seat adjustment CHEVROLET CAMARO 1967 1.G Chassis User Guide

BRAKES 5-7

LATCH PLATE

DIE BLOCK

TUBE
UPSET FLARE PUNCH

RAM GUIDE

STOP PLATE

Fig.
13—Flaring Operation--Position ing Tubing

2.
Remove the tubing from the die block and deburr

the inside and outside edges.

3.
Install compression couplings on tubing and dip end

of tubing to be flared in hydraulic fluid. This lubri-

cation results in better formation of the flare.

4.
Place on-half of the die blocks in the tool body with

the counterbored ends toward the ram guide. Now

lay the tubing in the block with approximately 1/2"

protruding beyond the end.

Fit the other half of the block into the tool body,

close the latch plate and tighten the nuts "finger

tight".

5. Select the correct size upset flare punch. One end

of this punch is counterbored or hollowed out to

gauge the amount of tubing necessary to form a

double lap flare. Slip the punch into the tool body

with the gauge end toward the die blocks. Install the

ram; then tap lightly until the punch meets the die

, blocks and they are forced securely against the

stop plate (fig. 13).

6. Using the supplied wrench, draw the latch plate

nut down tight to prevent the tube from slipping.

Tightening the nuts alternately (beginning with the

nut at the closed hole in the plate) will prevent

distortion of the plate. Remove the punch and the

ram. Now reverse the punch and put it back into the

tool body. Install the ram and tap it lightly until

the face of the upset flare punch contacts the face

of the die blocks (fig. 14). This completes the

first operation. Remove the ram and the punch.

7. To complete the flare, insert the pointed finish

flare punch and the ram into the tool body. Tap

the ram until a good seat is formed (fig. 15).

NOTE:
The seat should be inspected at inter-

vals during the finishing operation to avoid

over-seating.

LATCH

DIE BLOCK

TUBE
UPSET FLARE PUNCH
RAM GUIDE

RAM
1ST OPERATION

UPSET FLARE

PUNCH
2ND OPERATION

FINISH FLARE

PUNCH

Fig.
15—Flaring Operation—First and Second Flare

BRAKE ADJUSTMENT

Service Brake

Although the brakes are self-adjusting, a preliminary

or initial adjustment may be necessary after the brakes

have been relined or replaced, or whenever the length

of the adjusting screw has been changed. The final

adjustment is made by using the self-adjusting feature.

1.
With brake drum off, disengage the actuator from

the star wheel and rotate the star wheel by spinning

or turning with a small screw driver.

2.
Recommended

a. Use special Tool J-21177; Drum-to-Brake Shoe

Clearance Gauge, to check the diameter of the

brake drum inner surface (fig. 16).

Fig.
14—Flaring Operation—First Flare
Fig.
16—Using Drum-to-Brake Shoe Clearance

Gauge Tool J-21177

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-14

Fig.
23—Removing or Installing Cover Lower Mounting Screws
Fig.
24—Removing or Installing Trim Seal

8. Remove front cable from lever assembly using long

nose pliers as shown in Figure 25. Remove lever

from vehicle.

Installation

1.^
Install front cable in lever assembly using long

nose pliers as shown in Figure 25. Slide slack

cable through hole and place lever assembly in

position.

2.
Place forward mounting bracket in position and

secure plate and lever assembly to underbody with

four mounting bolts.

3.
Secure parking brake alarm switch to side of lever

assembly with washer and screw (fig. 24).

4.
Install trim seal on lever (fig. 24).

5. Insert the end of the trim seal into the slot in the

cover and slide the cover forward and down into

position.

6. Place the retainer in position. Secure retainer and

cover to underbody with six screws. It is necessary

to push the seat cushion down as shown in Figure 23

to gain access to the lower mounting screw hole on

each side.

7. Under vehicle, insert front cable stud through equal-

izer assembly and secure with nut.

8. Install return spring.

9. Adjust parking brake as outlined under Maintenance

and Adjustments in this section.

Front Cable

Removal

1.
Perform the complete parking brake lever removal

procedure above.

2.
Under vehicle, remove nut, washer, and bolt se-

. curing pulley to pulley bracket (fig. 22).

3.
Remove seal grommet from underbody cable hole.

4.
Pull front cable out of vehicle.

Installation

1.
Install seal grommet around front cable.

2.
Slide front cable into position through cable hole

and work seal grommet into installed position.

3.
Under vehicle, loop front cable around pulley wheel

and secure pulley wheel to bracket with bolt, washer,

and nut (fig..22).

4.
Perform the complete parking brake lever installa-

tion procedure above.
Removal

1.
Remove the cable clip retainers on the back side of

the frame rail from each of the rear brake cable

ends.

2.
Disconnect the cable at the rear wheel flange plate.

3.
Remove the cable ball out of the recess in .the brake

lever assembly clevis.

