition Coil (8 Cylinder).......................................... 6Y-7
Spark Plug Wires........................................................... 6Y-4 Removal........................................................................... 6Y-7
Timing Light Connections.......................................... 6Y-4 Installation...................................................................... 6Y-7
Tachometer Connections.............................................. 6Y-4 Ignition Coil (6 Cylinder).......................................... 6Y-7
Other Test Equipment.................................................. 6Y-4 Removal........................................................................... 6Y-7
Centrifugal/Vacuum Advance.................................... 6Y-5 Installation...................................................................... 6Y-7
Distributor......................................................................... 6Y-5 Diagnosis........................................................................... 6Y-7

GENERAL DESCRIPTION
There are two types of HEI distributors. The 8 cylinder Ignition Coil
distributor (fig. li) combines all ignition components in In the 8 cylinder HEI system, the igntion coil is built into
one unit. The ignition coil is in the distributor cap and the distributor cap. In the 6 cylinder HEI system, the
connects directly to the rotor. The 6 cylinder distributor ignition coil is mounted externally. The coil is somewhat
(fig. 2i) has an external mounted coil. Both operate
basically in the same manner as a conventional ignition
system except the module and pick-up coil of the HEI GROUND BA T. TE R M IN A L
system replace the contact points of the conventional (C O N N E C T E D T O
IG N IT IO N S W IT C H )
system.
The high Energy Igntion is a pulse triggered, transistor
controlled, inductive discharge ignition system. The
magnetic pick-up assembly located inside the distributor
contains a permanent magnet, a pole piece with internal
teeth, and a pick-up coil. When the teeth of the timer
core rotating inside the pole piece line up with teeth of
the pole piece, an induced voltage in the pick-up coil
signals the all electronic module to open the coil primary LA TCH (4)
circuit. The primary current decreases and a high voltage CONNECT TACHOM ETER
F R O M T H IS T E R M IN A L
is induced in the ignition coil secondary winding which TO GROUND.
is directed through the rotor and high voltage leads to T A C H T E R M IN A L
fire the spark plugs. The capacitor in the distributor is (S O M E T A C H O M E T E R S
for radio noise suppression. M UST CO NN ECT FROM
T H IS T E R M IN A L T O
The module automatically controls the dwell period, E N E R G IZ E R P O S IT IV E ( + )
CONSULT TACHOM ETER
stretching it with increasing engine speed. The HEI M A N U F A C T U R E R .)
system also features a longer spark duration, made
possible by the higher amount of energy stored in the
coil primary. This is desirable for firing lean and EGR Fig. l i 8 C ylinder H EI D istrib u to r
diluted mixtures.

TRUCK SUPP - SERVICE


ENGINE ELECTRICAL 6Y-3

true transformer with the windings surrounded by the


laminated iron core. A conventional coil has the iron
IG N IT IO N COIL
CONNECT TACHOMETER
FR OM THIS TERMINAL core inside the windings. Although the HEI coil operates
TO G R O U N D .
in basically the same way as a conventional coil, it is
(SOME TACHOMETERS
more effective in generating higher secondary voltage
when the primary circuit is broken.
MUST CONNECT FROM
CO NNECTOR THIS TERMINAL TO
ENERGIZER POSITIVE ( + ) .
BAT. TERM INAL SOME TACHOMETERS
(CONNECTED TO
IG N IT IO N SWITCH)
M A Y NO T W O R K AT ALL. Electronic Module
The electronic module is a solid state unit containing five
CONSULT TACHOMETER

H IG H ENERGY
IG N IT IO N DISTRIBUTOR
V . MANUFACTURER.)

complete circuits which control spark triggering,


switching, current limiting, dwell control and distributor
LEAD \
TO
SPARK
pick-up. Dwell angle is controlled by a transistor circuit
PLUG I
j within the module and is varied in direct relation to
engine speed.
Pick-Up Assembly
LATCH (4)
VA C U U M
UNIT The pick-up assembly consists of the following:
1. A rotating timer core with external teeth which is
H O U S IN G turned by the distributor shaft.
2. A stationary pole piece with internal teeth.
3. A pick-up coil and magnet which are located
between the pole piece and a bottom plate.
Centrifugal and Vacuum Advance
The centrifugal and vacuum advance mechanisms are
basically the same types of units that provide spark
Fig. 2i 6 Cylinder HEI Distributor
advance in the breaker-type system. Centrifugal advance
smaller physically than a conventional coil, but has more is achieved through the rotation of the timer core in
primary and secondary windings. It is built more like a relation to the distributor shaft. Vacuum advance is
achieved by attaching the pick-up coil and pole piece to
the vacuum advance unit actuating arm.

THEORY OF OPERATION
The pick-up coil is connected to transistors in the The electronic module delivers full battery voltage to the
electronic module. The electronic module is connected to ignition coil which is limited to five to six amperes.
the primary windings in the coil. As the distributor shaft There is no primary resistance wire in the HEI system.
turns the timer core teeth out of alignment with the teeth The electronic module triggers the closing and opening
of the pole piece a voltage is created in the magnetic of the primary circuit instantaneously with no energy
field of the pick-up coil. lost due to breaker point arcing or capacitor charging
The pick-up coil sends this voltage signal to the time lag. The capacitor in the HEI unit functions only as
electronic module, which determines from RPM when to a radio noise suppressor.
start current building in the primary windings of the This instantaneous and efficient circuit triggering enables
ignition coil. the HEI system to deliver up to approximately 35,000
Each time the timer core teeth align with the pole piece volts through the secondary wiring to the spark plugs.
teeth the pick-up coil magnetic field is changed creating Because of the higher voltage, the HEI system has larger
a different voltage. The pick-up coil sends this different diameter (8 millimeter) spark plug wires with silicone
voltage signal the electronic module which electronically insulation. The silicone wire is gray in color, more heat
shuts off the ignition coil primary circuit. This in turn resistant than standard black wire and less vulnerable to
collapses the coil magnetic field, induces high secondary deterioration. Silicone insulation is soft, however, and
voltage and fires one spark plug. must not be mishandled.

TRUCK SUPP SERVICE


5Y-4 ENGINE ELECTRICAL

Fig. 3i High Energy Ignition Basic Wiring

SERVICE OPERATIONS
Routine M aintenance Tachom eter Connections
The HEI system is designed to be free from routine In the distributor cap connector is a "tach" terminal.
maintenance. If component part replacement should Connect the tachometer to this terminal and to ground.
become necessary, however, several items specific to the Some tachometers must connect from the "tach"
HEI system should be noted. terminal to the battery positive ( + ) terminal. Follow
tachometer manufacturers instructions.
Electronic Module
The electronic module is serviced by complete replace C A U TIO N : Grounding "tach" terminal could
ment only. When replacing the module a liberal coating damage the H E I electronic module.
of special silicone grease MUST be applied to the metal
mounting surface on which the module will be installed. O ther Test Equipment
If this grease is not applied the module will not cool
properly which can cause the module to malfunction. A Oscilliscopes require special adaptors. Distributor
tube of this special silicone grease is supplied with each machines require a special amplifier. The equipment
replacement module. manufacturers have instructions and details necessary to
modify test equipment for HEI diagnosis.
Spark Plug Wires (Figs. 4i, 5i)
The 8 millimeter silicone insulation spark plug wire
boots seal more tightly to the spark plugs. Twist the boot
about a half turn in either direction to break the seal
before pulling on the boot to remove the wire.

W A R N IN G : Do N ot rem ove spark plug wires


w ith the engine run n in g . The higher
secondary voltage is capable of jum ping an
arc of greater distance and could cause an
electric shock.

Tim ing Light Connections


Timing light connections should be made in parallel
using an adapter at the distributor number one terminal. Fig. 4 i 8 Cylinder HEI Ig n itio n W iring

TRUCK SUPP - SERVICE


ENGINE ELECTRICAL 6Y-5

CYL NO. 6 6. Adjust ignition timing as described in Specification


CYL NO. 5 Section of this manual.
CYL NO. 4
CYL NO. 3 CYL NO. 2 Distributor Disassembly
and Assembly
-CYL NO. 1
Disassembly (Figs. 6i 8i)
1. Remove distributor as described above.
2. Remove rotor from distributor shaft by removing
two screws.
3. Remove two advance springs, weight retainer, and
advance weights.
4. Remove two screws holding module to housing and
move module to a position where connector may
removed from B and C terminals.
5. Remove wires from "W " and "G " terminals of
module.
6. Remove roll pin from drive gear.
C A U TIO N : Distributor gear should be sup
|V IE W C ]

Fig. 5 i6 C ylinder H EI Ignition W irin g ported in such a way that no damage will occur
Vacuum and Centrifugal
to distributor shaft while removing pin.
Advance Specifications 1. Remove gear, shim and tanged washer from
distributor shaft. Remove any burrs that may have
Vacuum and centrifugal advance specifications are listed been caused by removal of pin.
in the Specifications Section of this manual.
8. Remove distributor shaft from housing.
Distributor Removal and 9. Remove washer from upper end of distributor
Installation housing.
Removal 10. Remove three screws securing pole piece to housing
1. Disconnect wiring harness connectors at side of and remove pole piece, magnet and pick-up coil.
distributor cap. 11. Remove lock ring at top of housing and remove
2. Remove distributor cap and position out of way. pick-up coil retainer, shim and felt washer.
3. Disconnect vacuum advance hose from vacuum NOTE: No attempt should be made to service the
advance mechanism. shaft bushings in the housing.
4. Scribe a mark on the engine in line with rotor. Note 12. Remove vacuum advance mechanism by removing
approximate position of distributor housing in two screws.
relation to engine. 13. Disconnect capacitor lead and remove capacitor by
5. Remove distributor hold-down nut and clamp. removing one screw.
6. Lift distributor from engine. 14. Remove wiring harness from distributor housing.
Assembly (Figs. 6i - 9 i)
Installation
1. Install distributor using same procedure as for 1. Position vacuum advance unit to housing and
secure with two screws.
standard distributor.
2. Position felt washer over lubricant reservoir at top
2. Install distributor hold-down clamp and snugly of housing.
install nut.
3. Position shim on top of felt washer.
3. Move distributor housing to approximate position
relative to engine noted during removal. 4. Position pick-up coil retainer to housing with
vacuum advance arm over actuating pin of vacuum
4. Position distributor cap to housing with tab in base advance mechanism. Secure with lock ring.
of cap aligned with notch in housing and secure
with four latches. 5. Install pick-up coil magnet and pole piece. Loosely
install three screws holding pole piece.
5. Connect wiring harness connector to terminals on
side of distributor cap. Connector will fit only one 6. Install washer to top of housing.
way. 7. Install distributor shaft and rotate to check for even

TRUCK SUPP SERVICE


6Y-6 ENGINE ELECTRICAL

ADVANCE W EIGHT (2)


V A C U U M U N IT
A T T A C H IN G SC R EW S

SPRING (2)
T H IN " C
C A PA C IT O R W ASHER
PIC K U P
C O IL
LEADS

MODULE A T T A C H IN G
CONNECTOR SCREW

GROUND MODULE
SCREW

Fig. 6i Distributor Centrifugal Advance


Fig. 8i Top View of D istributor Housing

13 Position wiring harness with grommet in housing


notch.
14. Connect pink wire to capacitor stud, and black wire
to capacitor mounting screw. Tighten screw.
15 Connect white wire from pick-up coil to terminal
"W " module.
16 Connect green wire from pick-up coil to terminal
"G " of module.
17. Install centrifugal advance weights, weight retainer
(dimple facing down), and springs.
18. Install rotor and secure with two screws.
C A U TIO N : Notch on side o f rotor must engage
tab on cam weight base.
19 Install distributor as described above.

Fig. 7i Roll Pin Removal

clearance all around between pole piece and shaft


projections.
8. Move pole piece to provide even clearance and
secure with three screws.
9. Install tanged washer, shim and drive gear (teeth
up) to bottom of shaft. Align drive gear and install
new roll pin.
10. Position capacitor to housing and loosely install one
mounting screw.
11. Install connector to "B" and "C " terminals on
module with tab on top.
12. Apply special silicone oubricant liberally to bottom
of module and secure with two screws. Fig. 9 i Roll Pin In sta lla tio n

TRUCK SUPP - SERVICE


ENGINE ELECTRICAL 6Y-7

Ignition Coil8 Cylinder


Rem oval (Fig. lO i)
1. Disconnect battery wire and harness connector
from distributor cap. COVER

2. Remove three screws securing coil cover to


distributor cap.
3. Remove four screws securing ignition coil to
distributor cap.
4. Remove ground wire from coil. COIL
5. Push coil leads from under side of connectors and
remove coil from distributor cap.
Installation (Fig. lO i)
1. Position coil into distributor cap with terminals
over connector at side of cap.
SEAL
2. Push coil lead wires into connector on side of cap as
follows: black (ground) in center; brown next to
vacuum advance unit; pink opposite vacuum SPRING
advance unit.
3. Secure ignition coil with four screws. Place ground
wire under coil mounting screw.
4. Install coil cover onto distributor cap and secure
with three screws. ROTOR

Ignition Coil6 Cylinder VAC U U M


UNIT
Rem oval (Fig. 5i)
1. Disconnect ignition switch to coil lead at coil.
2. Disconnect coil to distributor leads at coil.
3. Remove 4 screws securing coil to side of engine and HOUSING
remove coil.
WASHER
Installation (Fig. 5i)
1. Install coil to side of engine with 4 screws. GEAR

2. Connect coil to distributor leads at coil.


3. Connect ignition switch to coil lead at coil.
Fig. lO iExploded View of 8 C ylin d er HEI D istrib u to r

DIAGNOSIS

SPARK PLUG W IRE from infinity to any value, replace cable being
1. Disconnect both ends of ignition cable being tested tested.
and clean terminals. 4. If the resistance of each cable is not within the
2. Set ohmmeter on high scale and connect ohmmeter following bands, replace the cable being tested.
to each end of cable being tested. Twist cable gently 0 to 15" Cable - 3000/10,000 ohms
while observing ohmmeter. 15 to 25" Cable - 4000/15,000 ohms
3. If ohmmeter reads above 25,000 ohms or fluctuates 25 to 35" Cable - 6000/20,000 ohms

TRUCK SUPP SERVICE


6Y-8 ENGINE ELECTRICAL

HIGH ENERGY IGNITION SYSTEM


D IA G N O SIS CHARTS
In tr o du ctio n U sin g the C h a r t s

This section presents a system atic m ethod of diag The charts are divided into three sections: step,
nosing and troubleshooting the High Energy Ig sequence and result.
nition system. The charts you w ill be using are STEP SEQUENCE RESULT
d iffe re n t fro m the ones you have used before.
u ~
AUTO TRANS

They aren't "g o no go" decision trees or tables. l e v e r ,N PARK ( o


A lw ays start at the first step and go through the
C o n d i t i o n Pos si bl e Cause Correction
com plete sequence fro m le ft to right.
STEP SEQUENCE RESULT

IT
Instead the new diagnosis and troubleshooting
charts use pictures plus a fe w words to help you
solve a problem ,
A sequence could be checking the b a ttery lead
term inal on the d istributor. Each sequence ends
w ith a result and tells you the next step to go to.
IGNITION ON

and symbols have replaced words.


