08 1963 CH-Engine Mechanical

SECTION 8
ENGINE MECHANICAL
CONTENTS OF THIS SECTION
Page
Six Cylinder Engine 230 cu. in. 8-1
Eight Cylinder Engine 283 and 327 Cu. in. 8-37
Eight Cylinder Engine 409 Cu. in. 8-37
Engine Cooling 8-42
SIX CYLINDER ENGINE

INDEX
Page Page
General Description 8-1 Engine Removed 8-24
Maintenance and Adjustments 8-2 Bearing Clearance 8-25
Service Operations Engine Installed 8-2 Connecting Rod Bearings 8-26
Intake and Exhaust Manifolds 8-2 Piston and Connecting Rod 8-27
Heat Riser Control Valve 8-3 Removal, Disassembly and Assembly.... 8-27
Crankcase Ventilation Section 7 Piston Pin 8-27
Valve Lifters 8-3 Piston Rings 8-28
Cylinder Head and Valve Mechanism 8-9 Cylinder Block 8-29
Valve Guide Bores 8-10 Inspection 8-29
Rocker Arm Studs 8-11 Repair 8-29
Valve Seats 8-11 Boring 8-29
Valves 8-12 Honing and Piston Fitting 8-30
Camshaft Lobe Lift 8-14 Piston and Connecting Rod Installation... 8-31
Crankshaft Pulley and Harmonic Balancer.... 8-15 Distributor Lower Bearing 8-31
Timing Gear Cover S-16 Engine Mountings 8-32
Camshaft 847 Engine Overhaul 8-33
Timing Gear 8-17 Engine Removal 8-33
Bearings 8-19 Transmission and Clutch Removal 8-33
Oil Pan 8-21 Engine Disassembly 8-33
Oil Pump 8-22 Engine Assembly 8-35
Rear Main Bearing Oil Seal 8-23 Engine Installation 8-36
Crankshaft Main Bearings 8-23 Special Tools 8-43
Engine in Vehicle 8-24
GENERAL DESCRIPTION
A completely new six cylinder engine figs. 1 and 3 arms in the valve train.
is used on 1963 passenger cars. It has seven main A new automatic choke system and closed crank
bearings, hydraulic valve lifters and hollow push rods case ventilation fig. 2 are standard equipment in
operate, and supply oil to, individually mounted rocker 1963.
PASSENGER CAR SHOP MANUAL.

ENGINE-6 CYL. 8-2
A gear type oil pump supplies oil through a full-flow

oil filter to the main oil gallery along hydraulic lifters
which supplies the main and cam bearings.
Fig. 1 -6-Cylinder Engine Fig. 2-Automatic Choke System and Positive Ventilation
MAINTENANCE AND ADJUSTMENTS

Engine maintenance consists of lubrication, service cedures are outlined in Section 2, Lubrication, and
and inspection performed at regular intervals to keep Section 7, "Tune-Up" of this manual.
the engine performing to its design level. These pro-
SERVICE OPERATIONS
Service operations include the removal, disassembly, Repair
cleaning, inspection, repair, assembly, and installation 1. Clean gaskets flanges on cylinder head and mani
or replacement of component parts. Items have been folds.
listed in order of engine disassembly whenever pos 2. Check for cracks on manifold castings.
sible. 3. If necessary to replace either intake or exhaust
manifold, separate them by removing 1 attaching
INTAKE AND EXHAUST MANIFOLDS bolt and 2 nuts at center of assembly. Reassemble
Removal manifolds using new gasket. Tighten finger tight
and torque 15-30 ft. lbs. after assembly to cylinder
1. Remove air cleaner wing nut and air cleaner. head.
2. Disconnect both throttle rods at bell crank and
remove throttle return spring. Installation
3. Disconnect fuel vacuum lines from carburetor. 1. Position new gaskets over manifold end studs on
On 6 cylinder engine remove clean air tubes to head and carefully install the manifold in position
choke making sure the gaskets are in place.
4. Remove carburetor. 2. Install bolts and clamp while holding manifold in
5. Disconnect exhaust pipe at manifold flange. place with one hand.
6. Remove manifold to head attaching bolts and 3. Tighten center clamp bolts to 25-30 ft. lbs. and
clamps and remove manifolds as an assembly. end bolts to 15-20 ft. lbs. fig. 7.
PASSENGER CAR SHOP MANUAL
ENGINE-6 CYL. 8-3
Fig. 3-Phantom Cross-Section
4. Connect exhaust pipe to manifold using a new The easiest method for locating a noisy valve lifter
packing seal. is by use of a piece of garden hose approximately four
5. Reverse Steps 1-4 of Removal to complete installa feet in length. Place one end of the hose near the end
tion procedure. of each intake and exhaust valve with the other end of
the hose to the ear.
MANIFOLD HEAT RISER VALVE In this manner, the sound is localized making it easy
Check manifold heat control valve fig. 8 for free to determine which lifter is at fault.
dom of operation. If shaft is sticking, free it up with Another method is to place a finger on the face of
G.M. Manifold Heat Control Solvent or its equivalent. the valve spring retainer. If the lifter is not function
ing properly, a distinct shock will be felt when the
VALVE LIFTERS valve returns to its seat.
Hydraulic valve lifters very seldom require atten The general types of valve lifter noise are as follows:
tion. The lifters are extremely simple in design, re 1. Hard Rapping Noise Usually caused by the
-
adjustments are not necessary, and servicing of the plunger becoming tight in the bore of the lifter
lifters require only that care and cleanliness be exer body to such an extent that the return spring and
cised in the handling of parts. oil pressure combined can no longer push the

ENGINE-6 CYL. 8-4
OIL PRESSURE
SENDING UNIT
FILTER BY-PASS
SYSTEM
Fig. 4-Oil System Diagram

ENGINE-6 CYL. 8-5
I
ha
I r
1%
Fig. 5-Cylinder Block and Explode

ENGINE-6 CYL. 8-6
ii
Fig. 6-Cylinder Head

ENGJNE-6 CYL. 8-7
c. Improper lash adjustment.

In most cases where noise exists in one or more
lifters, all lifter units should be removed, cleaned in a
solvent, reassembled, and reinstalled in the engine. If
dirt, varnish, carbon, etc. is shown to exist in one unit,
it more than likely exists in all the units, thus it would
only be a matter of time before all lifters caused
trouble.
In instances where parts are damaged, particularly
the plunger or lifter body, the complete lifter unit
should be replaced. However, in rare or emergency
cases an Arkansas hard stone may be used to remove
metal scratches or humps; and if after correcting, the
plunger will operate freely in the lifter body, the parts
Fig. 7-Manifold Torque Sequence may be thoroughly cleaned and the unit assembled
and installed.
A few precautions to follow when servicing the
valve lifters are:
1. Plungers are not interchangeable, they are a selec
tive fit at the factory. Should a plunger or lifter
body become damaged, it is necessary to replace
the whole unit.
2. The plunger must be free in the lifter body. A
simple test for this is to be sure the plunger will
drop of its own weight in the body.
3. There must be no excessive leakdown and there
must be no ball check valve leakage.
Removal
1. Disconnect crankcase vent hose and remove
rocker arm cover.
2. Note threads showing above rocker arm nuts,
then loosen nuts and pivot the rocker arms free
of the push rods.
3. Disconnect spark plug wires at plugs and high
Fig. 8-Manifold Heat Riser Valve tension lead from coil.
4. Remove distributor primary lead from coil, note
plunger back up to working position. Probable distributor rotor position and remove distributor.
causes are: Mark distributor housing with chalk at point of
a. Excessive varnish or carbon deposit causing rotor.
abnormal stickiness.
5. Remove push rod cover and gasket.
b. Galling or "pick-up" between plunger and bore
of lifter body, usually caused by an abrasive 6. Remove push rods and valve lifters.
piece of dirt or metal wedging between plunger NOTE: Valve lifters and push rods should be
and lifter body. placed in a rack in their proper sequence so
2. Moderate Rapping Noise-Probable causes are: they can be reinstalled in the same positions
a. Excessively high leakdown rate. in the cylinder block.
b. Leaky check valve seat. Disassembly and Assembly
c. Improper lash adjustment.
1. Hold plunger down with Tool J-4274 and using
3. General Noise Throughout the Valve Train-This the blade of a small screwdriver, remove plunger
will, in almost all cases, be a definite indication of and push rod seat retainer.
insufficient oil supply, or improper lash adjust
ment. 2. Remove push rod seat, plunger and ball check
4. Intermittent Clicking-Probable causes are: valve assembly and plunger lifter spring. Figure
9 shows a layout of the parts.
a. A microscopic piece of dirt momentarily caught
between ball seat and check valve ball. NOTE: It is not necessary to remove ball check
b. In rare cases, the ball itself may be out-of- valve from plunger for cleaning. Figure O
round or have a flat spot. shows a cross-section of lifter.
ENGINE-6 CYL. 8-8
9. Press down on push rod seat and remove pin Tool

J-4274-2. The hydraulic lifter is now completely
assembled, loaded with oil and ready for instal
lation.
‘? Installation
1. Install valve lifters in cylinder block.
2. Install push rods onto lifters and install push rod
cover with a new gasket.
Fig. 9-Valve Lifter Components
3. Install distributor position rotor to mark on
housing. Install spark plug and coil wires.
1. Body 3. Plunger & Ball Check 4. Push Rod Seat
2. Spring Valve 5. Retainer 4. Pivot rocker arms in place and turn adjusting
nuts the amount necessary to eliminate lash.
3. Thoroughly clean all* parts in cleaning solvent, 5. Adjust valve lash when lifter is on base circle of
then inspect them carefully. If any parts are dam cam as follows:
aged, the entire lifter assembly should be replaced. a. Remove distributor cap and crank engine until
distributor rotor points to number one cylinder
4. To reassemble drop lifter spring into lifter body. terminal with breaker points open. In this po
5. Install plunger and ball check valve assembly in sition the piston in number one cylinder is at
lifter body, being careful to line up the feed holes top center on compression stroke with both
in lifter body and plunger. lifters on base circle of cam and both valves
can be adjusted.
6. Fill assembly with SAE 10 oil, then insert end of
Tool J-4272 into plunger and press down solid, at b. Turn adjusting nut until all lash is removed
which point holes in lifter body and plunger as from valve train. This can be determined by
sembly will be aligned. checking push rod side play by hand while
turning adjustment nut slowly fig. 11. At this
7. Insert pin which is part of Tool J-4274-2 through point, turn adjusting nut one more turn to
both holes to hold plunger down against lifter place the lifter plunger in center of its travel.
spring tension. Remove tool from top of lifter. c. Follow Steps a and b for each cylinder in order
8. Fill assembly with SAE 10 oil, install push rod of firing order and adjust remaining valves one
seat and spring retainer. cylinder at a time. No further adjustment is
necessary.
6. Install rocker cover gasket, cover and ventilation
hose.
Fig. 10-Valve Lifter Cross-Section
1. Lifter Body 4. Chec k Ball 7. Plunger

2. Push Rod Seat 5. Ball Retainer 8. Plunger Spring
3. Metering Valve 6. Push Rod Seat Retainer Fig. 11-Adjust Valve Lash

ENGINE-6 CYL. 8-9
7. Start engine and check for oil leaks, and listen nuts, pivot rocker arms to clear push rods and
for noisy lifter. remove push rods.
NOTE: If lifters are noisy, refer to "Valve Lash," 8. Remove the cylinder head bolts, cylinder head
under "Tune-Up Procedures," Section 7. and gasket. Place cylinder head on blocks of wood
to prevent damage.
CYLINDER HEAD AND VALVE MECHANISM Disassembly
The condition of the cylinder head and valve 1. Remove rocker arm nuts, ball seats and rocker
mechanism, significantly determines the power, per arms.
formance and economy of a valve-in-head engine. Ex 2. Using Tool J-8062, compress the valve spring
treme care should be exercised when conditioning the and remove valve keys fig. 12. Release the
cylinder head and valves to maintain correct valve spring compressor tool and remove spring caps,
stem to guide clearance, correctly ground valves, valve spring seats, oil seals, springs and spring dampers.
seats of correct width and correct valve adjustment. 3. Remove valves from bottom of cylinder head and
place them in a rack in their proper sequence so
Removal
they can be assembled in their original positions.
1. Drain cooling system and remove air cleaner. 4. Remove water outlet and thermostat, then re
2. Disconnect accelerator pedal rod at bell crank on move thermostat housing.
manifold, fuel and vacuum lines at carburetor,
and crankcase vent hose at rocker cover. Cleaning
1. Clean all carbon from combustion chambers and
3. Disconnect exhaust pipe at manifold flange, then valve ports using Tool J-8089 fig. 13.
remove manifold bolts and clamps and remove
manifolds and carburetor as an assembly.
4. Remove fuel and vacuum line retaining clip from
water outlet and disconnect wire harness from
temperature sending unit and coil leaving harness
clear of clips on rocker arm cover.
5. Disconnect radiator hose at water outlet housing
and battery ground strap at cylinder head.
6. Disconnect wires and remove spark plugs, discon
nect coil to distributor primary wire lead at coil
and remove coil.
7. Remove rocker arm cover. Back off rocker arm
Fig. 13-Removing Carbon from Combustion Chamber
2. Thoroughly clean the valve guides using Tool

J-8101 fig. 14.
3. Clean all carbon and sludge from push rods and
rocker arms.
4. Clean valve stems and heads on a buffing wheel.
5. Clean carbon deposits from head gasket mating
surfaces.
6. Wash all parts in cleaning solvent and dry them
thoroughly.
Inspection
1. Inspect the cylinder head for cracks in the exhaust
ports, combustion chambers, or external cracks to
the water chamber.
2. Inspect the valves for burned heads, cracked faces
or damaged stems.
Fig. 12-Compressing Valve Springs 3. Check fit of valve stems in their respective bores.

