water pump CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
[x] Cancel search | Manufacturer: CHEVROLET, Model Year: 1967, Model line: CAMARO, Model: CHEVROLET CAMARO 1967 1.GPages: 659, PDF Size: 114.24 MB
Page 18 of 659
LUBRICATION 0-16
Every 12,000 miles (more frequently*, depending on
severity of service, if vehicle is used to pull trailers,
carry full loads during high ambient temperatures,
operate in mountainous terrain or operate under other
severe conditions--Remove fluid from the transmission
sump and add one and a half quarts of fresh fluid for
Camaro and Chevy II and two quarts for Chevrolet,
Chevelle, and Corvette. Operate transmission through all
ranges and check fluid level as described above.
•Except if vehicle is equipped with transmission pro-
vided in heavy duty service options. If so equipped,
drain converter and pump every 12,000 miles and add
approximately seven and a half quarts of fresh fluid
for Chevy II and nine quarts for Chevrolet and Chevelle.
TURBO HYDRA-MATIC
Lubrication. recommendations for the Turbo Hydra-
Matic are the same as outlined for the Powerglide
transmission except for fluid capacity and filter change
listed below.
After checking transmission fluid level it is important
that the dip stick be pushed all the way into the fill tube.
Every 12,000 miles — after removing fluid from the
transmission sump, approximately 7 1/2 pints of fresh
fluid will be required to return level to proper mark on
the dip stick.
Every 24,000 miles, or at every other fluid change--
the transmission sump strainer should be replaced.
FRONT WHEEL BEARINGS
It is necessary to remove the wheel and hub assembly
to lubricate the bearings. The bearing assemblies should
be cleaned before repacking with lubricant. Do not pack
the hub between the inner and outer bearing assemblies
or the hub caps, as this excessive lubrication results in
the lubricant working out into the brake drums and
linings.
Front wheels of all passenger car models are equipped
with tapered roller bearings and should be packed with a
high melting point water resistant front wheel bearing
lubricant whenever wheel and hub are removed.
CAUTION: "Long fibre" or "viscous" type
lubricant should not be used. Do not mix wheel
bearing lubricants. Be sure to thoroughly clean
bearings and hubs of all old lubricant before
repacking.
The proper adjustment of front wheel bearings is one
of the important service operations- that has a definite
bearing on safety. A car with improperly adjusted front
wheel bearings lacks steering stability, has a tendency to
wander or shimmy and may have increased tire wear.
The adjustment of these bearings is very critical. The
procedure is covered in Section 3 of this manual under
Front Wheel Bearings—Adjust,
MANUAL STEERING GEAR
Check lubricant level every 36,000 miles. If required,
add EP Chassis Lubricant.
POWER STEERING
On models equipped with power steering gear, check
fluid at operating temperature in pump reservoir. Add
GM Power Steering Fluid, or, if this is not available, use
Automatic Transmission Fluid "Type A" bearing the
mark AQ-ATF followed by a number and the suffix letter
'A'
to bring level to full mark on dip stick.
AIR CONDITIONING
After the first 6,000 miles, check all hose clamp
connections for proper tightness.
Every 6,000 miles check sight glass under the hood,
after the system has been in operation for several
minutes. Sight glass should be clear but may, during
milder weather, show traces of bubbles. Foam or dirt
indicate a leak which should be repaired immediately.
BRAKE MASTER CYLINDER
Check level every 6,000 miles and maintain 1/4" below
lowest edge of each filler opening with GM Hydraulic
Brake Fluid Supreme No. 11.
PARKING BRAKE
Every 6,000 miles, apply water resistant lube to park-
ing brake cable, cable guides and at all operating links
and levers.
CLUTCH CROSS-SHAFT
Periodic lubrication of the clutch cross shaft is not
required. At 36,000 miles or sooner, if necessary;
remove plug, install lube fitting and apply CHASSIS
LUBRICANT.
CHASSIS LUBRICATION
For chassis lubrication, consult the lubrication chart.
It shows the points to be lubricated and how often the
lubricant should be applied.
The term "chassis lubricant" as used in this manual,
describes a water resistant EP chassis grease designed
for application by commercial pressure gun equipment.
CHEVROLET CHASSIS SERVICE MANUAL
Page 27 of 659
HEATER AND AIR CONDITIONING 1A-4
CHEVROLET SHOWN AS
TYPICAL OF CHEVROLET
AND CHEVELLE
CHEVROLET
WITH CONSOLE
ONLY
THESE USED ON
CHEVROLET ONLY
Fig. 5— Heater Blower and
Air
Inlet (Chevrolet, Chevelle, Camaro)
Core
Replacement
1.