DSTEP
rr*ro7
AUTO TRANS
SEQUENCE RESULT

MANUAL TRANS

^ @ 0 )
CHECK CONNECT DISCONNECT R E P A I R OR
REPLACE
W ork through each step of the diagnosis and tro u b le
shooting charts till the system is repaired,
(2) (?) @ # To find where parts are located in the system just
SPARK NO S P A R K STARTS NO S T A R T VISUALLY
INSPECT look at the parts locator at the top of each chart.

TRUCK SUPP - SERVICE


ENGINE ELECTRICAL 6Y-9

HIGH ENERGY IGNITION SYSTEM

PROBLEM:
3-WIRE
engine CRANKS but CONNECTOR
COIL
WILL NOT START

ROTOR( 6
P ICK-UP C O IL
MODULE
STEP SEQUENCE RESULT
A U TO TRAIMS.
<TFT d 7>
LEVER IN PARK TEST LIG H T
ON
M A N U A L TRANS.

CONNECT TEST LIG H T ,


TEST LIG H T
TO BAT. LE A D
LEVER IN N E U T R A L OFF
TERM .


STARTS
- - 0 < )-
TEST LIG H T REPAIR TEST LIG H T
OFF LEAD OR
CONNECTOR
ON 7 - -

NO S TAR T
INSERT TEST LIG H T
IN RED B+ WIRE
R ED ^ J TEST LIG HT
ON

IG N IT IO N SW.
- - ) ---------( stop)

o
STARTS

o
REPAIR OR TEST LIG H T |
REPLACE AS ON |____
NECESSARY

NO STAR T

DISCONNECT
REMOVE A SPARK PLUG WIRE,
O VERRIDE
R E LA Y INSERT EXTENSION AN D
PERFORM SPARK TEST
-------------------------------------------- ,------------------------------------------
NO
CONNECT | SPARK
REMOTE
PROBLEM IS
STAR T SW.
NOT IG N IT IO N
SYSTEM
USING IN S U LA TE D PLIERS
CHECK
HOLD SPARK PLUG WIRE 1/4
FU E L SYSTEM
AW AY FROM ENG. BLOCK
EXTENSION SPARK P LU G S
W HILE C R AN K IN G ENGINE
F L O O D E D

TRUCK SUPP - SERVICE


6Y-10 ENGINE ELECTRICAL

HIGH ENERGY IGNITION SYSTEM

STEP SEQUENCE RESULT

------ ( YES )-------------


DETERMINE IF MODULE
o o TESTER WILL TEST BOTH
PICKUP COIL AND
MODULE MODULE WHILE CRANKING I--------- 1 N O ---------
TESTER

TEST PICKUP COIL

oo AND MODULE PER


TESTER M A N U
FACTURER'S
IF OK

. 0
REPLACE
MODULE PROCEDURES DEFECTIVE
TESTER PART
IF NOT OK

--------------( s to p )

STARTS

DISCONNECT
v V IS U A L L Y INSPECT
FOR MOISTURE, DUST
CRACKS, BURNS, ETC.
REPAIR AS
NECESSARY
~ g )~ NO
3 W IRE CONNECTOR STAR T

IF STEP 6
WAS PERFORMED

IF STEP 6
WAS NOT PERFORMED


IF OK

0 - 0 --------------------------------------
CHECK M ODULE
W ITH TESTER IF NOT OK REMOVE A N D
REPLACE M ODULE

REMOVE GREEN & WHITE


LEADS FROM MODULE

STARTS

.2
]
CONNECT
OHMMETER FROM
GROUND TO EITHER
LEAD
READS IN F IN IT E
(X 1000 SCALE)
1 .1
TRUCK SUPP SERVICE
ENGINE ELECTRICAL 6Y-11

HIGH ENERGY IGNITION SYSTEM


CONNECT OHMMETER REPEAT STEPS 10 A N D 11
ACROSS 2 LEADS WHILE M O V IN G VAC.
READS 500 TO ADVANCE WITH SCREW
DRIVER. IF READING.
1500 OHMS
IS STILL OK

RUNS SMOOTH

DOES NOT READ


500 TO 1500 OHMS REPLACE COIL
(P IC K U P)
RUNS ROUGH

OHMMETER
READS ABOVE 1 OHM
(X 1 SCALE) REPLACE
COIL
CONNECT
OHMMETER

READS 0 TO 1 OHM
(X 1 SCALE)

REPEAT STEPS!
j
OHMMETER
5 THRU 11
READS 6,000 TO
30,000 OHMS

CONNECT
OHMMETER READS MORE TH A N 30,000 REPLACE
OHMS OR LESS TH A N C 0|L
6,000 OHMS

TRUCK SUPP SERVICE


-12 ENGINE ELECTRICAL

HIGH ENERGY IGNITION SYSTEM

PROBLEM: engine RUNS ROUGH or CUTS OUT


STEP SEQUENCE RESULT
( > -----------------------------------

CHECK SPARK
PLUGS & PLUG WIRES
- ---------------------------------

REPAIR OR
REPLACE
0 -
r-j
RUNS SMOOTH

--------- ^ r - ----
RUNS ROUGH

-------Y E S ---------------

o o DETERMINE IF MODULE


TESTER WILL TEST BOTH
PICKUP COIL AND
MODULE MODULE WHILE CRANKING
------- 1 N O --------
TESTER

TEST PICKUP COIL


AND MODULE PER
TESTER M AN U
@ >-
F OK

FACTURER'S REPLACE
PROCEDURES DEFECTIVE ( s to p )
PART
IF NOT OK

- - ( stop)

STARTS

- V IS U A L L Y INSPECT
FOR MOISTURE, DUST
REPAIR AS
NECESSARY
DISCONNECT CRACKS, BURNS, ETC.
3 W IRE CONNECTOR NO START

IF STEP 3
WAS PERFORMED

IF STEP 3
WAS NOT PERFORMED

TRUCK SUPP SERVICE


ENGINE ELECTRICAL 6Y-13

HIGH ENERGY IGNITION SYSTEM

REMOVE GREEN & WHITE


LEADS FROM MODULE

STARTS

Jf1. V TH A N IN F IN IT Y REPLACE COIL


(PICK UP)
'
' (X 1000 SCA LE )
f CONNECT ^ ------------ NO START
OHMM ETER FROM ---------
GROUND TO EITHER READS IN F IN IT E
LEAD (x 1000 SCALE)

CONNECT OHMMETER, REPEAT STEPS 7 AN D 8


ACROSS 2 LEADS WHILE M O V IN G VAC.
ADVANCE WITH SCREW
READS 500 TO
DRIVER. IF READING
1500 OHMS IS STILL OK

STARTS

DOES NOT READ


500 TO 1500 OHMS REPLACE COIL
(PICK UP)
NO START

REPEAT STEPS

j
OHMMETER 5 THRU 8
READS 6,000 TO
30,000 OHMS

CONNECT
READS MORE TH AN 30,000 REPLACE
OHMMETER
OHMS OR LESS THAN COIL
6,000 OHMS

TRUCK SUPP SERVICE


6Y-14 ENGINE ELECTRICAL

DIAGNOSIS CHARTS
DELCOTRON GENERATOR
Introduction Using the Charts
This section presents a systematic method of diag The charts are divided into three sections: step,
nosing and troubleshooting the Delcotron Gen sequence and result.
erator system. The charts you will be using are STEP SEQUENCE RESULT
different fro m the ones you have used before.
They aren't "gono go decision trees or tables. D O C T T i O
/To n (Q

P o s s ib le C a u s e Always start at the first step and go through the


complete sequence from left to right.
STEP SEQUENCE RESULT

D (D

Instead the new diagnosis and troubleshooting | | ; L s


charts use pictures plus a few words to help you
solve a problem.
A sequence could be checking the generator belt
and replacing if necessary. Each sequence ends
with a result and tells you the next step to go to.

I G N I T I O N ON

and symbols have replaced words.


Work through each step of the diagnosis and trouble
^ ^ shooting charts till the system is repaired, ( stop)
CHECK CONNECT DI SCONNECT REPLACE CRANK
ENGI NE To find where parts are located in the system just
look at the parts locator at the top of each chart.

Parts Locator
CARBURETO R CLUSTER
CO NN EC TOR
C O IL

G ENERATOR

BATTERY

F U SE B L O C K

GENERATOR
BELT
CO NNEC TOR

TRUCK SUPP SERVICE


ENGINE ELECTRICAL 6Y-15

PROBLEM:
generator light ON engine RUNNING

GENERATOR FUSE BLOCK


BELT

SEQUENCE RESULT

G ENERATO R
L IG H T O FF
RE PLA CE IF
GO TO
NEC E SSA R Y STEP 2
CHECK ADJUST S T A R T E N G IN E
G ENERATOR T E N S IO N TO 80 LBS. G ENERATOR
B E LT L IG H T ON
(D IM OR B R IG H T )

C H EC K A L L G ENERATO R
IN D IC A T O R L IG H T O FF
L IG H T S

CH EC K FOR CAUSE S T A R T E N G IN E
T U R N E N G IN E IG N IT IO N ON G ENERATOR
IF A L L A N D RE PLA CE
OFF L IG H T ON
L IG H T S O FF G A U G E S FUSE

TEST L IG H T
F U L L Y B R IG H T

CO NN EC T
TEST L IG H T TE ST L IG H T GROUND
TO NO. 1 1/2 B R IG H T GENERATOR
T E R M IN A L "D "S H A P E D TE ST L IG H T
H O LE 1/2 B R IG H T

TEST V O LT A G E
R E G U LA T O R W ITH
REPLACE
APPROVED TESTER
V O LT A G E R E G U LA T O R

R E P A IR G E N E R A T O R

TRUCK SUPP SERVICE


6Y-1 ENGINE ELECTRICAL

TRUCK SUPP SERVICE


ENGINE ELECTRICAL 6Y-17

TRUCK SUPP - SERVICE


6Y-18 ENGINE ELECTRICAL

Chart 4 COI L CARBURETOR


GENERATOR( 1
BATTERY

PROBLEM:
battery UNDERCHARGED

GENERATOR( j
BELT V_

STEP SEQUENCE RESULT


RE P LA C E IF N E C E SSA R Y C O N N E C T TE S T
ADJUST TE N S IO N L IG H T BE TW EEN GO TO
TO 80 LBS. C A B L E 8. B A T T E R Y STEP 2
.POST
M A K E SURE NO TE S T L IG H T
J| o
AC CESSO RIES ON
W ERE L E F T O N,
IG N IT IO N O F F , GO TO

CH EC K DOORS CLO S ED STEP 3


GENERATO R U N D E R HO O D
T E ST L IG H T O F F
BELT LIG H T S D IS
N O D R A IN ON
C O N N E C TE D
BATTERY

TA P C A B L E A G A IN S T
POST

T R A C E & CO R R E C T TE S T L IG H T O FF
C O N T IN U O U S
T E ST L IG H T D R A IN ON B A T T E R Y GO TO
ON STEP 3

TE S T L IG H T ON

CONNECT
VO LTM ETER GO TO
(+) T E R M IN A L STEP 6
AND GROUND N EED LE ABOVE
9.0 V O L T S

R E C O N N EC T CO N N E C T GO TO
JUM PER C R A N K E N G IN E STEP 4
N E G A T IV E
(-} T E R M IN A L LO NG E N O U G H
C A B LE (O N H .E .I. D IS C O N N E C T
AND GROUND FOR S T A B IL IZ E D N E E D L E BE LO W
FE ED W IR E ) R E A D IN G 9.0 V O L T S

TEST B A T T E R Y
IF R E A D IN G IS GO TO
US IN G B A T T E R Y
W IT H IN .5 V O L T STEP 6
L O A D TEST
OF V O L T A G E A T GEN.
PROCEDURE BATTERY OK
C H A R G E AS
IF R E A D IN G IS N O T
S P E C IF IE D B Y
W IT H IN .5 V O L T OF
TEST
R E A D IN G A T GEN.
C H EC K FOR B A T T E R Y
C A B LE A N D S T A R T E R
TO D E L C O T R O N
C IR C U IT RE S IS TA N C E

GO TO
STEP 6

TRUCK SUPP SERVICE


ENGINE ELECTRICAL 6Y-19

STEP SEQUENCE RESULT


CONNECT
P LAC E C A R B .
V O LTM ETE R
ON H IG H STEP
ACROSS
FA ST ID LE CA M
BATTERY

D ISC O N N E C T
C O IL JU M PE R S T A R T E N G IN E
OR REC O N N EC T DO N O T TO U C H
H E I FE ED W IR E AC CELER ATO R
PEDAL

IF V O L T A G E
RE A D S LOW ER GO TO
H E A D L IG H T S -H I STEP 9
T H A N PR EV IO U S
R E A D IN G
A /C - HI
T U R N ON
ACCESSO RIES
R A D IO f/d IF V O L T A G E
R E A D S H IG H E R GO TO
BLOW ER TYPE T H A N P R E V IO U S STEP 8
D E FO G G E R R E A D IN G

IF M E TE R GO TO
RE AD S STEP 9
U N D E R 12.5

IF M E TE R GO TO
TURN O F F R E AD S STEP 10
ACCESSO RIES O V E R 15.5

IF M E TE R
W A IT U N T IL UPPER
VO LTM ETER READS
R A D IA T O R IN L E T AND
N E E D LE STOPS 12.5 TO 15.5
IS HO T
SEE NO TE

IF V O L T A G E
R E A D S H IG H E R GO TO
T H A N P R E V IO U S STEP 10
R E A D IN G
C H EC K
GROUND W V O LTAG E i_ IF V O L T A G E
GENERATOR R E A D IN G GO TO
R E A D S LOW ER
T H A N P R E V IO U S STEP 11
R E A D IN G

N O TE : IF N O T H IN G H A S BEEN F O U N D RE E D U C A T E O W N ER ON EX C E SSIVE ID L IN G ,
SLOW OR SH O R T D IS T A N C E D R IV IN G W IT H A L L ACCESSO RIES ON.