ENGINE-6 CYL. 8-10
Fig. 14-Cleaning Valve Guide Bores
NOTE: Excessive valve stem to bore clearance

will cause lack of power, rough idling and
noisy valves, and may cause valve breakage.
Insufficient clearance will result in noisy and
sticky functioning of the valve and disturb en
gine smoothness of operation. Intake valve Fig. 15-Checking Valve Spring Tension
stem to bore clearance should be .001" to .003"
while exhaust stem clearance should be .002" J-7049-6, .030" oversize to ream the bores for new
to .004". By using a micrometer and a suitable valves fig. 16.
telescope hole gauge check the diameter of
the valve stem in three places top, center and
bottom. Insert telescope hole gauge in valve
guide bore, measuring at the center. Subtract
highest reading of valve stem diameter from
valve guide bore center diameter to obtain
valve to valve guide clearance. If clearance is
not within limits use next oversize valve and
ream bore to fit using suitable reamer of Tool
set J-7049.
4. Check valve spring tension with Tool J-8056
spring tester fig. 15.
NOTE: On all models, springs should be com
pressed to 1-21/32" at which height it should
check 84-92 pounds. Weak springs affect
power and economy and should be replaced
if below 70 pounds.
5. Check valve lifters for free fit in block. The end
that contacts the camshaft should be smooth. If
this surface is worn or rough the lifter should be
replaced.
Repairs
Valve Guide Bore
Valves with oversize stems are available for inlet
and exhaust valves in the following sizes, .003", .015",
and .030". Use the %" diameter reamer sizes from
Reamer Tool Set J-7049, which are J-7049-7 Standard;
J-7049, .003" oversize, J-7049-5, .015" oversize and Fig. 16-Reaming Valve Guide Bores

ENGINE-6 CYL. 8-11
Fig. 19-Installing Rocker Arm Stud
in the head oversize studs, available in .003" or .013"

oversize, may be installed after reaming the holes with
Tool J-5715 for .003" oversize and Tool J-6306 for .013"
oversize as follows:
Fig. 17-Remove Rocker Arm Stud 1. Remove old stud by placing Tool J-5802 over the
stud, installing nut and flat washer and removing
Rocker Arm Studs stud by turning nut fig. 17.
Rocker arm studs that have damaged threads may 2. Ream hole for oversize stud, using Tool J-5715 for
be replaced with standard studs. If the studs are loose .003" oversize and Tool J-6036 for .013" oversize
fig. 18.
3. Coat press-fit area of stud with hypoid axle lubri
cant. Install new stud using Tool J-6880. Tool
should bottom on head fig. 19.
Valve Seats Cylinder Head

Reconditioning the valve seats is very important,
because the seating of the valves must be perfect for
the engine to deliver the power and performance built
into it.
Another important factor is the cooling of the valve
heads. Good contact between each valve and its seat in
the head is imperative to insure that the heat in the
valve head will be properly carried away.
Several different types of equipment are available
for reseating valve seats; the recommendations of the
manufacturer of the equipment being used should be
carefully followed to attain proper results.
Regardless of what type of equipment is used, how
ever, it is essential that valve guides be free from car
bon or dirt to insure proper centering of pilot in the
guide.
1. Install expanding pilot in the valve guide bore
and expand pilot by tightening nut on top of pilot.
2. Place roughing stone or forming stone over pilot
and just clean up the valve seat. Use a 46° stone
Fig. 1 8-Reaming Rocker Arm Stud Hole for the inlet and exhaust valve seats.

ENGINE-6 CYL. 8-12
3. Remove roughing stone or forming stone from

pilot, install finishing stone on pilot and cut just
enough metal from the seat to provide a smooth
finish.
4. Narrow down the valve seats to the proper width
of 1/ 6" to % 2" for the intake and exhaust.
NOTE: This operation is done by grinding the
port side with a 30° stone to lower seat and a
60° stone to raise seat.
5. Remove expanding pilot and clean cylinder head

carefully to remove all chips and grindings from
above operations.
NOTE: Valve seats should be concentric to

within .002" total indicator reading fig. 20.
Fig. 21-Valve Refacing Machine
line with the grinder wheel by moving the lever to

the left.
4. Turn the feed screw until the valve head just con
tacts wheel. Move valve back and forth across the
wheel and regulate the feed screw to provide light
valve contact.
5. Continue grinding until the valve face is true and
smooth all around the valve. If this makes the valve
head thin the valve must be replaced as the valve
will overheat and burn.
6. Remove valve from chuck and place stem in "V"
block. Feed valve squarely against grinding wheel
to grind any pit from rocker arm end of stem.
NOTE: Only the extreme end of the valve stem
is hardened to resist wear. Do not grind end of
Fig. 20-Checking Valve Seat Concentricity stem excessively.
Valves 7. After cleaning valve face and cylinder head valve
seat of grinding particles, make pencil marks
Valves that are pitted can be refaced to the proper about 1/4" apart across the valve face, place the
angle, insuring correct relation between the head and valve in cylinder head and give the valve ½ turn
stem on a valve refacing machine. Valve stems which in each direction while exerting firm pressure on
show excessive wear, or valves that are warped exces head of valve.
sively should be replaced. When a valve head which is
warped excessively is refaced, a knife edge will be 8. Remove valve and check face carefully. If all pen
cil marks have not been removed at the point of
ground on part or all of the valve head due to the
contact with the valve seat, it will be necessary to
amount of metal that must be removed to completely
reface. Knife edges lead to breakage, burning or pre repeat the refacing operation and again recheck
ignition due to heat localizing on this knife edge. If for proper seating.
the edge of the valve head is less than 1/ 2 thick after 9. Grind and check the remaining valves in the same
grinding, replace the valve. manner.
1. If necessary, dress the valve refacing machine Assembly
grinding wheel to make sure it is smooth and true.
Set chuck at 45° mark for grinding valves fig. 1. Starting with No. 1 cylinder, place the exhaust
21. valve in the port and place the valve spring and
cap in position. Place spring, shield, and cap on ex
2. Clamp the valve stem in the chuck of the machine. haust valves. Then using Tool J-8062, compress
3. Start the grinder and move the valve head out in the spring and install the oil seal and valve keys.

ENGINE-6 CYL. 8-13
LOCKS
CAP -
SEAL-
SHIELD"
Fig. 24-Checking Valve Spring Installed Height
Compressed air or a screwdriver, may be used

to hold the valves in place, used through the
Fig. 22-Valve Installation spark plug hole.
See that the seal is flat and not twisted in the Installation
valve stem groove and that the keys seat properly
in the valve stem groove fig. 22. 1. Place a new cylinder head gasket in position over
dowel pins in cylinder block fig. 25.
NOTE: Place valve springs in position with the
closed coil end toward the cylinder head.
2. Assemble the remaining valves, valve springs,

shields, spring caps, oil seals and valve keys in the
cylinder head using Tool J-8062. Check seals by
placing a vacuum cup shown in Figure 23 inset,
over valve stem and cap, squeeze vacuum cup to
make sure no oil leaks past oil seal.
I
A vacuum cup can be made from a small syringe
and a high voltage shield.
Fig. 25-Installing Head Gasket
2. Carefully guide cylinder head into place over

dowel pins and gasket fig. 26.
3. Use sealer on threads of cylinder head bolts, in
stall and run them down to the block.
4. Tighten the cylinder head a little at a time with a
Fig. 23-Vacuum Cup
torque wrench in the sequence shown in Figure
27. The final torque should be 90 to 95 ft. lbs.
Valve Spring Installed Height
5. Install valve push rods down through openings in
Check the installed height of the valve springs, using the cylinder head and seat them in lifter sockets.
a narrow, thin scale to measure from the top of the
shim or spring seat, in the head to the top of the 6. Install rocker arms, balls and nuts and tighten
valve spring shield. If this is found in excess of 12 ¾ 2, rocker arm nuts until all push rod play is taken
install a valve spring seat shim, approximately ‘/16" up fig. 28.
thick. At no time should the spring be shimmed to 7. Install thermostat housing, thermostat and water
give an installed height of less than 121/32" fig. 24. outlet using new gaskets and connect radiator
NOTE: If springs are to be changed with cyl hose.
inder head installed, Tool J-5892 may be used 8. Install temperature sending switch and tighten to
to compress springs for removal or installation. 15-20 ft. lbs.

__________________________________________________
__________________________________________________
ENGINE-6 CYL. 8-14
9. Clean all spark plugs with abrasive-type cleaner,

inspect for damage and set the gap at .035" using a
wire gauge.
10. Place new gaskets on plugs and install. Tighten
to 20-25 ft. lbs. If torque wrench is not available,
tighten finger tight and ½ turn additional.
11. Install coil then connect temperature sending unit
and coil primary wires, and connect battery
ground cable at cylinder head.
12. Clean manifold gasket surfaces and install new
gasket over manifold studs. Position manifold and
slide it into place over the studs, making sure it
seats against the gasket. Install bolts and clamps
and tighten as shown in Figure 7.
13. Connect throttle linkage and choke rod and ad
just as outlined in Section 10.
14. Connect fuel and vacuum lines to carburetor and
install lines in clip at water outlet.
15. Fill cooling system and check for leaks.
Fig. 26-Installing Cylinder Head
16. Adjust valve lash as outlined under "Valve Lift
ers" in preceding pages.
17. Install rocker arm cover, position wiring harness
FRONT in clips on cover.
4 18. Clean and install air cleaner.

19. Install and check crankcase vent valve.
Ii 4
CHECKING CAMSHAFT LOBE LIFT
NOTE: Procedure is similar to that used for
checking valve timing. If improper valve op
1 1’ eration is indicated, check the lift of each lobe
in consecutive order and record the readings.
Fig. 27-Cylinder Head Torque Sequence
1. Remove valve rocker covers and gaskets.
2. Remove rocker arms and balls.
3. Attach Tool J-8520 to stud.
4. Position clamp and indicator with ball socket
adapter of Tool J-8520 to push rod.
NOTE: Make sure push rod is in the lifter
socket.
5. Rotate the crankshaft balancer slowly in the di
rection of rotation until the lifter is on the heel
of the cam lobe. At this point, the push rod will be
in its lowest position.
6. Set dial indicator on zero, then rotate crankshaft
slowly, or attach an auxiliary starter switch and
"bump" the engine over, until the push rod is in
the fully raised position.
NOTE: Ground primary wire on coil, when
cranking engine.
7. Compare the total lift recorded from the dial indi
cator Tool J-8520 with specifications.
8. Continue to rotate the engine until the indicator
reads zero. This will be a check on the accuracy
Fig. 28-Rocker Arm Installation of the original indicator setting.

