low oil pressure CHEVROLET CAMARO 1967 1.G Chassis Owner's Manual

REAR SUSPENSION AND DRIVE LINE 4-33

Fig.
84—Drive Pinion Flange Removal

J-21057 for heavy-duty axle, press seal into bore

until it seats against shoulder (figs. 85 and 86).

CAUTION: Pinion oil seal flange must not bot-

tom against "carrier. Press seal into carrier

bore until it seats against internal shoulder -

do not apply unnecessary pressure after seal is

seated. To do so will destroy rubber seat ancl

distort seal. ;

11.
Position and align pinion flange on pinion shaft using

Tools J-9458 and
J-8614-1.
Tool J-9458-1 is

threaded onto pinion shaft and nut tightened against

J-9458-2 to pull flange on shaft (fig. 87). Remove
Fig.
86—Drive Pinion Flange Oil Seal

Installation (Heavy-Duty)

J-9458 after flange is seated.

NOTE: The position of the pinion and flange

was previously marked so that reinstallation

may be made with flange and pinion in same

relative position.

CAUTION: Do not attempt to hammer flange

onto pinion shaft. To do so will damage ring

gear and pinion.

12.

13.

14.

15.
Pack the cavity between end of pinion splines and

pinion flange with a non-hardening sealer (such as

Permatex Type A) prior to installing washer and

nut on pinion.

Install washer and a new self-locking nut on pinion

shaft. Tighten nut to remove end play and continue

alternately tightening in small increments and check-

ing preload with torque wrench until it is the same

as that recorded in Step 4.

Reassemble the rear universal joint, and torque

"V" bolt nuts to specifications.

Lower vehicle to floor and road test for leaks.

Fig.
85—Drive Pinion Flange Oil Seal

Installation (Light-Duty)
Fig.
87—Drive Pinion Flange Installation

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES
5-3

PRIMARY

SHOE

PAWL
WIRE LINK

OVERRIDE

LEVER

VERRIDE

SPRING

RETURN

SPRING

STAR
WHEEL

Fig.
3—Camaro
Pressure
Regulator
Valve
Fig.
4-Self-Adjusting
Brake

MAINTENANCE AND ADJUSTMENTS

In any service operation it is extremely important

that absolute cleanliness be observed. Any foreign matter

in the hydraulic system will tend to clog the lines, ruin

the rubber cups of the main and wheel cylinders and

cause inefficient operation or even failure of the braking

system. Dirt or grease on a brake lining may cause

that brake to grab first on brake application and fade

out on heavy brake application.

The split system consists basically of two separate

brake systems. When a failure is encountered on either,

the other is adequate to stop the vehicle. If one system

is not functioning, it is normal for the brake pedal lash

and pedal effort to substantially increase. This occurs

because of the design of the master cylinder which

incorporates ah actuating piston for each system. When

the rear system loses fluid and takes in air, its piston

will bottom against the front piston. When the front

system loses fluid and takes in air, its piston will

bottom on the end of the main cylinders body. The loss

of fluid in one of the systems causes an uneven hydraulic

pressure balance between the front and rear systems.

The brake pipe distribution and switch assembly, near

the main cylinder, detects the loss of pressure and il-

luminates the brake alarm indicator light on the instru-

ment panel. The pressure loss is felt at the brake pedal

by an apparent lack of brakes for most of the brake

travel and then, when failed chamber is bottomed, the

pedal will harden.

HYDRAULIC BRAKE FLUID

Use GM Hydraulic Brake Fluid, Supreme No. 11 or

equivalent when servicing brakes. This brake fluid is

satisfactory for any climate and has all the qualities

necessary for proper operation, such as a high boiling

point to prevent vapor lock and the ability to remain

fluid at low temperatures.
In the event that improper fluid has entered the system,

it will be necessary to service the system as follows:

1.
Drain the entire system.

2.
Thoroughly flush the system with clean alcohol,

188
proof,
or a hydraulic system cleaning fluid

such as "Declene".