TRUCK SUPP SERVICE


n

6Y-20 ENGINE ELECTRICAL

9 )C A R B U R E T O R
GENERATOR^ 1

battery (D
PROBLEM:
battery OVERCHARGED
(uses too much water)

SEQUENCE RESULT

B A TTE R Y OK
TEST B A T T E R Y
USIN G B A T T E R Y
L O A D TEST
PR O C ED U R E
BATTERY R E PLA C E
NO T O K BATTERY

PLACE C A R B .
ON H IG H STEP
F A S T ID L E CA M

C O NN EC T H
VO LTM ETE R
S T A R T EN G IN E
ACROSS
DO N O T TO U C H
BATTERY
A C C E LER ATO R
PEDAL

CH EC K
VO LTAG E
R E A D IN G R E A D IN G
IS
12.5 to 15.5
TURN O F F A L L
ACCESSO RIES

R E A D IN G P E R FO R M
W A IT U N T IL UPPER
VO LTM ETER IS NO T N E X T TWO
R A D IA T O R IN L E T AND
N E E D LE STOPS 12.5 to 15.5 STEPS 4 & 5
IS H O T I

IF R E PA IR
GROUNDED GROUND

CH EC K FOR
GROUNDED IF N O T TEST V O LT A G E ^
BRUSH L E A D G R O U N D E D R E G U LA T O R W IT H ' REPLACE
C LIP _________ _______________APPROVED TESTER V O LT A G E R E G U LA T O R
R E PLA C E R O TO R
IF S H O R TE D AN D VO LTAG E
RE G U LATO R

C H EC K FOR
S H O R TE D
F IE L D O HM M ETER
W IN D IN G S
R E PLA C E
IF NO T
VO LTAG E
SH O R TED
REG ULATO R

TRUCK SUPP SERVICE


SECTION 7A

AUTOMATIC TRANSMISSION
C O N TE N TS OF THIS SECTION

Turbo Hydra-Matic 350 Transmission.................................... 7A-1


Turbo Hydra-Matic 400/475 Transmission........................... 7A-5

TURBO HYDRA-MATIC 350 TRANSMISSION


INDEX

General Description........................................................................7A-1
Vacuum Modulator Assembly.................................................. .7A-1
Maintenance and Adjustments.................................................. .7A-2
Transmission Fluid...................................................................... .7A-2
Draining and Refilling Transmission............................... .7A-2
Shift Controls................................................................................. .7A-2
Column Shift Linkage - G Series......................................7A-2
Detent Downshift Cable..............................................................7A-2
Manual Shaft, Range Selector Inner Lever
and Parking Linkage Assemblies...........................................7A-3
Service Operations
Transmission Replacement..........................................................7A-3
Diagnostics...........................................................................................7A-5
Oil Pressure Check.........................................................................7A-5
Spring Tension Comparison Check.........................................7A-5

GENERAL DESCRIPTION

VACUUM M O D U LA TO R ASSEMBLY (FIG.


1G)

The engine vacuum signal is provided by the vacuum


modulator, which consists of a diaphragm and one
spring. The external spring applies a force which acts on
the modulator valve. This force acts on the modulator
valve so that it increases modulator pressure. Engine
vacuum acts in the opposite direction to decrease
modulator, or low engine vacuum, high modulator
pressure. High engine vacuum, and low modulator
pressure.

Fig. 1G Vacuum M odulator Assem bly

TRUCK SUPP - SERVICE


7A-2 AUTOMATIC TRANSM ISSIO N

MAINTENANCE AND ADJUSTMENTS

TR A N SM IS SIO N FLUID lever until it locks into mechanical stop in the


Draining and Refilling Transm ission
column assembly.
The oil pan should be drained and the strainer cleaned NOTE: Do not use indicator pointer as a reference
every 30,000 miles and fresh fluid added to obtain the to position the shift lever.
proper lever on indicator. For vehicles subjected to heavy 4. Attach rod (A) to shaft assembly (B) as shown (fig.
city traffic during hot weather, or in commercial use, 2G).
when the engine is regularly idled for prolonged periods 5. Slide swivel (D) and clamp (E) onto rod (A) align
or when vehicle is used for towing the oil pan should be the column shift lever and loosely attach as shown.
drained and the strainer cleaned every 15,000 miles.
Drain fluid immediately after operation before it has 6. Hold column lever against "neutral" stop "park"
had an opportunity to cool. position side.
7. Tighten nut (F) to 18 foot pounds.
8. Readjust indicator needle if necessary to agree with
W A R N IN G : Transm ission fluid tem perature the transmission detent positions.
can exceed 3 5 0 F.
9. Readjust neutral start switch if necessary to provide
the correct relationship to the transmission detent
positions.
SHIFT CONTROLS
C A U TIO N : Any inaccuracies in the above
CO LUM N SHIFT LINKAG E - G SERIES adjustments may result in premature failure of
(FIG. 2G) the transmission due to operation without
controls in fu ll detent. Such operation results in
reduced oil pressure and in turn partial
1. The shift tube and lever assembly must be free in engagement of the affected clutches. Partial
the mast jacket. engagement of the clutches with sufficient
2. Set transmission lever (C) in "neutral" position by pressure to cause apparent normal operation of
one of the following optional methods. the vehicle will result in failure of the clutches
or other internal parts after only a few miles of
NOTE: Obtain "neutral" position by moving operation.
transmission lever (C) counter-clockwise to "L I"
detent, then clockwise three detent positions to
"neutral" or obtain "neutral" position by moving DETENT D O W N SH IFT CABLE (FIGS. 3G and
transmission lever (C) clockwise to the "park" 4G )
detent then counter-clockwise two detents to
"neutral".
3. Set the column shift lever in "neutral" Removal
position. This is obtained by rotating shift 1. Push up on bottom of snap-lock and release lock
P. WASHER L. WASHER and detent downshift cable.
GROMMET
COLUMN SHIFT LEVER.
NUT F
2. Compress locking tabs and disconnect snap-lock
BUSHING assembly from bracket.
CLAMP
3. Disconnect cable from carburetor lever.
COLUMN ASSEMBLY
4. Remove clamp around filler tube, remove screw and
washer securing cable to transmission and discon
nect detent downshift cable.
Installation
1. Install new seal on detent downshift cable lubricant
seal with transmission fluid.
2. Connect transmission end of detent downshift cable
TRANSMISSION (7) RETAINER and secure to transmission case with bolt and
GROMMET
SHAFT ASSEMBLY B washer tightened to 75 inch pounds.
3. Route cable in front of filler tube and install clamp
Fig. 2G Colum n Shift Linkage - G Series around filler tube, modulator pipe and detent

TRUCK SUPP SERVICE


AUTOMATIC TR AN SM ISSIO N 7A-3

V-8 ENGINE

SNAP LOCK

ASSEMBLED

L-6 ENGINE

CAUTION: Flexible components (hoses,


wires, conduits, etc) must not be routed
w ithin 2 inches o f moving parts of
accelerator linkage forward of the Bracket
unless routing is positively controlled.

Fig. 3G D e te n t D ow nshift C able - G Series

downshift cable. Locate clamp approximately 2 NOTE: Before installing the propeller shaft,
inches above filler tube bracket. liberally lubricate splines of the transmission yoke
4. Pass cable through bracket and engage locking tabs with a Lithium soap base lubricant. The lubricant
of snap-lock on bracket. should seep from the vent hole (rear cap of yoke)
5. Connect cable to carburetor lever. when installing yoke on transmission output shaft.
It is essential that the vent hole is not obstructed.
Adjustm ent
With snap-lock disengaged, position carburetor to wide TR A N S M IS SIO N REPLACEM ENT
open throttle (W.O.T.) position and push snap-lock
downward until top is flush with rest of cable. The procedure for transmission replacement remains the
same with the addition of this note:
M A N U A L SHAFT, RANGE SELECTOR IN NER
LEVER
NOTE: If necessary, the catalytic converter may
have to be disconnected to provide adequate
AN D PARKING LINKAGE ASSEMBLIES clearance for transmission removal. This procedure
The procedure for removal and installation remains the will include removal of the converter support
same with the addition of this notation: bracket.

TRUCK SUPP SERVICE


7A-4 AUTOMATIC TRANSM ISSIO N

SNAP LOCK

SNAP LOCK

C - K AND P MODELS

Fig. 4 G D e te n t D ow nshift C able C-K and P Series

TRUCK SUPP - SERVICE


AUTOMATIC TR AN SM ISSIO N 7A-5

DIAGNOSIS
drive, 166 psi in LI or L2, and 254 psi in reverse for the
350 V-8.
While vehicle is stationary (service brake on), engine
speed set to maintain 12 inches hg. absolute manifold
pressure, transmission oil pressure gauge attached, and
vacuum modulator tube connected, the transmission
should read 85 psi in drive, 105 psi in LI or L2, and 129
psi in reverse for the 350 V-8.
SPRING TE N S IO N C O M P A R IS O N CHECK
Using tool J-2466, as shown in Figure 5G, compare the
load of a known good modulator with the assembly in
question.
a. Install the modulator that is known to be
acceptable on either end of the tool.
b. Install the modulator in question on the
opposite end of the tool.
Fig. 5GSpring Tension C om parison
c. Holding the modulators in a horizontal position,
OIL PRESSURE CHECK
bring them together under pressure until either
modulator sleeve just touches the tool. The
While vehicle is stationary (service brake on), engine indicator in the gage will show white if the
speed set to 1200 rpm, transmission oil pressure gauge modulator is acceptable. A non-conforming
modulator will cause the indicator to shift, thus
attached, and vacuum modulator tube disconnected, the showing blue. If white does not appear, the
transmission to line pressure tap should read 167 psi in modulator in question should be replaced.

TURBO HYDRA-MATIC 400/475 TRANSMISSION


INDEX

Maintenance and Adjustments.................................................. .7A-5


Transmission Fluid........................................................................7A-5
Draining and Refilling Transmission.................................7A-5
Detent Downshift Switch............................................................7A-6
Rear S eal..........................................................................................7A-6
Transmission Replacement.........................................................7A-6

MAINTENANCE AND ADJUSTMENTS


T R A N S M IS S IO N FLUID when vehicle is used for towing, oil pan should be
D raining and Refilling Transm ission
drained and filter replaced every 15,000 miles.
The oil pan should be drained and filter replaced every Drain fluid immediately after operation before it has
30,000 miles and fresh fluid added to obtain the proper had an opportunity to cool.
level on indicator. For vehicles subjected to heavy city
traffic during hot weather, or in commercial use, when
the engine is regularly idled for prolonged periods or W A R N IN G : Transm ission fluid tem perature
can exceed 3 5 0 F.

TRUCK SUPP SERVICE


7A-6 AUTOMATIC TRANSM ISSION

with the first idle open throttle application of the


PLUNGER accelerator pedal.
PLUNGER
TRANSMISSION REAR SEAL
CONTROL Removal
SWITCH
1. Remove propeller shaft.
2. Pry seal out with screw driver.
Installation-
P30 (42) SERIES
All Models Except CL
1. Use a non-hardening sealer on outside of seal
body; and using Tool J-21359, drive seal in place.
2. Re-install propeller shaft.
Model CL
PLUNGER 1. Use a non-hardening sealer on outside of seal
body; and using Tool J-24057 drive seal in place.
CK SERIES P30 (32) SERIES 2. Re-install propeller shaft.
Fig. 1LD e te n t D ow nshift Switch
TR A N S M IS S IO N R EPLACEM ENT
DETENT DO W N SHIFT SW ITC H The procedure for transmission replacement remains the
1. Install switch as shown in Figure 1L. same with the addition of this note:
2. After installing the switch, press the switch plunger NOTE: If necessary, the catalytic converter may
as far forward as possible. This presets the switch have to be disconnected to provide adequate
for adjustment. The switch will then adjust itself clearance for transmission removal. This procedure
will include removal of the converter support
bracket.

TRUCK SUPP SERVICE


SECTION 7M

CLUTCHES & MANUAL TRANSMISSIONS


C O N TE N TS OF TH IS SECTION

Clutch Controls............................................................................... 7M-1


Manual Transmissions................................................................. 7M-3

CLUTCH CONTROLS
INDEX

General Description (G Model)............................................... 7M-1

GENERAL DESCRIPTION
The clutch operating controls for "G " models (fig. IT) pedal is depressed, the pedal pull rod moves rotating the
are a mechanical type consisting of a pendant type cross shaft, pushing the clutch fork rod rearward and
pedal, return spring, pedal pull rod, cross-shaft, fork pivoting the clutch fork. This action moves the throwout
push rod, clutch fork and throwout bearing. The pedal
pull rod is routed vertically from the clutch pedal lever bearing against the clutch release fingers, releasing the
down through the toe panel to the cross shaft. When the clutch.

TRUCK SUPP SERVICE


7M -2 TRANSM ISSIONS

Fig. IT Clutch Linkage Assembly - G Models

TRUCK SUPP SERVICE


TR ANSM ISSIO NS 7M -3

MANUAL TRANSMISSIONS
INDEX

Service Operations......................................................................... 7M-3


Transfer Case Replacement....................................................... 7M-3

SERVICE OPERATIONS

TRANSFER CASE REPLACEM ENT (Figs. 1Q- Installation


3Q ) 1. Support transfer case in suitable stand and position
case to transmission adapter. Install bolts attaching
case to adapter and torque to 45 ft. lbs.
2. Remove stand as required and install bolts
attaching transfer case to frame rail. Bend lock tabs
Rem oval
after assembly.
1. Raise and support vehicle on hoist. Drain transfer 3. Install connecting rod to shift rail link or connect
case. shift levers to transfer case, as applicable.
2. Disconnect speedometer cable, back-up lamp and 4. Connect front prop shaft to transfer case front
TCS switch. output shaft.
3. Remove skid plate and crossmember supports as 5. Connect rear prop shaft to transfer case rear output
necessary. shaft.
4. Disconnect rear prop shaft from transfer case and 6. Install crossmember support and skid plate, if
tie up away from work area. removed.
5. Disconnect front prop shaft from transfer case and 7. Connect speedometer cable, back-up lamp and TCS
tie up shaft away from work area. switch.
6. Disconnect shift lever rod from shift rail link. On 8. Fill transfer case to proper level with lubricant
full time 4 wheel drive models, disconnect shift specified in the lubricant section of the Truck
levers at transfer case. Chassis Service Manual.
7. Remove transfer case to frame mounting bracket 9. Lower and remove vehicle from hoist.
bolts. CA U TIO N : Check and tighten all bolts to
8. Support transfer case and remove bolts attaching specified torques.
transfer case to transmission adapter. NOTE: Before connecting prop shafts to compan
9. Move transfer case to rear until input shaft clears ion flanges be sure locknuts are torqued to
adapter and lower assembly from vehicle. specifications.

