radiator CHEVROLET CAMARO 1967 1.G Chassis Owner's Guide
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Page 287 of 659
ENGINE 6-22
the camshaft gear (fig. 15L).
7.
Remove the camshaft and gear assembly by pulling it
out through the front of the block.
NOTE: Support camshaft carefully when re-
moving so as not to damage camshaft bearings.
Installation
1.
Install the camshaft and gear assembly in the engine
block, being careful not to damage camshaft bearings
or camshaft.
2.
Turn crankshaft and camshaft so that the valve tim-
ing marks on the gear teeth will line up (fig. 15L).
Push camshaft into position. Install camshaft thrust
plate-to-block bolts and torque to specifications.
3.
Check camshaft and crankshaft gear run out with a
dial indicator (fig. 16L). The camshaft gear"run out
should not exceed,.004" and the crankshaft gear run
out should not exceed
.003".
4.
If gear mm out is excessive, the gear will have to be
removed and any burrs cleaned from the shaft or the
gear will have to be replaced.
5.
Check the backlash between the timing gear teeth
with a dial indicator (fig. 17L). The backlash should
not be less than .004" nor more than .006".
6. Install fuel pump as outlined in Section 6M.
7.
Install grille as outlined in Section 13.
8. Install crankcase front cover as outlined.
9. Install radiator as outlined in Section 13.
10.
Install valve lifters as outlined.
TIMING GEARS
Replacement
With camshaft removed, crankshaft gear may be re-
moved using Tool J-8105 (fig. 18L). To install crankshaft
gear use Tool J-5590 (fig. 19L). For camshaft gear re-
placement, refer to Section 6, "Camshaft Disassembly"
of the Overhaul Manual.
Fig.
18L
- Removing Crankshaft Gear
Fig.
19L- Installing Crankshaft Gear
FLYWHEEL
Removal
With transmission and/or clutch housing and clutch re-
moved from engine, remove the flywheel.
Installation
1.
Clean the mating surfaces of flywheel and crankshaft
to make certain there are no burrs.
2.
Install flywheel on crankshaft and position to align
dowel hole of crankshaft flange and flywheel (fig.
20L).
NOTE: On Automatic Transmission equipped
engines, the flywheel must be installed with the
flange collar to transmission side (fig. 20L).
3.
Install bolts and torque to specifications.
SYNCHROMESH
CONVERTER
BOLT AREA -
DEPRESSED
•RING
GEAR
TRANS.,
AUTOMATIC
Fig. 17L
—
Checking Timing Gear Backlash
Fig. 20L r Flywheel Installation (Typical)
CHEVROLET CHASSIS SERVICE MANUAL
Page 290 of 659
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
Page 291 of 659
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
Page 295 of 659
ENGINE 6-30
c". Install the valve locks and release the compres-
sor tool making sure the locks seat properly in
the upper groove of the valve stem.
NOTE: Grease may be used to hold the locks
in place while releasing the compressor tool.
396 and 427
cu.
in.
Engines
a. Install new valve stem oil seal (coated with oil)
in position over valve guide.
b.
Set the valve spring and damper and valve cap in
place.
c. Compress the spring with Tool J-5892 and install
the valve locks, then release the compressor tool,
making sure the locks seat properly in the groove
of the valve stem.
NOTE: Grease may be used to hold the locks
in place while releasing the compressor tool.
7.
Install spark ,plug, using a new gasket, and torque to
specifications. -
8. Install and adjust valve mechanism as outlined.
CYLINDER HEAD ASSEMBLY
Removal
1.
Remove intake manifold as outlined.
2.
Remove exhaust manifolds as outlined.
3.
Remove valve mechanism as outlined.
4.
Drain cooling system (block).
5.
Remove cylinder head bolts, cylinder head and gas-
ket. Place cylinder head on two blocks of wood to
prevent damage.
Installation
CAUTION: The gasket surfaces on both the
head and the block must be clean of any foreign
ttter and free of nicks or heavy scratches.
