CHEVROLET CAMARO 1967 1.G Chassis Workshop 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 6-7

Tune Up should be checked whenever the Air Injection

Reactor System seems to be malfunctioning. Particular

care should be taken in checking items that affect fuel-air

ratio such as the crankcase ventilation system, the car-

buretor and the carburetor air cleaner. Carburetors and

distributors for engines with the Air Injection Reactor

System are designed, particularly, for these engines;

therefore, they must not be interchanged with or replaced

by a carburetor or distributor designed for an engine

without the Air Injection Reactor System.

Choke Adjustment (Fig. 11)

With Remote Choke

1.
Remove air cleaner and check to see that choke

valve and rod move freely.

2.
Disconnect choke r*od at choke lever.

Check choke adjustment as follows:

On all except 275 hp 327 cu. in. engines, hold

choke valve closed and pull rod up against stop. The

top of choke rod end should be 1/2 - 1 rod diameter
4.

5.
above top of hole in choke valve lever.

On 275 hp 327 cu. in. engines, hold choke valve

closed and push rod down against stop on thermostat

bracket. The top of the choke rod should be 1/2 - 1

rod diameter below the top of the hole in the choke

lever.

If necessary, adjust rod length by bending rod at off-

set. (Bend must be such that rod enters choke lever

hole freely and squarely.)

Connect rod at choke lever and install air cleaner.

3.
With Manual
Choke

1.
Remove air cleaner.

2.
Push hand choke knob in to within 1/8" of instrument

panel.

3.
Loosen choke cable at carburetor bracket and adjust

cable through the clip until the choke valve is wide

open.

4.
Tighten cable clamp at carburetor bracket and check

operation of choke valve to ensure full closed and

wide open positions.

INSTRUMENT CHECK-OUT

Instrument Hook Up

Connect vacuum gauge, dwell meter, tachometer and

timing light as recommended by the manufacturer of the

equipment being used.

Check and Adjust Dwell

1.
Start engine then ch^ck ignition dwell.

.2.
If dwell is not within specifications, adjust dwell as

follows:

V8 ENGINES

• With engine running at idle, raise the adjustment

screw window-and insert an Allen wrench in the

socket of the adjusting screw (fig. 12).

• Turn the adjusting screw as required until a dwell

reading of 30° is obtained. A 2° variation is al-

lowable for wear.

• Close access cover fully to prevent the entry of

dirt into the distributor.

NOTE: If a dwell meter is not available, turn
adjusting screw clockwise until engine starts to

misfire, then turn screw one-half turn in the op-

posite direction to complete adjustment.

IN LINE ENGINES

• Remove distributor cap and recheck point setting.

If dwell is still not within specifications check the

distributor as outlined in Section 6Y.

Check Dwell Variation

Slowly accelerate engine to 1500 rpm and note dwell

reading. Return engine to idle and note dwell reading. If

dwell variation exceeds specifications, check for worn

distributor shaft, worn distributor shaft bushing or loose

breaker plate.

WINDOW

"HEX" TYPE

WRENCH

Fig.
12 - Setting Point Dwell (V8)
Fig.
13 - Ignition Timing Marks

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
6-9

ROCHESTER
BV

IDLE

MIXTURE
ROCHESTER
2GV
HOLLEY 2300C

(PRIMARY)

IDLE

MIXTURE

SPEED
HOLLEY 2300

(SECONDARY)

LE IDLE

MIXTURE SPEED

MANUAL CHOKE
CARTER
YF

IDLE

MIXTURE
AUTOMATIC CHOKE

IDLE

MIXTURE

IDLE

SPEED
ROCHESTER
4MV

IDLE

MIXTURE

SIDE INLET
HOLLEY 4150

CENTER INLET

IDLE

MIXTURE
IDLE

MIXTURE
HOLLEY 4160

IDLE

MIXTURE

APPLICATION |

CARBURETOR
IN LINE

153

90
194

120
230

140
250

155
V-8

283

195
210
327

275 300 325 350
350

295
396

325 350
427

385 390 400 425 435

ROCH.
BV

1234

ROCH 2GV

1234

ROCH
4MV

1234
1-2

CARTER

YF
Man.

Auto.

2-4

1234

HOLLEY

4150
Side

Center

HOLLEY
4160

HOLLEY

2300
C Prim.

Sec.