Drain radiator.
2.
Remove the heater hoses at their connections beside
the air inlet assembly.
NOTE:
The hose from the
water,
pump
must go
to the top heater core pipe; the other hose runs
from the thermostat housing to the lower core
pipe. (See Figure 8)
3.
Remove the bowden cables (except the Chevrolet
defroster cable) and all electrical connectors from
the heater and defroster assembly.
4.
On the engine side of the dash, remove the nuts from
the core case studs coming through from the inside
of the car.
5. Inside the vehicle, remove the case to firewall
mounting screws and pull the entire heater and de-
froster assembly from the firewall (remove the
Chevrolet defroster cable at this time) then remove
the assembly from the vehicle and set on a bench.
6. Remove the core assembly retaining springs and
remove the core.
7. Install the replacement core.
NOTE:
Be sure the core to case sealer is
intact before replacing core. Replace with new
sealer if necessary.
8. Replace the core and core retaining springs.
9. Within the vehicle (after attaching the Chevrolet
defroster cable) insert the five studs on the heater
and defroster assembly through the holes in the
cowl and blower and air inlet assembly. Replace the
case to firewall mounting screws and (on the engine
side) the five stud nuts.
10.
Replace the remaining bowden cables and electrical
connectors.
11.
Replace heater hoses, being careful to reinstall
CHEVROLET CHASSIS SERVICE MANUAL
Page 36 of 659
HEATER
AND AIR
CONDITIONING
1A-13
AIR CONDITIONING
INDEX
Page
General Description
1A-13
Four-Season System
1A-13
Controls
1A-16
Comfortron System
. 1A-18
System Components
lA-19
Controls
1A-20
Universal System
. .
1A-21
Chevy
n
All-Weather System
•
1A-21
Corvette Four-Season System
. 1A-22
General Information
. . . 1A-26
Precautions
in
Handling R-12
1A-26
Precautions
in
Handling Refrigerant Lines
1A-28
Maintaining Chemical Stability
in the
Refrigeration System
1A-28
Gauge
Set 1A-29
Charging Station
IA-29
Leak Testing
the
System
1A-29
Vacuum Pump
1A-30
Availability
of
Refrigerant-12
. . 1A-30
Compressor
Oil 1A-31
Compressor Serial Number
1A-31
Inspection
and
Periodic Service
1A-31
Pre-Delivery Inspection
1A-31
6,000 Mile Inspection
1A-32
Periodic Service
, 1A-32
Installing Gauge
Set to
Check System Operation
....
1A-32
Performance Test
1A-32
Performance Data lA-r33
Comfortron System Operational Test
1A-33
Chevrolet Comfortron Tester
1A-34
Complete System Checks
1A-35
Maintenance
and
Adjustments ......
1A-37
Evaporator Comtrol Valve (POA)
.
1A-37
Page
Thermostatic Switch
1A-37
Expansion Valve
1A-41
Engine Idle Compensator
. . .
1A-42
Evacuating
and
Charging Procedures
1A-42
Purging
the
System
1A-42
Evacuating
and
Charging
the
System
1A-43
Checking
Oil . 1A-43
Component Replacement
and
Minor Repair
1A-45
Refrigerant Line Connections
1A-45
Repair
of
Refrigerant Leaks
1A-46
Preparing System
for
Replacement
of
Component Parts
. 1A-46
Foreign Material
in the
System
.
1A-47
Condenser
.
1A-48
Receiver-Dehydrator
1A-48
Evaporator
1A-49
Expansion Valve
1A-57
Evaporator Control Valve (POA)
1A-59
Thermostatic Switch
or
Blower Switch
. .
1A-59
All Weather-Pull Cable
1A-61
Blower Assembly
1A-62
Air Inlet Valve
.
1A-64
Blower
and
Evaporator Assembly
1A-64
Air Distributor Assembly
and
Outlet Ducts ...... 1A-64
Comfortron Automatic Control Components
1A-66
Collision Procedure lA-70
Four-Season Heater Components
1A-73
Comfortron Heater Components
. . . 1A-75
Compressor
1A-76
Wiring Diagrams
1A-78
Special Tools
.
1A-84
GENERAL DESCRIPTION
Four
air
conditioning systems
are
covered
in
this
section. They are:
1.
The
Four-Season System (Chevrolet, Chevelle,
Camaro and Corvette).
2.
The Comfortron System (Chevrolet).
