lock CHEVROLET CAMARO 1967 1.G Chassis Workshop 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 6-27

and spark plug shields.

4.
Remove exhaust manifold flange nuts, then lower ex-

haust pipe assembly (hang exhaust pipe from frame

with wire).

5.
Bend french lock tabs (fig. 3V), remove end bolts

then remove center bolts and remove manifold from

engine.

NOTE: A 9/16 thin-wall 6 point socket, sharp-

ened at the leading edge, then started on the head

of the bolt and tapped in place with a hammer,

simplifies bending of french locks.

Installation

1.
Clean mating surfaces on manifold and head, then

install manifold in position and install center bolts.

2.
Install end bolts with french locks under them.

3.
Torque center bolts to specifications, then torque end

bolts to specifications, and bend french lock tabs to

lock end bolts.

4.
Using a new flange gasket install exhaust pipe to

manifold flange.

5.
On 396 and 427 cu. in. engines, clean and install

spark plugs using new gaskets. (Torque spark plugs

to specifications.)

6. Install and connect Delcotron.

7.
Connect the battery ground cable.

8. Start engine and check for leaks.

ROCKER ARM COVER

Removal

1.
Remove air cleaner.

2.
Disconnect crankcase ventilation hoses (as required).

3.
Disconnect temperature wire from rocker arm cover

clips.

4.
Remove rocker arm cover.

CAUTION: DO NOT pry rocker arm cover

loose. Gaskets adhering to cylinder head and
Installation

1.
.Clean gasket surfaces on cylinder head and rocker

arm cover with degreaser then, using a new gasket,

install rocker arm cover and torque bolts to

specifications. .

2.
Connect crankcase ventilation hoses (if disconnected).

3.
Connect temperature wire at rocker arm cover clips.

4.
Install air cleaner.

VALVE MECHANISM

Removal

1.
Remove rocker arm covers as outlined.

2.
Remove rocker arm nuts, rocker arm balls, rocker

arms and push rods.

NOTE: Place rocker arms, rocker arm balls

and push rods in a rack so they may be rein-

stalled in the same location.

Installation and Adjustment

NOTE: Whenever new rocker arms and/or

rocker arm balls are being installed, coat bear-

ing surfaces of rocker arms and rocker arm

balls with Molykote or its equivalent.

1.
Install push rods; Be sure push rods seat in lifter

socket.

2.
Install rocker arms, rocker arm balls and rocker

arm nuts.

3.
Adjust valves when lifter is on base circle of cam-

shaft lobe as follows:

With Hydraulic Valve
Lifters

2L.
Crank engine until
mark on torsional damper

lines up with center or "0M mark on the timing

tab and the engine is in the number 1 firing posi-

tion. This may be determined by placing fingers

on the number 1 cylinder valve as the mark on the

rocker arm cover may be sheared by bumpii

end of rocker arm cover rearward with palm

hand or a rubber mallet.

Fig.
3V - Exhaust Manifold French Locks
Fig.
4V - Valve Adjustment (Hydraulic)

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-28

damper comes near the "0" mark on the front

cover.
11
the valves are not moving, the engine is

in the number 1 firing position. If the valves

move as the mark comes up to the timing tab, the

.
engine is in number 6 firing position and crank-

shaft should be rotated one more revolution to

reach the number 1 position,

b.
Valve adjustment is made by backing off the ad-

justing nut (rocker arm stud nut) until there is

play in the push rod and then tighten nut to just

remove all push rod to rocker arm clearance.

' this may be determined by rotating push rod with

fingers as the nut is tightened (fig. 4
V).
When

push rod does not readily move in relation to the

rocker arm, the clearance has been eliminated.

The adjusting nut should then be tightened an

additional 1 turn to place the hydraulic lifter

plunger in the center of its travel. No other

adjustment is required.

c. With the engine in the number 1 firing position

as determined above, the following valves may be

adjusted.

Exhaust - 1, 3, 4, 8

Intake - 1, 2, 5, 7

d. Crank the engine one revolution until the pointer

"(X" mark and torsional damper mark are again

in alignment. This is number 6 firing position.

