ENGINE 6-18
NOTE:
Bolts into crankcase cover should be
installed last. They are installed at an angle
and holes line up after rest of pan bolts are
snugged up.
Chevrolet and Camaro
a. If crankshaft was rotated while pan was off, place
timing mark at 6:00 o'clock position.
b.
Install oil pan and torque bolts to specifications.
c. Using a suitable jack (and a block of wood to prevent
damaging oil pan) raise engine enough to remove 2" x
4"
wood blocks, then lower engine.
d. On vehicles equipped with automatic transmission
install converter housing underpan, then connect
transmission cooler lines.
e. Install and connect starter.
f. Lower vehicle and install fan blades as outlined in
Section 6K.
g. Connect upper and lower radiator hoses.
h. Install through bolts in engine front mounts.
i. Connect battery positive cable.
j.
Fill radiator with coolant and fill engine with oil,
then start engine and check for leaks.
Chevelie
* a. Install oil pan and torque bolts to specifications.
b.
On vehicles equipped with automatic transmission,
install converter housing underpan.
c. Install starter.
d. Install engine as outlined.
Chevy II
a. Install oil pan and torque bolts to specifications.
Fig.
7L- Removing Oil Sea! (Lower Half)
Fig.
8L - Removing Oil Seal (Upper Half)
b.
On L6 engines, install front crossmember.
c. Connect steering idler arm.
d. Install starter and connect wires.
e. Connect battery cable, fill with oil, start engine and
check for leaks.
OIL PUMP
Removal
1.
Remove oil pan as outlined.
2.
Remove two flange mounting bolts, pickup pipe bolt,
then remove pump and screen as an assembly.
Installation
1.
Align oil pump drive shafts to match with distributor
tang, then install oil pump to block positioning flange
over distributor lower bushing. Use no gasket.
NOTE:
Oil pump should slide easily into place,
if not, remove and reposition slot to align with
distributor tang.
2.
Install oil pan using new gaskets and seals as
outlined.
CHEVROLET CHASSIS SERVICE MANUAL
ENGINE 6-20
Fig.
11 L
- J-21742 Centering Tool in Cover
tion from walking off the hub during installation
of damper.
2.
3.
Attach damper installer Tool J-22197 to damper.
Tighten fingers of tool to prevent weight from moving
(fig. 10L).
Position damper on crankshaft and drive into posi-
tion, using J-5590, until it bottoms against crankshaft
gear (fig. 10L). Remove installer tool.
4.
Install fan belt and adjust using strand tension gauge.
5.
If so equipped, install accessory drive pulley and
belt.
6. Install radiator core as outlined in Section 13.
7.
Fill cooling system and check for leaks.
CRANKCASE FRONT COVER
Fig.
121
- Installing Oil Seal (Cover Removed)
Fig. 13L- Installing Oil Seal (Cover installed)
Removal
1.
Remove oil pan as outlined.
2.
Remove crankshaft pulley and hub or torsional
damper as outlined.
3.
Remove crankcase front coyer attaching bolts, re-
move cover and gasket.
Installation
1.
Clean gasket surfaces on block and crankcase front
cover.
2.
Install centering Tool J-996 or Tool J-21742 in
crankcase front cover seal (fig. 11L).
3.
Coat the gasket with gasket sealer and place in posi-
tion on cover, then install crankcase front cover to
block and torque bolts to specifications.
4.
Remove centering tool.
NOTE: It is important that centering tool be
used to align crankcase front cover so that
crankshaft hub or torsional damper installation
will not damage seal and to position seal evenly
around the balancer or hub surface.
5.
Install crankshaft hub and/or torsional damper as
outlined.
6. Install oil pan with new gaskets and seals as outlined.
OIL SEAL (FRONT COVER)
Replacement
With Cover Removal
1.
With cover removed, pry old seal out of cover from
the front with screw driver being careful not to
distort cover.
2.
Install new seal so that open end of the seal is toward
the inside of cover and drive it into position with
ToolJ-995 (fig. 12L).
CHEVROLET CHASSIS SERVICE MANUAL
ENGINE 6-21
CAUTION: Support cover
•
at sealing area.