TRUCK SUPP - SERVICE


7M -4 TRANSM ISSIONS

4-SPEED TRANSMISSION WITH AUTOMATIC TRANSMISSION WITH


MODEL 205 TRANSFER CASE MODEL 203 TRANSFER CASE

3-SPEED TRANSMISSION WITH AUTOMATIC TRANSMISSION WITH


MODEL 20 TRANSFER CASE MODEL 205 TRANSFER CASE

K105 (FULL TIME)

SUPPORT AND BRACKET ASSEMBLY (ALL MODELS)

Fig. IQ Transfer Case Installation

TRUCK SUPP SERVICE


TR ANSM ISSIO NS 7M -5

In d ic a to r to be lo c a te d
a t d e p re s s io n

S h ift p a tte rn s h o u ld be in
h o r iz o n ta l p o s itio n d r iv e r

CARPET OR M A T

N o in s u la tio n to be in s ta lle d
u n d e r re ta in e r
W ith t r a n s c a s e in 2 w h e e l Hi
p o s it io n , a l ig n i n d i c a t o r p la t e
to c e n te r o f in d ic a t o r

Do n o t lu b ric a te b o lt th r e a d s ,
o n ly s h a n k g ro o v e .

Tv i e w I B

Fig. 2Q Model 20 Transfer Case Controls

TRUCK SUPP - SERVICE


7M -6 TRANSM ISSIONS

NOTE: Install Boot NOTE: No insulation


prior to installation of to be installed under
Nut & Knob. retainer

NOTE: No insulation
to be installed under NOTE: With trans case in
Retainer. 2 wheel H i" position, align
indicator plate to center of
NOTE: With trans case in shift lever.
Neutral" position, align
Indicator Plate to center
of S hift Lever.

NOTE: Do not lubricate


bo lt threads only shank
groove.

MODEL 203 MODEL 205

Fig. 3Q Transfer Case Controls

TRUCK SUPP - SERVICE


SECTION 8

FUEL TANK AND EXHAUST SYSTEM


C O N TE N TS OF TH IS SECTION

Fuel Tank ........................................................... 8-1 Exhaust System.................................. 5-1

FUEL TANK
Refer to the 1974 Light Duty Truck Service Manual for servicing of the
fuel tank, fuel line and evaporation control system with the following
exception:
COMPONENT PART REPLACEMENT
P MODELS AND 1 TON
CHASSIS (FRAME) MOUNTED TANKS
Refer to the 1974 Service Manual for 30 gallon fuel tank
mounted on a P20 or P30 model. Refer to Figure 1 for a
50 gallon fuel tank mounted on a P30 model.
Rem oval and Installation
1. Drain tank.
2. Remove filler neck.
3. Disconnect gauge unit fuel line and wiring. Ignition
switch must be in OFF position.
4. Remove bolts attaching tank supports to frame.
5. Remove tank complete with mounting brackets and
support straps.
6. Remove tank from brackets and support straps, if
necessary.
7. To install, reverse the removal procedures. Replace
all anti-squeak material.
Fig. 1 Fuel Tank (50 Gal.), Meter and Filler Neck-
P30 Model

EXHAUST SYSTEM
GENERAL DESCRIPTION
For alignment purposes, the muffler outlet flange is The catalytic converter requires the use o f unleaded fu el
notched and mates to a welded tab located on the outside only.
diameter of the tailpipe. The exhaust pipes and muffler
use locater tabs for alignment. Periodic maintenance of the exhaust system is not
The exhaust system on a vehicle under 6200 GVW has a required; however, if the car is raised for other service, it
catalytic converter between the front exhaust pipe and is advisable to check the general condition of the
the tailpipe. catalytic converter, pipes and mufflers.
The catalytic converter is an emission control device C A U TIO N : When jacking or lifting vehicle
added to the exhaust system to reduce hydrocarbon and
carbon monoxide pollutants from the exhaust gas stream. from fram e side rails, be certain lift pads do
The converter contains beads which are coated with a not contact catalytic converter as damage to
catalytic material containing platinum and palladium. converter will result.
8-2 FUEL TANK AND EXHAUST SYSTEM

COMPONENT PART REPLACEMENT

GENERAL
Exhaust System Pipes and Resonators Rearward of the
M ufflers Must Be Replaced W henever A New M uffler Is
Installed.

NOTE: When a muffler is replaced use sealing


compound at the clamped joint to prevent leaks.
New clamp released for 1975 is designed to make
an indentation in the exhaust pipe for improved
retention. When reinstalling clamp, align clamp
over indentation in exhaust pipe.
Truck exhaust systems vary according to series and
model designation. Series 10-30 trucks use a split-joint
design system in which the exhaust pipe-to-muffler are
clamped together and muffler-to-tailpipe connections are
welded together. All mufflers and tailpipes are welded
assemblies (no clamps) in 1975.
NOTE: All 10-20-30 series exhaust systems are
aluminized steel except: (1) "C " Series exhaust
pipes and (2) stainless steel exhaust pipes on
vehicles equipped with underfloor catalytic convert
ers. Always use correct replacement parts when
servicing these systems.
When installing a new exhaust pipe or muffler and
tailpipe, on any model, care should be taken to have the
correct alignment and relationship of the components to
each other. Particular care should be given 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 and rattles due
to improper clearances or obstructions to the normal flow
of gases. Leave all clamp bolts and muffler bolts loose
until all parts are properly aligned and then tighten,
working from front to rear.
Exhaust system hangers, hanger brackets, and clamps
which are damaged should be replaced to maintain
proper exhaust system alignment.
NOTE: When reinstalling exhaust pipe to mani
fold, always use new packings and nuts. Be sure to
clean manifold stud threads with a wire brush
when installing the new nuts.

TRUCK SUPP SERVICE


FUEL TANK AND EXHAUST SYSTEM 8-3

CONVERTER HEAT SHIELD


CK 10 Model
Refer to Figures 2 and 3 for converter heat shields.
CATALYTIC CONVERTER (FIGS. 4 and 5)
C K10 Model
Removal
1. Raise vehicle on hoist.
2. Remove clamps at front and rear of converter.
3. Cut converter pipes at front and rear of converter
and remove converter.
4. Remove support attaching converter-to-transmis-
sion or transfer case.
5. Remove converter pipe-to-exhaust pipe and con
verter pipe-to-tailpipe.
Installation
1. With sealer on exhaust pipe and tailpipe install
pipes into converter.
2. Loosely connect support attaching converter-to- 1. Install aspirator J-25077-2 (Fig. 6).
transmission or transfer case. 2. Connect air supply line to aspirator to create a
3. Install new "U " bolts and clamps at front and rear vacuum in the converter to hold beads in place
of converter. when fill plug is removed.
4. Check all clearance and tighten clamps and upport. 3. Remove converter fill plug with 3/4" hex wrench or
5. Lower vehicle and remove from hoist. Tool J-25077-3 and 4 (Fig. 7).
C atalyst Removal
If necessary, the catalyst in the converter can be replaced W A R N IN G : To prevent serious burns, avoid
on the car with Tool No. J-25077. contact with hot catalyst.

4. Clamp on vibrator J-25077-1 (Fig. 8).

AIR SUPPLY
LINE

J-25077-2

Fig. 4 Catalytic Converter - CIO Model Fig. 6 In sta llin g A sp ira tor

TRUCK SUPP SERVICE


8-4 FUEL TANK AND EXHAUST SYSTEM

5. Install empty catalyst container to converter (Fig.


9).
6. Disconnect air supply to aspirator and connect air
supply to vibrator. Catalyst will now drain from the
converter into the empty container.
7. When all the catalyst has been removed from the
converter, disconnect air supply to vibrator and
remove container from the converter.
8. Discard used catalyst.
Catalyst Installation
1. Fill container with approved replacement catalyst.
2. Install fill tube extension to the fixture J-25077-1
(Fig. 10).
3. Connect air supply to aspirator and vibrator.
4. Attach catalyst container to the fixture.
5. After the catalyst stops flowing, disconnect air
supply to the vibrator.
6. Remove vibrator and check that catalyst has filled
Fig. 7 Removing Fill Plug converter flush with fill plug hose. Add catalyst if
required.

J-25077-1

AIR SUPPLY
LINE

J-25077-1 CATALYST
CONTAINER

Fig. 8 In sta llin g V ib ra tor Fig. 9 C ontainer Installed on V ib ra tor

TRUCK SUPP SERVICE


FUEL TANK AND EXHAUST SYSTEM 8-5

7. Apply an anti-seize compound to the fill plug; 6. Install cover retaining channels on both sides of the
install and tighten to 50 ft. lbs. converter (Fig. 16).
7. Attach 2 clamps over retaining channels at each
Bottom Cover end of the converter (Fig. 17).
If, for any reason, the bottom cover of the converter is
torn or severely damaged, it can be replaced with a
repair kit.
Bottom Cover Replacement
1. Remove bottom cover by cutting close to the bottom
outside edge, Figure II and 12. Do not remove the
fill plug. The depth of the cut must be very shallow
to prevent damage to the inner shell of the
converter.
2. Remove insulation (Fig. 13).
3. Inspect inner shell of the converter for damage. If
there is damage in the inner shell, the converter
assembly must be replaced (Fig. 14).
4. Place new insulation in the replacement cover. Fig. 11 Removing Bottom Cover
Apply sealing compound, all around the cover after
the insulation is in position. Apply extra sealer at
the front and rear opening for the pipes (Fig. 15).
5. Install replacement cover on converter (Fig. 15).

Fig. 12 Removing Bottom Cover

Fig. 13 Catalytic Converter Insulation

Fig. 10 Fill Tube Extension

TRUCK SUPP SERVICE


8-6 FUEL TANK AND EXHAUST SYSTEM

Fig. 14 Catalytic Converter Inner Shell

Fig. 16 Installing Bottom Cover Retaining Channels

INSULATION
SEALING
COMPOUND

Fig. 15 Installing Bottom Cover Replacement

Fig. 17 Installing Bottom Cover Clamps

TRUCK SUPP SERVICE


FUEL TANK AND EXHAUST SYSTEM 8-7

DIAGNOSIS
EXHAUST SYSTEM

C O N D IT IO N P O S S IB L E C A U S E C O R R E C T IO N

Leaking Exhaust Gases Leaks at pipe joints. Tighten U -bolt nuts at


leaking jo ints to 30
foot-pounds.

Damaged or im p rope rly Replace seals or packing


installed seals or packing. as necessary.

Loose exhaust pipe heat tube Replace seals or packing as


extension connections. required. Tighten
stud nuts or bolts
to specifications.

Burned or rusted o u t exhaust Replace heat tube extensions


pipe heat tube extensions. as required.

Tighten clamps at leaking


connections to specified
Exhaust Noises Leaks at m anifold
torque. Replace gasket or
or pipe connections.
packing as required.

Burned o r blow n ou t Replace m u ffle r


m u ffle r. assembly.

Burned or rusted out Replace exhaust pipe.


exhaust pipe.

Exhaust pipe leaking Tighten attaching


at m an ifold flange. bolts nuts to 17 fo o t
pounds.

Exhaust m anifold Replace m an ifold .


cracked or broken.

Leak between m anifold Tighten m anifold to


and cylin d e r head. cylin de r head stud
nuts or bolts to specifications.

Loss o f engine power and/or Dislodged tu rn in g tubes and or Replace m u ffle r.


internal rattles in m u ffle r. baffles in m u ffle r.

Loss of engine power. Im ploding (inner wall collapse) Replace exhaust pipe.
of exhaust pipe (C T ruck)

TRUCK SUPP SERVICE


8-8 FUEL TANK AND EXHAUST SYSTEM

SPECIAL TOOLS

1. J-25077-1 Vibrator Include Catalyst


Container and Fill Tube Extension
2. J-25077-2 Aspirator

Fig. 1ST Special Tools

TRUCK SUPP SERVICE


SECTION 9

STEERING

INDEX

General Description........................................................... 9-1 Linkage Assembly............................................................... 9-2


Maintenance and Adjustments....................................... 9-1 Tie Rods................................................................................. 9-3
Power Steering Belt Adjustment.............................. 9-1 Power Steering System...................................................... 9-5
Power Steering Gear.................................................... 9-1 Power Steering P um p.................................................. 9-5
Component Replacement and R epair......................... 9-2 Hoses................................................................................. 9-5
Steering Linkage........................................................... 9-2 Special Tools......................................................................... 9-8

GENERAL DESCRIPTION

All 1975 truck models have basically the same steering systems as the
1974 models. All service procedures outlined in the 1974 Light Duty
Truck Service Manual apply as well to the 1975 truck steering systems
except as described below.

MAINTENANCE AND ADJUSTMENTS

POWER STEERING BELT A D JU S TM E N T confusing effects of the hydraulic fluid in the gear. The
Power steering belt adjustment for 1975 truck models is steering gear adjustment is made only as a correction
identical to the procedure outlined in the 1974 Light and not as a required periodic adjustment.
Duty Truck Service Manual, Section 9, Page 9-27 with The effect of improperly adjusted worm thrust bearings
the exception of a 1/ 2" square hole in the support or an improperly adjusted over-center preload could
bracket on some engines to aid in belt adjustment as cause a handling stability complaint.
shown in Fig. 1. Use a 1/2" drive ratchet or breaker bar
handle, inserted in the hole to assist in obtaining proper To properly adjust the power steering gear, the assembly
belt adjustment. M U S T be removed from the vehicle and adjustments
performed as outlined in the 1974 Chevrolet Passenger
POWER STEERING GEAR Car and Light Duty Truck Overhaul Manual, Section 9.
Adjustment of the power steering gear in the vehicle is For removal of the power steering gear assembly follow
discouraged because of the difficulty involved in the procedure as outlined under Power Steering Gear,
adjusting the worm thrust bearing preload and the in the 1974 Light Duty Truck Service Manual, Section 9.

TRUCK SUPP - SERVICE


9-2 STEERING

ADJUSTMENT HOLE
POWER ADJUSTMENT
ADJUSTMENT STEERING HOLE POWER
BOLT PUMP STEERING
ADJUSTMENT PUMP

LOWER ADJUSTMENT BOLT


C -K -G 1 0 -2 0 -3 0 L6 P 2 0 -3 0 L6 P 30 MOTOR HOME WITH 4 54 V -8

ADJUSTMENT POWER STEERING PUMP

ADJUSTMENT BO

ADJUSTMENT BOLT & NUT

C 1 0 -2 0 -3 0 WITH 4 5 4 V -8
Fig. 1 Power Steering Pump Adjustment-Typical

COMPONENT REPLACEMENT AND REPAIR

STEERING WHEEL (Fig. 2)

Removal
The service procedures for the removal and installation
of the steering wheel are identical to the procedures
outlined in the 1974 Light Duty Truck Service Manual,
Section 9 with the exception of the addition of a steering
wheel snap ring as shown in Figure 2. Refer to Page 9-29
of the 1974 Light Duty Truck Service Manual for proper
removal procedure.
When removing the steering wheel, remove the snap ring
as Step 3 in the removal procedure.
Installation
When installing the steering wheel, replace the snap ring
after tightening the steering wheel nut to proper torque
specifications.
STEERING LINKAGE
All service procedures for the 1975 steering linkage are
identical with those outlined in the 1974 Light Duty
Truck Service Manual, Section 9.