Under bolt threads in the block and threads on
Pie cylinder head bolt must be cleaned. (Dirt
will affect bolt torqueT)
1.
On engines using a STEEL gasket, coat both sides of
a new gasket with a good sealer, spread the sealer
thin and even. One method of applying the sealer that
will assure the proper- coat is with the use of a paint
roller. Too much sealer may hold the beads of the
gasket away from the head or block.
CAUTION: Use no sealer on engines using a
composition STEEL ASBESTOS gasket.
2.
Place the gasket in position over the dowel pins with
the bead up.
3.
Carefully guide cylinder head into place over dowel
pins and gasket.
4.
Coat threads of cylinder head bolts with sealing
compound and install finger tight.
5.
Tighten cylinder head bolts a little at a time in the
sequence shown on the torque sequence chart until
the specified torque is reached.
6. Install the exhaust manifold as outlined.
7.
Install the intake manifold as outlined.
8. Install and adjust the valve mechanism as outlined.
OIL
PAN
Removal
Chevrolet
and Camaro
1.
Disconnect battery positive cable.
2.
Disconnect distributor cap from distributor (to pr-e-
vent breaking distributor cap when engine is raised).
3.
Drain radiator, then disconnect lower radiator hose
at water pump and remove oil dip stick and tube
(where necessary). '
4.
Remove fan blade.
5.
Raise vehicle then drain engine oil;
6. Remove through bolts from engine front mounts.
Disconnect and remove starter.
7.
On vehicles equipped with automatic transmissions,
remove converter housing underpan.
8. Disconnect steering rod at idler lever then swing
steering linkage 4pwn for oil pan clearance.
9. Rotate crankshaft untii timing mark on torsional
damper is at 6:00 o'clock position.
10.
Using a suitable jack, and a block of wood to prevent
damaging oil pan, raise engine "enough to insert 2" x
4"
wood blocks under engine mounts (fig. 8V), then
lower engine onto blocks.
NOTE: If 2" x 4" wood blocks are cut 5-1/2"
long they can be used on all Chevrolet engines.
The 5-1/2" length up for In-line engines and the
4"
side up for V8 engines.
11.
Remove oil pan and discard gaskets and seals.
NOTE: -On the 396 and 427 cu. in. engine, the
oil pan has three 1/4" x 20 attaching bolts at ,
crankcase front cover. One located at each
corner and one at lower center.
Chevelle
1.
Remove engine from vehicle as outlined.
2.
Lower engine onto jack stands, one at each front
Tnaount and one at transmission extension.
CAUTION: Leave engine lift attached to en-
gine.
Do not remove all weight of engine off
engine lifET
3.
Remove starter.
4.
On vehicles equipped with automatic transmission
remove converter housing underpan.
5.
Remove oil pan and discard gaskets and seals.
Fig.
8V - Engine Blocked for Pan Removal
CHEVROLET CHASSIS SERVICE MANUAL
Page 296 of 659
ENGINE 6-31
Chevy II
1.
Disconnect battery positive cable.
2.
Drain engine oil.
3.
Disconnect and remove starter.
4 Disconnect steering idler arm bracket at right hand
frame rail and swing steering linkage down for pan
clearance.
5.
Disconnect* exhaust pipes at manifolds and allow
pipes to hang free.
6. Remove oil pan and discard gaskets and seals.
Corvette
1.
Disconnect battery positive cable then remove oil
dipstick and tube.
2.
Raise and support vehicle then drain engine oil.
3.
Remove starter and flywheel underpan.
4.
Disconnect steering linkage idler at frame and lower
the linkage.
5.
Remove oil pan and discard gaskets and seals.
6. On Hi-Performance engines, the oil baffle must
be removed before additional operations can be
performed.
NOTE: On the 427 cu. in. engine, the oil pan
has three 1/4" x 20 attaching bolts at crankcase
front cqver. One located at each corner and one
at lower center.
Installation
1.
