Chevrolet Light Duty Truck 1978 User manual

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FOREWORD
This manual includes procedures for diagnosis, maintenance and
adjustments, minor service operations, and removal and installation
for components of Chevrolet Light Duty Trucks. Procedures involv
ing disassembly and assembly of major components for these vehi
cles are contained in the 1978 Chevrolet Passenger Car and Light
Duty Truck Overhaul Manual. Wiring diagrams for 1978 trucks are
contained in a separate Wiring Diagram Booklet.
The Section Index on the contents page enables the user to
quickly locate any desired section. At the beginning of each section
containing more than one major subject is a Table of Contents,
which gives the page number on which each major subject begins.
An Index is placed at the beginning of each major subject within the
section.
Summaries of Special Tools, when required, and specifications
are found at the end of major sections.
When reference is made in this manual to a brand name, number,
or specific tool, an equivalent product may be used in place of the
recommended item.
This manual should be kept in a handy place for ready reference. If
properly used, it will enable the technician to better serve the own
ers of Chevrolet built vehicles.
All information, illustrations and specifications contained in this
literature are based on the latest product information available at
the time of publication approval. The right is reserved to make
changes at any time without notice.

1978
LIGHT DUTY
TRUCK
(SERIES 10-35)
CHASSIS SERVICE
ANUAL
CAUTION
This vehicle contains some parts dimensioned in the metric
system as well as in the customary system. Some fasteners
are metric and are very close in dimension to familiar cus
tomary fasteners in the inch system. It is important to note
that, during any vehicle maintenance procedures, replace
ment fasteners must have the same measurements and
strength as those removed, whether metric or customary.
(Num ers on the heads of metric olts and on surfaces of
metric nuts indicate their strength. Customary olts use ra
dial lines for this purpose, while most customary nuts do not
hav? strength markings.) Mismatched or incorrect fasteners
can result in vehicle damage or malfunction, or possi ly per
son tl injury. Therefore, fasteners removed from the vehicle
should e saved for re-use in the same locations whenever
possi le. Where the fasteners are not satisfactory for re-use,
care should e taken to select a replacement that matches
the original. For information and assistance, see your au-
thorzed dealer.
SECTION NA E
OA GENERAL INFOR ATION
OB LUBRICATION
1A HEATER
1B ANUAL
AIR CONDITIONING
2A FRA E
2B BU PERS
2C SHEET ETAL
2D BODY
3A FRONT ALIGN ENT
3B STEERING
3C FRONT SUSPENSION
3D REAR SUSPENSION
3E WHEELS AND TIRES
4A PROPSHAFT
4B DRIVE AXLE
4C FOUR WHEEL DRIVE
5BRAKES
6A ENGINE ECHANICAL
6B ENGINE COOLING
6C FUEL SYSTE
6D ENGINE ELECTRICAL
6E ENGINE E ISSION
6F ENGINE EXHAUST
7A AUTO ATIC
TRANS ISSION
7B ANUAL TRANS ISSION
7C CLUTCH
7D TRANSFER CASES
8CHASSIS ELECTRICAL
9ACCESSORIES
©1978 GenerJ Motors Corporation Printed in U.S.A.

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SECTION OA
GENERAL INFORMATION
CONTENTS OF THIS SECTION
Truck Model Identification.......................................... 0-1
Vehicle Identification Nu ber and Rating Plate ........ 0-1
Engine Nu ber ............................................................ 0-1
Unit and Serial Nu ber Locations.............................. 0-1
Service Parts Identification Plate................................. 0-1
Keys and Locks........................................................... 0-3
Towing ...... . ................................................................... 0-3
Vehicle Loading ........................................................... 0-3
TRUCK ODEL IDENTIFICATION
All 10-35 series odels are identified by the odel
syste shown in the chart on the following page. Basically
the designation consists of 7 characters, 2 letters followed
by five nu bers. The first letter indicates a odel and the
second identifies the chassis type. The first nu ber
designates the GVW range, the second and third identify
the cab-to-axle di ension or odel type and the last two
identify the cab or body style. See Figure OA-1.
VEHICLE IDENTIFICATION NU BER AND
RATING PLATE
A co bination vehicle identification nu ber and
rating plate used on all odels (fig. 0A-2) is located on the
left door lock pillar of C-K-G odels. On Forward Control
odels, it is attached to the dash and toe panel.
The vehicle identification nu ber sta ped on the plate
decodes into the infor ation shown in Figure 0A-3.
ENGINE NU BER
The engine nu ber indicates anufacturing plant,
onth and day of anufacture, and trans ission type. A
typical engine nu ber would be F1210TFA, which would
breakdown thus:
F - Manufacturing Plant (F-Flint, T-Tonawanda)
12 - Month of Manufacture (Dece ber)
10 - Day of Manufacture (tenth)
T - Truck
FA - Trans ission and engine type
UNIT AND SERIAL NU BER LOCATIONS
For the convenience of service technicians and
engineers when writing up certain business papers such as
Warranty Reports, Product Infor ation Reports, or
reporting product failures in any way, the location of the
various unit nu bers have been indicated. These unit
nu bers and their prefix or suffix are necessary on these
papers for various reasons - such as accounting, follow-up
on production, etc.
The prefixes on certain units identify the plant in which
the unit was anufactured and thereby per its proper
follow-up of the plant involved to get corrections ade
when necessary.
Always include the prefix in the nu ber.
Axles
Chevrolet Built
• On 10 Series, the Code is sta ped on Front of Right
Rear Axle Tube.
• On 20-35 Series, the Code is sta ped on Upper
Surface of the Right Rear Axle Tube.
Dana Built
• On Front Axles, code is sta ped on Front Surface
of Left Axle Tube.
• On Rear Axles, code is sta ped on Rear Surface of
Right Axle Tube.
Transmissions
• On 3-Speed Trans issions (except Tre ec), the Unit
Nu ber is located on Lower Left Side of Case Adjacent to
Rear of Cover.
• On Tre ec Trans issions, Unit Nu ber is located
on Upper Forward Mounting Flange of Case.
• On 70 4-Speed Trans issions, Unit Nu ber is
sta ped on Upper Center Front of Case. On Borg Warner
4-Speeds, Unit Nu ber is located on Left Side of Case
Rearward of Side Cover. Muncie 4-Speeds, Unit Nu ber
is located on Rear Face of Case below Retainer.
• On Auto atic 350 Trans ission, Unit Nu ber is
Located on Right Rear Vertical Surface of Oil Pan.
• On the Auto atic 400 Trans ission, Serial Nu ber
is Located on the Light Blue Plate on the Right Side of the
Trans ission.
Engines
• 6-Cylinder Engine Unit Nu ber Located on Pad at
Right Hand Side of Cylinder Block at Rear of Distributor.
• 8-Cylinder Engine Unit Nu ber Located on Pad at
Front, Right Hand Side of Cylinder Block.
Generators
Generator Unit Serial Nu ber is located on the Drive
End Fra e Below the Part Nu ber.
Batteries
Battery Code Nu ber is Located on Cell Cover Top
of Battery.
Starters
Starter Serial Nu ber and Production Date are
Sta ped on Outer Case, Toward Rear.
SERVICE PARTS IDENTIFICATION PLATE
The Service Parts Identification Plate (fig. OA-4) is
provided on all Truck odels. On ost series it will be
located on the inside of the glove box door, or, on Forward
Control series, it will be located on an inner body panel. The
plate lists the vehicle serial nu ber, wheelbase, and all
Production options or Special Equip ent on the vehicle
when it was shipped fro the factory including paint
infor ation. ALWAYS REFER TO THIS
INFOR ATION WHEN ORDERING PARTS.