3.
The All Weather System (Chevy n).
4.
The Universal System (Chevrolet, Chevelle, Chevy
n,
Camaro)
Underhood components (that
is, the
compressor,
con-
denser
and
receiver-dehydrator)
are
much
the
same
in
type,
location
and
method
of
attachment
on all of
the
above systems. The six-cylinder reciprocating compres-
sor
is
bracket-mounted
to the
engine
and
belt driven
from
the
crankshaft pulley.
The
condenser
is
mounted
ahead
of the
engine cooling radiator
and the
receiver-
dehydrator
is
mounted
in
the refrigerant line downstream
of
the
condenser.
All
cooling system components
are
connected by means
of
flexible refrigerant lines.
Evaporator size
and
location differ from system
to
system
as do
methods
of
temperature control
and air
supply
and
distribution.
FOUR-SEASON SYSTEM
The Four-Season system used
in the
Chevrolet,
Chevelle, Camaro,
and
Corvette vehicles
may be
iden-
tified
by the
fact that
it
uses
an
evaporator pressure
control known
as the POA
(Pressure Operated Absolute)
suction throttling valve.
Both
the
heating
and
cooling functions
are
performed
by this system.
Air
entering
the
vehicle must pass
through
the
cooling unit (evaporator)
and
through
(or
around)
the
heating unit,
in
that order, and the system
is
thus referred to
as a
''reheat" system.
The evaporator provides maximum cooling
of the air
passing through
the
core when
the air
conditioning sys-
tem
is
calling
for
cooling.
The
control valve acts in the
system only
to
control
the
evaporator pressure
so
that
minimum possible temperature
is
achieved without core
freeze-up.
The
valve
is
preset,
has no
manual con-
trol,
is
automatically altitude compensated,
and non-
repairable.
The heater core will be hot
at
all times since no water
valve
is
present
in
the system.
System operation
is as
follows (See Figure 24 and 25):
Air, either outside
air or
recirculated
air
enters
the
system
and is
forced through
the
system by the blower.
As
the air
passes through
the
evaporator core,
it
receives maximum cooling
if
the
air
conditioning controls
are calling
for
cooling. After leaving
the
evaporator,
the
air
enters
the
Heater
and Air
Conditioner Selector
Duct Assembly where,
by
means
of
manually operated
diverter doors,
it is
caused
to
pass through
or to
bypass
the heater core
in the
proportions necessary
to
provide
the desired outlet temperature. Conditioned airflow then
enters
the
vehicle through either
the
floor distributor
duct
or the
dash outlets. Remember that the heater core
CHEVROLET CHASSIS SERVICE MANUAL
Page 52 of 659
HEATER AND AIR CONDITIONING 1A-29
time as possible will be required to perform the
operation. Don't leave the system open any longer
than is necessary.
• Finally, after the operation has been completed and
the system sealed again, air and moisture should be
evacuated from the system before recharging.
GAUGE SET
The gauge set (fig. 41) is used when purging, evacua-
ting, charging or diagnosing trouble in the system. The
gauge at the left is known as the low pressure gauge.
The face is graduated into pounds of pressure and, in
the opposite direction, in inches of vacuum. This is the
gauge that should always be used in checking pressures
on the low pressure side of the system. When all parts of
the system are functioning properly the refrigerant
pressure on the low pressure side never fails below 0
pounds pressure. However, several abnormal conditions
can occur that will cause the low pressure to fall into a
partial vacuum. Therefore, a low pressure gauge is
required.
The high pressure gauge is used for checking pres-
sures on the high pressure side of the system.
The connection at the left is for attaching the low
pressure gauge line and the one at the right the high
pressure gauge line. The center connector is common to
both and is for the purpose of attaching a line for adding
refrigerant, discharging refrigerant, evacuating the sys-
tem and other uses. When not required, this line or
connection should be capped.
NOTE:
Gauge fitting connections should be in-
stalled hand tight only and the connections leak
tested before proceeding.
The hand shutoff valves on the gauge manifold do not
control the opening or closing off of pressure to the
gauges. They merely close each opening to the center
connector and to each other. During most diagnosing
and service operation, the valves must be closed. The
only occasion for opening both at the same time would be
to bypass refrigerant vapor from the high pressure to
the low pressure side of the system, or in evacuating
both sides of the system.
CHARGING STATION
The J-8393 Charging Station is a portable assembly of
a vacuum pump, refrigerant supply, gauges, valves, and
most important, a five (5) pound metering refrigerant
charging cylinder. The use of a charging ey'inder elim-
inates the need for scales, hot water pails, etc.