Thoroughly clean all gasket sealing surfaces.
NOTE: Use a new pan. gasket set.
2.
Install side gaskets on pan rails, using.gasket sealer
as a retainer.
3.
Install rear oil pan seal in groove in rear main
bearing cap with ends (fig. 9V) butting side gaskets.
4.
Install oil pan front seal in groove in .crankcaee front
cover, with ends butting side gaskets.
5.
If crankshaft was rotated while £>an was off, place
timing mark at 6:00 o'clock position.
6. Install oil pan and torque bolts to specifications.
NOTE: On 396 and 427 cu. in. engines, start
three 1/4" x 20 bolts into crankcase front cover
before tightening, any other pan bolts.
7.
Complete installation as follows:
Chevrolet
and Camaro
a. Using a suitable jack (and a block of wood to pre-
vent damaging oil pan) raise engine enough to re-
move 2" x 4" wood blocks, then lower engine.
b.
On vehicles equipped with automatic transmission
install converter housing underpan.
c. Install through bolts in engine front mounts.
d. Install and connect starter. Connect steering rod
at idler lever.
e. Lower vehicle and install fan blade.
f. Cbnnnect lower radiator hose, then install oil dip
stick tube and dip stick.
g. Connect distributor cap and battery positive
cable.
h. Fill radiator with coolant and fill engine with oil,
then start engine and check for leaks.
Chevelle
a. On vehicles equipped with automatic transmission
Fig.
9V - Oil Pan Gasket and Seal Location
install converter housing underpan.
b.
.Install starter.
c. Install, engine as outlined.
Chevy II
a. Connect exhaust pipe to manifold flange using new
packing seals.
b.
Connect steering idler arm bracket.
c. Connect starter wires..
d. Connect battery cable.
e. Fill with oil, start engine and check for leaks.
Corvette
a. Connect steering linkage.
b.
Install oil dip stick tube and dip stick then con-
nect battery cables.
c. Fill engine with oil, then start engine and check
for leaks.
OIL PUMP
Removal
1.
Remove oil pan as outlined.
2.
Remove pump to rear main bearing cap bolt and re-
move pump and extension shaft.
Installation
1.
Assemble pump and extension shaft to rear main
CHEVROLET CHASSIS SERVICE MANUAL
Page 297 of 659
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
Page 298 of 659
ENGINE 6-33
Fig.
13V - Installing TorsionaI Damper (283, 327 and 350)
4.
Remove accessory drive pulley, then remove tor-
sional damper retaining bolt (if so equipped).
5. Install Tool J-6978 to torsional damper and turn
puller screw to remove damper from crankshaft
(fig. 12V).
6. Remove tool.
Installation
CAUTION: It is necessary to use installer tool
to prevent the inertia weight section from walk-
ing off the hub during installation of damper.
283, 327 and 350 cu. in. Engines
(Except 327-325 HP & 350 HP)
1.
Coat front cover seal contact area (on torsional
damper) with engine oil.
Fig.
14V - Installing Torsional Damper (396 and 427)
2.
Attach damper installer Tool J-22197 to damper.
Tighten fingers of tool to prevent weight from moving
(fig. 13V).
3.
Position damper on crankshaft and drive into position
until it bottoms against crankshaft sprocket (fig.
13V).
Remove installer tool.
4.
Install accessory drive pulley.
5. Install radiator and shroud as outlined in Section 13.
6. Install fan pulley and fan as outlined in Section 6K.
7. Install fan belt and adjust to specifications using
strand tension gauge.
8. Fill cooling system, start engine and check for leaks.
396 and 427
cu.
in.
Engines
1.
Coat front cover seal contact area (on damper) with
engine oil.
2.
Place damper in position over key on crankshaft.
3.
Using Tool J-21058 pull damper onto crankshaft
(fig. 14V).
NOTE:
If engine or radiator has not been re-
moved from the vehicle a 1/2"- 20 x 5" bolt and
a
1/2"-20
nut may be used in place of the bolt
and nut of Tool J-21058.