TRUCK ODEL IDENTIFICATION
1. C = Chevrolet; T = G C Truck
2. Chassis Type _________________
3. GVW Range _________________
c c 0703 + E63+LG9
4. CA Dimension/ odel Type.
5. Cab or Body Style _______
6. Body Ordering Code _____
7. Engine Ordering Code __ _
©
Chassis Type
C— Conventional 4 x 2
G— Forward Control 4 x 2
(Body-Frame Integral)
K— Conventional 4 x 4
(Four Wheel Drive)
P— Forward Control 4 x 2
(Conventiona i)
©
Series/GVW Range
1— 4800 to 7300
2— 6400 to 8400
3— 6400 to 14.500
©
Cab or Body Style
03— Conventional Cab
(C-K models);'
Cutaway Van, Hi-Cube
Van (G models)
05— Chevy Van, Vandura
06— Suburban/Sportvan,
Rally Wagon with
Panel Rear Doors
16— Blazer, Jimmy
32— Motor Home Chassis
42— Forward Control
Chassis, Step-Van,
Value Van
43— Bonus Cab,Crew Cab
©
CA Dimension/ odel Type
05-
07-
08-
09-
10—
Blazer, Jimmy,
Step-Van, Value Van
42"/Pickup, Chassis-Cab
FC or Motor Home
Chassis, Step-Van, Value
Van
56"/Suburban,
Chassis-Cab, Pickup
-60"/FC Chassis, Chevy
Van, Vandura, Sportvan,
Rally Wagon,
Chassis-Cab, Step-Van,
Value Van
1 1— Motor Home Chassis
13— Chevy Van, Vandura,
Sportvan, Rally
Wagon, Cutaway
Van, Hi-Cube Van
14— 84"/FC or Motor Home
Chassis, Chassis-Cab,
Step-Van, Value Van
16— Cutaway Van,
Hi-Cube Van
1 8— Motor Home Chassis
©
Body Code
ZW9— Base Body
Z58— Blazer, Jimmy w/White
Top
Z59— Blazer, Jimmy w/Black
Top
Z64— RV Cutaway Van
E31 — Hi-Cube Van (1 O' Steel
96“ Wide)
E32— Step-Van, Value Van
(Steel)
E33— Step-Van, Value Van
(Aluminum)
E34— Hi-Cube Van (1 O' Steel
82" Wide)
E36— Hi-Cube Van ( 96" Wide
1 O' Aluminum)
E38— Hi-Cube Van (12' Steel
96" Wide)
E39— Hi-Cube Van (96" Wide
1 2' Aluminum)
E55— Suburban (w/End Gate)
E62— Stepside (Fenderside)
Pickup
E63— Fleetside (Wide Side)
Pickup
E94— Beauville Sportvan,
Rally STX
©
Engine Code
LD4— 250 Six
L25— 292 Six
LG9—305-2 V8
LS9— 350-4 V8
LF4— 400-4 V8
LF8— 454-4 V8
LF9 — 350-DIESEL
Fig. 0A-1-Truck Model Identification

MFD. BY GENERAL MOTORS CORPORATION
^ GVWRI I ^
GAWR FRONT I i GAWR REAR 1 I
VINI 1
CAMPER LOADING DATA
CWR1 I DIM A 1 1 DIM Bl 1
INFLATION DATA FOR TIRES FURNISHED WITH VEHICLE
FRONT I 1 PRESSURE □
REAR 1 1 PRESSURE □
Q WARRANTY VOIDED IF LOADED IN EXCESS OF RATINGS □ o
SEE OWNERS MANUAL FOR OTHER LOADING AND INFLATION DATA y
Fig. OA-2--Vehicle Identification Number and Rating Plate
Information
KEYS AND LOCKS
Two separate identifiable keys (with different cross
section) are provided for the lock cylinders of each vehicle.
The key codes are sta ped on the "knock out" plug in the
key head.
• K e y with square head (stamped " J " ) - or ignition
switch only.
0 Key with oval head (stamped " K ") - or a ll other
loc s.
TOWING
Proper lifting or towing equip ent is necessary to
prevent da age to the vehicle during any towing operation.
State (Provincial in Canada) and local laws applicable to
vehicles in tow ust be followed.
All Except Four Wheel Drive Trucks
Nor ally this vehicle ay be towed on all four wheels,
at speeds of less than 35 MPH (60 k /h), for distances up
to 50 (80 k /h), provided the driveline, axle and
trans ission, and steering syste are otherwise nor ally
operable. Use only towing equip ent specifically designed
for this purpose, following the instructions of the equip ent
anufacturer.
A separate safety chain syste ust be used. For such
towing the steering ust be locked, trans ission in neutral
and parking brake released. Attach ents ust be ade to
ain structural e bers of the vehicle. Do not attach to
bu pers or associated brackets. Re e ber that power
brake and power steering assists will not be available when
engine is inoperative.
The rear wheels ust be raised off the ground or the
drive shaft disconnected when the trans ission is not
operating properly or when a speed of 35 MPH (60 k /h)
or distance of 50 iles (80 k /h) will be exceeded.
CAUTION: I f a truc is towed on its front wheels
only, the steering wheel must be secured with the
wheels in a straight ahead position.
Four Wheel Drive Trucks
It is reco ended that the truck be towed with the
front wheels off the ground. The truck can be towed,
however, with the rear wheels off the ground if there is
da age in the rear wheel area. Refer to Figure OA-5.
STEEL TUBING REPLACE ENT
In the event that replace ent of steel tubing is required
on brake line, fuel line, evaporative e ission, and
trans ission cooling lines, only the reco ended steel
replace ent tubing should be used.
Only special steel tubing should be used to replace
brake lines. That is, a double layer and brazed steel tubing
eeting G.M. Specification 123M. Further, any other steel
tubing should be replaced only with the released steel tubing
or its equivalent. Under no condition should copper or
alu inu tubing be used to replace steel tubing. Those
aterials do not have satisfactory fatigue durability to
withstand nor al vehicle vibrations.
All steel tubing should be flared using the upset (double
lap) flare ethod.
VEHICLE LOADING
Vehicle loading ust be controlled so weights do not
exceed the nu bers shown on the Vehicle Identification
Nu ber and Rating Plate for the vehicle.
A typical exa ple of a truck in a loaded condition is
shown in Figure 0A-6. Note that the axle or GVW
capabilities are not exceeded.

19 8
LIGHT DUTY TRUCK
V.I.N. SYSTE IDENTIFICATION
Example 10000 Serial No.
Division Code Cab Engine Series
C-Chevrolet Chassis Code G.V.W. Class
T = G C Truck Type
Body Type or odel Plant
odel Designator Year Code
2. 3.
CHASSIS TYPE ENGINE CODE
Light Duty
cConventional Cab
GVan Engine Engine Engine Carb.
K4 x 4 Code Displacement Type Type
PForward Control A 3.8L (231) V/6 2-Bbl
TSteel T ilt Cab D4.1 L (250) L/6 1-Bbl
L5.7L (350) V/8 4-Bbl
M3.3L (200) V/6 2-Bbl.
R6.6L (400) V/8 4-Bbl.
S7.4 L (454) V/8 4-Bbl.
T4.8L (292) L/6 1-Bbl.
U5.0L (305) V/8 2-Bbl.
z5.7L (350) V/8 Dsl.
4.
SERIES
1-1/2 Ton
2-3/4 Ton
3-1 Ton
4-1/2 Ton (HD SUSP)
5.
BODY STYLE
2 Chassis Cowl & Forward Control Chassis
3 Chassis Cab
4 Cab & Pick-up Box or Hi-Cube Van
5 Van & Step Van
6 Sport Van & Suburban
7 Motor Home Chassis
8 Blazer, Jimmy
A —Lakewood GA.
B—Baltimore MD.
F—Flint (Chev) M l.
7.
PLANT CODE
J—Janesville Wl. V—Pontiac (GMC) Ml. 3—Detroit Ml.
S—St. Louis MO. Z —Fremont CA. 4—Scarborough Ont.
U—Lordstown OH. 1 —Oshawa Ont.
Fig. 0A-3--Vehicle Identification Number