(Tool J-971 may be used as support.)
Without Cover
Removal
1.
With crankshaft pulley and nub or torsional damper
removed, pry old seal out of cover from the front
with a large screw driver, being careful not to dam-
age the seal surface on the cover.
2.
Install new seal so that open end of seal is toward the
inside of cover and drive it into position with Tool
J-8340 (fig. 13L).
CAMSHAFT
Measuring Lobe Lift
NOTE: Procedure is similar to that used for
checking valve timing.. If improper valve
operation is indicated, measure the lift of each
push rod in consecutive order and record the
readings.
1.
Remove valve mechanism as outlined.
2.
Position indicator with ball socket adapter on push
rod (fig. 14L).
3.
Rotate the crankshaft slowly in the direction of rota-
tion until the lifter is on the heel of the cam lobe.
At this point, the push rod will be in its lowest
position.
4.
Set dial indicator on zero, then rotate the crankshaft
slowly, or attach an auxiliary starter switch and
"bump" the engine over, until the push rod is in the
fully raised position.
CAUTION: The primary distributor lead must
be disconnected from the negative post on the
coil and the ignition switch must be in the ON
position. Failure to do this will result in a
damaged grounding circuit in the ignition switch.
Fig.
15L - Timing Gear Marks
5.
Compare the total lift recorded from the dial indica-
tor with specifications.
6. Continue to rotate the crankshaft until the indicator
reads zero. This will be a check on the accuracy of
the original indicator reading.
7.
If camshaft readings for all lobes are within specifi-
cations, remove dial indicator assembly.
8. Install and adjust valve mechanism as outlined.
Removal
1.
Remove valve lifters as outlined,
2.
Remove crankcase front cover as outlined.
3.
Remove radiator as outlined in Section 13.
4.
Remove grille as outlined in Section 13.
5.
Remove fuel pump as outlined in Section 6M.
6. Align timing gear marks then remove the two cam-
shaft thrust plate bolts by working through holes in
Fig.
ML - Measuring Camshaft Lobe Lift
Fig.
16L - Checking Camshaft Gear Runout
CHEVROLET CHASSIS SERVICE MANUAL
ENGINE 6-26
6. Remove lifting device and lifting adapter then install
rocker arm covers as outlined.
7.
On synchromesh equipped vehicles, install clutch
cross-shaft engine bracket, then adjust and connect
clutch as outlined in Section 7.
8. Connect:
• Speedometer cable.
• Shift linkage at transmission.
• Transmission cooler lines (if so equipped).
9. Install propeller shaft.
10.
Remove jack stands and lower vehicle.
11.
Connect: \ '
Power steering pump lines (if so equipped).
Vacuum line to power brake unit (if so equipped).
Exhaust pipes at manifold flanges.
Accelerator linkage at pedal lever.
Fuel line at fuel pump.
Engine cooler lines (if so equipped).
Oil pressure gauge lines (if so equipped).
12.
Connect wires at:
Coil
Oil pressure switch
Temperature switch
Delcotron
Starter solenoid
13.
Install pulley, fan blade and fan belt as outlined in
Section 6K.
14.
Install radiator and shroud as outlined in Section 13.
15.
Install and adjust hood as outlined in Section 11.
16.
Connect battery cables.
17.
Fill with coolant, engine oil and transmission oil,
then start engine and check for leaks.
18.
Perform necessary adjustments and install air
cleaner.
INTAKE MANIFOLD
Removal
1.
Drain radiator and remove air cleaner.
2.
Disconnect:
Battery cables at battery.
Upper radiator and heater hose at manifold.
Accelerator linkage at pedal lever.
Fuel line at carburetor. ;
Wires at temperature sending switch and coil
(both sides).
Power brake hose at carburetor base.
Spark advance hose at distributor.
Crankcase ventilation hoses (as required).
3.
Remove distributor cap and mark rotor position with
chalk. Remove distributor clamp and distributor,
then position distributor cap rearward clear of
manifold.
4.
Remove coil.
5.
Remove manifold-to-head attaching bolts, then re^
move manifold, (with carburetor on) from engine and
discard gaskets and seals.