4.
Disconnect the cables at the equalizer connector and

remove the cables.

Installation

1.
Attach the rear cable balls on the rear cable ends

to the rear wheel recess in the brake lever assembly

clevis.

2.
Attach the cable assembly to the rear wheel flange

plate.

3.
Connect the cable assemblies along the frame rail

area.

4.
Insert the cable end through the equalizer and attach

to the equalizer connector.

5. Adjust as outlined under Maintenance and

Adjustments.

6. Lubricate the cables and all moving parts for

trouble-free operation—see Lubrication, Section 0.

Fig.
25—Removing or Installing Front Cable

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-17

mended shoe and lining assemblies. Otherwise,

serious fade or failure may occur.

1.
Inspect new linings and make certain there are no

nicks or burrs on bonding material on shoe edge

where contact is made with brake flange plate or

on any of the contact surfaces.

NOTE: Keep hands clean while handling brake

shoes.
Do not permit oil or grease to come in

contact with linings.

2.
If working on rear brakes, lubricate parking brake

cable.

3.
On rear brakes only, lubricate fulcrum end of park-

ing brake lever and the bolt with brake lube, then

attach lever to secondary shoe with bolt, spring

washer, lock washer and nut. Make sure that lever

moves freely.

4.
Before installation make certain the adjusting screw

is clean and lubricated properly.

NOTE: Loose adjustment may occur from an

adjusting screw that is not properly operating.

If the lubrication in the adjusting screw as-

sembly is contaminated or destroyed, the ad-

justing screw should be thoroughly cleaned and

lubricated.

5.
Connect brake shoes together with adjusting screw

spring, then place adjusting screw, socket and nut

in position.

CAUTION: Make sure the proper adjusting

screw is used ("L" for left side of vehicle,

"R"
for right side of vehicle). The star wheel

should only be installed with the star wheel

nearest to the secondary shoe and the adjusting

screw spring inserted to prevent interference

with the star wheel.
6. On rear wheels connect parking brake cable to lever.

7.
Secure the primary brake shoe (short lining—faces

forward) first with the hold-down pin and spring

using a pair of pliers. Engages shoes with the wheel

cylinder connecting links.

8. Install and secure the actuator assembly and second-

ary brake shoe with the hold-down pin and spring

using a pair of needle nose pliers. On rear wheels

position parking brake strut and strut spring.

9. Install guide plate over anchor pin.

10.
Install the wire link.

NOTE: Do not hook the wire link over the

anchor pin stud with the regular spring hook

tool. This may damage the cylinder boot seals.

Fasten the wire link to the actuator assembly ;

first, then place over the anchor pin stud by

hand while holding the adjuster assembly in the

full down position.

11.
Install actuator return spring.

NOTE: Do not pry actuator lever to install re-

turn spring. Ease it in place using the end of a

screw driver or other suitable flat tool.

12.
If old brake pull back (return) springs are nicked,

distorted or if strength is doubtful, install new

springs.

13.
Hook springs in shoes using Tool J-8049 by in-

stalling the primary spring from the shoe over the

anchor pin and then spring from secondary shoe

over the wire link end.

14.
Pry shoes away from backing plate and lubricate

shoe contact surfaces with a thin coating of brake

lube (fig. 29).

CAUTION:

facings.
Be careful to keep lubricant off

Fig.
29—Backing Plate Contact Surfaces
15.
After completing installation, make certain the actu-

ator lever functions easily by hand operating the

self-adjusting feature (fig. 30).

1.6. Follow the above procedure for all wheels.

17.
Adjust the service brakes and parking brake as

outlined under "Maintenance and Adjustments" in

this section.

Metallic Linings

Metallic brake linings which use special heat resistant

brake springs are available as an option. Service opera-

tions are the same as for standard brakes; however,

when new linings are installed, the linings should be

seated as described below.

NOTE: Brake shoes with metallic linings re-

quire specially finished brake drums (honed to a

20 micro-inch finish). Metallic linings are not

recommended for service replacement on ve-

hicles with standard brake drums that have not

been honed to specified finish.

Seating Metallic Linings

After the brakes have been adjusted, the following

recommended "lining seating" is as follows:

1.
Make six to eight stops from 30 MPH with moderate

pedal pressure to aid in seating and to mbdulate

any tendency to dive.

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-21

brake fluid. Coat the primary and secondary seals

on the secondary piston with clean brake fluid. Insert

the secondary piston spring retainer into the sec-

ondary piston spring. Place the retainer and spring

down over the end of the secondary piston until the

retainer locates inside of the lips of the primary

cup.

10.
Hold the master cylinder with the open end of the

bore down. Push the secondary piston into the bore

until the spring seats against the closed end of the

bore.