IMPORTANT: RETAIN THIS PLATE AS A PERMANENT RECORD
Fig. 0A-4-Service Parts Identification Plate
TIPS FOR TOW IN G FOUR W HEEL D R IV E V EH IC LES
FRONT W HEELS O FF THE G RO UND
FU LL TIM E (4X4)
AUTOMATIC TRANSMISSION PAR T TIM E (4 X 4)
MANUAL TRANSMISSION
1. TRANSFER CASE IN NEUTRAL
2. TRANSMISSION IN PARK
3. MAXIMUM SPEED 35 MPH
4. MAXIMUM DISTANCE 50 MILES
NOTE: For distances over 50 miles, disconnect rear propshaft at
rear axle carrier and secure in safe position.
1. TRANSFER CASE.IN 2 H
2. TRANSMISSION IN NEUTRAL
3. MAXIMUM SPEED 35 MPH
4. MAXIMUM DISTANCE 50 MILES
NOTE: For distances over 50 miles, disconnect the rear propshaft
at rear axle carrier and secure in safe position.
REAR W HEELS OFF THE G RO UND
CAUTION: When towing a vehicle in this position, the steering wheel should be secured to keep the front wheels in a straight ahead position.
FU LL T IM E (4 X 4) PART T IM E (4 X 4)
1. TRANSFER CASE IN NEUTRAL
2. TRANSMISSION IN PARK
3. MAXIMUM SPEED 35 MPH
4. MAXIMUM DISTANCE 50 MILES
NOTE: For distances over 50 miles, disconnect front propshaft at
front axle carrier and secure in safe position.
1. TRANSFER CASE IN 2 H
2. TRANSMISSION IN NEUTRAL
3. MAXIMUM SPEED 35 MPH
4. MAXIMUM DISTANCE 50 MILES
NOTE: For distances over 50 miles, disconnect the front propshaft
at front axle carrier and secure in safe position.
A LL FOUR W HEELS ON G RO UN D
FU LL T IM E (4 X 4) PAR T T IM E (4 X 4)
1. TRANSFER CASE IN NEUTRAL
2. TRANSMISSION IN PARK
NOTE: Do not exceed speed as per State laws for towing vehicles.
1. TRANSFER CASE IN 2 H
2. TRANSMISSION IN NEUTRAL
3. MAXIMUM SPEED 35 MPH
4. MAXIMUM DISTANCE 50 MILES
NOTE: For speeds or distances greater than above, both propshafts
must be disconnected at the axle carrier end and secured in a safe
position. It is recommended that both propshafts be removed and
stored in the vehicle.
NOTE: Do not exceed speeds as per State laws for towing vehicles.
Fig. OA-5~Towing Tips

LOADED— MAXIMUM GVWR: 6200-LBS.
FRONT GAWR: 3250 LBS. REAR GAWR: 3582 LBS.
^Front Curb 2261 lbs.
Front Cargo &
Pass. Load 450 lbs.
2711 lbs.
*Rear Curb 1549 lbs.
Rear Cargo &
Pass. Load 1940 lbs.
3489 lbs.
Fig. 0A-6--Typical Vehicle Loaded Condition

SECTION
LUBRICATION I
INDEX
Maintenance Schedule ......................................
....... OB-1
.... OB-4
Engine ................................................................
....... OB-1 Propeller Shaft Slip Joints....................................
.... OB-4
Oil and Filter Reco endations.................... ....... OB-1 Universal Joints
....................................................
.... OB-4
Drive Belts ......................................................
....... OB-3 Wheel Bearings..................................................... .... OB-5
Positive Crankcase Ventilation (P.C.V.) .........
....... OB-3 Brake Master Cylinder.........................................
.... OB-5
Air Injection Reactor Syste (A.I.R.) ...........
....... OB-3 Brake and Clutch Pedal Springs..........................
.... OB-5
Controlled Co bustion Syste (C.C.S.) ........
....... OB-3 Parking Brake....................................................... .... OB-5
Evaporation Control Syste (E.C.S.) .............
....... OB-3 .... OB-5
Early Fuel Evaporation (E.F.E.) Syste ........ .......
OB-3 Hood Latch and Hood Hinge..............................
.... OB-6
Air Cleaner ......................................................
....... OB-3 Body Lubrication
.................................................
.... OB-6
Fuel Filter .......................................................
....... OB-3 Speedo eter Adapter............................................
.... OB-6
Accelerator Linkage ........................................
....... OB-3 Co plete Maintenance Schedule
.........................
.... OB-6
Auto atic Trans ission....................................
....... OB-3 Reco ended Fluids & Lubricants ......................
.... OB-22
Manual Trans ission........................................
....... OB-4 Lubrication Diagra s...........................................
.... OB-23
Trans ission Shift Linkage...............................
....... OB-4 Conventional and Forward Control Models
..... ....
OB-23
Clutch ................................................................
....... OB-4 1/2 Ton G Models.............................................
.... OB-24
AINTENANCE SCHEDULE
A separate aintenance folder has been provided with
each vehicle which contains a co plete schedule and brief
explanation of the safety, e ission control, lubrication and
general aintenance it requires. The aintenance folder
infor ation is supple ented by this section of this anual,
as well as the separate vehicle and e issions warranty
booklet also furnished with each vehicle. Read all three
publications for a full understanding of vehicle aintenance
require ents.
The ti e or ileage intervals for lubrication and
aintenance services outlined in this section are intended
as a general guide for establishing regular aintenance and
lubrication periods for trucks with light and heavy duty
e ission control syste s (see Fig. OB-1). Sustained heavy
duty and high speed operation or operation under adverse
conditions ay require ore frequent servicing.
ENGINE
Oil and Filter Recommendations
The letter designation "SE" has been established to
correspond with the require ents of GM 6136-M. "SE"
engine oils will be better quality and perfor better than
those identified with "SA" through "SD" designations and
are reco ended for all light-duty gasoline trucks
regardless of odel year and previous engine oil quality
reco endations.
Diesel equipped vehicles require SE/CD engine oil. Oil ay
be used under certain te perature conditions. See Fig. OB-4.
011 Change Period
• Use only SE (SE/CD for Diesel) engine oil.
• Light Duty Emission Vehicles -Change oil each
12 onths or 7,500 iles (12 000 k ). If ore than 7,500
iles (12 000 k ) are driven in a 12 onth period, change
oil each 7,500 iles (12 000 k ). Change oil every 3,000
iles (4 800 k ) if vehicle is equipped with Diesel engine.
• Heavy Duty Emission Vehicles -Change oil
each 4 onths or 6,000 iles (9 600 k ). If ore than 6,000
iles (9 600 k ) are driven in a 4- onth period, change
oil each 6,000 iles (9 600 k ).
• Change oil each 3 onths or 3,000 iles (4 800 k )
(2 onths or 3,000 iles (4 800 k ) on Heavy Duty
E ission Vehicles), whichever occurs first, under the
following conditions:
- Driving in dusty conditions.
- Trailer pulling or ca per use.
- Motor Ho e use.
- Extensive idling.
- Short-trip operation at freezing te peratures (engine
not thoroughly war ed-up).
LIGHT AND HEAVY DUTY E ISSION CLASS VEHICLES
All States Except California
Heavy Duty Emission
C-10 Pick-Up & Cab Chassis
(Over 6000 Lbs. GVW)
C-K 10 Blazer, Jimmy
C-K 10-20 Suburban
C-20-30 Pick-Up &
Cab Chassis
K-10-20-30 Pick-Up &
Cab Chassis
P-10-20-30 Van &
F/C Chassis
California
C-K 10-20 Pick-Up & C-K 30 Pick-Up &
Cab Chassis Cab Chassis
C-K 10-20 Suburban P-30 Van & F/C Chassis
C-K 10 Blazer, Jimmy
P-20 Van & F/C Chassis _________________________________
NOTE: Calif, vehicles 8500 Lbs. GVW or less will be Light
Duty Emission Vehicles;over 8500 Lbs. will be Heavy Duty
Emission.
Fig. OB-1-Emission Class Designation
Light Duty Emission
C-10 Pick-Up (Except
over 6000 Lbs. GVW)

