
ENGINE 6-40
SPECIAL TOOLS
Fig.
2T - Engine Special Tools
1. J-4536
2.
J-1264
J-8058
J-5853
3.
J-8087
4.
J-8001
5.
J-7316
6. J-8037
7.
J-8020
J-8021
J-8032
J-22249
J-22147
J-22250
8. J-6994
9. J-9510
10.
J-5239
J-6305
J-8062
J-8101
J-5830
J-7049
14.
J-8089
11.
12.
13.
Engine Lift Kit
(0-200 ft. Ib.) Torque Wrench
(0-50 ft. Ib.) *
(0.-100 in. Ib.)
Indicator Set (Cylinder Bore)
Indicator Set (Universal)
Belt Tension Gauge
Piston Ring Compressor
(3 9/16") Piston Ring Expander
(3 7/8")
(4")
(3 15/16")
(4 3/32")
(4 1/4")
Piston Pin Assembly Tool
Piston Pin Assembly Tool
(3/8") Connecting Rod Guide Set
01/32") m
Valve Spring Compressor
Valve Guide Cleaner
(11/32") Valve Guide Reamer Set
(3/8")
Carbon Removing Brush
. 15. J-5860
16.
J-5715
J-6036
17.
J-6880
18.
J-5802
19.
J-9534
20.
J-9535
21,
J-22144
22.
J-8369
23.
J-6098
24.
J-0971
25.
J-6978
26.
J-22197
27.
J-21058
28.
J-1619
29.
J-5825
30.
J-8105
31.
J-5590
32.
J-0966
33.
J-21742
34.
J-22102
35.
J-8340
36.
J-5595
Cylinder Head Bolt Wrench
(.003") Rocker Arm Stud Reamer
(.013")
Rocker Arm Stud Installer
Rocker Arm Stud Remover
Distributor Lower Bushing Remover
Distributor Lower Bushing Installer
Oil Pick-up Screen Installer
Oil Pick-up Screen Installer
Cam Bearing Tool
Camshaft Gear Support
Torsional Damper Puller
Torsional Damper Installer
Torsional Damper and Sprocket Installer
Crankshaft Sprocket Puller
Crankshaft Sprocket Puller
Crankshaft Gear Puller
Crankshaft Sprocket or Gear Installer
Crankcase Cover Centering Gauge
Crankcase Cover Centering Gauge
Crankcase Cover Tool
Grankcase Cover Seal Installer
Crankcase Cover Seal Installer
CHEVROLET CHASSIS SERVICE MANUAL

SECTION 6K
ENGINE COOLING
INDEX
Page
General Description . . . 6K-1
Maintenance and Adjustments 6K-1
Coolant Level 6K-1
Coolant System Checks 6K-1
Periodic Maintenance 6K-2
Cleaning 6K-2
Reverse Flushing 6K-2
Radiator 6K-2
Page
Cylinder Block and Cylinder Head 6K-2
Hot Water Heater 6K-2
Fan Belt . 6K-2
Adjustment ....". 6K-2
Thermostat . 6K-2
Replacement 6K-2
Water Pump. . . . 6K-3
Removal 6K-3
Installation 6K-3
GENERAL DESCRIPTION
A pressure cooling system is provided for on all
models by a pressure type radiator cap (fig. 1). The
pressure type radiator cap used is designed to hold a
pressure above atmospheric pressure in the cooling
system. Excessive pressure is relieved by a valve within
the cap that opens to radiator overflow.
The water pump is a ball bearing, centrifugal vane
impeller type. It requires no care other than to make
certain the air vent at the top of the housing and the drain
holes in the bottom do not become plugged with dirt or
grease. Removal and installation of the water pump is
covered in this section. For overhaul procedures of the
water pump refer to Section 6K of the Passenger Chassis
Overhaul Manual.
For radiator, refer to Section 13 of this manual For
radiator shroud, refer to Section 11 of this manual.
Fig.
