torque CHEVROLET CAMARO 1967 1.G Chassis Repair Manual

REAR SUSPENSION AND DRIVE LINE 4-42

Fig.
113—Rear Suspension Special Tools (Chevrolet, Camaro, Chevelle and Chevy II)

1.
J-8614

2.
J-21057

3. J-21468

4. J-5748

5. J-21830

6. J-7574

7. J-7877

8. J-21474

9. J-9458
Companion Flange Remover—Consists of J-8614-1

Holder, J-8614-2 Nut and J-8614-3 Screw.

Drive Pinion Oil Seal Installer—Heavy-Duty Axle.

Drive Pinion Oil Seal Installer—Light Duty

Axle—Used with J-9458.

Positraction Torque Measuring Adapter.

Upper and Lower Control Arm Bushing Puller-

Consists of J-21830-2 Adapter, J-21830-4 Receiver,

J-21830-7 Bridge—Used with J-21058-6 Spacer,

and J-21830-3 Spacer.

Chevrolet Lower Control Arm Front Bushing

Remover/Installer—Consists of J-7574-4 Receiver,

J-7574-1 Remover, J-7574-2 Installer Adapter,

J-7574-3 Spacer.

Chevrolet Tie Rod Bushing Remover/Installer—Consists

of J-7877-1 Remover Adapter, J-7877-2 Bushing

Receiver, J-7877-3 Installer Adapter—Used with

j-7079-2
Handle.

Chevelle Control Arm Bushing Remover—Consists of

J-21474-5 Receiver, J-21474-1 Spacer and

J-21474-2 Adapter.

Drive Pinion Oil Seal Installer—Light Duty

Axle—Used with J-21468.
10.
J-21051 Rear Wheel Bearing and Oil Seal Installer-

Heavy Duty Axle—Used with J-7079-2.

11.
J-21491 Rear Wheel Bearing and Oil Seal Installer—Light

Duty Axle—Used with J-8092.

12.
J-2619 Rear Wheel Bearing and Oil Seal Remover (Slide

Hammer).

13.
J-8119 Rear Wheel Bearing and Oil Seal Remover—Used

with J-2619.

14.
J-21058 Upper and Lower Control Arm Puller—Consists of

J-21058-15 Screw and J-21058-8 Nut—Used

with J-21830.

15.
J-8092 Driver.Handle—Threaded Type.

16.
J-7079-2 Driver Handle—Insert Type.

17.
J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer.

18.
J-21991 Chevelle Upper Control Arm Carrier- Bushing

Remover Adapter.

19.
J-5853 Torque Wrench—In. lbs.

20.
J-5810 Torque Wrench Adapter (3/4" to 3/8")

21.
J-1313 Torque Wrench—ft. lbs.

Tools Not Illustrated

J-22553 Rear Spring Front Bushing Remover/Installer Consists

of J-22553-1 Receiver, J-22553-2 Installer—Used

with J-21978-1 Receiver, J-21058-8 Nut and

J-21058-15 Puller Screw.

CHEVROLET CHASSIS SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-43

Fig.
114—Rear Suspension Special Tools (Corvette)

1.
J-8111-23 Torque Control Arm Spacer Flaring Tool

2.
J-22602 Wheel Drive Spindle Remover

3.
J-9436 Wheel Drive Spindle Outer Bearing Installer

4.
J-21057 Drive Pinion Oil Seal Installer

5. J-8331 Wheel Drive Spindle Outer Bearing Remover

6.
J-7877 Strut Rod Bushing Replacement Sef

7. J-7817 Wheel Drive Spindle Bearing Cup Installer

8.
J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer

9. J-21556 Axle Drive Shaft "U" Joint Trunnion Sea! Installer

10.
J-5748 Positraction Torque Measuring Adapter

11.
J-7079-2 Driver Handle (Insert Type)

12.
J-8001 Dial Indicator Set

13.
J-8092 Driver Handle (Threaded Type)

14.
J-7055-1 Torque Control Arm Bushing Installer

15.
J-8614 Rear Axle Companion Flange Holder

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-22

2.
Replace ail push rods and pull back springs.

3.
Connect hose or line to wheel cylinder.

NOTE:
If replacing front wheel cylinder, con-

nect hose and inspect installation as outlined in

"Hydraulic Brake Hose Replacement".