°F - 2 0 0 20
i i 40 60 80
i i i 100
i
°C - 3 0 i i
- 2 0 - 1 0 i i i l
0 10 20 30 i 40
Tem p e rature Range A nticipate d B efore N ex t O il Chang e
Fig. OB-3-Oil Viscosity Chart Gasoline
• Operation in dust stor s ay require an i ediate
oil change.
• For Light Duty E ission Vehicles replace the oil
filter at the first oil change, and every second oil change
thereafter, if ileage 7,500 iles (12 000 k ) is the
deter ining factor. If ti e (12 onth) is the deter ining
factor, then change oil filter with every oil change. Change
oil filter every 3,000 iles (4 800 k ) if vehicle is equipped
with Diesel engine. For Heavy Duty E ission Vehicles,
replace the oil filter at the first oil change and every other
oil change thereafter using 6,000 iles (9 600 k ) or 12
onth as the deter ining factors. AC oil filters (or
equivalent) provide excellent engine protection.
The above reco endations apply to the first change as
well as subsequent oil changes. The oil change interval for the
engine is based on the use of reco ended oils and quality
oil filters. Oil change intervals longer than those listed above
will seriously reduce engine life and ay affect the
anufacturer’s obligation under the provisions of the New
Vehicle Warranty.
A high quality SE oil(SE/CD for Diesel) was installed in
the engine at the factory. It is not necessary to change this
factory-installed oil prior to the reco ended nor al
change period. However, check the oil level ore frequently
during the break-in period since higher oil consu ption is
nor al until the piston rings beco e seated.
NOTE: Non-detergent and other low quality oils are
specifically not reco ended.
Oil Filter Type and Capacity
• Throwaway type, 1 quart U.S. easure, .75 quart
I perial easure.
• 250 and 292 cu. in., AC Type PF-25. 305, 350, 400
and 454 cu. in., AC Type PF-35.
Crankcase Capacity (Does Not Include Filter)
• 292 L6 Engine; 5 quarts U.S. easure, 4.25 quarts
I perial easure.
• All other engines; 4 quarts U.S. easure, 3.25 quarts
I perial easure.
Recommended Viscosity
To help assure good cold and hot starting, as well as
axi u engine life, fuel econo y, and oil econo y, select
the proper oil viscosity for the te perature range
anticipated fro the chart in Fig. OB-3 and Fig. OB-4.
NOTE: SAE 5W-20 oils are not recommended for
sustained high-speed driving.
NOTE: For gasoline engine only use single viscosity
grade SAE 30 oil when prevailing te peratures will
allow. Use ulti-viscosity oils only when necessary for
starting at low te perature ranges in above chart. (It
ay be necessary to use an optional engine block heater
for starting when a bient te perature is approxi ately
-10°F(-23°C) or lower).
Checking Oil Level
The engine oil should be aintained at proper level.
The best ti e to check it is before operating the engine or
as the last step in a fuel stop. This will allow the oil
accu ulation in the engine to drain back in the crankcase.
USE THESE SAE VISCOSITY GRADES (SE/CD)
TEM PER AT UR E R AN GE AN TIC IP ATED BE FO RE NEXT OIL CHANGE
NOTICE: Use SAE 30 SE/CD oil when prevailing temp-
peratures are a ove 32*F ((fC). Use SAE 15W-40 SE/CD
oil when prevailing temperatures drop elow 32?F (CfC).
At temperatures elow & F (-IffC ), use the lock heater.
If circumstances do not allow you to use a lock heater,
use SAE 10W-30 SE/CD oil. If SE/CD oil is not availa le,
you may use SAE 10W-30 SE/CC oil. HOWEVER, we rec
ommend using the lock heater and SAE 15W-40 SE/CD
if at all possi le. If you must use 10W-30 oil (either SE/CD
or SE/CC), switch ack to the appropriate oil when pre
vailing temperatures rise a ove (fF (-life ).
Fig. OB-4--Oil Viscosity Chart Diesel

To check the level, re ove the oil gauge rod (dipstick), wipe
it clean and reinsert it fir ly for an accurate reading. The
oil gauge rod is arked "FULL" and "ADD". The oil level
should be aintained in the safety argin, neither going
above the "FULL" line nor below "ADD" line.
Supplemental Engine Oil Additives
The regular use of supple ental additives is specifically
not reco ended and will increase operating costs.
However, supple ental additives are available that can
effectively and econo ically solve certain specific proble s
without causing other difficulties. For exa ple, if higher
detergency is required to reduce varnish and sludge deposits
resulting fro so e unusual operational difficulty, a
thoroughly tested and approved additive - "G.M. Super
Engine Oil Supple ent" (or equivalent) - is available.
Drive Belts
Drive belts should be checked for proper tension every
7,500 iles (12 000 k ) or 12 onths on Light Duty
E ission vehicles, every 6,000 iles (9 600 k ) on Diesel
and 6,000 iles (9 600 k ) or 4 onths Heavy Duty
E ission vehicles. A loose belt will affect water pu p and
generator operation.
Crankcase Ventilation System
Replace Positive Crankcase Ventilation Valve (P.C.V.)
every 30,000 iles (48 000 k ) on Light Duty E ission
vehicles (except Diesel) and 24,000 iles (38 400 k ) on
Heavy Duty E ission vehicles. Clean all connecting hoses,
fittings and fla e arrestor. Clean oil fill tube breather cap
and filter asse blies (both valve covers) every 6,000 iles
(9 600 k ) and replace breather cap and valve asse bly and
flow control valve each 30,000 iles (48 000 k ) on diesel
equipped vehicles. At every oil change the syste should be
tested for proper function and serviced, if necessary. (Also
see aintenance schedule at end of this section.)
Air Injection Reactor System (A.I.R.)
Controlled Combustion System (C.C.S.)
The Air Injection Reactor syste should have the drive
belt inspected for wear and tension every 24 onths or 30,-
000 iles (48 000 k ) (4 onths or 6,000 iles (9 600 k )
on Heavy Duty E ission Vehicles), whichever occurs first.
In addition, co plete effectiveness of either syste , as well
as full power and perfor ance, depends upon idle speed,
ignition ti ing, and idle fuel ixture being set according
to specification. A quality tune-up which includes these
adjust ents should be perfor ed periodically to assure
nor al engine efficiency, operation and perfor ance.
Evaporation Control System (E.C.S.)
Every 30,000 iles (48 000 k ) 24,000 iles (38 400
k ) on Heavy Duty E ission vehicles or 24 onths, ( ore
often under dusty conditions) the filter in the base of the
canister ust be replaced and the canister inspected. Check
operation of bowl vent and purge valves.
Early Fuel Evaporation (E.F.E.) System
First 7,500 iles (12 000 k ) or 12 onths check valve
for freedo of operation. A binding condition ust be
corrected. Check hoses for cracking, abrasion or
deterioration. Replace parts as necessary.
Air Cleaner
CAUTION: D o not remove the engine air cleaner
unless temporary removal is necessary during
repair or maintenance o f the vehicle. When the air
cleaner is removed bac firing can cause fire in the
engine compartment.
NOTE: Under prolonged dusty driving conditions, it
is reco ended that these operations be perfor ed
ore often.
Replace the engine air cleaner ele ent under nor al
operating conditions every 30,000 iles (48 000 k ) on
Light Duty E ission vehicles 12,000 iles (19 200 k ) on
Heavy Duty E ission Vehicles except California 350-400
engines, replace every 24,000 iles (38 400 k ).
Fuel Filter
Light Duty Emission Vehicles -Replace filter
ele ent located in carburetor inlet every 12 onths or 15,-
000 iles (24 000 k ) whichever occurs first, or, if an in-line
filter is also used, replace both filters every 30,000 iles (48
000 k )
Heavy Duty Emission Vehicles -Replace filter
ele ent in carburetor inlet every 12 onths or 12,000 iles
(19 200 k ), whichever co es first, except Diesel and
California 350-400 engines which should be replaced every
24 onths or 24,000 iles (38 400 k ).
Accelerator Linkage
Lubricate with engine oil every 15,000 iles (24 000
k ) (12,000 iles (19 200 k ) Heavy Duty E ission
Vehicles) as follows:
1. On V8 engine, lubricate the ball stud at the
carburetor lever.
2. On L6 engine, lubricate the two ball studs at the
carburetor lever and lubricate the lever ounting stud. Do
not lubricate the accelerator cable.
AUTO ATIC TRANS ISSION
Fluid Recommendations
Use auto atic trans ission fluids identified with the
ark DEXRON® II or equivalent.
Check the fluid level at each engine oil change period.
Auto atic trans issions are frequently overfilled
because the fluid level is checked when the fluid is cold and
the dipstick indicates fluid should be added. However, the