3.
Replace all rubber parts of the system, including

brake hoses.

4.
Refill the system.

5. Bleed the system.

BLEEDING HYDRAULIC SYSTEM

The hydraulic brake system must be bled whenever

any line has been disconnected or air has in some way

entered the system. A ''spongy" pedal feeling when the

brakes are applied may indicate presence of air in the

system. The system must be absolutely free of air at

all times. Bleeding should be done on the longest line

first; the proper sequence to follow is left rear, right

rear, right front, and left front (fig. 5). Bleeding of

brake system may be performed by one of two methods—

either pressure or manual.

PRESSURE
BLEEDING

1.
Clean all dirt from top of main cylinder and remove

cylinder cover and rubber diaphragm.

2.
Reduce fluid level in main cylinder until reservoirs

are approximately half full.

NOTE:
Make sure brake fluid in bleeder equip-

ment is at operating level and that the. equipment

is capable of exerting 30 to 50 lbs. hydraulic

pressure on the brake system.

3.
Install brake bleeder adapter J-22489 (fig. 6) on

main cylinder. Connect hose from bleeder equipment

to bleeder adapter and open release valve on bleeder

equipment.

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

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 6-19

OIL SEAL (REAR MAIN)

Replacement

The rear main bearing oil seal can be replaced (both

halves) without removal of the crankshaft.

NOTE:
Always replace the upper and lower

seal as a unit. Install with the lip facing toward

the front of the engine.

1.
With the oil pan removed, remove the rear main

bearing cap.

2.
Remove oil seal from the groove by lifting the end

tab (fig. 7L) then clean seal groove.

3.
Lubricate the lip and O.D. of a new seal with engine

oil. Keep oil off the parting line surface. Insert

seal in cap and roll it into place with finger and

thumb,
using light pressure so beads on seal O.D.

are not cut by seal groove at cap parting line. Be

sure tabs on seal are properly located in cross

grooves.

4.
To remove the upper half of the seal, use a small

hammer to tap a brass pin punch on one end of seal

until it protrudes far enough to be removed with

pliers (fig. 8L).

NOTE:
Always clean crankshaft surface re-

moving all foreign deposits before installing a

new seal. Also clean seal groove.

5. Lubricate the lip and O.D. of a new seal with engine

oil. Keep oil off the parting line surface. Gradually

push with a hammer handle, while turning crank-

shaft, until seal is rolled into place. (Similar to in-

stalling a main bearing.) Be careful that seal bead

on O.D. is not cut. Compress seal towards crank-

shaft as much as possible.

6. Install the rear main bearing cap (with new seal) and

torque to specifications. Be sure cross seal tabs

are in place and properly seated.

CRANKSHAFT PULLEY AND HUB

(Chevy II with L4 Engine)

Removal

1.
Drain radiator and disconnect upper and lower radi-

ator hoses at radiator.

2.
Remove radiator core as outlined in Section 13.

3.
Remove fan belt. Remove crankshaft pulley from

pulley hub.

4.
Install puller Tool J-6978 to pulley hub with two

3/8"
x 2" and one 5/16" x 2" bolts and remove hub

then remove puller tool.

Installation

1.
Coat oil seal contact area on hub with engine oil

position hub over crankshaft and key and start hub

into position with a mallet. Using Tool J-5590 drive

onto crankshaft until it bottoms against crankshaft

gear.

NOTE:
Crankshaft extends slightly through hub

and a tool is necessary to drive hub completely

into bottomed position.

2.
Install pulley onto hub.

NOTE:
There are two 3/8" holes and one

5/16" hole that must be matched on hub in order
Fig.
9L - Removing Torsional Damper

to properly position timing mark.

3.
Install fan belt and adjust using strand tension gauge.

4.
Install radiator as outlined in Section 13.

TORSIONAL DAMPER

Removal

1.
Remove radiator core, as outlined in Section 13.

2.
Remove fan belt and (if so equipped) accessory drive

pulley and belt.