The chief advantage of this unit is savings. A very
definite savings in refrigerant and time can be obtained
by using this unit. Since the refrigerant is metered into
the system by volume, the correct amount may be added
to.
the system and charged to the customer. This, coupled
with the fact that the unit remains "plumbed" at all times
and thus eliminates loss of refrigerant in purging of
lines and hooking-up, combines to enable the operator to
get full use of all refrigerant purchased by the
dealership.
All evacuation and charging equipment is hooked to-
gether in a compact portable unit (fig. 42) which brings
air conditioning service down to the basic problem of
hooking on two hoses, and manipulating clearly labeled
valves.
Fig.
42—System Charging Station
This will tend to insure that the job will be done without
skipping operations. As a result, you can expect to save
time and get higher quality work, less chance of an over
or undercharge, or comeback.
The pump mount is such that the dealer may use his
own vacuum pump. The gauges and manifold are in com-
mon use. Thus a current air conditioning dealer can use
the equipment on hand and avoid duplication.
LEAK TESTING THE SYSTEM
Whenever a refrigerant leak is suspected in the system
or a service operation performed which results in dis-
turbing lines or connections, it is advisable to test for
leaks.
Common sense should be the governing factor in
performing any leak test, since the necessity and extent
of any such test will, in general, depend upon the nature
of the complaint and the type of service performed on
the system. It is better to test and be sure, if in doubt,
than to risk the possibility of having to do the job over
again.
NOTE:
The use of a leak detecting dye within
the system is not recommended because of the
following reasons:
1.
Refrigerant leakage can exist without any oil leakage.
In this case the dye will not indicate the leak, how-
ever, a torch detector will.
2.
The addition of additives, other than inhibitors, may
alter the stability of the refrigeration system and
cause malfunctions.
3.
Dye type leak detectors which are insoluble form a
curdle which can block the inlet screen of the ex-
pansion valve.
CHEVROLET CHASSIS SERVICE MANUAL
Page 253 of 659
BRAKES 5-20
boss to the front brakes will not contain a check
valve and spring. .
Removal
1.
Wipe main cylinder and lines clean with a clean
cloth. Place dry cloths below main cylinder area to
absorb any fluid spillage.
2.
Disconnect hydraulic lines at main cylinder. Cover
line ends with clean lint-free material to prevent
foreign matter from entering the system.
3.
Disconnect the push rod from the brake pedal.
4.
Unbolt and remove the main cylinder from the
firewall.
5.
Remove the main cylinder mounting gasket and boot.
6. Remove the main cylinder cover and dump out the
fluid. Pump the remaining fluid from the cylinder
by depressing the push rod.
Disassembly (Fig. 32)
1.
Clamp main cylinder in a bench vice.
2.
Remove push rod retainer.
3.
Remove secondary piston stop bolt from bottom of
front fluid reservoir.
4.
Remove the snap ring retainer and primary piston
assembly. Remove the secondary piston, piston
spring, and retainer by blowing air through the stop
bolt hole. (If no air is available, a piece of wire
may be used. Bend approximately 1/4 inch of one
end into -a right angle, hook the secondary piston
and pull it out.)
5.
Position main cylinder in vice with outlet holes
facing up.
6. Drill a 13/64 inch hole through both check valve
seats.
7 Tap out both seats using a 1/4 - 20 tap.
8. Install a spare brake line tube nut in the outlet
hole.
Place a flat washer on a one inch screw
(threaded to screw into tapped hole), and thread
screw into threaded hole in tube seat. Hold the
screw to keep it from turning and back out the
tube nut. This will remove the tube seat.
9. Repeat Step 8 above on second tube seat.
10.
Remove the check valves and springs from the cavi-
ties beneath the tube seats.
11.
Remove the primary seal, primary seal protector,
and secondary seals from the secondary piston.
Remove the piston extension screw securing the
primary piston spring to the primary piston. Re-
move the spring retainer, primary seal, primary
seal protector, and secondary seal from the pri-
mary piston.
Cleaning and Inspection
1.
Remove main cylinder casting from vice and inspect
the bore for corrosion, pits, and foreign matter.
Be sure that the outlet ports are clean and free of
brass cuttings from the tube seat removal operation.
2.
Inspect the fluid reservoirs for foreign matter.
Check the bypass and compensating ports to the
cylinder bore to insure that they are not restricted.
Do not use wire to check ports.