low reading is nor al since the level will rise as the fluid
te perature increases. A level change of over 3/4 inch will
occur as fluid te perature rises fro 60°F to 180°F (16°C
to 82°C).
Overfilling can cause foa ing and loss of fluid through
the vent. Slippage and trans ission failure can result.
Fluid level too low can cause slipping, particularly,
when the trans ission is cold or the vehicle is on a hill.
Check the trans ission fluid level with engine running,
the shift lever in PARK and the vehicle level.
NOTE: If the vehicle has recently been operated for
an extended period at high speed or in city traffic in
hot weather or the vehicle is being used to pull a trailer,
an accurate fluid level cannot be deter ined until the
fluid has cooled down - usually about 30 inutes after
the vehicle has been parked.
Re ove the dipstick and touch the trans ission end
of the dipstick cautiously to find out if the fluid is cool,
war or hot.
Wipe it clean and re-insert until cap seats. Re ove
dipstick and note readings.
• If the fluid feels cool, about roo te perature 65°F
to 85°F (18°C to 29°C) the level should be 1/8 to 3/8 inch
below the ADD ark. The dipstick has two di ples below
the " ADD " ark to show this range (fig. OB-1).
• If it feels war , the level should be close to the ADD
ark (either above or below).
• If it feels hot (cannot be held co fortably), the level
should be between the ADD and FULL arks.
Drain Intervals
The trans ission operating te perature resulting fro
the type of driving conditions under which your vehicle is
used is the ain consideration in establishing the proper
frequency of trans ission fluid changes.
Change the trans ission fluid and filter every 15,000
iles (24 000 k ) on Light Duty E ission vehicles except
Diesel and Heavy Duty E ission vehicles which are
changed every 12,000 iles (19 200 k ), if the vehicle is
usually driven under one or ore of the following conditions
which are considered severe trans ission service:
• In heavy city traffic where the outside te perature
regularly reaches 90°F (32°C).
• In very hilly or ountainous areas.
• Frequent trailer pulling.
• Co ercial uses, such as taxi, police car or delivery
service.
If you do not use your vehicle under any of these
conditions, change the fluid and filter every 60,000 iles (96
000 k ) on Light Duty E ission vehicles, 12,000 iles (19
200 k ) on Diesel and 24,000 iles (19 200 k ) on Heavy
Duty E ission vehicles.
To Change Automatic 400 and Automatic
350 transmission fluid , re ove fluid fro the
trans ission su p, add approxi ately 7.5 pints U.S.
easure (6.25 pints I perial easure) of fluid for the
Auto atic 400 and add 2-1/2 qts. U.S. easure (2 qts.
I perial easure) of fluid for the Auto atic 350, to return
level to proper ark on the dipstick.
3-AND 4-SPEED ANUAL TRAN ISSION
Lubricant
Every 12 onths or 7,500 iles (12 000 k ) on Light
Duty E ission vehicles (4 onths or 6,000 iles (9 600 k )
on Heavy Duty E ission vehicles), whichever occurs first,
check lubricant level and add lubricant, if necessary, to fill
to level of filler plug hole with SAE 80W or SAE 80W-90
GL-5 Gear Lubricant. If te peratures below +32°F (0°C)
are expected, use SAE 80W GL-5 Gear Lubricant only. For
those vehicles nor ally operated in Canada, use SAE 80W
GL-5 Gear Lubricant only.
TRANS ISSION SHIFT LINKAGE
( ANUAL AND AUTO ATIC)
Every 7,500 iles (12 000 k ) or 12 onths on Light
Duty E ission vehicles (6,000 iles (9 600 k ) or 4 onths
on Heavy Duty E ission vehicles), lubricate shift linkage
and, on Manual trans ission floor control, lever contacting
faces with water resistant EP chassis lubricant which eets
General Motors Specification GM6031-M.
Clutch
The clutch pedal free travel should be checked at
regular intervals.
Lubricate the clutch cross-shaft at fitting (on Series 10
Forward Control odels also lubricate the clutch linkage
idler lever at fitting) every 7,500 iles (12 000 k ) or 12
onths on Light Duty E ission vehicles (6,000 iles (9 600
k ) or 4 onths on Heavy Duty E ission vehicles) with
water resistant EP chassis lubricant which eets General
Motors Specification GM 6031-M.
REAR AXLES
Standard
Every 12 onths or 7,500 iles (12 000 k ) on Light
Duty E ission vehicles 4 onths or 6,000 iles (9 600 k )
on Heavy Duty E ission vehicles, whichever occurs first
and every 6,000 iles (9 600 k ) for Diesel, check lubricant
level and add lubricant, if necessary. Fill to level of filler
plug hole. Use SAE 80W or SAE 80W-90 GL-5 Gear
Lubricant. For those vehicles nor ally operated in Canada,
use SAE 80W GL-5 Gear Lubricant.
Positive Locking or Positraction
Every 12 onths or 7,500 iles (12 000 k ) on Light
Duty E ission vehicles; 4 onths or 6,000 iles (9 600 k )
on Heavy Duty E ission vehicles, whichever occurs first
and every 6,000 iles (9 600 k ) for Diesel, check lubricant
level and add SAE 80W or SAE 80W-90 GL5 gear
lubricant, if necessary, to fill to level of filler plug hole.
PROPELLER SHAFT SLIP JOINTS
Propeller shaft slip joints should be lubricated every
7,500 iles (12 000 k ) or 12 onths on Light Duty
E ission vehicle, 6,000 iles (9 600 k ) on Diesel and
6,000 iles (9 600 k ) or 4 onths on Heavy Duty
E ission vehicles with water resistant EP chassis lubricant
which eets General Motors Specification GM 6031-M.
UNIVERSAL JOINTS
All universal joints are the needle bearing type.
Lubricate those universal joints (depending on truck odel)
equipped with lube fittings every 7,500 iles (12 000 k )
or 12 onths on Light Duty E ission vehicles, 6,000 iles

(9 600 k ) on Diesel and 6,000 iles (9 600 k ) or 4
onths on Heavy Duty E ission vehicles with water
resistant EP chassis lubricant which eets General Motors
Specification GM 6031-M. More frequent lubes ay be
required on heavy duty or "Off the Road" operations.
WHEEL BEARINGS
Front
NOTE: Use wheel bearing lubricant GM Part No.
1051344 or equivalent which eets all require ents of
General Motors Specification GM 6031-M.
Due to the weight of the tire and wheel asse bly it is
reco ended that they be re oved fro hub before
lubricating bearings to prevent da age to oil seal. Then
re ove the front wheel hub to lubricate the bearings. The
bearings should be thoroughly cleaned before repacking
with lubricant.
Front wheels are equipped with tapered roller bearings
on all trucks. Wheel bearings should be repacked at each
brake relining or 30,000 iles (48 000 k ) for Light Duty
E ission vehicles and 12,000 iles (19 200 k ) for Heavy
Duty E ission and four wheel drive vehicles. Do not ix
wheel bearing lubricants.
CAUTION: "Long fibre " type greases should not
be used on roller bearing front wheels.
Rear
The rear wheel bearings receive their lubrication fro
the rear axle. When installing bearings which have been
cleaned, prelube with wheel bearing grease.
BRAKE ASTER CYLINDER
Check aster cylinder fluid level in both reservoirs
every 7,500 (12 000 k ) or 12 onths on Light Duty
E ission vehicles, 6,000 iles (9 600 k ) on Diesel and
6,000 iles (9 600 k ) or 4 onths on Heavy Duty
E ission vehicles. If the fluid is low in the reservoir, it
should be filled to a point about 1/4" fro the top rear of
each reservoir with Delco Supre e No. 11 Hydraulic Brake
Fluid or equivalent.
BRAKE AND CLUTCH PEDAL SPRINGS
Lubricate brake and clutch pedal springs every 7,500
iles or 12 onths (6,000 iles (9 600 k ) or 4 onths
on Heavy Duty E ission vehicles) with engine oil for all
odels.
PARKING BRAKE
Every 7,500 iles (12 000 k ) or 12 onths on Light
Duty E ission Vehicles, 6,000 iles (9 600 k ) on Diesel
and 6,000 iles (9 600 k ) or 4 onths on Heavy Duty
E ission vehicles clean and lubricate all parking brake
pivot points with water resistant EP chassis lubricant which
eets General Motors Specification GM 6031-M.
STEERING
anual Steering Gear
The steering gear is factory-filled with steering gear
lubricant. Seasonal change of this lubricant should not be
perfor ed and the housing should not be drained. No
lubrication is required for the life of the steering gear.
Every 30,000 iles (48 000 k ) on Light Duty
E ission vehicles (36,000 iles (57 600 k ) on Heavy Duty
E ission vehicles), the gear should be inspected for seal
leakage (actual solid grease-not just oily fil ). If a seal is
replaced or the gear is overhauled, the gear housing should
be refilled with No. 1051052 (13 oz. container) Steering
Gear Lubricant which eets GM Specification GM4673-M
or its equivalent.
NOTE: Do not use EP Chassis Lube, which eets GM
Specification GM 6031-M, to lubricate the gear. DO
NOT OVER-FILL the gear housing.
Power Steering System
Check the fluid level in the pu p reservoir at each oil
change period. Add GM Power Steering Fluid (GM
1050017 or equivalent) as necessary to bring level into
proper range on filler cap indicator depending upon fluid
te perature.
If at operating te perature (approxi ately 150°F
(66°C) hot to the touch), fluid should be between "HOT"
and "COLD" arks.
If at roo te perature (approxi ately 70°F or 21°C),
fluid should be between "ADD" and "COLD" arks. Fluid
does not require periodic changing.
Linkage and Suspension
Maintain correct front end align ent to provide easy
steering, longer tire life, and driving stability.
Check control ar bushings and ball joints for wear.
Lubricate tie rods, upper and lower control ar s, and
ball joints at fittings with water resistant EP chassis
lubricant which eets General Motors Specification GM
6031-M every 7,500 iles (12 000 k ) or 12 onths for
Light Duty E ission vehicles, 6,000 iles (9 600 k ) for
Diesel equipped vehicles and 6,000 iles or 4 onths on
Heavy Duty E ission vehicles.
Lubricate every 3,000 iles (4 800 k ) or 3 onths
(2 onths on Heavy Duty E ission Vehicles), whichever
occurs first, under the following conditions:
• Driving in dusty or uddy conditions.
• Extensive off-road use.
NOTE: Ball joints ust be at + 10°F (-12°C) or ore
before lubricating.
Keep spring to axle U bolts and shackle bolts properly
tightened (see Specifications Section for torque
reco endations). Check U bolt nuts after the first 1,000
iles (1 600 k ) of operation if the U bolt or U bolt nuts
are changed in service.