3.
Install Tool J-6978 to damper and turn puller screw

to remove damper (fig. 9L). Remove tool.

Installation

1.
Coat front cover oil seal contact area of damper with

engine oil.

CAUTION: It is necessary to use installer

Tool J-22197 to prevent the inertia weight sec-

Fig.
10L - Installing Torsional Damper

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-25

refer to Section 6 of the Chassis Overhaul Manual.

Because of the interchangeability and similarity of

many engines, engine sub-assemblies and engine parts,

regardless of which passenger vehicle they are used in,

typical illustrations and procedures are used except
where specific illustrations or procedures are necessary

to clarify the operation. Although illustrations showing

bench operations 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

battery.

3.
Remove hood as outlined in Section 11.

4.
Remove radiator and shroud as outlined in Sec-

tion 13.

5. Remove fan blade and pulley as outlined in Sec-

tion 6K.

6. Disconnect wires at:

• Starter solenoid

• Delcotron

• Temperature switch

• Oil pressure switch

• Coil

7. Disconnect:

• Accelerator linkage at pedal lever.

• Exhaust pipes at manifold flanges.

• Vacuum line to power brake unit at manifold (if

so equipped),

• Power steering pump lines at pump end (if so

equipped).

• Fuel line (from tank) at fuel pump.

• Engine cooler lines (if so equipped).

• Oil pressure gauge line (if so equipped).

8. Raise vehicle and place on jack stands.

9. Remove propeller shaft.

NOTE:
If plug for propeller shaft opening

in transmission is not available, drain

transmission.

10.
Disconnect:

• Shift linkage at transmission.

• Speedometer cable at transmission.

• Transmission cooler lines (if so equipped).

11.
On synchromesh equipped vehicles, disconnect clutch

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

gine bracket.

12.
Remove rocker arm covers as outlined, then attach

engine lifting adapter at the proper cylinder head bolt

locations.

13.
Remove front mount 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 re-

move crossmember.

NOTE:
On Chevrolets it will be necessary to

remove mount from transmission 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

plate.

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

a. 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
Transmissions

a. Position engine adjacent to the transmission and

align the converter with the flywheel.

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 bolts and torque to specifications.

5. Raise engine enough to install rear crossmember,

then install crossmember, install rear mount, lower

engine and torque rear mount to specifications.

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-26

6. Remove lifting device and lifting adapter then install

rocker arm covers as outlined.

7.
On synchromesh equipped vehicles, install clutch

cross-shaft engine bracket, then adjust and connect

clutch as outlined in Section 7.

8. Connect:

• Speedometer cable.

• Shift linkage at transmission.

• Transmission cooler lines (if so equipped).

9. Install propeller shaft.

10.
Remove jack stands and lower vehicle.

11.
Connect: \ '

Power steering pump lines (if so equipped).

Vacuum line to power brake unit (if so equipped).

Exhaust pipes at manifold flanges.

Accelerator linkage at pedal lever.

Fuel line at fuel pump.

Engine cooler lines (if so equipped).

Oil pressure gauge lines (if so equipped).

12.
Connect wires at:

Coil

Oil pressure switch

Temperature switch

Delcotron

Starter solenoid

13.
Install pulley, fan blade and fan belt as outlined in

Section 6K.

14.
Install radiator and shroud as outlined in Section 13.

15.
Install and adjust hood as outlined in Section 11.

16.
Connect battery cables.

17.
Fill with coolant, engine oil and transmission oil,

then start engine and check for leaks.

18.
Perform necessary adjustments and install air

cleaner.

INTAKE MANIFOLD

Removal

1.
Drain radiator and remove air cleaner.

2.
Disconnect:

Battery cables at battery.

Upper radiator and heater hose at manifold.

Accelerator linkage at pedal lever.

Fuel line at carburetor. ;

Wires at temperature sending switch and coil

(both sides).

Power brake hose at carburetor base.

Spark advance hose at distributor.

Crankcase ventilation hoses (as required).