ENGINE-6 CYL. 8-15
9. If camshaft readings for all lobes are within speci

fications, remove dial indicator assembly Tool
J-8520 from cylinder head stud.
10. Install all push rods and valve rocker arms and
balls. Adjust valve as outlined in this section.
11. Replace valve rocker covers and gaskets.
HARMONIC BALANCER
6 Cylinder Engine
Removal
1. Drain radiator and disconnect radiator hoses at
radiator.
2. Remove radiator core and fan belt.
3. Install Tool J-6978 to balancer and turn puller
screw to remove balancer fig. 29. Then remove
tool from balancer.
Fig. 30-Installing Harmonic Balancer
2. Remove harmonic balancer using Tool J-6978.

3. Drain engine oil and remove oil pan.
4. Remove timing gear cover attaching screws and
remove cover and gasket.
DRIVER
Fig. 29-Removing Harmonic Balancer
Installation
1. Coat front cover oil seal contact area of balancer
with engine oil.
2. Attach balancer installer tool to balancer as shown
in Figure 30.
CLAMP
NOTE: This tool is used differently for 8 cylin
der engines. Assemble as shown fig. 31 for
use here.
3. Position balancer on crankshaft and drive into
position until it bottoms against crankshaft gear.
Remove installer tool.
4. Install fan belt and adjust using strand tension PILOT
gauge.
5. Install radiator core and connect radiator hoses.
I
6. Fill cooling system and check for leaks.
TIMING GEAR COVER

Removal
1. Drain and remove radiator. Fig. 31-Installer Tool Assembly

ENGINE-6 CYL. 8-16
out of cover from front with a large screwdriver.

2. Install new lip seal with lip open side of seal
inside of cover and drive or press seal into place
with Tool J-0995 fig. 32.
b. Timing cover installed.
1. After removing harmonic balancer, pry seal out
of cover with a large screwdriver.
2. Install new lip seal with lip toward inside of
cover and drive it into position with Tool J-8340.
Oil Nozzle Replacement

1. Remove nozzle with pliers fig. 33.
2. Drive new nozzle in place oil hole in vertical
position using a suitable light plastic or rubber
hammer.
Installation
1. Clean gasket surfaces on block and cover.
2. Install centering Tool J-0966 over end of crank
shaft.
3. Coat the gasket with light grease and stick a new
cover gasket in position on block with light grease.
4. Install cover over centering tool fig. 34 and in
stall cover screws. Torque screws to 6 to 8 ft. lbs.
Remove centering tool.
Fig. 32-Installing Timing Gear Cover Oil Seal
NOTE: It is important that centering gauge be
Oil Seal Replacement used to align cover so that harmonic balancer
There are two methods of replacing the timing gear installation will not damage seal and to posi
cover oil seal as outlined below: tion seal to seal evenly around balancer hub
surface.
a. Timing cover removed.
5. Install harmonic balancer.
1. After removing timing gear cover, pry oil seal
6. Install oil pan with new gaskets and seals.
Fig. 33-Timing Gear Oil Nozzle Removal Fig. 34-Timing Gear Cover Installation

ENGINE-6 CYL. 8-17
7. Install radiator, connect hoses, fill cooling system

and check for leaks.
CAMSHAFT
Removal
1. Drain crankcase and radiator.
2. Remove radiator as described under "Engine Cool
ing." Fig. 36-Checking Camshaft Alignment
3. Remove grille assembly. See "Front End Sheet

Metal," Section 11. of the dial indicator indicates the high point of the
4. Remove valve cover and gasket, loosen valve shaft. Examine the camshaft bearings and if any bear
rocker arm nuts and pivot rocker arms clear of ing needs replacement, replace all bearings.
push rods.
5. Remove distributor noting position of rotor.
6. Remove coil and side cover and gasket. Remove Gear and Thrust Plate
push rods and valve lifters. If the inspection indicated that the camshaft, gear
7. Remove harmonic balancer using Tool J-6978. Re and thrust plate were in good condition, the camshaft
move oil pan and timing gear cover. end play should be checked fig. 37. This clearance
8. Remove the two camshaft thrust plate screws by should be .001" to .005".
working through holes in the camshaft gear fig.
35*-
Fig. 37-Checking Camshaft End Play

Fig. 35-Removing Camshaft Thrust Plate Screws
Disassembly
9. Remove the camshaft and gear assembly by pull
ing it out through the front of the block. 1. If the inspection indicated that the shaft, gear or
plate should be replaced, the gear must be re
NOTE: Support shaft carefully when removing moved from the shaft. This operation requires the
so as not to damage camshaft bearings. use of camshaft gear remover Tool J-791.
Inspection 2. Place the camshaft through the gear remover,
place end of remover on table of a press and press
The camshaft is cast alloy iron with bearing journal shaft out of gear fig. 38.
sizes all of the same dimension: 1.8692-1.8682.
These dimensions should be checked with a microm CAUTION: Thrust plate must be so positioned
eter for an out-of-round condition. If the journals ex that woodruff key in shaft does not damage it
ceed .001" out-of-round, the camshaft should be re when the shaft is pressed out of gear. Also,
placed.
support the hub of the gear or the gear will be
The camshaft should also be checked for alignment.
The best method is by use of "V" blocks and a dial seriously damaged.
indicator fig. 36. The dial indicator will indicate the Assembly
exact amount the camshaft is out of true. If it is out
more than .002" dial indicator reading, the camshaft To assemble camshaft gear, thrust plate and gear
should be replaced. When checking, the high reading spacer ring to camshaft, proceed as follows:
ENGINE-6 CYL. 8-18
Fig. 39-Checking Camshaft Gear Runout

Fig. 38-Removing Camshaft Gear
1. Firmly support shaft at back of front journal in an shaft and drive balancer onto shaft until it bot
arbor press. toms against crankshaft gear, using Tool J-5590.
2. Place gear spacer ring and thrust plate over end 10. Install valve lifters and push rods. Install side
of shaft, and install woodruff key in shaft keyway. cover with a new gasket. Attach coil and wires.
3. Install camshaft gear and press it onto the shaft Then install distributor, positioning rotor to mark
until it bottoms against the gear spacer ring. The as when removed.
end clearance of the thrust plate should be .001" 11. Pivot rocker arms over push rods and lash valves
to .005". as described under "Service Operations-Cylinder
Head and Valve Mechanism" in this section.
Installation
1. Install the camshaft assembly in the engine block,
being careful not to damage bearings or cams.
2. Turn crankshaft and camshaft so that the valve
timing marks on the gear teeth will line up fig.
75, push camshaft into position. Install camshaft
thrust plate to block screws and tighten 6-7½
ft. lbs.
3. Check camshaft and crankshaft gear runout with
dial indicator fig. 39. The camshaft gear run-
out should not exceed .004" and the crankshaft
gear runout should not exceed .003".
4. If gear runout is excessive, the gear will have to
be removed and any burrs cleaned from the shaft
or the gear replaced.
5. Check the backlash between the timing gear teeth
fig. 40. The backlash should not be less than
.004" nor more than .006".
6. Install timing gear cover and gasket.
7. Install oil pan with new gaskets.
8. Install harmonic balancer, using harmonic bal
ancer installer Tool J-8792.
9. Line up keyway in balancer with key on crank- Fig. 40-Checking Timing Gear Backlash

ENGINE-6 CYL. 8-19
12. Add oil to engine. Install the fan belt and adjust 7. Remove pilot from shaft and install on driver
using tension gauge. handle with shoulder to handle, then drive out
13. Install the radiator as described under "Engine front and rear bearings from outside to inside of
Cooling." block.
14. Install grille assembly. See "Front End Sheet Installation
Metal," Section 11.
Inner bearings should be installed first to prevent
15. Add cooling solution to radiator, start engine and damaging end bearings with screw shaft.
check for leaks.
16. Check and adjust timing. NOTE: Bearing O.D.’s #1 & #4 are 2.009-2.011
#2 & #3 are 1.999-2.001.
CAMSHAFT BEARINGS 1. Remove handle from pilot. Install inner bearing
on pilot.
Removal
2. Position inner, bearing and pilot to rear of inner
Camshaft bearings can be replaced while the engine bearing bore and install screw shaft with remov
is disassembled for overhaul, or without complete dis er adapter on it through the block from front of
assembly of the engine after camshaft and flywheel engine into pilot.
have been removed. Operation is easier if crankshaft is
removed also. 3. Align oil hole on bearing with oil hole from oil
gallery. Snug puller nut against adapter.
1. With camshaft and flywheel removed, drive out
expansion plug from rear cam bearing by driving 4. Using two wrenches, hold screwshaft and turn
from inside. puller nut to pull bearing into place fig. 42.
2. Position bearing pilot in inner bearing.

3. Install nut on puller screw far enough so puller
screw can be threaded into pilot while nut extends
out front of block.
4. Install remover section onto puller screw and then
install screw through cam bore and thread it into
pilot.
5. Using two wrenches, hold screw shaft and turn
puller nut to remove bearing fig. 41.
6. Repeat operation on other inner bearing from rear
of engine.
Fig. 42-Installing Camshaft Center Bearings
NOTE: Oil hole is on top side of bearing shell

and cannot be seen during installation, so first
align bearing shell oil hole with oil hole in
bore and mark opposite side of bearing and
block at bore to easily index oil hole during
installation.
5. Repeat operation from rear of engine to install
other inner bearing.
6. Install new number 1 bearing on pilot with drive
handle attached.
7. Align oil hole on bearing with oil hole from oil
gallery and drive bearing in from front of engine
fig. 43.
NOTE: The front bearing must be driven ap

proximately ¼" behind front of cylinder block
to uncover oil hole to timing gear oil nozzle
Fig. 41-Removing Camshaft Bearings fig. 44.
ENGINE-6 CYL. 8-20
Fig. 43-Installing Front or Rear Bearing Fig. 44-Timing Gear Oil Nozzle Oil Passage
Fig. 45-Oil Pan Removal Position

ENGINE-6 CYL. 8-21
3. Remove clutch housing-to-engine block bolt above

dowel on right side. Raise vehicle on hoist or
place on jack stands.
a. Rotate engine to align distributor rotor between
#3 and 5 plug wires. This gets #6 crankthrow
part way up.
4. Remove starter assembly and flywheel front cover
plate.
5. Remove front mount through bolts. DO NOT
loosen rear mount.
6. Install Tool J-6978 onto harmonic balancer and
use it as a crankshaft extension for jacking engine.
7. Jack engine as high as it will go with left side of
clutch housing flange riding in body tunnel and
right side just clearing tunnel and riding against
firewall.
NOTE: The engine will raise at an angle need
ed to remove pan.
8. Remove front engine mount frame bracket on
right side and remove oil filter.
9. Remove oil pan screws and lower oil pan to frame.
10. Remove oil pump to gain pan removal clearance,
then remove oil pan by sliding and rotating front
of pan to right of engine then rearward, down and
out at an angle to left rear corner of engine.
11. If oil pan gasket needs replacement, there is ade
quate clearance to clean gasket surfaces and oil
pan without removing pan from vehicle.
Oil Pan Removal with Powerglide