HOOD LATCH AND HOOD HINGE
Every 7,500 iles (12 000 k ) or 12 onths (6,000
iles (9 600 k ) or 4 onths on Heavy Duty E ission
vehicles), whichever occurs first, lubricate hood latch
asse bly and hood hinge asse bly as follows:
1. Wipe off any accu ulation of dirt or conta ination
on latch parts.
2. Apply lubriplate or equivalent to latch pilot bolt and
latch locking plate.
3. Apply light engine oil to all pivot points in release
echanis , as well as pri ary and secondary latch
echanis s.
4. Lubricate hood hinges.
5. Make hood hinge and latch echanis functional
check to assure the asse bly is working correctly.
BODY LUBRICATION
Nor al use of a truck causes etal-to- etal ove ent
at certain points in the cab or body. Noise, wear and
i proper operation at these points will result when a
protective fil of lubricant is not provided.
For exposed surfaces, such as door checks, door lock
bolts, lock striker plates, dovetail bu per wedges, etc. apply
a thin fil 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 eets General Motors Specification
GM 6031-M.
There are other points on bodies which ay
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 ay be ade by re oving
the tri . Door weatherstrips and rubber hood bu pers
should be lightly coated with a rubber lubricant.
UNDERBODY AINTENANCE
Corrosive aterials used for ice and snow re oval and
dust control accu ulate on the underbody. If allowed to
re ain, these aterials can result in accelerated rusting and
deterioration of underbody co ponents such as fuel lines,
fra e and floor pan, exhaust syste , etc. At least once each
year, preferably after a winter’s exposure these corrosive
aterials should be re oved by flushing the underbody
with plain water. Particular attention should be given to
cleaning out those areas where ud and other foreign
aterials collect.
SPEEDO ETER ADAPTER
On vehicles so equipped, lubricate adapter at fitting
with water resistant EP chassis grease which eets General
Motors Specification GM 6031-M every 7,500 iles (12 000
k ) or 12 onths on Light Duty E ission vehicles, 6,000
iles (9 600 k ) on Diesel equipped vehicles and 6,000
iles (9 600 k ) or 4 onths on Heavy Duty E ission
vehicles.
CO PLETE VEHICLE AINTENANCE
SCHEDULE
Four separate Maintenance Schedules are used for the
1978 light duty truck odels. Two schedules are used for
Light Duty E ission vehicles while Heavy Duty E ission
and Diesel equipped vehicles each have their own schedule.
Presented on the following pages are the Maintenance
Schedules, followed i ediately by the schedule
explanation.

CO PLETE VEHICLE AINTENANCE SCHEDULE I
Light Duty Emission System
this aintenance Schedule is applicable to all engines which do not contain the letter " IT in the
engine identification code (which begins with the numeral "S”) shown in the upper left corner of
the under hood "Vehicle Emission Control Information” label. (Example: .812Y2).
When To Perform Services Item
( onths or iles, Whichever Occurs First) No. Services
Section A—Lubrication and General Maintenance
Every 12 Months or 7,500 Miles A -1 Chassis Lubrication
(12 000 km) A-2 •Fluid Levels Check
A-3 •Engine Oil Change
A-4 ‘ Oil Filter Change
See Explanation A-5 Tire Rotation
A-6 Rear Axle Lube Change
Every 12 Months or 1 5,000 Miles
(24 000 km) A-7 'Cooling System Check
See Explanation A-8 Wheel Bearing Repack
Every 30,000 Miles (48 000 km) A-9 Manual Steering Gear Check
A-10 Clutch Cross Shaft Lubrication
Every 60,000 Miles (96 000 km) A-11 Auto. Trans. Fluid & Filter Change
Section B —Safety Maintenance
Every 1 2 Months or 7,500 Miles B-1 Owner Safety Checks
(12 000 km) B-2 Tire, Wheel and Disc Brake Check
B-3 ‘ Exhaust System Check
B-4 Suspension and Steering Check
B-5 Brake and Power Steering Check
Every 12 Months or 15,000 Miles B-6 ‘ Drive Belt Check
(24 000 km) B-7 Drum Brake and Parking Brake Check
B-8 Throttle Linkage Check
B-9 Underbody Flush & Check
Section C —Emission Control Maintenance
At First 6 Months or 7,500 Miles C-1 Thermo. Controlled Air Cleaner Check
(12 000 km )—Then at 1 8 Month/
22,500 Mile (36 000 km)
Intervals as Indicated in Log
C-2 Carburetor Choke Check
C-3 Engine Idle Speed Adjustment
C-4 E^E System Check
C-5 Carburetor Mounting Torque
C-6 Vacuum Advance System, Hoses Check
Every 12 Months or 1 5,000 Miles C-1 Fuel Filter Replacement
(24 000 km) C-8 PCV System Check
PCV Valve & Filter Replacement
Every 22,500 Miles (36 000 km) C-9 Spark Plug Wires Check
C-10 Idle Speed-Up Solenoid Check
C-11 Spark Plug Replacement
C-1 2 Engine Timing Adjustment & Dist. Check
C-1 3 Carburetor Vacuum Break Adjustment (1)
Every 24 Months or 30,000 Miles C-14 ECS System Check & Filter Replacement
(48 000 km) C-15 Fuel Cap, Tank and Lines Check
Every 30,000 Miles (48 000 km) C-16 Air Cleaner Element Replacement
•Also A Safety Service
•Also An Emission Control Service
(1) All 305, all 454, all high altitude and all C alifornia engines receive this service