TRUCK SUPP - SERVICE


STEERING 9-3

Figure 3 shows the latest linkage used on the G-Series TIE RODS
truck and the P-Series, Motor Home models. Service procedures for the 1975 tie rod assemblies are
IDLER ARM identical to those outlined in the 1974 Light Duty Truck
NOTE: The idler arm assembly should always be Service Manual, Section 9.
replaced if it is found that an up or down force of 25 Figures 4 and 5 show the updated tie rod clamp
pounds, applied at the relay rod end of the idler arm, relationships for 1975 models.
produces a vertical lash of more than 1/8 (total of
1/4") in the straight ahead position.

P-SERIES MOTOR HOME


STEERING
CONNECTING ROD

SUPPORT
,LEFT IDLER
PITMAN ARM ARM

IDLER ARM
ASSEMBLY STEERING
GEAR ASSEMBLY
RE LAY ROD
STEERING GEAR
M OUNTING BRACKET
TIE ROD
ASSEMBLY

STEERING GEAR
ASSEMBLY

PITMAN ARM

STEERING ARM

G-SERIES
Fig. 3 Steering Linkage

TRUCK SUPP SERVICE


9-4 STEERING

CLAMPING INSTRUCTIONS FOR


ALL LIGHT TRUCKS.

CAUTION: CLAMPS MUST BE A. A ll b o lts must be in s ta lle d in


BETWEEN AND CLEAR OF DIMPLES d ire c tio n shown.
BEFORE TORQUING NUT. B. Rotate both in n e r and outer t ie
rod sockets rearward to l i m i t o f
b a ll stud tr a v e l.
C. P o sitio n clamps w ith in angles shown.
D. Tighten clamps.
E. With th is same rearward ro ta tio n ,
A D J U S T E R S LE E V E a ll b o lt c e n te rlin e s must be
between angles shown.
FW D

CAUTION: CENTERLINE OF SLOT


V E R T IC A L L IN E IN CLAMP MUST BE IN THIS RANGE
A D JU S T E R
OF ADJUSTMENT.
S LE E V E NOTE: IMPORTANT - SLOT
FWD
IN ADJUSTER SLEEVE
MUST NOT BE WITHIN
OPEN AREA OF CLAMP
JAWS OR CLOSER THAN
.10 TO THE EDGE OF
CLAMP JAW OPENING.
CLAM P
ROTATE CLAMP TO MEET
REQUIREMENTS WITHIN
PROPER POSITION AS SHOWN

CAUTION: CENTERLINE OF SLOT


IN CLAMP MUST BE IN THIS
RANGE OF ADJUSTMENT.

C, K AND P SERIES
G SERIES
Fig. 4 Tie Rod Clamp Relationships

CAUTION: ENDS OF ADJUSTABLE


TIE ROD MUST BE HELD IN CORRECT
RELATIONSHIP TO EACH OTHER
AFTER ADJUSTMENT WITHIN + 2.

CAUTION: CLAMPS MUST BE


BETWEEN AND CLEAR OF
DIMPLES BEFORE TORQUING
NUT.
NOTE: STEERING CONNECTING
ROD MUST BE INSTALLED WITH
LONG END FORWARD.

S T E E R IN G G E A R
ASSEM BLY .10
C LAM P

NOTE: SLOT OF
ADJUSTER TUBE MAY
BE IN ANY POSITION A D J U S T E R TU B E
ON ARC SHOWN BUT NOT
CLOSER THAN .10 TO THE EDGE
OF CLAMP JAWS OR BETWEEN THEM
VIEW lA

Fig. 5 A djustable Connecting Rod Assem bly K Series

TRUCK 6U PP * SERVICE
STEERING 9-5

POWER STEERING SYSTEM

POWER STEERING P U M P (Fig. 6) Installation


1. Position pump assembly on vehicle (Fig. 6) and
install attaching parts loosely.
Removal
2. Connect and tighten hose fittings.
1. Disconnect hoses at pump. When hoses are 3. Fill reservoir. Bleed pump by turning pulley
disconnected, secure ends in raised position to backward (counter-clockwise as viewed from the
prevent drainage of oil. Cap or tape the ends of the front) until air bubbles cease to appear.
hoses to prevent entrance of dirt. On models with
remote reservoir, disconnect reservoir hose at pump 4. Install pump belt over pulley.
and secure in raised position. Cap hose pump 5. Tension belt as outlined under Pump Belt Tension
fittings. Adjustment .
2. Install two caps at hose fittings to prevent drainage 6. Bleed as outlined under Maintenance and
of oil from pump. Adjustments .
3. Loosen bracket-to-pump mounting nuts. POWER STEERING HOSES
4. Remove pump belt. All 1975 power steering hoses, hose routings and
attachments, and other power steering plumbing is
5. Remove pump from attaching parts and remove essentially the same as 1974 except as shown in Figures
pump from vehicle. 7, 8 and 9.

P20-30 292 L-6


G 10-20-30 250 L-6 EXCEPT MOTOR HOME

Fig. 6 Power Steering Pump M ounting.

TRUCK SUPP - SERVICE


9-6 STEERING

Fig. 7 Power Steering Hose R outing

TRUCK SUPP SERVICE


Hose must be
located as shown
within + 15 of
port C/L
FW D
V IE W C

V IE W A
Fig. 9 Power Steering

Rotate hose assembly to


rest against steering gear
housing cover.
CK S E R IE S L-6 A N D 3 5 0 V -8 G 30 C U T A W A Y V A N
W IT H H Y D R O B O O S T W IT H 3 5 0 V -8
V IE W B
P30 M O T O R H O M E W IT H 3 5 0 V -8
Hose

Hose must be
located as shown
Routing

within 15 of
port C/L pWD
With

V IE W C
Hydro-Boost

S T E E R IN G
Position hose
Rotate hose assembly assembly as close
to rest against steering as possible to the
gear housing cover. side of the pump assembly.
co
I
V IE W B
C -S E R IE S 4 5 4 V -8 W IT H P 20-30 W IT H L-6 A N D
HYDROBOOST HYDROBOOST P30 M O T O R H O M E W IT H 4 5 4 V -8
9-8 STEERING

1. PUMP PULLEY REMOVER J -2 5 0 3 4

2. PUMP PULLEY INSTALLER J -2 5 0 3 3

Fig. 10 Special Tools.

TRUCK SUPP SERVICE


SECTION 10

WHEELS AND TIRES


The 1975 wheel and tire maintenance and service ATTACHMENT OF DUAL WHEELS
operations remain essentially the same as outlined in the ON P300 MODELS
1974 Truck Service Manual. Minimum Tire Inflation
Pressure Tables and additional information for torquing
dual wheels on P300 models have been revised as listed To assure secure attachment of the dual disc wheels, it is
below to 1975 specifications. important that all dirt or rust scale be removed from the
mating surface of the wheels, hub, and clamp ring as
well as the stud and nut. POWER DRIVE NUTS THEN
MANUALLY INSPECT TORQUE AT 130-180 FT.
LBS. MANUAL TORQUE ONLY: 150-200 FT. LB.
DUAL WHEEL
TYPICAL WHEEL
M A X IM U M
M A X IM U M L O A D / '
PRESSURE STAMP
RIM SIZE: DIA. X W ID TH

WHEEL CODE
LETTERS

O P T IO N A L
L O C AT IO NS FOR
M A X IM U M PRESSURE
M A X IM U M LOAD/
STAMPS

SINGLE WHEEL
TYPICAL WHEEL
M a x i m u m p r e s su r e
M A X IM U M LOAD/
STAMP O P T IO N A L L OC ATI O NS
'M A X IM U M
FOR M A X IM U M LOAD
PRESSURE STAMP
WHEEL CODE
LETTERS

Fig. 1 Wheel Code Location

TRUCK SUPP SERVICE


10-2 WHEELS AND TIRES

TIRE LOAD & INFLATION PRESSURE


PASSENGER TYPE TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE
Tire Range Tire Load Limits at Various Inflation Pressures
Size Load 20 22 24 26 28 30 32 34 36 38 40
E78-15 B 970 1030 1080 1130 1180 1230 1270
F78-15 B 1060 1110 1160 1220 1270 1320 1370
G78-15 B 1140 1190 1260 1310 1370 1420 1470
G78-15 D 1140 1190 1260 1310 1370 1420 1470 1530 1570 1620 1670
GR78-15 B 1140 1190 1260 1310 1370 1420 1470
H78-15 B 1236 1309 1373 1436 1500 1555 1609
H78-15 D 1236 1309 1373 1436 1500 1555 1609 1664 1719 1774 1827
J78-15 B 1300 1370 1440 1500 1570 1630 1690
JR78-15 B 1300 1370 1440 1500 1570 1630 1690
L78-15 B 1382 1455 1527 1591 1664 1727 1791
LR78-15 C 1382 1455 1527 1591 1664 1727 1791 1855 1900
L78-15 D 1382 1455 1527 1591 1664 1727 1791 1855 1900
8.25-15 D 1136 1191 1255 1309 1364 1418 1473 1528 1572 1619 1664

TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE


TIR E S U SED AS SIN G LES
Tire Load Tire Load Limits at Various Inflation Pressures
Size Range 30 35 40 45 50 .. 55 60 65 60 75
TUBE TYPE TIRES MOUNTED ON 5 TAPERED BEAD SEAT RIMS
6.50-16 C 1270 1390 1500 1610
7.00-15 C 1350 1480 1610 1720
7.00-15 D 1350 1480 1610 1720 1830 1940 2040
7.00-16 C 1430 1560 1680 1800
7.50-16 C 1620 1770 1930 2060
7.50-16 D 1620 1770 1930 2060 2190 2310 2440
7.50-16 E 1620 1770 1930 2060 2190 2310 2410 2560 2670 2780
TUBELESS TIRES MOUNTED ON 15 TAPERED BEAD SEAT DROP CENTER RIMS
8-19.5 D 2110 2270 2410 2540 2680 2800

WIDE BASE T U B E L E S S T IR E S USED AS SIN G LES


Tire Load Tire Load Limits at Various Inflation Pressures
Size Range 30 35 40 45 50 55 60 65 70 75
7.00-14LT C 6 1030 1130 1220 1310
7.00-14LT D 8 1030 1130 1220 1310 1390 1470 1550
6.70-15LT C 6 1210 1320 1430 1520
C78-15LT C 1080 1180 1280 1370
H78-15LT C 1440 1580 1710 1830
>8.00-16.5 C 1360 1490 1610 1730
8.00-16.5 D 1360 1490 1610 1730 1840 1945 2045
8.00-16.5 E 1360 1490 1610 1730 1840 1945 2045 2145 2240 2330
8.75-16.5 C 1570 1720 1850 1990
8.75-16.5 D 1570 1720 1850 1990 2110 2240 2350
8.75-16.5 E 1570 1720 1850 1990 2110 2240 2350 2470 2570 2680
9.50-16.5 D 1860 2030 2190 2350 2500 2650 2780
9.50-16.5 E 1860 2030 2190 2350 2500 2650 2780 2920 3050 3170
10.00-16.5 C 1840 2010 2170 2330

TIR E S USED AS DUALS


Tire Load Tire Load Limits at Various Inflation Pressures
Size Range 30 35 40 45 50 55 60 65 75
_ 70
TUBE TYPE TIRES MOUNTED ON 5 TAPERED BEAD SEAT RIMS
6.50-16 C 1120 1225 1320 1420
7.00-16 C 1260 1365 1475 1580
7.00-16 D 1260 1365 1475 1580 1685 1780 1870
7.00-18 D 1710 1830 1950 2060 2170 2270
7.50-16 C 1430 1565 1690 1815
7.50-16 D 1430 1565 1690 1815 1930 2040 2140
TUBELESS TIRES MOUNTED ON 15 TAPERED BEAD SEAT DROP CENTER RIMS
8.00-17.5 D 1640 1790 1940 2075 2205 2335 2455
8.00-19.5 D 1850 1990 2110 2230 2350 2460
8.00-19.5 E 1850 1990 2110 2230 2350 2460 2570 2680 (#)
(Refer to Tire Load and Inflatio n Pressure Notes) (#) f780 lbs. at 80 lbs. pressure.

TRUCK SUPP SERVICE


WHEELS AND TIRES 10-3

TIRE LOAD AND INFLATION PRESSURE


TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE (Contd)
WIDE BASE TU B ELESS TIRES USED AS DUALS

Tire Load Tire Load Lim its at V arious Inflation P re ssu re s


Size R ange 30 35 40 45 50 55 60 65 70 75
8.00-16.5 C 1195 1310 1415 1520
8.00-16.5 D 1195 1310 1415 1520 1620 1710 1800
8.75-16.5 C 1380 1515 1630 1750
8.75-16.5 D 1380 1515 1630 1750 1855 1970 2070
8.75-16.5 E 1380 1515 1630 1750 1855 1970 207 0 2175 2260 2 360

Tire Load and Inflation Pressure Notes fo r 3 hours or m ore, or d riv en less th an 1 m ile. H o ttire in flatio n
p re s s u re : a fte r ve h ic le has been driven 10 m iles or at sp e ed s
of m ore th a n 60 m iles p er hour.
1. T ire inflation p ressu re m ay in c re a s e as m uch as 6 pounds per
squ are inch (psi) w h e n hot. 5. Loads should be d istrib u te d as ev en ly as possib le in th e cargo
a re a .
2. For con tinuous high sp e ed o p e ratio n , (o v e r 75 m ph) w ith
p a s s e n g e r ca r ty p e tire s in c re a s e tire in flatio n p re s s u re 4 6. V e h ic le s w ith lu g g ag e racks do not h av e a v e h ic le load lim it
pounds per s q u a re inch o v e r th e re c o m m e n d e d p ressu res up g re a te r th a n sp e cified .
to a m axim um of 32 poun ds p er sq u a re inch cold fo r load ra n g e 7. W h e n to w in g tra ile rs , th e a d d itio n al load on th e a x le induced
B tires, or 36 pounds p e r s q u are inch cold fo r load ra n g e C by th e tra ile r to n g u e load m ust not ca u se th e ax le load to
tires. S u s tain ed sp e ed s a b o ve 75 m ph a re not re co m m en d e d ex c e e d th e lim its s ta m p e d on th e G V W plate. T ire in flatio n
w h e n th e 4 pounds p e r s q u are inch ad ju s tm e n t w o u ld re q u ire p re s s u re s m ust be ad ju sted accordingly.
p ressu res g re a te r th a n th e m axim u m stated abo ve. 8. M a x im u m load m ust not e x c e e d th e m axim um tire load lim it as
3. For su s tained high sp e ed driving ove r 65 M P H , w ith truck ty p e in d icated by th e u n d e rsc o rin g in th e ta b le . M in im u m re c o m
tire s cold in flatio n p re s s u re s m ust be in cre a s e d 10 PSI ab o ve m en d e d cold in flatio n p re s s u re s fo r va rio u s lo ad s m ust co n
th o se sp ecified in th e a b o ve ta b le fo r th e load being ca rried . form to th e ta b le .
For special o p e ra tin g con ditio ns . . . such as c a m p e rs or o th er 9. The load a t m axim u m in flatio n pressu re s ta m p e d on th e tire
high c e n te r of g ra v ity loading v e h ic le s . . . cold inflation s id e w a ll of p a s s s e n g e r-ty p e tire s w ill d iffer fro m th e load
pressu res m ay be in c re a s e d up to 10 PSI. The to ta l in c re a s e in sh o w n in this ta b le. This is in a c c o rd a n c e w ith T ire and Rim
cold inflation p re s s u re s sh a ll not e x c e e d 10 PS I ab o ve th o s e A ss o ciatio n s ta n d a rd s re q u irin g a re duced loading fa c to r of
specified in th e a b o v e ta b le fo r th e load being ca rried . a p p ro x im a te ly 9 1 % fo r p a s s e n g e r-ty p e tire s used on tru ck s
4. Cold tire inflation p re s s u re : a fte r ve h ic le has bee n in o p e ra tiv e and m u ltip u rp o se p a s s e n g e r vehicles.