Transmission
1. Drain radiator and crankcase.
2. Disconnect:
a. Gas tank line at fuel pump.
b. Radiator hoses at radiator.
Fig. 46-Oil Pan Gaskets and Seals 3. Remove the clutch housing-to-engine block bolt
above dowel pin on each side.
8. Repeat previous Operations 6 and 7 to drive rear 4. Rotate engine to place distributor rotor between
bearing into position from rear of block. #3 and 5 plug wires. This gets #1 crankthrow part
way up.
NOTE: Rear bearing installed position is flush 5. Raise vehicle on hoist or place on jack stands.
with inner edge of rear cam bearing bore in
6. Remove converter cover pan and starter assembly.
block.
7. Remove front mount through bolts do not loosen
9. Install a new expansion plug at rear bearing. rear mount bolts, and disconnect transmission
vacuum modulator line at modulator so line is
OIL PAN not crimped in tunnel.
8. Install Tool J-6978 onto harmonic balancer hub
Oil Pan Removal with Synchromesh and use it as a crankshaft extension for jacking
Transmission engine.
Refer to Figures 45 and 46 9. Raise engine as high as it will go with rocker arm
The oil pan can be removed by either of two meth cover resting against firewall modulator vacuum
ods: 1 After engine removal or 2 with engine in line will be snug in tunnel but not crimped, and
vehicle as follows: accelerator linkage should be free or just touching
1. Drain radiator and oil pan. modulator line.
2. Disconnect: 10. Remove oil pan screws and lower to frame.
a. Gas tank line at fuel pump. 11. Remove oil pump and screen assembly, then re
b. Upper and lower radiator hose at radiator. move oil pan downward and rearward.
ENGINE-6 CYL. 8-22
1-i
Fig. 48-Oil Pump Installed
Removal and Disassembly

1. Drain oil, remove front engine mount through
bolts, raise engine front end and place a 12 inck
block between mount and support.
2. Remove starter.
3. Remove oil pan screws, lower pan to frame and
tilt to left side of engine for access to oil pump.
Fig. 47-Oil Pump Components 4. Remove two flange mounting bolts, pickup pipe
1. Pressure Control Valve 6. Cover Gasket
2. Spring 7. Idler Gear service bolt, and remove pump and screen as an
3. Retaining Pin 8. Drive Gear and Shaft assembly fig. 48.
4. Screws cover 9. Pump Body
5. Cover 10. Pick-up Screen and Pipe 5. Remove 4 cover attaching screws, cover, gasket,
idler gear and drive gear and shaft.
NOTE: Oil pan front seal curvature should 6. Remove pressure regulator valve and valve parts.
straddle front main bearing cap and rear of oil 7. If necessary, remove oil pump suction pipe and
pan will then just clear flywheel. screen by pulling from pump housing.
CAUTION: Do not disturb oil pickup pipe on
OIL PUMP screen. This pipe is located at assembly.
Oil pump fig. 47, consists of two gears and a pres 8. Wash all parts in cleaning solvent and dry using
sure relief valve enclosed in a two-piece housing and compressed air.
driven from the distributor drive shaft which in turn is
driven by a helix gear on the camshaft. Inspection
It is flange mounted to the cylinder block with 2
bolts and piloted on the outside of the lower distribu Should any of the following conditions be found dur
tor bronze bearing. ing inspection operations, the pump assembly should
be replaced.
Oil pressure passes through an opening in mounting
1. Inspect pump body for cracks or excessive wear.
flange to cylinder block, then into the full flow oil filter.
2. Inspect oil pump gears for excessive wear or
The pump cover is equipped with the pressure regu
lator valve that regulates oil pressure at approximately damage.
35 psi. @ 2000 rpm. 3. Check shaft for looseness in the housing.
The pump intake is of the fixed screen type. A mesh 4. Check inside of cover for wear that would permit
screen filters out small particles of dirt and sludge oil to leak past the ends of gears.
which may be present. 5. Check the oil pick-up screen for damage to screen,
or relief grommet.
NOTE: A baffle incorporated on the intake 6. Check pressure regulator valve plunger for fit in
screen has been designed to eliminate pressure housing.
loss due to sudden surging stops.
Assembly and Installation
In the event that a screen becomes plugged a steel
grommet opens and by-passes oil to the pump. 1. Place drive gear and shaft in pump body.
Inasmuch as the oil pump is serviced on an exchange 2. Install idler gear so that smooth side of gear will
basis, no repair operations other than disassembly and be toward the cover.
inspection operations are covered in this manual. 3. Install a new GENUINE Chevrolet gasket to as-

ENGINE-6 CYL. 8-23
UPPER
r
LOWER
Fig. 49-Rear Main Bearing Oil Seal
sure correct end clearance of the gears.

4. Install suction pipe and screen assembly to hous
ing with sealer and install cover and attaching
screws. Tighten screws 6 to 9 ft. lbs. torque and
check to see that shaft turns freely.
5. Install regulator valve plunger, spring, retainer
and pin.
6. Align oil pump drive shaft slot to match with dis
tributor tang, then install oil pump to block posi
tioning flange over distributor lower bushing. Use
no gasket.
NOTE: Oil pump should slide easily into place.
If not, remove and relocate slot or locate other
problem.
7. Install oil pan using new gaskets and seals as out
lined under "Oil Pan Installation." Fig. 50-Removing Oil Seal Upper Half
hammer and brass pin punch to tap one end of

REAR MAIN BEARING OIL SEAL seal until it protrudes far enough to be removed
Removal and Installation with pliers as shown in Figure 50.
The rear main bearing oil seal, shown in Figure 49, 6. Install new seal by rolling seal into groove similar
can be removed both halves without removal of the to installing main bearing.
crankshaft. NOTE: Lip of seal goes to front of engine.
NOTE: Always replace upper and lower seal as 7. Install bearing cap and torque bearing cap bolts
a unit. 60-70 ft. lbs.
1. Drain crankcase and remove oil pan. 8. Install oil pan and reffil with engine oil.
2. Remove rear main bearing cap.
3. Remove oil seal from groove, prying from bottom, MAIN BEARINGS
using a small screwdriver. The main bearings are of the precision insert type
and do not utilize shims for adjustment. If the clear
NOTE: Always clean crankshaft surface before ances are found to be excessive, a new standard or
installing a new seal. undersize bearing insert, both upper and lower halves,
will be required.
4. Insert a new seal well lubricated with engine oil
in bearing cap groove keep oil off of parting line NOTE: if, for any reason, main bearing caps
surface, this surface is treated with glue gradu are replaced, shimming may be necessary.
ally push with a hammer handle until seal is rolled Laminated shims for each cap are available for
into place. service. Shim requirement will be determined
5. To replace the upper half of the seal, use a small by bearing clearance.
PASSENGER CAR SMOP MANUAL
ENGINE-6 CYL. 8-24
thrust surface to the oil slinger and rotate the

crankshaft to pull bearing out fig. 51.
c. To install start the bearing side not notched
into notched side of block by hand, then use
pliers as before to turn shell half into place.
d. The last ¼" movement may be done by holding
just the slinger with pliers taped jaws or tap
in place with a drift punch.
9. Check bearing clearance as outlined under "Main
Bearing Clearance."
10. Install oil pan.
11. Install spark plugs.
Bearing Replacement-Engine Removed

The main bearings used as service replacement are
of high quality with close tolerances of fit and will not
require line reaming on installations. The close dimen
sional tolerances assure an equalized bearing surface
at all points on the crankshaft when replaced in sets.
1. Remove main bearing caps and connecting rod
caps and lift crankshaft out of cylinder block.
Push pistons to top of bores.
Fig. 51-Rear Main Bearing Removal Upper Shell
2. Inspect the crankshaft. All main bearing journals
are ground to 2.2978"-2.2988", and crankpin
The clearance may be checked with the engine in the journals to 1.999"-2.000".
vehicle by the plastigage method see "Main Bearing These dimensions should be checked with a mi
Clearance" below. When one bearing is being checked, crometer for out-of-round, taper or undersize. If
all the other main bearing caps must be in place and at the journals exceed .001" out-of-round or taper
required torque. The inspection and end play check the crankshaft should be replaced or reconditioned
should also be made as outlined under "Engine Over to an undersize figure that will enable the instal
haul." lation of undersize precision type bearings.
The crankshaft should also be checked for run-
Bearing Replacement-Engine in Vehicle out. To perform this operation, support the crank
NOTE: Main bearings may be replaced without shaft at the front and rear main bearing journals
removing the crankshaft. in "V" blocks and indicate the runout of both the
rear intermediate and front intermediate journals,
1. Remove oil pan. using a dial indicator. The runout limit of each of
2. Remove spark plugs. these journals is .002". If therunout exceeds .002"
3. Remove cap on main bearing requiring replace the crankshaft must be repaired or replaced.
ment and remove bearing from shell. 3. Remove old bearing shells from cylinder block and
4. Install a main bearing shell removing and install caps.
ing tool in the oil hole in the crankshaft. 4. Remove rear main bearing oil seal.
5. Install new bearing shells in the cylinder block
NOTE: If such a tool i’s not available, a cotter and caps.
pin may be bent as required to do the job.
NOTE: Main bearing shells with oil holes are
5. Rotate the crankshaft clockwise as viewed from the upper halves of the bearing shells and are
front of engine. This will roll upper bearing shell inserted between the crankshaft and cylinder
out of engine. block.
6. Oil new upper bearing shell and insert plain un
notched end of shell between crankshaft and 6. Carefully place the crankshaft in the bearings.
indented or notched side. Rotate the bearing into 7. InstalL the bearing caps as outlined under "Engine
place. Overhaul".
7. Install new bearing shell in bearing cap.
NOTE: The caps are marked with an arrow for
8. The rear main bearing journal has no oil hole identification purposes. The caps are to be in
drilling. To remove the upper bearing half proceed
stalled with the arrows pointing to the front of
as follows after cap is removed:
the engine.
a. Use a small drift punch and hammer to start
the bearing rotating out of block. 8. Check crankshaft end clearance as outlined under
b. Then use a pair of pliers to hold the bearing "Engine Overhaul".

ENGINE-6 CYL. 8-25
rest on the upper bearings and it can be assumed that

the total clearance can be measured between the cap
bearing and journal.
NOTE: To assure the proper seating of the
crankshaft, the rear main bearing oil seal
should be removed and all bearing cap bolts
should be at their specified torque. In addition
preparatory to checking fit of bearings, the sur
face of the crankshaft journal and bearing
should be wiped clean of oil.
1. Starting with the rear main bearing, remove bear
ing cap and wipe oil from journal and bearing cap.
2. Place a piece of Plastigage the full width of the
bearing parallel to the crankshaft on the journal
fig. 52.
CAUTION: Do not rotate the crankshaft while
the Plastigage is between the bearing and
journal.
3. Install the bearing cap and evenly tighten the re
taining bolts to 60-70 lb. ft. torque.
Fig. 52-Plastigage on Journal 4. Remove bearing cap. The flattened Plastigage will
be found adhering to either the bearing shell or
9. Check main bearing clearance as outlined below. journal. On the edge of Plastigage packing enve
10. Check new rear bearing oil seal. lope there is a graduated scale which is correlated
11. Install connecting rod bearings and caps. in thousands of an inch.
5. Without removing the Plastigage, check its com
Main Bearing Clearance pressed width at the widest point with the grad
Plastigage consists of a wax-like plastic material uations on the Plastigage envelope fig. 53.
which will compress evenly between the bearing and NOTE: Normally, main bearing journals wear
journal surfaces without damaging either surface. To evenly and are not out-of-round. However, if a
obtain the most accurate results with Plastigage, cer bearing is being fitted to an out-of-round jour
tain precautions should be observed. If the engine is nal be sure to fit to the maximum diameter of
out of the chassis and upside down, the crankshaft will the journal. If the bearing is fitted to the mini
mum diameter of the lournal and the journal is
out-of-round .001" or more, interference be-
Fig. 53-Measuring Plastigage Fig. 54-Measuring Crankshaft End Play

ENGINE-6 CYL. 8-26
Fig. 56-Measuring Plastigage
should be used. DO NOT FILE ROD OR ROD CAPS.