4.
Install drum and wheel.

5. Bleed brakes as outlined in this section.

ANCHOR PIN

Front Wheel

1.
Raise front of vehicle and place on jack stands.

2.
Remove wheel and drum as outlined in this section.

3.
Remove brake shoe pull back springs, link and guide

plate.

4.
Disengage anchor pin lock and remove anchor pin by

turning counterclockwise.

5. Place new lock plate on anchor pin and pass pin

through the hole in flange plate and screw into tapped

hole in spindle support.

6. Torque pin to 130 lb. ft. and lock by peening over

washer tabs.

7. Install brake shoe guide plate, link and pull back

springs.

8. Adjust brakes, install drum and wheel as outlined

in this section. Test brake operation.

Rear Wheel

Two type anchor pins are used in production for the

rear wheels. The riveted type is not serviced and if

failure or damage should occur to either the anchor

pin or flange plate, both parts will have to be replaced

and the threaded type anchor pin used.

Threaded Type

1.
Raise rear of vehicle and place on jack stands,

2.
Remove wheel and drum as outlined in this section.

3.
Remove brake shoe pull back springs, link and guide

plate.

4.
Remove anchor pin retaining nut and washer and

remove pin from flange plate.

5. Position anchor pin to flange plate, install lock

washer and nut, and torque pin to 80 lb. ft.

6. Install brake shoe guide plate, link and pull back

springs.

7. Adjust brakes and install drum and wheel as outlined

in this section.

8. Test brake operation.

BRAKE DRUMS

Front brake drums are the demountable type; that is,

they can be removed without removing the hub. Rear

brake drums are demountable and may be removed

wihtout removing the axle shaft.

A lanced "knock out" area (fig. 34) is provided in

the web of the brake drum for servicing purposes in

the event retracting of the brake shoes is required in

order to remove the drum.

A small screw driver or hooked wire may be inserted

to disengage the automatic adjuster actuating lever so

the star wheel may be turned.

Removal

1.
Raise vehicle and place on jack stand.
2.
Remove wheel and tire assembly, back off brake

adjustment and remove drum.

Inspection and Reconditioning

Whenever brake drums are removed they should be

thoroughly cleaned and inspected for cracks, scores,

deep grooves, and out-of-round. Any of these conditions

must be corrected since they can impair the efficiency

of brake operation and also can cause premature failure

of other parts.

Smooth up any slight scores by polishing with fine

emery cloth. Heavy or extensive scoring will cause

excessive brake lining wear and it will probably be

necessary to rebore in order to true up the braking

surface.

An out-of-round drum makes accurate brake shoe

adjustment impossible and is likely to cause excessive

wear of other parts of brake mechanism due to its

eccentric action.

A drum that is more than .008" out-of-round on the

diameter is unfit for service and should be rebored.

Out-of^round, as well as taper and wear can be ac-

curately measured with an inside micrometer fitted

with proper extension rods.

If drum is to be rebored for use with standard size

brake facings which are worn very little, only enough

metal should be removed to obtain a true smooth braking

surface.

If drum has to be rebored more than .020" over the

standard diameter, it should be rebored to .060" diameter

oversize and the brake facing should be replaced with

.030"
oversize facings.

A brake drum must not be rebored more than .060"

over the maximum standard diameter, since removal

of more metal will effect, dissipation of heat and may

cause distortion of drum. Chevrolet brake facing is

not furnished larger than .030" oversize and this will

not work efficiently in drums bored more than .060"

oversize.

Brake drums may be refinished either by turning or

grinding. Best brake performance is obtained by turning

drums with a very fine feed. To insure maximum lining

life,
the refinished braking surface must be smooth and

free from chatter or tool marks, and run-out must not

exceed .005" total indicator reading.