W HEEL CODE AND LIM ITS


WHEEL LIMITS
SIZE OF
CODE WHEEL MAX. MAX.
LOAD (LBS) PRESS (PSI)
BT 15 x 7 JJ 2040 70
BJ h 1 5 x 8 ^ 1760 40
BC h 1 5 x 7 JJ 1900 70
BS 15 x 8 .0 0 JJ 1760 40
DT 1 5 x 6 JJ 1670 55
AF 16.5 x 6.0 2680 85
XH 1 5 x 6 JJ 1670 55
XL 16 x 5.0 K 1800 55
XU 15 x 6 JJ 1670 55
BR 16 x 5.0 K 1800 55
CY 19.5 x 5.25 24 60 75
CF 16 x 5.50 F 2 4 40 70
FP 16.5 x 6.0 2350 70
BF 16.5 x 6.75 3 1 70 85
XS 16 x 6 .5 0 L 2780 85
BH 16.5 x 8 .2 5 2750 70
DA 15 x 7.0 JJ 1900 70
FT 15 x 6.0 JJ 1900 70
AX 15 x 6 JJ 20 40 70
AB 19.5 x 6.75 2780 85
YW 16 x 6 .0 0 24 40 75
CC 17.5 x 5.75 2455 70
CU 19.5 x 5.25 2800 85
CM 17.5 x 5.25 2 1 55 70

TRUCK SUPP SERVICE


10-4 WHEELS AND TIRES

MINIMUM TIRE INFLATION PRESSURE AT GROSS VEHICLE WEIGHT RATING (GVWR) (Lbs.)

Load Range Replaces Ply Rating


A 2
B 4
C 6
D 8
E 10

C, K 105 UTILITY K1Q , 15 P IC K U P K 10, 15 S U B U R B A N


P 1 0 ,1 5
2 WHEEL DRIVE 4 WHEEL DRIVE 4 WHEEL DRIVE 4 WHEEL DRIVE
5800 &
GVWR (Lbs.) 4900 5200 5700 4900 5400 6300 5200 5800 6400 6200 6800 7300 6300
LOAD
TIRE FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R
RANGE
i
E78-15 B 32 32 32 32
G78-15 B 32 32 32 32 32 32 ___ ___ ___ ___

*6.50-16LT C 1 45 45 45 45 45 45 45 45 45 45 45 45 _ 45 45 ___ ___ ___ ___ ___ ___

H78-15 B - 32 32 32 32 32 32 32 32 32 32 32 32 32 32 ___ ___ ___ ___ ___ ___

*7 00-15LT C 45 45 45 45 _ ___ 45 45 45 45 45 45 45 45 45 45 45 45
*10-15LT B 30 30 30 30 30 30 30 30 30 30 30 30 _
L78-15 8 28 30 28 30 32 32 32 32 32 32 32 32 32 32 30 32 30 32 ___ ___ 26 32
*7 00-16LT C 40 40 40 45 45 45 45 45 45 45 45 45 45 45 45 45 45 45 ___ ___ 35 45
LR78-15 C 28 30 28 30 34 34 34 34 34 36 34 36 34 36 34 36 ___ 34 36 26 32
L78-15 D 30 36 34 40 30 36
.

K20, 25 PICKUP P30, 35


& SUBURBAN P20, 25 SINGLE W HEEL
GVWR (Lbs.) 6800 7500 8400 6800 7500 8000 7600 9000
TIRE LOAD FR R
R FR R FR R FR R FR FR R FR R FR R
RANGE
8.75-16.5 | C 40 45 40 40 45 40 45
8.75-16.5 D 40 60 40 60 40 60 40 60 55 60
9.50-16 5 D 30 60 30 60 30 60 30 60 40 60 40
cn

10-16.5 D 30 60 30 60 30 45 30
o

7.50-16LT C 35 45 35 35 40 45 40 40 45
7.50-16LT D 35 60 35 60 35 40 60 40 60 40 4 5 60 45
7 .5 0 -1 6 L T E 35 75 - 35 75 40 75 40 75 75 45 75
9.50-16.5 E 40 75

P 30,35 P30, 35
Single DUAL WHEELS
GVWR (Lbs.) 7600 8200 9000 GVWR (Lbs.) 9000 10000 12000 14000
TIRE LOAD FR R FR R FR R LOAD
RANGE TIRE FR R FR R FR R FR R
RANGE
8.75-16.5 C 45 8.75-16.5 C 45 40 45 45
8.75-16 5 D 50 60 8.75-16.5 D 40 55
7.50-16 C 45 45 7.50-16 C 45 35 45 45
7.50-16 D 45 60 45 7.50-16 D 45 35 45 45
7.50-16 E 45 75 8-19.5 D 50 40 50 45 50 65 50
9.50-16.5 D __ 35 60 35 8-19.5 E 50 40 50 45 ----- 50 80
9.50-16.5 E 35 60 35 75

TRUCK S llP P - SERVICE


W H E E L S A N D T IR E S 1 0 -5

M I N I M U M T I R E IN F L A T I O N P R E S S U R E A T G R O S S V E H IC L E W E I G H T R A T IN G ( G V W R ) ( L b s . )

C10, 15 PICKUPS & C10, 15


CAB CHASSIS SUBURBANS
6000 & 6800 &
GVWR (Lbs.) 4900 5300 5400 6200 5400 6400 7000
TIRES LOAD FR R FR R FR R FR R FR R FR R FR R
RANGE
G78-15 B 32 32 32 32 32 32

H78-15 B 32 32 32 32 32 i 32 32 32

6.50-16LT C 45 45 45 45 45 45 45 45

7.00-15LT C 40 45 40 45 40 45 40 45

L78-15 B 28 32 28 32 28 32 28 32 28 32

7.00-16LT
LR78-15
. cc 40
28
45
36


40
28
45 40 45 40
36 28 36 28
45
36
40
28
45
36 28

36
L78-15 D 28 36 28 36 28 36

C20, 25 PICKUP C30, 35 PICKUP


& CAB CHASSIS C20, 25 SUBURBAN & CAB CHASSIS
GVWR (Lbs.) 6400 1 7100 7500 8200 7100 7500 8200 6600 7400 8200 9000 9600
TIRE LOAD FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R
RANGE
8.75-16.5 C 45 45 45 45 45
45 45 45
8.75-16.5 D 45 60 45 60 45 60
45 60 45 60
7.50-16LT C 40 45 40 60 40 45
40 45 40
10-16.5 C 35 45 35 45 35 45 35 60
7.50-16LT D 40 60 40 60 40 60 40 60 40 60
7.50-16LT E 40 75 40 75 40 75 40 75 40 75 40 75 40 75 40 75 40 75 40 75
9.50-16.5 D 35 60 35 60 35 60 35 60 35 60 35 60 35 60 35 60 35 60 35 60 35
9.50-16.5 E 35 75 35 75 35 75 35 75 35 |75

C30, 35 PICKUP & CAB/CHASSIS


DUAL REAR WHEELS
GVWR (Lbs.) 9000 10000
TIRE LOAD FR R FR R
RANGE
7.00-16LT C 45 45

7.50-16LT C 40 45 40 45
8.75-16.5 c 45 45 45 45
8.75-16.5 D 45 60 45 60
7.50-16LT D 40 60 40 60

TRUCK SUPP SERVICE


10-6 WHEELS AND TIRES

M IN IM U M TIRE INFLATION PRESSURE AT GROSS VEHICLE W EIGHT RATING (GVWR) (Lbs.)

CHEVY VAN
G11005 G11305 G11005 G11305 G21005 G21305 G31005
GVWR (Lbs.) 4800 5400 4900 5400 5600 5600 6400 6400 6400 6900 7100 7700 8100
LOAD
TIRE RANGE FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R
E78-15 B 32 28
F78-15 B 32 32 30 24 32 32
C78-15LT C 45 45 45 45
G R78-15 B 32 32 32 32
G 78-15 B 32 32 32 32
G 78-15 D 38 40 38 40
J78-15 B 32 32 32 32
JR78-15 B 32 32 32 32
H78-15LT C 40 45 40 45
8.00-1 6.5 C 40 45 40 45 45 45
8.00 16.5 D 45 65
8.75-1 6.5 C 35 45
8 .75-1 6.5 D 35 50 45 60
8.7 5 -1 6 .5 E 45 75

CHEVY VAN CUTAWAY


G31305 G31303 G31603
GVWR (Lbs.) 6600 7100 7300 7900 8400 8400 8900* 8900* 10,000*
LOAD
TIRE RANGE FR R FR R FR R FR R FR R FR R FR R FR R FR R
8.00-1 6.5 C 45 45 45 45 45 45
8.00-1 6.5 D 45 65
8 .7 5 -1 6 .5 C 35 45 45 45
8.75-1 6.5 D 35 50 45 60
8.7 5 -1 6 .5 E 45 75 45 75
*D u a l R e a r T ire s

SPORT VAN
G11006 G11306 G21006 G21306 G31306
GVWR (Lbs.) 5400 5600 5600 6400 6400 6600 7100 7300 7900 8400
LOAD
TIRE RANGE FR R FR R FR R FR R FR R FR R FR R FR R FR R FR R
F78-15 B 32 32
G 78-15 B 32 32 32 32
G R78-15 B 32 32 32 32
G 78-15 D 38 40 38 40
H 78-15LT C 40 45 40 45
J78-15 B 30 32 30 32
JR78-15 B 30 32 30 32
8 .0 0 ,1 6 .5 C 40 45 40 45 45 45
8.0 0 -1 6 .5 D 45 65
8.7 5 -1 6 .5 C 35 45
8.7 5 -1 6 .5 D 35 50 45 60
8.7 5 -1 6 .5 E 45 75

TRUCK SUPP SERVICE


SECTION 11
CHASSIS SHEET METAL
INDEX

General Description.............................................................. 11-1 Carburetor Air Inlet Snorkels-CK Series............. 11-1


M aintenance and Adjustm ents ..................................... 11-1 Rear Fender - CK Series.......................................... 11-2
Hood Lock Assembly-CK Series.............................. 11-1 Running Board - CK Series..................................... 11-2

GENERAL DESCRIPTION

The service procedures for all 1975 truck chassis sheet 1974 Light Duty Truck Service Manual, Section
metal are essentially the same as those outlined in the except as described below.

MAINTENANCE AND ADJUSTMENTS

To repair or replace either the hood lock assembly or the


carburetor outside air inlet snorkels, the radiator grille
must be removed prior to disassembly.
Refer to Section 13, Radiator and Grille, of the 1975
Light Duty Truck Service and Overhaul Manual for
proper procedures.
HOOD LOCK ASSEMBLY

Service procedure for the 1975 CK Series hood lock is


essentially the same as those outlined in the 1974 Light
Duty Truck Service Manual, Section 11. except for the
slight modification to the lock assembly due to the new
radiator grille as shown in Fig. 1.
CARBURETOR O UTSIDE AIR INLET
SNORKELS (Fig. 2)

Removal

1. Raise hood and remove carburetor air duct from


air snorkel by sliding duct rearward.
2. Remove two (2) screws attaching air snorkel to
radiator support and remove from vehicle. Fig. 1Hood Lock C atch and S u p p o rtCK Series

TRUCK SUPP SERVICE


11-2 CHASSIS SHEET METAL

SNORKEL LOCATION

L6 SNORKEL

Fig. 2 C a rb u re to r O utside A ir In let SnorkelsCK


Series Fig. 3 R ear Fender an d B raceCK Series

Installation

Reverse removal procedure to install snorkel.

Rear Fender CK-Series

Refer to Figs. 3 and 4 for removal and installation of


rear fenders and fender braces for both C and K Series
Trucks.
Running Boards CK-Series

Refer to Fig. 5 for removal and installation of running


boards and running board hangers.

Fig. 5 R unnin g Board, H anger, and B raceCK


Series

TRUCK SUPP SERVICE


SECTION 12
ELECTRICAL-BODY AND CHASSIS
NOTE: Except for the following changes, all information listed in
Section 12 of the 1974 Light Duty Truck Service Manual is applicable to
1975 light duty trucks. Refer to 1974 Light Duty Truck Service Manual
for any service procedure not contained herein.
LIGHTING SYSTEM
MAINTENANCE AND ADJUSTMENTS
HEADLAM P A D JU STM EN T The adapters will easily snap into position on the
aimer when properly positioned.
HEAD LA M P A IM IN G 2. Place aimers with floor slope adapters attached at
The headlamps must be properly aimed in order to the center line of each wheel on one side of the
provide maximum allowable road illumination. Head vehicle (fig. 4). Aimers must be placed facing each
lamps should be checked for proper aim at new car other. Make sure dials of all three adjusting knobs
predelivery, every 12 months, after installing a new are set at "0" (zero).
sealed beam unit or if front end sheet metal is adjusted 3. Level each aimer unit by turning knob of floor
or repaired. slope adapter (fig. 2) either clockwise or counter
Some state and local authorities have special or clockwise until the top level vial bubble of the
additional requirements for headlamp aiming and these headlamp aimer registers in the centered (level)
requirements should be followed. position.
Horizontal and vertical aiming of each sealed beam unit 4. Look into the top sight opening of either the front
is provided by two adjusting screws which move the or rear aiming unit and turn horizontal knob in
mounting ring in the body against the tension of the coil both directions until the split image is aligned.
spring (fig. 1). Both circular and rectangular headlamps
are aimed in the same manner. There is no adjustment 5. Transfer the plus or minus reading indicated on the
for focus since the sealed beam unit is set for proper horizontal dial to the floor slope offset dial (fig. 3).
focus during manufacturing assembly. Then return horizontal dial to a zero setting.
Before headlamp aiming process begins, it is necessary 6. Repeat steps 3 thru 5 for other unit.
to prepare vehicle as follows: NOTE: Unless the floor is abnormally sloped, it is
1. Remove any large amounts of mud or ice from not necessary to obtain floor slope readings for
underside of fenders. both sides of the vehicle. If for some reason floor is
2. Place vehicle on a fairly level flat surface. It is not
necessary that this surface be exactly level.
3. Make sure tires are properly inflated.
4. Clean headlamp lenses.
5. Fuel tank should be one half full. If heavy load is
normally carried in load area, it should remain
there.
6. Driver should remain in vehicle or an equivalent
weight placed in drivers seat.
7. "Rock" vehicle sideways so as to equalize the
springs. Also check springs for sag, broken leaves or
coils.
Using headlamp aiming device J-25300, aim headlamps
as follows:
1. Attach a floor slope adapterJ-25300-6 (fig. 2) to
each of the headlamp aimersJ-25300-1, -2 (fig. 3).