CAUTION: Install bolt in crankshaft with suffi-
cient thread engagement (min. 1/2").
4.
Remove tool from crankshaft.
5. Install damper retaining bolt and torque to specifica-
tions,
then install accessory drive pulley.
6. Install radiator and shroud as outlined in Section 13.
7. Install fan pulley and fan as outlined in Section 6K.
8. Install fan belt and adjust to specifications using
strand tension gauge.
9. On Corvettes, lower engine and install front mount
through-bolts.
10.
Fill cooling system, start engine and check for leaks.
327
cu.
in. (325 & 350 HP)
Engine
Install damper as outlined for 396 and 427 cu. in. en-
gines,
using a 7/16"-20 x 5" bolt and nut in place of the
bolt and nut furnished with J-21058.
CRANKCASE FRONT COVER
Removal
1.
Remove oil pan as outlined.
2.
Remove torsional damper as outlined.
3.
Remove water pump as outlined in Section 6K.
4.
Remove crankcase front cover attaching bolts and
remove front cover and gasket, then discard gasket
Installation
283, 327 and 350 cu. in.
Engine
1.
Make certain that cover mounting face and cylinder
block front face are clean and flat.
2.
Coat the oil seal with engine oil and using a new
cover gasket, coated with gasket sealer, install cover
and gasket over dowel pins and cylinder block.
3.
Install cover screws and torque bolts to
specifications.
4.
Install water pump as outlined in Section 6K.
5. Install torsional damper as outlined.
6. Install oil pan as outlined.
CHEVROLET CHASSIS SOVKZ MANUAL
Page 306 of 659
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
Page 307 of 659
ENGINE COOLING 6K-2
are indicative of exhaust gases leaking into the coolr
ing system.
Periodic Maintenance
Periodic service must be performed to the engine cool-
ing system to keep it in efficient operating condition.
These services should include a complete cleaning and
reverse flushing as well as a reconditioning service.
In the course of engine operation, rust and scale ac-
cumulate in the radiator and engine water jacket. The
accumulation of these deposits can be kept to a minimum
by the use of a good rust inhibitor but it should be
remembered that an inhibitor will not remove rust al-
ready present in the cooling system.
Two common causes of corrosion are: (1) air suction--
Air may be drawn into the system due to low liquid level
in the radiator, leaky water pump or loose hose con-
nections; (2) exhaust gas leakage—Exhaust gas may be
blown into the cooling system past the cylinder head
gasket or through cracks in the cylinder head and block.
Cleaning
A good cleaning solution should be used to loosen the
rust and scale before reverse flushing the cooling
system. There are a number of cleaning solutions avail-
able and the manufacturer's instructions with the particu-
lar cleaner being used should always be followed.
An excellent preparation to use for this purpose is GM
Cooling System Cleaner. The following directions for
cleaning the system applies only when this type cleaner
is-used.
1.
Drain the cooling system including the cylinder block
and then close both drain plugs.
2.
Remove thermostat and replace thermostat housing.
3.
Add the liquid portion (No. 1) of the cooling system
cleaner.
4.
Fill the cooling system with water to a level of about
3 inches below the top of the overflow pipe.
5. Cover the radiator and run the engine at moderate
speed until engine coolant temperature reaches 180
degrees.
6. Remove cover from radiator and continue to run the
engine for 20 minutes. Avoid boiling.
7. While the engine is still running, add the powder
portion (No. 2) of the cooling system cleaner and
continue to run the engine for 10 minutes.
8. At the end of this time, stop the engine, wait a few
minutes and then open the drain cocks or remove
pipe plugs. Also remove lower hose connection.
CAUTION: Be careful not to scald your hands.
NOTE:
Dirt and bugs may be cleaned out of
the radiator air passages by blowing out with air
pressure from the back of the core.
Reverse Flushing
Reverse flushing should always be accomplished after
the system is thoroughly cleaned as outlined above.