I—Pressure Radiator Cap
MAINTENANCE AND ADJUSTMENTS
Coolant Level
The radiator coolant level should only be checked when
the engine is cool, particularly on cars equipped with air
conditioning. If the radiator cap is removed from a hot
cooling system, serious personal injury may result
The cooling system fluid level should be maintained
one inch below the bottom of the filler neck of the radia-
tor when cooling system is cold, or at the bottom of the
filler neck when the system is warm. It is very impor-
tant that the correct fluid level be maintained. The seal-
ing ability of the radiator cap is affected when the cooling
level is too high.
All passenger car cooling systems are pressurized
with a pressure cap which permits safe engine operation
at cooling temperatures of
up
to 247°F.
When the radiator cap is removed or loosened, the
system pressure drops to atmospheric, and the heat
which had caused water temperature to be higher than
212°F, will be dissipated by conversion of water to
steam. Inasmuch as the steam may form in the engine
water passages, it will blow coolant out of the radiator
upper hose and top tank, necessitating coolant replace-
ment Engine operating temperatures higher than the
normal boiling point of water are in no way objectionable
so long as the coolant level is satisfactory when the
engine is cooL
Upon repeated coolant loss, the pressure radiator cap
and seat should be checked for sealing ability. Also, the
cooling system should be checked for loose hose con-
nections, defective hoses, gasket leaks, etc.
Coolant System Checks
1.
Test for restriction in the radiator, by warming the
engine up and then turning the engine off and feeling
the radiator. The radiator should be hot at the top
and warm at the bottom, with an even temperature
rise from bottom to top. Cold spots in the radiator
indicate clogged sections.
2.
Water pump operation may be checked by running the
engine while squeezing the upper radiator hose. A
pressure surge should be felt Check for a plugged
vent-hole in pump.
NOTE:
A defective head gasket may allow ex-
haust gases to leak into the cooling system.
This is particularly damaging to the cooling
system as the gases combine with the water to
form acids which are particularly harmful to
the radiator and engine.
3.
To check for exhaust leaks into the cooling system,
drain the system until the water level stands just
above the top of the cylinder head, then disconnect
the upper radiator hose and remove the thermostat
and fan belt. Start the engine and quickly accelerate
several times. At the same time note any appreci-
able water rise or the appearance of bubbles which
CHEVROLET CHASSIS SERVICE MANUAL

ENGINE COOLING 6K-2
are indicative of exhaust gases leaking into the coolr
ing system.
Periodic Maintenance
Periodic service must be performed to the engine cool-
ing system to keep it in efficient operating condition.
These services should include a complete cleaning and
reverse flushing as well as a reconditioning service.
In the course of engine operation, rust and scale ac-
cumulate in the radiator and engine water jacket. The
accumulation of these deposits can be kept to a minimum
by the use of a good rust inhibitor but it should be
remembered that an inhibitor will not remove rust al-
ready present in the cooling system.
Two common causes of corrosion are: (1) air suction--
Air may be drawn into the system due to low liquid level
in the radiator, leaky water pump or loose hose con-
nections; (2) exhaust gas leakage—Exhaust gas may be
blown into the cooling system past the cylinder head
gasket or through cracks in the cylinder head and block.
Cleaning
A good cleaning solution should be used to loosen the
rust and scale before reverse flushing the cooling
system. There are a number of cleaning solutions avail-
able and the manufacturer's instructions with the particu-
lar cleaner being used should always be followed.
An excellent preparation to use for this purpose is GM
Cooling System Cleaner. The following directions for
cleaning the system applies only when this type cleaner
is-used.
1.
Drain the cooling system including the cylinder block
and then close both drain plugs.
2.
Remove thermostat and replace thermostat housing.
3.
Add the liquid portion (No. 1) of the cooling system
cleaner.
4.
Fill the cooling system with water to a level of about
3 inches below the top of the overflow pipe.
5. Cover the radiator and run the engine at moderate
speed until engine coolant temperature reaches 180
degrees.
6. Remove cover from radiator and continue to run the
engine for 20 minutes. Avoid boiling.