Fig. 55-Plastigage on Crankpin 1. Drain oil and remove oil pan.
2. Remove the connecting rod bearing cap.
tween the bearing and journal will result in
3. Wipe bearing insert shell and crankpin clean of
rapid bearing failure. If the flattened Plastigage
oil.
tapers toward the middle or ends, there is a
difference in clearance indicating a taper, low 4. Place a piece of Plastigage the full width of the
spot or other irregularity of the bearing or jour bearing on crankpin parallel to the crankshaft
nal. Be sure to check the journal with a mi fig. .55
crometer if the flattened Plastigage indicates 5. Reinstall the bearing cap and evenly tighten the
more than .001" difference. retaining nuts to 35-45 ft. lbs. torque.
6. If the bearing clearance is not over .004" worn CAUTION: Do not turn crankshaft with the Plas
or .003" new or less than .001" the bearing in tigage installed.
sert is satisfactory. If the clearance is not within
these limits replace the insert. 6. Remove the bearing cap and without removing the
Plastigage, check its width at the widest point with
NOTE: If a new bearing cap is being installed
the Plastigage scale fig. 56.
and clearance is less than .001", check for
burrs or nicks; if none are found then install
NOTE: If the crankpin is out-of-round be sure
shims as required.
to fit the bearing to the maximum diameter of
7. A .002" undersize bearing may produce the proper the crankpin. If the flattened plastic is not uni
clearance. If not, it will be necessary to regrind form from end to end in its width, the crank-
the crankshaft journal for use with the next under pin or bearing is tapered, has a low spot or
size bearing. some other irregularity. Check the crankpin with
NOTE: Bearings are available in standard sizes a micrometer for taper if the flattened Plasti
and .002", .010", .020" and .030" undersize. gage indicates more than a .001" difference.
8. Proceed to the next bearing. After all bearings

have been checked rotate the crankshaft to see
that there is no excessive drag.
9. Check the end play by forcing the crankshaft to
its extreme front position. Check at the front side
of the rear main bearing with a feeler gauge fig.
54. This clearance should be from .002" to .006"
10. Install a new rear main bearing oil seal in the cyl
inder block and main bearing cap.
CONNECTING ROD BEARINGS

Service in Vehicle
Connecting rod bearing inserts are available in stand
ard sizes and undersizes of .001", .002", .010" and .020".
These bearings are not shimmed and when clearances
become excessive the next undersize bearing insert Fig. 57-Check Connecting Rod Side Clearance

_____ _______
ENGINE-6 CYL. 8-27
7. If the reading is not over .004" or not less than

.001" the fit is satisfactory. If however, the clear
ances are not within these limits, replace the bear
ing with the proper undersize bearing. L
NOTE: The insert bearing shells are not adjust

able and no attempt should be made to adjust
REMOVER AND
PISTON
PIN
J SPING
PILOT
1
SUPPORT
by filing the bearing cap.
INSTALLER
New bearing shell insert clearance should be .003"
maximum and .001" minimum.
8. Rotate the crankshaft after bearing adjustment to
be sure the bearings are not too tight.
9. Check connecting rod end clearance between con
necting rod cap and side of crankpin fig. 57. See
engine specifications for clearance. Fig. 59-Piston Pin Installation
10. Install oil pan with new gaskets and seals and re 4. Check connecting rods and pistons for cylinder
fill with engine oil. number identification and if necessary, mark them.
5. Remove connecting rod cap nuts and caps. Push
the rods away from the crankshaft and install caps
and nuts loosely to their respective rods.
6. Push piston and rod assemblies away from crank
shaft and out of the cylinders.
NOTE: It will be necessary to turn the crank
shaft slightly to disconnect some of the rods
and to push them out of the cylinder.
Disassembly
1. Install pilot of piston pin Removing and Installing
Tool J-6994 on piston pin.
2. Install piston and connecting rod assembly. on sup
port and place assembly in an arbor press as shown
in Figure 58. Press pin out of connecting rod.
3. Remove assembly from press and remove piston
pin from support and remove tool from piston
and rod.
Piston Pin Fit
Piston pins are a matched fit to the piston and are
not available separately. Piston pins will not become
loose enough to cause a knock or tapping until after
very high mileage and in such cases a new piston and
pin assembly should be installed. Wear limit for pin
clearance is .0011 maximum.
New piston pins should be capable of supporting their
Fig. 58-Removing Piston Pin own weight in either pin boss when coated with light
engine oil and at 600 F. Higher or lower temperatures
PISTON AND CONNECTING ROD will cause false indications. Pistons and pins are serv
iced as assemblies.
Removal
Assembly
1. Drain cooling system and remove cylinder head.
1. Lubricate piston pin holes in pistons and connect
2. Drain crankcase oil and remove oil pan. ing rod to facilitate installation of pin.
3. Remove any ridge and/or deposits from the upper 2. Position connecting rod in its respective piston so
end of the cylinder bores with a ridge reamer. that flange or heavy side of rod at the bearing end
NOTE: Move piston to the bottom of its travel will be towards front of piston cast depression
and place a cloth on top of piston to collect the in top of piston head.
cuttings. After ridge and/or deposits are re 3. Install piston pin on installer and pilot spring and
moved, turn crankshaft until piston is at the top pilot in support fig. 59.
of its stroke and carefully remove cloth with 4. Install piston and rod on support, indexing pilot
the cuttings. through piston and rod.

ENGINE-6 CYL. 8-28
5. Place support on arbor press, start pin into piston

and press on installer until pin pilot bottoms.
6. Remove installer and support assembly from pis
ton and connecting rod assembly.
7. Check piston pin for freedom of movement in pis
ton bore.
PISTON RINGS
Chevrolet piston rings are furnished in standard
sizes as well as .020", .030" and .040" oversizes.
Oil Control Rings
The oil control rings used on all engines consist of
two segments rails and an expander spacer.
Compression Rings
Compression rings in all engines are the deep section
twist type, %. wide.
This type compression ring takes its name, twist Fig. 61-Rolling Ring in Groove
type, from its installed position which is cocked or
twisted. It assumes and maintains this position for life NOTE:.lt is important that each ring be fitted to
sealing the sides of the ring, in piston grooves, against its indivdual cylinder for proper gap spacing
oil and blowby gas. and to its individual piston and groove for
All compression rings are marked with the letters proper groove clearance.
"GM" cast in the upper side of the ring. When install 2. Slip the ring in the cylinder bore; then using the
ing compression rings, make sure the side marked head of a piston, press the ring down into the cyl
"GM" is toward the top of the piston. inder bore about two inches.
Removal NOTE: Using a piston in this way will place the
ring square with the cylinder walls.
1. Remove piston rings by expanding them and slid
ing them off the ends of the piston. Tool J-8020 is 3. Check the space or gap between the ends of the
available for this purpose. ring with a feeler gauge fig. 60.
2. Clean piston ring grooves by carefully removing all 4. If the gap between the ends of the ring is below
particles of carbon. Also check for burrs or nicks specifications see "Engine Specifications" in Sec
that might cause rings to hang up. tion 15, remove the ring and try another for fit.
5. Fit each ring separately to.the cylinder in which
Installation it is going to be used.
1. Select rings comparable in size to the piston being 6. New pistons, rings and cylinder bores wear con
used. siderably during seating and gaps widen quickly;
however, engine operation will not become seri
ously affected if ring gaps do not become greater
than 1/32.
7. Carefully remove all particles of carbon from the
ring grooves in the piston and inspect the grooves
carefully for burrs or nicks that might cause the
rings to hang up.
8. Slip the outer surface of the compression ring into
the piston ring groove and roll the ring entirely
around the groove to make sure that the ring is
free and does not bind in the groove at any point
fig. 61. If binding occurs, the cause should be
determined and removed by carefully dressing
with a fine cut file. However, if the binding is
caused by a distorted ring, install a new ring.
9. Install the oil ring spacer in the oil ring groove
and position gap in line with piston hole. Hold
spacer ends butted and install steel rail on top side
of spacer. Position gap at least 1" to left of spacer
gap, then install second rail on lower side of spacer.
Fig. 60-Checking Ring Gap Position gap at least 1" to right of spacer gap.
ENGINE-6 CYL. 8-29
Fig. 62-Checking Groove Clearance
10. Flex the oil ring assembly in its groove to make Fig. 63-Checking Cylinder Out-of-Round and Taper
sure ring is free and does not bind in the groove der wall to determine the out-of-round condition.
at any point. If binding occurs, the cause should If cylinders were found to have more than .002
be determined and removed by carefully dressing out-of-round, boring will be necessary.
with a fine cut file. However, if the binding is
Repair
caused by a distorted ring, install a new ring.
11. Proper clearance of the piston ring in its piston The performance of the following operations is con
ring groove is very important in maintaining en tingent upon engine condition at time of repair.
gine performance and in preventing excessive oil If the cylinder block inspection indicated that the
consumption. Therefore, when fitting new rings, block was suitable for continued use except for out-
the clearances between the top and bottom sur of-round or tapered cylinders, they can be conditioned
faces of the ring grooves should be inspected fig. by honing or boring and honing.
62. Refer to "Engine Specifications" in Section 14 High limit standard size pistons are available for
for correct clearances. service use so that proper clearances can be obtained
for slightly worn cylinder bores and blocks requiring
12. The compression rings should be fitted so that the
clearance is .0012" to .0032" fig. 60 for new parts only light honing to clean up the bores. There are four
standard size pistons available for service under two
and up to *ØØ5J allowable wear limit.
part numbers. These aluminum pistons are selected
13. Assemble the rings to the pistons as they are fitted
by size and are unitized in groups of six for service*
and make a final test of the ring fit in the grooves
usage. In addition, aluminum pistons are serviced in
by repeating the fitting procedure given above.
.020", .0-30" and .040" oversizes. If the cylinders were
Expander ends must not align with the ring gap. found to have less than .005" taper or wear they can
NOTE: Identification marks on compression be conditioned with a hone and fitted with the high
rings must always be up. limit standard size pistons. A cylinder bore of less than
.005" wear or taper may not entirely clean up when
CYLINDER BLOCK fitted to a high limit position. If it is desired to en
Inspection tirely clean up the bore in these cases, it will be nec
1. Check the cylinder block for cracks in the cylin essary to rebore for an oversize piston. If more than
.005" taper or wear they should be bored and honed to
der walls, water jacket and main bearing webs.
the smallest oversize that will permit complete resur
2. Check the cylinder walls for taper, out-of-round
facing of all cylinders. The use of a dial gauge set up
or excessive ridge at top of ring travel. This should
with a pair of micrometers to the standard cylinder
be done with a dial indicator fig. 63. Set the bore size as outlined under "Cylinder Block-Inspec
gauge so that the thrust pin must be forced in tion," will aid in determining the size pistons for which
about 1/4" to enter gauge in cylinder bore. Center the cylinders must be bored.
gauge in cylinder and turn dial to "0." Carefully
work gauge up and down cylinder to determine Boring
taper and turn it to different points around cylin 1. Before using any type boring bar, the top of the
ENGINE-6 CYL. 8-30
Fig. 64-Cross-Hatch Finish Pattern
cylinder block should be filed off to remove any

dirt or burrs. This is very important. Otherwise,
the boring bar may be tilted which would result
in the rebored cylinder wall not being at right
angles to the crankshaft.
2. The piston to be fitted should be checked with a
micrometer, measuring just below the lower ring
groove and at right angles to the piston pin. The USE .0015 FEELER
STRIP WITH OTHER
cylinder should be bored to the same diameter as PISTONS
the piston and honed to give a clearance of .0006"
to .0010".
3. The instructions furnished by the manufacturer
of the equipment being used should be carefully
followed.
Honing and Piston Fitting

