1986 Chevy Truck Repair Manual

The 1986 Chevy Truck Repair Manual provides comprehensive guidance for maintaining and repairing C/K series trucks from the 1986 model year. This manual covers engine systems (including 4.3L V6, 5.0L V8, and 6.2L diesel), transmission, brakes, suspension, electrical systems, and routine maintenance procedures. Below are key sections for specifications, maintenance schedules, troubleshooting, and repair procedures.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Transmission & Drivetrain 5. Brake Systems 6. Suspension & Steering 7. Electrical Systems 8. Fuel System 9. Cooling System 10. Troubleshooting Guide 11. Safety Precautions

Vehicle Specifications

Key specifications for 1986 Chevy C/K series trucks including engine options, dimensions, and capacities.

Specification	Description
Engine Options	4.3L V6, 5.0L V8, 5.7L V8, 6.2L Diesel
Transmission	3-speed automatic, 4-speed manual, 5-speed manual
Wheelbase	117.5" (short bed), 131.5" (long bed)
Fuel Capacity	16-20 gallons (depending on model)
Oil Capacity	4-5 quarts (with filter)
Coolant Capacity	12-14 quarts
Gross Vehicle Weight	4,600-6,200 lbs
Brake System	Front disc, rear drum
Electrical System	12-volt negative ground
Tire Size	P195/75R15 to P235/75R15

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

Oil and filter change: Every 3,000 miles or 3 months
Air filter replacement: Every 15,000 miles
Fuel filter replacement: Every 30,000 miles
Spark plugs: Every 30,000 miles
Coolant flush: Every 24 months or 30,000 miles
Brake fluid: Check every 6 months, replace every 2 years
Transmission fluid: Every 30,000 miles
Timing belt: Every 60,000 miles (if equipped)

WARNING! Always use manufacturer-recommended fluids and parts. Failure to follow maintenance schedule may void warranty.

Engine Systems

Detailed repair procedures for engine components and systems.

Engine Removal: Disconnect battery, drain fluids, remove accessories, unbolt mounts
Cylinder Head: Torque sequence: 65 ft-lbs in proper sequence
Valve Adjustment: Set clearance to 0.015" (intake), 0.025" (exhaust)
Timing Chain: Align timing marks at TDC compression stroke
Carburetor Adjustment: Set idle mixture screws 1.5 turns out from seated position
Ignition System: Set initial timing to 4° BTDC with vacuum advance disconnected

Transmission & Drivetrain

Service procedures for manual and automatic transmissions.

Transmission fluid change: Use Dexron II for automatic, 80W-90 for manual
Clutch replacement: Adjust free play to 1-1.5 inches at pedal
U-joint service: Grease every 3,000 miles
Differential service: Change fluid every 30,000 miles
Transfer case: Use automatic transmission fluid for 4WD models

CAUTION! Support transmission properly when removing. Use jack stands for safety.

Brake Systems

Brake system maintenance and repair procedures.

Component	Specification
Brake Pad Thickness	Replace when less than 1/8" remaining
Rotor Thickness	Minimum: 1.215" (front), 0.990" (rear)
Brake Fluid	DOT 3
Master Cylinder	1" bore diameter
Bleeding Sequence	Right rear, left rear, right front, left front

Suspension & Steering

Steering and suspension component service.

Ball joints: Check for play; replace if movement exceeds 1/8"
Tie rod ends: Replace if any detectable play
Shock absorbers: Replace in pairs
Wheel alignment: Toe-in: 1/8" to 1/4", Camber: 0° to +1°
Power steering: Use Type F automatic transmission fluid

Electrical Systems

Wiring diagrams and electrical component testing.

Battery: 12V, 550 CCA minimum
Alternator: 63-85 amp output
Starter: 1.4 kW gear reduction type
Fuse Panel: Located under dashboard on driver's side
Wiring Color Codes: Red (power), Black (ground), Yellow (ignition)

Fuel System

Carburetor and fuel system service procedures.

Fuel pump pressure: 4-6 psi (mechanical), 9-13 psi (electric)
Carburetor float level: Set to manufacturer specifications
Fuel filter replacement: Located in fuel line near carburetor
Tank cleaning: Remove sediment and rust particles
Fuel line inspection: Check for cracks and leaks

Cooling System

Radiator, thermostat, and cooling system maintenance.

Thermostat: 195°F opening temperature
Radiator Cap: 15-16 psi pressure rating
Coolant Mixture: 50/50 ethylene glycol and water
Fan Clutch: Check for proper engagement
Water Pump: Replace if bearing play exceeds 1/16"

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery, ignition, fuel	Check battery voltage, spark at plugs, fuel delivery
Overheating	Coolant, thermostat, water pump	Check coolant level, thermostat operation, water pump flow
Poor fuel economy	Carburetor, timing, brakes	Adjust carburetor, check timing, inspect brake drag
Brake pull	Calipers, alignment, tires	Check stuck calipers, wheel alignment, tire pressure
Transmission slipping	Fluid level, bands, clutch	Check fluid level, adjust bands (automatic), clutch (manual)

Diagnostic Tip: Always start with simplest solutions first - check fluids, connections, and basic adjustments.

Safety Precautions

Essential safety procedures for all repair work.

Always disconnect battery before electrical work
Use jack stands - never work under vehicle supported only by jack
Wear safety glasses when using tools
Work in well-ventilated area when dealing with fuels and chemicals
Keep fire extinguisher nearby when working on fuel system
Allow engine to cool before opening cooling system

EMERGENCY: In case of accident or injury, call 911 immediately. Have first aid kit available.