Cleaning

New brake drums in parts stock are given a light.

coating of rust proofing oil to prevent the formation of

rust on the critical braking surfaces during the time

that the drums are in storage.

This rust proofing oil must be carefully removed

before the drum is placed in service to prevent any

of this oil from getting on the brake shoe facings, which

might cause an extreme brake grab condition.

It is recommended that a suitable volatile, non-toxic,

greaseless type solvent be used to clean the oil from the

braking surface of the new brake drums before they are

•placed in service to insure the cleanest possible surface.

Gasoline or kerosene should not be used as there is

danger that a portion of the diluated oil substance may

be left on the braking surface that may later cause

difficulty.

Installation

1.
Make brake adjustment as outlined in this section.

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-28

Fig.
40—Installing Piston in Caliper Bore Using

Tool J-22591
Fig.
41—Installing Boot Seal in Caliper Bore

Using Tool J-22592

5.
Check the fit of the piston in the bore using a feeler

gage.
Clearance should be as follows:

2 1/16 inch Bore .0045 to .010

1 7/8 inch Bore .0045 to .010

1 3/8 inch Bore .0035 to .009

If the bore is not damaged, and the clearance exceeds

either of the upper limits, a new piston will be required.

Assembly

1.
Assemble the seal in the groove in the piston which

is closest to the flat end of the piston. The lip on

the seal must face toward the large end of the

piston. Be sure lips are in the piston groove and do

not extend over the step in the end of the groove.

2.
Place the spring in the bottom of the piston bore.

3.
Lubricate the seal with dean brake fluid.

4.
Install the piston assembly in the bore using appli-

cable piston rign compressor Tool J-22639, 22629

or 22591 as shown in Figure 40. Use care not to

damage the seal lip as piston is pressed past the

edge of the bore. .

5.
Assemble the boot in the groove of the piston closest

to the concave end of the piston. The fold in the boot

must face toward the end of the piston with the seal

on it.

6. Depress the pistons and check that they slide

smoothly into the bore until the end of the piston is

flush with the end of the bore. If not, re check piston

assembly and location of the piston spring and the

seal.

7.
Position applicable boot seal installer Tool J-22592,

J-22628, or J-22638 over the piston and seat the

steel boot retaining ring evenly in the counterbore

as shown in Figure 41. The boot retaining ring must

be flush or below the machined face of the caliper.

Any distortion or uneven seating could allow con-

taminating and corrosive elements to enter the bore.
8. Position the t:O}> rings in the small cavities around

the brake fluid transfer holes in both ends of the

outboard caliper halves. Lubricate the hex head

. bolts with Delco Brake Lube or clip in clean brake

fluid. Fit caliper halves together and secure with

bolts.
Refer to torque specifications in rear of

manual for correct torque valves.

Installation

1.
Carefully mount the assembled caliper over the edge

of the disc. Use a putty knife to depress pistons so

that the caliper can be lowered into position on the

disc (fig. 42). Use care to prevent damage to boots

• on the edge of the disc as the caliper is mounted.

2.
Secure the caliper to the mounting bracket with two

hex head bolts. Refer to torque specifications in

rear of manual for correct torque values.

CAUTION: If replacing old shoe assemblies,

be sure to get the shoes in the same position

from which they were removed. New shoe as-

semblies have an arrow printed on the back,

showing the direction of forward disc rotation.

3.
Install the shoe and lining assemblies as outlined in

this section.

4.
On Chevrolet and Corvette front calipers, place a

new copper gasket on the male end of the front

wheel brake hose. On all models, install brake hose

in the calipers. With the wheels straight ahead,

pass the female end of the brake hose through the

support bracket.

5.
Make sure the tube seat is clean and connect the

break line tube nut to the caliper. Tighten securely.

6. Allowing the hose to seek a normal position, without

twist, insert hex of the hose fitting into the 12-point

hole in the support bracket and secure it in place

with the "V"-shaped retainer. Turn the steering

geometry from lock to lock while observing the hose.