With the engine in this position the following

valve may be adjusted.

Fig.
5V - Valve Adjustment (Mechanical)
Exhaust - 2, 5, 6, 7

Intake
-•
3, 4, 6, 8

With Mechanical Valve
Lifters

a. Crank engine until mark on torsional damper

lines up with center or "0" mark on the timing

tab and the engine is in the number 1 firing posi-

tion. This may be determined by placing fingers

on t£e number 1 cylinder valve as the mark on the

damper comes near the n0" mark on the front

cover. If the valves are not moving, the engine

is in the number 1 firing position. If the valves

move as the mark comes up to the timing tab, the

engine is in number 6 firing position and crank-

shaft should be rotated one more revolution to

reach the number 1 position.

b.
With the engine in the number 1 firing position as

determined above, adjust the following valves to

specifications with a feeler gauge (fig. 5V).

Exhaust - 4, 8

Intake - 2, 7. .

c. Turn crankshaft 1/2 revolution (180°) clockwise

and adjust the following valve to specifications

with a feeler gauge.

Exhaust -3,6

Intake - 1, 8

d. Turn crankshaft 1/2 revolution (180°) clockwise

until the pointer "0" mark and torsional-damper

mark are again in alignment. This is number 6

firing position. With the engine in this position,

adjust the following valves to specifications with

a feeler gauge.

Exhaust -5,7

Intake - 3, 4

e. Turn crankshaft 1/2 revolution (180°) clockwise

and adjust the following valves to specifications

with a feeler gauge.

Exhaust - 1, 2

Intake - 5, 6

f. Readjust valves (hot and running) as outlined

under "Engine Tune Up".

4.
Install rocker arm covers as outlined.

5.
Adjust carburetor idle speed and mixture.

VALVE LIFTERS

Hydraulic valve lifters very seldom require attention;

The lifters are extremely simple in design, readjust-

ments are not necessary, and servicing of the lifters re-

quires only that care and cleanliness be exercised in the

handling of parts.

Locating Noisy Lifters (Hydraulic)

Locate a noisy valve lifter by using a piece of garden

hose approximately four feet in length. Place one end of

the hose near the end of each intake and exhaust valve

with the other end of the hose to the ear. In this manner,

the sound is localized making it easy to determine which

lifter is at fault.

Another method is to place a finger on the face of the

valve spring retainer. If the lifter is not functioning

properly, a distinct shock will be felt when the valve re-

turns to its seat.-*

The general types of valve lifter noise are as follows:

1.
Hard Rapping Noise—Usually caused by the plunger

becoming tight in the bore of the lifter body to such

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 6-30

c". Install the valve locks and release the compres-

sor tool making sure the locks seat properly in

the upper groove of the valve stem.

NOTE: Grease may be used to hold the locks

in place while releasing the compressor tool.

396 and 427
cu.
in.
Engines

a. Install new valve stem oil seal (coated with oil)

in position over valve guide.

b.
Set the valve spring and damper and valve cap in

place.

c. Compress the spring with Tool J-5892 and install

the valve locks, then release the compressor tool,

making sure the locks seat properly in the groove

of the valve stem.

NOTE: Grease may be used to hold the locks

in place while releasing the compressor tool.

7.
Install spark ,plug, using a new gasket, and torque to

specifications. -

8. Install and adjust valve mechanism as outlined.

CYLINDER HEAD ASSEMBLY

Removal

1.
Remove intake manifold as outlined.

2.
Remove exhaust manifolds as outlined.

3.
Remove valve mechanism as outlined.

4.
Drain cooling system (block).

5.
Remove cylinder head bolts, cylinder head and gas-

ket. Place cylinder head on two blocks of wood to

prevent damage.

Installation

CAUTION: The gasket surfaces on both the

head and the block must be clean of any foreign

ttter and free of nicks or heavy scratches.

Under bolt threads in the block and threads on

Pie cylinder head bolt must be cleaned. (Dirt

will affect bolt torqueT)

1.
On engines using a STEEL gasket, coat both sides of

a new gasket with a good sealer, spread the sealer

thin and even. One method of applying the sealer that

will assure the proper- coat is with the use of a paint

roller. Too much sealer may hold the beads of the

gasket away from the head or block.