NOTE: Before washing parts, hands must be
clean. Do not wash hands in gasoline or oil
before cleaning parts. Use soap and water only.
3.
Use Declene or equivalent to clean all metal parts
thoroughly. Immerse parts in the cleaning fluid and
brush with hair brush to remove foreign matter.
Blow out all passages, orifices, and valve holes. Air
dry the parts and place on clean paper or lint-free
clean cloth.
NOTE: Be sure to keep parts clean until re-
assembly. Rewash parts, if there is any occa-
sion to doubt cleanliness.
4.
Check pistons for scratches or other visual damage;
replace if necessary.
Assembly (Fig. 32)
Use care when reassembling the main cylinder check
valves. Improper assembly of the check valve seats
will result in distortion of the seats. If this occurs,
there will be no check valve action and a loss of brake
pedal travel will result; the pedal will have to be pumped
one or more times before actual car braking occurs.
1.
Place the main cylinder in a vice with the outlet
holes facing up. Place the check valve springs, in
the outlet holes. Be sure the springs are seated
in the bottom of the holes. Place new rubber check
valves over the springs, being careful not to dis-
place the springs from the spring seats.
2.
Place new brass tube seats in the outlet holes. Be
sure seats are not cocked as this would cause burrs
to be turned up as the tube seats are pressed in.
. Thread a spare brake line tube nut into the outlet
hole and turn the nut down until the tube seat bot-
toms.
Remove the tube nut and check the outlet hole
for loose burrs, which might have been turned up
when the tube seat was pressed down. Repeat this
process to bottom the second seat.
3.
Put new secondary seals in the two grooves in the
end of the secondary piston assembly. The seal
which is nearest the end will have its lips facing
toward that end. The seal in the second groove
should have its lips facing toward the portion of
the secondary piston which contains the small com-
pensating holes.
4.
Assemble a new primary seal protector and primary
seal over the end of the secondary piston with the
flat side of the seal seats against the seal protector,
and the protector against the flange of the piston
which contains the small compensating holes.
5.
Assemble the new secondary seal into the groove on
the push rod end of the primary piston. The lips of
this seal should face toward the small compensating
holes in the opposite end of the primary piston.
6. Assemble the new primary seal protector and pri-
mary seal on the end of-the primary piston with the
flat side of the. seal seated against the seal protector,
and the protector against the flange on the piston
which contains the compensating holes.
7.
Assemble the spring retainer in one end of the
primary piston spring and the secondary piston
stop in the other end. Place the end of the spring
over the end of the primary piston with the spring
retainer seats inside of the lips of the primary
seal.
8. Remove all cleaning liquid from the threaded hole
in the primary piston. Place the piston extension
screw down through the secondary piston stop and
the primary spring retainer and screw it into the
primary piston until it bottoms out.
9. Coat the bore of the master cylinder with clean
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 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 299 of 659
ENGINE 6-34
Fig.
15V - Centering Tool in Cover (396 and 427)
396 and 427
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 install Aligning
Tool J-22102 in oil seal (fig. 15V) then using a new
cover gasket coated with gasket sealer, install cover
and gasket on cylinder block.
3.
Install cover screws and torque bolts to specifica-
tions,
then remove Aligning Tool J-22102.
4.
Install water pump as outlined in Section 6K.
5. Install torsional damper as outlined.
6. Install oil pan as outlined.
Fig.
17V - Installing Oil Seal (Cover Removed)
396 and 427
OIL SEAL (FRONT COVER)
Replacement
With Cover
Removal
1.
With cover removed, pry old seal out of cover from
the front with a large screw driver.
2.
Install new seal so that open end of the seal is toward
the inside of cover and drive it into position with
Tool J-995 on 283, 327 and 350 cu. in. engines
(fig. 16V) or Tool J-22102 on 396 and 427 cu. in.
engines (fig. 17V).
CAUTION: Support cover at sealing area to
avoid distorting cover.
Without Cover
Removal
1.
With torsional damper removed, pry old seal out of
cover from the front with a large screw driver, being
careful not to damage the surface on the crankshaft.
2.
Install new seal so that open end of seal is toward the
inside of cover and drive it into position with Tool
J-8340 on 283, 327 and 350 cu. in. engines (fig. 18V)
or Tool J-22102 on 396 and 427 cu. in. engines
(fig. 19V),
Fig.
16V - Installing Oil Seal (Cover Removed)
283,
327 and 350
Fig.
18V- Installing Oil Sea! (Cover Installed)
283,
327 and 350
CHEVROLET CHASSIS SERVICE 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