6. If manifold is to be replaced,,transfer:
Carburetor and carburetor mounting studs.
Temperature sending switch.
Water outlet and thermostat (use new gasket).
Heater hose adapter.
Choke coil.
Installation
1.
Clean gasket and seal surfaces of manifold, cylinder
heads and block.
2.
Install manifold end seals on block as shown (fig.
2V).
3.
Install side gaskets on cylinder heads using sealing
compound around water passages (fig. 2V).
4.
Install manifold bolts, and torque to specifications in
the sequence outlined on the Torque Sequence Chart.
5.
Install coil.
6. Install distributor with the rotor pointing at the chalk
mark, then install distributor cap.
NOTE:
If the crankshaft has been rotated while
the distributor was removed, time distributor to
number 1 cylinder as outlined in Section 6Y.
7.
Connect:
Battery cables at battery.
Upper radiator and heater hose at manifold.
Accelerator linkage at pedal lever.
Fuel line at carburetor.
Wires at temperature sending switch and coil
(both sides)!
Power brake hose at carburetor base.
Spark advance hose at distributor.
Crankcase ventilation hoses (as required).
Fill with coolant, start engine, check for leaks and
adjust timing and carburetor idle speed and mixture.
EXHAUST MANIFOLD
Removal
NOTE:
If equipped with "Air Injection Reactor
System", remove air manifold and tubes as out-
lined in Section 6T.
1.
Disconnect battery ground cable.
-
2.
Disconnect and remove Delcotron (as required).
3.
On 396 and 427 cu. in. engines, remove spark plugs
Fig. 2V - Intake Manifold Gasket and Seal Location
CHEVROLET CHASSIS SERVICE MANUAL
ENGINE 6-29
an extent that the return spring can no longer push
the plunger back up to working position. Probable
causes are:
a. Excessive varnish or carbon deposit causing ab-
normal stickiness.
b.
(Sailing or "pick-up" between plunger and bore of
lifter body, usually caused by an abrasive piece of
dirt or metal wedging between plunger and lifter
body.
2.
Moderate Rapping Noise--Probable causes are:
a. Excessively high leakdown rate.
b.
Leaky check valve seat.
c. Improper adjustment.
3.
General Noise Throughout the Valve Train-rThis
will, in almost all cases, be a definite indication of
insufficient oil supply, or improper adjustment.
4.
Intermittent Clicking—Probable causes are:
a. A microscopic piece of dirt momentarily caught
between ball seat and check valve ball.
b.
In rare cases, the ball itself may be out-of-round
or have a flat spot.
c. Improper adjustment.
In most cases where noise exists in one or more lifters
all lifter units should be removed, disassembled, cleaned
in a solvent, reassembled, and reinstalled in the engine.
If dirt, corrosion, carbon, etc. is shown to exist in one
unit, it more than likely exists in all the units, thus it
would only be a matter of time before all lifters caused
trouble.
Removal
1.
Remove intake manifold as outlined.
2.
Remove valve mechanism as outlined.
3.
Remove valve lifters.
NOTE: Place valve lifters in a rack so they
may be reinstalled in the same location.
Installation
1.
Install valve lifters.
NOTE: Whenever new valve lifters are being
installed coat foot of valve lifters with Molykote
or its equivalent.
2.
Install intake manifold as outlined.
3.
Install and adjust valve mechanism as outlined.
VALVE STEM OIL SEAL AND/OR VALVE SPRING
Replacement
1.
Remove rocker arm cover(s) as outlined.
2.
Remove spark plug, rocker arm and push rod on the
cylinders to be serviced.
3.
Apply compressed air to the spark plug hole to hold
tl*e valves in place.
NOTE: A tool to apply air to the cylinder is
available through local jobbers or may be manu-
factured. In manufacturing this Tool a AC-46N
Spark Plug or its equivalent is recommended.
This will make the Tool universal for all
Chevrolet engines. Chisel the spark plug as
shown, then drive the porcelain out of the plug
by tapping the center electrode against a hard
block. Using a 3/8" pipe tap, cut threads in the
remaining portion of the spark plug and assem-
ble as shown (fig. 6V).
Fig.
6V - Air Adapter Tool
4.