CAUTION: Use no sealer on engines using a

composition STEEL ASBESTOS gasket.

2.
Place the gasket in position over the dowel pins with

the bead up.

3.
Carefully guide cylinder head into place over dowel

pins and gasket.

4.
Coat threads of cylinder head bolts with sealing

compound and install finger tight.

5.
Tighten cylinder head bolts a little at a time in the

sequence shown on the torque sequence chart until

the specified torque is reached.

6. Install the exhaust manifold as outlined.

7.
Install the intake manifold as outlined.

8. Install and adjust the valve mechanism as outlined.
OIL
PAN

Removal

Chevrolet
and Camaro

1.
Disconnect battery positive cable.

2.
Disconnect distributor cap from distributor (to pr-e-

vent breaking distributor cap when engine is raised).

3.
Drain radiator, then disconnect lower radiator hose

at water pump and remove oil dip stick and tube

(where necessary). '

4.
Remove fan blade.

5.
Raise vehicle then drain engine oil;

6. Remove through bolts from engine front mounts.

Disconnect and remove starter.

7.
On vehicles equipped with automatic transmissions,

remove converter housing underpan.

8. Disconnect steering rod at idler lever then swing

steering linkage 4pwn for oil pan clearance.

9. Rotate crankshaft untii timing mark on torsional

damper is at 6:00 o'clock position.

10.
Using a suitable jack, and a block of wood to prevent

damaging oil pan, raise engine "enough to insert 2" x

4"
wood blocks under engine mounts (fig. 8V), then

lower engine onto blocks.

NOTE: If 2" x 4" wood blocks are cut 5-1/2"

long they can be used on all Chevrolet engines.

The 5-1/2" length up for In-line engines and the

4"
side up for V8 engines.

11.
Remove oil pan and discard gaskets and seals.

NOTE: -On the 396 and 427 cu. in. engine, the

oil pan has three 1/4" x 20 attaching bolts at ,

crankcase front cover. One located at each

corner and one at lower center.

Chevelle

1.
Remove engine from vehicle as outlined.

2.
Lower engine onto jack stands, one at each front

Tnaount and one at transmission extension.

CAUTION: Leave engine lift attached to en-

gine.
Do not remove all weight of engine off

engine lifET

3.
Remove starter.

4.
On vehicles equipped with automatic transmission

remove converter housing underpan.

5.
Remove oil pan and discard gaskets and seals.

Fig.
8V - Engine Blocked for Pan Removal

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 6-34

Fig.
15V - Centering Tool in Cover (396 and 427)

396 and 427
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 install Aligning

Tool J-22102 in oil seal (fig. 15V) then using a new

cover gasket coated with gasket sealer, install cover

and gasket on cylinder block.

3.
Install cover screws and torque bolts to specifica-

tions,
then remove Aligning Tool J-22102.

4.
Install water pump as outlined in Section 6K.

5. Install torsional damper as outlined.

6. Install oil pan as outlined.
Fig.
17V - Installing Oil Seal (Cover Removed)

396 and 427

OIL SEAL (FRONT COVER)

Replacement

With Cover
Removal

1.
With cover removed, pry old seal out of cover from

the front with a large screw driver.

2.
Install new seal so that open end of the seal is toward

the inside of cover and drive it into position with

Tool J-995 on 283, 327 and 350 cu. in. engines

(fig. 16V) or Tool J-22102 on 396 and 427 cu. in.

engines (fig. 17V).

CAUTION: Support cover at sealing area to

avoid distorting cover.

Without Cover
Removal

1.
With torsional damper removed, pry old seal out of

cover from the front with a large screw driver, being

careful not to damage the surface on the crankshaft.

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 on 283, 327 and 350 cu. in. engines (fig. 18V)

or Tool J-22102 on 396 and 427 cu. in. engines

(fig. 19V),

Fig.
16V - Installing Oil Seal (Cover Removed)

283,
327 and 350
Fig.
18V- Installing Oil Sea! (Cover Installed)

283,
327 and 350

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