TRUCK SUPP SERVICE


12-2 ELECTRICAL-BODY AND CHASSIS

abnormally sloped, it may require that different opening as one solid line. To remove "backlash"
readings be used for each side of the vehicle. In make final adjustment by turning horizontal
this instance, determine the floor level for BOTH adjusting screw in a clockwise direction.
sides of the vehicle. It is then necessary to set the 12. Repeat steps 9 thru 11 for other aimer.
floor slope offset dial of EACH aimer half-way
between the two readings obtained. For instance: 13. Make sure vertical dial is at zero.
+ 5 and 5 Readings Equal 0 Average NOTE: A zero setting is generally required. Some
+ 4 and 2 Readings Equal -I- l Average state or local authorities have special requirements.
+ 2 and 4 Readings Equal 1 Average Consult those authorities and use the special
Also, if one area is regularly used to aim requirement as required.
headlamps the floor slope adjustment procedures 14. Turn headlamp vertical screw (fig. 1) until the top
can be eliminated by using tape or paint to level vial bubble registers in the centered (level)
indicate on the floor the center line for the rear position.
wheel of all vehicles. Then check the floor level for 15. Repeat steps 13 and 14 for opposite aimer and
several vehicles with varying wheelbase measure headlamp.
ments. Indicate on the floor a front wheel center 16. Recheck target alignment on both aimers and
line for each wheelbase along with the plus or readjust horizontal aim if necessary.
minus reading for that position. Thereafter, each
time the headlamps are aimed, merely place the 17. Remove aimers by holding aimer securely with one
rear wheels of the vehicle on the rear wheel center hand while pressing the vacuum release button
line and transfer the plus or minus reading of the located on locking handle of aimer with the other
front wheel center line to the floor slope dial of the hand.
aiming unit. If headlamp aiming equipment is not available, use
7. Remove floor slope adapters from each unit and procedure described in Section 12 of 1974 Service
attach a headlamp adapter (fig. 5) as determined by Manual.
type of headlamps on the vehicle. There is an
adapter for all standard size and shape sealed beam
units.
8. Position aimer with headlamp adapter attached so
that the three guide points of the lamp are in
contact with the three steel inserts inside the
headlamp adapter. Secure aimer to headlamp by
pushing locking handle (fig. 3) forward to engage
rubber suction cap and then immediately pull
locking handle rearward until it locks in place.
Headlamp aimers must always be used in pairs and ADJUSTING KNOB
installed so that they face each other (fig. 6).
9. Check to make sure floor slope dials of the aimers
obtained in step 5 has not been disturbed. Make
sure horizontal dial is at zero.
10. Look into top sight opening of the aimer to see that
the split image target lines are visible in the
viewing port. If necessary, rotate each aimer
slightly to locate target.
11. Turn horizontal adjusting screw of headlamp (fig.
1) until split image of target line appears in sight

LEVEL VIAL
ONLY FOR CALIBRATION)

Fig. 2 Floor Slope A dapter J-25300-6

TRUCK SUPP SERVICE


ELECTRICAL-BODY AND CHASSIS 12-3

H O R I Z O N T A L DIAI

VERTICAL DIAL

L O C K I N G HANDLE

FLOOR SLOPE K N O B
FLOOR SLOPE

LEVEL V IA l

VERTICAL KN

H O R IZ O N T A L KN O B

S U C T I O N CUP

V I E W I N G PORT

LEVEL VIAL L O C K I N G HANDLE

AIMER J -2 5 3 0 0 - 2 S H O W N
AIMER J-25 300 -1 SIMILAR

Fig. 3 H e a d la m p A im er

TRUCK SUPP SERVICE


12-4 ELECTRICAL-BODY AND CHASSIS

AIMER J-25300-2

AIMER J-25300-1 AIMER J-25300-2

PORT
SIGHT OPENING TARGETS MUST FACE EACH OTHER
LEVEL

[FLOOR SLOPE ADAPTER!


jj-25300-6
RIGHT SIDE SHOWN. LEFT SIDE J-25300-2
GOES IN REAR AND J-25300-1 IN FRONT.
RIGHT SIDE SHOWN AIMEJ2 J-25300-1

Fig. 4 Floor Slope A djustm en t (Typical)

TRUCK SUPP - SERVICE


ELECTRICAL-BODY AND CHASSIS 12-5

' CIRCULAR HEADLAMP RECTANGULAR HEADLAMP


ADAPTER J-25300-4 ADAPTER J-25300-3

CIRCULAR HEADLAMP
ADAPTER J-25300-5

Fig. 5 H e a d la m p A dapters

HEADLAMP ADAPTER

VIEWING PORT LEVEL VIAL

HEADLAMP AIMER HEADLAMP AIMER


J-25300-2 J-25300-1

Fig. 6 Headlam p A im ing (Typical)

TRUCK SUPP SERVICE


12-6 ELECTRICAL-BODY AND CHASSIS

SERVICE OPERATIONS

HEADLAM PS W A R N IN G BUZZER
Replacement (Fig. 7)
1. Pull headlamp warning buzzer from LPS (Lamps)
socket of fuse panel.
2. Disconnect electrical connector from ACC (Accesso
ries) of fuse panel.
3. Disconnect electrical connector to instrument panel
harness.
4. Install replacement headlamp warning buzzer in
reverse sequence of removal.

W IR IN G DIAG RAM S
Truck wiring diagrams are shown in 1975 Light,
Medium and Heavy Duty Truck Wiring Diagram
Manual. BUZZER

Fig. 7 H ea d lam p W a rn in g B uzzer

TRUCK SUPP - SERVICE


SECTION 13
RADIATOR AND GRILLE
INDEX

General Description ..........................................................


13-1 Grille.................................................................................. 13-2
M aintenance and Adjustm ents..................................... 13-1 Coolant Recovery System.......................................... 13-2
Radiator Replacement................................................. 13-1

GENERAL DESCRIPTION
All service procedures outlined in the 1974 Light Duty are essentially the same for 1975 with the exception of
Truck Service Manual, Section 13, Radiator and Grille the following items.

MAINTENANCE AND ADJUSTMENTS


R A D IATO R REPLACEM ENT 10. Pressure Test system and radiator cap for proper
pressure holding capacity (15 psi). If replacement of
(All Except P30 (3 2 ) Chassis) cap is required, use the proper cap specified for
The removal of the 1975 radiator is identical to the your vehicle.
procedure outlined in the 1974 Light Duty Truck Service
Manual.
The installation procedure has been revised for 1975 as
follows:
Steps 1-5 are the same as outlined in 1974 Service
Manual.
6. Remove coolant recovery tank and empty of fluid.
Clean inside of tank thoroughly with detergent and
water, scrubbing sides clean, and then flush with
clean water and drain.
7. Reinstall tank.
8. (C-K Models) Insert coolant recovery hose in tank
as far as the first white stripe 13.5" (as shown in
Fig. 1).
9. Add sufficient ethylene glycol coolant, meeting GM
specification 1899-M, to provide the required
freezing and corrosion protection - at least a 50
percent solution (20 F). Completely fill radiator
and add sufficient coolant to the recovery tank to
raise the level to the "Cold Level" mark. Reinstall
recovery tank cap.
Fig. 1C oolant Recovery T a n k CK Series

I
TRUCK SUPP SERVICE
13-2 RADIATOR AND GRILLE

GRILLE

D 4 D IA T O R GRILLE UPPER P A N E L SERVICE PROCEDURES


Grille CK Series (Fig. 2)
Removal
H O O D L O C K SUPPORT

1. Remove the six (6) screws retaining grille to


brackets and support assembly.
R A D IA T O R
SU PPO RT 2. Remove bezels as required.
Installation
GRILLE ASSEM BLY
Reverse removal procedure.
A SSEM BLY
CAUTION: Grille is made of plastic. Do not
use excessive heat or harsh chemicals to clean
r.F ig . 2 0R a d ia t o r G_ r ...i l le C K S e r ie. s in this area or distortion and/or rpaint rpeeling6
could occur.

COOLANT RECOVERY SYSTEM

Removal and Installation (Fig. I).


Refer to Fig. I for removal and installation of coolant
recovery system on CK Series.

TRUCK SUPP - SERVICE


SECTION 15

ACCESSORIES
NOTE: Except for the following changes, all information listed in
Section 15 of the 1974 Light Duty Truck Service Manual is applicable to
1975 light duty trucks. Refer to 1974 Light Duty Truck Service Manual
for any service procedure not contained herein.

CRUISE MASTER
INDEX

General Description......................................................... 15-1 Component Part Replacement...................................... 15-7


Theory of Operation........................................................ 15-1 Regulator............................................................................ 15-7
Cruise Master Units....................................................... 15-2 Servo.................................................................................... 15-7
Maintenance and Adjustments..................................... 15-3 Column Mounted Engagement Switch.................... 15-7
Regulator............................................................................ 15-3 Diagnosis.............................................................................. 15-7
Servo U n it......................................................................... 15-4 Electrical System Troubleshooting............................. 15-7
Engagement Switch Test............................................. 15-8
Brake Release Switches................................................. 15-4 Harness Test.................................................................... 15-8
Electric.............................................................................. 15-4 Servo and Vacuum System Test.............................. 15-8
Vacuum............................................................................. 15-4 System Diagnosis C harts..............................................15-10

GENERAL DESCRIPTION
The Cruise Master is a speed control system which Installed Cruise Systems", the engage switch is mounted
employs engine manifold vacuum to power the throttle on the lower part of the instrument panel to the left of
servo unit. The servo moves the throttle, when speed the steering column. Two brake release switches are
adjustment is necessary, by receiving a varying amount provided: an electric switch disengages the regulator unit
of controlled vacuum from the regulator unit. The and a vacuum valve decreases the vacuum in the servo
speedometer cable (from the transmission) drives the unit to quickly return the throttle to idle position.
regulator, and a cable (from the regulator) drives the
instrument panel speedometer. The engagement of the The operation of each unit of the system and the
regulator unit is controlled by an engagement switch operation of the entire system under various circum
located at the end of the turn signal lever. On "Dealer stances is described under "Theory of Operation" below.

THEORY OF OPERATION
The purpose of the Cruise Master system is to allow the this switch will be on the instrument panel). The cruise
driver to maintain a constant highway speed without the system takes over speed control, and within engine
necessity of continually applying foot pressure to the limitation, maintains this speed regardless of changes in
accelerator pedal. Speed changes are easily made and terrain.
override features allow the vehicle to be stopped, slowed The Engagement Switch button performs these
or accelerated as described below. functions:

Engaging the Cruise System

I
The driver accelerates to the speed at which he desires to Above 30 mph, when partially depressed and
cruise and partially depresses and releases the cruise released, it engages the cruise system.
control engagement switch button located at the end of When depressed fully and held there, it disengages
the directional signal lever (on dealer installed systems, the system.

TRUCK SUPP - SERVICE


15-2 ACCESSORIES

3. When released slowly from the fully depressed CRUISE M ASTER U N ITS
position, it will engage the system at the existing
speed and cruise at that speed (above 30 mph).
Figures 3C and 4C show the units in the installed
position on the vehicles.
NOTE: See Fig. 1C Engage Switch Operation .
Speed Changes
1. The Engagement Switch, which is located at the end
of the directional signal lever (or bottom on
Override-The accelerator pedal may be depressed at any instrument panel), is used to control the system and
time to override the cruise system. Release of the for upward and downward speed adjustments.
accelerator pedal will return the vehicle to the previous 2. The Regulator (fig. 2C) is mounted in the
cruise speed. speedometer cable line. It is a combination speed
To Cruise At A Higher Speed-Depress the accelerator
sensing device and control unit. When engaged, it
pedal to reach the new desired speed. Then, fully depress senses vehicle speed and positions the Servo Unit to
and slowly release the cruise control engagement switch maintain the selected speed.
button. The system re-engages at the higher speed when 3. The Servo Unit is mounted on the left front inner
the button is slowly released. fender and is connected by a cable to the throttle
linkage. It opens or closes the throttle as dictated by
To Cruise At A Lower Speed-Disengage the system by the Regulator.
depressing the engagement switch button fully and 4. The Cruise Brake Release Switch, which is mounted
holding it there until the vehicle has decelerated to the on the brake pedal bracket, disengages the system
new desired speed; then release the button slowly. The electrically when the brake pedal is depressed.
system re-engages at the lower speed when the button is
slowly released. 5. The Cruise Brake Release Valve, which is mounted

T H E C R U I S E C O N T R O L E N G A G E S WI T CH
ASSEM BLIES, BOTH T U R N SIGNAL &
INSTRUMENT PANEL M OUNTED TYPES,
I N C O R P O R A T E T H R E E POS I TI ON S WI T C H E S .
T H E S E POS I T I ONS A R E :
(A) T H E R E L E A S E D " OR N O R M A L POSI TI ON
(B) T H E E N G A G E POS I TI ON
(C) T H E T R I M - D O WN POS I TI ON.

P A R T I A L L Y D E P R E S S I N G T H E E N G A G E S WI T CH
W I L L A C T I V A T E T H E S Y S T E M A N D IT W I L L
R E M A I N A C T I V I T E D W H E N T H E S WI T CH IS
R ELEASED . THE CRUISE SYSTEM IS
DEACTIVATED W HEN THE BRAKES ARE
A P P L I E D OR W H E N T H E E N G A G E S WI T CH IS
DEPRESSED FULLY AND H E L D IN T H E
T R I M - D O W N POSI TI ON.