7. While the engine is still running, add the powder
portion (No. 2) of the cooling system cleaner and
continue to run the engine for 10 minutes.
8. At the end of this time, stop the engine, wait a few
minutes and then open the drain cocks or remove
pipe plugs. Also remove lower hose connection.
CAUTION: Be careful not to scald your hands.
NOTE:
Dirt and bugs may be cleaned out of
the radiator air passages by blowing out with air
pressure from the back of the core.
Reverse Flushing
Reverse flushing should always be accomplished after
the system is thoroughly cleaned as outlined above.
Flushing is. accomplished through the system in a direc-
tion opposite to the normal flow. This action causes the
water to get behind the corrosion deposits and force
them out.
Radiator
1.
Remove the upper and lower radiator hoses and re-
place the radiator cap,
2.
Attach a lead-away hose at the top of the radiator.
3.
Attach a new piece of hose to the radiator outlet
connection and insert the flushing gun in this hose.
4.
Connect the water hose of the flushing gun to a water
outlet and the air hose to an air line.
5. Turn on the water and when the radiator is full, turn
on the air in short blasts, allowing the radiator to
fill between blasts of air.
CAUTION: Apply air gradually as a clogged
radiator will stand only a limited pressure.
6. Continue this flushing until the water from the lead-
away hose runs clear.
Cylinder Block and Cylinder Head
1.
With the thermostat removed, attach a lead-away
hose to the water pump inlet and a length of new hose
to the water outlet connection at the top of the engine.
NOTE:
Disconnect the heater hose when re-
verse flushing engine.
2.
Insert the flushing gun in the new hose.
3.
Turn on the water and when the engine water jacket
is full, turn on the air in short blasts.
4.
Continue this flushing until the water from the lead-
away hose runs clear.
Hot Water Heater
1.
Remove water outlet hose from heater core pipe.
2.
Remove inlet hose from engine connection.
3.
Insert flushing gun and flush heater core. Care must
be taken when applying air pressure to prevent
damage to the core.
Fan Belt
Adjustment
1.
Loosen bolts at Delcotron slotted bracket.
2.
Pull Delcotron away from engine until desired ten-
sion reading is obtained with a strand tension gauge.
Refer to Section 6, "Engine Tune-Up".
3.
Tighten all Delcotron bolts securely.
Thermostat
The thermostat consists of a restriction valve actuated
by a thermostatic element. This is mounted in the hous-
ing at the cylinder head water outlet above the water
pump,
thermostats are designed to open and close at
predetermined temperatures and if not operating properly
should be removed and tested as follows.
Replacement
1.
Remove radiator to water outlet hose.
2.
Remove thermostat housing bolts and remove water
outlet and gasket from thermostat housing (fig. 2).
3.
Inspect thermostat valve to make sure it is in good
condition.
4.
Place thermostat in hot water 25° above the temper-
ature stamped on the thermostat valve.
5. Submerge the valve completely and agitate the water
thoroughly. Under this condition the valve should
open fully.
6. Remove the thermostat and place in water 10° below
temperature indicated on the valve.
7. With valve completely submerged and water agitated
thoroughly, the valve should close completely.
8. If thermostat checks satisfactorily, re-install, using
a new housing gasket.
9. Refill cooling system.
CHEVROLET CHASSIS SERVICE MANUAL

SECTION 6M
ENGINE FUEL
CONTENTS OF THIS SECTION
Page
Carburetors 6M-1 Fuel Pumps .
Air Cleaners 6M-7 Special Tools
Page
6M-10
6M-12
CARBURETORS
INDEX
Page
General Description 6M-1
Service Procedures 6M-1
Preliminary Checks 6M-1
Idle Speed and Mixture Adjustment ........... 6M-1
Fast Idle Adjustment .................. 6M-3
Choke Adjustment 6M-3
Float Adjustment 6M-4
Page
Additional Adjustments 6M-4
Removal 6M-4
Test Before Installation 6M-5
Installation 6M-5
Fuel Filter Maintenance 6M-5
Choke Coil Replacement 6M-5
Throttle Linkage Adjustment . . 6M-6
GENERAL DESCRIPTION
Various carburetors (fig. lc) are used with Chevrolet,
Chevelle, Chevy II, Camaro and Corvette passenger
vehicles. These carburetors are designed to meet the
particular requirements of engines, transmissions and
vehicles, therefore carburetors that look alike are not
always interchangeable. (Refer to carburetor part num-
ber and/or specifications.)