11.
Position the master cylinder in a vise with the

open end of the bore up. Coat the primary and

secondary seal on the primary piston with clean

brake fluid. Push the primary piston assembly,

spring end first, into the bore of the master cylinder*

Hold the piston down and snap the lock ring into

position in the small groove in the I.D. of the bore.

12.
Push the primary piston down to move the secondary

piston forward far enough to clear the stop screw

hole in the bottom of the front fluid reservoir. Install

the stop screw.

13.
Install reservoir diaphragm in the reservoir cover

and install the cover on the main cylinder. Push

bail wire into position to secure the reservoir cover.

Installation

1.
Assemble the push rod through the push rod retainer,

if it has been disassembled.

2.
Push the retainer over the end of the main cylinder.

Assemble new boot over push rod and press it down

over the push rod retainer. Slide new mounting

gasket into position.

3.
Secure .the main cylinder to the firewall with mount-

ing bolts.

4.
Connect the push rod clevis to the brake pedal with

pin and retainer.

5. Connect the brake lines to the main cylinder.

6. Fill the main cylinder reservoirs to the levels

shown in Figure 8. Bleed the brake system as out-

lined in this section.

7. K necessary, adjust the brake pedal free play as

outlined in this section.

WHEEL CYLINDER (Fig. 33)

The wheel cylinder boots should be removed from a

cylinder body only when they are visibly damaged or

leaking fluid. Wheel cylinders having torn, cut, or heat-

cracked boots should be completely overhauled.

Removal

1.
Raise vehicle and place on jack stands.

Fig.
33-Chevelle Wheel Cylinder—Exploded View

1.
Push Rod Boot 6. Spring

2.
Piston 7. Piston Cup

3. Piston Cup 8. Piston

4.
Housing 9. Push Rod Boot

5. Fluid Inlet
2.
Remove wheel and tire assembly. Back off brake

adjustment, if necessary, and remove drum.

3.
Disconnect brake system hydraulic line from

cylinder.

4.
Remove brake shoe pull back springs.

5. Remove screws securing wheel cylinder to flange

plate. Disengage cylinder push rods from brake

shoes and remove cylinder.

NOTE:
On Chevrolet, it is necessary to re-

move the anchor pin which holds the front wheel

cylinder to flange plate to remove the front

wheel cylinder.

Disassembly

1.
Remove boots from cylinder ends with pliers and

discard boots.

2.
Remove and discard pistons and cups.

Inspection and Cleaning

NOTE:
Staining is not to be confused with

corrosion. Corrosion can be identified as pits

or excessive bore roughness.

1.
Inspect cylinder bore. Check for staining and corro-

sion.
Discard cylinder if corroded.

2.
Polish any discolored or stained area with crocus

cloth by revolving the cylinder on the cloth sup-

ported by a finger. Do not slide tfce cloth in a

lengthwise manner under pressure.

NOTE:
Before washing parts, hands must be

clean. Do not wash hands in gasoline or oil

before cleaning parts. Use soap and water to

clean hands.

3.
Wash the cylinder and metal parts in Declene or

equivalent.

4.
Shake excess cleaning fluid from the cylinder-. Do

not use a rag to dry the cylinder as lint from the rag

cannot be kept from the cylinder bore surfaces.

5. Check piston for scratches or other visual damage;

replace if necessary.

Assembly (Fig. 33)

1.
Lubricate the cylinder bore and counterbore with

clean brake fluid and insert spring - expander

assembly.

2.
Install new cups with flat surfaces toward outer

ends of cylinder. Be sure cups are lint and dirt free

before insertion. Do not lubricate cups prior to

assembly.

3.
Install new Durex pistons into cylinder with flat

surfaces toward center of cylinder. Do not lubri-

cate pistons before installation.

4.
Press new boots into cylinder counterbores by hand.

Do not lubricate boots prior to installation.

Installation

1.
Position wheel cylinder to brake flange plate. Install

screws and tighten securely.

NOTE:
On Chevrolet front wheels, mount front

wheel cylinders to the brake flange plate by

installing the threaded anchor pin through the

wheel cylinder housing and tighten to 130 lb. ft.

To secure, peen over the flat washer on the

anchor pin.

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE
6-8

Check
and
Adjust Ignition Timing
(Fig. 13)

1.
Disconnect
the
distributor spark advance hose
and

plug
the
vacuum source opening.

2.
Start engine
and run at
idle speed
(see
tune
up
chart).

3.
Aim
timing light
at
timing
tab.

NOTE:
- The
markings
on the
tabs
are in 2°

increments
(the
greatest number
of
markings
on

the
"A"
side
of the "O"). the "O"
markings
is

TDC
of
#1 cylinder
and all
BTDC settings fall
on

the
"A"
(advance) side
of "O".

4.
Adjust
the
timing
by
loosening
the
distributor clamp

and
,
rotating
the
distributor body
as
required, then

tighten
the
clamp.