Fig.
14 - Idle Speed and Mixture Screws

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-10

Fig.
15 - Crank case Ventilation Valve

a. If voltage is 9 volts or more and cranking speed

is satisfactory, the battery, starter, cables,

starter switch and ignition circuit to coil (by-

passing resistance wire) are in good condition.

b.
If below 9 volts, check circuit until difficulty is

located.

Meter reading below specification—Weak bat-

tery; defective cables, connections, switch or

starter; defective ignition circuit to coil.

Cranking speed below normal--Excessive re-

sistance in cables or starting motor; excessive

mechanical drag in engine.

Uneven cranking speed—Uneven compression,

defective starter or starter drive.

Ignition Switch

With voltmeter connected as described for the Cranking

Voltage Test, turn ignition switch to ON. Voltage should

drop to 5 to 7 volts as current is now passing through

high resistance wire connected between ignition switch

and (+) positive terminal of coil. If battery voltage of

12 volts is obtained, the starter solenoid is by-passing

the high resistance wire connected between ignition

switch and (+) positive terminal of coil, thus the starter

solenoid is not functioning properly to bypass the ignition

resistance wire or the ignition circuit is incorrectly

wired.

Distributor Resistance

Use equipment as directed by manufacturer.

Excessive
(t n ti ft

Fig.
16 - Cylinder Balance Test
Fig.
17 - Testing Cranking Voltage

resistance in primary circuit must be eliminated before

continuing with test procedure.

Secondary Resistance

Use equipment as dire6ted by manufacturer.

• Uniform "normal readings" as specified by manu-

facturer indicate all secondary circuit components

are in good condition.

• If all readings are "below normal," check for cor-

roded coil tower terminal, poorly connected or

broken coil wire, center cap electrode or rotor tip

burned, or an open secondary in coil.

• If readings are "higher than normal" at two or more

plugs adjacent in firing order, cross firing is oc-

curring in distributor cap or between spark plug ca-

bles concerned.

• If meter reads off scale to left, the coil polarity is

reversed. Check for reversed coil primary wires,

wrong coil or reversed vehicle battery connections.

Ignition Output and Secondary Leakage

Use equipment as directed by manufacturer.

• GOOD readings indicate both ignition output and

secondary insulation are good.

• If all readings are BAD or if ignition test calibrator

cannot be adjusted to Set Line, check for high re-

sistance in primary circuit, defective distributor

points, coil or condenser.

e If readings are BAD when certain plug wires are

lifted off, check for cracks or carbon tracks in dis-

tributor cap or defective insulation on those plug

wires being lifted off.

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
6-12

ENGINE
MECHANICAL

IN LINE

INDEX

Page

General Description . „ 6-12

Component Replacement and Adjustment 6-12

.Engine Assembly 6-12

Removal 6-12

Installation 6-13

Manifold Assembly 6-14

Removal . 6-14

Installation 6-14

Rocker Arm Cover . 6-14

Removal 6-14

mstallation . . . 6-14

Valve Mechanism
......
1 6-14

Removal 6-14

Installation and Adjustment . 6-14

Valve Lifters
..............
6-15

Locating Noisy Lifters
„.;....
6-15

Removal
.'.*...•
6-15

Installation . 6-15

Valve Stem Oil Seal and/or Valve Spring . 6-16

Replacement . 6-16

Cylinder Head Assembly . 6-16

Removal 6-16

Installation . 6-16

Oil Pan . » 6-17

Removal . . . ; . . 6-17

Installation
.........
. 6-17

Oil Pump . 6-18
Page

Removal . 6-18

Installation . 6-18

Oil Seal (Rear Main) . 6-19

Replacement 6-19

Crankshaft Pulley and Hub 6-19

Removal 6-19

Installation 6-19

Torsional Damper 6-19

Removal 6-19

Installation 6-19

Crankcase Front Cover . 6-20

Removal . 6-20

Installation 6-20

•
Oil Seal (Front Cover) 6-20

Replacement 6-20

Camshaft 6-21

Measuring Lobe Lift . ... .
.-.••.-.
6-21

Removal 6-21

Installation 6-22

Timing Gears
..••••.............••• 6—22

Replacement
6-22

Flywheel
6-22

Removal
* 6-22

Installation
6-22

Engine
Mounts
6-23

Replacement
(Front)
6-23

Replacement
(Rear)
. 6-23

GENERAL DESCRIPTION

The
In
Line engines
(fig. 1L)
covered
in
this section

are
the 1H3 cu. in. L4, the 194,
230
and
250
cu. in. L6,

regardless
of
which passenger vehicle they
are
used
in.