Presented below is a brief explanation of each of the
services listed in the preceding Complete Vehicle
Maintenance Schedule.
NORMAL VEHICLE USE— The owner's maintenance
instructions contained in this maintenance schedule
are based on the assumption that your vehicle will be
used as designed:
• to carry passengers and cargo within the lim ita
tions indicated on the VIN plate affixed to the edge
of the driver's door,
• on reasonable road surfaces within legal operating
limits,
• on a daily basis, as a general rule, for at least
several miles/kilometres, and
• on unleaded fuel.
Unusual operating conditions w ill require more
frequent vehicle maintenance as specified in the
respective sections included below.
After each of the follow ing maintenance services is
perform ed, it is recommended that you insert the
month, day and mileage in the maintenance schedule
under the appropriate "O w ner Service Log" column.
SECTION A— LUBE & GENERAL AINTENANCE
ITEM
NO. SERVICES
A-1 CHASSIS— Lubricate all grease fittings in front sus
pension and steering linkage. Also lubricate
transm ission shift linkage, hood latch, hood and
door hinges, and parking brake cable guides and
linkage, clutch linkage, propeller shaft slip joint,
universal join ts and brake and clutch pedal
springs. Lubricate suspension and steering lin
kage every 3 m onths or 3,000 miles (4 800 km)
when operating under dusty or muddy conditions
and in extensive off-road use. Also see Item B-8\
A-2 FLUID LEVELS— Check level of fluid in brake master
cylinder*, power steering pum pA, battery, en
gine*, axle, tra n sm iss io n, and w ind s h ield
washer*. Engine coolant should be checked for
proper level and freeze protection to at least -20°
F (-29° C) or to the lowest temperature expected
during the period of vehicle operation.* Proper
engine coolant also provides corrosion protec
tion.
Any significant fluid loss in any of these systems
or units could mean that a malfunction is develop
ing and corrective action should be taken im
mediately. A low fluid level in the brake master
cylinder reservoir(s) could also be an indicator
that the disc brake pads or drum brake linings
need replacing.
A-3 ENGINE OIL*— Change each 12 m onths or 7,500
miles (12 000 km), whichever occurs first under
normal driving conditions, or each 3 months or
3.000 miles (4 800 km) when the vehicle is oper
ated under the follow ing conditions: (a) driving in
dusty conditions, (b) trailer pulling, (c) extensive
idling or (d) short-trip operation at freezing tem
peratures (with engine not thoroughly warmed-
up). See your Owner's and Driver's Manual for
additional details on engine oil.
A-4 ENGINE OIL FILTER*— Replace at the first oil change
and every other oil change thereafter, if mileage
(7,500 miles) (12 000 km) is the determ ining factor.
If time (12 months) is the determ ining factor, then
change oil filter w ith every oil change.
A-5 TIRES— To equalize wear, rotate tires and adjust
inflation pressures as indicated in your Owner's
and Driver's Manual. Passenger Type Tires: Bias
or Bias-Belted, rotate every 7,500 miles (12 000
km); Radial, rotate first 7,500 miles (12 000 km)
and at least every 15,000 miles (24 000 km) there
after. Light Truck Type Tires: Bias or Bias-Belted,
rotate every 6,000 miles (9 600 km); Radial, rotate
first 6,000 miles (9 600 km) and at least every
12.000 miles (19 200 km) thereafter.
A-6 REAR AXLE— Change lubricant every 7,500 miles
(12 000,km) on all type rear axles or final drives
when using vehicle to pull a trailer.
FRONT AXLE AND TRANSFER CASE— Check every 7,500
miles (12 000 km). See Owner's and Driver's
Manual for further inform ation.
A-7 COOLING SYSTEM*— At 12-month or 15,000-mile
(24 000 km) intervals, wash radiator cap and filler
neck with clean water, pressure test system and
radiator cap for proper pressure holding capacity,
tighten hose clamps and inspect condition of all
cooling and heater hoses. Replace hoses if
checked, swollen or otherwise deteriorated. Clean
exterior of radiator core and air conditioning con
denser. Every 24 m onths or 30,000 miles (48 000
km), drain, flush, and refill the cooling system
with a new coolant solution as decribed in your
Owner's and Driver's Manual.
A-8 WHEEL BEARINGS— Clean and repack front wheel
bearings at each brake relining or 30,000 miles
(48 000 km), whichever comes first. Use a lubri
cant as specified in the "Recommended Fluid &
Lubricants" chart in this folder.
‘ Also a Safety Service
*Also an Emission Control Service
A-9 MANUAL STEERING GEAR— Check for seal leakage
around the pitman shaft and housing. If leakage
is evident (solid grease oozing out— not just oily
film ), it should be corrected immediately.
A-10 CLUTCH CROSS SHAFT— Lubricate clutch cross shaft
lever.
A-11 AUTOMATIC TRANSMISSION FLUID — Under normal
driving conditions, change the transm ission
fluid and service the sump filter every 60,000
miles (96 000 km). Under unusual conditions
such as constant driving in heavy city traffic,
trailer pulling, and com mercial applications,
services should be performed at 15,000-mile
(24 000 km) intervals. See your Owner's and
Driver's Manual for further details on transm is
sion care.
SECTION B— SAFETY AINTENANCE
NOTICE:— Items B-1 (a) thru (v) can be checked by the
owner, or driver while Items B-2 thru B-9 should only
be checked by a qualified mechanic. It is particularly
im portant that any safety systems which may have
been adversely affected in an accident be checked
and repaired as necessary before the vehicle is re
turned to use.
B-1 SAFETY CHECKS TO BE PERFORMED BY OWNER OR
DRIVER— The follow ing checks should be made
regularly during operation at no greater interval
than 12 m onths or 7,500 miles (12 000 km),
whichever occurs first, and more often when the
need is indicated. Any deficiencies should be
brought to the attention of your dealer or another
service outlet, as soon as possible, so the advice
of a qualified mechanic is available regarding the
need for repairs or replacements.
(a) STEERING COLUMN LOCK (EXCEPT VAN)— Check for
proper operation by attempting to turn key to
Lock position in the various transmission gear
ranges when the vehicle is stationary. Key
should turn to Lock position only when shift
lever is in Park ("P"). Key should be removable
only in Lock position.
(b) PARKING BRAKE— Check parking brake holding
ability by parking on a fairly steep hill and
restraining the vehicle with the parking brake
only.
CAUTION: Before making checks (c) or (d) below,
be sure to have a clear distance ahead and be
hind the vehicle, set the parking brake and firm ly
apply the regular brake. Do not depress ac
celerator pedal. Be prepared to turn off ignition