1. When the cylinders are to be honed only for use
Fig. 65-Checking Piston Fit
of standard high limit piston or for final finishing
after they have been rebored to within .002" of the NOTE: Thoroughly clean cylinder bores with
desired size, they should be finished with a hone. soap and hot water to remove all grit particles.
Rough stones may be used at first and fine stones
for the final operation. b. Insert the feeler ribbon and inverted piston into
2. Place the hone into a cylinder bore and expand the cylinder bore so that the center of the piston
pin is flush with the top surface of the cylinder
the stones until the hone can just be turned by
block. Keep the feeler ribbon straight up and
hand. Connect a ½" electric drill to the hone and
down and keep the piston pin parallel with the
drive hone at drill speed while moving hone up
crankshaft axis.
and down entire length of cylinder until hone
begins to run free. During this operation a liberal c. Pull the feeler gauge straight up and out, noting
amount of kerosene should be used as a cutting at the same time the scale reading which should
fluid to keep the stones of the hone clean. Move be between 7 and 18 pounds fig. 65.
hone slowly up and down with rough stones but d. If the scale reading is greater than the maxi
move hone up and down rapidly with the fine mum allowable pull, try another piston or
stones in the final operation. Final bore finish lightly hone the cylinder bore to obtain the
should show very fine uniform surface scratches proper fit.
in a cross-hatch pattern approximately to 60°
450 e. Should the scale reading be less than the mini
included angle shown in Figure 64. Cross-hatch mum allowable pull, try another piston, or if
pattern should be clean cut but not sharp, free standard size, try a standard high limit piston.
from torn or folded metal and imbedded particles. If proper fit cannot be obtained, it will be nec
3. Expand the stones against the cylinder bore and essary to rebore the cylinder to the next over
repeat the honing operation until the desired bore size piston.
diameter is obtained. f. Mark each piston after fitting to correspond
4. Occasionally during the honing operation, the cyl with the cylinder to which it has been fitted.
inder bore should be thoroughly cleaned and the Proceed to hone cylinders and fit the remaining
piston selected for the individual cylinder checked pistons.
for correct fit. CAUTION: Handlethe pistons with care and do
5. Check fit of the aluminum pistons in the following not attempt to force them through the cylinder
manner: until the cylinder has been bored to correct size
a. Invert the piston, skirt end up, and place a as this type piston can be distorted through
.0015" by ½" wide feeler ribbon, part of Tool careless handling.
J-5513 on the side of the piston 90° from the 6. Thoroughly clean the cylinder bores with hot
piston pin holes. water and soap. Scrub well with a stiff bristle
ENGINE-6 CYL. 8-31
Piston and Connecting Rod

Installation
1. Lightly coat pistons, rings and cylinder walls with
light engine oil.
2. With bearing caps removed, install Tool J-5239 on
bearing cap bolts as protection against nicking
crankpins.
3. Be sure ring gaps are spaced around piston, then
install each piston in its respective bore, using
Tool J-5239 on each assembly fig. 67. The side
of the piston with the cast notch in the top edge
of head should be to the front of the cylinder block
and the oil hole on connecting rod towards the
camshaft side of the engine. Guide the connecting
rod bearing into place on the crankshaft journals
with the long detail of Tool J-5239 fig. 66.
4. Install bearing caps and check the bearing clear
ance as described under Connecting Rod Bearings
-Service in Vehicle.
5. Install oil pan gaskets, seals and oil pan.
6. Install cylinder head gasket and head refer to
Fig. 66-Guide Tool Installed
Cylinder Head Installation.
brush and rinse thoroughly with hot water. It is 7. Refill crankcase and cooling system and check for
extremely essential that a good cleaning operation leaks.
be performed. If any of the abrasive material is DISTRIBUTOR LOWER BEARING
allowed to remain in the cylinder bores, it will
rapidly wear the new rings and cylinder bores in The distributor lower bearing is a bronze bushing
addition to the bearings lubricated by the contami pressed into the lower side of the engine block. Its
nated oil. The bores should be swabbed several upper inside diameter pilots the distributor shaft and
times with light engine oil and a clean cloth and the outside diameter extending below the block pilots
then wiped with a clean dry cloth. Cylinders the oil pump.
should not be cleaned with kerosene or gasoline. Some engines have a thrust washer at the upper end
Clean the remainder of the cylinder block to re of the bushing bore. The thrust washer, where used,
move the excess material spread during the hon may be replaced at the same time the bushing is re
ing operation. placed.
Fig. 67-Installing Piston in Cylinder Fig. 68-Removing Distributor Lower Bushing

ENGINE-6 CYL. 8-32
Fig. 69-Removing Distributor Shaft Thrust Washer

Fig. 71 -Installing Distributor Lower Bushing
The lower bushing will ordinarily require only a

clearance or wear check during engine overhaul. When 4. If thrust washer was removed, start new washer
distributor shaft-to-bushing clearance exceeds .0035", in position in bore and drive into place using Tool
the bushing should be replaced as follows with oil J-9535 fig. 70.
pump and distributor removed: 5. Using Tool J-9535 with driver-bolt in driver han
1. Install Tool J-9534 into bushing and using a slide dle, install driver into new bushing from large
hammer, remove the bushing fig. 68. inside diameter.
2. Using a drift up through bushing bore, drive thrust 6. Position bushing and driver to block and drive the
washer if installed out of bore and remove from bushing in position fig. 71, which is determined
block fig. 69. by tool bottoming against the block.
3. Clean bushing bore in block and check for burrs 7. Remove tool from bushing. It is possible that the
or damage. bushing with minimum I.D. will collapse enough,
during installation, to slightly seize the installer
arbor. If this happens, remove installer tool using
slide hammer in driver bolt hole of driver handle.
NOTE: This will not damage the bushing and
tool is designed for this purpose, should it
occur.
ENGINE MOUNTINGS
Engine mounts are the nonadjustable type, and sel
dom require service. Broken or deteriorated mounts
should be replaced immediately because of added strain
placed on other mounts and driveline components.
Front Mounts-Replace fIg. 72
1. Remove engine bracket-to-mount thru bolt nut
and washer.
2. Raise engine slightly to clear mount and remove
frame bracket-to-frame bolts, then lift out bracket
Fig. 70-Installing Distributor Shaft Thrust Washer
and mount assembly.
ENGINE-6 CYL. 8-33
10. Disconnect:
a. Shift linkage at transmission.
b. Speedometer cable at transmission.
c. Clutch linkage at cross-shaft Synchromesh
only.
11. Remove clutch cross-shaft engine bracket.
12. Remove rocker arm cover and attach lifting device.
13. Remove front mount through bolts.
14. Raise engine to take weight off front mounts, then
remove rear mount bolts.
15. Remove engine-transmission assembly from ve
hicle as a unit.
TRANSMISSION AND CLUTCH REMOVAL

Manual Transmission
1. Remove clutch housing cover plate screws.
2. Remove bolts attaching the clutch housing to en
gine block. Remove transmission and clutch hous
ing assembly.
Fig. 72-Engine Front Mount Assembly NOTE: Support the transmission as the last
mounting bolt is removed and as it is being
3. Install new mount to frame bracket. pulled away from the engine to prevent dam
4. Install frame bracket and new mount assembly to age to clutch disc.
frame finger tight. 3. Remove starter and clutch housing cover plate.
5. Lower engine into place and install thru bolt. Com 4. Loosen clutch-to-flywheel bolts a turn at a time
pletely lower engine and tighten all mount bolts. to prevent distortion of clutch cover until the
spring pressure is released. Remove all bolts,
Rear Mount clutch disc and pressure plate assembly.
See Sections 12 and 13 of this manual.
Automatic Transmission
ENGINE OVERHAUL 1. Lower the engine, secured by the hoist, and sup
port engine on blocks.
Engine Removal 2. Remove converter housing underpan bolts. Re
1. Drain cooling system and crankcase. move pan.
2. Remove air cleaner and disconnect battery cables 3. Remove flywheel-to-converter assembly attaching
at battery. bolts.
3. Scribe around hinges, then remove hood. 4. Support transmission and extension on blocks.
4. Remove radiator and fan blades. 5. Remove transmission-to-engine mounting bolts.
5. Disconnect wires at: 6. With the hoist attached, remove blocks from the
a. Starter solenoid. engine only and slowly guide the engine from the
transmission.
b. Generator.
c. Temperature switch. ENGINE DISASSEMBLY
d. Oil pressure switch.
1. Mount engine in stand Tool J-5856-02 and clamp
6. Disconnect: securely.
a. Accelerator linkage at manifold belicrank. 2. Remove engine ground strap, and oil dipstick.
b. Exhaust pipe flange at manifold.
3. Disconnect spark plug wires and primary wire at
c. Gas tank line at fuel pump. coil.
d. Vacuum line to power brake unit at manifold. 4. Remove the distributor hold-down clamp, discon
e. Power steering pump lines at pump end. nect vacuum line from vacuum spark control and
7. Raise vehicle and place on jack stands. lift the distributor up out of the engine.
8. Drain transmission if propshaft opening plug is not 5. Remove spark plugs and coil.
available. 6. Disconnect fuel line and vacuum line from fuel
9. Remove propshaft. pump, remove fuel pump bolts and fuel pump.

ENGINE 6 CYL. 8-34
7. Disconnect fuel and vacuum lines and choke rod 27. Remove starter.
at carburetor. 28. Remove oil pan.
8. Remove the lines by sliding them from the retain 29. Remove oil pump and pickup pipe retaining screws
ing clip at the cylinder head water outlet. and pump assembly.
9. Disconnect choke stove clean air tube and choke 30. Clean cylinder ridge with ridge reamer.
stove heat tube at carburetor and remove tubes 31. Check the connecting rods and pistons for cylinder
from the manifold. number identification and if necessary, mark them.
10. Remove generator mounting bolts, generator and 32. Remove connecting rod nuts and rod caps. Push
fan belt. rods away from the crankshaft and out of cylin
11. Remove the fan and water pump pulley. ders. Install caps and nuts loosely to their respec
12. Remove water pump and generator attaching tive rods.
brace.
NOTE: It will be necessary to turn the crank
Attach puller Tool J-6978 to harmonic balancer and shaft slightly to disconnect some of the rods
turn puller screw to remove balancer. and to push them out of the cylinder.
15. Remove two bolts attaching water outlet to ther
mostat housing and remove water outlet and ther 33. Remove piston rings by expanding them and slid
mostat. ing them off the ends of the pistons.
34. Remove main bearing cap bolts and remove the
16. Remove thermostat housing from cylinder head.
bearing caps.
17. Remove carburetor throttle rod and return spring 35. Lift the crankshaft with the flywheel attached out
from manifold pivot lever. of the block and place it where it will not get
18. Remove throttle and accelerator levers from mani damaged.
f old. 36. Lift bearing shells from block and bearing cap.
19. Remove carburetor attaching nuts and carburetor.
20. Remove bolts and retaining clamps attaching man Cleaning and Inspection
ifold to cylinder head and remove intake and ex 1. Wash all parts thoroughly in cleaning solvent.
haust manifold as an assembly.
2. Remove oil gallery plugs, located one at front and
21. Remove push rod cover. one at rear face of cylinder block. These plugs may
22. Loosen rocker arm adjustment nuts, pivot rocker be removed with a sharp punch or they may be
arms and remove push rods and valve lifters. drilled and pried out. This oil passage should be
23. Remove cylinder head attaching bolts and cylin thoroughly cleaned either by using compressed air
der head. or wire brush.
3. Clean all oil passages in the cylinder block and
24. Remove the timing gear cover attaching screws
crankshaft by blowing them out with compressed
and remove cover and gaskets.
air. It is good practice to blow them out separately.
25. Remove two camshaft thrust plate screws through On the block this can be done by plugging the
holes in the camshaft gear and remove camshaft holes in three of the bearings and placing the noz
gear and camshaft through the front of the block. zle of the air gun in the oil inlet of the cylinder
NOTE: Support shaft carefully when removing block and blowing through the remaining bearing
so as not to damage camshaft bearings. oil passages. Continue this until all passages are
clean. Blow through the passage to the camshaft
26. Remove crankshaft gear with gear puller Tool bearings.
J-8105 fig. 73. 4. Run a fine wire through the lubrication holes in
each connecting rod.
5. Blow out the rocker arm shaft oii line and the
passage up from the camshaft bearing.
6. Clean carbon from piston heads, ring grooves and
inside of piston head.
7. Check the cylinder block for cracks in the cylinder
walls, water jacket and main bearing webs.
8. Inspect the connecting rod bearings for fatigue,
pitted or damaged.
9. Determine whether or not pistons are to be re
placed. New piston assemblies with pins and rings
are required when the cylinders are to be honed
or rebored. If the pistons are to be used again,
check the piston pin fit in the pin bores. Refer to
Fig. 73-Removing Crankshaft Gear "Connecting Rod, Bearings, Pistons and Rings."
ENGINE-6 CYL. 8-35
10. Inspect the timing gears for excessive tooth wear 4. Install all bearing caps and bolts. Torque all main
and for loose hub in camshaft gear. Inspect the bearing cap bolts, except the rear main bearing 60
camshaft thrust plate for excessive wear. to 70 ft. lbs. When tightening rear main bearing
cap, torque bolts 10 to 12 ft. lbs. first, then tap
11. Check the cylinder head for being warped, for end of crankshaft rearward with a lead hammer
having clogged water passages, cracked valve seats this will locate bearing cap and bearing. Then
or worn valve guides. tap crankshaft forward this will line up both
12. Inspect the manifolds for excessive carbon in the upper and lower crankshaft bearing thrust sur
ports. Check the operation of the heat control faces. Proceed with final tightening of all main
valve and make sure that the gasket between the bearing cap bolts-60 to 70 ft. lbs. torque.
manifolds is in good condition.
5. Check crankshaft end play by forcing the crank
13. Inspect the oil pump gears for wear, check the shaft to its extreme front position. Check at the
shaft for looseness in the housing and the inside front side of the rear main bearing with a feeler
of cover for wear that would permit oil to leak gauge fig. 74. Clearance should be from .002"
past end of gears. Check screen for damage. to .006" with a new bearing. If greater than a max
imum .009" clearance, the rear main bearing must
NOTE: Instructions for inspection and repair of
be replaced.
the fuel pump, carburetor, air cleaner, genera
tor, starting motor, distributor, clutch and water
pump will be found in their respective sections
of this manual.
14. Check camshaft bearings for wear and if neces