This section covers
the
removal
and
installation
of en-

gine assemblies;
the
removal, installation
and
adjustment

of some sub-assemblies
and
replacement
of
some
com-

ponents.
For
service
to all
components
and
sub-assem-

blies (after removal)
and
removal
of
some sub-assem-

blies,
refer
to
Section
6 of the
Chassis Overhaul Manual.
Because
of the
interchangeability
and
similarity
of

many engine sub-assemblies
and
engine parts, regardless

of which passenger vehicle they
are
used
in,
typical illus-

trations
and
procedures
are
used except where specific

illustrations
or
procedures
are
necessary
to
clarify
the

operation. Although illustrations showing bench opera-

tions
are
used, most single operations, when
not
part
of a

general overhaul, should
be
performed
(if
practical) with

the engine
in the
vehicle.

COMPONENT REPLACEMENT
AND
ADJUSTMENT

ENGINE ASSEMBLY

Removal

1.
Drain cooling system
and
engine
oil.

2.
Remove
air
cleaner
and
disconnect battery cables
at 7.

battery.

3.
Remove hood
as
outlined
in
Section 11.

4.
Remove radiator
and
radiator shroud
as
outlined
in

Section 13.

5.
Remove
fan
blade
and
pulley
as
outlined
in
Section

6K.

6. Disconnect wires
at:

• Starter Solenoid
8.

• Delcotron
9.
Temperature Switch

Oil Pressure Switch

Coil

Disconnect:

Accelerator linkage
at
manifold bellerank.

Exhaust pipe
at
manifold flange.
.

Fuel line (from tank)
at
fuel pump.

Vacuum line
to
power brake unit
at
manifold
(if

so equipped).

• Power steering pump lines
at
pump
end (if so

equipped).

Raise vehicle
and
place
on
jack stands.

Remove propeller shaft.

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-13

Fig.
1L- In
Line Engines (Typical)

NOTE:
If plug for propeller shaft open-

ing in transmission is not available, drain

transmission.

10.

11.

12.
Disconnect:

• Shift linkage at transmission.

• Speedometer cable at transmission.

On synchromesh equipped vehicles, disconnect clutch

linkage at cross-shaft then remove cross-shaft en-

gine bracket.

Remove rocker arm cover as outlined, then attach

engine lifting adapter at the proper cylinder head

bolt locations.

13.
Remove front mount through bolts.

14.
Attach lifting device and raise engine to take weight

off front mounts, then remove rear mount bolts.

15.
Raise engine to take weight off rear mount, then

remove crossmember.

NOTE:
On Chevrolet vehicles it will be neces-

sary to remove mount from transmission before

crossmember can be removed.

NOTE:
On Camaro vehicles it will be neces-

sary to remove mount from transmission and

loosen rear frame cushion bolts before cross-

member can be removed.

16.
Remove engine-transmission assembly from vehicle

as a unit.

17.
Remove transmission (and clutch):

Synchromesh Transmission

a. Remove clutch housing cover plate screws.

b.
Remove bolts attaching the clutch housing to en-

gine block then remove transmission and clutch

housing as a unit.

NOTE:
Support the transmission, as the last

mounting bolt is removed, and as it is being
pulled away from the engine (to prevent damage

to clutch disc).

c. Remove starter and clutch housing rear cover.

d. Loosen clutch mounting bolts a turn at a time (to

prevent distortion of clutch cover) until the spring

pressure is released. Remove all bolts, clutch

disc and pressure plate assembly.

Automatic Transmission

SL.
Lower engine, secured by the hoist, and support

engine on blocks.

b.
Remove starter and converter housing underpan.

c. Remove flywheel-to-converter attaching bolts.

d. Support transmission on blocks.

e. Remove transmission-to-engine mounting bolts.

f. With the hoist attached, remove blocks from the

engine only and slowly guide the engine from the

transmission.

18.
Mount engine in stand.

Installation

1.
Attach lifting device to engine and remove engine

from engine stand.

2.
Install transmission (and clutch):

Synchromesh Transmission

a. Install the clutch on flywheel as outlined in Sec-

tion 7.

b.
Install clutch housing rear cover and starter.

c. Install transmission and clutch housing as out-

lined in Section 7.

d. Install clutch housing cover screws and tighten

securely.

Automatic Transmission

a. Position engine adjacent to the transmission and

align the converter with the flywheel.

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