Using Tool J-5892, to compress the valve spring, re-
move the valve locks, valve cap, and valve spring and
damper (fig. 7V).
5.
Remove valve stem oil seal.
6. Remove as follows:
283, 327 and 350 eu. in.
Engines
a. To replace, set the valve spring and damper,
valve shield and valve cap in place. The close
coiled end of the spring is installed against the
cylinder head.
b.
Compress the spring with Tool J-5892 and install
oil seal in the lower groove of the stem, making
sure the seal is flat and not twisted.
NOTE: A light coat of oil on the seal will help
prevent twisting.
Fig.
7V - Compressing Valve Spring
CHEVROLET CHASSIS SERVICE MANUAL
ENGINE 6-31
Chevy II
1.
Disconnect battery positive cable.
2.
Drain engine oil.
3.
Disconnect and remove starter.
4 Disconnect steering idler arm bracket at right hand
frame rail and swing steering linkage down for pan
clearance.
5.
Disconnect* exhaust pipes at manifolds and allow
pipes to hang free.
6. Remove oil pan and discard gaskets and seals.
Corvette
1.
Disconnect battery positive cable then remove oil
dipstick and tube.
2.
Raise and support vehicle then drain engine oil.
3.
Remove starter and flywheel underpan.
4.
Disconnect steering linkage idler at frame and lower
the linkage.
5.
Remove oil pan and discard gaskets and seals.
6. On Hi-Performance engines, the oil baffle must
be removed before additional operations can be
performed.
NOTE: On the 427 cu. in. engine, the oil pan
has three 1/4" x 20 attaching bolts at crankcase
front cqver. One located at each corner and one
at lower center.
Installation
1.
Thoroughly clean all gasket sealing surfaces.
NOTE: Use a new pan. gasket set.
2.
Install side gaskets on pan rails, using.gasket sealer
as a retainer.
3.
Install rear oil pan seal in groove in rear main
bearing cap with ends (fig. 9V) butting side gaskets.
4.
Install oil pan front seal in groove in .crankcaee front
cover, with ends butting side gaskets.
5.
If crankshaft was rotated while £>an was off, place
timing mark at 6:00 o'clock position.
6. Install oil pan and torque bolts to specifications.
NOTE: On 396 and 427 cu. in. engines, start
three 1/4" x 20 bolts into crankcase front cover
before tightening, any other pan bolts.
7.
Complete installation as follows:
Chevrolet
and Camaro
a. Using a suitable jack (and a block of wood to pre-
vent damaging oil pan) raise engine enough to re-
move 2" x 4" wood blocks, then lower engine.
b.
On vehicles equipped with automatic transmission
install converter housing underpan.
c. Install through bolts in engine front mounts.
d. Install and connect starter. Connect steering rod
at idler lever.
e. Lower vehicle and install fan blade.
f. Cbnnnect lower radiator hose, then install oil dip
stick tube and dip stick.
g. Connect distributor cap and battery positive
cable.
h. Fill radiator with coolant and fill engine with oil,
then start engine and check for leaks.
Chevelle
a. On vehicles equipped with automatic transmission
Fig.
9V - Oil Pan Gasket and Seal Location
install converter housing underpan.
b.
.Install starter.
c. Install, engine as outlined.
Chevy II
a. Connect exhaust pipe to manifold flange using new
packing seals.
b.
Connect steering idler arm bracket.
c. Connect starter wires..
d. Connect battery cable.
e. Fill with oil, start engine and check for leaks.
Corvette
a. Connect steering linkage.
b.
Install oil dip stick tube and dip stick then con-
nect battery cables.
c. Fill engine with oil, then start engine and check
for leaks.
OIL PUMP
Removal
1.
Remove oil pan as outlined.
2.
Remove pump to rear main bearing cap bolt and re-
move pump and extension shaft.
Installation
1.
Assemble pump and extension shaft to rear main
CHEVROLET CHASSIS SERVICE MANUAL
ENGINE 6-33
Fig.
13V - Installing TorsionaI Damper (283, 327 and 350)
4.
Remove accessory drive pulley, then remove tor-
sional damper retaining bolt (if so equipped).