Because many service procedures for the various
carburetors are similar, typical illustrations and pro-
cedures are used except where specific illustrations or
procedures are necessary to clarify the operation.
This section covers removal, installation and adjust-
ments (on engine) of carburetors. Also covered in this
section are maintenance procedures for choke coils,
throttle linkage and fuel filters. For carburetor .over-
haul procedures and additional adjustments (bench), re-
fer to Section 6M of the Overhaul Manual under the
carburetor being serviced.
Specifications for carburetors are located in the back
of this manual.
SERVICE PROCEDURES
Preliminary Checks
1.
Thoroughly warm-up engine. If the engine is cold,
allow to run for at least 15 minutes.
2.
Inspect torque of carburetor to intake manifold bolts
and intake manifold to cylinder head bolts to exclude
the possibility of air leaks.
3.
Inspect manifold heat control valve (if used) for free-
dom of action and correct spring tension.
Idle Speed and Mixture Adjustment (Except Air Injection
Reactor System)
NOTE:
This adjustment should be performed
with engine at operating temperature and park-
ing brake applied.
1.
Remove Air Cleaner.
2.
Connect tachometer and vacuum gauge to engine, then
set hand brake and shift transmission into neutral.
3.
As a preliminary adjustment, turn idle mixture
screws lightly to seat and back out 1-1/2 turns.
CAUTION: Do not turn idle mixture screw
tightly against seat or damage may result.
4.
With engine running (choke wide open) adjust idle
speed screw to specified idle speed, (automatic
transmission in drive, synchronized transmission in
neutral).
5. Adjust idle mixture screw to obtain highest steady
vacuum at specified idle speed.
NOTE:
On air conditioned vehicles, turn air
conditioning to the "on" position and hold the
hot idle compensator valve closed while adjust-
ing idle speed and idle mixture screws.
NOTE:
On Rochester BV carburetors the idle
mixture screw should be turned out 1/4 turn
from the "lean roll" position. The definition
of "lean roll" point is a 20 to 30 rpm drop
in engine speed obtained by leaning the idle
mixture.
6. Repeat Steps 4 and5 as needed for final adjustment.
NOTE:
If necessary, final adjustment of the \
carburetor may be made with the air cleaner
installed.
7. Turn engine off, remove gauges and install air
clearer.
CHEVROLET CHASSIS SERVICE MANUAL

ENGINE FUEL 6M-5
3.
Disconnect choke rod or choke cable.
4.
Disconnect accelerator linkage.
5.
If equipped with Automatic transmission, discon-
nect TV linkage.
6. Remove carburetor attaching nuts and/or bolts and
remove carburetor.
Test Before Installation -
It is good shop practice to fill the carburetor bowl
before installing the carburetor. This reduces the strain
on the starting motor and battery and reduces the pos-
sibility of backfiring while attempting to start the engine.
A fuel pump clamped to the bench, a small supply of fuel
and the necessary fittings enable the carburetor to be
filled1 and the operation of the float and'intake needle and
seat to be checked. Operate the throttle several times
and check the discharge from the pump jets before in-
stalling the carburetor.
Installation
1.
Be certain throttle body and intake manifold sealing
surfaces are clean.
2.
Install new carburetor to manifold flange gasket (if
required).
3.
Install carburetor over manifold studs.
4.
Start vacuum and fuel lines at carburetor.
5.
Install attaching nuts and/or bolts and tighten
securely.
6. Tighten fuel and vacuum lines.
7.
Connect and adjust accelerator and TV linkage.
8. Connect choke tube or choke rod.
9. Adjust idle speed and mixture, then install air
cleaner. #
Fuel Filter Maintenance
1.