3.
Remove distributor cap and mark rotor position with

chalk. Remove distributor clamp and distributor,

then position distributor cap rearward clear of

manifold.

4.
Remove coil.

5.
Remove manifold-to-head attaching bolts, then re^

move manifold, (with carburetor on) from engine and

discard gaskets and seals.

6. If manifold is to be replaced,,transfer:

Carburetor and carburetor mounting studs.

Temperature sending switch.

Water outlet and thermostat (use new gasket).

Heater hose adapter.

Choke coil.

Installation

1.
Clean gasket and seal surfaces of manifold, cylinder
heads and block.

2.
Install manifold end seals on block as shown (fig.

2V).

3.
Install side gaskets on cylinder heads using sealing

compound around water passages (fig. 2V).

4.
Install manifold bolts, and torque to specifications in

the sequence outlined on the Torque Sequence Chart.

5.
Install coil.

6. Install distributor with the rotor pointing at the chalk

mark, then install distributor cap.

NOTE:
If the crankshaft has been rotated while

the distributor was removed, time distributor to

number 1 cylinder as outlined in Section 6Y.

7.
Connect:

Battery cables at battery.

Upper radiator and heater hose at manifold.

Accelerator linkage at pedal lever.

Fuel line at carburetor.

Wires at temperature sending switch and coil

(both sides)!

Power brake hose at carburetor base.

Spark advance hose at distributor.

Crankcase ventilation hoses (as required).

Fill with coolant, start engine, check for leaks and

adjust timing and carburetor idle speed and mixture.

EXHAUST MANIFOLD

Removal

NOTE:
If equipped with "Air Injection Reactor

System", remove air manifold and tubes as out-

lined in Section 6T.

1.
Disconnect battery ground cable.
-

2.
Disconnect and remove Delcotron (as required).

3.
On 396 and 427 cu. in. engines, remove spark plugs

Fig. 2V - Intake Manifold Gasket and Seal Location

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE 6-32

Fig.
1GV - Removing Oil Seal (Lower Half)

bearing cap, aligning slot on top end of extension

shaft with drive tang on lower end of distributor

drive shaft.

2.
Install pump to rear bearing cap bolt and torque to

specifications.

NOTE:
Installed position of oil pump, screen

is with bottom edge parallel to oil pan rails.

3.
Install oil pan as outlined.

OIL SEAL (REAR MAIN)

Replacement

The rear main bearing oil seal can be replaced (both

halves) without removal of the crankshaft.
Fig.
12V - Removing Torstonal Damper

NOTE:
Always replace the upper and lower

seal as a unit.. Install with the lip facing toward

the front of the engine.

With the oil pan and oil pump removed, remove the

rear main bearing cap.

Remove oil seal from the groove by prying from the

bottom with a small screw driver (fig. 10V).

Lubricate the lip of a new seal with engine oil. Keep

oil off the parting line surface as this is treated with

glue. Insert seal in cap and roll it into place with

finger and thumb, using light pressure so seal tangs

at parting line do not cut bead on back of seal.

To remove the upper half of the seal, use a small

hammer to tap a brass pin punch on one end of seal

until it protrudes far enough to be removed with

pliers (fig. 11V).

NOTE:
Always wipe crankshaft surface clean

before installing a new seal.
1.

2.

3.

5.

Fig.
1IV - Removing Oil Seal (Upper Half)
Lubricate the lip of a new seal with engine oil. Keep

oil off the parting line surface as this is treated with

glue. Gradually push with a. hammer handle, while

turning crankshaft, until seal is rolled into place.

(Similar to installing a main bearing.) Be careful

that seal tangs at parting line do not cut bead on back

of seal.

6. Install the rear main bearing cap (with new seal) and

torque to specifications.

TORSIONAL DAMPER

Removal

1.
Remove fan belt, fan and pulley as outlined in Sec-

tion 6K.

2.
Remove the radiator and shroud as outlined in Sec-

tion 13.

NOTE:
If additional operations such as cam-

shaft removal are not being performed, the radi-

ator will not have to be removed
.on
Chevrolets

and Corvettes equipped with 396 and 427 cu. in.

engines.