T H E TR IM -DOW N S W I T C H POS I TI ON IS
NORMALLY U S E D TO D E C R E A S E THE
C R U I S I N G S P E E D . WHI L E T H E S WI T C H IS H E L D
IN T H E T R I M - D O WN POS I T I ON T H E C R U I S E
S Y S T E M IS O F F A N D T H E C A R S P E E D W I L L
G R A D U A L L Y D E C R E A S E . WHE N T H E D E S I R E D
C R U I S I N G S P E E D IS R E A C H E D , T H E S WI T CH IS
SLOW LY R E L E A S E D AND THE CRUISE S YST EM
W ILL R E-ENGAGE. IF T H E SWITCH IS
R ELEASED FROM THE TRIM -DOWN
POSI TI ON V E R Y R A P I D L Y , IT IS Q U I T E L I K E L Y
T H A T THE S Y S T E M WI LL NOT R E - E NG AG E .
THI S IS N O R M A L A N D IS A V O I D E D B Y A
S L O W E R , M O R E D E L I B E R A T E R E L E A S E OF
THE SWITCH FROM T H E TRI M-DOWN
POSI TI ON.

N O T E : A S P E E D - S W I T C H B U I L T I NTO T H E
REGULATOR ASSEM BLY PREVENTS
ENGAGING T H E C RU I SE S Y S T E M BELOW
APPROX. 30
MPH.

Fig. lC--Cruise M aster Engagement Switches

TRUCK SUPP - SERVICE


ACCESSORIES 15-3

on the brake pedal bracket, disengages the system


pneumatically when the brake pedal is depressed. HOLD
ENGAGE

6. The Cable and Casing Assemblies drive the TE R M IN A L


TE R M IN A L

regulator and speedometer.


O U T P U T TO
SPEEDOMETER

T O TEE'
FITTING

IN P U T F R O M
T R A N S M IS S IO N

LOCKNUT

O RIFICE TU B E &
CONNECTOR ASSEMBLY
F R O M E N G IN E
VACUUM
R FILTER & S O L E N O I D
H O U S IN G COVER

Fig. 2C- R egulator U n it

MAINTENANCE AND ADJUSTMENTS


The components of the Cruise-Master System are REGULATOR (FIG . 3C )
designed to be replaced should they become inoperative.
The Regulator is calibrated in such a manner during
manufacturing that overhaul operations are impractical.
However, one adjustment may be made to the Regulator One regulator adjustment is possible - Engagement
to correct speed drop or increase at the time of Cruising Speed Zeroing (to remove any difference
engagement. between engagement and cruising speed). No regulator
adjustment should be made, however, until the Servo
Cable adjustment has been checked and vacuum hoses
are checked for leaks, kinks, or other restrictions.
If the vehicle cruises at a speed a few mph above or
below the engagement speed, this error can be corrected
with a simple adjustment of the orifice tube in the
regulator (see fig. 2C).

CAUTION: Never remove orifice tube from


casting. It cannot be reinstalled once it has
been removed.

1. To check cruise speed error, engage Cruise-Master


at 60 mph.
2. If vehicle cruises below engagement speed, screw
orifice tube outward
3. If vehicle cruises above engagement speed, screw
orifice tube inw ard

NOTE: Each 1/4 turn of the orifice tube will

TRUCK SUPP SERVICE


15-4 ACCESSORIES

change cruise speed approximately one mph. Snug- An inoperative switch must be replaced. Switch
up lock nut after each adjustment. replacement procedure is similar to standard brake lamp
switch replacement.
If a Regulator is found to be defective and not simply Vacuum
out-of-adjustment, it must be replaced. During replace
ment, check the hoses which connect to the Regulator
and replace any which are cracked or deteriorated. The vacuum valve plunger must clear the pedal arm
when the arm is moved 5/16 inch, measured at the
switch (fig. 6C).
SERVO U N IT (FIG. 4C ) An inoperative (sticking, plugged, or leaking) vacuum
valve must be replaced. Vacuum valve replacement is
similar to brake lamp switch replacement. Be certain that
Before adjusting the Servo Cable, make sure the the hose to the valve is connected firmly and is not
carburetor is set at its lowest idle throttle position by cracked or deteriorated.
manually setting the fast idle cam at its lowest step with
the ignition switch "OFF". Adjust the cable so there is as
little lost motion at the Servo as possible (see Fig. 4C). COLUMN M O U N TE D E N G A G EM EN T
If the Servo Unit is found to be defective, replacement is SW ITCH
required. Note the condition of the hoses and replace
any which are cracked or deteriorated.
The engagement switch is serviced only by replacement
BRAKE RELEASE SW ITC HES (Fig. 5C) of the turn signal lever assembly.

Electric

The Cruise Master brake release switch electrical


contacts must be switched open when the brake pedal is
depressed .38" to .64", measured at the brake pedal.

TRUCK SUPP SERVICE


ACCESSORIES 15-5

CRUISE CONTROL CONTROL CABLE ADJUSTMENT


VACUUM HOSE
With Cable installed to Cable Bracket and Carburetor,
install Cable to Servo Bracket. Using second ball on
SERVO BOOT Servo Chain, install Servo Chain on Cable.

With throttle completely closed ( ignition off and fast idle


Cam off) adjust Cable Jam Nuts until Servo Chain is
almost tight ( some slack).Tighten Jam Nuts to specified
torque, then remove plastic retainer ( not shown) ( used to
retain boot in depressed position) and pull rubber boot
( part of Servo) over washer ( part of Cable).

Fig. 4 C -S e rv o C om posite (C-K Trucks)

TRUCK SUPP - SERVICE


15-6 ACCESSORIES

FW D /
f%

I B R A K E P ED AL IN
N O R M A L POSITION

B R A K E P ED AL P O S I T I O N ^
WHEN V A C U U M V A L V E
\ .38 TO .64

OPENS

IN S T A L L A T IO N OF S E LF-A D JU S TIN G
V A C U U M RELEASE V A L V E

1. Install m ounting clip in to bracket.


2. Depress brake pedal & push valve in to clip
u n til shoulder on valve asm bottom s o u t
against clip.
3. A djust valve by bringing pedal to normal
position so th a t valve is open when pedal
is depressed to dimension shown.

Fig. 6C Vacuum Valve

TRUCK SUPP SERVICE


ACCESSORIES 15-7

COMPONENT PART REPLACEMENT

REGULATOR CO LUM N M O U N TE D E N G A G EM EN T
SW ITCH
Replacement
Removal

1. Disconnect battery ground cable. 1. Disconnect the battery ground cable.


2. Disconnect speedometer cables at regulator. 2. Disconnect cruise master engagement switch wiring
3. Disconnect vacuum and wiring harness at regulator harness plug on steering column.
body. 3. Remove plastic protector from cruise master wiring
4. Remove regulator to bracket screws and remove harness on column.
regulator. 4. Remove turn signal lever (see Section 9 of this
Manual).
5. To install, reverse Steps 1-4 above.
5. Connect a 15" piece of piano wire to cruise master
wiring harness plug for installation before easing
turn signal lever assembly up and out of the
SERVO column.
Installation
Replacement

1. Attach new engagement switch harness plug to


piano wire routed through column.
1. Disconnect battery ground cable. 2. Pull connector and wire gently down column to
2. Disconnect vacuum line at servo can. prevent scraping wire insulation.
3. Remove servo cover. Disconnect ball chain from 3. Install turn signal lever (see Section 9 of this
cable retainer. Manual).
4. Remove servo to bracket screw(s) and remove servo. 4. Slide plastic wiring protector over harness and up
column.
5. To install, reverse Steps 1-4 above. 5. Connect cruise master wiring harness on column.
6. Adjust the servo cable as outlined in Figure 4C. 6. Connect battery ground cable.

DIAGNOSIS
ELECTRICAL SYSTEM TR O U B LES H O O TIN G release brake switch (electric) is adjusted as is
the standard stop light brake switch.
c. Replace electric brake switch if needed.
1. Check fuse and connector.
2. Check electric brake switch as follows: 3. Check clutch release switch (manual transmission
only) same as electric release switch above.
a. Unplug connector at switch.
b. Connect ohmmeter across cruise master contacts
on brake switch. The ohmmeter must indicate
no continuity when the pedal is depressed and
continuity when pedal is released. The cruise

TRUCK SUPP SERVICE


15-8 ACCESSORIES

Engagem ent Switch Test NOTE: When disconnecting or reconnecting the


main wiring harness connector from the Regulator,
care should be exercised so as not to damage the
Check engagement switch and connecting wiring as blade connectors or the wiring harness. The
follows: Unplug engagement switch connector (brown, disconnect may be facilitated by prying carefully
blue, black) at electrical wiring harness connector then on the plastic connector with a small screwdriver.
perform the following tests (fig. 1C).
T est# 1Connect ohmmeter between terminal #1
(brown wire) and terminal# 2 (blue wire). Continuity
shall be maintained until switch is depressed all the way 4. Measuring the solenoid coil circuit resistance
between point E (Hold Terminal) and ground, the
T e st# 2 Connect ohmmeter between term inal# 1 ideal resistance should be between 5 and 6 ohms. A
(brown wire) and terminal # 3 (black wire). No reading of less than 4 ohms indicates shorting in
continuity shall be shown; however, when the button is the coil circuit. A reading of more than 7 ohms
partially depressed, continuity shall be indicated. When indicates excessive resistance in the coil circuit.
the button is pressed all the way down, no continuity Either extremity indicates replacement of the
shall be shown. Regulator assembly. The main harness wiring from
point F to G (white wire) should also be checked
T est# 3Connect ohmmeter between terminal# 2 (blue for continuity.
wire) and terminal# 3 (black wire). Button released, no
continuity; however, when the button is depressed
partially and fully, continuity shall be shown. Servo and Vacuum System Test

Harness Test (see Fig. 7C ) To determine the condition of the diaphragm, remove
hose from the Servo Unit and apply 14 inches of vacuum
to the tube opening and hold in for one minute. The
vacuum shall not leak down more than 5 inches of
1. Disconnect engage switch wire harness connector vacuum in one minute. If leakage is detected, replace the
from the main harness connector (red, brown/ Servo. To utilize engine as a vacuum source, proceed as
white, and white wires). follows:

2. Connect ohmmeter between point C (brown/white 1. Disconnect Servo cable at carburetor and vacuum
stripe wire in main wire harness) and ground. Make hose from the Servo, then connect engine vacuum
sure the Regulator is well grounded to the chassis. directly to the Servo fitting.
The ohmmeter should read between 42 and 49
ohms. If a resistance either above or below the 2. Note position of Servo diaphragm.
value indicated is shown, then disconnect the 3. Start enginethe diaphragm should pull in.
connector from the Regulator and measure the 4. Clamp off engine vacuum supply line and check for
resistance of the brown/white stripe wire from leakage.
point C to D. It should measure 40 ohms 2 ohms.
3. If a resistance either above or below the value
indicated is shown, the main wiring harness should The cruise release brake valve (vacuum) and connecting
be replaced. hoses can likewise be checked using a vacuum pump.

TRUCK SUPP - SERVICE


E N G A G E M E N T SWITCH
( S H O W N IN "R E S T" P O S IT IO N )

CRU ISE RELEASE V A L V E


!
1

r 1 ^ 1 - ---------------- 1
1 i ^3 '
BROWN BLACK DK BLUE

V / V ' ' co n necto r

E N G A G E M E N T SW ITCH P O S ITIO N S
Fig. 7C--Electro-Pneum atic

REST P O S I T I O N
S chem atic

ACCESSORIES
1 5 -9
ELECTRO-PNEUMATIC SCHEMATIC D IA G R A M , CRUISE MASTER SYSTEM
15-10 ACCESSORIES

CRUISE MASTER TROUBLESHOOTING

CHECK I FOR SYSTEMS WITH ERRATIC CRUISE PERFORMANCE

CHECK II FOR INOPERATIVE SYSTEMS MAKE ALL TESTS WITH TRANSMISSION SELECTOR
IN ''PARK'' & PARKING BRAKE ON EXCEPT WHERE INDICATED OTHERWISE.
RECONNECT ANY DISCONNECTED HOSES AND/OR ELECTRICAL CONNECTORS
IN PROPER MANNER AT THE COMPLETION OF TEST.

FIG. 8 FIG. 9

CHECK I
1. CHECK SERVO CABLE ADJUSTMENT - MUST HAVE MINIMUM AMOUNT OF LOST MOTION
(SEE SERVICE ADJUSTMENT PROCEDURE, FIG. 4)

2. CHECK FOR PINCHED, KINKED, PLUGGED, OR DAMAGED VACUUM HOSES. ALSO CHECK
VACUUM FITTINGS.

3. CHECK SPEEDOMETER CABLE ROUTING. IT MUST NOT BE KINKED OR HAVE TOO SHARP
A TURNING RADIUS (NOT LESS THAN 6 RADIUS). CHECK DRIVE CABLE FOR DISTORTED
OR BENT TIPS. FERRULES MUST BE SNUG.

4. CHECK FOR A BINDING THROTTLE LINKAGE CONDITION.

5. CHECK ADJUSTMENT OF BRAKE RELEASE SWITCH & VACUUM RELEASE VALVE. (SEE
SERVICE & ADJUSTMENTS)

6. CHECK FOR PROPER OPERATING PROCEDURE OF THE ENGAGE SWITCH (SEE FIG. 1)

7. IF STEPS 1 THROUGH 6 DO NOT SOLVE THE PROBLEM PROCEED WITH CHECK H.

SPECIAL NOTE PERTAINING TO ENGAGEMENT-CRUISING SPEED ZEROING.

IF THE VEHICLE CRUISES BELOW ENGAGEMENT SPEED, SCREW THE ORIFICE TUBE OUTWARD.
IF THE VEHICLE CRUISES ABOVE THE ENGAGEMENT SPEED, SCREW THE ORIFICE TUBE
INWARD. EACH 1/4 TURN WILL CHANGE THE SPEED APPROXIMATELY ONE MPH. ENGAGEMENT
ACCURACY TESTING TO BE DONE AT 60 MPH. SNUG UP LOCK NUT AFTER EACH ADJUSTMENT.

CAUTION: DO NOT REMOVE ORIFICE TUBE FROM CASTING.

Fig. 8C--System Diagnosis Chart No. 1

TRUCK SUPP - SERVICE


ACCESSORIES 15-11

C H ECK n

Fig. 9C~System Diagnosis Chart No.2

TRUCK SUPP SERVICE


SECTION INDEX

SECTION NAME

1975
1 AIR CONDITIONING
COMPRESSOR
10-30 SERIES
TRUCK REAR AXLE
CHASSIS SERVICE DIFFERENTIAL CARRIER

and
O VERHAUL M A N U A L BRAKES

SU PPLEM ENT
ENGINE

OVERHAUL SECTION 6M CARBURETORS

The overhaul section of this manual includes new or re


vised procedures involved in disassembly and assembly of STARTING MOTOR
major components.
6Y SOLENOID AND
DELC0TR0N

AUTOMATIC
7A TRANSMISSION

CLUTCH AND
7M MANUAL TRANSMISSION

MANUAL
CHEVROLE