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 6

ENGINE

CONTENTS
OF
THIS SECTION

Page

Engine Tune Up
6-1
Torque Sequence

Engine Mechanical
(In
Line)
6-12
Special Tools
. .

Engine Mechanical (V8)
6-24
Page

6-39

6-40

ENGINE TUNE UP

INDEX

Page

General Description
. 6-1

Mechanical Checks and Adjustments
6-1

Spark Plug Removal
6-1

Test Compression
6-1

Service and Install Spark Plugs
6-2

Service Ignition System
6-3

Service Battery
and
Battery Cables
6-5

Service Delcotron
and
Regulator
6-5

Service
Fan
Belt
6-5

Service Manifold Heat Valve
6-5

Tighten Manifold
6-5

Service Fuel Lines
and
Fuel Filter ..........
6-6

Service Cooling System
6-6

Check and Adjust Accelerator Linkage
6-6

Service Crankcase Ventilation
6-6

Service
Air
Injection Reactor System
6-6

Choke Adjustment
6-7
Page

Instrument Cheek-Out
6-7

Instrument Hook-Up.
. 6*7

Check and Adjust Dwell
6-7

Check Dwell Variation
6-7

Check and Adjust Timing
6-8

Adjust Idle Speed
and
Mixture
6-8

Additional Checks and Adjustments
. 6-8

Testing Crankcase Ventilation Valve
. 6-8

Testing Cranking Voltage
6-8

Cylinder Balance Test
. 6-8

Battery
6-8

Ignition
; 6-8

Carburetor
6-11

Fuel Pump
6-11

Cooling System
. 6-11

Cylinder Head Torque and Valve Adjustment
..... 6-11

GENERAL DESCRIPTION

The engine tune up
is
important
to the
modern automo-

tive engine with
its
vastly improved power and perform-

ance.
The
higher compression ratios, improved electri-

cal systems
and
other advances
in
design, make today1 s

engines more sensitive
and
have
a
decided effect
on

power, performance and fuel consumption.

It
is
seldom advisable
to
attempt
a
tune up
by
correc-

tion
of one or two
items only. Time will normally
be

saved
and
more lasting results assured
if the
technician

will follow
a
definite
and
thorough procedure
of
analysis

and correction
of all
items affecting power, performance

and economy.

The tune
up
will
be
performed
in
two parts.
The
first

part will consist
of
visual and mechanical checks and
ad-

justments;
the
second part will consist
of
an instrument

checkout that
can be
performed with
any one of the
units
of service equipment available
for
this purpose. Always

follow
the
instructions provided
by the
manufacturer
of

the particular equipment
to be
used.

Additional checks
and
adjustments
are
included
in the

latter part
of
this section
for use as
required. Many
of

these operations
can be
used
to
isolate and correct trou-

ble located during
the
tune up. Where conditions
are
UB-

covered requiring major corrective action, refer
to the

appropriate section
of
this manual
or the
Passenger

Chassis Overhaul Manual
for
detailed service informa-

tion.

Typical illustrations
and
procedures
are
used except

where specific illustrations
or
procedures
are
necessary

to clarify
the
operation. Illustrations showing bench
op-

erations
are
used
for
clarification however
all
operations

can
be
performed
on the
vehicle.

MECHANICAL CHECKS
AND
ADJUSTMENTS

Spark Plug Removal

Remove any foreign matter from around spark plugs
by

blowing
out
with compressed
air,
then disconnect wires

and remove plugs.

Test Compression
(Fig. 1)

The compression check
is
important because
an
engine

with
low or
uneven compression cannot
be
tuned success-
fully.
It is
essential that improper compression
be cor-

rected before proceeding with
the
engine tune
up.

1.
Remove
air
cleaner
and
block throttle
and
choke
in

wide open position.

2.
Hook
up
starter remote control cable
and
insert

compression gauge firmly
in
spark plug port.