Disconnect fuel line connection at inlet fuel filter
nut.
2.
Remove inlet fuel filter nut from carburetor with a
1"
box wrench or socket.
3.
Remove filter element and spring (fig. 4c).
Fig. 5C-Choke Coil-L6 Engine
4.
Fig. 4C-Fuel Filter
Check element for restriction by blowing on cone
end, element should allow air to pass freely.
5.
Clean element by washing in solvent and blowing out.
Blow in opposite direction of fuel flow.
NOTE: Element should be replaced if plugged
or if flooding ocpurs. A plugged filter will
result in a loss of engine power or rough (pul-
sating) engine feel, especially at high engine
speeds.
6. Install element spring, then install element in car-
buretor so small section of cone faces out.
7.
Install new gasket on inlet fitting nut then install
nut in carburetor and tighten securely.
8. Install fuel line and tighten connector.
Choke Coil Replacement
L6 Engines (Fig. 5c)
1.
Remove air cleaner then disconnect choke rod upper
clip.
2.
Remove bolts attaching choke coil to manifold, then
remove choke coil and choke rod as an assembly.
3.
Disconnect choke rod from choke coil.
4.
Connect choke rod to new choke coil and install as-
sembly on manifold.
5.
Install bolts and tighten securely.
6. Adjust and connect choke rod as outlined.
7.
Start and warm-up the engine then check operation
of choke and install air cleaner.
V8 Engines (Fig. 6c)
1.
Remove air cleaner then disconnect choke rod upper
clip.
2.
Remove choke coil as follows:
WITH ROCHESTER 2GV CARBURETOR
• Remove the choke coil shield by prying with a
screw driver in the cut out provided then re-
move the choke rod.
CHEVROLET CHASSIS SERVICE MANUAL

ENGINE FUEL 6M-6
Fig.
6C-Choke Coil-V8 Engine
• Remove bracket and choke coil assembly.
WITH ROCHESTER 4MV AND
HOLLEY CARBURETORS
• Remove the choke coil shield by prying with a
screw driver in the cut out provided then lift
shield carefully over rod.
• Remove choke rod, bracket screw and choke
coil assembly
3.
Install a new choke coil assembly being sure the
locating tab is in the forward hole of the intake
manifold then install mounting screw.
4.
Complete installation as follows:
WITH ROCHESTER 2GV CARBURETOR
• Check that the choke rod eye of the coil is
below the stop tab on the bracket then install
the choke
ro
• Install the choke coil shield over the choke coil
and move shield to best fit along manifold.
WITH ROCHESTER 4MV AND
HOLLEY CARBURETORS
• Install the choke rod and adjust as necessary
(without choke coil shield installed).
• Disconnect choke rod upper end and lower choke
coil shield over choke rod and install over choke
coil.
• Move shield to best fit along manifold and con-
nect upper end of choke rod.
5. Be sure choke valve moves freely from full open
to full closed position.
6. Start and warm up the engine and check operation
of the choke.
7. Install the air cleaner.
Throttle Linkage Adjustment (Fig. 7c or 8c)
1.
Disconnect throttle rod swivel at throttle lever on
carburetor.
2.
On automatic transmission equipped vehicles dis-
connect TV rod at throttle lever.
3.
Hold carburetor throttle in wide open position, push
throttle rod rearward (to position accelerator pedal
at the floor mat) and adjust swivel to just enter hole
in throttle lever.
4.
Connect swivel to throttle lever and install accelera-
tor return spring.
CAMARO & CHEVY II V8
CHEVELLE & CHEVROLET
V8
CAMARO
&
CHEVY
II
V8
CHEVELLE &
CHEVROLET V8
ALL SERIES
IN LINE
ALL SERIES
INLINE
Fig.
7C—Throttle Linkage—Chevrolet, Chevelle, Chevy II and Camaro
CHEVROLET CHASSIS SERVICE MANUAL

ENGINE FUEL 6M-7
5. On vehicles equipped with automatic transmission
hold throttle rod in full throttle position, pull TV
rod to full detent position and adjust TV rod to just
enter hole on throttle lever, then connect TV rod at
throttle lever.