Flushing is. accomplished through the system in a direc-
tion opposite to the normal flow. This action causes the
water to get behind the corrosion deposits and force
them out.
Radiator
1.
Remove the upper and lower radiator hoses and re-
place the radiator cap,
2.
Attach a lead-away hose at the top of the radiator.
3.
Attach a new piece of hose to the radiator outlet
connection and insert the flushing gun in this hose.
4.
Connect the water hose of the flushing gun to a water
outlet and the air hose to an air line.
5. Turn on the water and when the radiator is full, turn
on the air in short blasts, allowing the radiator to
fill between blasts of air.
CAUTION: Apply air gradually as a clogged
radiator will stand only a limited pressure.
6. Continue this flushing until the water from the lead-
away hose runs clear.
Cylinder Block and Cylinder Head
1.
With the thermostat removed, attach a lead-away
hose to the water pump inlet and a length of new hose
to the water outlet connection at the top of the engine.
NOTE:
Disconnect the heater hose when re-
verse flushing engine.
2.
Insert the flushing gun in the new hose.
3.
Turn on the water and when the engine water jacket
is full, turn on the air in short blasts.
4.
Continue this flushing until the water from the lead-
away hose runs clear.
Hot Water Heater
1.
Remove water outlet hose from heater core pipe.
2.
Remove inlet hose from engine connection.
3.
Insert flushing gun and flush heater core. Care must
be taken when applying air pressure to prevent
damage to the core.
Fan Belt
Adjustment
1.
Loosen bolts at Delcotron slotted bracket.
2.
Pull Delcotron away from engine until desired ten-
sion reading is obtained with a strand tension gauge.
Refer to Section 6, "Engine Tune-Up".
3.
Tighten all Delcotron bolts securely.
Thermostat
The thermostat consists of a restriction valve actuated
by a thermostatic element. This is mounted in the hous-
ing at the cylinder head water outlet above the water
pump,
thermostats are designed to open and close at
predetermined temperatures and if not operating properly
should be removed and tested as follows.
Replacement
1.
Remove radiator to water outlet hose.
2.
Remove thermostat housing bolts and remove water
outlet and gasket from thermostat housing (fig. 2).
3.
Inspect thermostat valve to make sure it is in good
condition.
4.
Place thermostat in hot water 25° above the temper-
ature stamped on the thermostat valve.
5. Submerge the valve completely and agitate the water
thoroughly. Under this condition the valve should
open fully.
6. Remove the thermostat and place in water 10° below
temperature indicated on the valve.
7. With valve completely submerged and water agitated
thoroughly, the valve should close completely.
8. If thermostat checks satisfactorily, re-install, using
a new housing gasket.
9. Refill cooling system.
CHEVROLET CHASSIS SERVICE MANUAL
Page 308 of 659
ENGINE COOLING 6K-3
Fig.
2— Replacing Thermostat
Water Pump
Removal
1.
Drain radiator and break loose the fan pulley bolts.
2.
Disconnect heater hose, lower radiator hose and
by pass hose (as required) at water pump.
3.
Loosen Delcotron and remove fan belt then remove
fan bolts, fan and pulley.
4.
Remove pump to cylinder block bolts and remove
pump from engine.
NOTE:
On in line engines, pull the pump
straight out of the block first, to avoid damage
to impeller.
Installation
1.
Install pump assembly on cylinder block and tighten
bolts securely. Use on new pump to block gasket(s).
2.
Install pump pulley and fan on pump hub and tighten
bolts securely.
NOTE:
A guide stud (5/16"-24 x 1-1/2" bolt
with the head removed) installed in one hole of
the fan hub will aid in aligning hub, pulley and
fan.
Remove stud after starting the remaining
three bolts.
3.
Connect hoses and fill cooling system.
4.
Install fan belt and adjust as previously outlined.
5. Start engine and check for leaks.
CHEVROLET CHASSIS SERVICE MANUAL