CAUTION: Whenever
the
engine
is
cranked

CHEVROLET
C*
IS SERVICE MANUAL

ENGINE
6-3

(ROUND) Y~~fll^H

CENTRIFUGAL
A ^k

ADVANCE--jflgKpl

MECHANISM
UB|

CAM
KSK^2

LUBRICATOR
VlSMi

REPLACEMENT
^BK

-^ADJUST
SQUARELY

AND
JUST

TOUCHING
LOBE

OF
CAM
/ROTOR

HBB
__

I^BH^F
?
(SOUARE)

^K^ I /—
CAM

jKft^J / LUBRICATOR

H^T^
CAUTION!

QV NEVER
OIL

•L-^
CAM LUBRICATOR-

REPLACE
WICK

WHEN
NECESSARY
LATERAL

MISALIGNMENT
PROPER

LATERAL ALIGNMENT

Fig.
4- Distributor (V8)

CAUTION: Use extreme care
-when
using tap to

prevent cross threading. Also crank engine sev-

eral times to blow out any material dislodged

during cleaning operation.

7. Install spark plugs with new gaskets and torque to

specifications.

NOTE:
The following are some of the

greatest causes of unsatisfactory spark plug

performance.

•
Installation of plugs with insufficient torque to

fully seat the gasket.

•
Installation of the plugs using excessive torque

which changes gap settings.

•
Installation of plugs on dirty gasket seal.

•
Installation of plugs into corroded spark plug hole

threads.

8^ Connect spark plug wiring.

Service
Ignition System

1.
Remove distributor cap, clean cap and inspect for

cracks, carbon tracks and burned or corroded ter-

minals. Replace cap where necessary.

2.
Clean rotor and inspect for damage or deterioration.

Replace rotor where necessary.

3.
Replace brittle, oil soaked or damaged spark plug

wires.
Install all wires to proper spark plug. Proper

positioning of spark plug wires in supports is impor-

tant to prevent cross-firing.

4.
Tighten all ignition system connections.

5. Replace or repair any wires that are frayed, loose or

damaged.
Us
CORRECT
LATERAL MISALIGNMENT BY

j BENDING
FIXED CONTACT SUPPORT

[NEVER
BEND BREAKER LEVER

Fig.
5 - Point Alignment

Magnetic
Pulse(Breakerless)
Distributor

There are no moving parts in the ignition pulse ampli-

fier, and the distributor shaft and bushings have perma-

nent type lubrication, therefore no periodic maintenance

is required for the magnetic pulse ignition system. Refer

to Section 6Y for an analysis of problems and/or repair

procedures encountered on the Transistorized (Magnetic

Pulse) ignition system.

Standard
(Breaker Point) Distributor
(Figs.
3 or 4)

1.
Check the distributor centrifugal advance mechanism

by turning the distributor rotor in a clockwise direc-

tion as far as possible, then releasing the rotor to

see if the springs return it to its retarded position.

If the rotor does not return readily, the distributor

must be disassembled and the cause of the trouble

corrected.

2.
Check to see that the vacuum spark control operates

freely by turning the movable breaker plate counter-

clockwise to see if the spring returns to its retarded

position. Any stiffness in the operation of the spark

control will affect the ignition timing. Correct any

interference or binding condition noted.

3.
Examine distributor points and clean or replace if

riecessary.

DO
NOT SUCK

IN
TOO MUCH

ELECTROLYTE

TAKE
READING

AT
EYE LEVEL

Fig.
6 - Testing Specific Gravity of Battery

CHEVROtET
CHASSIS SERVICE MANUAL

ENGINE 6-6

CHOKE VALVE

COMPLETELY

CLOSED

PULL UPWARD ON

ROD TO END OF

TRAVEL

BEND ROD

TO ADJUST
ROD IN BOTTOM

OF SLOT

BOTTOM OF

ROD SHOULD

EVENWITH

TOP OF

HOLE
CHOKE VALVE

CLOSED

BOTTOM OF

ROD SHOULD

BE EVEN WITH

TOP OF HOLE

TOP OF ROD

SHOULD BE EVEN

WITH BOTTOM

OF HOLE (CHOKE

CLOSED)