5.
Stop engine
and
remove timing light
and
reconnect

the spark advance hose.

Adjust Idle Speed
and
Mixture
(Fig. 14)
(Except when

equipped with
Air
Injection Reactor System)

1.
As a
preliminary adjustment, turn idle mixture

screws lightly
to
seat
and
back
out 2
turns.

CAUTION:
Do not
turn idle mixture screw

tightly against seat
or
damage
may
result.

2.
With engine running
at
operating temperature (choke

wide open) adjust idle speed screw
to
bring idle

speed
to
specified
rpm
(automatic transmission
in
drive, manual transmission
in
neutral).

3.
Adjust idle mixture screw
to
obtain highest steady

idle speed
(1/4
turn
out
from lean roll).

4.
Repeat Steps
2 and 3 as
needed
for
final adjustment.

5.
Shut down
the
engine, remove gauges
and
install
air

cleaner.

Adjust Idle Speed
and
Mixture
(Fig. 14)
(With
Air

Injection Reactor System)

The recommended adjustment procedure
for Air
Injec-

tion Reactor System equipped engines
is as
follows:

1.
As a
preliminary adjustment, turn idle mixture

screws lightly
to
seat
and
than back
out 3
turns.

CAUTION:
Do not
turn idle mixture screw

tightly against seat
or
damage
may
result.

2.
With engine running
at
operating temperature, choke

wide open,
and
parking brake applied, adjust idle

specified idle speed (automatic

"drive"-manual transmission
in
to

in
screw

transmission

"neutral").

;3.
Adjust idle mixture screw (turn
in) to
"lean roll"

position; then turn screw
out 1/4
turn
(1/4
turn rich

from "lean roll").
The
definition
of
"lean roll" point

is
a 20 to 30 rpm
drop
in
engine speed, obtained
by

leaning
the
idle mixture.

4.
Repeat Steps
2 and 3 as
needed
for
final adjustments.

ADDITIONAL CHECKS
AND
ADJUSTMENTS

Testing Crankcase Ventilation Valve
(Fig. 15) 0

1.
Connect tachometer
and
vacuum gauge
as for
idle

speed
and
mixture adjustment.

2.
Set
parking brake, start engine
and
adjust idle speed

and mixture.

3.
Disconnect ventilation hose
at
valve, block opening
of

valve
and
read engine
rpm
change.

4.
A
change
of
less than
50 rpm
indicates
a
plugged

ventilation valve
-
replace
the
valve.

Cylinder Balance Test
(Fig. 16)

It
is
often difficult
to
locate
a
weak cylinder.
A com-

pression test,
for
example, will
not
locate
a
leaky intake

manifold,
a
valve
not
opening properly
due to a
worn

camshaft,
or a
defective spark plug.

With
the
cylinder balance test,
the
power output
of one

cylinder
may be
checked against another, using
a set of

grounding leads. When
the
power output
of
each cylinder

is
not
equal,
the
engine will lose power
and run
roughly.

Perform
a
cylinder balance test
as
follows:

1.
Connect
the
tachometer
and
vacuum gauge.

2.
Start engine
and run at 1500 rpm.

3.
Ground large clip
of
grounding leads
and
connect
in-

dividual leads
to all
spark plugs except
the
pair being

tested.

Divide
the
firing order
in
half
and
arrange
one
half

over
the
other.
The
cylinders
to be
tested together
ap-

pear
one
over
the
other.

L4 Firing Order
V8 Firing Order

1-8-4-3-6-5-7-2

1-6, 8-5, 4-7, 3-2

1-3-4-2
= 1-3

4-2

L6 Firing Order

1-5-3-6-2-4
=
=
1-4. 3-2

1-5-3

6-2-4
1-6, 5-2, 3-4
1-8-4-3

6-5-7-2

4.
Operate engine
on
each pair
of
cylinders
in
turn
and

note engine
rpm and
manifold vacuum
for
each pair.

A variation
of
more than
1
inch
of
vacuum
or 40 rpm

between pairs
of
cylinders being tested indicates that

the cylinders
are off
balance.

Battery

The battery should
be
checked with special testing

equipment
and to the
equipment manufacturers specifica-

tions.
See
Section 6Y
for
complete information
on
battery

tests.

Ignition

The following additional ignition checks
may be
made

with
any of
several pieces
of
equipment available
for un-

covering
the
source
of
engine difficulties.
The
specific

operating instructions
of the
equipment manufacturer

should
be
followed:

Cranking voltage

Ignition switch

Distributor resistance

Secondary resistance

Ignition output
and
secondary leakage

Cranking Voltage
(Fig. 17)

1.
Disconnect coil primary lead
at the
coil negative

terminal
to
prevent engine from firing during

cranking.

2.
Connect voltmeter between primary terminal
of coi|

(resistance wire side)
and
ground.

3.
Operate starting motor.

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

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