sary replace as previously outlined.
Bearing and Journal Inspection
In general, the lower half of the bearing shows a
greater wear and the most distress from fatigue. If
upon inspection the lower half is suitable for use, it
can safely be assumed that the upper half is also satis
factory. If the lower half shows evidence of fatigue,
distress, abrasion, erosion, scoring or the like, both
upper and lower halves should be replaced. Never
should one half be replaced without replacing the other
half.
If the running clearance of a bearing is too great
with the used inserts, it will be necessary to install
both upper and lower bearing halves. Should this be
come necessary, the crankshaft journals should be
checked with a micrometer for out-of-round, taper or
undersize. If out-of-round more than .001" or tapered, Fig. 74-Checking Crankshaft End Play
the shaft should be replaced or reconditioned. Check
the crankshaft thrust faces at the rear main bearing 6. Make necessary repairs or replacements on piston
for scoring or excessive wear. Experience has shown rings or pins and install piston and connecting rod
that clearance increase from wear in main bearings is assembly as previously outlined.
not only due to bearing wear, but is also due in part to
crankshaft journal wear. 7. Install oil pump over distributor lower bearing
and bolt in place. Torque to 9 to 11 ft. lbs.
ASSEMBLY 8. Install new oil gallery plugs in front and rear sur
faces of cylinder block.
1. Install a new rear main bearing oil seal in cyl
inder block and bearing cap, and install main bear 9. Install camshaft carefully to prevent damage to
bearing, align timing marks fig. 75 and install
ing upper halves shell-half with oil hole in cylin
der block. thrust plate retaining screws through camshaft
gear.
2. Carefully lower crankshaft into place. Be careful
not to damage the bearing surfaces. 10. Install timing gear cover oil seal in cover.
3. Check clearance of each main bearing following 11. Install timing gear cover gasket on block with
procedure outlined under "Main Bearing Clear grease and install cover over centering Tool J-0966.
ance" in this section. If the bearing clearances are Install cover screws and torque to 6-7½ ft. lbs.
satisfactory, apply a light coat of engine oil to the Remove centering tool.
journals and bearings. 12. Install harmonic balancer as previously outlined.

ENGINE-6 CYL. 8-36
Fig. 75-Align Timing Marks
13. Install oil pan with new gaskets and seals and in Fig. 76-Flywheel Installation Syn.
stall starter.
14. Install cylinder head gasket and cylinder head and
torque to 90 to 95 ft. lbs.
15. Install exhaust and intake manifold assembly. CONVERTER GEAR
Torque in sequence shown in Figure 7. BOLT AREA
16. Install valve lifters, push rods and push rod cover. DEPRESSED
17. Install rocker arms, pivot balls and stud nuts.
Turn nuts down enough to remove lash.
18. Turn crankshaft to align pulley timing mark at
TDC when push rods of number one cylinder are
down. Install distributor with rotor to number one
spark plug wire terminal. Tighten distributor
clamp.
19. Install spark plugs, coil, distributor cap and high
tension wires.
20. Install water pump and generator attaching brace.
21. Install thermostat housing, thermostat and water
outlet. Install temperature sending unit.
22. Install water pump pulley loosely.
23. Install generator and fan belt.
24. Install carburetor and connect choke rod from
manifold.
25. Install fuel pump and fuel line from carburetor to
fuel pump. Install vacuum spark line from car
buretor to distributor and route both fuel and
vacuum lines through clip on water outlet.
26. Install oil pressure sending unit.
27. Install flywheel-Line up dowel hole in flywheel
with dowel hole in crankshaft flange and bolt fly
Fig. 77-Flywheel Installation P.G.
wheel in place fig. 76. Torque to 45-50 ft. lbs.
Powerglide flywheel must be installed as shown
in fig. 77. a. Install transmission to engine as outlined in
Section 13.
28. On manual transmission models:
a. Install clutch disc, pressure plate, throwout b. Install starter and converter cover.
bearing, clutch housing and transmission as
outlined in Section 12. ENGINE INSTALLATION
b. Install clutch housing cover plate and starter.
On automatic transmission models: 1. Position engine in engine compartment as follows:
ENGINE V-8 8-37
a. Install engine lifting Tool J-4536-A to engine b. Install transmission filler tube and dipstick.
and lower engine and transmission into chassis 4. Connect carburetor linkage.
as a unit guiding engine to align front engine
5. Connect speedometer cable at transmission.
mounts with mounts on frame.
b. Install one rear transmission crossmember side 6. Check transmission lubricant level. Fill if neces
bolt, swing crossmember up under transmission sary.
mount and install bolt in opposite side rail. 7. Connect exhaust pipe to manifold and tighten
c. Align and install rear mount bolts. securely.
d. Install engine front mount bolts and remove 8. Connect wire harness to temperature sending
lifting tool from engine. unit; oil pressure sending unit and coil primary
terminal.
On manual transmission models: 9. Attach armature and field wires to generator.
a. Install cluteh cross shaft. Connect pedal and 10. Attach fuel line to fuel pump.
clutch fork push rods. Install return spring
from clutch fork to left engine mount. 11. Attach wires and battery cable to starter solenoid.
b. Connect transmission control rods to shifter 12. Install radiator assembly and fan.
levers on transmission side cover. Adjust con 13. Refill radiator and crankcase.
trol rods as outlined in TRANSMISSION SEC
TION. 14. Replace hood assembly, aligning previously scribed
marks.
On automatic transmission models: 15. Adjust valve lash and perform necessary tune-up
a. Connect transmission control rod and throttle procedures and check for oil and coolant leaks.
valve rod at transmission and adjust as out 16. Install rocker arm cover gasket, cover and crank
lined in TRANSMISSION SECTION. case ventilation hose.
V-8 ENGINES
INDEX
Page Page
General Description 283 and 327 8-37 Harmonic Balancer Installation 8-40
General Description 409 8-38 409 Engine Removal and Installation 8-40
Push Rod Assembly 8-38 Oil Pan Removal-409 Cubic Inch Engine 8-41
Piston Pin Installation 8-38
Piston Pin Fit 8-38 Oil Pan Removal-283 and 327
Cylinder Honing 8-39 Cubic Inch Engine 8-42
Fitting Pistons-409 Engine 8-39 Oil Pump-409 Engine 8-42
Flywheel Installation 8-39 Intake Manifold Seals 8-42
283 and 327 Cubic Inch V-8 Engines
The 283 cubic inch V-8 for 1963 fig. 78 is equipped
with a 2 barrel carburetor, single exhaust system and
327 cu. in. fig. 79 cylinder heads raising compression
ratio to 9.25:1.
Two 327 cubic inch engines RPO L-30 and L-74
are a further development of the 327 cubic inch engine
design incorporating dual exhaust systems and 4 barrel
carburetors, thermo-modulated cooling fan, 10.5 to 1
compression ratio and requiring premium fuel. Option
L-30 has a WCFB or 4GC carburetor, hydraulic lifters,
and 2" exhaust, while option L-74 has an AFB
aluminum carburetor, mechanical lifters and 2½"
exhaust.
Both 283 and 327 cubic inch engines have Delcotron
A.C. charging systems and positive crankcase ventila
tion a standard equipment. They have the Chevy II
type 360° aluminum clutch housing for synchromesh
transmission usage or use the aluminum powerglide.
Both engines have pad mounted starters. Fig. 78-V-S 283 Engine

ENGINE V-8 8-38
Fig. 79-V-S 327 Engine

Fig. 80-V-8-409 Engine
409 Cubic Inch Engines fig. 80

Three 409 cubic inch engines, offered in 1963, are
equipped with 2½" dual exhaust systems, thermo
modulated cooling fan, Delcotron A.C. charging
system and positive ventilation system.
RPO L-33 engine has a Rochester 4GC carburetor,
hydraulic valve lifters, cast iron inlet manifold and is
teamed with a 3-speed, 4-speed or Powerglide trans
mission.
RPO L-31 engine has an AFB carburetor, solid valve
lifters, special camshaft, aluminum inlet manifold
and is teamed with 3-or 4-speed transmission.
RPO L-80 is L-31 engine with dual AFB carburetion.
Push Rod Assembly

On engines that use push rods with a hardened
insert at one end, the hardened end is identified by a
color stripe and should always be installed toward the
rocker arm during assembly. The 409 cubic inch
engine exhaust push rods are longer than the intake
and carry different color stripe for further identifica
tion.
PISTON PIN INSTALLATION

283 and 327 cu. in.
Piston pins are pressed into the connecting rod
as in 1961 but a new support tool is necessary due Fig. 81-Piston Pin Removal V
to piston design changes. Tool J-9510 is used for
both 283 and 327 cubic inch engines figs. 81 & 82. Check Piston Pin Fit
PISTON PIN INSTALLATION Pin fit on 283 and 327 cubic inch engines and 409
hydraulic lifter engine is .00015 to .00025 in production.
409 cu. in. These new pistons should support the weight of the
Piston pins are pressed in the connecting rod as pin in the boss when coated with light engine oil.
in 348 cubic inch engines but a new support tool is The .001" wear allowance prohibits this method of
required to clear lower ring land on the larger checking to determine if wear is excessive. The 409
4%" piston. See Tool J-6994-5 figs. 83 & 84. high perf. cubic inch engine pin clearance is .00045"
ENGINE V-8 8-39
PISTON
PIN
1
PILOT
SPING1
SUPPORT
PISTON
PIN SUPPORT
REMOVER AND REMOVER AND
INSTALLER INSTALLER
Fig. 84-Piston Pin Installation WI