5. Install Tool J-6978 to torsional damper and turn
puller screw to remove damper from crankshaft
(fig. 12V).
6. Remove tool.
Installation
CAUTION: It is necessary to use installer tool
to prevent the inertia weight section from walk-
ing off the hub during installation of damper.
283, 327 and 350 cu. in. Engines
(Except 327-325 HP & 350 HP)
1.
Coat front cover seal contact area (on torsional
damper) with engine oil.
Fig.
14V - Installing Torsional Damper (396 and 427)
2.
Attach damper installer Tool J-22197 to damper.
Tighten fingers of tool to prevent weight from moving
(fig. 13V).
3.
Position damper on crankshaft and drive into position
until it bottoms against crankshaft sprocket (fig.
13V).
Remove installer tool.
4.
Install accessory drive pulley.
5. Install radiator and shroud as outlined in Section 13.
6. Install fan pulley and fan as outlined in Section 6K.
7. Install fan belt and adjust to specifications using
strand tension gauge.
8. Fill cooling system, start engine and check for leaks.
396 and 427
cu.
in.
Engines
1.
Coat front cover seal contact area (on damper) with
engine oil.
2.
Place damper in position over key on crankshaft.
3.
Using Tool J-21058 pull damper onto crankshaft
(fig. 14V).
NOTE:
If engine or radiator has not been re-
moved from the vehicle a 1/2"- 20 x 5" bolt and
a
1/2"-20
nut may be used in place of the bolt
and nut of Tool J-21058.
CAUTION: Install bolt in crankshaft with suffi-
cient thread engagement (min. 1/2").
4.
Remove tool from crankshaft.
5. Install damper retaining bolt and torque to specifica-
tions,
then install accessory drive pulley.
6. Install radiator and shroud as outlined in Section 13.
7. Install fan pulley and fan as outlined in Section 6K.
8. Install fan belt and adjust to specifications using
strand tension gauge.
9. On Corvettes, lower engine and install front mount
through-bolts.
10.
Fill cooling system, start engine and check for leaks.
327
cu.
in. (325 & 350 HP)
Engine
Install damper as outlined for 396 and 427 cu. in. en-
gines,
using a 7/16"-20 x 5" bolt and nut in place of the
bolt and nut furnished with J-21058.
CRANKCASE FRONT COVER
Removal
1.
Remove oil pan as outlined.
2.
Remove torsional damper as outlined.
3.
Remove water pump as outlined in Section 6K.
4.
Remove crankcase front cover attaching bolts and
remove front cover and gasket, then discard gasket
Installation
283, 327 and 350 cu. in.
Engine
1.
Make certain that cover mounting face and cylinder
block front face are clean and flat.
2.
Coat the oil seal with engine oil and using a new
cover gasket, coated with gasket sealer, install cover
and gasket over dowel pins and cylinder block.
3.
Install cover screws and torque bolts to
specifications.
4.
Install water pump as outlined in Section 6K.
5. Install torsional damper as outlined.
6. Install oil pan as outlined.
CHEVROLET CHASSIS SOVKZ MANUAL
ENGINE 6-36
Fig.
23V - Installing Crankshaft Sprocket
(283,
327
and
350)
8* Draw camshaft sprocket onto camshaft, using the
three mounting bolts. Torque to bolt specifications.
9. Lubricate timing chain with engine oil.
10.
Install crankcase front cover and torsional damper
as outlined.
CAMSHAFT
Measuring Lobe Lift
NOTE: Procedure is similar to that used for
checking valve timing. If improper valve opera-
tion is indicated, measure the lift of each push
rod in consecutive order and record the
readings.
1.
Remove valve mechanism as outlined.
2.
Position indicator with ball socket adapter on push
rod (fig. 26V).
3.
Rotate the crankshaft damper slowly in the direction
of rotation until the lifter is on the heel of the cam
lobe.
At this point, the push rod will be in its lowest
position.
Fig.
25V- Installing Timing Chain
Fig.
24V - Installing Crankshaft Sprocket
(396 and 427)
Fig.
26V - Measuring Camshaft Lobe Lift
CHEVROLET CHASSIS SERVICE MANUAL