^..BEND ROD TO

ADJUST

_PULL DOWNWARD

ON ROD TO CON-

TACT STOP

L6 (TYPICAL)

V8 327-275 HP

V8 350-295 HP
BEND ROI

TO ADJUST

PULL UPWARD ON

ROD TO CONTACT

STOP ON BRACKET

ALL V8 (EXCEPT 327-275 HP

AND 350-295 HP)

Fig.
11 - Remote Choke Adjustment

sequence outlined on Torque Sequence Chart. A slight

leak at the intake manifold destroys engine performance

and economy.

Service Fuel Lines and Fuel Filter

1.
Inspect fuel lines for kinks, bends or leaks and cor-

rect any defects found, • • •

2.
Inspect filter and replace if plugged.

NOTE:
If a complaint of poor high speed per-

formance exists on the vehicle, fuel pump tests

described in Section 6M should be performed.

Service Cooling System

1.
Inspect cooling system for leaks, weak hoses, loose

hose clamps and correct coolant level, and service

as required.

NOTE:
A cooling system pressure test, as de-

scribed in "Additional Checks and Adjustments"

in this section, may be performed to detect

internal or external leaks within the cooling

system.

Check and Adjust Accelerator Linkage

1.
Disconnect accelerator rod at carburetor throttle

lever.

2.
Hold carburetor throttle lever in wide position.

3.
Pull accelerator rod to wide open position. (On ve-

hicles equipped with automatic transmission, pull

through detent).

4.
Adjust accelerator rod to freely enter hole in carbu-

retor throttle lever.'

NOTE:
Accelerator linkage is outlined in de-

tail in Section 6M.
5. Connect accelerator rod at throttle lever.

Service Crankcase Ventilation (Fig. 10}

All engines have either "Positive" or "Closed Positive"

ventilation systems utilizing manifold vacuum to draw

fumes and contaminating vapors into the combustion

chamber where they are burned. Since it affects every

part of the engine, crankcase ventilation is an important

function and should be understood and serviced properly.

In both "Positive" and "Closed Positive" ventilation,

air is drawn through the engine, (through a regulating

valve) into the manifold, drawing' crankcase vapors and

fumes with it to be burned. "Positive" ventilation uses a

vented-meshed cap for clean air intake to the engine,

while . "Closed Positive" ventilation system draws the

clean air from the carburetor air cleaner and has a

nonvented oil filler cap.

1.
Ventilation valve may be checked as outlined under

"Additional Checks and Adjustments".

2.
Inspect for deteriorated or plugged hoses.

3.
Inspect all hose connections.

4.
On closed positive ventilation systems, remove flame

arrestor and wash in solvent then dry with com-

pressed air.

Service Air Injection Reactor System

Inspect air injection reactor system for evidence of

leaks,
deteriorated hoses, cracked air manifolds or tubes

and loose hose clamps. Inspect air injection pump belt

condition and tension. Make all necessary repairs as

outlined in "Section 6T".

Because of the relationship between "Engine Tune Up"

and "Unburned Exhaust Gases", the condition of Engine

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-11

Fig.
18 - Cooling System Pressure Test

Carburetor

Refer to Section 6M to perform adjustments such as

idle vent, float level, pump rod and secondary valve.

Fuel Pump

If the owner has complained of poor high speed per-

formance, the fuel pump may be at fault. Too low a

pump pressure or volume will cause a high speed "miss"

because of lack of fuel delievered to the carburetor,

while too high a pressure will cause carburetor flooding.

Check fuel pump as outlined in Section 6M.

Cooling System

The following test may be performed with pressure

testing equipment available commercially for this pur-

pose.
This test provides an excellent means of detecting

internal or external leaks within the cooling system.

1.
Remove radiator cap.

2.
Apply a test pressure of 3 pounds higher than the ra-

diator cap (fig. 18). i.e. 18 pounds for a 15 pound

cap.