Fig. 82-Piston Pin Installation V
Fig. 85-Cylinder Finish Pattern
to-cylinder wall clearance fit of .0035 to .0042 on the

passenger car 409 High-performance engine.
To obtain the proper piston fit by the scale tension
method, use Piston Fitting Scale J-5513 and attach a
seven to eight inch ribbon of ½" wide .004 feeler
stock to the scale, then proceed as follows:
NOTE: The J-5513 spring scale is furnished
with a .0015" feeler strip for piston fitting on
other Chevrolet engines.
Fig. 83-Piston Pin Removal WI 1. Wipe the cylinder, piston and feeler strip surfaces
clean and dry. The presence of oil on any of these
to .00055" and also cannot be checked in previous surfaces would cause an uneven pull on the feeler
method. The recommended method for checking pin strip.
fit on used pistons is with a dial bore gauge or inside 2. Insert the .004 feeler ribbon in the cylinder and
micrometer for the pin bore and a micrometer for the start the inverted piston into the bore with the
pin size. The pin and bores should be free of varnish feeler strip positioned adjacent to a piston pin
and scuffing when measuring. boss. While keeping the feeler ribbon straight in
The piston and pin assemblies are serviced as a the bore rotate the piston down into the cylinder
unit and should be replaced should the clearance until the piston pin is parallel to the crankshaft
exceed production specifications plus .001" wear axis, and the center of the pin is flush with the
tolerance. top of the cylinder bore fig. 65.
Cylinder Honing 3. Slowly pull the scale straight up until the feeler
strip starts to move, then pull steadily while noting
When finish honing a cylinder bore to fit a piston, the tension necessary to keep the ribbon moving.
the hone should be moved up and down at a speed to The scale reading should be in the range of 7 to
obtain very fine uniform surface finish marks in a 17 lbs. on hi performance 409 cu. in. engines.
cross-hatch pattern of approximately 45° to 65° in
cluded angle fig. 85. The finish marks should be 4. Hone the cylinder to fit the piston within the
clean cut but not sharp, free from imbedded particles range specified in Step 3.
and torn or folded metal. FLYWHEEL INSTALLATION
Piston Fitting-409 Engines Refer to fig. 86
When fitting replacement pistons, the piston should The crankshaft flywheel flange does not have a
be selected and the bore honed to provide a piston- dowel pin to align flywheel during installation but the

ENGINE V-8 8-40
DRIVER
CLAMP
Fig. 86-Align Dowel Holes
dowel hole is still in the flange. To install flywheel,

line up dowel hole in crankshaft flange with dowel
hole in flywheel using a drift punch, then install
flywheel mounting bolts. U
HARMONIC BALANCER INSTALLATION PILOT
On V-8 engines equipped with a balancer having
I
the inertia weight pressed on the hub, it is neces
sary to use installer Tool J-8792 to prevent the
inertia weight section from "walking" off the hub
during installation of balancer. This tool is designed
to be used on L-6 engines as well as V-8 and care
should be taken to proceed as follows when installing
the balancer: Fig. 87-Balancer Installer Tool
1. Thread the driver section of Tool into clamp

5. Disconnect:
section from shallow fingers to deep fingers
fig. 87. a. Battery cables at battery.
2. Arrange adapter pilot into end of driver with b. Wires at starter solenoid.
flat end out and lock in place with screw. c. Wires at generator.
3. Install tool over balancer as shown in Figure 88 d. Engine-to-body ground straps.
with pilot adapter in the bore of hub. Tighten e. Oil pressure indicator lead at engine.
threaded driver only finger tight to keep from f. Temperature indicator lead at sending unit.
pulling balancer apart. g. Coil leads at coil tachometer leads at coil if
equipped.
1963 409 ENGINE REMOVAL h. Spark plug wires at plugs.
with transmission as an assembly i. Both gas lines at fuel pump.
j. Radiator hoses at engine ends.
1. Drain cooling system, crankcase and transmission. k. Throttle control rod at pedal belicrank.
2. Scribe alignment marks around hood hinges and 1. Heater hoses at engine end.
remove hood.
m. Powerglide only Powerglide cooling lines at
3. Remove air cleaner and cover carburetor with a radiator and plug open ends.
cloth.
6. Remove fan and fan pulley assembly.
4. Air Conditioned Only-Remove air conditioning
7. Remove radiator core and shroud as assembly.
compressor from engine mounting and tie it to
fender near battery. 8. a. Remove power steering pump mount bolts and

ENGINE V-8 8-41
Step 14, then proceed as follows:

15. Remove fuel pump, then remove front mount
through bolts.
16. Powerglide Transmission -Disconnect transmis
sion TV rod at belicrank.
17. Remove clutch cross-shaft.
18. Place floor-type jack under transmission.
19. Remove converter underpan Powerglide or
flywheel cover bolts Synchromesh.
20. Remove clutch housing-to-engine bolts 2 hold
TV belicrank on Powerglide models.
21. .Powerglide Models-Install holding bracket on
converter.
22. Move engine forward and upward alternately
raise transmission jack also to slide engine from
clutch gear shaft, then raise and guide engine out
of vehicle.
23. Install engine on engine stand.
Fig. 88-Installer Tool in Place
swing pump into opening behind left headlight. Oil Pan Removal 1962 and 1963-409 cu. in.
or To perform any operation on 409 engine requiring
b. Disconnect pump lines and plug open ends. oil pan removal, the engine must be removed from the
vehicle. Use either method as outlined above for
9. Remove distributor cap with all high tension removal, then remove starter and oil pan.
leads attached and cover distributor with a cloth.
10. Power Brake Vehicle Only Disconnect brake
- Installation to Vehicle
pedal push rod at broke cylinder push rod pin, Reverse removal proceedure to install the engine.
then dismount power brake unit and move to side Then check:
against fender about 3-4 inches. 1. Crankcase oil level.
CAUTION: Do not push downward or twist the 2. Transmission oil level.
unit or fluid line damage may result. 3. Cooling system liquid level.
11. Raise vehicle and place on jack stands.

12. Remove rocker arm covers and install lifting Tool
J-4536 to engine using center cylinder head bolt
on each bank and attach engine lifting device.
13. Remove clutch cross-shaft frame bracket end
first, then slide it off engine ball stud.
14. Disconnect exhaust pipes at manifold flange.
15. Disconnect shift linkage and speedometer cable at
transmission.
16. Remove fuel pump then remove engine front
mount through bolts.
17. Remove transmission mount bolts then remove
mount from between crossmember and trans
mission.
18. Raise engine and move it forward and upward
alternately while sliding transmission from pro
peller shaft, then raise engine-transmission
assembly from vehicle.
Engine Removal without Transmission

The engine may be removed separately from the
transmission following the same procedure through Fig. 89-Removing Oil Pickup Tube and Screen

ENGINE V-8 8-42
4.
5.
6.
EARLY
SFig. 90-Manifold Seals
Engine tune up as needed.

Power steering fluid if equipped.
Brake fluid power unit was moved.
c
LATE
7. Air conditioning hose connection. Fig. 91-Installing Manifold Using Pilot

8. Check engine for leaks of any kind while running.
9. Battery water level.
Oil Pan Removal 283 and 327 cu. in. engines

The flange-mounted starter on these engines must
be removed for clearance to oil pan screws; follow
oil pan removal in 1961 Shop Manual and remove
starter after lowering exhaust system.
Oil Pump
The 1963 409 engine oil pump has a pin locking the
pickup tube and screen to the pump cover. Remove
the tube assembly using Tool J-8369 as shown in fig. 89
to drive the tube out of the cover. This will also move
the pin outward for installation of a new tube assem
bly. Drive the pin flush with cover to lock new tube
in place, then stake the pin with a center punch.
Intake Manifold Seals Fig. 92-Installing Fan Hub Using Locating Tool
The end seals on the intake manifold on the 283 and
327 Cu. In. Engines have a seal ridge on both sides except for fan hub location during assembly pro
fig. 90. A pilot tool made of wood can be used in cedures.
the distributor hole to guide the manifold down square The new 6 cylinder engine uses fan hub locating
ly into place. This would eliminate possibility of the gauge Tool J-9583 as shown in Figure 92.
seal rolling out of position if the manifold needed to
be shifted for alignment. Fig. 91 shows use of pilol The 283 and 327 engines use the end of Tool J-9608
tool. and 409 engines use step of same tool. Service pumps
for V-8 engines will have hubs located for 1962 and
1963 engines and should be relocated when used on
COOLING SYSTEM 1961 or earlier engines. Existing tools J-5775 for 283
Cooling systems on 1963 engines are essentially the pumps and J-7034 for 348 pumps should be used for
same as outlined in 1961 Passenger Shop Manual this purpose.

ENGINE V-8 8-43
SPECIAL TOOLS
Fig. 93-Engine Special Tools-6-Cylinder Engine
1. J-6098 Cam Bearing Replacer 10. J-8062 Valve Spring Compressor 18. J-0995 Timing Gear Cover Oil Seal Replacer
2. .1.9534 Distributor Lower Bushing Remover 11. J-8058 0-50 ft. lbs. Torque Wrench 19. J.0966 Timing Gear Cover Centering Gauge
3. J-9510 Piston Pin Remover and Installer 12. .1-1264 0-200 ft. lbs. Torque Wrench 20. J-8105 Crankshaft Gear Puller
4. .1-9535 Distributor Lower Bushing Installer 13. .1-8101 Valve Guide Cleaner 21. J-6978 Harmonic Balancer Puller
5. J-8037 Piston Ring Compressor 14. J-4822 Valve Guide Reamer Set 22. J-5513 Piston Fitting Scale
6. J-4536 Lift Kit 15. .1-5715 23. .1-7316 Fan Belt Tension Gauge
Rocker Arm Stud Hole Reamer
7. J-8792 Harmonic Balancer Installer J.6036 24. .1-8001 Indicator Set
8. J.0971 Camshaft Gear Remover 16. .1-6880 Rocker Arm Stud Installer J-8690.01 Universal Engine Adopter Not Shown
9. J-8089 Carbon Removing Brush 17. J-5802 Rocker Arm Stud Remover J-6585 Slide Hammer Not Shown

ENGINE V-8 8-44
Fig. 94-Special Tools-V-8
1. J.6994 Piston Pin Replacer 3. .1.9608 Fan Hub Locating Tool

2. .1.8792 Harmonic Balancer Installer 4. .1.9510 Piston Pin Replacer

08 1963 CH-Engine Mechanical

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SECTION 8

SIX CYLINDER ENGINE

PASSENGER CAR SHOP MANUAL.

A gear type oil pump supplies oil through a full-flow

MAINTENANCE AND ADJUSTMENTS

Fig. 3-Phantom Cross-Section

PASSENGER CAR SHOP MANUAL

Fig. 4-Oil System Diagram

PASSENGER CAR SHOP MANUAL

Fig. 5-Cylinder Block and Explode

PASSENGER CAR SHOP MANUAL

Fig. 6-Cylinder Head

PASSENGER CAR SHOP MANUAL

c. Improper lash adjustment.

9. Press down on push rod seat and remove pin Tool

Fig. 10-Valve Lifter Cross-Section

1. Lifter Body 4. Chec k Ball 7. Plunger

PASSENGER CAR SHOP MANUAL

Fig. 13-Removing Carbon from Combustion Chamber

2. Thoroughly clean the valve guides using Tool

PASSENGER CAR SHOP MANUAL

Fig. 14-Cleaning Valve Guide Bores

NOTE: Excessive valve stem to bore clearance

PASSENGER CAR SHOP MANUAL

Fig. 19-Installing Rocker Arm Stud

in the head oversize studs, available in .003" or .013"

Valve Seats Cylinder Head

PASSENGER CAR SHOP MANUAL

3. Remove roughing stone or forming stone from

5. Remove expanding pilot and clean cylinder head

NOTE: Valve seats should be concentric to

Fig. 21-Valve Refacing Machine

line with the grinder wheel by moving the lever to

PASSENGER CAR SHOP MANUAL

Fig. 24-Checking Valve Spring Installed Height

Compressed air or a screwdriver, may be used

2. Assemble the remaining valves, valve springs,

Fig. 25-Installing Head Gasket

2. Carefully guide cylinder head into place over

PASSENGER CAR SHOP MANUAL

ENGINE-6 CYL. 8-14

9. Clean all spark plugs with abrasive-type cleaner,

4 18. Clean and install air cleaner.

PASSENGER CAR SHOP MANUAL

9. If camshaft readings for all lobes are within speci

2. Remove harmonic balancer using Tool J-6978.

TIMING GEAR COVER

PASSENGER CAR SHOP MANUAL

out of cover from front with a large screwdriver.

Oil Nozzle Replacement

PASSENGER CAR SHOP MANUAL

7. Install radiator, connect hoses, fill cooling system

3. Remove grille assembly. See "Front End Sheet

Fig. 37-Checking Camshaft End Play

Fig. 39-Checking Camshaft Gear Runout

PASSENGER CAR SHOP MANUAL

2. Position bearing pilot in inner bearing.

Fig. 42-Installing Camshaft Center Bearings

NOTE: Oil hole is on top side of bearing shell