. 3. On Corvettes equipped with 427 cu. in. engines, re-

move engine front mount through-bolts and raise

front of engine enough for torsional damper to clear

frame crossmember.

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 6K

ENGINE COOLING

INDEX

Page

General Description . . . 6K-1

Maintenance and Adjustments 6K-1

Coolant Level 6K-1

Coolant System Checks 6K-1

Periodic Maintenance 6K-2

Cleaning 6K-2

Reverse Flushing 6K-2

Radiator 6K-2
Page

Cylinder Block and Cylinder Head 6K-2

Hot Water Heater 6K-2

Fan Belt . 6K-2

Adjustment ....". 6K-2

Thermostat . 6K-2

Replacement 6K-2

Water Pump. . . . 6K-3

Removal 6K-3

Installation 6K-3

GENERAL DESCRIPTION

A pressure cooling system is provided for on all

models by a pressure type radiator cap (fig. 1). The

pressure type radiator cap used is designed to hold a

pressure above atmospheric pressure in the cooling

system. Excessive pressure is relieved by a valve within

the cap that opens to radiator overflow.

The water pump is a ball bearing, centrifugal vane

impeller type. It requires no care other than to make

certain the air vent at the top of the housing and the drain

holes in the bottom do not become plugged with dirt or

grease. Removal and installation of the water pump is

covered in this section. For overhaul procedures of the

water pump refer to Section 6K of the Passenger Chassis

Overhaul Manual.
For radiator, refer to Section 13 of this manual For

radiator shroud, refer to Section 11 of this manual.

Fig.
I—Pressure Radiator Cap

MAINTENANCE AND ADJUSTMENTS

Coolant Level

The radiator coolant level should only be checked when

the engine is cool, particularly on cars equipped with air

conditioning. If the radiator cap is removed from a hot

cooling system, serious personal injury may result

The cooling system fluid level should be maintained

one inch below the bottom of the filler neck of the radia-

tor when cooling system is cold, or at the bottom of the

filler neck when the system is warm. It is very impor-

tant that the correct fluid level be maintained. The seal-

ing ability of the radiator cap is affected when the cooling

level is too high.

All passenger car cooling systems are pressurized

with a pressure cap which permits safe engine operation

at cooling temperatures of
up
to 247°F.

When the radiator cap is removed or loosened, the

system pressure drops to atmospheric, and the heat

which had caused water temperature to be higher than

212°F, will be dissipated by conversion of water to

steam. Inasmuch as the steam may form in the engine

water passages, it will blow coolant out of the radiator

upper hose and top tank, necessitating coolant replace-

ment Engine operating temperatures higher than the

normal boiling point of water are in no way objectionable

so long as the coolant level is satisfactory when the

engine is cooL

Upon repeated coolant loss, the pressure radiator cap

and seat should be checked for sealing ability. Also, the
cooling system should be checked for loose hose con-

nections, defective hoses, gasket leaks, etc.

Coolant System Checks

1.
Test for restriction in the radiator, by warming the

engine up and then turning the engine off and feeling

the radiator. The radiator should be hot at the top

and warm at the bottom, with an even temperature

rise from bottom to top. Cold spots in the radiator

indicate clogged sections.

2.
Water pump operation may be checked by running the

engine while squeezing the upper radiator hose. A

pressure surge should be felt Check for a plugged

vent-hole in pump.

NOTE:
A defective head gasket may allow ex-

haust gases to leak into the cooling system.

This is particularly damaging to the cooling

system as the gases combine with the water to

form acids which are particularly harmful to

the radiator and engine.

3.
To check for exhaust leaks into the cooling system,

drain the system until the water level stands just

above the top of the cylinder head, then disconnect

the upper radiator hose and remove the thermostat

and fan belt. Start the engine and quickly accelerate

several times. At the same time note any appreci-

able water rise or the appearance of bubbles which

CHEVROLET CHASSIS SERVICE MANUAL