switch im m ediately if engine should start. If pre
cautions aren't follow ed vehicle may move un
expectedly, possibly causing personal injury.
(c) STARTER SAFETY SWITCH (AUTOMATIC TRANSMISSION
VEHICLES)— Check starter safety switch by at
tem pting to start the engine with the trans
mission in each of the driving gears. The start
er should operate only in the Park ("P") or
Neutral ("N ") positions.
(d) STARTER SAFETY SWITCH (MANUAL TRANSMISSION
VEHICLES)— To check, place the shift lever in
neutral, depress the clutch halfway, and at
tem pt to start. The starter should operate only
when clutch is fully depressed.
(e) TRANSMISSION SHIFT INDICATOR— Check to be sure
automatic transm ission shift indicator accu
rately indicates the shift position selected.
(f) STEERING— Be alert to any changes in steering
action. The need for inspection or servicing
may be indicated by increased effort to turn
the steering wheel, excessive free play or un
usual sounds when turning or parking.
(g) WHEEL ALIGNMENT, BALANCE AND TIRES— In addi
tion to uneven or abnormal tire wear, the need
for wheel alignm ent service may be indicated
by a pull to the right or left when driving on a
straight and level road. The need for wheel
balancing is usually indicated by a vibration of
the steering wheel or seat while driving at
normal highway speeds. Check tire inflation
pressure (including spare tire) when tires are
"co ld " at least m onthly, or more often, if
driver daily check indicates the need.— See
Owner's and Driver's Manual Driver's Daily
Checklist.
(h) BRAKES— Be alert to illum ination of the brake
warning light or changes in braking action,
such as repeated pulling to one side, unusual
sounds either when braking or between brake
applications, or increased brake pedal travel.
Any of these could indicate the need for brake
system inspection and/or service.
(i) EXHAUST SYSTEM— Be alert to any change in the
sound of the exhaust system or a smell of
fumes which may indicate a leak or overheat
condition requiring inspection and/or service.
(See also Engine Exhaust Gas Caution and
Catalytic Converter inform ation in Owner's
and Driver's Manual and Item B-3 in this fol
der.)
(j) WINDSHIELD WIPERS AND WASHERS— Check oper
ation of wipers, as well as condition and
alignment of wiper blades. Check amount and
direction of fluid sprayed by washers during
use.
(k) DEFROSTER— Check performance by m oving
controls to "D ef" and noting amount of air
directed against the windshield.
(I) REARVIEW MIRRORS AND SUN VISORS—>Check that
mirrors and sun visors stay in the selected
position.
(m) HORN— Blow the horn occasionally to be sure
that it works. Check all button locations.
(n) LAP AND SHOULDER BELTS— Check belts, buckles,
latch plates, retractors, reminder systems,
guide loops, clips, and anchors for proper
operation and for damage.
(o) SEAT ADJUSTERS— Check that seat adjusters
(and swivel seat lock, if present) securely en
gage by pushing forward and backward (and
twisting) whenever seat is adjusted.
(p) SEATBACK LATCHES (IF SO EQUIPPED)— Check to see
that seatback latches are holding by pulling
forward on the top of each folding seatback.
(q) LIGHTS AND BUZZERS— Check all instrum ent
panel illum inating and warning lights, seat
belt reminder light and buzzer (if so equip
ped), interior lights, license plate lights, side
marker lights, headlamps, parking lamps,
identification or clearance lights, tail lamps,
brake lights, turn signals, backup lamps, and
hazard warning flashers. Have headlamp aim
checked every 12 months or 15,000 miles
(24 000 km) or more often jf light beams seem
to be aimed improperly.
(r) GLASS— Check for broken, scratched, dirty or
damaged glass on vehicle that could obscure
vision or become an injury hazard.
(s| DOOR LATCHES— Check for positive closing,
latching and locking.
(t) HOOD LATCHES— Check to make sure hood
closes firm ly by lifting on the hood after each
closing. Check also for broken, damaged or
missing parts which m ight prevent secure
latching.
(u) FLUID LEAKS— Check for fuel, water, oil or other
fluid leaks by observing the surface beneath
the vehicle after it has been parked for a while.
(Water dripping from air conditioning system
after use is normal.) If gasoline fumes or fluid
are noticed at any tim e, the cause should be
determined and corrected w ithout delay be
cause of the possibility of fire.
(v) SPARE AND JACK— Check that spare tire assem
bly and jack equipment are securely stowed
at all times.
B-2 TIRES, WHEELS AND DISC BRAKES— Check disc brake
pads for wear and surface condition of rotors
while wheels are removed during tire rotation
(see Item A-5). Check tires for excessive wear or
damage. Make certain wheels are not bent or
cracked and that wheel nuts have been tightened
to the torque value shown in the Owner's and
Driver's Manual. (See "In Case of Emergency"
section).
B-3 EXHAUST SYSTEM*—Check complete exhaust sys
tem including catalytic converter and nearby
body areas for broken, damaged, missing or
mispositioned parts, open seams, holes, loose
connections or other deterioration which could
perm it exhaust fum es to seep into the passenger
compartment. Any necessary corrections should
be made immediately. To help continue integrity,
exhaust system pipes and resonators rearward
of the muffler must be replaced whenever a new
muffler is installed. Also see Item B-1 (i).
B-4 SUSPENSION AND STEERING— Check for damaged,
loose or missing parts, or parts showing visible
signs of excessive wear or lack of lubrication in
front and rear suspension and steering system.
Questionable parts noted should be replaced by
a qualified mechanic w ithout delay.
B-5 BRAKES AND POWER STEERING— Check lines and
hoses for proper attachment, leaks, binding,
cracks, chafing, deterioration, etc. Any question
able parts noted should be replaced or repaired
immediately. When abrasion or wear is evident
on lines or hoses, the cause must be corrected.
B-6 ENGINE DRIVE BELTS*— Check belts driving fan, AIR
pump, generator, power steering pump and air
conditioning com pressor for cracks, fraying,
wear and tension. Adjust or replace as necessary.
B-7 DRUM BRAKES AND PARKING BRAKE— (See Item B-2 for
disc brake check.) Check drum brake linings for
wear or cracks and other internal brake compo
nents at each wheel (drums, wheel cylinders,
etc.). Parking brake adjustment also should be
checked w henever drum brake linings are
checked.
NOTICE: More frequent brake checks should be
made if driving conditions and habits result in
frequent brake application.
B-8 THROTTLE LINKAGE— Lubricate as covered in Own
er's and Driver's Manual. Check for damaged or
missing parts, interference or binding. Any de
ficiencies should be corrected without delay by a
qualified mechanic.
B-9 UNDERBODY—Corrosive materials used for ice and
snow removal and dust control can accumulate
on the underbody. If allowed to remain, these
materials can result in accelerated rusting and
deterioration of underbody components such as
fuel lines, frame and floor pan, exhaust system,
etc. At least once each year, preferably after a
winter's exposure, these corrosive materials
should be removed by flushing the underbody

with plain water. Particular attention should be
given to cleaning out those areas where mud
and other foreign materials collect.
SECTION C— E ISSION CONTROL AINTENANCE
SCHEDULE I
NOTICE: Additional recommended maintenance
instructions relating to vehicle use, evidence of
maintenance, and service replacement parts are
included in the New Vehicle Warranty Inform a
tion folder.
C-1 THERMOSTATICALLY CONTROLLED AIR CLEANER— Inspect
installation to make certain that all hoses and
ducts are connected and correctly installed. Also
check valve for proper operation
C-2 CARBURETOR CHOKE AND HOSES— Check choke
mechanism and vacuum break for proper oper
ation. Any binding condition which may have
developed due to petroleum gum formation on
the choke shaft or from damage should be cor
rected. Check carburetor choke hoses for proper
connection, cracking, abrasion or deterioration
and correct or replace as necessary.
C-3 ENGINE IDLE SPEED— Adjust engine idle speed accu
rately (following the specifications shown on the
label under the hood). Adjustments must be
made with test equipment known to be accurate.
C-4 EARLY FUEL EVAPORATION (EFE) SYSTEM— Check valve
for proper operation. A binding condition must
be corrected. Check thermal vacuum switch for
proper operation. Check hoses for cracking, ab
rasion or deterioration. Replace parts as neces
sary.
C-5 CARBURETOR MOUNTING— At designated intervals
torque carburetor attaching bolts and/or nuts to
compensate for compression of the gasket.
C-6 VACUUM ADVANCE SYSTEM AND HOSES— Check system
for proper operation and hoses for proper con
nection, cracking, abrasion or deterioration. Re
place parts as necessary.
C-7 FUEL FILTER— Replace filter in carburetor at desig
nated intervals or more frequently if clogged.
C-8 POSITIVE CRANKCASE VENTILATION SYSTEM (PCV)— Check
the PCV system for satisfactory operation at
15,000-mile (24 000 km) intervals, and clean filter.
Replace the PCV valve at 30,000-mile (48 000 km)
intervals. Replace deteriorated hoses.
The PCV filter (located in the air cleaner) should
be replaced whenever the air cleaner element is
replaced.
C-9 SPARK PLUG WIRES— Clean exterior of wires; re
move any evidence of corrosion on end term i
nals. Inspect spark plug wires for evidence of
checking, burning, or cracking of exterior insula
tion and tight fit at distributor cap and spark plugs
or other deterioration. If corrosion cannot be re
moved or other conditions above are noted, re
place wire.
C-10 IDLE SPEED-UP SOLENOID— Check for proper oper
ation. An inoperative solenoid must be replaced.
C-11 SPARK PLUGS— Replace plugs at 22,500-m ile
(36 000 km) intervals w ith type specified in
Owner's and Driver's Manual.
C-12 TIMING AND DISTRIBUTOR CAP— Adjust ignition tim
ing following the specifications shown on label
under hood. Also, carefully inspect the interior
and exterior of the distributor cap and rotor for
cracks, carbon tracking and terminal corrosion.
Clean or replace as necessary.
C-13 CARBURETOR VACUUM BREAK ADJUSTMENT— Inspect
vacuum break linkage for proper operation. A
binding condition must be corrected. Check
hoses for proper connection, cracking, abrasion
or deterioration. Replace parts as necessary.
Adjust vacuum break at specified intervals fol
lowing procedures and specifications found in
appropriate service manual.
C-14 EVAPORATION CONTROL SYSTEM (ECS)— Check all fuel
and vapor lines and hoses for proper connections
and correct routing as well as condition. Check
operation of bowl vent and purge valves, where
applicable. Remove canister and check for cracks
or damage. Replace damaged or deteriorated
parts as necessary. Replace filter in lower section
of canister. Off road operation of four wheel drive
vehicles may necessitate more frequent filter re
placement.
C-15 FUEL CAP FUEL LINES AND FUEL TANK—
1. Inspect the fuel tank, cap and lines for damage
which could cause leaks.
2. Remove fuel cap and inspect gasket for an
even imprint from the filler neck, and any in
dications of physical damage.
3. Replace any damaged or deteriorated parts.
C-16 AIR CLEANER ELEMENT— Replace the engine air
cleaner element at designated intervals. Opera
tion of vehicle in dusty areas w ill necessitate
more frequent replacements. Your dealer can be
of assistance in determ ining the proper re
placement frequency for the conditions under
which you operate your vehicle.
NOTICE: Do not operate the engine without the
air cleaner unless temporary removal is neces
sary during repair or maintenance of the vehicle.
When the air cleaner is removed, backfiring can
cause fire in the engine compartment.
OB-10 LUBRICATION