3.
If the pressure will not hold, there is either an

internal or external leak in the system.

Cylinder Head Torque and Valve Adjustment

Retorquing the cylinder head bolts is not necessary

unless a gasket has been replaced, or a leak is suspected.

Valve lash must always be adjusted after the head has

been torqued.

Before adjusting the valve lash, it is extremely impor-

tant that the engine be thoroughly warmed up to normal-

ize the expansion of all parts. This is very important

because during the warm-up period, the valve clearances

will change considerably.

Hydraulic

1.
After the engine has been normalized, remove rocker

arm covers and gaskets.

CAUTION: Do not pry rocker arm cover loose.
Gaskets adhering to cylinder head and rocker

arm cover may be sheared by bumping end of

rocker arm cover rearward with palm of hand

or a rubber mallet.

2.
With the engine running at idle, back off valve rocker

arm nut until the valve rocker arm starts to clatter.

3.
Turn rocker arm nut down slowly until the clatter

just stops. This is the zero lash position.

4.
Turn nut down 1/4 additional turn and pause 10 sec-

onds until engine runs smoothly* Repeat additional

1/4 turns, pausing 10 seconds each time, until nut

has been turned down 1 full turn from the zero lash

position.

NOTE: This 1 turn preload adjustment must be

done slowly to allow the lifter to adjust itself to

prevent the possibility of interference, between

the inlet valve head and top of piston, which

might result in internal damage and/or bent push

rods.
Noisy lifters should be replaced.

5.
Repeat Steps 2, 3 and 4 to adjust the rest of the

valves.

6. Clean gasket surfaces on cylinder heads and rocker

arm covers with degreaser then install rocker arm

covers, using new gaskets, and torque bolts to

specifications.

Mechanical

1.
Normalize the engine.

2.
Remove rocker arm covers and gaskets.

CAUTION: Do not pry rocker arm cover loose.

Gaskets adhering to cylinder head and rocker

arm cover may be sheared by bumping end of

rocker arm cover rearward with palm of hand

or a rubber mallet.

3.
Use a socket wrench on self-locking rocker arm stud

nut and adjust as needed to obtain valve lash (see

tune up chart) measured between rocker arm and

valve stem with a leaf type feeler gauge.

4.
Stop engine, clean gasket surfaces on cylinder heads

and rocker arm covers with degreaser then install

rocker arm covers, using new gaskets, and torque

bolts to specifications.

Fig.
19
- Oil Deflector Clips Installed

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-14

b.
Bolt transmission to engine, then raise engine and

transmission assembly and install flywheel to

converter attaching bolts.

c. Install converter
housing*
underpan and starter.

3.
Tilt and lower engine and transmission assembly into

the chassis as a unit, guiding engine to align front

mounts with frame supports.

4.
Install front mount through bolts and torque to

specifications.

5.
Raise engine enough to install rear crossmember,

then install crossmember, install rear mount, lower

engine and torque bolts to specifications.

6. Remove lifting device and lifting adapter then install

rocker arm cover 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.

9; Install propeller shaft.

10.
Remove jack stands and lower vehicle.

11.
Connect:

Power steering pump lines (if disconnected).

Vacuum line to power brake unit (if disconnected).

Fuel line at fuel pump.

Exhaust pipe at manifold flange.

Accelerator linkage at manifold bellcrank.

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.

MANIFOLD ASSEMBLY

Removal

1.
Remove air cleaner.

2.
Disconnect both throttle rods at bellcrank and re-

move throttle return spring.

3.
Disconnect fuel and vacuum lines at carburetor.

Disconnect choke cable on \A engines.

4.
Disconnect crankcase ventilation hose at rocker arm

cover.

5.
Disconnect exhaust pipe at manifold flange and dis-

card packing.

6. Remove manifold attaching bolts and clamps then

remove manifold assembly and discard gaskets.