NOTE:
If equipped with anti-stall device (dash-
pot),
set carburetor fast idle cam on high step
and adjust dash-pot to just contact throttle
lever.
327
CU.
IN.
427
CU.
IN.
Fig.
8C—Throttle Linkage-Corvette
AIR
CLEANERS
INDEX
Page
General Description 6M-7
Service Procedures . . 6M-8
Polyurethane. Element 6M-8
Maintenance 6M-8
Oil Bath 6M-8
Page
Maintenance
...........* 6M-8
Oil
Wetted
Paper
Element
6M-9
Replacement
* . 6M-9
Testing 6M-9
Tool J-7852 . 6M-9
GENERAL DESCRIPTION
Air cleaners on all models operate primarily to re-
move dust and dirt from the air that is taken into the
carburetor and engine. All air cleaners on engines
equipped with "Closed Positive" ventilation incorporate
flame arresters. Every 12,000 miles the flame ar-
resters should be removed, cleaned in solvent and blown
dry with compressed air.
An oil wetted polyurethane element air cleaner (fig. 1A)
is standard equipment on In Line engines. This type
cleaner element is reusable and should be removed,
cleaned, re-oiled and reinstalled every 12,000 miles or
more often during dusty or other adverse driving con-
ditions. The optional, oil bath air cleaner (available on
Chevrolets with L6 engine) should be cleaned and re-
filled with oil at oil change intervals.
On the V8 engines,, a replaceable, oil wetted paper
element type is used (fig; 2A). Both ends of me paper
element are bonded with plastisol sealing material.
The improved oil wetted paper elements have increased
filtering capacity over their dry paper predecessors.
Oil on the paper causes the element to become diBcolored
by a small amount of dirt but does not necessarily mean
the element is plugged or reduced in efficiency. Every
12,000 miles or more often during dusty or other adverse
driving conditions, either replace oil wetted paper ele-
ment or test element using ToolJ-7825.
CHEVROLET CHASSIS SOVICE/MANUAL

ENGINE FUEL 6M-8
^T^l^^/'-vN
COVER
BOTTOM
Fig. 1A—Polyurethane Element Air Cleaner
OIL RESISTANCE
SEAL
BOTTOM
BONDED PAPER
ELEMENT
COVER
Fig. 2A—Paper Element Air Cleaner
SERVICE
PROCEDURES
POLYURETHANE ELEMENT
Maintenance
1.
Remove cover wing nut, cover and filter element.
2.
Visibly check the element for tears or rips and re-
place if necessary.
3.
Clean all accumulated dirt and grime from air
cleaner bottom and cover. Discard air horn to air
cleaner gasket.
4.
/Remove support screen from element and wash
element in kerosene or mineral spirits; then squeeze
out excess solvent (fig. 3A).
NOTE: Never use a hot degreaser or any sol-
vent containing acetone or similar solvent*
5.
Dip element into light engine oil and squeeze out
excess oil.
NOTE: Never shake, swing or wring the ele-
me.nt to remove excess oil or solvent as this
may tear the polyurethane material. Instead,
"squeeze" the excess from the element.
6. Install element'on screen support (fig. 4A).
7.
Using a new gasket, replace air cleaner body over
carburetor air horn.
8. Replace the element in the air cleaner. Care must
be taken that the lower lip of the element is properly
placed in the assembly and that the filter material
is not folded or creased in any manner that would
cause an imperfect seal. Take the same precautions
when replacing the cover that the upper lip of the
element is in proper position.
9.<•
Replace cover and wing nut.
OIL BATH
Maintenance
L Remove air cleaner assembly.
2.
Remove cover and filter element assembly.
Empty oil out of
accumulated dirt.
cleaner and clean out all oil and
Fig. 3A—Cleaning Polyurethane Element
Fig.
4A—Polyurethane Support
CHEVROLET CHASSIS SERVICE MANUAL