7.
Check for cracks in manifold castings.

8. If necessary to replace either intake or exhaust

manifolds, separate them by removing one bolt and

two nuts at center of assembly. Reassemble mani-

folds using a new gasket. Tighten finger tight and

torque to specifications after assembly to cylinder

head. Transfer all necessary parts.
Installation

1.
Clean gasket surfaces on cylinder head and

manifolds*

2.
Position new gasket over manifold end studs on head

and carefully install the manifold in position making

sure the gaskets are in place.

3.
Install bolts and clamps while holding manifold in

place with hand.

4.
Torque bolts to specifications.

NOTE: On L6 engines center bolt and end bolt

torque differ.

5.
Connect exhaust pipe to manifold using a new

packing.

6. Connect crankcase ventilation hose at rocker arm

cover.

7.
Connect fuel and vacuum lines at carburetor.

8. On L4 engines connect choke cable and adjust as out-

lines in Section 6M.

9. Connect throttle rods at bellcrank and install throttle

return spring.

10.
Install air cleaner, start engine, check for leaks and

adjust carburetor idle speed and mixture.

ROCKER ARM COVER

Removal

1.
Disconnect crankcase ventilation hose(s) at rocker

arm cover.

2.
Remove air cleaner.

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 rocker

arm cover may be sheared by bumping end of

rocker arm cover rearward with palm of hand or

a rubber mallet.

Installation

1.
Clean gasket surfaces on cylinder head and rocker

arm cover with degreaser then, using anew gasket,

install rocker arm cover and torque bolts to

specifications.

2.
Connect temperature wire at rocker arm cover clips.

3.
Install air cleaner.

4.
Connect crankcase ventilation hoses.

VALVE MECHANISM

Removal

1.
Remove rocker arm cover 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,

socket.
Be sure push rods seat in lifter

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-15

2.
Install rocker arms, rocker arm balls and rocker

arm
nuts.
\
Tighten rocker arm nuts until all lash is

eliminated. .

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

shaft lobe as follows:

a. Mark distributor housing, with chalk, at each cyl-

inder position (plug wire) then disconnect plug

wires at spark plugs and coil and remove distri-

butor cap and plug wire assembly (if not previ-

ously done).

b.
Crank engine until distributor rotor points to

number one cylinder position and breaker points

are open. Both valves on number one cylinder

may now be adjusted.

c. Back out adjusting nut until lash is felt at the push

rod then turn in adjusting nut until all lash is re-

moved. This can be determined by checking push

rod side play while turning adjusting nut (fig. 2L).

When play has been removed, turn adjusting nut

in one full additional turn (to center lifter

plunger).

d. Adjust the remaining valves, one cylinder at a

time,
in the same manner.

4.
Install distributor cap and spark plug wire assembly.

5.
Install rocker arm cover as outlined.

6. Adjust carburetor idle speed and mixture.

VALVE LIFTERS

Hydraulic valve lifters very seldom require attention.

The lifters are extremely simple in design readjustments

are not necessary, and servicing of the lifters requires

only that care and cleanliness be exercised in the han-

dling of parts.

Locating Noisy Lifters

Locate a noisy valve lifter by using a piece of garden

Fig.
2L - Valve Adjustment
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

returns 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

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

abnormal stickiness.

b.
Galling or "pickup" 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—This

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, disasssmbled, cleaned

in a solvent, reassembled, and reinstalled in the engine.

If dirt, varnish, 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 valve mechanism as outlined.

2.
Mark distributor housing, with chlak, at each cylin-

der position (plug wire) then disconnect plug wires at

spark plugs and coil and remove distributor cap and

plug wire assembly.

3.
Crank engine until distributor rotor points to number

one position, then disconnect distributor primary lead

at coil and remove distributor.

4.
Remove push rod covers (discard gaskets).

5.
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 push rod covers, using new gaskets, and

torque bolts to specifications.

3.
Install distributor, positioning rotor to number one

cylinder position, then connect primary lead at coil.

4.
Install and adjust valve mechanism as outlined.

CHEVROLET CHASSIS SERVICE MANUAL